PROJECT 96 XR630

[Mick DMember]

A week of solid rain has seen most of Northern NSW inundated with floodwaters and me bored to tears. The floods meant there was to be no riding this weekend, so I figured I would find a project in the shed to get my teeth into. There is no shortage of projects in my shed but there was one that really stood out.
A 96 XR630 with a fried top end has been standing unloved in the shed for the last 6 months waiting for me to get motivated and fix it. I have been robbing parts off it to keep the other XR’s running and if I didn’t do something soon there would be nothing left to restore!!

I sat and sipped a beer considering my options, do I just tear the top end off and fix what needs fixing or strip the bike completely and start from scratch with a full restoration? After 5 minutes I decided that I am going to give it a full restore.
So armed with a carton of beer I tore into her.

It didn’t take long and I had her stripped down completely, as a previous owner in their “wisdom” had painted the frame with a paintbrush, I decided that I would take the frame to get sandblasted and resprayed. I am opting for a silver or dark grey at this stage but any suggestions would be appreciated.

Once I had the engine on the bench, it was time to stripe it down and see what the rattles and smoke was all about.

Just as I thought, a lack of oil has seen a nicely toasted cam and rocker gear.

Hmmm This doesn’t look good,the cam has chewed into it’s carrier in the head a bit,dunno what I am going to do about that yet, or if anything can be done at all. Suggestions anyone?

Then it was time to pull the head and barrel off to see what sort of carnage the bore and piston had been subjected to.

Hmmmm, the barrel doesn’t look to bad, I could just get away with a hone I think.

Although the piston hasn’t fared so well as it has a score mark on the skirt and a score across the ring grooves.

Now here comes the questions.

I was told when I bought this bike that it had a 628 kit installed, where would I get another piston and rings to fit at a reasonable price?
And how can I be sure I am getting the right size? The piston has a heap of numbers stamped into the top and they mean nothing to me.
They are as Follows;

099.93
07703-3
8564DB

Can anyone shed some light on what that all means??

As you can see I have a bit of work ahead of me before I will be roosting up the trails on it, I will add to this thread as I progress with the project. I will be trying to do this on the cheap by begging, borrowing and stealing parts if I can, as I have two kids that race MX and keep my bike funds at a minimum. So if anyone has bits and pieces for XR600’s, I would love to hear from you.

Needed.
A cam, standard is OK.
2nd hand after market pipe to suit ,stainless Staintune headers.

[glennMember]

Isant it amazing what we can get done on a rainy day,,, you know you now have to wait for another flood to start to put it back together

[Mick DMember]

Slowly but surely I will put her back together again.It is a good excuse to sip a beer or two in the shed.

[DavidMember]

Mick go see Lyndsay ProBore (6581 2533)about the head with the worn saddle area, he will fix that easily, he will also be able to make sense of the piston for you and will be able to sort a new one, he actually supplies the dealers in the area with pistons and rings, something the dealers wont tell you, you should see the repair he pulled off on the “unrepairable cases” he just did for me, and very reasonable for Old Bulls, dont forget to tell him I sent you and he will charge you $20 more and give it to me:side: …..did I say that or think it:blink:

[BillMember]

Mick the head and rocker cover will have to be retunnel bored and bearings fitted if you want to salavage it but you will have to take it to probore and dont think it would be worth it but its worth Giveing Lynsay a look.

Will see if i can get a cyl head with bent valves (if he still has it )

[Mick DMember]

I have a spare head as it turns out and it is in much better nick than the one I pulled off it. Might jam a seal kit in it and see how it goes.

[BillMember]

Sounds the go mate have you checked out the valve and guides ect

[Mick DMember]

KTM Bull wrote:

Quote:

Sounds the go mate have you checked out the valve and guides ect

Nah I haven’t pulled it apart yet. I will need some work I am sure.

[drewMember]

paint the frame orange!!!! You know you want to!

someone had to say it! menace is stuck without a connection by looks of it.

now on a cereal note.

Mick are you going to get the head ported?

i’d see what the head will cost to get repaired, as a spare . or are the 600 heads reasonable to get hold of?

[Bruce CurtisMember]

Honda topends have always been a bugger for this, the old 750/4s used to suffer oil starvation at revs and pick up the cam saddle material and pookak themselves.

I have seen worse fixed, and been reliable for donkeys.

Bc

[Anonymous]

Chrome the frame, it will look awesome

[Mick DMember]

Actually I have decided to paint it white again.

[Anonymous]

I think white is best Mick. It would have been funny if you it was chromed though

[Brendon CarreMember]

Good luck with the rebuild mick, missed you on this weekends ride mate, there was nobody to take pics of me upside down or flat on my back!!

[Mick DMember]

Moto wrote:

Quote:

I think white is best Mick. It would have been funny if you it was chromed though

Chrome would be a bit Woggy,me thinks.

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