Honda XR650R Repair Manual 2000-2007

This Clymer do-it-yourself repair and service manual, covers 2000-2007 Honda XR650R off-road motorcycles. Note: the XR600R 1991-2000 and XR650L 1993-2007 models are covered in the Clymer M221 manual.
Book Excerpt: 2000-2007 Honda XR650R Repair Manual TRANSMISSION INSPECTION Refer to Table 2 or Table 3 when measuring transmission components. Replace parts that are out of specification or show damage as described in this section.

CAUTION: Maintain the alignment of the transmission components when cleaning and inspecting the parts in this section.

1. Inspect the mainshaft, (Figure 30) and countershaft, (Figure 31) for:
1. Worn or damaged splines.
2. Missing, broken or chipped first gear teeth (mainshaft).
3. Worn or damaged bearing surfaces.
4. Cracked or rounded snap ring grooves.


2. Measure the mainshaft outside diameter at its clutch operating guide (A, Figure 30) and fourth gear (B) operating positions.
3. Measure the countershaft outside diameter at the following operating positions:
1. First gear (A, Figure 29).
2. Second gear (B, Figure 29).
3. Third gear (C, Figure 29).
4. Idle gear (D, Figure 29).


4. Check each gear for excessive wear, burrs, pitting, or chipped or missing teeth. Check the splines on sliding gears and the bore on stationary gears for excessive wear or damage.

BRAKES Refer to Table 1 for service intervals. Refer to Chapter 14 for brake service. BRAKE PAD WEAR

Inspect the brake pads for wear, scoring, grease or oil contamination or other damage. Refer to Figure 46 for the front pads and Figure 47 for the rear pads. Inspect the thickness of the friction material on each pad. If any one pad on the front or rear is worn to its wear limit grooves, or measure 1 mm (0.04 in.) or less, replace both pads. NOTE: Refer to Chapter Fourteen for brake pad service.

Subject: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Honda XR650R service, maintenance, repair. ISBN-10: 1599692031 | ISBN-13: 9781599692036 | Clymer M225