20. TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START XL200

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1 20. ENGINE DOES NOT START OR IS HARD TO START 20-1 ENGINE LACKS POWER 20-2 POOR PERFORMANCE AT LOW AND IDLE SPEED 20-3 POOR PERFORMANCE AT HIGH SPEED 20-4 POOR HANDLING 20-4 ENGINE DOES NOT START OR IS HARD TO START 1. Check the fuel flow to carburetor REACHING CARBURETOR NOT REACHING CARBURETOR Clogged fuel tube or fuel filter screen Sticking float valve Clogged fuel tank breather 2. Perform a spark test WEAK OR NO SPARK GOOD SPARK Faulty spark plug Fouled spark plug Broken or shorted spark plug wire Broken or shorted ignition coil Faulty ignition switch Faulty engine stop switch Loose or disconnected ignition system wires 3. Test cylinder compression LOW COMPRESSION COMPRESSION NORMAL Valve stuck open Worn cylinder and piston ring Damaged cylinder head gasket Seized valve Improper wires 4. Start by following normal procedure ENGINE DOES NOT FIRE ENGINE STARTS BUT STOPS Improper choke operation Carburetor incorrectly adjusted Intake pipe leaking Improper ignition timing (Faulty ignition coil or pulse generator) Fuel contaminated 5. Remove and inspect spark plug WET PLUG Flooded carburetor Choke closed Throttle valve open Air cleaner dirty

2 ENGINE LACKS POWER 1. Raise wheels off the ground and spin by hand WHEEL SPINS FREELY WHEELS DO NOT SPIN FREELY Brake dragging Worn or damage wheel bearing 2. Check tire pressure PRESSURE LOW Faulty tire valve PRESSURE NORMAL 3. Accelerate rapidly from low to second ENGINE SPEED LOWERED WHEN CLUTCH IS RELEASED ENGINE SPEED NOT CHANGED WHEN CLUTCH IS RELEASED Clutch slipping Worn clutch discs/plates Warped clutch discs/plates Weak clutch spring 4. Accelerate lightly ENGINE SPEED DOES NOT INCLEASE ENGINE SPEED INCREASE Carburetor choke closed Clogged air cleaner Restricted fuel flow Clogged muffler Pinched fuel tank breather 5. Check ignition timing IN 6.Test cylinder compression NORMAL IN Valve stuck open Worn cylinder and piston rings Leaking head gasket Improper valve timing 7. Check carburetor for clogging NOT CLOGGING CLOGGED Carburetor not serviced frequently enough 8. Remove spark plug FOULED OR DISCOLORED Plug not serviced frequently enough Spark plug is incorrect heat range NOT FOULED OR DISCOLORED 9. Check oil level and condition IN Oil level too high Oil level too low Contaminated oil 10. Remove cylinder head cover and inspect lubrication VALVE TRAIN NOT LUBRICATED PROPERLY Clogged oil passage Clogged oil control orifice VALVE TRAIN LUBRICATED PROPERLY 20-2

3 11. Check for engine overheating NOT OVERHEATING OVERHEATING Excessive carbon build-up in combustion chamber Use of poor quality fuel Clutch slipping Lean fuel mixture Wrong type of fuel 12. Accelerate or run at high speed ENGINE KNOCKS ENGINE DOES NOT KNOCK Worn piston and cylinder Wrong type of fuel Excessive carbon build-up in combustion chamber Ignition timing too advanced (Faulty CDI unit) Lean fuel mixture POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Check ignition timing IN Improper ignition timing (Faulty CDI unit) 2. Check carburetor pilot screw adjustment IN See section 4 3. Check for leaking intake pipe LEAKING Loose insulator clamp Damaged insulator NO LEAK 4. Perform spark test WEAK OR INTERMITTENT SPARK GOOD SPARK Faulty carbon or wet fouled spark plug Faulty ignition coil Broken or shorted spark plug wire Faulty engine stop switch Faulty ignition switch Loose or disconnected ignition system wires 20-3

4 POOR PERFORMANCE AT HIGH SPEED 1. Check ignition timing IN POSSIBLE CAUSE 2. Disconnect fuel tube at carburetor FUEL FLOWS FREELY FUEL FLOW RESTRICTED Clogged fuel line Clogged fuel tank breather Clogged fuel strainer screen 3. Remove the carburetor and check for clogged jets CLOGGED Clean jets NOT CLOGGED 4. Check valve timing IN Camshaft not installed properly 5. Check valve spring WEAK Faulty spring NOT WEAKENED POOR HANDLING 1. If steering is heavy POSSIBLE CAUSE Steering stem adjusting nut too tight Damaged steering head bearings 2. If either wheel is wobbling Excessive wheel bearing play Bent rim Improper installed wheel hub Swingarm pivot bearing excessively worn Bent frame 3. If the motorcycle pulls to one side Faulty shock absorber Front and rear wheel not aligned Bent fork Bent swingarm Bent axle 20-4

5 GENERAL INFORMATION HOW TO USE THIS MANUAL This service manual describes the service procedure for the. 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. 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 20

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