Krap!!!!

So..... I broke it. I pre soaked it with pen oil, was gentile.......to a piont.... right befor it broke!
Now what? Im 100 miles from any thing, no bike shops, machine shops, limited power tools, and a but load of plumbers tools.
I guess this would be a good time to yank the swing arm and lube up!, check the shock bushings, ect!

man that bike has had some serious neglect why don't people look after their pigs
Looks like you will need to drill it out and re-tap the threads maybe slightly larger...problem being the old thread will drop into the swinging arm and rattle around....would drive me nuts

Thats the plan tomarow, I did pick a project bike! It took me about 2 hours to get all the stickers off the beast. and I had time to buff out the tank, its red again. This bike was a "farm tool" and not very well taken care of, The air cleaner looks to be original.
Ill have her back up in no time,

Thanks Mauser

Wish you lived close to me, as I would love to tackle this job have plenty of tools and idea's to get it repaired.
Take your time and get decent drills and if your careful it will be all good

This shouldent be too bad, Im going to do both sides so they match. Im headed out to get a tap and drill bits, and some new hardware.

Try tapping the end of the thread lightly to see if you can break the corrosion free between the bolt and the frame.

There are a few achilles tendons on these bikes, you found one....another is the footpeg bolts. Get the hardened and a tad bit longer ones, they are on Ebay for about 8.00 plus shipping. I use never sieze on all that stuff. The reaction of two different types of metals caused that chain tensioner bolt to lock up, Burp knows ALL those terms and stuff. The oil in the forks is referred to as "whale snot", so change that. The choke plate in the carb can and does get sucked into the engine sometimes, remove that too. Change the cap on your radiator to a 1.8 or 1.6, they can be found easily and run "evans coolant" or "engine Ice", I run the latter as I was unable to find any Evans. As you have already found, people here like to help fellow pig owners, a unique and cool group of people. Many of us, (myself included) use Trailtech computers for the pig, I have a "vapor" model and it is a great asset on any ride. Have a great time and be careful, it's a hard habit to break, these bikes have some kind of force that really draws you in....it's all fun.

If I can help let me know.

Troop

Thanks Troop,
I found the BRP page first off, been reading all about the pit falls. I did get the tensioner bolt hoged out, a 10mm bolt to replace it,Had to turn down the head on the jam nught, belt sanded the bolt head to fit the chanel in the swing arm. Now I need to customize a couple wrenches to squize into the chanel. ..... ....sorry I can go on a rant some times.

I like the no BS talk here. My bike might never be a show bike, But it'll be solid enuff to take me places I have no business going!

This is the replaced bolt and jam nut, $50.00 and 200+ miles traveled! 1 hour of work time

Good work, 3 hours plus driving..that's expensive too. Did you put some Anti Sieze "never sieze" paste on the new bolt? I got my pig from a guy who literally never rode it, had original tires, no paint worn off anything, no scratches...I did everything the guru's here advised me to do, and I can tell you I have never had any problems because of the preventative maint. I am going to change the rear sprocket so I have 15/47 and get a new rear fender......I cracked it and did the field repair with a drill and zip ties. I need Rox Risers and heavier fork springs, probably a new chain too but I'm not riding until it gets cooler again. I also want to get a Clarke 4.3 tank and Tall seat. Seems there's always something to add....Wouldn't mind a pumper carb too!

This is my first bike in a while, I did not use anti sieze yet, Its a work in progress! I do intend to restore it to 'better than stock' condition. Im going to get to ride today for the first time In the dirt, un teatherd, on trails!

This is serious, I'm a big guy, 6'3, 230-40lbs...I though my bike had a worn out clutch when I was riding because it seemed to over-rev or the rpm would just jump instantly when I hit the gas....I thought the clutch was slipping until I started checking out the videos of me riding and realized that even with my weight that bike will roast the tire anywhere. What I though was a bad clutch was nothing more than wheel spin. On dry dusty fire roads the pigs drifts effortlessly, while I was caught up in the thrill and drifting everywhere I could I didn't realize that with the combined weight of myself and the bike that tires (rear) can be worn out after a very short period of time. I have never ridden is sand...like a beach or desert, but I would like to sometime. I am really hoping to find a few guys up here to ride with this fall, I have my bike ready to go even though there is much I want to do to it. I sold my CR500 and now am wanting another one.....go figure. Let us know how the ride went. I just noticed your swingarm sticker, does your bike have a lowering link? If you're a tall guy you may want to remove it if it's in there.

Troop

WOW!! What a blast!!! I did a full shake down! Up and down through the gears...even 5th! GOOD GAWD!! Now I know what Ive been missing!
Troop, I know about the drift now! a little air time, some small hills, washes, and flat out cross country desert riding!! Most the time in 2nd~3rd, but got into 5th a couple times.
Issues that I found,
#1 some times she slips out of 2nd, under low to mid power, and into 3rd some times. maybe bent shift fork?
What ever it is, I forsee a case splitting!
#2 Front wheel is cracked! Wasent when I check the spokes, and cleaned the dust off em! I did smack some rocks, but diddnt go down, Rim is still fairly true, like it was when I found it! Ive tacoed a front wheel once before, and broke spokes on dirt bikes, I didnt hit anything hard enuff to do damage today. so new rim? Why not? cant have a new front and an old rear! Thats like a boob job on a flabby butt!
And Ill have a rim for a paddle!!
Oh krap.....Im addicted!!!

Oh and Troop, I dont think it has a drop link, Im 6'1" and cant put my feet flat, it all tippy toes!
One other thing I notice is thers some oil comming out the breather tube into the air box, Its been dripping for w bit since I got back from the ride. The oil level is good. not over full. Maybe the filter?

Front wheel is dead easy, they are the same as the 250R and 400R go find a decent wheel on ebay

CR500 ? I found one cheep!

Found a 2001 for 1800.00, trying to do some trading..........Looks great but need to ride it first.

http://issuu.com/xr650r/docs/honda_xr650r_service_manual_2000-2007?mode=embed&documentId=080207201915-a9614fa8a33e47dcb595719384785a5c&layout=white


This may help you. It has helped me .

Thanks Troop,
Im looking at afew wheel sets, Ive seen the service manual, Im out of bike funds right now, but Ill be back in the game in a week!lol. I picked this bike up on a trade, less than $1k.....a lot less! so I can dump some cash into it and still be on top!
I found a fork/wheel set for cheep, but its off a cr500 and Im not sure if it will work with out a bunch of work. Maybe Ill just buy a new wheel set. Im wanting to find out about the shifting first, if I need to split the case, Im gona proble do a compleate top end.

chrislogan27 wrote:Thanks Troop,
Im looking at afew wheel sets, Ive seen the service manual, Im out of bike funds right now, but Ill be back in the game in a week!lol. I picked this bike up on a trade, less than $1k.....a lot less! so I can dump some cash into it and still be on top!
I found a fork/wheel set for cheep, but its off a cr500 and Im not sure if it will work with out a bunch of work. Maybe Ill just buy a new wheel set. Im wanting to find out about the shifting first, if I need to split the case, Im gona proble do a compleate top end.

A 680 kit would be nice!

I might look into that. Yhis is my first dirt bike in about 20 years, I m ight just keep it simple for now, till I get my dirt leggs again!