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Old 05-22-2014, 10:24 AM   #1
JDouglas OP
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Joined: Aug 2013
Location: Pacifist Northwest
Oddometer: 22
Wicked Have XR650L, Need Duct Tape

I picked this up last night. I knew the owner. His son had been riding it home from work last July when the son was struck by a drunk driver.

The son survived with some deficit.

The bike did suprisingly well. The damage is focused on the forks and handle bar. The front rotor is bent, fork tubes bent, clutch lever is broken, shift level is bent, (L) foot peg mount is bent in, turn signals broken and mounts snapped, plastics on front cracked, and the tank is dented. The bike will need to be inspected and re-titled when the work is done because the insurance company wrote it off.

The bike sat in an evidence yard for 10 months while the case was adjudicated. A quick once over and 10 minutes on a charger and it started right up. (Ironic as if I leave a battery on for ten minutes it will never start again.)

There are some pictures below. Also one bonus picture of the garage associated with the previous owner, which leads me to believe it was well maintained.










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Old 05-22-2014, 10:55 AM   #2
mcma111
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Easy Peasy. A few hours of wrenching and it will be like new.
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Old 05-22-2014, 11:21 AM   #3
Kyron
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That'll buff out

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Old 05-22-2014, 11:29 AM   #4
gravityisnotmyfriend
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Location: ((kg*m)/s^2), IA, USA
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Looks like an opportunity for a USD conversion.
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Old 05-22-2014, 12:23 PM   #5
ThumpnRed
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The forks might not be damaged... just twisted in the triples. Loosen up the clamping bolts and axle and see if it doesn't come back into shape.
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Old 05-22-2014, 03:49 PM   #6
smokeeater495
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Location: N.E. Indiana
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I agree on USD fork conversion. Or maybe an XR650R front end from Ebay. Then throw on an Acerbis or Clark gas tank.
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Old 05-22-2014, 04:28 PM   #7
JDouglas OP
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Quote:
Originally Posted by ThumpnRed View Post
The forks might not be damaged... just twisted in the triples. Loosen up the clamping bolts and axle and see if it doesn't come back into shape.

Sadly, any hope of that is gone.



So there may be hope that can be straightened since it's not creased, but then I saw this:



I can't imagine that can't be fixed (with any reliability) and still maintain a decent seal, can it?

As for the fuel tank, he tossed one in with the purchase, so I got that going for me. (Gunga, gunga, galunga.)

Being new to the XR650L, I will search the wisdom of the forums for this USD conversion of which you speak.
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Old 05-22-2014, 04:55 PM   #8
ThumpnRed
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It's toast. USD conversions can be really easy (and expensive) or a tad more complicated (and usually cheaper). The easiest is to get a CRFX front end and RSW triple clamps. You can then keep your stock speedo and everything bolts right on. Or... you can do the frankenstein route and use whatever forks you come across and figure it out as you go. I chose the later cuz I am CHEAP!


Quote:
Originally Posted by JDouglas View Post
Sadly, any hope of that is gone.



So there may be hope that can be straightened since it's not creased, but then I saw this:



I can't imagine that can't be fixed (with any reliability) and still maintain a decent seal, can it?

As for the fuel tank, he tossed one in with the purchase, so I got that going for me. (Gunga, gunga, galunga.)

Being new to the XR650L, I will search the wisdom of the forums for this USD conversion of which you speak.
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Originally Posted by Cigar Mike :With plastic buy two.
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Old 05-23-2014, 06:59 AM   #9
Kawidad
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You might check very carefully around the headstock, oil tank, down tube area. My buddy picked up an XRL that looked much like that and to his surprise he found the frame was bent in that area. The frame was not salvageable. The metal in that area is much thinner than it appears to be.
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Old 05-23-2014, 08:17 AM   #10
Stretch67
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Quote:
Originally Posted by Kawidad View Post
You might check very carefully around the headstock, oil tank, down tube area. My buddy picked up an XRL that looked much like that and to his surprise he found the frame was bent in that area. The frame was not salvageable. The metal in that area is much thinner than it appears to be.
He is at an advantage in that the bike had been in an impound lot for ten months... plenty of time for rust to develop in any frame cracks, making them easy to spot.
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Old 05-25-2014, 06:28 PM   #11
JDouglas OP
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I managed to find a single left fork leg on eBay cheap. It will work to get the bike operable and give me an idea of what to do long term. Funny that a rotor is going to be more expensive than fixing the suspension.
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Old 05-29-2014, 10:00 AM   #12
JDouglas OP
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Mission creep...

This was going to be a simple repair and go, but I'm not very skilled at simple.

I "had" to have the foot peg mount repaired. If I was going to do that, then why not have the frame powder coated and rebuild the motor. While I'm at it, why not big bore the thing, throw some heat sinks on, add an oil cooler, and forget about riding it any time soon or inexpensively. (As an aside, this is how my education went. I will have a PhD soon because I didn't understand something years ago.)

Some dissembling work.





Bathe the cat


Dissemble more:




Wish I was here:


Went to a shop and saw this.... It must be voodoo!
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Old 05-29-2014, 10:02 AM   #13
JDouglas OP
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Anyone know a decent machine shop to bore and hone this in South Puget Sound?
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Old 07-16-2014, 11:54 AM   #14
JDouglas OP
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July 16th Update on Progress

If you're interested, here is an update on my progress. I have the bike down to each individual part for inspection, repair, replacement or upgrade. I want this bike to be a long term adventurer, so I'm going to do it right to the best of my abilities. I'll be at it for some time, but I want to make it my "dream bike" without being too ridiculous.

I've started with the motor and frame.

Hotcams Stage 1 Cam https://www.thumpertalk.com/shop/Hot...-p4086972.html

Wiseco Piston https://www.thumpertalk.com/shop/Wis...-p4127844.html

Blockoff Kit (Smog Octopus Thingy Removal) https://www.thumpertalk.com/shop/IMS...-p4130506.html

Big Fin Welding and Port / Polish from XRsOnly http://www.xrsonly.com

I had the overbore done by Morrie at "The Wheelmaster" http://thewheelmaster.com/ This guy is awesome

I had the entire motor coated by Performance Coatings. They prepped and cleaned the surfaces and coated it with a thermo-dispersant coating to help keep the temperature down. http://www.performancecoatings.com/

I welded the damaged foot peg back to proper and then had it stripped /powder coated by Performance Coatings as well.

In retrospect, I should have added gussets to the rear frame. Having it already powder-coated is a dilemma. I may yet convince myself to do it.

I have ordered a 2nd gear (NX650) from partzilla. I dont like partzilla much but after calling and confirming they actually had the item in stock I did order it. The second gear OEM part number for 16T is 23421-MN9-010 and can be found here: http://www.partzilla.com/parts/detai...1-MN9-010.html

I also ordered the 5th gear. The best price I could find for it was from Japan. With shipping it was under 100 USD. YMMV with the exchange rate. The OEM part number is 23491-MW-2-780 and I found it here: http://www.motobike.jp/product/4586

Bigger Stator from procycle which reports a 25% increase to 260watts. http://www.procycle.us/bikepages/xr650l.html#electrical

Thats where I'm at right now. I'll update when I accomplish more. Oil cooler, carb and other motor bits still to do. Suggestions are always welcome.

Piece and Part Porn:



















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Old 07-16-2014, 12:34 PM   #15
mcma111
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Hot Cam...
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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
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