Noob XT600 3TB rebuild
Posted: Fri Aug 17, 2012 11:05 am
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:
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.
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
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.
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!
I stripped a bolt on the rear hub, it literally just disintegrated. Do I just drill it out and retap the hole?
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!
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:
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:
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.
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
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.
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!
I stripped a bolt on the rear hub, it literally just disintegrated. Do I just drill it out and retap the hole?
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!
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:
