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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 21 Jan 2009
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Xt600e falling apart

Hi all,
I'm currently in Brazzaville, The Congo and after a gruelling few days to get here the bike I think is falling apart.

The airfilter came loose quite a while back and not looking it has been sucking in dust so now the oil consumption is sky high and smoke constantly comes out the exhaust, hence I'm having piston rings sent from the UK, if the bore is scored then I'm stuffed. Any advice on replacing piston rings!

The starter motor works when it wants often requring a tap with a hammer to free up whatever inside is jamming, so a strip down and clean is required


The Monoshock, HAGON, lasted for less than 4 months and 20,000kms with the damper failing so now the bottom pin has well and truly jammed in, if not bent and is going to need a bloody large hammer and a new one making. I've had the stock shock sent out to me but the removal of the pin is the problem. Aaargh.

The Touratech panniers are being held on by straps, with large splits in the alu from the mount points, the locks have failed, the waterproof seals are no more and the bottom spot welded seals have failed too, the bike has been 'over' numerous times and has been crashed 3.

Just thought I'd let you know
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  #2  
Old 21 Jan 2009
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Good luck ..

Sorry to hear all that Geoff ... some unsolicited advice:

- Piston / piston rings: if the oil consumption is manageable, I'd recommend not to touch the engine. As long as there is enough oil in it (a friend of mine was in a similar situation and just checked and topped up oil every hour / 100 kms) it will keep running. You do risk damaging more / creating more problems opening it under primitive circumstances, without good gaskets etc
- Starter motor: as you say, clean it (the brushes) and it will be ok
- Shock: definetly something to take care of
- Panniers: I am sure you can find a guy there that can patch things up. Watertightness could also be achieved with plastic bags ...

Are you heading South or North?
Going North your first chance of parts will be Spain ... going South here are good shops in Windhoek.

Auke
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  #3  
Old 21 Jan 2009
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Fun

Sounds like you're having an adventure anyway - at the moment I'd prefer to be on a knackered bike in the Congo heading south rather than riding a healthy bike around recession doomed Blighty
Chin up - anywhere were we can read your story by the way ??
cheers
Dick
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  #4  
Old 21 Jan 2009
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Geoff:

If the worst comes to the worst, have a look at the link on this thread that I posted last week. Remarkably good advice in a remarkably easy to follow format ....

http://www.horizonsunlimited.com/hub...-helpful-40134

HTH, and best of luck...
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  #5  
Old 23 Jan 2009
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Repairs 2/3rds done

Hey folks,
Thanks for the replies. I've managed to remove the shock pin only after completely removing the swing arm with it still attatched and beat the shit out of it with a larger hammer I bought, Boy was it corroded! My fault for not regreasing it when fitting the new shock. The hagon unit is shot so the stock shock sent from the UK is on.

The Starter motor was black as the ace of spades inside. Again probably my fault for not realigning it correctly when I took it off in Dakar, a good clean, lube and it's running like a dream.

the piston rings aren't here yet, So I'm still in mind as to whether replace them once they've arrived or leave it but there's over 2,000kms to go from Brazzaville to Namibia!! Once ther I'll get a shop to check it over and do necessary repairs.

Pics and stories are on the blog, www.horizonsunlimited.com/tstories/geoffshing if you want to read as to how somebody can bumble their way through Africa North to South. I'm wanting to go around the world but may have to take a break, get some ddosh, buy a newer bike and then continue! LOL All part of the adventure!

I'll keep you posted!
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  #6  
Old 24 Jan 2009
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rings done!

I decided to go for it and change the rings, I've just received a 3 month extension on my visa so if it all went pete tong then I could wait it out.
The head was a pain in the arse to get off with hundreds of bolts I was constantly fearing would shear to get off! All went well, new rings fitted, valve alignment and it started the first attempt! It sounds a bit dodgy on the top end, maybe the valves are out by a bit, I don't have the adjustment tool for them. But it works! No smoke and the condition of the bore and piston were great, smooth as a babys arse!
The whole job took 9 hours, it was my first time doing rings so i took it easy. and doing the job with the engine still in the frame is a pain with REALLY difficult bolts to remove.
But as long as it doesn;t blow up on tomorrows test run I'll be really happy I managed to do the job in the Congo! Plus i'll have to worry about the bad sunburn I got whilst doing the job! Oh well!

I'll post pics on the blog tomorrow, I'm off to get pissed now!
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  #7  
Old 26 Jan 2009
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Hi Geoff,

Great to hear your getting the bike sorted and on your own merits! It will make the trip all the more memorable and satisfying.

I guess your from Edinburgh - yeah?

Best of luck for the remaining travels.......................west/ central Africa dont you just love its shear madness............

Regards Sam.




may the sun always shine in yer face and the wind always blow on your arse.
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Old 26 Jan 2009
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Edinburgh

Hey mate!
Yeah the trip has been a ball, difficult but as you said it'll be memorable! I'm originally English but lived in Edinburgh for 9 years. i'm an expat and have worked abroad, mainly in iraq as a bodyguard for the last 5 years so i'm not really scottish and 1/2 english, kind of strange really.

The trip is great, are you planning something yourself? You'd be amazed at the people you meet!

I have a blog if your interested..? www.horizonsunlimited.com/tstories/geoffshing

Take it easy and ride in the rain as much as you can, if you can do it well you can do anything! One of the things I remember well!
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Old 27 Jan 2009
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Keep going, Geoff! You're doing bloody well and it would be a shame if you didn't make it at least to Cape Town.

As for the XT600E, I have an '02 model and have never agreed with the comments from some HUBBers, like kentfallen, who seem to think the bike is bullet proof and hardly provide a useful and balanced opinion at their best.

As you know from working for Aegis, nothing is bullet proof; everything has a weakness. My XT hasn't fallen apart, but i've spent a freaking fortune replacing worn out or poorly performing parts. In my view, the old XT is over rated. Don't let the old hunk of Jap metal let you down: you're now an XTguard.

Good luck on the repairs. Safe onward journey,

Mike
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Old 27 Jan 2009
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Hey Geoff,

Had a quick look at your blog bring back some great memories.........................

I rode from Dumfries to Cameroon via the west coast route in 1997 in the good old convoy days have to admit was the best time of my life - take your time with your trip and savour every mad moment it truly is the only place to get adventure proper now.

When I rode down i was heading to Cape Town but there was a lot of civil unrest and was refused entry to CAR on more than one occassion, so ended up staying in Limbe Cameroon for two and half months! If you get the chance to visit Limbe do it and stay a few days its a great place to take it easy, the Wildlife centre was worth a visit back then but not sure about now. I enede up doing voluntary work there.

Will keep an eye on your blog pal, keep us posted of your progress.

All the best Sam.
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Old 30 Jan 2009
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valves

You can adjust the valve clearances with a feeler gauge. You don't need a special tool. Just take your time.
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