XR 600 Project

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

  1. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    45
    Location:
    Perth Australia

    I'm living in Australia and am getting all my parts from the states mostly through e bay. Works out cheaper than going to the bike shop down the road
    #41
  2. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    45
    Location:
    Perth Australia
    Finally got a new computer so I should be able to keep A better track of my progress. It has been slow and steady lately. Trying to get what I can done in between my million other jobs rennovating a house and work. The big shed turned out to not be so big when all the other crap went in and the work area is very tight so a bigger new shed is on the way. Can't wait to finally have a propper workshop.
    Smoothed out all the casting marks and disused castings from all the engine cases and components then had them all glass bead blasted.
    Before[​IMG]



    Smoothed out[​IMG]

    Blasted and finished[​IMG]

    Weld repair on a broken engine case[​IMG]
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    Origionally I had these parts soda blasted but this was no good. Wasn't abrasive enough to remove all the old baked on mud and blend in all the filing and machine marks. The glass bead blasting worked perfectly.

    The CRF tripple clamps i'm using were also given a work over. All of the casting marks were filed off and smoothed out then I polished them.[​IMG]
    [​IMG]
    Once all this was done the engine cases were asembeled and the whole lot masked up using heat proof tape ready for powdercoating. The tripple clamps are also getting powdercoated clear.[​IMG]

    The cylinder has had the sleve fitted and bored oversize ready to go, this was also blasted.[​IMG]

    I've also measured up the crank and pressed it apart ready to fit the new carillo rod. Haven't had a chance to put it back togeather yet. I had to make a special pin so I could get it apart without removing the counterbalance gear.[​IMG]

    Got all the parts to rebuild the head but before I do this I want to weld on a set of big fins.
    I also bourght this second hand to fit up[​IMG]
    I've never ridden with one on a dirt bike but after using one on my vtr roadie i'm guessing it'll be worth every cent.
    Still working on a heep of other bits and pieces as well and will keep updated as I get them done.
    #42
  3. srad600

    srad600 Been here awhile

    Joined:
    Sep 30, 2009
    Oddometer:
    690
    Location:
    Oakland, Kalli Fornia
    Very cool build. I did something similar to a '97 XRL and it was too much fun, these bikes are built like brick houses. The big fin head, oil cooler and big bore are the best mods ever for these bikes. Good luck and I'm looking forward to the final product.:freaky
    #43
  4. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    45
    Location:
    Perth Australia

    Good to know i'm on the right track with the mods. Feel free to post some pictures of your xr if you've got any, I find looking at what others have done a big help when figuring out what I want and how i'll do it.
    #44
  5. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    45
    Location:
    Perth Australia
    I made the decision today and the engine cases are going to be powdercoated with a textured saturn black similar to harley crankcases. I saw this photo on a cyclewizard post and think it looks awesome. This is what i'm shooting for with my engine.
    [​IMG]



    I won't be touching the bike for a while as i'm going to work offshore for 5 to 7 weeks. The speed of progress on this build is realy starting to frustrate me. On the upside when I get home the new shed will be going up and i'll have a few weeks off to get some work done on the XRF! ( Yes i've dubbed it the XRF)
    Mucked around with some minor stuff tonight.
    Broken rear brake reservoir cap replaced.
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    Fitting this cap highlighted yet another part to add to my genuine parts order. The rubber underneath is broken and needs replacing.
    At this stage i'm just making a list of everything that I need genuine so I can place one big order all togeather. Still can't believe how huge the savings are buying the same parts from the states including postage rather than from a honda dealer 10 mins away. I've shown them the prices and would prefer to buy local but they tell me they just can't come close to matching the prices.

    Fitted a rear caliper guard
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    As you can see the rear wheel is fitted apart from wheel spacers. I plan on making these from titanium hydraulic fittings I aquired from work :evil.
    That's a little lathe job to be done down the track. The cyclewizard chain adjusters also had to be machined out to fit the crf axle.

    The headlight is going to be from a 2012 yamaha wr 450. I think the light will suit the bike overall. But I mainly chose this light because the actual light is mounted high in the surround. Giving space underneath for the oil cooler. I plan on cutting out the section below the light to allow airflow through to the oil cooler. Definately not a cheap option but after looking at a lot of other lights it's one i'm most happy with. All mounts will be custom made once i get the front end in.
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    I did say at the start of this thread thad i'de build my own exhaust. Well that will be partly true when I get to making the middle section. Time is the hardest thing for me to spend on this project. Everytime i'm looking at it I just can't wait to get it built and go riding. I got a big gun big bore header off ebay to fit up, I've already bent the tube to make the mid section from, thats them in the background.
    [​IMG]

    And the part of this bike that I love the most is taking shape.
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    Ever since I was a kid and saw the Jonny Cambell HRC twin exhaust xr 600's racing in the baja 1000 I thought they looked awesome and always wanted one, now all that's left is to attach this to my XR and i'll have what I always wanted Gotta love building your own bike:beer
    [​IMG]

    As I said That's it for a few weeks while i'm at work. But the plan is in place to get stuck in and make some serious progress when I get back home.
    #45
  6. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    45
    Location:
    Perth Australia
    I ended up taking the easy option and buying an emig racing conversion stem to fit the crf front end.
    I heated the clamp and pressed it it using Loctite as a lubricant however a small shaving of alloy still pushed out. Gave the whole lot a spin in the lathe to clean it up and also remove the clear powdrcoat from the bearing mounting face.
    [​IMG]

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    Packed the new bearings with waterproof grease, fitted the new races into the frame and finally the front end went in.
    [​IMG]
    :clap
    Should be able to get on with a heep of other work now when I get time.
    Although i'm concentrating on finishing off my new workshop:D
    [​IMG]
    Looking foreward to finally having a proper work space.
    Engine powdercoating turned out perfect and was only 40 bux including triple clamps.
    #46
  7. Rocket_Rookie

    Rocket_Rookie Learning the ropes!

    Joined:
    Mar 8, 2012
    Oddometer:
    54
    Location:
    Gauteng, South Africa
    Thanks for the new post!

    I am always eager to see what it is that you have done recently.

    The bike is starting to look like something! I admire your hard work and dedication in creating something out of nothing.

    There is true and pure craftmanship in your building.

    I can assure you that I envy the final result already.

    Keep it up!
    #47
  8. Rocket_Rookie

    Rocket_Rookie Learning the ropes!

    Joined:
    Mar 8, 2012
    Oddometer:
    54
    Location:
    Gauteng, South Africa
    Krone, I envy this bike with all my heart!

    Wish it was mine! I would tear up the streets like never before!

    Please send more pics

    [​IMG][/QUOTE]
    #48
  9. davesupreme

    davesupreme grand poobah

    Joined:
    May 1, 2011
    Oddometer:
    1,846
    Location:
    palm harbor, fla
    keep it coming, boss!!!:eek1

    one of the best builds ever... that thing is gonna be excellent!!!:evil
    #49
  10. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    45
    Location:
    Perth Australia
    Thanks for the comments guys, sorry the progress has been so slow lately but i'm doing what I can when I can fit it in. After getting the triple clamps all done I came across this rg3 billett crf top clamp online for cheap. I was at work, bored, and wondering what else I could get for the beast so I just got it.
    [​IMG]
    Half sorted out the steering damper the other day. The damper its'self was bought off ebay second hand off an rmz 250. Not sure what size head nut these bikes run but it wouldn't fit over my xr billet head nut.
    [​IMG]
    After measuring the difference I decided to machine down the nut as it was only a couple of mil difference for it to fit over the nut nicely. I used the old xr stem to lock the new and old nuts togeather and spin it in the lathe then turn down the new nut to size.
    [​IMG]
    I was worried I wouldn't be able to tighten it properly after this but a ring spanner fits it perfectly and I can still tighten it properly.
    Clearance issue resolved! The damper now sits down over the head nut.

    [​IMG]
    Carried on and fitted the bar clamps for a look. I knew that it wouldn't quite work but the 4 bolt bar clamp patern on the rg3 top clamp will be perfect for fitting some home made mounts for the steering damper.



    [​IMG]

    [​IMG]
    Now need to make some mounts for the damper out of 5 mm alloy plate and spacers for the bar mounts to get the bars up and clear the top of the damper.
    Also been getting plenty done on the shed and will hopefully have a proper workshop evolving in the next four weeks or so.
    #50
  11. Rot Box

    Rot Box Been here awhile

    Joined:
    Oct 31, 2010
    Oddometer:
    252
    Location:
    Northern Utah
    Just stumbled across this. Can't wait to see more! :eek1
    #51
  12. Roadracer_Al

    Roadracer_Al louder, louder, louder!

    Joined:
    Aug 5, 2007
    Oddometer:
    1,753
    Location:
    Oakland, CA
    Looks like you and I have the same lathe - Victor 1640? Mine didn't come with the taper attachment. Nice!
    #52
  13. kapparone

    kapparone n00b

    Joined:
    Apr 26, 2012
    Oddometer:
    7
    Location:
    Milano Italy
    [​IMG]

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    #53
  14. kapparone

    kapparone n00b

    Joined:
    Apr 26, 2012
    Oddometer:
    7
    Location:
    Milano Italy
  15. srad600

    srad600 Been here awhile

    Joined:
    Sep 30, 2009
    Oddometer:
    690
    Location:
    Oakland, Kalli Fornia
    In the end I went with a more supermoto style finish, but we used many of the same mods. I wish I'd done the dual exhaust though, it looks awesome.

    I started with a bunch of parts.

    [​IMG]

    And a nice big lump

    [​IMG]

    Ended up with this. Yours will be nicer, for sure, but I had fun building it.
    [​IMG]

    [​IMG]

    Can't wait to see how your's turns out. :beer
    #55
  16. jagger_snitt

    jagger_snitt PIRATE OF DIXIE

    Joined:
    Aug 30, 2008
    Oddometer:
    66
    Location:
    Southeast,TN
    Any Updates?:lurk:lurk:thumb
    #56
  17. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    45
    Location:
    Perth Australia
    Seems like forever now since I even looked at the XRF
    Sad yes! My work and house renovation took over and the beast has been sitting there waiting for some more attention. Took some pics when I finally moved into the new shed.

    [​IMG]

    Bourght a 22 L tank as well that was the last purchase for a long time.

    [​IMG]

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    Still an absolute shitload of work to go yet and as always no time to get to it! Looking at the bike there is no way i'll finish it anytime soon and this was driving me mad looking at it and wanting to go riding so I emptied the bank account and bourght this to race the 2014 enduro season. 2007 Husaberg FE 450 90 KM ON THE CLOCK!!!!!!! Got it off an olg guy Basically brand new!! Good price as well Couldn't believe my luck on this deal!
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    This is a small section of the type of shit that has been absorbing all my spare time at home. The type of job that job that looks great when finished but halfway through you wish you'de never started.
    [​IMG]
    #57
  18. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    45
    Location:
    Perth Australia


    I wish it was mine. Belongs to a mate that lives about 20 mins from home, just close enough to get a bit done when possible and invaluable on a project like this.
    #58
  19. Motomechanic

    Motomechanic Adventurer

    Joined:
    Mar 26, 2012
    Oddometer:
    45
    Location:
    Perth Australia

    Awesome build srad 600! Especially the big fin head. I can see making this part soaking up a lot of time in the shed.
    :1drink
    #59
  20. jagger_snitt

    jagger_snitt PIRATE OF DIXIE

    Joined:
    Aug 30, 2008
    Oddometer:
    66
    Location:
    Southeast,TN
    Looking good! no worries thanks for the update I'll check back in a few months to give some more encouragement!
    #60