Archie's TE610 thread - Now for sale (R45k)

[Archangel]

Thanks for your help with the parts order Archie!

Pleasure. 

[chopperpilot]

Thanks for your help with the parts order Archie!

Pleasure. 

[BiG DoM]

The reason why some washers are compltely gone and others still look OK is the surfaces on the gear where they work. Those oblong holes are sheared out and some are rougher than others, so the washers that were on the smoother surfaces are still fine and the ones on the rough sheared edges are chewed up, that is why you must smoothen the edges in the gear where the washers work. It is very important.
BD the clutch is unaffected by the washers being worn as they only serve as a cush drive. Unless the springs and the plate is so worn that it catches on something....but it would have to be investigated and I assume would have to be much, much more worn for that to happen. Mine showed no change in clutch action when I replaced the washers and plate

I was referring to the wear on the basket fingers not the washers - they often cause judder or grab (although the wear pictured is not unusually bad). I would agree with the observation regarding the spring slots being punched out and not carefully finished in production, as with the washer mating surfaces, thus causing friction and premature and uneven wear. The washers are though also made in a pasta machine.

[sidetrack]

Archie have you checked your cam chain wear yet ? They also like to stretch and start to make contact with the inside of the stator housing. You can pull the adjuster to see how many clicks are left.

[Rough Rider]

Archie have you checked your cam chain wear yet ? They also like to stretch and start to make contact with the inside of the stator housing. You can pull the adjuster to see how many clicks are left.

Actually the camchain rubs against the reed valve when it has streched.

Have you checked the sticky on Cafe Husky regarding the clutch washers?

[Archangel]

Actually the camchain rubs against the reed valve when it has streched.

Haven't had a look. Will do that this afternoon. 

Have you checked the sticky on Cafe Husky regarding the clutch washers?

Ja, I saw that, thanks!

[Archangel]

Did any of you guys replace the 6 x clutch compression springs (item 43) while doing these mods?

[Kykdaar]

Did any of you guys replace the 6 x clutch compression springs (item 43) while doing these mods?

No, I checked mine against specifications (length) and they were all well within spec.

[Straatkat]

Did any of you guys replace the 6 x clutch compression springs (item 43) while doing these mods?

No, I checked mine against specifications (length) and they were all well within spec.

When you put in the new washers they are a bit thicker than the stock ones so you should be OK with the old springs.

[Archangel]

Straatkat, We're talking about the  actual clutch springs, not the the Cush springs...


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[Scrat]

Straatkat, We're talking about the  actual clutch springs, not the the Cush springs...


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I had an unexplained clutch slip on high speed in 6th gear... for the past 2 years... did 2x Amageza's like that with no issues and tried a few different options to sort this out suggested by different forums... no luck

Then about a month ago...
I replaced my 6x clutch springs and steel plates with new OEM ones ordered from Eddy2Race and......... we have a winner!! all sorted...
i think it was mainly the springs 3 of them measured just below spec 
cost was about R780 for everything.

Hope this info helps?

[Archangel]

In other words it might be worth replacing while it's open...


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[sidetrack]

In other words it might be worth replacing while it's open...


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Dont worry you will be opening it a lot   Kidding loved mine. All things to check :

Rocker bushes
Cam chain and guides (reed valve wear)
Cush hub spacers like you did
Clutch springs
The bag filters in the motor, they catch all the metal crap that the engine eats up
Battery tray cracks
Sub frame cracks
Foot peg bolts can break / stretch
My ignition wore out so you could remove key after switching it on, could be issue on older models
Check that the wires do not get rubbed through under the battery, happened to my friend on his Fi 610

[BiG DoM]

Can add:

Engine mounting bolts
All servicable bearings - wheel, suspension and steering head
Rocker cover - seal bolts and gaskets
Spaghetti side stand (first thing that gave on mine!)
Airbox threaded inserts
 

[Archangel]

Airbox threaded inserts

2 out of 4 of mine have stripped out. How did you guys fix them? Just put a bolt all the way through?

[sidetrack]

Airbox threaded inserts

2 out of 4 of mine have stripped out. How did you guys fix them? Just put a bolt all the way through?

Going to be fiddly to remove cover, how about new inserts ?

[Archangel]

Airbox threaded inserts

2 out of 4 of mine have stripped out. How did you guys fix them? Just put a bolt all the way through?

Going to be fiddly to remove cover, how about new inserts ?

Will surely just strip out again? I'm a fan of fixing the design, rather than running into the same issue over and over.

I might try to permanently fit a proper nut into the tube where the inserts went. Not sure how yet.

[BiG DoM]

Airbox threaded inserts

2 out of 4 of mine have stripped out. How did you guys fix them? Just put a bolt all the way through?

Going to be fiddly to remove cover, how about new inserts ?

Will surely just strip out again? I'm a fan of fixing the design, rather than running into the same issue over and over.

I might try to permanently fit a proper nut into the tube where the inserts went. Not sure how yet.

My fix was to remove the entire airbox    But one can do two things - put mini hose clamps on the back that compress the plastic so the insert does not spin or possibly better drill alongside the insert and Q-bond or epoxy them vas. The problem is once they spin you can struggle to get the screws out - some have had success with a power driver on fast reverse 

[Archangel]

My fix was to remove the entire airbox    But one can do two things - put mini hose clamps on the back that compress the plastic so the insert does not spin or possibly better drill alongside the insert and Q-bond or epoxy them vas. The problem is once they spin you can struggle to get the screws out - some have had success with a power driver on fast reverse 

I was wondering about that. Did you fit an aftermarket filter? Pics please!!!

I had something like this in mind...

[sidetrack]

Airbox threaded inserts

2 out of 4 of mine have stripped out. How did you guys fix them? Just put a bolt all the way through?

Going to be fiddly to remove cover, how about new inserts ?

Will surely just strip out again? I'm a fan of fixing the design, rather than running into the same issue over and over.

I might try to permanently fit a proper nut into the tube where the inserts went. Not sure how yet.

It was suggested to tighten screws only slightly with copper grease on the threads. They should have used those half turn d type screws.