I've just taken delivery of a superb XR650L, and I'm about to start preparing it for an overland trip in about a years time.
I've read a few accounts of preparing these bikes, and I'm looking for anything for sale in the UK really. It's totally stock at the moment, even got the smog kit on, so anything considered.

I'd also really like to talk to someone who has gone through this preparation process with an XRL, so if anyone would be willing to share some info with me, I'd really appreciate it.

Which tank's best, where to buy, after market exhausts, jetting kits, seat mods, custom made pannier racks, stator output details, strengthening the frame etc..

I'm guessing Chris Scott would be one of the best resources for this info, any idea if he's a the 2008 HU meeting? Or are any XRL owners going to the meeting?

Many thanks folks

Hi.
Im doing the same thing as you at the moment it seems.
Steve at XR Stuff sorted out an 22l acerbis tank (they are getting hard to come by now) for me and stocks all sorts of goodies for the XR series Hondas.
I'm a qualified mechanic and am doing the prep myself so if I can be of any help please feel free to email djorob@aol.com.
The rear subframe can do with some bracing, and if you are making your own racks incorporate this bracing into them.
A crush drive hub from a dominator would be kinder to the cluch basket and chain but you'd have to get it built up by a wheel builder. Keep the 18/21 sizes as tyres are easier to come by for 18" around the world.
You can get re-useable oil filters for this model which ,depending on how long/where you go, would save trying to locate or carrying replacements.
I will be using either Heidenau K60 or MEFO MFE99 tyres as they are about as 50/50 as they come with good wear rates (8-10k).
I have used the Heidenau on a GS1200 and they wore well and were ok off road, did 5k on them and they were about 40% worn rear and 20% front.
If you can catch Chris Scott he's a very nice guy who I'm sure will give you advice.
Grab an oil temp filler plug if you are going to a hot location as it's very handy.
If you need extra fuel capacity I'm just evaluating a 20l flexible fuel container that I'm hoping to distribute so let me know.
I'm looking into carb settings at the moment as well as jet changes for altitude so I'll let you know what I find.
Just the usual bearing changes in wheels, head ect. A grease nipple in the headstock would be a good move.
I trimmed the OE seat foam and re did it with a 1" sheet of memory foam which widened and flattened it out a bit to make long distances a bit more bearable. I know corbin do an up graded seat but I've heard from a couple of folks that they are crap.
Anyway, If I find anything juicy out about the XRL I'll let you know.
I'll be at the 08 meet so may catch up there.
Cheers.
Dave.

Dave, where did you get the Memory Foam from? Fancy supplying overseas?

any info would be nice..
cheers

Martyn

Dave, thanks for the input.
With a bit of luck it will be mutually beneficial, for us to be going through this process at the same time.

I've spent a while reading the (substantial) XRL modification info on the net, but I think the best info would be from the overlanding horses mouth.

How much was the tank? There are a few options on American Ebay, and prices are very good, assuming customs and excise don't get too carried away.
I read one bad report of putting the acerbis tank on the XRL, but it's difficult to judge how much weight to give this one review. There's a clarke tank for about a hundred quid, about 5 gallon I think, but it says it'll only go on the 93-96 models, or something similar. This seems odd, as I thought the bike had remained pretty much unchanged since 93, and all the other tanks seem to ft all years..?

I've already got a list as long as my arm, of mods I'm thinking of doing over the next year or so. This would probably give a veteran overlander a good giggle, but we've got to start somewhere eh?

Being a design engineer, I'm keen to design and build my own racks and panniers, and I was lucky enough to meet up with Vern, of 'Project VND', who is very knowledgeable in this area.
I'd also like to do a sump guard, possible including a water or tools unit.

The flexible fuel storage sounds good, and I'd like to see how you get on with it.
I've got a uni air filter on its way from america, but maybe a K&N would be better for the trip. I was thinking of a stage 1 jetting kit for the carb setup..?

I'm about to catch a ferry over to Laos now (what a goon, doing this whilst on holiday!), but I'll email you or soemthing in the next few days.

BTW, where did you get the bike, and what year, condition etc?
I know someone looking for one, and the only one I know of, is a VERY overpriced one in Bristol.

Anyhoo, catch you later..

Cheers

Hi Guys.
The memory foam came from a mate who works as a saddler (horse saddles ha ha), I can find out where he gets it if you like?
I looked into what tank and after a chat with an enduro racing buddy and went for the acerbis 22l.
It is not a good fit out of the box though!
In the end I altered both the rear bracket and re-located the frame mount a bit further back. Also made new front mounts as the standard didn't seem to line up well and were a bit flimsy in the way they mounted.
It was £200 new but I'm pretty sure it's the same tank as the 600 and the 250 with just different mounting points for each bike.
I'll galdy send you all the fitting details I worked out if you like?
I'm working on the sump guard this week.
I've gone heavy duty aluminium which is about 4" wider either side to accept 2 tool boxes just in front of the cases.
Very simple really, 2 bends of a flat sheet and 2 side plates, a mate has done the ally welding and I'm well pleased with it.
I can sort a pic out if you like.
I have a set of caja sahel panniers from a GS1200 which I'm going to use as they are quite tough, frames will be along the lines of overland equipments sort but not working on them as yet.
An oil covered type sponge type filter will probably suit better than a K&N paper element type.

The bike was ony £850 and is a 97 model, it didn't make any sense to spend more on a newer one as it's going to be re-built either way.
Was advertised in TBM magazine (you can put free want ads in with the form in the magazine.)
Frame will be plastic coated and various bits galv plated.
Also I think I might have a set of excel rims built up using the dommie hub I mentioned.
I'f I see one for sale I'll let you know.
I'm pleased with the flexible fuel carrier, it carries 20l and folds flat or rolls up and is quite tough, probably be around £35 each when I sort things.
I have not yet attacked the carb yet but that crappy smog set up was already gone.

Well keep in touch, and Merry Christmas.

Dave.

Hi mate,
what is the brand of your <flexible fuel carrier> , always good to see what other are using.

Good luck on your prep.

Hi.
It's an un-branded heavy duty carrier that I was evaluating for suitability before marketing.
When I sort things out I'll be putting a post on here in the for sale bit so keep a look out.
It's a very useful bit of kit though, especially for overland bikers.
Thanks for your interest.
Dave.