BHB's First XR600R + Winter Rebuild - Page 5

rcerrie · 01-30-2011, 09:36 PM

Nice, getting there!!!

artimious7@yahoo.com · 01-31-2011, 12:33 PM

Looking good!!

Brauhausbier · 01-31-2011, 12:51 PM

Quote:

Originally Posted by artimious7@yahoo.com

Looking good!!

Thanks so much for the props!!

Hope this week to get the engine fully cleaned up and get my newly bored cyclinder back from Rb Designs this weds!

Just got my big parts order in from OEMcycle today

Now just gearing up for the case split on Feb 12th.

Should have all those parts early next week.

wibby · 02-01-2011, 08:55 PM

I bought a caliper on CL

Dunno what was all over it but nothing would take it off

Here it is after soaking a day in Berryman's

I ended up using a wire wheel

Brauhausbier · 02-02-2011, 09:02 AM

Thanks for that tip on Berryman's Wibby!

I have this whole next weekend to work on my XR! I will run out and pick up some Berryman's chem dip. I als wanted to soak the carb too in a good Chem Dip. Will do!

Brauhausbier · 02-13-2011, 10:55 AM

Finally an update on the motor progress over the past two weekends. Finally have some forward momentum going

Using wire brushes and 2.5% Phosphoric Acid the case cleaned up nicely

Spent an afternoon cleaning up the case last weekend.

Brauhausbier · 02-13-2011, 11:18 AM

Yesterday with the invaluable help from my friend Luke (this is his ADV screen name too), we split the cases to replace the countershaft. In my short 11 year motorcycling career, this is my first case split

What an experience!

Here we go:

Right Cover Off

Clutch Basket Next

Used an air gun to remove the 27mm nut behind the clutch basket. That worked well.

Removed the kickstarter, oil pump, ignition sensor, etc to strip out the right side components completely.

Next up was the case split. This took some time and a lot of elbow grease. Definitely the most difficult task in the whole process was this center case separation.

Here we go.
I made a case splitter using two 4' lengths of 2x2 an used a chunk of 2x4 to make fulcrum and applied the pressure on opposite sides of the case through the cylinder opening:

The start of some separation

Finally got the case pins separated

The propane torch is coming in handy trying to loosen up the case pins

Success

The crankshaft and transmission look good for a 17 year old XR

The new countershaft

Look how crisp the splines are

The old splines (just for reference)

Brauhausbier · 02-13-2011, 11:49 AM

The transmission is out

Fun times - getting all the old gaskets off - much faster with two working

The side cases are looking cleaned up and ready for reassembly

New countershaft installed and transmission reassembled

Ready to reassemble the cases

Reassemble Right Side Case Components (Clutch Plates all above spec

)

New Ricky Stator

Right case cleaned up and ready for installation

Bottom end is completely finished!

Wow..a 10 hour marathon on the bottom end rebuild but we did it in just one day!

I'm greatly indebted to Luke for his assistance and knowledge

Luke, please enjoy the 4 cases of tasty beer from my employer Widmer Brewing and again a Big Thank You!

cpmodem · 02-14-2011, 12:22 PM

Looks great Eric. I can see the scientist in your method of operation. Looks like PO let the cs sprocket nut get lose.

sector · 02-14-2011, 05:18 PM

Wow! Impressive work!!

Brauhausbier · 02-14-2011, 06:25 PM

Quote:

Originally Posted by sector

Wow! Impressive work!!

Thanks Sector and CP! Hopefully I''ll get the cylinder head together by the end of the month! Got a new sleeve coming for the cylinder and the head is at a fantastic local moto cylinder head shop called Baisley Performance www.baisley.com just down the street from us! These guys have been just fantastic!

New KB valves, new OE valve springs, and new gaskets. Plus, the Baisley guys will bead blast the head and cylinder + polish. I can't say enough about Bailsely..absolutely A+

wibby · 02-14-2011, 06:34 PM

Did not see or or hear you mention bearings and crank seals

Woulda been a good time

mcma111 · 02-14-2011, 06:37 PM

Quote:

Originally Posted by wibby

Did not see or or hear you mention bearings and crank seals

It's not a 2 stroke...

wibby · 02-14-2011, 06:42 PM

Quote:

Originally Posted by mcma111

It's not a 2 stroke...

well duh

still I'd be replacing bearing while I had the chance

cheap insurance

Luke · 02-14-2011, 06:54 PM

Quote:

Originally Posted by wibby

well duh

still I'd be replacing bearing while I had the chance

cheap insurance

Disagree. The XR bearings are big, expensive, and reliable.

01-31-2011, 12:33 PM	#62
artimious7@yahoo.com Artimious7 Joined: Oct 2010 Location: Sonoma, Ca Oddometer: 13	Looking good!! __________________ _______________________________ 08 Honda CRF450r 98 Honda XR600r 97 Honda CR500 Hillclimber w/NOS GSXR 1100 Hillclimber (in 08 Honda 450r trim)

02-01-2011, 08:55 PM	#64
wibby BrotherFromAnotherMother Joined: Mar 2005 Location: Grass Pants Orygun Oddometer: 10,246	I bought a caliper on CL Dunno what was all over it but nothing would take it off Here it is after soaking a day in Berryman's I ended up using a wire wheel __________________ '05 DL650 '92 KDX200

02-02-2011, 09:02 AM	#65
Brauhausbier ^OP Searching for IPA Joined: Aug 2006 Location: SF Bay Area Oddometer: 1,356	Thanks for that tip on Berryman's Wibby! I have this whole next weekend to work on my XR! I will run out and pick up some Berryman's chem dip. I als wanted to soak the carb too in a good Chem Dip. Will do! __________________ 2006 KTM 950 1994 XR600R-Winter Rebuild 2011 Bug Murderers Assault Alaska Plan B Nekkid Fire Dancing

02-13-2011, 10:55 AM	#66
Brauhausbier ^OP Searching for IPA Joined: Aug 2006 Location: SF Bay Area Oddometer: 1,356	Finally an update on the motor progress over the past two weekends. Finally have some forward momentum going Using wire brushes and 2.5% Phosphoric Acid the case cleaned up nicely Spent an afternoon cleaning up the case last weekend. __________________ 2006 KTM 950 1994 XR600R-Winter Rebuild 2011 Bug Murderers Assault Alaska Plan B Nekkid Fire Dancing

02-13-2011, 11:18 AM	#67
Brauhausbier ^OP Searching for IPA Joined: Aug 2006 Location: SF Bay Area Oddometer: 1,356	Yesterday with the invaluable help from my friend Luke (this is his ADV screen name too), we split the cases to replace the countershaft. In my short 11 year motorcycling career, this is my first case split What an experience! Here we go: Right Cover Off Clutch Basket Next Used an air gun to remove the 27mm nut behind the clutch basket. That worked well. Removed the kickstarter, oil pump, ignition sensor, etc to strip out the right side components completely. Next up was the case split. This took some time and a lot of elbow grease. Definitely the most difficult task in the whole process was this center case separation. Here we go. I made a case splitter using two 4' lengths of 2x2 an used a chunk of 2x4 to make fulcrum and applied the pressure on opposite sides of the case through the cylinder opening: The start of some separation Finally got the case pins separated The propane torch is coming in handy trying to loosen up the case pins Success The crankshaft and transmission look good for a 17 year old XR The new countershaft Look how crisp the splines are The old splines (just for reference) __________________ 2006 KTM 950 1994 XR600R-Winter Rebuild 2011 Bug Murderers Assault Alaska Plan B Nekkid Fire Dancing

01-30-2011, 09:36 PM	#61
rcerrie Adventurer Joined: May 2009 Location: Knysna, South Africa Oddometer: 12	Nice, getting there!!!

02-13-2011, 11:49 AM	#68
Brauhausbier ^OP Searching for IPA Joined: Aug 2006 Location: SF Bay Area Oddometer: 1,356	The transmission is out Fun times - getting all the old gaskets off - much faster with two working The side cases are looking cleaned up and ready for reassembly New countershaft installed and transmission reassembled Ready to reassemble the cases Reassemble Right Side Case Components (Clutch Plates all above spec) New Ricky Stator Right case cleaned up and ready for installation Bottom end is completely finished! Wow..a 10 hour marathon on the bottom end rebuild but we did it in just one day! I'm greatly indebted to Luke for his assistance and knowledge Luke, please enjoy the 4 cases of tasty beer from my employer Widmer Brewing and again a Big Thank You! __________________ 2006 KTM 950 1994 XR600R-Winter Rebuild 2011 Bug Murderers Assault Alaska Plan B Nekkid Fire Dancing Brauhausbier screwed with this post 02-13-2011 at 11:56 AM

02-14-2011, 12:22 PM	#69
cpmodem Orange Caveman Joined: Nov 2004 Location: masa yee yah tee 59° 14' 9" N / 135° 26' 42" W Oddometer: 7,098	Looks great Eric. I can see the scientist in your method of operation. Looks like PO let the cs sprocket nut get lose. __________________ -cp DISCLAIMER: All observations made in this post are mine and based solely on my own anecdotal experiences, and may contain large doses of facetiousness. YMMV, of course. You are "on your own", and I take no responsibility if someone tries anything in this post and gets into trouble with the law, damages their person or property, or goes blind. Take everything you read or hear "anywhere" butt especially on the Web with a large dose of salt.

02-14-2011, 05:18 PM	#70
sector Beastly Adventurer Joined: Jun 2006 Location: S Oregon Coast and Kootenays BC Oddometer: 2,824	Wow! Impressive work!! __________________ 09 KTM 105 XC 07 Yamaha XT225 - Std Color 07 BMW F650 GS - Black

02-14-2011, 06:34 PM	#72
wibby BrotherFromAnotherMother Joined: Mar 2005 Location: Grass Pants Orygun Oddometer: 10,246	Did not see or or hear you mention bearings and crank seals Woulda been a good time __________________ '05 DL650 '92 KDX200

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