1988 XR600 Manual

The 1988 Honda XR600 is a dual-sport motorcycle featuring a 591cc air-cooled four-stroke single-cylinder engine, 5-speed transmission, front and rear disc brakes, and dual-purpose tires. Below are key sections for safety, features, maintenance, operation, and troubleshooting.

Features at a Glance

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

Feature	Description
Engine	591cc air-cooled four-stroke single-cylinder
Transmission	5-speed constant mesh
Front Brake	Single disc with dual-piston caliper
Rear Brake	Single disc with single-piston caliper
Tires	Dual-purpose front and rear
Starting System	Electric start with kick start backup
Fuel Capacity	2.8 gallons
Suspension Front	Air-adjustable fork
Suspension Rear	Pro-Link single shock
Weight	295 lbs (dry)

Installation & Assembly

Unpack and inspect contents. Assemble on level surface.

1. Install handlebars: Align with top clamp, tighten bolts to specification.
2. Mount front wheel: Insert axle, align brake disc, tighten axle nut.
3. Install battery: Connect positive then negative terminals.
4. Add fluids: Engine oil and coolant as specified.

WARNING! Motorcycle is heavy; use proper lifting techniques. Ensure all fasteners are torqued to specification.

First-Time Setup

Complete pre-ride inspection before operation.

1. Check tire pressure: Front 21 psi, Rear 25 psi.
2. Verify fluid levels: Engine oil and coolant.
3. Adjust suspension: Set sag and damping to rider weight.
4. Test controls: Throttle, brakes, clutch operation.

CAUTION! Always wear proper protective gear when operating motorcycle.

Specifications

• Engine Type: 591cc air-cooled four-stroke single-cylinder
• Bore x Stroke: 97.0mm x 80.0mm
• Compression Ratio: 9.0:1
• Fuel System: Single 38mm constant velocity carburetor
• Ignition: CDI electronic ignition
• 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
• Wheelbase: 58.3 inches
• Seat Height: 37.2 inches
• Fuel Capacity: 2.8 gallons

Controls and Settings

Main controls: Handlebar switches, foot controls, instrument cluster.

Handlebar Right: Throttle, front brake lever, engine stop switch, start button. Handlebar Left: Clutch lever, light switch, turn signals, horn. Foot Controls: Gear shift lever (left), rear brake pedal (right).

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

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

1. Engine oil change: Every 600 miles or 6 months
2. Oil filter replacement: Every other oil change
3. Air filter cleaning: Every 300 miles in dusty conditions
4. Chain adjustment: Every 200 miles
5. Valve clearance check: Every 1500 miles
6. Brake fluid change: Every 2 years
7. Spark plug replacement: Every 3000 miles

Tip: Always use genuine Honda parts for replacement.

Operating Instructions

Proper operation techniques for various conditions.

1. Starting procedure: Turn fuel on, choke for cold starts, press start button.
2. Shifting: Use clutch smoothly, shift at recommended RPM ranges.
3. Braking: Use both brakes together, front brake provides 70% stopping power.
4. Off-road operation: Stand on pegs, weight back for climbs, forward for descents.
5. Highway operation: Maintain safe following distance, use turn signals.

WARNING! Always operate within your skill level and road conditions.

Safety Features

Key safety systems: Brakes, lighting, controls. Always inspect before riding.

Care & Cleaning

Clean after riding in wet or muddy conditions. Use mild soap and water.

CAUTION! Avoid high-pressure spray on bearings and electrical components. Dry thoroughly after washing.

Regulatory Information

Meets DOT and EPA standards for street use. Copyright © 1988 American Honda Motor Co., Inc. For support, contact authorized Honda dealership or Honda Customer Service.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel valve, spark plug, compression; use choke for cold starts.
Poor performance	Air filter, carburetor	Clean air filter; check carburetor jets and settings.
Hard shifting	Clutch adjustment, oil	Adjust clutch cable; check oil level and condition.
Brakes weak	Pads, fluid, air in lines	Inspect pads; bleed brakes if spongy.
Electrical issues	Battery, connections	Check battery voltage; clean and tighten connections.

Reset: Disconnect battery for 30 seconds to reset electrical system.

Service: Contact authorized Honda dealership for major repairs.