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Old 08-05-2011, 01:35 PM   #1
seth0941 OP
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My XR650L build in Photos

Okay, I HATE typing so there will not be much of that going on here. I will post some basic info on each photo but feel free to ask questions.

I got my 1994 Honda XR650L in June of 2011. This is my first dual sport bike. I have been riding for about 15 years and decided to sell the Jeep, Harley, and get an AV bike.


I intend on setting it up as something I can go on the highway and logging roads with and be gone in the woods for a week at a time.

I also do lots of ultralight hiking so I have lots of gear that I can pack onto the bike.

Here is a photo of me.




This is the Jeep I sold, I used the funds from this to buy the XRL

If you want more info on the jeep just ask.




And here is the Harley I sold. I used this money to order some parts and riding gear.

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Old 08-05-2011, 01:45 PM   #2
seth0941 OP
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The day I got it

Well, here is the XRL the day I got it.
It is a 94 with about 10K miles on it.
What I know about it is

New clutch
New clutch cable with a second new clutch cable in place
Custom rear fender rack
Clark 4.7gal tank
Cobra slip on.
New Renthal 46T rear sprocket
New Renthal O-ring chain
DR front master cylinder cover
DR rear shark fins
DR front rotor cover
DR chain guide cover

Aside from that it is all stock (as far as I know)







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Old 08-05-2011, 02:00 PM   #3
seth0941 OP
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My first mod.

I had some side racks off a Royal Enfield that I had sold a while back and I wanted some bags for the XRL.

So I started building some mounts. They turned out okay I guess. The only tools I have to work with is a gravel carport, cheap Harbor Freight welder, angle grinder and my brain.




















Here is a short video.

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Old 08-05-2011, 02:04 PM   #4
steveWFL
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Nice, may I ask what size steel tubing you used, and what you used to bend it? I may fire up the Miller Welder vs. purchase mine.... Thanks
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Old 08-05-2011, 02:10 PM   #5
seth0941 OP
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Quote:
Originally Posted by steveWFL View Post
Nice, may I ask what size steel tubing you used, and what you used to bend it? I may fire up the Miller Welder vs. purchase mine.... Thanks
The bent tubing was all like that. All I did is add my own mounting points. The racks came off an Royal Enfield. The tubing I used is thick wall 1/2 tubing. and some 1.5" X 1/8" strap.

Here is a photo of the racks on the Enfield. Sorry I am not more help.

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Old 08-05-2011, 02:15 PM   #6
seth0941 OP
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New Fender

I just did not like the look of the big front fender. So I ordered a Acerbis Supermoto / Supermotard Front Fender and installed it. I had to re-rout the wires that go under the lower clamp. Also the red did not match.



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Old 08-05-2011, 02:18 PM   #7
seth0941 OP
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Color change

do to the fact that I did not like the blue on the side covers and my front fender was an off color and the OD green panniers did not look right I broke out the Crylon plastic fusion.









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Old 08-05-2011, 02:37 PM   #8
zoo mob
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Looks sharp. I've got a '93 and may do some similar cosmetic mods.
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Old 08-05-2011, 03:36 PM   #9
RoadHawg14
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Looks Awesome!
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Old 08-05-2011, 04:41 PM   #10
steveWFL
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Quote:
Originally Posted by seth0941 View Post
The bent tubing was all like that. All I did is add my own mounting points. The racks came off an Royal Enfield. The tubing I used is thick wall 1/2 tubing. and some 1.5" X 1/8" strap.

Here is a photo of the racks on the Enfield. Sorry I am not more help.
Seth thanks, I misread you used the same tubes from the sweet Enfield and fabbed them up for the 650. Your project looks great
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Old 08-05-2011, 06:16 PM   #11
jobear89
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Nice build so far, are you planning on doing any thing to the engine or suspension?
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Old 08-05-2011, 06:25 PM   #12
seth0941 OP
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Quote:
Originally Posted by jobear89 View Post
Nice build so far, are you planning on doing any thing to the engine or suspension?
For now the engine is stock. I plan on deleting the smog kit and in the future I plan to add a stage 1 cam and maybe go with a big bore kit.

As for the suspension all I plan on doing is changing the front shock oil to something thicker and stiffen up the rear.

90% of my riding is on the street but I will be doing logging roads too. I do not plan on doing and real trail riding.

seth0941 screwed with this post 08-05-2011 at 06:41 PM
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Old 08-05-2011, 06:37 PM   #13
thebigman
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Quote:
Originally Posted by seth0941 View Post
For now the engine is stock. I plan on deleting the smog kit and in the future I plan to add a stage 1 cam and maybe go with a big bore kit.

As for the suspension all I plan on doing is changing the front shock oil to something thicker and stiffen up the rear.

90% of my riding is on the street but I will be doing logging foads too. I do not plan on doing and real trail riding.

Be careful with cam selection , Some of them on the market are real POS.

Post up in the xrl sign in and ask about this , Steve or someone else will let you know the one's to stay away from.
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Old 08-05-2011, 06:37 PM   #14
seth0941 OP
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See the light

So today I added some driving lights. They are cheap $20 part store lights but they will work if I have a headlight failuer when riding at night. (been there done that)

I added a wire to the empty fuse location in the fuse box and installed a fuse there. I then made a "dash board" to house the waterproof switch. The switch is easy to see and get at with gloves on. Power to the switch is on with the key.

I also broke a turn signal yesterday so I installed some cheap ones from the local shop.








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Old 08-05-2011, 06:41 PM   #15
seth0941 OP
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Quote:
Originally Posted by therealbigman View Post
Be careful with cam selection , Some of them on the market are real POS.

Post up in the xrl sign in and ask about this , Steve or someone else will let you know the one's to stay away from.
Thanx for the warning.. It is not a plan for the near future but something I am thinking about for sometime down the road.
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