My build up: Big Red Dog... ;)

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My build up: Big Red Dog... ;)

Post  bigkuri on Fri Nov 29, 2013 12:26 pm

I've been meaning to start this thread for a while, just a way of tracking what I've done to my bike, which also may be useful for others for ideas/upgrades....

First about me; I'm a Kiwi farm-boy from the South Island Otago region; growing up riding bikes in extreme environments, so riding very tough terrain usually with no tracks or paths. I dabbled a bit in competition, doing ok for a while before University and work took over. I rode MX, Enduro, Hare and Hounds, even a bit of trials (KX, CR, RM, XR, beta, etc..). Moved countries a few times, started to get into road-racing, got too fast, and am now returning to dirt bikes.

My bike! The XR650R I bought is bike number 67 I've owned; purchased on a bit of a rush/whim as I always wanted one - they came out about when I gave up racing, so I never competed on it, but always wanted to try Smile

I was suckered into a 2006 rego, just as you don't see many of them. It looked ok from pictures, so I rashly jumped in and bought it on trust and unseen. Listed as full service, 6,700 km (5k miles), 2 previous owners...







On the way home popped into Mauser's for a cuppa, and started to notice a few things... Front forks were almost solid, rear shock was a lightweight pogo stick, engine a bit of a rattle, clutch cover was polished clean....

I rode it almost all the way home, making it about 5 miles from my door before a rattle started to be louder than the exhaust note. I shut it off and literally coasted into Chiswick Honda where they kindly put it in their bike lock-up.

A few days later my "new" BRP looked like this:



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Re: My build up: Big Red Dog... ;)

Post  bigkuri on Fri Nov 29, 2013 12:43 pm

The strip down was pretty easy, I immediately felt at home with the bike from all the similarities to the other XRs I've owned; 250, 500, 600, 650L....
 
 

 

 
 
The root cause of the massive rattle was pretty easy to find; failed auto cam chain tensioner. I think this is common, still not sure if just "one of those things", or a part you should replace as maintenance every so often, or...?
 
Cam guides look ok, but they are cheap, so....
 

 
 
The rest of the engine was looking ok, most things within tolerance, although there was a fair bit of wear.
 

 

 
 
Not so good was opening up the pot, and finding a very worn piston, with the "double ridges" in the cylinder which are usually from highly revved engines - a top ridge from the top of the piston, and a second lower ridge from the rings.
 

 

 

 

It was about this stage my mates started calling the bike the Big Red Dog instead of BRP! And it kind of stuck... Smile The wankers Wink
 
One thing I was now certain about - this bike has done more than 6,700 km!..  Plus I received the full ownership papers which state the truth of having 6 previous owners.  So she's had a bit of use. No bad thing.  Let the rebuild begin! Smile


Last edited by bigkuri on Mon Dec 02, 2013 7:47 pm; edited 1 time in total

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Re: My build up: Big Red Dog... ;)

Post  bigkuri on Fri Nov 29, 2013 1:10 pm

There is not actually a lot to see in a top end refresh like this! So instead and a last post for now, just a slightly depressing list of the parts from Honda...

Head
PFKL1010917 O-RING 1 O-Ring for Head Cover Water Joint £2.18
PFKL271657 GASKET, CYLINDER HEAD 1 Top Gasket £23.44
PFKL1021720 DOWEL PIN, 14X20 2 Top Dowel Pins £5.64
Valve
PFKL270435 SEAL, VALVE STEM (ARAI) 4 £25.76
PLUS TWO INLET VALVES
Cam
PFKL305531 CHAIN, CAM (122L)(BORG-WARNER) 1 £55.83
PFKL306542 LIFTER COMP., TENSIONER 1 £64.26
PFKL992748 WASHER, SEALING, 6MM 1 For Tensioner top bolt £1.05
PFKL307696 GASKET, TENSIONER LIFTER 1 £3.51
PFKL306977 COLLAR, TENSIONER, 6X9 1 Collar for Cam Guide Tensioner £2.32
PFKL306910 TENSIONER, CAM CHAIN 1 Guide 1 £34.59
PFKL308022 GUIDE, CAM CHAIN 1 Guide 2 £22.49
Cylinder
PFKL268821 GASKET, CYLINDER 1 Bottom Gasket £6.95
PFKL313890 COLLAR, OIL PATH, 18MM 1 Oil path collar for bottom of cylinder £1.99
PFKL1010044 O-RING, 17X3 (ARAI) 1 O-Ring for oil path collar £1.60
PFKL1021720 DOWEL PIN, 14X20 2 Bottom Dowel Pins
Piston
PFKL284832 RING SET, PISTON (STD.)(RIKEN) 1 Rings £49.86
PFKL288757 PISTON (STD.) 1 Standard Piston £73.85
PFKL291912 PIN, PISTON 1 Cotter Pin £17.30
PFKL996824 CLIP, PISTON PIN, 23MM 2 Cotter Pin Clips £1.06
Clutch
PFKL262254 GASKET, CLUTCH COVER 1 Clutch gasket £5.58
PFKL261046 GASKET, OIL FILTER COVER 1 Oil filter gasket £2.95
Shipping Shipping £8.29
VAT VAT £82.12
PFKL263374 GASKET, R. COVER 1 Main clutch gasket £11.17
PFKL314145 ELEMENT, OIL FILTER 2 £5.40
Shipping Shipping £6.54
VAT VAT £4.97


Ouch....

As a side note on who I used:

Honda Parts were ordered online from Lings Honda. Simple and pretty quick so they must have a fairly large stock. Any issues I called them and found them responsive and fair.
http://www.lingshondaparts.com/

I had the cylinder re-bored and re-plated at Langcourt. It was a great price and just so easy; £140 all up, and a great job.
http://www.langcourt.com/page27.html


More later...

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Re: My build up: Big Red Dog... ;)

Post  Mauser on Fri Nov 29, 2013 1:15 pm

Did you have to go for a larger re-bore piston/rings ?....or did the re-plate thingy bring it back to stock size ?....piston price and other bits don't seem bad but I guess when you add them all up it soon grows to a BIG bill Smile.....love the pictures keep them coming.

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Re: My build up: Big Red Dog... ;)

Post  bigkuri on Fri Nov 29, 2013 1:29 pm

Hey matey.

I went completely stock. Langcourt lets you know if not possible - they hone it, then plate it "extra thick" and hone down the plating to the desired size. So it has 100mm piston. The fitted rings were at the tighter side of the specification, so it worked out perfectly.

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Re: My build up: Big Red Dog... ;)

Post  bigkuri on Fri Nov 29, 2013 1:34 pm

While I'm here... (blaming Mauser for posting and interrupting my work Wink)

I also started buying some upgrades to the bike. Loads of research, plus looking at what was around second hand for cheap!

Fuel Tank Aceribis Safari 24 litre
Clutch Case Guard
Cool tape for tank
15t Sprocket
L&R aluminum/alloy dual-core radiator
Swingarm Locknut Tool
45t Rear Sprocket
Fork Seals
Magnetic Drain Plug
Air filter spare
Baja Designs Team Honda Oil Sight Tube
XRs Only High Performance Thermostat
XRs Only Billet Choke Plate
XRs Only High Performance 1.6 Radiator Cap
XRs Only Skid Plate
XRs Only High Performance Clutch Springs
Custom Wilbers rear shock
Fork seals and dust covers
Risers
The "usual" carb mods - new pilot and main jets, new needle as on the pig-pen site
Mefo SuperExplorer on the rear, and Mitas MT21 on the front - a nice combo for Morocco trip
I also needed a few more engine parts: the clutch case, as well as being polished, was also cracked in several places, plus some bits and bobs.

Goodies... Smile

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Re: My build up: Big Red Dog... ;)

Post  Mauser on Fri Nov 29, 2013 2:45 pm

wow someone win the lottery...I have to search ebay for all the items I want or beg them from Paul @ xr650r.co.uk lol.....I will post my latest mod when it's fitted no clues and no guessing allowed BRP smile 

Don't forget the pictures of all this 650R Porn plz ?

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Re: My build up: Big Red Dog... ;)

Post  bigkuri on Fri Nov 29, 2013 2:49 pm

I should have said I also bought another two XR650R, and did them up and sold them on. Helped finance mine! The other two were gems.... Smile

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Re: My build up: Big Red Dog... ;)

Post  Mad Frosty on Fri Nov 29, 2013 6:36 pm

Wish you lived closer to me , i have loads of parts to fit and no time ( no confidence also ) ,


BTW is that michelin ac 10 on your bike on these pictures ?
I have noticed that my old fender was not 100% alligned with the front wheel , after changing to the CRF fender the difference is even more obvious ( because the pointy end of the CRF fender ) , i was wondering if my wheel is installed correctly but seeing yours made me realise it must be normal as yours looks the same , i think the wheel sits slightly off center because the brake disk is on one side only scratch 

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Re: My build up: Big Red Dog... ;)

Post  bigkuri on Sat Nov 30, 2013 10:15 am

Yep, they were AC10s. Okay tyre but any road sections eat them pretty quick, and I think they flex a bit too much on the piggy. Better on lighter less powerful bikes?

I'm mechanically minded but was heavily helped by a proper mechanic friend, Carlos, who used to work on Honda race teams back in the day. With my work he ended up doing most of the stuff, there will be examples of his fab welding skills later! Smile

The engine bits were done in two main parts orders, but the goodies were bought slowly, most secondhand over three months. My wife later banned me from eBay! Wink
The part that hurt the most was the Wilbers 642 shock, but now I've been down into Sahara and back I have to say it was worth every penny! My mates BRP I built up we used a HyperPro with custom progressive spring, which is also lovely. Dare I say the HyperPro almost takes first prize...

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Re: My build up: Big Red Dog... ;)

Post  bigkuri on Sun Dec 01, 2013 11:41 am

So, a few parts and bits started to come together.
First off, and a job I hated doing (nerves!) was the oil sight tube from XRs Only. These are a very underwhelming item when you look at the kit and think of the expense! But the tubing is special heat-resistant stuff, and the fittings and instructions top quality. More importantly the ease of checking your oil level is just awesome Cool 






Next a go at the forks. Taking off the top of the forks resulted in this weird toxic stench. Gods it was nasty stuff in there, whatever it was.



Didn't do much to the forks, just stripped them completely, reassembled with new seals and oil, and adjusted them to my weight.  A note that I used a "fork seal kit" from eBay having both seals and wipers, however it is the wrong kit, and only the seals fit - the wipers are those off a XR600. I should have just ordered OEM....


Next the carb; new jets, needles, and a little billet choke plate from XRs Only




Meanwhile, the engine was coming together, not many pictures as they are all dead boring! Assembled, nice new clutch cover in place





Getting somewhere....




Meanwhile Carlos has used his mad welding skills to fab up a tanker brace, a little light though, so we strengthened it a bit after this shot




Even nicer was Carlos' job on the right footpeg






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Re: My build up: Big Red Dog... ;)

Post  bigkuri on Sun Dec 01, 2013 11:55 am

And just a shot of the most boring "bolt-on" that $20 will buy you....



The clutch cover. Stuck on with high temp silicon it does the trick!

The cheap radiators arrived from China. I was pleasantly impressed with the quality. Roughly double the thickness of core means they keep the bike a lot cooler - proved several times in Southern Morocco in the big dunes when my mates bikes were boiling.





A small note that the fitting of these radiators was slightly off for a few reasons. I wrote to the eBay seller who has proved to be a real gent, and I'm currently working with him to provide better dimensions for the fitting points before he releases a version 2 early next year (Feb 2014). Basically as the core is so thick, it changes the angle that which the radiators point down. Will post a link and results when version-2 is released! A great upgrade though which together with a XRs Only radiator cap and thermostat prevented my bike boiling even once, unlike the others...

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Re: My build up: Big Red Dog... ;)

Post  Mad Frosty on Sun Dec 01, 2013 8:29 pm

watching this space .waiting 

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Re: My build up: Big Red Dog... ;)

Post  Mauser on Sun Dec 01, 2013 9:04 pm

Never fancied doing the oil sight tube....never seems the right way to solve the oil level issue....must have a ponder and find a way without drilling the frame or using a piece of plastic tube.. Smile....love the pictures and by the way the fork oil is whale snot....listen up 

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Re: My build up: Big Red Dog... ;)

Post  BuRP on Mon Dec 02, 2013 9:09 am

"... plastic tube..."

Yeah, it IS plastic.... but hardly the soft flexible stuff you would expect! Quite hard, resilient to bending in fact.
I got this thing too, and a) was surprised with the quality, and B) looooove the ease-of-use now by merely peeking if there's oil visible.

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Re: My build up: Big Red Dog... ;)

Post  AURORA on Mon Dec 02, 2013 9:24 pm

Who did you buy the Chinesee radiator from on Ebay?

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Re: My build up: Big Red Dog... ;)

Post  bigkuri on Mon Dec 02, 2013 9:32 pm

AURORA wrote:Who did you buy the Chinesee radiator from on Ebay?
winner_racing_international

If you are interested, just hang off a month or two so we can work through getting the right fighting measurements. I need to strip the bike and measure the mods I made to the radiator, then Winner-Racing will incorporate and get on the market. Other than the slight needed tweak to the fitting I am impressed with the radiators - really made a huge difference to keeping the bike cool.

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Re: My build up: Big Red Dog... ;)

Post  Mad Frosty on Mon Dec 02, 2013 10:10 pm

BuRP wrote:"... plastic tube..."

Yeah, it IS plastic.... but hardly the soft flexible stuff you would expect! Quite hard, resilient to bending in fact.
I got this thing too, and a) was surprised with the quality, and B) looooove the ease-of-use now by merely peeking if there's oil visible.
I like the idea of sight tube , but i hate the idea of drilling my frame and related possible issues with this solution , keeping it stock for now .study 

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Re: My build up: Big Red Dog... ;)

Post  Mauser on Mon Dec 02, 2013 11:18 pm

Mad Frosty wrote:
BuRP wrote:"... plastic tube..."

Yeah, it IS plastic.... but hardly the soft flexible stuff you would expect! Quite hard, resilient to bending in fact.
I got this thing too, and a) was surprised with the quality, and B) looooove the ease-of-use now by merely peeking if there's oil visible.
I like the idea of sight tube , but i hate the idea of drilling my frame and related possible issues with this solution , keeping it stock for now .study 
Exactly there has got to be a better way of making a decent sight tube, still looks like a home made job to me; banjo bolts would have been better with a pre-formed tube. anyone got a picture of the oil in the tube with their engine running ?.

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Re: My build up: Big Red Dog... ;)

Post  AURORA on Tue Dec 03, 2013 5:48 am

Bummer. I found this post on the radiators after I just ordered two new fluidyne radiators for $280. I read the aluminum on the Fluidyne radiators are a stronger grade of aluminum. Who knows?!?Frustrated 

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Re: My build up: Big Red Dog... ;)

Post  BuRP on Tue Dec 03, 2013 10:21 am

Aurora, at ease ma bru: those Fluidynes are cheap!
Some total idiots are demented enough to fork out waaaayyyy more for some Ozzi rads.


It's a pity that posting a pic is so difficult here, otherwise I'd show you my still shiny brandnew Ozzi-set....






razz 

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Re: My build up: Big Red Dog... ;)

Post  Mauser on Tue Dec 03, 2013 1:18 pm

AURORA wrote:Bummer. I found this post on the radiators after I just ordered two new fluidyne radiators for $280. I read the aluminum on the Fluidyne radiators are a stronger grade of aluminum. Who knows?!?Frustrated 
Those were a great price 2 thumbs sure I have seen them for nearly twice that price ?.

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Re: My build up: Big Red Dog... ;)

Post  Mad Frosty on Tue Dec 03, 2013 8:18 pm

Fluidynes = the best rads , end of conversation BRP smile 

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Re: My build up: Big Red Dog... ;)

Post  BuRP on Wed Dec 04, 2013 1:31 pm

Erm ColdOne, not true, the Ozzi stuff is almost a dimension better still. Seen Fluidines but this stuff is simply amazing - quite like their price beat head 

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Re: My build up: Big Red Dog... ;)

Post  AURORA on Wed Dec 04, 2013 3:03 pm

Interesting, some pictures of the Aussie radiators would be nice.Bananatool 

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