Honda XR650L Thumpster

osteoderm said:
Looks like we've been working on parallel ideas! Your photoshopped tank/frame mockup looks mighty familiar to what's sitting in my shop now:

I'm stoked to see where you end up taking your mongrel thumpster!
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Thanks Osterderm. I'm definitely in when you get to working on that fun looking project. I'm curious to know how that reverse cone sounds on there.

DesmoBro said:
Any thoughts for a front fender?
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No thoughts on a front fender yet. I'm taking a few steps back from the design phase to work on the motor first.

Problem: Smokes for first 5min after startup. Some excessive clickity clacks from the valve train.

At least this is what send me into the top end in the first place, boy did I find some surprises...
 
It is clear that some sort of ghost or foul creature has been living inside my combustion chamber. The camshaft and rockers are shot. I'll replace the valves and seals. Piston and Cylinder head can be cleaned up and Rings replaced. The actual cylinder itself looks great.
 

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It's hard to tell in these photos but the rockers are actually worn till they're concave! One of them is actually worn all the way through. There's a hole in the rocker pad! I guess there was no valve clearance?

Here's a list of parts needed for a rebuild...

Camshaft Assy
Bearing
Piston Rings
Bolts Misc.
Tappet Cap - broke a corner off one while trying to get it open
Gasket Set
Spark Plug
Spark Plug Socket
Rockers
Valves
Oil Filter
 

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Just cam across this thread. Reminds me of a bike we built.

1016671_10152011683444992_631660121_n.jpg


Build it anyway you like and screw these folks you seem to be narrow minded conformist......oh, I don't know what standards to judge it by, I don't know what definition, yadayadayada.

Screw the definitions of those cookie-cutter classes. Kudos to you for being a bit creative and thinking outside the box instead of following some defined class definition and building a bike that looks like 1000 others that do fit in well defined classes.

On the other hand, curse you! I've got a couple of XR600's sitting in the back. No you have gone and given me some thoughts on building one of them...and I don't really need another project right now.

Oh and you other folks with your well-defined styles, don't feel bad. At the Ton-up Ypsi bike show they were handing out the awards. The announcer said that they didn't know where to put the next bike, but that they all loved it and thought it was a bad-ass looking bike and wanted to give it an award. So they decided to give it the Best of Show Small Cafe Racer Award. It's the bike pictured above.
 
Cuba Libre said:
Specs?
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Started off as one of these:
9088729_250r.jpg

1985 Honda ATC250R

Removed rear axle assembly and sub-frame, cut of steering neck.

Installed CBR600 F2 swingarm wheel/brake. Rear shock is from an '87 Yamaha SRX.
Made new steering neck and changed rake to 27deg to accommodate a complete Buell 900 XB front end.
Tank is from an early '80's Honda CX500C.
Made rear frame loop. Seat was made for us by Ian out at Cafe Racer Seat and Tank.
Headlight CB360
Radiators are CRF450R aluminum units.
Head light & radiator mounts we fabricated.
Engine was a race-tuned engine years ago. Ported to match a CR250 that was a championship flattrack engine.
39mm Keihin Flatslide, V-force reed cage, FMF pipe. We modded pipe for the under seat exit. When DYno'd years ago engine was putting out 55 RWHP.
Front brake master cylinder Honda VF500F, rear master cyl, CRF450.
Pro-taper bars
We painted it in the paint scheme of the Honda RS750 flat-trackers, specifically Bubba Shobert's championship winning bike.

Like I mentioned above, around 55 RWHP. Wet weight ready to roll came in at 245lbs.
And it passed its LEO inspection as a street-legal vehicle. :)

https://www.youtube.com/watch?v=I3J7LO79CwQ
 
The bike looks grea screw the nay sayers! That atc250 is bonkers, I love it too! I would leave it high, most of my bikes are "too tall" for conventional styles and I really prefer the way they look/handle. Can't wait to see it done!
 
CharlieT said:
Just cam across this thread. Reminds me of a bike we built.

1016671_10152011683444992_631660121_n.jpg


Build it anyway you like and screw these folks you seem to be narrow minded conformist......oh, I don't know what standards to judge it by, I don't know what definition, yadayadayada.

Screw the definitions of those cookie-cutter classes. Kudos to you for being a bit creative and thinking outside the box instead of following some defined class definition and building a bike that looks like 1000 others that do fit in well defined classes.

On the other hand, curse you! I've got a couple of XR600's sitting in the back. No you have gone and given me some thoughts on building one of them...and I don't really need another project right now.

Oh and you other folks with your well-defined styles, don't feel bad. At the Ton-up Ypsi bike show they were handing out the awards. The announcer said that they didn't know where to put the next bike, but that they all loved it and thought it was a bad-ass looking bike and wanted to give it an award. So they decided to give it the Best of Show Small Cafe Racer Award. It's the bike pictured above.
Click to expand...

EEK! Mis matched wheels! :eek: That's equivalent to a beer crime in my neck of the woods..
 
After a bit of downtime I finally got all the parts i need and now I'm putting her all back together...

I had to send out the cylinder head to get the cracked valve seat fixed. While it was there they media blasted the head and did full valve job with my new valves. So fresh, so clean.

Hopefully the new valve seals will fix the smoking on startup issue. The old ones were pretty crusty.
 

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I got to do my first supermoto track day ever a few weeks ago. It was so much fun. SoCalSupermoto is a group that gives how-to ride supermoto lessons. For $230 bucks they give you a race ready drz400sm, pay your track fees, and give you lessons how how to ride supermoto. The track was about 80% street, 20% dirt. I had a blast and would love to do it again. I highly recommend this to anyone in the SoCal area.
 

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I am sure you had fun! Supermoto is the most fun for the buck in my book (see my avatar). Get that outside elbow up and foot pressure on the outside peg in the turns, bang it down a couple of gears and back it in :)
 
Does anyone know of a remote reservoir shock that will bolt onto the xr650l? I need a remote reservoir shock so I can modify and brace the subframe without the stock gas reservoir getting in the way.
 
Been incredibly busy at work for the last several months and had no time to work on the bike. I'm freeing up again so I'm jumping back into this forgotten project.

This gas tank is off a Hodaka Ace. It looked a little too tall so I cut the mid section out to drop the height of the tank. I removed the frame channel and am working on making a new one. I have everything tack welded in place. I really wanted to try my hand a making a gas tank even though it might not work out great.
 

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More work
 

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What's really allowed me to take the XR off the road and into the shop was the purchase of my new (to me) 2007 DRZ400SM. It's a blast to ride as is, and I've been commuting on it daily.
 

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