Honda XL/XR 500-650 Singles (79-90) Repair Manual

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Service hints / Torque specifications / Safety First / Special tips / Expendable supplies / Parts replacement / Serial numbers / Hand tools / Tun-up and troubleshooting tools / Mecahnic's tips / Off Road rules / Safety

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Excessive vibration / Front suspension and steering / Brake problems

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Pre-checks / Service intervals / Tires and wheels / Battery / Periodic lubrication / Periodic maintenance / Tune-up

CHAPTER FOUR / 1979-1982 500 CC ENGINES
Engine principles / Engine cooling / Servicing engine in frame / Engine removal/installation / Cylinder head cover / Cylinder head / Reed valve assembly (XR500R) / Valves and valve components / Camshaft / Camshaft chain and dampers / Cylinder / Piston, piston pin and piston rings / Ignition advance mechanism / Oil pump and oil filter screen / Kickstarter / Crankcase / Crankshaft and connecting rod / Balancer system / Break-in procedure / Specifications

CHAPTER FIVE / RFVC ENGINES
Engine principles / Engine cooling / Servicing engine in frame / Engine removal/installation / Cylinder head cover and camshaft / Camshaft chain tensioner / Cylinder head / Valves and valve components / Cylinder / Piston, piston pin and piston rings / Primary drive gear / Oil lines / Camshaft chain / Crankcase and crankshaft / Balancer system / Kickstarter / Break-in procedure / Specifications

CHAPTER SIX / CLUTCH AND TRANSMISSION
Clutch / Clutch cable / External shift mechanism / Transmissions / 5-speed transmission / Internal shift mechanism / Specifications

CHAPTER SEVEN / FUEL AND EXHAUST SYSTEMS
Carburetor / Carburetor adjustments / Throttle cable / Choke cable replacement (models so equipped) / Fuel tank / Fuel filter / Gasoline/alcohol blend test / Crankcase breather system / Evaporative emission control system / Air filter case / Exhaust system / Specifications

CHAPTER EIGHT / ELECTRICAL SYSTEM
Charging system (XL series models) / Alternator rotor / Alternator stator / Voltage regulator/rectifier / A/C regulator test (XL500R, XL600R) / Capacitor discharge ignition / Mechanical ignition advance mechanism / Pulse generator / Ignition coil / Lighting system / Electrical components / Fuse (XL series models) / Wiring diagrams / Specifications

CHAPTER NINE / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Handlebar / Steering head and stem (loose ball bearings) / Steering head bearing races / Front fork / Inspection / Specifications

CHAPTER TEN / REAR SUSPENSION
Rear wheel / Rear hub / Final driven sprocket / Swing arm / Pro-Link / Dual shock absorbers / Pro-Link suspension system / Shock absorber / Pro-Link pivot arm assembly / Pro-Link pivot arm bearing / Specifications

CHAPTER ELEVEN / BRAKES
Drum brakes / Front drum brake / Front disc brake / Front brake pad replacement / Front master cylinder / Front caliper / Front brake hose replacement / Front brake disc / Bleeding the system / Rear drum brake / Brake cable / Specifications

WIRING DIAGRAMS

Models covered:
1982 HONDA XL500R XL500 XL 500 R
1979 1980 1981 HONDA XL500S XL500 XL 500 S
1983 1984 1985 1986 1987 HONDA XL600R XL600 XL 600 R
1979 1980 HONDA XR500 XR 500
1981 1982 1983 1984 HONDA XR500R XR500 XR 500 R
1985 1986 1987 1988 1989 1990 HONDA XR600R XR600 XR 600 R
Dual Sport Dualsport