Right Crankcase Cover Removal; Clutch Removal; Clutch Arm Disassembly/Assembly - Honda XL200 2001 Shop Manual

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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.

CLUTCH ARM DISASSEMBLY/ASSEMBLY

Remove the cotter pin and remove the clutch lifter lever and
return spring.
Visually inspect the clutch arm for bending or damage.
Install the clutch arm on the right crankcase cover in the reverse
order of removal.
NOTE
• Install the return spring as shown.
CLUTCH
REMOVAL
Remove the oil pump (page 2-5).
Remove the screws and oil filter rotor cover.
Hold the primary drive and driven gear with a gear holder,
remove the lock nut using special tools.
Remove the lock washer and oil filter rotor.
TOOLS:
Gear holder
Lock nut wrench, 20x24 mm
Extension bar
CLUTCH/GEARSHIFT LINKAGE
RIGHT CRANKCASE COVER
SPRING COTTER PIN
LIFTER ARM
SCREWS
COVER
PRIMARY DRIVE
GEAR HOLDER
BOLT
OIL PUMP
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