Great videos, thanks for the upload. I strongly recommend dipping every part in a tray of motor oil as motor goes back together. That first startup with dry metal on metal is very hard on the parts.
Hey thanks for commenting! I too had an issue with getting the cylinder off, and I had to use a rubber mallet to slowly knock it loose from each corner. Just be careful not to hit the fins too hard as they can break. The vibrations should eventually help dislodge the metals from each other. Hopefully this message helps and gets to you quick enough. Good luck with your project!
If the old cover has the old gasket stuck onto it then it may be that the gasket does indeed create some extra spacing, but I cannot confirm this. Maybe try to apply a thicker coat of silicone gasket maker and let it dry before connecting the case cover. It seems that the washer on the kick starter is pushing against the cover and stopping the action. Hopefully the replacement cover you're using is the correct one also. I wish I could be of more help. Hope you get the issue resolved!
Very good video, fingers tell a lot of good tips. Too bad there isn't a voice. But thanks a lot for these great video's! I will need them in a week or two when i'm rebuilding my engine from the base up.
Hey CJ, glad these vids will be helpful. We wanted to add voice too, but at the time our best option was labels. So awesome to hear you're rebuilding your engine. What is your plan? Keep it stock, or modify it? What year? Cheers!
@@XRLand Hi there, as i type i'm baking off the engine in an oven. I will do an original rebuild, only thing is i will have the cylinder bored to 98mm with a prox piston. I ordered a bunch of parts ($$$$$$$$ :S ) , a 2nd hand distributionchainguide, 2nd hand transmission axle with the sprocket on it, bearings that can't be replaced other than OEM. According to the partsorder i will start the end of Januari. Looking forward to it! Your video's will be a good guide as well!
Thanks for the update! Yes the parts add up quickly don't they $$$! A bit scary, but worth it when it all comes together. Have a smooth rebuild and enjoy the journey. Looking forward to seeing a video posted of her running!
Awesome tutorials man helped me out.. unfortunately I didn't read the description and installed the pulse generator rotor wrong so no big deal I will lay the bike on its side and pull the cover off but I couldn't figure why I was getting no spark I imagine that would do it!?
Does the kickstarter need to be preloaded and to what extent? I see you were pointing at some stuff while lowering the kicker. The book says line up the dots on the gear and shaft
I have a 1987 Honda xl600r and I have a issue with the kick starter. It does't want to recoil when I tighten down the crankcase but when I loosen the case up a bit it works. The kick starter spring is in place as it should be. Now does the gasket act as a shim too, I only used the silicone? But when I put on the old broken cover on and tighten it down it works. Any Information would be nice, Thanks
I have problem with my pig. The Kickstarter won't return in place if I kick it. But in some kicks I can still hear normal click like tdc but it won't return. I think the spring broke? Can you help me?
Thank you for making the videos. This is exactly xr650l guys need. This is the exact procedure from what I can tell. This is my first motor to get in to. Countershaft... I can't get the cylinder to break loose from the case, any ideas?
what are you doing to the kick start gears when you put the kick starter on and rotate it? I am currently in the middle of a rebuild and am stuck trying to get the kick starter on right
Me too! Finally got mine to fire up, but my kickstart lever won't return. I have been in there multiple times trying to preload the spring but it never seems to have enough (if any) preload. Any ideas?
Ronayers.com, but there are better places if you live on the west coast. I like babbits, rocky mountain atv, and bikebandit. Thanks for your comment. Ride safe!
At 2:55 you show install of pulse generator 180 deg off! Later views show you corrected it without notifying the viewer. I bet there are many viewers that wish you didn't catch it and kicked your ass off like they did! LOL
Good video's, but as ole mate said, not only is the pulse generator 180' out it is also initially installed back to front ( or upside down if you prefer) so the induction lobe doesn't pass directly in front of pickup coil. Hope people pick this up also, or there will be some tears in their cornflakes.
That is not fun. Did you replace the kickstarter lever, or did you replace the shaft that it rides on also? The shaft has a heavy spring that helps it return, and it needs to be properly set into a notch on the case. If you only replaced the lever, then it seems a bit odd, but I would then guess that the return spring broke. This happened to my brother.
cleanupguyable This is just a hobby, and I had not done an XR600 prior to this experience. If you're into mechanics and tinkering in the garage, then this is one of the perfect engines/bikes to begin with and learn on (An xr80 is another great bike to learn on). Having a good set of tools, and the correct tools, will make the job possible and more fun. I didn't have much experience prior to this rebuild, but I used the Honda factory service manual and it made it doable. Good luck if you decide to tackle the job. Greetings from California/US.
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put oil into oil pump (0:16)
oil pump (0:44)
oil pump bolts (0:58)
replace oil pipe seals (1:03)
oil pipe (1:24)
oil pipe bolt and nut (1:33)
cam chain sprocket (2:03)
cam chain tensioner (2:23)
cam chain (2:30)
primary drive gear (2:45)
pulse generator rotor (2:50)
oil pump drive gear (2:57)
drive gear lock nut and washer (3:03)
pulse generator (3:12)
oil pump driven gear (3:27)
kickstarter shaft (3:35)
idler gear and bushing (3:57)
clutch outer (4:07)
clutch lifter rod and push rod tip (4:15)
thrust washer (4:24)
clutch center (4:28)
clutch lock nut and washer (4:37)
clutch pressure plate and clutch plates (4:48)
clutch springs and bolts (4:53)
Great videos, thanks for the upload. I strongly recommend dipping every part in a tray of motor oil as motor goes back together. That first startup with dry metal on metal is very hard on the parts.
Hey thanks for commenting! I too had an issue with getting the cylinder off, and I had to use a rubber mallet to slowly knock it loose from each corner. Just be careful not to hit the fins too hard as they can break. The vibrations should eventually help dislodge the metals from each other. Hopefully this message helps and gets to you quick enough. Good luck with your project!
I did tighten it! Thanks for checking! Have a great week.
If the old cover has the old gasket stuck onto it then it may be that the gasket does indeed create some extra spacing, but I cannot confirm this. Maybe try to apply a thicker coat of silicone gasket maker and let it dry before connecting the case cover. It seems that the washer on the kick starter is pushing against the cover and stopping the action. Hopefully the replacement cover you're using is the correct one also. I wish I could be of more help. Hope you get the issue resolved!
Después arrancó? Creo que pusistes captor mal
Siii
Very good video, fingers tell a lot of good tips. Too bad there isn't a voice. But thanks a lot for these great video's! I will need them in a week or two when i'm rebuilding my engine from the base up.
Hey CJ, glad these vids will be helpful. We wanted to add voice too, but at the time our best option was labels. So awesome to hear you're rebuilding your engine. What is your plan? Keep it stock, or modify it? What year? Cheers!
@@XRLand Hi there, as i type i'm baking off the engine in an oven. I will do an original rebuild, only thing is i will have the cylinder bored to 98mm with a prox piston. I ordered a bunch of parts ($$$$$$$$ :S ) , a 2nd hand distributionchainguide, 2nd hand transmission axle with the sprocket on it, bearings that can't be replaced other than OEM. According to the partsorder i will start the end of Januari. Looking forward to it! Your video's will be a good guide as well!
Thanks for the update! Yes the parts add up quickly don't they $$$! A bit scary, but worth it when it all comes together. Have a smooth rebuild and enjoy the journey. Looking forward to seeing a video posted of her running!
Awesome tutorials man helped me out.. unfortunately I didn't read the description and installed the pulse generator rotor wrong so no big deal I will lay the bike on its side and pull the cover off but I couldn't figure why I was getting no spark I imagine that would do it!?
Does the kickstarter need to be preloaded and to what extent? I see you were pointing at some stuff while lowering the kicker. The book says line up the dots on the gear and shaft
I have a 1987 Honda xl600r and I have a issue with the kick starter. It does't want to recoil when I tighten down the crankcase but when I loosen the case up a bit it works. The kick starter spring is in place as it should be. Now does the gasket act as a shim too, I only used the silicone? But when I put on the old broken cover on and tighten it down it works. Any Information would be nice, Thanks
Hey mate did you ever work out what was causing this problem I’m experiencing that atm can’t work it out
Thanks
I have problem with my pig. The Kickstarter won't return in place if I kick it. But in some kicks I can still hear normal click like tdc but it won't return. I think the spring broke? Can you help me?
I can't get the audio to play, I have to do a top end on my 86 XR600R and these videos would really help me out
clutch bolt how NM?
Good videos,
But what is the pulse generator rotor alignment? I've seen that you changed it after showing us at first, what's the actual alignment?
The first installation is incorrect. When the video progresses, the proper alignment is shown.
Thank you for making the videos. This is exactly xr650l guys need. This is the exact procedure from what I can tell. This is my first motor to get in to. Countershaft... I can't get the cylinder to break loose from the case, any ideas?
what are you doing to the kick start gears when you put the kick starter on and rotate it? I am currently in the middle of a rebuild and am stuck trying to get the kick starter on right
Me too! Finally got mine to fire up, but my kickstart lever won't return. I have been in there multiple times trying to preload the spring but it never seems to have enough (if any) preload. Any ideas?
These are great videos but there is no audio
Does the timing chain have to line up with a mark on the lower cam chain sprocket?
Does the outer clutch have to line up with any marks? I have a clymer manual but it is a little confusing
Nice videos very helpful! Where did you get new parts?
Ronayers.com, but there are better places if you live on the west coast. I like babbits, rocky mountain atv, and bikebandit. Thanks for your comment. Ride safe!
04:46 I hope, you fix clutch lock nut on shaft.
At 2:55 you show install of pulse generator 180 deg off! Later views show you corrected it without notifying the viewer. I bet there are many viewers that wish you didn't catch it and kicked your ass off like they did! LOL
yz250a Good catch! I would have said something had I noticed myself. Thanks for your helpful addition.
Good video's, but as ole mate said, not only is the pulse generator 180' out it is also initially installed back to front ( or upside down if you prefer) so the induction lobe doesn't pass directly in front of pickup coil. Hope people pick this up also, or there will be some tears in their cornflakes.
I cant get my kickstart to jump back up after replacing it, do you know why?
That is not fun. Did you replace the kickstarter lever, or did you replace the shaft that it rides on also? The shaft has a heavy spring that helps it return, and it needs to be properly set into a notch on the case. If you only replaced the lever, then it seems a bit odd, but I would then guess that the return spring broke. This happened to my brother.
XRLand yeah i replaced my spring and hooked it onto the case but it doesn't seem to come back when kicking it.
@@ItsComplicatedAF hello, did you solve the problem?
@@olegariotorres5519 hi, no i sold the bike shortly after replacing the spring idk if it got solved or not.
@@ItsComplicatedAF oh okay, thanks
Is that your Job or did you do something like that befor ?
Can I do this too without any experience ?
Greets from Germany
cleanupguyable This is just a hobby, and I had not done an XR600 prior to this experience. If you're into mechanics and tinkering in the garage, then this is one of the perfect engines/bikes to begin with and learn on (An xr80 is another great bike to learn on). Having a good set of tools, and the correct tools, will make the job possible and more fun. I didn't have much experience prior to this rebuild, but I used the Honda factory service manual and it made it doable. Good luck if you decide to tackle the job. Greetings from California/US.