Honda XR600 has a cult following around the globe, and for good reason. As the original king of the Baja 1000, this is one of the biggest singles to ever tear the desert. And while it may look dated compared to modern machines, it’s still a great bike to own — and customize.
Australian custom store Ellaspede there is a special soft spot for the venerable XR. One of the first custom motorcycles they ever built was based on the 1998 model XR600 [below]back in 2011. And now they’ve pulled that very similar thing rival back to the workshop to make up.
Hughan Seary of Ellaspede says: “It’s always hard to let go of first love, so this XR600 was used for promotional missions and shows throughout the years, until the engine was built. new and pulled out of the frame. But when the client’s works come first, then it stagnates in the following years, waiting in the wings of the second hire of a lifetime. “
When their 10th birthday came last year, the Ellaspede team decided it would be the perfect time to revive Honda. Around that time, a customer, Tom, happened to decide that he wanted a custom XR600 of his own. He had the right sponsor and a specific direction in mind — but then he visited the workshop, and his plans quickly changed.
“We took him on a memory walk of the original XR600 we still own,” explains Hughan. “It seems like a perfect match to put him behind bars in this new build.”
One of the big ideas for the second pass at the XR involved a larger electric starter motor. Tom jumped into Facebook Marketplace and found a dismantled NX650 Ruler, complete with an engine rebuild kit. Along with that, the project was officially launched.
The Dominator engine was passed on to Wayne at All Carts & Cycles, who rebuilt it with a larger piston, a solid carriage job, and some unnamed internal upgrades.
While that was happening, Ellaspede tore the XR600 down on its nuts and bolts in preparation for the rework. “We have learned a lot over the past 10 years of building bikes,” says Hughan. “There are a lot of things that we want to update or upgrade based on that research, to make sure the XR600 is once again the best it can be.”
High on the list is Honda’s complete suspension overhaul. Ellaspede bought a pair of old Honda CRF forks, then stripped them, cleaned and repainted them black. They also shortened them by 100mm, then paired the XR600 body with CRF spokes to fit the bike, and shipped a new spacer to reassemble the original 18” front wheel.
The rear shock absorber has been upgraded to a more powerful unit with an external reservoir, but it’s not a straight exchange. Ellaspede had to rebuild the shock and shorten its travel, plus they had to modify the upper mount on top of the frame itself.
The rebuilt Dominator factory has been returned to the frame with a 42 mm Mikuni muffler. Ellaspede kept the same double-walled exhaust they built for Honda the first time around, but added new baffles and re-coated everything.
Next, they built a new battery box to make room for the new air filter and to accommodate the extra electrical bits that weren’t present in older starter-only engines. And since neither the XR600 or the Dominator wire loom would be suitable without substantial mods, they also built a new system from the ground up.
Other minor upgrades include Daytona Velona speed, Koso Thunderbolt LED headlights and Hawkeye LED taillights. Ellaspede attached the taillights to the same recessed housing they built before and kept the original Posh turn signals. There is also a USB charging port on the front.
The rest of the work was largely focused on refreshing substandard parts and making minor tweaks, such as lengthening the side stand. But for the general aesthetic, Tom is happy to keep things mostly the same.
“I really loved the look of the original build and still do to this day,” he said. “Even with so many XR builds scattered across the web, I have yet to see an XR like it. I put it down on the textbook XR600 frame, the unusual color scheme, the 18F/18R wheel combination and the fat tires really resonated with this bike.”
With that in mind, Ellaspede has kept the original Honda XL500’s fuel tank, but added new fenders at both ends. The original seat had a big ‘630’ number on it regarding engine power, so that has to go. The crew put it away for nostalgia, and built a new unit from scratch with matching green stitching.
With newly added Heidenau K60 tires, Tom’s refurbished Honda XR is ready for delivery. “Now that the bike is complete, it continues to grow for me,” he tells us. “Congratulations to the legends at Ellaspede for holding this amazing machine for me for the best 12 years!”
“One thing is for sure, Sick keep this bike for years to come — I’m sure it will outlast me! “
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