Grand Prix 125
Main Motorcycle: 2000 TT600
Join Date: Sep 2012
Location: St. Louis, MO
Sounds like a good learning opportunity. While I don't know much specifically about the TT600 engine, it's a pretty simple DOHC 4 cylinder. Breaking down and rebuilding an engine is really pretty straight forward. It really just takes a basic tool set and some stuff that can be rented from an autoparts store like Autozone. It all comes down to putting forward the effort, taking your time, documenting things, taking pictures, organizing and bagging things as they come apart. Like you said, the dry run disassembly can be done with the aerated block. Like most manuals say "assembly is the reverse of disassembly."
If #2 is just needing to be hot-tanked and refreshed, you can pull the reciprocating bits (pistons, rods and crank) and then do a basic rings, bearings and gaskets job to get it back to running order. Have the head checked for any warpage. You'll have to research things like torque specs, ring gap, clearances on the bearings and how much you can take off the head to remain within spec, but it's not rocket science. Seek out some sharp gearheads in the area to find a trustworthy machine shop. You'll have to evaluate the condition of the bore as far as crosshatching and ridge left from ring wear. If the bore is sketchy, then your going to have to look into boring and oversized pistons, if it's even feasible...
I might sound like an expert to some, but I'm far from it. I've only rebuilt one engine so far. Long story short my "project" car sucked a piece of metal into the #1 cylinder ~12 years ago. Prior to that I was a wash/wax, oil, brakes and plugs sort of car guy, IIRC I was around 23yo. Well, I wasn't going to sell the car so I had no option but to learn how to fix the issue. My dad (pretty experienced car guy) helped me a bit, but I was mostly on my own with the internet and some manuals. I don't put a whole lot of miles on it, but besides some piston slap, the engine fired right up after the rebuild and still runs great (even after some abuse at the drag strip). After the fact, I found out that I should have sought out a newer, stouter version of that engine to base my rebuild on. I simply did a re-hone and re-ring, that's partially why it slaps when cold. Chalk it up to being young, poor and inexperienced I guess. Anyways...
The only way to learn is to do. I'm sure I've forgotten some stuff, but like I said, just take your time, document as you go, do plenty of research and don't be intimidated. Doing that rebuild gave me a ton more confidence to do my own work on my cars. Although it didn't work out perfectly, it's probably one of the best learning experiences in my life.
2000 TT600 | Black and Yellow | TOR pipe, K&N, 10166 map and some other stuff.
Last edited by SquarEuro; 11-19-2012 at 04:22 PM.