5-1/2 years ago during a move, I parked the motorcycle and did not drain the fuel bowls. You need to be a member in order to leave a comment. Find a small washer that fits fairly snugly over the needle at the thickest part at the top. Feel free to post any or all of these photos here at the forumsWe have the Photo Gallery. I haven't seen innovative welding like this since watching the BMW frame repair at Mongolia during the 'Long Way Round' movie with Ewan McGregor and Charley Boorman. Here's a list of all the Member benefits on the HUBB. Lower speeds, you're more concerned with the pilot, and a 65, which is stock for North America, apparently is all Moose can provide. You may need or benefit from a leaner main jet at your altitude and engine tune, but thiscan only betested at higher rpmwith the engine's performance under open throttle. very interesting stuff moses. You cannot paste images directly. Details We're not a big multi-national company, just two people who love motorcycle travel and have grown a hobby into a full time job and a labour of love. Is the "choke" set up properly? I'll update on this point. If I pay attention, it sounds like farm equipment, and makes me wonder. If the bike is "uncorked", a 175 main jet at sea level might be even better than the 180, though these engines will tolerate slight enrichment. WebMaking the XR650R run right! 
As Mosessays, these bikes are pretty fun despite not being the latest tech. In the end, a grinder might be counter-productive as the weld material looks extremely porous and any diminishing of thematerialvolume might lead to leaks. This section will help you to plan your trip, whether it's to the next state, country or all the way around the world! You need to lower adjustable needle a bit to lean the mixture. Create stability by usingyour hand throttle, gently blipping (nomajor rpm changes, please, this is not a premix two-stroke!) Somehow I must have been using a top dead center from an alternate universe. If completely cold, I either place the choke on half-choke or full choke for just a few kicks with the ignition turned off and compression release lever pulled in. To comment on some of the questions you had - GO WITH WHAT MOSESSAYS. I ordered the needles and brushes, so I will disarm and clean the carb. 
Also clean the fuel line. I do not have exhaust mods beyond the Power-Up Tip with a larger opening. Once you're very sure the engine should start, trust that it will and don't over-fuel it. We're both very fortunate not to have the California suction valve system and other one-off pieces for the Golden State models. I hope other xr650r owners will post what they found in their bikes before they "uncorked" their BRP. Check it out now, and add your information if we didn't find you. ME ask YOU for advice ? 1984 was still an era when getting a dirt motorcycleengine to run right and last a long timeheld priority. Credits: This article was published from forum topics posted by Dave Closs and Brian Jackson. Thank you for your help, I'll keep you posted with those changes and the result. Stage 1 tuning is just rightand plenty! The down side is the seat height, I'm 5'8" and shrinking. The Keihin is hypersensitive to float height. If you review my XR650R coverage at the magazine site and forums, the Pulstar plug comes up. Drain carb of gas. (Schematic can be found in a service/shop manual or online from a Honda parts sources.) Here is the Honda "factory" N.A. In still air, you can hear a P51 from miles away. If the needle still has the tab it's pretty easy to figure out how far you're turning it. It is not that it took me so long, but I also did the wiring to DC and got all my lights LEDs. I weigh about 150# and a 2x4 provides about the same cushion. Generally understood is that "uncorking"involves a list of changes, which includes the 175 main jet (selection is a no brainer, this is the OE main jet outside the U.S. for engines identical to ours). (The ignition was stock and tested fine.). For a desert playa or sagebrush 'Hare-and-Hound', however, either is the XR350R or XR500R is in its element. Rolling past 1/4 throttle involves the needle height setting and gradually becomes a main jet size concern as the throttle gets wider and the slide with needle rises. I plan to jet rich enough to cover my near sea level riding and only change if I encounter problems. The engine would not idle and only ran smoothly from approximately 1/4-throttle and upward. There are no shipping fees, no waiting and you can access the manual from anywhere. They will encourage you, share their experiences and advice on how to do it! The Wide open throttle reply or the turn gas off reply or the 2 turns out on the Idle/Air mixture screw reply ? It start from the second kick when cold, and sometimes surprises me starting on the first. Compared to the rest of Hondas off-road roster, including the Africa Twin, MX-inspired 450RL and even the 300L Rally, the XR650L looks like it should come with vintage registration. XR650L TM40 Installation Instructions (See available PDF for printable version) Be safe no smoking or open flame. The downside of running too rich is that the excess fuel will wash lubricant from the cylinder wall and cause premature pistonring and cylinder wall wear. Add yourself to the Updates List for each event! Per much appreciated good advice I took the carb out last night with the intentions of cleaning it. yikes! Never force parts, and always center the pieces carefully. Replace the stock manifold with part number 16211-MBN-640. I didn't have to lift it as far. Forum member DavidEasum wasan early viewer/renterof the HD video. Once I corrected them, all was good and the bike has been running great ever since. Also, I may need to get a carb rebuit kit that have those emulsion tubes I have read on the forums. Wondering what this motorcycle adventure travel gig is all about? This gets very tricky and changes are usually so subtle that you need a dyno (except idle adjustments) to be able to measure effects acurately. @justin, I adjusted the screw and had some good results. I'm now running the OEM Honda replacement parts, including a new flame trap screen, new OEM air filter and a new air box "O-ring" that seals between the black air box and the white side cover's lip. When does the auto-decompressor is completely off? Using spark plugs as an indicator is tough because you will cycle through many different throttle positions putting 30-50 km on your bike. and, "is the jetting on point?" Have YOU ever wondered who has ridden around the world? You need a bigger pilot jet first off. Upon graduation, he wound upperforming aircraft engine impeller repairs. The decompression lever has its normal free play. Well, thats the big picture. "Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." But when i had it on the third I was wondering if you installeda header on your bike. Theres nothing glamorous or techy about the XR650L, but as long as the world needs a bulletproof, tried-and-true machine, the XR will continue to sell. I ride my XL650L (2015) at 4000-6000 or so feet (high desert also). duringthe upper engine rebuild. I am certain that you will find the 190 main jet excessive, but that will be at mid- to full throttle. For your riding, especially at higher altitudes, a 165 main jet would be plenty, certainly not harmful, as a place to start. New to the HU site? Thanks for the reply. The air-cooled, SOHC engine features a gear-driven counterbalance shaft to smooth out the thumpers operation, and its low end torque makes the five-speed transmission more than adequate. WebThe XR's Only Mikuni Pumper Carburetor 42mm will reveal the hidden performance within your Honda XR650L. Copyright 4WD Mechanix Magazine Honda's Power-Up Kit does call for the 68s and also a needle change if necessary. The needle and seat change is not as crucial as the needle position, which should be 3rd clip position (from the top) for starters. Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes! Given the bends and twists in the muffler assembly, off-setting even slightly would have dire consequences when trying to reinstall the muffler! I tried it today. You'll get a real kick out of the off-pavement and on-pavement testing. I have ridden my 1982 XR500R in all these areas with not much noticeable change except starting when hot can take an extra few kicks at higher elevations. A handful of my school chums were into British rock. I've always changed mixture screw adjustments 1/4 turn at a time on any bike I'm fiddling with. Note:There's a jetting chart and comments at http://xr650r.us/jetting/. The Moose kit has raised my brow as to the 145RD jet in mine. (The Denso K22PR-U11 is an alternative if the NGK is not readily available.) I'm considering that Pulstar plug for my next step. 3. Stock is #152 and you may need #150. The XR650R should be upshifted and not flogged. I am having the exact problem and wanted to know. That is a great movie! It had been run without an air filter and with questionable carb condition and cooling system for an unknown period of time. I can tell with my enginethat the 172 mainjet will workwell at ouraltitude and with the Stage 1 camshaft. You must have JavaScript enabled in your browser to utilize the functionality of this website. Cam chain and sprocketswereworn for typical wear and tear.. needle = 53E on the second to the bottom position. The cleaner thoroughly cleansed the carburetor body,fuel passageways and other carburetor parts by simplyfollowing the directions. Formerly swamped my XR650L and posted what I did to get the bike going again. The rubber boot was still in the airbox but the plastic is not. Could you tell which is the best brand, OEM, Pivot Works, All Bearings, Moose Racing, etc.? Feel free to stack 1 or more washers to tune the needle for desired results. You should try it, specially because you already have the stage 1 cam. Thanks for your informative post. Make notes about the engine's speed/throttle opening for each photo. You'll be thrilled with the HotCams Stage 1 camshaft choice, stable idle, incredible torque from bottom to roll-on and through the mid-range. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." It is working better, but still a bit sluggish when try to accelerate abruptly from iddle. See the trailer here! When you buy through links on our site, we may earn an affiliate commission.Copyright ThumperTalk, Inc. - All rights reserved.ThumperTalk is a registered trademark. We also ride in Eastern Oregon where the elevation runs between 3-5k. ? With the spark plug removed and the rear wheel raised slightly off the ground, you can put the transmission in a higher gear (4th or 5th) and control the rotation of the crankshaft by slowly rotating the rear wheel. Book, eBook, Audiobook. The world has changed, and the Bonnevilles and Lebarons are gone. I would not adjust the needle height and as another poster said the air mixture screw only affects idle, so this is not likely to affect your problem. Iupgraded my press with a 20-tonair-over-hydraulic jack (https://www.harborfreight.com/20-ton-air-hydraulic-bottle-jack-69593.html)that offers relatively slow and controlled application of force. WebOur Honda XR650L (air cooled engines) kit includes a pre-jetted Mikuni TM40-6 pumper carb with pre-installed adapters, and push/pull throttle cables. (Imagine trying to sell a brand new Honda XR650Rmotorcycle at the dealership and having to go through a five minute ritual with guesswork about whether the engine would start! Of course, the Stage II camshaft impacts tune, but rule out these other possibilities. Once these four criteria are okay, you can look for vacuum leaks, carburetor issues andignition/spark troubles. Do publishers accept translation of papers? Check now Rated 5.00 out of 5 based on 3 customer ratings ( 3 customer reviews) Retail Price $ 1,303.99 Our Price $ 1,099.90 Availability: In Stock (Changes Daily) Complete Throttle Assembly ($ 89.90) Complete OEM Part by Graham Field After changing carb settings go for 30-50 kilometers ride, get back and reinspect the spark plug color even if the bike feels much better. I use NGK, the OEM replacement heat range plugs. My favorite cult classic XR650R movie, "Dust to Glory",shows howrace positions actually change during a pit restart. Often, you're not only restoring threads and preserving an expensive casting, the Time-Sert upgrade actually providesa significant improvement overa factory thread design. Keihin carburetor bodies look like new whendipped and rinsed,and blowing outthe passageways with compressed air further restores the carburetor. requirements, and California models (XR650R AC designation) were even more restricted by a draconian reshape and air flow restriction inthe rubber intake manifold and the intake air box. That should fix your stuttering issues completely. 1. DavidSo, we get Netflix and watched "Blood Ties". Given that these engines have been tortured by factory 112 and 125 main jetting, with 145bantered around as a "performance" jet in the aftermarket,170 is certainly a place to start at Burundi for an uncorked (Honda Power-Up spec) or European specengine. I will contemplate ordering a 68s if I'm not happy with how things turn out. The Honda XR650Ris carbureted andstill kick start era, but it does not need to be a hardship to start or warm up. The engine should run okay with these jets, and if it is running very poorly with the 175 and 68S, with the needle in the original 3rd position, I would check forother possibilities and not change the jets yet. Primary jetting is for 4,000-4,500 feet. Using old fuel line and an Allen bolt, assembly time 10 minutes. Use a XR650r carb I did that. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Hello all, I have just broken the 8000km mark, on my hopefully RTW trip aboard my Honda XR650L. Remove side panels, seat and fuel tank; Remove the screw that holds the rear brake reservoir. A clogged fuel line could also cause issues. 3. The motorcycle had, in Western Americanhorse language,been "ridden hard and put away wet". sometimes i get pretty winded just getting it to start, not counting all the times right foot slips off kick start lever and right foot peg jams into the shinouch. We sold the '83 XR200R when our youngest son went to collegein 1999 or would otherwise still have it, too. I have no problem with these primary/secondary carburetors whatsoever, they have worked flawlessly under every kind of operating and starting situation without the need to re-jet from 2500-7000 feet altitudeBase tuning/jetting is for approximately 4000-4500 feet elevation. Run the carburetor out of fuel before shutting it off, or at least down a bit. In other words, changes to a carburetor are based on how your bike reacts to a specific throttle position. I painted it with barbecue paint (800 F test - best I could get), and tomorrow it will be put to the test. I think it could have been used much more, but I got it for a good price. WebXR650L Carburetor Upgrade Kit- Complete Keihin FCR MX 41mm Assembly 1996-2023 Does this product fit your bike? To get this bike's motor back into shape, I pretty much followed Moses's video on the top end rebuild to the letter - except for the cam. How important is the 175 main jet and 68s pilot? Just open up a new topic, and we'll discuss it! There's no inventory to take on, nothing to ship and no customer service to deal with. Fortunately, welding is as much a hand/eye and intuitive application as it is academic and technical. https://www.youtube.com/c/roadreadywithmosesludel, http://www.hondapartshouse.com/oemparts/a/hon/5053e96bf870021c54be3708/air-suction-valve-ac, Honda Euro and Australian XR650R Models.bmp, http://forums.4wdmechanix.com/forum/35-places-you-have-been/, http://www.xr650r.co.uk/service/carb/carb.shtml, http://www.4wdmechanix.com/Testing-the-Enerpulse-Pulstar-Spark-Plugs.html, Berryman Chemtool Carburetor and PartsCleaner, I am testing an Enerpulse Pulstar spark plug, http://teknikmotorsport.com.au/Honda-XR650R-Suspension-Mods, http://www.posilock.com/products/manual-pullers/manual-pullers, https://www.harborfreight.com/20-ton-shop-press-32879.html, https://www.harborfreight.com/20-ton-air-hydraulic-bottle-jack-69593.html. See the following photo for the tab on the carb. What's the most bomber air filter option? The Road Heroes DVD helps answer the question - Why Go? Other issues with idle and especially a speed flare-up would include an air leak. The relay would close the circuit on the wire lead when you turn on the ignition key and open the circuit/lead when you turn off the key. Rare, limited use cycles that have been in "storage" often bring $6000. Already have an HU account? Use the factory parts schematic to identify your carburetor parts. Learn more about Stack Overflow the company, and our products. : If you ever want to plan a ride out in the desert, I'd be happy to coordinate. Lean mixtures can overheat the engine, cause detonation, and damage the rings, piston and valves of the engine. Folks will ship and travel distances to get an XR650R. Sorry for the long answer it REALLY makes you sound just ignorant to talk about "alloy" as always ALUMINUMTHINK man! This is the acetylene supply. Quality machine work, a fresh cylinder and upgrade piston choice, renewed valvesand proper assembly technique will have this motorcycle living up to its legendary reputationwith a 175 main jet and 68* pilot jet in its Keihincarburetor! I actually liked the Lightning 650 twin on the road, it was far less weighty and more nimble than the A75R, although the A75R triple cylinder engine was significantly smoother and did tolerate extended high rpm operation. Our favorite places compass still bears strongly NW. Thanks Scott! My approach was an attempt to match rpm ranges, which are not comparable. I will do those tests this weekend and get back to you. You can see how much traction the song had at the time, this is still the late 60s: https://www.youtube.com/watch?v=hMCjdnC40nI. Top cover and fuel bowl screws are fused to the carb body. The engine fired on the second kick. So, thefix wasn't complicated: I replaced the primary carburetor's pilotjet with a $6 Keihin replacement jet and purchasedtwo overhaulgasket sets. I stoppedfollowing this myth by concentrating on stabilizing theengine with the handthrottle on the extremely rareoccasions when the engineseems hesitant to idle. This is simple enough. As you know, my motor (Euro model)is fried from overheating/dirt ingestion/bad maintenance Hi, DavidI've beenvery busy with Michelin T63 tire testing on the Honda XR650R, you'll enjoy the road testing and also the addition of TCI Products racks and Nelson-Rigg bags As for jetting, here isa PDFwith Euro and Australia specifications: You should have a 175 main jet, a 65 pilot jet and the needle clipin the third groove from the top. These intrepid women share their tips to help you plan your own motorcycle adventure. I would rather build a longer cable(s) to provide a layout similar to stock. It might not have been done in the "clean room" environment you would prefer, but I guess it'll have to do the trick. 4. I live in good 'ol Colorado. If doing so allows normal starting and idle, do a traditional wide-open-throttle run and shutdown. We're at 4,200 to 4,400 feet elevation, depending upon which end of the valley we stand. I'm running PIAA on the Ram truck and did a video recently that's at the magazine site. The chassis was in excellent condition, which substantiated the mileage claim. Stock is #152 and you may need #150. Having some trouble getting the carb just right. Not sure if it's gonna hold up under the temps generated by this bike, but we'll see. You could just get on a plane with your credit card and passport and buy or rent everything you need when you get there. The only other thing in the vat is water. In summertime (now), I'm pulling the choke off completely after the engine starts. The engine'sperformance is excellent, with no signs of air flow restrictions, and I'm good with "stock"!. I am aware of the XRs Only Mikuni kit which is a pumper for 450 or so and the Sudco Keihin FCR41 kit which is 550. Might have to sell the bike for cheap. The video shares my riding venues and why I selected this spark plug. The B Team rider can't get the XR650R to fire promptly, andthe A Team ridersails byGood tale about the XR650R and hard starting, but don't let this get you down. Also expected is the removal of the "user removable" air box restrictions. (This is fairly easy to do.) I have two good Oregon friends who ride on- and off-highway, one with an XR650R dual-sport conversion, he's based at Portland and works at Warn. An air leak could explain why this problem was worse with the Stage II camshaft, which wants to draw more available air/fuel. Not abused, just thoroughly used! Temperatures between 65F to 95F (with that humidity it seems to be 105F). Make sure there are no gasoline fumes in the muffler before welding! 99101-357-1750 (Main Jet 175) 3) Remove the throttle cables, hoses, choke cable, fuel line, rear brake reservoir and its bracket. The magazine recently purchased a 2000 Honda XR650R motorcycle with less than 1000 original miles on the bike. The account of how little they needed to get going again does draw attention to Honda reliability. 4. Smoother, easier starting. Despite the low mileage, this engine was busy overheating its upper cylinder and valves. (To assure an accurate reading, makesure the auto-decompression mechanism is not holding the valves openwhen performing a compression test!). But other than draining the carb I never removed, disassembled, and cleaned it. I haven't pursued the needle position or type, would bet it's stone stock since the carburetor's top looks unopened. What I was happy about, is that there was a new fuel screw in the kit. Don't race off to buy a $700 replacement carburetor just yet! Top cover and fuel bowl screws are fused to the carb body. Lots better throttle response at low rpm. Havent gotten it to start on the second clip. The first three video linksat this page are each helpful and focuson Honda XR650R work:http://www.4wdmechanix.com/?s=time-sert. Like you, I've ridden a very long time without feeling compelled to do manywheel stands. The rule of thumb for any motorcycle work is minimal use of force, just enough to get the job done! Try a 52 or maybe even a 55. Check now Rated 5.00 out of 5 based on 3 customer ratings ( 3 customer reviews) Retail Price $ 1,303.99 Our Price $ 1,099.90 Availability: In Stock (Changes Daily) Complete Throttle Assembly ($ 89.90) Complete OEM Part Check now Rated 5.00 out of 5 based on 3 customer ratings ( 3 customer reviews) Retail Price $ 1,303.99 Our Price $ 1,099.90 Availability: In Stock (Changes Daily) Complete Throttle Assembly ($ 89.90) Complete OEM Part The jetting job is harder than I thought, but really interesting. Hang the reservoir out of the way. The worst of it is hidden by the side cover. Aside from the 65 pilot, the Moose kit came with a 125 (yikes!) That's actually better than the Baja racing versions of these engines. Again, I go for just enough enrichment for a very smooth and stable idle, nothing more or less. Not sure where your market is located. I live in Puerto Rico, and use my bike everyday commuting to my job. XR650R was originally for off-highway only use, an enduro motorcyclewithout street use equipment. Like your bike, my engine had a half-baked approach. It's very forgiving unless you do something really wild. should I ditch that darn K&N? Tools are wonderful when used correctly. Put the spark plug back in (using a tiny bit of motor oil on the spark plug threads (not the electrode, just threads) will help reducing risk of stripping cylinder head threads) and get to the carb. WebXR650L Performance Upgrade Kit- Complete Carb Assembly 1996-2023 Does this product fit your bike? 4. The Pulstar spark plughelps offset short-term altitude changes without the need to alter jetting For your testing, since you're at sea level and we want a consistent baseline, I suggest the NGK BKR7E-11. It looks like it's been about a year since you visited this forum of yours -- I found the information discussed heresuperhelpful. Does this reverse the rotation? I'm sorry to read about your misfortune with your xr650r. I have read about lowering that seat height but in doing so it changes the geometry to the detriment of the bike so I don't plan on doing anything except possibly finding a softer seat. Honda XR650L carb problems - My experience. The main jet in my XR650R was 145rd, the slow jet was 65s, the needle was the same as in the power up kit and in the 3rd slot. After installation, recheck the operation of the throttle and adjust of necessary. Your change to the 180 mainjet will help. Now it's due for a clearance check and changing out the break-in oil. Must have been an option for those who really want to rattle the windows. Have a safe and very Happy New Year! Lay out all of your carburetor parts for an accounting. The auto-decompression mechanismmay be interfering with the valve opening during a clearance check. I painted it with barbecue paint (800 F test - best I could get), and tomorrow it will be put to the test. Check for air leaks. I have a Harbor Freight 20-ton bottle jack press (current version shown here, mine is 20 years old and still going strongly: https://www.harborfreight.com/20-ton-shop-press-32879.html). I would say that first thing you need to do is grinding off the mixture screw tab as described in Dave's Carb mod here: http://www.4strokes.com/tech/honda/xr650lcarbmods/ Please also note that you don't need all these mods because they are enrichening mixture a bit, which is something you want to avoid, you need only the mixture screw tab grinding. Will be filming from the bike, I'll share the link after our ride. A bent inner stem on this screw would makeit impossible to set a stable idle. I run about 1/4 mile, get back home and felt the engine hot and turn it off. It can probably be found elsewhere as well. My needle preference is3rd clip position from top of needle, and the 172 mainjet works well for me. "Very informative and practical." 175 seems a little fat. I don't over-rev this engine and shift well below redline by instinct, there's absolutely no need to wring out this engine, it enjoys being upshifted and laying down torque in the next gear up. So thats where I'm at! I'm sure many have stories of performance gains and unleashing latent horsepower from aftermarket air filters. You could also try adjusting the mixture screw to 2 turns out to see if that helps when hot. Wear eye protection. To get a sense of what goes on, watch the meetings trailer here! We can discuss fine tuning and carburetor staging laterFor others, keep in mind that tuning is altitude and temperature sensitive. Whenthe enginefires,typically on the first run through these steps,Iimmediately take the choke lever down to half or even off, depending upon the air temperature. The leak down test pinpointed leaking intake and exhaust valves; a look inside the cylinder (through the spark plug hole) alsoindicated scoring atthe upper wall of the Nikasil cylinderplating. Like you I don't plan a cam change because I want smooth power throughout the RPM range and hotter cams tend to produce power in more of a sudden rush at a certain RPM. Second is that I confirm that this bike feels relatively sick at these altitudes due to the mixture being too rich for a given air pressure. The flat-slide design has little or no need for altitude compensation and is much easier to work on and dial in for optimal perforance than the O.E.M. If this resonates, enjoy the flashback. Now the carb has: 180 main, 68S slow jet, needle on the 3rd with the shim. 1) Make sure the fuel petcock valve is set to off. Being closer to the source, I'd likely pay the $20 extra for them to install the cover. Touch-and-go here! Find somewhere a #150 main jet that fits your carb and replace yours with that one. Upon tear down, which you can follow in the HD video linked above, the engine's upper cylinder looked more like a Baja 1000 Racefinisher than 1000 miles of reasonable recreational riding. See the trailer here! He's da man! Big Gun header and muffler, wrapped with a Lava Rock/Titanium Wrap. If I happen to get overly zealous with the choke and create a hard start or stall upon starting, I turn off the ignition, pull in the compression release lever, hold the throttle well open, and kick through 4-5 times to clean out the cylinder.
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