XT600e starter removal
 

Sorry if I'm being stupid but what's the best way to get the starter motor out of my 2003 600e? The manual says exhaust off and take it out that way. I don't think the exhaust has ever been touched so thoughts of snapped studs/bolts and stripped threads fill my head. The other option looks to be by removing the carb - a pain but just time consuming. (It's definately the starter. The battery and relay are fine. The starter doesn't work even with direct power to the terminals)

Probably the easiest way is to remove it together with the left hand stator cover, you have to drain the oil first, or just lie the bike on its side. Make sure you have gaskets eady to replace.

if you take off just the starter motor, then the exhaust must come off, and you also have to undo the circlip on the magneto side, under a small cover, above magneto. There is also a paper gasket there to look out for, if you dont have a spare one.

Remove exhaust and you have acess out, dont bother removing stator cover. Mine was stuck so you maybe have to remove carb to get the best acess to remove. If its stuck use a socket over the starter drev and give it a little knock.

yeb, take the exhasut of. You can spray penetrant oil on the bolts, nuts, and also on the flanges that sit against the head, as that can corrode stuck, in the days up to the operation, and see if it does anything.

Lucky
 

Thought I'd update and also another question. The exhaust come off very easily.
:D
I had other jobs to do so just kept spraying the nuts every day till now. I suspect it had never been touched so was still at factory torque rather than gorilla torque. I won't use the old nuts. Should I get new originals or use brass nuts? I can't find flanged brass nuts so it would have to be nuts and washers.

I bought oem nuts from boats and used stainless steel studs. I had to drill mine out though so no choice but to replace. I wasnt sure what size and type of nuts i needed so thats why i stuck with original.

Bill

They are simple M6 nuts with a standard (coarse) thread so easy to get.

My header bolts on the TT600RE (same lump) were seized and totally mashed, so I had no option but to remove the carbs, which was a total pain in the arse. The rubbers on the manifold outlets tore so be careful.

Yeah i realise that now but at the time i was removing them i thought id place safe and use oem nuts and studs. I ended buying stainless steel studs as well and used them with the oem nuts.

Bill