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Old 23-01-10, 06:15 PM   #1
Tim in Belgium
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Default Honda XR600R Engine Swap Pt.1

As I had a free afternoon I thought I'd make a start on the XR engine swap after it gave out on me just outside of Helmsley at the end of October.

One XR up on its newly purchased stand.



One replacement engine from a breaker, with guarantee fast running out, must get it in!



Remove side panels:





Remove tank and seat:



Undo front sprocket stuff, and various control cables:



The complicated wiring 4 of the 5 connections that had to be undone:



Carb removed and strapped to frame:



Exhaust removed too:



Drain the metal flake effect oil, not good:





Remove all engine mounts:



Then lift out engine:





Next jobs are to flush out the frame/headstock oil tank, clean the screen filter, clean the replacement engine, touch up a few bits of the frame with paint, mount the new motor, get a front sprocket that matches the splines on the output shaft, connect 5 wires, oil lines and control cables, change oil and filter on new motor, fit bodywork, start the beast up, then LETS OFF ROAD!
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Old 23-01-10, 09:34 PM   #2
Tim in Belgium
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Default Re: Honda XR600R Engine Swap Pt.1

Slight wiff of petrol throughout the house after I spilt a few hundred mls whilst emptying the tank
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Old 23-01-10, 09:41 PM   #3
the_lone_wolf
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Default Re: Honda XR600R Engine Swap Pt.1

Chop chop Timbo, we leave on Wednesday
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Old 23-01-10, 10:35 PM   #4
speedplay
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Default Re: Honda XR600R Engine Swap Pt.1

The beauty of dirtbikes..

Next to bugger all plastic bits to remove before you get to the insides
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Old 24-01-10, 12:01 AM   #5
Tim in Belgium
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Default Re: Honda XR600R Engine Swap Pt.1

But they Fubar on you when you least expect.















PS Lozzo if you are reading, how's the tool chest??
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Old 24-01-10, 09:46 AM   #6
speedplay
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Default Re: Honda XR600R Engine Swap Pt.1

Quote:
Originally Posted by Tim in Belgium View Post
But they Fubar on you when you least expect.

True, but they tend to get a bit more of a hard life.
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Old 24-01-10, 09:27 PM   #7
Tim in Belgium
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Default Re: Honda XR600R Engine Swap Pt.1

Haven't had the chance to work mine hard yet
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Old 21-04-10, 08:17 PM   #8
Tim in Belgium
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Default Re: Honda XR600R Engine Swap Pt.1

This is going back together now after a bit of a hiatus. I'd redone the wiring connectors where there were differences with the original loom. A few days ago I flushed/washed out the dry sump tank in the frame that had been contaminated with various scraps of metal. Yesterday I finally swapped the spark plug round (it had taken me a while to find a socket to fit)

This evening I chucked the "new" engine in complete with mud:



Bolted up the mounts:



Carb has now been attached to engine and air filter/box. Wiring is all attached, just working out wher a few of the breather hoses go, and will buy a new oil filter for it on Friday evening. So hopefully will have it running by the weekend, then I'll just be waiting on a front sprocket that fits, that was ordered today too.
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