2000-2007 Honda XR650R Service & Repair Manual

HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recom- mendations to ensure that the vehicle is in peak oper- atill'g .condition. Perfurming the first scheduled maintenance is very impOJitant. It compensates for the initial wear that occu.r.s during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for remova l/ installation of components that may be required to perform service described in the following sections. Sections 4 through 17 describe parts of the motorcycle, grouped according to location. !' . . ! ._ 7'-ind the section you want on this page, then turn to ' -1he table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting ,---..,. " or the section. ~'~~e subsequent pages give detailed procedure. If you don't know the source of the trouble, go to section 19, Troubleshooting. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED r' BASIC KNOWLEDGE OF MAINTENANCE ON ) HONDA MOTORCYCLES, MOTOR SCOOTERS OR ATVS. · HONDA MOTOR CO., LTD. 0 SERVICE PUBLICATION OFFICE Date otlssue: February, 2000 © HON'IDA MOTOR CO., LTD. z <( a: 1- w > a: c c z <( w ~ (!) z w (J) u; (J) <( ::c (.) I -I CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAUINSTALLA TION CYLINDER HEAD/VALVES CYLINDER/PISTON CLUTCH/KICKSTARTER/ GEARSHIFT LINKAGE ALTERNATOR CRANKCASE/CRANKSHAFT I BALANCER TRANSMISSION FRONT WHEEUSUSPENSION/ STEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE ELECTRICAL SYSTEM (.)<( we.>---====================================== _,_.- w~ WIRING DIAGRAMS TROUBLESHOOTING

r IMPORTANT SAFETY NOTICE fN'?f.1;iUH9 Indicates a strong possibility of severe personal injury or death if instructions are not followed. CAUTION: Indicates a possibility of equipment damage if instructions are not followed. NOTE: Gives helpful information. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoroughly th at neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected. Type Codes •Throughout this manual, the following abbreviations are used to identify individual model. •The asterisk (*)indicates that this manual is applicable for the corresponding area type. Code Available Area Type ED * European direct sales E U.K. F France G Germany u * Australia SA South Africa ND North Europe SW Switzerland SD Sweden Fl Finland N Norway IT Italy B Belgium H Netherland AR Austria SP Spain D(DK, DM) * General export (km/h, mph)

r ') ( .......... ~·~ : ? ., "?SrJUtiWt! ; l .. SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be expl ained specifically in the text without the use of the symbols. ~ e Replace the part(s) with new one(s) before assembly . , Use recommended engine oil, unless otherwise specif ied. , Use molybdenum oil soluti on (mixture of the engin e oil and mol ybd enum grease in a ratio of 1 : 1). _..ww Use multi-purpose grease (Lithium based multi -purpose grease NLGI # 2 or equivalent). Use molybdenum disulfide grease (containing more than 3 % molybdenum disulfide, NLGI # 2 or ~ equivalent). Example: Molykote ® BR-2 plus manufactured by Dow Corning, U. S. A Multi- purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide pa ste (containing more than 40 % molybdenum disulfide, NLGI # 2 or equivalent). ~ Example: Molykote® G-n paste, manufactured by Dow Corning, U.S. A Honda Moly 60 (U. S. A only) Rocol ASP manufactured by Rocol Limited, U. K. Rocol Paste manufactured by Sumico Lubri ca nt, Japan ~ Use silicone grease. cw Apply a locking agent. Use a middl e strength locking agent unless oth erwise specified. .t'mD! Apply sealant. I Use DOT 4 brake fluid. Use the recomm ended brake flu id unless otherwise specified . ... Use Fork or Suspension Fluid.

1. GENERAL INFORMATION GENERAL SAFETY 1-1 SERVICE RULES 1-2 MODEL IDENTIFICATION 1-3 SPECIFICATIONS 1-4 TORQUE VALUES 1-12 GENERAL SAFETY CARBON MONOXIDE r lf the engine must be running to do some work, make ~re the area is well vent ilated. Never run the engine in an "-· Jclosed area. r The exhaust contains poisonous carbon monoxide gas · "\.at can cause loss of consciousness and may lead to ' death. Run the eng ine in an open area or with an exhaust evacuation system in an enclosed area. GASOLINE Work in a well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is stored. Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. T COMPONENTS ( Engine and exhaust system parts become very hot and " "mai n hot for some time after the engine is run. Wear { ) sulated gloves or wait until the engine and exhaust system have cooled before handling these p art s. USED ENGINE OIL Used engine oil may cause ski n cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. TOOLS LUBRICATION & SEAL POINTS CABLE & HARNESS ROUTING EMISSION CONTROL SYSTEM BRAKE DUST 1-16 1- 18. 1-20 1-23 Never use an air hose or dry brush to clean the brake assemblies. Inhaled asbestos fibers have been found to cause respiratory disease and cancer. BRAKE FLUID CAUTION: Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. NITROGEN PRESSURE For shock absorber with a gas-filled reservoir: • Use only nitrogen to pressurize the shock absorber. The use of an unstable gas can cause a fire or explosion resulting in serious injury. • The shock absorber contains nitrogen under high pressure. Allowing fire or heat near the shock absorber could lead to an explosion that could result in serious injury . • Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explosion and serious injury if it is heated or pierced. 1-1

GENERAL INFORMATION COOLANT Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the ethylene glycol does ignite, you will not see any flame, but you can be burned. •Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flame. • Coolant (ethylene glycol} can cause some skin irritation and is poisonous if swallowed. KEEP OUT OF REACH OF CHILDREN. • Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. ( ~UTION: ' / ' Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages. - Using tap water may cause engine damage. l l · .._,/ If it contacts your skin, wash the affected areas immediately with soap and water. If it contacts your eyes, flush them thoroughly with fresh water and get immediate medical attention. If it is swallowed, the victim must be forced to vomit, then rinse mouth and throat with fresh water before obtaining medical attetion. Because of these dangers, always keep from the reach of children. Recycle used coolant in an ecologically correct manner. SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. ?· Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English 'lsteners. · ..... nstall new gaskets, 0-rings, cotter pins, and lock plates when reassembling. · 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. r-ie-tt er reassembly, check all parts for proper installation and operation. :.: _) oute all electrical wires as show on pages 1-20 through 1-22, Cable and Harness Routing. 1-2

MODEL IDENTIFICATION ED type: FRAME SERIAL NUMBER (1) FRAME SERIAL NUMBER The frame serial number is stamped on the right side of the steering head. CARBURETOR IDENTIFICATION NUMBER (3) CARBURETOR IDENTIFICATION NUMBER The carburetor identificat ion number is stamped on the right side of the carburetor body. I GENERAL INFORMATION Utype: (2) ENGINE SERIAL NUMBER The engine serial number is stamped on the lower left side of the crankcase. COLOR LABEL (4) COLOR LABEL The color label is attached to the sub frame behind the left side cover. When ordering color-coded parts, always specify the designated color code. 1-3

GENERAL INFORMATION SPECIFICATIONS -GENERAL DIMENSIONS ITEM Overall length Overall width Overall height Wheelbase (ED, DK types) (U type) Seat height Footpeg height Ground clearance Dry weight (ED, DK types) (U type) Curb weight (ED, DK types) (U type) ,,.- FRAME Frame type ~ ) r ,) ENGINE r .,) ( ~) 1-4 Front suspension Front cushion stroke Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Tire brand (Front/Rear) Front brake Rear brake Caster angle Trail length Fuel tank capacity Fuel tank reserve capacity Type Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train · Intake valve opens closes Exhaust valve opens closes Lubrication system Oil pump type Cooling system Air filtration Enaine drv weiQht 2,255 mm (88.8 in) 825 mm (32.5 in) 1,245 mm (49.0 in) 1,485 mm (58.5 in) 1,490 mm (58.7 in) 939 mm (37.0 in) 411 mm(16.2in) 305 mm (12.0 in) 131 kg (289 lbs) 133 kg (293 lbs) 142 kg (313 lbs) 144 ka (317 lbs) Semi-double cradle Telescopic fork 285 mm (11.2 in) Swingarm 307 mm (12.1 in) SPECIFICATIONS Nitrogen gas filled damper with reserve tank 3.00-21 51P 4.50- 18 70P TR8/TR8 (IRC) Hydraulic single disc brake Hydraulic single disc brake 27°32' 108 mm (4.3 in) 10.0 e (2.64 US gal, 2.20 Imp gal) 4.5 e (1 .19 us qal, 0.99 Imo aal) Gasoline, liquid cooled 4-stroke SOHC Single cylinder inclined 13° 100.0 X 82.6 mm (3.94 X 3.25 in) 649 cm 3 (39.6 cu-in) 10.0: 1 4-valve, single chain driven SOHC 15° BTDC 45° ABDC 45° BBDC 15° ATDC Forced pressure and dry sump Trochoid/double rotor Liquid cooled Oiled polyurethane foam 40.9 ka (90.2 lbs)

GENERAL INFORMATION - GENERAL (Cont'd) ITEM SPECIFICATIONS CARBURETOR Carburetor type Piston valve type Throttle bore 42 mm (1.7 in) DRIVE TRAIN Clutch system Multi-plate, wet Clutch operation system Cable operated type Transmission Constant mesh, 5-speed Primary reduction 1.651 (71 /43) Gear ratio 1st 3:083 (37/12) 2nd 2.125 (34/16) 3rd 1.666 (30/18) 4th 1.333 (28/21) 5th 1.115 (29/26) Final reduction (ED, DK types) 3.429 (48/14) (U type) 2.733 (41 /15) Gearshift oattern Left foot ooerated return svstem, 1- N- 2- 3-4-5 t, ELECTRICAL lanition svstem CDI (Caoacitive Discharae lanition) () "-·· 1-5

GENERAL INFORMATION ~ LUBRICATION SYSTEM ITEM STANDARD SERVICE LIMIT Unit· mm (in) Engine oil capacity At drainina 1.56 2 (1.65 US nt, 1.37 lmn nt) At oil filter chanae 1.6 2 (1.7 US at, 1.4 Imo at) At disassemblv 2.0 2 (2.1 US at, 1.8 Imo at) Recommended engine oil HONDA 4·stroke oil or equ ivalent motor oil API service classification: SE, SForSG Oil pump rotor A, 8 Bodv clearance 0.15- 0.22 (0.006- 0.009) 0.35 (0.014) Tio clearance 0.15 (0.006) 0.20 (0.008) Side clearance 0. 03-0.08 (0.001 - 0.003) 0.10 (0.004) ELS ~FU YSTEM i ITEM SPECIFICATIONS Carburetor identification ED, DKtvoes PE78C number Utvoe PE78D Main jet ED, DK tvoes # 175 Utvoe # 112 Slow iet # 65 Jet needle clio oosition 3rd aroove from too ! Pil ot screw ooeninq see oaae 5· 15 Float level 16.0 mm (0.63 in) Idle soeed 1,400 ± 100 min· 1 (rom) Throttle grip free play 2.0-6.0 mm (1/16 -1 /4 in) - COOLING SYSTEM ITEM SPECIFICATIONS Coolant capacity Radiator and enaine 1.52 2 (1 .61 US at, 1.34 Imo at) Reserve tank 0.20 2 (0.21 US at, 0.18 Imp qt) Radiator cao relief oressure 108- 137 kPa (1.1-1.4 kaf/cm 2 , 16- 20 osi) Thermostat Beain to ooen 80-84 °C (176 -1 83 °F) Fully open 95 °C (203 °F) Valve lift 8 mm (0.3 in) minimum Standard coolant concentration 50 % mixture with soft water ,) 1-6

GENERAL INFORMATION - CYLINDER HEAD/VALVES Unit mm (in) ITEM STANDARD SERVICE LIMIT Decomoressor lever free olav 5.0- 8.0 (3/16-5/16) Cylinder Valve clearance at standard 600 kPa (6.12 kgf/cm 2 , 87 psi) compression (decornoressor annlied) at 400 min- 1 (rpm) Valve clearance at 1 mm (0.04 in) 1, 100 kPa (11.22 kgf/cm 2 , 160 psi) (decomoressor not aoolied) at 400 min- 1 (rom) Cvlinder head waroaqe 0.10 (0.004) Valve, Valve clearance IN 0.15 ± 0.02 (0.006 ± 0.001) valve guide EX 0.20 ± 0.02 (0.008 ± 0.001) Valve stem O.D. IN 6.575-6.590 (0.2589-0.2594) 6.56 (0.258) EX 6.555- 6.570 (0.2581-0.2587) 6.55 (0.258} Valve quide l.D. IN/EX 6.600 - 6.615 (0.2598 -0.2604) 6.655 (0.2620) Stem-to-guide clearance IN 0.010- 0.040 (0.0004-0.0016) 0.12 (0.005) EX 0.030-0.060 (0.0012-0.0024) 0.14 (0.006) Valve guide projection IN 16.3- 16.5 (0.64 - 0.65) above cvlinder head EX 16.3- 16.5 (0.64-0.65) ') Valve seat width IN 1.1 - 1.3 (0.04-0.05) 2.0 (0.08) EX 1.3- 1.5 (0.05- 0.06) 2.0 (0.08) Valve spring Inner IN/EX 44.0 (1.73) 43.0 (1.69) free lenQth Outer IN/EX 45.2 (1 .78) 44.2 (1.74) Rocker arm Rocker arm l.D. IN/EX 14.000- 14.018 (0.5512-0.5519) 14.05 (0.553) Rocker arm shaft O.D. IN/EX 13.966-13.984 (0.5498-0.5506) 13.91 {0.548) Rocker arm-to-shaft clearance IN/EX 0.016-0.052 (0.0006-0.0020) 0.14 (0.006) Camshaft Cam lobe height IN 41.158-41.398 (1 .6204-1.6298) 41.00 (1.614) EX 41.196-41.436 (1.6219 - 1.6313) 41 .05 (1.616) Run out 0.03 (0.001) j) 1-7

2000-2007 Honda XR650R Service & Repair Manual

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