NEW PROJECT! 1994 Honda XR600R Supermoto

[xrocket21]

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?

[breakdirt916]

Hell yeah!!

[TheIglu]

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.

[Not Sure]

Great bike. Always has been one of my favorites.

[MattR302]

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.

[tls25rs]

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

[typeone]

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.

On my old KDX

my buddy is still enjoying it. think he's been doing more DS than trail on it lately.

[xrocket21]

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.

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.

[xrocket21]

Parts are rolling in

[R7]

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

[xrocket21]

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....

[black]

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

[xrocket21]

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!

[black]

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

[breakdirt916]

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

more, more, more!

[black]

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

[xrocket21]

Almost $50 for a new carb boot!!!



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

[Kurlon]

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

[xrocket21]

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.

[Gixxer]

Purple plastics would look sick on this bitch

[xrocket21]

Purple plastics would look sick on this bitch

[csmutty]

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.

[xrocket21]

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

[csmutty]

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?

[xrocket21]

Are there pics of it in this thread?

Bottom of post #11, no sign of attachment where it broke off, smooth rubber