* Does not cover water cooled XR650R models

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

Index

Wiring Diagrams

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