Part 3 - Honda XR600 Adventure Build

We’ve made good progress and the bike is slowly getting re-assembled. We’ve run into a few small issues that required some special orders – tank rubber / insulation above top frame tube, wiring insulation to run town main frame, washers for chain slider and a few others.
I tried to fit up some old tapered handlebars I had lying around, along with some universal adaptors however it wasn’t to be as the adaptors appeared to be different diameter to the bars themselves. I have settled on the standard size 7/8 bars for now – Pro-Tapers in a Henry /Reed bend. At least the cables all reach.
We fitted all new cables (Clutch, Throttle and Decompression Lever).
The clutch perch I had on the bike was broken. I had a spare universal easy pull perch and lever and it’s come up really nice with the new cable. Fingers crossed the clutch will hold up for a while.


This photo shows the decomp cable all in place, new spark plug cap and plug, new exhaust studs and the high pressure fuel line that we’re routing the wiring in. We might replace it with the genuine heat reistant material once it arrives as the fuel line wont fit into the plastic bracket that holds it and the oil line against the frame.


We ended up going for a new airbox. The old one was hacked up and had a few unessesary holes drilled into it.


We’re routing all the cables properly now, but getting them all into place in this photo after we re-wrapped and re-soldered some dodgy splicing that took place over the last 20 years. You can also see where we started to fit up the frame accessories (stand, peg mounts etc) as well at the gear shifter, brake pedal etc. A bit of work went into getting the brake pedal feeling ‘tight’ again, trying a few different shims and washer to space it out and getting it feeling new again.


Carby cleaned and back in place. Choke lever still broken – it’ll have to do.


We threw the muffler on to check everything cleared with the new airbox in place. You can see part of the updated chain guard as well. Also new grease nipples to the linkages and swing arm.


Trial fit of the new plastics. US model rear guard doesn’t have the light cut-out. I’m going to run a different setup on the numberplate holder, tail and brake though anyway. The flat rear guard adds to a smoother finish.


Case saver fitted. Sprocket all cleaned up, gear lever straightened and painted. Sprocket cover is being modified to fit over this for legalities and registration.


Rebuilt the throttle housing: It is a little worn with the ‘pull’ side cable hole a little more elongated than it should be. A good clean and grease and fresh coat of paint to seal it all back up.


Some goodies arrived in the post today from XRs Only. Awesome shipping…California to Sydney in 7 days. Very Happy.
I’ve picked up the rebuilt shock and fork from Tekniks. Nick showed me a project XR he’s working on too….that sounded exciting. Will get the springers fitted up on the weekend. It’s all coming together now. 

More updates soon.
Scott.