The XT550 Thread: Info, Stories and Mods Inside!

Discussion in 'Thumpers' started by XTwarrior, Feb 16, 2010.

  1. Zecatfish

    Zecatfish XTique Rider

    Joined:
    Dec 30, 2006
    Oddometer:
    7,928
    Location:
    Arkansas USA

    If that wire is BROWN like it looks, that should be a turn signal.
    It looks to small to be a main ground.
    #21
  2. netjustin

    netjustin b00b

    Joined:
    May 15, 2009
    Oddometer:
    89
    Location:
    Monterey, CA USA
    I purchased a motor for my XT600E but despite advertising it was actually an XT550. The engines are different in several ways, but after some research and some interesting trials, I have concluded the 550 is a bolt in replacement with relatively minor modifications required to make the swap.

    Matches between the 550 and 600 engines:
    • intake port configuration; use the same carbs if desired
    • exhaust port configuration; use the same exhaust header if desired
    • chassis mount points; use the same engine mounts
    • clutch disks; steel and friction plates match, as well as springs, but 600 requires an additional wave spring not used in 550
    • oil feed line; oil feed inlet is designed and located the same on both models
    • spark plug; threads match between both, and access to the plug for removal is equally absurd on both
    • camshaft; cams are interchangeable between models and (if I remember correctly) have identical lift and duration specs
    • oil filter, cover, and o-rings; direct match
    • fasteners; same quantity and dimensions, more or less, throughout
    Mismatches:
    • ignition system; 550 uses CDI* and 600 uses TCI. none of coil, ignition box, or harness are interchangeable without internal modifications
    • oil reservoir and return line; 550 uses an external reservoir, whereas 600 returns oil to in-frame reservoir. return line is different length and construction
    • engine L/R side cover and gasket; close but not interchangeable
    • countersprocket; 550 uses an offset spline "key" whereas 600 uses a centernut
    • countersprocket alignment; 550 countersprocket is positioned a few mm inward, toward the center case**, compared to the 600
    * As a side note, I was initially befuddled by a faulty ignition. To save money over a $500 factory replacement I tried the Wayne Gum ignition referenced in the 1st post. I could not be happier with how it runs, and the wiring matched my harness perfectly. Highly recommended at one 1/4 the price.
    **The countersprocket alignment did not appear to generate additional chain noise or movement in operation, nor difficulty in adjustment. However, you should expect the chain to stretch faster than stock if this difference is not reconciled at the rear hub. Smaller than stock countersprocket may compound this issue.


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    #22
  3. Zecatfish

    Zecatfish XTique Rider

    Joined:
    Dec 30, 2006
    Oddometer:
    7,928
    Location:
    Arkansas USA
    The TT600/XT600 uses a different manifold from the XT550. The 550 might work on the 600, but not the other way around.
    I think your going to find that the XT600 carb is going to be jetted a bit rich for the 550 mill too.
    I got a perfectly working 550 carb I'll trade you if it is. Its to lean on the TT600 mill in my 550.
    #23
  4. netjustin

    netjustin b00b

    Joined:
    May 15, 2009
    Oddometer:
    89
    Location:
    Monterey, CA USA
    Yes, jetting will be an issue with an engine swap. Anyone who plans to use overbore, aftermarket intake or exhaust etc should think about rejetting immediately.

    Thanks for the tip about the manifold, I did not attend to swap these; only the carburetor.
    #24
  5. BIG ED XT FAN

    BIG ED XT FAN Long timer

    Joined:
    Feb 18, 2006
    Oddometer:
    1,261
    Location:
    Finger Lakes Western New York
    Have a photo of the front-end? :evil:evil:evil:evil:evil
    #25
  6. G600

    G600 Been here awhile

    Joined:
    May 18, 2009
    Oddometer:
    496
    Location:
    Iceland

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font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:Calibri; mso-fareast-theme-font:minor-latin; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} .MsoChpDefault {mso-style-type:export-only; mso-default-props:yes; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:Calibri; mso-fareast-theme-font:minor-latin; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} .MsoPapDefault {mso-style-type:export-only; margin-bottom:10.0pt; line-height:115%;} @page Section1 {size:612.0pt 792.0pt; margin:72.0pt 72.0pt 72.0pt 72.0pt; mso-header-margin:35.4pt; mso-footer-margin:35.4pt; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-priority:99; mso-style-qformat:yes; mso-style-parent:""; mso-padding-alt:0cm 5.4pt 0cm 5.4pt; mso-para-margin-top:0cm; mso-para-margin-right:0cm; mso-para-margin-bottom:10.0pt; mso-para-margin-left:0cm; line-height:115%; mso-pagination:widow-orphan; font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin;} </style> <![endif]--> Bart, thanks.
    Zecatfish, the wire looks brown on the pic but is black. Agree I don’t think it is ground. I will check again.
    #26
  7. G600

    G600 Been here awhile

    Joined:
    May 18, 2009
    Oddometer:
    496
    Location:
    Iceland

    Thanks, this is VERY interesting.

    How do the two engines compare? Do you feel that the 600 (when it lived) had more power? What about throttle response??
    #27
  8. scottpoley

    scottpoley Been here awhile

    Joined:
    Jan 12, 2005
    Oddometer:
    577
    Location:
    Upstate NY Finger Lakes
    Had an XT550 a while ago and sold it w/ the owners manual and shop manual. Six months later I run into the guy, who says "You ripped me off! Every time I check the oil it's a quart down and when I put a quart in, it blows oil out the breather tube!".
    Me: "Uh, did you check the owner's manual for the proper way to check the oil?"
    Him: "WTF! I know how to check the oil!!"

    So I explain it to him. Looks dumbfounded, turns and walks away, shaking his head.

    Moral: You can give them the manual, but that doesn't mean they're going to read it!
    #28
  9. netjustin

    netjustin b00b

    Joined:
    May 15, 2009
    Oddometer:
    89
    Location:
    Monterey, CA USA
    I can not give the 550 a fair appraisal because the motor as purchased had a few thousand dollars in performance upgrades for racing. It looks dirty and it's a sleeper motor.

    I do know the 550 is a lighter plant. I had to lift both engines by hand for the swap, and while I wish I had taken a moment to get them on a scale, I did notice what felt like a substantial weight difference. 15-20 lb. A big part of this weight difference is in the starter motor, starter clutch, heavier flywheel (to connect to starter), starter idler gear.

    So the 3-4 horsepower difference between the two motors might be a wash when you factor in the weight difference!
    #29
  10. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    G600 - I also had a missing Ground wire in my system and I found a bolt all by it's lonesame, so I cleaned the spot up with some light grinding and made that bolt my new ground. Haven't had an issue in 2,000 miles :D . You can also try splicing into the battery ground for a better ground option depending on the wire length available.

    Netjustin - WOW! Nice motorcycle, lots and lots of custom stuff done! Thanks for the info as well, I'll add it to the original post shortly. Looks like a damned blast!

    I believe the Wayne Gum Hyperpak actually comes with a diagram of what all the wires do since they all go through the CDI at one point. My CDI had 11 wires and the Hyperpak had 12, I forget which one I didn't use but everything works fine.

    Going to hopefully (weather permitting) ride the XT to a friend of mine's shop to have the front rim trued. Has a nasty vibration above 60 and I have this thing geared real high; does 85 on a flat at only 4,500 RPM's and I ride it at 85 the whole time I'm on a highway.


    P.S. - Does anyone know how to link just to a single post in a thread, and not the whole thread?
    #30
  11. Zecatfish

    Zecatfish XTique Rider

    Joined:
    Dec 30, 2006
    Oddometer:
    7,928
    Location:
    Arkansas USA
    Click on the posting #30
    http://www.advrider.com/forums/showpost.php?p=12218499&postcount=30


    I can tell you that a stock XT550 vs TT600 (note using the XT550 flywheel/stator on the TT600) that there is no comparison.
    The Stock 550 is rated 38HP, TT600 is rated 48HP.
    You really notice the difference in the seat of the pants and that the 600 just almost refuses to bog, just crack the throttle and it surges forward.
    #31
  12. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    Excellent, thank you for that :) Maybe if/when the XT engine fails me I'll have to source a TT600 motor for it :evil

    Updated some info; namely added ALL of the stock carburator settings and valve clearances under General Info :D
    #32
  13. Bart

    Bart Constant Lurker

    Joined:
    Sep 25, 2003
    Oddometer:
    2,963
    Location:
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    If it is a signal wire then the wiring harness is all screwed up because it is way too far fwd in the frame. I'll check my manual for you. Give me a few minutes.
    #33
  14. Bart

    Bart Constant Lurker

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    I'll get one for you. It was just a straight swap. I might have gotten a bearing swap kit but it was easy peasy!
    #34
  15. Bart

    Bart Constant Lurker

    Joined:
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    Oddometer:
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    According to my Yamaha OEM Manual black is a ground and judging by the location it is the ground wire for the Voltage regulator. Other items that have a ground connection are:

    CDI
    CDI Magneto
    Neutral switch
    Sidestand Switch (I bet it might be this one and the switch was removed)
    Rear brake switch

    That is it by the wiring diagram in the manual.
    #35
  16. Bart

    Bart Constant Lurker

    Joined:
    Sep 25, 2003
    Oddometer:
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    As requested. 96 YZ250 front end on my XT550

    [​IMG]
    #36
  17. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    How much work was it to fit to the front end? I've always been interested in a front end swap but I am not one for machine work. I like things that mash together with very little grinding :rofl

    Does anyone have any idea of seats that may fit on the XT against the tank? I remember someone finding a modern bike seat that fit quite well but was a little narrow, but i can't seem to find it via google.

    On another note, not looking forward to how dirty the XT is after it's been in a barn for almost a year with little riding.

    EDIT
    #37
  18. Bart

    Bart Constant Lurker

    Joined:
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    Oddometer:
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    It was 7 yrs ago but I think it was a straight swap. There was no grinding or machining required for sure. If you stick with Yamaha and measure bearing race inside and outside diameter, you can usually buy conversion kits for about $35.

    I hope this helps.

    :1drink
    #38
  19. Zecatfish

    Zecatfish XTique Rider

    Joined:
    Dec 30, 2006
    Oddometer:
    7,928
    Location:
    Arkansas USA
    If you do the swap without a longer shock out back, your going to end up with a chopper. :lol3

    BTW that shim/spacer cost me $20 at the machine shop.
    #39
  20. netjustin

    netjustin b00b

    Joined:
    May 15, 2009
    Oddometer:
    89
    Location:
    Monterey, CA USA
    Thanks there is a bit of work there and it has paid off. There are plenty of details I forgot the first time around. Similarities like the rocker cover vent, centercase breather, and dissimilarities like the 600 smog canister and different clutch cable. Again, all relatively minor as the these are all remedied with bolt ons. No new engineering required.

    I seem to remember this too, that I left one of the Hyperpak connectors disconnected with some electrical tape on the end. But everything that required a connection, in my harness, got one.

    Good luck with that front wheel. I like your gearing, sounds like you are perfectly equipped to keep those highway R's down!
    #40