1986 Honda XL600R Service Manual
The 1986 Honda XL600R is a dual-sport motorcycle featuring a 591cc RFVC (Radial Four-Valve Combustion) four-stroke engine, dual carburetors, 5-speed transmission, dual-sport capabilities, and electric start. This service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for proper servicing and operation. Below are key sections for safety, specifications, maintenance, troubleshooting, and technical data.
General Information
Key components: 591cc RFVC engine, dual carburetors, electric start, dual-sport tires, front and rear disc brakes.
| Component | Description |
|---|
| Engine Type | 591cc RFVC 4-stroke single cylinder |
| Carburetion | Dual Keihin CV carburetors |
| Starting System | Electric start with kickstarter backup |
| Transmission | 5-speed constant mesh |
| Frame Type | Steel semi-double cradle |
| Suspension Front | Air-adjustable telescopic fork |
| Suspension Rear | Pro-Link single shock |
| Brakes Front | Single disc |
| Brakes Rear | Single disc |
| Fuel Capacity | 2.8 gallons (10.6 liters) |
Specifications
- Engine Displacement: 591cc
- Bore x Stroke: 100.0 x 75.5mm
- Compression Ratio: 9.0:1
- Carburetor: Dual Keihin 32mm CV
- Ignition System: CDI electronic ignition
- Transmission: 5-speed, wet multi-plate clutch
- Final Drive: #520 chain
- Front Tire: 3.00-21
- Rear Tire: 5.10-17
- Wheelbase: 58.3 inches (1480mm)
- Seat Height: 34.8 inches (885mm)
- Dry Weight: 324 lbs (147kg)
Periodic Maintenance
Regular maintenance schedule for optimal performance and longevity.
- Oil Change: Every 600 miles - Use 10W-40 motorcycle oil
- Oil Filter: Replace every other oil change
- Air Filter: Clean every 600 miles, replace as needed
- Spark Plug: Check/replace every 3,000 miles - NGK DR8ES-L
- Valve Clearance: Check every 3,000 miles - IN: 0.004 in, EX: 0.005 in
- Chain Adjustment: Every 600 miles - 1.0-1.4 inches play
- Brake Fluid: Replace every 2 years
- Carb Sync: Synchronize every 3,000 miles
WARNING! Always use motorcycle-specific oil. Never use automotive oil.
Engine Service
Engine disassembly, inspection, and reassembly procedures.
- Cylinder Head Removal: Remove tank, carbs, exhaust before head removal
- Valve Adjustment: Engine cold, set to TDC compression stroke
- Piston Removal: Remove cylinder after head removal
- Clutch Service: Remove right side cover, measure plate thickness
- Transmission: Split cases for gear inspection
- Torque Values: Cylinder head bolts: 20 ft-lbs, spark plug: 13 ft-lbs
CAUTION! Use proper torque wrench for all fasteners.
Fuel System
Dual carburetor service and fuel system maintenance.
- Carb Removal: Drain fuel, disconnect cables and hoses
- Carb Cleaning: Disassemble, clean jets with compressed air
- Float Level: Set to 12.5mm from carb body
- Pilot Jet: #65, Main Jet: #122 (standard settings)
- Fuel Filter: Replace if clogged
- Fuel Tank: Inspect for rust, clean as needed
Tip: Always sync carburetors after service.
Electrical System
Battery, charging system, ignition, and lighting.
| Component | Specification |
|---|
| Battery | 12V 10Ah |
| Charging Output | 200W @ 5000 RPM |
| Spark Plug Gap | 0.028-0.031 inches |
| Headlight | 12V 60/55W |
| Fuses | Main: 20A, Headlight: 10A |
| Stator Resistance | 0.1-1.0 ohms (yellow to yellow) |
WARNING! Disconnect battery before electrical work.
Chassis & Suspension
Frame, suspension, and steering maintenance.
- Fork Service: Change fork oil every 2 years - 486cc per leg
- Steering Head: Check bearing play, adjust as needed
- Rear Shock: Check for oil leaks, adjust preload
- Wheel Bearings: Inspect for play, repack annually
- Swingarm: Check pivot bearings for wear
- Tire Pressure: Front: 22 psi, Rear: 28 psi (street)
Brake System
Front and rear disc brake service and maintenance.
- Brake Pads: Replace when worn to 1mm thickness
- Brake Fluid: DOT 4, bleed system annually
- Disc Inspection: Check for warping and minimum thickness
- Caliper Service: Clean and lubricate slider pins
- Master Cylinder: Inspect for leaks, rebuild if necessary
CAUTION! Never reuse brake fluid.
Troubleshooting
| Symptom | Possible Cause | Corrective Action |
|---|
| Hard starting | Dirty carbs, weak battery | Clean carbs, charge/replace battery |
| Poor idle | Carb sync, valve clearance | Sync carbs, adjust valves |
| Oil consumption | Worn rings, valve seals | Compression test, inspect engine |
| Electrical failure | Stator, regulator | Test charging system components |
| Brake drag | Stuck caliper, contaminated fluid | Clean caliper, bleed brakes |
| Chain noise | Loose chain, worn sprockets | Adjust chain, replace sprockets |
Wiring Diagrams
Complete electrical schematics for troubleshooting and repair.
- Main Harness: Color-coded wiring diagram
- Ignition System: CDI unit, pulse generator, coil
- Charging System: Stator, regulator/rectifier
- Lighting Circuit: Headlight, taillight, turn signals
- Starting System: Starter motor, solenoid, safety switches
Service Support: Contact Honda dealer for technical assistance
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