Hey all. New guy here. I did a search for this and didn't come up with much, so bear with me and/or point me in the right direction if this has been covered elsewhere and I'm being n00b-ish. I'm looking for maintenance advice and a good source for local and/or mail order parts. I'm a trained mechanic, former independent shop owner and ex-Ducati/Triumph/KTM/Aprilia dealer service manager (NYC/LA/SF bay area) so I'm doing this work myself. As the title suggests, I have a SM610 I bought used from a member here, back when I lived in NorCal. I'm now in Philly. The bike just hit 7500 miles and the service reminder came on. The 12,000 kilometers is between the 10k and 15k kilometer services indicated in the Factory Service Manual ("coupon C" and "coupon D"). I don't have service records handy and I've done nothing to the bike since I bought it used, so I'd rather err on the side of safety this time. The bike runs fine except for being hard to find neutral with the engine running at idle, which seems to be common to this model. It also seems to be a bit down on power compared to other competitive bikes - haven't had a chance to dyno it yet. It does have a Leo Vince pipe and (allegedly) some efi programming. According to the FSM, the 12k kilometer service is the bigger one, and includes: replace engine oil and filter replace spark plug replace air filter replace brake fluid replace coolant replace drive chain and rear sprocket replace fork oil and overhaul (!!!) check cam chain clean engine oil suction filter clean fuel filter check/adjust valve clearance and the usual host of "check the entire bike from front to back", it seems So, yeah, some of that seems silly. I'm planning on replacing the engine oil and filter, replacing the coolant, looking at the air filter and replacing it if necessary, ditto with the spark plug and cam chain, adjusting the valves, and cleaning the oil suction filter and fuel filter. Any words of wisdom about parts I should replace while I'm in there? Are there any aftermarket parts that are better/longer lasting than OEM? I assume drain plug gaskets. Is the valve cover gasket (or any of the other ones) reuseable? Am I going to need special tools to do any of this, and if so where can I buy, rent or borrow them? Anything going to trip up a first time Husky mechanic? Thanks in advance! - S.
The only gaskets I have always reused are the two crankcase gaskets. If you want to replace the cam chain, you'll need a flywheel puller (35 mm x 1.5 mm if I remember well) and you should check the two chain sliders and this reed valve: At 13.5 k km I checked the piston rings-cylinder clearances and the rings sizes were the same of the new ones! No need to change them. If you want to descale the piston: remember that the head gasket isn't cheap: here in Italy it costs 42 €, and if you remove the head, you'll have to replace the gasket under the cyilinder, too (but it's much cheaper). Here are a pair of tips: Your engine is at TDC when the two dots on the cranksahaft gear and on the counter-shaft gear are aligned (if you remove those gears, align the dots when reassembling): In this photo, I was pulling the piston rod towards the top, so the engine was at TDC. You can also notice that my crankshaft was damaged, in fact later I got it welded: Why did it happen? Because I didn't aligned the crank with the oil pump shaft, which is here, in the right crankcase: http://imageshack.us/f/819/pompealobi.jpg/ So, don't do the same mistake. I suggest that you get a workshop manual to know all the things you have to check and the wear limits of the parts.
