Honda XR650L Weight Loss Thread

Discussion in 'Thumpers' started by Brtp4, Feb 11, 2012.

  1. Brtp4

    Brtp4 Powdercoat it.

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    Fellow ADV Riders,

    In the process of a motor rebuild, and am looking for ways to remove weight from an XR650L. I have been doing this gradually over time, but with no real idea how much, and a lot of of what I find online is vague.

    My goal to get as close as possible to an XR600R (278 lbs.) without sacrificing reliability. Everyone has different ways of <s></s>modifying their bike. Mine is to make the bike more simple, and not to sacrifice reliability. The good news is that much of the L&#8217;s excess are superfluous parts and removed with little consequence to either convenience or reliability.

    Note: I do not think it is possible to make a "light" version of a bike that starts at 324 lbs. This is 50 &#8211; 100 pounds overweight for off road use, and it cannot be made into a CRF or KTM 450. Anyone who has ridden one knows the thing is heavy. However, for various reasons we own them anyway. If possible. please refrain from pointing out the obvious: that it is heavy, that other bikes are lighter, and that one will never match the other.

    Looking for help to build an accurate database of component weights. This means postal or shipping scales only, not bathroom scales, no guesses, estimates, rounding, etc. It also means doing apples >< apples comparisons, i.e. either excluding or including necessary hardware on both ends of the equation.

    Using a shipping scale, with fractions expressed in tenths, not ounces, here is what I have so far:

    Item and Weight


    Tanks
    Stock Fuel Tank (with stock steel cap), 7.96
    Fuel Tank Wings (pair), 1.85
    Clarke 4.0 Gallon Tank, 4.6
    IMS 4.7 Gallon Tank, 4.91
    Acerbis 5.8 gallon tank, 8.34

    Controls
    Stock Handlebars, 2.16
    7/8&#8221; Aluminum Handlebars w/pad, 1.58
    1.125&#8221; Pro Taper CR High handlebars, 1.65
    Rox 3.5" Bar Risers, .8
    Rox 2" Bar Risers, .66
    OE Mirror (each), .56
    Ken Sean Mirror (each), 0.56
    Stock Handshields (pair), 0.41
    Acerbis Multiplo Handguards, 2.3
    Acerbis Rally 2 composite Handguards, 1.3
    Cycra Pro Bend, 2.26
    Scotts Steering Stabilizer w/ clamp and pin, 1.28

    Instruments
    OEM Instrument Brackets, TBD
    OEM Speedo drive and mechanical cable, .70
    Trail Tech Vapor, TBD

    OEM Ignition Switch, 1.1
    Baja Designs Ignition Switch, 0.48
    OEM Horn, .33
    Baja Designs Horn, .28

    Lights
    OEM Headlight and Brackets, 2.3 (estimate)
    CRF-X Headlight, 1.26
    Baja Designs Headlight, 1.62
    OEM Tail Light, 1.46
    WPS Taillight, 0.3
    OEM Front Signals (each - w/brackets), 0.42
    OEM Rear Signals (each), 0.56
    Baja Designs Turn Signals, 0.2
    Reflectors, .16

    Forks and Triple Clamps
    OEM XRL Forks, 20.98
    CR / CRF Showa Twin Chamber Forks pair, 20.03
    OEM Triple Clamp assy, 4.84
    CRF Triple Clamp Asy, 6.19
    CRF-X Triple Clamp Asy, 6.28
    Emig Racing CRF conversion triple assy 4.29
    XRL Upper Triple, 1.7
    OEM XRL Lower Triple, 1.65
    OEM CRF Lower Triple, 1.98
    BRP CRF Lower, 1.65
    RSW Fork Brace, 0.7

    Frame Stuff:
    Frame before powdercoating, 27.0
    Frame after removing all extra brackets and powdercoating 27.39
    Stock Engine Guard (bars), 1.25
    MSR / Moose / Utah Sports Skidplate, 2.95
    Seat Strap, .18
    Passenger Pegs (pair), 2.1
    Rear Subframe, 1.3
    OEM Seat Lock/frame tab (must be ground off), .78
    OEM Pegs, .56
    IMS Pro Pegs, 1.00
    Cheap Chinese Pegs, .84
    OEM Kickstand, 1.21
    OEM Suspension Link, .85
    Devol Lowering Link, .95
    OEM XRL Shock, 9.72
    OEM XRL Spring, 4.76

    Body:

    OEM XRL Front Fender, 1.44
    Aftermarket Front Fender, 1.19
    Stock Rear Fender, .92
    CRF Rear Fender, .84
    OEM XRL Left side cover, .87
    Fuel Tank Graphics, .28
    Side panel graphics, .22

    Intake Gear:
    Airbox Assy w/ intake boot and foam filter, 2.78
    Airbox Snorkel, .07
    OEM Air filter, .76
    K+N Air Filter, 1.05
    Uni Foam Filter (dry), .17
    Throttle cable (each), 0.32
    Choke lever and cable (for FCR conversions), 0.22
    Smog Pump and Hoses, 2.03

    Exhaust:
    Stock Silencer, 7.28
    FMF Q4 Silencer, 6.9
    FMF Powercore, 6.3
    DG, 6.07
    Stock Headpipe, 3.1
    FMF Stainless Headpipe, 1.9

    Battery and Battery Holder

    OEM Battery, 6.9
    Shorai Battery, 1.85
    OEM Battery box - bracket - cover, 2.81
    OEM Battery bracket (&#8220;band&#8221;), 0.24

    Guards:

    OEM Plastic Chain GUIDE, 0.44
    XRs Only Chain Guide, 0.76
    OEM Plastic Disc Guard, .16
    OEM Caliper Carrier, .66
    XRs Only Rear Disc Guard / Caliper Carrier, 1.16
    Rear Master Cylinder Guard, TBD
    OEM Plastic chain GUARD, 0.26

    Wheel Stuff:

    OEM XRL Front Wheel Assembly (w/o tire), TBD
    CRF Front Wheel Assembly (w/o tire), TBD

    OEM Front Rim only, 3.4
    CRF OEM Front Rim Only, 3.2
    Takasago Front Rim Only, 3.31
    OEM XRL Front Hub, 2.2
    Talon Front Hub, 1.9
    OEM XRL front axle - nut- spacers, TBD
    OEM Front Axle - Nut - Spacers TBD

    OEM XRL Rear Wheel Assy TBD
    OEM XRL Rear Axle TBD
    OEM Rear Wheel Steel Spacers, .28
    OEM Rear Wheel Center Hub Spacer, .48
    OEM Steel Snail Adjusters .33
    CycleWizard Alu Snail Adjusters, .29
    OEM Rear Sprocket 45t, 1.91
    Aluminum rear sprocket 48t, .73
    Supersprox Alu / Steel rear sprocket 48t, 1.65

    Tires:
    OEM Front Tire, TBD
    OEM Rear Tire, TBD
    Dunlop D606 Front Tire, TBD
    Dunlop D606 Rear Tire, TBD
    Michelin T63 Front Tire, TBD
    Michelin T63 Rear Tire, TBD


    Tubes:
    Standard Front Inner Tube, 1.1
    Standard Rear Inner Tube, 1.36
    HD Front Inner Tube, 2.26
    Ultra HD Front Inner Tube, TBD
    HD Rear Inner Tube, 2.68
    Ultra HD Rear Inner Tube, TBD
    TuBliss System Front, 1.52
    TuBliss System Rear, 1.68

    Misc
    OEM Flywheel, 8.18
    Flywheel (lightened), 6.48
    OEM Starter, 3.28
    OEM XR600 Kickstart Lever, TBD
    Sidestand Switch, 0.25
    OEM Fender Tool Bag, .52
    OEM Tool Kit, 1.54

    Weight Adds:


    Misc
    Garmin 60, .45
    Giant Loop Mojavi, 2.86
    Giant Loop Coyote, 4.76
    Giant Loop Fandango Tank bag, 1.82
    Wolfman Enduro Tank bag, 1.04
    Tow Strap, .6
    My Tool Kit w/ tool wrap, 3.84


    Hoping to get some help from inmates on this, please either post up or PM item weights if you have or can get them. Also, if I have left anything out, please advise. I will drop this into a spreadsheet to auto calc net gain/loss, which I hope to be able to attach here. If not I'll figure out some other way to pass it along.

    Thanks,

    BP

    [​IMG]
    #1
    treelinerider likes this.
  2. Brtp4

    Brtp4 Powdercoat it.

    Joined:
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    FWIW I see a lot of fudging on real net loss / gain, by listing things removed, but not always things put back on. For example, pulling the engine guard bars off saves weight.....but a skidplate adds even more back on. Adding HD tires and tubes add a ton of weight. Again, hoping to get real component weights of items removed, substituted, and added on.


    BP


    [​IMG]
    #2
  3. mcma111

    mcma111 Long timer

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    Big bars need the adapters which is an additional weight.
    #3
  4. Brtp4

    Brtp4 Powdercoat it.

    Joined:
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    Does anyone have any of these items loose and laying around?

    XRL Front wheel assembly w/o tire
    XRL rear wheel assy w/o tire
    OEM Front Tire, TBD
    OEM Rear Tire, TBD
    Dunlop D606 Front Tire, TBD
    Dunlop D606 Rear Tire, TBD
    OEM XRL front axle - nut- spacers, TBD

    BP
    #4
  5. kubiak

    kubiak Long timer

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    you can save a little by replacing the inner wheel spacers between the bearings with aluminum ones if you have stock steel ones.
    #5
  6. Brtp4

    Brtp4 Powdercoat it.

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    Kubiak!! Thought you had moved on to bigger and more multi-cylinder things...

    You would not have the weights of those by any chance, eh?

    BP
    #6
  7. mcma111

    mcma111 Long timer

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    I have some of these items but no scale...
    #7
  8. kubiak

    kubiak Long timer

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    no but i remember holding up two wheels and one felt heavier for sure then i changed out the bearing spacer sleeve and that was it. tires and hd tubes weigh a lot too but you have that covered already on the list.
    #8
  9. mcma111

    mcma111 Long timer

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    The reason you don't have any steering stops is because you didn't put any on. Look below the wiring hoop and you'll see the stop I put on each side of my XR600 frame for it's CRF USD fork swap.

    [​IMG]
    #9
  10. kubiak

    kubiak Long timer

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    i got so involved in weight drop on my xrl that i bought a digital scale at harbor freight that weighed grams,ounces and lbs for weighing little parts i modded or shaved off.. it was only around 12 bucks too! i remember getting the xrl under 300 lbs for sure. it was around 292 at the very lightest stage.
    #10
  11. mcma111

    mcma111 Long timer

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    Was that with Helium in the tires??
    #11
  12. kubiak

    kubiak Long timer

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    no lol! i was cutting every mount and tab off the frame and drilling lightning holes in lots of stuff besides all the regular weight saving stuff. most of the weight over the xr600 is the electric start equipment. the best xr i ever had was my 89 xr600. that thing was 264lbs stock because of stock magnesium side cases,stainless exhaust,aluminum cylinder with nicasil liner that year. after adding rear disc and crf forks it was the bomb!
    #12
  13. Brtp4

    Brtp4 Powdercoat it.

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    It seems sub-300 dry is within reach. If they truly are 324 stock - something I doubt - netting 30 lbs is not that hard. The new Lithium Ion batteries are a big help, they are 5+ lbs off themselves. Passenger pegs are 2. Smog equip and plastic tank are at least 5. Hardest thing seems to be not regaining too much on the wheels and tires.

    BP
    #13
  14. kubiak

    kubiak Long timer

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    i remember taking a lot off the rear section by taking off the stock rear brakelight assy,fender under frame piece,fender bag and fender and replacing all that with a crf fender and aftermarket taillight which weighed about 1 lbs.i think cr frontends were about 5 lbs less?replacing all the stock dash and speedo frame equipment with a trailtech took a chunk off too.
    #14
  15. kubiak

    kubiak Long timer

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    i forgot to mention i drilled the brake rotors with lots more holes,
    #15
  16. thebigman

    thebigman bout a dollar 3.98

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    I'll see about getting some weights on some stuff tomorrow , I have some loose stuff laying around and a pretty decent scale . :deal
    #16
  17. Gildus

    Gildus Been here awhile

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    Wow - takes serious analysis and planning to shed that kind of weight. Looks like you're approaching it the right way. :thumbup

    #17
  18. Brtp4

    Brtp4 Powdercoat it.

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    If you have ever wondered why these things are so heavy, hold the right footpeg assembly in your hands. It weighs 1.65 pounds.

    BP


    [​IMG]
    #18
  19. thebigman

    thebigman bout a dollar 3.98

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    Damn BP

    My Bad ,

    you still needing some weights , if so , I will get on it tomorrow , :deal
    #19
  20. Brtp4

    Brtp4 Powdercoat it.

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    No worries.....all good.

    I am gonna see if I can get mine under 300...

    BP
    #20