• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

TE630 engine removal and rebuild

Yea, no biggy about the breather. The gaskets between the head pipes and the head. Couldn't find the old ones either.
 
XlEnduroman, sorry to hear that. I'm a little bummed on mine too but I'm going to give it another chance. Love the bike when it's running. Does everything I need. Very well.
 

Just needs oil, coolant, and the tank. Getting close! Now I can't wait til spring. I do have this to hold me over thankfully.
 
Well hype train just left the station! I don't remember the old 610 having the exhaust gasket, so i think it's one of those 630 "new" parts. In any case, good job and keep us posted!
 
Cranked the engine over tonight. Turned free, no strange noises. Left the fuel disconnected. Wanted to see if it would build oil pressure, then realized it doesn't have an oil pressure light lol. Daughters 4th birthday on Saturday, so I won't get a chance to actually start it until Sunday. Nervous.
 
When I had mine out and torn down I didn't fully fire it up until I was 100% certain that I had good oil circulation (you know- when you put the right side engine cover back on you want to be 100% certain you've aligned the tab of the oil pump w/ the key slot it fits into, in the engine.) So anyway I loosened the upper banjo bolt of the line that supplies the head/cams, then put it in high gear,and then hand turned the wheel many times until I saw oil coming out of that upper connection.

And don't forget- prior to a real start up- to hook it up to iBeat and re-set the TPS. I don't know how crucial that really is, but I wanted to go by the book (and probably wouldn't have cared much about doing so, but I'd given the TB a good cleaning when I had it off so thought it best to go ahead and do so.)
 
Good tip on the oil line trick. I'll pull the plug and do just that. Don't have ibeat, and didn't do anything with the TB other than pull it off the head and put it back on. Hope it's ok
 
Good stuff on the rebuild! Reminds me of when I fully rebuilt my 510 and threw in a 530 BB kit while I was at it. I used to have a SM610 and these 630's look like the 610 bottom end with the 450/510 top end. Never really noticed until I read through this thread
 
Yup, that's how I understand the 630 engine came to be, bottom end of the 610 with the dohc setup off the 150/510.

I have the bike completely assembled, cleaned, filled with oil, coolant, gas in tank, and air in the tires.
Confirmed oil flow to the top end last night by following EricV's suggestion too.

I'm afraid to start it. Or, more accurately, I'm afraid to start it and discover I've f'd something up.
 
Ditto what Thumperama said. I applaud what you've done- I had a mechanic handle the complex stuff so good for you. I gotta admit once I re-fitted the engine and went through all the rest I was apprehensive also, but as Thumperama said you've just gotta take a deep breath and hit the button (and don't be timid...give it a proper crank and expect some smoke, and not perfect running the first few seconds.)

I'll tell you what, though....because I was so apprehensive here's what I did: 1.) I re-reviewed and went over ALL of what I learned to be the have-to-do's, double checks, etc. 2.) although I had a trusted mechanic transfer all of my internals into my needed new engine casing I thought "hmmm, what if something does go wrong...I guess I want a video/audio of this initial start up"- in the event that I had to show him what transpired, either for troubleshooting or for "warranty" work to rectify, 3.) and as it pertains to you, it wouldn't hurt to have the video/audio to bounce off of us if you do hear anything weird.

You've hand turned the engine and have probably quadruple checked everything you can. I think if you had something to worry about you'd have heard it in the turn-overs. Keep us posted!
 
Might get a chance tomorrow night, if not on the weekend for sure. It's not my first engine work, I had the jugs off the Hawk and installed a 700 piston kit and new cams. Didn't split the cases tho. It is however, still running, and quite good at that considering a it's almost 30 years old. Might as well take this opportunity to show it off.
 
What is the idle speed right now? Because it sounds a little bit low. Raise the idle to 1700-ish and it might get quieter.
 
I agree, it's a little low. It was cold out too. I have to reset the idle, and do some tuning with the JD tuner, as judging by the state of the piston top and combustion chamber, I'm fairly confident it's running too rich. The carbon build up in the chamber and piston may have resulted in detonation and contributed to my early rod bearing failure.
 
Sounds like a husky to me. Noisy chatter like head of the 450/510. Hopefully you have a good amount of oil and spark plugs to break it in. Good job on the rebuild!
 
Sounds good to me! 610/630 engine blocks have never been particularly silent, and those noises in the video sound like normal to me. Hell of a job bushwa!
 
Hi bushwa,really exited for you and glad you've got it back together and running.
I started my 07 610 rebuild the same time as you and hadn't checked your thread since Xmas. I got mine back together on the weekend just gone and was extremely worried just like you were. It started, ran a bit rough the first time but adjusted the idle and was fine after that.
I took it for a test ride down my street to make sure it would work under load. Nice and easy 1st then 2nd all good, then 3rd and all of a sudden locked rear wheel and stalled engine. On trying to restart the starter motor was only making a clunk sound. After a sleepless night I took the bike to a mate we popped the left cover off and couldn't turn the fly wheel. Then popped the clutch cover off and we'll let me just say DOH.image.jpeg image.jpeg
I forgot to bend the lock washer on the right hand crank nut and it unwound and jammed against the back of the oil pump. I haven't undone the nut yet as its jammed on the thread and we didn't have an inch and a half rattle gun socket. So I've parked the bike for the moment so I can get my DR ready for a trip to speed week. I'll get onto it next month.
I hope your first test run goes well and I haven't scared you too much. If your worried check your photos you took before you put your covers on. Cheers PHIL
 
I'm sorry for you, Philmeup.
At least, since you've shared your experience, it will be useful to us.
Anyhow, the socket required, at least here in Italy, is a 38 mm; I guess it's the same in the US. A 1.5 in should fit decently, too, I think.
Does the crankshaft spin free now that you've removed the cover?
 
Oh damn. That sucks. Now, I didn't take pictures befor I got the covers on. Or at least I don't think I did. Think I may pull the covers to check. I may have forgot the washer on the drain plug as well.
 
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