Honda XR600R 1991-2000, XR650L 1993-2019 Repair Manual

This Clymer M221 repair and service manual covers Honda XR600R 1991-2000 and XR650L 1993-2019 dirt bikes equipped with Radial Four Valve Combustion (RFVC), air-cooled, four-stroke, single-cylinder engines.

Note: the Honda XR650R 2000-2007 is covered in the Clymer #M225 manual.

Book Excerpt: Honda XR600R 1991-2000, XR650L 1993-2019 Repair Manual IGNITION SYSTEM

TROUBLESHOOTING NOTE: If the problem is intermittent, perform the tests with the engine cold, then hot. Then compare the results.

1. Perform the Spark Test described in this chapter.
2. Test the ignition coil as described in Chapter Ten or Chapter Eleven. Note the following:
1. If the ignition coil is good , perform step 4.
2. If the ignition coil fails to pass the test described in Chapter Ten or Chapter Eleven, the ignition coil is probably faulty. However, before replacing the ignition coil, take it to dealership and have them test the spark with an ignition coil tester. replace the ignition coil if faulty and retest the ignition system.
3. (A) On XR600R model, test the engine stop switch as described in Switches in Chapter Ten. Note the following:
1. If the switch is good perform step 6.
2. If the switch fails the test, then the switch is faulty and must be replaced. Replace the switch and retest the ignition system.
4. (B) On XR650L models,test the engine stop switch as described in Switches in Chapter Eleven. Note the following:
1. If the switch is good perform step 5.
2. If If the switch fails the test, then the switch is faulty and must be replaced. Replace the switch and retest the ignition system.

OIL PUMP

The oil pump is located on the right side of the engine next to the clutch. The oil pump can be removed with the engine in the frame. REMOVAL/INSTALLATION

1. Remove the clutch as described in Chapter 6.
2. Remove oil pump driven gear (Figure 64).
3. Remove the nut (A, Figure 65) and bolt (B ) securing the oil tube, and remove the oil tube.
4. Remove the bolts (Figure 66) securing the oil pump to the crank case, and remove the oil pump assembly.
5. Before installing the oil pump, make sure the oil control orifice and O-ring (Figure 67) are installed in the inlet on the crankcase.
6. Install the locating dowels in either the oil pump (A, Figure 68) or in the crankcase.
7. Pour engine oil into the pump inlet hole (B, Figure 68). At the same time rotate the pump shaft counterclockwise until oil flows out the pump outlet hole.
8. Install the oil pump and tighten the screws securely.
9. Make sure the O-ring seals are in place on each end of the oil tube.
10. Install the oil tube. Tighten the retaining nut and bolt securely.
11. After reassembling the engine, start the engine and let idle for about one minute. Loosen the oil return tube fitting (FIgure69) and make sure oil flows from the connection. Retighten the oil tube fitting.

The Honda XR600R-XR650L Repair Manual (1991-2019) by Clymer provides color wiring diagrams, step-by-step DIY repair procedures, and expert photos / exploded views to help the home mechanic tackle any maintenance, repair or service procedure. You will enjoy the satisfaction gained by working on your Honda dirt bike yourself. You will also save money in the process.

Pick up your Clymer M221 manual today so you can get to know the internals of your Honda XR 600R / 650L motorcycle as soon as possible. You will be happy you did.

Subject: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019 Honda XR600R, XR650L service, maintenance, repair. ISBN-10: 1620923645 | ISBN-13: 9781620923641 | UPC: 024185915744 | Clymer M221