HONDA XL/XR/TLR125-200 * 1979-1987MER PUBLICATIONS ‘Business Magazines & Media Msctve Ofer Tity M. Anions ries fon Wall Rich Hathaway MAFIKETINGISALES AND ADMINISTRATION ber Ran Seriew eee Sale Monger Marne Desh seder Se Mamertooross oso ener ‘Cooaey Hale ‘ease Irn Manager ACUAWIK DIRECTORIES Tecoma Seca yon Jaq SHoP SERVICE MANUALS INTERTEC SERVI EC SERVICE MANUALS Sata pment CONTENTS ‘QUICK REFERENCE DATA... ‘CHAPTER ONE GENERAL INFORMATION ‘aml opaizion ‘Stop se ae Enogeeg tli ee “roubehontng a neg equips (CHAPTER TWO ‘TROUBLESHOOTING a ‘Stating dies Elsi! pte Poor perfomance Gouna sen (Cute and ransisson Chae Dive win Fass Bake (CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP sie msiteance Routine chek Presiecs Engae tne “irs and wheels Stones ‘Grantee beater Bose Gel tinny (US medels of) utente) Pere action CHAPTER FOUR ENGINE aa Engine princes ol EEE enete in fame Pon, ison pian pision rings Teston advance and pls generator ‘Glin ead cover and cama ‘Cha chain Sinatra Se ate components one x gial sine (L125 sd XLS ice 1982) Fal ant len ea (neal tanks oly) Pos er Crunrsetcather syste (US. models ons) Edo yer 8125 a4 XLS) 1975869) ‘Sing am (at shock mot) ‘Swingarm (reLisk roel) ‘CHAPTER TEN BRAKES root end er bake ee Rear rake ele (2008) te poll asemy CHAPTER ELEVEN FRAME AND REPAINTING . ican sdenand) Foote: WIRING DIAGRAMS .sons (cone Mae ens) 124s ga 72 bem tS np on) maser E1U5 plaster, tno) fat asone cua paige oatmeal 0985 9 09 er 082 me) Sus ot Gti talme os) Bicciniece Bae thig ocrCLYMER: HONDA XL/XR/TLR125-200 * 1979-1987CLYMER: HONDA XL/XR/TLR125-200 * 1979-1987INTRODUCTION This dae, compressive manual covers a 1979-1987 Honda XUXR/TLR 135-200 sage The cepen ext” ges complete infrsaton on ‘Mailenance, rerair and ovetiaul Hunde of ‘hotos and drawings guide You trout every stp, ‘he book incudes al you need to know tee ue Honda rnning pt Were pain are prt Gr the ownermechants, comple prosdares ae sven, Ecualy import, dif jobs ae poiied out Such ‘operations are arally mote economically performed bya dealer or independent erage "A shop manuals reernce. You want to Be able son eatin fA al Che ok ne is design with this in ind All chapters ae ‘hum tbed, Important items are inde at te ‘ear of the book aly al he mos equal wed {postion and apace ae summarized on tie the font of the BonkCHAPTER ONE GENERAL INFORMATION ‘The voublshootng, mlsesace, ‘nen, i stepped i hs Book en spl othe er a ome ‘ean The tex fe seompate fy Help ‘hots snd diagrams to make the job a ea ndcorret spss. ‘Troublshootng. aie, tne-up, and repalr ate nt Gc es wht odo of average eliza, with soe mania Sigs and not aad pt thee Hanke dy an perform tf the proedures tt teow Tome ase, a eat ab may egies or Silat resonaly eipete f the home ter an its fecommended that ou take the Jo wo your dealer, a competet mest, cram sew MANUAL ORGANIZATION “This chapter poses seea infomation, safe and ance nA nclied re i Dt recommenced shop and emegty tls a wea a bref description of troubishooting 2ndruneup equipment w"Chaper Tmo pees methods snd sags: sions for ick snd accuse sabres ard Bes repuie_of problems. Tiosblshooing. pro: Sele ican ial Sans nd pea ‘Chapter Tre eran al pei ice on a vutne matennc ec oes dear notre ning wel Gs Tee theneal toca ‘ottetapers ontbevsriou stuomblee ‘Sabseqen caper corer stele ems sucha he rune, tansmision and daca Sysem Esch of tive chpten provides lem, inspection, repay and assay owedres ina sissies oat a ‘pur pract forthe home meant Ince hese case i sal ste a 1s expense to tae the reais mae by 8 esr or compete tear shop. Ese ‘pesfitions are aca a he ppropat= antes ‘When speci tools are equred wo pat ‘ected inte ama ele tea ay be pos thectons Ne menivemstane sbe'oindasluble ortofelviewease,aed fo enphasve aes wre Sebago eal if Pope arrarinka A vaannclatt to Thor seu shay pool 8) oF as cul re psec a san {opositlenesanen dsc, sevice HINES ane. tor, a4 rst Wil be ved eee ete aleeoscet yo Sheet alongs. ‘Mon of theses proeirescoved te sunisfoté and can be promes y {Sted Sone fn 900 sons our oo Shiite werpng Say pein inlig mr essenby of he oie Sens opin, fr cample, rie te tye of es sd be wero ane hee eflomed ty a shop equped foe sch vor fiesta oy co doe a gous Bee eset etree ice Reon meanrenst Utes you hn he | Sisan xupaet ers nut bebe “eet nid son mae Oe rele pas rl fe wore en sre san Mls yo sin se is cea stesso ‘Seay Bisrauon ae ex on ues Bopsasticstys Wer tos re reid Sie eae ay cei for forming ehh compte Ding ditenbiy of pars hcp a fon Siened 10 sepurste them, Nowe se {enene wheteeething car tom ~ bt For as or even weeks In wih ine ‘Sify tld ou pare may ve become Taz all iar ial rt or teton, aed al maing prs 0 poston Record ‘ember a hes of ay sine hy ae Sed ypc in pst ch gs Wing soul be ged with masking tape animated ascarh wits one Asi ere oo menor soe SGconectng ws: Neer run the cnie ith Ihe Bey icone he strstr cold esciut damaees, Frist ised sracs fron pyc ante orcomesion. Kp sone ad ake Maottpaedsutices, ie GENERAL INFORMATION eeennoniney ote of vey ih bs and stews ean often te red ty tatng wan pea ‘line Liu Wren or WD.) ieee Fores pas cee Fone ‘roid bat ule sna ey ey ‘Avoid Mame cap whe worn ea cing ey ofa sh fi rogue naa force rag ese (Coe all orgs ater remoing pars o pt mot yom. sais id det cn nn ‘ion of eld ons. Genera, ou thal aa fhe pus may teeny dsasembe I the Iaure: hi coat fon ses pete alee, Inplace they tl fallow during sembly. ‘Wal cic and rake component sandpaper, but emery cloth end ol doa mh Carburetors ae best_cleaned by ass senblng them nd scaly te prs aa om ‘eet cn ot ots anda panes te re ‘sy damage. Usecompeesel iso lon ot the carburetor bot ey i the lat ha een removed “Take our tine and dhe job ih Donat fovges that a nety rebut egies Be ‘oka ine same eon Ret asout ‘e's med! or he pope renin ee Frofesoeal mcr an work fr years aed nee sin atin aye Io ‘het fon tke of enmon se td Sep goog eas a wie 1. Neer we pole aba cane ste 2. Neve mole ore torhin evel of animate has sock cenne vet ‘utes are Bone turd, Higy plone idoren ta formed Sue te SE 5. hen losnag gh or sack mt be ‘sed by shat meal open ke wrench 9. Keep feestingalser handy andesite it & fated for gue (Css) ade (Gas fee Conan expense spies are nesay ‘Testindepree olbl cement nae No, spec fooknt compounds leone Ihsan ap rene and carartr cleaners ty be uit Clans he avaible st ‘hte avataheat sperma swoP T0015) For comlee svg ab eal You wi el a aornent of eda bab ols gee,fed below sad shown fa Figur wil le ou tandemes rosie reas 4, Mosorjl00 A (orga eauimen) Impact ariver Ser waterproof sealing tape (Gut ars) 4. Hovectmp ste) fashion A Thepachsic J, Passat bore (for ci) A. Waters nd clesner 1, Raps frezan up A few simple toss ais cared on the ‘molars can mea the difference beeen walking © riding back to carp orto wbere ‘eparcanbemade See igure. A few esi spare pars carried in your Ach or van can preset dy or weekend of riding rom beng poled. See Figures. b Drive chain master Spark lus Spat lag wren (Chsch/brake ever Sine watergoot seaig tape (dct) Inthe Track Cont eabes hot, ich, bake) Tiepatch kit Tuepump on Tot rd art het be od Ibemorroce sot nding hee ef eo re sera error oat TROUBLESHOOTING AND "TUNEL ¥QUIPMENT Votimetr, Obmmcte. ad Ammer seod voter required For meters, 5 insrumen’ covering 020 sls sats tary. One ois avo har 02 oh le ces) for testing reas pm In ‘Sida wontass whee voltage ops re much "an chance meant eral estan “Thi instrament well Tor cheng con iy toner and sor iis) and tne festa “ine ammeter rears eecical cre Ammer for more we shoal over 30 pees and 0250 sper. These ae eal forchecting tater) chap afd Stang t= ‘Shera inexpensive ons (volkahnniie ‘anmei) combne al thee Snare to ne hich is ely i 4 00 Boe. See Fi tres Homer the mete ranges areusaly ‘oo smal fr notoroyee work Hssromeve ‘The bydrometer goes ‘nity contin al chargIt esol in cach el. general cline, ngand valve condition See eulsemsandinic Ngee. Extension lnc sc saa fo acd toreacheyinder Dre Meter Contact Beater Point gion Oni) JA dell mcr measures the divance in eres of cam eatin sat the break pins win led whi the enencisruning Since inuraments ek accurscy at owe spt The ‘hang of 25 pn how rae Strobe Timing Light scons very acura ign ting. The Mathes a peel the same nat at ‘mir es, at which time the ting tas (on the enn shuld aia. Rete 4 Char “ive fo exact lotion ofthe timing ah oreee oe he om inexpensive ne bo eed 2 ee Srncnie CHAPTER Two a a a eect Sep nay Coca erenser tee, Srigieisnaai terse = — TROUBLESHOOTING i ‘elt es kere ere Zion pscive sted oul A suite manos css oat Sowevr. mist b cable us fat b apse for a eens wih deed necton for i lure to wan. To engine ore Seg combuaton chante, ton, 88d eExtinglier _ fc ening rexeity ws nrg tre ening oreo ay ene eile shoul he eo tot Cas Sart so tat you can make problnn, Hs imports (0 uadestand 35 epoca pastc ast fannie protabccne Ne et ee enter cee mee {Bi cauc an anemprto vey i ios ine SP 2 fads sears fe bape cos ae ‘emt cn hao ne ar | OUST pve as ‘Staredefce nl bee ime chee Tie woainioatag masts. bch rt teri stapes ‘aes pl septom snd the inca veins frag aod Coreg Monte" ae no, howe, the oa staeniNe oirnicuLttes Peods;thoeny ses span to Haring ay he ot canon Even problem, bi at pnd ocbhoctig moter seat hn id up a oe chess bre om tig, common "toms Ney Blow cing a seco ioe nena prac onstarer, fin ermine wha bs shedCHAPTER TWORASTRREeO - ‘TROUBLESHOOTINGBese tiTROUBLESHOOTING "DLE/LoW-sPeeD MioRANGE Wich sPeEDhr 10, Check ne cont ates fe MEI nd gacing, Transmission oll 3856 ao at ease pnge in wet cats 1120 Ger anderen a,c tee Bon of he sens or aphagm sd al Sethe ch ots are snug and ur teens FP Qulch dras—Make sure lve fee Bt “HE fo ret that ic fails to sere {ile Chk cor warped pistes ore upian Gave hich owen) a ity ory may ni he i sing. ‘ fom shifts hard Ese i ransmision 10 shift Check the Sletot sae or bending Fie sre 19), Inspeat the shite and ears for 4. Transmission stout of geer—Thiscan used by wor engagement dogs oa mor o ‘hmaesl sie gare 0), The even teaelon he seltormay bemiad ste, 5. Transmion i niey—Nojses weal i Sate the absence of ubration or meat ad ‘amaze to sears, eating or shims ‘en 10 disasemble The tannsion and ‘areuly inspection nee st ca DRIVE TRAIN Drive wan problems outing in Figure 2) aie fom noamal” wear and Ieoret ‘CHASSIS Cassis problems ae outinedin Figure 23, 1. Motoreel pulls 10 one side—Chesk {orsuspension AND HANDLNG susreso ano vanounc commucD =‘ao FANDLNG CONTINUED cus SEE [TROUBLESHOOTINGsyst ef rn Raat nt ee Sa eer scck sts Dt eager Pao Sorat rarest a nears bee eid =) ae ‘head adjus TS cole, Aso hc te ne Seen ee oe ASIC IGNITION CIRCUS @ conrncrsnennen srs = e Sei eae eres ox rote aps then ar worn key er eh ie eh) ae had ohm ep hh nape Incas bake en ow ai oe, ance aba elite ascan tm Wate ong post fre Ao et ere en ne 2% Bakes tick or gis ma be cn fact afte: Chk ato fr force ceeding toy od Sy ntedbe. HurctRcAL systeat any eal pen ptens cnt sacs enti eee oan Bom tan Sania Ines set sores, « meee wa. ss of wa ante o i ier atamin device as nl a a val seers ise a Spent ae puss oa theaonon hein go = wins Wiig poles shoud Fiteynie— tte ss that may sey a motor TA ee eer of one ype Ini hora on Ua Sion degra a he oud ots lets I wie mat be tg foition on he wing dass Incorcoing a cna oa ee ees vampire ant coals cin (CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP subjected to renendous bet, sexe a ‘bration. When aelsed any ke Beomes vclabe and actualy angcous to Se To cen te bike proper mins, ook ito {he tuneup tool and pas and check ot he een atrcanis metro foro king ‘ompounds and seas Fgae Also cat fagine degiesier, Ike Gunk or Bel Ray Degreaser, for clang your engi prior 19 sorting “The more you get involved in your Honda ‘hemor jou wil at o work ont Sart out by doing simple tne-up. lbsction and ‘mintenanee: TaeBe the mors inti obsas ou tecome more sequined with he be “The Honda singles covered in this ook sre some of the most reliable bikes alle Bat 'ogin the umost in safe perform nd ‘cle rom thm, neces to make Detodic inspections ane’ adjustments I ffequntyRappens tat minor problems ave found daring sch inspections hat are simple and inapensive 1 comes fhe tine Bt which cul! Ted to se robe i ot This chapter explains lubrication, snantesne and tuneup postu Tale 5 seed factory maintenance hdle (ables 18 re loci at ihe end of ke ‘hae. ROUTINE CHECKS ‘The following simple checks should be Petformed at cach sop ats sevice tation sor on serie models whensterth el fant ered Engine Oi Leet Refer to Checking Engine Ol Lee! une Perot Labecation i ts chaiee General Tspction 1, Quick inspect the engineer sets ofoi or fut eage 2 Check the tires for embeiat sones Pry {hem outwith yoursiton he. 3 Make sure alles woke ee- 2) ee a it eo Es cuunrrey LUBRICATION, 1 Check ose tat both he Height a (oa feet 2 Makesare that he eng il wich mots During tester thr the heals, {alight ocean il sich fled to operate ‘rope refer te Chanter Seven PRE-CHBECKS ‘The following check soul be pxormed pero the fst de of ted. inspect el ines and tings formes. 2 Make sure the fuel tail fh 5 Make ure th ens ests comet 3. Check thcoperation ofthectteh and agus, {hee poy inte cable neces S Check the trond the trae lve Make sure ihe opto propery wih Bo Make sue me engine kil wich works Prone Pe Check the whe! spokes and rim aks fr Tse abuse rece inspect he conten of the romt ad ear Suspemion make sre thts ge sd 32 Check th onion of he dive cain for 10. Check tie presire, Refer to Tale 2, 1 Chk the ent te fo damage. 12. Check the tighinss of al tener, ‘Spey engine mounting haat SERVICE INTERVALS. are recommended by the Tatory Sect fnsute lone sevice from your Honda, However ifthe ke x run an ao ih humid he beuonserzcrmste done more feqaey 1a prevent possible rest Simage For convenience When miaining your mmoctcjels, most ofthe series shown “Tale are dette intistape- However Some procedures whic requre mare than ior disassembly or sjstnent are covered ‘ewhere nthe approprite chapter, MAINTENANCE AND TUNEUP a ‘TIRES AND WHEELS Tire Presete Tire pressure should be shocked snd aise io maintain the smootness of te ‘rood tation and hein en oe he ‘minimum Iie eat of the fe Asie, ‘Sate gnupe Fare) can pics ot 3 few ells and shoud be aod yur ‘motorjete taal a "The appropriate ‘rssureare shown ia Table? “Thetis ake alot ofpunshment so ingest them period for eases mete ay stvaons se fu fads alo ther objet inthe tir mark iskeaton witha ahora flor removing Thi wl Belp sae th alee repair Refer to Chapter Eh fo ie huni reps notin ‘Chek fel ali lions concerning ‘minim ead dep Messe the te pat hecoteroftheti ea nga ad ‘deh este (Pure 4) sal ter Hoa ‘scommends replacement wh he ont fr rear ead depth 8m (1/8 a) oe epins thereat ths pi ‘eet Spe Tension “Tap cach spoke witha wrench The bpner the pick of sound makes the HONE ‘oles The loner he sound feasency fe looser the spoke. Apne is ond aun” one ormorespokes as loos hte emt as desert unr Ihr in hater Eh i spect Frequently inspect the condition of the ‘ee in asin as ben eget mig Inve ben noah oknosk ow ofabinea Inpcoper tt agent cor esas sever Vibration sad result im an unset (CRANKCASE BREATHER HOSE (US. MODELS ONIX) Inspec te condition of he rete oses {ogee ad deterioration esa ‘Meese ampere at (ite 3)ey a deo jeatbenfeg ames Tho 9 After the battery has been fll ‘esharged of repaced. inal 255) ‘ese removal ene, Ye reser te nas moved tery eva be seo rate | ‘retro hata rene sail ramon pa 8, fare Then cher th tery ad dara Teng Frome engi eb eter condition. Use a eo MAINTENANCE AND TUNUP a ‘MIBRICATION ManvreNANCRANDTUNEUR gg sunbed duo: fom 1006 1.309 raher thn oe ih clone ee To et hy. fiom ghee the rater talkin cp ical ed eleme te peso tll Don sree eter aia fers eal Seen hen ball sn tunel wk cl fom whe eae Thespeii gv of eisai inch a tex calls anexcent neon of tcc noe ‘Sn. A fal red ell wil ad 1210, le 3 sellin ‘pod cnditn aes oot mois ncepiy Fusipea See Dain te caring pro, ihy ‘pete e tal yk heeft boning ses Ingipark conics olen Iie ere comeing i tates ‘harper Neer hag bat thei frame tee he cone ‘nt tha md rhage Ingen sm ees on IEA ram Hl core te fice |, nme pose (1) cher ed ate pos the (baer ead sad he mepte () eugee Jeo he ep) Brey ea, 2, Remove all et caps fom He atest he er w 6 vas or ree va depending ot nodes econo heey ne ee Seon 2. Aer the by hs ben cas abou § sows aro comme head ‘hea he ese pvt les in be le fr teatro cag 4:Chan iba c anbatry epermct Inthe ile mean ran he oy me et dao ny prof te ie front Thebes When spain the ob ery ithanwore be ze fo cge h compel) etic gay 12001280) belee linge ke Fale ‘dos, oeing the beni alow eee eve willpemancty amass thn ae FERIODIC LUBRICATION Retro Figure7 fr mar bison pins. lls ssid acetng nay wish is aninscaion af bow dicka 8 The Seay of Avie Engineers (SAE) em haces il rosy by numbers elle wey Tk (hcvy ok ve higher vissty seme hr ‘tintin ois Ferennplea Sei GAE Ja 5 slighol wiles 90 weet (SAE ogre fed hea, The veo afte cla ethno dois is abs popes, -LUBRICATION, MAINTENANCE AND TUNE-UP. » Cloning Soret Atanterofuiven cine li ngre aa ress ced ality rene onfebiy waterproshold be wid Pgote 9, Iabresting salves beserhan lon od Srenvous es, Some components eget tse oa ium based melybenum ds S ommended pe tev Insll the dipoles ap and Chaogog ngne Oi and Siege the Honda ory andsoukibe_ Chaning nin Oi and Ta 3 pinch, tough, te wrong Iabran is _Reglarcilchangs wll coatute more to ter han none ata Correct ie staton a2 engine longevity th soon as posite Operation’ pevformed. The ttory-=e = se % ae Cal “Siete eat ae nei enamel sen eth sesso The Delete ord ree. yw dese SEL ani br repaint ocd ‘eames ole oP tek cam Do tad ey fio ig ‘les eo a ey ll eh lage to res ape ol an patie aud Treacle si ed ‘esl 2 Dap end © Gaceitrpe Amnvicempetia se vans er ert 9 aa eto (0 cy (checerre cnt, co a sore Fever ie pot oe foal provide crde neh ‘ther fs with motor oto ee the dmercan Petron he | | © ey here ae umber of ys, sila, Te easiest wy in Asin io = allen plan fete Tien the opted pace. held 4 | Ee | LUBRICATION, MAINTENANCE AND TUNEUP a 1, Place the bite onthe siden, 2 Sah nie ad et ech oering Sut the eagine ff and lace dn ge Utger ths eine dein pl. 4. Remove the 24 mm den pug (Figure 14, Remove the springandi eran Fig 15, Remove the dpe icp (gre 16) this wll seed up thew ao 5. Le i a for at east 15.20 mina Daring tise tn the eine over coupe of mes wih the etstarer to dan any 6 Clea ec iter ere pringand peg in Solvent and thoroughly ay with compressed Sie Inspectbe condition ofthe rset, Figure 17) for hous or defects replace a0 nesesary.Thorouphl clea out he ain plug in ihe canine with shop tig td ingpct the consvon of the O-ing sal (0, Figure 17) te daa plug Replace ifshe fer sre SPE 4 agate Sa oii Sanne 1 ung i cet PS roe, 2) sc. he na arves Remove ibe teal ne ie em ibn era lic oct A — decomprenor lever os he aah = = poninay Tecpaycopaimato0 ia thing ese od fies wen Cigar aromatic sad rou US ‘Remove he srens (Figure 24 scaring ee ea eaten in Chante ier mean sean pe oa ew I Sone ee Jon st ode Spetand ch rks TE am he ee ch cet ee ast. al te wel (ie 25) ee ay Pe... Sn eae ee ata envi sata ba : te Sgt i at “These itera esume th evel 6 madi cacy I pet ce ald sc erase ised mr ea tas revemene Sreme alterna Seer iene osLUBRICATION, MAINTENANCE AND TUNE-UP_ 12 On model with aia forks, ste @® fea o0 allccept XLOOGR and TLSOIR to 435.2 pi 03.05 yen) On XLID0R and ‘Tia, ina forks w 56 ph (O04 {cm Do rte compres oni $l andoperted i panp sachs tbe 3 * CW Mtinpamp (Fig 37) of euvalen- es : Never ase any pe of competed gx se cen oft pt ot Tha Net rea te "ar cael naar ea: pce fie nea en ame” eee a oe tie ott sr eaioae ees ® 13, Road este bike a check for ek sore Iyer nmeanr ean ama ff wean yh Tee nemo fton) eae Drive Cala Labreton Oil the dive cain every 300 miles (00 km) or sooner if becomes dy. A propery Prune cain. wil provide mami i nd est milk ce oF wood Hoc) wader the engce to support the bike sear 2 Sui be taoarision to NEUTRAL. 3 Ol te toiom rua of the chao wih 3 ommercat chain Tubiant Fire 38. CConcentae on geting te leet own Seeneen the se plates pins shines and rolls ofeach i Sr Orrastipe Donsacenge cat Sab tae co aoe ee te ing tse "chain tat ‘poche formate fora th i pe chm test ar 4. Route the wheel 10 beep the uno ‘orion ofthe chain within each, Continue ‘Shall ofthe bain i abrinedeicus -— se Ge carotene To en seam hal be etd aig Seen an cr mere = een wdhartraie opr ie on Enea Ska he feaneaeirccnscs Se ere ea vn ese feta tne Cnr = ferences es) ars eo Seb manic ae... etic eee, ee mite ane Tabanan See Wat lena ar hesens tonietccatetteatie EY ysis ae nt oe name el area ‘rowel <2 Giana enc nents of i: 3 Mew ese neo teenage cantik a — Repicrtay ne mom pe ai pee sill fee cen fo i dor Sea en ae See aan Me a tne Ne Pe el gl suo a Pri Sepia Lins Pik spesion vey ui tka Ah Haid pene gn (Pe 40, Ue ‘bea Sade se NGL Na? sind ae 1 Nespas a fali in tol pax eee pes othe fc ea set a, ‘eines The fino, Sher hehe ansaid wes, Saleen teem ‘Siete it AP Oo, ‘Masia iene sorted ho “Metsotebncaonatis eee yee. eile cis of cit from te LUBRICATION, MAINTENANCE AND TUNE-UP © piste ontanrearbascamevery whenever tc wheal semanea 1, Removethe whee as dotted under Fost {ite Romo anion Cater eh ot ea he Remoa alana 2 emo apnea fom the alpvt au Pibion arcs of he bach 6 Reasemble the brake sembly reat ate describe in scape the cable from the instrument (Figure 1), 2 Pll the cable rom he eae sea ‘eae onthe cable i conaminatd, ‘orouehly clean offal od grease + Thorwphy est the cablewithagod rade ‘aoliporpose arse and eins ino the 5 "Make sue he eae comet eed ina Miscellaneous Lebrcation Points Labrie the catch ever, front ak ve. sidestana pivot plat and ootpeg piv pts Use 1OW20mo0e iL— —_ wamcarion, MAmvTeNANce AND TUNEUP. ss ieee rive chain; never intalla new chain over. Aer the deve chain has ben ase 19 a : Seow sprockee Replacement chain as hecoect moun of fie play la Sal Se tebe Foon oi ithe dive chai guar (igure $6) 2 : 2 RLI2SS—DID 42EGM ty 124 inks or res above thetopsuraccofthe cin. This 8 tan be wed ata efrence point for fatare b XLISSS—DID 42SDSM by 120s or hecane RK 428 FD by 120 ks Ae the dive chain es ben aust, he sie fear ake pe foe play met beast 3 eM chaque Rear Brake Peal dsnent ald cases sonen sos chaplt ae Drive Chain Adasinent 4 Sihalon the top ofthe ivechain rn CORIBS nd D0) the reat sprocket fo se ha 1 comely Tye die cain shold te checked and San ites Gavaciacies aie nee ete came Memeyins somes Mele ee Glasto onesdeortheotherIBsndC. Flare when te eel $5)thewheaisincoreeyligndand mus b> onsets. Ree o Sip 4 Te Tighien the rear sale aut to 60-80 Norn (Ga:sf et) Install ew coterinand bend ‘nen the top surface of the lover fun ofthe ‘hs sajcen tothe tensioner mm (Vs in) fom the bottom suc of the sng rm (Figure $7), Adjust the chain before he frcelay in dvressed tothe servic mitt Theende over comple mm (in) Gite ‘Oa XR200 models, the correct amount of ways nat oot pm: neer cain reply is when the tp sara f the wean aidone Tomer run of the chain, adjacent 10 theFE wean te - fectnnstosopon hike secre wiht a Pare ew sii ee ee eet ees Bas Shee aera 58 eee rt pene Seer ae Sa ae ae ee ee oo oe See eto aa 69-0845 125s XRN-155205 Is TH LUBRICATION, MAINTENANCE AND TUNE.UP. ss sore tara dal fe py mn bess over aa hae ee Di al ale (Stn SR a) Chena the dive hiner 300 snes 00 En Oh the XE2OOR and TLR200, push he chain up at poiot midway Wee the greet he ovr ha ie 5. coret iepay 30. Tate in) fr the NE2OOR aed 2533 mim (8 rhe TLRa00 : ‘On the XROOOR, push the chain wp a « bein midy beeen he spc CI ‘On the TLR2OO ithe dive sist the mfr, this can be alse a well See Mallcsion to: Poem TLR 1 Place he tke one sie and 2 Shift the ssn nto NEUTRAL 4. Loosen the sentir 0) 4 Tum both ake salads (igure 61) aval sours inoue or Scat cat aduser mark ais withthe sopper pin on isis of he suing rm (gue 6, 5 Roe te ear et move te chain to nother postion and recheck he sen ais ry near ost eva 50 tatees he teh he re ne ie eet er gah aro pe sf te csr ta ber es then 6S alone th hain fom the ar sci ose at tis carey ales. The fas shoud tee the rear spocc in 3 Sie (A, Pure 9) It coke 1 55 ete ker (Bo Fg 5) ‘earwbel cnc abort aad est be enced Relea Sey 7, Taha the ear ae tut 080-110 Non Grson) Aller dive tins brn ated 1 He core soon of fe pl, dls sll Tele he ive chan pur Fee 39) ticly aor the tp afk sa toe ak {pee rn ee eer bak ole ly sented Seder Rear Biche Pod Abiinen a eer (CHAPTER THgee LUBRICATION, MAINTENANCE AND TUNE.UP Dit Cina Cain Tn acon-recommendal mage interval for clearing the dive hin bu ti fod practice to emo, hoouehy ceanasd iat the chain every 2008 miles 3300 1) are fren iden deny TT Remove the arive chain a decid under Drie Chain Removal Talon i Chap Nine solvent and allow to soak for about a ha four. Move i round andes dag this 3,01 Ovieg tio, cy sb be ot and rinse aay lose pa Csi ‘thot Ovi any bg seed Sots tet bel ec ena Shen haeg up io oul 2 < Ater laning te eas, cute i feo he cagg, NE TTP 3. ay the etn along ance and pl the chain aut Menor the dance eo Be soeced umber of ps eed Table 6 and compureta"dinenin A ip Fete techn hae seh te serice imi tment ie ape Repscement hain numb aos Koes # XLIBSS“DID sO by eink & NLIESS=Dib DSM by 120 © XRIES"DID 24 ty 135s 4 Xt0—s 50 by 103 nk f XLIOR-Ds 80 by 14 ins, E XRabOR— Ds $00 1 ns. TLH2O0=DS 520 by 6 lnk 6 Check the ane fs ofthe nme ps (Figure) Toy shuld sity plied on SoH yay mtn Aut arnt ear i Drea airss SUAPTER THEE _YYBRICATION, MAINTENANCE AND TUNE-Up Prot Brake Level Aajsiment “Te ont rae cable sald beaded so tat brake lever fre playin 20.50 min (Sadis CHAPTER THREE ypRICATION. MAINTENANCE AND TUNF-UP Go Fi ee =e soe ae poo & 1% Model XR2COR—15-20 mm (9/8-3/4 Allotier modele—20-90 mm G/41 1/4 Freely isthe distance the peal travels from the atest postion to whe applcd Bastion (Fgue 78) when the pedal is Epiy Gepresst by ad Rotate the rear wheel and check for brake rag. Alo operate he pal several times to make sure reuse sles positon Immediately ater reas ‘ach Adjstmene ‘The clutch fe pla austment should be cho st the intra shown in Table 1 ‘Cutch ajastnet sited 0 te ever fice play. The cable adjsiment kes up ack ‘ois for ajsting te catch mechanism Tithe proper amount of fe ply aio! Be achieved by ing this adjustment procedure, the cable hae stretched to the poi st recs to be replaced. Rees 19 Clutch Cable Teplacement i Chap Five Tide tock the rer protstive boo. 2 Loosen the lsknut onthe hand over and ‘evo inte aster bare (Flue 73) ot To mm (4 in) of fee ply is foea., Tighten the locknat. eee Pacheco he sand 2 Gis a cake ots este, $e hase hei orton, loses ie Helo hun she Rees ee THs oc a as ie tae eels a ascent nh ‘Rear Brake Pedal cy FSP at he ra pial ote didn ‘secre cer Tom te se et od ofthe ate og one te anit off pyren Pe pa ee tng er one hh Se 3. Atte hand ever, loosen the locknut and Turn the adjuster to! alte ny a toNaré ‘head lever Tin the oka 4 On he pi tandside ofthe engine oosen ‘helotkntand tr the adjuster bare Fire SI)an te corer amount ofleser fees 5 baie ihn he loknut 5) Ih necessary, repeat Step 2 for fine sdusinent 6 After adjustment is completed, check that ‘he lckrus ae ht on both the hand levee teria side ofthe cgi Tes iethe be and make sur the etch ‘Soprating corey ‘Trot Adjustment and Operation The throlle grip should have 2-5 mm (8-1/8 tn) of rotational free play. It Adsense, sid ick he ater Beet fosen he leek (Fe $2) ap tur the adjser atthe tote grip in of ou > achieve poe fie py ron Tighe te Tithe proper amount offre play cannot be ‘rodced by ie adjuster tte hvac gp thes a sional adjustment pin ae Aopofbecerbureor Remove the seat snd he ni Chapa Sc Lose thease Figure) Famous of fre phy ‘eleckast nd ica achieve the prope Tiahestelotinu, CHAPTER THRE) {WBRICATION, MAINTENANCE AND TUNE-UP Starter DecompresorAdjosiment This proecre prune al models exept the XLI2SS whichis ot equipped wil a sone éecompreso, 1, Place the bike onthe sdestand 2 Remove the uel tank at dosribed under Fuel Tonk Removal Inalaion in Chapt Siu 3. "Remove tho 2 inspection hole covers ‘Figure #4) onthe fan crankcase cover ‘ilake testo ate teenie by hand Route te crash wth the wo onthe alimatr rte Tom the ul countrlochie {itl te pst et fo dead center (FDC) on. CHAPTER THmmpy 6, Make ure the“T” mark onthe leator ovo align with te fed eich inthe case (igwe 86). ST Messe he fe ply 3 the ip ofthe valve ner lever (8, Figure 85) The covet amount off play |-? mm (204-010) 8. To aac te fe play ose Ie ockaut (C Flare 88) and ara the adjusting nt (D, igre i) ntl he corectsmoust of fe pl) Isachieved Tighten the oe. Veep sptaesed coc ret mbar cee ade ete terencdeans Farmed et abe lesan me 9, Isl the valve adjusting covers the srk Bg beso ale coves an ef Ale Caner “he i cleaner clement shold be removed sd cleaned at ihe iter hewn n Table ‘Te sir cleaner removes dst and abrasive ‘panies fom the ir eft the iene he arburior snd engine Withost the ait LUBRICATION. MAINTENANCE AND TUN A 44. On XR2008 modes remove the ing 2 (A Fae 89) sera he lar bat Hig ih le tar op Pee 5) so alte sir cnet an Soe Figwe 8) out ofthe a bos 48 On al eer mods emote te wing Su (A Fire 90 and pune Seto holder (@, Figure 99) ou ofthe sir bon Remove 6: Wipe ot eit of hs box wih 2 shape ad caning sen. Rete ang feign mate that ay have pase tough 2 tion cement Mat nee dra be ger) Pekan the semest sen in caning ‘chet un al din removes Thoweph dy ana dean shop clo unl a solvent fea is emoved Lt iy fo about ne ioe cleaner element fom the ‘placed Dom Pun th @ damaged {Pours small amount of SAE 80 or SAE 90 sari orfeam sie ont the clement nd work into the pores fam materi Do not overstate the ements 10 much fi wil resi airflow. The cement will be Alscolored by the ol and shoul ave an oven felon lndeting tht ihe oll 6 dsiibuted ‘rely I the fam i ler cil wa se et fhe cement dry for another hour prer 10 fanalaton, If Insalled foo. soon, the Chemical carci inthe special far a er ‘SI mil be drawn ito the engine and may ‘use damage Sins the air cleaner clement oto the tlement holder {Appl ight cont of multiparpose pease to the esde sealing edge of the cement there teats saint he airbox. TTT te ar cleaner clement and holder Into the ir box. On XR2O0R models make Src thatthe “UP” mark acing up tovard {he top. On all other models, make Sue that the “TOP” mark is fing up toward the top.Se Mate sure thet the ale cleaner clement is propel sated saint the sr box cavrioy Ae nergy el is ane oer alow dad ot ihe cron ind eg cay penance damage 12. On XR2OOR modal, binge down the oie be eae 1B. On al mcs, ns te wine mt and 1 On at we i ogee sxc the xR200R Spe te salng pet on Ls sige con, Fels if neces Apply si se of Slipspoe pase to te sling le fe Bike othe Sie corr Tis wi pees ‘ed ah sal etcen the clement ad fesdecorr nl came her a 5 ope Sal th CHAPTER THeep Fas Stralner (XL1885) cro lg 92 for his procedure 1 Tun the ft su ae es OFF 2 Une bee 2 Use ca, Oring set anc ites fom th fonom athe fad sh JEEP dinar oft ean 2. Glan er ren mith «mean nd blowout wih compressed ait [UBRICATION, MAINTENANCE AND TuNE-UP place the ler seroon if ts broken i any eS ee oF and-ighten the fc cup an then gen thaifeal torque of 3-5 Nom G-4 lb). Do fol overtehten the fuel cup ost may be damage Tum the foc! shuto valve o the ON posiion and chock for leaks. Fal Shutoff Valve and Filter Renal Installation The itera fel filter in the fel shut valve removes parties in the fuel whieh fight otherwise enter the carburetor. Tas fould cause the Foat needle Yo say an the pen position or clog one ofthe es P'Tum the fil smut valve to the OFF postion (A. Figure 93) and remove the fs line fom the valve (B, Fare 93). The fil ten concer Be removed ot Iefin aces da al fl fom 2 esl a longer pice of dean fuel ine © theatre and pce he loa cod ito cles, AaB metal conte I te fel Set Gan ican brewed. 3-Tum the fel shu ave 10 the RES Boston and open the fol lec. This il Se phe Ho of fk ram GR'On models wih «mt fel ee tre ihe akon Pg 90 sing Ie shave tothe el ak ar oO $8 On mos with a pic fe ok ‘emo the wrens (C igre 3) ig ie fel half ave the el tank and 07 ae tae "Aer removing the valve, inset nore fear hop Tg the eps XEnk to sop the sling of it eno he ‘in and ame. 6 Remove te fel er . sabe Gen ith a mel ‘othr and ew aut wn Replace if it is defective. cee 2s by ‘erg thos enor sep Data oo ial ie pe bn vale and te rks Che for el ‘after installation is completed, oa Foe Tine inspection Inspect the condition of he il ine from the fe tno he carburetor (B,Figue 93, Wiis cracked or sarin to dtrore mus beeplanah: Mae sre the all Rose slamps rein plac and holding sce, WARNING 4 daa ead fl iver ei fd had Cranhcae Breather (US. Moats nly) To cean out he breather system, remove the drain lug (Fire 88) an rain out all rene fom the Bose ine atthe steals ‘Shown in Tale Ths peoton ould be permet Troe eee costicahc coat ‘ng done at al oe esl the «a9; make sore the clamp is vit ete wo Chapter Six for more complete dete onthe beter stem. pak Arestr Cleaning "Te spark neste sould be cleaned at he ingrals shown in Table (he XL ei the sarees Pied an US. model en ean bun a al do ot Jef tha can eeraton sth Beh ye toe Wer a ret! yo tht re ofan re hard Ree to mer oro nthe” ‘ese oes100 179 x11255 ad XL18 motels Te cer cone he spark a [iintee os ga rere fom te end Scns ‘ ster mode ror he sre Tipoiayceeg hema andremove (Renate oe Be Gra mod xe the 1979 XLI235 OHSS Hoc open te male wih onesie Seon os L125 nd XLESS mode, farther on. SSantcenpeandriteptbout20sne Persist exten me a Pe sotib me Cons wl exe Sop comngont e mlopnig A Fenbetapsclf emovc te shops desire mle coo Stage he eso ie mater 0 Gatppelh Is dame dette Spyro nai li 64 Ge 179 XLDSS ad NLIBSS ede, fal te yk esr Onan nsal emu et nd igen hese sy nore QcxR08 pts do nsrenctie2 Srrspenttedcic ial encn Tee mounting scr be Inada al ts ye spr aretha pipe Wht Bearings “gE 6 t6 cton-ecommenicd mi eal cami dpc te vie ey shod be srved whcnens ‘ly fee temoved fromthe hed ns pase ces Be httond of ence fSniamnatce, The svi procedures ee ‘veri Cape it and Chaps Ning ‘Stecting Head Adjsineat Check Tie steering head is fited with loose iets i 8 a font fork tubes and. gently rock the 0 BSembly back and fort you can to Seeing Head tdjsinent® alto Sern ea CHAPTER THRp yBRICATION, MAINTENANCE AND TUNE-UP Wheel Hubs, Rims and Spokes Cesk wel bbs a ims for Beds and ether signs of damage. Chock bth wisi fr broken or bent spokes. Repee amare oF broken spokes as Geseribed uner Wher it Chapter Eight, Puck cach spoke with 204" fngeriie aur singotapcack one witha small hammer. Al poke shoud emi thetame sound A spoke at 0 CN will have higher pich tan he thers one att toolot wif haves oer ph fel of oF two spolcs re sghly out of aise adja them wih a spoke wench inde thi Purpose Iinrerealle, newt shld Beers 8 ae. Rafer 1 Spoke Adhiusimsent im Chapter Eight. j ot Suspension Check 1 Aol te fet ra nd pam he es spat dows gaat pie Ca wa oad et arse AE 2, Mae sure he wand lover or ie sats rigueur ce 3. Gh te hw he hanetar oer ‘ols gar swine phan Ron Niankodn ce at Anus sewing efor ane tghge 99), me 48. On aoe me ae are theo ‘serv ah an tha he a a ih Ee (nd ma a se. to Chap Bi fr cr cer Rear Suspeasion Check 1, Place a milk crate oF wood lx) under The engine to support iter with he ea whetoff ie gown 3 pus hard onthe rear whe devas) 10 het fr ode pay the tea swing am SROn dunl-shock modes, check the Tighiess of the upper and ower shock ‘orber mounting bs ad uF 100, Sh On Pro-Link model, make sue al shock Shorber and nkage bol and tae Uh ter to igre 101, gure 102 and Figure 10s TR. onduashock mode's make se the eat ati hut sik andthe citer pis pee igure 100, {BP 0a ProrLink modes, make sure the ‘ettocking eral ut th (Far 105). ‘Three no cove ino hese modes 1S Cheek he thes beer brake oaks is rigre 106) Make sue he cover20 CHAPTER THngy ‘an nuts are lone, ferto Chapt Sor correct procedures and torae Nis Bots and Other Fasteners Constn vibration ean loosen many ofthe fisenes on the motoreyete. Check the thos ofall fens epi hs of 4. Engine mounting hadrare Engine cease covers 6 Handibar nd font forks Gesahi icer € Keksenet ever £ rake pda an ever © hawt gsm BHICATION, MAINTENANCE AND Tunp yp Slcosiand Rubber CL Motes) The rbbee si ME Ho on he ded ts ne Stes pi a tn oe wn 1 te mele ne (gee te lowe be elsive md nea enor ihe bot and race te Rake ENGINE TUNE UP A complet tne sod be peor at e itera hon Tae On XL and TLR sets mode moe Seat une ups may be requ te bs is hen pany spas tae oe ites mol itu nace ke is neo ae up tebe pr teach ce, Te sunt of denon of ef “tuneup pba ea oe ube ot ope dein it Forte puss of ths feet: tancap is eral aden an aiiennee io" cour peak ea pesos Tl sumnarnstene-p spits The sprpagshoal be a led a every oer tie of Ie odes and bore you te TeaneGiBren set in 43 enie ee eet ‘Sowing oer Gets or lace the airless cen at ate canoes © Ast oat cain enson Runs compression tt Coss eee pag iG nd wii in fabs he bree spend Fr pevorm a aap on your Hendy wil ead te lowing tos oa eames Tm oar pg wrench i Souter sone an sorted sockets © Rutter pies I tol Tor acing the wave © tans" (Honde Vale Adining ‘Wan put Na 7908-25000)2 CHAPTER Tipry ygsiCATION, MAINTENANCE AND TUNEp ee 1 Spark pg wire fever gauge an garer tor £ Compresion sae lgniton timing igh fe Ponable uchoreter ; f—\ 2 Dorian eee =S ‘Valve Clearance Adjestment Valve clearance sdusiment mst be made vith the engine cool at room lepers (below 95°F35°C). The cone otake valve Figaro ‘Geaance shoo ia Table 6 s a aseenis “The exist valve is ose at he fot of fhe copie andthe intake valve tthe ret of the npn 1, Pace the bike onthe sidesand, 2 Remove the seat and the foc tank (A Figee 165) a5 decribed cer Fic! Ta Removal Teallation in Caper Sa 3. Use the 24 mim each = ‘eres ool Kit 40d rem te ‘jsines covers, Figare 108) 4 Disconnect the spark pl led (C,W 0 ter ins, epic ite $ Ramone he. 2 awrtion tle cove gee 19) cto hee sce ove eset ak ug (A, Few 10) his ake Wee oe etapa 7, Moai ccna wih he she fat Tore cnsuorintn, fate pion tp end coe CF) (he compen che, sone ama Cin Teer Aine ve ime the cm can std we snc td evap ack. Ta wl ae eng EST eter 30 foe i ce‘PIC tt he op oie pn Te ‘ae ste empresa reson srens sigan te aero elt he pt fey cine ea a Se By ee Sees fea ee sen sei i Table 6 = ee yal Cet ee eran se ee ce feito sa Nea 6 feb Correct Spark Pog Heat Range re earnin ME Ota : i ee terperatsres. Use a cold pg fo high sped high eee voltage po itgreto cog oenterienmnste impetion t should be permed at fame aes poss, ba gots ot that i raged or causes Secreta ie prs Fei oh of cost i ale sence a ett Mang SS ROCT eteectaiags Iori be ltr ere pate ees See Ta core sins Sir sre phn bon Te ding is higher thas noma temp Be SVE 1 bul of eben deporte the combeston ham onthe psn om wl Show teats ia 2 i “The reach nui of pg is ale inom. A loge tan aor plagcoulneee with is ‘arching permanent an see Sang ee Figure 118. Refer o Table 7 for recomend spark pap beatrarges, one ce mor oft flowing ly ems 1 Alen inde ad set © Incomset vale serarce © Nae leakage bored wae fice) 4. Worn or roken pinion ng Midjoted ster dacongenor ee ee Spark Pag Remavalleaaing, play exxpton XLI258 mods) ihe ead gaskets osy perfoo avert te determine ubich eer componeat i fal 1 Grasp he pt plug lend (gure 16) near Pouraboutoneleopeonetagiooithoughhe the fl ab pole and pal off te pag,pe ak a6 ‘Mii tock othepo tists tbreak lone. 22 Blow avay any dittathas secs in ‘espa pl wel Then cll heck hee the peg rere outer ronan 3 Remove the spark pla wih an 18 mm sath lis wrench sore Wp ie me py ‘rm ewer fee anfle tone Yo) 4 Teese pacar: Lok ora broken ‘Seale porea ecesiey ed cess fad exesive carts ool sing Ian of these problems are preset epic tela IF A serge cay gupetioesure ailitle conan srt Youn nest aking wl ut 4, Renor te nest tg fst Door sel pictt ee hn WHRICATION, MAINTENANCE AND TUNE-UP 5, Usa spac pag nrc ad ihe be ples dial 14 2 earn pet har oat with be hl yo oe mln ol ‘ppped pl and reusing the 0 pst ce) ‘hn deal Do aot oven Ths wil xl Sut h tetand est a ‘eli 5 sl he spare plo et: make se so a Reasg Spark Pgs Mach sformaion abou cic a sar pl Derimane can bs deri by a ei itn of the sar log: Thin mate "date petri oe =e JERlde te east real Sole eyes. a 2. Tur he lesion sich othe OFF por: toe Beers cesing he ote tad see Acousy shit NEUTRAL cant and nie ee ane hep lr nein Can “tome at oy Tes iui or brad ples toe hot ase be paced wits eee ‘ood lg wlan oy ray eerie ‘ads ine fom Gtk Mtn Bae Ret Pie wh shu ig te ha tr er {atest ovens ety athe pe eg tun egy stds ‘le, hep St cg wy oe TE the plug elit lik nator samp se olf onertbe feg endans ca. ton yerovertheate ofa. An sia plu cate lensed, bats Ber enon ig ‘All nd ae euppednith caper di cong pti som (DD, Te em wc So beater pots a Sig ots ve 1 be "pscret ining ean a i as feng etnanes sfc, Bere staring on is poco ee tial acti wo toe ewan sem. Nake sel costs eh a Fo ‘rosa ental god comes we can Site Tre ikon einen 2S aps nd itso opening SMe te ning male (hare im) 4 Caacta pb concer (Fee 12) fe ewig be mane anton. "Comet ing iat (Figure 2 flowing emuuibcwersisnetiar ‘evan ene feito herp foliose. noneCHAPTER THREE. “ms dyascente as ‘fitter ecco ‘SPARK PLUG CONDITION » 7. Adbst the de spect speed if necesary as ewtted ir Courier “le Goat Aistnen inthis chair sia Ye ng ak het intow nd ale eg gr 12) Spin caret ihe Fat Sa 2 ig hone pi ane an ‘continus with this procedure. e 10) Remove the pe peter enter and tase igre 2 1 Loe i sts ing he bse le (A Fiewe 129. Rote ihe bus: pate sckrtato sane ety? ‘utero edhe ng. Thin the sve ett he nga ae timing Repeat th ep oag. s ‘ome Besar to tighten he sew car core tage pet ee 12. Afr timing is comet, check the ar sap of the inion. pulse Taser a fat on-magct eer gauge between the pale {everar and the protion on the rotor (igure 129} The slearance should be 0348 tm (0012-0016 ta). If the cesance is {rene looen either or bot screws ( Figure 128) and csrfully move the pulse senersoroatleve the comet clearance Tals check the ignition advance lgnment. Restart the engine and incase noe speedo 1950 rpm Tgiion advance begins a 1,980 rom for all model. At his rune speed the laiion advance marks Should jst ego liza wih he xed index snark (Pgare 130), Full gation advance is hioved at ihe engine sped specified in Table. Ile speed and iming are comet but al advance isieoret ero Ign Advance “Mochariinslspection in Chapter Seven, 14, Disconnect he Unig Ups and portable tachometer,(CHAPTER THREp usnIcaTI02 1S, lsall the pulse generator cover and ‘pst andthe ing mark heb Cararetor Ide Mistare ‘The dle mixture (plot screw) i preset at the factory and is or to be reet Do tot jas the pilot screw unless the carburetor Tas teen overhauled. Is, refro lde Sed and Maxtre Adjustment in Chapt Six lee Speed Adjustment Before making this adjustment, the at leaner must be clean and the engine must Have adequate compression: sce Comresion Tet in” this chapter. Otherwise, i procedure cannot be done prope IP Place the bike on the siestand 2 Connect » portable tachometer folonng 2. Sit the eneine and let it reach normal ‘operating temperature on 4 Sete dle pee by tring he le ses Slop srew (Figure 131 or Figure 132, 5 Seale forthe coves spesd ‘Open and cose the tote 2 couple f limes, check for. variation in ile seat Reatjot i neces. WARNING With the engine tiling. re he Fanta om et se Wiese Iacrenesdarng the moreno aye threat reds a Incoety rtd rush the ae, Coes shi rien in ocr thebhen unser MAINTENANCE AND TUNE-UP ana ee 0 rad sane te Portable tachometer. storace Sora moms fiery can cae seros oben sada geal droga afte es ‘weer cures, Duty Winco tt vile spec psa hb fri, Selecting Saag Area Sees ie neta Pee en weer aces wha 2 re a oe epee ata ke coup tho mates Tae bulla ee eeteataadtenn okt ee a Se ale eee eet recs ba Preparing Bike fer Storage carta preparation il nize dein sss take i exit estore the bike fo $e ear Use te following poet 1. washoventhing eompleey Make cen 1 RONG ai om al Behar to ese Josette he cooing fins onthe head and2 ‘lier Comply dry all parts of the Seis to remove all molssre. Wax a Taine and poled srr ncling ay Gromed ane SR tein for aout 20-0 mines 10 Samp nih cope Dre Fri of he tine since ea ol change Pile ene wih she normal xaniy and ce SP al gin om the fel tnt, she Jnurconnesing Hose and the crburiors. eave the fuel shutoff valve in the RES Festion Asan akernivea el wosrae $n) be ded othe al Ts presenative Zalahio fom many motorsele sop sad Trin equipnent supoers EP Lebete the drive shai and cont Gabi rel 1 specie proces fhe Shine 5: Remove ihe sutplogand pour aout one isp of SAE 1087/30 moor ol it he Gylinder. Tura the ensne over afew Felton by Hand oii Ye ol ad teins he pe On Xt see modes remove the bate, fom te Saree evens of spas in hb tox esc wh Hal sade luton wh clean end ean the damage Soe the acy ior etaad ree every 3 wel 4, One seo salou for wince or Delon! smge is te Engas Proccsh Dope (Pare 13) tat evs no te Sour plage tigen vapor he ine, eke, bre ind toe sic works pi rant ad id Garage A: ated tobe aoe fr up to 2 yeas and ‘rae rom the Bosisioe Company 12) Now Fan Rowe, Pectoral, New Hunpshire 0458. The eialog inter Gs Pils “Eagne Prosion Digemsr™ & Tapert pasicbag oer heen ofthe aller to preci ie enty af maine 4, Check thei presents hecoret ‘sur and move hee athe srep nes | Pacetsecaryonamicaicr oonbts ahecs ofthe ound Abe ke wih tap, tanks or top doth" Pact this cover sa 2p py 1s pls as may tap ATION, MAINTENANCE AND TuNE.up CHAPTER THREE pm TLR200 ONLY. ® 7 ‘moisture. Leave room for air 10 circulate around the veice Inspection During Storaee “Try 10 inspect the bike weekly while io ‘orae. Any detenoration shouldbe coreted 85 soon as possible. For example, if corrosion fright metal parse abserved, cover them with alight oat orereascorilcone spay set thorough polishing Turn the engine over a couple of limes—don' start it use the kickstarer with the tio suite inthe OFF potion Restoring the Bik to Serice A bike that hasbeen propery prepared and stored in a sulable area requires nly ight ainlenance to restore ito servi, Is advisable, however, o peter atone. 1, Before removing he bike from the storage Sta. eile the ties ote corel prssoes Air loss during storage may have neat) Aatcned the res and moving the bike ct ‘ause amaze tres and ims 1. tama omen.CHAPTER THRE MAJOR CONTROLS AND COMPONENTS 19. ton pe nt 1 ttn ee 2. Araor 8. Rents rset nk hook 2 1 ben ea adeno 3 Bie sana 1h Spode ret = BRICATION, MAINTENANCE Ap TUNE yp attoved io dram nthe ke ad Mor Dpto he ul pape 2. When the bike sought the wa arin ts alt i psa 38 Sd Tum he ful shut wane te OFF Donon and fil ee) nk ah FE sane SCT the fe shut vane 1 he RES Poston an ehh ores in te ise ‘container under the int oe fot bie eet ‘rs are danger alone del efor: Bip of et 4, Ope te ain sew anton ever c ffsovass thik fal snon To ful stot vaveto he oa le the din ew = OTT SN pete . in this chapter. sc i a ee {ory pore rm Aor wi prio an frie cri hd face. ey ‘spr aero GENERAL SPECIFICATIONS Gene information and spesication are liged in Table 7. Ref to Figure 164 and Figure 135 forthe lstion ofall major SERIAL NUMBERS. ‘You mst know the mode sel numbers are VIN suber for epson purposes So tometines when dene replacement Ferme sei amber stumped onthe euhand ie of the searing bea (ge (Soy The vice semicon cunier Ai ion he ihcband se fhe ering (er gue 137) The engine serial number ‘lel on the ttm, fthand Sef the ice bbw the exh ever Pu {pp foe crburtrseneation number feened onthe ngkthand ide of the rete body a shew a igre 139,PARTS REPLACEMENT Honds makes frequen changes during ‘model year, sonie minor and some relatively Iaajr. When sou order pars roma dealer or ‘ther pars dismbotor, slays onder by engine forchassis mombr Write the aumbets down CHAPTER THRpy Rae een emecine ns Pee acAci ee ees eee Bee aiipenicscrcay ee Eater Be tients ccc ‘exchange or refund. 2 wBBICATION, MAINTENANCE aND Tune yp ee re 68 mle (1.200 or mot a ear Neck ed etch et py 190 ine 90k =k Jerry 2000 mies (2,200 km) XL18S5, Teo modeee eer [ees ao “Mipeand pect were en bees CHAPTER Thay Hrs ot taeepan ton gt amy wisn co {gBRICATION, MAINTENANCE AND Tuneup es = ates, a = esti pa, a M906 (57H ae), = a Es — = Bo. oe ezsnm 40) tm 75nd saunas) tame oh) “atl ORE CMAN LENGTH a Tie 3 BATTERY STATE OF chanae a Seni Bat of hare oy peo Gaemnsny tage (Ghriy Greater teenie} fteeam ett) ‘Srehet carpe ss) Sremmaerate) Meetear ag ats) amma Rarer 50mTNE SPECIFICATIONS atnm eset) 050 0082) tam 0) aes ates Seg maks ‘ise ep [WBRICATION, MAINTENANCE AND TUNE-UP [Eeecroee itn cet 82 Jee emer ‘he ae 7 on ae tera See ate ‘tte ae 8) (ison ae 1 cade fe, SOE Ci Seatac ees ae ‘ee ise an} Weta, yo wears ie Se" be a dnp at ‘kd ar ‘etwoe om ‘sam om ‘few pe sewn om conan)| WBRICATION, MAINTENANCE AND TUNE.UP | Table GENERAL SPEGiFCATIONS cemtnune) fate ew sea = Bee Hibeigite trees sania ES SRE RE = pers HUSHEN ioe = HEE RERE B Pan {TUS Co (65 tere tatep oe = UREEEMES! Cag a8. oar ostiep ay Huan mania) ime eei) ‘io 3) Bm ti) toeon (sie) Bone) Bombs) eatery ma(63 immer) dinars ny Mien Beem Gen) ‘stem 8 in) 250m (nn) Bsen{ita ‘Bien (iri) | Maem (iat) Pcs petit, Ene