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XR650L: Fuel and Intake


The XR650L is a dual-sport motorcycle, air-cooled 644 cc (39.3 cu in) SOHC dry-sump single-cylinder 4-stroke.  Part of the Honda XR series. It was released in 1992 as a 1993 model. It combines the RFVC engine from the proven NX650 Dominator dual sport with the lighter, off-road capable XR600R chassis.

Chain Size:       Front Sprocket:       Rear Sprocket:       Front Tire:       Rear Tire:       Spark Plug:
520X110 15T 45T 3.00x21 4.60x18 DPR7EA-9


Fuel and Intake

Geared for the do-it-yourselfer that already has a TM40 or HS40. This kit supplies everything you need to convert it for use on your bike.

Kit includes intake and air boot adapters, throttle cables, choke knob, accelerator pump nozzle, a wide selection of main and pilot jets plus a TM40 tuning manual.

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All the advantages of a flatslide pumper carburetor at a much friendlier price than a Keihin FCR.

Our complete genuine Mikuni TM40 pumper carburetor kit comes with alloy adapter rings bonded to the carburetor body for a firm reliable fit in the stock air boots. We also include new 3" longer than stock throttle cables, a remote mounted choke knob, complete instructions along with a wide range of main jets and pilot jets for fine tuning or to accommodate bikes with extensive modifications.

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Add Lighter Return Spring
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These Mikuni carburetors are correctly sized and easily fitted to your Honda XR600 and XR650L stock motor mounting flange after removing the locator tags and also match the air box when using the silver anodized air-box adapter. This adapter is fitted prior to delivery when purchasing complete kits. For this Mikuni carburetor to operate correctly the motorcycles air box must be opened up to allow more air flow in. Using a hole saw, a 45mm diameter hole will be sufficient for a Suzuki DR650 but some Honda’s require way more. The best process is to keep opening up the air-box until no more improvement is noticed and you will be surprised at the difference. The kit also comes with throttle cables and a 1/4 turn quick action throttle which must be lubed before fitment. The carb comes with a couple of  Honda specific adjustments made and pre jetted for your engine. A specially made size 30 pump nozzle is fitted as the accelerator pump circuit on TM42 carbs will not work properly on Honda’s or Kawasaki’s without it.

Climate, altitude and fuel density from different octane fuels all have varying effects on final fine tuning as does cam, exhaust and cylinder head porting etc. For this reason, we have included what we have found to be a range of jets to allow you to tune to most variables.

This carb fits with most aftermarket large capacity tanks.  Some larger capacity tanks do not allow the fitment of this carb without modification. A competent person can easily heat and depress the contact area around the throttle mechanism allowing for clearance on problem tanks. Polyethylene tanks start their life as lump of poly that when melted evenly spreads itself around a rotating mold, to later carefully heat with a heat gun any section of a tank and change the shape has no effect on the integrity of the poly itself unless pushed too far, thinning it. We recommend having this professionally done for the reason some people may neglect to properly remove all the fuel from an existing tank or if not competent may make a mess of it. 

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XR650L '93 - '25

Designed for use with stock engines using either stock or aftermarket exhaust and air filters.

  • Provides a simple and affordable solution to carburetor tuning problems.
  • Allows you to tune your bike for increased power and smoothness while retaining fuel economy.
  • Includes a guide booklet on how to install and use your jet kit to its full potential.
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Our own jet kit for the Mikuni TM40 carburetor.

Includes new main jets, pilot jets and a new needle with e-clip.

Comes with a printed Mikuni tuning manual and a jetting suggestion chart.

  Not for the stock carburetor Fits TM40 conversions Only

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Genuine KEIHIN replacement parts for your FCR41 pumper carb. Ensure your beast is getting fed when it needs it!

  Not for the stock carburetor. Fits FCR41 conversions only.

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XR650L '93 - '09

Quality rebuild kit by Moose Racing. Comes with everything you need to get your stock carburetor back in shape!

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XR650L '93 - '25

Contains genuine KEIHIN parts to rebuild your FCR41 pumper. Fresh o-rings and float needle insure you don't end up with a crank case full of fuel.

  Not for the stock carburetor. Fits FCR41 conversions only.

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This Kit replaces vital components in the BST40 Carburetor including new a Float, Needle Valve, Gaskets, Seals, Diaphragm, Spring and Float Bowl Screws to return the stock Mikuni BST40 Carburetor to like-new operation. As a bonus we have included Viton o-rings for the float assembly and 4 stainless steel allen screws.

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  • Include top cover gasket, jet needle E-ring and washer, throttle valve seal, pilot air O-ring, fuel joint O-ring, accelerator pump O-ring, needle valve O-ring, needle valve retainer screw, needle valve assembly, float bowl O-ring/gasket, overflow hose, float bowl screws, accelerator pump rod boot
  • Genuine Mikuni parts properly replace worn or mistreated components for the TM42 carburetor
  • Includes all the parts needed to rebuild TM42 carburetor
Ships in 3-5 business days

Has your TM40 carburetor been sitting for too long and now needs to be rebuilt? Then what you need is this TM40 Rebuild Kit that contains Genuine Mikuni replacement parts.

This kit includes:

  • Needle Clip and Washer
  • Top Cover Gasket
  • A/P Nozzle O-Ring, Plug and Rubber Cap
  • Fuel Screw O-Ring, Washer and Spring
  • Float Bowl O-Ring
  • Pilot Fuel Screw
  • Drain Plug O-Ring
  • #3.8 Needle Valve Assembly
  • O-Ring for the Starter Circuit and Needle Valve
  • New Screws for the Float Bowl
  • Vent Hose
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Softer return spring for your TM40 carburetor.

This replaces the stock return spring that comes with the TM40 carburetor creating a 25% lighter throttle feel.

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Universal fit. May require additional adjustment or modification.

Genuine Keihin spring, washer, and oring for the fuel screw of FCR and FCR MX carbs.

Just the parts…
Fuel screw spring, washer, o-ring (fuel screw not included)

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Replacement socket head (Allen) screws in case you strip out the stock JIS heads on your TM40 bowl. The originals can be stripped out when doing any tuning or carburetor maintenance. Sold in a pack of four, all for the bowl.

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XR650L '93 - '25
  • Increased air flow over the stock air filter.
  • Designed to increase horsepower and throttle response.
  • Easily fits inside the factory air box.
  • Larger surface area over foam filters which offers longer service intervals in dusty conditions.
  • Four layers of premium cotton gauze provides outstanding filtration.
  • Washable & re-usable, never wears out.
  • One filter will last the lifetime of your bike.
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XR650L '93 - '25

These Twin Air Dual-Stage air filters deliver unbeatable performance and protection which is why they are the hands-down choice of more world and national champions than all other filters combined. Twin Air's fused layers of open-pore foam and fine inner foam trap even the smallest particles without restricting airflow. This filter kit includes a new air filter cage.

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XR650L '93 - '25
  • Designed to fit in the factory air box exactly like original filter
  • The best selling replacement air filter for competition motorcycles and ATVs
  • Unique two stage design allows for easy and complete cleaning
  • Dual layer of foam, can be serviced separately
  • Thin Ultra Seal base is virtually impossible to tear and has a built-in "Grease Groove"
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Universal fit. May require additional adjustment or modification.

Sold in 6 packs

  • Compatible with many air filter boxes. Easy to install by drilling 1’’ holes in airbox housing and snap fitting vents in.
  • May be cleaned and re-oiled
  • More air flow allows you to add more fuel to your intake mixture, increasing performance.
  • 1" Diameter

Not legal for use on pollution controlled vehicles in the state of California.

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Universal fit. May require additional adjustment or modification.

Quick release one-piece clamps that saves space. These are great for fuel lines, controlling wires, and can be used many times.

Comes with 4 each of 8mm, 9mm 10mm, and 12mm.

No special tools needed, from Helix Racing.

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