Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
XT600e starter removal XT600e starter removal
Register FAQ Calendar Today's Posts
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Alessio Corradini, on the Salar de Uyuni, Bolivia, of two locals

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


Photo by Alessio Corradini,
on the Salar de Uyuni, Bolivia,
of two locals



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 6 Apr 2018
Registered Users
HUBB regular
  
Join Date: Jan 2015
Location: Hampshire
Posts: 36
XT600e starter removal
Sorry if I'm being stupid but what's the best way to get the starter motor out of my 2003 600e? The manual says exhaust off and take it out that way. I don't think the exhaust has ever been touched so thoughts of snapped studs/bolts and stripped threads fill my head. The other option looks to be by removing the carb - a pain but just time consuming. (It's definately the starter. The battery and relay are fine. The starter doesn't work even with direct power to the terminals)
Reply With Quote
  #2  
Old 6 Apr 2018
Registered Users
HUBB regular
  
Join Date: Mar 2014
Posts: 77
Probably the easiest way is to remove it together with the left hand stator cover, you have to drain the oil first, or just lie the bike on its side. Make sure you have gaskets eady to replace.

if you take off just the starter motor, then the exhaust must come off, and you also have to undo the circlip on the magneto side, under a small cover, above magneto. There is also a paper gasket there to look out for, if you dont have a spare one.
Reply With Quote
  #3  
Old 6 Apr 2018
xtrock's Avatar
Registered Users
Veteran HUBBer
  
Join Date: May 2013
Location: Norway
Posts: 1,364
Remove exhaust and you have acess out, dont bother removing stator cover. Mine was stuck so you maybe have to remove carb to get the best acess to remove. If its stuck use a socket over the starter drev and give it a little knock.
Reply With Quote
  #4  
Old 7 Apr 2018
Registered Users
Veteran HUBBer
  
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
yeb, take the exhasut of. You can spray penetrant oil on the bolts, nuts, and also on the flanges that sit against the head, as that can corrode stuck, in the days up to the operation, and see if it does anything.
Last edited by Jens Eskildsen; 8 Apr 2018 at 20:48.
Reply With Quote
  #5  
Old 10 May 2018
Registered Users
HUBB regular
  
Join Date: Jan 2015
Location: Hampshire
Posts: 36
Smile Lucky
Thought I'd update and also another question. The exhaust come off very easily.

I had other jobs to do so just kept spraying the nuts every day till now. I suspect it had never been touched so was still at factory torque rather than gorilla torque. I won't use the old nuts. Should I get new originals or use brass nuts? I can't find flanged brass nuts so it would have to be nuts and washers.
Reply With Quote
  #6  
Old 10 May 2018
awolxt's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Apr 2011
Location: wirral
Posts: 270
I bought oem nuts from boats and used stainless steel studs. I had to drill mine out though so no choice but to replace. I wasnt sure what size and type of nuts i needed so thats why i stuck with original.

Bill
Reply With Quote
  #7  
Old 11 May 2018
Registered Users
HUBB regular
  
Join Date: Jan 2015
Location: Hampshire
Posts: 36
They are simple M6 nuts with a standard (coarse) thread so easy to get.
Reply With Quote
  #8  
Old 11 May 2018
Gold Member
Veteran HUBBer
  
Join Date: Oct 2011
Location: Cambridge, UK
Posts: 672
My header bolts on the TT600RE (same lump) were seized and totally mashed, so I had no option but to remove the carbs, which was a total pain in the arse. The rubbers on the manifold outlets tore so be careful.
Reply With Quote
  #9  
Old 11 May 2018
awolxt's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Apr 2011
Location: wirral
Posts: 270
Yeah i realise that now but at the time i was removing them i thought id place safe and use oem nuts and studs. I ended buying stainless steel studs as well and used them with the oem nuts.

Bill
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
XT600E Carb Removal? Guest121 Yamaha Tech 25 30 May 2023 16:37
XT600e Starter issues OZXT600e Yamaha Tech 14 5 Jun 2016 07:12
Rocker cover removal - XT600E charlesm87 Yamaha Tech 3 3 Feb 2014 18:43
XT600E spark plug black on removal, what to do? Rfothy Yamaha Tech 4 20 Feb 2013 18:55
97' XT600E start failing / starting circuit cutoff relay p/n ? jamesahkXT600e Yamaha Tech 1 9 Jun 2012 03:43

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

ALL Dates subject to change.

2025 Confirmed Events:

  • Virginia: April 24-27 2025
  • Queensland is back! May 2-4 2025
  • Germany Summer: May 29-June 1 2025
  • CanWest: July 10-13 2025
  • Switzerland: Date TBC
  • Ecuador: Date TBC
  • Romania: Date TBC
  • Austria: Sept. 11-15
  • California: September 18-21
  • France: September 19-21 2025
  • Germany Autumn: Oct 30-Nov 2 2025

Add yourself to the Updates List for each event!

Questions about an event? Ask here

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

Adventurous Bikers – We've got all your Hygiene & Protection needs SORTED! Powdered Hair & Body Wash, Moisturising Cream Insect Repellent, and Moisturising Cream Sunscreen SPF50. ESSENTIAL | CONVENIENT | FUNCTIONAL.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 08:05.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top