Call all XR600R!!!

[mcma111]

The hex is the new design and the slot is the old.

[deejay_xr]

Originally Posted by mcma111

The hex is the new design and the slot is the old.

Makes sense

Strangely, a lot of parts sites mention the slot type in the parts list with the fiche, but not the hex.
Leading me to think ´twas the other way round

[luckyjr]

Use and lot of anti-seize on your new one and don't over torque. I had to take the side cover off to get a easy-out in far enough to get mine out.

[Royal Club]

Originally Posted by deejay_xr

Tried it, no cigar...



What I was thinking, I'll try that later on.

Good news is, I found a used one at a wrecker of the old type, i.e. with a hex instead of the slot. Apparently they DO exist

Did your hex wrench fit snug? I ordered a new cap from CMSNL in HEX shape and my Metric hex wrench wont fit properly, the hex in the cap is a bit bigger..

[deejay_xr]

Originally Posted by luckyjr

Use and lot of anti-seize on your new one and don't over torque. I had to take the side cover off to get a easy-out in far enough to get mine out.

Good tip, I used copper grease on it, but apparently I overtightened it just far enough. It was already pretty damaged.
Stupid...

Originally Posted by Royal Club

Did your hex wrench fit snug? I ordered a new cap from CMSNL in HEX shape and my Metric hex wrench wont fit properly, the hex in the cap is a bit bigger..

Don´t know yet, the guy will be mailing it this week

[Royal Club]

Originally Posted by deejay_xr

Good tip, I used copper grease on it, but apparently I overtightened it just far enough. It was already pretty damaged.
Stupid...




Don´t know yet, the guy will be mailing it this week

if anything, new ones are pretty cheap.
http://www.cmsnl.com/honda-xr600r-19...m_90087mn1670/

[deejay_xr]

Originally Posted by Royal Club

if anything, new ones are pretty cheap.
http://www.cmsnl.com/honda-xr600r-19...m_90087mn1670/

Pretty sweet, wasn´t familiar with that site yet !

This´ll save a boatload on shipping and customs since they´re based in The Netherlands.
What´s your experience with them?

Edit: HOTDAMN they're expensive

Did a little comparison on some parts I've ordered from the States in the past, some are about the same and then some are stupid expensive !

[Captain115]

Gotta grab a 30mmm socket so I can undo the primary drive nut and then I'll be able to split the cases today hopefully.

There's a fair bit of that metal from before sitting on the bottom of the crankcases, near where the internal oil screen sits.

Had a look at the clutch basket and it is slightly notched...what's the general consensos in lightly sanding these down a little? I know some people swear by it, others reckon you should just buy a new basket (which is definitely not happening). The clutch worked fine when it was running, really heavy but smooth. Also the bottom of the basket where the first of the plate sits is quite scratched up, does this matter at all?

Thanks,
John

PS, mcma111 what grease do you use in your 'building a XR650L engine' thread during the assembly? Like the green stuff you use to hold various washers and dowel in place?

[deejay_xr]

Originally Posted by Captain115

Had a look at the clutch basket and it is slightly notched...
The clutch worked fine when it was running, really heavy but smooth. Also the bottom of the basket where the first of the plate sits is quite scratched up, does this matter at all?

Then leave it well alone, you have enough things to worry and spend on unfortunately, this isn't one of 'em

Do you have a pic of the scratches ?

[mcma111]

Bel Ray waterproof grease. Good stuff. Use it for everything.

http://www.belray.com/bel-ray-waterproof-grease

Clutch basket. Go ahead and file the notches down.

[Royal Club]

Originally Posted by Captain115

Gotta grab a 30mmm socket so I can undo the primary drive nut and then I'll be able to split the cases today hopefully.

There's a fair bit of that metal from before sitting on the bottom of the crankcases, near where the internal oil screen sits.

Had a look at the clutch basket and it is slightly notched...what's the general consensos in lightly sanding these down a little? I know some people swear by it, others reckon you should just buy a new basket (which is definitely not happening). The clutch worked fine when it was running, really heavy but smooth. Also the bottom of the basket where the first of the plate sits is quite scratched up, does this matter at all?

Thanks,
John

PS, mcma111 what grease do you use in your 'building a XR650L engine' thread during the assembly? Like the green stuff you use to hold various washers and dowel in place?

As Mcma and deejay said, the notches can be filed down..

Originally Posted by deejay_xr

Pretty sweet, wasn´t familiar with that site yet !

This´ll save a boatload on shipping and customs since they´re based in The Netherlands.
What´s your experience with them?

Edit: HOTDAMN they're expensive

Did a little comparison on some parts I've ordered from the States in the past, some are about the same and then some are stupid expensive !

cms aint cheap overall. but saves the hassle with customs and shipping..

[Captain115]

Alright so the case is split.

First off, bulk metal shards:



Secondly, I took the transmission out, slipped and a variety of the cogs cam off onto the bench. Softly mind you, but now I'm not 100% of the order.



I used the 'building XR650L engine' thread to help but my main question is do the smaller dogs slot into the indented side or the less indented side? I was thinking more indented (as can be seen in the photo below on the right) so the smaller gear is more fully 'inside' the larger one?



My shitty paint example:



Also, what am I looking for in the gears to know if they need to be replaced? Because after a quick glance, there does not seem to be any that are obviously destroyed...so where did the metal come from then??

Cheers,
John

[mcma111]

Captain,

Does it look like the cases have ever been apart? Perhaps all that metal is from a prior melt down and the PO didn't open the cases to clean it up.

Here is the transmission layout:

[mcma111]

Here is how the XR transmission operates:

http://www.justxr.com/jaw/gearbox.html

[Royal Club]

http://www.motor-forum.nl/forum/list.../#zwakkepunten
scroll down a bit