1Likes
-
1
Post By backofbeyond
|
5 Sep 2014
|
Registered Users
New on the HUBB
|
|
Join Date: Sep 2014
Location: Zion, UT
Posts: 1
|
|
1984 XT600 Engine Disassembly HALTED
I'm in the process of removing the top end cover of the engine on my 1984 XT 600.
I began to hear a knocking sound with 500 miles left on my cross country trip. The motorcycle had been performing with less than peak power for the better part of a trip lasting several thousand miles. I checked and cleaned and rechecked and cleaned the carb a few times, never to much gain. I finally took notice of the shape of the 30 year old boots. They were showing cracks, potentially letting unfiltered air into the fuel/air mix.
Now that I am getting into the engine, I can see that the right-side intake valve is caked in crud. Now is where I do not know how to proceed: to take off the top end cover, my Clymer's manual says to find top dead center. Well, every time I kickstart the motor I'm nearly positive I'm finding top dead center; this is one of the basics of starting a kickstart motorcycle, I believe. According to the manual, the top dead center is found by aligning the inscribed " lT " on the rotor assembly in the center of the quarter-size window at the top of the left-side crankcase cover. When this is aligned, the rocker arms will have "free play" allowing them to be wiggled, it says. I am unable to align the marking and as far as I can tell, at no point is there "free play". As I approach the inscribed " lT " when turning the rotor by hand, the rotor rotates freely, or slightly falls, just past this mark. This position is what I would say is the top dead center by feel alone. I'm confused and I hope that my description of the problem is not confusing to you, the reader. Thanks in advance to those who read.
|
5 Sep 2014
|
Registered Users
Veteran HUBBer
|
|
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
|
|
Get a manual (download from this site) and read the part aboaut setting the valve clearences.
|
5 Sep 2014
|
|
Contributing Member
Veteran HUBBer
|
|
Join Date: Jul 2005
Location: Wirral, England.
Posts: 5,673
|
|
You can't find TDC... (Top dead centre).
The |T mark will indicate top dead centre AND bottom dead centre.
So, if by rotating the Alternator 180 there is no free play, rotate another 180 and try again.
The sure way to know if you have TDC is to remove the spark plug and slide a long, thin probe (screw driver will do). As you turn the engine the piston will go up and down. As will your probe.
When the piston is at it HIGHTEST point in the barrel and the mark |T is showing, you will be at top dead centre.
__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.
|
6 Sep 2014
|
Registered Users
Veteran HUBBer
|
|
Join Date: Apr 2005
Location: Oxford UK
Posts: 2,116
|
|
The piston goes up and down in the barrel and every time it's as high as it will go that's tdc. But the rocker arms can only be free play wiggled every second time the piston comes to tdc. You'll need to work out which of the two tdc's is which.
Ted route is the way to go. Take the plug out and poke something thin down the plug hole. Turn the engine over slowly - otherwise the screwdriver or whatever you're using can get jammed in place, and feel the piston come up. When it gets to the top (you don't need to be exact - near enough is good enough) check for wiggle. If the valves are held down or moving you need to turn the engine over once to the next tdc and check again.
A quick way of doing it is to take the plug out and put your finger loosely over the plug hole. Turn the engine over and you'll feel air escaping past it on the compression stroke. That's the correct tdc.
|
23 Sep 2014
|
Registered Users
New on the HUBB
|
|
Join Date: Sep 2014
Posts: 5
|
|
Take the spark plug out, and use a pencil to put it in the spark plug hole. Spin the stator rotor counter-clockwise, and stop when the pencil starts to go back down again, then find the highest point the pencil goes to. The valve clearances arent much on these bikes, it may be hard at first. If there is no wiggle, rotate the engine 180 degrees (piston goes back down, then back up). Im betting your knocking noise is a bad piston/bore, but check the easy stuff first.
|
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
HTML code is Off
|
|
|
|
Next HU Events
ALL Dates subject to change.
2025 Confirmed Events:
- Virginia: April 24-27 2025
- Queensland is back! May 2-4 2025
- Germany Summer: May 29-June 1 2025
- CanWest: July 10-13 2025
- Switzerland: Date TBC
- Ecuador: Date TBC
- Romania: Date TBC
- Austria: Sept. 11-15
- California: September 18-21
- France: September 19-21 2025
- Germany Autumn: Oct 30-Nov 2 2025
Add yourself to the Updates List for each event!
Questions about an event? Ask here
See all event details
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.
"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™ 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!
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.
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.
|
|
|