Building A XR650l Engine

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

  1. farrington300

    farrington300 No wait....What?

    Joined:
    Sep 27, 2009
    Oddometer:
    527
    Location:
    Denver CO
    got it out!!!! The motor was coated in years of oil and dirt. I really couldnt get a good hand on it. So I put down some card board...bike on its right and about 5 mins of twisting, the motor was on the floor and the bike back on the kick stand. I blew out my back about 3 weeks ago, so this is all risky business... but I was also about to get it up onto the bench. Top end totaly apart. So far, I need a cam, sealed cam bearing, cam chain, valve job, valve seals, piston, rings, etc. The cases will be split tomorrow eve. New counter shaft, 5th gear, and 2nd gear will go in. :deal
    #81
  2. farrington300

    farrington300 No wait....What?

    Joined:
    Sep 27, 2009
    Oddometer:
    527
    Location:
    Denver CO
    Got everything taken apart down to the flywheel. I have a puller...wrong size. Now Im off to the dealer to blow some money.
    #82
  3. 1Bonehead

    1Bonehead Fearless of Falling

    Joined:
    Sep 30, 2010
    Oddometer:
    1,113
    Location:
    Marylanstain
    :clap
    :ear:freaky
    #83
  4. Gas Hog

    Gas Hog Two Wheel Fanatic

    Joined:
    Dec 31, 2008
    Oddometer:
    1,088
    Location:
    Beachside on the sand
    Steve,
    Great write up!
    You obviously have been inside a bunch of these, I came across a new in the crate 2000 XR650R..:eek1
    Don't really need (sorry for the 4 letter word) but they have such history..plus I am a sucker for "new in the crate" old bikes.
    With the new technology of today's bikes would this be a beast to go after? :wink:
    Gary
    #84
  5. Keith

    Keith Slabbing it

    Joined:
    Nov 29, 2006
    Oddometer:
    928
    Location:
    901
    That is a really neat idea.
    #85
  6. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
    Oddometer:
    13,078
    Location:
    San Francisco,Ca.

    If it floats your boat, do it.
    #86
  7. farrington300

    farrington300 No wait....What?

    Joined:
    Sep 27, 2009
    Oddometer:
    527
    Location:
    Denver CO
    Is there a place to buy a complete gasket kit (like the ones on ebay) but with OEM gaskets?

    I was thinking of buying an ebay gasket kit, so I have a little of everything and picking up an OEM center case gasket. Thoughts?
    #87
  8. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
    Oddometer:
    13,078
    Location:
    San Francisco,Ca.

    With those aftermarket gasket sets you may as well throw your money away. WAIT, I know. Use the dollar bills to make gaskets...

    No really. I only use OE gaskets except for the over size head gaskets. Then I use Wiseco or Cometic. Cometic makes Wiseco gaskets anyway.

    I only but the gaskets that I need and not the sets.
    #88
  9. Reposado1800

    Reposado1800 Juicy J fan!

    Joined:
    Dec 8, 2006
    Oddometer:
    5,806
    Location:
    5th and Main
    That looks like pitting from moister. That can even happen from high humidity forming condensation in a cold engine.
    #89
  10. farrington300

    farrington300 No wait....What?

    Joined:
    Sep 27, 2009
    Oddometer:
    527
    Location:
    Denver CO
    Kinda what I was thinking. Just needed a slap on the back of the head to remind me.


    PS So far this xr650l has cost me just a little over $320,000. As I was rebuilding my motor, I realized I needed a new piston, among other parts, but I also realized that I needed a new shop to work in. So I bought a new shop, O and the shop came with a new house as well. :lol3
    #90
  11. mendoteach

    mendoteach Long timer

    Joined:
    Apr 29, 2007
    Oddometer:
    1,681
    Location:
    Mendocino, NorCal
    Beautiful write up Steve. You are a real talent. Curiously, how much does the Foster's help?:rofl:rofl
    #91
  12. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
    Oddometer:
    13,078
    Location:
    San Francisco,Ca.
    It helps quite a bit. Keeps my spirits up. Only $2.00 a can.

    [​IMG]
    #92
  13. Ben99r1

    Ben99r1 Long timer

    Joined:
    Mar 2, 2006
    Oddometer:
    3,092
    Location:
    Pomona, Calif.
    Because now I am going to send you my motor. Ben.
    #93
  14. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
    Oddometer:
    13,078
    Location:
    San Francisco,Ca.

    Cool.

    PM Sent
    #94
  15. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
    Oddometer:
    13,078
    Location:
    San Francisco,Ca.
    So I have heard from Susanna. Her friend did the engine installation and finished the bike build. No pictures from that end. The bike runs and is getting broken in. Susanna will be posting some pictures when she can.
    #95
  16. Carter Pewterschmidt

    Carter Pewterschmidt Long timer

    Joined:
    Nov 23, 2010
    Oddometer:
    1,107
    Location:
    Milwaukee
    That looks like the work of a legitimate technician.
    #96
  17. MightyZeus

    MightyZeus Been here awhile

    Joined:
    Nov 19, 2005
    Oddometer:
    339
    Location:
    East Bay
    Well ladies and gentleman, the bike is finished and I enjoyed my first real ride on it yesterday! For those of you lacking patience to read my entire post, I will summarize it by saying



    I $%#*ing LOVE IT!

    I grew up riding d-sports and have been drooling over owning a thumper for years and finally have a very strong running XR. It’s fantastic, and I am grateful for all of Steve’s work. If it wasn’t for him reaching out and expressing his confidence in being able to rebuild the completely disassembled engine, who knows how long it would have taken before I found myself on two wheels.



    $2361 later I have an XR with a fresh motor and 40-50 mpg transportation that costs me $75 per year to insure. Woot woot! My fiancé retrieved my "new" bike last Wednesday in San Francisco, not far from Steve's place.
    Our good friend Lawrence installed the engine, added a battery, new chain and sprocket, changed the brake fluid, performed a safety inspection, checked torques, replaced spark plug, lubed pivots and cables, set front and rear tire pressures and checked brake pads. His only recommendation was to replace the tires within the next couple hundred miles. He also recommended I replace the oil and filter, check screen and retorque frame bolts. Lawrence changed the oil after his first test ride on the bike and cleaned the frame tank and oil lines.



    Originally I planned on physically being involved with installing the engine and tying up the loose ends needed to make it a functional ride. Time became extremely scarce and Lawrence is starting up a new venture and couldn’t have the bike just sitting in his garage for indefinite amounts of time just taking up space. So, I had him button it up on his own. After identifying parts that were needed to be replaced and ordering them, he worked on it between other bike jobs and notified us last week when he finished it.



    Michael pulled in around 10pm with the XR in the back of his truck, and I was so pooped I so much as nodded at it and crashed out for the night. The next morning I wanted to ride it but had to rush off to work, then had night class and it wasn’t until Friday morning that I swapped out of my jammies and snuck a scoot on it around our neighborhood before work.



    Brrrrapp!



    It started strong. I turned the gas on, tossed a leg over and precariously tip toed down our steep driveway. I lifted my feet to the broad pegs and tootled down the street into the crisp morning air. The sun was just rising and the air hinted of Fall. Four streets and five minutes later I reluctantly returned to the garage and raced to get to work. It was fabulous. My bike I can ride whenever I want woith no weirdness of borrowing someone else’s bike.



    Saturday morning I took it out onto to the open seas; I-80 my first interstate ride – a quick hop to a dental appointment. I was nervous out on the open interstate and had some mental blocks about it being a new engine and keeping aware of proper break-in procedures but everything worked just fine. After the dentist’s dremel or whatever the hell it was he had in my mouth making the high pitched notes that leave you sweating and ringing your fingers, I was much more relaxed to get back on the XR. I shot over the San Rafael-Richmond bridge to meet my girlfriend Shannon off Lucas Valley Road exit.



    We headed to Infineon with hopes of riding passenger in a racey car on the big track or riding passenger in one of the autocross cars. Michael was helping instruct auto cross. Longer story shorter we scored rides on the big track! I found a Lotus (hee hee) with a driver named Cappy. Shannon found a Subaru to ride passenger in. Sitting passenger in the Lotus hauling balls was SOMETHING ELSE. My face was stuck in a perma-grin all day from riding my moto for the first real time, from whipping around the carousel 15 or so times in a fast light car - and the smiles continued when I sat passenger with Michael in his Miata around the auto cross track – a completely different experience. It was my first time riding along with him. The track was uber tight. I was thinking “man I am not sure I could ride my motorcycle through this course in 2x the time!



    Shannon and I headed off west on Highway 37 and out Lucas Valley Road making our way out to Olema. From there we went to Bolinas and had a beer at Smileys. (Hint, don’t order the “Philly cheesesteak.”) Originally we thought we’d get in some summery swim time at Bass Lake or in a river but it was “freezing” out there, coated in a thick fog. It was such a delight to ride the thump[er over roads I have traversed so many times in a car, my Suzuki SV650 and BMW F800S – absorbing the bumps and taking the twists intuitively.



    We took Fairfax-Bolinas Road and headed along a ridgeway towards Mt Tamalpais’ East Peak where we stopped and took in the sights and snapped some pics.



    [​IMG]


    [​IMG]


    [​IMG]


    [​IMG]


    [​IMG]



    [​IMG]



    Then headed down the mountain and split paths in Corte Madera. The ride home over the Richmond Bridge was a bit sketchy but only because of the gnarly wind that was blowing. As soon as I realized it was trying to kick my ass I pushed back and stayed steady.



    Last bit of news is that the first tank suggests the bike yields 100 miles per tank. I ran out of gas at 75 miles on the trip, whereby I put it in reserve and refueled at the next gas station.



    I look forward to many more safe and fun rides ... and panniers! :clap
    #97
  18. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
    Nov 5, 2008
    Oddometer:
    4,154
    Location:
    Columbus, GA
    GOOD JOB STEVE!

    And welcome ladies!

    christian
    #98
  19. Barron

    Barron M0DAH0LIC

    Joined:
    Mar 24, 2006
    Oddometer:
    2,471
    Location:
    Yokosuka, Japan
    In comparison to adding the NX650 second gear to 650L how difficult is the kicker mod?

    -Barron
    #99
  20. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
    Oddometer:
    13,078
    Location:
    San Francisco,Ca.
    It's almost the same thing. The NX gear is on the countershaft and that has to be changed for the XR600 kicker set up. So the amount of work is the same.

    In other works a COMPLETE TEAR DOWN of your engine.