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mcma111 08-06-2011 06:16 PM

Building A XR650l Engine
 
OK for all of you folks that haven't delved into the deep inner workings of your XR650l or for that matter XR600 engine here is a by the numbers engine reassembly. Hell, anyone can take an engine apart. It's putting it back together correctly that's the bitch.

Here's the story on this poor engine. The person that I am building it for got the bike for free in a well, well done (cooked) condition. This is the most severely cooked engine I have encountered.

I saw a post from the current owner in the ADV flea market looking for a XRL engine. I recognized her avatar and sent her a PM inquiring as to why she needed a engine. Seems that she took this lump to a shop and was given a VERY high repair estimate. I told her that no matter what condition the engine was in, it could be saved.

As she didn't know me from a hole in the ground I suggested that she call my machinist, Mike, at Engine Dynamics in Petaluma for references. Upon getting a glowing recommendation from the shop she decided to bring me the engine.

I wasn't home when she dropped the engine off but upon my return later I took a quick peek and sent her an e-mail with what I saw. I looked on the computer for some parts at Cheapcycleparts and made up a list which I sent her. She placed the order and I waited for the parts to arrive.

In the mean time I took the crank assy, cylinder and head to the machine shop. She ordered a Pro-X rod and a Wiseco 101mm 10.5cr and gaskets from E-bay that were sent to the machine shop. Upon the parts arrival the machine work began.

While we were waiting for the machine work to be completed she decided to replace all of the bearings in the engine. Another Cheapcycleparts order and the wait for them to arrive. I picked up the machine work last Wednesday (which coincided with a small local brewery that has $3.00 pint day) and the bearings came in Thursday.

Today, Saturday 8/6 I started the rebuild.


Can you say TOAST

http://i479.photobucket.com/albums/r...d/DSC_0551.jpg

http://i479.photobucket.com/albums/r...d/DSC_0550.jpg

Oil? What oil???
http://i479.photobucket.com/albums/r...d/DSC_0549.jpg

By the way. Here is my garage. Aw crap. Should'a taken that bra down. Opps

http://i479.photobucket.com/albums/r...d/DSC_0498.jpg

Someone asked to see the tools for the disassembly. These should get the motor apart but by the time I'm done putting it back together I'm sure there will be a whole bunch more on the bench.

http://i479.photobucket.com/albums/r...d/DSC_0499.jpg

New OE parts

http://i479.photobucket.com/albums/r...d/DSC_0500.jpg

Some of the bearings

http://i479.photobucket.com/albums/r...d/DSC_0502.jpg

The dead rod

http://i479.photobucket.com/albums/r...d/DSC_0503.jpg

http://i479.photobucket.com/albums/r...d/DSC_0504.jpg

The new rod

http://i479.photobucket.com/albums/r...d/DSC_0505.jpg

The repaired cam center journal

http://i479.photobucket.com/albums/r...d/DSC_0506.jpg

Flip side of the head. Valve job completed.

http://i479.photobucket.com/albums/r...d/DSC_0507.jpg

The new bore

http://i479.photobucket.com/albums/r...d/DSC_0508.jpg

The new Wiseco piston

http://i479.photobucket.com/albums/r...d/DSC_0509.jpg

Look what they ship the pistons in. Ain't it cute...

http://i479.photobucket.com/albums/r...d/DSC_0510.jpg

The naked left side case

http://i479.photobucket.com/albums/r...d/DSC_0511.jpg

Right side

http://i479.photobucket.com/albums/r...d/DSC_0512.jpg

Loaded with the new bearings

http://i479.photobucket.com/albums/r...d/DSC_0514.jpg

http://i479.photobucket.com/albums/r...d/DSC_0513.jpg

Let's warm up the case to accept the crank assy

http://i479.photobucket.com/albums/r...d/DSC_0521.jpg

Lay down here it comes

http://i479.photobucket.com/albums/r...d/DSC_0516.jpg

Line up the dot's

http://i479.photobucket.com/albums/r...d/DSC_0522.jpg

The crank and counter-balancer dropped right in

http://i479.photobucket.com/albums/r...d/DSC_0523.jpg

Splines? What splines. 16,000 miles

http://i479.photobucket.com/albums/r...d/DSC_0517.jpg

http://i479.photobucket.com/albums/r...d/DSC_0518.jpg

New shaft

http://i479.photobucket.com/albums/r...d/DSC_0519.jpg

Swapping out the counter-shaft

http://i479.photobucket.com/albums/r...d/DSC_0520.jpg

So when you assemble the transmission into the left case there is a washer on the end of the counter-shaft. I put grease on the gear to hold the washer from falling off. Trick #1

http://i479.photobucket.com/albums/r...d/DSC_0525.jpg

Putting the two transmission shafts and the shift fork assy in at one time. Trick #2

http://i479.photobucket.com/albums/r...d/DSC_0528.jpg

http://i479.photobucket.com/albums/r...d/DSC_0529.jpg

http://i479.photobucket.com/albums/r...d/DSC_0530.jpg

All in

http://i479.photobucket.com/albums/r...d/DSC_0531.jpg

A little wiggling and the shift drum goes in

http://i479.photobucket.com/albums/r...d/DSC_0532.jpg

The crank and transmission in place

http://i479.photobucket.com/albums/r...d/DSC_0535.jpg

Right side engine case drops into place

http://i479.photobucket.com/albums/r...d/DSC_0536.jpg

I have this thing about putting steel bolts in aluminum cases. I oil the bolts. All of them. Trick #3

http://i479.photobucket.com/albums/r...d/DSC_0538.jpg

http://i479.photobucket.com/albums/r...d/DSC_0539.jpg

The star part on the end of the shift drum

http://i479.photobucket.com/albums/r...d/DSC_0541.jpg

The bottom end together

http://i479.photobucket.com/albums/r...d/DSC_0542.jpg

Priming the oil pump

http://i479.photobucket.com/albums/r...d/DSC_0543.jpg

Don't forget the dowel for the pump

http://i479.photobucket.com/albums/r...d/DSC_0544.jpg

Oil pump in place. The dowel that goes between the oil pump and the clutch cover gets grease to keep it from jumping ship. Trick #4

http://i479.photobucket.com/albums/r...d/DSC_0547.jpg

http://i479.photobucket.com/albums/r...d/DSC_0548.jpg


Gunning on the cam drive and clutch drive sprockets along with the pulse generator trigger.

http://i479.photobucket.com/albums/r...d/DSC_0546.jpg

New clutch

http://i479.photobucket.com/albums/r...d/DSC_0552.jpg

Don't forget to oil the friction plates. I cut the blister off of the package to oil the plates in. Trick #5

http://i479.photobucket.com/albums/r...d/DSC_0553.jpg

Gun on the new clutch hub. Who ever disassembled the engine broke one of the spring posts off. Doh

http://i479.photobucket.com/albums/r...d/DSC_0554.jpg

Clutch hub holder. With all of the plates in place you hold the hub like this as you gun the nut on. Easy Peasy. Trick #6

http://i479.photobucket.com/albums/r...d/DSC_0555.jpg

What's missing here?? I forgot to put the cam chain tensioner guide in. Off comes the clutch assy.

http://i479.photobucket.com/albums/r...d/DSC_0556.jpg

Outer clutch hub. Don't forget the bearing and push rod cap.

http://i479.photobucket.com/albums/r...d/DSC_0557.jpg

Clutch side done. I leave the clutch cover off until I have the cam in place as it makes getting the cam chain onto the drive sprocket much easier. trick #7

http://i479.photobucket.com/albums/r...d/DSC_0558.jpg

mcma111 08-06-2011 06:30 PM

OK, the bottom end is done. Now for the top end.

Make sure the cylinder is really clean. Yes, there was some black stuff on the cloth after I wiped down the cylinder.

http://i479.photobucket.com/albums/r...d/DSC_0559.jpg

Put a ring in the cylinder and push it down 1" with the piston

http://i479.photobucket.com/albums/r...d/DSC_0560.jpg

Checking ring end gap. With Wiseco piston sets it seems like I never have to file fit the rings.

http://i479.photobucket.com/albums/r...d/DSC_0561.jpg

Put one of the wrist pin keeper clips on and apply some assembly lune

http://i479.photobucket.com/albums/r...d/DSC_0563.jpg

Lube the rod

http://i479.photobucket.com/albums/r...d/DSC_0564.jpg

Pin in place and the other pin keeper clip in

http://i479.photobucket.com/albums/r...d/DSC_0565.jpg

Ring compressor with a couple of pieces of 3/4" ply to hold the piston still while I install the cylinder

http://i479.photobucket.com/albums/r...d/DSC_0566.jpg

Oil them bolts

http://i479.photobucket.com/albums/r...d/DSC_0567.jpg

And the washers, per the factory service manual

http://i479.photobucket.com/albums/r...d/DSC_0568.jpg

Torquing down the cylinder. 36lbs in 2 steps

http://i479.photobucket.com/albums/r...d/DSC_0569.jpg

mcma111 08-06-2011 06:53 PM

My cam chain tensioner holder.

http://i479.photobucket.com/albums/r...d/DSC_0570.jpg

Install the tensioner and hold it all of the way back

http://i479.photobucket.com/albums/r...d/DSC_0571.jpg

Place the screw driver like this and tap it with the hammer

http://i479.photobucket.com/albums/r...d/DSC_0572.jpg

Tensioner held in place

http://i479.photobucket.com/albums/r...d/DSC_0573.jpg

Dowels and head gasket in place

http://i479.photobucket.com/albums/r...d/DSC_0574.jpg

Torquing the cylinder head. 25lbs in 3 steps

http://i479.photobucket.com/albums/r...d/DSC_0575.jpg

Starter ring gear goes on

http://i479.photobucket.com/albums/r...d/DSC_0576.jpg

Goop up the stator wire grommet

http://i479.photobucket.com/albums/r...d/DSC_0577.jpg

Starter reduction gears go on

http://i479.photobucket.com/albums/r...d/DSC_0578.jpg

Stator cover on

http://i479.photobucket.com/albums/r...d/DSC_0579.jpg

Don't forget to route the wires through here

http://i479.photobucket.com/albums/r...d/DSC_0583.jpg

Starter on

http://i479.photobucket.com/albums/r...d/DSC_0580.jpg

Starter gear cover on. Notice I had the stator wires routed incorrectly here

http://i479.photobucket.com/albums/r...d/DSC_0581.jpg

The neutral switch has a really small thread. Be very careful that you don't over tighten the nut or you'll be buying a new switch. Ask me how I know this. Thanks son...

http://i479.photobucket.com/albums/r...d/DSC_0582.jpg

On to the cam installation. Don't forget this little fella. Part of the cam auto decompressor assy

http://i479.photobucket.com/albums/r...d/DSC_0584.jpg

The cam center journal gets a dollop of assembly lube and the cam goes in

http://i479.photobucket.com/albums/r...d/DSC_0585.jpg

Piston at TDC, cam drive sprocket marks aligned

http://i479.photobucket.com/albums/r...d/DSC_0586.jpg

On to the rocker cover. The rockers were TOAST

http://i479.photobucket.com/albums/r...d/DSC_0587.jpg

http://i479.photobucket.com/albums/r...d/DSC_0588.jpg

The cam hardly had any wear but it was bad none the less

http://i479.photobucket.com/albums/r...d/DSC_0589.jpg

http://i479.photobucket.com/albums/r...d/DSC_0590.jpg

Reusing the steel, laminated rocker cover gasket. Wipe it down with lacquer thinner and place it on a piece of cardboard. Smear a thin coat of Hondabond on the bottom side of it

http://i479.photobucket.com/albums/r...d/DSC_0591.jpg

A thin coat on the head

http://i479.photobucket.com/albums/r...d/DSC_0592.jpg

The top of the gasket

http://i479.photobucket.com/albums/r...d/DSC_0594.jpg

And the rocker cover. Notice the new rocker arms

http://i479.photobucket.com/albums/r...d/DSC_0593.jpg



http://i479.photobucket.com/albums/r...d/DSC_0593.jpg

http://i479.photobucket.com/albums/r...d/DSC_0593.jpg

Seal the rocker arm shafts. The rubber bands hold the rocker arms up in position. Trick #8 Trick

http://i479.photobucket.com/albums/r...d/DSC_0595.jpg

mcma111 08-06-2011 06:54 PM

The rocker cover in place. This is where I called it for the day

http://i479.photobucket.com/albums/r...d/DSC_0597.jpg

techforlife 08-06-2011 06:56 PM

:clap

You puttin in the NX 2nd aren`t you Steve.........:ear

That center journal repair looks odd......is it smooth where the cam sits???? it looks rough.also rough where the gasket goes too.could just be the pics though,just wondering.......good job...:freaky


B

mcma111 08-06-2011 06:57 PM

The guy that took the engine apart lost some of the fasteners. Luckily I have this

http://i479.photobucket.com/albums/r...d/DSC_0596.jpg

mcma111 08-06-2011 07:00 PM

The NX650 gear is in the picture of all the OE parts. The cam journal looks weird but is smooth. There is a couple of pimples where the gasket goes but it is of no matter. The sealant will take care of that.

Wattner 08-06-2011 07:12 PM

WOW.... That is AWESOME!!!!!! Thanks Steve :clap:clap:norton:clap:clap

thebigman 08-06-2011 07:17 PM

Subscribed to xr650l engines , 1301 , credit course. :deal

techforlife 08-06-2011 07:23 PM

Quote:

Originally Posted by mcma111 (Post 16567909)
The NX650 gear is in the picture of all the OE parts. The cam journal looks weird but is smooth. There is a couple of pimples where the gasket goes but it is of no matter. The sealant will take care of that.

Yup i thought you were puttin in the NX gear,,i saw it in the photo...Steve what do they charge to repair the center journal,,just for my records:wink:

B

Reposado1800 08-06-2011 07:24 PM

Did you put in an extra used cam or get that old one reground?

mcma111 08-06-2011 07:35 PM

B,

I forget how much he charged for the journal repair. The bill has all of the labor lumped together.

Clayjars

I used one of my spare OE cams. I'll probably keep the damaged one for a Mega Cycle core if I do one some day. No sense in using a perfectly good cam if I have a damaged one.

techforlife 08-06-2011 07:39 PM

Quote:

Originally Posted by mcma111 (Post 16568141)
B,

I forget how much he charged for the journal repair. The bill has all of the labor lumped together.

Clayjars

I used one of my spare OE cams. I'll probably keep the damaged one for a Mega Cycle core if I do one some day. No sense in using a perfectly good cam if I have a damaged one.


Hummmmmm........what would you charge me for that cam Steve,,after it`s been welded up by Mega Cycle....i`m thinkin of goin into the motor again this winter for a cam upgrade:wink::wink::wink::wink:

:freaky

:deal

B

brucifer 08-06-2011 07:44 PM

Make sure that one thing goes on top of that deal. :lol3

mcma111 08-06-2011 07:44 PM

Between the regrind cam and the rocker arms it's about $500.00. I think it's $214.00 or so for the cam and $62.00 for each rocker arm.


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