Honda XL500, XR500, XL600, XR600 Repair Manual 1979-1990

The 1979-1990 Honda XL500, XR500, XL600, XR600 DIY repair manual by Clymer, covers the following models:

• Honda XL500S, 1979-1981
• Honda XL500R, 1982
• Honda XR500, 1979-1980
• Honda XR500R, 1981-1984
• Honda XL600R, 1983-1987
• Honda XR600R, 1985-1990

Note: the 1993-2007 Honda XR600R 1991-2000 and XR650L is covered in Clymer manual #M221.

Book Excerpt: 1979-1990 Honda XL500, XR500, XL600, XR600 Repair Manual CRANKCASE DISASSEMBLY

1. Remove all exterior engine assemblies as described in this chapter and other related chapters.
1. Cylinder head cover and cylinder head
2. Cylinder and piston
3. Alternator
4. External shift mechanism
5. Oil pump
6. External portion of the kickstarter assembly
2. Remove the engine as described in this chapter.
3. Remove the ignition advance mechanism (A, Figure 120), clutch assembly (B, Figure 120) and small oil pipe (C, Figure 120). Refer to Chapter Six for clutch removal.
4. Remove the bolt (Figure 121) securing the camshaft chain tensioner and remove the tensioner assembly.
5. Remove the camshaft drive chain (A,Figure 122), the front balancer holder lockbolt (B, Figure 122) and spring (C, Figure 122).
6. Remove the bolts (Figure 123) securing the balancer chain guide and remove it.

TROUBLESHOOTING

EXCESSIVE VIBRATION Usually this is caused by loose engine mounting hardware. Otherwise, this can be difficult to find without disassembling the engine. FRONT SUSPENSION AND STEERING Poor handling may be caused by improper tire pressure, a damaged or bent frame or front steering components, a worn front fork assembly, worn wheel bearings or dragging brakes. BRAKE PROBLEMS Sticking disc brakes may be caused by a stuck piston in a caliper assembly or a warped pad shim. A sticking drum brake may be caused by worn or weak return springs, dry pivot and cam bushings or improper adjustment. Grabbing brakes may be caused by greasy linings which must be replaced. Brake grab may also be due to an out-of-round drum. Glazed linings will cause loss of stopping power.

Subject: 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990 Honda XL500, XR500, XL600, XR600 service, maintenance, repair. ISBN-10: 1599691426 - ISBN-13: 9781599691428 | Clymer M339-8