Honda XR650L build

[kennyw]

Well over a year ago, I picked this bike up from a friend on a trade.



The frame was broken and patched back together so he had purchased a newer frame but never got around to fixing it before buying a new bike.



He helped me tear it down and I went to work cleaning and painting the good frame.









Then, reassembly... new tires, tubes, bearings, etc.







At this point I turned attention to the motor. While it was out, replace seals and leaking gaskets. But I hit a snag with a couple broken valve cover bolts stuck in the head. I managed to safely remove one out of them but got stuck with the last one.

















Started to think drilling and helicoil was the only option left but put it off. Then moved to the new property and got busy for almost 9 months. Eventually, I found a used head and started putting it back together in the last couple weeks.

 

[Desert_K5]

As an old has been racer, I'm in for the build. Never had an L model, but raced the 600r's for a while. @Fastereddie remember these old tanks.

 

[kennyw]

I finished putting the motor together and started reassembly in the frame today. Still need to finish the fuel system and chain drive tomorrow but getting close finally.

 

[kennyw]

Carb installed and chain drive rebuilt. Had to order new exhaust gaskets and a couple more small parts before I can finish.

 

[kennyw]

New arrival.

 

[max 02]

Nice! I’ve alwas wanted a XL.

Good job!

 

[kennyw]

Just curious about the weight difference. The new LED headlight is actually slightly heavier.


Installed the new taillight and turn signals on the rear fender.


The taillight is a cheap one off Ebay that looks like the XR600 taillight but dual element bulb. Eventually I'll find an LED bulb that fits the housing. The 1157 replacements I have do not fit.
https://www.ebay.com/itm/Universal-...-/141878698506?_trksid=p2349624.m46890.l49292



Turn signals are cheap flush mount LEDs
https://www.amazon.com/dp/B01N9Z1OV0?ref=ppx_pop_mob_ap_share

 

[kennyw]

When your wife secretly shops for googly eyes for your dirt bike but orders a 4 pack and you work from home to intercept the package... her quad gets them too.

 

[kennyw]

More progress, battery relocated under the seat. Assembled the last few bits. Only a valve adjustment at from being ready to start now.

 

[AJMBLAZER]

Where was the battery before?

 

[kennyw]

Where was the battery before?

In the plastic pod hanging off the left rear.

 

[AJMBLAZER]

Dang...under the seat seems much more bettah.

 

[max 02]

In the plastic pod hanging off the left rear.

View attachment 345390

Really!? I was wondering what that was for?
Good call moving it!

 

[kennyw]

Really!? I was wondering what that was for?
Good call moving it!

This bike was based on a 600cc dirt bike with no battery. They just scabbed the battery box on the side and threw covers over it.

 

[max 02]

This bike was based on a 600cc dirt bike with no battery. They just scabbed the battery box on the side and threw covers over it.

Ok but why did you find a better spot for it then the Honda engineers?

 

[kennyw]

Ok but why did you find a better spot for it then the Honda engineers?

I can now use the empty space for a tool box for carrying tire spoons, basic hand tools, etc. Some guys eliminate the side pod all together and use the flat XR600 side cover instead. Eliminating the side pod saves 9 lb of mass up high.

 

[kennyw]

Wrapping up the rebuild with a test ride. Still a few little details like brake lights and turn signals. I also need to replace the battery box with tool storage.

 

[TreeFarm]

This thing is super cool. Makes me really miss my modernized 600r. They are such great bikes if you dont mind the weight.

 

[JoshHefnerX]

Reminds me of my klr650 sitting out in the garage. Is that the factory tank?

 

[kennyw]

Is that the factory tank?

No, aftermarket 4.2 gallon tank added at some point by a PO.