Building A XR650l Engine

[mcma111]

The engine comes out the right side. You should be able to do this yourself. Unless your a 98lb weakling. I always have the bike on a box or now that I have a lift, straight up 'n down. Simply rock the engine to the right so the top end is out some and then heave. I usually have my right hand at the right head corner with fingers in the exhaust port and the left hand grabs the shift lever. The engine weighs about 115 lbs.

[2manyrides]

I know how it is when you have a question, you need the answer NOW.
So this may be too late.

Motor out on right side. Kicker serves as a handle at some points.
This is a one man job.
Do it on the kick stand. No need to lay the bike over, in fact that might be a tougher way to wiggle it past the frame tabs.

edit; Steve beat me to it!

[mcma111]

Originally Posted by 22manyrides

Kicker serves as a handle at some points.

Kicker?? What kicker???


This is a XR650L

[2manyrides]

Originally Posted by mcma111

Kicker?? What kicker???


This is a XR650L

Well, isn't there a way to convert 650l's to a kickstart?
That'd give him a handle!

[mcma111]

Originally Posted by 22manyrides

Well, isn't there a way to convert 650l's to a kickstart?
That'd give him a handle!

Yes there is. I do have some parts in the garage right now.

Think their owner will miss them?

XR650l Kicker is another episode...

[farrington300]

got it out!!!! The motor was coated in years of oil and dirt. I really couldnt get a good hand on it. So I put down some card board...bike on its right and about 5 mins of twisting, the motor was on the floor and the bike back on the kick stand. I blew out my back about 3 weeks ago, so this is all risky business... but I was also about to get it up onto the bench. Top end totaly apart. So far, I need a cam, sealed cam bearing, cam chain, valve job, valve seals, piston, rings, etc. The cases will be split tomorrow eve. New counter shaft, 5th gear, and 2nd gear will go in.

[farrington300]

Got everything taken apart down to the flywheel. I have a puller...wrong size. Now Im off to the dealer to blow some money.

[1Bonehead]

Originally Posted by mcma111

XR650l Kicker is another episode...

[Gas Hog]

Steve,
Great write up!
You obviously have been inside a bunch of these, I came across a new in the crate 2000 XR650R..
Don't really need (sorry for the 4 letter word) but they have such history..plus I am a sucker for "new in the crate" old bikes.
With the new technology of today's bikes would this be a beast to go after?
Gary

[Keith]

Originally Posted by mcma111

...The sealant. I let it dry a day and peel it off like a rubber band. Inside it actually stays in place. I have done this many times with no problem...

That is a really neat idea.

[mcma111]

Originally Posted by Gas Hog

Steve,
Great write up!
You obviously have been inside a bunch of these, I came across a new in the crate 2000 XR650R..
Don't really need (sorry for the 4 letter word) but they have such history..plus I am a sucker for "new in the crate" old bikes.
With the new technology of today's bikes would this be a beast to go after?
Gary

If it floats your boat, do it.

[farrington300]

Is there a place to buy a complete gasket kit (like the ones on ebay) but with OEM gaskets?

I was thinking of buying an ebay gasket kit, so I have a little of everything and picking up an OEM center case gasket. Thoughts?

[mcma111]

Originally Posted by farrington300

Is there a place to buy a complete gasket kit (like the ones on ebay) but with OEM gaskets?

I was thinking of buying an ebay gasket kit, so I have a little of everything and picking up an OEM center case gasket. Thoughts?

With those aftermarket gasket sets you may as well throw your money away. WAIT, I know. Use the dollar bills to make gaskets...

No really. I only use OE gaskets except for the over size head gaskets. Then I use Wiseco or Cometic. Cometic makes Wiseco gaskets anyway.

I only but the gaskets that I need and not the sets.

[Reposado1800]

Originally Posted by Sourjon

Hmmm.... I wonder. Bad gear from the start maybe? Here's the cam from my original motor. Bad casting? 28K mi and the rest of the motor looked very good. I hadn't noticed any noises or issues when I swapped but found this when I pulled the cover. The rocker still looked fine. I wonder if this gear might have had the same problem from the factory. It is under a lot more load than the cam.


John

That looks like pitting from moister. That can even happen from high humidity forming condensation in a cold engine.

[farrington300]

Originally Posted by mcma111

With those aftermarket gasket sets you may as well throw your money away. WAIT, I know. Use the dollar bills to make gaskets...

No really. I only use OE gaskets except for the over size head gaskets. Then I use Wiseco or Cometic. Cometic makes Wiseco gaskets anyway.

I only but the gaskets that I need and not the sets.

Kinda what I was thinking. Just needed a slap on the back of the head to remind me.


PS So far this xr650l has cost me just a little over $320,000. As I was rebuilding my motor, I realized I needed a new piston, among other parts, but I also realized that I needed a new shop to work in. So I bought a new shop, O and the shop came with a new house as well.