BHB's First XR600R + Winter Rebuild

Discussion in 'Thumpers' started by Brauhausbier, Jan 2, 2011.

  1. rcerrie

    rcerrie Adventurer

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    Knysna, South Africa
    Nice, getting there!!!
    #61
  2. artimious7@yahoo.com

    artimious7@yahoo.com Artimious7

    Joined:
    Oct 31, 2010
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    14
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    Sonoma, Ca
    Looking good!!
    #62
  3. Brauhausbier

    Brauhausbier Focused

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    Thanks so much for the props!!

    Hope this week to get the engine fully cleaned up and get my newly bored cyclinder back from Rb Designs this weds!

    Just got my big parts order in from OEMcycle today:clap:clap:clap

    Now just gearing up for the case split on Feb 12th.:eek1

    Should have all those parts early next week.:thumb
    #63
  4. wibby

    wibby BrotherFromAnotherMother

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    I bought a caliper on CL

    Dunno what was all over it but nothing would take it off

    Here it is after soaking a day in Berryman's

    [​IMG]

    I ended up using a wire wheel

    [​IMG]
    #64
  5. Brauhausbier

    Brauhausbier Focused

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    Thanks for that tip on Berryman's Wibby! :clap:clap:clap

    I have this whole next weekend to work on my XR! I will run out and pick up some Berryman's chem dip. I als wanted to soak the carb too in a good Chem Dip. Will do!
    #65
  6. Brauhausbier

    Brauhausbier Focused

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    Finally an update on the motor progress over the past two weekends. Finally have some forward momentum going :freaky

    Using wire brushes and 2.5% Phosphoric Acid the case cleaned up nicely:clap

    Spent an afternoon cleaning up the case last weekend.
    [​IMG]

    [​IMG]

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    #66
  7. Brauhausbier

    Brauhausbier Focused

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    Yesterday with the invaluable help from my friend Luke (this is his ADV screen name too), we split the cases to replace the countershaft. In my short 11 year motorcycling career, this is my first case split:eek1 What an experience!

    Here we go:

    Right Cover Off
    [​IMG]

    Clutch Basket Next
    [​IMG]

    Used an air gun to remove the 27mm nut behind the clutch basket. That worked well.
    [​IMG]

    Removed the kickstarter, oil pump, ignition sensor, etc to strip out the right side components completely.

    Next up was the case split. This took some time and a lot of elbow grease. Definitely the most difficult task in the whole process was this center case separation.

    Here we go.
    I made a case splitter using two 4' lengths of 2x2 an used a chunk of 2x4 to make fulcrum and applied the pressure on opposite sides of the case through the cylinder opening:
    [​IMG]

    The start of some separation
    [​IMG]

    Finally got the case pins separated
    [​IMG]

    The propane torch is coming in handy trying to loosen up the case pins
    [​IMG]

    Success:freaky
    [​IMG]

    The crankshaft and transmission look good for a 17 year old XR:evil
    [​IMG]

    The new countershaft:clap
    [​IMG]

    Look how crisp the splines are:D
    [​IMG]

    The old splines (just for reference):puke1
    [​IMG]
    #67
  8. Brauhausbier

    Brauhausbier Focused

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    The transmission is out

    [​IMG]

    Fun times - getting all the old gaskets off - much faster with two working :clap
    [​IMG]

    The side cases are looking cleaned up and ready for reassembly
    [​IMG]

    New countershaft installed and transmission reassembled
    [​IMG]

    [​IMG]

    Ready to reassemble the cases
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    [​IMG]

    [​IMG]

    Reassemble Right Side Case Components (Clutch Plates all above spec:clap)
    [​IMG]

    New Ricky Stator
    [​IMG]

    Right case cleaned up and ready for installation
    [​IMG]

    Bottom end is completely finished! :freaky:freaky:freaky:freaky

    [​IMG]

    [​IMG]

    [​IMG]

    Wow..a 10 hour marathon on the bottom end rebuild but we did it in just one day!

    I'm greatly indebted to Luke for his assistance and knowledge:clap:clap:clap

    Luke, please enjoy the 4 cases of tasty beer from my employer Widmer Brewing and again a Big Thank You! :slurp:slurp:slurp:slurp:freaky:freaky
    #68
  9. cpmodem

    cpmodem Orange Caveman

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    masa yee yah tee 59° 14' 9" N / 135° 26' 42" W
    Looks great Eric. I can see the scientist in your method of operation. Looks like PO let the cs sprocket nut get lose.
    #69
  10. sector

    sector Long timer

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    S Oregon Coast and Kootenays BC
    Wow! Impressive work!! :clap
    #70
  11. Brauhausbier

    Brauhausbier Focused

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    Thanks Sector and CP! Hopefully I''ll get the cylinder head together by the end of the month! Got a new sleeve coming for the cylinder and the head is at a fantastic local moto cylinder head shop called Baisley Performance www.baisley.com just down the street from us! These guys have been just fantastic! :clap New KB valves, new OE valve springs, and new gaskets. Plus, the Baisley guys will bead blast the head and cylinder + polish. I can't say enough about Bailsely..absolutely A+:thumb
    #71
  12. wibby

    wibby BrotherFromAnotherMother

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    Did not see or or hear you mention bearings and crank seals :ear

    Woulda been a good time :evil
    #72
  13. mcma111

    mcma111 Long timer

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    It's not a 2 stroke...:lol3 :lol3 :lol3
    #73
  14. wibby

    wibby BrotherFromAnotherMother

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    well duh

    still I'd be replacing bearing while I had the chance

    cheap insurance
    #74
  15. Luke

    Luke GPoET&P

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    Disagree. The XR bearings are big, expensive, and reliable.
    #75
  16. Brauhausbier

    Brauhausbier Focused

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    Thanks Wib!

    I did replace the countershaft case seal and the gear shift seal on the left side case. :thumb
    #76
  17. Brauhausbier

    Brauhausbier Focused

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    I'll second that! :lol3

    Thanks so much Luke! I'll give you a buzz when the top end is ready to bolt together! :lol3
    #77
  18. wibby

    wibby BrotherFromAnotherMother

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    Depends where you get them

    Peterman got all my bottom end bearings and seals on the KDX for right at $50
    #78
  19. Brauhausbier

    Brauhausbier Focused

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    New parts are trickling in this week:clap

    Received the new 100mm cylinder sleeve yesterday from XR's Only and delivered that to Basiley's High Performance http://www.baisley.com/ at lunch today. The cylinder and head had been cleaned and polished and looked brand new.:thumb Looks like they will get the cyclinder re-sleeved this next week.

    Also received the new HotCam Stage 1, and new rockers:freaky
    [​IMG]

    [​IMG]

    Plan is to get the head together the first week of March.

    Cheers!
    #79
  20. rorybellows

    rorybellows lost in the sauce

    Joined:
    Jun 9, 2008
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    404
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    pee-enn-dubya
    im gonna be watchin this...
    #80