I just picked up a 1989 XT600 with a fresh engine rebuild. I like the bike very much but it is very hard to start. I know thumpers can be grouchy when it come to starting but I think there is more going on here.

It keeps firing back against the kick starter almost every kick. I bring it to TDC then go just by it and give it a good smooth kick and at the end BANG and I think about going to the hospital. When I do get it running it runs well and has no problem starting when it is hot (well so far, I have only put 12 miles on it so far).

After trying to start it for a few minutes it will leak gas out on the carb. I pulled the carb and found the choke was sticking and have fixed that problem I hope.

The bike looks to be fully stock other then someone pulling some of the baffles. The carb has a 48 pilot jet and 122.5 main.

I want to run this bike to and from work (35 miles) and need it to be able to start in temps as low as 45 deg (cold mornings here in Maine). I will also be using it with the family on the weekends offroad. I am not looking for the max power this thing can make. I just want it to be a bit more friendly.

What I would like to know:

-Does the jetting sound rigth for the kind of driving I want to do?

-Could I be dealing with a timing problem? If so how can I confirm and correct the problem.

-Am I missing something?

As someone who has worked for many years on auto and aircraft engines I feel with some input I can solve this problem. I was thinking a timing problem but I know thumpers are not of this world and seem to live by diffrent rules.

Any help would be great.
Thanks

I used to own one. great bike.

No throttle when starting, keep your hand well away.

make sure air filter clean.

make sure valve clearances are correct ( do not take it on trust they are ok, check them yourself)

Do you have a decompressor fitted? if that is wrongly adjusted it will make your life hell. I took mine off and did not notice any real difference.

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The Honda CT90...... who needs 600cc to see the world?

I would try turning the throttle stop screw down so you know the throttle slide is closed.
No throttle when starting if it does not fire try turning the throttle screw so it opens the slide just slightly untill it fires
If my bike kicks back from cold I turn the choke off as I guess there must be fuel in the cylinder to cause the kick back and with choke its likley to flood.
You should also check the plug make sure its the correct type
good luck

Hi Stig,

all good advice above,

I'd highlight to make sure the decompressor cable is adjusted correctly.

I find best way for starting mine is no throttle, 1 slow kick, then it starts on a firm constant kick to the bottom of stroke and held there.(or two)

a list of jet sizes here Wartungsdaten Tenere-Modelle

USA models may vary?, I think the Clymer manual lists jet sizes also.

I hope this helps,

not sure if you said what model you have?

cheers
andy

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Thanks very much for the great info guys.

I am going to mess with it tomorrow. I ordered a shop manual tonight so I can check the valve setting and timing of the cam and ignition system.

I will let you all know what I come up with.

Thanks again very much.

I would get the manual then put your carb back to exact factory settings and work from there as a bench mark...

The carb should never leak unless the float valve is stuck ! I'd be pulling that carb about and checking its clean and the jets are correct etc.

Once you're pretty sure the carb is ok, if its still not running you should be checking for a nice clean spark !!

__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

I ordered a manual last night and I think you are right on. I am going to pull them tomorrow. I will let you all know what I find.

Thanks very much.

hey stig,
ya the advice above is sound. but, what you said sounds exactly what happened to me, i'll explain. i did a full rebuild on my 92 xt because 5th gear moaned and it was worn, when i rebuilt the engine it sounded just like yours, now, it turns out it'll run ok (ish) when your out one tooth on the cam, but it'll be a lousy starter... i removed the chain and bought a new one... when i compaired the two chains there was a bit of streching in the old one as expected, but i was wrong putting it together and also very lucky not to damage it at all... but the new chain with the correct timing made it humm with awe.... get yourself a timing light and remove the timing screw, all the instructions for this are in the clymer manual,
i really hope you get to the bottom of this, if you want to put some two stroke oil in with the petrol to lube the moving parts of the carbs, theres a chance your floats needle might be getting worn too... and also the sliding barrell in the secondary carb, the oil helps troubleshoot this before total dissasembley ....ken