Let the Mods begin

Hi guys, I just joined the site tonight and wanted to say hello, also

I just bought a 2002 XR650L today. It is pretty much mod-less (previous owner was worried about voiding the extended warrantee). I havent even ridden it much except for the test ride. But after reading some posts on this forum I want to uncork.

So tell this newbie....what exactly is involved in uncorking?

Where should I start. One thing is for sure...I want to make it easyier to start! Also...it need a battery. Any recommendations or are all the batterties pretty much the same?


I heard the battery can be changed out for a lighter one, a ktm 525??? There are links to go to on this site that give you pics and detailed instructions on how to rejet your carb and the size sprockets to use. Getting a uni-filter and removing your snorkel on your air box goes with the rejetting. Get a slip-on after market exhaust also.

I hope that dave dosent mind but here is word for word what dave posted for me (I saved it so I could get it right)

"The smog block-off itself doesn't add any power, but it does relieve the popping on decel, and the occaisional very-low-rpm stall.

For the XR650L the baja designs/dyno-jet kit is not needed, and on some bikes doesn't work worth a damn. In my opinion, the kit is a rip-off and your money is much better spent elsewhere. Yes, some people use the kit and it seems to work OK. Some of those 'kit' people have done the mods with the keihin jets and have found it to be much better than the kit- myself included.

There is, however, a cheap absolutely-guaranteed recipe to wake the beast up. There are several converts on this board, and on other baords where I've been spreading this recipe.


You drill the off-center holes in the slide to 5/32 of an inch. There are 3 holes, one in the middle for the needle and 2 off to the side- drill the 2 not in the center.

THE NEEDLE: When you pull the slide, the needle is held into the bottom of the slide by a little yellow widget that you press down on and turn a little with a screwdriver or an 8mm socket. When you remove that, the needle comes right out. Notice that the needle sits in a small recessed section, a little well. Find a small washer that meets the following


1) is about 20-30 thousands of an inch thick.

2) fits fairly snugly over the needle at the thickest part at the top.

3) has the same outside diameter as the top of the needle.

You just put the needle through the washer like you would a washer on a bolt so that the needle will be raised up out of the slide by the thickness of the washer. Some have found washers like this in a kit at radio shack. I found one that I had to make a little smaller on the outside diameter in my "supplies".

If you do this, remove the snorkel, and grind off the tab on the bowl that keeps you from spinning the low-speed mixture screw around, and put in a good air filter, you'll wonder how you managed to ride the bike without these mods. If the mixture screw is out more than 2-3/4 turns, you need to go up on the pilot jet.

The suggestion to replace the screws on the carb with allen heads is an excellent one as well. I replaced the 4 bowl screws, the 4 screws in the top, and the 2 that hold on the throttle cover.

The slide gets raised when vacuum is applied at the bottom of the slide, and the holes are how the air leaves the area above the slide. Hence, the bigger the holes the faster the air can leave.

I'm running stock exhaust, K&N filter, and run a 55 pilot and 158 main (both keihin jets from Baja Designs), and this setup is rich enough to run with the baffle out. Note that there is a 55S short pilot jet, and the 55 regular pilot jet will work but you have to trim the slosh baffle in the bowl a little, as it can move a little and partially cover the pilot jet.


Pete, where in CT are you at? I'm just outside new britain.


PS thumper245- thanks for posting a reprint! Saved me some typing.


I live in East Lyme...work in Middletown CT. This is my first dirt bike in long time. (last one was 198? IT 175). Bike is fun to ride already...can't wait to "wake it up".


Pete, where in CT are you at? I'm just outside new britain.


PS thumper245- thanks for posting a reprint! Saved me some typing.

No prob. Dave it is the least that I could do. Thaks for posting.

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