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Old 07-04-2008, 06:12 PM   #1
Olas OP
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'92 XT600 Rebuild w/ pics

I recently purchased a cheap XT600 with 5000 miles on the clock off of a fellow ADVer and decided to tackle this as a project. The bike is mostly all there, but very rough. I know it's been ran with out oil circulating where it should, I started it when I got it over and there were sounds coming from the top end that you knew were just not good.

So today, I started digging into it and for the most part, things did look a little dry up top but not as bad as I thought they'd be.



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Old 07-04-2008, 06:15 PM   #2
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So first to come out where the carburetors, don't look too bad, a little dirty on the outside but they were working fine so I'll leave those aside.





Then, off came the exhaust followed by the airbox... Mostly all the parts on this bike look great, just a little dirty is all.





Okay, so now on to the more interesting stuff...
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Olas screwed with this post 07-04-2008 at 06:48 PM
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Old 07-04-2008, 06:21 PM   #3
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This is the starter gear mechanism, looking a little dry.. The gasket did not survive so I'll have to order a new one of those.

I love how everything is so accessible on this bike, I really didn't have to take much off before I was getting to the rocker cover and the camshaft. Another "it doesn't look as bad as I thought it would" picture.






The camshaft definitely looks a little rough though, not really scored but you can tell it was lacking lubrication.





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Old 07-04-2008, 06:29 PM   #4
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Tomorrow I'm going to take the head of and inspect the cylinder/piston. This is where I suspect most of the damage has been done.. And also look at the oil pump.

I need to figure out why oil was not getting to where it should.. Bad piston rings? Something with the oil pump? Oil passages clogged? This is my first engine tear down (this deep, at least) so I'm going to need some help from you fine folks.. I've done valve seals and head gaskets before but never really had to trouble shoot a problem like the one at hand here.

I'm hoping the more I tear into it the more obvious it will be what's wrong with it. Thanks for checking this out, next chapter will begin tomorrow night..
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Old 07-05-2008, 02:52 PM   #5
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Now..on to the bad stuff.

I took the engine out of the frame today and was able to get the head and cylinder off. It was farily simple, even by myself, now I can see what's wrong here..





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Old 07-05-2008, 02:54 PM   #6
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Ugly

The piston is in really bad shape and it caused damage to the cylinder wall.





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Old 07-05-2008, 02:57 PM   #7
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I need to see about fixing the cylinder and getting a new piston...Any recommendations here?

I guess Wiseco makes some big bore kits for these bikes, need to look more into that and see what other options are out there..


Most of the bike is sitting on the table right now


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Old 07-05-2008, 04:55 PM   #8
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You don't need to pull the engine to get the head and barrel off,it can be done in place easily enough.Pistons are available from 95mm to 101mm.I am running a 97mm ProX in mine.You might want to pull the oil pump for a closer look as to why there seemed to be a lack of oil....or did it just run dry....
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Old 07-05-2008, 05:06 PM   #9
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I recognize that bike. I don't know much about it, just saw it sitting in the garage of the other ADV'er.

What I noticed was that the oil smelled very much like gear oil. If someone poured gear oil in there, that would probably explain a lack of lubrication.

Of course, there's a whole chicken/egg thing there. Could be that someone threw the gear oil in to try to mask the sounds...
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Old 07-06-2008, 06:54 AM   #10
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Quote:
Originally Posted by motu
You don't need to pull the engine to get the head and barrel off,it can be done in place easily enough.Pistons are available from 95mm to 101mm.I am running a 97mm ProX in mine.You might want to pull the oil pump for a closer look as to why there seemed to be a lack of oil....or did it just run dry....

You are right about not having to pull the engine but since there were only two more bolts holding it in place at that point I just went ahead and did it to make things easier. That's good to know about the different piston sizes.. Where did you order yours from?

Quote:
Originally Posted by 309
I recognize that bike. I don't know much about it, just saw it sitting in the garage of the other ADV'er.

What I noticed was that the oil smelled very much like gear oil. If someone poured gear oil in there, that would probably explain a lack of lubrication.

Of course, there's a whole chicken/egg thing there. Could be that someone threw the gear oil in to try to mask the sounds...
I thought the same thing when I drained the oil that was in there, it smelled different for sure. Hopefully the bottom end is not too screwed up.
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Old 07-08-2008, 02:45 PM   #11
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I just put a 95mm Wiseco high compression piston in mine when I rebuilt it, but it already had one in it, just was a bit banged up.
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Old 07-09-2008, 10:14 AM   #12
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Quote:
Originally Posted by alexk243
I just put a 95mm Wiseco high compression piston in mine when I rebuilt it, but it already had one in it, just was a bit banged up.
Hey Alex, where did you purchase the Wiseco piston from and what did you pay for it?
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Old 07-10-2008, 08:46 AM   #13
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Quote:
Originally Posted by asaracho
Hey Alex, where did you purchase the Wiseco piston from and what did you pay for it?
I got it from from Part Warehouse. I get most of my part from there for all of my projects. They are slightly cheaper than bike bandit and if you talk to Steve Dumek there he can set you up with the piston and everything you need if you give him dimensions and stuff. I have had good experiance working with him through most of my ordering issues.

I think I ended up paying $162 for the piston plus shipping.
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Old 07-10-2008, 09:07 AM   #14
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Quote:
Originally Posted by asaracho
Hey Alex, where did you purchase the Wiseco piston from and what did you pay for it?



wiseco

Model YearsBore x Stroke (mm)Bore Size (mm)Wiseco PistonPrice Per PistonRepl. Ring SetRepl. Pin & ClipsComplete Top End Gasket Kit
Standard Compression
XT6001984-9695 X 84954797M09500$168.37 3740XHS550 W5689 W5726
SRX6001984-96964797M096003780XH1984-87 1988-96
Tenere6001984-96974797M09700$185.21 3819XHCW22$31.16 $50.76
11.5:1 Compression
XT6001984-9695 X 84954596M09500$187.47 3740XHS550 W5689 W5726
SRX6001984-96964596M096003780XH1984-87 1988-96
Tenere6001984-96CW22$31.16 $50.76
10:1 Compression
XT6001984-9695 X 84984607M09800$196.40 3858XHS550 W5689 W5726
SRX6001984-961984-87 1988-96
Tenere6001984-96CW22$31.16 $50.76
10.75:1 Compression (Crankcase clean-up required)
XT6001984-9695 X 841014607M10100$196.40 3977XHS550 W5689 W5726
SRX6001984-961984-87 1988-96
Tenere6001984-96CW22$31.16 $50.76



http://www.wiseco.com/Catalogs/Power...aCycleDirt.pdf
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Old 07-10-2008, 09:21 AM   #15
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Wiseco Piston Assembly - 95mm Bore

Dennis Kirk Part #: 4797M09500
Manufacturer Part #: 4797M09500
Your Price: $159.99

Wiseco Piston Ring Set

Dennis Kirk Part #: 3740XH
Manufacturer Part #: 3740XH
Your Price: $30.99
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Do one thing every day that scares you. Baz Luhrmann
Women and cats will do as they please,
and men and dogs should relax and get used to the idea.
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Adventure is discomfort recounted at leisure. Flash / GSWayne
Chrome don't get ya home. Rob Nye
Stamp Out Hoplophobia in Our lifetimes.
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