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Old 02-11-2012, 04:50 PM   #1
Brtp4 OP
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Honda XR650L Weight Loss Thread

Fellow ADV Riders,

In the process of a motor rebuild, and am looking for ways to remove weight from an XR650L. I have been doing this gradually over time, but with no real idea how much, and a lot of of what I find online is vague.

My goal to get as close as possible to an XR600R (278 lbs.) without sacrificing reliability. Everyone has different ways of modifying their bike. Mine is to make the bike more simple, and not to sacrifice reliability. The good news is that much of the L’s excess are superfluous parts and removed with little consequence to either convenience or reliability.

Note: I do not think it is possible to make a "light" version of a bike that starts at 324 lbs. This is 50 – 100 pounds overweight for off road use, and it cannot be made into a CRF or KTM 450. Anyone who has ridden one knows the thing is heavy. However, for various reasons we own them anyway. If possible. please refrain from pointing out the obvious: that it is heavy, that other bikes are lighter, and that one will never match the other.

Looking for help to build an accurate database of component weights. This means postal or shipping scales only, not bathroom scales, no guesses, estimates, rounding, etc. It also means doing apples >< apples comparisons, i.e. either excluding or including necessary hardware on both ends of the equation.

Using a shipping scale, with fractions expressed in tenths, not ounces, here is what I have so far:

Item and Weight


Tanks
Stock Fuel Tank (with stock steel cap), 7.96
Fuel Tank Wings (pair), 1.85
Clarke 4.0 Gallon Tank, 4.6
Clarke or IMS 4.7 Gallon Tank, TBD
Acerbis 5.8 gallon tank, 8.34

Controls
Stock Handlebars, 2.16
7/8” Aluminum Handlebars w/pad, 1.58
1.125” Pro Taper CR High handlebars, 1.65
Rox 3.5" Bar Risers, .8
Rox 2" Bar Risers, .66
OE Mirror (each), .56
Ken Sean Mirror (each), 0.56
Stock Handshields (pair), 0.41
Acerbis Multiplo Handguards, 2.3
Acerbis Rally 2 composite Handguards, 1.3
Cycra Pro Bend, 2.26
Scotts Steering Stabilizer w/ clamp and pin, 1.28

Instruments
OEM Instrument Brackets, TBD
OEM Speedo drive and mechanical cable, .70
Trail Tech Vapor, TBD

OEM Ignition Switch, 1.1
Baja Designs Ignition Switch, 0.48
OEM Horn, .33
Baja Designs Horn, .28

Lights
OEM Headlight and Brackets, 2.3 (estimate)
CRF-X Headlight, 1.26
Baja Designs Headlight, 1.62
OEM Tail Light, 1.46
WPS Taillight, 0.3
OEM Front Signals (each - w/brackets), 0.42
OEM Rear Signals (each), 0.56
Baja Designs Turn Signals, 0.2
Reflectors, .16

Forks and Triple Clamps
OEM XRL Forks, 20.98
CR / CRF Showa Twin Chamber Forks pair, 20.03
OEM Triple Clamp assy, 4.84
CRF Triple Clamp Asy, 6.19
CRF-X Triple Clamp Asy, 6.28
Emig Racing CRF conversion triple assy 4.29
XRL Upper Triple, 1.7
OEM XRL Lower Triple, 1.65
OEM CRF Lower Triple, 1.98
BRP CRF Lower, 1.65
RSW Fork Brace, 0.7

Frame Stuff:
Frame before powdercoating, 27.0
Frame after powdercoating, TBD
Stock Engine Guard (bars), 1.25
MSR / Moose / Utah Sports Skidplate, 2.95
Seat Strap, .18
Passenger Pegs (pair), 2.1
Rear Subframe, 1.3
OEM Seat Lock/frame tab (must be ground off), .78
OEM Pegs, .56
IMS Pro Pegs, 1.00
Cheap Chinese Pegs, .84
OEM Kickstand, 1.21
OEM Suspension Link, .85
Devol Lowering Link, .95
OEM XRL Shock, 9.72
OEM XRL Spring, 4.76

Body:

OEM XRL Front Fender, 1.44
Aftermarket Front Fender, 1.19
Stock Rear Fender, .92
CRF Rear Fender, .84
OEM XRL Left side cover, .87
Fuel Tank Graphics, .28
Side panel graphics, .22

Intake Gear:
Airbox Assy w/ intake boot and foam filter, 2.78
Airbox Snorkel, .07
OEM Air filter, .76
K+N Air Filter, 1.05
Uni Foam Filter (dry), .17
Throttle cable (each), 0.32
Choke lever and cable (for FCR conversions), 0.22
Smog Pump and Hoses, 2.03

Exhaust:
Stock Silencer, 7.28
FMF Q4 Silencer, 6.9
FMF Powercore, 6.3
DG, 6.07
Stock Headpipe, 3.1
FMF Stainless Headpipe, 1.9

Battery and Battery Holder

OEM Battery, 6.9
Shorai Battery, 1.85
OEM Battery box - bracket - cover, 2.81
OEM Battery bracket (“band”), 0.24

Guards:

OEM Plastic Chain GUIDE, 0.44
XRs Only Chain Guide, 0.76
OEM Plastic Disc Guard, .16
OEM Caliper Carrier, .66
XRs Only Rear Disc Guard / Caliper Carrier, 1.16
Rear Master Cylinder Guard, TBD
OEM Plastic chain GUARD, 0.26

Wheel Stuff:

OEM XRL Front Wheel Assembly (w/o tire), TBD
CRF Front Wheel Assembly (w/o tire), TBD

OEM Front Rim only, 3.4
CRF OEM Front Rim Only, 3.2
Takasago Front Rim Only, 3.31
OEM XRL Front Hub, 2.2
Talon Front Hub, 1.9
OEM XRL front axle - nut- spacers, TBD
OEM Front Axle - Nut - Spacers TBD

OEM XRL Rear Wheel Assy TBD
OEM XRL Rear Axle TBD
OEM Rear Wheel Steel Spacers, .28
OEM Rear Wheel Center Hub Spacer, .48
OEM Steel Snail Adjusters .33
CycleWizard Alu Snail Adjusters, .29
OEM Rear Sprocket 45t, 1.91
Aluminum rear sprocket 48t, .73
Supersprox Alu / Steel rear sprocket 48t, 1.65

Tires:
OEM Front Tire, TBD
OEM Rear Tire, TBD
Dunlop D606 Front Tire, TBD
Dunlop D606 Rear Tire, TBD
Michelin T63 Front Tire, TBD
Michelin T63 Rear Tire, TBD


Tubes:
Standard Front Inner Tube, 1.1
Standard Rear Inner Tube, 1.36
HD Front Inner Tube, 2.26
Ultra HD Front Inner Tube, TBD
HD Rear Inner Tube, 2.68
Ultra HD Rear Inner Tube, TBD
TuBliss System Front, 1.52
TuBliss System Rear, 1.68

Misc
OEM Flywheel, 8.18
Flywheel (lightened), 6.48
OEM Starter, 3.28
OEM XR600 Kickstart Lever, TBD
Sidestand Switch, 0.25
OEM Fender Tool Bag, .52
OEM Tool Kit, 1.54

Weight Adds:


Misc
Garmin 60, .45
Giant Loop Mojavi, 2.86
Giant Loop Coyote, 4.76
Giant Loop Fandango Tank bag, 1.82
Wolfman Enduro Tank bag, 1.04
Tow Strap, .6
My Tool Kit w/ tool wrap, 3.84


Hoping to get some help from inmates on this, please either post up or PM item weights if you have or can get them. Also, if I have left anything out, please advise. I will drop this into a spreadsheet to auto calc net gain/loss, which I hope to be able to attach here. If not I'll figure out some other way to pass it along.

Thanks,

BP

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Brtp4 screwed with this post 03-25-2014 at 12:49 PM
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Old 02-11-2012, 05:01 PM   #2
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FWIW I see a lot of fudging on real net loss / gain, by listing things removed, but not always things put back on. For example, pulling the engine guard bars off saves weight.....but a skidplate adds even more back on. Adding HD tires and tubes add a ton of weight. Again, hoping to get real component weights of items removed, substituted, and added on.


BP


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Brtp4 screwed with this post 02-19-2012 at 12:50 PM
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Old 02-11-2012, 05:31 PM   #3
mcma111
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1-1/8" Bars

Big bars need the adapters which is an additional weight.
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BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 02-11-2012, 06:03 PM   #4
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Does anyone have any of these items loose and laying around?

XRL Front wheel assembly w/o tire
XRL rear wheel assy w/o tire
OEM Front Tire, TBD
OEM Rear Tire, TBD
Dunlop D606 Front Tire, TBD
Dunlop D606 Rear Tire, TBD
OEM XRL front axle - nut- spacers, TBD

BP
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Brtp4 screwed with this post 03-04-2012 at 10:17 AM
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Old 02-11-2012, 06:39 PM   #5
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you can save a little by replacing the inner wheel spacers between the bearings with aluminum ones if you have stock steel ones.

kubiak screwed with this post 02-11-2012 at 06:48 PM
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Old 02-11-2012, 06:59 PM   #6
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Quote:
Originally Posted by kubiak View Post
you can save a little by replacing the inner wheel spacers between the bearings with aluminum ones if you have stock steel ones.
Kubiak!! Thought you had moved on to bigger and more multi-cylinder things...

You would not have the weights of those by any chance, eh?

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Old 02-11-2012, 07:09 PM   #7
mcma111
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Quote:
Originally Posted by Brtp4 View Post
Steve, do you have any of these items loose and laying around?

Stock Fuel Tank (with stock steel cap) TBD
Fuel Tank Wings (pair) TBD
Stock Handlebars TBD
OE Mirror (each) TBD
OEM Horn
OEM Tail Light TBD
Reflectors TBD
Seat Strap TBD
Stock Engine Guard (bars) TBD
Stock Silencer TBD
OEM Rear Sprocket 45t TBD


BP

I have some of these items but no scale...
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Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 02-11-2012, 07:12 PM   #8
kubiak
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Quote:
Originally Posted by Brtp4 View Post
Kubiak!! Thought you had moved on to bigger and more multi-cylinder things...

You would not have the weights of those by any chance, eh?

BP
no but i remember holding up two wheels and one felt heavier for sure then i changed out the bearing spacer sleeve and that was it. tires and hd tubes weigh a lot too but you have that covered already on the list.
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Old 02-11-2012, 07:14 PM   #9
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The reason you don't have any steering stops is because you didn't put any on. Look below the wiring hoop and you'll see the stop I put on each side of my XR600 frame for it's CRF USD fork swap.

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Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 02-11-2012, 07:19 PM   #10
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i got so involved in weight drop on my xrl that i bought a digital scale at harbor freight that weighed grams,ounces and lbs for weighing little parts i modded or shaved off.. it was only around 12 bucks too! i remember getting the xrl under 300 lbs for sure. it was around 292 at the very lightest stage.
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Old 02-11-2012, 07:37 PM   #11
mcma111
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Quote:
Originally Posted by kubiak View Post

i remember getting the xrl under 300 lbs for sure. it was around 292 at the very lightest stage.
Was that with Helium in the tires??
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Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 02-11-2012, 07:49 PM   #12
kubiak
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Was that with Helium in the tires??
no lol! i was cutting every mount and tab off the frame and drilling lightning holes in lots of stuff besides all the regular weight saving stuff. most of the weight over the xr600 is the electric start equipment. the best xr i ever had was my 89 xr600. that thing was 264lbs stock because of stock magnesium side cases,stainless exhaust,aluminum cylinder with nicasil liner that year. after adding rear disc and crf forks it was the bomb!
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Old 02-11-2012, 08:34 PM   #13
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It seems sub-300 dry is within reach. If they truly are 324 stock - something I doubt - netting 30 lbs is not that hard. The new Lithium Ion batteries are a big help, they are 5+ lbs off themselves. Passenger pegs are 2. Smog equip and plastic tank are at least 5. Hardest thing seems to be not regaining too much on the wheels and tires.

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Old 02-11-2012, 08:45 PM   #14
kubiak
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Originally Posted by Brtp4 View Post
From my math, sub-300 dry seems within reach. If they truly are 324 stock - something I doubt - netting 30 lbs is not that hard. The new Lithium Ion batteries are a big help, they are 5+ lbs off themselves. Passenger pegs are 2. Smog equip and plastic tank are at least 5. Hardest thing seems to be not regaining too much on the wheels and tires.

BP
i remember taking a lot off the rear section by taking off the stock rear brakelight assy,fender under frame piece,fender bag and fender and replacing all that with a crf fender and aftermarket taillight which weighed about 1 lbs.i think cr frontends were about 5 lbs less?replacing all the stock dash and speedo frame equipment with a trailtech took a chunk off too.
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Old 02-11-2012, 08:49 PM   #15
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i remember taking a lot off the rear section by taking off the stock rear brakelight assy,fender under frame piece,fender bag and fender and replacing all that with a crf fender and aftermarket taillight which weighed about 1 lbs.i think cr frontends were about 5 lbs less?replacing all the stock dash and speedo frame equipment with a trailtech took a chunk off too.
i forgot to mention i drilled the brake rotors with lots more holes,
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