2002 XT600E trouble...
 

Hi all, I'm looking for some tips. I've not had my XT long. :helpsmilie:

I was out riding recently and shortly after setting off the bike suddenly stops firing properly and stops. :( I checked fuel taps (acerbis tank so I have 2) no apparent problem. It wouldn't start again straight away but after standing for a bit it restarted and off I went. Only for the same thing to happen shortly after. This happened several more times. Each time after a rest it would restart (battery etc seemed fine). Eventually I worked out that if I kept to low speed and throttle she would just about keep chugging along, although not running right at all. Got home.

Next morning, bike won't start at all. disconnected fuel line and fuel was coming through OK. My bike didn't come with the standard tool kit so I haven't been able to check the spark plug yet. Anyone got a direct link to a tool which fits/works well? Or can just confirm the right size?

So, what's wrong? Am I missing some obvious thing to check?

I have a feeling the bike is running very rich anyway. This is because she would bang, pop and spit some flame when I shut the throttle. Actually, there definitely seemed to be fuel because when the bike was grinding to a halt there would be big bangs/flame like none of the fuel was being burnt and it was all being dumped in the hot exhaust.

Also now and again the bike also stalls when it should just be idling. Not sure if that's connected or much of a problem? (Apart from being a pain)

End can and air filters are aftermarket. Let me know if I've missed out any salient information!

Thanks for reading :thumbup1: While the bike is in bits I'm on the bus, please help!!!!!!

I had this EXACT problem in Brazil..

In the carb there is a tiny little filter under the FLOAT VALVE SEAT (edited). You have to strip the carb right down to get to it.

These filters are prone to getting gummed and clogged. It doesnt take much to do it.

Its a common but strangly very unknown problem with the XT when you fit the Acerbis tank because the filters in the Acerbis are pretty shit...

Popping and banging is due to not enough fuel, not too much !!

So remove the carb, take off the float bowl, unscrew the main jet and (if i remember correctly) you have to full out the brass shim which holds the jet, and its under there..

Of course, if you scared of stripping your carb down this much (you really are down to tiny pieces), then a bike shop shouldnt charge you more than 30 mins labour if you just give them the carb...

Of course, you should be checking the plug and air filter first and these are quick n easy checks.

ted

Thanks, I'll start there. Need to learn this stuff sometime, might as well be now!

Hi, i have a similar problem with my XT600E 02 but only happens at low speed. The problem began 2 weeks ago while trail riding in the snow (great fun ) and now the bike won't start properly (it sometimes start with choke off but only for a few seconds). i have ordered new plug, cap and air filter. This filter behind the main jet can you buy replacements? Cheers Andy

Do you mean "Nozzle, Main 2". It's #41 in the parts fiche for the carb.

One thing to check also is the vent to the tank. We had a prankster that rode with us that would screw a sheetmetal screw into the end of the vent line when you were away from the bike. Of course you would take your gas cap off and look into the tank which would vent the tank and you could ride for a while longer until it ran out of air again. Sometimes gas caps will get something stuck in their tiny vent hole.

This was the first thing that I thought too - but then he later said that fuel was flowing freely (although some fuel would still get through with a blocked vent).

This was the first problem I ever diagnosed all by myself, with my first bike many years ago. I had given it a good clean and polish (I used to in those days) and afterwards it would only run for about 800 metres and then die. Five minutes later, all was well - until it had run another km or so. I sat by the side of the road and worked it all out from first principles. Obviously fuel, but no blockages in the fuel line. Suddenly, a light-bulb went on in my head, a cleaned out the chrome polish powder from the filler cap vent and - bingo.

The certain test is to run it without the fuel filler cap in place. If it runs OK then, you've found the problem. If not, well, it hasn't cost you anything :-)

I did try it with the fuel filler cap removed! No joy.

Your luck sounds like mine, it can never be something simple. :frown: Let us know what you find out.

Carb filter
 

Tedm is not quite right ... the little filter is not on the main jet, but on the float valve seat.

In order to remove, remove carbs, remove float bowl, remove float, remove float valve seat. Take the little f*cker off and shoot it. Slowly. And make sure to install inline filters in the fuel hoses.

Auke

AHHHH yes of course ! I remember now..

The filter prevents the bowl filling up anything more than a trickle. Hence why if you leave the bike sitting for a while, it fills enough to start and maybe ride a little...

My memory aint what It was :oops2:

So should I have a particular substance for cleaning it?

BTW Ted, after reading your blog I'm a little concerned to be taking advice from someone who electrocuted themselves in a swimming pool! :rofl:

Seriously though, I enjoyed reading, sounds like a great trip :thumbup1:

Actually, I'm still not certain that this completely accounts for my symptoms... If some fuel was getting through eventually i.e. why it started each time after stopping, then why wouldn't it start the next morning? Seems a coincidence that it would be just at that point that it blocked completely?

Maybe I have >1 problems... but what do I know I'm a mechanical dunce. Anyone hazard a guess?

Go with the dunce idea. It's safest.

It's what I always do. :thumbup1:

hahah. Being electricuted zapps my brain into life :)

Clean the filter with carb cleaner or even petrol. Soak it in it. If its really blocked then you might need compressed air.

If this isnt the problem then it could be a number of things and you will have to try them.

Like I said, a clean plug and air filter can go along way and should be the first thing you try really but from your symptons it does seem like a fuel starvation problem.

Try the filter first then post back if it doesnt work.