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**no1sun** · #1 4 Sep 2019

This is my first post on this forum. I bought an XT600E 1990 last year that had been stripped down and rebuilt. Turns out that it was more a cosmetic rather than mechanical refurbish. Anyway, after carrying out carb overhaul, valve check, starter motor overhaul, chain and sprockets, electrics, brakes, built a pannier rack and replaced most fasteners with stainless, new battery, spring washers and loctite..... the bike is running great but has always been a bit noisy. Never had a big single so never thought anything of it.
I was off on a trail behind Tyndrum, Scotland, through Glen Lyon and this consisted of a rocky road and going through some streams (deeper than I first thought lol) lots of standing up and in 2nd/ 3rd gear. Next day the bike was sounding more rattly than normal especially at lower revs. Decided to check the primary gear/ balance shaft sprocket (clutch side) and it was loose. On further inspection the key was also sheared.
I purchased some 7mm x 7mm key steel and fitted into the key way. The length is around 30mm. Torqued the nut to 120 Nm (think this should have been 60 Nm?) build back up with new oil and filter and the engine is super quiet.