SuperMoto Junkie banner

610 mod database (relevant posts only)

358K views 779 replies 161 participants last post by  Ald 
#1 ·
Here's a chance for us to list all the modifications to the 610 both major and minor for helping when doing our own wrenching and to make suggestions for better engineering. Let's add pics when possible and please don't hijack this thread with beer consumption, tail chasing, hooligan stories....keep those where they belong in the "Lobby". That way we can keep this simple, use less bandwidth and make referencing a whole lot easier.
 
#131 ·
Just a little update- I disconnected the TPS, and switched to the iridium NGK plug [CR8EIX], and the 4500=ish hiccup/stutter is completely gone.
 
#132 ·
Mounted a 7S battery this weekend. Quite a bit smaller than the stocker or standard replacement.



Glued rubber to the floor of the tray and made two aluminum brackets, one for each side. Bend the top over to accomodate the rubber retention strap. Riveted the brackets onto the tray.





Glued two 1" rubber stoppers together then cut to fit the distance between the fender and the battery. Drilled a small hole through the fender and the stoppers. Rubber cemented the base of the stopper to the fender and scewed the stopper in place using a sheet metal screw (use a fender washer under the screw head to prevent fatique).



Use the stock retention strap side to side.



Use the tool retention band for where the old strap went.



Battery won't go anywhere, terminals are nowhere near the subframe. Ground strap and power take off won't chafe. Don't need any foam.

NoPoz
 
#137 ·
All you have to do is cut the box off just inside the cover bolts that way you can still bolt the left over part of the box onto the mounting bolts and then bolt the cover back on to the left over box. Hope that makes sense?

Or you could just do this mod!:laughingr
 
#142 ·
Not sure how much if any performance I gained from doing this since I did the air box, filter, plug and rejet all at the same time, but it seems like it should help something????? :headscrat this is the intake side of the carb. If you look at your is will have casting marks and square edges!
 
#151 ·
MotionPro Flywheel Puller P/N 08-0349

This works for the 610, and it got delivered by MotionPro in a reasonable amount of time. It is not listed in the applications list as working on the 610. It only list a bunch of Yamaha. Works fine none the less.

Thanks for whoever clued me in on this. Forgot who it was, and this maybe a repost?
 
#155 ·
Not sure if anyone else is having this problem but I had gas leaks from two different place on my tank and decided to investigate today. One source was from under the aftermarket gas cap plate and it was so bad gas came out when wheeling and water went in when washing the bike.

The first problem area was three-fold. First of all the threaded brass inserts in the plastic part of the tank were raised about 1 millimeter and stopped the plate from being tightened all the way down to the plastic before it bottomed out. I'd imagine this would be a problem with the stock cap too.

Here's some pics after I dremeled the raised inserts down. Don't worry about sparks, they're brass.





This worked to perfectly flatten the mounting area but then I noticed the bottom of the plate itself hit the inside radius of the tank near the back and so I ground that back a bit too.



And last the bolts were a bit too long and bottomed before tightening so they got ground down as well.

The other gas leak I thought was from the overflow and vent tubes where they connected to the tank nipples but then discovered they too were a millimeter too long and also were bottoming out before seating into place so I ground a mil off them too.

 
#157 ·
I love the looks of this exhaust. How silent is it when u put everything inside the pipe in comparison to the stock pipe?? I don't wanna be afraid to rev it up without waking the neighborhood?
The pipe becomes loud when you rev it up, but it is possible to modify the eaters to get max. power with min. noise. But its still a Husky, your neighbours will wake up anyway when you rev it up :laughingr
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top