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Honda XL200 User Manual

Honda XL200
146 pages
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XL200
Manual del Propietario
Owner’s Manual

Table of Contents

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Honda XL200 Specifications

General IconGeneral
Compression Ratio9.0:1
IgnitionCDI
Transmission5-speed
Final DriveChain
Rear BrakeDrum
Front Tire2.75-21
Rear Tire4.10-18
Fuel SystemCarburetor
Fuel Capacity10.5 liters
Engine4-stroke, single-cylinder, air-cooled

Summary

Important Information

Operator and Passenger Capacity

Motorcycle designed to carry operator and one passenger. Exceed max weight capacity.

Dual Purpose Use

Motorcycle is designed for “dual purpose" use (on/off-road).

Manual Usage Recommendation

Read this manual carefully for safety messages and information.

A Few Words About Safety

Safety Information Sources

Safety alerts found in labels and messages throughout the manual.

Safety Labels

Labels on the motorcycle provide important safety information.

Safety Messages

Identified by alert symbol and signal words DANGER, WARNING, or CAUTION.

Signal Word Meanings

Explains DANGER, WARNING, and CAUTION meanings and types of safety information.

Safety Headings and Sections

Information presented in Headings, Safety Sections, and Instructions.

MOTORCYCLE SAFETY

General Safety Guidelines

Take responsibility for your safety and understand challenges.

Wear Protective Gear

Always wear a helmet, eye protection, boots, gloves, and protective apparel.

Visibility on Road

Make yourself visible to other drivers; use bright clothing and signals.

Protective Apparel

Recommended Gear

Helmet, eye protection, boots, gloves, long pants, long-sleeved jersey are recommended.

Helmet and Eye Protection

Importance of helmets and face shields/goggles for safety.

On-Road Gear

Additional recommended gear for on-road riding.

Off-Road Gear

Additional recommended gear for off-road riding.

Off-Road Hazard Awareness

Off-Road Hazard Awareness

Be alert for terrain challenges, keep speed low.

Riding Within Limits

Avoid exceeding personal abilities or hazardous conditions.

Bike Maintenance for Safety

Keep your motorcycle properly maintained and inspect before rides.

Load Limits and Guidelines

Capacity and Loading

Motorcycle designed for rider/passenger; not cargo.

Weight Limit Warning

Overloading or improper loading can cause crashes and injury.

Maximum Weight Capacity

153 kg (337 lbs) for rider, passenger, and accessories.

Loading Guidelines

Cargo Loading Recommendations

Keep cargo small, light, secure, and close to the center.

Accessory and Modification Warnings

Modifying or using non-Honda accessories can be unsafe.

Improper Accessories/Modifications Warning

Can cause crashes leading to serious injury or death.

PARTS LOCATION

Handlebar Controls Layout

Identifies controls on the right and left handlebars.

Instrument Panel Overview

Shows and names the speedometer, odometer, indicators, etc.

Motorcycle Components

Motorcycle Components

Identifies fuel valve, air cleaner, helmet holder, side stand, tool compartment.

Engine Compartment Components

Engine Compartment Components

Identifies fuse, battery, oil filler cap/dipstick, rear brake pedal.

Instruments and Indicators

Instrument Panel Components

Details of speedometer, odometer, gear range, indicators, tripmeter.

Instrument Functions

Instrument Functions

Describes the function of each instrument and indicator shown on page 17.

MAJOR COMPONENTS

Front Brake System

Describes the hydraulic front disc brake and fluid level check.

Front Brake Fluid Level Check

Procedure to check and fill front brake fluid.

Rear Brake

Rear Brake Pedal Height Adjustment

Adjusts pedal height using stopper bolt and lock nut.

Rear Brake Adjustment

Procedure to adjust rear brake pedal free play.

Clutch

Clutch Adjustment

Adjusts clutch cable free play at the lever and lower end.

Normal Clutch Lever Free Play

Specification for clutch lever free play is 10-20 mm.

Fuel Valve

Fuel Valve Operation

Explains OFF, ON, and RES positions of the fuel valve.

Fuel Valve Positions

OFF (not in use), ON (main supply), RES (reserve supply).

Fuel Tank

Fuel Tank Capacity

Total capacity is 8.5 liters, including reserve.

Refueling Procedure

How to remove and close the fuel fill cap, use unleaded petrol.

Fuel Handling Warning

Petrol is flammable and explosive; handle with care.

Petrol Containing Alcohol

Gasohol Usage Guidelines

Guidelines for using gasohol with ethanol or methanol.

Engine Oil Level Check

Oil Level Check Procedure

Procedure to check engine oil level using dipstick.

Oil Level Check Steps

Steps to check oil level between UPPER and LOWER marks.

Oil Level NOTICE

Running with insufficient oil pressure can cause serious damage.

Tyre Requirements

Tyre Specifications

Tyres must be proper type, size, good condition, and correctly inflated.

Tyre Inflation Warning

Improperly inflated tyres can cause crashes and injury.

Tyre Air Pressure

Importance of correct inflation for handling, tread life, comfort.

Tyre Pressure Specifications

Recommended Cold Pressures

Recommended cold tyre pressures for front and rear.

Tyre Inspection

Check treads and sidewalls for wear, damage, foreign objects.

Tread Wear Limit

Replace tyres before tread depth reaches minimum limit.

Tyre Repair and Replacement

Tube Repair and Replacement

Procedures for tube repair and tyre replacement.

Tyre Replacement Warning

Installing improper tyres can affect handling and cause crashes.

Recommended Tyre Sizes

Front: 2.75-21 45R, Rear: 4.10-18 60R.

ESSENTIAL INDIVIDUAL COMPONENTS

Ignition Switch Location and Function

Location and function of the ignition switch.

Ignition Switch Key Positions

LOCK, OFF, ON functions and key removal.

FEATURES

Steering Lock Operation

How to lock and unlock the steering.

Steering Lock Warning

Do not turn key to LOCK while riding.

Helmet Holder

Helmet Holder Usage

Location and use of the helmet holder.

Helmet Holder Warning

Do not ride with helmet secured by holder.

Side Covers

Removal and installation of side covers for maintenance access.

Seat

Seat Removal and Installation

Procedures for removing and installing the seat.

Headlight Aim Vertical Adjustment

How to adjust headlight aim using a screw.

OPERATION

Pre-ride Inspection

Importance of checking the motorcycle before each ride.

Pre-ride Inspection Warning

Improper maintenance or failure to correct problems can cause crashes.

Pre-ride Inspection Checklist

List of items to check before riding.

Starting the Engine

Engine Exhaust Warning

Motorcycle exhaust contains poisonous carbon monoxide gas.

Starter Operation Limit

Do not use electric starter for more than 5 seconds at a time.

Starting Preparation

Confirm transmission neutral, engine stop switch RUN, fuel valve ON.

Normal Temperature Starting Procedure

Steps for starting in normal air temperature.

High Temperature Starting Procedure

High Temperature Starting Procedure

Steps for starting in high air temperature (no choke).

Low Temperature Starting Procedure

Steps for starting in low air temperature (use choke).

Choke Usage NOTICE

Extended choke use may impair lubrication and damage engine.

Flooded Engine Procedure

Steps to clear a flooded engine.

Carburetor Drain Tube

Function and notice regarding the drain tube.

Running-in

Running-in Period

Pay attention during first 500 km (300 miles).

Running-in Restrictions

Avoid full-throttle starts and rapid acceleration.

Riding Guidelines

Review safety, ensure side stand is retracted.

Shifting

Proper Shifting Technique

Prevents engine and transmission damage.

Upshifting Guidelines

Upshift before exceeding upper limit speed for each gear.

Downshifting Guidelines

Downshift at speeds indicated in the table to avoid overrevving.

Low Altitude Riding

Low Altitude Operation (2LA Type)

Air-fuel mixture leans, affecting driveability; carburetor can be modified.

Low Altitude Modification Warning

Sustained operation with mods at high altitudes may flood engine.

Braking Procedure

Gradually apply front/rear brakes, pull clutch before stopping.

Braking Safety

Braking Safety Reminders

Avoid wheel lock, reduce speed before turns, smooth actions in wet conditions.

Braking on Grades

Use engine braking (downshifting) and intermittent brakes on steep grades.

Brake Application Notice

Continuous application can overheat brakes. Foot on pedal/hand on lever can cause false signals.

MAINTENANCE

Importance of Maintenance

Essential for safety, economy, trouble-free riding, and reducing air pollution.

Maintenance Warning

Improper maintenance can cause crashes and injury.

Maintenance Safety

Maintenance Safety Procedures

Perform tasks with basic skills; difficult tasks by professionals.

Maintenance Safety Warning

Failure to follow instructions can cause injury or death.

General Safety Precautions

Engine off, cool parts, ventilate, avoid petrol around sparks/flames.

Tool and Skill Requirements

Read instructions, have required tools and skills.

Maintenance Schedule

Maintenance Schedule Overview

Specifies service intervals and items needing attention.

Service Recommendations

Consult dealer for individual needs and conditions.

Maintenance Items and Intervals (1/2)

Maintenance Items and Intervals (1/2)

Lists items like Tank/lines, Fuel filter, Throttle, Choke, Air cleaner, Spark plug, Valve clearance, Engine oil, Oil strainer, etc.

Maintenance Items and Intervals (2/2)

Maintenance Items and Intervals (2/2)

Lists Drive chain, Brake pads/shoes, Rear brake, Stoplight switch, Clutch, Battery, Headlight, Side stand, etc.

Tool Kit

Tool Kit Contents

Lists the tools provided for roadside repairs and adjustments.

Serial Numbers Location

Location of frame and engine serial numbers for reference.

Colour Label and Air Cleaner

Colour Label Information

Location and purpose of the colour label for replacement parts.

Air Cleaner Servicing

Procedure for cleaning the air cleaner.

Engine Oil and Strainer Screen

Engine Oil Quality and Change

Importance of oil quality and changing oil/cleaning strainer.

Used Engine Oil Disposal

Proper disposal methods for used engine oil.

Engine Oil Change Procedure

Steps for changing engine oil using a torque wrench.

Spark Plug Recommendations

Recommended Spark Plugs

Recommended spark plugs for standard and cold climates.

Spark Plug Heat Range

Adjusting heat range for riding conditions.

Spark Plug Replacement

Spark Plug Replacement Procedure

Procedure for removing, inspecting, and installing spark plugs.

Spark Plug Gap Specification

Specification for spark plug gap.

Spark Plug Tightening NOTICE

Securely tighten spark plug to avoid engine damage.

Throttle Operation

Throttle Operation Check

Check smooth rotation and free play of throttle grip.

Throttle Free Play Specification

Standard free play is 2-6 mm.

Idle Speed Adjustment

Procedure and specification for adjusting idle speed.

Idle Mixture Adjustment

Idle Mixture Adjustment Procedure

Procedure for adjusting pilot screw for fuel mixture.

Drive Chain Service

Service life depends on lubrication and adjustment.

Drive Chain Inspection

How to check drive chain slack and wear.

Drive Chain Slack

Drive Chain Slack Specification

Allow 35-45 mm vertical movement.

Drive Chain and Sprocket Inspection

Check for wear, damage, lubrication, and kinks.

Drive Chain Adjustment

Drive Chain Adjustment Procedure

Steps to adjust chain slack and align rear wheel.

Rear Axle Nut Torque

Specification for tightening the rear axle nut.

Chain Wear and Lubrication

Chain Wear Inspection

Check wear label and replace if excessively worn.

Chain Lubrication and Cleaning

How to lubricate and clean the O-ring drive chain.

Front and Rear Suspension Inspection

Suspension Check Procedure

Inspect fork assembly, swingarm bearings, fasteners.

Side Stand Check

Check side stand spring, assembly, and pivot area lubrication.

Wheel Removal

Wheel Removal Safety

Do not depress brake lever when wheel is off.

Front Wheel Removal Procedure

Steps to remove the front wheel.

Front Wheel Installation

Front Wheel Installation Procedure

Reverse of removal procedure, torque specifications.

Torque Specifications

Front axle and axle holder nut torque values.

Rear Wheel Removal

Rear Wheel Removal Procedure

Steps to remove the rear wheel, including drive chain.

Rear Wheel Installation

Rear Wheel Installation Procedure

Reverse of removal procedure, torque specification.

Front Brake Pad Wear

Inspect front brake pads for wear to the cutout.

Rear Brake Shoe Wear

Rear Brake Wear Indicator

Check rear brake wear indicator arrow and reference mark.

Brake Lining and Drum Cleaning

Cleaning procedure and warning about decreased efficiency.

Battery

Battery Operation and Warning

Consequences of insufficient electrolyte, sulfuric acid hazards.

Battery Electrolyte Level

Electrolyte Level Check

Procedure to check and add distilled water.

Electrolyte Handling NOTICE

Handling battery fluid and breather tube connection.

Battery Removal

Battery Removal Procedure

Steps to disconnect and remove the battery.

Fuse Replacement

Indicators of fuse failure; see dealer for repair.

Fuse Rating NOTICE

Never use a fuse with a different rating.

Main Fuse

Main Fuse Location and Rating

Specifies fuse location and 15A rating.

Main Fuse Replacement

Procedure for replacing the main fuse.

Stoplight Switch Adjustment

Procedure to adjust stoplight switch timing.

Bulb Replacement

Bulb Replacement Safety

Bulbs get hot; let them cool before servicing.

Bulb Usage Restriction

Do not use bulbs other than specified; lighting equipment not legal for highway use.

Headlight Bulb Replacement

Procedure for replacing the headlight bulb.

Stop/Taillight Bulb Replacement

Stop/Taillight Bulb Procedure

Procedure for replacing stop/taillight bulbs.

Front/Rear Turn Signal Bulb Replacement

Procedure for replacing turn signal bulbs.

CLEANING

Motorcycle Cleaning Recommendations

Use mild detergent, avoid high pressure spray.

Washing the Motorcycle

Step-by-step guide to washing the motorcycle.

Post-Wash Checks

Test brakes, lubricate drive chain.

Finishing Touches and Road Salt

Finishing Touches

Use spray cleaner/polish or wax for a quality finish.

Removing Road Salt

Wash with cool water and dry/wax to prevent rust.

STORAGE GUIDE

Extended storage requires steps to reduce deterioration.

Storage Procedure

Storage Procedure

Change oil, empty fuel tank, spray inside with rust-inhibiting oil.

Storage Warning

Petrol is flammable and explosive.

Cylinder Rust Prevention

Pour oil into cylinder, remove spark plug.

Battery Storage

Store battery protected from freezing and direct sunlight.

Removal from Storage

Removal from Storage Procedure

Uncover, clean, check oil, charge battery, test ride.

SPECIFICATIONS

Dimensions

Overall length, width, height, wheelbase, seat height.

Weight

Dry weight.

Capacities

Engine oil, fuel tank, reserve supply, passenger, load capacity.

Engine Details

Engine Details

Type, cylinder, bore, displacement, compression, HP, torque, spark plug, gap, valve clearance, idle speed.

Frame and Suspension Specifications

Frame and Suspension Details

Caster, trail, tyre sizes/models, suspension types, brake types.

Transmission Specifications

Transmission Details

Type, clutch, gearshifting, ratios, final reduction.

Electrical System

Battery, starting system, ignition system, generator, fuse.

Lighting System

Headlight, stoplight, turn signals, indicator bulb specifications.

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