That hole you're mentioning...ain't it the one on top of the oil filter? that's a normal hole that you use to bleed the air in the oil system!

If you're talking about something else just ignore what I said :rofl:


Vando :innocent:

it looks like it's been a minor upgrade to supply more oil to the gearbox,it should be ok to blank it off

You might be right wolfzero it could be the bleed hole,maybe this is an upgrade to make it self bleed ?

trying to upload a picture of it, its called an oil delivery pipe number 5

Oh it's that.... I thought you were talking about the OUTER casing lol

I do have that copper pipe on my 1990 XT600E... in mine, If I want to remove the e-start motor I have first to remove that metal pipe...

I don't know how it works...it might take oil from the outer casing into the center case or it could be the other way around...

If you're engine doesn't have the other end for that pipe I suggest you do one of two things... easier is to just put a screw that closes that OR much harder, have machine a way to put that oil feed line in your carter!

I'd go with the first option tho :rofl:

Vando :innocent:

Can't get crankcase altered as it's different on the inside so looks like the first option,should be ok if earlier cases never had that pipe

have a look here

www.xt600.de

under the words Zusatzschmierung für den 5. Gang

on newer engines it was added a hole that brings fresh oil over fifth gear, trying to avoid well known pitting problems. I think that this is the tube you are talking about. Maybe you could follow the instructions in linked webpage.

It's not in English :(

not had chance to look into it fully but looks cyberzar is right that its an extra lube to the gear box. our 4tp gear boxes have a stronger 5th gear anyway so it should not be a problem.
i'd keep a look out on fleabay for the later cases as they do pop up now and then i got a brand new set in stock for the next project they are very expensive new i think they are about £800 a pair.

should the crankcases slot together flush without any pressure ?
mine go together ok until the last 2-3 mm then have to be pulled together with the bolts,i took them apart dozens of times and cant see what could be causing it.
they went flush no problem with the internals out.

there will be a bit of resistance its probably just the bearings and shafts seating correctly coat everything you can in oil to help.
when the two halves are assembled turn the engine by hand check the crank and balance shaft turn free i'd also turn the gearbox output shaft by hand and check all gears can be selected too if thats ok then it should be fine to carry on assembling the rest of it.

Everything seems to be nice to turn except the gears,they do turn but not as easy as they did before I put the crankcase together,all the gears are selecting ok,I can turn the gear shaft by hand it just feels like it's got a bit of resistance.

give the input and output shafts a tap with a rubber hammer to seat them correctly and see if that helps

Will give it a try tomorrow

Hi widget, you can use any 3AJ engine as a donor, first used on the Tenere 88-91 then offered on XT600 electric start models from 91-2003, if you can get the wiring loom ect from the donor bike it would be helpful otherwise fit your old generator to the new engine, on your model the clutch cable runs down the right side of the bike and operates through the clutch housing, on the earlier model it runs down the left side and operates through a linkage mounted through the top ot the gearbox, so if its an earlier engine get the clutch cable with the engine, its not a bad swap. I did it the other way, I fitted a 2003 XT600 engine in my 89 Tenere. if you really had no choice you could also fit the earlier 1VJ engine with electric and kick start, but they have plenty of week points, only as a last resort, good luck gary