Great vid. I made up an engine cradle for my rebuild and bolted it to the work stand, makes removing the parts so much easier, saves struggling with an engine always wobbling about, and safer too...
Interesting video - but I hope you won’t mind two suggestions and a piece of information: 1); rather than bashing on your ratchet with a hammer - use an impact gun or a simple piece of pipe on the ratchet handle (much more effective and less likely to damage anything); 2) use a rubber mallet when trying to jar parts loose (less likely to break delicate cooling fins than a lead maul); 3) those “washers” are actually called shims and they are crucial to correct fit and function of the engine so it is vital to get them back into the same places they came from. I would also recommend getting a shop manual to avoid the guess work and an engine stand to avoid tossing the whole assembly onto the floor while wrestling with it.
I am having trouble finding the fifth gear. The part number you show doesn't show up in the parts breakdown. Also the part that DOES show up in the breakdown is a 21 tooth gear with a different part number. So I am curious as to how you got that fifth gear with that part number. I can't find it anywhere. Can you help?
I am replying to my own comment here. I feel like a real "ding-dong" because I guess I didn't really look hard enough. The part or parts are available on Ebay but they come from Japan. I was wrong to assume I could find them on Honda's parts website. All I had to do was a search on Ebay and BAM! there they were. I don't care where they come from or anything but am happy they are available. I just need to plan ahead since they will take a little while to get here. I also found an entire engine gasket kit from MotoSport. Ye!Haw! I am excited to get this party started. And I will try to video the whole "surgery" like you did. If it turns out OK, I will post it. In the mean time...Thank You Phil for this video as it helps so very much!!!
I like to know where you getting Annex 650 gears from please respond back I'm very interested my second gear on my bike and I'm thinking about doing the same thing as I want to replace my second and fifth gear to
No way a stock XR650L tops out at 70 mph. I've had two of them, as well as 2 1980s xr600 l, and 2 Yamaha XT 600. The Hondas would reach at least 100 on the speedo and the Yamahas 105. Even with speedometer error there still at least doing in the 90s and that's with stock gearing. And I usually go up a tooth in the front, because the low first gear especially on the Honda is useless except in rare conditions where you need to be going 1 or 2 mph. Especially in the southwest where you typically have miles and miles of long-distance open space
@@riyaandrayplay6856 unless they change something from the 1980s, it should at least do close to 100. Maybe they dumbed the bike down like they've done with American Education since the 1960s.
Pardon my ignorance, but how is this mod different than just changing the front and rear sprockets? Don't you get the same result? Say I want to improve highway riding by making the gearing taller. I can go with a larger sprocket in the front or a smaller one in the rear or change both sprockets. Problem solved. How is this mod different or better than just changing the sprockets? Great video, by the way. Thanks for sharing your knowledge.
This mod changes the gaps between the gears somewhat. The stock XR650L has an awkward jump from 1st to 2nd; putting in a different 2nd gear is how you fix that.
You made the comment implying that the stock Honda gear ratio spread is more suitable for Offroad, but I cannot for the life of me figure out any situation that they're more beneficial. If they had an equally spaced wide ratio 5-speed it makes the bike better both on and off road. I don't know what Honda was thinking. Perhaps they were thinking this bike would attract unskilled first-time buyers that don't know how to use a clutch and take off in first gear without stalling the bike? As for the 5th gear being too close to Fourth, that's also stupid and counterintuitive. you want a high 5th gear for lower cruising RPM on long fire roads and the highway. Perhaps they also wanted to limit the top speed my doing this? Either way it's sad that after all these years they've handicap the bike with these ratios, it would be even better with the six-speed
It makes sense if you think the bike is basically underpowered for its weight, and many do. Moving the 5th gear higher up gives the bike more speed for less RPM. This all works better if you're going to bump the power up too.
@@patwest1815 modified or not if you look at a Dyno chart of any big singles, they're already making most of their torque Peak at lower RPM so should be able to handle Highway cruising speeds with a much higher 5th gear and lower RPM. If you're carrying a passenger in bags fighting a headwind and going up a hill, well that's the purpose of 4th gear
wait wait wait..... stock they top out at what?!?! I've got a 2019 with a yoshi pipe and everything else stock, and I've done 98pmh. then again im only 150lbs small frame
I have a 2016 with a yoshi pipe also Daves mod desnorkled oil cooler smog block off other various plastic changes and I am 235 6 foot had it going almost 95 1 tried sprocket changes still topped out at 92-95. Great bike just not the fastest!
@@jeremybrunes38 You won't hold that at that speed on the Freeway. The top freeway speed is about 70mph without this Mod, if you don't want to burn it up. They say this bike is Dual purpose, but it is basically a DIRT BIKE. A Dirt Bike has no reason to ever use speeds above 70 mph, but on rare occasions. Few of us ever ride Baja and bust our ribs, and get plates in our arms, resulting in helicopter rides.
Just picked up 2021 Xr650l new. I would never let any one to take it apart, And butchered it up, it’s sad what I just saw. I always thought the factory assembled engine works best. Maybe it’s not all that we want some time but that’s how it was built to work best. Never believed in overhauled engine.
This is a very common modification on the xr650l. Many people have done this due to the huge jump between 1st and 2nd gear. It's normal to rebuild the top end on these bikes at around 20,000 miles. I guess you'll just buy a new one.
You have a good point but it totally depends on who rebuilds it, if they know what they're doing, and if they make any mistakes. Honda definitely screwed up this Engine with the gear ratios, and I can see no good reason behind it.
The idea is you can get an almost as good and longer lasting bike for less money than a KTM. For long range adventure biking it would be the better choice.
Man, I really appreciate you doing this video and taking all the time and effort to educate. All of us learn some new tricks as well. Thanks again.
Just did my first top end rebuild on my kid's dirt bike. Always remarkable to me how similar motorcycle engines are. Thanks for the vid.
Very thankful for this. Im replacing a stripped countershaft.
When I did this mod I only had to take the cases back apart once. Forgot a washer. 😢
Great vid.
I made up an engine cradle for my rebuild and bolted it to the work stand, makes removing the parts so much easier, saves struggling with an engine always wobbling about, and safer too...
Love the 2x4 trick!! Great detailed vid. Cheers
Awesome idea with the cardboard map-out!
Awesome video, thank you!
Interesting video - but I hope you won’t mind two suggestions and a piece of information:
1); rather than bashing on your ratchet with a hammer - use an impact gun or a simple piece of pipe on the ratchet handle (much more effective and less likely to damage anything);
2) use a rubber mallet when trying to jar parts loose (less likely to break delicate cooling fins than a lead maul);
3) those “washers” are actually called shims and they are crucial to correct fit and function of the engine so it is vital to get them back into the same places they came from.
I would also recommend getting a shop manual to avoid the guess work and an engine stand to avoid tossing the whole assembly onto the floor while wrestling with it.
All good points. Thanks
Nice job Phil. 👍
Best xr 650l engine work video on youtube by a big margin.
Nice work, I wish you made your video 2 years ago ; ) I wouldn't have bought a case splitter for my rebuild.
Sounds like this bike is designed to turn us into engine rebuilders ;)
thenx
I am very interested in the XR650L project !!!!
Is it necessary to have to remove the cover from the side of the magnetic flywheel? Thanks for the video!
Sir howmuch size pick up coil honda nx650
Tops out at 70? Stock?
Mine goes over 100...
Where do you get the new gears?
What state are you in sir?
I am having trouble finding the fifth gear. The part number you show doesn't show up in the parts breakdown. Also the part that DOES show up in the breakdown is a 21 tooth gear with a different part number. So I am curious as to how you got that fifth gear with that part number. I can't find it anywhere. Can you help?
I am replying to my own comment here. I feel like a real "ding-dong" because I guess I didn't really look hard enough. The part or parts are available on Ebay but they come from Japan. I was wrong to assume I could find them on Honda's parts website. All I had to do was a search on Ebay and BAM! there they were. I don't care where they come from or anything but am happy they are available. I just need to plan ahead since they will take a little while to get here. I also found an entire engine gasket kit from MotoSport. Ye!Haw! I am excited to get this party started. And I will try to video the whole "surgery" like you did. If it turns out OK, I will post it. In the mean time...Thank You Phil for this video as it helps so very much!!!
bet know one knew that was the dude on storage wars brother
Where do we get the gears and parts to do this?
I like to know where you getting Annex 650 gears from please respond back I'm very interested my second gear on my bike and I'm thinking about doing the same thing as I want to replace my second and fifth gear to
No way a stock XR650L tops out at 70 mph. I've had two of them, as well as 2 1980s xr600 l, and 2 Yamaha XT 600. The Hondas would reach at least 100 on the speedo and the Yamahas 105. Even with speedometer error there still at least doing in the 90s and that's with stock gearing. And I usually go up a tooth in the front, because the low first gear especially on the Honda is useless except in rare conditions where you need to be going 1 or 2 mph. Especially in the southwest where you typically have miles and miles of long-distance open space
Yea my new 2022 does 110mph bone stock lol
@@riyaandrayplay6856 unless they change something from the 1980s, it should at least do close to 100. Maybe they dumbed the bike down like they've done with American Education since the 1960s.
I don't know why he said 70 but the usual reason quoted for this gear change is less strain for long range driving at 80+.
Im afraid to push these big single cylinders at high rpms for more than a few seconds ive never done over 65 on my 1993 L
Yes I've had my 2012 up to 90 mph
Yea im wondering how much this is going to cost me at the Honda shop 🤦♂️
4:40 Birkenstocks
Pardon my ignorance, but how is this mod different than just changing the front and rear sprockets? Don't you get the same result? Say I want to improve highway riding by making the gearing taller. I can go with a larger sprocket in the front or a smaller one in the rear or change both sprockets. Problem solved. How is this mod different or better than just changing the sprockets? Great video, by the way. Thanks for sharing your knowledge.
This mod changes the gaps between the gears somewhat. The stock XR650L has an awkward jump from 1st to 2nd; putting in a different 2nd gear is how you fix that.
You made the comment implying that the stock Honda gear ratio spread is more suitable for Offroad, but I cannot for the life of me figure out any situation that they're more beneficial. If they had an equally spaced wide ratio 5-speed it makes the bike better both on and off road. I don't know what Honda was thinking. Perhaps they were thinking this bike would attract unskilled first-time buyers that don't know how to use a clutch and take off in first gear without stalling the bike? As for the 5th gear being too close to Fourth, that's also stupid and counterintuitive. you want a high 5th gear for lower cruising RPM on long fire roads and the highway. Perhaps they also wanted to limit the top speed my doing this?
Either way it's sad that after all these years they've handicap the bike with these ratios, it would be even better with the six-speed
It makes sense if you think the bike is basically underpowered for its weight, and many do. Moving the 5th gear higher up gives the bike more speed for less RPM. This all works better if you're going to bump the power up too.
@@patwest1815 modified or not if you look at a Dyno chart of any big singles, they're already making most of their torque Peak at lower RPM so should be able to handle Highway cruising speeds with a much higher 5th gear and lower RPM. If you're carrying a passenger in bags fighting a headwind and going up a hill, well that's the purpose of 4th gear
wait wait wait..... stock they top out at what?!?! I've got a 2019 with a yoshi pipe and everything else stock, and I've done 98pmh. then again im only 150lbs small frame
I have a 2016 with a yoshi pipe also
Daves mod desnorkled oil cooler smog block off other various plastic changes and I am 235 6 foot had it going almost 95 1 tried sprocket changes still topped out at 92-95. Great bike just not the fastest!
@@jeremybrunes38 You won't hold that at that speed on the Freeway. The top freeway speed is about 70mph without this Mod, if you don't want to burn it up. They say this bike is Dual purpose, but it is basically a DIRT BIKE. A Dirt Bike has no reason to ever use speeds above 70 mph, but on rare occasions. Few of us ever ride Baja and bust our ribs, and get plates in our arms, resulting in helicopter rides.
Just picked up 2021 Xr650l new.
I would never let any one to take it apart, And butchered it up, it’s sad what I just saw. I always thought the factory assembled engine works best. Maybe it’s not all that we want some time but that’s how it was built to work best. Never believed in overhauled engine.
This is a very common modification on the xr650l. Many people have done this due to the huge jump between 1st and 2nd gear. It's normal to rebuild the top end on these bikes at around 20,000 miles. I guess you'll just buy a new one.
Let me know when you wanna sell your bike! I'll buy it $1,000 when you hit 20k miles and need a rebuild :)
You have a good point but it totally depends on who rebuilds it, if they know what they're doing, and if they make any mistakes. Honda definitely screwed up this Engine with the gear ratios, and I can see no good reason behind it.
@@7x779 I rebuild mine, top and bottom. I even swapped in the NX650 gears. If you want me to rebuild yours I could but it would cost you $$
Y don't U guys just go buy
KTM's because your defenetly not Honda people. Wasn't all the time
and money on a fad.
The idea is you can get an almost as good and longer lasting bike for less money than a KTM. For long range adventure biking it would be the better choice.
You think the XRL is a fad? Lol
@@_Bryant.Ryeah it's just that honda xr fad thing it's been going on for over 50 years now 🙂