JW's BRP XRR Build 2012

Discussion in 'Thumpers' started by jwalters, Aug 18, 2012.

  1. jwalters

    jwalters Farkle Proliferator

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    You know it's even easier than that! Just call Motion Pro, they know the XRR cables well. Just tell them you want 2 inches longer over stock in a compression and clutch cables and they will make them to order. No time wasted sending in your old cables and no extra shipping fee!

    #61
  2. DocAxeYarYar

    DocAxeYarYar RideDualSport.com

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    Awesome job, looking forward to seeing more! Any thoughts about running a small lithium battery to power an E-vest on longer rides?
    #62
  3. Keith

    Keith Slabbing it

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    I was never satisfied with the Baja Designs rear taillight when I had my XR. It let in water and dirt, so as to make the light a lot less visible. Maybe you could see about sealing it up to prevent that.

    Also, some thought may be given to the LED insert that replaces the stock taillight bulb. It's real bright and has a brake light function as well. DRC makes it and it's available from Wheeling Cycle Supply. Other places too, I'd imagine.

    You have a very nice build there and it gives me thought for my new to me XRR.
    #63
  4. jwalters

    jwalters Farkle Proliferator

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    Both excellent suggestions! That's why I like doing these threads, cause it inevitably leads to good feedback. Anti-crush sleeves and now these: :deal


    Buell787753, I wasn't thinking about it, but it would be nice to use my heated Aerostich vest on this thing, especially this fall yet up here in Northern Minnesota. I don't want the heavy battery on the bike all the time, so I think I'm going to wire up an SAE plug to my existing battery pack, so that I can plug in a spare battery and keep it in a bag on the rear rack. That way it's there when I need it and not there during most of the summer when I'm cursing the heat!



    I got some clear silicone, I think I'm going to do as you say and seal up the unit as much as possible. I would like to put something back into the stock taillight housing, it's sort of an eye sore right now. I'm going to look into that DRC unit. I hadn't see those before. thanks!


    #64
  5. Keith

    Keith Slabbing it

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    Sycl batteries has their 4 cell battery on sale. With the discount code as posted in the vendors section, tax and shipping were essentially covered.
    #65
  6. jwalters

    jwalters Farkle Proliferator

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    Back home and back to putz'n on the XRR. Just finished up a bunch of small jobs. I bought a CRF450 mudguard to keep some of the spray off the rear shock. I didn't like the existing mounting points into the soft plastic on the back side of the airbox so I made some new holes and custom fit the CRF mud flap on the XRR. From my KTM 990 experience, I know you have to be careful those plastic mud guards don't slowly eat into the soft aluminum on the swinger, but I have good clearance all around on the gaurd.
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    Bolted on a new 50T rear sprocket, new chain and new front sprocket. I slapped some anti-seize on the chain adjuster bolts and had to make some minor cuts to the white plastic side covers to get them to fit around the new sub-frame rack. All in all, just a bunch of little fitment issues expected with any new piece of kit. I won't have my Renazco seat for a few more weeks, but my spare seat is doing just fine for around the woods.

    All I can say is, this bike is awesome!!!! The 50T rear sprocket really wakes it up too. I might have to shim the needles a bit on the carbs, because the new FMF header along with the cooler temps seems to be causing the bike to run a bit lean. I'll have plenty of time to dial it in over the long winter. For now I want to get some miles on it, and re-torque the important bits. This winter I might powder coat the rims black, install a speedo and radiator fan. We'll see, I have too many other projects to get going on! :lol3 Thanks for tuning in, I'm saying this bike is officially DONE!

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    #66
  7. Sean-0

    Sean-0 straya carnt

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    Nice work the bike looks good .. i like the front fender :evil
    can you take a fe pics of your plastic's issue u had fitting on the rack

    im about to purchase a subframe and am wondering if i should get the rear luggage rack version or just the subframe ??

    ....Again bike came out real nice .. you have done a good job
    #67
  8. jwalters

    jwalters Farkle Proliferator

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    Well, I thought this build was done, but I've put about 200 miles on the bike now and there are a few minor tweaks I need to do over the winter. I was glad I got some miles on the bike before winter sets in. If I have any luck, I'll have a few more hundred miles on the odometer before the new year.

    Minor Issues:
    1. The standard 3" rise in the Emig Racing Triple tree brought the handlebars closer to the rider. So the height was about right but the riding position for my tall frame was a little cramped. I need the bars farther forward. Some Rok Pivoting bar risers should be the solution! We'll see!
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    2. The other thing I noticed was the bike seemed to be running very lean at mid throttle (ie needles and needle jet). The addition of the FMF header seems to have opened the bike up a bit, so I'm going to slap the FMF jet kit in and dial that in over the warmer spring months. Kinda funny, FMF usually throws in a few stickers as a "thank you" for the purchase. For some reason they through in a pack of 50! What the heck am I going to do with 50 FMF stickers?
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    3. I also wanted to get a mount for my GPS on the XR. I'm finding myself exploring more and more backroads and the handheld GPS seems to be the way to go over my 550 Zumo. $30 worth of parts and I have the mount ready to go!
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    4. I also need to figure out how to stop my coolant hoses to stop leaking when the bike warms up. The engine isn't overheating, but the hose clamps on my aftermarket hoses don't seem to seal the coolant very well. I think I'm going to try some wider hose clamps and possibly some different hoses if that doesn't fix the problem.

    5. Lastly, as many others have dealt with, my Acerbis petcocks are weeping fuel ever so slowly that my garage starts to smell like a bomb after a few days. I'm going to play around with some larger O-rings to see if I can fix the leakage.

    That's it for now. It's been a while since I've had a small bike like the XRR. I love it! :clap
    #68
  9. Lutz

    Lutz Killer Rabbit

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    Hmmm... 2013 MNSS sponsored by FMF?

    I love how you can say that and be totally serious.
    #69
  10. jwalters

    jwalters Farkle Proliferator

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    Well, not as small as my Suzuki, but yes a 650 feels pretty small to me... :rofl


    What a sweet sweet machine....
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    #70
  11. oldxr

    oldxr Long timer

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    I have a xrr .I did a major whole bike upgrade 2 years ago and have been riding it more than my road bike.A suggestion-if you install a speedo unit like a trailtech vapor you can drill and tap a temp sensor hole in the thermostat housing instead of using that plastic t that you cut a hose to install.Less parts to leak.I have been running ironman sprockets with a rk x ring chain lubed with triflon.No noticable wear on sprockets.you will probably need a better seat.The seat concepts seat is working good for me but if you are tall there are other off the shelf options -like a guts tall seat.Or send it to a custom builder.I can run highway good with 15-47 gearing and still be so-so on single track-but I am not that big of a guy.I did a top end rebuild on my motor and would not use a hotcams cam again.No problems with quality or performance-just the fact that the auto decomp on the oem cam is now gone and the engine has to be in a very special place just past tdc to start.If I did the top end again I would have a cam specialist like web camshafts or megacycle reweld the oem cam and the oem rockers.There is a post right now on thumpertalk about grinding .050" of of the throttle slide to eliminate off idle bog.Even with the 68s pilot jet and the b53e needle 4 notches down I still had a big lean spot from 1500 to 3000 rpm that I found when I dynoed my bike.I went back to the near-new edelborck carb that came with the bike.It runs much better but after another dyno run found I a little rich and lost 3 hp on top.I installed a leaner needle but I havent been back to the dyno yet.The Hodakaguy brace is awesome-I have layed my bike down on both sides and the brace keeps the tank off of the radiators and makes the tank easier to install.Most people have installed a Keihin fcr carb.Another little trick is to run a cdi box from an early xr400-more initial advance +1000 rpm more revs.The oil level sight tube kit is nice to have.
    #71
  12. jwalters

    jwalters Farkle Proliferator

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    I have a Tailtech vaper, not sure if I'm going to install it or not, but that's a good idea!

    The seat has been on order with Renazco since I started this build, I have two stock seats so the one pictured is just the one I'm bumming around on until my Renazco seat is finished late December. I have his seats on my KTM 990 as well and really like them. I've used Corbin, Meyer saddles and others, but I really like the Renazco workmanship.


    Thanks OldXR. This advise will come in handy! It's helpful to see what others are doing. I'm actually going to try to de-tune this bike somewhat, as I hope to use it in a South Ameica trip in a few years. So I am concerned with reliability as I am with power. I"ll run her fat and cool!

    Thanks again!
    -jw
    #72
  13. jwalters

    jwalters Farkle Proliferator

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    Bike has been running good this winter! From a few months ago, here.

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    #73
  14. DocAxeYarYar

    DocAxeYarYar RideDualSport.com

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    Congratulations on the excellent job with building your XRR! It looks awesome and works even better I bet!

    You mention maybe powder coating the rims. I thought about that on my bike, and enquired with Woody's Wheels. They recommend against powder coating because the baking process will soften the rims. The rims are already soft, and the front has tendancy to crack. I had Wood's lace my stock hubs with oversize stainless spokes/nipples and new Axcel rims. It worked out great! Just a thought if you want to bullet proof your wheels for carrying more weight on long adventure rides!
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    #74
  15. jwalters

    jwalters Farkle Proliferator

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    Thanks for the heads up. I might just give em some paint, and clear coat the heck out of em. Hell, it's a dual sport, so I don't mind if it get's chipped up over the years, i can always just repaint them.

    Thanks again for the advice!

    #75
  16. award900

    award900 Been here awhile

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    Lurk
    #76