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Old 03-04-2009, 06:03 PM   #31
Olas OP
the darkness
 
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Joined: Aug 2007
Location: Englewood, CO
Oddometer: 3,948
Valves (Stem O.D)







Intake
5.475-5.490mm
5.46mm
#1: 5.460mm

(0.2156-0.2161in.)
(0.215in.)
(0.215in.)



#2: 5.460mm



(0.215in.)




Exhaust
5.467-5.477mm
5.45mm
#1: 5.486mm

(0.2152-0.2156in.)
(0.218in.)
(0.216in.)

#2: 5.473mm

(0.2155in.)


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Old 05-26-2009, 09:47 AM   #32
Olas OP
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Small progress made...

Ok, so the weather has been crap lately with all this rain and of course have no excuses to not work on this bad boy so here we go... Sorry for the lack of pictures, I cannot find the USB cable for my camera so I've resorted to using my cell phone.

I split the cases today:



All of the parts inside of the cases seem to be in ok shape. The only damaged parts i've found in the bottom end so far are the shifter shaft splines and the kickstart gear sprocket. It seems something came loose at one point in the right side cover and got jammed in between the kick start gear and the bottom of the case.

Anyway, as soon as I find those replacements i'll be able to start reassembling the motor.

The crankshaft bearing came out with the crankshaft so it will need to be replaced. Anyone have any suggestions on how to get it off the crankshaft? Manual recommends a bearing puller, will any bearing puller do the trick here?



Thanks for looking!
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Old 05-28-2009, 04:06 PM   #33
Olas OP
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Well, got the bearing off the crankshaft and pressed the new one on with the help of Dan. Also, I just picked up an extra bottom end from a 1995 XR250R. So... I've got lots of spares to play with now.

I still need a few bearings before I can start to reassemble the engine but once I get those i'm guessing that I can have the bottom end back together in a day. Also need to drop off the cylinder at the machine shop to bore it out to the next size.

Today I got organized, next i'll examine parts and determine what's good and what's not... etc.. Progress! I can't wait to get this little bike going.

The paint on the frame is not looking too bad so I think i'll just clean it all up good, regrease everything and get 'er going without spending too much time worrying how it's going to look. Trail bikes don't need to be pretty.





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Old 05-28-2009, 04:30 PM   #34
Jimmy the Heater
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Please keep us posted!!! Great Project!
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Old 05-28-2009, 11:03 PM   #35
Olas OP
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Quote:
Originally Posted by Jimmy the Heater
Please keep us posted!!! Great Project!
Will do. I'm going to try to go to the bearing shop tomorrow to see if they have what I need.
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Old 05-29-2009, 05:28 AM   #36
Blakebird
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Old 06-02-2009, 04:05 PM   #37
Olas OP
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Sweet....

Today I replaced all of the bearings inside of the crankcase, installed the crankshaft, inspected the transmission gears and installed them. This is my first time splitting the cases on anything and am surprised at how simple this stuff really is. As long as you have a Honda manual you should have zero issues.

This is where I left off today because I had to head in to work:



At the last minute I decided to use most of the parts from the spare bottom end I bought. I'm using the crankcase halves and transmission from the '95 and using the crankshaft and balancer from the '87. By mixing and matching I can hopefully create a reliable machine.

I am dropping the cylinder and piston off at the local machine shop tomorrow morning and might have it back as soon as Friday. I'm trying to hammer out as much as I can right now because in a week and a half i'll be in my hometown of Mazatlan, chilling on the beach drinking some ballenas.



More coming soon....

P.S. Sorry for the lack of pictures but if anyone has any questions on how I did any of the work, please ask!! It's all been very simple so far.
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'92 XT600, '87 XR250R
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Old 06-02-2009, 06:16 PM   #38
Olas OP
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Question for the engine gurus...

So, when I took apart the spare bottom end I bought, I noticed that the rod had virtually no play (side to side/top to bottom) at all on the crankshaft. The one from the '87 has some side to side play and no up and down play but it is still within spec. I always thought there should be some side to side play so when I found this one with out any I was taken aback.

?
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Old 06-03-2009, 04:10 PM   #39
Olas OP
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More work today...

Finished putting the rest of the transmission in today and joined the cases. Very simple and easy to work on. I'm going to love this bike, I already know it.

Also dropped off the cylinder and piston today at the machine shop. Will pick it up on friday and continue to do some work then also.




So, now i've got this:



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Old 06-03-2009, 05:36 PM   #40
ehatcher
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Joined: Aug 2005
Location: Eastern PA
Oddometer: 2,361
Nice bike!

Thinking about a rebuild on my 87. Mechanicly, it is decent and it runs great, but cosmeticly it could use a tear down, repaint and new hardware.

Keep up the thread - good info!

Here is mine from this past winter:




Eric
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ehatcher screwed with this post 06-03-2009 at 05:43 PM
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Old 06-08-2009, 04:59 PM   #41
Olas OP
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Hit a bump.

Something bad was bound to happen. I was torquing the head on to the cylinder and before it even hit the mark, one bolt stripped out the threads from the cylinder.

Any recommendations as to how to fix it? Time sert or Helicoil, which would be better in this matter?

Anyhoo, I was this far but I will have to undo some work now to fix those damn threads:











I even cleaned out the carburetor that I bought off ebay:



Ok, I leave for mexico in about a week so I'm going to order parts and get everything I need hopefully so that when I get back I can get this puppy running. The stripped thread issue is pissing me off but at least it's fixable.

Cheers!
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Rebuild threads:
'92 XT600, '87 XR250R
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Old 06-08-2009, 06:14 PM   #42
Blakebird
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IMO, Time-sert is preferable to Heli-Coil, but I'd call someone who knows to get their opinion on the best fix.
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Old 06-09-2009, 03:00 PM   #43
Indy Unlimited
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I agree with Blakebird. Time-sert is needed for the heavy torque of the head bolts. Looks like your project is coming along pretty well. Good job Alfredo!
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Indy Unlimited screwed with this post 06-09-2009 at 04:12 PM
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Old 06-10-2009, 09:18 AM   #44
Olas OP
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Thanks, guys. Yeah, Dan, it was going really well until those threads stripped out. It looks like someone had stripped it out before and installed a helicoil, which came out with the bolt. I'm looking for a shop now that can do timeserts, the kits are expensive and I only need one 10 mm insert!
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Old 07-13-2009, 04:57 PM   #45
Olas OP
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Slight update..

I'm back from Mexico and started working on the XR again. I helicoiled the threads and all is good now. I'm to the point where the engine is all together now. Tomorrow I will take some pics after I install the carburetor and the airbox and hopefully get it running (!!).

Any tips, tricks for getting the oil flowing through the lines before I actually start the bike? I want to make sure oil is getting to the head before I start it up.
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