Engine Inspection – Liquid Cooled: XR650R XL650R

General
Bore 100.0 mm (3.94 inches)
Stroke 82.6 mm (3.25 inches)
Displacement 649 cc (39.6 cubic inches)
Cylinder compression
Decompresser applied 600 kPa (87 psi) at 400 rpm
Decompresser not applied 1, 100 kPa (160 psi) at 400 rpm
Rocker arms
Rocker arm inside diameter
Standard 14.000 to 14.018 mm (0 .5512 to 0.5519 inch)
Limit 14.05 mm (0 .553 inch)
Rocker shaft outside diameter
Standard 13.966 to 13.984 mm (0.5498 to 0.5506 inch)
Limit 13.91 mm (0.548 inch)
Shaft-to-arm clearance
Standard O.016 to 0.052 mm (0.0006 to 0.0020 inch)
Limit 0.14 mm (0.006 inch)
Camshaft
Lobe height
Intake
Standard 41.158 to 41.398 mm (1 .6024 to 1.6298 inches)
Limit 41.00 mm (1 .614 inches)
Exhaust
Standard 41.196 to 41.436 mm (1.6219 to 1.6313 inches)
Limit 41.05 mm (1.616 inches)
Journal diameter Not specified
Camshaft runout limit 0.03 mm (0.001 inch)
Cylinder head, valves and valve springs
Cylinder head warpage limit 0.10 mm (0.004 inch)
Valve stem runout Not specified
Valve stem diameter
Intake
Standard 6.575 to 6.590 mm (0.2589 to 0.2594 inch)
Limit 6.56 mm (0.258 inch)
Exhaust
Standard 6.555 to 6.570 mm (0.2581 to 0.2587 inch)
Limit 6.55 mm (0 .258 inch)
Valve guide inside diameter (intake and exhaust)
Standard 6.600 to 6.615 mm (0.2589 to 0.2604 inch)
Limit 6.63 mm (0.261 inch)
Stem-to-guide clearance
Intake
Standard 0.010 to 0.040 mm (0.0004 to 0.0016 inch)
Limit Not specified
Exhaust
Standard 0.030 to 0.060 mm (0.0012 to 0.0024 inch)
Limit Not specified
Valve guide projection from cylinder head (intake and exhaust) 16.3 to 16.5 mm (0.64 to 0.65 inch)
Valve seat width
Intake
Standard 1.1 to 1.3 mm (0.04 to 0.05 inch)
Limit 2.0 mm (0.08 inch)
Exhaust
Standard 1.3 to 1.5 mm (0.05 to 0.06 inch)
Limit 2.0 mm (0.08 inch)
Valve face width Not specified
Valve spring free length
Inner spring
Standard 44.0 mm (1 .73 inches)
Limit 43.0 mm (1.69 inches)
Outer spring
Standard 45.2 mm (1. 78 inches)
Limit 44.2 mm (1 .74 inches)
Cylinder
Bore diameter
Standard 100.00 to 100.015 mm (3.9370 to 3.9376 inches)
Limit 100.05 mm (3.939 inches)
Taper and out-of-round limits 0.05 mm (0.002 inch)
Surface warpage limit 0.05 mm (0.002 inch)
Piston
piston diameter
Standard 99.96 to 99.99 mm (3.935 to 3.937 inches)
Limit 99.86 mm (3.931 inches)
piston diameter measuring point (above bottom of piston) 20 mm (0.8 inch)
piston-to-cylinder clearance
Standard 0.010 to 0.055 mm (0.0004 to 0.0022 inch)
Limit 0.19 mm (0.007 inch)
Piston pin bore in piston
Standard 23.002 to 23.008 mm (0.9056 to 0.9058 inch)
Limit 23.03 mm (0.907 inch)
Piston pin bore in connecting rod
Standard 23.020 to 23.041 mm (0.9063 to 0.9071 inch)
Limit 23.05 mm (0.907 inch)
Piston pin outer diameter
Standard 22.994 to 23.000 mm (0.9053 to 0.9055 inch)
Limit 22.98 mm (0.905 inch)
Piston pin-to-piston clearance
Standard 0.002 to 0.014 mm (0.0001 to 0.0006 inch)
Limit 0.070 mm (0 .003 inch)
Piston pin-to-connecting rod clearance
Standard 0.020 to 0.047 mm (0.0008 to 0.0019 inch)
Limit 0.067 mm (0.0026)
Piston ring markings
Top R
Second RN
Top ring side clearance
Standard 0.045 to 0.080 mm (0.0018 to 0.0031 inch)
Limit 0.095 mm (0.037 inch)
Second ring side clearance
Standard 0.025 to 0.060 mm (0.0010 to 0.0024 inch)
Limit 0.075 mm (0.003 inch)
Oil ring side clearance Not specified
Ring end gap
Top
Standard 0.25 to 0.40 mm (0.010 to 0.016 inch)
Limit 0.55 mm (0.022 inch)
Second
Standard 0.40 to 0.55 mm (0.016 to 0.022 inch)
Limit 0. 70 mm (0 .028 inch)
Oil ring side rails
Standard 0.20 to 0.70 mm (0.008 to 0.028 inch)
Limit 0.90 mm (0.035 inch)
Clutch
Spring free length
Standard 49.0 mm (1.93 inches)
Limit 46.0 mm (1.81 inches)
Friction plate thickness
Discs “A” (outer six friction plates)
Standard 3.22 to 3.38 mm (0.127 to 0.133 inch)
Limit 3.0 mm (0.118 inch)
Disc “B” (innermost friction plate)
Standard 2.92 to 3.08 mm (0.115 to 0.121 inch)
Limit 2.69 mm (0.106 inch)
Friction and metal plate warpage limit 0.30 mm (0.012 inch)
Clutch housing inside diameter
Standard 29.000 to 29.021 mm (1.1417 to 1.1426 inch)
Limit 29.05 mm (1.144 inch)
Clutch housing bushing (guide)
Inside diameter
Standard 21.990 to 22.035 mm (0 .8657 to 0.8675 inch)
Limit 22.05 mm (0.868 inch)
Outside diameter
Standard 28.959 to 28.980 mm (1.1401 to 1.1409 inch)
Limit 28.91 mm (1.138 inch)
Mainshaft outside diameter at clutch housing bushing (guide)
Standard 21.967 to 21.980 mm (0.8648 to 0.8654 inch)
Limit 21.94 mm (0.864 inch)
Oil pump
Outer rotor-to-body clearance
Standard 0.15 to 0.22 mm (0.006 to 0.009 inch)
Limit 0.35 mm (0.014 inch)
Inner-to-outer rotor clearance
Standard 0.15 mm (0.006 inch)
Limit 0.20 mm (0.008 inch)
Side clearance (rotors-to-straightedge)
Standard 0.03 to 0.08 mm (0.001 to 0.003 inch)
Limit 0.10 mm (0.004 inch)
Kickstarter
Shaft outside diameter
Standard 21.959 to 21.980 mm (0.8645 to 0.8654 inch)
Limit 21.91 mm (0.863 inch)
Pinion gear inside diameter
Standard 22.020 to 22.041 mm (0.8669 to 0.8678 inch)
Limit 22.09 mm (0.870 inch)
Idler gear inside diameter ‘
Standard 23.000 to 23.021 mm (0.9055 to 0.9063 inch)
Limit 23.11 mm (0.910 inch)
Idler gear bushing inside diameter
Standard 20.013 to 20.031 mm 0.7879 to 0.7886 inch)
Limit 20.05 mm (0.789 inch)
Idler gear bushing outside diameter
Standard 22.959 to 22.980 mm (0.9039 to 0.9047 inch)
Limit 22.90 mm (0.902 inch)
Countershaft outside diameter at idler gear
Standard 19.980 to 19.993 mm (0.7866 to 0.7871 inch)
Limit 19.94 mm (0.785 inch)
Shift drum and forks
Fork inside diameter
Standard 14.000 to 14.021 mm (0.5512 to 0.5520 inch)
Limit 14.03 mm (0.552 inch)
Fork shaft outside diameter
Standard 13.957 to 13.968 mm (0.5495 to 0.5499 inch)
Limit 13.95 mm (0.549 inch)
Fork ear thickness
Standard · 5.93 to 6.00 mm (0.233 to 0.236 inch)
Limit 5.90 mm (0.23 inch)
Shift drum outside diameter
Right side 19.959 to 19.980 mm (0.7858 to 0.7866 inch)
Left side 11 .966 to 11.984 mm (0.4711 to 0.4718 inch)
Shift drum groove width Not specified
Transmission
Gear inside diameters
Mainshaft fourth, fifth
Standard 28.000 to 28.021 mm (1 .1024 to 1.1032 inches)
Limit 28.08 mm (1.104 inches)
Countershaft first
Standard 23.000 to 23.021 mm (0.9055 to 0.9063 inch)
Limit 23.04 mm (0.907 inch)
Countershaft second
Standard 28.000 to 28.021 mm (1.1024 to 1.1032 inches)
Limit 28.08 mm (1 .104 inches)
Countershaft third
Standard 31.000 to 31 .025 mm (1.2205 to 1.2215 inches)
Limit 31.05 mm (1 .222 inch)
Bushing inside diameters
Mainshaft fourth
Standard 24.985 to 25.006 mm (0.9837 to 0.9845 inch)
Limit 25.02 (0.985 inch)
Countershaft first
Standard 20.000 to 20.021 mm (0.7874 to 0.7882 inch)
Limit 20.04 (0.789 inch)
Countershaft second
Standard 25.000 to 25.021 mm (0.9843 to 0.9851 inch)
Limit 25.04 (0.986 inch)
Countershaft third
Standard 27 .995 to 28.016 mm (1.1022 to 1.1030 inch)
Limit 28.04 (1 .104 inch)
Bushing outside diameters
Mainshaft fourth, fifth
Standard 27 .959 to 27 .980 mm (1 .1007 to 1.1016 inch)
Limit 27.93 mm (1.100 inches)
Countershaft first
Standard 22.959 to 22.979 mm (0.9039 to 0.9047 inch)
Limit 22.93 mm (0.903 inch)
Countershaft second
Standard 27 .959 to 27 .980 mm (1.1007 to 1.1016 inch)
Limit 27 .93 mm (1.100 inches)
Countershaft third
Standard 30.950 to 30.975 mm (1.2185 to 1.2195 inch)
Limit 30.92 mm (1.217 inches)
Gear-to-bushing clearances
Mainshaft fourth, fifth, countershaft second
Standard 0.020 to 0.062 mm (0.0008 to 0.0024 inch)
Limit 0.10 mm (0.004 inch)
Countershaft first
Standard 0.021 to 0.062 mm (0.0008 to 0.0024 inch)
Limit 0.10 mm (0.004 inch)
Countershaft third
Standard 0.025 to 0.075 mm (0.0010 to 0.0030 inch)
Limit 0.13 mm (0.005 inch)
Mainshaft diameter (at fourth gear)
Standard 24.967 to 24.980 mm (0.9830 to 0.9835 inch)
Limit 24.94 mm (0.982 inch)
Mainshaft diameter (at clutch housing bushing)
Standard 21.967 to 21.980 mm (0.8648 to 0.8654 inch)
Limit 21.94 mm (0.864 inch)
Countershaft diameter (at kickstarter idler gear)
Standard 19.980 to 19.993 mm (0.7866 to 0.7871 inch)
Limit 19.94 mm (0.785 inch)
Countershaft diameter (at first gear)
Standard 19.980 to 19.993 mm (0.7866 to 0.7871 inch)
Limit 19.94 mm (0.785 inch)
Countershaft diameter (at second gear)
Standard : 24.972 to 24.993 mm (0.9831 to 0.9840 inch)
Limit 24.95 mm (0.982 inch)
Countershaft diameter (at third gear)
Standard 27 .959 to 27 .980 mm (1.1007 to 1 .1016 inch)
Limit 27.93 mm (1.100 inch)
Shaft-to-bushing clearance
Mainshaft fourth
Standard 0.005 to 0.039 mm (0.0002 to 0.0015 inch)
Limit 0.06 mm (0.002 inch)
Countershaft first
Standard 0.007 to 0.041 mm (0.000 to 0.0016 inch)
Limit 0.06 mm (0.002 inch)
Countershaft second
Standard 0.007 to 0.049 mm (0.0003 to 0.0019 inch)
Limit 0.06 mm (0.002 inch)
Countershaft third
Standard O.015 to 0.057 mm (0.0006 to 0.0022 inch)
Limit 0.06 mm (0.002 inch)
Crankshaft and balancer
Connecting rod side clearance 0.050 to 0.650 mm (0.002 to 0.026 inch)
Connecting rod big end radial clearance (limit) 0.05 mm (0.002 inch)
Crankshaft runout limit 0.05 mm (0.002 inch)
Balancer shaft journal diameter Not specified
Torque Specifications
Engine mounting fasteners
Hanger plate nuts
8mm 26 Nm (20 ft-lbs)
10mm 54 Nm (40 ft-lbs)
Hanger plate bolt (at rear of transmission) 26 Nm (20 ft-lbs)
External oil hose and pipe bolt
Upper (at steering head) Not specified (tighten securely)
Lower (at bottom of frame downtube) 37 Nm (27 ft-lbs)
At engine Not specified (tighten securely)
Cylinder head cover bolts
6 mm bolts 12 Nm (108 in -lbs)
8 mm bolts 23 Nm (17 ft-lbs)
Cam sprocket bolts 20 Nm (14 ft-lbs) (2)
Decompressor lifter lever bolt 12 Nm (108 in -lbs) (2)
Cam chain tensioner lifter bolts (on back of cylinder) 12 Nm (108 inch-lbs)
Cam chain tensioner bolt (behind right crankcase cover) 12 Nm (108 inch-lbs) (2)
Cylinder head nuts (10 mm) 67 Nm (49 ft-lbs) (1)
Cylinder-to-crankcase bolts 12 Nm (108 in -lbs)
Crankcase cover bolts (right and left) 12 Nm (108 in-lbs)
Clutch lever perch bolts 10 Nm (84 in-lbs)
Clutch spring bolts 12 Nm (108 in -lbs)
Clutch locknut 118 Nm (87 ft-lbs) (1)
Flywheel (alternator rotor) bolt See Chapter 5
Primary drive gear locknut 118 Nm (87 ft-lbs) (1)
Engine sprocket bolts See Chapter 6
Mainshaft bearing set plate bolt 12 Nm (108 in-lbs)
Oil pump stopper plate screw Securely
Oil pump plate bolts 12 Nm (108 in -lbs)
Shift cam-to-shift drum bolt 12 Nm (108 in -lbs) (2)
Shift cam stopper arm bolt 12 Nm (108 in -lbs)
Shift pedal pinch bolt Not specified
Kickstarter bolt 26 Nm (20 ft-lbs)
Crankcase bolts 12 Nm (108 in-lbs)
Mainshaft bearing retainer bolt 12 Nm (108 in -lbs) (2)
(1) Apply clean engine oil to the bolt threads and underside of bolt head
(2) Apply non-permanent thread locking agent to the bolt threads

Leave a Reply

Your email address will not be published. Required fields are marked *