Description
This Honda XL XR 500-650 1979-1990 Repair Manual by Clymer provides detailed service information, step-by-step repair instruction and maintenance specifications for 1979-1990 Honda XL500R XR500 XL600 XR600 motorcycles.
Honda XL500R 1982
Honda XR500 1979-1980
Honda XR500R 1981-1984
Honda XL600R 1983-1987
Honda XR600R 1985-1990
1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990
(See item M221 for Honda 1991-2000 XR600R and XR650L service coverage)
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 (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 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
WIRING DIAGRAMS
