speedyj
New member
So I was given this previous runner (2 seasons ago) by a buddy. It has been cuddling with an XLT600 for 2 years in an enclosed trailer up in Haliburton, ON and had been largely ignored. I had heard it needed much love:
- broken wiring harness
- headlight bulb busted
- tail light not working
- choke cable/lever busted
- suspension seized
- possible oil injection not working or plugged
- Windshield busted
- Hood straps missing/busted held down w/ bungee cords
The season was largely over here 3 weeks or so ago so I had him drag it home for me. The price was right
It was filthy even though it has been stored inside the trailer. The mice had gotten into everything. The air box, the carb, the y-pipe intake - all full of ......bird seed
I pulled the y-pipe and found more inside the cylinders. Yay. I started the rebuild.
Day 1: cleaning. Out came the spray nine and I cleaned from the top down. The seat wasn't chewed. The hood vents were all trashed (still looking for replacements btw....). Hours of wiping everything down. Airbox out, remnants of windshield removed. What was left of the vents, removed. Tank shroud off and found more bird seed. Seat removed and more leaves, bird seed and mouse nest sh*t. Vacuumed the entire belly pan out of rust, dirt and crud. Scrubbed it all down with an old toothbrush and more spray nine.
Day 2: cleaning. Out came the carb, boot and choke lever/cable assembly. Carb throat full of bird seed. Y-pipe pulled and more bird seed. Out comes the Dyson vac to suck it all up. Bird seed in the cylinders. I pull it over and can hear it crunching in there Tear down the carb, soaked, cleaned and reassembled. Off to Royal for:
- new windshield
- new spark plugs
- new hood straps
- new choke cable (wrong one as it turned out)
- new headlight bulb
- 5 feet of new fuel line
got back and installed all new parts. Gave the hood a good polish. Paint comes up pretty decent.
Day 3: Started polishing the running boards and rear grab handle. Flushed tank and found a spout inside it! New fuel strainer installed. All the old fuel lines were brittle and so yellow you couldn't see fuel flow from the outside. New tank vent line cut and installed. New tank fuel level white vinyl on the side and new fuel line there to the bottom. Finally new fuel line to the pump and then to the carb. Repaired wiring harness front and rear with crimped connections and heat shrink over everything. Dressed clutch faces w/scotchbrite pad. Compression test on both cylinders shows 127 & 131 - not bad.
Fuel tank filled and got it pumping from the tank on spray. She fired right up Will it stay running? I watch through the new clear lines and the premix leaves the tank and makes its way to the pump. The pump works fine too. She starts to idle I let her run for 10 mins or so and watch as more mouse fluff and bird see fountains out of the cooling vent. Marked a line on the oil tank and will watch tomorrow after a longer run to see if she's drawing any oil through the injector.
Photos attached. More to come. Nice to hear this old girl run again.....
- broken wiring harness
- headlight bulb busted
- tail light not working
- choke cable/lever busted
- suspension seized
- possible oil injection not working or plugged
- Windshield busted
- Hood straps missing/busted held down w/ bungee cords
The season was largely over here 3 weeks or so ago so I had him drag it home for me. The price was right
It was filthy even though it has been stored inside the trailer. The mice had gotten into everything. The air box, the carb, the y-pipe intake - all full of ......bird seed
I pulled the y-pipe and found more inside the cylinders. Yay. I started the rebuild.Day 1: cleaning. Out came the spray nine and I cleaned from the top down. The seat wasn't chewed. The hood vents were all trashed (still looking for replacements btw....). Hours of wiping everything down. Airbox out, remnants of windshield removed. What was left of the vents, removed. Tank shroud off and found more bird seed. Seat removed and more leaves, bird seed and mouse nest sh*t. Vacuumed the entire belly pan out of rust, dirt and crud. Scrubbed it all down with an old toothbrush and more spray nine.
Day 2: cleaning. Out came the carb, boot and choke lever/cable assembly. Carb throat full of bird seed. Y-pipe pulled and more bird seed. Out comes the Dyson vac to suck it all up. Bird seed in the cylinders. I pull it over and can hear it crunching in there
Tear down the carb, soaked, cleaned and reassembled. Off to Royal for:- new windshield
- new spark plugs
- new hood straps
- new choke cable (wrong one as it turned out)
- new headlight bulb
- 5 feet of new fuel line
got back and installed all new parts. Gave the hood a good polish. Paint comes up pretty decent.
Day 3: Started polishing the running boards and rear grab handle. Flushed tank and found a spout inside it! New fuel strainer installed. All the old fuel lines were brittle and so yellow you couldn't see fuel flow from the outside. New tank vent line cut and installed. New tank fuel level white vinyl on the side and new fuel line there to the bottom. Finally new fuel line to the pump and then to the carb. Repaired wiring harness front and rear with crimped connections and heat shrink over everything. Dressed clutch faces w/scotchbrite pad. Compression test on both cylinders shows 127 & 131 - not bad.
Fuel tank filled and got it pumping from the tank on spray. She fired right up
Will it stay running? I watch through the new clear lines and the premix leaves the tank and makes its way to the pump. The pump works fine too. She starts to idle I let her run for 10 mins or so and watch as more mouse fluff and bird see fountains out of the cooling vent. Marked a line on the oil tank and will watch tomorrow after a longer run to see if she's drawing any oil through the injector.Photos attached. More to come. Nice to hear this old girl run again.....
Attachments
yamahamark
Member
Wow that's a lot of work but that sled is really clean for its year and age. Wish someone would give me a sled that nice.LOL
speedyj
New member
Well for the price and the approximately $240 I have into it, I figured my time as worth it
Word of note: don't leave out the 'starter' or choke jet out of the carb - a rather large smoke show will ensue ...
