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Old 12-17-2008, 11:08 AM   #46
sc-razor
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Joined: May 2008
Location: NW Arkansas
Oddometer: 3,746
Very nice gents. I love me some XR's!
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Old 12-17-2008, 01:45 PM   #47
Owyhee
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Joined: Oct 2007
Location: The Horse Latitudes
Oddometer: 508
I loved my 1999 XR600 so much I got a 1991 to keep it company.

1999 XR600R (purchased in 2005 for $2000)

1995 CR500 forks (easy and cheap mod!)
5.8 gallon Acerbis tank (not yet installed)
Thumper Racing turn down for stock muffler (not installed yet)
Fat bar and clamp (not yet installed)
TM38 flatslide carb (not yet installed)
Moose skidplate
Moose handguards
Moose toolbag
Street plate

A few years ago after doing the fork swap...


1991 XR600R (purchased in boxes in 2007 for $350)

1996 CR500 forks (not yet installed)
1988 XR's Only head
-big fins
-KW valves
-Ti springs
-Ti keepers
-port n' polish
1991 XR's Only head (for sale?)
-port n' polish (maybe only on exhaust side?)
WB E Series slip on
Baja Designs DS kit
200w stator
HSR40 pumper (not yet installed)
1986 WP Super Adjuster shock (awaiting reassembly)
1985 ATC350X oil cooler (eventual plumbing nightmare)
Moose tool bag
Acerbis handguards with blinkers (new, for sale)

In Dec of '07 before I put it in storage...


This has left me with scads of parts cluttering the garage like the original front end off of the 1991, a spare stock muffler or two, some tanks, and a whole bunch of other stuff that'll end up on eBay once I get off my butt and get them listed.

"O"
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Old 12-17-2008, 07:16 PM   #48
DirtHopper
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Location: AZ
Oddometer: 408
Still working on mine

If you guys help me pray to the parts gods, maybe I'll get them before friday so I can finish the lower end of the motor and order me up some top end parts to finish her up

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Old 12-17-2008, 11:07 PM   #49
keowidan
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Location: Louisville, KY
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Dear most benevolent Part God(s),
I beseech thee to make with the parts for this stalwart XR, safely and swiftly.


Amen.
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Old 12-18-2008, 01:18 PM   #50
JAB
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Quote:
Originally Posted by Owyhee
1995 CR500 forks (easy and cheap mod!)
I've got a '91 also. Is the swap worth it and is it a bolt on deal?
Thanks, JAB.
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Old 12-18-2008, 01:32 PM   #51
jake28
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Location: Bay Area, CA
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Quote:
Originally Posted by JAB
I've got a '91 also. Is the swap worth it and is it a bolt on deal?
Thanks, JAB.
I did CR250 forks on my XR500 and the only modifications needed were to the stem. The bearing were the same and I just needed the stem modified by the local machinist. 40 bucks for the stem swap and mods and then it bolted up easy.
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Old 12-18-2008, 01:43 PM   #52
Owyhee
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Quote:
Originally Posted by JAB
I've got a '91 also. Is the swap worth it and is it a bolt on deal?
Thanks, JAB.
The older CR forks are an easier swap than the newer CRF forks as the older CR stems share the top bearing size and stem length with the XR600. The 1989 CR500 actually shares both bearing sizes but the 1989-1991 USD forks are sub-par.

The swap is really easy.
1) Remove forks and top clamp from CR500
2) Take bottom clamp, stem, and top bearing to your favorite local machine shop, pay them $40 to press the stem out, machine the bottom bearing area on the stem to fit the top bearing, and press the stem back in
3) Reuse the XR600's bearings, reassemble fork and bolt on

There are some issues with the USD forks...
1) CR500 forks have the pinch bolts facing forward. Some other CR and CRF forks have the pinch bolts on the rear causing problems clearing the stock tank. I have a stock, a 4.3 IMS, and a 5.8 Acerbis and there's no real problems with fork/tank clearance using 1995-1996 CR500 forks.
2) The USD forks are slightly longer (3/4" if memory serves) and sit a touch higher in the stroke. It choppers out the ride a touch even with the forks pulled all the way up. I'm going to compensate for this by raising the rear of my 1991 with a shock off of a 1986 XR600 which (if memory serves) is 1/4 inch longer than the newer ones.
3) The CR500 top clamp has rubber mounted bar clamps. These sit a touch higher than the stockers and I ran out of free play on the clutch and had to move it 3" toward the center of the bike.

Other than that, it's like the forks were meant to be on there. The steering stops even line up. Some people re-use the XR600s wheel and brake. I just got them off eBay ($40 wheel/axle, $10 front brake with bolts). Fender bolt patterns are the same. The stock XR600 headlight straps will stretch over the larger CR tubes but will put up a fight going on and off.

"O"

Owyhee screwed with this post 12-18-2008 at 04:13 PM
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Old 12-18-2008, 01:44 PM   #53
Jeff@TheQuadShop
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Location: Crestwood, Kentucky
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Quote:
Originally Posted by JAB
I've got a '91 also. Is the swap worth it and is it a bolt on deal?
Thanks, JAB.
It will only be a bolt on if you buy the Emig steering stem. The other option is having the CR stem machined to fit the XR bearings.

Here is my 93 on the TAT last year.

























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Old 12-18-2008, 10:57 PM   #54
Gummee!
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Joined: May 2004
Location: NoVA for now...
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Quote:
Originally Posted by jake28
I was randomly reading through this thread this morning, dreaming of the various projects I would love to do with an XR600: street tracker, USD conversion, cafe racer, frame swap into a supermono racer...

Then this evening I walked into a friend's motorcycle shop and a mutual friend of ours was sitting there talking about how he had just picked up a 1997 XR600R project bike but didn't have any place to keep it or time to invest in it. I raised my hand and I am now the proud owner of said bike for what my friend bought it for: 200 bucks.

That being said, the thing is a total POS at the moment: wiring is hacked, front end is shot although the rear seems to be in good shape, the carb is somehow frozen shut, I think someone fiddled with it and reassembled it badly, and the motor gains compression but the loses it just past TDC, I think an exact valve is too tight.

Despite the work required, I'm happy with my purchase. Now, depending on whether or not it is truly street legal, it will either become a cheap city bike or the basis of a wild transformation.
If you can't get CA to see it as an on-road MC (check on it, it may not be as easy as yer hopin), I can. I live in AZ, and am a WY resident. I can plate damn near anything. I'll even give ya the $200 for the bike!

M
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Old 12-19-2008, 07:08 PM   #55
bigtrailie
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Thumb Easy street legal conversion - cheap

Check with the guys at Sicass Racing www.sicassracing.com

These are some great guys who put together kits for just about any dirtbike. They hooked me up.
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'04 KTM 950 ADVENTURE (black) - '05 Honda XR650R (plated) - '97 Honda XR600R (plated) - '99 Honda Valkyrie Interstate (joy rides with my wife and kids)
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Old 12-19-2008, 07:11 PM   #56
bigtrailie
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XR600 - tall handlebars suggestions???

Have any of you found a good way to raise the handlebar height on your XR600? I once heard someone mention using an ATV bar, but I was concerned about the cables being long enough to accommodate the swap. What else have you guys tried?
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'04 KTM 950 ADVENTURE (black) - '05 Honda XR650R (plated) - '97 Honda XR600R (plated) - '99 Honda Valkyrie Interstate (joy rides with my wife and kids)
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Old 12-19-2008, 07:56 PM   #57
Owyhee
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I have both a right side up (stock XR600 forks) and USD (95/95 CR) top clamp with bolt-on risers for fat bars. With about an extra 1/4" lift cable length is a problem.

"O"
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Old 12-19-2008, 10:11 PM   #58
Blakebird
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Location: Parker, CO
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Quote:
Originally Posted by bigtrailie
Have any of you found a good way to raise the handlebar height on your XR600? I once heard someone mention using an ATV bar, but I was concerned about the cables being long enough to accommodate the swap. What else have you guys tried?
I use a CR Hi bend, and have 1 1/8" Moose bars, so I get a bit of rise from the TAG adaptors. Not quite enough for extended periods standing.

I'm going to try a set of Rox risers, plenty of adjustment possibilities...

http://www.roxspeedfx.com/cgi-bin/ca...?subcat_id=268
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Old 12-19-2008, 10:26 PM   #59
GodSilla
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Just buy another pair of top h/bar clamps amd slightly longer bolts and invert the current top h/bar clamps, you'll gain approx, 22mm, which doesn't sound much but the difference is marked. Standard cables work with this.
It transformed mine when standing, from feeling like I was going to pitch over the bars to a nice comfy standing position. Did I say it was cheap too?
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Old 12-20-2008, 10:14 AM   #60
bigtrailie
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Cheap too?!?

Sweet! Thanks. That was just the type of solution I was hoping for. Any chance you could post a pic? I'm many miles from my XR600 (up north) and I'd like to be sure I've purchased what I need before I head up to the cabin.

Thanks again. (and if you can't post it no biggie... i haven't figured out how to do that yet either)
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