Building a Honda XR650L

Discussion in 'Thumpers' started by Sycklemotor, Aug 10, 2013.

  1. Sycklemotor

    Sycklemotor Been here awhile

    Joined:
    Jul 2, 2007
    Oddometer:
    273
    Location:
    USA
    After wanting a tricked out Honda XR650L for years I have finally decided to build one.I have had 77 motorcycles total- a little of everything. I have built a few nice bikes ( mostly BMW's) so this is not my first.And although I do not make my living doing it ( I have) ) I am a certified Ducati tech.I have spent most of my life working with metal and welding.
    I have lurked on the forums for about a year learning and listening.There are some very knowledgeable folks on ADV. I hope that as the project progresses I will get their input and advice.I welcome suggestions. I already have a good start on the project and will start to try and regularly post updates.

    So here goes:
    I started with a 2007 Honda XRL that I purchased on EBAY. It was a mess.I tore it all apart and sold most of it.I kept only what I thought I would use. Most of what I'm doing to the bike is a direct result of reading the forms on ADV. I am impressed with how many sharp, mechanically minded and ingenious people are here!
    Got down to the frame and agonized over painting or powder coating. Even thought about nickel plating as I can get that for free. I know the owners of St. Louis Plating and we work favors back and forth.In the end I opted for powder coating( happy so far).
    I knew I needed to gusset the frame due to cracking .Even though I do not think I will be loading the bike as heavily as some here do.
    I would have done a more extensive job If I were going to load it heavily.
    I also removed the brackets for the wings as well as the piece that keeps your right boot off of the frame. ( Thanks Gary Emig!)

    These photos show the frame gussets welded in. I used MIG to try to mimic factory welds.
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    #1
    enduro16 likes this.
  2. Sycklemotor

    Sycklemotor Been here awhile

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    Here are some photos of the frame during powder coating and some finished brake parts.
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    #2
  3. Sycklemotor

    Sycklemotor Been here awhile

    Joined:
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    Here are some photos of installed swing arm, rear fender, etc.
    I replaced all swingarm bearings and seals as well as steering stem bearings and linkage bearings.I am trying to use mostly new parts. The bike is just too nice to cut corners on.
    I am not in any hurry to finish it. I figure it to be done by spring.
    I really debated powder coating the swingarm but the one I had was not in great shape so I thought I'll try it and If I don't like it I'll change it out later.
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    #3
  4. Sycklemotor

    Sycklemotor Been here awhile

    Joined:
    Jul 2, 2007
    Oddometer:
    273
    Location:
    USA
    Sorry about the previous photos,still figuring this out!

    Here is my plan for the build. I want it as light as possible, reliable.

    711 Motor by CW with 2,5th gear change
    Warp 9 wheels,hubs,rear rotor, dual rim locks front and rear
    CRF450R forks, re valved, re sprung,new seals and oil.
    Emig triple clamps and damper
    MEFO tires
    IMS 4.0 gal. tank
    Sutton oil cooler
    CRF450R oversize front rotor, caliper, EBC pads
    Renazzco seat
    UFO bodywork-white for XR600R
    Relocated battery -anti gravity, junk all battery box, frame etc.
    Mikuni HSR45 carb
    Rear shock by Race Tech with 12Kg. rear spring
    Wolfman Enduro tool bag
    Vapor dash unit
    Baja Designs HID Race Light
    LED turn signals- flush mount
    IMS foot pegs
    Gold O ring chain
    steel braided brake lines with Titanium bleeders and banjo bolts
    Xr's only chain guide, shark fin,skid plate,
    Billet fuel cap
    Mucho titanium bolts
    Cycra hand guards
    FMF Power bomb header with FMF Q4 silencer
    About a million little things!

    Blasted parts ready to plate
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    #4
    Tallbastid likes this.
  5. DQook

    DQook Hawaii NX125

    Joined:
    Jun 25, 2012
    Oddometer:
    37
    Location:
    Oahu North Shore Hawaii
    Go go go!!!!!!!!!
    #5
  6. thebigman

    thebigman XR's all the way . Big Thumps or V-twins

    Joined:
    Jul 9, 2010
    Oddometer:
    3,889
    Location:
    Texas Gulf Coast
    Subscribed ................................................:deal:clap
    #6
  7. Sycklemotor

    Sycklemotor Been here awhile

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    USA
    Marko,
    I have some stock parts for you.You purchased most of the stock parts from me earlier and I figured I would donate them to you.I really appreciate the way you and Steve from San Francisco take care of the people on the list.
    I am really liking the XRL list!
    So if you PM me your address I will get the misc. parts sent down to you- no charge. Mostly little stuff. I also have an oil line for the XR400 oil cooler you got from me.
    #7
  8. Kawidad

    Kawidad Long timer

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    Jul 9, 2005
    Oddometer:
    6,304
    Location:
    Central Coast, Cal
    Nice!!!

    :lurk
    #8
  9. bobbed06

    bobbed06 Cavalera Conspirator

    Joined:
    Aug 25, 2010
    Oddometer:
    1,287
    Location:
    That one place......
    What rear tire is that??? Subscribed to this build....
    #9
  10. MartiniUp

    MartiniUp Long timer

    Joined:
    Jul 14, 2010
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    3,276
    Location:
    TX
    :clap more more!
    #10
  11. techforlife

    techforlife CDI REPAIR

    Joined:
    Sep 21, 2008
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    4,578
    Location:
    Moncton,New Brunswick
    Now this should be interesting.......i like a good build thread...

    Question though.if you are plating the springs,,you know you should build a jig to stretch them slightly so the coils don`t get plated together,,then peel the first time used??????????

    Are you putting a cush hub on it..:wink:

    Oil cooler??????? or big fin head????

    First beers on me:freaky

    B
    #11
  12. Sycklemotor

    Sycklemotor Been here awhile

    Joined:
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    Oddometer:
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    Can't help it, I'm a neat freak when it comes to bikes. I really like to be organized while working on one.
    Here are a few update photos I took while straightening up the shop.
    Got some new parts in this week also.
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    Emig damper post set up.
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    New Emig Damper
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    Sensor bracket-still need to JB weld the magnet on.
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    New chain
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    Here is the FMF exhaust. Header came off the bike I bought-I just cleaned it up.Bought the Muffler on Flea Bay for a good price. Also got the Titanium heat shield for the header off Flea Bay. I plan on TIG welding standoffs to the header to accept the shield.
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    XR's Only skid plate-Black anodized
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    XR's only skid plate-Black anodized
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    #12
    ADVBedouin and Noprogram like this.
  13. Sycklemotor

    Sycklemotor Been here awhile

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    It is a MEFO Explorer,130/80/18 DOT Approved.
    #13
  14. Sycklemotor

    Sycklemotor Been here awhile

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    I did stretch the springs before plating. Using those as my spares and new ones for the build.

    No cush hub being used.

    I will do Sutton oil cooler. Not sure about Big Fins yet. CW and I talked about it early on and decided no. But we'll see.
    Doing a 711cc with all mods-2nd and 5th gear,ported,SS valves,oil pump mod,etc.etc.
    #14
  15. kubiak

    kubiak Long timer

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    madera california
    wow that is one nice build!
    #15
  16. a572mike

    a572mike Adventurer

    Joined:
    Jul 21, 2013
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    40
    Location:
    Great Falls, Montana
    WOW!! Very impressive!
    #16
  17. joexr

    joexr Banned

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    Jan 4, 2011
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    5,022
    I have great respect for a man who builds things himself rather than saying here's my money because I can't.:clap
    #17
  18. bobbed06

    bobbed06 Cavalera Conspirator

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    Thank You Kind Sir......:freaky
    #18
  19. mitchn06

    mitchn06 Been here awhile

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    May 3, 2012
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    SoDak
    this is fantastic, and you sir are a very organized person. I like it! looking good!
    #19
  20. techforlife

    techforlife CDI REPAIR

    Joined:
    Sep 21, 2008
    Oddometer:
    4,578
    Location:
    Moncton,New Brunswick
    I really like the Q2 can myself.......i got my dirt cheap new on ebay last year...i like the color of it and it sounds sweet too...i put a red XR`s Only skidplate on mine:lol3

    Before i installed my skidplate i put Brown Bread sound deading on the inside......i get no sound applification or echo with it on,,worked well...

    http://www.b-quiet.com/brownbread.html

    Lots of other brands arround do the same thing,,

    B
    #20