Honda XR650 Rebuild Part 1 - Valve Cover, Head, Cylinder Removal

Initial Video
• I Got a Free 2006 Hond...
Inspection Camera Diagnosis
• Harbor Freight CEN TEC...
Link to Service Manual I used
archive.org/de...
Rebuild Kit
www.ebay.com/i...
Cylinder
japan.webike.n...
Due to factors beyond the control of Hank's Garage, I cannot guarantee against improper use or unauthorized modifications of this information. Hank's Garage assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. Use this information at your own risk. Hank's Garage recommends safe practices when working on vehicles and or with tools seen or implied in this video. Due to factors beyond the control of Hank's Garage, no information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Hank's Garage.

[@vlad_sadici]

Hello! We are in this process right now, of demounting the engine. We stuck a little bit at the stage of extracting the cylinder block out ( min. 18.00 ). Which tool did you used for this step? A rubber hammer? If yes, then how heavy is it? Do you have any other suggestions if this piece, the cylinder block, is over stucked there? We are thinking that this part was never dismounted. The engine has over 50 000 kilometers by now. Thank you!

[@johnwakeley5662]

I’ve got a 1993 Honda XR650L which I’m going to be tearing apart soon. Thanks for the videos 🙏

[@Queeeeeesh]

How the hell did u get the center 10mm out ? I had to unbolt the bottom to cock it off to the side in order to get that bolt to clear the side of the frame..

[@emilhammarstrom8138]

Your videos are super helpful, currently rebuilding a Honda Dominator (same engine) and these really help a lot

[@joemarshall120]

How long did it take for the cylinder to arrive from Japan?

[@hanksgarage_]

About a week surprisingly

[@thebad1234]

thanks i was waiting for this one on the bike

[@joshuajewell1785]

great video. I am about to do something similar to my XR. I was riding on the highway and slowly lost power before it stalled. Now it starts briefly, spits out tons of white smoke for about a minute and then stalls. It will shift between gears without stalling and starts up fine but the smoke is nuts. Pure white. So far I've taken off the cylinder head cover, the head is next. I'm hoping for just a badly leaking piston seal. It's been burning through oil like crazy for a while but the smoke and stalling is new.

[@Swimfinz]

Joshua.. same here. Ive had a few rounds of 650L electrical gremlins. Two cdi's, kickstand switch removal. My bike died in traffic. I was pulling my hair out. 15k on Odo. No compression, egads. I sure thought my dilemma was electrical. Local shops want $1500-$3k for engine top end rebuild. No. Time for me to roll up my sleeves.

[@Gibson_Branch]

I was riding home on mine and noticed oil on my boot. Investigated, base gasket blew and was spitting oil out the front, only at highway speed rpm. Absolutely no other issues or symptoms. Glad I don't have to pull the engine completely!

[@patrickczernizer2317]

Hey so I'm trying to get the cylinder on webike. And it keeps saying it can't gather my card info and it won't go through. Did you have any trouble with ordering? Thanks

[@hanksgarage_]

No I didn’t

[@Swimfinz]

Patrick..I had the same problem as you. They sent me emails saying "for Japan Honda products only." The webbike website is nice, but checking out is not smooth.I thought all went okay---finally. I checked my credit card and purchase did not go through. I'm just starting in pulling my engine apart. Might go with the 1mm larger piston and overbore of cylinder wall. Nikasil I believe. Fun project.

[@patrickczernizer2317]

@@Swimfinz so I ended up setting up a pay pal account and it went right through. Showed up at my house in Montana in 3 days! Fastest shipping ever. And completely oem product from Honda. Very pleased. Starting it up today. Wish me luck

[@Swimfinz]

@@patrickczernizer2317 wow! Wtg! Thanks for the PayPal tip. Happy riding!

[@cartonvera]

I need all these parts thanks for sharing. I have locally offered winseco piston but I rather have that new and stock. Again thanks

[@nikagurabanidze2792]

Hello, could you please tell me where to find manual what you were using ?

[@hanksgarage_]

It’s all in the description

[@nikagurabanidze2792]

Thanks a lot 💪

[@CTC7599]

Saving this video mainly for the parts links you provided. Had to get hauled home after I had a sudden bog in power and now she's slow to crank. Plenty of oil in the system but smoking out the dipstick when i checked. Assuming the worst but hoping for the best. Thanks for the info.

[@robkrpds3889]

can I ask something ?? isn't the bike the same as the honda fmx 650???

[@garagedchaos6353]

I pressed a new sleeve into my cylinder, sleeve was $100 then bored to a 101 for $95. La sleeves I’ve used for a couple motors.

[@GRACEVENTURES]

did you do the cam chain?

[@ChrisKAloha]

Any idea where I can get my head serviced? One of the exhaust valve seats broke

[@tylerhunt891]

I am sending mine to XRsOnly in California, they are pretty good from what I hear