87 XR600 frame to XL600 transplant

[brantc]

I have a complete, bought it running, rode it, 87 XL600 with a bent frame.

I also have access to a pretty complete 87 XR600 with Super Trapp, a low/no compression motor, missing back wheel, seat and carbs.

Its Frankenstein time.

So what should I do? I am really interested in just doing a frame swap but they are not exactly the same....

The most obvious difference is the down tube. On the XL its round and on the XR its square.

I like to ride the back dirt roads(dual sport tires), cross streams, no serious MX.

I want it to be street legal and pull wheelies in 3rd gear....

I'm looking for a good plan or ideas. I will also post some pictures. If there are other threads that have covered this please let me know....

This is your chance to design someone elses project bike....

[Beyond The Pale]

Well from what I understand, the XL engine should fit in the XR frame. The XR suspension is better than the XL stuff so I would try and use as much of the XR stuff as possible.

The plate goes with the frame, so if the XR is not street legal then the final product using the XR frame will not be either.

[brantc]

Well from what I understand, the XL engine should fit in the XR frame. The XR suspension is better than the XL stuff so I would try and use as much of the XR stuff as possible.

The plate goes with the frame, so if the XR is not street legal then the final product using the XR frame will not be either.

Shazbot....... So I have to use an XL frame to be street legal???

Can I put XR swing arm, shock linkage onto the XL??

Anybody have a XL frame for sale??????

[Beyond The Pale]

From registering a few old off the books bikes all that they seem to want is the decal/plate on the frame that says the bike meets the EPA standards. Take a look at your XL and it should be there. The one of the XR frame is the same shpae and size, but says off road emissions.

For a frame ebay might work. It might take a while, but one is sure to show up there. Just make sure it has papers before bidding.

I know that people have used XR suspension on the XL. Don't remember the particulars. Do some searches in this forum and you should find all the info that you need.

[cyclewizard]

Couldn't you take the plate from the xl an pop rivet it to the xr frame?

If there's a will there's a way.

[brantc]

Well this has turned into a project as the rear frame sections are different.

The airbox on the XL is bigger for the battery and stuff.

So if I want to use this stuff I have to transplant the rear sections.

[Leget]

Why not just move the engine from the XL to the XR?

I took an engine from a 1983 XL600 and put it in a 1990 XR600 chassis.

The only things that are different (that I found) were the oil lines running to the frame and the engine brackets.

But if you have two (mostly) complete bikes then thats not a problem for you.

[brantc]

Why not just move the engine from the XL to the XR?

I took an engine from a 1983 XL600 and put it in a 1990 XR600 chassis.

The only things that are different (that I found) were the oil lines running to the frame and the engine brackets.

But if you have two (mostly) complete bikes then thats not a problem for you.

I want it to be street legal and thats tough in California. So if I do enough work it becomes a custom frame....

New Law in Custom Motorcycles for 2006:

In December 2003, the U.S. Environmental Protection Agency (EPA) published a Final Rulemaking (FRM) establishing more stringent emission for highway motorcycles for the year of 2006.

Amongst a higher emissions standard for all manufactured motorcycles for 2006, the other major item in EPA 420 is a once-in-a-lifetime exemption for a custom motorcycle (Special Construction) for your own personal use, as long as you don't sell it for at least five years.

This EPA rule allows for the construction of your custom motorcycle and it refers to your lifetime. You are allowed one EPA-exempt custom motorcycle that has no restrictions on how and where it may be used under this rule. The exemption is for the motorcycle owner's lifetime.

Under this federal law, you are not allowed to sell your EPA-exempt special construction motorcycle for five years after the date of final assembly, even in case of death, bankruptcy, or divorce. After five years, your EPA-exempt motorcycle can be sold. If you do sell your EPA- exempt motorcycle, you will not be allowed to own another exempt special cunstruction motorcycle.

The new regulations will only affect new motorcycles produced for the 2006 and later model years. Anything manufactured prior to the 2006 model year will not be affected and will remain legal to own and operate.

You can see the EPA's "Final Rule for Cleaner Highway Motorcycles," along with other supporting documents, at http://www.epa.gov/otaq/roadbike.htm

My bike should be done April 15th 2008.

frames: XL on the left.

??

[brantc]

[brantc]

Update on the transplant.

Decided to buy a XL600R frame and repaint it. To try and swap a XR600 frame to an XL is nearly impossible as almost nothing is interchangeable.

Ask me why.....

MMMMMMMM blue.

[brantc]

So I think I'm making progress. We have a new frame and it looks good.

The thing that lead me down this path was the bike I though was running a little hot....... So I pulled off the gas tank which allowed me to see the bent frame. It was really bent.

So now since I have the motor out might as well look at it.

So why not take the valve cover off.....

[brantc]

Hmm, not good. The whole area looks a little burnt, smells burnt.

My friend say "Go for it, dude, pull the head....."

OK.

Yep, blown head gasket. ??

And the cylinder??

Looks like it sat for awhile....... And has a blown head gasket...

Well I guess I'm glad I caught it......

The saving grace???

The bottom end looks to be in great shape and doesnt smell burnt....

So my question to all of you is.

Who does a package deal with a cylinder, piston, clean/replace the valves, cam, rocker/s.

And after this whole project, I know what is interchangeable between a 87 XL600 and XR600(frame,swing arm, link for sale), so if you have questions let me know.

After this............ Fuel injection...

http://www.microsquirt.info/

Well at least we have the mancave to do it in....

[brantc]

Oh and of course my condolences to RC30's friend. I have never seen a 2 piece motor.

[Rodriquez86]

You say you bought a xr600r frame but that blue one is a xl frame I believe?

[brantc]

You say you bought a xr600r frame but that blue one is a xl frame I believe?

Yes, the new blue is the 87 XL600 frame I bought to replace my bent one(87 XL600), after I bought an 87 XR600 frame thinking I could just swap them out.

[martinfan30]

Make sure to take a peek into the bottom end with the head off. Look for any pitting on the gear faces. If there is, rebuild the trans.

[mrfixit54016]

I need a set of decent passenger pegs for my 1985 XL600R and I could use the plastic guards that protect the passengers feet. Let me know if you might be able to help...

Thanks!

[Motosprtman]

I am hoping that the exhaust mounts the same, as I just ordered a FMF powercore IV for my 86 XL600R and it is for a XR600R. I think it will work though.