Honda XR650R Shop Manual – PDF DOWNLOAD
DESCRIPTION:
Honda XR650R Shop Manual – PDF DOWNLOAD
HOW TO USE THIS MANUAL:
Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition. Perf0rming the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period.
Sections 1 and 3 apply to the whole motorcycle.
Section 2 illustrates procedures for removal/ 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.
- Find the section you want on this page, then turn to the 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.
- The subsequent pages give detailed procedure.
- If you don’t know the source of the trouble, go to section 19, Troubleshooting.
TABLE OF CONTENTS:
Honda XR650R Shop Manual – PDF DOWNLOAD
Honda XR650R Shop Manual......................... 1 Contents..................................... 2 Important Safety Notice...................... 3 Symbols...................................... 4 1. GENERAL INFORMATION........................... 5 General Safety............................... 5 Model Identification......................... 7 Specifications............................... 8 Torque Values................................ 16 Tools........................................ 20 Lubrication & Seal Points.................... 22 Cable & Harness Routing...................... 24 Emission Control System...................... 27 2. FRAME/BODY PANELS/EXHAUST SYSTEM.............. 29 Service Information.......................... 29 Seat......................................... 30 Side Covers.................................. 30 Radiator Shroud.............................. 30 Front Fender................................. 31 Front Visor.................................. 31 Rear Fender/Mud Guard........................ 32 Fuel Tank.................................... 33 Sub Frame.................................... 33 Exhaust Pipe/Muffler......................... 36 Skid Plate................................... 39 3. MAINTENANCE................................... 41 Service Information.......................... 41 Maintenance Schedule......................... 43 Fuel Line.................................... 45 Throttle Operation........................... 45 Air Cleaner.................................. 46 Spark Plug................................... 47 Valve Clearance.............................. 48 Engine Oil................................... 50 Engine Oil Filter............................ 52 Decompressor System.......................... 53 Engine Idle Speed............................ 53 Radiator Coolant............................. 54 Cooling System............................... 54 Drive Chain/Sprocket......................... 55 Drive Chain Sliders.......................... 58 Brake Fluid.................................. 59 Brake Pad Wear............................... 60 Brake System................................. 60 Brake Light Switch........................... 61 Headlight Aim................................ 61 Clutch System................................ 61 Side Stand................................... 62 Suspension................................... 62 Spark Arrester............................... 64 Nuts, Bolts, Fasteners....................... 64 Wheels/Tires................................. 65 Steering Head Bearings....................... 65 4. LUBRICATION SYSTEM............................ 66 Service Information.......................... 67 Oil Strainer Screen Cleaning................. 68 Oil Pump..................................... 69 Check Valve.................................. 73 Oil Pipe..................................... 73 5. FUEL SYSTEM................................... 76 Service Information.......................... 77 Air Cleaner Housing.......................... 80 Crankcase Breather........................... 80 Carburetor Removal........................... 81 Carburetor Disassembly....................... 81 Carburetor Assembly.......................... 85 Carburetor Installation...................... 90 Pilot Screw Adjustment....................... 91 6. COOLING SYSTEM................................ 92 Service Information.......................... 93 System Testing............................... 95 Coolant...................................... 96 Thermostat................................... 98 Radiator.....................................100 Water Pump...................................102 Radiator Reserve Tank........................104 7. ENGINE REMOVAL/INSTALLATION...................106 Service Information..........................107 Drive Sprocket Removal.......................108 Engine Removal...............................109 Engine Installation..........................111 Drive Sprocket Installation..................114 8. CYLINDER HEAD/VALVES..........................116 Service Information..........................117 Cylinder Compression.........................120 Cylinder Head Cover Removal..................120 Cylinder Head Cover Disassembly..............122 Camshaft Removal.............................123 Cylinder Head Removal........................126 Cylinder Head Disassembly....................127 Valve Guide Replacement......................129 Valve Seat Inspection And Refacing...........130 Cylinder Head Assembly.......................133 Cylinder Head Installation...................135 Camshaft Installation........................135 Cylinder Head Cover Assembly.................138 Cylinder Head Cover Installation.............139 9. CYLINDER/PISTON...............................142 Service Information..........................143 Cylinder Removal.............................145 Piston Removal...............................146 Piston Installation..........................149 Cylinder Installation........................151 10. CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE.........152 Service Information..........................153 Clutch.......................................155 Right Crankcase Cover Removal................163 Primary Drive Gear...........................165 Kickstarter..................................167 Gearshift Cam................................172 Right Crankcase Cover Installation...........172 11. ALTERNATOR...................................174 Service Information..........................175 Left Crankcase Cover Removal.................176 Flywheel Removal.............................177 Flywheel Installation........................178 Left Crankcase Cover Installation............178 12. CRANKCASE/CRANKSHAFT/BALANCER................180 Service Information..........................181 Crankcase Separation.........................183 Crankshaft/Balancer Removal..................185 Crankcase Bearing Replacement................187 Crankshaft/Balancer Installation.............192 Crankcase Assembly...........................194 13. TRANSMISSION.................................198 Service Information..........................199 Transmission Removal/Disassembly.............201 Transmission Inspection......................202 Transmission Assembly/Installation...........204 14. FRONT WHEEL/SUSPENSION/STEERING..............208 Service Information..........................209 Front Wheel..................................212 Fork.........................................217 Handlebar....................................229 Steering Stem................................233 15. REAR WHEEL/SUSPENSION........................238 Service Information..........................239 Rear Wheel...................................242 Shock Absorber...............................247 Shock Linkage................................262 Swingarm.....................................267 16. HYDRAULIC BRAKE..............................274 Service Information..........................275 Brake Fluid Replacement/Air Bleeding.........277 Brake Pad/Disc...............................279 Front Master Cylinder........................281 Rear Master Cylinder.........................283 Front Brake Caliper..........................286 Rear Brake Caliper...........................289 Brake Pedal..................................293 17. ELECTRICAL SYSTEM............................296 Service Information..........................297 Ignition System Inspection...................301 Ignition Timing..............................304 ICM (Ignition Control Mudule)................305 Ignition Ciol................................305 Alternator...................................305 AC Regulator.................................306 Regulator/Rectifier..........................306 Headlight....................................308 Tail/Brake Light.............................308 Turn Signal Light............................309 Speedometer..................................309 Handlebar Switches...........................310 Engine Stop Switch...........................311 Front Brake Light Switch.....................311 Rear Brake Light Switch......................311 Horn.........................................311 Turn Signal Relay............................312 18. WIRING DIAGRAMS..............................313 19. TROUBLESHOOTING..............................319 Engine Does Not Start Or Is Hard To Start....319 Engine Lacks Power...........................320 Poor Performance At Low And Idle Speed.......321 Poor Performace At High Speed................322 Poor Handling................................322 INDEX............................................323
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