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Old 03-20-2014, 01:05 PM   #391
cms81586
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Quote:
Originally Posted by mcma111 View Post
This gives me an idea. Since my son recently blew up his XRL and is at my place right now (I'm at work) prepping the bike for the motor removal I'll email him this thread for him to read. There will be a test!!
What are you charging for a rebuild these days? I posted up a while back about the countershaft splines on my bike being shot. I'm considering just sending it your way for a NX 2nd gear, new countershaft, cam chain (if needed), and a top end job. It began smoking like a locomotive upon startup about 6 months ago and it's getting worse. From maybe 3-4 seconds of smoke to a good 30 seconds or so until it stops. At that rate I imagine it's burning a decent amount of oil during startup (no smoke once running) and so at this point I'm being extra vigilant with oil levels until it's fixed.

The bike is an 04 with 21k hard desert miles on the clock. I tossed on a R countershaft sprocket about 8k ago to hold off any more accelerated wear on the countershaft but want to get it taken care of. I got the bike for a steal with 6k miles on it for $2000 a few years ago and have gotten a lot of enjoyment out of it. I'm at a point where I need to either put some money into it now or face a big bill later on. Was initially planning on tearing the motor apart myself but I have a kid due next week and my time is short right now. Any help is appreciated, and if you provide part numbers for the minimum you know I'll need I can purchase them all and have them shipped to you as well.
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Old 03-20-2014, 03:25 PM   #392
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BMW's
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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 03-20-2014, 06:29 PM   #393
brayjay
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Very informative thread sir, I am just about ready to install my new piston and rings and was wondering if you install the piston and rings dry or with oil. Also what kind of assembly lube do you recommend for the con rod small end and piston pin. Thanks in advance.
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Old 03-22-2014, 06:39 AM   #394
FongMan
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I don't own an BRP, but that was a great read!! Great info to have when I
Go bike hunting.....
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Old 03-22-2014, 04:59 PM   #395
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Originally Posted by brayjay View Post
Very informative thread sir, I am just about ready to install my new piston and rings and was wondering if you install the piston and rings dry or with oil. Also what kind of assembly lube do you recommend for the con rod small end and piston pin. Thanks in advance.

I use a piston assembly oil. I can't remember the name right now. I apply some to the rings (sparingly) and coat the lower part of the cylinder. Once the cylinder is bolted down I rotate the engine and I wipe the excess off of the top of the piston. Again I can't remember what lube I use on the cam. I'll have to go look.
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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 03-23-2014, 06:00 PM   #396
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Compression Check, Rebuild Limbo - How low can you go?

Quote:
Originally Posted by beltsnbraces View Post
Steve, do you ever keep an eye on the compression throughout the life of an engine.
I've picked up a 2005 xrl recently with about 10.000 mil on the clock. I checked the compression among other things and it was 145 psi with engine warm, decompression disabled and throttle wide open. It increased to 160 psi after I've squirted some oil down the plug hole. I expected a bit more but in saying that I've got really no reference. The manual wants the compression to be 199 psi but that would be for a new engine obviously.
Any comments would be appreciated......and thanks heaps for sharing your knowledge.
Cheers
Chris

2007, 23500 miles, fully warmed up
60 PSI, decompression enabled
120 PSI, decompression disabled

Wet compression test
62 PSI, decompression enabled

It starts harder than it used to when cold, but it does start and it runs/starts great after warmed up. Sometimes white smoke when cold. Uses more oil than it used to, but I don't know exactly how much.

I thought maybe my compression tester (new, Taiwanese from Sears) was junk or not installed properly, but it doesn't seem to leak, and I hooked it up to my air compressor and it read the same as the regulator.

62 is a long way from 92. But it runs good?
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Old 03-23-2014, 07:13 PM   #397
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More that likely the rings are going south. At your miles it looks like it's time to pull the top end for a look see. Perhaps a valve job will also be needed.
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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 03-23-2014, 08:56 PM   #398
JD_Mckoy
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Hi Steve, can you answer me this do I need to re sleeve my cylinder to accomodate a 102.4 piston? is the web cam 450/451 profile ok for every day riding 256 deg duration some 26 deg above stock grind.
Thanks
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Old 03-24-2014, 04:48 AM   #399
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Originally Posted by JD_Mckoy View Post
Hi Steve, can you answer me this do I need to re sleeve my cylinder to accomodate a 102.4 piston? is the web cam 450/451 profile ok for every day riding 256 deg duration some 26 deg above stock grind.
Thanks

If you have a XR650l the 102.4 piston can go right in the stock sleeve. If you have a XR600 then No, you need a bigger sleeve.

That Web Cam looks fine. You do need a high compression piston and performance valve springs.
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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 03-25-2014, 12:50 PM   #400
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Quote:
Originally Posted by mcma111 View Post
If you have a XR650l the 102.4 piston can go right in the stock sleeve. If you have a XR600 then No, you need a bigger sleeve.

That Web Cam looks fine. You do need a high compression piston and performance valve springs.
One more thing since im going to open up the moto I was considering installing the nx gears whats the advantage of the nx second & fift gears?
Thanks much.
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Old 03-25-2014, 02:58 PM   #401
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The XRL has a rather big gap when shifting from first to second. You most likely don't notice it on the street but you sure do if on the trails. By installing the 16 tooth NX650 second gear it closes up the 1-2 shift gap and moves it to the 2-3 shift which is not as noticeable as you are moving at a faster rate of speed. The NX650 fifth gear is kind of like an overdrive. I am installing one in my CW big block XRL motor and in my son's XRL which is a well built motor. I really don't think a stock motor has the guts to pull the NX fifth gear.
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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 03-29-2014, 12:05 PM   #402
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Piston head Gasket

For a 101mm JE piston can I use my old OEM gasket? If not what is best gasket set? Top end and clutch case?
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Old 03-29-2014, 01:44 PM   #403
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For a 101mm JE piston can I use my old OEM gasket? If not what is best gasket set? Top end and clutch case?

NEVER reuse a head gasket. Your only asking for trouble.

http://www.ebay.com/itm/261370490687...84.m1423.l2649

Clutch cover gasket OE.
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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 03-30-2014, 02:42 PM   #404
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Quote:
Originally Posted by mcma111 View Post
NEVER reuse a head gasket. Your only asking for trouble.

http://www.ebay.com/itm/261370490687...84.m1423.l2649

Clutch cover gasket OE.
More great wisdom from Steve, people need to listen
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Old 04-02-2014, 01:05 AM   #405
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Laugh 10k

Knocking on the door of 10,000 post's Steve. I sure you have helped with alot more than 10,000cc's of XR's within those posts. !

ALL HAIL THE XR GURU !
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