Product Name:
Honda XR600R 1985-1991 Service Repair Manual
Covered Years:
1985, 1986, 1987, 1988, 1989, 1990, 1991
Target User:
Owners and mechanics seeking to perform service and repairs on the Honda XR600R
Model Segment:
Performance Enduro / Dual-Sport Motorcycle
Value Proposition:
Provides dealer-level repair information at a fraction of the cost of professional service, empowering DIY enthusiasts.
Features:
Printable sections for workshop use, detailed specifications, factory procedures, fault finding guides.
Primary Coverage:
Comprehensive service, repair, maintenance, and restoration
Estimated Page Count:
Refer to actual manual's compiled pages; likely substantial for full coverage
Type:
Service and Repair Manual
Format:
Digital Download (PDF)
Engine Systems:
Complete engine service, engine firing order, timing chain service, clutch removal and installation, gearbox service, gearbox removal and installation, cooling system
Fuel And Exhaust:
Fuel system service, exhaust system service
Suspension And Chassis:
Front suspension, suspension (general), bodywork
Electrical And Brakes:
Electrics, wiring diagrams, brake servicing procedures
Drivetrain:
Transmission, driveshaft
Frame And Forks:
Frame inspection, front fork service and adjustment procedures.
Rear Suspension:
Rear shock absorber service, linkage maintenance, and adjustment procedures.
Wheels And Tires:
Wheel bearing service, tire pressure recommendations, and general wheel maintenance (though specific tire sizes are usually in general specs).
Fuel Tank And Seat:
Removal and installation procedures for fuel tank and seat.
Lighting And Indicators:
Headlight, taillight, and any indicator system operation and troubleshooting.
Maintenance And Routine:
Factory maintenance schedules, routine maintenance procedures
Diagnostics And Troubleshooting:
Fault finding, diagnostic procedures
Repair And Rebuild:
Factory repair procedures, complete engine service, gearbox repair, clutch repair, suspension repair, bodywork repair
Engine Rebuild:
Complete engine disassembly, inspection, repair, and reassembly instructions.
Carburetor Tuning:
Detailed procedures for jetting, cleaning, and adjusting the carburetor for optimal performance.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and specific testing procedures.
Depth:
Professional quality, comprehensive coverage suitable for dealer technicians and home mechanics, enabling full rebuild and restoration
Special Tools:
Implied coverage of specialized tools required for specific factory procedures, as would be detailed in a professional service manual.
Specifications Detail:
Detailed specifications for all major components, including torque values, clearances, and tolerances.
Engine Type:
4-Stroke Single Cylinder, Air-Cooled, OHC
Displacement:
591 cc (36.1 cu in)
Bore X Stroke:
97.0 mm x 79.0 mm (3.82 in x 3.11 in)
Compression Ratio:
Approximately 8.5:1 to 9.0:1 (varies by specific year/model revision)
Horsepower Estimate:
Approximately 45-50 HP (actual figures vary by year and modifications, exact figures within manual).
Torque Estimate:
Refer to manual for precise torque figures; typically strong low-end and mid-range power for off-road use.
Carburetion:
Single Carburetor (e.g., Keihin 36mm, with specific model variations)
Fuel Type:
Unleaded Gasoline
Ignition System:
CDI (Capacitor Discharge Ignition)
Engine Configuration:
Single Cylinder, Four-Stroke
Cooling Method:
Air Cooling
Oil Change Interval:
Refer to manual for specific intervals based on usage; typically every 1,000-2,000 km or annually.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions; interval varies greatly with environment.
Engine Oil Type:
SAE 10W-40 API SG or higher motorcycle-specific oil
Transmission Oil Capacity:
Refer to manual; typically around 1.2 - 1.5 liters (1.3 - 1.6 US qt) for engine and transmission combined.
Brake Fluid Type:
DOT 3 or DOT 4
Fork Oil Type:
Specific viscosity and quantity detailed in the manual (e.g., SAE 10W fork oil).
Coolant Type:
N/A (Air-cooled engine)
Common Wear Items:
Cam chain tensioner wear, carburetor jetting issues due to age/modifications, clutch wear, general wear and tear on suspension components.
Electrical Faults:
Aging wiring insulation, CDI unit reliability, stator output degradation can occur.
Starting Problems:
Kick-starter mechanism robustness, carburetor cleanliness, and ignition timing can affect starting.
Carburetor Problems:
Poor idle, hesitation, or stalling often related to clogged jets, incorrect float level, or worn seals.
Brand Focus:
Honda's long history in off-road motorcycle development, particularly in the dual-sport and motocross segments.
Xr Series:
The XR600R is part of Honda's esteemed XR line, known for its robust performance and reliability in demanding off-road conditions.
Key Advancements:
XR600R saw improvements in suspension, braking, and engine tuning across its production run, with this manual covering a significant portion of its development.
Production Period:
1985-1991 (as covered by this manual)
