Brakes (all models)

Specifications
Disc brakes
Brake fluid type Dot 4
Brake pad minimum thickness 2 mm (0.08 inch)
Front disc thickness
XL600R, XR600R
1983 through 1987
Standard 3.5 mm (0.14 inch)
Limit 3.0 mm (0.12 inch)*
1988 and later models
Standard 3.0 mm (0.12 inch)
Limit 2.5 mm (0.10 inch)*
XR650L
Standard 4.0 mm (0.16 inch)
Limit 3.5 mm (0.14 inch)
XR650R
All except Australian models
Standard 2.8 to 3.2 mm (0.11 to 0.13 inch)
Limit 2.5 mm (0.10 inch)
Australian models
Standard 3.3 to 3.7 mm (0.13 to 0.15 inch)
Limit 3.0 mm (0 .12 inch)
Rear disc thickness
XL600R, XR600R
Standard 4.5 mm (0.18 inch)
Limit : 4.0 mm (0.16 inch)*
XR650L
Standard 5.0 mm (0.20 inch)
Limit 4.0 mm (0.16 inch)
XR650R
All except Australian models
Standard 3.8 to 4.2 mm (0.15 to 0.17 inch)
Limit 3.5 mm (0.14 inch)
Australian models
Standard 4.3 to 4.7 mm (0.17 to 0.19 inch)
Limit 4.0 mm (0.16 inch)
Disc runout limit
XL600R, XR600R
Front 0.30 mm (0.012 inch)
Rear 0.15 mm (0 .006 inch)
XR650L
Front 0.30 mm (0 .012 inch)
Rear 0.40 mm (0.020 inch)
XR650R
Front 0.20 mm (0.008 inch)
Rear 0.30 mm (0.012 inch)
Drum brakes
Brake lining minimum thickness
Brake pedal height
Drum diameter
XL600R
Standard 130 mm (5.12 inches)
Wear limit 131 mm (5.16 inches)*
XR600R
Standard 110 mm (4.33 inches)
Limit 111 mm (4.37 inches)*
*Refer to marks cast into the drum (they supersede information printed here)

 

Brake Lever, Brake Pedal, Clutch Lever, Brake Switch, Freeplay, Choke Stroke (all models)

Rear brake shoe lining thickness limit 2 mm (0.08 inch)
Front brake lever freeplay
XL600R, 1985 XR600R See text (Section 4)
1986 and 1987 XR600R 1 to 8 mm (1/8 to 5/16 inch)
1988 and later XR600R 0.6 to 8.0 mm (1/32 to 5/161nch)
XR650L Not specified
XR650R 10 to 20 mm (3/8 to 3/4 inch)
Rear brake pedal freeplay (drum brake models) 20 to 30 mm (3/4 to 1-1/4 inch)
Rear master cylinder pushrod length (disc brake models)
XR600R, XR650L 71 mm (2.8 inch)
XR650R 68 mm (2.68 inch)
Rear brake light switch adjustment
XL600R 10 mm (3/8 inch)
XR650L Not available
Clutch lever freeplay 10 to 20 mm (3/8 to 3/4 1nch)
Throttle grip free play 2 to 6 mm (3/32 to 1/4 inch)
Choke valve stroke (XL600R) 5 to 7 mm (3/16 to 9/32 inch)
Decompressor freeplay
XL600R
1983 through 1987
Kickstarter decompressor 1 to 3 mm (1/32 to 1/8 inch)
Manual decompressor 1 to 2 mm (1/32 to 3/32 inch)
XR600R
1985 through 1987
Kickstarter decompressor 1 to 2 mm (1/32 to 3/32 inch)
Manual decompressor 5 to 8 mm (3/16 to 5/16 inch)
1988 on (manual) 5 to 8 mm (3/16 to 5/16 inch)
XR650L Not adjustable
XR650R 5 to 8 mm (3/16 to 5/16 inch)
Minimum tire tread depth
Dual-sport models (XL600R, XR650L) 3 mm (1/8 inch)
Off-road models (XR600R, XR650R) Not specified