The Honda XR650L is famously durable, simple and capable—but that doesn’t mean it cannot be improved.
My 2012 XR650L remains remarkably close to its original factory specification. However, a handful of carefully selected upgrades can make this old-school dual-sport motorcycle more comfortable, practical and enjoyable to ride.
For this edition of The Garage Report, I take you through five basic modifications every Honda XR650L owner should consider.
Watch the complete Garage Report:
Improving My Honda XR650L
Modifying a motorcycle doesn’t always mean chasing maximum horsepower or replacing every factory component.
The most worthwhile upgrades often address the small frustrations encountered every time the motorcycle is ridden.
On the XR650L, the standard handlebar position can feel low when standing, the original rear-light assembly is bulky, the paper air filter is inconvenient to carry as a spare, and the narrow foot pegs provide limited support.
The standard exhaust system is also heavy and restricts some of the character I expect from a large-capacity single-cylinder motorcycle.
These five upgrades focus on making my XR650L more comfortable and manageable without compromising the simplicity that makes it so appealing.
1. Fit Handlebar Risers
The first modification I recommend is a set of handlebar risers.
The standard XR650L handlebar sits relatively low, which may be acceptable when riding seated but becomes more noticeable when standing through technical terrain.
A low handlebar can force taller riders to bend forward excessively. This places additional strain on the rider’s arms, shoulders and lower back while making it more difficult to maintain a relaxed standing position.
I fitted a small 25 mm riser to my motorcycle.
That modest increase lifts the handlebar out of my lap and creates a more natural position when standing. It also provides slightly more space to move around the motorcycle during technical off-road riding.
Handlebar risers can improve:
- Standing comfort
- Control through technical terrain
- Rider posture
- Weight distribution
- Leverage over the front wheel
- Confidence during longer off-road sections
The correct riser height will depend on the rider’s height, riding position and preferences.
Fitting excessively tall risers can affect the motorcycle’s steering feel and place unnecessary tension on the cables and brake hose. Before installation, owners should confirm that the throttle cables, clutch cable, wiring and front brake hose retain sufficient movement throughout the steering range.
For my XR650L, the 25 mm riser provides a useful improvement without creating an excessively tall or unnatural handlebar position.
2. Replace the Bulky Rear-Light Assembly
The second modification is a smaller rear-light and number-plate assembly.
Honda’s original rear-light unit is large, heavy-looking and visually dated. It may be functional, but it extends considerably from the rear mudguard and makes the back of the motorcycle appear unnecessarily bulky.
A compact tail-tidy conversion immediately cleans up the XR650L’s appearance.
My setup uses:
- A smaller rear light
- A compact number plate
- A tidier rear-mudguard arrangement
- White illumination for the number plate
The result is a cleaner and more modern-looking rear end without removing the essential lighting required for road use.
Number-plate illumination is particularly important. A small rear light should still include a white downward-facing light—or be paired with a separate plate light—so the registration plate remains visible at night.
Owners should also ensure that the rear light and number plate remain securely mounted. The XR650L is designed to operate over rough terrain, where vibration and repeated impacts can loosen poorly fitted brackets.
A tail tidy may primarily be a cosmetic upgrade, but it also removes some of the unnecessary bulk from the back of the motorcycle.
3. Upgrade the Air Filter
The factory XR650L uses a paper air filter housed within a relatively bulky metal structure.
Paper filters can work perfectly well for normal road use, but riders who regularly travel through dust or carry spare filters may prefer a more traditional off-road-style alternative.
I opted for a compact enduro-style foam air filter.
The smaller filter is easier to carry as a spare and better suited to the practical requirements of trail and adventure riding. If the filter becomes excessively dirty during a longer trip, having a compact replacement packed with my luggage can be useful.
A suitable aftermarket air filter can provide several benefits:
- A more compact design
- Easier storage as a spare
- Better suitability for dusty riding
- Simple cleaning and servicing
- Reusability when maintained correctly
Air-filter maintenance is critical on any motorcycle used in dusty conditions.
Fine dust entering the engine can accelerate wear to the piston, cylinder and valve train. I therefore inspect the filter regularly, clean it using the correct products and apply suitable filter oil where required.
The filter must also seal correctly against the airbox. Increased airflow means very little if dust can bypass the filter through an incorrectly fitted sealing surface.
This is a simple upgrade, but it makes my XR650L easier to maintain when it is used as intended.
4. Install a Larger Header and Lighter Silencer
The fourth modification is an upgraded exhaust system.
The factory XR650L header pipe has an internal diameter of approximately 29 mm. A larger aftermarket header can increase that diameter to around 35 mm, allowing the engine to breathe more freely.
Pairing the larger header with a less restrictive silencer may improve throttle response and give the motorcycle a deeper, more appropriate exhaust note.
The objective isn’t to make the XR650L unnecessarily loud.
A large single-cylinder motorcycle should have some character, but the exhaust still needs to remain tolerable during longer rides and considerate of other road and trail users.
One of the clearest advantages is the potential weight reduction.
The standard silencer weighed approximately 2.9 kg, while the aftermarket unit weighed around 1.7 kg. Replacing the original component would therefore remove approximately 1.2 kg from my motorcycle.
That is a meaningful saving from a single component—particularly because the silencer is positioned relatively high on the bike.
Reducing weight higher up can help the motorcycle feel easier to manage when changing direction, riding slowly or recovering from a loss of balance.
An aftermarket exhaust may offer:
- A potential reduction of approximately 1.2 kg
- A deeper exhaust note
- Improved exhaust flow
- Sharper throttle response
- Less visual bulk
- Greater engine character
However, replacing the exhaust should not be treated as an isolated modification.
Exhaust Changes May Require Rejetting
Many XR650L owners believe the motorcycle is set relatively lean from the factory.
Installing a larger header, freer-flowing silencer and less restrictive air filter changes the amount of air moving through the engine. The standard carburettor jetting may no longer provide the correct fuel mixture after those changes.
Running excessively lean can cause:
- Increased engine temperature
- Hesitation or surging
- Poor throttle response
- Popping during deceleration
- Difficult starting
- Potential long-term engine damage
I would therefore consider increasing the carburettor jet sizes when fitting a freer-flowing intake and exhaust system.
There is no universal jetting specification that will suit every motorcycle. The correct setup depends on the exhaust, air filter, altitude, temperature and condition of the engine.
In South Africa, altitude is particularly relevant. A motorcycle operating in Gauteng may require a different carburettor setup from one used primarily at sea level.
The safest approach is to have the air-fuel mixture checked and the carburettor tuned for the motorcycle’s actual configuration and riding environment.
5. Fit Wider Foot Pegs
The final recommendation—and the most noticeable comfort upgrade I made—is a set of wider foot pegs.
The original XR650L foot pegs are narrow and provide a relatively small platform beneath my boots.
That becomes uncomfortable during longer rides and particularly noticeable when standing for extended periods. A small peg concentrates the rider’s weight across a narrow section of the foot, which can create pressure and fatigue.
The wider aftermarket pegs fitted to my motorcycle provide a substantially larger contact area.
This improves:
- Standing comfort
- Boot support
- Stability over rough terrain
- Control during braking and acceleration
- Confidence when shifting body weight
- Grip in wet or muddy conditions
A wider peg distributes my weight more evenly and provides a stronger platform from which to control the motorcycle.
The difference is immediately visible when the factory and aftermarket components are placed alongside each other.
For riders who regularly use the XR650L off-road, wider foot pegs may deliver the greatest day-to-day improvement of all five modifications.
They don’t add power or dramatically change the motorcycle’s appearance, but they improve the connection between rider and bike every time I stand.
Which XR650L Modification Should You Do First?
The correct order will depend on how the motorcycle is used.
For riders who spend considerable time standing on gravel roads or technical trails, handlebar risers and wider foot pegs should be the priorities. Together, they can transform the standing riding position and reduce fatigue.
Owners focused on appearance may begin with the smaller rear-light assembly.
Riders planning dusty adventures may get the most value from the compact foam air filter, while those wanting reduced weight and additional engine character may prefer to begin with the header and silencer.
My suggested upgrade order would be:
- Wider foot pegs
- Handlebar risers
- Air-filter upgrade
- Tail tidy and compact rear light
- Header, silencer and appropriate carburettor tuning
I place the ergonomic upgrades first because they improve the motorcycle without affecting engine reliability or requiring additional tuning.
The exhaust modification should be approached as a complete intake, fuelling and exhaust package rather than simply fitting the loudest available silencer.
Keep Reliability at the Centre of Every Modification
The XR650L’s greatest strength is its mechanical simplicity and proven reliability.
I want every upgrade to preserve those qualities.
Poorly manufactured accessories, incorrect carburettor tuning and badly routed cables can create problems that were not present on the standard motorcycle.
Before fitting a modification, I consider:
- Whether it solves a genuine problem
- Whether it affects another system
- Whether replacement parts remain available
- Whether it can withstand off-road vibration
- Whether it remains legal for road use
- Whether the motorcycle can easily be returned to standard
The best XR650L build is not necessarily the one with the longest accessory list.
It is the motorcycle that has been modified thoughtfully for its rider and intended use.
Final Thoughts
My Honda XR650L doesn’t require extensive modification to become a more comfortable and practical motorcycle.
Five relatively straightforward upgrades can address some of its most noticeable weaknesses:
- A 25 mm handlebar riser improves my standing position
- A compact rear light cleans up the bulky tail
- An enduro-style foam filter is easier to maintain and carry
- A larger header and lighter silencer can reduce weight and improve character
- Wider foot pegs provide substantially better comfort and control
Of the five, the wider foot pegs produced the most noticeable improvement in everyday comfort.
The exhaust offers the largest measurable weight saving. Replacing the standard silencer with the aftermarket example shown reduces the motorcycle’s mass by approximately 1.2 kg.
The important thing is to modify the motorcycle according to how it is genuinely used.
I started with comfort and control, preserved the XR650L’s reliability and made one considered improvement at a time.
Watch the complete Garage Report, subscribe to the Torque & Throttle Motorcycle Co YouTube channel, and join me for more practical motorcycle maintenance and modification features.
