XT600e rebuild questions
 

Hi all
I’m just finishing my rebuild of a 2002 600e, but due to the project taking longer than I’d hoped and the manual I have being not an exact match I have a few niggling questions I’m hoping can be answered.

1. On the right of the carb there’s a pipe with a barrel shaped object in the end. Can’t find a home for it - any help?
2. Bottom of the airbox, right hand side is a pipe which I think would be to the bonked off inlet manifold. Where does this pipe go? Is it just a drain now? Seems odd to leave it open.
3. I have a plastic/rubber bung, about 6mm OD. Can’t find a home - thought it was is the battery box but nope. Any ideas?
4. Do I have to cross the throttle and choke cables on the top of the bars or can the drop down own side and cross in between the trees?
5. The airbox to carb tubes show signs of sealant but this isn’t mentioned in the manual. Do these need sealing again?

Sorry for the long post - want to get this finished now.
Thanks in anticipation,
Jim
Attachment 24432

Attachment 24433

Its a breather & doesn't have a home, just cable tie it up under the tank/seat.

https://www.horizonsunlimited.com/hu...-hose-go-47965

Mezo.

Thanks Mezo. That’s one down :-)

1 yep just pass it through frame so sits on top of airbox. Make sure the small foam filter in the end is clean and oiled

2 This is the crankcase breather hose, should go to the top of the crankcase on LHS. Should be a short piece of pipe protruding from crankcase to put pipe on. Smaller hose should go to crankcase next to that hose, this being the oil tank breather hose

3 Possibly from airbox drain pipe at bottom of airbox. should be a small bit of clear pipe with a bung in it.

4 Throttle/ clutch cables? Ive never seen an XT with clutch actuating lever on the RHS of crankcase as we never got them in oz but I would think would cross over at top of bars so there is a smooth run for the cables where they have to go. You want the cables to not have any sharp bends for free movement.

5 Shouldnt be any sealant anywhere on the airbox tubes. Possibly from a previous repair?

That`s right, the second generation 600E is known as a 4PT & they have the clutch actuator on the RHS of the engine, well except for Australia,,,,Yamaha shipped the 4PT to Australia but they was all fitted with the older 3TB motors, good eh.

Essentially we got sold all the leftover engines.

Mezo.

I’m almost there, and thanks for all the help so far.

I’m still a bit confused about my 3rd query.
On the RHS airbox are 2x hose connections.
One is larger and straight and goes to the main crankcase breather.

Under this is a second slightly smaller connection with an elbow moulded in, exiting toward the centre of the bike and slightly downwards.
I currently have no idea where this goes, if anywhere.

This, and the leftover rubber plug I have are stumping me. Oh, and no foam in my carb vent - oh well :-)

ok that smaller hose from the airbox is just a drain hose that exits below the bike. It also requires a bung in the end otherwise it will suck in unfiltered air. The bung required is likely the one you have left?

preferable to have foam in the carb vent as you will get grit in the carb diaphragm area otherwise

Yeah a pity as those series 2 engines had the final 5th gear upgrade which in theory was a good thing

I’ve got the bike running now thanks to everyone’s help.

Is it right that the exhaust headers are glowing cherry red? I’ve swapped them for stainless and the originals are a thicker material which may account for it but wanted to check.
I’ve reset the carb after refurbing so I guess it could be running hot?

Thanks
Jim

Well doesn't sound too good, they shouldn't glow.

But more information is needed
Do they glow when just idling ?
does the bike run really well across the Rev range?
What's the colour of the spark plug?
if you do 10 minutes of highway does it feel like it's overheating/slowing?
the most likely reason I can think of is a clogged silencer, does the bike sound too quiet ?

Hi Turboguzzi.
I’ve not ridden the bike yet for a few reasons so cannot answer some of your questions.
Only really idled it. It revs ok, but does pop a little when rolled back off
It’s a full rebuild including carb. I set the needle on the bottom of the carb to 2.5 turns out.
I will take a look at the plug this morning.