That frame repair looks great. Did you notice a cracked rear engine mount? I have three XR500 frames and interestingly enough all three had a cracked rear engine mount/tab in the same spot. I also had some small cracks were the seat and air filter box cross members meet the frame rails. I think the stress of getting too much air combined with the sharp angles caused the cracks. Newer XR frames look to have curved ends on those cross members which probably handles the stress better.
Originally Posted by JimRidesThis
Any hints on removing the cam chain tensioner?
I recall you just pull the pin on top that keeps the tensioner shaft from moving to the right, and then just grab the tab and pull it out while giving it a twisting motion. Once the shaft is out then tensioner can be removed from the top.
There is a pdf manual recently linked on The XL600 thread if you don't have one.