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QUICK REFERENCE DATA
Chapter One / General Information
Manual organization / Warnings, cautions and notes / Safety / Serial numbers and information labels / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications
Chapter Two / Troubleshooting
Electrical component replacement / Starting the engine / Engine will not start / Poor engine performance / Fuel system / Engine / Engine lubrication / Leakdown test / Clutch / Gearshift linkage / Transmission / Electrical testing / Starting system (XR650L) / Charging system (XR650L) / Ignition system / Front suspension and steering / Rear suspension / Brakes
Chapter Three / 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
Chapter Four / Engine Top End
Cylinder head cover and camshaft / Camshaft chain tensioner / Cylinder head / Valves and components / Cylinder / Piston, pin and rings
Chapter Five / 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
Chapter Six / Clutch and External Shift Mechanism
Clutch cable / Right crankcase cover / Clutch release lever / External shift mechanism
Chapter Seven / Transmission and Internal Shift Mechanism
Internal shift mechanism
Chapter Eight and Chapter Nine/ 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
Chapter Ten and Chapter Eleven/ 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
Chapter Twelve / Wheels, Tires and Drive Chain
Front and rear wheel / Front and rear hubs / Wheel service / Drive chain / Sprockets / Tires / Wheel balance
Chapter Thirteen / Front Suspension and Steering
Handlebar / Handlebar grips / Front fork / Steering head / Steering play check and adjustment / Steering head bearing races
Chapter Fourteen / Rear Suspension
Shock absorber / Shock linkage / Swing arm
Chapter Fifteen / 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
Chapter Sixteen / 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
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