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Old 04-17-2009, 10:57 PM   #1
handirifle OP
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Is it possible?

To convert an XL600R to elec start, WITHOUT replacing the motor or bike ?
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Old 04-17-2009, 11:57 PM   #2
kta
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yes
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Old 04-18-2009, 12:01 AM   #3
WhereAmI
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I for the life of me can't remember where I saw it, but someone out there makes an e-start kit but if i remember it costs somewhere between $1000-$1500
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Old 04-18-2009, 12:07 AM   #4
Zombie_Stomp
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Anything is possible, but you are going to need some money and most of an XR650L engine. There are also XL600LMs with elecric start, but being that they are more rare than the XR650Ls in the states, you might as well go with stuff from the XR650L engine.

Now, to get started, realize that one of the engine parts I'm talking about that you will need for the conversion is the left half of the crankcase. This has a shaft that the starter gear slides out on that is not present in the XL600R left case half.

So basically, you need an XR650L engine.

The battery needs to be bigger to crank the e-start, so you're looking at a customized air box. Use the XL dual carb head on the XRL engine so that you don't have to deal with single carb intake tract issues, I've been there and back with the XL frame. Just trust me on this one, or you can read through all my posts to see exactly why I am advising this.

Then you can read through a fellow XL enthusiast's thread on his use of an XR650L engine with an XL600 dual carb head on it and how the auto-decompression cam from the XR650L will not fit in the head, leading to an imperfect decompression process involving very careful use of the manual decompressor lever whilst electric starting. This would lead you to want a rare XL600LM dual carb head, which would probably have the best of both worlds: the dual carb ports and manifold with the faculties for the auto-decompression cam. Despite this, you may be able to get some machine work done to fit the more desirable cam, and you would need the XR650L rocker box to go with it. The special cam requires a hole with a spring and bushing in it to work, which could be machined. There may be other needs for the proper fitment that I can't see or remember right now.

Questions?

Edit : I revisited the thread I brought up in that link and realized that you've been there already. So don't you already know the answer?
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Zombie_Stomp screwed with this post 04-18-2009 at 12:13 AM
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Old 04-18-2009, 06:29 AM   #5
mcma111
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No
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Old 04-18-2009, 08:38 PM   #6
handirifle OP
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Quote:
Originally Posted by mcma111
No
Have we met ?
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Old 04-18-2009, 08:52 PM   #7
handirifle OP
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Well, it was a thought anyway.
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Old 04-19-2009, 12:40 PM   #8
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Have we met ?


No, I don't think so.

Why my short answer? Well to make the XL600 an electric start first you need a place to put the starter. No mounting bosses on the XL cases.

2nd, you need a starter reduction gear set, ring gear and stator cover like a XR650l.

3rd, you need a bigger battery to spin the starter. Where is it going to go??

4th, Well, I think you get the point.
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BMW's
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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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Old 04-19-2009, 08:07 PM   #9
Zombie_Stomp
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Quote:
Originally Posted by mcma111
Have we met ?


No, I don't think so.

Why my short answer? Well to make the XL600 an electric start first you need a place to put the starter. No mounting bosses on the XL cases.

2nd, you need a starter reduction gear set, ring gear and stator cover like a XR650l.

3rd, you need a bigger battery to spin the starter. Where is it going to go??

4th, Well, I think you get the point.
I thought about it more carefully and saw why the real answer was "no", which is because of this starter gear set. I remember looking at the XR650L crank case and it is shaped differently in the area around the clutch pushrod and all of that, where there is a special area for that gear not present on the XL engine cases. That's why the part about "can it be done without changing the engine" is answered with "no". But leave it to me to jabber on and on about these bikes at every opportunity.
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Old 04-20-2009, 07:37 AM   #10
mcma111
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How To Convert XL600 To Electric Start

Slap some XL600r decals on a XR650l





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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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Old 04-20-2009, 01:40 PM   #11
Seikkailu_R
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Try find decent PD04 (XL600LM or XL600RM).
Or learn to live with kickstart

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Old 04-20-2009, 01:45 PM   #12
lvdukerider
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I have owned both 1986 XL600R and 1993 XR650L and they both have their strong points. Anything is possible with enough time money but I would either get your XL in a proper state of tune and learn the starting drill, (mine was very easy to start) or just buy another bike with electric start, either to replace or augment your XL600R. I know its not what you asked but I used to try to reenginer stuff back in my younger days and kick myself today with the money and time I invested, I could have just bought some really cool new, or almost new stuff. If your just attacking this project to see if you can do it than keep us posted on your progress and disregard my comments.
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