The XL600 thread

Discussion in 'Thumpers' started by Gregster, Jul 6, 2007.

  1. HeadTrauma

    HeadTrauma ¯\_(ツ)_/¯

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    My guesses:

    1.) It makes more room to access the star wheel/detent for the shift drum.

    2.) It will have to come off anyway if the cases are going to be split.

    I really wouldn't mind if Honda had kept using the upper and lower case halves like their old bikes had. It may still be a pain to open the bottom end, but at least the top end didn't have to come off most of the time. Earlier this year I had to replace a kickstart shaft(common) in a low-mileage XL175. Although the Clymer manual said the whole thing had to come apart, I was able to pull the bottom case without disturbing the head or cylinder.
  2. Waldo308

    Waldo308 Grouchy Olde Pharte

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    Aug 21, 2008
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    Southern Kommiefornia
    HeadTrauma has it right. The wheel and detent are firmly in place so the damage is inside the case. Even if I didn't have to split the cases for that reason, the engine has to come apart anyway.

    This bike sat collecting dust for about 12 years without being started. During the abbreviated ride to the local mountain it was becoming obvious that every single seal on the engine was weeping oil. By the time I got back with the truck (about 45 minutes), there were three separate oil puddles under the engine.

    I'm afraid it's time. Since it has to come apart, we're going to check every single part and replace all of the seals, any bearings that show any significant wear and anything that is not in spec. Will probably also hone the barrel and put in new rings.

    So, the clutch will be coming out.....that is, after I follow your advice to reinstall the plates to get the nut off.

    Thanks again folks.
  3. Zombie_Stomp

    Zombie_Stomp Aspiring human

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    Cool, another rebuild. If you haven't read Gregster's rebuild thread, it would be a great idea to do so, his photos and hands-on layman's description of everything is super-helpful. There should be a link to it in any of his posts, his is the forst of this thread. He inspired and enlightened me in my rebuild quest, which led to much, much tinkering over the last two years.

    Now I've got a 1998 XR600 bottom end with 1983 kickstart stuff and clutch cover in it, bolted to a 1985 xr600 cylinder with a wiseco piston inside it and an OEM 1983 rebuilt head and an aftermarket heed gasket that is on it's third use and doing fine. And with all this, the bike is running it's best in two years. I've learned that they're just parts, you have to learn to make them work for you!

    Oh yeah, go read Gregster's rebuild thread. Contact me if you have trouble splitting the cases, I know a few tricks he doesn't show.
  4. Waldo308

    Waldo308 Grouchy Olde Pharte

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    Thanks Zombie. It was reading your story that gave me the confidence to go ahead and go forward with starting the rebuild.

    I have been reading through all of the XL600 threads having to do with the engine and will read Gregster's thread again. It's been about 4 months since I read it so I need to go through it again.

    Thanks for the offer of help when I need it. No doubt I'll be posting at some critical point!

    Regards,
  5. Zombie_Stomp

    Zombie_Stomp Aspiring human

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    Thanks, I wish I could get those warm fuzzies over a rebuilt as when I first stumbled upon those first threads by greg and ere109, and my bike in the summer of 2007. Those were the days.
  6. yondering

    yondering Long timer

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    Oddometer:
    1,100
    Location:
    NW Wa. state
    I weighed a friend's 1987 XL600R yesterday, thought I'd share the info for anyone that might need it:
    148 lbs on the front tire, 186 lbs on the rear (334 lbs total). This weight was with the bike ready to ride, with a partial tank of gas, no rider of course.
  7. UncleDirt

    UncleDirt Uncivil to idiots.

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    :norton Yep, Rebuilds are always best enjoyed when someone else is doing them. Enjoy.
  8. JStory

    JStory Long timer

    Joined:
    Dec 21, 2004
    Oddometer:
    2,927
    Location:
    Dixon, CA
    Some mods that I finished today.
    Old-school round headlight. No stock parts were harmed during this mod.
    Brackets fabbed up, ready to install.
    [​IMG]

    Brackets, turn signals and headlight shell mounted. Turn signals are Buell Ulysses rear signals. These can be bent over 90* in any direction without breaking, and cost about $10.
    [​IMG]

    A couple shots of the completed installation. Assistance and ADV salute provided by my kid.
    [​IMG]
    [​IMG]

    Next. New FMF Q muffler. I ordered it from OEM Cycle.
    The 1.75 inch. Its quieter than the Supertrapp, but still sounds good.
    Here it is all mounted up. Its a little lower than the Supertrapp it replaced, but not a big deal to me since I don't do any hardcore off-roading.
    [​IMG]

    With the side cover. Doesn't work so well with the cover. I need to work on that some more.
    [​IMG]

    Here's a close-up of where I cut the mid-pipe. Thats the side cover mount screw just left and above the muffler clamp. You can see the swage in the pipe just left of the clamp. Thats the exact location of the cut.
    [​IMG]
  9. UncleDirt

    UncleDirt Uncivil to idiots.

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    That headlight, is a seriously, brilliant, most excellent mod! Now I'm copying your rear rack.
    Dave
  10. crag antler

    crag antler In the woods lurking

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    Florida Cracker in Southern Maine
    I really like the headlight too. If only I had one of my GS1100 big ole 8" light hanging around.
  11. MortimerSickle

    MortimerSickle Semi-Adventurer

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    :thumb
  12. mcma111

    mcma111 Long timer

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    A couple shots of the completed installation. Assistance and ADV salute provided by my kid.
    [​IMG]


    Damm Kid's
  13. Zombie_Stomp

    Zombie_Stomp Aspiring human

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    Makes me wanna get one of them big-ass baja lights. I'll probably just get this auxillary one, as I'm not giving up on my 1983 Paris Dakar XL600 cloning experiment just yet:
    [​IMG]
    And Mortimer Sickle: all we needed was your thumbs up, perfect. You've been rocking that sig. line for as long as I've seen you on here.
  14. UncleDirt

    UncleDirt Uncivil to idiots.

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    Is that white and black thing right behind the "A" in Honda a cup holder? Coool.
  15. handirifle

    handirifle Been here awhile

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    450
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    Central Coast, CA.
    I like it. What headlight is that? Nice work on the brackets. How'd you cut them?
  16. JStory

    JStory Long timer

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    Dixon, CA
    Head light from eBay. The brackets are made of 3/4 x 3/4 x 1/8 aluminum angle, and 1/8 aluminum plate. I cut the side plates on a band saw, and cleaned them up on a belt/disk sander.
  17. handirifle

    handirifle Been here awhile

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    Central Coast, CA.
    Nice work. Sounds like my kind of "engineering".:D Did you use the stock headlight switch?
  18. rolosmoneypit

    rolosmoneypit Adventurer

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    Jun 12, 2009
    Oddometer:
    55
    i need to find a post i saw some time back with a link to an oil temp dipstick. Not the xr only brand one ive heard too many bad things about that one... tahnks
  19. Zombie_Stomp

    Zombie_Stomp Aspiring human

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    In XL600 news, I like the way my turn signal has ben malfunctioning lately. It has been blinking really fast when I first apply the signal and then erratically until it tapers off into it's normal blinking tempo. I feel that this has improved my visibility on the freeway at night, probably giving a few drivers the sensation that they are being somehow pulled over by a towtruck. :D I had picked up an electronic (black plastic box) replacement at the junkyard that I found sitting around, don't know if it's any good but I tossed it in my cut-out deployed airbags bag and got them both for free. I like mine and will ride it this way forever if it keeps up.

    I had recently re-covered my seat with a cover I made also. I made it an inch too small in either direction, so it was stretched really taut, enlarging some of the stitch holes. Well today, it was next to this really shiny trailer and the bright sun reflecting off the trailer melted the seat and one of the seams gave way. It also melted the textured surface of the vinyl smooth and shiny in a large area near there. All the while I was inside the trailer cleaning, oblivious that this was happening. My co-worker/boss's kids were all like, "Hey, hey, I bet I can hold my hand on this seat cover longer than you can!" "Let's have a contest!"

    Aw man, and that particular vinyl was left over from a project that my seamstress mentor did for a more recent AC/DC video, too! True story, far as I know. I had made that cover with the red stripe of tarp material first. I discovered that using tarp material isn't good because it's not stretchy so it creates wrinkles that don't stretch out. It also doesn't mold to your ass as you sit, therefore puts your as to sleep on most rides. I then got the seat "Back in Black", but I think the video she was doing costumes for was for "Stiff Upper Lip" or soemthing more recent of theirs. Whatever it was, their leftover vinyl made for a cover that was better than "stiff under ass" like the first one.

    Oh well, it's a good excuse to make another one more correctly. Besides, Fully Geed is sending me his old stock seat and stuff, so I'll have a project seat I can really take my time on. Hoping to do some supplementary foam or a full re-foam job myself.

    Bike runs great, just gotta do heli-coils in one bolt hole holding the rocker box on to stop a slow oil weep. I just cleaned the side of the engine off so it's gotta get done soon. I got a compliment the other day on the bike "That's bad ass, dude!" and then I got these preppy chicks in a BMW rolling down their window next to me in Downtown Portland with their makeup and dresses totally hitting on me saying, "Heeeey, I like your bike, that's coool, man!" They totally had the hots for me. :D
  20. HeadTrauma

    HeadTrauma ¯\_(ツ)_/¯

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    Dang, I gotta move over to Portland. There certainly wan't anything heappening at McDermitt weekend. :D