Engine overhaul
 

The oil consumption of my Tenere becomes annoyingly high (1L/1500km after 105.000km). So I am looking into the possibilities of replacement parts.

I expect that I have to replace the piston, rings and valve stem seals, top and bottom gasket. Yamaha parts cost like 350 euro.

Does anybody have experience with replacing these (maybe on a XT660X or R). Do I need to hone the cylinder before putting in a new

Also looking into the bigger bore of Off-The-Road, 700cc sounds nice , experience somebody? Parts cost approx. the same as Yamaha's but bored out cylinder is an extra 289 euro.

I would say you would need a rebore at that mileage.

Get your cylinder bored to a 102mm, then use a CP 11.5:1 piston for a Raptor 700.

http://www.ebay.com/itm/Raptor-700-102mm-11-5-1-CP-TECH-piston-Kit-PUMP-GAS-/110709467696?pt=Motors_ATV_Parts_Accessories&vxp=m tr&hash=item19c6cc6a30

Or with gaskets.

http://www.ebay.com/itm/Raptor-700-102mm-11-5-1-CP-TECH-piston-Kit-Gaskets-/110709467661?pt=Motors_ATV_Parts_Accessories&vxp=m tr&hash=item19c6cc6a0d

Thanx, that looks very good.

If you use the Raptor 700 piston use the Raptor head gasket & the XT660 base gasket.

You can get cheaper pistons, but I would only use a CP piston as it has a longest piston skirt & will last linger than the Wisco & JE pistons.

The anwer to my question I did not asked yet :)

About the cylinder, can a normal rebuilding company bore it up. Or should it be something special because of the Nicasil?

That doesn't sound that bad at 100k... looking for some details on oil consumption for Tenere I found some reports of roughly new Tens with over 500ml / day during RTW or 1l/1000km... mine seems to eat some oil too under heavier riding but inside the engine everything seems normal and in manual specs/tolerances - just had it opened and split to pieces at 27k due to gearbox issues.

I am using it for commuting, 170km a day. Right now I have to fill up every week which is starting to annoy me. For the rest no problems and it runs like it is virgin.

The bore will need to be bored to 102mm & replated with Nicasil

Finally did the repairs. After 130.000km the piston-cilinder play was still within its limits. Replaced the piston rings and valve seals.
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Blocked the secundair air system
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It is running like new. Curious to see what the oil consumption became. This weekend new oil and filter and then up to 200.000km.