Almost have the engine. Need to remove the starter and it should be all.
I removed AIS system. Will it show errors if I removed AIS? Link bearins are dry..


I think the akrapovic exhaust I got, still has cat's inside. I do not care about cat and emissions, but I read it might start fire if unburnt fuel piles up before cat.

Yesterday I spent over 8 hours on my bike. Removed engine(had only 3 more bolts to remove). Cleaned up engine, frame and other parts from years of grease and muck... nasty near the chain area.
Removed tail parts and spent over a hour to install rubber flap there. Tried different ways but at the end I used large rubber flap to cover the whole area. Two bolts hold it under the exhaust bracket and two hold in place under rear luggage rack. Will see how it works out someday.

Keeping the AIS cause of the O2 sensor. But I blocked the pipe. Will remove the catalytic converter for better exhaust flow(cut cat open and then weld back together).

Greased rear swing bearings. Have two more bearings to do on the rear shock. Also cleaned up bolts from rust and greased them.
Chain rivets are done, getting stuck and pretty hard to move. The chain should have done more than 20k km's for sure. Will order new chain and sprockets with rear wheel dampers. Will do the mods to increase the life of them. Link: http://www.xt660.com/showthread.php?p=211578#post211578

Parts will be in the picture + Prox piston set ~150€. So around 680€for parts. 170€ engine work. +120 DID 520VX2 and JT sprockets. + Rear wheel dampers. So over 1k €..

Good luck getting all back together again.

So I ordered parts. Total 576€. However.... this has happened:

Extra 235€and 4 weeks. It is being shipped to UK for nikasil repair and then back. I think I should get it running next month. Must get new sprockets and chain aswell. Also new rubber dampers for wheel. Did the mod also. Used galvanized steel of 23,5X1,2MM.

Got bored today and cleaned my titanium exhaust pipes with red synthetic steel wool. Not 100% clean but better than before



Also yesterday was the beginning of Estonian Motorcycle season where I couldn't attend with my bike but filmed at the side of road. It was raining the whole day and still everyone came.
https://www.youtube.com/watch?v=7dC-HkJ2Onc

No news from the engine yet. Cylinder still somewhere between UK and no idea about the parts.

Good luck with the bike. ...that was a lot of bikes you filmed! Steve

So today I finally got it running again
First start: https://www.youtube.com/watch?v=MQQVUhJMRAs

It took 4 weeks for cylinder nikasil restore. Then over a week because stupid postage and customs problem...
Got engine back yesterday. It took me from 7.30 PM to 00:00. Next day 8.30am to 2:00PM to get everything back onto frame.. It was pain in the ass to get the crash bars fitting. And everything else... just tiny problems that took over 30 minutes to fix each...
Bought new chain with front 14 sprocket and rear 45. Chain is DID 520VX2 and sprockets are JT. Also extra 4L motul 5000 10w40 with filter.




Painted the exhaust.... nice and shiny...

But... that paint is awful(Motip heat resistant spray 800c). It came off sooo easly and when I started the bike outside, then the rain washed it off instantly...



It was raining in the evening. But when you have not ridden over a month... It doesn't matter at all what weather you have outside. And what would be better to break in the engine in easy forest trails where you can use different rev's.

That motor sounds as sweet as a nut now. Well done.

Awesome, sounds good. I hope mine eventually starts that easy...

Thanks!
Theres small ticking sound but that was even before rebuild. Might be compression pin but who knows...
Did a 190km long trip today. It was great. Never done so long distances and Tenere was great, only my butt hurts

It had different kinds of gravel roads and only 30km tarmac. Will edit the video someday of this ride.

Since the speedo lied even with 15 teeth sprocket, then now with 14 teeth its even worse. When I want to ride 90kmh then I must ride 104kmh according to Teneres speedo. Speedo healers should work but I went for cheaper way

Reciever with ziptie between fork and brake support and the magnet glued to disc.
Wheel size set for 2153 and its spot on with the GPS speed with my Mitas c17 front knobbie.

Also the gear shift spring was worn, so it didn't return to its default position.
Grinded one spot off to get the pin out. Then made new spring out of random spring I found with the pliers. Will weld it someday, so it won't jump out cause I grinded it off before. Works like a charm.