XR600R Torque Specs

XR600R 1985 to 2000

General Service Torques

Oil drain plug in frame
XR600R
1985 through 1987 35 to 45 Nm (25 to 33 ft-lbs)
1988 and later 40 Nm (29 ft-lbs)
Oil drain plug in crankcase
1983 through 1987 models 30 to 40 Nm (22 to 29 ft-lbs)
1988 and later 25 Nm (18 ft-lbs)
Oil filter cover bolts
1983 through 1987 models 8 to 10 Nm (60 to 84 in-lbs)
1988 and later 12 Nm (108 in-lbs)
Oil strainer screen to frame 55 Nm (40 ft-lbs)
Hose fitting to oil strainer screen 40 Nm (29 ft-lbs)
Crankcase oil strainer screen bolt 40 Nm (29 ft-lbs)
Spark plug 18 Nm (156 in-lbs)
Valve adjusting screw locknut 25 Nm (18 ft-lbs)
Valve adjusting hole cover
Through 1997 Not specified
1998 and later XR600R 15 Nm (132 in-lbs)
Crankshaft hole cap (exc XR650R)
Through 1997 Not specified
1998 and later 15 Nm (132 in-lbs)
Timing hole cap
Through 1997 Not specified
1998 and later 10 Nm (84 in-lbs)

Wheels Torques

Front axle
1983 through 1987 models 50 to 80 Nm (36 to 58 ft-lbs)
1988 through 1992 models 65 Nm (47 ft-lbs)
1993 and later models 85 Nm (61 ft-lbs)
Front axle holder nuts
1983 through 1987 models 10 to 14 Nm (84 to 120 in-lbs)
1988 and later models 12 Nm (108 in -lbs)
Rear axle nut
1983 through 1987 models 80 to 110 Nm (58 to 72 ft-lbs)
1988 and later models 95 Nm (69 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
1983 through 1987 1 to 2 Nm (9 to 16 in-lbs)
1988 through 1990 3 Nm (24 in-lbs)
1991 and 1992 1 Nm (9 in-lbs)
1993 and later 1.5 Nm (13 in-lbs)
Steering stem nut
1985 to 1987 95 to 140 Nm (69 to 101 ft-lbs)
1988 and later 118 Nm (85 ft-lbs)
Handlebar bracket bolts
1985 through 1987 22 to 30 Nm (16 to 22 ft-lbs)
1988 on 27 Nm (20 ft-lbs)
Upper triple clamp bolts
1985 through 1987 25 to 30 Nm (18 to 22 ft-lbs}
1988 through 1990 33 Nm (24 ft-lbs)
1991 on 28 Nm (20 ft-lbs)
Lower triple clamp bolts
1985 through 1987 30 to 35 Nm (22 to 25 ft-lbs)
1988 on 35 Nm (25 ft-lbs)

Suspension Torques

Front forks
Damper rod Allen bolt 15 to 25 Nm (11 to 18 ft-lbs)
Fork bottom bolt (1988 and later) 35 Nm (25 ft-lbs)
Fork cap-to-fork tube
1985 through 1987 15 to 30 Nm (11 to 22 ft-lbs)
1988 and later 23 Nm (17 ft-lbs)
Fork cap locknut (1991 and later) 60 Nm (43 ft-lbs)
Fork piston retainer (1991 on) 35 Nm (25 ft-lbs)
Rear shock absorber upper mounting bolt
1985 through 1987 40 to 50 Nm (29 to 36 ft-lbs)
1988 on 45 Nm (33 ft-lbs)
Rear shock absorber lower mounting bolt
1985 through 1987 25 to 35 Nm (14 to 25 ft-lbs)
1988 through 1990 30 Nm (22 ft-lbs)
1991 on 35 Nm (25 ft-lbs)
Shock arm-to-swingarm
1985 through 1987 60 to 80 Nm (43 to 57 ft-lbs)
1988 on 70 Nm (51 ft-lbs)
Shock arm-to-shock link
1985 through 1987 40 to 50 Nm (29 to 36 ft-lbs)
1988 on 45 Nm (33 ft-lbs)
Shock link-to-frame
1985 through 1987 40 to 50 Nm (29 to 36 ft-lbs)
1988 on 45 Nm (33 ft-lbs)
Swingarm pivot bolt nut
1985 through 1987 80 to 100 Nm (58 to 72 ft-lbs)
1988 and later 90 Nm (65 ft-lbs)

Final Drive (Sprockets) Torques

Engine sprocket bolts  Not specified
Rear sprocket bolts/nuts
1985 through 1987 34 to 40 Nm (24 to 29 ft-lbs)
1988 on 44 Nm (32 ft-lbs)

Brake Calipers, Disks and Drums Torques

Front Caliper
1983 through 1987
Caliper bracket bolts 20 to 30 Nm (14 to 22 ft-lbs)
Upper slider pin-to-bracket 20 to 25 Nm (1 4 to 18 ft-lbs)
Lower slider pin-to-bracket 15 to 20 Nm (84 to 168 in -lbs)
Pad pins 15 to 20 Nm (84 to 168 in-lbs)
1988 on
Caliper bracket bolts
1988 to 1992 27 Nm (20 ft-lbs)
1992 and later 30 Nm (22 ft-lbs)
Slider pin-to-caliper 23 Nm (17 ft-lbs)
Slider pin-to-caliper bracket 13 Nm (120 in-lbs)
Pad pins 18 Nm (156 in-lbs)
Pad pin plugs 3 Nm (26 in -lbs)
Rear caliper
Allen head slider pin-to-caliper 28 Nm (20 ft-lbs)
Slider pin-to-bracket 13 Nm (1 20 in -lbs)
Pad pins 18 Nm (1 56 in -lbs)
Pad pin plugs 3 Nm (26 inch-lbs)
Brake line union bolts
1983 through 1987 Not specified
1988 on 35 Nm (25 ft-lbs)
Brake disc-to-wheel bolts
1985 through 1987 models 14 to 16 Nm (1 20 to 144 in -lbs)
1988 through 1990 models 15 Nm (1 32 in-lbs)*
1991 and later models 20 Nm (1 68 in-lbs)*
Front master cylinder Mounting bolts
1983 through 1987 Not specified
1988 on 27 Nm (20 ft-lbs)
Pivot bolt locknut
1983 through 1987 Not specified
1988 on 10 Nm (84 inch-lbs)
Rear master cylinder mounting bolts Not specified
*Replace the bolts with new ones whenever they’re removed

Engine Torques

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) (1)
Cam sprocket bolts 20 Nm (14 ft-lbs)
Main rocker shafts 27 Nm (20 ft-lbs)
Sub-rocker shafts (2)
Intake 27 Nm (20 ft-lbs)
Exhaust 23 Nm (17 ft-lbs)
Cam chain tensioner bolt
Through 1997 Not specified
1998 and later 12 Nm (108 inch-lbs) (2)
Cylinder head main bolts
1983 through 1987 models 27 to 32 Nm (20 to 23 ft-lbs)
1988 and later 36 Nm (26 ft-lbs)
Cylinder head small nuts/bolts
Through 1997 Not specified
1998 and later 12 Nm (1 08 inch-lbs)
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
Through 1997 Not specified
1998 and later 12 Nm (1 08 in-lbs)
Primary drive gear locknut
1985 through 1987 70 to 80 Nm (50 to 58 ft-lbs)
1988 and later 110 Nm (80 ft-lbs)
Clutch locknut
1985 through 1987 70 to 80 Nm (50 to 58 ft-lbs)
1988 and later 110 Nm (80 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 Not specified
Crankcase bolts 12 Nm (1 08 in-lbs)
Crankshaft bearing retainer bolt
Through 1997 Not specified
1998 and later 25 Nm (18 ft-lbs)
Center shift fork-to-shaft bolt 15 Nm (132 in-lbs)

Exhaust Pipes and Mufflers Torques

Exhaust pipe-to-cylinder head nuts
1985 through 1987 8 to 12 Nm (72 to 108 in-lbs)
1988 through 1990 27 Nm (20 ft-lbs)
1991 and later 17 Nm (144 in-lbs)
Muffler clamp bolts 27 Nm (20 ft-lbs)
Muffler mounting bolts
1983 through 1987 20 to 30 Nm (15 to 22 ft-lbs)
1988 through 1990 70 Nm (51 ft-lbs)
1991 and later 35 Nm (25 ft-lbs)

Ignition and Electrical System Torques

Alternator rotor bolt
1983 through 1987 100 to 120 Nm (72 to 87 ft-lbs)
1988 and later 125 Nm (90 ft-lbs)*
Timing hole cover 84 in-lbs
*Apply oil to the bolt threads and head

 Frame and Bodywork Torques

Seat mounting bolts  Not available
Footpeg bolt/nut
1985 to 1987 models 50 to 60 Nm (36 to 43 ft-lbs)
1988 and later models 65 Nm (47 ft-lbs)
Skid plate/bar Not available
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 (XR600R)

Identification mark
1985 through 1987 PH52A
1988 PD8AA
1989 and 1990 PD8AD
1991 and later (except 1998 and later California) PD8AF
1998 and later California PDM18
Jet sizes and settings
Standard main jet (sea level to 5000 ft)
1983 through 1987 (primary and secondary) 122
1988 through 1990 165
1991 and later (except 1998 and later California) 152
1998 and later California 128
Slow jet
1983 through 1987 45
1988 60
1989 and later (except 1998 and later California) , 62
1998 and later California 58
Jet needle clip position
1983 through 1987
Primary 4th groove from top
Secondary 2nd groove from top
1988 and later 3rd groove from top
Mixture screw setting (turns out from lightly seated position) – see Section 4
Standard
1983 through 1987 1-3/8
1988 2-5/8
1989 through 1997 2
1998 and later (except California)
Initial setting 2
Final setting : 3/4
1998 and later California
Initial setting 1-1/8
Final setting 1/2 in from standard final setting (see Section 4)
High altitude 1/2-turn in from standard final setting (see Section 4)
Float level
1983 through 1987 18.0 mm (0.71 inch)
1988 and later 14.5 mm (0.57 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)