Yet Another XR600 Rebuild Thread

Discussion in 'Thumpers' started by brucifer, Mar 25, 2012.

  1. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,674
    Location:
    Eureka, Ca.
    Okay, so I was on the lookout for another plated XR600. Found a '95 model in Sacramento and after a few e-mails back and forth a deal was struck and an agreement was made to meet up half way between us.
    Upon veiwing the bike for the first time I was a little let down because it was rougher than I was led to believe but since the guy was good enough to drive the distance I asked of him I didn't try to lowball and gave him the agreed upon price and we headed our seperate ways.
    Later on as I looked a little closer I found more and more wrong.

    The bike as it was when first unloaded at its new home.
    [​IMG]
    [​IMG]
    One of the things I found later--a dent in the frame. That will need to be fixed.
    [​IMG]
    A little later on I noticed some weirdness going on at the countershaft sprocket. There was a bolt threaded into the end of the countershaft with some spacers. I removed all of that and the sprocket and was greeted with splines that are junk. They're almost non-existant. Didn't take a pic of it unfortunately but I will later.
    So........the engine needs to come completely apart. Started stripping the bike at work...... More later....
    #1
  2. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,674
    Location:
    Eureka, Ca.
    A good part of it stripped at work.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    After stripping the paint from the engine, it was clear that it had been bead blasted, or some kind of media blasted, while it was assembled. :huh
    All the boltheads, clutch arm and any little brackets had all been blasted, removing of course, the protective zinc plating.
    This particular bolt was broke off in the main case and just stuck in the hole with sealer.
    [​IMG]
    Finished stripping the bike at my house.
    [​IMG]
    [​IMG]
    #2
  3. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,674
    Location:
    Eureka, Ca.
    Disassembled the top end of the engine. The bore is out of spec so time for cylinder enlarging. :evil
    Found another broken bolt. The longest one that goes from the rocker cover into the cylinder with the 10mm head. Again, it was stuck in the hole and held in by sealer. :bluduh
    [​IMG]
    I'll be using this transmission from a '97 bottom end I had sitting on the shelf. Pretty cherry. The countershaft splines have almost zero wear. :clap
    [​IMG]
    #3
  4. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
    Nov 5, 2008
    Oddometer:
    4,158
    Location:
    Columbus, GA
    whaaaaaaaaaaaaaaaaaaaaaaat????????????? another xr600 rebuild thread??????????????

    nooooooooooooooooooo! wait yeaaaaaaaaaaaaaaaaaaaaaaah!

    can the world take so much xr stuff??????????????????????????

    lets see

    good to see you have one again!:D

    cheers bud

    christian
    #4
  5. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
    Oddometer:
    14,805
    Location:
    San Francisco,Ca.
    While your ordering parts don't forget the little wire spring on the shift shaft.

    Hoe does the small end of the rod look? Loose? Or OK.
    #5
  6. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,674
    Location:
    Eureka, Ca.
    Hey Christian! :wave


    Steve- There's some galling going on on the small end. The '97 rod looks much better but I bought a Pro-X rod kit anyhow.

    I've never had to buy one of those little springs before. Do they just get weak or something?

    Also Steve, look at the two gears second from right on both shafts, 5th gear I think; they both look dark like they've gotten hot. Is that normal? It's been a while since I looked at gears and don't remember.
    I guess when I bust into the '95 bottom end I'll find out.
    #6
  7. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
    Nov 5, 2008
    Oddometer:
    4,158
    Location:
    Columbus, GA
    hey bruce...

    Sort of related...I noticed my OLD countershaft was blue and discolored towards the output end...Where it would ride the bearing...

    After looking closely and comparing to the one steve sent me...I noticed the innermost oil hole was plugged up...

    So Im assuming the coloring was heat related...

    might be the same with the gear although I would assume they all get like that after time no?

    And sorry for asking but...

    Is there anyway you can take a pic of the rear end of your bike?

    Like a pic of the swingarm/frame looking straight forward?

    I never could find a pic of this shot on the nets and wanted to see one after I had the crash...and was worried about the frame or swingarm being tweaked...

    again good luck bud!

    christian
    #7
  8. mcma111

    mcma111 Long timer

    Joined:
    Jul 17, 2007
    Oddometer:
    14,805
    Location:
    San Francisco,Ca.
    Bruce,

    One of the first guys I helped here on ADV had a XR600 that quite shifting and it turned out to be that spring. It's like $3.00 or so. To dam cheap NOT to replace just cause.

    The gear bluing is not from running hot it's just how Honda made them. I have a few transmissions and they are all different colors. Take a close look at the gear tooth face where it would mate with it's neighbor. Normally it's either second or third gear SETS on the XR600 that go bad. The gear tooth face will look rough, pitted. If so replace BOTH gears.
    #8
  9. Ivanych

    Ivanych Ivanych

    Joined:
    Jan 24, 2011
    Oddometer:
    248
    Location:
    St. Petersburg. Russia
    Hi Bruce!
    Accept congratulations from me!:clap
    It will be a Wonderful project!!!:thumb
    OH !!!!!! How I envy You guys!!!!!!
    Blue color on gears appears from nitriding (processing of details of nitrogen to increase the hardness of the surface). This process looks as overheating often.
    #9
  10. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
    Nov 5, 2008
    Oddometer:
    4,158
    Location:
    Columbus, GA
    just like the crank is...

    the coloring though on my cs shaft was definitely different then the bluing...on the rod/crank

    I also saw the plugged oil hole and thought...hmmm

    anywhoo
    #10
  11. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,674
    Location:
    Eureka, Ca.
    Christian- No problem. I'll get a pic for ya when I start the reasembly.

    Steve- The rest of the gears look great. I just thought it odd that only two gears had the dark coloring.

    Ivan- Hey man, good to see you! Thanks for the congrats. Again, just the two gears had me wondering.
    #11
  12. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
    Nov 5, 2008
    Oddometer:
    4,158
    Location:
    Columbus, GA
    thanks bud! sounds great..

    take care
    #12
  13. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,674
    Location:
    Eureka, Ca.
    Not too much going on right now. The frame is at my buddies house getting some paint. I did however finish pulling the engine down.
    Some pics.
    [​IMG]
    First, I removed the stator cover...
    [​IMG]
    [​IMG]
    Then, the flwheel. No surprises here. Good. You can see some of the crappy splines on the countershaft in this pic. On to the clutch side.
    [​IMG]
    Everything looks good here too. The whole thing smells like burnt oil though.
    [​IMG]
    The main cases split. Looks good in here too. Nice.
    [​IMG]
    The whole mess.
    [​IMG]
    The first new part. Coolio.
    #13
  14. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,674
    Location:
    Eureka, Ca.
    Got the frame back. Did a base coat clear coat in silver. My buddy Don, who did the work, was able to pull most of the dent out of the bottom tube. Definately good enough for who it's for. :D

    [​IMG]
    [​IMG]
    #14
  15. 2manyrides

    2manyrides shifty charactor

    Joined:
    Aug 17, 2008
    Oddometer:
    1,772
    Location:
    Citrus Heights Ca.
    Oh ya...dent magic! Seems like that really bothered you alot. I was dissapointed with my first frame dent to run out after a msr skid right after.

    Good color to use, (silver) did you decide on the plastics?
    #15
  16. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,674
    Location:
    Eureka, Ca.
    Hey 22many! Yeah, I decided to make her look like a 2000 model. Going with red. I went back and forth mentally between the stock white and the red but in the end, I think red just looks right on a Honda dirt bike.
    #16
  17. 2manyrides

    2manyrides shifty charactor

    Joined:
    Aug 17, 2008
    Oddometer:
    1,772
    Location:
    Citrus Heights Ca.
    :deal Red...oh so much better than white.:wink:
    #17
  18. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,674
    Location:
    Eureka, Ca.
    The reassembly slowly begins.

    [​IMG]

    Couple of pics for Christian.

    [​IMG]
    [​IMG]
    Are these the angle you needed?

    Another new part.:D
    [​IMG]
    #18
  19. elsalvadorklr

    elsalvadorklr southern xr rider

    Joined:
    Nov 5, 2008
    Oddometer:
    4,158
    Location:
    Columbus, GA
    hey bruce!!!!!!!!!!

    nice red tank man awesome

    hey yeah that's the angle of the pic...its a little blurry but it works!

    what I noticed when taking a look at my rear end(jaja) is that the swingarm looks like its bent to the left, in other words its not symetrical as the right side has more of an inward angle as it goes aft towards the wheel

    yours looks exactly the same so thanks so much...:D

    awesom frame color and cherry red tank! man!

    sexy

    cheers
    #19
  20. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,674
    Location:
    Eureka, Ca.
    Yeah, sorry for the blurry. I was kinda in a hurry and wasn't real steady with the camera. :bluduh I'll try to not let that happen in the future. :D
    #20