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Old 08-10-2013, 10:46 PM   #1
Sycklemotor OP
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Joined: Jul 2007
Location: Eureka, Missouri
Oddometer: 178
Building a Honda XR650L-Russ Roberts

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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Old 08-10-2013, 10:57 PM   #2
Sycklemotor OP
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Location: Eureka, Missouri
Oddometer: 178
Powder coated frame and parts

Here are some photos of the frame during powder coating and some finished brake parts.







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Old 08-10-2013, 11:10 PM   #3
Sycklemotor OP
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Location: Eureka, Missouri
Oddometer: 178
Starting some assembly

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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Old 08-10-2013, 11:49 PM   #4
Sycklemotor OP
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Joined: Jul 2007
Location: Eureka, Missouri
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My plans for the bike and some parts photos

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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Old 08-11-2013, 12:18 AM   #5
DQook
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Location: Oahu North Shore Hawaii
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Go go go!!!!!!!!!
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Old 08-11-2013, 06:45 AM   #6
thebigman
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Location: Texas Gulf Coast
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Subscribed ................................................ eal
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Marko

08 xr650l ,99 xr650l, 10 HDXR1200X ,84atc200s 85atc200s, 80ct110 ,99xr70, 04xr650l ,

Dumb ass people do dumb ass things

thebigman screwed with this post 08-11-2013 at 06:12 PM
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Old 08-11-2013, 07:32 AM   #7
Sycklemotor OP
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Location: Eureka, Missouri
Oddometer: 178
Quote:
Originally Posted by therealbigman View Post
Subscribed .................................................: deal
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.
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Old 08-11-2013, 09:05 AM   #8
Kawidad
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Location: Central Coast, Cal
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Nice!!!

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Old 08-11-2013, 09:15 AM   #9
bobbed06
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Location: That one place......
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What rear tire is that??? Subscribed to this build....
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Old 08-11-2013, 09:38 AM   #10
MartiniUp
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more more!
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Old 08-11-2013, 09:38 AM   #11
techforlife
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Location: Moncton,New Brunswick
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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..

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

First beers on me

B
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Old 08-11-2013, 09:50 AM   #12
Sycklemotor OP
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Joined: Jul 2007
Location: Eureka, Missouri
Oddometer: 178
Working on orginization of parts!

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.

Emig damper post set up.


New Emig Damper



Sensor bracket-still need to JB weld the magnet on.






New chain

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.


XR's Only skid plate-Black anodized

XR's only skid plate-Black anodized
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Old 08-11-2013, 09:55 AM   #13
Sycklemotor OP
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Joined: Jul 2007
Location: Eureka, Missouri
Oddometer: 178
Quote:
Originally Posted by bobbed06 View Post
What rear tire is that??? Subscribed to this build....
It is a MEFO Explorer,130/80/18 DOT Approved.
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Old 08-11-2013, 09:59 AM   #14
Sycklemotor OP
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Joined: Jul 2007
Location: Eureka, Missouri
Oddometer: 178
Quote:
Originally Posted by techforlife View Post
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..

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

First beers on me

B
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.
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Old 08-11-2013, 10:32 AM   #15
kubiak
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Location: madera california
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wow that is one nice build!
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