~~~1983 Honda XL600R Total Engine Rebuild~~~

Discussion in 'Thumpers' started by BThresher183, Jan 12, 2015.

  1. mcma111

    mcma111 Long timer

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    No grease
    #41
  2. brucifer

    brucifer Long timer

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    Wish I'd have known you needed a left side case, I have one I'd have given you for shipping charges--with a crank and rotor stuck to it. :D
    #42
  3. BThresher183

    BThresher183 Adventurer

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    AHH! I did get one for 49.99 free shipping, great shape. I should have asked!
    #43
  4. BThresher183

    BThresher183 Adventurer

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    Anyone know the name of the 2 seals (or where to buy them) that go around the sprocket and shift lever? Can't seem to find them in the parts schematic, and I don't think they come with the gasket kit. Thanks!
    #44
  5. mcma111

    mcma111 Long timer

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    Countershaft seal is on the transmission page of the parts fich

    OIL SEAL (25X45X7) (ARAI)
    91204-MG3-003
    $6.06

    Shift shaft seal is on the shift drum page

    OIL SEAL (14X28X7) (ARAI)
    91202-965-003
    $4.10
    #45
  6. BThresher183

    BThresher183 Adventurer

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    Ah ok, I was looking all over and couldn't find them. Thanks!!
    #46
  7. BThresher183

    BThresher183 Adventurer

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    Anyone have a Speedometer pickup unit that goes on the front wheel? Mine stripped all the gears inside while on the interstate, and the local mechanic replaced it with a (Suzuki?) one that seemed to fit perfect. But it doesn't register anything on the speedometer itself. My guess is that the unit spins in the opposite direction of the original one. Just thought I'd check before I hit up ebay.
    #47
  8. mcma111

    mcma111 Long timer

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    I might/should have one but I won't be able to check until tonight or tomorrow

    BTW... The ODO drive assy is repairable

    Drive gear:

    GEAR, SPEEDOMETER
    44806-KF0-000
    $20.60

    It's plastic and easily stripped
    #48
  9. BThresher183

    BThresher183 Adventurer

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    Yeah, the guy never gave me my old one back. This was before I became somewhat mechanically inclined. Didn't give it much thought at the time. I'd even take a broken one and repair it at this point. I have a (Viper?) Electronic system on it right now that I would like to take off, as I don't trust it's accuracy. Would make room for a gps. If you have a working/broken one, let me know what you'd like for it. Appreciate it!
    #49
  10. BThresher183

    BThresher183 Adventurer

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    Also just talked to my coworker about my bike, and there is a performance engine machine shop right on my way to work. I'll definitely have them check my top end out.
    #50
  11. BThresher183

    BThresher183 Adventurer

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    Do I need gasket sealer when putting the crankcase back together? Or can I just put the gasket on and close the cases? The mating surfaces look just fine.
    #51
  12. mcma111

    mcma111 Long timer

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    Gaskets go on dry.
    #52
  13. BThresher183

    BThresher183 Adventurer

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    Thought so, just wanted to double check. Any luck locating a speedo assembly? Much appreciative of your help and advice.
    #53
  14. mcma111

    mcma111 Long timer

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    I spaced out. I'll see if I can remember this afternoon.
    #54
  15. mcma111

    mcma111 Long timer

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    Found it
    #55
  16. BThresher183

    BThresher183 Adventurer

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    So...I got back to getting the crankcase put back together with the new gasket. Took me about an hour of tapping around the edges, tightening the bolts, and repeat. I got it together and tightened up, and the shaft where the clutch assemble sits will not rotate at all. If I stick my fingers inside where the cylinder mounts, I can move/spin the gears on that assembly from the inside of the case. I really don't want to take this damn thing apart again. Any advice would be much appreciated. Thanks
    #56
  17. mcma111

    mcma111 Long timer

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  18. mcma111

    mcma111 Long timer

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    It should not take you an hour to get the cases together. At most a couple of minutes. And you definitely DO NOT use the bolts to pull the cases together unless you want to be buying new ones after you crack yours in the process.
    #58
  19. BThresher183

    BThresher183 Adventurer

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    Then that makes me think I need more help than I thought. I didn't use the bolts to pull it together, but just to hold the case in place while I tap on the opposite side. I starting to feel pretty discourage because to took so much effort to put together that I know it will take me hours to get them apart again (the first time separating they were stuck together hard). I may just sent it to the motor shop in the next town over and have them deal with it. I got your Private message, I'll give you a call at some point.
    #59
  20. mcma111

    mcma111 Long timer

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    Don't throw in the towel yet. Call me before you send the engine out.
    #60