XR650R Torque Specs

XR650R 2000 to 2007

General Service Torques

Coolant drain bolt 12 Nm (108 in-lbs)
Oil drain plug in frame 25 Nm (18 ft-lbs)
Oil drain plug in crankcase 25 Nm (18 ft-lbs)
Oil filter cover bolts 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 37 Nm (27 ft-lbs)
Spark plug 18 Nm (156 in-lbs)
Valve adjusting screw locknut 25 Nm (18 ft-lbs)
Valve adjusting hole cover 12 Nm (1 08 in-lbs)
Timing hole cap 10 Nm (84 in-lbs)

Wheels Torques

Front axle 88 Nm (65 ft-lbs)
Front axle holder nuts 12 Nm (108 in-lbs)
Rear axle nut 93 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 (seat bearings) 20 to 30 Nm (14 to 22 ft-lbs)
Final torque 8 Nm (69.5 in-lbs)
Steering stem nut 98 Nm (72 ft-lbs)
Handlebar bracket bolts 27 Nm (20 ft-lbs)
Upper triple clamp bolts 28 Nm (20 ft-lbs)
Lower triple clamp bolts 33 Nm (24 ft-lbs)

Suspension Torques

Fork cap-to-fork tube  ?
Fork bottom bolt 54 Nm (40 ft-lbs)
Fork cap-to-damper rod 15 Nm (132 in-lbs)
Fork cap-to-fork tube 30 Nm (22 ft-lbs)
Rear shock absorber upper mounting bolt 45 Nm (33 ft-lbs)
Rear shock absorber lower mounting bolt 45 Nm (33 ft-lbs)
Shock arm-to-swingarm 78 Nm (58 ft-lbs)
Shock arm-to-shock link 69 Nm (51 ft-lbs)
Shock link-to-frame 69 Nm (51 ft-lbs)
Swingarm pivot bolt nut 108 Nm (80 ft-lbs)
Swingarm pivot adjusting nut
Stage 1 12 Nm (108 in-lbs)
Stage 2 Loosen until under no torque
Stage 3 7 Nm (5.1 in-lbs)
Adjusting nut lock nut 64 Nm (47 ft-lbs)

Final Drive (Sprockets) Torques

Engine sprocket bolts 12 Nm (108 in-lbs)
Rear sprocket bolts/nuts 42 Nm (31 ft-lbs)

Brake Calipers, Disks and Drums Torques

Front Caliper
Caliper bracket bolts 30 Nm (22 ft-lbs)
Slider pin-to-caliper 23 Nm (1 7 ft-lbs)
Slider pin-to-caliper bracket 23 Nm (17 ft-lbs)
Pad pins 18 Nm (1 56 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 35 Nm (25 ft-lbs)
Brake disc-to-wheel bolts (do not reuse) 20 Nm (168 in-lbs)*
Front master cylinder Mounting bolts 10 Nm (84 in-lbs)
Rear master cylinder mounting bolts 13 Nm (108 in -lbs)

Engine Torques

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) Tighten securely
Lower (at bottom of frame downtube) 37 Nm (27 ft-lbs)
At engine 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 125 Nm (90 ft-lbs) (1)
Primary drive gear locknut 118 Nm (87 ft-lbs) (1)
Engine sprocket bolts 12 Nm (108 in-lbs)
Mainshaft bearing set plate bolt 12 Nm (108 in-lbs)
Oil pump stopper plate screw Tighten 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 threads and head
(2) Apply non-permanent thread lock to bolt threads

Exhaust Pipes and Mufflers Torques

Exhaust pipe-to-cylinder head nuts 18 Nm (156 in-lbs)
Muffler clamp bolts 20 Nm (168 in-lbs)
Muffler mounting bolts 32 Nm (24 ft-lbs)

Ignition and Electrical System Torques

Alternator rotor bolt 125 Nm (90 ft-lbs)*
Timing hole cover 84 in-lbs
*Apply clean engine oil to bolt threads and head

Frame and Bodywork Torques

Footpeg bolt/nut 54 Nm (40 ft-lbs)
Skid plate/bar Not available
Sidestand
Step 1 Tighten bolt to 10 Nm (84 in-lbs)
Step 2 Loosen bolt 1/8-turn
Step 3 Tighten nut to 40 Nm (29 ft-lbs)
Sidestand bracket-to-frame bolts
8 mm bolt 26 Nm (20 ft-lbs)
10 mm bolt 36 Nm (29 ft-lbs)
Subframe
Upper bolt 26 Nm (20 ft-lbs)
Lower bolts 42 Nm (31 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 (XR650R)

North American models  
Identification mark  
2000 to 2006  
Except California PE78A
California PE78B
2007 PE78E
Jet sizes and settings  
Main jet  
Standard 125
High altitude 122
Slow jet 65
Jet needle clip position  
Standard 2nd groove from top
High altitude Top groove
Mixture (pilot) screw setting (turns out from lightly seated position) – see Section 4  
Initial setting  
Standar  
Except California and all 2007 USA models 2
California and after 2007 USA models 1-1/5
Final setting 5/8 in from standard final setting (see Section 4)
High altitude 1/4-turn in from standard final setting (see Section 4)
Float level 16.0 mm (0.63 inch)
   
Except North American models  
Identification mark  
European and general export PE78C
Australia : PE780
Jet sizes and settings  
Mainjet  
European and general export 175
Australia : 112
Slow jet 65
Jet needle clip position 3rd groove from top
Mixture (pilot) screw setting (turns out from lightly seated position)  
Initial setting 1-3/4
Final setting 3/4 in from standard final setting (see Section 4)
Float level 16.0 mm (0.63 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)