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Mike90240

'83 XL600R Carb / Brake Rebuild Questions

6 posts in this topic

Hey Group! Just dusted off my 1983 XL600R, (orig Owner) Been garage stored since '97/8. The gas was drained from carbs & fuel turned off. After washing some dust off, Oil/Filter(s)/Plug change, the only repair done was to replace the fuel line from tank to carb. She fired up with new gas in the tank!! No smoking, only a small fuel leak, appears to be float bowl gaskets. Still needs front brake rebuild/replace of Master Cylinder & Caliper. M/C was dry, has compressed plunger, caliper is fairly tight on rotor (F wheel turns with effort).

Two questions:

1) Honda only sells a complete gasket & o-ring kit @ $31 per carb (2). Any cheaper alternative to only replace float bowl gaskets? Or will I need most of those o-rings also?

2) Since the master cylinder was dry, with powder inside, plunger is compressed, and stays there. Also Caliper is fairly tight on rotor, obviously at a minimum rebuild of both is needed. Was thinking about buying a used but working set from a later XR/XL, and wonder at caliper fitting problems (please list for me years of interchangability) A Honda Svc Manager says as long as bolt hole spacing is the same on caliper it is very workable, what do you think?

Note: She fired up without even being choked, and I did not even kick her enough to break a sweat! and idled by herself!

Thanks in advance for the advice. Mike B.

And a 3rd question, any advice on creating a spare SuperMoto front rim, any easy swaps with another models front wheel? Or should I buy another std front rim & re-lace?

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Hello and welcome to the flock. First I think any of the xl, xr calipers will fit (bolt spacing the same of course) but I think I would just get the one for it, some people complain about the brake being weak but we used to ride with drum front brakes so I say to them- put on your big boy pants and ride.

The carbs, yea I know kits only from honda , but you might try Keyster carburetor parts, have not looked but if anyone has the gaskets piece by piece, they are it.

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I have always wondered if you could just get some thin gasket material and trace out the pattern and make a gasket yourself.

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You sure the leak is from the float bowls?

I know on my own bike, when it sits for long periods of time with no gas in the carbs, the o-rings that seal the fuel crossover tube between the carbs will shrink up and leak for a day or two then they swell back up and stop leaking. This has happened several times.

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:ride:

You sure the leak is from the float bowls?

I know on my own bike, when it sits for long periods of time with no gas in the carbs, the o-rings that seal the fuel crossover tube between the carbs will shrink up and leak for a day or two then they swell back up and stop leaking. This has happened several times.

:thumbsup: a most XLint suggestion!

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The crossover tubes are also suspect, although more likely the float gaskets, judging where the gas is leaking (observed) gonna change both areas.

Thanks, keep those suggestions comming, Mike

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