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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 3 Mar 2019
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New 86 xt600 owner
Just picked up a 1986 xt600 for $450. Missing lights and gauges but good runner.

First I plan to go over the electric system. Then add all light back on. But at same time I plane to modify it to use the 95-02 plastics,tank and seat. As I plan to install a larger aftermarket 5+ gallon tank. While doing that I will send the carbs to be rebuilt.

My plan is a reliable. Go anywhere bug out bike capable of 80+. And at least 250 miles.

Any helpful ideas welcome!
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  #2  
Old 3 Mar 2019
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So far...bike leaked oil really bad.....stator cover was cracked and welded in past. Pulled it and found it was fine but had no gasket. Added gasket cleaned up and replaced. Found out oil leak was from crack in block from impact that damaged side cover. Cleaned and repaired crack. No more leaks. Replaced right side cover gasket aswell.

Handle bars bent. Ordered new ones.

Parts ordered so far. All are OEM where possible...
Ignition switch.
Oil
Oil filter
Clutch and brake levers.
Gasket set.


Basically get it running right and back you factory then do upgrades
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  #3  
Old 3 Mar 2019
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A picture would tell a lot on how the bike has been treated, c'mon, dont be shy, we surely seen worse



From the 5 gallon tank thing and going 80mph sounds that you are going to put that thing through it's paces a bit. Nice, but with a bike that sounds like it had a rough history (how many miles without seeing the gauges?) i would do a full engine dismantle and check even before seeing how well it runs. For instance, gearboxes are not the strongest point in these bikes and you dont really want to get caught out in middle of nowhere.



Leave $$$ too for a steering/swingarm bearings, full front suspension rebuild and an after market shock, stock rear is not really rebuildable.


just my 2 cents of course...
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  #4  
Old 3 Mar 2019
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What country you located in ? Can help with recommendations or possible parts sources . The newer plastics and tank is quite different and will need a lot of work to mount on the older frame .
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'86 XT600/3TB motor,,, '88 XT600, ,,'92 XT600e,,, '08 Husky TE510,,, '05 DRZ463,,, '95 KLX650 ,,,'96 KLX650
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  #5  
Old 3 Mar 2019
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Cant get pics to upload. But more info..

Just pulled clutch cover, same as stator, no gasket. Decompression cable broke. Waiting on new gaskets then will fix. Also just ordered new cable.

I am located in spring city tn.
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  #6  
Old 3 Mar 2019
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Also anybody have pics of the stock swing arm? Was told it was replaced with aftermarket
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  #7  
Old 4 Mar 2019
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I did pick up a speedo and headlight assembly with wiring and everything off of a 93 xt250. Lines up fine but will it work on the 600? Other then shape of the headlight itself the only difference I saw was that the speedo says 80 where as the xt600 speedo whent to 100.

Anybody know if it will work?
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  #8  
Old 11 Mar 2019
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Tank bought and on it's way. Total with shipping was $105usd
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  #9  
Old 11 Mar 2019
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So I need fast help. New harness and ignition is in al set to test fire.....then found a fuel leak...bottom of carb bowl. What do I do with this part?

Seen in pic. The spot I'm pointing at.....




Never mind figured it out......but the needle dosent stick...and it still leaks
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Last edited by Glsawyer; 11 Mar 2019 at 22:37.
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  #10  
Old 11 Mar 2019
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Also I looked at Yamaha for the fuel bowl gasket and it showed a flat gasket. Not a rubber oring style.

Is it ok to use a standard flat style gasket?
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  #11  
Old 11 Mar 2019
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Also should this piston move?
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  #12  
Old 11 Mar 2019
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yes, piston should move

take no offense, but if you are asking that then i think you are going to face a serious challenge in this rebuild....


as for the leak, it looks like you need an o-ring, part number 22 in the list


https://www.ronayers.com/oemparts/a/...e27/carburetor
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  #13  
Old 11 Mar 2019
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Ty. I'm ordering a rebuild kit now. Soaked carb in diesel and was able to remove piston. Cleaned it up with scotch brite pad. Now it works as it should. So just need new gaskets and should be ok.
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  #14  
Old 12 Mar 2019
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Wow........just wow....more I fix more I find wrong.

Chain rubbing frame and swing arm, reason...chain guide missing. Ordered new one.

Cost so far:
Chain guide $45
Chain $90
Plug $3.50
Gauges $50
Bars $70
Grips $10
Desert tank $105
Throttle tube $15
Left side controls $30
Levers and hardware $50
Wiring harness $45
Ignition $35
New fuel lines $20....bought extra
Oil change $40
Various other small parts and gaskets $100
Cost of bike $450
Trailer and fuel to get bike $50


Still to buy.
Battery $?
Re do seat $75
Tires $?
Tubes $?
Racelight headlight $?
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  #15  
Old 12 Mar 2019
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Total so far $1208.50

And now carb trouble
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