Rebuilding a broaken engine on a Yamahe Tenere XTZ660

And here we have a 1993 Yamaha Tenere XTZ660.
Original components used:
Crankshaft nut 90170-20274
Engine magnet key 90280-16053
Balancer shaft lock washer 90215-16242
OIL SEAL 93101-14092
Clutch basket lock washer 90215-20231
Crankshaft gear key 90282-07042
Crankshaft nut lock washer 90215-20197
The block, right side cover, crankshaft, sprocket, and balancer shaft were sourced from eBay.
Tools used in the video:
Kipex cobras
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Recommend using a torque wrench:
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JIS screwdriver:
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Impact screwdriver:
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Check out the channel updates on:
Instagram: / restorationvalve
Tiktok: / restoration_valve
Check out the eBay store for the spare parts from the projects: www.ebay.com/u...

[@nicolasghislain2332]

Thanks for sharing your work!

[@jeangaelcognat4988]

Encore du beau travail....Merci pour le partage et le montage 😊😊😊

[@slivkishowafghanistan]

Thanks man, just as I was starting my top end rebuild this video popped up. It really helps having a reference now, especially due to content for this model being rare as heck.

[@bve7397]

Hey man! At how much km did you have to do a top end? Looking to buy ine with 50k km but im scared its gonna need allot of work, I dont know how long these engines typicaly last.

[@jorgevillaelx7723]

Muy buen video...gracias..seguire tu canal...

[@lifeexpert3053]

Always excellent 👌 work 💯

[@jh-tech5546]

Nice job!

[@luisramirez-su3fm]

alguien me puede confirmar parece la altura de la biela concuerda de el de raptor 660 ya ke este motor y el 600cc usan la cadena de raptor 660 el cigueñal de la parte del clutch y magneto parece la misma figura y largor

[@bve7397]

Any idea why mine always has a hard time starting? Runs good but pain im the ass to start, carbs r clean and valves in spec

[@luisramirez-su3fm]

Yo ke ustedes no le uniera puesto el balanceador ni balineras de balanceador ni el engrane no sabia ke un motor de esto si no le ponen el balanceador jala mas fuerte asta los raptor 700 y 660 sin balamceador jalan mas chido

[@tonyireland1434]

Hi great video man very informative, i was looking at one of these a 92 model around a 100 k kms he says when it gets warm it sits at 2500 rpm and wont come down to tickover !!! He,s looking for 1500 it's ok I'm just a bit concerned about the engine, what do you think ????

[@restorationvalve]

@@tonyireland1434 the high idle speed should be the cause of the carburetor and/or vacuum leak. Believe it just needs a cleaning and adjusted correctly.

[@LeslieWhittle-f2o]

thank you sir i have the exact same bike dont no if any one can help ive rebuilt mine but can not buy header pipes have a doner bike 2015 super motad with brand newr dominatoer headers exhaudt bbut thr headers just need a little tweeking bend to fit the1991 can anyone help please thank you

[@restorationvalve]

Sounds like you’ll have to find someone local with a pipe bender or a correct exhaust that could fit better in your region. Wish I could help out, but unfortunately I don’t have anything that could bend exhaust pipes or an exhaust that fits for this bike. But if you need some other parts, there are a few parts from this Yamaha model on the eBay store, that’s described in the video description.

[@LeslieWhittle-f2o]

@@restorationvalve thanh you i m8

[@bve7397]

Hey man nice bike and rebuild! Was wondering what went wrong with yours.. looking into buying one of these, one up for sale with about 50k km on the odo. Since yours has a little more im worried that this might be a too high milleage to buy it at? Some people say the engines last to well over 100k km, so I was wondering if your bike was a exception or not..because im not looking to rebuild it any time soon, I won't have time for that.

[@restorationvalve]

@@bve7397 I’m not the proud owner of this Dakar legend, I only had the pleasure of rebuilding the engine. On of the nuts, holding the sprocket came loose and let the balancer gear to jump timing and hit the crank rod. Overall the engine seemed in pretty good shape before this happen. Presume that the nut came loose because one of the previous owners had taken of the gears and not used new lock washers

[@bve7397]

@@restorationvalve Thanks helps allot! Is it a dakar legend?? Man gets me excited! Hoping to learn some offroad with it and commute on it, planning to keep it for a while.

[@794corry]

Hey, I saw your video about the Yamaha Tenere XTZ 660. Really great, it just goes a bit fast. Is there a way to get the video in normal speed or view it on your KZbin channel? It would help me enormously with my own engine block. Thank you in advance Wannes

[@restorationvalve]

Hi, Thanks. Unfortunately most of the videos were filmed in time lapse mode. You can use the KZbin speed settings to slow it down as best as it can.

[@Roolis77]

Cool, video! was it new engine case or used?

[@restorationvalve]

The engine block was used. As far as I could find, there weren’t any new blocks for this model. Also, I don’t doubt that it would had an adequate price for it, which not all clients would like to pay.

[@humansloth2]

💪🙂👍

[@nandog1024]

Wath is the scrassh cause !!???? The bomb !!!!

[@restorationvalve]

The crankshaft nut came loose, the gears jumped timing and the balancer shaft kit the crank rod

[@juzik43]

Hello, what valve clearance do you set for the intake exhaust?

[@restorationvalve]

@@juzik43 as per the manual, 0.09-0.13mm for the intake and 0.16-0.20mm for the exhaust when the engine is cold.

[@juzik43]

@@restorationvalve OK thanks

[@trailtrashgarage]

Did you do anything to the piston, rings or cylinder wall?

[@restorationvalve]

The piston, rings and the cylinder are the original ones, they weren’t damaged.

[@trailtrashgarage]

@@restorationvalve cool. I need to rebuild my 2006 DR650 motor to repair a left case issue. Motor has great compression and the Cylinder is Nikisil coated but most people are telling me I should still lightly scuff the cylinder and replace the piston rings. Thoughts?

[@restorationvalve]

@@trailtrashgarage if the rings measure out to be in their required tolerances, then there’s no reason to replace them. I haven’t had any engines with Nikasil coatings. I’ve seen M539 channel dealing with that type of engines, if I remember correctly, he didn’t scuff up any of them, because that coating is a very thin layer. I personally would not recommend scuffing up the surface, just cleaning it and lightly applying some engine mineral oil. FYI, not a cheap thing, but ProCylce has a big bore kit that includes a steel sleeve.

[@trailtrashgarage]

@@restorationvalve thanks for the input. Ordering anything from Procycle and having it shipped to Canada where I’m located is out of the budget unfortunately.

[@nerijusba1983]

🤩🤩🤩🤩🤩👍👍👍👍