Honda XR650R Suspension
HOME This page was put together to help the Owner of his wild bucking Oinker, to make BRP (Big Red Pig) into a lean smooth running squealer! Some like to do the work on their Bike to make it more theirs...Others to save Money or can't afford the killer prices of suspension shops...Some for the challenge.....
Start Here At This Page -> Shocks 101 KYB & Showa Service page
Good pages to show how to take the shock apart and back together !!!!
I weighed 190 pounds back when this page was made and I jumped on a regular basis
and
run the whoops as fast as I can till I can’t hold on any longer
and fly off.
Special needs I have; My Left wrist has been shattered. I have had five surgeries on it. The wrist corporal bones are fused and there is a screw through the wrist. The Ulna bone has been cut in the clear, leaving the wrist connected to the other bone only. So, the wrist free floats about an inch. This left me wanting a plush suspension to handle this. I want a pillow soft landing when coming off the 60’ table tops. The Whoops gave me fits no matter what I set the adjusters to at speeds any more then 30mph. I thought this bike was suppose to just fly through the whoops? They make it look so easy when to BRP is flying along the BAJA 1000! My bike has to be able to do that! I also don’t want to feel the 5’ drop offs when dropping off the side of a wash. The flash floods of the desert leave wide trenches that have 4~ 8’ walls that sneak up on you when your flying across where there are no trails. I have done my best to fix the twisting and yanking that goes on when fighting the rocks. This is very painful for the bad wrist. I have a Scotts steering Dampener and a Super Brace fork brace. I still hate the rocks. (The jagged 2’ ones that are all bunched together, the round ones are ok)
. I am using RaceTech Ultra Slick Suspension fluid ($24 a qt) right now but, I like the Maxima Light 75-390 3wt better for the money($8 a qt). It feels much plusher then stock and is 1/3rd the cost of RaceTech Ultra Slick.
Let all the Nitrogen out and remove bladder
Two
of the picture on getting the cap off and removing the bumper/
seal body didn’t turn out. Here are
some more picture and when I get the rest I’ll put more of this
together.
You need to drill a bleeder hole in the bumper/seal assembly. This part is talked about in the links above and here are some pictures.
Seal Head Shaft Seal
I put notches for the air to go to the hole. I drill the hole in the grove that the washer goes in. Chamfer the hole inside and outside. I put Synthetic grease on both sides of the base washer (real thin) and the lip of the seal. (inside and out)
Filling the shock with oil and getting all the air out can be a big messy job. I have a submersion tank but, that costs a lot of money to fill with oil for just one shock. My small tank has 4 gallons in it and at $10 a quart that is major $$$. I found an cheaper way for just doing your own shock. Use a traffic cone. Just cut the lip off the top of the cone and then again (real straight) about 12" down. Throw the bottom away. Now when you are ready to put the shock together slide the 12" of cone (small side first) on to the shock. I used a flat screw driver to help it on, it should be real tight. It should look like this:
Make sure it's the right height to still work and put your zip ty on. Fill the shock with oil till it's about 3" over full. Put the shaft in and work the air out of the valve. Let it sit and do it again many times till you are sure you have all the air out.
Just to share the shim stacks and a Gold Valve setup. Some of these shim setups are found in shocks that were taken apart from "Big Name Suspension Shops". With there special light trick oil. All stacks are starting at the valve and moving out. These are not just tables made up from Gold Valve charts or guessing but, hours of feed back from racers. Riders that compared Barnum's, Racetech, Precision Concepts, Baja Designs suspensions and have settled with one of these shim stacks to race with. I am limited to only a few and some only one of each of these shops setups. Most of what I have from other shops has become out dated as fast as I get it. PC uses 2.5wt fluid, RB uses 5wt, RT Uses 5wt, if you pay more they will use the US1 (that is 3~5 wt ultra slick), BD uses 5wt. (at least it was this way when I wrote this)
I get my shims from here: Race Tech
All are 12mm Shims
(# of shims this size) Thickness X Outside diameter
With the lighter fluid most riders would start with the adjusters set at Compression 16 and rebound 12 clicks out.
Shock Shim Setups
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Stock Setup 5wt oil |
Single Track & Super Plush This is the setup for everything from Duel Sport, Desert to Single track Maxima 3wt light fluid Stops bottoming about as good as stock
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Desert Racing, plusher then stock big rocks, big whoops, 4'+ drop offs, Racing 2.5wt or 3wt fluid
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Baja Racing, as plush as stock, Serious Racing 2.5wt or 3wt fluid |
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Rebound |
Rebound |
Rebound |
Rebound |
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(10) .25mm X 34mm |
(8) .25mm X 34mm |
(8) .25mm X 34mm |
(8) .25mm X 34mm |
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(1) .10mm X 28mm |
(1) .10mm X 28mm |
(1) .10mm X 28mm |
(1) .10mm X 28mm |
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(1) .30mm X 34mm |
(3) .25mm X 34mm |
(4) .25mm X 34mm |
(1) .25mm X 34mm |
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(1) .30mm X 32mm |
(1) .30mm X 34mm |
(1) .30mm X 34mm |
(1) .10mm X 24mm |
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(1) .30mm X 30mm |
(1) .30mm X 32mm |
(1) .30mm X 32mm |
(3) .25mm X 34mm or (4) |
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(1) .30mm X 28mm |
(1) .30mm X 30mm |
(1) .30mm X 30mm |
(1) .30mm X 34mm |
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(1) .30mm X 26mm |
(1) .30mm X 28mm |
(1) .30mm X 28mm |
(1) .30mm X 32mm |
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(1) .30mm X 24mm |
(1) .30mm X 26mm |
(1) .30mm X 26mm |
(1) .30mm X 30mm |
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(1) .30mm X 23mm |
(1) .30mm X 24mm |
(1) .30mm X 24mm |
(1) .30mm X 28mm |
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(1) .30mm X 23mm |
(1) .30mm X 23mm |
(1) .30mm X 26mm |
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(1) .30mm X 24mm |
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(1) .25mm X 23mm |
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(1) .25mm X 21mm |
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Compression |
Compression |
Compression |
Compression |
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(7) .20mm X 38mm |
(6) .20mm X 38mm |
(6) .20mm X 38mm |
(6) .20mm X 38mm |
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(1) .10mm X 32mm |
(1) .10mm X 32mm |
(1) .10mm X 32mm |
(1) .15mm X 26mm |
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(1) .10mm X 30mm |
(1) .10mm X 30mm |
(1) .20mm X 38mm |
(1) .20mm X 38mm |
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(1) .25mm X 38mm |
(1) .20mm X 38mm |
(1) .10mm X 30mm |
(1) .10mm X 30mm |
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(1) .25mm X 36mm |
(3) .25mm X 38mm |
(3) .25mm X 38mm |
(4) .25mm X 38mm |
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(1) .25mm X 34mm * |
(1) .25mm X 36mm |
(1) .25mm X 36mm |
(1) .25mm X 36mm |
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(1) .25mm X 32mm |
(1) .25mm X 32mm |
(1) .25mm X 32mm |
(1) .25mm X 32mm |
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(1) .25mm X 30mm |
(1) .25mm X 30mm |
(1) .25mm X 30mm |
(1) .25mm X 30mm |
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(1) .25mm X 28mm |
(1) .25mm X 28mm |
(1) .25mm X 28mm |
(1) .25mm X 28mm |
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(1) .25mm X 26mm |
(1) .25mm X 26mm |
(1) .25mm X 26mm |
(1) .25mm X 26mm |
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(1) .25mm X 24mm |
(1) .25mm X 24mm |
(1) .25mm X 24mm |
(1) .25mm X 24mm |
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(1) .25mm X 22mm |
(1) .25mm X 22mm |
(1) .25mm X 22mm |
(1) .25mm X 22mm |
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(1) .25mm X 21mm |
(1) .25mm X 21mm |
(1) .25mm X 20mm or 21mm |
(1) .25mm X 20mm or 21mm |
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(1) .70mm X 17mm** |
(1) .70mm X 17mm** |
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* Notice that this shims is removed from the compression stack and used in the rebound stack.
** not that important.
The most important thing that helps is to see what shims do what and wwhere you can compromise for your riding style. Your not using many different shims, some are just moved to a new place.
The nut that holds the shim/valve assembly onto the shaft must have a torque setting of 25 pounds and no more then 30 pounds.
Over the years from before the first 2000 XR650R hit the show room floor the ultimate suspension for the XR650R has been sot after. The first for the Late 1999 Baja Race had major dollar Titanium parts and special fork tubes, in the end most of it wasn't needed for the money it cost. Most technology was from KX500 and XR626~XR640cc 600's suspension and the slow growth away from that thinking to fit the new bike on the block. The weight being centered different and the slight different rake and tail, with the higher speeds through bigger, bad whoops made it apparent that "last years thinking" wasn't going to work. Killer Trophy trucks making mountainous whoops was killing the average Baja racer. Some haven't moved head fast enough or thinking, "good enough, is good enough" for the average Joe. Making it hard for the beginner Baja/desert racer get up to speed. Most of my first XR650R Suspensions were close to what I was thought for XR600's. Then I concentrated on the compression slow stack, not giving enough attention to the rebound. Clearing 60~70 feet was an issue, and the desire to clear the water at the Adelanto Grand Prix was a dream of mine. Seeing some XR650R with Barnum's and Baja Designs suspension setup for trail riders, totally suck in the whoops North of San Felipe made me try to tune closer to the real world needs of Baja Racing, again, still a little to stiff for most riders but, getting real close to what works in the high speed, haze of anything can happen. Coming back to the direction Precision concepts was going and going further away from XR's only and Barnum, I think I now have a suspension that can do most everything you can throw at it. The Baja 1000 setup has it's limits of extreme air time. Much more responsive to taming the rough chatter, and jagged rocks. Baja 500 setup is closer to a very aggressive race setup for the Baja 500 and Baja 250. The Baja 250 setup is a little to stiff to Race a long desert race and is made more for the guy that wants to jump his bike on the MX track now and then or out back with his friends and still do long hard trail rides. The desert setup is just that and is the best all around setup with my bike being a stiffer version of that. The Trail riding setups are for those that want the best ride possible being able to handle up to 4' drop offs, some small jumping, basically a plush ride that can do more then stock setup could ever dream of doing. I am sold on the thinner fluid that PC uses, I just use a different brand.
Cutting Stock Springs To Make them Stiffer! Click Here->Stiffer Springs
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FORK & SHOCK SPRING RATE GRAPH / APPLICATION & RIDER WEIGHT |
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I buy my springs at Lindemann
Engineering: 79405 Hwy 111 Ste 9-270
La Quinta, CA 92253 (909) 838-4587
They are fast and Honest about having the spring or not! I have found Some of the others are not or they rely on what the computer tells them and they don't have it.....then starts the three month wait!
I DO NOT agree with how stiff of the springs Lindemann Engineering recommends! Or how stiff Race Tech Recommends! It seems they use a computer program that is setup for the MX track. XR's Only and the others are right on the money. \\
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CR500 KYB Shock 46mm Gold Valve 2.5wt fluid My Bike |
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Rebound |
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(8) .25mm X 34mm |
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(1) .10mm X 28mm |
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(4) .30mm X 34mm |
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(1) .30mm X 32mm |
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(1) .30mm X 30mm |
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(1) .30mm X 28mm |
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(1) .30mm X 26mm |
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(1) .30mm X 24mm |
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(1) .30mm X 23mm |
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(1) .30mm X 21mm |
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(1) .25mm X 20mm |
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(1) .25mm X 18mm |
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Compression |
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(6) .20mm X 38mm |
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(1) .15mm X 26mm |
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(4) .20mm X 38mm |
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(1) .25mm X 38mm |
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(1) .25mm X 36mm |
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(1) .25mm X 32mm |
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(1) .25mm X 30mm |
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(1) .25mm X 28mm |
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(1) .25mm X 26mm |
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(1) .25mm X 24mm |
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(1) .25mm X 22mm |
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(1) .25mm X 18mm |
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(1) .40mm X 16mm |
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Stock Setup 5wt oil |
Gold Valve 5wt oil (BD) |
Bike form another Shop (5wt oil) RB |
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Rebound |
Rebound |
Rebound |
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(10) .25mm X 34mm |
(4) .30mm X 34mm |
(7) .25mm X 34mm |
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(1) .10mm X 28mm |
(1) .20mm X 34mm |
(1) .10mm X 28mm |
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(1) .30mm X 34mm |
(1) .10mm X 25mm |
(1) .10mm X 24mm |
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(1) .30mm X 32mm |
(7) .30mm X 34mm |
(1) .25mm X 34mm |
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(1) .30mm X 30mm |
(1) .25mm X.30mm |
(1) .10mm X 28mm |
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(1) .30mm X 28mm |
(1) .25mm X.30mm |
(1) .30mm X 34mm |
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(1) .30mm X 26mm |
(1) .25mm X 28mm |
(1) .30mm X 32mm |
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(1) .30mm X 24mm |
(1) .25mm X 26mm |
(1) .30mm X 30mm |
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(1) .30mm X 23mm |
(1) .25mm X 24mm |
(1) .30mm X 28mm |
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(1) .30mm X 26mm |
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(1) .30mm X 24mm |
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(1) .30mm X 23mm |
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Compression |
Compression |
Compression |
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(7) .20mm X 38mm |
(4) .20mm X 38mm |
(3) .20mm X 38mm |
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(1) .10mm X 32mm |
(2) .25mm X 38mm |
(1) .10mm X 32mm |
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(1) .10mm X 30mm |
(1) .15mm X 26mm |
(1) .10mm X 30mm |
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(1) .25mm X 38mm |
(1) .25mm X 38mm |
(3) .20mm X 38mm |
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(1) .25mm X 36mm |
(1) .25mm X 36mm |
(1) .25mm X 38mm |
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(1) .25mm X 34mm |
(1) .25mm X 34mm |
(1) .25mm X 36mm |
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(1) .25mm X 32mm |
(1) .25mm X 30mm |
(1) .25mm X 34mm |
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(1) .25mm X 30mm |
(1) .25mm X 28mm |
(1) .25mm X 32mm |
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(1) .25mm X 28mm |
(1) .25mm X 26mm |
(1) .25mm X 30mm |
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(1) .25mm X 26mm |
(1) .25mm X 24mm |
(1) .25mm X 28mm |
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(1) .25mm X 24mm |
(1) .25mm X 20mm |
(1) .25mm X 26mm |
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(1) .25mm X 22mm |
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(1) .25mm X 24mm |
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(1) .25mm X 22mm |
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(1) .20mm X 20mm |
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(1) .20mm X 18mm |
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CR500 KYB 46mm Valve shock (Stock XR650R uses 44mm Valve). Remember to use the CR500 cap and seal head assembly, Use the XR650R rod.
