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XR680R build/rebuild |
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05-22-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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XR680R build/rebuild
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.  |
05-22-2009
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Supermoto Abuser
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Join Date: Aug 2008
Location: Santa Cruz, CA
Posts: 149
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all your stuff is awesome.
definitely looking forward to this!
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05-23-2009
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Supermoto User
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Join Date: Oct 2008
Posts: 14
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That's PORN! Love the colour!
Think I wrote that on thumpretalk too :hihi
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Xr650r-Sm and Husqvarna Wr 125 in the garage! 
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05-26-2009
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Supermoto Junkie
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Join Date: Aug 2006
Posts: 526
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Hey Manu love your bikes.... hey whats the number on that ohlins?
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05-26-2009
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Supermoto Junkie
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Join Date: Sep 2006
Location: Valley of the Sunburn
Posts: 3,269
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Black frames on the pig are so beautiful, they should've done it from the factory!
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Frustra fit per plura quod potest fieri per pauciora
A little nonsense now and then is relished by the wisest men.
*We* are the music makers... and *we* are the dreamers of dreams.
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05-26-2009
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Supermoto Junkie
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Join Date: Aug 2006
Posts: 526
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Quote:
Originally Posted by XR-MANU
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Thanq |
05-26-2009
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Supermoto Junkie
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Join Date: Aug 2006
Posts: 526
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Hey Manu i know that ohlins no longer has that shock, so if you come accross one please let me know!
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05-27-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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Check pm. |
05-28-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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Update.
Modified billet CRF clamps by Applied + CRF steeringdamper
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06-02-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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06-02-2009
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Supermoto Junkie
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Join Date: Sep 2006
Location: Valley of the Sunburn
Posts: 3,269
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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.
__________________
Frustra fit per plura quod potest fieri per pauciora
A little nonsense now and then is relished by the wisest men.
*We* are the music makers... and *we* are the dreamers of dreams.
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06-02-2009
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Supermoto Abuser
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Join Date: Nov 2006
Posts: 180
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Quote:
Originally Posted by 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.
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+1   |
06-09-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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06-09-2009
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Supermoto Abuser
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Join Date: Aug 2008
Location: Santa Cruz, CA
Posts: 149
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looks awesome man!
thanks for all the help, I just about finished up my crf rear end on mine.
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06-11-2009
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Supermoto Abuser
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Join Date: Jun 2007
Posts: 189
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Wow! Very nice! Any idea what led to the crank failure? Was the old motor hot or just stock?
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06-12-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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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.  |
06-12-2009
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Supermoto User
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Join Date: Jun 2009
Posts: 1
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Thats amazing. I love the flat black on the frame. Looks great. That actually just inspired me!
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06-13-2009
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Supermoto Abuser
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Join Date: Dec 2008
Location: greece,europe
Posts: 100
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great build up as always ,manu 
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"Yes,it's a supermoto... and yes, it's a BMW!!!"
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06-13-2009
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Supermoto Junkie
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Join Date: Mar 2006
Location: IA
Posts: 1,275
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Looking like a champ. Wish I had some cool skills like that.
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06-15-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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FCR41 bored to 43mm by VHM.
Smoooooth power ... and plenty of it. 
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06-17-2009
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Supermoto User
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Join Date: Aug 2008
Posts: 3
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How did you get the crf panels to fit?
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06-18-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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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 . |
06-18-2009
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Supermoto Junkie
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Join Date: Sep 2006
Location: Portugal
Posts: 1,075
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looking good XRManu!!!
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ZIPPER
94´XR600R
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06-18-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
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A preview on the - homemade- graphics.
Damn... it should be "680RR"  |
06-19-2009
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Supermoto User
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Join Date: Dec 2006
Posts: 28
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XRMANU,
What kind of clutch are you using?
Do you know if there is a slipper type available in the market?
Best regards
__________________
'97 Suzuki DR650 - sold
'01 Honda XR650R 'tarded
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06-19-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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OEM clutch with the Scott Summers mods and a mix of OEM springs with HD HRC ones for a not too firm clutch pull.
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06-20-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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06-26-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
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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.
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06-26-2009
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Supermoto Junkie
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Join Date: Sep 2006
Location: Portugal
Posts: 1,075
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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!!
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ZIPPER
94´XR600R
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06-26-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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06-27-2009
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Supermoto Junkie
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Join Date: Sep 2006
Location: Portugal
Posts: 1,075
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Quote:
Originally Posted by XR-MANU
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ok..now that was helpful...always thought google was only good for porn..guess i was wrong..duhhh
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ZIPPER
94´XR600R
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06-29-2009
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Supermoto User
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Join Date: Dec 2006
Posts: 28
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Quote:
Originally Posted by 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.
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Ok thanks.
And the slipper clutch, do you know where can I get one?
Regards
__________________
'97 Suzuki DR650 - sold
'01 Honda XR650R 'tarded
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06-29-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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Don't think there is a slipper for the 650R.
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06-29-2009
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Supermoto Addict
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Join Date: Jul 2007
Posts: 253
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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?
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06-29-2009
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Supermoto Addict
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Join Date: Aug 2004
Location: UK
Posts: 424
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Quote:
Originally Posted by 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?
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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... |
06-30-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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He uses clamps around the inner legs to mount the front fender.
UFO makes a front fender like that.
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06-30-2009
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Supermoto Addict
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Join Date: Jul 2007
Posts: 253
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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 |
07-01-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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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.
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07-09-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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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.
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07-11-2009
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Supermoto Junkie
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Join Date: Aug 2008
Location: Austin, Tx
Posts: 890
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My god. You MUST make a how to on the crf rear end!
__________________
2004 XR650R
"Yeah, its fast"
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Beautiful |
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07-14-2009
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Supermoto User
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Join Date: Oct 2006
Location: Northern Colorado
Posts: 80
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Beautiful
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
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SuperMofo
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07-14-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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Thx.
The CRF rear end is from a 450 FROM '05.
I polished the engine cases with Scotch brite pads and WD40
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07-17-2009
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Supermoto User
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Join Date: Mar 2008
Location: Dacono, CO
Posts: 37
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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
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'02 XR650R Sumo
'00 XR400R Dirt Only
'93 R1100RSL Sport Touring
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10-28-2009
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Supermoto Abuser
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Join Date: Apr 2008
Posts: 103
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__________________
It's cool to know nothing 
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10-28-2009
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Supermoto Addict
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Join Date: Sep 2004
Location: AALST-BELGIUM
Posts: 397
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Hebt zeker iets vandoen? |
10-29-2009
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Supermoto Abuser
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Join Date: Apr 2008
Posts: 103
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Quote:
Originally Posted by XR-MANU
Hebt zeker iets vandoen? |
nen discount op men zwarte plastieken? of toekomstige excells
__________________
It's cool to know nothing
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