87 ATK/xr600 Rebuild

Discussion in 'Thumpers' started by dcarver, Jul 2, 2010.

  1. dcarver

    dcarver Been here awhile

    Joined:
    Oct 5, 2007
    Oddometer:
    118
    3 or so years ago, on the way to SX races in San Francisco, my buds unmercifully harassed me about failing to complete the ATK project.
    "Tell me again how you have a complete rolling chassis and it STILL ain't running?" asked Jack. "Hell it's only been apart for 7 or so years" I retorted. Besides, I'm a busy MoFo".

    That's when Jack chimed in; "I'll stuff that engine back in the frame, wire it up with Baja Designs components, fix all the broken crap for you. Toss me a 1,000 bill and I'll make it happen, parts cost only, free labor." :D

    "I'll ask you again tomorrow, Jack, when you aint been drinking" sez I.
    Roll onto tomorrow, and Jack is sticking by his story.

    So, after spending some time under Jack's tutelage, the ATK is ready to make the journey back home. it should be back sometime August 2010.

    The only problem is a nagging ignition issue. After running for a bit, it loses spark. I just happen to have some spare parts laying around the house (I raced MX on this bike 87-91) so I can throw them on shot gun style and see what happens. IIRC I have ign coil, rotor, stator, cdi. But that motor always had weak ignition - although it would always run.

    Researching the net, it *appears* that CDI modules are no longer available for 87 and earlier XR's. I hate to think about buying an 88 or newer just for parts, but I can and will if needed..

    Anyone have a parts line for new/used CDI modules, 87 or older?

    Here's an obligatory pix.


    [​IMG]

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    For those wondering, yes it is CA street licensed and even insured...:freaky
    #1
  2. mcma111

    mcma111 Long timer

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    Jul 17, 2007
    Oddometer:
    13,078
    Location:
    San Francisco,Ca.
    I have the CDI from my 92 XR600 and a brand new Ricky Stator available.
    #2
  3. BikePilot

    BikePilot Long timer

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    Jul 5, 2005
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    11,251
    Location:
    Tampa
    Way cool!
    #3
  4. dcarver

    dcarver Been here awhile

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    Oct 5, 2007
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    118
    From what I can tell, the 92 CDI is different than 87 or older. I need to find a knowledgeable XR guru...
    #4
  5. dcarver

    dcarver Been here awhile

    Joined:
    Oct 5, 2007
    Oddometer:
    118
    Hey Inmates..

    OK, it's been some time.. but I have the ATK back in the shop. Long and good story about a bud who 'volunteered' to do the heavy lifting..

    I hope this is OK - but should anyone GAF about an 87 ATK rebuild...



    Admins, if I really just screwed the pooch, please just slap me, not kill me. I love this place.
    #5
  6. dcarver

    dcarver Been here awhile

    Joined:
    Oct 5, 2007
    Oddometer:
    118
    Project ATK is getting closer and closer to being an bike actually worthy of abusing in the dirt as all good dirt bikes should be. Today got her 'lifted' off the suspension to remove forks and rear shock. I gotta say Thanks to my bud Gupster for building the bike rack and lift.. I'm getting to old to be crawling on the floor like the 'good old days'..

    Front forks and rear shock ready for Independent Race Shop, San Luis Obispo, CA.[​IMG]
    1989? CR 250 cartridge forks. Supposedly the 'ones' to have. After IRS gets done with them, I'll have a better idea of what they 'really' are.. [​IMG]
    Yeah, it's a bit scary to put a 5k dirt bike up in the air with a 17k HD sitting underneath. That's why I have the big turnbuckles and custom jack under the ATK.[​IMG]
    And TieDowns too! [​IMG]
    The exhaust is another issue I don't know what to do with.. The rear tire hits, it needs be spaced about 3/8" away. I'm considering just building a new system from scratch and be done with this headache.
    [​IMG]
    Naked, the forks are rear shock are both leaky. I hope severe corrosion hasn't eaten at the internals. [​IMG]
    Back in the day, I had RaceTech do the work. Hopefully, IRS can do a good job locally for less money..[​IMG]
    When done, this bike must be able to handle severe abuse, run reliably, and handle great. I have another motor for her, it was the race engine, which I'll detune, rebuild, and stab into later. Just because she is old school does NOT mean it can't work. [​IMG]
    #6
  7. Duken4evr

    Duken4evr Been here awhile

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    Mar 10, 2011
    Oddometer:
    360
    Location:
    Parker, CO
    Cool project! You are right. Old school can still work. They may not be "current" anymore, but the big bore 4 strokes are still very fast in open western terrain. A set up and well ridden XR650 to this day is still very fast. The newer stuff is better suspended and trades on lighter weight and agility. Nothing hangs a long lazy wheelie and hauls ass quite like the old school big boys though. Had an XR600 years ago, so I know from experience :evil
    #7
  8. Rot Box

    Rot Box Been here awhile

    Joined:
    Oct 31, 2010
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    248
    Location:
    Northern Utah
    The ATK chassis was so far ahead of its time in handling and weight I have a hard time calling them old school--even though they probably are lol :D The 87 CR cartridge forks were legendary but I 'think' the 88 (89 went inverted) forks can be re-valved and sprung to be just as good. My 85 ATK had the inverted 4043 WP's on it which I upgraded to the later (4045?) 43mm inverts from a 97. By doing that I gained the huge front brake rotor, Brembo components, Talon/Excel front wheel, and the really cool billet ATK clamps. Everything was bolt on... Not trying to hyjack your thread just giving you some food for thought it was well worth the upgrade.

    I'm watching this one close thanks for sharing it with us.
    #8
  9. creaky

    creaky Been here awhile

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    Apr 4, 2008
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    Indiana
    You get the lucky dog award! I looked far and wide for one of those ATK kits when I had my HRC628, never came up with one. Great project, keep it coming.
    #9
  10. macrae85

    macrae85 Been here awhile

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    Sep 28, 2010
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    Location:
    New Zealand,Scotland,Arizona USA.
    Want one! :)
    #10
  11. McGoo 69

    McGoo 69 n00b

    Joined:
    Jul 17, 2013
    Oddometer:
    8
    do you have any pics of the carb manifold? i need to convert my twin carb to single
    #11
  12. dcarver

    dcarver Been here awhile

    Joined:
    Oct 5, 2007
    Oddometer:
    118
    Hey Guys,


    Thanks for all the nice comments. New job has me kinda way too occupied, but did get some new things done on the ATK in July.

    I hope this re posts fairly well from by blog...
    the Candy Butt Association!



    2013-07-27 ReRouteOilLine

    Permalink Submitted by dcarver on Sun, 09/01/2013 - 21:37.
    Re-Routing the Oil Cooler Line - too close to exhaust header​
    What a PITA this job was.The line running up to the oil cooler was contacting the header.

    [​IMG]
    These pix don't show it, but I had to re-bend the line after pivoting the engine on the front mounts...
    [​IMG]


    While at it, re-wrapped the header with heat tape.
    Yes, the Ty-Rap has been replaced. This was a mock-up pix.
    [​IMG]


    I need new rims and exhaust system.
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    I think the exhaust wrap turned out good.
    [​IMG]
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    I need a new silencer. Looking for an oval unit that will provide greater clearance to the rear tire.
    [​IMG]
    x ​
    [​IMG]


    If you have any ideas on how build/buy a custom oval silencer, let me know?

    [​IMG]
    This is my 'mule' engine. The real motor is being built in La Pine, Oregon, by a fella named Ray.....
    [​IMG]
    #12
  13. dcarver

    dcarver Been here awhile

    Joined:
    Oct 5, 2007
    Oddometer:
    118
    I will get you some pix soon. If you have more time than me, check out this link. I am not fully happy with this set up - but it is working..

    Hope this helps...

    dcarver
    #13