XR600- Donkey Fix Up & Full Rebuild

Hey guys, I´ve been a Iong time lurker around the site but never took the time to sign up, didn´t think I could contribute that much.
This just changed so let´s see if I´m worthy...

I ride the streets but was always looking out to see if the opportunity presented itself and I could bring home my first love - the XR600.

Since I was around 13 and a few of my friends older brothers started showing up with that mean, bada**** XRs, Huskys and Husas, I wanted one.
That growl coming up the street...was my wet dream at the time.
Got older and somehow the bike elluded me. Rode some CRM125, DTR125, Bandit400, CBR F3 and now the F4i Sport.

Well, last week it finally happened, I just picked up my donkey



**Update**

Ok, just thought I would update this first post to give you an ideia of what to expect of this rebuild and include the parts list and mods.

**Parts List**

Countershaft - 100
Sprocket & Chain kit - 90
Tires - 100
Gear Shifter - 15
Gasket kit - 45
Spark Plug - 3
Exhaust - 50
Carb Hoses - 3
Dust/Oil Seals - 20
All Bearings - 50
Caliper Seals - 10
Pads - 15
Front Rotor - 40
SS Brake Lines - 40
Brake Switch - 5
Nipples - 5
Levers - 10
M22 x 1.5 - 7

**Mods / Extras**

Strip & Paint - Free
Lightened Flywheel - Free
Rewoud Stator - Free
CRF450 Plastic Kit - 65
Handguards - 15
628cc Kit - 200
Suspension Valve & Spring - 120
Oil cooler - 25


Guess that´s about it. If any more comes up, I´ll update again

Got her really cheap (for Portugal at least) and she runs good. No knocks, no smoke and easy starter.

That´s not good enough for me
I take pride in my toys so the plan is to do a full tear down and rebuild. She won´t be my main transport and I´ve got the time to mess with her.

Ok, I know that some of you might be thinking that it´s just another rebuild. You´re right. But it´s my rebuild

Already have her down to the bone, but since I´ve enjoyed watching and following other members threads, I think it´s only fair to share my own, right?

Just want to apologize for the initial lack of disassembly photos but my camera card acted up and lost most of them.

Took her home and started immediately to crack nuts and bolts



Anyway, the disassembly is pretty much straightforward and like all others.
I was pretty satisfied, all the zerk fittings were greased and everything went smooth with no stripped nor broken bolts.

At first sight she might look ok, but no. She´s a crude,slimey ugly mess.









This will be fun

This doesn´t look good...



But I already knew that.

What I didn´t expect was to see the calipers in this state. I truly think I should´t rode her home when I picked her up :eek1





I´ve spent the better part of an hour to completely remove the pistons from both calipers. They were as nasty as... I don´t know, never seen calipers like this ones!!

Nice! Keep' em coming

I'm in. I have a spare front XR caliper for you. PM me your name and address and I'll sent it to you. Hopefully the postage won't be an arm and a leg.

Wow!
Thanks mcma111!

I knew the people around here help each other out but that was fast. Really appreciate it man, parts around here are though
to source. I resort to the Uk and States.

Actually, I´ll pm you in a few.

Ok, let´s get this thing rolling.

One of the reasons that this bike was so cheap... the coutershaft.

It´s welded so, it has got to go.



Notice the shifter, it´s welded too.

well there goes the good buy!

welcome to the forums, and have fun!

First good news of the day, all rockers, sub rockers and cam look in tip top condition.

All journals are smooth and in spec and the center of the valve cover where the cam sits, is good too.





Pretty clean also.
I think someone was here before. Don´t know if you can see but the bolt that hold the tensioner
is almost rounded....

Stem seals shot and a bit on the rich side for sure. These valves are going to be a pain to clean.

Let´s see if they seal after cleaning and lapping them...

Thanks!

I bought her knowing about the countershaft and that´s why I got her for cheap.

The guy selling her was asking double of what I offered. Called me nuts!
I told him that if that the shaft was in good condition, I would put the full asking price in his hand but if not,
I would bring her for half. He said ok so I asked for an allen key and removed the aluminium sprocket cover that completely covered the zone.

Voila! CHeap XR600

youre a smart and lucky man!

whats that a possible buyer touching my bike? that doesnt fly down here! jajaja

awesome deal

hey thos valves lool ok

just clean them up with some solvent

new seals and good to go

it all depends on what and how much you want to spend

once again good luck

christian

Gotta go guys, tomorrow I´ll update on the cleaning part and give you a parts list and expected price for the whole shebang.

Already have most of the needed stuff but not everything.

Thanks Cristian.
I followed your rebuild thread even before coming a member.
Well done man, she turned out really good.
It´s an awesome feeling, grab an old bag of bolts and turn it into a proud ride!
For me at least. That´s why I try to replace only what´s necessary and the rest it´s all clean, polished and fixed, if possible.

Go get 'em slick! I have a few extra parts laying around too. Shoot me a pm if you start finding yourself needing replacements!

Thanks man. Appreciate it, really.

I guess for now i´m set. Except for the countershaft and sprocket cover. Got any lying around

What do you think about this shaft in ebay? The splines look ok but the end of it look like it has some scoring

http://www.ebay.com/itm/85-90-Honda-XR600-R-XR-600-Trans-Transmission-Counter-Gear-Shaft-Countershaft-/170842564129?pt=Motorcycles_Parts_Accessories&hash=item27c702a621&vxp=mtr#ht_2248wt_952

I´ve started on the engine but can´t go any further. My brother has my air gun and I´m still waiting for the flywheel puller
so it has to wait a few more days for the tear down.



While waiting, there´s the cleaning part. Not that fun, but part of it.
This has to be fixed, it seems the previous owner did not check his chain clearance that often...

It might not look like it but this loom was a mess. Cut & stripped wires and some funny home lightbulbs connections...