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Old 01-16-2013, 10:07 PM   #61
crobox OP
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Quote:
Originally Posted by dirtyron View Post
looking good christian. been considering one of these myself.if only they kicked over as easily as an xr650r.
Is this Ron DT?
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Current Bikes: 2002 XR650L, Nighthawk, 1986 Honda XL600R, 1988 Hondasuki KLNX250R, 1988 BMW R100GS (dead)
Previous Bikes: Honda XL250R (2 of them), Honda XL600R, Kawasaki KLR600, BMW K1100LT, BMW R60/6, BMW K75, Husqvarna 430XC
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Old 01-17-2013, 06:44 AM   #62
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yeah, ron here. lets ride!
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Old 01-17-2013, 09:16 AM   #63
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Hey Ron- good to see you on here! No big surprise, really.

Well it'll be a little while before I'm ready to go for a ride. I've sold 3 bikes in the last year, two of which were runners. And this bike is currently the closest thing I've got to a runner... so like I said it will be a little while. But when this bike is done, anyone reading this thread will know it!

See you around
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Previous Bikes: Honda XL250R (2 of them), Honda XL600R, Kawasaki KLR600, BMW K1100LT, BMW R60/6, BMW K75, Husqvarna 430XC
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Old 01-19-2013, 12:37 PM   #64
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When I picked up my head from my buddy who did the valves we talked a bit about "gasket matching" and other ways to reduce turbulence in the intake and exhaust passages.

Here is how the intake passages matched up to the insulating spacer before I did any work:



And after some die grinder and dremel work:



I know it looks like the inside surfaces are all full of grinding marks, but they are from a pretty fine sanding drum and are quite smooth to the touch.

I did similar smoothing work on the exhausts, although I didn't do any diameter enlarging on those the way I did on the intakes.
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Current Bikes: 2002 XR650L, Nighthawk, 1986 Honda XL600R, 1988 Hondasuki KLNX250R, 1988 BMW R100GS (dead)
Previous Bikes: Honda XL250R (2 of them), Honda XL600R, Kawasaki KLR600, BMW K1100LT, BMW R60/6, BMW K75, Husqvarna 430XC
Click HERE for my Cummins 4BT International Scout build thread www.christianristow.com
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Old 01-19-2013, 12:41 PM   #65
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And after re-assembling and bolting down the head and cam, putting the crank at TDC, and pulling the forward side (the "pull" side) of the cam chain taught, I found this:



You can see that the witness marks on the sprocket do not align with the gasket mating surface. I'm pretty sure this means the cam chain is stretched. I posted this pic in the main XL600 thread for feedback, and I'm including it here just for continuity.

-Christian
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Previous Bikes: Honda XL250R (2 of them), Honda XL600R, Kawasaki KLR600, BMW K1100LT, BMW R60/6, BMW K75, Husqvarna 430XC
Click HERE for my Cummins 4BT International Scout build thread www.christianristow.com
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Old 01-19-2013, 12:53 PM   #66
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How about rotating the engine to see if in fact there are the three cam marks.
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Old 01-19-2013, 12:54 PM   #67
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The surface of your intake ports should not be smooth anyway , but you should polish the exhaust ports.
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Old 01-19-2013, 02:11 PM   #68
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I received the 3/4" x .120 wall stainless tubing in the mail yesterday, and made some progress today on the rack / pannier mount system.

Here is what it looks like now:



The larger diameter (3/4") tubing coming out towards the sides of the bike will be one of the main supports for the panniers. This tube is supported pretty directly by the rear-most mount points of the frame (which you can see I beefed up earlier with triangulation in the sub-frame), so most of the weight on the rear rack, and much of the weight of the panniers, will go straight down into these points. There will be two other points of attachment to the bike as well. You can also see the diagonal tubing that I added, which goes from the very rear of the top rack down into this same area just discussed, the mount-points at the rear of the bike frame. I made a provision to run the turn signal wires within these diagonal tubes, which you can see mocked up (the green and orange wires disappearing into the tube). Purpose-specific tabs on the rear rack carry not only the turn signals, but also the rear fender.
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Previous Bikes: Honda XL250R (2 of them), Honda XL600R, Kawasaki KLR600, BMW K1100LT, BMW R60/6, BMW K75, Husqvarna 430XC
Click HERE for my Cummins 4BT International Scout build thread www.christianristow.com
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Old 01-19-2013, 02:15 PM   #69
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Quote:
Originally Posted by mcma111 View Post
How about rotating the engine to see if in fact there are the three cam marks.
Yep, I'm gonna do that is soon as this guy lets me!



Maybe tonight.....
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Previous Bikes: Honda XL250R (2 of them), Honda XL600R, Kawasaki KLR600, BMW K1100LT, BMW R60/6, BMW K75, Husqvarna 430XC
Click HERE for my Cummins 4BT International Scout build thread www.christianristow.com
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Old 01-19-2013, 03:50 PM   #70
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Quote:
Originally Posted by mcma111 View Post
how about rotating the engine to see if in fact there are the three cam marks.

nope. No third mark.
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Previous Bikes: Honda XL250R (2 of them), Honda XL600R, Kawasaki KLR600, BMW K1100LT, BMW R60/6, BMW K75, Husqvarna 430XC
Click HERE for my Cummins 4BT International Scout build thread www.christianristow.com
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Old 01-19-2013, 03:54 PM   #71
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Looks like you will be purchasing a new cam chain.
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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 01-19-2013, 06:44 PM   #72
davek181
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I put a cam chain in mine at 40K, and the marks still didn't line up perfectly. I wasn't too concerned since they rarely line up perfect on any bike or car I have worked on. It ran fine, and was much quieter.
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Old 01-19-2013, 07:55 PM   #73
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Hmmm... conflicting opinions.... what to do? what to do?

I'll take Sunday to think it over.

Seems wise to replace it. But saving money and time is always attractive.

Simply writing that last line makes me think I'll end up replacing it....
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Old 01-19-2013, 08:16 PM   #74
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I'll add my .02.

I rebuilt two XR5 RFVC engines not too long ago. One 83 and one 84. One was running and needed freshening up because it consumed some oil, the other was literally a parts bike with the engine in pieces, along with another 84 parts bike (enough parts to build the second bike).

First, the cam sprocket for these old RFVC only had two marks on them, like yours. I think the extra alignment mark came later.

When putting the top ends back on after the valve replacement, I tried to use the cam chains that I had on hand. All three of the used cam chains showed stretching just like yours.

I decided that I was only going to do the rebuild job one time (famous last words, I know ) so I bought two new chains from XRsOnly.

Both new chains lined up the marks perfectly upon installation.

The bikes do perform well after the rebuilds, which is what I was after.
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Old 01-19-2013, 09:44 PM   #75
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Quote:
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Yep, I'm gonna do that is soon as this guy lets me!



Maybe tonight.....
I reckon a good doctor would be able to do something about those feet!!!
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