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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 18 Jun 2009
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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
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Old 19 Jun 2009
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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
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http://aukemarieke.blogspot.com
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Old 19 Jun 2009
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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
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