Honda XR650R Technical Specifications

[DaveS]

This is a test thread to agree a layout for technical specifications threads on other bikes. Comments on usefulness, layout, etc.. very welcome.

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 XR650R
Covers the years (unknown).
Covers the models:

ED - European Direct Sales
DK - General Export
U - Australia

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

Pictures


Dimensions
Length: 2255 mm (88.8 in)
Width: 825 mm (32.5 in)
Height: 1245 mm (49.0 in)
Wheelbase: ED, DK - 1425 mm (56.1 in), U - 1490 mm (58.7 in)
Seat Height: 939 mm (37.0 in)
Ground Clearance: 305 mm (12.0 in)
Dry Weight: ED, DK - 131.0 kg (289 lbs), U - 133.0 kg (293 lbs)
Curb Weight: ED, DK - 142.0 kg (313 lbs), U - 144.0 kg (317 lbs)

Frame
Frame Type: Semi-double cradle
Front Suspension: Telescopic fork
Front Wheel Travel: 285 mm (11.2 in)
Rear Suspension: Swingarm
Rear Wheel Travel: 307 mm (12.1 in)
Front Tyre (Tire) Size: 3.00-21 51P
Rear Tyre (Tire) Size: 4.50-18 70P
Tyre (Tire) Brand FR/RR: TR8/TR8 (IRC)
Front Brake: Hydraulic single disc
Rear Brake: Hydraulic single disc
Caster Angle: 27 degrees 32'
Trail Length: 108 mm (4.3 in)
Fuel Tank Capacity: 10.0 l (2.64 US Gal, 2.2 Imp Gal)
Fuel Tank Reserve Capacity: 4.5 l (1.19 US Gal, 0.99 Imp Gal)

Engine
Type: Petrol (Gasoline), liquid cooled 4-stroke SOHC
Cylinder Arrangement: Single cylinder inclined 13 degrees
Bore and Stroke: 100.0 x 82.6 mm (3.94 x 3.25 in)
Displacement: 649 cm cubed (39.6 cu-in)
Compression Ratio: 10.0:1
Valve Train: 4-valve, single chain driven SOHC
Intake Valve Opens: 15 degrees BTDC
Intake Valve Closes: 45 degrees ABDC
Exhaust Valve Opens: 45 degrees BBDC
Exhaust Valve Closes: 15 degrees ATDC
Lubrication System: Forced pressure and dry sump
Oil Pump Type: Trochoid/double rotor
Cooling System: Liquid cooled
Air Filtration: Oiled polyurethane foam
Engine Weight: 40.9 kg (90.2 lbs)

Carburettor (Carburetor)
Carburettor (Carburetor) type: Piston valve
Throttle Bore: 42 mm (1.7 in)

Drive Train
Clutch System: Multi-plate, wet
Clutch Operation System: Cable operating
Transmission: Constant mesh, 5 speeds
Primary Reduction: 1.651 (71/43)
Final Reduction:

ED, DK - 3.429 (48/14)
U - 2.733 (41/15)

Gear Ratio 1st: 3.083 (37/12)
Gear Ratio 2nd: 2.125 (34/16)
Gear Ratio 3rd: 1.666 (30/18 )
Gear Ratio 4th: 1.333 (28/21)
Gear Ratio 5th: 1.115 (29/26)
Gearshift Pattern: Left operated return system 1 - N - 2 - 3 - 4 - 5

Electrical
Ignition System: CDI (Capacitive Discharge Ignition)

Lubrication System
Engine Oil Capacity:

at draining 1.56 l (1.65 US qt, 1.37 Imp qt)
at disassembly 2.0 l (2.1 US qt, 1.8 Imp qt)
at filter change 1.6 l (1.7 US qt, 1.4 Imp 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 (0.006)
Body clearance: 0.15 - 0.22 (0.006 - 0.009)
Side clearance: 0.03 - 0.08 (0.001 - 0.003)

Fuel System
Carburettor Identification Number:

ED, DK: PE78C
U: PE78D

Main Jet:

ED, DK: #175
U: #112

Slow Jet: #65
Jet Needle Clip Position: 3rd groove from top
Pilot Screw Opening: Factory setting 1 3/4 turns out
Float Level: 16.0 mm (0.63 in)
Idle Speed: 1400 +/- 100 rpm
Throttle Grip Free Play: 2 - 6 mm (1/16 - 1/4 in)


Cooling System
Coolant Capacity:

Radiator and engine: 1.52 l (1.61 US qt, 1.34 Imp qt)
Reserve tank: 0.20 l (0.21 US qt, 0.18 Imp qt)

Radiator Cap Relief Pressure: 108 - 137 kPa (1.1 - 1.4 kgf/cm squared, 16 - 20 psi)
Thermostat:

Begins to open: 80 - 84 degrees C (176 - 183 degrees F)
Fully open: 95 degrees C (203 degrees F)
Valve Lift: 8mm (0.3 in) minimum

Standard Coolant Concentration: 50% mixture with soft water

Cylinder Head / Valves
Decompressor Lever Free Play: 5 - 8 mm (3/16 - 5/16 in)
Cylinder Compression:

Valve clearance at standard (decompressor applied): 600 kPa (6.12 kgf/cm squared, 87 psi) at 400 rpm
Valve clearance at 1 mm (0.04 in) (decompressor not applied): 1100 kPa (11.22 kgf/cm squared, 160 psi) at 400 rpm

Valve Clearances:

IN: 0.15 +/- 0.02 (0.006 +/- 0.001 )
EX: 0.20 +/- 0.02 (0.008 +/- 0.001 )

Clutch
Clutch Lever Free Play: 10 - 20 (3/8 - 3/4)
Clutch Spring Free Length: 49.0 (1.93)

A (6 Discs): 45.5 (1.79) Service Limit - 44.5 (1.75)
43.2 (1.70) Service Limit - 41.6 (1.64)

Clutch Disc Thickness:

A (6 Discs): 3.22 - 3.38 (0.127 - 0.133) Service Limit 3.00 (0.118 )
B (1 Disc): 2.92 - 3.08 (0.115 - 0.121) Service Limit 2.69 (0.106)

Clutch Plate Warpage Service Limit: 0.30 (0.012)

Front Wheel / Suspension / Steering
Cold Tyre (Tire) Pressure: 175kPa (25 psi)
Front Wheel Rim Runout Service Limit: Radial 2.0 (0.8 ), Axial 2.0 (0.8 )
Fork Spring Free Length: 506 (19.9) Service Limit 496 (19.5)
Fork Tube Runout Service Limit: 0.20 (0.01)
Recommended Fork Oil: Pro Honda Suspension Fluid SS - 7
Fork Oil Level: 120 (4.7)
Fork Oil Capacity: 637 cc
Compression damping adjuster standard position: 11 clicks out from full in
Rebound damping adjuster standard: 9 clicks from full in

Rear Wheel / Suspension
Cold Tyre (Tire) Pressure: 125 kPa (18 psi)
Rear Wheel Rim Runout Service Limit: Radial 2.0 (0.8 ), Axial 2.0 (0.8 )
Drive Chain Slack: 20 - 30 (13/16 - 1 3/16)
Drive Chain Length (at 41 pins / 40 links) Service Limit: 638 (25.1)
Drive Chain Size / Link:

ED, DK: DID 520VM-110LE or RK520KZO-110LE
U: DID 520VM-108LE or RK520KZO-108LE

Compression damping adjuster standard position: 6 - 10 clicks out from full in
Rebound damping adjuster standard position: 11 - 15 clicks out from full in

Disc Brakes
Specified Brake Fluid: Dot 4
Brake Disc Thickness:

ED, DK: 2.8 - 3.2 (0.11 - 0.13) Service Limit 2.5 (0.10)
U: 3.3 - 3.7 (0.13 - 0.15 ) Service Limit 3.0 (0.12)

Brake Disc Runout: Service Limit 0.20 (0.008 )

Electrical System
Spark Plug:

Standard Riding: NGK BKR7E-11, DENSO K22PR-U11
High Speed Riding: NGK BKR8E-11, DENSO K24PR-U11

Spark Plug Gap: 1.0 -1.10 (0.039 - 0.043 )
Headlight Bulb: 12 V 35/35 W
Taillight Bulb: 12V 21/5 W

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):

Valve Adjust Cover Hole Bolt 4 x 6 mm: 12 (1.2, 9)
Oil Drain Bolt (at crankcase) 1 x 12 mm: 25 (2.5, 18 )
Valve Adjusting Lock Nut 4 x 8 mm: 25 (2.5, 18 )
Spark Plug 1 x 14 mm: 18 (1.8, 13)
Oil Pump Plate Bolt 2 x 6 mm: 12 (1.2, 9)
Water Pump Assembly Bolt 2 x 6 mm: 13 (1.3, 9)
Thermostat Housing Cover Bolt 2 x 6 mm: 12 (1.2, 9)
Cylinder Head Nut 4 x 10 mm: 44 (4.5, 33) NOTE 4
Head Cover Bolt 2 x 8 mm: 23 (2.3, 17)
Head Cover Bolt 8 x 6 mm: 12 (1.2, 9)
Cam Sprocket Bolt 2 x 7 mm: 20 (2.0, 14) NOTE 1
Cam Chain Tensioner Bolt 2 x 6 mm: 12 (1.2, 9) NOTE 1
Cylinder Bolt 2 x 6 mm: 12 (1.2, 9)
Kickstarter Pedal Pinch Bolt 1 x 8 mm: 37 (3.8, 27)
Flywheel Bolt 1 x 12 mm: 127 (13.0, 94) NOTE 4
Left Crankcase Cover Stud Bolt 4 x 6 mm: 12 (1.2, 9)
Timing Hole Cap 1 x 14 mm: 10 (1.0, 7)

Frame N-m (kgf-m, lbf-ft):

Exhaust Pipe Joint Nut 4 x 8 mm: 18 (1.8, 13)
Exhaust Pipe Clamp Bolt 1 x 8 mm: 20 (2.0, 14)
Muffler Mounting Bolt 2 x 8 mm: 32 (3.3, 24)
Muffler Clamp Bolt 1 x 8 mm: 20 (2.0, 14)
Muffler Mounting Bolt 2 x 8 mm: 32 (3.3, 24)
Exhaust Pipe Protector Bolt 2 x 6 mm: 12(1.2, 9)

Maintenance N-m (kgf-m, lbf-ft):

Fuel Valve Mounting Bolt 2 x 6 mm: 9 (0.9, 6.5)
Down tube Oil Drain bolt 1 x 8 mm: 39 (4.0, 29)
Rear Brake Pedal Adjuster Lock Nut 1 x 8 mm: 18 (1.8, 13)
Side Stand Pivot Nut 1 x 10 mm: 39 (4.0, 29)
Spark Arrestor Bolt 3 x 6 mm: 12 (1.2, 9)
Rim Lock 2 x 8 mm: 13 (1.3, 9)

Lubrication N-m (kgf-m, lbf-ft):

Down Tube Oil Strainer 1 x 27 mm: 54 (5.5, 40)
Oil inlet Pipe Bolt 1 x 12 mm: 37 (3.8, 27)

Front Wheel / Suspension / Steering N-m (kgf-m, lbf-ft):

Front Brake Disc Bolt 4 x 6 mm: 20 (2.0, 14) NOTE 1
Front Axle 1 x 16 mm: 88 (9.0, 65)
Front Axle Holder Nut 4 x 6 mm: 12 (1.2, 9) NOTE 5
Fork Center Bolt 2 x 27 mm: 54 (5.5, 40) NOTE 1
Fork Cap Bolt 2 x 43 mm: 30 (3.1, 22)
Steering Stem Nut 1 x 24 mm: 98 (10.0, 72)

Rear Wheel / Suspension / Steering N-m (kgf-m, lbf-ft):

Rear Brake Disc Bolt 4 x 6 mm: 20 (2.0, 14) NOTE 1
Rear Axle Nut 1 x 16 mm: 93 (9.5, 69) NOTE 5
Driven Sprocket Nut 6 x 8 mm: 42 (4.3, 31) NOTE 5
Swingarm Pivot Nut 1 x 18 mm: 108 (11.0, 80) NOTE 5
Shock Absorber Upper Mounting Nut 1 x 10 mm: 44 (4.5, 33) NOTE 5
Shock Absorber Lower Mounting Nut 1 x 10 mm: 44 (4.5, 33) NOTE 5
Shock Arm-to-Swingarm Nut 1 x 12 mm: 78 (8.0, 58 ) NOTE 5
Shock Link-to-Shock Arm Nut 1 x 12 mm: 69 (7.0, 51) NOTE 5
Shock Link Nut 1 x 12 mm: 69 (7.0, 51) NOTE 5
Shock Absorber Spring Lock Nut 1 x 56 mm: 29 (3.0, 22)
Swingarm Pivot Lock Nut 1 x 28 mm: 64 (6.5, 47)
Side Stand Mounting Bolt 1 x 8 mm: 26 (2.7, 20)
Side Stand Mounting Bolt 2 x 10 mm: 39 (4.0, 29)

Hydraulic Brake N-m (kgf-m, lbf-ft):

Brake Hose Oil Bolt 4 x 10 mm: 34 (3.5, 25)
Brake Lever Pivot Bolt/Nut 1/1 x 6 mm: 6 (0.6, 4.3)
Brake Lever Adjuster Lock Nut 1 x 5 mm: 6 (0.6, 4.3)
Front Caliper Mounting Bolt 2 x 8 mm: 29 (3.0, 22) NOTE 1
Caliper Bleed Valve 2 x 8 mm: 6 (0.6, 4.3)
Rear Master Cylinder Mounting Bolt 2 x 6 mm: 12 (1.2, 9)
Pad Pin 2 x 10 mm: 18 (1.8, 13)
Pad Pin Plug 2 x 10 mm: 3.0 (0.3, 2.2 )
Front Caliper Pin Bolt 1 x 8 mm: 23 (2.3, 17) NOTE 1
Front Caliper Bracket Pin Bolt 1 x 8 mm: 23 (2.3, 17) NOTE 1
Rear Caliper Pin Bolt 1 x 12 mm: 27 (2.8, 20)
Rear Caliper Bracket Pin Bolt 1 x 8 mm: 13 (1.3, 9) NOTE 1
Brake Pdeal Pivot Bolt 1 x 8 mm: 25 (2.6, 19)
Rear Master Cylinder Push Rod Lock Nut 1 x 8 mm: 18 (1.8, 13)

NOTE 1: Apply locking agent to the threads.
NOTE 2: Apply grease to the threads and seating surface.
NOTE 3: Stake.
NOTE 4: Apply oil to the threads and seating surface.
NOTE 5: U-nut

[Mudwiz]

Easy way is :

"Hang on!" .

[416cc]

[kaupo]

Can anyone share the info on the eye-to-eye length of a XR650R rear shock unit? Googled it without any luck. Thanks!