My XRR, or "All I want for Christmas is a bionic leg."

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Rad air scoops

Post  DoctorXRR on Sun Jul 08, 2012 1:28 pm

Mauser wrote:Have you tried the rad air scoops on ?, when I fitted my Devol rad guards the air scoops didn't fit as well as before, not sure how you will get on with bigger rads and guards ?
If by the air scoops you mean the side scoops that bolt on, no those wont fit with the larger tank and such. The plastic guards also on the stock radiators dont fit, I have to go with just the Unabiker guards. Ive seen the Unabikers, Fluyidine, Acerbis 6.3 gal, and HodakaGuy tanker brace all work together....thats a lot to fit up!

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New XR650R farlkle

Post  DoctorXRR on Tue Jul 31, 2012 2:25 am

Here is the latest farkle to roll in, steel sub-frame to replace the alloy one.  This will give me more security in carrying heavier loads, or at least not be too worried about tweaking the stock one.  Its available with integrated luggage rack, but I like the small ManRack I got, which will bolt on easy.
My only complaint was the sub-frame was poorly packed, no bubble wrap or padding, only a plastic bag in a box. The box was badly damaged, but I think the sub-frame came out. I will email them and mention the need for better packing. If you order from them make sure to request its packed well.

From Globtrottin: http://shop.globetrottin.com/category.sc;jsessionid=926BFEA97DC80E83F3ADF121A69EB22F.qscstrfrnt01?categoryId=14





DirtBagz next???
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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  Mauser on Tue Jul 31, 2012 8:56 am

Ouch very expensive for steel....I could have made you 1 from Gold cheaper banana

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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  DoctorXRR on Tue Jul 31, 2012 6:22 pm

Mauser wrote:Ouch very expensive for steel....I could have made you 1 from Gold cheaper banana

I wish it was cheaper too, but I dont have a tubing bender, welder, and powder coater, and if I did would'nt know how to use them!
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Build Update

Post  DoctorXRR on Sun Aug 12, 2012 5:41 pm

Progress report on the XR650R. Got the rear steel subframe installed, tires mounted on wheels, and the radiators, hoses and Uniguards on. Of course, nothing is really a straight forward "bolt on" when you start adding major structural type farkles. For now I am sticking with the stock gearing, figure I will wearout the stock chain/sprocket, and see how I like the stock gearing. Most likely I will go up one tooth on countershaft, or down three in the back.

The subframe mounted pretty good, but needed a little minor pulling and prodding. For some mysterious reason the rear fender had about 1/8th inch gap where it bolted on, so we cut some spacers on hand to fill the gap. A few bolts were too long, since the original subframe was alloy, and larger square section, instead of the smaller steel sections on the replacement. The steel subframe only weighs a bit over 1 lb more than the stock one, so that's not bad for the extra strength, and no worries when traveling with a heavier dual sport load. The steel sub frame blends right in, the untrained observer could never tell the difference.

The Unabikers take a lot of time and patience to install, getting the back braces in is tough, when you have little room to work with tools. I had no ball-end allens which you need, and have to be longer than usual. Northern tool had the ticket, and I got two full sets of allen sockets, with 1/4 drive extension, and I was good to go! You have to be diligent about not dinging your radiator fins while messing around in there. But the Uniguards are ROCK SOLID, while the rads still have some give from the rubber mounts.

Here are some pics with sidecovers, seat, and tank mocked up.

Next items: spin balance the wheels, install Baja Designs dual sport kit, install tank, take bike to mechanic for upgraded clutch bushing replacement.



Unabikers full installed! Big thanks to Unabiker for swapping out the regular guards for deep guards I needed.



Manracks luggage rack installed, and some sticker love for the bike!



Ayer's Garage custom Honda red on the side covers. http://www.ayersgarage.com/

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Congrats on the new bike!

Post  Bump on Wed Aug 29, 2012 7:04 pm

Interesting project.

My only guess on the barely used frame and the seriously abraded side case is an engine swap. You might see if that engine is the original case number from the original pink.

Or just live with and enjoy but just in case I'd pull the head and check the intake valves based on what I saw on that filter.

Best of luck!
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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  Mauser on Wed Aug 29, 2012 7:15 pm

The paint on the cases is thinner than a human hair listen up you could look at the cover and wear the paint off....if you read the original bike reviews even with a brand new bike after 1 ride the paint was disappearing.... beat head
More porn pictures please Doc ?

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The bike was never intended for the UK

Post  Bump on Fri Aug 31, 2012 5:17 pm

It's one thing to wear off paint or decals but it is quite another to abrade metal enough to polish it. California does not check engine VINs on titles so swapping engines is an easy thing especially for MX guys. And as everyone knows it is far cheaper to have a steady stream of replacement parts for your race bike by buying another bike than buying parts through Honda. When the bike is sold it's easiest to find someone who can wax poetic about thin crappy paint while emptying his wallet.

The bike was designed by a racer in So Cal for other racers in So Cal to dominate races in the So Cal / Baja / Nevada deserts and then market that wins out to everywhere else. Alot of people bought into it although I think serious racers here would prolly say the KX500 is the real king of Baja. Honda never wanted to make the bike. That we have this great bike is simply the result of the force of one man's personality. Most of the 2500 bikes produced annually were sold in So Cal. The only reason you have one is that Ogilvie forced every dealer to take one every year. Most traded for something easier to sell. The race bikes that weren't crushed were sold out to dealers several states away (with a few notable suggestions like the Tonopah bike and some in museums) after winning the 1000. Most of those sold surreptitiously to the public went to Denver. I think I wrote all this up on this site when it first showed up several years ago now. It's a great story.

The bike was almost unique in that it existed for one sort of racing only and was sold to the public to meet the few rules necessary for a few races. If Ogilvie saw how the bike has become some sort of behemoth with ridiculous armor and all the usual Advrider style hoedads he'd be laughing loud and long.

With your deep XR650R knowledge I'm sure I'm just telling you that of which you are already keenly aware. I'm certain you could school me on the two 1X XR650Rs in my garage as well.

Would you mind if we get back to the OP project? Intake valves are the first to go for bikes in dirty air or that use aftermarket air filters.


Last edited by Bump on Fri Aug 31, 2012 7:28 pm; edited 1 time in total
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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  rikco on Fri Aug 31, 2012 6:31 pm

nice story Burp

Shocked

in the netherlands i never met another xrr in traffic so i think if i say 50+ bikes? all the xrr's in holland crazy

i keep mine till i cant walk anymore bow lol!

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You can still find new ones here

Post  Bump on Fri Aug 31, 2012 7:30 pm

Thanks for the kind words.
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Bionic leg XRR

Post  DoctorXRR on Mon Sep 10, 2012 2:45 am

Good point on the motor and frame numbers I will check that. Its always tough trying to figure out all the potential angles. We checked the valves, intakes were a bit tight. The clutch basket and plates are all in good shape, do not look abused. Also, the clutch bushing was not updated, but thankfully the main shaft is in good shape, no scoring there.

The Baja Designs dual sport kit is going on nicely, 50wt halogen headlight, handlebar switch, keyed kill switch, brake light, LED tail-light and a speedometer.

The kit comes with turnsignals, but we won't be using them since they are not necessary to pass the inspection.






I also took the opportunity to remove the original skid plate and to clean the motor and frame more:


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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  DoctorXRR on Sun Sep 16, 2012 1:42 am

The chain adjusting bolts snapped off in the swingarm, due to corrosion on the threads.
All I can say is thank goodness for the SwingArm Buddy!
The most difficult (and most important) part of the procedure is drilling out the broken bolts. You have to work your way up to with two smaller diameter drill bits before using the 3/8" bit provided in the kit. At least one of the smaller bits needs to be extra-long, otherwise your it will not clear the swingarm and you will drill crooked. Also critical, is making a very deep center punch mark - in the center of the broken bolt. I hit the center punch several times to be sure to get a deep punch mark. The finished 3/8" hole must be centered in the swingarm... not a procedure for the squeamish!

The kit makes a very solid repair and I applied anti-seize to the new adjusting bolts. The only down-side to the kit, is the new bolts are 5/16" american, which means you have to use a 1/2 wrench to adjust your chain, which may mean having to pack an extra wrench in your tool kit, although you might still get away with using a 13mm metric.

The steel insert is slightly over-sized compared to the 3/8" drill bit, so it is a good press fit into the swingarm.






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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  chrislogan27 on Sun Sep 16, 2012 3:25 am

I like it!!! Did the kit come with parts for both sides?
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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  Mauser on Sun Sep 16, 2012 8:51 am

Silly question but once you had drilled the old bolt out why didn't you just drop in the next size metric thread ?...same as original but slightly larger....those old English threads are well past their sell by date and you guys really need to go metric ina big way, I stopped using them over here in the UK in the 80's...no more BSF,BSW, UNC, UNF, BA banana
So come on America catch up with the rest of the world beat head
Glad your sorted anyway Doc; you could always get a stainless adjuster bolt and have the head adjusted down to a metric size so you can stop with your metric spanners ?

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Swingarm Buddy

Post  DoctorXRR on Sun Sep 16, 2012 2:13 pm

chrislogan27 wrote:I like it!!! Did the kit come with parts for both sides?

Yes, it came with both sides, ran about $40 USD for the kit.
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Swingarm Buddy II

Post  DoctorXRR on Sun Sep 16, 2012 2:22 pm

Mauser wrote:Silly question but once you had drilled the old bolt out why didn't you just drop in the next size metric thread ?
Glad your sorted anyway Doc; you could always get a stainless adjuster bolt and have the head adjusted down to a metric size so you can stop with your metric spanners ?

Good points! I was surprised it is not a metric fix, since all the bikes its going on are all metric. What I do like about the kit is the stainless insert, which resolves the potential problem of every having the bolt seize again (of course, liberal doses of anti-seize will prevent it). I was working the adjuster bolts with Liquid Wrench to get them out, and was getting a bit of movement. But, I had to really toruqe on them to get any movement, and I guess it just made them weak, and "TINK" each side went.

I like your idea of getting some stainless hardware and grind them down a bit to fit a metric wrench!

I was going to work hard on carrying just the right amount of tools on the bike, no more than really needed.

Thanks!
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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  Mauser on Sun Sep 16, 2012 3:34 pm

Biggest question is why on earth did Honda use this method in the first place....? they could have asily placed an insert in the subframe from new and saved all the grief for you and others....glad mine wasn't seized along with swinging arm bolt razz

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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  BuRP on Mon Sep 17, 2012 2:07 pm

Honda KIS'ed it, remember this is a race bike - lightest solution, and there's nothing wrong with if you keep a check on it.
So btw, the orange stuff has the exact same, bolts in ali.
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Finally Together!

Post  DoctorXRR on Mon Sep 24, 2012 12:32 am

We made a big push this weekend, by installing an upgraded clutch hub bushing, installing the tank, finalizing the baja designs install, tightening all frame fittings, routing cables and installing the TCI Products skid plate and engine gards.
The beast runs, and is ready to roll bones at the Roll The Bones Rally and go to Big Bend Ranch State Park!













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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  Mauser on Mon Sep 24, 2012 7:51 am

Nahhh don't do it, keep this baby in the house to look at and build another not so nice bike for the rally.

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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  MA$TER_E on Mon Sep 24, 2012 6:46 pm

Mmmmm drool purdy! I agree, put that bike in a glass box and build another to beat up, it looks great nice
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Re: My XRR, or "All I want for Christmas is a bionic leg."

Post  Focker on Fri Sep 28, 2012 2:35 pm

DoctorXRR wrote:
The only thing missing is a swingarm sticker that reads - XR650RForum.com. No I don't have any but it wouldn't be to hard to commission one from your local sign shop. BRP smile

Nice bike...Reminds me of the museum piece I once had.

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My XRR

Post  DoctorXRR on Sat Sep 29, 2012 2:46 am

Thanks for the compliments, it wont ever be this clean again. Plan on wearing it out! Had a hell of a time locating a inner clutch hub, finally found a good one from a guy parting out a bike in New Mexico. Tho' Im not a fan of parting out good bikes, I was glad to find the part. I also found a complete used clutch assy in good shape, so got that as a spare. I'm a bit concerned that 5 years from now parts may get scarce for these bikes. Not many were sold in the US, so the number of used ones getting broked down will start to decline also. Ask me how I know, try finding good quality spares for a 1984 900 Ninja I restored! Old bikes are no cheaper than new bikes!
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Re: My XRR, or "All I want for Christmas is a bionic leg."

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