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Old 09-28-2010, 08:39 PM   #16
TourPros
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Joined: Dec 2008
Location: Hood River, OR
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Big 6 for sure

While some say the Orange bikes are this and that and this bike does better at this or what have you. I have towed many Orange, /green and Yellow bikes out of situations with my 97 XR600.

This weekend it gets put back together and I am gitty.

The rebuild (due to seizing of the wrist pin MY OWN FAULT!) includes. Hot Rod Connecting rod, new cam, cam chain and sprockets, new third gear, piston, rings, valves and valve springs. So it should be good for a while to come.

These are great machines for sure
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I really like what your are trying to do. I'm just not sure about how you are trying to do it. It's been a pressure working with you and the pleasure was all yours. If you need me I'll call ya..
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Old 09-29-2010, 12:44 AM   #17
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Quote:
Originally Posted by TourPros
While some say the Orange bikes are this and that and this bike does better at this or what have you. I have towed many Orange, /green and Yellow bikes out of situations with my 97 XR600.

This weekend it gets put back together and I am gitty.

The rebuild (due to seizing of the wrist pin MY OWN FAULT!) includes. Hot Rod Connecting rod, new cam, cam chain and sprockets, new third gear, piston, rings, valves and valve springs. So it should be good for a while to come.

These are great machines for sure
I too have towed a rainbow of differant colored bikes back to the pits. I've also used my XR to tow logs back to camp to be cut up for fire wood. It's quite a sight when my buddies with thier arm loads of sticks see me draging a 20 foot log behind the Big 6. And when it comes to throwing a roost, I'm sorry but there's none better.

Sounds like you're replacing the whole valve train, you should consider new cam bearings also. They're cheap enough and then you won't have to worry about your top end for another 10 years. When's the last time a 450 owner said that?
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Old 09-29-2010, 12:59 AM   #18
badcooky
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Joined: Oct 2007
Location: At QLD Australia
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Quote:
Originally Posted by XRider
Being a shameless show-off I thought I start a thread for one of my favorite bikes, it's a plated 1996 XR600R. As some of you have heard me say before about the Big 6, there's newer, there's lighter, and there's faster, but few are as much fun and none are more reliable. My goal with this project was to mod the engine to make monster power, have enough lights so it could be seen from space, run on pump gas (91 r+m/2), and not lose the legendary reliability. This is the result, 52 horse power and 170 watts pointing down the trail.



I have lots more pictures and I'm happy to share any of the details involved with building this bike. I did all of the work myself so everything will be a first hand account. I also have pictures of the head after porting and polishing if you guys would like to see them. I suppose I should start with a parts list.

Head:
Kibblewhite Black Diamond Valves
Mega-Cycles full race cam grind #173X12
Kibble racing valve springs w/h titanium retainers
Machined valve guides (required to accomodate .405" lift cam)
Intake runners ported and port matched, exhaust runners ported, matched, and polished.
3 Angle valve seats.

Intake:
41mm FCR pumper carb (cha-ching)
Uni-Filter and back-fire screen
9 filtered air box vents
Tossed the snorkle

Exhaust: It sets off car alarms and makes babies cry!
FMF SS PowerBomb header (wrapped)
FMF Ti4 Titanium muffler & mid-pipe

Cyl:
Re-Sleeved with an XRs Only sleeve (thicker)
JE 10.5:1 comp ratio 628cc piston

Electrical:
Baja Designs dual sport kit
Baja Designs 250 watt re-wound stator (it's the sh#t)
55/60 watt headlight
Dual 55 watt projector beam halogen off road lights shock mounted on a light bar of my design. They come on automaticly when the high beam is switched on.

I know I've left some stuff out but it's getting late and I need to call it a day. Thanks for checking out the thread, I'm pretty proud of how this bike turned out.

XRs Forever!
Does well.
Do i see buddy pegs on that thing?
Who in their right mind...on the back .. oh never mind.
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Old 09-29-2010, 01:03 AM   #19
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The light bar

Here's some pics of the light bar. It's made out of 6061 T6 aluminum and mounts between the fender and the lower triple clamp. The "wings" have tabs that hold each light that are mounted with rubber gromets. This limits the vibration so the bulbs have a normal life span and provides a bit of flex in the event of a crash. This is the 3rd version of the lightbar and after repeated crash testing (I'm gettin' too old for this sh#t) I've yet to break it.
The lights look like they're out in the breeze and would be easily knocked off. But if you draw a line from the bottom of the front tire to the end of the handle bar, everything inside that line won't hit the ground in a crash. That's not to say that if it falls over on a stump it won't break but I've dumped it many times and so far so good.



I have the lights pointing outward about 10 degrees so they shine into the turns.



The shock mounts.



It's hard to see in this picture but behind the headlight mask I've stashed the AC reg and the relay for the light bar.

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Old 09-29-2010, 01:06 AM   #20
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Building a torque monster is not without it's liabilities. Only the most expencive chains and sprockets stand a chance of making it out alive. Sadly that sprocket is not that old.

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Old 09-29-2010, 01:17 AM   #21
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Quote:
Originally Posted by BigNastybrp
sweet looks good I need to come over and that thing run.
Anytime brother!
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Old 09-29-2010, 01:29 AM   #22
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I'd like take this opertunity to invite anyone with an XR600 to showcase it on this thread and tell us what you've done. I always like seeing something I haven't thought of so even if it's just a new way to safty wire the foot pegs, I want to see it. I'm just nuts about the big Honda and if you're reading this you must be too. So it's show time guys, what do ya' got!





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XR628R Plated and highly modified
CR500R Still rips after all these beers
RZ350L Kenny Roberts Special
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Old 09-29-2010, 02:33 AM   #23
TourPros
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Location: Hood River, OR
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Quote:
Originally Posted by XRider
I too have towed a rainbow of differant colored bikes back to the pits. I've also used my XR to tow logs back to camp to be cut up for fire wood. It's quite a sight when my buddies with thier arm loads of sticks see me draging a 20 foot log behind the Big 6. And when it comes to throwing a roost, I'm sorry but there's none better.

Sounds like you're replacing the whole valve train, you should consider new cam bearings also. They're cheap enough and then you won't have to worry about your top end for another 10 years. When's the last time a 450 owner said that?


I forgot to list them but bearing are done as well
__________________
Hell I've been thrown into better places and got friends I ain't even used yet.
Hug those you love often And turn life up !!!
I really like what your are trying to do. I'm just not sure about how you are trying to do it. It's been a pressure working with you and the pleasure was all yours. If you need me I'll call ya..
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Old 09-29-2010, 02:51 AM   #24
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Quote:
Originally Posted by badcooky
Does well.
Do i see buddy pegs on that thing?
Who in their right mind...on the back .. oh never mind.
Hey, good to hear from the Bad man! My ex-wife, who was a very brave woman, used to ride on the back. There's nothing like a nice long ride on a fire road with the woman you love hanging on for dear life and a bike too loud to hear what she's saying. Ah, good times!
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XR628R Plated and highly modified
CR500R Still rips after all these beers
RZ350L Kenny Roberts Special
BMW 1150GS It's like ridding a Barkalounger
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Old 09-29-2010, 07:57 AM   #25
BigNastybrp
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Hey Xrider,
52 hp is that at the crank or on the dyno? My xr6 dyno run was only 37 hp but thats good for me
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Old 09-29-2010, 01:06 PM   #26
run8nova
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Nice,, Are you still making the light bar?? Do you run that size of carb only after changing displacement, or can I use one after cam change. I can't believe how much info I've gotten on this web site about my old thumper.. Sure glad it's still in my garage. Mike
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Old 09-29-2010, 01:48 PM   #27
elsalvadorklr
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Joined: Nov 2008
Location: Columbus, GA
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ill bite, here is mine! just finished maybe 75 miles on rebuild.1988.

Prox piston, kibblewhites, new cam bearings, camchain, case bearings.Ebay crank rod...Painted frame and plastics,new boots and custom seat cover.
Ignore the honda logos!

Here she is:




Cheers thanks xrider!
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Old 09-29-2010, 01:54 PM   #28
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Quote:
Originally Posted by run8nova
Nice,, Are you still making the light bar?? Do you run that size of carb only after changing displacement, or can I use one after cam change. I can't believe how much info I've gotten on this web site about my old thumper.. Sure glad it's still in my garage. Mike

I'm still making the light bars, PM me and we'll see about getting you one.

The 41mm FCR carb is about the same size as the stocker so if properly jetted you can add one any time. The biggest reason for switching to the FCR is for the accelerator pump. The smooth bore flat slide is a better design but the pump wakes the engine right up. It makes it so you can rip the throttle open as fast as you can and there's no bog what so ever. If there was one single thing that made the biggest differance I'd say it was the FCR.
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XR628R Plated and highly modified
CR500R Still rips after all these beers
RZ350L Kenny Roberts Special
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Old 09-29-2010, 01:58 PM   #29
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Quote:
Originally Posted by elsalvadorklr
ill bite, here is mine! just finished maybe 75 miles on rebuild.1988.

Prox piston, kibblewhites, new cam bearings, camchain, case bearings.Ebay crank rod...Painted frame and plastics,new boots and custom seat cover.
Ignore the honda logos!

Here she is:




Cheers thanks xrider!

Nice! It looks almost brand new, good job.But tighten that chain, it's too loose. You're also under inflating your front tire for riding on the street. That's why it's wareing funny.
__________________
XR650R Plated Supermoto
XR628R Plated and highly modified
CR500R Still rips after all these beers
RZ350L Kenny Roberts Special
BMW 1150GS It's like ridding a Barkalounger
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Old 09-29-2010, 02:05 PM   #30
elsalvadorklr
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Joined: Nov 2008
Location: Columbus, GA
Oddometer: 4,151
Quote:
Originally Posted by XRider
Nice! It looks almost brand new, good job.But tighten that chain, it's too loose. You're also under inflating your front tire for riding on the street. That's why it's wareing funny.
Thanks!
Just tightened the chain! and that tire is a tkc that came off my KLR! 6k miles on it but it still is better than what came with the bike! It all ai had to get a roller...surprising what 120 pounds less feels like, front tire wise...no wobble!


Cheers bud!

Christian
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