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So I,ve just rebuilt the xt 600 after the fifth gear problem and followed the book......filled it with oil and started to crank it over by the electric motor and smoke everywhere... found a black wire coming from the loom to the negative side of the battery had completely melted the plastic coating.,
What have I done to cause such a short circuit? have I done something wrong when fitting the alternator? answers on a postcard to ......any help more than welcome

Check all your wiring... didnt forget that big fat black groundwire that connects to the bolts holding the back of the starter? I almost did...

mine is a 2002 model and does not have the black lead just the one to the body....

Osmund you are the man......I missed that one out completely and will now connect it back up and replace the wire I burt out.....thanks again...:thumbup1:

Don't forget to nicely weld the new wiring and fit some shrink wrap on there!

Good luck ;)

Vando

will do..:D

I actually enjoy doing electric repair work... wish I could do it for ya!

I've fixed some wiring on my XT's wiring lol and I plan on checking every single piece of wiring is working good next time I head back home on the end of July.
I'll also post some pictures of my modded ligths switch! ;)


Vando :cool4:

job done and now waiting for my swinging arm bush to arrive,cranked the motor over with no plug to make sure I had good oil pressure and will ride it to break it in later this week,any body got any thoughts on how to run it in? hard or soft...?

It's always best to run in with higher revs and therefore less load on the engine. That is to say, don't slog it in at low revs in high gear. Have you replaced the pistons then?

Geoff

Hey Kenny, have a read of this Break In Secrets--How To Break In New Motorcycle and Car Engines For More Power
It's a good idea add sufficient oil & fuel, then ride it straight away(to put some load on the engine) once first started, rather than letting it warm-up first.
I have seen Jap bikes run & warmed up & checked etc after new rings fitted & then ridden. Resulting with the rings never bedding-in & a smokey engine.
Bob

Just replaced the two fifth gears which were badly worn and changed the camchain too as it had done 79 000 kms.

It had been worked on by the previous owner who replaced and bored out the piston to 2nd oversize but had not had the head looked at.The head was warped so I had it skimmed,the exhaust valves were blowing as they had not been seated properly so had them done too.

The piston was well within tolerances to the bore so just had new rings put in but they will be needed to be bedded in.

I will wait till the swinging arm bearing comes and will re assemble it all ready for a 30 km ride where I will bed it in,I,m going for the hard ride idea and will not mollycoddle the engine too much as I beleive a good hard ride will give a good gas seal around the rings....maybe I ,m wrong but I beleive modern day engines are different from 20 years ago and I think it will handle it ok....I,m running mineral oil which I will change after about 400 kms to semi synthetic.

I ll let you know how it goes....

Interesting... ill follow this.. Im going to run it in hard when I change my piston too.
I remember when we were 16 and drove 50cc. Mine was dead lazy. The neighbourhood bully bought a brand new TS-X, fired it up and just drove like crazy. His moped went waaaay better than ours, with no other mods done.
I give that to the hard break-in..

Good luck :-)

Cheers mate ,I ll let you know how it goes....:thumbup1: