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NEW PROJECT! 1994 Honda XR600R Supermoto

  1. #1
    TWINS! xrocket21's Avatar
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    NEW PROJECT! 1994 Honda XR600R Supermoto

    Bringing back from the dead for a friend. He hit a deer like 8 years agoand it has sat since.



    Ordered today:
    -new chain (gold!)
    -new levers
    -new pegs
    -new LED headlight
    -new grips
    -new handguards with led turn signals

    Need to change brake fluid and oil, repair trailtech mount, clean carb, overall cleaning...

    Need a battery solution, currently it is 8 AA nicads?, and mirrors.

    Know a good way to clean the motor some easily with all those fins?

    Oil suggestions? Rotella?

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  2. #2

    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Hell yeah!!

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    Super Moderator TheIglu's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Power washer for the motor. Let Simple Green soak in for 10 minutes first to loosen everything up.

    I'd also recommend replacing all fuel and vacuum lines. Cheap and easy insurance.

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    Lifer Not Sure's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Great bike. Always has been one of my favorites.

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    Awesomeness, Inc. MattR302's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    On my old KDX, the previous owner had installed a light kit, and had a fairly large battery in the tail pack powering it.

    I replaced that battery with a Milwaukee M12 battery adapter (not this exact one but similar https://www.amazon.com/Battery-adapt.../dp/B08LCDJG5M)
    That way whenever I went to ride it, I could just pop in the Milwaukee battery. Easy to get a larger amp-hour battery or carry a second battery if going on a longer ride. I also replaced the 35w H4 halogen headlight with a real low wattage LED H4.

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  6. #6
    ^ It's my bike and my car tls25rs's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by xrocket21 View Post
    Know a good way to clean the motor some easily with all those fins?

    Oil suggestions? Rotella?
    Depending on how good you want to get the motor I have seen some videos of people using C02 vapor blasting to clean things up

    Rotella is always the answer

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  7. #7
    Lifer typeone's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    awesome project, i gotta dig up a pic of the one my neighbor had. man we had some amazing sumo rides together (i had an SXV550 at the time), he bought it off a guy down in Brooklyn that built it up to a T. had all the trick tweaks, i'll see if he still has the specs. might help down the line.

    Quote Originally Posted by MattR302 View Post
    On my old KDX
    my buddy is still enjoying it. think he's been doing more DS than trail on it lately.

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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by TheIglu View Post
    Power washer for the motor. Let Simple Green soak in for 10 minutes first to loosen everything up.

    I'd also recommend replacing all fuel and vacuum lines. Cheap and easy insurance.
    Thanks, Ill try simple green and the pressure washer.

    Good call on replacing lines.

    Quote Originally Posted by MattR302 View Post
    On my old KDX, the previous owner had installed a light kit, and had a fairly large battery in the tail pack powering it.

    I replaced that battery with a Milwaukee M12 battery adapter (not this exact one but similar https://www.amazon.com/Battery-adapt.../dp/B08LCDJG5M)
    That way whenever I went to ride it, I could just pop in the Milwaukee battery. Easy to get a larger amp-hour battery or carry a second battery if going on a longer ride. I also replaced the 35w H4 halogen headlight with a real low wattage LED H4.
    I believe this setup actually charges the battery independently, so I don't think the Lipo setup would work. I like the idea though. This is why I am changing the headlight to LED, I was told it was dim. Cant find a good led rear though so I am going to try to make what is there work. There are a few UFO fenders on ebay that fir the xr600, but white only and not LED and no blinkers so it doesnt really help at all.

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  9. #9
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Parts are rolling in


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  10. #10
    Don't bother me! R7's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by TheIglu View Post
    Power washer for the motor. Let Simple Green soak in for 10 minutes first to loosen everything up.

    I'd also recommend replacing all fuel and vacuum lines. Cheap and easy insurance.
    Spray everything down with WD-40 first, even scrub it a bit with a toothbrush. Simple green is a great mild cleaner for an after every ride type cleaning, but doesn't cut it for the once a year/once in a lifetime type cleaning. Castrol super clean or Krud cutter is a great cleaner if used with caution.
    Whatever cleaner you use, don't let them sit long before rinsing , never let them dry, and always spray the finish product with WD- 40 to prevent corrosion.

    Cool project for sure

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  11. #11
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Got the new foot pegs installed.



    New chain vs the old chain



    Got the headlight installed, handguard with built in turn signals, levers, and grips installed



    Glued the trailtech mount back together and installed a new battery, polished the handlebars a bit



    Next, the carb needs a GOOD cleaning



    Polished the swingarm and tried to clean the case some, without luck



    Ordered a new carb boot and air filter today



    So I need to figure out a new battery, clean and install the carb and filter, and clean out or replace the gas tank as well as bleed the brakes.

    I looked it up and it says it takes 2.4 quarts of oil, but I barely got 2 in and it overflowed, not sure what is going on there....

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  12. #12
    suburban ghetto living... black's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    You might need to measure oil level while it's running. Like the xr650r

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  13. #13
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by black View Post
    You might need to measure oil level while it's running. Like the xr650r
    The owner DID mention that...

    Also, I was told it has a piston, headwork, and a cam in it? Possibly bored out carb, as well was the muffler that's clearly on it!

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  14. #14
    suburban ghetto living... black's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by xrocket21 View Post
    The owner DID mention that...

    Also, I was told it has a piston, headwork, and a cam in it? Possibly bored out carb, as well was the muffler that's clearly on it!
    It does? Nice?.... My friend has the hop up kit in the Xr650r.. it is a beast.... the 650 is beast... the hop up kit makes it just monster.

    https://www.thumpertalk.com/forums/t...r-hop-up-kits/

    hop up kit might need premium gas only fyi. if I recall dual carbs on the 600????? My other buddy had a 600 said it was a Pain to kick over. YMMV

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    hmmmm......

  15. #15

    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    oh help me lawd, I love build threads on older motos

    more, more, more!

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  16. #16
    suburban ghetto living... black's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by xrocket21 View Post
    The owner DID mention that...

    Also, I was told it has a piston, headwork, and a cam in it? Possibly bored out carb, as well was the muffler that's clearly on it!
    standard to drill out the exhaust ont he xr650r and other items such as airbox etc remove all the emission crap put on at factory. probably same for the 600

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    hmmmm......

  17. #17
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Almost $50 for a new carb boot!!!



    Ordered the wrong size filter, new one on the way.

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  18. #18
    Lifer Kurlon's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Be happy you can still source one, they're getting near impossible to find new for lots of bikes of that era now.

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  19. #19
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by Kurlon View Post
    Be happy you can still source one, they're getting near impossible to find new for lots of bikes of that era now.
    Im getting excited to kick this bitch over! I think we are close. The owner is sourcing a brand new tank.

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  20. #20
    Lifer Gixxer's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Purple plastics would look sick on this bitch

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    Your park avenue leads to..

  21. #21
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by Gixxer View Post
    Purple plastics would look sick on this bitch
    NEW PROJECT! 1994 Honda XR600R Supermoto-giphy-gif

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  22. #22
    Your Father csmutty's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by xrocket21 View Post
    Almost $50 for a new carb boot!!!



    Ordered the wrong size filter, new one on the way.
    Those compression limiters look nice. Interesting that it looks like they have ejector pins on each side of the limiters in the mold.

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  23. #23
    TWINS! xrocket21's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by csmutty View Post
    Those compression limiters look nice. Interesting that it looks like they have ejector pins on each side of the limiters in the mold.
    Tell me you work in manufacturing without telling me you work in manufacturing

    Very weird how the original separated, VERY clean break

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  24. #24
    Your Father csmutty's Avatar
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by xrocket21 View Post
    Tell me you work in manufacturing without telling me you work in manufacturing

    Very weird how the original separated, VERY clean break
    Are there pics of it in this thread?

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  25. #25
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    Re: NEW PROJECT! 1994 Honda XR600R Supermoto

    Quote Originally Posted by csmutty View Post
    Are there pics of it in this thread?
    Bottom of post #11, no sign of attachment where it broke off, smooth rubber

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