The 1986 Honda XR600R is a legendary dual-sport motorcycle featuring a 591cc air-cooled four-stroke single-cylinder engine, 5-speed transmission, front and rear drum brakes, and rugged off-road capabilities. This service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for the complete motorcycle system. Below are key sections for safety, technical data, maintenance schedules, engine service, chassis, and electrical systems.
Key components: 591cc RFVC engine, dual carburetors, steel frame, long-travel suspension, and dual-purpose tires.
| Component | Description |
|---|---|
| Engine Type | Air-cooled 4-stroke single cylinder RFVC |
| Displacement | 591cc |
| Bore x Stroke | 97.0mm x 80.0mm |
| Compression Ratio | 8.3:1 |
| Carburetion | Dual Keihin PD61A |
| Ignition | CDI electronic |
| Transmission | 5-speed constant mesh |
| Final Drive | #520 chain |
| Front Suspension | Air-adjustable fork |
| Rear Suspension | Pro-Link single shock |
Regular maintenance intervals for optimal performance and longevity.
WARNING! Always perform maintenance on cool engine in well-ventilated area.
Complete engine disassembly, inspection, and reassembly procedures.
CAUTION! Use proper torque values and follow assembly sequence precisely.
Dual carburetor service and fuel delivery system maintenance.
Tip: Always use fresh fuel and stabilizer for storage periods.
Frame, suspension components, and steering system service.
| Component | Service Procedure |
|---|---|
| Front Fork | Oil change (486ml per leg), seal replacement, spring inspection |
| Rear Shock | Nitrogen recharge, oil change, bushing replacement |
| Steering Head | Bearing adjustment/replacement, race inspection |
| Swingarm | Pivot bearing service, alignment check |
| Wheels | Spoke tension, rim runout, bearing replacement |
Complete electrical system diagnosis and repair.
Front and rear drum brake service and adjustment.
WARNING! Test brakes at low speed after service before normal operation.
| Symptom | Possible Cause | Corrective Action |
|---|---|---|
| Hard starting | Fuel delivery, spark, compression | Check carburetor, spark plug, valve clearance |
| Poor performance | Clogged jets, timing, air filter | Clean carburetors, check ignition timing, replace air filter |
| Oil consumption | Worn rings, valve seals | Compression test, inspect valve guides |
| Electrical failure | Battery, stator, regulator | Test charging system, check connections |
| Transmission issues | Worn gears, shift mechanism | Inspect shift forks, gear engagement |
Complete electrical schematics for the 1986 XR600R showing all circuits, connectors, and component locations.
Key Circuits: Ignition system, charging system, lighting circuits, handlebar switches, ground points.
| Component | Torque Value | Notes |
|---|---|---|
| Cylinder Head Nuts | 32 Nm (23 ft-lbs) | Cross pattern sequence |
| Spark Plug | 12 Nm (9 ft-lbs) | Do not overtighten |
| Oil Drain Plug | 30 Nm (22 ft-lbs) | Replace crush washer |
| Axle Nuts | 80 Nm (58 ft-lbs) | Front and rear |
| Sprocket Nuts | 45 Nm (33 ft-lbs) | Use thread locker |
| Engine Mount Bolts | 55 Nm (40 ft-lbs) | Check periodically |
Service Note: Always use calibrated torque wrench and proper sequence.
Technical Support: Contact Honda customer service or authorized dealer for additional assistance.