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