Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Honda Tech
XR650L engine rebuild... XR650L engine rebuild...
Register FAQ Calendar Today's Posts
Honda Tech Honda Tech Forum - For Questions specific and of interest to Honda riders only.
Photo by Hendi Kaf, in Cambodia

I haven't been everywhere...
but it's on my list!


Photo by Hendi Kaf,
in Cambodia



Reply
Page 1 of 2 1 2
 
LinkBack Thread Tools Display Modes
  #1  
Old 23 Jul 2003
POB/London's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Jul 2002
Location: London / IOW
Posts: 486
XR650L engine rebuild...
Anyone had to do this?
Any tips / tricks?

__________________
=-=-= ON THE EDGE! =-=-=
My XR650L Pan-Med Expedition Site!

Reply With Quote
  #2  
Old 23 Jul 2003
Registered Users
Veteran HUBBer
  
Join Date: May 2002
Location: London, UK
Posts: 635
yup. easy.
engine is a close fit in the frame so you might prefer to drop it in the frame, remove the rocker cover and then lift it out.
its a Dommie engine so just get a manual and honda/pattern gasket set for whatever you're about to do.
if you're going into the gear box, you can fit a kickstart, but its way expensive - see my thread from March/April. that said, it starts well on the kick so it gives me some reassurance.
unless you need to, don't bother removing the alternator rotor. you can do everything except remove the crank while the rotor is in place. remember to loosen the nut on the right side of the crank before removing the clutch, chain etc as the rear brake and 5th gear allows you to apply enough torque to avoid needing an air tool.
have fun
Rich
Reply With Quote
  #3  
Old 24 Jul 2003
POB/London's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Jul 2002
Location: London / IOW
Posts: 486
Thx Rich - thought you might know a thing or 2 about this. Not my fault (damn mechanics) but the red and white baby's totally seized solid. I took the top end off and it's VERY bad news....

Will keep everyone posted....
__________________
=-=-= ON THE EDGE! =-=-=
My XR650L Pan-Med Expedition Site!

Reply With Quote
  #4  
Old 28 Jul 2003
Registered Users
Veteran HUBBer
  
Join Date: May 2002
Location: London, UK
Posts: 635
sorry to hear that, Lewis. oil starvation? I've heard of reputable people doing that to Dommie's. can't the mechanic get you a replacement dommie engine? might be easier and cheaper.
good luck
Reply With Quote
  #5  
Old 30 Jul 2003
POB/London's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Jul 2002
Location: London / IOW
Posts: 486
Yep - within 1000 miles of getting it back from the garage. It seems that the mechanic's "assistant" filled the tank and left it at that. My dipstick oil temp monitor was helpfully telling me the air temp in the oil tank (didn't reach level of oil) and so everything appeared fine until the engine died.

The place in question is being a bit slippery, but I may be able to get some help. On the other hand, this might be an opportunity to fit a big-vore kit, a Paris-Dakar cam and a kicker... although I haven't decided whether to do it myself or not.
__________________
=-=-= ON THE EDGE! =-=-=
My XR650L Pan-Med Expedition Site!

Reply With Quote
  #6  
Old 30 Jul 2003
Registered Users
HUBB regular
  
Join Date: Aug 2002
Location: Copenhagen, Denmark
Posts: 40
Hey Lewis,

You're having a belt of bad luck there mate, good to see you're keeping a positive attitude! Don't let them drag you down...

Cya on the road...
Aubrey
Reply With Quote
  #7  
Old 31 Jul 2003
chris's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Jun 2000
Location: GOC
Posts: 3,335
is it worth naming and shaming the mechanic who employs muppet assistants? that way he has less chance of destroying somebody else's engine.

on this train of thought i would like to nominate sid morams, the official honda dealer in slough, berks, uk as employing at least one v. dangerous 'mechanic' (the stupid b****** who worked on my af twin) and offering a v. v. poor service.

hope you get back on the road soon.
cheers
ChrisB
Reply With Quote
  #8  
Old 1 Aug 2003
POB/London's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Jul 2002
Location: London / IOW
Posts: 486
Chris,

I will definitely name and shame the place, but for the time being I'm trying to be pleasant and give him a way out. That way I might get some free parts/labout by way of compensation. Ideally he would claim on his insurance and pay for me to get the bike fixed elsewhere, but I don't think that's about to happen!

Progress though. Today I bought a complete and running Japanese-assembled Dommie 650, with kick and electric start. I'm hoping to do a Richard Lees and bastardise both engines to give me a kick and elec start XRL with a slight overbore (670cc?) and high performance bearings....

BTW, the Dommie was pretty cheap, and the rest of it (ranging from good to average nick for a 1990 bike) is now for sale. Nothing's dented.

Some progress. Things may be looking up!

[This message has been edited by POB/London (edited 01 August 2003).]
__________________
=-=-= ON THE EDGE! =-=-=
My XR650L Pan-Med Expedition Site!

Reply With Quote
  #9  
Old 4 Aug 2003
Registered Users
HUBB regular
  
Join Date: Jun 2002
Location: London, UK
Posts: 49
Hi,
I'm thinking of getting a XRL... have no idea where to find one though. Where did you get yours from ?

hope you're getting it sorted...

good luck,
__________________
Simon
Reply With Quote
  #10  
Old 5 Aug 2003
POB/London's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Jul 2002
Location: London / IOW
Posts: 486
I bought mine provately in Surrey. Unfortunately they don't come up very often. How much were you hoping to spend? If you've got some cash then getting a brand new import shouldn't be a problem - there's a company advertising in the back of TBM who import a couple of batches a year I think. Other than that, you could drop CS a line via the Desert Riders website... Although Chris has sold his, one of the other 2 may still have a bike for sale.

HTH. When mine's all back in one piece you're welcome to have a look. BTW, I had a twinlamp Tenere before the XR, so I understand your predicament perfectly (and you're doing the right thing!)
__________________
=-=-= ON THE EDGE! =-=-=
My XR650L Pan-Med Expedition Site!

Reply With Quote
  #11  
Old 6 Aug 2003
Registered Users
HUBB regular
  
Join Date: Sep 2002
Location: Worcester, UK
Posts: 61
This place can import them new, Mark J(can't remember his HU tag) got his from here.
http://www.kjmsuperbike.co.uk

I am currently in email conversations with David Silver Spares about parts. They are really helpful and were always good in the past for my grey import CBR400. You can get stuff at 25pc off the Honda price if you are prepared to wait 3 weeks. News so far is that they can get pretty much anything if they can find the part number. They couldn't get me a genuine honda workshop manual so it looks like I am stuck with the breeze block sized Clymer :-( My guess is that all the other parts I asked about overlap with the XR6 or the Dommie and Honda UK can't be arsed to obtain anything else....although they did get me prices for plastics and they are not the same as XR6 or Dommie so who knows.

Cheers Andy.
Reply With Quote
  #12  
Old 7 Aug 2003
POB/London's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Jul 2002
Location: London / IOW
Posts: 486
All part numbers can be found here:

http://houseofmotorcycles.bikebandit...model_dept_yea r=1995&model_dept_mfr=Honda&model_dept_id=170588&m odel_dept_name=XR650L

Sorry it's a long link! As far as plastics goes, you can get someone from the XRLUG to order you some plastics from the US. Prices are:

- Both side covers $ 98
- Front fender $ 57
- Rear fender $ 35
- Visor set $ 55

I also know that almost all chassis components are identical to the last of the XR600's (apart from head bearings) and most engine parts are interchangeable with the Dommie. My plan is to get the NX650 Haynes manual and work it out from there.

Correct me if I'm wrong, but isn't the cam profile and carburation the only difference between the 2 engines? I was wondering if gear ratios are the same....

__________________
=-=-= ON THE EDGE! =-=-=
My XR650L Pan-Med Expedition Site!

Reply With Quote
  #13  
Old 7 Aug 2003
POB/London's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Jul 2002
Location: London / IOW
Posts: 486
£4499 for a brand new XRL.

Bargain.
__________________
=-=-= ON THE EDGE! =-=-=
My XR650L Pan-Med Expedition Site!

Reply With Quote
  #14  
Old 7 Aug 2003
Registered Users
Veteran HUBBer
  
Join Date: May 2002
Location: London, UK
Posts: 635
so far, I've needed my kick-start 3 times and its worked first kick each time. not at all sure why the electric spins, but occasionally doesn't fire up. just one of those things?
Lewis - why do you want to bore the injun? I wish it wasn't such a slug, but got 133kmh fully laden on a gravel road and shagged MT21 yesterday. dunes this arvo!
Reply With Quote
  #15  
Old 8 Aug 2003
Registered Users
HUBB regular
  
Join Date: Sep 2002
Location: Worcester, UK
Posts: 61
Hi,

bikebandit site is wonderful, thanks POB. I have got a fiche and was looking at getting it scanned and converted to PDF's...perhaps I won't bother now.

I didn't ask for prices for any engine internals so I don't really know what the differences are or whether you can get the parts easily in the UK. At the UK HU rally I had a good look at a dommie engine and at least one of the side covers is different...not very helpful I know but..

Rich, my CBR400 does this sometimes and it's got me foxed. There seems to be no reason for it. I am currenlty experimenting with giving the throttle a little blip before I turn the ignition off, the idea being that it might leave fresh charge in the chamber making it more likely to start off the button. As you can tell, I'm cluthing at straws now ;-) If you work it out, let me know and receive guru worship in return.

Andy.
Reply With Quote
Reply
Page 1 of 2 1 2

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

25 years of HU Events
Be sure to join us for this huge milestone!

ALL Dates subject to change.

2025 Confirmed Events:

Virginia: April 24-27
Queensland is back! May 2-5
Ecuador June 13-15
Germany Summer: May 29-June 1
CanWest: July 10-13
Switzerland: Date TBC
Ecuador: Date TBC
Romania: Date TBC
Austria: Sept. 11-14
California: September 18-21
France: September 19-21
Germany Autumn: Oct 30-Nov 2

Add yourself to the Updates List for each event!

Questions about an event? Ask here

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

Adventurous Bikers – We've got all your Hygiene & Protection needs SORTED! Powdered Hair & Body Wash, Moisturising Cream Insect Repellent, and Moisturising Cream Sunscreen SPF50. ESSENTIAL | CONVENIENT | FUNCTIONAL.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 06:17.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top