Honda XL200 2001 Manuals

Manuals and User Guides for Honda XL200 2001. We have 1 Honda XL200 2001 manual available for free PDF download: Shop Manual

Honda XL200 2001 Shop Manual (258 pages)

Brand: Honda | Category: Motorcycle | Size: 7 MB

How to Use this Manual
2
Contents
2
Model Identification
4
General Information
5
Service Rules
5
Specifications
6
Torque Values
8
Tools
10
Cable and Harness Routing
14
Lubrication
21
Lubrication System Troubleshooting
23
Engine Oil Level Check
24
Engine Oil Change/Oil Filter Screen
24
Engine Oil Filter Rotor
25
Oil Pump Removal
26
Oil Pump Disassembly
26
Oil Pump Inspection
26
Oil Pump Assembly
27
Oil Pump Installation
28
Maintenance
31
Maintenance Schedule
33
Fuel Line
34
Fuel Strainer Screen
34
Throttle Operation
34
Carburetor Choke
35
Air Cleaner
35
Spark Plug
36
Valve Clearance
36
Carburetor Idle Speed
37
Drive Chain Inspection and Adjustment
38
Drive Chain Cleaning and Lubrication
38
Drive Chain Slider
39
Battery
39
Brake Fluid
40
Brake Pads/Shoes Wear
40
Brake System
40
Brake Light Switch
41
Brake Pedal Height
41
Brake Pedal Free Play
41
Headlight Aim
42
Clutch System
42
Side Stand
43
Suspension
43
Wheels/Tires
44
Steering Head Bearings
45
Cylinder Compression
45
Fuel System
47
Fuel System Troubleshooting
49
Carburetor Removal
50
Carburetor Disassembly
50
Carburetor Assembly
55
Float Level Inspection
56
Carburetor Installation
60
Pilot Screw Adjustment
61
Idle Drop Procedure
61
Air Cleaner Case Removal
62
Air Cleaner Case Installation
62
Fuel Tank Removal
63
Engine Removal/Installation
66
Engine Removal Procedure
68
Engine Installation
69
Cylinder Head/Valves
73
Cylinder Head/Valves Troubleshooting
75
Cylinder Head Cover/Camshaft Removal
76
Camshaft Inspection
77
Tensioner Lifter Inspection
78
Cylinder Head Cover Disassembly
78
Rocker Arm/Shaft Inspection
78
Cylinder Head Removal
79
Cylinder Head Disassembly
80
Cylinder Head Inspection
80
Valve Inspection
81
Valve Guide Inspection
81
Valve Guide Replacement
82
Valve Seat Inspection/Refacing
83
Valve Seat Grinding
84
Cylinder Head Assembly
86
Cylinder Head Installation
87
Camshaft/Cylinder Head Cover Installation
88
Cylinder/Piston
94
Cylinder Removal and Inspection
96
Piston Removal
97
Piston/Piston Ring Inspection
97
Piston Installation
99
Cylinder Installation
100
Clutch/Gearshift Linkage
103
Clutch/Gearshift Troubleshooting
105
Right Crankcase Cover Removal
106
Clutch Removal
106
Clutch Arm Disassembly/Assembly
106
Clutch Inspection
108
Clutch Installation
109
Gearshift Linkage Removal
112
Gearshift Linkage Installation
113
Right Crankcase Cover Installation
114
Alternator/Starter Clutch
118
Left Crankcase Cover Removal
120
Alternator/Pulse Generator Replacement
121
Reduction Gear Inspection
122
Flywheel Removal
123
Starter Clutch
123
Starter Idle Gear Inspection
123
Starter Clutch Inspection/Disassembly
124
Starter Clutch Assembly
125
Flywheel Installation
126
Left Crankcase Cover Installation
127
Crankshaft/Transmission
131
Crankshaft/Transmission Troubleshooting
133
Crankcase Separation
134
Transmission Disassembly
135
Transmission Inspection
135
Transmission Assembly
136
Transmission Installation
138
Transmission Bearing Replacement
139
Crankshaft Removal
140
Crankshaft Inspection
141
Crankshaft Installation
141
Crankcase Assembly
142
Front Wheel/Suspension/Steering
146
Front Wheel/Suspension/Steering Troubleshooting
148
Handlebar Removal
149
Handlebar Installation
150
Front Wheel Removal
153
Front Wheel Inspection
153
Front Wheel Bearing
154
Front Wheel Disassembly
154
Front Wheel Assembly
155
Front Wheel Installation
156
Fork Removal
157
Fork Disassembly
158
Fork Inspection
160
Fork Tube/Slider/Piston
160
Fork Tube Bushing
160
Fork Assembly
161
Fork Installation
163
Steering Stem Removal
164
Bearing Race Replacement
166
Bottom Cone Race Replacement
166
Rear Wheel/Suspension
171
Rear Wheel/Suspension Troubleshooting
173
Rear Wheel Removal
174
Rear Wheel Inspection
174
Rear Wheel Disassembly
175
Rear Wheel Installation
177
Rear Brake Removal
178
Rear Brake Inspection
178
Rear Brake Disassembly
178
Rear Brake Pedal Removal
181
Shock Absorber Removal
182
Shock Absorber Inspection
182
Shock Absorber Disposal
183
Shock Absorber Installation
183
Shock Linkage
184
Shock Arm
185
Swingarm Removal
186
Swingarm Disassembly
187
Swingarm Pivot Bearing Replacement
187
Swingarm Assembly
188
Swingarm Installation
188
Hydraulic Brake
192
Hydraulic Brake Troubleshooting
194
Brake Fluid Replacement/Air Bleeding
195
Brake Pad/Disc
196
Brake Pad Replacement
196
Front Master Cylinder Removal
198
Front Master Cylinder Disassembly
198
Front Master Cylinder Inspection
199
Front Master Cylinder Assembly
199
Brake Caliper Removal
200
Brake Caliper Disassembly
200
Front Master Cylinder Installation
200
Brake Caliper Assembly
201
Brake Caliper Installation
202
Fairing/Exhaust System
204
Front Fairing
205
Side Cover/Seat Removal
205
Side Cover/Seat Installation
206
Rear Fender
207
Exhaust System Removal/Disassembly
207
Exhaust System Assembly/Installation
208
Battery/Charging System
210
Battery/Charging System Troubleshooting
212
Battery Removal/Installation
213
Battery Inspection
213
Battery Charging
214
Charging System Inspection
215
Leakage Test
215
Regulated Voltage/Amperage Inspection
215
Regulator/Rectifier
216
Alternator
217
Ignition System
219
Ignition System Troubleshooting
221
CDI Unit System Inspection
222
Ignition Coil Inspection
222
Pulse Generator Inspection
223
Excitor Coil Inspection
224
Ignition Timing
225
Electric Starter Trobleshooting
228
Starter Motor Does Not Turn
230
Starter Motor Removal
231
Starter Motor Disassembly
231
Starter Motor Inspection
232
Starter Relay Switch Inspection
235
Diode Removal/Installation
236
Diode Inspection
236
Lights/Meters/Switches Troubleshooting
239
Headlight Bulb Replacement
241
Tail/Brake Light Bulb Replacement
242
Turn Signal Light Bulb Replacement
242
Combination Meter Bulb Replacement
243
Turn Signal Relay Inspection
243
Combination Meter Removal
244
Combination Disassembly
244
Combination Assembly
244
Ignition Switch Inspection
245
Handlebar Switch
245
Clutch Switch
247
Horn
247
Wiring Diagram
250
Troubleshooting
252
Engine Does Not Start or Is Hard to Start
252
Engine Lacks Power
253
Poor Performance at Low and Idle Speed
254
Poor Performance at High Speed
255
Poor Handling
255

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Honda XL200 2001 Manuals

Honda XL200 2001 Shop Manual (258 pages)

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