SERVICE INFORMATION 5-1 ENGINE REMOVAL/ ENGINE INSTALLATION 5-3 SERVICE INFORMATION 5-1 ENGINE REMOVAL 5-2 GENERAL

Transcription

1 ENGINE REMOVAL/ XL INSTALLATION SERVICE INFORMATION 5-1 ENGINE REMOVAL 5-2 ENGINE INSTALLATION 5-3 SERVICE INFORMATION GENERAL When removing the engine, support the motorcycle on its center stand. 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 5-1

2 ENGINE REMOVAL/INSTALLATION XL

3 ENGINE REMOVAL/INSTALLATION XL200 ENGINE REMOVAL CARBURETOR Drain the engine oil (page 2-3). Remove the following: Carburetor Spark plug cap Muffler Clutch cable Disconnect the alternator and pulse generator connector. CLUTCH CABLE CONNECTOR EXHAUST PIPE Remove the gearshift pedal. Remove the bolts and drive sprocket cover. Remove the following: Fixing plate bolts. Fixing plate. Drive chain. Drive sprocket. GEARSHIFT PEDAL DRIVE CHAIN DRIVE SPROCKET COVER 5-2 FIXING PLATE DRIVE SPROCKET

4 XL200 Disconnect the starter motor cable. ENGINE REMOVAL/INSTALLATION STARTER MOTOR CABLE Remove the engine hanger nuts, bolts hanger plates and engine from the frame. NUT/BOLT GROUND CABLE ENGINE INSTALLATION ENGINE HANGER PLATE NUT/BOLT COLLAR Install the engine in the frame and install the rear engine hanger bolts and collars. NOTE Install the long collar to the right, shorter collar to the left. Install the nuts on the rear hanger bolts. Install the front engine hanger plate, bolts and nuts. HANGER PLATE NUT/BOLT 5-3

5 ENGINE REMOVAL/INSTALLATION XL200 Install the top engine hanger plates, bolts and nuts. Install the skid plate. Tighten the engine hanger nut to the specified torque. TORQUE: 10 mm nut: 61 N.m (6.1 kg.m, 44 ft-lb) 8 mm nut: 28 N.m (2.8 kg.m, 20 ft-lb) REAR AND TOP NUT/BOLT FRONT AND TOP Install the drive sprocket and fixing plate onto the countershaft and tighten the bolts. REAR AND UNDER FIXING PLATE FRONT AND TOP DRIVE SPROCKET Install the starter motor terminal cable and tighten the terminal nut securely. Install the ground cable and tighten the bolt. DRIVE CHAIN STARTER MOTOR CABLE NUT 5-4 GROUND CABLE

6 XL200 Connect the alternator/pulse generator connectors and neutral switch connector. ENGINE REMOVAL/INSTALLATION CONNECTOR Install the drive sprocket cover and tighten the bolts. Install the gearshift pedal and tighten the bolt. Install 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. GEARSHIFT PEDAL CARBURETOR CLUTCH CABLE DRIVE SPROCKET COVER SPARK PLUG CAP EXHAUST PIPE 5-5

7 GENERAL INFORMATION HOW TO USE THIS MANUAL This service manual describes the service procedure for the XL200. Throughout the manual, the following abbreviations are used to identify individual models. Code DK 2LA Area (type) General Type Latin America Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operation condition. CONTENTS GENERAL INFORMATION 1 LUBRICATION 2 MAINTENANCE 3 FUEL SYSTEM 4 ENGINE REMOVAL/INSTALLATION 5 Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Section 1 through 3 apply to the whole motorcycle, while section 4 through 18 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, service information and troubleshooting for the section, the subsequent pages give 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 oblication whatever. Not part of this publication may be reproduced without written permission. ELECTRIC STARTER FRAME ENGINE CYLINDER HEAD/VALVES 6 CYLINDER/PISTON 7 CLUTCH/GEARSHIFT LINKAGE 8 ALTERNATOR/STARTER CLUTCH 9 CRANKSHAFT/KICKSTARTER/ TRANSMISSION 10 FRONT WHEEL/SUSPENSION/STEERING 11 REAR WHEEL/SUSPENSION 12 HYDRAULIC BRAKE 13 FAIRING/EXHAUST SYSTEM 14 CHARGING SYSTEM 15 IGNITION SYSTEM 16 ELECTRIC STARTER 17 LIGHTS/METERS/SWITCHES 18 WIRING DIAGRAM 19 TROUBLESHOOTING 20