How long to fix engine???

**Tenere Tom** · #1 13 Apr 2008

Reallistically how long should this take?

I have an old ('84) XT600 Tenere - it has a 3rd gear selection problem and I want to drop out the old engine and replace the botom end and re-fit all my old bits to it.

I have a replacement bottom end (no clutch/flywheel, etc), a full gasket set, a good set of tools and a bucket full of enthusiasm.

I just want to know how long it 'should' take so I can find the best time to start. I just don't want to be off the road for longer than I have to be. I work just 5 days at the moment so I'd like to have it all done over a weekend - is this possible?

Tom

**bingbong007** · #2 13 Apr 2008

If you know what the problem is,and have all the right bits, you should just be able to do it in a weekend, two days, if things go to plan.
Some people frown at manuals, but unless your a proffesional get one!, they will save you alot of time and money and help you put it all back together safely.
I recently stripped a bike and engine ,changed the starter clutch and put it all back together, i would have done it in two days if it was not for needing some tools ie a 36mm socket for the sprocket nut, and orings and gaskets that i didnt even know exsisted! Theres always something you havent got !!
Good luck

**cyberzar** · #3 13 Apr 2008

is possible but would be good if you study the whole process with mister Clymer

you need also a pneumatic gun to remove clutch and a special tool for flywheel, plus the thing (spessors) to measure valves position

considering all, two days, 16 hours (maybe more) should be enough. But you could also find that

screw that could slow down your process, so be prepared for a longer time if luck is not with you.

Keep doing a lot of pictures when you disassemble, keep small boxes and cardboard pieces with holes for screws, it could help in the reverse process. If you never did it, a friend could help in some operations when removing the engine as it's a 50Kg boy...

**Tenere Tom** · #4 13 Apr 2008

Thanks for the replies guys!!!

I have a Clymer manual to hand so it should be pretty straight forward.
As mentioned before the fly wheel puller could be a prob - I might have to pick one up if the one I have doesn't fit.

As for the weight issue - the manual suggests removing as much as you can while the engine is in the frame so you are not struggling on a bench trying to undo that realy tight nut with the engine rolling about.

Thanks again Tom

**andylarkin** · #5 13 Apr 2008

Can you give us an update when you get it done, as I am in a similar position as you with the same bike (not YOUR bike obviously, but you know what I mean!).

Any potential pitfalls would be greatly appreciated.

Cheers

Andy

**aukeboss** · #6 14 Apr 2008

If you are not planning to replace the crankshaft bearing on the left side, just leave the flywheel in place. Just handle the left hand side with the crankshaft very carefully.

Indeed, if you have all the bits and pieces, gaskets, tools, etc, you could even do it in 8 hours.
As you say, you have a gasket set - if it is not orginal Yamaha, you WILL have oil leaks after a few thousand of km's. At least get yourself all the gaskets and oil seals in the top end original from Yamaha. Th O-rings in the bottom do not matter so much.
Further, the liquid gasket that is used to seal the two crankcase halves and the valve cover MUST harden at least 24 hours at room temperature before you start the engine ... otherwise again, you WILL have oil leaks.

Auke

**Tenere Tom** · #7 14 Apr 2008

I'm not splitting the gearbox I'm using so I don't have to worry about that side of things.
As for not using Yamaha gaskets - they were going to cost more than double what I paid for the set I got (which were still pricey in my opinion).

I will be splitting the offending gearbox to actually see what the problem actually is. I'll post some pics too if anyone is intrested.

Tom

**John Evans** · #8 18 Apr 2008

Hi

Does that mean you might have a spare right hand side crank case cover (kick start model) you would like to sell me. Good luck with your project.

John

**John Evans** · #9 19 Apr 2008

Sounds good - but I can't send you a private message until I have made 8 posts - (6 more needed now so ... how can I contact you?)

John

**Tenere Tom** · #10 19 Apr 2008

I can be contacted on 07787878201 normal hours GMT (don't call me in the middle of the night!!!)

All the best Tom

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