Honda XR600R 1991-2000 & XR650L 1993-2012 Service & Repair Manual (ECM221)


Honda XR600R 1991-2000 & XR650L 1993-2012 Service & Repair Manual

The Online Manual is not a printed product, not a PDF and not a download. Valid for 36 months

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This service manual provides specific, detailed instructions for performing everything from basic maintenance and troubleshooting to a complete overhaul of the Honda XR600R-650L Series motorcycle. Do-it-yourselfers will find this service and repair manual more comprehensive than the factory manual, making it an indispensable part of your tool box.
1991-2000 HONDA XR600R
1993-2019 HONDA XR650L


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

More details
Part number: ECM221
Language: English

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  • All colour step-by-step guides for over 200 jobs with 700+ photos
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  • Troubleshooting section – quickly find the cause of a problem
  • Colour wiring diagrams help track problems quickly and easily
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  • Dictionary of automotive terms
  • Quick links to popular DIY tasks and other jobs linked to your task
  • Conversion calculator – imperial and metric units
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