1984 XL600R Build

[brucifer]

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.
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.

[mcma111]

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]

Originally Posted by mcma111

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.

[BIG ED XT FAN]

Originally Posted by brucifer

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

[brucifer]

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.

[Ghost_Mutant]

Originally Posted by brucifer

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.

[brucifer]

Originally Posted by Ghost_Mutant

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.

[brucifer]

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.

[Ghost_Mutant]

Originally Posted by brucifer

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

[Ivanych]

Originally Posted by brucifer

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.

[Ivanych]

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!!!!

[Carter Pewterschmidt]

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.

[brucifer]

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.

[henrymartin]

That's quite the motor!

I'll follow this for a while too. Damn, visiting this site just keeps getting more and more expensive.

I love (and hate) frame up resto work. Seems that every one of mine lately has been stripped down to frame (the last 4 anyway).

If I can ask about how much was the powder on the frame...people here charge crazy money for that.

[brucifer]

Hey Henry! Good to see ya here.

It was $150.00 for the frame and the two upper motor mount plates.