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Old 12-07-2008, 08:14 PM   #1
oregon07klr OP
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Location: Higher Oregon 42` 14' 54"N 121` 48'17W
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XR600R CRF/USD conversion

Posted this on TT. But thought some people might like to see it.

Sold my pool table on craigslist to a guy in GP and he would tack on another $150 to the asking price if I would come over and set it up for him. Sweet. Thinking to myself as I browse the motorcycle listings in GP, "Killer, I got $650 to put towards the XR!"



First mistake of many was to mention the sale to the wife. Sure she would notice it gone...but I could think of an excuse then. Not now. Now I found a whole front end of a CRF/X for $300. We're talking rim, tire, forks, tripples, speedo cable, brake and line, bearings, stem...all of it! I had just started reading on TT of people converting to USD so I called the guy up.


http://www.thumpertalk.com/forum/sho...d.php?t=682050

http://home.comcast.net/~ledrocnoc/CRFClampMods/

http://www.thumpertalk.com/forum/sho...&highlight=usd


"I'll take $200 for it."

Even better!

I go drop the pool table, and pick up the front end and haul ass home. It's late so I dont look it over too well.


The next day I start taking everything apart, cleaning up parts, looking things over, and tear into the XR.

CRF Showa forks




CRF tripples



The start of something quick, easy and cheap.......or is it?




This is mistake two. Tearing into the bike the weekend before thanks giving. I have the thought in my head, that if I get the stems to a machine shop monday, they are are just going to drop everything and turn down the stem and make a bushing for me. This way, I'll have the bike back together by thursday and be set for the long weekend! Awesome!



more....
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Old 12-07-2008, 08:15 PM   #2
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....more....

so monday comes and I head to a recommended machinist to have the stem turned down. I don't know for sure if the XR400 stem and the one off of my XR are the same...but I'll bet they are.

I take the CRF stem/tripples and my XR stem and explain what I need. All of the qualities of the XR stem on the CRF stem except the bottom inch-ish. And a bushing for the top CRF clamp. He understands but says he can't do metric threads. Bummer. I go drop the forks off to have the seals replace and the mechanic recommends another machinist. So I go back, tell him I really want the XR threads and take the stems etc. to the recommended machinist. Oh, this is the next day....So, tuesday afternoon. The other machinist, Tim is real cool and understands right off what I need. He acts like it's no big task, but says he cant get someone on it until Monday.....


Oh, well....kinda bummed but who the f**k do I think I am?


In the mean time I get the forks back and am just waiting on the stem.



Tuesday I get the call that the parts are done. I owe $221. Holy cow. I thought I had read about people getting that shit done for ~$50?!! I could buy the Emig set up for $180!

I call Tim and talk to him and we both walk away happy. Don't mean to be a cheap guy, but that's a lot!

So I got the stem and bushing in the top clamp. Cool.







more.....
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Old 12-07-2008, 08:18 PM   #3
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finished 'er up

Pressed the bearings on to the new stem with a pipe and hammer. Greased them up and put the triples on the bike.



Slid the forks up thru the tripples and snugged them up along with the top triple.





Intalled wheel and odometer.




This is the fully locked left. No clearence issues. Perfect.


The only thing I was missing from the CRF frontend was the bar claps and rubber bushings. I ordered them last week and got the call today that they were in. Great. Stopped by the shop after work and they had ordered the wrong part. The guy new I was bummed and new I was eyeing some Pro Taper fat bars and some fat bar clamps the last time, so he cut me a KILLER deal on them.


Now I have all the parts to complete the swap.

I get home, and get right to work installing the bars.




After finding a comfortable postition, I finished installing the levers, kill switch, and throttle.



I couldn't get the decompression lever to reach so I just removed the cable completely. Anyone know if this will cause problems? Not having it connected?







Got a few things to check over and stuff to torque but should be able to take 'er out tomarrow afternoon.
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Old 12-07-2008, 08:59 PM   #4
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The decompressor is nice so you can clear it out when you drop it when it's hot and it floods.
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Old 12-07-2008, 09:44 PM   #5
slackmeyer
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The only time I ever used the decompression lever was to get the kick starter just over TDC before I really kicked. But it's not really necessary for that. If your auto-decompress is set right, you probably won't miss it. You could mount it somewhere else, maybe?
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Old 12-08-2008, 06:16 AM   #6
oregon07klr OP
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decomp

I was thinking about setting it up like a choke. Pull a lever and it stays open till you shut it off? Anyone ever do anything like this?
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Old 12-08-2008, 06:20 PM   #7
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Now that I think about it, could you just take the cable off, and make the lever on the cylinder head a little bit bigger so you could just activate it directly? As long as it wouldn't break anything when you crashed.

BTW, nice conversion there. Hopefully that front brake will work better than the one on the XR that I had.
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Old 12-08-2008, 08:47 PM   #8
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Excellent walkthrough Seth! Looks like you got it figured out really well.
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Old 12-13-2008, 08:04 AM   #9
oregon07klr OP
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Larger tank

Looking at getting a larger tank this winter. Am wondering if I will have any clearance issues with it? Either the Clarke 4.7 or the Aceribis 6 gal.

Anyone?
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Old 12-13-2008, 08:55 AM   #10
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Clearance Issues

It's gonna hit.

If you look at the photos above you will see the stock steering stop on the XR600 is in the center bottom front of the head tube. Look at the bottom triple clamp, the bosses for the stop on the CRF/CR use the rear, angled area to stop against the side of the head tube. I used some 3/8" thick by 3/4" keyway keys and welded them to the bottom sides of my frame. Dry fit the triple clamps and fork tubes along with the tank and then ground them down till the fork tubes ALMOST hit the tank. Then it was off to the powder coaters for a new paint job...
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Old 12-14-2008, 01:23 PM   #11
oregon07klr OP
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tryin to follow

I think I know what you are saying.....but the bumpers on the bottom tripple are hitting the XR stop on the front of the frame....?





You are saying that the forks can turn too much or....?
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Old 12-14-2008, 05:08 PM   #12
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Yep

They do turn to much and will hit your tank. Do a dry fit with the tubes and the tank. You will see what I'm talking about. If you look closely at the frame to triple clamp contact it is not a very good contact patch. Go look at a CR or CRF for an idea as to it's contact area. After all it's a dirt bike and they do have a habit of crashing. At least mine does when I'm playing on it. What I'm trying to get at it is that a larger contact surface is preferable to a small one given the choice.
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87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 12-14-2008, 05:55 PM   #13
oregon07klr OP
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I get it. So best bet is to get the tank I want and make the stops work with that tank? I should be able to make it work with either tank right? Whats the average MPGs from the 600R? I just got the trip cable working and haven't been able to check milage. Hoping to get 200+ miles with a new tank....


Thanks for the input.
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Old 12-15-2008, 07:57 AM   #14
mcma111
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Tank Size

200 miles on a tank is possible with a 4+ gallon tank on the pavement. You might want to go +1 on the counter shaft sprocket though for street use. Factor in riding style, WFO ?? or trails, jetting the works...
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87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 12-15-2008, 09:17 AM   #15
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I think the triples from a 99 CR250/500 will work with your stops.
This pic is with the CRF clamps on a Transalp which has the same headtube dimensions.



Here's the CR 250 clamps. The stops align perfectly.Plenty of clearance even on the Transalp with it's radiators and larger tank.




You could add metal to the existing stop and file it to get it perfect if you wanted to go with what you have.
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