Honda XR650R SHOP MANUAL – PDF DOWNLOAD

Description

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 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. ‘”” . the section you want on this page, then turn to ‘-~ e table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting r” )\Or the section. ,~’.w/he subsequent pages give detailed procedure.
• If you don’t know the source of the trouble, go to section 19, Troubleshooting. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS 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 BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS ORATVS.

IMPORTANT SAFETY NOTICE

WARNING

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 him self thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected.\

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.

3.A Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English .

4.stall new gaskets, O-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 -After 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
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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