Yah that boats.net sight is good. I like it because it shows all the other bikes & atvs that use a certain part. Its nice for cross referencing parts.

This all makes sense. I have read elsewhere that replating is never the same. I know from experience with welding that aluminum is a porous metal that will absorb oil & debris to some extant. Welding old used aluminum can be a bugger due to oil & dirt soaking into it over time.

I am glad you brought refurbishing these Nikasil cylinders up. Something I have been wondering is this; I understand why Nikasil can't be honed, obviously to do so ruins the plating. What I don't understand is why no one talks about just boring the Nikasil cylinders out & resleeving them with cast iron sleeves. Can this be done? I assume it can. I mean to say the cylinders between the XT & the TT only differ in that the XT has a cast iron sleeve & the TT is Nikasil coated aluminum barrel right? So can the TT cylinders just get bored out, sleeved with cast iron & essentially converted to a standard XT style cylinder?

The below pic is what the 1984 TT600 service manual says for gearing specs. Note that 2nd gear in this manual is saying 27/16 while the GearingComander is saying 27/17. I bet you are right. The GearingCommander has mistakes I believe.


I just did a little cross referencing of parts & I believe you are correct that there were some gearing changes during the 83-89 years. I have seen some transmission parts numbers for 83-89 XT & TT are the same, some transmission parts numbers for 83-85 XT & TT are the same, some transmission parts numbers for 86-89 XT & TT are the same, & some transmission parts numbers for 83-89 and even newer into the 1990s XT & TT are the same. When I have a moment I will compare out all the different parts & see what I can come up with for what went where when. Considering some parts between the 1983-1985 XT550s & XT600s differ with the 86-89 XT600s while the GearingCommander says 83-89 XT600s are all the same it is a safe bet that the GearingCommander has several errors.

Does anyone have the specs for gearing on the various XTs between 83-89?

All this sounds legit. I have read this via cross referencing parts & assumed all this to be correct.

I am not sure of the difference in kicking over the too fly wheels as I didn't have the my TT with a light weight fly wheel very long. The heavier fly wheel has to carry more force as it spins just cause of the physics of the whole scenario. When I had both fly wheels in my shop I weighed them. The 1985 TT fly wheel was 4lbs 8oz and the 1986 fly wheel was 6lbs 7.7oz. I don't have the TT fly wheel any more. I wish I did. I meant to measure its inner & outer diameters. I believe that while the inner diameter is the same between the two fly wheels the outer diameter is different. That is why if a TT or XT swap fly wheels the pulse pickup needs to be swapped too. It may have to due with something else though. When I swapped the fly wheel off my XT into my TT motor I swapped the stator & pulse pickup into my TT case & everything worked fine. I have read when the pulse pickups are not swapped things don't work. Maybe it has to due with some other aspect besides external width though I am not sure.

I just want to say thanks jjrider for helping get all this together. I don't always pay attention to member names on these forums. Today I just noticed we have been conversing on these topics across two forums & a couple different threads for over a month now. By far & large the info you have brought to these threads & other threads that I now realize you had a hand in with others folks have been a huge help. Thanks a lot for the help.