My XR650L Build Video | 20K Thank You! XR650 Built Up & Modified Video Mishmash

Starting mid 2019 building and modifying my 1993 XR650L these videos are just a mishmash of the things I did to my bike these are not How-To videos just a video diary of what I did.
The Honda XR650L is the picture of versatility. Off-road, it dominates the trail with the right combination of power, suspension and durability. And when you’re on the road, its light overall weight, electric starter and excellent fuel efficiency make it great for commuting or even long trips.
While the graphics will catch the eye, what really sets the XR650L apart is its ultra-tough 644cc overhead cam engine that has torque and power to spare. And because it’s air-cooled, it’s easy to maintain. Plus, the engine’s gear-driven counterbalancer reduces tiring vibrations, so you can ride comfortably for hours on end.
Monster trail or monster commute, the XR650L has got you covered.
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#xr650L #dualsportcanada #hondaxr

[@HeddleTown]

✪ *PATREON:* ►►www.patreon.com/HeddleTown ✪ *SUBSCRIBE FOR UPDATES:* ►►bit.ly/HeddleTown_YT ✪ *MY WEBSITE:* ►► heddletownsenduroride.com/ ✪ *CHECK OUT OUR SHIRTS & HOODIES:* ►►teespring.com/stores/heddletowns-enduro-ride

[@allistairneil8968]

Finally someone who bothered to put in a kickstarter! Well done and something you will never regret.

[@HeddleTown]

HaHa Ya thanks it does work good and its the ultimate backup!

[@discoveror9576]

As a 72 year old engineer (who just learned to ride in 2023 ... and rode 6,000 miles, first year), I was astonished that you picked such a HEAVY bike (within ~35 pounds of my KTM 390 Adventure, wet) ... because everything I heard about dirt/trail riding said "the lighter the better". I watched dirt riders think that a 275 pound was 'heavy'! Weight is relative, I suppose. I would have thought that someone of your capability and experience would have chosen something ~100 pounds lighter?

[@HeddleTown]

Well a lot is done to my bike and it weighed in at 315lbs. I removed a lot to get the weight down.. this bike is not only near and dear to me as Ive owned it since the mid 90s and its never let me down! Sometimes getting home on a very reliable bike is far more important than what your on! I own multiple bikes so it's not my only choice in the garage! I should add a good rider is good on anything..

[@knifecharlatan8912]

I love seeing folks tear into their machines! It's a really intimate experience between man and machine. Awesome!

[@HeddleTown]

Yeah it's good to get to know the motor really well easer to fix thanks

[@chrislollich525]

U know Y because XR'S rule!!!!! THANK'S from NOR-CAL!!!

[@USMC-Sniper-0137]

1993? WOW! Mine is the 2004 and near nothing has changed! Parts are so interchangeable and I love my XR650L !! Ride on brother!

[@matthewkrisowaty7053]

Sweet build man.. came out really great.. I love building up bikes ..riding tweeting them.. oh man when it’s all set up for the rider it’s like magical..! I have done over 46 machines during my yrs.. has made me love the sport and riding them is so rewarding when you know you built it your way.. so congratulations and enjoy her !

[@HeddleTown]

Thank very much its is pretty dialed in! :)

[@Ramcat_Vlogs]

Kk bike makes awesome sprockets I ordered one and had it in 1 1/2 weeks from Italy 🇮🇹!

[@HeddleTown]

That's awesome I've never needed one!

[@johnheckscher7138]

I have one of those KK bike sprockets and it's good 👍🏻

[@easy4steve]

thx for sharing ,,,lol the old XR ,, the sound … ohhh ,,,, never forget it . never owned a 650 , but 250 400 and 600 ,,, fell off those more times that I would like to remember , now on ktm ,,, happy with ktm .

[@Hunter-bp7eo]

That old girl has some sweet lipstick!! Nice work bro... Looking forward to more vids..

[@USA01930]

incredible video man thanks

[@chrisiollich4890]

Right on another XR DUDE I'm rebuilding my XR650L, more is to be revealed, U know Y because XR'S RULE!!!!! THANK'S from NOR-CAL!!!! PS.just SUBSCRIBED.

[@HeddleTown]

That's awesome thanks man yes love all my bikes but the old XR is special!

[@Scoottoots]

Wow, lots of work done. Should be good for the next decade eh :-)

[@XR650L_GUY]

That head is cracked between the intake ports. Kinda common in the old days.

[@XR650L_GUY]

Nice job ! I've got mine torn down now and adjusted the frame, prepping for red paint.

[@idnld1588]

Superb video and build. The legendary XR650 is practically the very definition of a reliable bike. And WAY more character than what’s on the shelf today. Question: typical days riding - what kind of mileage and range does that aftermarket tank get you?

[@HeddleTown]

300k plus depending how you ride!

[@cmbscx1084]

Bang on. Love it. Great choice in Mods. Look forward to some riding vids.

[@brianflickinger1490]

Awesome build on that XR!

[@ps.adv.9851]

Amazing bikes. Best dual sport bike I ever owned. I had to sell due to availability of spares. Thanks for sharing this video.

[@kenbrownlee4170]

New subscriber Wow awesome channel! 👏 especially for us newer riders.

[@HeddleTown]

Thanks, glad you enjoy the videos!

[@dennisodson4572]

Nice video. I would really like a complete parts breakdown of your front end set up.

[@robertnocerajr3985]

Yeah I definitely agree with leaving the passenger pegs on.. besides occasional women passengers.. they provide protection.. pretty much crash bar’s

[@garrycampbell1211]

Like your videos looking into xr650l great info /Garry =Ireland

[@HeddleTown]

Thanks! Yes its one of my all time favorite motorcycles will never sell this one!

[@whalley1390]

man that thing is so cool!!

[@glossblack1098]

Wow the Honda looks awesome. Hope to see some videos on how it performs. Also looking forward to more training videos. They have helped me a lot over past 2 years going from novice rider to intermediate confident rider. Cheers

[@HeddleTown]

Thanks I'm glad to hear the pointers help I will be making more for sure! The XR is working good videos already filmed just have to edit and upload! :)

[@khaccanhle1930]

Amazing work. I would like to get an XR 650, but all the work needed to optimize it usually dissuades me. I do mostly single track on 250 or 125, but I would like a big thumper for open terrain.

[@tipofthespearrealtors]

Don't get it twisted, these bikes are still capable stock and are very cheap and easy to uncork and bring them to their full potential. I have one that I uncorked myself (with very little mechanical knowledge and experience) and it brought out all the power you need and made it a much more capable machine. Pick one up, you won't regret it!

[@johnmeurer4780]

Love the videos. Currently I'm converting the suspension and brakes on my 83 xl600r supermoto. Installing a 97 cr250 front end and a xr650l rear end. Trying to figure out good rear shock for my supermoto set up.

[@johnmeurer4780]

Nice that you were able to add that kickstart with the old xr500 counter shaft.

[@zip7806]

Asking a Video Favor. " Could you please do a walk through about your garage space and how its organized".. I have what looks about the same space between two tall boy containers. I'm close to finishing a Roof so I can Move in... I have been so out of order, back and forth between both containers with side doors. I am Greatly Inspired by your shop space. Thanks.

[@laosgpsmapmidnitemapper9411]

another great video, congrats on the 20,000 !! Sweet bike, from a Honda guy too. The Countershaft >> Well love those older models with the beefy splines however>>>> I think you will find that more splines is Better. as it is spreading the load over a larger contact area and resulting in less wear, /what do you think? and the big thumper has higher peak loads! than a smaller motor and or a 2T for instance, so that drive line will wear out faster. I put 200,000 K's on my XL600 all over Asia - Back in The Day> Cheers

[@HeddleTown]

Awesome yes its hard to say the more spline doesn't change the fact that each single spline is pretty thin so with the big thick splines it would take a lot to hammer thru them! Either way lets call it an experiment! :)

[@Mark-vx5dt]

Nice xr! Please do a follow up on how the hot cams works out as you put the miles down. I've got a '01 650L with a few of the same mods. FCR carb, programmable ignition, cush drive, FMF pipe and more, but am waiting for my engine to get properly tired out before going in.

[@HeddleTown]

Will do if you run good oil and keep the cam in spec it should last a long time my last one lasted 20 years I think it was a Hot Cams as well!

[@GreaseAndGravel]

Awesome mods, man! Two quick questions: 1) did you brace the subframe for the rack and bags? If so, did you just make something from steel? 2) what do you use to stick the DIY alu case protector on? Love the channel and those skills vids... really need to put in some hours myself! Cheers

[@HeddleTown]

Yes I did make some subframe braces and welded them in, reach out on one of my medias if you want some pictures! I just used Silicone to stick that alu protector on! I have my own version of a skid turn video coming for this Friday should be helpful to lots of people! Thx

[@GreaseAndGravel]

@@HeddleTown Thanks, I appreciate the reply. Will definitely check out that skid turn vid! I'd love to learn how to do a skid turn with both feet on the pegs. Cheers

[@Ducrider999]

Best vid ever. great presentation

[@HeddleTown]

Thank appreciate that! :)

[@MrStrglide]

Fab

[@survivaldirtbikesllc5710]

Rad vids

[@henocsilva562]

love it, just bought my own Xr650, been binging on these build videos and yours is really good

[@samhill65]

I'm interested in the Digital Dash.

[@1969tonksy]

Cool video, thanks for sharing and well done on the 20k subscribers.. You run a very interesting channel and looking forward to seeing more great videos... Ride safe

[@zardportugal]

Top work.

[@aaronmwangi757]

Wow amazing

[@bretaschleman8289]

Nice work bro.

[@HeddleTown]

Thank you sir!

[@monocogenit1]

Sweet bike. Mine is similar. Cr125 forks. Have you thought about an oil cooler? I have the Sutton cooler.

[@HeddleTown]

Thanks, no I don't need an oil cooler its always worked fine for me! :)

[@monocogenit1]

@@HeddleTown cool. Thanks. Gets pretty warm down here in TX

[@czrider6300]

Question. The triple clamps would likely have a different off set. So how does it turn now? Thx.

[@johnhamilton2680]

Great stuff. Wish you the best.

[@HeddleTown]

To you as well!

[@richardhartley7094]

love your video's keep them coming 👍🇬🇧

[@HeddleTown]

Thanks will do! :)

[@stevebrittain3807]

what tank bag is that?(looks like a good fit & size). Great video BTW,informative & to the point👍

[@ianferrier235]

Congratulations on 20k ,how do you source your parts, example the shaft swap knowing a 500 would fit a 650? Very interesting thanks heddle town 👍🏻👍🏻

[@HeddleTown]

Thanks glad you like it.. for that shaft I hit an XR group and chatted with some guys that have done it! For most other stuff there are sources online for most bike models to look up actual OEM part numbers I than have 2 pages open and cross reference part numbers! :)

[@willeypoboy5607]

Nice job. I went with emigg triple clamps & crf 450 forks and upgraded rear spring. Different animal now!

[@jeremymonk8572]

Awesome build! So I have an 07 xr650l and would like to do that fork swap you did. It just so happens I have a 98 cr250 laying around. I'm curious what the triple clamps you got were? I'd love to do that upgrade. Thanks for your time.

[@brianmetzker5225]

I am loving the Chanel. Some great mods on your XR, thanks for sharing.

[@mikebrowne4028]

Insane build and excellent work. Quick question on the triple clamps. I couldn't hear but did you say "Wicked" as i am trying to research an USD conversion cost and if worth it.

[@HeddleTown]

The triple clamps are made by RSW if you search that name for XR650L clamps you should find them! It is worth it if done correctly because you get much better front suspension and the key and handlebar lock work properly with the proper clamps!

[@bpowa]

What happened to the ktm690? Why the xr650 and not the 690 for exploring?

[@zbob2257]

Great Video! Awesome XR! I love mine too but I really need to do something with suspension. May I ask what rear shock are you using? Cheers! Wish you all the best

[@HeddleTown]

Thanks! The rear shock is completely stock it may have been re-valved many years I cant remember had the bike 27 years!

[@Jtstrigel]

Once again another great video. I've got my bike pretty dialed in. I have to mention I am by no means even an armature mechanic. But now I just look forward to fixing something on my KTM. Its my new hobby. So watching your video makes me want to rebuild something else, but as I said right now everything is running well so I won't touch anything. But on these bikes it's just a manner of days and something will break. On a side note I'm not used to this because my street bike you would just start and go. But how boring is that right?

[@rickbrooks1608]

Thank you for showing some of your bike build. I have a 2015 XR650L and I'm going to be doing some engine mods in the future. Is your bike standard bore and compression ratio?

[@HeddleTown]

No the bike is at one size over it's a 101 mm about 9 to 1 :00 or either 9.5 to 1 wiseco

[@mrsmel269]

kick ass getting ours on friday !!!! #livetoride

[@donmason356]

I would like to see how you replaced the gears on the shafts

[@leonwatts6134]

hotcams are noisey with there clearance set at .15 .20 instead of .10 .12 i think im going to set at .12 .15 instead and see how it goes

[@korymcquiston2778]

What did you set your valve clearance to? Did the hot cam change it?

[@robertnocerajr3985]

Yeah great message here.. I have a 94 xr650l I love your kickstart... and I enjoy all of your stuff.. my bike is fine but I’m curious about the fcr pumper carburetor and how much it is going to be better.. Robert jr New Jersey here pine barrens xr650l owner

[@tacostwowheels4934]

Nice upload!!

[@sierraromeo3809]

Awesome mods.... Bike looks great.

[@HeddleTown]

Thanks!

[@963moto]

Awesome bike and video. Got a 93 engine in my XRL, still runs great. Putting the FCR41 on it this weekend. You mind if I ask what altitude you are at and what jetting you ended up with? I've watched most of your videos and your XRL sounds like its spot on!

[@nicks_ride]

Solid build! Did you make a video doing the Kickstart install?

[@HeddleTown]

I did not its pretty easy and some good info at thumper talk!

[@hmmv4]

Get ahold of a wr250r ,those things get a ton of views.

[@HeddleTown]

Ya popular bike for sure!

[@dlrmon1]

Nice Build...making the “L” Cool again. I would be interested in knowing what engine top end mods you did...I’m currently dual sporting an XR628r...definitely could use the gear mod’s. Thanks

[@1boehm]

awesome vid=subbed i actually started looking for parts to swap 2n and 5th, don't you have to swap out the other gears on the other shaft also so they line up correctly?

[@HeddleTown]

Awesome I appreciate that! No apparently you don't need any other gears they mesh just fine I guess Honda has it figured out to be able to do that! The overall diameter is really minor is the reason I guess!? Thx

[@diesel7391]

Nice. Someday I will build one. What did you do on the clutch cover side for kick start you added

[@jamesbramblett3346]

Curious....will the xr650l start, using kick start, if your battery is dead? Nice looking xr 👌🏽

[@dlrmon1]

Yes...old school setup...I believe it will even start with the battery removed.

[@hitsomebody1]

Great Video. What parts do I need to gather to add a kickstart to my XR? I'm out in the back country all the time in Central California.

[@HeddleTown]

Thanks! If you search Google for "xr650l kickstart" look for the article on Thumper talk it outlines the parts needed and the procedure!

[@tomcostello3095]

Where did you buy your second and fifth gear replacement, I have a xr650l and wanted to replace those gears as well.

[@HeddleTown]

There is tons of them on eBay I recently looked a couple days ago! :)

[@sdqsdq6274]

hmmm i dont get it , how the shaft can get worn like this ?

[@madeinussr7000]

what does the replacement of the gears of the second and fifth gear give and what gears do you put there?

[@HeddleTown]

Honda Nx650 gears make a better space from 1st to 2nd and better overdrive for 5th!

[@madeinussr7000]

@@HeddleTown Ok, thnx

[@robrozek9265]

Quick question my left side case has gotten a puncher from the gear shifter do l need to take the engine out of the bike great channel l like you're up grades happy trails

[@HeddleTown]

No just pull the cover and JB weld the inside and outside or replace with another part.. its fairly easy! Thanks

[@chrisiollich4890]

U beat me to the punch, I used JB weld the putty type, that was 5 years ago, and it's still good.

[@robertweeks2039]

Nice job.How do you like the tranny mods.I don't own a XR 650 but are thinking about buying one as My DR tranny failed on a cross Canada ride.I need a durable bike.The DR weak point is the tranny.Those Honda gears look like they are made better in your video. Is that the North Thompson River in the video?I live in BC and would like to talk to you.........Bob

[@hansottosmotos]

Hi, and great video's! I wanted to ask you what exact parts you use for a podfilter setup? I want to try some rejet on my stock XR650L carb, but its really a nightmare to get the airboxboot on. Actually i got the airbox used and it may have shrinked on the rubber, but its the hardest job to get it properly on, so i want to consider a Podfilter for permanent install. If you have the partnumbers of the parts you use, i would really appreciated to get them.

[@MrKalon52]

Dope bike. I’m considering the Suzuki dr650. Any thought on that bike?

[@michaelwebster2416]

How many miles was on this xr650l engine before the new build?

[@muleavenger9772]

I wish I could do this to my bike but I am not a good mechanic. Not sure where I would go to be honest.

[@kadarbalkaran9811]

how did you do the front suspension

[@pinarellobikeride793]

Suggestion, about the parts you upgraded bike with , and where you got the parts and their names so If I wanted to get same, can know what to look for with certainty. thx.

[@rolandrodriguez3854]

Tired of complaints about output shaft wear! Apply a good moly grease on shaft a couple of times per year. Spline Wear DISAPPEARS. NOT ROCKET SCIENCE! Minimize metal to metal contact. Jeez!

[@HeddleTown]

HaHa I know what you mean I did nothing to mine in 27 years it lasted I always tell people dont do anything just ride it!

[@tipofthespearrealtors]

Slapping on a sprocket from the xr600r gives a much tighter tolerance and solves this issue 🤙🏻

[@currst]

Great video! I have a question. I moved my license plate to the bottom of my fender and need to mount a light for it to ride at night. Can I wire into the tail light?

[@HeddleTown]

I missed this message! Yes you can for sure just use the running light wire NOT the brake light wire!

[@currst]

@@HeddleTown I appreciate your help!

[@keithusam6350]

Great Channel!! How did you get it down to 300 pounds

[@HeddleTown]

I have an accurate scale coming in the mail but I recently weighed it on a larger scale come out a 310lbs so should be close to 300 I remove literally everything you can from the L model! :)

[@keithusam6350]

@@HeddleTown thx for the quick reply. I have the L and love it but soooo heavy. So I bought a xr400 also. It's a great bike to. Much lighter. Keep the videos coming. Great job and I spread the word. Thx!

[@bullyboy585]

Hey do you have a web site where I can find some lower fork guards like the ones on your xr650L

[@HeddleTown]

I do have a website heddletownsenduroride.com the fork guards are just stock 2001 CR250 fork guards! You mean the stickers.. there kind of custom jobbies?! 😁

[@zl2848]

Are you in New Jersey by any chance?? I'd love to have you work on my bike for me.

[@HeddleTown]

Canada!

[@robertnocerajr3985]

Robert jr New Jersey here pine barrens xr650l owner.. ocean county

[@tipofthespearrealtors]

How did the 2nd amd 5th gear swap work out? I'd love a shorter gap from 1st to 2nd and to get a little more out of 5th...

[@HeddleTown]

Exactly why I did and worked flawless 5th is much better for longer rides and the 2nd is too good to be true!

[@NOS370]

Does upside down forks come standard on them

[@milostrickovic6770]

How much is that FMF exsaust for xr 650?

[@HeddleTown]

Im not sure it depends where you purchase it there popular so hard to find right now Im told!

[@bullyboy585]

What front fender do you have on your xr650?

[@HeddleTown]

Crf 450

[@JosephL6174]

What are the 2nd and 5th gears did you use were they for a different bike model?

[@HeddleTown]

Yes NX650 same engine though!

[@seancarr9907]

@@HeddleTown does it matter what year from the NX650? I was looking at the print and it's shows a 25t and a 21t for the fifth from the nx650

[@BikerBenny]

No rear spring upgrade?

[@HeddleTown]

Nope

[@matthewblyther8778]

how much do those triple clamps run?

[@HeddleTown]

I think they were around $350US

[@matthewblyther8778]

@@HeddleTown not bad at all compared to the other sets ive looked at then. have a set of cr125 forks ive been wanting to put on my 650l. just waiting to get them reworked for my weight and riding first. thanks for the price info

[@user-pr8vw8nl8i]

Нихуя не понял... Но очень интересно!

[@earlgray4333]

Why wouldn’t you just save your money and buy a real dirtbike.

[@HeddleTown]

HaHa That's awesome its as real as it gets.. that and I own 8 other motorcycles! Check my other vids! ;)