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Old 06-24-2007, 07:10 PM   #1
Zombie_Stomp OP
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Reviving my new (used) '83 Honda XL600R

I have just scored the deal of all deals: a 1983 Honda XL600R for $50! I had posted an ad on Craigslist wanting an old XL, for under $800. About a month later, this guy says I can just haul it away for $50. I must be getting back some good karma I deserved.
It is complete except rear turn signals, the front fender sags a little because of a lateral crack near the mounting bolts, the front headlight fairing cracked, the speedometer is beat up, I don't know if it still works, the manual decompression valve panel (I think that's what it is) on the side of the engine is not pt back together, and it has not been run in about 2 years. The tank is clean, but the carbs are probably not. The title is there, the prev. owner gave it to me just signed by the owner before him- he didn't bother 'cause it was just his trail bike.
The course of action I would like to take is to apply for the title, then get it running, and go take it out somewhere to get a feel for it on some dirt, then go through with my endorsement and plate, and possibly MSF course.
I've ridden scooters since I was 15, have hopped them up plently (aftermarket 70cc kits, carbs, pipes, variators and gears) and have *some* idea how to ride, just need to get familiar with the gears, and the size of the bike.
I'm thinking of starting with reassembling that decompression valve, cleaning the carbs and air filter, clean and regap the plug, and seeing how far that gets me. I'm all ears for any input from you guys who have worked on these XL's. So I'm new to the forums, and wanted to introduce myself and my new wheels, so Hello, I'm Joel!
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Old 06-24-2007, 07:22 PM   #2
DELTATANGO
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Sweet. Almost free is even sweeter.

Add an oil change.

You can find everthing on the Internet.
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Old 06-24-2007, 08:02 PM   #3
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42941.0 miles. Any stats on how much longer well maintained 600cc rfvc engines tend to go on running for? This will help me decide whether to A) raise money and rebuild the top end, b)whole engine, or c)just run it till it needs rebuild.
Or any other suggestions...
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Old 06-24-2007, 08:10 PM   #4
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ere109 is your guy......

http://www.advrider.com/forums/showthread.php?t=188797

http://www.advrider.com/forums/showthread.php?t=224984
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Old 06-24-2007, 08:44 PM   #5
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Oh yeah, I read all his resto/rebuild projects so far, an I'm hooked! I'll contact him directly then.
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Old 06-24-2007, 09:49 PM   #6
Gregster
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Good score - you'll have fun with that bike.
I recently rebuilt my '84 XL600R also.
Lots of detailed pictures in this thread:
http://www.nbdsc.ca/forum/viewtopic.php?t=274
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Old 06-24-2007, 11:30 PM   #7
ere109
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Thanks, Mountain.
Yes, I've got a little bit of knowledge about these things...
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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 06-25-2007, 02:01 AM   #8
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Quote:
Originally Posted by Gregster
Good score - you'll have fun with that bike.
I recently rebuilt my '84 XL600R also.
Lots of detailed pictures in this thread:
http://www.nbdsc.ca/forum/viewtopic.php?t=274
I read that whole thread from beginning to end! Addictive, these resto threads are, ere109 and gregster!
I am going to give getting it running a shot, and hopefullly come across a good engine to rebuild while I still ride the original out. Then I could continually cycle one out for the other. I'm sure you can attest, gregster, judging by your engine installation, that the XL600R engine must be taken out to do the top end, as ere109 warned may have been the case, whereas the XR600R does not - have we come to a concensus on that?
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Old 06-25-2007, 09:00 PM   #9
Gregster
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Quote:
Originally Posted by Zombie_Stomp
I read that whole thread from beginning to end! Addictive, these resto threads are, ere109 and gregster!
I am going to give getting it running a shot, and hopefullly come across a good engine to rebuild while I still ride the original out. Then I could continually cycle one out for the other. I'm sure you can attest, gregster, judging by your engine installation, that the XL600R engine must be taken out to do the top end, as ere109 warned may have been the case, whereas the XR600R does not - have we come to a concensus on that?
Once you've got all the peripheral stuff removed,
the engine isn't that bad to take out and put back in.
I've had mine out and back in 3 times now because of my own stupidness.
You'll learn the trick to sliding in, without even scuffing the paint,
though it may seem like a pain in the but at first.
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Old 06-26-2007, 12:14 AM   #10
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Is it true what the honda book says, you need a jack under the engine to maneuver the engine out? Or will a milk crate under the frame to hold the bike level suffice? I'm also wondering how heavy the engine is by itself and if I'll be able to do it alone. Thanks. And I hope you get yours running really soon, gregster. I will feel victorious since I've been reading and watching the thread intently.
Z
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Old 06-26-2007, 08:43 AM   #11
ere109
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I lifted my engine out and put it back in by myself. That may not be the ideal way to do it, though. There were a few scuffs when I was done. The thing probably weighs 90 pounds.
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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 06-26-2007, 10:12 AM   #12
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Quote:
Originally Posted by Zombie_Stomp
Is it true what the honda book says, you need a jack under the engine to maneuver the engine out? Or will a milk crate under the frame to hold the bike level suffice? I'm also wondering how heavy the engine is by itself and if I'll be able to do it alone. Thanks. And I hope you get yours running really soon, gregster. I will feel victorious since I've been reading and watching the thread intently.
Z
Naw, you don't need a jack.
Put your frame on a strong box or a milk crate (you may need a piece of 3/4" plywood if you're using a milk crate because the milk crates aren't quite tall enough). Just make sure the bike will sit still and not fall over.
Remove all the peripheral stuff.
Then take the 5 mounting bolts out, remove the rear, front, and head brackets,
The engine will just sit where its suposed to be in the frame.
Stand on the right side of the bike facing the rear.
Reach over the frame with your right arm and grab hold of the head or what ever you feel comfy with, and grab hold of the stator cover with your left.
Rock the engine back and forth a tiny bit to see where it wants to go.
It moves one way or the other to clear the brackets.
You need to move the engine forward about 1/2 or 3/4 inch to clear the rear lower bracket (it is fixed).
Then I think you tip the head out towards the right side (towards you).
There may be a tiny bit more rocking involved.
Find a position where the engine will rest while you move your right hand back over to the right side.
Lift her out.

You may want to place a rag over the lower frame tubes or tape them with electrical tape if you are worried about scratches.
Watch for the stator and pulse generator wires if you have not removed them already.
Go slow, don't be rushed, and plan your moves before you make them.
Have a second strong box or milk crate right beside the bike so that you can place the engine on it when it is free from the frame.
***Watch your fingers so that they don't get pinched between the frame and engine***
***And for God's sakes watch your back !!! These engines do weigh upwards of 100 pounds, so if you can't remember what it feels like to dead lift 100 lbs, you'll soon find out.***
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Old 06-26-2007, 11:01 AM   #13
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I will surely remember this for future reference. Right now I'm still hanging on to the idea of getting it running without rebuilds- I got the carbs out and cleaning them and shimming the primary needle jet is underway.
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Old 06-26-2007, 11:06 AM   #14
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Old 06-26-2007, 03:56 PM   #15
ere109
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Yeah, it'll just start like magic with some new gas, oil, and a carb clean. Maybe a new plug wouldn't hurt.
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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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