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A summer/winter project: '92 XT600 rebuild A summer/winter project: '92 XT600 rebuild
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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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  #31  
Old 30 Nov 2008
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Nice work.

I hope the gasket sealer stuff hasn't squeezed out on the inside, like it has on the outside.

If it has, bits can break away and block oil pipes, or oil feeds etc.

It'd be a real shame to strip it again if this may have happened, but it's better than have it run dry of oil again.
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  #32  
Old 25 Dec 2008
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She's aliiiive!
Got her started a couple of days ago without any fuzz. Fired right up and it was so smooth and quiet that you would have never known it had been down in such a way! I'm really happy about this. I took her out for the first test ride today and it handled well, except for I did the classic mistake of over filling with oil and had a mess going by the time I got back home. No problems after that though! I plan on continuing the break in process tomorrow and then changing the oil/filter not too long after that.

Note: I ended up reusing the oil pump that came on this bike and it's been working well so far. I did order a new one but it has been backordered.

Next project: An XT550 that I bought along with an spare frame/engine and suspension off of a yz and many other parts. The bike is two states over so I will have to go pick it up sometime. Stay tuned!

Here are some pics I took the night I got her running, it was dark out so the quality is not the best. I will post more soon.







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  #33  
Old 25 Dec 2008
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If you look closely at the last picture, you will notice one of the valve covers is missing. Well, the oil pressure is so good that it blew it off! It'd been cracked by someone else previously and I tried to JB weld it while I'm waiting for the new ones. Didn't hold up too well but I sure was pleased to see the stream of oil coming out of there!
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  #34  
Old 3 Jan 2009
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did you reuse the original cylinder head or did you have to buy a new item?
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  #35  
Old 5 Jan 2009
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Quote:
Originally Posted by xtaddo View Post
did you reuse the original cylinder head or did you have to buy a new item?
Yes, I did. The surfaces weren't scored too bad so I decided to reuse. The cam was still in spec even. I will probably replace the camshaft once I can find a used one in good condition.
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  #36  
Old 5 Jan 2009
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Update
I rode took the bike for a 20 mile run today, it was all my fingers could handle before the froze! It runs good, and strong. Engine is smooth and quiet, bravo! Here is a picture from earlier today:




To do list:

- Paint all plastics
- Find side covers (anyone have some they want to sell?)
- Change oil and keep riding it!

Thanks to all of you for your help!
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  #37  
Old 5 Jan 2009
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Nice job. What are you going to paint the plastics with? I fancy doing something similar with mine, but I have never painted plastic before, only metal. Do you need special flexible paint? I'm serious.

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  #38  
Old 5 Jan 2009
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Quote:
Originally Posted by BlackDogZulu View Post
Nice job. What are you going to paint the plastics with? I fancy doing something similar with mine, but I have never painted plastic before, only metal. Do you need special flexible paint? I'm serious.
Thanks!

I'm going to use Krylon Fusion, a spray paint specially made for painting plastics. It works real well if you take your time and do it right. I like to do a base layer, let it dry for 24 hours, wet sand with a really fine grit (500-600) then apply another layer of paint. Let that dry and wet sand again if you need to. When you're finished with all the layers it's good to let it sit for at least 4-5 days in room temperature so that the paint will last you for a while.
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  #39  
Old 5 Jan 2009
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Thanks for the info. Does this stuff need a primer?
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  #40  
Old 5 Jan 2009
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Quote:
Originally Posted by BlackDogZulu View Post
Thanks for the info. Does this stuff need a primer?
No primer needed, all you need is a clean surface!
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  #41  
Old 6 Jan 2009
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Great news. Will investigate! Thanks.
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  #42  
Old 12 Jan 2009
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since you seem to be such a great photographer, maybe you could show some of us plastic painting newbies how its done in picture format?

Appreciate the great thread! Keep up the good work!

JAMES
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  #43  
Old 12 May 2009
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2500 miles later...




Notice the replacement side cover?



I rebuilt the bike when it had 5535 miles and i'm going over the 8000 mile mark today. The bike's been running great, with no issues, really. Only thing i've come up against is a knock that happens when the engine is really hot and I go to start it back up and while riding in the rain one day it stalled on me but it started back up and I made it home no problem. It's a fun bike and my 2006 TE610 has been neglected the past couple of months because this bike inspires me to just go! Plus the seat is 100X more comfortable on the XT than the TE.
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  #44  
Old 12 May 2009
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Hi Olas
Thought this might intrest you for your YZ /XT project
www.schotterfun.de - Heos
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