11 - front wheel
Contents
1. REARVIEW MIRROR MASTER CYLINDER Remove the knuckle guard and rearview mirror aa Remove the master cylinder holder and master cylinder ATTENTION Suspend the master cylinder with a suitable wire at least as hight as originally installed so as to prevent air from getting into the brake fluid Remove the screws and separate the throttle housing Disconnect the throttle cables then remove the throttle pipe Remove the screw and right handlebar switch housing Remove the knuckle guard and rearview mirror Remove the screws and clutch lever bracket Remove the screws and left handlebar switch housing HANDLEBAR BOLTS Remove the bolts handlebar upper holders and handlebar F amp gt UPPER HOLDER 11 3 FRONT WHEEL SUSPENSION STEERING INSTALLATION Install the handlebar Align the punch marks on the handlebar with the top edge of the lower holders Place the upper holders on the handlebar with the punch marks facing forward Install the holder bolts and tighten the forward bolts first then the rear bolts TORQUE 27 N m 2 7 kg m 20 ft lb If the handlebar grips were removed apply Honda Bond A or its equivalent to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe Wait 3 5 minutes and install the grip Rotate the grips for even application of the adhesive NOTE Allow the adhesive to dry for an hour before using Install the rig2. condition 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 AMAZONIA 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 GENERAL INFORMATION CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL INSTALLATION CYLINDER HEAD VALVES CYLINDER PISTON CLUTCH GEARSHIFT LINKAGE ALTERNATOR STARTER CLUTCH CRANKSHAFT KICKSTARTER TRANSMISSION FRONT WHEEL SUSPENSION STEERING REAR WHEEL SUSPENSION HYDRAULIC BRAKE FAIRING EXHAUST SYSTEM CHARGING SY
3. ft lb Check the rim runout page 11 7 FRONT WHEEL SUSPENSION STEERING INSTALLATION Install the right dust seal brake disc Tighten the brake disc mounting bolts to the specified torque TORQUE 20 N m 2 0 kg m 14 ft lb Install the hub cover and tighten the screws Install the right side collar Install the soeedometer gear retainer in the left side hub aligning its tangs with the slots in the hub Install the shims fill the soeedometer gear box with grease and install the drive gear Install the dust seal and the soeedometer gear box in the wheel hub aligning the tangs of the retainer with the slots in the speedometer gear box 11 10 XL200 SCREW DUST SEAL 7 w ee BOLT SIDE COLLAR RETAINER SHIM ALIGN RETAINER XL200 INSTALLATION Fit the caliper over the disc taking care not to damage the brake pads Clean the axle and axle holder Install the axle holder with tis UP mark facing upward Install the axle holder nuts but do not tighten them yet ATTENTION Set the tang on the gearbox under the stopper on the left fork leg Tighten the axle to the specified torque TORQUE 60 N m 6 0 kg m 43 ft lb With the front brake applied pump the fork up and down several times to seat the axle and check for front brake operation Tighten the upper axle holder nuts first then the lower nuts TORQUE 12 N m 1 2 kg m 9 ft lb Connect the speedometer cable and tig
4. the hub NOTE Replace wheel bearings in pairs BEARING SPEEDOMETER GEAR BOX DISASSEMBLY Remove the speedometer gear box dust seal and soeedometer gear retainer Remove the side collar from the left hub Remove the hub cover and brake disc NOTE Check for disc warpage see page 13 5 COLLAR BRAKE DISC HUB COVER REMOVER SHAFT WHEEL BEARING REPLACEMENT Remove the wheel bearings and distance collar from the wheel hub TOOLS Bearing remover head 15 mm Bearing remover shaft NOTE Never reinstall oil bearings Once the bearings have been removed they must be replaced with a new one 11 8 i a a REMOVER HEAD XL200 FRONT WHEEL SUSPENSION STEERING DRIVER Pack all new bearing cavities with grease Drive the right bearing in using the following tools NOTE Install the bearings with its sealed side facing out TOOLS Driver Attachment 32 x 35 mm Pilot 15 mm Install the distance collar Drive the new left bearing in using the same tools ASSEMBLY SPEEDOMETER GEAR BOX DRIVE GEAR RIGHT WHEEL BEARING eae FRONT WHEEL BRAKE DISC SHIM DUST SEAL HUB COVER SCREW DISTANCE COLLAR DUST SEAL COLLAR WRENCH Place the rim on the work bench Place the hub with the left side down and begin lacing with new spokes Tighten the spokes in 2 3 progressive steps TOOLS Spoke nipple wrench 4 5 x 5 1 mm TORQUE 3 5 N m 0 35 kg m 2 5
5. 1 FRONT WHEEL SUSPENSION XL200 STEERING SERVICE INFORMATION FRONT WHEEL TROUBLESHOOTING FORK HANDLEBAR STEERING STEM SERVICE INFORMATION GENERAL e A contaminated brake drum or shoe reduces stopping power Discard contaminated shoes and clean a contaminated drum with a high quality brake degreasing agent e This section covers maintenance of the front wheel fork and steering stem Refer to section 13 for front hydraulic brake service e Support the motorcycle securely using a hoist or work stand SPECIFICATIONS UNIT mm in ITEM STANDARD SERVICE LIMIT Axle shaft runout 0 008 Si eS a Fork fluid capacity 384 cc f Fork oil level 139 5 47 Fork spring free length 80 8 3 18 79 2 3 12 B 506 5 19 94 496 4 19 54 TORQUE VALUES Front axle nut Handlebar upper holder bolt Handlebart lower holder nut Fork oil drain bolt Fork top pinch bolt Fork bottom pinch bolt Fork cap Fork socket bolt Steering stem nut 60 N m 6 0 kg m 43 ft lb 27 N m 2 7 kg m 20 ft lb 26 N m 2 6 kg m 19 ft lb 0 8 N m 0 08 kg m 0 6 ft lb 21 N m 2 1 kg m 15 ft lb 33 N m 3 3 kg m 24 ft lb 23 N m 2 3 kg m 17 ft lb 21 N m 2 1 kg m 15 ft lb 105 N m 10 5 kg m 76 ft lb 11 1 FRONT WHEEL SUSPENSION STEERING XL200 27 N m 2 7 kg m 20 ft lb 60 N m 6 0 kg m 43 ft lb ec a a 12 N m 1 2 kg m 9 ft lb 11 0 FRONT WHEEL SUSPENSION STEERING TOOLS Special Steering stem sock
6. EARING RACE LOWER BEARING BOTTOM CONE a el O O DUST SEAL aa x FRONT WHEEL SUSPENSION STEERING STEM NUT TOP THREAD TOP CONE RACE O UPPER BEARING Q UPPER BEARING RACE va J ly a UP CG STEERING STEM C TOP THREAD UPPER BEARING Apply grease to all bearing area Install the lower bearing Install the steering stem upper bearing top cone race and top thread Tighten the top thread until it is sung against the top cone race fw LOWER BEARING STEERING STEM TOP THREAD FRONT WHEEL SUSPENSION STEERING XL200 STEERING STEM Turn the steering stem left and right several times Retighten the top thread and then back it 1 8 turn Check that there is no vertical play and that the steering stem rotates smoothly TOP BRIDGE Install the following top bridge washer stem nut fork Tighten the stem nut to the specified torque TORQUE 105 N m 10 5 kg m 76 ft lb Install the removed parts in the reverse order of removal STEM NUT WASHER FORK 11 22 XL200 FRONT WHEEL SUSPENSION STEERING NOTAS 11 23 HOW TO USE THIS MANUAL This service manual describes the service procedure for the XL200 e Throughout the manual the following abbreviations are used to identify individual models Area type General Type 2LA Follow the Maintenance Schedule Section 3 recommendations to ensure that the vehicle is in peak operation
7. KET BOLT BACK UP RING FORK TUBE BUSHING Before assembly wash all parts with a high flash point or non m flammable solvent and wipe them off completely Install the slider bushing back up ring and oil seal onto the fork tube NOTE e Install the back up ring with the chamfered side facing the slider bushing e Coat the oil seal lip with the recommended fork fluid Install the rebound spring onto the fork piston Install the fork piston into the fork tube as Install the oil lock piece onto the fork piston OIL SEAL OIL LOCK PIECE Clean and apply a locking agent to the fork socket bolt threads Install a new sealing washer and socket bolt SOCKET BOLT 11 15 FRONT WHEEL SUSPENSION STEERING Hold the fork slider in a vise with piece of woods or shop towel Tighten the fork socket bolt to the specified torque TORQUE 21 N m 2 1 kg m 15 ft lb NOTE lt the socket bolt turn together with the fork piston temporarily install the fork spring and fork bolt Place the slider bushing over the fork tube until it rests on the slider Using the fork seal driver drive the bushing into place Install the back up ring and drive the oil seal using the fork seal driver TOOLS Oil seal driver body Oil seal driver attachmet Install the oil seal stop ring into the groove of the fork slider Install the dust seal Compress the fork spring fully and pour in the specified amount of fork fluid Oil capacity 384 cc Pump
8. NNECTORS HOLE SCREWS CLUTCH LEVER BRACKET WIRE BANDS a N REARVIEW MIRROR XL200 FRONT WHEEL REMOVAL Support the motorcycle with a work stand or box under the engine Disconnect the speedometer cable from the speedometer gear box by removing the cable setting screw Loosen the front axle holder nuts Remove the axle and the front wheel NOTE Do not operate the front brake lever after the front wheel is removed The caliper piston will move out and make assembly difficult INSPECTION Axle Place the axle in V blocks and measure the runout with a dial indicator Service limit 0 2 mm 0 008 in The actual runout is 1 2 of the total indicator reading Wheel rim Check the wheel rim runout by lacing the wheel in a turning stand Spin the wheel by hand and read the runout using a dial indicator Service limit Actual 2 0 mm 0 08 in Radial 2 0 mm 0 08 in Tighten any loose spokes TORQUE 3 5 N m 0 35 kg m 2 5 ft lb FRONT WHEEL SUSPENSION STEERING SCREW SPEEDOMETER SPEEDOMETER CABLE aa GEAR 11 7 FRONT WHEEL SUSPENSION STEERING XL200 WHEEL BEARING Remove the brake panel and dust seal Turn the inner race if each bearing with your finger the bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Remove and discard the bearings if the races do not turn smoothly quietly or if they fit loosely in
9. STEM IGNITION SYSTEM ELECTRIC STARTER ELECTRIC STARTER LIGHTS METERS SWITCHES WIRING DIAGRAM TROUBLESHOOTING
10. et Ball race remover Steering stem driver Fork seal driver body Fork seal driver attachment Common Spanner Bearing remover head 15 mm Bearing remover shaft Driver Attachment 32 x 35 mm Pilot 15 mm Attachment 37 x 40 mm Lock nut wrench 30 x 32 mm TROUBLESHOOTING Hard Suspension e Steering top thread too tight e Damaged steering head bearing race e Insufficient tire pressure e Faulty tire Steers To One Side Or Does Not Track Straight e Bent fork e Bent front axle e Wheel installed incorrectly e Faulty steering head bearing e Bent frame e Faulty wheel bearing e Worn swingarm pivot components Front Wheel Wobbling e Bent rim e Worn wheel bearings e Bent or loose spoke e Faulty tire 11 2 07916 KA50100 07953 MA00000 07946 4300101BR 07947 KA50100 07947 KL40100 07701 0020300 07746 0050400BR 07746 0050100BR 07749 0010000BR 07746 0010100BR 07746 0040300BR 07746 0010200BR 07716 0020400BR Wheel Turns Hard e Faulty wheel bearing e Faulty soeedometer gear Soft Suspension e Weak front fork spring e Insufficient fork oil Hard Suspension e Bent fork tubes e Clogged fluid passage Front Suspension Noisy e Insufficient fluid in fork e Loose front suspension fasteners e Lack of grease in speedometer gear XL200 XL200 FRONT WHEEL SUSPENSION STEERING WIRE BAND HANDLEBAR REMOVAL Remove the wire bands Disconnect the front brake switch connectors
11. he speedometer cable and tighten the clamp screw Install the front firing Install the front wheel STEERING STEM REMOVAL Remove the following handlebar front wheel Remove the bolts and front fender 11 18 BOTTOM PINCH BOLT STEERING STEM CLAMP SCREW SPEEDOMETER CABLE FRONT FENDER BRAKE HOSE XL200 Remove the steering stem nut and washer Remove the fork and top bridge Remove the top thread Remove the following top cone race upper bearing steering stem lower bearing FRONT WHEEL SUSPENSION STEERING STEM NUT WASHER TOP THREAD TOP CONE RACE UPPER BEARING gt y T i gt STEERING STEM 11 19 I MA LOWER BEARING FRONT WHEEL SUSPENSION STEERING BEARING RACE REPLACEMENT Remove the bearing races using the special tool TOOL Ball race driver Install the new bearing races using the special tools TOOLS Driver Attachment 37 x 40 mm BOTTOM CONE RACE REPLACEMENT Avoid damaging the steering stem thread temporarily install the stem nut Remove the bottom cone race dust seal and dust seal washer Install a new dust seal washer and bottom cone race Press a new bottom cone race onto the steering stem using the special tool TOOL Stem bearing driver 11 20 XL200 BALL RACE DRIVER ATTACHMENT BOTTOM CONE RACE BEARING DRIVER STEM NUT STEERING STEM XL200 INSTALLATION LOWER B
12. ht handlebar switch housing aligning its locating pin with the hole on the handlebar Install the screws and tighten the forward screw first then the rear screw 11 4 HOLE PIN XL200 XL200 FRONT WHEEL SUSPENSION STEERING THROTTLE PIPE Apply a light coating of grease to the throttle pipe sliding surface of handlebar and throttle cable end Install the throttle grip on the handlebar THROTTLE CABLE Connect the throttle cable end to the throttle pipe Install the throttle cable guide CABLE GUIDE SCREWS Install the screws and tighten the forward screw first then the rear screw f i MASTER CYLINDER HOLDER BOLT Place the front master cylinder on the handlebar and install the ka master cylinder holder with its UP mark facing up Align the end of the holder with the punch mark on the handlebar Tighten the upper bolt first then the lower bolt UP MARK 11 5 PUNCH MARK FRONT WHEEL SUSPENSION STEERING Connect the front brake switch connectors Install the knuckle guard and rearview mirror Install the left handlebar switch housing aligning its locating pin with the hole on the handlebar Install the screws and tighten the forward screw first then the rear screw Install the clutch lever bracket Install the screws and tighten the forward screw first then the rear screw Connect the clutch switch wire connectors Install the wire bands 11 6 XL200 CO
13. hten the setting screw FORK REMOVAL Remove the front wheel Loosen the bolts and release the brake hose from the clamp Loosen the screw and remove the speedometer cable clamp Remove the bolts and front brake caliper Remove the front firing FRONT WHEEL SUSPENSION STEERING UP MARK a SCREW SPEEDOMETER CABLE CLAMP BOLTS BRAKE CALIPER 11 11 FRONT WHEEL SUSPENSION STEERING XL200 Loosen the top and bottom pinch bolts and lower the fork legs then remove j BOTTOM PINCH BOLT TOP PINCH BOLT CLAMPS Remove the fork boot clamp and remove the boot BOOT DISASSEMBLY Carefully remove the fork bolt The fork bolt is under spring pressure Use care when removing it and wear eye and face protection FORK CAP FORK SPRING Remove the fork spring A spring seat and fork spring B Pour out the fork fluid by pumping the fork tube several times 11 12 XL200 FRONT WHEEL SUSPENSION STEERING SOCKET BOLT Hold the fork slider in a vise with piece of woods or shop towel Remove the fork socket bolt NOTE If the socket bolt turn together with the fork piston temporarily install the fork spring and fork bolt STOP RING Remove the dust seal and stop ring In quick successive back and forth strokes pull the fork tube out from the slider The slider bushing gives resistance and the fork tube bushing must be forced out BACK UP RING FORK TUBE BUSHING Remove the
14. oil lock piece from the piston Remove the piston and rebound spring from the fork tube Remove the oil seal back up ring and slider bushing from the fork tube NOTE Do not remove the fork tube bushing unless it is necessary to replace it with a new one OIL SEAL OIL LOCK PIECE FRONT WHEEL SUSPENSION STEERING INSPECTION FORK SPRING Measure the fork springs free length SERVICE LIMIT A 79 2 mm 3 12 in B 496 4 mm 19 5 in FORK TUBE SLIDER PISTON Check the fork tube slider and piston for score marks scratches or excessive or abnormal wear Check the rebound spring for damage Check the piston ring for wear or damage Replace any componenis that are worn or damage Set the fork tube in V blocks and rear the runout with a dial indicator SERVICE LIMIT 0 2 mm 0 008 in The actual runout is 1 2 of the total indicator reading FORK TUBE BUSHING Visually inspect the slider and fork tube bushing Replace the bushing if there is excessively scoring or scratching or if the teflon is worn so that the copper surface appears on more than 3 4 of the entire surface Replace the back up ring is distorted 11 14 SLIDER FORK TUBE XL200 BACK UP RING XL200 FRONT WHEEL SUSPENSION STEERING ASSEMBLY FORK CAP g7 URING BAND BOOT FORK SPRING PISTON RING g7 Ne DUST SEAL SLIDER L FORK PISTON STOP AING REBOUND SPRING a BACK LUP RING SLIDER BUSHING m FORK SOC
15. the fork tube slowly several times to stabilize the fork oil level Compress the fork all the way and measure the oil level from the top of the tube Oil level 139 mm 5 47 in 11 16 OIL SEAL DRIVER DUST SEAL XL200 ATTACHMENT SLIDER BUSHING XL200 FRONT WHEEL SUSPENSION STEERING Install the fork spring B with the tapered end facing down Install the fork spring B spring seat and fork spring A into the fork tube O RING Install a new O ring onto the fork bolt and install it loosely NOTE Install the fork bolt but do not tighten yet BOOT Install the fork boot with its breather holes toward the rear INSTALLATION Install the fork leg aligning its top with the upper surface of the top bridge as shown TOP BRIDGE 11 17 FRONT WHEEL SUSPENSION STEERING Tighten the fork bottom pinch bolts to the specified torque TORQUE 33 N m 3 3 kg m 24 ft lb Tighten the fork bolt to the specified torque TORQUE 23 N m 2 3 kg m 17 ft lb Tighten the fork top pinch bolts to the specified torque TORQUE 21 N m 2 1 kg m 15 ft lb Push the fork boot up until they just touch the bottom of the steering stem then tighten the clamp screw Route the brake hose properly then install the front brake caliper and tighten the mounting bolts to the specified torque TORQUE 31 N m 3 1 kg m 22 ft lb Install the brake hose between the hose clamp then tighten the bolts Clamp t
Download Pdf Manuals
Related Search