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Old 02-09-2013, 06:21 AM   #271
The Dogger
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Cheers deejay

That's got it off , thanks. Can you confirm that part no. 6 in your diagram is a washer or grommet that fits in the oil filter? ie when you replace the oil filter that washer is already in place ?

Now to remove the clutch.......any pointers there greatly appreciated

Cheers

The Dogger screwed with this post 02-09-2013 at 06:22 AM Reason: speling
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Old 02-09-2013, 06:25 AM   #272
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Originally Posted by The Dogger View Post
Cheers deejay

That's got it off , thanks. Can you confirm that part no. 6 in your diagram is a washer or grommet that fits in the oil filter? ie when you replace the oil filter that washer is already in place ?

Now to remove the clutch.......any pointers there greatly appreciated

Cheers
Yep, thatīs it, itīs already in place in every filter.

For removing the clutch basket you can either order a tool from Ebay, mineīs from EBC, cost about 20 USD I believe.
Or what some people do is wedge a penny or some other type of SOFT (you DONīT want to damage the teeth) coin in between the gears so they are stuck while you apply pressure to the bolts.
It wouldnīt be my way of doing it, but apparently it works

Edit: One of these http://www.ebay.com/itm/390527909921...470021&vxp=mtr
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Old 02-09-2013, 02:39 PM   #273
Walterxr650l
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Quote:
Originally Posted by The Dogger View Post
Cheers deejay

Now to remove the clutch.......any pointers there greatly appreciated

Cheers

Quote:
Originally Posted by mcma111 View Post

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



The clutch can be gunned off, the same way Steve shows to gun it on.

Walter
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Old 02-09-2013, 02:45 PM   #274
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Wow. Thanks Walter.
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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 02-09-2013, 03:00 PM   #275
The Dogger
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The clutch can be gunned off, the same way Steve shows to gun it on.

Walter
Yeahbut......I saw those photo's , but there must be a stage before that ( in the removal procedure ) that prevents the whole shebang from turning while the 4 bolts are removed ...........

That's what I was after......I had seen the penny trick on here before , and when I tried it I couldn't get it to jam up without falling out. Hence , asking for advice

I don't have access to an airgun , is that likely to be a problem ?

EBC clutch holder ordered and an it's way

Thanks
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Old 02-09-2013, 03:12 PM   #276
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Clutch Removal

You remove the four bolts that hold the springs and outer clutch hub and the nut on the main shaft are right there. Gun the nut off and the whole clutch hub comes off. All you have to do is grasp the clutch assy to keep it from spinning as you gun it off. No gun? Then you will need a clutch hub holder as you wrench it off.
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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 02-09-2013, 03:51 PM   #277
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OK , got it , thanks
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Old 02-09-2013, 06:46 PM   #278
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OK , got it , thanks
Yep, clutch tool would be the way to go, for us non-privileged people
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Old 02-09-2013, 07:02 PM   #279
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You can never have enough tools.
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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 02-09-2013, 07:05 PM   #280
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Originally Posted by mcma111 View Post
You can never have enough tools.
Correct !

And I'm well on my way, the problem remains that nice tools tend to be expensive...
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Old 05-07-2013, 08:24 PM   #281
JSeward
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Question piston direction

Quote:
Originally Posted by mcma111 View Post
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

Hi Brilliant thread, has helped me heaps with my NX650 rebuild/custom. Just a query, though, does it matter that the arrow on the piston in the photos is pointing to the exhaust rather than the inlet ? manuals I've read says needs to point to the inlet, and now I'm a bit confused. Spose it depends on the piston geometry? i.e. if its symetrical it doesnt matter
CHeers
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Old 05-07-2013, 09:33 PM   #282
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Different pistons have different marking. The piston pictured is a Wiseco and there is a small arrow pointing toward the exhaust.

This is my other XRL with a JE piston. Bigger valve pockets on the intake side:

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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 05-10-2013, 05:06 PM   #283
JSeward
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Thanks for clearing that up. The piston I am looking at it a flat top and I am pretty sure it's a wossner but can't find any info on the direction of the arrow

Cheers

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Old 06-15-2013, 02:20 AM   #284
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I'm always of mind that the money you spend on tools to do it yourself will pay for themselves in not having to pay someone else to do work later on down the road. This thread has been helpful, I'm in the process of tearing down my xrl that overheated in a +40mph headwind trying to do 65+ with less than optimal jetting DOH! As soon as I started slightly slowing down and more throttle didn't do anything I hit the kill switch and let it cool, rode back the 20 miles keeping to 4th and using a little 1/2 choke just to make certain. That was two summers ago (not counting this one) and it was fine except for the slight burning oil smell on decel. Until this spring when it decided to smoke up a two stroke style storm while accel during warmup. My machine shop here has the jug and it's barely scuffed up with one small groove that they say will hone out just fine. Just shined up the skirt a hair and ordering new rings soon. Oh and valve stem seals as that could be part to blame. Stupid thing is sitting in the garage with an unlucky 5777.2 miles on it. I think next time I'm going with a Doctor, just have to reinforce that gangly oil cooler hanging off the side :) (Gotta justify the welder somehow right!)

Oh and a xr650r style CS sprocket. Is there any issues with chain alignment or is it all good?
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Old 06-15-2013, 03:18 AM   #285
AndyCBR
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Quote:
Originally Posted by Notabiker View Post
I'm always of mind that the money you spend on tools to do it yourself will pay for themselves in not having to pay someone else to do work later on down the road. This thread has been helpful, I'm in the process of tearing down my xrl that overheated in a +40mph headwind trying to do 65+ with less than optimal jetting DOH! As soon as I started slightly slowing down and more throttle didn't do anything I hit the kill switch and let it cool, rode back the 20 miles keeping to 4th and using a little 1/2 choke just to make certain. That was two summers ago (not counting this one) and it was fine except for the slight burning oil smell on decel. Until this spring when it decided to smoke up a two stroke style storm while accel during warmup. My machine shop here has the jug and it's barely scuffed up with one small groove that they say will hone out just fine. Just shined up the skirt a hair and ordering new rings soon. Oh and valve stem seals as that could be part to blame. Stupid thing is sitting in the garage with an unlucky 5777.2 miles on it. I think next time I'm going with a Doctor, just have to reinforce that gangly oil cooler hanging off the side :) (Gotta justify the welder somehow right!)

Oh and a xr650r style CS sprocket. Is there any issues with chain alignment or is it all good?

The chain alignment will be off a little but not enough to worry about.

It is common to have to possibly do a little bit of dremel or die grinder beveling on the side of the sprocket that faces the engine in order for it to seat fully and allow the keeper to hit the slot (remember you are installing the R sprocket backwards).

Hope this helps.
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