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
