Mezo`s 1988 XT600 Rebuild Thread (Project Ténéré)

Discussion in 'Thumpers' started by Mezo, Feb 3, 2010.

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  1. Ron Seida

    Ron Seida Adventman

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    Home sweet Home!
    :thumb
    Yup, we know how to get er done, eh! :slurp.
    Now, regarding that piston. Experience has shown me that if you have gone this far into the motor and it looks like that, it is probably worth the money to re sleave it. That being said, measure the bore for oversize, taper and out of round, check the specs. You may get lucky, or you may be able to buy an over size piston and bore to it´s spec, the best and most economical option. Most important, try to find out what caused the scratches in the first place :huh. Piss poor maintinence, or did something let go and rattle around in there? Have fun Mezo!
    #61
  2. Mezo

    Mezo Banned

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    Im busy selling my life & packing boxes, moving out in ten days.

    Had a knock on the door & my screen turned up from Eagle Screens :D

    [​IMG]


    [​IMG]

    Like i said im going to add my own flavor to the build & this is my idea for the front screen (adhesive vinyl graphic) keeps a bit of the original look with the added bling on top :evil

    [​IMG][​IMG][​IMG]
    #62
  3. cyberzar

    cyberzar n00b

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    ok I'm here.. subscribed by menu BTW but just want say hello to XTfriends
    #63
  4. Mezo

    Mezo Banned

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    Hello XT friend :wave

    Glad somebody is following this, i can bore you to death with my new graphics ive been tossing around with tonight. :evil

    [​IMG]

    I made them light blue slanty things, pretty good for an Electrician :D

    What do you reckon Newbie, has the old Sparky got other talents eh? :deal

    Mezo.
    #64
  5. Wolfdog

    Wolfdog Not Scared

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    Mezo,

    in reguard to the sate of your bore, I would'nt wast a second of thought energy trying to decipher if it can be honed out, just get it rebored, i can see enough in the photo that if you just hone it, its going to be an oil burner.

    check what size it is, if by chance its already on its max 1 mm over size then it will be 608cc which is the standard size of an SRX 600, by memory there is another 2 over size's for the SRX, 0.5mm and 1mm.

    and of course there is the after market world with various different options for your bore size.
    #65
  6. Mezo

    Mezo Banned

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    Ahh, hello you must be the detective who found me on ebay :D

    I was trying to find that link, even with translation "Babelfish" i could not see the tab & i do not speak German.

    So your not interested in my kitchen table & chairs delivered to Italy?

    Mezo. :thumb
    #66
  7. cyberzar

    cyberzar n00b

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  8. cyberzar

    cyberzar n00b

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    for the kitchen sorry.. already moved once from one continent to another and deliver by air is toooooo expensive :rofl
    #68
  9. ztaj

    ztaj jatz

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    watching with interest as I plan on doing something similar with the wifes XT,it's an 87 red and white one, just as soon as we can find her another bike to ride/fall off.

    Thread hijack.........
    Popescu
    Any idea what would cause oil to be blown up the breather lines into the airbox. We have been told it's just too much pressure, the bike had a top end rebuild twice last year, every thing else seems normal.It means we have to keep an eye on the oil and it smells like a burning oil field when it's running. Also a pic of your crash bars would be good. Thanks for the links too.
    #69
  10. Mezo

    Mezo Banned

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    Thanks, i went to see a printer this week. I had mailed lots of people to ask if they would do it & no was the reply, seems most print company's just want to do the easy stuff & when in involves a little bit of thought & effort on the PC its all to hard. I took my tank & all plastics down to his shop & set it up on his office floor, like you see in that blue design i did its going to be like that. The main tank graphic with the "600" removed. I measured up various part of the bike to give him measurements.

    The order went like this,

    Main Yamaha tank graphic (blue/yellow) minus the numbers "600" x 2
    Reproduction side panel stripes (blue/yellow) x 2
    Front screen graphic all in yellow like above (YAMAHA/Toureg man) x 1
    Large tank graphics "Gauloises/Blondes" x 2
    Smaller "Gauloises/Blondes" for mudgaurd & side panels x 4
    MOTUL x 3
    TENERE x 3
    MICHELIN x 3
    SONAUTO x 3
    Michelin man (running towards you) x 3
    Gauloises "Winged Helmet" x 2

    So im waiting for the chap (fellow biker) to get back to me with a price $$
    He has said its OK to clear coat over them, which is important because i want the graphics to be in the paint rather than stickers slapped on after.
    You may of noticed there was no YAMAHA graphic in the order apart from on the front screen, the only other YAMAHA will be on the side of the seat, i will have to get it recovered in plain dark blue vinyl & then apply adhesive stencil "YAMAHA" & spray it with white spray.

    The paint job itself is a bit of a problem, had one quote of $2500 to paint the tank & plastics :huh

    At this stage if i can get the equipment ill paint it myself, hell if i can respray a MK1 Escort when i was a spotty 17yr old im sure i can spray a motorbike at age 43. Its almost 100% certain im going to stuff the paint falling off on my trip, i don't want to be worrying about scratching the thing its going to be used & abused so why waste money.


    Wolfdog, yep we agreed over beer it would be better to re-bore it or else it will be a smokey oil burner, i said a fast oil burner though eh :evil so the lads said "just re-bore it Mezo" hey im only trying to save some cash here.

    Managed to buy a secondhand DryRider jacket off a fellow inmate ($125) also got a self inflating mat from the army surplus store here in Perth, also got myself a new Camelback 3ltr with plenty of pockets, also picked out a tent.

    So much to do, so little time.

    Mezo.
    #70
  11. Dino3310

    Dino3310 Been here awhile

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    cant wait for this to be finished Mezo, its gonna look friggen hot mate.
    as for the $2500 paint job:puke1 what a crock of sh#t... you could go out and buy the compressor with spray unit and do it your self for 1/2 the price:D
    shop around mate there should be some cheaper quotes than that.
    #71
  12. Dino3310

    Dino3310 Been here awhile

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    we all spotty 17yr olds at heart mate, why else would we be adventure riding and doing up old bikes:rofl
    #72
  13. Gustavo.Ramos

    Gustavo.Ramos Long timer

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    Hey Mezo, just toss those drawings into a decent photoshop, corel, maybe even PDF, measures, color codes and i'll ask a friend of mine to see if they can print it in a timely fashion, and i'll send it back to you. I'm on the other end of the globe, but we have UPS, FedEx, DHL, and if everything fails: mail pigeons...

    Cheers,
    #73
  14. popescu_mihailraul

    popescu_mihailraul Adventurer

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    $ 2500 is a little bit on the rude side, Mezzo.
    The only thing to be careful about will be the lacquer you apply at the end. Some of them contain solvents that might melt down the stickers. Happened to a guy i know.
    So, better to test before on a little corner of the sheet on which you have the stickers printed.


    Mezzo, hope you do not get angry on me for answering on your topic, but i thought it might interest someone else.

    When the piston rings are heavily used a lot of compression (burnt fuel/smoke under pressure) from the burning chamber will go beside them, inside the crankcase, raising the pressure sometimes too much to be bearable.
    In this time, on the crankcase you have a valve done from a steel ball and a spring. This stays on its place, keeping everything at its place, as much time as the pressure inside the crankcase is ok.
    When too much smoke gets inside, pressure will rise and the spring of the valve will be compressed, will push the ball from the hole he closes and send the under pressure smoke, through a hose to the air filter box.
    This under pressure smoke will always take for a walk with him oil vapours.
    The bigger the oil quantity in the filter airbox there are 2 problems:
    - either the piston rings/piston kit/cylinder is at its replacement time
    - either somebody has poured more than the necessary 2 litres of oil when he has changed the oil.

    The second one happens much more often and i will tell you why.
    After a capital repair or when changing the oil, when you pour the new oil, before pouring it all the oil box gets filled at the maximum (usually after 1.5 litres).
    So you have to start the engine and let it flow inside the engine (very important here, at the first start is to unscrew the upper screw from the oil filter compartment, in order to check the oil flow through the system - all the manuals describe this properly so i will stop here).
    Normally, after little start, there will be no more oil in the box. All you have to do would be to fill the other half litre and finish.

    Do not be scared of the oil box being empty even with this final half liter poured inside!
    Pour the half little and let it go.


    Here comes the big mistake a lot of people do.
    As much as the engine is only running idle, on the center or the side stand, the oil pump will not work properly and will not send back in the oil box enough oil. I am not very technic. I do not know why, but this is what happens.
    Lot of people flow the 2 litres of oil and then let the motorcycle idle in order to check the oil level in 1 or 2 minutes.

    When they check it, they have a shock seeing no oil in the oil box. And most of them will pout more and more oil. I know cases of guys who have flown even 4 litres of oil.

    What should you do?
    You should put yourself on the saddle and ride the bike few hundred meters. Only when in torque/in gear (i don`t know how to say in english - running, placed in gear and spinning) and a little bit revved the engine, the oil pump will run and send oil in the box.
    After this, when you will stop, open the box and check the level you will see i didn`t lied you.
    Maybe 1-200 ml of oil added.

    Biggest chance for oil in the air filter box to come from an overoiled engine.
    Usually, some of it is burnt (as this engine has high tolerances and eats the surplus).
    But in some cases you can end up with worn valve semerings (hope i said correctly - rubber protection with spring inside) or oil spilled inside the air box.

    I will help you with the schemes for the central stand and the crashbars.
    I do not want to look like an userious guy (i am a little bit lazy, must recognize) but please be a little bit patient with me. I am still waiting for parts to come from all over the world (max. 1 week) and i will also start a total rebuild. It will be much easier to do those pics and schemes when i will move into the garage for good.
    #74
  15. Mezo

    Mezo Banned

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    Valve stem oil seals :evil

    Its very easy for me to understand you Raul, you speak the same kind of English as my late father did.

    Thanks for the info, stuff i did not know. And that`s the great thing about forums, you can pull together the knowledge on any subject you choose.

    Its 5am in the morning, i have sold most of what i own over the past few weeks & i am in the middle packing boxes getting ready to move out. Once i have shifted up in to the hills at a mates place the build will start real quick.

    On another subject totally, i was looking round the local bike wreckers at XT parts, mainly at tanks & fairings they have just incase they had one better than mine. I found all sorts of parts whilst looking around but one thing did catch my eye was an original & very clean standard silencer, i thought to myself "i bet there's a bloke somewhere who would kill for this" So if your chasing a real nice standard silencer, i know where there is one sitting on a shelf.

    Mezo. :thumb
    #75
  16. popescu_mihailraul

    popescu_mihailraul Adventurer

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    Mezo, very nice of you.
    I guess somebody will want it after all. I will talk to my buddies and see if there`s someone interested.
    My exhaust is so full of rust that it dances inside when i shake it (kinda cool, actually:D). I would have bought the one you found but i want to change mine for a lighter one (some oval one :evil - hope i`ll get a good price on ebay).
    Very cool is that i tried to split mine in two in order to take the rust outside. I used a very small electric cutter with cutting disc (we call it "biax" here)

    [​IMG]

    and realized that i worked in vain 1 hour. The exhaust is in fact an "exhaust into exhaust". Like a exhaust in a shell its exact shape, only little bit bigger. A pain ..., really.

    On the other side - don`t bother your thoughts with a nice, poshy, fuel tank. The Tenere tanks are all big and bend-able even with crash-bars on the bike (you should see mine :huh).
    I got dreaming when the snow started round here and haunted the internet one monthe to found a very nice one. Found it in Switzerland. Lot of money spent for a tank i`ll use only on parades or to give it to the next owner (don`t think will be one too soon). Yes, i chilled out. But, on the real side, MAYBE (:D) a uselless investition.

    Wish you all the strength you need at work and see you `round here!
    In few days all the parts will come to my door and i`ll start working too. Also i started a website with a friend of mine (already up on the internet, but no content yet) - it`s called tenere3aj.info.
    Hope we`ll get together there also and feel good.
    All the best, Mezzo !
    Have a good night and good sleep. Here it`s only 23:45...
    #76
  17. Mezo

    Mezo Banned

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    I have just bookmarked http://tenere3aj.info/

    I have a few sites myself Raul & may be able to help you in the graphic department ? i could give you some ideas possibly? One of my sites is and another interest of mine is www.honda-red-rocket.com i did the graphics for that.

    Mezo. :thumb
    #77
  18. ztaj

    ztaj jatz

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    Thankyou for the reply Popescu, but the bike has only done about 3000 k on top end re-build, and I have been very carefull with quantities and procedure when doing oil changes.
    I guess it's just something this bike does. I can send you more questions via p.m.
    End of thread hijack........ as you were Mezo :D
    #78
  19. popescu_mihailraul

    popescu_mihailraul Adventurer

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    Hey Mezo, still sleeping :lol3??? (I just woke up 2 minutes ago :bore. Mhmm, coffe smells nice from the kitchen...)
    Thank you for your offer!
    I just met a chopper guy (Virago owner) who moved into the city and he`s doing websites + hosting. He`ll host the site on his server and also do the graphics and stuff. If anytime in trouble, Mezo, i`ll start a fire (on top of my block of flats??? :lol3) and call for your help from mountain peak to mountain peak until the kangaroos will see it and tell you :D.
    I`ll be the guy posting tutorials (mostly) on "How to..." and different infos.
    The site will be interactive and opened for everybody to share info.
    In fact this will be his purpose. I decided to make it as i`m tired of searching info on the 3 AJ on tens of sites all over the internet and because i will start my rebuild project and i don`t want to loose this oportunity.

    Wait your pm`s.

    All the best to all!
    Raul.
    #79
  20. Mezo

    Mezo Banned

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    Nothing much to report today, been busy packing boxes & loading on to my friends truck.

    I have ordered a Dell Mini 9 today to use on my trip, it has built in 3G mobile broadband & a built in webcam so ill be able to Skype friends as long as i have a 3G connection, im also taking my 3rd generation 32gb iphone as well. The idea is i can take quality pics with my Nikon & upload & share on ADV with the Mini 9 as i travel around & as a back up or in an emergency i can also use the iphone to take pics & upload as well (not so good quality).

    Im also about to order/buy a Garmin 660 GPS loaded with the latest Australian maps.

    Im going with this tent, i have sat inside this tent in the shop & was happy for it to be my home for a few months, it weighs just under 9kg but more importantly its a four man dome tent which i can stand upright in (1.8m) very handy if i pull some hot backpacker on my trip & invite her back to my tent (use your imagination guys) :evil

    So many things to sort in a short time, i still do not know my luggage system yet? the lads at the beer fest all said go with soft rather than aluminum for reasons like breaking your leg or bike with hard system. I have been reading up on a local mob & ADV member who has a company called Steel Pony they have goods reports from riders.


    Mezo.
    #80
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