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Old 10 Jan 2014
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Join Date: Oct 2013
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XT600 E Starting Issue Troubleshoot
UPDATE: I've now solved this, check my latest update below: In short it was the carb and the timing.


Have just had a bad time of starting our two XT600s after 3 weeks in the garage. We rebuilt the engines of these in the autumn so this wasn't good news! Not something I'd like to deal with once we bust them out of a crate in Kazakhstan.

Bike A: 1991 3TB with older bodywork & frame
Bike B: 1993 3TB with newer 4PT style frame and bodywork

Prior to Christmas both bikes were rebuilt and running fine clocking 200miles each with a first oil change. Cold starts might be ~20 seconds of cranking if the bike was left more than a week but if used the day before would start on the button.

Tonight Bike B started after >3minutes cranking. Bike A ran the battery flat and wouldn't start. After what felt like 10 minutes backfiring happened after a few turns and I quit for the night.

I've been trying to put a plan together - all help most appreciated!

Code:
ENGINE
Just rebuilt, 200miles done - second oil change.

VALVES
Clearances correct as per service manual. 
Rechecked 100miles after rebuild and OK.

INTAKE MANIFOLD
O-rings on intake boots were in good nick when refitted.

AIR
Removed side of air box bypassing filter, didn't get things going.

FUEL
Removed fuel cap - fuel flowing into carb. 
On covering carb air snorkel while cranking fuel is being drawn in. 
Fuel pipes are new and flow well. 
Backfire indicates we've got some fuel somewhere

CARB
Haven't touched it in rebuild.

SPARK
New plug done 200 miles, had no spanner tonight. 
Backfiring occuring - will check condition/spark tomorrow

STARTER/BAT
Charged and turning over just fine - jumped from bike B once run low.


With all this my feeling is these are likely culprits:
  1. Spark plug condition
  2. Carb - I've not serviced this, any ideas what I could be looking for once I get it apart for a clean?
  3. Timing (please no!) on rebuild I lined up the horizontal marks on the top cam wheel and at the bottom the middle of the elongated 'H' symbol which felt at TDC. Took my time over this and if I got it apart would be hard pressed to do this better/different. Do I need a timing light? or is it worth the guess of moving the chain a tooth (and which way?). When it was previously running it seemed fine - maybe a little low on power.

Experience / advice welcome. I'll give it another go tomorrow

Cheers

Tom
Last edited by tk0345; 19 Jan 2014 at 16:55. Reason: issue solved
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