XR100R rebuild

[Longshot270]

Got ahold of a 1986 XR100 and have been slowly rebuilding it as money allows. The pics on this post were taken over the course of a month.

Here is how it looked when I first brought it home.


I couldn't stand that front fender because it was warped sideways really bad so it was one of the first things I took off. Also found a gas tank for $20 at a local shop. Not intended for this bike but it works.


Painted the handlebars and cleaned up the front forks.


Had to build a temporary stator cover so I wouldn't get a stick in it while testing the bike out for a weekend of riding.

Made a new one yesterday that is going to look sick after I paint it.

Then finally decided to take apart the engine to see if the rings were bad. They weren't too bad but the engine cylinder was not in very good shape.

While the engine was out I did some repainting.


Honed the cylinder

The big rough patch you can see at the bottom of the cylinder is fine because it is below the rings.

Today I'll see if I can't fix an issue that came up yesterday with the cam chain jumping timing that showed up after rebuilding the engine. From here progress is going to be slowing down because replacement parts for the engine are expensive.