Honda XL/Xr600r and Xr650l/R, 1983-2008
Honda XL/Xr600r Xr650l/R 1983-2008 by Alan AhlstrandGet other Honda repair manual hereHaynes offers the best coverage for cars trucks vans SUVs and motorcycles on the market today. Each manual contains easy to follow step-by-step instructions linked to hundreds of photographs and illustrations. Included in every manual: troubleshooting section to help identify specific problems; tips that give valuable short cuts to make the job easier and eliminate the need for special tools;notes cautions and warnings for the home mechanic; color spark plug diagnosis and an easy to use index. Integracar aims to present a extensive range of maintenance guides. All the same owners manuals can sometimes be designed for different nations and the vehicles released for those countries. That means not all owners manuals may be acceptable for your selected vehicle. If you have any queries whether or not a particular service manual is suitable for your motor vehicle feel free to make contact with us hereHonda XL/Xr600r Xr650l/R 1983-2008 by Alan Ahlstrand come here
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Replacing the gearbox synchronizer in a Honda XL, XR600R, or XR650L involves several key components and steps. Here’s a general overview of the main components and the process involved:
### Main Components:
1. **Gearbox Assembly**: The central piece of the transmission where the synchronizer is located. You will need to disassemble this to access the synchronizer.
2. **Synchronizer Rings (or Synchronizers)**: These are the components that help the gears mesh smoothly. They are crucial for allowing gear changes without grinding.
3. **Gears**: The individual gears that the synchronizers interact with. Depending on wear, these may also need inspection or replacement.
4. **Shift Forks**: These components help move the gears into place during shifting. Ensure they are not worn or damaged.
5. **Bearings**: Bearings support the gears and shafts within the gearbox. Inspect these for wear as you may need to replace them.
6. **Clutch Assembly**: While not directly part of the gearbox, the clutch may need to be removed to access the gearbox components.
7. **Gasket/Sealant**: New gaskets or sealant are needed to ensure there are no leaks when reassembling the gearbox.
### Process Overview:
1. **Preparation**: Gather necessary tools and replacement parts. Drain the oil from the gearbox.
2. **Remove the Engine**: Depending on the model, you may need to remove the entire engine from the frame for easier access.
3. **Disassemble the Gearbox**: Remove the side cover and any other components that obstruct access to the gearbox. Take note of the order of disassembly.
4. **Inspect Components**: Check the synchronizer rings, gears, shift forks, and bearings for wear and damage. Replace any components as necessary.
5. **Replace the Synchronizer**: Remove the old synchronizer rings and install the new ones, ensuring they are seated correctly.
6. **Reassemble the Gearbox**: Follow the reverse order of disassembly, ensuring that all components are properly aligned and seated.
7. **Reinstall the Engine**: If the engine was removed, carefully reinstall it into the frame.
8. **Fill with Oil**: Refill the gearbox with the appropriate oil.
9. **Test**: After reassembly, perform a test run to ensure that the gearbox operates smoothly and that the new synchronizer is functioning correctly.
### Tips:
– **Document Your Work**: Take pictures or notes during disassembly to aid in reassembly.
– **Consult the Service Manual**: Always refer to the specific service manual for your model for detailed instructions and torque specifications.
– **Use Quality Parts**: Ensure you use OEM or high-quality aftermarket parts for best performance.
This process can be complex, so if you’re unsure, consulting a professional mechanic or referring to detailed service manuals specific to the Honda XL, XR600R, or XR650L is recommended.
To replace the transmission output shaft on a Honda XL, XR600R, or XR650L, follow these steps:
1. Remove the engine from the frame.
2. Drain the oil and remove the clutch cover.
3. Take off the clutch assembly and remove the primary drive gear.
4. Unscrew and extract the output shaft retaining bolt.
5. Carefully pull out the output shaft, ensuring no damage to surrounding components.
6. Install the new output shaft, reversing the removal steps.
7. Reassemble the clutch, cover, and engine, then reinstall it in the frame.
8. Refill with oil and test the bike.