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Old 05-09-2013, 04:02 AM   #8041
Royal Club
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Quote:
Originally Posted by voltz View Post
so....my new front caliper arrived today from England and it's not right :(




can anyone shed some light on the differences ? the ad stated it was for 1985
to 97 XR600
the black one is for the 85/86/87 xr's if i'm correct.. it should fit too, but with different pads..
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Old 05-09-2013, 04:26 AM   #8042
mcma111
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Quote:
Originally Posted by Alaskajeff View Post
Don't do what? Please explain.

Try to modify that Kush sprocket.
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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 05-09-2013, 06:05 AM   #8043
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Quote:
Originally Posted by Captain115 View Post
Sooooo I re-read this XR rebuild http://www.advrider.com/forums/showthread.php?t=397357 and got down to the bit where he finds a plug and turns out it's the transmission plug that sits in the end of the countershaft to help oiling...

I had a look, and I don't have this piece and I don't think I can buy it separately? I assume it is pretty important, so where should I go from here? Get one from a used shaft (heyyy Steve...)?

Thanks!



Cool, I'll keep an eye out for a spare set of XR wheels then!

Cheers,

John

I just looked at a spare countershaft. The plug is inside about 1" or so.
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BMW's
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79 R100s
91 R100gs

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 05-09-2013, 09:21 AM   #8044
Zombie_Stomp
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Question XR 600 crank?

Anyone here have an extra xr600 crankshaft they want to sell? That is probably in spec? We have 2 and one of them the new wrist pin from the piston kit definitely rattles around in the con rod when jiggled. The other one has some movement but not as much. I don't think there should be any human detectable movement there, but haven't had a pro with a micrometer check it out. This is for a 1996 xr600 my brother and I are building for him. The second crank, if usable, is from a 1985 xr600, that shouldn't pose any problems, right?
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Old 05-09-2013, 11:50 AM   #8045
Alaskajeff
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Quote:
Originally Posted by mcma111 View Post
Try to modify that Kush sprocket.
That is my plan Steve. Thanks Just wanted to throw out what everyone thought of the other option.
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Old 05-09-2013, 12:08 PM   #8046
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Quote:
Originally Posted by Alaskajeff View Post
That is my plan Steve. Thanks Just wanted to throw out what everyone thought of the other option.
I said DO NOT modify the sprocket
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BMW's
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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 05-09-2013, 12:37 PM   #8047
Alaskajeff
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NEW V2 45 tooth Honda M10 Kush Sprocket to fit XR600 & 650L

I just got this TODAY from KUSH and after much thought and advice I figured it best to NOT modify this already drilled and sized sprocket and get the undrilled version and have it modified to fit my 88 XR600.
Pictures on request, it's still wrapped in bubble wrap! I'll let it go for $100 shipped. Here is the link to the manufacturer.

http://www.kushsprockets.com/sprockets

These are the years it will fit:
91-00 XR600
93-09 XR650L
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Old 05-09-2013, 02:04 PM   #8048
voltz
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incorrect ad

Quote:
Originally Posted by Royal Club View Post
the black one is for the 85/86/87 xr's if i'm correct.. it should fit too, but with different pads..
thanks Royal
to fit it I would need the caliper mount as well,as the slide configuration is different.
I think the ad was incorrect
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voltz screwed with this post 05-09-2013 at 02:12 PM
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Old 05-09-2013, 02:13 PM   #8049
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So my xr600r is weeping oil out the kickstart seal. What all is involved in replacing this?Remove the kickstart lever, remove the case, pop the oil one out, tap in the new one with a socket , throw it back together? Where's the best place I can buy the correct oil seal for my 94 ?
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Old 05-09-2013, 02:29 PM   #8050
mcma111
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Quote:
Originally Posted by T4EaterJonny View Post
So my xr600r is weeping oil out the kickstart seal. What all is involved in replacing this?Remove the kickstart lever, remove the case, pop the oil one out, tap in the new one with a socket , throw it back together? Where's the best place I can buy the correct oil seal for my 94 ?

Pull the kick lever. Stab the seal with an ice pick and pry it out. Either order the Honda seal or go to a bearing house and get
Oil Seal (20 X32 X6) 91202-KJ9-003
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BMW's
58 R26
79 R100s
91 R100gs

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 05-09-2013, 03:39 PM   #8051
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Rear Shock done.

Thanks for the advice on my rear shockie build up lads.. she's finished off and looking SCHMICKO ! I waited until a test ride before posting just in case the thing drop its guts. The new springs front and rear are a h.u.g.e improvement, the front end was a complete mess to ride before the springs went in, I used 7 weight oil. The rear is awesome, really transformed the bike, so much better in the bush now...

.....I put bolts thru the mounts, placed it in a vice on the floor to operate through the stroke, to get the air bubbles to the top...this is also a good way to wreck your back...

I used a spirit level to square the mounts up before bolting it in.
Rode along a dry river as far as I could go during the test ride. You can just see the pig there on the right, only made it about 1 klm before going got too tough.

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Old 05-09-2013, 03:42 PM   #8052
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Oil plug in countershaft

Ok team,

I am definitely missing this oil plug in the end of the countershaft, that I posted about yesterday. Since it looks like it is impossible to source one, and Steve said it is important to have, I am thinking I will just try and find something similar to maintain oil pressure/flow in the countershaft.

But I'm not entirely sure where the plug sits...between the idler gear oil hole and shaft hole? or in front of both of them, completeing blocking the shaft? See my sweet diagram for more info. If any of you have a spare countershaft sitting around, or some good photos when you did a rebuild please post them up (and if you have an old shaft with a spare plug, pm me ).

Cool, good chat.

John

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Old 05-09-2013, 04:56 PM   #8053
mcma111
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I just finished typing a PM and now I see this post. The plug goes where the green mark is. Just inside the end of the shaft. My shaft has 6 stake marks around the hole to retain the plug. It would not go where the blue mark is as it would starve the outer most gear of oil.
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BMW's
58 R26
79 R100s
91 R100gs

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 05-09-2013, 05:31 PM   #8054
ThumpnRed
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Quote:
Originally Posted by Zombie_Stomp View Post
Anyone here have an extra xr600 crankshaft they want to sell? That is probably in spec? We have 2 and one of them the new wrist pin from the piston kit definitely rattles around in the con rod when jiggled. The other one has some movement but not as much. I don't think there should be any human detectable movement there, but haven't had a pro with a micrometer check it out. This is for a 1996 xr600 my brother and I are building for him. The second crank, if usable, is from a 1985 xr600, that shouldn't pose any problems, right?
I have one from an 86 XR600R sitting out in the shop.
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Old 05-09-2013, 07:20 PM   #8055
Captain115
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Quote:
Originally Posted by mcma111 View Post
I just finished typing a PM and now I see this post. The plug goes where the green mark is. Just inside the end of the shaft. My shaft has 6 stake marks around the hole to retain the plug. It would not go where the blue mark is as it would starve the outer most gear of oil.
Ahh sorry about that Steve. I ended up having another 15 minutes before a conference so I whipped up the diagram for fun.

Using your measurements (thanks!) I bought a 10mm diameter welsch plug and ground it down till it was about 4mm high. Bought some Permatex weld stuff (like JB Weld) and plugged it all in, making sure it didn't block the first oil hole.

I would like to say that this has been a success. So if this every happens to anyone else on the net, just get a 10mm plug and stick it in!

Thanks again Steve,

John

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