05 - Engine Removal-installation.pdf

5.

XL200

SERVICE INFORMATION ENGINE REMOVAL

5-1 5-2

ENGINE INSTALLATION

ENGINE REMOVAL/ INSTALLATION

5-3

SERVICE INFORMATION GENERAL • When removing the engine, support the motorcycle on its center stand. • The following components require engine removal for service. – Crankshaft (Section 10) – Cylinder head/valves (Section 6) – Cylinder/piston (Section 7) – Gearshift drum (Section 10) – Transmission (Section 10) • The following components can be serviced with the engine installed in the frame.. – Alternator (Section 9) – Camshaft (Section 6) – Carburetor (Section 4) – Clutch (Section 8) – Gearshift linkage (Section 8) – Oil pump (Section 2)

5

5-1

ENGINE REMOVAL/INSTALLATION

5-0

XL200

XL200

ENGINE REMOVAL/INSTALLATION CARBURETOR

ENGINE REMOVAL Drain the engine oil (page 2-3). Remove the following: – Carburetor – Spark plug cap – Muffler – Clutch cable

CLUTCH CABLE

EXHAUST PIPE CONNECTOR

Disconnect the alternator and pulse generator connector.

BOLTS Remove the gearshift pedal. Remove the bolts and drive sprocket cover.

GEARSHIFT PEDAL DRIVE CHAIN

DRIVE SPROCKET COVER BOLTS

Remove the following: – Fixing plate bolts. – Fixing plate. – Drive chain. – Drive sprocket.

FIXING PLATE

5-2

DRIVE SPROCKET

XL200

ENGINE REMOVAL/INSTALLATION STARTER MOTOR CABLE

Disconnect the starter motor cable.

GROUND CABLE NUT/BOLT Remove the engine hanger nuts, bolts hanger plates and engine from the frame.

ENGINE NUT/BOLT

HANGER PLATE

COLLAR

ENGINE INSTALLATION Install the engine in the frame and install the rear engine hanger bolts and collars. NOTE • Install the long collar to the right, shorter collar to the left. Install the nuts on the rear hanger bolts.

HANGER PLATE Install the front engine hanger plate, bolts and nuts.

NUT/BOLT

5-3

XL200

ENGINE REMOVAL/INSTALLATION

Install the top engine hanger plates, bolts and nuts.

NUT/BOLT REAR AND TOP

FRONT AND TOP

Install the skid plate. Tighten the engine hanger nut to the specified torque. TORQUE: 10 mm nut: 61 N.m (6.1 kg.m, 44 ft-lb) 8 mm nut: 28 N.m (2.8 kg.m, 20 ft-lb)

REAR AND UNDER FIXING PLATE

FRONT AND TOP DRIVE SPROCKET

Install the drive sprocket and fixing plate onto the countershaft and tighten the bolts.

DRIVE CHAIN STARTER MOTOR CABLE

BOLTS NUT

Install the starter motor terminal cable and tighten the terminal nut securely. Install the ground cable and tighten the bolt.

GROUND CABLE

5-4

BOLTS

XL200

ENGINE REMOVAL/INSTALLATION CONNECTOR

Connect the alternator/pulse generator connectors and neutral switch connector.

BOLTS Install the drive sprocket cover and tighten the bolts. Install the gearshift pedal and tighten the bolt.

GEARSHIFT PEDAL

DRIVE SPROCKET COVER

CARBURETOR

SPARK PLUG CAP

CLUTCH CABLE

EXHAUST PIPE

Install the following: – Exhaust pipe – Carburetor – Spark plug cap – Clutch cable Route the wire harness and cables properly. After installation, perform the following adjustment: – Clutch cable adjustment – Drive chain slack adjustment – Throttle grip free play – Rear brake free play Fill the crankcase with recommended engine oil to the proper level.

5-5

GENERAL INFORMATION

HOW TO USE THIS MANUAL

CONTENTS

This service manual describes the service procedure for the XL200. • 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.

Section 1 through 3 apply to the whole motorcycle, while section 4 through 18 describe parts of the motorcycle, grouped according to location.

ENGINE

Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period.

GENERAL INFORMATION

1

LUBRICATION

2

MAINTENANCE

3

FUEL SYSTEM

4

ENGINE REMOVAL/INSTALLATION

5

CYLINDER HEAD/VALVES

6

CYLINDER/PISTON

7

CLUTCH/GEARSHIFT LINKAGE

8

ALTERNATOR/STARTER CLUTCH

9

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.

ELECTRIC STARTER

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.

FRAME

If you don’t know the source of the trouble, go to section 20 TROUBLESHOOTING.

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