XL600R Torque Specs

XL600R 1983 to 1987

General Service Torques

Oil drain plug in frame 25 to 32 Nm (18 to 23 ft-lbs)
Oil drain plug in crankcase 30 to 40 Nm (22 to 29 ft-lbs)
Oil filter cover bolts 8 to 10 Nm (60 to 84 in-lbs)
Oil strainer screen to frame 35 to 45 Nm (25 to 32 ft-lbs)
Hose fitting to oil strainer screen 40 Nm (29 ft-lbs)
Crankcase oil strainer screen bolt 35 to 45 Nm (25 to 32 ft-lbs)
Spark plug 18 Nm (156 in-lbs)
Valve adjusting screw locknut 25 Nm (18 ft-lbs)
Valve adjusting hole cover Not specified
Crankshaft hole cap Not specified
Timing hole cap Not specified

Wheels Torques

Front axle 50 to 80 Nm (36 to 58 ft-lbs)
Front axle holder nuts 10 to 14 Nm (84 to 120 in-lbs)
Rear axle nut 80 to 110 Nm (58 to 72 ft-lbs)
Wheel spokes 4.0 Nm (36 in-lbs)
Rim lock locknut 13 Nm (108 in-lbs)

Steering Torques

Steering stem adjusting nut
Initial torque (to seat bearings) 20 to 30 Nm (14 to 22 ft-lbs)
Final torque 1 to 2 Nm (9 to 16 in-lbs)
Steering stem nut 80 to 120 Nm (58 to 87 ft-lbs)
Handlebar bracket bolts 18 to 30 Nm (13 to 22 ft-lbs)
Upper triple clamp bolts 18 to 30 Nm (13 to 22 ft-lbs)
Lower triple clamp bolts 30 to 35 Nm (22 to 25 ft-lbs)

Suspension Torques

Front forks – XL600R, XR600R, XR650L
Damper rod Allen bolt 15 to 25 Nm (11 to 18 ft-lbs)
Fork cap-to-fork tube 15 to 30 Nm (11 to 22 ft-lbs)
Rear shock absorber upper mounting bolt 40 to 50 Nm (29 to 36 ft-lbs)
Rear shock absorber lower mounting bolt 40 to 50 Nm (29 to 36 ft-lbs)
Shock arm-to-swingarm 90 to 120 Nm (65 to 87 ft-lbs)
Shock arm-to-shock link 40 to 50 Nm (29 to 36 ft-lbs)
Shock link-to-frame Not specified
Swingarm pivot bolt nut 80 to 100 Nm (58 to 72 ft-lbs)

Final Drive (Sprockets) Torques

Engine sprocket bolts Not specified
Rear sprocket bolts/nuts 32 to 35 Nm (23 to 25 ft-lbs)

Brake Calipers, Disks and Drums Torques

Front Caliper
Caliper bracket bolts 20 to 30 Nm (14 to 22 ft-lbs)
Lower slider pin-to-bracket 15 to 20 Nm (132 to 168 in-lbs)
Upper slider pin-to-bracket 20 to 25 Nm (14 to 18 ft-lbs)
Pad pins 15 to 20 Nm (132 to 168 in-lbs)
Brake line union bolts 30 to 40 Nm (22 to 29 ft-lbs)
Brake hose to master cylinder 30 to 40 Nm (22 to 29 ft-lbs)
Brake disc-to-wheel bolts front and rear 14 to 16 Nm (1 20 to 144 in -lbs)
Rear drum brake arm pinch bolt 8 to 12 Nm (72 to 108 inch-lbs)
Front master cylinder Mounting bolts Not specified
Pivot bolt locknut Not specified
Pedal pivot bolt 35 to 45 Nm (25 to 33 ft-lbs)

Engine Torques

Engine mounting bolts 30 to 37 Nm (22 to 27 ft-lbs)
8 mm bolts 35 to 45 Nm (25 to 33 ft-lbs)
Front 10 mm mounting bracket bolts 55 to 65 Nm (40 to 47 ft-lbs)
Rear and top 10 mm mounting bolts
External oil hose and pipe nuts 40 Nm (29 ft-lbs)
Cylinder head cover bolts
6 mm small head bolt 10 Nm (84 in-lbs)
6 mm regular head bolts 12 Nm (108 in-lbs)
8 mm bolt 23 Nm (17 ft-lbs)
Cam sprocket bolts 20 Nm (14 ft-lbs)
Main rocker shafts 27 Nm (20 ft-lbs)
Sub-rocker shafts
Intake 27 Nm (20 ft-lbs)
Exhaust 23 Nm (17 ft-lbs)
Cam chain tensioner bolt Not specified
Cylinder head main bolts 27 to 32 Nm (20 to 23 ft-lbs)
Cylinder head small nuts/bolts  Not specified
Cylinder main bolts 50 Nm (36 ft-lbs)
Cylinder small bolts Not specified
Intake manifold (carburetor insulator) bolts Not specified
Right and left engine cover bolts 12 Nm (108 in-lbs)
Clutch spring bolts 8 to 12 Nm (72 to 108 in-lbs)
Primary drive gear locknut 50 to Nm (36 to 43 ft-lbs)
Clutch locknut 50 to Nm (36 to 43 ft-lbs)
Shift cam plate to shift drum bolt 12 Nm (108 in-lbs)
Shift drum stopper arm bolt 25 Nm (18 ft-lbs)
Shift pedal pinch bolt 8 to 12 Nm (72 to 108 in-lbs)
Crankcase bolts 12 Nm (1 08 in-lbs)
Crankshaft bearing retainer bolt Not specified
Center shift fork-to-shaft bolt 15 Nm (132 in-lbs)

Exhaust Pipes and Mufflers Torques

Exhaust pipe-to-cylinder head nuts 18 to 25 Nm (13 to 18 ft-lbs)
Muffler clamp bolts 15 to 25 Nm (13 to 18 ft-lbs)
Muffler mounting bolts Not specified

Ignition and Electrical System Torques

Alternator rotor bolt 100 to 120 Nm (72 to 87 ft-lbs)
Timing hole cover 84 in-lbs

 Frame and Bodywork Torques

Seat mounting bolts 8 to 12 Nm (72 to 108 in-lbs)
Footpeg bolt/nut 38 to 48 Nm (27 to 35 ft-lbs)
Skid plate/bar 8 to 12 Nm (72 to 108 in-lbs)
Sidestand 35 to 45 Nm (25 to 33 ft- lbs)

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)

 

Drive Chain (all models)

Drive chain frame slider minimum thickness 6 mm (0.24 inch}
Drive chain length
XL600R Not specified
XR600R
1985 through 1987 (109 pins)
Standard 1730 mm (68.1 inches)
Limit 1765 mm (69.5 inches)
1988 on (111 pins)
Standard 1762 mm (69.4 inches)
Limit 1780 mm (59.7 inch}
XR650L Not specified
XR650R (41 pins) 638 mm (25.1 inches)
orive chain master link (XR650L and XR650R models)
Pin projection (from side plate, before staking) 1.2 to 1.4 mm (0.05 to 0.06 inch)
Pin diameter (after staking) 5.5 to 5.8 mm (0.217 to 0.228 inch}

Suspension (all models)

Specifications
Front forks
Oil type
1983 through 1987 Automatic transmission fluid
1988 on, except XR650R models Pro-Honda SS7 suspension fluid or equivalent
XR650R models Pro Honda HP fork oil, SW, or equivalent
Oil capacity
XL600R 455 cc (15.4 fl oz)
XR600R
1985 through 1987 631 cc (21 .3 fl oz)
1988 through 1990 643 cc (21.74 fl oz)
1991 and 1992 580 cc (19.61 fl oz)
1993 on 585 cc (19.78 fl oz)
XR650L 564 cc (19.1 fl oz)
XR650R 637 cc (21.5 fl oz)
Oil level (fork fully compressed and spring removed)
XL600R 150 mm (5.9 inches)
XR600R
1985 through 1987 127 mm (5.0 inches)
1988 through 1990 110 mm (4.3 inches)
1991 on
Standard oil level 125 mm (4.92 inches)
Maximum oil level 115 mm (4.53 inches)
Minimum oil level 135 mm (5.31 inches)
XR650L 145 mm (5.70 inches)
XR650R 120 mm (4. 70 inches)
Fork spring free length limit
XL600R 557 .0 mm (21 .93 inch)
XR600R
1985 through 1987 566.0 mm (22.28 inch}
1988 and 1990 (short spring) 62.0 mm (2.441 inches)
1988 and 1990 (long spring) 577.0 mm (22.717 inches)
1991 on 570.0 mm (22 .441 inches)
XR650L 576.0 mm (22.68 inches)
XR650R 506 mm (19.9 inches)
Fork tube bend limit 0.2 mm (0.008 inch)
Rear suspension
Rear shock absorber spring free length
XL600R
Standard 276.0 mm (10 .87 inches)
Limit 273 mm (10.75 inches)
XR600R
1985 through 1987
Standard 234.0 mm (9.2 inches)
Limit 231 mm (9.1 inches)
1988 through 1990
Standard 242.3 mm (9.54 inches)
Limit 240.0 mm (9.45 inches)
1991 on
Standard 215.5 mm (8.48 inches)
Limit 213.3 mm (8.40 inches)
XR650L
Standard 225.3 mm (8.87 inches)
Limit Not available
XR650R Not available
Rear shock absorber spring installed length
XL600R (standard) 265 mm (10.43 inches)
XR600R
1985
Standard 225.2 mm (8.87 inches)
Maximum 230.2 mm (9.06 inches)
Minimum 220.2 mm (8.67 inches)
1986 and 1987
Standard 218.9 mm (8.62 inches)
Maximum 223.9 mm (8 .81 inches)
Minimum 213.9 mm (8.42 inches)
1988 through 1990
Standard 234 mm (9.21 inches)
Maximum 229 mm (9.02 inches)
Minimum 239 mm (9.41 inches)
1991 and later
Standard 200 mm (7.87 inches)
Maximum 195 mm (7.68 inches)
Minimum 205 mm (8.07 inches)
XR650L
1993
Standard 200.3 mm (7.89 inches)
Maximum 205 mm (8.1 inches)
Minimum 195 mm (7.7 inches)
1994 and later
Standard 206.5 +/- 3.6 mm (8.13 +/- 0.1 42 inches)
Maximum Not specified
XR650R (standard) 236.5 mm (9 .31 inches)

Ignition and Electrical Systems (all models)

General
Battery
XL600R
Type 12V, 3Ah (amp-hours)
Specific gravity See Chapter 1
XR650R
Type 12V, 8Ah (amp-hours)
Specific gravity See Chapter 1
Fuse rating ·
XL600R 10 amps
XR650L
Main fuse 20 amps
Other three fuses (ignition,headlight,speedometer/tail/marker lights) 10 amps
Charging system voltage 13.7 to 15.3 volts AC
XL600R, XR650R
AC regulator voltage
XL600R
1983 through 1986 13.5 to 14.5 volts at 5000 rpm
1987 13.7 to 14.2 volts at 5000 rpm
XR600R 13.5 to 14.5 volts at 5000 rpm
XR650L 14.7 to 15.5 volts at 5000 rpm
XR650R 13.5 to 14.5 volts at 4500 rpm
AC regulator resistance (XR600R) 1 to 90 k-ohms
Alternator stator coil resistance
XL600R
Charging coil 0.95 to 1.29 ohms
Lighting coil 0.4 to 0.55 ohms
Exciter coil 230 to 320 ohms
XR600R
Exciter coil
1985 through 1990 230 to 320 ohms
1991 on 50 to 200 ohms
Lighting coil
1985 through 1987 0.44 to 0.60 ohms
1988 on 0.1to1 .0 ohms
XR650L
Charging coil 0.2 to 1.2 ohms
Lighting coil , Not specified
Exciter coil Not specified
XR650R
Exciter coil 50 to 200 ohms
Lighting coil 0.1 to 1.0 ohms
Pulse generator resistance
XL600R, XR600R 360 to 440 ohms
XR650L 423 to 517 ohms
XR650R 180 to 280 ohms
Ignition coil resistance (at 20-degrees C/68-degrees F)
1983 through 1987 XL600R
Primary resistance 0.1 to 0.3 ohms
Secondary resistance
With plug cap attached 8500 to 11,000 ohms
With plug cap detached 3700 to 4500 ohms
XR600R
Primary resistance 0.1 to 0.3 ohms
Secondary resistance (with plug cap detached)
1985 through 1987 (with plug cap connected) 7400 to 11,000 ohms
1988 through 1990 (with plug cap detached) 7400 to 11,000 ohms
1991 and later (with plug cap detached) 2000 to 4000 ohms
XR650L
Primary resistance 0.19 to 0.23 ohms
Secondary resistance (with plug cap detached) 6500 to 9700 ohms
XR650R Not available
Ignition Timing
XL600R
At idle (F mark aligned with index notch)
1983 models 6-degrees BTDC @ 1200 rpm
1984 and later models 11 -degrees BTDC @ 1300 rpm
At full advance 31 -degrees BTDC@ 4000 rpm
XR600R
1985 through 1987 models
At idle (F mark al igned with index notch) 11-degrees BTDC @ 1300 rpm
At full advance 31-degrees BTDC @ 4000 rpm
1988 and later models
At idle (F mark aligned with index notch) 6-degrees BTDC @ 1300 rpm
At full advance 31-degrees BTDC @ 3500 rpm
XR650L
At idle (F mark aligned with index notch) 8-degrees BTDC @ 1300 rpm
At full advance 28-degrees BTDC @ 4000 rpm
XR650R
At idle (F mark aligned with index notch) 6-degrees BTDC @ 1300 rpm
At full advance 31 -degrees BTDC@ 3500 rpm

Carburetor (XL600R)

Identification mark
1983 PH60A
1984 49 states PH64A
1984 California PH66A
1985 49 states PH68A-B
1985 California PH68B-B
1986 and later 49 states PH68G
1986 and later California PH68H
Jet sizes and settings
Standard main jet (sea level to 5000 ft)
1983
Primary 125
Secondary 112
1984 49 states (primary and secondary) 120
1984 California (primary and secondary) 118
1985 and later
Primary 118
Secondary 115
High altitude main jet (5000 ft to 6500 ft) Same as standard
High altitude main jet (above 6500 ft)
1983 Same as standard
1984 49 states (primary and secondary) 112
1984 California (primary and secondary) 110
1985 and later
Primary 115
Secondary 112
Slow jet
1983 55
1984 and 1985 65
1986 and later 62
Jet needle clip position Not specified
Mixture screw setting (turns out from lightly seated position)
Sea level to 5000 ft
1983 1
1984 and 1985 2
1986 on , 1-1/2
Above 5000 ft
1983 2-Jan
1984 1-1/2
1985 and later 1-3/8
Float level
1983 and 1984 20.0 mm (0.79 inch)
1985 and later 18.0 mm (0.71 inch)

Compression (all models)

Cylinder compression (standard)
XL600R 12.5 kg/cm2 (175 psi)
XR600R
1985 through 1987 12.5 +1- 1.5 kg/cm2 (175 +1- 21 psi)
1988 on
Decompressor applied 5 +1- 1 kg/cm2 (71 +1- 14.2 psi)
Decompressor not applied 14 +/- 1 kg/cm2 (200 +/-14.2 psi)
XR650L
Decompressor applied 6.5 +1- 1 kg/cm2 (92 psi)
Decompressor not applied 14 +1- 1 kg/cm2 (200 psi)
XR650R
Decompressor applied 6.12 kg/cm2 (87 psi)
Decompressor not applied 11.22 kg/cm2 (160 psi)