Honda Xl600r Engine Rebuild Part 2: Bottom End Inspection

Basket case rebuild of a 1987 Honda XL600r motorcycle with complete assessment of the outer components of the bottom end. Using parts from my years of collecting, I have almost everything to rebuild it except for a few small items and the major gaskets. As part of the tear down, I explain the role of every single part, how to check them for wear and show you the points of failure common to these engines. This includes the engine case, shifter and brake pedals, side covers, main shaft, clutch, oil pump, timing chain, small end of the crankshaft etc.
The intent of these videos is to help beginners understand how these bikes work and how to fix them when they don't! By using used parts and simple tools, it is possible to do a lot of the work yourself and keep the cost of repairs to a minimum. I hope you enjoy it and please subscribe to see lots more that are in the works!

[@ChuckCalamari]

Will be following, currently rebuilding my 1986 XL600R. First time with this bike. The loose oil collar piece was a good tip to watch for.

[@svennussbaumer3823]

Just great. I am rebuilding my XL600R at the moment. Very good explaination. Thanks. Looking forward for the next part.

[@jasonselinger]

Thanks man! I love these bikes! What year is yours?

[@svennussbaumer3823]

1983

[@DropMyBassBro]

Thanks for making this video, it helped a lot in rebuilding some of the bottom end components. Do you know where to source the aluminum fitting connecting the case cover to the oil pump?

[@jasonselinger]

Yup, I once got one from my Honda dealer. They still stock a surprising number of parts.

[@mariopham3989]

Hello, I love your stand, could you please share the dimensions of that stand? I would like to create one as well. It would spare us the time to measure and design that thing from scratch if you do not mind to share :). Keep up the good work

[@jasonselinger]

You just have to measure the mounting points on the engine and make it to fit. Then you can make one for any engine.

[@pete-mz9vr]

Do you have a video showing how you built the engine stand?

[@jasonselinger]

Sorry, I don’t. It’s a very simple thing though, just three brackets welded together to fit the case.

[@svennussbaumer3823]

Would you replace the o rings of the oil pump pipe? I dont have them!😂

[@jasonselinger]

They’ve got to be really cheap and readily available, so yes I will be replacing them.