Honda XL500, XR500, XL600, XR600 Repair Manual 1979-1990

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Item # M339-8  ISBN: 9781599691428




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This repair manual covers Honda XL500S 1979-1981, XL500R 1982, XR500 1979-1980, XR500R 1981-1984, XL600R 1983-1987, and XR600R 1985-1990 off-road bikes.

Note: See Clymer manual M221 for Honda XR600R 1991-2000 and XR650L 1993-2007.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Notes, cautions and warnings | Service hints | Torque specifications | Safety first | Special tips | Expendable supplies | Parts replacement | Serial numbers | Basic hand tools | Tune-up and troubleshooting tools | Mechanic's tips | "Off the road" rules | Safety

CHAPTER TWO: TROUBLESHOOTING
Operating requirements | Emergency troubleshooting | Engine starting | Engine performance | Engine noises | Excessive vibration | Front suspension and steering | Brake problems

CHAPTER THREE: LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks | Pre-checks | Service intervals | Tires and wheels | Battery (XL series) | Periodic lubrication | Periodic maintenance | Tune-up

CHAPTER FOUR: 1979-1982 500 CC ENGINES
Engine principles | Engine cooling | Servicing engine in frame | Engine removal/installation | Cylinder head cover | Cylinder head | Reed valve assembly (XR500R) | Valves and valve components | Camshaft | Camshaft chain and dampers | Cylinder | Piston, piston pin and piston rings | Ignition advance mechanism | Oil pump and oil filter screen | Kickstarter | Crankcase | Crankshaft and connecting rod | Balancer system | Break-in procedure

CHAPTER FIVE: RFVC ENGINES
Engine principles | Engine cooling | Servicing engine in frame | Engine removal/installation | Cylinder head cover and camshaft | Camshaft chain tensioner | Cylinder head | Valves and valve components | Cylinder | Piston, piston pin and piston rings | Primary drive gear | Oil lines | Camshaft chain | Crankcase and crankshaft | Balancer system | Kickstarter | Break-in procedure

CHAPTER SIX: CLUTCH AND TRANSMISSION
Clutch | Clutch (1979-1982 500 cc models) | Clutch (1983-1984 XR500R, 1983-1990 XL600R and XR600R) | Clutch cable replacement | External shift mechanism (1983-1984 XR500R, XL600R and XR600R) | External shift mechanism (all other models) | Transmissions | 5-speed transmission (1979-1982 500 cc engines) | 5-speed transmission and internal shift mechanism (1983-1984 XR500R, XL600R and XR600R) | Internal shift mechanism (1979-1982 500 cc models) | Internal shift mechanism (1983-1984 XR500R, XL600R and XR600R)

CHAPTER SEVEN: FUEL AND EXHAUST SYSTEMS
Carburetor | Carburetor adjustments | Throttle cable replacement | Choke cable replacement (models so equipped) | Fuel tank | Fuel filter | Gasoline/alcohol blend test | Crankcase breather system (U.S. only) | Evaporative emission control system (1984-1990 California XL series models only) | Air filter case | Exhaust system

CHAPTER EIGHT: ELECTRICAL SYSTEM
Charging system (XL series models) | Alternator rotor | Alternator stator | Voltage regulator/rectifier (XL series models) | A/C regulator test (XL500R, XL600R) | Capacitor discharge ignition | Mechanical ignition advance mechanism (XL500S, XL500R, XR500, 1981-1982 XR500R) | Pulse generator | Ignition coil | Lighting system | Electrical components | Fuse (XL series models) | Wiring diagrams

CHAPTER NINE: FRONT SUSPENSION AND STEERING
Front wheel (drum brake) | Front wheel (disc brake) | Wheel inspection (all models) | Front hub | Wheels | Tire changing | Tire repairs | Handlebar | Steering head and stem (loose ball bearings) | Steering head bearing races | Front fork (all models) | Front fork (XL500S, XR500) | Front fork (1981-1982 XR500R) | Front fork (XL500R, XR500R [1983-1984], XR600R and XL600R) | Inspection (all models)

CHAPTER TEN: REAR SUSPENSION
Rear wheel (dual-shock) | Rear wheel (Pro-Link) | Rear wheel inspection (all models) | Rear hub inspection (all models) | Rear hub (XL500S, XL500R, XR500, 1981-1982 XR500R, XR600R) | Rear hub (1983-1984 XR500R, XR600R) | Final driven sprocket (XL500S, XL500R, XL600R) | Swing arm (dual-shock) | Swing arm (Pro-Link) | Dual shock absorbers | Pro-Link suspension system | Shock absorber (Pro-Link) | Pro-Link pivot arm assembly (XL500R, 1981-1982 XR500R) | Pro-Link pivot arm assembly (1983-1984 XR500R, XL600R, XR600R) | Pro-Link pivot arm bearing replacement (XR600R)

CHAPTER ELEVEN: BRAKES
Drum brakes | Front drum brake | Front disc brake | Front brake pad replacement | Front master cylinder | Front caliper | Front brake hose replacement | Front brake disc | Bleeding the system | Rear drum brake | Brake cable (drum brake models)

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 XL500, XR500, XL600, XR600 Repair Manual 1979-1990