XR650L Wallet Lightening

Discussion in 'Thumpers' started by techforlife, Apr 13, 2012.

  1. techforlife

    techforlife CDI REPAIR

    Joined:
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    Moncton,New Brunswick
    Well......i intended on pulling the engine,getting a few engine mods done/refresh and just a general cleaning/lubing of the whole bike...:lol3:lol3

    Ya.....well that exploded into about 2k of parts coming back from Florida with my folks,,who stay there for the winter...and come back early April..

    To say i got carried away is an understatement (according to me lovely wife)...:D


    Sooooooooo...i`ve been talked(read conned) into a rebuild thread by TheBigMan(thanks Biggy:puke1) ,so here we go..

    I took this....

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    And pulled the engine out in the late fall and stripped the bike to it`s bones..

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    My real intention was to really clean the shit out of it,,regrease,and reassemble:lol3

    Well about xmas time i decided i was going to repaint the frame,,i figured out the cost of the spray cans/versus getting the proper gun and supplys and spraying it properly..a friend of mine who is way cool was going to blast it for me..

    Well.......then i remembered my company owns a PC shop:rofl....and decided to call and find out how much it would cost to get it powder-coated,and also see what colors they had,,i figured it would be too costly..but what the hell,couldn`t hurt to call.....well he sends up a sample of steel done in what he called pearl silver...then tells me 140 bucks...which i have to add 10% onto for employees for the company i work for.......well f that..i`m not going to work my arse off cleaning/blasting/painting for that kinda money,,probably cost me more than that in the end anyway,,and spraying something with a dozen round pipes on it is no friggin treat neither,,BTDT........so off she went,,he told me 2 weeks........


    So the next day it shows up at the shop all done,,quick 2 weeks:eek1


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    Well it turned out pretty sweet.......then i realized i forgot to send the subframe:cry FFS .........so i sent it down,,it returned the next day,,done for free:clap..

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    Oh..........i flushed the oil tank throughly before it went out...........then i flushed the oil tank about 4 times with gas after the powder coating was done,you DO NOT want sand going throught the oil pump/engine....i then flushed the frame resevoir three times with clean engine oil.....i was not taking any chances..and did not want flash rusting of the internal oil resevoir after cleaning it out with gas neither...


    B
    #1
  2. techforlife

    techforlife CDI REPAIR

    Joined:
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    Oddometer:
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    Well,in the tradition of getting carried away with a job........i decided that the new frame wasn`t gonna look cool with all the black painted parts looking weathered/rusted.so i decided to repaint those..i thought i was just going to do the upper triple clamp as it looked a little weathered/paint chipped......but noooooooooo once i got into this i had a dozen parts to prep/sand...:huh but i think it was worth it to see it all shiny and clean for about the first or second ride...

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    The frame for the battery box definately needed some paint though,it was starting to rust...

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    Then it was time to start assembling some of this crap...


    I decided to put in new steeering bearings,,they had water intrusion and were starting to stick some...then i put the trips on..

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    Then i spent some time cleaning the airbox out and installed it again..and the left footpeg..

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    Then the right footpeg backet got installed..

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    I spent some time cleaning the battery box,,it was getting pretty nasty inside..
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    Putting the wiring harness back on...


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    Then the regulator and ignition coil..


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    Reinstalled the side stand...and new switch that i got from a fellow ADVrider for next to free:wink:


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    Asssembled the passenger pegs again........and installed those..


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    So here`s where the frame is at....for now anyway..i gotta lug this into the garage this weekend before it gets to heavy/bulky and is a problem carrying up the basement stairs...

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    So that`s it for now......i`m gonna get into the engine reassembly alittle today,,i had the crank rebuilt by CycleWizard......so stay tuned...more pics to come...:clap:clap

    :wink:


    B
    #2
  3. malignity

    malignity The Hurt Locker

    Joined:
    Mar 8, 2012
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    409
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    Sanford, MI
    Awesome. I look forward to the rest of this thread.
    #3
  4. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
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    13,207
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    San Francisco,Ca.
    This thread looks strangely familiar.
    #4
  5. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
    Nov 5, 2008
    Oddometer:
    4,154
    Location:
    Columbus, GA
    how to we send beers?

    cheers
    #5
  6. techforlife

    techforlife CDI REPAIR

    Joined:
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    FFS........every XRL rebuild looks "familiar" to you .........:lol3

    Just crack open a beer and watch,,,this is gonna get entertaining..:wink:


    B
    #6
  7. techforlife

    techforlife CDI REPAIR

    Joined:
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    I`ll PM my addy..........but you better send express,,i`m getting really low on those suds ya know:freaky


    B
    #7
  8. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
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    Columbus, GA
    that the least I can do with all the help you gave me on my rebuilds

    let me know! jajaja

    cheers
    #8
  9. Kawidad

    Kawidad Long timer

    Joined:
    Jul 9, 2005
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    5,109
    Location:
    Central Coast, Cal
    :lurk:super
    #9
  10. AZ TOM

    AZ TOM Long timer

    Joined:
    Oct 21, 2008
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    4,208
    Location:
    Prescott AZ
    I refuse to feel inferior even though my bike will never look like this:D Keep up the outstanding work:wink:
    #10
  11. techforlife

    techforlife CDI REPAIR

    Joined:
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    Moncton,New Brunswick

    :wave


    B
    #11
  12. techforlife

    techforlife CDI REPAIR

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    Alrighty then..............

    On to the engine for a bit i guess:wink:

    This is one of the shit load of boxes i opened today...

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    Just like freekin xmas here the last few days,,,,,and i`ve got another pile of boxes coming sometime soon too:clap


    Here`s what`s in this one...

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    CW gave the crank some lovin...........new rod,,,trued and balanced it too.........:clap yeaaaaaaaahaaaaaaaaa:lol3


    Getting hungry,time for lunch.........oh crap..not this shit again...


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    So after freezing the crank for 1/2 hour and heating the case at 225 for 20 minutes....

    Out of the oven comes the case,,supported to give clearance..

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    Don`t forget that oil slinger washer,,,you`ll be pissed to find it later on...

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    And dropped the crank in the case 1/2 with a plop........:lol3


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    B
    #12
  13. techforlife

    techforlife CDI REPAIR

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    So.off into the basement to start assembling..

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    I had Biggy get me the FMZX650 overdrive fifth gear,,,and he sent it to CW......who sent it on to my folks in florida with the crank...

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    Here`s the 2 gears..side by side....the new FMX gear is on the right...

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    And here she is assembled to the shaft,,ready to go in........i already had the NX650 second gear on the other shaft as i put that in a couple of years ago....

    I intend on running 14/45 gear set on the bike this year,,with the overdrive i`ll still be able to fly down the highway........i may even go to a 48 rear sprocket,,though i think with all the engine work,,,,more low end won`t be needed:lol3:lol3:lol3

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    And in goes the shift forks and both sets of shafts in one shot...easy as pie:wink:

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    Now.......get a big f`in screwdriver.......and while twisting the screwdriver in between the balancer gear teeth.........insert a pin to hold them in place so you can get the balancer gear in the case..

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    Then throw that in place,,making sure to align the dots...

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    I bought a full set of gaskets off fleabay.........K&S makes a really nice set of gaskets for the XR.....silicone lined just like OE.......perfect fit,never had an issue with this aftermarket set........and you get EVERYTHING except oil seals....

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    So after getting the trans in and balancer,on went the other case side..

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    Make sure after torquing the bolts all to spec you razor blade this off flush....or you`ll have nasty oil leaks there,,a dab of high heat silcone will be added there before installing the cylinder base gasket....


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    Now........i bought a used oil pump off fleabay from a seller i`ve dealt with before,,the bike had 56 miles on it...i pulled the pump apart to see...yup..........no wear at all..hadta have low miles on it to look this good...

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    I replaced my oil pump about 12k ago at the last rebuild,,it showed slight wear,,so now i have a spare i guess..:deal


    The reason for pulling the engine apart this year was purely to mod it more,......More compression.........porting the head,,new HRC clone CW cam...KibbleWhite valves,springs,Ti locks........102mm JE piston at 10.5-1 with the head reworked/shaved ......:wink::wink: should be interesting this year........i`ll post up pics of the head and cylinder when it gets here...

    My folks had to send part of my parts with a friend as i had bought so much shit that it was over their limit when coming across the border...splitting up the parts with 2 people saves me duty charges:wink::wink:


    B
    #13
  14. ThumpnRed

    ThumpnRed Pig Wrangler

    Joined:
    Aug 30, 2009
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    Eye Duh Hoe
    Lemme get this straight... you powder coated and primped everything and are going to put the footpegs on all skunky looking?!:deal
    :lol3

    I'll be watching you... no more short cuts!:freaky
    #14
  15. techforlife

    techforlife CDI REPAIR

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    It`s not gonna be that sweet,,trust me......i`m lazy as hell...i`ll go so far then say screw it:lol3

    B
    #15
  16. techforlife

    techforlife CDI REPAIR

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    Yup.not touching the pegs,,fuck em.......they`ll get all shitty lookin anyway.......then again...so will everything i painted to i suppose:huh


    You outta see the plastics:puke1...now there`s some nasty scratched up shit right there.......and if they didn`t want a left nut to replace them i would..:puke1


    :freaky

    :lol3

    F i love long weekends...been off 2 days already...i think i`ll take monday and tuesday off too..:D

    B
    #16
  17. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
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    Columbus, GA
    x2 on the k and s kit!

    I also bought a K and S complete oil seal kit, great too

    cheers
    #17
  18. ThumpnRed

    ThumpnRed Pig Wrangler

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    :lol3Once the snow melts... DONE! time to ride... paint it next winter!:evil
    #18
  19. techforlife

    techforlife CDI REPAIR

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    Now........The Tricks & Tips part of this rebuild,,,more later too........:wink:


    Not everyone has one of these......

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    Or the knowledge to use one without over tightening either,,soooooooo when you get to the point where you have to remove/install the crank nut or the clutch retaining nut what do you do without damaging stuff.......well..get yourself a penny and a smallish C-clamp..........

    Put the C-clamp over the installed clutch plates and arround the back of the basket on the gear.MAKE SURE that the round small cup fits on the clutch plates WITHOUT hitting the actual clutch basket or you risk breaking the basket.....it`s surprizing how little clamping force is needed to keep the inner hub from turning on the clutch,,and you won`t break any posts off the inner basket this way either..


    So clamp it down lightly,,like so..


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    So now that turns as one solid piece...........


    Now..drop a PENNY in like so......this is for tightening the hub nut down...if you want to remove it........put the penny on the opposite/underneath side...

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    Now get out the torque wrench and tighten it down to 87 ft/lbs on this nut and then stake the nut in place.........

    Word of caution here........torque it down reasonably fast once you feel it getting tight,,turning the torque wrench really slow will drag the penny through and eat it.........won`t hurt anything......but you`ll go through a pile of pennys (ask Dave.he`s got some cool ones from his rebuild:lol3)..

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    Now onto the crank nut........insert the penny on the bottom side of the clutch gear like so..

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    Then torque it down to 80 ft/lbs.........

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    Only one penny was harmed in the making of this thread:lol3

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    When the cylinder and head gets here i`ll show you how to install the cam chain tensioner easily.......without f`ing arround with stupid zip ties and shit.....it`s not rocket science:wink: shouldn`t be that hard...takes up time you could be drinkin and shit..:freaky


    B
    #19
  20. techforlife

    techforlife CDI REPAIR

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    Yup........i`m doing selective cleaning/painting......i gotta get going here,,times a wastin ...:lol3

    :freaky

    B
    #20