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Old 08-06-2011, 05:16 PM   #1
mcma111 OP
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Joined: Jul 2007
Location: San Francisco,Ca.
Oddometer: 10,085
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





Oil? What oil???


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



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.



New OE parts



Some of the bearings



The dead rod





The new rod



The repaired cam center journal



Flip side of the head. Valve job completed.



The new bore



The new Wiseco piston



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



The naked left side case



Right side



Loaded with the new bearings





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



Lay down here it comes



Line up the dot's



The crank and counter-balancer dropped right in



Splines? What splines. 16,000 miles





New shaft



Swapping out the counter-shaft



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



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







All in



A little wiggling and the shift drum goes in



The crank and transmission in place



Right side engine case drops into place



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





The star part on the end of the shift drum



The bottom end together



Priming the oil pump



Don't forget the dowel for the pump



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






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



New clutch



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



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



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



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



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



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

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Steve in SF

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

mcma111 screwed with this post 08-06-2011 at 06:41 PM
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Old 08-06-2011, 05:30 PM   #2
mcma111 OP
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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.



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



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



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



Lube the rod



Pin in place and the other pin keeper clip in



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



Oil them bolts



And the washers, per the factory service manual



Torquing down the cylinder. 36lbs in 2 steps

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Steve in SF

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 08-06-2011, 05:53 PM   #3
mcma111 OP
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My cam chain tensioner holder.



Install the tensioner and hold it all of the way back



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



Tensioner held in place



Dowels and head gasket in place



Torquing the cylinder head. 25lbs in 3 steps



Starter ring gear goes on



Goop up the stator wire grommet



Starter reduction gears go on



Stator cover on



Don't forget to route the wires through here



Starter on



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



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...



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



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



Piston at TDC, cam drive sprocket marks aligned



On to the rocker cover. The rockers were TOAST





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





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



A thin coat on the head



The top of the gasket



And the rocker cover. Notice the new rocker arms









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

__________________
Steve in SF

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

mcma111 screwed with this post 10-02-2012 at 03:55 PM
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Old 08-06-2011, 05:54 PM   #4
mcma111 OP
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The rocker cover in place. This is where I called it for the day

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Steve in SF

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 08-06-2011, 05:57 PM   #5
mcma111 OP
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The guy that took the engine apart lost some of the fasteners. Luckily I have this

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Steve in SF

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 08-06-2011, 06:00 PM   #6
mcma111 OP
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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.
__________________
Steve in SF

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 10-02-2012, 01:19 PM   #7
Ben99r1
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A thin coat on the head



The top of the gasket

Steve. I need some advice. I have a oil leak coming from the bottom of the dowel on the cylinder cover. Its the dowel on the other side of the cam sprocket. I think the problem is the bolt broke when the motor was being taken apart. It was drilled out and a sert/helicoil was placed in. I don't think it was placed in far enough. That's what is causing the oil leak. I plan to take the cylinder cover off when a new dowel comes in. My plan to fix this is to file down the new dowel whatever is sticking out more than the dowel on the other side. Do you think that would work? Or can you suggest a way that might work to fix the problem? Thanks, Ben

Ben99r1 screwed with this post 10-02-2012 at 01:28 PM
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Old 10-02-2012, 03:29 PM   #8
mcma111 OP
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If you have to Heli-Coil a dowel hole it should be big enough to keep using the dowel. You can use the rocker cover as a guide. Keep the other dowel in place and bolts on either side of the drilled hole. Make sure that the dowel has clearance, is short enough so that it keeps the rocker cover from mating to the head. You may have to shorten the dowel. When installing a Heli-Coil be sure that the top coil is between one to two threads below the surface of the head.
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Steve in SF

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 08-06-2011, 05:56 PM   #9
techforlife
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You puttin in the NX 2nd aren`t you Steve.........

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...


B
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Old 05-07-2013, 07:24 PM   #10
JSeward
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Question piston direction

Quote:
Originally Posted by mcma111 View Post
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.



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



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



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



Lube the rod



Pin in place and the other pin keeper clip in



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



Oil them bolts



And the washers, per the factory service manual



Torquing down the cylinder. 36lbs in 2 steps

Hi Brilliant thread, has helped me heaps with my NX650 rebuild/custom. Just a query, though, does it matter that the arrow on the piston in the photos is pointing to the exhaust rather than the inlet ? manuals I've read says needs to point to the inlet, and now I'm a bit confused. Spose it depends on the piston geometry? i.e. if its symetrical it doesnt matter
CHeers
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Old 05-07-2013, 08:33 PM   #11
mcma111 OP
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Different pistons have different marking. The piston pictured is a Wiseco and there is a small arrow pointing toward the exhaust.

This is my other XRL with a JE piston. Bigger valve pockets on the intake side:

__________________
Steve in SF

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 05-10-2013, 04:06 PM   #12
JSeward
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Thanks for clearing that up. The piston I am looking at it a flat top and I am pretty sure it's a wossner but can't find any info on the direction of the arrow

Cheers

JSeward screwed with this post 05-10-2013 at 04:21 PM
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Old 06-15-2013, 01:20 AM   #13
Notabiker
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Location: Used to be middle of Alaska, now 400 miles south!!
Oddometer: 22
I'm always of mind that the money you spend on tools to do it yourself will pay for themselves in not having to pay someone else to do work later on down the road. This thread has been helpful, I'm in the process of tearing down my xrl that overheated in a +40mph headwind trying to do 65+ with less than optimal jetting DOH! As soon as I started slightly slowing down and more throttle didn't do anything I hit the kill switch and let it cool, rode back the 20 miles keeping to 4th and using a little 1/2 choke just to make certain. That was two summers ago (not counting this one) and it was fine except for the slight burning oil smell on decel. Until this spring when it decided to smoke up a two stroke style storm while accel during warmup. My machine shop here has the jug and it's barely scuffed up with one small groove that they say will hone out just fine. Just shined up the skirt a hair and ordering new rings soon. Oh and valve stem seals as that could be part to blame. Stupid thing is sitting in the garage with an unlucky 5777.2 miles on it. I think next time I'm going with a Doctor, just have to reinforce that gangly oil cooler hanging off the side :) (Gotta justify the welder somehow right!)

Oh and a xr650r style CS sprocket. Is there any issues with chain alignment or is it all good?
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Old 08-06-2011, 07:31 PM   #14
notaduc
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Wow, amazing write up/photo essay!!!!!

But what happened to the part where you press the crank apart, install the new connecting rod, then press it back together and dial indicate it back to zero?
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Old 08-06-2011, 07:33 PM   #15
mcma111 OP
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Quote:
Originally Posted by notaduc View Post
Wow, amazing write up/photo essay!!!!!

But what happened to the part where you press the crank apart, install the new connecting rod, then press it back together and dial indicate it back to zero?

That part is done by my machinist. I have asked to see some of his operations but he won't let me watch...
__________________
Steve in SF

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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