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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 7 Feb 2008
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XT600 prep: How to improve long distance performance & reliability

As per the 'how to lighten the bike' thread...

Please help us to make a "Definitive Bike Prep" list for XT600s, since we've bought two, and will be prepping them this year.

Soo - next question is:

What modifications have you done/ would you recommend, to IMPROVE LONG DISTANCE PERFORMANCE of an XT600?

Please tell me whether you've done it, did it work, what products you used etc....

I will, again, collate all the answers and hopefully make a definitive list (for our purpose) but publish it here too, so all the ideas are in one place.

Thanks!!
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  #2  
Old 7 Feb 2008
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XT600 Mods for the Long Road

Suspension linkage:
Replace needle roller bearings and plastic bushes, with phosphor bronze bushes and stainless carriers. [Awesome Mawson- maximum bikes.com]

Fuel Filters:
Install inline fuel filter(s). Remove the shitty little filter on top of the float needle seat.
Fuel line set up http://www.horizonsunlimited.com/hub...ods#post153070 [TedMagnum]

Foot Pegs:
Get a welder to bend some flat bar around your existing pegs ,weld it and then put some notches in it with a grinder. Extremely simple and cheap to do [ Dodger ]

I made up some "extenders" for the footpegs. these took about an hour to make adding to the originals, and what a difference! mmmmmm comfy feet!!!! http://www.horizonsunlimited.com/hubb/equipping-bike-whats-best-gear/this-makes-easier-your-feet-30866?highlight=feet [Martynbiker]

Carbon Fibre Fork Protectors:
Wind spoiler GPS protector, made from 1/8 makrolon, warmed it up with hot air gun, fixed it to a bracket from indicator bolts and handlebar strut
Heated grip switch and 12v power socket bolted to the bracket also - clock just fills a space [ Mick DB1 ]

Suspension
Progressive spring in the front fork, and either have the original rear damper rebuilt or buy good quality replacement.[ FredXTZ ]

Crash Bars & Tank Guards
Manufacture german company Hepco & Becker.[AnteK] Riky Cross

Use some thick rubber sheet to attach to the inside edge of your gear and brake lever this should stop the levers bending in and damageing your engine case when you drop the bike, punch two rows of holes in the rubber and then attach to the lever useing cable ties.

Use a steel plate to protect the engine in front of the front sprocket in the event of the chain snapping it should prevent the chain knocking a hole in your motor

Oil Temp Meter
KEDO (KEDO - Performance Products) sells dipstick meters; art.no. 91037 for XT500/550/600/660 at 43,90 EUR. For Ténéré '86- art.no. 91496 at 49,90 (under side plastic thanks to the location of oil tank). [TenereHeikki]

Change Oil
I've changed my engine oil to Elf 10W-40 Moto 4 ECO Synthetic Fortified. (Solves issue of finding neutral when bike is hot) [goodwoodweirdo ]

Tyres & Tubes
when you fit new inner tubes & tyres,fit the tougher tubes IE Michelin Airstop,cut your old tube and fit it around the new tube befor fitting inside the tyre(obviously cut of the old valve)it gives double protection [unknown]

Seat
Cut the seat foam out of the middle of the seat,buy some tougher foam only wider and not so deep,cut to fit the hole in the seat,wrap a piece of sheep skin around the new foam,fit the old cover back on,it gives a wider and lower seat,if you add another piece of sheepskin on top it gives extra comfort.

Cooling System
Extra cooling fins for both the filter cover and the tapit adjusters

Centre Stand (SW-motec) http://www.horizonsunlimited.com/hub...ods#post153070 [TedMagnum ]

Fender official Yamaha fender extender. [TedMagnum ]

Sparkplugs
Replace with buy an NGK jetski plug cap (helps with wet riding issues) [ISWoolley]

1VJ Airbox
close the two original air intakes of 1vj airbox (above cylinder head). instead of changing the rear cap, you can simply leave the air filter box open. need to change jetting [ Klaus XT600]
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Last edited by XT GIRL; 8 Feb 2008 at 04:40.
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  #3  
Old 8 Feb 2008
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Update

Suspension linkage:
Replace needle roller bearings and plastic bushes, with phosphor bronze bushes and stainless carriers. [Awesome Mawson- maximum bikes.com]

Fuel Filters:
Install inline fuel filter(s). Remove the shitty little filter on top of the float needle seat.
Fuel line set up http://www.horizonsunlimited.com/hub...ods#post153070 [TedMagnum]

Foot Pegs:
Get a welder to bend some flat bar around your existing pegs ,weld it and then put some notches in it with a grinder. Extremely simple and cheap to do [ Dodger ]

I made up some "extenders" for the footpegs. these took about an hour to make adding to the originals, and what a difference! mmmmmm comfy feet!!!! http://www.horizonsunlimited.com/hubb/equipping-bike-whats-best-gear/this-makes-easier-your-feet-30866?highlight=feet [Martynbiker]

Carbon Fibre Fork Protectors:
Wind spoiler GPS protector, made from 1/8 makrolon, warmed it up with hot air gun, fixed it to a bracket from indicator bolts and handlebar strut
Heated grip switch and 12v power socket bolted to the bracket also - clock just fills a space [ Mick DB1 ]

Suspension
Progressive spring in the front fork, and either have the original rear damper rebuilt or buy good quality replacement.[ FredXTZ ]

Crash Bars & Tank Guards
Manufacture german company Hepco & Becker.[AnteK] Riky Cross

Use some thick rubber sheet to attach to the inside edge of your gear and brake lever this should stop the levers bending in and damageing your engine case when you drop the bike, punch two rows of holes in the rubber and then attach to the lever useing cable ties.

Use a steel plate to protect the engine in front of the front sprocket in the event of the chain snapping it should prevent the chain knocking a hole in your motor

Oil Temp Meter
KEDO (KEDO - Performance Products) sells dipstick meters; art.no. 91037 for XT500/550/600/660 at 43,90 EUR. For Ténéré '86- art.no. 91496 at 49,90 (under side plastic thanks to the location of oil tank). [TenereHeikki]

Change Oil
I've changed my engine oil to Elf 10W-40 Moto 4 ECO Synthetic Fortified. (Solves issue of finding neutral when bike is hot) [goodwoodweirdo ]

Tyres & Tubes
when you fit new inner tubes & tyres,fit the tougher tubes IE Michelin Airstop,cut your old tube and fit it around the new tube befor fitting inside the tyre(obviously cut of the old valve)it gives double protection [unknown]

Seat
Cut the seat foam out of the middle of the seat,buy some tougher foam only wider and not so deep,cut to fit the hole in the seat,wrap a piece of sheep skin around the new foam,fit the old cover back on,it gives a wider and lower seat,if you add another piece of sheepskin on top it gives extra comfort.

Cooling
Extra cooling fins for both the filter cover and the tapit adjusters

Add oil cooler

Centre Stand (SW-motec) http://www.horizonsunlimited.com/hub...ods#post153070 [TedMagnum ]

Fender official Yamaha fender extender. [TedMagnum ]

Sparkplugs
Replace with buy an NGK jetski plug cap (helps with wet riding issues) [ISWoolley]

1VJ Airbox
close the two original air intakes of 1vj airbox (above cylinder head). instead of changing the rear cap, you can simply leave the air filter box open. need to change jetting [ Klaus XT600]

IVJ Gearbox (5th gear issue)
Uprate the gears or fit a 96 onwards XT motor. (not interchangeable) [David Lambeth]

5th gear shouldn't be used below 4000...4500 rpm. avoid hard accelerating from low revs. always try to keep revs between 4500 and 5500. use secondary ratio 14/40 [KlausXT600]
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Last edited by XT GIRL; 8 Feb 2008 at 04:55.
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  #4  
Old 9 Feb 2008
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Quote:
Originally Posted by impasto View Post
......
IVJ Gearbox (5th gear issue)
Uprate the gears or fit a 96 onwards XT motor. (not interchangeable) [David Lambeth]

5th gear shouldn't be used below 4000...4500 rpm. avoid hard accelerating from low revs. always try to keep revs between 4500 and 5500. use secondary ratio 14/40 [KlausXT600]
What is the problem with the 5th gear? I have a 3TB I believe which is a 1993 model xt600.
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  #5  
Old 11 Feb 2008
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Bamaboy What is the problem with the 5th gear? I have a 3TB I believe which is a 1993 model xt600.

From what I've read, models before a certain year which I can't remember, the 5th gear tends to break into small parts and damaging the engine...
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Old 11 Feb 2008
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Quote:
Originally Posted by bacardi23 View Post
Bamaboy What is the problem with the 5th gear? I have a 3TB I believe which is a 1993 model xt600.

From what I've read, models before a certain year which I can't remember, the 5th gear tends to break into small parts and damaging the engine...
That is nice to know!

However it has not happened yet after 55K Kilometers. It may happen tomorrow?

I will have to look on the net and see if I can find something about that.

Just looked into it, no need for me to worry. I don't have a 1VJ I have a 3TB. maybe I need to take a course on reading comprehension?
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Last edited by Bamaboy; 11 Feb 2008 at 21:50.
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  #7  
Old 12 Feb 2008
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3Tb is better,but not bullit proof

3Tb has a stronger gear box,but the same thing can happen too it as the 1VJ if you load the gears in low revs. Keep your rpm at 4500 when rideing in 5th gear.Doing this will help to increse the life of your gearbox.
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  #8  
Old 12 Feb 2008
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Originally Posted by tomwest View Post
3Tb has a stronger gear box,but the same thing can happen too it as the 1VJ if you load the gears in low revs. Keep your rpm at 4500 when rideing in 5th gear.Doing this will help to increse the life of your gearbox.
Thanks! I wish that I had an rpm gauge! My model did not come with one. I usually do not put it into 5th until after 80 kph and usually cruise at 90 - 120 on the freeways. So, I guess that I should be safe?

My gears do seem hard to change sometimes but I have had the bike for about two years and have gotten used to that. It does stay in gear and never slips out, except when I do not properly put it into 2nd gear.
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