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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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Old 23 Apr 2012
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Join Date: Aug 2004
Location: dublin
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XT Rebuilt


That's it I Just put the my 98 XT 600 apart after 110 000 km...I just started to rebuilt it, first was the front head bearing, the fork spring and seals, then swing arm bearings, and all bearing for the shock.

Removing all the rust, primer and black satin for the frame, swing arm and fork legs. Mat black for the tank

I'm now started to work on the engine top end...valve stem seals...

I made a few pictures and will post some more in the following weeks.
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Last edited by gwel; 9 Oct 2012 at 19:33.
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Old 10 May 2012
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Join Date: Jun 2008
Location: Seville (E) / Geneva (CH)
Posts: 530
Please keep posting your progress (supported with pictures, please)!

I love to see these works and skills in action (maybe because I lack them?).

Nice job.

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Old 13 May 2012
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Hi Esteban ,

Well thanks for your interest I do what I can but to be fair the XT is so simple it makes thing very easy...

This one has a bit of history which makes me want to keep it.

Bought in Paris in 2002 at 8000 km from a policewoman!!, I move to Ireland where I now live.

For 10 years... off road in Ireland, touring scotland, wales, france, every day commute, week end....

The bike was stolen once in Dublin and recovered 3 month later...by the police.

Then stolen another time a year later or so in front of my house !!!!! and found I it one day after in a field 500 metres away.

Then I left Ireland for one year and left the XT in a yard for a year but the cover burst so was left under the element rain, winter etc... but after new battery started straight away.

I crashed it once left the mountain road on one side of the road there was the moutain , I wasn't paying attention..and you know it's dangerous....driving your motorcycle with the cliffs the turn and stuff, was doing only 60km/h and sudenly I made a sharp turn there was a 2 metres ditch,I took off flew into the air and landed in the field I was lucky land flat on by belly the bike was burried halfway in the ditch and survived and so did I not a scratch , was very lucky

So in the end after 110000 km one evening it died on the road returning from work the rust got the best of the electrical and just sopped ! the fork was leaking, the front head bearing were shot, the rear shock too the brake disc worned out and so were the swing arm bearings...the silencer cracked, and the rear part of the frame!

the seat vinyl opened, the carb intake leaking... the engine though still going strong not a problem making smoke... at start but ok

I was looking at Kedo to rebuild engine but even though German work will be perfect, it's bit steep for my wallet. Bring the frame for powder coating, carbs for ultrasound cleaning....

But I thought f**** it will do it myself, spray can for powder coating, petrole +tooth brush sand paper elbow grease for sand blasting

Bought some polishing kit from the internet to work on engine...so I hope will get good before after picture...an all other rusty bits

Valve work soon...will ad some pic tomorrow.

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Old 14 May 2012
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Interesting story !
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Old 14 May 2012
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Today i fitted the swing arm.

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Old 14 May 2012
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With a bit of time left started to de rust the exhaust header, that would be the first stage before I start the proper polishig, but already looks much better.

And looked at tthe sumpguard as well
Attached Thumbnails
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Old 15 May 2012
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mine has 87000, on the odometer, and I bought it only last december, so I want to ride her first but would like to do a similar Job.
looking good.
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Old 29 Oct 2013
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Location: scotland
Posts: 50
I have 41 kms on mine and it BADLY needs an overhall,
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