Clutch casing damage

[simplesimon1]

Hi to everyone on this forum.
Ive had a problem with my 1vj tenere. I thought the engine had seized on a run but after stripping the head and clutch casing off I found that the primary drive gear locking washer had broken and allowed the nut to rub on the clutch casing.
Do you think this casing is syill usable?. I have attached a photo of the casing and my bike.
The bike has a xt600e 4pt engine and if the clutch caseing is shot Im thinking to fit a casing with a kick start if its possible.
If I do this can I still fit the decompresser lever to my later 4pt head?.
Also, my bike is fitted with the latter wireing loom wich I think has the TCI ignition and not the CDI.
Would I still be able to kick start the bike with a flat battery?.
Sorry for all the questions. I love this bike and have ridden many off road adventures around portugal and spain in the last 10 years and hope for many more years from this bike.
Big thanks for any responses.

[Peen]

Hi, your casing might still be ok as long as the seal under where its damaged is untouched as that passage is an oil feed I believe.

You might struggle with fitting a kickstart to a 4pt engine though, the 4pt clutch mechanism is in the clutch casing you have and there is no hole for the kickstart shaft in the casing, the previous models which are cast and machined to take a kickstart shaft and the auto-decompressor mechanism had the clutch mechanism in the left side crank casing. Ive heard of people fitting a kickstart to the 4pt engine, I think they machined out the casing to take it, but did not have the auto-decompressor. Your head should take the decompressor though, at least my 3aj head did which I fitted a kickstart and auto-decompressor to, I dont think the cylinder head changed from the 3aj onwards, you just need to pop out the blanking cap on the rocket cover and fit the decompressor parts.

Im also pretty sure the TCI ignition on the 4pt relies on the battery for its spark, so no battery, no spark, although it might still start on a nearly flat battery thats too weak to crank the engine.

[simplesimon1]

Hi Peen
Thanks so much for your reply.
The oil seal in the clutch casing has some damage and will need replaceing. The casing has just burred over a little so I will take my chances with it I think.
I totally understand what you say about the clutch casing needing to be machined. It looks like the casting is still strengthend on the inside so it may be worth trying.
The other problem I have is there is now play in the primary drive gear which was the reason for the locking washer breaking.
Am I right in thinking the key that locks this gear onto the crank is made softer than the crank and gear?.
It looks like the gear and the crank have not worn so changing the key should fix this but I cans see that this gear must have no play at all or it will just happen again.
Again, thanks for your response.
This forum has been a great source of info for me.

[Peen]

Yes, I would definitely replace the key. If the key breaks, the the gear can go out of time with the balance shaft gear connected to it and your balance shaft weight will hit the big end on the conrod and bad things will happen.

I had a similar issue to you on my old 4pt xt600e years ago. The nut on the balance shaft gear came loose, the key was very damaged, but luckily stayed in place, I replaced the key and it was ok after this. This was a result of lugging the engine at too low rpm, causing too much shock loading through the engine and rattling the nut loose and breaking the lock washer like yours. A known issue with these bikes.

Also, dont quote me on this, but Im not sure if the primary gearing changed for the later xt600e. By this i mean the gearing from the crank to the gearbox via the clutch hub, and since the kickstart gear runs onto the clutch hub, an older kickstart might not work with the later engine. I am not 100% sure on this though, you might have to do some research first. I am sure I have heard of people converting a 4pt engine to a kickstart.

[simplesimon1]

I will be changing the primary drive gear key and locking washer, also cam chain and sprocket, pison rings and valve seals.
Ive also got a xt600z 55w which im hoping to get started (has not run in a year) to use for my trail rideing while the 1vj is off the road.
Ive had 3 tenere 600's in the last 30 years and there still the most fun.
Thanks for shareing what you have learnt about these engines.