Building A XR650l Engine

Discussion in 'Thumpers' started by mcma111, Aug 6, 2011.

  1. 1Bonehead

    1Bonehead Fearless of Falling

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    :clap:clap:clap
    #61
  2. Break_Syncro

    Break_Syncro Been here awhile

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    Thanks Steve, extremely good info, great pics, and valuable tricks!

    Awesome ADV Fellow! :freaky
    #62
  3. Keith

    Keith Slabbing it

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    That sure was a neat photo essay, nice pics.

    Is it me or were those cases still really dirty when you put them back together? The cylinder was so nice and clean in comparison.

    That's a lot of sealant on that cam cover gasket.
    #63
  4. mcma111

    mcma111 Long timer

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    Correct on all points.

    The cylinder and head were bead blasted at the machine shop.

    The sealant. I let it dry a day and peel it off like a rubber band. Inside it actually stays in place. I have done this many times with no problem.

    This is my motor from a recent build.

    Blasting the cases

    [​IMG]

    Clear coating them

    [​IMG]

    Center cases cleared and clutch/stator cases powder coated

    [​IMG]
    #64
  5. farrington300

    farrington300 No wait....What?

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    Steve,

    Do you coat the motor with anything post bead blasting?
    #65
  6. mcma111

    mcma111 Long timer

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    Yes. Dupont 222 mid coat something or another. Shoot it straight out of the can. Here is what I shot:

    [​IMG]
    #66
  7. mcma111

    mcma111 Long timer

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    Where was I???

    Oh yeah, last Saturday after a long day in the garage i stopped for the day with the engine almost completed.

    This is where I left off

    [​IMG]

    So Sunday 22manyrides came down from Sacramento to have me open his XR600 engine to find the source of a second gear whine.

    Found it

    [​IMG]

    OK, so it's a shitty picture of the gear teeth all pitted. For a better pic go look on the Call All XR600!!! thread

    It turned out that with the gear giving up a bunch of material the piston picked up a couple of pieces and took them for a ride. Up 'n down, up 'n down they went and the cylinder got a couple of nice gouges in it. Off to Engine Dynamics goes his cylinder and piston. Back comes a honed cylinder and the piston. A new set of standard bore rings are on order and as of now his engine looks like this after I went through my stash of transmission gears and picked out two second gears and reassembled the lower end. What's up with two second gears you ask?? Well if one gear is bad or damaged it will fuck up it's mate. I didn't even have to look at the other gear as I could FEEL the rough edges of the gear that the pictured gear caused.

    [​IMG]

    When doing these builds I leave the clutch cover off to make getting the cam chain on the drive gear easier. Trick # I forget...

    Anyhow here is the engine in question. All done.

    [​IMG]

    As you can see the rocker cover has some sealant oozing out. I will wait until it drys and pick it off like a rubber booger.

    Not pictured is the customers carb that I am doing Dave's Mods to. 55/160 jets are the order of the day to take into account the 101mm 10.5CR Wiseco piston.

    So this brings us to the end of this build. I called my customer and she is on her way right now to pick up her freshly refurbished engine. She and her significant other will finish the engine installation.

    Until next time, Steve in SF
    #67
  8. thebigman

    thebigman bout a dollar 3.98

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    Nice Instuctional thread Steve, First Class, :clap
    #68
  9. mcma111

    mcma111 Long timer

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    Thanks Big
    #69
  10. Sourjon

    Sourjon TAT'erd

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    Any thoughts on what caused the gear to go bad like that?

    John
    #70
  11. mcma111

    mcma111 Long timer

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    To much riding in the one gear. Last year I bought an XR600 engine from Southern California that ran in the desert that had a bad third gear set. This gear is from a Northern California engine, slightly slower average speeds is my guess. With the exception of these bad gears both engines were spotless inside so it wasn't bad oil.
    #71
  12. 2manyrides

    2manyrides shifty charactor

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    Thanks Steve, I can't wait to scratchout again!:thumb

    Sourjon...
    Thoughts on gears?

    Well, it's a N Cal bike, they get used in the high country alot and 2nd gear is the MOST used.
    That's the theory anyway. But I am disapointed a little.
    I bought that 600 late last year from a 1 family usage.
    It was billed as a well maintained, un-adulterated, low milage bike. And it looked and ran like it.
    I had a chance to look it over carefuly, and ride it shortly. Gear sounds didn't jump out at the time,
    but it was shortly after taking posession that I noticed, (like day 1).
    And I rode it on 4 trips after. Grinding all the while.
    Such a nice one, I gotta have this fixed.
    And reguarding the grind...if you hear it, you know what it's leading to.:eek1

    [​IMG]

    [​IMG]

    Leads to total distruction of your ride.
    Gremlins floating round throughout the oil system.

    But who really knows why this happened...
    Might be it was run low on oil at some point, but the motor had never been apart before. So it wasn't fried.
    Over heating? I'm still guessing as my bought new 92 which has been ridden all through the mountains in second gear...
    never developed any grinding.
    #72
  13. Sourjon

    Sourjon TAT'erd

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    Hmmm.... I wonder. Bad gear from the start maybe? Here's the cam from my original motor. Bad casting? 28K mi and the rest of the motor looked very good. I hadn't noticed any noises or issues when I swapped but found this when I pulled the cover. The rocker still looked fine. I wonder if this gear might have had the same problem from the factory. It is under a lot more load than the cam.
    [​IMG]

    John
    #73
  14. Sourjon

    Sourjon TAT'erd

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    Gremlins are never a good thing inside an engine :) See my reply to Steve.

    John
    #74
  15. farrington300

    farrington300 No wait....What?

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    Hey guys,

    I am getting ready to pull my motor out of the frame. All bolts and wires removed... Two questions. Im guessing the the motor comes out of the right side of the bike? And second, is it possible to do it by yourself, or should I call in help. Can I lay the bike on its side and sort of drop the motor out with gravity?
    #75
  16. mcma111

    mcma111 Long timer

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    The engine comes out the right side. You should be able to do this yourself. Unless your a 98lb weakling. :eek1:lol3 :eek1:lol3 :eek1:lol3 I always have the bike on a box or now that I have a lift, straight up 'n down. Simply rock the engine to the right so the top end is out some and then heave. I usually have my right hand at the right head corner with fingers in the exhaust port and the left hand grabs the shift lever. The engine weighs about 115 lbs.
    #76
  17. 2manyrides

    2manyrides shifty charactor

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    I know how it is when you have a question, you need the answer NOW.
    So this may be too late.

    Motor out on right side. Kicker serves as a handle at some points.
    This is a one man job.
    Do it on the kick stand. No need to lay the bike over, in fact that might be a tougher way to wiggle it past the frame tabs.

    edit; Steve beat me to it!
    #77
  18. mcma111

    mcma111 Long timer

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    Kicker?? What kicker???


    This is a XR650L
    #78
  19. 2manyrides

    2manyrides shifty charactor

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    Well, isn't there a way to convert 650l's to a kickstart?
    That'd give him a handle!
    #79
  20. mcma111

    mcma111 Long timer

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    Yes there is. I do have some parts in the garage right now.

    Think their owner will miss them?

    XR650l Kicker is another episode...
    #80