European XR650R Bike Specifications
Dimensions
Length: 2255mm
Width: 825mm
Height: 1245mm
Wheelbase: ED, DK - 1425 mm, U - 1490mm
Seat Height: 939mm
Ground Clearance: 305mm
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: 285mm
Rear Suspension: Swingarm
Rear Wheel Travel: 307mm

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
Fuel Tank Capacity: 10.0 litres ~ 2.2 Gallons
Fuel Tank Reserve Capacity: 4.5 litres ~ 0.99 Gallons

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: 42mm

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 litres
At disassembly 2.0 litres
At filter change 1.6 litres
 
Tip clearance: 0.15mm
Body clearance: 0.15mm - 0.22mm
Side clearance: 0.03mm - 0.08mm
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: 16.0mm
Idle Speed: 1400 +/- 100 rpm
Throttle Grip Free Play: 2mm - 6mm


Cooling System
Coolant Capacity:
Radiator and engine: 1.52 litres
Reserve tank: 0.20 litres

Radiator Cap Relief Pressure: 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 minimum
Standard Coolant Concentration: 50% mixture with soft water

Cylinder Head / Valves
De-compressor Lever Free Play: 5mm - 8mm
 

Valve Clearances:

IN: 0.15mm +/- 0.02mm
EX: 0.20mm +/- 0.02mm
 
Clutch
Clutch Lever Free Play: 10mm - 20mm
Clutch Spring Free Length: 49.0mm
A (6 Discs): 45.5mm Service Limit - 44.5mm
43.2mm Service Limit - 41.6mm
 
Clutch Disc Thickness:
A (6 Discs): 3.22mm - 3.38mm Service Limit 3.00m
B (1 Disc): 2.92mm - 3.08mm Service Limit 2.69mm
Clutch Plate Warpage Service Limit: 0.30mm

Front Wheel / Suspension / Steering
Cold Tyre Pressure: 25 psi
Front Wheel Rim Run Out Service Limit: Radial 2.0mm, Axial 2.0mm
Fork Spring Free Length: 506mm Service Limit 496mm
Fork Tube Run Out Service Limit: 0.20mm
Recommended Fork Oil: Pro Honda Suspension Fluid SS - 7
Fork Oil Level: 120mm
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 Pressure: 18 psi
Rear Wheel Rim Run Out Service Limit: Radial 2.0mm, Axial 2.0mm
Drive Chain Slack: 20 - 30 (13/16 - 1 3/16)
Drive Chain Length (at 41 pins / 40 links) Service Limit: 638mm
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

Rear Wheel Bearings
Disc Side 6004 2RS (20 ID x 42 OD x 12 Thick):
Sprocket Side 6205 2RS (20 ID x 47 OD x 15 Thick)

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

ED, DK: 2.8mm - 3.2mm Service Limit 2.5mm
U: 3.3mm - 3.7mm Service Limit 3.0mm
Brake Disc Run Out: Service Limit 0.20mm

Electrical System
Spark Plug:
Standard Riding: NGK BKR7E-11, DENSO K22PR-U11
High Speed Riding: NGK BKR8E-11, DENSO K24PR-U11
Spark Plug Gap: 1.0mm -1.10mm
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)
 
 
US XR650R Bike Specifications
 

Reduced stator output typically 55 watts.
Single beam plastic headlight, engine kill switch
Rear Fender with single tail light filament bulb
Restricted air box and re-jetted carburettor to suit
No rectifier fitted the bike is purely run on AC

 

Model Variations Chart
 
  North American European Direct sales U Australian D,DK,DM General export
Stator 55 Watt 74 watt 74 watt 74 watt
Headlight 34 Watt, Plastic 34/34, Glass 34/34, Glass 34/34, Glass
Blinkers No Optional * Yes Yes
Brake Light No Yes Yes Yes
Horn No No Yes Yes
Corked Yes No Dlr. Discretion** No
OTD Jetting 125/65s/2nd 175/65s/3rd 112/65s/3rd 175/65s/3rd
Tires Dunlop D739FAJ/K695 IRC TR8 D/S IRC TR8 D/S IRC TR8 D/S
Speedo 99mi Odo Yes Yes Yes
Gearing 14/48 14/48 15/41 14/48
Mirrors No One Yes Yes
Keylock No Yes Yes Yes

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