xr600 single handed rebuild with a twist

Discussion in 'Thumpers' started by idler, Sep 28, 2013.

  1. Ghost_Mutant

    Ghost_Mutant looking for bionics

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    Magnesium can be TIG welded. I had exactly the same break on my 83 XR5 stator cover and managed to weld the broken piece back on with a 'poor man's TIG' setup. That's a arc welder, TIG torch/Argon plumbing, and a high frequency adapter. I cleaned the heck out of the pieces and used a bolt to clamp the broken piece for welding. I used a pulsing technique by turning on/off the HF adapter and left the gas flowing, no filler rod.

    I did this repair on the bike after removing the gas tank and draining the carbs. Covered the exposed portions with a fire resistant welders blanket.

    Not exactly easy, and my repair isn't the best looking on on the planet, but it can be done.

    Alternative is to make a bracket (some folks have even used a washer of the right size and screwed it onto the remaining mount. Or you can buy a bracket from XRsOnly.
    #21
  2. idler

    idler Adventurer

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    ok, thanks ghost mutant, i stand corrected. i remember watching magnesium burn in chemistry at school and had visions of being left with only the gears and crank after my cases went up. thus the importance of the argon!

    which hand is the flywheel bolt thread?
    #22
  3. idler

    idler Adventurer

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    also presumably you had the broken bit - i sadly don't.
    #23
  4. Noprogram

    Noprogram High Plains Drifter

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    The XR600 is a great project bike and good luck....one step at a time and you'll be fine. I did an XR6 (2000) a few years ago.

    [​IMG]

    The flywheel does need a special puller...Motion Pro make them can get them off ebay and BikeBandit etc. -Even better if you can maybe borrow one off one of the XR6 Ockers since it's not neccessarily an everday tool.

    As you undoubtably know good tools make a lot of difference between a job well done and a soul destroying 'cluster-debacle' :baldy....there's so many junk tools out there. I'd recommend getting good quality six point sockets as they have better contact and a good set of open ended/ring spanners...a good set will have tight tolerances, no jaw flex and not overly large external dimensions in the thickness and diameter (so you can get them into tight places).

    I also found the Bahco socket spanners good for getting into the external cylinder and head nuts/bolts since they have good clearance. The Koken 3/4" drive sockets will get down into the cylinder bolts. -I have 1/2", 3/4" and 1/4" sets for the varying tasks. Good tools make everything so much less painful and will save you money and time.

    If you soak everything in something like Penetr8 it makes to a lot easier to remove, especially those fragile engine cover bolts. There's a number of home made recipes available as well.

    Top end sputtering sounds more like a carb issue to me?....strip and rebuild so you know where it's all at anyway.

    Maybe grind and insert a threaded tube into the clutch cable post and quick steel it over it as an adhoc fix?...there's still material there and the load is mostly taken on the post.

    Great to see the progress so far...have fun!
    #24
  5. idler

    idler Adventurer

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    i am going back to the uk on 07/12 with an empty bag so as to bring back as much of my tool kit as possible.

    tickled it with a dremel which we tickled it with but alas it was no match for a mig welder.

    i am toying with cutting the shaft behind the kickstarter as i will have to replace it anyway. the alternative is buy an angle grinder.

    anyone know where to come by an m22 bolt on a sunday in melbourne?
    #25
  6. lookfar

    lookfar from the land of OZ

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    Bunnings?
    #26
  7. Ghost_Mutant

    Ghost_Mutant looking for bionics

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    That piece is extremely fragile, I was amazed that I broke mine. Its one of those things where Honda didn't do it right:lol3


    Here is the post with the KLR style washer fix, probably your cheapest and quickest solution:
    http://www.advrider.com/forums/showpost.php?p=15244393&postcount=4032
    #27
  8. Mike the Yank

    Mike the Yank Been here awhile

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    My clutch cable holder looks like yours, a couple of zip ties has held it for over a year now! Next order from XR's only will have to get a new one.
    #28
  9. RFVC600R

    RFVC600R GOT SAND? NO!

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    Get some measuring calipers and measure that cam. :D It's a little tricky, but it can be done by a noob. Have someone who is familiar double check your measurements.

    I think the stator covers are the same for for big RFVC engines, if so, I might have a XL600R stator cover that's not broke. PM me if you want it.

    I also remember MCMA111 had a link for a bracket to fix it right without replacing the cover, Much better looking than that KLR style thing
    #29
  10. idler

    idler Adventurer

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    ok, so i have split the cases which involved cutting the kickstarter off. [​IMG]


    [​IMG]


    [​IMG]
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    #30
  11. idler

    idler Adventurer

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    [​IMG]




    [​IMG]
    this was a dog to shift, made a bush tool to hold the output sprocket then had to get onto the bench and make up about a meter of breaker bar for each lever.


    [​IMG]
    #31
  12. lookfar

    lookfar from the land of OZ

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    Seeing as how you are this deep into it, it would be a good idea to replace the output shaft with a more recent one that uses the fine splines.
    #32
  13. idler

    idler Adventurer

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    splitting them was quite time consuming. in the end i had to chock them up on the top case and tap the primary shaft to get that back dowel off.

    also who has an opinion on the gear condition and the output splines?

    got a friend who has an ultrasonic cleaner so i think i will pop the flywheel off when i get the bolt, clean them up and sling them over to him.

    is painitng them a bad idea? will it insulate them?

    actualy if anyone wants to suggest anything else to switch out now would be a good time.

    thanks
    #33
  14. idler

    idler Adventurer

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    one more thing - where is good for honda parts in oz?
    #34
  15. mcma111

    mcma111 Long timer

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    Why did you have to cut the kicker off?
    #35
  16. RFVC600R

    RFVC600R GOT SAND? NO!

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    It was welded on. :lol3 I don't see why people do fix things correctly. This XR seems to be in good hands now.
    #36
  17. Mike the Yank

    Mike the Yank Been here awhile

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    [​IMG]

    XR's only, currently out of stock but a good thing when you get to that part.
    #37
  18. Homerb

    Homerb Been here awhile

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    I'd re use that output shaft, but l am a tightarse.
    #38
  19. lookfar

    lookfar from the land of OZ

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    I would too....
    #39
  20. idler

    idler Adventurer

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    Progress has recently resumed with my moving house and getting lumbered with a smaller garage....

    on the upside I got the frame back;
    [​IMG]
    [​IMG]

    and i brought a disk brake rear swingarm/wheel assembly;

    [​IMG]

    it came with a spares bike attached to it much to my girlfriends discontent;

    [​IMG]

    now to get shot of that fucking dining table to make way for my workbench.
    #40