XR600- Donkey Fix Up & Full Rebuild

MacNoob, you´re right. It is a heater core. My dad told me after he checked better the car.
Iwas cleaning it and it struck me that the honeycomb was way too dense to be from an
oil system. I ran some solvent and old oil to check the flow and it would pose no problem, I think.

Either way, I scraped the ideia to mount this one, it´s a bit big.
I´m trying to source something like the old vfr,cb,cbr hondas had.

Hey guys, I´ve got my frame and parts back!!!

It´s pretty nice, I told my brother to make it all black but he made a bit of his
magic and added some gold to it and it turned out excellent! I´ll post some detailed
photos tomorrow.

I got in the zone and didn't take alot of pictures.



Just greased all the linkages and assembled it. Pretty straigth forward stuff except for the
steering stem bearings, they can be a pain. The rear CRF450 fender is still in the works.

Assembly tip: put the airbox first

Don't know if you recognize the triple but when I bought it I didn´t know what it was.
It turned out to be a Scotts with the fat bar mount. Not bad for a suprise... top and bottom
for 45



Also got my cylinder and 98mm Prox





And my old girl enjoying the day



She was pretty interested in my activities

For now I haven´t done any more assembly but I had to fix a little mishap... when I was cleaning
my case for paint, I dropped it Still could catch it it my foot but it was already late. It broke
a piece on the front engine mount

I´m not to worried about it. I'll try to fix it it JB and if it holds, fine, if the vibration is too much
for it and it brakes, I´ll source one.
For the time being, here's my fix...

the tools of the trade


Some cardboard rolled up and stuffed in the case. This way I'll assure a relatively round bore and when
it's time to remove it, only a tiny bit of cardboard will stick to it making it easy to remove.

The aluminium tape it's to hold the JB and give it a rough side shape while the small grid will hopefully
add some resistance to vibration. It has 3 small ones





We'll see if it holds.

Who wants to get the bets rolling?

You should have had the broken piece welded back on.

Hey Steve, you´re right. I should, but around here the cost of welding aluminium is
kinda of high. For the money I can get a side case. I´ll run it and see if it holds, if it doesn't...
I rather get a case.

Looking good, man! Your furry companion looks like she's enjoying the sunshine. :)

Perhaps consider the time, labor and expense of tearing the engine down.

Do it right the first time.

Where were you going to fit the oil cooler? I just grabbed one from xtz600!

I know, I know... if it brakes on the first ride I'll punch myself for it.

nikolic- it usually goes in front of of the steering tube or the front of the frame midway between
the tank and bash plate. As long as it gets cool air, it's good.
I also got a new oil cooler from a Yamaha XJ 550. The one I got was a bit big and not appropriate.

Yep, pretty much the only thing she does now, she s 17 and enjoying retirement. Eat, dump it and sleep

I meant "where" as where in the lubrication system, where to connect it?

Hey nikolic, sorry for the late reply, been pretty busy around here.
Didn't understand it the first time. I have a diagram that another member
has done, I'll just upload it to photobucket in a few and post it here ok?

Here you go

It's never too late for a right answer


edit: here's a few pics of it: http://www.4strokes.com/tech/honda/xr650l_oil_cooler1/default.asp

Hey guys, sorry for waiting. I´m opening a new coffee shop and priorities changed a bit.

Enough of excuses, right? It´s update time

She´s pretty much finished, but I´ll give you the run down.

Ok, so after I fixed the broken piece of the case I started on the wheels which
were not as bad to straight as I initially thought







Did the same to the back wheel on my improvised stand and they turned out ok

Mounted the new disc and wheels





Also retrofitted the rear fender and side panels from the CRF450, handguards and some decals

In the meantime my rod arrived!!
I was suprised to see the original honda big end rod, it was not that bad for 18 years of abuse







The new, shiny one looks better