Yamaha XT600E 'do I really need another motorcycle?' Scrambler


Been Around the Block
So, thappened yesterday... Frame is titled, wheels looks straight, brakes seem to do something and that's about it.
Mileage, history, if she's a runner,... is anyone's guess.

Let's just say, if she runs with just an oil change it's a bargain, otherwise I'll kick myself for it taking up space I don't have.

Behold my latest purchase, a 2003 Yamaha XT600E!

This could be fun. The plan is to butcher her to some kind of rat scrambler/desert sled. Looking to make a fun, functional machine out of her with a vintage vibe and a hint of 'je m'en fous' (that's fancy french for 'I don't give a f**k'). The idea is to have a fun light streetable machine which I can take out on the dirt whenever I like to and can take a drop or two (which will inevitably happen).
I was looking for something with knobby tires for a while. Never owned a Yamaha nor a 1 cil 4-stroke. The wife didn't think of this as a valid argument to buy this heap of scrap but while I'm in the shed she has her peace so it's a win-win.
So I started off by giving her a good clean. Doesn't look too bad underneath the dirt and grime... brake lever and pedal bent back into shape, flushed the brakes with new oil, few small bits sorted and checked.

Hooked up a battery and after chasing a ignition issue due to a loose ground managed to get her to run a few seconds before dying. Not a bad sign so far. Found out the intake boots are shot, ordered apair of new ones together with a bunch of other parts like chain + sprokets, lights, tank, seat, fenders, exhaust bits,... long story short I got more worth of parts coming my way than the bike has cost me... can't wait for everything to arrive!
Stripped out the front end, cleaned up the frame in the rear and mocked up some exhaust bends. Took some measurements to make a first version of the front headlight panel, hopefully I'll get to making it later this week.
So got the bike running, the intake boots did the trick. Carbs don't seem to need work at all, checked the jets while they were off the bike and were clean as a whistle.

I also did a little mock up of tank and seat, the problem i'm having is the tank tunnel isn't wide enough for the oil in frame tank and tubes so there will be some fiddling with that over the next week or so...

Also made a first try at a front plate, not too sure about it yet, looks a bit bulky to me so probably going to change it later on. Any input is welcome.
Ijust spent 16 hrs riding around on the 250 versions of this. Slow circles in a parking lot but I want a dual sport now real bad. For the front, put some holes in the sides and see if it takes some bulk away.
As the tank didn't want to fit due to the oil in frame neck. The front of the tank tunnel was too narrow and at the back I could fit another tank in with al the leftover space. I decided to bite the bullet and make it fit like it should.
Cut out the tunnel and made my own, after a lot of cutting and grinding welded it all up, a dozen of leaks patched up and about 6 - 7hrs of work but she's done!



Not my best welds by far but it will have to do. I will put an epoxy liner on the inside for peace of mind.
Atleast I improved the fuel capacity by a few liters I guess...


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Got a little more work done, bend and welded in a new frame hoop, and mocked up the fender, seat and exhaust. Still thinking about how on hell i'm going to mount the seat firm but easily removable. Some pics to give you guys an idea of what's going on.

Oh and because the weather was pretty nice got a chance to take the missus out for a ride on the CB! ;)
Yesterday build myself a frame to mount the seat to, which in turns mounts to the frame. This gives me a solid seat fixture which can easily removed.


Still need to trim the back of the seat a bit to clear the fender. Fender is rubber mounted to avoid vibrations which could cause the taillight to prematurely break down, so any contact with the hardmounted seat is something to avoid.

Also gave the tank a coat of epoxy sealant just for the peace of mind.

Next jobs is to fully mount and weld up the exaust and start on the front end of the bike.
Last few week tried working on the bike after work when life let me. Starting to get there, won't be the most beautiful bike but that was never the intention, function is key here...

The cheap china tank needed some love, especially after the metalwork, a thin skim of filler and a lot of sanding...

Brackets for the rear fender welded on, exhaust welded up and taillight mocked up. Still need to think of where to mount the licence plate but I'll get there when I get there I guess...


I hope the exhaust won't produce too much heat, otherwise I'll have one droopy indicator...

Exhaust painted and wrapped to avoid melting the airbox.

And I made myself some side covers to tidy it all up.

Now thinking about paint/colour schemes for the bike. Would like some kind of vintage looking livery that's not too hard to paint. Something that stands out and goes well with the silver frame paint.
Decisions, decisions....
Love the exhaust on this beast, is that a Cone Engineering muffler? Its really coming together nicely.
Love the exhaust on this beast, is that a Cone Engineering muffler? Its really coming together nicely.
It's from caferacerwebshop.com, listed as 'handmade exhaust' but no stamp on the muffler or lettering on the box it came in. Looks well made, came with a mounting bracket which needed to be welded on in the desired position and RVS exhaust clamp for just under €110. Well worth the money imo.
nice work.
Thanks, trying my best ;)
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