New Owner Intro (49L) + New Questions [Rebuild, Brakes, Suspension]

[leicaboss]

Hey all,

Last week, I finally picked up my 1985 XT600 (49L, manufacturing date of 12/'84) - I bought it from a fellow mid-20's rider. The bike had been in his family for well over 10 years, and he actually learned on the bike. I had some hiccups registering this expired/out-of-state bike, but I'm happy to say that it's finally registered in California!

With 15.5k miles or so on the odometer, she's in surprisingly decent shape for a 30 year old motorcycle; the seat is the only area that looks terrible.



I am surprisingly excited about my XT600, especially having just sold my street bike ('09 Monster 696) - I am loving this bike on San Francisco's bumpy roads. However, due to a wrist injury and not being able to ride for the next 5-6 weeks, I have decided to work on rebuilding the motor as well as improving areas that could use them.

Please provide your advice on the following areas that I want to improve, I've spent at least 10-15 hours reading but I still have much to learn, since most of the mods apply to the later XT's:

• Rebuilding motor to "freshen" things up
• Front-end swap (w/ different bike) VS stock fork rebuild + springs, oil, emulators. The front-end conversion to a more modern bike will give me more options, in case I want to run Supermoto wheels (less likely atm). Mainly, it would let me run better brakes and improve adjustability and stiffness. I want to consider the swap vs overhauling and replacing parts on my current fork, if I'll end up spending the same amount.
• Rear shock upgrades? Seems a bit soft, even for me 170lb/77kg rider. I read about Ohlins, Wilbers, and Works shocks - but it seems that my model might not be compatible with all.
• Front brake upgrade - San Francisco is a dangerous place to ride, need to be able to stop QUICK. The newer XT can take the larger rotors and caliper adapter, but my 49L has no upgrade options besides new sintered pads, SS lines, and good fluid. Before dumping money into improving my current fork and brakes - I want to consider the front-end swap; since I have a feeling the costs might be similar and I might potentially end up being unhappy with the current system.

Having and sharing some tools with friends, I also bought:

• Clymer XT600 manual
• K&N Oil Filters (x4)
• Yamaha OEM Cam Timing Chain
• Full stainless steel bolt replacement set
• Full gasket set (made by "Athena")
• XT200 wide rider footpegs
• Adjustable "shorty" levers (somewhat small hands)

Here are things I would like to add, but it's not a priority:

• Clarke or Acerbis large tank
• Replace or fix speedo/tach
• Reupholster or replace seat cover
• Newer handlebars + controls (the old controls feel cheap)
• New exhaust, or custom setup (will avoid if it actually makes less power)

Finally, thanks so much for reading. For most of the repairs and mods, my friend(s) and I will be tackling ourselves. We have most of the tools and have access to a friend's shop after-hours. I'm not necessarily too worried about "labor" since we'll be doing the work, it's more about getting the results I need out of my suspension and brakes and the money I'll be spending on those components (whether it's a new front-end, or parts for my stock suspension).

[steveloomis]

First thing, throw the clymer manual away, they are terrible and wrong. Get a genuine yamaha manual, they are available on line for the asking.

Before jumping into rebuilding the engine, first do some tests. 15K miles is nothing. DO a compression test. Normal is 150 to 170lbs. My 86 xt has about the same mileage and measures 170 lbs.

I recently freshened up mine by stopping all the oil leaks, new seals etc. You will probably have to take the rocker box off, clean and reseal it using Yamabond sealer. While apart look at the camshaft for wear and deep scratches, look at the rocker arm faces too. If the oil has been changed and filter changed the cam will be fine. After reassembling the rocker box, you MUST set the valve clearance. All of this is in the Yamaha manual as to disassembly and valve settings.

If you have low compression, adjust the valves first. If still low, squirt some oil in the cylinder then do another compression test. If compression is better then the rings/piston/cylinder may need attention. If no change then the valves may need to be replaced. Replacing and lapping the valves is a job for a shop, just take them the head after removing it. You cannot grind the valves other than lapping them in and it may be all they need.

Good luck, ask for advice here and other xt600 forums. Plenty of folks to help you.

[steveloomis]

See below in red

Originally Posted by leicaboss

Hey all,

Last week, I finally picked up my 1985 XT600 (49L, manufacturing date of 12/'84) - I bought it from a fellow mid-20's rider. The bike had been in his family for well over 10 years, and he actually learned on the bike. I had some hiccups registering this expired/out-of-state bike, but I'm happy to say that it's finally registered in California!

With 15.5k miles or so on the odometer, she's in surprisingly decent shape for a 30 year old motorcycle; the seat is the only area that looks terrible.



I am surprisingly excited about my XT600, especially having just sold my street bike ('09 Monster 696) - I am loving this bike on San Francisco's bumpy roads. However, due to a wrist injury and not being able to ride for the next 5-6 weeks, I have decided to work on rebuilding the motor as well as improving areas that could use them.

Please provide your advice on the following areas that I want to improve, I've spent at least 10-15 hours reading but I still have much to learn, since most of the mods apply to the later XT's:

• Rebuilding motor to "freshen" things up
• Front-end swap (w/ different bike) VS stock fork rebuild + springs, oil, emulators. The front-end conversion to a more modern bike will give me more options, in case I want to run Supermoto wheels (less likely atm). Mainly, it would let me run better brakes and improve adjustability and stiffness. I want to consider the swap vs overhauling and replacing parts on my current fork, if I'll end up spending the same amount. ( You will have work to do to make it all work out, ask for advice)
  
• Rear shock upgrades? Seems a bit soft, even for me 170lb/77kg rider. I read about Ohlins, Wilbers, and Works shocks - but it seems that my model might not be compatible with all.
• Front brake upgrade - San Francisco is a dangerous place to ride, need to be able to stop QUICK. The newer XT can take the larger rotors and caliper adapter, but my 49L has no upgrade options besides new sintered pads, SS lines, and good fluid. Before dumping money into improving my current fork and brakes - I want to consider the front-end swap; since I have a feeling the costs might be similar and I might potentially end up being unhappy with the current system.

Partzilla is best price for Genuine parts.

Having and sharing some tools with friends, I also bought:

• Clymer XT600 manual (JUNK)
• K&N Oil Filters (x4)
• Yamaha OEM Cam Timing Chain
• Full stainless steel bolt replacement set
• Full gasket set (made by "Athena")( have better luck with genuine Yam)
• XT200 wide rider footpegs
• Adjustable "shorty" levers (somewhat small hands) (will make pull harder)

Here are things I would like to add, but it's not a priority:

• Clarke or Acerbis large tank
• Replace or fix speedo/tach (turn upside down, soak drive with light oil like 3in1)
• Reupholster or replace seat cover Replace, be careful. Europe model covers are different.
• Newer handlebars + controls (the old controls feel cheap) ( I replaced my left control switch with chinese made one from eBay. Actually quite good about 10 bucks)
• New exhaust, or custom setup (will avoid if it actually makes less power) (Nothing wrong with stock exhaust)

Finally, thanks so much for reading. For most of the repairs and mods, my friend(s) and I will be tackling ourselves. We have most of the tools and have access to a friend's shop after-hours. I'm not necessarily too worried about "labor" since we'll be doing the work, it's more about getting the results I need out of my suspension and brakes and the money I'll be spending on those components (whether it's a new front-end, or parts for my stock suspension).