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Honda XL200 2001 Shop Manual

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SH O P MANU AL
XL200
1
MOTO HONDA DA AMAZÔNIA LTDA 2001.

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Summary of Contents for Honda XL200 2001

  • Page 1 SH O P MANU AL XL200 MOTO HONDA DA AMAZÔNIA LTDA 2001.
  • Page 2 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 3 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 4 GENERAL INFORMATION XL2 0 0 MODEL IDENTIFICATION (1) The frame serial number is stamped on the right side (2) The engine serial number is stamped on the lower of the steering head. left side of the crankcase. (3) The carburetor identification number is on the right side of the carburetor body.
  • Page 5 The exhaust contains poisonous carbon monoxide gas. SERVICE RULES • Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that do not meet HONDA’s design specifications may damage the motorcycle. • Use the special tools designed for this product.
  • Page 6 GENERAL INFORMATION XL2 0 0 SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2.093 mm (82.40 in) Overall width 830 mm (32.7 in) Overall height 1.143 mm (45.00 in) Ground clearance 235 mm (9.25 in) Wheelbase 1.389 mm (54.68 in) Seat height 825 mm (32.48 in) Footpeg height 235 mm (9.25 in)
  • Page 7 XL2 0 0 GENERAL INFORMATION ITEM SPECIFICATION DRIVE TRAIN Clutch Multi-plate, wet Transmission 5 Speed, constant mesh Primary reduction 3.0909 (68/22) Gear ratio 2.7692 (36/13) Gear ratio 1.7222 (31/18) Gear ratio 1.2631 (24/19) Gear ratio 1.0000 (22/22) Gear ratio 0.851 (23/27) Final reduction 3.230 (13/42) Gear shift pattern...
  • Page 8 GENERAL INFORMATION XL2 0 0 TORQUE VALUES ENGINE Item Qty. Thread Torque Dia. (mm) kg.m (ft-lb) Lubrication system: Oil filter rotor lock nut 8,5 (61) Oil pump cover screw 0,3 (2) Maintenance: Spark plug 1,8 (13) Timing hole cap 0,6 (4) Crankshaft hole cap 0,8 (6) Cylinder head/valves:...
  • Page 9 XL2 0 0 GENERAL INFORMATION FRAME Item Qty. Thread Torque Dia. (mm) kg.m (ft-lb) Engine removal/installation: Engine hanger bolt (Front: 8 mm) 2,8 (20) (Front: 10 mm) 6,1 (43) (Upper: 8 mm) 2,8 (20) (Upper: 10 mm) 6,1 (43) (Lower: 10 mm) 6,1 (43) Front wheel/suspension/steering: Front axle nut...
  • Page 10 GENERAL INFORMATION XL2 0 0 TOOLS Description Tool number Maintenance: Tappet adjuster 07708-0030300BR Tappet adjusting wrench 10 x 12 mm 07708-0030200 Spoke nipple wrench C. 5.8 x 6.1 mm 07701-0020300 Fuel system: Float level gauge 07401-0010000BR Pilot screw wrench 07908-4730001 Cylinder head/valves: Valve spring compressor 07757-0010000BR...
  • Page 11 XL2 0 0 GENERAL INFORMATION Description Tool number Crankshaft assembly collar 07965-VM00100 Crankshaft assembly shaft 07965-VM00200 Thread adaptor 07965-KA30000 Universal bearing puller 07631-0010000BR Driver 07749-0010000BR Attachment, 28 x 30 mm 07946-1870100 Attachment, 32 x 35 mm 07746-0010100BR Attachment, 42 x 47 mm 07746-0010300BR Attachment, 72 x 75 mm 07746-0010600BR...
  • Page 12 GENERAL INFORMATION XL2 0 0 LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Oil through sliding surface Engine oil Oil pump rotor surface Oil filter rotor lock nut threads Rocker arm shaft surface Valve adjusting nut threads Cylinder head cap (8 mm) nut threads Cam sprocket bolt threads Cam chain surface Piston skirt and piston ring...
  • Page 13 Locking agent Exhaust pipe protector bolt threads Muffler protector bolt threads Fork cap O-rings Fork fluid Fork oil seal lips Handle grip Honda Bond A or Master cylinder piston cups equivalent Caliper piston seals DOT 4 brake fluid 1 -9...
  • Page 14 GENERAL INFORMATION XL2 0 0 CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses: • A loose wire, harness or cable can be a safety hazard. After clamping, check each wire to be sure it is secure. •...
  • Page 15 XL2 0 0 GENERAL INFORMATION 1 -1 1...
  • Page 16 GENERAL INFORMATION XL2 0 0 1 -1 2...
  • Page 17 XL2 0 0 GENERAL INFORMATION 1 -1 3...
  • Page 18 GENERAL INFORMATION XL2 0 0 1 -1 4...
  • Page 19 XL2 0 0 GENERAL INFORMATION NOTES 1 -1 5...
  • Page 20 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 21 2. LUBRICATION XL2 0 0 SERVICE INFORMATION ENGINE OIL CHANGE/OIL FILTER SCREEN TROUBLESHOOTING ENGINE OIL FILTER ROTOR ENGINE OIL LEVEL CHECK OIL PUMP SERVICE INFORMATION GENERAL • If engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area.
  • Page 22 XL2 0 0 LUBRICATION CAMSHAFT CRANKSHAFT MAIN SHAFT OIL FILTER ROTOR OIL PUMP COUNTERSHAFT 2 -0...
  • Page 23 LUBRICATION XL2 0 0 TROUBLESHOOTING Oil level low • External oil leak • Worn valve guide or seal • Worn piston rings or incorrect piston ring installation • Oil not added frequently enough • Worn cylinder Oil contamination • Oil not change often enough •...
  • Page 24 XL2 0 0 LUBRICATION FILLER CAP/DIPSTICK ENGINE OIL LEVEL CHECK • If the engine must the running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
  • Page 25 LUBRICATION XL2 0 0 FILTER SCREEN SPRING Make sure that the oil filter screen, sealing rubber, screen cap and O-ring are in good condition. Install the oil filter screen with its sealing rubber toward the crankcase. SCREEN CAP Install and tighten the oil filter screen cap to the specified torque. TORQUE: 15 N.m (1.5 kg.m, 11 ft-lb) Fill the crankcase with the recommended engine oil.
  • Page 26 XL2 0 0 LUBRICATION SCREW OIL PUMP REMOVAL Remove the right crankcase cover (page 8-3). Rotate the crankshaft clockwise until the pump mounting screws are accessible through the gear cover. Remove the two screws and the oil pump. OIL PUMP DISASSEMBLY Remove the following: —...
  • Page 27 LUBRICATION XL2 0 0 Measure the rotor tip clearance. SERVICE LIMIT: 0.20 mm (0.008 in) Measure the end clearance. NOTE • Measure the clearance with the gasket installed. SERVICE LIMIT: 0.15 mm (0.006 in) ASSEMBLY (5) SCREW (3) OUTER ROTOR (2) PUMP BODY (1) GEAR COVER (4) PUMP COVER...
  • Page 28 XL2 0 0 LUBRICATION Install the rotor shaft and pump gear into the pump body. Install the gear cover. GASKET PUMP COVER Install the outer and inner rotors. Install the gasket and pump cover. NOTE • Align the boss on the cover with the groove in the pump body.
  • Page 29 LUBRICATION XL2 0 0 NOTES 2 -8...
  • Page 30 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 31 3. MAINTENANCE XL2 0 0 SERVICE INFORMATION BRAKE FLUID 3-10 MAINTENANCE SCHEDULE BRAKE PADS/ SHOES WEAR 3-10 FUEL LINE BRAKE SYSTEM 3-11 FUEL STRAINER SCREEN BRAKE LIGHT SWITCH 3-11 THROTTLE OPERATION HEADLIGHT AIM 3-12 CARBURETOR CHOKE CLUTCH SYSTEM 3-12 AIR CLEANER SIDE STAND 3-13 SPARK PLUG...
  • Page 32 MAINTENANCE XL2 0 0 TORQUE VALUES Fuel strainer cup 4 N.m (0.4 kg.m, 2.9 ft-lb) Rear axle nut 90 N.m (9.0 kg.m, 65 ft-lb) TOOLS Tappet adjusting wrench 07708-0030300BR Spoke nipple wrench 07701-0020300 3 -2...
  • Page 33 XL2 0 0 MAINTENANCE MAINTENANCE SHEDULE The following items require some mechanical knowledge. Certain items (particularly those marked *and**) may require more tecnical information and tolls. Consult their authorized Honda dealer. ITEM Operation PERIOD 1.000 km 3.000 km 6.000 km each...km...
  • Page 34 MAINTENANCE XL2 0 0 FUEL VALVE FUEL LINE FUEL LINE Replace the fuel line if it is cracked damaged or leaking. If the fuel flow is restricted, inspect the fuel line and fuel strainer for blockage. Clean or replace as necessary. FUEL VALVE FUEL STRAINER SCREEN Gasoline is extremely flammable and is explosive under...
  • Page 35 XL2 0 0 MAINTENANCE ADJUSTER Throttle grip free play can be adjusted using the adjuster at the handlebar. Slide the rubber cover off the lower mount and loosen the lock nut. Turn the adjuster to obtain 2-6 mm (1/16 - 1/4 in) of free play. Then tighten the lock nut and slide the rubber cover back.
  • Page 36 MAINTENANCE XL2 0 0 SPARK PLUG Clean any dirt from around the spark plug base. Disconnect the spark plug cap and remove the spark plug. Visually inspect the spark plug electrodes for wear. The center electrode should have square edges and the side electrode should have a constant thickness.
  • Page 37 XL2 0 0 MAINTENANCE FEELER GAUGE Check the valve clearance by inserting a feeler gauge between the adjusting screw and valve stem. Valve clearance: IN/EX: 0.10±0.02 mm (0.004 ± 0.0008 in) VALVE ADJUSTER Adjust by loosening the lock nut and turning the adjusting screw until there is slight drag on the feeler gauge.
  • Page 38 MAINTENANCE XL2 0 0 35 -45 mm (1-3/8 - 1-3/4 in) DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION • Never inspect or adjust the drive chain while the engine is running. When the drive chain becomes extremely dirty, it should be cleaned before lubrication. Turn the engine off, place the motorcycle on its side stand and shift the transmission into neutral.
  • Page 39 XL2 0 0 MAINTENANCE DRIVE SPROCKET INSPECTION Check the drive and driven sprocket for wear or damage. NOTE • Be sure to replace the chain and sprockets as a set. The combination of an elongated chain and new sprocket(s) or the combination of a worn sprocket(s) and a new chain will result in rapid wear of the new component(s).
  • Page 40 MAINTENANCE XL2 0 0 BRAKE FLUID Check the front brake fluid level. If the level is near the lower level mark, check the brake pad wear. Check the entire system for leaks. WEAR LINE BRAKE PADS/SHOES WEAR FRONT BRAKE PAD WEAR Check the brake pads for wear.
  • Page 41 XL2 0 0 MAINTENANCE STOPPER BOLT BRAKE PEDAL HEIGHT To adjust: Loosen the stopper bolt lock nut and turn the stopper bolt. Retighten the lock nut. NOTE After adjusting the brake pedal height, check the rear brake light switch and brake pedal free play and adjust if necessary.
  • Page 42 MAINTENANCE XL2 0 0 HEADLIGHT AIM Adjust vertically by turning the vertical adjusting screw. Turn the adjusting screw clockwise direct the beam up. • An improperly adjusted headlight may blind oncoming drivers, or it may fail to light the road for a safe distance. CLUTCH SYSTEM SCREW CLUTCH LEVER...
  • Page 43 XL2 0 0 MAINTENANCE SIDE STAND RUBBER SIDE STAND Check the side stand spring for damage or loss of tension. Spring tension is correct if the measurements fall under 2 kg.f, when pulling the side stand lower end with a spring scale. Check the side stand assembly for freedom if movement.
  • Page 44 MAINTENANCE XL2 0 0 Move the swingarm side ways with force to see swingarm bushings are worn. Replace if excessive worn. Check the shock absorber for leaks or damage. Tighten all rear suspension nuts/bolts to the specified torque values (page 1-5). NUTS, BOLTS, FASTENERS Tighten bolts, nuts and fasteners at regular interval shown in the Maintenance Schedule (pag.
  • Page 45 XL2 0 0 MAINTENANCE STEERING HEAD BEARINGS Place a block or work stand under the engine to raise the front wheel off the ground. Check that the handlebar rotates freely and that the control cable does not interfere with handlebar rotation. If the handlebar moves unevenly, binds or has vertical play, inspect and adjust the steering head bearings (see section 11 or 22).
  • Page 46 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 47 4. FUEL SYSTEM XL2 0 0 SERVICE INFORMATION PILOT SCREW ADJUSTMENT 4-14 TROUBLESHOOTING ACCELERATOR PUMP ADJUSTMENT 4-15 CARBURETOR AIR CLEANER HOUSING 4-15 FUEL TANK 4-16 SERVICE INFORMATION GENERAL • Gasoline is extremely flammable and is explosive under certains condition. Work in a well ventilated area with the engine stopped.
  • Page 48 XL2 0 0 FUEL SYSTEM 4 -0...
  • Page 49 FUEL SYSTEM XL2 0 0 TROUBLESHOOTING Engine won’t start Afterburn when engine braking is used • Too much fuel getting to the engine • Lean mixture in slow circuit – Air cleaner clogged – Flooded carburetor Backfiring or misfiring during acceleration •...
  • Page 50 XL2 0 0 FUEL SYSTEM BOLTS CARBURETOR REMOVAL • Gasoline is extremely flammable and is explosive under certain condition. Work in a well ventilated area. Do not smoke or allow flames or sparks in the work area or where gasoline is stored. •...
  • Page 51 FUEL SYSTEM XL2 0 0 Check the diaphragm for a tear deterioration. Check the rod for wear and trueness. DIAPHRAGM SCREW Remove the following: – Screws – Float chamber FLOAT CHAMBER BAFFLE PLATE FLOAT – Float pin – Float – Float valve –...
  • Page 52 XL2 0 0 FUEL SYSTEM SCREW Remove the following: – Screws – Carburetor top cover CARBURETOR TOP COVER SPRING – Spring SCREW – Throttle link attaching screw – Nut/washer NUT/WASHER THROTTLE VALVE ASSEMBLY – Washer – Throttle drum/spring – Throttle valve assembly THROTTLE DRUM/SPRING WASHER 4 -5...
  • Page 53 FUEL SYSTEM XL2 0 0 MAIN JET/JET NEEDLE HOLDER/JET NEEDLE – Main jet/jet needle holder/jet needle – Slow jet – Pilot screw NOTE • Do not try to remove the float valve seat from the carburetor body. • Before removing the pilot screw, record the number of turns until it seats lightly.
  • Page 54 XL2 0 0 FUEL SYSTEM THROTTLE VALVE Inspect the throttle valve for wear or scratches. Inspect the jet needle for damage. JET NEEDLE SCREW Remove the following: – Two screws – Cover – Spring – O-ring – Diaphragm COVER Blow open all carburetor body openings with compressed air. 4 -7...
  • Page 55 FUEL SYSTEM XL2 0 0 ASSEMBLY (1) NUT (2) SPRING (4) SPRING (5) THROTTLE DRUM (14) SCREW (35) BOOT (7) SCREW (34) CARBURETOR BODY (6) CO- (30) FLOAT VALVE (8) CARBURETOR (33) JET NEEDLE TOP COVER (26) FLOAT (32) SLOW JET (31) PILOT SCREW (9) SCREW (3) DIAPHRAGM...
  • Page 56 XL2 0 0 FUEL SYSTEM SCREWS SPRING O-RING Install a new O-ring into the groove in the carburetor body. Install the cover and tighten the screws securely. NEEDLE JET/NEEDLE JET HOLDER/ MAIN JET SLOW JET Install the following: – Needle jet/needle jet holder/main jet –...
  • Page 57 FUEL SYSTEM XL2 0 0 O-RING Install the O-ring into the groove in the carburetor body. Install the float chamber aligning the overflow tube on the chamber with the hole in the baffle plate as shown. FLOAT CHAMBER SCREWS Install and tighten the float chamber screws. BOOT Install the accelerator diaphragm and dust boot.
  • Page 58 XL2 0 0 FUEL SYSTEM THROTTLE VALVE JET NEEDLE SPRING Install the jet needle into the throttle valve. Install the spring on the set plate, then install the set plate into the throttle valve. SET PLATE SCREWS Install and tighten the screws. SPRING Install the link arm and spring.
  • Page 59 FUEL SYSTEM XL2 0 0 THROTTLE LINK Install the throttle link aligning the cut-out of the link to the cut-out on the throttle drum. SCREW Install the washer and nut, then tighten the nut securely. Install and tighten the link arm screw. NUT/WASHER SPRING Install the spring as shown.
  • Page 60 XL2 0 0 FUEL SYSTEM GASKET Install a new gasket onto the top cover. TOP COVER SCREW Install and tighten the cover screws. AIR VENT TUBE DRAIN TUBE Install the following: – Air vent tube – Drain tube – Fuel tube FUEL TUBE ALIGN Installation...
  • Page 61 FUEL SYSTEM XL2 0 0 SUPPORT BRACKET NOTE • After installation, turn the fuel valve ON, and check that there is no fuel leaks. Install the fuel tank support bracket and tighten the bolts. Perform the following adjustment: – Throttle grip free play –...
  • Page 62 XL2 0 0 FUEL SYSTEM 5. Turn the pilot screw 1/2 turn out from the initial setting. 6. If the engine speed increases by 50 min -1 ( rpm) or more, turn the pilot screw out by continual 1/2 turn increments until engine speed does not increase.
  • Page 63 FUEL SYSTEM XL2 0 0 FUEL TANK REMOVAL • Gasoline is extremely flammable and is explosive under certain condition. Work in a well ventilated area. Do not smoke or allow flames or sparks in the work area or where gasoline is stored. •...
  • Page 64 XL2 0 0 FUEL SYSTEM NOTES 4 -1 7...
  • Page 65 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 66 ENGINE REMOVAL/ INSTALLATION XL2 0 0 SERVICE INFORMATION ENGINE INSTALLATION ENGINE REMOVAL 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) –...
  • Page 67 XL2 0 0 ENGINE REMOVAL/INSTALLATION 5 -0...
  • Page 68 ENGINE REMOVAL/INSTALLATION XL2 0 0 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.
  • Page 69 XL2 0 0 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 HANGER PLATE NUT/BOLT COLLAR ENGINE INSTALLATION Install the engine in the frame and install the rear engine hanger bolts and collars.
  • Page 70 ENGINE REMOVAL/INSTALLATION XL2 0 0 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 FRONT AND TOP...
  • Page 71 XL2 0 0 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 Install the following: –...
  • Page 72 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 73 CYLINDER HEAD/VALVES XL2 0 0 SERVICE INFORMATION VALVE GUIDE REPLACEMENT TROUBLESHOOTING VALVE SEAT INSPECTION/REFACING 6-10 CYLINDER HEAD COVER/CAMSHAFT CYLINDER HEAD ASSEMBLY 6-13 REMOVAL CYLINDER HEAD INSTALLATION 6-14 CYLINDER HEAD REMOVAL CAMSHAFT/CYLINDER HEAD COVER CYLINDER HEAD DISASSEMBLY INSTALLATION 6-15 SERVICE INFORMATION GENERAL •...
  • Page 74 XL2 0 0 CYLINDER HEAD/VALVES 27 N.m (2.7 kg.m, 20ft-lb) 10 N.m (1.0 kg.m, 7ft-lb) 15 N.m (1.5 kg.m, 11ft-lb) 12 N.m (1.2 kg.m, 9ft-lb) 14 N.m (1.4 kg.m, 10ft-lb) 10 N.m (1.0 kg.m, 7ft-lb) 4 N.m (0.4 kg.m, 3ft-lb) 12 N.m (1.2 kg.m, 9ft-lb) 10 N.m (1.0 kg.m, 7ft-lb) 8 N.m (0.8 kg.m, 6ft-lb)
  • Page 75 CYLINDER HEAD/VALVES XL2 0 0 TORQUE VALUES Valve adjusting hole cap 15 N.m (1,5 kg.m, 11 ft-lb) Valve adjusting screw lock nut 14 N.m (1,4 kg.m, 10 ft-lb) Cylinder head cover 8 mm cap nut 27 N.m (2,7 kg.m, 20 ft-lb) Cylinder head cover 6 mm socket bolt 10 N.m (1,0 kg.m, 7 ft-lb) Cam sprocket bolt...
  • Page 76 XL2 0 0 CYLINDER HEAD/VALVES BOLTS CYLINDER HEAD COVER/CAMSHAFT REMOVAL Remove the following: – starter motor – crankshaft/timing hole caps Remove the bolts, cam chain tensioner lifter and gasket. CAM CHAIN TENSIONER INDEX MARK Align the “T” mark on the flywheel with the index mark on the left crankcase cover by turning the crankshaft counterclockwise.
  • Page 77 CYLINDER HEAD/VALVES XL2 0 0 CAP NUT/SEALING WASHER Remove the engine hanger plate. Remove the cylinder head cover cap nuts/sealing washers and flange bolts in a gradual, crisscross pattern. Remove the cylinder head cover. HEAD COVER BOLTS CAMSHAFT DOWEL PIN Remove the camshaft.
  • Page 78 XL2 0 0 CYLINDER HEAD/VALVES TENSIONER LIFTER TENSIONER LIFTER INSPECTION Remove the cam chain tensioner lifter sealing bolt and O-ring. Check the lifter operation: – the tensioner shaft should not go into the body unless it is pushed. – When it turned clockwise with a screwdriver, the tensioner shaft shoud be pulled into the body.
  • Page 79 CYLINDER HEAD/VALVES XL2 0 0 CYLINDER HEAD SOCKET BOLT/WASHER CYLINDER HEAD REMOVAL Remove the following: – cylinder head cover – engine from the frame – cylinder head socket bolt/washer – cylinder head GASKET DOWEL PIN – cam chain guide – gasket –...
  • Page 80 XL2 0 0 CYLINDER HEAD/VALVES PIVOT BOLT/WASHER SOCKET BOLT CYLINDER HEAD DISASSEMBLY Remove the cam chain tensioner pivot bolt, washer and cam chain tensioner. Remove the socket bolts and carburetor insulator. CAM CHAIN TENSIONER INSULATOR While compressing the valve spring with a valve spring compressor, remove the valve cotters.
  • Page 81 CYLINDER HEAD/VALVES XL2 0 0 VALVE Inspect the valve for trueness, burning, scratches or abnormal stem wear. Measure the valve stem O.D. SERVICE LIMIT: 5.44 mm (0.214 in) 5.42 mm (0.213 in) Insert each valve into the valve guide and check the valve movement in the guide.
  • Page 82 XL2 0 0 CYLINDER HEAD/VALVES VALVE SPRING Measure the valve spring free length. SERVICE LIMIT: Inner: 38.0 mm (1.50 in) Outer: 43.5 mm (1.71 in) VALVE GUIDE DRIVER VALVE GUIDE REPLACEMENT Chill valve guides in the freezer section of a refrigerator for about an hour.
  • Page 83 CYLINDER HEAD/VALVES XL2 0 0 VALVE GUIDE REAMER After driving in the valve guide, ream it with a valve guide reamer. NOTE • Use cutting oil on the reamer during this operation. • Always rotate the reamer clockwise, never counterclockwise. Clean the cylinder head thoroughly to remove any metal particles.
  • Page 84 XL2 0 0 CYLINDER HEAD/VALVES VALVE GUIDE REAMER VALVE SEAT GRINDING Honda Valve Seat Cutters, a grinder or equivalent valve seat refacing equipament are recommended to correct a worn valve seat. NOTE • Follow the refacer manufacturer’s operating instructions. Use a 45 degree cutter to remove ant roughness or irregularities from the seat.
  • Page 85 CYLINDER HEAD/VALVES XL2 0 0 Using 60 degree cutter, remove the bottom 1/4 of the oil seat. Remove the cutter and inspect the area you have just removed. Install a 45 degree finish cutter and cut the seat to proper width. Make sure that all pitting and irregularities are removed.
  • Page 86 XL2 0 0 CYLINDER HEAD/VALVES Refinish the seat to specifications, using a 45 degree finish cutter. After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pressure. After lapping, wash all residual compound off the cylinder head and valve.
  • Page 87 CYLINDER HEAD/VALVES XL2 0 0 Tap the stems gently with a plastic hammer to firmly seat the cotters. • Support the cylinder head above the work bench surface to prevent valve damage. O-RING Check the insulator O-ring is in good condition, replace if necessary.
  • Page 88 XL2 0 0 CYLINDER HEAD/VALVES DOWEL PIN GASKET Clean the cylinder head gasket surface of any gasket materials. NOTE • Do not allow dust and dirt to enter the engine. Install the dowel pins, new O-ring and new cylinder head gasket. CYLINDER HEAD Install the cylinder head Install a new sealing washer and the tensioner pivot bolt through...
  • Page 89 CYLINDER HEAD/VALVES XL2 0 0 CAMSHAFT Apply oil to the cam lobes and camshaft bearings. Install the camshaft in the cylinder head, positioning the cam lobes down as shown. Pour fresh oil into the oil pocket in the cylinder head until the cams are submerged.
  • Page 90 XL2 0 0 CYLINDER HEAD/VALVES CAM CHAIN Install the cam sprocket with its timing marks facing out. Install the cam chain over the sprocket as shown. NOTE • If it is difficult to install the chain over the sprocket, make sure the chain is set properly on the timing sprocket.
  • Page 91 CYLINDER HEAD/VALVES XL2 0 0 SOCKET BOLT SCREW Tighten the cam chain tensioner lifter mounting bolts. TORQUE: 12 N.m (1.2 kg.m, 9 ft-lb) Remove the wire holder piece from the tensioner lifter. Install and tighten the screw with a new O-ring. Tighten the screw to the specified torque.
  • Page 92 XL2 0 0 CYLINDER HEAD/VALVES NOTAS 6 -1 9...
  • Page 93 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 94 7. CYLINDER/PISTON XL2 0 0 SERVICE INFORMATION PISTON REMOVAL TROUBLESHOOTING PISTON INSTALLATION CYLINDER REMOVAL CYLINDER INSTALLATION SERVICE INFORMATION GENERAL • Clean all disassembled parts with clean solvent and dry them by blowing them off with compressed air before inspection. SPECIFICATIONS Unit: mm (in) ITEM Standard...
  • Page 95 XL2 0 0 CYLINDER/PISTON 7 -0...
  • Page 96 CYLINDER/PISTON XL2 0 0 CYLINDER CYLINDER REMOVAL Remove the engine. Remove the cylinder head. Remove the cylinder. DOWEL PINS Remove the following: – Gasket – Dowel pins Clean off any gasket material from the cylinder surface. NOTE • Be careful not to damage the gasket surface. GASKET INSPECTION Check the cylinder for warpage with a straight edge and a feeler...
  • Page 97 XL2 0 0 CYLINDER/PISTON Measure the cylinder for taper at three levels in an X and Y axis. Take the maximum reading to determine the taper. SERVICE LIMIT: 0.10 mm (0.004 in) (2) TOP Measure the cylinder for out of round at three levels in an X and Y axis.
  • Page 98 CYLINDER/PISTON XL2 0 0 Temporarily install the piston rings in their proper positions with PISTON the marks facing up. Measure the piston ring-to-ring groove clearance with a feeler gauge. SERVICE LIMIT: Top: 0.09 mm (0.004 in) Second: 0.09 mm (0.004 in) Inspect the piston for wear or damage.
  • Page 99 XL2 0 0 CYLINDER/PISTON Measure the connecting rod small end I.D. SERVICE LIMIT: 15.06 mm (0.593 in) Calculate the piston pin-to-connecting rod clearance. SERVICE LIMIT: 0.10 mm (0.004 in) PISTON INSTALLATION (1) PISTON RING MARK PISTON RING INSTALLATION NOTE • Insert the outside surface of the ring into the proper ring groove and roll the ring around in the groove to make sure that the ring has a free fit around the piston’s circumference.
  • Page 100 CYLINDER/PISTON XL2 0 0 PISTON PISTON INSTALLATION Place clean shop towel in the crankcase to prevent the piston pin clips or other parts from falling into the crankcase. Apply oil to the outer surface of the piston pin. Install the piston with the “IN” mark facing the intake side. Install the piston pin and new piston pin clips.
  • Page 101 XL2 0 0 CYLINDER/PISTON NOTAS 7 -7...
  • Page 102 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 103 CLUTCH/GEARSHIFT LINKAGE XL2 0 0 SERVICE INFORMATION CLUTCH TROUBLESHOOTING GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL RIGHT CRANKCASE COVER INSTALLATION 8-11 SERVICE INFORMATION GENERAL • This section covers removal and installation of the clutch, oil filter rotor and gearshift linkage. All these operations can be done with the engine installed in the frame.
  • Page 104 XL2 0 0 CLUTCH/GEARSHIFT LINKAGE 10 N.m (1.0 kg.m, 7 ft-lb) 12 N.m (1.2 kg.m, 9 ft-lb) 95 N.m (9.5 kg.m, 68 ft-lb) 85 N.m (8.5 kg.m, 61 ft-lb) 8 -0...
  • Page 105 CLUTCH/GEARSHIFT LINKAGE XL2 0 0 TROUBLESHOOTING Clutch lever too hard • Damaged, kinked or dirty clutch cable • Improperly routed clutch cable • Damaged clutch lifter mechanism • Faulty clutch lifter plate bearing Clutch will not disengage or motorcycle creeps with clutch disengaged •...
  • Page 106 XL2 0 0 CLUTCH/GEARSHIFT LINKAGE BOLT RIGHT CRANKCASE COVER REMOVAL Drain engine oil into an clean container. Remove the rear brake adjuster and return spring. Remove the skid guard. Remove the bolts and the right crankcase cover. NOTE • Loosen the bolts in a crisscross pattern in 2-3 steps. Remove the gasket and dowel pins.
  • Page 107 CLUTCH/GEARSHIFT LINKAGE XL2 0 0 BOLT SPRING Remove the clutch lifter guide. Remove the clutch bolts, clutch lifter plate and clutch spring. NOTE • Loosen the bolts a crisscross pattern in 2-3 steps. LIFTER GUIDE LIFTER PLATE CLUTCH CENTER HOLDER Install the clutch center holder and remove the clutch lock nut.
  • Page 108 XL2 0 0 CLUTCH/GEARSHIFT LINKAGE LIFTER BEARING INSPECTION Check the lifter bearing for damage. Turn the bearing inner race with your finger. Also check that the bearing outer race fits tightly in the clutch lifter plate. Replace the bearing if necessary. SPRING Measure the clutch spring free length.
  • Page 109 CLUTCH/GEARSHIFT LINKAGE XL2 0 0 CLUTCH OUTER Check the slots in the clutch outer for nicks or indentations made by clutch discs. Measure the clutch outer I.D. SERVICE LIMIT: 28.04 mm (1.104 in) Measure the clutch outer guide O.D. and I.D.s. SERVICE LIMIT: O.D.: 27.93 mm (1.100 in) I.D.: 20.02 mm (0.788 in)
  • Page 110 XL2 0 0 CLUTCH/GEARSHIFT LINKAGE CLUTCH OUTER GUIDE SPLINE WASHER Install the clutch outer guide, clutch outer and spline washer. CLUTCH OUTER Assemble the pressure plate, discs, plates and clutch center. (1) PRESSURE PLATE NOTE • Stack the discs and plates alternately. •...
  • Page 111 CLUTCH/GEARSHIFT LINKAGE XL2 0 0 BOLT Stake the lock nut against the mainshaft groove. BOLT STAKE Install the clutch springs and lifter plate, and tighten the bolts in a crisscross pattern in 2-3 steps. LIFTER PLATE CLUTCH CENTER LOCK NUT LIFTER GUIDE Install the clutch lifter guide.
  • Page 112 XL2 0 0 CLUTCH/GEARSHIFT LINKAGE OIL FILTER ROTOR WASHER Install the oil filter rotor. Apply oil to the lock nut threads. Install the lock washer and lock nut. NOTE • Install the lock washer with its “OUT SIDE” facing out. •...
  • Page 113 CLUTCH/GEARSHIFT LINKAGE XL2 0 0 GEARSHIFT SPINDLE Remove the gearshift spindle. STOPPER PLATE STOPPER PLATE BOLT Remove the following: – Stopper plate bolt – Shift drum stopper plate – Dowel pin – Stopper arm bolt – Stopper arm – Return spring RETURN SPRING STOPPER ARM BOLT INSPECTION...
  • Page 114 XL2 0 0 CLUTCH/GEARSHIFT LINKAGE DOWEL PIN Install the dowel pin into the hole in the shift drum. Hold the stopper arm using a screwdriver, then install the stopper plate aligning hole in the plate with the dowel pin on the shift drum.
  • Page 115 CLUTCH/GEARSHIFT LINKAGE XL2 0 0 CLUTCH CABLE Connect the clutch cable to the clutch lifter arm, then install the right crankcase cover. RIGHT CRANKCASE COVER Install the tighten the bolts in a crisscross pattern in 2-3 steps. Install the rear brake adjuster and return spring. Install the skid guard.
  • Page 116 XL2 0 0 CLUTCH/GEARSHIFT LINKAGE NOTES 8 -1 3...
  • Page 117 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 118 ALTERNATOR/STARTER CLUTCH XL2 0 0 SERVICE INFORMATION STARTER CLUTCH TROUBLESHOOTING FLYWHEEL INSTALLATION LEFT CRANKCASE COVER REMOVAL LEFT CRANKCASE COVER INSTALLATION FLYWHEEL REMOVAL SERVICE INFORMATION GENERAL • This section covers removal and installation of the starter reduction gear, alternator, pulse generator and starter clutch. These operation can be done with the engine installed in the frame.
  • Page 119 XL2 0 0 ALTERNATOR/STARTER CLUTCH 5 Nm (0.5 kg.m, 4 ft-lb 75 Nm (7.5 kg.m, 53 ft-lb) 9 -0...
  • Page 120 ALTERNATOR/STARTER CLUTCH XL2 0 0 CONNECTORS LEFT CRANKCASE COVER REMOVAL Drain the engine oil. Remove the seat. Disconnect the alternator, pulse generator and neutral switch connectors. BOLT COLLAR Remove the drive sprocket cover. Remove the collar and disconnect the neutral switch wire from the switch.
  • Page 121 XL2 0 0 ALTERNATOR/STARTER CLUTCH PULSE GENERATOR ALTERNATOR/PULSE GENERATOR REPLACEMENT Remove the bolts and pulse generator from the case cover; but not disconnect pulse generator wire connector yet. BOLTS CLAMP PULSE GENERATOR Release the pulse generator wire from the clamp on the pulse generator.
  • Page 122 ALTERNATOR/STARTER CLUTCH XL2 0 0 CLAMP PULSE GENERATOR Clamp the pulse generator wire securely as shown. Connect the pulse generator wire connector on the pulse generator terminal. WIRE GROMMET Insert the wire grommet into the groove in the left crankcase cover.
  • Page 123 XL2 0 0 ALTERNATOR/STARTER CLUTCH IDLE GEAR FLYWHEEL REMOVAL Remove the left crankcase cover (page 9-2). Remove the starter idle gear shaft and idle gear. SHAFT FLYWHEEL HOLDER Hold the flywheel using the flywheel holder and remove the flywheel bolt and washer. TOOL: Flywheel holder FLYWHEEL...
  • Page 124 ALTERNATOR/STARTER CLUTCH XL2 0 0 DRIVEN GEAR STARTER CLUTCH INSPECTION/DISASSEMBLY Check for an inoperable one-way clutch. The driven gear should turn counterclockwise smoothly, but should not turn clockwise. DRIVEN GEAR Inspect the starter driven gear teeth for damage or abnormal wear.
  • Page 125 XL2 0 0 ALTERNATOR/STARTER CLUTCH STARTER CLUTCH ASSEMBLY (6) WASHER (3) FLYWHEEL (2) ONE-WAY CLUTCH OUTER (1) DRIVEN GEAR (5) ONE-WAY CLUTCH ONE-WAY CLUTCHOUTER Apply clean engine oil to the one-way clutch rollers. Install the one-way clutch in the clutch outer facing its flange toward the flywheel.
  • Page 126 ALTERNATOR/STARTER CLUTCH XL2 0 0 DRIVEN GEAR Install the starter driven gear into the one-way clutch by turning it counterclockwise. WASHER FLYWHEEL INSTALLATION NOTE • Check that there is not debris inside the flywheel before installation. The magnets attract steel filings and other ferrous material.
  • Page 127 XL2 0 0 ALTERNATOR/STARTER CLUTCH DOWEL PIN LEFT CRANKCASE COVER INSTALLATION Install the dowel pins and new gasket. GASKET Install the left crankcase cover and tighten the bolts. NOTE • Do not pinch the neutral switch wire when installing the left crankcase cover.
  • Page 128 ALTERNATOR/STARTER CLUTCH XL2 0 0 O-RING COVER Install a new O-ring on the reduction gear cover and apply small amount of clean engine oil to the O-ring. Install the reduction gear cover and tighten the bolts securely. BOLTS CONNECTOR Connect the alternator, pulse generator and neutral switch connectors.
  • Page 129 XL2 0 0 ALTERNATOR/STARTER CLUTCH NOTAS 9 -1 1...
  • Page 130 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 131 CRANKSHAFT/ TRANSMISSION XL2 0 0 SERVICE INFORMATION 10-1 CRANKCASE BEARING REPLACEMENT 10-8 TROUBLESHOOTING 10-2 CRANKSHAFT 10-9 CRANKCASE SEPARATION 10-3 CRANKCASE ASSEMBLY 10-11 TRANSMISSION 10-4 SERVICE INFORMATION GENERAL • The crankcase must be separated to repair the crankshaft, transmission. • Remove the following parts before separating the crankcase. –...
  • Page 132 XL2 0 0 CRANKSHAFT/TRANSMISSION 12 N.m (1.2 kg-m, 9ft-lb) 1 0 -0...
  • Page 133 CRANKSHAFT/TRANSMISSION XL2 0 0 TOOLS Special Crankshaft assembly collar 07965-VM00100 Crankshaft assembly shaft 07965-VM00200 Threaded adaptor 07965-KA30000 – Remover shaft, 15 mm 07936-KC10100 – Remover head, 15 mm 07936-0010200 – Remover weight 07741-0010201BR Common Universal bearing puller 07631-0010000BR Driver 07749-0010000BR Attachment, 32 x 35 mm 07746-0010100BR Attachment, 37 x 40 mm...
  • Page 134 XL2 0 0 CRANKSHAFT/TRANSMISSION CABLE HOLDER CRANKCASE SEPARATION Remove the right crankcase cover bolt and clutch cable holder. BOLT BOLT Remove the cam chain and the left crankcase bolts. NOTE • Loosen the bolts in a crisscross pattern in 2-3 steps. RIGHT CRANKCASE Place the left crankcase down and remove the right crankcase.
  • Page 135 CRANKSHAFT/TRANSMISSION XL2 0 0 SHAFT DRUM TRANSMISSION DISASSEMBLY Remove the shift fork shaft and remove the shift forks. Remove the shift drum. Remove the mainshaft and countershaft as an assembly from the crankcase. Disassemble the mainshaft and countershaft. FORK GEAR INSPECTION Inspect each gear for wear or damage and replace if necessary.
  • Page 136 XL2 0 0 CRANKSHAFT/TRANSMISSION FORK Check the shift fork for any wear, bending or damage. Measure the shift fork I.D. SERVICE LIMITS: 12.05 mm (0.474 in) Measure the shift fork claw thichness. SERVICE LIMITS: 4.50 mm (0.177 in) Check the shift fork shaft for bend, worn or damaged Measure the shift fork shaft O.D.
  • Page 137 CRANKSHAFT/TRANSMISSION XL2 0 0 MAINSHAFT: SPLINE SNAP RING WASHER WASHER SPLINE WASHER M1 GEAR (13 T) M4 GEAR (22 T) M5 GEAR (27 T) M2 GEAR (18 T) M3 GEAR (19 T) SPLINE WASHER SPLINE WASHER SNAP RING SNAP RING COUNTERSHAFT: SNAP RING...
  • Page 138 XL2 0 0 CRANKSHAFT/TRANSMISSION MAINSHAFT INSTALLATION Install the mainshaft and countershaft as an assembly into the left crankcase. NOTE • Make sure the thrust washer stays in place during this operation. COUNTERSHAFT RIGHT SHIFT FORK CENTER SHIFT FORK Install the shift forks into the shifter grooves with their marks facing down.
  • Page 139 CRANKSHAFT/TRANSMISSION XL2 0 0 BEARING SET PLATE TRANSMISSION BEARING REPLACEMENT Remove the crankshaft (page 10-9). Remove the bolts and right mainshaft bearing set plate. BOLTS BEARING Drive the crankshaft and mainshaft bearings out of the right crankcase. Remove the countershaft bearing from the right crankcase using special tools.
  • Page 140 XL2 0 0 CRANKSHAFT/TRANSMISSION BEARING Apply a locking agent to the bolt threads and install the bearing set plate onto the right mainshaft bearing. TORQUE: 12 N.m (1.2 kg.m, 9 ft-lb) BOLTS Drive new bearings into the left crankcase. Mainshaft bearing: –...
  • Page 141 CRANKSHAFT/TRANSMISSION XL2 0 0 CRANKSHAFT INSPECTION Measure the side clearance at the connecting rod big end with a feeler gauge. SERVICE LIMIT: 0.5 mm (0.02 in) FEELER GAUGE CRANKSHAFT Measure the radial clearance at the connecting rod big end at two points in the direction indicated by the arrows.
  • Page 142 XL2 0 0 CRANKSHAFT/TRANSMISSION CRANKCASE ASSEMBLY COLLAR Install the left crankcase onto the crankshaft. Draw the crankshaft into the left crankcase using the special tools. TOOLS: Crankcase assembly collar. Crankcase assembly shaft. CRANKCASE ASSEMBLY SHAFT DOWEL PINS GASKET CRANKCASE ASSEMBLY Install the dowel pins and new gasket.
  • Page 143 CRANKSHAFT/TRANSMISSION XL2 0 0 CAM CHAIN Install the cam chain. BOLT CAM CHAIN GUIDE PLATE BOLT Install the clutch cable holder and right crankcase bolts and tighten the bolts securely. After tightening, check the transmission operation. Install the removed parts in the reverse order of removal. CABLE HOLDER 1 0 -1 2...
  • Page 144 XL2 0 0 CRANKSHAFT/TRANSMISSION NOTAS 1 0 -1 3...
  • Page 145 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 146 FRONT WHEEL/SUSPENSION/ STEERING XL2 0 0 SERVICE INFORMATION 11–1 FRONT WHEEL 11–7 TROUBLESHOOTING 11–2 FORK 11–11 HANDLEBAR 11–3 STEERING STEM 11–18 SERVICE INFORMATION GENERAL • A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated drum with a high quality brake degreasing agent.
  • Page 147 XL2 0 0 FRONT WHEEL/SUSPENSION/STEERING 27 N.m (2.7 kg.m, 20 ft-lb) 21 N.m (2.1 kg.m, 15 ft-lb) 33 N.m (3.3 kg.m, 23 ft-lb) 60 N.m (6.0 kg.m, 43 ft-lb) 12 N.m (1.2 kg.m, 9 ft-lb) 1 1 -0...
  • Page 148 FRONT WHEEL/SUSPENSION/STEERING XL2 0 0 TOOLS Special Steering stem socket 07916 - KA50100 Ball race remover 07953 - MA00000 Steering stem driver 07946 - 4300101BR Fork seal driver body 07947 - KA50100 Fork seal driver attachment 07947 - KL40100 Common Spanner 07701 - 0020300 Bearing remover head, 15 mm...
  • Page 149 XL2 0 0 FRONT WHEEL/SUSPENSION/STEERING WIRE BAND HANDLEBAR REMOVAL Remove the wire bands. Disconnect the front brake switch connectors REARVIEW MIRROR MASTER CYLINDER Remove the knuckle guard and rearview mirror. Remove the master cylinder holder and master cylinder. 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.
  • Page 150 TORQUE: 27 N.m (2.7 kg.m, 20 ft-lb) UPPER HOLDER HANDLEBAR 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.
  • Page 151 XL2 0 0 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.
  • Page 152 FRONT WHEEL/SUSPENSION/STEERING XL2 0 0 Connect the front brake switch connectors. Install the knuckle guard and rearview mirror. CONNECTORS HOLE SCREWS 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.
  • Page 153 XL2 0 0 FRONT WHEEL/SUSPENSION/STEERING SCREW SPEEDOMETER CABLE 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. SPEEDOMETER GEAR BOX Loosen the front axle holder nuts.
  • Page 154 FRONT WHEEL/SUSPENSION/STEERING XL2 0 0 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 the hub.
  • Page 155 XL2 0 0 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 –...
  • Page 156 FRONT WHEEL/SUSPENSION/STEERING XL2 0 0 SCREW DUST SEAL 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. BOLT BRAKE DISC SIDE COLLAR...
  • Page 157 XL2 0 0 FRONT WHEEL/SUSPENSION/STEERING ”UP” MARK 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. Set the tang on the gearbox under the stopper on the left fork leg.
  • Page 158 FRONT WHEEL/SUSPENSION/STEERING XL2 0 0 Loosen the top and bottom pinch bolts and lower the fork legs, then remove. 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.
  • Page 159 XL2 0 0 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. DUST SEAL STOP RING Remove the dust seal and stop ring.
  • Page 160 FRONT WHEEL/SUSPENSION/STEERING XL2 0 0 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) INNER CYLINDER FORK TUBE/SLIDER/PISTON Check the fork tube, slider and piston for score marks, scratches, or excessive or abnormal wear.
  • Page 161 XL2 0 0 FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY BACK-UP RING FORK TUBE BUSHING Before assembly, wash all parts with a high flash point or non- flammable solvent and wipe them off completely. Install the slider bushing, back-up ring and oil seal onto the fork tube.
  • Page 162 FRONT WHEEL/SUSPENSION/STEERING XL2 0 0 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 It the socket bolt turn together with the fork piston, temporarily install the fork spring and fork bolt.
  • Page 163 XL2 0 0 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.
  • Page 164 FRONT WHEEL/SUSPENSION/STEERING XL2 0 0 TOP PINCH BOLT 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.
  • Page 165 XL2 0 0 FRONT WHEEL/SUSPENSION/STEERING Remove the steering stem nut and washer. STEM NUT/WASHER Remove the fork and top bridge. TOP THREAD Remove the top thread. TOP CONE RACE UPPER BEARING Remove the following: – top cone race – upper bearing –...
  • Page 166 FRONT WHEEL/SUSPENSION/STEERING XL2 0 0 BALL RACE DRIVER BEARING RACE REPLACEMENT Remove the bearing races using the special tool. TOOL Ball race driver DRIVER Install the new bearing races using the special tools. TOOLS Driver Attachment, 37 x 40 mm ATTACHMENT BOTTOM CONE RACE BOTTOM CONE RACE REPLACEMENT...
  • Page 167 XL2 0 0 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION STEM NUT LOWER BEARING RACE LOWER BEARING TOP THREAD BOTTOM CONE RACE TOP CONE RACE DUST SEAL UPPER BEARING UPPER BEARING RACE STEERING STEM TOP THREAD UPPER BEARING Apply grease to all bearing area. Install the lower bearing.
  • Page 168 FRONT WHEEL/SUSPENSION/STEERING XL2 0 0 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: –...
  • Page 169 XL2 0 0 FRONT WHEEL/SUSPENSION/STEERING NOTAS 1 1 -2 3...
  • Page 170 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 171 – A work stand or box is required to support the motorcycle. – Use genuine Honda bolts for the rear suspension linkage and shock absorber pivot and mounting; ordinary bolts lack adequate strength for these applications. Also take not of the installation direction of these bolts since they must be installed correctly.
  • Page 172 XL2 0 0 REAR WHEEL/SUSPENSION 1 2 -0...
  • Page 173 REAR WHEEL/SUSPENSION XL2 0 0 TOOLS Spanner 07701-0020300 Driver 07749-0010000BR Attachment, 32 x 35 mm 07746-0010100BR Attachment,, 42 x 47 mm 07746-0010300BR Pilot, 15 mm 07746-0040300BR Bearing remover head, 15mm 07746-0050400BR Bearing remover shaft 07746-0050100BR Pilot, 15 mm 07746-0040500BR TROUBLESHOOTING Rear Wheel Wobbling Suspension Noise •...
  • Page 174 XL2 0 0 REAR WHEEL/SUSPENSION ADJUSTER SPRING REAR WHEEL Removal Raise the rear wheel off the ground by placing a jack or work stand under the skid plate. Remove the rear brake adjuster and remove the brake rod and spring. CHAIN ADJUSTER AXLE Loosen the drive chain adjusting nuts.
  • Page 175 REAR WHEEL/SUSPENSION XL2 0 0 • Driven sprocket WORN Check the driven sprocket teeth for wear or damage and replace if necessary. NOTE Inspect the drive chain and drive sprocket whenever DAMAGED NORMAL checking the driven sprocket. • Wheel bearing BEARING Remove the snap ring, driven sprocket and dust seal.
  • Page 176 XL2 0 0 REAR WHEEL/SUSPENSION DRIVEN SPROCKET NOTE Tap the sprocket in several locations with a piece of wood or a soft hammer if it is hard to remove. REMOVER HEAD Remove the left and right bearings and distance collar using the special tool.
  • Page 177 REAR WHEEL/SUSPENSION XL2 0 0 DRIVER Pack all new bearing cavities with grease. Drive the left bearing in using the following tools. NOTE Install the bearing with its sealed side facing out. TOOLS Driver Attachment,, 42x47 mm Pilot, 15 mm Install the distance collar.
  • Page 178 XL2 0 0 REAR WHEEL/SUSPENSION Install the brake rod spring, joint piece, brake rod and adjusting nut. Adjust the drive chain slack. REAR BRAKE REMOVAL A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated drum with a high quality brake degreasing agent.
  • Page 179 REAR WHEEL/SUSPENSION XL2 0 0 BRAKE ARM Remove the brake arm pivot bolt, nut and brake arm. Remove the indicator plate and brake cam. Remove the dust seals. BOLT ASSEMBLY BRAKE ARM INDICATOR PLATE DUST SEAL SHOE DUST SEAL BRAKE CAM CAM SEAT SPRING BOLT...
  • Page 180 XL2 0 0 REAR WHEEL/SUSPENSION CAM SEAT Install the brake cam seat, aligning its tabs with the projection of the brake panel. Apply grease to the sliding surfaces of the anchor pin and brake cam and install the brake cam. Avoid getting grease on the inside of the brake drum or braking power will be reduced.
  • Page 181 REAR WHEEL/SUSPENSION XL2 0 0 RETURN SPRING REAR BRAKE PEDAL REMOVAL Remove the brake pedal adjusting nut and brake rod from the brake arm. Unhook the brake pedal return spring and brake switch spring. Remove the brake pedal pivot pinch bolt, shaft and dust seals, then remove the brake pedal.
  • Page 182 XL2 0 0 REAR WHEEL/SUSPENSION LOWER MOUNTING BOLT SHOCK ABSORBER REMOVAL Raise the rear wheel off the ground by placing a box or workstand under the skid plate. Remove the side covers. Remove the shock link-to-shock arm bolt and shock absorber lower mounting bolt.
  • Page 183 REAR WHEEL/SUSPENSION XL2 0 0 DISPOSAL OF THE SHOCK ABSORBER DRILL BIT Center punch the damper case to mark the drilling point, PLASTIC BAG approximately 15 mm (0.59 in) from the top surface. Wrap the damper unit inside a plastic bag. Support the damper unit upright in a vise as shown.
  • Page 184 XL2 0 0 REAR WHEEL/SUSPENSION SHOCK LINK BOLT/NUT LOWER MOUNTING BOLT SHOCK LINKAGE Raise the rear wheel off the ground by placing a box or workstand under the skid plate. Remove the following: – shock arm-to-shock link bolt/nut – shock absorber lower mounting bolt/nut –...
  • Page 185 REAR WHEEL/SUSPENSION XL2 0 0 DRIVER SHAFT SHOCK ARM Press the needle bearing out of the shock arm using the special tool. TOOL Driver shaft SHOCK ARM Pack the new needle bearings with grease. 4.5 mm Carefully press the needle bearing into the shock link to the (0.18 in) specified depth below the surface of the pivot on both side using the special tool.
  • Page 186 XL2 0 0 REAR WHEEL/SUSPENSION “UP” MARK LOWER MOUNTING BOLT Temporarily install the all mounting bolts/nuts, then tighten the nuts to the specified torque. TORQUE: 45 N.m (4.5 kg.m, 32 ft-lb) SHOCK LINK BOLT/NUT LOWER MOUNTING BOLT SWINGARM REMOVAL Remove the rear wheel. Remove the shock link-to-swingarm bolt/nut.
  • Page 187 REAR WHEEL/SUSPENSION XL2 0 0 SCREWS DISASSEMBLY Remove the drive chain guard and drive chain slider. CHAIN SLIDER BOLTS PIVOT COLLAR Remove the dust seal caps and pivot collar. DUST SEAL CAP SWINGARM PIVOT BEARING REPLACEMENT Drive out the pivot bushings. Do not damage the swingarm.
  • Page 188 XL2 0 0 REAR WHEEL/SUSPENSION DRIVER ATTACHMENT/PILOT Pack the new needle bearings with grease. Carefully press the needle bearing with the pivot bushing into the swingarm pivot using the special tools. TOOLS Driver Attachment, 32x35 mm Pilot, 20 mm SWINGARM PIVOT COLLAR ASSEMBLY Apply grease to lip of the new dust seals.
  • Page 189 REAR WHEEL/SUSPENSION XL2 0 0 DRIVE CHAIN COVER Install the drive chain cover onto the swingarm, aligning its cut- out with the hook on the swingarm. HOOK LOWER MOUNTING BOLT Temporarily install the shock absorber lower mounting bolt/nut and shock link-to-swingarm bolt/nut. Install and tighten the mounting bolts.
  • Page 190 XL2 0 0 REAR WHEEL/SUSPENSION NOTAS 1 2 -1 9...
  • Page 191 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 192 13. HYDRAULIC BRAKE XL2 0 0 SERVICE INFORMATION 13-1 BRAKE PAD/DISC 13-4 TROUBLESHOOTING 13-2 MASTER CYLINDER 13-6 BRAKE FLUID REPLACEMENT/ BRAKE CALIPER 13-8 BLEEDING 13-3 SERVICE INFORMATION GENERAL • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
  • Page 193 XL2 0 0 HYDRAULIC BRAKE 1.5 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) 2.5 N.m (0.25 kg.m, 18 ft-lb) 13 N.m (1.3 kg.m, 9 ft-lb)
  • Page 194 HYDRAULIC BRAKE XL2 0 0 TOOLS Special Snap ring pliers 07914-3230000BR Blake bleeding tool 07468-0010001BR TROUBLESHOOTING Brake lever soft or spongy Brake lever hard • Air in the hydraulic system • Clogged/restricted brake system • Leaking hydraulic system • Sticking/worn caliper piston •...
  • Page 195 XL2 0 0 HYDRAULIC BRAKE MASTER CYLINDER BRAKE FLUID REPLACEMENT/AIR BLEEDING Check the master cylinder parallel to the ground • Avoid spilling fluid on painted, plastic or rubber parts. Place a shop towel over these parts whenever the system is serviced.
  • Page 196 HYDRAULIC BRAKE XL2 0 0 If the brake bleeder is not available, perform the following procedure. Pump up the system pressure with the lever until these are not air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt.
  • Page 197 XL2 0 0 HYDRAULIC BRAKE Insert new outside pad and push the caliper piston in allow clearance for installation of the new left side pad. Install new left pad. Install the pad pin by pushing the pads against the caliper to depress the pad spring.
  • Page 198 HYDRAULIC BRAKE XL2 0 0 MASTER CYLINDER HOLDER FRONT MASTER CYLINDER REMOVAL • Avoid spilling fluid on painted, plastic or rubber parts. Place a shop towel over these parts whenever the system is serviced. NOTE • When removing the brake hose bolt, cover the end of the BOLTS hose to prevent contamination.Secure the hose to prevent fluid from leaking out.
  • Page 199 XL2 0 0 HYDRAULIC BRAKE MASTER CYLINDER INSPECTION Check the primary and secondary cups for wear, deterioration or damage. Check the master cylinder and piston for scoring or other damage. Measure the master cylinder I.D. SERVICE LIMIT: 12.755 mm (0.5022 in) Measure the master piston O.D.
  • Page 200 HYDRAULIC BRAKE XL2 0 0 MASTER CYLINDER PUNCH MARK BOLTS INSTALLATION Place the master cylinder on the handlebar and install the holder and two mounting bolts with holder’s “UP” mark facing up. Align the end of the holder with the punch mark on the handlebar, then tighten the upper bolt first, then the lower bolt.
  • Page 201 XL2 0 0 HYDRAULIC BRAKE PISTON SEAL Push the dust and piston seals in an lift them out. Clean the seal groove with clean brake fluid. • Be careful not to damage the piston sliding surface. DUST SEAL CALIPER INSPECTION Check the caliper pistons for scoring or other damage.
  • Page 202 HYDRAULIC BRAKE XL2 0 0 Install the pad spring on the caliper. PAD SPRING CALIPER BOLTS INSTALLATION Apply a locking agent to the caliper mounting bolt threads. Install the caliper and bracket assembly on the fork leg and tighten the bracket bolts to the specified torque. TORQUE: 31 N.m (3.1 kg.m, 22 ft-lb) Connect the brake hose eyelet joint with two new sealing washers, then tighten the oil bolt to the specified torque.
  • Page 203 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 204 FAIRING/ EXHAUST SYSTEM XL2 0 0 SERVICE INFORMATION 14-1 SEAT/SIDE COVER 14-3 TROUBLESHOOTING 14-1 REAR FENDER 14-4 FRONT FAIRING 14-2 EXHAUST SYSTEM 14-4 SKID PLATE 14-2 SERVICE INFORMATION GENERAL • Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. •...
  • Page 205 FAIRING/EXHAUST SYSTEM XL2 0 0 BOLT FRONT FAIRING Remove the bolts and front fairing. FAIRING SOCKET Disconnect the headlight socket. Installation is in the reverse order of removal. NOTE • At installation, align the bosses on the front fairing with the hole in the steering stem.
  • Page 206 XL2 0 0 FAIRING/EXHAUST SYSTEM SEAT SEAT Remove the seat mounting bolts and seat. BOLT INSTALLATION Installation is in the reverse order of removal. NOTE • At side cover installation, install the side cover boss with the frame grommet. • At seat installation, align the hook of the seat with the fuel tank mounting bracket.
  • Page 207 FAIRING/EXHAUST SYSTEM XL2 0 0 REAR FENDER Remove the seat and side covers. Disconnect the tail/brake light and turn signal connectors. Remove the bolts, collars and turn signal units. Remove the mounting screws. Pull the rear fender backward, then remove. Install is in the reverse order of removal.
  • Page 208 XL2 0 0 FAIRING/EXHAUST SYSTEM MUFFLER ASSEMBLY/INSTALLATION Assembly and installation is in the reverse order of removal. NOTE • At assembly, replace the protector washers with new ones. • At installation, replace the exhaust pipe gasket with a new one. TORQUE: Muffler mounting bolt: Front:...
  • Page 209 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 210 BATTERY/CHARGING SYSTEM XL2 0 0 SERVICE INFORMATION 15-1 CHARGING SYSTEM INSPECTION 15-5 TROUBLESHOOTING 15-2 REGULATOR/RECTIFIER 15-6 BATTERY 15-3 ALTERNATOR 15-7 SERVICE INFORMATION GENERAL • The battery gives off explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation when charging or using the battery in an enclosed space.
  • Page 211 XL2 0 0 BATTERY/CHARGING SYSTEM Y… YELLOW P… PINK G… GREEN R… RED B… BLACK (2) REGULATOR/RECTIFIER P G B R (4) MAIN FUSE 15A (1) IGNITION SWITCH (5) ALTERNATOR (3) BATTERY 1 5 -0...
  • Page 212 BATTERY/CHARGING SYSTEM XL2 0 0 TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. Remove the battery (page 15-6). Check the battery condition using the recommended battery tester. Incorrect • Faulty battery RECOMMENDED BATTERY TESTER: BM-210-AH ar BM-210 BATTERY MATE or equivalent Correct 2.
  • Page 213 XL2 0 0 BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the left side cover. Disconnect the negative cable first from the battery, then disconnect the positive cable. Remove the battery holder band and remove the battery. Installation is in the reverse order of removal. NOTE •...
  • Page 214 BATTERY/CHARGING SYSTEM XL2 0 0 Measure the specific gravity of each cell with hidrometer. Fully charged: 1.27-1.29 Need charging: Below 1.23 NOTE • If the difference in specific gravity between cells exceeds 0.01, re-charge the battery. If the difference in specific gravity is excessive, replace the battery.
  • Page 215 XL2 0 0 BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION (1) NEGATIVE TERMINAL LEAKAGE TEST Turn the ignition switch off, and disconnect the ground (-) cable from the battery. Connect the ammeter (+) probe to the ground cable and the ammeter (-) probe to the battery (-) terminal. (3) NEGATIVE With the ignition switch off, check for current leakage.
  • Page 216 BATTERY/CHARGING SYSTEM XL2 0 0 REGULATOR/RECTIFIER REGULATOR/RECTIFIER SYSTEM INSPECTION Remove the fuel tank. Disconnect the regulator/rectifier 4P connector. Check the connector for loose or corroded terminals. Measure the following between the connector terminals of the wire harness side. Item Terminals Standard Battery charging Red (+)
  • Page 217 XL2 0 0 BATTERY/CHARGING SYSTEM CONNECTOR REGULATOR/RECTIFIER REMOVAL Remove the fuel tank. Disconnect the regulator/rectifier connector. Remove the bolt and regulator/rectifier unit. Installation is in the reverse order of removal. CONNECTOR ALTERNATOR Remove the left side cover. Disconnect the alternator 6P connector. Measure the resistance between the pink and yellow wire terminals.
  • Page 218 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 219 16. IGNITION SYSTEM XL2 0 0 SERVICE INFORMATION 16-1 PULSE GENERATOR 16-4 TROUBLESHOOTING 16-2 EXCITER COIL 16-5 CDI SYSTEM INSPECTION 16-3 IGNITION TIMING 16-6 IGNITION COIL 16-3 SERVICE INFORMATION GENERAL • If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
  • Page 220 XL2 0 0 IGNITION SYSTEM B…BLACK R…RED L…BLUE Y…YELLOW W…WHITE G…GREEN (5) CDI UNIT (2) ENGINE STOP SWITCH (1) IGNITION SWITCH (3) IGNITION COIL (9) PULSE GENERA- (8) ALTERNATOR (10) SPARK PLUG 1 6 -0...
  • Page 221 IGNITION SYSTEM XL2 0 0 TROUBLESHOOTING • Inspect the followings before diagnosing the system. – Faulty spark plug. – Loose spark plug cap or spark plug wire connections. – Water got into the spark plug cap (Leaking the ignition coil secondary voltage). •...
  • Page 222 XL2 0 0 IGNITION SYSTEM CONNECTOR CDI UNIT SYSTEM INSPECTION If the problem is weak or no spark, inspect as follows: NOTE • Check the system components and lines step-by step according to the troubleshooting on page 16-2 • This method does not include an inspection of the ignition timing advance system at the CDI unit.
  • Page 223 IGNITION SYSTEM XL2 0 0 PLUG WIRE If the resistance is (open wire), disconnect the spark plug cap and measure the secondary coil resistance as shown. Standard: 10.8 - 16.2 kΩ (20°C/68°F) IGNITION COIL BOLT REMOVAL/INSTALLATION Disconnect the spark plug cap. Disconnect the ignition coil connector.
  • Page 224 XL2 0 0 IGNITION SYSTEM CONNECTOR If the measurement is out of specification, disconnect the pulse generator connector and measure the resistance between the Blue/Yellow and Ground. Standard: 293 - 358 Ω (20°C/68°F) If the resistance still out of specification, replace the stator. EXCITOR COIL INSPECTION NOTE...
  • Page 225 IGNITION SYSTEM XL2 0 0 IGNITION TIMING Warm up the engine. Stop the engine and connect a timing light to the spark plug wire. NOTE • Read the instructions for timing light for operation. Remove the timing hole cap. • If the engine must be running to do some work, make sure the area is well-ventilated.
  • Page 226 XL2 0 0 IGNITION SYSTEM NOTES 1 6 -7...
  • Page 227 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 228 17. ELECTRIC STARTER XL2 0 0 SERVICE INFORMATION 17-1 STARTER RELAY SWITCH 17-7 TROUBLESHOOTING 17-1 DIODE 17-8 STARTER MOTOR 17-3 SERVICE INFORMATION GENERAL • Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.
  • Page 229 XL2 0 0 ELECTRIC STARTER R…RED B…BLACK LG…LIGHT GREEN G…GREEN Y…YELLOW (4) STARTER RELAY SWITCH/ MAIN FUSE 15 A (3) BATTERY (8) NEUTRAL INDICATOR (6) STARTER MOTOR LG/R (7) IGNITION SWITCH (9) DIODE (2) STARTER SWITCH NEUTRAL SWITCH (8) CLUTCH SWITCH 1 7 -0...
  • Page 230 ELECTRIC STARTER XL2 0 0 NOTE • The starter motor should turn when the transmission is in neutral or the clutch is disengaged. • Check the following before troubleshooting the system. – Burned fuse – Loose battery and starter motor cables –...
  • Page 231 XL2 0 0 ELECTRIC STARTER CABLE STARTER MOTOR REMOVAL • With ignition switch OFF, remove the negative cable at the battery before servicing the starter motor. Remove the exhaust pipe. Remove the starter cable nut and starter motor cable. Remove the bolts, ground cable and starter motor. GROUND CABLE BOLTS REAR COVER...
  • Page 232 ELECTRIC STARTER XL2 0 0 ARMATURE INSPECTION Inspect the commutator bars for discolorations. Bars discolored in pairs indicate grounded armature coil, in which case the starter motor must be replaced. CONTINUITY NO CONTINUITY Check for continuity between individual commutator bars and the armature shaft;...
  • Page 233 XL2 0 0 ELECTRIC STARTER BUSHING Check the rear cover bushing for wear or damage. DUST SEAL Check the dust seal and bushing of the front cover for wear or damage. BUSHING Assembly (2) SET PLATE (1) BOLT (3) O-RING (4) CASE (5) LOCK WASHER (6) ARMATURE...
  • Page 234 ELECTRIC STARTER XL2 0 0 REAR COVER O-RING SET PLATE Install the brushes in the brush holder as shown. Install the following: – O-ring – Set plate – Brush holder – Rear cover NOTE • When install the brush holder assembly on the rear cover, align the tab of the holder with the groove of the rear cover.
  • Page 235 XL2 0 0 ELECTRIC STARTER INDEX MARK O-RING BOLT Align the index marks of the front cover and motor case. Install the O-rings, set plates and bolts. Tighten the bolts securely. Apply oil to the O-ring and install it on the starter motor. O-RING SET PLATE CABLE...
  • Page 236 ELECTRIC STARTER XL2 0 0 Continuity (1) CONNECTOR Disconnect the starter relay switch 4P connector. Check the continuity between the Green/Red terminal of the starter relay switch 4P connector and body ground. There should be continuity when the transmission is in neutral or when the clutch lever is pulled.
  • Page 237 XL2 0 0 ELECTRIC STARTER NOTES 1 7 -9...
  • Page 238 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 239 LIGHTS/METERS/ SWITCHES XL2 0 0 SERVICE INFORMATION 18-1 IGNITION SWITCH 18-6 TROUBLESHOOTING 18-1 HANDLEBAR SWITCH 18-6 HEADLIGHT 18-2 BRAKE LIGHT SWITCH 18-7 TAIL/BRAKE LIGHT 18-3 CLUTCH SWITCH 18-8 TURN SIGNAL LIGHT 18-3 HORN 18-8 COMBINATION METER 18-4 SERVICE INFORMATION GENERAL •...
  • Page 240 XL2 0 0 LIGHTS/METERS/SWITCHES 1 8 -0...
  • Page 241 LIGHTS/METERS/SWITCHES XL2 0 0 BOLT HEADLIGHT BULB REPLACEMENT Remove the bolts and front fairing. FAIRING SOCKET Remove the headlight socket. RETAINER Remove the dust seal and unhook the retainer. BULB Remove the bulb and replace with a new one. Installation is in the reverse order of removal. 1 8 -2...
  • Page 242 XL2 0 0 LIGHTS/METERS/SWITCHES SCREWS UNIT REPLACEMENT Remove the headlight beam adjusting screw. Remove the bracket screw, then remove the headlight unit. Installation is in the reverse order of removal. TAIL/BRAKE LIGHT BULB REPLACEMENT Remove the screws and tail/brake light lens. Push the brake light bulb in, turn it counterclockwise and remove Pull out the tail light bulb and remove it.
  • Page 243 LIGHTS/METERS/SWITCHES XL2 0 0 BULB Push the bulb in, turn it counterclockwise and remove it. Install the bulb in the reverse order of removal. TURN SIGNAL RELAY INSPECTION If the turn signals do not work properly, check for the following items: –...
  • Page 244 XL2 0 0 LIGHTS/METERS/SWITCHES REMOVAL Remove the combination meter 6P connector. Remove the combination meter bulb sockets from the combination meter, then remove the sub-harness. Disconnect the speedometer and tachometer cable. Remove the cap nuts, washers and combination meter assembly. BULB SOCKET DISASSEMBLY Remove the screws, wire clamp and combination meter upper...
  • Page 245 LIGHTS/METERS/SWITCHES XL2 0 0 IGNITION SWITCH INSPECTION Remove the front fairing. Disconnect the ignition switch wire connector. Check for continuity between each terminal. There should be continuity between the circuit marked “O-O” in the tables below. COLOR REMOVAL Disconnect the ignition switch wire connector. Remove the mounting bolts and ignition switch.
  • Page 246 XL2 0 0 LIGHTS/METERS/SWITCHES LIGHTING SWITCH DIMMER SWITCH Check for continuity between each terminals. There should be continuity between the circuit marked “O-O” in the tables below. See section 12 for removal. Lighting, dimmer switch Lighting Dimmer • TURN SIGNAL SWITCH HORN SWITCH Color Color...
  • Page 247 LIGHTS/METERS/SWITCHES XL2 0 0 CONNECTOR CLUTCH SWITCH Remove the front fairing. Disconnect the brake light switch wire connectors. There should be continuity with the brake lever is squeezed. There should be no continuity with the brake lever is released. CLUTCH SWITCH HORN Disconnect the horn wire connectors and connect a fully charged 12V battery to the horn terminals.
  • Page 248 XL2 0 0 LIGHTS/METERS/SWITCHES NOTES 1 8 -9...
  • Page 249 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 250 19. WIRING DIAGRAM XL2 0 0 1 9 –1...
  • Page 251 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 252 20. TROUBLESHOOTING XL2 0 0 ENGINE DOES NOT START OR IS POOR PERFORMANCE AT LOW HARD TO START 20-1 AND IDLE SPEED 20-3 ENGINE LACKS POWER 20-2 POOR PERFORMANCE AT HIGH SPEED 20-4 POOR HANDLING 20-4 ENGINE DOES NOT START OR IS HARD TO START Possible cause 1.
  • Page 253 TROUBLESHOOTING XL2 0 0 ENGINE LACKS POWER Possible cause 1. Raise wheels off the ground WHEELS DO NOT SPIN FREELY • Brake dragging and spin by hand • Worn or damage wheel bearing WHEEL SPINS FREELY 2. Check tire pressure PRESSURE LOW •...
  • Page 254 XL2 0 0 TROUBLESHOOTING Possible cause • Excessive carbon build-up in 11. Check for engine overheating OVERHEATING combustion chamber • Use of poor quality fuel • Clutch slipping NOT OVERHEATING • Lean fuel mixture • Wrong type of fuel 12. Accelerate or run at high speed ENGINE KNOCKS •...
  • Page 255 TROUBLESHOOTING XL2 0 0 POOR PERFORMANCE AT HIGH SPEED POSSIBLE CAUSE • Faulty CDI unit 1. Check ignition timing INCORRECT • Faulty pulse generator CORRECT 2. Disconnect fuel tube at FUEL FLOW RESTRICTED • Clogged fuel line carburetor • Clogged fuel tank breather •...
  • Page 256 HYDRAULIC BRAKE based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the FAIRING/EXHAUST SYSTEM right to make changes at any time without notice and without incurring any oblication whatever.
  • Page 257 MOTO HONDA DA AMAZÔNIA LTDA.

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