My Recently Acquired, 2005 Honda XR650L

[SpudRider]

You're prompting me to check my old XR250R. I don't recall seeing any countershaft wear, but I'm not sure if I really looked.
If your eyes are like mine, use a magnifying glass, WaG. :lol:

Spud :)

[SpudRider]

Yesterday I reversed my CST, Surge I, front tire. Here is the condition of the tire after 1,300 miles of riding, mostly on pavement.

http://i442.photobucket.com/albums/qq146/spudrider/CST%20Surge%20I%20Front%20Tire/Tirewear012.jpg

http://i442.photobucket.com/albums/qq146/spudrider/CST%20Surge%20I%20Front%20Tire/Tirewear015.jpg

Here is the conditon of my Maxxis, Maxx Cross, IT rear tire after 1,000 mile of riding, mostly on pavement.

http://i442.photobucket.com/albums/qq146/spudrider/Maxxis%20Maxx%20Cross%20IT%20Rear%20Tire/Tirewear019.jpg

Today the high temperature approached 50 degrees, Fahrenheit; therefore I went for a nice ride. :)

http://i442.photobucket.com/albums/qq146/spudrider/CST%20Surge%20I%20Front%20Tire/Tirewear006.jpg

I love springtime. :D

Spud :)

[Weldangrind]

Me too. I'm getting the itch to ride, real bad.

[katoranger]

Does reversing the tire provide better wear?

[SpudRider]

Does reversing the tire provide better wear?
Yes, it does, Allen. :) The knobs on my front tire were beginning to get a little backward slant resulting from aggressive braking. By reversing the front tire, I hope to even out this wear. ;)

Spud :)

[katoranger]

I noticed that wear on the original CST that my lifan had. I was thinking that was your reasoning for the rotation.

[SpudRider]

About three weeks ago I decided to substitute chain rollers for the "chain slipper," and the chain guide slider on my XR650L. Today I inspected my chain guide rollers after 1,000 miles of wear. Here is a photograph of the front roller.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Chain%20Rollers/FirstMalad2011223.jpg

Here is a photograph of the rear roller.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Chain%20Rollers/FirstMalad2011224.jpg

Here is a photograph of both rollers.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Chain%20Rollers/FirstMalad2011222.jpg

I believe the sizes I selected for these chain guide rollers is very close to ideal, and I am pleased with their wear after 1,000 miles. :) The bolt for the rear roller had loosened a little, but it was still securely attached to the chain guide. Based upon these promising results, I am going to keep using these chain guide rollers. :D

The roller I substituted for the chain slipper looks almost new! I believe this roller is perfectly sized for this application. :D

Spud :)

[Weldangrind]

Spud, was that to preserve chain life? What was the original slipper material?

[SpudRider]

Spud, was that to preserve chain life? What was the original slipper material?
I substituted the chain rollers because they are more durable than the rubber "sliders" they replaced, WaG. ;) The stock, chain guard slider also produces a bit of friction, increasing chain drag. :roll: The chain rollers should require less inspection, and less maintenance. Also, the chain rollers should be less expensive to maintain. :)

Spud :)

[Weldangrind]

Thank you. I never thought of that.

[SpudRider]

Thank you. I never thought of that.
You're welcome. :) Here are some photographs of the chain roller I substituted for the "chain slipper."

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Chain%20Rollers/XR650LChainslipperroller001.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Chain%20Rollers/XR650LChainslipperroller007.jpg

This roller appears almost new after 1,000 miles of wear. :D I greatly prefer employing this chain roller to the stock, rubber "chain slipper." ;)

Spud :)

[Weldangrind]

I can see where the stock slider would rob a little horsepower; that's a good idea. :idea:

Most Chinese 125 pit bikes use a similar system, but the rollers are of poor quality. Yours are clearly better; where did you find them?

[SpudRider]

I can see where the stock slider would rob a little horsepower; that's a good idea. :idea:

Most Chinese 125 pit bikes use a similar system, but the rollers are of poor quality. Yours are clearly better; where did you find them?
Thank you, WaG. :) Since I installed the chain rollers, my 520, X-ring drive chain seems to turn more easily when I lubricate it. Therefore, I think I have significantly reduced the drag induced by the rubber sliders. ;) The chain guide slider on the XR650L is notorious for fast wear, and troublesome maintenance. :roll: When I bought this Honda it had 7,800 miles on the odometer, and the chain guide slider was badly worn. In fact, the chain was actually cutting a kerf in the bolts that held it in place, producing a great deal of chain fricition in the process! :x

Two of the chain rollers are Primary Drive rollers from Rocky Mountain ATV/MC. The smallest, most rearward roller is marketed by Moose Racing. If you wish, you can read my installation thread at the following link. :)

http://www.advrider.com/forums/showthread.php?t=667646

Spud :)

[FastDoc]

Thanks for the education on chain rollers, Brother Spud! My KLX came with them, now I know enough to appreciate them. :D

[SpudRider]

Thanks for the education on chain rollers, Brother Spud! My KLX came with them, now I know enough to appreciate them. :D
You're welcome, Brother Bill. :)

Spud :)

[davidsonsgccc]

any reduction in drag on a smaller bike such as the zong sounds like possibly a noticable gain. i think i will try that. thanks for the idea.

[SpudRider]

any reduction in drag on a smaller bike such as the zong sounds like possibly a noticable gain. i think i will try that. thanks for the idea.
You're welcome. :) Quite frankly, I think you could completely remove the chain guide on the Zong, and substitute a lower chain guard, such as the rubber "shark fin" on my XT225 swingarm. ;)

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Shorai%20Battery%20Relocation/MidOctoberRides290.jpg

I believe chain guides are necessary on larger bikes, with more suspension travel, to insure the chain will not become disengaged from the rear sprocket. However, I don't think a chain guide is needed on the Zong. ;) As you can see, my XT225 swingarm doesn't employ a chain guide, merely a lower chain guard. :)

Spud :)

[SpudRider]

I grew tired of cleaning the baked mud off my bike’s exhaust header. :roll:

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20FMF%20Hi-Flo%20Exhaust%20Header/ReservationSnowRecon011.jpg

Therefore, several days ago I installed a stainless steel, FMF, Hi-Flo header. :)

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20FMF%20Hi-Flo%20Exhaust%20Header/FuseBoxCoverHeader010.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20FMF%20Hi-Flo%20Exhaust%20Header/FuseBoxCoverHeader013.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20FMF%20Hi-Flo%20Exhaust%20Header/FuseBoxCoverHeader015.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20FMF%20Hi-Flo%20Exhaust%20Header/FuseBoxCoverHeader018.jpg

Based upon the color of the header, and my engine's performance, I think the stock, carburetor jetting is just about right for my altitude. :) What do you gentlement think? :?:

Spud :)

[JTCAndrew]

I Think it looks good. In Fact I'm curious what the seat height on that bad boy? I Probably wouldn't be able to touch ground but I'd love to see how much power that baby has.....Sweet Ride......I like it!

[Weldangrind]

I think that header needs to be polished, but I have a compulsion when it comes to polishing metals. :lol:


It never occurred to me to read performance by header colour.

[FastDoc]

Bike looks good and the weather looks good too Spud! Enjoy the ride.

I'm scrubbing my planned visit to Missoula. Lots of snow and ice along 90. Can't fly due to low instrument conditions high winds and ice. My car won't go in that stuff, and my truck is too old.

Enjoy your weather! You have North Montana beat by a mile!

[SpudRider]

I Think it looks good. In Fact I'm curious what the seat height on that bad boy? I Probably wouldn't be able to touch ground but I'd love to see how much power that baby has.....Sweet Ride......I like it!
Thank you, Andrew. :) The stock seat height for the XR650L is 37 inches. 8O I installed a 1.5-inch lowering link, and the bike is still tall for me, but manageable. :roll: The XR650L is definitely not a motorcycle for the "vertically challenged." ;)

Spud :)

[SpudRider]

I think that header needs to be polished, but I have a compulsion when it comes to polishing metals. :lol: ...
Brother Derryk, I installed the stainless steel header to avoid extra cleaning. :lol:
...It never occurred to me to read performance by header colour.
I learned this technique while choosing the proper carburetor jets for my Zong. ;) My XT225 header would not turn golden in color until I leaned the main jet to the proper size. If the exhaust header turns bright blue, your engine is running too lean. ;)

Spud :)

[SpudRider]

Bike looks good and the weather looks good too Spud! Enjoy the ride.

I'm scrubbing my planned visit to Missoula. Lots of snow and ice along 90. Can't fly due to low instrument conditions high winds and ice. My car won't go in that stuff, and my truck is too old.

Enjoy your weather! You have North Montana beat by a mile!
Thank you, Brother Bill. :) Montana is beautiful, but I prefer to visit there in summer. ;) Idaho gets plenty cold enough to suit me. :roll: I don't think I'll be moving to Montana; I hate winter. 8)

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20FMF%20Hi-Flo%20Exhaust%20Header/PrestonRide013.jpg

Spud :)

[dwholler]

Hi Spud.

I have a 1997 XR650L, which i am doing some of the mods you have done (or going to do). I have an IMS tank on the way and interested in getting a lowering link.

I find that my bike ran very lean as stock and often would overheat during hot weather. It would cause the throttle to spit and sputter in the lower rpm range. That's why I am trying these changes. (i am about 300ft above sea level)

rejetted my carb (richer to the next size bigger main jet than stock)
installed KN air filter. Hopefully this will solve my overheating issue.

Some advise.... if you ever pull off the carb to clean or jet make sure not to over tighten when you put the choke cable back on to the carb. I made this mistake and slightly overtightened the collar that holds the choke down to the carb, and the threads stripped on the choke collar nut. This is deceiving as the collar nut looks metal, but i think its some sort of hard plastic. So don't overtighten!

I also have a question for you regarding the lowering link that you installed. Did it come with bearings or did you have to use the stock ones? Did you need to have to do any other mods to the suspension other than adjusting the front shocks in the triple tree?

Oh by the way.. my sons zong sierra is still running! Have had it two years now and still running great! Best $1600 I have spent in a while.

thanks,

Dave

[SpudRider]

…I find that my bike ran very lean as stock and often would overheat during hot weather. It would cause the throttle to spit and sputter in the lower rpm range. That's why I am trying these changes. (i am about 300ft above sea level)

rejetted my carb (richer to the next size bigger main jet than stock)
installed KN air filter. Hopefully this will solve my overheating issue…
It’s good to hear from you again! I hope you are well, Dave. :D Indeed, these bikes run lean at sea level with the stock jets. ;) However, the stock jets are working great for me at 4,600-9,000 feet above sea level. :)
…Some advise.... if you ever pull off the carb to clean or jet make sure not to over tighten when you put the choke cable back on to the carb. I made this mistake and slightly overtightened the collar that holds the choke down to the carb, and the threads stripped on the choke collar nut. This is deceiving as the collar nut looks metal, but i think its some sort of hard plastic. So don't overtighten!…
Thanks for the warning, Dave. :)
…I also have a question for you regarding the lowering link that you installed. Did it come with bearings or did you have to use the stock ones? Did you need to have to do any other mods to the suspension other than adjusting the front shocks in the triple tree?…
I installed a Performance Design lowering link, and I like it very much! :) This lowering link comes with bushings, and grease zerks. The manufacturer claims his bushings are superior to needle bearings, and I am inclined to agree with him. ;) This link lowered my bike about 1.5-inches. I did not make any other modifications to the suspension other than raising the forks 1-inch in the triple tree. :)
…Oh by the way.. my sons zong sierra is still running! Have had it two years now and still running great! Best $1600 I have spent in a while.

thanks,

Dave
You’re welcome, Dave. ;) The Zong is a great little bike! I’m glad your son is enjoying his motorcycle. :D

Spud :)

[dwholler]

Thanks Spud

I finished my mods to my XR today and took small spin around town. It was a beautiful day here today in jersey.

I ordered the lowering link and it came in friday. Nice quality built item from
Performance Design. Next weekend will try to get the link installed.


Here is a pic of my 97 XR650L today, after I installed my IMS tank.
http://farm6.static.flickr.com/5310/5604201871_1127e52c3a_b.jpg

[SpudRider]

That is a nice looking bike, Dave. :) Since your family owns both an XR650L, and a Zong, it is obvious you are an intelligent man who also possesses good taste! :lol:

When I installed my Performance Design lowering link, I had a busy friend come over to help me. I wanted to make sure we got the job done as quickly as possible, and I did not want to forget anything; therefore, I wrote up some instructions to follow beforehand. I posted the instructions at the following link; perhaps you will find them helpful. :)

http://www.thumpertalk.com/forum/showthread.php?t=937403

Spud :)

[JTCAndrew]

Nice XR Dave - That seat height actually looks low enough for someone my size! LOL I'm 5'4. I Had taken about 3" of FOAM out from underneather the cover of my "q" which really really helped out with feeling comfortable with touching the ground. I think in a couple of years I'll probably be looking for an KLX250 or a Honda like yours - Thats sweet. Thanks for sharing your picture.....Andrew :D

[JTCAndrew]

Nice write-up Spud - I'm your documentation will help others. Great Job!

[SpudRider]

Nice write-up Spud - I'm your documentation will help others. Great Job!
Thank you, Andrew. :)

Spud :)

[dwholler]

thanks guys... It has been some work, but its coming along nicely.

Spud thanks for the directions! I'm sure they will help me out immensely.

Here is a pic of the bike when i purchased it two years ago with 8000 miles on it. (it has 10,000 on it now)



http://farm6.static.flickr.com/5108/5604990202_d1c7dc355c_z.jpg

[Weldangrind]

That's a nice looking bike, dwholler. 8) That new tank makes all the difference.

[SpudRider]

That's a nice looking bike, dwholler. 8) That new tank makes all the difference.
Indeed, the XR650L looks much better without the "elephant ears" serving as air scoops. ;)

Spud :)

[SpudRider]

Some of the lower trails in the mountains are becoming accessible as the snow melts in Idaho! I am discovering the XR650L is very capable in off road riding. :D

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Trips/Malad%204-27/MaladArbon4-27112.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Trips/Malad%204-27/MaladArbon4-27264.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Trips/Malad%204-27/MaladArbon4-27361.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Trips/Malad%204-27/MaladArbon4-27225.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Trips/Malad%204-27/MaladArbon4-27296.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Trips/Malad%204-27/MaladArbon4-27170.jpg

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Trips/Malad%204-27/MaladArbon4-27267.jpg

Spud :)

[FastDoc]

The BRP is no ordinary XR650L. Its an XR650LL. The second 'L' is for Lightened. :P

[SpudRider]

The BRP is no ordinary XR650L. Its an XR650LL. The second 'L' is for Lightened. :P
You are correct again, oh wise physician. ;) I weighed the items I removed from my XR650L. However, I have not weighed the items I added to my bike. Therefore, my final, weight reduction figure is an estimate, but I believe it is a fairly accurate estimate. Without further ado, here are my calculations.

Weight of items removed from my XR650L:

Stock Battery & Battery “Suitcase”: 10.25 Lb
Stock Fuel Tank: 7.0 Lb
Stock Exhaust Header, minus heat shield: 3.0 Lb
Stock Headlight and Bracket: 3.0 Lb
SMOG Pump, Hoses, and associated hardware: 2.0 Lb
Stock Tail Light & License Plate Holder: 2.0 Lb
Passenger Foot Pegs: 1.5 Lb
Fuel Tank "Elephant Ears": 1.0 Lb
Engine Guard: 1.0 Lb

Total Weight Removed: 30.75 Lbs

Weight of items added to my XR650L:

Clarke 4.7-gallon Fuel Tank: 3.5 Lbs (estimate)
FMF Hi-Flo Header: 2.5 Lbs (estimate)
Baja Designs Headlight: 2.0 Lbs
Shorai Battery & foam: 1.25 Lbs
WPS Tail Light: 0.5 Lbs (estimate)

Total Weight Added: 9.75 Lbs

Net Weight Loss: 21.0 Lbs

Most of this removed weight was highly placed on the motorcycle. Here are my weight reduction modifications, listed in order of weight removed.

Net Weight Loss Figures

1) Shorai battery relocation: 9.0 Lbs
2) Clarke 4.7-gallon fuel tank replacing the stock fuel tank and air scoops: 4.5 Lbs
3) Removing SMOG pump and associated hardware: 2.0 Lbs
4) Removing Passenger Foot Pegs: 1.5 Lbs
4) WPS tail light replacing the stock tail light and license plate holder: 1.5 Lbs
5) Removing Engine guard: 1.0 Lbs
6) Baja Designs headlight replacing stock headlight and bracket: 1.0 Lbs
7) FMF Hi-Flo Header replacing stock header: 0.5 Lbs

I am very glad I removed the 21 pounds of highly placed weight from my XR650L. My bike feels much more nimble after the weight reduction. In stock form, my XR650L weighed 20 pounds less than a Suzuki DR650SE, and 29 pounds more than a Suzuki DR-Z400S. After shedding 21 pounds, my XR650L weighs 41 pounds less than a Suzuki DR650SE, and only 8 pounds more than a Suzuki DR-Z400. :D

P.S. If you examine my figures, you will note almost half of the total weight loss from my bike resulted from my Shorai battery relocation.

http://www.advrider.com/forums/showthread.php?t=666195

Spud :)

[SpudRider]

So far I have ridden about 16,000 miles on my Honda XR650L; the more I ride this bike, the better I like it!

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Trips/Early%20August%20Rides%202011/EarlyAugustRides151.jpg

I'm pleased to report the Dunlop, D952 rear tire I recently installed is working great, and is wearing like iron. :) I installed the size 110/90-18 tire, and I really enjoy the lower profile, and the resulting, lower saddle height I get from this rear tire. :)

Spud :)

[FastDoc]

I gotta hand it to you Brother Spud! You sure do get the mileage in! Enjoy and Ride On! :P

[prisoneruntochrist]

Spud this bike is pure awesomeness !!! I like the red tank,
And u have all the trails you would ever want to ride in!!!
<<---- this guy is jealous-----
Luke :wink:

[SpudRider]

Spud this bike is pure awesomeness !!! I like the red tank,
And u have all the trails you would ever want to ride in!!!
<<---- this guy is jealous-----
Luke :wink:
Thank you, Luke. :) Welcome to the XR650L fraternity! You can learn a lot about your recently acquired Honda by reading the XR650L thread at ADVRiders. ;)

http://www.advrider.com/forums/showthread.php?t=114834

I suggest you also check out the XR650L forums at 4Strokes.com.

http://www.4strokes.com/forums/forum.asp?FORUM_ID=156

Finally, you can learn a lot about your bike at the ThumperTalk forum. ;)

http://www.thumpertalk.com/forum/forumdisplay.php?f=22

However, please don't leave us here! Forum members Deputy Gene and myself own XR650L motorcycles, and we would love to have you stay here with us! It's a pleasure to have a Christian brother join us on these forums. :D I'm sure I also speak for the other members of these forums. ;)

Spud :)

[FastDoc]

It's a pleasure to have a Christian brother join us on these forums.

+1!

You speak for me in this regard, Brother Spud! :D

[SpudRider]

The OEM, XR650L counteshaft sprocket is notorious for stripping the splines from the bike's countershaft. 8O Therefore, about 27,000 miles ago, I switched to a wider C/S sprocket designed for the XR650R motorcyle. :)

When first installing the wider, XR650R C/S sprocket, the inside portion of the countershaft is higher than the worn splines on the outside of the countershaft. After riding several thousand miles with the XR650 C/S sprocket, the unworn portion of the splines will slowly wear down until the wear is even across the countershaft. At that time it appears the wider, XR650R C/S sprocket greatly reduces, or completely arrests further wear of the countershaft splines. Here’s a photographic review of my experience employing the XR650R C/S sprocket on my XR650L’s countershaft for the last 27,000 miles.

First, here is a photo of my countershaft splines before I started employing the XR650R CS sprocket. I bought my XR650L with 7,800 miles on the odometer, and the previous owner had only employed the OEM, Honda C/S sprocket. My bike had 10,000 miles on the odometer when I captured this photograph, and installed my first, XR650R C/S sprocket.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Countershaft%20and%20XR650R%20Sprockets/countershaftsplines007.jpg

This is a photo of my countershaft after employing the XRR sprocket for 1,200 miles.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Countershaft%20and%20XR650R%20Sprockets/CSSplinesChainRollerInspection006.jpg

Here is a photograph of my countershaft after employing the XR650R CS sprocket for 4,000 miles.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Countershaft%20and%20XR650R%20Sprockets/XRLCSsplinesCSsprocket008.jpg

Here is my XR650L countershaft after employing the XR650R countershaft sprocket for 5,600 miles.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Countershaft%20and%20XR650R%20Sprockets/ChainrollersXRRsprocketinspection006.jpg

Here is a photograph of my countershaft splines after employing the XR650R CS sprocket for 7,700 miles.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Countershaft%20and%20XR650R%20Sprockets/spudrollersandsplines018.jpg

Here is a photograph of my countershaft splines after employing two, XR650R countershaft sprockets for a combined total of 10,400 miles.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Countershaft%20and%20XR650R%20Sprockets/cssplinessprocketsdrivechain7-8-11013.jpg

Here is a photograph of my countershaft after employing three, XR650R countershaft sprockets for a total of 12,750 miles.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Countershaft%20and%20XR650R%20Sprockets/CSsplinesroller026.jpg

At this point I switched from a PBI, XR650R C/S sprocket to an even wider, Primary Drive, XR650R C/S sprocket. The wider PD sprocket engages the countershaft even deeper, and has worn away some of the inside chamfer on the countershaft itself. This last photograph was taken after employing the XR650R C/S sprockets for 27,000 miles.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Countershaft%20and%20XR650R%20Sprockets/BSBandCSsplines033.jpg

My countershaft/bike now has 37,000 miles on the odometer.

Spud :)

[FastDoc]

It's holding up well. :P

What was the reason Honda went with a different sprocket in the first place?

[SpudRider]

It's holding up well. :P

What was the reason Honda went with a different sprocket in the first place?
The XR650R was designed after the XR650L. ;) Therefore, I believe Honda designed the larger, XR650R C/S sprocket to correct the problems with the XR650L sprocket. :roll:

Spud :)

[FastDoc]

Makes sense.

[SpudRider]

About a week ago I installed four new items on my XR650L. :D

Tusk T-10 CR High Bend Handlebars
D-Flex Handguards with Spoilers
Pro Taper Pillow Top Grips
Tusk Grip Heater Kit

http://www.rockymountainatvmc.com/p/43/53/218/947/-/12330/Tusk-T-10-Aluminum-7-8%2522-Handlebar/tusk+handlebars
http://www.rockymountainatvmc.com/p/44/54/229/1036/-/9550/Tusk-D-Flex-Handguards-Spoilers/tusk+d-flex+handguards%252Fspoilers
http://www.rockymountainatvmc.com/p/43/53/218/998/-/23097/Tusk-Grip-Heater-Kit/tusk+grip+heater+kit
http://www.rockymountainatvmc.com/p/44/54/229/709/-/19923/Pro-Taper-Pillow-Top-MX-Grips/pro+taper+pillow+top+grips

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Handlbars%20Barkbusters%20Grips/Novridesandgripheaters285.jpg

I really like the Tusk T-10 handlebars; they are very similar in quality to the Pro Taper handlebars I installed on my Zong. :D The D-Flex Handguards fit the T-10 handlebars very well, and I did not need to castrate my control levers. ;)

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Handlbars%20Barkbusters%20Grips/Novridesandgripheaters291.jpg

The Tusk Grip Heater Kit works great, and I am very pleased with this purchase. I mounted the grip heater switch to the inside of my Baja Designs headlight shroud. I have perviously installed the Pillow Top grips on my Zong, and they are superb. :D

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Handlbars%20Barkbusters%20Grips/Novridesandgripheaters286.jpg

The Tusk grip heaters kept my hands toasty warm all day long, even while riding on the summit of Big Southern Butte. :D

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Handlbars%20Barkbusters%20Grips/Novridesandgripheaters301.jpg

Here's a view from the summit looking northwest to Arco.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Handlbars%20Barkbusters%20Grips/Novridesandgripheaters307.jpg

Arco is 23 aerial miles distant from the butte. You can see the Big Lost Range of mountains in the far background of the following photograph.

http://i442.photobucket.com/albums/qq146/spudrider/XR650L%20Handlbars%20Barkbusters%20Grips/Novridesandgripheaters306.jpg

I can't believe I waited this long to install grip heaters! The Tusk grip heaters are the greatest thing since sliced bread! :D

Spud :)

[FastDoc]

I miss Arco....

I like grip heaters. Next best thing to heated gloves but more convienent and aways there. The Gold Wing has them.

I have considered adding them to the KLX but I run heated gloves on it. The YZ has no electrical system per se, and Little Sweetie has such a small battery I don't trust it, and I don't ride her in cold weather anyways.

[MICRider]

Love love love grip heaters! Some mornings my commute is only a little above zero (Celsius) and the grip heaters make a huge difference! :D

Only catch 22 with mine is that I bought the Oxford ones where the elements are built right into the supplied grips... I'd like to try some different grips now (like your pillow tops) but I can't. Next time around I will go for the element type ones that you use your own grips with ;).

[SpudRider]

Besides being able to choose different grips, the Tusk Grip Heater Kit is regularly priced at $20. I just checked the vendor's website, and the Tusk kit is now on sale for $9.99! 8O

http://www.rockymountainatvmc.com/p/43/53/218/998/-/23097/Tusk-Grip-Heater-Kit/tusk+grip+heater+kit

Spud :)

[FastDoc]

I'll buy a pair. I'll use them somewhere....

Too good a price to pass up!

[FastDoc]

Are they thin enough to get the grips back on easily enough?

I assume you glue the heaters to the bars/throttle tube and do not glue the grips on, just dlide them into place?

[TCCKSR]

wow those look like an awesome option for cold weather riding over the $150 heat grips I keep looking at.

[FastDoc]

I also like that it seems as if you can replace the grips as much as you need to and save the heaters.

[SpudRider]

Are they thin enough to get the grips back on easily enough?

I assume you glue the heaters to the bars/throttle tube and do not glue the grips on, just dlide them into place?
Yes, the Tusk Grip Heaters are thin enough to make installing the grips very easy, especially if you use compressed air. :D You are correct, Doc. The grip heaters have a sticky backing covered with paper; you merely remove the paper backing, and stick the grip heaters on the trottle tube and left handlebar. Then you install the grips. I didn't use any glue when installing the grips. ;)

Spud :)

[SpudRider]

I also like that it seems as if you can replace the grips as much as you need to and save the heaters.
Yes, that's correct. :D

Spud :)

[SpudRider]

wow those look like an awesome option for cold weather riding over the $150 heat grips I keep looking at.
The Tusk Grip Heater Kit works great! It's an exceptional deal. :)

Spud :)

[SpudRider]

A while back I bought a PWM (Pulse Width Modulator) device to substitute for the 10-ohm resistor which controlled the "low" setting on my Tusk Grip Heaters. Several days ago I installed the device, and attached it with velcro to the inside of my headlight shroud.

http://i442.photobucket.com/albums/qq146/spudrider/Tusk%20Grip%20Heaters/firstbsb2013005_zps1a0038d8.jpg

http://i442.photobucket.com/albums/qq146/spudrider/Tusk%20Grip%20Heaters/firstbsb2013015_zpsc25a83e1.jpg

I wired the PWM device in the the following method, using a DPCO (Double-pole, Double-throw, Center Off) switch from Radio Shack.

http://i442.photobucket.com/albums/qq146/spudrider/Tusk%20Grip%20Heaters/TuskwithPWMDevice_zpsc96432d4.jpg

I'm pleased to report the PWM device works great. It's nice to be able to modify the heat output of the "low" setting, and not waste a lot of power through the 10-ohm resistor. :D

http://i442.photobucket.com/albums/qq146/spudrider/Tusk%20Grip%20Heaters/firstbsb2013001_zps6daee127.jpg

Spud :)

[Weldangrind]

Does it act like a rheostat?

[SpudRider]

Does it act like a rheostat?
Yes, it does. The PWM is a solid state device which rapidly turns the circuit on and off. Therefore, it allows you to control the current flowing through a device, but it uses very little power itself. ;) Here's a link to the Wiki thread on pulse width modulation. :)

http://en.wikipedia.org/wiki/Pulse-width_modulation

I bought this PWM device on eBay for $5.69, delivered. :D

http://www.ebay.com/itm/DC-5V-24V-4A-48W-LED-Light-Dimmer-Adjustable-Bright-Controller-/150755952542?pt=US_Lighting_Parts_and_Accessories&hash=item2319c1479e

Spud :)

[Weldangrind]

Brilliant! Thanks for the links.

[SpudRider]

You're welcome. :) Thank you for the kind words, Weld. ;)

Spud :)

[FastDoc]

I'm impressed Spud! :D

You copied the wiring diagram from a Medtronics pacemaker? :lol:

[SpudRider]

I'm impressed Spud! :D

You copied the wiring diagram from a Medtronics pacemaker? :lol:
No, I designed the wiring system, and created the diagram by myself. ;) I hope I didn't violate any copyrights! 8O

Spud :lol:

[FastDoc]

Just joking as I was impressed with the precision and complexity of your wiring diagram. :D

[SpudRider]

Thank you, Doc. :) The $5 PWM device works great! I don't how I ever went without grip heaters for so long. ;) You know it can get cold at these elevations, even in the summertime, after the sun has set. The heated grips are very nice to have at all times of the year in East Idaho. :)

Spud :)

[FastDoc]

I love heated grips! Indeed I used them riding into work this morning on the Gold Wing.

[Darkrider]

Sorry about digging this up spud but i gotta say i quite enjoyed reading through this build. If i ever end up getting another XR im thinking it will probably be a 650L like this one. My last one was a highly modified R that i used to race in rally events. So there is a good chance that what i remember of that build will more then likely end up on what ever L i get. Plus a healthy dose of mods from yours for good measure!