XR650R Top End | Tear Down

XR650R Top End! First we tear the top end down to see what we need!
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[@larryambrose5078]

XR650R is my Favorite Dirt Bike of All Time. I rode my 02 650R for 17 yrs and about 70,000 mi. CA, AZ, CO, UT, ID, WY, MT, NM, NV. Sold 2 yrs ago and now on an 03 650R. So many call it the BRP, I prefer to call them "The Dominator"! Ride On!!!

[@highlandcycles]

It is my hands down favorite motorcycle ever

[@ntrpe]

Stoked for this series! Owning my XR has made me really interested in learning all about maintenance and the mechanics of these mythical creatures.

[@highlandcycles]

Awesome! Stay tuned

[@trashguy]

Stoked for the series man, in the process of a full rebuild on my pig.

[@highlandcycles]

Right on

[@chrisnelson380exc]

So glad to see you fix up your old friend! Your joy is infectious! I like to see you fix your DIRT BIKE!!!!

[@highlandcycles]

Thanks Chris! I’m stoked!

[@patapouf75]

me too best bike ever...

[@racesla]

Nice copper washer tip.

[@highlandcycles]

Thanks!

[@LongShotMoto]

Thank you for sharing this… I can’t wait to watch the whole series to learn a few things here and there 😉

[@highlandcycles]

Heck yeah

[@micheleandcharliemiller9093]

Thanks for so much info on these bikes . I have a question about the sump screen, after removing the right side engine cover the screen is at the bottom and can be pulled out and cleaned. How often should this be cleaned? Page 4-2 of the Honda service manual. T
hanks Charlie

[@highlandcycles]

Not super often. Maybe every 40 hrs

[@micheleandcharliemiller9093]

@@highlandcycles Thanks for the help.

[@micheleandcharliemiller9093]

@@highlandcycles After removing the right foot peg mount I found a steel shim between the frame and matting surface of the peg mount. The shim has the holes for the bolts and a rectangle tab pointing up. Looks like a tab for a ground wire but it has nothing attached to it. Is this to keep the the aluminum surfaces from wearing against each other? Thanks for your videos and insight. Charlie

[@highlandcycles]

@@micheleandcharliemiller9093 I think that’s what it’s for but I’m not sure

[@200xcBruce]

The valve seats are just aluminum correct? If so, can the valve seats be machined and fitted with a harder seat like I think is in the newer heads? Think they are coated somehow. Sorry I cannot donate but I have a scrap yard locally, and may be able to locate a 02 650 swing arm.

[@highlandcycles]

Would love a swing arm if you could find one. Let me know if you find one and I can get you some money.

[@ericraherimanjato9688]

What type of motor oil was used on that engine

[@highlandcycles]

Belray 10/40

[@turbopete7794]

Why are you packing a pistol while wrenching in your shop?

[@highlandcycles]

Because I can. That is the only real reason

[@turbopete7794]

@@highlandcycles fair enough!

[@tybot1980]

That is an excellent reason. Because you can and just in case. Same reason you keep a fire extinguisher around.

[@assymcgee2616]

Good video. Love the XR650R. I literally just rebuilt the top end of mine a couple months ago as well, complete with full head/valve machine work done, so it’s neat to watch someone else go through the same process I just did. I had the same issue with the intake valves beating themselves into the valve seats, which I learned is a common issue with these bikes after many miles. I can attest as well that keeping your oil changed and full, and air filter clean that these XRs will be very faithful to you no matter what you do with it. I was too amazed how awesome my cylinder, Piston/rings, and cam/rockers looked when I had it apart after knowing my bikes history. The PO of mine also ran my XR through the Baja 1000, once racing and one time prerunning. I race it now in XCs and hare scrambles, take leisurely trail rides, and then put a Timbersled on it in the wintertime, and it runs like it just came off the showroom floor. Kudos to you for giving your beloved pig some love, and I’m excited to hear your plans to give it a little refreshing. It’s true what they say, they just don’t make them like they used to! Long love the XR650R!! P.S yes the cam swap makes a huge difference, combined with using the air filter side panel cutout. You won’t be disappointed by doing this mod.

[@highlandcycles]

Thanks man. I know these bikes well. We built a full HRC motor for the 07 1K and it was a fire breather.