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asf
San Francisco, CA
USA
261 Posts |
Topic started on 08/22/2006 at 11:08:34 PM
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So I have started my XR restoration and I'm going to create a photo journal of the process and of course everyone's expertise is greatly appreciated.
I've had my XR for about 6 months now, and have decided to make it a little motard project.
Today I started the diassembly. I am going to powdercoat the frame and crack open the cases. She needs a new timing chain, tensioner, and guide. I was able to get the valves close but not perfect last check. She doesnt burn any oil and starts up perfectly if I kick at the top of the stroke.
Found more rust than I wanted on the header studs, 2 of which sheared in half. Time to get a stud extractor. The two bolt method isnt getting me far enough.
all the plastics came off, tank off, most of the wiring taped and removed. Got my EBC super rotor in the mail today. Holy crap this thing is BIG.
The frame gets separated from the motor this weekend. Anyone have any tips on how to best get that motor off the frame (or vice versa?)
Anyways, this is just the start, I'll be doing the carbs, Kubiak suggested a pilot and main and seeing as how I'll be running his old exhaust, I think I'll stick to his tried and tested formula (plus we both live relatively close together and therefore same weather, altitude, etc.
Im updating the rear end to a disk setup. Welding should get started in 2 weeks...
Hopefully will get some good pictures to go with the words. |
89 XR600R - ASF's 89 XR600r Project
- Donated to the support of 4Strokes.com |
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kubiak
Madera, CA
USA
5206 Posts |
Posted on 08/23/2006 at 12:09:25 PM
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| cant wait to see the pics!!! |
89 XR600R Motard
06 XR650L Motard
06 XT225 wife's bike |
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asf
San Francisco, CA
USA
261 Posts |
Posted on 08/23/2006 at 11:58:23 PM
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Well for starters here she was the day I picked her up.
Since then I've added:
Polisport Headlight
Maier Front 250 Fender
Maier MX rear fender
Tank stickers
Seat cover
Avon gripsters
Wired up a key and speedo
Uni filter
New battery (baja designs RC car setup :))
Ditched the fork guards and boots
Baja Designs LED brake light
Front brake banjo bolt switch
What is planned:
1995 Rear end transplant
SM wheels off stock hubs
EBC rotor and pads
Galfer lines
Front and rear springs to my weight
Kubiak's custom exhaust
Misc carb and motor maintenance (happy with stock performance)
Chain and 15t front 40t rear sprocket
Clutch plates
cam chain and associated guides/tensioner/sprocket
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89 XR600R - ASF's 89 XR600r Project
- Donated to the support of 4Strokes.com |
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4Putter
New Jersey
USA
723 Posts |
Posted on 08/24/2006 at 06:21:14 AM
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What a monster. I friggin love it!  |
01 XR650R - Uncorked, pipe cored, (jetting 68S, 175), filter, Renthal Fat bars.
Son rides my 84 XR500R with Supertrapp. |
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HapyCurmudgin
Niagara, NY
USA
376 Posts |
Posted on 08/24/2006 at 06:33:39 AM
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whirjagit them 55 gallon hand guards?
them things are HUGE.
i want some, i keep getting prickers in my gloves. |
06 XR650L |
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4Putter
New Jersey
USA
723 Posts |
Posted on 08/24/2006 at 08:30:26 AM
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Happy--those are actually hi-def dvd players. The '89 600R came standard with them. |
01 XR650R - Uncorked, pipe cored, (jetting 68S, 175), filter, Renthal Fat bars.
Son rides my 84 XR500R with Supertrapp. |
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asf
San Francisco, CA
USA
261 Posts |
Posted on 08/24/2006 at 09:33:30 AM
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HapyCurmudgin,
They're great, I can actually fit a bag of groceries or small children in them when I get in a pinch.
They were acerbis guards mounted to bark busters. They were one of the first things to go! |
89 XR600R - ASF's 89 XR600r Project
- Donated to the support of 4Strokes.com |
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asf
San Francisco, CA
USA
261 Posts |
Posted on 08/24/2006 at 09:39:12 AM
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4Putter,
IT was love at first site. It basically had extremely low miles, but was cosmetically challenged. Owner said it sat outside for over 1 year uncovered after he got his new XR650r. When I got it the last shop that did the valve adjustment did one a little off, so it had a few miles with one valve a little off spec but no problems as far as I could tell. But I could tell by the way the dualsport kit was installed and the overall condition of the rest of the bike that whoever owned and worked on it before me was very careful and sprung for all the high dollar goodies. |
89 XR600R - ASF's 89 XR600r Project
- Donated to the support of 4Strokes.com |
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asf
San Francisco, CA
USA
261 Posts |
Posted on 08/29/2006 at 11:26:41 AM
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Im pulling the rear end today...a little pic of the progress so far. My spanner wrench is too big for the steering nut so...I need to wait on the proper wrench to come in, then its the motor and off to the powdercoater!
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89 XR600R - ASF's 89 XR600r Project
- Donated to the support of 4Strokes.com |
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asf
San Francisco, CA
USA
261 Posts |
Posted on 08/31/2006 at 1:29:10 PM
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Rear end is off, jets are in and ready to go into the carby (along with a bottle of carb cleaner:). Motor comes out tonight if I get the time...
One question for all, I did notice that when she was all together, the amount of air coming out of the tranny vent was enough to feel on my ankle (yes I am guilty of wearing trainers at times). Does that seem like too much and is it a sign that i should look at replacing anything specific?
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89 XR600R - ASF's 89 XR600r Project
- Donated to the support of 4Strokes.com |
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kubiak
Madera, CA
USA
5206 Posts |
Posted on 08/31/2006 at 8:42:53 PM
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| there should be air shooting out,on my new xr 650l there is air shooting out of the crankcase hose even.as long as it wasnt smoking or using too much oil it should be good for a long time still. |
89 XR600R Motard
06 XR650L Motard
06 XT225 wife's bike |
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asf
San Francisco, CA
USA
261 Posts |
Posted on 09/05/2006 at 10:36:00 PM
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Got almost everything off, steering nut was a PITA. I am stuck on the two lower engine studs, they are practically seized on the frame :( Previous owner used way too much red loctite and not enough antisieze.
Anyone know if those lower mounting studs are threaded all the way through? Can I tap them out with a punch and mallet? The nuts came right off. But the studs dont want to rotate.
Will I destroy anything if I use a 2 foot breaker bar? Are they threaded to the cases? I'm going to let them soak in WD40 and heat cycle them tomorrow, but I need to know what I am risking if I try a breaker bar on them. I tried my electric impact wrench, but it just made alot of noise and no results. |
89 XR600R - ASF's 89 XR600r Project
- Donated to the support of 4Strokes.com |
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atkxr600
Flint, MI
USA
94 Posts |
Posted on 09/06/2006 at 03:56:14 AM
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No, they are not theaded thru the frame. What has probably happened is they have accumulated some rust between the motor mount bolt, and the clearance hole in the frame.
Hit them again with the impact, try turning them in both directions. Forward/back forward/back. Hopefully that will break them loose. Then use a long steel rod to drive them through from the other side.
Try to aviod hammering on them until you have them broke loose, or you risk mushrooming the end of the bolt, then it won't ever go through that hole.
The thing about the two foot breaker bar that would scare me is breaking the the head of the bolt off. But I guess if that happens, you drive them through from that side and buy new ones. |
ATK-XR600R |
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asf
San Francisco, CA
USA
261 Posts |
Posted on 09/06/2006 at 10:42:00 PM
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atkxr600,
The front was actually siezed on the spacer. The frame is now nekkid, going to the welders and then a nice shiny powdercoat. The motor is getting opened as we speak. The motor ran so well I am hesitant to fiddle with it but putting a new chain in can do nothing but help. I'm going to inspect the valves and post some pics up soon. Thanks for all the help so far!! |
89 XR600R - ASF's 89 XR600r Project
- Donated to the support of 4Strokes.com |
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asf
San Francisco, CA
USA
261 Posts |
Posted on 09/07/2006 at 12:06:04 PM
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Pulled off the top, one of the rockers is gouged and needs replacing. I need to measure the cam lobes but all looks smooth and shiny there. The chain looks great but I am going to invest the $30 to replace it since the real investment is the time to open everything up. I dont want to have to do this again any time soon.
A few questions:
1. The shop manual said not to lose the dowel locator. What is it, where is it, and what am I looking for? I didnt see anything fall off...
2. There is a spring in the manual that goes over this small post located and the rear of the cover. What is this post and what does it do?
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89 XR600R - ASF's 89 XR600r Project
- Donated to the support of 4Strokes.com |
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atkxr600
Flint, MI
USA
94 Posts |
Posted on 09/07/2006 at 6:17:48 PM
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Theres a couple of dowels they could be referring to, the cover is located on the head with dowels. And the cam is trapped right to left with dowels. Could be either one. As far as a spring goes, I'm not sure.
There is a spring return on the decompression release, but is on the outside of the cover. Some pics Please?
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ATK-XR600R |
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Topic |
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ASF's 89 XR600r Project - Finally DONE!
