Noob XT600 3TB rebuild

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What Bike or Bikes Do You Own?: Honda VFR800Fi, XT600E 3TB
Location: London, UK

Noob XT600 3TB rebuild

Post by Username »

Hi folks,

So I got my hands on a 1990 XT600 3TB and Im in the proccess of fixing it up a bit. Its a backyard job
as I dont have a garage, its also my first restore job on a bike this age and I hope to take advantage of
all the great information available here and elsewhere on the web. Here's the bike:

Image

Im planning on keeping it mostly standard, with exception to the following things:

1. Aluminium rims
2. Better suspension
3. Better brakes
4. Long range tank
5. Better lightning
6. New exhaust can
7. Luggage rack
8. Plastics

Im on somewhat of a tight buget,= and will try to salvage whatever is possible but will probably splash out a bit on new
suspension parts. Ive got my eyes on a Wilbers eco line shock and fork springs. It also looks like spending is
unavoidable in order to get a good set of aluminium rims set up with the old hubs. I found a cheap long range
tank in Germany which should be here soon.

Image

I need a good XT parts supplier in the UK, I know the likes of wemoto and ebay which Ive used extensively
while fixing up my VFR. I will need things like seals, bolts and bushes, small stuff. If anyone can point me in the right
direction i would really appreciate it.

Ive started tearing down the old girl

Image

Encountered my first problem, its the same issue on both pipes. It looks like those inner bolts are
right in the path of flying debris fromt he front wheel. Id like to keep the downpipes as new ones
are freaking expensive. They will be blasted and heat coated.

Image

Really battled with this bolt, it was seized up very well. But Ive managed to get the engine out now.
I actually found a loose bolt on the swingarm linkage without a nut!

Image

I stripped a bolt on the rear hub, it literally just disintegrated. Do I just drill it out and retap the hole?

Image

I found and ordered a set of SS bolts and nuts, which I hope to use to replace some of the crappy rusted engine
fasteners. Im dreading opening the engine, as Im anticipating many more stripped bolts!

Image

So Ive got the engine and and forks off now too, this weekend I will consentrate on degreasing and cleaning,ordering
and taking stock of all the parts, see what is salvagable and hopefully be able to generate a list of critical parts definitely needed.

The motivation behind this project is this. I took a new 660 Tenere for a spin not long ago and loved it. But there is now way
I can afford one, I was qouted rediculous prices for insurance. I pay a grand total of £15 a month in insurance for this bike.
Im not hoping to build a Ten out of this bike, but Im aiming to come damn near!

I love my VFR but its thirsty, expensive and much faster than my license will allow.
My knees are also not huge fans the relatively cramped position over long distances. So Im hoping to build a fun and fairly capable
bike to take me to work and back for a penny, as well as something that can take me and the girlfriend places when we feel like it.

Thats it for now, I will keep posting with updates and questions. Thanks for reading! Here are some more random pics:

Image

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Magic*
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What Bike or Bikes Do You Own?: XT600E 3TB 1998
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Re: Noob XT600 3TB rebuild

Post by Magic* »

Good start, do not give up and good luck :yess:
Ekman
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And other brand too like Husky 250/610. And Suzuki rmx, kawasaki kx 250. Honda Atc 250r.
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Sv: Noob XT600 3TB rebuild

Post by Ekman »

Keep it up and good luck:-) I will follow your progress here. Hope it goes the way you planned:-) Nice to see that more people take care of nice classic Yamahas :-)
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Mezo
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Re: Noob XT600 3TB rebuild

Post by Mezo »

Welcome, :wave:

Engine out, powdercoat the frame, strip the engine. :nod:

Mezo.
"A wise man makes his own decisions, an ignorant man follows public opinion"
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Re: Noob XT600 3TB rebuild

Post by GeoffD »

Username wrote:

I stripped a bolt on the rear hub, it literally just disintegrated. Do I just drill it out and retap the hole?

Yeah... It's a common problem on these bikes.... drill it out (very carefully) & retap it...
The future is not what it used to be....
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Re: Noob XT600 3TB rebuild

Post by Danjet600 »

:popcorn:
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What Bike or Bikes Do You Own?: Honda VFR800Fi, XT600E 3TB
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Re: Noob XT600 3TB rebuild

Post by Username »

Thanks folks. Got all the parts ordered by type into plastic containers, and as im working outside im forced to be extra organised:

Image

Biggest job that needs doing: Strenghtening the frame where the original exhaust used to be. I will also have
to have two brackets fabbed as the tank will not fit that frame, but might go further and build a complete
carrier that fits between the frame and the channel underneath the tank. Might make a nice little storage
cubby if done right. Ill take some more pics of the frame/tank tonight.

Found some notes on fitting this tank to a 3TB here: http://www.xt600.de/xt_werkstatt/_baste ... er_neu.jpg

Then there is the seat, it wont fit the profile of the tank. Ill have to cross that bridge later...
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Mezo
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Re: Noob XT600 3TB rebuild

Post by Mezo »

One of the aftermarket exhaust guys sells the strengthening bracket for your subframe, it comes with the pipe.

Could be Staintune?

Mezo.
"A wise man makes his own decisions, an ignorant man follows public opinion"
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