The XL600 thread

[crobox]

Originally Posted by m2h

Am considering trying to add an oil cooler to my '86 while I have the motor out. Has anyone tried or heard of fitting a later model XR400 cooler? Don't really know the dimensions but read on Thumper Talk of one or two xl600 owners who have done it but gave no real description of how.
Wondering how much cooling it would provide as it don't look very big!
Read about using coolers from JC Whitney etc. but at 11" X 6" X 3/4" might be a mission to fit in.
Interesting discussion maybe?

I added an oil cooler, which was a generic aftermarket unit. There are several posts about how and where I added it starting around post #146 (page 10) in my build thread. There is also a bit of discussion about how useful it is; who could benefit from one; who maybe doesn't need one.

Hope it helps a little.

-Christian

[davek181]

Originally Posted by m2h

Am considering trying to add an oil cooler to my '86 while I have the motor out. Has anyone tried or heard of fitting a later model XR400 cooler? Don't really know the dimensions but read on Thumper Talk of one or two xl600 owners who have done it but gave no real description of how.
Wondering how much cooling it would provide as it don't look very big!
Read about using coolers from JC Whitney etc. but at 11" X 6" X 3/4" might be a mission to fit in.
Interesting discussion maybe?

I put an XR400 cooler on my XL600. I had to weld mounts on the steering head to hold it in place, and get a little creative with braided lines and AN fittings but it wasn't too horrible to do as I remember. If you are interested I can send pics and try to revive my memory as to the details. The biggest problem was the choice of fittings and layout, but it worked out once I started mounting things. It seemed impossible to do with the stainless braided lines till I discovered a tool to put the fittings on.

I have a temp dipstick and it seemed to drop my temps about 50 degrees on a hot summer day. There was also the advantage of extra oil capacity provided by the lines and cooler.

[m2h]

Originally Posted by crobox

I added an oil cooler, which was a generic aftermarket unit. There are several posts about how and where I added it starting around post #146 (page 10) in my build thread. There is also a bit of discussion about how useful it is; who could benefit from one; who maybe doesn't need one.

Hope it helps a little.


-Christian

Thanks Christian Any help is much appreciated. This project has cost shitloads more than I anticipated (didn't envisiage a rebore etc) so I am looking to make the most of all the info you guys provide in this thread
M2H

PS, Just went thru your rebuild Christian Awsome job mate, a man after my own heart although I don't have the same resources

[m2h]

Originally Posted by davek181

I put an XR400 cooler on my XL600. I had to weld mounts on the steering head to hold it in place, and get a little creative with braided lines and AN fittings but it wasn't too horrible to do as I remember. If you are interested I can send pics and try to revive my memory as to the details. The biggest problem was the choice of fittings and layout, but it worked out once I started mounting things. It seemed impossible to do with the stainless braided lines till I discovered a tool to put the fittings on.

I have a temp dipstick and it seemed to drop my temps about 50 degrees on a hot summer day. There was also the advantage of extra oil capacity provided by the lines and cooler.

Thanks Dave, Would appreciate that very much. The xr400 cooler is about $96us on partzilla but i'll see if I can maybe get a used one here but am not holding my breath! I read that these bikes tend run pretty hot so any cooling has got to be good and as I replied to Christian this bike owes me big time.
Am having a ball doing the wrenching, just waiting on some gaskets b4 the final assembly.

M2H

[joesm333]

Hello all,

Well good new after some help from folk on here i manage to track down a new head for my xl600r to replace the one that had been repaired by PO with epoxy and had sprung a leak....shock horror haha.



Well after cleaning it up removing some sheared off studs and grinding the valves in it was all good to go again.....oh yeah new timing chain and stainless exhaust while i was at it too.



Then a few trips out on Salisbury Plain in the wet as we have had loads of rain here in blighty....flooded it once in one of those 'oh thats a bit deeper than i thought moments'.



So all well really the end......yeah right!!

I've started a new job in scotland so got my bike ready to come up.....long distance fuel tank from acrebis. Set off all going well despite being damn cold -7 cold for here anyway. About 50 miles in.....cough....oh what was that hummm. Then nothing so rolled to a stop on the side of the A417. Few things sadder than a bike on the hard shoulder.

http://joesm333.smugmug.com/Other/Mo...959077_J7n7B8z

So had a look about......oil everywhere. No compression. So from my limited knowledge of these things head gasket? Anyways after a bit of sorting got a lift/flight to work and the bike taken home. New gasket ordered will see how a i get on when i'm next reunited with my bike.

The only thing i can think is that head gasket failed as i refitted the old one (even though it had only done 500 miles) any pearls of wisdom greatly recived. Oh if anyone knows where you can get carb kits (prefereably in the uk) for these wonderful machines that would help too.

Keep it rubber side down,

Joe

[davek181]

Originally Posted by m2h

Thanks Dave, Would appreciate that very much. The xr400 cooler is about $96us on partzilla but i'll see if I can maybe get a used one here but am not holding my breath! I read that these bikes tend run pretty hot so any cooling has got to be good and as I replied to Christian this bike owes me big time.
Am having a ball doing the wrenching, just waiting on some gaskets b4 the final assembly.

M2H

It has been a long time since I installed it so it is a little fuzzy in my brain but I have refreshed my memory from old notes and observations of the install.

I test fitted for location then welded two 6mm nuts to the side of the oil tank for mounting the cooler. I welded a little shelf underneath it too copying the 400.

I had previously searched many posts and installs myself with hookups ranging from cutting off stock oil lines and using rubber hoses to fabricating new steel lines. I settled on AN fittings and hoses, kind of copying an install I found online using the same. It seemed more leakproof and durable and within my fabricating skills.

First I got the parts:
Oil tank: 16mm female adapter to 6 AN male, and a 45 degree hose end.

Left cooler: 16mm female adapter to 6 AN male, and a 90 degree low profile hose end.

Right cooler: 14mm female adapter to 6 AN male, and a 120 degree hose end.

Crankcase hose: 18mm male adapter to 8 AN male, an 8-6 AN reducer, and a straight hose end.

6’ of 6 AN hose.

Then I started fitting fittings and cutting hose and installing ends and routing hoses and such. I almost gave up the project over the difficulty and bleeding fingers resulting from trying to put AN fittings on the hoses. I discovered a tool, called Koul tool that made the task nearly effortless. I did have to reposition the oil tank breather hose by careful bending and reroute the hose from head to tank.

It took 2 fittings to get from 18mm original hose down to 8 AN, then down to 6 AN, to adapt to the hose and keep the whole thing one size hose.

Then a couple more fittings to adapt to the oil tank, then a short length of hose to the 120 degree and 14mm adapter to get onto the cooler'

The other side of the cooler required a 16mm adapter and a 90 to turn the hose around the front of the steering head and down to the original oil line.

I tried to put the captions under the respective pictures to make the read easier but was unable to comprehend how to do it so you are destined to do some scrolling.

[crobox]

Dave-
Thanks for that last installment of "Carbs 101"... the bits about the pilot jet and air screw!
Carb knowledge growing daily!
Cheers,
Christian

[davek181]

Hey, no problem, glad to share what little knowledge I have. Just ask and I will explain what I can.

I wish I could soak up some of your fabrication skills so easily, but alas that can't be learned in a simple narrative.


Dave

[skeptic]

Originally Posted by m2h

Hi Guys, Anyone have any advice on opening up the dia of the banjo bolt holes to allow a bit more oil flo to the head? I don't think this would dramatically reduce flo to anywhere else and may add a little more cooling. As always its good to pick the forum brains
M2h

I just drilled them out to 1/8 inch.
I thought every little bit of increased flow helped.

[mcma111]

Christian,

Any pic's of the oil cooler mounts on the side of the frame? What did you use?

[m2h]

Originally Posted by davek181

It has been a long time since I installed it so it is a little fuzzy in my brain but I have refreshed my memory from old notes and observations of the install.

I test fitted for location then welded two 6mm nuts to the side of the oil tank for mounting the cooler. I welded a little shelf underneath it too copying the 400.

I had previously searched many posts and installs myself with hookups ranging from cutting off stock oil lines and using rubber hoses to fabricating new steel lines. I settled on AN fittings and hoses, kind of copying an install I found online using the same. It seemed more leakproof and durable and within my fabricating skills.

First I got the parts:
Oil tank: 16mm female adapter to 6 AN male, and a 45 degree hose end.

Left cooler: 16mm female adapter to 6 AN male, and a 90 degree low profile hose end.

Right cooler: 14mm female adapter to 6 AN male, and a 120 degree hose end.

Crankcase hose: 18mm male adapter to 8 AN male, an 8-6 AN reducer, and a straight hose end.

6’ of 6 AN hose.

Then I started fitting fittings and cutting hose and installing ends and routing hoses and such. I almost gave up the project over the difficulty and bleeding fingers resulting from trying to put AN fittings on the hoses. I discovered a tool, called Koul tool that made the task nearly effortless. I did have to reposition the oil tank breather hose by careful bending and reroute the hose from head to tank.

It took 2 fittings to get from 18mm original hose down to 8 AN, then down to 6 AN, to adapt to the hose and keep the whole thing one size hose.

Then a couple more fittings to adapt to the oil tank, then a short length of hose to the 120 degree and 14mm adapter to get onto the cooler'

The other side of the cooler required a 16mm adapter and a 90 to turn the hose around the front of the steering head and down to the original oil line.

I tried to put the captions under the respective pictures to make the read easier but was unable to comprehend how to do it so you are destined to do some scrolling.

Thanks very much Dave good piks! Am looking for one now as it seems the easiest mod I've seen so far.
M2H

[m2h]

Originally Posted by skeptic

I just drilled them out to 1/8 inch.
I thought every little bit of increased flow helped.

Thanks mate. Yeah I've just done that job, I don't know the pressure the oil pump delivers especially as it constricts to about 2mm thru the riser pipe and then empties into a 6mm hole to fill the gallery before the cam bearing. It's seems more of a flooding system than true pressure feed to me. Guess it works tho Happily!!
M2H

[RFVC600R]

I got my gasket kit in today from Japan. http://cgi.ebay.com/ws/eBayISAPI.dll...m=140932160137 Its not OEM but it seems good quality. I'm going to get gasket paper and make copies of the paper ones so I will have those if/when another leak pops up. I'm figuring since this has all the gaskets, I might as well as change all the gaskets. I will not be spitting the cases since that gasket isn't leaking. I've also noticed lately that there is timing chain slap when the engine is cold. Shouldn't be any since the engine was rebuilt 5k miles ago then again it does leak pretty bad. It could be the tensioner, mistakes happen in rebuilds. but im getting a new timing chain just to be safe. Any recommendations?? I'm putting the bike down on the 27th and hopefully not long I'm trying to go in ready.

I also want to change the valve seals because the bike smokes very rarely and randomly on start up But I don't know anything about how to do that.... I'm reading up on it later but some XL600 specifics will be appreciated

What kind of gasket sealant should I use??

My surgery list
1.Gasket kit
2. Torque Wrench
3. Some kind of gasket sealant
4. copper coat
5. Timing chain
6 decompresser seals Thanks to Moparmanpete for showing me where to get them

Anything else?? ANY input will be great as this will be my first time doing this.

I bought a new electric impact wrench when I changed my fork seals, I've only used a couple times and im itching to use it for dis-assembly

[crobox]

Originally Posted by Dracus124

I also want to change the valve seals because the bike smokes very rarely and randomly on start up But I don't know anything about how to do that.... I'm reading up on it later but some XL600 specifics will be appreciated

My friend, who ground my valves, told me to use a little loctite on the valve seals, where they snap on to the collars in the head.

I did as he said.

-C

[Carter Pewterschmidt]

This guy thinks he's got one that's worth a bunch of money. Rare to boot!

http://milwaukee.craigslist.org/mcy/3687541066.html