1988 XR600R Service Manual Haynes

The 1988 XR600R Service Manual Haynes provides comprehensive maintenance and repair information for the Honda XR600R motorcycle. This manual covers engine overhaul, transmission service, electrical systems, chassis maintenance, troubleshooting procedures, and routine maintenance schedules. Below are key sections for specifications, maintenance procedures, troubleshooting, and technical data.

1. General Information 2. Engine 3. Cooling System 4. Fuel System 5. Electrical System 6. Transmission 7. Chassis 8. Suspension 9. Brakes 10. Troubleshooting 11. Maintenance Schedules

General Information

Key components: 4-stroke single-cylinder engine, air cooling system, 5-speed transmission, dual-sport capabilities.

Feature	Description
Engine Type	4-stroke single-cylinder air-cooled
Displacement	600cc
Bore x Stroke	97mm x 80mm
Compression Ratio	9.0:1
Transmission	5-speed constant mesh
Final Drive	Chain
Frame Type	Semi-double cradle steel
Suspension Front	Telescopic fork
Suspension Rear	Pro-Link single shock
Brakes Front	Single disc
Brakes Rear	Single drum

Engine

Complete engine service procedures including disassembly, inspection, and reassembly.

Engine removal: Disconnect battery, drain coolant, remove exhaust and intake systems.
Cylinder head: Valve adjustment, camshaft service, head gasket replacement.
Cylinder and piston: Inspection, measurement, piston ring installation.
Crankshaft and bearings: Inspection and replacement procedures.
Engine installation: Reverse removal procedure with proper torque specifications.

WARNING! Engine components are heavy; use proper lifting equipment. Follow torque specifications precisely.

Cooling System

Air cooling system maintenance and inspection procedures.

Cooling fins: Clean regularly to maintain proper heat dissipation.
Thermal sensor: Test and replace if faulty.
Air flow: Ensure no obstructions in cooling passages.
Overheating diagnosis: Check for lean fuel mixture, timing issues.

CAUTION! Do not operate engine with blocked cooling fins. Risk of engine damage.

Fuel System

Carburetor: Keihin PD series, 38mm
Fuel Capacity: 2.8 gallons
Fuel Type: Regular unleaded gasoline
Air Filter: Foam element, requires regular cleaning
Fuel Lines: Inspect for cracks and deterioration
Float Level: Adjust to 14.5mm specification
Jet Sizes: Main jet #152, pilot jet #62
Throttle Cable: Adjust free play to 2-3mm

Electrical System

Complete electrical system diagnosis and repair procedures.

Battery: 12V 5Ah, maintain proper electrolyte levels. Ignition System: CDI ignition, spark plug NGK DR8ES-L. Charging System: AC generator output 140W at 5000 rpm. Lighting: Headlight 35/35W, brake light 21W. Wiring: Color-coded harness, inspect for damage and corrosion.

Transmission

5-speed constant mesh transmission service and adjustment.

Transmission oil: SAE 10W-40, capacity 1.7 liters.
Shift mechanism: Inspect shift forks and drum for wear.
Clutch: Adjust cable free play to 10-15mm at lever.
Gear inspection: Check for chipped teeth and excessive wear.

Tip: Change transmission oil every 1000 miles for optimal performance.

Chassis

Frame inspection and maintenance procedures.

Frame inspection: Check for cracks and damage at stress points.
Steering head bearings: Adjust and lubricate regularly.
Swingarm pivot: Check for play and lubricate bearings.
Footpegs and controls: Ensure proper operation and lubrication.
Chain adjustment: Maintain 1.5-2.0 inches of free play.

WARNING! Always support motorcycle securely when working on chassis components.

Suspension

Front and rear suspension service and adjustment.

Front forks: Oil level 135mm from top, SAE 10W fork oil.
Rear shock: Preload adjustment, nitrogen pressure check.
Wheel bearings: Inspect for smooth operation and replace if rough.
Seals: Replace leaking fork and shock seals immediately.

WARNING! Use proper tools for spring compression. Risk of serious injury.

Brakes

Front disc and rear drum brake maintenance.

Front disc: Pad wear limit 1.5mm, rotor thickness limit 3.5mm. Rear drum: Adjust cable for proper lever travel. Brake fluid: DOT 4, change every 2 years. Brake lines: Inspect for cracks and deterioration.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Spark plug, carburetor	Check spark, clean carburetor, adjust fuel mixture
Overheating	Lean mixture, timing	Check carburetor jets, verify ignition timing
Poor performance	Air filter, exhaust	Clean air filter, check for exhaust restrictions
Transmission noise	Worn gears, low oil	Inspect gears, check oil level and condition
Electrical failure	Battery, stator	Test battery voltage, check stator output

Reset: Clear trouble codes if applicable.

Service: Refer to authorized Honda service center for complex issues.