Right Side Footpeg Replacement Post

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There are other posts on this site about the weakness of the right side peg bolts and post. Animal house sells modified posts which are much stronger and wrap around the frame. Baja Designs also offers a similar kit but may have discontinued it.

Animal House Designs Peg Replacement Post

Check Your XR650R Thermostat

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The Honda XR650R Thermostat is known to fail regularly. This isn’t a drastic issue, but will cause your engine to run under non optimum temperature conditions if not treated. It’s a good idea to check your thermostat from time to time and if it looks something like the photo below then it is time to be replaced.

Honda XR650R Thermostat

Oil Sight Tube for XR650R

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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 someĀ 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.

Oil Flow of the XR650R

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The Honda XR650R is a dry sump motor just like all the other Honda XR’s. The majority of oil is stored in the oil tank above the motor. By having the oil tank high up it means that the oil pressure pump will always have a good stream of oil from which to pull. Oil is pulled (so to speak) by the pressure pump down through the oil strainer on the front of the frame. Oil is circulated through the top end of the motor, across the crank, and into the transmission. It is then sucked up out of the sump through a screen by the scavenging pump and pushed back up into the tank in the frame through the plumbing on the right side of the frame. It’s a very simple system which is reliable and simple to monitor.

Honda XR650R lubrication system and oil flow

XR650R Review by Australasian Dirt Bike Magazine

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An Australian dirt bike magazine wrote a great review of the bike many years ago. Here are all the scanned in pages.

Warning: They are VERY big images!

XR650R Review Page 1

XR650R Review Page 2

XR650R Review Page 3

XR650R Review Page 4

XR650R Review Page 5

XR650R Review Page 6

XR650R Review Page 7

XR650R Review Page 8

Honda XR650R Gearing Calculator – What Gearing to Use!

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Selecting the proper final drive ratio for the XR650R is important for optimum performance and comfort on your selected terrain. The stock gearing is a 14 tooth on the front sprocket and a 48 tooth on the rear sprocket.
Many owners dual sporting their bike will run a 15 tooth front sprocket and will drop a tooth or two on the front. Riders doing mostly tight technical trail work will drop to a 13 tooth front sprocket and possibly go up a tooth or two on the rear.

The stock ratio of 14/48 is pretty versatile.

A one tooth adjustment on the front sprocket is equivalent to approximately 3 teeth on the rear. So 14/48 gearing is roughly the same as 15/51.

If you would like to calculate the optimum gearing for your bike based on your average and max speeds you can use this Honda XR650R Gearing Calculator. It is an Excel spreadsheet (*.xls) file and will require Microsoft Excel to open. If you do not have Excel then use Open Office – it is a free download (and better in my opinion).

I have preset all the inputs for transmission gearing, chain size, RPMS, and swingarm lengths. Just change out the 14/48 combo for other values and watch the speed calculations change.

Note: Changing to a 15 tooth countershaft sprocket on the XR650R will require your XR650R to have a Case Saver that fits.

Stant Manufacturing Radiator Cap for the XR650R

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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.

Swapping the KX500 Radiator Cap onto the XR650R

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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 1992-1996 Kawasaki KX500 Radiator cap is 1.8 Bar and can be swapped directly onto the XR650R. The Kawasaki part number is: 49085-1059

There is also a SRC 1.6 Radiator Cap for the XR650R available new. As well as a Stant Manufacturing Radiator cap for the XR650R.

SRC High Pressure Radiator Cap for the XR650R

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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

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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 anĀ XR400R CDI into the XR650R.

There is also a Big Gun CDI for the XR650R.

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