The XT550 Thread: Info, Stories and Mods Inside!

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

  1. netjustin

    netjustin b00b

    Joined:
    May 15, 2009
    Oddometer:
    89
    Location:
    Monterey, CA USA
    Like hobie says, you da man!!! Nice work.

    Do it! There are so many coolness points available in a build like that.

    As far as the box, just wrap your in/out wires in some shrink wrap and make an epoxy time capsule out of the rest. Spray paint desired color, slap a Yamaha Racing inkjet label on and call it good. :)
    #61
  2. Bart

    Bart Constant Lurker

    Joined:
    Sep 25, 2003
    Oddometer:
    2,963
    Location:
    Air Transport Central
    The problem is not so much with set-up, at Really high speeds the valve springs cannot open and close the valves fast enough for the next cycle to come around. I had an early 90's CBR600 with an HRC Race Kit. The HRC Race Kit included stiffer springs for just this reason. It increased the rev limit.
    #62
  3. Zecatfish

    Zecatfish XTique Rider

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

    The jump to 36 degrees timing at a the correct rpm should produce a nice hit. :evil . I would suggest adjusting it to the lowest rpm possible without its pinging. To much timing to quick makes detonation, on a side note one rpm will be great on cool days and then higher on hit days.

    I've had the stock engine detonate on single track on hot summer days just off idle.

    If you decide to toss another together let me know I'd be interested in buying it. My bike is a total mix match anyway. I really like the added power of the TT600 mill verses the XT550 mill.
    #63
  4. G600

    G600 Been here awhile

    Joined:
    May 18, 2009
    Oddometer:
    494
    Location:
    Iceland
    <o:p> </o:p>
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{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]--> Faulty rectifier/regulator &#8211; will the stator be destroyed if disconnected?

    My &#8217;83 XT550&#8217;s rectifier/regulator is faulty. I don&#8217;t know in what way, but there is no voltage over the battery.
    <o:p> </o:p>
    If the rectifier/regulator failure results in too low resistance the stator probably will burn (too much current).
    <o:p> </o:p>
    If I disconnect the rectifier/regulator the voltage will go up, but how high? Is it possible that the voltage will go high enough to destroy the isolation?
    <o:p> </o:p>
    Zecatfish, thanks for the info. I have enjoed reading about your work on your XT, good stuff. I have not yet tested the DIY CDI since I don&#8217;t know excaclty how the stator will react if I disconnect the rectifier unit, and since I don&#8217;t know how much current the stator is pumping out now, I don&#8217;t what to run the engine for more than couple of minutes at the time&#8230;.
    #64
  5. Zecatfish

    Zecatfish XTique Rider

    Joined:
    Dec 30, 2006
    Oddometer:
    7,928
    Location:
    Arkansas USA
    If you just unhook the reg/rectifier and leave the wires open it should not hurt anything and run it off the battery.

    The XT is a three phase stator. You need to keep that in mind if you go aftermarket on the reg/rectifier. I wish I could help there.
    PM Big Ed XT Fan he might have one.
    #65
  6. BIG ED XT FAN

    BIG ED XT FAN Long timer

    Joined:
    Feb 18, 2006
    Oddometer:
    1,261
    Location:
    Finger Lakes Western New York
    Yes, i have one!! Thump-on!!:evil:evil:evil:evil:evil
    #66
  7. Bart

    Bart Constant Lurker

    Joined:
    Sep 25, 2003
    Oddometer:
    2,963
    Location:
    Air Transport Central

    Just don't rev up the engine. At Idle or slightly above it should be OK but if you rev up the engine it will increase the output and then you will likely burn something out like a head light bulb or maybe something more expensive.
    #67
  8. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    Awesome work G600 :eek1 I like doing things myself but I don't think I'd attempt to build a CDI, good stuff!


    Well, got back from vacation 2 days ago, and ran into 2 problems; The fiance's car has a bad rear main seal failure and then she got laid off the next day :cry Unless they bring her back relatively shortly (if at all) I won't be able to spend too much on the XT.

    Last night I did get to torch the frame though. The old man has the torch so he made it nice and red and then I bent it into place. Bent the left peg and right peg to be more in line. One negative to bending the left peg back is that the kick stand was also bent in the crash so it leans very far over. I'll have to work on that.
    #68
  9. G600

    G600 Been here awhile

    Joined:
    May 18, 2009
    Oddometer:
    494
    Location:
    Iceland
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Name="TOC Heading"/> </w:LatentStyles> </xml><![endif]--><style> <!-- /* Font Definitions */ @font-face {font-family:"Cambria Math"; panose-1:2 4 5 3 5 4 6 3 2 4; mso-font-charset:0; mso-generic-font-family:roman; mso-font-pitch:variable; mso-font-signature:-1610611985 1107304683 0 0 159 0;} @font-face {font-family:Calibri; panose-1:2 15 5 2 2 2 4 3 2 4; mso-font-charset:0; mso-generic-font-family:swiss; mso-font-pitch:variable; mso-font-signature:-1610611985 1073750139 0 0 159 0;} /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-unhide:no; mso-style-qformat:yes; mso-style-parent:""; margin-top:0cm; margin-right:0cm; margin-bottom:10.0pt; 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: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]--> XTwarrior, sorry to hear about your fiancé. Hope things work out OK.
    <o:p> </o:p>
    &#8220;nice and red&#8221;&#8230; huh.. You guys are not messing about straightening the frame. That bike sure had taken some beating. Wow&#8230;
    <o:p> </o:p>
    The regulator/rectifier in my bike seems to be OK after all. After some more measuring I decided to try again with the battery from my EXC400. Bingo, the battery voltage was 14.5 volts when the bike was running. I only tried for a short time, but for now I think it is ok.
    <o:p> </o:p>
    So&#8230; the point is&#8230; a good battery seems to be vital in the XT550, for the charging system to work correctly. If the battery is shot, you will measure some silly numbers over the battery, both DC and AC (at least in my bike). It has a one phase stator (unlike the XT600) so the regulated voltage is more &#8221;uneven&#8221;. Maybe that matters&#8230;
    #69
  10. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    Ya, I hope it works out too. We were shopping for a new car for her Monday, then she got laid off Tuesday. nice big kick in the nuts for us :(

    The previous owner wrecked it in a head on collision so the frame was bent when we got it. Finally got it hammered out so my pegs aren't aligned in opposite directions :rofl

    Also figured out why my case cover is leaking....it has NO gasket on, just copper sealant :huh I'll just ignore the part where I'm the fool who put the copper sealant on when I lost the gasket and didn't want to order a new one.....

    To prep a gasket surface, i want to razorblade and then finish up with alcohol? What type of alcohol?
    #70
  11. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    Got around to doing some more little things on the bike. Put the new gasket on the case cover in hopes that it stops leaking oil. I'm not sure if I did it right but I used a razor to clean off the gunk, then sanded using 400 grit to clean the surface, and finally hit the surface up with some MAF cleaner (leaves no residue supposedly) to take the grease off. Then slabbed some Yamabond 5 on the case and cover metal, and slipped the gasket on. Finally, I finger tightened the case down for drying overnight. The yamabond 5 was liquid instead of thicker/gel like that I've used before. It seemed a bit thin but that's what the dealership suggested and it was very sticky.

    Cleaned up a bit:

    [​IMG]


    Also, got pictures of the before/after for the XT footpegs. (Don't know how to rotate but the left peg was caused by frame damage, the right peg itself is bent and I'll have to replace or maybe torch later.)

    [​IMG]

    [​IMG]


    And about 5 minutes ago I found some new friends!

    [​IMG]
    #71
  12. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    [​IMG]

    One busy mouse!
    #72
  13. goodcat8

    goodcat8 I can pass this guy.....

    Joined:
    Feb 19, 2008
    Oddometer:
    3,050
    Location:
    Los Angeles
    #73
  14. Bart

    Bart Constant Lurker

    Joined:
    Sep 25, 2003
    Oddometer:
    2,963
    Location:
    Air Transport Central

    I like to use plastic scotchbrite pads in isoprpyl or methyl hydrate to prep the surface. One slip with the blade and you could score the surface and create a leak. A piece of acrylic sharpened on one end works good as a scraper without the risk of damaging the aluminum mating surfaces. That is what we use in the aviation industry where one slip can ruin a whole wing!
    #74
  15. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    That is one sharp looking XT goodcat! Makes mine look like a junk pile on wheels :rofl

    Bart, I used a wood wedge to scrape the surface clean, then took 600 grit to it to clean it off and finished up with some MAF air sensor cleaner to remove all oil/dirt. Just took her for a 45 minute ride and beat on it as hard as I comfortably could and she didn't yield. Also, no engine leaks!

    [​IMG]




    Also, this is a handy measuring cup I got from Bed Bath and Beyond (what? they are the only place that I could find something like this!). It measures in ounces, and has a hole with a trigger plug in it that makes it easy to measure out fluids. Works great too!

    [​IMG]
    #75
  16. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    So....how hard are forks to take apart and put together?

    My weekend project will be doing the forks, adding the higher weight oil, new fork seals, and possibly a PVC preload piece if it will work. The problem is I have never pulled forks apart and not sure how to go about it :D
    #76
  17. royalthumper

    royalthumper n00b

    Joined:
    Mar 23, 2010
    Oddometer:
    4
    Location:
    Alaska
    Hey thumper fans. So I popped my cherry when I bought an 83' Xt550 last fall. Its been sitting in the garage all winter until yesterday when I pulled her out. She starts up fine although when i'm in first she coughs out blue smoke. I remember the guy i bought it from said that there were some leaky valve seals. is this most likely the problem and if so is it a pain to fix. Also where can i find a kickstand for her? Also cleaning the carburetor would probably help her run more smoothly.
    Thanks for helpin out a NOOB
    #77
  18. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    I would definitely clean the carb and maybe replace the gas if it is old. I've seen old gas put out blue smoke, though not a ton.

    The valves on the XT are relatively easy to get at if you are handy with tools. It is possible to remove the top end from the bike with the engine bolted in, but it is a very VERY tight fit. You have to take the gas tank off. Then I loosened the cam cover and slid it out over the cam chain with some coaxing. It seems like it won't clear the frame and cam, but with a little puzzle solving skills it does :D

    I admittedly haven't gone farther than that, having no consumption issues at this point. I went that deep to service the cam chain itself when we thought it had skipped.

    Whether or not the valve seals are the issue stands to be seen. I'd say replace the gas, and clean the carbs good and see if the smoke cleans up. I mean, it is the cheapest and easiest thing to do first, and it never hurts to clean the carbs. If it doesn't then I'd dive into the valve seals, and maybe pull the cylinder to look for worn/bad rings or piston wall damage.

    Also, I haven't looked into it, but maybe see if XT500/XT350 kickstands are the same from around those years.
    #78
  19. XTwarrior

    XTwarrior My bike is older than me

    Joined:
    Jul 21, 2007
    Oddometer:
    281
    Location:
    Allentown PA
    Was wondering, does everyone else's XT550 topend sound like it is being starved of oil all the time? I don't know how to describe it well, but my top end makes what seems to be the sound that poorly lubricated cams would make, minus any scratchy or squeaking sounds. I'd almost say knocking but I know my engine is jetted rich so it shouldn't be knocking, and the engine is stock minus a pipe and a jet kit. The noise doesn't get better or worse with warming up.

    I'm worried maybe somehow a line is clogged or my oil pump could be bad? Can I test the oil pump in any way?
    #79
  20. G600

    G600 Been here awhile

    Joined:
    May 18, 2009
    Oddometer:
    494
    Location:
    Iceland
    I did the seals on the XT550 I had many years ago. I don't recall any problems taking the forks apart, they are simple. If I remember correctly I had to make a "holder tool" (I hope I am not mixing up bikes). This holder tool was a bolt and a steel rod welded together. You need it when you loosen the bolt at the bottom of the fork.

    Are you sure the seals are shot? If they are leaking you can often clean them, sometimes seals leak because of dirt, not wear. Unlike the modern forks, there are small screws at the bottom of the XT550's forks you can use to get the oil out... so oil replacement is dead easy.
    #80