1987 Honda XR600 Manual

The 1987 Honda XR600 is a dual-sport motorcycle featuring a 591cc air-cooled four-stroke single-cylinder engine, 5-speed transmission, front disc brake, rear drum brake, dual-purpose tires, and electric start. This manual covers safety precautions, maintenance procedures, specifications, troubleshooting, and repair instructions for proper operation and longevity of your motorcycle.

Features at a Glance

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

Feature	Description
Engine Type	591cc air-cooled four-stroke single-cylinder
Transmission	5-speed constant mesh
Starting System	Electric start with kick starter backup
Front Brake	Hydraulic disc brake
Rear Brake	Mechanical drum brake
Fuel Capacity	2.8 gallons (10.6 liters)
Seat Height	36.6 inches (930mm)
Dry Weight	295 lbs (134 kg)
Suspension Front	Air-adjustable fork
Suspension Rear	Pro-Link single shock

Safety Precautions

Always wear proper protective gear and inspect motorcycle before riding.

1. Wear helmet, eye protection, gloves, and protective clothing.
2. Check tire pressure and condition before each ride.
3. Verify brake operation and fluid levels.
4. Ensure all lights and signals are functioning properly.
5. Check chain tension and lubrication.

WARNING! Never operate motorcycle under influence of alcohol or drugs. Always follow traffic laws and ride defensively.

Maintenance Schedule

Regular maintenance ensures optimal performance and safety.

1. Daily: Check tire pressure, brakes, lights, fuel level.
2. Every 600 miles: Change engine oil and filter.
3. Every 1200 miles: Adjust chain, check valve clearance.
4. Every 2400 miles: Replace air filter, spark plug.
5. Every year: Replace brake fluid, check wheel bearings.

CAUTION! Use only Honda Genuine parts or equivalents. Improper maintenance may void warranty.

Specifications

• Engine: 591cc air-cooled four-stroke single-cylinder
• Bore x Stroke: 97.0 x 80.0 mm
• Compression Ratio: 9.0:1
• Carburetor: 38mm constant velocity
• Ignition: CDI electronic ignition
• Transmission: 5-speed constant mesh
• Final Drive: #520 chain
• Front Tire: 3.00-21
• Rear Tire: 5.10-18
• Fuel Type: Regular unleaded (87 octane)

Controls and Instruments

Familiarize yourself with all controls before riding.

Right Handlebar: Throttle control, front brake lever, engine stop switch, start button.

Left Handlebar: Clutch lever, light switch, turn signal switch, horn button.

Instrument Panel: Speedometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators.

Foot Controls: Gear shift lever (left), rear brake pedal (right), kick starter.

Engine Maintenance

Proper engine care ensures longevity and performance.

1. Oil Change: Drain when warm, replace with 10W-40 motorcycle oil.
2. Air Filter: Clean with solvent, re-oil with filter oil.
3. Spark Plug: Replace with NGK DR8ES-L, gap 0.028-0.031 inch.
4. Valve Clearance: Intake 0.002 inch, exhaust 0.003 inch.
5. Carburetor: Adjust idle speed to 1400 ± 100 rpm.

Tip: Always warm up engine before riding for optimal performance.

Electrical System

12-volt DC system with battery and charging system.

1. Battery: 12V 8Ah, maintain proper fluid level.
2. Charging System: AC generator with rectifier/regulator.
3. Fuses: Main fuse 20A, spare fuse included.
4. Bulbs: Headlight 60/55W, brake/tail 21/5W, turn signal 21W.

WARNING! Disconnect battery before electrical work to prevent shorts.

Brake System

Front disc and rear drum brake maintenance.

1. Front Brake: Check pad wear, replace if less than 1mm.
2. Brake Fluid: Use DOT 4, change annually.
3. Rear Brake: Adjust free play at pedal, check shoe wear.
4. Brake Lines: Inspect for cracks or leaks.

CAUTION! Test brakes at low speed after maintenance before normal riding.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel valve, spark plug, air filter
Poor performance	Dirty air filter, clogged jet	Clean air filter, inspect carburetor
Hard shifting	Low oil, clutch adjustment	Check oil level, adjust clutch cable
Brakes weak	Worn pads, air in lines	Replace pads, bleed brake system
Battery dead	Charging system, connections	Test charging system, clean terminals

Emergency: Carry basic tools and spare fuse for roadside repairs.

Storage Guidelines

Proper storage prevents damage during extended non-use.

1. Fill fuel tank and add fuel stabilizer.
2. Change oil and filter.
3. Remove battery and store on charger.
4. Clean and lubricate chain.
5. Store in dry, covered location.

CAUTION! Do not store with fuel in carburetor to prevent gum formation.

Warranty Information

Limited warranty coverage for 12 months from purchase date. Covers defects in materials and workmanship. Does not cover normal wear, improper maintenance, or accident damage. Keep purchase receipt for warranty claims. Contact authorized Honda dealer for service.