1987 Honda XL600R Service Manual PDF

The 1987 Honda XL600R is a dual-sport motorcycle featuring a 591cc air-cooled four-stroke RFVC engine, dual carburetors, 5-speed transmission, 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. Below are key sections for technical data, 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 & Clutch 8. Brake System 9. Troubleshooting 10. Specifications 11. Wiring Diagrams

General Information

Introduction to the 1987 Honda XL600R motorcycle, including model identification, safety precautions, and general service information.

Component	Description
Model Code	XL600R
Engine Type	RFVC 4-stroke single cylinder
Displacement	591cc
Bore x Stroke	100.0 x 75.5mm
Compression Ratio	9.0:1
Carburetion	Dual Keihin PD61A
Ignition	CDI electronic
Starter	Primary kick
Transmission	5-speed constant mesh
Final Drive	#520 chain

Maintenance Schedule

Recommended service intervals and procedures for optimal performance and longevity.

Pre-ride inspection: Check tires, controls, lights, oil level.
Every 600 miles: Change engine oil, check chain adjustment.
Every 2,400 miles: Clean air filter, check valve clearance.
Every 4,800 miles: Replace spark plug, check brake pads.
Every 7,200 miles: Change fork oil, check wheel bearings.

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

Engine Service

Complete engine disassembly, inspection, and reassembly procedures.

Cylinder head removal: Remove camshaft, check valve clearance.
Cylinder and piston: Measure cylinder wear, piston clearance.
Crankshaft and connecting rod: Check big end play, rod alignment.
Camshaft and timing: Set cam chain tension, check timing marks.
RFVC system: Service radial four-valve combustion chamber.

CAUTION! Engine components are precision machined; handle with care to avoid damage.

Chassis & Suspension

Frame: Steel semi-double cradle design.
Front Suspension: 41mm air-adjustable forks, 10.2 inches travel.
Rear Suspension: Pro-Link single shock, 9.8 inches travel.
Front Tire: 3.00-21 4PR
Rear Tire: 5.10-17 6PR
Wheelbase: 58.3 inches
Ground Clearance: 11.8 inches
Seat Height: 35.2 inches
Fuel Capacity: 2.8 gallons

Electrical System

Complete electrical system diagnosis and repair procedures.

Battery: 12V 10Ah, charging system output: 0.2kW at 5,000 rpm.

Ignition: CDI system testing, pulse generator inspection, ignition coil resistance checks. Lighting: Headlight (60/55W), brake/tail light (21/5W), turn signals (21W). Starting: Primary kickstarter mechanism, neutral safety switch. Charging: Three-phase AC generator, rectifier/regulator testing.

Fuel System

Dual carburetor service and fuel delivery system.

Carburetor removal: Disconnect fuel lines, throttle cables.
Carburetor disassembly: Clean jets, check float level.
Synchronization: Balance dual carburetors using vacuum gauges.
Fuel tank: Remove and clean, check petcock operation.
Air filter: Clean foam element, re-oil properly.

Tip: Always use fresh fuel and stabilize if storing motorcycle.

Transmission & Clutch

5-speed transmission service and clutch system maintenance.

Clutch inspection: Check plate thickness, spring free length.
Transmission disassembly: Remove shift drum, forks, gears.
Gear inspection: Check for wear, pitting, proper engagement.
Shift mechanism: Inspect shift drum stopper, return spring.
Chain drive: Adjust #520 chain to 1.2-1.6 inches play.
Sprockets: Check for hooking, replace as set with chain.

WARNING! Transmission components must be properly aligned during reassembly.

Brake System

Front and rear disc brake service and maintenance.

Front brake: Single piston caliper, 256mm disc. Rear brake: Single piston caliper, 220mm disc. Brake fluid: DOT 4, change every 2 years. Pad replacement: Minimum thickness 1.5mm. Brake line inspection: Check for cracks, leaks, deterioration.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Valve clearance, carburetion	Adjust valves to 0.005in (IN), 0.006in (EX); clean carburetors.
Poor performance	Clogged jets, ignition timing	Clean carburetor jets; check CDI timing advance.
Transmission jumping out of gear	Worn dogs, shift fork	Inspect gear engagement dogs; replace worn components.
Excessive oil consumption	Worn rings, valve guides	Measure cylinder; replace rings; check valve stem seals.
Electrical failure	Stator, regulator	Test stator output (0.2kW); check regulator rectification.

Reset: Clear trouble codes by disconnecting battery if applicable.

Specifications

Dry Weight: 319 lbs
Oil Capacity: 2.5 quarts (with filter change)
Fork Oil: 10W, 17.7 oz per leg
Valve Clearance: IN 0.005in, EX 0.006in (cold)
Spark Plug: NGK DR8ES-L
Battery: 12V 10Ah
Headlight: 60/55W halogen
Max Power: 43 hp @ 6,000 rpm
Max Torque: 37 lb-ft @ 5,000 rpm

Wiring Diagrams

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

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