General Information

Troubleshooting

Lubrication, Maintenance and Tune-Up

Pre-ride inspection / Engine oil / Oil line strainer / Oil strainer screen / Air filter / Control cable inspection and lubrication / Clutch lever adjustment / Drive chain / Wheel bearing inspection / Emission control system (XR650L) / Spark plug / Valve clearance adjustment / Starter decompression lever adjustment (XR600R) / Compression test / Tune up

Engine Top End

Cylinder head cover and camshaft / Camshaft chain tensioner / Cylinder head / Valves and components / Cylinder / Piston, pin and rings

Engine Lower End

Engine removal-installation / Starter gear assembly / Flywheel and starter clutch / Kickstarter / Oil pump / Oil lines / Oil strainer screen / Primary drive gear / Camshaft chain and guides / Crankcase and crankshaft / Break-in

Clutch and External Shift Mechanism

Clutch cable / Right crankcase cover / Clutch release lever / External shift mechanism 

Transmission and Internal shift mechanism 

Fuel, Emmision Control and Exhaust Systems

Carburetor / Adjustments / Throttle cable / Choke cable / Fuel tank / Fuel valve / Crankcase breather system / Evaporative emission control system / Pulse seondary air injection system / Air box 

Electrical System

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

Wheels, Tires and Drive Chain

Front and rear wheel / Front and rear hubs / Wheel service / Drive chain / Sprockets / Tires / Wheel balance

Front Suspension and Steering

Handlebar / Handlebar grips / Front fork / Steering head / Steering play check and adjustment / Steering head bearing races

Rear Suspension

Shock absorber / Shock linkage / Swing arm

Brakes

Brake fluid / Brake service / Front and rear brake pads / Front and rear brake caliper / Front and rear brake master cylinder / Brake hose replacement / Brake disc / Brake pedal / Brake system draining / Brake bleeding

Body

Left side cover / Right side cover / Seat / Left hand guard / Right hand guard / Front fender / Rear fender / Air shroud (XR650L) / Frame guard / Sidestand

Color Wiring Diagrams 

Models covered: 

1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 XR600R XR600 R XR 600 R

1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 XR650L XR650 XR 650 L