For many riders, the XR600R needs no introduction. Honda’s air‑cooled thumper became a desert legend in the ’80s and ’90s, powering multiple Baja 1000 victories and cementing itself as one of the most charismatic off‑road machines ever produced. Even decades after production ended, the XR600R remains a cult favorite due to its durability, simplicity, and unmistakably raw character. 

That enduring appeal is what brought the bike to SBRally, a Barcelona shop known for rally‑focused builds and detailed restorations, where this late-90s XR was fully stripped down and rebuilt from the frame up for a customer racing the Morocco SandRaiders Rally. Combining refurbished OEM components with carefully selected modern parts, the goal was to preserve the XR’s original character while elevating its performance and functionality “to the next level,” says the shop.

The foundation of the bike remains the XR600R engine, but with a hybrid twist that has become a favorite among XR enthusiasts. The build retains the XR600R’s original bottom end while bolting on the top-end, left‑side crankcase and electric‑start system from a Honda 650 Dominator, a combination that keeps the XR’s lively, aggressive personality intact while adding more power and the practicality of push‑button starting. The motor has already been broken in and shows just over a thousand kilometers since the rebuild, giving the team confidence in its readiness for Morocco.

One of the most transformative upgrades is the complete CRF450 front end with fully-adjustable USD forks, rebuilt in‑house using Showa suspension components. The conversion required machining the steering stem, adapting bearings, and sourcing a compatible CRF hub before lacing it to a heavy-duty Moose Racing rim. The result is a far more controlled and modern feel at the front, a significant improvement over the XR’s original air‑assisted fork. The updated geometry pairs cleanly with the new rally tower, giving the bike a stance that blends classic XR lines with contemporary rally proportions.

Navigation and cockpit equipment reflect the same philosophy of modernization. SB Rally installed the latest Rebel X Sports Ultralight Rally Kit, fitted with the brand‑new “Rally” windshield that offers increased height and coverage for digital navigation equipment. The tower houses the new Caretta digital navigation tablet from Carpe Iter, one of the first units mounted on a customer build, paired with an Ursae System controller for precise rally‑style input. The cockpit is rounded out with Renthal 604 handlebars, Doubletake Mini mirrors, Progrip foam grips, and a Domino quick‑action throttle. SB Rally also removed the throttle return cable, a common race‑prep technique that gives the throttle a lighter, more responsive feel.

Fuel range was a priority for the owner, who plans to tackle long desert stages, so the bike now carries an Acerbis 22‑liter (5.8 gallons) tank. The added capacity gives the XR the autonomy needed for Morocco’s long dune sections, without compromising the bike’s balance. The seat was reupholstered with a custom cover inspired by the 1996-1997 XR designs, and all plastics were replaced, including the rear fender and lighting. At the owner’s request, the traditional XR rear tool bag was deleted, though the mounting points remain available for future use.

The rear wheel mirrors the front in approach, using the original XR hub refinished and laced to a heavy-duty Moose Racing rim with polished spokes. A new chain, fresh sprocket, and mousse‑equipped Michelin Tracker tires complete the setup. After testing both 140 and 120 widths at the rear, SB Rally recommended the narrower tire option for improved agility and throttle response, a change that noticeably sharpened the bike’s handling.

The bike retains a rare Arrow Paris‑Dakar exhaust, homologated for both the XR and Dominator platforms. The header pipes were stripped, polished, and refinished with high‑temperature black coating, paired with a gloss‑black heat shield. Red accents on the engine and swingarm were preserved at the owner’s request, adding a subtle nod to the bike’s previous life while tying the build together visually.

The result is a machine that feels both familiar and entirely new, says SB Rally. With upgraded suspension, expanded range, contemporary navigation equipment, and a refreshed engine, this XR600R is ready for its next chapter carving through Morocco’s desert.

Photos by SBRally