The Clymer shop service and repair manual. It has all the necessary info to do any maintenance or repairs to your XR650L.
The DG RST (Reduced Sound Technology) muffler is the quietest DG muffler and is designed especially for dual-sport machines (Just 89db @ 3200 RPM). A new baffle design dissipates sound waves reducing noise output in a very efficient manner. This new design also stretches out the time between muffler repacks. Included is a Stainless Steel mid-pipe, USFS Approved Spark Arrestor and a new Aluminum end cap.
You may want to consider a new exhaust gasket that goes between the header and the muffler.
X3 EVO represents the off-road evolution: LeoVince has combined all its experience in the off-road world with cutting-edge materials and Italian design, enhancing freedom in its purest form.
The X3 EVO body is made of AISI 304 stainless steel with TIG welds handcrafted by specialized operators, to guarantee long-lasting performance. X3 EVO will allow you to face the most extreme environments and conditions because it does not fear water or mud, nor wear over time.
The LV logo is their tribute to a motorcycle culture that we have loved for 70 years and is laser etched on the body of the exhaust: it is as endless as their passion.
They manufacture the end cap in 100% real carbon, with their special 2x2 twill carbon fiber, specifically designed to resist high temperatures and make the X3 EVO even lighter.
The matte clear coating, in addition to enhancing the carbon texture, protects the end cap from wear and UV rays, keeping the X3 EVO always in a perfect shape.
The sound of X3 EVO is already unmistakable at low revs. X3 EVO has a direct interior, specially conceived to channel the exhaust gas in an optimal way, to unleash a deep sound, giving a new voice to your bike.
The X3 EVO's Spark arrester has been tested and approved by the United States Forest Service and is essential for off-road riding in compliance with regulations, with more peace of mind, more respect for the environment and more fun.
The EVO R series draws on our rich heritage of making power. Offered for various off road MX and sport ATV models, the EVO R is a tried-and-true series that will save weight, add noticeable performance gains and sound tremendously better than stock.
DG Performance exhausts help your engine breathe better, resulting in increased throttle response, power and torque.
The V2 Series Slip-On muffler features:
Standard sound level is approximately 98 db and quiet core inserts are available separately.
This Lightweight Slip-On weighs approximately 5.5 lbs and bolts directly to the stock headpipe.
It is equipped with a US Forest Service-approved spark arrestor.
Genuine Honda replacement exhaust gaskets.
The EVO R series draws on our rich heritage of making power. Offered for various off road MX and sport ATV models, the EVO R is a tried-and-true series that will save weight, add noticeable performance gains and sound tremendously better than stock.
Here's an easy way to add a Tach to your motorcycle.
The Trail Tech Vapor Speedometer/Tachometer units are custom designed for an exact fit. They feature a bright white backlit LCD display, waterproof connections, and all parts needed for a complete installation. These units accept AC and DC power input, and automatically switch to internal power if external power is removed. Power connectors are included. Permanent solid-state memory guarantees that data is never lost, even without power. Units are available in black.
Trail Tech provides a one year warranty and unlimited free phone and email support.
Unit functions:
Antigravity Batteries introduce the ground-breaking "RE-START (RS)" line of batteries. These are the first batteries with built-in jump starting! They intelligently monitor their status, and just before going completely dead, puts itself to sleep with just enough energy to get your vehicle started again. Simply press the RE-START button located on the battery, then start your bike and ride away!
These are an extremely lightweight (2.3 lbs.) and high-powered Lithium-Ion replacement battery for motorcycles. These batteries offer the first Battery Management System (BMS) found on a powersport battery and includes low-voltage cut-off, over discharge, over-charge, and thermal protections with real time lithium-ion cell balancing. Highly recommend using a lithium charger to maintain the life of the battery.
3 Year warranty
Product Size is just 5.9"L x 3.5"W x 3.74"H. If you need spacers, select the optional Foam Kit to pad the battery in the battery box.
Shorai batteries deliver more energy faster, with less weight and with less wear on the battery per start cycle than any other brand or technology available on the market today.
Weight (lbs): 2.45 lbs
Weight (kg): 1.11 kg
Cold Cranking Amps: 285
Polarity: [+ -]
Dimensions: 5.8"x 3.4" x 3.5"
Self-adhesive foam shims are included and insure a great fit to the battery box, as well as extra vibrational an thermal insulation.
Now available in the original version or the Ultra version. The original uses the front two emitters for low beam and then switches to the rear two emitters for high beam. The Ultra uses the front two emitters for low beam and then runs all 4 emitters on high beam at a reduced wattage. Wattage is 38 watts on low and 38 watts on high.
This bulb uses 4 Cree XHP 50 emitters, capable of more than 2500 lumens each. At 5000 lumens on each function, this is the brightest Cyclops H4 bulb.
*UNIVERSAL PART, PLEASE CHECK YOUR APPLICATION FOR FITMENT
This kit is not just a bulb, but an entirely new LED specific headlight! A specially designed adjustable steel mounting bracket replaces the stock unit. Included is a wiring harness and all the required hardware to make this installation quick and easy and entirely plug and play. No cutting, drilling, or wiring modifications are necessary. The headlight features separate low and high beam projectors in a custom headlight shell designed specifically for this LED bulb.
This kit is available with either a chrome or black chrome reflector in the headlight.
Check out the images for stock vs. LED patterns and brightness. (Images are of a DR/DRZ unit, but the light unit is the same as that on the XRL.)
This kit includes the all new Morimoto 4×6 LED headlight and pre-assembled JNS Engineering adjustable mounting bracket set. It’s a one beer, plug & play installation.
This is the best performing and highest quality headlight they currently offer.
The low beam pattern is bright, very uniform, and features a proper upper cut-off (Left Hand Drive, ie USA).
The high beam is amazingly bright eliminating the need for auxiliary lighting.
The materials, construction, and aesthetics are all top notch. You won’t be disappointed!
Low Beam: 20W, 2,400 Lumens
High Beam: 35W, 4,300 Lumens
Color Temperature: 5,000k
DOT Compliant
Beam Pattern: Left Hand Drive. (USA)
This DOT kit includes LED headlight assembly with plug-and-play wiring harness, a specially designed adjustable steel mounting bracket, and all the required installation hardware.
No cutting, no drilling, no wiring modifications! Installation takes 5 minutes.
This kit is highly recommend over the non-DOT kit. The low beam has extra punch and a proper beam pattern cut-off. The high beam throws light far and wide. It’s already a crowd favorite!
Two colors to choose from, Chrome or Black. Light output and beam pattern are the same for either color.
This device will pulse your brake light automatically. There are over 1000 possible pattern combinations with individually programmable Flash Speeds, Pre-Delay, and Flash Durations, as well as a disable feature to disable the unit. This device gives the end user the widest range of possibilities for customizing your tail light safety flash. With simple programming setup using only your brake lever, their is no disassembly or removing of the seat required to change the programming on the device.
Features:
This heavy duty aluminum bracket is specifically designed for mounting auxiliary LED lights to the front of your XR650L without interfering with your large aftermarket fuel tank. If your bike needs improved lighting this mount is the best place to start!
– 0.190″ 5052 Aluminum
– Laser cut
– CNC formed
– Powder coated black
– Includes stainless mounting hardware and JNS stickers.
LED auxiliary lights are sold separate.
The SignalMinder unit is designed as a plug-in accessory for many Japanese bikes. SignalMinder uses a microprocessor to cancel the turn signals at one of three selectable time outs; 10, 20 or 30 seconds.
You can also make it so that all four of your signal lights also act as running lights and establish a dual-channel system on your bike. With the dual-channel system, when you activate the RIGHT turn signal three times in succession, you get 4-way hazard flash lights.
Connecting the 12 volt supply from the brakes to the SignalMinder, also allows for a brake flash option.
There are many options and configurations using this electronic tool.
No wire cutting required. The kit includes Scotchlok connectors to tap into existing wires.
This is a standard H4 bulb that has a 80 watt low beam and a 100 watt high beam. This is an easy lighting upgrade that should not over tax a stock charging system.
We start with Excel or Sun rims, OEM hubs, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike.
Our pro shop then laces and trues your wheels to perfection, giving you the highest quality set of custom wheels available.
Add tires to your wheel order and we will throw in tubes and mount and balance them at no additional charge.
We start with an Excel rim, OEM hub, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike. Optional upgrades include SUN rims available in 3 colors.
Our pro shop then laces and trues your wheel to perfection, giving you the highest quality custom wheel available.
Add a tire to your wheel order and we will throw in a tube and mount and balance it at no additional charge.
We start with an Excel rim, OEM hub, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike. Optional upgrades include SUN rims available in 3 colors.
Our pro shop then laces and trues your wheel to perfection, giving you the highest quality custom wheel available.
Add a tire to your wheel order and we will throw in a tube and mount and balance it at no additional charge.
Did you go to an electronic speedo? SM Wheels? Something where you don't need the stock speedo drive? Then you need this to make up for that lost space and protect the bearings.
Wheel bearing kit contains all of the bearings and seals required to re-fit a wheel.
Wheel bearings typically fail from water and dirt contamination. These wheel bearing were developed in partnership with KML Bearing and is designed for the difficult operating environment of the Power Sport industry.
Premium EMQ quality, hi-speed-bearing featuring low drag, double lip rubber seals which provide superior exclusion of water, dirt and to improved grease retention.
Type TC Nitrile Elastomer wheel seals are specifically designed to keep out water and dirt.
Packed with Chevron SR1-2 high-performance grease with rust and oxidation inhibitors.
The rubber coated outside diameter creates an optimum seal at the hub.
Steel garter spring guarantees constant pressure on the axle shaft over the life of the seal.
| Description | QTY per Kit |
| Ball Bearing | 2 |
| Seal | 2 |
An excellent replacement for the stock fork boots. These are great for protection from dirt, rocks and other contaminants. These boots utilize the latest advances in material technology to adapt to fork and styling demands. These high quality fork boots are 1/4 the price of the OEM factory replacements.
| Top Diameter | Bottom Diameter | Length |
| 42 mm | 45 mm | 60mm |
Helps protect vulnerable fork tube and seal from dust, dirt, and corrosive elements. Hook & loop (Velcro) fastening on back side makes installation or removal for cleaning a breeze.
Complete kit to replace the bearings and seals in the XR650L shock linkage. Includes the lower shock bearing.
| Kit Contents: | |
|---|---|
| Spherical Bearing | 1 |
| Snap Ring | 2 |
| Seal | 8 |
| Needle Bearing Shaft | 3 |
| Needle Bearing | 6 |
| Bushing | 2 |
Kouba lowering link will lower the rear suspension 1.75". Comes with bearings and seals installed for a quick and easy installation.
Disclaimer: Lowering the front and/or rear of your motorcycle will change the geometry and may affect the handling, use caution after making changes/adjustments.
Fork brace precision machined from aluminum barstock. Drilled and tapped for optional lower fender attachment.
Hard anodized black for corrosion protection. Fits OEM forks. Split design allows for installing in minutes without having to remove the forks.
The complete fork upgrade kit - your choice of springs and Race Tech Gold Valves. Also includes a set of top quality fork seals and 5W fork oil to complete the job. Everything you need to transform your mushy stock forks into suspension that really works.
You can select from various straight rate springs to customize the package to your needs.
Stock Spring Rate for XR650L: 0.44 kg/mm
Lightweight, for reduced unsprung mass. Straight rate springs will give better control in the rough stuff. Sold in pairs.
Bushings are dyno-tested to 500,000 strokes with less wear than OEM bushings
Mount Barkbusters standard aluminum bar handguards to 1-1/8" motorcycle handlebars with the Barkbusters Tapered handlebar saddle clamp set.
What's in the box:
These are all you need to mount your current Barkbusters Handguards when you upgrade to a tapered oversized 1 1/8" handlebar.
PSR has a new shark fin rear rotor protector for the big XR and XRL. CNC machined from forged aluminum and then anodized gun metal in color. This unit bolts to the stock caliper bracket.
Protect that vulnerable rear master cylinder with this thick aluminum guard from JNS Engineering. CNC laser cut then formed and given a clean black powder coat finish. Includes new button head screws and aluminum spacers.
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.
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.
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:
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.
All the parts you need to freshen up your brake master cylinder. New piston, seals, return spring, boot and snap ring.
Made by Nissin, an OEM supplier in Japan
Made with heat-treated carbon steel for longer wear life and reduced galling. Stock size, simple bolt-on procedure.
Upgrade your Honda XR650L with a Subframe Brace Kit, designed to enhance strength and rigidity for your bike. This complete kit connects the frame and subframe, reinforcing the structure to support increased load capacity—perfect for riders using side cases, top cases, and rear racks.
Key Features:
High-Quality Materials: Attachment points are machined from 6061-T6 billet aluminum for superior strength and durability.. The 6.5mm thick support bars are laser-cut for a perfect fit.
Easy Installation: No cutting, drilling, welding, or modifications required for installation. Easy 20 min installation.
Enhanced Load Capacity: Provides added rigidity and support to the subframe, improving bike stability when carrying additional gear.
Exhaust Compatibility: Compatible with both STOCK Exhaust and FMF Exhaust systems.
Pro-Series foot pegs are made of stainless steel and are hard coated to prevent drooping. These pegs are 50mm x 75mm.
50mm step width provides better grip and control
Pegs that are designed for real adventure, providing a level of comfort not seen with other pegs. 2.25" by 3.5" makes for a platform that you can stand on for long periods with no worries. All necessary parts included for a direct bolt-on application.
Available in a beautiful anodized black or clear aluminum for durability and protection from the elements.
Tapered roller bearings provide decreased maintenance, less wear, smoother operation and longer life.
This set of high quality replacement steering stem bearings includes:
A quality set of replacement throttle cables from Motion Pro.
A high quality replacement clutch cable.
A set of replacement brake and clutch levers. Standard length.
Extra protection for your motor! Strong magnet at the end of the plug picks up metallic flakes in your oil, protecting your engine!
For the frame drain on your XR650L ,extra protection for your motor! Strong magnet at the end of the plug picks up metallic flakes in your oil, protecting your engine!
This is all you need to not only change your oil, but protect your motor as well. We include a magnetic drain plug, to help catch stray metal pieces, a 5-pack of oil filters, and new O-Rings to replace any you have that may be leaking or worn.
Iridium spark plugs are made with premium quality materials.
Iridium plugs last longer than standard ones, meaning you won't have to replace them as often.
Sold individually, unless otherwise stated.
E3 Resistor Spark Plugs
The unique design of the electrode maximizes the power generated by the spark plug through Diamond Fire technology. This electrode combines advanced performance capabilities and innovative technology to enhance the shape of the flame kernel. Consequently, the flame front ignites the air/fuel mixture more rapidly, accelerates heat transfer into the combustion chamber, and creates a more concentrated pressure front, facilitating a quicker pressure rise during the cylinder power stroke. The outcome is a more efficient combustion process and improved engine performance, making this a truly premium spark plug.
Keep your motor running right with fresh spark plugs!
NGK is one of the world's largest manufacturer of spark plugs, whose products are used as original equipment (OE) on countless motorcycle and automobile models.
Honda XR650L rear shock upgrade. The experts at Cogent Dynamics know suspension! A proven performance rear shock for your XR650L for use under the most demanding conditions and on the roughest terrain worldwide.
Damping rates optimized to your specific needs, giving you the best ride comfort, traction and control. Frequency and velocity sensing valving works great over wide ranging conditions. Low internal friction. All CNC machined components for top quality and performance. Compact and rigid design with internal separator piston. Adjustable for spring preload and rebound damping. Fully serviceable shock is designed for the long haul.
*Spring color may vary due to specification requirement and availability.
| Standard Spring | 10.71 kg/mm |
| Heavy Duty Spring | 12.50 kg/mm |
| Low Shock | 1.5 inches lower |
This kit will replace your stock sprocket bolts and nuts with new hardware.
Factory Honda replacements in a convenient kit.
Quality steel front sprockets. Choose 13T through 15T. The stock size for the XRL is 15T. Go down in tooth count for faster acceleration.
Quality steel rear sprockets.
Color may vary based on manufacturer availability, quality will not be compromised.
Now you can have minimum output shaft wear, minimum chain drive wear with the FRITZCO DRIVELINE sprocket. The design of their sprockets provide correct chain alignment, allows for full spline contact with the XR650L's output shaft, fit the counter shaft either way, and straight up no hassle installation with the OEM two bolt retainer and fasteners (except 13 tooth that comes with it's own quick change retainer). Their sprockets are machined from alloy steel that is comparable in every way to OEM Honda and the best offered by other manufactures. The sprockets are then given a heat treatment that provides a compatible sprocket for the Honda output shaft and longest wear life possible.
A way to double the sprockets life would be to have a sprocket that fits on the shaft either way so both sides of the teeth can be used. Bear in mind you can't wear one side of the teeth all the way through, then flip the sprocket, and expect double life. You must reverse when a normal wear pattern develops.
16 tooth sprocket is the biggest front sprocket that will run with the standard 110 link chain and 45 tooth rear sprocket on an XR650L
The OEM cover will require modifying to use the 16 tooth sprocket on your XR650L.
High Quality chain. Will need to be cut to fit your sprocket combination.
Chain slippers undergo degradation over time due to friction associated with the chain's movement. To maintain optimal operational performance, it is advised to replace worn components with authentic Honda parts.
Chain guides experience degradation over time as a result of chain friction. To ensure optimal performance replace worn components with genuine Honda parts.
Chain sliders undergo performance degradation over time due to the friction experienced by the chain. To maintain optimal functionality, it is recommended to replace worn components with genuine Honda parts.
Replacement Acerbis left-hand side fuel tank petcock.
For Acerbis tanks only.
An OEM type replacement for the mighty XRL from the folks at Fuel Star. Single inlet that threads directly onto the stock fuel tank. Also works on the adapters that come on some aftermarket large capacity plastic tanks (like IMS).
Kit comes with a new Petcock, O-Ring, Fuel Line and Fuel Line Clamps! Everything you need for a complete fuel connection replacement.
You want a lighter replacement for your heavy steel stock tank? Don't need the extended range (or bulk) of the big Acerbis or Clarke tank? The 4.0 gallon tank from IMS might be just right. Includes cap, uses stock petcock.
Get better range from your XR650L by adding a Clarke 4.7 gallon fuel tank. Cannot use stock shrouds.
Available in Natural, White, Black, and Red. Natural color is recommended if you wish to easily see the fuel level in the tank. Includes cap, uses stock petcock.
If you need a replacement cap for your Acerbis tank, why not go bling? These caps have a carbon fiber pattern molded into them that is extremely realistic. Looks like the real thing. Topping off the cap is a CNC Machined metal vent cap. This eliminates the need for a lengthy vent tube that gets in the way. The vent cap allows air to vent into the tank but does not allow fuel to splash out during normal use or during a tip over.
These caps fit Acerbis tanks only.
Quality MX style rear fender from Maier.
Quality replacement rear fender from Maier.
Molded using a very durable, lightweight 1/8" thick polycarbonate - giving the windshield a high impact strength and making it shatter-resistant with a superior light transmission quality. Mounts quickly and easily onto the stock headlight cowling for a clean factory look. Drilling of the cowling is required, hardware is included. Removal for trail riding is also quick and easy.
Only Clear screens are available at this time.
Parabellum LTD. has continued the highly demanded Rally Shield line by fitting up the 1993-present Honda XR650L. This is an upright Dakar Rally inspired shield, designed to protect the rider without interfering with off-road riding. For on-road riding the Rally shield protects the rider’s chest from fatiguing air blasts while keeping the head in clean air. Duck behind it in the cold or the rain to keep from experiencing the brunt of the elements. During off-road riding the Rally windshield protects the rider from mud, dust, roots, rocks, or branches without becoming invasive. Whether standing on the pegs or ducking behind it, you will be impressed at the protection it offers. Their Rally shields have been tested in the toughest conditions including an entire SORCS hare scramble season.
*The Rally shield for the XR650L is 12.5 inches tall 12.5 inches wide at the bottom and 8.5 inches wide at the top and is made from military grade 1/8 inch cast acrylic.
Two feeler gauges on a single tool. Angled to make checking the clearances easier.
Stock valve clearances are .004" intake and .005" exhaust (.10mm int. and .13mm exh.)
This anodized billet piece, brings a touch of color to your bike. Available in red or blue, it replaces the stamped steel clevis that connects your brake pedal to the master cylinder.
Simple, lightweight rack made from rugged 1/8" 5052 Aluminum, with a rigid 5-point mounting system.
Low profile allows for easy seat removal.
Features:
Note: Placement of this top rack does require removal of the stock tool bag.
