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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.
Photo by Sean Howman, The Pamir highway in an unseasonably cold late October, Tajikistan

I haven't been everywhere...
but it's on my list!


Photo by Sean Howman,
The Pamir highway in an unseasonably
cold late October, Tajikistan



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  #1  
Old 28 Jan 2008
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xt600E head removal
Quick question. Can you remove the rocker cover and head without removing the engine on a 1991 xt600e .
thanks
Dave
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  #2  
Old 29 Jan 2008
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You can on my 1990 3aj. you need to remove the bottom engine mount bolt at the back of the engine and the two front mounting bolts plus the top mounts, then let the engine tilt forward. dont forget the allen bolt under the top mounting when you go to remove the rocker cover!! cheers T
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Old 29 Jan 2008
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Did that on my 1993 XT600E. The allen bolt under the top mounting is a pain to get at without the right tool. Good luck.
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  #4  
Old 29 Jan 2008
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Thanks guys, its that allen bolt i'm having trouble with. An allen key has snapped off in the head of the screw.
Dave
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Old 29 Jan 2008
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I had problem with that bolt too. some one had tryed to take it out and rounded it. There is an quite easy solution if you have access to a welding torch(asetylen,oxygen) Take a smal nozzle(80L or 100L) and heat the bolt up until the head is dark red. Then you use a centerpunch or a smal tisel, and tap the bolt gently anti clock wise to open it. It might work without heating as well, but usualy you don´t have to hit it so hard if it´s heated up.


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Old 29 Jan 2008
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The extra hour you need to get the engine out and in is made up easily when working nicely on a workbench with nothing in your way.
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  #7  
Old 29 Jan 2008
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The head of the allen bolt for mine was stripped too. Welding did not help as the space is quite narrow and there are so many wires around that area too. My mechanic advised me to use a blunt end metal rod and hammer with enough force to loosen the threads of engine bolts before opening them. That helped and I eventually opened that bolt using a chisel and hammering again with sufficient force all around the bolt while the engine was still in the frame. If I were to do this again, I will take the engine out.
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Old 29 Jan 2008
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I managed to remove the bolt. I welded a 8mm short bolt onto the allen head which loosened the bolt but a blob of weld wouldn't let the bolt spin so i had to diagonally drill the heads off the allen then lift the rocker up and unscrew the rest of it. I now wish i had removed the lump in the first place.
Also i cannot see where the head was blowing from but it was definately blowing!!
Dave
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Old 30 Jan 2008
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a stupid sugestion...?
And you are sure that it wasn´t the exhaust gaskets that were leaking?
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Old 30 Jan 2008
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Quote:
Originally Posted by XT600Abuser View Post
you may have to drop engine for access Dave. no doubt martynbiker will have some ideas when he comes back from his ban. I have emailed him to have a look at this thread.
Banned ? how do you get banned off here ?
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Old 30 Jan 2008
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Not exhaust gaskets, the compression had vastly dropped and smoke was coming out of the gasket. I have just removed two broken exhaust studs by welding a nut onto the stud and quenching with water.
Are the 43f inlet manifold rubbers suitable for my 2kf engine ? as both broke on removal.
Dave
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