XJR650L aka XR650L over 35 mods - engine and chassis 

Keep it coming. I enjoyed seeing your mods. Especially the ones you machined yourself.

got one those pupies,must have with all the gear mods

I have a few more videos on the bike. Search my channel: robinsongguitars. I have a later video with over 50 mods. Now there are about 60 mods, give or take. I did put larger footpegs as shown in a later video. The snorkel and oil separator were removed before I bought the bike. I ran a short extension on the crankcase vent hose under the seat and installed a 5/8" Uni crankcase filter. This also required blocking off the hose nipple on the front side of the airbox to keep dirt out. Works great. Thank for the comment.

The countershaft can't be tapped as it is case hardened. I ended up machining a piece of SAE4130 steel with a knurl on the OD to slip inside the bore on the countershaft with about .030" clearance. Thread size is 3/8-16. This leaves enough wall thickness on the bushing. I cleaned everything well with acetone to remove all oils, etc, scored up the bore on the inside of the shaft with a Dremel to help hold the bushing in with JB Weld. NOTE: The bushing does not hold the sprocket on; it just is an anchor to hold the large cover with about .010" preload. The cover helps hold the moly grease on the splines and helps keep the sprocket face to run true.

Thankyou for the reply! I figured you found a way to tap it, and thought that was a great idea, ill look into what you did. eliminate play and help eliminate wear!

Yeah you’re right. Splitting cases is not on my bucket list. But I love the kickstarter

These sprockets seem to be good, although pricey. The only downside I can see is they are not reversible on the splines.

I am using a Pro-X piston which has a flat top instead of the OEM piston that is slightly dished. The Pro-X piston raises the compression by around 1 point. I also am using a full FMF exhaust. That is their Hi-Flo header (not Power Bomb) and Powercore 4 muffler. This increases the mid-range and top slightly, not to mention saving a few pounds. I am even running a Fritzco 16t countershaft sprocket on the street. It pulls 5th gear easily on the open road at about 60-65 with the 5th gear mod. When I dual sport the bike I run a 15t. I even did some pretty technical off road rides running 14/48 sprockets. Even with all the mods the bike is still a little heavy for serious technical off road riding. I exclusively use Fritzco sprockets as the splines are wider and save wear on the countershaft splines. I have also designed a cool sprocket mount that eliminates all axial play on the countershaft sprocket. I use a good moly grease on the splines to help eliminate wear. This is the same stuff you would use on CV joints. Check out my other entries on the same bike: over 50 mods, oil cooler, Acerbis 5.8 gallon tank. Thanks for posting.

Had an XRR. the E button is nice

Bet you don't even know what a clicker is...