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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 24 May 2012
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XT600E Carb Removal?

Hi,

My 2003 XT600E is leaking fuel from the carb overflow. I think it's got some crap in there from when I had to put it on reserve recently.

I've got the workshop manual and the carb removal appears pretty straightforward but we all know sometimes this is not the case. Is it as easy as the manual suggests or is it a total arse of job and should I just take it to my friendly mechanic?

Thanks
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Old 24 May 2012
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Both

Easy after a few times, but can be a bitch first time.

Theres not much to it tho. I was being way to gently trying to pry it out the first time I removed it.
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Old 25 May 2012
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If its like the older XT`s there is a method, i have a tutorial i can send you originally done by the lads in Brazil & translated by myself.

I will post it to you, check your PM`s.

And please don't go posting the links you see all over this forum, it sucks my bandwidth allowance.

Mezo.
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Old 25 May 2012
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Thanks guys, Mezo, that guide is great, thank you.
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  #5  
Old 25 May 2012
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Quote:
Originally Posted by TheBaldReverend View Post
Thanks guys, Mezo, that guide is great, thank you.
No problems, it comes out the left side & you have to swing the left intake rubber to get it out, i think you slacken the top intake bolt & remove the lower & just turn it up out of the way? i used this to guide to do mine & it worked fine.

Edit: When you go to put it back smear a bit of grease/oil/wash up liq around both rubber boots, make insertion that much easier, LoL

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  #6  
Old 26 May 2012
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Well, after riding the bike to work and back, it seems the problem might have fixed itself. I'm hoping it was the float sticking temporarily.

I suppose I'll just have to keep an eye on it, I'd rather not have to delve into the carbs unless I really have to.
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Old 26 May 2012
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just close the petcock just before you park the bike!
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Old 26 May 2012
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That's what I'm doing, but I can't help keep popping out into the garden and turning it back on to see if it will leak
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Old 26 May 2012
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Lol..

The raptor carb on my XT600E also leaks from time to time because even tho I have a fuel filter, there is alot of garbage that finds it's way into the carb bowls and clogs the valve seat, letting the carb overfill and making it leak....

Well, I always close the petcock!
AND ALSO SHOULD ALL OF YOU!

Or else, fuel vapors will go into the engine and mix with the engine oil and that just wastes the oil in much shorter time than it should!



Vando
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Old 27 May 2012
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You can also give it a firm knock or three with the handle of a screwdriver (when its leaking) & that will dislodge any grit in the needle valve.

Mezo.
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Old 23 Jun 2012
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Well a bit of an update - the overflow issue seemed to have stopped but the bike didn't seem quite right. I'm not sure if it was in my mind as I was conscious of the overflow problem but I thought I definitely heard a few light 'pops' on the overrun, like the bike was running lean, so I decided to bite the bullet and get the carbs out. It wasn't too bad, got them out in the end but have hit a snag. The pin that holds the needle valve in is a very tight fit. I had to resort to giving it a tap to get it moving. Now it's moved but sitting flush with the bit of the carb holding it. I'd hoped if I got it moving it would be easy to pull out.





Should it be that hard to get out? The only other carb I took apart was on a Gas Gas and that pin literally fell out.

Cheers
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Old 23 Jun 2012
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Scrap that, got it out but how do you get the needle valve seat out? I undid the screw that holds it in but it won't budge.

Also, the needle valve has a definite line/ridge on the pointy bit at the top, I assume from where it sits in the valve seat, does that mean it needs replacing?

Finally the inlet manifold thing that goes into the head from the carb looks like this



The rubber is coming away from the metal, do I need a new one?

Cheers
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Old 23 Jun 2012
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Hey there.

I'd suggest to change with new manifolds, you don't want the engine sucking dust and other unwanted stuff when the rubber peels off completely, do you?

That's the same problem I had, although mine was more serious (one manifold had peeled off). I ordered new ones off eBay.

Cheers!
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Old 24 Jun 2012
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The housing of the needle valve you mean? the needle should just drop out but the housing that has the filter behind is a tight fit.

Just get some pliers to it & wiggle/turn back & forth whilst pulling & it will come out, imagine pulling a tooth out.

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Old 24 Jun 2012
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Quote:
Originally Posted by TheBaldReverend View Post
the needle valve has a definite line/ridge on the pointy bit at the top, I assume from where it sits in the valve seat, does that mean it needs replacing?
Yes, it's worn out. The answer to your problem, I think.
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