The XL600 thread - Page 458

Stretchah · 02-02-2013, 12:25 AM

Quote:

Originally Posted by davek181

I have a spare set of 85 CR500 forks laying around. It is stepped also on the top. I measured the axle on it and it is 17mm in size. I compared the axle on an 87 model through an online lookup and they all use the same axle those years. So it is confirmed 17mm axle, 6003 bearings.

Cheers for confirming that Dave :)

cyclewizard · 02-02-2013, 03:51 PM

Quote:

Originally Posted by Carter Pewterschmidt

Milled and decked the head surface, new bronze guides, seals, with some port and bowl work. Should be fun!

Also put a five angle performance valve job on it 75/60/45/30/15 degree's... opened the intake ports to 30.56mm's from the 26.87mm's the head came with, used a bowl hog and enlarged both the intake and exhaust pockets for better/more flow, glass beaded the rocker box and head. Installed new KW valves..

daviethebiker · 02-02-2013, 04:44 PM

I recently bought a new chain slider for the swingarm on my 1987 XL600R. When I took the swingarm off I felt reassembly was going to be tough as the swingarm was very hard to get apart from the frame. I cleaning everything and put the new chain guide on and got ready to install the swingarm but I can't get the swingarm to slide into position. Is it easier if I loosen the other engine mount in the rear ? Are there any tricks to make re-installing the swingarm easier ? Thank you.

Edouard_Bracame · 02-02-2013, 04:50 PM

Quote:

Originally Posted by God of Speed

that is exactly the problem, the xr600 pilot jet was too big for the thread, the honda dealer looked at me

so i bought in the current one and they measured it up and told me to wait 2 weeks for the new one because the only ones they had ready were the same #65! lame!

thanks man

A solution for these jet size is to buy a set of mini carburator reamer, you just enlarge the fuel passage with the mini reamer, and if the hole is too big and you want to reduce your jet size , you just meld some soldering lead in the passage and then you bore it using mini drill bit(Dremel), and then you finish it with your reamer.

I'm reading the all thread and I'm @ page 96...

davek181 · 02-03-2013, 07:21 AM

Quote:

Originally Posted by daviethebiker

I recently bought a new chain slider for the swingarm on my 1987 XL600R. When I took the swingarm off I felt reassembly was going to be tough as the swingarm was very hard to get apart from the frame. I cleaning everything and put the new chain guide on and got ready to install the swingarm but I can't get the swingarm to slide into position. Is it easier if I loosen the other engine mount in the rear ? Are there any tricks to make re-installing the swingarm easier ? Thank you.

There must be something else going on here, the swingarm is not that hard to get back in. I have extra wheels with mounted tires ready for a quick swap and on the rear. I scavenged up enough parts to outfit a spare swingarm I have figuring that would be a faster swap than fiddling with axles and adjusters and stuff. The hardest part for me is holding the end caps in place while sliding the swinagarm into place, and that is really not that hard at all.

I would study a parts breakdown online (like Babbits online, or partszilla) and make sure all of the pieces are in their respective places and the dust seals on the ends fit tightly and bottom out on the ends of the arm. Maybe someone folded the seals over in the dust caps and somehow got it forced back together. It would be really hard to bend the frame there making it tighter, and loosening motor mounts wouldn't help anything there either in my opinion, but that is easy enough to try. Swingarms are very much alike between models so even if it were the wrong one it should still fit. i think 500, 600, 650l, even 250 and 350 all interchange easily.

I would try to test fit it without the seals on the end first to see what the measurement is between the frame and arm, then go from there. If someone assembled it with pieces missing and pinched it together there, I bet you could jack it back out with a bottle jack or similar device.

daviethebiker · 02-03-2013, 01:56 PM

Thank you davek181. I had tried the bottle jack yesterday and again today, even after loosening the other engine mount, but I just couldn't get it to fit. After taking a little break and relaxing I went out and the swingarm went in with a little extra push and jiggling. I went to assemble the pro-link and noticed I had another stripped nut for one of the linkage bolts. The linkage is cleaned, regreased and assemble, just need the last nut to finish. Riding days are with me again !

Carter Pewterschmidt · 02-03-2013, 08:34 PM

Quote:

Originally Posted by daviethebiker

Thank you davek181. I had tried the bottle jack yesterday and again today, even after loosening the other engine mount, but I just couldn't get it to fit. After taking a little break and relaxing I went out and the swingarm went in with a little extra push and jiggling. I went to assemble the pro-link and noticed I had another stripped nut for one of the linkage bolts. The linkage is cleaned, regreased and assemble, just need the last nut to finish. Riding days are with me again !

A little late but I found the swing arm goes in really easy if you pull it through from in front of it's mount point rather than pushing it in through the back. Don't know if that trick works with the motor in though.

Carter Pewterschmidt · 02-03-2013, 08:36 PM

Quote:

Originally Posted by cyclewizard

Also put a five angle performance valve job on it 75/60/45/30/15 degree's... opened the intake ports to 30.56mm's from the 26.87mm's the head came with, used a bowl hog and enlarged both the intake and exhaust pockets for better/more flow, glass beaded the rocker box and head. Installed new KW valves..

Yeah, What he said

12120 · 02-03-2013, 09:18 PM

Anyone put one in? Experience with them, trouble, one to stay away from?

I would am thinking of doing it. Should just need a H4/9003 kit to do it with. Just wondering about any feedback on it. Also I have ask this before, but is there a source for carb bowl orings?

Thanks Chris

brokeagain · 02-04-2013, 08:36 AM

Quote:

Originally Posted by 12120

Anyone put one in? Experience with them, trouble, one to stay away from?

I would am thinking of doing it. Should just need a H4/9003 kit to do it with. Just wondering about any feedback on it. Also I have ask this before, but is there a source for carb bowl orings?

Thanks Chris

Honda still sells gasket kits for the carburetors, and should be able to be ordered from any online store or motorcycle shop. I'm not sure if they sell the individual O-rings, but I did just pick up two gasket kits a couple of months ago. I don't know if there are different gasket kits for the different year bikes, because the carbs change slightly (at least between '83 and '84).

Hope that helps.

davek181 · 02-04-2013, 10:35 AM

I haven't done the HID conversion but I have pondered it. The advantages of course are the higher light output, but the disadvantages outweigh that in my opinion.

The major disadvantage on an XL is the necessary Dc conversion to the headlight. I have read stories of lights shutting off due to voltage and/or battery reserves being low, and an XL is marginal that way anyhow since the DC circuitry is not utilized or designed very heavy. Bulb expense and vibration resistance fears compound my reluctance.

Maybe as an auxiliary light but there I would probably opt for LED driving lights instead keeping in mind current draw limitations.

Dracus124 · 02-04-2013, 11:04 AM

I broke a zerk off of my linkage..... Now what??

mcma111 · 02-04-2013, 11:14 AM

Easy out or left hand drill bit.

cam14 · 02-04-2013, 12:53 PM

In the process is putting my XL600 back together and want to do something a little different with the air filter. I would like to install dual air filters directly on the carbs and by-pass the factory air box. My factory air box is pretty beat up already and the rubber snorkels makes remove and installing the carbs very difficult.

Has anyone documented their successful factory air box replacement? Have not have not found anything whilst searching.
If I removed the air box completely, then where does one mount the battery and related wiring?

TIA

davek181 · 02-04-2013, 01:49 PM

My experience with aftermarket air filters, especially pod filters, especially K&N is that they are slightly better than no filter at all. They will filter out the sticks and rocks, but let damaging dust come right through. If you are running on only pavement and never in the dust, then maybe your rings will last a little longer.

I would hunt eBay for a better air filter box if yours is damaged beyond belief and run either a factory Honda( preferable and still available ) or a twin air filter.

02-03-2013, 09:18 PM	#6864
12120 Gnarly Adventurer Joined: Apr 2012 Location: SW Washington USA Oddometer: 143	Hid Anyone put one in? Experience with them, trouble, one to stay away from? I would am thinking of doing it. Should just need a H4/9003 kit to do it with. Just wondering about any feedback on it. Also I have ask this before, but is there a source for carb bowl orings? Thanks Chris __________________ If you find yourself in a fair fight, your tatics are wrong. '83 XL 600r

02-04-2013, 11:04 AM	#6867
Dracus124 SAND EATER! Joined: Dec 2011 Location: Twentynine Palms Oddometer: 472	I broke a zerk off of my linkage..... Now what?? __________________ '83 Honda XL600R valve seat RIDE RED!

02-04-2013, 11:14 AM	#6868
mcma111 Beastly Adventurer Joined: Jul 2007 Location: San Francisco,Ca. Oddometer: 7,965	Easy out or left hand drill bit. __________________ 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

02-04-2013, 12:53 PM	#6869
cam14 Gnarly Adventurer Joined: Jun 2010 Location: Texas Oddometer: 112	replace factory air box In the process is putting my XL600 back together and want to do something a little different with the air filter. I would like to install dual air filters directly on the carbs and by-pass the factory air box. My factory air box is pretty beat up already and the rubber snorkels makes remove and installing the carbs very difficult. Has anyone documented their successful factory air box replacement? Have not have not found anything whilst searching. If I removed the air box completely, then where does one mount the battery and related wiring? TIA

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02-02-2013, 04:44 PM	#6858
daviethebiker Adventurer Joined: Dec 2012 Location: Watsonville, CA Oddometer: 11	I recently bought a new chain slider for the swingarm on my 1987 XL600R. When I took the swingarm off I felt reassembly was going to be tough as the swingarm was very hard to get apart from the frame. I cleaning everything and put the new chain guide on and got ready to install the swingarm but I can't get the swingarm to slide into position. Is it easier if I loosen the other engine mount in the rear ? Are there any tricks to make re-installing the swingarm easier ? Thank you.

02-03-2013, 01:56 PM	#6861
daviethebiker Adventurer Joined: Dec 2012 Location: Watsonville, CA Oddometer: 11	Thank you davek181. I had tried the bottle jack yesterday and again today, even after loosening the other engine mount, but I just couldn't get it to fit. After taking a little break and relaxing I went out and the swingarm went in with a little extra push and jiggling. I went to assemble the pro-link and noticed I had another stripped nut for one of the linkage bolts. The linkage is cleaned, regreased and assemble, just need the last nut to finish. Riding days are with me again !

02-04-2013, 10:35 AM	#6866
davek181 Gnarly Adventurer Joined: Aug 2007 Location: Idaho Oddometer: 156	I haven't done the HID conversion but I have pondered it. The advantages of course are the higher light output, but the disadvantages outweigh that in my opinion. The major disadvantage on an XL is the necessary Dc conversion to the headlight. I have read stories of lights shutting off due to voltage and/or battery reserves being low, and an XL is marginal that way anyhow since the DC circuitry is not utilized or designed very heavy. Bulb expense and vibration resistance fears compound my reluctance. Maybe as an auxiliary light but there I would probably opt for LED driving lights instead keeping in mind current draw limitations.

02-04-2013, 01:49 PM	#6870
davek181 Gnarly Adventurer Joined: Aug 2007 Location: Idaho Oddometer: 156	My experience with aftermarket air filters, especially pod filters, especially K&N is that they are slightly better than no filter at all. They will filter out the sticks and rocks, but let damaging dust come right through. If you are running on only pavement and never in the dust, then maybe your rings will last a little longer. I would hunt eBay for a better air filter box if yours is damaged beyond belief and run either a factory Honda( preferable and still available ) or a twin air filter.