Noobie building an XR650L

[lugnut50]

I've spent many days reading through the forum and have had all my questions answered except 1....

What is the best way (if any) to move the battery on an XRL so that great big lump isn't hanging off the side of my sweet new ride?

[michaeln]

Put it in the airbox, remove the rubber snorkel and use a K&N sock filter. Then you can use an XR600R side panel on the left side.

It'll suck in the rain and in crosswinds though.

I'm leaving mine where it is.

[MGS781]

I used a battery out of a CRF230. The battery is small, about half the size of the stocker but still has 130 CCA. I cut the top off the air box and made a platform out of aluminum. I then used a side plate off of a XR600R and cut holes in it to let the air in. I also reshaped the side plates to look more modern.

good Luck,

MGS

[lugnut50]

MichaelN: Why would crosswinds create a problem?

[lugnut50]

I used a battery out of a CRF230. The battery is small, about half the size of the stocker but still has 130 CCA. I cut the top off the air box and made a platform out of aluminum. I then used a side plate off of a XR600R and cut holes in it to let the air in. I also reshaped the side plates to look more modern.

good Luck,

MGS

Have you experienced the problems michealn talks about?

[MGS781]

The holes are not big enough for much rain to get in. Regardless, the air filter is an oiled foam type which will not pass water. I do worry about the transmission breather vent, I will be replacing it with a foam type soon.

MGS

[michaeln]

MichaelN: Why would crosswinds create a problem?
One of the reasons for an airbox is to give the carb an undisturbed area to draw air from. When you have an open air filter crosswinds can cause high and low pressure areas around the sock filter, and the air can be very turbulent.

Airboxes, when properly designed and with enough area to give good airflow, are a good thing.

[MGS781]

One of the reasons for an airbox is to give the carb an undisturbed area to draw air from. When you have an open air filter crosswinds can cause high and low pressure areas around the sock filter, and the air can be very turbulent.

Airboxes, when properly designed and with enough area to give good airflow, are a good thing.

I see every KTM factory SM with holes in the airbox cover similar to mine, this is where I got the idea. In short my design does not eliminate the airbox, only change where the box draws air from. The box does flow more air, I needed to go up a main jet size to make teh bike run right.

MGS

[michaeln]

I agree, opening the airbox up for more airflow can be good, if the bike is jetted appropriately for it.

What I was talking about is not the mod you did, but the one where people take an XR650L's whole electronics package (fuses, stock-sized large battery, CDI) and move the whole mess into the airbox.

That doesn't leave enough room for the filter to stay inside the airbox, so the rubber boot that connects the airbox to the carb goes away and is replaced by a K&N or UNI sock filter, which is now totally outside the airbox.

The way you did it, on the other hand, is clever!

BTW, I see all those mods to the engine in your .sig... is that stuff actually installed in your engine now? How's it run?

[MGS781]

You caught me. All that stuff (piston and cam) is sitting on my work bench at the moment. I need a special tool to remove the timing chain. Once I get the tool, everything will be going in with two fingers crossed. I love the bike, I just want a little more grunt. I will keep everyone posted after I finish the engine build.

MGS

[michaeln]

I'm going to buy one of those tools too, as I have to change my timing chain. It's Honda part # 07973-MG30003, $31.06 from Service Honda. You'll need a clutch basket holder too, I am going to get the Motion Pro one #08-008, $30.30.

Can I add all the stuff I'd like to have on my bike to my .sig? ;-)

[veloboa]

I too have also made the mods that MGS781 has done (thanks to his help, he turned me on to the battery I needed - BTW Thanks for all your help MGS turned out awesome). :bowdown: But I left the air filter (K&N) in it's origianl place. All my electronics are in my airbox (many mods to make this work, (MGS will attest to that I'm sure, but it can be done). I actually extended the back of my airbox which I fabricated from alum. and still have the clearence for suspension travel. I cut slots on the throttle side of the bike in the airbox similar to the configuration that cover the countersprocket (which I also cut out) so it gets plenty of air. I plan on removing any extra wiring that is no longer needed due to this mod. I did not want to do this yet, because I wanted to make sure all this would work first :thumbup:

01 XR650L, Big Gun Exhaust, Kehien 41mm pumper- 185 main, and more

[MGS781]

veloboa,

I am glad it worked out for you. Sounds like you took a slightly different approach, but the result was the same. I did have to make a ton of wiring mods, spent the better part of a day making sure everything fit under the seat. One more hint, if you run flush mounts in the rear and remove the helmet lock thing, the bike will look very slim from the back.

I am very jealous of your carb, I may hit you up for jetting help when I get mine.

MGS

[veloboa]

No problem. I am in FL. (sea level) so jetting may be a little different than your location, nevertheless anything I can do to help. I recommend that carb. for this bike it will definitely wake it up (from the looks of it you woke her up already.)

I'm still working on mine, I plan on porting and polishing the head, 10.5:1 piston and a all around cam of some sort. I'm jealous of your oil cooler!!

[vince80]

all those mods sound pretty cool, any pics of finished product?

[MGS781]

michaeln,

I just got an email from Service Honda, they don't sell Honda tools for whatever reason. I did manage to get the tool from Ron Ayers for a few dollars more. The tool will take 3-4 weeks to get I am told.

MGS

[michaeln]

Thanks MGS, good info. Since I work at a shop I probably wouldn't have ordered it from them anyway, but I appreciate knowing about their policy.