HONDA XR600R Service Repair Manual

1988-2000 XRSOOR ..

OJ GENERAL INFORMATION GENERAL SAFETY SERVICE RULES MODEL IDENTIFI CAT ION SPECIFICATIONS GENERAL SAFETY , II , -, , -, ' -2 ' -3 If, hr rngin, mllst be r"""ing to do some .... ork, make slIn ' Ir e (I na is "'ell·~"t;laud. Never ru n tir e engine in an encloud a na. Tire exlraust contains poisonous carbon monoxide gas tlltl! ell" CIHI5e loss ofconsciousnns and may lead todeat h. Inhaled asbestos Jibers hQI'I! been found to cause rupiratory disease and concer. Never use an air hose or dry brush 10 clean breake or clutch as- sembliu. SERVICE RULES TORQUE VALUES TOOLS CAB LE & HARNESS ROUTING ' -5 ' -7 ' -9 Gasoline is ex t nmdy j1llmmable (llld is uplosire " nder u- rtoi" conditions. Do not smoke or allow flamu or sparks in the "'Ork ana or "'he" gasoline is stored. • Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that do not meet HONDA 's design specifications may damage the motorcycle . • Use the special tools designed for this product . • Install new gaskets , O-rings, cotter pins. lock plates, etc. when reassembling. • When torquing a series of bolts or nuts , begin with the larger-diameter or inner bolts first, and tighten to the specified torque diagonally, unless a particular sequence is specified. • Clean parts in non -flammable or high flash point solvent upon disassembly. lubricate any sliding surfaces before reassembly. • After reassembly, check all parts for proper installation and operation. • Use only metric tools when servicing this motorcycle. Metric bolts, nuts. and screws are not inte rchangeable with English fasteners. The use of incorrect tools and fa$teners may damage the motorcycle. • Route all electrical wires as shown on pages 1-9 through 1-12, Cable and Harness Routing, and away from sharp edges and areas where they might be pinched between moving parts. 1-1

GENERAL INFORMATION MODEl IDENTIFICATION The engine serial number is stamped on the lower left side of the crankcase. The ca rburetor identifi cation number is on the right side of the carbu r etor body. 1-2 The frame serial number is stamped on the right side of the steering head. The color code label is attached to the left frame tube under the seat. When ordering a color coded part, always specify its designated color code.

GENERAL INFORMATION SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2,160 mm (85.0 in) Overall width 900 mm (35 .5 in) (8 model) 980 mm (35 .4 in) (U model) Overall height 1.210 mm (48 .0 in) (8 model ) 1,220 mm (48 .0 in) (U model) Ground clearance 335 mm ( 13 .2 in) Wheelbase 1,460 mm ( 57 .5 in ) (8 model) 1,455 mm (57 .3 in) (U model) Seat height 940 mm (37.0 in) Foot peg height 418 mm (16 .5 in) (l) / 420 mm (16 .5 in) (R) Dry weight / Curb weight 120.5 kg (26 . 5Ib)/ 130. 5kg 1 287 .S Jb) FRAME Type Semi double cradle Front suspension. travel Telescopic 280 mm 11 ' .0 in) Rear suspension, travel Pro-link 280 mm ( 11 .0 in) Tire size (8 model) (U model ) Front 80/ 100- 215IM 3. 00 - 21-4PR Rear '10/ 10Q- 1864M 4.50 - 18- 4PR Tire pressure Front 15 Psi ( 1 00 kpa, 1.0 kg /cm 2 ) Rear 15 Psi ( 1 00 kpa, 1.0 kg/ cm 2 ) Front brake , swept area Disc, dual piston caliper Rear brake, swept area Drum , leading/ trailing shoes Fuel capacity 10 .0 l it (2 .7 U.S. gal. 2.3 Imp gal) Fuel reserve capacity 2.0 lit (0.5 U.S. gal. 0.4 Imp gal) Caster 62' Trail 118 mm (4 .6 in) Front fork oil capacity 643 cc (2 1.8 oz) ENGINE Type Gasoline, air -cooled 4-stroke SOHC Cylinder arrangement Single cylinder inclined 15" Bore and stroke 97 x 80mm(3 .B2 x 3. 15in) Displacement 591 cc (36 .1 cu in) Compression ratio 9. 0: 1 Valve train 4-valve, single chain driven SOHC, RFVC Oil capacity 2.31it (2.4 U.S. qt, 2.0 Imp qt) Lubrication system Forced pressure and dry sump Air filtration system Oiled polyurethane foam Cylinder compression 500 ± 100 kPa (5 ± 1 kg/ cm 2, 71 .1 ± 14 .2 psi) De- compressor effected Intake valve Opens 5" (BTCD) at 1 mm lift Closes 40" (ABDC) at 1 mm lift E)(haust valve Opens 45 " (BBD C) at 1 mm lift Closes 5" (ATDC) at 1 mm lift Valve clearance Intake 0. 10 mm (0 . 004 in) E)(haust 0. 12 mm (0 . 005 in) CARBURETOR Type Piston valve 1.0 . number PD8AA Main jet ;I: 165 (B model), ;I: 135 (U model) Pilot screw 2-5/ 8 turns out Float level 14.5 mm (0.57 in) Idle speed 1, 300 ± 100 min · 1 (rpm ) 1-3

GENERAL INFORMATION ITEM SPECI FI CATION DRIVE TRAIN Clutch Wet multi -plate Transmission 5-speed constant mesh Primary reduction 2. 188 (70 / 32) Gear ratio I 2.385(31 / 13) Gear ratio II 1.647 (28/1 7) Gear ratio III 1. 250 (25/20) Gear ratio IV 1.000 (23 / 23) Gear ratio V 0. 840 (21 / 25) Final redu ction 3.571 ( 50/ 14) Gear shift pattern Left foot operated return system (1-N-2-3-4-5) ELECTRICAL Ignition CDI Ig nition tim ing Initial 6' BTDC at 1, 300 ± 250 min -' (rpm) (F mark) Full advance 31 ± 2' BTDC at 4,000 min " (rpm) Alternator AC generator 150 W / S,OOO min " (rpm) Spark plug Standard DPR8EA-9 (NGK) or X24EPR- U9 (ND) For extended high DPR9EA-9 (NGK) or speed riding X27EPR- U9 (NO) Spark plug gap 0.8- 0.9 mm (0.031-0.035 in) Headlight 12 V/ 35 W (8 model) 12 V/ 25 W (U model) Tai l/ Stop light 12 V/ 15/ 21 W (8 model) 12V/ 18/ 5W(U model ) Turn signal light 12 V/ 1 0 W (U model only) Speedometer light 12 V/ 3 W High beam indicator light 12 V/ 2 W Position light 12 VI 4W 1-4

I I GENERAL INFORMATI ON TORQUE VALUES ENGINE Item Spark plug Crankcase drain plug Oil filter cover bolt Valve adjusting lock nut Cylinder head bolt Cam sprocket bolt Cylinder head cover bolt (8 mm) (6 mm) (6 rnm SHI Rocker arm shaft Sub-rocker arm shaft IN . EX . Cylinder bolt Clutch lock nut Drive gear lock nut Flywheel bolt Gearshi ft drum bolt Shift drum stopper arm bolt Gearshift return spring pin Shift fork set bolt Kick starter stopper plate Crankcase bolt (nut) Crankcase cover bolt FRAME I tem Down tube drain plug Oil strainer Oil inlet pipe flare nut (lower ) t upper ) Oil o utlet hose flare nut Side stand pi vot bolt Fuel tank mounting bolt Engine hanger bolt (10 mm) (Smml Exhaust pipe joint nut Exhaust pipe clamp Exhaust muffler mount bolt Right footpeg bolt Handlebar holder bolt Front axle Front axle holder nut Fr ont spoke Front wheel rim lock Fork upper pinch bolt Fork lower pinch bolt Fork cap Fork bottom bolt Throttle pulley pivot screw 1-5 a'ty Thread Torque N·m Ikg-m. ft - lbJ Remarks Oia. (mm) 1 -- 18 ( 1.8 , 13) 1 -- 25 (2.5, 18 ) 3 6 9 (0 .9, 7) • 8 25 (2.5, 18) • 8 36 (3.6, 26) 2 7 20 (2.0, 14) 1 8 23 (2.3, 17) 1 6 12 (1.2, 9) 12 6 10 (1.0, 7) • " 28 (2.8, 20) • 1. 28 (2.8 , 20) • 12 23 (2.3, 17) • 10 50 (5.0, 36) 1 18 110 n 1.0, 80 ) 1 18 110 (11.0, 80 ) 1 12 125 02.5,90) 1 6 12 (1.2, 91 1 8 25 (2.5,18) 1 8 24 (2.4, 171 1 7 150.5,11' 2 8 25 (2. 5, 1S) 9(3 ) 6 12 (1.2 , 9) 9 6 12/1.2 , 9) O'ty Thread Torque N·m (kg·m, ft · lb) Remarks Dia. (mm) 1 10 40 (4 .0, 29) 1 27 55 (5.5, 40 ) 1 18 40 (4 .0 , 29) 1 16 40 (4.0, 29) 1 ,. 40 (4 .0 ,2 9) 1 10 40 (4 .0 , 29) 2 6 10 ( 1.0, 7) 5 10 50 (5.0, 36) 6 8 27 (2.7, 20 ) • 8 27 (2.7, 20) 2 8 27 (2.7, 20) 2 8 70 (7.0, 51) 2 10 65 (6.5, 47) • 8 27/2 .7, 20) 1 12 65 (6.5, 47) 2 6 12(1.2,9) -- -- 4 (0.4, 3) 1 8 13 (1.3,9) • 8 33 (3.3 , 24) • 8 33 (3.3, 24) 2 -- 23 /2.3, 16) 2 8 35/3.5, 25) Apply lOCTITEe 242 or equivalent 1 5 4.3 10.43, 31

GENERAL INFORMATION Item Q'ty Thread Torque N'm Ikg-m, ft -rb) Remarks Dia. (m m) Steering bearing adjusting nut 1 26 3 (0.3, 22\ Steering stem nut 1 24 118 (".8. 85) Front brake disc 6 6 lS ( l.S,l1f Brake master cylinder bleeder screw 1 8 6 (0.6, 41 Rear axle nut 1 16 95 (9.5, 69) Rear spoke -- -- 4 (0.4, 31 Rear wheel rim lock 1 13 (1.3, 91 Final driven sprocket 6 10 46 (4.6, 33 ) Apply oil Rear shock absorber upper mount 1 10 45 14.5, 331 Rear shock absorber lower mount 1 10 30 (3.0, 22) Swingarm pivot nut 1 14 90 (9.0, 65) Shock arm-to-swingarm bolt 1 12 4514.5, 33) Shock arm-lo -shock link bolt 1 10 45 (4 .5, 33) Shock link-la-frame bolt 1 10 70(7.0,51) Rear shock spring adjuster lock nut 1 50 90 (9.0, 65) Rear s hock hose joint bolt 1 10 30 (3.0, 22) Rear shock hose lock nut 1 12 30 (3.0, 22) Rear shock piston rod end nut 1 12 38 (3.8, 27) Apply LOCTITE® 242 or equivalent Brake pedal pivot bolt 1 12 40 (4.0, 29) Brake caliper bolt 2 8 27 (2.7, 20) Brake caliper bleeder screw 1 8 6 (0.6, 41 Brake pad pin 2 10 18 (1.8, 13) Fuel valve 2 6 10 ( 1.0, 71 Gearshift pedal 1 6 10 (1.0, 71 Kick starter arm 1 8 27 (2.7, 20) Brake hose joint bolt 2 10 35 (3.5, 25) Torque specifications listed above are for the most Important tightening POintS. If a specification IS not hsted, follow the standard torque values below. STANDARD TORQUE VALUES Item N·m (kg-m. ft-Ib) Item N·m ( kg -m, ft-Ib) 5 mm bolt and nut 6 (0.6, 4) 5 mm screw 4 (O A, 3) 6 mm bolt and nut 10(0.1,7) 6 mm screw and 6 mm bolt 9 (0.9, 7) 8 mm bolt and nut 22 (2.2, 16) with small (8 mm) head 10 mm bolt and nut 35 (3.5, 25) 6 mm flange bolt and nut 12 (1.2, 9) , 2 mm bolt and nut 55 (5.5, 40 ) 8 mm flange bolt and nut 27 (2.7, 20) , ° mm flange bolt and nut 40 (4.0, 29) 1-6

GENERAL INFORMATION TOOLS SPECIAL DESCRIPTION TOOL NUMBER REFER TO SECTION Bearing puller catch 07931-MK20100 10 Knock pin puller set 07936 - MA70DOO )6 - Remover weight 07741 - 0010201 - Slider shaft 07936- MA 70100 Tensioner holder 07973-MG30003 6 Valve guide reamer 07984 - 5510000 6 Bearing remover set 07936 - 3710001 } 10 , - Spindle 07936 - 3710600 13 - Remover handle 07936 - 3710100 - Remover weight 07741 .... 0010201 Bearing remover. 1 5 mm D7936 - KC1D500 10 Remover handle 07936 - MK50100 10 Remover weight 07741 - 0010201 10 Crankcase assembly tool 07931 - KFOOOOO }10 - Collar 07931 - KFOO100 - Thread adapter 07931 - KFOO200 - Shaft puller 07931 - ME40000 Oil seal driver attachment 07GAD - SD40101 10 Ball race remover 07953 - MJ1000 12 Slider weight 07947 - KA50100 12 Fo rk seal driver attachment 07947 - KA40200 12 Steering stem nut wrench 07916 - KA50100 12 Compression gauge 07908 - KK60000 3 attachment Steering stem driver 07946 - 4300101 12 Bearing driver 07946 - MJ00100 13 Damping valve wrench 07920 - KA30001 13 Bea ring driver base 07HMF - KS60100 13 Spherical bearing driver 07946 - KA30200 13 Needle bea ring remover 07931 - MA70000 13 Snap ring pliers 07914 - 3230001 I. Slider guide, 14 mm 07974 - KA40000 13 Piston ring sleeve 07974-KA30201 13 Slider guide attachment 07974 - KA30100 13 1-7

COMMON DESCRIPTION Wrench, 10 x 12 mm Adjusting wrench A Spoke wrench , 5.8 x 6.1 mm Float level gauge Valve guide driver , 6 .6 mm Valve spring compressor Wrench, 17 x 27 mm Extension bar Attachment, 32 x 35 mm Pilot, 20 mm Pilot, 40 mm Primary gear holder Clutch center holder Driver Flywheel holder Rotor puller Attachment , 52 x 55 mm Attachment, 62 x 68 mm Attachment, 72 x 75 mm Pilot, 17 mm Attachment, 42 x 47 mm Pilot , 25 mm Pilot, 35 mm Wrench , 30 x 32 mm Pilot , 15 mm Remover head, 1 5 mm Remover shah Remover head, 1 7 mm Remover head. 20 mm Retainer wrench A Retainer wrench body Attachment, 24 x 26 mm Driver Attachment , 20 mm I.D . Attachment , 37 x 40 mm VALVE SEAT CUTTER DESCRIPTION 38 .5 mm flat cutter 40 mm seat cutter 35 mm seat cutter 37 .5 mm intake cutter 6 .6 mm cutter holder TOOL NUMBER 07708 - 0030200 07708 - 0030300 07701 - 0020300 07401 - 0010000 07742 - 0010200 07757 - 0010000 07716 - 0020300 07716 - 0020500 07746 - 0010100 07746 - 0040500 07746 - 0040900 07724 0010100 07724 - 0050001 07749 - 0010000 07725 - 0040000 07733 - 0020001 07746 - 0010400 07746 - 0010500 07746 0010600 07746 - 0040400 07746 - 0010300 07746 - 0040600 07746 - 0040800 07716 - 0020400 07746 - 0040300 07746 - 0050400 07746 - 0050100 07746 - 0050500 07746 - 0050600 07710 - 00 10100 07710 - 0010401 07746 0010700 07746 - 0020100 07746 - 0020400 07746 - 0010200 TOOL NUM8ER 07780 - 0012400 07780 0010500 07780 - 0012300 07780 - 0014100 07781 0010201 GENERAL INFORMATION REFER TO SECTION 3 3 3 4 6 6 8 8 8, 12 , 13 8, 10,13 10 8 8 8, 10 , 12 , 13 9 9 10 10 10 10, 13 10, 12, 13 10 10 12 12 12 12 , 13 13 13 13 13 13 13 13 10 , 13 REFER TO SECTION I 6 1-8

GENERAL INFORMATION CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses: • A loose wire , harness or cable can be a safety hazard. Ahar clamping , check each wire to be sure it is secure. • Do not squeeze 8 wire against a weld or the end of its clamp . • Secure wires and wire harnesses to the frame with their re- spective bands 8t the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wife harneses. • Route harnesses so they Bre not pulled taut or have excessive slack. • Protect wires and harnesses with electrical tape or tubing where they contact a sharp edge or corner. Clean the at- taching surface thoroughly before applying tape. • Do not use wires or harnesses with damaged insulation. Repair by wrapping them with protective tape or replace them. • Route wire harnesses so as to avoid sharp edges or corners. • Avoid the projected ends of bolts and screws . • Keep wire harnesses away from the exhaust pipes and other hot parts . • Be sure grommets are seated in their grooves properly. • After clamping. check each harness to be certain that it is not interfering with any moving or sliding parts. • After routing. check that the wire harnesses are not twisted or kinked. • Wire harnesses routed along the handlebar should not be pulled taut , have excessive slack, or interfere with adjacent or surrounding parts in any steering position . • Do not bend or twist control cables. Damaged control cables will not operate smoothly and may sti ck or bind. 1-9 o x x x ~ x 0: CORRECT x: INCORRECT

HONDA XR600R Service Repair Manual

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