Engine Inspection – Air Cooled: XR650L XR600R XL600R

Main rocker arms
Rocker arm inside diameter
Standard : 11.590 to 11 .518 mm (0.4528 to 0.4535 inch)
Limit 11.55 mm (0.455 inch)
Rocker shaft outside diameter
Standard 11.466 to 11.484 mm (0.4514 to 0.4521 inch)
Limit 11.41 mm (0.449 inch)
Shaft-to-arm clearance
Standard 0.016 to 0.052 mm (0.0006 to 0.0020 inch)
Limit 0.14 mm (0.006 inch)
Sub-rocker arms
Rocker arm inside diameter
Intake
Standard 8.000 to 8.015 mm (0.3150 to 0.3156 inch)
Limit 8.05 mm (0.317 inch)
Exhaust
Standard 7.000 to 7.015 mm (0.2756 to 0.2762 inch)
Limit 7.05 mm (0.278 inch)
Rocker shaft outside diameter
Intake
Standard 7.969 to 7.972 mm (0.3137 to 0.3138 inch)
Limit 7.92 mm (0.312 inch)
Shaft-to-arm clearance
All except XR650L
Standard 0.033 to 0.043 mm (0 .0013 to 0.0017 inch)
Limit 0.08 mm (0 .003 inch)
XR650L
Standard 0.028 to 0.046 mm (0.0011 to 0.0018 inch)
Limit 0.01 mm (0 .004 inch)
Camshaft Lobe height
XL600R
Intake
Standard 31.023 mm (1.2214 inches)
Limit 30.85 mm (1.215 inches)
Exhaust
Standard 30.976 mm (1.2195 inches)
Limit 30.81 mm (1 .213 inches)
XR600R
Intake
Standard 31 .155 to 31.315 mm (1.2266 to 1.2329 inches)
Limit 31.05 mm (1 .222 inches)
Exhaust
Standard 31.091 to 31 .251 mm (1.2241 to 1.2304 inches)
Limit 31.00 mm (1.220 inches)
XR650L
Intake
Standard 31.101 to 31.341 mm (1 .2244 to 1.2339 inches)
Limit 30.48 mm (1 .200 inches)
Exhaust
Standard 31.072 to 31.312 mm (1.2233 to 1.2328 inches)
Limit 30.45 mm (1.199 inches)
Camshaft Journals – All Engines
Journal diameter Not specified
Bearing journal inside diameter Not specified
Camshaft runout limit
All except XR650L 0.04 mm (0.002 inch)
XR650L 0.03 mm (0 .001 inch)
Camshaft side clearance (endplay)
XL600R
Standard 0.05 to 0.25 mm (0.002 to 0.010 inch)
Limit 0.40 mm (0.016 inch)
XR600R XR650L " Not specified
Cylinder head valves and valve springs
Cylinder head warpage limit 0.10 mm (0 .004 inch)
Valve stem runout
All engines Not specified
Intake Valve stem diameter
Standard 6.575 to 6.590 mm (0.2589 to 0.2594 inch)
Limit 6.56 mm (0.258 inch)
Exhaust Valve stem diameter
All except XR650L
Standard 6.560 to 6.575 mm (0.2583 to 0.2589 inch)
Limit 6.55 mm (0.257 inch)
XR650L
Standard 6.565 to 6.575 mm (0.2585 to 0.2589 inch)
Limit 6.55 mm (0.257 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 0.065 mm (0 .0026 inch)
Exhaust
XL600R
Standard 0.030 to 0.055 mm (0.001 2 to 0.0022 inch)
Limit 0.08 mm (0.0031 inch)
XR600R
1985 through 1987
Standard 0.025 to 0.050 mm (0.001 0 to 0.0020 inch)
Limit 0.08 mm (0.0031 inch)
1988 and later
Standard 0.025 to 0.055 mm (0.001 0 to 0.0022 inch)
Limit 0.08 mm (0.0031 inch)
XR650L
Standard 0.030 to 0.055 mm (0.001 2 to 0.0022 inch)
Limit 0.08 mm (0.0031 inch)
Valve spring free length
Inner spring
Standard 35.1 mm (1 .240 inches)
Limit 34.1 mm (1 .34 inches)
Outer spring
Standard 36.0 mm (1 .42 inches)
Limit 35 .0 mm (1.38 inches)
Valve seat width (intake and exhaust)
Standard 1.2 to 1.4 mm (0.05 to 0.06 inch)
Limit 2.0 mm (0.08 inch)
Valve face width
Intake
Standard 1.20 to 1.85 mm (0.04 7 to 0.071 inch)
Limit 2.6 mm (0 .10 inch)
Exhaust
Standard 0.9 to 1.7 mm (0.04 to 0.67 inch)
Limit 2.4 mm (0.09 inch)
Sub-chamber valve (1983 through 1985 XL600R)
Stem run out Not specified
Stem diameter
Standard 4.970 to 4.985 mm (0.1957 to 0.1963 inch)
Limit 4.96 mm (0.195 inch)
Guide inside diameter
Standard 5.010 to 5.028 mm (0.1972 to 0.1980 inch)
Limit 5.02 mm (0.199 inch)
Stem to guide clearance Not specified
Seat width limit , 1.5 mm (0.059 inch)
Face width
Standard 1.00 to 1.40 mm (0 .039 to 0.0551 inch)
Limit 2.0 mm (0.08 inch)
Spring free length
Standard 40.5 mm (1 .594 inches)
Limit 39.3 mm (1.55 inches)
Cylinder Bore
XL600R
Standard 100.00 to 100.01 mm (3.934 to 3.940 inches)
Limit 100.1 2 mm (3.942 inches)
XR600R (1985 through 1990)
Standard 97.000 to 97.010 mm (3.8189 to 3.8193 inches)
Limit 97.12 mm (3.823 inches)
XR600R (1991 and later)
Standard 97.010 to 97.020 mm (3.8193 to 3.8197 inches)
Limit 97.13 mm (3.824 inches)
XR650L
Standard 100.00 to 1 OO.Q1 mm (3.934 to 3.940 inches)
Limit 1 00.12 mm (3.942 inches)
Taper and out-of-round limits 0.05 mm (0.002 inch)
Surface warpage limit 0.10 mm (0 .004 inch)
Piston diameter
XL600R
Standard 99.95 to 99.98 (3.935 to 3.936 inches)
Limit 99.85 mm (3.93 inches)
XR600R
Standard 96.96 to 96.99 mm (3.8173 to 3.8284 inches)
Limit 96.96 mm (3.813 inches)
XR650L
Standard 99.96 to 99.99 mm (3.9354 to 3.9362 inches)
Limit 99.85 mm (3.931 inches)
Piston diameter measuring point (above bottom of piston)
All except XR650L 10 mm (0.40 inch)
XR650L 25 mm (1.0 inch)
Piston-to-cylinder clearance
Standard
XL600R 0.01 to 0.06 mm (0.0004 to 0.002 inch)
XR600R
1985 through 1987 , 0.02 to 0.06 mm (0 .001 to 0.002 inch)
1988 on 0.01 to 0.06 mm (0 .0004 to 0.002 inch)
XR650R
Limit
All except XR650L 0.02 to 0.05 mm (0.0008 to 0.002 inch)
XR650L 0.10 mm (0.004 inch)
Piston pin bore in piston
Standard 0.12 mm (0.005 inch)
Limit 24.002 to 24.008 mm (0.9450 to 0.9452 inch)
Piston pin bore in connecting rod
Standard 24.03 mm (0.946 inch)
Limit 24.020 to 24.041 mm (0.9457 to 0.9465 inch)
Piston pin outer diameter
All except XR650L
Standard 24.07 mm (0.948 inch)
Limit 23.989 to 23.995 mm (0.9444 to 0.9447 inch)
XR650L
Standard 23.96 mm (0.943 inch)
Limit 23.992 to 23.996 mm (0.9446 to 0.9447 inch)
Piston pin-to-piston clearance
Standard 23.96 mm (0.943 inch)
XL600R 0.002 to 0.014 mm (0.0001 to 0.0006 inch)
XR600R 0.007 to 0.019 mm (0.0003 to 0.0007 inch)
Limit 0.07 mm (0.003 inch)
Piston pin-to-connecting rod clearance
All except XR650L Not specified
XR650L 0.024 to 0.149 mm (0.0009 to 0.0019 inch)
Top ring side clearance
Standard
1983 through 1987 0.030 to 0.065 mm (0.0012 to 0.0026 inch)
1988 on 0.015 to 0.045 mm (0.0006 to 0.0018 inch)
Limit 0.12 mm (0.006 inch)
Second ring side clearance
Standard 0.01 5 to 0.045 mm (0.0006 to 0.0018 inch)
Limit 0.12 mm (0.006 inch)
Oil ring side clearance Not specified
Ring end gap (XL600R)
Top and second
Standard 0.20 to 0.40 mm (0.008 to 0.016 inch)
Limit 0.5 mm (0 .02 inch)
Oil ring side rails
Standard 0.20 to 0.90 mm (0 .01 0 to 0.030 inch)
Limit Not specified
Ring end gap (XR600R)
Top
Standard 0.20 to 0.40 mm (0 .008 to 0.016 inch)
Limit 0.5 mm (0.020 inch)
Second
Standard 0.35 to 0.55 mm (0.014 to 0.022 inch)
Limit 0.65 mm (0.026 inch)
Oil ring side rails
Standard 0.20 to 0.90 mm (0.008 to 0.040 inch)
Limit Not specified
Ring end gap (XR650L)
Top
1993 through 1996 0.20 to 0.40 mm (0.008 to 0.016 inch)
1997 and later 0.20 to 0.35 mm (0.008 to 0.014 inch)
Second
1993 through 1996 : 0.35 to 0.55 mm (0.01 4 to 0.022 inch)
1997 and later 0.35 to 0.50 mm (0.01 4 to 0.020 inch)
Oil ring side rails
Standard 0.20 to 0.70 mm (0.008 to 0.030 inch)
Limit Not specified
Clutch Spring free length
XL600R
Standard 44.3 mm (1.744 inches)
Limit 42.7 mm (1.68 inches)
XR600R,XR650L
Standard 44.7 mm (1 .76 inches)
Limit 43.1 mm (1.70 inches)
Friction plate thickness
Standard 2.92 to 3.08 mm (0.115 to 0.121 inch)
Limit 2.6 mm (0.10 inch)
Friction and metal plate warpage limit 0.15 mm (0.006 inch)
Clutch housing bushing inside diameter
XL600R, XR600R
Standard 21.99 to 22.035 mm (0.8657 to 0.8675 inch)
Limit 22.05 mm (0.868 inch)
XR650L Not specified
Clutch housing bushing outside diameter
XL600R, XR600R
Standard 26.959 to 26.980 mm (1 .0614 to 1.0622 inch)
Limit 26.91 mm (1.059 inch)
XR650L Not specified
Clutch housing bushing clearance to crankshaft
XL600R Not specified
XR600R (limit) 0.14 mm (0.006 inch)
XR650L Not specified
Clutch housing inside diameter
XR650L Not specified
Standard 27.00 to 27.021 mm (1.0630 to 1.0638 inches))
Limit 27.05 mm (1.065 inches
XR650L Not specified
Oil pump
Outer rotor-to-body clearance
Standard 0.15 to 0.21 mm (0.006 to 0.008 inch)
Limit 0.25 mm (0.01 0 inch)
Inner-to-outer rotor clearance
Standard 0.15 mm (0.006 inch) or less
Limit 0.20 mm (0.008 inch)
Side clearance (rotors-to-straightedge)
Standard 0.02 to 0.08 mm (0.001 to 0.003 inch)
Limit 0.12 mm (0.005 inch)
Kickstarter
Shaft outside diameter
Standard 21.959 to 21.980 mm (0.8645 to 0.8654 inch)
Limit 21.90 mm (0.862 inch)
Pinion gear inside diameter 1983 through 1986
Standard 22.00 to 22.033 mm (0.8661 to 0.8674 inch)
Limit 22.12 mm (0.871 inch)
1987 on
Standard 25.500 to 25.521 mm (1.0039 to 1.0048 inches)
Limit 25.58 mm (1.007 inches)
Pinion bushing inside diameter
Standard 21 .995 to 22.01 5 mm (0.8660 to 0.8667 inch)
Limit 22. 07 mm (0.869 inch)
Pinion bushing outside diameter
Standard 25.465 to 25.485 mm (1.0026 to 1.0033 inches)
Limit 25.41 mm (1.004 inches)
Idler gear inside diameter
Standard 20.00 to 20.021 mm (0.7874 to 0.7822 inch)
Limit 20.11 mm (0.792 inch)
Idler gear bushing inside diameter
Standard 16.00 to 16.01 8 mm 0.6299 to 0.6366 inch)
Limit 16.03 mm (0.631 inch)
Idler gear bushing outside diameter
Standard 19.959 to 19.980 mm (0.7858 to 0.7866 inch)
Limit 19.90 mm (0.783 inch)
Shift drum and forks
Fork inside diameter
XL600R, XR600R
Standard 14.000 to 14.018 mm (0.5512 to 0.5519 inch)
Limit 14.05 mm (0.553 inch)
XR650L
Standard 14.000 to 14.018 mm (0.5512 to 0.5519 inch)
Left 14.000 to 14.015 mm (0.5512 to 0.5518 inch)
Center 14.000 to 14.018 mm (0.5512 to 0.5519 inch)
Right 14.05 mm (0.553 inch)
Fork shaft outside diameter
Standard 13.966 to 13.984 mm (0.5498 to 0.5506 inch)
Limit 13.90 mm (0.547 inch)
Fork ear thickness
Standard 4.93 to 5.00 mm (0.194 to 0.1 97 inch)
Limit 4.50 mm (0.18 inch)
Shift drum groove width limit Not specified
Transmission
Gear inside diameters
Mainshaft fourth (XL600R)
Standard 25.020 to 25.041 mm (0.9850 to 0.9859 inch)
Limit 25.10 mm (0.988 inch)
Mainshaft fourth (XR600R, XR650L)
Standard 28.020 to 28.041 mm (1.1 031 to 1.1040 inches)
Limit 28.10 mm (1.1 06 inches)
Mainshaft fifth
Standard 28.000 to 28.021 mm (1.1024 to 1.1032 inches)
Limit 28.08 mm (1.1 06 inches)
Countershaft first
Standard 25.020 to 25.041 mm (0.9850 to 0.9859 inch)
Limit 25.10 mm (0.988 inch)
Countershaft second
Standard 28.020 to 28.041 mm (1 .1031 to 1.1040 inches)
Limit 28.10 mm (1.1 06 inches)
Countershaft third 1983 through 1987
Standard 25.020 to 25.041 mm (0.9850 to 0.9859 inch)
Limit 25.10 mm (0.988 inch)
1988 and later
Standard 28.020 to 28.041 mm (1.1 031 to 1.1040 inches)
Limit 25.10 mm (0.988 inch)
Bushing inside diameters
Countershaft first
Standard 20.020 to 20.041 mm (0.7882 to 0.7890 inch)
Limit 20.01 mm (0.791 inch)
Countershaft second, countershaft third (XR650L),
mainshaft fourth
Standard 25.020 to 25.041 mm (0.9850 to 0.9859 inch)
Limit 25.10 mm (0.988 inch)
Bushing outside diameters
Mainshaft fifth
Standard 27.949 to 27.980 mm (1 .1004 to 1.101 6 inch)
Limit 27.90 mm (1.098 inches)
Countershaft first
Standard 24.984 to 25.005 mm (0.9836 to 0.9844 inch)
Limit 24.93 mm (0.981 inch)
Countershaft second, countershaft third (XR650L)
Standard 27.979 to 28.000 mm (1.1015 to 1.1024 inches)
Limit 27.93 mm (1.100 inches)
Gear-to-bushing clearances
Mainshaft fifth
Standard 0.020 to 0.072 mm (0.0008 to 0.0028 inch)
Limit 0.10 mm (0.004 inch)
Mainshaft fourth, 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 0.015 to 0.057 mm (0.0006 to 0.0022 inch)
Limit 0.10 mm (0.004 inch)
Mainshaft diameter (at fourth gear)
Standard 24.972 to 24.993 mm (0.9831 to 0.9840 inch)
Limit 24.92 mm (0.981 inch)
Mainshaft diameter (at clutch housing bushing)
XL600R Not specified
XR600R (limit) 21.91 mm (0.863 inch)
Countershaft diameter (at kickstarter idler gear)
Standard 15.966 to 15.984 mm (0.6286 to 0.6293 inch)
Limit 15.93 mm (0.627 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 24.92 mm (0.981 inch)
Countershaft diameter (at third gear)
Standard 24.959 to 24.980 mm (0.9826 to 0.9835 inch)
Limit 24.92 mm (0.981 inch)
Shaft-to-gear clearance
XL600R, XR600R
Mainshaft fourth
Standard 0.027 to 0.068 mm (0.0011 to 0.0027 inch)
Limit 0.10 mm (0.004 inch)
Countershaft third
Standard 0.041 to 0.082 mm (0.0016 to 0.0032 inch)
Limit 0.15 mm (0.006 inch)
XR650L Not specified
Shaft-to-bushing clearance
Countershaft first
Standard 0.027 to 0.061 mm (0.0011 to 0.0024 inch)
Limit 0.10 mm (0.004 inch)
Countershaft second (and countershaft third,
mainshaft fourth on XR650L models)
Standard 0.027 to 0.069 mm (0.0011 to 0.0027 inch)
Limit 0.10 mm (0.004 inch)
Crankshaft and balancer
Connecting rod side clearance
XL600R, XR600R
Standard 0.050 to 0.650 mm (0.0020 to 0.0256 inch)
Limit 0.80 mm (0.031 inch)
XR650L 0.050 to 0.450 mm (0.002 to 0.01 77)
Connecting rod big end radial clearance
Standard 0.006 to 0.018 mm (0.0002 to 0.0007 inch)
Limit 0.05 mm (0.002 inch)
Runout limit 0.10 mm (0.004 inch)
Balancer shaft diameter XL600R
Standard 16.977 to 16.995 mm (0.6684 to 0.6691 inch) )
Limit 16.95 mm (0.667 inch
XR600R, XR650L Not specified

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