2002 xt600e engine rebuild/replacement questions

[N67]

hi there

disassembling engine after the session of excessive smoking.
broken piston skirt and some vertical crack on cylinder wall for now
more details and photos bit later.

for now just curious to know, *IF* it's only about piston and cylinder, which years/codes to avoid as a replacement?
also, is cylinder sleeve (separately) could be a reliable solution (press fit etc.)?

considering mileage (reaching 170k) and overall amount of scars, used to think about new engine as well even before this issue. same question here, which years to avoid in terms of fitment?

[xtrock]

Originally Posted by N67

hi there

disassembling engine after the session of excessive smoking.
broken piston skirt and some vertical crack on cylinder wall for now
more details and photos bit later.

for now just curious to know, *IF* it's only about piston and cylinder, which years/codes to avoid as a replacement?
also, is cylinder sleeve (separately) could be a reliable solution (press fit etc.)?

considering mileage (reaching 170k) and overall amount of scars, used to think about new engine as well even before this issue. same question here, which years to avoid in terms of fitment?

Hi, yes best is to find a used low mileage, years from 90-02. The 96-02 best engine with, gearbox issue sortet 5th gear and top cover welded differently so it wont crack. You can change sleave, you have bits of piston all over engine so it must be teared apart.

[N67]

Originally Posted by xtrock

Hi, yes best is to find a used low mileage, years from 90-02. The 96-02 best engine with, gearbox issue sortet 5th gear and top cover welded differently so it wont crack. You can change sleave, you have bits of piston all over engine so it must be teared apart.

thanks for info.
will try to go with 96-02 engine option, but so far not sure if current budget will allow this, so maybe will have to find cylinder-piston kit instead.
how about earlier years in such case? checking some stuff online and so far older cylinders visually look similar...

meanwhile, here's the main character of the dark story above -


yep, some archeology must took place in the engine. oil rings were also broken (partially), luckily, at least their remains were successfully captured by the magnets.

[xtrock]

Originally Posted by N67

thanks for info.
will try to go with 96-02 engine option, but so far not sure if current budget will allow this, so maybe will have to find cylinder-piston kit instead.
how about earlier years in such case? checking some stuff online and so far older cylinders visually look similar...




meanwhile, here's the main character of the dark story above -


yep, some archeology must took place in the engine. oil rings were also broken (partially), luckily, at least their remains were successfully captured by the magnets.

You dont know what was captured or not before entire engine is dismantled, dont take easy shortcut changing cylinder/piston and start up.. End up with new failure and heavy damage on cylinder walls/piston. Before 90 it was 2kf cylinder, after its 3tb up to 02, its expensive for piston wiseco is 190$ + cylinder. Total overhaul with gaskets and bearings + some workshop help is fast 1500$. I would think its easy to find a used old bike one for 2-3000$.

[N67]

thanks again for infos.
guess after finishing the engine disassembly will have more clear idea as well as further plans.

[xtrock]

Originally Posted by N67

thanks again for infos.
guess after finishing the engine disassembly will have more clear idea as well as further plans.

If you doing rebuild buy new rod with bearing when you first have to dismantle everything, i would never reuse the rod bearing after this. And maybe a part of the reason piston failed is slack in that bearing. Anywaysits importan to do maintence before this happens, no piston last forever, pre change parts is alot cheaper than total rebuilds after all is crashed.