The Honda XR650L: a legendary dual-sport motorcycle revered for its simplicity, reliability, and go-anywhere capability. It's a machine that has conquered trails, backroads, and even continents. However, even this iconic bike isn't without its quirks and potential issues. Understanding these common problems can help you keep your XR650L running strong for years to come.

So, What Are the XR650L's Achilles Heels?

Let's dive into the known issues that XR650L owners often encounter, providing insights and potential solutions to keep you on the road (or trail!).

1. The Dreaded Countershaft Spline Wear

This is arguably the most talked-about and feared issue with the XR650L. The countershaft, which connects the engine to the sprocket, has splines that can wear down prematurely.

  • Why It Happens: The primary culprit is insufficient lubrication. The stock setup relies on splash lubrication, which can be inadequate, especially during extended high-speed riding or aggressive off-road use. Over time, the splines lose their sharp edges and eventually fail, leading to a loss of power to the rear wheel.
  • Symptoms: Slipping chain, unusual vibrations, difficulty shifting, and ultimately, complete loss of drive.
  • Solutions:
    • Preventative Maintenance is Key: Regularly inspect the countershaft splines during sprocket changes. Use a quality molybdenum disulfide (moly) grease specifically designed for high-pressure applications.
    • Upgrade the Lubrication: Several aftermarket options exist to improve countershaft lubrication. These include oilers that directly feed oil to the splines.
    • Consider a Hardened Countershaft: When replacing the worn countershaft, opt for a hardened aftermarket version. These are significantly more durable and resistant to wear.
    • Chain Maintenance: Keep your chain properly adjusted and lubricated. A loose or dry chain puts extra stress on the countershaft splines.

2. The Lean Factory Jetting Blues

The XR650L, in its stock form, is notoriously lean from the factory. This is largely due to emissions regulations.

  • Why It Happens: A lean air/fuel mixture means there's too much air and not enough fuel. This can lead to several problems.
  • Symptoms: Hard starting, especially when cold; poor throttle response; surging at steady speeds; overheating; and potential engine damage over the long term.
  • Solutions:
    • Jetting Adjustment: This is the most common and effective solution. Replace the stock jets with larger ones to richen the mixture. A popular modification is the "Dave's Mods," which involve adjusting the pilot jet, main jet, and needle.
    • Airbox Modification: Opening up the airbox slightly can improve airflow and help balance the richer jetting. Be careful not to overdo it, as excessive airflow can negatively impact performance.
    • Aftermarket Exhaust: While not strictly necessary, an aftermarket exhaust can improve performance and further optimize the air/fuel mixture. However, it often requires further jetting adjustments.
    • Fuel Mixture Screw Adjustment: Fine-tune the fuel mixture screw for optimal idle and low-speed performance.

3. The Weak Subframe Saga

The XR650L's subframe, particularly the area around the rear fender mounts, can be prone to cracking, especially when carrying heavy loads or experiencing rough terrain.

  • Why It Happens: The subframe wasn't designed for excessive weight or repeated impacts. Luggage racks and heavy gear can exacerbate the problem.
  • Symptoms: Cracks in the subframe, particularly around the rear fender mounting points.
  • Solutions:
    • Reinforcement: Weld gussets or additional support to the subframe to strengthen it. Several aftermarket kits are available for this purpose.
    • Careful Loading: Avoid overloading the rear of the bike. Distribute weight evenly and use lightweight luggage whenever possible.
    • Proper Luggage Racks: Invest in a high-quality luggage rack that is designed to distribute weight effectively.
    • Regular Inspection: Regularly inspect the subframe for cracks, especially after riding in rough conditions.

4. The Oil Consumption Conundrum

Some XR650L owners report excessive oil consumption, particularly in older models or those with high mileage.

  • Why It Happens: Worn piston rings, valve stem seals, or cylinder bore wear can allow oil to seep into the combustion chamber and burn.
  • Symptoms: Blue smoke from the exhaust, low oil levels, and the need to frequently add oil.
  • Solutions:
    • Compression Test: Perform a compression test to assess the condition of the piston rings and valves.
    • Leak-Down Test: A leak-down test can help pinpoint the source of the oil leak.
    • Top-End Rebuild: If the piston rings or cylinder bore are worn, a top-end rebuild may be necessary. This involves replacing the piston, rings, and potentially re-boring the cylinder.
    • Valve Stem Seal Replacement: If the valve stem seals are leaking, they can be replaced without a full top-end rebuild.
    • Use High-Quality Oil: Using a high-quality motorcycle-specific oil can help reduce oil consumption and protect the engine.

5. The Electrical Gremlins

Like any motorcycle, the XR650L can experience electrical issues.

  • Why It Happens: Vibration, corrosion, and age can all contribute to electrical problems.
  • Symptoms: Intermittent starting problems, flickering lights, dead battery, and other electrical malfunctions.
  • Solutions:
    • Check Connections: Inspect all electrical connections for corrosion or looseness. Clean and tighten them as needed.
    • Battery Maintenance: Keep the battery properly charged and maintained. Replace it if it's old or weak.
    • Wiring Inspection: Carefully inspect the wiring harness for damaged or frayed wires. Repair or replace any damaged wires.
    • Fuse Check: Check the fuses to ensure they are not blown. Replace any blown fuses with the correct amperage.
    • Regulator/Rectifier Issues: The regulator/rectifier can fail, leading to overcharging or undercharging of the battery. Test the regulator/rectifier to ensure it's functioning properly.

6. The Soft Suspension Setup

The stock suspension on the XR650L is generally considered to be soft, especially for aggressive off-road riding or heavier riders.

  • Why It Happens: The stock springs and damping are designed for a wide range of riders and riding conditions.
  • Symptoms: Excessive suspension dive under braking, poor handling in corners, and bottoming out on rough terrain.
  • Solutions:
    • Spring Upgrade: Replace the stock springs with stiffer springs that are appropriate for your weight and riding style.
    • Fork Oil Upgrade: Using a heavier weight fork oil can improve damping and reduce fork dive.
    • Aftermarket Cartridge Kits: For more advanced suspension performance, consider installing aftermarket cartridge kits in the forks. These kits provide adjustable damping and improved control.
    • Rear Shock Upgrade: Replace the stock rear shock with an aftermarket shock that offers adjustable damping and rebound.

7. The Weak Headlight

The stock headlight on the XR650L is notoriously weak, especially for night riding.

  • Why It Happens: The stock headlight uses a relatively low-wattage bulb.
  • Symptoms: Poor visibility at night.
  • Solutions:
    • Bulb Upgrade: Replace the stock bulb with a higher-wattage bulb. Be careful not to exceed the wiring harness's capacity.
    • LED Headlight: Upgrade to an LED headlight for brighter and more efficient lighting.
    • Auxiliary Lights: Install auxiliary lights for additional illumination.

Frequently Asked Questions

  • Q: Is the XR650L reliable? A: Yes, the XR650L is generally considered a very reliable motorcycle, known for its simple design and robust engine. With proper maintenance, it can last for many years and miles.

  • Q: How often should I change the oil on my XR650L? A: Honda recommends changing the oil every 2,000 miles or every six months, whichever comes first. More frequent oil changes are recommended for aggressive riding or dusty conditions.

  • Q: What is "Dave's Mods" for the XR650L? A: "Dave's Mods" refers to a series of carburetor modifications that improve the XR650L's performance by optimizing the air/fuel mixture. It typically involves adjusting the pilot jet, main jet, and needle.

  • Q: Can I ride the XR650L on the highway? A: Yes, the XR650L can be ridden on the highway, but it's not its ideal environment. The bike's single-cylinder engine and soft suspension can make it less comfortable for long highway trips.

  • Q: Is the XR650L good for beginners? A: The XR650L can be suitable for beginners with some off-road experience, but its tall seat height and weight can be challenging for some. It's best suited for riders who are comfortable with a larger motorcycle.

In Conclusion

While the Honda XR650L has its share of potential issues, these are generally well-documented and manageable. By understanding these common problems and taking preventative measures, you can ensure your XR650L provides years of reliable and enjoyable riding. Addressing the countershaft spline wear proactively is crucial for long-term reliability.