• MOTORCYCLE SERVICE MANUAL

MOTORCYCLE SERVICE MANUAL

MOTORCYCLE SERVICE MANUAL

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MODELS COVERED:

XL500S (1979-1981)
XL500R (1982)
XR500 (1979-1980)
XR500R (1981-1984)
XL600R (1983-1987)
XR600R (1985-1990)

This Honda motorcycle manual is 424 pages.

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
 

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Product Specifications

General Information

Brandclymer
Label@HONDA XL/XR 500-600 1979-1990
Universemoto
Categorymanuel_d_entretien
Supplier Part #CM3398
ITL ID252-M3398

Dimensions & Physical

Weight 1.764 lbs
Length0
Width0
Thickness0

Vehicle Fitment

Total Applications15
Applications HONDA XL500 1979HONDA XL500 1980HONDA XL500 1981HONDA XL600R 1983HONDA XL600R 1984HONDA XL600R 1985HONDA XL600R 1986HONDA XL600R 1987HONDA XR500 1979HONDA XR500 1980HONDA XR500R 1981HONDA XR500R 1982HONDA XR500R 1983HONDA XR500R 1984HONDA XR600R 1990
Makes HONDA
Models XL500XL600RXR500XR500RXR600R
Years 1979198019811982198319841985198619871990

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most items in store come with a manufacture defect warranty to give you peace of mind. we always strive to keep our customers happy with any issues on fitment or quality.

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If what you ordered does not fit, we will do a quick check for fitment via pictures of the item and your machine to verify. if the fitment widget was wrong-return cost is on us and a refund or instore credit will apply. Any other return is subject to a re-stocking fee and customer pays for return freight.

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most products leave same day if orderd before 11am. or next day if after that. delivery is anywhere from 2-7 days depending location in canada.

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