1986 XL600R Service Manual

The 1986 XL600R is a dual-sport motorcycle featuring a 591cc air-cooled four-stroke RFVC engine, 5-speed transmission, dual carburetors, front and rear disc brakes, and dual-purpose tires. This service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for the complete motorcycle system including engine, transmission, electrical, suspension, and braking components.

1. General Information 2. Specifications 3. Periodic Maintenance 4. Engine Service 5. Fuel System 6. Electrical System 7. Transmission 8. Suspension & Steering 9. Brakes 10. Troubleshooting 11. Wiring Diagrams

General Information

This manual provides detailed service information for the 1986 Honda XL600R. Includes safety precautions, tool requirements, and general maintenance procedures.

Section	Description
Identification	Frame and engine serial number locations
Safety First	Important safety precautions for service work
Tools & Equipment	Recommended service tools and specifications
Maintenance Schedule	Regular service intervals and requirements
Lubrication Points	All lubrication locations and recommended lubricants

Specifications

Engine Type: 591cc air-cooled 4-stroke RFVC single cylinder
Bore x Stroke: 100.0 x 75.5mm
Compression Ratio: 9.0:1
Carburetion: Dual Keihin 32mm constant velocity
Ignition: CDI electronic ignition
Transmission: 5-speed constant mesh
Final Drive: #520 chain
Front Suspension: 41mm telescopic fork, 9.8 inches travel
Rear Suspension: Pro-Link single shock, 9.4 inches travel
Front Brake: Single disc, 256mm
Rear Brake: Single disc, 220mm
Fuel Capacity: 2.8 gallons (10.6 liters)
Dry Weight: 319 lbs (145 kg)

Periodic Maintenance

Regular maintenance schedule and procedures to ensure optimal performance and longevity.

Daily/Pre-Ride: Check tire pressure, fuel level, brake operation, chain tension
Every 600 miles: Change engine oil, check/adjust chain, inspect brakes
Every 2,400 miles: Clean air filter, check valve clearance, inspect spark plug
Every 4,800 miles: Replace spark plug, check carburetor synchronization
Every 7,200 miles: Replace air filter, check wheel bearings, inspect suspension

WARNING! Always use genuine Honda parts and recommended lubricants. Follow torque specifications precisely.

Engine Service

Complete engine disassembly, inspection, and reassembly procedures.

Component	Service Procedure
Cylinder Head	Valve adjustment, camshaft service, rocker arm inspection
Cylinder & Piston	Bore measurement, piston ring replacement, cylinder honing
Crankshaft & Connecting Rod	Bearing clearance check, rod alignment, crank runout measurement
Clutch	Plate inspection, spring measurement, basket service
Oil Pump	Clearance check, rotor inspection, pressure testing

Valve Clearance: Intake 0.002 in (0.05mm), Exhaust 0.003 in (0.08mm)

Fuel System

Dual carburetor service, fuel tank maintenance, and fuel line procedures.

Carburetor disassembly and cleaning
Float level adjustment: 12.5mm
Pilot screw setting: 2-1/8 turns out
Main jet: #122, Slow jet: #65
Fuel petcock service and filter replacement
Throttle cable adjustment and lubrication

CAUTION! Always drain fuel tank before service. Use compressed air to clean jets.

Electrical System

Complete electrical system diagnosis and repair procedures.

Battery: 12V 8Ah, specific gravity 1.280
Charging System: AC generator output 14V 21A at 5000 rpm
Ignition System: CDI unit testing, pulse generator inspection
Lighting: Headlight 60/55W, brake/tail 21/5W, turn signals 21W
Starter: Brush inspection, commutator service, clutch engagement

Transmission

5-speed transmission service, shift mechanism, and clutch operation.

Transmission disassembly and gear inspection
Shift fork measurement and replacement criteria
Shift drum service and detent mechanism
Clutch cable adjustment: 10-20mm freeplay at lever
Oil capacity: 2.0 liters (2.1 US qt)
Recommended oil: SAE 10W-40 motorcycle oil

Suspension & Steering

Front fork service, rear shock maintenance, and steering head procedures.

Component	Service Procedure
Front Forks	Oil change (486cc per leg), seal replacement, spring inspection
Rear Shock	Nitrogen charge check, seal service, spring preload adjustment
Steering Head	Bearing adjustment, race inspection, torque specification
Wheels	Bearing replacement, rim runout check, spoke tensioning

Brakes

Front and rear disc brake service, pad replacement, and hydraulic system maintenance.

Front brake pad thickness: Replace if less than 1.0mm
Rear brake pad thickness: Replace if less than 1.0mm
Brake fluid: DOT 4, replace every 2 years
Rotor thickness: Front min 4.0mm, Rear min 4.5mm
Caliper service: Piston seal replacement, slide pin lubrication
Master cylinder: Cup replacement, bore inspection

WARNING! Always bleed brakes after service. Test brakes at low speed first.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Weak battery, dirty carbs, valve adjustment	Check battery voltage, clean carburetors, adjust valves
Poor idle	Clogged pilot jets, vacuum leaks	Clean pilot circuits, check intake boots
Transmission jumps out of gear	Worn dogs, bent shift fork	Inspect transmission gears, replace worn components
Oil consumption	Worn rings, valve seals	Perform compression test, inspect valve guides
Electrical failure	Bad regulator, stator failure	Test charging system components, replace as needed

Wiring Diagrams

Complete electrical schematics for the 1986 XL600R including color codes and connector locations.

Main harness routing and connection points
CDI ignition system schematic
Lighting circuit diagrams
Charging system wiring
Starter circuit and safety interlock

Service Support: For technical assistance contact Honda Customer Service or authorized dealers.