QUICK REFERNCE DATA
CHAPTER ONE | GENERAL INFORMATION
Manual organization | Service hints | Torque specifications | Safety first | Special tips | Parts replacement | Expendable supplies | Serial numbers | Tune-up and troubleshooting tools | "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 | Crankcase breather hoses (XL series models) | Battery (XL series models) | Periodic lubrication | Periodic maintenance | Engine tune-up
CHAPTER FOUR | ENGINE
Engine principles | Engine cooling | Servicing engine in frame | Engine removal|installation | Cylinder head and camshaft | Camshaft and rocker assemblies | Cam chain | Valves and valve components | Cylinder | Piston, piston pin and piston rings | Oil filter rotor and primary drive gear (1975-1976 XR75) | Primary drive gear | Oil pump | Crankcase and crankshaft | Cam chain and tensioner | Kickstarter | Break-in procedure
CHAPTER FIVE | CLUTCH AND TRANSMISSION
Clutch operation | Clutch | Clutch release mechanism | Clutch cable | External shift mechanism | Drive sprocket | Transmission and internal shift mechanism | Preliminary transmission inspection (all models) | 4-speed transmission and internal shift mechanism (XR75) | 4-speed transmission and internal shift mechanism (XL75 and XL80S) | 5-speed transmission and internal shift mechanism | Internal shift mechanism inspection
CHAPTER SIX | FUEL AND EXHAUST SYSTEMS
Carburetor operation | Carburetor service | Carburetor adjustments | Throttle cable | Fuel tank | Crankcase breather system (U.S. XL series models) | Evaporative emission control system (California XL series models only) | Exhaust system
CHAPTER SEVEN | ELECTRICAL SYSTEM
Charging system | Rectifier | Voltage regulator|rectifier (1982-on XL100S) | Alternator | Contact breaker point ignition | Ignition coil | Lighting system (XL series models) | Switches | Horn (XL series models) | Fuse (XL series models)
CHAPTER EIGHT | FRONT SUSPENSION AND STEERING
Front wheel | Front hub | Wheels | Tire changing | Tire repairs | Handlebar | Steering head | Front fork
CHAPTER NINE | REAR SUSPENSION
Rear wheel (dual-shock models) | Rear wheel (Pro-Link models) | Rear hub and driven sprocket inspection (all models) | Rear hub and driven sprocket (XR80R and XR100R) | Rear hub and driven sprocket (all other models) | Drive chain | Shock absorbers (dual-shock models) | Swing arm | Swing arm (Pro-Link models) | Pro-Link system | Shock absorber (Pro-Link models) | Pivot arm assembly
CHAPTER TEN | BRAKES
Drum brakes | Front brake cable | Rear brake pedal assembly
CHAPTER ELEVEN | FRAME
Sidestand | Footpegs | Frame
SUPPLEMENT | 1993 AND LATER SERVICE INFORMATION
Engine starting | Engine performance | Engine tune-up | Carburetor | Electrical component replacement | Alternator | Rotor | Ignition coil | Pulse generator | CDI unit
INDEX
WIRING DIAGRAMS
