Brakes - XL600V-H to L (1987 to 1990) models
Brake fluid type — DOT 4
Front caliper bore ID
- Standard — 30.230 to 30.280 mm
- Service limit — 30.29 mm
Front caliper piston OD
- Standard — 30.148 to 30.199 mm
- Service limit — 30.14 mm
Front master cylinder bore ID
- Standard — 12.700 to 12.743 mm
- Service limit — 12.76 mm
Front master cylinder piston OD
- Standard — 12.657 to 12.684 mm
- Service limit — 12.65 mm
Front disc thickness
- Standard — 4.5 mm
- Service limit — 3.5 mm
- Front disc maximum runout — 0.3 mm
- Rear brake shoe lining thickness — 2 mm minimum
Rear drum ID
- Standard — 130 mm
- Service limit — 131 mm
Brakes - XL600V-M to P (1991 to 1993) models
Brake fluid type — DOT 4
Front caliper bore ID
- Standard — 30.230 to 30280 mm
- Service limit — 30.29 mm
Front caliper piston OD
- Standard — 30.148 to 30.199 mm
- Service limit — 30.14 mm
Front master cylinder bore ID
- Standard — 11.000 to 11.040 mm
- Service limit — 11.05 mm
Front master cylinder piston OD
- Standard — 10.850 to 10.910 mm
- Service limit — 10.84 mm
Rear caliper bore ID
- Standard — 38.180 to 38.230 mm
- Service limit — 38.24 mm
Rear caliper piston OD
- Standard — 38.115 to 38.148 mm
- Service limit — 38.11mm
Rear master cylinder bore ID
- Standard — 14.000 to 14.043 mm
- Service limit — 14.05 mm
Rear master cylinder piston OD
- Standard — 13.957 to 13.984 mm
- Service limit — 13.95 mm
Disc thickness (front and rear)
- Standard — 4.8 to 5.2 mm
- Service limit — 4.0 mm
- Disc maximum runout — 0.3 mm
Brakes - XL600V-R to T (1994 to 1996) models
Brake fluid type — DOT 4
Front caliper bore ID
- Standard — 27.000 to 27.050 mm
- Service limit — 26.99 mm
Front caliper piston OD
- Standard — 26.935 to 26.968 mm
- Service limit — 26.97 mm
Front master cylinder bore ID
- Standard — 11.000 to 11.043 mm
- Service limit — 11.05 mm
Front master cylinder piston OD
- Standard — 10.957 to 10.984 mm
- Service limit — 10.95 mm
Rear caliper bore ID
- Standard — 38.180 to 38.230 mm
- Service limit — 38.24 mm
Rear caliper piston OD
- Standard — 38.115 to 38.148 mm
- Service limit — 38.11 mm
Rear master cylinder bore ID
- Standard — 14.000 to 14.043 mm
- Service limit — 14.05 mm
Rear master cylinder piston OD
- Standard — 13.957 to 13.984 mm
- Service limit — 13.95 mm
Disc thickness (front and rear)
- Standard — 4.8 to 5.2 mm
- Service limit — 4.0 mm
- Disc maximum runout — 0.3 mm
Brakes - XL600V-V to X (1997 to 1999) models
Brake fluid type — DOT 4
Front caliper bore ID
- Standard — 30.230 to 30.280 mm
- Service limit — 30.29 mm
Brakes - XL600V-V to X (1997 to 1999) models (continued)
Front caliper piston OD
- Standard — 30.148 to 30.199 mm
- Service limit — 30.14 mm
Front master cylinder bore ID
- Standard — 12.700 to 12.743 mm
- Service limit — 12.76 mm
Front master cylinder piston OD
- Standard — 12.657 to 12.684 mm
- Service limit — 12.65 mm
Front disc thickness
- Standard — 4.5 mm
- Service limit — 3.5 mm
- Front disc maximum runout — 0.3 mm
Rear caliper bore ID
- Standard — 38.180 to 38.230 mm
- Service limit — 38.24 mm
Rear caliper piston OD
- Standard — 38.115 to 38.148 mm
- Service limit — 38.11 mm
Rear master cylinder bore ID
- Standard — 14.000 to 14.043 mm
- Service limit — 14.05 mm
Rear master cylinder piston OD
- Standard — 13.957 to 13.984 mm
- Service limit — 13.95 mm
Rear disc thickness
- Standard — 4.8 to 5.2 mm
- Service limit — 4.0 mm
- Rear disc maximum runout — 0.3 mm
Brakes - XL650V models
Brake fluid type — DOT 4
Front caliper bore ID
Upper bore
- Standard — Not available
- Service limit — 32.040 mm
Lower bore
- Standard — Not available
- Service limit — 30.040 mm
Front caliper piston OD
Upper piston
- Standard — Not available
- Service limit — 31.910 mm
Lower piston
- Standard — Not available
- Service limit — 29.910 mm
Front master cylinder bore ID
- Standard — Not available
- Service limit — 13.043 mm
Front master cylinder piston OD
- Standard — Not available
- Service limit — 12.955 mm
Front disc thickness
- Standard — 4.5 mm
- Service limit — 3.5 mm
- Front disc maximum runout — 0.3 mm
Rear caliper bore ID
- Standard — 38.180 to 38.230 mm
- Service limit — 38.24 mm
Rear caliper piston OD
- Standard — 38.003 to 38.148 mm
- Service limit — 38.09 mm
Rear master cylinder bore ID
- Standard — 14.000 to 14.043 mm
- Service limit — 14.055 mm
Rear master cylinder piston OD
- Standard — 13.957 to 13.984 mm
- Service limit — 13.945 mm
Rear disc thickness
- Standard — 5.0 mm
- Service limit — 4.0 mm
- Rear disc maximum runout — 0.25 mm
Brakes - XRV750 models
Brake fluid type — DOT 4
Front caliper bore ID
- Standard — 27.000 to 27.050 mm
- Service limit — 27.06 mm
Front caliper piston OD
- Standard — 26.968 to 26.935 mm
- Service limit — 26.92 mm
Front master cylinder bore ID
- Standard — 12.700 to 12.743 mm
- Service limit — 12.75 mm
Front master cylinder piston OD
- Standard — 12.657 to 12.684 mm
- Service limit — 12.64 mm
Front disc thickness
- Standard — 4.5 mm
- Service limit — 3.5 mm
- Front disc maximum runout — 0.3 mm
Rear caliper bore ID
- Standard — 38.180 to 38.230 mm
- Service limit — 38.24 mm
Rear caliper piston OD
- Standard — 38.115 to 38.148 mm
- Service limit — 38.11mm
Rear master cylinder bore ID
- Standard — 14.000 to 14.043 mm
- Service limit — 14.05 mm
Rear master cylinder piston OD
- Standard — 13.957 to 13.984 mm
- Service limit — 13.95 mm
Rear disc thickness
- Standard — 5.0 mm
- Service limit — 4.0 mm
- Rear disc maximum runout — 0.25 mm
Wheels
Maximum wheel runout (front and rear)
- Axial (side-to-side) — 2.0 mm
- Radial (out-of-round) — 2.0 mm
- Maximum axle runout (front and rear) — 0.20 mm
Tyres
Tyre pressures — see Daily (pre-ride) checks
Tyre sizes
XL models
- Front — 90/90-21 54S
- Rear — 130/80-17 65S
XRV750-L to N (1990 to 1992) models
- Front — 90/90-21 54H
- Rear 130/90-17 65S
XRV750-P models onwards (1993-on)
- Front — 90/90-21 54S
- Rear — 140/80-R17 69H
*Refer to the owners handbook or the tyre information label on the swingarm for approved tyre brands.
Torque settings
- Brake caliper bleed valves — 6 Nm
- Brake disc bolts — 42 Nm
- Brake hose banjo bolts — 34 Nm
- Front axle — 64 Nm
- Front axle clamp nuts — 12 Nm
- Front brake master cylinder clamp bolts — 12 Nm
- Rear axle nut — 90 Nm
- Rear brake master cylinder bolts — 12 Nm