Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
xt600 cylinder head & cam worn xt600 cylinder head & cam worn
Register FAQ Calendar Today's Posts
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by George Guille, It's going to be a long 300km... Bolivian Amazon

I haven't been everywhere...
but it's on my list!


Photo by George Guille
It's going to be a long 300km...
Bolivian Amazon



Reply
Page 1 of 2 1 2
 
LinkBack Thread Tools Display Modes
  #1  
Old 2 Nov 2010
Registered Users
New on the HUBB
  
Join Date: Nov 2010
Location: Kent
Posts: 14
xt600 cylinder head & cam worn
Hi to all (just joined 2day)
Help needed with 1985 xt600 C reg recently purchased bought it with a nasty top end noise (metallic rattle) have stripped the top off, the cam + journals are scored and dont look good so i think it needs another head / cam etc unless anyone can tell me otherwise ?
The question is the frame / engine nos. are 43F but the head are cylinder are 34L is this right or is it a problem or are the parts interchangeable?
Reply With Quote
  #2  
Old 3 Nov 2010
Registered Users
New on the HUBB
  
Join Date: Nov 2010
Location: Kent
Posts: 14
forgot to say if anyones got a complete head ? let me know
thanks
Reply With Quote
  #3  
Old 3 Nov 2010
Registered Users
Veteran HUBBer
  
Join Date: Jan 2001
Location: Stockholm
Posts: 651
heads up
Yes, the parts are interchangeable - see earlier posts of the intricacies of Yammie part numbering.

How badly scored are the bearing surfaces. They tend to look pretty bad before they are actually shot. Does the camshaft have play when installed? Bad camshaft is also usually a sign of bad or no lubrication, and then normally first the piston goes. You sure that is not the problem?

If they really are bad, you could get a machine shop replace the bearing surfaces in the head / cover with steel shells and use a replacement camshaft (second hand). Might have one lying around, but I'll only know in a week or two.
__________________
Auke
http://aukemarieke.blogspot.com
Reply With Quote
  #4  
Old 3 Nov 2010
Registered Users
New on the HUBB
  
Join Date: Nov 2010
Location: Kent
Posts: 14
pics
Hi thanks for the reply i have just uploaded some pics to show the scoring dont know about the piston yet as i havent taken the head off yet.
As for the lubrication im with you i think it was lack of maintenance oil & filter were very dirty

xt600 cylinder head & cam worn-landscape.jpg

xt600 cylinder head & cam worn-engine01019.jpg
Reply With Quote
  #5  
Old 4 Nov 2010
Registered Users
Veteran HUBBer
  
Join Date: Jan 2001
Location: Stockholm
Posts: 651
Not new, but might still work ..
It does not look too bad, indeed some scoring but not over teh whole bearing surface. Should it be bombproof after repairs or can you take some slight chances? That is, you do not want to be stuck in the middle of Congo with a broken camshaft.

I'd first check piston / cilinder and cam chain - those are the parts that rattle if worn. I actually would not know what noise a camshaft would make.

I also notice an enormous amount of liquid gasket on the mating face cover / head. The 2 are supposed to be joined metal-to-metal with only a very small amount of liquid gasket. Reason is, the 'bearings' for the camshaft are drilled like that, so that state should be copied at reassembly.

Success!
__________________
Auke
http://aukemarieke.blogspot.com
Reply With Quote
  #6  
Old 6 Nov 2010
Registered Users
New on the HUBB
  
Join Date: Nov 2010
Location: Kent
Posts: 14
Aukeboss when you say
"I also notice an enormous amount of liquid gasket on the mating face cover / head. The 2 are supposed to be joined metal-to-metal with only a very small amount of liquid gasket. Reason is, the 'bearings' for the camshaft are drilled like that, so that state should be copied at reassembly."

there is actually a gasket in amongst all that sealant ? but what you say does make sense

Engine is now stripped indeed the piston is quite badly scored and the cylinder bore has some wear so i think it will be a new piston and rebore also the cam chain adjuster is on full adjustment
Attachment 4052

Think i found what may of caused the bad lubrication some runny chewing gum like sticky substance in the bottom of the engine think it was maybe like some kind of leak stopper or something but it probably blocked it all up
Attachment 4053

also have tried searching earlier posts for the intrices of the engine numbering but no joy do you know would a 3AJ cylinder fit

thanks
Reply With Quote
  #7  
Old 6 Nov 2010
Registered Users
New on the HUBB
  
Join Date: Nov 2010
Location: Kent
Posts: 14
xt600 cylinder head & cam worn-06112010198.jpg

xt600 cylinder head & cam worn-06112010199.jpg

dont think the pics came out in prev post
Reply With Quote
  #8  
Old 6 Nov 2010
Registered Users
Veteran HUBBer
  
Join Date: Jan 2001
Location: Stockholm
Posts: 651
a gasket?!
There should definitely NOT be a gasket there, or you have a version from out of space. Just remove all the goo, and install camshaft in the head and the cover on the head. Camshaft should turn easily. Little test should confirm my statement. Might also be the cause of your lubrication problem: the gap between camshaft and bearing increased, increasing oil flow to the head and thus reducing oil flow to other parts.
Plus the white goo thing off course. I'd just take the whole engine apart now, since that hardly increases the cost, and you'll be able to clean everything thoroughly. You will of course see the gears which might also need replacement, etc.

The noises you heard were definitely piston / cilinder and / or cam chain. That's good news for the cam shaft and head!

3AJ cilinder fits on this engine. Yes, it will fit on the lower end, but will the head fit onto it? The 3AJ cilinder has 2 bolts at rear and front end of the cam chain tunnel, the earlier version has only one. I'd just do the rebore, more effective than installing a cilinder with unknown history etc.
__________________
Auke
http://aukemarieke.blogspot.com
Reply With Quote
  #9  
Old 18 Nov 2010
Registered Users
New on the HUBB
  
Join Date: Nov 2010
Location: Kent
Posts: 14
new parts ?
ok so i have got a replacement top end from a 1984 TT600 ? the head is marked 1KJ its in perfect condition as is the cam result! the cylinder is marked 3AJ its aluminium with nikasil (are they all like this) its slightly worn and scored the piston is worse
I have tried the new head on the original cylinder 34L but it doesnt fit? the 2 bolts dont line up
is it worth replating and new piston the 3AJ cylinder or should i try and get a head to fit the 34L cylinder which is better?
thanks
Reply With Quote
  #10  
Old 20 Nov 2015
Registered Users
New on the HUBB
  
Join Date: Nov 2015
Location: Netherlands
Posts: 2
xt600 camshaft bearing wear
Another possibility is machine the bearing bore and insert metal replacement journals .

In Germany is a company that will do the job for You, they use proper bearing journals coated with babbits metal .

Another solution to do it Yourself and use bronze journals. The journals used in this xt are porous, so they hold a mall amount of oil when engine is not running .
Attached Thumbnails
xt600 cylinder head & cam worn-p1000726.jpg  

xt600 cylinder head & cam worn-p1000752.jpg  

xt600 cylinder head & cam worn-pennetje-erin-afvijlen-passen-afvijlen  

Last edited by jw222; 20 Nov 2015 at 14:44. Reason: photo upload
Reply With Quote
  #11  
Old 20 Nov 2015
Registered Users
Veteran HUBBer
  
Join Date: Mar 2007
Location: UK
Posts: 4,343
Quote:
Originally Posted by jw222 View Post
Another possibility is machine the bearing bore and insert metal replacement journals .

In Germany is a company that will do the job for You, they use proper bearing journals coated with babbits metal .

Another solution to do it Yourself and use bronze journals. The journals used in this xt are porous, so they hold a mall amount of oil when engine is not running .
An excellent first post so, to the HUBB.

I well recall being a tad surprised at the lack of bearing journals in the head of my TT600R when I took the head off a few years ago.
__________________
Dave
Reply With Quote
  #12  
Old 20 Nov 2015
R.I.P. 25 November 2021
Veteran HUBBer
  
Join Date: Feb 2010
Posts: 688
Quote:
Originally Posted by aukeboss View Post
There should definitely NOT be a gasket there, Might also be the cause of your lubrication problem: the gap between camshaft and bearing increased, increasing oil flow to the head and thus reducing oil flow to other parts.
Bang on.

Mezo.
Reply With Quote
  #13  
Old 21 Nov 2015
Registered Users
Veteran HUBBer
  
Join Date: May 2013
Location: Wisconsin, USA
Posts: 827
After 5 years I think he got it fixed by now


A simple TIG weld up of the journal and remachining of the bore works . For a mild worn journal a person can just face .005-.01" of the top face of the head (or cover , which ever side is worn worse ) and rebore the journals with no welding.
I'd be very Leary of those bushings sliding sideways or spinning and jamming with no locking notches like main crank bearings in auto motors.

Kawasaki also casts a little pocket in the middle of the bottom journals to hold oil for start-up till oil is fully circulating. A person can drill a few small dimples in the Yamaha journal that doesn't have any to do the same to help out.
Reply With Quote
  #14  
Old 21 Nov 2015
Registered Users
New on the HUBB
  
Join Date: Nov 2015
Location: Netherlands
Posts: 2
I've tried TiG welding , however this was a disaster . Possibly due to the composition of the material or the oil soaked in the pores of the aluminium .

The danger of dislocating the journals is minimum, axially they are fixed by the camshaft, the pin stops rotation .

I'll post the results after the engine has run a considerable time .
Reply With Quote
  #15  
Old 21 Nov 2015
Registered Users
Veteran HUBBer
  
Join Date: Mar 2007
Location: UK
Posts: 4,343
Quote:
Originally Posted by jjrider View Post
After 5 years I think he got it fixed by now
Yes. I have wondered what happened to aukeboss; 2010 might be the last year that he posted here (and his blog shows that year as his last input).
__________________
Dave
Reply With Quote
Reply
Page 1 of 2 1 2

« Previous Thread | Next Thread »

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

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
KLE cylinder head ranfog Kawasaki Tech 3 25 Jan 2009 19:42
Cylinder head quietening modifications John Roberts BMW Tech 8 25 Sep 2008 19:18
XL600LMF cylinder head xr200 Honda Tech 1 17 Jan 2007 16:37
Dommie cylinder head mikechips Honda Tech 2 13 Oct 2003 14:22
Cylinder head studs Sean Kelly BMW Tech 6 15 Mar 2003 19:41

 
 

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!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

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 10:15.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top