ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 04-01-2011, 06:08 PM   #196
Brauhausbier OP
Focused
 
Brauhausbier's Avatar
 
Joined: Aug 2006
Location: SF Bay Area
Oddometer: 1,367
Quote:
Originally Posted by canyncarvr View Post
..just following along...but that was the piston it ran into I presume?

Valves can run into cylinders, but that is usually part of stuffing oversized valves in a head.

If you didn't know this engine was an interference design, you do now!

Good to hear you're back on track.
Thanks for following along

What I belive was happening is this:

- The cam chain was off the drive gear and so tight it was moving by friction alone on the inside of the cam drive gear spline

- as we kicked the bike to try to make it start, the cam chain turned but slipped since it was only spinning on the spline.

- Totally out of timing, the intake valves ran into the piston

I'm sure this happened the first couple of kicks and no wonder why it wouldn't fire. Bent Valves. Lesson learned. It's been a very educational week about 4 stroke motor building

At least I didn't give in and bring it to shop! Kept the faith
Brauhausbier is offline   Reply With Quote
Old 04-01-2011, 07:31 PM   #197
mcma111
Beastly Adventurer
 
mcma111's Avatar
 
Joined: Jul 2007
Location: San Francisco,Ca.
Oddometer: 11,580
Life

Live 'n Learn


It's all a process.
__________________
Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

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
mcma111 is offline   Reply With Quote
Old 04-02-2011, 08:55 AM   #198
elsalvadorklr
southern xr rider
 
Joined: Nov 2008
Location: Columbus, GA
Oddometer: 4,149
keep the faith! you can do it! jajaj

EDIT.. look like a bunch of us will have these powercore 4's on. please report...
elsalvadorklr is offline   Reply With Quote
Old 04-02-2011, 07:44 PM   #199
creaky
Gnarly Adventurer
 
creaky's Avatar
 
Joined: Apr 2008
Location: Indiana
Oddometer: 176
Fellas, I have to throw in my $.02 here...I read in previous posts about the cam being 180 off. It is not possible to get the cam 180 off in the XR600 engine because it is a wasted spark engine, that is, the spark occurs on every revolution of the crankshaft. The cam lobes should be facing down when installing the cam cover so that there is no pressure on the rocker arms to overcome when tightening the cover screws.
__________________
'98 BMW F650
'96 XR400
'98 Moto Guzzi V11

"Once you go over the hill, you start picking up speed!"
creaky is offline   Reply With Quote
Old 04-02-2011, 10:03 PM   #200
Brauhausbier OP
Focused
 
Brauhausbier's Avatar
 
Joined: Aug 2006
Location: SF Bay Area
Oddometer: 1,367
Top End Day - Redux

Okay...back at it


Cleaned up all the head surfaces with Lacquer Thinner - great tip from mcma111


Pic of the OE Intakes valves back on the head after swapping out the bent KB's I destroyed. Nice job of cleaning those up by the boyz at Baisley's!


Getting all the head surfaces cleaned up


Lost the cam chain off the drive gear while getting the head on - same thing that happened when I did the top end the first time. Pulled the Right side cover to properly re-set the cam chain on the drive gear. Really the only way to do it right. This is where I messed up on the first go around. Exact same scenario. Doing it right this time.


Cam Chain on drive gear


Set HotCam at TDC - Lobes are down, marks on the cam gear are at 9, 12, and 3 O'clock. Tensioner is in. Cam chain is on the drive gear


All in!


Used Permatex Non-Hardbinding Sealant to seal up the valve cover tight. Put a thin layer on all surfaces including both sides of the valve gasket to make a sealant "sandwich" - another great tip from mcma111. Used rubber bands to hold up the sub rockers for assembly - thanks for the tip mcma111

Whew - all together - set valves for HotCam at 0.15mm intake/ 0.20mm exhaust


New problem - my choke spring is toast. Tried for over 2 hours to cut, mangle, rewind, and no go. Can't buy one off any OEM supplier. Anyone happen to have a choke spring for the Kehein 38mm OE Carb?? Works ok manually, but would be nice to have some spring action in the choke.

I'm cleaning up the sealant on the head tomorrow and will get the carb back in and give her a test fire tomorrow! Wish me luck
Brauhausbier is offline   Reply With Quote
Old 04-02-2011, 10:06 PM   #201
mcma111
Beastly Adventurer
 
mcma111's Avatar
 
Joined: Jul 2007
Location: San Francisco,Ca.
Oddometer: 11,580
Luck

Your done. Starts in first handful of kicks. Good Luck.
__________________
Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

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
mcma111 is offline   Reply With Quote
Old 04-02-2011, 10:09 PM   #202
Brauhausbier OP
Focused
 
Brauhausbier's Avatar
 
Joined: Aug 2006
Location: SF Bay Area
Oddometer: 1,367
Quote:
Originally Posted by mcma111 View Post
Your done. Starts in first handful of kicks. Good Luck.
Thanks so much for all our help mcma111!

I picked up a 16 penny nail today to replace the resistor in the spark plug boot! I'm on that tomorrow morning That's a killer mod and thanks for everything Steve!
Brauhausbier is offline   Reply With Quote
Old 04-02-2011, 11:37 PM   #203
Blakebird
r-u-n-n-o-f-t
 
Blakebird's Avatar
 
Joined: Feb 2004
Location: Parker, CO
Oddometer: 15,665
jeebuz...after all you've been thru with this, I sure hope you like the bike once it's running
__________________
IBA #11735 . 1968-present
Blakebird is offline   Reply With Quote
Old 04-02-2011, 11:54 PM   #204
Brauhausbier OP
Focused
 
Brauhausbier's Avatar
 
Joined: Aug 2006
Location: SF Bay Area
Oddometer: 1,367
Quote:
Originally Posted by Blakebird View Post
jeebuz...after all you've been thru with this, I sure hope you like the bike once it's running
Thanks Blake. Been working on this rebuild for 4 months now...and my birthday is tomorrow too.

It would be nice present to hear that motor come to life

I'm thinking about that FCR off the CRF450 as a possible mod?

Too much work for the cheap price, or pay the $600 for the Sudco kit?

Pissed my choke spring is toast on the OE Keihin
Brauhausbier is offline   Reply With Quote
Old 04-02-2011, 11:54 PM   #205
MortimerSickle
Semi-Adventurer
 
MortimerSickle's Avatar
 
Joined: Dec 2005
Location: Rainville, Orygun, where moss is a road hazard.
Oddometer: 12,033
Quote:
Originally Posted by Brauhausbier View Post
...
I picked up a 16 penny nail today to replace the resistor in the spark plug boot!
...
Maybe brass mo betta?
__________________


I miss round headlights.

"When I was a young man, I liked to race my horse...." -
G.H.W.S. 1878-1962
MortimerSickle is offline   Reply With Quote
Old 04-03-2011, 12:28 AM   #206
DRZ400SM1981
One meaty Adventurer
 
DRZ400SM1981's Avatar
 
Joined: Oct 2009
Location: Capitola
Oddometer: 53
Looking good, but 16 penny?

Brauhausbier,

Happy almost Birthday! Bikes looking great. Hopefully just a day away from starting her up. If Steve's says it's good, it should be.

Look on Ebay for an FCR. I've been looking for a week or so and you can get and FCR from a CRF450 and the throttle assemble for around $225. Get a NOSS Adapter and jets and your in for around $300. A lot better than $600 and only a little bit of leg work.

And what is the mod with the 16 penny nail? Never heard of that one.
DRZ400SM1981 is offline   Reply With Quote
Old 04-03-2011, 12:53 AM   #207
Brauhausbier OP
Focused
 
Brauhausbier's Avatar
 
Joined: Aug 2006
Location: SF Bay Area
Oddometer: 1,367
Quote:
Originally Posted by DRZ400SM1981 View Post
Brauhausbier,



And what is the mod with the 16 penny nail? Never heard of that one.
Mcma111 told me about this one:

Uncrew the spark plug brass in the spark plug boot.

There is a spring and resistor back behind the brass spark plug cap.

Cut a 16 Penny Nail, or bearing rod (same diameter) to that resistor length and bolt her back up. Better spark with a direct electrical path (resistor removed). Sweet and cheap mod! The best kind

Thanks for the tips on the FCR from the CRF450! I might just have to do that one
Brauhausbier is offline   Reply With Quote
Old 04-03-2011, 01:41 AM   #208
Ladybug0048
Bug Sister
 
Ladybug0048's Avatar
 
Joined: Nov 2005
Location: Spokane Valley, WA (the dry side of the mountains)
Oddometer: 10,802
Happy Birthday and I hope your birthday wish comes about. Vrrrrrooooooooooommmmmmmm (I didn't know how to spell the sound an XR makes )
Ladybug0048 is offline   Reply With Quote
Old 04-03-2011, 01:57 AM   #209
Brauhausbier OP
Focused
 
Brauhausbier's Avatar
 
Joined: Aug 2006
Location: SF Bay Area
Oddometer: 1,367
Quote:
Originally Posted by Ladybug0048 View Post
Happy Birthday and I hope your birthday wish comes about. Vrrrrrooooooooooommmmmmmm (I didn't know how to spell the sound an XR makes )
Thanks Ladybug! I need to get some sleep Cheers!
Brauhausbier is offline   Reply With Quote
Old 04-03-2011, 05:31 AM   #210
Blakebird
r-u-n-n-o-f-t
 
Blakebird's Avatar
 
Joined: Feb 2004
Location: Parker, CO
Oddometer: 15,665
Quote:
Originally Posted by Brauhausbier View Post
Thanks Blake. Been working on this rebuild for 4 months now...and my birthday is tomorrow too.
Happy Birthday, BHB... and I hope you hear the bike run on your birthday.


You know that people are going to be asking you questions about these bikes now....you've learned more than many of us have on this one build

__________________
IBA #11735 . 1968-present
Blakebird is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 02:58 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014