Honda XR650R Motorcycle Service and Repair Manual (2000-2007) M225
Includes Color Wiring Diagrams.
This service manual provides specific, detailed instructions for performing everything from basic maintenance and troubleshooting to a complete overhaul of the Honda XR650 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.
Models:
2000-2007 Honda XR650R
See Clymer Manuals M225 for 1991-2000 XR600R and 1993-2007 XR600L models.
Quick Reference Data
Chapter One / General Information
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications
Chapter Two / Troubleshooting
Starting the engine / Engine will not start / Poor engine performance / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Kickstarter / Drive train noise / Electrical testing / Front suspension and steering / Brakes / Specifications
Chapter Three / Lubrication, Maintenance and Tune-Up
Pre-ride inspection / Maintenance and service intervals / Tune-up / Test ride / Air filter / Crankcase breather inspection / Engine oil and filter / Engine and frame oil strainer screens / Compression test / Ignition timing / Spark plug / Valve clearance / Decompressor adjustment / Fuel hose and fuel strainer screen inspection / Throttle cable / Engine idle speed / Pulse secondary air injection (PAIR) system / Spark arrestor cleaning / Control cable inspection and lubrication / Drive chain and sprockets / Specifications
Chapter Four / Engine Top End and Exhaust System
Cylinder head cover Camshaft and cam chain tensioner / Cylinder head / Valves and valve components / Cylinder / Piston and rings / Cylinder stud / Decompressor cable / Specifications
Chapter Five / Engine Lower End
Removal and installation / Oil pipes and oil strainer screen / Crankcase / Crankcase seal and bearing / Shift shaft / Balancer shaft / Crankshaft / Specifications
Chapter Six / Clutch and Primary Drive
Clutch cover / Clutch release lever / Right crankcase cover / Oil strainer screen / Oil pump / Check valve / Primary drive gear / Cam chain, drive sprocket and rear chain guide / Kickstarter and kick idle gear / External shift mechanism / Clutch cable / Specifications
Chapter Seven / Transmission and Internal Shift Mechanisms
Mainshaft / Countershaft / Inspection / Internal shift mechanism / Specifications
Chapter Eight / Fuel and Emission Control Systems
Fuel tank / Fuel valve / Air box / Carburetor / Float level / Pilot screw (idle drop procedure) / High altitude adjustment / Rejetting / Throttle cable replacement / Crankcase breather system / Pulse secondary air injection (PAIR) system / Specifications
Chapter Nine / Electrical System
Connectors / Left crankcase cover / Stator and ignition pulse generator / Flywheel / Ignition system testing / Ignition timing / Ignition coil / Ignition control module (ICM) / Engine stop switch / Lighting system testing / AC regulator / Headlight / Taillight / Wiring diagram / Specifications
Chapter Ten / Cooling System
Cooling system safety / Cooling system inspection / Pressure test / Radiators / Coolant reserve tank / Thermostat / Water pump / Specifications
Chapter Eleven / Wheels and Drive Chain
Front wheel / Tripmeter gear unit / Rear wheel / Front and rear hubs / Wheel service / Drive chain / Sprocket replacement / Tire changing / Specifications
Chapter Twelve / Front Suspension and Steering
Handlebar / Handlebar grip replacement / Steering head / Steering play check and adjustment / Steering head bearing races / Front fork / Fork service and adjustment / Specifications
Chapter Thirteen / Rear Suspension
Shock absorber / Shock linkage / Swing arm / Rear suspension adjustment / Specifications
Chapter Fourteen / Brakes
Service / Brake bleeding / Brake fluid draining and flushing / Front and rear brake pads / Front and rear brake caliper / Front and rear master cylinder / Brake hose / Brake pedal / Brake disc / Specifications
Chapter Fifteen / Body and Subframe
Seat / Side covers / Radiator shrouds / Skid plate / Front visor / Tripmeter and cable / Footpeg and mounting bracket / Sidestand / Subframe / Specifications
Color Wiring Diagram
