!!! 1986 XL600R Adventure Bike Rebuild !!!

Discussion in 'Thumpers' started by crobox, Dec 27, 2012.

  1. crobox

    crobox Been here awhile

    Joined:
    Nov 28, 2012
    Oddometer:
    359
    Location:
    Taos, NM
    [​IMG]

    Welded it up today, and did some preliminary cleanup with a flap disc. Not as hard a welding job as I'd feared, although I did make up a complicated jig to keep it from deflecting and warping while I welded it. Next up, figure out how to mount it. (It is just sort of stuck on for this pic)
    #21
  2. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,687
    Location:
    Eureka, Ca.
    Nice! Looking good, man. :thumb
    #22
  3. Reposado1800

    Reposado1800 Juicy J fan!

    Joined:
    Dec 8, 2006
    Oddometer:
    5,815
    Location:
    5th and Main
    Sweet!
    #23
  4. crobox

    crobox Been here awhile

    Joined:
    Nov 28, 2012
    Oddometer:
    359
    Location:
    Taos, NM
    [​IMG]
    #24
  5. Moparmanpete

    Moparmanpete The Cracken has risen!...maybe? NOPE

    Joined:
    Jul 15, 2012
    Oddometer:
    426
    Location:
    ohio
    Slick!
    #25
  6. crobox

    crobox Been here awhile

    Joined:
    Nov 28, 2012
    Oddometer:
    359
    Location:
    Taos, NM
    I've been posting concurrently in the main XL600 thread about my engine's top end. For the sake of the continuity of this thread I will recap.

    I bought, on eBay, a re-bored cylinder and Wiseco 101mm piston.

    [​IMG]

    I posted in the XL600 thread some concern I had about possible downsides to using a "high compression" piston (Wiseco claims 11:1, but most folks on here are saying this piston is 10.5:1, tops). However, the consensus seems to be "go ahead and use it", even with the stock cam. So that's what I will do.

    I'm pretty sure I am going to change up the color scheme of the engine a little... black bottom end, bare metal cylinder and head, and black valve cover. I've already sand-blasted the head. I'll blast this newly bored cylinder soon, then install it.

    Here are pics of the bore and cylinder which are the ones I will be replacing. Even though they are clean and good looking, I figure that if I can use the 101mm Wiseco and the stock cam with no pinging, then I might as well.

    [​IMG]

    [​IMG]

    OK, that's all for now I guess.

    -Christian
    #26
  7. Stretch67

    Stretch67 Mad Scientist

    Joined:
    Mar 22, 2006
    Oddometer:
    9,183
    Location:
    Bent, But Not Broken
    Very nicely done with the fairing. :clap
    #27
  8. MartiniUp

    MartiniUp Long timer

    Joined:
    Jul 14, 2010
    Oddometer:
    2,400
    Location:
    TX
    Nice work, you are obviously a patient man. I personally think the original color scheme of that tank is beyond improvement. In fact, it is in fact perfection perfected. But its your bike, screw it up till your hearts content. :D
    #28
  9. davek181

    davek181 Long timer

    Joined:
    Aug 2, 2007
    Oddometer:
    1,180
    Location:
    Idaho
    Good work. I love to see these old relics reclaimed.

    Oh, wait. I ride one too. It also seems to be in a constant state of reclamation.

    Next on my list of projects USD forks and rear disc brake.
    #29
  10. crobox

    crobox Been here awhile

    Joined:
    Nov 28, 2012
    Oddometer:
    359
    Location:
    Taos, NM
    Thanks for the kind and supportive words, mr. Martini :wink:

    I actually like the red/white/blue tank, and I like the red/white/blue color scheme of 1987, as long as there is no gold. I agree that that is a pretty awesome color scheme.

    However, that is NOT what I started with. My bike was a tired and ugly mish-mash of parts, all of which needed refreshing or replacing.

    Plus, I am just one of those guys who prefers to have something a little (or a lot) different than what anyone else has. Being one of those guys, I think it's the best way to be!
    #30
  11. davek181

    davek181 Long timer

    Joined:
    Aug 2, 2007
    Oddometer:
    1,180
    Location:
    Idaho
    Keep doing what you are doing, looks awsome. I think it is great you are making an effort to individualize your bike. While it may not be the color scheme I would have chosen I think it looks like a top notch job. besides, who am I to judge what you do to your own bike. Keep up the good work and we will all be jealous when it is done and shames our motley rides.

    I too likesd the stock tank colors, but I dumped them in favor of a larger tank years ago. I wish I had the skill/time to do something to make my bike look better. My own wife has called it an abomination. That is ok with me because I prefer function first.
    #31
  12. crobox

    crobox Been here awhile

    Joined:
    Nov 28, 2012
    Oddometer:
    359
    Location:
    Taos, NM

    :rofl
    #32
  13. crobox

    crobox Been here awhile

    Joined:
    Nov 28, 2012
    Oddometer:
    359
    Location:
    Taos, NM
    I play around with the photoshop drawing AS I build the bike, incorporating things I'm actually doing to the bike in the shop, as well as playing around with different visual ideas that I might incorporate in the future.

    Here is the current state of the photoshop image:

    [​IMG]

    Changes incorporated into this image are:

    - Fuel tank changed back to stock metal tank (was a Clarke tank previously)
    - Blue rear fender with incorporated tail light
    - Side panel showing blue number plate (not sure if I'm gonna do that or not yet....)
    - Rims showing only the middle part painted orange; side walls of rims remaining aluminum color. This has the big advantage of the orange paint not getting super scratched during tire changes. Also a little less flashy than previous design.

    A few things which WILL be part of the final form of the bike, but are not in this image, are:
    - Bike will have (and has always had) a Supertrapp muffler
    - Bike will have a rear rack and pannier racks, fabricated from stainless
    - Front fairing will be different
    - Engine will be: Transmission cases black, cylinder and cylinder head bare metal, valve cover black
    - Header probably wrapped
    #33
  14. davek181

    davek181 Long timer

    Joined:
    Aug 2, 2007
    Oddometer:
    1,180
    Location:
    Idaho
    It is good to have a vision, my bike seems to evolve by happenstance mostly.

    I love the stock tank shape and looks, but it is so limited in capacity I have opted for the ugly big one. I have learned to take the ugly comments in stride. They do lessen somewhat when my XL eats their XRL for lunch in performance. Luckily I don't normally ride with people that have extraordinary machines.

    Does your taillight have a two filiment fixture? No problem if not, you can simulate two filiments with a resistor trick. I have used that method before

    I agree with the super trapp. I have alternated back and forth in the past, but now my stock exhaust is permanently relegated to duty on the weight lifting bench where it belongs.

    Racks are very handy. I wish I had the fabricating skills to cutom build one out of exotic materials. I built one with a chainsaw mount out of common iron, it worked but it was kinda ugly too. I later took the easy way out and bought one that looks better.

    When I first looked at the picture, the wheels really stood out. I was wondering how you were going to accomplish that. Actually still am wondering. Looks like a lot of work with wheel lacing involved to me.

    A different fairing will change the look for sure. Again fabrication skills needed.

    As far as engine color goes, I am one of those crazies that really likes the red engine. ( I know, there is one in every crowd)

    I have pondered pipe wrapping too, but I am lazy and it would probably elicit even more psyche damaging ugliness comments from my wife.

    Keep up the work and inspire us to do something too.
    #34
  15. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,687
    Location:
    Eureka, Ca.
    Oh no....not the dreaded header wrap! Ugh...:(: :lol3

    Just like the aesthetics of the stock tank, I like the looks of the tubular exhaust painted or coated up---real nice like. :D

    Maybe leave the rims all silver and put some orange accents elsewhere?

    Keep up the great work, man.
    #35
  16. crobox

    crobox Been here awhile

    Joined:
    Nov 28, 2012
    Oddometer:
    359
    Location:
    Taos, NM
    Yes.

    Well, lucky me! Mine came with a Supertrapp, and it's the only muffler I've got.

    I used to work mostly in regular carbon steel, but these days I do almost everything with stainless and aluminum. I hate rust, don't particularly love painting, and I do LOVE the shiny look of those metals.

    No... no lacing and unlacing. Just lots of careful masking with blue painters' tape. Somewhere buried in the main XL600 thread are some posts about someone else painting their rims using a similar method.


    That is already done. See earlier posts in this thread.


    You know, I used to love the red engine too. I really did! And to be honest, I still do... it's just that it doesn't work with this color scheme. I think on a red/white/blue bike with silver rims and suspension parts, the red engine looks awesome.

    Ha ha! Jury is still out on pipe wrapping... I understand it's good for performance.....

    Thanks man. It's just my winter project. I love doing this kind of stuff.
    #36
  17. crobox

    crobox Been here awhile

    Joined:
    Nov 28, 2012
    Oddometer:
    359
    Location:
    Taos, NM
    Isn't the pipe wrap good for performance? School me. (Pipe is already nicely painted)

    I have played in photoshop with orange accents in various other places. At this time, the semi-orange rims look the coolest to me. I'm not afraid of the work. I love it!

    and... Thanks!
    #37
  18. crobox

    crobox Been here awhile

    Joined:
    Nov 28, 2012
    Oddometer:
    359
    Location:
    Taos, NM
    Current state of the engine, with Wiseco piston and new cylinder installed. Bi-color engine coming together! Waiting to get the head back from my friend who is doing the valves.

    [​IMG]
    #38
  19. Ivanych

    Ivanych Ivanych

    Joined:
    Jan 24, 2011
    Oddometer:
    250
    Location:
    St. Petersburg. Russia
    GOOD LOOKS!!!!!!!!!!!!!:clap
    #39
  20. Moparmanpete

    Moparmanpete The Cracken has risen!...maybe? NOPE

    Joined:
    Jul 15, 2012
    Oddometer:
    426
    Location:
    ohio
    Pipe wrap benifets? :ear
    #40