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Old 10-02-2013, 03:03 AM   #16
idler OP
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Location: melbourne
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after looking at the photo of the rocker i also had to check again but i think it is fine. - it is at least smooth and consistent.

the cam chain tensioner is a nicely made part although quite heavy for what it is.

I went by the hardware store to try and pick up a 12mm socket with an OD <20mm. Seemingly with everywhere flogging cheaper tools the material quality has reduced which is why the socket wall OD has increased.
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Old 10-02-2013, 04:31 AM   #17
lookfar
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Go to a specialist tool shop and ask for a 12mm single hex deep socket

Single hex will not damage the studs, and is a bit stronger.

Looking at the pic of your XR, it looks like the forks are a cartridge type from a later model. The '89 version did not have the step in the fork tubes in the triple tree area.

FYI, the swingarm chain slider that you have there is NLA from Honda.

This might be useful linky for you as well.
http://www.advrider.com/forums/showp...&postcount=195
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lookfar screwed with this post 10-02-2013 at 04:39 AM
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Old 10-02-2013, 03:01 PM   #18
juddrussell
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looks good! keep it up!
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Old 10-04-2013, 09:40 PM   #19
idler OP
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some more photos;









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Old 10-04-2013, 09:45 PM   #20
idler OP
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some work to do;


i think this has had it.





so i am off to buy a grinder to get the kick starter off.

not sure how to tackle the clutch cable anchor - the case is magnesium which is good except for welding.

does the flywheel need a specialist puller?
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Old 10-04-2013, 10:27 PM   #21
Ghost_Mutant
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Quote:
Originally Posted by idler View Post




not sure how to tackle the clutch cable anchor - the case is magnesium which is good except for welding
Magnesium can be TIG welded. I had exactly the same break on my 83 XR5 stator cover and managed to weld the broken piece back on with a 'poor man's TIG' setup. That's a arc welder, TIG torch/Argon plumbing, and a high frequency adapter. I cleaned the heck out of the pieces and used a bolt to clamp the broken piece for welding. I used a pulsing technique by turning on/off the HF adapter and left the gas flowing, no filler rod.

I did this repair on the bike after removing the gas tank and draining the carbs. Covered the exposed portions with a fire resistant welders blanket.

Not exactly easy, and my repair isn't the best looking on on the planet, but it can be done.

Alternative is to make a bracket (some folks have even used a washer of the right size and screwed it onto the remaining mount. Or you can buy a bracket from XRsOnly.
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Old 10-04-2013, 11:04 PM   #22
idler OP
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ok, thanks ghost mutant, i stand corrected. i remember watching magnesium burn in chemistry at school and had visions of being left with only the gears and crank after my cases went up. thus the importance of the argon!

which hand is the flywheel bolt thread?
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Old 10-04-2013, 11:05 PM   #23
idler OP
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also presumably you had the broken bit - i sadly don't.
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Old 10-04-2013, 11:26 PM   #24
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The XR600 is a great project bike and good luck....one step at a time and you'll be fine. I did an XR6 (2000) a few years ago.



The flywheel does need a special puller...Motion Pro make them can get them off ebay and BikeBandit etc. -Even better if you can maybe borrow one off one of the XR6 Ockers since it's not neccessarily an everday tool.

As you undoubtably know good tools make a lot of difference between a job well done and a soul destroying 'cluster-debacle' ....there's so many junk tools out there. I'd recommend getting good quality six point sockets as they have better contact and a good set of open ended/ring spanners...a good set will have tight tolerances, no jaw flex and not overly large external dimensions in the thickness and diameter (so you can get them into tight places).

I also found the Bahco socket spanners good for getting into the external cylinder and head nuts/bolts since they have good clearance. The Koken 3/4" drive sockets will get down into the cylinder bolts. -I have 1/2", 3/4" and 1/4" sets for the varying tasks. Good tools make everything so much less painful and will save you money and time.

If you soak everything in something like Penetr8 it makes to a lot easier to remove, especially those fragile engine cover bolts. There's a number of home made recipes available as well.

Top end sputtering sounds more like a carb issue to me?....strip and rebuild so you know where it's all at anyway.

Maybe grind and insert a threaded tube into the clutch cable post and quick steel it over it as an adhoc fix?...there's still material there and the load is mostly taken on the post.

Great to see the progress so far...have fun!
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Old 10-05-2013, 12:44 AM   #25
idler OP
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i am going back to the uk on 07/12 with an empty bag so as to bring back as much of my tool kit as possible.

tickled it with a dremel which we tickled it with but alas it was no match for a mig welder.

i am toying with cutting the shaft behind the kickstarter as i will have to replace it anyway. the alternative is buy an angle grinder.

anyone know where to come by an m22 bolt on a sunday in melbourne?
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Old 10-05-2013, 02:38 AM   #26
lookfar
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Quote:
Originally Posted by idler View Post
i am going back to the uk on 07/12 with an empty bag so as to bring back as much of my tool kit as possible.

tickled it with a dremel which we tickled it with but alas it was no match for a mig welder.

i am toying with cutting the shaft behind the kickstarter as i will have to replace it anyway. the alternative is buy an angle grinder.

anyone know where to come by an m22 bolt on a sunday in melbourne?

Bunnings?
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The early bird catches the worm, but the second mouse gets the cheese.
Growing old is mandatory... growing up is optional.
1985 XL250R
1985 XL600R 1988 XR600
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Old 10-05-2013, 10:09 AM   #27
Ghost_Mutant
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Quote:
Originally Posted by idler View Post
also presumably you had the broken bit - i sadly don't.
That piece is extremely fragile, I was amazed that I broke mine. Its one of those things where Honda didn't do it right


Here is the post with the KLR style washer fix, probably your cheapest and quickest solution:
http://www.advrider.com/forums/showp...postcount=4032
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Old 10-06-2013, 07:38 PM   #28
Mike the Yank
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My clutch cable holder looks like yours, a couple of zip ties has held it for over a year now! Next order from XR's only will have to get a new one.
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Old 10-06-2013, 09:17 PM   #29
RFVC600R
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Get some measuring calipers and measure that cam. It's a little tricky, but it can be done by a noob. Have someone who is familiar double check your measurements.

I think the stator covers are the same for for big RFVC engines, if so, I might have a XL600R stator cover that's not broke. PM me if you want it.

I also remember MCMA111 had a link for a bracket to fix it right without replacing the cover, Much better looking than that KLR style thing
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Old 10-07-2013, 03:53 AM   #30
idler OP
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ok, so i have split the cases which involved cutting the kickstarter off.












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