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Thread: XR600R Engine Rebuild help? Auck - Rodney retired mechanic?

  1. #1
    Join Date
    28th November 2005 - 12:33
    Bike
    85 XR600R, 98 ZZR1100
    Location
    Warkworth
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    2

    XR600R Engine Rebuild help? Auck - Rodney retired mechanic?

    I have an '85 XR600 which I bought as a non-runner, pulled down, got rebored and new piston, plus some head work done.
    Before reassembly I had the nagging feeling that things in gearbox land may not be 100% (when rotating motor and going through the gears, there seems to be quite some time to engage 4th/5th from memory) so while the motor was out, decided to split the cases and investigate...

    And, that's as far as I got. The cases will not split no matter what I do! They are slightly separated but won't come any further.
    I have a manual and reckon there is no spare bolts hidden away holding things together. Anyone know a secret I don't?

    I am not wanting to spend a truckload (wife puts house renovation ahead of two-wheeled $$) but happy to pay someone for their expertise and hours required to sort and perhaps carry on where I left off.

    So if you can recommend a spanner man who knew XRs back in the day and could be keen, let me know your recommendations.

    Cheers, Dave

  2. #2
    Join Date
    11th June 2011 - 16:30
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    Honda vfr 750 fn 1992 x2 90red
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    Double check there be a bolt or perhaps right side clutch side,
    put picture up.

    Sent from my SOV31 using Tapatalk

  3. #3
    Join Date
    9th January 2011 - 22:25
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    Big red vibrator
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    gentle heat around crank bearing, whole thing in the oven works as well.

  4. #4
    Join Date
    16th June 2007 - 02:46
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    Two wheeler
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    Quote Originally Posted by actungbaby View Post
    Double check there be a bolt or perhaps right side clutch side,
    put picture up.

    Sent from my SOV31 using Tapatalk
    As above. I'm doing the same on an old XS750 and there is one last hidden crankcase bolt hidden away behind the clutch assembly. The good old Haynes manual does warn you about it though. Of course, may be totally different to yours

  5. #5
    Join Date
    1st March 2017 - 06:23
    Bike
    1976 Honda GL1000, plus implements
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    taking the long way...
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    450
    Quote Originally Posted by admenk View Post
    As above. I'm doing the same on an old XS750 and there is one last hidden crankcase bolt hidden away behind the clutch assembly. The good old Haynes manual does warn you about it though. Of course, may be totally different to yours
    The "good old Haynes manuals" tend to work on a new or near new machine. An old one has all sorts of extra stuff to work through.
    Try the "gentle heat" method, should help to loosen the various shafts stuck in cases
    High miles, engine knock, rusty chrome, worn pegs...
    Brakes as new

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