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SlickSix 06-01-2012 03:51 PM

XR600- Donkey Fix Up & Full Rebuild
Hey guys, Iīve been a Iong time lurker around the site but never took the time to sign up, didnīt think I could contribute that much.
This just changed :D so letīs see if Iīm worthy...

I ride the streets but was always looking out to see if the opportunity presented itself and I could bring home my first love - the XR600.

Since I was around 13 and a few of my friends older brothers started showing up with that mean, bada**** XRs, Huskys and Husas, I wanted one.
That growl coming up the street...was my wet dream at the time.
Got older and somehow the bike elluded me. Rode some CRM125, DTR125, Bandit400, CBR F3 and now the F4i Sport.

Well, last week it finally happened, I just picked up my donkey :clap


Ok, just thought I would update this first post to give you an ideia of what to expect of this rebuild and include the parts list and mods.

**Parts List**

Countershaft - 100
Sprocket & Chain kit - 90
Tires - 100
Gear Shifter - 15
Gasket kit - 45
Spark Plug - 3
Exhaust - 50
Carb Hoses - 3
Dust/Oil Seals - 20
All Bearings - 50
Caliper Seals - 10
Pads - 15
Front Rotor - 40
SS Brake Lines - 40
Brake Switch - 5
Nipples - 5
Levers - 10
M22 x 1.5 - 7

**Mods / Extras**

Strip & Paint - Free
Lightened Flywheel - Free
Rewoud Stator - Free
CRF450 Plastic Kit - 65
Handguards - 15
628cc Kit - 200
Suspension Valve & Spring - 120
Oil cooler - 25

Guess thatīs about it. If any more comes up, Iīll update again

SlickSix 06-01-2012 03:58 PM

Got her really cheap (for Portugal at least) and she runs good. No knocks, no smoke and easy starter.

Thatīs not good enough for me :evil
I take pride in my toys so the plan is to do a full tear down and rebuild. She wonīt be my main transport and Iīve got the time to mess with her.

Ok, I know that some of you might be thinking that itīs just another rebuild. Youīre right. But itīs my rebuild :freaky

SlickSix 06-01-2012 04:06 PM

Already have her down to the bone, but since Iīve enjoyed watching and following other members threads, I think itīs only fair to share my own, right?

Just want to apologize for the initial lack of disassembly photos but my camera card acted up and lost most of them.

Took her home and started immediately to crack nuts and bolts

Anyway, the disassembly is pretty much straightforward and like all others.
I was pretty satisfied, all the zerk fittings were greased and everything went smooth with no stripped nor broken bolts.

SlickSix 06-01-2012 04:13 PM

At first sight she might look ok, but no. Sheīs a crude,slimey ugly mess.

This will be fun

SlickSix 06-01-2012 04:21 PM

This doesnīt look good...

But I already knew that.

What I didnīt expect was to see the calipers in this state. I truly think I shouldīt rode her home when I picked her up :eek1

Iīve spent the better part of an hour to completely remove the pistons from both calipers. They were as nasty as... I donīt know, never seen calipers like this ones!!

Grover6 06-01-2012 04:23 PM

Nice! Keep' em coming:clap

mcma111 06-01-2012 04:25 PM

I'm in. I have a spare front XR caliper for you. PM me your name and address and I'll sent it to you. Hopefully the postage won't be an arm and a leg.

SlickSix 06-01-2012 04:30 PM


Originally Posted by mcma111 (Post 18817263)
I'm in. I have a spare front XR caliper for you. PM me your name and address and I'll sent it to you. Hopefully the postage won't be an arm and a leg.

Thanks mcma111!

I knew the people around here help each other out but that was fast. Really appreciate it man, parts around here are though
to source. I resort to the Uk and States.

Actually, Iīll pm you in a few.

SlickSix 06-01-2012 05:05 PM

Ok, letīs get this thing rolling.

One of the reasons that this bike was so cheap... the coutershaft.

Itīs welded so, it has got to go.

Notice the shifter, itīs welded too.

elsalvadorklr 06-01-2012 05:07 PM

well there goes the good buy!

welcome to the forums, and have fun!

SlickSix 06-01-2012 05:13 PM

First good news of the day, all rockers, sub rockers and cam look in tip top condition.

All journals are smooth and in spec and the center of the valve cover where the cam sits, is good too.

Pretty clean also.
I think someone was here before. Donīt know if you can see but the bolt that hold the tensioner
is almost rounded....

SlickSix 06-01-2012 05:18 PM

Stem seals shot and a bit on the rich side for sure. These valves are going to be a pain to clean.

Letīs see if they seal after cleaning and lapping them...

SlickSix 06-01-2012 05:26 PM


I bought her knowing about the countershaft and thatīs why I got her for cheap.

The guy selling her was asking double of what I offered. Called me nuts!
I told him that if that the shaft was in good condition, I would put the full asking price in his hand but if not,
I would bring her for half. He said ok so I asked for an allen key and removed the aluminium sprocket cover that completely covered the zone.

Voila! CHeap XR600

elsalvadorklr 06-01-2012 05:39 PM

youre a smart and lucky man!

whats that a possible buyer touching my bike? that doesnt fly down here! jajaja

awesome deal

hey thos valves lool ok

just clean them up with some solvent

new seals and good to go

it all depends on what and how much you want to spend

once again good luck


SlickSix 06-01-2012 05:41 PM

Gotta go guys, tomorrow Iīll update on the cleaning part and give you a parts list and expected price for the whole shebang.

Already have most of the needed stuff but not everything.

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