XR600- Donkey Fix Up & Full Rebuild

SlickSix · 06-01-2012, 03:51 PM

Hey guys, I´ve been a Iong time lurker around the site but never took the time to sign up, didn´t think I could contribute that much.
This just changed

so let´s see if I´m worthy...

I ride the streets but was always looking out to see if the opportunity presented itself and I could bring home my first love - the XR600.

Since I was around 13 and a few of my friends older brothers started showing up with that mean, bada**** XRs, Huskys and Husas, I wanted one.
That growl coming up the street...was my wet dream at the time.
Got older and somehow the bike elluded me. Rode some CRM125, DTR125, Bandit400, CBR F3 and now the F4i Sport.

Well, last week it finally happened, I just picked up my donkey

**Update**

Ok, just thought I would update this first post to give you an ideia of what to expect of this rebuild and include the parts list and mods.

**Parts List**

Countershaft - 100
Sprocket & Chain kit - 90
Tires - 100
Gear Shifter - 15
Gasket kit - 45
Spark Plug - 3
Exhaust - 50
Carb Hoses - 3
Dust/Oil Seals - 20
All Bearings - 50
Caliper Seals - 10
Pads - 15
Front Rotor - 40
SS Brake Lines - 40
Brake Switch - 5
Nipples - 5
Levers - 10
M22 x 1.5 - 7

**Mods / Extras**

Strip & Paint - Free
Lightened Flywheel - Free
Rewoud Stator - Free
CRF450 Plastic Kit - 65
Handguards - 15
628cc Kit - 200
Suspension Valve & Spring - 120
Oil cooler - 25

Guess that´s about it. If any more comes up, I´ll update again

SlickSix · 06-01-2012, 03:58 PM

Got her really cheap (for Portugal at least) and she runs good. No knocks, no smoke and easy starter.

That´s not good enough for me

I take pride in my toys so the plan is to do a full tear down and rebuild. She won´t be my main transport and I´ve got the time to mess with her.

Ok, I know that some of you might be thinking that it´s just another rebuild. You´re right. But it´s my rebuild

SlickSix · 06-01-2012, 04:06 PM

Already have her down to the bone, but since I´ve enjoyed watching and following other members threads, I think it´s only fair to share my own, right?

Just want to apologize for the initial lack of disassembly photos but my camera card acted up and lost most of them.

Took her home and started immediately to crack nuts and bolts

Anyway, the disassembly is pretty much straightforward and like all others.
I was pretty satisfied, all the zerk fittings were greased and everything went smooth with no stripped nor broken bolts.

SlickSix · 06-01-2012, 04:13 PM

At first sight she might look ok, but no. She´s a crude,slimey ugly mess.

This will be fun

SlickSix · 06-01-2012, 04:21 PM

This doesn´t look good...

But I already knew that.

What I didn´t expect was to see the calipers in this state. I truly think I should´t rode her home when I picked her up

I´ve spent the better part of an hour to completely remove the pistons from both calipers. They were as nasty as... I don´t know, never seen calipers like this ones!!

Grover6 · 06-01-2012, 04:23 PM

Nice! Keep' em coming

mcma111 · 06-01-2012, 04:25 PM

I'm in. I have a spare front XR caliper for you. PM me your name and address and I'll sent it to you. Hopefully the postage won't be an arm and a leg.

SlickSix · 06-01-2012, 04:30 PM

Quote:

Originally Posted by mcma111

I'm in. I have a spare front XR caliper for you. PM me your name and address and I'll sent it to you. Hopefully the postage won't be an arm and a leg.

Wow!
Thanks mcma111!

I knew the people around here help each other out but that was fast. Really appreciate it man, parts around here are though
to source. I resort to the Uk and States.

Actually, I´ll pm you in a few.

SlickSix · 06-01-2012, 05:05 PM

Ok, let´s get this thing rolling.

One of the reasons that this bike was so cheap... the coutershaft.

It´s welded so, it has got to go.

Notice the shifter, it´s welded too.

elsalvadorklr · 06-01-2012, 05:07 PM

well there goes the good buy!

welcome to the forums, and have fun!

SlickSix · 06-01-2012, 05:13 PM

First good news of the day, all rockers, sub rockers and cam look in tip top condition.

All journals are smooth and in spec and the center of the valve cover where the cam sits, is good too.

Pretty clean also.
I think someone was here before. Don´t know if you can see but the bolt that hold the tensioner
is almost rounded....

SlickSix · 06-01-2012, 05:18 PM

Stem seals shot and a bit on the rich side for sure. These valves are going to be a pain to clean.

Let´s see if they seal after cleaning and lapping them...

SlickSix · 06-01-2012, 05:26 PM

Thanks!

I bought her knowing about the countershaft and that´s why I got her for cheap.

The guy selling her was asking double of what I offered. Called me nuts!
I told him that if that the shaft was in good condition, I would put the full asking price in his hand but if not,
I would bring her for half. He said ok so I asked for an allen key and removed the aluminium sprocket cover that completely covered the zone.

Voila! CHeap XR600

elsalvadorklr · 06-01-2012, 05:39 PM

youre a smart and lucky man!

whats that a possible buyer touching my bike? that doesnt fly down here! jajaja

awesome deal

hey thos valves lool ok

just clean them up with some solvent

new seals and good to go

it all depends on what and how much you want to spend

once again good luck

christian

SlickSix · 06-01-2012, 05:41 PM

Gotta go guys, tomorrow I´ll update on the cleaning part and give you a parts list and expected price for the whole shebang.

Already have most of the needed stuff but not everything.

06-01-2012, 03:51 PM	#1
SlickSix ^OP Gnarly Adventurer Joined: May 2012 Location: Portugal Oddometer: 177	XR600- Donkey Fix Up & Full Rebuild Hey guys, I´ve been a Iong time lurker around the site but never took the time to sign up, didn´t think I could contribute that much. This just changed so let´s see if I´m worthy... I ride the streets but was always looking out to see if the opportunity presented itself and I could bring home my first love - the XR600. Since I was around 13 and a few of my friends older brothers started showing up with that mean, bada** XRs, Huskys and Husas, I wanted one. That growl coming up the street...was my wet dream at the time. Got older and somehow the bike elluded me. Rode some CRM125, DTR125, Bandit400, CBR F3 and now the F4i Sport. Well, last week it finally happened, I just picked up my donkey Update Ok, just thought I would update this first post to give you an ideia of what to expect of this rebuild and include the parts list and mods. Parts List Countershaft - 100 Sprocket & Chain kit - 90 Tires - 100 Gear Shifter - 15 Gasket kit - 45 Spark Plug - 3 Exhaust - 50 Carb Hoses - 3 Dust/Oil Seals - 20 All Bearings - 50 Caliper Seals - 10 Pads - 15 Front Rotor - 40 SS Brake Lines - 40 Brake Switch - 5 Nipples - 5 Levers - 10 M22 x 1.5 - 7 Mods / Extras** Strip & Paint - Free Lightened Flywheel - Free Rewoud Stator - Free CRF450 Plastic Kit - 65 Handguards - 15 628cc Kit - 200 Suspension Valve & Spring - 120 Oil cooler - 25 Guess that´s about it. If any more comes up, I´ll update again SlickSix screwed with this post 06-02-2012 at 04:20 AM Reason: Parts list & Mods

06-01-2012, 04:25 PM	#7
mcma111 Beastly Adventurer Joined: Jul 2007 Location: San Francisco,Ca. Oddometer: 7,981	I'm in. I have a spare front XR caliper for you. PM me your name and address and I'll sent it to you. Hopefully the postage won't be an arm and a leg. __________________ 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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06-01-2012, 03:58 PM	#2
SlickSix ^OP Gnarly Adventurer Joined: May 2012 Location: Portugal Oddometer: 177	Got her really cheap (for Portugal at least) and she runs good. No knocks, no smoke and easy starter. That´s not good enough for me I take pride in my toys so the plan is to do a full tear down and rebuild. She won´t be my main transport and I´ve got the time to mess with her. Ok, I know that some of you might be thinking that it´s just another rebuild. You´re right. But it´s my rebuild

06-01-2012, 04:06 PM	#3
SlickSix ^OP Gnarly Adventurer Joined: May 2012 Location: Portugal Oddometer: 177	Already have her down to the bone, but since I´ve enjoyed watching and following other members threads, I think it´s only fair to share my own, right? Just want to apologize for the initial lack of disassembly photos but my camera card acted up and lost most of them. Took her home and started immediately to crack nuts and bolts Anyway, the disassembly is pretty much straightforward and like all others. I was pretty satisfied, all the zerk fittings were greased and everything went smooth with no stripped nor broken bolts.

06-01-2012, 04:13 PM	#4
SlickSix ^OP Gnarly Adventurer Joined: May 2012 Location: Portugal Oddometer: 177	At first sight she might look ok, but no. She´s a crude,slimey ugly mess. This will be fun

06-01-2012, 04:21 PM	#5
SlickSix ^OP Gnarly Adventurer Joined: May 2012 Location: Portugal Oddometer: 177	This doesn´t look good... But I already knew that. What I didn´t expect was to see the calipers in this state. I truly think I should´t rode her home when I picked her up I´ve spent the better part of an hour to completely remove the pistons from both calipers. They were as nasty as... I don´t know, never seen calipers like this ones!!

06-01-2012, 04:23 PM	#6
Grover6 Gnarly Adventurer Joined: Sep 2010 Oddometer: 162	Nice! Keep' em coming

06-01-2012, 05:05 PM	#9
SlickSix ^OP Gnarly Adventurer Joined: May 2012 Location: Portugal Oddometer: 177	Ok, let´s get this thing rolling. One of the reasons that this bike was so cheap... the coutershaft. It´s welded so, it has got to go. Notice the shifter, it´s welded too.

06-01-2012, 05:07 PM	#10
elsalvadorklr Beastly Adventurer Joined: Nov 2008 Location: el salvador Oddometer: 3,960	well there goes the good buy! welcome to the forums, and have fun!

06-01-2012, 05:13 PM	#11
SlickSix ^OP Gnarly Adventurer Joined: May 2012 Location: Portugal Oddometer: 177	First good news of the day, all rockers, sub rockers and cam look in tip top condition. All journals are smooth and in spec and the center of the valve cover where the cam sits, is good too. Pretty clean also. I think someone was here before. Don´t know if you can see but the bolt that hold the tensioner is almost rounded....

06-01-2012, 05:18 PM	#12
SlickSix ^OP Gnarly Adventurer Joined: May 2012 Location: Portugal Oddometer: 177	Stem seals shot and a bit on the rich side for sure. These valves are going to be a pain to clean. Let´s see if they seal after cleaning and lapping them...

06-01-2012, 05:26 PM	#13
SlickSix ^OP Gnarly Adventurer Joined: May 2012 Location: Portugal Oddometer: 177	Thanks! I bought her knowing about the countershaft and that´s why I got her for cheap. The guy selling her was asking double of what I offered. Called me nuts! I told him that if that the shaft was in good condition, I would put the full asking price in his hand but if not, I would bring her for half. He said ok so I asked for an allen key and removed the aluminium sprocket cover that completely covered the zone. Voila! CHeap XR600

06-01-2012, 05:39 PM	#14
elsalvadorklr Beastly Adventurer Joined: Nov 2008 Location: el salvador Oddometer: 3,960	youre a smart and lucky man! whats that a possible buyer touching my bike? that doesnt fly down here! jajaja awesome deal hey thos valves lool ok just clean them up with some solvent new seals and good to go it all depends on what and how much you want to spend once again good luck christian

06-01-2012, 05:41 PM	#15
SlickSix ^OP Gnarly Adventurer Joined: May 2012 Location: Portugal Oddometer: 177	Gotta go guys, tomorrow I´ll update on the cleaning part and give you a parts list and expected price for the whole shebang. Already have most of the needed stuff but not everything.