XR680R build/rebuild

[XR-MANU]

It's nearly a year that I had a crank failure.At last I found the time to rebuild the engine, had most of the parts to built a 680 laying around for years now.After the crank probs I had a reason to go for it. With the engine out it was time to make my XR like I wanted it for a long time. Black coated frame and swingarm, red billet Applied clamps (ex-CRF) ,CRF steering damper, CRF plastic...

This is the start.
Enjoy.

Steering head modified to accept CRF steering damper.



Coated frame





Rebuild engine: all new bearings,cam chain,oil pump,dynamic balanced crank with Falicon rod and HD big end bearing (XR's only)...






680 kit : modified Wiseco 102.4 mm piston 11/1 with Nicasil cylinder



More to come.

[spaceman spiff]

all your stuff is awesome.
definitely looking forward to this!

[loy]

That's PORN! Love the colour!

Think I wrote that on thumpretalk too :hihi

[equalz]

Hey Manu love your bikes.... hey whats the number on that ohlins?

[carlsoti]

Black frames on the pig are so beautiful, they should've done it from the factory!

[XR-MANU]

Hey Manu love your bikes.... hey whats the number on that ohlins?

Thanks

Ohlins -> http://www.ohlins.com/Products/Mount...s/MI_HO086.pdf

[equalz]

Thanks

Ohlins -> http://www.ohlins.com/Products/Mount...s/MI_HO086.pdf

Thanq

[equalz]

Hey Manu i know that ohlins no longer has that shock, so if you come accross one please let me know!

[XR-MANU]

Check pm.

[XR-MANU]

Update.

Modified billet CRF clamps by Applied + CRF steeringdamper

[XR-MANU]

[carlsoti]

I can't help but think of a line from one of Andy Samberg's goofy songs...

"..and I jizzed..in my pants."

Very sexy.

[benscrazy]

I can't help but think of a line from one of Andy Samberg's goofy songs...

"..and I jizzed..in my pants."

Very sexy.

+1

[XR-MANU]

While we are doing some motor work further (cc-ing and maybe lightening the 680 piston a bit) a sneak preview of the body work.It's not final ,different things to come...

[spaceman spiff]

looks awesome man!
thanks for all the help, I just about finished up my crf rear end on mine.

[HardLiquor]

Wow! Very nice! Any idea what led to the crank failure? Was the old motor hot or just stock?

[XR-MANU]

It had a stage 2 Hotcam,HRC piston, 1mm OS intake valves, light flywheel, hi rev cdi, headwork, FCR 43mm,airboxmod,Twin Air SM filter with home made screen, Monnier EVO exhaust system... it was freaking fast

I hope it will be even better now.It should.

[Helikelby]

Thats amazing. I love the flat black on the frame. Looks great. That actually just inspired me!

[bmwelvis]

great build up as always ,manu

[pookiebear]

Looking like a champ. Wish I had some cool skills like that.

[XR-MANU]

FCR41 bored to 43mm by VHM.
Smoooooth power ... and plenty of it.

[gtirron]

How did you get the crf panels to fit?

[XR-MANU]

Elbow grease ...and a lot of time/ patience

It's not the first time I do this (check my other projects) but is always working out better and better .

[Carlos Dionisio]

looking good XRManu!!!

[XR-MANU]

A preview on the - homemade- graphics.



Damn... it should be "680RR"

[alwayswot]

XRMANU,

What kind of clutch are you using?

Do you know if there is a slipper type available in the market?

Best regards

[XR-MANU]

OEM clutch with the Scott Summers mods and a mix of OEM springs with HD HRC ones for a not too firm clutch pull.

[XR-MANU]

Just test fitted the can of the French Patevo system that I received this week. It's should give me a gain of 3hp over my current Monnier Evo system ,I hope so (it cost 800 euro new) . I bought it slightly used (60km riding time)



Check out the unique design of the endcap, the exhaust flow al so goes trough the side of the cap. But I think the inner plug will be gone after my run in.


This Patevo guy knows his job. His XR is Monobike (roadrace) champion in France and current leader of the running championship. He's using a very special engine with a 13/1 piston and a longer custom made Carrillo rod.
Check out his website and bike.
http://patevo.free.fr/index.php?lng=fr
http://patevo.free.fr/galerie/browse...0XR650R&lng=fr


Look for the carbon wheels

[XR-MANU]

The workshop took a little fat of the big Wiseco piston/piston pen to match the HRC piston weight as much as possible. Time to degree the cam and clay check the valve clearance.

[Carlos Dionisio]

do me a favor and expain how you do a clay test and what tools you need...
i need to know how its done...that worked out Wiseco piston looks tits!!

[XR-MANU]

http://books.google.be/books?id=Ro3_...esult&resnum=1
http://www.carcraft.com/howto/116_07.../photo_05.html

Google is your friend,my friend

[Carlos Dionisio]

http://books.google.be/books?id=Ro3_...esult&resnum=1
http://www.carcraft.com/howto/116_07.../photo_05.html

Google is your friend,my friend

ok..now that was helpful...always thought google was only good for porn..guess i was wrong..duhhh

[alwayswot]

OEM clutch with the Scott Summers mods and a mix of OEM springs with HD HRC ones for a not too firm clutch pull.

Ok thanks.

And the slipper clutch, do you know where can I get one?

Regards

[XR-MANU]

Don't think there is a slipper for the 650R.

[jgixxer1]

I wish I knew where to get a hold of some of those clamps that go at the bottom of the forks to hold a monobike style low front fender like that patevo.com bike. I'm in the process of trying to figure out how to mount an R1 fender on my cr500. If the website was in English I'd shoot him an email and make him an offer he couldn't refuse to make me a set.

Anyone ever mounted a Monobike style fender?

[stoo]

I wish I knew where to get a hold of some of those clamps that go at the bottom of the forks to hold a monobike style low front fender like that patevo.com bike. I'm in the process of trying to figure out how to mount an R1 fender on my cr500. If the website was in English I'd shoot him an email and make him an offer he couldn't refuse to make me a set.

Anyone ever mounted a Monobike style fender?

Can't you just use a fork brace and bolt the fender to that?

Although if your CR has USD forks then it's not really gonna work, I suppose...

[XR-MANU]

He uses clamps around the inner legs to mount the front fender.


UFO makes a front fender like that.

[jgixxer1]

After looking around a bit I found these headlight brackets that I can modify a little. Not necessarily the exact ones I'm gonna get, but atleast now I'm on the right track. $85 sounds pretty steep for what it is.

http://xpostreetfighter.com/detail.aspx?ID=68

[XR-MANU]

Update.

Clay checked the valves/piston and degree the Stage 2.

I had to cut the valve pockets deeper for some more safety with the extra compression.

[XR-MANU]

Airbox fixed.

I did the design in Auto Cad and a fellow member of the Belgian SM forum did the laser cutting for me.
A free flowing set up and it's holding the filter by it self.

[loy]

Looks very nice! Laser cutting is the shit, hehe.

I made mine with a simple saw
http://www.sporthoj.com/forum/attach...6&d=1230474447

[Wolfe]

My god. You MUST make a how to on the crf rear end!

[Crabenho]

Nice work MANU. My buddy and I are doing something similar to our XR's as we speak. Frames and gear are currently at the powdercoater. Couple of questions:

What year CRF fender set-up is that? (I second the "How To" request)

What did you use to polish / finish your engine?

More questions to come, I'm sure. Keep up the XR addiction.

Thanks,
Chris

[XR-MANU]

Thx.

The CRF rear end is from a 450 FROM '05.
I polished the engine cases with Scotch brite pads and WD40

[RRM]

WOW...very cool work. I am the "other one" building a supermoto with Crabenho. We talked about polishing the engine, so thank you for the info. Keep the pictues rolling

[baajes]

hmm just stumbled upon this page. Manu live's only a few miles away and i have seen his new beast in the flesh. I can assure you, it's just amazing!

Here some updated pics he posted at our belgian supermotard forum:

[XR-MANU]

Hebt zeker iets vandoen?

[baajes]

Hebt zeker iets vandoen?

nen discount op men zwarte plastieken? of toekomstige excells

[creepy]

Wow this is an awesome XR build.
Do you have any pics of the details on the subframe mounts and mods needed to mount the CRF tail on the bike?
Just a quick look with a CRF panel shows me how different everything lines up.
I was going to start with the rear fender but its really all integrated. Looks like the seat pan was trimmed to fit the panels which need to be placed along with the fender

[XR-MANU]

Some pics of my 680 after a 200 km ride out with a our local Supermotard forum, 30% off-road/70% small back roads.Some off-road section where very slippery after days of rain ,specially with (slightly) cut slicks and all the torque of the 680.Even with 15x 38 gearing and the rear wheel way back...