1987 Honda XL600R Service Manual

The 1987 Honda XL600R is a dual-sport motorcycle featuring a 591cc air-cooled four-stroke RFVC engine, dual carburetors, 5-speed transmission, dual-sport capabilities with both on-road and off-road performance, electric start with kickstart backup, front disc brake, rear drum brake, and dual-purpose tires. Below are key sections for maintenance procedures, specifications, troubleshooting, and repair instructions.

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

General Information

Key components: 591cc RFVC engine, dual carburetors, 5-speed transmission, electric start system, front disc brake, rear drum brake, dual-purpose tires.

ComponentDescription
Engine TypeAir-cooled 4-stroke RFVC single cylinder
Displacement591cc
Bore x Stroke97.0 x 80.0 mm
Compression Ratio9.0:1
CarburetionDual Keihin CV32
Ignition SystemCDI electronic
Starting SystemElectric & kickstart
Transmission5-speed constant mesh
Final Drive#520 chain
Fuel Capacity2.8 gallons (10.6 liters)

Specifications

Periodic Maintenance

Regular maintenance schedule for optimal performance and longevity.

  1. Oil Change: Every 600 miles or 6 months - Use 10W-40 motorcycle oil
  2. Oil Filter: Replace every other oil change
  3. Air Filter: Clean every 300 miles, replace every 6000 miles
  4. Spark Plug: Check every 1500 miles, replace every 6000 miles - NGK DR8ES-L
  5. Valve Clearance: Check every 1500 miles - IN: 0.002 in, EX: 0.003 in
  6. Chain Adjustment: Every 300 miles - 1.0-1.4 inches free play
  7. Brake Fluid: Replace every 2 years - DOT 4

WARNING! Always use motorcycle-specific oil; automotive oil can damage clutch.

Engine Service

Engine disassembly, inspection, and reassembly procedures.

  1. Cylinder Head Removal: Remove tank, carbs, exhaust before head bolts
  2. Valve Adjustment: Set piston at TDC compression stroke
  3. Piston Removal: Remove cylinder after head removal
  4. Clutch Service: Drain oil, remove right cover, replace plates
  5. Transmission: Split cases for gear inspection
  6. Carb Synchronization: Use vacuum gauges for dual carb balance

CAUTION! Use proper torque sequence for head bolts to prevent warping.

Fuel System

Dual carburetor service and fuel system maintenance.

  1. Carb Removal: Drain fuel, disconnect cables and hoses
  2. Carb Cleaning: Disassemble, clean jets with compressed air
  3. Float Level: Set to 12.5mm from carb body
  4. Pilot Screw: Factory setting: 2-1/8 turns out
  5. Fuel Filter: Replace annually or when clogged
  6. Fuel Tank: Clean and inspect for rust annually

Tip: Always use fresh fuel and stabilizer for storage.

Electrical System

Battery, charging system, ignition, and lighting maintenance.

ComponentSpecification
Battery12V 10Ah
Charging Output14V 20A at 5000 RPM
Spark Plug Gap0.028-0.031 in (0.7-0.8 mm)
Headlight12V 60/55W
Tail Light12V 21/5W
FuseMain 20A, Headlight 10A

WARNING! Disconnect battery before electrical work to prevent shorts.

Chassis & Suspension

Frame, swingarm, forks, and shock service procedures.

  1. Fork Oil Change: Use 10W fork oil, 486ml per leg
  2. Steering Head Bearings: Check for play, adjust as needed
  3. Wheel Bearings: Inspect for smooth rotation, replace if rough
  4. Chain & Sprockets: Replace as set when worn
  5. Tire Pressure: Front 22 psi, Rear 28 psi (street use)

Brake System

Front disc and rear drum brake maintenance.

  1. Front Brake Pads: Replace when worn to 1mm thickness
  2. Brake Fluid Flush: Every 2 years with DOT 4 fluid
  3. Rear Brake Shoes: Replace when worn to wear indicator
  4. Brake Adjustment: Adjust rear brake cable for proper free play
  5. Rotor Inspection: Check for warping and minimum thickness

CAUTION! Never reuse brake fluid; always use fresh fluid.

Troubleshooting

SymptomPossible CauseCorrective Action
Hard startingFuel delivery, spark, compressionCheck fuel flow, spark plug, compression test
Poor idleCarb sync, vacuum leaksSynchronize carbs, check intake boots
OverheatingLean mixture, low oilCheck carb jets, oil level and quality
Electrical failureBattery, stator, regulatorTest charging system components
Oil consumptionWorn rings, valve sealsCompression test, inspect valve seals
Transmission issuesWorn gears, shift mechanismInspect shift forks and gear dogs

Wiring Diagrams

Complete electrical schematics for troubleshooting and repair.

Note: Refer to color codes for proper wire identification.

Torque Specifications

ComponentTorque Value
Cylinder Head Bolts20 ft-lb (27 Nm)
Spark Plug13 ft-lb (18 Nm)
Oil Drain Plug22 ft-lb (30 Nm)
Axle Nuts65 ft-lb (88 Nm)
Sprocket Bolts22 ft-lb (30 Nm)
Wheel Spokes3.6 ft-lb (4.9 Nm)
Engine Mount Bolts29 ft-lb (39 Nm)

WARNING! Always use calibrated torque wrench for critical fasteners.

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