tt600 36a/59x rebuild

[Mezo]

Well id has has MAGNESIUM cast on it don't weld it as if its aluminium as it will destroy the whole cover, if yu cant find a competent Magnesium welder just use JB Weld or buy a second hand cover.

Mezo.

[peman]

Well id has has MAGNESIUM cast on it don't weld it as if its aluminium as it will destroy the whole cover, if yu cant find a competent Magnesium welder just use JB Weld or buy a second hand cover.

Mezo.

Not sure what your on mezo, but i like it! i assume wrong thread?

[Mezo]

Well id has has MAGNESIUM cast on it don't weld it as if its aluminium as it will destroy the whole cover, if yu cant find a competent Magnesium welder just use JB Weld or buy a second hand cover.

Mezo.

Not sure what your on mezo, but i like it! i assume wrong thread?

Well first time for everything?

Cant bloody remember what thread i was supposed to answering to either?

Mezo.

[peman]

OK more goods have turned up.
12v horn


Front fender guard of coarse gold. the hard part will be drilling the new fender.


And i finally tested the xt spring i got from xtrider and can say its good very good, can put that to bed now.
Will continue to round up all the parts i need for it in the next few months, then gets striped down again, and powder coated, new plastics etc and once finished will be road duties mostly,
using it in off road is just too harsh to it and i just can't justify it. i will get a wr or yz for off road only. won't hurt to see it get destroyed.

[peman]

Ok so iv'e been thinking about the future with the tt, i'm a bit on the fence about using it for traveling, a few concerns are the lack of bigger tank, 12v conversion, cush drive, rear rack, etc,
or go xt for long distances and use tt for serious off road stuff.
But the thing is i want a bike ready to go by september, that's when i go for my bike licence, i don't think i can save enough money by then to buy a xt, then go over it then service it, etc.

So i will do what i do best and that is to make things work to my liking, so i will see if i can tick some of these things off the list by september!
The biggest thorn in my side is the 12v conversion, electrics aren't my best skill so i might just stick with the 6v for now and limit night travel.
the list below is the main list.

no.1 cush drive
no.2 rear rack
no.3 highway gearing
no.4 bigger tank 11 litre standard
no.6 rebuild wheels
no.7 shock bump stop fitted, destroyed the new one when spring broke!

And this doesn't include the cosmetic stuff
The first thing i looked at was the cush drive, as luck would have it when i brought the second tt it had xt wheels on it, mainly a cush rear wheel. (was badly fitted to the swingarm)



How the widow maker is at the moment



So the best description for the cush rear wheel would be square peg in a round hole, not going to work, side clearance too tight, rear sprocket off line, axle thinner than tt, scrap it!
So i ordered a yz 490 rear sprocket that has 44 teeth will see how that goes. (hub is the same as tt)

next on the list, bigger tank, the only way i see this possible is with a 1997ish tt600r acerbis tank, 21litre? i know it's not a bolt on fit but it's the closest i think would fit, i have herd that a xr600 tank is close, but i don't know for sure.

Rebuild the wheels should be easy, i will just throw them at john titman racing and get them back rebuilt, gold naturally, i want them right!

The rack should be easy for me, i'll get some tubular steel and make something up, got some idea's.

The next 3 months should be busy, and fun!

Any suggestions, idea's, tips etc are most welcome.

[Mezo]

Any suggestions, idea's, tips etc are most welcome.

I think mounting a washing basket trolley on the front guard is a bad move.

Mezo.

[peman]

Any suggestions, idea's, tips etc are most welcome.

I think mounting a washing basket trolley on the front guard is a bad move.

Mezo.

Hey mezo! as always you are here to help us with these first world problems

[xtzrick]

Astralite wheels never came with a cush drive


Their solution was to machine larger mounting holes in the sprocket, make spacers that fill the gap between the mounting bolt & sprocket the same thickness as the sprocket out of polyurethane (thick washers made out of the same stuff used on rally car suspensions)

Then sandwich the sprocket & bushes between 2 outer plates.

It works but you have to get sprockets made to order

Rick

[peman]

Astralite wheels never came with a cush drive


Their solution was to machine larger mounting holes in the sprocket, make spacers that fill the gap between the mounting bolt & sprocket the same thickness as the sprocket out of polyurethane (thick washers made out of the same stuff used on rally car suspensions)

Then sandwich the sprocket & bushes between 2 outer plates.

It works but you have to get sprockets made to order

Rick

Bloody hell, a lot of effort for cushness.. i might see what hub i could fit to the tt at lest get the sprocket spacing right, maybe ttr or something.

I know they do need it as the two xt engines i took apart both gearboxes had 3rd and 5th gear pitting, where as the tt gearbox is perfect, sounds contradictive but the tt was of road most of it's life where as the xt's were on the road(more miles), i assume they wouldn't have lasted no where nearly as long as they did, so i don't feel like wreaking the good gearbox i have. more research.

[Fred333]

hi peman, regarding cushdrive:
did you have a closer look on my rebuild?
you allready got everyting!
the sprocketcarrier from the xt has to be maschined down so that there will be no space for a sealing anymore
an easy task. get the studs out. put helicoils in.
get some countersunk screws , a sealed bearing
drill the according countersunk in the original xt sprocket.. shorten the xt axle.
get bushes to make the axle fit to the swingarm. make a spacer for the left side. about 4 to 6 mm high.
..... and thats it....
later on i will post a picture.
cheers olli