WIRING DIAGRAM FOR 1984 YAMAHA XT600
Side pods constructed to hold
fuel tank, Oil tank constructed from 316 stainless
battery and other things.
and nearly mounted.
transmission oil cooler.
The XT600 engine has a dry sump arrangement and is fitted with a
small oil cooler (6" x 2") and also has a separate oil tank. The old
oil tank is quite long so I have made a shorter one out of a bit of 4"
stainless steel tube, 10" long. The capacity is 2 litres (1/2 Gallon),
about the same as the original. The inlets/outlet/filler are brass
B.S.P. reducing bushes, silver soldered in place. The new oil
cooler is approx. 10" x 5" and will have two small 12 volt fans mounted
29 DEC 03
Mounted on Axle
I have used a rear
caliper off a Mitsubishi Magna. It
even has a lever for a hand brake. The whole caliper and backing plate
is made of aluminium and is very light. I purchased two from the Trumps car wrecking yard in Wynyard
for $10. They even threw in the hand brake cable. They
have lots of them and virtually no demand, hence the low price.
For another $5 I got about 4 metres of steel brake line and enough
fittings for the ends. The line can be joined using 1/4" copper tube
and silver soldering using a mini butane blowtorch. In the first photo
I have drawn a line where I cut the the bottom end of the backing plate
off. I then mounted it to some 25 mm x 3 mm angle iron using
head screws as shown in the second photo. See pics down the page.
29 DEC 03
Old fuel tank resurrected, 7
litres and will be able to carry a jerry can as well.
5 JAN 04
The other photos of the cut down
caliper backing plate
The pic on the right shows
where the aluminium backing plate was machined off using a cut off 3/8"
drill in a drill press, then filed up to give a flat area for the angle
iron to sit. Also the 5/16" countersunk head allen key screws are used
in the new holes.
9 JAN 04
The paint is drying - I used 3/4 of a litre of X15 orange. The
colour does not show up very well under artificial light. Will paint
the suspension parts black.
16 JAN 04
Back end going back together
Will put better photos on soon - the
late afternoon sun makes for poor photos ( taken about 8:00pm )
The engine fired up first kick after
fixing the dodgy connection on the coil primary. The oil cooler and
fans work a treat. The oil stays very cool.
Our first drive and victim
It made up the back yard under its own power
21 JAN 04
Top view of shortened Escort rack
Battery and fuel
Regulator (top left)
Chain guide and tensioner
Oil cooler covered in mesh
Used an old sprocket to pull chain down closer in line with
swing arm pivot. Turned up two bushes to take 608 ball bearings
to support sprocket. There are 4 holes to allow adjustment up
and down . The bottom guide roller is a nylon roller also turned
up to take two 608 ball bearings and is fitted into
a slotted hole to give fine adjustment. There is more strain on the top
roller, therefore the 4 fixed position holes. The oil cooler is covered
in mesh to protect from rocks thrown up from the back wheels. The two
120 mm 12 volt fans
($23 each from Altronics) suck air from behind the seat and blow though
the cooler. This works extremely well and the oil remains very
Ugly air filter
A bit of 3" ducting is fitted on to the two original air
pipes and I have used the original filter from the XT600 in a spring
loaded sandwich to keep it sealed. I am thinking about changing to a
pod filter in the same position. The oil tank is sitting in its holder
on rubber strips and held in position with a couple of
I have re-used the original muffler
and added a short piece of new pipe to bring it around to the back.
a quick 5 minute drive on the local reserve I am impressed with the
smooth ride, and the power of this machine. With only 100 x 20
metres of undulating ground to play with, I managed to get peak revs in
3rd gear, get airborne and stop again. Can't wait to get out again.
Anybody building a Sidewinder should enjoy a very similar experience.
Ok, Have been out again and all ran well, however the bearing bushes
holding the idle sprocket failed after a couple of runs. There was not
enough meat in the section centering the sprocket. Performance wise the
"X-15" had plenty of power and the handling was good but I have
not been into any rough tracks yet.
I have just
modified the upper rear suspension mount to allow the fitting of a new
rear spring and shock, and make a little bit more room for the seat. It
needs a bit more suspension travel and be slightly stiffer. I
am still using the XT600 mono shock but now have room to install a
longer unit with more travel. I just have to make the necessary
calculation for the new spring rates.
Since test firing up the "X-15" after the mods, I have found that
my battery is at the end of its life and won't run the fuel pump
the Rectifier/Regulator has failed. After pricing
second hand and new R/Rs,
I decided to make a R/R and after doing a bit of research, am close to
perfecting the design. A saving of about $50 over a second hand R/R.
Might get out next weekend for a run as it has been a while. I had a
knee op at the end of Jan and the started
the mods after I got back on my feet. Hope to get some good action pics
as well. A film clip would be nice but I need to get a loan of a VCR
Just a few photos at different angles of the X-15, me and
I have an new battery ( 7
amp/hour ) and the
home-made regulator is
working, BUT after all my work and research I have found that the
alternator winding is faulty with a short to earth ( rewind
quoted at $270 ) however it is still charging. I will need to get one
eventually. Have solved alternator winding problem, I fitted a toroidal
isolation trasformer (1:1) These transformers are lighter than iron
core transformers and less lossy at higher frequencies.
Due to an incident earlier in the
year that exposed the slight weakness of the top front
shock/spring mounts, I have re-designed them and made changes to
increase the stiffness
and the amount of travel. The shocks
were somewhat longer than the springs which
resulted in the shocks bottoming out and bending the mounts and the
The new top housings allow the shock to be more extended so the springs
take more load.
View after old mounts removed
Side view of finished
view of finished
The whole spring
Mount to be
Shocker extender section
1" N.B. stainless pipe welded to
flat plate and
bolted to angle iron with 5/16 caphead bolts.
2.25" heavy gauge exhaust tube with 5/8" round stubs welded on. The washers on top are
yet to be welded.
STILL TO DO:
and more no doubt.