Make Alp Great Again XL600V Rebuild Project

Discussion in 'Some Assembly Required' started by Mr. Mota, Mar 1, 2017.

  1. Mr. Mota

    Mr. Mota Adventurer

    Joined:
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    Thanks man! I bought both, went back and forth on which one to use, settled on the remover. Read more than a few times that the converter can only handle a thin layer of rust. If the rust is thick enough than only the surface will convert but the rust underneath remains. Might use it on the tank though. Wouldn't want to see that turn yellow.

    More spray painting. Had another go with the epoxy primer because it looked like it was sprayed on thin. Really cleaned out the spray gun properly this time and there was so much gunk in there. Sprayed so much better after. Sprayed the top coat too and man that stuff is a lot harsher on the lungs and lingers. Had to improve ventilation. All in all not too bad but still plenty of room for improvement. Didn't properly cover more than a few spots on the swingarm.

    Preparing the alloy parts. The frame came back from the powder coater in the city and it looks awesome. Great to see it in good shape for once instead of the state it was in before. Big step forward in the project. Also got the rims back from the sand blaster. Will try to do some work on them with aluminium brazing rods to fill up the rim rot. Especially on the rear. Need to get my hands on a torch first. Will be able to kick the project into first gear in a week and a half and start putting the bike back together again.



    Attached Files:

    #21
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  2. PTYCHRIS

    PTYCHRIS Adventurer

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    Hello, I was following your rebuild, which I found to be very intresting. Will there be more videos on the progress ?
    Did you finish your rebuild? Do you have a ride report for the trip here in ADV rider ?
    I just completed a trip through Chile and Argentina. I sent my bike from Panama in a container, I found a very resourceful customs agent in Valparaiso, which I can refer if you are shipping to there from New Zealand.
    #22
  3. Gedrog

    Gedrog Long timer

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    You will see more vids on yo-tube when you start watching the ones above I think its up to day 44
    #23
  4. plumer1kt

    plumer1kt Adventurer

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    he's in day 46 now!
    what about the caliper pistons mr.mota?
    you used the old ones?
    #24
  5. PTYCHRIS

    PTYCHRIS Adventurer

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    Gedrog - Thanks for the info, will look it up.
    #25
  6. Mr. Mota

    Mr. Mota Adventurer

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    Nice to have you along for the ride man. That is nice, bet you had a great ride! Mind naming a few of your favorite locations and tracks/roads? As for that agent drop me a message here or on facebook, thanks. And yes I'm still on the project, did not update here for a couple of weeks and then the build really kicked off again and there was no time to even make the videos. Back on that too.

    Cheers for helping the man out!

    Ha yes indeed! gave them a very fine sanding in some spots and in with the old. Still a struggle man to be honest and even this time I sliced a bit off the dust seal while trying to get one in but so be it. We'll see how that turns out. Nothing like the rear piston which went in pretty smooth.

    A lot has been happening since the last post. Less text this time and more video and pics. Lots more pics too. Re-assembly has really kicked off now and Alp is starting to look more like a bike again with every passing day.










    Spray painting the aluminium parts with etch primer. It is getting colder by the day here so perfect spray painting days are becoming a rarity.
    xrv-P1440954.JPG

    Radiators will get a fresh coat too. Only one layer of topcoat though and none of the fins to keep the cooling abilities intact. As long as they look better than they did before since they are mostly out of sight anyway. xrv-P1440956.JPG

    This is the moment where things start to get real. Bike support ready, freshly powder coated frame ready to receive all the parts! xrv-P1440970.JPG

    And here is a fine selection of those parts painted black. Handlebar came from the Honda shop that way. Standard dirtbike handlebar. Lower than the oem Transalp one so will need risers. This is a really pleasant sight, looking forward to getting most of it back on the bike. xrv-P1440985.JPG


    #26
  7. Mr. Mota

    Mr. Mota Adventurer

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    Want a small early easy victory so start out with the headlight. The fork clamps and the steering-head bearings follow soon after. Sent a mate back in the Netherlands a picture and he says the bike looks like Wall-E.
    xrv-P1440989.JPG

    Wire harness goes onto the bike and I am surprised by how unfazed I am with that. Should have asked me a year ago to only have a look at the wire harness and that would have freaked me out. Now it doesn't look all that bad. Maybe that will change if I have to do some actual fault finding. Hope not. Work on the Chinese footpegs for an XR600 from eBay which look and feel sturdy. Need to grind off quite a bit off the original support for them to fit. Maybe I overdid it on the right one so that could use a spot of weld later on to lift them back up again a bit. New handlebar clamps and of course the new handlebar. xrv-P1440993.JPG

    Forks get a good clean with scotchbrite pad and degreaser. Don't know if that effects the clear coat, if there is any left at all. Not looking for a chrome like finish here with sanding and whatnot. Also don't want to go that way because then they will require a lot more maintenance. xrv-P1440994.JPG

    Ok, now we are beginning to have a bike on our hands! Alp is slowly coming back to me. xrv-P1440995.JPG
    #27
  8. Mr. Mota

    Mr. Mota Adventurer

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    And there is the swingarm! Got some help with putting my first ever bearings in. Made a bearing puller/presser with a long nut, bolts and washers. Really like how they designed the inside so you cannot pull the bearings in too far without excessive force.
    xrv-P1440999.JPG

    Some nice long neoprene panty hoses for the lady! Will they protect enough like the rubber boots? We'll find out. xrv-P1450002.JPG

    Airbox goes in a lot easier than it came out. Finish rebuilding the calipers, reused the original pistons in the front caliper. Still had a tough time getting them in and one cut into the dust seal again. Rear brake foot peddle back on. Hopefully the spring connecting to the rear light won't have to be adjusted because that was a bit of a hassle when I did that in Japan once. Some more electrical components. Filled up the handlebar with the throttle, brakes, switches and the new mirrors. They are pretty flimsy and plasticy but I instantly like the new look compared to the previous round ones. xrv-P1450005.JPG

    One of the holes on the chainguard needs to be drilled out just a bit more in order to bolt onto the swingarm. Pretty happy with this piece. Got it off the wreckers back in Holland when browsing parts. I wonder if this was ever in production somewhere or if someone just made this themselves or had it made. xrv-P1450016.JPG
    #28
  9. PerGrus

    PerGrus Offroad is not off topic

    Joined:
    Jun 16, 2008
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    Bestcoast, Göteborg, SWE
    Congratulations that the Transalp is back, just seen episode 57. Been there, done that, almost bought the T-shirt.
    Last 2 1/2 year swapping engines 12 times. If You ever need Transalp parts don't hesitate to ask - plenty of them.
    (or AT-parts) 416 Mm TA-AT, looking forward to Your next report - go for it!
    Midwinter were You are now - Midsommer here in Gothenburg (soon) Left hand for greetings/Per
    #29
  10. iconman

    iconman Good vibrations

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    Denmark South West WA
    Been watching your episodes on the tube Pedro and really loving the build. I wish I had done something like your trip when I was younger - very envious. Looking forward to the final episodes. Cheers, Richard.
    #30
  11. Mr. Mota

    Mr. Mota Adventurer

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    Cheers man and thanks for the offer! As I progressed deeper into the project and more things came to light I now realize I should have gotten a donor bike. Though that would have involved sending a friend around the country to do my bidding and then post parts etc. But for a future project like this, cheap donor bike for sure! Though I'm not planning on going off into the deep end like this again for a while ha. 12 Times, damn! I could not get myself to pull the whole engine out again for painting last weekend so I only pulled off the side covers. Though on the upside thieves will think twice now "Nice looking bike but look, the cylinders and the heads aren't painted!". Full on winter here now, nippy garage.

    It is never too late Richard. Oldest fella I met riding was a 65 year old german on a TA650 and he was going the distance too! Great to have you along for the build.

    Definitely needs an update here. Bike is back on the road after a long downtime down south and started like a dream after a short crank. Meanwhile moved back to the middle of South Island and continued the build there. Everything feels so smooth on the bike and the exhaust! How I got by for so long without an aftermarket one is nuts. Plenty to do still and more than a few surprises that needed work. Lost a few bolts on the 300km maiden voyage too but nothing critical. Loctite is my friend now.

    Top frame is on, more electric is back and trying out a new can
    xrv-P1450022.JPG

    Rims painted and rebuilt with new bearings and seals. Painting spoked rims was the hardest spray paint job so far. Etch primer, epoxy primer and barely a couple of coats of topcoat and I was out. Did not opt for clear because I did not want a shiny finish but apparently there is a thing called "matt clear" so my loss. Though all in all with the time spent on the rims and the lacking durability of the paintjob I should have powdercoated them instead. Not that I wasn't warned. If you have a job then certainly a few hours there will pay for the powdercoat and spray painting them yourself will actually cost you a lot!
    xrv-P1450037.JPG

    Taping up the rally fearing to get the alignment right. Not a hard job but certainly time consuming. Fairing had to come on and off more than a few times. In the end ended up going for the vague outline of holes that were already on there. Which did not fair well for the hole above the headlight. Should have had it a bit more to the left. Also had to bang around the tank brackets a bit to get them well aligned.
    xrv-P1450040.JPG
    But once fitted it was all worth it!
    xrv-P1450042.JPG





    #31
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  12. Mr. Mota

    Mr. Mota Adventurer

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    Get a peak of what is to become before I take the rally fairing and the tank off.
    xrv-P1450043.JPG
    Use the last of the epoxy primer to paint the tank. Final paint job still far away and at least it won't rust.
    xrv-P1450048.JPG

    Such a beautiful beast of a tank and looking good in black too. Going from an 18L TA tank to 24L! That is a 120km range increase on a good day, 100km offroading. We'll find out for real what the real range is once on the dirt.
    xrv-P1450052.JPG
    The last parts to go on the motorcycle all clean and ready to go. The box now empty of all the consumable parts which is a small victory in itself.
    xrv-P1450054.JPG


    #32
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  13. Mr. Mota

    Mr. Mota Adventurer

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    Fenders and rear light on. Had to do some playing around with the wires. Brake light stayed on and that turned out to be much later because of the front brake switch. Used a standard bolt for the lever which did not let it return and engage the switch properly (don't know the name of the type of bolt that should go there, thick smooth upper half of the bolt without thread). Fairings not painted yet but the main goal here is to get the bike on the road again.
    xrv-P1450055.JPG
    The greatest gift I've ever gifted to myself and all wrapped up nicely by Honda Santa. Apparently they modded the engine so that it doesn't need oil anymore.

    - Oversize pistons
    - Oversize rings
    - New cam chains
    - Rebore
    - Inlet + exhaust valve cutting (Had new exhaust valves but Honda put the old ones back in, said they were in good condition)
    - Valve seat cutting
    - New gudgeon pins
    - Athena gasket set
    xrv-P1450062.JPG

    Made a nice comfy bed for the engine after the big operation!
    xrv-P1450064.JPG
    Ready to go! Still want to paint it but that is for later since it is all about getting the bike road ready.
    xrv-P1450067.JPG

    #33
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  14. Bonnie & Clyde

    Bonnie & Clyde Wishing I was riding RTW

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    :lurk
    #34
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  15. Mr. Mota

    Mr. Mota Adventurer

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    There is the engine, nice and comfy back where it belongs. Ready for at least another 100k or so we pray to the gods of pistons and oil. Basically hugged the engine awkwardly back into the frame. There was one thump on the frame that made me cringe but all was good.
    xrv-P1450070.JPG

    Put on the elephant ears for cooling. Fingers crossed that the radiators got through all the man handeling well without leaks. That orange relay handing on the fork is $1 from eBay and seems to be working well for the new indicator leds. Adjustable too.
    xrv-P1450078.JPG
    Chain, sprocket and rear wheel back in the game. Black on black is starting to look real good.
    xrv-P1450079.JPG
    Getting the engine head rubbers on for the carburetors took way too much time. New ones and they were hard as! Could not get them go on normally. Had to resort to all sorts of sins like CRC and a lot of rubber hammer banging. But even then it took more than a few times with an ever increasing regret as every failed attempt sliced another thin piece off the inside of the rubber. The regret was offset by an ever decreasing caring though and an increasing desire to just get the goddamn thing on there! Then it still had to be broken in from the carburetor side but me and Jorge double tagged it with an almighty push which concluded with a loud pop! She was finally broken in. Front wheel is back too and now we got ourselves a mean looking machine. xrv-P1450087.JPG
    #35
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  16. Mr. Mota

    Mr. Mota Adventurer

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    Airbox of course also needed a bit of a wiggle. Especially the rubber to the front is stubborn as. Header pipes back on witch will get a nice paint job later on. Basically she is good to crank now. Hook up a bottle of petrol to the fuel line and fingers crossed. Crank it, bit more, adjust the choke, mild rumble, getting close, and then ignition and the bike roars back into life! I could not believe it for a few seconds. What a feeling to have made that happen.
    xrv-P1450092.JPG
    Almost 3am but now I want to hear it with the exhaust on too! Hook up the new Delkevic exhaust and she is sounding sweet. How did manage to get by so long stock.
    xrv-P1450095.JPG
    Saddle back on which is going to get a new cover and needs to be cut a bit in order to make it fit properly. Tank goes back on too. Ran into trouble with the lefthand fuel tap which was blocked by the coolant pipe going into the engine. Ended up bending the pipe for about 45 degrees and cut a piece off the tap and now it sits barely without touching. Bit it fits and no more pressure on the coolant pipe. We're almost there! xrv-P1450106.JPG
    #36
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  17. Mr. Mota

    Mr. Mota Adventurer

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    Alp is back on the road and it feels amazing. Everything turning and rolling like new. More impressive is the new found sense of freedom which feels so familiar but was lost for a few months. Almost hit a sheep during the night time maiden voyage and almost lost the chain guard on the way. Now doing some minor jobs on the bike and enjoying the Central Otago winter sunshine again. Having two wheels at your disposal makes all the difference.


    Time to hook up the second fuel tap on the righthand side of the tank with some new fuel line.
    #37
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  18. JagLite

    JagLite Long timer

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    Anchorage Alaska
    :clap :ricky
    #38