1988 97 XR600R Shop Manual

The 1988 Honda XR600R is a durable dual-sport motorcycle featuring a 644cc air-cooled four-stroke single-cylinder engine, 5-speed transmission, front and rear disc brakes, and robust suspension for off-road capability. This shop manual provides comprehensive service, maintenance, and repair procedures for mechanics and enthusiasts. Below are key sections covering specifications, maintenance schedules, engine service, chassis, electrical systems, and troubleshooting.

1. General Information 2. Maintenance Schedule 3. Engine Service 4. Chassis and Suspension 5. Electrical System 6. Fuel System 7. Troubleshooting 8. Torque Specifications 9. Wiring Diagrams

General Information

Overview of the 1988 XR600R model, including identification numbers, safety precautions, and tool requirements.

Component	Description
Model Code	XR600R
Engine Type	644cc air-cooled 4-stroke single
Frame Number Location	Steering head
Engine Number Location	Left crankcase
Recommended Tools	Standard metric wrench set, torque wrench, feeler gauges

Maintenance Schedule

Regular maintenance intervals for optimal performance and longevity.

Oil Change: Every 600 miles or 6 months.
Air Filter Cleaning: Every 300 miles in dusty conditions.
Valve Clearance Check: Every 1,200 miles.
Spark Plug Replacement: Every 3,000 miles.
Chain Adjustment: Every 500 miles.

WARNING! Always disconnect battery before servicing electrical components. Use proper safety gear.

Engine Service

Detailed procedures for engine disassembly, inspection, and reassembly.

Cylinder Head Removal: Remove cam chain tensioner, camshaft, and head bolts.
Piston and Cylinder: Inspect for wear; measure cylinder bore.
Crankshaft and Connecting Rod: Check bearing clearance and rod play.
Camshaft and Valves: Adjust valve clearance to 0.05mm intake, 0.08mm exhaust.
Clutch: Replace friction plates if worn beyond service limit.

CAUTION! Label all parts during disassembly for correct reassembly.

Chassis and Suspension

Frame: Steel cradle type; inspect for cracks or damage.
Front Suspension: Telescopic fork; oil capacity 486ml per leg.
Rear Suspension: Pro-Link system; check swingarm bearings.
Brakes: Front and rear disc; pad wear limit 1mm.
Wheels and Tires: Rim runout limit 2.0mm; tire pressure 15 psi off-road.

Electrical System

Testing and servicing the ignition, charging, and lighting systems.

Ignition System: CDI unit; spark plug gap 0.8-0.9mm. Charging System: Output 14V DC at 5000 RPM. Battery: 12V 4Ah; maintain electrolyte level.

Fuel System

Carburetor service and fuel delivery components.

Carburetor Model: Keihin PD97A.
Main Jet: #152.
Pilot Jet: #62.
Float Height: 18.5mm.
Idle Speed: 1200 RPM.

Tip: Clean fuel filter and tank periodically to prevent clogging.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Spark plug, fuel delivery	Check spark; clean carburetor; verify fuel flow.
Poor performance	Clogged air filter, ignition timing	Clean air filter; check CDI and timing.
Oil leakage	Worn gaskets, loose bolts	Replace gaskets; tighten to specified torque.
Brakes dragging	Stuck caliper, worn pads	Clean and lubricate caliper slides; replace pads.
Electrical failure	Dead battery, faulty stator	Test battery voltage; check stator output.

Reset: None required for mechanical systems.

Service: Refer to Honda dealership for genuine parts.