XR600- Donkey Fix Up & Full Rebuild

Yeh, I was thinking of scoring some hubs to lace it to 17"s but I wanted some bigger rotors without buying a specific kit $$$
Will see.

I have been using powersportsplus.com, pretty much the cheapest, fast delivery (even when it stops in customs)
and reliable. Small parts is only around 12euro in shipping.

Yup, that´s the one I was thinking.

Yeah oversized rotors for XR hubs are a little rare, therefore expensive. I had the luck of buying a set of sumo wheels complete with entire front brake set-up

I'll remember that site !

A pretty penny indeed. I´ve seen used sumo sets going for around 500e :huh

Not going to happen, my grandpa always side "If I can make it, why buy it?" and I live by it

one to you grandpa

I´ll keep an eye on ebay and if something turns up cheap , I´ll snacth it.

Some small updates on the Donkey.

The clutch basket is pretty notched, but I have to run it as is for now.
A small smoothing should keep me happy until I find a better one.

All new bearings, thanks to my brother in law

He works in a machining/tooling factory and got me ALL the bearings, including the Honda so called
specially ground bearing, and seals, except for the small one in the clutch arm, Kudos to the man.

Any chance we can get some of that action over here?

my clutch basket was exactly the same

the correct way of repairing this is to use a flat file and sandpaper and go against the grain of the "grooves"

you would never imagine I had nothing but a new clutch in my bike as its baby butt smooth

with sandpaper only you have the issue of possibly taking too much material off...or leaving a non flat surface

another trick is to grindd the metal plates (in a circular fasshion) on the clutch pack on a glass window with very coarse sandpaper and then aligning them in a pattern different to when they came off the bike

this will give you A LOT OF EXTRA MILES on an otherwise USED clutch system

cheers

Hey cristian, thanks, that´s my method I do it with sandpaper and it only touches the
high spots so it´s all good. I´ve done that to my CBR clutch and after 15k it´sstill holding smooth.
Tha clutch plates already got the treatment

What do you mean? the bearings?

well thera ya go...

awesome

I like honda clutches,,,they last

Yup. I'm scared to look up honda prices.

left crank bearing about 50

right or special bearing 70

cs bearings about 30

other assorted another 50...

something like that jajaja

yeah, taht's why. If I can get err thing for about a hun USD, I'd like that.

Just posted this in another thread but if you can help, I´d be apreciated.

On the left side crankcase cover, there´s a small recession where the little dowel
that actuates the clutch pushrod, sits. Can you confirm that the recession on the cover
is completely cilindrical without any irregularities?

It´s where the piece #11 sits and I had a hell of a time removing mine. So much that I broke
it. Only now realized that the recession on mine is not completely round.

^^^
Sorted, brucifer showed me the light

This is what I was talking about



We can see that it was the chain rubbing for a long time



A bit of drilling to remove the lump, a bit of JB and hopefully will be fixed.

Got some new parts, incluiding some CREE Leds



Since my brother hasn´t brought me the frame, I´ve got to do something to keep me
occupied

Old cover



Primed x2


Base coat x3


Clear x3

that looks good.

Thanks beechum, I´ll paint the rest this week if all goes well.

Regarding those bearings. I can ask my brother in law if he can score some more but
i´ll make no promises.
He got me all the bearings over a rather long period of time, I bought the bike in April and
only last week I could assemble everything, not that I was in a hurry. His factory stocks
are pretty well controlled. I´ll give it a shot anyway.

In the meantime, what I can give you are all the bearings numbers and all the engine seals
measures. They´re all, except the clutch actuator arm seal, pretty standard and way cheaper
if you buy them in your local hardware store. Especially the seals.

I can post them if you want.

That looks exactly like a heater core to me, not an oil cooler! Made for coolant, not for oil. Not sure what would happen if you put oil through it. I'm no Jaguar expert, maybe they use an oil cooler that looks like that, but it sure looks like a heater part to me.