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XR650L Smog System Removal

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4Strokes
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XR650L Smog System Removal

Postby 4Strokes » Fri May 13, 2016 11:37 am

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 in the airbox, and a fair amount depending on how hard the bike is ridden. See procedure 24 for details.

Colored text corresponds to that color text in the photo.

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Smog Pump & Oil Separator
1) Remove smog pump and oil separator. Two 10mm nuts allow removal of smog pump. Smog pump. Oil separator.

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Smog Equipment Removed
2) This is the goal. The finished product with all smog equipment removed.

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Remove 5mm Bolts
3) Remove these 5mm bolts then install the IMS block-off plates in there place. Front view of smog pump.

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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.

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Right Smog Block-Off Plate
5) Right smog block off plate. Remove 2 bolts and install blockoff plates reusing hardware. Left smog blockoff plate.

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Right-Front Smog Block-Off Plate
6) Right-front smog block-off plate location. Photo taken from behind front wheel.

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IMS Smog Block-Off Kit
7) IMS Smog Block-Off Kit.

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Smog Tube Removal
8) Remove metal smog tubes from front of head. Left side shown. T-handle allen wrench or socket is needed here.

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Smog Tube Bolts Removed
9) Both bolts removed from left side of head. Both sides must be unbolted to remove smog tubes.

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Smog Tube Free of Head
10) The four allen-head bolts are removed and the smog tubes are free from the head.

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Smog Tubes & Air Pump
11) Smog tubes and air pump removed. Remove 4 allen bolts and two 10mm nuts for the assembly.

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Installing IMS Block-Off Plate
12) Install the left-side smog block-off plate. I used hi-temp liquid gasket maker to seal it all up.

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Smog Pump Bracket
13) This is the smog pump bracket located under the pump itself. Remove it by removing two 10mm bolts.

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Right-Side Block-Off Plate
14) Right side smog block-off plate installed.

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What it Should Look Like
15) Removal of the oil separator. Smog pump hose will be shortened and attached to trany case.

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Slide Oil Separator Up
16) To remove the oil separator, slide it up and off the metal mounting strap.

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Transmission Vent
17) Pull hose from oil separator and smog pump, cut to length, reattach, and run between trany vent and airbox.

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Airbox Vent Hose
18) Pull top airbox vent hose. Pull air box vent connector. Insert large rubber plug in hole just created.

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Airbox Vent Plug
19) Large rubber plug inserted.

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Oil Separator
20) The oil separator and all of its hoses detached.

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Carb Vent Hoses
21) Carb vents may differ per year. Remove hose and plug T-connector. Remove smog pump from bike.

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Carb Vent Hose
22) Close-up of other end of hose at the T-connector.

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