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Old 02-04-2012, 06:56 AM   #1
brucifer OP
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1984 XL600R Build

Okay, I'm going to document, as well as I can, the restore/modification of my '84 XL600. It will be a long, drawn out process I'm sure as I don't get to work on it as much as should and, as always, money is tight.
I plan to add a little newer suspension and brakes as well as engine impovements all the while keeping it looking like an '84 XL600.
Some of you may know this bike from my thread over on TT but if you don't and would like to see where I started on this bike, go over to TT and click on the XR600/650 forum and search out XL600R/XR650L Hybrid thread. http://www.thumpertalk.com/topic/503...brid/page-1?hl
Alright, we'll pick up where I am now.

I stripped the bike down to the frame and did a few mods. First I test fit an XR650L swingarm and it was a virtual bolt-on deal. Then, eyeballed the position for the rear brake pedal pivot and master cylinder bracket and tack welded them in place. I then took the frame to work and had my boss' son weld them up for me. I ended up doing the pivot twice because I wasn't happy where I had positioned it the first time.
A few pics.






The shock I'm hoping to use is from a 1988 XR600 that I purchased from an inmate.
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2014.5 Kawasaki KLR650 NE-2008 Yamaha TTR110-2006 Buell XB12SS-1996 Honda XR600R-1993 Kawasaki KX500-1984 Honda XL600R/XR650L Hybrid-1984 Yamaha TT600L-1980 Honda CB750F-1977 Yamaha TT500

brucifer screwed with this post 03-06-2014 at 07:09 AM
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Old 02-04-2012, 07:06 AM   #2
mcma111
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Bruce,

Don't forget to install the rear brake master cylinder reservoir mounting bracket.

And if your going to powder coat the frame wash out the oil tank first.
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Old 02-04-2012, 07:22 AM   #3
brucifer OP
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For the front end, I was going to keep the XR650L assembly I had installed earlier but then I found a complete minus the wheel '93 CR500 fork assembly on ebay and decided to go that route.
After I bought it I was told that the '93 stuff wasn't really that great of a setup. Oh well. It's what I have and will work fine for now. I can always change it out later if I'm not happy with the results.
To install it on the XL, I had to swap the stem for one from an '84 CR500. I just happened to have a triple assembly for an '84 CR5 lying around and the stem happened to be what was needed. Just had to machine a bushing for the lower clamp to stem interface.
Pics.




After the test fitting, the frame and top motor mounts were taken to the powder coater. I also rattle canned the triple clamp assembly. Strangely enough, they came out nice.
The frame came out awesome. More pics later.
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2014.5 Kawasaki KLR650 NE-2008 Yamaha TTR110-2006 Buell XB12SS-1996 Honda XR600R-1993 Kawasaki KX500-1984 Honda XL600R/XR650L Hybrid-1984 Yamaha TT600L-1980 Honda CB750F-1977 Yamaha TT500
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Old 02-04-2012, 07:25 AM   #4
brucifer OP
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Originally Posted by mcma111 View Post
Bruce,

Don't forget to install the rear brake master cylinder reservoir mounting bracket.

And if your going to powder coat the frame wash out the oil tank first.
G'morning Steve! I have an idea for the master res. Tank was clean.
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2014.5 Kawasaki KLR650 NE-2008 Yamaha TTR110-2006 Buell XB12SS-1996 Honda XR600R-1993 Kawasaki KX500-1984 Honda XL600R/XR650L Hybrid-1984 Yamaha TT600L-1980 Honda CB750F-1977 Yamaha TT500
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Old 02-04-2012, 07:44 AM   #5
mcma111
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Hope you clean the oil tank before putting oil in it. Take a look at my Phoenix build and you'll see what I had to tend with. That blast media is nasty stuff.
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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 02-04-2012, 07:52 AM   #6
BIG ED XT FAN
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Quote:
Originally Posted by brucifer View Post
G'morning Steve! I have an idea for the master res. Tank was clean.
Hi, Bruce, Nice build. I like them xr 500/600 too. Scott Summers always made them xrs look good.
Half your garage is honda , and your 2nd is Yamaha how do you know what to take on a ride?
Thump-On!!! ED
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Old 02-04-2012, 07:56 AM   #7
techforlife
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Hey Bruce......looks like a great build.....




B
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Old 02-04-2012, 08:36 AM   #8
brucifer OP
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Quote:
Originally Posted by mcma111 View Post
Hope you clean the oil tank before putting oil in it. Take a look at my Phoenix build and you'll see what I had to tend with. That blast media is nasty stuff.
Yeah, I plan to flush, flush and more flush before anything.

Quote:
Originally Posted by BIG ED XT FAN View Post
Hi, Bruce, Nice build. I like them xr 500/600 too. Scott Summers always made them xrs look good.
Half your garage is honda , and your 2nd is Yamaha how do you know what to take on a ride?
Thump-On!!! ED
Hi Ed! Well, I am partial to me old Honda and Yamahas but I pretty much like everything.

Quote:
Originally Posted by techforlife View Post
Hey Bruce......looks like a great build.....




B
Hi Brian! Thanks, we'll see. lol.
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Old 02-04-2012, 03:38 PM   #9
brucifer OP
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More pics.






The company who did the powder coat work on the frame is Pacific Powder Coating in Arcata Ca. They do great work and are very reasonable. Nice people as well.
The pictures don't do it justice. It looks orange here but it's red. I'll try some inside shots later.
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Old 02-04-2012, 05:35 PM   #10
jgrady1982
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Cool! Finally another XL6R build!
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Old 02-04-2012, 06:46 PM   #11
kubiak
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wow!
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Old 02-04-2012, 06:56 PM   #12
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Beautiful work. Nothing like a frame up restoration. The frame, triples, and CR500 USD forks all look awesome. The XR600 shock was also a good find. This will end up being better suspended and lighter than a new XR650L and still be air cooled. Very cool.

Keep it light.

I hope you use a lithium battery and other light bits ... this bike deserves it!!
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Old 02-05-2012, 05:56 AM   #13
Billtr96sn
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I'm gonna be. watching this one
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Old 02-05-2012, 09:18 AM   #14
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Quote:
Originally Posted by brucifer View Post
For the front end, I was going to keep the XR650L assembly I had installed earlier but then I found a complete minus the wheel '93 CR500 fork assembly on ebay and decided to go that route.
After I bought it I was told that the '93 stuff wasn't really that great of a setup. Oh well. It's what I have and will work fine for now. I can always change it out later if I'm not happy with the results.

I like what you're doing with the old XL6 Bruce. Its what I would be doing if I owned one

Can you elaborate further on the CR500 KYB forks? Why is it not that great of a setup? Adjustment issues? Don't tell me the average rider can tell that these forks are 1 mm smaller in diameter compared to the latest USD

Didn't you get to reuse the XL wheel with the CR5 forks? Or is it the XRL wheel you will be using?

Yes, I've seen mentioned in various discussions on USD fork setups about the sub par performance of the CR5 USD forks, but nothing with the specifics in a nice list/summary. If anyone has a good link to such information, feel free to post it, I'll read it.
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Old 02-05-2012, 11:10 AM   #15
brucifer OP
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Originally Posted by Ghost_Mutant View Post
I like what you're doing with the old XL6 Bruce. Its what I would be doing if I owned one

Can you elaborate further on the CR500 KYB forks? Why is it not that great of a setup? Adjustment issues? Don't tell me the average rider can tell that these forks are 1 mm smaller in diameter compared to the latest USD

Didn't you get to reuse the XL wheel with the CR5 forks? Or is it the XRL wheel you will be using?

Yes, I've seen mentioned in various discussions on USD fork setups about the sub par performance of the CR5 USD forks, but nothing with the specifics in a nice list/summary. If anyone has a good link to such information, feel free to post it, I'll read it.
Hey GM, good to see ya!

I really don't know why they say that about the forks. Maybe adjustment issues? I didn't see any adjustment on the top caps. Could be some on the bottom; I haven't actually looked there yet.

Not sure which wheels I'll be using yet. I was thinking of using a CR5 hub and lacing a new rim and spokes to it. Whichever wheels I use will have new spokes and rims.
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