Building A XR650l Engine - Page 18

Spud Rider · 01-20-2013, 10:51 PM

Quote:

Originally Posted by AndyCBR

I was kinda thinking that. The original design spring is pretty cheesy. When I took it apart I thought something was wrong as it is just one bent wire hanging out in the open.

Thanks,
Andy

You're welcome, Andy.

Spud

Ivanych · 01-21-2013, 12:09 AM

Quote:

Originally Posted by AndyCBR

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I'm in the middle of my rebuild and have a question about the superseded part number for the gearshift drum detent spring.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 If you're down there already is it worthwhile to get the superseded spring?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.

mcma111 · 01-21-2013, 03:06 AM

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.

crobox · 01-23-2013, 09:08 PM

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.

mcma111 · 01-24-2013, 04:25 AM

Dave? Who's Dave???

brucifer · 01-24-2013, 05:27 AM

Hey man.....Dave's not here.

crobox · 01-24-2013, 07:30 AM

Quote:

Originally Posted by mcma111

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!

elsalvadorklr · 01-24-2013, 08:14 AM

too late now man, the damage is DONE!

jajajajajajajajja

crobox · 01-24-2013, 10:00 AM

Sorry for calling you Dave, Steve. No one likes that sort of thing. My apologies.

mcma111 · 01-24-2013, 12:28 PM

No worries. For some reason most people I say my name to when on the phone reply DAVE?

crobox · 01-24-2013, 04:58 PM

Quote:

Originally Posted by mcma111

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!!

veryoldbiker · 01-31-2013, 06:04 PM

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.

mcma111 · 01-31-2013, 06:36 PM

The rod was replaced with a Pro-X rod kit.

Different engine but the same rod kit.

veryoldbiker · 01-31-2013, 07:49 PM

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.

The Dogger · 02-09-2013, 04:00 AM

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

01-21-2013, 03:06 AM	#258
mcma111 ^OP Beastly Adventurer Joined: Jul 2007 Location: San Francisco,Ca. Oddometer: 8,005	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. __________________ 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

01-23-2013, 09:08 PM	#259
crobox Gnarly Adventurer Joined: Nov 2012 Location: Taos, NM Oddometer: 196	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. __________________ Current Bikes: 1986 Honda XL600R, 1988 Hondasuki KLNX250R, 1988 BMW R100GS (dead) Previous Bikes: Honda XL250 (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

01-24-2013, 04:25 AM	#260
mcma111 ^OP Beastly Adventurer Joined: Jul 2007 Location: San Francisco,Ca. Oddometer: 8,005	Dave? Who's Dave??? __________________ 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

01-24-2013, 05:27 AM	#261
brucifer Beastly Adventurer Joined: Nov 2007 Location: Eureka, Ca. Oddometer: 1,626	Hey man.....Dave's not here. __________________ 2006 KLR650-2002 Husaberg FC550E w/2008 FE550E engine-2000 Buell M2 Cyclone-Plated 1995 XR600R-1984 Honda CR500R-1984 Honda XL600R/XR650L Hybrid-1984 Yamaha TT600L-1981 Honda XR500R-1980 Honda CB750F

01-24-2013, 10:00 AM	#264
crobox Gnarly Adventurer Joined: Nov 2012 Location: Taos, NM Oddometer: 196	Sorry for calling you Dave, Steve. No one likes that sort of thing. My apologies. __________________ Current Bikes: 1986 Honda XL600R, 1988 Hondasuki KLNX250R, 1988 BMW R100GS (dead) Previous Bikes: Honda XL250 (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

01-24-2013, 08:14 AM	#263
elsalvadorklr Beastly Adventurer Joined: Nov 2008 Location: el salvador Oddometer: 3,963	too late now man, the damage is DONE! jajajajajajajajja

01-24-2013, 12:28 PM	#265
mcma111 ^OP Beastly Adventurer Joined: Jul 2007 Location: San Francisco,Ca. Oddometer: 8,005	No worries. For some reason most people I say my name to when on the phone reply DAVE? __________________ 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

01-31-2013, 06:04 PM	#267
veryoldbiker n00b Joined: Mar 2011 Location: New Brunswick, Canada Oddometer: 2	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.

01-31-2013, 06:36 PM	#268
mcma111 ^OP Beastly Adventurer Joined: Jul 2007 Location: San Francisco,Ca. Oddometer: 8,005	The rod was replaced with a Pro-X rod kit. Different engine but the same rod kit. __________________ 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

01-31-2013, 07:49 PM	#269
veryoldbiker n00b Joined: Mar 2011 Location: New Brunswick, Canada Oddometer: 2	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.

02-09-2013, 04:00 AM	#270
The Dogger Adventurer Joined: Dec 2011 Location: Great Britain Oddometer: 82	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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