1987 Honda XR600R Manual

The 1987 Honda XR600R is a legendary dual-sport motorcycle featuring a 591cc air-cooled four-stroke single-cylinder engine, 5-speed transmission, dual carburetors, front and rear disc brakes, and rugged off-road capabilities. This manual covers safety precautions, specifications, maintenance procedures, troubleshooting, and operational guidelines for proper ownership and maintenance of this iconic motorcycle.

1. Features at a Glance 2. Safety Precautions 3. Specifications 4. Maintenance Schedule 5. Controls and Instruments 6. Engine Maintenance 7. Transmission & Drive System 8. Brake System 9. Electrical System 10. Troubleshooting

Features at a Glance

Key components: 591cc RFVC engine, dual carburetors, Pro-Link rear suspension, front and rear disc brakes, steel frame, and dual-sport capabilities.

Feature	Description
Engine	591cc air-cooled four-stroke single-cylinder RFVC
Carburetion	Dual Keihin 32mm constant-velocity carburetors
Transmission	5-speed constant mesh
Suspension Front	43mm air-adjustable fork with 11.6 inches travel
Suspension Rear	Pro-Link single shock with 11.6 inches travel
Brakes Front	Single disc 256mm
Brakes Rear	Single disc 220mm
Fuel Capacity	2.8 gallons (10.6 liters)
Dry Weight	295 lbs (134 kg)
Seat Height	37.2 inches (945 mm)

Safety Precautions

Always wear proper protective gear and follow safety procedures.

Wear helmet, eye protection, gloves, and protective clothing
Check motorcycle condition before each ride
Never operate under influence of alcohol or drugs
Follow all traffic laws and regulations
Keep hands and feet away from moving parts

WARNING! Motorcycle operation requires skill and attention. Always ride within your limits and ability.

Specifications

Engine Type: 591cc air-cooled four-stroke single-cylinder RFVC
Bore x Stroke: 97.0mm x 80.0mm
Compression Ratio: 9.0:1
Carburetion: Dual Keihin 32mm CV
Ignition: CDI electronic
Transmission: 5-speed constant mesh
Final Drive: #520 chain
Front Suspension: 43mm air-adjustable fork
Rear Suspension: Pro-Link single shock
Brakes: Front and rear disc
Fuel Capacity: 2.8 gallons

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Service	Every 600 mi	Every 2,400 mi	Every 4,800 mi
Engine oil change	✓	✓	✓
Oil filter replacement		✓	✓
Air filter cleaning		✓	✓
Spark plug replacement			✓
Valve clearance check			✓
Chain adjustment	✓	✓	✓
Brake fluid change			✓

Controls and Instruments

Familiarize yourself with all controls before operation.

Left Handlebar: Clutch lever, horn button, turn signal switch, high/low beam switch

Right Handlebar: Front brake lever, engine stop switch, start button, throttle

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

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

Engine Maintenance

Proper engine maintenance is critical for performance and reliability.

Oil Change: Drain oil when warm, replace with 1.9 quarts of 10W-40 motorcycle oil
Oil Filter: Replace oil filter every other oil change
Air Filter: Clean with solvent and re-oil with air filter oil
Spark Plug: Replace with NGK DR8ES-L, gap 0.028-0.031 inches
Valve Clearance: Check and adjust to 0.002 inches intake, 0.003 inches exhaust
Carburetor Adjustment: Pilot screw 2 turns out, main jet #152

Transmission & Drive System

Maintain proper chain tension and lubrication.

Check chain tension: 1.2-1.6 inches free play
Lubricate chain regularly with chain lube
Check transmission oil level regularly
Inspect sprockets for wear and replace if hooked
Adjust chain alignment using swingarm marks

Tip: Always clean chain before lubrication for best results.

Brake System

Front and rear disc brakes require regular inspection and maintenance.

Check brake pad thickness: Replace if less than 0.08 inches
Inspect brake discs for scoring or warping
Check brake fluid level in reservoirs
Bleed brakes if spongy feel or air bubbles present
Use DOT 4 brake fluid only

WARNING! Never use petroleum-based fluids in brake system.

Electrical System

12-volt DC system with CDI ignition and electric start.

Battery: 12V 6Ah maintenance required

Charging System: AC generator

Headlight: 60/55W halogen

Fuses: Main fuse 20A, spare fuses in fuse box

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Fouled spark plug, stale fuel	Replace spark plug, drain old fuel
Poor idle	Clogged pilot jet, vacuum leak	Clean carburetor, check intake boots
Overheating	Low oil, lean mixture	Check oil level, adjust carburetion
Chain noise	Loose chain, worn sprockets	Adjust chain tension, replace sprockets
Brake fade	Contaminated pads, old fluid	Replace pads, bleed brake system
Electrical failure	Blown fuse, bad connection	Check fuses, clean connections

Service: Contact authorized Honda dealer for major repairs

Parts: Use genuine Honda parts for best performance and reliability