![Reply](https://www.horizonsunlimited.com/hubb/images/buttons/reply.gif) |
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
30 Mar 2010
|
Registered Users
HUBB regular
|
|
Join Date: Apr 2008
Location: Alesund, Norway
Posts: 53
|
|
Two questions.. for now...
Hi
As Im trying to take apart my engine xt600z (3ds) i have two questinos to ask you who have done this before...
1 - Are the rotor and "starterwheel/sprocket" one piece? Extremely hard to pull it off, no success yet. I see 3 hex bolts in there, do I take them out and separate it?
2 - Will the clutch come off in one piece with all plates in it, or do I have to take it down piece by piece?
Ill probably bomb you guys with questions for a while. Its my first time tearing down this thing, Ive searched the forum ,found many answers but not all, so please bear with me
Thanks
Osmund
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
30 Mar 2010
|
![palace15's Avatar](https://www.horizonsunlimited.com/hubb/images/avatars/Avatar116.jpg) |
Registered Users
Veteran HUBBer
|
|
Join Date: Feb 2005
Location: LONDONISTAN, England
Posts: 1,034
|
|
Do you have a manual? If not, try www.carlsalter.com hope this helps.
__________________
'He who laughs last, was too slow to get the joke'
Never confuse the map with the journey.
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
30 Mar 2010
|
![bacardi23's Avatar](https://www.horizonsunlimited.com/hubb/images/avatars/Animal017.gif) |
Registered Users
Veteran HUBBer
|
|
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
|
|
I don't remember about the flywheel but the clutch will come off without having to take the plates off!
I do remember that my flywheel was a pain to come off! It's really tight! it has to be....
All you gotta do is remove the clutch springs and remove the big nut in the middle of the clutch!
Vando
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
31 Mar 2010
|
Registered Users
Veteran HUBBer
|
|
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
|
|
Miss,Miss....I know this..
Right ..I,ve just done this and caused a lot of damage....
First the rotor...you get your three high tensile steel bolts and a round disc/puller and load up the puller really really tight then hit the end of the puller shaft with a hammer...seriously....and it will pop off with some force. Mine jumped off about a foot and landed on the floor.....it was horizontal at the time.
The next side is the clutch.....the way to do it is with a rattle gun....air operated.....I tried with a strap wrench and broke the outer leg of the clutch basket ....then I tried to hold the three legs on the inside and broke one of them off. I just bought a second hand clutch from e bay at 200 bucks.!!
Took the whole engine into work tonight and I sh..t you not I gunned the rattle gun twice and the nut came off( not forgetting too bend over the tab washer)
Its on the back seat of the car as I,ve just got home from work....you can check my earlier posts about the clutch breaking.
I,m pulling mine apart for the fifth gear problem so if I come across any problems I ll post it ....good luck with the engine strip....you can also you tube it ...just put in yamaha srx600 engine...and there is a dutch guy stripping the engine which is the same as the xt just about but not using any pullers or really straining to get bolts undone so I think he had it already stripped before....good luck and take care....
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
31 Mar 2010
|
Registered Users
Veteran HUBBer
|
|
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
|
|
Sorry ...the answer to your first question about the clutch is to take the five bolts out and remove the cover then remove all the disc,s and stack them up one on top of each other and underneath is the large nut with a tab washer on it...unbend the tab washer and use a pnuematic rattle gun to remove the large nut......you will only damage the rotating assemblies by trying to hold them.........
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
31 Mar 2010
|
Registered Users
HUBB regular
|
|
Join Date: Apr 2008
Location: Alesund, Norway
Posts: 53
|
|
Thank you guys for very good info. Ill go get a rattlegun first thing when the shops open again... AFTER EASTER!! :-( getting impatient now, hehe.
Better get a proper puller too, only reason I didnt get it was that it cost $100..but seems like I cant do it without it...
Found the workshop manual for the xt600e, and thats pretty helpful
Thanks again, and enjoy easter holydays :-)
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
31 Mar 2010
|
Registered Users
Veteran HUBBer
|
|
Join Date: Aug 2009
Location: Dorset UK
Posts: 395
|
|
$100 sound a lot - there are loads of universal puller about for a fraction of that (eBay) that should do the job?
NB: Clutch plates - I think there is a thicker one in amongst that lot somewhere????? SO check as you remove them to keep them in order.
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
1 Apr 2010
|
![bacardi23's Avatar](https://www.horizonsunlimited.com/hubb/images/avatars/Animal017.gif) |
Registered Users
Veteran HUBBer
|
|
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
|
|
There are only 2 discs (they are the same) but are different from all the rest plus, don't forget to put in the disc-shim that works as a small spring!
Vando
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
5 Apr 2010
|
Registered Users
HUBB regular
|
|
Join Date: Apr 2008
Location: Alesund, Norway
Posts: 53
|
|
Alright!!! The crankshaft is off!!!!
The Rotor took me a couple of days to get off, but it came off tonight with my homemade puller. Would have saved me a lot of trouble if the stores were open and I could have bought a decent one...
Clutch was easy, just looked a bit scary before I started with all the springs and plates.. actually had a makita battery rattlegun that took the nut on the clutch so I didnt have to hold it and maby damage it.. Excellent!!
Otherwise its going great, thanks to you guys, for good help and mailed manuals..
I use a lot of papercups and plates to keep a system on parts and screws, and it seems to work fine.
Biggest mistake so far is that I didnt clean the engine properly before I started... Didnt even cross my mind, so THATS a lesson learned.. Much harder to do it piece by piece as I go...
Now Im going to restore the crankshaft. Actually I found a shop 40km away that has been doing that since the 80`s, so Ill try them this time.
Do you guys always use new gaskets when reassembling, or just the silicone-gasket?
Osmund
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
6 Apr 2010
|
Registered Users
Veteran HUBBer
|
|
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
|
|
I bought a complete gasket set from e bay and already used the valve seals but I need some liquid gasket for the crankcase halves....use sparingly....
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
8 Apr 2010
|
Registered Users
HUBB regular
|
|
Join Date: Apr 2008
Location: Alesund, Norway
Posts: 53
|
|
Just talked to the guys doing the crankshaft; it will be NKR 3000 (£300) to fix it. Only £40 for labour, the rest in parts. A conrod-kit + the left side bearing.. A bit more than I was hoping for, but then at least it will be as new
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
17 Apr 2010
|
Registered Users
HUBB regular
|
|
Join Date: Apr 2008
Location: Alesund, Norway
Posts: 53
|
|
Crank pin...
Just picked up my restored crankshaft today, and got the old parts too..
No wonder the engine didnt sound right.. conrod was worn at the small end, and check out the crank pin...a groove going halfway around..
And just to ask, why are the exkaust-valves white, while the intake valves are black? Does that mean anything?
![Two questions.. for now...-valves.jpg](https://www.horizonsunlimited.com/hubb/attachments/yamaha-tech/3223d1670199678t-two-questions-for-now-valves.jpg)
Osmund
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
17 Apr 2010
|
Registered Users
Veteran HUBBer
|
|
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
|
|
No idea as when mine came off everything was black.....hope some one will come along with an answer ..
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
18 Apr 2010
|
Registered Users
Veteran HUBBer
|
|
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
|
|
White does often mean lean, and lean means hot.
The tip on the sparkplug seems white to, is it?
|
![Old](https://www.horizonsunlimited.com/hubb/images/statusicon/post_old.gif)
18 Apr 2010
|
![wolfzero's Avatar](https://www.horizonsunlimited.com/hubb/images/avatars/Avatar066.gif) |
Registered Users
Veteran HUBBer
|
|
Join Date: May 2009
Location: uk
Posts: 434
|
|
looks like you're running a wee bit lean i'd raise the needle a clip as its probably when running at 3/4 throtle on that worn engine thats done it.
the reason the exhaust valves are white and the inlets still black is due to the exhaust valves always run hotter as there is nothing to cool them you have cold air and fuel mixture cooling the top side of the inlet valves but there is just hot exhaust gas on the top side of the exhaust valves.
__________________
XT 630 SUPERMOTO
GSXR750L ![Cool4](https://www.horizonsunlimited.com/hubb/images/smilies/cool4.gif) KMX200
RF900 & GSX400X Impulse Projects
3.9 V8 Rangerover
|
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
|
|
|
|
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.](/stuff/ripcord/ripcord-logo-250.jpg)
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!](/stuff/grahamfield/graham-field-2021-280.jpg)
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.
|
|
|