Part 4 - Honda XR600 Adventure Build

Ok folks, so after a very busy Christmas period and not updating the build up for a while. Here goes the latest:

 
We retro-fitted a universal speedo to the standard mounting, which will do fine for the blue slip and down the track I plan on getting a digital unit with a few more functions. I’ve ‘borrowed’ the nice mirrors from my Husky.

 
I bit the bullet and got some new discs: RHK Quake wave discs Front and Rear. Nice.

 
A few of the Genuine Honda parts order. Oil return line, tank rubbers.

 
A beaut fork brace – billet. From RSW Racing in the states.

 
Nice new valve covers. You may have noticed the chipped one in previous photos.

 
I forget to take a step back every now and again to realise the overall progress – often getting caught up in the detail. After an afternoons work we could really see it coming together.

 
The Staintune headers had seen better days. We scrubbed, buffed and polished these guys to get them like this. Not bad eh!? New copper exhaust seals and new studs with anti-seize. You can also see the back of the cut down CR front guard here too.

 
Rear wheel assembly back together. New Disc. New Pads, Calliper sand blasted, cleaned then clear coated. Then rebuilt with new seals and polished pistons. Braided line. New wheel bearings.

 
Universal heated grips, new grips, and new donuts. Gotta figure out power for a accessories. Will tackle that later!

 
We got a new headlight and shroud from the states. I really like the look of it – keeping it original. Main problem is (didn’t think before ordering) US model is not road compliant so no high/low beam. Looking to retro fit H3 or H4 globe into that fitting. Might be interesting. Also threw on new JET barkbusters.


Here you can see the front brake master cylinder. Had a few drama’s getting this thing to bleed up. Full treatment on the caliper as per the rear. Braided line. New Disc. Borrowed an air powered ‘suction’ bleeder to get it happening, great invention.

 
Easy pull clutch perch. New cables. Heated grips LHS. 

 
Shock in. Chainguard on. New braided line. You can see one of the new gussets we added here too.

 
I threw the rack on for a trial fit, and to figure out what to do with number plate locating, tail light etc.

 
While we re-wired the front end and tried to figure out a lighting solution I got to planning a custom dash to hold a few switches, a 12v cig socket for charging etc. Here we are getting ideas.

 
All of the wiring has been re-sleeved in a plastic tube/shielding. All non-factory connections have been tidied up with waterproof connections as well.

 
 
Here’s the ‘final’ colution for the number plate/tail light/blinker set up. Again, borrowing from the Husky, I got some nice blinkers. LED light from Supercheap Auto. Not bad I reckon.

 
We tidied up the rear end wiring too. We’ll tuck this away eventually – but just to show how we’re keeping it neat!

 
Progress on the dash.

 
And yes, here we are getting excited. First lot of oil since the pull down.

 
 
And finally a test fit up of the new outfit – shrouds, tank, headlight, windscreen. 


We fitted up the tank the next day, checked oil levels and decided we’d see if she started. This is actually the first time my father heard it run…
Once we had the tank and everything on, we turned the fuel tap on only to see fuel flowing from the overflow. A stuck float bowl? That’s what we figured at first. We eventually got it sorted – took it off, stripped and cleaned again. Inspected the jets (#155 and #62) I’ll double check that…
But eventually she sparked up, only about 5 meaningful kicks actually. Used the old XR technique from back in the 250 days –and also the kill switch, full throttle and decomp in to clear it trick. Worked every time.

As you can see in the short clip I overlooked a couple of things, so may look like a bit of a goose in the clip (left choke on!)….but hey we were all excited to hear her fire up.