Honda XLR200R Service Manual Download Page 3

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Summary of Contents for XLR200R

Page 1: ...1 HONDA MOTORS JAPAN SERVICE MANUAL XLR200R XR200R...

Page 2: ...me Electrical Parts and so on focusing on their specific functions and maintenance specifications Written specifications and contents may change without prior notice due to improvements on the vehicle...

Page 3: ...medium strength c 3 1 to item 3 1 Specialized grease not indicated in above are referred to by name SYMBOLS I MARK These symbols are used throughout this manual to indicate caution regarding procedure...

Page 4: ...1 2 LUBRICANTS AND SEALANTS 1 16 MAINTENANCE DATA 1 2 WIRING DIAGRAM 1 17 MAINTENANCE SPECIFICATIONS 1 5 TROUBLESHOOTING 1 21 TORQUE 1 12 MACHINE NUMBER LOCATION COLOR LABEL Engine Number Location Col...

Page 5: ...eight Total 233 kg 3 1 263 Foot peg Height 295 mm 4 1 000 Caster 26 0 5 0 838 Trail 96 mm Final Type Chain Frame Type Semi double cradle Reduction Deceleration Ratio 3 230 42 1 13 Braking Distance 14...

Page 6: ...2 0mm Horizontal 2 0mm Axle turn 0 2mm Tires Tire Pressure Single Rider Front 1 75 kg cm Rear 1 50 kg cm Two Rider Front 1 75 kg cm Rear 1 50 kg cm Tire Size Front 2 75 21 45P Rear 4 10 1859P Tire Typ...

Page 7: ...h Ignition system Spark Plugs Standard NGK DPRSEA9 Nippondenso X24EPR U9 Plug Gap 0 S 0 9 mm I gnition Timing F mark BTDC 15 1 400 rpm Lights Meters and Switches Light Bulbs Headlight Hil La beam 12V...

Page 8: ...e 2 Body Clearance 3 Side Clearance Carburetor Format Setting Mark Throttle Valve Diameter Venturi Diameter I ilot Screw Opening Float Level Idling rpm Jet Needle Clip Setting Position Main Jet Slow J...

Page 9: ...0 5 465 mm 5 42 mm EX 5 430 5 445 mm 5 40 mm Valve Guide Inner Diameter IN 5 475 5 485 mm 5 50 mm EX 5 475 5 485 mm 5 50 mm Valve Stem ta Guide Clearance IN 0 010 0 035 mm 0 06 mm EX 0 030 0 055 mm 0...

Page 10: ...stbn Ring ta Ring Groove Clearance Top 0 025 0 055 mm Opening Top Second Oil Siderail Assembly Indicator Clutch Gearshift linkage Clutch Operation Format Lever Free Play Format Disc Thickness Al BI Pl...

Page 11: ...Inside Diameter Shaft Outer Diameter STANDARD Constant Mesh 5 Speed Return 1 N 2 3 4 5 20 020 20 041 mm 23 020 23 041 mm 19 520 19 541 mm 23 020 23 041 mm 20 020 20 041 mm 22 984 23 005 mm 19 479 19...

Page 12: ...kg em Rear 1 50 kg em Tire Size Front 2 75 21 45P Rear 4 10 1859P Tire Brand Front Fuji Tire Wing 2000 Trail Sports Re ar Fuji Tire Wing 2000 Trail Sports Drive Chain Slack Using Sidestand 25 35mm Siz...

Page 13: ...t Disc Thickness 3 5 mm 3 0mm Vibration 0 30 mm Master Cylinder Inside Diameter 12 700 12 743 mm 12 76 mm Master Piston Outside Diameter 12 657 12 684 mm 12 64 mm Caliper Cylinder Inside Diameter 27 0...

Page 14: ...n Coil Type MP14 Resistance 20 Primary coil 0 20 0 220 Secondary coil with plug cap 7 8 8 4kO without plug cap 2 8 3 4kO Peak Voltage More than 100V Pulse Generator Resistance 20 293 3580 Peak Voltage...

Page 15: ...inder Head Bolt 1 Cam Sprocket Bolt 2 Chain Tensioner Socket Bolt 2 Sealing Screw 1 Cam Chain Tensioner Slider Bolt 1 Clutch Gearshift Linkage Clutch Center Lock Nut 1 Shift Stopper Arm Bolt 1 Gearshi...

Page 16: ...Axle Holder Nut 4 6 1 2 Caution 10 Fork Cap 2 34 2 2 Fork Socket Bolt 2 8 2 0 Caution 1 Wheel Front Axle 1 12 6 5 Rear Axle Nut 1 l6 9 5 Caution 10 Brake Disc Bolt 4 6 2 0 Driven Sprocket Nut 6 8 3 7...

Page 17: ...Holder 07GMB KTOI OO j I 9 Wrench 20X24 mm 07716 0010100 Ext Bar 07716 0020500 Pin Driver 3 0 mm 07744 0010200 Outer Driver 72X75 mm 07746 0010600 10 Pilot 28 mm 07746 0041100 Driver Handle A 07749 00...

Page 18: ...eedle Brg Remover 07931 MA70000 Outer Driver 28X30 mm 07946 1870100 Pilot 20 rnm 07746 0040500 I Driver Handle A 07749 001 0000 Helical 8rg Remover 07946 KA30200 Driver Shaft 07946 MJ00100 Spanner C 5...

Page 19: ...tio C1 C2 C4 Gear Inside Surface Clutch Outer Guide Flywheel Bolt Screw Honda Clutch Center Lock NUt Screw Ultra U 4 Stroke MC Use Cylinder Head Cover Nut Screw SAE 10W30 Tappet Adjuster Lock Nut Scre...

Page 20: ...Ultra U API Class SE SF or SG engine oil Front Brake Master Piston Lever Brake Grease Brake Lever Part Piston Caliper Pin Bolt Bracket Pin Bolt Front Master Piston Cap DOT4 Brake Fluid Front Brake Cal...

Page 21: ...N WIRE HARNESS Brake Hose R Handle Switch Coupler Meter Coupler R Handle Switch Coupler L Handle Switch Coupler L Winker Wire R Winker Signal light Wire Winker Relay Main Switch Coupler Speedometer Ca...

Page 22: ...MAINTENANCE INFORMATION Throttle Cable Pulse Generator Wire Clutch Cable Brake Hose High Tension Cord Throttle Cable Rear Stoplight Switch Wire Main Wire Harness Speedometer Cable Clute Cable 1 19...

Page 23: ...INFORMATION Carburetor Air Vent Tube Rear Stoplight Switch Wire Pulse Generator Wire Fuel Tube Fuse Box Starter Motor Cable AC Generator Wire Stop Light Wire R Winker Wire Starter Motor Cable Battery...

Page 24: ...lug and turn gasoline cock OFF Open throttle wide and re start f NO sparks or Ignition problem c lgnition System weak sparks STRONG spar s 1 Loosen carburetor drain crew check if there is sufficient g...

Page 25: ...d opening I NO change Improvemenl l Rich Air Mixture I fuel System NO pressure low pressure J Cylinder head problem I Cylinder Head Cylinder piston problem I cylinder Pislon f Improvement J Pilot scre...

Page 26: ...uate plug heating Improvement l Rich air mixture Io fuel System t fFRt e m ov e a ir c le an e r iel em e n 1 an d c h ec kkiiifff Improvement l Clogged air cleaner engine improves Rich air mixture o...

Page 27: ...ire pressure NOT slippery NORMAL Wheels does not l o Brake drag spin freely Ic Braking system Drive chain drag Wheel bearing defect Defective wheel installation low tire pressure o Faulty tire valve P...

Page 28: ...MEMO...

Page 29: ...but also of electric sparks Gasoline may also explode make sure that there is good ventilation in your work area Mufflers must be handled when already cold In this chapter we explain the removal and a...

Page 30: ...that the side cover tongue or nail is not damaged WORK I PART NAME NO NOT E S Removal Procedure Installation is reverse order of removal L Side Cover 1 Bolt 3 2 Screw 1 3 L Side Cover 1 R Side Cover 4...

Page 31: ...hen installing align seat hook to frame FRONT FENDER REMOVAL AND INSTALLATION Removal Procedure Remove bolt and collarI then remove front fender Installation Procedure Reverse removal procedure When i...

Page 32: ...LLATION I MUFFLERS FRONT COVER REMOVAL AND INSTAllATION 1 _ WORK I PART NAME NO NOT E S Removal Procedure Installation procedure is reverse of removal 11 Bolt 4 2 Headlight Connector 3 3 Front cover 1...

Page 33: ...LATED WORK Siae Cover Removal Q2 21 Seat Removal Q2 31 WORK PART NAME NO NOT E S Removal Procedure Installation procedure is reverse of removal 1 1 Tail Stoplight Coupler 1 2 Winker Connector 5 3 Bolt...

Page 34: ...NDER PIPE REMOVAL AND INSTALLATION 1 3 5 kg m 1 3 2 I1ilil WORK PART NAME NO NOT E S Removal Procedure Installation is reverse order of removal 1 Front Upper Engine Hanger Nut Bolt Frame Side 111 2 Bo...

Page 35: ...Removal C 2 3 WORK PART NAME NO NOT E S Removal procedure Installation is reverse order of removal 1 Exhaust Pipe Joint Nut 2 2 Muffler Band Bolt 1 Loosen only 3 Muffler Bolt IFront 1 14 Muffler Bolt...

Page 36: ...finishing work turn fuel cock to ON and make sure there is no fuel leak Remove Seat 0 2 3 Turn fuel cock to OFF remove fuel tube Remove fuel tank bolt and collar Raise fuel tank rear portion and pull...

Page 37: ...MEMO...

Page 38: ...ECKING I ADJUSTMENTS B 0 E I N 0 T E S E R 1 6 F I M 0 E o V o 0 V M E R I N 0 E 0 V M E N T R N E 0 G H K Y T R N M H Y T S S H S H Replacement of brake hose t Every 4 years B 0 R S E A M W D K A H I...

Page 39: ...edal 20 30 mm NOT E S Show steering stem Show eering sten a o 0 Lever ____ ____ ________ __1 __1 t ________ A_t_ti P_O_f_le_v_ r_ 1_0_ _2_0_m __ m __ ________________ KD K A Operation stroke and effic...

Page 40: ...rs flegular 1 75 1 50 W roads Tire specifications 2 75 21 4 10M18 H 45 P 59 P E Tire cracks and damage 0 0 0 E W Tire groove depth and Tread Front wheel 0 8 mm up to L abnormal wear out 0 0 0 Rear whe...

Page 41: ...S P A damage at arm S E R 0 N M I s 0 0 N N S S A Oil leak and damage Y H B 0 S o S C 0 T K R E B E M R Sticking at connectiOlis 0 Lever free play Slack T C 0 Lever type L 0 R U At lever edge 10 20 m...

Page 42: ...cer function Electrical system M 0 No required service A L Fluid volume Electrical system 0 0 No reQuired service B A S T Fluid specific gravity Electrical system E 0 No reql lired service Y MF Batter...

Page 43: ...mm N 0 0 EXHAUST 0 08 0 12 mm U N I T M L Oil impurities and volume Oil Volull e U Dip Stick gauge type B BetWeen MAX and MIN Volume R 0 0 I C a A T I 0 Oil leak 0 0 N S T y Oil volume 0 S t E Clogged...

Page 44: ...only A R f R R 1 0 E 0 V R C I T E 0 W R R M E 0 Dirt and damage f T B 1 0 0 E R 0 C Y T R 0 E N R G U S I M S B 0 T E R R A T I 0 N N 0 M Function E T 0 E R S E P M Looseness in assembly and 0 X I U...

Page 45: ...Gauge Engine Volume Rear Tire Wear Out Rear Brake Shoe Wear Out Rear Wheel Rear 3 8 Air Pressure Throttle Grip Front Brake Reserved Tank Fluid Volume Check Front Brake Lever Air in Free Play Headligh...

Page 46: ...Brake Caliper lPadWear Front Brake Hose Wear Break Timing Hole Cap Ignition Timing CHECKING AND ADJUSTMENT Fuel Line Leak Rear Suspension Looseness Damage Oil Air Cleaner Element Dirt Clogging Damage...

Page 47: ...eaner case hole Installation is the reverse of removal procedure VALVE CLEARANCE Checking Valve clearance checking and adjustment should be con ducted when the engine is cold 35 degrees or below Remov...

Page 48: ...nd turn adjuster screw insert standard thickness gauge of medium thickness and adjust clearance Fix adjust screw and tighten lock nut Torque 1 4 kg m Tappet Adjuster I W ench Wrench 10 x 12 mm 07708 0...

Page 49: ...adequately Put in neutral gear start on warm l Ip Turn throttle stop screw and adjust idling Idling rpm 1 400 100rpm DRIVE CHAIN Replacement The drive chain uses master link joint pin type When repmci...

Page 50: ...MEMO...

Page 51: ...embly Make sure that foreign objects do not get into engine when removing and assembling the oil pump Check that there is no oil leak after installing the oil pump TROUBLESHOOTING Low Oil Volume Oil c...

Page 52: ...LUBRICATION SYSTEM OIL LUBRICATION FLOW Camshaft Crankshaft Main Shaft Oil Filter Rotor Countershaft 4 2...

Page 53: ...Work Removal and Installation ot Hight Crank Case Cnver 0 9 2 WORK I PART NAME NO NOT E S Removal Procedure Installation is reverse order of removal procedure Oil Pump 1 Oil Pump Screw 2 2 Oil Pump A...

Page 54: ...Bar Assembly 07724 0010200 07716 0020100 07716 0020500 Apply engine oil to screw part of oil tilter rotor lock nut and attach facing primary drive gear Insert gear holder between clutch outer gear Pri...

Page 55: ...Pump Removal and Installation 4 3 WORK I PART NAME NO NOT E S Disassembly Assembly is reverse of disassembly 1 Oil Pump Plate Screw 2 2 Oil Pump Plate 1 3 Inne r Rotor 1 When assembling match the notc...

Page 56: ...MEMO...

Page 57: ...always remove the gasoline from the carburetor float chambe r The gasoline in the float chamber may deteriorate clogging the slow jet with gum like substance which results in idling defects TROUBLESH...

Page 58: ...al and Installation 2 3 WORK PART NAME Removal 1 Connecting Tube Band Screw 21 Air Cleaner Case Bolt 3 Ground Cable Air Cleaner Case I 5 Resonator 5 2 Regulator Rectifier Removal and Installation 14 7...

Page 59: ...Installation 2 2 Fuel Tank Removal and Installation 2 8 WORK PART NAME Removal 1 Connecting Tube Band Screw 2 Carburetor Air Vent Tube 3 Carburetor Drain Tube 4 Throttle Valve 5 Nut 6 Carburetor 7 a...

Page 60: ...FUEl SYSTEM CARBURETOR DISASSEMBLY AND ASSEMBLY 18 19 23 20 21 24 40 39 33 37k 1Ioiiiii O rmg 4 13 0 4 1 5 4 23 27 3 2 Air Cut Valve Tube location 3 7 17 16 1 15 i 14 r lower right Align 6...

Page 61: ...g 1 6 Baffle Plate 1 7 Float Pin 1 8 _Float 1 9 Float Valve 1 10 Main Jet 1 11 Needle Jet Holder 1 12 Needle Jet 1 13 Slow Jet 1 Pilot Screw 14 Pilot Screw 1 When disass unblirig record number of scre...

Page 62: ...01 Damaged to tlie pilot screw seat will occurM the pilot screw is tightened against the seat Warm up engine Stop engine connect tachometer Start engine use throttle stop screw to adjust to standard e...

Page 63: ...MEMO...

Page 64: ...s are n ot damaged in the process When following procedures and installing the engine protect the frame with tape The following components can be serviced with the engine installed in the frame AC Gen...

Page 65: ...ENGINE REMOVAL AND INSTALLATION DRIVE SPROCKET REMOVAL AND INSTALLATIO N 2 OUT IN 1 6 2...

Page 66: ...2 2 Drive Sprocket Cover 1 3 Drive Sprocket Set Plate Bolt 2 4 Drive Sprocket Set Plate 1 When installing attach plate to countershatt align plate and sprocket bolt hole then assemble 5 Drive Sprocke...

Page 67: ...ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION 4 14 6 0 kg m LL i 8 L 9 3 5 kg m 10 3 5 kg m _ _ 1 13 20 6 4 19 15 3 5 kg m 3 12 14 I 18 5 10 18 3 5 kg m 15 16 16 3 5 kg m...

Page 68: ...t Pipe and Muffler Removal and Installation 2 7 Carburetor Removal and Installation 5 3 Orjve Sprocket Removal and Installation 7 2 WORK I PART NAME NO NOT E S Removal Installation is reverse order of...

Page 69: ...MEMO...

Page 70: ...tected generally by measuring compression pressure or by listening to the sound of the engine top end When encountering starting defects or defects at low speed check the crankcase breather tube fot s...

Page 71: ...CYLINDER HEAD VALVE CYLINDER HEAD REMOVAL 12 14 1 13 15 ____ 16 19 20 18 7 7 2...

Page 72: ...cam chain with a piece of wire to prevent it from falling into the crankcase 10 Cylinder Head Cover Bolt 4 11 Cylinder Head Cover Nut Sealing Washer 4 4 12 Cylinder Head Cover Assembly 1 13 Cam Shaft...

Page 73: ...ve rocker arm shaft plate Temporarily attach the rocker arm shaft using the appropriate 6mm bolt cylinder head cover bolt or similar Pull 6mm bolt remove rocker arm shaft Installation is reverse order...

Page 74: ...heir original position Related Work Cylinder Head Removal 0 7 2 WORK PART NAME NO NOT E S Disassembly Installation is reverse order of removal 1 Cam Chain Tensioner Slider Bolt Washer 1 1 2 Cam Chain...

Page 75: ...CYLINDER HEAD VALVE CYUNDER HEAD INSTALLATION 2 7 kg m _ o 16 1 2 24 6 25 J 1mru 3 Bond 125 11 4 kg m 8 5 12 Hole 3 13 1 11 14 4 1 0 kg m 20 1 21 1 2 kg m 19 f JF 7 6...

Page 76: ...2 7 Camshaft 1 Installation 7 8 8 Cylinder Head Cover Assy 1 9 Tappet Adjust Screw 2 10 Tappet Adjust Screw Lock Nut 2 111 Rocker Arm 2 12 Rocker Arm Shaft 2 Installation 7 4 13 Rocker Arm Shaft Plat...

Page 77: ...qriver to install cam chain tensioner and gasket while in lock position Install sealing washer and cam chain tensioner socket bolt then tighten to specified torque Torque 1 2 kg m Remove screwdriver a...

Page 78: ...olt 1 2 kg m Put cam chain onto cam sprocket While aligning t e cam sprocket index mark to the cylinder head cover attach cam sprocket to the cam shaft Attach cam sprocket bolt and tighten to the spec...

Page 79: ...MEMO...

Page 80: ...by the screwdriver and that the fins are not hit too hard as to cause damage Parts should be cleaned then dried adequately using compressed air prior to inspection TROUBLESHOOTING Compression Pressure...

Page 81: ...CYLINDER AND PISTON CYLINDER PISTON REMOVAL AND INSTALLATION 80ss 3 v 1 11 8 2...

Page 82: ...n Guide 1 When installing align edge to crankcase groove When installing align boss to cylinder groove 21 Cylinder 1 31 Dowel Pin 2 4 Gasket 1 5 Piston Pin Clip 2 6 Piston Pin 1 7 Piston Assy 1 When i...

Page 83: ...MEMO...

Page 84: ...ine Crankcase must e dismantled before maintenance can be conducted on the t ansmission shift drum shift fork T ROUBLESHOOTING Clutch Lever Too Hard Damaged kinked or dirty clutch cable Damaged clutch...

Page 85: ...CLUTCH GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL AND INSTALLATION 3 4 5 t1I 2 7 9 _ I EJ 9 2...

Page 86: ...replenish engine oil to correct level Related Wor Engine Oil Removal and Replenishment Under Pipe Removal and Installation 0 2 6 WORK I PART NAME NO NOT E S Removal Installation is reverse order of r...

Page 87: ...CLUTCH GEARSHIFT LINKAGE CLUTCH REMOVAL 10 9 6 S TooLj 9 6 5 3 2 9 4...

Page 88: ...utch Lifter Plate Bearing 1 5 Clutch Spring 4 6 Clutch Center Lock Nut 1 Removal 10 9 6 7 Lock Washer 1 8 Clutch Center 1 r Remove whole assy 9 Judder Spring 1 10 Spring Seat 1 111 Clutch Disc A 1 Int...

Page 89: ...lder Wrench 20 x 34 Extension Bar Installation Attach lock nut to main shaft 07GMB KT70100 07716 0020100 07716 0020500 Fix clutch center using clutch center holder then tighten lock nut Torque 8 5 kg...

Page 90: ...nstallation c 9 4 8 WORK PART NAME NO NOT E S Removal Installation is reverse of removal 1 Change Pedal Bolt 1 2 Change Pedal 1 3 Gear Shift Spindle Washer 111 When installing align spindle spring bos...

Page 91: ...CLUTCH GEARSHIFT LINKAGE CLUTCH INSTALLATION 6 S 15 16 17 9 8 14 13 S 5 kg m rG3l q9 6 9 10...

Page 92: ...ch attach then lock 5 Pressure Plate 1 6 Clutch Plate 4 r Install as a whole assy 7 Clutch Disc B 4 8 Clutch Disc A 1 Attach clutch disc A boss to shallow groove of clutch outer 91 Judder Spring Seat...

Page 93: ...MEMO...

Page 94: ...4 8 Cylinder Piston e 8 Cylinder Head e 7 Starter Motor e 16 7 When removing the crankshaft make sure nofta scratch or damage the main bearing During assembly apply engine oil to main bearing TROUBLES...

Page 95: ...CRANKSHAFT TRANSMISSION CRANKCASE DISMANTlING AND ASSEMBLY 7 Oiru Three Bond 1141 5 4 10 2 Locations where sealing material is to be applied Three Bond 1141...

Page 96: ...PART NAME NO NOT E S Dismantling Assembly is reverse order of removal 1 Cam Chain Guide P ate Bolt 1 1 2 Cam Chain 1 3 Left Crankcase Bolt 10 When installing check that the crankcase is tightly attac...

Page 97: ...CRANKSHAFT TRANSMISSION CRANKCASE BEARING Right Crankcase o 3 l i 1 11 o Left Crankcase 2 10 4 o 8 n 4 2 kg m o D 5 7 6...

Page 98: ...val and Installation 1 0 6 WORK I PART NAME NO NOT E S Lett Crankcase 1 Main Shaft Bearing 1 2 Countershaft Bearing 1 Right Crankcase 3 Crankshaft Bearing 1 4 Bearing Set Plate Bolt 2 5 Bearing Set Pl...

Page 99: ...CRANKSHAFT TRANSMISSION CRAKSHAFT TRANSMISSION REMOVAL AND INSTALLATION 4 1 7 10 6...

Page 100: ...work Crankcase Dismantling and Assembly 1 0 2 WORK I PART NAME NO NOT E S Removal Assembly is reverse of removal 1 Shift Fork Shaft 1 2 Left Shift Fork 1 Attach with L mark facing L crankcase 3 Center...

Page 101: ...CRANKSHAFT TRANSMISSION MAIN SHAFT DISMANTLING AND ASSEMBLY 3 2 1 4 Q 9 8 10 11 2 11 5 19 All SHIFT GEAR GROOVES All GEAR MOVING PARTS 10 8...

Page 102: ...veled surfaces facing the turning part The beveled surface of the snap ring should be attached facing the direction of the side with load Related Work Transmission Removal and Installation C 1 0 6 WOR...

Page 103: ...CRANKSHAFT TRANSMISSION COUNTERSHAFT DISMANTLING AND ASSEMBlY 4 1 3 ___I N ALl SHIFT GEAR GROOVES ALL GEAR MOVING PARTS 10 10 16 5 171 16 14 11...

Page 104: ...g the turning part The beveled surface of the snap ring should be attached facing the direction of the side with load Related Work Transmission Removal and Installation c 10 6 WORK I PART NAME NO NOT...

Page 105: ...MEMO...

Page 106: ...wheels Handle wheels wi h care When removing the tire from the rim use tire lever and rim protector in order to protect the rim from damage TROUBLESHOOTING Hard Steering Steering stem nut too tight D...

Page 107: ...FRONT WHEEL SUSPENSION STEERING HANDLE BAR REMOVAL AND INSTALLATION Align UP Mark 4 Align 18 14 Q 17 24 8 9 Iiijijijffi 11 13 2 21 25 2 6 kg m 25 2 6 kg m 11 2...

Page 108: ...le Housing Screw 2 Attach from top 7 Throttle Housing Cover 1 Align handle punch mark 8 Throttle Cable Guide 1 9 Throttle Cable 1 10 Throttle Housing 1 11 Throttle Grip 1 12 Right Handle Switch Screw...

Page 109: ...FRONT WHEEL SUSPENSION STEERING FRONT WHEEL REMOVAL 6 2 4 6 5 kg m J 3 1 2 kg m 3 1 2 kg m 5 11 4...

Page 110: ...T operate brake Jever After installing operate brake lever and push out the piston caliper WORK I PART NAME NO NOTES Removal Installation is reverse order of removal 11 Speedometer Cable Screw 1 2 Spe...

Page 111: ...FRONT WHEEL SUSPENSION STEERING FRONT WHEEL DISMANTLING AND ASSEMBLY 11 9 r rn Daphne Eponex No 0 i 10 11 iijijffifl 4 2 7 6 5 3 2 0 kg m II 5 1 iijijffifl 1 iijijffifl 8 7 6 11 6...

Page 112: ...NO NOT E S Dismantling Assembly is reverse order of removal 1 Oust Seal 2 2 Speedometer Gear Retainer 1 3 Brake Disc Bolt 4 4 Brake Disc 1 Install with mark facing out 5 Hub Cap 1 6 Left Wheel Bearing...

Page 113: ...FRONT WHEEL SUSPENSION STEERING FORK REMOVAL AND INSTALLATION 512 8 kg m 61 3 3 kg m 71 11 fit m 11 8...

Page 114: ...ME NO NOT E S Removal 1 Brake Hose Clamp Bolt 2 Brake Hose Clamp Left side only 3 Caliper Bolt 4 Front Brake Caliper After removing caliper do not suspend caliper from hose 5 Fork Top Bolt Loosen only...

Page 115: ...FRONT WHEEL SUSPENSION STEERING FORK DISMANTLING 4 15 2 10 16 11 10...

Page 116: ...1 4 O ring 1 5f Fork Spring A 1 6 Spring Seat 1 7 Fork Spring B 1 Remove fork oil along with spring 8 Dust Seal 1 9 Stop er Ring 1 I CIUTIONI Do not scratch fork tube surface 10 Fork Socket Bolt 1 11...

Page 117: ...NT WHEEl SUSPENSION STEERING FORK ASSEMBLY 14 JL 13 1 11 1 2 3 1 71 Liquid a ring 400 4 1 Liquid a ri CUSKLOII 3 all 4 t SJ 21 5 j 20 10 12 2 0 kg m 1 6 11 12 CIlIHIOI 17 Y 19 2 2 kg m J 181 II CIiSHI...

Page 118: ...ide Bush 1 6 Oil Lock Piece 1 7 Fork Tube 1 8 Rebound Spring 1 9 Fork Piston Ring 1 10 Fork Piston 1 11 Sealing Washer 1 12 Fork Socket Bolt 1 If the fork piston turns with the socket bolt temporarily...

Page 119: ...c 1 1 2 Front Fender Removal C 2 3 WORK PART NAME Removal 1 Steering Stem Nut Washer 2 Top Bridge 3 Steering Top Thread Dust Seal 4 Upper Inner Race 5 Upper Bearing 6 Steering Stem 7 Lower Bearing B L...

Page 120: ...MEMO...

Page 121: ...braking system checking and maintenance 1m Use only genuine replacement bolts and nuts for all suspension pivot and mounting points Do n t step on wheel nor exert unnecessary pressure and weight on t...

Page 122: ...REAR WHEEL SUSPENSION REAR WHEEL REMOVAL AND INSTAl LATION Pin 13 9 8 7 5 9 5 kg m 13 12 12 2...

Page 123: ...S Removal Installation is reverse order of removql 1 Brake Adjuster 1 2 Brake Arm Pin 1 3 Brake Rod 1 4 S pring 1 5 Rear Axle Nut 1 Loosen axle nut loosen chain adjuster completely remove chain from...

Page 124: ...REAR WHEEL SUSPENSION REAR WHEEL DISMANTLING ASSEMBLY 3 7 kg m 6 1 3 r Fjijffi 2 3 7 kg m 2 1 6 5 12 4 4 4...

Page 125: ...as ing agent Wheel bearings must be replaced as a set Related Work Rear Wheel Removaillnstallation e 12 2 WORK I PART NAME NO NOT E S Removal Attachment is reverse order of removal 1 Driven S rocket N...

Page 126: ...REAR WHEEL SUSPENSION REAR CUSHION REMOVAL ANO INSTALLATION 3 I 3 4 5 kg m 1 2 4 5 kg m 12 6...

Page 127: ...of hole 0 1 10 Do not remove gas except when disposing of the cushion unit Support frame adequately using jack raise rear wheel before operating Use genuine bolts and nuts for installing cushion Rela...

Page 128: ...genuine bolts and nuts for installing cushion linkage WORK I PART NAME NO NOT E S Removal Installation is reverse of removal 1 Rear Cushion Lower Bolt Nut 111 2 Cushion Conn Rod Bol t Nut Cushion Arm...

Page 129: ...collar and dust seal lip when assembling Related work Cushion Linkage Removal and Installation 12 8 WORK PART NAME NO NOT E 5 Removal Assembly is reverse of removal 11 Cushion Control Pivot Collar 1...

Page 130: ...epth 4 0 mm Spherical Bearing Driver 07946 KA30200 Insert the bearing by pushing on the side with markings Cushion Arm Needle 89arings Swing Arm Side Use hydraulic press to remove needle bearings Driv...

Page 131: ...07946 MJ00100 Insert new needle bearings into the specified depth Specified Depth 4 0 mm Spherical Bearing Driver 07946 KA30200 Push on the side with markings to insert bearings REAR WHEEl SUSPENSION...

Page 132: ...REAR WHEEL SUSPENSION SWING ARM REMOVAL AND INSTAllATION 3 6 4 3 10 5 kg rn 12 12...

Page 133: ...olt near swing arm Related Work Rear Wheel Removal and Installation Q12 121 WORK PART NAME NO NOT E S Removal Installation is reverse order of removal 1 Chain Cover Bolt 2 2 Chain Cover 1 3 Cushion Ar...

Page 134: ...REAR WHEEL SUSPENSION SWING ARM DISMANTLING AND ASSEMBLY 7 10 11 1 3 0 6 kg m 4 5 6 9 1 2 iijijijffi 1 9 10 iijijijffi 10 _ 12 14...

Page 135: ...se order of removal 1 iSust Seal Cap 1 2 Pivot Collar 1 3 Chain Slider Screw 1 4 Chain Slider 1 Align boss to swing arm hole during assembly 5 Driven S rocket Guard Plate Bolt 2 6 Driven Sprocket Guar...

Page 136: ...dle Bearing Remover 07931 MA70000 Insert new needle bearings and side collar until the side collar hits swing arm Outer DriverI 28 x 30 mm Pilot 20 mm Driver Handle A 07946 1870100 07746 0040500 077 9...

Page 137: ...MEMO...

Page 138: ...llow oil or oil products to come in contact with the brake drum interior or lining surfaces In the event of such contact clean and _degrease the brake drum and replace brake shoe When adding brake flu...

Page 139: ...g Dirty brake drum Brake shoes worn at cam contact area Brake arm serrations improperly engage Abnormal Noise From Brakes Defec tive brake lining Worn out brake drum Uneven wear out of brake lining Di...

Page 140: ...s a set Do not operate brake lever while replacing brake pads After replacing operate brake lever to push out pads WORK I PART NAME NO NOT E S Removal 1 Installation is reverse of removal 1 Pad Pin Pl...

Page 141: ...liper piston remove f jrst the brake pad then push out the the caliper piston using the lever before draining the brake fluid Related Work Front Brake Pad Removal and Installation 0 13 3 Brake Fluid R...

Page 142: ...WORK I PART NAME NO NOTES Dismantling Assembly is reverse order of removal 1 Pad Spring 1 2 Pad Retainer I 3 Bracket Pin Bolt 1 Do not remove unless necessary 4 Bracket Pin Bolt Boots 1 5 Caliper Pin...

Page 143: ...stallation is reverse of removal 1 Right Rear View Mirror 1 2 Brake Lever Pivot Bolt Nut 1 1 3 Knuckle Guard 1 4 Brake Lever 1 5 Oil Bolt 1 6 Sealing Washer 2 7 Brake Hose 1 8 Front Stoplight Switeh C...

Page 144: ...Cylinder Removal and Installation 10 13 6 WORK I PART t JAME NO NOT E S Dismantling Assembly is reverse of dismantling 11 Front Stoplight Switch Screw 1 12 Front Stoplight Switch 1 13 Master Cylinde...

Page 145: ...as a set Related Work Rear wheel removal and installation 12 2 WORK PART NAME NO NOT E S Dismatling Assembly is reVerse oLf dismantling 1 Brake Shoe 2 2 Brake Shoe Spring 2 3 Brake Arm Bolt Nut 111 4...

Page 146: ...er of removal 1 Rear Stoplight Switch Spring 1 2 Rear Brake Return Spri 19 1 3 Brake Adjuster 1 4 Brake Arm Pin 1 5 Spring 1 6 Brake Pedal Bolt 1 7 Brake Pedal Piyot 1 8 Brake Pedal Assy 1 9 Dust Seal...

Page 147: ...MEMO...

Page 148: ...period of time disconnect the negative cable Accelerated recharging is for emergency situations only This can shorten the battery s useful life If cycles of complete discharg e and full recharge are...

Page 149: ...L SYSTEM AC GENERATOR LOCATION OF ELECTRICAL SYSTEM COMPONENTS Regulator Rectifier Main Fuse 15A Battery AC Generator Main Fuse 15A 3P Black Green Red Green e Batterv o Regulator Rectifier 0 AC genera...

Page 150: ...k current e 14 6 Standard Value 0 rnA or below NORMAL Start engine and measure electic current between the terminals 00 14 61 Standard Value 14 14V 5 OOOrpm ABNORMAL I NORMAL Check the regulator recti...

Page 151: ...Standard value battery voltage Check resistance at AC generator 14 1 0 Terminal connection yellow to yellow Standard value 0 1 to 1 0 Q 20 OC NORMAL Check regulator rectifier unit 14 7 14 4 ABNORMAL...

Page 152: ...r and call a physician immediately In case the liquid gets in contact with clothing take clothing off immediately and wash off the battery liquid Always turn off the ignition switch before disconnecti...

Page 153: ...before performing this test Required voltage should be more than 13 V Warm up engine Install a fully charged battery Connect digital circuit tester between battery terminals Remove starter relay switc...

Page 154: ...ified testers may cause display of abnormal resistance values making it difficult to conduct testing properly Sanwa Genuine Tester 07308 0020001 analog type Kowa Tester TH 5H analog type Use the follo...

Page 155: ...ElECTRICAL SYSTEM AC GENERATOR AC GENERATOR REMOVAL AND INSTAllATION 2 1 5 1171 14 I 7 5 kg m 9 13 24 17 I Three Bond 1141 Pin 23 16 I 22 Clamp C a 18 1 0 kg m 20 19 0 5 kg m 14 8...

Page 156: ...13 Flywheel 14 Woodruff Key 15 Washer Left Crankcase Cover Dismantling 16 Cord Clamp 17 Stator Grommet 18 Stator Bolt 19 Pulse Generator Socket Bolt 20 Cord Guide 21 Stator 22 Pulse Generator Connect...

Page 157: ...ove left side cover 2 21 Disconnect AC generator from 3P coupler Measure resistance of the yellow terminal of coupler on the engine side Termina Connection yellow to yellow Standard Value 0 1 to 1 0 n...

Page 158: ...MEMO...

Page 159: ...FF while a current is flowing the circuit produce excess voltage and may damage the unit Most ignition system defects are caused by improper connection of couplers and connectors Check those connectio...

Page 160: ...ch Ignition Coil P lse Generator e Batterv 15 2 Ignition Switch Neutral Switch Engine Stop Switch Red Red I O 4 Black Main Fuse ISA Black Yellow SparkPluy COl Unit Engine Stop Switch COl Unit Main Fus...

Page 161: ...coil 15 6 Terminal connection blacklyellow to body ground Standard value more than 100 V i NORMAL Remove COl unit coupler connection Measure pulse generator peak voltage at COl unit coupler harness s...

Page 162: ...EM Terminal connection bluelyellow I I to body ground I I Standard value more than O 7 V ABNORMAL I Defective pulse generator NORMAL 15 4 Cut or shortea mue yellow terminal cord Cut or shorted green t...

Page 163: ...ylinder pressure check with the plug and cap in normal position If spark plug is removed and tested by itself peak voltage tends to be higher Le ave the spark plug in the cylinder head attach good spa...

Page 164: ...mal connect adapter to pulse generator coupler Measure peak voltage again and compare with previous result Connection Method blue yellow cord tenninal to body ground If peak voltage at pulse generator...

Page 165: ...lug cap from plug Remove high tension cord from clamp Disconnect ignition coil primary side terminal cord Remove ignition coil Inst311atioh is reverse order of removal CHECKING PULSE GENERATOR Remove...

Page 166: ...r and replace if defective Warm up engiri Stop engine support with side stand Remove timing hole cap Connect timing light to high tension cord Start engine During idling if the flywheel F mark is alig...

Page 167: ...MEMO...

Page 168: ...st rter motor maybperate unexpectedly causing injury to operator Checking of the starting mechanism should be done following the troubleshootin g chart Irefer 16 3 in the correct procedure Refer to 1...

Page 169: ...Motor 16 2 Main Switch Starter Switch Switch Main Fuse 15A Battery Neutral Switch Starter Relay Switch Green Red Clutch I Switch j Starter Switch Red Ignition Switch L Red Black Black Blue __________...

Page 170: ...toT Inspect that the transmission gear location are in starting position If gear is in neutral the starter motor will turn regardless of clutch switch condition If gear is in a position other than neu...

Page 171: ...starter relay switch 4P coupler then check ground line 1 Green red terminal and neutral switch ground line do not grip clutch lever while gear is in neutral position Terminals to connect green red to...

Page 172: ...Connect a fully f l Corinection defectofstarterrelayswitchi4P coupler charged battery to the starter relay switch as shown in drawing belo While it is connected to battery check circuit connection be...

Page 173: ...ection of starter motor cable Faulty starter motor Wear or damaged starter motor brush Starter Motor Turns But Engine Qoes Not TUrn Starter motor is running backward Case assembled improperly Terminal...

Page 174: ...us injury R fer to wiring Diagrams 1 18l to correctly install cables and wires Related Work Exhaust Pipe Muffler Removal and Installation Q2 7 WORK I PART NAME NO NOT E 5 Removal Installation is rever...

Page 175: ...STARTING MECHANISM STARTER CLUTCH STARTER MOTOR DISMANTLING AND ASSEMBLY 7 r HI S S 11 9 20 _ _ 12 6 Hn 171 4 Align...

Page 176: ...rd order and number for easy assembly 7 Front Cover 1 During assembly align notch with starter motor case marking 8 O ring 1 9 Lock Washer 1 10 Insulation Washer 1 11 Shims Record order and number for...

Page 177: ...removed engine oil will flow out Prepare a clean oil pan and place it under the engine to receive the oil WORK I PART NAME NO NOT E S Removal Assembly is reverse of removal 1 Starter Reduction Gear C...

Page 178: ...t Fly Wheel Holder Torque Bit 07725 0040000 07703 0010100 Remove one way clutch outer one way clutch Installation Wash one way clutch apply clean engine oil into one way clutch retainer Face one way c...

Page 179: ...the screws Hold the flywheel using the flywheel holder insert torque bolts then screw firmly Torque 1 6 kg m Flywheel Holder Torque Bit 07725 0040000 07703 0010100 Attach starter driven gear by turni...

Page 180: ...MEMO...

Page 181: ...ring replacement this will leave grease or oil on the bulb surface This will then become a hot spot which can cause cracking on or damage to the bulb surface Pay careful attention to the following whe...

Page 182: ...ES LOCATION OF LIGHTS METERS AND SWITCHES Main Switch R Front Winker Bulb Headlight Bulb Front Stoplight Switch Rear Stoplight Switch L Front Winker Bulb R Rear Winker Bulb Bulb Horn Battery Neutral S...

Page 183: ...bare hands after turning off Start work ol ly when the bulb has sufficiently cooled WORK I PART NAME NO NOT E S Removal Attachment is reverse order of removal 1 Bolt 4 2 Front Cover 1 3 Dust Cover 1...

Page 184: ...counter clockwise Attachment is reverse of removal procedure When attaching align lens boss hole in case Lens TAIL STOPLIGHT BULB Bulb Screw Remove screw then remove lens _ Rel love bulb by turning co...

Page 185: ...ring diagram 1 18 to correctly install wires and cables Related Work Front Cover Removal and Installation 2 4 WORK I PART NAME NO NOT E S Removal Installation is reverse order of removal 1 Speedometer...

Page 186: ...LIGHTS METERS SWITCHES METER DISASSEMBLY AND ASSEMBLY 5 4 3 6 7 9 clamp light green black black brown green black brown green blue Dran ae Slkv Blue 17 6...

Page 187: ...amp Related Work Meter Removal and Installation 0 17 5 WORK I PART NAME NO NOT E S Dismantling Installation is reverse order of removal I 1 Bulb Socket 4 I 2 Bulb 4 I 3 Speedometer Screw 2 4 Lower Cov...

Page 188: ...nstall wires and cables Related Work Front Cover Removal and Installation 2 4 Meter Removal and Installation 0 17 5 WORK PART NAME NO NOT E S Removal Installation is reverse order of removal I 1 Main...

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Honda XLR200R, Service Manual

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