XT600E - All mods explained with pictures.
 

Iv spent about 6 months prepping and researching upgrades and mods for my 2003 XT600E. Its finally finished so I thought id show you guys some pictures and explain what Iv done. If you want to know where I got anything, then please PM me.

http://www.tedmagnum.com/gallery/alb...28Large%29.jpg


Firstly I fitted an oil temperature guage as oil temp is critical in the hot climates I will be travelling. £30

http://www.tedmagnum.com/gallery/alb...28Large%29.jpg



Next came the modified CRD bashguard from David Lambeth - £90

http://www.tedmagnum.com/gallery/alb...28Large%29.jpg


I decided on an SW Motech Centre Stand as its great for oiling the chain or removing the rear wheel £100

http://www.tedmagnum.com/gallery/alb...28Large%29.jpg

Took me 15 mins and is very stable.

http://www.tedmagnum.com/gallery/alb...28Large%29.jpg

Dashboard is APICO risers with Renthal far bars. I fitted a brace for the touratech lockable mount for the Garmin 2610 GPS. You can also see a 12V accessory socket. GPS is wired directly to the battery as is the socket. Both with inline fuses

http://www.tedmagnum.com/gallery/alb...28Large%29.jpg

http://www.tedmagnum.com/gallery/alb...Large%29~0.jpg

Handguards cost £30 and a replaced the horrible hard grips with a softer compound.

http://www.tedmagnum.com/gallery/alb...28Large%29.jpg

I bought a Quill Stainless BS marked exhaust from ebay for £100. Best bargain yet ! Its road legal and not too loud but its a little louder than the AWFUL original can. Its about half the weight too and wont rust.

http://www.tedmagnum.com/gallery/alb...28Large%29.jpg


I replaced the seat bolts with these. Makes getting the seat on and off a doddle.

http://www.aavplastics.com/m8bolt.jpg


The Tank is a 23L Acerbis which is also available from David Lambeth or Touratech. The sheepskin used to be a rug and works wonders for your bottom.

http://www.tedmagnum.com/gallery/alb...28Large%29.jpg


11/05/07 Fitted the Gorilla 7007 alarm. Its direct to battery and seems very good upto now. Cost me £50 direct from the states. Its connects straight to the battery and has a velcro mounted tilt senor. The unit also detects knocks. Only comes with one fob but they are available for $16. Upto 3 can be used.

It fits perfectly where the original binned tools went. I swapped the battery and tool rubber straps around for a better fit.


http://www.tedmagnum.com/gallery/alb...Large%29~0.jpg


I fitted a genuine yamaha rear rack. I think its one of the best out there.

http://www.tedmagnum.com/gallery/alb...Large%29~0.jpg




I also got a 550lb Spring from David Lambeth.#

Nice pics. Once you've got the MM's on, you'll be ready to come down to Spain for a test ride :mchappy: .

We met a guy today in the village with Givi's on a Tiger, but when he saw our MM's, he was sold on them - you won't be disappointed.

Ted- v nice but it looks WAY too clean, go get it dirty!!

Yer far far too clean. Iv only just finished it today as was waiting for the shock spring.

Give it twelve months and it will be a rat bike :)

Hey Ted when are you going on your trip!

Hey

Well now my debts are cleared and the bike is prepped, im saving £500 a month so its looking like the second half of 2008.

Hi Ted,

Your bike looks ace! And very familiar! (mine's got the same centre stand and same tank and is the same blue from the same year!)

You should see mine now though! A bit scruffier! :(

I like your seat bolt idea, that's one thing that really bugs me!

Will pm you about that sump guard, can't quite spring for the TT one! (£150)

Matt

Hey Ted
I also ment to ask where you are going! How wide is the center stan? I would really like one on my TTRE!
Cheers George

Tedmagnum
quick question about you're handlebar clamps

Did you buy the complete replacement fat bar clamps and get rid of the original yamaha clamps, or are they the type that sit into the original clamps and raise the bars up by a inch or so?

Thanks

I couldnt find anywhere that made the risers for the XT so i got the APICO adaptors. They sit in the originals also raise the bars about 1.5" which is a bonus.

The fat bars dont need a bracing clamp. I put one on solely to hold the Touratech GPS mount.

Hi Ted,

Have sprung for a bash plate fron Dave Lambeth. For info. to others considering one: the price has gone up to £115, however this includes VAT, fixings (oversized to standard) and delivery within the UK.

Spoke to Dave, seems like a good bloke, gave me some good advice about what was and what wasn't worth doing on the XT. :)

Once I get a sheepskin sorted our bikes are going to look like 'before and after' pix! :))

Matt

Replacement Seat Bolts
 

Ted!

Where did you get the replacement seat bolds from?

I've had a few ideas of my own, which involved welding butterflys to some 'normal' bolts - but your solution is much more practical.

I just can't find a supplier out here in sunny Spain.

---
Smokin' Lizard.

Hey Matt. Its a good bash plate, you wont be dissapointed.

Daves very knowledgable about the XT but remember its all about personal preference and what feels right for someone isnt right for another.

Get some cash sorted and we can show off our blinged Xt's off in South America 2008 :)

Hey smokin.

I was looking around myself with little luck. I posted the same question on another forum Motorcycle forums, news, articles, biking and events from Visordown.com, and someone posted me some. He said he had them off an old clothes rail..

They are pretty common in many applications. Think about cupboard door knobs, knob handles for clothes racks, weight benches. Anything thats adjustable by hand really.

That picture i use was for demonstative purposes and I found it here.

Standard Plastic Parts

Scroll to the botton of the page. Make sure you get the correct thread size though.

seat bolts
 

good idea those seat bolts, I use these stainless steel one's for two years now:
Knurled thumb screws Plastic with St. Steel male thread GN 421

Finished off with some lovely Metal mules.

http://www.tedmagnum.com/gallery/alb...Large%29~0.jpg

Im going to refit my screen and do some dashboard adjustment.

I will post up pics when its finished.

Mmmm
 

Nice disposable BBQs

:clap:


Jess is looking hot! (all that TLC's gotta be good for her)

Front mudguard for XT600E
 

Do any of you guys know of an aftermarket lower front mudguard for the XT600e that will stop all the crap being thrown up onto the engine?

This is definitely the most annoying, rust creating part of this bike.

Any ideas

Ste

Fornt Mudguard Extender
 

Hello,

I have just done this mod to my xt, the bit you need is called a - Flap, Front Fender, part no 3tb-21521-01. I got mine from honda kawasaki suzuki yamaha motorcycle parts (netherlands) costs around 22 pounds delivered.

Easily fitted and perfect for stopping muck getting thrown over the exhaust studs and over the engine etc.
Hope this helps.

XT600E front fender
 

Hi Andy,

Thanks for the information. Do you have a photo of the fender on your bike?
The web site you mentioned doesn't have any info. How does it attach to the front forks?

Ste

XT600E Front Fender Extender
 

Hello Ste,

The part i mention in my last post is a genuine yamaha part that you fix on to your existing mudguard, to extend the mudguard down in front of the engine by approx seven inches(175mm). it is moulded in the same shape as your mudguard so is a perfect fit and is easily attached by three small pop rivets(i used small stainless bolts and nyloc nuts). Wonder why they were not fitted as standard?.
If you goto Smokin` Lizard downloads - parts catalogue, (very handy)you will find a picture in section D4- i have`nt got a digital camera.
Hope this makes it a bit clearer.

Andy.

Thanks Andy for the explanation. Does this extension really stop the crap from hitting the engine and lower frame, I guess not but it must help!

Each and every XT I have seen has the usual water/gravel blasted rust on the lower frame and after riding in rain has eventually caused me electrical problems, due to the water being thrown up and onto the frame and around the underside of the tank. BMW have a lower front mudguard on the GS and I managed to cobble one together on an early XT that did the job really well (cabled tied around the upper fork legs) but looked naff.

Ste

Hey up Ted
would it be cheeky of me to copy some of yer modifications ??
I will tell folk who's bike bits I have copied
Any more pictures of the centerstand would be helpful
I can see it fits around the suspension pivot, but what does it bolt to, and what does it stop up against when lowered, not engine casings I guess
I will post my mods very soon, feel free to copy owt yer see
Good look with your travels
Mick :D

of course you can matey !!

Ill try and sort more pictures of the centre stand. Its great and VERY useful. There is a stopper built into the design on the stand.

Trust me. Easy to fit and very safe and secure.

XT600E '03 mods
 

Hello people! The mods I did on my XT600E '03: bashplate(CRD), centerstand(SW-Motech), handlebar-risers(SW-Motech, 30mm), iron-braided brake-lines(Goodridge, front&back), Hyperpro springs(front&back), K&N air-filter, CRD-exhaust, Hepco&becker luggage-rack and alu-boxes, tyres Metzeler Tourance. Things to do: seat(for more long-distance comfort), handguards(Acerbis), large fueltank(23lt. Acerbis), eventually GPS equipment. XT-greetings, Hans van Langen.

XT600e Screen
 

Just thought I would mention that I have fitted a MRA Customshield. The fitting kit and screen went on no trouble. My bars are totally standard and excepted the kit ok. The screen needs two new holes but performs well.

</title><Actinic:BASEHREF VALUE="http://bikehps.demonweb.co.uk/acatalog/"/><meta name="ACTINICTITLE" content="MRA Screens for Naked Bikes"><meta http-equiv="Content-Type" content="text/html; charset=iso-8859-1"><script language="JavaScript"> </script

Ste

As requested I have taken pictures of the SW-motec centre stand in the upright position, new dash with RAM mount GPS and my fuel line set up and the official Yamaha fender extender.

http://tedmagnum.com/gallery/albums/...28Large%29.jpg

http://tedmagnum.com/gallery/albums/...28Large%29.jpg

http://tedmagnum.com/gallery/albums/...28Large%29.jpg


http://tedmagnum.com/gallery/albums/...28Large%29.jpg


http://tedmagnum.com/gallery/albums/...28Large%29.jpg



You can see the pictures in more detail here.

Ted Magnum - New XT600E - Travel Bike

Just a word of warning about the screen, the mountings will come loose regularly-even with loctite, and it will eventually disintegrate. My wifes did in Patagonia. The bolts are not metric by the way so spares may be a good idea.
Not saying it's crap, just that it may not last as long as you would hope. I have a secdem paris dakar screen on mine and it's still hanging in there after 40 odd kkm.

god, tell me about it. What a nightmare it was getting a hex key to fit in. I ended up grinding down a 4.5 to fit the bolts and the pitch is imperial too...

Grrrrrrrrrr. Ill be using Blue loctite on it. Usually reserved for cam gears ;)

Bar risers
 

Hi would those bar risers work with standard bars as I want to lift mine up a bit so my XT matches the riding position of my TTR:Beach: . Cheers Stu

Sure of course ! The standard bars are 1". Just make sure you get 1" risers.

How much was the tank & spring
Kev

Prices were on the first page but just for you !!

The tank was about £200

http://www.racespec.co.uk/rs_shop_final/enter.html

and the spring about £60 from David Lambeth.

One thing I tried to do on mine was change the mirrors so I could see past my shoulders :censored: ! Replaced the small, square OEM mirrors with rectangular, "universal Yamaha", black plastic "flag" mirrors. Better, but not much. I just ordered M10x1.25x45mm mirror extensions from Motorcycle and Scooter Mirror Extensions. My plan is to separate the OEM mirror head from the base, and insert the 45mm extension in between (like the Web site's photo on a Suzuki DR650). The extension will not work to raise the mirror (due to the Yammie's right/left-hand thread combo), but that's OK with me. I'm also ordering a seat cover from Sweet Cheeks* seat cover (once I measure the seat) to widen the seat for me instead of looking for a Corbin.

Just found this thread from last year...

Its crazy lol... The amount of time and more importantly MONEY that I spent was mad..

So, now im back and I battered the bike I can say with hand on heart what I wish i hadnt done to the bike..

1. Gorilla alarm. It drained the battery at a phenominal rate and went off all the time. Piece of junk. Just get a cable lock.

2. Fat bars and risers. Not neccessary and makes repairs and adjustments auwkard. Let alone fitting accessories to the oversized tube.

3. Metal Mule luggage. Im a softbag man now !! 10x cheaper and lighter and not a repair nightmare after a spill.

4. 12v Socket.. used it once in 7 months to charge my walkman. Only £7 though :)


I have to say that the centre stand, bash plate, brush guards, big tank and screen are the only mods anyone really needs for the XT. Sheepskin was needed for long days too.

Happy riding.

Hi Ted, thanks for the update. I am preping a 2002 XTat the moment for next summer and will be taking your latest advice. Do you have a trip report from your last trip? Andy

I have just found this thread and even if I'll go with a ttr and not an xt this was helpful. Especially the part about the luggage.

Hard or soft luggage is one of the questions that has the potential to basically paralyze me, not to mention keep me up at night...

Cheers mate!

Go Soft
 

I got hard boxes for my TTR, used them once, got soft-bags.

the soft bags full weigh the same amount as the boxes empty.

shaun

My blogs in my sig mate.. Touring Ted

Nice one Ted, read your set up thread just after you had departed, and checked your blog out. Fantastic that you also took the time to tell us about the 'in hindsight'.

I was looking at mods that would improve an XT, so your level of detail and the photoes were spot on.

I had issues with my alarm on a road adventure 10 years back, and haven't used one since. I had European breakdown assistance then, but still lost two days of my trip. The chain weighs some, but then that's re-assuring in itself!

I had opted for soft luggage too, but that's because green laning I've had my leg kicked off the peg, and if a bit of hard luggage was behind my leg, it would have nowhere to be kicked off to, if you see what I mean. It really would have been wedged between a rock and a hard place.

I still fancy the 12v socket, but like you, although it's an incredibly useful addition, I may not use it. Surely you charged your phone on it though?

:oops2:Hi Ted, i realised after i posted the reply that you had a blog link, Friday afternoon brain fade.
i have already bought some soft luggage for my XT, did you have any problems keeping your soft panniers off the exhaust and out the back wheel? I was going to make some sort of bracket / guard for them, do you think this is needed? Andy

So now I've got her. I'm glad you spent all that dosh Ted, and not so glad that you "battered" her; you didn't tell me that bit...lol! And that bloody screen all but disintegrated.

I love the sheepskin and the noise; and so does everyone else!

Just finished prepping her for another jaunt up to the Carribean Coast - how is the weather in Blighty, by the way? ;)

Well, I left the metal mule pannier rails on the bike which kept the panniers off the side and gave them an anchor point. If i had another XT and used soft bags, i would deffo build or buy a steel rack system to do that again.

I think it is needed as the exhaust sits high on the XT..

haha I been "battered" in a passionate and almost sexual way lol :scooter:

Way to make me jelous man.. weather here is un shockingly awful. Overcast, windy, rain and now its getting bloomin cold !

I think id much rather be heading up the Colombian coast watching life and chicas ! :)

p.s. I told you to keep those screen bolts tight.

Thanks a lot, Ted! There I was with my new (to me) XT600E, happy to be back in the XT fold after years on sportsbikes and tourers, and satisfied with the standard product: XT for the winter commute, ST1300 for the longer trips. Now I am looking at spending at least another grand bringing it up to spec so I can tour on the XT as well. The shopping list is growing. If only you hadn't started this thread!

XT600e & Quill exhaust
 

Hello.

Dragging up an old but very interesting thread with my first post here. Ted, that was a great looking bike you had there, I remember reading about your travels on/from Visordown.

Anyway, to get to the point of my post. Ted, did you ever get the Quill pipe working well? I read on another thread about the fuel consumption issues you had with it. I ask because I am just putting back on the road an XT and one of the things I am changing is the exhaust. I think I might follow your lead in terms of rack, fender extender and centre stand, BTW.

Cheers,
sloth :)

(I'd have sent a PM but I haven't earned that right yet!)

Hey there..

The quill pipe worked great.. No complaints whatsoever.

I can't blame it for fuel comsuption as I never really knew what it would be with the standard.

What killed my economy was having heavy metal mule boxes full of junk, far too much weight and refusing to ride any slower than 70mph anywhere.. lol.

Another guy on an older XT600 got the same MPG as me so I dunno !!

As for the mods, the centre stand and rack are good ones ! Don't bother with the rear shock, alarm or aluminium luggage.

Ted :thumbup1:

Cheers Ted, that's useful information. :) I shall get a Quill can ordered then (I've already got a set of those Devil pipes from Kedo that are mentioned in another thread on here).

I've had one fight to get the thing onto my motocross stand, which then made a funny wheezy noise and would not lift the XT more than an inch :(, so the centre stand looks like a real boon. I suppose I ought to make sure I can get the thing to run before I spend much more money on it though!

Daft question, but why does the fuel hose tee off from tank & carbs then disappear up into the "unknown"....?

The tank has 2 taps on opposing sides. The "unknown" pipe is dissapearing to the othe side of the tank. Bit of a pain but helps get down to the dregs..