XT600E: Pop, silence, eek

Discussion in 'UK Motorcycles' started by The Older Gentleman, Jun 5, 2008.

  1. Took the 600E to work and back today: round trip of 80 miles, so ideal
    for flagging up any minor issues.

    On the way to work, at one point, it died on the overrun for a second.
    Hmm: carb might need tweaking? Or carbs, as it has two.

    About 20 minutes later, it did it again and this time there was a pop
    from the exhaust, so I knew it was ignition related. That'll be the
    sidestand switch or clutch cutout, then. A hundred to one. Poxy things.
    After that, it just ran cleanly.

    Anyway, on the way back from work, I was just peeling off the A21 onto
    the M25, overtaking a car on the bend, doing 75mph, and I lost all
    drive. Aaarrggh.

    It's interesting how quickly a 600cc single slows on a dead engine. What
    was irritating was that the car slowed as well, to let me past. I was
    right by his driver's window. I slowed down some more. So did he. I was
    still alongside him I made frantic hand gestures and he got the message.
    At 45mph he accelerated away, and I pulled onto the M25 hard shoulder.

    Bollocks.

    OK, start with the obvious. Let's have a look at the clutch interlock.
    OK, that wire runs here, behind the headlight, and hey! The headlight
    guard is just held on with poppers, so we'll remove it, have a rummage,
    and wiggle it, and unplug it, wiggle it, plug it in again and...

    Brmmmm.....

    I rock.

    I hate these poxy switches and cutouts with a deep and abiding loathing.
    They always go wrong in the end.
     
    The Older Gentleman, Jun 5, 2008
    #1
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  2. The Older Gentleman

    SD Guest

    True.
     
    SD, Jun 5, 2008
    #2
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  3. The Older Gentleman

    Nige Guest

    Clutch switches are the devils own invention. Stand interlocks i can
    understand to a dgree, but clutch switches are pointless.
     
    Nige, Jun 5, 2008
    #3
  4. The Older Gentleman

    TOG@Toil Guest

    Hm. Well, whatever it was, I haven't fixed it. It stuttered again
    today on the way into work. I've now disconnected the clutch switch
    and I'll see if it does it again. If it does, I'll bypass the
    sidestand switch. Then the kill switch, and if I need a last resort,
    I'll clean up all the ignition-related wiring connections.

    My money's on the clutch or sidestand interlock, though. I hate bloody
    intermittent electrical glitches as much as I hade ignition
    interlocks. If something's dead, well, fine, you can work through
    until you find the break. Intermittents are a PITA.
     
    TOG@Toil, Jun 5, 2008
    #4
  5. The Older Gentleman

    TOG@Toil Guest

    Yup. Just the ignition, which is why I suspect the interlock(s) and
    not the fusebox or ignition switch. I think the XT only has a single
    fuse system anyway.

    <Downlaods wiring diagram pdf>

    Yes, as I thought.
    Indeed
     
    TOG@Toil, Jun 5, 2008
    #5
  6. The Older Gentleman

    TOG@Toil Guest

    Oh, and a browse of the manual reveals that a duff neutral light
    switch can also cause probs. But the neutral light is working
    perfectly, so I think I can discount that.
     
    TOG@Toil, Jun 5, 2008
    #6
  7. The Older Gentleman

    Eddie Guest

    < snip lots of quoted text >

    Learn to snip, newbie!
    Not necessarily: the neutral light on the 9R appears to work correctly,
    but it won't run in neutral with the sidestand down unless I hold the
    clutch in.

    I think the resistance in the switch circuit is a /tad/ high; there's
    just enough current to light the lamp, but not quite enough to convince
    the ignition lockout circuit.
     
    Eddie, Jun 5, 2008
    #7
  8. The Older Gentleman

    Ofnuts Guest

    Then you bought the wrong bike, the XT600 has a pretty crap wire harness.
     
    Ofnuts, Jun 5, 2008
    #8
  9. The Older Gentleman

    TOG@Toil Guest

    A lot of early late 1980s/early 1990s Yamahas did. Think 600
    Diversion.

    Anyway, I think (crosses fingers) it's fixed now. I took it down the
    road to buy some contact cleaner and yes, it cut out again and then
    chimed in and then cut out again. I had the clutch interlock
    disconnected, so that couldn't be the culprit now. And the neutral
    light took a second to come on (don't ask).

    So I had a look at the fuse after all. The fusebox holder had come
    apart, and the fuse, still clipped into the wires, was waving around
    loose. Replaced it in the holder, bound up the holder with tape, and
    for good measure cleaned the contacts of the connector for the
    sidestand switch, as they were filthy.

    And rode it around Tunbridge Wells for 15 minutes. Seems fine. We
    shall see.
     
    TOG@Toil, Jun 5, 2008
    #9
  10. The Older Gentleman

    Ofnuts Guest

    After the XT600 I had a XTZ660 and 1) the rectifier/regulator developed
    loose connections likely due to vibrations(*) and 2) after an engine
    rebuild around 35K miles, the same rectifier/regulator caught fire and
    took with it most of the bike electrics: all lit lightbulbs and battery
    (but, fortunately, not the expensive ignition controller). Stranded 50.5
    km from home, with and insurance contract covering the case above 50km
    (though their first estimate was 48km, I wasn't happy :)

    (*) I brought it to the Yamaha shop next door and the owner/manager died
    on me: "Must be the regulator! Aarrgh!"(**). Eventually fixed it myself.

    (**) Called the medics (actually the firemen). When I left they were
    using a defibrillator. When I came back in the evening a sign on the
    door said "Closed due to death".
     
    Ofnuts, Jun 5, 2008
    #10
  11. Remind me not to pick an argument with you!

    --
    Ivan Reid, School of Engineering & Design, _____________ CMS Collaboration,
    Brunel University. Ivan.Reid@[brunel.ac.uk|cern.ch] Room 40-1-B12, CERN
    GSX600F, RG250WD "You Porsche. Me pass!" DoD #484 JKLO#003, 005
    WP7# 3000 LC Unit #2368 (tinlc) UKMC#00009 BOTAFOT#16 UKRMMA#7 (Hon)
    KotPT -- "for stupidity above and beyond the call of duty".
     
    Dr Ivan D. Reid, Jun 5, 2008
    #11
  12. And it behaved fine, and then died again on the M25. The other electrics
    were all working perfectly. So it's not the fuse.

    Coasted to a halt on the hard shoulder. Decided it now had to be the
    sidestand switch. Kicked down the stand. Kicked it up again. And it
    started. OK, it's definitely the sidestand switch.[1]

    And I've been running around town this evening[2] and it's working fine.
    But the sidestand switch needs to be bypassed, I think.

    [1] Probably.
    [2] Went to see Twelfth Night at the Regents Park open air theatre.
    There are few better ways of spending a nice summer evening in London.
     
    The Older Gentleman, Jun 6, 2008
    #12
  13. The Older Gentleman

    platypus Guest

    Actresses. <shrug>
     
    platypus, Jun 6, 2008
    #13
  14. In message
    What am I supposed to be expecting to fail on mine?
     
    Steve Fitzgerald, Jun 12, 2008
    #14
  15. Connections, basically. The electrical components themselves are OK,
    but the bits that join them seem to corrode away.
     
    The Older Gentleman, Jun 12, 2008
    #15
  16. I think I've had that when the thing failed to start. Bad connection in
    the starter circuit sorted out by those fine chaps in South Woodford.
     
    Steve Fitzgerald, Jun 12, 2008
    #16
  17. I'm not surprised. Nice bike, the 600 Diversion, but as they get older
    they do seem to attract the electrical gremlins.
     
    The Older Gentleman, Jun 12, 2008
    #17
  18. Yup. I like it. Dull as dishwater but gets me to work every day and
    about to hit 50k. I gather it's good for about 100k if I don't do
    anything silly.

    I'm quite liking the Fazer after WM lent me one to play with on a recent
    service.
     
    Steve Fitzgerald, Jun 12, 2008
    #18
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