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Old 12-13-2006, 11:23 AM   #1
ere109 OP
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XR600 Rebuild Tutorial

It only took a month longer than the original estimate, and $23 more than the original quote, but I just picked my cylinder up from the shop. That means I'm going home tonight (after a trip for some new tools) to reassemble my XR600R. I'm planning to take lots of pictures so I can report the whole thing tomorrow. Hopefully this re-assembly will go smoothly.
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XL600 rebuild http://www.advrider.com/forums/showthread.php?t=224984

ere109 screwed with this post 12-14-2006 at 01:26 PM Reason: change title
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Old 12-13-2006, 11:24 AM   #2
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Old 12-13-2006, 01:17 PM   #3
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Sweet I owned 2 86 xr600r's at the same time. Both were overbored and suped up with XR's only parts. One was a 654cc! That thing was awsome.

However if you are upgrading the cams you need to upgrade the rocker arms as well. The guy I bought the second one from had the top end rebuilt before I got it. He had a performance cam installed. I rode it around quite a bit and had a blast. It started ticking pretty loud after awhile and I assumed it was the cam chain tensioner as it took a dump on my other one and sounded exactly the same. I told this to the guy I sold it to (for dirt friggincheap). Well he ran that thing around a good bit then decided to do the tensioner. The hardened cam had hollowed out the rocker arm lobes/followers till there was almost nothing left. We all looked at it and couldn't believe the thing was still running. I mean they were fucked.

So if you are replacing the cam find out from those who designed the cam if it is compatible with the stock rockers. Obviously the hardened metal of the cams on my bike was way tougher than the stock followers.
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Old 12-13-2006, 01:42 PM   #4
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Interesting thoughts. My bike was taken apart because it was making a low-end knocking noise. I wonder if it could be worn rockers. How bad did yours look? Mine have small divots, but I didn't think they'd affect performance...
I'll put it back together and fire it up with my new piston and rings. If the noise is still there, it won't take much to pull the cam chain out and buy a new one. How did you troubleshoot/test the tensioner? All I know is that the one-way bearing in mine still works.
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'13 BMW R1200GSA 90th Anniversary, '03 Honda XR650R, '83 Honda XL600R Supermoto (Project) XR600 rebuild http://www.advrider.com/forums/showthread.php?t=188797
XL600 rebuild http://www.advrider.com/forums/showthread.php?t=224984
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Old 12-13-2006, 01:53 PM   #5
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Good on ya Eric! On the cam, all aftermaket cams now, of which there are two I know of, are compatable with the stock rockers. They are Hotcams, and Poweroll. Both say stock rockers are fine, but you can buy aftermarket rockers and Id do it for the price, as well as new valve guides and porting and such as long as the head is off....but for your project just whip it back together and start it up!
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Old 12-13-2006, 02:09 PM   #6
wickerman777
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Quote:
Originally Posted by ere109
Interesting thoughts. My bike was taken apart because it was making a low-end knocking noise. I wonder if it could be worn rockers. How bad did yours look? Mine have small divots, but I didn't think they'd affect performance...
I'll put it back together and fire it up with my new piston and rings. If the noise is still there, it won't take much to pull the cam chain out and buy a new one. How did you troubleshoot/test the tensioner? All I know is that the one-way bearing in mine still works.
Well you know how they are kind of hemispherical? Well these were completely concave as in matching the shape of the cam lobes concave. Like I said we couldn't believe it still ran.

As for the tensioner on my other XR, i didn't diag it. My friend who is a honda mechanic listened to the bike and told me it was the tensioner and rails. He was right cause after they got pulled and replaced the noise went away not to mention the visual condition of the rails.

Not trying to scare ya, just something to look into. Another friend of mine who is an old mechanic mentioned something about old honda followers not going through the hardening process long enough and there were some failures with aftermarket cams being used. Can't say for sure. My other XR I'm quite sure had a performance cam in it (don't know about the rockers) and never had any issues.
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Old 12-13-2006, 04:10 PM   #7
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Good Luck!
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Old 12-13-2006, 08:07 PM   #8
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How's it coming???

Hope you get'r running.

Cheers!
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Old 12-13-2006, 09:04 PM   #9
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The adventure begins

As some may already know, this bike was a true basketcase when I bought it. The previous owner said the bike had started to make a knock, so he tore it apart and couldn't figure out how to get it back together. Bad for him, bad for me, but I got it cheap, so I'll be ok.
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'13 BMW R1200GSA 90th Anniversary, '03 Honda XR650R, '83 Honda XL600R Supermoto (Project) XR600 rebuild http://www.advrider.com/forums/showthread.php?t=188797
XL600 rebuild http://www.advrider.com/forums/showthread.php?t=224984
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Old 12-13-2006, 09:06 PM   #10
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So I've got four bins full of parts. Luckily, I haven't found anything yet that i DIDN'T have a part for. Hopefully when I get to the end I don't have any parts left...
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'13 BMW R1200GSA 90th Anniversary, '03 Honda XR650R, '83 Honda XL600R Supermoto (Project) XR600 rebuild http://www.advrider.com/forums/showthread.php?t=188797
XL600 rebuild http://www.advrider.com/forums/showthread.php?t=224984
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Old 12-13-2006, 09:08 PM   #11
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I rushed home after work and started assembling my plan. First thing to do was file down all of the previous gasket sealant from the mated surfaces. I started with the girlfriend's nail file before realizing it would work a lot faster with an actual file. A quick trip to the hardware store landed me a 6" mill file. Perfect.
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Old 12-13-2006, 09:10 PM   #12
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Next, it seemed like an intelligent thing to do to draw an outline of my stator cover gasket. Now, if I ever need to replace it, I've got a copy to work from.
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Old 12-13-2006, 09:11 PM   #13
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Ok, now it's time to get down to business. I open up my new Wiseco piston and rings, excited about the shininess of it all. Piston looks good, pin and clips are there, rings...
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Old 12-13-2006, 09:14 PM   #14
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Darnit if there isn't a broken middle ring in this box! I got ripped off. But it's too late to wait a week for another ring. I want this bike now!
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Old 12-13-2006, 09:15 PM   #15
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The gap on the new top ring was a perfect .012", and that should sorta make up for using the worn old ring from the previous cylinder. I hope. Look at that hone job!
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