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 (models 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 models 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)
COLOR WIRING DIAGRAMS
The Honda XL500, XR500, XL600, XR600 manual by Clymer is the best reference book for repair and service information for your Honda XR-XL motorcycle.
Publisher: Clymer Manuals — 2007
Author: Ed Scott, Ron Wright
Binding: Paperback — 7 x 10 inches
Pages: 410 — Hundreds of b&w photos and illustrations
ISBN: 9781599691428
The Manual Store LLC
2229 Skyline Dr
Carroll, IA 51401
U.S.A.
Toll-Free: (888)659-2953
