Busted xr650l

[XmikeR]

So last fall the bike failed on a trip up to Tunkwa Lk. It started to make a slapping sound and blowing blue smoke. With thoughts of broken rings, blown bearings, and other nightmares, I rode slowlyback to the cabin, and proceded to drink my problems away. Once home, I put the bike in the barn and forgot about it till lately. Well it's almost the season, so I'm going to need it running! I've rebuilt heavy equipment, but never gone into the guts of my bike, so I bought the Clymer manual, and cleaned out a space in the barn to work. After a bit of reading, and some pressure washing, I jacked the bike up, and got on with the job.





TheClymer manuals are great!Step by Step for dummies. Pull off the seatand the tank. Remove the spark plug wire, and plug. Pull the breather tube off, and remover the valve adjustment covers.



Once I'de removed the valve adjustment covers, I pulled the timing covers offandfound Top Dead Center on the compression stroke. This gave all valves the freeplay to check. Nothing to tell from that, so I turned the bike over while holding my finger on the adjustment bolt of each valve.



The problem is in the front right valve, It had a slap and knock to it while the other three felt smooth and tight. So the next step is to remove the valve/crankshaft cover.

Phew!And I thought it was a crackedpiston ring. Wooooohhhoooooo!:dr:

Will post more tomorow after having another go at it.The Nucks are kicking the crap out of Minnesota, and I want to catch the third:hb:

 

[Phoenix]

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[XmikeR]

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bring that popcorn and some beer over buddy. Im about to take er apart.

 

[sparklr]

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Phoenix wrote:

Classic:tup:

 

[Phoenix]

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I'd be right overbut I'm out of popcorn,

 

[joker650]

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The problem is in the front right valve, It had a slap and knock to it while the other three felt smooth and tight. So the next step is to remove the valve/crankshaft cover.

Phew!And I thought it was a crackedpiston ring. Wooooohhhoooooo!

SO what do think .....?

Worn valve guide?

If the guide is worn enough that could have caused the oil burning also.

Was the filter clean?

 

[XmikeR]

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Joker, Yup, the filter was clean . I had just replaced it and the oil before the fatal ride.I pulled off the valve cover and had a look, I found my rockers are quite worn, and the cam lobes as well. Im going to micrometer them tomorowto see if i need to replace.I took the valve assembly off, and cleaned it up a bit. WhenI hadit runningdown here, it wasa bit too rich, and then i took it up there, sothere is a lot of soot and creosote build up on the valve heads, and the piston head. And yes I do think it's the valve guides, or the front right one in particular. Im going to have the valves lapped and redone. It dumped quite a bit of oil getting back to the cabin, so that would explane the burnt crap floating around on top of the piston. The piston itself looks pretty good, and the cylander walls are ok too. I'll post some more and some pics tomorow. cheers.

 

[sparklr]

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Hmm, looks like beverage consumption costs will quickly overtake repair costs.:shock:

:hb:

 

[XmikeR]

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Part 2



Back to the beast..... I pulled the carb and the exhaust off.



Went on to pulling off the cylander head cover. Its a bit of a jigsaw trying to get it out, it only works one way. The rockers are built right into the cover. Easy!!!



Made sure that the cam/timing chain was nice and tight, and hadn't jumped a tooth. It was good to go, as was the chain tensioner.



Carefully, soas not to drop the chain off the bottom gear, I tied it up with wire, and removed the head.



Im going to take the rockers, camshaft, and head to the shop. Going to have a valve job and lapping. Also I'll get a pro opinion on whether I have to replace the cam and rockers. I mic'd them, and they were within the service limits, but still quite worn. Pulling the bike apart made me appreciate some good penetrating lubricant! And im not talking about the moovit either.



More to follow after my journey to the machine shop.

 

[tomcycle]

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MIke The only name I could come up with to do the machining is

Mongoose Machine
& Engineering
#1 - 1943 Broadway Street
Port Coquitlam, BC
Canada, V3C 2N2

http://www.mongoosemachine.com/index.htm

give em a call and see what they say

Maybe someone else here could recommend a good motorcycle machine shop?

Tom

 

[joker650]

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U could pm Ryanwright on this site.

He has a machine shop and does bike motors.

But he is here in the'Loops.

 

[XmikeR]

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Thanks guys. I found that Clearbrook Yamaha does it's own machining. Im going to take it it to have the head done tonight.

 

[Island Hopper]

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I would second Toms suggestion for Mongoose Machining.... I've been shipping work to them since the late 70s and they've always been good.....


How many KMs on your Honda at this point?

 

[XmikeR]

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The bike has about 25000km on it. Two years of hard riding. I want it done this week, so I'm not shipping it, or driving it too far.

 

[skidmark43]

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I too have had good luck with Mongoose here in PoCo.

They've mostly done boring & replating (nicasil) for me. For other machining I've been a customer of Wally Routledge in Langley. Brilliant guy who several dealers sub their work to.

 

[old trials guy]

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Of more concern on followers and cams is the degree of "galling" or pitting. Being hard surfaced components even slight roughness is not a good sign as once the surfacing is penetrated the part will deteriorate rapidly. Also, Honda plain bushes cams into cylinder heads so inspect the bearing and journal surface carefully. RFVC heads use a complicated rocker system and high wear is not uncommon.

I too highly recommend Mongoose. Jayisa great guy with a ton of knowledge. I wouldn't take my machining needs to anyone else and they are the best for high performancevalve grinding as he has state ofthe art equipment.

My 2 cents....otg

 

[joker650]

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Cam-it



Get that power u always wanted.:ted:

 

[XmikeR]

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:ted:.........................................OK

 

[Bugsinteeth]

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Glad you are looking into getting the Red beast ready for spring.

PM sent regardingrepair work

 

[XmikeR]

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New Rockers $200

New Cam $200

Headwork $300

Asst. gaskets and goodies $100

Exchange rate $100

Getting out and Riding with you guys again...........priceless



Some things in life can't be bought, for everything else

there's MASTERCARD!

(just waiting for parts delivery from Cali now, more updates to follow)