Yet another XL600 project...

[Moparmanpete]

[JimRidesThis]

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 -

[brucifer]

Nice! Looks like the upper engine mount worked out just fine for you.

[JimRidesThis]

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

[Moparmanpete]

Looking Great Jim! Keep Going!





Be sure to start it outside I didn't
http://youtu.be/fSwzr4a-Ozc

[mcma111]

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Looking at the parts site the original part # has been superseded by: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.

[mcma111]

That was fast. They just called back and the bearing is available. Local dealer wants about $27.00 each.

[JimRidesThis]

Originally Posted by mcma111

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

[JimRidesThis]

Originally Posted by Moparmanpete

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

[mcma111]

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.

[Moparmanpete]

Bump!

[JimRidesThis]

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.

[Moparmanpete]

When one door closes another door opens

Hang in there!

[Ivanych]

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!

[Homerb]

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