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Old 01-21-2013, 12:09 AM   #256
Ivanych
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Location: St. Petersburg. Russia
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Quote:
Originally Posted by AndyCBR View Post
Steve,

I'm in the middle of my rebuild and have a question about the superseded part number for the gearshift drum detent spring.

On earlier bikes (like my 2003) this spring is a single wire affair and is just looped around to put some pressure on the detent fork.

On later models the spring appears to have been upgraded to a coil type spring.

Is this a common point of failure in this model? If you're down there already is it worthwhile to get the superseded spring?

The spring I'm talking about is #10 in the pic (from the 2003 fiche). #27 does not show up as available on the 03 fiche but the part #10 is the newer part number if you look at the 09 fiche (only one spring is depicted in the 09 fiche)

Thanks in advance for any advice.

Best,
Andy

Hi!
I ordered the new spring for installation in my old XR500R motor.
I think this will work, I'll watch when he comes.
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Old 01-21-2013, 03:06 AM   #257
mcma111 OP
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I would use the later spring. I have only heard of one failing on a fellas XR600. The transmission would not shift at all. Matter of fact I have it on my list of tid-bits I need for when I assemble my CW engine.
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BMW's
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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 01-23-2013, 09:08 PM   #258
crobox
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Great thread Dave. The backlog of parts you have for these engines, which is mentioned once or twice, begins to give me an idea of the relationship you have with them.

Thanks for the service to the community.
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Current Bikes: 2002 XR650L, Nighthawk, 1986 Honda XL600R, 1988 Hondasuki KLNX250R, 1988 BMW R100GS (dead)
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Old 01-24-2013, 04:25 AM   #259
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Dave? Who's Dave???
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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 01-24-2013, 05:27 AM   #260
brucifer
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Hey man.....Dave's not here.
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Old 01-24-2013, 07:30 AM   #261
crobox
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Quote:
Originally Posted by mcma111 View Post
Dave? Who's Dave???

Oops. That was the last thing I did before going to bed... it was late!

Substitute "Steve" into above comments, and leave the meaning otherwise unchanged!
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Current Bikes: 2002 XR650L, Nighthawk, 1986 Honda XL600R, 1988 Hondasuki KLNX250R, 1988 BMW R100GS (dead)
Previous Bikes: Honda XL250R (2 of them), Honda XL600R, Kawasaki KLR600, BMW K1100LT, BMW R60/6, BMW K75, Husqvarna 430XC
Click HERE for my Cummins 4BT International Scout build thread www.christianristow.com
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Old 01-24-2013, 08:14 AM   #262
elsalvadorklr
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too late now man, the damage is DONE!


jajajajajajajajja
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Old 01-24-2013, 10:00 AM   #263
crobox
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Sorry for calling you Dave, Steve. No one likes that sort of thing. My apologies.
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Current Bikes: 2002 XR650L, Nighthawk, 1986 Honda XL600R, 1988 Hondasuki KLNX250R, 1988 BMW R100GS (dead)
Previous Bikes: Honda XL250R (2 of them), Honda XL600R, Kawasaki KLR600, BMW K1100LT, BMW R60/6, BMW K75, Husqvarna 430XC
Click HERE for my Cummins 4BT International Scout build thread www.christianristow.com
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Old 01-24-2013, 12:28 PM   #264
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No worries. For some reason most people I say my name to when on the phone reply DAVE?
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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 01-24-2013, 04:58 PM   #265
crobox
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Quote:
Originally Posted by mcma111 View Post
No worries. For some reason most people I say my name to when on the phone reply DAVE?
Well there are certain phonetic and syllabic similarities...

Anyway, like I said before... Great thread!!
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Current Bikes: 2002 XR650L, Nighthawk, 1986 Honda XL600R, 1988 Hondasuki KLNX250R, 1988 BMW R100GS (dead)
Previous Bikes: Honda XL250R (2 of them), Honda XL600R, Kawasaki KLR600, BMW K1100LT, BMW R60/6, BMW K75, Husqvarna 430XC
Click HERE for my Cummins 4BT International Scout build thread www.christianristow.com
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Old 01-31-2013, 06:04 PM   #266
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Massively informative thread

I am in the market for a 2001 XR650L and it was a great thing to view this thread.
I can get the bike for 600 bucks but it needs a rebuild as the owner states there was an oiling failure.

With this pictorial I can tear open the engine with confidence and I will hopefully find less damage than the owner suspects.

One thing I cannot tell from the post is whether or not the connecting rod is OEM or not. I know the crank is pressed but the fiche for this bike shows the rod and crank as one part number.

If it is aftermarket where did you get it? There seems to be a lot of hopping up on these engines but I want to go for a stock and hopefully cheaper rebuild.
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Old 01-31-2013, 06:36 PM   #267
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The rod was replaced with a Pro-X rod kit.

Different engine but the same rod kit.

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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 01-31-2013, 07:49 PM   #268
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Now to make a list for this do you have any other vendors?

I ask because I do not readily trust local resources and you have done this many times before.
149.99 for the crank pin and rod is super cheap from my point of view.

All in all it looks as if fixing this is like working on a really big wristwatch.
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Old 02-09-2013, 04:00 AM   #269
The Dogger
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Right Crankcase cover/clutch/camchain

Hi Steve

I'm in the process of removing the right side crankcase cover. I've followed the steps in the Clymer manual,Brake pedal , kickstart and bolts plus the 3 nuts at the bottom all off. The manual then states to simply remove the cover , taking care not to lose the locating dowels.

Mine won't budge. I've applied a little heat and tapped lightly with a rubber mallet..........nothing.

Can you shed any light please ? Can I give it mighty smacks ? I'm not clear on where exactly these dowels are.

I'm replacing my camchain . Do I need a clutch holder tool , or do you have a trick way ?

I've read this excellant thread a few times , which has inspired me to delve into this myself rather than farm it out , but I am worried about causing damage due to any hamfisted bodgery on my part

Many thanks for any tips

Cheers

Stu

The Dogger screwed with this post 02-09-2013 at 04:01 AM Reason: Poor wording
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Old 02-09-2013, 04:50 AM   #270
deejay_xr
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Quote:
Originally Posted by The Dogger View Post
Hi Steve

I'm in the process of removing the right side crankcase cover. I've followed the steps in the Clymer manual,Brake pedal , kickstart and bolts plus the 3 nuts at the bottom all off. The manual then states to simply remove the cover , taking care not to lose the locating dowels.

Mine won't budge. I've applied a little heat and tapped lightly with a rubber mallet..........nothing.

Can you shed any light please ? Can I give it mighty smacks ? I'm not clear on where exactly these dowels are.

I'm replacing my camchain . Do I need a clutch holder tool , or do you have a trick way ?

I've read this excellant thread a few times , which has inspired me to delve into this myself rather than farm it out , but I am worried about causing damage due to any hamfisted bodgery on my part

Many thanks for any tips

Cheers

Stu
You removed the oil line as well right?

Tap the case on the sides along the split between case and engine block, pick the spots where the most meat is and whack away. If you use a rubber mallet you won't soon break anything, but be careful not to tap on the protrusions with the allen bolt holes, they're fragile.

Tapping head-on on the kickstart axle helps as well

Dowels are the nr 23 parts (sorry bout the big image guys)

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