Softcover – 312 pages – Honda XR650R 2000 – 2007 Clymer Owners Service Repair Manual covers 2000-2007 Honda XR650R off-road motorcycles.Contents: Quick Reference Data General InformationManual organization / Warnings cautions and notes / Safety / Serial numbers / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications TroubleshootingStarting the engine / Engine will not start / Poor engine performance / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Kickstarter / Drive train noise / Electrical testing / Front suspension and steering / Brakes / Specifications Lubrication Maintenance and Tune-UpPre-ride inspection / Maintenance and service intervals / Tune-up / Test ride / Air filter / Crankcase breather inspection / Engine oil and filter / Engine and frame oil strainer screens / Compression test / Ignition timing / Spark plug / Valve clearance / Decompressor adjustment / Fuel hose and fuel strainer screen inspection / Throttle cable / Engine idle speed / Pulse secondary air injection (PAIR) system / Spark arrestor cleaning / Control cable inspection and lubrication / Drive chain and sprockets / Specifications Engine Top End and Exhaust SystemCylinder head cover Camshaft and cam chain tensioner / Cylinder head / Valves and valve components / Cylinder / Piston and rings / Cylinder stud / Decompressor cable / Specifications Engine Lower EndRemoval and installation / Oil pipes and oil strainer screen / Crankcase / Crankcase seal and bearing / Shift shaft / Balancer shaft / Crankshaft / Specifications Clutch and Primary DriveClutch cover / Clutch release lever / Right crankcase cover / Oil strainer screen / Oil pump / Check valve / Primary drive gear / Cam chain drive sprocket and rear chain guide / Kickstarter and kick idle gear / External shift mechanism / Clutch cable / Specifications Transmission and Internal Shift MechanismsMainshaft / Countershaft / Inspection / Internal shift mechanism / Specifications Fuel and Emission Control SystemsFuel tank / Fuel valve / Air box / Carburetor / Float level / Pilot screw (idle drop procedure) / High altitude adjustment / Rejetting / Throttle cable replacement / Crankcase breather system / Pulse secondary air injection (PAIR) system / Specifications Electrical SystemConnectors / Left crankcase click on
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Fixing a manual transmission on a Honda XR650R involves several key components and steps. Here are the main components you’ll need to focus on:
1. **Transmission Gears and Shafts**: Inspect the gears for any signs of wear, damage, or chipping. This includes the input shaft, output shaft, and any intermediate shafts. If the gears are damaged, they will need to be replaced.
2. **Clutch Assembly**: The clutch plays a crucial role in the operation of a manual transmission. Check the clutch plates, springs, and basket for wear. A worn-out clutch can lead to poor shifting and difficulty engaging gears.
3. **Shift Forks**: These components guide the movement of the gears during shifting. Inspect the shift forks for wear or bending, as damaged shift forks can cause issues with gear engagement.
4. **Shift Drum and Mechanism**: The shift drum is responsible for the engagement and disengagement of the gears. Ensure that it’s functioning correctly and that the detent mechanism is in good condition.
5. **Bearings and Seals**: Check all bearings for smooth operation and replace any that are worn or damaged. Seals should also be inspected for leaks, as these can lead to oil loss and subsequent transmission failure.
6. **Transmission Oil**: Ensure that you are using the correct type of oil for the transmission. Fresh oil is vital for proper lubrication and performance.
7. **Case and Housing**: Inspect the transmission case for cracks or damage. Ensure that all mounting points and alignment are correct when reassembling.
### Steps for Repair:
1. **Disassembly**: Remove the transmission from the bike, then disassemble it carefully, noting the order of components for reassembly.
2. **Inspection**: Thoroughly inspect each component for wear or damage.
3. **Replacement**: Replace any damaged or worn parts, including gears, bearings, and seals.
4. **Reassembly**: Carefully reassemble the transmission, ensuring everything is aligned correctly and to the manufacturer’s specifications.
5. **Testing**: Once reassembled, test the transmission for proper operation before reinstalling it back into the bike.
### Final Tips:
– Always refer to the Honda XR650R service manual for specifications, torque settings, and detailed procedures.
– Use high-quality replacement parts to ensure longevity and performance.
– If you’re unsure about any step, consider consulting a professional mechanic or technician experienced with Honda motorcycles.
By focusing on these components and following the correct procedures, you can effectively repair the manual transmission on a Honda XR650R.