1979-1984 XR185 / XR200 Service & Repair Manual

SHOP MANUAL XR1B5·200

IMPORTANT SAFETY NOTICE ij#.i@aS Indicates a strong possibility of severe personal injury or loss of life if instructions are not fo llowed. CAUTION: Indicates a possibi lity of personal injury or equipment damage if instructions are not followed. NOTE: Gi ves he lpful information. Detailed descriptions of sta ndard workshop procedures, safety principles and service operations are not included. It is important to note that this manual cont ains some wa rn ings and cautions against some specific service methods which could cause PERSONAL I NJURY to serv ice personnel or could damage a vehicle or render it unsafe. Please understand th at those warnings could not cover all conceivable ways in which service, whet her or not recommended by Honda might be done or of t he poss- ibly hazardous consequences of each conceivable way , nor could Honda investigate all such ways . Any one using se rvice procedures or tools, whether or not recommended by Honda must sa ti sfy himself thoroughly t ha t neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected.

~ HONDA ~ XR200 HOW TO USE THIS MANUAL Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 15 describe parts of the motorcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration and all the required specifications, torque values, general instructions, tools and troubleshooting for the section. The subsequent pages give detailed procedures. If you don 't know the source of the trouble , go to section 16 , Troubleshooting. Refer to the addendums at the back of the shop manual for information on 1980 and subsequent XR200's. Date of Issue: November, 1 983 @ American Honda Motor Co., Inc. 1 983 - All Rights Reserved CONTENTS

2 MODEL IDENTIFICATION The vehicle identification number (VIN) is on the steering head right side. The engine serial number is stamped on the crankcase lower le ft side. ' HONDA XR185·200 The frame serial number is stamped on the steering head left side. \ The carburetor identification number is on the carbu· retor body right side. Date of Issue: July, 1981 © American Honda Motor Co., Inc. 1981 ·All Rights Reserved

~ H~~~A 1. GENERAL INFOMATION 3 GENERAL SAFETY 1- 1 SE RVI CE RULES 1-1 SPEC IFI CATIONS 1 -2 TORQUE VALUES 1- 4 TOOLS 1 -5 WIR IN G DIAGRAM 1- 6 CABLE & HARNESS ROUTING 1- 7 MAINTENANCE SCHEDULE 1- 9 GENERAL SAFETY IMijiWli 'M'•Mitd If rile engine must be nmning to do some work, make sure the area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas. Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in your work area. SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that don't meet HONDA's design specifications may damage the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. 4. Install new gaskets, 0-ring, cotter pins, lock plates, etc. when reassembling. 5. When torquing bolts or nuts, begin with the larger-diameter or inner bolt first. Then tighten to the specified torque diagonally in 2·3 steps, unless a particular sequence is specified. 6. Clean parts in non-flammable or high flash point solvent upon disassembly. 7. Lubricate any sliding surfaces before reassembly. 8. After reassembly, check all parts for proper installation and operation. Date of Issue: December, 1978 © HONDA MOTOR CO., LTD. 1-1

4 GEN ERAL INFORMATION SPECIFICATIONS DIMENSIONS Overall length Overall w idth Overall he ight Wheel ba se Seat height Foot peg height Minimum ground clearance Dry weight FRAME Type Front suspension, travel Rear suspension, travel Front ti re size, pressure Rear ti re size, pressure Front brake Rear brake Fuel capacity Fuel reserve capacity Caster Trail Front fork oil capaci ty ENG I NE Type Cylinder arrangement Bore x stroke Displacement Compression ratio Valve t rain Maximum hosepower Maximum torque Oil capacity Lubrication system Air filtrat ion system Cylinder compression Intake valve OPEN CLOSES Exhaust valve OPEN CLOSES Valve clearance CARBURETOR Type Main jet Pilot screw opening Float level Idle speed Bore 1-2 2,060 mm (81.1 in) 840 mm (33.1 i n) 1,145 mm (45.1 in) 1,325 mm (52.2 in) 860 mm (33.9 in) 345 mm (13.6 in) 285 mm (11.2 in) 98 kg (214.1 lb) Diamond HONDA XR185 Telescopic 216 mm (8.5 in) Swing arm 191 mm (7 .5 in)' 2.75- 21- 6PR 1.0 kg/cm 2 (14.2 psi) 4.10- 18-6PR 1.0 kg/cm 2 (14.2 psi) Cable operated leading·trailing shoes Rod operated leading·trailing shoes 7.0 lit (1.8 US gal., 1.5 Imp gal) 1.5 lit (0.4 US gal., 0.3 Imp gal) 61 ° 30' 122 mm (4.8 in) 170 cc (5.75 ozs) Gasoline. air·cooled 4·stroke Single cylinder incli ned 15° 63 .0 x 57.8 mm (2.48 x 2. 28 in) 180.2 cc ( 11 . 01 cu in) 10.0: 1 Overhead camshaft chain driven 18.0 BHP/9,000 rpm 1.58 kg·mn ,500 rpm ( 11 .49 lb-ft/7 ,500 rpm) 1.11it (1.2USqt,l.Oimpqt) 0 .9 lit (0. 98 US qt. 0.82 I mp qt) after draining Forced pressure and wet sump Oiled polyurethane foam 14.0 kg/cm 2 (199 ps i) 45° ABDC . 15° 8TOC} 45 o BBDC at 1 mm lift 15° ATDC 0.05 mm (0.002 in) (Cold) 0.08 mm (0. 003 in) (Cold) Piston valve # 115 Factory pre set 12.5 mm (0.49 in) 1,300 rpm 24 mm (0. 95 in) Date of Issue: December, 1978 © HONDA MOTOR CO .• L TO.

~ HONDA ~ XR18 5 GENERAL INFORMATI ON DRIVETRAIN Clutch Transmission Primary reduction Gear ratio Gear ratio Gear ratio Gear ratio Gear ratio Gear ratio Final reduction Gear shift pattern Drive chain ELECTRICAL Ignition Ignition timing initial Full advance Alternator Spark plug Spark plug gap Headlight Taillight Speedometer I ight Date of Issue: December, 1978 © HONDA MOTOR CO., LTO. I II Ill IV v VI 5 Wet multi-plate type 6-speed constant mesh 3.333 3.083 1.941 1.450 1.130 0.923 0.785 3.866 Left foot operated return system 1-N-2-3-4-5-6 428 125 links CDI 10° ± 2° BTDC at 1,950 ± 150 rpm 30° ± 2° BTDC at 3,150 ± 150 rpm A.C. generator USA model X24ES-U (NO) D8EA (NGK) Canada model X24ESR-U (NO) DR8ES-L (NGK) 0.6-0.7 mm (0.024-Q.028 in) 6V 25/25W 2 cp (3W) 2 cp (3W) 1-3

6 TORQUE VALUES ENGINE Item Cylinder head Flywheel Clutch outer Oil filter rotor Oil filter screen cap FRAME Item Steering stem nut Fork cap bolt Front fork top bridge Handlebar holder Steering stem Front axle nut Engine hanger bolt (Upper) (Front) (Rear) Rear axle nut Final driven sprocket Rear brake torque arm Rear shock absorber Foot peg Gearshift pedal Kick starter pedal Swing arm pivot bolt GENERAL INFORMATION Q'ty Thread dia. (mm) 4 8 1 8 16 16 36 O'ty Thread dia. (mm) 1 22 2 2 7 4 8 4 8 1 12 3 8 4 8 2 10 1 14 4 10 2 8 4 10 2 8 1 6 1 6 1 12 ~ HONDA ~ XR185 Tightening Torque kg·m ft·lb 1.8-2.0 13 - 14 4.0-5.0 29 -36 4.0-5.0 29 -36 4.0-5 .0 29 -36 1.0-2. 0 7 - 14 Tightening Torque kg·m ft·lb 6.0-9.0 43 -65 1.5- 3.0 11 -22 0.9-1.3 7 - 9 2.0- 2.5 14 -18 2.0-2.5 14 -18 4.0-5.0 29 -36 2.7-3.3 20 -24 2.7- 3.3 20 -24 · 3.0-4.0 22 -29 6.0-8.0 43 -58 5.5-6 .5 40 - 47 1.8-2.5 13 - 18 3.0-4.0 22 -29 1.8-2.3 13 -17 0.8- 1.2 6 - 9 0.8-1.2 6 - 9 4.0- 5.0 29 -36 Torque specifications listed above are for the most important tightening points. If a torque specification is not listed, follow the standards given below. STANDARD TORQUE VA LUES Type 5 mm bolt. nut 6 mm bolt, nut 8 mm bolt, nut 10 mm bolt, nut 12 mm bolt, nut 1-4 Torque kg-m (ft·lb) 0. 45-0.6 (3.3- 4.3) 0.8- 1.2 ( 6-9 ) 1.8-2.5( 13-18) 3.0-4.0 ( 22-29 ) 5.0-6.0 ( 36- 43 ) Type 5 mm screw 6 mm screw 6 mm flange bolt, nut 8 mm flange bolt, nut 10 mm flange bolt, nut Torque kg·m (ft· lb) 0.35- 0.5 (2. 5-3.6) 0.7- 1.1 ( 5-8 ) 1. 0-1.4( 7- 10) 2.4- 3.0 ( 17-22) 3.0. -4.0 ( 22- 29 ) Date of Issue : December, 1978 © HONDA MOTOR CO., LTD .

Q\ HONDA ~ XR185 TOOLS SPECIAL TOOLS Description Hex wrench 6 mm Valve guide reamer Clutch outer holder Ball race remover COMMON TOOLS Description Pin spanner Valve adjusting wrench 10 x 12 Valve adjuster A Lock nut wrench 20 x 24 Socket wrench 30 x 32 Extension Valve guide remover 5.5 Valve guide driver B. Rotor puller Universal holder Bearing driver outer 37 x 40 Bearing driver outer 42 x 47 Driver handle outer A. Driver pilot 12 Driver pilot 15 Float level gauge Valve spring compressor Fork seal driver Fork seal driver attachment C Nipple wrench B 4.5 x 5.1 Nipple wrench C 5.8 x 6.1 Shock absorber compressor Date of Issue: December, 1978 © HONDA MOTOR CO., LTO. GENERAL INFORMATION 7 Tool No. Ref. Page 07917- 3230000 11-13 07984- 0980000 6-12 07923- 1070001 8- 4, 8- 8 07944- 1150001 11-20 Interchangeabi I ity Tool No. (Common-+special tool) Ref. Page 07702-0010000 07916- 3710100 11 - 19,1 1- 21 07708- 0030200 tr---07908-3230000 3- 5 07708-0030300 3- 5 07716- 00201 00 8- 4, 8- 5, 8- 7, 8- 8 07716- 0020400 11-21 07716- 0020500 11 -21 07742- 0010100 07942- 3290100 6-11 07742- 0020200 07942- 3290200 6- 11, 6- 13 07733- 001 0000 07933 -2000000 9- 3 07725-0010101 8- 5, 9- 2, 9- 3 07746- 0010200 07945- 0980000 11 - 8, 11 - 20 07746- 0010300 07946- 9350200 12- 6 07749- 001 0000 ----cP7949-3oooooo 12- 6, 11 -20 07746- 0040200 07949-6 11 0000 11 - 8 07746- 0040300 12- 6 07401- 0010000 4- 9 07757- 0010000 07957-3290001 6- 9, 6- 16 07747- 0010100 07947- 3550000 11-15 07747-0010300 11-15 07701- 0020200 3-15 07701- 0020300 3-15 07959-3290001 12- 10, 12- 11 1-5

~~ 2= o= = ~ z 0 1- < ~ a: 0 u. z _, < a: w z UJ (!) CO l SPE EDOMETER LIGHT 6V3W ENGINE STOP SWITCH ral ~~Nf G Bk/W GRO~ME) G '--- -- r -.... , J\ l = "" r J a~~~ c@ '----- ---- -~ 1 : B~k/RW . I : (R) lk/R ~ LIGHTING· DIMMER SWITCH Y ...... Yell ow .__ __ ___l ::E c LIGHTING.OIMMER. SWITCH CONTINUITY COl UNIT t SPARK PLUG Br ······ Brown Bk ...... Black B ...... Blue ac: CD c - c::a CD z:: c TL Hi Lo OFF Hi ON (N) Lo W ... ... White Gr ...... Grey LG ...... Li ght Green LB ...... Li gh t Bl ue R ...... Red 0 .... Orange G ..... Green P · .. Pink - a:: - =- co . r--0 Ol~ ~...I '- . Q) • .nO Eu eva: ~0 0~ .. o ~~ ~~ -o -z ~0 ~I O (Q) <0 I ~

1979-1984 XR185 / XR200 Service & Repair Manual

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