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Old 05-03-2013, 05:27 AM   #7456
lookfar
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Joined: Feb 2011
Location: Cairns, FNQ
Oddometer: 549
Quote:
Originally Posted by Homerb View Post
Well the cases are apart and its not real good news. A mysterious chunk of aluminium got wedged between the gears on the crankshaft and the balancer.

As this aluminium was chewed up buy the balancer gears, its caused the balancer drive gear on the crankshaft to slip and rotate about 100 degrees from where it should be. This caused the balancer and crankshaft to collide, effectively seizing the engine. The hole in the gear should line up with the crank pin!

Somehow I've avoided any obvious damage to the cases.

Unfortunately it feels like the big end bearing is buggered, and it was only one hour old! I'll have my crankshaft guy look at it on Monday, hopefully its not bent, and just needs another rod kit fitted, or maybe just a new bearing if I'm lucky.

If the crank is screwed, so am I, at $1100 for a replacement!

The other problem is the bottom of the cylinder sleeve has a big chunk broken out of it. Not sure how that happened. Luckily I've got a spare sleeve which I fitted to the barrel this arvo. I'll just have to get it bored to suit the oversize piston.

My biggest concern is where the hell did the chunk of aluminium come from??? Ive checked every piece of the engine from the valve cover down, and I can't for the life of me figure out its origin. This worries me, cos what else am I missing, and I sure dont want to rebuild this thing again only for it to go bang a second time.

Heres a couple of pics of whats left of the mystery piece. Any ideas???
Maybe we could start an XL600 guessing competition? Name this fragment!!!

Is the piston complete?
Hasn't got a bit missing from the skirt?
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Old 05-03-2013, 05:43 AM   #7457
brucifer
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Location: Eureka, Ca.
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Lookfar, that was my first thought.
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Old 05-03-2013, 05:46 AM   #7458
Homerb
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Checked and triple checked the piston. Looks like new and all there. Better check it again though!
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Old 05-03-2013, 07:28 AM   #7459
Reposado1800
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Joined: Dec 2006
Location: 5th and Main
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Quote:
Originally Posted by Dracus124 View Post
Now that's some shit right there

I'm curious as hell what that chunk is. Where's MCMA??


Anyway, my bike has been hard to start last couple days, then today it just wouldn't start. Checked sparky, it looked fine,good color, nice blue spark. I put a new spark plug in anyway and kicked it over, started right up, cool! I went around town and some trails for about 30 mins with no problems, ran excellent as it should. Get home and I try to start it again, nothing. I then accused my cheap stator, but everything electric all read excellent on the multimeter. I hope my carb(s) are just dirty, I Knew the bike was coming up on a carb cleaning ~1K miles, I figured I could atleast get there before I'd get any problems. Gonna pull them tomorrow and check my valves while they soak. Sorry guys, mainly just typed this up to keep my thoughts somewhere
Valve seat coming loose when hot.
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Old 05-03-2013, 07:38 AM   #7460
mcma111
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Quote:
Originally Posted by Dracus124 View Post

Now that's some shit right there

I'm curious as hell what that chunk is. Where's MCMA??

Well if I had the engine in front of me I might be able to say where that piece came from but from where I'm sitting I can't see it.
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Old 05-03-2013, 08:11 AM   #7461
Reposado1800
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Quote:
Originally Posted by mcma111 View Post
Well if I had the engine in front of me I might be able to say where that piece came from but from where I'm sitting I can't see it.
It looks like a piece of the clutch basket, or something was dropped inside during assembly. Not many aluminum parts inside to do that.
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Old 05-03-2013, 08:14 AM   #7462
davek181
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Location: Idaho
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Interesting shrapnel indeed. There appears to be no paint on it and as I remember all the internal cases are painted. I took a look at my spare cases and see nothing that looks similar to that and unpainted. If I had the parts to rotate around in my hand and study I might get a better idea too.

I am curious what broke the cylinder without hurting the piston. If something big enough to do that got around the crank area to do that there should be other signs too. If the same piece did both then it had to travel a rather circuitous path to get there.

The broken pieces look to have a polished/finished surface on it, possible former snap ring groove? did you look real close at the clutch hub and basket? Is there any signs of former threads? Did you account for all the broken cylinder pieces too?

Not trying to insult intelligence or anything, just rambling on and guessing myself from clues present.

I had a tiny piece of something get loose in my engine after many thousands of miles of running and it got between the crank gears out at the oil pump gears. It bent the end of the crank a little and I was able to bend it back to true. Curiously a few miles after repairing that the crank web broke on the flywheel side. (possibly unrelated to that incident) It wasn't till actual reassembly with a different crank that I found the broken piece, it was stuck to the pulse coil.
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Old 05-03-2013, 11:55 AM   #7463
transalper
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Joined: Apr 2002
Location: MN, USA
Oddometer: 305
XL600R rack on a XL350R?

Hey guys,

I'm in the market for a pannier rack for my 84XL350R. The TCI rack for the xl600 looks tempting, but I do not want to pull the trigger without some confirmation that it will fit.

Sorry if this question has been asked before.

Thanks!

Jay in MN
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Old 05-03-2013, 12:25 PM   #7464
Carter Pewterschmidt
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What a mess inside there man, sorry to hear about it.
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Old 05-03-2013, 12:27 PM   #7465
RFVC600R
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Location: SAND LAND
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Quote:
Originally Posted by Reposado1800 View Post
Valve seat coming loose when hot.
I guess cleaning the carbs fixed the valve seats, it starts fine now. And it didn't matter if it was hot or cold, just wouldn't do anything, not even a cough. I'm going to go pick up a spare engine on monday. its from an 87' XL. Gonna rebuild it, slap it in the bike, then rebuild the old one. So if a valve seat grenades my engine soon, it wont be a big deal. Wouldn't valve seat noise come from the top of the engine? the noise was lower when it happened..... like down in the stator area, though I wasn't listening for too long, you gotta be a maniac to keep an engine running with that noise.

No ideas on the shrapnel anyone??
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Old 05-03-2013, 12:50 PM   #7466
scrubby81
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OK not saying that it was left but you said that bearing was an hour old. When the motor was apart did something get left behind? I have seen new engines come in that the valves wouldn't adjust or they don't turn over with a rag wrapped up in the cam.
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Old 05-03-2013, 02:10 PM   #7467
JimRidesThis
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Location: Cumbria, UK
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Quote:
Originally Posted by Homerb View Post
Well the cases are apart and its not real good news.
My first thoughts would be a fragment of piston but you already checked. I hope it isn't too prohibitive or expensive to fix.
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Old 05-03-2013, 02:28 PM   #7468
RFVC600R
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Well the XL is going up for sale, I will be picking up a 650L, getting tired of the 30 year old gremlins. Ole' reliable has become ole' piece of crap. now it isn't wanting to start again, fucking turd I got too much money lost in this thing it just sucks it keeps having problems, and its only been recently. I really love the bike Rebuilt engine with receipts doesn't mean it was done right as I've come to learn. I don't want to be riding a time bomb. Soo mad...
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Old 05-03-2013, 04:26 PM   #7469
Carter Pewterschmidt
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Location: Milwaukee
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Quote:
Originally Posted by Dracus124 View Post
Well the XL is going up for sale, I will be picking up a 650L, getting tired of the 30 year old gremlins. Ole' reliable has become ole' piece of crap. now it isn't wanting to start again, fucking turd I got too much money lost in this thing it just sucks it keeps having problems, and its only been recently. I really love the bike Rebuilt engine with receipts doesn't mean it was done right as I've come to learn. I don't want to be riding a time bomb. Soo mad...
Old bike problems...
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Old 05-03-2013, 04:27 PM   #7470
mcma111
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Dracus,

Mechanical or electrical? If there is an engine problem put the engine in a box and send it to me. I'll go through it. Correctly this time.
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