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idler 09-28-2013 04:41 AM

xr600 single handed rebuild with a twist
Hi Guys,

I have loved reading the xr rebuilds and have wanted one for a while so here is my single handed rebuild (i broke my arm a couple of weeks back) with lots of pics, and a few new ideas.

Ethanol is cheap here and i am considering setting it up to run on that.

Anyways, on thursday i almost got a free bike as the seller was so stoned he droped the cash which i saw driving out. I gave it back to him and he recounted it!?!

the bike is somewhat rough but i think the motor may have been rebuilt possibly with a 630 cylinder? the seller had a crack at making into a 'desert racer' he said. I understand this to mean he threw away the headlight etc... and put on a big tank.

i stripped it down today, and there are some issues;
1 the kickstart is welded on
2 he said the bike splutters at high rpm - stators??
3 the carb seems to stick

the plan is to put it back on the road so it will need lights, blinkers, mirrors, and a kickstand switch.

the frame will get reinforced and then powdercoated

considering rebuilding the motor - can i trust him? out put splines are average. i will sort some more photos out tomorrow. welcome on board and i look forward to your advice.


idler 09-28-2013 05:02 AM

idler 09-28-2013 05:03 AM

mcma111 09-28-2013 08:43 AM

Trust only yourself. You can't go wrong.

idler 09-28-2013 01:29 PM

looks like the motor is getting rebuilt then.

its a 1990 motor - what would you change/upgrade?

I think for ethanol i can increease the CR.

has anyone ever tried total seal piston rings?

does the barrel look stock to you folk?

finally does anyone know of a good powdercoating joint in melbourne?

mcma111 09-28-2013 01:55 PM


Originally Posted by idler (Post 22434069)

does the barrel look stock to you folk?

Yes. My X-Ray glasses are in the shop for service so I can't say anything about inside.

adventurer 09-28-2013 03:56 PM

Gday Tc
Congratulations on the purchase, I saw it listed on Ebay the other week.
There are quite a few XR600 guys in Australia on this board and we also have a thread in the Australian area of this board.
Did the bike come with the compliance plate as I noticed that its not on the bike and I think you need that for registration?
Anyway good luck, looks like a great project and there is plenty of guys on this forum passionate about the XR600 to offer advice.


Mike the Yank 09-28-2013 10:31 PM

Nice pick up!
I don't think you need a kick stand switch over here.
Aftermarket is your friend! :rofl
I had a bad stator, ran smooth, didn't start for crap though, I think you should look at carb for high speed miss.
Chech the carb cables on the right side where they pass the frame for the sticking carb issue.
Good luck, they are a beast when they run right.

idler 09-29-2013 03:37 AM

idler 09-29-2013 03:46 AM

it was all going so well and then i had to call it a day

so i am buying a drill tomorrow then i guess.

Thanks for your advice and comments, As for the compliance plates i checked the frame and engine numbers which are present. I did not know anything about a compliance plate, can i persuade vic roads with the frame and engine numbers if it has been registerd before?

WTFMATE 09-29-2013 04:28 AM

Chuck the VIN in here mate and see if its been rego'd before

I have been told that if it has previously rego'd you can get away with no compliance plate.

You may also want to go here and do a search to see if it is stolen or written off

It can be a bit tricky to work out how to get the search certificate, make sure you download the PDF report at the end.

idler 09-29-2013 05:43 PM

Brilliant advice - i have ran both and she was registered and is clear of any history. I will confirm that i can register her without the CP with vic roads.

found out she is actually an 89.

idler 10-01-2013 04:44 AM

I am quite good at starting projects and not so great at finishing them so I have decided to push forwards with this one and get the frame shot blasted and powdercoated.

I went to a local firm; Mansutti Bros who i thought would be a couple of brothers in a shed but turned out to be quite a big company. I agreed on $150 for the powdercoating and a small amount of prep - I stripped the frame before but they will have to blast away the rust.

Having got shot of that I pulled the head of the motor;

this is the first time i have seen a bearing not supported all the way around

I am guessing this cam has been replaced as the wear does not look like 23 years of use.

my spanners are not the greatest - they wanted to round the head of the bolt because their jaws were made slightly to wide. I have made the difficult decision to treat my self to a decent set.

96.5mm, looks pretty good;

I had to stop here as my sockets are to wide to extract the cylinder bolts.

The plan is to hold onto this bike for a long time, I already know we are going to get along. I say this because you might wonder why go any further but I am going to rebuild her from the ground up firstly so i know she is sound and secondly because this is stralia and i want to find whats out there.

Homerb 10-01-2013 05:00 AM

Look after that camshaft, Idler, theyre no longer available from Honda and as rare as rocking horse poo used.
I rebuilt my XL600RMG earlier this year, and found the best prices for parts was from, in the US if you dont mind the wait.

Mike the Yank 10-02-2013 01:36 AM

By this pic I think you need at least one rocker, and I would have a real good look at your cam. Rockers are still available, and Steve aka MCMA from the Yank 600 board might be able to help with a cam if you have the time. They are "Hard faced" so once the wear goes past the hardned part they wear quick.
Keep up the good work!

Edit: looked again maybe it is just the angle of the shine?

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