Honda XR650R Repair Manual 2000-2007

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Item # M225  ISBN: 9781599692036




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This repair and service manual covers Honda XR650R 2000-2007.

Note: the XR600R 1991-2000 and XR650L 1993-2007 models are covered in the Clymer M221 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
Troubleshooting | Starting the engine | Engine will not start | Poor engine performance | Fuel system | Engine | Engine lubrication | Cylinder leakdown test | Clutch | Gearshift linkage | Transmission | Kickstarter | Drive train noise | Electrical testing | Front suspension and steering | Brake system |

Chapter Three: Lubrication, Maintenance and Tune-Up
Pre-ride inspection | Maintenance and service intervals | Tune-up | Test ride | Air filter | Crankcase breather inspection | Engine oil and filter | Engine and frame oil strainer screens | Compression test | Ignition timing | Spark plug | Valve clearance | Decompressor adjustment | Fuel hose and fuel strainer screen inspection | Throttle cable adjustment \Engine idle speed adjustment | Pulse secondary air injection (PAIR) system inspection | Spark arrestor cleaning | Cooling system | Clutch adjustment | Control cable inspection and lubrication | Brakes | Drive chain and sprockets | Tires and wheels | Wheel bearing inspection | Steering | Front fork | Rear shock absorber | Rear swing arm and linkage | Headlight inspection | Sidestand inspection | Fasteners | Engine break-in | Specifications

Chapter Four: Engine Top End and Exhaust System
Exhaust system | Cylinder head cover \Camshaft and cam chain tensioner | Cylinder head | Valves and valve components | Cylinder | Piston and piston rings | Cylinder stud replacement | Decompressor cable replacement | Specifications

Chapter Five: Engine Lower End
Engine | Oil pipes and oil strainer screen | Crankcase | Crankcase seal and bearing replacement | Shift shaft | Balancer shaft | Crankshaft | Specifications

Chapter Six: Clutch and Primary Drive
Clutch cover | Clutch | Clutch release lever | Right crankcase cover | Oil strainer screen | Oil pump | Check valve | Primary drive gear | Cam chain, drive sprocket and rear chain guide | Kickstarter and kick idle gear | External shift mechanism | Clutch cable replacement | Specifications

Chapter Seven: Transmission and Internal Shift Mechanisms
Transmission operation | Transmission service | Mainshaft | Countershaft | Transmission inspection | Internal shift mechanism | Specifications

Chapter Eight: Fuel and Emission Control Systems
Fuel tank | Fuel valve | Air box | Carburetor | Float level adjustment | Pilot screw adjustment (idle drop procedure) | High altitude adjustment | Carburetor rejetting | Throttle cable replacement | Crankcase breather system | Pulse secondary air injection (PAIR) system (2000-2006 California models and 2007 on U.S. models) | Specifications

Chapter Nine: Electrical System
Electrical connectors | Left crankcase cover | Stator and ignition pulse generator | Flywheel | Ignition system testing | Ignition timing | Ignition coil | Ignition control module (ICM) | Engine stop switch | Lighting system testing | AC regulator | Headlight | Taillight | Wiring diagram | Specifications

Chapter Ten: Cooling System
Cooling system safety | Cooling system inspection | Pressure test | Radiators | Coolant reserve tank | Thermostat | Water pump | Specifications

Chapter Eleven: Wheels and Drive Chain
Front wheel | Tripmeter gear unit | Rear wheel | Front and rear hubs | Wheel service | Drive chain | Sprocket replacement | Tire changing | Specifications

Chapter Twelve: Front Suspension and Steering
Handlebar | Handlebar grip replacement | Steering head | Steering play check and adjustment | Steering head bearing races | Front fork | Fork service | Front fork adjustment | Specifications

Chapter Thirteen: Rear Suspension
Shock absorber | Shock linkage | Swing arm | Rear suspension adjustment | Specifications

Chapter Fourteen: Brakes
Brake service | Brake bleeding | Brake fluid draining and flushing | Front brake pad replacement | Front brake caliper | Front master cylinder | Rear brake pad replacement | Rear brake caliper | Rear master cylinder | Brake hose replacement | Rear brake pedal | Brake disc | Specifications

Chapter Fifteen: Body and Subframe
Seat | Side covers | Radiator shrouds | Skid plate | Front visor | Tripmeter and cable | Footpeg and mounting bracket | Sidestand | Subframe | Specifications

Index | Color wiring diagram

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 XR650R Repair Manual 2000-2007