XR No 5

Bought a rough XR back in June this year which needs a fair bit of work.  It came with a few nice extras but otherwise was pretty bad.  My plan is to restore it back to its former glory, or at least get it as good as I can without breaking the bank.

2003 XR with CRF front end, FCR40 MX carb, Gold supermoto wheels plus offroad wheels.  Thats where the good news stopped.



On closer inspection I found that the countershaft is worn and will need to be replaced..



Along with the countershaft the bike needs a new clutch, new swingarm bearings, FCR40 carb boot adapter to use the std airbox as I dont like the idea of the cone filter.  I have a replacement transmission, new clutch, new brakes (caliper and disc sm setup) and various other parts ready to go..

The engine will be getting stripped and depending on what I find may have new bearings and a new rod & piston while I am in there.

I am nearly ready to strip the motor and get the frame, swingarm and subframe powder coated along with a few other bits..

This is where I am at the moment...



I will post up progress soon..

More piccies please   

Going to open up a 2003?
ALL bearings & seals new, plus CS, plus.............
crank, clutch, piston, valves etc etc etc, whatever you will find - and you will find stuff, that's normal for such an age.

But, it's also worth doing it, you'll end up with nigh-on new then   

I don't get it Burp? You think all that will need doing or not? Never had to rebuild the motor on any of the other XR's I have had so this is all new to me. Not sure what to expect really, if the countershaft is wrecked I was just guessing the rest of the motor might be too!

Sorry, what I mean is that when you open an engine - which is quite a bit of work in any case - you replace ALL that is needed. And, this thing being old already (10+ years!) means I'd renew all what is a bearing or seal for starters, plus whatever you will find.... and I bet that will be more than just the CS.
Pay attention to everything but especially the crank, and use the workshop manual (which you DO have I hope?) for the various things to check.
Hey, you'll end up with 2 things: a new engine plus the knowledge all is fine, so piece of mind for a long time to come!
Have fun!

Ok cheers. Yes I used to work for a honda dealer here in South Wales so have 'borrowed' the workshop manual. Plus my uncle in law is one of the mechanics who has worked there for 15 years so he will be doing the motor work for me. I will post up what I find in the next few weeks and take plenty of pics..

"plenty of pics"


LOL, Mauser will be glued to the screen       
Sounds like you're organized, great!

Going to the powder coaters tomorrow to drop some stuff off so will get some before pics. Need to get the motor cleaned before it comes apart too. By the looks of the bike it hasn't had much off road use, but that's why the countershaft is wrecked. Lots to do..

Been down the coaters today and dropped off most of the bike.

I need to get my hands on the inner plates from the swingarm or at least 1. Honda don't list these individually only as a complete swingarm.



Does anyone have any ideas where I can get one?

have you tryed your local honda dealership , if not one should be able to repair yours and recoat it ,
good luck
mike

Easy , find someone in your area who does CNC laser or water cutting and have exact copy of the part made .

A handy mate of mine is going to knock some up for me so all sorted   

Parts should be ready from powder coating next week too   

Frosty,

who gave you the right to get clever here hmm?
Excellent idea, was going to say same - but that handy mate will probably effect same without millions worth of machinery, just a bit more work then.

You dont need to buy the machinery just have the part made by someone who already have the equipment , the cost to add one small part to 1,5 X 3 meter sheet of metal they are commonly using its very small , and it takes 10 minutes to draw the part in the CAD software .

i have a spare swingarm with damage laying around with that part, if you need it just holla   

Ricko I may take you up on that! PM me a price etc if you like please! Top man!

Got some stuff back from the pc.

The rear shock is still silver   

It looks great   

That frame and swingarm look SWEEET! Can't wait to see the finished bike Are you aiming for a Supermoto or Dualsport or somewhere in the middle?

Love the black frame Look forward to the build!  

always intended to weigh the stock frame but..., so what does the stock frame/swingarm weigh?

subscribe.

Been slow progress lately due to a house move but back on track soon. Have a garage now too so things will start moving again now.

Slow its not exactly what i would call the progress   


  

Mad Frosty wrote:Slow its not exactly what i would call the progress   


  

Haha, ok so NO progress would be better.