Spark Plugs (all models)

XL600R, XR600R and XR650L
Type
Standard NGK DPR8EA-9 or NO X24EPR-U9
Extended high speed riding NGK DPR9EA-9 or NO X27EPR-U9
Cold climates (below 5C/41F) NGK DPR7EA-9 or NO X22EPR-U9
Gap 0.8 to 0.9 mm (0.031 to 0.035 inch)
XR650R
Type
Standard NGK BKR7E-11 or NO K22PR-U11
Extended high speed riding NGK BKR8E-11 or NO K24PR-U11
Gap 1.0 to 1.1 mm (0.039 to 0.043 inch)
Ignition timing full advance
XL600R 31-degrees BTDC @ 4000 rpm
XR600R 31-degrees BTDC@ 3500 rpm
XR650L 28-degrees BTDC @ 4000 rpm
XR650R 31-degrees BTDC @ 3500 rpm

 

Valve Clearance (all models)

Check with engine COLD (best to leave overnight)

XL600R
Intake 0.05 mm (0.002 inch)
Exhaust 0.10 mm (0.004 inch)
XR600R
Intake 0.10 mm (0.004 inch)
Exhaust 0.12 mm (0.005 inch)
XR650L
Intake 0.10 +1- 0.02 mm (0.004 +1- 0.001 inch)
Exhaust 0.12 +1- 0.02 mm (0.005 +1- 0.001 inch)
XR650R
Intake 0.15 +1- 0.02 mm (0.006 +1- 0.001 Inch)
Exhaust 0.20 +1- 0.02 mm (0.008 +1- 0.001 inch)

 

Brake Lever, Brake Pedal, Clutch Lever, Brake Switch, Freeplay, Choke Stroke (all models)

Rear brake shoe lining thickness limit 2 mm (0.08 inch)
Front brake lever freeplay
XL600R, 1985 XR600R See text (Section 4)
1986 and 1987 XR600R 1 to 8 mm (1/8 to 5/16 inch)
1988 and later XR600R 0.6 to 8.0 mm (1/32 to 5/161nch)
XR650L Not specified
XR650R 10 to 20 mm (3/8 to 3/4 inch)
Rear brake pedal freeplay (drum brake models) 20 to 30 mm (3/4 to 1-1/4 inch)
Rear master cylinder pushrod length (disc brake models)
XR600R, XR650L 71 mm (2.8 inch)
XR650R 68 mm (2.68 inch)
Rear brake light switch adjustment
XL600R 10 mm (3/8 inch)
XR650L Not available
Clutch lever freeplay 10 to 20 mm (3/8 to 3/4 1nch)
Throttle grip free play 2 to 6 mm (3/32 to 1/4 inch)
Choke valve stroke (XL600R) 5 to 7 mm (3/16 to 9/32 inch)
Decompressor freeplay
XL600R
1983 through 1987
Kickstarter decompressor 1 to 3 mm (1/32 to 1/8 inch)
Manual decompressor 1 to 2 mm (1/32 to 3/32 inch)
XR600R
1985 through 1987
Kickstarter decompressor 1 to 2 mm (1/32 to 3/32 inch)
Manual decompressor 5 to 8 mm (3/16 to 5/16 inch)
1988 on (manual) 5 to 8 mm (3/16 to 5/16 inch)
XR650L Not adjustable
XR650R 5 to 8 mm (3/16 to 5/16 inch)
Minimum tire tread depth
Dual-sport models (XL600R, XR650L) 3 mm (1/8 inch)
Off-road models (XR600R, XR650R) Not specified

Lubricants and Fluids (all models)

Engine/transmission oil
Type Pro Honda GN4, HP4 (without moly additives) four-stroke motor oil, or equivalent
Viscosity 10W-40
Standard
Optional
10 to 90-degrees F 20W-40 or 20W-50
0 to 80-degrees F 10W-30
Capacity (approximate – add as necessary to bring to appropriate level)
Oil change
XL600R 2.0 liters (2.1 US qts)
XR600R, XR650l 1.9 liters (2.0 US qts)
XR650R 1.5 liters (1.6 US qts)
After engine overhaul
XL600R 2.5 liters (2.6 US qts)
XR600R, XR650L 2.3 liters (2.4 US qts)
XR650R 2.0 liters (2.1 US qts)
Coolant (XR650R)
Type Pro Honda HP coolant or 50/50 mixture of equivalent ethylene glycolbased, silicate-free antifreeze and distilled water*
Capacity
Engine/radiator 1.5 liters (1.6 US qts)
Reserve tank 0.2 liters (0.21 US qts)
Air filter oil (for foam filters) Honda Foam Filter Oil or SAE 80 or 90 gear oil
Brake fluid DOT4
Drive chain lubricant Chain lube formulated for 0-ring chains, or SAE 80 to 90 gear oil
Miscellaneous
Wheel bearings Medium weight, lithium-based multi-purpose grease (NLGI no. 3)
Swingarm pivot bushings Molybdenum disulfide paste grease or more molybdenum disulfide containing 40 percent
Cables and lever pivots Medium weight, lithium-based multi-purpose grease (NLGI no. 3)
Brake pedal/shift lever/throttle lever pivots Medium weight, lithium-based multi-purpose grease (NLGI no. 3)

XR600R and XL600R Routine Maintenance Schedule

Every 300 miles
Lubricate and inspect the drive chain and sliders*

Every 4,000 miles on XR600L or every 30 operating days (approximately 1,000 miles) on XR600R through 1997
Perform all of the daily checks plus:
Inspect the brakes
Check the brake pads and shoes for
Check the brake fluid level
Check and adjust the valve clearances
Check the decompressor system
Clean the air filter element*
Clean the air cleaner housing drain tube
Check the crankcase breather (XL600R)
Check the evaporative emission control system (XL600R California models)
Inspect the battery (XL600R)
Check/adjust the throttle lever freeplay
Check choke operation
Check/adjust the idle speed
Change the engine oil and filter and clean the strainer screen (in the frame downtube)
Check the tightness of all fasteners
Inspect the suspension
Clean and gap the spark plug
Check/adjust the clutch
Check the exhaust system for leaks and check fastener tightness; clean the spark arrester
Inspect the wheels and tires
Check the cleanliness of the fuel system and the condition of the fuel line
Clean the fuel tap strainer screen
Inspect the steering system and steering head bearings
Check the sidestand operation

Every 600 miles or 6 months on 1998 and later models
Perform all of the daily checks plus:
Inspect the brakes
Check the brakes pads and shoes for wear
Check the brake fluid level
Clean the air filter element*
Clean and gap the spark plug
Check the decompressor system
Check and adjust the valve clearance
Check engine idle speed
Change the engine oil and filter
Check/adjust the clutch
Inspect the wheels and tires

Every 1 ,200 miles or 12 months on 1998 and later models
Perform all of the daily and 600-mile checks plus:
Check the cleanliness of the fuel system
Clean the fuel tap strainer screen
Check/adjust the throttle lever freeplay
Check choke operation
Clean the engine oil strainer screen (in the frame down-tube)
Check the tightness of all fasteners
Inspect the steering system and steering head bearings
Inspect the suspension
Inspect the sidestand
Check headlight aim

Every two years or 2,400 miles
Replace the brake fluid
Replace the fork oil**

* More often in dusty, sandy or wet conditions.
** Honda doesn’t give a service interval for this
operation, but changing the fork oil on a regular
basis will ensure conitinued good handling of
the bike and reduce wear to the internal fork
components.