XR600R 1996 Supermoto rebuild, need help.

[_mrp_]

Picked this sucker up for 1500$ it is CA plated, but honestly shouldnt be. Needless to say it has the cr500 forks and excel wheels, with a shot rear tire, leaking valve cover and non working lighting aside from the headlight.

Got her tore down today and need help with two issues.

The rear brake pedal/lever has alot of side to side play, its almost 2012, who has the best fix for this? I assume it is the frame thats worn out as searching reveals that to be a consistent issue.

The next is the decompression?!

what is the proper way to fix this?

Pic after i removed the destroyed plastics and 5 gallon pos clarke tank!

Also where should I look for a full harness for this bike for headlight turn tail etc, currently nothing works most is hacked at best, and the horn button is the kill switch

[Horri]

Decompression lever::,,Tappet cover seems to be missing the spring and retainer arm for the spring and cable..The Tappet cover needs to come off,,you then pull a metal pin out and the arm comes out of the cover..replace spring ,,fit retainer arm..

Wiring harness::,,Depends on your State regulations what you'd use..Plenty on Ebay for the non indicator XR600 bikes as you seem to have in the US..,,Otherwise you may need to cobble together an XL600 loom which comes with all the necessary bits for horns/indicators etc..Match it to an XL600 Ricky Stator and off you go..

Brake pedals on 600s are always a bit wobbly..Wouldn't worry about it unless it's plainly flogged out at the retaining bolt..,,,spacer it with a large washer if that options possible ,then see how it is...or fit a well lubed copper shim over the bolt..

Edited November 11, 2011 by Horri

[_mrp_]

Is the decompression affecting the performance of the bike how it is, or is it simply for starting when its hot?

I can start the bike up fine in the cold with just the choke, so can it be left as is for now?

I will try your fix with a washer on the lever, I think both side cases and valve cover will be coming off soon to inspect everything. I will get them bead blasted and powder coated along with some of the other parts off the bike including the rusted stainless fmf pipe

The bike also appears to be very low on oil so hopefully no damage has occured I only rode it a half mile or so never even got off the choke.

[_mrp_]

Ended the day cleaned up like so;

[uranys]

If you can start it, your bike probably still has the auto decompressor on the cam. The manual one is nice to clear it out if it floods, pull the lever, hold the throttle open and kick it through an dozen times. You can leave it be, as long as it's not engaging it won't hurt anything.

The problem with fixing the brake lever is that the hole usually ends up being oval so you can't just shim it. If it's really bad you can drill it and press in a piece of appropriately sized tubing.

I made my own harness, it wasn't too hard, but time consuming.

Nice bike, I think you will like it when you get it sorted.

[JoeBlow Kokomo]

is that rear shock stock? (doens't look it)

RockyMountain sells a wiring harness separately.

[513rider]

That's a steal for $1500! Keep the pics and progress coming.

[voodoolord]

Where in Cali are ya?

[_mrp_]

I am near San Francisco. Here are some more pics.

I was going to strip to bare frame but because im working on EVERYTHING, that would kill a week or atleast a few days...so i foil/taped all the components off and painted it black crinkle paint...In two minutes ill be going over any overspray with solvent!

[asb77]

If you don't hear any odd noises coming from the top end you're probably ok on the oil but do be carefull, I've learned from experience that low oil will kill the head, at least, on these bikes very quickly. I advise cleaning out the screen on the bottom of the down tube (unscrew the fitting that the oil line hooks to) at least every other oil change, it will clog with what I guess are clutch fibers and oil starve the engine, and make sure the oil level is up. Others may argue I don't need to do it so often or at all but I'm a little gun shy about this and warn people about it after having to replace a head, cam, piston and sleeve and most of the trans (it took time and multiple teardowns to realize all the damage or I might have just junked the bike) by not cleaning it. In case you don't already know warm the bike up, shut it off, pull out the dipstick, wipe it off, reinsert it without screwing it in then read the oil level.

[_mrp_]

Thanks for the info on cleaning the screen, i want to flush the entire motor/trans with something, havent decided yet.

[_mrp_]

Before

wire wheel

a quick coat of 1500 degree rustoleum header paint ran out of paint. Might actually go back over it with a high gloss as the matte black usually gets a more gray tone to it after it gets hot:foul:

Tomorrow... I will hopefully order a new black headlight and fender, hydraulic banjo brake switch for the brake light, and probably the Aloop plastic kit. Oh and the xr only lowering link.

[zrxer]

Is this the bike that was for sale in Grass Valley or Auburn?

[_mrp_]

Yep the guy pretty much rode it like a dirt bike....He raped it something good, but she is getting put back together

Aloop smx kit is 3-4 week wait, so i painted the tank satin black with some flex add, real paint not out of a rattle can and you cant buy it in CA

Also using the tailamp and fender top off my klx250sf i sold. It is temporary, but it holds and iluminates the plate, and allows me to shorten the bike a bit, I will also be cuttingthe Powercore shorter, and putting a foot bar, and edge led tailiamp.

I really want the ALOOP kit as mounting this seat is like riding a fatgirl for all 5'6" of me...

[loom34432]

Looks like your decompression spring is broken; there is a seal in the cover behind the spring. Mine was leaking last year, its an easy fix. Pull the pin and remove the shaft. You can see the seal then. Replace seal , install new spring, install shaft and pin and you're done.

[_mrp_]

Any tips for axle slider on the rear? Not sure how i would install one as the right(?) side has no hole in the axle nut? Is that normal?

Also need some help finding the chain guide,or plastic/rubber piece that wraps around the swingarm and the chain slides on it? Where do I get a new one? Any with a vertical tab to keep the chain away from the tire?

Anyone cut down a FMF powercore before?

How about a hydraulic clutch setup?

http://www.ebay.com/itm/CNC-CLUTCH-LEVER-HYDRAULIC-MASTER-CYLINDER-DIRT-BIKE-/220756046991?hash=item336615f48f&item=220756046991&pt=Motorcycles_Parts_Accessories&vxp=mtr#ht_7760wt_1058

Looks like fun and I love the red lever!

[voodoolord]

chinese clutch lever?

[_mrp_]

Forgot to take a pic but it now has exhaust and an air filter..

Waiting for the new headlight and front fender, which i may not install

Also the paint got beatup on the frame when I put the pipe on, and a nick in the gastank I need to touch up.

[voodoolord]

Man Im really disappointed. I thought it was going to look like this....

[_mrp_]