13. HYDRAULIC BRAKE SERVICE INFORMATION 13-1 XL200 BRAKE PAD/DISC 13-4 MASTER CYLINDER 13-6 BRAKE CALIPER 13-8

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1 XL HYDRAULIC BRAKE SERVICE INFORMATION 13-1 TROUBLESHOOTING 13-2 BRAKE FLUID REPLACEMENT/ BLEEDING 13-3 BRAKE PAD/DISC 13-4 MASTER CYLINDER 13-6 BRAKE 13-8 SERVICE INFORMATION GENERAL t A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc wit a ig quality brake degreasing agent. Inaled asbestos fibers ave been found to cause respiratory disease and cancer. Never use an air ose or dry brus to clean brake assemblies. Spilling fluid on painted, plastic or rubber parts will damage tem. Place a clean sop towel over tese parts wenever te system is serviced. KEEP OUT OF REACH OF CHILDREN. Bleed te ydraulic system if it as been disassembled or if te brake feel spongy. Do not allow foreign material to enter te system wen filling te reservoir. Avoid spilling brake fluid on painted, plastic or rubber parts. Place a rag or sop towel over tese parts wenever te system is serviced. Always ceck te brake operation before riding te motorcycle. SPECIFICATIONS UNIT: mm (in) ITEM Standard SERVICE LIMIT Brake fluid DOT4 Brake disc tickness 3.0 (0.12) Brake disc runout 0.3 (0.01) Master cylinder I.D ( ) (0.5022) Master piston O.D ( ) (0.4978) Caliper cylinder I.D ( ) (1.065) Caliper piston O.D ( ) (1.059) 13 TORQUE VALUES Brake ose oil bolt Brake caliper mounting bolt Master cylinder cover screw Brake lever pivot nut Front brake ligt switc screw Caliper pin bolt Caliper bracket pin bolt Brake pad pin Brake pad pin plug Brake bleeder valve 35 N.m (3.5 kg.m, 25 ft-lb) 31 N.m (3.1 kg.m, 22 ft-lb) 1.5 N.m (0.15 kg.m, 1,1 ft-lb) 10 N.m (1.0 kg.m, 7 ft-lb) 1.0 N.m (0.10 kg.m, 0.7 ft-lb) 23 N.m (2.3 kg.m, 17 ft-lb) 13 N.m (1.3 kg.m, 9 ft-lb) 18 N.m (1.8 kg.m, 13 ft-lb) 2,5 N.m(0.25 kg.m, 1.8 ft-lb) 6 N.m (0.6 kg.m, 4.3 ft-lb) 13-1

2 HYDRAULIC BRAKE XL N.m (0.15 kg.m, 1 ft-lb) 10 N.m (1.0 kg.m, 7 ft-lb) 10 N.m (1.0 kg.m, 7 ft-lb) 35 N.m (3.5 kg.m, 25 ft-lb) 23 N.m (2.3 kg.m, 16 ft-lb) 6 N.m (0.6 kg.m, 4 ft-lb) 35 N.m (3.5 kg.m, 25 ft-lb) 13 N.m (1.3 kg.m, 9 ft-lb) 2.5 N.m (0.25 kg.m, 18 ft-lb) 18 N.m (1.8 kg.m, 13 ft-lb) 13-0

3 HYDRAULIC BRAKE XL200 TOOLS Special Snap ring pliers Blake bleeding tool BR BR TROUBLESHOOTING Brake lever soft or spongy Air in te ydraulic system Leaking ydraulic system Contaminated brake pads/disc Worn caliper piston seal Worn master cylinder piston seal Worn brake pads/disc Contaminated caliper Caliper not sliding properly Low fluid level Clogged fluid passage Warped/deformed brake disc Sticking/worn caliper piston Sticking/worn master cylinder piston Contaminated master cylinder Bent brake lever Brake lever ard Clogged/restricted brake system Sticking/worn caliper piston Caliper not sliding properly Clogged/restricted fluid passage Worn caliper piston seal Sticking/worn master cylinder piston Bent brake lever Brake drag Contaminated brake pads/disc Misaligned weel Worn brake pads/disc Warped/deformed brake disc Caliper not sliding properly 13-2

XL200 BRAKE FLUID REPLACEMENT/AIR BLEEDING MASTER CYLINDER HYDRAULIC BRAKE Ceck te master cylinder parallel to te ground Avoid spilling fluid on painted, plastic or rubber parts.

Stop operating te brake wen fluid stops flowing out of te bleed valve. BLEED VALVE t A contaminated brake disc or pad reduces stopping power.

4 XL200 BRAKE FLUID REPLACEMENT/AIR BLEEDING MASTER CYLINDER HYDRAULIC BRAKE Ceck te master cylinder parallel to te ground Avoid spilling fluid on painted, plastic or rubber parts. Place a sop towel over tese parts wenever te system is serviced. BRAKE FLUID DRAINING Connect a bleed ose to te bleed valve. Loosen te caliper bleed valve and pump te brake lever. Stop operating te brake wen fluid stops flowing out of te bleed valve. BLEED VALVE t A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean te contaminated disc wit a ig quality brake degreasing agent. BRAKE FLUID FILLING/AIR BLEEDING BLEED HOSE Do not mix different types of fluid since tey are not compatible. Fill te master cylinder wit DOT4 brake fluid to te upper level. Connect te Mityvac Brake Bleeder Nº 6860 or equivalent to te bleed valve. NOTE Ceck te fluid level often wile bleeding te brakes to prevent air from being pumped into te system. Do not mix brake fluid types and never reuse te contaminated fluid wic as been pumped out during brake bleeding, because tis will impair te efficiency of te brake system. Wen using a brake bleeding tool, follow te manufacturer s operating instruction. Pump te brake bleeder and loosen te bleed valve. Add fluid wen te fluid level in te master cylinder is low to prevent drawing air into te system. Repeat te above procedures until no air bubbles appear in te plastic ose. NOTE If air is entering te bleeder from around te bleed valve treads, seal te tread wit teflon tape. BRAKE BLEEDER BLEED VALVE 13-3

HYDRAULIC BRAKE XL200 If te brake bleeder is not available, perform te following procedure.

Operate te brake lever, ten open te bleed valve 1/2 turn and close te valve. NOTE Do not release te brake lever until te bleed valve as been closed. 2.

Tigten te bleed valve. TORQUE: 6 N.m (0.6 kg.m, 4.3 ft-lb) BLEED HOSE Fill te reservoir wit DOT4 brake fluid to te upper level.

5 HYDRAULIC BRAKE XL200 If te brake bleeder is not available, perform te following procedure. Pump up te system pressure wit te lever until tese are not air bubbles in te fluid flowing out of te reservoir small ole and lever resistance is felt. 1. Operate te brake lever, ten open te bleed valve 1/2 turn and close te valve. NOTE Do not release te brake lever until te bleed valve as been closed. 2. Release te brake lever slowly and wait several seconds after it reaces te end of its travel. BLEED VALVE Repeat step 1 and 2 until bubbles cease to appear in te fluid at te end of te ole. Tigten te bleed valve. TORQUE: 6 N.m (0.6 kg.m, 4.3 ft-lb) BLEED HOSE Fill te reservoir wit DOT4 brake fluid to te upper level. COVER SCREWS UPPER MARK Reinstall te diapragm and master cylinder reservoir cover. t A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean te contaminated disc wit a ig quality brake degreasing agent. BRAKE PAD/DISC BRAKE PAD REPLACEMENT t A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean te contaminated disc wit a ig quality brake degreasing agent. NOTE Always replace te brake pads in pairs to assure even disc pressure. DIAPHRAGM DIAPHRAGM PLATE Remove te pad pin plug and loosen te pad pin. Pull te pad pin out if te caliper. Remove te brake pads PAD PIN PLUG/PAD PIN BRAKE PAD

XL200 HYDRAULIC BRAKE Insert new outside pad and pus te caliper

depress te pad spring. Tigten te pad pin to te specified torque.

m, 13 ft-lb) BRAKE PAD Install and tigten te pad pin plug to te

8 ft-lb) PAD PIN PAD PIN PLUG BRAKE DISC BRAKE DISC Disc

6 XL200 HYDRAULIC BRAKE Insert new outside pad and pus te caliper piston in allow clearance for installation of te new left side pad. Install new left pad. Install te pad pin by pusing te pads against te caliper to depress te pad spring. Tigten te pad pin to te specified torque. TORQUE: 18 N.m (1.8 kg.m, 13 ft-lb) BRAKE PAD Install and tigten te pad pin plug to te specified torque. TORQUE: 2.5 N.m (0.25 kg.m, 1.8 ft-lb) PAD PIN PAD PIN PLUG BRAKE DISC BRAKE DISC Disc Tickness Measure te brake disc tickness SERVICE LIMIT: 3.0 mm (0.12 in) Disc Warpage BRAKE DISC Measure te brake disc for warpage. SERVICE LIMIT: 0.3 mm (0.01 in) 13-5

HYDRAULIC BRAKE FRONT MASTER CYLINDER REMOVAL Avoid spilling fluid on painted, plastic or rubber parts. Place a sop towel over tese parts wenever te system is serviced.

Remove te oil bolt and disconnect te brake ose. Remove te master cylinder older bolts, older and master cylinder. DISASSEMBLY Remove te pivot nut/bolt and brake lever.

7 HYDRAULIC BRAKE FRONT MASTER CYLINDER REMOVAL Avoid spilling fluid on painted, plastic or rubber parts. Place a sop towel over tese parts wenever te system is serviced. NOTE Wen removing te brake ose bolt, cover te end of te ose to prevent contamination.secure te ose to prevent fluid from leaking out. Drain te front brake ydraulic system (page 13-3). Remove te oil bolt and disconnect te brake ose. Remove te master cylinder older bolts, older and master cylinder. DISASSEMBLY Remove te pivot nut/bolt and brake lever. Remove te screw and front brake ligt switc. MASTER CYLINDER BOLTS XL200 HOLDER BRAKE LIGHT SWITCH Remove te piston boot, snap ring and waser from te master cylinder body. SNAP RING TOOL: Snap ring pliers SNAP RING PLIER Remove te piston and spring. Clean te inside of te master cylinder and reservoir wit brake fluid. MASTER CYLINDER SPRING MASTER PISTON 13-6

XL200 INSPECTION MASTER CYLINDER HYDRAULIC BRAKE Ceck te primary and secondary cups for wear, deterioration or damage. Ceck te master cylinder and piston for scoring or oter damage.

4978 in) NOTE MASTER PISTON MASTER CYLINDER Te master piston, piston cups, spring, waser and snap ring, must be replace as a set.

SPRING MASTER PISTON Clean te master cylinder wit compressed air. Assemble te master cylinder. Dip te piston cups in clean brake fluid before assembly.

8 XL200 INSPECTION MASTER CYLINDER HYDRAULIC BRAKE Ceck te primary and secondary cups for wear, deterioration or damage. Ceck te master cylinder and piston for scoring or oter damage. Measure te master cylinder I.D. SERVICE LIMIT: mm ( in) Measure te master piston O.D. SERVICE LIMIT: mm ( in) NOTE MASTER PISTON MASTER CYLINDER Te master piston, piston cups, spring, waser and snap ring, must be replace as a set. ASSEMBLY Wen installing te cups, do not allow te lips to turn inside out. Be certain te snap ring is seated firmly in te groove. SPRING MASTER PISTON Clean te master cylinder wit compressed air. Assemble te master cylinder. Dip te piston cups in clean brake fluid before assembly. SNAP RING Install te waser, snap ring and boot. TOOL: Snap ring pliers. SNAP RING PLIER Apply silicone grease to te pivot and install te brake lever. Install and tigten te brake lever pivot nut to te specified torque. TORQUE: 10 N.m (1.0 kg.m, 7 ft-lb) Install te brake ligt switc and tigten te screw to te specified torque. TORQUE: 1.0 N.m (0.10 kg.m, 0.7 ft-lb) BRAKE LIGHT SWITCH 13-7

HYDRAULIC BRAKE INSTALLATION Place te master cylinder on te andlebar and install te older and two mounting bolts wit older s UP mark facing up.

m, 7 ft-lb) Connect te brake ose eyelet joint wit a new sealing wasers and tigten te oil bolt to te specified torque. TORQUE: 35 N.m (3.5 kg.

Place a sop towel over tese parts wenever te system is serviced. Drain te brake fluid from te ydraulic system. Remove te brake pads.

Remove te brake caliper bracket bolts, ten remove te brake caliper and bracket as an assembly.

9 HYDRAULIC BRAKE INSTALLATION Place te master cylinder on te andlebar and install te older and two mounting bolts wit older s UP mark facing up. Align te end of te older wit te punc mark on te andlebar, ten tigten te upper bolt first, ten te lower bolt. TORQUE: 10 N.m (1.0 kg.m, 7 ft-lb) Connect te brake ose eyelet joint wit a new sealing wasers and tigten te oil bolt to te specified torque. TORQUE: 35 N.m (3.5 kg.m, 25 ft-lb) Fill te master cylinder to te proper level and bleed te brake system. BRAKE REMOVAL Avoid spilling fluid on painted, plastic or rubber parts. Place a sop towel over tese parts wenever te system is serviced. Drain te brake fluid from te ydraulic system. Remove te brake pads. Place a clean container under te caliper and remove te oil bolt, sealing waser and eyelet joint from te caliper. Remove te brake caliper bracket bolts, ten remove te brake caliper and bracket as an assembly. DISASSEMBLY Remove te following: Caliper bracket Brake pad retainer Pad spring Caliper/bracket pin boot Pistons from caliper cylinder If necessary, ligtly apply compressed air to te caliper fluid inlet to get te piston out. Place a sop rag under te caliper to cusion te piston wen it is expelled. Use te air in sort spurts. t Do not bring te air nozzle too close to te inlet or te pistons may be forced out wit excessive force tat could cause injury. MASTER CYLINDER BOLT BOLT BOOT XL200 PUNCH MARK BOLTS SEALING WASHER EYELET JOINT SEALING WASHER BRACKET BOOT 13-8

XL200 HYDRAULIC BRAKE Pus te dust and piston seals in an lift tem out. PISTON SEAL Clean te seal groove wit clean brake fluid.

Measure te caliper piston O.D. SERVICE LIMIT: 26.89 mm (1.0587 in) Ceck te caliper cylinder bores for scoring or oter damage.

065 in) ASSEMBLY Coat te new piston seals and dust seals wit clean brake fluid and install tem in te seal grooves of te caliper.

10 XL200 HYDRAULIC BRAKE Pus te dust and piston seals in an lift tem out. PISTON SEAL Clean te seal groove wit clean brake fluid. Be careful not to damage te piston sliding surface. DUST SEAL INSPECTION Ceck te caliper pistons for scoring or oter damage. Measure te caliper piston O.D. SERVICE LIMIT: mm ( in) Ceck te caliper cylinder bores for scoring or oter damage. Measure te caliper cylinder inside diameter. SERVICE LIMIT: mm (1.065 in) ASSEMBLY Coat te new piston seals and dust seals wit clean brake fluid and install tem in te seal grooves of te caliper. Lubricate te caliper cylinders and pistons wit clean brake fluid and install te pistons into te caliper cylinders wit te closed end of te piston facing te pad side. PISTON PISTON SEAL Apply silicone grease to te pivot boots and install tem making sure tat tey are seated in te caliper and bracket grooves properly. Install te pad retainer on te caliper bracket. Coat te caliper and bracket pins silicone grease. Assemble te caliper bracket. DUST SEAL PISTON BRACKET PIN 13-9

m, 22 ft-lb) Connect te brake ose eyelet joint wit two new sealing wasers, ten tigten te oil bolt to te specified torque. TORQUE: 35 N.m (3.5 kg.

11 HYDRAULIC BRAKE XL200 Install te pad spring on te caliper. INSTALLATION Apply a locking agent to te caliper mounting bolt treads. Install te caliper and bracket assembly on te fork leg and tigten te bracket bolts to te specified torque. TORQUE: 31 N.m (3.1 kg.m, 22 ft-lb) Connect te brake ose eyelet joint wit two new sealing wasers, ten tigten te oil bolt to te specified torque. TORQUE: 35 N.m (3.5 kg.m, 25 ft-lb) BOLTS PAD SPRING Fill te master cylinder wit DOT 3 or DOT4 brake fluid from a sealed container and bleed any air te front brake system. Install te brake pads. SEALING WASHER EYELET JOINT 13-10

12 GENERAL INFORMATION HOW TO USE THIS MANUAL Tis service manual describes te service procedure for te XL200. Trougout te manual, te following abbreviations are used to identify individual models. Code DK 2LA Area (type) General Type Latin America Follow te Maintenance Scedule (Section 3) recommendations to ensure tat te veicle is in peak operation condition. CONTENTS GENERAL INFORMATION 1 LUBRICATION 2 MAINTENANCE 3 FUEL SYSTEM 4 ENGINE REMOVAL/INSTALLATION 5 Performing te first sceduled maintenance is very important. It compensates for te initial wear tat occurs during te break-in period. Section 1 troug 3 apply to te wole motorcycle, wile section 4 troug 18 describe parts of te motorcycle, grouped according to location. Find te section you want on tis page, ten turn to te table of contents on page 1 of tat section. Most sections start wit an assembly or system illustration, service information and troublesooting for te section, te subsequent pages give detailed procedures. If you don t know te source of te trouble, go to section 20 TROUBLESHOOTING. All information, illustrations, directions and specifications included in tis publication are based on te latest product information available at te time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves te rigt to make canges at any time witout notice and witout incurring any oblication watever. Not part of tis publication may be reproduced witout 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

SERVICE INFORMATION 11-1 FRONT WHEEL/SUSPENSION/ STEERING XL FRONT WHEEL 11 7 FORK STEERING STEM 11 18

SERVICE INFORMATION 11-1 FRONT WHEEL/SUSPENSION/ STEERING XL FRONT WHEEL 11 7 FORK STEERING STEM 11 18 XL200 11. FRONT WHEEL/SUSPENSION/ STEERING SERVICE INFORMATION 11 1 TROUBLESHOOTING 11 2 HANDLEBAR 11 3 FRONT WHEEL 11 7 FORK 11 11 STEERING STEM 11 18 SERVICE INFORMATION GENERAL A contaminated brake