Front forks
- Fork oil type — 5 W fork oil
Fork oil capacity
- XL600V models — 549 cc
- XL650V models — 542 cc
- XRV750-L to N (1990 to 1992) models — 635 cc
- XRV750-P models onward (1993-on) — 648 cc
Fork oil level*
- XL600V models — 125 mm
- XL650V models — 141 mm
- XRV750-L to N (1990 to 1992) models — 118mm
- XRV750-P models onward (1993-on) — 106 mm
- Fork air pressure - XRV750-L to S (1990 to 1995) models — 0 to 5.7 psi (0 to 0.4 Bar)
Fork spring free length
XL600V-H to R (1987 to 1995) models
- Standard — 571.5 mm
- Service limit — 565.5 mm
XL600V-T to X (1996 to 1999) models
- Standard — 612 mm
- Service limit — 605 mm
XL650V models
- Standard — 599.4 mm
- Service limit — 589.2 mm
XRV750-L to N (1990 to 1992) models lipper spring
- Standard — 52.2 to 55.2 mm
- Service limit — 49.6 mm
Lower spring
- Standard — 575.7 to 578.7 mm
- Service limit — 546.9 mm
Front forks (continued)
Fork spring free length (continued)
XRV750-P models onward (1993-on)
Upper spring
- Standard — 68.3 mm
- Service limit — 66.9 mm
Lower spring
- Standard — 564.1 mm
- Service limit — 552.8 mm
- Fork tube runout limit — 0.2 mm
*Oil level is measured from the top of the tube with the fork spring removed and the leg fully compressed.
Rear shock absorber
Spring free length
XL600V-H and J (1987 and 1988) models
- Standard — 259.5 mm
- Service limit — 256.5 mm
XL600V-K to X (1989 to 1999) models
- Standard — 268.5 mm
- Service limit — 265.5 mm
XL650V models
Not available
XRV750-Lto N (1990 to 1992) models
- Standard — 238.0 to 241.0 mm
- Service limit — 233.0 mm
XRV750-P models onwards (1993-on)
- Standard — 245.5 mm
- Service limit — 240.6 mm
Spring installed length
XL600V-H and J (1987 and 1988) models
- Standard — 254.8 mm
- Maximum — 258.5 mm
- Minimum — 249.8 mm
XL600V-K to X (1989 to 1999) models
- Standard — 262.9 mm
- Maximum — 266.5 mm
- Minimum — 257.8 mm
XL650V models
- Standard — 193.9 mm
Maximum and minimum
Not available
XRV750-L to N (1990 to 1992) models
- Standard — 230.5 mm
- Maximum — 235.5 mm
- Minimum — 222.5 mm
XRV750-P models onward (1993-on)
- Standard — 242.7 mm
Maximum and minimum
Not available
Rear suspension linkage - XL600V-H and J models
Suspension linkage arm bush ID
Shock absorber pivot
- Standard — 15.103 to 15.158 mm
- Service limit — 15.188 mm
Swingarm pivot
- Standard — 18.099 to 18.159 mm
- Service limit — 18.195 mm
Linkage rod pivot
- Standard — 15.103 to 15.158 mm
- Service limit — 15.188 mm
Suspension linkage arm collar OD
Shock absorber pivot
- Standard — 15.040 to 15.055 mm
- Service limit — 15.010 mm
Swingarm pivot
- Standard — 17.947 to 17.980 mm
- Service limit — 17.911 mm
Linkage rod pivot
- Standard — 15.040 to 15.055 mm
- Service limit — 15.010 mm
Rear suspension linkage - XL600V-H and J models (continued)
Suspension linkage rod bush ID at shock absorber pivot
- Standard — 17.103 to 17.153 mm
- Service limit — 17.187 mm
Suspension linkage rod collar OD at shock absorber pivot
- Standard — 16.966 to 16.984 mm
- Service limit — 16.932 mm
Final drive
Drive chain slack and lubricant (see Chapter 1)
Drive chain
Type Length
- XL600V-H to R (1987 to 1995) models DID 525V8-LE or RK 525SMO-LE 118 links. Length: 118 links
- XL600V-T to W (1996 to 1998) models DID 525HV8 or RK 525SMOZ5 118 links. Length: 118 links
- XL600V-X (1999) models DID 525H-LJF4 or RK 525SMOZ5-JFZ 120 links. Length: 120 links
- XL650V models DID 525HV or RK 525ROZ1 110 links. Length: 110 links
- XRV750-Lto N (1990 to 1992) models DID 525V8-LE or RK 525SMO-Z3XLE 124 links. Length: 124 links
- XRV750-P to T (1993 to 1996) models DID 525V8 or RK 525SMO-Z4 124 links. Length: 124 links
- XRV750-V models onwards (1997-on) DID 525V8 or RK 525SMO-Z5 124 links. Length: 124 links
Joining link pin projection from side plate (unstaked)
- DID type chain — 1.15 to 1.55 mm
- RK type chain — 1.20 to 1.40 mm
Joining link staked ends diameter
- DID type chain — 5.50 to 5.80 mm
- RK type chain — 5.55 to 5.85 mm
Sprocket sizes Front (engine) sprocket
- XL600V and XL650V models — 15T
- XRV750 models — 16T
Rear (wheel) sprocket
- XL600V models — 47T
- XL650V models — 48T
- XRV750-L to N (1990 to 1992) models — 46T
- XRV750-P models onward (1993-on) — 45T
Torque settings
- Front brake master cylinder clamp bolts — 12 Nm
- Front fork clamp bolts in bottom yoke — 33 Nm
- Front fork clamp bolts In top yoke — 27 Nm
- Front fork damper rod bolt — 20 Nm
- Front fork top bolt — 23 Nm
- Front sprocket retainer plate bolts — 10 Nm
- Handlebar holder clamp bolts — 26 Nm
Rear sprocket nuts
- XL600V and XL650V models — 45 Nm
- XRV750-L to N (1990 to 1992) models — 46 Nm
- XRV750-P models onward (1993-on) — 98 Nm
- Shock absorber mounting bolt nuts — 44 Nm
- Sidestand pivot bolt — 10 Nm
- Sidestand pivot bolt nut
- XL600V and XRV750 models — 40 Nm
- XL650V models — 30 Nm
Steering head bearing adjuster nut (see text)
- XL600V-H and J (1987 and 1988) models — 4 to 6 Nm
- XL600V-K to P (1989 to 1993) models — 2.5 to 3.5 Nm
- XL600V-R to X (1994 to 1999) models — 5 Nm
- XL650V models — 5 Nm
- XRV750 models — 11 Nm
Steering stem nut
- XL600V-H to P (1987 to 1993) models — 100 Nm
- XL600V-R to X (1994 to 1999) models — 105 Nm
- XL650V models — 105 Nm
- XRV750-L to N (1990 to 1992) models — 100 Nm
- XRV750-P models onward (1993-on) — 128 Nm
- Swingarm pivot bolt nut XL600V models — 110 Nm
- XL650V models — 90 Nm
- XRV750-L to N (1990 to 1992) models — 110 Nm
- XRV750-P models onward (1993-on) — 106 Nm