XR 600 Project

Discussion in 'Some Assembly Required' started by Motomechanic, Mar 27, 2012.

  1. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    44
    Location:
    Perth Australia
    Flat out with work this week, and didn't get as much done as I had hoped. But my mountain of parts is still growing and almost all the bits i've ordered are here.

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    I managed to get the linkages fitted with new bearings this week and cleaned up ready to go.

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    Old vs new. Footpegs have grown a lot in the last 20 years!

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    I'm not up to speed with different alluminium grades and want to buy a piece to turn up my new head stem. If anyone knows what grade of alloy would be suitable to make this part out of please let me know.:ear
    #21
  2. duxrneet

    duxrneet Been here awhile

    Joined:
    Jul 20, 2009
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    671
    Location:
    Melbourne, AUS
    I will be looking on with great admiration. It's good to know that there was an XR out there that looked uglier than mine :D
    -Subscribed
    #22
  3. sailah

    sailah Lampin' it

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    Turning expensive metal into scrap

    Not a metallurgist but check this out for a primer, there should be an about aluminum tab

    http://www.mcmaster.com/#standard-aluminum-hollow-tubing/=h9aya9

    Any reason why you couldn't turn down an existing stem? That would probably be cheaper and take the guess work out of aluminum
    #23
  4. DRjoe

    DRjoe Long timer

    Joined:
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    Sunshine coast qld
    you could cut the stem off just leaving enough for teh bearings to sit on and then put a long bolt through the tripples where the stem usualy goes.
    (I think that made sense)
    #24
  5. deejay_xr

    deejay_xr Been here awhile

    Joined:
    Mar 20, 2012
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    Netherlands
    I forgot / too lazy to read back, but I guess those would be the USD's from a CR or CRF ??

    If you have the CR/CRF stem that goes with the triples and forks you can have it machined down to accomodate the XR bearings using the .pdf drawings in this thread

    http://www.thumpertalk.com/topic/555802-cr-steering-stem-specificationspics/


    Read all the way through, along the thread someone posted the .pdf drawings that are still hosted for download, and some revisions were made. Drawings are for a CR stem, but I'm almost (!) certain that the CRF stems are identical, you'd have to measure to be sure though.

    The stem from my '01 CR250 USD's is being shipped to the US to have this machining work done as we speak to fit the forks in my XR600R

    Plus, the CR/CRF stem is made of some kind of stainless, which I would say is preferable to an aluminium stem, just to be safe.

    I've been following your thread quietly, looking good man! Good luck !
    #25
  6. sailah

    sailah Lampin' it

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    I have a bunch of stems laying around. If I can find one that meets the minimum specs of those drawings, I can machine it and send it to you if that makes your life easier.

    No promises that I have one though.
    #26
  7. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
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    Perth Australia
    All the help is great thanks guys! I've got a copy of the drawing to machine the crf stem and I have access to a lathe so that'll be on top of the to do list. I was worried about machining it down because it's roughly 4mm to take off and I had my concerns about the strength of the finished part. Having witnessed some horrific bike accidents in the past I don't want a weak point holding the front end togeather. BUT looks like everyone else has been doing it and I haven't heard any bad feedback. Just being paranoid I guess. Thanks for the offer to machine one up for me sailah:thumb

    In the mean time any real plan of what i'm doing first has sort of gone out the window and i'm just sorting out as many bits ready to go as possible. Cleaning up the engine cases at the moment and my ocd side is starting to take over. I have to keep telling myself it's only a dirt bike. At this rate it'll end up looking better than my SP2.
    I've also been wondering what size to build this engine up as. Changed my mind a bit and am now thinking the bigger the better so I ordered one of these to start with.
    [​IMG][/IMG]

    I've seen a sleve available to go 720cc but am still not sure. At least 650 though
    #27
  8. deejay_xr

    deejay_xr Been here awhile

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    It'd still be a damn sight sturdier than an aluminium stem, plus if you were to make a stem from scratch the dimensions would ultimately be the same.

    That piece of Carillo steel is sexy ! :1drink
    #28
  9. kapparone

    kapparone n00b

    Joined:
    Apr 26, 2012
    Oddometer:
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    Location:
    Milano Italy
    compliment the bike you're doing 'ok!
    Have you thought of mounting the twin exhaust crf 250?
    I'm 'following from Italy and expect to continue your work soon ....
    Krone
    #29
  10. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    44
    Location:
    Perth Australia
    Not a lot of progress has happened since my last update, I've been away working for three weeks and have been itching to get some more done on the bike. One thing this did achieve though was to allow me to go on another shopping spree:D
    Plus a few parts i've been waiting on have finally turned up. One of them is my new shock, It's out of a 2005 model and so gets rid of the old remote resevoir with a hose attaching it to the shock. I haven't stripped it fully yet but the body has been hard anodised so i'm hoping theres a gold valve installed.
    [​IMG][/IMG]

    When I removed the spring I took measurements of the length and travel so I could make this adjustable bar to aid with the positioning of the subframe
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    The only reason I use stainless steel for these type of things is I get it for free from work.

    Once fitted this allows me to lock the rear suspension in the bottomed out position. With a new tyre in the full rearward position I can then position the subframe and ensure that nothing clashes. Also handy so I can wheel the bike around when the shock is removed.
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    Other bits that turned up are my Cyclewizard chain adjusters and valve covers.[​IMG][/IMG]
    The quality of these parts is first rate and the adv rider member who I got them through, Mendoteach is a champion. Thanks again for all your help.

    I bought a used 41mm kiehin fcr flat slide carb seems ok but i'll strip it later to inspect and set up for the xr.
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    And other bits and pieces
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    I should be home for the next few months so I'm keen to get as much as I can done. The steering stem is still top of the list to get done followed by machining and welding of the swingarm to accept a crf rear hub and disc brake setup.
    #30
  11. singletrackslayer

    singletrackslayer Legalize singletrack

    Joined:
    Jul 29, 2011
    Oddometer:
    524
    Location:
    Morningwood, CO
    Im in!

    Ive been a professional aluminum welder in years past too. Can throw you some advice when Im not workin so much and have more time. You make me wanna build one now . . .
    #31
  12. Roadracer_Al

    Roadracer_Al louder, louder, louder!

    Joined:
    Aug 5, 2007
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    1,717
    Location:
    Oakland, CA
    Looks like a great project!

    In

    I have similar aspirations for my wife's DR650...
    #32
  13. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    44
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    Perth Australia
    Thanks for the offer silgletrackslayer, I hope to be getting into some of the welding and fab in the coming months. I'll post some pictures of my efforts for some critique.
    Sadly not a lot of major progress since the last upgate still just tackling one job at a time. I've been looking at houses which sucks heeps of time as well. Good news is I boutght one, even better news is it's got a big shed so I can get set up properly. Can't wait to be working off a bench for a change and have a vice plus mount my grinders ect properly. Still almost two months off yet but something to look foreward to.

    I've started sorting out what's needed to make new oil lines and hoses. All the standard fittings on the frame and oil cooler are JIS a japanese standard tube fitting and not that common. I'll be cutting them all off and welding on JIC fittings a much more common and readily available type of fitting that I can get for nix from work. I have also cut up the old oil lines and removed the special ends that go into the engine. I'll get these plated and reuse them later on new hose.
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    I also did a small repair to the stator cover. As I mentioned early in this thread this bike was ridden on the salt flats a lot and it has eaten into the magnesium engine side covers in some areas overall it's not that bad I can just clean it up with a file and get them powdercoated, however this one needed a little clean up.
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    One of my last big ticket items is now sorted out as well. The tyres that came on the bike are great but not DOT approved so I had to buy new tyres. I'm going for full rego and have to take it over the pits and so needed something that would pass the inspection. I'll keep the old ones to use later or for a trip. Also went for a set of ultra heavy duty tubes.
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    Got these crf 450 wheels for a good price off ebay through extreme powersports Australia. My experience with these guys was great and I'll get a set of motard wheels off them as well whenever the build is finished.
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    Put all that lot togeather and I've got these ready to go.
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    I'm currently working on machining the swing arm to take the crf axle and brake this will take me a little while to get sorted, plus plenty of other smaller jobs. :thumb
    #33
  14. kapparone

    kapparone n00b

    Joined:
    Apr 26, 2012
    Oddometer:
    7
    Location:
    Milano Italy
    check it out!!!
    Ciao
    Krone

    [​IMG]

    [​IMG]
    #34
  15. SlickSix

    SlickSix Been here awhile

    Joined:
    May 24, 2012
    Oddometer:
    185
    Location:
    Portugal
    Been following you and we need updates man!

    Your build is coming along nicely, faster than mine, and it´s making me itch.
    I´m waiting on my frame and some parts that my brother painted but the waiting is
    killing me. I´ve got a few boxes of new and shiny stuff to fit but still no frame!!!!

    Come on man, it´s our food...:freaky
    #35
  16. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    44
    Location:
    Perth Australia
    Progress is still happening slowly. My Computer crashed and burnt so that's why I haven't posted any updates lately. I'm at work for a week at the moment and can finally give you guys somesort of update, unable to post pics for the moment. The slot in the rear of the swingarm has been machined to accept the crf axle. It has also had all brackets ect cut off. The slot has also been extended foreward by the difference in the radius from the new axle to the old one. This ensures the new axle will have the same centerline when it is right foreward.
    I have decided to make a new steering stem rather than machine the crf item. I just don't like the idea of reducing the wall thickness of that part. I have done all the measurements and drawn up the stem and spacer that i need to make in cad. Just need time to get it done now.

    I bought a cylinder sleve and forged piston kit (102mm). Engine displacement will be 650cc. I've been doing a lot of work preparing the engine for soda blasting, removing casting marks and a weld repair on a front sprocket cover mount. I've removed the broken exhaust studs and tapped the holes ready for helicoils. I've stripped the head and rocker cover completely including pushing out the old valve guides. The rockers aren't in bad condition with only one needing replacement along with it's piviot shaft. A number of the 6mm threads in the head were stripped so I've drilled out all of the 6mm threads in the top end and tapped them ready to be fitted with helecoils. No more stripped threads here, ever. Still got some to do but I hope the get the engine ready for blasting within the next two weeks.
    I'll post pics as soon as I get the chance and try to keep the progress rolling.
    #36
  17. ffjmoore

    ffjmoore Adventurer

    Joined:
    Jul 19, 2012
    Oddometer:
    80
    Location:
    Fresno Ca.
    Yeah whats up with this build?
    #37
  18. xr6

    xr6 Adventurer

    Joined:
    Jan 4, 2012
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    27
    Update please!:clap
    #38
  19. Rocket_Rookie

    Rocket_Rookie Learning the ropes!

    Joined:
    Mar 8, 2012
    Oddometer:
    54
    Location:
    Gauteng, South Africa
    You have done some good work. I guess it is easier to restore these bikes in the US, than in South Africa. The most simple part can not even be bought here, never mind the engine parts.

    I am afraid that the day will come when I have no choice than to repair my XR with imported parts which will cost me a fortune.

    Keep on building!

    looking forward to an update and final product.

    Regards
    #39
  20. Rocket_Rookie

    Rocket_Rookie Learning the ropes!

    Joined:
    Mar 8, 2012
    Oddometer:
    54
    Location:
    Gauteng, South Africa
    She will be a beauty when finished.
    #40