BHB's First XR600R + Winter Rebuild

[Brauhausbier]

Originally Posted by mcma111

Boy, that's about $60.00 to $135.00 more than the guy near me charges for an XR frame and bits. Side stand, peg mount, etc.

Thanks Steve. I'll keep hunting around. I'm still getting a frame of reference on powdercoating Cheers!

[WB-PDX]

Originally Posted by Garthe

Isn't that a lot ($ 1,500) to spend on a XR 600 R that looks like that and you have to tear it apart and rebuild it from the ground up.

The bike came with $500 (used parts value) worth of uninstalled 'extras', a plate with brand new tags, and a BD kit with all the fixings - It was a good value in any location.

I know the bike *looks* stock in the pictures, but the list of parts\mods the bike had when sold is massive.

There's also no reason anyone 'had' to tear that bike apart.

[Brauhausbier]

Originally Posted by WB-PDX

The bike came with $500 (used parts value) worth of uninstalled 'extras', a plate with brand new tags, and a BD kit with all the fixings - It was a good value in any location.

I know the bike *looks* stock in the pictures, but the list of parts\mods the bike had when sold is massive.

There's also no reason anyone 'had' to tear that bike apart.

I still feel good about the deal. I'm not complaining. I was looking for a cheap XR that I could rebuild. I must be going through that mid-life crisis that I was hearing about...adding more projects into one's life must be a sign.

You have to admit wade, that bike had not been cleaned in years

[WB-PDX]

Originally Posted by Brauhausbier

You have to admit wade, that bike had not been cleaned in years

I hosed it off, sprayed it with cleaner, then hosed it again, and wiped it down after every ride.

[Brauhausbier]

Originally Posted by WB-PDX

I hosed it off, sprayed it with cleaner, then hosed it again, and wiped it down after every ride.

no worries..every part will get shiny once again

[Dino3310]

Originally Posted by WB-PDX

The bike came with $500 (used parts value) worth of uninstalled 'extras', a plate with brand new tags, and a BD kit with all the fixings - It was a good value in any location.

I know the bike *looks* stock in the pictures, but the list of parts\mods the bike had when sold is massive.

There's also no reason anyone 'had' to tear that bike apart.

i thought it was a good deal for the buyer, you would pay a shit load more over here for one so 1500us would be a steal for me

[mcma111]

Originally Posted by WB-PDX

I hosed it off, sprayed it with cleaner, then hosed it again, and wiped it down after every ride.

Ya get better results if you give it a little hand work. You know, a brush or a sponge. Works wonders on that sticky mud. Eh?

[Ladybug0048]

Super ! ! ! Another thread to follow during these cold winter months. I enjoy seeing what you guys are up to even though I'm doing good to know the difference between a screw driver and a hammer. Maybe if I follow enough of these I will absorb something.

Subscribed.

[Zombie_Stomp]

If "more projects" means one is having a mid life crisis, my mid life crisis is the most project-loaded one in history!
See post #88:
http://advrider.com/forums/showthrea...=464630&page=6

[Brauhausbier]

High freezing levels on Mt Hood = no snowboarding this weekend (rain at 10K feet).

But another free day for the XR rebuild project. This is keeping me busy in mid winter

Had the grateful help of our resident PDX airline pilot FlyJosh yesterday to help me finish stripping down the XR to the frame and get the top end off the motor

Rear Swing Arm Removal




This XR is grimy, oily, and just plain caked with layers of grease and road grime

However...not one bolt was over torqued or rusted together I was amazed.

[Brauhausbier]

Next up Headers - extra crispy





Steering Head - the breaking bar I picked up recently for doing a valve adjustment on my KTM950 is really coming in handy today Picked up a 30mm socket last night just for this job. Glad I did



Stem Bearings and races look damn good!


Question for those XR folks out there...I'm concerned by the play of the front sprocket on the spline. There is some forward and rear play of the sprocket on the spline. Not sure if this is typical, or if the sprocket is worn, or the spline is worn? Here are a couple of pics to show the play:

[Brauhausbier]

Now on to the motor - first up valve cover removal


Check out how bright and shiny the inside of the motor is

Cam Chain Tensioner

Hot Cam looks in very good shape

Cam Journals look good

Removing head

Head is off!

Piston looks original and is a 97mm (a bit worn at 96.7mm)

Valves appear to be in good shape

[Brauhausbier]

Needed to make a tool run to Harbor Freight to remove the cylinder base..I did not have any rubber mallets. Brought back a one and a two pound rubber mallet for this job (and some fresh JB weld-FlyJosh took a hammer to the fins on the cylinder while I wasn't looking and snapped off a corner. I'm going to see if I can JB weld that corner back on at some point).

Success! The two pound mallet did the trick! Found the tip on TT! Hit from underneath in an upwards motion. One good blow and that did the trick! (see the missing fin corner from Flyjosh's hammer)


Sleeve looks amazing just like the rest of the internals


Ughhhhh.....got the motor off the frame

For the final push for tonight my wife Debbie joined me in cleaning up the frame. I hope to get the frame and a few parts into the paint shop this week


Looking ready for the paint shop



This week - get frame and parts to a paint shop (prep and powdercoat), order new 100mm JE Piston and sleeve, make an appointment at RB Designs www.rb-designs.com for a re-sleve and valve job, and hopefully pick up the suspension from Promotion Suspension this week www.promotionsuspension.com. This should keep me busy.. Cheers!

[MortimerSickle]

Originally Posted by Brauhausbier

...
Question for those XR folks out there...I'm concerned by the play of the front sprocket on the spline. There is some forward and rear play of the sprocket on the spline. Not sure if this is typical, or if the sprocket is worn, or the spline is worn? Here are a couple of pics to show the play:

Some (not much) play is normal, but if you have a too-hard aftermarket sprocket you could end up with this:



If your splines are straight you're good, but I recommend running only OEM front sprockets.

I have be running aftermarket fronts on my XL500 since 1979 with no ill effects, but as you can see in the pic, my XR600 was not so lucky.

I will buy no more aftermarket front sprockets.



Edit: I see you have the finer spline. I don't know whether play of any amount is normal on that model, but still, any damage should plainly show. And, I would still use only OEM sprockets.

[flyjosh]

That engine was beautiful.

And that chipped fin gives it some street cred