The 1987 Honda XL600R is a dual-sport motorcycle featuring a 591cc four-stroke single-cylinder engine, dual carburetors, 5-speed transmission, electric and kick start, dual-sport tires, front and rear disc brakes, and dual-purpose suspension. This manual covers safety precautions, specifications, maintenance procedures, troubleshooting, and operational guidelines for proper ownership and maintenance.
Key components: 591cc RFVC engine, dual carburetors, 5-speed transmission, dual-sport capability, electric and kick start.
| Feature | Description |
|---|---|
| Engine Type | 591cc air-cooled four-stroke single-cylinder |
| Carburetion | Dual Keihin CV carburetors |
| Starting System | Electric and kick start |
| Transmission | 5-speed constant mesh |
| Front Suspension | Air-adjustable telescopic fork |
| Rear Suspension | Pro-Link single shock |
| Front Brake | Single disc |
| Rear Brake | Single disc |
| Fuel Capacity | 2.8 gallons (10.6 liters) |
| Seat Height | 34.6 inches (880mm) |
Handlebar controls: throttle, clutch lever, front brake lever, engine stop switch, starter button, horn, turn signals, headlight dimmer.
Instrument Cluster: Speedometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators.
Key Positions: OFF, ON, PARK (tail light only), LOCK (steering lock).
WARNING! Always check controls for proper operation before riding.
Regular maintenance intervals for optimal performance and safety.
| Service Item | Every 600 mi | Every 3,000 mi | Every 6,000 mi |
|---|---|---|---|
| Engine Oil | Replace | Replace | Replace |
| Oil Filter | - | Replace | Replace |
| Air Filter | Clean/Inspect | Clean/Replace | Replace |
| Spark Plug | Inspect | Replace | Replace |
| Valve Clearance | - | Check/Adjust | Check/Adjust |
| Brake Fluid | Inspect | Replace | Replace |
| Chain Adjustment | Check/Adjust | Check/Adjust | Check/Adjust |
Engine oil capacity: 2.2 quarts (2.1L) with filter change. Use SAE 10W-40 motorcycle oil.
Valve Clearance: Intake 0.002 in (0.05mm), Exhaust 0.003 in (0.08mm). Adjust when engine is cold.
Dual carburetor system requires synchronization for optimal performance.
CAUTION! Work in well-ventilated area; no smoking near fuel.
12-volt DC system with battery maintenance requirements.
Battery Maintenance: Check electrolyte level monthly; keep terminals clean and tight.
Hydraulic disc brakes front and rear require periodic fluid changes.
WARNING! Never reuse brake fluid; always use fresh fluid from sealed container.
Dual-sport suspension setup for on-road and light off-road use.
Tire Pressure: Front 22 psi, Rear 28 psi (check when cold).
| Symptom | Possible Cause | Corrective Action |
|---|---|---|
| Hard starting | Fuel, spark, compression | Check fuel flow, spark plug, valve clearance |
| Poor idle | Carb synchronization | Synchronize carburetors; clean pilot circuits |
| Electrical failure | Battery, connections | Check battery voltage; clean terminals; test stator |
| Oil consumption | Worn rings/valve guides | Compression test; inspect valve seals |
| Brake drag | Stuck calipers | Clean and lubricate caliper pins; replace fluid |
Emergency: Always carry basic tools and tire repair kit.
Proper storage procedures to prevent damage during extended non-use.
CAUTION! Store in cool, dry place away from direct sunlight.