Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Daniel Rintz, Himba children, Namibia

The only impossible journey
is the one
you never begin

Photo by Daniel Rintz,
Himba children, Namibia



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 18 Jun 2009
sanderd's Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Aug 2007
Location: the netherlands
Posts: 162
TT600R 2003 3AJ topend rebuild and more

Hi all,

you might noticed my post on rear rim replacement. I'm in Medellin now and plan on doing major service, besides the rim.

This will include:
-Compression check (lately not a lot of resistence when kicking).
-Top end rebuild (200cc oil every 400km is a bit too much)
-preventive change of clutchplates (now 50000 on the clock, of which 45000 with luggage). Got clutchdrag, cannot find neutral easy, doesn't slip yet but it doesn't seam to release properly, feels like plates stick. which is not a nice experience when putting in gear with cold engine on choke)
-inspection/grease rearlink barrings
-check steering head baering, but they seem fine.
-the usual replacement of wear and tear parts. (pads, oil, filter, valve check)
-new chain+sprocket set

Colombia just seems the right place for it ;-)

Questions:

-What are typical parts to e replaced with a topend rebuild? Just cilinder bore (do i really need that??), piston set (+0.5mm oversize when bored), valve stem seals? In the proces i will check valve seats, to see those are ok.

-Clutch replacement. Based on crosscheck partnummers TT is same as same enginemodel XT. but i'd like to have 1 hand confirmation. What is the enginetype, 3AJ?

-Can i do the top end with engine in frame?

-Are there any recommended other check/replacements while i'm at it?
(distribution chain?)


any thoughts, questions and experience is welcome

Sanderd
Reply With Quote
  #2  
Old 19 Jun 2009
Registered Users
Veteran HUBBer
 
Join Date: Jan 2001
Location: Stockholm
Posts: 651
some remarks

I never did major engine work on my TTR, but did do a lot on our two Tenere's, which have almost identical engines.

-Compression check (lately not a lot of resistence when kicking). ** Why do that if you will rebuild the topend anyway? It will tell you nothing about the state of the oilrings, only about the two upper piston rings.
-Top end rebuild (200cc oil every 400km is a bit too much) ** The rule of the thumb is that revision @ 1 liter / 1000 km - you are not there yet. If you know that your bikes drinks oil, just make sure to top up in time
-preventive change of clutchplates (now 50000 on the clock, of which 45000 with luggage). Got clutchdrag, cannot find neutral easy, doesn't slip yet but it doesn't seam to release properly, feels like plates stick. which is not a nice experience when putting in gear with cold engine on choke) ** Easy operation, why not? Although not sure that it will cure the problem. Could also be the oil you are using.
-inspection/grease rearlink barrings
-check steering head baering, but they seem fine.
-the usual replacement of wear and tear parts. (pads, oil, filter, valve check)
-new chain+sprocket set

Colombia just seems the right place for it ;-)

Questions:

-What are typical parts to e replaced with a topend rebuild? Just cilinder bore (do i really need that??), piston set (+0.5mm oversize when bored), valve stem seals? In the proces i will check valve seats, to see those are ok.
** If you do this, in my experience no use to just install new piston rings /piston. Better then to rebore to oversize
Parts (all Yamaha original!!):
- Head gasket
- Little oil seal (rubber cilinder) 2x (1 between crankcase and cilinder, 1 between cilinder and head)
- Base gasket
- O-ring around cilinder barrel
- Non-hardening liquid gasket, high temperature
-Clutch replacement. Based on crosscheck partnummers TT is same as same enginemodel XT. but i'd like to have 1 hand confirmation. What is the enginetype, 3AJ? ** Think so - you could cross-reference via kedo.com, their catalogue. The 3AJ stamped on your cilinder just indicates that this part was first used in the 3AJ. Your engine type is 5CH or something.

-Can i do the top end with engine in frame?
** On all Tenere's and XT's yes. If the Italians have been smart, also on your TT. Do not forget the allen bolt hidden between the upper frame mountings. Take off the carbs,undo all allen bolts and tilt the valve cover backwards
-Are there any recommended other check/replacements while i'm at it?
(distribution chain?) ** Nothing else. If you can get a good chain, and have access to the correct puller for the flywheel, go for it.

Please let me know how things go in Colombia; I will be there in September and also might need some work done on the Tenere's. Are you heading S or N?

Regards,
Auke
__________________
Auke
http://aukemarieke.blogspot.com
Reply With Quote
  #3  
Old 19 Jun 2009
sanderd's Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Aug 2007
Location: the netherlands
Posts: 162
hi Auke,

Thanks for your input.

The compression thing is more out of cusiosity: is it lower, or is it just that my right leg is stronger than before? :-)

I'm heading south, but need another month or so to see Colombia.

ciao,
sander
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
Top End rebuild Lamin Sambou Yamaha Tech 9 3 Jun 2009 17:30
speedo rebuild? carwyn Yamaha Tech 4 8 Feb 2009 14:30
Top end rebuild bolla Yamaha Tech 3 15 May 2006 20:28
Top End Rebuild Geoff van de Merwe Yamaha Tech 4 23 Dec 2002 03:11
Engine Rebuild t0by Kawasaki Tech 4 26 Sep 2002 15:43

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now
, and add your information if we didn't find you.

Next HU Eventscalendar

HU Event and other updates on the HUBB Forum "Traveller's Advisories" thread.
ALL Dates subject to change.

2024:

Add yourself to the Updates List for each event!

Questions about an event? Ask here

HUBBUK: info

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.




All times are GMT +1. The time now is 21:48.