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Old 12-03-2012, 02:13 PM   #76
Moparmanpete
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Old 12-19-2012, 12:06 PM   #77
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Talking It's progress ... sort of

Well, the engine is still in bits, all for the need of balancer shaft bearings! They're out of stock items in Europe and Japan; I haven't investigated US sources yet, but I'm not hopeful. I think I can have the 'nearest' bearings (15id x 42od x 13w) machined to size - out to 17mm inner diameter (doable) and 1mm off the total width of the bearing shell, I'm not certain whether they can do that, I didn't ask my bearing guy.

In the meantime...

I decided to build up the engine cases, barrel, head, etc. and slip the motor back into the frame - boy, was that easy with no engine internals! This evening I've made the top motor-to-frame plates from 5mm Ally and I was going to fit the exhaust so I could figure out what to do about a right-hand side panel... more of that to come, but here's where it stands tonight -



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Old 12-19-2012, 01:23 PM   #78
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Nice! Looks like the upper engine mount worked out just fine for you.
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Old 12-19-2012, 02:02 PM   #79
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I'm really pleased with it how it's working out so far, the photo's probably flatter the finish but honestly, I don't want to build something that I'm frightened to get dirty. Your 'do a proper engine rebuild' idea was inspired though. I'm really looking forward to the moment when I can kick that motor over (I think!). Hopefully the rest of the will hold up OK ... particularly my crucial bit of frame welding and those top mounts
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Old 12-19-2012, 02:35 PM   #80
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Looking Great Jim! Keep Going!





Be sure to start it outside I didn't
http://youtu.be/fSwzr4a-Ozc
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Old 12-19-2012, 04:37 PM   #81
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Jim,

I just looked at Cheapcycleparts and they show the counter balancer bearings. I suppose some one (me) on this side of the pond could buy them and send them to you. Interested?

Looking at the parts site the original part # has been superseded by:
Bearing, Radial Ball (16 X44 X13) (Toyo) 91005-MK4-701 $19.32

I'm on hold waiting for parts to answer the call to see if the bearings are available.

No dice. Parts counter is busy and they will supposedly call me back. I left them the part # to check on.
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Old 12-19-2012, 04:40 PM   #82
mcma111
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That was fast. They just called back and the bearing is available. Local dealer wants about $27.00 each.
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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 12-20-2012, 12:32 PM   #83
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Quote:
Originally Posted by mcma111 View Post
Jim,

I just looked at Cheapcycleparts and they show the counter balancer bearings. I suppose some one (me) on this side of the pond could buy them and send them to you. Interested?
Hi Steve,

That's very kind of you. I guess it's probably best to leave it 'til after Christmas/New Year if that's OK with you - everything seems to go crazy over here for a couple of weeks. I'll PM you so we can figure out the money side of things, in the meantime the bearings I need are these ones...

http://www.cheapcycleparts.com/produ...aring-17x42x12

I've emailed them to see if they have the bearings and if they'll ship direct. I might have a better chance of bypassing HM Customs if it looks like it's coming from a private individual though

I also need one of these...

http://www.cheapcycleparts.com/produ...pring-follower

I think they're the only discontinued parts I need, but I'll make an inventory over the next week or so.

Thanks again
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Old 12-20-2012, 12:36 PM   #84
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Thumb

Quote:
Originally Posted by Moparmanpete View Post
Be sure to start it outside I didn't
http://youtu.be/fSwzr4a-Ozc
I hope mine sounds that nice Pete, you've done a good job there
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Old 12-20-2012, 01:43 PM   #85
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Jim,

Let me know what you need and I'll get them together for you. I have been sending stuff to Christian in El Salvador for his XR600 over the last couple of years. Simply drop it off at the post office. Although the last parts I sent Christian I sent Express only to fine the postal system in El Salvador went on strike and he didn't get the parts for weeks. That was an expensive error.
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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 01-13-2013, 12:08 PM   #86
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Bump!
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The Virus's RR http://advrider.com/forums/showthread.php?t=826703
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Old 01-14-2013, 02:22 PM   #87
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Cry Doh!

There's a that saying goes "you don't get the ups without the downs". Well, all things being equal, so far it's mainly been ups with the XL, but now I've hit a down.

I eventually tracked down a pair of balancer shaft bearings and found an alternative supply (from Massey Ferguson ) for a couple of missing shims for the gearbox layshaft. Here are the cases with new bearings ready to build! So far so good...



Yesterday I got to work.

Transmission in...

...check

Selector forks in...

...check

Shift drum in...


Crank and balancer shaft in...

...check

This evening I put the cases together to check I had gears and they all selected OK , split the cases again, popped in the gasket and a thin spread of Hylomar and everything went back together, bottom end built. Only when I spun the crank I heard a regular 'clunk' with each rotation. Despite inspecting for wear when I stripped it out, about the only thing I didn't inspect closely was the drive gear for the balance shaft and, you've guessed it, there's a significant chunk out of one of the teeth - I can't believe I missed it. Looks like I need a replacement crank.

Brrrm Tssk!

I'll post a pic of the offending toothy gap when I've got some motivation to pull the cases apart again.
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Old 01-14-2013, 03:34 PM   #88
Moparmanpete
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When one door closes another door opens

Hang in there!

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"The reward is in the doing of it" "If you don't go when you to want to go, when you do go you'll find you've gone" BM
08 Wildfire 150 Scoot "The Virus"
The Virus's RR http://advrider.com/forums/showthread.php?t=826703
87 XL600R "The Cracken" deceased till further notice
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Old 01-14-2013, 10:00 PM   #89
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Hold on!
Whatever you do, you do for the best!!!

Excuse me, I want to seize the moment.
You can do two measurements for me?

I'm trying to install the crankshaft XL/XR600 in the XR500R and I need a little help with the measurements.
I have a few questions for the continuation of the movement further.
1. Which thickness (size) of the left crankcase a XL600? (from the main connectors to cover the stator)
2.What size (depth) in the cover the stator (of connectors up to supports the stator)?


Thank you!
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Old 01-15-2013, 04:11 AM   #90
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Hang on a second Jim, I have a feeling the balance shaft drive gear is a press fit onto the crankshaft, and you may be able to get a gear from a buggered crank fitted to your crankshaft. Need to talk to a crankshaft rebuilder to be sure.
Or it may be cheaper to fit a used crank if you can find one. Lots on ebay.com
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