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Honda XR650R Parts, Service, and Repair | XR650R Aftermarket Parts

XR650R Aftermarket Parts

ROX Risers on the Honda XR650R


The stock Honda XR650R handlebars are mounted fairly low and are also toed in slightly. Most riders of average or tall heights will be more comfortable with the handlebars raised. There are all sorts of ways to accomplish this, through blocks, new triple trees or bar mounts, taller bars, and also, by using the pivoting handlebar risers manufactured by ROX. They are a billet aluminum piece that allow the bars to be boosted up as well as rotated forward slightly.

For most tall riders this will be just enough of a change to make all the difference, especially when standing.

ROX Handlebar Risers

Here is a set mounted on the BRP (along with some standard aluminum riser blocks).

Honda XR650R Rox Handlebar Risers

Akrapovic Exhaust for XR650R


Akrapovic exhausts are extremely well made and highly regarded exhaust systems. Their performance and sound on the Honda XR650R are both excellent. They are quality made and well supported. The price however is about double any other exhaust system on the market. They are extremely expensive.

Honda XR650R Akrapovic Exhaust

Flow Aftermarket Exhaust for the XR650R


There are dozens of exhausts available for the Honda XR650R. The Flow brand (re-branded) exhaust is one of the cheapest around. It gets mixed reviews from many people regarding it’s build quality and performance. The general consensus is that it should be avoided. But if it was dirt cheap I might be tempted to give it a try.

Honda XR650 Aftermarket Flow Exhaust

Oil Sight Tube for XR650R


Oil site tubes are a popular modification that allow you to see at a quick glance what the oil level is. It involves drilling a couple holes in the oil tank and connecting them with a small tube.

Honda XR650R Oil Sight Tube

The kits are provided by Animal House, Barnums Pro, and Baja Designs. I think XR’s Only has them as well.

Or you can make your own. The fitting part number is SS-400-202 from Swagelok for stainless or B-400-2-2 for brass.

Quarter inch hose can be had from nearly any supplier. McMaster Carr, Grainer, even an auto parts store. You’ll also need the drill bit, a tap, and some teflon tape.

Empty your oil, drill a pilot hole, a slightly undersized hole and tap in small increments (to see where your fitting stops rotating) . Presurize the frame resevoir with a compressor or by having a friend blow on a hose duct taped to the oil fill port (this way most chips will fall outwards).

Lean the bike to the right and pour a little oil. It will drive some chips that stayed on the inside of the reservoir down towards the opening at the bottom.

Stant Manufacturing Radiator Cap for the XR650R


There are a few options for swapping out the Honda XR650R radiator cap. You can swap the KX500 radiator cap onto the XR650R, or you can buy the SRC Racing XR650R Radiator cap, or you can but the cap produced by Stant Manufacturing in California.

I have read great reviews of the Stant caps, they seem to be built very well. However, I am not positive of the pressure rating of their cap for the XR650R. I have read it is 1.6 Bar, but I have also read it is 1.8 Bar. If anyone knows for sure please send me the info or comment on this post.

SRC High Pressure Radiator Cap for the XR650R


Many owners will swap the 1.1 Bar rated radiator cap that comes stock on the XR650R for an aftermarket unit. The goal is the prevent the radiators from boiling over as easily. It’s a somewhat debated topic in that using a higher pressure cap will increase the strain throughout the entire system. Most have positive experiences with switching radiator caps. Personally, I prefer to keep mine stock.

The SRC (Scott Summers Racing Components) unit is rated at 1.6 Bar and is part number 1672. It looks like this:

You can also swap the radiator cap from a KX500 onto the XR650R. As well as a Stant Manufacturing Radiator cap for the XR650R.

Procom CDI for the XR650R


One of the lesser known CDI units for the XR650R is the Procom part number PE-C-MH650-A. They claim the following:

  • Improved Timing curves
  • Higher Rev Limit
  • Overrides for full performance at all times (who knows what that means)
  • Increased Spark Energy
  • Improved Throttle Response
  • Easier Starting
  • Plug-in Module Replacement (just means it’s plug-n-play)

Another option – and potentially cheaper is swapping an XR400R CDI into the XR650R.

There is also a Big Gun CDI for the XR650R.

Big Gun CDI Unit for the XR650R


There are several CDI units which can be swapped onto the XR650R for improved performance. Big Gun makes one for around $120 called the Over Rev. Like the others it advances the timing slightly and raises the rev limiter.

Another option – and potentially cheaper is swapping an XR400R CDI into the XR650R.

There is also a Procom CDI for the XR650R.

XR650R Oversize Front Brake – EBC – QTM – Brake King


Upgrading the stock front rotor to an oversize unit is a great upgrade for the XR650R. It provides improved stopping power and improved feel at the lever. This upgrade is great in particular for bikes running street duty, or bikes that are carrying extra gear or *ahem* a heavy rider.

There are three options.

1.) EBC Oversize Front Brake Rotor Kit

Most popular is the EBC Oversize Front Rotor. These are 280mm rotors and can be purchased with the caliper mount for under $150.

Honda XR650R EBC Oversized Rotor

2.) QTM Oversize Front Brake Rotor Kit.

The QTM unit is 270mm and comes with powder coated caliper mount and rotor mount. They are around $150 if you can still find them.

3.) Brake King Oversize Front Brake Rotor Kit

The Brake King kit is also 270mm and  is about double the price of the other units, but very high quality. It comes with a light weight wavy rotor.

XR650R Case Saver – Chain Protection – Several Options


It’s a good idea to run a case saver on any bike, but especially a powerful off-road bike like the XR650R. There are several case savers available for the BRP.

This is the stock unit that came with the bike. For most purposes it is of decent quality and effectiveness, but aftermarket units are much stronger.

Scott Summers Racing makes one. It is of good quality, but I have read a story or two about them snapping during a high speed chain brake. Honestly though – sometimes there is just bad luck involved. These seem to be a quality unit. It should be noted that this unit will not allow you to run a 15 tooth countershaft sprocket without a little trimming.

Kiwi Sports in New Zealand makes this larger unit. At first glance it appears to offer great protection. However, it has been said that it is the poorest choice of all. The Kiwi Sports unit mounts to a smaller

XR’s Only Makes a couple different units. These are widely regarded as the most stout unit because they use a spacer to attach the guard to a larger case bolt rather than the smaller bolt most other units attach to. They make both a 14 tooth version and a 15 tooth version.

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