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Project Grandson's bike - XT600Z

Discussion in 'Other Projects - Other Bikes (non 250's)' started by Murdo, Apr 1, 2021.

  1. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    My Bike:
    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, FT500 plus a few others.
    With the cases apart I was able to get the drive shaft out and stripped down.
    XT600 005.jpg
    I built up the splines with the TIG using an ESAB tool steel rod. Into the lathe with a tipped tool and took back to original OD.
    XT600 008.jpg
    Then made a holder for my 5" angle grinder to mount onto the carraige so I could used travel and crossfeed to recut the splines. I used a thin blade first to cut the edges on the slight angle to match the remaining spline, then a new square edge grinding disc to clean out the material between.
    XT600 011.jpg
    Cleaned the burrs off with a wheel in my Dremel and checked the fit. Then with the thin blade back in the grinder and turned 90deg I cut the groove for the lock tab.
    XT600 012.jpg
    Will do the gear selector shaft tomorrow.
     
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  2. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, FT500 plus a few others.
    With parts arriving he has been able to start bolting bits on.
    XT600 015.jpg XT600 017.jpg
    New repo instruments 'look the goods'.
    XT600 019.jpg
     
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  3. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    My Bike:
    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, FT500 plus a few others.
    Have the engine together now and he came over yesterday and we got it fitted and torqued up and the swingarm finally fitted (it pivots on back of gearbox) and back wheel in.
    XT600 engine 008.jpg
     
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  4. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    He came to stay over last weekend so we could spend more time on bike.
    He now has all the electrics in and working (just waiting on ordered battery to arrive) and I showed him how to cut and fold up a battery box from 2mm alloy sheet. I finished welding it today and painted ready for him to fit on Saturday.
    More XT600 008.jpg
    More XT600 012.jpg More XT600 010.jpg
     
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  5. kiffsta

    kiffsta Senior Member

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    It will be good as new , such an effort from where it was
     
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  6. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    My Bike:
    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, FT500 plus a few others.
    The boy had a busy day last weekend, got the front rim spoked up, tyre fitted and wheel in, seat re-foamed and cover fitted, speedo cable lubed and hooked up and brake hose fitted.
    XT600 001.jpg XT600 003.jpg
     
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    Last edited: Aug 11, 2021
  7. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    My Bike:
    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, FT500 plus a few others.
    We have had the engine running and all seems good. Got the tank painted too.
    KLR250 003.jpg
    And last weekend got the stickers fitted and clear coat on tank. Unfortunatly I got a run in the clear so will need a bit of attention.
    KLR250 018.jpg
     
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  8. ShaneP

    ShaneP Well-Known Member

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    Wow, seems your recovery has gone well, you've been very busy. Good to see. Your health, not just your work.
     
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  9. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Thanks Shane. I am a bit better but the bulk of the work is being done by the Grandson.
     
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  10. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Proud young man with his bike. He is now working two part time jobs during the school holidays to save up for rego and insurance. So proud of him.
    Tenere done 001.jpg
     
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  11. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    My Bike:
    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, FT500 plus a few others.
    Last Saturday night at 9.30pm I got a call to go and pick him up from about 10Km out of town. He is a bit quiet about how it happened, but the result is that the piston broke up.

    Sore head 011.jpg
    It looks to have been cracked through the oil ring holes for some time as there was carbon deposits through the crack.
    Sore head 013.jpg
    After breaking up the piston got smacked with the balancer shaft (which runs very close to the crank) resulting in many alloy bits spread through the case.
    Sore head 015.jpg
    This required a full strip down and cleaning of all bearings, galleries and oil pump. Fortunately there was no damage other than the piston, as he said it lost power and he pulled in the clutch before it stopped. The barrel has a couple of small marks which I honed out and the head is untouched. With some new gaskets he has the bottom back together and is just awaiting a new piston kit.
    A shame as it has been going so well and he has been riding it everywhere (school, work, etc) but another of life lessons for him.
     
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  12. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Have a new Prox piston fitted and all back together. Waiting on him bringing new oil so we can start it.
    xxx 005.jpg
     
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  13. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    He brought over a new bottle of oil and we filled the tank and spun with plug out on drill to get oil pressure. Started on third kick and sounds good. He is now off to go the long way home to run in.
     
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  14. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Grandson has been working hard (and still going to school) and saving his pennies and was lucky enough to pick up this 2009 DR650 as his next ride. Lucky he didnt have to spend much on it (it had been sitting in a shed since 2013), just lots of cleaning and servicing, new tyres, battery and chain. Off for blue slip and rego tomorrow.
    Two FT's 002.jpg
    This is why you don't leave the fuel tap turned on when you stick a bike in the shed for years.
    Gun licence 027.jpg
     
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  15. ShaneP

    ShaneP Well-Known Member

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    Damned if you do, damned if you don't. Corrosion and perished rubbers of it is dry. Plastic fuel tanks can do and crack, apparently.
     
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  16. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Mason has sold the Tenere to a museum somewhere near Sydney. Sad to see it go after so much effort to restore it but was always a bitch to start.
     
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