in this blog i will have it about my project, restauring an old honda xr600r into a supermotard. i bought the motor with 2 engines (1 was for dissassembly) for 350€. i brought it home and started to strip it down .

this is how i bought him

so here i started the stripping. 

having the airfilter-box removed was quiet a job! because there is not much space between the frame and the airfilter-box

yes,! i did it ! all alone ! taking the (a part of) engine out for the first time! 

here is a part of the engine. even only that part of the engine is quiet heavy ! :O 

here is an inside look, the piston broke in 2 pieces in this engine... you can see some metal debris 

stripping the front was easy, just some easy screws and done

here from anither sperpective

to remove the rear swingarm you have to remove the (rear)suspension, not that difficult

old ugly gray brakes 

so i first removed the backwheel before removing the swingarm

broken tooth :(, I had to buy a newone anyway

without backwheel 

and here without the swingarm, it is easy to remove, the swingarm is only fixed by 2 screws, 

(1 in the rear suspension and 1 in the frame)

detaching and removing the brake-cables and gas-cable and the clutch cable

to remove the frontwheel loossen the 4 screws here

then you can unscrew the wheelnut from the other side

once the wheel removed i started to dissassemble the front suspension. is only holden by 4 screws 

removing the brake cable

here you have the frame with the steering and all the cables still attached to it 

the two forks 

the front calipper with allmost no more brakepads.... have to change that .

rear calipper with the mount

up vieuw from the handlebar with some electronica still on it 

finally got the handlebar off... it was quiet messy with all the cables still on it but I did it 

here is the frame, only the frame ! :D 

now sanding can start and then painting !

to limit depenses i sanded by hand with papersand and some machine 

this was the broken engine that I opened to take out the good pieces for later use/sell

SO i painted the frame by hand to and the endresult was better than expected! i used black metal paint for fences and it work good. i paid for the paint 12€ instead of 150 if i wanted to do it by a professional  

the weelrims i sanded by hand and used spraypaint from Motip.

after 2-3 layers i sprayed some layers of clear coating lak

i was satisfied of the results

the plastics I first sprayed them with a Primer base coat to fill all the cutts and wholes and inperfections

those need a cleen-up for better performances

after cleaning

as new !! :D 

now they have to fit perfectly 

clean 

Starting the rebuild! finally! swingarm and rear susspenssion are fixed on . the front forks to.

the new motor waits to be installed 

the wheels were put on 

new gaskets are indispensable for a good working motor to avoid leakages or power loss

i tried to clean the saddle with thinner with a very good result! but watch out ! thinner can bite trough the plastic. so put some thinner on it, use a shiffon or paper towel and quickly clean it up

result ! 

here is the top of the motor with the camshaft 

clean and new sealings

motor readdy to mount on the frame

i have putt some decals on the rims to make them nicer

yes i have done it, alone! the motor is in the frame.

that thing is so f*ucking heavy 

keihin carburator 

electonical cables and the handlebars are on :) also the lazer exhaust

some plastic had to be redone so i refilled the wholes with other plastic and sanded it then spayed it with base color 

the rear sprocket needed some adjustmenys for the screws 

the new metallic red candy color, it has a nice look. i wanted to use RED to stay in the "honda color" section 

candy red front with black

anodized blue screws for the finishing touch

this is the back where i repaired the wholes 

the plastics are put on the motorcycle and the xr 600 gets his final form 

ALMOST readdy just neads some adjustments and some little points have to be done 

At this point I have allready started the bike , he turned on after 10 minutes kicking, bad carburator mod

i have painted some more parts candyred 

whell now he is finished :)