1986-1999 XR200R Service & Repair Manual

B8·99 XR200R

IMPORTANT SAFETY NOTICE IndiC/Jtu II sIrQn, possibility 0/ S'~'trt pnsona/ injury or Joss of li/~ if ifU1TUctiOf/$ art n ot jolID .. :td. CAUTION : Indicates Q po$SibilifY oj personal injury or equipment damage if Instructions are nof followed. NOTE: Gives hel pfu l information. Detailed descriptions of standard workshop procedures. safety principles and service operations are nol included. 11 IS imponant to note that th IS manual contains some warnings and cautions agamst some speclhc service methods which could cause PERSONAL INJURY 10 service personnel or could damage a vehicle or render it unsafe. Plea se understand thai thoss warnings could not cover aU conceivable ways in which service. whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways . Anyone using service procedures or tools, whether or not recommended by Honda, must satisfyhimseJf thoroughly that neither personal safety nor vehicle safety wiN be jeopardized by the service methods or tools selected. 1

HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recom - mendations to ensure that the vehicle is in peak oper- ating condition and the emission levels are within the standards set by the California Air Resources Board. Sections 1 through 3 apply to the whole motorcycle, whi le sections 4 through 15 descr ibe 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 illus- tration, service information and troubleshooting f or the section. The subsequent pages give detailed procedures. If you don't know what the source of the trouble is, refer to section 16, Troubleshooting . CONTENTS GENERAL INFORMATION ~BRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAO/V ALVES w ~===========-~======== Z CYLINDER/PISTON ~ r==CLlrn~UCmLlPi~~~EA~iHlFr===~====== ALTERNATOR REAR WHEEL/ BRAKE/SUSPENSION REAR FENDER /EXHAUST PIPE ELECTRICAL SYSTEM WIRING DIAGRAM TROUBLESHOOTING INDEX

GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES TOOLS CABLE & HARNESS ROUTING GENERAL SAFETY ,., ,., , ·2 , ·3 '·4 ,·5 ' ·7 afeu is wd/-I't!ntilated. Nel'ef run lhe engine in a closed area. The exhaust comain! poisonous carbon monoxide gas, thaI may cause loss 0/ consciousness and lead to (Iel/th. SERVICE RULES 1. GENERAL INFORMATION EMISSION CONTROL SYSTEMS (AFTER '97/CALIFORNIA TYPE ONLYI NOISE EMISSION CONTROL SYSTEM IU .S.A. ONLYI VEHICLE EMISSION CONTROL INFORMATION LABEL (AFTER '97/CALIFORNIA TYPE ONLY) ¥! , . , 5 '· '6 , · '6 Casvline is rxfremely flammable and is exp{osil't! under certain condilions. Do not smoke or allow flames or sparks in your working afta or when' gasolint is stored. • Use genuine HONDA Of HONDA- re commended parts and lubricants or their equivalents. Parts that do not meet HONDA 's design specifications may damage the motorcycle . • Use the special tools designed for this product. • Install new gaskets, D-rings , cotter pins, lock plates, etc. when reassembling. • When torquing a series of bolts or nuts, begin with the larger-diameter or inner bolts first, and tighten to the specified torque diagonallv, unless a parti cular sequence is specified . • Clean parts in non-flammable or high flash point solvent upon disassemblv. Lubricate any sliding surfaces before reassembly. • After reassembly check aU parts for proper installation and ope rat ion. • Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motor cycle. • Route all electrical wires as shown on pages 1-7 through '- '4, Cable and Harness Routing, and away from sharp edges and areas where they might be pinched between moving parts. 1-1

GENERAL INFORMATION MODEL IDENTIFICATION '86 shown: After '86 similar The frame senal number is stamped on the right side 01 the steering head. IC ARBURETOAIDI'Nl·IIIF1ICATIS~~~~ ;. The carburetor identification number is on the right side of the carburetor body. 1-2 The vehicle identification number (V IN f is on the left side of the sleering head. The engine serial number is stamped on the lower left side of the cran kcase . The color label is attached on the left frame tube under the seat. When ordering a color coded part , always specify Its designated color code.

GENERAL INFORMATION SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overalileogth (,S6 'S8, '90 - '91 :) 2,035 mm (80.1 in) (After '92:) 2,045 mm (80.5 in) Overall width 865 mm (3 4.1 in) Overall height ('86 - '88, '90 - '91:) 1,180 mm (46.5 in) (After '92:) 1,130 mm 144.5 in) Ground clearance 305 mm (12.0 in) (After '92:) 277 mm (10.9 in) Wheelbase 1,360 rnm (53.5 in) Seat height 885 mm (34.8 in) (After '92:) 850 mm (33.5 in) Fool peg height 380 mm 115.0 in) (After '92:) 340 mm (13.4 in) Dry weight ('86 - 'S8, '90-'91:1 98 kg (216Ib) (After '92:) 101 kg (223Ib) FRAME TVpe Semi double cradle Fron! suspension, travel ('86 - '88, '90 - '9 1: ) Telescopic 254 mm (10.0 in) (Afte r '92:1 Telescopic 208 mm (8.2 in) Rear suspension, travel ('86 - '88, '90- '91:) Pro-link 245 mm 19.6 in) (After '92:) Pro-link 211 mm 18.3 in) Front tire size, pressure 80/100-21 51M, 100 kPa(1 .0 kg/cm', IS psi) Aear tire size, pressure 100/100-17 SSM, 100 kPa (l .0 kg/cm l, 15 psi) Front brake, swept area Internal expanding shoes, 86.3 em' (13.4 sQ. in) Aear brake, swept area Internal expanding shoes, 86.3 em' (13.4 sQ. in) Fuel capacity 9.0 lit (2.4 U.S. gal, 2.0 Imp gall Fuel reserve capacity 1.5 lit (0.4 U.S. gal, 0.3 Imp gal) Caster ('86 - '88, '90 - '91:) 64" (After '92:) 63° Trail ('86 - '88, '90 - '91:) 100 mm (3.9 in) (Aft er '92:) 113.6 mm (4.47 in) Front fork oil capacity ('86 - '88, '90 - '91:) 350 cc (1 1.8 U.S. OZ, 12.3 Imp oz) (After '92:) 377 cc 112.8 U.S. OZ, 13.3 Imp 02) ENGINE Type Gasoline, air-cooled 4-stroke SOHC Cylinder arrangement Single cyl inder inclined IS" Bore and stroke 65.5 x 57.8 mm (2.6 x 2.3 in) Disp(acement 195 cc (1'.9 cu in) Compression ratio 10.0: I Valve train 2-valve, single chain driven SOHC Maximum horsepower 19.0 PS/9,OOO rpm Maximum torque 1.7 kg-m, 7,000 rpm Oil capacity 1.1 lit (1.16 U.S. qt, 0.97 Imp qt) Lubrication system FOfced pressure and wet sump Air filtration system Oiled polyurethane foam Cylinder compression 1,373 kPa (14.0 kgJcm2, 199 psH Intake valve Opens 15° (BTOC) at I mm lift Closes 45° (ABDC) at 1 mm lift Exhaust valve Opens 45" (BBDC) at I mm lift Closes 15" (ATDC) at 1 mm lift Valve clearance Intake 0.05 mm (0.002 in) Exhaust 0.08 mm (0.003 in) CARBURETOR Type Piston valve Identification number ('86 - '97:) PD97A (After '97~xcept California type:) P097A (After '97/Cali fornia type:) P097B Venturi dia. 26 mm (1.0 in) Mainjel ('86:) #112 ('87 - '97:) #110 (After '97~xcept California type:) #110 (After ·97/California type:) #102 Slow jet ('86 - '97:) '38 (After ·97~xcept California type:) '''' (After '97/California type:) #35 Jet needle selting ('86:) 2nd groove (After '86:) 3rd groove Pilot screw (see page 4-1 1) Float level 12.5 ± 0.5 mm (0.49 ± 0.02) Idle speed 1,300± 100 rpm 1-3

GENERAL INFORMATION ITEM DRIVE TRAIN Clutch Transmission Primary reduction Gear ratio I Gear ratio II Gear ratio II I Gear ratio IV Gear ratio V Gear ratio VI Final reduction Gear shih pattern elECTRICAL Ignition Ignition timing Initial Full advance Alternator Spark plug For cold climate (below 5°C/41"F) Standard For extended high speed riding Spark plug gap '86 through '88: Headlight Teillight TORQUE VALUES ENGINE ITEM THREAD DIA. mm Oil filter screen cap 36 Valve clearance adjusting screw lock nu t 6 Cam chain tensioner adjusting bolt 16 Cvlinder head cap nu t , 6 mm cylinder head bolt 6 6 mm socket bolt 6 Cam sprocket bolt 6 Carburetor insulator bolt 6 Pulse rotor mounting bolt 6 Oi l filter rotor nut 16 Clutch center nut 16 Flywheel bolt , Kickstarter pedal bolt 8 FRAME ITEM THREAD CIA. mm Fuel tank mount i ng screw 6 Fuel valve mounting screw 6 Seat mounti ng bolt 6 8 mm engine mounting bolt 8 10 mm engi ne mounting boll 10 Exhaust pipe socket bolt 8 Exhaust pipe flange nut 6 Steering bearing adjusting nut 26 Steering stem nut 24 Fork upper pinch bolt 8 Fork lower pinch bolt 8 Hand lebar holder bolt , Fro nt axle nut 12 Front ax le holder nut 6 Fork cap boll J2 Fork socket bolt 10 Spoke Be3.5 1-4 SPECIFICATION Wei mu lti·plate 6-speed constant mesh 3.333: 1 2.769 : , 1.941: 1 1.450 : 1 t, 130: 1 0.923: 1 0.785 : 1 3.615: 1 (drilill sprocket 13l , drivsn sprocket 47T) left foot operated return system t 1 - N - 2 - 3 - 4 - 5 - 6) COl (Capacitive Discharge Igniti on ) lOa BTDC at idle IF mark) JO° BTDC at 3,500 ± 1 SO rpm 108 W{5,OOO rpm DR7ES (NGK) X22 ESR-U (DENSO) DABES-l (NGK) X24ES A-U (DEN SO) OASES (NGK) X27ESR-U (DENSD) 0.6 - 0.7 mm (0.024 - 0.028 in) 12 V 35 W 12V3.4 W TORQUE 10 - 20 N·m (1.0 - 2.0 kg -m, 7 - 14 ft·lb) 17 - 23 N·m 11.7 - 2.3 kg·m, 12 - 17 ft -Ib) 15 - 22 N·m (1 .5 - 2.2 kg-m, 11 - 16 ft-Ib) 28 - 30 N·m (2.8 - 3.0 kg-m. 20 - 22 ft-Ib) 8 - 12 N·m (0.8 - 1.2 kg-m. 6 - 9 ft-Ib) 8 - 12 N·m (0.8 - 1.2 kg -m, 6 - 9 ft -Ib) 8- 12 N·m (0.8 -1 .2 kg-m, 6 - 9 ft-Ib) 8 - 12 N·m (0.8 -1 .2 kg-m. 6 - 9 ft-Ib) 8 - 12 N·m (0.8 -1.2 kg-m. 6 - 9 ft-Ib) 40 - 50 N·m 14 .0 - 5.0 kg-m. 29 - 36 ft·lb) 40 - 50 N·m (4 .0 - 5,0 kg-m. 29 - 36 ft -Ib) 45 - 55 N·m (4.5 - 5.5 kg -m. 33 - 40 ft·lb) 20 - 35 N·m (2.0 - 3.5 kg-m. 14 - 25 ft -Ib) TORQUE 8- 12 N·m (0.8 1.2 kg-m. 6 9 ft-Ib) 5 - 9 N·m (0.5 - 0.9 kg-m, 4 - 6 ft -Ib) 8 - 12 N'm (0.8 - 1.2 kg -m. 6 - 9 ft-Ib) 30 - 40 N·m 13 .0 - 4.0 kg -m. 22 - 29 ft -Ib) 55 - 65 N·m (5.5 - 6.5 kg -m. 40 - 48 ft -Ib) 12 - 15 N·m 11.2 - 1.5 kg -m. 9 - 11 ft -Ib) 8 - 12 N'm (0.8 - 1.2 kg -m. 6 - 9 ft-Ib) 1.0 - 2.0 N·m (0.' - 0.2 kg -m . 0.7 - 1.4 ft-Ib) 95 - 140 N·m (9.5 - 14.0 kg-m, 69 - 101 ft·l b) 25 - 30 N·m 12,5 - 3.0 kg-m. 18 - 22 ft-Ib) 30 - 35 N·m (3.0 - 3.5 kg -m. 22 - 25 ft ·lb) 24 - 30 N·m (2.4 - 3.0 kg-m, 17 - 22 ft -Ib) 50 - 80 N·m (5.0 -8.0 kg-m, 36 - 58 ft-lb) 10 -14 N'm (1 .0 - 1.4 kg-m, 7 - 10 ft -Ib) 25 - 35 N·m (2.5 - 3.5 kg-m, 18 - 25 ft -Ib) 25 - 35 N·m (2.5 - 3.5 kg-m. 18 - 25 ft-Ib) 2.5 - 5.0 N·m (0.25 - 0.50 kg ·m, 1.8 - 3.6 ft-Ib) j 1 1 1 1

GENERAL INFORMATION ITEM THREAD OIA . mm TORQUE Rim lock 6 10 - 15 N'm (1.0 - 1,5 kg -m . 7- 1' ft-Ib) Front brake arm bolt 6 8- 12 N·m 1 0.8-1.2 kg-m , 6-9 ftolh ) Final driven sprocket nut 8 34 - 40 N·m (3.4 - 4.0 kg -m , 25-29 ft-lb l Rear axle nut 16 80 - 1,0 N'm (8.0 - " .0 kg-m. 58-80 ft-Ib l Rear shock absorber mounting bolt (upper ) 10 40-50 N' m (4 .0 - 5.0 kg-m. 29 - 36 ft -Ibl (lower ) 10 40 - 50 N·m (4 .0 - 5.0 kg -m , 29 - 36 ft -I bl Swingarm pivot nut 14 80 - 100 N·m (8 .0 - 10 .0 kg-m, 58 - 72 tHb ) Shock arm -ta- swing arm bolt 12 90 -1 20 N'm (9 . 0- 12.0 kg -m, 65- 87 h-Ib ) Shock arm - ta- shock link bolt 10 40 - 50 N·m (4.0- 5.0 kg -m , 29-36 ft-Ib ) Shock link - la- frame bolt 10 40-50 N·m (4.0 - 5.0 kg-m . 29 - 36 ft-Ib ) Rear brake arm bolt 6 8- 12 N·m m.8 - 1.2 kg - m. 6- 9 ft -Ib l Damper rod end nut (' 86-'S8 , '90 - '91: ) 12 24 - 29 N·m ~ 2.4 - 2 . 9 kg·m, 17 - 21 ft -Ib) Compression damping valve (' 86- ' 88 , ' 90 -' 91: ) 24 25 - 35 N·m (2.5 - 3.5 kg -m , 18 - 25 ft -Ib) Reservoir hose oil bolt (' 86 - '88, '90 - '91 " 10 25 - 35 N'm (2.5- 3.5 kg -m, 18 - 25 ft -Ib) Reservoir hose joi nt lock nut (' 86 - '88 , '90 - '91 :) 12 20-25 N·m (2.0-2 .5 kg-m, 14-18 ft ·lb) Rear shock spring l ock nut 46 80 - 100 N·m (8 .0 - 10 .0 kg -m. 58 - 72 ft -Ib) Muffler mounting bolt 8 20 - 30 N·m 12 .0- 3.0 kg-m, 14 - 22 ft -Jb ) Fork drain bolt 4 1 - 2 N'm 10 . 1 - 0.2 kg-m, 0.7- 1.4 ft -Ib) Foot peg bolt 10 55-65 N·m 1 5.5-6.5 kg-m, 40-47 ft-Ib ) Brake pedal bolt 8 24 - 30 N'm 1 2.4 - 3.0 kg-m , 17 - 22 fHb ) Gearshift pedal bolt 6 8 - 1 2 N'm W .8 - 1.2 kg-m, 6- 9 fHb ) Kick starter pedal bolt 8 20-35 N·m iZ.0-3.5 kg-m , 14-25 ft-Ib ) Side stand pivot bolt 10 35 - 45 N·m 1 3.5 - 4.5 kg -m, 25 - 33 ft ·lb) Exhaust pipe protector bolt 6 10 - 14 N·m (1 .0 - 1.4 kg -m, 7 - 1 0 ft -Ib) To rQue speclftcatlons listed above are for the most Important fasteners. If a specification IS not listed , fonow the standards below. STANOARD TORQUE VALUES TYPE TORQUE N·m (kg-m, ft-Ib) TYPE TORQUE N·m (kg-m, ft -Ib) 5 mm bolt , nut 4.5 - 6.0 (0.45 - 0.6, 3.3-4.3) 5 mm screw 3.S- S (0. 35 - 0.S, 2.S- 3.6) 6 mm bolt, nut 8- 12 W .8 - 1.2 , 6 - 9) 6 mm screw 7-11 (0.7- 1.1, 5- 8) 8 mm bolt, nut 18 - 25 1 1.8-2.5 , 13-181 6 mm bolt with 7- 11 (0.7- 1.1.5 - 8) 10 mm bolt , nut 30 - 40 ( 3.0 - 4.0 , 22-291 8 mm head 12 mm bolt, nut 50 - 6015.0 - 6.0,36-43) 6 mm flange bolt , nut 10 - 14 (1.0 - 14, 7- 10 ) 8 mm flange bolt, nut 24 - 30 (2.4 - 3.0,17 - 22 ) 10 mm ftange batt, nut 35-45 (3.5-4 .5, 25 - 32) TOOLS VALVE SEAT CUTTERS DESCRIPTION TOOL NUMBER ALTERNATIVE TOOL/NUMBER REF. TO PAGE Seat cutter, 27.5 mm (45 0 IN) 07780 - 0010200 ) 6· 10, 11 Seat cutter, 33 mm (45 0 EX ) 07780-0010800 6- 10, 11 Flat cutter , 33 mm (32 0 IN) 07780-0012900 Not available in U.S.A . EQuivalent 6- 10.11 Flat cutter , 28 mm (32 0 EX) 07780 - 0012100 commercially available in U.S.A. 6- 10, 11 Interior cutter, 30 mm (60 0 IN/EX) 07780 - 0014000 6· 10, 11 Cutter holder, 5.5 mm 07781 -0010101 6- 10," 1-5 .

GENERAL INFORMATION COMMON DESCRIPTION TOOL NUMBEA Carburetor float level gauge 07401 - 0010000 Wrench. l Ox 12 mm 07708 - 0030 200 - Adjusting wrench A 07708 - 0030300 : Spanner C, 5.8 x 6.1 mm 07701 - 0020300 Re tainer wrench attachment 07710 - 0010100 Retainer wrench body 07710 - 0010401 Wrench, 20 x 24 mm 07716-0020100 Wrench, 30 x 32 mm 07716 - 0020400 : EKtansion bar 07716-0020500 Gear holder 07724 - 0010200 Flywheel holder 07725 - 0040000 - Flywheel puller 07733 - 0010000 Valve guide driver, 5.5 mm 07742 - 0010100 Attachment, 24 x 26 mm 07746 -00 10700 Attachment, 32 x 35 mm 07746-00 10100 Attachment, 37 x 40 mm 07746 - 00 10200 Attachment, 42 x 47 mm 07746 -00 10300 Attachment, 52 x 55 mm 07746 - 00 10400 Pilot, 15 mm 07746-0040300 Pilot, 17 mm 07746-0040400 Pilot, 20 mm 07746 - 0040500 Pilol. 30 mm 07746 -00 40700 Bearing remover shah 07746 - 0050100 Bearing remover head, 15 mm 07746 - 0050400 Beering remover head, 17 mm 07746 - 0050500 Dri ver 07749 - 0010000 Valve sorino compressor 07757 - 0010000 SPE CIAL DESCRIPTION TOOL NUMBER Fork seal driver 07947 - 2730100 Steering stem socket 07916 - KA50100 Ball race r emover 07953 - 4250002 St eering stem driv er 07946 - 4300101 Needle bearing remover 07931 - MA70000 07946 - KA30200 =l Spherical bearing driver Spherical bearing driver 07HMF - HCooloo -i Slider guide, 14 mm 07974 - KA40000 -l Damping valve wrench 07920 - KA30001 Clutch center holder 07923 - 9580000 Holder attachment 07930 - KA50100 Bearin.} remover, 15 mm 07936 - KC10000 --, - removerassy, 15 mm 07936 - KC10500 - remover head, 15 mm 07936 - KC10200 ---j - remover shah , 15 mm 07936 - KC10100 ~ - remover sliding wei ght 07741-0010201 Valve guide reamer, 5.5 mm 07984 - 0980000 1-6 ALTERNATIVE TOOL/NUMBEA or equivale nt comm ercially available in U.S. A. or equivalen t commercially available in U.S.A. not avaitable in U.S.A. or equivalent commercially available in U.S.A. 07933 - 3000000 ALTERNATIVE TOOlJNUMBER or 07947 3710101 or equivalent commercially available in U_S.A. or 07953 - MJ 1000B Or 07953 - MJ1000A 07946 - MBOOOO and 07946 - KA6000A or GN -HT-5 4 Not available in U.S.A or 07936 - 3710600 07936-37 10100 07936 - 371020A or 07936 - 3710200 IU.S.A_ only) not available in U.S.A. Or 07HGB - oo1010B or 07HGB - 001010A and 07HGB - oo1020B or 07HGB - oo1020A no t available in U.S.A. or 07936 - 371020A or 07936 - 3710200 or 07984 - 0980000 REF . TO PAGE 4-9 3-7 37 3-17 12 -4, 6 1 2-4,6 8-5,7 ' ' -l a, 21 8-5,7,11-18,19,21 8·4,7 9·2,3 9-3 6-8,9 12-28 10-8, 11 -7,12 -26 12-6 10-8,11-19 10-8 10--8, 11-7 12-6 10-8, 12-26 10-8 11-6,12-5 11-6 12-5 10-8,11-7,19, 12-6,27,28 6-7,12 REF . TO PAGE 11-16 11 -19,20 11 -19 11-20 12-27 12-23, 28, 29 12-29 12-17 12-20,21 8-5,7 11-16 10-8 10-8 10-8 10-8 10-8 6-8 • 1 1 1 • 1 J I ,

1986-1999 XR200R Service & Repair Manual

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