While waiting on a few parts and some milder weather... the blizzard has kept us close to home on Christmas, so I set about the winter rebuild of the xt600 engine.
The process went as follows -- new (used) cases -- the latest model year that came with a kickstart -- 1990, I think. Cleaned up at a transmission shop, old bearings removed, new bearings installed. New xt600 cylinder with overbored piston -- .30 over, I think. Starting to put it all together in the nice, warm inside environment...
The workstation -- a bit crowded, but it forces me to be disciplined and not leave tools and crap strewn about the place. Ziplock bags are the greatest invention, as all the parts as removed are being put back into their place.
Case halves came together quite nicely. Have a shopping list of new seals on the pink sheets, and since the photo I've installed the oil pump (with new o-rings), kickstart idler gear, and and kickstart spring mechanism. Under all that went the shift detent arm and shifter. Once I get the seals ordered (mainly the one for the balance shaft), I can finish the right side and start on the left. New camchain will be installed as well. I also plan to send the head off for a rebuild. The cam journals look OK, so a valve job will suffice. A very satisfying experience!
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