Used 1983-1984 Honda XR500R Motorcycle Service Manual

Description

This used 258 page, 1983-1984 Honda XR500R Motorcycle Service Manual is a used reproduction of the original service manual, printed by Honda.  Manual has been comb bound as the original binder fell apart.

This manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1983-1984 Honda XR500R motorcycles.

This manual is based on the 1983 model. Any information that differs between the ’83 and ’84 models is noted. Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 16 describe parts of the motorcycle, grouped according to location. This manual is really easy to use compared to a PDF. Find the section you want on the index page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, general instructions, specifications, torque values, tools and troubleshooting for the section. The subsequent pages give detailed procedures for the section. If you are not familiar with this motorcycle, read section 17 Technical Features. If you don’t know what the source of the trouble is, refer to section 18, Troubleshooting.

This manual includes the following information:

General Information
General Safety
Service Rules
Model Identification
Specifications
Torque Values
Tools
Wiring Diagram
Cable & Harness Routing
Items Requiring Frequent Replacement
Inlet Duct Cap And Muffler Diffuser Pipe

Lubrication
Service Information
Troubleshooting
Engine Oil Level Check
Engine Oil Change
Engine Oil Filter Replacement
Oil Strainer Nut
Crankcase Oil Screen
Lubrication Points

Maintenance
Service Information
Maintenance Schedule
Competition Maintenance Schedule
Engine^
Fuel Line And Fuel Filter
Throttle Operation
Carburetor Choke
Air Cleaner
Spark Plug
Valve Clearance
Engine Decompressors
Ignition Timing
Carburetor Idle Speed
Cylinder Compression
Chassis
Drive Chain
Brake Fluid
Brake Shoe/pad Wear
Front Brake
Rear Brake
Headlight Aim
Clutch
Suspension
Side Stand
Wheel/spokes
Steering Head Bearing
Spark Arrestor Cleaning
Nuts, Bolts, Fasteners

Fuel System
Service Information
Troubleshooting
Fuel Tank
Air Cleaner Case Removal
Crankcase Breather
Carburetor Removal
Carburetor Disassembly
Carburetor Assembly
Carburetor Installation
Air Screw Adjustment
Carburetor Synchronization
Temperature And Altitude

Engine Removal And Installation
Service Information
Engine Removal
Engine Installation

Cylinder Head And Valves
Service Information
Troubleshooting
Cylinder Head Cover Removal
Cylinder Head Cover Disassembly
Reed Valve Removal
Cam Chain Tensioner Removal
Camshaft Removal
Cylinder Head Removal
Cylinder Head Disassembly
Valve Seat Inspection And Refacing
Cylinder Head Assembly
Cylinder Head Installation
Camshaft Installation
Cylinder Head Cover Assembly
Cylinder Head Cover Installation

Cylinder & Piston
Service Information
Troubleshooting
Cylinder Removal
Piston Removal
Piston Installation
Cylinder Installation

Clutch, Oil Pump, Kickstarter
Service Information
Troubleshooting
Right Crankcase Cover Removal
Clutch
Oil Pump
Drive Gear
Kick Starter
Gear Shift Cam Plate
Right Crankcase Cover Installation

Alternator
Service Information
Left Crankcase Cover Removal
Flywheel Removal
Flywheel Installation
Left Crankcase Cover Installation

Crankcase, Crankshaft Balancer
Service Information
Troubleshooting
Crankcase Separation
Balancer/crankshaft Removal
Crankshaft/balancer Installation
Crankcase Assembly

Transmission
Service Information
Troubleshooting
Transmission Disassembly
Transmission Assembly

Front Wheel, Suspension, Steering
Service Information
Troubleshooting
Headlight
Speedometer
Handlebar
Front Wheel
Front Forks
Steering Stem

Rear Wheel, Brake, Suspension
Service Information
Troubleshooting
Rear Wheel
Shock Absorber
Swing Arm
Brake Pedal

Hydraulic Brake
Service Information
Troubleshooting
Brake Fluid Replacement/air Bleeding
Brake Pad/disc
Master Cylinder
Brake Caliper

Rear Fender, Exhaust Pipe

Ignition System
Service Information
Troubleshooting
Spark Plug
Ignition Coil
Alternator
Cdi Unit
Pulse Generator
Ignition Timing
Engine Stop Switch
Ac Regulator

Technical Features
Radial Four Valve Combustion, R.F.V.C. Engine
Dual Carburetors

Troubleshooting
Engine Does Not Start Or Is Hard To Start
Engine Lacks Power
Poor Performance At Low And Idle Speeds
Poor Performance At High Speed
Poor Handling