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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    Just sent you a pm. Make a price :freaky
  2. SlickSix

    SlickSix Been here awhile

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    Ok, some updates.

    Already have the new chain and spring fitted and took some photos comparing the stretch on the old one :eek1

    Did not expect to see so much difference, let me just upload them
  3. SlickSix

    SlickSix Been here awhile

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    DID chain

    [​IMG]

    side by side :eek1

    [​IMG]
  4. SlickSix

    SlickSix Been here awhile

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    Now, here´s the kicker.
    Can´t get her to fire no matter what, tryed all proven ways to start a thumper and no go.

    After the rebuild, she started in 3-4 kicks, but heard the racket and shut her off.

    The timing is good and there´s not much to go wrong when installing the chain and tensioner spring so I went through
    all the electrics again measuring and checking the connections. Everything checks out and I do have spark, but it´s a weak ass one

    Next, I went to check the stator output at cranking speed and only got 30-35 vac max.
    Altough the resistance checks out, the volts produced are not enough to fire the plug in the cilinder.
  5. SlickSix

    SlickSix Been here awhile

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    I thought that was strange, since when I picked her up, she fired in 2-3 kicks and after the rebuild too.

    Then, I thought about it for a while and got to the conclusion that (?) although the spark is weak, it was enough to fire when the compression was low due to wear on the piston and rings but now with a new heart, the 30 vac are not up to the job.

    Another new task to learn, winding up the stator. That should be fun. Hey, it´s all in the spirit of the game right :lol3
  6. Jack90210

    Jack90210 quia ego nominor leo

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    Ah man.

    The suspense is killing me! :D
  7. elsalvadorklr

    elsalvadorklr southern xr rider

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    mike the yank just rewound his stock stator....I rewound my oem one twice

    its easy just use very high quality high temp exposy to seal the winding after you rewind....ok?

    good luck

    yes 30vac is not enough...wasnt on my mild modded bike...my ricky stator was giving me 25 to 30vac as fast as I could kick

    new stator and done

    christian

    check my thread for pics of the reound exciter coil...ask mike the yank for some pics too...he just did this and had success! I would order RICKY stator as a backup just in case if you can!
  8. SlickSix

    SlickSix Been here awhile

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    The suspense is killing you ?!
    What about me??? I´m itching to get dirty and as soon as I think that today ill be the day, something comes up!

    The day after I had her finished and all wrapped up, I got all geared up and ready to do some mean break in...
    only to have the cam chain rattling about! Damn, I was pissed :ruskie

    Christian, I saw your thread and have a bunch of them bookmarked, I think I´ll be ok.
    If I need, I´ll ask you for help :deal
  9. elsalvadorklr

    elsalvadorklr southern xr rider

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    I know the feeling man!

    good luck!:D
  10. SlickSix

    SlickSix Been here awhile

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    Thanks, when there´s a will...

    I won´t be buying a new stator, I want to learn it the hard way :lol3

    Also, a FCR and USDs are in the woks so...:freaky
  11. elsalvadorklr

    elsalvadorklr southern xr rider

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    nice usds are the best mod, well and the revalved shock...they make you go fast over rough terrain

    suspension first engine mods after

    what fcr? 39 or 41? from what bike or new????????????????? jejejejeje
  12. SlickSix

    SlickSix Been here awhile

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    05 CRF450, 40mm is already sourced for very good price

    USDs,not so much. An arm and a leg they want!
  13. SlickSix

    SlickSix Been here awhile

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    By the way, do ypu have the specs of your conversion at hand? can you pm?

    I think that 01+ CRF250 front end is all good right?
  14. elsalvadorklr

    elsalvadorklr southern xr rider

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    I never know how to tag threads or bookmark my own

    its all cr250r,mine is a 2002 not crf however they share the same specs and dimensions...the valving is only different between the crf450x and the r versions...the crf450x are notoriusly stiffer than the others

    steve helped me out big time...

    yes the swap is a major success

    let me search for the thread

    christian

    here you go:

    http://www.advrider.com/forums/showthread.php?t=774934
  15. SlickSix

    SlickSix Been here awhile

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    Thanks man, I was under the impression that it would have to be CRF not CR.

    That might be a bit cheaper around here
  16. elsalvadorklr

    elsalvadorklr southern xr rider

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    they are the same dimensionally however the valving changes a bit from X to cr only

    the x has the advantage if you use their wheel of retaining the SPEEDOMETER thats all

    I used an Xwheel on cr250r forks the 1999 to 2002 models also have the benefit of using the same caliper mount for the brakes so no need to use a bracket

    ask steve for this detailed info...I used 2002 model cr forks and it needed absolutely no mods

    cheers
  17. SlickSix

    SlickSix Been here awhile

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    Hey guys, she´s finished!

    I´m trying her out in a few minutes but before I just wanted to update this.

    As you know, my stator was very weak, although in spec the spark was a joke so I bought some wire and went to business.

    I did not see any burn marks in the exciter coils...

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  18. SlickSix

    SlickSix Been here awhile

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    Wired and epoxied

    [​IMG]

    [​IMG]

    if you noticed, I only wired 1 of the 2 exciter coils. Why?
    Well, when researching the stator rewind diy, I followed Jaws threads and bought the same wire as he did. Do you see a problem there?

    He rewind an US spec stator with only one pole and those stators require thinner wire to get more turns around the pole. The Euro version uses thicker wire and gets less turns around each poles.

    I decided to wire it like the US version, around one pole and 240k ohms. It´s all good, nice big sparkly spark :clap
  19. SlickSix

    SlickSix Been here awhile

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    Look what the cat brought home :clap
    It was from a 05 CRF450 and it´s in pretty good shape, the slider, ac. pump, needle and orings all check out.

    Here it´s already cleanned and rejetted with #165,42# and stock OBELR needle.

    [​IMG]

    I made a connecting pipe measuring 56mm ID x 58mm OD x 4mm in lenght.
    It bolted up nicely and I had to eliminate the return cable from the stock XR. The pull cable had to be shortened about 7cm. I

    It clears the tank and frame, no problems whatsoever :freaky
  20. SlickSix

    SlickSix Been here awhile

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    Since it didn´t came with the hotstart, I had to plug where the rod enters the carb and if
    you look closely, that blue dot on the inside had to be closed too, otherwise the carb still pulls air and it
    would be like the hotstart was on all the time.

    I choose to plug it with gasket maker, that way it´s easily reversible if needed.


    [​IMG]

    [​IMG]


    Here it´s fitted and ready to pull some horsies

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