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  #1  
Old 22-02-2017
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XR600 Double Rebuild

I originally posted this on advrider but thought it might be of interest to some on here also.......

Myself and a good mate of mine, Paul (not currently on dbw but will be soon hopefully) have recently rebuilt 2 XR600's, so I thought we'd share some pics and info. During the course of the rebuild we've picked up a heap of knowledge on XR's, from this forum and elsewhere on the net. Hopefully this thread might contain some useful info or ideas for others.

My bike's an '89 model, Paul's is a 91. I'll focus more on my bike and let Paul explain more about his when he joins up.

I must admit, I do have a bit of a thing for the 89 model XR600's. Must be the colour, and they had the twin header pipes, but also a few negatives such as a rear drum brake and inferior suspension compared to the 1991 and later models. Here's what they looked like back in 1989.......



And the 91 model.......



Our aim was to restore both bikes back to very good condition, not necessarily like brand new but pretty good nonetheless, while keeping the look of the bikes as close to original as possible. I've seen a lot of rebuilt XR's on the internet where the owner has done all the hard work getting everything right mechanically, but then goes and puts the wrong plastics, seat cover or stickers etc on, and the bike just looks awful. That's just my opinion anyway, each to their own. But both myself & Paul decided early on not to do this.

Originally, my plan was to just rebuild my 89 model as it was, with one main mod - a rear disc conversion. But somewhere along the way the plan changed from “mostly original” to “build the ultimate XR600” lol. My bike ended up with the following mods –

Rear disc conversion
USD forks (99 CR250)
Later model shock
FCRMX41 carb
Oil cooler (XR400)
Acerbis 22L tank
Staintune muffler
Plus a heap of minor things, trailtech speedo, fat bars, grips, handguards, bashplate, tail light etc

So enough talk, here's some pics...........

Here's my 89 at the beginning. I've seen worse, but it certainly wasn't in great condition




And Paul's bike -




We actually started with 3 bikes, and ended up with 2......
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'89 XR600
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Old 22-02-2017
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Stripping them down -







For the rear disc conversion, we made a bracket for the master cylinder, copying the one on the 91 as closely as possible. Also a pivot mount for the brake lever


Oil cooler mounts


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'89 XR600
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Old 22-02-2017
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Both frames were sandblasted and primed




Here's Paul painting them in 2 pac white




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'89 XR600
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Old 22-02-2017
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Whilst the frames were being done, we hunted down parts required for the mods.

USD forks for both bikes - mine now runs forks from a 2002 CR250. I also picked up a CRF450 front end, these forks are now on Paul's bike. Originally Paul's bike had 1991 CR250 forks


I replaced the original 1989 model shock on mine with one from a later model, 1995 I think it is. The size difference is huge -

The rubber bump stop was missing so I got the shock rebuilt and revalved by MPE motorcycles at Caloundra, and a new bump stop added

FCR41MX carb from a CRF450, and also triple clamps from a 99 CR250. These are compatible with the 2002 CR250 forks
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Old 22-02-2017
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My engine was stripped down, and the internals were found to be mostly good. The head, barrel and some other parts were vapour blasted by Pioneer Finishes at Caboolture. The end result is excellent.


Here's my motor being reassembled -


Starting to look a bit like a bike again -




Paul's bike coming together


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'89 XR600
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Old 22-02-2017
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We painted the stator cover & clutch cover on my motor. Also added an XR's Only clutch cable bracket




FCR installed. We machined an aluminium adapter for the airbox boot. The intake manifold is from an XR650L


Making progress -






Paul's bike again


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'89 XR600
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Old 22-02-2017
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Couple of shots of the side of mine -




The Staintune muffler for my bike was pretty dinged up. We tried to pull out the worst of them by welding a slide hammer to it. This didn't really work as the material is fairly thin and didn't pull back evenly. So the plan was to pull the dents out as best we could, then use some kind of filler to bog up what was left. Sand flat and paint it black. This probably would have looked ok, but then Paul's father came up with the idea of cutting a piece of stainless steel tube and welding it over the top. The finished job looks fantastic. Staintune mufflers to suit the 88 - 90 model twin header pipes are very hard to find secondhand so I was very happy that we could make this one look as good as it does.




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Old 22-02-2017
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Acerbis 22L tank fitted








Brand new XR400 oil cooler


One side is modified to suit a banjo bolt. Milled flat and tapped M12 x 1.5


M12 x 1.5 banjo bolt to suit 3/8 flexible transmission cooler hose




The oil line from the motor to the cooler uses part of the steel XR600 oil line at the bottom, then flexible hose, then part of an steel XR400 oil line at the top. The line from the cooler to the tank is flexible line with a 180 degree loop of tube in the middle to prevent kinking. A barbed fitting screws onto the frame. We spent a lot of time on these oil lines, and changed them several times before coming up with this setup.
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Old 22-02-2017
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Mount plate for a Trailtech Vapor. I also wanted a key and indicator dash lights. I ended up flipping the plate the other way so the key is on the other side.




LED indicators mounted. Notice the nice new wiring? Paul made brand new wiring looms for both bikes, exact replicas of the original looms


The rear brake reservoir & line is a bit tricky to fit around the twin header exhaust. We bent up a piece of steel oil line for this
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Old 22-02-2017
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Here she is, nearly finished. Shame about the creases in the seat cover


Paul's bike with big tank fitted. Forks have since been changed to CRF450 forks


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'89 XR600
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