Adapting aluminum to the XR frame meant rethinking chassis architecture from the steering head to the drive chain adjusters.

Wrapped around the 650 single, a twin-spar frame layout (similar to the CR's frame) would have made the XR too wide between the rider's knees, and leave too little room to accommodate the 2.6-gallon plastic fuel tank. Instead, XR engineers created a single-backbone design to keep the bike slim between the rider's knees for a roomy ergonomic profile and ample maintenance access.

In designing the XR650R chassis, Honda engineers exploited aluminum's inherent tunability, varying the size and shape of key frame components to build a rigid structure that puts precise amounts of bump-absorbing flex exactly where it's needed.

Convex outer faces on the main backbone build in extra rigidity. Running the swingarm pivot through the crankcase, rather than behind it, reduces flex. The tapered, CR-style closed-end aluminum swingarm mirrors the rest of the tuned-flex chassis character, continuously varying wall thickness throughout its length.

SUSPENSION

Fork improvements include a 25-percent-greater cartridge diameter than the XR600R unit, and the XR650's 46mm Kayaba (KYB) fork is adjustable for compression and rebound damping, providing 11.2 inches of travel. Less slider below the axle means less metal to get hung up on rocks and ruts. Increasing slider diameter above and below the new l7mm front axle, delivers extra rigidity, to make things like steering out of a rut much easier.

Changes are major at the rear end. Working through a new, more rigid Delta-type Pro-Link system, the KYB shock carries a piggyback-style remote reservoir on its left side, to make adjustments easier. Shock shaft diameter is increased 2mm beyond XR600R specs, and greater shock stroke increases rear wheel travel to 12.1 inches. Lightweight aluminum rims at both ends are laced to smaller, lighter hubs, via straight-pull spokes. The net result is a stronger wheel, less unsprung weight and less time spent tightening spokes.

That removable subframe is also aluminum, and the main frame incorporates an engine oil tank with an easy-to-use dipstick.

Tapered-roller steering head bearings maintain precise steering action and are low maintenance.

Twin-piston front and single-piston rear calipers squeeze large, 240mm stainless steel rotors for excellent stopping power. A CR250R motocross front master cylinder handles the braake fluid.

• Comfortable seat allows easy rider movement.
• Large fenders should keep mud off your riding gear.
• Enduro-style headlight and taillight.
• There. s an integrated headlight/number-plate.
• Neat item: a one-piece high-impact plastic skidplate protects the engine cases, water pump and hoses.
• The XR650 has a resettable, easy-to-read, three-digit odometer.
• High-quality controls include those great Honda grips and dogleg levers with brush guards.
• The manual compression-release lever is mounted on top of clutch lever, where it won't jam your thumb.
• Aluminum shift lever has a folding tip and the brake pedal is also aluminum.
• Another nice touch is the easy access foam air filter.
• Naturally, the 650 has a USDA-qualified spark arrestor/muffler to keep the tree police happy.
• Believe it or not, the bike comes with a transferable six-month limited warranty.
• Ownership also ncludes a one-year complimentary Membership in the Honda Rider's Club of America. Benefits include discounts, travel benefits, roadside assistance.

• Optional competition parts, including intake manifold, carburetor jets, muffler insert, are avaiable from dealers.