1984-1985 XR200R XR250R Service & Repair Manual

SHOP MANUAL XR2DDR / 25DR

,---------- IMPORTANT SAFETY NOTlCE ---------, fJ&I;liiiit· ' CAUTI ON: NOTE : In di cates Q strong possibility of severe pers onal injury or loss of li fe If instructions are not fo llowed. Indicates a possibility of persono/ injury or equipmenr damage ;[ instructions are not fol/owed. Gives helpful in/ormation. Detailed descriptions of standard workshop procedures. safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceiva bl e ways in which service, whether or not recommended by Honda mi\tlt 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, wtlether or not recommended by Honda must sarsdy himself rhoroughly that neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected.

HOW TO USE THIS MANUAL Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 16 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, general instructions! specifications, torque values, working prac- tices, tools and ' troubleshooting for the section. The subsequent pages give detailed procedures for the section. If you don't know what the source of the trouble is , read section 18, Troubleshooting. If you are not familiar with this motorcycle, read section 17 Technical Features. GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM I ENGINE REMOVALIINSTALLATION I CYLINOER HEAOIVALVES ~ I CYLINOER/PISTON ~ I CLUTCH/ OIL PUMP/KICK STARTER I ALTERNATOR I CRANKCASE/ CRANKSHAFT/ BALANCER TRANSMISSION FRONT WHEEL/SUSPENSION/STEERING ~ I REAR WHEEL/ BRAKE/SUSPENSION U $I ~ HYORAULIC BRAKE F================= REAR FENOER/EXHAUST PIPE IGNITION SYSTEM TECHNICAL FEATURES TROUBLESHOOTING

MODEL IDENTIFICATION XR200R: DATE OF MANUFACTURE T he frame serial number is sta mped on the left side of the steering head. The vehicle identi ficat ion number (VINI is on the right side of the steering head. CARBURETOR IDENTIFICATION NUMBER The carburetor identification number is on the left side of the carburetor body. XR:250R ENGINE SER I AL NUMBER The engine serial number is stamped on the IO'Nef left side of the crankcase. The color code label is attached on the left frame tube under the seat. When ordering a color coded part, always specify its designated color. J I

1. GENERAL INFORMATION GENERAL SAFETY 1- 1 SERVICE RULES 1- 1 SPECIFICATIONS 1- 2 TORQUE VALUES 1- 4 TOOLS 1- 6 WIRING DIAGRAM 1- 8 CABLE & HARNESS ROUTING 1- 10 ITEMS REQUIRING FREQUENT REPLACEMENT 1- 14 GENERAL SAFETY ''''QW!ij If the engine must be running /0 do some J«)rk, mo.ke sure the area is well-ventilated. Never run the engine in Q closed area. The exhaust contains pouonous carbon monoxide gas. SERVICE RULES Gasoline is extremely fiommtlble and is explosive under certain conditions. Do not smoke or aI/ow flames or sparks in you r working area. 1. Use genuine HONDA or HONDA-recommended parts and lubricanu or their equivslenu. Parts that do not meet HONDA's desi!Jl specifications may damage the motorcycle. 2. Use the special tools designed for this product. 3. Use only metric tools wnen servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the-motorcycle. 4. Insta ll new gaskets, Q·rings, cotter pins, lock ~Iates, etc. when reassembling. 5. When tightening bolts or nuts, begin with la rge r·diameter or inner bolts first, and tig,ten to the specified torque diagonal ly in 2-3 steps, unless a particular sequence is specified. 6. Clean parts in non·flammable or hi~ flash point solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly. check all parts for proper installation and operation. 8. Route all electrical wires as shown on page1-10Cable and Harness Rooting and always away from sharp edges and areas where they might be pinched between moving parts. 1·1 ..

GENERAL INFORMATION SPECIFICATIONS ITEM DIMENSIONS Dlleralilength Overall width Overall height Ground clearance Wheel base Seat height Foot peg height Dry weight FRAME Type Front suspension, tra vel Rear suspension, travel Front tire size, pressure Rear tire size, pressure Front brake lining swept area Front brake, swept area Rear brake, swept area Fuel capacity Fuel reserve capacity Caster Trail Front fork oil capacity ENGINE Type Cylinder arrangement Bore x Stroke Displacement Compression ratio Valve train Maximum horsepower Maximum torQue Oil capacity '84, After 'B4: Lubrication system A ir filtration system Cylinder compression Intake valve Opens Closes Exhaust valve Opens Closes Valve clearance Intake Exhaust 1·2 XR200 R 2035 mm (BO.1 in) 865 mm (34.1 in) 1180 mm (46.5 in) 1360 mm (53.5 in) '365 mm 153.7 in} 905 mm (35.6 in) 395 mm (15.6 in) 101 kg (223 Ibs) Semi double cradle Telescopic 254 mm (10.0 in) Pr ating 246 mm ( 9 .7 in) 3. 00 - 21(6 PA l. 15 psi ( 1 00 kPa, 1.0 kgfcm1) 110/ 90- 17 (6 PAl, 15 psi (l ookPa, 1,Okg/cm 1 ) 86.3 em' (13.3 sq. in) 86.3 em 1 03 .3 sq. in) 9.0.2 (2.4 US gal) 1.5.2 (0.4 USgal) 64 0 10Smm (4.1 in ) 355 cc (12 oz) Gasoline, air-cooled 4 -s troke SOHC Single cylinder inclined 15° 67 x 56.5 mm (2.6 x 2.2 in) 199 cc (12 .1 cu. in) 11.0: 1 4·valve, chain driven overhead camshaft 23 PS/9000 rpm 2.0 kg·ml7500 r pm 1.3.2 (l.4USql. 1. 11mp qt ) 1.6.2 (1.1'us Qt , 1.4 Imp qt ) Forced pressure and wet sump Oiled polyurethane foam 13~ 15kg/cm2 (185-2 13 psi) 5° (BTDC) 35° (ABDC) 5° (BBDC) 35'0 (ATDC) 0. 05 mm (O.D02 in) 0. 08 mm (0.003 in) XR250 R , , , , • • • 105 kg (230 Ibl , , • 15 psi (100 kPa, 1.0 kg/ em') 4. 60- 17 (6 PA) 15 psi (100 kPa, 1.0 kg/cm 2 ) 342.8 em' , , , 397 cc (13.4 oz) , • 75 x 56 .5 mm (2.9·x 2.2 in) 249 cc (15.2 cu. in) 10.2: 1 , 28 PS / 8500 rpm 2.4 kg·mnOOO rpm , • , • 10° (BTDC) 40° (ABDC) 10 0 (BBDC) 40 0 (ATDC) , j I

GENERAL INFORMATION ITEM X R200R XR250R CARBURETOR Type Pi ston valve , 1.0. number '84 : PH31A PH42A After '84: PH32A PH41A Ma in jet ' 84 : Primary #98 , Secondary w 95 Primary # 1 08, Secondary # 105 After '84: Pr i mary #98 , Secondary # 98 Primary # 100, Secondary #98 Air screw '84' , -3/8 turns out 1-1/4 turns out After '84: 1-1/8 turns out 1 turn out Float level 18 mm (0.71 in) , Idle speed 1300 ± 100 rpm - DRIVE TRAI N Clutch Wet mult i- plate tYpe Transmission 6-speed, constant mesh , Pri mary reduction 3 .3 16 3.100 Gear ratio I 2.769 Gear ratio II 1,941 , Gear ratio III 1.450 , Gear rat io IV 1.174 , Gea r rat io V 0.960 , Gear rat io V I 0.a15 , Final reduction 3.846 , Gear shift pattern Left foot operated return system , ELECTRICAL Ignition system COl I gnition timing Initial 8" ± 2° BTDC at 1900 ± 200 rpm , Full 28° ± 2° BTOC at 43OO :t 200 rpm • advance Spark plug OPR9Z, OPR8Z (NGK) , X27GPR·U, X24GPR·U (NO) Spark pl ug gap 0.6- 0.7 mm (0.02- 0.03 in) Headlight 6 V- 35w , Ta i llight 6V 2CP • 1·3

GENERAL INFORMATION TORQUE VALUES ENGI NE ITEM Q' TV THREAD DIA TORQUE N·m (kg -m , ft · lb ) Valve adjusting screw lock nut 1 6 17- 23 N- mt1.7 - 2.3 kg -rn , 12- 17 ft-Ib) Cylinder head bolt 4 10 47 - 53 N·m (4.7- 53 kg-m, 34-38 ft-Ib) Cam sprocket bolt 2 7 18- 22 N-m (1 8- 2.2 kg-m, 13- 16 ft -Ib) Cylinder head cover 6 mm boll I. 6 8- 12 N-m (0.8- 1.2 kg-m. 6- 9 ft · lb) 8 mm bo lt 2 8 26 - 30 N'm (2.6- 3.0 kg-m , , 9- 22 ft-Ib) Rocker arm shaft 2 - 25- 30 N·m (2. 5- 3.0 kg -m, 18-22 ft -Ib) Sub- rock er arm shaft IN 2 - 25- 30 N'm (2.5- 3.0 kg- rn , 18 - 22 ft -Ib) Sub-rocker arm shaft EX 2 - 20 - 25 N'm (2.0- 2.5 kg -m, 14-18 ft - tb) Clutch lock nut 1 16 50 - 60 N-m (5 .0 - 6.0 kg-m . 36 - 43 ft · lb) Drive gear lock nut 1 18 50 - 60 N'm (5.0- 6.0 kg-m, 36-43 ft -Ib ) Right crankcase cover 17 6 8- 12 N·m (0.8- 1.2 kg-m, 6- 9 ft-Ib\ Flywheel 1 - 80 - 100 N'm (8 .0- 10.0 kg -rn , 58- 72 ft·lb) left crankcase cover 8 6 8- 12 N·m (O.B- 1.2 kg-m, 6- 9 fl -tb) Gearshift return spring 1 8 22- 26 N'm (2.2- 2 .6 kg -m . 16-19 fl -Ib) Drain plug 1 - 20 - 30 N·m(2 .0 - 3.0 kg-m. 14- 22 ft -Ib) I FRAME ITEM Q' TV THREAD DIA TORQUE N·m ( k9 -m , ft - Ibl Steering stem nut 1 24 95 - 140 N'm (9.S- 14 .0 kg -m. 69 - 101 fI - lb) Steering bearing adjusting nut 1 26 1- 2N ' m{0.1- 0 .2 kg-m, 0.7- 1 4 ft -Ibl Handle holder ' • 8 18- 30 N'm ( 18- 30kg-m, 13 - 22 ft-Ib ) Front fork upper pinch bolt 4 8 25 - 30 N·m (2. 5- 3 .0 kg-m, 1B- 22 ft-Ib) Front fork lower pinch bolt 4 8 30 - 35 N'm (3.0- 3 .5 kg -m . 22 - 25 ft-Ib ) Front axle holder 4 6 10- 14N·m (I .0- 1 4 kg-m, 7-10 ft-Ib l Front axle nut 1 12 50- 80 N'm (5.0- B.O kg-m. 36 -58 ft -Ib) Front fork top boll 1 34 15- 30 N'm (3.2- 4 2 kg -m , 23 -3 0 It -Ib) Front f ork socket bolt . 3: XR250R 2 12 32- 42 N'm (1 5- 3.0 kg-m . 11-22 ft -Ib) Front fork drain bolt 1 4 1- 2 N·m(O.I- o 2 kg-m . 0 7- 1.4 ft -Ib) Rear cushion hose lock nut (Fuel lank) 1 12 20 - 25 N'm (20- 2.5 kg-m, 14-18 ft-Ib) Front fork sockel bolt XR200 R 2 10 20 - 26 N·m (2.0- 2.S kg-m . 14- 19 ft-Ib) Rear axle nul 1 16 BO-1 10 N'm (8 .0- 11 .0 kg -m, 58 - BO ft -Ib) Final dnven sprocket 6 8 27- 33 N'm (2 .7- 3.3 kg -m, 20- 24 ft -I b) Rear fork pivot 14 2 BO- l00N·m(B .0-l0.0kg-m , 58 - 72 fI -lb) Rear sh oc k absorber (up per ) 1 10 40 - 50 N'm (4.0- 5.0 kg-m . 29 - 36 ft -Ib) (l ower) 1 10 40 - 50 N'm (4 0- 5.0 kg -m. 29 - 36 ft-Ib ) Shock arm-t o-swi ng arm 1 12 90 - 120 N·m (9.0-12 .0 kg-m . 65 - B7 ft -I b) Shock arm-to · shock link 1 10 40- 50 N· m(4 .0- 5.0 kg -m, 29-36 ft -Ib) Shock IInk-lo -frame 1 10 40- 50 N·m (4 .0 - 5 0 kg-rn, 29 - 36 ft-Ib) Fr ont brake caliper bolt 2 8 20 - 30 N·m (2.0- 3 .0 kg -m. 14-22 ft-Ib) Front di SC 4 6 14- 16N· m(14 - 1 6 kg-m , 10- 12 ft-tb) Brake hose joint (Brake hose) 1 10 30- 40 N·m (3. 0- 4 .0 kg-m, 22 - 29 fI-lb) (Ma sto r cylinder) 1 10 12- 15N·m(1 .2- 1 5 kg-m, 9-11 ft -Ib) Oil bolt cali per 1 10 30- 40N ' m(30 - 4 .0 k9-rn , 22 - 29 ft-lb) 1·4