Honda XR600R 1991-2000, XR650L 1993-2007 Repair Manual

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Item # M221  ISBN: 9781599691572




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This repair and service manual covers Honda XR600R 1991-2000 and XR650L 1993-2007 dirt bikes equipped with Radial Four Valve Combustion (RFVC), air-cooled, four-stroke, single-cylinder engines.

Note: the XR650R 2000-2007 is covered in the Clymer M225 manual.

Table of Contents

Quick Reference Data

Chapter One: General Information
Manual organization | Warnings, cautions and notes | Safety | Serial numbers and information labels | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage | Specifications

Chapter Two: Troubleshooting
Electrical component replacement | Starting the engine | Engine will not start | Poor engine performance | Fuel system | Engine | Engine lubrications | Leakdown test | Clutch | Gearshift linkage | Transmission | Electrical testing | Starting system (XR650L) | Charging system (XR650L) | Ignition system | Front suspension and steering | Rear suspension | Brake system

Chapter Three: Lubrication, Maintenance and Tune-Up
Pre-ride inspection | Engine oil | Oil line strainer | Oil strainer screen | Air filter | Control cable inspection and lubrication | Throttle cable adjustment | Choke cable adjustment (XR650L) | Clutch lever adjustment | Brakes | Drive chain | Tires and wheels | Wheel bearing inspection | Front fork | Steering | Rear suspension adjustment | Rear suspension lubrication | Battery (XR650L) | Carburetor | Fuel system | Emission control system (XR650L) | Spark plug | Ignition timing | Valve clearance adjustment | Starter decompression lever adjustment (XR600R) | Exhaust system | Compression test | Tune up | Specifications

Chapter Four: Engine Top End
Cylinder head cover and camshaft | Camshaft chain tensioner | Cylinder head | Valves and valve components | Cylinder | Piston, piston pin and piston rings | Specifications

Chapter Five: Engine Lower End
Servicing engine in frame | Engine removal-installation | Starter gear assembly (XR650L) | Flywheel and starter clutch (XR650L) | Flywheel (XR600R) | Kickstarter (XR600R) | Oil pump | Oil lines | Oil strainer screen | Primary drive gear assembly | Camshaft chain and guides | Crankcase and crankshaft | Engine break-in | Specifications

Chapter Six: Clutch and External Shift Mechanism
Clutch cable | Right crankcase cover | Clutch | Clutch release lever | External shift mechanism | Specifications

Chapter Seven: Transmission and Internal Shift Mechanism
Transmission | Internal shift mechanism | Specifications

Chapter Eight: Fuel and Exhaust Systems (XR600R)
Carburetor | Carburetor adjustments | Throttle cable replacement | Fuel tank | Fuel valve | Air box | Crankcase breather system | Exhaust system | Specifications

Chapter Nine: Fuel, Emission Control and Exhaust Systems (XR650L)
Carburetor | Carburetor adjustments | Throttle cable replacement | Choke cable replacement | Fuel tank | Fuel valve | Crankcase breather system | Evaporative emission control system (California models) | Pulse seondary air injection system | Air box | Exhaust system | Specifications

Chapter Ten: Electrical System (XR600R)
Electrical component replacement | Electrical connectors | Alternator | Voltage regulator | Ignition control module | Pulse generator | Ignition coil | Headlight | Taillight | Engine stop switch | Specifications

Chapter Eleven: Electrical System (XR650)
Electrical component replacement | Electrical connectors | Charging system | Alternator | Voltage regulator-rectifier | Ignition system | Ignition control module | Pulse generator | Ignition coil | Starting system | Starter | Starter relay | Clutch diode | Lighting system | Switches | Instrument cluster | Horn | Fuses | Specifications

Chapter Twelve: Wheels, Tires and Drive Chain
Front wheel | Rear wheel | Front and rear hubs | Wheel service | Drive chain | Sprockets | Tires | Wheel balance | Specifications

Chapter Thirteen: Front Suspension and Steering
Handlebar | Handlebar grips | Front fork | Steering head | Steering play check and adjustment | Steering head bearing races | Specifications

Chapter Fourteen: Rear Suspension
Shock absorber | Shock linkage | Swing arm | Specifications

Chapter Fifteen: Brakes
Brake fluid | Brake service | Front brake pads | Front brake caliper | Front brake master cylinder | Rear brake pads | Rear brake caliper | Rear brake master cylinder | Brake hose replacement | Brake disc | Rear brake pedal | Brake system draining | Brake bleeding | Specifications

Chapter Sixteen: Body
Left side cover | Right side cover | Seat | Left hand guard | Right hand guard | Front fender | Rear fender | Air shroud (XR650L) | Frame guard | Sidestand | Specifications

Color Wiring Diagrams

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Honda XR600R 1991-2000, XR650L 1993-2007 Repair Manual