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Honda XR650L 2021, Manual

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Summary of Contents for XR650L 2021

Page 1: ...Contents Vehicle Safety P 2 Operation Guide P 16 Maintenance P 30 Troubleshooting P 72 Information P 79 Specifications P 100 2021 XR650L 31MGW690 MOM 17582 2008...

Page 2: ...e you to take responsibility for keeping your vehicle well serviced and maintained Also observe the break in guidelines and always perform the pre ride inspection and other periodic checks in this man...

Page 3: ...maintaining a vehicle You must use your own good judgment You will find important safety information in a variety of forms including Safety labels on the vehicle Safety Messages preceded by a safety a...

Page 4: ...Safety Precautions P 9 Riding Precautions P 10 Accessories Modifications P 13 Off Road Safety P 14 Loading P 15 This section contains important information for safe riding of your vehicle Please read...

Page 5: ...ways wear an approved helmet and protective apparel 2 P 9 Before Riding Make sure that you are physically fit mentally focused and free of alcohol and drugs Check that you and your passenger are both...

Page 6: ...ur area where you can learn from experienced riders Also be sure to read Tips Practice Guide for the Off Highway Motorcyclist that came with your new vehicle Ride Defensively Always pay attention to o...

Page 7: ...mmended maintenance Never exceed load limits 2 P 15 and do not modify your vehicle or install accessories that would make your vehicle unsafe 2 P 13 If You are Involved in a Crash Personal safety is y...

Page 8: ...tain a dangerous amount of carbon monoxide Never run your vehicle inside a garage or other enclosure 3WARNING Running the engine of your vehicle while in an enclosed or even partially enclosed area ca...

Page 9: ...portant safety information and may warn you of potential hazards that could cause serious injury Read these labels carefully and don t remove them If a label comes off or becomes hard to read contact...

Page 10: ...12in Rear 3 0mm 0 12in Up to maximum weight capacity Front 150kPa 1 50kgf cm 22psi 2 2 Rear 150kPa 1 50kgf cm 22psi Up to 90kg 200lbs load Maximum weight capacity 149kg 328lbs Tire size Front 150kPa 1...

Page 11: ...of the vehicle Ride defensively in response to weather and road conditions Helmet Should be safety standard certified high visibility and correct size for your head Must fit comfortably but securely...

Page 12: ...ill need more serious off road gear In addition to your helmet and eye protection we recommend off road motorcycle boots and gloves riding pants with knee and hip pads a jersey with elbow pads and a c...

Page 13: ...se engine braking with intermittent use of the brakes to reduce speed For full braking effectiveness operate both the front and rear brakes together Engine Braking Engine braking helps slow your vehic...

Page 14: ...Slowly lean the vehicle to the left until its weight rests on the side stand 4 Turn the handlebar fully to the left u Turning the handlebar to the right reduces stability and may cause the vehicle to...

Page 15: ...te on public roads Before deciding to install accessories on your vehicle be certain the modification is safe and legal 3WARNING Improper accessories or modifications can cause a crash in which you ca...

Page 16: ...can assist each other in case of trouble Familiarity with your vehicle is critically important should a problem occur far from help Never ride beyond your ability and experience or faster than condit...

Page 17: ...hicle Do not place objects near the lights or the muffler Also follow these guidelines when you ride off road on rough terrain Do not carry a passenger Keep cargo small and light weight Make sure it c...

Page 18: ...7 Engine oil fill cap dipstick P 56 Rear brake fluid reservoir P 58 Front suspension compression damping adjuster P 69 Front brake fluid reservoir P 58 Rear suspension rebound damping adjuster P 70 En...

Page 19: ...ox P 78 Drive chain P 62 Side stand P 61 Shift lever P 25 Battery P 50 Main fuse P 78 Helmet holder P 29 Spark arrester P 55 Front suspension compression damping adjuster P 69 Rear suspension compress...

Page 20: ...Total distance ridden Odometer Odometer and Tripmeter read in miles Speedometer This shows your speed in miles per hour Shows proper speed range for each gear Tripmeter Distance ridden since you last...

Page 21: ...ealer check for problems Comes on when the transmission is in Neutral Comes on to indicate that the side stand ignition cut off system is activated when the side stand is put down High beam indicator...

Page 22: ...f when operating the starter motor u In an emergency switch to the Stop position to stop the engine Low beam High beam Ignition switch Switches the electrical system on off locks the steering u Key ca...

Page 23: ...nded Locking a Turn the handlebar all the way to the left b Push the key down and turn the ignition switch to the LOCK position u Jiggle the handlebar if the lock is difficult to engage c Remove the k...

Page 24: ...e is used to control the flow of fuel from the fuel tank to the carburetor ON normal position for riding OFF for parking storing or transportation RES for extra fuel to get to a gas station for refuel...

Page 25: ...aust system Normal Air Temperature 10 35 C 50 95 F a Make sure the fuel valve is in the ON position b Make sure the engine stop switch is in the Run position c Turn the ignition switch to the ON posit...

Page 26: ...y open less than 1 8 in press the start button Low Air Temperature 10 C 50 F or Below a Follow steps 1 6 under Normal Air Temperature b Warm up the engine by opening and closing the throttle slightly...

Page 27: ...fting Up From 1st to 2nd 12 mph 20 km h From 2nd to 3rd 19 mph 30 km h From 3rd to 4th 25 mph 40 km h From 4th to 5th 31 mph 50 km h Shifting Down From 5th to 4th 22 mph 35 km h From 4th to 3rd 16 mph...

Page 28: ...sition after refueling to avoid running out of fuel with no reserve P 22 Refueling and Fuel Guidelines P 12 Opening the Fuel Fill Cap a Open the lock cover insert the ignition key and turn it clockwis...

Page 29: ...ighly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately Operati...

Page 30: ...To close the cap align the tabs of the fuel fill cap to the slots of the filler neck with the arrow mark on the cap towards the rear of the vehicle c Turn the cap clockwise until the arrow mark point...

Page 31: ...it counterclockwise to unlock Hang your helmet on the holder pin and push it in to lock Remove the key 3WARNING Riding with a helmet attached to the holder can interfere with the rear wheel or suspen...

Page 32: ...55 Engine Oil P 56 Brakes P 58 Side Stand P 61 Drive Chain P 62 Wheels P 63 Clutch P 64 Throttle P 67 Other Adjustments P 68 Adjusting the Front Suspension P 68 Adjusting the Rear Suspension P 70 Ple...

Page 33: ...maintaining your vehicle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations an...

Page 34: ...ther or not you should perform a given task Follow these guidelines when performing maintenance Stop the engine and remove the key Place your vehicle on a firm level surface using the side stand or a...

Page 35: ...Your dealer meets all of these requirements All scheduled maintenance is considered a normal owner operating cost and will be charged to you by your dealer Keeping an accurate maintenance record will...

Page 36: ...km or 6 months Engine Oil Filter Engine Idle Speed Secondary Air Supply System Evaporative Emission Control System 3 Maintenance Level Maintenance Legend Intermediate We recommend service by your dea...

Page 37: ...64 Side Stand 61 Suspension Spark Arrester Muffler 55 Nuts Bolts Fasteners Wheels Tires 4 47 63 Steering Head Bearings 4 Notes 1 2 3 At higher odometer readings repeat at the frequency interval establ...

Page 38: ...km 16 000 miles 25 600 km 20 000 miles 32 000 km 24 000 miles 38 400 km 28 000 miles 44 800 km 32 000 miles 51 200 km 36 000 miles 57 600 km 40 000 miles 64 000 km 44 000 miles 70 400 km 48 000 miles...

Page 39: ...ar and air pressures are within limits 2 P 47 Lights horn and turn signals operate normally Check the condition of the drive chain Adjust slack and lubricate as needed 2 P 45 Check the following items...

Page 40: ...ight Check the rims for any damage 2 P 63 Oil level is between the upper and lower marks 2 P 56 Refuel when needed 2 P 12 2 P 26 Be sure the fuel fill cap is securely fastened 2 P 26 Clutch lever oper...

Page 41: ...nd throttle grip 2 P 67 Drive chain Check the slack 2 P 62 adjust the slack and lubricate 2 P 46 as needed Fuses Check that you have a full supply of spare fuses Nuts bolts Check the major nuts and bo...

Page 42: ...ned on the color label The color label is attached to the frame behind the left side cover 2 P 53 3WARNING Installing non Honda parts may make your vehicle unsafe and cause a crash in which you can be...

Page 43: ...r eyes u Wash your eyes repeatedly with cool water for at least 15 minutes Using water under pressure can damage your eyes Electrolyte splashes onto your skin u Remove affected clothing and wash your...

Page 44: ...harging If you use electrical accessories that drain the battery or you do not ride frequently we recommend that you charge the battery every 30 days using a charger designed specifically for your Hon...

Page 45: ...electrical on your vehicle stops working check for and replace any blown fuses 2 P 78 Inspecting and Replacing Fuses Turn the ignition switch to the OFF position to remove and inspect fuses If a fuse...

Page 46: ...e following standards JASO T 903 standard 1 MA SAE standard 2 10W 30 API classification 3 SG or higher 1 The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are t...

Page 47: ...d or equivalent Drive Chain The drive chain must be inspected and lubricated regularly Inspect the chain more frequently if you often ride on bad roads ride at high speed or ride with repeated fast ac...

Page 48: ...cate with the recommended lubricant Recommended lubricant Pro Honda HP Chain Lube or equivalent Do not use a steam cleaner a high pressure cleaner a wire brush volatile solvent such as gasoline and be...

Page 49: ...r pressure when your tires are cold If you decide to adjust the tire pressure for a particular off road riding condition make changes a little at a time Inspecting for Damage Inspect the tires for cut...

Page 50: ...es Also inspect the valve stems for their positions A tilted valve stem indicates the tube is slipping inside the tire or the tire is slipping on the rim See your dealer 3WARNING Riding on tires that...

Page 51: ...peed rating and load range Remember to replace the inner tube whenever you replace a tire The old tube will probably be stretched and it could fail if installed in a new tire 3WARNING Installing impro...

Page 52: ...the battery 5 Disconnect the positive terminal from the battery 6 Remove the battery taking care not to drop the terminal nuts Installation Install the parts in the reverse order of removal Always con...

Page 53: ...t backward Installation 1 Insert the tab into the recess under the frame 2 Tighten the seat mounting bolts securely 3 Fasten the belt over the seat and tighten the belt attaching bolt securely 4 Insta...

Page 54: ...roud Removal 1 Remove the socket bolts 2 Remove the shroud Installation Install the parts in the reverse order of removal Removing Installing Body Components u Shroud Maintenance 52 Socket bolts Shrou...

Page 55: ...he left side cover Installation 1 Align the left side cover with the air cleaner housing 2 Push each quick release fastener into its slot lift its D ring and turn it clockwise until it is secure Remov...

Page 56: ...ut Installation 1 Position the right side cover so the prongs are aligned with the frame grommets 2 Push both prongs in 3 Install the attaching bolt and tighten it Removing Installing Body Components...

Page 57: ...mended for this procedure Because of the possible fire hazard check that there are no combustible materials in the area before purging the spark arrester 1 Remove the bolts spark arrester lid and gask...

Page 58: ...pright position on a firm level surface 4 Remove the oil fill cap dipstick and wipe it clean 5 Insert the oil fill cap dipstick until it seats but don t screw it in 6 Check that the oil level is betwe...

Page 59: ...The engine contains a crankcase oil level check bolt Remove the bolt and check that the level is flush with the lower edge of the hole If it is install and tighten the bolt start the engine and check...

Page 60: ...d that the fluid level is between the LOWER level and UPPER level marks If the brake fluid level in either reservoir is below the LOWER level mark or the brake lever and pedal freeplay becomes excessi...

Page 61: ...ront Inspect the brake pads from below the brake caliper 2 Rear Inspect the brake pads from the rear right of the vehicle If necessary have the pads replaced by your dealer Always replace both left an...

Page 62: ...witch Hold the brake light switch and turn the adjusting nut in the direction A if the switch operates too late or turn the nut in the direction B if the switch operates too soon Brakes u Adjusting th...

Page 63: ...k the spring for damage or loss of tension 3 Sit on the vehicle shift the transmission to Neutral and raise the side stand 4 Start the engine pull the clutch lever in and shift the transmission into g...

Page 64: ...mission to Neutral Stop the engine 2 Place your vehicle on its side stand on a firm level surface 3 Check the slack in the lower half of the drive chain midway between the sprockets Drive chain slack...

Page 65: ...oose spokes may result in instability at high speeds and possible loss of control It is not necessary to remove the wheels to perform the recommended service in the Maintenance Schedule 1 Inspect the...

Page 66: ...16 in 10 20 mm Check the clutch cable for kinks or signs of wear If necessary have it replaced by your dealer Lubricate the clutch cable with a commercially available cable lubricant to prevent prema...

Page 67: ...st cover 2 Loosen the upper lock nut 3 Turn the upper clutch cable adjuster until the freeplay is 3 8 13 16 in 10 20 mm 4 Tighten the upper lock nut and check the freeplay again 5 Install the rubber d...

Page 68: ...lower adjusting nut until the freeplay is 3 8 13 16 in 10 20 mm 4 Tighten the lower lock nut and check the clutch lever freeplay 5 Start the engine pull the clutch lever in and shift into gear Make s...

Page 69: ...ose automatically or if the cable is damaged have the vehicle inspected by your dealer Freeplay at the throttle grip flange 1 16 1 4 in 2 6 mm Adjusting the Throttle Freeplay 1 Slide the cable boot 2...

Page 70: ...pressure gauge Standard air pressure 0 psi 0 kPa 0 kgf cm2 Maximum air pressure 6 psi 40 kPa 0 4 kgf cm2 3 If air pressure is insufficient add air with a bicycle air pump Do not exceed the maximum re...

Page 71: ...Turning the adjuster screw one full turn advances the adjuster 4 positions Turn clockwise to increase compression damping hard or turn counterclockwise to decrease compression damping soft The standar...

Page 72: ...ounterclockwise to decrease rebound damping soft The standard position is approximately 13 17 clicks from the maximum setting so that the slit on the adjuster aligns with the reference punch mark NOTI...

Page 73: ...decrease compression damping soft The standard position is approximately 7 11 positions from the maximum setting so that the punch mark on the adjuster aligns with the reference punch mark NOTICE Do n...

Page 74: ...Engine Will Not Start P 73 Tire Puncture P 74 Electrical Trouble P 75 Battery Goes Dead P 75 Burned out Light Bulb P 75 Blown Fuse P 78 Troubleshooting...

Page 75: ...2 P 23 Check that there is gasoline in the fuel tank Starter Motor Does Not Operate Check the following items Check the correct engine starting sequence 2 P 23 Check for a blown fuse 2 P 78 Check for...

Page 76: ...new one and it may fail while you are riding If you need to make a temporary repair by patching a tube or using an aerosol sealant ride cautiously at reduced speed and have the tube replaced before y...

Page 77: ...r NOTICE Jump starting using an automobile battery can damage your vehicle s electrical system and is not recommended Bump starting is also not recommended Burned out Light Bulb Follow the procedure b...

Page 78: ...Install a new bulb and parts in the reverse order of removal u Install the dust cover with its TOP mark facing up Do not touch the glass surface with your fingers If you touch the bulb with your bare...

Page 79: ...in the reverse order of removal Front Rear Turn Signal Bulb 1 Remove the turn signal lens by removing the screw 2 Slightly press the bulb and turn it counterclockwise 3 Install a new bulb and parts i...

Page 80: ...fuses one by one to check for a blown fuse Always replace a blown fuse with a spare of the same rating 4 Close the battery compartment cover 5 Reinstall the left side cover NOTICE If a fuse fails rep...

Page 81: ...Transporting Your Vehicle P 85 You the Environment P 86 Vehicle Identification Number P 87 Emission Control Systems P 88 High Altitude Carburetor Adjustment P 92 Oxygenated Fuels P 93 Authorized Manu...

Page 82: ...key holder may cause damage to the area surrounding the ignition switch Instruments Controls Other Features Ignition Switch Leaving the ignition switch in the ON position with the engine stopped will...

Page 83: ...spot potential problems In particular seawater and salts used to prevent ice on roads promote the formation of corrosion Always wash your vehicle thoroughly after riding on coastal or treated roads W...

Page 84: ...rakes u If your vehicle has any matte painted parts do not apply a coat of wax to the matte painted surface Washing Precautions Follow these guidelines when washing Do not use high pressure washers u...

Page 85: ...plenty of water and a mild detergent to clean matte painted surfaces Dry with a soft clean cloth Aluminum Components Aluminum will corrode from contact with dirt mud or road salt Clean aluminum parts...

Page 86: ...be riding for an extended period follow these guidelines Wash your vehicle and wax all painted surfaces except matte painted surfaces Coat chrome pieces with rust inhibiting oil Lubricate the drive c...

Page 87: ...dealer Transporting Your Vehicle If your vehicle needs to be transported it should be carried on a motorcycle trailer or a flatbed truck or trailer that has a loading ramp or lifting platform and moto...

Page 88: ...es Put oil and other toxic wastes in approved containers and take them to a recycling center Call your local or state office of public works or environmental services to find a recycling center in you...

Page 89: ...l number uniquely identify your vehicle and are required in order to register your vehicle They may also be required when ordering replacement parts You should record these numbers and keep them in a...

Page 90: ...n byproducts including carbon monoxide CO oxides of nitrogen NOx and hydrocarbons HC Gasoline evaporation also emits hydrocarbons Controlling the production of NOx CO and HC is important for the envir...

Page 91: ...d and maintained according to the instructions provided Compliance with the terms of the Distributor s Warranties for Honda Motorcycle Emission Control Systems is necessary in order to maintain a vali...

Page 92: ...adsorb fuel vapor from the fuel tank and carburetor while the engine is off The vapor is drawn into the engine and burned while riding Crankcase Emissions Control System The engine is equipped with a...

Page 93: ...ry to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED T...

Page 94: ...perated at high altitudes Above 6 500 ft 2 000 m a rich mixture can cause driveability problems reduce engine performance and increase fuel consumption To compensate you can have the carburetor adjust...

Page 95: ...ne containing methanol methyl alcohol If you accidentally fill your fuel tank with an oxygenated fuel containing higher percentages you may experience performance problems To resolve the problem have...

Page 96: ...es scooters and ATV The Winter Storage Guide in conjunction with the Owner s Manual and Service Manual can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda man...

Page 97: ...Warranties Booklet It is important to realize that your warranty applies only to defects in material or workmanship of your Honda Your warranty coverage does not apply to the normal wear and deteriora...

Page 98: ...discovered that an aftermarket or recycled part installed on the vehicle is defective or was installed incorrectly and caused damage to another part of the vehicle otherwise covered under warranty Th...

Page 99: ...the Service Manager of your Honda dealer If a misunderstanding occurs and you aren t satisfied with your dealer s handling of the situation we suggest you discuss your problem with the appropriate me...

Page 100: ...intenance and unexpected repairs It has the latest available service information from Honda and also handles warranty inspections and repairs The parts department offers Honda Genuine Parts Pro Honda...

Page 101: ...that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or American Honda Motor...

Page 102: ...city Rider and 1 passenger Minimum turning radius 5 2 ft 1 6 m 1 Including rider passenger all luggage and accessories 2 Includes the weight of the luggage and added accessories Displacement 39 3 cu i...

Page 103: ...Recommended engine oil API Service Classification SG or higher except oils labeled as energy conserving or resource conserving on the circular API service label SAE 10W 30 JASO T 903 standard MA Pro...

Page 104: ...A Other fuse 10 A Torque Specifications Oil filter cover bolt 9 lbf ft 12 N m 1 2 kgf m Crankcase drain bolt 18 lbf ft 25 N m 2 5 kgf m Frame drain bolt 29 lbf ft 39 N m 4 0 kgf m Rear wheel axle nut...

Page 105: ...Information Record VIN Engine No Color Label Code Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Manager 103...

Page 106: ...thalates and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as...

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