The Honda XR650L: a legend in the dual-sport world, a machine celebrated for its rugged simplicity and go-anywhere capability. But even legends have their quirks. While the XR650L is renowned for its reliability, understanding its common issues can save you time, money, and frustration on the trail. This article dives deep into the potential problems that XR650L owners might encounter, offering insights and solutions to keep your trusty steed running strong for years to come.

The XR650L: A Love Affair with Simplicity (and its Consequences)

The XR650L's charm lies in its simplicity. It's a carbureted, air-cooled machine that hasn't changed drastically in decades. This old-school design contributes to its reliability, but it also means certain components are more susceptible to wear and tear, or simply haven't benefited from modern advancements. Think of it like a classic car: dependable, but requiring a different approach to maintenance than a modern vehicle.

The Dreaded Starting Issues: Why Won't My XR650L Fire Up?

One of the most frequently reported problems with the XR650L is difficulty starting, especially when cold. Several factors can contribute to this:

  • Lean Jetting: From the factory, the XR650L is often jetted lean to meet emissions standards. This means it's not getting enough fuel, especially at lower temperatures. The solution? Re-jetting the carburetor with slightly larger jets, particularly the pilot jet, is a common and effective fix. Many riders opt for a Dynojet kit or similar aftermarket solution.

  • Choke Issues: The choke enriches the fuel mixture for cold starts. Make sure the choke cable is properly adjusted and functioning correctly. A broken or misadjusted choke can prevent the engine from starting or cause it to run poorly when engaged.

  • Valve Adjustment: Improper valve clearance can significantly impact starting. Valves that are too tight can prevent proper sealing, leading to compression loss and hard starting. Regular valve adjustments are crucial for maintaining engine performance and ease of starting. Check your owner's manual for the recommended intervals.

  • Spark Plug Problems: A fouled or worn spark plug can also cause starting issues. Inspect the spark plug for signs of wear or carbon buildup. Replace it with the recommended type and gap.

  • Fuel Quality: Old or contaminated fuel can wreak havoc on the carburetor and make starting difficult. Always use fresh fuel and consider adding a fuel stabilizer if the bike will be stored for an extended period.

  • Battery Condition: While the XR650L's starting system isn't overly demanding, a weak battery can still struggle to turn the engine over, especially in cold weather. Ensure your battery is fully charged and in good condition. A load test can help determine its health.

The "XR650L Jerkiness": Carburetor Woes and How to Fix Them

Many XR650L owners complain about a "jerky" throttle response, especially at low speeds and during transitions from closed to open throttle. This is often attributed to the lean factory jetting mentioned earlier.

  • Lean Surge: The lean fuel mixture can cause the engine to hesitate or surge when you open the throttle. This is particularly noticeable in the lower RPM range. Re-jetting the carburetor is the most common solution.

  • Accelerator Pump Issues: The XR650L's carburetor has an accelerator pump that squirts extra fuel into the intake when you quickly open the throttle. If the accelerator pump is malfunctioning or not properly adjusted, it can cause a lag or stumble. Inspect the pump diaphragm for cracks or tears and ensure the nozzle is clean and unobstructed.

  • Throttle Cable Play: Excessive throttle cable play can also contribute to jerky throttle response. Adjust the cable to minimize slack without causing the throttle to bind.

  • Air Leaks: Air leaks in the intake system can lean out the fuel mixture and cause erratic engine behavior. Check the intake manifold, carburetor boots, and vacuum lines for cracks or loose connections.

The Oil Consumption Conundrum: Why Is My XR650L Drinking Oil?

Oil consumption is a concern for some XR650L owners, especially on older or high-mileage bikes. Several factors can contribute to this:

  • Worn Piston Rings: Worn piston rings are a common cause of oil consumption in older engines. As the rings wear, they lose their ability to seal against the cylinder walls, allowing oil to seep into the combustion chamber. A compression test and leak-down test can help diagnose this issue.

  • Worn Valve Seals: Worn valve seals can also allow oil to leak into the combustion chamber, particularly when the engine is idling or decelerating.

  • Overfilling the Oil: Overfilling the oil can cause it to be forced past the seals and into the airbox. Always check the oil level according to the manufacturer's recommendations.

  • Improper Break-in: Improper break-in of a new or rebuilt engine can lead to premature wear of the piston rings and cylinder walls, resulting in increased oil consumption.

  • Oil Viscosity: Using the wrong oil viscosity can also contribute to oil consumption. Use the oil viscosity recommended in your owner's manual.

The Weak Subframe: A Cargo Carrier's Nightmare

The XR650L's subframe is known to be relatively weak, especially compared to its robust engine. This can be a concern for riders who carry heavy loads or frequently ride off-road.

  • Cracking at Welds: The subframe is prone to cracking at the welds, particularly where it connects to the main frame. This is often caused by excessive weight or repeated impacts.

  • Bent Subframe: The subframe can also bend under heavy loads or during crashes.

  • Solutions: Reinforcing the subframe with aftermarket braces or welding is a common solution. It's also important to avoid overloading the bike and to be mindful of the terrain.

The Electrical Gremlins: Tracking Down Shorts and Faults

While generally reliable, the XR650L's electrical system can occasionally experience issues.

  • Charging System Problems: The charging system can fail, leading to a dead battery. Check the stator, rectifier/regulator, and wiring for faults.

  • Wiring Issues: The wiring harness can become brittle and cracked over time, leading to shorts and intermittent electrical problems. Inspect the wiring for damage and repair as needed.

  • Blown Fuses: Blown fuses are a common symptom of electrical problems. Identify the cause of the blown fuse before replacing it.

  • Grounding Issues: Poor grounding can cause a variety of electrical problems. Ensure all ground connections are clean and tight.

The Suspension Shortcomings: Bumps and Bruises

The XR650L's suspension is adequate for casual riding, but it's often considered too soft for aggressive off-road riding or carrying heavy loads.

  • Soft Springs: The stock springs are too soft for many riders, especially those who are heavier or carry luggage. Upgrading to stiffer springs is a common and effective modification.

  • Poor Damping: The damping is also inadequate, leading to a bouncy and uncontrolled ride. Revalving the forks and shock can significantly improve the suspension performance.

  • Fork Flex: The forks can flex excessively, particularly during hard braking or cornering. Fork braces can help improve rigidity.

Frequently Asked Questions (FAQ)

  • Why is my XR650L so hard to start when it's cold? This is often due to lean factory jetting. Re-jetting the carburetor with slightly larger jets can help.
  • What's the best way to improve the XR650L's suspension? Upgrading the springs and revalving the forks and shock are common and effective modifications.
  • Is the XR650L reliable? Yes, the XR650L is generally considered a very reliable motorcycle, especially with proper maintenance.
  • What is the recommended oil for the XR650L? Refer to your owner's manual for the recommended oil viscosity and type.
  • How often should I adjust the valves on my XR650L? Check your owner's manual for the recommended valve adjustment intervals.

Keeping Your XR650L Happy: Preventative Maintenance is Key

The best way to avoid many of these problems is to perform regular preventative maintenance. This includes:

  • Regular Oil Changes: Change the oil and filter at the recommended intervals.
  • Valve Adjustments: Keep the valves properly adjusted.
  • Air Filter Cleaning: Clean or replace the air filter regularly.
  • Chain Maintenance: Keep the chain clean, lubricated, and properly adjusted.
  • Tire Pressure: Maintain proper tire pressure.
  • Visual Inspections: Regularly inspect the bike for any signs of wear, damage, or leaks.

By addressing these common issues and performing regular maintenance, you can keep your Honda XR650L running strong and enjoying many years of reliable service. Remember, a little proactive care goes a long way in preserving this legendary dual-sport machine.