Honda XL600v Transalp - 1996 Project

[guitarcarfanatic]

So...came across an MOT failure locally...

Seller pictures:





Couldn't resist - need a project and this bike was tidy plus super cheap. Plus, good excuse to FINALLY do my DAS.

Here she is...



1996...7 Previous Owners (last one for 10 years)...33K...been off the road for 6 of the last 10.

MOT fail was for:

Severely Leaking Rear Shock

Worn Rear Tyre

Dangerously Loose Drivechain

Advisories for:

Blowing Exhaust

Front Forks Misting

Front Tyre Near Limit


So, she starts and runs great. A quick blast down the track at the back of my house confirmed no issues. Changes smooth etc.

Time to order some bits...

[guitarcarfanatic]

So plan of attack = I have ordered...

2 New Tyres

New Fork Seals/Oil

New Front/Rear Sprockets

New Chain

S/H Rear Shock

Oil Filter, Air Filter, Engine Oil, Coolant, Brake Fluid... Etc.

New exhaust gaskets

I've stripped down most of the bodywork etc. and tomorrow giving everything a detailed clean. It's very grimy/grubby!

Today, I took the old chain off and sprockets, removed the rear shock and removed the exhaust...then the fun began.

The blow was being caused by a snapped manifold bolt. Not cool! Previously, someone had tried to silicone a nut on haha! So 3 hours later, I managed to get the broken stud out (was just about to give up and weld it, but the double nut method worked with skinny locking nuts cammed off against each other on the tiny amount of thread that remained and plenty of plusgas...albeit went through about a dozen nuts as they would only work for half a dozen tiny turns of the spanner). Exhaust is a little tatty so ordered some VHT exhaust paint to give it a spruce up.

Here was the offending bolt...

[jjones]

Nice project

[Unbusy]

Sounds like it was neglected a tadge. The tlc and the service items you are doing should see it sail through the mot and then you have a cracking bike. I think I would like to do a similar project. Gumtree
here I come!

[dern]

Nice. While you've got the forks apart you may as well some new bushes. They're not expensive.

[guitarcarfanatic]

So work has been moving forward on the bike. First job was to start stripping it down and cleaning all the grime... I also re-painted the side and centre stands. And the brake and gear pedals.







Then I moved onto removing the forks to replace the seals...





I also removed the chain, sprockets etc. ready for replacement and fitted a secondhand rear shock.

Then I removed the exhaust and patched a hole in the rear box (JB Weld Exhaust). A bit of VHT paint and it's back on the bike looking acceptable...





Got both wheels off now and new tyres are fitted tomorrow. Then I can get the wheels back on, fit the new chain/sprockets and get the bike back on the ground. Then I can change oil and coolant (will be easier when I can get it up to temperature). I have new sparkplugs as well, but waiting on Amazon to deliver the tool!

Then she is ready for the MOT and I need to get my MOD1 booked in!!

[crofty1984]

Good for you! Hope it all goes well.

[guitarcarfanatic]

So she's pretty much done. Everything on my list ticked off!









I also fitted an LED headlight bulb (premium, not budget so beam pattern is as it should be).

LOW:



HIGH:



I start my DAS next week and then will get her MOTed.

[pessimal]

what bulb did you use?

[guitarcarfanatic]

It was about £20 - one of the Cree LED bulbs with heatsink/fan. I got mine from Amazon Warehouse and they don't stock it in normal shop anymore. But go on amazon and you will find a few options. Try to get one of the better priced/reviewed ones - (mine is 75w equivalent apparently). They are similar to these...https://www.amazon.co.uk/Headlight-Conversion-headlamp-Replace-Halogen/dp/B071ZKJWBM/ref=sr_1_17_sspa?ie=UTF8&qid=1536665600&sr=8-17-spons&keywords=cree+h4+bulb&psc=1

Some you have to glue into position after a bit of trial/error, but the ones I got had locating tabs and match the original beam pattern almost exactly.

[guitarcarfanatic]

So...after passing my test, took her for the MOT. Not expecting any surprises as I had the fail sheet from August and it's been sat in my garage being pampered since.

She failed on corrosion to the rear wheel - common issue and looks like previous owner had tried to hide with filler/paint!!

Shame this garage didn't mention when they fitted my new tyres mind...

Anyway, secondhand wheels are super rare so contacted a few wheel re-builders. Seems it's the busy season for them and looking at 4-6 weeks minimum....plus about £300 notes.

A bit of creative searching found me a mint wheel off a 650 (same rear) from Italy. Ordered and due to be delivered next week!

So panic over, but just the faff of getting the new tyre on old wheel swapped onto new wheel and then being able to take it for the re-MOT.

[V1nce Fox]

Nice save and a very useful bike. Looks great.

[Tango13]

JE sell a 696cc kit for the 650 engine, not sure if it would fit the 600 though?

Two Brothers Racing in the US used to tune the 650 Hawk to produce some respectable power, maybe fit some 17" rims and some sticky tyres too

[Rubin215]

Tango13 said:

Jfit some 17" rims and some sticky tyres too

That would have been my route after the knacked rear wheel
Plenty of proper (ie alloy) wheels on eBay.

[guitarcarfanatic]

All MOTed and running lovely - heated grips on order though....far to chilly!

[TheClient]

Just to say I now own this bike, currently doing all fluids, new tyres, discs and pads etc... still runs great

[guitarcarfanatic]

TheClient said:

Just to say I now own this bike, currently doing all fluids, new tyres, discs and pads etc... still runs great

I did see this pop up on Facebook. Enjoy, she did me proud. Exhaust has been changed since I owned it (it was due) and looks like the decent DID gold chain I put on has been swapped out as well (odd considering only 6000 miles since I sold!).

But I did all fluids, sparks, filters, and front pads. Hope she treats you well