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Old 05-09-2013, 08:35 PM   #8056
joexr
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I think you should solder a plug in there instead of glueing. Are you willing to risk damage and another teardown?
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Old 05-10-2013, 02:08 AM   #8057
voltz
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Quote:
Originally Posted by voltz View Post
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
So, I can purchase a new caliper from local shop for $200.
Will be sending the new one back

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Old 05-11-2013, 02:52 AM   #8058
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Quote:
Originally Posted by voltz View Post
So, I can purchase a new caliper from local shop for $200.
Will be sending the new one back

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why pay 200 for a new one when you can get a used CRF caliper for 50 or so probably.
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Old 05-11-2013, 03:24 AM   #8059
voltz
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Quote:
Originally Posted by Royal Club View Post
why pay 200 for a new one when you can get a used CRF caliper for 50 or so probably.
with a used one I don't know what I'm getting,is the crf caliper the same ?
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Old 05-11-2013, 03:33 AM   #8060
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Quote:
Originally Posted by voltz View Post
with a used one I don't know what I'm getting,is the crf caliper the same ?
I have a 2003 (or 4) crf450 caliper. Pads are the same (one pin to hold them) mounting distance bolt/bolt is 102mm's

edit: what you are getting is not 26years of screwing around in a caliper.
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Old 05-11-2013, 03:58 AM   #8061
voltz
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Quote:
Originally Posted by Royal Club View Post
I have a 2003 (or 4) crf450 caliper. Pads are the same (one pin to hold them) mounting distance bolt/bolt is 102mm's

edit: what you are getting is not 26years of screwing around in a caliper.
you lost me a bit there Royal,

so you are saying the crf caliper is a Nissin caliper the same as the XR600 ?

just did a quick check for the crf 450 caliper on ebay but can't quite get a good enough picture to make sure they are the same,as for price they don't seem to be much cheaper.

I didn't understand the "26 years of screwing around in a caliper"
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Old 05-11-2013, 02:20 PM   #8062
elsalvadorklr
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Quote:
Originally Posted by voltz View Post
with a used one I don't know what I'm getting,is the crf caliper the same ?
well I have one...too bad shipping to australia is prohibitive

certainly not $200!

nissin calipers are used in a million bikes...If you dont want to buy new, take yours off and start searching scrapyards...you can mix and match hoses, pads, and pistons for example...all good

cheers
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Old 05-11-2013, 02:36 PM   #8063
voltz
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Yeah, understood
I know Nissen calipers are widely used but there are quite a few different configurations of them, I had bought that other caliper from England which came to a total of $160 with postage which was wrong item so I figured $200 locally would be the best :-)
Next I need to work out a motard setup

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Old 05-11-2013, 07:53 PM   #8064
Todd36
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Trailtech Vapor??

Is anybody running a Vapor on their XR600R? I cant seem to find an application specific model for our bikes? Im trying to get my bike Tagged in Oklahoma and would like to run one. Thanks for any info or links you guys can provide.
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Old 05-11-2013, 09:33 PM   #8065
beechum1
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If no one answers, just call them. They're really helpful and friendly everytime I have.
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I used to say "one day" a lot. But then I got scared I would wait one day too long. So I am doing it all now
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Old 05-11-2013, 11:33 PM   #8066
Captain115
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Hi everyone,

So I've spent the last two days rebuilding the engine (finally!) as the parts came in on Friday. Partzilla might have good OEM and shipping prices to Oz but waiting for parts to be backordered is painful.

Anyway I went to my parents to complete this, I was visiting them anyway and it let me use some of my dad's tools. Beer was consumed and the rebuild came along fairly smoothly I think. Photos to come.

Had to file the rings a fair bit to get to the correct gap, possibly because of the tight clearance. Yep, same machinist as benno, same technique. However I had a long talk with him and feel confident that it should be fine. And if it isn't he said he will happily replace parts for free. We shall see.

Anyway, I'd gotten the bottom end back together and everything was going swimmingly. Well one of the fingers of the clutch broke off, but apart from that, everything went fine.

Massive ups to Steve's "Building an XR650L" thread, which I followed step by step! Benno's, Bull's and Christian's threads were also a huge help as I could use the photos to orientate and check my work.

Oh and this guy does a whole video series! FANTASTIC! http://www.youtube.com/xrland

I only needed to buy one tool (1/2" drive extension bar)!

Hondabond'ed the stator grommet and put a dab at the front and rear case split to stop leaks. Used Steve's grease trick to keep the washers on the transmission when assembling it. Swore at the difficulty of juggling the transmission and forks and shifter (but got it all fine). Replaced the oil seals for the kickstarter, countershaft and gear shift and replaced the spring for the gearshifter prongs and tensioner.

I found that it is a little difficult to select fourth and fifth by hand, as it often gets stuck between the gears. Works better if the transmission is being spun, I guess the dogs line up better?

Used assembly lube on the small end and piston circlips ala Steve. Mine is green though, not the cool blood red lube that he uses

So everything was fine....until I got to putting the cam in. The new cam looks lovely, so I went to put the sprocket holder and auto decomp mechansim from the old to the new....how the fuck do you get the sprocket holder off the cam?

Looked in the manual...you have to press it off. Like with a hydraulic press. Why is it that not a single other rebuild even mentioned this? So yeah, be warned if you don't have a press, you'll need to give your old and new cams to a machine shop with a press in order tp swap the cam gear holder over! That's where I am at the moment, waiting till tomorrow so I can go find somewhere that will do this for me.

Photos to come soon.


Quote:
Originally Posted by joexr View Post
I think you should solder a plug in there instead of glueing. Are you willing to risk damage and another teardown?
Yeah man, I hear you, would be heartbreaking for it to come out and destroy everything so followed your advice. Thanks for the tip!

Cheers,

John

Captain115 screwed with this post 05-13-2013 at 04:21 PM
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Old 05-12-2013, 12:19 AM   #8067
rogervize
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Just found this bike on Ebay Australia(Melbourne)..

Wish I had some spare cash
http://www.ebay.com.au/itm/281103932...84.m1423.l2649
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Old 05-12-2013, 12:34 AM   #8068
Captain115
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Shit man, good find! That looks awesome, and there are some good extras for that price! Though I would be worried that the bike has "..been rejected to suit the head port and polish job" haha.
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Old 05-12-2013, 02:17 AM   #8069
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Old 05-12-2013, 05:01 AM   #8070
Airguitar
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Looks like a good start. Does it run? What type of things does it need? Mine looked very similar when I started with it. HIDE YOUR CREDIT CARDS NOW!! You will thank me later

BTW I don't think the license plate is big enough.......
I already have done a lot on it. fixed oil leaks from the kick starter shaft and replaced o rings at the oil pump lines. it needs a chain guide, a shock rebuild and a decent sprocket cover. the headlight also needs replacement.
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