Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech

Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

LinkBack Thread Tools Display Modes
Old 27 Jul 2010
Registered Users
Veteran HUBBer
Join Date: Dec 2008
Location: Denmark
Posts: 1,056
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.


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
Reply With Quote
Old 27 Jul 2010
Contributing Member
Veteran HUBBer
Join Date: Aug 2008
Location: Sweden
Posts: 101
.....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!
Reply With Quote
Old 27 Jul 2010
wolfzero's Avatar
Registered Users
Veteran HUBBer
Join Date: May 2009
Location: uk
Posts: 433
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
Attached Thumbnails
Remove ignition switchon xt600e 2003-dsc00861a.jpg  



RF900 & GSX400X Impulse Projects
3.9 V8 Rangerover
Reply With Quote
Old 27 Jul 2010
Registered Users
Veteran HUBBer
Join Date: Dec 2008
Location: Denmark
Posts: 1,056
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.
Reply With Quote
Old 27 Jul 2010
Registered Users
Veteran HUBBer
Join Date: Dec 2008
Location: Denmark
Posts: 1,056
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.
Reply With Quote

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

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 2003 parts maual hikeifulike Yamaha Tech 32 20 Mar 2011 18:47
XT600E (2003) dipstick cousent Yamaha Tech 2 13 Jul 2009 12:49
2003 Transalp Ignition Barrel Problem Chris1200 Honda Tech 9 6 Jul 2009 14:37
Confused with a rattle(XT600e-2003) FRIXOS Yamaha Tech 8 13 Oct 2007 09:51
Large tank xt600e 2003 jimmy Yamaha Tech 3 16 Sep 2004 19:15


HU DVD Summer Special!

Now that summer is here, get On the Road! Take 30% off the Achievable Dream - On the Road! 2-DVD set until August 31 only. Get On the Road! Learn the tips to staying healthy, happy and secure on your motorcycle adventure!

Our veteran travellers share their tips (and great stories) for staying healthy, happy and secure on your motorcycle adventure.

"A fantastic, informative and inspirational DVD."

"It's brilliant - thank you very much!"

Check it out at the HU Store! Remember to use Coupon Code 'ONTHEROAD' on your order when you checkout.

Renedian Adventures

Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!

What turns you on to motorcycle travel?

Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!

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 R80 G/S motorcycle.

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 (22 this year!); 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, the HUBB or to receive the e-zine. 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.

Books & DVDs


All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.

Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!

All times are GMT +1. The time now is 19:02.