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Old 02-04-2012, 06:56 AM   #1
brucifer OP
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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.






The shock I'm hoping to use is from a 1988 XR600 that I purchased from an inmate.
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2014 Kawasaki KLR650 NE-2008 Yamaha TTR110-1996 XR600R-1993 Kawasaki KX500-1984 Honda XL600R/XR650L Hybrid-1984 Yamaha TT600L-1977 Yamaha TT500-1980 Honda CB750F

brucifer screwed with this post 03-06-2014 at 07:09 AM
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Old 02-04-2012, 07:06 AM   #2
mcma111
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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.
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87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 02-04-2012, 07:25 AM   #3
brucifer OP
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Originally Posted by mcma111 View Post
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.
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Old 02-04-2012, 07:52 AM   #4
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Originally Posted by brucifer View Post
G'morning Steve! I have an idea for the master res. Tank was clean.
Hi, Bruce, Nice build. I like them xr 500/600 too. Scott Summers always made them xrs look good.
Half your garage is honda , and your 2nd is Yamaha how do you know what to take on a ride?
Thump-On!!! ED
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Old 09-13-2014, 12:03 AM   #5
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My XL 600 R lost compression so I took it apart a few years ago. Couldn't figure out what to do so I took advantage of an 81 XR 500 I picked up for $200, Someone had taken the cam cover off and couldn't get it back together. That was easy, but the front brake was a joke so I put the front forks from the 600 that I already modified with hydraulics, on the 500. I have to say I love the simplicity of the 500, but the Head Light is a joke. Ricky Stator wasn't much help and hasn't returned my inquiry. Any way, I've been hankering to put the 600 back together so I am anxious to learn whatever I can https://www.facebook.com/video.php?v...ype=3&theatern.https://www.facebook.com/video.php?v...type=3&theater

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Old 10-22-2014, 05:44 AM   #6
brucifer OP
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I'm getting back on this thing with a renewed interest. I can't believe it's been nearly 7 years since I started this cluster!!!! lol.

Okay, so I've decided to go all XR650L on the engine. That will for sure cure the starting issue. I have the stock head that came with the bottom end that I'm using but had to purchase a cylinder as I used the original cylinder for another build. The original rocker cover was broken so I purchased one of those a well. I have two cams to choose from--an HRC 628 copy or a Megacycle 148X9--both of which still have the auto-decomp attatched. So, with the starting issue dealt with, I'm much more excited to get this thing moving forward.

To you guys who have been with me from the start--if there are any of you left --I apologize for dragging this thing out for so long and I WILL finish this project.
Although I have a few other bikes I'm working on as well, this one will take priority.

Since everyone likes pics, here's one of the head and the other ebay parts and two of my three helpers. Proof I'm actually doing SOMETHING. Hopefully I'll have more productive photos soon.

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Old 02-04-2012, 07:22 AM   #7
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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.




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.
The frame came out awesome. More pics later.
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Old 02-05-2012, 09:18 AM   #8
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Quote:
Originally Posted by brucifer View Post
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. Its what I would be doing if I owned one

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

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.
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Old 02-05-2012, 11:10 AM   #9
brucifer OP
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I like what you're doing with the old XL6 Bruce. Its what I would be doing if I owned one

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

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.
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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Old 02-05-2012, 11:35 AM   #10
brucifer OP
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Couple inside shots of the frame.




Here we have the makings of what eventually will power the bike. From left to right: The hot rod engine that was in the bike before the strip down. It's an XR650L bottom end with a 675cc big bore kit in an XL600 cylinder topped off with an XR500 head w/Kibblewhite valves and Megacycle cam #148x9 w/hardwelded rockers and performance valve springs.
Next to it is a '97 XR600, and on the far end is the original lower end from the bike.
I want to use the original cases to keep the numbers matching but I haven't decided what combination I want to stuff IN the cases.

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Old 02-06-2012, 05:29 PM   #11
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Originally Posted by brucifer View Post
From left to right: The hot rod engine that was in the bike before the strip down. It's an XR650L bottom end with a 675cc big bore kit in an XL600 cylinder topped off with an XR500 head w/Kibblewhite valves and Megacycle cam #148x9 w/hardwelded rockers and performance valve springs.
Next to it is a '97 XR600, and on the far end is the original lower end from the bike.
I want to use the original cases to keep the numbers matching but I haven't decided what combination I want to stuff IN the cases.

Quite the hodgepodge of RFVC components there

Any problems running that XR5 head? Did you use the old style cam chain with the XRL bottom end? Valve cover from the XL6?

Did you do anything to seal up the oil chamber so it doesn't leak out around the cam bearing where the valve cover meets the XR5 head?

How well did the combo work?

Details please
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Old 05-18-2012, 01:22 AM   #12
Ivanych
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Originally Posted by brucifer View Post
Couple inside shots of the frame.




Hi Mr. Brucifer!
What color (RAL number) has the paint for painting the frame of your bike?
It is OEM HONDA color?
I have to paint the frame in the near future and I can't choose a color: black or red.
Thank you.
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Old 02-05-2012, 01:27 PM   #13
Ivanych
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HI Brucifer!!!!
You started a great topic and great work!!!!!!
Show more photos, details, tricks.
I'm going to go on the your traces (I will be like the fox) in the construction of my XR500R.
Interesting any more details!!!!
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Old 02-05-2012, 01:35 PM   #14
Carter Pewterschmidt
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Powder coating the frame is the way to go. I painted mine with epoxy spray paint and it was a pita to get an even coat.
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Old 02-05-2012, 04:04 PM   #15
brucifer OP
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Thanks for following along guys and I really appreciate the kind words.

Ivan- I hope I can live up to your expectations! I'll share whatever tips etc. I can here---if there is any.
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