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JohnBG

'87 XL600R Rebuild Update

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Well, we got some more work done this weekend on our father/son project dirt bike. A few weeks ago, I had bought a used '87 Honda XL600R that had been sitting awaile for $300, and after a thourough carb cleaning we thought we had it running except it was spewing oil out thru a crack near the cylinder base.

Well, I managed to find an old cylinder/piston combo from a parted out XL600R rig on eBay for $50 and bought a top end gasket kit for $28, all of it arrived this week, so on Saturday, it was time to remove the engine from the frame and start rebuilding the top end. My buddy Chris offered to help with the rebuild and since he's got more room in his shop, once we got the motor outta the frame, we toted the motor over there to do the rebuild.

Once we got into the top end of the motor, I was shocked that the darn thing had run at all, or didn't grenade during the few minutes that I actually had it running two weeks ago. The cylinder bolts were barely hand tight, if that, and the bolts holding the sprocket to the cam shaft were hanigning only by a tread or two. :bonk: The previous owner, who claimed to had recently did a top end rebuild on it (before it sat for a year) was either a blithering idot, weak wristed, or had no idea what a torque wrench was for! :thumbsup:

Despite all that, within three hours (including a break for pizza), my son, Chris and I managed to replace the cylinder and piston, and rebuild the top end, set the valves, and have it back together. I feel much better about the motor now. This sucker is gonna rip! :eek:

Sunday afternoon, it was out to the old "redneck paint booth" to repaint the exhast pipe, spark arrestor, foot pegs, shift lever and kick starter. I also prepped and degreased the engine for a new coat of red paint. I need to order a new set of rear brake pads for it, as there is no back brake (past the limit). Hopefully by this next weekend, I'll have the paint work done and the bike reassembled and ready to ride. :thumbsup:

Here's a few pictures...

Engine ready to come out: http://www.russianiron.com/forums/index.php?act=Attach&type=post&id=32508

Engine removed: http://www.russianiron.com/forums/index.php?act=Attach&type=post&id=32509

Staring the teardown: http://www.russianiron.com/forums/index.php?act=Attach&type=post&id=32510

Top end disassembled: http://www.russianiron.com/forums/index.php?act=Attach&type=post&id=32511

New cylinder installed: http://www.russianiron.com/forums/index.php?act=Attach&type=post&id=32512

It's an engine again! http://www.russianiron.com/forums/index.php?act=Attach&type=post&id=32513

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