Honda XL125, XL185, XL200, XR185, XR200, TLR200 Repair Manual 1979-2003
Item Description Table of Contents Specifications
The 1979-2003 Honda XL125, XL185, XL200, XR185, XR200, TLR200 repair manual by Clymer covers:
Honda XL125S, 1979-1982, 1984-1985
Honda XL185S, 1979-1983
Honda XL200R, 1983-1984
Honda XR185, 1979
Honda XR200, 1980-1984
Honda XR200R, 1981-1983, 1986-1988, 1990-2003
Honda TLR200, 1986-1987
Book Excerpt: 1979-2003 Honda XL125, XL185, XL200, XR185, XR200, TLR200 Repair Manual
ENGINE All models covered in this book are equipped with an air-cooled, 4-stroke, single cylinder engine with a single overhead camshaft.
The crankshaft is supported by 2 main ball bearings. The camshaft is chain-driven from the timing sprocket on the left-hand side of the crankshaft and operates rocker arms that are individually adjustable.
Engine lubrication is by wet sump with the oil pump located on the right-hand side of the engine adjacent to the clutch. The oil pump delivers oil under pressure throughout the engine and is gear driven off of the crankshaft.
The engine used in the various models is the same basic unit with different compression ratios and different bore and stroke dimensions to achieve varying displacements.
This chapter contains information for removal, inspection, service and reassembly of the engine. Table 1 provides complete specifications for the engine and Table 2 lists all of the engine torque specifications. Table 1 and Table 2 are located at the end of this chapter.
TIRES AND WHEELS: TIRE PRESSURE Tire pressure should be checked and adjusted to maintain the smoothness of the tire, good traction and handling and to get the maximum life out of the tire.
A simple, accurate gauge (Figure 3) can be purchased for a few dollars and should be carried in your motorcycle tool kit. The appropriate tire pressures are shown in Table 2.
TIRE INSPECTION The tires take a lot of punishment, so inspect them periodically for excessive wear, cuts, abrasions, etc. If you find a nail or other object in the tire, mark its location with a light crayon prior to removing it. This will help locate the hole for repair.
Refer to Chapter Eight for tire changing and repair information.
Check local traffic regulations concerning minimum tread depth. Measure the tread depth at the center of the tire tread using a tread depth gauge (Figure 4) or small ruler.
Honda recommends tire replacement when the front or rear tread depth is 8 mm (1/8 in.) or less. Replace the tire(s) at this point.
WHEEL SPOKE TENSION Tap each spoke with a wrench. The higher the pitch of sound it makes, the tighter the spoke. The lower the sound frequency, the looser the spoke.
A ping is good; a klunk says the spoke is too loose. If one or more spokes are loose, tighten them as described under Wheels in Chapter Eight.
TABLE of CONTENTS:
General Information
Troubleshooting
Lubrication, Maintenance and Tune-up
Engine
Clutch and External Gearshift Linkage
Transmission and Internal Shift Mechanism
Fuel and Emission Systems
Exhaust System
Electrical System
Wheels, Tires and Drive Chain
Front Suspension and Steering
Rear Suspension
Brakes
Body and Frame
Wiring Diagrams
Subject: 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Honda XL/XR/TLR125-200 service, maintenance, repair. ISBN-10: 0892878630 | ISBN-13: 9780892878635 | Clymer M318-4
Publisher: Clymer Manuals
Pages: 348 – Hundreds of bw photos and illustrations
Binding: Paperback – 7 x 10 inches
ISBN: 978-0-89287-863-5
Years: 1979 – 2003
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