Honda XL200 2001 Shop Manual Download

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XL2 0 0

1-3

ITEM

SPECIFICATION

DRIVE TRAIN

Clutch

Multi-plate, wet

Transmission

5 Speed, constant mesh

Primary reduction

3.0909 (68/22)

Gear ratio

2.7692 (36/13)

Gear ratio

1.7222 (31/18)

Gear ratio

1.2631 (24/19)

Gear ratio

1.0000 (22/22)

Gear ratio

0.851 (23/27)

Final reduction

3.230 (13/42)

Gear shift pattern

1-N-2-3-4-5

ELECTRICAL

Ignition system

CDI (Capacitive Discharged Ignition)

Ignition timing

Initial

15°BTDC at 1.300 min

-1

(rpm)

Full advance

32°BTDC at 5.000 min

-1

(rpm)

Alternator output

0,125 kW/5.000 min

-1

(rpm)

Spark plug

DP8EA-9 (NGK) X24EP-U9 (DENSO)

Spark plug gap

0.8-0.9 mm (0.03 - 0.04 in)

Headlight (low/High)

12 V-35/35 W

Tail/stop light

12 V-5/21 W

Turn signal light

12 V-10 W x 4

Instrument light

12 V-3.4 W

Neutral indicator

12 V-3.4 W

High beam indicator

12 V-1.7 W

Turn signal indicator

12 V-3.4 W

GENERAL INFORMATION

Summary of Contents for XL200 2001

Page 1: ...SH O PMANU AL XL200 MOTO HONDA DA AMAZÔNIA LTDA 2001 1 ...

Page 2: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 3: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 4: ...FICATION 1 The frame serial number is stamped on the right side of the steering head 2 The engine serial number is stamped on the lower left side of the crankcase 3 The carburetor identification number is on the right side of the carburetor body ...

Page 5: ...e motorcycle Use the special tools designed for this product Install new gaskets O rings cotter pins lock plates etc when reassembling When torquing bolts or nut begin with the lager diameter or inner bolts first and tighten to the specified torque diagonally unless a particular sequence is specified Clean parts in non flammable or high flash solvent upon disassembly Lubricate any sliding surfaces...

Page 6: ...6 13 Trail 95 mm 3 7 in Front fork oil capacity 384 cc ENGINE Type 4 Stroke 0HC Cylinder arrangement Single cylinder 15 inclinded from vertical Bore x Stroke 63 5 x 62 2 mm 2 50 x 2 45 in Displacement 196 9 cm3 12 01 cu in Compression ratio 9 0 1 Valve train Chain driven OHC Over Head Camshaft Oil capacity 1 4 liter 1 5 US qt 1 2 Imp qt Lubrication system Forced pressure and wet sump Air filtratio...

Page 7: ...2 3 4 5 ELECTRICAL Ignition system CDI Capacitive Discharged Ignition Ignition timing Initial 15 BTDC at 1 300 min 1 rpm Full advance 32 BTDC at 5 000 min 1 rpm Alternator output 0 125 kW 5 000 min 1 rpm Spark plug DP8EA 9 NGK X24EP U9 DENSO Spark plug gap 0 8 0 9 mm 0 03 0 04 in Headlight low High 12 V 35 35 W Tail stop light 12 V 5 21 W Turn signal light 12 V 10 W x 4 Instrument light 12 V 3 4 W...

Page 8: ...t linkage Clutch center lock nut 1 16 95 9 5 68 Gearshift drum stopper arm bolt 1 6 12 1 2 9 Crankcase crankshaft Bearing set plate socket bolt 2 6 12 1 2 9 Alternator Flywheel bolt 1 10 75 7 5 54 Ignition system Pulse generator mounting bolt 2 5 5 0 5 3 6 Electric starter starter clutch Starter clutch mounting socket bolt 6 6 16 1 6 12 XL2 0 0 1 4 GENERAL INFORMATION Torque Torque Fasteners type ...

Page 9: ...ber upper mounting bolt 1 10 45 4 5 32 Rear shock absorber lower mounting bolt 1 10 45 4 5 32 Shock arm mounting bolt Frame side 1 10 45 4 5 32 Shock link mounting bolt Shock arm side 1 10 45 4 5 32 Shock link mounting bolt Swingarm side 1 10 45 4 5 32 Brake system Brake hose oil bolt 2 10 35 3 5 25 Front brake caliper mounting bolt 2 8 31 3 1 22 Other fasterners Side stand pivot bolt 1 10 31 3 1 ...

Page 10: ...t cutter 33 mm 32 EX 07780 0012900 interior cutter 30 mm 60 IN EX 07780 0014000 cutter holder 5 5 mm 07781 0010101 Clutch Gearshift linkage Pin driver 3 0 mm 07744 0010200 Clutch center holder 07GMB KT70100 Lock nut wrench 20 x 24 mm 07716 0020100 Extension bar 07716 0020500BR Gear holder 07724 0010200 Alternator starter clutch Flywheel holder 07725 0040000BR Rotor puller 07733 0020001BR Inner han...

Page 11: ... Pilot 28 mm 07746 0041100 Front wheel suspension steering Bearing remover head 15 mm 07746 0050400BR Bearing remover shaft 07746 0050100BR Steering stem socket 07916 KA50100 Steering stem driver 07946 4300101BR Fork seal driver 07947 3710101BR Rear Wheel Suspension Bearing remover head 17 mm 07746 0050500BR Bearing remover shaft 07746 0050100BR Needle bearing remover 07931 MA70000BR Spherical bea...

Page 12: ... molybdenum oil Each O ring Each ball and needle bearing Each oil seal lip Camshaft lobes Molybdenum disulfide Piston pin outer surface oil a mixture of 1 2 Valve stem Valve guide sliding surface engine oil and 1 2 Valve guide Valve stem slinding surface molybdenum disulfide M3 M5 gear inner surface grease C1 C2 C4 gear inner surface Clutch outer guide outer surface Crankcase bearing set plate soc...

Page 13: ...hrottle cable slider surface Rear brake arm pivot shaft Side stand pivot sliding surface Drive chain tensioner roller sliding surface Each dust seal lips Fork socket bolt threads Locking agent Exhaust pipe protector bolt threads Muffler protector bolt threads Fork cap O rings Fork fluid Fork oil seal lips Handle grip Honda Bond A or Master cylinder piston cups equivalent Caliper piston seals DOT 4...

Page 14: ...all surfaces thoroughly before applying tape Do not use wires or harnesses with damaged insulation Rapair the wires by wrapping them with protective tape Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Keep wire harnesses away from the exhaust pipes and other hot parts Be sure grommets are seated in their grooves properly After clamping check each ...

Page 15: ...XL2 0 0 GENERAL INFORMATION 1 11 ...

Page 16: ...XL2 0 0 1 12 GENERAL INFORMATION ...

Page 17: ...XL2 0 0 GENERAL INFORMATION 1 13 ...

Page 18: ...XL2 0 0 1 14 GENERAL INFORMATION ...

Page 19: ...XL2 0 0 GENERAL INFORMATION 1 15 NOTES ...

Page 20: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 21: ...ea The exhaust contains poisonous carbon monoxide gas that can cause loss of conciousness and may lead to death Run the engine in an open area or with an exhaust evacuation system in an eclosed area Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to th...

Page 22: ...XL2 0 0 LUBRICATION 2 0 CRANKSHAFT OIL FILTER ROTOR OIL PUMP COUNTERSHAFT MAIN SHAFT CAMSHAFT ...

Page 23: ...il leak Worn valve guide or seal Worn piston rings or incorrect piston ring installation Oil not added frequently enough Worn cylinder Oil contamination Oil not change often enough Faulty head gasket Worn piston rings XL2 0 0 2 2 LUBRICATION ...

Page 24: ...GE OIL FILTER SCREEN t NOTE Remove the oil filter screen cap Operate the starter motor 2 3 seconds to completely drain any residual oil Clean the oil filter screen Drain the oil while the engine is warm and the motorcycle is on its side stand The oil filter screen and spring will come out when the oil filter screen plug is removed Use box wrench or 24 mm socket to prevent rounding the corners on t...

Page 25: ...ed torque TORQUE 15 N m 1 5 kg m 11 ft lb Fill the crankcase with the recommended engine oil Engine oil capacity 1 1 liter 1 16 US qt 0 97 lmp qt at draining Start the engine and let it idle for 2 3 minutes and stop the engine With the motorcycle upright on level ground make sure the oil level is at the upper mark Be sure there are no oil leaks ENGINE OIL FILTER ROTOR Remove the right crankcase co...

Page 26: ...e pump mounting screws are accessible through the gear cover Remove the two screws and the oil pump INSPECTION Measure the outer rotor to body clearance SERVICE LIMIT 0 25 mm 0 010 in LUBRICATION 2 5 DISASSEMBLY Remove the following screws oil pump cover gasket inner and outer rotors bolts gear cover rotor shaft pump gear ...

Page 27: ...m 0 008 in ASSEMBLY LUBRICATION 2 6 Measure the end clearance NOTE SERVICE LIMIT 0 15 mm 0 006 in Measure the clearance with the gasket installed 1 GEAR COVER 8 PUMP GEAR 9 ROTOR SHAFT 7 INNER ROTOR 6 GASKET 4 PUMP COVER 5 SCREW 3 OUTER ROTOR 2 PUMP BODY 10 BOLT ...

Page 28: ...outer and inner rotors Install the gasket and pump cover NOTE Install and tighten the screws TORQUE 3 N m 0 30 kg m 2 2 ft lb Check for smooth operation of the oil pump Align the boss on the cover with the groove in the pump body INSTALLATION Install new O rings into the crankcase Install the oil pump and tighten the screws Install the right crankcase cover ...

Page 29: ...XL2 0 0 2 8 LUBRICATION NOTES ...

Page 30: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 31: ...PRESSION 3 15 SERVICE INFORMATION GENERAL Engine oil level check page 2 3 Engine oil change page 2 3 Oil filter screen clean page 2 3 Throttle grip free play 2 6 mm 1 16 1 4 in Spark plug DP8EA 9 NGK X24EP U9 DENSO Spark plug gap 0 8 0 9 mm 0 03 0 04 in Valve clearance IN EX 0 10 mm 0 004 in Idle speed 1 400 100 rpm Cylinder compression 1 350 kPa 13 5 kg cm2 192 psi 450 min 1 rpm Frame Clutch leve...

Page 32: ...XL2 0 0 3 2 TORQUE VALUES Fuel strainer cup 4 N m 0 4 kg m 2 9 ft lb Rear axle nut 90 N m 9 0 kg m 65 ft lb TOOLS Tappet adjusting wrench 07708 0030300BR Spoke nipple wrench 07701 0020300 MAINTENANCE ...

Page 33: ...0 Stop light switch Adjust 3 000 Clutch cable Check adjust and lubricate 3 000 Battery Check and refill 1 000 Headlight beam Adjust 3 000 Side stand Check 3 000 Front and rear suspension Check 6 000 Front suspension oil Change 12 000 Tires Check and calibrate 1 000 Wheel rims and spokes Check and adjust 3 000 Steering column bearings Check adjust and lubricate 9 000 Screws nuts and fasteners Check...

Page 34: ...ry FUEL STRAINER SCREEN t Turn the fuel valve OFF Remove the fuel cup O ring and strainer screen and drain the contents of the cup into a suitable container Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in your working area or where gasoline is stored Wash the strainer screen a...

Page 35: ...R CLEANER Remove the left side cover Remove the following four screws four washers air cleaner case cover element setting nut air cleaner element Inspect and clean the element according to the Maintenance Schedule Wash the element away any accumulated dust or dirt by gently squeezing it in non flammable or high flush point solvent t h Install the element in the reverse order of removal Cleaning th...

Page 36: ... NOTE Remove the valve adjuster covers Adjust the valve clearance while the engine is cold below 35 C 95 F 3 6 SPARK PLUG Clean any dirt from around the spark plug base Disconnect the spark plug cap and remove the spark plug Visually inspect the spark plug electrodes for wear The center electrode should have square edges and the side electrode should have a constant thickness Discard the spark plu...

Page 37: ...r covers Check the O rings is in good condition istall the timing hole cap CARBURETOR IDLE SPEED NOTE Shift the transmission into neutral and support the motorcycle level ground Inspect and adjust the idle speed after all engine maintenance items have been performed and are within the specifications The engine must be warm for accurate idle speed inspection and adjustment Warm up the engine for ab...

Page 38: ...TORQUE 90 N m 9 0 Kg m 65 ft lb Tighten the adjusting nuts Recheck the drive chain slack and free wheel rotation After adjustment the adjuster s alignment mark is within the red zone of the chain wear indicator label replace the drive chain and both sprockets Never inspect or adjust the drive chain while the engine is running When the drive chain becomes extremely dirty it should be cleaned before...

Page 39: ... upper level t The battery electrolyte contains sulfuric acid Protect your eyes skins and clothing If electrolyte gets in your eyes flush them thoroughly with water and get prompt medical attention Add only distilled water Tap water will shorten the service life of the battery Inspect the battery fluid level in each cell If the chain slider becomes worn through to the swingarm the chain will begin...

Page 40: ... the 䉭 mark on the brake panel when the brake lever or pedal is applied MAINTENANCE BRAKE PADS SHOES WEAR FRONT BRAKE PAD WEAR Check the brake pads for wear Replace the brake pads if the wear line on the pads reaches the edge of the brake disc h Always replace the brake pads as a set to assure even disc pressure BRAKE SYSTEM Inspect the brake hose and fittings for deterioration cracks and signs of...

Page 41: ...out if the adjusting nut is seated on the brake arm pin Always adjust the brake pedal free play after adjusting brake pedal height After adjusting the brake pedal height check the rear brake light switch and brake pedal free play and adjust if necessary BRAKE LIGHT SWITCH NOTE Adjust the brake light switch so that the brake light will come on when the brake pedal is depressed and brake engagement ...

Page 42: ...sure the clutch lever free play at the tip of the clutch lever FREE PLAY 10 20 mm 2 5 3 4 in An improperly adjusted headlight may blind oncoming drivers or it may fail to light the road for a safe distance Minor adjustments are made with the upper adjuster Pull the cover back Loosen the lock nut and turn the adjuster Tighten the lock nut and install the cover Major adjustments are made with the lo...

Page 43: ...e the side stand is not bent SUSPENSION Front Check the action if the fork by compression the suspension several times Check the entire for assembly for sign of damage Replace any components which cannot be repaired Tighten all nuts and bolts to the specified torque values page 1 5 Rear Check the operation of the shock absorber by pressing down on the end of the seat several times Support the moto...

Page 44: ...that all cotter pins and safety clips are in place WHEELS TIRES Check the tires for cuts imbedded nails or other damage Check and adjust the tire pressure NOTE Recommended tire pressure Check the tread depth at the center of the tires Replace the tire if the tread depth reaches the service life Minimun tread depth Front 3 0 mm 0 12 in Rear 3 0 mm 0 12 in Inspect the wheel rims and spokes for damag...

Page 45: ...see section 11 or 22 CYLINDER COMPRESSION Warm up the engine Stop the engine and remove the spark plug Insert the compression gauge Place the choke lever fully closed position Open the throttle grip fully and crank the engine with the starter motor NOTE Cylinder compression 1 350 kPa 13 5 kg cm2 192 psi Low compression can be caused by Improper valve adjustment Valve leakage Worn piston ring or cy...

Page 46: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 47: ...ll not operate smoothly and may stick or bind Gasoline is extremely flammable and is explosive under certains condition Work in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the work area or where gasoline stored If the engine must be running to do some work make sure the area us well ventilated Never run the engine in an enclosed area The exhaust contain...

Page 48: ...XL2 0 0 FUEL SYSTEM 4 0 ...

Page 49: ...ch mixture Choke valve in ON position Float valve faulty Float level too high Air jets clogged Flooded carburetor Engine stall hard to start rough idling Fuel line restricted Ignition malfunction Fuel mixture too lean rich pilot screw adjustment Fuel contaminated deteriorated Intake air lead Idle speed misadjusted Float level misadjusted Fuel tank breather hole clogged Afterburn when engine brakin...

Page 50: ...tank support bracket Loosen the drain screw and drain the fuel into an approved gasoline container Loosen the cable lock nuts and remove the throttle cable from the throttle drum Loosen the cable clamp screw and disconnect the choke cable Loosen the carburetor insulator band and connecting tube band screws then remove the carburetor upward DISASSEMBLY Remove the three screws and the accelerator di...

Page 51: ...eness Remove the following Screws Float chamber Float pin Float Float valve Baffle plate Inspect the float valve seat for grooves and nicks Check the operation of the float valve FUEL SYSTEM FLOAT CHAMBER SCREW ROD DIAPHRAGM FLOAT VALVE FLOAT PIN BAFFLE PLATE FLOAT VALVE SEAT FLOAT VALVE ...

Page 52: ...llowing Screws Carburetor top cover Spring Throttle link attaching screw Nut washer Washer Throttle drum spring Throttle valve assembly SPRING CARBURETOR TOP COVER SCREW NUT WASHER SCREW THROTTLE DRUM SPRING WASHER THROTTLE VALVE ASSEMBLY ...

Page 53: ...if necessary Damaged the pilot screw seat will occur if the screw is tightened against the seat Do not try to remove the float valve seat from the carburetor body Before removing the pilot screw record the number of turns until it seats lightly Use this as a reference for reinstallation Remove the jet needle by pressing it out from the throttle valve side carefully Remove the spring and link arm R...

Page 54: ...the throttle valve for wear or scratches Inspect the jet needle for damage Remove the following Two screws Cover Spring O ring Diaphragm Blow open all carburetor body openings with compressed air COVER SCREW JET NEEDLE THROTTLE VALVE ...

Page 55: ...HOLDER 28 MAIN JET 27 BAFFLE PLATE 24 O RING 23 FLOAT CHAMBER 22 SCREW 20 SPRING 18 SCREW 19 DIAPHRAGM COVER 21 DIAPHRAGM 30 FLOAT VALVE 34 CARBURETOR BODY 2 SPRING 4 SPRING 5 THROTTLE DRUM 7 SCREW 8 CARBURETOR TOP COVER 3 DIAPHRAGM 26 FLOAT 25 FLOAT PIN 6 CO VER 10 LINK ARM 14 SCREW 9 SCREW 12 SPRING 13 SET PLATE 16 JET NEEDLE 15 SPRING 11 SCREW 17 THROTTLE VALVE ...

Page 56: ...ition as noted during removal Install the following Float valve Float Float pin Baffle plate FLOAT LEVEL INSPECTION With the float valve seated and the float arm just touching the valve measure the float level using the float level gauge Float level 14 0 mm 0 55 in TOOL Float level gauge 07401 0010000BR NOTE The float cannot be adjusted Replace the float assembly if the level is out of specificati...

Page 57: ...ng the overflow tube on the chamber with the hole in the baffle plate as shown Install and tighten the float chamber screws Install the accelerator diaphragm and dust boot Install the diaphragm spring and cover Tighten the cover screws FUEL SYSTEM SCREWS FLOAT CHAMBER O RING DIAPHRAGM BOOT SPRING SCREWS ...

Page 58: ...ate then install the set plate into the throttle valve Install and tighten the screws Install the link arm and spring Install the throttle valve to the carburetor body Install the washer throttle drum and spring SCREWS SET PLATE THROTTLE VALVE JET NEEDLE SPRING LINK ARM SPRING WASHER THROTTLE DRUM WASHER ...

Page 59: ...r and nut then tighten the nut securely Install and tighten the link arm screw Install the spring as shown Check the linkage operation as follow Open the throttle slightly by pressing on the throttle drum Then release the throttle Make sure that there is no drag FUEL SYSTEM NUT WASHER SCREW THROTTLE LINK SPRING THROTTLE DRUM ...

Page 60: ...ing Air vent tube Drain tube Fuel tube Installation Installation is essentially the reverse order of removal Install the carburetor by aligning its intake pipe boss with the insulator groove NOTE Route the throttle and choke cables properly SCREW TOP COVER GASKET FUEL TUBE AIR VENT TUBE DRAIN TUBE INSULATOR SCREWS ALIGN ...

Page 61: ...nufacturer s operating instructions 4 Start the engine and adjust the idle speed with the throttle stop screw Idle speed 1 400 100 min 1 rpm Damaged the pilot screw seat will occur if the screw is tightened against the seat The pilot screw is factory pre set and not adjustment can be done unless it is replaced The engine must be warm for accurate adjustment Then minutes of stop and go riding is su...

Page 62: ... the engine speed drops 50 min 1 rpm 9 Turn the pilot screw 1 2 turn in from the position obtain step 8 10 Adjust the idle speed with the throttle stop screw AIR CLEANER CASE REMOVAL Remove the following Seat Both side covers Battery Starter relay switch Muffler Loosen the air connecting tube band screw Remove the bolts and regulator rectifier unit Remove the air cleaner case mounting bolts Pull t...

Page 63: ...hroud and fuel tank mounting bolts then remove the fuel tank Installation is in the reverse order of removal NOTE After assembly make sure there are not fuel leaks Gasoline is extremely flammable and is explosive under certain condition Work in a well ventilated area Do not smoke or allow flames or sparks in the work area or where gasoline is stored Wipe up spilled gasoline at once ...

Page 64: ...XL2 0 0 FUEL SYSTEM 4 17 NOTES ...

Page 65: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 66: ...d The following components require engine removal for service Crankshaft Section 10 Cylinder head valves Section 6 Cylinder piston Section 7 Gearshift drum Section 10 Transmission Section 10 The following components can be serviced with the engine installed in the frame Alternator Section 9 Camshaft Section 6 Carburetor Section 4 Clutch Section 8 Gearshift linkage Section 8 Oil pump Section 2 5 1 ...

Page 67: ...5 0 XL2 0 0 ENGINE REMOVAL INSTALLATION ...

Page 68: ...ator and pulse generator connector Remove the gearshift pedal Remove the bolts and drive sprocket cover Remove the following Fixing plate bolts Fixing plate Drive chain Drive sprocket ENGINE REMOVAL INSTALLATION CLUTCH CABLE EXHAUST PIPE CARBURETOR CONNECTOR GEARSHIFT PEDAL DRIVE SPROCKET COVER BOLTS FIXING PLATE DRIVE SPROCKET DRIVE CHAIN BOLTS ...

Page 69: ...NSTALLATION Install the engine in the frame and install the rear engine hanger bolts and collars NOTE Install the nuts on the rear hanger bolts Install the long collar to the right shorter collar to the left Install the front engine hanger plate bolts and nuts GROUND CABLE STARTER MOTOR CABLE ENGINE HANGER PLATE NUT BOLT NUT BOLT COLLAR NUT BOLT HANGER PLATE ...

Page 70: ... m 20 ft lb Install the drive sprocket and fixing plate onto the countershaft and tighten the bolts Install the starter motor terminal cable and tighten the terminal nut securely Install the ground cable and tighten the bolt ENGINE REMOVAL INSTALLATION NUT BOLT REAR AND UNDER FRONT AND TOP REAR AND TOP FRONT AND TOP DRIVE CHAIN BOLTS FIXING PLATE DRIVE SPROCKET GROUND CABLE BOLTS STARTER MOTOR CAB...

Page 71: ... the following Exhaust pipe Carburetor Spark plug cap Clutch cable Route the wire harness and cables properly After installation perform the following adjustment Clutch cable adjustment Drive chain slack adjustment Throttle grip free play Rear brake free play Fill the crankcase with recommended engine oil to the proper level CONNECTOR GEARSHIFT PEDAL DRIVE SPROCKET COVER BOLTS CLUTCH CABLE EXHAUST...

Page 72: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 73: ...8 0 003 Valve seat width 1 1 1 3 0 043 0 051 1 5 0 06 XL2 0 0 6 SERVICE INFORMATION 6 1 TROUBLESHOOTING 6 2 CYLINDER HEAD COVER CAMSHAFT REMOVAL 6 3 CYLINDER HEAD REMOVAL 6 6 CYLINDER HEAD DISASSEMBLY 6 7 VALVE GUIDE REPLACEMENT 6 9 VALVE SEAT INSPECTION REFACING 6 10 CYLINDER HEAD ASSEMBLY 6 13 CYLINDER HEAD INSTALLATION 6 14 CAMSHAFT CYLINDER HEAD COVER INSTALLATION 6 15 SERVICE INFORMATION GENE...

Page 74: ...5 kg m 11ft lb 12 N m 1 2 kg m 9ft lb 12 N m 1 2 kg m 9ft lb 10 N m 1 0 kg m 7ft lb 10 N m 1 0 kg m 7ft lb 4 N m 0 4 kg m 3ft lb 8 N m 0 8 kg m 6ft lb 6 N m 0 6 kg m 4ft lb 10 N m 1 0 kg m 7ft lb 14 N m 1 4 kg m 10ft lb 27 N m 2 7 kg m 20ft lb ...

Page 75: ...d or stethoscope If the performance is poor at low speeds check for white smoke in the crankcase breather tube If the tube is smoky check for a seized piston ring Compression too low hard starting or poor per Excessive smoke formance at low speed Worn valve stem or valve guide Valves Damaged stem seal Incorrect valve adjustment Faulty cylinder or piston Section 7 Burned or bent valves Incorrect va...

Page 76: ...ton is at T D C on the compression stroke by checking for clearance at both rocker arms If the piston is not at T D C on the compression stroke rotate the crankshaft 360 degrees counterclockwise and recheck Remove the cam sprocket cover Remove the cam sprocket bolts by holding the crankshaft Remove the cam sprocket from the camshaft flange then remove the cam chain from the sprocket NOTE Suspend t...

Page 77: ... it Clean off any sealant material from the head cover and cylinder head mating surface CAMSHAFT INSPECTION Turn the outer races of camshaft bearings with your finger The bearings should turn smoothly and quietly Also check that the inner races fit tightly on the camshaft Measure the height of each cam lobe and inspect it for wear or damage SERVICE LIMIT Intake 31 30 mm 1 232 in Exhaust 31 20 mm 1...

Page 78: ... INSPECTION Inspect the rocker arm slipper surfaces for excessive wear Inspect the rocker arms and shafts for wear or damage NOTE Measure the I D of each rocker arm SERVICE LIMIT 12 05 mm 0 474 in Measure the O D of each rocker arm shaft SERVICE LIMIT 11 93 mm 0 470 in Calculate the rocker arm to shaft clearance SERVICE LIMIT 0 08 mm 0 003 in If the rocker arms require servicing or replacement ins...

Page 79: ...ket dowel pins Clean off any gasket material from the cylinder head and cylinder mating surfaces Remove the cam chain tensioner Check the cam chain tensioner for excessive wear or damage Check the cam chain guide for excessive wear or damage CYLINDER HEAD VALVES CYLINDER HEAD SOCKET BOLT WASHER CAM CHAIN GUIDE GASKET DOWEL PIN CAM CHAIN TENSIONER CAM CHAIN GUIDE ...

Page 80: ...compressor and remove the following spring retainers outer and inner valve springs spring seats inlet and exhaust valve NOTE Remove the carbon deposits from the combustion chamber Clean off any gasket materials from the cylinder head surface Mark all disassembled parts to ensure correct reassembly INSPECTION CYLINDER HEAD Check the spark plug hole and valve area for cracks Check the cylinder head ...

Page 81: ... reaming Measure and record each valve guide I D with a ball gauge or inside micrometer SERVICE LIMIT IN EX 5 50 mm 0 217 in Calculate the stem to guide clearance SERVICE LIMIT IN 0 06 mm 0 002 in EX 0 08 mm 0 003 in NOTE If the stem to guide clearance exceeds the service limit determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace the guides as ...

Page 82: ...avy gloves when handling the heated cylinder head h Support the cylinder head and drive out the valve guide from the valve port with a valve guide driver h TOOL Valve guide driver 5 5 mm Avoid damaging the cylinder head Do not use a torch to heat the cylinder head it may cause warping Place a new O ring on the new valve guide Install a valve guide from the top of the cylinder head h TOOL Valve gui...

Page 83: ... exhaust valves thoroughly to remove the carbon deposits Apply light coating if Prussian Blue to the valve seats Lap the valves and seats using a rubber hose or other hand lapping tool Remove the tool and inspect the width of each valve seat STANDARD 1 1 1 3mm 0 04 0 05 in SERVICE LIMIT 1 5 mm 0 06 in If the valve seat is too wide too narrow or has low spots the seat must be ground h The valve can...

Page 84: ...ended to correct a worn valve seat NOTE Follow the refacer manufacturer s operating instructions Use a 45 degree cutter to remove ant roughness or irregularities from the seat NOTE Reface the valve seat with a 45 degree cutter when a valve guide is replaced Using 32 degree cutter remove 1 4 of the exiting valve seat material VALVE GUIDE REAMER ...

Page 85: ...D SEAT WIDTH 1 1 1 3 mm 0 04 0 05 in Apply thin coat of Prussian Blue to the valve seat Press the valve through the valve guide and onto the seat to make a clear pattern NOTE If the contact area is too high on the valve the seat must be lowered using a 32 degree flat cutter The location of the valve seat in relation to the valve face is very important for good sealing If the contact area is too lo...

Page 86: ...ing seats and new valve stem seals Lubricate each valve stem with engine oil Insert the intake and exhaust valve into the valve guides Install the valve spring seats springs and retainers NOTE Install the valve springs with the narrow pitch end facing the combustion chamber Compress the valve spring and install the valve cotters h TOOL Valve spring compressor To prevent loss of tension do not comp...

Page 87: ...e cam chain tensioner washer and pivot bolt Tighten the pivot bolt to the specified torque TORQUE 10 N m 1 0 kg m 7 ft lb CYLINDER HEAD INSTALLATION Place the bottom end of the cam chain guide into the groove in the left crankcase and its bosses in the grooves in the cylinder upper surface NOTE Make sure that the cam chain is properly installed on the timing sprocket as shown CYLINDER HEAD VALVES ...

Page 88: ... the specified torque TORQUE 10 N m 1 0 kg m 7 ft lb CAMSHAFT CYLINDER HEAD COVER INSTALLATION CYLINDER HEAD COVER ASSEMBLY Apply oil to the rocker arm shafts Install the rocker arms and rocker arm shafts in the cylinder head cover With the rocker arm shaft reliefs on the inside install the rocker arm shaft plate Tighten the setting screw securely CAMSHAFT CYLINDER HEAD COVER INSTALLATION Install ...

Page 89: ... Do not apply sealant to the oil passage Apply oil to the cap nut threads Install the new sealing washers cap nuts and flange bolts Tighten the cap nut in a crisscross pattern in 2 3 steps TORQUE 27 N m 2 7 kg m 20 ft lb Tighten the flange bolts and setting bolt in a gradual crisscross pattern TORQUE 10 N m 1 0 kg m 7 ft lb Align the T mark on the flywheel with the index mark on the left crankcase...

Page 90: ...ing the crankshaft Apply oil to the cam sprocket bolts and install them Tighten the bolts to the specified torque TORQUE 12 N m 1 2 kg m 9 ft lb Turn the tensioner shaft clockwise with a small screwdriver to retract the tensioner and hold it in the fully retracted position NOTE Wedge the tensioner shaft with a piece of wire to hold the tensioner The tensioner will forced out by the spring when it ...

Page 91: ... O ring onto the sprocket cover Install the sprocket cover with its oil pocket facing down as shown Install and tighten the cover bolts securely Apply clean engine oil to the O rings of the adjusting hole caps Install and tighten the cap bolts TORQUE 15 N m 1 5 kg m 11 ft lb Install and tighten the timing hole cap and crankshaft hole cap TORQUE Timing hole cap 6 N m 0 6 kg m 4 ft lb Crankshaft hol...

Page 92: ...XL2 0 0 CYLINDER HEAD VALVES 6 19 NOTAS ...

Page 93: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 94: ...001 0 002 0 09 0 004 Second 0 015 0 045 0 0006 0 0017 0 09 0 004 Top 0 20 0 35 0 008 0 014 0 5 0 02 Second 0 35 0 50 0 014 0 020 0 7 0 03 Oil ring side rail 0 20 0 70 0 008 0 028 0 9 0 04 Cylinder to piston clearance 0 010 0 040 0 0004 0 0016 0 10 0 004 Connecting rod small end I D 15 010 15 028 0 5909 0 5917 15 06 0 593 Connecting rod to piston pin clearance 0 010 0 034 0 0004 0 0013 0 10 0 004 X...

Page 95: ...XL2 0 0 CYLINDER PISTON 7 0 ...

Page 96: ...eck the cylinder for warpage with a straight edge and a feeler gauge SERVICE LIMIT 0 10 mm 0 004 in Inspect the cylinder bore for wear or damage Measure the cylinder I D at three places middle and bottom area of piston travel and in two directions at right angles to each other SERVICE LIMIT 63 60 mm 2 504 in Measure the piston O D page 7 4 and calculate the piston to cylinder clearance using the m...

Page 97: ... piston pin clip with pliers Press the piston pin out of the piston from the opposite side with your finger Remove the piston Remove the piston rings being careful not to damage them NOTE Spread each piston ring and remove it by lifting up at a point opposite side PISTON PISTON RING INSPECTION Clean the top of the piston Inspect for evidence of pitting or deterioration Use and old piston ring to r...

Page 98: ...cond 0 7 mm 0 03 in Oil 0 9 mm 0 04 in Measure the piston O D at 10 mm 0 4 in from the bottom of the skirt SERVICE LIMIT 63 42 mm 2 495 in Compare this measurement against the service limit and use it to calculate piston to cylinder clearance see page 7 2 Measure the piston pin bore I D in two direction at right angle to each other SERVICE LIMIT 15 04 mm 0 592 in Measure the piston pin O D at the ...

Page 99: ...each other as shown After installation the piston rings should be free to rotate in the grooves Insert the outside surface of the ring into the proper ring groove and roll the ring around in the groove to make sure that the ring has a free fit around the piston s circumference Be careful not to damage the piston and piston rings during installation Do not interchange the top ring with the second r...

Page 100: ...any gasket material from the cylinder gasket surface on the crankcase NOTE Do not damage the gasket surface Do not let any material fall into the crankcase CYLINDER INSTALLATION Install the following Dowel pins New cylinder gasket Coat the cylinder piston rings grooves and piston with clean engine oil Install the cylinder while compressing the piston rings with your finger NOTE Install the cylinde...

Page 101: ...XL2 0 0 CYLINDER PISTON 7 7 NOTAS ...

Page 102: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 103: ... If the shift forks drum and transmission require servicing remove the engine and separate the crankcase Section 9 SPECIFICATIONS UNIT mm in ITEM STANDARD SERVICE LIMIT Lever free play 10 20 2 5 3 4 Spring free length 37 9 1 492 34 9 1 374 Disc thickness 2 92 3 08 0 115 0 121 2 60 0 102 Plate warpage 0 20 0 008 Clutch outer I D 28 000 28 013 1 1023 1 1028 28 04 1 1039 Clutch outer guide I D 19 983...

Page 104: ...XL2 0 0 CLUTCH GEARSHIFT LINKAGE 8 0 10 N m 1 0 kg m 7 ft lb 12 N m 1 2 kg m 9 ft lb 85 N m 8 5 kg m 61 ft lb 95 N m 9 5 kg m 68 ft lb ...

Page 105: ...ity or oil additive used Clutch slips Clutch lifter sticking Worn clutch discs Weak clutch springs No clutch lever free play Hard to shift Misadjusted clutch cable Damaged or bent shift fork Bent shift fork shaft Worn gear dogs Incorrect engine oil viscosity Transmission jumps out of gear Damaged or bent shift fork Bent shift fork shaft Damaged stopper arm Worn gear engagement dogs or slots Gearsh...

Page 106: ...fter lever and return spring Visually inspect the clutch arm for bending or damage Install the clutch arm on the right crankcase cover in the reverse order of removal NOTE Install the return spring as shown CLUTCH REMOVAL Remove the oil pump page 2 5 Remove the screws and oil filter rotor cover Hold the primary drive and driven gear with a gear holder remove the lock nut using special tools Remove...

Page 107: ...nch 20 x 24 mm Extension bar Remove the following Washer Clutch center Clutch discs Clutch plates Pressure plate Remove the spline washer clutch outer and clutch outer guide Remove the primary drive gear and woodruff key from the crankshaft NOTE Do not lose the woodruff key CLUTCH GEARSHIFT LINKAGE LIFTER GUIDE LIFTER PLATE BOLT SPRING EXTENSION BAR LOCK NUT WRENCH CLUTCH CENTER HOLDER CLUTCH OUTE...

Page 108: ...ry Measure the clutch spring free length SERVICE LIMIT 34 9 mm 1 37 in NOTE Clutch springs should be replaced as a set if one or more is beyond the service limit Check for plate warpage on a surface plate using a feeler gauge SERVICE LIMIT 0 20 mm 0 008 in Replace the clutch discs if they show signs of scoring or discoloration Measure the clutch disc thickness SERVICE LIMIT 2 6 mm 0 10 in NOTE Clu...

Page 109: ...0 788 in Measure the mainshaft O D at clutch outer guide SERVICE LIMIT 19 95 mm 0 785 in Check the clutch center for nicks or indentation made by the clutch plates INSTALLATION Install the woodruff key on the crankshaft Install the primary drive gear aligning the gear groove with the woodruff key Apply oil to the primary drive gear teeth CLUTCH GEARSHIFT LINKAGE CLUTCH OUTER GUIDE CLUTCH OUTER MAI...

Page 110: ...e lock washer with the OUTSIDE mark facing out Apply oil to the clutch center lock nut threads Install the lock nut with the chamfered side facing in Hold the clutch center with the clutch center holder tighten the lock nut to the specified torque TORQUE 95 N m 9 5 kg m 68 ft lb CLUTCH OUTER CLUTCH OUTER GUIDE SPLINE WASHER LOCK WASHER CLUTCH CENTER LOCK NUT EXTENSION BAR CLUTCH CENTER HOLDER 6 CL...

Page 111: ...bolts in a crisscross pattern in 2 3 steps Install the clutch lifter guide Clean the oil filter rotor Check the oil through pipe operates freely without binding If necessary remove the B clip and replace faulty part CLUTCH GEARSHIFT LINKAGE BOLT LIFTER PLATE CLUTCH CENTER LOCK NUT BOLT STAKE LIFTER GUIDE OIL FILTER ROTOR ...

Page 112: ...n tighten the lock nut to the specified torque TORQUE 85 N m 8 5 kg m 61 ft lb Install the oil pump Check the oil filter cover gasket is in good condition replace if necessary Install the gasket onto the oil filter cover Install the oil filter rotor cover and tighten the screws securely GEARSHIFT LINKAGE REMOVAL Remove the oil pump Remove the clutch page 8 3 Remove the bolt and gearshift pedal OIL...

Page 113: ...g for damage and inspect the gearshift spindle for wear or bending INSTALLATION Install the stopper arm return spring and stopper arm Install and tighten the stopper arm bolt to the specified torque TORQUE 12 N m 1 2 kg m 9 ft lb CLUTCH GEARSHIFT LINKAGE GEARSHIFT SPINDLE RETURN SPRING STOPPER ARM BOLT STOPPER PLATE STOPPER PLATE BOLT GEARSHIFT SPINDLE STOPPER ARM BOLT STOPPER ARM RETURN SPRING ...

Page 114: ... tighten the stopper plate bolt Install the washer onto the gearshift spindle Install the gearshift spindle with the spindle return spring attached to the lug on the crankcase securely Install the gearshift pedal and tighten the bolt Install the clutch Install the oil pump RIGHT CRANKCASE COVER INSTALLATION Install the dowel pins and new gasket STOPPER PLATE ALIGN DOWEL PIN GEARSHIFT SPINDLE WASHE...

Page 115: ... the tighten the bolts in a crisscross pattern in 2 3 steps Install the rear brake adjuster and return spring Install the skid guard Refill the crankcase to the upper level mark with recommended oil Inspect and adjust the clutch lever free play CLUTCH GEARSHIFT LINKAGE RIGHT CRANKCASE COVER CLUTCH CABLE BOLTS ...

Page 116: ...XL2 0 0 CLUTCH GEARSHIFT LINKAGE 8 13 NOTES ...

Page 117: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 118: ...UNIT mm in 9 1 ITEM STANDARD SERVICE LIMIT Starter reduction gear Gear I D 10 016 10 034 0 3943 0 3950 10 10 0 398 Shaft O D 9 991 10 000 0 3933 0 3937 9 95 0 392 Starter idle gear Gear I D 10 016 10 034 0 3943 0 3950 10 10 0 398 Shaft O D 9 991 10 000 0 3933 0 3937 9 95 0 392 Starter driven gear I D 22 010 22 031 0 8665 0 8673 22 07 0 869 O D 45 660 45 673 1 7976 1 7981 45 60 1 7952 TORQUE VALUES...

Page 119: ...XL2 0 0 ALTERNATOR STARTER CLUTCH 9 0 75 Nm 7 5 kg m 53 ft lb 5 Nm 0 5 kg m 4 ft lb ...

Page 120: ...ting bolt and guide from the left crankcase Remove the bolts and starter reduction gear cover Check for a fatigued or damaged O ring Remove the starter reduction gear and gear shaft Inspect gear and shaft see page 9 5 Remove the bolts and left crankcase cover NOTE Remove the gasket and dowel pins Loosen the bolts in a crisscross pattern in 2 3 steps to prevent crankcase cover distortion ALTERNATOR...

Page 121: ...connect the pulse generator wire connector from the pulse generator NOTE Pull the connector do not pull the wire Remove the wire clamp the starter mounting bolts and the stator Install the stator into the left crankcase cover Insert the wire grommet into the groove in the left crankcase cover Apply a locking agent to the threads of the stator bolt threads Install and tighten the bolts securely BOL...

Page 122: ...ulse generator and tighten the bolts to the specified torque TORQUE 5 N m 0 5 kg m 4 ft lb REDUCTION GEAR INSPECTION Check the teeth for excessive or abnormal wear or evidence of insufficient lubrication Measure the I D of the starter reduction gear and the O D of the gear shaft SERVICE LIMIT Reduction gear I D 10 10 mm 0 398 in Reduction gear shaft O D 9 95 mm 0 392 in ALTERNATOR STARTER CLUTCH W...

Page 123: ...heel holder Attach the flywheel puller and remove the flywheel TOOL Flywheel puller Remove the woodruff key STARTER CLUTCH STARTER IDLE GEAR INSPECTION Inspect the starter idle gear teeth for damaged or abnormal wear Measure the starter idle gear I D and idle gear shaft O D SERVICE LIMIT Idle gear I D 10 10 mm 0 398 in Idle gear shaft O D 9 95 mm 0 392 in SHAFT IDLE GEAR FLYWHEEL FLYWHEEL HOLDER F...

Page 124: ...uld not turn clockwise Inspect the starter driven gear teeth for damage or abnormal wear Hold the flywheel using the flywheel holder then remove the one way clutch from the flywheel by removing three starter clutch bolts Check the one way clutch rollers for wear or damage ALTERNATOR STARTER CLUTCH DRIVEN GEAR DRIVEN GEAR BOLTS FLYWHEEL ONE WAY CLUTCH ...

Page 125: ...e way clutch in the clutch outer facing its flange toward the flywheel Install the one way clutch outer to the flywheel Clean and apply a locking agent to the threads of the starter clutch bolts Install the bolts through the flywheel and tighten them to the specified torque TORQUE 16 N m 1 6 kg m 12 ft lb 3 FLYWHEEL 2 ONE WAY CLUTCH OUTER 5 ONE WAY CLUTCH 1 DRIVEN GEAR 6 WASHER ...

Page 126: ...ttract steel filings and other ferrous material Clean the tapered hole in the flywheel and tapered portion of the crankshaft of any burrs or other fault Apply oil to the flywheel bolt threads Install the washer and flywheel bolt Hold the flywheel with the flywheel holder tighten the bolt to the specified torque TORQUE 75 N m 7 5 Kg m 54 ft lb Apply clean engine oil to the sliding surfaces of the i...

Page 127: ...ot pinch the neutral switch wire when installing the left crankcase cover Run the wire harness through the crankcase groove and set the wire guide plate with the mounting bolt NOTE Install the neutral switch collar Do not pinch the wires when installing the guide plate Install the starter reduction gear and shaft GASKET DOWEL PIN COLLAR GUIDE PLATE BOLT SHAFT REDUCTION GEAR ...

Page 128: ...f clean engine oil to the O ring Install the reduction gear cover and tighten the bolts securely Connect the alternator pulse generator and neutral switch connectors Install the seat and side covers Install the drive sprocket cover and tighten the bolts Fill the engine with recommended oil ALTERNATOR STARTER CLUTCH ...

Page 129: ...XL2 0 0 ALTERNATOR STARTER CLUTCH 9 11 NOTAS ...

Page 130: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 131: ... 959 19 980 0 7858 0 7866 19 91 0 784 Countershaft O D At C 1 bushing 16 466 16 484 0 6482 0 6489 16 41 0 646 At C 2 bushing 19 974 19 987 0 7863 0 7868 19 92 0 784 At C 4 gear 19 959 19 980 0 7857 0 7866 19 90 0 783 Gear to bushing M 3 0 040 0 082 0 001 0 003 0 10 0 004 clearance C 4 0 040 0 082 0 001 0 003 0 10 0 004 Bushing to shaft C 1 0 016 0 052 0 0006 0 002 0 08 0 003 clearance C 2 0 013 0 ...

Page 132: ...XL2 0 0 CRANKSHAFT TRANSMISSION 10 0 12 N m 1 2 kg m 9ft lb ...

Page 133: ...R Attachment 62 x 68 mm 07746 0010500BR Attachment 72 x 75 mm 07746 0010600BR Pilot 15 mm 07746 0040300BR Pilot 17 mm 07746 0040400BR Pilot 20 mm 07746 0040500BR Pilot 35 mm 07746 0041100 TROUBLESHOOTING Hard to shift Bent shift fork Bent shift fork shaft Transmission jumps out of gear Worn gear engagement dogs or slots Damaged or bent shift fork Bent shift fork shaft Damaged shift drum stopper ar...

Page 134: ...OTE Loosen the bolts in a crisscross pattern in 2 3 steps Place the left crankcase down and remove the right crankcase NOTE h Do not pry the crankcase halves apart with a screw driver Separate the right and left crankcase from each other by tapping them at several locations with a soft hammer Remove the gasket and dowel pins RIGHT CRANKCASE GASKET BOLT BOLT CABLE HOLDER ...

Page 135: ... 0 908 in Measure the I D and O D of the gear bushings SERVICE LIMITS I D C1 16 55 mm 0 652 in C2 20 05 mm 0 789 in O D C1 19 43 mm 0 765 in C2 22 93 mm 0 903 in Check the mainshaft and countershaft splines and sliding surfaces for wear or damage Measure the O D of the mainshaft and countershaft in the locations as shown SERVICE LIMITS A M3 gear 19 91 mm 0 784 in B C1 bushing 16 41 mm 0 646 in C C...

Page 136: ...e the shift drum if the grooves are damaged or excessively worn ASSEMBLY NOTE Assemble the mainshaft and countershaft Coat each gear bushing shift fork shift fork shaft shift drum shift drum journal mainshaft and countershaft with transmission oil Install the snap ring with its chamfered side facing the gear Turn the inner race of each bearing with your finger The bearings should be turn smoothly ...

Page 137: ... WASHER M4 GEAR 22 T M5 GEAR 27 T M2 GEAR 18 T SPLINE WASHER SNAP RING SNAP RING SNAP RING SPLINE WASHER SPLINE WASHER SPLINE WASHER SNAP RING M3 GEAR 19 T M1 GEAR 13 T WASHER WASHER C1 GEAR 36 T C4 GEAR 22 T C3 GEAR 24 T C5 GEAR 23 T C2 GEAR 31 T WASHER WASHER WASHER WASHER BUSHING BUSHING ...

Page 138: ...g this operation Install the shift forks into the shifter grooves with their marks facing down NOTE The shift forks are marked L for left C for center and R for right Install the shift drum Install the shift fork shaft After installation check for smooth transmission operation L MARK C MARK R MARK SHAFT DRUM LEFT SHIFT FORK RIGHT SHIFT FORK CENTER SHIFT FORK COUNTERSHAFT MAINSHAFT ...

Page 139: ...emover weight Remove the countershaft oil seal and bearing from the left crankcase Remove the mainshaft bearing from left crankcase using special tools Drive new bearings into the right crankcase Mainshaft bearing Driver Attachment 42 x 47 mm PIlot 20 mm Countershaft bearing Driver Attachment 32 x 35 mm Pilot 15 mm Crankshaft bearing Driver Attachment 62 x 68 mm Pilot 22 mm CRANKSHAFT TRANSMISSION...

Page 140: ... x 75 mm Pilot 35 mm Apply grease to the new countershaft oil seal lips and install it CRANKSHAFT REMOVAL Remove the crankshaft from the crankcase using a hydraulic press If the left crankshaft bearing remains on the crankshaft remove it with universal bearing puller If the bearing remains in the left crankcase drive it out from the outside Discard the left crankshaft bearing NOTE Always replace t...

Page 141: ...n the direction indicated by the arrows SERVICE LIMIT 0 05 mm 0 002 in Set the crankshaft on a stand or V blocks and read the runout using a dial indicator SERVICE LIMIT 0 10 mm 0 004 in INSTALLATION Install the threaded adaptor on the crankshaft Install the left crankcase bearing CRANKSHAFT TRANSMISSION THREADED ADAPTOR CRANKSHAFT CRANKSHAFT FEELER GAUGE CRANKSHAFT 1 CRANKSHAFT 80 mm 3 1 in 70 mm...

Page 142: ...all the dowel pins and new gasket Pour oil into the crankshaft connecting rod big end oil hole Install the right crankcase on the left crankcase NOTE Make sure that the gasket stays in place during this operation Install the left crankcase bolts and tighten and tighten them securely NOTE Tighten the bolts in a crisscross pattern in 2 3 steps RIGHT CRANKCASE BOLTS DOWEL PINS GASKET CRANKCASE ASSEMB...

Page 143: ...cable holder and right crankcase bolts and tighten the bolts securely After tightening check the transmission operation Install the removed parts in the reverse order of removal CRANKSHAFT TRANSMISSION CABLE HOLDER BOLT BOLT CAM CHAIN GUIDE PLATE CAM CHAIN ...

Page 144: ...XL2 0 0 CRANKSHAFT TRANSMISSION 10 13 NOTAS ...

Page 145: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 146: ...t axle nut 60 N m 6 0 kg m 43 ft lb Handlebar upper holder bolt 27 N m 2 7 kg m 20 ft lb Handlebart lower holder nut 26 N m 2 6 kg m 19 ft lb Fork oil drain bolt 0 8 N m 0 08 kg m 0 6 ft lb Fork top pinch bolt 21 N m 2 1 kg m 15 ft lb Fork bottom pinch bolt 33 N m 3 3 kg m 24 ft lb Fork cap 23 N m 2 3 kg m 17 ft lb Fork socket bolt 21 N m 2 1 kg m 15 ft lb Steering stem nut 105 N m 10 5 kg m 76 ft...

Page 147: ...11 0 XL2 0 0 FRONT WHEEL SUSPENSION STEERING 12 N m 1 2 kg m 9 ft lb 60 N m 6 0 kg m 43 ft lb 33 N m 3 3 kg m 23 ft lb 21 N m 2 1 kg m 15 ft lb 27 N m 2 7 kg m 20 ft lb ...

Page 148: ...l Turns Hard Steering top thread too tight Faulty wheel bearing Damaged steering head bearing race Faulty speedometer gear Insufficient tire pressure Faulty tire Soft Suspension Weak front fork spring Steers To One Side Or Does Not Track Insufficient fork oil Straight Bent fork Hard Suspension Bent front axle Bent fork tubes Wheel installed incorrectly Clogged fluid passage Faulty steering head be...

Page 149: ...y installed so as to prevent air from getting into the brake fluid Remove the screws and separate the throttle housing Disconnect the throttle cables then remove the throttle pipe Remove the screw and right handlebar switch housing Remove the knuckle guard and rearview mirror Remove the screws and clutch lever bracket Remove the screws and left handlebar switch housing Remove the bolts handlebar u...

Page 150: ...A or its equivalent to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe Wait 3 5 minutes and install the grip Rotate the grips for even application of the adhesive NOTE Allow the adhesive to dry for an hour before using Install the right handlebar switch housing aligning its locating pin with the hole on the handlebar Install the screws and tighten t...

Page 151: ...ble end Install the throttle grip on the handlebar Connect the throttle cable end to the throttle pipe Install the throttle cable guide Place the front master cylinder on the handlebar and install the master cylinder holder with its UP mark facing up Align the end of the holder with the punch mark on the handlebar Tighten the upper bolt first then the lower bolt Install the screws and tighten the ...

Page 152: ...le on the handlebar Install the screws and tighten the forward screw first then the rear screw Install the clutch lever bracket Install the screws and tighten the forward screw first then the rear screw Connect the clutch switch wire connectors Install the wire bands FRONT WHEEL SUSPENSION STEERING CONNECTORS PIN HOLE SCREWS CLUTCH LEVER BRACKET SCREWS REARVIEW MIRROR WIRE BANDS ...

Page 153: ...s removed The caliper piston will move out and make assembly difficult INSPECTION Axle Place the axle in V blocks and measure the runout with a dial indicator Service limit 0 2 mm 0 008 in The actual runout is 1 2 of the total indicator reading Wheel rim Check the wheel rim runout by lacing the wheel in a turning stand Spin the wheel by hand and read the runout using a dial indicator Service limit...

Page 154: ... the speedometer gear box dust seal and speedometer gear retainer Remove the side collar from the left hub Remove the hub cover and brake disc NOTE Check for disc warpage see page 13 5 WHEEL BEARING REPLACEMENT Remove the wheel bearings and distance collar from the wheel hub TOOLS Bearing remover head 15 mm Bearing remover shaft NOTE Never reinstall oil bearings Once the bearings have been removed...

Page 155: ...using the same tools Install the bearings with its sealed side facing out Place the rim on the work bench Place the hub with the left side down and begin lacing with new spokes Tighten the spokes in 2 3 progressive steps TOOLS Spoke nipple wrench 4 5 x 5 1 mm TORQUE 3 5 N m 0 35 kg m 2 5 ft lb Check the rim runout page 11 7 SPEEDOMETER GEAR BOX DUST SEAL SHIM DRIVE GEAR RETAINER RIGHT WHEEL BEARIN...

Page 156: ...er gear retainer in the left side hub aligning its tangs with the slots in the hub Install the shims fill the speedometer gear box with grease and install the drive gear Install the dust seal and the speedometer gear box in the wheel hub aligning the tangs of the retainer with the slots in the speedometer gear box FRONT WHEEL SUSPENSION STEERING BOLT BRAKE DISC SCREW DUST SEAL SIDE COLLAR RETAINER...

Page 157: ... m 6 0 kg m 43 ft lb With the front brake applied pump the fork up and down several times to seat the axle and check for front brake operation Tighten the upper axle holder nuts first then the lower nuts TORQUE 12 N m 1 2 kg m 9 ft lb Connect the speedometer cable and tighten the setting screw FORK REMOVAL Remove the front wheel Loosen the bolts and release the brake hose from the clamp Loosen the...

Page 158: ...arefully remove the fork bolt t The fork bolt is under spring pressure Use care when removing it and wear eye and face protection Remove the fork spring A spring seat and fork spring B Pour out the fork fluid by pumping the fork tube several times FRONT WHEEL SUSPENSION STEERING BOTTOM PINCH BOLT TOP PINCH BOLT BOOT CLAMPS FORK CAP FORK FORK SPRING ...

Page 159: ...essive back and forth strokes pull the fork tube out from the slider The slider bushing gives resistance and the fork tube bushing must be forced out Remove the oil lock piece from the piston Remove the piston and rebound spring from the fork tube Remove the oil seal back up ring and slider bushing from the fork tube NOTE Do not remove the fork tube bushing unless it is necessary to replace it wit...

Page 160: ...at are worn or damage Set the fork tube in V blocks and rear the runout with a dial indicator SERVICE LIMIT 0 2 mm 0 008 in The actual runout is 1 2 of the total indicator reading FORK TUBE BUSHING Visually inspect the slider and fork tube bushing Replace the bushing if there is excessively scoring or scratching or if the teflon is worn so that the copper surface appears on more than 3 4 of the en...

Page 161: ...e slider bushing back up ring and oil seal onto the fork tube NOTE Install the rebound spring onto the fork piston Install the fork piston into the fork tube Install the oil lock piece onto the fork piston Clean and apply a locking agent to the fork socket bolt threads Install a new sealing washer and socket bolt Install the back up ring with the chamfered side facing the slider bushing Coat the o...

Page 162: ...nstall the back up ring and drive the oil seal using the fork seal driver TOOLS Oil seal driver body Oil seal driver attachmet Install the oil seal stop ring into the groove of the fork slider Install the dust seal Compress the fork spring fully and pour in the specified amount of fork fluid Oil capacity 384 cc Pump the fork tube slowly several times to stabilize the fork oil level Compress the fo...

Page 163: ...d fork spring A into the fork tube Install a new O ring onto the fork bolt and install it loosely NOTE Install the fork bolt but do not tighten yet Install the fork boot with its breather holes toward the rear INSTALLATION Install the fork leg aligning its top with the upper surface of the top bridge as shown O RING BOOT TOP BRIDGE UPPER SURFACE ...

Page 164: ...w Route the brake hose properly then install the front brake caliper and tighten the mounting bolts to the specified torque TORQUE 31 N m 3 1 kg m 22 ft lb Install the brake hose between the hose clamp then tighten the bolts Clamp the speedometer cable and tighten the clamp screw Install the front firing Install the front wheel STEERING STEM REMOVAL Remove the following handlebar front wheel Remov...

Page 165: ...move the steering stem nut and washer Remove the fork and top bridge Remove the top thread Remove the following top cone race upper bearing steering stem lower bearing STEM NUT WASHER TOP THREAD LOWER BEARING STEERING STEM TOP CONE RACE UPPER BEARING ...

Page 166: ...REPLACEMENT Avoid damaging the steering stem thread temporarily install the stem nut Remove the bottom cone race dust seal and dust seal washer Install a new dust seal washer and bottom cone race Press a new bottom cone race onto the steering stem using the special tool TOOL Stem bearing driver FRONT WHEEL SUSPENSION STEERING BALL RACE DRIVER ATTACHMENT DRIVER STEM NUT BOTTOM CONE RACE BEARING DRI...

Page 167: ... grease to all bearing area Install the lower bearing Install the steering stem upper bearing top cone race and top thread Tighten the top thread until it is sung against the top cone race STEM NUT TOP THREAD TOP CONE RACE UPPER BEARING UPPER BEARING RACE STEERING STEM DUST SEAL BOTTOM CONE RACE LOWER BEARING LOWER BEARING RACE ...

Page 168: ...e is no vertical play and that the steering stem rotates smoothly Install the following top bridge washer stem nut fork Tighten the stem nut to the specified torque TORQUE 105 N m 10 5 kg m 76 ft lb Install the removed parts in the reverse order of removal FRONT WHEEL SUSPENSION STEERING STEERING STEM STEM NUT WASHER FORK TOP BRIDGE ...

Page 169: ...XL2 0 0 FRONT WHEEL SUSPENSION STEERING 11 23 NOTAS ...

Page 170: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 171: ...not allow fire or heat near the shock absorber Before disposal of the shock absorber release nitrogen TORQUE VALUES Rear axle nut 90 N m 9 0 kg m 64 ft lb Spoke nipple 3 5 N m 0 35 kg m 2 5 ft lb Swingarm pivot nut 90 N m 9 0 kg m 64 ft lb Rear shock absorber upper mounting bolt 45 N m 4 5 kg m 32 ft lb Rear shock absorber lower mounting bolt 45 N m 4 5 kg m 32 ft lb Shock arm mounting bolt Frame ...

Page 172: ...XL2 0 0 REAR WHEEL SUSPENSION 12 0 ...

Page 173: ... Faulty rear damper Loose fasteners Shock linkage pivots worn or need lubrication Steers To One Side Or Does Not Track Straight Bent rear axle Axle alignment chain adjustment not equal on both sides Poor Brake Performance Improper brake adjustment Worn brake lining Contaminated linings Worn brake drum Worn brake cam Brake arm serration improperly engaged XL2 0 0 12 2 TOOLS Spanner 07701 0020300 Dr...

Page 174: ... sprocket then remove the rear wheel Remove the brake panel INSPECTION Axle runout Place the rear axle in V blocks and measure the runout SERVICE LIMIT 0 2 mm 0 008 in The actual runout is 1 2 of the total indicator reading Wheel rim runout Check the wheel rim runout by placing the wheel in turning stand Then spin the wheel by hand and read the wheel rim runout with a dial indicator SERVICE LIMIT ...

Page 175: ...r race should turn smoothly and quietly Also check that the bearing outer race fits tightly in the wheel hub Replace the bearing if the inner race does not turn smoothly quietly or if it fits loosely in the hub NOTE Replace the bearings in pairs Damper rubber Remove the driven sprocket Check the damper rubbers for wear or fatigue DISASSEMBLY Remove the side collar dust seal Remove the snap ring an...

Page 176: ...piece of wood or a soft hammer if it is hard to remove Remove the left and right bearings and distance collar using the special tool TOOLS Bearing remover head 15 mm Bearing remover shaft ASSEMBLY REAR WHEEL RIGHT WHEEL BEARING DUST SEAL DAMPER RUBBER DISTANCE COLLAR REAR WHEEL BEARING DRIVEN SPROCKET NUT SNAP RING COLLAR WASHER ...

Page 177: ...acing out INSTALLATION Install the brake panel Place the slot in the brake panel over the tang on the swingarm and then install the drive chain onto the sprocket Install the following drive chain adjusters drive chain adjusting plates axle from the left side axle nut Adjust the drive chain slack page 3 9 Tighten the axle nut to the specified torque Torque 90 N m 9 0 kg m 64 ft lb REAR WHEEL SUSPEN...

Page 178: ...egreasing agent Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use and air hose or dry bush to clean the brake assemblies INSPECTION Measure the rear brake drum I D SERVICE LIMIT 111 0 mm 4 37 in Measure the brake lining thickness SERVICE LIMIT 2 0 mm 0 08 in DISASSEMBLY NOTE Pull the brake shoes apart and remove them from the brake panel Always replace brake...

Page 179: ...ut and brake arm Remove the indicator plate and brake cam Remove the dust seals Apply grease to the lip of dust seals then install them into the brake panel REAR WHEEL SUSPENSION BRAKE ARM INDICATOR PLATE SHOE BRAKE CAM DUST SEAL CAM SEAT BRAKE PANEL NUT BOLT SPRING DUST SEAL ...

Page 180: ... wide groove on the brake cam Install the brake arm aligning the punch marks on the brake arm and cam Install the pinch bolt and nut tighten the nut TORQUE 10 N m 1 0 Kg m 7 ft lb Install the brake shoes and springs t NOTE Install the brake panel on the rear wheel and install the wheel Adjust the rear brake If the brake shoes are reused be sure to reassemble them in their original positions A cont...

Page 181: ... brake switch spring Remove the brake pedal pivot pinch bolt shaft and dust seals then remove the brake pedal Remove the cotter pin and joint pin then remove the brake rod from the brake pedal Installation is in the reverse order of removal NOTE Apply grease to the brake pedal pivot and dust seal lips After installation adjust the following brake pedal height brake pedal free play brake light swit...

Page 182: ...orber upper mounting bolt and lower the shock absorber then remove INSPECTION Visually inspect the shock absorber for oil leak or other damage Check for the damper rod for bend or damage damper unit for deformation or oil leaks upper mount bushing for wear or damage Check for smooth damper operation h If necessary replace the shock absorber as an assembly Do not disassemble the shock absorber SHOC...

Page 183: ...ide the bag this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start INSTALLATION Install the shock absorber from the bottom Install and tighten the upper mounting bolt to the specified torque TORQUE 45 N m 4 5 kg m 32 ft lb Do not use a dull drill bit which could cause build up of excessive heat and pressure inside the damper leading to...

Page 184: ...and pivot collars for wear or damage SHOCK LINKAGE BEARING REPLACEMENT SHOCK LINK Press the needle bearing out of the shock link using the special tools TOOL Driver shaft Pack the new needle bearings with grease Carefully press the needle bearing into the shock link to 4 0 mm 0 16 in below the surface of the pivot on both side using the special tool TOOL Driver shaft NOTE Install the bearings with...

Page 185: ...k link to the specified depth below the surface of the pivot on both side using the special tool SPECIFIED DEPTH Shock link frame side 7 0 mm 0 28 in Shock absorber side 4 5 mm 0 18 in NOTE Apply grease to lip of the new dust seals Install the dust seals and pivot collars Install the bearings with their marks facing out INSTALLATION Install the shock arm and shock link NOTE Install the shock arm w...

Page 186: ...ve the rear wheel Remove the shock link to swingarm bolt nut Remove the shock absorber lower mounting bolt nut Remove the drive chain cover Unhook the brake pedal return spring from the swingarm Remove the swingarm pivot nut bolt and swingarm SHOCK LINK BOLT NUT LOWER MOUNTING BOLT SHOCK LINK BOLT NUT UP MARK LOWER MOUNTING BOLT BOLT CHAIN COVER SWINGARM RETURN SPRING PIVOT BOLT NUT ...

Page 187: ... SWINGARM PIVOT BEARING REPLACEMENT Drive out the pivot bushings h Do not damage the swingarm Remove the needle bearing from the swingarm pivot using the special tool TOOL Needle bearing remover REAR WHEEL SUSPENSION DUST SEAL CAP PIVOT COLLAR CHAIN SLIDER BOLTS SCREWS PIVOT BUSHING NEEDLE BEARING NEEDLE BEARING REMOVER ...

Page 188: ...se to lip of the new dust seals Install the pivot collar and dust seal caps Install the drive chain slider and drive chain guard INSTALLATION Install the swingarm on the frame and install the pivot bolt and nut Tighten the pivot nut to the specified torque TORQUE 90 N m 9 0 kg m 64 ft lb Hook the brake pedal return spring DUST SEAL PIVOT COLLAR SWINGARM DRIVER ATTACHMENT PILOT BOLTS DRIVE CHAIN SL...

Page 189: ... cut out with the hook on the swingarm Temporarily install the shock absorber lower mounting bolt nut and shock link to swingarm bolt nut Install and tighten the mounting bolts TORQUE 45 N m 4 5 kg m 32 ft lb Install the rear wheel REAR WHEEL SUSPENSION PIVOT COLLAR DRIVE CHAIN SLIDER SCREW BOLTS DRIVE CHAIN GUARD SWINGARM DUST SEAL CAP ...

Page 190: ...XL2 0 0 REAR WHEEL SUSPENSION 12 19 NOTAS ...

Page 191: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 192: ... brake degreasing agent Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use an air hose or dry brush to clean brake assemblies SPECIFICATIONS UNIT mm in ITEM Standard SERVICE LIMIT Brake fluid DOT4 Brake disc thickness 3 0 0 12 Brake disc runout 0 3 0 01 Master cylinder I D 12 700 12 743 0 5000 0 5017 12 755 0 5022 Master piston O D 12 657 12 684 0 4983 0 4994...

Page 193: ...0 15 kg m 1 ft lb 18 N m 1 8 kg m 13 ft lb 10 N m 1 0 kg m 7 ft lb 10 N m 1 0 kg m 7 ft lb 35 N m 3 5 kg m 25 ft lb 23 N m 2 3 kg m 16 ft lb 13 N m 1 3 kg m 9 ft lb 6 N m 0 6 kg m 4 ft lb 35 N m 3 5 kg m 25 ft lb 2 5 N m 0 25 kg m 18 ft lb ...

Page 194: ... Sticking worn master cylinder piston Contaminated master cylinder Bent brake lever Brake lever hard Clogged restricted brake system Sticking worn caliper piston Caliper not sliding properly Clogged restricted fluid passage Worn caliper piston seal Sticking worn master cylinder piston Bent brake lever Brake drag Contaminated brake pads disc Misaligned wheel Worn brake pads disc Warped deformed bra...

Page 195: ...he system Repeat the above procedures until no air bubbles appear in the plastic hose NOTE If air is entering the bleeder from around the bleed valve threads seal the thread with teflon tape Check the fluid level often while bleeding the brakes to prevent air from being pumped into the system Do not mix brake fluid types and never reuse the contaminated fluid which has been pumped out during brake...

Page 196: ... step 1 and 2 until bubbles cease to appear in the fluid at the end of the hole Tighten the bleed valve TORQUE 6 N m 0 6 kg m 4 3 ft lb NOTE Remove the pad pin plug and loosen the pad pin Pull the pad pin out if the caliper Remove the brake pads Always replace the brake pads in pairs to assure even disc pressure HYDRAULIC BRAKE Fill the reservoir with DOT4 brake fluid to the upper level Reinstall ...

Page 197: ...per to depress the pad spring Tighten the pad pin to the specified torque TORQUE 18 N m 1 8 kg m 13 ft lb Install and tighten the pad pin plug to the specified torque TORQUE 2 5 N m 0 25 kg m 1 8 ft lb BRAKE DISC Disc Thickness Measure the brake disc thickness SERVICE LIMIT 3 0 mm 0 12 in Disc Warpage Measure the brake disc for warpage SERVICE LIMIT 0 3 mm 0 01 in BRAKE PAD PAD PIN PAD PIN PLUG BR...

Page 198: ...e pivot nut bolt and brake lever Remove the screw and front brake light switch When removing the brake hose bolt cover the end of the hose to prevent contamination Secure the hose to prevent fluid from leaking out Avoid spilling fluid on painted plastic or rubber parts Place a shop towel over these parts whenever the system is serviced Remove the piston and spring Clean the inside of the master cy...

Page 199: ... cups do not allow the lips to turn inside out Be certain the snap ring is seated firmly in the groove The master piston piston cups spring washer and snap ring must be replace as a set Clean the master cylinder with compressed air Assemble the master cylinder Dip the piston cups in clean brake fluid before assembly Install the washer snap ring and boot TOOL Snap ring pliers Apply silicone grease ...

Page 200: ...he brake fluid from the hydraulic system Remove the brake pads Place a clean container under the caliper and remove the oil bolt sealing washer and eyelet joint from the caliper Remove the brake caliper bracket bolts then remove the brake caliper and bracket as an assembly DISASSEMBLY Remove the following Caliper bracket Brake pad retainer Pad spring Caliper bracket pin boot Pistons from caliper c...

Page 201: ...SEMBLY Coat the new piston seals and dust seals with clean brake fluid and install them in the seal grooves of the caliper Lubricate the caliper cylinders and pistons with clean brake fluid and install the pistons into the caliper cylinders with the closed end of the piston facing the pad side Apply silicone grease to the pivot boots and install them making sure that they are seated in the caliper...

Page 202: ...embly on the fork leg and tighten the bracket bolts to the specified torque TORQUE 31 N m 3 1 kg m 22 ft lb Connect the brake hose eyelet joint with two new sealing washers then tighten the oil bolt to the specified torque TORQUE 35 N m 3 5 kg m 25 ft lb Fill the master cylinder with DOT 3 or DOT4 brake fluid from a sealed container and bleed any air the front brake system Install the brake pads H...

Page 203: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 204: ... all fo the exhaust pipe fasteners Always tighten the exhaust clamps first then tighten the mounting fasteners If you tighten the mounting fasteners first the exhaust pipe may not seat properly Always inspect the exhaust system for leak after installation TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged...

Page 205: ...dlight socket Installation is in the reverse order of removal NOTE At installation align the bosses on the front fairing with the hole in the steering stem SIDE COVER SEAT REMOVAL Side cover Remove the bolt and side cover FAIRING EXHAUST SYSTEM FAIRING BOLT SOCKET SCREW SIDE COVER ...

Page 206: ...g bolts and seat INSTALLATION Installation is in the reverse order of removal NOTE At side cover installation install the side cover boss with the frame grommet At seat installation align the hook of the seat with the fuel tank mounting bracket HOOK SEAT BOLT SIDE COVER BOLT ...

Page 207: ...e reverse order of removal EXHAUST SYSTEM t REMOVAL DISASSEMBLY Remove the exhaust pipe joint nuts Loosen the exhaust pipe clamp and remove the muffler mounting bolts Remove the muffler exhaust pipe and gasket Remove the bolts washers and muffler protector Remove the bolts washers and exhaust pipe protector Do not service the exhaust system while it is hot FAIRING EXHAUST SYSTEM REAR FENDER BOLTS ...

Page 208: ...ar 61 N m 6 1 kg m 44 ft lb Exhaust pipe clamp bolt 18 N m 1 8 kg m 13 ft lb Exhaust pipe joint nut 10 N m 1 0 kg m 7 ft lb At assembly replace the protector washers with new ones At installation replace the exhaust pipe gasket with a new one GASKET EXHAUST PIPE BOLT WASHER BOLT WASHER EXHAUST PIPE JOINT NUT EXHAUST PIPE PROTECTOR EXHAUST PIPE CLAMP BOLT MUFFLER MOUNT BOLT MUFFLER MUFFLER PROTECTO...

Page 209: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 210: ...g the charging system check for proper use and maintenance of the battery Check if the battery is frequently under heavy load such as having the headlight and taillight ON for long periods of time without riding the motorcycle The battery will self discharge when the motorcycle is not in use For this reason charge the battery every two weeks to prevent sulfation from forming Filling a new battery ...

Page 211: ...XL2 0 0 BATTERY CHARGING SYSTEM 15 0 2 REGULATOR RECTIFIER Y YELLOW P PINK G GREEN R RED B BLACK 1 IGNITION SWITCH 5 ALTERNATOR 4 MAIN FUSE 15A R R B G Y P P G B R Y 3 BATTERY ...

Page 212: ...ry voltage using digital multimeter 15 4 Install the battery page 15 3 Start the engine Measure the charging voltage page 15 4 Compare the measurement to result of the following calculation STANDARD MEASURED BATTERY VOLTAGE MEASURED CHARGING VOLTAGE 15 5 V at 5 000 min 1 rpm Check the regulator rectifier connector voltage and resistance page 15 6 Faulty regulator rectifier Incorrect Correct Open c...

Page 213: ... lines inscribed on the side of the battery If levels are approaching the LOWER level line remove the battery take off the filter caps and refill to the UPPER level with distilled water h After refilling replace each of the filler caps firmly Always refill batteries with distilled water Tap water contains minerals that will shorten the life of the battery Filling the battery above the UPPER level ...

Page 214: ...minal After charging recheck the battery specific gravity and recharge the battery if necessary Replace the battery with a new one if the battery specific gravity below 1 23 t The battery gives of explosive gases keep sparks flames and cigarettes away Provide adequate ventilation when charging or using the battery in an enclosed space If the difference in specific gravity between cells exceeds 0 0...

Page 215: ...in the tester While measuring current do not turn the ignition switch ON A sudden surge of current may blow out the fuse in tester REGULATED VOLTAGE AMPERAGE INSPECTION t NOTE Start the engine and warm it up to operating temperature then turn the ignition switch OFF Connect the multimeter between the battery terminals Start the engine and increase the engine speed gradually and measure the voltage...

Page 216: ...ss or poor ground If the above items are all OK check the regulator rectifier Provided the circuit on the wire harness side is normal and there are no loose connections at the connector inspect the regulator rectifier unit by measuring the resistance between the terminals Replace the regulator rectifier unit if the resistance value between the terminal is abnormal BATTERY CHARGING SYSTEM Item Term...

Page 217: ...olt and regulator rectifier unit Installation is in the reverse order of removal Measure the resistance between the pink and yellow wire terminals Standard White Green 0 1 1 0 Ω 20 C 68 F Yellow Pink 0 1 1 0 Ω 20 C 68 F If the resistance is not within the specification replace the stator page 9 3 ALTERNATOR Remove the left side cover Disconnect the alternator 6P connector ...

Page 218: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 219: ...k plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine For stator removal and installation see section 9 Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present If the engine must be running to do some work make sure the area is well ventilated Never run t...

Page 220: ... IGNITION SYSTEM 16 0 5 CDI UNIT 2 ENGINE STOP SWITCH B W B R B R L Y L Y B Y G G W 3 IGNITION COIL 9 PULSE GENERA TOR 1 IGNITION SWITCH 8 ALTERNATOR 10 SPARK PLUG B BLACK R RED L BLUE Y YELLOW W WHITE G GREEN ...

Page 221: ...Check the CDI unit connectors for loose or poorly contact Normal Check the ignition coil resistance at the CDI unit 4P connector page 16 3 Normal Measure voltage between Black White and Green terminals of CDI unit Continuity should exist with ignition switch ON Normal Check the pulse generator resistance at the CDI unit 4P connector Faulty ignition coil Faulty spark plug wire Loose or poorly conta...

Page 222: ...ance system at the CDI unit ITEM TERMINAL STANDARD 20 C 68 F Ignition primary coil line Black Yellow Green 0 4 0 6 Ω Pulse generator coil line Blue Yellow Green 293 358 Ω Exciter coil line Black Red Green 100 300 Ω Ignition switch Ignition switch at ON and engine stop Black white Green Battery voltage switch at RUN Ignition switch at OFF and engine No continuity stop switch at OFF Ground line Gree...

Page 223: ...ector Remove the bolts and ignition coil Installation is in the reverse order of removal PULSE GENERATOR INSPECTION NOTE Remove the left side cover Disconnect the CDI unit connectors It is not necessary to remove the pulse generator from the engine Measure the resistance between the Blue Yellow and Green terminals Standard 293 358 Ω 20 C 68 F IGNITION SYSTEM PLUG WIRE SPARK PLUG CAP CONNECTOR IGNI...

Page 224: ...IL INSPECTION NOTE Remove the left side cover Disconnect the CDI unit connectors It is not necessary to remove the pulse generator from the engine If the measurement is out of specifications disconnet the exciter coil Black Red connector and measure the resistance between the Black Red and body ground Standard 100 300 Ω 20 C 68 F If the resistance still out of specification replace the stator Meas...

Page 225: ...00 min 1 rpm Check the F mark begins to move when the engine speed reaches the advance start rpm At 3 000 min 1 rpm the ignition timing is correct if the index mark is between the to advance marks If the engine must be running to do some work make sure the area is well ventilated Never run the engine an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of conscio...

Page 226: ...XL2 0 0 IGNITION SYSTEM 16 7 NOTES ...

Page 227: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 228: ...ep according to the trouble shooting chart page 17 2 Always turn the ignition switch OFF before servicing the starter motor The motor could suddenly start causing serious injury 17 1 Item Standard Service limit Starter motor brush length 12 5 13 0 0 49 0 51 8 5 0 33 TROUBLESHOOTING Starter motor turns slowly Starter relay switch clicks but engine does not turn over Low specific gravity in battery ...

Page 229: ... NEUTRAL SWITCH 6 STARTER MOTOR 7 IGNITION SWITCH 8 CLUTCH SWITCH 2 STARTER SWITCH 9 DIODE G G R G R Y R Y R R B LG R 3 BATTERY 4 STARTER RELAY SWITCH MAIN FUSE 15 A R RED B BLACK LG LIGHT GREEN G GREEN Y YELLOW 8 NEUTRAL INDICATOR ...

Page 230: ...ay coil ground line green red terminal for continuity with transmission into neutral and clutch lever released Connect the starter relay switch connector With the ignition switch ON and the starter button pushed measure the starter relay voltage at the starter switch connector Faulty starter motor Loose or disconnected starter motor cable Faulty starter relay switch Faulty neutral switch Faulty cl...

Page 231: ...nd starter motor cable Remove the bolts ground cable and starter motor With ignition switch OFF remove the negative cable at the battery before servicing the starter motor Nut Washer Insulated washers DISASSEMBLY Remove the following O ring Bolt Front cover Rear cover Front cover armature NOTE Note the location and number of the thrust washers when disassembling so they can be reinstalled in their...

Page 232: ...imit 8 5 mm 0 33 in ELECTRIC STARTER Check for continuity between individual commutator bars and the armature shaft there should be no continuity Also check for continuity between pairs of commutator bars there should be continuity Check for continuity between cable terminal and the brush the indigo covered wire or the insulated brush holder There should be continuity Check for continuity between ...

Page 233: ...ear or damage Assembly Check the dust seal and bushing of the front cover for wear or damage 1 BOLT 2 SET PLATE 3 O RING 4 CASE 5 LOCK WASHER 6 ARMATURE 7 SHIM 11 O RING 12 BRUSH 18 O RING 17 FRONT COVER 16 NUT 15 WASHER 13 SET PLATE 14 INSULATED WASHER 9 SPRING 10 REAR COVER 8 BRUSH HOLDER ...

Page 234: ...the tab of the holder with the groove of the rear cover Lock washer O ring Front cover Insulated washer Shim NOTE At lock washer installation apply grease to the dust seal At front cover installation do not damage the dust seal Install the shims in the correct position as recorded ELECTRIC STARTER Insulated washer Washer Nut Install the following Motor case Armature O ring Shim Rear cover NOTE Ins...

Page 235: ...or a Click sound from the starter relay switch If the starter relay switch does not click check the voltage and continuity INSPECTION Voltage Measure the voltage between the Yellow Red terminal of the starter relay switch 4P connector and body ground The battery voltage should appear when the starter button is pushed with the ignition switch ON and the transmission in neutral INSTALLATION Install ...

Page 236: ...e some resistance when transmission is in neutral Operation Connect a fully charged 12 V battery to the Yellow Red and Green Red terminals of the starter relay switch Check the continuity between the switch large terminal There should be continuity DIODE REMOVAL INSTALLATION Remove the seat Remove the diode from the wire harness INSPECTION Check for continuity with an ohmmeter Normal direction Con...

Page 237: ...XL2 0 0 ELECTRIC STARTER 17 9 NOTES ...

Page 238: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 239: ...ust be aligned when reconnecting In order to isolate the electrical failure check the continuity of the electrical path through the part A continuity check can usually be made without removing the part from the motorcycle by simply disconnecting the wires and connecting a continuity tester or ohmmeter to the terminals or connections SPECIFICATIONS 18 1 ITEM SPECIFICATIONS Headlight 12 V 35 35 W Ta...

Page 240: ...XL2 0 0 LIGHTS METERS SWITCHES 18 0 ...

Page 241: ...the bolts and front fairing Remove the headlight socket Remove the dust seal and unhook the retainer Remove the bulb and replace with a new one Installation is in the reverse order of removal LIGHTS METERS SWITCHES FAIRING BOLT SOCKET RETAINER BULB ...

Page 242: ... is in the reverse order of removal TAIL BRAKE LIGHT BULB REPLACEMENT Remove the screws and tail brake light lens Push the brake light bulb in turn it counterclockwise and remove it Pull out the tail light bulb and remove it Install the bulb in the reverse order of removal TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw and turn signal lens SCREWS SCREW LENS ...

Page 243: ...f the items listed above do not show any problems proceed as follows Remove the front fairing Disconnect the turn signal conector and short it with an auxiliary wire Turn the ignition switch and check the turn signal operation The turn signals do not work Short or open circuit in the main wiring The turn signals light on Faulty turn signal relay Loose conector COMBINATION METER BULB REPLACEMENT Re...

Page 244: ...ter then remove the sub harness Disconnect the speedometer and tachometer cable Remove the cap nuts washers and combination meter assembly DISASSEMBLY Remove the screws wire clamp and combination meter upper cover Remove the trip meter knob then remove the speedometer ASSEMBLY Assemble the combination meter in the reverse order of removal BULB SOCKET ...

Page 245: ...ed O O in the tables below REMOVAL Disconnect the ignition switch wire connector Remove the mounting bolts and ignition switch Install the ignition switch in the reverse order of removal NOTE Apply a locking agent to the ignition switch bolt threads HANDLEBAR SWITCH Remove the front fairing Disconnect the handlebar switch wire connectors LIGHTS METERS SWITCHES IGN E BAT BA1 OFF O O ON O O COLOR B ...

Page 246: ... lever is squeezed There should be no continuity with the brake lever is released REAR Remove the left side cover Disconnect the rear brake light switch 2P connector There should be continuity with the brake pedal is depressed There should be no continuity with the brake pedal is released TURN SIGNAL SWITCH HORN SWITCH LIGHTING SWITCH DIMMER SWITCH STARTER SWITCH ENGINE STOP SWITCH CONNECTOR REAR ...

Page 247: ... is released HORN Disconnect the horn wire connectors and connect a fully charged 12V battery to the horn terminals The horn is normal if it sounds when the battery is connected across the terminals Horn does not sound check the ignition switch and horn switch If both switch normal check for open or short circuit in light green wire and green wire LIGHTS METERS SWITCHES CLUTCH SWITCH CONNECTOR 2 B...

Page 248: ...XL2 0 0 LIGHTS METERS SWITCHES 18 9 NOTES ...

Page 249: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 250: ...XL2 0 0 19 WIRING DIAGRAM 19 1 19 ...

Page 251: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 252: ...en or shorted ignition coil Faulty ignition switch Faulty pulse generator Faulty engine stop switch Loose or disconnected ignition system wires 2 Perform a spark test WEAK OR NO SPARK GOOD SPARK Improper choke operation Carburetor incorrectly adjusted Intake pipe leaking Improper ignition timing Faulty ignition coil or pulse generator Fuel contaminated 4 Start by following normal procedure ENGINE ...

Page 253: ...RELEASED ENGINE SPEED LOWERED WHEN CLUTCH IS RELEASED Faulty CDI unit Faulty pulse generator 5 Check ignition timing INCORRECT ENGINE SPEED INCREASE Valve stuck open Worn cylinder and piston rings Leaking head gasket Improper valve timing 6 Test cylinder compression 7 Check carburetor for clogging INCORRECT Carburetor not serviced frequently enough CLOGGED CORRECT NORMAL 8 Remove spark plug Plug n...

Page 254: ... ENGINE KNOCKS ENGINE DOES NOT KNOCK POOR PERFORMANCE AT LOW AND IDLE SPEED 1 Check ignition timing CORRECT INCORRECT Possible cause Improper ignition timing Faulty CDI unit See section 4 2 Check carburetor pilot screw adjustment INCORRECT CORRECT Loose insulator clamp Damaged insulator 3 Check for leaking intake pipe LEAKING Faulty carbon or wet fouled spark plug Faulty CDI unit Faulty ignition c...

Page 255: ...r clogged jets CLOGGED NOT CLOGGED Camshaft not installed properly 4 Check valve timing INCORRECT CORRECT Faulty spring 5 Check valve spring WEAK NOT WEAKENED POOR HANDLING 1 If steering is heavy POSSIBLE CAUSE Steering stem adjusting nut too tight Damaged steering head bearings Excessive wheel bearing play Bent rim Improper installed wheel hub Swingarm pivot bearing excessively worn Bent frame 2 ...

Page 256: ...e detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZÔNIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblic...

Page 257: ...MOTO HONDA DA AMAZÔNIA LTDA ...

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Honda XL200 2001, Shop Manual

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