Blondie, XTZ660 rebuild

[qwertylolman]

Kind of blog, mainly for me to not forget what I have done with my Blondie xD

This bike came to me with own history. We had guy called Oleg Beketov on Ukraine. 'Had' because now he is in Poland or somewhere else, not because of others reasons :) Sometimes he take money and don't buy a motorcycle in Europe to move it to Ukrainian customer, sometimes he does. Strange guy... Well, this guy once bring my XTZ to Ukraine. First owner was Igor 'Et', he is really tall man, 2 meters high :) XTZ for him like scooter xD

Btw, look at his handmade customshop plate on exhaust xD Came from Poland with this aftermarket

Well, Et crashed once, on his trip to Lviv. And forgot to add some oil... I heared few versions of this story, but as result - engine was rebuilded. With forged Wossner piston. Unfortunatelly, I don't know whic size was used. It was rebuilded in er... bad conditions. I cannot find photos from those rebuild. In Ukraine we have a lot of 'garage' services for repairing bikes and cars. But it's not a nice one garage with lighting and a lot of new tools. Usually, those 'services' looks like this, but it's not the worst case, because it's my garage xD At least, I don't use old soviet or low quality tools to repair my motorcycles. Blondie was repaired 'on knees' with some shitty tools.


I've had a desire to buy this motorcycle at that time, but I've had no money :(

After this she was sold to one guy who is cannot handle with tenere because he isn't tall and strong enough. He give motorcycle to his friend, to let him try what adventure bike is. As result, he crahsed and repaired fairings :) I'm not sure if I can find photo, but right red part of fairing (I called this part 'cheek') was compiled from pieces like puzzle.
Later she was sold to southern part of Ukraine, guy was touring a little on Blondie for few months. And he found some HD, which was his dream and so one...

At those time I wanted to switch my chinese supermoto to something more interesting and have found my old desire on ukrainian motorcycle online community's 'Sales' section :)



Since spring of 2012 I'm planning to rebuild this motorcycle but my plans crumbling every time...

Enough for history, I think :)

[qwertylolman]

So, my frist full-size ride on this motorcycle, 400km. Many thanks to my father, it was really good that he forced me not to ride by myself. Another boring story, I will skip it.
So first failures on our first 20km:
- dead rectifier
- dead accumulator
- poorly installed strob lights and switch for general lighting

Blondie made other 380km by bus

While I was trying to fix issues above, I found that air box was sucking air from everywhere.
So at our first week I've fixed:
- new rectifier (from some Honda)
- new accumulator (Varta)
- remove strobes and switch, changed few connectors
- new air filter
- left side cover for air box was 'glued' with sealant, new seals for right side cover
- new engine oil (previous owners used Motul. I don't like Motul. It's expensive and has a lot of fakes, engine is dirty after this oil. Mol Dynamic is my choice, it's cheap and nice :) )

But my first rebuild was ahead... I planned to make rebuild in winter, but not so deep. New wires, new paint on frame, rims, hubs, fairings...

So one day I was going to office when suddenly engine stops with some knocking. And this was the reason

[Mezo]

FARK

Never seen that before, soemone has been in there before & never used locktite on them bolts i reckon.

Mezo.

[qwertylolman]

As result I've bought few used parts for replacement:
- gear box (old gear was so-so)
- generator (rotor + stator)
Engine was rebuilded from scratch. What my mechanic showed me was terrifying... Almost every screw was overtightened, many threads in bad conditions. And on her first rebuild previous mechanic assembled tensioners in this way.


I've decided to disassemble whole motorcycle and assemble it from the scratch to be sure that any other future faults will be only my faults.

So frame was repainted with my favourite color xD RAL3024


- new bearings, seals and bushes for rear suspension. Only thing left is shock absorber. I realy want to install some WP shock absorber...
- new bushes, seals and oil for fork
- repair kits for front and rear calipers, new pads (Breaking)
- renew wiring


I wasn't satisfied with headlight, so decided to try some headlight from car






Headlight was still awfull, so I decided to try bi-xenon lenses


And this is pre-crash version of my girl. Tank started to 'sweat' with fuel. You can see spot near



It's hard to ride without windshieldwith...

I've started to make model for cutom fairings inspired by KTM 640 touring bike.




Booooooo! :)

[qwertylolman]

2Mezo
Unfortunatelly, locktite is used rarely in Ukraine :( Owners can use anything, from sealants to cyanoacrylate glue or just overtighten. But not the locktite
To overtight is kind of bad habit. In post soviet countries it came from soviet motorcycles and cars. You can open manual for old Ural or KMZ and you will not find moments for tightening. So almost every mechanic will tight the screw based on his 'feelings' and power and habit.

[qwertylolman]

On the next day after my birthday I've got to an accident and crashed my girl. My plans gone wrong... again :(





Oh. by the way, I've installed Acrapovic. Fuel mixture with stock jets is not good, but engine's temperature and plug is ok.
And I've had some unknown issue with carburetor. I was playing with carb settings for week but mixture was still poor on fuel. Then replaced carburetor with another one with settings from manual and miracle! Everything is perfect!

And this is my biggest pain in the ass. Decided to replace with USD fork.



What I am doing now:
- fixing after crash issues (new bars, handlebar, mirrors, crank side covers, exhaust pipes)
- waiting for goods for USD fork. I've got one from 89' CR500.
- have xtz660 front hub with taskago rim

What I am planning:
- K&N air filter?
- air intake from upped side of fuel tank?
- fuel tank from o pieces, maybe some usuall but made from plastic (found plastic tank on 30l from some Italian answer to XTZ)
- rear suspension from WP
- increase clearance
- replace rear wheel, it's in an awfull condition after first owner's crash

[qwertylolman]

Finally, starting to mount usd fork and new handlebar.
- custom steering axle, sizes the same as original xtz660
- allballs bearings for xtz660 in steering axle
- allballs bearings from cr500 1989 in wheel
- stock cr500 wheel axle
- allballs outer spacers for cr500 1989
- xt600 hub with takasago rim (2.6x21")
- original wheel inner spacer bored out to 17mm
- msr pro raptor clutch
- zeta sx-3 handlebar, model motard high
- zeta mounts for 28mm handlebar

[Mezo]

Mezo.

[jibber]

nice forks

[Mezo]

nice forks

They look so much like WP`s did Honda use White Power forks?

Mezo.