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Pictures of the restoration of a 1995 XR600. Bought the bike for 300$ on craigslist. I decided to rebuild with a scrambler theme. Couldn't bring myself to chop the frame, so all scrambler inspire mods are reversible (I might want to go back one day). Currently about 85% done. Day 1 vs Today Day 1: Head and many parts were packed up in boxes. Engine Removed: Rear master cylinder was pretty filthy Bought a $20 sand blaster and blasted all parts DYI powdercoating setup. I used this to powder coat the entire bike. Went with the $50 chicago powder coating gun. Was an ok setup but if I could do it again i would go with the eastwood powdercoating setup. Prebaking parts Coating parts After 20 minutes in the oven and 10 minutes to cool its done. Turned out alright. Cylinder Camshaft was toast. Never seen a more warn cam Rocker arms were also absolutely horrible as well. This thing must've been run with no oil for a while by the PO. Head journals are probably not good as well. In stock form the stator doesn't produce very much power (only uses 6 of the 12 cores). I would like to run aftermarket lights so I decided to re wind it. Fingers were basically bleeding by time I finished. I went with 18-gauge wire, wrapped all cores at 72 turns per core. Should produce around 200 watts i believe. Taking the rest of the engine apart. removing clutch basket Apparently the flywheel is torqued down to around 100 ft-lbs. I should've taken it off when the engine was in the bike. Instead I ended up cracking the case like an idiot trying to get the flywheel off. Had to order a used case from ebay (got a good deal, was around $100). Head before Head and cases after powder coating it. Used larger oven for these parts. Had to split the cases so I could replace the broken case and powder coat. Transmission forks/gears looked ok... I think. Main bearing had too much play, had to replace it and a few other bearings. Engine and transmission completely disassembled. Bottom end re assembled and cases powdercoated. Frame was pretty rusty. Sandblasted it at home but I couldnt fit it in my oven to powder coat. Decided to Linex the frame because all the powder coating places wouldnt return my calls. Here it is with the engine installed. Wheel bearings and linkage were pretty gross. Ultrasonic cleaner for about $100. This is probably my favorite purchase of all time. Makes everything so much easier. U Taking apart rear shock Shim stack looked fine. Debated some valve upgrades but ultimately decided it wasnt worth it since i will be mostly street now. I did replace the seals while i was there Replaced front fork seals and powder coated as well. Sandblasting fork Installed a LED headlight. Installed DG slip on (cheapest available). Ended up switching tanks from the above pictures for better fitment. Went with a Shinko705 rear tire, waiting on the front tire still. TODO: Front Tire Front brake Taillight Engine lights (why not) Find a way to create some custom side covers to go below seat. Put stock exhaust heat shield back on Fork seal savers ....I think thats it