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super moto xt600e
the wet weather has stopped me from going for a blast on the gixxer so i thought i'd post a thread on my super moto'd xt600e
bought the bike as a non runner as the starter clutch was slipping it already had super moto wheels on it and was not in too bad shape i fixed the starter clutch by shortening the spring that holds the cam rollers inside the starter clutch assembly. re covered the seat with some black vinyl and fixed the tail light as the old one was smashed up looked like someone had gone to far with a wheelie the plastic tail piece was trashed too http://i577.photobucket.com/albums/s...to/Photoxt.jpg |
fitted a shotgun style rear light and i cut the rough end off the tail plastics and sprayed it but the paint soon cracked it looked ok for a short while tho :thumbup1:
http://i577.photobucket.com/albums/s.../taillight.jpg it had a pro duro can on it which had a big hole and dent in it so i patched it with some aluminium plate :rolleyes2: http://i577.photobucket.com/albums/s...o/canpatch.jpg |
the plastics were a bit rough so i had covered them with black sticky back plastic but soon got some proper black ones and fitted an accerbis front fender
http://i577.photobucket.com/albums/s...ewplastics.jpg http://i577.photobucket.com/albums/s...sumofender.jpg |
the exhaust headers were rotten so replaced them with stainless headers :cool4:
i got some early model WP forks that were fitted to ktm bikes i couldn't fit the standard clocks onto the ktm yokes so fitted an accerbis headlight too :thumbup1: i made some new air scoops for the tank out of alloy sheet :rolleyes2: http://i577.photobucket.com/albums/s...o/ktmfofks.jpg |
i fitted new carbs off a suzuki 650 freewind which improved performance :thumbup1:
so i had to upgrade the front brake disk so used one off a R6 which bolted straight onto the xt hub :thumbup1: made a bracket for the ktm caliper which is a tiny brembo 1 but very effective http://i577.photobucket.com/albums/s...oto/r6disk.jpg |
then it broke big time :thumbdown:
the woodruff key on the crank sheared off and the balance shaft and conrod had a collision so hard it smashed the crankcases :( the cases are cracked all the way through to the output shaft on both sides of the engine http://i577.photobucket.com/albums/s...o/DSCF0201.jpg http://i577.photobucket.com/albums/s...o/DSCF0205.jpg http://i577.photobucket.com/albums/s...o/DSCF0207.jpg http://i577.photobucket.com/albums/s...o/DSCF0208.jpg it bent the cast iron balance shaft too :thumbdown: http://i577.photobucket.com/albums/s...o/balance1.jpg http://i577.photobucket.com/albums/s...o/balance2.jpg http://i577.photobucket.com/albums/s...o/balance3.jpg |
took the old engine out and the frame looked ok but tatty :rolleyes2:
http://i577.photobucket.com/albums/s...o/DSCF0004.jpg so i had i powder coated in cadbury purple http://i577.photobucket.com/albums/s...o/DSCF0018.jpg it looked so nice was a shame to cover it up with the tank http://i577.photobucket.com/albums/s...o/DSCF0023.jpg |
well as i'd got a spare engine i thought i would give it a good going over and do some improvement new oversize high comp piston and a few tweeks to the head
http://i577.photobucket.com/albums/s.../xt6piston.jpg http://i577.photobucket.com/albums/s...6pistontop.jpg http://i577.photobucket.com/albums/s...o/DSCF0005.jpg http://i577.photobucket.com/albums/s...o/DSCF0003.jpg |
engine back in the frame :thumbup1:
http://i577.photobucket.com/albums/s...to/engine1.jpg http://i577.photobucket.com/albums/s...to/engine2.jpg modified an r6 swingarm to fit lighter alloy rear wheel off a yzf600 :cool4: http://i577.photobucket.com/albums/s...6swingarm1.jpg http://i577.photobucket.com/albums/s...6swingarm2.jpg |
Nice project,I hope you were'nt too far from home when the balanceshaft got miss-timed.I know it's a bit of a daft question but do you know why the woodruff key failed?Thats a mechanical that I really don't want to witness!
I plan on doing the supermoto stuff with my 43F XT next year,this years funds have gone on a new gearbox/clutch late model oil pump &rebore:(.Still while it's apart I've got the frame powdercoated.. Why did you fit the Suzuki carbs,and did they fit easily or did you have to mod the airbox etc??The reason I'm asking is that I'm thinking of upgrading the carbs on my bike at a later date and I'm trying to see whats best. |
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the suzuki carbs wont work with the air box as the rubber hoses wont fit and you have to cut the inlet stubs on the head, you need to make a new throttle cable plate too. i used them cos i got em cheap and the mikuni jets are readily available and i new i would need to re jet for the bigger piston. before the engine broke i'd already planned to do a tuned motor. |
Wow. Thanks for the story and pics. What you have done to the bike is impressive
Sorry to see damage to the original engine. I can see the engine you are using now is the older version. Do you know if the internals of the two engines are more or less the same, or if they changed a lot of parts when they (Yamaha) upgraded the engine in 1996? Do you have any pictures of the gearbox from the destroyed engine? Can you see some pitting on the gears? How many KM had the engine done before the brakedown? What about the electrics? Is there a difference between the old and the new engine? Is the ignition the same? |
the new engine is still a later model bottom end so should not give any problems regards reliability the 4tp motor that was fitted internals are in excelent condition so i could probably build a new motor from them without any problems :cool4:
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WOOOOOOOOOOOOOOOOOOOWWWWWWW!!!!
OMG -- !!! I didn't even bother reading the write-up - the pictures had me in tears of despair and tears of ecstacy in quick succession!! That is the most TRAGIC crank case I have EVER seen... i think I would have needed therapy. However -- that is also the most GORGEOUS head and piston I have ever seen... coooool......shhiiiinnnneeeeyyyyyyy !!! VERY impressed with the swingarm - do tell us about the yummy rear brake assembly! What about handling? Have you taken it on the track? After answering all the above, you really should stop showing off. It's quite nauseating. :rolleyes2: |
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that piston is a wossner and its a work of art :thumbup1: the rear brake is actually off the front of a gsxr i fitted the yzf wheels so i then altered the front brake and fitted a gsxr caliper so the rear is the other one of the pair :cool4: its not completed yet so its not even been on the road its the making of the rear brake hanger thats stopped progress that broken mill is holding things up :thumbdown: the front forks were on before it went bang so i can tell you they certainly improved stability and handling :thumbup1: the swingarm is slightly longer so it should help keep the front planted but is not so long as to affect the cornering :cool4: |
the front brake and wheel were already fitted prior to the big bang and worked perfect that gsxr caliper was an absolute pleasure to use it gave great feel and had loads of stopping power :thumbup1:
http://i577.photobucket.com/albums/s...frontbrake.jpg the rear is just in mock up at the moment but it does already work well i think i'm gonna have to be carefull with the stopping power of that caliper :rolleyes2: http://i577.photobucket.com/albums/s...earcaliper.jpg |
Bike is looking fine I must say!
Tell me something... How did you manage to align the chain? What rear shock are you using and what "adjustments" did you have to make? If you could share that knowledge it would be very helpful no my project :scooter: Vando :innocent: |
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the rear shock is the same as the oe one except its got more damping adjustment. :cool4: the linkage is all original and the swingarm was modified so that it all worked the same as the yamaha original design to avoid any handling problems. |
XT oem or R6 oem? Lol :P
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xt configuration obviously as the r6 config would be too harsh and restrict movement/travel which would compromise the handling way too much.
you can't just bolt on suspension cos it looks pretty if it works on one bike it does not mean it will work on another. |
Wow that engine looks nearly as bad as mine :(
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Nice Work Wolf! :thumbup1:
Again....takin' plenty of notes here......definitely some mods I wanna try on mine. :cool4: |
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the wider swingarm and wheel will allow me to use a 160 rear tyre easily i could go wider but i think the 160 is fine and does not compromise the handling :cool4:
http://i577.photobucket.com/albums/s.../xt600back.jpg i could not find any new black fork guards so made some out of pvc guttering still got to refit the alloy air scoops i made on the tank. http://i577.photobucket.com/albums/s...frontright.jpg |
show us those damn air scoops! lol
Vando :innocent: |
i already did show the air scoop pics they are on posts #3+4 :thumbup1:
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Yes you have! my bad! I thought those were the stock plastic ones chrome painted :rofl:
Could you post a couple of pictures to show us how you made the oem rear shock fit on that swingarm? Thanks Vando :smartass: |
i just made a bracket that holds the original linkage in the correct position without drilling a hole through the swingarm like the oe one has :rolleyes2:
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Could ya try to take a picture of it?
I would be really thankfull to see how you did it looks like so I can have an idea on how to make one for my XT/ '06 YZ250F swingarm linkage... it can be just a close-up with it fitted on your bike A picture is worth a thousand words ;P Vando :innocent: |
my set up will not work on the yz swingarm the r6 swinger is a lot more beefy and gives more scope for adjustment thats why i used it :rolleyes2:
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Hi..
yeah I know that! I'm not doing one just like yours lol :) I need a custom one to fit on my YZ swingarm specs.. I just wish I could see yours so when I do have to make mine I can have a general idea of what has to be done to make one... Vando :innocent: |
i'll post a pic when i get a chance as its all gotta come out again to weld up a permanant assembly when i get myself a tig welder :thumbup1:
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That'll be even bette..
When you planning on getting that TIG? lol jk :P Thanks! Vando :innocent: |
the rear linkage is held in place with a steel bracket and braced in position from the r6 swingarm lower linkage mounting
http://i577.photobucket.com/albums/s...o/rearlink.jpg the tig welder is still just on the want list too many other priorities are taking the tool fund money at the moment |
Hey, does that swingarm have an offset rear shock mount position? I can't really see it from that picture..
Vando :) |
no its oe mount is not offset i spaced it to give it the correct positioning everything lines up correct and functions as per yam spec :rolleyes2:
except that swingarm is about 1.5 killo's lighter and i can put whatever tyre in the rear i want :thumbup1: |
Very nice thread... :thumbup1:
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Very nice build you have going there!
The pictures of the exploded motor are scary. Thanks for posting Pawlie |
thanks pawlie
that motor going bang was no fun :thumbdown: i'd recommend anybody doing a service to swap out the main woodruff key on the crankshaft, mine had completely shattered i'll be swapping mine every two oil changes a piece of key steel costs £10 and will make at least 4 keys so £2.50 a pop is a lot less than anything up to £500 for brand new engine cases plus new crank, balance shaft and full gasket set :( |
wolfzero was it the key on the flywheel side or clutch side that went on yours ?
mine was sheared off in the flywheel and the nut was not tight so i am guessing thats what caused mine to go |
woodruff key
it is the key on the clutch side it drives the balance shaft and also the primary drive gear, the reason your flywheel key is sheared is because your engine stopped so suddenly the weight and momentum of the flywheel actually sheared off that key.
if the key on the flywheel had sheared first the engine would have mis fired and stalled to a halt without any major damage, this would be due to the ignition timing not being correct as the ignition pick up is triggered off the flywheel. |
Excellent posts wolfzero.
Your bike looks great, you obviously know what your doing.:thumbup1: |
cheers steve its more down to common sense than anything else.
i just started work on a brake and gear lever set up which should save even more weight i need a standard 97 on xt600e wet bike weight to do a proper comparison :cool4: |
just started cutting out some footrest brackets out of alloy if they work out ok i'll post some details if they don't work i'll see what i can do to make em work :rolleyes2:
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Awesome thread and thank you for the pictures!! It's always interesting to see the modifications others are doing to their bikes. I'll be keeping an eye on this thread...
The engine damage in those pictures is unreal! Hope that doesn't happen to me, i'd have a hard time finding a spare engine here in the U.S. I'll be keeping an eye on that woodruff key in the future! Thanks again, Alfredo |
R6 brakes?
Hi...
I´m going to upgrade the brakes on my ´84 XT600 supermoto, and I noticed that you used a front brake disc from an R6. What year R6 was that, as I see several discs selling on ebay, but they only seem to fit a few specific R6 model years? If possible I would like to get a disc that fit´s the XT hub. What size carbs are the Suzuki´s? I have twin 34mm Mikuni flatslides fitted which have been very hard to tune properly. I hope that since the cylinder head has recently been ported it will be easier to adjust..:-) Best Regards Tinus |
late model yzf600 (thundercat) and early model r6 disks bolt straight onto the xt front hub but they are 310mm diameter so you need a spacer to fit the front brake caliper as the xt disk is a lot smaller :rolleyes2:
the suzi carbs are 32mm and were ok on the standard motor i'm still working on a correct jetting for the modded motor :thumbup1: |
Thanks for the reply.
No problem with fabricating a spacer. I´m friends with a guy that has access to a CNC mill..:-) I actually came upon a disc from an R6 at a good price yesterday on ebay, so I bought it. Hope it fits, and if not we should be able to modify it. I just got my bike started again after renovation, and I found that one of the intake rubbers was broken, which may explain why it was very hard to get the jetting right. I had drilled the main jets to 2,3-2,4mm or so, and the bike still seemed to run lean. The jets that ABP Racing in Germany delivered with the carbs was 130 and 135. I ran it for a short trip with 142,5 jets tonight, and it seemed to do ok. Regards Tinus |
yeh i've got to get round to ordering some jets i did have some old 120's which i increased to roughly 140's so i'll start at some proper 140's and see what results i get the 130's worked ok on the standard motor :thumbup1:
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Hello all and Greetings from Finland!
Nice moto you have build. Here is my rat moto: http://2yfmzq.bay.livefilestore.com/...w/15072009.jpg I think I have the same front end than you do. I made big changes during last winter. I still have some things to do like: exhaust modification and maybe paint. This is only 613cc with high pressure Wiseco, sylinder head modification and Mikuni TM34-B65 with K&N filters. You can find more photos from: Prätkät - Windows Live Feel free to comment... Best regards, SuperiorMotard |
looks like you have a lot later model forks than mine i keep looking out for ones like you have the extra adjustment on damping would come in handy :cool4:
i quite like the stealth black look :thumbup1: |
Front fork is from KTM enduro bike. Front brake is from Gasgas. Looks in my bike are stealth like, sounds are not...
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i know that feeling mine is way too loud i'm gonna have to make a db killer for it :innocent:
the to do list is getting longer as it nears completion its the finishing off thats taking so long :rolleyes2: |
been doing work on my house so the xt was on hold for a while, now the dark nights are here i'm back in the workshop:rolleyes2:
so its tweaking time again :cool4: footpegs and levers are first on the list of tweaks so i'll be posting pics as and when i work them out :thumbup1: |
i had always found the original brake lever tip a bit to small.
so i've used the tip from a spare gear shift lever so it still folds if struck but gives me a bit more to get my toe onto :thumbup1: new pegs were meant to go on my gsxr and are modified easily to fit the xt mounts http://i577.photobucket.com/albums/s...o/PICT0230.jpg http://i577.photobucket.com/albums/s...o/PICT0239.jpg http://i577.photobucket.com/albums/s...o/PICT0233.jpg |
finaly got a quality gear shift lever to fit :thumbup1:
it needed some adjustment with a vice and a spacer putting on the shifter shaft to stop it rubbing on the engine casing :innocent: http://i577.photobucket.com/albums/s...o/PICT0245.jpg http://i577.photobucket.com/albums/s...o/PICT0248.jpg |
Clean looking shift lever WZ :thumbup1:
Need to look into getting 1 of those.:mchappy: |
yz 250 lever actually but it does need some work to give it the right throw and a spacer to keep it from rubbing on the 600e's wider cases.
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new updates will be coming soon i havent forgot i've just been busy :innocent:
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Great job on the seat.
I love the tail end, I think the original number plate holder is too big and ugly, I am going to modify mine. But most of all I love the air scoops you made. You must have had training or work with metal. |
air scoops are not hard to make its all bent by hand and just trimed with an edging strip :thumbup1:
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Been looking at a few companies online selling sheet metal. Did you buy the aluminium polished or did you do that yourself? Is it 1mm thick and where did you get the edging strip? |
1mm thick is about right i had the stuff i used lying around for a while so not got exact specs. :innocent:
the trim is Panel edge trim "u" channel i got mine from a kit car shop.:thumbup1: i've not had chance to get down the workshop yet to trace them to make a guide template, the template will be slightly larger than the finished item as they need extra trimming once the bends are in. the alluminium is easy to polish especially if its new stock with the protective film on it :mchappy: |
OK, thanks for the info.
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finally got down the workshop and got hold of the template i used for making the air scoops out of a sheet of alluminium.:innocent:
the down side is its too big for the scanner :( so i've taken a pic and put sizes on in mm, the overall size for the sheet required is 330mm x 375mm. If any body wants a paper copy of the template i'll make some and send it via the post as long as you cover postage :rolleyes2: its not an exact fit but will give you a good guide to making your own and it works for both sides of the tank :cool4: http://i577.photobucket.com/albums/s...o/PICT0368.jpg |
old broken scoop and i only had this one when i bought the bike the other side was missing completly :(
http://i577.photobucket.com/albums/s...o/PICT0370.jpg ok the new bit aint brilliant but its better than nowt and i had been given the aluminium so it cost a couple of quid for the black edge trim and the other trim was left over screen trim off my gsxr :thumbup1: http://i577.photobucket.com/albums/s...o/PICT0371.jpg |
Hey, that looks really nice.
Got other pictures where you can see the whole bike with theese things on? Good job. |
Thanks for doing that wolfzero.
I ordered 2x 1mm thick 500mm x 500mm aluminuim sheets and they arrived last friday. Have cut the left side roughly to shape with tin snips. I find it quite difficult to cut, the snips get in the way and kink the metal a bit. Not like cutting paper with scissors. The plastic scoop I took off broke in the same place as yours because one of the screws has corroded into the metal thread inside the grommet. One screw on the other side is also corroded into the thread so i'll try to cut that without breaking the incredibly brittle scoop. What year of manufacture is your XT. I ask because the scoops look a bit different to mine. If it's the same as mine I will be grateful for a copy of the template. |
cheers jens i had them on the bike prior to the engine big bang, pics 3 & 4 on this thread but when i get a nice day i'll do some new shots of the whole bike.
03XT600E mines a 1996 model which is an early 4pt but should be the same as yours, its tricky to cut the internal curves i did rough cuts then trimed and filled to refine the details where required. |
I've got a 23ltr acerbis tank, I just appreciate the work you've done :=)
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latest pics of the bike complete with the home made tank air scoops on :thumbup1:
http://i577.photobucket.com/albums/s...o/PICT0386.jpg http://i577.photobucket.com/albums/s...o/PICT0395.jpg http://i577.photobucket.com/albums/s...o/PICT0399.jpg |
It is looking very impressive wolfzero.
I see you have changed/altered the front and rear footrests. I took the front/rear foot rests, rear brake pedal, side stand and gear changer off to get them powdercoated, pick them up Friday. Silver gloss. I wanted chrome effect but only a couple of places sin the Uk seem to do that. Your air scoops look slick. I know you said you used car trim on the bottom. The trim at the top where it follows the profile of the tank looks different, is it? |
Hey all!
Wolf.. do you know what you're missing on the bike?! this: Yamaha XS750 Special Kick Starter XS 750 NR 1977 77 : eBay Motors (item 250591280501 end time Mar-14-10 20:19:40 PDT) It's the kickstart I got on mine! I just don't remember the exact year but that one looks just the same! I'll be able to check it in two weeks when I head back home for Easter holidays! I must say, it is ALOT STRONGER than the XT's kickstart! and looks better! :innocent: and Yes, there's no need for the decompressor mechanism! I might be adding the decomp to mine but only because I had a partial (right) Achilles tendon rupture...better be carefull than sorry... Vando :cool4: |
03XT600E the trim that follows the tank profile is screen trim i had left over from re-dooing my gsxr750 screen:innocent:
the rear foot rests are just cheepo universal ones, the front pegs are billet race pegs that were supposed to go on the gixxer but i got another set for that:cool4: bacardi23 that kick start is no different than mine except the colour, mine is not a standard xt kick anyway its a drop forged one for a srx600 which was used in supermono racing:thumbup1: the kick is not for everyday use as i've got a heavy duty battery hidden away for the electric start :rolleyes2: i was just to lazy to stick the battery on charge the other day:cool4: |
oh ok lol...
I thought you'd like to add some more "bling" to the bike :D Have you thought of painting your XT? personally, I think there are too many different colors and shades on her.. I unno... it's your bike...you should have it the way you like her! :cool4: btw, what's your opinion on those Stebel buzzers someone mentioned around here in Yamaha-tech? Vando :innocent: |
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I just gave an opinion on how I might do it? =o
Maybe I expressed myself wrong? :confused1: In the last few pictures you posted the color of the frame to me looks a slightly different than the fuel tank.. that's what I tried? when saying different colors/shades... (maybe it was the "and" between colors and shades?) :frown: |
the frame is powder coated in cadbury purple from the boost yamaha team and the tank is a metalic purple thats a couple of shades darker than the original tank colour to bring the contrast down but keep the original colour scheme :cool:
this is still a budget bike and everything except the frame powdercoating (my oven is not big enough) has been done by me :thumbup1: |
Ho-ly sheep shit boy-o, you got a cool bike. :thumbup1:
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Ho-ly sheep shit boy-o, you got a cool bike. :thumbup1:
now that's a comment i can enjoy :tongue3: makes the project feel even better when i'm not the only one who likes the look of the beast :w00t: |
i finally got a chance to try out the beast on the road the other day:thumbup1: but it sucks :rolleyes2: i mean it really sucks i used some pipercross air filter material to make some individual filters and when i gave it a big handfull it sucked the centre's out of the filter material :thumbdown: thankfully it went straight through the engine without causing any damage :cool4:
i also under estimated how lean the carbs were running i had upped the main jets to 140's from 135's but was way off i've gone upto 165's and it runs spot on now :thumbup1: http://i577.photobucket.com/albums/s...o/PICT0409.jpg |
damn :eek3: nice to know it didn't do any harm to your engine!
I thought that material was way stronger than that... btw..the holes look very romantic? hearts? :rofl: you getting the bike dynoed anytime soon? :) |
Appologies if this is a daft question 600E with kick start did the E not mean electric only and if so is it an early side case and mechanism ????
Would be real handy for that day the battery will go flat in the middle of no where.... |
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vando i though the filter material was gonna be strong enough but it was a bit of old stock so must have gone a bit weak and when i first saw the holes i was a bit worried but then just had to laugh looks like the beast is starting to live up to its nickname :rolleyes2: its not run in yet so it will be a while before it goes for a dyno run |
Hi Wolfzero, love what your doing here and very inspirational having not long ago become the proud owner of a very similar XT to yours. Though still very standard. Don't suppose you still have the original wheels that came with your bike do you?
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sorry but my original sumo wheels are in storage for another project.
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UPDATESSSS WANTED :cursing: lol
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very nice work! you obviously know your stuff to make it sound so easy like you do.
Here's a few pics of my bike: http://urbanoia.net/wp-content/uploa...10-300x199.jpg http://urbanoia.net/wp-content/uploa...fr-300x199.jpg (XT600 Motard – so far… – bleg and Trailtech vapor dash for the XT – bleg for some write-ups) i will soon be fitting an EBC 320mm disc kit. I would like to have used a YZF-600/1000 disc like you originally did, but sadly i lack the skill and equipment (but primarily skill) to make a caliper bracket. Look forward to hearing more about your progress. Cheers, Phil |
Real nice looking bike :)
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just logged in after a few years away and wondering how many folk found my xt600 project:mchappy:
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Quite a few. Now please update bier I'm interested.
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Great project. What compression are you using? Any heat issues? What Suzuki are the carbs from? I have been working on a similar project , but have not been able to get much info on how the high compression piston performs with a stock cam or even a aftermarket cam. I was looking into using two mechanical carbs with a split cable like those used on an old RD 350 road bike. An update would be great. THUMPTHUMP
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Yes same here, have high comp piston, race cam, hard vent springs, but iam not changing unless its really make a big difference??
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Can u send me the air scoop designs for the tank? I will convert it in an AutoCAD design and post it here so anyone can have it
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looks like photobucket has stopped the 3rd party hosting so no pics.
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Amazon and eBay images broken by Photobucket's 'ransom demand' - BBC News Wayne |
@Wolfzero Welcome back buddy!
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can you please send the picture in my mail kargas13@yahoo.gr so i can convert in a 2d design and post a dropbox link here?
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