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Old 11-18-2014, 08:04 PM   #1
Bluffskier OP
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Long story short, I'm building, in the planning phase, a light (er) weight XRL using an xr600 bottom end with some parts swapped over, but was wondering what was the lightest years of the XR600 engine.

I saw a reference to '88 and '89 as being lighter overall and engine internals were lighter as well.

Wondering if this is true and how much lighter they actually are than mid 90's engine.

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Old 11-18-2014, 08:12 PM   #2
AZ TOM
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I could be wrong but I think the lighter weight was frame & bike. Engine I think similar less E-start?
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Old 11-18-2014, 08:41 PM   #3
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Sounds about right IMO.

Yea this "Back to the Future" plan of building this bike from an older XR came to me after deciding to put a kick start on my '07 XRL, NX650 5th and a lower 2nd, so I was thinking, why not put in a higher compression piston like an XRR one? Well, the bike runs out of revs like super fast, by the time I get the front end off the ground I'm out of steam, so I was reading how an XRR bottom end, with the XRL cylinder and an over sized XRR piston might fit the bill, bore it out to a comparable 650ish size and use my clutch basket and primary from the L. Then put my electronics on a diet.
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Old 11-18-2014, 08:41 PM   #4
BIG ED XT FAN
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Laugh XR 600 Motor?

All xr 600 are the same in weight!!!!
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Old 11-18-2014, 08:57 PM   #5
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The ones with single carbs
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Old 11-19-2014, 04:21 AM   #6
Bluffskier OP
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Sweet... now to find a xr600r engine!

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Old 11-19-2014, 08:46 AM   #7
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Pretty sure the '88/'89 XR600R's had a plated cylinder. Which weighs less than an iron liner. So going big-bore on that motor kinda looses that advantage.
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Old 11-19-2014, 09:38 AM   #8
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The manual for the XR600 states 43.5 kg for the motor.
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Old 11-19-2014, 10:42 AM   #9
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If your looking for more rpm Main Jet aka CW can build you a 750 short stroke roller rocker XR650L motor. Apparently the front wheel doesn't like to stay on the ground in any gear.


I may ride a little fast and someday it may catch up and bite me in the ass but maybe not if I give it just a little more gas.
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Old 11-19-2014, 10:47 AM   #10
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dont get me started guys Ill be back with a vengeance

here goes

88-90 were the bling years of xr600 doesnt mean they are the best just bling and YES lighter

first off engine:

lightened idle, starter and balancer gears
clutch gear(cant remeber)
when I say lightened they are NOT thinner or different shape they have holes in them to save weight
nicasil plated cylinder(no liner, so yes lighter)
lighter exhaust and pipes the pipes weigh nothing!
the balancer weight is rebuildable it has springs inside the gear itself is a twin gear gear that snaps into place when you rebuild with the crank
yes its lighter and smoother as there is no slop between the crank gear and balancer
other year balancers are solid

PISTONs on 88-90 bikes are shallower skirt and slightly lighter than other years they also have a smaller piston pin length and weigh signficantly less than newer years

all in all when I investigated how much lighter the 88-90 engines where its not enough to say wow, however those in the know would argue the engine was 1-2lbs lighter.

now when you take into account the stainless extremely thin walled pipes and very light exhaust(even though its crappy black) you do have more savings

also the engine sides covers are magnesium over alloy more grams saved there and the rear wheel drum is magnesium like earlier year xrs as well.


88-90 bikes overall are around 8-10lbs lighter than say a late model xr600.


on my rebuild thread you can see my 88 rebuild wieght including usds and a smaller oem replacement clarke tank.

however my wheels were new black heavier rims, and the stainless spokes added much weight over stock, I also had guards and a bag and heavy tires(thick tubes)

stock rims and spokes are much lighter than replacements stainless spokes, same applies to sprockets

cheers

cant remember my weight exactly but for some reason 287lb with oil sounds about right I just called it a sub 300lbs missile since Im small it doesnt matter if its 250lb or 350lb they suck equally once I go down which I did a lot! jajaj
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Old 11-19-2014, 11:04 AM   #11
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dont get me started guys Ill be back with a vengeance

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Old 11-19-2014, 11:06 AM   #12
mcma111
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BTW....

Excel rims are lighter than the much thicker OE DID rims.

Yes the 9 gauge stainless spokes are slightly heavier than the OE spokes but their strength make up for it.
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Old 11-19-2014, 11:43 AM   #13
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Quote:
Originally Posted by Bluffskier View Post
Long story short, I'm building, in the planning phase, a light (er) weight XRL using an xr600 bottom end with some parts swapped over...
I've already done that.

I bought a running XR600R and used everything I wanted off of it and put it onto the XR650L frame. I had a pretty good idea third gear in the XR600R was bad when I bought it, but I wanted to do some transmission gear swapping anyway.

The frame was pretty hammered on the donor bike and wheel bearings were shot, but I wasn't using any of those.

So, I got the XR600R engine into the XR650L, used the XR600R carb, but kept all the XR650L electronics intact, just swapped over the XR650L stator and pulse coil to the XR600R engine.

I used a bunch of other XR600R small parts too. I have a spare set of wheels with dirt tires too if I decide to use them. Of course the rear only fits if it's from the later models. 88-90 still had a rear drum brake.

The pulser (the thing with the tab that triggers the pulse coil) on the XR600R and XR650L engine will swap either way, but one of them has a longer tab. I don't know how that would affect the XR650L CDI using the XR600R pulser and I couldn't tell any difference from originally using the XR600R one then switching to the XR650L one after the engine rebuild and gear swap.

I used the XRL primary gears, XRL first gear, NX second and Euro NX fifth gear. I went with 15/48 sprockets and with that combination I have overall lower gearing but only increased the RPM by 60 (yes 60, not 600) compared to a completely stock XR650L at ~60-65mph. Which is thanks to the NX fifth gear.

I too wanted to use a 88-90 engine, mostly because I wanted the plated cylinder for it's heat dispersion quality, but the magnesium side covers and lightened gears would have been a nice addition. The problem is finding one that has the original cylinder that hasn't been sleeved.

I do have a 88-90 exhaust, but that is going on my XL600R (if it fits) because it's more of a street only ride and I don't want to damage such a hard to find OEM part.

My whole reasoning for using the XR600R engine is that I feel the kickstart is easy enough and it was a quick way to drop some weight off of the bike and gaining a little more performance while keeping the engine stock except for a stock size overbore to clean the cylinder up. Fuel economy didn't take a hit either, it's still pretty much the same as with the XR650L engine, just has a little more zip.
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Old 11-19-2014, 06:03 PM   #14
elsalvadorklr
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Quote:
Originally Posted by mcma111 View Post
BTW....

Excel rims are lighter than the much thicker OE DID rims.

Yes the 9 gauge stainless spokes are slightly heavier than the OE spokes but their strength make up for it.
than the xrl RIMS YES

not the xr600 jajaja

remember the xrl rims are double walled and weird 32ffront vs 36 spoke

the stainless spokes arent "slightly" heavier they are almost twice as heavy, however yes they are stronger


its good to be back nothing like having steve slam ya


jajajaja
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Old 11-20-2014, 06:47 AM   #15
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Thank you so much for your replies. I have some more insight, just need to part out my Waveblaster and wait for a bike to pop up on CL or the forums.

Wonderer, that's pretty much what I have in mind, might tinker around and swap the cdi and electrical, there are some good threads on the out there too, but don't was the extra heat.

Elsalvadorklr, I might source the 89 xrr, being every pound counts as your dropping weight, but will moat likely end up with a mid 90's hoopty to build from.

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