Don’t forget to change out the thin OEM countershaft sprocket with a wider type Fritzco sprocket. This is supposedly the “weakness” to the XR650L in that the OEM sprocket will eventually wear grooves into the countershaft. Not sure as to how often this actually happens but a $25 investment is worth it.
It's actually not an issue at all if you apply moly grease to the splines like the owner's manual says, but for some reason that practice has been forgotten and so people are wearing out their countershafts. The Fritzco is insurance against that for sure, though!
Depends on what area of the country you live in. In the North East it's thick woods and mud, and mud. A Yamaha TW200 or a much smaller conventional dirt bike would rule. Probably not need anything larger than a 350 four stroke in the north east as you'd be traveling on snow machine trails, ATV trails, wooded single tracks and secondary roads.
For the worst case scenario you should remove the cv type carburetor and replace it with a slide carb like on the xr600. Also a kickstarter should be added. Replacing the stock headlight with LED is not a good idea, because if the LED burns out you're stuck with nothing. Carrying a spare light bulb for a stock light is easyier. Less electronics and good to go. The subframe support system was a really good idea
Halogen bulbs can break super easily, that's not a very good idea either lol. if you really wanted to you could keep a spare/ 3 inch slim light bar for a backup. which would also still put off more light than a standard halogen bulb.
Then it's best to use the original headlight, but instead of using halogen bulbs, buy some LED bulbs for that headlight, so they can be changed easily, in case of burning out. The problem with the modern headlight used in the video is that it uses a built in LED, and in case of going bad, you have to replace the whole headlight. We're talking about a bike for the tough times. I'd add a spare CDI unit to the bike, and since it's a Honda XR650L, the small piston ring gap should be also adressed, same as putting on an aftermarket oil cooler.@@bluemorpho4941
The XR identifier has yes, but the 650l has been around for 30 years. 1993-2023. That’s why Honda releases the 30 year anniversary additions we used in this video.
I love my 650L….its not as slick as my 400R but it’s plated and works pretty damn good off-road IMO…. Not sure why these classics don’t get more love but the simplicity can’t be denied…Nice build you guys did there..👍
They're not exciting and new, that's what all these influencers and big review channels make their money off of. However it's clear that a lot of people love old school bikes like this. The DR650 is very popular, as well as the Tw200. The KLX300, XT250 and the Crf300 haven't changed much at all from their previous variants (other than a small displacement change and EFI) and have been sold for quite a while too.
@@alm4132 A lot of the people I talk to would love an XR650, but the seat height turns them away. I think it's a mixture of seat height + not shiny and new.
I had a XR 650R Great bike but no electric start so down the road it went . Crash and kick got old real quick.. I just bought a 2019 Africa Twin.I been watching your videos for a year or more. Keep up the great reviews .. Around Bend Oregon out on 2 wheels
Muffler to make it quieter Flat Black Low gearing to carry more weight, and lower fuel usage at low speeds. emp shielding headlight mod. one for just enough light. And one mode for bright light. A EDC holder
Looks great guys love my 93 owned since the mid 90's and never let me down! Tons done to it almost all you can do! Lots of vids on my channel.. heres an old pros tip though never ever drill aluminum bars it creates a weak spot and can very easily snap off. Cut the little locating tab off instead!
Really good video. Great to see you out riding a core bike again and motocamping(which brought me to your channel in the first place). Always loved the Honda XR’s. Looking forward to gen 2 of the build.
7:55 the amount of fiberglass that is coming out of that new exhaust is wild. Looks like sparkles in the air. Definitely shoulda done that first start with it outside.
Was really looking forward to this. One thing I didn’t notice you guys put on the bike but I highly recommend is a front fork brace. Makes a big handling difference
Scott Summers developed one for Honda while dominating the GNCC series for a few years. If you do not know of him look him up. Should be some vid's of him. Honda should still be paying him for how many of them he sold for the company. I have been an XR guy from way back the first year the XR75 that altered the course of my life from stick and ball sports to a lifetime of dirtbike riding and racing. I have a 250 air cooled 4 stroke with ele start, KTM suspension, going to have to look into this build. Thanks P.S. Scott Summers used to sale the fork braces, Might look and see.
Replace front 650L sprocket with the one from the 650R. You guys should make a video of the Suzuki DR650 as well. Of the old thumpers the DR is my favorite.
I had the 1989 XR600R until October of 2022 when I reluctantly sold my old girl. She never missed a beat and I rode sand , mud rock gardens and the Aussie bush. The bike was a little heavy at 125 KG or 275 lbs and if it fell on you was one heavy bench press but man that thing would just tractor. I ran 14/48 sprockets and it would just eat up the bush. Any prolonged Highway I swapped out the front sprocket 15T to drop the revs a bit bit without needing to change chain. I mainly trailered the bike to the Bush with all the tools and camp gear . Many a guy has taken a 600 around the world, across the Aussie desert and the testament to how good those engines and bikes were and still are. Honda's only real competitor to the Yamaha Teneré 700 but in a single cylinder.
Great video, guys. I remember when these bikes were first introduced in the mid 80s, and its nice to see that they're still just as relevant now as they were back then. I would like to have seen the before and after weight comparison on this build.
I love the 5.8 gallon plastic tank. All ADV bikes should have a 5+ gallon tank. If you don't want the weight up high, you don't need to fill it all the way, and the added volume can be used to protect the rest of the bike in a fall and as fairings for the rider's legs. My baby GS has a pitiful 2.9 gallon tank so I'm forced to carry fuel which is dumber than dirt, and nobody makes an aftermarket tank for the G310GS, even though it's my only real complaint about that bike.
I’d agree in principle, but in recent years I’ve stated thinking about the problem in terms of range rather than capacity.. For my riding, I think 250 miles is the bare minimum for an adv bike; on a crf300l, that probably means about 4.5g. For a big 1250 GSA, it’s over 6. Bonus fact; the largest tank I’m aware of for the 300 is 3.5g. Boo, hiss. Yes, supplementary tanks solve that, but still. :)
Loving the content. Am I the only one who noticed the Surfire Siletto....then your kit. Alumni? IYKYK. Thank you. Purchased my XR650L March of 2023. Love it.
I bought a new 2022 XR650. And for a bike that only cost $99 a month I have way too much fun! In 6000 miles all I've had to do is 3 oil changes and adjust the valves once.
@@bbaz6729 A lot of people still do credit even if they can afford the total down. If there is a credit option with a good rate why not? It's less out of pocket.
For very little money you can build a bracket out of perforated garage opener railing and install it right under the headlight in between where those round reflectors are. That gives you the chance to put any rectangular 7” or bigger LED LIGHT for highway or off road riding. That rear tire will go bald soon, I personally recommend the Dunlop Trailmax mission, it’s a serious 50/50 tire and fits perfectly to this motorcycle. About the emissions air filters carburetors it’s all a dream because the motorcycle has only five speeds doesn’t matter what you do you never will be cruising like you do on your crotch rocket. It’s a good bike to have it in your collection. Thank you for this video 🤩👏🏻
Forgot to mention Amazon carries an on/off switch independent and directly to the battery, so no need to be cutting or stripping the original motorcycle cables. Just search LED light on/off switch comes with the positive and negative to the battery, on/off switch to the handle bar and positive and negative to the light. These lights are less than 40 watts and the battery will support it without need to change the stator. With that output in lumens you can go off road as fast as you desire, good luck 👍🏼
Happy we think alike, would be nice to see a video of that, even as a short format UA-cam Short, plenty of people would love an " EMP Proofing a Motorcycle video" too bad half of them on the market have transistors and PCB boards all over the place@@backcountryadvmoto
I have a bike I built with an 87 honda 250x engine it is very fuel efficient and the bike handles well on and off road. I have decided it is no longer the ideal machine for emergency situations because winter hit and u can't ride a bike in deep snow and definitely not ice on roads, for a chunk of the year I have no vehicle for that situation so I figure a 4 weeler might be better suted for me
Fun vid. When I was looking for this type of bike to replace my KTM 790 with something more off road worthy I ended up getting the SWM Superdual 650 after a lot of research. It is 8K new, has a way more powerful water cooled engine, EFI, adjustable suspension, windshield, full crash bars, full engine protection, rear grab handles, super stout rear rack, center stand, auxiliary lights... ALL STOCK. If people would look outside the box some there are some really cool bike out there. I've been hammering it all over the western US the last 8 months, best 50/50 bike I've tried, and I have ridden a lot of bikes. The AJP PR7 is also VERY cool but not factory street legal.
Thanks for this great, informative video fellas. I was researching adv bikes that aren't outrageously priced for my personal real-world prepper bug-out bike. I liked the KLR650, however after research I considered the DR650, but after seeing this video I feel this bike is much more appropriate for my personal opinions on what a real bug-out bike and it's capabilities should be. You guys hit the nail on the head with the upgrades...Reliability, Range, Safety. Thank you!
This was therapeutic! I've owned just about every dirt bike under the sun, but I always have a special place in the corner of the shop for the pig, which is my second one! Accessorizing is almost as fun as the ride!
might be getting an 84 xl600r, similar bike, also just doesn't seem to die from what I've heard, definitely hoping to build it up as a daily/survival type bike
I have a 2017 that I bought new, I did pretty much all the mods you guys did, I recommend getting rid of the octopus emissions thing, that actually hurts the engine by causing backfires and overheating, it serves no purpose but keep Californian regulators happy. I also changed the carburetor for a Mikuni HSR pumper, if you do that, disconnect the pump and save yourself a lot of hours of unsuccessful jetting tests, with the pump connected it never runs right, with the pump disconnected it runs the way it should have from factory.
This is the first video I’ve seen on your channel. Very impressed. Used to work for Honda motorcycles. Very familiar with the XR650L. Honda suspension is good on that motorcycle. I personally used race tech suspension on mine. What was the chest pouch you were wearing? Also, what was the deal with the radio? Look forward to future videos!
This is one of the reasons I bought a 2023 also, solid bike. A great, simple platform for many different builds. A larger stator. A real build is swapping 2nd, 5th gear, 14t-48t drivetrain, change that spinnaker of a front fender for higher speeds, I run a trail tech vapor for rpm, and oil temp, head temp. I haven't decided on carb yet
I have a 2020 XRL that I bought new. I ride in sand washes that are strewn with rocks. Very challenging. The Honda is excellent in that stuff. I have not touched the suspension. I am 220 in street clothes. I am an older rider at 72 so I bought a smaller lighter dual sport for the more technical stuff. But it is no match in the deep sand for the Honda which is why I won't ever get rid of it. The other thing is, that I checked the valve clearances at 600 miles and then again at a little over 3000 miles and they were still within factory spec! I do plan on adding a oil cooler. I debated doing that for a long time since I don't want another thing exposed that can get crush or damaged in a fall. But, I concluded that the benefits out weigh the risk. I have been using the Motoz rear tires with very good success. These bike tend to eat rear tires since there is no cush drive. I agree with your assessment that the Honda is still relevant and awesome after all these years.
The XR650L is the fatter, slower brother to the XR600R. The XR650R is a totally different bike and Honda shouldn't have even referred to it as an XR. I love the XR650L and XR650R so much (I've owned the former and traveled the US and Canada on it and I currently own the R). The R is the king of Baja. The XR650L forks would explode before it reached 1000 miles of whoops, I'm sure. Just a suggestion, with that weight on the rear, you are going to either want to weld a frame reinforcement or get the SW-Motech subframe braces. The frames are prone to cracking at the rear-most joint.
Totally agree about the 650 R. That bike was and is amazing. Wish they could’ve just added an electric start to that bike and called it good. As far as your second part of your comment. Maybe rewatch the video. I put a reinforcement on the rear subframe and talk about it extensively a couple times in the video 👍🏻
The XR650L forks are essentially the same as the XR600R forks, just different spring rates, and the XR600R won the Baja from 1996-1998, and the XR650R won from 1999-2005. The XRL could do 1000 miles of whoops pretty easily. Not as nicely as a 600R or 650R, since it weighs a bit more, but it could do it.
I had the XR650R that I fully made street legal thanks to Rocky Mnt and XR's Only. That was a great bike and there is a video of me out there riding not to far from your location while my buddy was filming on his XR650L. We switched at one point so he could try the R out. All I will say is "2 completely different bikes" one not better than the other but just engineered for 2 different things. I wish I still had that bike but now that I'm older the electric start, plush suspension and air cooled engine don't sound bad. Though I will miss the power my R made and the way it would fly through the desert at 65-110 with ease!
I love the project and the XR is a time tested platform and there's a reason they still make them. @Mike H - Did you black out your Rally? Looks sick! I'm a huge fan of both of you guys channels. I think you are missing the point in a few areas of having a reliable Bugout / SHTF bike. - - Why change to a Li battery? I don't think they are as reliable as standard Gel or stock batt. They don't like cold and I've seen too many problems with them that the weight savings isn't worth it IMO. Why put a loud pipe on a bugout bike? Draw's attention while the stock is nice and stealthy. The weight savings on a 650 pig is negligible. Stock Brake and shifters are also easy to bend back into shape after a fall vs the aluminum ones that can just snap. For reliability in SHTF I'd stay stock and carry spares. Bash plate isn't just for bottoming out. It protects the bottom from smaller rocks flying up especially in the desert conditions like you guys were in. I'd also get a spare CDI/ECU and put it in a faraday bag for the future. I'm a survival genera fan so these things stuck out to me.
Quality video - excellent information. Who doesn't love wrenching on a brand new bike adding all those add-ons! Music reminded me of On any Sunday...lol. Let's see some more...
I hope you add a fork brace, It stabilizes the front end in the washy sand. Then a scotts above bar stabilizer allows you to get to the oil fill and takes away the rock dives on rocky two track!
No one ever keeps these long. Too old of a design, no tach, no engine cooling, tank too small, too tall for 90% of people. People keep KLR’s for 30k miles.
@@slalomkingspeak for yourself. I’ve had mine for over 3 1/2 years now and do hare scrambles with it all the time. Any adventure bike that you plan on actually riding needs an oversized tank. Air cooled, I drop it, I don’t have to worry about breaking radiators. It’s tall, I’ll give you that, but if you’re 6’ tall you’re fine, 90% aren’t built for a 340lbs adventure bike anyways. No tach? You’re probably better off in a car if you can’t distinguish how to shift based on sound. It’s an old design, if it isn’t broke, don’t fix it. Klr’s weigh what feels like a metric ton, I would hate to own something so heavy and so underpowered.
Great upgrades with that slick LED light and boss 5.6 gallon tank? The guard looks beefy and the larger pegs will be nice, need do that on my GS. Awesome that these are still so cheap and basic new, good for Honda and Suzuki.
I actually went to buy one of these one time and Honda thumbed their nose at my well established 790 credit score. I could have got my credit union to do it, but it kinda hacked me off at them. Bought a Suzuki dr650 from next door. I don’t doubt that Honda is a jam up machine. The dr650 is every bit as much bike with a cult like following and aftermarket support to match. Funny what happens when a manufacturer put out a solid machine, with a solid design,and sells it unchanged for 30 years. It is kind of a blank canvas when you get it, then you focus it to your needs and riding style as you modify it over the years. Since 2010 mine has morphed into an adventure bike with windshield, oversized fuel tank, carb re jet,exhaust, large panniers, top trunk, and more comfy seat. It has taken me back and forth to work, a few times through a disaster zone after a hurricane and a wicked flood faithfully for 20,000 miles and counting. Not a single issue, oil change and air filter service every 5000 miles after 500 mile break in service.adjusted the valves once. And swapped out several tires. I just got my harley back from a friend I sold it to, both kids about to be in school, so the mrs is showing intrest in learning to ride and getting her motorcycle endorsement. So the Ol trusty dr is about to morph into a supermoto. Lowering kit, supermoto aluminum mag rims that accept tubeless tires. To drop the seat height down to a level she can build confidence with as a new rider. Might even re jet the carb to factory settings and re install the factory exhaust to calm the power back down as it will do roll on wheelies in first and second as is if cranked on. Just enough power to get down the interstate, but extremly forgiving in stock form.
650 would be a downgrade as far as Off-road capability.......250 is usually a full sprung Dirt Bike, better clearance, it will go Faster and better in single track and tighter stuff. 650 would be a heavy slug in tighter more nasty off-road terrain, don't care what anyone says.....if you want an upgrade, go 450cc.
Good bike, great build, pleasant video. (even if you did repeat yourself) 😂 I like the Tusk footpegs. Are they "the best"? Who knows but I'm happy with them. The "emissions stuff" consists of an EGR system and a crankcase ventilation oil vapor capture. Know what you're getting into and make good decisions. Following some guy's recipe on the internet (no matter how popular) can lead to regrets. Not just for you but for the bike's next owner. 😅 I don't get the "bugout" thing? Is that code for escaping the family to execute a precision camping trip?
Re-jetting a carb can really wake a bike up. Did it to my Crf230f and it feels like a 250 now with the t6 pro circut exhaust. A 110 is what I used but for a 650 it would be probably 138 or even higher with a ballsy exhaust. It allready had some power but jetting and exhaust wakes a bike up.
Is lowering a reasonable thing to do? With stock 13” clearance ot could lose 2-3” and still have as much clearance as a suzuki dr . But it would be a xr650L and all that implies. So… lower ?
Its nice, kind of curious what the over cost of every thing including the bike is. i am sticking with my KLR650 2022 :) my over all build with luggage and all the upgrades nearly what you have done minus a few things like lights, carb,tank. I am in to mine with cost of the bike armor and gear, $8,500. put new tires on this year $200.
Hi from Greece excellent presentation and perfect project think air filter was stock I mean not changed with after market? The other problem budget motorcycles like XR or others brands not coming in Greece and you can't find it
Like the video. Like all the options. All cool stuff. Bug out to me in this would be bug out to a moto camp trip in the woods. However, this is NOT a BUDGET bike build. Unless 2k+ is the budget.
Moving to a place where there are only dirt roads so I am thinking about getting something to replace my Dyna. I can't decide if I wanna get something like this or go for some bigger adventure bike. Most of my riding is gonna be on washboard roads and I won't be hitting any really crazy trails. I ride solo and camp so I need some storage but not much more than a backpack and a bedroll. Any suggestions I just can't make up my mind.
Now lower it I did mine I am 6ft 4 and it still fits me great and makes it a entirely different bike . I live in Marana Az if you want to ride mine . Plus a couple other things have been done. Be safe RIDE ON
Rackless systems keep the weight lower and forward. Thus it does not adversly impact handling as much. Strap it on tight and keep the heavy stuff low and center.
The XR600R was the predecessor to the XR650R, both baja champions. The L is kind of a spin off of the older XR600R that is meant to be more of a cheap, reliable dual sport without any bells and whistles.
I just wanna point out that in terms of efficiency, a 650 is actually a huge bike. I'm 6' and 160 lbs. and I'm gettin around great on a Honda cb125, and doin over 100 miles per gallon (which would be super important in a bug-out bike..) so for me a 250 would be huge. I mean how often do you need to go 70 mph anyway, and in a bug-out situatio, think about it. just food for thought.. cool build tho , sick video
i have a 22 klr i decked out with tusk stuff. it already had the bigger tank dont see why you didint go with klr cheaper and fuel injection. good video looks fun.
The KLR is a great option, but when we are talking about the worst case scenario, the more simple the bike is the better. For instance, the KLR is water cooled. What happens if you punch a hole in a radiator that is too big to patch. The bike is basically dead. The XR is air cooled so though it’s not a performance machine, it is reliable and has less things to go wrong.
Bought mine new in 03 I’ve put this bike through hell . Oil changes valve adjustments chains and sprockets hand guards . I’ve ridden enduros ,dual sport rides + long road miles . motor is getting a little tired so I guess she due for a top end rebuild, not bad for twenty years. Something lighter is called for for eastern off road racing so I own a two stroke KTM also great concept for a bugout bike 😎
I’d go with an XR400. Kick start. Put a battery eliminator on it and a 4.5 gal tank. Better fuel economy. Better off road ability. LED lights. Lighter, simpler, bullet proof.
I've ridden this bike for a long time and it was exceptional good. A solid bike for all terrains.
Don’t forget to change out the thin OEM countershaft sprocket with a wider type Fritzco sprocket. This is supposedly the “weakness” to the XR650L in that the OEM sprocket will eventually wear grooves into the countershaft. Not sure as to how often this actually happens but a $25 investment is worth it.
We actually did that, but I didn’t mention it in the video. Totally forgot to thanks for the heads up though. I will mention it in the next video.
It's actually not an issue at all if you apply moly grease to the splines like the owner's manual says, but for some reason that practice has been forgotten and so people are wearing out their countershafts. The Fritzco is insurance against that for sure, though!
I have replaced counter shafts on 200 and 250 Hondas.
@@aTuWitty Yeah moly grease is also used on splined machine shafts. Without it they will fail in a short amount of time.
@@backcountryadvmoto I'm curious what size sprocket you put on. You were hitting 80+ mph and find it hard even with a 15 tooth.
The legendary XR650L is always the right answer.
Depends on what area of the country you live in. In the North East it's thick woods and mud, and mud. A Yamaha TW200 or a much smaller conventional dirt bike would rule. Probably not need anything larger than a 350 four stroke in the north east as you'd be traveling on snow machine trails, ATV trails, wooded single tracks and secondary roads.
@@SHL-ge3wn TW’s are cool too! Love those fat tires!
I grew up on the XR 600 R. They’re *basically* the same. That thing never failed me. If it ain’t broke, don’t fix it.
For the worst case scenario you should remove the cv type carburetor and replace it with a slide carb like on the xr600. Also a kickstarter should be added. Replacing the stock headlight with LED is not a good idea, because if the LED burns out you're stuck with nothing. Carrying a spare light bulb for a stock light is easyier. Less electronics and good to go. The subframe support system was a really good idea
Just out of curiosity, how many LEDs have you seen burnt out? I haven't seen any. I've seen plenty of regular bulbs that have failed though.
Solid ideas for sure, I think the only thing I'd do differently is run a Lectron carb or something similar
LED will still be going way after you starve
Halogen bulbs can break super easily, that's not a very good idea either lol.
if you really wanted to you could keep a spare/ 3 inch slim light bar for a backup. which would also still put off more light than a standard halogen bulb.
Then it's best to use the original headlight, but instead of using halogen bulbs, buy some LED bulbs for that headlight, so they can be changed easily, in case of burning out. The problem with the modern headlight used in the video is that it uses a built in LED, and in case of going bad, you have to replace the whole headlight. We're talking about a bike for the tough times. I'd add a spare CDI unit to the bike, and since it's a Honda XR650L, the small piston ring gap should be also adressed, same as putting on an aftermarket oil cooler.@@bluemorpho4941
The XR has been around longer than 30 years I've got one in my shop that's 42 years old still runs and rides great.
The XR identifier has yes, but the 650l has been around for 30 years. 1993-2023. That’s why Honda releases the 30 year anniversary additions we used in this video.
Not the L version
Not 650l
I love my 650L….its not as slick as my 400R but it’s plated and works pretty damn good off-road IMO….
Not sure why these classics don’t get more love but the simplicity can’t be denied…Nice build you guys did there..👍
They're not exciting and new, that's what all these influencers and big review channels make their money off of.
However it's clear that a lot of people love old school bikes like this. The DR650 is very popular, as well as the Tw200.
The KLX300, XT250 and the Crf300 haven't changed much at all from their previous variants (other than a small displacement change and EFI) and have been sold for quite a while too.
Maybe the seat height? Tallest bike I've ever sat on.
@@alm4132 A lot of the people I talk to would love an XR650, but the seat height turns them away. I think it's a mixture of seat height + not shiny and new.
If the 400r had a magic button it would basically be the perfect bike.
I had a XR 650R Great bike but no electric start so down the road it went . Crash and kick got old real quick.. I just bought a 2019 Africa Twin.I been watching your videos for a year or more. Keep up the great reviews .. Around Bend Oregon out on 2 wheels
Muffler to make it quieter
Flat Black
Low gearing to carry more weight, and lower fuel usage at low speeds.
emp shielding
headlight mod. one for just enough light. And one mode for bright light.
A EDC holder
Looks great guys love my 93 owned since the mid 90's and never let me down! Tons done to it almost all you can do! Lots of vids on my channel.. heres an old pros tip though never ever drill aluminum bars it creates a weak spot and can very easily snap off. Cut the little locating tab off instead!
Looking forward to the rest of the build! I had a 95 XR 600 and loved it so much except the 2 foot long kick starter!!
Really good video. Great to see you out riding a core bike again and motocamping(which brought me to your channel in the first place). Always loved the Honda XR’s. Looking forward to gen 2 of the build.
Outstanding video guys! I'm going soon to get my new 650. Mickey 59 in NY
7:55 the amount of fiberglass that is coming out of that new exhaust is wild. Looks like sparkles in the air. Definitely shoulda done that first start with it outside.
Hahaha yeah for sure 😷
Was really looking forward to this. One thing I didn’t notice you guys put on the bike but I highly recommend is a front fork brace. Makes a big handling difference
Thanks I’ll add that to the list
Scott Summers developed one for Honda while dominating the GNCC series for a few years. If you do not know of him look him up. Should be some vid's of him. Honda should still be paying him for how many of them he sold for the company. I have been an XR guy from way back the first year the XR75 that altered the course of my life from stick and ball sports to a lifetime of dirtbike riding and racing. I have a 250 air cooled 4 stroke with ele start, KTM suspension, going to have to look into this build. Thanks
P.S. Scott Summers used to sale the fork braces, Might look and see.
Replace front 650L sprocket with the one from the 650R. You guys should make a video of the Suzuki DR650 as well. Of the old thumpers the DR is my favorite.
It was the XR600R 8 times in a row and 12 time's total Larry Rossler and Bruce Ogilve R.I.P. RIP in Peace Bruce 🙏
Bigger fuel tank and the gear mod for gears 2 and 5. And being in Az maybe give an oil cooler a thought too.
how much bigger should they get?
They put a 5 gallon tank on it. How much bigger do you want?
great video, brings back memories of Trans Am Trail ride 22 years ago, keep up the great content in AZ
I'm totally digging your XR650 build, old school badass!
I had the 1989 XR600R until October of 2022 when I reluctantly sold my old girl. She never missed a beat and I rode sand , mud rock gardens and the Aussie bush. The bike was a little heavy at 125 KG or 275 lbs and if it fell on you was one heavy bench press but man that thing would just tractor. I ran 14/48 sprockets and it would just eat up the bush. Any prolonged Highway I swapped out the front sprocket 15T to drop the revs a bit bit without needing to change chain. I mainly trailered the bike to the Bush with all the tools and camp gear . Many a guy has taken a 600 around the world, across the Aussie desert and the testament to how good those engines and bikes were and still are. Honda's only real competitor to the Yamaha Teneré 700 but in a single cylinder.
This is great! Loving the classic bike build.
I hope you did Dave's mods for the carb when rejetting. The fork brace is a must for the XRL when you are riding offroad as someone mentioned.
Great video, guys. I remember when these bikes were first introduced in the mid 80s, and its nice to see that they're still just as relevant now as they were back then. I would like to have seen the before and after weight comparison on this build.
This is the unicorn! And it's old skool!! Nice bloody work.
I love the 5.8 gallon plastic tank. All ADV bikes should have a 5+ gallon tank. If you don't want the weight up high, you don't need to fill it all the way, and the added volume can be used to protect the rest of the bike in a fall and as fairings for the rider's legs. My baby GS has a pitiful 2.9 gallon tank so I'm forced to carry fuel which is dumber than dirt, and nobody makes an aftermarket tank for the G310GS, even though it's my only real complaint about that bike.
I’d agree in principle, but in recent years I’ve stated thinking about the problem in terms of range rather than capacity.. For my riding, I think 250 miles is the bare minimum for an adv bike; on a crf300l, that probably means about 4.5g. For a big 1250 GSA, it’s over 6. Bonus fact; the largest tank I’m aware of for the 300 is 3.5g. Boo, hiss. Yes, supplementary tanks solve that, but still. :)
Always thought the TW would be a good fit.
Easy to wheel indoors for cover too.
Loving the content. Am I the only one who noticed the Surfire Siletto....then your kit. Alumni? IYKYK. Thank you. Purchased my XR650L March of 2023. Love it.
I bought a new 2022 XR650. And for a bike that only cost $99 a month I have way too much fun! In 6000 miles all I've had to do is 3 oil changes and adjust the valves once.
That's impressive for the bike, but you couldn't afford to buy it outright? It's cheaper than some pedal road bikes?
@@bbaz6729not everyone has 5-6k spare
@@bbaz6729 A lot of people still do credit even if they can afford the total down. If there is a credit option with a good rate why not? It's less out of pocket.
For very little money you can build a bracket out of perforated garage opener railing and install it right under the headlight in between where those round reflectors are. That gives you the chance to put any rectangular 7” or bigger LED LIGHT for highway or off road riding. That rear tire will go bald soon, I personally recommend the Dunlop Trailmax mission, it’s a serious 50/50 tire and fits perfectly to this motorcycle. About the emissions air filters carburetors it’s all a dream because the motorcycle has only five speeds doesn’t matter what you do you never will be cruising like you do on your crotch rocket. It’s a good bike to have it in your collection. Thank you for this video 🤩👏🏻
Forgot to mention Amazon carries an on/off switch independent and directly to the battery, so no need to be cutting or stripping the original motorcycle cables. Just search LED light on/off switch comes with the positive and negative to the battery, on/off switch to the handle bar and positive and negative to the light. These lights are less than 40 watts and the battery will support it without need to change the stator. With that output in lumens you can go off road as fast as you desire, good luck 👍🏼
I always said this bike is the perfect for a SHTF or EMP situation.
We’ve wrapped the CDI to make it EMP proof. Not much left to do to make it last the worst case senecio
Happy we think alike, would be nice to see a video of that, even as a short format UA-cam Short, plenty of people would love an " EMP Proofing a Motorcycle video" too bad half of them on the market have transistors and PCB boards all over the place@@backcountryadvmoto
I have a bike I built with an 87 honda 250x engine it is very fuel efficient and the bike handles well on and off road. I have decided it is no longer the ideal machine for emergency situations because winter hit and u can't ride a bike in deep snow and definitely not ice on roads, for a chunk of the year I have no vehicle for that situation so I figure a 4 weeler might be better suted for me
Fun vid. When I was looking for this type of bike to replace my KTM 790 with something more off road worthy I ended up getting the SWM Superdual 650 after a lot of research. It is 8K new, has a way more powerful water cooled engine, EFI, adjustable suspension, windshield, full crash bars, full engine protection, rear grab handles, super stout rear rack, center stand, auxiliary lights... ALL STOCK. If people would look outside the box some there are some really cool bike out there. I've been hammering it all over the western US the last 8 months, best 50/50 bike I've tried, and I have ridden a lot of bikes. The AJP PR7 is also VERY cool but not factory street legal.
Excellent build guys! Cant wait to see more on this!
Thanks brother
My local dealer has one on the floor. It's so tempting to grab it... even though I have a KLR and 501S in the garage.
Good video. I had a XR600R in the 90s. I wish we could get the XR650L in Europe 😢
I paid $1800 for my xr650L. Ride it all the time. Was doing 85 on the highway the other day. Great offroad also. It also has a 5.8 gallon tank.
How is the pull from 65 to 85 mph
Thanks for this great, informative video fellas. I was researching adv bikes that aren't outrageously priced for my personal real-world prepper bug-out bike. I liked the KLR650, however after research I considered the DR650, but after seeing this video I feel this bike is much more appropriate for my personal opinions on what a real bug-out bike and it's capabilities should be. You guys hit the nail on the head with the upgrades...Reliability, Range, Safety. Thank you!
This was therapeutic! I've owned just about every dirt bike under the sun, but I always have a special place in the corner of the shop for the pig, which is my second one! Accessorizing is almost as fun as the ride!
That's really an awesome build!!! A small windscreen and you could travel that bike anywhere you want to go and have a blast doing it. 😊😊😊
Excited to see what else you do with this. I have a 2015 XR that I've neglected for some time. Makes me want to go out and get it back up to snuff.
might be getting an 84 xl600r, similar bike, also just doesn't seem to die from what I've heard, definitely hoping to build it up as a daily/survival type bike
I have a 2017 that I bought new, I did pretty much all the mods you guys did, I recommend getting rid of the octopus emissions thing, that actually hurts the engine by causing backfires and overheating, it serves no purpose but keep Californian regulators happy. I also changed the carburetor for a Mikuni HSR pumper, if you do that, disconnect the pump and save yourself a lot of hours of unsuccessful jetting tests, with the pump connected it never runs right, with the pump disconnected it runs the way it should have from factory.
This is the first video I’ve seen on your channel. Very impressed. Used to work for Honda motorcycles. Very familiar with the XR650L.
Honda suspension is good on that motorcycle. I personally used race tech suspension on mine.
What was the chest pouch you were wearing?
Also, what was the deal with the radio?
Look forward to future videos!
This is one of the reasons I bought a 2023 also, solid bike. A great, simple platform for many different builds. A larger stator. A real build is swapping 2nd, 5th gear, 14t-48t drivetrain, change that spinnaker of a front fender for higher speeds, I run a trail tech vapor for rpm, and oil temp, head temp. I haven't decided on carb yet
Swapping 2nd and 5th for what? Clue me in?
Husqvarna 701 front fender use that & xr250r Baja headlight this will give a new front look to bike
Total cost if you were purchasing all that you up graded? Roughly. Nice to see you out and riding. Although no Moose yet. Yep it’s me. Ha Take care.
I have a 2020 XRL that I bought new. I ride in sand washes that are strewn with rocks. Very challenging. The Honda is excellent in that stuff. I have not touched the suspension. I am 220 in street clothes. I am an older rider at 72 so I bought a smaller lighter dual sport for the more technical stuff. But it is no match in the deep sand for the Honda which is why I won't ever get rid of it.
The other thing is, that I checked the valve clearances at 600 miles and then again at a little over 3000 miles and they were still within factory spec! I do plan on adding a oil cooler. I debated doing that for a long time since I don't want another thing exposed that can get crush or damaged in a fall. But, I concluded that the benefits out weigh the risk. I have been using the Motoz rear tires with very good success. These bike tend to eat rear tires since there is no cush drive. I agree with your assessment that the Honda is still relevant and awesome after all these years.
Interested what jets Rocky Mountain sent to match the exhaust pipe ?
setup looks nice I just got my 2023 looking to do something similar for mine.
Infelizmente no Brasil não temos esta moto! A Nossa última fabricada foi a XR 250 que ficou até 2008 somente. Parabéns !!!
I wish I had an XR 650L and go adventures like you guys did.
The XR650L is the fatter, slower brother to the XR600R. The XR650R is a totally different bike and Honda shouldn't have even referred to it as an XR. I love the XR650L and XR650R so much (I've owned the former and traveled the US and Canada on it and I currently own the R). The R is the king of Baja. The XR650L forks would explode before it reached 1000 miles of whoops, I'm sure.
Just a suggestion, with that weight on the rear, you are going to either want to weld a frame reinforcement or get the SW-Motech subframe braces. The frames are prone to cracking at the rear-most joint.
Totally agree about the 650 R. That bike was and is amazing. Wish they could’ve just added an electric start to that bike and called it good. As far as your second part of your comment. Maybe rewatch the video. I put a reinforcement on the rear subframe and talk about it extensively a couple times in the video 👍🏻
@@backcountryadvmoto that should be the bike that Honda would sell worldwide like cupcakes
The XR650L forks are essentially the same as the XR600R forks, just different spring rates, and the XR600R won the Baja from 1996-1998, and the XR650R won from 1999-2005. The XRL could do 1000 miles of whoops pretty easily. Not as nicely as a 600R or 650R, since it weighs a bit more, but it could do it.
I had the XR650R that I fully made street legal thanks to Rocky Mnt and XR's Only. That was a great bike and there is a video of me out there riding not to far from your location while my buddy was filming on his XR650L. We switched at one point so he could try the R out. All I will say is "2 completely different bikes" one not better than the other but just engineered for 2 different things. I wish I still had that bike but now that I'm older the electric start, plush suspension and air cooled engine don't sound bad. Though I will miss the power my R made and the way it would fly through the desert at 65-110 with ease!
Rock solid video kyle. Really enjoyed this build, and what a great camping spot too. It’s time to go ride and camp.. keep crushing it.
I love the project and the XR is a time tested platform and there's a reason they still make them. @Mike H - Did you black out your Rally? Looks sick! I'm a huge fan of both of you guys channels. I think you are missing the point in a few areas of having a reliable Bugout / SHTF bike. - - Why change to a Li battery? I don't think they are as reliable as standard Gel or stock batt. They don't like cold and I've seen too many problems with them that the weight savings isn't worth it IMO. Why put a loud pipe on a bugout bike? Draw's attention while the stock is nice and stealthy. The weight savings on a 650 pig is negligible. Stock Brake and shifters are also easy to bend back into shape after a fall vs the aluminum ones that can just snap. For reliability in SHTF I'd stay stock and carry spares. Bash plate isn't just for bottoming out. It protects the bottom from smaller rocks flying up especially in the desert conditions like you guys were in. I'd also get a spare CDI/ECU and put it in a faraday bag for the future. I'm a survival genera fan so these things stuck out to me.
Quality video - excellent information. Who doesn't love wrenching on a brand new bike adding all those add-ons! Music reminded me of On any Sunday...lol. Let's see some more...
Glad you enjoyed it!
I hope you add a fork brace, It stabilizes the front end in the washy sand. Then a scotts above bar stabilizer allows you to get to the oil fill and takes away the rock dives on rocky two track!
Interesting, similarly I converted my old XR628R into a Dual-Sport. It’s my one bike that has never let me down...
curious if you can link or talk about the radio your carrying in your backpack. Great video as usual, thank you
The radio is a Baofeng UV82HP a.co/d/8nGbFaF
If anyone wants a XR650L with 3K miles on it and all the sparkels, I have one for sale in NW Wyoming.
Below $3k?
@@solosix3991 The stock bike is worth $5K and I have over $2K in farkles, what do you think.
No one ever keeps these long. Too old of a design, no tach, no engine cooling, tank too small, too tall for 90% of people. People keep KLR’s for 30k miles.
I had mine 12 years and i love it for what it is
@@slalomkingspeak for yourself. I’ve had mine for over 3 1/2 years now and do hare scrambles with it all the time.
Any adventure bike that you plan on actually riding needs an oversized tank. Air cooled, I drop it, I don’t have to worry about breaking radiators. It’s tall, I’ll give you that, but if you’re 6’ tall you’re fine, 90% aren’t built for a 340lbs adventure bike anyways. No tach? You’re probably better off in a car if you can’t distinguish how to shift based on sound. It’s an old design, if it isn’t broke, don’t fix it.
Klr’s weigh what feels like a metric ton, I would hate to own something so heavy and so underpowered.
as far as i know please correct me if im wrong the only xr to win the baja 8 times is the xr650r totally different bike i own one
That is correct. I say that in the video. “The predecessor the 650R” is what one
I'm loving it . I just think a 650 is too much for me mabie 250 or 400 cc. what do you all think
Great upgrades with that slick LED light and boss 5.6 gallon tank? The guard looks beefy and the larger pegs will be nice, need do that on my GS.
Awesome that these are still so cheap and basic new, good
for Honda and Suzuki.
I've been a huge fan of this bike ever since I was a kid, watching all UA-cam videos of it, unfortunately it's not available in Europe 😭
I actually went to buy one of these one time and Honda thumbed their nose at my well established 790 credit score. I could have got my credit union to do it, but it kinda hacked me off at them. Bought a Suzuki dr650 from next door. I don’t doubt that Honda is a jam up machine. The dr650 is every bit as much bike with a cult like following and aftermarket support to match. Funny what happens when a manufacturer put out a solid machine, with a solid design,and sells it unchanged for 30 years. It is kind of a blank canvas when you get it, then you focus it to your needs and riding style as you modify it over the years. Since 2010 mine has morphed into an adventure bike with windshield, oversized fuel tank, carb re jet,exhaust, large panniers, top trunk, and more comfy seat. It has taken me back and forth to work, a few times through a disaster zone after a hurricane and a wicked flood faithfully for 20,000 miles and counting. Not a single issue, oil change and air filter service every 5000 miles after 500 mile break in service.adjusted the valves once. And swapped out several tires. I just got my harley back from a friend I sold it to, both kids about to be in school, so the mrs is showing intrest in learning to ride and getting her motorcycle endorsement. So the Ol trusty dr is about to morph into a supermoto. Lowering kit, supermoto aluminum mag rims that accept tubeless tires. To drop the seat height down to a level she can build confidence with as a new rider. Might even re jet the carb to factory settings and re install the factory exhaust to calm the power back down as it will do roll on wheelies in first and second as is if cranked on. Just enough power to get down the interstate, but extremly forgiving in stock form.
I have a 1994 XR250L and love it but I have reached my limits on it and am looking to upgrade to the 650L looks like a great bike.
650 would be a downgrade as far as Off-road capability.......250 is usually a full sprung Dirt Bike, better clearance, it will go Faster and better in single track and tighter stuff. 650 would be a heavy slug in tighter more nasty off-road terrain, don't care what anyone says.....if you want an upgrade, go 450cc.
I like the LED lights but which ones are still warm enough to melt snow/ice?
Great video and awesome build.
Could you share what jetting settings and air fuel mixture settings you did? Building my own xr650l. Thanks
Good bike, great build, pleasant video. (even if you did repeat yourself) 😂
I like the Tusk footpegs. Are they "the best"? Who knows but I'm happy with them.
The "emissions stuff" consists of an EGR system and a crankcase ventilation oil vapor capture. Know what you're getting into and make good decisions. Following some guy's recipe on the internet (no matter how popular) can lead to regrets. Not just for you but for the bike's next owner. 😅
I don't get the "bugout" thing? Is that code for escaping the family to execute a precision camping trip?
Re-jetting a carb can really wake a bike up. Did it to my Crf230f and it feels like a 250 now with the t6 pro circut exhaust. A 110 is what I used but for a 650 it would be probably 138 or even higher with a ballsy exhaust. It allready had some power but jetting and exhaust wakes a bike up.
This was a great video. I just sold a 2003 250 and now I want this 650 lol
Is lowering a reasonable thing to do? With stock 13” clearance ot could lose 2-3” and still have as much clearance as a suzuki dr . But it would be a xr650L and all that implies. So… lower ?
How you gonna refine fuel?
Its nice, kind of curious what the over cost of every thing including the bike is. i am sticking with my KLR650 2022 :) my over all build with luggage and all the upgrades nearly what you have done minus a few things like lights, carb,tank. I am in to mine with cost of the bike armor and gear, $8,500. put new tires on this year $200.
Rode one of these from new in 94 until 2019. It was a great bike.
How many miles did you get on her
Hi from Greece excellent presentation and perfect project think air filter was stock I mean not changed with after market? The other problem budget motorcycles like XR or others brands not coming in Greece and you can't find it
Great work guys!!! Did i see you changed the dash out? And what did you go with on jetting?
What about the upgraded speedo? What other info does it give you and what’s the price, difficulty of install, time of install etc?
Nice adventure guys! Definitely a keeper and a bike perfect to build on ad develop to the perfect bugout bike.
Theres an 85' 650 on market place for $3,500 right now! Man i wish i had the money. Its street legal ready for trail or street. Sweet build
whats the prize tag after all mods from new ? thx 4 video. :)
Very cool bike, I want it! Thanks for the content.
Like the video. Like all the options. All cool stuff. Bug out to me in this would be bug out to a moto camp trip in the woods. However, this is NOT a BUDGET bike build. Unless 2k+ is the budget.
Why not delete the factory speedometer? Would save a pound or 2
How many miles per tank fill do you get with that 5.8 gallon tank installed?
Moving to a place where there are only dirt roads so I am thinking about getting something to replace my Dyna. I can't decide if I wanna get something like this or go for some bigger adventure bike. Most of my riding is gonna be on washboard roads and I won't be hitting any really crazy trails. I ride solo and camp so I need some storage but not much more than a backpack and a bedroll. Any suggestions I just can't make up my mind.
I've had many Honda Enduros I now ride in Africa twin but I would love to have a 650 build
The second motorcycle is XT660R? 🤔
@Backcountry Adv Moto
Do you still have the stock parts you removed or did you get rid of them
Now lower it I did mine I am 6ft 4 and it still fits me great and makes it a entirely different bike . I live in Marana Az if you want to ride mine . Plus a couple other things have been done. Be safe RIDE ON
Phenomenal work
Highly recommend the super thick front sprocket from Super Pinion, twice as thick as the Fritz
I did add the front sprocket. Just forget to mention it 👍🏻
Rackless systems keep the weight lower and forward. Thus it does not adversly impact handling as much. Strap it on tight and keep the heavy stuff low and center.
What handlebar bend did you guys choose and what adapter are you running if these bars are fatter than stock? Thanks!
The XR600R was the predecessor to the XR650R, both baja champions. The L is kind of a spin off of the older XR600R that is meant to be more of a cheap, reliable dual sport without any bells and whistles.
I just wanna point out that in terms of efficiency, a 650 is actually a huge bike. I'm 6' and 160 lbs. and I'm gettin around great on a Honda cb125, and doin over 100 miles per gallon (which would be super important in a bug-out bike..) so for me a 250 would be huge. I mean how often do you need to go 70 mph anyway, and in a bug-out situatio, think about it. just food for thought.. cool build tho , sick video
How often do you need to go 70? The damn speed limit is 75- 80 mph and even then everyone is going 5-10mph over the speed limit.
Sure you’re right, normally, but In a bug-out scenario? The interstate is gridlocked. You’ll be weaving traffic or on the shoulder or in the ditch.
What kind of milidge did you get with The new yets in The carb?
i have a 22 klr i decked out with tusk stuff. it already had the bigger tank dont see why you didint go with klr cheaper and fuel injection. good video looks fun.
The KLR is a great option, but when we are talking about the worst case scenario, the more simple the bike is the better. For instance, the KLR is water cooled. What happens if you punch a hole in a radiator that is too big to patch. The bike is basically dead. The XR is air cooled so though it’s not a performance machine, it is reliable and has less things to go wrong.
Bought mine new in 03 I’ve put this bike through hell . Oil changes valve adjustments chains and sprockets hand guards . I’ve ridden enduros ,dual sport rides + long road miles . motor is getting a little tired so I guess she due for a top end rebuild, not bad for twenty years. Something lighter is called for for eastern off road racing so I own a two stroke KTM also great concept for a bugout bike 😎
What actually do you mean by Bugout??? Haven't heard the term before.
I’d go with an XR400. Kick start. Put a battery eliminator on it and a 4.5 gal tank. Better fuel economy. Better off road ability. LED lights. Lighter, simpler, bullet proof.