Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Honda Tech
Honda Tech Honda Tech Forum - For Questions specific and of interest to Honda riders only.
Photo by Daniel Rintz, Himba children, Namibia

The only impossible journey
is the one
you never begin

Photo by Daniel Rintz,
Himba children, Namibia



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 1 Aug 2004
Registered Users
New on the HUBB
 
Join Date: May 2004
Location: London, UK
Posts: 8
Xl600lm monster

Why is it that fettling with bikes usually opens up a large can of worms?

I decided to replace my cam chain, tensioner, and guides as it was getting a bit noisy. So setting aside a few days to get on with it i got out the spanners.

Everything went fine, engine out of frame on work bench, rocker cover off, i started to undo the cylinder head bolts and noticed one very under torqued compared to the others!Sure enough when it came out i noticed that tell tale sign of aluminium in the bolt thread arrgh!!!

Resolved to the fact that it was going to have to be fixed, i unbolted the barrel. Inspecting the bore and piston, i could see it was time for a rebore. time for horror number two...

On measuring the bore and piston i noticed it wasn't anwhere near the 100mm for the Xl but nearer 97.8 of the XR600.

So now i realise that the previous owner has replace the standard XL barrel, piston, and head (cam-shaft is XR spec to)with that from a XR! Not only that but when i cleaned the piston i noticed it stamped with 1.00mm! so it has already been rebored a couple of times!

...So my question after al this ramble is...

is the barrel at it's rebore limit (it has a steel liner not coated ali)?
Or should i get it re-sleeved back to original XR spec?

Is there a good and trusted company in or around London to get this done (or in the UK)?

Are there problems waiting to happen with any of the other components because of this XL/XR mix?

Cheers

Stuart (off the road)
Reply With Quote
  #2  
Old 3 Aug 2004
Registered Users
HUBB regular
 
Join Date: Jul 2001
Location: Norway
Posts: 68
Dont worry, the xlm actually has a bore of 97.0 mm, but i am not surre of how big overbore you can have on these bikes. Stripping the treads on these bikes is rather common.

frode
Reply With Quote
  #3  
Old 3 Aug 2004
Registered Users
New on the HUBB
 
Join Date: May 2004
Location: London, UK
Posts: 8
Frode,

Thanks for your reply

I've only just found this out! both the Clymer and Haynes manuals said that the 87 XL model where 100mmx74mm,bore and stroke, i suppose it just shows that you can't beleive everything you read!!!

I found out that the bore and stroke is actually 97mmx80mm (same as the XR) on the German site: www.xl600.de

Apparently Wiseco do a 100mm piston which is 3mm over-size! I have spoken to an engineer and says it is alright to go this large.

...But know i've found out that the con-rod needs replacing as well!!! what a money pit this bike is becoming!

Cheers

Stuart
Reply With Quote
  #4  
Old 4 Aug 2004
Registered Users
Veteran HUBBer
 
Join Date: Dec 2001
Location: St-Niklaas, Oost-Vlaanderen, Belgium
Posts: 127
Hi Stuart,

I've been riding an XL600LM overland to S-E-Asia,still gotta continue to Oz.It's an '86 engine which i rebuilded as well.Didn't have any problems with the piston or big things like you mention.But had problems with alu treads coming out on 3 out of the 4 bolts of the cilinder.Putted helicoils and that did the job.No prob's now even after 45.000 k's.
I was just wondering.Wouldn't it be a cheaper solution an less pain in the ass if you buy another engine.If you look around,i can't imagine there so expensive.I bought my whloe bike for a 1000 Euro.And even later another one in better condition for my girlfriend(which she sold again) for 1250Euro.
Maybe i'm wrong but just thought abou tit as another option.
Hope everything works out well.

Cheers.
P.S.:I think that german website is reliable,so why don't you ask the people there?
Reply With Quote
  #5  
Old 4 Aug 2004
Registered Users
HUBB regular
 
Join Date: Jul 2001
Location: Norway
Posts: 68
I do not think there is an manual out for your model PD04,XL600LM , at least clymer is refering to the PD03, XL600R. The conrod is an pressfit solution whit the crank, so the only solution is to buy an new, that is horrible expensive. I know it is possible to buy an new NX650 engine, maybee there is posible to buy an XLM as well? I do not think crank shaft problem is comon on these RFVC engines, so an used bike/engine can be a solution. But as you have experienced, buying used is a lottery.

god luck
Frode



[This message has been edited by frnas (edited 04 August 2004).]
Reply With Quote
  #6  
Old 4 Aug 2004
Registered Users
Veteran HUBBer
 
Join Date: Dec 2001
Location: St-Niklaas, Oost-Vlaanderen, Belgium
Posts: 127
Hey,

I've got a copy of a workshop manuel.But can't help you on it right now as I'm in Thailand and I'll be home for a few weeks somewhere end of august beginning of september.If you still want it then,you can let me know.I 'll need to scan everything then.
Anyway,like I said before,a used engine could be a solution as frnas says as well.

Good luck!
Reply With Quote
  #7  
Old 5 Aug 2004
Registered Users
New on the HUBB
 
Join Date: May 2004
Location: London, UK
Posts: 8
Thanks for the replies.

I did think about a second hand engine, but the breakers i contacted had already taken parts off (for other braken XL's!), and you never know what your getting with second hand. I could end up in the same position i'm in now.

The engineer who is doing my rebore, also does crank-shaft rebuilds. Wiseco do a 3mm over-bore piston at 100mmm bore (629cc), and conrods as well.

I've worked out that it will cost a bit over a second hand engine, but i'll be getting a like new engine out of it, and i will at least know the engines mechanical history.

Thanks again

Stuart

P.s Bossit is the manual for the PD04 model? As i have the Haynes and Clymer, but they only cover the PD03.
Reply With Quote
  #8  
Old 5 Aug 2004
Registered Users
Veteran HUBBer
 
Join Date: Dec 2001
Location: St-Niklaas, Oost-Vlaanderen, Belgium
Posts: 127
Hey Stuart,

Seems that it's all gonna work out fine.Good to hear that!Yes the manual I'm talking about covers the PD04.If you give me your mail adress I'll drop you a line when I'm home and see or i can manage to scan and sent it,if you're interested.

Keep in touch,
Cheers,Bossit
Reply With Quote
  #9  
Old 7 Aug 2004
Registered Users
New on the HUBB
 
Join Date: May 2004
Location: London, UK
Posts: 8
Bossit,

Thanks for the offer of the catalogue,
My e-mail is

iamstuartjenkins at hotmail dot com (delete the spaces ;o))

Happy riding

Stuart
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now
, and add your information if we didn't find you.

Next HU Eventscalendar

HU Event and other updates on the HUBB Forum "Traveller's Advisories" thread.
ALL Dates subject to change.

2024:

Add yourself to the Updates List for each event!

Questions about an event? Ask here

HUBBUK: info

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.




All times are GMT +1. The time now is 19:56.