The story so far - '92 XJ 600 N

[TheGreatMrGonzo]

Got my bike back in November off a guy in Irlam. Off eBay the ad boasted the bike in fairly descent condition, looking to move to a bigger bike, restricted (As I need to be) and a few other odds and ends. Seemed a little too good for the £700 they were asking for it, but went up to see it anyway.

Bike was pretty much as described when I got there, paintwork wasn't fantastic, engine was pretty grubby, covered in oil where the gaskets hadn't been replaced when they should have and when he turned the engine on - Rattled like F**k! Owner said it was "Something to do with the oil pump.." which is ridiculous, the oil pump is tiny and wouldn't cause a noise like that.

Despite the noise I found the money for the bike and to insure it and went to pick it up. again the engine was rattling its nackers off but rode around all night until 4am early the next morning. Ended up running out of fuel half way down the M56 towards Chester - But that's a story for another day :')

A week later and an engine diagnostic on the noise from my tutor developed into a suspect stretched cam chain and worn tensioners which all seemed fair. So two days later I brought the bike in for what was only meant to be three weeks at the latest only to find that after a partial engine strip that the cam chain is only accessible via a complete engine strip.

After dismantling the engine to every single component another problem occurs in the form of the big end bearings were shot requiring replacement! After a further three months of waiting for information of two independent mechanics, no colour codes were visible on the bearings meaning I was not able to order any!

After that bumming bit of news I decided to order a second hand crankshaft that come supplied with big end bearings and con-rods. For £45 inc. delivery off eBay it was a steal, especially considering it's almost like new.

So as it stands today, I received new main bearings to fit the new crank into the casings ready to be built up tomorrow and the following week. The pictures here are from when the engine was taken apart 4 months ago and more pictures will be added to this topic as I begin the rebuild

Rocker cover off:

Clutch:

Clutch and basket taken out:

Head removed:

Barrels removed:

Crankcase halves split:

Discolouration on the crankshaft (A common fault):

Grubby pistons:

Cleaned up gasket mating surfaces:

Before:

After:

More picture as everything progresses will follow up as soon as I get a chance to take them and upload them to Photobucket

[blackhat250]

Was ther not a split link on the cam chain,,, so it could be removed after the head was off,

[drewpy]

the start chains can rattle at low rpm's too. they have a pretty basic tensioner system.

Irlam is just down the road from me too.

All part of the fun though

[Tommy xs]

what collage you at ben, is it halton in widnes ?

[TheGreatMrGonzo]

No split link in the cam chain unfortunatly, not one in the new one either, Yamaha genuine ones dont have them for mine.

Yeah the cam chain gives the XJ the 'Yamaha rattle' on mine but this was literally rattling its balls off, wasn't healthy at all.

No Tommy they don't have a motorcycle workshop there, I go to Mid-Cheshire in Hartford.

[TheGreatMrGonzo]

After the engine was stripped and I was awaiting delivery of parts and other various things, I decided to take at a few things while the bike was stood around. First on the agenda was a carburettor strip and clean because they were suspect for causing a flat spot from about 2,500 to 3,000 rpm:

I forgot to take a picture of the state of them before I put them through an ultrasonic cleaner but here's a picture of them after when I was putting the floats and jets back in:

Put new LED indicators on and soldered up the LED Relay to the original Relay:

Stripped the lights, clocks and brackets off the front:

Painted the clock bracket:

Got some ultra-low Renthal bars:

New handlebar grips and bar-end mirrors:

Polished up the exhaust to a mirror finish:

[TheGreatMrGonzo]

Decided the engine needed a new lick of paint as well, so this is what it now looks like:

Sump:

Rocker cover:

Engine mounts:

Sprocket cover and clutch cover:

Engine casings:

New main bearings are now in place:

All parts ready for the engine build:

[Tommy xs]

No Tommy they don't have a motorcycle workshop there, I go to Mid-Cheshire in Hartford.

didn't think Halton did co's hadn't heard of anyone doing a coase there look's like a pretty good setup they have there, not rushing you for the lift space then while your waiting for parts

[TheGreatMrGonzo]

didn't think Halton did co's hadn't heard of anyone doing a coase there look's like a pretty good setup they have there, not rushing you for the lift space then while your waiting for parts

Had to take the bike off the ramp and put it to one side a few times but I've had my own ramp set-up with the chassis for a good month or so now, all my work for it has been based around it so the tutor has left me to it :')

The course itself is fantastic, covers a wide variety of things you'll come across in a garage working on diagnostics and stuff, got all the equipment for use on bikes as well: Tyre machine, pressurised air lines, solvent and water parts washes, stack tool boxes, computer diagnostic equipment. It's all there

[Tommy xs]

sounds brilliant. I see your tax has run out, I hope you remembered to put it on sorn? lol

[TheGreatMrGonzo]

sounds brilliant. I see your tax has run out, I hope you remembered to put it on sorn? lol

Haha well spotted, I actually re-taxed it for 6 months because I was only planning on the bike being off the road for 3-4months or so, still insured as well

[Tommy xs]

that cost yer big time then! so it'll be due again soon, you could have suspended your insurance if you'd had it on sorn

you'll prob have to mot it as well by the time its finished.

[TheGreatMrGonzo]

It'll be due about a month after I've got it back on the road, looking at June for Tax renewal, MoT is due in July as well :')