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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)

INDEX