XR 600 Project

[singletrackslayer]

Im in!

Ive been a professional aluminum welder in years past too. Can throw you some advice when Im not workin so much and have more time. You make me wanna build one now . . .

[Roadracer_Al]

Looks like a great project!

In

I have similar aspirations for my wife's DR650...

[Motomechanic]

Thanks for the offer silgletrackslayer, I hope to be getting into some of the welding and fab in the coming months. I'll post some pictures of my efforts for some critique.
Sadly not a lot of major progress since the last upgate still just tackling one job at a time. I've been looking at houses which sucks heeps of time as well. Good news is I boutght one, even better news is it's got a big shed so I can get set up properly. Can't wait to be working off a bench for a change and have a vice plus mount my grinders ect properly. Still almost two months off yet but something to look foreward to.

I've started sorting out what's needed to make new oil lines and hoses. All the standard fittings on the frame and oil cooler are JIS a japanese standard tube fitting and not that common. I'll be cutting them all off and welding on JIC fittings a much more common and readily available type of fitting that I can get for nix from work. I have also cut up the old oil lines and removed the special ends that go into the engine. I'll get these plated and reuse them later on new hose.
[IMG][/IMG]

I also did a small repair to the stator cover. As I mentioned early in this thread this bike was ridden on the salt flats a lot and it has eaten into the magnesium engine side covers in some areas overall it's not that bad I can just clean it up with a file and get them powdercoated, however this one needed a little clean up.
[IMG]

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One of my last big ticket items is now sorted out as well. The tyres that came on the bike are great but not DOT approved so I had to buy new tyres. I'm going for full rego and have to take it over the pits and so needed something that would pass the inspection. I'll keep the old ones to use later or for a trip. Also went for a set of ultra heavy duty tubes.
[IMG][/IMG]


Got these crf 450 wheels for a good price off ebay through extreme powersports Australia. My experience with these guys was great and I'll get a set of motard wheels off them as well whenever the build is finished.
[IMG][/IMG]

Put all that lot togeather and I've got these ready to go.
[IMG][/IMG]

I'm currently working on machining the swing arm to take the crf axle and brake this will take me a little while to get sorted, plus plenty of other smaller jobs.

[kapparone]

check it out!!!
Ciao
Krone

[SlickSix]

Been following you and we need updates man!

Your build is coming along nicely, faster than mine, and it´s making me itch.
I´m waiting on my frame and some parts that my brother painted but the waiting is
killing me. I´ve got a few boxes of new and shiny stuff to fit but still no frame!!!!

Come on man, it´s our food...

[Motomechanic]

Progress is still happening slowly. My Computer crashed and burnt so that's why I haven't posted any updates lately. I'm at work for a week at the moment and can finally give you guys somesort of update, unable to post pics for the moment. The slot in the rear of the swingarm has been machined to accept the crf axle. It has also had all brackets ect cut off. The slot has also been extended foreward by the difference in the radius from the new axle to the old one. This ensures the new axle will have the same centerline when it is right foreward.
I have decided to make a new steering stem rather than machine the crf item. I just don't like the idea of reducing the wall thickness of that part. I have done all the measurements and drawn up the stem and spacer that i need to make in cad. Just need time to get it done now.

I bought a cylinder sleve and forged piston kit (102mm). Engine displacement will be 650cc. I've been doing a lot of work preparing the engine for soda blasting, removing casting marks and a weld repair on a front sprocket cover mount. I've removed the broken exhaust studs and tapped the holes ready for helicoils. I've stripped the head and rocker cover completely including pushing out the old valve guides. The rockers aren't in bad condition with only one needing replacement along with it's piviot shaft. A number of the 6mm threads in the head were stripped so I've drilled out all of the 6mm threads in the top end and tapped them ready to be fitted with helecoils. No more stripped threads here, ever. Still got some to do but I hope the get the engine ready for blasting within the next two weeks.
I'll post pics as soon as I get the chance and try to keep the progress rolling.

[ffjmoore]

Yeah whats up with this build?

[xr6]

Update please!

[Rocket_Rookie]

You have done some good work. I guess it is easier to restore these bikes in the US, than in South Africa. The most simple part can not even be bought here, never mind the engine parts.

I am afraid that the day will come when I have no choice than to repair my XR with imported parts which will cost me a fortune.

Keep on building!

looking forward to an update and final product.

Regards

[Rocket_Rookie]

She will be a beauty when finished.