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  #1  
Old 26 May 2009
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Cool My 1990-2003 XT600E mods

Hey there!

Here is a list of mods I want to do on mine,comments are welcome(PLZ lol)
  1. - 1989 kickstart (I've already fitted) .
  2. - 02 YZ 250 front end DONE (fresh 10w oil and new oil seals DONE).
  3. - UNIVERSAL triple clamps, one 7/8" and other is top triple clamp 1-1/8th (BOUGHT).
  4. - Pro Taper fat bars (BOUGHT) Yamaha blue square pad (missing).
  5. - Engine paint (done it but will probably have to redo it).
  6. - Full 2003 XT600E (deep purplish blue) bodywork. (only missing both black side tank fairings)
  7. - DIY YZ250F/YZ450F/WR450/CR450F stock exhaust. (BOUGHT)
  8. - complete 2006 YZ250F rear end (BOUGHT) but depending on how dificult it'll be to fit...I might sell it at a higher price LOl and cut some costs.. lol
  9. - KEDO.com stainless steel header pipes.
  10. - YZ or similar gear shifter DATA at hand. no money lol
  11. - passenger springloaded footpegs..
  12. - frame sandblasting/paintjob. (Work in progress)
  13. - New aluminum rims (stock XT600E 21"x1.85 front and 17"x2.50 rear because here in Portugal we have a very restrictive MOT laws) black with blue stripes with Buchanan HD stainless steel spokes and nipples.
  14. I already got ASV F1 silver "unbreakable" levers and one even has a little "hot start" lever that I'll use for the Manual decompresser ;P
  15. Will also check if a 2005 WR450 throttle tube with a aluminum balls bearing inner tube will work on the XT ;D OVERRIDE: Bought a KTM 640Supermoto throttle with cables for 30€ shipped.

What do you guys think, any comments? try to shoot me down lol


Ride safe!

Vando

Last edited by bacardi23; 3 Feb 2010 at 20:27.
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  #2  
Old 26 May 2009
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got any more info on fitting the kickstart? Looks like you've done a fir few mods - any chance of a few pictures of the finished article?
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  #3  
Old 26 May 2009
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Quote:
Originally Posted by apexTwin View Post
got any more info on fitting the kickstart?
Here we go again!!!
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  #4  
Old 26 May 2009
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Hi Bacardi23
I am trying to fit a set of 05 WR forks to my XT but have a problem with the steering stem.
Did you use the oringal XT stem or get the YZ machined down to fit the XT bearing,
I have had my WR stem machined down for the bearing but if I get a thread cut on the stem for the headrace adjusting nut the top yoke will be a loose fit, I was going to get a spacer made for the inside of the yoke but the machine shop said it will be so thin it may break. I was also thinking of getting the top yoke bored out so I can use a thicker spacer.
What did you do I am sure there is an easier way.
I think the YZ and WR forks are the same except for the internals but I also think after 05 they use a longer steering stem
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Old 26 May 2009
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Don't worry Tom, I got it handled

Quote:
Originally Posted by apexTwin View Post
got any more info on fitting the kickstart? Looks like you've done a fir few mods - any chance of a few pictures of the finished article?

For the kickstart you can read this, it has all the parts that you need to get in order to fit everything into place:

http://www.horizonsunlimited.com/hub...ck-start-30064

If you want to add a manual decompresser the info is also in that thread...

READ EVERYTHING I MENTION IN THAT THREAD!

If after that you still have any doubts PM me, email me or just add me on MSN....

Vando
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  #6  
Old 26 May 2009
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Quote:
Originally Posted by bolla View Post
Hi Bacardi23
I am trying to fit a set of 05 WR forks to my XT but have a problem with the steering stem.
Did you use the oringal XT stem or get the YZ machined down to fit the XT bearing,
I have had my WR stem machined down for the bearing but if I get a thread cut on the stem for the headrace adjusting nut the top yoke will be a loose fit, I was going to get a spacer made for the inside of the yoke but the machine shop said it will be so thin it may break. I was also thinking of getting the top yoke bored out so I can use a thicker spacer.
What did you do I am sure there is an easier way.
I think the YZ and WR forks are the same except for the internals but I also think after 05 they use a longer steering stem

****As off 2004 the forks went from 46 to 48mm diameter**** (at least for the YZ 2-strokes but that is irrelevant for this)

First of all I beg you to take a look at this!

Universal Triple Clamp Yamaha YZ YZF 04 05 7/8":eBay Motors (item 270393852412 end time May-26-09 17:31:06 PDT)

I've seen several of these from this seller end at the 25USD so "SNIPE" IT (bet on the last few seconds) lol

I wish they had one of these sets for my forks :\


As for the rest here it goes:

I machined my YZ steering stem...

In order to do this I had my XT's frame to check everything was good!

What I did on my YZ triple clamps was:
  • Cut the lower bearing carefully with a Dremmel to avoid damaging the stem.
  • Press out the steering stem. (be carefull, it has a "ring" on the bottom of the lower triple clamp that is barelly noticeable that you need to take off before you press out the stem!)
  • Measure the stem on where the lower bearing fits to ensure the XT's lower bearing fits tight in there! ( I was lucky here, the stem from the YZ triple clamps that I had where the exact match for the XT's lower bearing! 30mm i think it had)
  • For the NUT, I machined a thread for the XT's NUT...if I recon it was thread #1 or #2 BUT get that measured as I am not sure!!( there is a special tool for measuring this that looks like the Sparkplug gap measuring thingy)
  • As for the top bearing, I had to machine the YZ stem a little more right after the end of the new NUT thread that you just had machined so the top XT's bearing would slide into the correct place and sit on the XT frame holes as they should!
  • As for the big NUT that goes on top of the triple clamps I just used the YZ's nut to lock everything into place....
Do use new bearings!


Any doubts just reply here,PM,email or MSN me! lol

Have fun!
Vando
(yes, Vando is my name lol)
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  #7  
Old 26 May 2009
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You could also post some pictures here so I can see what you have done to that steering stem....

And as you will notice, after putting the front forks you will see that the forks DO hit your fuel tank!
you will have to fabricate at least one over steering stopper (harder) or make TWO over steering stoppers one and weld them to the XT's frame so the forks do not hit the fuel tank!

Vando
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  #8  
Old 26 May 2009
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those triple clamps have a start of $25 but he has a reserve thats close to the buy it now

i used some ktm650 yokes as they already had fat bar mounts and made an upper bearing to fit the ktm spindle and the xt upper bearing race so there was no need to either press out the xt one or make a collar/spacer for the upper ktm yoke
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  #9  
Old 26 May 2009
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Thanks Vando,

Note to self: "must remember to use search function before asking questions"
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Old 26 May 2009
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No reserve on those triple clamps... I've bought from him two upper triple clamps from that same manufacturer "UNIVERSAL" one for 15.50 (1-1/8th clamp) and the other for 11.01 (7/8th clamp) with a total of 38.46 including s/h... you just have to SNIPE them at the end and hope for the best :P

anyway, I'm off to bed lol I'm falling asleep----------DREAM-->


Vando
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  #11  
Old 1 Jun 2009
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Updates

  • Bought an All Balls Fork Dust Seal kit for my new forks for 31.50$
  • 2006 YZ250F swingarm for 45$ + 15$ for s/h... a real bairgain!!!
I will be looking for a 1999-2009 YZ/WR 125/450 rear wheel hub.. Yamaha OEM part# 5ET-25311-00-00

If anyone one has a good one hanging around in the garage just let me know and make me an offer


Vando
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  #12  
Old 1 Jun 2009
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the swingarm you just bought has a different type of shock linkage so you will have a lot of work to do getting that to fit.
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Old 1 Jun 2009
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Hey

I know I know.. I'll have alot of work ahead lol
I gotta have something to do this summer besides women, riding, partying, and fishing(mostly spear fishing!


I must say that the 06 YZ250F rear suspension I bought looks awesome! I'll post a picture or two this afternoon...

SOO I'm studying on which angle would be the best for the XT although it might be a loooooooong time till I get it shipped and delivered from my family in the US to my home in Azores (Portugal)....

What I'll probably do is make a solid rack with several mounting position splines or holes for mounting the shock, fix it to the XT's frame and that way I can just try the bike on each setting and see what works better for me.. lol

If it is a splines one, I'll have to make a special moving rear shock fixation mount which would give me more options but more work! lol

What do you think guys about that? lol

Vando


link: http://www.horizonsunlimited.com/hub...y-design-43163

Last edited by bacardi23; 1 Jun 2009 at 17:41. Reason: added link on bottom...
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  #14  
Old 9 Jun 2009
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If you don't show us some pics, I'll and then so that you will

:P

P.S.: just playing with the emoticons, but really, some piiics would be nice
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  #15  
Old 11 Jun 2009
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I'm currently not at my island and won't be there until end of July sooo pics and everything will have to wait...
As for the swingarm and related, they are still in the US and will probably stay there until around christmas lol

One thing I can say is that I bought a Fox full body armour jacket and a full matte black TMS off-road helmet both NEW and really cheap off flebay of course!

helmet: Auctiva Image Hosting
Vando
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