Rebore

[Indigo]

Hi fellow xtz fans.
I have had my 1999 model xtz 660 tenere for a long time now. My last big ride she was chewing through the oil .approximately one litre per 1000 km. With 90000 on the clock it was obviously time for a top end rebuild.
I have now removed the barrel. And on inspection I was surprised to find no obviously wear . For example I expected to see a lip at the top of the barrel. There is nothing. I read somewhere that some xtz have crome bores. Is that correct.?
My Question is.....So is it standard procedure to simply have my barrel rebored to accommodate an over size piston. Or is there some other process involved.

[donnybach]

Do you want an overbore? Just measure it and see if it needs one or not. If it’s within limits just hone it (£10 tool), and fit new rings etc. Is it definitely burning oil or is it seeping out like XTs do? I’d measure everything while it’s apart, replace worn bushes/bearings etc, and seals, and rebuild it. Check valves and seatings too.

[Indigo]

Thanks Donnyback.
Sounds like good advice to me.
She is definitely not dropping oil so I am
Assuming she is burning it. The blue smoke is
A clue. As I don't have the equipment to measure the barrel.
I'm going with the assumption that after 90000 km
She would need a thorough going over.
On top of all the things you mentioned i have
Also order a new cam chain.
Looking forward to the next adventure.

[donnybach]

Sounds good. Need to do mine next winter.

[dzl]

Very definately a rebore and oversize piston, especially as you have it apart anyway and its cheap to do! Highly recommend Yanaha genuine piston and rings as they are very high quality and generally cheaper than aftermarket. Here in oz can get a piston/ rings and piston pin for $190 AU. Get your machinist to rebore cyl piston clearance at lower end of yamaha recommendation at .002"/ .05mm. While the bore is off I would try and inspect transmission gears, 5th gear in particular for pitting if possible. May need an engine inspection camera.

[Indigo]

Thanks dzi.
I did notice the price of the genuine piston. cheap.
However I was put off because as I was looking at them on line and each component had to be purchased separately.
I didn't feel confident enough to chose the correctly matching parts. I ended up purchasing a wasner kit + 0.5.

[Indigo]

Hi fellow xtz tragics
Just following up from my post.
Well I spent the entire Christmas brake
Putting the tenere back together.
The misses has gone to Brisbane to be with
Her folks. So I mad it my Christmas mission.
I know I had to stay on it or there was a
Real possibilities she may never run again.
Well I'm pleased to say she is all back in one pieces.
And running sweet with a little work left to do
New tyre , new seat skin and than it rego inspection.
Can't wait to get back out there on the old girl again.
Thanks for your comment's.