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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 7 Apr 2012
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Engine Cuts out when warm

I recently bought a 2003 Xt600E and I am new to the forum. I love the bike so far, but I am discovering that if I start and ride it for a while, stop and switch it off for a few minutes. It starts fine but when I put it in gear and try to drive off it cuts out. I then have to put it back in neutral and start it again. It usually starts of OK the second or third time.
Comments welcome, thanks
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  #2  
Old 7 Apr 2012
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I'm sure someone will soon be able to help you. I'm more of a expert bike cleaner/polisher than a mechanic. My hands are like a babies bum still (47 year old medically retired / worn out bike cop in case your wondering).

If I were you I'd look first at fuel starvation - a blocked fuel filter etc. Secondly the Carb (blocked jet, mixture etc).

Once you have checked the fuel side of things the next thing to look at is air intake (filter and housing) and then finally (and the biggest pain to sort out) - electrical faults (including spark and HT lead / coil).

Sounds like it's probably something silly and minor (hopefully cheap to solve too). You really can't go much wrong with a Yamaha XT6E. These things are simply legendary...

You watch, the very next post will say I'm totally WRONG! lol.

Mezo is probably the best person to help you out?

Good luck.
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Old 7 Apr 2012
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It sounds alot like the sidestand switch...
If you turn her on and keep the clutch in when you put her in gear Without letting of the clutch, does she stall?


Vando
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  #4  
Old 7 Apr 2012
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If its not one of your safety switches (clutch or sidestand when in gear) then...

I had a problem with my DR650 when riding and it would heat up and stall. I pinned it down to a combination of

- possible vapour lock in my inline fuel filter and fuel starvation to the carb.
- my carb was FKIN filthy. Rip ya carby out. take off the bottom half at least, get a can of carb cleaner and spray the sh*t out of it, cleaning the bowl jets etc. Don't use wire or anything to clean your needles
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  #5  
Old 7 Apr 2012
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Thanks for your replies:
bacardi23: When I keep the clutch in nothing happens, I have to take it out of gear and then the engine will start, but sometimes the second time I attempt to drive off it stalls again and I have to go through the procedure of taking it out of gear again and starting the engine again.

brianrossy: Carbs are a total mystery to me as are electrics, I will ask a friend of mine who knows to check the carbs.

Kentfallen: Thank you for your reply I am much like you when it comes to mechanics and I was a bike cop back in the 80s. It was much easier to leave the bike into the garage to have it repaired.

I love the simplicity of the XT and how much fun it is to ride.
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Old 7 Apr 2012
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If the bike won't start in gear with the clutch lever pulled in and only starts in neutral, that is the classic symptom of a failed clutch switch. Bypassing the clutch switch and sidestand switch should solve the problem of having to only start the bike in neutral and avoid future problems with these annoying "safety" devices.

If the bike still stalls then it may also be time for a good carb cleaning. On a 10 year old bike that has spent any amount of time sitting, it would be surprising not to have to clean the carb. Hopefully it's just a simple failed switch.

Cheers,
John Downs
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Old 8 Apr 2012
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Gotta agree with everyone it certainly sounds like the safety switches, i think you just unplug them out of the look from memory?

I know that`s the case for the clutch switch on the 3AJ, i didn't have to short the wires out it was simply just unplugged & started fine.

Just follow the wire back from the switches till you find where its connected & pull it out.

Mezo.
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  #8  
Old 8 Apr 2012
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Thank you all for your very speedy and helpful replies. It is great to have such expertise available from all over the world.

I will check out the clutch switch and get the carbs cleaned.

Many thanks again
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  #9  
Old 10 Apr 2012
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HI
I disconnected the clutch and side stand switch and it is still happening.

It starts fine in neutral and when I put it into gear it cuts out. I am wondering is it the neutral switch needs replacing? I need to ride it to my friends to get the carbs done but I can't get going.
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  #10  
Old 10 Apr 2012
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you have to connect the wires together!!! on both connections!
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  #11  
Old 11 Apr 2012
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Thanks I'll try that tomorrow
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  #12  
Old 11 Apr 2012
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Zofo,

Keep us all updated. I'm sure we will get there eventually. Posting on the thread keeps it at the top where your more likely to find someone who has experienced the same kind of problem and will be able to impart knowledge (help you).

I presume you are working on the idea that it's a simple side stand electrical problem?

I presume you have already downloaded a .pdf version of the XT600E service manual and .pdf parts manual on the links at the top of the Yamaha page? If not why not... Save them on your PC, you never know when you will need them.

I think the service manual and the parts manual will help you work out which parts need looking at closer...

It's always the simple niggly things that take so long to solve....

Hang in there matey.
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  #13  
Old 11 Apr 2012
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Thanks

It worked . I'd just disconnected the side stand switch yesterday, but thanks for the advice and I joined the wires and off she goes.

Hi Kentfallen I've downloaded the manuals thanks
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  #14  
Old 12 Apr 2012
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Make sure you have joined them securely. If they vibrate loose when you are riding, the engine will stop. Could be embarrassing/dangerous.

FWIW, I disconnect the clutch switch on every bike I own. I hate them, mainly because they prevent you from starting the bike one-handed. That means I have to put my helmet down, and it's usually wet or muddy ...

Edit: or does the s/s switch just enable the starter? Can't remember.
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Last edited by BlackDogZulu; 12 Apr 2012 at 01:33. Reason: Brain fade
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  #15  
Old 13 Apr 2012
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Thanks for that, I'll have another look at the joint.
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