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Thread: TTR635 Project

  1. #61
    Registered User ls400x's Avatar
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    More things to replace! If I hadn't bought so many parts so far I would give up.



    Completely broken off dog, maybe that's what cause the cracked cases if it went between some gears?






  2. #62
    Registered User ls400x's Avatar
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    I put new bearings and seals into the donor Husky front wheel and swapped the Bridgestone Trailwing over that came with the TT. Cleaned up the brake rotor, loctited the bolts and tensioned the spokes while I was at it.


  3. #63
    Registered User ls400x's Avatar
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    Reduced steer tube to 28mm diameter from 29mm to suit the standard and common bearings.




  4. #64
    Registered User ls400x's Avatar
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    It's been a while since an update, my brother's DR650 purchase has spurred it on a bit. Triples went in ok, minor tweaking to finish off, overall a pretty easy conversion. It runs the standard sealing system and bearing sizes. A secondhand pair of XT600 cases were sourced from USA, so far everything looks interchangeable. I picked up a new KX450F muffler for $50 and hope to adapt it.









    Last edited by ls400x; 06-12-13 at 08:09 PM. Reason: alcholol

  5. #65
    Formerly a stupid_cunt fly510's Avatar
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    still waiting for wheelie pics
    RB26......................Again

  6. #66
    Registered User ls400x's Avatar
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    Wheelies + Fraser Island is the plan. Can't wait.

  7. #67
    Registered User ls400x's Avatar
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    I got everything cleaned up, corrosion inhibitor applied and bagged in logical groups. I also did a stock take and marked up a parts book. Cases were heated up in the oven to about 80 degrees C so the bearings would drop in. The gearbox counter shaft assembly was put together with 2 new gears. New oil pump also installed.

    I decided I'm going to buy a new gearbox primary shaft as the bore that the clutch push rod runs in didn't clean up with emery in the lathe and I wasn't happy with it.

















    Last edited by ls400x; 27-12-13 at 06:42 PM.

  8. #68
    Registered User Potsy's Avatar
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    Yamaha dealer must love you

  9. #69
    Registered User ls400x's Avatar
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    Unfortunately Yamaha Australia has got none of my business so far due to their partzilla x 3 pricing

  10. #70
    Jak Sie Masz! trent from punchy's Avatar
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    I came here expecting this

    www.markpakula.com
    2017 Subaru Impreza Hatch - for the grind
    2015 Cervelo S2 - for the fitness
    2005 Honda Accord Euro - for the wife
    1991 CBR250RR - for the fun

  11. #71
    Registered User ls400x's Avatar
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    New fiber plates and springs




  12. #72
    Registered User ls400x's Avatar
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    Headset finally finished. Ended up pretty neat I thought.






  13. #73
    Registered User ls400x's Avatar
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    Posted off the crank today to have a new rod/big end bearing/pin/main bearing installed. Kinda bummed that I couldn't do it myself. Need to buy a press.

  14. #74
    Registered User ls400x's Avatar
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    I got the crank back for truck bike today after waiting foreverr for freight across the country and back. Guy fucked it up somehow and it's too narrow overall width and too little big end side clearance. Overall width would be within tolerance if the side clearance was also. Fuck.

  15. #75
    Formerly a stupid_cunt fly510's Avatar
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    is this done yet? Im hanging out for 2000rpm wheely action.
    RB26......................Again

  16. #76
    Registered User ls400x's Avatar
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    Wheely action still some time away...

    Finally got my crank back. I originally sent it in April. Crank Shaft Rebuilding Services in NT refuse to communicate about refunding the cost of freight to fix their fuck up. Bunch of cunts etc...

    I haven't re-measured it again yet and I'm half expecting to find problems.

  17. #77
    Non Compos Mentos Gammaboy's Avatar
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    If you have issues with the crank again - I've got a guy.
    "Where can we get hold of a Vincent Black Shadow?" "Whats that?" "A fantastic bike," I said. "The new model is something like two thousand cubic inches, developing two hundred brake-horsepower at four thousand revolutions per minute on a magnesium frame with two styrofoam seats and a total curb weight of exactly two hundred pounds."

  18. #78
    Registered User ls400x's Avatar
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    Thanks

  19. #79
    arboreal bukkake briney's Avatar
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    just as a brief aside, did you pull the seals out of the gearbox bearing? it might shit if you don't. otherwise, looks like an awesome project.
    Quote Originally Posted by Skompa View Post
    The throttle linkages jammed on the CDs in my old Triumph 2000 and stuck it at WOT.

    I didn't realise for about 15 mins as it never broke the speed limit.

  20. #80
    Registered User ls400x's Avatar
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    I think there was at least 1 bearing with a seal facing but no photos in the FSM showed it. I popped them out like you suggested.

    Today's update! Cases buttoned up. It took about 10 test goes to get it right and identify that the oil pickup was fouling preventing the cases fully coming together.


























  21. #81
    Registered User ls400x's Avatar
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    Bit more today










  22. #82
    Formerly a stupid_cunt fly510's Avatar
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    Rad. Eta to wheelie pics?

  23. #83
    Registered User CA18escort's Avatar
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    Looking good Luke, I just order a 685cc Big bore kit for the KLR.

  24. #84
    Registered User ls400x's Avatar
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    Nice, make sure you post up some photos!

  25. #85
    Registered User ls400x's Avatar
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    Seals I popped out of the balance shaft bearing and gearbox shaft bearing are meant to be in there. Fuck. Cases have to be split, 2 new bearing. No mention in the manuals, only found out by chance browsing xt600 rebuild threads.

  26. #86
    arboreal bukkake briney's Avatar
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    did the balance shaft bearing have a seal in the case? from vague memory the crank cases vent through the balance shaft somehow? why do the bearings need the seals? when i rebuilt mine it had all unsealed bearings and no problems. the oil has to run through them for lube and cooling.
    Quote Originally Posted by Skompa View Post
    The throttle linkages jammed on the CDs in my old Triumph 2000 and stuck it at WOT.

    I didn't realise for about 15 mins as it never broke the speed limit.

  27. #87
    Registered User ls400x's Avatar
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    Apparently a seal is needed on the balance shaft bearing because it forms part of the scavenge oil pump pressure side path I think (along with the seal in the case)and the gearbox one is needed to pressurize the the hollow shaft. I can't find a lube circuit diagram though and can't physically check the cases right now to confirm.

    http://www.tenere.co.uk/forum/viewto...=1509&start=70

    It is never clearly mentioned in the service manual, but the two LH gearbox bearings should be the sealed type with the inner seals removed. This allows some of the return oil to lube the inner part of the gearbox shafts and gears.

    If the outer seals are left out (no seals at all), oil may not fully return to the oil tank and the lube to the gearbox would be compromised.
    Last edited by ls400x; 03-01-17 at 07:55 PM.

  28. #88
    Registered User ls400x's Avatar
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    It's confirmed, I can't ignore it. The scavenge pump does feed those cavities behind the LH gearbox bearings from the clutch actuator bore. The resistance to flow from the bearing seals forces oil to flow through the gearbox shafts and lubricate the gears. So leaving them out could reduce the life of the gear bushings/axles, reduce the volume coming out of the jets spraying 5th gear etc and maybe cause an inadequate flow rate back to the oil tank.



    Other less relevant findings:

    Ignition timing change with black/red wire disconnected.



    xt600 ignition timing



    Last edited by ls400x; 25-09-14 at 09:18 PM.

  29. #89
    Registered User ls400x's Avatar
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    Quote Originally Posted by 9triton View Post
    wow -no messing about !

    i allways worry when i pull them apart -takes years to get back together
    Well it's been 3.5 years haha. Smashing it over the last couple of days though. I re-painted the frame because I didn't like the previous job. Engine is low gloss ceramic paint. It rolls kinda.



    Big jobs to go:
    1. Work out what to do with the back wheel. Spokes/rim/bearings/seals are trashed. I'd like to go cush drive. TT600RE apparently came with cush that would be bolt in but it's unlikely that I would be able to find one. Option 2 is an XT600 hub and adapt it. Otherwise maybe a DR650 wheel. I have a Husky TE610 rear wheel that would would with spacing, bearings and shifting the rim over a bit on the spoke adjustment but not real easy and no cush. It would match the front Husky wheel though.
    2. Speedo. Because I have a Husky front end I can no longer use the Yammie cable speedo. Thinking Trail Tech Vapor.
    3. Headlight. I like the look of the tube frame Baja Design ones but they cost way too much for me. The original could be adapted but looks crazy without the original fork protector fill underneath it.
    4. Rebuild the forks with new bushings and seals. I probably should have persevered with the original ones...oh well
    5. Make a handle bar mounted switch for open-circuiting the red/black CDI wire for dual ignition maps.
    6. Buy a muffler because the KX450 one I had intended to use just doesn't work in just enough ways to make it a pain and because I sold the original one for $10.
    7. Needs a new bump stop in the shock.
    Last edited by ls400x; 03-01-17 at 08:18 PM.

  30. #90
    Registered User ls400x's Avatar
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    As it stands today. Oil tank painted and stainless screws for it and the outer engine cases.




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