I have an XR650L for the trip but plan to rebuild it so as to make it more comfortable and capable of withstanding the road ahead. Honda is one of the worlds largest manufacturers of small engines and it's bikes hold a race pedigree that's tried and proven to the present day, from the Paris Dakar to the Australian Safari.
The XR650L was chosen because-
-it is tall(I'm 6'2"), and has good ground clearance.
-it is still manufactured in Japan and still sold in America so parts are readily available.
-Honda dealerships are prolific throughout the world.
-It's air cooled meaning it has less parts(eg no water pump or radiator).
-It has a reliable RFVC head with race pedigree.
-A more common 18" rear and 21" front tyre makes finding tyres easier.
-At 650cc, the engine will provide exceptional low down torque for climbing hills and hauling luggage.
Disadvantages and fixes-
-Weak rear sub frame. This can be strengthened with chrome moly tube or replaced with a new stronger sub frame. Powder coating in white afterwards can help with corrosion control and spotting oil leaks.
http://www.horizonsunlimited.com/hubb/honda-tech/difference-between-xr650r-l-38180
Xr650l rear subframe reinforcment https://drivetribe.com/p/2014-honda-xr650l-enduro-hill-moto-N2zNjRthR6GslGqrdUKxtw?iid=ZHMahI9-QjWsvHFPxIDWyg
-Engine can get hot on occasions. This can be fixed with a good aftermarket auxiliary oil cooler.
http://www.advrider.com/forums/showthread.php?t=652313
-Off road gearing makes long road legs less than ideal. This can be fixed with different internal gears and final drive chain sprockets.
http://www.justxr.com/jaw/gearbox.html
http://ridedualsport.com/forum/index.php?topic=2038.0
-A solid cast rear hub can induce more shock than necessary in the gearbox. This can be fixed via the inclusion of an aftermarket billet cushion drive hub or original NX650 Dominator rear cushion drive hub.
http://www.horizonsunlimited.com/hubb/tech/chain-82923
-Rims can be soft. Aftermarket rims can be acquired.
-Fuel tank is small. Acerbis makes a 24 litre tank.
-Headlight is poor. Baja designs sells race lights that provide exceptional lighting.
Scott Dorrer from the US sells high/low beam kits for the Baja race light.
http://advrider.com/index.php?
Upgraded replacement stators with a higher output are available -
http://www.electrosport.com/dirt-bikes/honda/xr650l-93-09/stator-3-phase.html
-There is no kick start(only electric). An XR600R right hand side engine cover and all the kick start parts can be fitted to the XR650L engine. The heavy standard battery can be replaced with a small lithium battery with inbuilt charge protection/management.
https://www.thumpertalk.com/forums/topic/734150-want-to-add-a-kickstart-to-your-xr650l-heres-how/
-The carburetor is suburban at best. This can be replaced with a Mikuni TM42 Flatslide Pumper Carburetor. Varying jets can be sourced for changes in altitude. This carburetor coupled with a Staintune header and pipe can improve throttle response and top end power.
-Factory suspension is adequate but has limited adjustment and isn't set up for carrying luggage or a pillion over long road legs. Wilburs or Ohlins make fully adjustable rear shocks for the prescribed application and load to be carried. Front suspension can be improved by replacing the front end with a complete Suzuki DRZ conventional front end with new custom valves and springs. At 49mm in diameter, these DRZ forks are a considerable upgrade, but retain the long term reliability and hardiness of a conventional right side up front end.
Larger disc and calliper offset brackets are available for the DRZ400E front end on ebay and elsewhere for supermoto conversions.
-The seat is a narrow motocross seat not suited for long journeys. A new seat can be upholstered or sourced for long distance comfort.
http://www.corbin.com/honda/9395xr650.shtml
Steering Stabiliser(under bar mounted)-
http://shock-treatment.mybigcommerce.com/drz-400-sub-mount-kit-fat-bars/
http://www.scottsonline.com/Stabilizer_Purchase2.php?Make=Suzuki&Model=DRZ&Bike_ID=4677&Year=2009&Size=400&Fred=%20dirt&BI_ID=71556
Rebuild Thread ADV-
http://advrider.com/index.php?threads/building-a-xr650l-engine.713831/
https://advrider.com/f/threads/honda-xr650l-weight-loss-thread.763772/page-6
The XR650L was chosen because-
-it is tall(I'm 6'2"), and has good ground clearance.
-it is still manufactured in Japan and still sold in America so parts are readily available.
-Honda dealerships are prolific throughout the world.
-It's air cooled meaning it has less parts(eg no water pump or radiator).
-It has a reliable RFVC head with race pedigree.
-A more common 18" rear and 21" front tyre makes finding tyres easier.
-At 650cc, the engine will provide exceptional low down torque for climbing hills and hauling luggage.
Disadvantages and fixes-
-Weak rear sub frame. This can be strengthened with chrome moly tube or replaced with a new stronger sub frame. Powder coating in white afterwards can help with corrosion control and spotting oil leaks.
http://www.horizonsunlimited.com/hubb/honda-tech/difference-between-xr650r-l-38180
Xr650l rear subframe reinforcment https://drivetribe.com/p/2014-honda-xr650l-enduro-hill-moto-N2zNjRthR6GslGqrdUKxtw?iid=ZHMahI9-QjWsvHFPxIDWyg
-Engine can get hot on occasions. This can be fixed with a good aftermarket auxiliary oil cooler.
http://www.advrider.com/forums/showthread.php?t=652313
-Off road gearing makes long road legs less than ideal. This can be fixed with different internal gears and final drive chain sprockets.
http://www.justxr.com/jaw/gearbox.html
http://ridedualsport.com/forum/index.php?topic=2038.0
-A solid cast rear hub can induce more shock than necessary in the gearbox. This can be fixed via the inclusion of an aftermarket billet cushion drive hub or original NX650 Dominator rear cushion drive hub.
http://www.horizonsunlimited.com/hubb/tech/chain-82923
-Rims can be soft. Aftermarket rims can be acquired.
-Fuel tank is small. Acerbis makes a 24 litre tank.
-Headlight is poor. Baja designs sells race lights that provide exceptional lighting.
Scott Dorrer from the US sells high/low beam kits for the Baja race light.
http://advrider.com/index.php?
Upgraded replacement stators with a higher output are available -
http://www.electrosport.com/dirt-bikes/honda/xr650l-93-09/stator-3-phase.html
-There is no kick start(only electric). An XR600R right hand side engine cover and all the kick start parts can be fitted to the XR650L engine. The heavy standard battery can be replaced with a small lithium battery with inbuilt charge protection/management.
https://www.thumpertalk.com/forums/topic/734150-want-to-add-a-kickstart-to-your-xr650l-heres-how/
-The carburetor is suburban at best. This can be replaced with a Mikuni TM42 Flatslide Pumper Carburetor. Varying jets can be sourced for changes in altitude. This carburetor coupled with a Staintune header and pipe can improve throttle response and top end power.
-Factory suspension is adequate but has limited adjustment and isn't set up for carrying luggage or a pillion over long road legs. Wilburs or Ohlins make fully adjustable rear shocks for the prescribed application and load to be carried. Front suspension can be improved by replacing the front end with a complete Suzuki DRZ conventional front end with new custom valves and springs. At 49mm in diameter, these DRZ forks are a considerable upgrade, but retain the long term reliability and hardiness of a conventional right side up front end.
Larger disc and calliper offset brackets are available for the DRZ400E front end on ebay and elsewhere for supermoto conversions.
-The seat is a narrow motocross seat not suited for long journeys. A new seat can be upholstered or sourced for long distance comfort.
http://www.corbin.com/honda/9395xr650.shtml
Steering Stabiliser(under bar mounted)-
http://shock-treatment.mybigcommerce.com/drz-400-sub-mount-kit-fat-bars/
http://www.scottsonline.com/Stabilizer_Purchase2.php?Make=Suzuki&Model=DRZ&Bike_ID=4677&Year=2009&Size=400&Fred=%20dirt&BI_ID=71556
Rebuild Thread ADV-
http://advrider.com/index.php?threads/building-a-xr650l-engine.713831/
https://advrider.com/f/threads/honda-xr650l-weight-loss-thread.763772/page-6
