Honda XL600

Honda
XL600 RM, built in 1986
XL600
Manufacturer	Honda
Production period	1983 to 1987
class	motorcycle
design type	Enduro
Motor data
air-cooled 4-stroke gasoline engine
Displacement  (cm³)	589
Power  (kW / PS )	31.6 kW (44 PS) at 6000 rpm 20.0 kW (27 PS) at 5500 rpm (27 PS version)
Torque  ( N m )	49 Nm at 5000 rpm 42 Nm at 3500 rpm (27 hp version)
Top speed (  km / h)	151
transmission	5 courses
drive	Chain drive
Brakes	Disc brake at the front, drum brake at the rear
Wheelbase  (mm)	1420
Seat height (cm)	89.5
Empty weight  (kg)	151
Previous model	Honda XL500R
successor	Honda NX650 Dominator

The XL600 is an all -terrain motorcycle from the Japanese vehicle manufacturer Honda . The Enduro was produced from 1983 to 1987 in several series, color versions and special models.

The XL600R (model PD03) was launched in 1983 as the larger displacement sister of the XL500R . It was changed in many details and equipped with a hydraulically operated disc brake system at the front. In addition to the first model, the XL600R , other variants and types were produced under the corresponding designation. A distinction is made between the XL600 models:

• PD03 XL600R
• PD03 XL600L Paris-Dakar (special model of the standard XL 600 R )
• PD04 XL600LM
• PD04 XL600RM
• PD05 XL500R (reduced displacement for Austria for insurance reasons, otherwise the same engine)
• The Honda XL600V Transalp is not dealt with here

For allocation to the year of manufacture based on the chassis numbers, see the model history below.

Model history

For the origin of the enduro idea, the competing manufacturers and the first offer of an off-road motorcycle equipped with a so-called Pro-link central spring strut by Honda, see also XL500R . The PD03 model offered from 1983 onwards was revised from 1985 onwards. Among other things, these were a revised engine in technical details, more comfortable frame-mounted pillion footrests (previously attached to the swing arm), a stronger telescopic fork (diameter now 41 mm, previously 39 mm). The PD03 special model XL600L Paris-Dakar was equipped with a larger tank and had a different design.

A list of all manufacturing years makes it easier to determine the actual year of construction (since the year of first registration is not necessarily also the year of manufacture because there were some slow-moving goods). The first digits of the 11-digit chassis number (e.g. PD035000123) and the engine version of the XL600 on delivery are mentioned. The model code noted on the color label under the seat on the frame next to the specified original color indicates the year of construction (D is e.g. XL600R D = 1983, XL600RE = 1984, XL 600 RF = 1985 etc.):

Model	(Model model year)	FG no.	Version PS	Engine identification	Color finish	country
1983	(XL600R D model)	PD0350	44 hp	PD03E-50	R-110; NH-1; NH-111	AR, B, CM, E, ED, F, G, IT, SA, SD, SW, U
1983	(XL600L D model)	PD0350	44 hp	PD03E-50	R-110	B, F
1984	(XL600R E model)	PD030-EM	44 hp	PD03E-50	R-110	CM
1984	(XL600L E model)	PD0361	44 hp	PD03E-51	R-119	B, ED, F, IT, SW
1985	(XL600R F model)	PD0351	44 hp	PD03E-52	R-119, R-134, NH-138, NH-1	AR, FI, CM, E, ED, F, G, IT, SA, SD, SW, U
1985	(XL600R F model)	PD0370	27 hp	PD03E-60	R-119, R-134, NH-138, NH-1	GII
1986	(XL600R G model)	PD030-GK3	44 hp	PD03E-53	NH-138	CM
1987	(XL600R H model)	PD0352	44 hp	PD03E-52	R-134, NH-138, NH-1	G, F
1987	(XL600R H model)	PD0371	27 hp	PD03E-60	R-134, NH-138, NH-1	GII
1987	(XL600R H model)	PD030-HK4	44 hp	PD03E-54	NH-138	CM
1985	(XL600LM F model)	PD0450	44 hp	PD04E-50	NH-138	B, E, ED, F, G, IT, N, SA, SP, SW
1986	(XL600RM G model)	PD0451	44 hp	PD04E-51	R-134, NH-138, NH-1	B, ED, F, G, IT, SW, U
1986	(XL600RM G model)	PD0460	27 hp	PD04E-60	R-134, NH-138, NH-1	GII
1987	(XL600LM H model)	PD0452	44 hp	PD04E-51	NH-138, B-119	B, B2, ED, F, F2, G, GII, IT, IT2, N2, SP, SP2, SW

1. ↑ color code NH-1 = black; NH-111 = Cortina white; R-110 = Monza Red; R-134 = battle red; R-119 = lightning red; NH-138 = Shasta white; B-119 = seagull blue
2. ↑ country code AR = Austria; B = Belgium; CM = Canada; E = England; ED = Europe direct sales; F = France; G = Germany 44ps; GII = Germany 27 hp; IT = Italy; SA = South Africa; SD = Sweden; SW = Switzerland; U = Australia; FI = Finland; B2 = Belgium 27 hp; F2 = France 27 hp; IT2 = Italy 27 hp; N2 = Norway 27 hp; SP2 = Spain 27 hp

For model code or Vehicle Identify Number, see VIN

Source: Honda spare parts catalog - Microfiche status 1989 for PD03 and PD04

technology

The almost identical, air-cooled single-cylinder engine with the designation Radial Four Valve Combustion (RFVC) works in all models . With a cylinder bore of 100 mm and a piston stroke of 75 mm (PD03), the four-stroke engine has a displacement of 589 cm³ and generates a nominal output of 44 HP (32 kW) at a speed of 6500 rpm without throttling . Due to the insurance classes that were valid in Germany at that time, the various models were also available on the market as a 27 HP version with a different chassis number (see list). The throttling was made by a different camshaft and different carburetor jets. The piston runs in an aluminum cylinder with a cylinder liner made of gray cast iron . The gas exchange takes place by four radially arranged valves of an overhead camshaft via rocker arm side and intermediate drag levers are operated. In the first models, a fifth, smaller valve was used for decompression during kick start. The transmission has five gears. The strong engine vibrations typical of single-cylinder engines are reduced by a balance shaft driven by a gear wheel . The engine lubrication works by pressure circulation with a dry sump. The engine of the PD03 is started with a kick starter, this is made easier by an automatic decompression mechanism. The XL600RM and LM were also offered with a starter .

A weak point in the engine was the cylinder head with the camshaft with plain bearings in the middle of the three bearings, as well as the valve seats, which often fell out of their guides during higher mileage or heavy use. The second weak point is the alternator, of which the "ignition charging coil" of the "ignition primary coil" often fails. In contrast to the later models, the RFVC engines used on the XL500 still tend to leak oil on the cylinder head.

It can be seen as the basis for the development of the drives of later models such as the NX650 Dominator , SLR650 , XBR500 , GB500 Clubman or, from 2005, the Honda FMX650 . The successful basic design of the engine, which was first installed in the XL600, has been retained until today (2014) and is found in the Honda XR650L , which is offered in the USA.

Technical specifications

Dimensions (PD03 only, L model in brackets)

• Total length: 2110 mm (2225 mm)
• Total width: 865 mm
• Total height: 1235 mm
• Seat height: 895 mm
• Ground clearance: 375 mm
• Weight: empty 135 kg (141 kg)

frame

• Frame type: Semi-double swing frame
• Steering head bearings: tapered roller bearings
• Trail: 118 mm
• Caster angle: 28 ° 30
• Front travel: 229 mm
• Rear travel: Pro-Link 203 mm
• Front tires: 90 / 90-21 54S ENDURO3 front
• Rear tires: 130 / 80- 17 65S ENDURO3 (SAHARA)
• Swing arm bearing: needle bearing
• Fork tube diameter: 39 mm, from year of construction 1985 41 mm
• Fuel tank: 12 l / 2 l reserve (20 l / 6 l reserve)

engine

• Design: Air-cooled 4-stroke gasoline engine with single overhead camshaft
• Cylinder arrangement: single cylinder, 15 ° inclination, 4 valves
• Bore and stroke: 100 mm × 75 mm
• Displacement: 589 cm ³
• Compression: 8.6: 1
• Valve drive: 4 valves operated by a toothed chain-driven overhead camshaft via rocker arm and secondary rocker arm
• Valve clearance: inlet: 0.05 mm; Outlet: 0.10 mm (with a cold engine; however, 0.08 mm or 0.12 mm are recommended; see also discussion in the relevant forums below)
• Maximum power:
  • 31.6 kW (44 hp) at 6000 rpm
  • 20.0 kW (27 PS) at 5500 rpm (27 PS version)
• Max. Torque:
  • 49 Nm at 5000 rpm
  • 42 Nm at 3500 rpm (27 PS version)
• Lubrication system: pressure circulation lubrication with dry sump
• Oil quantity: 2.0 l when changing oil and filter, 2.5 liters after revision

Carburetor

• Carburettor: piston slide carburetor passage 28 mm; Primary and secondary carburetors
• Float height: 18.0 mm
• Main jet (default value): primary 122, secondary 100
• Idle speed: 1300 ± 100 / min.

Power transmission

• Clutch: multi-plate oil bath clutch
• Transmission: 5-speed continuous engagement
• Primary reduction ratio: 2.1875: 1
• Standard version sprocket / pinion: 41 teeth / 15 teeth (with 44 HP version)
• Final drive: roller chain

Electrical equipment

• Voltage: 12 volts
• Ignition system: Contactless CDI ignition system
• Spark plug: Normal case: DPR8EA-9 (NGK)
• Spark plug gap: 0.8-0.9 mm
• Battery capacity: 12 volts - 3 Ah

literature

• Repair instructions from Bucheli No. 5083/5084 ISBN 3-7168-1704-X (German)
• Jochen Kuch: Honda motorcycles since 1970. - 1st edition. Motorbuch-Verlag, Stuttgart 2009. (Typenkompass) ISBN 978-3-613-02989-7

Web links

Commons : Honda XL600  - Collection of pictures, videos and audio files