Detail Photos XR650R Dual Sport

XR650R Project Detail Photos

Utah Sport Cycle chain guide. The Honda mounting brackets look like they could break off. Now I understand why Summers Racing sells replacement brackets.	Pro Moto Billet sharkfin won't provide mud protection, but it looks good for cool running in hot, dry regions. Caliper guard is from Works Connection.	Shift and brake levers were bored, accomodating brake snakes to protect the levers.	The seat was converted to quick release using push-button stainless anchor pins, accomplished by drilling out the threads of the nut that's welded to the frame under the seat. The shaft fits snug but I'll need to add a collar inside to take up 1/4 inch of slack length.
Here's the seat-mounting pin: McMaster-Carr Part No. 92385A058, 5/16 x 2.5 inch. The next size down is 2-inch and that's too short.	IMS Pro Series steel footpeg is longer, wider, and stronger than stock.	Magura hydraulic clutch and new compression release lever from Summers Racing. Handgrips are ProGrip Gel 714.	Slave cylinder of hydraulic clutch (red arrow). Kiwi Case Saver helps prevent a jammed chain from breaking the case (yellow arrows).
Temperature gauge oil dipstick from summers racing (yellow arrow). The blue indicator light is for the headlight high-beam.	Analog back-lit speedo with non-resettable odo and resettable trip meter. I moved this to the right side of the triple clamp after adding the GPR stabilizer.	A front brake switch is required by the state of Illinois (left). The Baja kit comes with one hydraulic switch for the rear. You'll have to purchase an extra if you're doing the front. Brake hose contacts plastic handguard (right). Should be OK, but I'll have to keep an eye on it.
The Baja handlebar switch. Bottom is off and kills the engine. Position 2 is hot and runs a tiny lamp for daylight offroad. Positions 3 and 4 run the high and low beams. Gray is a kill switch. OEM kill switch is gone. Arrow points to Magura kit compression release.	The Honda keyed ignition switch is mounted to the headlight shoud. The other hole is where the turn signal used to be.	Honda XR650L rear turn signals mounted on a home made bracket. This keeps them inboard of the damage zone, and clear of the RACK-IT and saddlebags.	The Baja stalks were stiff, but the XR650L ones are flexible. I broke a Baja turn signal the first time I fell over, before switching to these.
These holes vent the radiators, and also stiffen the sides of the gas tank.	View of the left fuel petcock.	A kink formed in the right fuel line because the petcock exits forward (left photo). It was fixed by splicing some bent stainless tubing into the line (right photo), which also keeps it farther from the exhaust. Heat-reflective tape coats the whole underside of the tank.
GPR steering stabilizer easily fits under the cross bar of my Renthal XR Desert Bend handlebars. Resistance is continuously adjustable. 2 feels comfortable for slow speed, 3-4 feels good on the freeway. Speedometer was moved to a custom bracket on the right-top triple clamp.

XR650R Dual Sport Project & Travels

XR650R Project Detail Photos