General
Capacity
- XL600V models — 583 cc
- XL650V models — 647 cc
- XRV750 models — 742 cc
Bore
- XL600V models — 75.0 mm
- XL650V models — 79.0 mm
- XRV750 models — 81.0 mm
Stroke
- XL600V and XL650V models — 66.0 mm
- XRV750 models — 72.0 mm
Compression ratio
- XL600V and XL.650V models 9.2 to 1
- XRV750 models 9.0 to 1
Cylinder compression
- XL600V-H to P (1987 to 1993) models 157 to 185 psi (11.0 to 13.0 Bar)
- XL600V-R to X (1994 to 1999) models 164 to 192 psi (11.5 to 12.5 Bar)
- XL650V models 164 to 224 psi (11.5 to 15.5 Bar) @ 400 rpm
- XRV750 models 157 to 213 psi (11.0 to 15.0 Bar) @ 400 rpm
Cooling system — Liquid cooled
Clutch — Wet multi-plate
Transmission — Five-speed constant mesh
Final drive — Chain and sprockets
Camshafts, rockers and cam chain - XL600V-H and J (1987 and 1988)
Cam chain tensioner projection (max) — 6 mm
Camshafts
Intake lobe height
- Standard — 38.222 mm
- Service limit — 38.00 mm
Exhaust lobe height
- Standard — 38.131 mm
- Service limit — 37.90 mm
Journal diameter
- Standard — 21.959 to 21.980 mm
- Service limit — 21.90 mm
Camshaft bearing oil clearance
- Standard — 0.141 to 0.220 mm
- Service limit — 0.23 mm
Camshaft runout
- Standard — 0.03 mm
- Service limit — 0.05 mm
Rockers Rocker shaft diameter
- Standard — 11.966 to 11.984 mm
- Service limit — 11.83 mm
Rocker arm internal diameter
- Standard — 12.000 to 12.018 mm
- Service limit — 12.05 mm
Rocker arm-to-shaft clearance
- Standard — 0.016 to 0.052 mm
- Service limit — 0.22 mm
Camshafts, rockers and cam chain - XL600V-K to X (1989 and 1999)
Cam chain tensioner projection (max) — 6 mm
Camshafts
Intake lobe height
- Standard — 38.094 to 38.284 mm
- Service limit — 38.074 mm
Exhaust lobe height
- Standard — 38.118 to 38.308 mm
- Service limit — 38.098 mm
Journal diameter
- Standard — 21.959 to 21.980 mm
- Service limit — 21.95 mm
Camshaft bearing oil clearance
- Standard — 0.050 to 0.111 mm
- Service limit — 0.13 mm
Camshaft runout
- Standard — 0.03 mm
- Service limit — 0.05 mm
Rockers
Rocker shaft diameter
- Standard — 11-966 to 11.984 mm
- Service limit — 11.83 mm
Hocker arm internal diameter
- Standard — 12.000 to 12.018 mm
- Service limit — 12.05 mm
Rocker arm-to-shaft clearance
- Standard — 0.016 to 0.052 mm
- Service limit — 0.22 mm
Camshafts, rockers and cam chain - XL650V models
Cam chain tensioner projection (max) — 6 mm
Camshafts
Intake lobe height
- Standard — 38.189 mm
- Service limit — 38.17 mm
Exhaust lobe height
- Standard — 38.213 mm
- Service limit — 38.19 mm
Camshafts, rockers and cam chain - XL650V models (continued)
Camshafts (continued)
Journal diameter
- Standard — 21.959 to 21.980 mm
- Service limit — 21.95 mm
Camshaft bearing oil clearance
- Standard — 0.040 to 0.093 mm
- Service limit — 0.13 mm
Camshaft runout
- Standard — 0.03 mm
- Service limit — 0.05 mm
Rockers Rocker shaft diameter
- Standard — 11.966 to 11.984 mm
- Service limit — 11.96 mm
Rocker arm internal diameter
- Standard — 12.000 to 12.018 mm
- Service limit — 12.03 mm
Rocker arm-to-shaft clearance
- Standard — 0.016 to 0.052 mm
- Service limit — 0.07 mm
Camshafts, rockers and cam chain - XRV750 models
- Cam chain tensioner projection (max) — 6 mm
Camshafts
Intake lobe height
- Standard — 38.381 mm
- Service limit — 38.10 mm
Exhaust lobe height
- Standard — 38.407 mm
- Service limit — 38.20 mm
Journal diameter
- Standard — 21.959 to 21.980 mm
- Service limit — 21.94 mm
Camshaft bearing oil clearance
- Standard — 0.050 to 0.111 mm
- Service limit — 0.15 m
Camshaft runout
- Standard — 0.03 mm
- Service limit — 0.05 mm
Rockers
Rocker shaft diameter
- Standard — 11.966 to 11.984 mm
- Service limit — 11.95 mm
Rocker arm Internal diameter
- Standard — 12.000 to 12.018 mm
- Service limit — 12.04 mm
Rocker arm-to-shaft clearance
- Standard — 0.016 to 0.052 mm
- Service limit — 0.08 mm
Cylinder head
Warpage (max) — 0.10 mm
Valves, guides and springs - XL600V-H to L (1987 to 1990) models
Intake valve
Stem diameter
- Standard — 5.475 to 5.490 mm
- Service limit — 5.45 mm
Guide bore diameter
- Standard — 5.500 to 5.520 mm
- Service limit — 5.56 mm
Stem-to-guide clearance
- Standard — 0.010 to 0.045 mm
- Service limit — 0.10 mm
Seat width
- Standard — 0.9 to 1.1 mm
- Service limit — 1.5 mm
Valves, guides and springs - XL600V-H to L (1987 to 1990) models (continued)
Intake valve (continued)
Spring free length - outer spring
- Standard — 46.00 mm
- Service limit — 44.30 mm
Spring free length - inner spring
- Standard — 37.18 mm
- Service limit — 35.58 mm
Guide projection height (above cylinder head) — 19.4 to 19.6 mm
Exhaust valve
Stem diamete
- Standard — 6.565 to 6.570 mm
- Service limit — 6.55 mm
Guide bore diameter
- Standard — 6.600 to 6.620 mm
- Service limit — 6.65 mm
Stem-to-guide clearance
- Standard — 0.035 to 0.050 mm
- Service limit — 0.11 mm
Seat width
- Standard — 0.9 to 1.1 mm
- Service limit — 1.5 mm
Spring free length - outer spring
- Standard — 45.99 mm
- Service limit — 44.29 mm
Spring free length - inner spring
- Standard — 44.82 mm
- Service limit — 43.32 mm
Guide projection height (above cylinder head) — 17.9 to 18.1 mm
Valve clearances — see Chapter 1
Valves, guides and springs - XL600V-M to T (1991 to 1996) models
Intake valve
Stem diameter
- Standard — 5.475 to 5.490 mm
- Service limit — 5.46 mm
Guide bore diamete
- Standard — 5.500 to 5.512 mm
- Service limit — 5.55 mm
Stem-to-guide clearance
- Standard — 0.010 to 0.037 mm
- Service limit — 0.08 mm
Seat width
- Standard — 0.9 to 1.1 mm
- Service limit — 1.5 mm
Spring free length - outer spring
- Standard — 42.14 mm
- Service limit — 40.00 mm
Spring free length - inner spring
- Standard — 38.11mm
- Service limit — 36.00 mm
Guide projection height (above cylinder head) — 19.4 to 19.6 mm
Exhaust valve
Stem diameter
- Standard — 6.555 to 6.570 mm
- Service limit — 6.54 mm
Guide bore diameter
- Standard — 6.600 to 6.615 mm
- Service limit — 6.69 mm
Stem-to-guide clearance
- Standard — 0.030 to 0.060 mm
- Service limit — 0.08 mm
Seat width
- Standard — 0.9 to 1.1 mm
- Service limit — 1-5 mm
Spring free length - outer spring
- Standard — 42.83 mm
- Service limit — 40.50 mm
Valves, guides and springs - XL600V-M to T (1991 to 1996) models (continued)
Exhaust valve (continued)
Spring free length - inner spring
- Standard — 38.81 mm
- Service limit — 36.0 mm
Guide projection height (above cylinder head) — 17.9 to 18.1 mm
Valve clearances — see Chapter 1
Valves, guides and springs - XL600V-V to X (1997 to 1999) models
Intake valve
Stem diameter
- Standard — 5.475 to 5.490 mm
- Service limit — 5.45 mm
Guide bore diameter
- Standard — 5.500 to 5.520 mm
- Service limit — 5.56 mm
Stem-to-guide clearance
- Standard — 0.010 to 0.045 mm
- Service limit — 0.10 mm
Seat width
- Standard — 0.9 to 1.1 mm
- Service limit — 1.5 mm
Spring free length - outer spring
- Standard — 42.14 mm
- Service limit — 40.00 mm
Spring free length - inner spring
- Standard — 38.11 mm
- Service limit —36.00 mm
Guide projection height (above cylinder head) — 19.4 to 19.6 mm
Exhaust valve
Stem diameter
- Standard — 6.565 to 6.570 mm
- Service limit — 6.55 mm
Guide bore diameter
- Standard — 6.600 to 6.620 mm
- Service limit — 6.65 mm
Stem-to-guide clearance
- Standard — 0.035 to 0.050 mm
- Service limit — 0.10 mm
Seat width
- Standard — 0.9 to 1.1 mm
- Service limit — 1.5 mm
Spring free length - outer spring
- Standard — 42.83 mm
- Service limit — 40.50 mm
Spring free length - inner spring
- Standard — 38.81 mm
- Service limit — 36.0 mm
Guide projection height (above cylinder head) — 17.9 to 18.1 mm
Valve clearances — see Chapter 1
Valves, guides and springs - XL650V models
Intake valve
Stem diameter
- Standard — 5.475 to 5.490 mm
- Service limit — 5.47 mm
Guide bore diameter
- Standard — 5.500 to 5.512 mm
- Service limit — 5.53 mm
Stem-to-guide clearance
- Standard — 0.010 to 0.037 mm
- Service limit — 0.07 mm
Seat width
- Standard — 0.9 to 1.1 mm
- Service limit —1.5 mm
Spring free length - outer spring
- Standard — 42.14 mm
- Service limit — 40.58 mm
Valves, guides and springs - XL650V models (continued)
Intake valve (continued)
Spring free length - inner spring
- Standard — 38.11mm
- Service limit — 36.47 mm
Guide projection height (above cylinder head) — 19.4 to 19.6 mm
Exhaust valve
Stem diameter
- Standard — 6.555 to 6.570 mm
- Service limit — 6.55 mm
Guide bore diameter
- Standard — 6.600 to 6.615 mm
- Service limit — 6.66 mm
Stem-to-guide clearance
- Standard — 0.030 to 0.060 mm
- Service limit — 0.11mm
Seat width
- Standard — 0.9 to 1.1 mm
- Service limit — 1.5 mm
Spring free length - outer spring
- Standard — 42.83 mm
- Service limit — 41.25 mm
Spring free length - inner spring
- Standard — 38.81 mm
- Service limit — 37.51 mm
Guide projection height (above cylinder head) — 17.9 to 18.1 mm
Valve clearances — see Chapter 1
Valves, guides and springs - XRV750 models
Intake valve
Stem diameter
- Standard — 5.475 to 5.490 mm
- Service limit — 5.46 mm
Guide bore diameter
- Standard — 5.500 to 5.512 mm
- Service limit — 5.55 mm
Stem-to-guide clearance
- Standard — 0.010 to 0.037 mm
- Service limit — 0.08 mm
Seat width
- Standard — 0.9 to 1.1 mm
- Service limit — 1.5 mm
Spring free length - outer spring
- Standard — 42.14 mm
- Service limit — 40.00 mm
Spring free length - inner spring
- Standard — 38.11 mm
- Service limit — 36.00 mm
Guide projection height (above cylinder head) — 19.4 to 19.6 mm
Exhaust valve
Stem diameter
- Standard — 6.555 to 6.570 mm
- Service limit — 6.54 mm
Guide bore diameter
- Standard — 6.600 to 6.615 mm
- Service limit — 6.69 mm
Stem-to-guide clearance
- Standard — 0.030 to 0.060 mm
- Service limit — 0.12 mm
Seat width
- Standard — 0.9 to 1.1 mm
- Service limit — 1.5 mm
Spring free length - outer spring
- Standard — 42.83 mm
- Service limit — 40.50 mm
Spring free length - inner spring
- Standard — 38.81 mm
- Service limit — 36.0 mm
Guide projection height (above cylinder head) — 17.9 to 18.1 mm
Valve clearances — see Chapter 1
Cylinders - XL600V models
Bore diameter
- Standard — 75.00 to 75.015 mm
- Wear limit — 75.17 mm
Taper (max) — 0.05 mm
Ovality (max) — 0.05 mm
Warpage (max) — 0.10 mm
Cylinders - XL650V models
Bore diameter
- Standard — 79.00 to 79.015 mm
- Wear limit — 79.05 mm
Taper (max) — 0.05 mm
Ovality (max) — 0.05 mm
Warpage (max) — 0.10 mm
Cylinders - XRV750 models
Bore diameter
- Standard — 81.00 to 81.015 mm
- Wear limit — 81.15 mm
Taper (max) — 0.05 mm
Ovality (max) — 0.08 mm
Warpage (max) — 0.05 mm
Pistons - XL600V models
Piston diameter (measured 10.0 mm up from skirt, at 90° to piston pin axis)
- Standard — 74.965 to 74.990 mm
- Service limit — 74.84 mm
- Oversizes — +0.25 mm. +0.50 mm
Piston-to-bore clearance
- Standard — 0.010 to 0.050 mm
- Service limit — 0.32 mm
Piston pin diameter
- Standard — 17.994 to 18.000 mm
- Service limit — 17.80 mm
Piston pin bore
- Standard — 18.002 to 18.008 mm
- Service limit — 18.05 mm
Piston pin-to-bore clearance
- Standard — 0.002 to 0.014 mm
- Service limit — 0.025 mm
Connecting rod small-end internal diameter
- Standard — 18.016 to 18.034 mm
- Service limit — 18.09 mm
Piston pin-to-connecting rod small-end clearance
- Standard — 0.016 to 0.040 mm
- Service limit — 0.029 mm
Pistons - XL650V models
Piston diameter (measured 12.0 mm up from skirt, at 90° to piston pin axis)
- Standard — 78.970 to 78.990 mm
- Service limit — 78.92 mm
- Oversizes — +0.25 mm, +0.50 mm
Piston-to-bore clearance
- Standard — 0.010 to 0.035 mm
- Service limit — 0.13 mm
Piston pin diameter
- Standard — 19.994 to 20.000 mm
- Service limit — 19.98 mm
Piston pin bore
- Standard — 20.002 to 20.008 mm
- Service limit — 20.02 mm
Piston pin-to-bore clearance
- Standard — 0.002 to 0.014 mm
- Service limit — 0.03 mm
Connecting rod small-end internal diameter
- Standard — 20.016 to 20.034 mm
- Service limit — 20.04 mm
Pistons - XL650V models (continued)
Piston pln-to-connecting rod small-end clearance
- Standard — 0.016 to 0.040 mm
- Service limit — 0.06 mm
Pistons - XRV750 models
Piston diameter (measured 10.0 mm up from skirt, at 90° to piston pin axis)
- Standard — 80.970 to 80.990 mm
- Service limit — 80.85 mm
- Oversizes — +0.25 mm. +0.50 mm
Piston-to-bore clearance
- Standard — 0.010 to 0.045 mm
- Service limit — 0.15 mm
Piston pin diameter
- Standard — 19.994 to 20.000 mm
- Service limit — 19.98 mm
Piston pin bore
- Standard — 20.002 to 20.008 mm
- Service limit — 20.03 mm
Piston pin-to-bore clearance
- Standard — 0.002 to 0.014 mm
- Service limit — 0.04 mm
Connecting rod small-end internal diameter
- Standard — 20.016 to 20.034 mm
- Service limit — 20.05 mm
Piston pin-to-connecting rod small-end clearance
- Standard — 0.016 to 0.040 mm
- Service limit — 0.060 mm
Piston rings - XL600V models
Ring-to-groove clearance
Top ring
- Standard — 0.015 to 0.045 mr
- Service limit — 0.10 mm
2nd ring
- Standard — 0.015 to 0.045 mi
- Service limit — 0.10 mm
End gap (installed)
Top ring
- Standard — 0.10 to 0.30 mm
- Service limit — 0.50 mm
2nd ring
- Standard — 0.10 to 0.30 mm
- Service limit — 0.50 mm
OH ring
- Standard — 0.20 to 0.70 mm
- Service limit — 0.90 mm
Piston rings - XL650V models
Ring-to-groove clearance
Top ring
- Standard — 0.025 to 0.055 mm
- Service limit — 0.11 mm
2nd ring
- Standard — 0.015 to 0.045 mm
- Service limit — 0.10 mm
End gap (installed)
Top ring
- Standard — 0.20 to 0.35mm
- Service limit — 0.7 mm
2nd ring
- Standard — 0.35 to 0.50 mm
- Service limit — 0,7 mm
Oil ring
- Standard — 0.20 to 0.80 mm
- Service limit — 1-0 mm
Piston rings - XRV750 models
Ring-to-groove clearance
Top ring
- Standard — 0.015 to 0.045 mm
- Service limit — 0.08 mm
2nd ring
- Standard — 0.015 to 0.045 mm
- Service limit — 0.08 mm
End gap (installed)
Top ring
- Standard — 0.20 to 0.35mm
- Service limit — 0.7 mm
2nd ring
- Standard — 0.35 to 0.50 mm
- Service limit — 0.7 mm
Oil ring
- Standard — 0.20 to 0.80 mm
- Service limit — 1.0 mm
Clutch - XL600V models
Friction plate (see Section 17 for identification)
Type A
- Quantity — 6
- Thickness — 2.92 to 3.08 mm
- Service limit — 2.6 mm
Type В
- Quantity — 1
- Thickness — 2.92 to 3.08 mm
- Service limit — 2.6 mm
Plain plate
- Quantity — 6
- Warpage (max) — 0.3 mm
Springs
- Free length — 39.0 mm
- Service limit — 37.4 mm
Input shaft diameter at clutch housing guide
- Standard — 21.967 to 21.980 mm
- Service limit — 21.92 mm
Clutch housing guide
Internal diameter
- Standard — 21.991 to 22.016 mm
- Seivice limit — 22.09 mm
External diameter
- Standard — 31.959 to 31.975 mm
- Service limit — 31.92 mm
Clutch housing Internal diameter
- Standard — 32.000 to 32.025 mm
- Service limit — 32.10 mm
Oil pump drive sprocket internal diameter
- Standard — 32.000 to 32.025 mm
- Service limit — 32.10 mm
Clutch - XL650V models
Friction plate (see Section 17 for identification)
Type A
- Quantity — 7
- Thickness — 2.62 to 2.78 mm
- Service limit — 2.3 mm
Type В
- Quantity — 1
- Thickness — 2.92 to 3.08 mm
- Service limit — 2.6 mm
Plain plate
- Quantity — 7
- Warpage (max) — 0.3 mm
- Springs Free length — 44.2 mm
- Service limit — 42.2 mm
Clutch - XL650V models (continued)
Input shaft diameter at clutch housing guide
- Standard — 21.967 to 21.980 mm
- Service limit — 21.95 mm
Clutch housing guide
Internal diameter
- Standard — 21.991 to 22.016 mm
- Service limit — 22.09 mm
External diameter
- Standard — 31.959 to 31.975 mm
- Service limit — 31.92 mm
Oil pump drive sprocket internal diameter
- Standard — 32.025 to 32.145 mm
- Service limit — 32.15 mm
Clutch - XRV750 models
Friction plate
Quantity 7
- Thickness — 3.72 t 3.88 mm
- Service limit — 3.6 mm
Plain plate
- Quantity — 6
- Warpage (max) — 0.15 mm
- Springs Free length — 41.2 mm
- Service limit — 39.0 mm
Input shaft diameter at clutch housing guide
- Standard — 24.967 to 24.980 mm
- Service limit — 24.95 mm
Clutch housing guide
Internal diameter
- Standard — 24.991 to 25.016 mm
- Service limit — 25.03 mm
External diameter
- Standard — 34.968 to 34.984 mm
- Service limit — 34.96 mm
Oil pump drive sprocket internal diameter
- Standard — 35.025 to 35.075 mm
- Service limit — 35.10 mm
Starter clutch - XL600V models
Starter driven gear hub external diameter
- Standard — 57.749 to 57.768 mm
- Service limit — 57.60 mm
Starter clutch - XL650V models
Starter driven gear hub external diameter
- Standard — 57.749 to 57.768 mm
- Service limit — 57.73 mm
Starter driven gear hub internal diameter
- Standard — 37.000 to 37.025 mm
- Service limit —37.10 mm
Starter clutch - XRV750 models
Starter driven gear hub external diameter
- Standard — 57.749 to 57.768 mm
- Service limit — 57.73 mm
Starter driven gear hub internal diameter
- Standard — 40.000 to 40.021 mm
- Seivice limit — 40.10 mm
Connecting rods - XL600V and XL650V models
- Side clearance Standard — 0.05 to 0.20 mm
- Service limit — 0.30 mm
Bearing oil clearance
- Standard — 0.028 to 0.052 mm
- Service limit — 0.07 mm
Connecting rods - XL600V and XL650V models (continued)
Big-end internal diameter
- Size code 1 — 43.000 to 43.008 mn
- Size code 2 — 43.008 to 43.016 mn
Crankpin diameter
- Size code A — 39.982 to 39.990 mn
- Size code В — 39.974 to 39.983 mn
For connecting rod small-end specifications see under 'Pistons'
Connecting rods - XRV750 models
Side clearance
- Standard — 0.15 to 0.30 mm
- Service limit — 0.4 mm
Bearing oil clearance
- Standard — 0.028 to 0.052 mm
- Service limit — 0.10 mm
Big-end internal diameter
- Size code 1 — 46.000 to 46.008 mn
- Size code 2 — 46.008 to 46.016 mn
Crankpin diameter
- Size code A — 42.982 to 42.990 mn
- Size code В — 42.974 to 42.982 mn
For connecting rod small — end specifications see under 'Pistons'
Crankshaft and bearings - XL600V and XL650V models
Main bearing oil clearance
- Standard — 0.025 to 0.041 mm
- Service limit — 0.06 mm
- Runout (max) — 0.05 mm
Crankshaft and bearings - XRV750 models
Main bearing oil clearance
- Standard — 0.025 to 0.041 mm
- Service limit — 0.10 mm
- Runout (max) — 0.03 mm
Transmission - XL600V models
Gear ratios (No. of teeth)
H to R (1987 to 1995) models
Primary reduction — 1.888 to 1 (68/36T)
Final reduction — 3.133 to 1 (47/15T)
- 1st gear — 2.571 to 1 (36/14T)
- 2nd gear — 1.777 to 1 (32/18T)
- 3rd gear — 1.380 to 1 (29/21T)
- 4th gear — 1.125 to 1 (27/24T)
- 5th gear — 0.961 to 1 (25/26T)
T to X (1996 to 1999) models
Primary reduction — 1.888 to 1 (68/36T)
Final reduction — 3.133 to 1 (47/15T)
- 1st gear — 2.500 to 1 (35/14T)
- 2nd gear — 1.722 to 1 (31/18T)
- 3rd gear — 1.333 to 1 (28/21T)
- 4th gear — 1.111 to 1 (30/2/Т)
- 5th gear — 0.961 to 1 (25/26T)
Gear ID
Input shaft 4th and 5th gears, output shaft 2nd and 3rd gears
- Standard — 28.000 to 28.021 mn
- Service limit — 28.04 mm
Output shaft 1 st gear
- Standard — 24.000 to 24.021 mn
- Service limit — 24.04 mm
Gear bushing OD
Input shaft 4th and 5th gears, output shaft 2nd and 3rd gears
- Standard — 27.959 to 27.980 mn
- Service limit — 27.94 mm
- Output shaft 1st gear Standard — 23.959 to 23.980 mn
- Service limit — 23.94 mm
Transmission - XL600V models (continued)
Gear bushing ID
Input shaft 4th gear, output shaft 2nd and 3rd gears
- Standard — 25.000 to 25.021 mm
- Service limit — 25.04 mm
Output shaft 1 st gear
- Standard 20.016 to 20.037 mm
- Service limit — 20.06 mm
Gear-to-bushing clearance
- Standard — 0.020 to 0.062 mm
- Service limit — 0.10 mm
Input shaft OD at 4th gear bush point
- Standard — 24.959 to 24.980 mm
- Service limit — 24.90 mm
Output shaft OD
1st gear bush point
- Standard — 19.980 to 19.993 mm
- Service limit — 19.92 mm
2nd and 3rd gear bush point
- Standard — 24.959 to 24.980 mm
- Service limit — 24.90 mm
Shaft-to-bushing clearance
- Standard — 0.005 to 0.047 mm
- Service limit — 0.06 mm
Gear backlash
1st gear
- Standard — 0.089 to 0.170 mm
- Service limit — 0.24 mm
2nd, 3rd, 4th and 5th gears
- Standard — 0.068 to 0.136 mm
- Service limit — 0.18 mm
Transmission - XL650V models
Gear ratios (No. of teeth)
- Primary reduction — 1.763 to 1 (67/38T)
- Final reduction — 3.200 to 1
- 1st gear — 2.500 to 1 (35/14T)
- 2nd gear — 1.722 to 1 (31/181)
- 3rd gear — 1.333 to 1 (28/21T)
- 4th gear — 1.111 to 1 (30/27T)
- 5th gear — 0.961 to 1 (25/26T)
Gear ID (input shaft 4th and 5th gears, output shaft 1st, 2nd and 3rd gears)
- Standard — 28.000 to 28.021 mm
- Service limit — 28.03 mm
Gear bush OD (input shaft 4th and 5th gears, output shaft 1 st. 2nd and 3rd gears)
- Standard — 27.959 to 27.980 mm
- Service limit — 27.95 mm
Gear bush ID (input shaft 4th gear, output shaft 2nd and 3rd gears)
- Standard — 25.000 to 25.021 mm
- Service limit — 25.03 mm
Gear-to-bush clearance (input shaft 4th and 5th gears, output shaft 1st, 2nd and 3rd gears)
- Standard — 0.020 to 0.062 mm
- Service limit — 0.08 mm
Input shaft OD
4th gear bushing point
- Standard — 24.959 to 24.980 mm
- Service limit — 24.95 mm
Crankcase journal A
- Standard — 19.980 to 19.993 mm
- Service limit — 19.96 mm
Crankcase journal В
- Standard — 21.967 to 21.980 mm
- Service limit — 21.94 mm
Output shaft OD
2nd and 3rd gear bush point
- Standard — 24.959 to 24.980 mm
- Service limit — 24.95 mm
Transmission - XL650V models (continued)
Output shaft OD (continued)
Crankcase journal A
- Standard — 21.967 to 21.980 mm
- Service limit — 21.94 mm
Crankcase journal В
- Standard — 21.967 to 21.980 mm
- Service limit — 21.94 mm
Shaft-to-bushing clearance (input shaft 4th gear, output shaft 2nd and 3rd gears)
- Standard — 0.020 to 0.062 mm
- Service limit — 0.08 mm
Transmission - XRV750 models
Gear ratios (No. of teeth)
L to N(1990 to 1992) models
- Primary reduction — 1.763 to 1 (67/38T)
- Final reduction — 2.875 to 1 (46/16T)
- 1st gear — 3.083 to 1 (37/12T)
- 2nd gear — 2.062 to 1 (33/16T)
- 3rd gear — 1.550 to 1 (31/20T)
- 4th gear — 1.272 to 1 (28/22T)
- 5th gear — 1.083 to 1 (26/24T)
P models onwards (1993-on)
- Primary reduction — 1.763 to 1 (67/38T)
- Final reduction — 2.812 to 1 (45/16T)
- 1st gear — 3.083 to 1 (37/12T)
- 2nd gear — 2.062 to 1 (33/16T)
- 3rd gear — 1.550 to 1 (31/20T)
- 4th gear — 1.272 to 1 (28/22T)
- 5th gear — 1.083 to 1 (26/24T)
Gear ID
Input shaft — 3rd and 5th gears
- Standard — 28.000 to 28.021 mm
- Service limit — 28.04 mm
Output shaft 1 st, 2nd and 4th gears
- Standard — 31.000 to 31.025 mm
- Service limit — 31.05 mm
Gear bushing OD
Input shaft 3rd and 5th gears
- Standard — 27.959 to 27.980 mm
- Service limit — 27.94 mm
Output shaft 1st, 2nd and 4th gears
- Standard — 30.950 to 30.975 mm
- Service limit — 30.93 mm
Gear bushing ID
Input shaft 3rd gear
- Standard — 25.000 to 25.021 mm
- Service limit — 25.04 mm
Output shaft 2nd gear
- Standard — 27.995 to 28.016 mm
- Service limit — 28.04 mm
Gear-to-bushing clearance
Input shaft 3rd and 5th gear
- Standard — 0.020 to 0.062 mm
- Service limit — 0.10 mm
Output shaft 1 st, 2nd and 4th gears
- Standard — 0.025 to 0.075 mm
- Service limit — 0.11mm
Input shaft OD
3rd gear bushing point
- Standard — 24.972 to 24.993 mm
- Service limit — 24.95 mm
Crankcase journal A
- Standard — 19.980 to 19.993 mm
- Service limit — 19.96 mm
Crankcase journal В
- Standard — 24.980 to 24.993 mm
- Service limit — 24.96 mm
Transmission - XRV750 models (continued)
Output shaft OD
2nd gear bushing point
- Standard — 27.967 to 27.980 mm
- Service limit — 27.95 mm
Crankcase journal A
- Standard — 27.972 to 27.990 mm
- Service limit — 27.95 mm
Crankcase journal В
- Standard — 19.980 to 19.993 mm
- Service limit — 19.96 mm
Shaft-to-bushing clearance
Input shaft 3rd gear
- Standard — 0.007 to 0.049 mm
- Service limit — 0.08 mm
Output shaft 2nd gear
- Standard — 0.015 to 0.049 mm
- Service limit — 0.08 mm
Selector drum and forks - XL600V models
Selector fork end thickness
- Standard — 5.93 to 6.00 mm
- Service limit — 5.63 mm
Selector fork bore ID
- Standard — 13.000 to 13.018 mm
- Service limit — 13.04 mm
Selector fork shaft OD
- Standard — 12.966 to 12.984 mm
- Service limit — 12.90 mm
Selector drum OD at the left-hand journal
- Standard — 13.966 to 13.984 mm
- Service limit — 13.90 mm
Selector drum and forks - XL650V models
Selector fork end thickness
- Standard — 5.93 to 6.00 mm
- Service limit — 5.60 mm
Selector fork bore ID
- Standard — 13.000 to 13.021 mm
- Service limit — 13.04 mm
Selector fork shaft OD
- Standard — 12.966 to 12.984 mm
- Service limit — 12.90 mm
Selector drum OD at the left-hand journa
- Standard — 11.966 to 11.984 mm
- Service limit — 11.90 mm
Selector drum and forks - XRV750 models
Selector fork end thickness
- Standard — 5.93 to 6.00 mm
- Service limit — 5.90 mm
Selector fork bore ID
- Standard — 13.000 to 13.021 mm
- Service limit — 13.04 mm
Selector fork shaft OD
- Standard — 12.966 to 12.984 mm
- Service limit — 12.95 mm
Lubrication system
Oil type, viscosity and capacity — see Chapter 1
Oil pressure (at oil pressure switch, with engine warm)
- XL models — 64 psi (4.5 Bar) @ 6000 rpm, oil @ 80°C
- XRV models — 71 to 85 psi (5.0 to 6.0 Bar) @ 5000 rpm. oil @ 80°C
Oil pump rotor tip-to-outer rotor clearance
- Standard — 0.15 mm
- Service limit — 0.20 mm
Oil pump outer rotor-to-body clearance
- Standard — 0.15 to 0.22 mm
- Service limit — 0.35 mm
Lubrication system (continued)
Oil pump rotor end float
- Standard — 0.02 to 0.07 mm
- Service limit — 0.10 mm
Torque settings
Engine mounting bolts - XL600V models
- Upper front mounting brackets bolt nuts — 27 Nm
- Upper front mounting bolt nut — 55 Nm
- Lower front mounting bolt nut — 55 Nm
- Swingarm pivot/rear mounting bolt nut — 110 Nm
Engine mounting bolts - XL650V models
- Upper front mounting brackets bolt nuts — 27 Nm
- Upper front mounting bolt nut — 55 Nm
- Lower front mounting bolt nut — 55 Nm
- Swingarm pivot/rear mounting bolt nut — 90 Nm
Engine mounting bolts - XRV750-L to N (1990 to 1992) models
- Mounting bracket-to-frame bolts/nuts — 33 Nm
- Mounting bracket-to-engine 8 mm bolts/nuts — 33 Nm
- Mounting bracket-to-engine 10 mm bolts/nuts — 55 Nm
- Swingarm pivot/rear mounting bolt nut — 110 Nm
Engine mounting bolts - XRV750-P models onwards (1993-on)
- Lower frame section bolts/nuts — 55 Nm
- Cylinder head bracket-to-frame/engine bolts/nuts — 53 Nm
- Mounting bracket-to-frame bolts/nuts — 32 Nm
- Mounting bracket-to-engine 8 mm bolts/nuts — 32 Nm
- Mounting bracket-to-engine 10 mm bolts/nuts — 53 Nm
- 10 mm engine mounting bolts/nuts — 53 Nm
- Swingarm pivot/rear mounting bolt nut — 106 Nm
Oil cooler and distributor - XRV750 models
Cooler mounting bolts — 12 Nm
- Pipe union and retaining plate bolts — 12 Nm
- Pipe guide bolts — 12 Nm
- Valve cover bolts — 10 Nm
- Camshaft main holder bolts and nuts — 23 Nm
- Camshaft end holder bolts — 10 Nm
- Camshaft sprocket bolts — 23 Nm
- Cam chain tensioner mounting bolts — 10 Nm
Cylinder head nuts/bolts
- 10 mm nuts - XL600V-H and J (1987 and 1988) models — 43 Nm
- 10 mm nuts - all other models — 47 Nm
- 8 mm nut/bolts — 23 Nm
- 6 mm bolt — 12 Nm
- External oil pipe - XL600V-H to К (1987 to 1989) models 6 and/or 7 mm bolts — 10 Nm
- 8 mm bolt — 23 Nm
- Clutch nut XL600V-H and J (1987 and 1988) models — 90 Nm
- XL600V-K to X (1989 to 1999) models — 128 Nm
- XL650V models — 128 Nm
- XRV750 models — 128 Nm
- Clutch release plate bolts — 12 Nm
- Oil pump driven sprocket bolt — 15 Nm
- Clutch cover bolts — 12 Nm
- Gearchange selector drum cam plate bolt — 12 Nm
- Gearchange stopper arm bolt — 12 Nm
- Primary drive gear bolt — 88 Nm
Starter clutch bolts
- XL600V-H and J (1987 and 1988) models — 23 Nm
- All other models — 30 Nm
- Cylinder studs 8 mm stud — 20 to 30 Nm
- 10 mm studs — 30 to 50 Nm
- Crankcase bolts 8 mm bolts — 23 Nm
- 6 mm bolts — 12 Nm
- Connecting rod nuts XL600V and XL650V models — 34 Nm
- XRV750 models — 42 Nm