gatosbros XR600/650L scramblers

Discussion in 'Some Assembly Required' started by jesusgatos, Nov 28, 2011.

  1. ScF

    ScF Adventurer

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    Shortening the spark plug wire is pretty easy especially if you use the aftermarket plug cap like is shown in the photo. It comes with a small brass connector that both clips on the end of the plug and you "pinch" it on the cut down stub of the coil wire outer sheath. The coil wire has a center conductor that you is soft and you will need to use a razor blade or an Xacto knife to cut around the outer sheath, stripping it from the inner wire. You can practice this on the long end of the coil wire before you start doing it on the short stub that you are going to use sticking out from the ignition coil.

    The decompression lever mod is up to you as are any of these suggestions. You made the comment about clearance and I gave you a way to fix it. If you want to do it on your own bike or suggest it to someone using your kit on their bike, they can do the same thing. Two 1/2" long welds and it is moved over about 1/2' for added clearance and still fully functional and out of sight. You could probably just bend the lever arm towards the engine and get most of the clearance, then cut/weld the cable bracket to match it.

    With the dip in your tank, the carb will not pull the fuel from the deep front end of the tank. Unless you are going to ride a wheelie constantly, there will be a fair amount of fuel in the front of the tank that is not usable. There is simply not enough vacuum pull through the carb to act as a fuel pump and raise that fuel up to the petcock and then to the carb. The normal fuel system on your bike is a Gravity fed system and gravity won't work uphill! You CAN use one of the small Mikuni vacuum pumps that are available from Sudco and other carb vendors. Using a vacuum line that you insert into your intake manifold it will pump/suction fuel from the low sections of your tank up to the petcock, through the Mikuni pump and then to your carb. They are about 2" square and maybe 3/4" thick and fairly lightweight aluminum.

    If this was an FI system then you would already have a fuel pump and it wouldn't matter.

    Some more ideas for you to work on.

    Swiss
    #81
  2. jesusgatos

    jesusgatos fishing with dynamite

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    So it's just like putting together custom spark plug wires for any other engine. OK, good to know.

    This tank doesn't hang down any further than any of the other aftermarket tanks for these bikes, and I know some of those do trap unusable amounts of fuel, but I'm going to add pickups and then the engine will suck-up as much as it can and I'm not going to worry about any last little bit that might be left over. The float bowl is still several inches below the height of the lowest part of the tank, so hoping that it won't be much of a problem.
    #82
  3. jesusgatos

    jesusgatos fishing with dynamite

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    Have been spending most of my time helping my brothers get ready to launch GatosBros, but snuck out to the garage for a few hours this afternoon.

    Started by stabilizing the new inner steel templates. Set the tank on the mock-up frame to check symmetry, then shimmed the gaps and then filled with bondo in sections. Was able to get it pretty darn close.

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    These pics show the difference lines of the old vs. new inner steel templates. Also shown is the interference with the manual decompression lever on the XR600.

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    Cutting-back the old steel templates and carving-out the foam. Went a bit deeper than I needed to, just so I could build the bondo up a little thicker.

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    This is what it looks like right now, after building-up and sanding a few layers of bondo that follow the contour lines of the new steel templates.

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    Kinda hard to tell what changed unless you look at an older picture right next to it. See how it's a little bit softer, more continuous curve along the front edges of the tank now, where before it had that awkward, abrupt angle. Think it's going to look a lot better like this.

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    #83
  4. JStory

    JStory Long timer

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    What are the tire sizes? They're fat enough to add a little "modern" to the old school scrambler theme without going supermoto.
    #84
  5. jesusgatos

    jesusgatos fishing with dynamite

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    Those are 18" wheels. 3.5 in the rear and 2.15 up front. Have been running a 19/17 (2.5 & 4.25) setup on my KTM, and I really like that too. Tires are just whatever. Will probably end up running something like TKC80's or Michelin T63's or Mitas E09's or Michelin T63's or something along those lines.

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    #85
  6. JStory

    JStory Long timer

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    Thanks
    #86
  7. Dexter2811

    Dexter2811 Been here awhile

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    Jesus!!!! that's looking good!

    What about all those handles on the KTM??
    #87
  8. jesusgatos

    jesusgatos fishing with dynamite

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    We've been using 1" footman loops and Voile straps to lash our gear down. We got the idea from these guys. Cheap, simple, super-modular and very secure. Yeah they look a little bit funny, but we've used them to haul ridiculous loads and they flat-out work. Usually camping gear, but Robo-Boogie rode his 450EXC from Chico all the way out to Virginia City on SM wheels with his dirt wheels and riding gear strapped to the back fender with Voile straps. Got to the race, swapped out his dirt wheels, unpacked his riding gear, raced, packed up and swapped wheels again, cruised through Tahoe to say Hi to our grandparents, and then rode all the way back to Chico. Think that's probably over a 400 mile round-trip, not counting the race. Voile straps rock, and I prefer using footman loops to cutting holes in plastic, but we've been working on a better solution...

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    #88
  9. jesusgatos

    jesusgatos fishing with dynamite

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    Box full of carburetors showed-up today. Thanks Mike!

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    #89
  10. OaklandStrom

    OaklandStrom Long timer

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    Damn! That's gonna make your bike really fast.
    #90
  11. ben2go

    ben2go Moto Flunky

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    Lets review this a little more.

    You have

    2 weeks supply of carbs

    or

    1 a month plus a couple just in case of a break down

    or

    1 a year for 14 years

    or 1 a day for 2 weeks or 14 day which ever you prefer.

    Anyway you look at it,you'll never have a carb issue.Rebuild a few and swap out when a problem occurs.

    :lol3:lol3:lol3
    #91
  12. jesusgatos

    jesusgatos fishing with dynamite

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    Haha. Planning on building a few more of these bikes...
    #92
  13. Pablo83

    Pablo83 Sleep, Wrench, Ride

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    So what does a box of FCRs cost?
    #93
  14. cyclewizard

    cyclewizard Long timer

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    You hit the lotto!!!!!! damn what a find bros......
    #94
  15. ThumpnRed

    ThumpnRed Pig Wrangler

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    Looks like you are missing a few slides:deal
    #95
  16. STFU

    STFU Found

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    have any stock carbs you want to get rid of cheap?
    #96
  17. jesusgatos

    jesusgatos fishing with dynamite

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    If you can find another box, lemme know!

    Not yet, but sure. Can let you know when I get to that point. Thing is, the one bike we've already torn down had a Mikuni on it that I sold a while ago, and the other two bikes are still complete/running. Might just swap-out for FCR's sooner than later though. Guess there's really no reason not to. Will have one 600 carb and one 650L carb.
    #97
  18. jesusgatos

    jesusgatos fishing with dynamite

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    Designed these CRF conversion tripleclamps for the XR650R and now am trying to figure out what I need to change to make them fit the XR650L. Going to run late-model CRF forks on at least one of the bikes, but want to adapt XR650R forks to a few of the others.

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    Left to Right: XR650L, XR650R, CR500, CR/F
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    #98
  19. Cumbacheech

    Cumbacheech XRated

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    I am sure there are a bunch of XRL owners who would be interested... I know I would be! Would be nice to have the steering stops, maybe even a spot on the triple clamp to attach the key switch...

    :lurk


    Cumbacheech
    #99
  20. jesusgatos

    jesusgatos fishing with dynamite

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    The more I look at the gas tank, the more I've come to realize that I absolutely hate the way it looks. But it's so hard to throw away all the work you put into something like that, just kept working on it, and re-working it. Trying to save it. Even though it clearly wasn't working. So I'm done with it. But it's not all time wasted. Instead of starting over and hand-shaping another tank, I'm just going to have this one laser-scanned. That will give me the basic geometry of the underside of the tank and the areas I modified to increase the volume. From there I can re-shape the tank in Solidworks and that will be a lot faster/easier. Well, maybe not faster or easier, but I've been trying to improve my surface modeling skills and this will be good practice. The most difficult part of the whole process is going to be turning a CAD model into something tangible. Have got a friend with a CNC router and am thinking that we'll have a plug made out of wood. But I'm super busy with other projects right now and my friends are getting anxious. They want to ride their bikes. Wondering if maybe you guys can help me pick out some tanks to use in the meantime. Any suggestions?