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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 details.]


1995 Honda XR650L smog system
1. Remove smog pump and oil separator. Green: Two 10mm nuts allow removal of smog pump. Red: Smog pump Blue: Oil separator
XR650L with smog system removed
2. This is the goal. The finished product.
Front view of smog pump
3. Red: Remove these 5mm bolts then install the IMS block-off plates in there place. Blue: Front view of smog pump.
Smog block-off plate location
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.



Right-side smog block-off plate location
5. Red: Right smog block off plate. Remove 2 bolts and install blockoff plates reusing hardware. Blue: Left smog blockoff plate.
Right-front smog block-off plate location
6. Right-front smog block-off plate location. Photo taken from behind front wheel.
IMS Smog Block-Off Kit
7. IMS Smog Block-Off Kit.
Left-side smog tube
8. Remove metal smog tubes from front of head. Left side shown. T-handle allen wrench or socket is needed here.
Both bolts removed from left side of cylinder head
9. Both bolts removed from left side of head. Both sides must be unbolted to remove smog tubes.
The four allen-head bolts are removed
10. The four allen-head bolts are removed and the smog tubes are free from the head.
Smog tubes and air pump removed
11. Smog tubes and air pump removed. Remove 4 allen bolts and two 10mm nuts for the assembly.
Installation of the left-side smog block-off plate
12. Install the left-side smog block-off plate. I used hi-temp liquid gasket maker to seal it all up.
Smog pump bracket
13. This is the smog pump bracket located under the pump itself. Remove it by removing two 10mm bolts.
Right side smog block-off plate installed
14. Right side smog block-off plate installed.
Next is the removal of the charcoal canister
15. Removal of the oil separator. Smog pump hose will be shortened and attached to trany case.
Removal of the charcoal canister
16. To remove the oil separator, slide it up and off the metal mounting strap.
This is the transmission vent connection
17. Pull hose from oil separator and smog pump, cut to length, reattach, and run between trany vent and airbox.
Airbox vent hose connections
18. Red: Pull top airbox vent hose. Blue: Pull air box vent connector. Green: Insert large rubber plug in hole just created.
Large rubber plug inserted
19. Large rubber plug inserted.
Evaporative charcoal canister and hoses
20. The oil separator and all of its hoses detached.
Carb vent hoses
21. Carb vents may differ per year. Remove hose & plug T-connector. Remove smog pump from bike.
Close-up of hose at the T-connector
22. Close-up of other end of hose at the T-connector.
Cap from smog block-off kit installed
23. Rubber cap from smog block-off kit installed.
Vent hose routing
24. Vent hose routing. For option of leaving oil separator see pic 1, pic 2 and pic 3.
Vent hose connected at transmission
25. Close-up of vent hose connected at trany.
Removed smog equipment
26. Smog equipment and oil separator removed.
Smog equipment laid out
27. Smog equipment and oil separator laid out as it was on the bike.
XR650L with smog equipment removed
28. 1995 Honda XR650L with smog equipment and oil separator removed.

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.


Other Related Articles: 4Strokes.com Honda Technical: DIY Smog Block-Off for the XR650L


Related Forums Topic: Smog Removal Completed


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.

4Strokes.com Technical: Honda Related

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