!!! 1986 XL600R Adventure Bike Rebuild !!!

[mcma111]

I put some grease on the collar and place it in the pump.

[brucifer]

^^^What Steve said.

[mcma111]

Have you seen my engine build? Although it's a XR650l the engines are basically the same. Cylinder and head torque's are different.

http://www.advrider.com/forums/showthread.php?t=713831

[crobox]

I spent yesterday doing the other attachment arms between the pannier racks and the bike frame. You can see them in this picture...

Within the last few days I have also applied the Honda decals to the tank and put on a few coats of protective clear coat. So the tank is basically done.



I have also been working out the pannier-to-rack attachment system. I will be using lockable draw latches, McMaster Carr part number 1406A57. The goal is for them to be super easy to use, easy on and off, and lockable to the bike.

[crobox]

Thanks Steve... No I have not read your thread... but will do so today.

[davek181]

I put it in the pump assembly and carefully put the cover on. I have cocked that sleeve too in the past juggling around the kickstarter and oil tube and whatever else is in the way. Might try gluing it into place with grease for assembly.

[Carter Pewterschmidt]

Looking good so far. Word of advise on the Wiesco piston. I put one in my stock engine with stock exhaust and it pinged like crazy, even with race gas. Ran much better with the supertrapp so once that motor is together don't try using a stock muffler.

[crobox]

Thanks Carter. How many discs in your Supertrapp?

[Carter Pewterschmidt]

I run it with an open end cap. It's loud but the muffler hasn't been repacked yet. I'm doing a few upgrades to the bike in spring and I'll repack the muffler then. I'll post up a sound clip for everyone.

[crobox]

Making a new oil-tube, AKA dowel.

Turning it from a piece of 1" aluminum on my new little South Bend lathe.



Here is the new tube next to the old one. 10mm OD x 8mm ID x 7mm long



I also made new locator dowels for the cylinder head, as those were mysteriously absent. Made those from stainless. No pictures.

[crobox]

Originally Posted by Carter Pewterschmidt

I run it with an open end cap. It's loud but the muffler hasn't been repacked yet.

Like... no end on it at all?

[crobox]

A few nights ago I worked out the basics of the design for the pannier attachment system. Here is the current state of the drawing:



This is the view from the back, or wheel side, of the right-side case. The orange outer lines are the Pelican case itself. The black is the rack, which lives on the bike. And the green is the various parts that will bolt to the case and "clip," or attach, to the rack. I will have to make adjustments to the placement of the latches to accommodate the exhaust, but I will wait until I have the latches and cases in hand to fine tune that stuff.

I already ordered two Pelican 1500 cases in silver. I might paint them... not sure. I have photoshop experiments with different paint jobs, but I think there are enough photoshop images of different colored Pelican cases in this thread already!

[davek181]

Originally Posted by crobox

Thanks Carter. How many discs in your Supertrapp?

I run 12 discs. A number derived after many high speed runs up a long 7% grade on my commute home.

[Carter Pewterschmidt]

Originally Posted by crobox

Like... no end on it at all?

One of these guys



As I stated it makes some noise, but I live in Harley country so it's tame in comparison. I still do hope the re pack tones it down quite a bit. After I put this thing on I don't run out the gears as frequently as I used to in an effort of good social manners.

[crobox]

Sorry for calling you Dave, Steve. No one likes that sort of thing. My apologies.