1986 Honda XL600R Service Manual PDF

The 1986 Honda XL600R is a dual-sport motorcycle featuring a 591cc RFVC four-stroke engine, dual carburetors, 5-speed transmission, dual-sport capabilities, and electric start. This service manual covers maintenance, repair procedures, specifications, and troubleshooting for the complete motorcycle system. Below are key sections for safety, maintenance schedules, engine service, chassis, electrical systems, and troubleshooting.

1. General Information 2. Maintenance Schedule 3. Engine Service 4. Chassis & Suspension 5. Electrical System 6. Fuel System 7. Transmission & Drive 8. Brake System 9. Troubleshooting 10. Specifications 11. Wiring Diagrams

General Information

Key components: 591cc RFVC engine, dual carburetors, 5-speed transmission, electric start, dual-sport tires, front and rear suspension systems.

Component	Description
Engine Type	591cc RFVC 4-stroke single cylinder
Carburetion	Dual Keihin carburetors
Transmission	5-speed constant mesh
Starting System	Electric and kick start
Front Suspension	Air-adjustable telescopic fork
Rear Suspension	Pro-Link single shock
Front Brake	Single disc
Rear Brake	Drum brake
Fuel Capacity	2.8 gallons (10.6 liters)
Weight	324 lbs (147 kg)

Maintenance Schedule

Regular maintenance intervals for optimal performance and longevity.

Oil change: Every 600 miles or 6 months
Oil filter: Replace with every oil change
Air filter: Clean every 1,000 miles, replace every 6,000 miles
Spark plug: Check every 3,000 miles, replace every 6,000 miles
Valve clearance: Check every 3,000 miles
Chain adjustment: Every 500 miles
Brake fluid: Replace every 2 years

WARNING! Always use genuine Honda parts and recommended lubricants. Disconnect battery before servicing electrical components.

Engine Service

Complete engine disassembly, inspection, and reassembly procedures.

Cylinder head removal: Remove camshaft, check valve clearance (0.05mm intake, 0.08mm exhaust)
Piston and cylinder: Measure piston clearance (0.02-0.04mm), check cylinder bore
Crankshaft and connecting rod: Check big end play (0.35-0.55mm)
Camshaft and timing: Set timing marks alignment
Oil pump: Check for proper operation and clearance

CAUTION! Use proper torque specifications for all fasteners. Clean work area thoroughly before engine disassembly.

Chassis & Suspension

Front Fork: Air pressure 0-6 psi, oil capacity 486cc per leg
Rear Shock: Spring preload adjustment, 5 positions
Steering Head: Bearing adjustment and lubrication
Wheels: Spoke tension check, rim runout maximum 2.0mm
Tires: Front 3.00-21, Rear 4.60-17, pressure 22 psi front/28 psi rear
Swingarm: Bearing inspection and lubrication

Electrical System

Complete electrical system diagnosis and repair procedures.

Battery: 12V 10Ah, specific gravity 1.280. Charging System: Output 200W at 5000 rpm. Ignition System: CDI electronic ignition, timing 15° BTDC at 1500 rpm.

Testing procedures: Stator resistance 0.1-1.0Ω, pulse generator 50-200Ω, ignition coil primary 0.1-0.3Ω, secondary 13-19kΩ.

Fuel System

Dual carburetor service and adjustment procedures.

Carburetor removal: Disconnect fuel lines and throttle cables
Float level: 14.5mm, main jet #122, pilot jet #65
Sync procedure: Use vacuum gauges to balance carburetors
Fuel valve: Reserve position provides additional 0.8 gallons
Air cutoff valve: Test for proper operation

Tip: Always clean fuel tank and replace fuel filter during carburetor service.

Transmission & Drive

5-speed transmission service and final drive maintenance.

Clutch adjustment: Free play 10-20mm at lever
Transmission oil: Capacity 1.9 liters, change every 3,000 miles
Drive chain: Size 520, slack 20-30mm
Sprockets: Front 15T, rear 45T, check for wear
Shift mechanism: Inspect shift forks and drum for wear

WARNING! Always replace chain and sprockets as a set. Never operate with worn drive components.

Brake System

Front disc and rear drum brake service procedures.

Front Disc: Pad thickness minimum 1.5mm, rotor thickness minimum 3.5mm, brake fluid DOT 4. Rear Drum: Lining thickness minimum 2.0mm, adjustment at lever.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Weak battery, dirty carbs	Charge battery, clean carburetors, check valve clearance
Poor performance	Clogged air filter, ignition timing	Clean/replace air filter, check ignition timing and advance
Oil consumption	Worn piston rings, valve seals	Compression test, inspect cylinder and valves
Transmission noise	Worn gears, low oil	Check transmission oil level, inspect gears and bearings
Electrical failure	Bad stator, regulator	Test charging system components, check connections

Reset: Disconnect battery for 30 minutes to reset ECU if equipped.

Specifications

Engine: 591cc RFVC 4-stroke single, bore x stroke 100.0 x 75.5mm
Compression: 9.0:1
Power: 43 hp @ 6,500 rpm
Torque: 37 lb-ft @ 5,500 rpm
Fuel System: Dual Keihin 32mm carburetors
Ignition: CDI electronic
Transmission: 5-speed constant mesh
Final Drive: Chain 520
Frame: Semi-double cradle steel
Seat Height: 34.6 inches
Ground Clearance: 10.6 inches

Wiring Diagrams

Complete color-coded wiring diagrams for entire electrical system including charging, ignition, lighting, and starting circuits. Diagrams show wire colors, connector locations, and component identification.

Service: Contact authorized Honda dealer for genuine parts and technical support.