1994 Honda XR600R Rally from Barcelona’s SB Rally Works…
In 1985, Honda released what would become one of the most iconic off-road bikes ever produced, the Honda XR600R. A successor to the XR500R, the new 591cc big-bore thumper was intended to compete with the Yamaha TT600. In the years to come, it dominated the Baja 1000, won a slew of unexpected enduro championships with Scott Summers in the saddle, and earned its place as one of the most beloved off-road bikes in history.
“The Honda XR600R has become one of the most revered and influential dirt bikes in the world. From its introduction in the mid-80s to its final production in 2000, the XR600R captured the hearts of off-road riders, racers, and adventurers alike.” –XR Specialists
Today, the XR600R is nothing short of an icon, and builders, racers, and enthusiasts continue to breathe new life into the aging workhorses. The 1994 XR600R rally bike you see here comes from Barcelona’s SB Rally Works, a company born nearly 20 years ago as Solo Buell — a workshop started by two friends passionate about the innovative machines of Erik Buell. Several years ago, the team transitioned from tarmac to trail:
“After 15 years dedicated to what we love most, we wanted to take another step, to leave the asphalt and venture onto the tracks and trails, to cover our motorcycles with dust and mud… Welcome to SB Rally!”
Today, SB Rally Works specializes in rally kits and parts, navigation equipment, and full-blown builds. Thirty years after the XR600R rolled off the production line, the SB team set out to transform the vintage thumper into a modernized rally raider.
“We’ve carried out a rally build of this Honda XR600R, starting with a complete rebuild and combining its original character with modern components, mechanical upgrades, and equipment specifically designed for long off-road journeys. The goal: to preserve the personality of this classic and adapt it to the needs of its owner, without sacrificing the advantages offered by modern technology.”
Highlights include an NX650 Dominator cylinder with electric start, modern USD forks, rally tower with navigation tablet and handlebar controls, 21-liter (5.55-gallon) fuel tank, engine protection, Excel rims with mousse-filled Michelin Enduro Tracker tires, and more. Below, the SB Rally team gives us the full story on this rally-spec Honda XR600R.
In the Builder’s Words…
There are motorcycles that, no matter how many years pass, still possess something special. The 1994 Honda XR600R is one of them. A true benchmark in enduro and off-road riding, it remains an excellent base for a custom build three decades later.
At SB Rally Works, we’ve carried out a rally build of this Honda XR600R, starting with a complete rebuild and combining its original character with modern components, mechanical upgrades, and equipment specifically designed for long off-road journeys.
The goal: to preserve the personality of this classic and adapt it to the needs of its owner, without sacrificing the advantages offered by modern technology.
Engine Rebuild and Chassis Upgrade
One of the most important aspects of this build was the engine rebuild, incorporating a Honda Dominator cylinder and an electric starter system — a particularly interesting modification for a motorcycle of this type.
We also completely updated the front end, adapting components from a modern motocross bike and improving the braking system to complement the new suspension.
The chassis has been reconditioned and finished with powder coating, while the electrical system has been renewed and adapted to the new components. This combination of work allows this XR to be updated without losing its identity.
RebelX Ultralight Kit and Digital Navigation
To transform the Honda XR600R into a rally-equipped motorcycle, we installed a RebelX Ultralight Rally Kit, specifically adapted to the characteristics of this model. The kit includes a Carpe Iter digital navigation tablet, along with an Ursae System remote control for managing navigation functions from the handlebars.
The package also includes a Renthal 603 handlebar, Progrip foam grips, and Acerbis handguards, aiming for a comfortable riding position and good control of the motorcycle on challenging terrain.
Another key element is the 21-liter Acerbis fuel tank, which provides greater range for long rides and off-road adventures.
Wheels, Protections, and Custom Finishes
The chassis features Excel rims fitted with Michelin Enduro Tracker tires and mousses, a setup designed for riding on varied terrain without relying on conventional inner tubes.
Underbody protection is provided by an AXP skid plate, while S3 footpegs and a 48-tooth Renthal sprocket complete the equipment package.
We’ve also worked on the ergonomics, creating a new seat foam and cover adapted to this build. Finally, new plastics and a custom SB Rally livery have been installed, achieving an aesthetic that combines the classic character of the XR with the look of a modern rally bike.
A Honda XR600R with Plenty of Life Left
The result is a motorcycle that maintains the essence of the original XR but incorporates modern solutions to continue enjoying it off-road. This rally-prepped Honda XR600R proves that a solid classic base can still offer endless possibilities when combined with a meticulous rebuild and the right components.
At SB Rally Works, we work with all kinds of enduro, trail, and off-road motorcycles, from modern models equipped with the latest technology to classics that deserve a second life. Do you have a knobby bike and a project in mind? Write to us at [email protected] and tell us what you’d like to do. We’ll take care of the rest! 👊💨
Build Video
Follow the Builder
Web: sbrally.com
Instagram: @sbrally
YouTube: @sb-rally
More Rally Bikes…
RFVC Rally Raider: Honda XR600R Rally - 1994 Honda XR600R Rally from Barcelona’s SB Rally Works… In 1985, Honda released what would become one of the most iconic off-road bikes ever produced, the Honda XR600R. A successor to the XR500R, the new […]
Sahara Bound: Ducati Desert Sled “2118” - Africa Ready: Ducati Scrambler Desert Sled from De Angelis Elaborazioni… If you haven’t heard yet, the 2027 Dakar Rally is returning to Europe (Portugal) and Africa (Morocco) after many years in Saudi Arabia and South […]
Sahara Ready: BMW HP2 Enduro “Cassiopeia” - Built for La Ruta: BMW Desert Bomber from Giorgio De Angelis… In 2005, in order to celebrate the 25th anniversary of the genre-defining, Dakar-winning R80G/S, BMW launched the HP2 Enduro — in the company’s own […]
Basement-Built XL600V: Honda Transalp 600 Enduro - XL-Size Enduro: Marc Pfaffl’s Retrofitted Transalp… In the late 80s, Honda unveiled the XL600V Transalp as a “Rally Tourer” that could combine street performance, off-road capability, and long-distance touring comfort. At its heart was a […]
Tornado Rally: Honda XR250 Tornado Enduro - From Chopper to Rally Bike: Honda Tornado 250 from Argentina’s Industria Chernobyl… Introduced in 2001, the Honda XR250 Tornado (Tornado 250) was a lightweight air-cooled 250cc dual-sport developed mainly for Latin American markets and produced […]
2WD Dakar Legend: Yamaha WR450F 2-Trac - Remembering Yamaha x Öhlins’ Hydraulic 2WD Enduro… Every so often, a motorcycle appears that seems to point toward an entirely different future. The Yamaha WR450F 2-Trac was one of those machines. At first glance, it […]
Brothers to Dakar: S2D Race Team and Their Husqvarna FR450 Rally Bikes - Brothers Carl and Craig Searles race the Dakar Rally… The Dakar Rally is regarded as the world’s most grueling off-road race, a 5000-mile battle across some of the most epic, difficult terrain on the planet. […]
Desert Bomber: BMW “R1300RR” Rally Bike - “What would BMW build today if they decided to create a factory Boxer rally machine?” BMW was one of the earliest, most influential, and most successful manufacturers in the Paris-Dakar Rally. The R80G/S won the […]
Dakar Legends: Gilera RC600 & RC750 Rallye - Italy’s Big Thumper in the Twin-Cylinder Era… By the late 1980s, the Paris-Dakar Rally was no longer a romantic expedition but an escalating arms race among the major manufacturers. Twin-cylinder prototypes were growing larger and […]
Underworld Champion: Royal Enfield 865 “Wildfire” Rally Bike - What if Royal Enfield had Built a Big Twin Paris-Dakar Rally Bike? While we love to watch the 450 singles of today’s Dakar Rally, we can’t help but harbor a heavy nostalgia for the big […]
Desert Bomber: BMW R80G/S Paris-Dakar Rally Bike - The Boxer That Changed the Desert Forever… In 1981, the Paris-Dakar Rally was still raw — more expedition than sport, more survival than spectacle. Riders crossed the Sahara on machines that were barely adapted from […]
Gravel Express: Suzuki XF650 Freewind Adventure Rally - Hessler Motorsport’s Suzuki Freewind ADV Rally… Available from 1997 to 2002, the Suzuki XF650 Freewind was a European-style all-rounder built around the proven air-cooled lump from the DR650 dual-sport. Though a single cylinder, the Freewind […]
Desert Boxer: BMW R900RR Dakar Rally Bike - Dakar Legends: Last Roar of the Desert Bombers… In the late 1990s and early 2000s, BMW found itself at a turning point in rally-raid racing. The boxer twin had already written one of the most […]
The Honda EXP-2: The Two-Stroke Desert Racer - Honda’s 400cc “Experimental 2-Stroke” Baja 1000 / Dakar Rally Bike… In the mid-1990s, as emissions regulations tightened worldwide and the future of two-stroke off-road bikes looked increasingly uncertain, Honda did something nobody expected: it built […]
A Lighter T7: Custom Yamaha Ténéré 700 - From Superslab to Singletrack: A Lightweight Yamaha T7 from SPKS Lab… The Yamaha Ténéré 700 (T7) represents something of an answered prayer for ADV riders who’d been wishing for a modern, affordable, streamlined middleweight adventure […]
