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2004 XR 650R new to me refresh

Discussion in 'Thumpers' started by Tysonb, Feb 23, 2019.

  1. Tysonb

    Tysonb Now rolling on a 98 R1100GS, and an 04 XR650R

    Joined:
    Oct 16, 2015
    Oddometer:
    42
    Location:
    Lewisporte, Newfoundland, Canada
    98438B70-4B83-442B-B39E-84641757F3C4.jpeg 7F711E3C-E065-4C09-A629-7240FE553246.jpeg So I went ahead and bought a used 2004 XR650R for what I think is a good price ($3800 CAD). Before the snow melts, I plan on doing the repairs it needs as well as make some changes.

    Current state:

    It seems to be fairly stock with the addition of a Baja Designs light and fairing kit
    The front rim seems to have a slight crack in the weld
    It starts and runs well with no smoke
    Play in the rear wheel but not sure if rear wheel or swing arm bearings


    Planned Maintenance:

    Swapping the Baja Designs fairing for my black Britanica Composites Lynx fairing with LED ( 28 and 40 watt) which has room for a GPS mount and 12V power supply
    Replace all bearings (except head - they were recently done)
    Oil and filter of course
    Redo fork seals and new oil
    Rebuild rear shock if necessary
    New clutch cover (not broken but worn)
    Uncork the muffler
    Replace front rim
    New spark plug

    Add the following:

    Bark Busters
    LED turn signals
    Stage 2 cams (removal of decompression lever)
    Rear rack of some sort (something that braces up the sub frame a bit)
    Trail Tech Vapor with indicators kit (neutral, left, right, temp (or something else))
    Ricky Stator to power the LEDs and charge the battery
    Hand warmers because it is cold where I live
    Anti Gravity 4 cell battery to ensure everything lights up (still small and light though)
    Jet kit
    Newer levers (I like shorter levers)
    New mirrors (I have adventure mirrors on my current bike)

    My good friend is a Red Seal Journeyman motorcycle mechanic and was the guy who showed me the bike when it came up for sale in the local classifieds. He also came to get it with me because he was excited for me to get it as we are also riding pals. He has a souped up 86 XT 600. I plan on doing all of the electrical at once so it is all pretty and we don’t have to tear anything apart later on.

    Later considerations are a larger gas tank (I have Rotopax 1G that will go on for now), bigger more comfy seat, and carb upgrade.

    I have read about issues with the peg bots on the right side, so I want to get that taken care of with it being a safety issue. Overall, want to keep the maintenance intervals close to stock and keep this beast running for a very long time. I suspect that my next Dual Sport will electric in 15-20 years.

    I will post progress pics here in future edits.

    Questions:
    Is there anything else that I should consider for my new to me Big Red Pig?
    Do any of you have any parts that I need and want to sell them (PM me directly)?
    The control unit for lights and turn signals is somewhat cheesy. Any recommendations for a better unit?

    Stay tuned for updates although they will be somewhat slow to begin with.

    Suggestions from this thread:

    Check restricted intake rubber between the carb and the head and remove
    Seat concepts seat for comfort
    #1
  2. Tysonb

    Tysonb Now rolling on a 98 R1100GS, and an 04 XR650R

    Joined:
    Oct 16, 2015
    Oddometer:
    42
    Location:
    Lewisporte, Newfoundland, Canada
    06 May, 2019

    • Found the front rim to be broken at the seam - replaced rim and is now on
    • Bark Busters on
    • Rear adjuster bolts were both seized, got one out and after MAP gas, had to drill out and helicoil
    • All swing arm bearings were badly seized and now replaced
    • Wheel bearings have all been replaced
    • Chain roller bearings replaced
    • Front rotor was badly cupped, now replaced
    • Chain, and rings were in good shape, cleaned and lubed
    • Carb was soda blasted and jetted
    • Oil was clean, but replaced along with new filter
    • Coolant replaced
    • Brake fluid replaced
    • ManRacks rack and rear fender brace added
    • Kick start was a little too far on the spline and rubbing on the frame so cut the spline and added sturdy c-clip to keep it off the frame and now nice and tight
    • Leak down test showed well in spec
    • Valves checked and adjusted back into spec
    • Ricky Stator 200W stator installed
    • Custom mount created for Britannia Concepts fairing 32 watt low, 40 watt High LED beams, 12V DC outlet, Garmin RAM mount GPS mount powered in
    • Hand Warmers installed
    • Wiring diagram created, actual wiring starting tomorrow

    Some things were worse than expected, but we are in the endgame now as it were. Sorry for the photo quality - shitty old feature phone in the shop. Pics in no specific order

    55528B70-0A3C-4FEC-8E6D-0BDD35855DF6.jpeg 3717D0D6-4406-405D-9776-04C4D632A7F0.jpeg 18DE0A8D-1CE6-4B86-A4A0-F5EA30677602.jpeg 1F50E01E-9992-4374-A79B-1DBCFA10DB9F.jpeg 28F90D39-834E-4F1C-9851-315E37363369.jpeg 52B21973-D40B-40E1-97B4-47115ABFCF59.jpeg B3F48D13-594A-494E-9C57-27B1337678B5.jpeg 02A85B31-3F5D-46A7-B511-5E9FF1C35025.jpeg 10E73EFB-ABDB-454E-9BA5-75D6159A8014.jpeg
    #2
  3. Bhart89

    Bhart89 Long timer Supporter

    Joined:
    Nov 12, 2013
    Oddometer:
    1,471
    Location:
    Indianapolis, IN
    You’ll probably want a seat concepts or other aftermarket. These R’s don’t share the couch like seat most XRks are known for.
    #3
  4. Tysonb

    Tysonb Now rolling on a 98 R1100GS, and an 04 XR650R

    Joined:
    Oct 16, 2015
    Oddometer:
    42
    Location:
    Lewisporte, Newfoundland, Canada
    I forgot to add that to the list - considering a seat concepts tall and wide.

    For the record, I am 47, 6’1” and 250#s, so not the smallest guy on a bike, but I certainly am a bit big for my previous 250s.
    #4
  5. skibootdog

    skibootdog Been here awhile

    Joined:
    Jun 26, 2006
    Oddometer:
    378
    Location:
    ocean city maryland
    A lot of the xr650r bikes still have the restricted intake rubber between the carb and the head still in place.
    #5
  6. Tysonb

    Tysonb Now rolling on a 98 R1100GS, and an 04 XR650R

    Joined:
    Oct 16, 2015
    Oddometer:
    42
    Location:
    Lewisporte, Newfoundland, Canada
    Thanks, I will add it to the list.
    #6
  7. skibootdog

    skibootdog Been here awhile

    Joined:
    Jun 26, 2006
    Oddometer:
    378
    Location:
    ocean city maryland
    Don't forget the exhaust endcap mod for better flow
    Make sure the carb vent hose goes up and over the frame tube
    If the chain adj bolts are seized try map gas
    Check foot peg mount bolts go to grade 8 or better
    #7
  8. Tysonb

    Tysonb Now rolling on a 98 R1100GS, and an 04 XR650R

    Joined:
    Oct 16, 2015
    Oddometer:
    42
    Location:
    Lewisporte, Newfoundland, Canada
    Thread updated, see second post.
    #8
  9. BikePilot

    BikePilot Long timer

    Joined:
    Jul 5, 2005
    Oddometer:
    11,966
    Location:
    Golden CO
    Nice work Sir! I love my 650R, quite a machine!
    #9
  10. Tysonb

    Tysonb Now rolling on a 98 R1100GS, and an 04 XR650R

    Joined:
    Oct 16, 2015
    Oddometer:
    42
    Location:
    Lewisporte, Newfoundland, Canada
    Another update...

    The wiring is complete and now being tucked away. The custom hardware to hold the battery and fairing had holes drilled to save weight, then painted.

    Electrics include:
    Handwarmers with hi lo
    Turn signals
    Brake light
    Garmin gps mount
    12vdc outlet
    Low beam 30 watt LED
    High beam Baja Designs 40 watt LED


    Early photo of mounting hardware and wiring. The steel hardware was removed, holes drilled, and painted black and then reassembled a few days after this photo.

    B930367F-9AAB-4748-80BE-3D2E16E4D90C.jpeg


    Coolant temp sensor
    2E33A492-69F7-4EEB-9BDA-0F457527E9BF.jpeg

    Key, speedo mounted on fairing.

    21584A20-B8B0-4482-895F-BEAAE9161CE8.jpeg

    New decomp lever hand guards, and cheapo turn signals.

    DD5DD048-2E8C-4ABE-B53D-296ABC41F4C0.jpeg

    Looking forward to posting final pics.

    Attached Files:

    #10
    BikePilot, filippp and ridesmoothfast like this.