Restoring 1983 Honda XL600R part 1

[@savyourselffreedom2149]

I'll second that your son is very lucky to have a dad with so much knowledge God bless you both and thanks for sharing your experience. Cheers from Australia

[@punkrockdidi]

Bought a 1984 XL 600 R yesterday (well i actually traded it) .It runs,pretty well.For the moment i just have to do its main maintenence but im plannig on a full restoration.So your channel is a blessing to me 😊

[@damienabiwashburn1299]

Thank you for that, your son is lucky to be taught how to do that in person, the video is next best thing. Well done.

[@tylerben6254]

sorry to be so off topic but does anyone know of a method to log back into an instagram account? I was stupid forgot the password. I would love any help you can offer me.

[@jabariemilio4173]

@Tyler Ben Instablaster ;)

[@tylerben6254]

@Jabari Emilio I really appreciate your reply. I got to the site through google and I'm waiting for the hacking stuff atm. Takes quite some time so I will get back to you later with my results.

[@tylerben6254]

@Jabari Emilio it did the trick and I actually got access to my account again. I am so happy:D Thanks so much, you really help me out !

[@jabariemilio4173]

@Tyler Ben You are welcome :)

[@rubbabubba6489]

I have an '83 I'd like to rebuild best I can for road worthiness. Nowhere as clean as yours but all there and price was right.. Been using it as a trail bike. I need to make space to work on it. When I get to it I'm sure your vids are going to be a huge help. Thanks for taking the time to record and post your rebuild

[@tempest411]

I picked up one of these 12 years ago. I disassembled it at the time, bought a bunch of parts for it, but it's languished as other things came up. I do look forward to getting back to it in a year or so. I'm pretty sure I have a new chain, guides and rocker arms for it. They were all available at the time.

[@builtrodewreckedit]

I had that same bike when i was in high school. What a tank but it moved good. It was the first bike i ever rebuilt the top end on.... then i fell in love with two strokes because there so simple

[@TheRedQueensChamber]

I love the fact of how busy you keep yourself doing all the things you love. I am trying so hard to keep myself busy but lately it seems more like I keep striking out. Ya know I'm in Wisconsin

[@deborahchesser7375]

Nice work. I too learned to work on motors like yourself. If I didn’t fix my bike, I didn’t ride. I’m picking up an 87’ XL 600 soon, I can’t wait.

[@bigdmc1]

Deborah chesser Thanks I had an 86 years ago I did a lot of modification to it but found out the hard way it’s best to leave them stock

[@deborahchesser7375]

bigdmc1 I agree, stock is best. There’s always a trade off when you start to modify

[@iancampbell582]

Great video dude but calm down...chillax its just an engine.You will enjoy it more and things will go a lot smoother.

[@gbb1419]

You the man I just pulled my cover off my front timing chain tensioner broke too

[@rozzyretreat3300]

Good knowledge had a 600r 30yrs ago like new paid 1800dollars cherry red they made em GOOD 🇦🇺

[@kylereddy4649]

Part 2 ?? Your video was so good keep them coming 👌🏼

[@worldtouroperator9698]

Brother Great Job. Thanks a lot . Bravissimo e saluti dall' Italia. Sei un grande !!! grazie davvero . un abbraccio .

[@JradandYman]

Thanks for the awesome video! Looking forward to more!

[@martinpruckl8091]

HONDA is glad About those Fans !!! Pretty Nice Job Guys !!!

[@BtsGangsta]

Do a video on the carbs please!

[@bluejack644]

What a beauty. My dream bike.

[@nickwarner2453]

Can’t wait for more parts

[@robertmuller9132]

When I look in top end, first thing I do is wiggle the rod. The dopes insist on putting roller crank in all these things. My guess is planned obsolescence. Good fun show young man.

[@EDP1]

this was my fav motorbike.

[@motorslayernfs8467]

Great video thank you very much!👌💪💯🙏❤️‍🔥

[@unappreciatedfew3701]

How many fellow Dad`s out there would give anything to go back in time and do this project with their Dad or Grandfather?

[@stevecurd3944]

fantastic vid,ive just purchased a 1983 XL600r which has been stored for 10 years for £500 totally original,would you suggest doing a full engine rebuild after being stored for so long

[@overbuiltautomotive1299]

just a tip someone may see spring on tensioner sound good cold but hot clickin so to me spring is only bad part but most replace the whole thing but i would just do spring as a sprag that works works and its not like they even turn at all plus japan stuff is not typically weakly made stuff but all spring die with time if used ..Thanks for video now i can see in mine with out pulling it a part yet it low on compression n smoking a bit ill re ringing unless it has a bad lip in bore laping vales and seals and that spring and timing slides and chain.. i would used the higher compression and drilled oil holes on oil ring land area very possibly well if it had higher compression in first place but i would weight match the piston the what came in it for balance by grinding on it if needed God bless Jesus is king . i built my fist engine at 13 was stressful but it ran fin in the end lol

[@giuliogiulio1]

that was awesome i wish i seen this 17 yrs ago! haha

[@martinpruckl8091]

Great Job Sir !!

[@rabbicovidstein4421]

You can use timing chain tensioners and guides from the newer xr650l's, but you also have to use the xr650l timing chain and sprockets for it to work....

[@rabbicovidstein4421]

ooops after watching the rest of your video guess you already knew that lol

[@airhammerdan]

If you are in my boat where there is obvious mechanical failure & glitter in your oil, YOU MUST strip the motor down to the bare case (press out the bearings) and wash/inspect it thoroughly. I wouldnt trust flushing or a little brake cleaner to get particles out of the roller bearings. Honda still makes them.

[@dalemurray6834]

careful when putting the kick start idle gear back on it only fits one way.( have replaced 30 or so clutch baskets because it was fitted incorrectly)

[@Timespartan111]

can you upload a video on the right side engine assembly when you get around to it? thanks it would help a lot of us out

[@DF4Trap]

Great tutorial!

[@Evdath]

Thank You

[@cjsgarage3662]

Heard some info i didn't knew about. Well done! Did my engine rebuild as well, what kind of crosshatch angle did you get with the flexhone?

[@glennadriannapoll3248]

M M Iyybg76s8rur77rrur

[@cjsgarage3662]

@@glennadriannapoll3248 keyboard stuck :D

[@jackmichael9606]

Hi, I want to restore my 1984 Honda XL600R and would like to know if you can recommend a Honda store that can supply parts & accessories for my old Honda? Thanks and hoping for your help.

[@A-6864]

I have xl 600 1987 pd04 and I need to replace the segments! Which one are and where to buy them from? Cheers

[@osalcedoucmsae]

I just picked up an 86 Xl600r motor for parts(minus electronics) for my 85. the person I bought it from says the 86 motor has great compression (my 85 has spit oil out of the exhaust but runs). what do you recommend if i where to try to get the spare engine running?the spare engine has been sitting out (covered for a while) or should I even try? thanks!!

[@bigdmc1]

Omar S I wouldn’t trust what anyone says I would do a complete rebuild at least take the whole top end off and inspect everything replacing any worn part

[@CastleBomb44]

nice bike!

Hi, thanks for sharing this wonderful project. I have a question about the « screw » at 25.20. I have a little oil leak at this point, can I screw hard this one to reduce the leak or does it change the setting of the internal chain tensioner ? (Sorry for my bad English, thx for a reponse)

[@hansottosmotos]

Hi, great rebuild. Im thinking about doing the same, but its an 650L. I wanted to ask you, how important is it to go through the oilpumpsystem while in there. Im thinking about wear to make sure it delivers enough pressure in the system. Are there any problems with wear on that system? Mine has maybe 40k miles on it at least. I know i need to replace something if not all on the cam chain system while in there. Apart from that its working ok. No oil consumption or and lack of power

[@mastermoarman]

hey i had a 86 xr600r. i have sold the bike long ago. but i found a bunch of carbs for it in a box when moving if your interested

[@bigdmc1]

MasterMoparMan Thanks for the offer but the ones that are on it are good so really I have no need for them

[@jaymorano990]

Appreciate the video. Doing exact same project now. Can I pick your brain about using the 650 timing chain retrofit and using a 650 cam replacement? We are headed to do the same. Appreciate if we could chat.

[@bigdmc1]

I’m not sure if the cam would interchange Because they are different strokes and I believe a different design but I may be wrong never tried that

[@gbb1419]

Mine smokes out the front and burns oil like crazy is that rhe piston rings?

[@bigbelconut]

You don't need a ring compressor, the piston goes in the cylinder from the bottom, that's why there is such a big chamfer on the cylinder.

[@paulhaines5755]

Have you had issues with the oil pump ball/check valve on these bikes not fully sealing? (Smoking at start-up being the prime indication of a problem). If so, what did you do? Reseat the ball somehow? Install a new one? Thanks! Paul

[@bigdmc1]

Paul Haines I have no idea I’ve never had to worked on the oil pump but the smoke at start up has nothing to do with oil pump that would be bad valve seals

[@paulhaines5755]

@@bigdmc1Thanks bigdmc! Your vids are great. I do have some information on this and I’ll share if you don’t mind + it might help you or others. I’ve got an 84 XR500R fully restored that I did a couple years ago (look at my channel if you are interested). All new everything including valve guides, seals, conrod, piston, rings etc. The bike smokes at startup - not too bad but it lasts for like 30 seconds. Doesn’t do it every time - it is intermittent which left me scratchin’ my head. No big deal but it bugs me so I did some research and found that many dry sump bikes do this because of oil pump ball valve leaking oil while it sits, filling the sump in the case. This causes a higher than normal oil pressure condition and the oil is burned off until the level is back to normal. I want to fix mine and didn’t know if you have ever worked on one since it looks like you are very experienced so I’m just fishing for advice. I might try to seat the ball with some lapping compound but not sure yet. Thanks! Paul

[@paulhaines5755]

I forgot something right out of the gate: I’m assuming your bike, XL600 is dry sump oil system? I should probably add that on my bike (XR500R) it’s a “valve” that is being pressed onto a mating orifice by a spring. I had it apart but I don’t recall exactly what it looked like. I think maybe the valve has a ball shaped end on it that has to seat on a mating surface in the pump. There-in lies the problem. Even with a new valve, you might not get a good seat and it’s not worth it to get a new pump and very likely you can only find a used pump which is no guaranteed solution. Seems to me lapping is a good option. The valves are still available new so maybe a new valve and a lapping process would be the ticket. This is a problem on many bikes - Harley’s, too. Just more info for you to ponder… Thanks, Paul

[@DavidBownes-k7r]

Does it matter how the cam sprocket goes on? Can you get it wrong?

[@dannysosa5727]

Hey man how goes it, I just acquired one of these machines . It runs great but smokes like a mother . Any ideas or run through process of elimination ideas on this machine ? before I dig in stupid

[@bigdmc1]

It will need a top end rebuild new rings more than likely will need boated out to the next size over and new valve seals

[@DanTheRazorRamone]

Any idea where I can get rockers for this engine less thank 53$ US? Or is this just what I have to except in price range ?

[@fredericraymond648]

HI BIG DMC1, is your name Dave? So here is my question for you: You bought the narrower cam chain version of the XR650L, along with the new narrower cam chain slider and cam chain tensionner. Did you have to also get a newer (narrower) lower sprocket and (narrower) Cam sprocket? Also, you've put heat shrink at the bottom of the chain tensionner, but did you need to put heatshrink on the cam chain slider too? or just the tensionner? Thanks

[@bigdmc1]

No my name is Darrin and yes you have to change the bottom sprocket and the top sprocket all still available from Honda and the heat shrink tubing just goes over the bottom part of the front slider the rear slider is held in with a bolt

[@fredericraymond648]

Big thanks Darrin, your videos are fun to watch and are helping a lot of people. I liked your 86 XL600 too,with the Yoshimuta exhaust. Will you make another video riding the 83, maybe popping a wheelie.? :) So you found your missing rocker arm? You seem to have experience with the XL600s.Take care

[@bridgeguy5270]

How did you get the cam chain tensioner in?

[@bigdmc1]

Bridge Guy You just drop it in from the top and then push the axle through a one-way bearing so you can turn up One Direction freely and then once it’s in you have to put a pin through that hole on top and put a special made key in place to hold it in the down position so you can get the cam chain in you can see me remove that key just after I check the cam timing and install the permanent dowel pin back in it

[@steves2301]

You might have the cam sprocket 180' out. There is a mark at 12 o'clock.

[@deborahchesser7375]

Steve S doesn’t matter

[@filiplaskovski9993]

Do the 83 models have coated cylinders or sleeves ?

[@bigdmc1]

They all have sleeves

[@jefflorge5412]

where did you get your piston rings from?

[@bigdmc1]

Jeff Lorge from the Honda dealer they’re still available I believe it’s the same as the XR650 L

[@michaelwachsmuth1583]

Why did you suspect the tensioner? 84 in wisco 😁

[@larsemilegebergsimonsen3830]

At 22.14 How do you figure out which stroke was the compression stroke without the valves? I got mine apart now, but didn't remember to take notice of where it was set before hand... And also the cam is supposed to face lopes down right?

[@bigdmc1]

Line up the marks on the fly wheel that’s why I put the side cover on

[@dermerlo]

Why have you painted the head with powder and the carter cover with spray paint?

[@lazarusrize]

Go Pack Go!

[@unclequack5445]

You painted it before you took it apart? your new at this yeah?

[@nigelwolfe6150]

If I would restore one of these I would find a later donor bike with electric start and transplant the eniter motor and electrics onto the 83! Would be a total keeper then! The 83 was the PERFECT wheelie machine! It could make a wheelie EXPERT out of a so so rider instantly! I have never been a great wheelie dude UNTIL I bought me an 83 XL600! I could wheelie that bike through the gears from day one! On fire roads I could loft the front through water crossings etc without trouble! The ONLY reason I sold that bike early on? They are a TOTAL BITCH to start hot....they start nicely cold but hot it is always a gamble you are very likely to lose! Honda tried everything including TWO carburetors ...(one to get it started lol)...in the end they just started putting E buttons on all their big singles I guess.....not sure when the first starter appeared....

[@unclequack5445]

So you fixed it with wore out parts?

[@scottalanclymer]

Way too late obviously to tell you this, but heat shrink tubing turns to mush in hot engine oil. Anyone wanting to see what I mean just put some in a glass bowl (tubing and motor oil) put it in your oven at 300F for an hour and see the result. Goop.

[@johnmeurer4780]

I just took out my friend xl600r 83. He just bought it and it has cam chain noise. So we pulled the engine and I noticed that the cam bearing was put on backwards and It was missing that rubber plug on that last head bolt.(I dont think its necessary) The rockers and cam look fine thankfully. I'm changing it to the xr650l cam chain, guides, sprockets and a new tensioner + spring. I'm now wondering if the noise I was hearing was a lack of oil in the head because the bearing was put on backwards. Would it stop the oil through the cam? I wonder if the seller was just in there to change the cam and rockers before and put the bearing on backwards and ran into the new noise after reassembly and just immediately posted it for sale to recoup some of the money he put into it. I think seller was lieing. He said he rode it like this for couple thousand miles and everything was fine. I think the rockers and cam would have been eaten up bad if he did. It sound pretty bad. But it has great compression. I own a 83 xl600r my self, yet to tear into it but I have significantly less compression when kicking it and I removed my auto decompression and his auto decompression is installed and working fine. What's your opinion to the backwards bearing? Also your videos have really helped me out! this is my first engine I have torn into my self and really make all the judgment on its condition.

[@bigdmc1]

I don’t think the bearing on backwards would make it noisy it might cause it to ware sooner than usual you might double check make sure the cam chain tensioner is working properly that one-way bearing sometimes will stop working and cause it to release tension on the cam chain so I would replace that as well

[@johnmeurer4780]

@@bigdmc1 I have all new tensioner spring chain guides sprockets coming. That's what I suspected the noise was. Thanks for your opinion on it!

[@bigdmc1]

John Meurer Also on the 83 model you have to have the automatic compression release cable on the kickstart unless you strap the lever From moving otherwise it will Make noise

[@johnmeurer4780]

@@bigdmc1 make noise in the head or on the kickstarter? I removed it in my 83 xl600r and it didn't make a difference, in how it feels when I kick it or the sound. the manual decompression cable is required because is will tick around on the exhaust rocker. The automatic decompression goes to the 5th valve in the head, which is a dumb idea in my opinion.

[@GamingwithKandA]

WD-40 is a solvent. A cleaner. It's not a substitute for lubrication.

[@bustersmith5569]

where do you get the parts they dont make anymore ?

[@bigdmc1]

There are a few companies making aftermarket parts and you can check eBay for used parts but it’s getting harder and harder to find them

[@bustersmith5569]

@@bigdmc1 thank you ... I'll keep looking,,,

[@nednelp9051]

How much did you pay?

[@Muffin1280]

Do you still have the chain sliders and would you maybe sell them to me?

[@bigdmc1]

I still have the used ones I bought from eBay I would sell

[@Muffin1280]

@@bigdmc1 please get in touch with me [e-mail]

[@stevenrichards3699]

How many miles on this bike ?

[@bigdmc1]

About 19,000

[@stevenrichards3699]

@@bigdmc1 Thanks, I have one with 10,000 miles.

[@ChrisC1946]

Mine broke too.

[@PatPetrey]

GPG!

[@jethro9341]

Can you give us links to where you are getting your parts? I have an 84 I'm working on. Parts are a bitch to find.

[@bigdmc1]

Did you watch all three of my videos I explain how most of the parts I get are from the Honda dealer for an XR650L

[@KaarelNogu]

@@bigdmc1 many thanks for the video! Might save my 87' XL600 LM. Which year XR650 cam chain, sprockets and tensioners you were using?

[@bigdmc1]

Kaarel Nõgu It doesn’t matter they should all be the same

[@lucasking4197]

Did ya Search long thats half the battle

[@CodysGarage]

LOL @ pokemongo comment! :D

[@dariobrzovic9838]

congrats on this video ,educative and fun .also I have a question ABOUT kzbin.info/www/bejne/aJ2bp3mal6iVn9U AT 6:13 ON VIDEO what is the cylinder ware gap tolerance - spacing,is it 0.05 cm or 0.10 ,none or how much?, i want to rebuild my xl600r 1986 is the same engine but it has a starter...

[@williecosgrove]

A Fool and his Tools , Piston should be installed from the BOTTOM of the block not the TOP

[@overbuiltautomotive1299]

wd40 on bolts for TQ ing bolts never man use 10w 30 or 20w50 oil think film strength w40 has none

[@MrXzionn]

Cant watch it, you breathe to loud

[@eduardosampoia5480]

What form of OCD do you suffer from?