XR600- Donkey Fix Up & Full Rebuild

Discussion in 'Thumpers' started by SlickSix, Jun 1, 2012.

  1. SlickSix

    SlickSix Been here awhile

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    While waiting for the shop to press it, the head was assembled with new seals and springs

    [​IMG]

    Had to fit a new plug boot and wire to the coil

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    Since I was doing electrical stuff, decided to make some LEDs taillight

    [​IMG]
  2. SlickSix

    SlickSix Been here awhile

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    Got the crank from the shop along with the lightened flywheel. Not much was removed, around 400grs

    Sorry about the lack of assembly photos but I just forgot, was in the zone and in no time it was done

    [​IMG]

    Got the timing right but the chain is a bit streched, half a tooth. I think it will be alright

    [​IMG]
  3. SlickSix

    SlickSix Been here awhile

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    Off to the frame it goes. A little of cardboard, a wiggle here and there and it´s in place

    [​IMG]

    The cooler was next. Easy mod, if you´re unsure how, just search for it or ask, there´s nothing to it.
    I got one from a 125cc with pretty good flow, cut the oil rail and just connected the original ones that
    came with the cooler.

    I think the pictures speak for themselves

    [​IMG]

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  4. nikolic

    nikolic Been here awhile

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    Nice job on that cooler! How did you fit CRF plastics? How does the left one fit on the air filter? :huh
  5. MacNoob

    MacNoob piney fresh

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    That timing chain doesn't look good at all. If it's not fitting tight to the bottom of the gear teeth I wouldn't run it like that.
  6. elsalvadorklr

    elsalvadorklr southern xr rider

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    also look at the tensioner...the tab on the actual stem/axle that you grab should be pretty much parallel with the fins on the head(or did you not have the screw in to toghten it down? jejeje)

    but way nice install on the cooler!!!!!

    Im assuming you are not going to run a high fender or stock one but use a sumo like short fender?

    cheers
  7. techforlife

    techforlife CDI REPAIR

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    They don`t fit to the bottom of the teeth even new,,,,,,,just the way they are made......but if the lines are off 1/2 tooth,the chain is toast.......

    B
  8. SlickSix

    SlickSix Been here awhile

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    Hey nikolic, thanks, it did turned out pretty good. The front and rear fender were pretty easy but the side panels
    took a bit more work.

    It´s hard to explain, pm me if you need photos and more info ok?
  9. SlickSix

    SlickSix Been here awhile

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    Thanks Christian the oil cooler was easy and turn out ok.

    Yes, the bolt was not holding the tensioner at this time, I was test fitting the cam chain and turning the motor by hand
    just to be sure the timing was ok and since I dry fitted the piston, I turn it a bunch of times to help seating the rings before I kick her to life, which SHOULD be tomorrow!!

    I do know the chain is a bit streched but I´ll run it for now and if she´s really noisy, I´ll change it but for now she stays.

    The fender itself it´s the same as the rest of the plastics, from a 07 CRF450. It´s not fitted at the moment but it´s ready to
    go.
    I had to trim it in the back or it would hit the frame itself , even with spacers. Also trimmed at the front, but that´s just personal taste, I really dislike having a huge sail at the front.

    Oh, I betting the oil cooler that Steve bought will be arriving soon right :freaky
  10. SlickSix

    SlickSix Been here awhile

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    I need some help here guys.
    I'm in the process of adapting my exhaust, which is all I need to kick her to life but my problem is not related to that.

    It´s electrical. Not even sure that´s a problem but i think so.

    Ok, let´s see if I can paint you the picture.

    -When first saw the bike, she started cold at the 4th or 5th kick
    -Hot, she started 2nd kick
    -Had front lights
    -Never missed on the short way home

    Got her home and stripped everything and this is what I´ve found:

    -Nothing connected to the AC regulator and no cables with similar connections
    -The DC rectifier was disconnected too but has the connectors in place on the loom
    - My stator (european model) has 5 wires and they´re all connected to the loom but nothing to connect to the AC regulator
    -No frame grounds whatsoever and one eye type that sits between the Coil and the frame was cut and not connected
    -My PG had 1.1mm air gap

    It´s my understanding that the stator needs to be grounded to the frame if it´s not internally grounded right? Since mine has 5 wires coming out, I suppose it´s NOT grounded internally, although it works. Haven't found any ground to the frame.

    Which leads me to the one between the Coil and frame. Why cutting it? Doesn't the frame ground acts as a CDI ground too?

    How the hell do I to connect the stator to the AC regulator if they don´t share the same connectors? They're still the OEM ones. The stator ones are bullets and the AC are females spades. And if it´s not connected, how on earth would the lights not burn?

    Just trying to understand and since I'll be adding taillights, I want to have it done properly and not burn my CDI or something else.

    Also, I have like 10 different electrical schemes but not a single one is like my setup. They share similarities but none is equal. Mind you thatg I run an European version.

    Any help is really appreciated, I want to kick her tomorrow, I´m reaaaaaaaaally itching here guys
  11. elsalvadorklr

    elsalvadorklr southern xr rider

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    hey slick

    you should have at least the coil ground at the coil itself...

    on the xr600 thread when I was diagnosing my problems with the stator someone posted 2 pics of the european model xr600 and the normal us xr600

    take a peek there or search on the web for the electrical diagram for the european model which has WAY MORE WIRES than we do...or non european models do...

    I remember clearly however that you still had a ground at the coil...

    I also seem to remember that the headlight loom had a ground in addition to the normal stator one...

    Ill try and search for those diagrams again..

    are you sure your stator is stock?

    cheers
  12. SlickSix

    SlickSix Been here awhile

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    Hey Christian, thanks. If you could find them it would be nice. I´ve searched everywhere and I do have a few
    european and australian diagrams, but none of them are like my loom. Im stumped.

    The coil itself might ground itself at the supporting tab, but what about the rest ?!
    I´ve found zero ground points on the frame and the AC has no connections leading from the stator or loom and I´m pretty sure the stator is stock.

    I just don´t want to risk my CDI, who knows if the previous seller didnt rig her just to get by? I wanna have her in trust worthy conditions
  13. elsalvadorklr

    elsalvadorklr southern xr rider

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    you have something wrong...sounds like the previous owner wired it how he wanted it

    so you are saying you have to regulators? one dc and the other ac?

    I thought that the eurpoean or dualsport models only had 1 reg rec that is dc...but not 2

    I would rig up your bike however the european schematoc shows...

    ps. the gap on the pg is theoretically non adjustable however its says .9mm or thereabouts on my manual...
  14. mcma111

    mcma111 Long timer

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    The XR600 wiring harness should have a ground (green) that is attached by one of the two top air box bolts.
  15. elsalvadorklr

    elsalvadorklr southern xr rider

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  16. SlickSix

    SlickSix Been here awhile

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    Hey Steve how you doing?

    I should have but there were none and when I clean up the loom I didn´t see anything hacked near the airbox.
    I do have 3 wires to the coil: 2 for it and 1 which I do beleive it´s the ground but it was just cutted without the eye thing.

    That´s my concern, that due to the hacking of lights and horn and such, the owner needed to float (?) the ground near the coil. But how did she run without a single ground point??? Will she blow if I connect the ground and AC???

    Man, I hate electrics!

    Christian,I have that scheme is pretty much what I have on the bike but the layout is different.

    The loom has 3 wires to the coil, the pulse generator connector is at the front and my AC doesn´t have the same connectors as the stator.
  17. SlickSix

    SlickSix Been here awhile

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    Hell yeah!!

    I got it :freaky

    I found a small post by XRider, a big thanks by the way, in which in told another advrider how to test the lighting side of the stator on a 94 XR and since the readings are different from previous years I decided to test it too.

    Then it hit me, the previous owner removed everything except the front light and since he was not running the horn and blinkers, he must´ve decided to wire the lights using the DC with the capacitor, thus eliminating the need to wire the AC to the loom.

    Ahh, it feels good to be on the right track :lol3
  18. elsalvadorklr

    elsalvadorklr southern xr rider

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    well thats what I was starting to guess, that the po simply eliminated the need for the ac regulator...

    you still need grounds though...

    at least 2

    one with an eye at the green coil and you can splic one in or see if you have a green available that can be attached to the airbox bolt like steve said

    Im using 3...one extra that I got with the new rocky stator in case I ever want to add more lighting via a dc reg/rec but I dont need any as all I use is the headlight and tailight...

    get that baby running so we can see some pics and mayubve a vid? :deal:deal:deal

    cheers
  19. SlickSix

    SlickSix Been here awhile

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    Hey guys I´ve got some more photos for you but still haven´t started her ...

    Was all ready to go, I just needed to prime the pump and tighten the rocker caps... well,well looky here I found
    that one of the caps was cracked :cry
    Off to Honda dealer and I´m still waiting for it. At least I caught it in time right?

    Ok, I wasn´t planning to do the graphics now but since I have to wait for the cap, why not?

    Bought some 3m auto vinyl and had a friend cut the graphics

    CRF450 trimmed fender at the front and back
    CRF150 gear lever
    Blue glove covering the broken cap

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  20. nikolic

    nikolic Been here awhile

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    just great, but I might notice that you're missing a CRF forks... :deal