xr600 top end rebuild ?

Can u put rings and piston in a 92 xr600 with out removing motor.Thanks guys.

Yes you can. It's a tight fit, but the cylinder head cover will come off with the bike in the frame. After that the rest comes apart with lots of room. Take the tank off and wash the bike so no dust or dirt will fall into the engine when it's apart.

When you have the cylinder off, look in the crankcase and see what the tranny gears look like. You can see most of them from the hole. I ended up replacing a couple of gears because they looked really bad.

I found it is a lot easier to get the cam chain on if you take the right side cover off. It likes to slip off the bottom sprocket and it's hard to get it back on with the cover in place. It also makes it easier to get the tensioner back in too.

When I did my bike, I didn't do the cam chain. A month later it started making lots of chain slapping noise. The tensioner was shot. I had to take it apart again and I replaced the tensioner and the cam chain.

Check the valves in the head for leaks when it's apart. The valves are usually the first thing to go on a 600. A simple test it to spray some carb cleaner in the intake and the exhaust. A little will seep through even if it's good. If a lot goes through then that valve needs to be fixed too.

A leak down test is another way to tell if your vavles/rings are bad without tearing apart the motor.

cleonard, do you happen to know if the 91-2000 600R's have to be re-bored during a rebuild or can you simply replace the rings? I seem to recall that the cylinder is nicksil (not sure of the spelling).

A leak down test is another way to tell if your vavles/rings are bad without tearing apart the motor.

cleonard, do you happen to know if the 91-2000 600R's have to be re-bored during a rebuild or can you simply replace the rings? I seem to recall that the cylinder is nicksil (not sure of the spelling).

I'm not 100% sure of the years, but I think that 88 thru 90 were Nikasil. Before and after that, the cylinder is a steel sleeve and can be bored. When I took my 93 apart because of oil blowing out the crankcase breather, the rings were wasted. It has a steel sleeve. The ring end gap was like .125. I didn't even measure it, I just laughed. The max is much smaller. Something like .025, but I'm not sure. My piston measured fine, very little wear. Same with the bore. The piston to bore clearance was just about like new. Well within spec. Same with bore taper and out of round. Because of that, I just replaced the rings.

Thanks guys

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