The Honda XR650L is a capable adventure machine, but like many motorcycles, it has its weak spots. While we've previously covered the notorious CDI failures, today we're diving into the transmission-related issues that affect XR650L owners. Based on our years of experience helping our customers with the XR650L, as well as its dual-sport peers like the Suzuki DR650 and the Kawasaki KLR650, here's what you need to know about keeping your XR's drivetrain running strong.
XR650L Wide Ratio Transmission Upgrade Kit
If you've ridden an XR650L for any length of time, you've probably experienced two of its most frustrating characteristics: the large gap between 1st and 2nd gear that makes smooth riding difficult when the trail gets tough and the short 5th gear that forces your engine to scream at highway speeds. These issues have a large impact on the bike's usability in both dirt and street riding.
The XR650L community has long recommended swapping in the 2nd and 5th gears from the NX650, but those parts have been difficult to get in the US, requiring owners to source parts from Japan or Europe. ProCycle is excited to announce our complete XR650L transmission upgrade kit, which includes genuine OEM gears, a complete gasket set for proper sealing, and gearshift reset and return springs that often need replacement during transmission work. With our kit, you can get everything you need for this upgrade without the hassle of international shipping, tariffs, customs delays, or getting stuck with knock-off parts.
With our complete kit, the 2nd gear upgrade eliminates the jarring transition from 1st, creating smooth power delivery for technical off-road sections. The 5th gear upgrade drops highway RPMs significantly, transforming the bike's street manners and reducing engine wear at highway speeds. This performance upgrade makes the XR650L much more usable, transforming it into the bike it should have been from the factory. The improved gear spacing enhances both safety and enjoyment, whether you're navigating technical trails or covering highway miles.
Shop XR650L Wide Ratio Transmission Upgrade Kit
The Missing Cush Drive Problem
Unlike most of its competitors, the XR650L lacks a cush drive system in its rear wheel hub. This seemingly minor omission has significant consequences for the entire drivetrain. Without cushions to absorb shock, every bump, pothole, and gear change sends harsh impacts straight through the chain to your sprockets. This shows up as premature wear on the clutch and countershaft sprocket, often requiring replacement much sooner than expected. This stands in contrast to bikes like the Suzuki DR650, which includes a cush drive hub from the factory, where we rarely see the same level of countershaft sprocket wear.
Warp 9 Wheel Upgrade with Cush Drive Hub
For riders seeking a permanent solution, our Warp 9 replacement wheels for the XR650L include an integrated cush drive hub. This upgrade eliminates the problem at its source rather than just treating the symptoms. The cush drive uses polyurethane cushions inside the hub assembly to absorb drivetrain and road shock before it reaches the sprocket so that they don't get transmitted to the chain and other driveline components. The Warp 9 wheels look great, too, allowing you to further customize the appearance of your XR650L.
Fritzco Countershaft Sprocket Upgrade
A popular and more cost-effective solution to this problem is replacing the stock countershaft sprocket with a Fritzco sprocket. These sprockets are much beefier than the OEM Honda part, offering superior wear resistance and extended service life. The Fritzco sprocket's clever design also allows it to be flipped and run in the opposite direction once one side begins wearing down, allowing you to extend its service life.
The Countershaft Damage Trap
We have encountered customers who opted for lower-cost, narrower aftermarket countershaft sprockets instead of higher-quality options like the Fritzco. While these may seem like bargains initially, they can lead to much more expensive problems down the road. Over time, these inferior sprockets can cause wear on the countershaft splines themselves. The splines gradually shift and deform, preventing proper mating between the countershaft and sprocket. Once this occurs, the transmission must be opened and the countershaft itself must be replaced -- a significantly more complex and expensive repair than simple sprocket replacement. We offer genuine OEM countershafts for these situations, but prevention is always preferable to cure.
Shop XR650L Replacement Countershafts
While the ProCycle transmission upgrade kit is popular as a standalone modification, it becomes an absolute no-brainer when countershaft replacement is already necessary due to spline wear. Since the transmission must be opened for countershaft work anyway, adding the gearing upgrade requires minimal additional labor while dramatically improving the bike's usability.
Conclusion
The XR650L's transmission issues are real, but they're not insurmountable. Whether you choose the cost-effective Fritzco sprocket upgrade, invest in the permanent Warp 9 cush drive solution, or opt for our comprehensive transmission upgrade, ProCycle has the expertise and parts to keep your XR running reliably.
With proper parts selection and preventive maintenance, your XR650L's transmission can provide years of reliable service across all types of terrain. If you have any questions, please e-mail, call, or text us. We are happy to help!