Reddit reviews Honda XR600R 1991-2000 & XR650L 1993-2012: This manual does not cover XR650R models (Clymer Powersport)
We found 1 Reddit comments about Honda XR600R 1991-2000 & XR650L 1993-2012: This manual does not cover XR650R models (Clymer Powersport). Here are the top ones, ranked by their Reddit score.
Ok I got ya on this. I recently had all three bolts on my oil filter cover snap in the casing while I was working on it. (p.s if that ever happens to you, do not torque them to 7 ft/lbs as stated in the manual, just tighten to snug)
The reason this happens is that Honda cheaped out on screws, I guess in the event that those break before more important parts do. It's scary but not the end of the world
First thing I would always recommend is either downloading a factory service manual if you can find one. As well as BUY A HAYNES / CLYMER MANUAL. It will save you in the future.
a quick google turns up this, tada:
https://thumpertalk.com/forums/topic/610432-xr650l-owners-manual-inside/
and heres the clymer link to buy one:
https://www.amazon.com/Honda-XR600R-1991-2000-XR650L-1993-2012/dp/1620921537/ref=sr_1_1?gclid=EAIaIQobChMI-Nv0_9vm4wIVhRx9Ch1KeQ5-EAAYAiAAEgLtS_D_BwE&hvadid=177528169391&hvdev=c&hvlocphy=9032056&hvnetw=g&hvpos=1t2&hvqmt=e&hvrand=6356380794860257313&hvtargid=kwd-10840489131&hydadcr=6586_9585033&keywords=clymer+xr650l&qid=1564835915&s=gateway&sr=8-1
So back to these screws. you need to extract em. good news is they are soft and easy to extract. use a speed out kit : https://www.amazon.com/Ontel-SpeedOut-Damaged-Screw-Extractor/dp/B00IRL3WP4/ref=sr_1_3?crid=2BIIO15IIO5JY&keywords=screw+extractor&qid=1564835981&s=gateway&sprefix=screw+ex%2Caps%2C203&sr=8-3
Basically what you are gonna do is use one side of the bit to drill a cone shaped hole in the top if the screw, then take it out, flip it around, and use the other side to SLOWLY extract it. Boom, easy and out. just go slow and don't rush it. you will thank yourself.
If you do mess up the threads, consider installing a helicoil so it can easily be saved in the future.
Next you need to find the screw. Your amazing new manual will have the parts diagrams all in it, so start there. If you just can't be bothered to read, we have the glorious internet! Hondapartshoues, Babbits online, and many others will help you find the size.
Look how easy it is! Here is the diagram for the screw in question:
https://www.babbittsonline.com/oemparts/a/hon/5054117cf870021c54bee45d/handle-switch-cable
It is a m5x16 panhead screw. I personally would go down to your local ace, and get the same size screw in a harder material. Either 10.9 or stainless, or even chromey bois as they will have it all. But if you just must must must have OEM, order it from that site. I am guilty of this sometimes even though it is so much more expensive.
Anywho good luck! hope this helps.
Anywho good luck!