XR650R Dual Sport Project & Travels

Problems & Solutions - XR650R Project

Some problems had to be expected during the project, given the number of parts that were involved. Lots of internet research (see Links), and discussions with suppliers before purchasing reduced the number of surprises.  Here's what was learned from those things that did pop up.

• Front turn signals
  The Baja kit front turn signal brackets normally mount to the headlight shell.  In this position the turn signals knocked against the Acerbis gas tank with just a slight turn of the handlebars.  The solution was to purchase handguards with integrated turn signals from UFO.

• Rear turn signals
  The Baja kit rear turn signal brackets mount to the forward rear-fender mounting bolts, but so does the RACK-IT luggage rack.  This caused a problem.  The initial solution was to mount the turn signal brackets to the forward mounting bolts of the Baja tail light piece (look at the yellow arrows).  This will work if you're not mounting saddlebags, although the Baja stalks don't bend much and the left signal will be vulnerable.  The final solution was to mount Honda XR650L turn signals on a simple bracket.  Now they're compatable with the RACK-IT and saddlebags, and more damage proof to boot.

• RACK-IT Luggage rack
  Fitting the luggage rack from Pro Moto Billet was somewhat problematic.  The rear mounts bolt to the frame at a place where there's a globby weld.  It uses the seat mounting bolts for its forward points.  As this photo shows, grinding the frame welds wasn't enough.  Forcing the alignment caused excess wear on the seat bolt threads.  Eventually I drilled the holes in the photo and put in bolts.  I also replaced the seat bolts with button-actuated stainless anchor pins from McMaster Carr, converting the seat and rack front-mount points to quick release (see details page).

• Magura/SRC hydraulic clutch & Baja handlebar switch housing
  The Magura hydraulic clutch has a little adjusting knob on the end of the master cylinder plunger.  This knob contacted the Baja turn signal switch housing when the clutch lever was depressed.  The interference was only slight, but it affected the clutch feel and probably would have caused something to break.  The solution was to grind the surface of the switch housing to create some clearance.  It's OK now, but a second problem occurred.  The Magura developed a leak at the slave cylinder early in its life, forcing me to speed-shift my way home.  Summers Racing modifies the Magura clutch before sale.  I don't know which part caused the failure, but I do know that Magura had to get parts from SRC to repair it.  It has since been remounted.

• Right fuel petcock exits in wrong direction
  The right fuel petcock exits forward, forcing a 180 degree turn in the rubber fuel line in a crowded area, and causing a kink to develop.  This was fixed by inserting a piece of 1/4 inch stainless tubing in the line to make the bend.

• SRC right foot peg bolt shim kit
  The Summers Racing kit arrived sans a required spacer washer.  An appropriate replacement was found in the shop.

• Baja Analog Speedometer
  My first speedometer was inaccurate at all speeds, plus at high speed the needle wavered all over the place.  Baja Designs agreed to replace it and the second one was OK.

• SRC magneto case vent - definitely buy this!
  This is not a problem report, it is an endorsement!  Summers recommends this product to prevent unseating of the magneto case seals from pressure build-up inside the compartment.  We discovered how important this is during installation.  My unvented stock bike showed evidence of leakage past the seal after only 1.4 miles of operation.  For only $12, this is cheap insurance.