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Old 08-06-2011, 05:16 PM   #1
mcma111 OP
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Location: San Francisco,Ca.
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Building A XR650l Engine

OK for all of you folks that haven't delved into the deep inner workings of your XR650l or for that matter XR600 engine here is a by the numbers engine reassembly. Hell, anyone can take an engine apart. It's putting it back together correctly that's the bitch.

Here's the story on this poor engine. The person that I am building it for got the bike for free in a well, well done (cooked) condition. This is the most severely cooked engine I have encountered.

I saw a post from the current owner in the ADV flea market looking for a XRL engine. I recognized her avatar and sent her a PM inquiring as to why she needed a engine. Seems that she took this lump to a shop and was given a VERY high repair estimate. I told her that no matter what condition the engine was in, it could be saved.

As she didn't know me from a hole in the ground I suggested that she call my machinist, Mike, at Engine Dynamics in Petaluma for references. Upon getting a glowing recommendation from the shop she decided to bring me the engine.

I wasn't home when she dropped the engine off but upon my return later I took a quick peek and sent her an e-mail with what I saw. I looked on the computer for some parts at Cheapcycleparts and made up a list which I sent her. She placed the order and I waited for the parts to arrive.

In the mean time I took the crank assy, cylinder and head to the machine shop. She ordered a Pro-X rod and a Wiseco 101mm 10.5cr and gaskets from E-bay that were sent to the machine shop. Upon the parts arrival the machine work began.

While we were waiting for the machine work to be completed she decided to replace all of the bearings in the engine. Another Cheapcycleparts order and the wait for them to arrive. I picked up the machine work last Wednesday (which coincided with a small local brewery that has $3.00 pint day) and the bearings came in Thursday.

Today, Saturday 8/6 I started the rebuild.


Can you say TOAST





Oil? What oil???


By the way. Here is my garage. Aw crap. Should'a taken that bra down. Opps



Someone asked to see the tools for the disassembly. These should get the motor apart but by the time I'm done putting it back together I'm sure there will be a whole bunch more on the bench.



New OE parts



Some of the bearings



The dead rod





The new rod



The repaired cam center journal



Flip side of the head. Valve job completed.



The new bore



The new Wiseco piston



Look what they ship the pistons in. Ain't it cute...



The naked left side case



Right side



Loaded with the new bearings





Let's warm up the case to accept the crank assy



Lay down here it comes



Line up the dot's



The crank and counter-balancer dropped right in



Splines? What splines. 16,000 miles





New shaft



Swapping out the counter-shaft



So when you assemble the transmission into the left case there is a washer on the end of the counter-shaft. I put grease on the gear to hold the washer from falling off. Trick #1



Putting the two transmission shafts and the shift fork assy in at one time. Trick #2







All in



A little wiggling and the shift drum goes in



The crank and transmission in place



Right side engine case drops into place



I have this thing about putting steel bolts in aluminum cases. I oil the bolts. All of them. Trick #3





The star part on the end of the shift drum



The bottom end together



Priming the oil pump



Don't forget the dowel for the pump



Oil pump in place. The dowel that goes between the oil pump and the clutch cover gets grease to keep it from jumping ship. Trick #4






Gunning on the cam drive and clutch drive sprockets along with the pulse generator trigger.



New clutch



Don't forget to oil the friction plates. I cut the blister off of the package to oil the plates in. Trick #5



Gun on the new clutch hub. Who ever disassembled the engine broke one of the spring posts off. Doh



Clutch hub holder. With all of the plates in place you hold the hub like this as you gun the nut on. Easy Peasy. Trick #6



What's missing here?? I forgot to put the cam chain tensioner guide in. Off comes the clutch assy.



Outer clutch hub. Don't forget the bearing and push rod cap.



Clutch side done. I leave the clutch cover off until I have the cam in place as it makes getting the cam chain onto the drive sprocket much easier. trick #7

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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

mcma111 screwed with this post 08-06-2011 at 06:41 PM
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Old 08-06-2011, 05:30 PM   #2
mcma111 OP
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OK, the bottom end is done. Now for the top end.

Make sure the cylinder is really clean. Yes, there was some black stuff on the cloth after I wiped down the cylinder.



Put a ring in the cylinder and push it down 1" with the piston



Checking ring end gap. With Wiseco piston sets it seems like I never have to file fit the rings.



Put one of the wrist pin keeper clips on and apply some assembly lune



Lube the rod



Pin in place and the other pin keeper clip in



Ring compressor with a couple of pieces of 3/4" ply to hold the piston still while I install the cylinder



Oil them bolts



And the washers, per the factory service manual



Torquing down the cylinder. 36lbs in 2 steps

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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
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Old 08-06-2011, 05:53 PM   #3
mcma111 OP
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My cam chain tensioner holder.



Install the tensioner and hold it all of the way back



Place the screw driver like this and tap it with the hammer



Tensioner held in place



Dowels and head gasket in place



Torquing the cylinder head. 25lbs in 3 steps



Starter ring gear goes on



Goop up the stator wire grommet



Starter reduction gears go on



Stator cover on



Don't forget to route the wires through here



Starter on



Starter gear cover on. Notice I had the stator wires routed incorrectly here



The neutral switch has a really small thread. Be very careful that you don't over tighten the nut or you'll be buying a new switch. Ask me how I know this. Thanks son...



On to the cam installation. Don't forget this little fella. Part of the cam auto decompressor assy



The cam center journal gets a dollop of assembly lube and the cam goes in



Piston at TDC, cam drive sprocket marks aligned



On to the rocker cover. The rockers were TOAST





The cam hardly had any wear but it was bad none the less





Reusing the steel, laminated rocker cover gasket. Wipe it down with lacquer thinner and place it on a piece of cardboard. Smear a thin coat of Hondabond on the bottom side of it



A thin coat on the head



The top of the gasket



And the rocker cover. Notice the new rocker arms









Seal the rocker arm shafts. The rubber bands hold the rocker arms up in position. Trick #8 Trick

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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

mcma111 screwed with this post 10-02-2012 at 03:55 PM
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Old 08-06-2011, 05:54 PM   #4
mcma111 OP
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The rocker cover in place. This is where I called it for the day

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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
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Old 08-06-2011, 05:56 PM   #5
techforlife
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You puttin in the NX 2nd aren`t you Steve.........

That center journal repair looks odd......is it smooth where the cam sits???? it looks rough.also rough where the gasket goes too.could just be the pics though,just wondering.......good job...


B
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01 XR650L,102mm JE 11.25:1..NX650 second gear,FMX650 fifth gear,ported CW head,KW valve train,MegaCycle 173X25.FCR MX pumper.42/158 NVCT needle.Cycra probend CRM,Scott`s sharkfin,Xr`s Only casesaver.FMF "Q2",Sutton Oil Cooler,Clarke 4.0,Red XR`s Only skidplate,Doubletake mirrors,Manracks Rotopax rack..one Minature Schnauzer
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Old 08-06-2011, 05:57 PM   #6
mcma111 OP
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The guy that took the engine apart lost some of the fasteners. Luckily I have this

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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 08-06-2011, 06:00 PM   #7
mcma111 OP
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The NX650 gear is in the picture of all the OE parts. The cam journal looks weird but is smooth. There is a couple of pimples where the gasket goes but it is of no matter. The sealant will take care of that.
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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
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Old 08-06-2011, 06:12 PM   #8
Wattner
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WOW.... That is AWESOME!!!!!! Thanks Steve
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Old 08-06-2011, 06:17 PM   #9
thebigman
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Subscribed to xr650l engines , 1301 , credit course.
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Old 08-06-2011, 06:23 PM   #10
techforlife
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Quote:
Originally Posted by mcma111 View Post
The NX650 gear is in the picture of all the OE parts. The cam journal looks weird but is smooth. There is a couple of pimples where the gasket goes but it is of no matter. The sealant will take care of that.
Yup i thought you were puttin in the NX gear,,i saw it in the photo...Steve what do they charge to repair the center journal,,just for my records

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Old 08-06-2011, 06:24 PM   #11
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Did you put in an extra used cam or get that old one reground?
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Old 08-06-2011, 06:35 PM   #12
mcma111 OP
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B,

I forget how much he charged for the journal repair. The bill has all of the labor lumped together.

Clayjars

I used one of my spare OE cams. I'll probably keep the damaged one for a Mega Cycle core if I do one some day. No sense in using a perfectly good cam if I have a damaged one.
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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
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Old 08-06-2011, 06:39 PM   #13
techforlife
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Quote:
Originally Posted by mcma111 View Post
B,

I forget how much he charged for the journal repair. The bill has all of the labor lumped together.

Clayjars

I used one of my spare OE cams. I'll probably keep the damaged one for a Mega Cycle core if I do one some day. No sense in using a perfectly good cam if I have a damaged one.

Hummmmmm........what would you charge me for that cam Steve,,after it`s been welded up by Mega Cycle....i`m thinkin of goin into the motor again this winter for a cam upgrade





B
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01 XR650L,102mm JE 11.25:1..NX650 second gear,FMX650 fifth gear,ported CW head,KW valve train,MegaCycle 173X25.FCR MX pumper.42/158 NVCT needle.Cycra probend CRM,Scott`s sharkfin,Xr`s Only casesaver.FMF "Q2",Sutton Oil Cooler,Clarke 4.0,Red XR`s Only skidplate,Doubletake mirrors,Manracks Rotopax rack..one Minature Schnauzer
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Old 08-06-2011, 06:44 PM   #14
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Make sure that one thing goes on top of that deal.
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Old 08-06-2011, 06:44 PM   #15
mcma111 OP
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Between the regrind cam and the rocker arms it's about $500.00. I think it's $214.00 or so for the cam and $62.00 for each rocker arm.
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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
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