Call all XR600R!!!

Discussion in 'Thumpers' started by CSMonte, Dec 8, 2008.

  1. Royal Club

    Royal Club Been here awhile

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    It has a burr on it which makes setting the valve lash pretty annoying..
  2. mcma111

    mcma111 Long timer

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    In that case there is nothing else need to be changed but that one rocker.
  3. martin.kryjom

    martin.kryjom Adventurer

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    HI
    I have rebulid my Honda XR 600 R for last 2 years, 95% parts are new, includng new ohlins shock and new ( old but i have found in a shop new) 1992 cardrige syste forks.
    I have also Scott steering stabilizer.
    Today i went first time for a road ride. Above 100 km /h ( 60 ml) bike sarts to wobble, from right to left, like a snake.
    What may be a problem? All stuff is new , is wrong suspension set up?, bad preasure in a tires?What else?
    Please advice
  4. beechum1

    beechum1 Dandole Gas al Burro

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    Need a kicker return spring. Anyone have an extra?
  5. mcma111

    mcma111 Long timer

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    I have a spring
  6. mcma111

    mcma111 Long timer

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    Check your steering stem bearing pre-load. Might be to tight.
  7. martin.kryjom

    martin.kryjom Adventurer

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    HI
    What is proper Torq spec for that? Do U know may be?
  8. beechum1

    beechum1 Dandole Gas al Burro

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    I started on that 2nd 600 motor pulling the kicker axle I broke the spring. Is that something to be careful of or was it a good thing it broke now?
  9. Royal Club

    Royal Club Been here awhile

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    My manual says 3nm :huh

    [​IMG]
  10. mcma111

    mcma111 Long timer

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    Ham fisted mechanic. :lol3
  11. elsalvadorklr

    elsalvadorklr southern xr rider

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    dont overtighten the stem nut, that just tightens the clamp onto the steering stem retainer...

    make sure you can tap the retainer locknut till you have nice movement from side to side, you should be able to tap one end of the bars and the whole front end should move fully to one side...if it doesnt its too tight, if its too soft you will notice the wobble when riding at high speed

    youll get a feel for it after a few tightenings

    :D
  12. beechum1

    beechum1 Dandole Gas al Burro

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    And if when you tighten it, it feels Notchy, you need new races and bearings.
  13. elsalvadorklr

    elsalvadorklr southern xr rider

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    eggzactly!

    classic no grease overtightening scenario...

    you must lube in my opinion every 3 months or so

    what happens is since the xr is oil frame cooled the grease melts out or dries up a lot faster (cause the heat reached the stem tube) than an aluminum water coold frame, people simply let them go un serviced and they die a quick death...

    bad bad
  14. Captain115

    Captain115 Been here awhile

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    Hey Steve,

    In total I rode maybe 3-4km max. Probably closer to 2...I forgot to connect the speedo so not really certain. As soon as I noticed the knocking I turned around and headed back.

    It was the 99.8mm wossner, exact same piston that benno ended up with. Cleared to 1.5 not 2.5 but not sure if that's the problem especially with that knock.

    I installed the piston as per the machinists recommendations: little oil on the rings but otherwise dry.

    When I get time I'll get my crank and rod checked and maybe replaced. There's no vertical play in the rod but it does incline on an angle a bit, like bennos. Perhaps with a clearance this tight it just can't tolerate any problems with the big end. I'll check the crank bearings too.

    Thanks Steve,

    John
  15. elsalvadorklr

    elsalvadorklr southern xr rider

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    I just dont get it, that machinist is DUMB plain and simple, stubborn and dumb, he did the exact same thing to benno, you think he would realize he had something to do with that other meltdown and not do the same thing to yours...

    wossner specify extra loose tolerances even compared to other forged pistons like wiseco and je...


    really this is beyond maddening even to me! I feel so bad for you man

    like steve says there is maybe a chance you still had debri in the cases too and that scratched up the cylinder a bit too..

    btw Im a fan of dry installs now it has its benefits...:D

    just lube the piston skirts...and pin rod
  16. mcma111

    mcma111 Long timer

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    1.5- 2.5 is this metric?
  17. voltz

    voltz Rebuilding

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    John,sorry about your troubles.

    when you say clearance are you talking 1-2.5 thou ?

    a general rule of thumb is 1 thou per inch of bore size (from memory)
    I would expect as Steve has said 3-4 thou

    that piston skirt does look like it has started to 'pick up' on the bore :eek1
  18. Dino3310

    Dino3310 Been here awhile

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    Here that..
    when i got my bore done i took it to a motor reconditioners and gave him the wossner specs and told him no different... done, had no problems... nothing worse that a mechanic who knows better than the manufacturer:eek1. so the crank went to the crank specailist the head went to the motor recon specailist and the rest was up to me and me mate(mechanic).

    sorry to hear of your troubles John
    im i reading right that this is the same bloke Benno took his too?
  19. Captain115

    Captain115 Been here awhile

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    Thanks for the consolation everyone, I'm pretty down about it.

    Spent the past 10 weeks waiting to get it all together, everything seemed like it was on the right track: I'd finish the build, complete my thesis and then go for a big ride with my Dad for a few weeks. A celebration for leaving the monetary sinkhole that is university, finally getting the fuck out of there.

    But nope, looks like there were other plans in store for me.

    Yes, it is the same guy who did Benno's, and the same clearance. That is in imperical measurements, 1.5 thousandths, where as the box says 0.3mm (like 2.4 thousandths or something? But again like Benno, it seems this guy knows his shit. I know, I know he didn't do it to the manufacturers specs and there are two failed rebuilds on the similar piston in the similar engine with the same machinist. No great stats. But I truly believed him, and possible got burnt by it. Go figure. Not too pissed about that strangely.

    No, I have a feeling that the knocking is a separate issue to the tight clearance. Especially as it was knocking when I tore it down the first time. Sure I checked the lateral play (in spec), the bearings seemed ok and there wasn't any vertical play but seeing as how it still has this knock after I had replaced everything except the big end and main bearings leads me to consider it could be a problem there.

    Unlikely? Probably, but I don't have much else to go on. I know that if I put it back together and it still knocked because I didn't take the time to check the bottom end I would lose my shit...more than I already have. I'll get him to clearance the Wossner spec now too, well if I can still use the same piston without a re-bore.

    Thanks everyone. Fucking annoying but there it is.

    Cheers,

    John
  20. Royal Club

    Royal Club Been here awhile

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    erm... Is he the only one who can do this type of work...?

    If not i'd move on to another person who can and wants to deliver work you asked for..