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Honda Motorcycle XR600R (1991 - 2000)

Complete coverage for your vehicle

Written from hands-on experience gained from the complete strip-down and rebuild of a Honda Motorcycle XR600R, Clymer can help you understand, care for and repair your Honda Motorcycle XR600R. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your Honda Motorcycle XR600R can help maintain its resale value, save you money, and make it safer to drive.

Printed manual

Au $79.95
Au $57.95

Free postage in Australia with orders over $59

Online manual

Au $79.95
Au $44.95
One-time purchase

The Online Manual is not a printed product, not a PDF and not a download.

Access this manual immediately on your internet browser on your mobile, desktop or tablet.

Choose the Clymer manual that is right for you with our complete comparison guide Printed manualThe original and best, delivered to your door Online manualA feature-loaded digital edition of the original manual
Maintenance schedule Simple weekly checks and servicing guides to keep you on the road Printed manual Digital manual
Comprehensive procedures Guide you through every step from minor adjustments to major overhaul Printed manual Digital manual
Fully illustrated With hundreds of photos Printed manual Digital manual
Hints and practical advice From the DIY experts provide inside information Printed manual Digital manual
Specifications and data Enable testing and measuring for wear Printed manual Digital manual
Wiring diagrams Enable tracing of electrical faults Printed manual Digital manual
All colour Photos and wiring diagrams which can be enlarged Printed manual Digital manual
Easy search Find the task you are looking for quickly Printed manual Digital manual
Print-at-home Take the sections you need to the workshop Printed manual Digital manual

Printed manual

The original and the best, delivered to your door
Au $79.95
Au $57.95

Online manual

All the content of a printed manual, plus much more
Au $79.95
Au $44.95
One-time purchase

What's covered

What's covered: 
Honda XR600R, 1991-2000
Honda XR650L, 1993-2019

Does not cover XR650R models

Table of contents

This Honda Motorcycle manual is 336 pages.


Chapter One / General Information
 Manual organization / Warnings, cautions and notes / Safety / Serial numbers and information labels / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

Chapter Two / Troubleshooting
Electrical component replacement / Starting the engine / Engine will not start / Poor engine performance / Fuel system / Engine / Engine lubrication / Leakdown test / Clutch / Gearshift linkage / Transmission / Electrical testing / Starting system (XR650L) / Charging system (XR650L) / Ignition system / Front suspension and steering / Rear suspension / Brakes

Chapter Three / Lubrication, Maintenance and Tune-Up
Pre-ride inspection / Engine oil / Oil line strainer / Oil strainer screen / Air filter / Control cable inspection and lubrication / Clutch lever adjustment / Drive chain / Wheel bearing inspection / Emission control system (XR650L) / Spark plug / Valve clearance adjustment / Starter decompression lever adjustment (XR600R) / Compression test / Tune up

Chapter Four / Engine Top End
Cylinder head cover and camshaft / Camshaft chain tensioner / Cylinder head / Valves and components / Cylinder / Piston, pin and rings

Chapter Five / Engine Lower End
Engine removal-installation / Starter gear assembly / Flywheel and starter clutch / Kickstarter / Oil pump / Oil lines / Oil strainer screen / Primary drive gear / Camshaft chain and guides / Crankcase and crankshaft / Break-in

Chapter Six / Clutch and External Shift Mechanism
Clutch cable / Right crankcase cover / Clutch release lever / External shift mechanism

Chapter Seven / Transmission and Internal Shift Mechanism
Internal shift mechanism

Chapter Eight and Chapter Nine/ Fuel, Emmision Control and Exhaust Systems
Carburetor / Adjustments / Throttle cable / Choke cable / Fuel tank / Fuel valve / Crankcase breather system / Evaporative emission control system / Pulse seondary air injection system / Air box

Chapter Ten and Chapter Eleven/ Electrical System
Charging system / Alternator / Voltage regulator-rectifier / Ignition system / Ignition control module / Pulse generator / Ignition coil / Starting system / Starter / Starter relay / Clutch diode / Lighting system / Switches / Instrument cluster / Horn / Fuses

Chapter Twelve / Wheels, Tires and Drive Chain
Front and rear wheel / Front and rear hubs / Wheel service / Drive chain / Sprockets / Tires / Wheel balance

Chapter Thirteen / Front Suspension and Steering
Handlebar / Handlebar grips / Front fork / Steering head / Steering play check and adjustment / Steering head bearing races

Chapter Fourteen / Rear Suspension
Shock absorber / Shock linkage / Swing arm

Chapter Fifteen / Brakes
Brake fluid / Brake service / Front and rear brake pads / Front and rear brake caliper / Front and rear brake master cylinder / Brake hose replacement / Brake disc / Brake pedal / Brake system draining / Brake bleeding

Chapter Sixteen / Body
Left side cover / Right side cover / Seat / Left hand guard / Right hand guard / Front fender / Rear fender / Air shroud (XR650L) / Frame guard / Sidestand

Color Wiring Diagrams

Models covered:
1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 XR600R XR600 R XR 600 R
1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 XR650L XR650 XR 650 L
Dual Sport Dualsport

Clymer Manuals Honda XR600R Manual
Clymer Manuals Honda XR650L Manual
Clymer Manuals Honda XR600R Online Manual
Clymer Manuals Honda XR650L Online Manual

Print manual

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# of pages: 
Publication date: 
8.5 x 11

Online manual

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With a Haynes Online Manual in an online format you get all the trusted content of a printed manual, with additional features to help you get the job done. Take your entire manual with you on every journey.

Key features:

  • All colour step-by-step guides for over 200 jobs with 700+ photos
  • Image zoom feature for close-up view of jobs
  • Brand-new “how to” video tutorials covering key repair tasks
  • Print complete sections to take with you into the workshop
  • Troubleshooting section – quickly find the cause of a problem
  • Colour wiring diagrams help track problems quickly and easily
  • Easy search feature – find your job fast
  • Dictionary of automotive terms
  • Quick links to popular DIY tasks and other jobs linked to your task
  • Conversion calculator – imperial and metric units