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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.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

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  #1  
Old 24 Jan 2003
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Small parts...

Have you ever had problems with the following:

* rear brake linkage / master cylinder?
* gear / brsake levers holing engine cases?
* axles / caliper bolts shearing?
* spoke breakages / wheel damage?
* fairing / tank fitting hardware failure?

-----

I'm running through a list and prioritising work on the 3AJ; it seems I won't be able to afford everything.
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Old 24 Jan 2003
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I've had a rear wheel spoke broken several times [not the same one] during the past years on a 1992 XTZ660. Replaced one every time and no further extra problems.


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Old 27 Jan 2003
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I was chatting to Ernie at Overland Solutions today (he's doing some work on my 1VJ) and he mentioned your bike (I think) was going in later this month. Anyway, I'd definitely go for some engine bars... its a small job for him and it will save you laods of trouble when you drop your bike... the problem is that wehn you drop it (as I have done many times) the gear lever bends in and cracks your engine casing... big hassle in the middle of nowhere...

so thats my recommendation ,

bon voyage,

Simon
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Old 28 Jan 2003
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Thanks for the tip! I was hoping to get him to make up some engine bars that could be used to also carry water / fuel.

As well as that he'll be doing racks for my side cases and reconstructing the rear carrier. NOTE: The standard XT carrier is very weak. I had a small topcase in London and it broke on both sides!

I'll also get him to modify the sidestand, and maybe even fabricate a front fairing + headlight protector, a bit like this:

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Old 28 Jan 2003
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I was looking at the *lovely* wheels at DL's place the other day.

A reconditioned XT hub with double seals and new Excel black rims. Lovely new heavy duty spokes too.

Definitely worth thinking about, but not cheap, unfortunately. I may change the wheels...
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Old 28 Jan 2003
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Of your list, the only thing I noticed (in the uk) was the rear brake lever bent inwards and scratched the engine case.
On my North African trip, including multiple getoffs, none of the items on your list caused me trouble. I had, however, had the wheels respoked before going - they were, after all 12 years old & in my case, rusty

I did find, however, that the tabs on the frame that I used to attach my luggage (the same attachement points as the standard rack) bent over time, so I'll be reinforcing those soon.


Have fun
Neil
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Old 28 Jan 2003
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most useful thing i can recommend is to locktite all bolts securing racks/etc to the bike. i lost almost all my bolts at least twice on my trip, seems chris scott wasn't joking when he said locktite everything! (obviously not the engine bolts).

engine bars are a good thing to stop the engine casing being cracked (another thing i did during one of my numerous falls), but watch out on the 3AJ that you can fit engine bars if you have a kick starter installed - i think the two clash for the same space.

be wary of mounting luggage on the handle bars/front of the bike, as it can affect the steering quite seriously, particularly if it is a container holding a liquid which can slosh from side to side, thus accentuating the weight distribution.

good luck!

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