Posts
18
Joined
3/3/2025
Location
US
Hello Vital,
I have been reeding and enjoying all those bike builds for the better part of 20 years, jet never signed up to post.
I have build and restored a hand full of bikes over the years and most of them were Honda’s The xr600 to me always had such a thick cool looking engine. But I had never owned one or even riden one, untill now.
These are becoming scarse here in Holland, so the first one I found on marketplace was mine.
It is very hard to start, but I figured some practice would get that sorted
Roel
So after changing the plug, measuring the coil resistance and watching videos on the starting procedure it still is hard to start.
Then a PD04 electric start engine poped up online
It had a cracked cylinder head so i swaped the original head onto the E-start cases. It still has a kickstarter too. Fired first kick.
The XR engine looks cool to me but the flimsy suspention does not match.
I had a crf fork laying in the garage so I made that fit
So with the new fork, the rear swingarm could use some beefingup
I got a 2016 crf shock and swingarm and brakes
Had to modify the frame at the top shock mount and at the lower linkage side. Then put my crf wheels in to testfit
Also the kickstand spring pin on the frame was worn, so I made a new one
The Shop
Luxon 4-Post Bar Mounts
$189.95 - $239.95
Free shipping: VITALMX
Next thing I found is a set of crf wheels, excel rims and Talon hubs with a crush drive/ damper on the sprocket.
For the rally tower I drew up some plates and tried some things with plywood.
When I was happy I 3D printen the plates to testfit
Cool build man. Had a xr600…this build makes me want another. I will keep my eye on this build.
nice build man! the XRs are awesome dirtbikes ✌️
So after mocking up it is time for paint powdercoat and chrome.
Took the engine apart and pulled all the bearings
The cases will get cerakoted:
Swingarm and rims get wetblasted
The frame came back from powdercoat:
Got the parts back from wetblasting and zink plating
Finaly got the cases back from cerakote, he did a nice job
Its been a while since i worked on the XR.
I got the cylinder honed an the crank rebuild with a new conrod. So now i started to put the engine back together. All bearings are new aswell.
Sick build
So I got a bunch of those expensive little bags (no the other kind…)
Also a new Cam and camfollowers.
This is becomming a moneypit, but no way back now.
The bottom-end is all back together and in the frame.
XR600s are awesome on dirt roads 3rd, 4th, 5th gear!
And this year is one of my favorite years. Absolutely love the bronze lower engine cases against the red tank and blue seat.
The interesting bit for me is to see if the central cam bearing can be fixed. It was worn like most. Cut the existing bearing to a langer diameter and put a custom brass bearing
Wow nice work I miss my XL75 & XR200.
Pit Row
So sick!
Not done yet but its a runner
I still have to do the seat propperly, rear brake and some other small stuff
This is the kind of build thread that I love.
This week I put on a new fuel tab and the signiture blue toolbag. Rode it to full it up with fuel. Still Some bits to do.
The bike is now finished.
Had the shock rebuild by a shop since it leaked.
Rejeted and now it runs pretty good. Put 150km on it now
Final pics:
Incredible build. Job well done.
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