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-   -   1984 XL600R Build (http://www.advrider.com/forums/showthread.php?t=761778)

brucifer 02-04-2012 05:56 AM

1984 XL600R Build
 
Okay, I'm going to document, as well as I can, the restore/modification of my '84 XL600. It will be a long, drawn out process I'm sure as I don't get to work on it as much as should and, as always, money is tight.
I plan to add a little newer suspension and brakes as well as engine impovements all the while keeping it looking like an '84 XL600.
Some of you may know this bike from my thread over on TT but if you don't and would like to see where I started on this bike, go over to TT and click on the XR600/650 forum and search out XL600R/XR650L Hybrid thread. http://www.thumpertalk.com/topic/503...brid/page-1?hl
Alright, we'll pick up where I am now.

I stripped the bike down to the frame and did a few mods. First I test fit an XR650L swingarm and it was a virtual bolt-on deal. Then, eyeballed the position for the rear brake pedal pivot and master cylinder bracket and tack welded them in place. I then took the frame to work and had my boss' son weld them up for me. I ended up doing the pivot twice because I wasn't happy where I had positioned it the first time.
A few pics.

http://i122.photobucket.com/albums/o...rakeFab002.jpg
http://i122.photobucket.com/albums/o...rakeFab001.jpg
http://i122.photobucket.com/albums/o...thesky/027.jpg
http://i122.photobucket.com/albums/o...thesky/024.jpg

The shock I'm hoping to use is from a 1988 XR600 that I purchased from an inmate.

mcma111 02-04-2012 06:06 AM

Tab
 
Bruce,

Don't forget to install the rear brake master cylinder reservoir mounting bracket.

And if your going to powder coat the frame wash out the oil tank first.

brucifer 02-04-2012 06:22 AM

For the front end, I was going to keep the XR650L assembly I had installed earlier but then I found a complete minus the wheel '93 CR500 fork assembly on ebay and decided to go that route.
After I bought it I was told that the '93 stuff wasn't really that great of a setup. Oh well. It's what I have and will work fine for now. I can always change it out later if I'm not happy with the results.
To install it on the XL, I had to swap the stem for one from an '84 CR500. I just happened to have a triple assembly for an '84 CR5 lying around and the stem happened to be what was needed. Just had to machine a bushing for the lower clamp to stem interface.
Pics.

http://i122.photobucket.com/albums/o...thesky/028.jpg
http://i122.photobucket.com/albums/o...thesky/026.jpg

After the test fitting, the frame and top motor mounts were taken to the powder coater. I also rattle canned the triple clamp assembly. Strangely enough, they came out nice. :lol3
The frame came out awesome. More pics later.

brucifer 02-04-2012 06:25 AM

Quote:

Originally Posted by mcma111 (Post 17907567)
Bruce,

Don't forget to install the rear brake master cylinder reservoir mounting bracket.

And if your going to powder coat the frame wash out the oil tank first.

G'morning Steve! I have an idea for the master res. Tank was clean. :D

mcma111 02-04-2012 06:44 AM

Hope you clean the oil tank before putting oil in it. Take a look at my Phoenix build and you'll see what I had to tend with. That blast media is nasty stuff.

BIG ED XT FAN 02-04-2012 06:52 AM

Quote:

Originally Posted by brucifer (Post 17907643)
G'morning Steve! I have an idea for the master res. Tank was clean. :D

Hi, Bruce, Nice build. I like them xr 500/600 too. Scott Summers always made them xrs look good. :lol3
Half your garage is honda , and your 2nd is Yamaha how do you know what to take on a ride?:lol3
Thump-On!!! ED:rofl:clap:clap:clap:freaky

techforlife 02-04-2012 06:56 AM

Hey Bruce......looks like a great build.....

:lurk


B

brucifer 02-04-2012 07:36 AM

Quote:

Originally Posted by mcma111 (Post 17907730)
Hope you clean the oil tank before putting oil in it. Take a look at my Phoenix build and you'll see what I had to tend with. That blast media is nasty stuff.

Yeah, I plan to flush, flush and more flush before anything.

Quote:

Originally Posted by BIG ED XT FAN (Post 17907763)
Hi, Bruce, Nice build. I like them xr 500/600 too. Scott Summers always made them xrs look good. :lol3
Half your garage is honda , and your 2nd is Yamaha how do you know what to take on a ride?:lol3
Thump-On!!! ED:rofl:clap:clap:clap:freaky

Hi Ed! Well, I am partial to me old Honda and Yamahas but I pretty much like everything.

Quote:

Originally Posted by techforlife (Post 17907785)
Hey Bruce......looks like a great build.....

:lurk


B

Hi Brian! :wave Thanks, we'll see. lol.

brucifer 02-04-2012 02:38 PM

More pics.

http://i122.photobucket.com/albums/o...dtriple001.jpg
http://i122.photobucket.com/albums/o...dtriple002.jpg
http://i122.photobucket.com/albums/o...dtriple003.jpg
http://i122.photobucket.com/albums/o...dtriple004.jpg

The company who did the powder coat work on the frame is Pacific Powder Coating in Arcata Ca. They do great work and are very reasonable. Nice people as well.
The pictures don't do it justice. It looks orange here but it's red. I'll try some inside shots later.

jgrady1982 02-04-2012 04:35 PM

Cool! Finally another XL6R build! :clap

kubiak 02-04-2012 05:46 PM

wow!

zen rider 02-04-2012 05:56 PM

Beautiful work. Nothing like a frame up restoration. The frame, triples, and CR500 USD forks all look awesome. The XR600 shock was also a good find. This will end up being better suspended and lighter than a new XR650L and still be air cooled. Very cool.

Keep it light.

I hope you use a lithium battery and other light bits ... this bike deserves it!!

Billtr96sn 02-05-2012 04:56 AM

I'm gonna be. watching this one

Ghost_Mutant 02-05-2012 08:18 AM

Quote:

Originally Posted by brucifer (Post 17907629)
For the front end, I was going to keep the XR650L assembly I had installed earlier but then I found a complete minus the wheel '93 CR500 fork assembly on ebay and decided to go that route.
After I bought it I was told that the '93 stuff wasn't really that great of a setup. Oh well. It's what I have and will work fine for now. I can always change it out later if I'm not happy with the results.


I like what you're doing with the old XL6 Bruce.:thumb Its what I would be doing if I owned one:D

Can you elaborate further on the CR500 KYB forks? Why is it not that great of a setup? Adjustment issues? Don't tell me the average rider can tell that these forks are 1 mm smaller in diameter compared to the latest USD:rofl

Didn't you get to reuse the XL wheel with the CR5 forks? Or is it the XRL wheel you will be using?

Yes, I've seen mentioned in various discussions on USD fork setups about the sub par performance of the CR5 USD forks, but nothing with the specifics in a nice list/summary. If anyone has a good link to such information, feel free to post it, I'll read it.:ear

brucifer 02-05-2012 10:10 AM

Quote:

Originally Posted by Ghost_Mutant (Post 17914606)
I like what you're doing with the old XL6 Bruce.:thumb Its what I would be doing if I owned one:D

Can you elaborate further on the CR500 KYB forks? Why is it not that great of a setup? Adjustment issues? Don't tell me the average rider can tell that these forks are 1 mm smaller in diameter compared to the latest USD:rofl

Didn't you get to reuse the XL wheel with the CR5 forks? Or is it the XRL wheel you will be using?

Yes, I've seen mentioned in various discussions on USD fork setups about the sub par performance of the CR5 USD forks, but nothing with the specifics in a nice list/summary. If anyone has a good link to such information, feel free to post it, I'll read it.:ear

Hey GM, good to see ya!

I really don't know why they say that about the forks. Maybe adjustment issues? I didn't see any adjustment on the top caps. Could be some on the bottom; I haven't actually looked there yet.

Not sure which wheels I'll be using yet. I was thinking of using a CR5 hub and lacing a new rim and spokes to it. Whichever wheels I use will have new spokes and rims.


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