OPERATION: Winter Rebuild

So let me tell you all a story about a guy (let's call him "Ben") who bought an XR650R this summer. It all started about spring time when "Ben" decided he wanted to get into dual sport riding. Through all of his diligent research he finally decided on the infamous BRP. Knowing nothing about "dirtbikes" and having only ever riden street bikes he decided that a BRP fit the bill for good power, off road performance and enough durability to get him back to the house after a day in the hills. So the quest was on to find a street legal XR650R. Low and behold there was one in my (I mean his) town! And after much deliberation and haggling (and a few test rides by "Ben's" buddies with much more dirtbike experience than he) the bike was his!! First came new spockets and a chain before "Ben" realized that he hadn't even ridden a bike in 4-5 years! So the decision was made to ride the bike all summer to get used to his new piggy and get to know his new best friend. Once little Benny felt comfortable on his BRP he wanted to show it the same love he had recieved from his beast of a machine. So with as much trepidation as a factory worker doing orthoscopic surgery, OPERATION: WINTER REBUILD was initiated. Last weekend "Ben" began the teardown with hopes that his machine would be amongst the most dependable BRP's around. It wasn't until last night that "Ben" realized he may just be in way over his head but never the less he presses on! So what point did I (I mean he) get to when he came to this realization you ask? Well, a picture is worth a thousand words... https://i.servimg.com/u/f46/17/76/25/26/bike_t12.jpg

So I thought I would share with you my "oh crap" moment from last night. I thoght it was funny since I a m a rookie bike builder. Just thought some of you veterans would get a kick out of it. Enjoy! Ben

LOL! Good story. Don't worry to much, as long as there are no pieces left over when its all back together you'll be fine.

Whats in store for this "Ben" fellows winter rebuild? Engine? Bearings? Suspension? Details man we need details

Word of advice: if there's bits left after the assembly then make a bicycle out of them!



Yeah, tell us what yer planning 2do, we will either giggle or be impressed!
Seriously, tell us?

First of all I'm not near as meticulous as DRXRR with his rebuild, however my plans include:
CRF Fork conversion
powdercoat on rims, hubs, and spokes
recharge rear shock
brakes
plastics
vapor computer
dunlop 606's
general engine tuning (nothing too major it's already a one kick bike)
lots of powder coating on engine covers and controls
rewiring (previous owner used el cheapo connectors)
install led turn signals(not "needed" but am tired of signaling with my arm)
bark busters

We will see how the build goes contingent upon funding. Not sure what kind of money I'll be able to get my hands on (my financial manger is one tough cookie!!). So really it is kind of a budget build but thats the current list of hopes. How far it gets and how long it takes may be a different story but hoping to be done within a few months. BTW if anyone wants to buy a perfectly good front end assembly off of my 02 BRP let me know I'm getting rid of everything from the rims to the bar clamps (to fund the new conversion) Ben

That's a good list, I wont giggle; out loud anyway I just bought a set of CRF450 forks and will be doing the conversion soon too. Still need to get the bearing kit (no machining required) and for simplicity would like a CRF front wheel, axle and spacers so i'm running a whole CRF front end.

So with the 606's I presume you're staying with the 18"/21" wheels, any inclinations to do 17's? Wink wink say no more

Edit:

Oh and are you thinking bigger rotor or just pads for the brakes. I just had a really bad experience with the EBC supermoto rotor. Avoid that P.I.T.A if you can...

Eventually I would love to do a set of 17" supermoto wheels but for now I'm just going to stick with the 18 and 21. Not totally sold on 606's but they seam to be the standard for dual sporting. Would be open to suggestion on a tire that is dot approved and can handle street and rocky(mountainous) terrain about 50/50. Ben

benjamin1031 wrote:Eventually I would love to do a set of 17" supermoto wheels but for now I'm just going to stick with the 18 and 21. Not totally sold on 606's but they seam to be the standard for dual sporting. Would be open to suggestion on a tire that is dot approved and can handle street and rocky(mountainous) terrain about 50/50. Ben

I'm running the 606's on my XRR. They probably see 60/40. Been holding up pretty good considering how many wheelies I like to do I'm sure they'd last longer if I'd stop doing that so much... LOL! yeah right

enigma racing did my front end such nice job it also allows for the gpr damper just under hadle bars

Very cool your going to have fun with the rebuild! Becarefull removing the swingarm pivot, it can be a bear. Same with rear axel adjusting bolts in the swing arm. Use lots of Liquid Wrench or other product to help break thorugh any corrosion.

On your wheels, I would not recommend powder coating stock rims and the spokes/nipples. That is a lot of effort, but I understand that heat from powder coating can soften rims, and the front rim is prone to cracking on XR650Rs. Mine was cracked and no good, did not know it till I sent the wheels to Woody's Wheelworks for a full rebuild. New rims and oversize spokes from Woody's would be great, but its costly. Otherwise I would stick to just truing the stock wheels and making sure the rims and spokes are in good condition. Check carefully for cracks in the front rim. [/b]

Thanks DRXRR!! The fron wheel I have is aftermarket but I'm planning on switching to a CRF front end entirely anyways. You don't need a XRR front end as a spare do ya??? Can't start my swap till I sell my current front end ( boss said ). Will definately head your warnings on the swingarm! Any other advice for me? Ben

Score!! I found an emig racing triple clamp on CL for 250.00!!!!!!!!!!!! Going to get it tomorrow. I also just bought forks with a fresh rebuild from an 05 CRF250 for 200.00 bucks on eBay!! I can't wait for spring!!! Will post pics of the swap soon! Ben

Keep us posted on the build! I'm going in for surgery in 2 weeks, Ill be splitting the cases as soon as I'm able to sit on the stool at the work bench!
I have my boys for the heavy lifting! I'm getting all the goodies for the project.

Got the triple clamp, forks and new pro taper fat bars on!!
Also on the floor in the garage:
Dunlop 606's
Excel Rims (black)
Spokes
Trailtech Vapor
Rear fender
ASV controls
Cycra Bark Busters

This represents my to do list but soon I will be on the trails!!

Is it just me or is the backend slightly low ?.

Keen eye my bretheren from across the pond!! The rear tends to ride low when the rear shock is out. Which by the way I just had rebuilt by my local shop. It was a good thing I did because they say "It was the worst they'd ever seen."

benjamin1031 wrote: Keen eye my bretheren from across the pond!! The rear tends to ride low when the rear shock is out. Which by the way I just had rebuilt by my local shop. It was a good thing I did because they say "It was the worst they'd ever seen."

Ahhh that explains it and there was me thinking the rear wheel wasn't there just shows what little I know and why Burp is a 650R Goddess all hail Burp wherever he is

So I'm very excited to report that my beast runs again!!! I have to admit that running without some act of god was somewhat shall we say "questionable." I made a very bad mistake when I first started. I unplugged all the wiring thinking my memory was better than it was. So at this point I have it running but the only way to shut it off is to cut off the fuel. While I have a few issues to iron out my piggy runs again!!! Pictures to come soon.

benjamin1031 wrote:So at this point I have it running but the only way to shut it off is to cut off the fuel.

Ah, how your post makes me get all sentimental now, remembering back my youth vaguely with the stupid things I used to do...
Here's an idea from a now-wise well-salted bike-dickhead: put it in 1rst gear, pull brake & let out clutch? I bet you it'll stop a lot quicker than waiting until it petrol-starves

Nudge nudge bro, and some piccies will go down well

It's kind of hard to stall the engine out when your wheels aren't present.

[img][/img][img][/img][img][/img]

I know crappy pics from my iPhone but pics none the less. Haven't had much time to work on it lately but all I have left is the installation of the Vapor comp, hub powder coating, wheel lacing and reassembly. I can hear the snow melting on the San Juan Mountains!!! Maybe I'll do a tune up ride in Moab first... Yipeeeeeeeeeee

Also, something I failed to mention... I figured out the wiring so now I can even shut my bike off after I start it. It's the little victories that make it all worth it. hahaha

Put in a work day on the piggy! Just lack a couple of finishing touches before ill be able to ride again!! Those touches are fill and bleed the front brake and install the front wheel. I can't wait to show you guys!! Pickies to come soon... Ben

I'll let the pictures speak for themselves.
[img][/img][img][/img][img][/img][img][/img]

BIKE looks good ,
Are you happy with the LEOVince exhaust ?

Mad Frosty wrote:BIKE looks good ,
Are you happy with the LEOVince exhaust ?

It's what came with the bike when I purchased it so I really don't have a comparison. It's labeled as "white brothers" but they sold out right? It's a little loud for my taste but I've not had any issues with it. Ben