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Old 03-25-2012, 01:30 PM   #1
brucifer OP
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Yet Another XR600 Rebuild Thread

Okay, so I was on the lookout for another plated XR600. Found a '95 model in Sacramento and after a few e-mails back and forth a deal was struck and an agreement was made to meet up half way between us.
Upon veiwing the bike for the first time I was a little let down because it was rougher than I was led to believe but since the guy was good enough to drive the distance I asked of him I didn't try to lowball and gave him the agreed upon price and we headed our seperate ways.
Later on as I looked a little closer I found more and more wrong.

The bike as it was when first unloaded at its new home.


One of the things I found later--a dent in the frame. That will need to be fixed.

A little later on I noticed some weirdness going on at the countershaft sprocket. There was a bolt threaded into the end of the countershaft with some spacers. I removed all of that and the sprocket and was greeted with splines that are junk. They're almost non-existant. Didn't take a pic of it unfortunately but I will later.
So........the engine needs to come completely apart. Started stripping the bike at work...... More later....
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Old 03-25-2012, 01:49 PM   #2
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A good part of it stripped at work.





After stripping the paint from the engine, it was clear that it had been bead blasted, or some kind of media blasted, while it was assembled.
All the boltheads, clutch arm and any little brackets had all been blasted, removing of course, the protective zinc plating.
This particular bolt was broke off in the main case and just stuck in the hole with sealer.

Finished stripping the bike at my house.

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Old 03-25-2012, 01:58 PM   #3
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Disassembled the top end of the engine. The bore is out of spec so time for cylinder enlarging.
Found another broken bolt. The longest one that goes from the rocker cover into the cylinder with the 10mm head. Again, it was stuck in the hole and held in by sealer.

I'll be using this transmission from a '97 bottom end I had sitting on the shelf. Pretty cherry. The countershaft splines have almost zero wear.
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Old 03-25-2012, 02:05 PM   #4
elsalvadorklr
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whaaaaaaaaaaaaaaaaaaaaaaat????????????? another xr600 rebuild thread??????????????

nooooooooooooooooooo! wait yeaaaaaaaaaaaaaaaaaaaaaaah!

can the world take so much xr stuff??????????????????????????

lets see

good to see you have one again!

cheers bud

christian
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Old 03-25-2012, 02:45 PM   #5
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Quote:
Originally Posted by brucifer View Post


While your ordering parts don't forget the little wire spring on the shift shaft.

Hoe does the small end of the rod look? Loose? Or OK.
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Old 03-25-2012, 05:11 PM   #6
brucifer OP
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Hey Christian!


Steve- There's some galling going on on the small end. The '97 rod looks much better but I bought a Pro-X rod kit anyhow.

I've never had to buy one of those little springs before. Do they just get weak or something?

Also Steve, look at the two gears second from right on both shafts, 5th gear I think; they both look dark like they've gotten hot. Is that normal? It's been a while since I looked at gears and don't remember.
I guess when I bust into the '95 bottom end I'll find out.
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Old 03-26-2012, 08:27 AM   #7
elsalvadorklr
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hey bruce...

Sort of related...I noticed my OLD countershaft was blue and discolored towards the output end...Where it would ride the bearing...

After looking closely and comparing to the one steve sent me...I noticed the innermost oil hole was plugged up...

So Im assuming the coloring was heat related...

might be the same with the gear although I would assume they all get like that after time no?

And sorry for asking but...

Is there anyway you can take a pic of the rear end of your bike?

Like a pic of the swingarm/frame looking straight forward?

I never could find a pic of this shot on the nets and wanted to see one after I had the crash...and was worried about the frame or swingarm being tweaked...

again good luck bud!

christian
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Old 03-26-2012, 09:19 AM   #8
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Bruce,

One of the first guys I helped here on ADV had a XR600 that quite shifting and it turned out to be that spring. It's like $3.00 or so. To dam cheap NOT to replace just cause.

The gear bluing is not from running hot it's just how Honda made them. I have a few transmissions and they are all different colors. Take a close look at the gear tooth face where it would mate with it's neighbor. Normally it's either second or third gear SETS on the XR600 that go bad. The gear tooth face will look rough, pitted. If so replace BOTH gears.
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Old 03-26-2012, 09:44 AM   #9
Ivanych
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Hi Bruce!
Accept congratulations from me!
It will be a Wonderful project!!!
OH !!!!!! How I envy You guys!!!!!!
Blue color on gears appears from nitriding (processing of details of nitrogen to increase the hardness of the surface). This process looks as overheating often.
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Old 03-26-2012, 11:39 AM   #10
elsalvadorklr
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just like the crank is...

the coloring though on my cs shaft was definitely different then the bluing...on the rod/crank

I also saw the plugged oil hole and thought...hmmm

anywhoo
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Old 03-26-2012, 12:59 PM   #11
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Christian- No problem. I'll get a pic for ya when I start the reasembly.

Steve- The rest of the gears look great. I just thought it odd that only two gears had the dark coloring.

Ivan- Hey man, good to see you! Thanks for the congrats. Again, just the two gears had me wondering.
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Old 03-26-2012, 01:01 PM   #12
elsalvadorklr
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Quote:
Originally Posted by brucifer View Post
Christian- No problem. I'll get a pic for ya when I start the reasembly.

Steve- The rest of the gears look great. I just thought it odd that only two gears had the dark coloring.

Ivan- Hey man, good to see you! Thanks for the congrats. Again, just the two gears had me wondering.
thanks bud! sounds great..

take care
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Old 03-31-2012, 06:31 PM   #13
brucifer OP
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Not too much going on right now. The frame is at my buddies house getting some paint. I did however finish pulling the engine down.
Some pics.

First, I removed the stator cover...


Then, the flwheel. No surprises here. Good. You can see some of the crappy splines on the countershaft in this pic. On to the clutch side.

Everything looks good here too. The whole thing smells like burnt oil though.

The main cases split. Looks good in here too. Nice.

The whole mess.

The first new part. Coolio.
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Old 04-02-2012, 05:50 PM   #14
brucifer OP
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Got the frame back. Did a base coat clear coat in silver. My buddy Don, who did the work, was able to pull most of the dent out of the bottom tube. Definately good enough for who it's for.


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Old 04-02-2012, 05:57 PM   #15
2manyrides
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Oh ya...dent magic! Seems like that really bothered you alot. I was dissapointed with my first frame dent to run out after a msr skid right after.

Good color to use, (silver) did you decide on the plastics?
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