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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 27 Jul 2010
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Remove ignition switchon xt600e 2003

Hey, i've run into a problem.

I'm about to take my ignitionswitch of for repair, but im stuck.

I've drilled out the 2 screws fromt he top with the "brake of heads" and now the iginition barrel itself is loose. I then removed then handlebar, and then the top triple clamp, and i know have the triple clamp with the ignition on, and cant get any further.

The ignition barrel itself is loose, but i cant dismount it.

Pics:







As i see it, i need to drill out the bolts or what they are from the bottom (picture 3 and 4) to then removed the gulden screws seen from the side between the barre and the ignition itself in the last picture.

But im not sure if I do this, than i can assemble the whole thing again, and even with a new ignition switch, this would also had to be done (as i see it) to mount it.

What dont I see, or is this really the way to go? The bike stands in the yard, disassembled with tools and nuts verywhere, so please help
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Old 27 Jul 2010
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.....you need to drill out (or weld a nut on and turn) the two screws close to the steering lock pin (the lower ones in pic#3).

Good luck!
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Old 27 Jul 2010
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as bubbla said drill the two shear studs red crosses if you are precise with a 7mm drill bit as soon as you're through the top of the stud the cap of the stud will come off stop drilling that one and do the same to the other one.
the old lock will then come off and you will be left with the 2 bolt studs sitting proud of the yoke which should just unscrew with pliers
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Old 27 Jul 2010
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Thanks a to guys.

I got impation and have it all sorted out, doing what you said

Pictures of one diiirty ignition switch later, hope it does it.
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Old 27 Jul 2010
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Heres some pics:

Heres the heads drilled of:



Nuts removed:



Ignition getting disassebled, looking dirty and greasy:



Here's some oily connection:



Cleaned up:



Hope that sorts out my problem. Once in a while, perhaps 2-3 times a week, all the light and ignition shut of, and the bike stalls. sometimes it happens suddently from a clear sky, other time it cuts out a few times, before dying.

I can then turn the key to off, back to on, and if fires right up, and everything is good again.

All connecters have been cleaned out aswell (previously)

Last edited by Jens Eskildsen; 28 Jul 2010 at 08:45.
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