1986 XR600R Basket case - Hope to revive!

Discussion in 'Thumpers' started by LandsVW, Oct 20, 2012.

  1. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    I've received the Triple clamp from fellow ADV reader (thank you!). I've got it installed with the key. I'm still trying to figure out how to mount the speedometer though. Anyone have any brilliant ideas? I'm building little metal brackets, but they seem like they'd allow the bottom of the headlight housing to bounce up and fall off the pins in the fender bracket?

    I wonder if anyone has a picture of a successful mounting system? Remember, it's now 1985 XL600 headlight/key/speedometer mounting into a XR650L triple clamp.

    thanks!

    L
  2. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
    Oddometer:
    13,104
    Location:
    San Francisco,Ca.
    The heck with brackets. Just install one of these:



    [​IMG]
  3. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    Ha, I wish! maybe next winter? I'll keep designing... :) fiduciary restraints confine me to 'making do'...
  4. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    I was able to completely wire the bike today, used the stator from the XL, and have spark! Still wondering if I can run the bike w/o damaging any of the electronics if there is no battery? At least for a test? Should I unhook the regulator/rectifier?

    Also, As I understand it, there are 3 circuits on the stator: 1-AC for ignition. 2-AC for headlight, 3-AC for other power that is then converted into DC to charge battery and run the other lights? is this correct?

    Does anyone know what the other flat blade connector is that is right next to the turn signal relay? My relay has only 2 blades. The third wire is green so I suspect ground?

    I have my headlight/speedometer installed. Zip ties are mans best friend :) however, another ADV inmate will be helping me get some factory brackets in a few months hopefully, so I can complete the install.

    Tomorrow I'd like to start and go riding! that's my tentative plan...
  5. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    Every journey begins with kick starting an XR/XL600. got her running, drove on fumes to the gas station, filled up with premium 92, went on an easy 2 mile ride! Another day I'll get her warm and change the oil and filter, ready for the spring. Still need a rechargeable battery, so that is my next mission.
  6. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    I found a laptop battery at a recycle store for 5$. it was approx 14 volts. I figured it would be worth buying in the attempt to make a dry cell small system for my bike. I got it home, broke it open, and found that it had 8 3.7 volt rechargable cells. They were dual series ( I think that's what it's called) then paralleled for a total of 3.7X4. I cut the circuit board away from it, and soldered on leads, directly. I am charging it on a 12v 600ma trickle charger. So far so good! the cells are taking the charge and are up to around 10 volts. I will charge it overnight and then check again. I figure I can attach this very compact battery system to a place just inside the right hand sidecover. May not work, but I think it will.

    I have found several more parts bikes including one for sale in the Medford area listed on Craigslist. Haven't bought another one though.

    Enjoying the journey: current goal is to title/tag during my spring break which comes up in early March. Every day I want to go ride, but with the thicker oil, the temperature hovering around 40, and not being street legal, the effort really isn't worth it. Once I get at least 2 of those 3 things in my favor I'll ride ;)
  7. Mike the Yank

    Mike the Yank Been here awhile

    Joined:
    Jun 27, 2012
    Oddometer:
    457
    Location:
    MILLJURAH Vic. Aus
    They sound like Lipo's, hate to say but you will need all that circuit board stuff to make sure they don't over charge, over charge them and they can exploded and burst into flames.
  8. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
    Nov 5, 2008
    Oddometer:
    4,154
    Location:
    Columbus, GA
    well said

    computer batteries are not lead acid batteries or similar they need a very specific charging rate...

    I used to be a very skilled electric hobby car enthusiast...and batteries and how to charge and DISCHARGE them is a science that you can learn a lot from

    lipos
    and all the new lithium style batteries need very specific charging and especially the need to not be overcharged they are also designed to be drained to almost zero volts...and charged back up fully...

    nicads and nimhs are better at this but they simply are not designed to be topped off all the time..its really easy to make a battery pack the problem is on a bike they will simply burn up(how long do tusk brand battery packs last? like 6 months?) even the big dualsport kits come with crap batteries.

    you need to think about getting a small deep cycle marine style or rv type unit...

    just my thoughts and cents

    good luck on the bike, coming along great:D
  9. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    thanks for the good info. I guess my question is this then: I have no room for a bigger battery. But I'm scared running w/o a battery is going to damage the charging system?

    any thoughts or ideas?

    thanks,

    L
  10. JensEskildsen

    JensEskildsen Long timer

    Joined:
    Mar 24, 2009
    Oddometer:
    1,086
    Location:
    Denmark
  11. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    Aha, perfect! Source? I can google it, ;) anything special about the wiring, or just hook to battery terminals?

    I guess Boeing is having probs with lipo's, I shoulda paid attention to the news...

    I also did google research and sealed lead and niCad might be appropriate... Just enough to protect electronics and get the lights to come on.
  12. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    Now I am learning all about capacitors. Voltage, obviously must be higher than the charging rate - so 15 or higher? What about the top number? Does the capacitor care if it is rated for 450 but only 13.5 is being fed? Second number mF or uF. This is the amount of charge that the capacitor can hold. Bottom number? I see 150000 on the one in the picture, and another post had 68000. What is the practical range?

    Thanks,

    L
  13. JensEskildsen

    JensEskildsen Long timer

    Joined:
    Mar 24, 2009
    Oddometer:
    1,086
    Location:
    Denmark
    Cant help you much, that one came with the bike when I bought it :shog
  14. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
    Oddometer:
    13,104
    Location:
    San Francisco,Ca.
    I've got one if you want it. I'll have to look for it.
  15. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    Awesome, I'll take it! :) PM me?
  16. davek181

    davek181 Been here awhile

    Joined:
    Aug 2, 2007
    Oddometer:
    993
    Location:
    Idaho
    I built a capacitor pack for my XL out of off the shelf capacitors ar radio shack. I bought three 2700 mf capacitors. (the biggest ones they had) Soldered them together in parallel on a circuit board I bought there too.

    Put it in my XL, changed all my instrument lights and taillight to LED. When I kill the engine the neutral light will stay on for about 15 seconds on reserved power. Turn signals, horn and lights all work great when running. Heated grips too.
  17. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
    Nov 5, 2008
    Oddometer:
    4,154
    Location:
    Columbus, GA
    very nice

    I want to do the capacitor and bridge rectifier for my horn off my ac regulator...one if these days:D on an xr6
  18. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    So far, I think I've figured out that 4500uF and 20 volts is about the minimum. I have seen people (on the web) using 150,000uF and up to 40 volts. I dunno what the top voltage could actually be, but the uF determines amount of power stored, or practically speaking, the length of the charge - how long the lights will stay on... Steve mentioned possibly having one for me, but I'll have your plan as a backup... maybe rob some capacitors from some old electronics or something... I could try some higher voltage ones from a computer power supply maybe, just to see if the capacitor 'cares' what the higher voltage is. The higher uF also takes longer for a charge to be built up but that shouldn't be anything to consider in this application, especially as the ignition circuit is separate from lights on these bikes.
  19. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    I spend an hour installing the capacitor that was sent to me (thank you Steve) and rerouting wiring, finding places for odd electrical bits, and etc.

    Got it! I finished up about 7:30 - just in time for dark! So, rode around the block admiring turn signals, and brake lights. The speedometer lights don't work, the high/low beam switch is kinda crazy so i guess I'll clean it, and the rear brake light switch has yet to be installed.

    Verrrry nice. Tomorrow I think would be a good day for a longer ride down the road to see what she's like.

    Continued updates! Maybe even a picture!
  20. LandsVW

    LandsVW Been here awhile

    Joined:
    Oct 20, 2012
    Oddometer:
    330
    Location:
    Tri City, Oregon
    I took the bike out on Sunday. Seemed to run good but felt a little 'poppy' for lack of a better term as the RPM's went up. I don't know if this is jetting, or because of my newer muffler and baffle (XR400), or maybe another carburetor problem that I need to work out. Went very quickly to highway speed though in 1-3 gears (which was 45 in our residential are). Was hard to start but I've figured out a bit more on how to start it: compression, then compression release. the kick start goes from hard to easy then hard again. If I push it just a little more into the next 'hard' spot, then bring it to the top and give a kick, it usually pops. Doesn't usually catch but gets better with each kick until it's running.
    Then, I came home and changed the oil and filter to Rotella 15-W40. I will pull the plug at some point and see how rich or lean she's running. May go out and ride a bit tonight after Track practice...

    L