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This XR650R Repair Manual Honda by Clymer provides service, maintenance and repair information for 2000-2007 Honda XR650R offroad motorcycles. It includes 312 pages, a color wiring diagram and hundreds of illustrations and original photographs developed from the complete disassembly of the machine.

This manual covers the following offroad motorcycles:

2000 Honda XR650R
2001 Honda XR650R
2002 Honda XR650R
2003 Honda XR650R
2004 Honda XR650R
2005 Honda XR650R
2006 Honda XR650R
2007 Honda XR650R

When you purchase this manual you will have access to the following information:

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

Wiring Diagram