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XR50 2003 50cc Modified

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  • XR50 2003 50cc Modified

    Picked up the XR50 a few years ago for just over $700 off EBay with only a quick 5 hour return trip for this one, started first kick and went thru the gears ok but had a bit of a leak from the sump plug and the head had been replaced with a China head but it ran ok and was basically good to go:

    2002 XR50 Pic 3 S.jpg


    Off home for a bit of TLC but just as it rolled into the shed it just fell apart, Nichole has seen this happen many times before :

    DSC03276.jpg


    I had a very tidy CRF50 roller that donated it's rear swingarm and forks with heavy duty springs and bushes, replaced the original plastics with the old plastics from my other XR50 and installed an almost new CRF50 head, barrel and carb that I also picked up off EBay:

    DSC03271.jpg

    DSC03277.jpg

    DSC03279.jpg


    Safe and reliable for my kids to ride for now
    Classic Honda 50's Australia - Visit our online store at - www.classichonda50saustralia.com.au

    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

  • #2
    I absolutely hate oil leaks and I soon worked out that the sump plug had been stripped and the thread had been poorly repaired resulting in a cracked engine case and the gearshift shaft was bent pretty bad as well so I removed the original engine and replaced it with a spare CRF50 TB V2 108cc stroker engine that I had till I was able to repair the original motor:

    DSC05289.jpg


    Just had to machine up a few fuel tank spacers for carburettor clearance and it fit like a glove, ready for some adult fun as the kids were now too scared to ride it:

    DSC04124.jpg


    Can never stop at one bike they seem to breed when you put them near other bikes :

    Dsc05290S.jpg

    Dsc05293S.jpg
    Classic Honda 50's Australia - Visit our online store at - www.classichonda50saustralia.com.au

    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

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    • #3
      Was told that the bike had been raced for two years by the first owner and all of the new owners kids had learn't to ride on it and there were kids everywhere so I did not expect to see the bottom end in very good condition but I was surprised to see that it was one of the cleanest motors internally that I had ever seen, I like farm bikes as farmers tend to look after and service their equipment:

      Dsc03274 S.jpg

      Dsc03275 S.jpg


      The gearshift lever was a little bent although it was still working ok and surprisingly didn't leak at all:

      Dsc07006 S.jpg


      Then the motor was put away in the project waiting room for almost two years till I got around to rebuilding the stock motor
      Classic Honda 50's Australia - Visit our online store at - www.classichonda50saustralia.com.au

      PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

      Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

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      • #4
        What exhaust do you have on there ,,?
        its engine oil madge ,,,
        Your soaking in it ,,!!

        Comment


        • #5
          With the stock set-up I just run a modified stock pipe and with the TB 108 I have a Fast 50s 1" exhaust that is a tad loud.
          Classic Honda 50's Australia - Visit our online store at - www.classichonda50saustralia.com.au

          PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

          Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

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          • #6
            A new centre case solved the stuffed sump plug problem:
            DSC07012.jpg


            Transmission was like new but had a strange pattern on the face of the teeth on the gears, will see how it goes:
            DSC02453.jpg


            Lubed up ready to go back together:
            DSC02456.jpg


            DSC02458.jpg


            DSC02461.jpg


            DSC02465.jpg
            Classic Honda 50's Australia - Visit our online store at - www.classichonda50saustralia.com.au

            PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

            Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

            Comment


            • #7
              Can't leave anything stock so I installed a Kitaco stock head race cam, mild port job, re-cut the valve seats to drop the valves into the head and move the valve seat contact to the outer edge of the valve face and match ported the inlet manifold.

              A modded stock exhaust with an XR/CRF70 carburettor and inlet manifold running a short foam pod air filter tops off the engine set-up.

              The forks already had heavy duty springs so I added a Takegawa rear shock which works well with my 90kg load.

              Tiny inlet port feeding the stock 19mm inlet valve, I take the inlet port out to 16mm:
              DSC02469.jpg


              Exhaust port needs a clean up:
              DSC02470.jpg


              The combustion chamber is quite small and houses a 19mm inlet valve and 16mm exhaust valve:
              DSC02472.jpg


              Stock cam on the left and the Kitaco stock head race cam on the right:
              DSC02473.jpg


              Match the inlet manifold to the inlet port:
              DSC02482.jpg


              DSC02487.jpg


              Match the other end to the carb insulator plate:
              DSC02490.jpg


              Inlet port almost finished:
              DSC02497.jpg


              Exhaust port cleaned up:
              DSC02499.jpg


              Cut new multi angle valve seats:
              DSC02521.jpg
              Classic Honda 50's Australia - Visit our online store at - www.classichonda50saustralia.com.au

              PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

              Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

              Comment


              • #8
                is that a crack in the case?
                You have two parts of brain, 'left' and 'right'. In the left side, there's nothing right. In the right side, there's nothing left.

                Comment


                • #9
                  Please no which one, there was lots of weird casting flash.
                  Classic Honda 50's Australia - Visit our online store at - www.classichonda50saustralia.com.au

                  PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

                  Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

                  Comment


                  • #10
                    just taking the piss...... Dex taught me that
                    You have two parts of brain, 'left' and 'right'. In the left side, there's nothing right. In the right side, there's nothing left.

                    Comment


                    • #11
                      Clutch side of the engine close to finished:
                      DSC02535.jpg


                      Flywheel side of the engine ready to close up:
                      DSC02536.jpg


                      This is the last thing I like to see before the engine is ready to bolt up, oil pump drive sprocket engaged, tensioner roller and guide roller in place and remember the two little O rings that sit behind the stator plate:
                      DSC02539.jpg


                      Cam sprocket aligned:
                      DSC02541.jpg


                      Ready for the clutch and head covers, the clutch was in great condition, cleaned out the usual grey paste from under the top cover and just gave the stock plates a figure eight lap on wet and dry paper, cleaned then oiled the plates for assembly:
                      DSC02544.jpg


                      Helpful tool that you can make to install the oil pump drive shaft to the drive shaft sprocket after the engine is assembled, wont work with some stroker cranks including the TB 51mm crank where you need to install the drive shaft when bolting the centre cases together:
                      DSC02547.jpg


                      Ready for the flywheel cover and round one with the stock Honda 50 carb:
                      Dsc02554 C.jpg
                      Classic Honda 50's Australia - Visit our online store at - www.classichonda50saustralia.com.au

                      PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

                      Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

                      Comment


                      • #12
                        That big split where the two half's meet ,,?

                        Hahhah ..
                        its engine oil madge ,,,
                        Your soaking in it ,,!!

                        Comment


                        • #13
                          im sorry Jaimie but im still waiting for my free roller rocker head after i hit the 1000 posts mark.
                          You have two parts of brain, 'left' and 'right'. In the left side, there's nothing right. In the right side, there's nothing left.

                          Comment


                          • #14
                            Sorry I have to delete 952 of your posts due to complaints from the Communications Ombudsman.
                            Classic Honda 50's Australia - Visit our online store at - www.classichonda50saustralia.com.au

                            PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

                            Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

                            Comment


                            • #15
                              few more than that i recon
                              You have two parts of brain, 'left' and 'right'. In the left side, there's nothing right. In the right side, there's nothing left.

                              Comment

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