backofbeyond thanks for the info on the Chris Scott site, I found it very useful.

Molly what do you mean "re-do the battery box" are you referring to structurally reinforcing this or relocating it elsewhere?

Both options have been done on the XR-L. A California company called Baja Designs used to produce (may still produce?) various things for the XR-L. One of the "kits" was a new, stronger battery box. But I also heard of owners re-locating the battery as well but never saw this in person. It would be a BIG JOB as so much of the key electronics are based around the current battery box location.

Best to simply reinforce it. Not a big deal. But the rear sub frame is more a concern if running panniers or a tail bag. Mine bent, but did not break and I carried at most a 15 lbs. bag on the rear rack. But DID ride in HORRENDOUS terrain at full speed. (I was much younger and braver then!)

Many other guys I rode with broke sub frames but not much else broke on the bike. A few did wear out top ends from running low on oil. That Honda radial valve head is NOT one of Honda's better designs. But with a cooler and good oil I'm betting it would hold up to tough use.

Thanks molly. It's a little concerning regarding the sub frames. How much bracing do you think is required to make it up to the job. I did see some no welding bolt on kit to reinforce it - anyone know if these are any good?

Where did you take your bike molly? Sounds like it did some serious adventure. What sort of mileage range did you get out of a tank if ridden hard offroad?

Me and my XR-L did limited "adventures". Only one 1500 mile Baja trip and several organized dual sport rides here in California and Nevada and some street riding and commuting.

I struggled with Carb jetting on my XR-L so fuel economy was never great, around 42 to 45 MPG (US gallon). This was my fault, not the Honda's.

The bike was VERY TALL for me as well. (38" seat height I believe) It was a pretty good road bike and one of the best of 650's off road if set up correctly. (mine was not)

Somehow I fell out of love with it ... sold it after just a year from new. I was still racing two strokes then ... so the XR-L felt heavy by comparison, and I fell down a lot riding it. I rarely fall, even on race bikes. So never did any extended travels on the bike beyond Baja and local riding, never "bonded" with the bike, but MANY DO ... and many get them going really well. Remember, my experience was back in 1993 or so.

Reinforcing sub frame is quite basic and most good welders/fabricators can do the job in a few hours work. Search for threads on ADV Rider on XRL 650 builds. Some have documented this.

.... is the way to go. Same rolling chasis as the xr600 with a more tractable engine and road going niceties.
Did nearly 5,000 in North America on one and perfect for the job. A friend did the same on a DR 650 and followed me with green eyes for hundreds of miles in the dirt.
The only problem is getting a decent one now.

....... 700 miles in one day was the longest days..... not a problem with a Corbin seat and big acerbis tank

I've had a few XT600's. I now own a XR650L

The 650L is better in most ways apart from it's weak subframe. That's fixed with 30 mins welding or bolt on braces. Easy fix.

The XR650L suspension is worlds better than the cheap junk on the XT600E. But with that you have to get along with a very tall seat height. It's a real off-road capable bike. The XT is not...

The XR has DID Alloy rims where the XT has Chrome steel junk.

The 650 shares the same engine with the Dommie so spares are easy but it does have a shorter gear box. Not massively different though. I put a Dommie engine in mine as I had a spare.

The 650 also has that extra 50cc. And you can feel it. It can tour at 70 mph as the XT is a 60 mph machine.

As far as reliability goes, the Yamaha edges it if you get a later one with the truly indestructible 4PT engine. The Honda 650 is a very very good engine but it is sensitive to bad people who don't check it's oil. And yes, it can run a little hot but unless you're spinning the back wheel in sand dunes all day , it won't effect you. Put a cooler plug in it or fit an oil cooler.

If I had to choose one for a 'Forever' bike, it would be the XR650L by a long way.

A nice XR650L is Europe is VERY rare though. They appear on Ebay from time to time and mostly they have been abused to hell and need a lot of work.

I've had four of them as I restore and sell them.

__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

Great comments on the XR650L Ted!
The Honda suspension is quite heavy duty, good 43mm forks ... but it's not exactly plush. Some riders have had front and back re-valved for plushness. Worth it if going off road. Original XR650L was set up as a sort of high speed Desert racer, not great on tight, slow, technical trails. So the suspension mods help if this is your planned use.

The bike is VERY TALL ... like KTM 640 tall ... mine was hard for me at 5'6". When you add big tank (Acerbis, IMS or Safari) it can feel top heavy for a short rider. Wide Pegs are a nice addition.

In Northern EU overheating not a problem, but as you say, in truly HOT conditions it can be an issue. IMO, the key is using really good synthetic oil.
An Oil Cooler would be on my list. Cranking in hard in deep sand, you MUST let it cool down once in a while. Also, some add extended cooling fins to help cooling.

High speed riding keep an eye on oil level ... will naturally drop a bit. No big deal. Check it at fuel stops. Don't over fill it ... many do this.

The oil checking routine on the Honda is weird, many get it wrong. Engine must be 100% hot to get an accurate reading. All XL's, XR's and the XR-L have this issue with the oil in frame set up.

One thing not mentioned is battery box and how it's hung off the left side panel of the bike. Most electronics here as well. In rough riding I've seen them BREAK OFF, and left hanging. Not good. Baja Designs used to make a kit to strengthen the box, no longer. So, figure a way to make it stronger.

Everything else is Honda quality, good electrics/charging, DID Alu wheels,
Nissin brakes.

Sorry guys I love my 34L xt600 Tenere as standard it has the 30L tank and a small oil cooler, the seat is shorter with extra padding for long days in the seat, the luggage space is bigger with having shorter seat, the hight is perfect for 5.6 and its three times cheaper than the xr650, the xt you can travel the world straight out of the tin with the xr650 you have to make mods that cost as much as a nice Tenere.