Honda XL650V Technical Specifications

[Lutin]

These specifications are intended as a guide and do not constitute official measurements or specifications. If you are unsure please get a Honda approved mechanic to check or maintain your bike.

All units in millimetres mm (inches in) unless otherwise specified.

Honda XL650V

Covers the years:
2000 to 2003 (V-Y to V-3)
2004 onwards (V-4 to V-7)

Please post up specs of other variations if you have them.

Pictures



Dimensions
Length: 2265 mm (89.2 in) V-Y to V-3
Length: 2257 mm (88.9 in) V-4 onwards
Width: 865 mm (34.0 in) V-Y to V-3
Width: 922 mm (36.3 in) V-4 onwards
Height: 1280 mm (50.4 in) V-Y to V-3
Height: 1318 mm (51.9 in) V-4 onwards
Wheelbase: 1501 mm (59.1 in) All models
Seat height: 850 mm (33.5 in) V-Y to V-3
Seat height: 843 mm (33.2 in), optional low seat 813 mm (32.0 in) V-4 onwards
Ground clearance: 225 mm (8.9 in) V-Y to V-3
Ground clearance: 192 mm (7.6 in) V-4 onwards

Dry weight: 175.0 kg (386 lbs) V-Y to V-3 #
Dry weight: 192.0 kg (423 lbs) V-4 onwards
Curb weight: 194.0 kg (428 lbs) V-Y to V-3 #
Curb weight: 212.0 kg (467 lbs) V-4 onwards

# These weights are those quoted in the Haynes manual. There is evidence to suggest that they are incorrect and the actual weights are closer to the later models, ie 192 / 212 Kgs.

Frame
Frame type: Single downtube with double loop cradle of rectangular section.
Front suspension: Telescopic fork
Front wheel travel: 200 mm (7.9 in)
Rear suspension: Swingarm
Rear wheel travel: 187 mm (7.4 in)
Front tyre size: 90/90-21 54S
Rear tyre size: 120/90-17 64S
Front brake: Hydraulic twin discs 276 mm (10.9 in), twin piston sliding caliper.
Rear brake: Hydraulic single disc 240 mm (9.4 in) single piston sliding caliper
Caster angle: 28º 04'
Trail length: 120 mm (4.7 in)
Fuel tank capacity: 19.6 litres (4.3 Imp Gal)

Engine
Type: Petrol, liquid cooled 4-stroke SOHC 52º V-twin, 3 valves per cylinder
Bore and Stroke: 79.0 x 66.0 mm (3.11 x 2.6 in)
Displacement: 647 cm³ (39.48 in³)
Compression Ratio: 9.2:1
Valve train: 3-valve, single chain driven SOHC
Lubrication system: Forced pressure with wet sump
Oil pump type: Trochoid/double rotor
Cooling system: Liquid cooled

Carburettors
Carburettors type: 2 x Keihin CV
Throttle bore: 34 mm (1.34 in)

Drive Train
Clutch system: Wet multi-plate, cable operated
Transmission: Constant mesh, 5 speeds
Primary reduction: 1.736
Final reduction: 3.200
Gear ratios:
1st: 2.500
2nd: 1.722
3rd: 1.333
4th: 1.111
5th: 0.961

Gear-shift pattern: Left operated return system 1 - N - 2 - 3 - 4 - 5

Lubrication System
Engine oil capacity:
at draining 2.10 litres (1.80 Imp qt, 2.2 US qt)
at disassembly 2.90 litres (2.60 Imp qt, 3.1 US qt)
at filter change 2.30 litres (2.0 Imp qt, 2.4 US qt)
Recommended engine oil: Honda 4-stroke oil or equivalent motor oil. API service classification: SE, SF or SG Viscosity.
Oil pump rotor:
Tip clearance: 0.15 mm (6 thou)
Body clearance: 0.15 mm to 0.22 mm (6 thou to 9 thou)
Rotor end float: 0.02 mm to 0.07 mm (0.8 thou to 3 thou)

Fuel System
Main jet: 132
Pilot jet: 38
Pilot screw setting (turns out): 3
Float height: 7.0 mm
Idle speed: 1200 ± 100 rpm
Throttle grip free play: 2.0 – 6.0 mm (1/16 - 1/4 in)

Cooling System
Coolant capacity: Approximately 2.0 litres.
Radiator cap opening pressure: 13 to 18 psi (0.9 to 1.25 Bar)
Thermostat:
Opening temperature: 80 to 84º C (176 to 183º F)
Fully open: 95º C (203º F)
Valve lift: 8.0 Mm (0.3 in) minimum
Standard coolant concentration: 50% mixture with soft water

Cylinder Head / Valves
Valve clearances:
Inlet: 0.13 to 0.17 mm (5 thou to 7 thou)
Exhaust: 0.18 to 0.22 mm (7 thou to 9 thou)

Clutch
Clutch lever free play: 10 – 20 mm (0.4 to 0.8 in)
Clutch spring free length: 43.2 mm (1.70 in)
Clutch disc thickness:
A (7 Discs): 2.62 to 2.78 mm (0.103 to 0.109 in). Service limit: 2.30 mm (0.091 in)
B (1 Disc): 2.92 to 3.08 mm (0.115 – 0.121 in). Service limit: 2.60 mm (0.102 in)
Clutch plate warpage service limit: 0.30 mm (0.012 in)

Front Wheel / Suspension / Steering
Cold tyre pressure:
29psi (2.00 bar), Rider only
29psi (2.00 bar), Rider and pillion

Fork spring free length: 599.4 mm (23.6 in). Service limit: 589.2 mm (23.2 in)
Fork tube runout service limit: 0.20 mm (8 thou)
Fork oil type: 5 W fork oil
Fork oil level: 141 mm (5.55 in)
Fork oil capacity: 542 cc

Rear Wheel / Suspension
Cold tyre pressure:
29psi (2.00 bar), Rider only
32psi (2.25 bar), Rider and pillion
Drive chain slack: 35 to 45 mm (1.4 to 1.8 in)
Drive chain: DID 525 112 – 120 links or RK 525S 112 – 120 links

Disc Brakes
Specified Brake Fluid: Dot 4
Front brake
Disc thickness: 4.5 mm (0.18 in). Service limit: 3.5 mm (0.14 in).
Disc maximum run-out: 0.30 mm (12 thou)
Rear brake:
Disc thickness: 5.0 mm (0.20 in). Service limit: 4.0 mm (0.16 in).
Disc maximum run-out: 0.25 mm (10 thou)

Electrical System
Ignition System: Digital with electronic advance
Spark plug type:
DPR8EA-9 (NGK) or X24EPR-U9 (DENSO) – standard.
DPR9EA-9 (NGK) or X27EPR-U9 (DENSO) – high speed riding
Spark plug gap: 0.8 – 0.9 mm (30 – 40 thou)
Battery: 12 Volt, 10 Ah
Alternator output:
368 W at 5000 rpm UK models.
310 W at 5000 rpm European
Regulator / Rectifier output: 14.0 to 15.0 Volts at 5000 rpm
Headlight bulb: 60 / 55 Watts
Tail light bulb: 21 / 5 Watts
Speedo light: 1.7 Watts
High beam indicator: 1.7 Watts
Turn signal lights: 21 Watts
Turn signal indicator: 3.4 Watts x 2
Neutral indicator: 3.4 Watts
Oil pressure indicator: 1.7 Watts
Immobiliser (HISS) indicator: 3.4 Watts
Fuses:
Main: 30 Amp
10 Amp x 4, 15 Amp x 1, V-Y to V-3 models.
10 Amp x 4, 15 Amp x 2, V4 models onwards.

Torque Values
Unless specified all bolts should be tightened to the following torque values.

Standard Fasteners N-m (kgf-m, lbf-ft):
5 mm Bolt and nut: 5 (0.5, 3.6)
6 mm Bolt and nut: 10 (1, 7)
8 mm Bolt and nut: 22 (2.2, 16)
10 mm Bolt and nut: 34 (3.5, 25)
12 mm Bolt and nut: 54 (5.5, 40)
5 mm Screw: 4 (0.4, 2.9)
6 mm Screw: 9 (0.9, 6.5)
6 mm Flange bolt (8 mm Head: Small flange): 9 (0.9, 6.5)
6 mm Flange bolt (8 mm Head: Large flange - engine only): 12 (1.2, 9)
6 mm Flange bolt (10 mm Head) and nut: 12 (1.2, 9)
8 mm Flange bolt and nut: 26 (2.7, 20)
10 mm Flange bolt and nut: 39 (4.0, 29)

Engine N-m (kgf-m, lbf-ft):
Engine / transmission oil drain plug: 30 N-m (3.1 kgf-m, 22 lbf-ft)
Engine / transmission oil filter: 9.8 N-m (1.0 kgf-m, 7 lbf-ft)
Rocker arm adjusting screw locknut: 23 N-m
Spark plugs: 14 N-m
Front sprocket retainer plate bolts: 10 N-m

Front Wheel / Brakes
Front axle shaft: 64 N-m (6.5 kgf-m, 47 lbf-ft)
Front axle holder nuts: 12 N-m (1.2 kgf-m, 9.0 lbf-ft)
Brake caliper mounting bolt: 33 N-m (3.4 kgf-m, 25 lbf-ft)
Brake caliper bleed valves: 6 N-m
Brake hose banjo bolts: 34 N-m

Rear Wheel
Rear axle nut: 88 N-m (9.0 kgf-m, 65 lbf-ft)
Rear sprocket nuts: 45 N-m

Frame / Suspension
Front fork clamp bolts (bottom yoke): 33 N-m
Front fork clamp bolts (top yoke): 27 N-m
Front fork damper rod bolt: 20 N-m
Front fork top bolt: 23 N-m
Handlebar holder clamp bolts: 26 N-m
Shock absorber mounting bolts nuts: 44 N-m
Sidestand pivot bolt: 10 N-m
Sidestand pivot bolt nut: 30 N-m
Steering head bearing adjuster nut: 5 N-m
Steering stem nut: 105 N-m

[StumpyFingers]

OEM Front Disc Part Number: 45251 MCB 771 Non sided so x2.