How To: Battery Relocation Mod on XR650L

This mod is challenging, but it is doable! You need a Dremel and a cup of coffee if that means anything! My video isn't perfect, I'm missing a few minor steps, but will explain all that in the video towards the end-- I might've been running out of patience lol. Anyways, even if this helps you in the slightest bit I'd appreciate a like as it means a lot-- if you don't like this then rather than just dislike the video also leave me a comment as to why so I can improve these types of videos in the future! Thanks for watching!
Notes:
- I used a UFO panel for an XR600r as it's compatible
- You WILL need a Dremel
- I used a Shorai LFX09A2 battery

[@robertcedeno3904]

Nice work man, keep it up you got all my support 💯

[@one_terrabike3151]

I really do appreciate it! 🙂

[@Rob_Basich]

One of the best tutorials I've seen.

[@one_terrabike3151]

I appreciate it! Thanks for watching! 😁

[@ryanking2314]

This video helped me better my bike. Thanks so much for this advice😄

[@one_terrabike3151]

Glad to hear it!

[@jaredpaddick]

Can anyone tell me why putting the battery in front of the air filter is a better idea than leaving it where it is….

[@zachbennett520]

How are you? Awesome video, what did you do about the blinker and twilight wires? How did you disconnect them ? I’m Having trouble

[@christophermackenzie4100]

Hi and thanks for the video! We met this past weekend at the top of the mountain( can't remember the name, big rock garden intersection) I was ridding the XR650L and chatted for a minute. I am in the process of reinstalling the batterie box and using your video for reference as to how things where before removal! Looking forward to riding together one day :-)

[@one_terrabike3151]

Yep! Glad you found the channel too 😁. Hope it helps and of course we'll ride together one day 😁

[@CBRadioOperator]

thanks for posting this, liked and subbed

[@one_terrabike3151]

I appreciate it! 🙂

[@ichibangrom9735]

Good job Dude!! I am doing this to my XR. What kind of side plate did you use? Thanks for video. Liked and subbed

[@one_terrabike3151]

XR600R (UFO sells the set for >$40 USD). Also, thank you!

[@ichibangrom9735]

@@one_terrabike3151 Thanks right back at ya!!! Did you use stock battery or one of those light lithium iod ones?

[@ToxicBeamer]

just got the battery relocation done on my bike with bunch of other things including the smog delete on my bike and had to have a shop do it since im working 7 days a week which sucks since i barely have free time at the moment. im not sure if it the smog delete or the lectron carb i had installed causes machinegun like deacl pops but im loving it since now it popping like my modded/tuned charger R/T

[@one_terrabike3151]

Sounds awesome! Just check your plugs if you can sometime to make sure it's running properly (aka not too lean) 😁. Thanks for watching!

[@jamespolucha8790]

Why does everyone want to move the battery? What do we gain from this

[@GGas700]

Holy Huge pipe, what kind is that ? Noticed the Header and what looks like a Supertrapp,, If so , where did you buy it at ? How much ? Nice Xr , great video and Look fwd to seeing more of your mods. Thank you from SA,Tx

[@one_terrabike3151]

I use the XR's Only Header & XR's Only Supertrapp Competition Exhaust and it ran me ~$550 total as I got it on the end of the year sale. Also, thank you!

[@GGas700]

ONE_ TerraBike Have u considered a Pumper Carb ? , I heard it really wakes up the XR , with that exhaust system u have that would be a killer mod. Thanks for the reply

[@mekaniko1390]

Good work so clean Were are you located sir?

[@one_terrabike3151]

North Georgia :)

[@pinarellobikeride793]

So was this for better center of balance reasons you did a redo on it? Also, does the different battery work ok in general as it looks a little smaller then OEM, Just wondering if its smaller capacity is sufficient enough.

[@one_terrabike3151]

Did it for weight reduction as a lot of people said it totally changed their bike and to just make a video for people to reference if they wanted to do it! And it works perfectly alright! Lithium can be smaller and offer many benefits over a conventional battery EXCEPT in cold cranking amps which was problematic for me when I went camping in SUPER COLD areas.

[@munkyassproductions9178]

Nice job. The stock battery box is absurd

[@one_terrabike3151]

It makes electrical more accessible, but if it's not your daily you're absolutely right!

[@davebuchanan9761]

Awesome!!

[@one_terrabike3151]

Thank You! 🙂

[@rond.2862]

Just recently bought my XR650 with this mod done to it. Battery is woefully undersized ( 14 A/Hr vs 19 and 210 CCA vs 285 CCA for a Shorei in stock configuration). Doing this mod is overworking the battery since it doesn’t have much capacity and shortening its life. These Shorei batteries aren’t cheap so stressing it is not a good idea. Second point is now you have a rats nest of wiring on top of the air box. Honda puts a lot of thought into their bikes and the stock location enables easy access to the battery, fuses, and CDI in case of emergencies. When and if your bike craps out, if you do this mod you have to remove the two bolts to remove the seat. Not something you want to do off-road riding to replace the CDI with your spare (a known issue with the CDI). So now you have an underpowered battery, fuses, and CDI exposed to moisture all in a location not easily accessible. This is IMHO a VERY BAD idea if you consider the negatives of doing a mod just for looks. I’m in the process of putting my bike back to the way it’s supposed to be.

[@curtn7076]

Great video 👌. Hey, where to you get your exhaust header and pipe. I have a supertrapp that I love but the rust is bad where it connects to the header.

[@one_terrabike3151]

both from XR's Only :)

[@curtn7076]

@@one_terrabike3151 thanks!

[@izzy-is2dp]

I see you did the oil cooler upgrade to yours. Was it a hard install and do you think it’s worth it/a good upgrade?

[@one_terrabike3151]

Very easy to install thanks to Sutton's GREAT instructions! He provides a manual and diagrams of exactly how to do it :). It lowered my oil temps 20-30 degrees F, and I'd say its a great mod that's well worth the money. The exception is riders that ride TOUGH single track and the oil cooler lines could possibly snag on branches

[@izzy-is2dp]

@@one_terrabike3151 thanks for the response! I’ve been looking into the Sutton’s cycle kit and think I’m gonna go with it just trying to find out as much info first. Much appreciated!

[@WILLY52368]

I'd like to redo battery mod, my fuses and cdi are stuffed in the air box but I know my carb is starving for air with all that in there. Your relocation looks good, maybe some patience going into it but like you said doable and neat looking too. Battery seats ok?

[@one_terrabike3151]

I actually undid the mod as I needed more space for electrical components and quick access... however it worked wonderful the way I had it as shown in the video. The seat has plastic 'ribs' underneath it that might need shaved off with a dremel

[@WILLY52368]

@@one_terrabike3151 That's what I was thinking, how were you going to get the seat back on because it looked like it the battery was too high. So where and how much of the seat did you needed to mod to get it to fit please? Also I gotta say you have some of the best video when it comes to the XR650L, I only wish I had the necessary tools and place to wrench. This housing complex limit the kind of vehicle work done on property plus I don't have a garage.

[@dboutdoors6180]

Great tutorial, I will be tackling this job tomorrow! Thanks!

[@azxp]

Cool mod would have like to see the finished project, but nicely done. Curious if you have any good videos on how to lower or fit the bike? I am 6 feet tall, and I can barely touch the ground. Yours looks like human sized. Any videos or advice to make my bike fit me? Thanks in advance.

[@one_terrabike3151]

Mine is stock now, but when I bought it it had a lowering link installed and the PO had dropped the fork forks about an inch so it was shorter. If you do a lot of off-road riding a lowering link may hinder you as you lose some clearance but I don't know your riding style. I don't have a video on this but it's quite simple. Loosen the front fork clamp bolts (12mm) and tighten them once they're an inch shorter (you'll see an inch or so above the upper triple clamp instead of flush), and then underneath the rear shock you'll see the suspension linkage (look up pictures if you don't know what this is), and then remove the two bolts.... And install the new linkage 😁

[@azxp]

@@one_terrabike3151 Thank you for the response. One last question. Are you 6 ft tall or shorter? Did you just get used to how tall it was or are you over 6ft tall, and it is good for you? I mean if the bike is just too tall for you, and you got used to it, maybe I will just keep trying to get used to how tall it is.

[@one_terrabike3151]

@@azxp 6'1" or so. I am able to flat foot it when still but on the trails it is indeed well tall. I'm glad I had it lowered while I was learning to ride but as I got better the height aspect wasn't nearly as important as you don't really need to put your feet down if you're riding correctly often times. Perhaps look into adjusting your suspension to run softer so your weight compresses the bike more this making it easier to manage. [Edit] I believe they make lowing seats too if you don't want to lose clearance.

[@azxp]

@@one_terrabike3151 You are awesome; Thanks fro the info!

[@one_terrabike3151]

@@azxp anytime! 😁

[@fc1133]

Nice video. Too bad we cannot see the bike after the mod from further away to get a better look! : ). thanks for posting.

[@one_terrabike3151]

I regret that myself lol. But you're welcome & thanks for watching :)

[@fc1133]

@@one_terrabike3151 😊😊😊

[@johnnywishbone1349]

Would Honda just redesign this bike and come out with the CRF650L already! I’ve been waiting for years now. Lithium battery, new plastics, signals, headlight, EFI. If they want to do more than that cool if not fine.

[@one_terrabike3151]

I know right 😂. The 450L is alright but the maintenance involved in that bike is ridiculous! So, if it had the things you mentioned (if not more) ... I'd also want it to be reliable!

[@yafois988]

I was considering a lithium battery swap on a XR650L so briefly looked and found one, that says Is a replacement, How proper is another "buy it and SEE "story I think, the Lith measuring 6.25 x 4.75 x 3.75. While the OEM supposedly as per spec measures 5.94 x 3.46 x 4.21. So can you say this Lith One I gave Dim on, would work as doing this same relocate with its dimensions? Or do I need one that does NOT exceed the OEM Dim spec? thx

[@one_terrabike3151]

If the website says it'll fit our bike go for it! Most people get Shorai lithium batteries or Antigravity lithium. If you're unsure of dimensions just measure the inside of your battery box 😎

[@fltc80]

How is the XL500, father to the XR650L set up, I know it didn't have electric start- not sure about the CDI. It would be great if that setup or parts of it could be borrowed for this conversion. I'm interested not in switching to a flat left sidecover but would like a toolbox or tool tube there, that way I could eliminate the tool bag & install a large rack instead of my smaller wrap around style rack Batman

[@one_terrabike3151]

I cant really speak for that bike, but you could always empty out the battery box as shown in the video, keep the box, and use it as a tool box instead :)

[@fltc80]

@@one_terrabike3151 that's the reason I want to do this

[@SWTrailsAndWheels]

Your videos are awsomely useful. I just bought a 2013 XR650L a couple of weeks ago and am in the process of modding and studying future mods. With respect to the battery I'm thinking of starting with simply switching to a Li-ion battery for the overall weight savings but leaving in stock location. Bike is a bit top heavy and the relocation would appear to place the weight higher though it is definitely more centralized. Initial mods are tusk dualsport tires, heavy duty tubes, rimlocks, pegs, thicker front sprocket, and tusk wraparound handguards. Over time I want to focus on weight savings so will do exhaust, jetting, Li-ion battery, I bought the desmog kit but am having second thoughts on installing it, minimal weight savings (~2lbs), no performance gain and only an emissions increase does not seem worth bothering.

[@one_terrabike3151]

Desmog does actually make a difference! It helps to reduce backfiring which is annoying and to some people -- they say it burns oil (I can't attest to that as I didn't pay attention but you might want to read more on that)... I actually removed my lithium ion battery as it had a much harder time starting in the cold (34° F ish) and went back to a 190CCA battery. The relocation to me was more aesthetic than a functional improvement which is why I did the mod...and quickly undid it. The rest of your mods are perfect it seems 😁👌

[@Alan-fx9xb]

​@@one_terrabike3151 why did you undid the battery relocation?

[@emilzonreyes9275]

ok but what is interesting to know is if the chair is well adjusted as it was before the modification

[@one_terrabike3151]

Oh absolutely! I had it wired differently the first time around and the chair (seat) would not fit without some serious pushing! Now, the way shown in the video it's just as easy to install and remove as before! 🙂

[@opplez1159]

to those who have had this mod for a fair amount of time, how much is the risk of the components getting wet increased? especially with pressure washing the bike after riding

[@one_terrabike3151]

The likelihood of damage/corrosion over time is high. I actually undid the mod as it became annoying to service electrical on the trail. If you do this mod, care about accessibility, and element resistance the newest, best solution is Spectrum Motos battery relocation box. It's a slimmer profile battery box that can use the XR600 side panels! Super cool!

[@opplez1159]

@@one_terrabike3151 thanks for your reply. i actually found the battery box youre talking about and was wondering which is a better option since the aftermarket one requires a very small battery so it may not last as long. and a smaller cdi i believe though since you just confirmed my suspicions ill consider the aftermarket box more seriously

[@one_terrabike3151]

The Ignitech CDI is far more reliable than the OEM one. So that's an improvement. Size of the battery won't matter as long as you keep it on a lithium battery tender. They'll do just fine! 😎

[@opplez1159]

@@one_terrabike3151 thanks for your input!

[@jaredmouret9723]

I've always seen topics about this mod, but what's the purpose? A cleaner look behind the fender?

[@arthurconrod9825]

All this work to loose 3" width.

[@one_terrabike3151]

Looks and weight. My recommendation nowadays is not to do this mod actually. Get a spectrum moto battery box or just get a lithium battery for the box. You'll still notice a difference!

[@jaredmouret9723]

@@one_terrabike3151 that was my thoughts, exactly. Li.battery and upgraded exhaust on the other side should be a very good weight reduction yet a balance of low weight on both sides, stay safe bro.

[@emilzonreyes9275]

my question is did you have to modify the chair or install it without any problem

[@one_terrabike3151]

There are two holes on the seat pan that look like 3/4" tubes... you'll have to cut those down, but most aftermarket seats (if you have one) already have those removed! Thanks for watching!

[@anthonygreen6870]

What side plastic did you use to replace?

[@one_terrabike3151]

UFO side panels for an XR600r

[@gavind9487]

FYI, battery connection convention is Earth - disconnect first, reconnect last.

[@one_terrabike3151]

Absolutely right! Could've done better there! :)

[@thedtmann]

Have you had any trouble with the battery or rectifier since installation?

[@one_terrabike3151]

The modification would have no ill effects on the rectifier, but I undid the mod a while back to regain electrical accessibility and reassurance that if it died on the road i could replace it with one from the parts store and keep going

[@bigmower]

What I do not get is why would you want to move the battery?

[@one_terrabike3151]

It's an aesthetic some people like :)

[@charlietuna1971]

Nice.

[@one_terrabike3151]

I think so too! It doesn't look as far as is feels anymore 😂

[@emilzonreyes9275]

excuse the battery when installed under the chair is it damaged?

[@one_terrabike3151]

The battery isn't even touched my the chair (seat), so I'd say if left loose it *might* get damaged if you hit a ton of bumps off road but I later added 3M Plastic Fasteners (similar to Velcro) to hold it in place so it wouldn't bounce around under the chair (seat)

[@larrychick154]

Just completed mine. I secured the fuse box as you did. It’s safe front getting wet there?

[@one_terrabike3151]

I had no issues while I had it like that! I later undid the mod in order to keep repair videos consistent with the average XR though. If you're worried you can always carry extra fuses or use a Ziploc bag secured via a zip tie. Kind of tacky but it would work if that's a concern 😁

[@larrychick154]

@@one_terrabike3151 thanks for the reply. Glad to hear that you had no issues. Carrying extra fuses is a good idea and I’ll definitely add some to the tool bag. I put some electrical tape around it for now and I ordered some wiring harness loom covers and I’ll figure out a way to put that over it for a little cleaner look. Cheers!

[@jamespolucha8790]

Why not just leave the old battery box on for storage like a hidden saddlebag

[@tarheelwearwolf]

Confused on what you did to the plastic to make it look clean

[@one_terrabike3151]

Dremel most of the plastic and then just file/sandpaper the rest 😁

[@kalencoleman5725]

How do you disconnect the diodes?

[@one_terrabike3151]

I don't exactly know which component you're referring to along the wiring harness. If you have Instagram, look up my account there and send me a photo and I can help further 😁

[@emilzonreyes9275]

Can you send me the dimensions of this battery that you used?

[@one_terrabike3151]

Dimensions: Length 4.45" X Width 2.28" X Height 3.50"

[@paulboshoff9384]

@@one_terrabike3151 Hi. What battery did you use for this? The stock XR650L bat is too big and I'm sifting through the Shorai battery list to try and figure out which one will work. Any advice would be great.

[@LynchE1]

Would this work with a xr250l

[@one_terrabike3151]

I cant say for sure as I've never had the opportunity to work on a XR250L. I do know the 250l is a sweet bike and personally I'd just get out on the trails and ride rather than worry about doing this to your 250L. It's largely aesthetic :). Thanks for watching!

[@LynchE1]

@@one_terrabike3151 ok thank you

[@GM-he3um]

So you used the same batt?

[@one_terrabike3151]

You can use that battery in the battery box or do the relocation. Either method will still reduce your bike's weight 😁

[@ejpilarski3595]

What side panel did you put on in place?

[@one_terrabike3151]

I used a UFO panel for an XR600r as it's compatible

[@SeptemberTwentyThird]

Just buy a xr650r. So many pepole buy a duel sport, and then spend so much time and money to convert there bikes to a regular dirt bikes. Just buy a regular dirt bike if you hit the trails that often.

[@one_terrabike3151]

That would be ideal :)

[@chrislollich6064]

Go ahead and keep kicking, with the L , just push a button. Thanks from NOR-CAL.

[@xrxr6709]

Мне было интересно маслины радятор как ставить

[@one_terrabike3151]

Сейчас было бы немного глупо удалить его, но всякий раз, когда мне нужно будет поработать над движком и мне нужно будет его удалить, я сделаю видео! [It'd be a little silly to uninstall it now, but whenever I have do any engine work and need to remove it I'll make a video!]

[@cmbscx1084]

For the noob XR650L owner like me, what does all this extra work actually do? Short of battery weight savings, it seems like it is for looks only. Does this aid in future luggage placement or?? Anyone ever done a before and after weight bias?

[@one_terrabike3151]

Most people do this mod in hopes of losing weight on their XR while others do it for the looks. I did this mod to my XR and actually choose to undo it as it had some quirks I didn't like whatsoever. For example maintenance on electrical components is much harder as well as the carburetor as it's all stuffed so close. I also did it to remove stress from the subframe but ultimately just bought dirtracks crash bars which add support.... As someone who uses my XR as my daily this was where I made the decision to undo the mod....it was *slightly* lighter but I wasn't pleased at all with the drawbacks.... Some people will and do love this mod but that just wasn't me. I'd advise just buying the Lithium battery for ~4-5lbs weight loss if anything but not this entire mod... I will close with this is my personal opinion and findings rather than facts 🙂👌. Best of luck and enjoy your XR!

[@89pdg]

Don't do this mod

[@one_terrabike3151]

It's great if losing weight is the goal, but for people doing long adventures in the middle of nowhere and accessibility is important- you are correct!

[@jcflyer6213]

A pointless mod....

[@matthewolson4963]

Bro, way to complicated

[@one_terrabike3151]

For some it is still worth it. My advice to people is to just get a lithium battery for weight savings or get the Spectrum Moto battery box.

[@matthewolson4963]

Awesome!!