20 Most Recent 1985 Honda XR 600 R Questions & Answers

Yeah Gregg is correct, especially when it's intermittent as you are stating. Start at the beginning with the easiest first. You don't want to just start swapping parts blindly. Motorcycle batteries don't last, in your explanation you said spark is on off some days, is this just on trying to start it or when it is running? How old are plug wires? No cracking or loose connections? All safety switched are good and clean? Kickstand switch, ignition switch, grounds, actual plugs? It's hard to diagnose when it is not happening all the time. But like I said when it does start at the simplest things always, do some testing, work from the start of the system of ignitiin. You know, put in key, check, turn key, turn to start, push start. Nothing? Check battery, battery good? Then check starter, voltage? Good? Then check spark- spark or no? Yes ? Well wait until it don't again. Then check coils and grounds, check coils for proper resistance according to manual, check proper voltage to ecm , check manual or online and it will tell you what to check to confirm that it is working right.
But remember little things first. Batteries, safety switches, grounds, plug wires, plugs, connections and wire condition.
Start at the beginning and if you need any help let me know. All I ride are pre 98 and below Honda's so I'm very familiar with your system.

throw it back at the shop, if you did the work strip it and check it all again

failing to idle indicates a blockage in the idle circuit this could be from a blocked idle jet or emulsion tube some cars have an idle circuit solenoid that cuts of the circuit when the switch is off there by stopping engine run on on shut down the idle screw should stop the engine if all that way in and run it rough if too far out it should be about 2 turns out from full in position test the circuit by removing the screw and placing the finger over the hole if it still cuts out the the problem is in the idle circuit. another point is a vacuum leak from a badly fitted inlet gasket, carby gasket or ant vacuum line not connected.

IF YOU PAID SOMEONE TO REBUILD YOUR ENGINE TAKE IT BACK TO THEM AND SHOW THE BASKET DAMAGE THE PROPER BUSHINGS WERE NOT USED THAT'S WHY THE DAMAGE AND IT WILL ONLY GET WORSE..NOW YOU MIGHT HAVE A VACUUM LEAK IN FACT ID BET ON IT ESPECIALLY IF THROTTLE RESPONSE IS IFFY AND NOT COMING BACK TO IDLE..BACKFIRE IS CAUSED BY RICH MIXTURE NOT GETTING COMPLETE BURN WHICH RELEASES RAW FUEL INTO TAIL PIPE CAUSING EXPLOSION IN TAIL PIPE..HOPE ALL GOES WELL..

Hi sounds like fuel problem, try draining tank, check fuel filter for debris then refill with good quality fuel. Add a big dose of in tank fuel cleaner. Check spark plug[s] replace if necessary, spray ignition sealer/damp start around HT coil. Check air filter and clean as necessary. Make sure choke, if fitted, is working properly. Check ignition switch for water flush with WD 40 or similar then spray in silicon oil. Check engine kill switch is operating properly and has no water ingress.

replace coil and see if that sorts it

There is not adjustment on the float bowl level. The only adjustments on the carb are air-fuel and idle. The air-fuel mixture screw should be all the way in and one and a half a turn out. And the idle should just be set to the ear. Meaning start the bike and idle it down until it dies, then turn 3/4 of a turn up. These adjustments will cause the bike to get hot. If it is running too lean it will overheat.

Yes it is possible. You can use the electric starter taken off a Honda XR650 or buy a XR650 electric start kit which fits on the XR600 for about $800 (Non-Honda Parts) or $1600 (complete kit using OEM Honda parts) from Joe Racer. Click on the links below to read more:

http://www.joeracerproducts.com/index.php?module=electricstart

http://www.thumpertalk.com/forum/thread/400259/xr600-electric-start

http://www.horizonsunlimited.com/hubb/honda-tech/electric-start-xr600r-8916

If air doesn't work, I have made a tool that helped. I got a bolt that fit into where the brake line goes, (Banjo bolt) drilled a hole through it, and thread tapped it to accept a grease fitting on the top. Then I pump grease into it to force out the piston. (s)

two things come to mind firstly isthe machine correctly in neautral or have you picked up a flse neautral between gears if it is in fact properly in neautral tnhen I would be checking both the kickstart return spring & your selector mechanism

2.0 - 2.4 kgf m for 6 mm bolt
8 mm bolt 2.6 - 3.0 kgf m

Go to bikebandit.com. That website has model specific schematics.

Go to http://www.carlsalter.com/motorcycle-manuals.asp and down load a free manual.