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1987 XR600R Tracker/brat build

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Hello,

 

I'm new to the forum, I got a 1987 XR600R a few weeks ago and I will be rebuilding the thing over the course of the next few months. This is the thread I will be posting all the work in.

 

My name is Yvo, 29 and I'm from the Netherlands. I own a 1978 Honda CB750 F1/F2 that is in pieces right now. I have been rebuilding it for the last 2 years and it got completely out of hand. Check it out, the link is in my profile.

 

The XR I got to commute for the first two months and it needs some minor work to adapt it. 
I bought it of a guy that already did a bunch of work on it. He rebuild the XR600R engine with the help of a seized XL600. Not sure what has been swapped out, I will have to ask him for when I will take this apart and rebuilt it.

 

I would love to add an electric start (for ease, I'm lazy) and convert to a single Mikuni CR carb in the end. Can I get a later model crankcase and head, and swap the lot over?

 

The PO put a CR250 fork in it, new swing arm, 17" Supermoto wheels and some smalls. He is a welder, specialised in stainless, and he built a new high flow pipe with a Leovinci X3 on it. Sounds like a beast.

 

It has new plastics all around and brand new seat. It needs a bunch of electrical work, it will get a new loom at the end of the month. Might install a battery for safety, if it dies on the highway I have no lights of course.

 

I'm looking to put a Dominator DR02 tank on it, anyone has experience with this? The frames look identical, as does the seat. This gives me another 2,5 gallons/10 liters approx.

 

For now I will keep it as is besides the tank and electrics, because I need to ride to work. 

 

When I finish the CB I will take this apart and make new fenders and a tank out of steel. Giving it more of a tracker/brat look, but still rideable in the rain. Getting a new paint job, have a look inside the engine and maybe convert it, new seat and new headlight/taillight. 

 

Here some pictures and video:

http://vid1328.photobucket.com/albums/w531/InAquaVeritas/XR600R/IMG_7559_zpswf1jrvam.mp4

 

IMG_7717_zpsvmd9uhac.jpg

 

IMG_7712_zpsxjnxycjq.jpgDecompression chamber was leaking.

 

IMG_7711_zpsjhids4al.jpg

Problem is I have a 5 bolt head, but a 3 bolt cover.

 

Ordered the right cover and new gasket, fixed for now with some liquid gasket in between the old metal ones. Hope it holds!

Edited by InAquaVeritas
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Here's mine, its basically a not so pretty dirt version of yours. 87 xr600r with cr forks and an 83 xl600r motor.

awesome bikes

 

Blackwoods what headers do you have on that 83 of yours

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Wow, thats my style! Really cool bike and yeah, like i said in your other thread, thats an xl motor. Search this forum and you will find a ton of old threads about interchanging xl/xr/xrl depending on what you want. Welcome to the forum.

Scott

I though so after some googling, but wanted to be sure! Thanks for the info and I will do a lot of searches on the forum when I start on the engine. 

 

Here's mine, its basically a not so pretty dirt version of yours. 87 xr600r with cr forks and an 83 xl600r motor.

I love full dirt look as well, we don't have any trails here so its just uncomfortable to ride knobbies. 

 

WOW, Both of your bikes are really awesome! 👍

Thanks man! Appreciate it!

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Y

 

Ya, that would be the XL decomp setup , there should be a cable going down to the kick lever . You'll need to make sure it is adjusted properly or it will leak compression when it is running.

Yeah, it does have a decomp cable running up from the kick, but also one coming off the handlebar. 

 

I've contacted the PO to find out what has been taken off the XR and whats XL. Would make life a lot easier! I will try to adjust the cable, see of that works. The lever on the handlebars don't have any resistance when pulled, so the valve is probably stuck in the open position.
Weirdly enough I rode it home for a good 50 km/30 miles, filled her up, kicked and started, rode another 800 m/0.5 mile home and the next day it was leaking compression.

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Y

Yeah, it does have a decomp cable running up from the kick, but also one coming off the handlebar.

I've contacted the PO to find out what has been taken off the XR and whats XL. Would make life a lot easier! I will try to adjust the cable, see of that works. The lever on the handlebars don't have any resistance when pulled, so the valve is probably stuck in the open position.

Weirdly enough I rode it home for a good 50 km/30 miles, filled her up, kicked and started, rode another 800 m/0.5 mile home and the next day it was leaking compression.

Handlebar lever should hook to a cam type lever near the right exhaust valve.

kicker cable will go to the decomp valve on the top/back of the head. this valve vents into the chamber behind the cover that you say is leaking. This valve is known to leak and cause low compression but it could just be a sticky cable.

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Hi Ivo!
Are you working at Tin can Customs? 🙂

I'm also from the netherlands.. 🙂
I have build a cb750 with a turbo and a lot of new stuff on it.

Next to that I own a xr600 sm as a "city bike" (my second one, I had my first one when I started offroad stuff years ago).. s00o nice to have a light bike without a battery.

I wanted to turn it into a tracker also, but it's so nice as a SM bike, that I installed a FCRMX 41mm carb and decided to fit a cush hub, a 654cc kit, a new exhaust and a hotcam. So keeping it as-iss.
 

6.jpg

20150427_200118.jpg

Edited by Ilja

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Handlebar lever should hook to a cam type lever near the right exhaust valve.

kicker cable will go to the decomp valve on the top/back of the head. this valve vents into the chamber behind the cover that you say is leaking. This valve is known to leak and cause low compression but it could just be a sticky cable.

The cables are all working, but I think the valve is stuck open/bent/ruined otherwise. Going to have to dig into that next weekend...woohoo...

 

Hi Ivo!

Are you working at Tin can Customs? 🙂

I'm also from the netherlands.. 🙂

I have build a cb750 with a turbo and a lot of new stuff on it.

Next to that I own a xr600 sm as a "city bike" (my second one, I had my first one when I started offroad stuff years ago).. s00o nice to have a light bike without a battery.

I wanted to turn it into a tracker also, but it's so nice as a SM bike, that I installed a FCRMX 41mm carb and decided to fit a cush hub, a 654cc kit, a new exhaust and a hotcam. So keeping it as-iss.

 

Hey Ilja,

 

Where do you live? I'm near Utrecht right now. I did work on my CB at Tin Can, but finishing it at home. Will work on my XR at home or somewhere else as well. Have you build your CB at Tin Can?

Looks sick man! CBR wheels and swingarm? No issues with the springs in such a horizontal position? Did Jeroen from VVM shorten the swingarm?

 

Who did the turbo? Seen someone with a homemade manifold and turbo for a CB550. Insane bike! 

 

I'm going to fit it with a single 41mm carb as well, need to make a 2into1 manifold as I have a twin carb 87 head. The head is already ported, haven't seen it yet but if its nice I'll keep it. Otherwise I'll probably get a newer 600 or 650 cilinder and head, and build that up: 650 first gear to fill the gap, 41mm carb, ported head, new cam, hone, rings, bearings if need be.

 

Handmaking new fenders, headlight unit, tank (with help).

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Checked with the PO on the engine. Its all 1987 XR600R except for the carb and clutch. Will be digging into the head next weekend, if not the weekend after. It will get a new loom at the end of the month, along with new sprockets for better highway gearing.

Anyone looking to change sprockets on any bike with any setup, check out www.gearingcommander.com to see what all the ratios do.

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The cables are all working, but I think the valve is stuck open/bent/ruined otherwise. Going to have to dig into that next weekend...woohoo...

 

Hey Ilja,

 

Where do you live? I'm near Utrecht right now. I did work on my CB at Tin Can, but finishing it at home. Will work on my XR at home or somewhere else as well. Have you build your CB at Tin Can?

Looks sick man! CBR wheels and swingarm? No issues with the springs in such a horizontal position? Did Jeroen from VVM shorten the swingarm?

 

Who did the turbo? Seen someone with a homemade manifold and turbo for a CB550. Insane bike! 

 

I'm going to fit it with a single 41mm carb as well, need to make a 2into1 manifold as I have a twin carb 87 head. The head is already ported, haven't seen it yet but if its nice I'll keep it. Otherwise I'll probably get a newer 600 or 650 cilinder and head, and build that up: 650 first gear to fill the gap, 41mm carb, ported head, new cam, hone, rings, bearings if need be.

 

Handmaking new fenders, headlight unit, tank (with help).

Hey Yvo,

I live in Nijmegen... I have the Tin can customs guys on facebook, so I recognised the bikes in the background lol!

Its got CBR wheels and front fork, blackbird swingarm and xjr shocks. Painting the rims gold at the moment and the shocks yellow.

Swingarm is a modified blackbird one, nothing changed on length. Shocks work fine like this. :-)

I build the turbo stuff myself.... in fact its my second turbo build as I wanted to have a "simple" turbo bike.

I also have a tread on SOHC forums if your interested: http://forums.sohc4.net/index.php/topic,127179.0.html

Still solving some small issues with oil draining and pinging because of oil mist, otherwise it works very good. 

 

 

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Hey Yvo,

I live in Nijmegen... I have the Tin can customs guys on facebook, so I recognised the bikes in the background lol!

Its got CBR wheels and front fork, blackbird swingarm and xjr shocks. Painting the rims gold at the moment and the shocks yellow.

Swingarm is a modified blackbird one, nothing changed on length. Shocks work fine like this. :-)

I build the turbo stuff myself.... in fact its my second turbo build as I wanted to have a "simple" turbo bike.

I also have a tread on SOHC forums if your interested: http://forums.sohc4.net/index.php/topic,127179.0.html

Still solving some small issues with oil draining and pinging because of oil mist, otherwise it works very good. 

 

Nice man, Nijmegen must be nice to ride around. Its def nice around here.

 

I have a ZX6R '04 swingarm, but that needed to shortened by +/- 10 cm/4". It was way too long, would be like a drag bike, no turns that way. Thats why I asked. I'll def have a look at your build on SOHC. What was your not so "simple" turbo bike then?

How does the XR behave with 41mm? 

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Nice man, Nijmegen must be nice to ride around. Its def nice around here.

 

I have a ZX6R '04 swingarm, but that needed to shortened by +/- 10 cm/4". It was way too long, would be like a drag bike, no turns that way. Thats why I asked. I'll def have a look at your build on SOHC. What was your not so "simple" turbo bike then?

How does the XR behave with 41mm? 

Welll... yes and no.. yes, its a nice environment with some hills and forests.. no because the maximum speeds are very low everywhere, lots of slow old aged people and you can't overtake anyone anywhere.

The blackbird swinger is also quite long.... a bit too long in fact, but I'm reluctant to shorten it. I can weld aluminum at home but it will defo loose strenght when welding.

Well, it helps against wheelies.. ;-)

My other turbo is a z650 with 750 turbo engine.... ive attached some pics. 

The FCR41MX carb works perfectly! Idles much better, no sticky idle, midrange much much better and top end also improved. Got it for 125 euros of a 03 ktm 450 or something....

 

10405622_269297416603421_6453997188431523882_n.jpg

10351587_269297386603424_3883435896229297930_n.jpg

20151220_154210.jpg

Edited by Ilja

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Welll... yes and no.. yes, its a nice environment with some hills and forests.. no because the maximum speeds are very low everywhere, lots of slow old aged people and you can't overtake anyone anywhere.

The blackbird swinger is also quite long.... a bit too long in fact, but I'm reluctant to shorten it. I can weld aluminum at home but it will defo loose strenght when welding.

Well, it helps against wheelies.. ;-)

My other turbo is a z650 with 750 turbo engine.... ive attached some pics. 

The FCR41MX carb works perfectly! Idles much better, no sticky idle, midrange much much better and top end also improved. Got it for 125 euros of a 03 ktm 450 or something....

 

True about the speed limit and oldies. Too bad!

 

That bike is insane! How is it to ride a turbo 70's bike? If you want to shorten it, Jeroen from VVM Racing in Spaarnwoude did mine and did a hell of a job. Not sure he ever wants to do it again, but if you can convince him he's the best guy I can think of to do it.

 

Was looking into changing my carb from a double to single, but it seems like a ton of work or a head swap. The head I have is ported, so would love to keep it. Also would love a single carb, for ease of tuning and a single air filter. Gives me some space under the seat for a battery and lock.

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True about the speed limit and oldies. Too bad!

 

That bike is insane! How is it to ride a turbo 70's bike? If you want to shorten it, Jeroen from VVM Racing in Spaarnwoude did mine and did a hell of a job. Not sure he ever wants to do it again, but if you can convince him he's the best guy I can think of to do it.

 

Was looking into changing my carb from a double to single, but it seems like a ton of work or a head swap. The head I have is ported, so would love to keep it. Also would love a single carb, for ease of tuning and a single air filter. Gives me some space under the seat for a battery and lock.

The kawasaki turbo is absolutely rediculous at 15-20 psi, if you give full throttle at 5th gear the acceleration is like entering warp speed..

Should have between 150 and 200hp but theres NOTHING comparable to turbo acceleration and the way it makes torque.

The honda has a smaller turbo and handles more friendly, but is a bit more responsive in low rpm and turbo spools earlier. Less crazy top end but thats ok since that engine doesnt handle 150hp. 

I wouldnt bother too much about the ported head. Without a 41mm carb it won't make much difference anyways.. Try to get a newer head but beware as I think the shock is also placed differently, I think I remember people having big issues fitting a single carb on those bikes. The engine studs are probably also different diameter, that changed somewhere around 90ies.

 

Edited by Ilja

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The kawasaki turbo is absolutely rediculous at 15-20 psi, if you give full throttle at 5th gear the acceleration is like entering warp speed..

Should have between 150 and 200hp but theres NOTHING comparable to turbo acceleration and the way it makes torque.

The honda has a smaller turbo and handles more friendly, but is a bit more responsive in low rpm and turbo spools earlier. Less crazy top end but thats ok since that engine doesnt handle 150hp. 

I wouldnt bother too much about the ported head. Without a 41mm carb it won't make much difference anyways.. Try to get a newer head but beware as I think the shock is also placed differently, I think I remember people having big issues fitting a single carb on those bikes. The engine studs are probably also different diameter, that changed somewhere around 90ies.

 

Would love to ride a good turbo bike one day, need a bit more time in the saddle first. First I'll push my CB to the limit, it has gained a good 15 hp on the port and tune so far. It'll get flat slide carbs and a good run on the dyno.

 

I just found out in a different thread that I have an XL head, probably an entire XL motor. I will run if for now, but I will start looking for either a crankcase with elect. start that fits my frame and start either building a later model head on there or gut the current motor and put that in the other case. Not sure yet. Need to fix the decomp valve first, will do all the electrics next weekend. 

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So, I finally have the time to start tearing in to the bike and making it run again.

Besides fixing the decomp valve, I'm going to try and fit a different tank, re-doing all the wiring and mount blinkers and stuff, mount a horn, fix the brake reservoir, put new sprockets on, new chain, add some headlight business for better visibility and have the thing tuned properly

 

IMG_7822_zpsvsfib7fk.jpg

Tearing down the plastics to get the engine out.

 

IMG_7821_zpsgxrmfksk.jpg

Bought a Dominator tank, seat, side covers and fender for €10,-! Normally the tank alone is 50!!

It is WAY TOO BIG! I figured out a way of mounting it, but will need some serious rubber and some steel. Want to make it fit without mods, as it will get a custom tank later on and not sure how that will work out. Will post pics when I try.

The Dominator tank is a 20L steel tank, so a cheap and hopefully easy way to boost range.

 

44415d30-212c-4fbb-8e96-9adc57c19555_zps

The bolt that holds the exhaust to the frame, also wedges the mount for the rear brake reservoir in there. Problem is that vibrations are so massive, it keeps shaking the bolt out (I know, Loctite is your friend and saviour). The stuff you see there is burned brake fluid....

 

IMG_7820_zpsb5zo3p4h.jpg

This is whats left of the reservoir. I was also riding with a frayed front brake line, I'm almost happy it doesn't run now! (Did change the front line already)

 

I hope I'll be able to mock the tank tomorrow, just to see where this could go. 

 

Anyone know of a good low profile oil filler cap? 

Edited by InAquaVeritas

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