XR650L Smog and Oil Separator Removal on 4Strokes.com
4Strokes.com Honda Technical: XR650L Smog & Oil Separator
Removal by Gary Crawford
I used info from 4Strokes.com and instructions from an IMS Smog
Block-Off Kit to remove the smog equipment and oil separator from my '95 XR650L.
I took the following pictures and made notes. Hope it helps you! [Note: Removing
the oil separator is optional. If removed you may see oil, and a fair amount
depending on how hard the bike is ridden, in the airbox. See procedure 24 for
1. Remove smog pump and oil separator. Green:
Two 10mm nuts allow removal of smog pump. Red:
Smog pump Blue: Oil separator
2. This is the goal. The finished product.
3. Red: Remove these 5mm
bolts then install the IMS block-off plates in there place. Blue:
Front view of smog pump.
4. Remove allen bolts and pull tubing from each side
of head. Install 2 blockoff plates reusing hardware. I put liquid
gasket on plates before installing them.
5. Red: Right smog block
off plate. Remove 2 bolts and install blockoff plates reusing hardware.
Blue: Left smog blockoff plate.
6. Right-front smog block-off plate location. Photo
taken from behind front wheel.
7. IMS Smog Block-Off Kit.
8. Remove metal smog tubes from front of head. Left
side shown. T-handle allen wrench or socket is needed here.
9. Both bolts removed from left side of head. Both
sides must be unbolted to remove smog tubes.
10. The four allen-head bolts are removed and the smog
tubes are free from the head.
11. Smog tubes and air pump removed. Remove 4 allen
bolts and two 10mm nuts for the assembly.
12. Install the left-side smog block-off plate. I used
hi-temp liquid gasket maker to seal it all up.
13. This is the smog pump bracket located under the
pump itself. Remove it by removing two 10mm bolts.
14. Right side smog block-off plate installed.
15. Removal of the oil separator. Smog pump hose will
be shortened and attached to trany case.
16. To remove the oil separator, slide it up and off
the metal mounting strap.
17. Pull hose from oil separator and smog pump, cut
to length, reattach, and run between trany vent and airbox.
18. Red: Pull top airbox
vent hose. Blue: Pull air box vent connector.
Green: Insert large rubber plug in hole
19. Large rubber plug inserted.
20. The oil separator and all of its hoses detached.
21. Carb vents may differ per year. Remove hose &
plug T-connector. Remove smog pump from bike.
22. Close-up of other end of hose at the T-connector.
23. Rubber cap from smog block-off kit installed.
24. Vent hose routing. For option of leaving oil separator
see pic 1, pic
2 and pic 3.
25. Close-up of vent hose connected at trany.
26. Smog equipment and oil separator removed.
27. Smog equipment and oil separator laid out as it
was on the bike.
28. 1995 Honda XR650L with smog equipment and oil separator
What an improvement! Looks like a engine now! I noticed less popping
on deceleration but it has not gone away. I also notice the power seems to come
on smoother now. There is obviously some weight savings as well. I would also
think the engine may run a little cooler due to the increased airflow around
the head with all the tubes, hoses and pump removed.
Other Models: This is what worked on my 1995 Honda XR650L. Yours
may differ slightly with respect to the carb vent hoses. Some models have four
vent hoses, a diaphragm mounted to the frame on the left side, oil vent filter
housing, and/or possibly a fuel vapor canister. The smog block-off kit instructions
said the diaphragm and oil separator can also be removed.
Credits: Article written and submitted by Gary Crawford; Special
thanks to Dave Closs for taking the time to notify us of incorrect use of terms:
"charcoal canister" and "evaporative canister" replaced
with "oil separator" in addition to the 'oil separator removal' being
optional. Final article and images edited by 4Strokes.com.
Disclaimer: The instructions above are for informational
purposes only. There is no guarantee that you or your bike will not endure damage
or injury by using the above information. As with any modification, proceed
at your own risk.