Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => Husqvarna => Topic started by: Kykdaar on September 30, 2015, 08:43:06 am

Title: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on September 30, 2015, 08:43:06 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Sputnik080 on September 30, 2015, 08:55:57 am
Nice!

Hou die een dop.  :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: RedWolf on September 30, 2015, 09:01:50 am
Sjoe, lyk my jy het te veel geld deesdae. Begin nou bikes soos posseels versamel.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Sláinte Mhaith on September 30, 2015, 09:03:22 am
 :peepwall:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on September 30, 2015, 11:53:33 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on September 30, 2015, 11:54:32 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on September 30, 2015, 11:55:50 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on September 30, 2015, 11:56:52 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on September 30, 2015, 11:58:12 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on September 30, 2015, 12:00:52 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on September 30, 2015, 12:03:07 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: wolf skaap on September 30, 2015, 12:18:19 pm
(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=180719.0;attach=439581;image)

Neat idea  ;)
Title: Re: Kykdaar's SM610 rebuild thread
Post by: the_BOBNOB on September 30, 2015, 12:35:25 pm
nice going  :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: chopperpilot on September 30, 2015, 01:12:12 pm
Paar laat nagte wat vir jou voorle! :o

Geniet die rebuild! :thumleft:

Altyd pret om aan bikes te werk! ;)
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Rough Rider on September 30, 2015, 01:15:01 pm
(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=180719.0;attach=439581;image)

Neat idea  ;)

All you have to do is weld around the rim, it then just falls out.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on September 30, 2015, 02:58:14 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on September 30, 2015, 02:59:47 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: chopperpilot on September 30, 2015, 07:38:12 pm
Paar laat nagte wat vir jou voorle! :o

Geniet die rebuild! :thumleft:

Altyd pret om aan bikes te werk! ;)

Ja, ou Matie se ek het spanner koors. Ek dink hy is reg ;)

Kan nie aan die DR werk nie - die bleddie ding wil net nie breek nie, so nou moet ek projek werk doen
My DR het die 3 dae in Swazi soos 'n horlosie geloop.

Een 1190 met gebreekte agterrem lever, en een 690 met clutch probleme is huistoe gestuur.

PM my wat jy vir 610 nr. 2 betaal het.

Moet jy nog die Hyde goodies kry? Dinge gaan maar stadig daar. Wag nog vir die 2de bashplate. Kan vir Terence skakel.


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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on September 30, 2015, 07:42:40 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: chopperpilot on September 30, 2015, 07:51:48 pm
Terence het my terug gebel en Roxy se details vir my gegee, maar dinge gaan so dol hier by my dat ek nog nie daarby uitgekom het nie.

Bly om te hoor jy geniet die DR en die nuwe naald :thumleft:

Sal jou PM
Dankie!


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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Titanic on September 30, 2015, 08:00:42 pm
Subscribe
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 05, 2015, 09:03:14 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 05, 2015, 09:17:48 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 05, 2015, 09:35:44 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: sidetrack on October 05, 2015, 03:05:39 pm
Debris could be from the cup washers, many posts on that subject.

http://www.wilddog.za.net/forum/index.php?topic=128417.msg2482154#msg2482154 (http://www.wilddog.za.net/forum/index.php?topic=128417.msg2482154#msg2482154)
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 05, 2015, 03:36:57 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: sidetrack on October 05, 2015, 09:15:31 pm
Debris could be from the cup washers, many posts on that subject.

http://www.wilddog.za.net/forum/index.php?topic=128417.msg2482154#msg2482154 (http://www.wilddog.za.net/forum/index.php?topic=128417.msg2482154#msg2482154)

I checked the cup washers visually, they are fine - all intact and of uniform thickness with no worn out springs or any rattling going on. By the look of the pins they also seemed to be original.

Will do some measuring with the vernier and check against the manual this weekend, but my basic philosophy is that if it ain't broken, then don't fix it ;D 
Good to hear  :thumleft: Saw some okes on SM's tearing around PTA East on Sunday, looked liked great fun !
Title: Re: Kykdaar's SM610 rebuild thread
Post by: evansv on October 05, 2015, 10:24:51 pm
 :sip:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 06, 2015, 06:18:32 am
What you are seeing are some typical and pretty well documented 610 issues and 'fixes'. The top frame mounting bolts that are loose and have vibrated with iron oxide/filings are found on almost all 610's - normally a quick fix with Nylok nuts … yours look like the holes may have elongated but probably not an issue. I am surprised the clutch washers are OK - generally a good precautionary and pretty easy fix (maybe more a weakness on later models?). Battery tray also a documented weakness - check for wiring loom abrassion in same area (mine was OK and I fitted a lighter Ultrabatt). Check the foot peg bolts and mating surfaces - often need to be flatted and high tensile bolts fitted. Oh and wait till you get to the swing arm and linkage bearings …. may not be so bad if a SM model?
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 06, 2015, 07:43:06 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: sidetrack on October 06, 2015, 01:43:33 pm
So what is the plan :

a) Ride two 610's at once
b) Start a Husky collection
c) Turn one into a dual sport
d) Take both apart and build one minter from the two

I would go for option c  :biggrin:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 06, 2015, 01:58:41 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 10, 2015, 06:39:46 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 10, 2015, 06:45:58 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 10, 2015, 06:54:25 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 10, 2015, 07:53:40 pm
Do not by new OEM washers. There are two guys making the washers - I will look up the details (must be here on this thread). The one guys supplies the rivets as well which you will need.

Side cover was probably not aligned properly once when re-fillted  causing that lobe damage - I see some other graunching behind the nut as well.  :o
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 10, 2015, 08:03:12 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 10, 2015, 08:08:24 pm
Ja you are probably right - could not see clearly. I would be tempted to leave that lobe like that but is a difficult call. I cannot find the details of the guy I bought the washers from - will need to check on Cafe Husky. It was quick and efficient - came straight through in a padded envelope.

Ok remembered his forum name on Adventure Rider is Indy Unlimited - you will need to PM him there or e-mail: d2eng@comcast.net

Also see:
http://www.cafehusky.com/threads/help-debris-found-in-my-engine-610-630-clutch-issues.16604/ (http://www.cafehusky.com/threads/help-debris-found-in-my-engine-610-630-clutch-issues.16604/)

I got two sets of washers a few years back (and I think alanB took the other). I got a brake and clutch shop to do the riveting.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 10, 2015, 08:25:36 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 11, 2015, 08:18:23 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 11, 2015, 08:51:57 am
Can anyone confirm the steering stem bearing sizes? Got a suspicion mine might not be spec as the bottom bearing had to be lifted by 2 spacers in order to make good contact with the bottom race.

Well that was how I found it - so am a bit unsure.

You will find most of the basic maintenance info in our threads or over at CH. Look here for steering head bearings.

http://www.wilddog.za.net/forum/index.php?topic=131482.0 (http://www.wilddog.za.net/forum/index.php?topic=131482.0)

If I recall correctly mine had at least one spacer as well. (Chances are that it has never been replaced anyway). Also look at sealing up the cutout in the steering head that was evidently for a steering lock … allows dust and crud in.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: alanB on October 11, 2015, 10:09:04 am
(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=180719.0;attach=441574;image)

This is caused by misalignment of the oil pump little tab thingy that needs to fit in that slot when you tighten the clutch cover, very common issue on the Husky.  If you dont align the two, then its apparently very easy to break that slot when you tighten up the oilcase.

BTW, check that nut is good and tight, mine came loose and it took me (actually Conrad) a while to find the source of the knocking sound that resulted.

To answer your question.  Obviously none of us like the idea of a graunched part in our beautiful engines, but if the oil pump still engages and works properly, that's probably more a cosmetic injury than anything else.  Provided its not going to break off at a later date?
Title: Re: Kykdaar's SM610 rebuild thread
Post by: alanB on October 11, 2015, 10:11:49 am
(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=180719.0;attach=439579;image)

This also very common on the Husky, its actually caused by the battery restraint IMO.  They use a silly little rubber band to hold the battery down.  this causes the battery to jack hammer those welds as you hit bumps etc and eventually the welds go.

I've used two really big cable ties and cranked the battery down really hard onto its support, so it cant bounce up and down.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: alanB on October 11, 2015, 10:28:57 am
Quote
Check the foot peg bolts and mating surfaces - often need to be flatted and high tensile bolts fitted.

I have a simple but unpopular fix for the bad footpeg plate/bolt design - just change the bolts regularly.

The design is bad in that the bolts have to withstand quite a bad bending moment because the peg plates dont have a nice wide flat surface to mate with, where the surface could absorb the bending moment and thus reduce the bending moment on the bolt.  As you ride you are basically constantly hammering on a lever arm with your whole body weight.  Its almost like working the bolt back and forth with continual impacts on a long lever.  The bolts have to withstand that on their own without any support from the frame.

No bolt, no matter how strong, is going to last in that environment IMO, without a crack developing and steadily growing.  Its a classic fatigue problem.

If you know anything about fatigue, its all about the number of cycles to failure.  The crack will develop at a steady rate, governed by the number of stress cycles it undergoes.  The bolt will eventually fail when the crack eats into the bolt to the point that the remaining surface area is insufficient to withstand the stress of the next cycle.  This takes a reasonably long time.

So all you need to do is routinely replace the bolts before then!

So I just put in new 8.8 bolts every six months or so.  Its cheap and easy, and effective.

Most people dont seem to like this idea though, so you see quite elaborate fixes proposed on some of the forums.  But without redesigning the frame to provide a wider flat mating surface between the peg plate and the frame its not really possible IMO, and there simply isnt enough space down there as far as I can see.  
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 11, 2015, 10:54:51 am
Alan you confirm my observations above  :thumleft: 

Unfortunately I do not agree with your take on the foot peg issue as you can take the foot pegs off and carefully dress the mating surfaces so that there is a proper full contact patch - not difficult with a bit of patience and a file (a Dremel tool is probably best). I did mine and replaced with HT spec bolts and Loctite - and have never needed to touch them again.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: alanB on October 11, 2015, 11:04:09 am
Each to his own  :thumleft:

I did say my solution was unpopular.

I would also suggest that if you take your footpeg bolts for crack testing, you might find that they are cracked.  I suspect all well ridden Husky footpeg bolts are cracked to some extent, regardless of what you do.

From what I've seen most people only experience footpeg bolt failure once, after owning the bike a long time.  So I think it takes a few years of hard riding for those bolts to eventually fail.

By replacing the bolts frequently you will never get to that point.

But anyway, use it/dont use it.

I just think my suggestion is a foolproof, cheap easy solution.  8)
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 11, 2015, 02:15:18 pm
Thanks for the help and pointers gents. I know that I am probably covering ground that you have already done, but I appreciate the assistance.

Ja, I played around with the oil pump alignment to that shat end slot. Very easy for a ham-fisted mechanic to use force putting the cover back without realising what he is breaking. The engine probably chewed that piece up as well. If so, then it is quite amazing how strong all the gears and teeth are - I have not yet seen any chipped or damaged gears.

Things are coming along nicely now. Taking the stuff yhat must be bead / sand blasted in tomorrow, followed by the aluminium welding, followed by the red anodising.

Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 11, 2015, 04:03:06 pm
So was playing around with the clutch and also thinking about how I was going to tighten tge centre nut when finished with it when I remembered a clutch holding tool I made many moons back for my XR650R.

Went scratching around in the shed and found it buried under other stuff in the corner.  Tried it on the SM clutch centre and it fitted like a glove :biggrin:

Also received a mail from Dan regarding the washers -

Sorry Andre, no longer have any or plans to make any more.
Great motor! Enjoy the rebuild. I did my top end at 40,000 miles and the crank was still great.

Regards, Indy

So there you have it - will now get OEM washers and pins and then have Basil's engineering do the work for me.


Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 11, 2015, 04:40:42 pm
There is another guy making the washers as well - I think he is the one who sells the rivets as a kit. Cafe Husky and AdvRider will have his details. Do not buy the OEM ones they will just wear again  ::) - you need the high grade hardened ones that these guys make. I will see if I can find his details - think he is in E.Europe.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: alanB on October 11, 2015, 05:19:57 pm
There is another guy making the washers as well - I think he is the one who sells the rivets as a kit. Cafe Husky and AdvRider will have his details. Do not buy the OEM ones they will just wear again  ::) - you need the high grade hardened ones that these guys make. I will see if I can find his details - think he is in E.Europe.

Ja I second that, rather get proper washers made.  You should never have parts in the engine self destructing the way those things do IMO.

I think Rough Rider had some made for him locally?  Maybe you could contact him.

If you ask Indy, he should be able to send you the material and heat treatment process he used - he sent it to me, but its on an old laptop, I may even have published it here somewhere. 

Shouldn't be difficult to get an engineering shop to machine some up out of suitable steel and heat treat them?

They arent very complex shapes or anything.

Title: Re: Kykdaar's SM610 rebuild thread
Post by: sidetrack on October 11, 2015, 06:01:06 pm
I just gave the whole setup to Basils with the steel grade needed and they sorted it all out.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 11, 2015, 06:04:19 pm
I just gave the whole setup to Basils with the steel grade needed and they sorted it all out.

Ja, thinking of doing the same.

I am no engineer - what steel grade is needed for the washers and rivets?
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 11, 2015, 07:00:03 pm
Lots of info here in addition to Cafe Husky

http://advrider.com/index.php?threads/husqvarna-te-sm-610-index-thread.156431/ (http://advrider.com/index.php?threads/husqvarna-te-sm-610-index-thread.156431/)
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 11, 2015, 07:19:02 pm
OK I have PM'ed the other guy (_luke_) at Cafe Husky who was also making the cup washers. Lets see what he says. He is from Slovakia.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 11, 2015, 07:59:49 pm
Lots of info here in addition to Cafe Husky

http://advrider.com/index.php?threads/husqvarna-te-sm-610-index-thread.156431/ (http://advrider.com/index.php?threads/husqvarna-te-sm-610-index-thread.156431/)

Great thread that :thumleft:

OK I have PM'ed the other guy (_luke_) at Cafe Husky who was also making the cup washers. Lets see what he says. He is from Slovakia.

Thanks, much appreciated.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: alanB on October 11, 2015, 11:30:45 pm
Here's the reply I got from Indy when I originally asked him about his washers

Quote
Hi Alan,
 
SAE4140 die steel material heated to 1200 degrees F with agitated oil quenching and then tempered at 700 degrees F to yield an approx  44RC hardness.
 
Tempering is necessary for the hammering application we have with the clutch to provide extra toughness
 
We then machine them to the finished dimensions.
 
Remember to use a vise to squeeze half the spring and cups while you slip the clutch hub over. The tap the spring to center it in the space and repeat for all 6 springs.
 
These babies will out last your bike!
 
I got 2 sets with over 50,000 km each on them and no signs of excessive wear.
 
Regards, Dan

From this thread http://www.wilddog.za.net/forum/index.php?topic=128417.0 (http://www.wilddog.za.net/forum/index.php?topic=128417.0)
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 12, 2015, 07:03:52 am
Here's the reply I got from Indy when I originally asked him about his washers

Quote
Hi Alan,
 
SAE4140 die steel material heated to 1200 degrees F with agitated oil quenching and then tempered at 700 degrees F to yield an approx  44RC hardness.
 
Tempering is necessary for the hammering application we have with the clutch to provide extra toughness
 
We then machine them to the finished dimensions.
 
Remember to use a vise to squeeze half the spring and cups while you slip the clutch hub over. The tap the spring to center it in the space and repeat for all 6 springs.
 
These babies will out last your bike!

 
I got 2 sets with over 50,000 km each on them and no signs of excessive wear.
 
Regards, Dan

From this thread http://www.wilddog.za.net/forum/index.php?topic=128417.0 (http://www.wilddog.za.net/forum/index.php?topic=128417.0)

Thanks Alan :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 12, 2015, 04:12:23 pm
OK I have PM'ed the other guy (_luke_) at Cafe Husky who was also making the cup washers. Lets see what he says. He is from Slovakia.

Got a reply - he has washers. Waiting for price.  :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Scrat on October 12, 2015, 05:06:27 pm
OK I have PM'ed the other guy (_luke_) at Cafe Husky who was also making the cup washers. Lets see what he says. He is from Slovakia.

Got a reply - he has washers. Waiting for price.  :thumleft:

Hey - also interested in these washers if we can get a few.....  :pot:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 12, 2015, 05:14:36 pm
OK I have PM'ed the other guy (_luke_) at Cafe Husky who was also making the cup washers. Lets see what he says. He is from Slovakia.

Got a reply - he has washers. Waiting for price.  :thumleft:

Excellent, thanks :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: blazes on October 12, 2015, 05:28:19 pm
OK I have PM'ed the other guy (_luke_) at Cafe Husky who was also making the cup washers. Lets see what he says. He is from Slovakia.

Got a reply - he has washers. Waiting for price.  :thumleft:

Hey - also interested in these washers if we can get a few.....  :pot:

Maybe worth our while to do a bulk buy and keep them just in case  ::)
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 12, 2015, 05:40:31 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on October 13, 2015, 10:35:56 pm
I made my own washers and heat treated them and I pulled my cover off 5000km later and no wear yet, so they work great.
If you guys want to get some washers I can get some turned up by a buddy of mine with a CNC lathe and then I will heat treat them myself to spec.  I might have to have 200 or more made, maybe the rivets at the same time, and make these things available to the Husky guys out there.
No need to run all over the world to get them, it is really not rocket science!
Let me know if anybody want, then I will get onto it and we should have some in a week or so.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: blazes on October 14, 2015, 05:22:21 am
I made my own washers and heat treated them and I pulled my cover off 5000km later and no wear yet, so they work great.
If you guys want to get some washers I can get some turned up by a buddy of mine with a CNC lathe and then I will heat treat them myself to spec.  I might have to have 200 or more made, maybe the rivets at the same time, and make these things available to the Husky guys out there.
No need to run all over the world to get them, it is really not rocket science!
Let me know if anybody want, then I will get onto it and we should have some in a week or so.


I am in for three sets -- two sets with rivets. Sure with the Dollar being so strong they will be sought after in the usa .
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 14, 2015, 06:33:26 am
Streetcat  ;)  that is really awesome - good move. As you say not rocket science as we have the steel and hardening processes on our doorstep.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: alanB on October 14, 2015, 07:06:33 am
I made my own washers and heat treated them and I pulled my cover off 5000km later and no wear yet, so they work great.
If you guys want to get some washers I can get some turned up by a buddy of mine with a CNC lathe and then I will heat treat them myself to spec.  I might have to have 200 or more made, maybe the rivets at the same time, and make these things available to the Husky guys out there.
No need to run all over the world to get them, it is really not rocket science!
Let me know if anybody want, then I will get onto it and we should have some in a week or so.


 :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: chopperpilot on October 14, 2015, 07:34:44 am
I made my own washers and heat treated them and I pulled my cover off 5000km later and no wear yet, so they work great.
If you guys want to get some washers I can get some turned up by a buddy of mine with a CNC lathe and then I will heat treat them myself to spec.  I might have to have 200 or more made, maybe the rivets at the same time, and make these things available to the Husky guys out there.
No need to run all over the world to get them, it is really not rocket science!
Let me know if anybody want, then I will get onto it and we should have some in a week or so.
Dalk 'n stel washers en rivets neem vir die 610 wat erens op my wag!👍


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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 14, 2015, 07:45:54 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 14, 2015, 06:50:30 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Rough Rider on October 15, 2015, 08:44:52 am
Was at Basil's engineering today. Sidetrack had his clutch re-done there some years ago.

The business has been sold on to someone else, still open, but the new guy does not do riveting of clutch baskets anymore. 

Will have to find another engineering shop for the job it seems.

Pretty simple job, all you need is a ball peen hammer and an anvil.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on October 15, 2015, 11:11:19 am
I scratched around in my Husky box and found full drawings I made when I turned the washers and rivets, I will just draw it up a little neater and take to my CNC guy and see what he says. I might have to do quite a lot, but all Husky guys would need them some time or another. I am sure I will move them.
As for the riviting it is really easy, you just need a solid piece of steel and a ball peen hammer to do a first class job, just as RR says. I think I used  a piece of 40mm round bar clamped in the vice as an anvil to peen it on. It helps if you have a second pair of hands to hold it while you peen.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 15, 2015, 12:50:21 pm
I took mine to a local brake and clutch shop that I think 'nailed' them with a hydraulic machine - was also quick and simple.  :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: alanB on October 15, 2015, 06:30:23 pm
Only tricky thing about the riveting as far as I understand it is tha you need to heat them red hot and then do the peeing so that when they cool down afterwards they contract and really clamp those plates together.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 15, 2015, 06:32:36 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on October 15, 2015, 10:35:22 pm
The standard rivets are a real sloppy fit, 5,85 dia rivet in a 6,15 hole. I will be making them 6,1mm. I hammered mine down and they are really tight. Spoke to my CNC guy today, will have a price by tomorrow.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 16, 2015, 07:37:34 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on October 16, 2015, 07:45:05 pm
No word yet. If I have nothing by Monday I will follow up.
Nice thing, once the washers are done you never have to do them again.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BOER! on October 16, 2015, 07:53:47 pm
I will also be in for a set of washers pls
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 17, 2015, 07:10:39 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 17, 2015, 07:24:48 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 17, 2015, 08:49:07 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 17, 2015, 08:52:22 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Ganjora on October 18, 2015, 04:10:28 am
Proper job you're doing there.
Remeber: we're watching...
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 18, 2015, 07:17:15 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 18, 2015, 07:21:06 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: chopperpilot on October 18, 2015, 08:29:05 am
Puik werk A!

Baie netjies. Bly die top end lyk goed!


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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 18, 2015, 08:52:45 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: chopperpilot on October 18, 2015, 08:58:04 am
Goed om te hoor!

My Husky kennis is beperk. Leer hier saam met jou...

'n 610 TE bly in my visier!


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Title: Re: Kykdaar's SM610 rebuild thread
Post by: chopperpilot on October 18, 2015, 08:59:16 am
Waarmee het jy die head (valves) en piston so mooi skoon gemaak?


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Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 18, 2015, 12:12:42 pm
Many recommend fitting the APE manual timing chain adjuster - should consider it while you are about it.

Also the tappet cover bolts are notorious for leaking oil through the threads and onto the header etc. These need careful attention with silicone to prevent you having to go back in there … been there done that!  ::)

Great rebuild.  :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on October 18, 2015, 12:22:25 pm
+1 on the manual cam chain tensioner.
The shavings in the oil could be from the disintegrating clutch washers, mine was gone at 10 000km and also destroyed the plate that holds them in, had to replace that and the springs as they were also damaged by being so loose. I posted pictures at the time, will see if I can find a link.
You are really doing a great job. How many Km's has the engine done?
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on October 18, 2015, 12:26:50 pm
Found it! look at reply no 33
http://www.wilddog.za.net/forum/index.php?topic=137781.20 (http://www.wilddog.za.net/forum/index.php?topic=137781.20)
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 18, 2015, 04:04:14 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Sláinte Mhaith on October 18, 2015, 06:21:28 pm
Mooi rooi tool trolley wat jy daar het.  ;) ;D
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 18, 2015, 06:37:12 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Sláinte Mhaith on October 18, 2015, 08:44:56 pm
 :thumleft: :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on October 20, 2015, 09:34:24 am
Good news gentelmen, I got the quote on the washers and rivets, a set consisting of 12 washers and 3 rivets will be R422.00.
I should have them in my hands in a week or so, depending on how fast I can get a gap to collect when they are finished.
I have ordered quite a lot as these guys don't want to talk to you unless you order hundreds (preferably thousands). Anyway we will have enough for the 10 Huskies in South Africa and then some.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 20, 2015, 10:00:25 am
Good job!  :thumleft: Are the washers hardened ?
Title: Re: Kykdaar's SM610 rebuild thread
Post by: StuartC on October 20, 2015, 10:11:01 am
Proper effort Andre !
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on October 20, 2015, 10:35:29 am
Good job!  :thumleft: Are the washers hardened ?

Yip they are made from the Bohler equivalent of EN24 and I will heat treat them myself in a foil packet and temper them to around 48Rc, so they will be much harder than the stock washers and also very tough. Just remember to polish the ends of the slot in the gear where the washers press up against as the slot is sheared out and the edges are rough. Just use a stick with some sandpaper folded over it to sand the ends smooth, 360 or 220 grit should do.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 20, 2015, 11:26:39 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: alanB on October 20, 2015, 11:33:24 am
Good news gentelmen, I got the quote on the washers and rivets, a set consisting of 12 washers and 3 rivets will be R422.00.
I should have them in my hands in a week or so, depending on how fast I can get a gap to collect when they are finished.
I have ordered quite a lot as these guys don't want to talk to you unless you order hundreds (preferably thousands). Anyway we will have enough for the 10 Huskies in South Africa and then some.

Well done Bertie

Maybe you should post on Cafe Husky.

After that when the demand takes off start a company and retire? :biggrin:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: alanB on October 20, 2015, 11:35:04 am
Many recommend fitting the APE manual timing chain adjuster - should consider it while you are about it.

Also the tappet cover bolts are notorious for leaking oil through the threads and onto the header etc. These need careful attention with silicone to prevent you having to go back in there … been there done that!  ::)

Great rebuild.  :thumleft:

I used copper washers on mine and the irritating oil seepage issue stopped!  :thumleft:

Second the comments on the quality of the rebuild, its going to a superb bike when its done  :ricky:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 20, 2015, 11:50:51 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: sidetrack on October 20, 2015, 01:07:45 pm
I admire your gusto  :biggrin: Check the rocker bushes as well, apparently they wear. My 610 always had a noisy tappety topend that I could never fix.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 20, 2015, 02:12:32 pm
I admire your gusto  :biggrin: Check the rocker bushes as well, apparently they wear. My 610 always had a noisy tappety topend that I could never fix.

Seen this claim as well and that some swop them over which helps?
Title: Re: Kykdaar's SM610 rebuild thread
Post by: chopperpilot on October 20, 2015, 03:24:50 pm
Straatkat

Ek is nog steeds in vir 'n stel wassers en rivets vir my toekomstige 610!


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Title: Re: Kykdaar's SM610 rebuild thread
Post by: sidetrack on October 20, 2015, 03:24:55 pm
I admire your gusto  :biggrin: Check the rocker bushes as well, apparently they wear. My 610 always had a noisy tappety topend that I could never fix.

Seen this claim as well and that some swop them over which helps?
Yes turned mine 180 degrees, helped for about 5 mins before the noise returned.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on October 20, 2015, 10:48:45 pm
Straatkat

Ek is nog steeds in vir 'n stel wassers en rivets vir my toekomstige 610!



Excellent news - I am in for three sets please. A set for each of my bikes and a spare set.

Ek maak notas, sal almal kontak as hulle gereed is.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 23, 2015, 04:59:34 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 23, 2015, 08:37:03 pm
Who did you order the spares through in the end?
Title: Re: Kykdaar's SM610 rebuild thread
Post by: zetman on October 23, 2015, 11:02:13 pm
 :ricky: Wow daai casings lyk splinternuut gan jy hulle clearcoat of verf  gee?

Title: Re: Kykdaar's SM610 rebuild thread
Post by: 1ougat on October 24, 2015, 05:32:14 am
 :sip:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on October 24, 2015, 07:25:00 am
:ricky: Wow daai casings lyk splinternuut gan jy hulle clearcoat of verf  gee?



Of powdercoat?
Title: Re: Kykdaar's SM610 rebuild thread
Post by: BiG DoM on October 24, 2015, 08:14:18 am
or ceramic coat?
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 24, 2015, 02:03:01 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 30, 2015, 12:36:02 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Rough Rider on October 30, 2015, 12:59:18 pm
You can still see the original hone marks on the barrel  :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on October 30, 2015, 01:26:56 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Straatkat on November 13, 2015, 09:26:50 pm
I collected the cush drive washers and rivets for the clutch yesterday and heat treated them today, so we are ready to rock.
I think I am going to start a new topic.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on November 13, 2015, 09:29:39 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: chopperpilot on November 13, 2015, 10:02:36 pm
I collected the cush drive washers and rivets for the clutch yesterday and heat treated them today, so we are ready to rock.
I think I am going to start a new topic.
Ek stel nog belang in 'n stel Straatkat.👍


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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on November 15, 2015, 08:20:11 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on November 16, 2015, 05:18:43 pm
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on December 09, 2015, 08:30:34 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Ganjora on December 09, 2015, 08:50:37 am
i love gold rims
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Sláinte Mhaith on December 09, 2015, 09:10:36 am
The problem I am sitting with is what colour should I make the frame, swing arm and hubs to tie into the gold rims at the bottom and the red and white plastics on the top?

Seems that gold rims might be a bit limiting and that I should have gone black or silver for a red and white top? What you guys think?

A few photo's I have found on the net

This looks good

(http://blog.toeffcenter.ch/wp-content/uploads/2015/05/Honda-Africa-Twin-CRF-1000-2.jpg)

But this does not

(http://i.imgur.com/2CHtSP3.jpg)


Maybe keep the frame dark ???
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on December 09, 2015, 09:20:52 am
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Title: Re: Kykdaar's SM610 rebuild thread
Post by: Sláinte Mhaith on December 09, 2015, 09:55:49 am
PS. I like the way the gold forks help to tie the rims to the bike.
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Scrat on December 09, 2015, 10:33:13 am
Busy surfing the Net to look for alternatives to the OEM timing chain -

Seems there are 3 possibilities from DID -

 DID SCA0412A SDH
 DID SCA0412SV-122
 DID SCR0412SV-122
 
The SV is apparently stronger (and more expensive) due to the fact that it uses "new bolts, which through the use of special coatings are characterized by higher resistance to abrasion compared to SCA0404A SDH; SCA0409A SDH, SDH SCA0412A"

Anyone else went down this road before and can give some advice or insight?

Hey there Kykdaar,

I also did some research to get the proper chain and ended up taking my original chain to Craigs in Maitland , as far as i can remember it was the DID SCR0412SV-122
BUt they only had it in 126 size ( the engineer there help me to shorten it and install the master link) cost was about R650
Chain in and no issues for past 2 years... (including 2x AMageza's ) think it has moved one click ...  :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Kykdaar on December 09, 2015, 11:14:37 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on December 09, 2015, 11:34:28 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: alanB on December 09, 2015, 11:58:53 am
I for one cant wait to see the results  :thumleft:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on December 09, 2015, 12:08:12 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on December 09, 2015, 02:19:52 pm
waars die fotos van jou jewish racing gold colour rims?

Lekker tappit!

vra ek mos kykdaar noudie dag waste kleur is sy tappit cover en of hy hom gaan verf, toe se hy my nee, dis n suursteen huis, hy gaan hom nie verf nie!

 :imaposer: :imaposer:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on December 09, 2015, 02:46:42 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on December 09, 2015, 02:56:05 pm
waars die fotos van jou jewish racing gold colour rims?

Lekker tappit!

vra ek mos kykdaar noudie dag waste kleur is sy tappit cover en of hy hom gaan verf, toe se hy my nee, dis n suursteen huis, hy gaan hom nie verf nie!

 :imaposer: :imaposer:

 :middlefinger:   :imaposer: :ricky:

hahaha touchy much????
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Straatkat on December 10, 2015, 06:45:54 pm
Andre, ek weet dis nou te laat, maar so 'n charcoal kleurtjie kan ook baie mooi lyk op die rims, dan bou jy 'n 610SM Dark!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on December 10, 2015, 06:54:22 pm
Personally I think gold rims are zef and very '70's … JPS Racing …  O0
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on December 10, 2015, 07:01:30 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on December 10, 2015, 07:03:43 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Straatkat on December 10, 2015, 09:31:36 pm
Hoe maklik is dit om die kleur te verander?
So terloops jou en Michael se washers is gereed. Sal miskien kom draai na die Swazi naweek.
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on December 10, 2015, 10:00:41 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: sidetrack on December 10, 2015, 10:18:17 pm
Black will always be in fashion  :biggrin:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on December 10, 2015, 10:21:03 pm
Black is the new gold  O0
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on December 11, 2015, 07:43:16 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on December 11, 2015, 08:19:24 am
Black is the new gold  O0

Just for that reason I will be doing them in silver :biggrin:

nee!!!!!!!!!!!!!!!!!

ry eers n bietjie met jou jewish racing gold rims pappie!

en as ons klaar gelag is, kan jy hulle anti zef kleur maak!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on December 11, 2015, 08:23:53 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on December 11, 2015, 10:47:10 am
Black is the new gold  O0

Just for that reason I will be doing them in silver :biggrin:

nee!!!!!!!!!!!!!!!!!

ry eers n bietjie met jou jewish racing gold rims pappie!

en as ons klaar gelag is, kan jy hulle anti zef kleur maak!

 :biggrin: Jy is lekker grootmond nou. Waarom het jy nie die oom vroer gese dat dit gaan k@k lyk nie?

en jy sou na enige iets geluister het!!!! hahahaha hopeloos te oud en hardkoppig, plus dan sou ek nie nou vir jou kon lag nie!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on December 11, 2015, 10:54:42 am
Die youngsters donner jou rond!

Darem bly om te sien Matie gesels darem weer bietjie hier!


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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on December 11, 2015, 10:59:46 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on December 11, 2015, 11:09:41 am
Die youngsters donner jou rond!

Darem bly om te sien Matie gesels darem weer bietjie hier!


Sent from my iPad using Tapatalk

 ;D Hy dink hy het die laaste lag in, maar dit is altyd ons ou manne wat die laaste lag :deal: 

hahaha teen die pas wat jy dinge doen en keuses maak lyk dit of ek nog baie gaan lag, so nee weet dis nie die laaste lag vir jou nie!!!!!!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on December 11, 2015, 11:18:39 am
Hierdie een is vanoggend na 6 jaar se getroue diens, aan sy nuwe baas afgelewer.

(http://images.tapatalk-cdn.com/15/12/11/ae926149ad0f4dc07cbba897c10ae838.jpg)




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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on December 11, 2015, 11:20:19 am
Toemaar, hierdie een is nog veilig!

(http://images.tapatalk-cdn.com/15/12/11/48d504d9a1b0304f2b8955c2618e8bad.jpg)


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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on December 11, 2015, 11:21:13 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on December 11, 2015, 11:22:17 am
Die DR was net 5 minute op Gumtree, toe bel die ou wat my vrou se DR 200 gekoop het, en koop die wit DR.

Nou's daar plek, en $$$ vir 'n 610 TE!


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Title: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on December 11, 2015, 11:25:37 am
Ek sien jy werk met n plan.

Besig om plek te maak vir n TE? >:D
Dink nie mamma is al bewus van hierdie plan nie!🙀

Belangrik vir haar dat ek gelukkig is, en sy bly nie lank kwaad nie!👍

En het darem nie haar KTM kleur Cross Polo verkoop nie!😉


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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on December 11, 2015, 11:29:31 am
hahahahaha

urban dictionary definition:

Jewish racing gold

Jewish racing gold is the description of certain shades of the colour gold. It is most often applied to cars painted in a gold colour, though can also be applied to describe other items of this colour.

It is derived from the stereotype of Jewish women of a certain age having a prediliction to gold-coloured clothing and accessories, and is therefore mildly perjorative.

Shabbat shalom, her car is jewish racing gold!

lekker oom, of sal ek se tannie kykdaar
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on December 11, 2015, 12:48:41 pm
Ja kugel bling wiele!  >:D
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Straatkat on January 01, 2016, 03:42:41 pm
Andre, hoe vorder jou build? Gedink jy kan al baie ver wees met al die vakansie! Dis nou as jy nie by die een of ander eksotiese strand le en mojito's drink nie. :)
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on January 01, 2016, 04:51:34 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Straatkat on January 02, 2016, 08:32:47 pm
 :thumleft:
Title: Re: Kykdaar's SM610 rebuild thread
Post by: Renier on January 02, 2016, 08:42:26 pm
Sjoe, lyk my jy het te veel geld deesdae. Begin nou bikes soos posseels versamel.
Rykste ou op die forum... jy nie geweet nie?  ;) ;)

ek soek ook so bike! lyk na groot sports.
leke rebuild Kykdaar, high five!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on January 03, 2016, 07:52:43 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on January 03, 2016, 07:03:21 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Straatkat on January 03, 2016, 10:46:40 pm
Ja Andre, so leer mens, die eind resultaat is meer belangrik as om 'n bietjie meer tyd te bestee. Jou build gaan stunning wees! Mooiste SM in die land!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on January 04, 2016, 07:38:08 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Straatkat on January 04, 2016, 09:05:31 pm
En as jy dit met 'n goeie 2K verf en clearcoat verf is dit baie duursaam, en dink net aan al die kleure wat jy nou tot jou beskikking het.
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on January 04, 2016, 10:13:42 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on January 05, 2016, 09:14:20 am
Ja Andre, so leer mens, die eind resultaat is meer belangrik as om 'n bietjie meer tyd te bestee. Jou build gaan stunning wees! Mooiste SM in die land!

Dankie Bertie :thumleft:

Bietjie met Matie ge-chat vandag oor die pro's en cons van powdercoating. Grootste probleem is die moontlikheid van chips optel en die feit dat jy dit nie nou en dan n touch-up kan gee nie..

So, ek gaan die kompressor nader sleep, my fancy spraygun gaan soek wat erens nog weggepak is en my spaypainting skills weer opskerp.

Die lekker van dit is dat ek dadelik kan begin (al die powdercoaters hier is nog toe) en dat ek heeltemal in beheer is van die proses, en dus ook die end resultaat.

Ek wil net gou double check:

Watse compressor praat jy van?

Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on January 05, 2016, 06:12:14 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on January 05, 2016, 07:12:29 pm
Daai smart Puma van my wat ek vir jou geleen het ;D
Rente?


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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on January 06, 2016, 09:45:12 am
meer soos my smart puma wat jy leen...



Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on January 06, 2016, 09:50:58 am
meer soos my smart puma wat jy leen...




Rente...anderkant toe! :pot:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on January 06, 2016, 10:12:17 am
Bliksem, kykdaar kykdaar die Honda CRF450 op page 1! http://www.wilddog.za.net/forum/index.php?topic=65652.0;topicseen (http://www.wilddog.za.net/forum/index.php?topic=65652.0;topicseen)

jou husky kan maar in daai rigting gaan, bliksem!

Chopper, met die hoeveelheid wat ek vir kyk daar skuld, sal ek nie sommer die rente in een leeftyd kan terug maak nie!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on January 06, 2016, 01:10:08 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 01, 2016, 08:27:11 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on February 02, 2016, 09:54:55 am

But I digress - We have some wonderfully talented people on the forum with skills far in excess of what most of us can only dream of. I was lucky enough to meet one such dog recently and this was the result of our barter transaction -


Bliksem na so gelekkery voel dit of my gat ook sommer moet blink!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 10, 2016, 01:32:55 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on February 10, 2016, 05:44:09 pm
ja looks like needed a welded bolt on the old stub? Also looks like  a Wurth Timesert fix? Kakked myself on a swing arm once in similar fashion …  ::)
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 10, 2016, 06:47:23 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on February 10, 2016, 07:40:03 pm
So how did Francois the fuckupfixer magician get it out?  :biggrin:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 10, 2016, 08:09:07 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on February 10, 2016, 09:02:16 pm
He fitted the Timesert as well I am guessing? So he drilled the out the old bolt rather than extracting it. I had an engineering firm recommended to me in PE who would get a stub out … I drove a 250km roundtrip and they fucked it up  worse than I would have in an attempt to weld onto it - then broke an Easy Out off in it! I had said to them not to use an Easy Out as it will be impossible to drill if it breaks.  :dousing: In the end I took it out of their hands and got in my car and fooked off home. I got it right in the end with great satisfaction and swearing but had to drill, tap and fit a Timesert.
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 10, 2016, 09:06:55 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on February 10, 2016, 09:36:26 pm
You really need to make sure that the surfaces on the frame and footrest are flatted to mate as flush as possible and use HT bolts. This is where the weakness originates and has been documented on a few sites - the two surfaces are most often not true putting the entire force on the Italian spaghetti bolts … You really do not want them to fail while you are up on the pegs! I know alanB says rather just change the bolts regularly but my take is do a proper fix and rest assured. I used a Dremel tool and then a small file by hand and a black felt tip marker to  check the mating surfaces were true … (where there is contact the marker is removed). With your frame stripped it should be even easier.
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 11, 2016, 08:48:01 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: TK on February 11, 2016, 11:46:58 pm
I had one of the foot pegs come off on a Swaziland trip. Both HT bolts broke clean off.....even with having matted the surfaces previously. Managed to easyout the first one and then broke the easy out on the second one........fuck did I swear. Managed to drill the easyout out (probably a crap easyout) but damaged some of the threads. With that just made a decision to drill and tap  all to M10.
Will probably change them out in a couple of months time.
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on February 12, 2016, 07:12:01 am
I had one of the foot pegs come off on a Swaziland trip. Both HT bolts broke clean off.....even with having matted the surfaces previously. Managed to easyout the first one and then broke the easy out on the second one........fuck did I swear. Managed to drill the easyout out (probably a crap easyout) but damaged some of the threads. With that just made a decision to drill and tap  all to M10.
Will probably change them out in a couple of months time.

I would be interested in the HT spec bolt you used for it to break clean off.
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: TK on February 12, 2016, 07:57:30 am
Sometimes HT is not the answer. I will have to look into that. Did contemplate S/S with a nice big head. Maybe rather have them bend than brake off. Gives a warning sign before you buy a farm.
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Scrat on February 12, 2016, 08:16:39 am
You really need to make sure that the surfaces on the frame and footrest are flatted to mate as flush as possible and use HT bolts. This is where the weakness originates and has been documented on a few sites - the two surfaces are most often not true putting the entire force on the Italian spaghetti bolts … You really do not want them to fail while you are up on the pegs! I know alanB says rather just change the bolts regularly but my take is do a proper fix and rest assured. I used a Dremel tool and then a small file by hand and a black felt tip marker to  check the mating surfaces were true … (where there is contact the marker is removed). With your frame stripped it should be even easier.

Thanks, I will definitely do this whilst the frame is still bare and unpainted.
:laughing4: :laughing4: :laughing4:

Had the same thing happen to me on the special stage of day 2 @ amageza last year!! luckily it was in the dunes and thus had a "soft" landing  :P

Managed to find my footpeg in the sand and had to ride another 600km witout a righthand footpeg  :ricky: managed to stuck a "kameeldoring branch" between frame and bashplate.... boer maak n plan!

needless to say we got to the bouviac that evening at 10:30 and Had to do some major planning to fix that damm footpeg. Eddy 2 Race came to the rescue and  managed to magically get it sorted for me that evening before 12:00!! He's the Husky whisperer!  :thumleft:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 14, 2016, 06:45:19 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 14, 2016, 06:58:33 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on February 14, 2016, 07:45:07 pm
Jy het my vote! Dalk omdat ek 'n Suzi fan ook is!

Blou rims is cool!


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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on February 15, 2016, 11:42:50 am
Finally got some quality time to spend with the  bike.

Time to tackle the frame after the last stuck bolt was removed.

Was sandblasted some time ago and started forming some surface rust. Also quite a bit of residue powder coating needed removal - seems the sandblaster just assumed that the frame was qoing to be powder coated, so was not particularly thorough.

Got some real nasty paint stripper and went to work. If this stuff gets on your skin you drop everything and run for the soap and tap ;D

So next step was to get rid of the rust. Used the stuff below and was very impressed - gets rid of rust pronto.

Only problem is that as soon as the frame is rinsed off, a thin coat of flash rust forms nearly immediately which is a bummer.

As soon as the frame dried it was time to break out the sanding paper, wire brush and steel wool. A few hours later the flash rust was off, the frame was clean and it was time to apply a few thin coats of grey primer to treat the frame

Still far from finished with it before final priming, but at least it wont rust.




Hahahaha sien dit het n child resistant cap. jy moes seker ekle keer vir ma gaan vra het om vir jou oop te maak!!!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: alanB on February 15, 2016, 01:58:59 pm
As far as those footpeg bolts go - I know nobody likes to hear it, but the easiest solution is just to replace the bolts periodically (once a year should be fine, unless you are racing IMO).

The fact that the bolt broke off when you tried to take it out tells me it was probably cracked, quite badly before hand.

I bet you guys if you all take your existing bolts out and take them for crack testing at least 50% will be cracked!

Its a bad design that will just keep causing those bolts to crack IMO.  That's not the end of the world, because it takes quite a long time for the cracks to grow big enough to become a problem.  It costs about R5 to get new bolts and 10 minutes to replace them!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Straatkat on February 15, 2016, 10:08:26 pm
Alan, as always you have the most sensible solution, you really cannot argue with that logic!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on February 16, 2016, 07:11:19 am
My logic and basic physics tells me that properly mated contact surface areas will give a stronger fixture and not put as much pressure and leverage on the bolts. Larger diameter and/or HT bolts and/or replacing them as a service items are possible other work arounds. 
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 17, 2016, 12:21:34 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on February 17, 2016, 01:34:15 pm
Take it back for them to get that ripple out … will only stretch bigger  ::)
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 17, 2016, 03:06:53 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on February 17, 2016, 09:58:10 pm
Take it back for them to get that ripple out … will only stretch bigger  ::)

Ja, I noticed that but was not sure if it would be a problem.

Thanks, spoke to them and taking it back. They happy to sort it out.

I am sure they will just tension it up.  :thumleft:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on February 19, 2016, 06:24:25 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on February 19, 2016, 08:59:31 pm
Much better  :3some:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 24, 2016, 06:29:19 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on June 17, 2016, 10:53:48 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on September 25, 2016, 06:36:49 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Ganjora on September 25, 2016, 07:41:41 pm

Then it went back into its corner.....

You are obviously are unaware of my trademark "its corner".
As we know each other, i will not allow legal proceedings to take place,  this time...
This time,  Kykdaar.
This time...
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on September 25, 2016, 09:16:06 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Straatkat on September 26, 2016, 09:12:11 pm
Looking good Kykdaar. Have you finally decided on the colour scheme, I see white wheels, blue seat, black frame. Just wondering!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on September 26, 2016, 09:51:32 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Archangel on September 28, 2016, 03:49:11 pm
Looking good. I actually like the blue and yellow more than the red and white, so I'm excited to see ho this turns out.  :thumleft:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on September 29, 2016, 07:29:59 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on September 29, 2016, 08:25:08 pm
The lower shock mount bearing on my 610 TE was completely dry at 8200 km, but fortunately not damaged. After greasing with Bel Ray I had no more play in the rear suspension. Swingarm bearings were fine, added a bit of grease.


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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on September 29, 2016, 08:33:15 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on September 29, 2016, 08:41:05 pm
You were fortunate then :thumleft:
👍


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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on October 01, 2016, 06:53:33 am
Decided that whilst I am getting ready to assemble the running chassis I will quickly do the swingarm and linkage bearings and seals. After all, it is not all just about the looks.

Swingarm was straight forward and easy.....then I got to the linkage.

Man, whoever designed that rear shock bottom linkage set-up was probably pissed, or stupid, or both. Clearly he never intended that bearing to be ever removed after fitting because he chose to secure each side with oversize circlips (which you need a crowbar to bend) and then designed the bearing flanges so that you cannot get to them in any event. F@rkin idiot.


I did a full write up on this on Cafe Husky (including doing the swing arm bearings) - not sure if you looked at this? Yes I drilled holes to be able to get under the circlips with a pick. Honestly not such a big deal once you get your head around it and real peace of mind to know that it is all good and done properly. This is unfortunately the price you pay in maintenance on a linkage suspension. Did you fit extra seals - this is the answer imho.

Link for Linkage fix: http://www.cafehusky.com/threads/rear-linkage-bearings-bushes.39776/ (http://www.cafehusky.com/threads/rear-linkage-bearings-bushes.39776/)

Link for Swingarm fix: http://www.cafehusky.com/threads/swingarm-bearings.39835/ (http://www.cafehusky.com/threads/swingarm-bearings.39835/)

 :thumleft:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on October 01, 2016, 07:40:47 am
Ha Ha  :lol8:  - Yes indeed you read my thread because you used my photographs of the parts! I recognised my finger that has a scar from a NT Cutter running up the side  :o

PS: Thanks BiG DoM for the tutorial before I did this job  :thumleft:

 :ricky:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on October 01, 2016, 08:04:20 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on October 02, 2016, 07:46:52 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Archangel on October 02, 2016, 08:59:09 pm
Nice progress!!! Nothing motivates you like a rolling chassis...  :deal:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on October 03, 2016, 07:41:20 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on October 18, 2016, 08:50:31 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on October 18, 2016, 10:03:35 pm
Locksmith should be able to cut a key. :thumleft:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on October 18, 2016, 10:09:15 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Archangel on October 19, 2016, 05:03:29 pm

Re-assembly has commenced in all earnest and bike is coming together nicely. Will post an update with some photos soon.

Cant wait... 🍿


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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on October 30, 2016, 06:32:00 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on October 30, 2016, 06:35:51 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Archangel on October 30, 2016, 09:23:01 pm
Flip that bike is starting to look very nice! I've always had an appetite for a motard, but have never owned one. Maybe one day...

Sent from my SM-G920F using Tapatalk

Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on October 30, 2016, 09:36:54 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on November 14, 2016, 08:01:52 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on November 14, 2016, 08:06:09 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on November 14, 2016, 08:56:39 pm

Seems the engine was rebuilt sometime in the future past judging from the bearings - m8stly SKF but with a few NSK bearings in between.

Next steps are replacing all bearings and seals and fixing the crank.

 Fixed. :thumleft:  Good thorough tear-down job.
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: chopperpilot on November 14, 2016, 10:00:35 pm
Mechanical puzzle! Geniet dit! Ek hou dop!


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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on November 15, 2016, 07:24:03 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 03, 2017, 07:03:26 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: zetman on April 03, 2017, 07:12:14 pm
 :biggrin: Befok  :ricky:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: GDA1 on April 03, 2017, 08:22:50 pm
Looks good, keep it coming


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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: BiG DoM on April 03, 2017, 08:47:59 pm
Fresh  :thumleft:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 11, 2017, 10:14:35 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Groenie on April 11, 2017, 03:01:24 pm
Pornografie! Ban die bliksem!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 11, 2017, 04:10:58 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: sidetrack on April 11, 2017, 04:30:23 pm
Baie mooi  :thumleft: Mis my 2006 610 erg
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Tom van Brits on April 11, 2017, 04:57:56 pm
Dit het nou n helse klomp effort gevat om hierdie threat te 'refresh' tot ek al die fotos kon sien maar was die moeite werd!
Dit is n baie netjies engine en ek kry die indruk van kwaliteit as ek so na als kyk.....n bike en n half!
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 11, 2017, 05:08:26 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Groenie on April 12, 2017, 09:00:57 am
Hier's een van my favourite pics.

Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 12, 2017, 09:32:52 am
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Straatkat on April 12, 2017, 01:58:57 pm
Andre you bare doing such a good job. I can see you are enjoying every minute.
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 23, 2017, 04:46:58 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 23, 2017, 04:58:33 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 23, 2017, 05:05:42 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 23, 2017, 05:14:05 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Kykdaar on April 23, 2017, 05:17:08 pm
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Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Tom van Brits on April 24, 2017, 01:53:29 pm
Gelukkig he jy n spaar barrel!! Lyk netjies  :thumleft:
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: sidetrack on May 02, 2017, 10:14:39 pm
Once everything was ready and tripple checked I applied grey loctite gasket sealer to the crankcase halves and closed the bottom end up.

Started to play around with the fitment of the crankshaft, clutch and counterbalancer gears and loosely assembled them without their woodruff keys to make sure of the fitment. Turned the engine around and prepared to install the new cam chain I got from Runner - an upgraded DID and not the standard Husqvarna part - and the reed valve, before I re-fitted the flywheel. At that stage I also wanted to add the new cam chain guides I was convinced I already bought.

After turning the garage upside down I realised that I, in fact, never bought it so I left things as they are for now.   
Husqvarna one is spaghetti - I see you got a good one Made in Japan  8)
Title: Re: Kykdaar's SM610 rebuild and restore thread
Post by: Matie spero on August 17, 2017, 10:53:55 am
Pornografie! Ban die bliksem!

jy dink die is erg?

jy moet die goed sien wat hy vir my op whatsapp stuur!!!

sommige is sommer videos, van die eerste keer wat hy aan konppies vat!!!

walglik