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SHOP MANUAL

XR2DDR/25DR

, - - - - - - - - - -IMPORTANT SAFETY NOTlCE- - - - - - - - - ,


fJ&I;liiiit'
CAUTI ON:
NOTE :

In dicates Q strong possibility of severe personal injury or loss of life If instructions are no t fo llowed.
Indicates a possibility of persono/ injury or equipmenr damage ;[ instructions are not fol/owed.
Gives helpful in/ormation.

Detailed descriptions of standard workshop procedures. safety principles and service operations are not included. It is
important to note that this manual contains some warnings and cautions against some specific service methods which
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand

that those warnings could not cover all conceiva ble ways in which service, whether or not recommended by Honda
mi\tlt be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such
ways. Anyone using service procedures or tools, wtlether or not recommended by Honda must sarsdy himself
rhoroughly that neither personal safety nor vehicle safety will be jeopardized by the service method or tools selected.

HOW TO USE THIS MANUAL


Sections 1 through 3 apply to the whole
motorcycle, while sections 4 through 16
describe parts of the motorcycle, grouped
according to location.

GENERAL INFORMATION
LUBRICATION
MAINTENANCE

Find the section you want on this page, then


turn to the table of contents on page 1 of
that section .

FUEL SYSTEM

I
I

Most sections start with an assembly or


system illustration , general instructions!
specifications, torque values, working practices, tools and ' troubleshooting for the
section. The subsequent pages give detailed

procedures for the section.


If you don 't know what the source of the
trouble is, read section 18, Troubleshooting.
If you are not familiar with this motorcycle,
read section 17 Technical Features.

I
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I
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~

ENGINE REMOVALIINSTALLATION
CYLINOER HEAOIVALVES
CYLINOER/ PISTON
CLUTCH/ OIL PUMP/ KICK STARTER
ALTERNATOR
CRANKCASE/ CRANKSHAFT/ BALANCER
TRANSMISSION
FRONT WHEEL/SUSPENSION/ STEERING

I
$I
~

REAR WHEEL/ BRAKE/ SUSPENSION

HYORAULIC BRAKE

F=================
REAR FENOER/EXHAUST PIPE
IGNITION SYSTEM
TECHNICAL FEATURES
TROUBLESHOOTING

MODEL IDENTIFICATION
XR:250R

XR200R:

ENGINE SER IAL NUMBER

DATE OF MANUFACTURE
T he frame serial number is stamped on the left side of the

steering head.

The engine serial number is stamped on the IO'Nef left side

of the crankcase.

The vehicle identificat ion number (VINI is on the right side


of the steering head.

CARBURETOR IDENTIFICATION NUMBER

The carburetor identification number is on the left side of


the carburetor body.

The color code label is attached on the left frame tube

under the seat. When ordering a color coded part, always


specify its designated color.

1. GENERAL INFORMATION
GENERAL SAFETY

1- 1

SERVICE RULES

1- 1

SPECIFICATIONS

1- 2

TORQUE VALUES

1- 4

TOOLS

1- 6

WIRING DIAGRAM

1- 8

CABLE & HARNESS ROUTING

1- 10

ITEMS REQUIRING FREQUENT REPLACEMENT

1- 14

..

GENERAL SAFETY
''''QW!ij
If the engine must be running /0 do some J)rk, mo.ke
sure the area is well-ventilated. Never run the engine
in Q closed area. The exhaust contains pouonous

Gasoline is extremely fiommtlble and is explosive


under certain conditions. Do not smoke or aI/ow
flames or sparks in your working area.

carbon monoxide gas.

SERVICE RULES
1. Use genuine HONDA or HONDA-recommended parts and lubricanu or their equivslenu. Parts that do not meet HONDA's
desi!Jl specifications may damage the motorcycle.
2. Use the special tools designed for this product.
3. Use only metric tools wnen servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English
fasteners. The use of incorrect tools and fasteners may damage the-motorcycle.
4. Install new gaskets, Qrings, cotter pins, lock ~Iates, etc. when reassembling.
5. When tightening bolts or nuts, begin with largerdiameter or inner bolts first, and tig,ten to the specified torque diagonally
in 2-3 steps, unless a particular sequence is specified.
6. Clean parts in nonflammable or hi~ flash point solvent upon disassembly. Lubricate any sliding surfaces before
reassembly.
7. After reassembly. check all parts for proper installation and operation.
8. Route all electrical wires as shown on page1-10Cable and Harness Rooting and always away from sharp edges and areas
where they might be pinched between moving parts.

11

GENERAL INFORMATION

SPECIFICATIONS
X R200R

ITEM

DIMENSIONS

Dlleralilength

2035 mm (BO.1 in)

Overall width

865 mm (34.1 in)

Overall height

1180 mm (46.5 in)


1360 mm (53.5 in)

Ground clearance
Wheel base

'365 mm 153.7 in}


905 mm (35.6 in)
395 mm (15.6 in)

Seat height
Foot peg height

Dry weight

FRAME

X R250R

101 kg (223 Ibs)

Type

105 kg (230 Ibl

Front suspension, tra vel

Semi double cradle


Telescopic 254 mm (10.0 in)

Rear suspension, travel

Prating

246 mm ( 9 .7 in)

3.00- 21(6 PAl.

Front t ire size, pressure


Rear tire size, pressure

15 psi ( 100 kPa, 1.0 kg fcm1)

15 psi (100 kPa, 1.0 kg/ em')

110/ 90- 17 (6 PAl,


15 psi (l ookPa, 1,Okg /cm 1 )

15 psi (100 kPa, 1.0 kg/cm 2 )

4 .60- 17 (6 PA)

Front brake lining swept area

Front brake, swept area

86.3 em' (13.3 sq. in)

Rear brake, swept area

86.3 em1 03.3 sq. in)

Fuel capacity

9.0.2 (2.4 US gal)

Fuel reserve capacity

1.5.2 (0.4 USgal)

Caster

64

Front fork oil capacity

355 cc (12 oz)

Type

Gasoline, air-cooled 4-s troke


SOHC

Cylinder arrangement

Single cylinder incl ined 15


67 x 56.5 mm (2.6 x 2.2 in)

Bore x Stroke
Displacement

199 cc (12 . 1 cu. in)

Compression ratio

11.0: 1
4valve , chain driven overhead
camshaft
23 PS/9000 rpm
2.0 kgml7500 rpm

Valve train
Maximum horsepower
Maximum torQue
Oil capacity

'84,
After 'B4:

1.3.2 (l.4USql. 1. 11mp qt)

397 cc (13.4 oz)

75 x 56 .5 mm (2.9x 2.2 in)


249 cc (15.2 cu. in)

28 PS / 8500 rpm

1.6.2 (1.1'us Qt, 1.4 Imp qt )

A ir filtration system

Oiled polyurethane foam

Cylinder compression

13 ~ 15kg/cm2 (185-2 13 psi)

Exhaust valve
Valve clearance

10.2: 1

2.4 kgmnOOO rpm

Forced pressure and wet sump

Opens

5 (BTDC)

10 (BTDC)

Closes

35 (ABDC)

Opens

5 (BBDC)

Closes

35'0 (ATDC)

40 (ABDC)
0
10 (BBDC)
0
40 (ATDC)

Intake

0 .05 mm (O.D02 in)

Exhaust

0 .08 mm (0.003 in)

,
,
,

Lubrication system

Intake valve

12

10Smm (4 .1 in )

Trail

ENGINE

342.8 em'

GENERAL INFORMATION

ITEM

CARBURETOR

X R200R

Type

1.0. number
Main jet

Air screw

Pisto n valve

'84 :

PH31A

PH42A

PH32A

PH41A

'84 :
After '84 :

Primary #98, Secondary w95


Pri mary #98, Secondary # 98
, -3/8 turns out
1-1/8 turns out
18 mm (0 .71 in)
1300 100 rpm

'84 '

Float level
Idle speed

Wet multi-plate tYpe

Clutch

6-speed , constant mesh

Transmission

3 .316
2.769
1,941

Primary reduction

Gear ratio I
Gear rat io II

Gear ratio III

1.450
1.174

Gear rat io IV
Gear rat io V I

0.960
0.a15

Final reduction

3.846

Gear rat io V

Gear sh ift pattern


ELECTRICAL

Left foot operated return system

Ignition system

Ignition timing

Spark plug gap

Primary # 108, Secondary # 105


Primary # 100, Secondary #98
1-1/4 turns out

1 turn out

,
3.100

,
,
,
,
,

,
,

COl
Initial
Full
advance

Spark plug

After '84 :

After '84 :

DRIVE TRAI N

XR250R

8" 2 BTDC at 1900 200 rpm


28 2 BTOC at 43OO :t 200 rpm
OPR9Z, OPR8Z (NGK)
X27GPRU, X24GPR U (N O)

0.6- 0 .7 mm (0.02- 0 .03 in )

Headlight

6 V - 3 5w

Taillight

6V 2CP

13

GENERAL INFORMATION

TORQUE VALUES
ENGI NE
ITEM
Valve adjusting screw lock nut
Cylinder head bolt
Cam sprocket bolt
Cylinder head cover 6 mm boll

Q ' TV

THREAD DIA

1
4
2

6
10
7
6
8

I.

TORQUE Nm (kg-m , ft lb )

1747 1882625 25 2050508-

23 N-mt1.7- 2.3 kg -rn,


53 Nm (4 .7- 53 kg-m,
22 N-m (1 8 - 2.2 kg-m,
12 N-m (0.8- 1.2 kg-m .
30 N'm (2.6- 3 .0 kg-m ,
30 Nm (2.5- 3 .0 kg -m ,
30 N'm (2.5- 3 .0 kg-rn ,
25 N'm (2.0- 2 .5 kg -m ,
60 N-m (5 .0 - 6 .0 kg-m .
60 N'm (5.0- 6 .0 kg-m,
12 Nm (0.8- 1.2 kg-m,
80- 100 N'm (8 .0 - 10 .0 kg-rn,

12 - 17 ft-Ib)
34-38 ft-Ib)
13- 16 ft -Ib)

6- 9
, 9- 22
18-22
18 - 22

ft lb)
ft -Ib)

Drive gear lock nut

2
2
2
2
1
1

Right crankcase cover

17

Flywheel
left crankcase cover

1
8
1
1

Q ' TV

THREAD DIA

TORQUE Nm (k9 -m , ft -Ibl

1
1

24
26
8
8
8
6
12

95 - 140 N'm (9 .S- 14 .0 kg -m. 69- 101 fI-lb)

8 mm bolt
Rocker arm shaft
Sub-rock er arm shaft IN
Sub-rocker arm shaft EX
Clutch lock nut

Gearshift return spring


Drain plug

16
18
6
6
8

822 20-

12 Nm (O.B- 1.2 kg-m,

ft-Ib)

ft -Ib)

14-18 ft -tb)
36 - 43 ft lb)
36-43 ft -Ib)
6 - 9 ft -Ib\
58- 72 ft lb)

6- 9 fl -tb)

26 N'm (2.2- 2 .6 kg -m . 16-19 fl -Ib)


30 Nm(2 .0 - 3 .0 kg -m . 14- 22 ft -Ib)

FRAME
ITEM
Steering stem nut
Steering bearing adjusting nut
Handle holder '
Front fork upper pinch bolt
Front fork lower pinch bolt
Front axle holder
Front axle nut
Front fork top boll
Front f ork socket bolt . 3 : XR250R
Front fork drain bolt
Rear cushion hose lock nut (Fuel lank)
Front fork sockel bolt

XR200R

Rear axle nul


Final dnven sprocket
Rear f or k pivot
Rear shock absorber (upper)
(lower)
Shock arm-t o-swing arm
Shock arm-toshock link
Shock IInk-lo-frame
Front brake calipe r bolt
Front diSC
Brake hose joint (Brake hose)
(Mastor cylinder)
Oil bolt caliper

14

4
4
4
1
1
2
1
1
2
1
6
14
1
1
1
1
1
2
4
1
1
1

34

12
4
12
10
16
8
2
10
10
12
10
10
8
6
10
10
10

2N 'm{0. 1118- 30 N'm (1825- 30 Nm (2. 530- 35 N'm (3 .0 -

10-

14Nm ( I .0 -

50- 80 N'm (5.015- 30 N'm (3.2 32 - 42 N'm (1 5 2 Nm(O. I 120- 25 N'm (2020- 26 Nm (2.0-

0 .2 kg-m, 0 .7- 1 4 ft -Ibl


30kg-m, 13 - 22 ft-Ib )
3 .0 kg-m, 1B- 22 ft-Ib)
3 .5 kg -m . 22 - 25
1 4 kg-m, 7-10
B.O kg-m. 36-58

ft-Ib )
ft-Ib l
ft -Ib)

4 2 kg -m , 23 -30 It-Ib)
3 .0 kg-m . 11-22 ft -Ib)
2 kg-m . 0 7- 1.4 ft -Ib)
2 .5 kg-m, 14-18 ft-Ib)

2 .S kg-m . 14- 19
BO- 1 10 N'm (8 .0 - 11 .0 kg -m , 58- BO

ft-Ib )

27 - 33 N'm (2 .7- 3 .3 kg -m , 20- 24


BO- l00Nm(B .0-l0.0kg-m , 58- 72

ft -Ib)
fI -lb)
ft -Ib)

40-

40-

50 N'm (4.0- 5 .0 kg-m . 29- 36


50 N'm (4 0 - 5 .0 kg -m . 29- 36

90- 120 Nm (9.0-12 .0 kg-m . 65- B7


40- 50 Nm(4 .0 - 5 .0 kg -m , 29-36
40- 50 Nm (4 .0 - 5 0 kg-rn , 29- 36

20- 30 Nm (2.014- 16Nm(1430- 40 Nm (3. 012- 15Nm(1 .230- 40N 'm(30-

3 .0 kg -m . 14-22
1 6 kg-m , 10- 12
4 .0 kg-m, 22 - 29
1 5 kg-m , 9-11
4 .0 k9-rn, 22- 29

ft -Ib)

ft-Ib )
ft -Ib)
ft -Ib)
ft-Ib)
ft-Ib)
ft-tb)
fI-lb)
ft-Ib)

ft-lb)

GENERAL INFORMATION
FRAME
ITEM

a 'TV

THREAD DIA

TORQUE N m Ikg-m. ft lbl

25- 5 .0 Nm (0.25- 0.5 kg-m, 1.8 - 3 .6 ft-Ib)


4- 7 N'm (0.4 - 07 kg-m, 2.9 - 5 . 1 ft -Ib)

Spoke nipple

Caliper bleed screw


Caliper pad hanger pin

35
8

10

Brake arm

10
10

Engine hanger

8 mm bolt
10mm bolt

Step arm

Brake pedal mount boll

Change pedal

6
6

Kick arm Joint


Side stand pivot

10

Exhaust pipe clamp bolt

2
2

8
8

Exhaust pipe 10lnl nut

I Fuel tank

15- 20 N'm ~ 1.5- 2 ,0 kg-m.


8- 12 N'm (0 .8- 1.2 kg-m.
25 - 35 Nm (2 .5 - 3 .5 kg-m .
35 - 45 Nm (35-4 .5 kg-m ,
35 - 45 N'm (3.5-45 kg-m .
8 - 12 Nm (0 8-1 2 kg-m,

25- 33 h -Ibl
25- 33 ft-Ib)
6- 9 ft .lbl

8 - 12 N'm (0.8 - 1 2 kg-m.

6- 9 ft-Ib)

11-14 ft -Ib)

6-9 ft -Ib)
18- 25 h -Ib)

20- 35 Nm 12.0- 3 .5 kg-m. 14- 25 ft.lb)


35- 45 N'm (3 .5 - 4 .5 kg-m, 25- 33 ft -Ib)
15- 25N m(15 - 2 .5kg-m. l'-18ftlb)

8 - 12 N'm(O 8 - 12 kg-m,
8 - 12 N'm (0.8 - 1.2 kg-m,

6- 9 ft-Ib )
6-9 ft -Ib)

Torque specifications listed above are f or the most important tightening points. If a specification is not listed follow
the standards below

STANDARD TORQUE VALUES

TYPE

5 mm
6 mm
8 mm
10 mm
12 mm

bolt, nut
bolt, nut
bolt, n",
bolt, nu,
bolt, nu'

TORQUE Nm tkg-m , h -Ib)

4 5818 3050 -

6 .0
12
25
40
60

(0.45-0.6, 3 3 - 4 3 )

I 0 .8 - 1.2, 6- 91
I 1.8 - 2 .5, 13 - 18)
I 3.0 - 4 .0 , 22 - 29)
I 5.0-6 .0 , 36 - 43)

TYPE

5 mm screw
6 mm screw
6 mm flange bolt, 001
8 mm flange bolt, nut
10 mm flange bolt, nut

TORQUE N'm tkg -m . h -Ib)

3.5 7102430-

5
11
14
30
40

(0.35-0.5 , 2.5- 3.6)


( 0.7 - 1.1, 5- 8 I
( 1.0- 1.4, 7- 10 )
( 2.4- 3.0, 17- 22 )
( 3 .0 - 4.0 , 22 - 29 )

15

GENERAL INFORMATION

TOOLS
SPEC IAL
DESCRIPTION

NUMBER

Valve guide re8mer


Clutch center holder

07984- 2000000

Rotor puller

07933-3000000
07936 - KC10500
07936-3710200

Bearing remover, 15 mm
Remover weight
Threaded adaptor
Shaft puller
Fork seal driver
Fork seal driver weight
(XR250R only)
Fork seal driver attachment
(XR250A only)
Fork seal driver
(XR200A only)

Ball race remover

07923 - KE1000 1

ALTERNATIVE

Cammerciallv

a~ailable In

NUMBER

6
8

U.S,A

Remover weight

07741-0010201

9
10, 11
, D, 1" 13

07947-3290000

10
10
10
12

07931 - KFOO200
07931 - ME40000

07947 - 1310000
0794 7- KA501 00

REF .SECTION

07947-KA30200

12

07947-3710101

12
12
12

Steering stem driver

07953-4250002
07946 - 4300001

Steering stem socket


Pin spanner
Pin spanner
Piston slider
Bearing remover, 20mm
Remover handle

07916- 3710100
89201-KA4-810
89201 - KA4- 810
07974- KA30300
07936- 3710600
07936- 3710100

Slider guide, 14mm


Spherical bearing
driver, 14 mm

07974-KA40000
07946-KA30200

12
12
13
13
13
13
13
13

Snap ring pliers

07914- 3230001

14

16

Steering stem driver

07946-M800000

Attachment

GN- HT-54 U.S.A only

Not available in U.S.A.

CO MM ON
DESCRIPTION
Valve adjusting wrench .

NUMBER

ALTERNATIVE

NUMBER

Commercia llv available in

REF.SECTION

07708-0030200
07708-0030300

U.S.A ,
U.S.A.

Valve spring compressor

07701 -0020300
07401 - 0010000
07757-0010000

Valve guide driver, 5.5mm

07742-0010100

Extension bar

07716-0020500
077 16 - 0020100

8, 12

10 x 12mm
Adjustment wrench
Spoke wrench
Float level gauge

lock nut wrench


Flv wheel holder
Vniversal holder

Attachment, 62x68mm
Driver
Attachment, 32 x 35 mm

Valve adjustment wrench


Commercially available in

89201 -200-000

3
3
4
6

Commercially available
in U .S.A

8, 12

07725-0040000
07725-0030000

B, 9

07746-0010500
07749- 0010000

10
10, 11.12,13
10,11 , 12 , 13

Pilot , 15 mm

07746-0010100
07746-0040300

Attachment, 42 x 47 mm

07746~0010300

Attachment, 37 x 40 mm

07746-0010200

Pilot, 15mm

07746-0040300

Pilot, 20mm

0774 6- 0040500

Pilot, 17mm

07746-0040400

Pilot, 22mm

07746- 0041000

11, 13
11, 13
11 , 13
11

Bearing remover head, 15mm

07746-0050400

12, 13

Bearing remover shaft, 15 mm

07746-0050100

Hex wrench , 6 mm

07914-3230000

Socket wrench, 30 x 32 mm

07716- 0020400

Retamer wrench

07710-0010401

Retainer wrench attachment

07710-0010100

Universal bearing puller

07631-0010000

Sanwa electr ic tester


Kowa Digital meter

07308--0020000
KSAHM-32003

10, 11.12
11, 13
11 , 13

Commercially available
In U .S.A

12, 13

12
12
13

EqUivalent commercially
available in U .S.A .

13
16
16

USA only

16

17

GENERAL INFORMATION

'84:

WIRING DIAGRAM

18

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.6

dI ~ ~

I "'I i
L,

~
I

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L

'-.

--'

-,

", iii

: prill

,I,

oil

a.

"

~!=

~~

o~

'1

I ~I~

.~
~

-;,.~> ~ ~
0'"

r- ~~ :_

~-~f

".

II

,
0

<

.
.:::l '!!5

,..

di '"

~
_

" ~ " !Ii

<:>

"

.;

...-11

o
o
rr-

"'"
:::.:::
I
N

o
M
o
o

r ---'

~~

W/ V G

r---'::~;E rH.-G
II

""

I Aw.tube
I
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~ .~ SUB WI RE (OP)I

'!'"-~W ----f'"

,
I

'_ '>,..,.,-1

~G...,..-(\

r "'~ "'--L..(J
TAil LIGHT 6V2cP(3W)
I

,I

-I

""

,..-

/
(

' /V ~

GI"" ~lil' k
G

...

.,;

L r _ ... J

BIBr

CQ:""

,,

r - - --,

'...D...'
"i
9,,1
J
L 1_I-

HEADLIGHT 6V3$W

i"

REGULATOR (OP)

ENGINE STOP SWITCH

L_ oG___ .J

GG1:-{~\~I(:,1

I I:

~G~ ~~:~
r

L.....-G
BlI V

~Y~lR

-=-

~'~ -I

IGNITION COIL

CO l UNIT

1M." (OP)

1 SP'.KPLUG

"-1.

PULSE GENERATOR

ALTERNATOR

-=

'"
m

ENGINE STOP SWITCH CONTINUITY

IG

&

FREE

...

CD

PUSH :)-

r.

COLOR BII'

BI

,
,

e.,,,
....'" , ......

."'''"

YELLOW

.m

.~'E

...

LlGHf BLt.(

'"rJ>
..,

UGHT GREEN

"'"

0030Z - IU(Q - 770

'"s:J>
-<

GENERAL INFORMATION

CABLE & HARNESS ROUTING


Note the following when touting cables and wire

harnesses.
A lose wire harness or cable can be 8 safety

hazard. After damping, check each wire to be


sure it is secure.
Do not squeeze wires against the weld or end of
iU clamp when a weld-on clamp is used .
Secure wires and wire harnesses to the frame
with their respective wire bands at the
designated locatfons. Tighten the bands so that
only the insulated surfaces contact the wires or
wile harnesses.

Route harnesses so they are not pulled taut or


have excessive slack.

Protect wires and harnesses with electrical tape


or tubes if they are contact a sharp edge or corner. Clean the anaching surface thoroughly
befOfe applying tape.
Do not use wires or harnesses with a broken insulator . Repair by wrapping them with a protective tape or replace them.
Route wire harnesses to avoid sharp edges or
corner.
Also avoid the projected ends or bolts and
screws.
Keep wire harnesses away from the e:JI:haust
pipes and other hot parts.
Be sure grommets are seated in their grooves
properly .
After clamping. check each harness to be certain
that it is not interfering w ith sny moving or
sliding parts.
Wire harnesses routed along the handlebars
should not be pulled taut, have e:JI:cessive slack,
be pinched. or interfere with adjacent or surrouding parts in all steering positions .
After routing, check that the wire harnesses Bre
not twisted or kinked .

110

X
fa

GENERAL INFORMATION

XR200Ro

THROTTLE CABLE

CABLE

FRONT BRAKE
CASLE

XR250Ro

THROTILE CABLE

SPEEDOMETER
CABLE

CLUTCH CABLE
FRONT BRAKE
HOSE

111

GENERAL INFORMATION

XR200R:

CLUTCH CABLE

FRONT BRAKE CABLE

WIRE BANDS

ENGINE STOP BUnON


WIRE HARNESS

TH ROTTLE CABLE

XR250R:

FRONT BRAKE HOSE

CLUTCH CABLE

WIRE BANDS
ENGINE STOP BUTTON
WIRE HARNESS

THR OTTLE CABLES

112

GENERAL INFORMATION

'f;f;~;:::::::;:::-----

TAl L LIG HT WI R E

CRANKCASE BREATHER
TUBE

1-13

GENERAL INFORMATION

ITEMS REQUIRING FREQUENT REPLACEMEN T


ENGINE OIL
NOTE

ITEM

Change after first 350 km (200 mil; thereafter every 1,600 kg (1 ,000 mil

Engine oil

FAST WEARING COMPONENTS


NOTE

ITEM

Service limit : 107 pins

Drive chain

Drive and driven sprockets


Chain guide slipper
Chain slider
Cab,les

1,716 mm (67.56 in)

Replace whe n damaged or worn

OTHER COMPONENTS TO BE REPLACED AS REQUIRED


ITEM

NOTE

Cylinder head gasket


Gaskets, a-rings

Replace whe never the engine is disassembled

Clutch disc

Service limit : Thickness 2.7 mm (0. 11 in)

Tires

Service limit : Tread depth B mm 10 .3 in)

Spark plug
Fender
lights
Handlebar
Throttle housing
Grip

Replace whe n damaged or worn

Gear shift pedal

Rear brake pedal


Air cleaner element

Brake shoes
Brake pads
. XA250A only

1-14

Replace when the" 6 " mark aligns index mark

GENERAL INFORMATION

NOISE EMISSION CONTROL SYSTEM [U.S.A. ONLY [

The u .S, Environmental Protection Agency requires manufacturers to certify that motorcycles built after January " 1983
will comply with applicable noise emission standards for one year or 3,000 km (1,865 miles) after the time of sate to the
ultimate purchaser, when operated and maintained according to the instructions provided. Noise Emission Control
System is necessary in order to keep the noise emission control system in effect. (USA only).

TAMPERING WITH T HE NOISE CONTROL SYSTEM IS PROH I BITED : Federal law proh ibits the follow ing acts or the
causing thereof : (I) The removal or render ing inoperative by any person, other than for purposes of maintenance, repair,
or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or
element of design has been removed or rendered inoperative by any person.

AMONG THOSE AC TS PRESUMED TO CONSTITUTE TAMPERING ARE T HE ACTS LI STE D BE LOW :


1. Removal of, or pUllCtu r ing the muffler, bafflers, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving part s of the vehicle, o r parts of t he exhaust or intake system, with parts ot her than those speci
fied by the manufacturer.

115

LUBRICATION

2-0

2. LUBRICATION
SERVICE INFORMATION

2- 1

TROUBLESHOOTING

2- 1

ENGINE OIL LEVEL CHECK

2- 2

ENGINE OIL CHANGE

2- 2

OIL FILTER CHANGE

2- 3

ENGINE OIL STRAINER CLEANING

2-3

LUBRICATION POINTS

2- 4

SERVICE INFORMATION
This section describes inspection and replacement of engine oil, oil filter and cleaning of the oi l strainer.
Oil pump service is described in Section 8.

SPECIFICATIONS
'84:
Oit Capacity

~ (1 .3 U.S. qt, 1,1 Imp. qt) After didssembly


1.1 .I! (1.2 U.S. qt, 1.0 Imp, qt) After draining
1.6 .1! (1 .7 U.S. qt, 1.7 Imp. qt) After disassemblv

1.3

After '84 :

1.4 .1! 11 .5 U.S qt, 1.2 Imp. qtl After draining

Oil recommendation

Use HONDA 4ST ROK E O IL or equivalent.


API SE RVICE CLASSIFICATION: SE or SF
VISCOSITY: SAE 20W-50/ 10W-40
NOTE:

.. Use SAE 10W-4Q oif when the outside temperature


is.belowOC (32 F).
Other viscosities shown in the chart below may be used
when the average tem perature in your riding area is
within the indicated range.

OIL VISCOSITIES

-20

-10

10

20

30

"'

4O C

TORQUE VALUE
Drain plug 20-30 Nm (2.0-3.0 kg-m. 14-2 1 ftlb)

Oil leyel Too low


, . Normal oi l consumption
2. External oil leaks
3. Worn piston rings

Oil Contamination
1. Oil not changed often enough
2. Faulty head gasket

21

LUBRICATION

ENGINE Oil lEVEl CHECK


Support the motorcycle upright on level ground.

Check the oil tevet with the dipstick,


Do not screw in the cap when making thi s check.

If the oil level is below the lower level mark on the


oil filler cap/dipstick, fill to the upper level mark

with the recommended oil.

UPPER LEVEL

i(
LOWER LEVEL

ENGINE Oil CHANGE

84 :

NOTE

Change engine oil with the engine warm and


the motorcycle on its side stand to assure
complete and rapid draining.

Remove the oil filler -cap/dipstick and drain plug.


Operate the kickstarter several times while pushing
in the engine stop switch to drain any oil which
may be left in the engine .
After the oil has drained, check that the drain plug

sealing washer is in good condition, and install the


plug .

TOROUE : 20-30 N' m (2.0- 3.0 kg-m, 14- 21 ft -tb)


NOTE

Clean the engine oil strainer, if required,


before filling the crankcase.

DRAIN PLUG

After '84:

Fill the crankcase with the correct quantity of the


recommended oil.
Install the oil filler cap/dipstick.
Start the engine and let it idle for 2-3 minutes.
Stop the engine and wait a few minutes then check
that the oil level is at the upper level mark with the
motorcycle upright. Check that there are no oil
teaks.

DRAIN PLUG

22

I
I

LUBRICATION

OIL FIlTER CHANGE

FILTER COVER

Drain the engine oit. (page 22) Remove the oil filter
cOlier bolts and cover.

FILTER ELEMENT
Install a new filter element, and install the oil filter
cover, bolts and drain plug.

NOTE

Make sure that the Oring on the oil filter


cover and in the right crankcase cover are

in good condition .

Install the oil filter into the crankcase


cover 50 that the side with the rubber seal
is facing out, toward the oil f ilter cover.

ENGINE OIL STRAINER CLEANING


NOTE
Perform this maintenance before filling the
engine with oil.

Remove the skid plate and kick starter pedal.


Loosen the adjusting nut and disconnect the clutch
cable at the lower end.

Remove the right foot peg.


Remove the brake pedal.
Disconnect the brake cable from the pedal.

Remove the right crankcase cover.

-I

SKID PLATE

23

LUBRICATION

Remove the oil strainer and clean it.


Install the oil strainer.
Install a new right crankcase cover gasket.

Install the removed parts in the reverse order of


disassembly.
Adjust the brake pedal (Page 3- 1 7), clutch lever
(Page 319) and starter decompressor (Page 3' 0) .
Fill the crankcase with the recommended oil (Page

21 ).

LUBRICATION POINTS
Use general purpose grease when not specified here.
Apply oil or grease to the other sliding surfaces and

cables not shown here.

REAR SHOCK ABSORBQR


UPPER BUSHING

BRAKE FLUID
(XR250R

FRONT FOI"

l lUBRICANT 1

(ATF)

CHAIN

/"AI_l BEARING

(Grease when
replacing bearings)

BRAKE CAM

-~

BALL BEAR ING


(Grease when replacing
bearings)

.,

SPEEDOMETER
GEAR

BRAKE CAM
(XR200R only)

ENGINE

SIDE STAND
BRAKE PEDAL

_ fiiiiW

SHOCK ABSORBER UPPER MOUNT BUSHINGS


SUSPENS ION LINKAGE PIVOTS

SW I NG ARM PIVOT

24

3. MAINTENANCE
SERVICE INFORMATION

3-2

MAINTENANCE SCHEDULES

3- 3

COMPETITION INSPECTION

3- 5

ENGINE
FUEL LINE
THROTTLE OPERATION

3-6
3-6

CHOKE LEVER

3-7

AIR CLEANER

3- 7

SPARK PLUG

3- 8

VALVE CLEARANCE

3- 9

ENGINE DECOMPRESSORS

3- 10

IGNITION TIMING

3-11

CARBURETOR IDLE SPEED

3 - 12

CYLINDER COMPRESSION

3-12

CHASSIS
DRIVE CHAIN

3 - 13

FRONT BRAKE : XR200R

3- 16

BRAKE FLUID

3 - 17

REAR BRAKE

3 - 17

BRAKE SHOE/ PAD WEAR

3- 18

HEADLIGHT AIM

3 - 18

CLUTCH

3 - 19

SUSPENSION

3- 20

SIDE STAND

3 - 21

WHEEL/ SPOKES

3- 22

STEERING HEAD BEARINGS

3- 22

SPARK ARRESTER CLEANING

3- 23

NUTS, BOLTS, FASTENERS

3 - 23

3-1

MAINTENANCE

SERVICE INFORMATION
SPECIFICAT IONS
X R200R

ITEM
ENGINE

Initial

Ignition timing

8 2 8TDC at 2000 200 rpm

Full advance 2So 2 STDC at 4050 200 rpm

Spark plug

DPR92, DPRS2 (NGK)


X27GPRU, X24GPRU (NO)

Spark plug gap

0.6--0.7 mm (0.02--0.03 in)

Valve clearance

IN

0.05 mm (0.002 in)

EX

O.OS mm (0.003 in)

Idle speed
Cylinder compression

FRAME

Drive chain slack


Rear brake pedal free play

> S mm (3/16

Tire size
Tire pressure
psi (kPa, kg /cml)

1 2 mm (1 /32 1/16 in)

20 30 mm (314 1 1/ 4 in)

,
,

3.00 21 (6 PRJ

Rear

110/90-17 (6 PAl

Front

,
,

Front

15 (100, 1.0)

5116 in)

,
,

35 45 mm (13/8 13/4 in)


10 20 mm (3/8 3/4 in)

Clutch lever free play

13 - 15 kg/cm 2 (185 213 psi)

25 30mm (1 1- 1/ 4 in)

Front brake lever free play

1300 100 rpm

2 6mm( 1/S 1/ 4 in)

Throttle grip free play

,
,

Manual decompressor lever free play


Starter decompressor lever free play

X R250R

4.60 - 17 (6 PRJ

Rear

TORQUE VA LUES
Rear a)([e nut
Spoke nipple
Rim lock
Val ve adjusting screw lock nut
Side stand pivot

80- 110 N'm


2.5- 5.0 Nm
10- 15 Nm
17-23 N'm
35- 45 Nm

(8.0- 11 .0 kg-m, 58-80 ft -Ib)


(0.25- 0.5 kgm, 1.8- 3.6 ftlb)
(1 .0- 1.5 kgm, 7- 11 ft -Ib)
(1 .7 - 2.3 kgm, 12- 17 ftlb.)
(3.5-4.5 kgm , 25-33 ftlb)

TOO LS
Spoke wrench
Wrench,10 x 12mm
Adjusting wrench A

32

07701 - 0020300 (Commercially available in U.S.A.)


07708- 0030200
07708- 0030300 or 89201 - 200- 000 (Commercially available in U .S.A.)

MA INT EN ANCE
'84

MAINTENANCE SCHEDULES
Perform The PRE R IDE INSPECTION in the Owner's Manual at each maintenance period .

I : Inspect and Clean, Adjust, Lubricate or Replace if necessary.


C: Clean
A: Replace
A: Adjust
l " Lubr icate

FREQUENCY
ITEM

BREAK
IN
MAINT.
200 mi.

(350 kml

ENGINE Oil FILTER SCREEN

2 3

C, every 500 mi. (800 km)

3 8

4 3

3 6
3-8
3-9

NOTE 1

FUEL F I LTER

FUEL LINE
I

VALVE CLEARANCE

STARTER DECOMPRESSQA

THROTTLE OPERATION

CARBURETOR IDLE SPEED

3 '0
3 6
3- 12

CARBURETOR CHOKE

3 7

NOTE 1

I, L

DRIVE CHAIN SLIPPER

I
I

..

3 '3
3-15
3 '5
3 '8
3-18
3-17

BRAKE PAD WEAR

NOTE 2

BRAKE FLUID

NOTE 2

BRAKE SYSTEM

NOTE 1

13- 16,3- 17,3- 1B

HEADLIGHT AIM

CLUTCH

3 '8
3 '9

SUSPENSION

SWING RAM BEARING

I, L

I, L

3-21

REAR SUSPENS ION LINKAGE

I, L

I, L

3-21

REAR SHOCK ABSORBER UPPER BUSHINGS


SIDE STAND

..

I, L every 300 mi. (500 km)

DRIVE CHAIN GUIDE SLIDER


BRAKE SHOE WEAR

PAGE

ENGINE OIL fiLTER

DRIVE CHAIN

REFER TO

(1,600 km)

2-2
2 3

NOTE 1

SPARK PLUG

1,000 mi.
R

AIR CLEANER

EVERY

ENGINE OIL

REGULAR SERVICE INTERVAL

I (2 YEARS RJ

I, L
I

3 20, 3 21

3-21

3 23

NUTS, BOLTS , FASTENERS

NOTE 1

WHEELS!SPOKES

NOTE 1

3 23
3 22
3 2'

SPARK ARRESTER

STEERING HEAD BEARINGS


I
I
SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS THE PROPER
TOOLS AND IS MECHANICALLY QUALIFIED.
IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ON.lY BY AN AUTHORIZED
HONDA DEALER.
NOTES: 1. Service more frequently when ridden in unusually wet or dusty cond itions.
2. XR250R only.

33

MAINTENANCE

After '84 :
MAINTENANCE SCHEDULES
Perform the PREA IDE IN SPECTION in the Owner's Manual at each maintenance period .
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary.

C: Clean
R: Replace
A : Adju st

L'

Lubricate

~
ITEM

FUEL LINE

FUEL STRAINER SCREEN

THROTIlE OPERATION

AIR CLEANER

'N

REGULAR SERVICE INTERVAL

MAl NT.
200 mi .
EVERY

4- 3
3 6
3 8

VALVE CLEARANCE
ENGINE OIL

ENGINE OIL FIL TEA

2- 3

OECOMPRESSOR SYSTEM

,
,

3- 10

CARBURETOR IDLE SPEED

NOTE 1

" L

BRAKE PAD WEAR

NOTE 3

BRAKE FLUID

NOTE 3

BRAKE SYSTEM

HEADLIGHT AIM

,
,
,

SIDE STAND

3-18

I (2 years -A)

3- 17

,
,
,
,

3- 16,3 17,3 18

NUTS, BOLTS, FASTENERS


WHEELS/ SPOKES
STEERING HEAO BEARINGS

" L

REAR SUSPENSION LINKAGE


NOTE 2

3- 12

3 '5

SWINGAAM BEARING

SPARK ARRESTER

2- 2

,
,

SUSPENSION

3- .

3- 13

CLUTCH SYSTEM

3- 8

I , L every 300 mi. (500 kml

BRAKE SHOE WEAR

3- 6

DRIVE CHAIN SLIPPER

PAGE

C every 500 mi. (800 km)

DRIVE CHAIN GUIDE SLIDER

(1 ,600 km)

,
,

DRIVE CHAIN

REFER TO

NOTE 1

1,000 mi.

,
,

350 Km

SPARK PLUG

BREAK -

,
,
,

" L
C

3- 15

3- 18

3-18

3 ,.
3- 21

3 20, 3- 21
3 21
3- 21
3- 23
3- 23

3 22
3 22

SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER , UNLESS THE OWNER HAS PROPER TOOLS
AND IS MECHANICALLY QUALIFIED .

IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED


HONDA DEALER .

NOTES : 1. Service more frequently when ridden in unusually wet or dusty conditions.

2. USA onlV.
3. XR250R only .

34

MAINTENANCE

COMPETITION INSPECTION
Check all items before each race.
Refer to the Maintenance Schedule (Pages 3-3, 3-4) for regular service intervals.
ITE MS

ALL PRE RIDE INSPECTION

ITEMS

INSPECT FOR

ACTION

As listed

ENGINE OIL

Contaminants

Change

FUEL LINE

Deterioration, damage or leakage

Replace

VALVE CLEARANCE

Correct clearance

Adjust

CAM CHAIN

Abnormal noise

Adjust

CARBURETOR IDLE

Correct idle speed

Adjust

CARBURETOR CHOKE

Proper operation

Adjust

DECOMPRESSION MECHANISM

Proper free play

Adjust

CLUTCH D ISCS

Wear

Replace

A l A CLEANER ELEMENT

Contamination or tears

Clean or replace

Tightness. proper heat range, and

Tighten, replace or secure

SPARK PLUG

NOTE 1

hightension terminal security

STEERING HEAD

Free rotation of handlebars and

Adjust or tighten

steering stem nut tightness


FRONT SUSPENSION

Smooth operation, air pressure,


oil quantity, no oil leaks and
good boot condition

Replace or adjust

REAR SUSPENSION

Smooth Dperation, oil leaks


and spring height

Replace

SWING RAM BEARING

Smooth operation

Replace

REAR SUSPENSION
LINKAGE BUSHINGS

Wear

Replace

BRAKE SHOES

Wear beyond service limit

Replace

BRAKE PADS

Wear beyond service limit NOTE 2

Replace

DR IVE CHAIN

Length : 1,700.2mm (66 .94 in)


107 pins, max .

Replace

SPROCKETS

Wear and secure installation

Replace or tighten

SEAT

Security

Tighten

HEADLIGHT

Proper beam aim

Adjust

SPEEDOMETERfTRIPMETER

Proper operation

Replace

CONTROL CABLES

Smooth operation, kinks and


correct routing

Lubricate or replace

ENGINE MOUNTING BOLTS

Tightness

Tighten

NOTE 1 Competition use may cause rapid clutch disc wear.


NOTE 2 XR250R only.

35

MAINTENANCE

FUEL LINE

FUEL

\~--.

Replace the fuel line if it is cracked, damaged or


leaking.
If the fuel flow is restricted, inspect the fuel line
and fuel strainer (page 43) for blockage, Clean or
replace as necessary.

THROTTLE OPERA nON


Check for smooth throttle full opening and automatic full closing in all sleering positions.
Make sure there is no deterioration, damage. or
kinking in the throttle cable, and that the throttle
grip free play is 2-6 mm 11/8-114 in) at the
thronle grip flange.

Minor adjustments are made with the upper


adjuster.
Adjust free play by loosening the lock nut and
turning the adjuster.
Tighten the lock nut.
Recheck throttle operation. Replace any damaged
parts.

NUT

36

MAINTENANCE
LOCK NUT

LOWER

Throttle grip free play can be adjusted at either end


of the throttle cable.
Major adjustments are made with the lower adjuster
on the carburetor.

NOTE
Before making major adjustments with the
lower adjuster, adjust the upper adjuster
located on the bandlebar all the way into the
throttle grip housing.

CHOKE LEVER

CHOKE LEVER

Check choke le'oJer operation.


If the choke lever moves stiffly , clean and lubricate
the pivot . Recheck the lever's movement.

AIR CLEANER

LEFT SIDE COVER

Remove the left side cover.

37

MA INTENANCE

::=

ELEMENT ~~:;==....

Remore the wing nut, and remove the element from

the air cleaner case.

Wash the element in non-flammable or high flash


point solvent. and let it dry.
Soak the element in gear oil (SAE #80-90) and
squeeze out excess.

Install the removed parts in t he reverse order o f


disas~mblv .

~ - ~_ D" _ ~ _

SPARK PLUG

\ '

Disconnect the spark plug cap and remove the spark


plUg.

WASH I N
SOLVENT

SQUEEZE OUT
SOLVENT
THOROUGHLY

GEAR OIL
(SAE #80- 90l

\t,

SQUEEZE OUT
EXCESS Oil

Visually inspect the spark plug. Discard it if t he


insulator is cracked or chipped.
Measure the spark plug gap with a wire-type feeler

gauge.
Adjust the gap by bending t he side electrode
carefully.

CHECK : GAP, DEPOSITS, WEAR

SPA RK PLUG GAP: 0.6-0.7 mm 10.02-0.03 in)

::===}===

STANDARD SPARK PLUG


U .S.A. model

DPR92

(NG K)

X27GPRU (NO)

Make sure the sealing washer is in good condit ion.

Install the spark plug and connect the spark plug


"p.
NOTE
Turn the spark plug finger tight, then ti ghten
with a spark plug wrench.

T
CHECK

38

DAMAGE

0 .6- 0.7 mm
(0.02-0.03 in)

MAINTENANCE

VALVE CLEARANCE
NOTE

Inspect and adjust valve clearance while the

engine is cold (below 35 C/95FL


Make sure the decompressor valve lifters
have some f ree play during this maintenance.
Remove the seat.

Turn the fuel valve OFF, disconnect the fuel line,


and remove the tank.
Remove the crankshaft and timing mark hole caps.
Remove the valve adjuster covers .
Rotate the flywheel counterclockwise to align the

"T" mark with the index notch on the left


crankcase cover.

Make sure the piston is at TOC (Top Dead Center)


on the compression stroke.
Check the' clearance of all four valves by inserting a
feeler gauge between the adjusting screw and the
sub-rocker arm.

NOTE

When checking the clearance, slide the feeler


gauge from the inside out in the arrOw direction.
VALVE CLEARANCES:
Intake
0.05 mm 10.002 in)
Exhaust: 0.08 mm 10.003 Inl

ADJUSTER WRENCH A

07708 - 0030300 OR 89201 - 200- 000


AVAILABLE IN U.S.A

Adjust by loosening the lock nut and turning the ad justing screw until there is a slight drag on the feeler
gauge.
Hold the adjusting screw and tighten the lock nut.
TORQUE :

17-23 N-m
11.7-2.3 kg-m, 12-17 ftlb)

Adjust the starter and manual decompressor


play (Page 3-101.

fr~e

Install the removed paris in the reverse order of


disassembly .

SCREW

39

MAINTENANCE

ENGINE DECOMPRESSORS
KICK STARTER
NOTE

Always adjust the decompressor linkage


(manual end kickstarter) after adjusting the

valve cleara nce !pSg8 39)


Remove the cranksahaft and timing hole caps.
Rotate the flywheel counterclockwise to align the
" T " mark with the iode)!: notch. Make sure that the
piston is at TDC IT op Dead Center) on the compre ssion stroke.

.~

______-:" _,,NUT

Measure kickstarter decompressor cable free plav


at tile tip of the decompressor valve lifler lever.

FREE PLAY : 1-2 mm 11132-11161


Adjust by loosening the lock nut and turning the ad
justing nut .
CAUTION

Excessive free play causes hard slorting. Insufficient fru play may calise erralic engine idling
and va/I'e dall/age.

Tighten the lock nut.


Operate the kickstarter and check the operation 01

the decompfessor mechanism.


Recheck ffee play.

XR250R : MAN UAL


Measure the free play Bt the tip of the manual
decomplessOf level.

FREE PLAY: 5 - 8 mm 13"6 - 5/16 Inl

5- 8 mm (3116- 5116 in )

310

MAl NTENANCE

Adjust by turning the manual decompressor adjuster at the engine . After adjusting, tighten the
lock nut .
Recheck hee play at the lever.

IGNITION TIMING
NOTE

The Capacitive Discharge Ignition system is


factory pre-set and cannot be adjusted.

Ignilion liming inspection procedures are


given to inspect the function of the COl com-

ponents .
Remove the timing hole cap.
Connect 8 tachometer and timing lighl.

Start the engine .


The ignition timing at idle is correct if the index
notch aligns with the "F" mark at idle (1 ,300 rpm) .
To check the advance, fai se the engine speed to
4,05('1 rpm; the indell notch should be between the
advance marks .
II the ignition liming is incorrect, check the COl unit,
pulse lotor and pulse generator, and replace faulty
parts. Refer to Section 16, Ignition System.

311

MAINTENANCE

CARBURETOR IDLE SPEED


NOTE

Inspect and adjust idle speed after all other


engine adjustments afe within specifica-

tions.
The engine must be warm for accurate idle
inspection and adjustment. Ten minutes of

stop and go riding is sufficient.


Warm up the engine, shift to NEUTRAL. and hold

the motorcycle upright . Connect a tachometer.


Turn the throttle stop screw to obtain the specified

idle speed .
IDLE SPEED: 1.300 100 rpm

CYLINDER COMPRESSION
Warm up the engine.
Stop the engine and remove the spark plug.
Disconnect the kickstarter decompressor at the
cylinder head.
Connect a compression gauge.
Open the throttle grip all the way.

Operate the kickstarter pedal several times and


check the gauge reading.
NOTE
Check that there is no leakage at the gauge
connection.
COMPRESSION: 13-15 kg/cm 2 (185-213 psil
l ow compression can be caused by:
Improper valve adjustment
Valve leakage
leaking cylinder head gasket
WOIn piston rings or cylinder
[nproper decompressor adjustment
High compression can be caused by:
Carbon deposits in combustion chamber or on the
piston crown.
Disconnect the compression gauge , then reinstall
the kickstarter decompressor linkage.
Adjust the kickstarter decompressor free play , as
required .
Reinstall the spark plug.

312

,..-_ _..:! HFIOl;".E STOP SCREW

MAINTENANCE

DRIVE CHAIN
ADJUSTMENT
Turn the engine off. Raise the rear wheel off t he
ground by placing a work stand or bOll ur'lder the

engine. Shifl the transmission into neutral.


Measure the slack in the upper drive chain run mid-

way between the sprockets .


STANDARD SLACK: 35 - 45 mm

11 318 - 13/4 in)

Adjust as follows:

Loosen the rear axle nut, then turn both adjusters


equally until the chain slack is corre ct.
CAUTION

Be Slife the same urijllSler IfIdex marks align with


IIII' stopper pins 01/ both sides oj Ihe swingarm.

Tighten the a,de r1ut.


TORQUE: 80 - 110 N m (8 .0-11.0 kg-m,
58 - 80 ft -Ib)

flEMOVA L
When the drive chain becomes extremely diny. it
should be removed and cleaned prior to lubrication.
Remove the drive sprocket cover.
Remove the chain retaining c1ip carefully.
Remove the master link and remove the drive chain.
CAUTION

Be core/ul nOlto lose the O-rings when the clip


ol1d mosier link ore removed.
NOTE
For maximum service life, the drive chain
should be deaned and lubricated before each
outing.

313

MAINTENA NCE

Clean the drive chain with a non-flammable or high


flash point solvent that will not damage the a -rings

and wipe dry.


CAUTION

Do not use Q steam cleaner, high pressure


washers or aerosol cI'a;n lubricants (formulated for nona-rillg cllains) as these will

o _ _

;:: KEROSEN E' ,\\

damage the O-rings.

"71
SAE 80
OR SAE
90 GEAR OIL

LUB RI CATE

Inspect the drive chain and Q' rings for possible


wear or damage. Replace the chain, if it is worn ex-

cessively or damaged.
Measure the drive chain length with the chain held
so that all links are straight.
SERVICE LI M IT: 1,7 16 mm

105 PINS LENGTH ;


STA NDA RD; 1,699 mm 166.8 9 in'
SERVICE LIMIT: 1,71 6 rnm {67.56 in)

Lubricate the drive chain wilh SAE 80 or 90 gear


oil.

Measure a span of 107

PinS

Inspect the sprocket teeth for excessive wear or


damage. Replace if necessary.
NOTE

Never install a new drive chain on worn


sprockets or a worn chain on new sprockets.
Both chain and sprockets must be in good
condition, or the new replacement chain or
sprockets witt wear rapidly.

WEAR

DAMAGE

o
NORMA L

314

MAINTENANCE

CHAIN SLIPPER

Check the chain slipper and the chain guide slider


for wear.
CAUTION

If the elwin slipper becomes worn to the swing


arm, Ihe chain

wi/{

begin to weDr against the sw-

jng arm,

~--1.'~" -: ~.
.2

:)

Measure the chain slipper and replace it if its thickness is less than specified,
SERVICE LIMIT: 15 mm 10.6 inl

15mm
(0.6 in)

-.'.-.

-~....

CHAIN GUIDE SUDER

Inspect the chain guide slider for wear and replace


it if you can see the chain through the wear limit

opening.

WEAR LIMIT OPErillNG

INSTALLATION
InstaU the drive chain.
Install the master link with O-rings and chain retain jng clip.
Install the drive sprocket cover.
Adjust the drive chain.
CAUTION

OUT
CHA IN RETAINER CLI P

(NO SPACE)

Do nol QSSJ'mble the drive chain without Ihe


four O-rings.
Rasure Ihot Ihere is nO space between Ihe master
/ink and chain retaining clip.

MASTER LINK

a-RINGS

315

MAINTENANCE

XR200R : FR ONT BRAKE


Measure the front brake lever free play at the tip of

the brake lever.


FREE PLAY : 25-30 mm '1-1-114 in)

ADJUSTER

Adjust as follows:
Perform minor adjustments with the upper adjuster.

Pull the cover off.


l oosen the lock nut and tum the adjuster to obtain
the specified free play .
Tighten the lock nut and install the cover.

Perform major adjustments with the lower adjuster,

Loosen the bolts attaching the front brake cable


guide.
Loosen the lock nut and tum the adjuster to obtain
the specified free play.

Tighten the lock nut.


Retighten the brake cable guide bolts.

316

LOCK NUT

MAINTENANCE

X R250R : BR AK E FLU I D
Check the f ront brake fluid reservoir level. If the

level is near the lower level mark, remove the cover


and diaphragm. Fill the reservoir with

D OT~4

Brake

Fluid'.
If the level was low, check the entire syst em tor

leaks.
CAUTION

Do not remove the cover until/he handlebar


has been turned so thaI/he reservoir is level.
A void operating the broke lever with the cap
removed. Brake fluid wiff squirt out if the
lever is puffed.

Do nOI mix different types oj fluid, as they


are no/ compatible with each other.
LOWER LEVEL MARK
Refer to section 14 for brake bleeding procedures.

STOPPER BOLT

REAR BRAKE
BRAKE PEDAL HEIGHT
To adjust:

l oosen the lock nut and adjust the pedal height by


turning the stopper bolt. Tighten the lock nut.
A djust the brake pedal free play.

BRAKE PEDAL FREE PLAY


NOTE
Adjust the brake pedal free plav after adjusting the brake pedal height.
Measure the brake pedal free plaV.
FREE PLAY: 20 - 30 mm (3 /4 - 1-1/4 inl
Adjust t he free play by turning the adjuster at the
end of the cable.

317

MAINTENANCE

BRAKE SHOE/ PAD WEAR


BRAKE SHOE WEA R
Replace the brake shoes if the arrow on the brake
arm aligns with the reference mark "l::,." on the

brake panel when the pedal freeplay is adjusted


correctly.
Check the brake cable, brake pedal, and brake arm
for loose connections, excessive play, or other
damage. Replace or repair as necessary.

" 6." MARK

XR250 R: BRA KE PAD WEA R


Check the brake pads for wear.
Replace the brake pads if the wear line on the pads
reaches the edge of the -brake disc (page 14~5).
CAUTION

Always replace the brake pads as a set 10 aSSllre


even disc pressure.

HEADLIGHT AIM
Adjust the vertical beam by turning the adjusting
screw on the headlight cover.

318

MAINTENANCE

CLUTCH
Measure the clutch free play at the lever end.
FREE PLAY : 10 - 20 mm 13/8 - 3/4 inl

10-20 mm
(3/8-3/4 in)

......._ ......;L
; O.CK NUT
Adjust as follows :

Minor adjustments are made with the upper adjuster.

pun the cover back.


loosen the lock nut and turn the adjus ter.
Tighten the lock nut and install the cover.

Major adjustments are made with the middle adjuster. Turn the upper adjuster all the way in and back

1 turn.
loosen the middle adjuster lock nut and turn the
out

adjuster.
Tighten the lock nuts.

Check clutch operation.

319

MAINTENANCE

SUSPENSION
FRONT
Check the action of the front forks by compressing

them sel/efsl times.


Check the entire fork assembly for signs of leaks, or

damage.
Replace any components which are unrepairable.
Torque all nuts and botts.

Do not ridt! a vehicle with faulty suspmsion.

Loose, worn, or damaged suspension parts may


. and rider control.

Check the front fork air pressure when the forks are
cold.
Uft the front wheel off the ground by placing a work
stand or box under the engine.
Remove each air valve cap and measure the air
pressure.

RECOMME ND ED
AIR PRESSURE :
o psi (0 kPa, 0 kg/cm 2 )

320

__...____~A~I~R2:~~~~

VALVE

MAINTENANCE
REAR
Place the motorcycle on a work stand or box to
raise the reaf wheel off the ground.
Move the rear wheel sideways with force to see if
the swing arm bearings or wheel bearings afe worn.
Replace if eltcessively worn.
Check the entire re.::lr suspension to be sure everything is securely mounted and not damaged or
distorted.
Torque all nuts and bolts.
Pump grease into the swing arm pivot bearings
through the grease fitting on the swing arm.
Pump molybdenum disulfide IMoS2) paste into the
linkage bushings through the grease fittings on the
linkage pivots.
NOTE

Use MOS2 paste (containing more than 45 %


of MOS2 as follows:
MOL YKOTE G-n PASTE manufactured
by Dow Corning U.S.A .
ROeDL PASTE manufactured by Sumico
Lubricant Co., LTO" Japan.
Other lubricants of equivalent quality .

SIDE STAND
Check the side stand spring for damage and loss of
tension.
Check that the side stand assembly is not bent and
moves freely .
Tighten the pivot bolt if necessary.

TORQUE: 35 - 45 Nm (3.5 - 4.5 kg-m .


25-33 ft -Ibl

SIDE

SPRING

321

MAINTENANCE

WHEEL/ SPOKES
TIRE PRESSU RE
NOTE

The pressures should be checked when the


tires are COLD.
Tire pressure:
Front: 15 psi (100 kPa, 1.0 kg/ em' J
Rear: 15 psi (100kPa . l .0kg/cm1 )
XR200 R

X R25QR

Front

3.00 -21 (6 PA )

3.00-21 (6 PR I

Rear

10190-1816 PR ) 4.60 - 17 (6 PRI

SPOK E NIPP LE WRENCH, 5.8 x 6. 1 mm


0770 1- 0020300 COMM ERC IAL LY AVAI LAB LE IN U.S.A

/'

Check the tires for cuts, imbedded nails or other

sharp objects.

Check the cleat height.


SERVICE UMIT: 8 mm (0.3 in)
Tighten the wheel spokes and rim lock.
TORaUE VALUES:
SPOKE NIPPLE: 2 .5 - 5 .0 Nm
(0 .26 - 0 .50 kg-m .
1 .8 - 3 .6 ft -Ibl
RIM LOCK:

10- 15 Nm

11 .0 - 1 .5 kg-m . 7 - "

ft -Ibl

STEERING HEAD BEARINGS


Raise t he front wheel o ff the ground and check t hat

the handlebar rotat 8s f reelv . Check t hat t he con trol


cables do not interfere with handlebar rot ation. If
t he handlebar moves unevenly, binds, or has vertical movement , adjust the steering head bearings
by turning t he steering head adjusting nut (Page

1230).

BEAR INGS

322

MAINTENANCE

SPARK ARRESTER CLEANING


Remove the front and rear muffler lids.
Start the engine and increase rpms to blow carbon
out of the exhaust pipe while momentarily creating
exhaust system back pressure by blocking the end
of the muffler with a shop towel. Repeat unti l
carbon stops coming out.

Do not perform this operation while the


t'XOOUSI

system is hOf.

Perform this operation in a well ventilated


area, free from fire Iw:ard.
Use adequate eye protection.
After cleaning the spark arrester, install the muHler
lids and gaskets and tighten the bolts.
GASKET

.-

NOTE

Be sure that the muffler lid and gasket are in


good condition and the bolts are tightened
securely.
CAUTION

Be sure that the spark arrester screws are


securely in place.

NUTS, BOLTS, FASTENERS


Tighten bolts, nuts and fasteners at regular interlJals
as shown in the Regular Maintenance Schedule
(Page 3-3 and 34).
Check that all chassis nuts and bolts are tightened to
their correct torque values (Page ' 4 and 15).
Check that all cotter pins and safety clips are in
place.

323

FUEL SYSTEM

4-0

4. FUEL SYSTEM
SERVICE INFORMATION

4- 1

TROUBLESHOOTING

4-2

FUEL TANK

4- 3

A IR CLEANER CASE

4- 4

CRANKCASE BREATHER

4- 5

CARBURETOR REMOVAL

4- 6

CARBURETOR OISASSEMBL Y

4- 7

FLOAT CHAMBER

4- 7

CARBURETOR ASSEMBL Y

4-14

CARBURETOR INSTALLATION

4-15

A IR SC REW AOJUSTMENT

4- 15

CARBURETOR SYNCHRONIZATION

4-16

TEMPERATURE AND A LTITUDE

4- 16

SERVICE INFORMATION
GENERAL

When disassembling fuel system parts, note t he locations of the arings. Replace them wi th new ones on reassembly.
The carburetor float bowls have a drain screws that can be loosened to drai n residual gasoline.

SPEC IFICAT IONS


Fuel tank capacity

Reserve capacity

9.0 lit (2.4 US gal, 2.0 Imp gal)


1.5 lit (004 US gal, 0.3 Imp gal)

Typ'

Piston valve

'.~~. ~~~~~

Identification number

Jet needle setting

Primary

Floo' ,",,

Aft"
4th ,move

18 mm 10.7 1 ;,1

Air screw opening

Aft"

:~!

Primary
Main jet

Secondary

Ah,,:g:

Slow jet

l:m 10m, 0",

2O<1 9'00va

Aft"

:~r~~' out

f~

After

2- 6 mm (1/8-1/4 ;,1

;, "" pl,y

Aft,,'

1,30Q 100rpm
I

~9,2y~!1~

#98

#-"'-

I I

,
,

# 45

TOO L
COMMON
Float level gauge

07401 - 0010000

TORGU E VALUE
Fuel tank mounting bolt

8- 12 Nm 10,8-1.2 kg-m, 6-9 ftlbl

41

FUEL SYSTEM

TROUBLESHOOTING
Engine Cranks But Won't Start
1. No fuel in tank
2. No fuel to cylinder
3.
4.

Too much fuel getting to cylinder (air deaner clogged or carburetor malfunction)
No spark at plug (ignition malfunction)

Engine Idlas Roughly, Stalls, or Runs Poorly


1. Idle speed incorrect
2 . Ignition malfunction
3. Low compression (Section 6)
4. Rich mixture (Air cleaner clogged or carburetor malfunction)
5.

Lean mixture (Air cleaner or carburetor malfunction)

6.

Fuel contaminated

Lean Mixture
1.

Carburetor fuel jets in on position

2.
3.
4.
5.
6.

Fuel cap vent blocked


Fuel filter clogged
Fuel line kinked or restricted
Float valve faulty
Float level too low

Rich Mixture
,.

Choke stuck closed

2.
3.
4.
5.
6.

Float valve faulty


Float 1ellel too high
Carburetor air jets clogged
Sticking float
Dirty air cleaner

42

FUEL SYSTEM

FUEL TANK

STRAP

FUEL TAN K REMOVAL


Remove the seat.
Turn the fuel valve OFF and disconnect the fuel line.

Remove the mounting strap, bolts and tank.

flames or sparks.
Check that fuel flows out of the fuel valve freely.
If flow is restricted, clean the fuel strainer.

FUE L TANK INSTA LLAT ION


Install the fuel tank with the two mounting bolts

and strap.

FUEL LINE

BOLT

Connect the fuel tube .


Install the seat.
NOTE

After assembling, make sure there are no


fuel leaks.
Do not overtighten the fuel valve screws.

FUEL CAP BREATHER TUBE

FUEL TANK

STRAP

FUEL STRA INER

C>

.~FUEL LINE
(}

8-12 Nm (0.8-1.2 kg-m,


6- 9 ftlb)

FUEL VALVE

8-12 Nm (0.8-1.2 kg-m,

6-9 ft-fb)

43

FUEL SYSTEM

AIR CLEANER CASE


REMOVAL
Remove the seat and side covers.

SlOE COVER

Loosen the air cleaner connecting tube clamps.


Disconnect the air cleaner connecting tube from the
carburetor.

BOLTS
Remove the air cleaner mounting bolts.
Remo ve the air cleaner case from the frame through
the left by pressing down on the rear left of the case
and sliding it forward.

44

FUEL SYSTEM

INSTA L LAT ION


Install the air cleaner in the reverse order of reo
moval.

NOTE
Apply sealing agent to the case connecting

face all the way around.


AIR CLEANER INLET DUCT

A lA CLEAN ER CASE

LEMENT HOLDER

AIR
ER
CONNECTI NG TUBE

CRANKCASE BREATHER
Route the crankcase breather tube as shown.

CRANKCASE BREATHER

45

FUEL SYSTEM

CARBURETOR REMOVAL
Remove the seat and fuel tank.

Remove the side covers.

SIDE COVER
INSULATOR

FUEL LINE

Disconnect the fuel line from the carburet or.

l oosen the drain screws and dra in the fuel into a


suitable container.

from flames or
l oosen the carburetor clamps.
Remove the three bolts attaching Ihe carburetor
insulator to the cylinder head.
Pull the carburetors and carburetor insulator away

from the engine through the left side.

THR OTT LE CABLES

Disconnect the throttle cables and remove the car


buretors.

,
I

4-6

FUEL SYSTEM

CARBURETOR DISASSEMBLY
THROTTLE STOP SCREW

AIR CUT-OFF VALVE

~~

.,

~~~
NEEDLE JET

.~
o

/""'0_

~,

SLOW~"
a
I

JET

JET NEEDLE

AIR SCREW

NEEDLE JET HOLDER

'CHOKE

MAIN JET

THROTTLE VALVE

VALVE

FLOAT CHAMBER
Remove the four float chamber screws and the float

chambers.

47

FUEL SYSTEM
FLOAT, FLOAT VALVE AND JETS

FLOAT

Remove the float pin, float and float valve.

VA LVE SEAT
Inspect the float valve and its seat for grooves,
nicks, or contamination.
Inspect the operation of the float valve.
Check the f loat for deformation or presence of fuel.

Remove the jet holder, main jet, needle jet holder,


needle jet and slow jet.
Turn the air screw in and carefully count the number of turns before it seats lightly. Make a note of

this to use as a reference when reinstall ing the air


screw.
CAUTION

Damage to the air screw seal will occur


air screw is tightened against the seat.

;f the

Remove the air screw and inspect it. Replace it if it


is worn or damaged.

48

FLOAT VALVE

FUEL SYSTEM

NEEDLE JET HOLD""

Check each part for wear or damage .


Blow open all jets with compressed air.

FLOAT LEVEL
Measure the float level with the float tang just contacting the float valve.
SPECIFICATION : 18 mm (0.71 in)
Adjust the fl oat level bV care fu llv bending the float

lang.

FLOAT CHAMBER ASSEMB LY


Assemble the float chamber compo nents in the
reverse order of disassembly .

CARBURETOR SEPARATION!
DISASSEMBLY

THR OTTLE STOP SCREW BRACKET

Remove the throttle stop screw bracket f rom the


carburetor body .

49

FUEL SYSTEM

JOlNT
Remove the carburetor attachment screws.
Carefully separate the ball joint from the ball stud
on the secondary throttle drum .

5E(;0'1O,,'RY THROTTLE
PR IMARY
CAI,BURETOR

DRUM
BA LL JOINT

SECONDARY

CARBURETOR

Carefully separate the primary and secondary carburetors.

FUEL JOINT

Remove the twO screws attaching the carburetor


top cover and the cover.

... '
d-

410

FUEL SYSTEM
LINK

THR OTTLE VA L VE ASSEMBLY

SH AFT

On the primary carburetor, remove the link arm set


screw , link arm shaft, plastic washer and throttle

valve assembly from the throttle bore.

SE T SC REW

LI NKAGE

PLAST IC WASHER
EW

On the secondary carburetor, remove the throttle


linkage screw.
Remove the link arm set screw, throttle linkage and
tl'Hottle valve assembly.

THROTTLE

VE

Remove the two screws attaching the link arm to


the throttle valve and separate the link arm from the
throttle valve.

LI NK

411

FUEL SYSTEM
VALVE

JET NEEDLE

Remove the jet needle set spr ing and jet need le.
Check the throttle valve and jet needle for wear,
nicks or other damage.
Assemble the throttle valve in the revef1e order of

disassembly .
NOTE

Install the jet needle clip on the Jet needle.


STANDARD

XR200R

XR250A

-l- 4th groolle

~P~d~m~'~'!Y_ _ _

2nd groove
~s.~o~o~"~d~':'Y!"'-_J 2nd groove 2nd groove
Align the hole in the link arm with the
threaded hole in the link arm shaft and in-

stall the set screw, _ _ _ _ _ _ _ __ _---.J

SPRING

LINK ARM

Blow open all passages with compressed air before


install ing jets and valves.

AIR CUT-OFF VA LVE


Remove the two screws attach ing the air cut-off
valve and its cover.

"

412

FUEL SYSTEM
SPRING

Remove the spring. disphragm and a-ring.


Check the diaphragm for pin holes or other damage.
Assemble the air cut-off valve in the reverse order
of disassembly.

NOTE
Install the aring with its flat face toward the
carburetor body side.

DIAPHRAGM

CHOK E VA L VE

SCREW

Aemo . . e the choke lever pivot screw and choke


lever.
Remove the choke valve nut, spring and valve from
the carburetor.

LEVER
CHOKE VALUE NUT
Check the choke valve and spring for nicks, grooves
or other damage.
Install the choke valve in the reverse order of removal.

SPRING

VALVE

413

FU EL SYSTEM

CARBURETOR ASSEMBLY

BALL STUD

A I R JOINT

Coat new O-rings with oil and install them on the air
joint and fuel joint pipes.
Put the primary and secondary carburetors together
with the air and fuel joint pipes.

Push the ball stud, on the secondary. primary


throttle drum, into the ball joint.

FUEL JOINT
PRIMARY CA.RFIlJAETOR

Secure the carburetors together wi th the two attaching screws.

SCREWS

CARBURETOR

Align the groove of the throttle stop screw bracket


with the air vent tube and install the bracket on the
carburetor body with the two attaching screws.

I
Rorn.E STOP
SCREW BRACKET

414

FUEL SYSTEM

Inspect throttle operation as described below :


Open the th rottle slightly by pressing on the
throttle linkage. Then release the throttle .
Make sure that there is no drag when opening
and closing the throttle.

',.,.

CARBORETOR INSTALLATION
Installation is essentially the reverse order of removaL

NOT E
Route the throttle and choke cable properly.
(page 1- 10 thru 1 13).
Perform th e following inspections and adjust-

ments.
Throttle operation (page 3-6).
Idle speed (page 3- 12) ,

AIR SCREW ADJUSTMENT


Turn the air screw clockwise until it seats lightly

a.nt. \'n~f\ back it out to standard setting .


,sTANDARD :

'84
After '84

XR200R: 1-3/8turn50ut
XR200R : 1-1/8 turns out

'84
After '84

XR250R: 1-1/4 turns out


XR250R : 1 turn out

CAUTION

Damage to the air screw seat will occur if the


ai' screw is t" Iitened against the seat.
Warm the engine up to operating te mperature.
Stop the engine and connect a tachometer.
Start the engine and adjust the idle speed to 1,300
100 rpm with the throttle stop screw.

4-15

FUEL SYSTEM

Check that the engine speed increases YTloothly by


turning the throttle grip.
Turn the air screw until the highest idle speed is obtained.
Reset the idle speed to 1,300 t 100 rpm with the
throttle stop screw.

J
SECONDARY CARBURETOR
ADJUSTMENT
1. Check that there IS B clearance between the
throttle link and adjusting screw.
2. Turn the throttle stop screw in or out until the
correct idle speed is obtained.
3 . Adjust the clearance between the adjusting
screw and throttte link to 0 .4 - 0 .5 mm by turning the adjusting screw ,
4 . Check that the clearance between the secondary lever and primary l ink lever is 3.54.0 mm

SECONDARY CARBURETOR
CRANK TIP

PRIMARY
CARBURETOR
CRANK

ADJUSTING
SCREW

1
o

1
TEMPERA TURE AND AlIllUDE

Use the chan at right to determine if carberalor ad

justments are necessary because of changes in


temperature and altitude. Draw a line straight up
from vour temperature to vour altitude. Where
those lines intersect, draw a horizontal line straight
to the left. Where that line meets the left edge of
the chart is vour correction factor.

,<2

'.00
0.9 8
0 .96

------

'------------

------~

-----

0.94
0 .92

-----

o"c
3:tF

Om 10 h i

-,..... 1500 m 149 20 hi

~ lOOOm{9 840 ftl

I
- 10"C
14" F

I
10" C 2{tC
50" F SifF

Temperature

4-16

-------

0.90

lO C
8S" F

40 C
l04" F

FUEL SYSTEM

MA I N JETS

To adjust the main jet Size, multiply the standard


main jet size by your correction factor.
If the correction factor is 0.95, or below, ra ise the

iet needle clip by one position and turn in the air


screw 1/ 2 turn.
If the correction factor is above 0.94 , adjustments

to the jet needle and air screw are not necessary.

For example: (XR200R Primary setting)


At a temperature of 30C (86F) and an altitude of
3,000 m (9480 ftL c arbure tor recom mendat ions are
as follows:
Main jet

Standard Carburetor Sett ing

Primary
Main jet

Secondary

98 x 0 .92 - 90. 10 IF90)


Jet needle
4 - 1 .. 3
3rd groove
Air screw opening

13/8+ 1/ 2 " ' 7/8

Jel net!dle

PrimlWy

wiling

Secondary

Air iCrew opening

XR250A

XR200R

hem
'84

#98

. ,OS

After '84

' 98

.,.100

'84

.9S

After '84

~98

#" 105
98
2ndllfoove

4th groove

I
I

'8'

2nd groove

2nd liJ foove

1-3 /B turn$ out

1-14turnlOUI

After '84 ll(BturnSoul

. 1

turns OUI

417

ENGINE REMOVAL & INSTALLATION

8-12 N-m 10.8 - 1.2 kg-m,


6-9 ftlb)

30-37N -m (3.0-3.7 kg-m,

22-27 ft-Ib)

55-65 Nm (5.5-6.5 kg-m,


40- 48 ftlb)

30-37 N'm
(3.0-3.7 kg-m .
22-27 ftlb)

10 Nm

(8.0-1 1.0 kg-m,


58-80 ft -Ibl

55-65 Nm (5.5-6.5 kg-m, 40-48 ftlb)

5-0

5.

REMOVAL &INSTALLA liON

SERVICE INFORMATION
ENGINE REMOVAL

5- 1

5-2
5-4

ENGINE INSTALLATION

SERVICE INFORMATION
GENE RA L

During removal and installation. support the motorcycle on a workstand or box.


A jack or adjustable support is required to maneuver the engine.

Parts requiring engine removal for servicing:

Cylinder
Crankshaft
Balancer
Transmission

Section
Section
Section
Section

7
10
TO
11

SPECI FICAT IONS


Engine weight

Oil capacity

'84:

After '84:

XA200R: 30.5 kg
XR250R: 31.0 kg
1.3 lit (1.4 US qt,
1.1 lit (1.2 US qt,

(67.2Ibs)
(B8.3Ibs)

1.1 Imp qt) after disassembly


1.0 Imp qt) after draining

1 .6lit (1 .7 US qt, 1.7 Imp qt) after disassembly

,.4 lit ( 1.5 US qt, 1.2 Imp qt) after draining

TORQUE VA LUES
Engine hanger bolts:
8 mm bolt
10 mm bolt
Foot peg bolt
Exhaust pipe clamp boh
Exhaust pipe joint nut
Rear axle nut

55-65 N'm (5.5- 6.5 kgm, 40- 48 fttb)


35-45 Nm (3.5-4.5 kgm, 25-33 ft -tb)
15 - 25 Nm (1.5-2.5 kgm, 11 - 18 ft-Ib)

Fuel tank mounting bolt

8 - 12N.m

30-3 7 Nm

(3.0-3.7 kgm, 22-27 fHb)

8 - 12 Nm (0.8-1.2 kg-m,
6-9 ft -Ib)
80- 110 Nm (8.0- 11.0 kgm, 58-80 ftlb)
(0 .8-1 .2 kg-m,

6- 9 ftlb)

51

ENGINE REMOVAL & INSTALLATION

ENGINE REMOVAL
Remove the fuel tank, seat and side covers.
Remove the skid plate.
Drain the oil from the engine (page 22).

SKID PLATE

loosen the exhaust pipe clamp bolts. Remove the


exhaust pipe joint nuts and remove the exhaust
pipe.

Remove the rear brake pedal pivot bolt and the


pedal.
Remove the two bolts attaching the right foot peg

I
I

and the foot peg.

PULSE GENERATOR

Remove the alternator connectors.


Disconnect the pulse generator wire coupler. Remove the spark plug cap.

Remove the carburetors (page 46) .

I
SPARK PLUG CAP

52

ENGINE REMOVAL & INSTALLATION

Disconnect t he clutch cable and remove the cable


from the clutch cable clamp .

Disconnect the crankcase breather tube from the

crankcase.

l oosen the rear axle nut and turn the dri ve chain
adjuste rs to loosen the chain.
Remove the drive chain by removing the master link
clip.

MASTER LINK
REAR ENG INE BRACKET_ _ _,;UPPER ENGINE BRACKET
Place a jack or padded block under the engine .

Remove the upper, front and rear engine brackets.


Remove the front and rear engine hanger bolts.
Lower the jack and remove the engine from the
right side.

BRACKET

53

ENGINE REMOVAL & INSTALLATION

ENGINE INSTALLATION
Install the engine in the reverse order of removal,
noting the following:

Replace any damaged or leaking e)(haust pipe gaskets.

Tighten all bolts to the proper torque specifications.


Route all wire harnesses and cables properly (Page
'10).

8mmBOLTS

COLLAR

BmmBOLTS

~~1!I"i

TORQUE : 8 mm BOLT

10mmBOlT
Exhaust pipe clamp bolt
Exhaust pipe joint nut

Foot peg bolt


Fuel tank mounting bolt

30-37 N'm (3.0-3.7 kg-m , 22-27 ttl


55-65 N -m (5.5-6.5 kg -m , 40- 48 tt)
, 5-22 N-m (1.5-2.2 kg-m, 11 - 18 ft -Ibl
8 - 12 N-m (0.8-1.2 kg -m , 6- 9 ft -Ibl
35-45 N -m (3.5-4.5 kg -m . 25 - 33 ft -Ib)
8 - 12 N-m (0.8-1.2 kg -m . 6 - 9 ft -Ib)

Perform the following inspections and adjustments:


Engine oil (page 22)
Throttle grip free play (page 3.6)
Decompressor cable adjustment (page 310)
Drive chain (page 3-'2)
Aear brake pedal free play (page 317)
Clutch lever free play (page 3-19)
Check all electrical connections

54

MEMO

CYLINDER HEADIVALVES
26 - 30 N'm (2.6- 3.0 kg -m ,

19 - 22 fl -tb)

8- 12 Nm (0 .8 - 1.2 kg -m ,

25-30 Nm 12.5-3.0 kg -m ,
18- 22 ft lbl

6 - 9 fl -tb)

25- 30 Nm (2 .5- 3.0 kg -m,


18- 22 fl tb)

20- 25 Nm 12.0- 2.5 kgm,


15- 18 ftlb)

~'---~J

47 - 53 Nm (4.7- 5.3 kg-rn,


ft-Ibl

17 - 2 3 Nm ( 1. 7 - 2.3 kg -m , _ _...::;~'-:/;~;;::"",
12 - 17 fltb)

18-22 Nm (1 .8- 2.2 kg.m,._ _ _ _ _~\_~~~


13- 16 ftlb)

8-1

N'm (0 .8 - 1.2 kg-m

6 - 9 fl -tb )

6-0

I
I

6. CYLINDER HEAD/VALVES
SERVICE INFORMATION

6-1

TROUBLESHOOTING

6-3

CYLINDER HEAD COVER REMOVAL

6-4

CYLINDER HEAD COVER DISASSEMBL Y

6-5

CAMSHAFT REMOVAL

6-7

CYLINDER HEAD REMOVAL

6-8

CYLINDER HEAD DISASSEMBLY

6- 10

VALVE SEAT INSPECTION AND REFACING

6-13

CYLINDER HEAD ASSEMBL Y

6-16

CYLINDER HEAD INSTALLATION

6- 17

CAMSHAFT INSTALLATION

6-19

CYLINDER HEAD COVER ASSEMBLY

6-21

CYLINDER HEAD COVER INSTALLATION

6-23

III

SERVICE INFORMATION
GENERAL
This section covers maintenance of the cylinder head, valves, camshaft and rocker arms .

Pour clean engine oil into the oil pockets in the cylinder head to lubricate the cam .

6 1

CVLlNDER HEADIVALVES
SPECIFICATIONS
STANDARD

ITEM

SERVICE LIMIT

13 15 kg/cm 2 ! 185 213 psi)

Compression

Camlih

Camshaft

'N

29 .06mm ( 1 , 144 in)

XA250R

29.252 mm (1 .152 in)


29.529 mm (1.163 in )

EX XR200R

29. 196 mm (1.149 in)

29 .01 mm (1 142 in)

XR250R

29.330 mm (1.155 in)

29 . 14mm ( 1. 147 in )

XR200R

0 .04 mm (0.002 in)

Run out

1.0.

Sub-rocker arm

'N
EX

Sub-rocker arm shaft

0 .0.

29 .34 mm (1 . 155 in)

'N
EX

Sub-rocker arm-te-shaft clearance

7 .000- 7 .015 mm (0.2756-0 .2762 in)


7 .000- 7.015 mm (0.2750- 0 .2762 in)

7.05 mm (D.27S in)


7 .05 mm (0 .278 in )

6 .972 - 6 .987 mm (0.2745 - 0 .2751 in)


6 .972 - 6 .987 mm (0.2745- 0 .2751 in )

6 .92 mm (0.272 in)

0 .013 - 0 .043 mm (0 .0005- 0 .0017 in)

0 . 10 mm (0 .004 in)

6 .92 mm (0.272 in)

Rocker arm

1.0.

1 1.500- 11 .518 mm (0.4528- 0.4535 in)

11 .53 mm (O.454 in)

Rocker arm shaft

O.D.

11.466- 11 .484 mm (0.4514- 0 .4521 in)

11 .41 mm (0.449 in)

0 .016-0 .052 mm (0 .0006- 0 .0020 in)

0 . 10 mm (0 .004 in)

Rocker arm shaftto arm clearance


Valve spring

Free length
Preload/ length

Valve

Stem O.D.
Guide I.D.

Cylinder head

37.9 mm (1 .49 in)

Outer

38 .30 mm (1.508 in)

37.1 mm (1.46 in)

Inner

15.0 1.0 kg122.5 mm (33.2 2.3 Ib/ 0.88 in)

Outer

45.4 + 3.0 kg / 26.0 mm (100.3 7 .0 Ib/ l .02 in)

'N

5.475-5.490 mm

(0.2 155- 0.2161 in)

5.46 mm (0.215 in)

EX

5.467 - 5.477 mm

(0.2152--0.2 156 in)

5.45 mm (0.214 in)

'N

5.500- 5.512 mm

(0.2165-0.2170 in)

5.53 mm (0.218 in)

EX

5.500- 5.512 mm

(0.2 165--0.2170 in)

5.53 mm (0.218 in)

Stem toguide

'N

0.0 10- 0.037 mm

(0.0004--0.0015 in)

0.07 mm (0.0027 in)

clearance

EX

0.023- 0.045 mm

(0.0009--0.0018 in)

0.08 mm (0.0031 in)

Valve face

'N

1.2- 1.4 mm

(0.05- 0.06 in)

2.0 mm (0.08 in)

width

EX

1.2-1.4 mm

(0.05- 0.06 in)

2.0 mm (0.08 in)


0.10 mm (0.004 in)

Warpage
Valve seat
width

62

38 .83 mm (1 .529 in)

Inner

IN/ EX

1.2- 1.4 mm

(0.05-0.06 in)

2.0 mm (0.08 in)

CYLINDER HEAD/VALVES
TORQUE VALUES
Cylinder head bolt
Cam sprocket bolt
Cylinder head cover 6 mm SH

47 - 53 N'm (4.7-5.3 kg-m, 34-38 ft -Ib)

8 mm bolt
Rocker arm shaft
Sub-rocker arm shaft IN
Sub-rocker arm shaft EX
Valve adjuster lock nut

26-30 N'm
25 - 39 Nm
25 - 30 Nm
20-25 N'm
17-23 N'm

18 - 22 Nm (1.8 - 2.2 kg-m, 13-16 ft-JbJ


8 - 1 2 Nm (0.8 - 1.2 kg-m, 6 - 9 ft- )b)

(2.6-3.0 kg-m, 19-22 ftlb)


(2.S - 3.0 kg-m, 18-22 ft -Ib)
(2.5 - 3 .0 kg -m, 18 - 22 fHb)
12.0 - 2.5 kg -m, 15 - 18 ft -)hl
(1.7- 2.3 kg-m, 12- 17 ft-Ib)

TOOLS
SPECIAL

Valve guide reamer, 5.5 mm

07984 - 2000000

COMMON
Valve guide driver, 5.5 mm
Valve spring compressor

07742-0010100
07757-0010000 (or 07957- 3290001)

VALVE SEAT CUTTER (The following are commercially available in the U.S .A .)

Valve seat cutter


Valve flat cutter
Valve interior cutter
Cutter holder

29 mm
30 m m
30 mm
5.5 mm

07780- 0010300
07780-00 12200
07780- 00 14000
07781-00 10101

TROUBLESHOOTING
Engine top-end problems are usually performance-related and can usually be diagnosed by a compression test.
Engine noises can usually be traced to the top-end with a sounding rod or stethoscope.
Low Compression
1. Valve
- Incorrect valve adjustment
- Burned Of bent valves
- Incorrect valve timing
- Broken valve spring
2 . Cylinder head
- Leaking or damaged head gasket
- Warped or cracked cylinder head
3. Cylinder and piston (Refer to Section 7)
4. Decompressor out of adjustment

Excessive Noise
, . Incorrect valve adjustment
2. Sticking valve or broken valve spring
3. Damaged or worn rocker arm or camshaft
4 . Loose or worn can chain
5. Worn or damaged cam chain tensioner
6. Worn cam sprocket teeth
Poor Idling
1. Compression too low
2. Decompressor out of adjustment
Kick Starting Difficult
1 . Decompressor out of adjustment

High Compression
1. Excessive carbon bui ldup on piston crown or
combustion chamber

6-3

CYLINDER HEADIVALVES

CYLINDER HEAD COVER REMOVAL


Remove the seat and fueltank.
loosen the decompressor cable lock nut and remove
the cable from the valve lifter lever and cable
holder.

DECOMPRESSOR CABLE

Remove the engine upper hanger bolt.


Remove the spark plug cap.

Turn the crankshaft counterclockwise and align the


"T" mark on the alter rotor with the index mark
on the left crankcase cover. Verify the engine is at
T.D.C. on th~ compreuion stroke by removing all
valve covers and checking for movement at both
adjusters. If no movement is felt, rotate the crankshaft 360 and re-align the "T" mark .
Remove the cylinder head cover bolts and the

cover.

64

CYLINDER HEADIVALVES

Remove the dowel pin and head cover gasket.

CYLINDER HEAD COVER DISASSEMBLY

SUB-FIO(;KI'~

ARM SHAFTS

SUll- R()CK:E ry,A R MS

Remove the sub-rocker arm shafts, sealing washers,


wave washers and sub-rocker arms from the cylinder
head cover.

SUll-R'OCI(ER ARM SHAFTS

Remove the valve adjuster covers.

Remove the rocker arm shafts, copper washers,


wave washe rs and rocker arms from the cyl inder
head cover.

65

CYLINDER HEADIVALVES

Remove the dowel pin. valve lifter lever and spring.

ROCKER ARM AND SUB-ROCKE R ARM


INSPECTION
Inspect the rocker arms and sub-rocker arms for

damage, wear or clogged oil holes.

NOTE
If any rocker arms and sub-rocker arm reo
quires replacement, inspect the cam lobes for
scoring, chipping or flat spots.

Measure the 1.0. of each rocker arm and sub-rocker


arm.

SERVICE LIMITS:
ROCKER ARM: '1 .53 mm (0.454 in)
SUB-ROCKER ARM :
IN : 7.05 mm (0.278 in)
EX : 7.05 mm (0.278 in)

ROCK ER ARM SHAFT AND SU BROCK ER ARM SHAFT INSPECTION


Inspect rocker arm shafts and sub-tocker arm shafts
for wear or damage.

Measure the 0 .0 . of the shaft.


SERVICE LIMITS :
ROCKER ARM: 11.41 mm (0.449 in)
SUB ROCKER ARM :
IN : 6.92 mm (0.272 in)
EX: 6.92 mm 10.272 in}

66

,
l

CYLINDER HEADIVA LVES

CAMSHAFT REMOVAL

CAM SPROCI(ET BOLT

Remove the crankshaft hole cap and timing hole

cap.
Turn the crankshaft and remove the cam sprocket
bolts.
CAUTION

Be careful nor to drop the boIls infO the


crankcase.

CAMSHA FT

RE

Pull the cam sprocket off the camshaft flange


shoulder and remove the cam chain from the cam

sprocket.
Suspend the cam chain with a piece of wire to keep
it from falling into the crankcase.
Remove the camshaft and sprocket.

BA L L BEARINGS
Remove the camshaft ball bearings from the cam~
shaft.

CAMSHAFT

67

CYLINDER HEADIVALVES
CAMS HAFT BEARING INSPECTION

SERV ICE LI MIT :


Check each camshaft bearing for play or damage.
Replace a bearing with a new one if it is noisy or has
excessive play .

SERVICE LIMIT:

io-

](~

~:n:

- -

1l"Y

~"L

AXIAL

RADIAL

CAMSHAFT INSPECTION
Check each cam lobe for wear or damage.
Measure the cam lobe height.
SERVICE LIMIT :
XR200R:

INTAKE :
EXHAUST :
XR250R :
INTAKE :
EXHAUST:

29.06 mm (1 .144 in)


29.01 mm 11 .142 in)
29.34 mm (1.155 in)
29.14mm 11 .147 in)

CAMSHAFT RUNOUT
Check camshaft runout with a dial indicator.
SuPPOrt both ends of the camshaft with turning
stand. Use 1/2 of the total indicator reading to

determine (unout.

SERVICE LIMIT: 0.04 mm (0,002 in)

I
o

68

CYLINDER HEADIVALVES

CYLINDER HEAD REMOVAL


Remove the cylinder head cover (page 64).

Remove the exhaust pipe (page 15-2).


RemOlle the carbure t or (page 4-6).

RemOlle the oil pipe bolts, sealiing washers and oi l


pipe.

Remove the cap on the cylinder head.


Remove the cam chain tensioner and bolts.

Remove the six cylinder head bolts.


NOTE

l oosen the bolts in a crisscross pattern in two


or more steps.
Remove the cylinder head.
CAUTION

Be careful not
mating surfaces.

/0

damage the cylinder head

69

CYLINDER HEAD/VALVES

Remove the cylinder head gasket and dowel pins.

CYLINDER HEAD DISASSEMBLY


Remove the valve spring cotters, ret ainers, springs,
and valves with a valve spring compressor.
CAUTION

To prellemloss oj tension, do not compress the


valve springs more than necessary /0 retrlOl'1! the
COllers.
NOTE
Mark all parts to ensure that they are
reassembled in their original locations.
Remove the spring seats and valve stem seats.

Remo ve the carbon deposits from the combustion


chamber.
Carefully clean any gasket material from the
cylinder head.

610

VALVE SPR I NG COMPRESSOR

CYLINDER HEADIVAlVES

CYLI NDER HEA D INSPECTION


Check the spark plug hole and valve areas for
cracks.
Check the cylinder head diagonally two ways for
warpage with a straight edge and a feeler gauge.

SERVICE LIMIT :

0.10 mm (0.004 in)

VA LVE SPRI NG INSPECTI ON


Measure the free length of the inner and out er valve
springs.
SER V ICE LIMITS :
INNER : 37.9 mm 0 ,49 in )
OUTER : 37 .1 mm (1 .46 in)

VALV E/VA LVE GUIDE INSPECTI ON


Inspect each valve for trueness, burning. scr atches
or abnormal stem wear.
Check t he valve movement in t he guide. Measure
and record each valve stem a.D.

SERVICE LIMITS :
INTAKE :
5.46 mm (0,215 in)
EXCHAUST : 5.45 mm (0.214 in)

611

CYLINDER HEADIVALVES

Measure and record each .... alve guide 1.0. using a


ball gauge or inside micrometer.

NOTE
Ream the guides to remove the carbon buildup before checking the valve guide 1.0.

SERVICE LIMIT :

INTAKE
EXHAUST

5.53 mm (0.218 inl


5,53 mm (0.218 in)

Calculate the stem-taguide clearance.

VALVE STEM-lO-GUlDE CLEARANCE


SERVICE LIMITS :
INTAKE :
0.07 mm (0.0026 in)
EXHAUST : 0.08 mm (0 .0031 Inl

NOTE
If the stem-te-guide clearance exceeds the
service limit, determine if a new guide with

VA LVE GUIDE DRIVER


07742- 0010100

standard dimensions would bring the


clearance within tolerance . If so, replace
guides as necessary and ream to fit.
If stem-te-guide clearance still exceeds the service
limit when new guides ars installed, replace the

valves.
NOTE

Refaee valve seats whenever new valve


guides are installed.

VALVE GUIDE REPLACEMENT


Suppon the cvlinder head and drive out the guide
from the combustion chamber side.
CAUTION

Do not damage (he cylinder head dUring guide


remoyal.
Install a new valve guide from the top of the head,
then check that it wasn't damaged during installation.

612

VALVE GUID E DR IVER


07742- 0010100

CYLINDER HEADIVALVES

Ream the new valve guides after instatlation.

VALVE GU IDE ASAMER


079842000000

NOTE

Use cutting oil on the reamer during this


operation.
Aotate the reamer while inserting and remov~
ing it.
Rafaee the valve seats (Page 6- 13),
Clean the cylinder head thoroughly to remove any
metal particles.

VALVE SEAT INSPECTION


AND REF ACING
Apply a light coating of Prussian Blue to each valve

face. Lap each valve and seat using a ru bber hose or


other hand-lapping tool.
CAUTION

Valves cannot be ground. 1/ the valve face is


burned or badly worn or if il contacts the seat
unevenly, rep/ace the Mfve.

Inspect the width of each valve seat.

SERVICE LIMIT : 2 .0 mm (0.08 in)

Measure the valve face

SERVICE LIMIT: 2.0 mm (0.08 in)


If the seat is too wide, too narrow, or has low spots,
the seat must be refinished for good sealing.
NOTE

Follow the refacer manfacturer's operating instructions.

6-13

CYLINDER HEADIVALVES
VA LVE SEAT CUTTERS

60'

cunER FLAT 30 mm

CUTTER SEAT 29 mrn

CUTTER INTERIOR 30 mm

077800012200

07780001 0300

07780-0014000

VALVE SEAT GRINDING


Using a 45 degree cutter, remove any roughness or
irregularities from the seat .

NOTE
Rafsee the seat with a 45 degree cutter when
the valve guide is replaced.

CUTTER HOLDER
D7781-{)010101

Using a 32 degree cutter, remove 114 of the existing valve seat material.

614

CYLINDER HEAD/VALVES

Use a 60 degree cutter and remove the bottom 1/4


of the old seat.

Use a 45 degree finish cutter and cut the seat to the


proper width.

NOTE
Make sure that all pitting and irregularities are
removed. Refinish if necessary.

"- 1.2- 1.4

mm

'\. (0.05-0.06 in)

NOTE

The location of the valve seat in relation to the


valve face is very imponant for good sealing
and maximum valve service.
Apply a thin coating of Prussian Blue to the vatve

seat.
Press the valve through the valve guide and onto
the seat to make a clear pattern.
Remove to inspect the valve.
If the contact area is too high on the valve, the seat
must be lowered using a 32 degree flat cutter.
Refinish the seat to the correct width using a 45
degree finish cutter.

32"

615

CYLIND ER HEADN ALVES


If the contact area is too Iowan the valve, the seat
must be raised using a 60 degree inner cutter.
Refinish the seat to COHect width, using a 45 degree
finish cutter.

~~~~~~~=

CONTACT TOO LOW

After cutting the seat. applv lapping compound to

the valve face, and lap the valve using light pressure.
After lapping. wash all residual compound off the
cylinder head, valve, and valve guide.

CYLINDER HEAD ASSEMBLY

RETAINER

lubricate each valve stem with oil. then insert the


valvas into the valve guides.

Install new valve stem seals.


Install the valve spring seat. springs and retainers.

The spring's tightly wound coils shou ld face in


toward the combustion chamber.

/~.

STEM SEAL

616

i'

INNER

VALVE

SPR I NG

CUTTERS

CYLINDER HEADIVAlVES
VA L VE SPRING COMPRESSOR
Compress the valve springs using the valve spring

compressor, then install the valve cotters.


CAUTION

To prevt'1II foss oj tension. do not compress the


valve spring move than necessary.

Support the cylinder head above the working


bench surface to prevent possible valve damage,

then gently tap the valve stems with a plastic

hammer to seat the cotters.

CYLINDER HEAD INSTALLATION

-,.

--~.----------~

----------.--."

DOWE L PINS

Clean any gasket material from the cylinder surface.


Install the dowel pins and new gasket.

617

CYLINDER HEAD/VALVES
DOWEL PIN

Install the cylinder head.


Apply engine oi l to the cylinder head bolts and

tighten them in a crisscross pattern in two or more


steps.
TORQUE :
10 mm bolts: 47-53 Nm (4.7-5.3 kg-m,

34-38 ftlbl
Install two dowel pins on the cylinder head.

Make sure that the a-ring on the cylinder head bolt


hole cap is in good condition, then install the cap.

Make sure that the oil pipe and bolts are clean and

the sealing washers are good condition.


Install the oil pipe with six seating washers and three
oit bolts.

618

CYLINDER HEADIVALVES

Install the tensioner set plate and tighten the 'bolts.

TENSIONER SET PLATE

Pull the tip of cam chain tensioner with the pliers

and then, insert the cotter pin into the hole in the
tensioner, as shown.

CAMSHAFT INSTALLATION

RIGHT BEARING

LEFT BE,'HIING

Apply engine oil to the camshaft bearings and install


them onto the camshaft; the sealed bearing goes on
the sprocket right side with the seal facing out.

SEAL FACES OUT

619

CYLINDER HEADIVA LVES


INDEX

CAM SHAFT

Place the cam sprocket outside the cam chain with


its dished face fac ing the right side.
Install camshaft through the sprocket and cam
chain.
Turn the crankshaft and align the "T" mark on the

flywheel with the index notch on the left crankcase

cover.

SPROCKET

CAM SPI'OIFKETBOL T

Align the t iming marks on the cam sprocket with


the upper surface of the cylinder head and install
the cern chain over the sprocket without rotating
Ole sprocket.

Position the cam sprocket ont o the shoulder of the


camshaft and install the cam sprocket bolt.
Turn the crankshaft and install the other sprocket

bolt .
Tighten the sprocket bolts to the specified torque.

TORQUE :

17-23 Nm (1 .7-2.3 kgm,


12-17 ftlb)

TIMING MARKS

Turn the crankshaft and Bligh theT 'mark with the


index notch and make S\Jr8 that the timing marks on
the sprocket align with the upper surface of the
cylinder head.

Remove the pin from the cam chain tensioner.

620

CYLINDER HEADIVALVES

CYLINDER HEAD COVER


ASSEMBLY

ROCKER ARM A

Install the wave washers and rocker arms A and B


as shown.

MARK A

ROCKER ARM B

Apply engine oil to the rocker arm shafts.

Install the rocker arm shafts and copper washers and


tighten the shaft to the specified torque.
TORQUE: 25-30 N'm 12.5-3.0 kg-m,
18-22 ftlb}

621

CYLINDER HEADN ALVES


SUB-ROCKER

WAVE WAISHER'

SUBRoeIKEF ARM A

Install sub-rocker arms A, Band F, and the wave


washers as shown.

SUBROCKER ARM SHAFTS


Apply engine oil to the sub-rocker arm shafts.
Install the sub-rocker arm shafts and sealing
washers and tighten the shafts.
TORQUE :

IN 25 -30 Nm

12.5- 3 .0 kg-m, 18 - 22 fl -Ib)


EX 20 - 25 Nm
(2. 0 - 2 .5 kg-rn, 15 - 18 fl-Ib)

Adjust the valve clearance.


Make sure the O-ring is properly seated in the
groove of the valve cover.

Install the valve covers.

Install the valve lifter lever and spring as shown.


Apply grease to the lifter lever dowel pin to prevent
it from falling into the crankcase when installing the
cylinder head cover.

Align the cut-out of the lever shaft with the hole in


t he cylinder head cover and insert the dowel pin.
Adjust the valve clearance (page 39).

622

CY LINDER HEAD/VALVES

Install the exhaust pipe (page 152) .


Install the carburetor (page 4-15),
Install a new cylinder head cover gasket and dowel
pin.

NOTE
Be carefu l not to damage the silicone coat ing
on the gasket surfaces.
Pour clean engine oil into t he oil pockets in the
cylinder head so that t he com lobes are complete
submerged.

CYLINDER HEAD COVER


INSTALLATION
Clean the cylinder head mating surface of the

cylinder head covel.

Loosen all the valve adjusting screws and install the


cylinder head cover.
Tighten the cylinder head cover bolts to the
specified torque.

TORQUE :
8mmboh :

26-30 N' m

(2.6- 3.0 kg-m, 19- 22 ft -Ib)


6mmboh :

8 - 12 N m
10 .8 - 1.2 kg-m,

6-

9 ft-lb )

NOTE
Tighten the head cover bolts in a crisscross
pattern in two or more steps.

Adjust the valve cfearance (page 3-9),

623

CYLINDER HEADIVA LVES


_ _...,_ _~,.;:U~P;P~ER HANGER PLATE
Install the engine upper hanger plate and Tighen
bolts to specified Torque.

TORQUE :

Install the spark plug cap.


TORQUE : 47-53 N-m 14.7-5.3 kg-m, 34-38 h lb)

1
SPARK PLUG CAP

Connect the decompressor cable to the valve lifter


lever.

Install the fuel tank and seat.


Perform the following inspections and adjustments.
Throttle grip free plug play (page 36) .

Oecompressor cable adjustment (page 3-10).

624

MEMO

CYLINDER/ PISTON

47 - 53 Nm
(4.7- 5 .3 kg-m , 34 - 38 ft lb )

7-0

7. CYLINDER/PISTON
SERVICE INFORMATION

7- 1

TROUBLESHOOTING

7-2

CYLINDER REMOVAL

7- 3

PISTON REMOVAL

7-5

PISTON INSTALLATI ON

7- 9

CYLINDER INSTALLATION

7-9

SERVICE INFORMATION
SPECIFICATIONS
STANDARD

ITEM
Cylinder

1.0.

SERV ICE LIM IT

XR200R

67 .00-67.01 mm (2.638-2.6939 in)

67 .11 mm(2.642in)

XR250R

75.00- 75.01 mm (2.953- 2.954 in)

75.1 t mm (2.957 in)

Taper

0.05 mm (0.002 in)

Out of round

0.05 mm (0.002 i n )

Warpage across top

0.10 mm (0.004 in)

Piston, piston rings and piston pin


Piston 0.0 . at skirt XA20QA

66.960- 66.985 mm (2.6362- 2.6372 in)

66.89 mm (2 .632 in)

XR250R

74.960- 14.985 mm (2.9512- 2.9522 in)

74.88 mm (2.948 in)

Piston pin bore

17.002- 17.008 mm (0.6694-0.6696 in )

, 7.07 mm (0.672 in)

Piston pin-to-piston clearance

0.002- 0.014 mm (0.0001 - 0.0006 in)

0.07 mm (0.003 in)

Top/ second

0.1-0.3 mm (0.004-0.012 in)

0.41 mm (0.016 in )

Oil (Side rail)

0.2- 0.7 mm (0.008- 0.028 in)

0.86 mm (0.034 in)

Top

0.015-0 .045 mm (0.0006- 0.0018 in)

0.12 mm (0.006 in)

Second

0.015- 0.045 mm (0.0006-0.00 18 in)

0.12 mm (0 .006 in)

0.01 - 0.04 mm (0.0004-0.0016 in)

0.10 mm (0.004 in)

17.000- 17.006 mm (0.6693- 0.6695 in)

16.97 mm (0.668 in)

Piston ring end gap

Pisto n ringtogrove clearance

Cyl inderto piston


Piston pin 0 .0 .

Clearance

TORQUE VA LUES
Cyl inder bolt : 47- 53 Nm (4.7-5.3 kgm, 34 - 38ft-lbl

71

CYLINDER/PISTON

TROUBLESHOOTING
low Compre.sWn
1. Worn cylinder

Of

piston rings

Exc ive Smoke


1. Worn cylinder. piston, or piston rings
2 . Improper Installation of piston rings
3. Scored or scretched piston or cylinder wall

Overheating
1. Excessive carbon buildup on piston crown or combust ion chamber
KllOcklng or Abnormal Noise
1. Worn piston and cylinder
2 . Excessive carbon build-up on piston crown or combustion chamber

72

CYLINDER/ PISTON

CYLINDER REMOVAL
Remove the cylinder head (Section 6).

Remove the two cylinder head base mounting bolts.


Remove the cam chain guide.

BOLTS

Remove the four cylinder mounting bolts.


NOTE

Lposen t he bolts in a crisscross pattern in two

or more steps.

Remove the cylinder.

73

CYLINDER/ PISTON

Remove the dowel pins and cylinder gasket.

Clean any gasket material from

th~

cylinder surface.

NOTE

Gasket material will come off easier if it is soak


ed in solvent.

CYLINDER INSPECTION
Inspect the cylinder bore for wear or damage.
Measure the cylinder 1.0.
SERVICE LIMITS :

XR200R: 61.11 mm (2.642 in)


XR250R: 75.11 mm (2.957 in)
NOTE

Check for out of round on the X and Y allis at


three locations.
Calculate the taper and out of round.
SERVICE LIMITS :
OUT OF ROUND :
TAPER :

74

0.05 mm (0.002 In)


0 .05 mm 10.002 in)

CYLINDER / PISTDN

Inspect the top of the cylinder for warpage.


SERVICE LIMIT ;

0. 10 mm (0.004 inl

PISTON REMOVAL
Place dean shop towels in the crankcase to keep

the piston pin clips, o r other parts from falling into


the crankcase.
Remove the piston pin clips with needle nose pliers.
Press the piston pin out of the piston.

CLIP

PISTON/PISTON RING INSPECTION


Remove the piston rings.
Inspect the piston for damage and the ring grooves
for wear.
CAUTION

Pis/on rings ure easily broken; lake care not 10


damage them during removal.

75

CYLINDER / PISTON

Measure the piston ringtagroo .... e clearance.


SERVICE LIMIT :

TOP

0.12 mm (0.006 tnl

2nd

0 .12 mm (0.006 in)

Insen each piston ring into the cylinder. above 20


mm 10.750 in) in fr om the bottom.
To ensure that it's square in the bore, use a piston
to push it in.
Measure the ring end gap.

SERVICE LIMIT :
TOP
0.41 mm (0.016 in)
2nd
0.41 mm (0.016 in)

Measure the piston diameter 10 mm from the bot-

tom.
SERVICE LIMIT :

XR200R : 66.89 mm (2.632 in)


XR250R : 74.88 mm (2.948 inl
Calculate the piston-ta-cylinder clearance by subtracting the piston 0 .0 . from the cylinder 1.0. (Page

SERVICE LIMIT :
0 . 10 mm 10.004 In)

76

CYLINDER/ PISTON

Measure the piston pin hole I.D.


SERVICE LIMIT ;

17.01 mm 10.672 in)

Measure the piston pin 0.0.


SERVICE LIMIT :

16.97 mm (0.668 in)

Calculate the piston-Io-piston pin clearance.

SERVICE LIMIT : 0 .07 mm (0.003 inl

PISTON RING INSTALLATI ON


Clean the piston ring grooves t horoughly by holding
a ring in the grooves while turning the piston.

CAUTION

Do not use a wire bmsh to clean ring lands, or


cut fands deeper with a cleaning 1001.

77

CYLINDER/ PISTON
Install the piston rings with the manufacturing
marks facing up.

~~. _____--r ;raJ

CAUTION

A void pislon and piston ring damage during


ins/al/otion.
Stagger the compression (1 51 an~ 2nd) and oil rings
(side rails) 120 degrees apart as shown.

TOP RI NG

-----~

------....."......

SECONb RING

NOTE

Install the oil ring spacer first, then install the


side rails.

OIL RI NG

After installation, rings should be free to rotate in

the grooves.

PI STON RING

TOP/:~
~.J'r-SSII"O:cE"R'OA I L

:r

.......

~~~~~~~~~SPACER

20mm
ORMORE~____~~

78

SIDE RA il
GAP

CYLINDER /PISTON

PISTON INSTALLATION

"IN" MARK

Install the piston and piston pin. Position the piston


"IN" mark on the intake valve side.
Install new piston pin clips.

NOTE
Do not align t he piston pin clip end gap with

the piston cut-out.


Place a shop towel around the piston skirt and
in the crankcase t o prevent the piston pin
clips from falling into the crankcase.

PISTON PIN

PISTON PIN CLIP

CYLINDER INSTALLATION
Clean any gasket material from the cylinder base
surface.

Apply a liquid sealant to the crankcase mating area

to prevent oilleak5.
Install a new cylinder base gasket and dowel pins.

Place the piston at stet dead center.

79

CYLINDER/ PISTON

COBt the cylinder bore, piston and piston rings with


fresh engine oil.
Carefully lower the cylinder over the piston by com-

pressing the piston rings. one 8t 8 time .


CAUTtON

Do no/ jore(' the cylinder over Q ring: you may


domage the piston Gnd piston ring.

PISTON

Apply engine oil to the cylinder bolts and tighten


t hem in crisscross pattern in two or more steps.

TOROUE : 47 - 53 Nm 14 .7-5.3 kg-m,


34- 38 ft -Ibl

Install the cam chain guide.

NOTE

Fit the cam chain guide tab in the cylinder


cutout as shown.
Push the guide in until it bottoms in t he crankcase guide hole.

InstaU the dowel pins in the top of the cylinder.


Install a new cylinder head gasket.
Tighten the cylinder base bolts .

Instan the cylinder head IPage

710

617).

..,

MEMO

CLUTCH/ OIL PUMP/ KICK STARTER

22-26 Nm (2 .2- 2 .6 kg -m.


16- 19 ft -Ib)

8- 12Nm (0 .8 - 1.2 kg-m ,

6- 9 ft -Ib)

50- 60 Nm (5.0- 6.0 kg-m .


36-43 ftlb)

8- 12 Nm (0.8- 1.2 kgm ,


6- 9 ftlb)

8-0

8. CLUTCH/OIL PUMP/KICK STARTER


SERVICE INFORMATION

8-1

TROUBLESHOOTING

8-2

RIGHT CRANKCASE COVER REMOVAL

8-3

CLUTCH

8-5

OIL PUMP

8-10

DRIVE GEAR

8- 19

KICK STARTER

8-21

GEAR SHIFT CAM PLATE

8-26

RIGHT CRANKCASE CDVER INSTALLATION

8 - 27

SERVICE INFORMATION
GENERAL
This section covers removal and installation of the dutch, oil pump. kick starter, and right crankcase cover. AU these opera

lions can be accomplished with the engine installed .


When the existing clutch discs are replaced, coat new discs with engine oil prior to assembly_

ITEM
Clutch

STANDARD

Lever free play (at lever end)

Spring free length

Spring preload/length

10 20 mm (3/8-3/4 in)
33.7 mm (1.33 in)
29.7 kg/2 1 mm (65.5Ib/D.S3 in)

SERVI CE LIMIT

32 .2 mm (1.27 in)

Disc thickness
Plate warpage
Clutch outer I.D.

2.92-3.08mm (0. 11 5-0. 121 in)

2.69 mm (0. 105 in)

25.000-25.021 mm (0.9843-0.9851 in)

0.30 mm (0.01 in)


25.04 mm (0.986 in)

Outer guide 0.0.

24.959-24.980 mm (0.9826-0.9835 in)

24.17 mm 10.952 in)

I.D.

20.0 10-20.035 mm 10.7878-0.7888 in)

19.90 mm 10.783 in)

Oil pump
0.15 mm (0.006 in) max.

0.20 mm (0.008 in)

Outer rotortobody clearance

0,10-0.21 mm 10.004-0.008 in)

0.25 mm (0.010 in)

Rotorto-cover clearance

0.02-0.0!:J mm 10.00 1- 0.003 in)

0.12 mm (0.005 in)

Starter idle gear I.D.

19.0 10 - 19.034 mm 10.7484-0. 7494 in)

19.13 mm (0.753 in)

Starter idle gear bushing I.D.

15.000- 15.018 mm (0.5906-0.59 13 in)

14.97 mm (0.589 in)

Inner rotortoouter rotor clearance

Kick starter

O.D.

18.959-18.980 mm (0.7464-0.7472 in)

18.92 mm (0.745 in)

Kick starter gear I.D.

22.020-22.041 mm (0.8669-0.8678 in)

22.12 mm (0.871 in)

Kick starter spindle O.D.

21.959-2 1.98 mm (0.8645-0.8654 in)

21.91 mm (0.863 in)

81

j
CLUTCH/OIL PUMP/ KICK STARTER
TORQUE VALUES
Clutch lock nut
Drive gear lock nut
Right crankcase cover
Stopper arm bolt

50 - 60
50 - 60
8 - 12
22-26

Nm
Nm
N-m
N'm

15.0 - 6 .0 kg-rn, 36 - 43 ft-lb)


15.0 - 6.0 kg-m, 36 - 43 It-Ibl
(0.8 - 1.2 kg-m, 6- 9 ft -Ib)
(2.2- 2.6 kg-m, 16- 19 ft- Ib)

TOOLS
SPE CIA L
Clutch center holder

07923 - KE 10001 OR

07724-05000 00

(Commercially available in U .S.A.)

COMMON
lock nut wrench, 20 X 24 mm
Extension
Flywheel holder

07716-0020 100 (Commercially available in U.S.A.)


07716 - 0020500 (Commercially available in U.S.A.!
07725-0040000 (or band strap wrench commercially
available in U.S.A ,)

TROUBLESHOOTING
Faulty clutch operation can usually be corrected by adjusting the clutch lever free play.

Clutch Slips When A ccelerating


1. No free play

2. Discs worn
3. Springs weak
Clut ch Will not Dlsengege
1. Too much free play
2. Plates warped
Motorcvcle Creeps With Clutch Disengaged
1. Too much free play
2. Plates warped.
Excessive l ever Pressure
1. Clutch cable kinked, damaged or dirty
2. lifter mechanism damaged
Clutch Operation Feels Rough
1. Outer drum slots rough
2. Dirty clutch cable
l ow oil Pressure
1. Faulty oil pump
2 . Oil pump drive gear broken

I
I

8-2

CLUTCH/OIL PUMP/ KICK STARTER

RIGHT CRANKCASE COVER REMOVAL


Drain oil from the engine and oil tank (Page 22).
Remove the kick starter pedal.
Disconnect the rear brake rod.
DisconneCt the decompressor cable at the kick
starter lever.
Disconnect clutch cable from clutch arm.

Remove the oil pipe bolt and sealing washers on

right crankcase cover.

OILPIPEBOLT

Remove the right foot peg bohs and foot peg.


Remove the bolts holding the right crankcase cover.
and remolle the cover.

Remove the oil pipe from the right crankcase cover.

Remove the dowel pins and gasket.

GASKET

83

CLUTCH/ OIL PUMP/ KICK STARTER


CAM FOLLOWER
SNAP RING

SHAFT

CAM FOLLOWER SHAFT OISASSEMBLY


Remove the snap ring, cam, retu rn spring and camshaft.

j
CAM

SPRING

CLUTCH LIFTER ARM DIASSSEMBLY


Remove the clutch lifter pin, clutch spring and

clutch lifter arm.

SPRING

Remove the bolt and oil seal setting plate.

LIFTER ARM

I
84

CLUTCH/ OIL PUMP/ KICK STARTER

CLUTCH
REMOVAL
Remove the four clutch bolts and springs.
Remove the clutch lifter collar and clutch lifter
plate.

NOTE

Loosen the bolts in a criss cross pattern in


2-3 steps.

CLUTCH LIFTER COLLAR


Check the needle bearing for wear, excessive play or
damage and replace if necessary.
Remove the clip, needle bearing and washer from
clutch lifter co llaL

NElW l :E BEARING
EXTENS ION 07716-0020500 OR
ACIALLYAVAILABLE IN U.S.A .
Temporarily install the foot peg

Attach the clutch center holder to the pressure plate


with four clutch bolts and remove the lock nut.
Remove the clutch center holder .

CLUTCH
HOLDER 07923-KE10001
OR COMMERC IALLY AVA ILABLE IN U.S.A.

8-5

CLUTCH OIL PUMP/ KICK STARTER

Remove the lock washer. Then remove the clutch

assemblv.

Remove the clutch center, discs, plates thrust


washer and pressure plate from clutch outer.

..

Remove the clutch outer guide and clutch outer


gear from the mainshaft.

CLUTCH OUTER GEA R

86

CLUTCH/ OIL PUMP/ KICK STARTER


INSPE CTIO N
SPRIN GS
Measure the free length of each spring.
SERV ICE LIMIT: 32.2 mm (1.27 in)

Replace if shorter than the service limit.


NOTE

Clutch springs should be replaced as a set if


one or mo re is beyond the ser'lice limit.

CLUTCH DISC
Replace the discs if they show sings of scoring or

discoloration.
Measure the d isc thickness.
SERVICE LIMIT: 26.9 mm (0.105 in)

NOTE

Clutch discs and p lates should be replaced as a


set if anyone is beyond the service limit.

CLUTCH PLATE
Check fo r plate warpage on a su rface plate, using a
feeler gauge.
SER V ICE LIMIT: 0.30 mm 10.01 in)

87

CLUTCH/ OIL PUMP/ KICK STARTER

CLUTCH OUTER AND OUTER GUIDE


Check the slots in the outer drum for nicks, cuts or
indentations made by the friction discs.
Measure the I.D. of the clutch outer gear and t he

1.0. and 0.0. of the outer guide.


SERVICE LIMIT

CLUTCH OUTER GEAR

25.04 mm (0.986 in)


OUTER GUIDE 0 .0. 24.17 mm (0.952 in)
I.D. 19.90 mm (0.783 in)

INSTALLATION
Install the clutch outer gear and the clutch outer

guide.

CLUTCH OUTER GUIDE

~~

I
CLUTCH OUTER GEAR

Install the thrust washer onto the clutch outer.


Install the clutch discs, plates and pressure plate on

the clutch center.


NOTE

Stack the discs and plates alternately as


shown.
Coat new clutch discs wi t h engine oil.

88

CLUTCH/ OIL PUMP/ KICK STARTER


CLUTCH PRE5"UFIE PLATE

Install the dutch center into the clutch outer by


aligning the tabs on the discs with the slots of the
clutch outer.

CLlJT(;H OUTER

CLUTCH CENTER

LOCK W <HER

Install the clutch assemblv on the maiHshaft.


Install the lock washer with the mark "out side"
facing Qut.

G~~~~~~10RIN U .S.A.

'=.!
Install the clutch center holder to the clutch center.
Tighten the lock nut to the specified torque.

TORQUE : SO-60 Nm (5.0-6.0 kgm.


36-43 ftlbl
Remove the clutch center holder.

79:'~~:~)'?~~~.~~OR 07724
HOLDER
- 0050000
OR COMMERC IALLY AVA IL ABLE IN U.S.A.

89

CLUTCH/OIL PUMP/ KICK STARTER

Install the clutch lifter plate.


Install the clutch bolts in crisscross pattern in 2- 3
steps .
TOROUE : 8- 12 Nm (0.8- 1.2 kg-m, 6-9 ft.J b)
Install the clutch l ifter collar.

OIL PUMP
OIL PUMP REMOVA L
Remove the clutch (Page 8-51.
Remove the oil pump cover.

Remove the oil pump driven gear.

Remove the dowel pin and D-ring.


Remove the bolts attaching t he oil pump and the oil
pump from the right crankcase.

810

CLUTCH/ OIL PUMP/ KICK STARTER


OIL PUMP SEAT

Remove the dowel pins and oil pump seat.

DOWEL PINS

'84'
OIL PUMP DISASSEMB LY

811

CLUTCH/OIL PUMP/ KICK STARTER

Remove the oi l pump body screws.

'84 :
OIL PUMP INSPECTION

ROTOR

Measure the tip clearance between t he inner and


outer rotors.
SERVICE LIMIT: 0.20 mm (0.008 in)

RO TOR

Measu re the clearance between the outer rotor and


the pump body.

SERV ICE LIMIT: 0.25 mm (0.010 in)

PUMP

812

CLUTCH/OI L PUMP/ KICK STARTER

Measure the pump end clearance.

SERVICE LIMIT: 0 .12 mm (0.005 in)

'84:

DOWE L PIN

OI L PUMP ASSEMBLY
Insta l l the inner and outer rotors in the pump body.

Install the dowel pin on the pump body.

ROTO R

ROTOR

Slide the pump gear shaft through the pump cover

and install the cover on the body.

Tighten the cover screws.

813

CLUTCH/OIL PUMP/ KICK STARTER

After '84:
OIL PU MP DI SASSEMBLY

Remove the oil pump body screws.

OUTER RO'fOR B

INNER ROTOR B

RemOlle the oil pump cover from the oi l pump

body .
Remove the outer rotor B and inner rotor B from
the oil pump cover.

OIL PUMP COVER

814

CLUTCH/ OIL PUMP/ KICK STARTER


INNER ROTOR A

DOWEL PIN

Remove the plate from the oil pump body.


Remove the inner rotor A and outer rotor A from

the oil pump body.


Remove the dowel pin.

OUTER ROTOR A

OIL PUMP PLATE

After '84 :
INSPECTION
~easure the tip clearance between the inner and
outer A rotors.

SERV ICE LIMIT : 0.20 mm (0.008 in)

INNER

Measure the clearance between the outer rotor A


and the pump body .

SERV ICE LIMIT : 0.25 mm (0.010 in)

QUTE R ROTOR A

8-15

CLUTCH/OIL PUMP/ KICK STARTER


STRAIGHT EDGE

Measure the end ctearance of rotors A.


SERVICE LI MIT: 012 mm (0.005 in)

OUTER ROTOR 8

Install the rotor shaft and measure the tip clearance


between the inner and outer B rotors.
SERV ICE LIM IT: 0.20 mm (0.008 in)

INNER ROTOR B

Measure the clearanC1! between the outer rotor B


and the pump cover.

SERV ICE LIMIT: 0.25 mm (0.010 in)

OUTER ROTOR B

816

CLUTCH/ OI L PUMP/ KICK STARTER


<TO'.,o."T EDGE

Measure the end clearance of rotors 8.


SERV ICE LI MI T : 0 .12 mm (0.005 in)

ASSEMBLY

Oil PUMP BODY

Install the inner and outer rotors A into the oil


pump body .
Install the dowel pin and oil pump plate on the oil
pump body .

DOWE L PIN

OIL

PLATE

Install the oil pump shaf in the oil pump cover.


Install inner and outer rotors B i n the oil pump

shafe. then slip the oil pump body onto the cover.
Tighten the three oil pump screws.

OIL PUMP COVER

817

CLUTCH/OIL PUMP/ KICK STARTER

OIL PUMP INSTALLATION


Install the oil pump seat and dowel pins.

Install the oil pump onto the oil pump seat and
tighten the three bolts.
Install the dowel pin and a newaring.

Install the oil pump driven gear over the oil pump

shaft.
Install the oil pump gear cover.
Install the clutch (Page 88).

OIL PU M

818

p'GEA:R'C:Dim:-

CLUTCH/OIL PUMP/ KICK STARTER

DRIVE GEAR

FLYWHEEL HOLDER

REMO VA L
Remove the dutch (Page 8-5).
Remove the left crankcase cover (Page 92).
Hold the flywheel with the flywheel holder.

Remove the oil pump cover.


Remove the oil pump driven gear.

Remove the primary drive gear lock nut, lock


washer, oil pump driven 9f!ar and pulse generator

rotor.

Remove the primary drive gear.

Remoye the pulse generator from right crankcase.

819

CLUTCH/ OIL PUMP/ KICK STARTER

INSTALLATION
Install the primary drive gear over the crankshaft.
Install the pulse generator and tighten two bolts.
Route the pulse generator wire and install the wi re
gramet into the groove in the right crankcase as
shown.

NOTE
The primary dri ve gear, pulse generator rotor,

and oil pump drive gear will only go on in one


position because of the extra-wide aligning
spline.

PULSE GENERATOR ROTER

Install the pulse generator roter. Install the


lock washer

"our SIDE" facing out.

Install the lock nut and tighten to the specifie tor-

Que .
TORQUE: 50- 60 N'm
(5.0-6.0 kgm, 36- 43 ft lb)
Remove the flywheel holder and install the left

crankcase cover.
Install the oil pump cover.
Install the oil pump driven gear.

Install the clutch (Page 8-8).

820

CLUTCH/ OIL PUMP/ KICK STARTER

KICK STARTER
DISASSEMB LY
Remove the clutch (Page 85).

Remove the thrust washer, kick starter cam, spring


and spring seat from the spindle.

Install the kick starter pedal on the kick starter


spindle.
Pull the pedal out while rotating it counterclockwise

until the kick drive ratchet is released fr om the


stopper plate. Turn the spindle clockwise until it
will no longer go.
Release the hook end of the return spring from the

crankcase groove; remove the kick starter spindle.

l
SPRING

Remove the stopper plate, starter _die gear and

bushing.

821

CLUTCH/ OIL PUMP/ KICK STARTER

Remove the collar, return spring. spring seat, rat


chet spring and ratc het from the spindle.

RFTURN SPR ING

Remove the snap ring, washer and pinion gear from


the spindle.

SNAP

Measure the 1.0. of the kick starter gear.

SERVICE LIMIT: 22.12 mm (0.871 in)

Measure the 0 .0. of the kick starter spindle.


SERVICE LIMIT: 21 .91 mm (0.863 in)

822

COLLAR

CLUTCH/OIL PUM P/ KICK STARTER

INSPECTION
Measure the I . 0 . ofthek ' k

SERVICE LIMIT '


Ie starte idle gear
. 19.13mml 0.753 in)
.
M

easure the I. 0 . andOD f


SERVICE LIMIT'
. . 0 the Idle gea bush
1.0. 1497 .
Ing
.
mm(O
0.0. 1892
.589 in)
.
mm (0.745 in)

ASSEMBLY

KICK STAR1'." GEAR

ER

Install the th rust washer k'


washe
r and snap ring 0 ver theIck
starter gear ' thrust
spindle

SNAP

823

CLUTCH/ OIL PUMP/ KICK STARTER


RATCH ET

Align the punch marks on the ratchet and the spindle and install the ratchet over the spindle.

PU"CH MARK
RA-rCHET SP RIN G

Install the ratchet spring and spring seat.


Instal! the return spring and insert its end into the

hole in the spindle.


Install the collar aligning its groove with the spring
end inserted into the hole in the spindle.

AN SPR ING
IDLE GEAR BUSHING

INSTALLATION
Install the stane idle gear bushing with its flange
facing in.

824

CLUTCH/OIL PUMP/ KICK STARTER

Install the starter idle gea and stopper plate.

Hook the kick starter return spring on the crankcase.


Temporarily install the kick starter pedal on the
kick shaft and rotate the shaft counterclockwise
until the ratchet stub is clear of the stopper plate.
Push the kick starter assembly into the crankcase.

WASHER

Install the spring seat and cam spring.


Align the punch marks on the starter cam and the
spindle and install the starter cam.

,.

CAM

THRUST WASHER

825

CLUTCH/OIL PUMP/ KICK STARTER

GEAR SHIFT CAM PLATE


REMOVAL
Remove the clutch (page 85).

Remove the stopper arm pivot, stopper arm, washer


and spring.

RemOlle the bolt and gear shift cam.


Remove the dowell pin on the gear shift drum.

INSTA LL ATION
Install the dowel pin onto the hole of the shift
drum.
Align the hole in the gear shift cam with the dowel
pin on the shih drum and install the cam plate .

826

CLUTCH/ OIL PUMP/ KICK STARTER

Apply locking agent to the threads of the gear shift

cam bolt and tighten it.

Install the spring, washer, stopper arm and pivot.

Tighten the stopper arm bolt .


TORQUE: 22- 26 N-m
(2.2-2.6 kg-m , 1S-19ft-lb)
Install the clutch (page 8-8 ).

RIGHT CRANKCASE COVER


INSTAllATION
Clean the oil filter screen and install it.

Apply liquid sealer to the crankcase cover matering

surface and install the dowel pins and gasket.

GASKET

827

CLUTCH/OIL PUMP/ KICK STARTER

Install the right crankcase cover while pushing the

cam follower lever down.


Check the operation of the decompression and
clutch levers after installing the cover.
Tighten the right crankcase cover bolts.

TOROUE: 8-12 N' m (0.8- 1.2 kg m. 6-9 ftlbl


Install the right foot peg.

CAM FOLLOWER LEVER

Make sure that the oil pipe and oil pipe bolt are
clean and the sealing washers are in good condition.
Tighten the oil pipe bolt with two sealing washers.
Connect the decompressor cable to the cam fol lower leller.
Connect the clutch cable to the clutch lever.

Install the kick starter.


Connect the rear brake rod.

Fill the engine with the recommended oil (Page

2-2)_
Adjust the starter decompressor (Page 3.10).
Adjust the clutch free play (Page 319).
Adjust the rear brake (Page 3-17) ,

828

MEMO

ALTERNATOR

80- 100 Nm
58- 72 ft. lb)
(8.0- 10.0 kg m.

8- 12 Nm
6 9 ft .l b)
(0.8 1.2 kgm.

9-0

9. ALTERNATOR
SERVICE INFORMATION

9- 1

LEFT CRANKCASE COVER REMOVAL

9- 2

ALTERNATOR STATOR REMOVAL

9- 2

FLYWHEEL REMOVAL

9- 3

FLYWHEEL INSTALLATION

9- 3

ALTERNATOR STATOR INSTALLATION

9- 4

LEFT CRANKCASE COVER INSTALLATION

9- 4

SERVICE INFORMATION
GENERAL
This section pertains to removal and installation of the alternator. These operations can be accomplished with the engine in
the frame after removing the left crankcase cover.

For alternator inspection, refer to section 16.

TORQUE VA LUES
Flywheel

SO- 100 Nm (8.0-10.0 kg-m, 58- 72 ft-fb)

Left crankcase cover

8-12 Nm (0.8-1.2 kg-m, 6-9 ftlb)

TOOLS
COMMON
Flywheel holder

07725 - 0040000 or Band Strap wrench (commercially


available in U.S.A.)

Rotor Pulier

07933-3000000

91

ALTERNATOR

LEFT CRANKCASE COVER REMOVAL


Remove the seat and fuel tank. l oosen the wire
band attaching frame and disconnect the alternator

wire connectors.
Remove the alternator wire from frame by unhooking its clamp.

Disconnect the clutch cable.


Remove the drive sprocket and left crankcase

cover.

ALTERNATOR STATOR REMOVAL


Remove the three screws attaching the alternator
stator to the Jeft crankcase and the stator.

92

A LTERN ATOR

FLYWHEEL REMOVAL

FLYWHEEL HOLDER 07725-0040000 OR


IN U.S.A.

Hold the flywheel wi th the f lywheel holder.


Remove the flywheel bolt.

Remove the fly wheel using the rotor puller.

FLYWHEEL HOLDER 07725-0040000 OR

FLYWHEEL INSTALLATION

ROTOR PULLER
07933-3000000

COMMERCIALLY AVAILABLE IN U.S.A.

Install the flywheel by a ligning the woodruff key on


the crankshaft with the flywheel keyway.
Hold the flywheel with the flywheel holder and
tighten the flywheel bolt.

TORQUE;

t"

80- 100 N-m


(8.0- 10.0 kg-m, 58-72 ft-Ib)

9-3

ALTERNATOR

AlTERNATOR STATOR INSTALLATION

SCREWS

Install the stator onto the left crankcase cover and


tighten the three screws.
Route the stator wire and install the wire grommet
into the groove in the cOlier as shown.

RE GROMMET

LEFT CRANKCASE COVER


INSTALLATION
I nstall the two dowel pins and a new gasket.

DRIVE SP ROCK ET COVER


Install the left crankcase cover end tighten the
cover bolts.

TORQUE : 8-12 N-m


(0.8- 1.2 kg-m , 6-9 ft.lb)

Install the drive sprocket cover and tighten the


cover bolts.

Connect the alternator wire connector and install


the wire bands on the frame .

Install the fuel tank and seat.


Fill the engine with the recommended oil (Page

2-21 .

9-4

MEMO

CRANKCASE/CRANKSHAFT/ BALANCER

10-0

10. CRANKCASE/CRANKSHAFT /BALANCER


SERVICE INFORMATION

10- 1

TROUBLESHOOTING

10- 2

CRANKCASE SEPARATION

10- 3

BALANCERI CRANKSHAFT REMOVAL

10- 5

CRANKSHAFTI BALANCER INSTALLATION

10- 9

CRANKCASE ASSEM BL Y

10- 10

SERVICE INFORMATION
GENERAL
The crankcase must be separated to repair the crankshaft, connecting rod, transmission and balancer.
Remove the following parts before separating the crankcase.
ENGINE REMOVAL ................... ................... .. .... ... .. .. . ... Section 5
CYLINDER HEAD ...................................................... , ....... Section 6
CYLINDER/ PISTON . ... ... ... . ... . .... .. .. .... .. .. ... . ... .. .. .. .... ... ....... Section 7
CLUTCH /OIL PUMP/ KICK STARTER
....... . Section 8
ALTERNATOR ....... . ....... ....... . ......... . ............................... Section9

SPECI FICAT IONS


ITEM
Crankshaft

STANDARD

SERV ICE LIMI T

Connecting rod big end side


clearance

0.050- 0.650 mm (0.0020-0.0256 in)

0.80 mm (0.031 in)

Connecting rod big end


radial clearance

0.006- 0.018 mm (0.0002-0.0007 in)

0.05 mm (0.002 in)

Connecting rod small end


1.0.

17.016- 17.034 mm (2.6699-O.6706 in)

17.06 mm (0.672 in)

Crankshaft runout

O.l Omm (0.004 in)

TORQUE VA LUES
Crankcase

10-14 Nm (1.0-1.4 kg-m, 7- 10 ftlb)

TOOLS
SPECIAL

Bearing remover, 15 mm
Remover weight
Thread adapter
Shaft puller
Fork seal driver

07936-KC10500 (USA only)


07936 - 37 10200
07931 - K F00200
07931 - ME40000
07947 - 1310000

COMMON

Driver
Attachment, 32 x 35 mm
Attachment, 62 x 68 mm
Pilot, 15 mm

07749- 001 0000


07746- 00 10 100
07746-00 10500
07746-0040300

101

I
CRANKCASE/ CRANKSHAFT/ BALANCER

TROUBLESHOOTING
ellc8ulve Noise

1. Crankshaft
- Worn connection rod bearings.
- 8enl connecting rod .
- Worn crankshaft bearings .
2. Balancer
- Improper installation .

I
I

1
10-2

CRANKCASE /CRANKSHAFT/ BALANCER

CRANKCASE SEPARA nON


Remove the bolt attaching the cam chain tensioner
and remoye the tensioner.
Remove the cam chain and cam chain drive sprocket.
Remove the brea ther plate from the right crankcase.

Remove the bearing set plate.

Remove the bolts attaching the drive sprocket fixing plate.


Remove the plate and sprocket.

___

0;

103

CRANKCASE/C RANKSHAFT/ BALANCER

Remove the left crankcase bolts.

Place the left crankcase side down and separate the


right crankcase from the left crankcase white tapp-

ing them at several locations with a soft hammer.


CAUTION

Do IlOt pry between the left and right

crankcases.

LEFT CRANKCASE
DOVVEL PINS
Remove the gasket and dowel pins.

104

CRANKCASE/CRANKSHAFT/ BALANCER

BALANCER/ CRANKSHAFT REMOVAL


Remove the transmission (Section 111.

Remove the crankshaft and balancer from the left


crankcase with a press.
CAUTI ON

Be careful not to damage the crankcase gasket

surface.

COMMERCIALLY AVA ILABLE IN U.S.A.


Remove the left crankshaft bearing with a bearing
puller if it is removed with the crankshaft. Discard
the bearing.

CAUTION

Always rep/ace the left bearing with a new


one if it is removed with the crankshaft.

105

CRANKCASE/CRANKSHAFT/ BALANCER

CRANKSHAFT INSPECTION
Set the crankshaft on a truing itand or V blocks and
measure the runout using a dial indicator.
SERVICE LIMIT: 0.10 mm (0.004 in)

Measure the connecting rod big end side clearance


with a feeler gauge.
SERVICE LIMIT: 0 .80 mm (0.031 in)

Measure the connecting rod big end radial clear-

ance.
SERV i ce LIMIT: 0.05 mm (0.002 in)

106

CRANKCASE /CRANKSHAFT/ BALANCER

Measure the 1.0. of the connecting rod small end.


SERVICE LIMIT: 17.06 mm (0.672 in)

Spin the crankshaft bearings by hand and check for


play.
A bearing must be replaced if it is noisy.

-t

-rr~

IT

,
,

II

1('1

Cl1:

AXIAL

RADIAL

BALANCER GEAR INSPECT ION


Check the balancer gear for wear or damage.

107

CRANKCASE /CRANKSHAFT/ BALANCER

BEAR ING RE PLACEM ENT


Remove the crankshaft bearing from the right
crankcase.

Remove the left crankshaft bearing if it is left on


the crankcase.

RIGHT CRANKCASE BEARING

RIGHT BALANCER BEARING

Remove the right and left balancer bearing with the


special tool.

BEARING
R, 15 mm07936-KC10SOO
REMOVER WEIGHT 07936-37 10200

A 07749-00 10000
Install new crankshaft bearings into the crankcases.

ATTACH
,62x6Bmm
07746-00 10500

108

CRANKCASE/CRANKSHAFT/ BALANCER
Install the balancer bearings into the right and left
crankcases.

DRIVER

x 35 mm 07746--00 10100

PILOT, 15 mm 07746-0040300

CRANKSHAFT /BALANCER INSTALLATION


Clean the crankcase mating surfaces before assembl
ing and check for wear or damage.

NOTE

If there is minor roughness or irregu larities


on the crankcase mating surfaces, dress
them with an oil stone.
After cleaning, lubricate the crankshaft
bearings and other contacting surfaces with
clean engine oil.

Install the crankshaft into the left crankcase with


the balancer into the left crankcase aligning the line
on the crankshaft weight with balancer shaft.

CRANKSHAFT WEIGHT

LINE

BALANCER GEAR

109

CRANKCASE/CRANKSHAFT/ BALANCER

Install the crankshaft into the right crankcase with


a special tool while aligning the mark on balancer
outer gear with the mark on crankshaft balancer
gear.
Install the transmission (Section 11 )

THREAD ADAPTER 0793 1-KFOO200


SHAFT PULLER
07931-ME40000
FORK SEAL DR I VER 07947-1310000

NOTE

As hammers damage the crankshaft. it is neces


sary to use a special tool to install it.

CRANKCASE ASSEMBLY

DD!~EL

PINS

Install the transmission (page 1 ' 7).

Install the two dowel pins and a new gasket.

GASKET

Assemble the right and left crankcases being careful


to align the dowel pins and shafts.
CAUTION

Don 'f force the crankcase halves together; if

Ihere is excessh'e force required, something is


wrong. Remove the r;gllt crankcase and check
for miwligned parts.

1010

CRANKCASE/C RANKSHAFT/ BALANCER

Install and tighten the left crankcase bolts in a


crisscross pattern in 2-3 steps.

TORQUE: 10- 14 N' m

'1 ,0- 1.4 k g-m , 7- 10 ft-Ib}

Install the drive sprocket with the fixing plate and


bolts.

BREATHER PLATE
Install the bearing set plate on the mainshaft

bearing.

BEARING SET PLATE

1011

CRANKCASE /CRANKSHAFT/ BALANCER

Install the breather plate on the right crankcase.

Install the cam chain drive sprocket.


NOTE
The cam chain drive sprocket will only go on
one position because of extra-wide aligning
spline.

Install the cam chain.

Install the bearing set plate, cam chain tensioner and


bolt.

DR IVE SPROCKET

1012

CAM CHAIN

MEMO

TRANSMISSION

11-0

11. TRANSMISSION
SERVICE INFORMATION

11 - 1

TROUBLESHOOTING

11 -2

TRANSMISSION DISASSEMBL Y

11 - 3

TRANSMISSION ASSEMBL Y

11 - 7

SERVICE INFORMA liON


GENERAL
The crankcase must be separated to service the transm ission .

The gear sh ift cam plate can be ser viced w ith (he engine i nstall ed in the frame (Section 8).

SPECIFICATIONS
mm (i n )

XR250R

XR200R

ITEM

STANDARD
M5
M6
Cl
C3
C4
C2

Gear I.D .

SERVICE LIMIT

22.020-22.041 (0.8669-0.8678)
23.020-23.041 10.9063- 0.9071)
23 .000- 23 .021 10,9055- 0.9063)

22.08 (0.869)

23 .09 (0.909)

23 .07 (0.908 )

22.020- 22.041 (0.8669-0.8678)

22.08 (0.869)

22.020- 22.041 (O.B669 T O.8678)

22.08 (0.869)

22.014- 22.020
(0.7880- 0.7882)

22 .08 (0.869)

25.020- 25.041
22.959- 22 .980
22.951 - 22.980
22.020- 22.041
24 .972- 24 .993
0 .040-0.082
0.020- 0.070
0.027- 0.069
2 1.959- 21.980
21 .959 21.980
21 .959- 21 .980
21.959- 21.980
0 .040- 0.082
0 .040- 0.082

25.09 (0.98B)

(0.9850- 0.9859)
(0 .9039- 0 .9047)
(0 .9035- 0 .9047)
(0.8669-0.8678)
(0 .9831-0.9840)
(0.0016- 0 .0032)
(0.0008- 0.0028)
(0.0011-0.0027 )
W.8645- 0.8654)
(0.8645 0 .8654)
(0 .8645- 0.8654 )
(0.8645- 0.8654)
(0 .0016- 0 .0032)

(0 .0016-0.0032)
0 .040- 0.082 (0.0016- 0 .0032)

C2

0.061 - 0.082 (0.0024- 0 .0032)

1.0.
0.0.

13.000- 13.021 (0.5118-0. 5126)

Cl0.0.

C2 1.0.
0 .0.

M6
Cl
C2
Mainshaft 0 .0.
M5
Counter shaft 0.0. C2
C4
C3
M5
Shafttoilear
clearance
C3
C4
Gear to
bushing clearance

Shaftto bushing
clearance
Shift fork
Shift fork shaft
Shift fork claw
thickness

STANDARD

22.92 (0.902)
22 .90 (0.90 1)
21.98 (0.865)
24 .90 (0.980)
0. 10 (0.004)
0.10 (0.004)
0.10 (0.004)
21.91 (0.863)
21.91 (0.863)
21.9 1 (0.863)
21.91 (0.863)
0.15 (0.006)
0.15 (0.006)
0.15 (0.006)

0.0.

Gear bushing M6

SERV ICE LIMIT

III

0 .15 (0.006)

12.966- 12.983 (0.5105-0.5111 )

13.05 (0.5 14)


12.90 (0.528)

4.930- 5.000 (0.1941 - 0 .1969)

4.5 (0.18)

111

TRANSMISSION

TOOLS
SPECIAL
Bearing remover, 15 mm

07936-KC10500 (U.S.A. only)

Remover weight

07936-3710200

COMMON
Driyer
Attachment, 32 x 35 mm
Attachment, 37 x 40 mm

Attachment, 42 )( 47 mm
Pilot, 15 mm
Pilot, 17 mm
Pilot, 20 mm

Pilot, 22 mm

07749--00 10000
07746-0010100
07746-0010200
07746-0010300
07746-0040300
07746-0040400
07746-0040500
07746-004 1000

TROUBLESHOOTING
Hard to Shift
1.

Improper clutch adjustment; too much free

2.
3.

Shift forks bent


Shift shaft bent

4.

Shift drum cam groove damaged

play

112

Transmission Jumps Out Of Gear


1. Gear dogs worn
2. Shift shaft bent
3.

Shift drum stopper broken

4.

Shift forks bent

TRANSMISSION

TRANSMISSION DISASSEMBLY

SHIFT FORK SHI'. I

Separate the crankcase (Section 10).


Remove the shift fork shaft, then remove the shift
forks and shift drum.

Remove the gear shift spindle.

COUNTER
Remove the mainshaft and countershaft as an assembly.

Disassembly the mainshaft and countershaft.

113

TRANSMISSION

IN SP ECTION
Check each gear dog for excessive or abnormal wear.
Inspect the 1.0. of each gear.
SERVICE LIMIT:
M5

22.08 mm 10.869 in)

M6

23.09 mm (0.909 in)

Cl

23 .07 mm (0.909 in)

C3

22 .08 mm (0.869 in)

C,

22 J8 mm (0.869 in)

C2

25 .09 mm (0.988 in)

Measure the 1.0 . and 0 .0. of each gear bushing.


SERVICE LIMIT

M6 0 .0 . 22.92 mm (0 .902 in)

Cl 0 .0 . 22.90 mm (0.901 in)


C2 1.0.

21 .98 mm (0.865 in)

C2 0 .0 . 24 .90 mm (0 .980 in)

Calculate the clearance between the gear and bush


ing.

SERVICE LIMIT: M6: 0.10 mm (0.004 in)


Cl : 0.10 mm (0.004 in)

C2 : 0 ,10 mm (0.004 in)


Measure the mainshaft and countershaft 0 .0 .
SERVICE LIMIT:
A M5: 21 .91 mm (0.863 in )
B C2 : 21 .91 mm (0.863 in)
C C4 : 21 .91 mm (0.863 in)
o C3 : 21 .91 mm (0.863 in)
Calculate the clearance between t he shaft and gear
or bushing.
SERVICE LIMIT:
M5: 0.15 mm (0.006
C3 : 0.15 mm (0.006
C4 : 0.15 mm (0.006
C2 : 0 .15 mm (0.006

114

in)
in)
in)
in)

TRANSMISSION

Measure the 1.0. of the shift fo rk .


SERVICE LIMIT: 13.05 mm (0.514 in)

Measure the th ickness of the shift fork claw.


SERV ICE LIMIT: 4.5 mm (0. 18 in)

Measure the 0, 0 . of t he shift fork sha ft.

SERVICE LIMIT: 12.90 mm (0.528 in)

Inspect the shift drum grooves and replace the


drum if they are damaged or show excessive wear.

115

TRANSMISSION
BEA RI NG
BEAR ING RE PLACEMENT
A bearing must be rep laced if it noisy or has excessive plav.
Remove the countershaft oil $8al in the left crankcase cover.
Remove the countershaft bearings from the right
and left crankcases.
Remove the mainshaft bearing from the right crankcase.

COUNTER SHA FT BEA RING


12 mm
BEA RI NG
,15 mm (U.S.A. ONLY)

07936- KC105oo
Remove the mainshaft bearing from t he left crank-

case cover. using the special tool.

RE MOV ER WEIG>IT
07936-37 10200
DRI V ER

Install the bearings into the crankcase with the


following tools.

Left Mainshaft
ATTACHMENT, 32 x 35 mm
PILOT, 15 mm

07746- 0010100

DRIVER

07749-0010000

Right Mainsheft
ATTACHMENT, 42 x 47 mm
PILOT, 20 mm

DRIVER
Left Countershaft
ATTACHMENT. 42 x 47 mm
PILOT, 22 mm

07746- 0040300

07746- 0010300
07746- 0040500
07749-0010000

DRIVER

01746- 0010300
07746-0041000
07749-0010000

Righi Counterlhaft
ATTACHMENT, 37 x 40 mm
PILOT, 17 mm
DRIVER

07746-0010200
07746- 0040400
07749-0010000

116

TRANSMISSION

TRANSMISSION ASSEMBLY
Check the gears for freedom of movement or rota-

tion on the shaft.


Check that the snap rings are seated in the grooves.

C2 GEAR

CQUNTERSHAFT

~~

GEAR

~rf'J) ~

~l
M2 GEAR

GEAR

M5 GEAR
MAINSHAFT

Align the hole in the M6 gear bushing with the hole


in the mainshaft when installing.

MAINSHAFT

117

TRANSMISSION

INSHAFT
Install the mainshaft and countershaft into the left
crankcase as an assembly.

Install the gear shift drum.


Install the shift forks as shown.

Insert the shift fork shaft into the shift forks.

118

TRANSMISSION
SHIFT SP,,"O._,

GEAR SHIFT SPINDLE


Inspect the gear shift spindle for wear or damage.

Disassemble and replace parts as necessary.


Install the spindle return spring. snap-rings and
spring on the gear shift spindle.

Align the return spring with the pin bolt and install
the shift spindle while pulling the shift plate.
Assemble the crankcase (Section 10).
Install the shift cam plate, stopper arm (Page 826, 8-27) and gear shift pedal and check the transmission for smooth shifting_

-0

~'l+SH I FTPLATE

RETURN SPRING

11-9

FRONT WHEEL/
SUSPENSION/STEERING

X R200 R :
95-140 N'm (9 .5- 14.0
18-30

(1 .8- 3.0 kgm, 13-22 ft-Ib)

15-30 Nm (1.5-3.0 kg-m, 11 - 22 ftlb)

L~~~~::~=~~:::::::::"" '"

(3.0-3.5 kgm, 22-25 ft-Ib)

2.5 - 5.0 N'm IU.''' - U.' kg-m , 1.8 - 3.6 ft -Ib)

8 - 12 N'm (0 .8-1.2 kg -m , 6 - 9 h -Ib)

12-0

Nm (2 .0 - 2.6 kgm, 14- 19 ft-Ib)

FRONT WHEEL/
SUSPENSION/STEERING

XR250R:
18-30 N-m 0,8-3.0 kg-m, 13- 22 ft-Ih)
95-140 Nm (9.5-14.0 kg-m , 69-101 ft-lbJ

15-30 N-m (1.5-3.0 kg-m, 11-22

18- 25 ft-Ib)

50-80 Nm (5.0-8.0 kg-m, 36-58 ft-Ib)

"\,""

L_~~~~=~=~~~N.m (3.0-3.5 kg-m, 22-25 ftlb)

'lO- 14N-m

(g

.4 kg-m, 7-10 ft-Ib)

14-16 N-m (lA-1.6

10- 12ftlb)

--"-----f---II-~

(2.'J- 3.0 kg-m, 14-22 ft-Ib)

2.5- 5 .0 Nm (0.25-0.5

. 1.8- 3.6 ft- Ib)

32-42 N-m (3.2-4.2 kg-m, 23- 30 ft-Ib)

121

12. FRONT WHEEL SUSPENSION/STEERING


SERVICE I NFORMATION

12-2

TROUBLES HOOTI NG

12-3

HEADLIGH T

12-4

SPEEDOME TER

12- 5

HANDLEB AR

12-5

FRONT WH EEL

12-8

FRONT FO RKS

12- 20

STEERING STEM

12-27

SERVICE INFORMATION
GENE RA L

A work stand or box is required to suppa rt the motorcycle.

SPEC IFICATIONS
XR250R

XA200R

STANDARD

SERIVCE LIMIT

STANDARD

0 .2 mm (0.01 in )

Axle shaft run out


Front wheel rim

Radial

2.0 mm (0.08 in)

runout

Axial

2 .0 mm (0.08 in)

Front fork spring free


length

87 mm (3.42 in )

498 mm ( 19.61 in)

Front fork tube runout


Front fork oil level

fronl fork air pressue

Opsi (0 kPa.

Brake drum
Brake shoes thickness

78.5 mm (3.09 in)


504 .5 mm (19.86 in)

0 .2 mm (0.0 1 in )

14 6 mm (5 .7 5 in )

150 mm (5.9 1 in)

a kg /cm 2)

"4 .a

mm (4 .33 in)

OmmI0.1Sin)

11 1 mm (4.37 in)
2.0 mm (0.08 in)

TORQUE VALU ES
Steering bearing adjustment nut

1 .0 - 2.0 Nm (0. 1 ~0 . 2 kg.m, 0 .7-1 .4 ftlb)

95- 140 Nm
front fork upper pinch bolt
25- 35 Nm
Front fork lower pinch bolt
30- 35 Nm
lB - 30 Nm
Handlebar holder
Front axle
50- 80 Nm
Front axle holder
10- 14Nm
Fork cap
15- 30 Nm
Front fork socket bolt
XR2.DOR: 20- 26 Nm
XR250R: 32-42 Nm
2.5- 5.0 Nm
Spokes
Brake disc (XR250R only)
14- lSN m
Front brake caliper bolt
20- 30 Nm
Brake arm (X A250R only)
B- 12 Hm
Steering slem nut

122

SERVICE LIMIT

(9.5- 14.0 kg . m , 69- 101 ftlb)


(2.5-3.5 kg-m, 18-25 ft-Ib)
(3.0-3.5 k9-m, 22-25 ft-Ib)
(1.8-3.0 kg-m. 13 - 22 ft-Ib)
(5.0-8.0 kg-m, 36-58 ft-Ib)
(1.0-1.4kg-m , 7 - 10ft-lb)
(1.5-3.0 kg -m, 11-22 ft-Jb)
(2.0-2 .S kg-m. 14- 19 ft-Ib)
(3.2-4 .2 kg-m , 23-30 ft-Ib)
(0.25-0.5 kg-m, 1.8 - 3 .6 ft-Ib)
(1.4-1 .6kg-m,10- 12ft-lb)
(2 .0 - 3 .0 kg-m, 14- 22 ft-Ib)
(0.8- 1.2 kg -m , 6- 9 ft -Ib)

FRONT WHEEL/
SUSPENSION/ STEERING

TOOLS
SPECIAL
Hex wrench, 6 mm
Ball race remover

07917-3230000

Commercially available in U.S.A.

07953-4250002

Steering stem driver


Steering stem socket

07946-4300001 or 07946-MBOOOOO and GNHT54 (U .S.A only)

Fork seal driver

07947-3710101 : XR200R
07947-KA30200 : X R250R
07947 - KA50100: XA250R

07916-3710100

Fork seal driver attachment


Fork seal driver weight

0'

07947 -3290000
COMMON

Attachment, 32 x 35 mm
Driller

Pilot, 15 mm
Socket wrench, 30 x 32 mm

Extension bar
Attachment, 42 x 47 mm
Beanng remover shaft
Bearing remover head, 15 mm

07746-0010100
07749-00 10000
07746-0040300
07716-0020400 """1-

07716-0020500

---.r- Commercially available in U.S.A.

07746-0010300 or 07945-3330100
.
.
07746-0050100 L..
07746--0050400 --1- CommerCially available in U .S.A.

TROUBLESHOOTING
Hard Steering
1. Steering stem nut too tight.

2.
3.
4.

Faulty steering stem 'bearing.


Damaged steering stem bearing.
Insufficient tire pressure.

Steen to One Side or Does Not Track Straight


1. Bent front forks.
2. Bent front axle, wheel installed incorrectly.
Front Wheel Wobbling
1. Bent rim.
2. Worn front wheel bearing.
3. Bent or broken spokes.
4. Faulty tire.
5. Axle not tightened properly.

Hard Suspension
1. Incorrect fluid weight in front forks.
2. Incorrect fork air pressure.
3. Fork tube bent.
Front Suspension Noise
1. Slider binding.
2. Insufficient fluid in forks.
3. Loose front fork fast eners.
Improper Brake Perform ance
1. Brake shoes contaminated.
2. Brake shoes worn.
3. Brake cam worn.
4. Brake drum worn.
5. Brake arm serrations improperly engaged.

Soft Suspension
1.
2.
3.

Weak fork springs.


Insufficient fluid in front forks.
Incorrect fork air pressure.

123

FRONT WHEEL/
SUSPENSION/STEERING

HEADLIGHT

HEADLIG HT CASE MOUNT ING BANDS

RE MOVA L
Remove the headlight case mounting bands and remove the head light case.

Disconnect the headlight wire connectors.


Remove the headlight.

WIRE CONNECTO RS

Remove the clip securing the headlight bulb socket


and socket, and replace the headlight bul b, if neces-

BULB ~OI'KET

sary.
Remove the headlight adjusting screw and the two
mounting screws, then remove the headlight.

INSTA LLATI ON
Install the headlight in the reverse order of removal.
Adjust the headlight vertical beam (Page

3-18).

SCREW

124

FRONT WHEEL/
SUSPENSION /STEER ING

SPEEDOMETER
REMOVAL
Remove the headlight case (Page 124).
Disconnect the speedometer cable.
Remove the speedometer mounting nuts and the

speedometer.

INSTALLATION
$quirt a small amount of oil into the speedometer
cable before connecting it.
Install the speedometer in the reverse order ot
removal.

SPEEDOMETER CABLE

HANDLEBAR

BAND

REMOVAL
Remove the wire band securing the engine stop
switch wire.

MANUAL DECOMPRESSOR

ER BRACKET

Remove the engine stop swit ch.


Disconnect the clutch cable and remove the clutch

L EVER BRACKET

lever bracket.
Remove the left grip rubber.
XR250R: Disconnect the manual decompres$or
cable and lever bracket.

XR200 R

STOPSWI TCf<~~~----------~

125

FRONT WHEEL/
SUSPENSION/STEERING
THROTTLE GRIP

Remove the throttle grip.


XR250R: Remove the brake master cylinder.

THROTTLE GRIP

Remove the handlebar holder bolts, upper holders


and handlebar.

INSTA LLAT ION


Install the handlebar.
Align the punch mark on the handlebar with t he top
edge of the lower holders.

Place the upper holders on the handlebar wit h the


punch marks facing forward.
Tighten the forward bolts first, then tighten the rear
bolts.
TORQUE: 18-30 Nm
fl.8-3.0 kg-m. 13-22 ft-Ibl

126

BRAKE MASTER
CYLINDER

FR ONT WHEE l!
SUSPENSION/STEERING
PU"CH MARK
_ _ _ _ __
Align the puch mark on the handlebar with the split
of the brake lever bracket and install the bracket.

PU"CH MARK

Tighten ,th.e screws securely.


XA250R: Install the front brake master cylinder

with "UP" on the holder facing up. Align the end of


the holder with the handlebar punch mark.
T ighten the upper bolt first, then the lower bolt.

XR200R

XA259 A

"UP" MARK

Apply light grease to the throttle grip sliding surface


and slide the throttle grip over the nahdlebar.

XR250R

Align the split line of the throttle grip with the


punch mark on the handlebar.

Tighten the forward screw first , then the rear screw.

XR250R
SCREWS

127

FRONT WHEEL/
SUSPENSION/ STEERING

PUNCH MARK
Install the clutch lever bracket with the dot mark on
the holder facing up. Align the end of the holder
with the handlebar punch mark. T ighten the upper

screw first, then the lower screw.


Connect the clutch cable.
Install the engine stOP switch and connect its wires

to the wire harness.


Install the left grip rubber.
XR250A: Install the manual decompressor lever
bracket.
Align the split line of the manual decompres$or
bracket with punch mark on the handlebar.

Connect the decompressor cable.


XR200A

XR250R

PU"CHMARK

WIRE BAND
Install the wire band.
Adjust the clutch !page 319)
Adjust the throttle cable (page 36)

XR250R: Aiust the manual decompres$or cable


(page 3-9)

FRONT WHEEL
FRONT WHEEL RE MOVA L
Raise the front wheel off the ground by placing a
,block or safety stand under the engine.

X R200 R: Re move the brake cable clamp bolts.


Disconnect the front brake cable from the brake
lever on the front wheel.
Disconnect the speedometer cable from speedometer gearbox,

XR250R: Remove the front fork guard,

CABLE

128

METER

FRONT WHEEL!
SUSPENSION/ STEERING

XR250R: Disconnect the speedometer cable from


the speedometer gearbox at the front wheel.

Loosen the axle shaft holder nuts and remove the


front axle.

Remove the front wheel.

SPEEDOMET~E~R~~;::O:;;
AXLE INSPECTION
Set the axle in V blocks and measure Ihe (unout.
The actual runout is 1/ 2 of the total indicator read
ing.
SERVICE LIMIT: 0.2 mm (0.01 in)

WHEEL
Check the rim runout by placing the wheel on a
truing stand. Then spin the wheel by hand, and read
the runout using a dial indicator.
SERVICE LIMITS:

Radial

2.0 mrn (0.08 in)

Axial

2.0 mm (0.08 in)

Check the spokes and tighten any that are loose.


TORQUE: 2.5-5.0 N'm
10.25-0.5 kg-m, 1.8-3.6 ft-Ib)

00
0 0
06 a
0

129

FRONT WHEEL/
SUSPENSION/ STEER ING

XR200R: BRAKE DRUM


Remove the brake panel.
Measure the drum J.D .

SERVICE LIMIT: 111 mm 14.37 in)

Replace the brake drum if the 1.0. is larger than the


service limit .

X R200R : BRAKE LINING


Measure the brake lining thickness.

SERVICE LIMIT: 2 .0 mm (0.08 in)

Replace the brake shoes if they are thinner than the


service limit .

SPEEDOMETER

XR200 R: BRAKE PANEL DI SASSEMBLY


Pull the brake shoes apart and remove them from
the brake panel.
Remove the springs.

12-10

FRONT WHEEL/
SUSPENSION/STEERING

BRAKE CAM
Remove the brake cam by removing the brake arm
and indicator plate. Remove the dust seal.

Remove the speedometer gear and the dust seals


from the brake panel.

XR200R: BRAKE PA NE L ASSEMBLY

BAAKESHOES------~

DUST SEAL
BRAKE PANEL

SPEEDOM ETER GEAR

1211

FRONT WHEEL/
SUSPENSION/STEERING

~EEDDMETER GEAR

XR200R : BRAKE PANEL ASSEMBLY

Install the speedometer gear and the dust seal.


NOTE

[ Applv grease to the speedometer gear.

Install the dust seals to the brake panel.

INDICATOR PLATE

ApplV grease to the slid ing surface of the brake cam .

Install the brake cam.


Instal! the brake wear indicator plate .
Install the brake arm aligning its punch mark with
the cam punch mark.
Tighten the brake arm bolt.
TORQUE ;

8-12 N m

(0.8- 1.2 kg-m, 6- 9 ft-Ib)

1212

BRAKE ARM

FRONT WHEEL/
SUSPENSION/ STEERING

Install the brake shoes and return springs.

oil or grease to contact Ihe


Install the brake panel to the wheel hub.
Install the front wheel (page 1218)

X R200R : FRONT WHEEL DISASSEMBLY


Remove the wheel bearings and the distance coliar
from the hub.

/
NOTE

Never reinstall old bearings, once the bearings


have been rem oved. They must be replaced

wi th new ones.

L BEAR IN G REMOVER
15 mm 07:146:-"iOsii4CIO
WHEEL BEAR IN G REMOVER SHAFT 077 46 ~0050100 OR
COMMERC IALLY AVA ILABLE IN U.S.A.

XR250R: FRONT WHEE L .D ISASSEMBLY


Remove the speedometer gear box.
Remove the right seal and speedometer gear re-

ta iner.

RIGHT SEAL

SPEEDOMETER GEAR
RETAINER

1213

FRONT WHEE L!
SUSPENSION /STEERING

.. " .

BAAK
Remove the left seal.

Remove the brake disc mounting nuts and disc.

DISC

Remove the wheel bearings and distance collar


from the wheel hub.

NOT E

Never reinstall old bearings; once the bearings


have been removed, they must be replaced
with new ones.

WHEEL BEARING
A HEAD 15 mm 07746-0050400
WH EEL BEARING REMOVER SHAFT 077 46-0050 100 OR
COMME RCIALLY AVAI LAB LE IN U.S.A.

WHEEL BEARIN G
Check the wheel bearing play by placing the wheel
on a truing stand and spinning the wheel by hand.
Replace the bearings with new ones if they are noisy
cr have excessive play.

AX IAL '

1214

RAD IAL

WHEEL/
FRONT
SION/STEERING
SUSPEN

FRONTWHE EL ASSEMBLY
AIMLOCK

XR200R:

DUST SEAL

CO LL AR

BEAR I NG

XR250 R:

SPEEDOMETER

8EA~ I NG

GEAR BOX

BRAKE DISC

DUST SEA L

1215

FRONT WHEEL/
SU SPENSION/ STEER ING

X R200R: FRONT WH EE L ASSEMB LY


If the bearings were removed, they should be re placed with new ones.
Pack the new bearing cavities with grease .

Drive in the left bearing and install the distance


collar.
Drive in the right bearing.
NOTE

Install the bearings with the sealed ends


to ward the outside .
Be sure to drive the bearings in squarely.

DR IVER 07749- 00 10000


PI LOT 15 mm 07746-0040300

Apply grease to the inside of the dust seal.


Instal! the dust seal and distance collar.

XR250R: FRON T WHEE L ASS EMB LY


Pack all bearing cavities with grease.
Drive in the left bearing first and press the distance
collar into place.
Drive in the right bearing squarely making sure that
it is fully seated and that the sealed side is facing
out.

ATTACHMENT
x 35 mm 07746-0010 100
DRIVER 07749-0010000
PI LOT 15 mm 07746 0040300

1216

FRONT WHEEL/
SUSPENSION/ STEER ING

Attach new gaskets to the brake disc stud bolts.


Install the brake disc onto the wheel hub.
Tighten the brake disc nuts.
TORQUE : 14- 16 N' m

(1 .4- 1.6 kgm, 10- 12 ft lbl

BRIIKE DISC

51

COL LAR

Install the left seal and side collar.

SPEEDOMETER GEARBOX

Install the speedometer gear retainer into the wheel


hub, aligning the tangs with the slots.

Install the right seal.


Install the speedometer gearbox into the wheel hub,
aligning the tangs with the slots.
Clean the brake disc with a high quality degreasing
agent.

1217

FRONT WHEEL/
SUSPENSION/STEERING

FRONT WHEEL INSTALLATION


XA200 R: Install the front wheel, aligning the boss
on the left fork leg wi th the groo .... e in the brake
panel.

XR250R: Fit the caliper over the disc, taking care


not to damage the brake pads. AI igh the speedo-

meter gearbO)( with the tang on the right for k leg


as shown.

Clean the axle shaft and holder.


Install the holder with "UP" facing upwards.
Install the axle holder nuts but do not tighten at
this time.
X R25Q R: Align the speedometer gearbox with the

tang on the right fork leg as shown.


Tighten the axle to the specified torque:
TORQUE ; 50-80 N'm

(5.0-8.0 kgm,

36-~8

ft lb)

\,

1218

........,:;.
X"'
R250R

FRONT WHEEL/
SUSPENSION/ STEERING
FORK TUB E

Connect the speedometer cable .


XR20QR: Connect the front brake cable. Adjust
the front brake free play.

XR200R

With the front brake applied, pump the front forks


up and down several times to seat the axle in the
axle holder.

Torque the axle shaft holder nuts, the upper nuts


first, then the lower nuts in 2-3 steps.

TORQUE : 10- 14 Nm O .O- 1.4kg-m , 7- 10 ft- lb)

1219

I
FRONT WHEEL!
SUSPENSION/STEERING

FRONT FORKS

BRAKE CAB L E
CLAMP

SPEEDOMETER

BRAKE

REMOVA L
Remove the front wheel.
Remove the speedometer cable clamp from the
right fork leg.

XA250R: Remove the brake hose clamp bolts.


Remove the caliper mounting bolts and caliper from
the left fork leg.

!/
XR250 U
CABLE CLAMP

CA LI PER
BOLTS

ur"',m"r.

Loosen the upper and lower front fork pinch bolts

and remove the front forks.

LOWER PINCH BOLTS


AIR VA LVE

DI SASEMBLY
Loosen the fork boot clamps and remove the boot.
Remove the air valve cap.
Depress the air valve and release front fork air
pressure.

CAUTION
If air pressure is not released before disassembling, the fork tube cap may become
a projectile.
TIle cap is also wuier spring pressure. Use
care when removing and WetJf eye and face
protection.

TUBE CAP

1220

FRONT WHEE L!
SUSPENSION/ STEERING
HEX WRENCH 6 mm 07917-3230000
_-------iCOMI~ E'R(:IIAL.LY AVAILABLE IN U.S.A)

Drain the fork oil by removing the drain plug.


Hold the fork slider in a vise with soft

ja~

or a

shop towel and hold the fork piston with a holder.


Remove the hex bolt.

CA UTION
Do /lor distort tlte fork slider in a vise.

FORK BOLT
Hold the tube in a vise with soft jaws or a shop
towel, avoiding the sliding surface.

Remove the fork cap boh.


CAUTION

The cap bolts are under spring pressure. Use


core whm removing and wetlr eye and face
protection.

Remove the fork spring, fork piston and rebound

spring.

Pour out any remaining fork fluid by pumping the

fork several t imes.

1221

FRONT WHEEL/
SUSPENSION/STEERING

Remove the snap ring.


In quick successive back and forth strokes, pull the
fork tube out from the slider. The slider bushing

gives resistance and the fork tube bushing must


force it out .

FORK SLIDER

DUST

Remove the dust seal, oil seal, back-up ring and


slider bushing from the fork tube.

I
BACKUP RING

>LIDE'R BUSHI NG

INSPECTiON
FORK SPRING FREE LENGTH
Measure the fork spring (AI and (B) free length.

SERV ICE LIMIT :


XR200R:
Fork spring (AI 81 mm (3.42 in)
Fork spring (B) 498 mm (19.61 in)
XR250R:
Fork spring (A) 78.5 mm (3.09 in)
Fork spring (8) 504,5 mm (19.86 in)

Replace the spring if it is shorter than the service


limit.

1222

10--- FREE LENGTHI-- - . . j

FRONT WHEEL/
SUSPENSION/ STEERING
FORK TU BE/ FORK SLI DER / PI STON
Check the fork tube, fork slider and piston for score

marks, scratches, or excessive or abnormal wear.


FORK TUBE

Replace any components which are worn or damag-

'd.
Check the fork piston ring for wear or damage.
Check the rebound spring for fat igue or damage.

FORK PISTON

FORK SLIDER

FORK TUBE
Set the fork tube in V blocks and read the runout.
SERV ICE LIMIT: 0.2 mm (0.01 in)

Check the bushings for excessive wear Of scratches.


If copper appears on more than 3/4 of the entire
surface, replace the bushings.

BACK-U P RING

BUSHI NG

Replace the back-up ring if there is distortion at the


check points shown.
Check the fork piston ring for wear or damage.
Check the rebound spring for fatigue or damage.

--,

.....;\f---'~

CQPPE A
SURFACES
CH ECK POINTS

1223

FRONT WH EEL/
SUSPENSION/ STEER ING
ASSEMB LY
Clean all parts with non-flammable or high flash
point solvent

FORK TUBE

SPRING (B)

BOOT CLAMP

(J

BOOT

"I

SPRINGIAI,,/

DUST

~S EAl

~SNAPRING

~O I LSEAL
~

PISTON

WASHER

-~~I
OIL LOCK PIECE

I
SOCKET BOLT

OIL LOCK PIECE


Insert the rebound spring and pisttvl into the fork
tube.
Place the oil lock piece on the end of the piston and
insert the fork tube into the slider.

1224

FRONT WHEEL/
SUSPENSION/ STEERING
HEX WRENCH 6 mm
07917 - 3230000 (COMMERCIALLY AVAILABLE IN U.S.A)
Place the fork slider in a vise with soft jaws or a

shop towel.
Apply lock ing agent to the socket bolt threads and
torque the bolt .

NOTE

Temporarily install the fork springs, seat


washer, spacer and fork tube cap to tighten

the socket bolt.


TORQUE :

X R200R : 20-26 N'm 12.0-2.6 kg-m, 14-19 ftlb)


X R250R : 32-42 N' m (3.2- 4.2 kg-m, 23-30 ftlbl

FORK SEAL DRIVER WE IGHT


XR250A: 07947 - KA501 00 or 07['9=-4=7_- .::.
32:::9:.:0.::.
00
.::.0=---_ _ __ - ,

Place the slider bushing over the fork tube until it

rests on the slider. USing a fo rk seal driver and


attachment, drive the bushing into place.
Install the back -up plate.

OI L SEA L

Coat the oil seal l ip with the recommended fork oil.


Drive the oil seal into place using the fork sea l driver

BACKUP
PLATE

and attachment.
Drive in the dust seal until you can see the circlip
groove. Then install the circlip.

SLIDER
BUSH ING

Install the drain bolt with sealing washer.


Pour in the specified amount of ATF.

AHAC HM"

FlUID CAPACITY: 651 cc (22.0 a u)


Compress the front fork all t he way and measure
the oil levet from the top of the tube.

XR250A : 07947- KA30200


FORK SEAL DRIV E R
XA200R : 07947- 3710 10 1

NOTE
Be sure t he oil level is the same in both fork
tubes.
STANDARD OIL LEVEL :
XR200R : 146 mm (5.75 in)
XR250R : 150 mm (5.91 in)

O I L LEVEL

Maxim um XR200R :
Slightly stiffer f ork
oil level
146 mm (5.75 in) spring effect when
XR250R:
f ork is charged
150 mm (5,9 1 in) with standard air
pressure.
Minimum XR2ooR :
Slightly softer fork
oil level
186 mm (7.32 in) spring effect when
XA250 R:
fork is charged
190 mm (7.48 in) with st andard air
pressure.

FORK OI L

1225

FRONT WHEEL/
SUSPENSION/STEERING

Install the spring A. spring B and the spring guide.


Instalt t he fork cap.
TORQUE: 15-30 N'm (1 .5-3.0 kg-m. 11 -22 ft -Ibl
SPRI

SPRING
GUIDE

"'i+--SP'"NG

FORK CAP

aOOT aREA-'H"R HOLES

Instln the fork boot with its much breather holes

towards the rear.

INSTAL LATI ON
Slip the fork tubes through the fork bridge and
steering stem, while rotating them by hand.
Align the lower groove of fork tube with the top
surface 01 the fork bridge.
Tighten the upper and lower fork pinch bolts.

TORQUE :

Upper: 25-35 N' m {2.5- 3.5 kg.m. 18- 25 ft-Ibl


Lower: 30- 35 Nm (J.G-3.S k g-m, 22- 25 ft-Ib)
NOTE
Ensure that the lower groove of each tube

81ings with the top of the fork bridge.

1226

FRONT WHEEL/
SUSPENSION/ STEE RI NG

Push the fork. boots up unti l they jUst touch the

steering stem and tighten the clamp.


Install the f ron t wheel (Page 12- 18 ),

XR250R :
Install the speedometer cable and

brak.e hose

clamps.

Install the front wheel (Page 12- 181,


Install the brake caliper (Page 14-12),

Make sure all weight is otf the front wheel. and


charge the forks with air, if desired.
CAUT ION

Use

low-volume low-pressure pump to ch(JTge

the jorks with air.

STEERING STEM
FORK BRIDGE RE MOVA L
Remove the headlight.

Disconnect the wires at the connectors.


Remove the following parts:
- Speedo meter.
-

Handlebar.
Front wheel.
Front fender.
Front fork (Page 12-20 )

1227

FRONT WHEEL/
SUSPENSION/STEERING
SOCKET WRENCH 30 x 32 mm 07716-0020400,
EXTENSION BAA 07716-0020500 OR

COMMERCIALLY

ILABLE IN U.S.A:..
, _ _ _ _- - ,

Remove the steering stem nut.


Remove the front fork. (1229)
Remove the fork top bridge.

Remove the bearing adjusting nut.

Remove the seal, upper bearing and steering stem


from the head tube.

STEERING STEM

BEARING REPLACEMENT
NOTE

Always replace the bearing and bearing races


as a set.
Remove the lower bearing from the steering stem.

SEAL

1228

A BEARING

FRONT WHEEL/
SUSPENSION / STEERING

Remove the upper and lower bearing races from the


steering head .

DRIVER 07749- 00100000


Install new bearing races.

NOTE
If the motorcycle has been involved in an acci-

dent, examine the area a round t he steering


head for cracks.

A1TI,el;;"E"T 42 x 47 mm
07746- 0010300 OR 07945-3330 100
Install the dUst seal .
Install the lower bearing using a hydraulic press and
Steering Stem Driver .

.~

STEE RI NG
DRIVER
07946-430000 1 OR 0746-MBOOOOO AND
ATTACHMENT GN HT54 ~U.S.A ONLY)

1229

FRONT WHEE L!
SUSPENSION/STEERING

AND UPPER BEAR ING

INSTA LLATI ON
Pack the bearing cavities with bearing grease.

Install the steering stem into the steering head and


install the upper bearing and seal.

~~'ir


STEER I NG STEM
STEE RI NG STEM SOCKET
10100

Tighten the bearing adjustment nut.


TORQUE: 1 .0 - 2 .0 Nm
(0 .1 - 0 .2 kg m , 0. 7 - 1 .4 ft lb)

Turn the steering stem lock'la-Iock 5 times to seat


the bearing and tighten the adjustment nut again.
Repeat the bearing tightening and steering stem
turning sequence twice.
If the nut does not t ighten after turning the steering
stem the first or second time, remove the nut and
inspect it and the steering stem t hreads for dirt or
burrs.

EXTENS ION BAR 077 16-0020500


COMMERC IA L LY AVA ILABLE IN U.S.A.

Install the fron t forks (Page 12-26).


Install t he fork top bridge and tighten the stem nut.

TO ROUE: 95-140 N'm

(9.5- 14.0 kgm, 69- 101 ft -Ib )


Recheck the steering stem adjustment before in
st alling the removed parts.
Install the removed parts in the reverse order of
removal.

W~~~~~~3~O~X

LOCK NUT
32 mm
077 16 - 0020400
COMMERC IAL LY AVA I LAB LE IN U .S.A.

1230

MEMO

REAR WHEEL/ BRAKE/


SUSPENSION

40-50 Nm (4.0-5.0 kgm, 29-36 ft-Ib)

80-100 Nm
(8.0- 10.0 kg-m, 58 - 72 ft-Ib)
2.5-5.0 Nm (0.25- 0 .5 kg-m,
1.8-3.6 I
40- 50 Nm
1O< "(4.0-5;Okg.m, 29-36 ftlb)

40-50 Nm
14.0-5.0 kgm,
29-36 ftlb)
80- 1'ON.m

.O kg-m,
58-80 ftlb)

""'" -====-..

90-120 Nm (9.0-12.0 kgm,


65-87 ft-Ib)

8-12 Nm 10.8-1.2 kg-m, 6-9 ftlb)

13-0

13. REAR WHEEL/BRAKE/SUSPENSION


SERVICE INFORMATION

13- 1

TROUBLESHOOTING

13- 2

REARWHElL

13- 3

SHOCK ABSORBER

13- 13

SWING ARM SUSPENSION LINKAGE

13- 27

BRAKE PEDAL

13~1

SERVICE INFORMATION
GENERAL
A work st and or box is required t o support the motorcycle,
Use genuine rear suspension linkage and shock absorber pivot/mount bolt s.
Note instatlation direction of the bolts.

Th~ UQr shock Qbsorb~r contains nitrog~n under high preuure. Do not ailo", flU or heat near the shock absorb,,_
lh sure to ufease nitrogen gtu pressure be/ore disposal.

Brake dust may contain asbestos K'h ich CQ1'/ be harm/ul lo )'our health.

Do not use comprtssed air 10 clean brake drurru or brake pands.


Use Q vacuum K'ith Q sealed dust col/ector.
WeDf Q protectil'e Jace mtuk Qnd thoroughly -wash )'our hands K'hen /inished.

SPEC IF ICAT IONS


XR200R
IT EM
Rear wheel runout

STANDARD

SERVICE LIMIT

Radial

2.0 mm (0.08 inl

Axial

2.0 mm (0.08 in)

Rear axle runout


Rear brake drum 1.0.
Rear brake shoe l ining thickness

110 mm {4.33 inl


4.0 mm (0.16 in)

XR250R

STANDARD

,
,

0.2 mm (0.01 in)

111 mm (4.37 in)

I SERV ICE LI MIT

2 .0 mm (0.08 in)

Rear shock absorber spring free length 267.5 mm(10.53 in) 264.5 mm(10.4 1 in)

131

REAR WHEEL/BRAKE!
SUSPENSION
TORQUE VALUES
- Spokes

2.5 - 5.0 N'm (0.25-0.5 kg -m, l.B - 3 .6 ft lb)


27 - 33 Nm (2.7-3.3 kg -m, 20 - 24 ft-Ib)

Fina! drillen sprocket


Rear axle nut
Rear shock absorber (upper)
(lower)
Swing arm pivot bolt
Shock arm-ta-swing arm
Shock arm-ta-shock link
Shock link-to-frame
,Brake arm bolt

80 - 110 Nm (8- 11 .0 kg -m . 58 - 80 fHb)


40 - 50 Nm (4. 0 - 5.0 kg-m, 29 - 36 ft -Ib)
40 - 50 Nm (4 .0 - 5.0 kg -m, 29 - 36 ft -Ib)
BO - 100-N'm 18.0 - 10.0 kg-m. 58 - 72 ft -Ib)

90 - 120 N'm 19.0 - 1 2 .0 kg -m, 65 - 87 ft -Ib)


40 - 50 N'm 14 .0-5.0 kg-m, 29 - 36 ft-Ibl
40 - 50 N-m 14 .0-5.0 kg-m, 29 - 36 ft -Ib)
8- 12 N-m

(0.8- ' .2 kgm, 6-9 ftlbl

TOOLS
SPECIAL
Swing arm bearing remover
Bearing
Bearing
Bearing
(
Bearing

rem over set


remover, 20 mm
remover handle
remover weight

M~67X -03B-X XXXX

(U.S.A. only)
07936 - 37 10000
07936 - 37 10600)
07936 - 3710 100
07936 - 3710200
or 07936 - 371 0201

Piston ring slider

07974 - KA30300
(Not available in U.S.A )

After B4 :
Slider guide, 14 mm
Spherical bearing driver , 14 mm

07974- KA40000
07946- KA30200

COMMON
Attachment, 32 x 35 mm
Attachment, 37 x 40 mm

Attachment, 42 x 47 mm
Driver
Pilot, 17 mm
Pilot, 20 mm
Retainer wrench body

Retainer wrench attachment


Bearing remover expander
Bearing remover collet, 17 mm

07746 07749 07746 07749 07746 077 4 6 07710 07710 07746 07746 -

0010100
0010200
0010300
0010000
0040400
0040500
0010401
0010100
00501 OO ~
0050500 .... ~

Commercially available in U.S.A


OPTIONAL
Pin spanner
Pin spanner

89201 - KA4 - B l 0
89202 - KA4 - 810

TROUBLESHOOTING
Wobble or Vibration in Motorcycle
1. Bent rim
2 . Loose wheel bearings
3 . Loose or bent spokes
4 . Damaged tire
5 . Axle not tightened properly
6 . Swing arm pivot bearing worn
7. Chain adjusters not adjusted eQually
Soft Suspension
1 , Weak spring
2. Improper rear suspension damping or spring
preload adjusting
Herd Suspension
1. Improper rear suspension damping or spring
preload adjusting
2 . Spring thrust sleeve binding
3 . Bent shock absorber rod
4 . Swing arm pivot bearings damaged

132

Suspension Noise
1. Faulty rear damper
2 . Loose fastene rs
3 . Worn suspension linkage pivot bushings
Poor Brake Performance
1. Improper brake adjustment
2. Worn brake shoes
3 . Brake linings Oily, greasy or dirty
4 . Worn brake cam
5 . Worn brake drum
6 . Brake arm serrations improperly engaged
7 . Brake shoes worn at cam contac t area

REAR WHEEL/BRAKE!
SUSPENSION

REAR WHEEL
REAR W HEEL REMOVAL
Raise the fear wheel off t he ground by placing a
workstand or box under the engine.
Pulllhe brake arm pin holder foward and disconnect
the brake rod from the brake arm.

Loosen the rear axle nut.


Turn both adjusters so the rear wheel can be moved
all the way forward for maximum drive chain slack .

Move the rear wheel forward and "hook" the adjusters over the st opper pins on the swingarm .

AXLE NUT

Der311 the drive chain from the drive sprocket. lift


the stopper plate clear of the pin on the swingarm' s
right side.
Remove the rear wheel w ith the feafaxle.

133

REAR WHEEL/ BRAKE/


SUSPENSION
IN SPECTIO N
A X LE SHA FT
Set the axle on V blocks and measure the runout.
The actual runout is 1/ 2 of the t otal indicat or
reading.

SERVICE LIMIT: 0 .2 mm (0 .01 inl

REA R W HEEL BEA RIN G PLAY


Check t he wheel bearing play by placing the wheel
in a truing stand and spinning the wheel by hand.
Replace the bearings with new ones if they are
noisy or have excessive play.

J'I T
-

II
.i'l
AX IAL

REAR W HEEL RIM RUNOUT


Check the rim runout by placing the w heelan a tru ing stand. Turn t he wheel by hand and measure the
fu nout using a dial indicat or.
SERVICE LIMIT:
Radial: 2 .0 mm (0.08 in)
A xi al : 2 .0 mm (0.08 in)
Tighten any loose spokes.
TORQUE : 2.5- 5.0 N'm
10 .25 - 0 .5 kg -m. 1.8 - 3 .6 ft-Ib)

134

RAD IAL

REAR WHEEL/ BRAKE/


SUSPENS ION

REAR BRAKE DRUM 1.0.


Measure the rear brake drum 1.0.
SERVICE LIMIT: ,,, mm 14.37 in)

FINAL DRIVEN SPROCKET


Check the condition of the final driven sprocket
teeth.
Replace the sprocket if worn or damaged.

GOOD

REPLACE

NOTE

The drive chain and drive sprocket must also


be inspected if the driven sprocket is worn or
damaged.

BRAKE LINING
Measure the rear brake lining thickness.
SERVICE LIMIT : 2 .0 mm 10.08 in)

135

REAR WHEEL/ BRAKE/


SUSPENSION

RE A R BRA KE SHOE DISASS EM BLY


Remove the brake shoes and springs from the
brake panel.

SPRI NG

Remove the brake arm, wear indicator plate.


Remove the brake cam and the special washer from
the brake panel.

Check the brake cam seats for wear or damage and


replace if necessary.

CAME SEA LS

136

REAR WHEEL/BRAKE!
SUSPENSION

RE A R BRAK E SHOE ASS EMB LY


WEAR INDICATOR PLATE

flo~ ~

BRAKE ARM

BRAKE CAM

"H,,,. SHOES

BRJ'KECAM SEA LS

Install the brake cam seals to the brake panel.

BR,'KE ARM

Insta ll the brake cam and the special washer to


brake panel.
Al ign t he wear indicator tab with the cut.out in the
brake cam and install the indicator over the cam.

Install the brake arm aligning the punch mark with


the cam punch mark.

Tighten the brake arm bolt.


TORQUE: 8-12N-m (0 .8- 1.2 kg -m , 6 - 9 ftlbl

SPEC IAL WASHER

IND ICATOR PLATE

137

REAR WHEEL/BRAKEI
SUSPENSION

Install the brake shoes on the brake panel as shown.

A con tam ilia ted brake fining reduces stopping


power. Keep grease off the linings. Wipe ex-

cess

cam.

Install the brake panel to the rear wheel and install


the rear wheel (Page 13- 12),

DR IVEN SPROCKET

RE A R WHEEL DI SASSEMBLY
Remove the driven sprocket bolts and the sprocket.

RE TA INER WRENCH
BODY 07710-001040 1
Remove the bearing retainer using the retainer

wrench and attachment.

138

RETAI NER WRENCH

ATIACH

07710-0010100

II

REAR WHEEL/BRAKE/
SUSPENSION

Remove the wheel bearings and distaf'lce collar with

WHEEL BEARING REMOVER EXPANDER 07746-0050100


WHEEL BEARING REMOVER COLLET, 17 mm 07746-0050500
OR
I

special tools.
NOTE

Never reinstall old bearings; once the bearings


are removed, they must be replaced with new

ones.

ASSEMB LY

BEAR ING
EAAING

~l. ~
DUST SEAL

BEARING
RETAINER

f4fqg)d

~@' 1Jt;

COLLAR

AIM LOCK
DRIVEN SPROCKET

139

REAR WHEEL/BRAKE!
SUSPENSION

Pack all bearing cavities with grease.


Drive the right bearing in first, then press the

distance collar into place.


Drive the left bearing in.

CAUTION
Dri~ the bearif1K$ in squarely, witll the $eLlled
sides facing out, nuiking turt! they ort! fully
seared.

RETAINER SIDE:
ATTACHMENT, 42 x 47 mm

01746- 0010300
BRAKE SIDE:
ATTACHMENT, 37)C 40 mm

07746- 0010200

ATTACHMENT, 42 x 47 mm

07749-0010000
Use the driver and attachment to drive a new dust
seal into the bearing retainer.

BEARING RETAINER
ATTACHMENT

Grease the bearing retainer and install it into the


hub with the retainer wrench and attachment.

RETAINER WRENCH
BODY 07710- 0010401

1310

REAR WHEEL/ BRAKE/


SUSPENSION

Peen the bearing retainer in four places with a ~n'


rer punch.

...

II..._:::;;;~V~E~N SP R:.:O;C~K;E~T=-.;;;::

~
~~

Install the driven sprocket onto the hub and tighten


t he bolts.

TORQUE: 27-33 Nm
12.7- 3.3 kg-rn, 20-24 ft-Ibl

Grease the dust seat and install the collar.

1311

REAR WHEEL/BRAKE!
SUSPENSION

REAR WHEEL INSTALLATION


Install the brake panel in the brake drum.
Insert the rear axle through the right chain adjuster,
stopper plate, brake panel. wheel hub, side collar
and le ft chain adjuster and install the axle nut.

Place the rear wheel into the 5wingarm, aligning the


brake panel s lol with the tang on the swingarm.

Install the drive chain .

Slip the stopper plate over the pin on the swing arm.
Connect the brake rod to the brake arm.
Adjust the drive chain slack (Page 3 - 13).

Tighten the axle nul.


TORQUE : 80 - 1 10 Nm
18.0-11.0 kg-m, 58 - 80 ft lbl
Adjust the feaf brake pedal free play Wage 3 - 7).

1312

REAR WHEE L/BRAKE!


SUSPENSION

SHOCK ABSORBER

MOUNT BANDS

-'""""

REMO VA L
Raise the rear wheel off the ground by placing 8
workstand or box under the engine.

Remove the seat.


Remove the side covers .
l oosen the shock reservoir mount band and remove
the reservoir.
Remove the air cleaner (Page 37) .

NOTE
Seal the carburetor inlet with tape or clean
cloth to keep dirt and debris from entering the
intake tract.

UPPER MOUNT
Remove the upper and lower shock mount bolts
then remove the shock absorber .

ADJUSTI NG;.N;;U;.:T~_r

DISASSEMBLY
Hold the upper shock mount in a vise with soft jaws
or 8 shop towel.
loosen the lock and adjusting nUls.
CAUTION

Be careful /lot to damage rhe hose connection in


a I'ise.

NOTE

IThe pin spanners ar e optional tools.

PIN
PIN SPANNER

- KA4 - S10
89202- KA4 - S10

1313

REAR WHEEL/BRAKE/
SUSPENSION

SPRING SEAT

Remove the spring seat and spring.

SHOCK ABSORBER SPR ING INSPECTION


Measure the spring free length.

SERVICE LIMIT:
XR200R: 267.5 mm (10.53 in)
XR250R; 264.5 mm (10.41 in)

DAMPER INSPECTION
Visuallv inspect the damper unit, reservoir hose and
reservoir for dents, oil leaks or other faults. Replace
the damper unit if necessary,

Inspect the damper rod and oil seal. Replace the


damper rod if the rod is bent or scored, or the seal
is leaking.

1314

FREE LENGTH

REAR WHEEL/BRAKE/
SUSPENSION

DISASSEMB LY
Remove the valve cap.
Depress the schrader varve to release the nitrogen
from the reservoir, then remove the valve core.

CAUTION
Poim the reservoir charging l'a/ve Q\\.\:ly

from you when discharging the nitrogen.


Do not remoile 'he valve core before dis-

charging 'he nitrogen.

VALVE CAP

Remove the reservoir hose joint bolts, then separate


the reservoir, hose and damper.
Drain the ATF from the hose and damper. Pump

the damper backandforth several times to drain


most of the A TF from the damper.
To drain the ATF from the reservoir, go to page
(13-23) ,

Remove the damper rod cap and tape or tie it to the

antibottoming rubber bumper, SO it won't get in


the way.
Push in the damper seal until you have good access
to the circlip.
You'll need two small screwdrivers to remove the
circlip.

DAI.P"R ROD CAP

DAMPER SEA L

13-15

REAR WHEEL/BRAKEI
SUSPENSION

The circlip groove in the damper is ramped towards


the inside to give the circlips a square shoulder on
which to seat securely.
To remove the circlip, first push one end of the
circlip out of its groove, then slip the second screw'
driver between the circlip and the damper to act as a
ramp. Now, use the other screwdriver to pull the cir
clip completely out.

Pull the damper rod assembly out of the damper.

}
C1RCLtPS

After '84:
DAMPER ROD DISASSEMBLY
Remove the piston ring and Q'rings (See page 3-2 1)

I I

CAUTION
Do not gel lint or dir! on tire damper rod

parts, do not wear gloves while working 011


the dizmper rod.
o

Be careful not to grind more than O.5mm


(0.02 in) from the end of the damper rod
described below.

This procedure does not apply to the '84

--- -

model

l1

Unstake the dampe r rod end nut with a grinder as


shown.

"
OR SHOP TOWE l

Place the damper rod in a vise with soft jaws or a


shop towel being careful not to distort the lower
mount.
Carefully remove the end nut and disca rd it.

If the damper rod is cracked or otherwise damaged,


replace the assem bly.
Remove the burrs from the end of the damper rod
and inspect it thoroughly.

=-.\

LOWER MONT

1316

I
-"

0.05mm (0.02 in)

REAR WHEEL/ BRAKE/


SUSPENSION
Pry the compression valve assembly from the

DAMPING VALVE ASSEMB L Y

damping valves assembly by hand.


Remove the washer, piston and damping valves from

PIST ON

the damper rod.

NOTE

Pass a piece of wire through the disassembled


valves to ensure correct reassembly.

COMPRESSION VALVE ASSEMBLY

Remove valve stoppers A and B and the compression


valves as an assembly.

COM PRESSION ASSEMB L Y

t =~--,--ll~I~
\

~LVE STOPPER A

VA L VE STOPPER 8

rl
,

VINYL TAPE

CASE CAP

Tape the damper rod end threads with vinyl tape to


avoid damaging the seal holder.
Remove the seal holder from the damper rod.

Remove the case cap and rubber bumper from the


damper rod.
Remove the tape from the end threads.

SEAL

1317

REAR WHEEL/ BRAKE/


SUSPENSION
SEAL HOLDER

SEAL ~~~7 METAL

Inspect the oil and dust seal lips for excessive wear,
scratches or damage and replace the seal holder with
a new one if necessary.
Inspect the seal holder metal for wear. If the metal
is worn so that the copper surface appears, replace
the seal holder with a new one.

DUST

DAMPER ROD INSPECTION

LIP

Inspect the damper rod sliding surface for scoring,


wear or damage.
Replace the damper rod assembly if it iii worn excessively or damaged.

DAMPER ROD ASSEMBL Y


Before assembly. wash all parts with a high flash
point or non-flammable solvent anti blow dry

with compressed air. Make sure there is no dust


or lint on any parts.
NOTES'

Never assemble valves which might have


gotten dusty or otherwise contaminated
during the reassembling process.
Disassemble them and thoroughly clean
with solvent and reassemble.
Use care to avoid getting solvent on O-rings
and seals .
The valve arrangement and number of
valves shown is typical.
There may be variations.
VALVE STOPPER A

END NUT

VALVE ST()PF'ER B

~ r"'~
DAMPING VP,L". ASSEMBLY

1318

COMPRESS ION VALVE ASSEMBLY

REAR WHEEL/ BRA KE/


SUSPENSION
DAMPER ROD THREADS CORRECT ION
Remo ve burrs from the damper rod end and correct

the threads with a die.


Clean the damper rod with solvent after correcting
the threads.

NOTE

Make sure the orifice in the damper rod is not

clogged by metal burrs.

Install the rubber bumper and case cap over the


damper rod, noting the installation direction.
Install the special tool onto the damper rod.
Install the seal holder carefully over the damper rod.

NOTE

DER
GUIDE,14mm
07974 - KA40000

The seal holder oil seal and dust seals are


filled with grease . Be careful not to remove

grease from the seals .


Be careful not to damage the dust seal lip,

Assemble the compression valves and valve stoppers


A and B and install them onto the damper rod.

COMPRESSION VALVE ASSEMBLY

STOPPER VALVE A

STOPPER VALVE B

1319

REAR WHEEL/ BRAKE /


SUSPENSION

Install the piston onto the damper rod and assemble


the damping valves, noting the installation sequenCi!.
CAUTION

Be careful not to bind the compressioll vailles


when installing the piston onto the damper
rod.

Install the washers onto the damper rod with its


polished surface down.
Screw a new end nut on the damper rod while
pressing the piston down .
Place the damper rod in a vise with soft jaws or a

shop towel, being careful not to damage the lower


mount .
Make sure that the valves are not binding and tighten
the end nut.
TORQUE : 24-29 N.m 12.4-2.9 kgm. 1721 ft-lb)

Stake the end of the damper rod in three places as


shown to secure the end nut.

1320

DAMPING VALVE ASSEMBLY

PISTON

REAR WHEEL/ BRAKE/


SUSPENSION

After '84:

SPHER ICAL BEAR I NG DRIVER , 14 mm

SPHER ICAL BEARING REPLACEMENT

07946- KA30200

Check the spherical bearing for wear or damage.


If it is worn or damaged , it must be replaced .

Remove the oil seals and outer side collar.


Press out the spherical bearing from the rear shock
abosrber.
Press in a ne w spherical bearing using the special tool.
Install the outer side collars and oil seats.

- -,

ASSEMBl Y

.n,,,':HR

CI

PISTON RING

RESERVOIR

SPRING

'84:
DAMPER ROD ASSEMBLY

After '84 :
DAMPER AOD ASSEMBLY

1321

REAR WHEEL/BRAKE/
SUSPENSION

DAM PER CASE

Coat a new O'ring and piston ring with clean shock


oil or silicone grease.

Install the Oring on the damper seal body.


Coat the inside of the damper case with clean shock
oil and insert the rod assembly.

O-RING

Set up the special tool on the case, install the O-ring


and piston ring on the piston rod, and slide the
piston rod into the damper case.
NOTE
Install the piston ring in the special tool,
being careful that the ring end gap and slit
in the tool are staggered.
Install the piston rod into the damper case
while kneading the rod slightly so that the
piston ring will not interfere with the case.
PISTON RING

SEAL BOOY

Install the cirdips securely.

CIRCUPS

Hold the upper shock mount in a vise with soft

jaws or a shop towel as shown.


Pull out the damper rod all the way.
Fill the damper with shock oil.
NOTE
For extreme operating conditions, use Bel
Ray L T-56 or Golden Spector Light shock oi l .

1322

REAR WHEEL/BRAKEI
SUSPENSION

SERV ICING THE RE SER VO IR


Remove the Phillips screw from the center of the
compression damping adjustment knob.
Using the special tool, remove the compression
damping valve from the reservoir; turn counter
clockwise to remove,

Reinstall the valve core into the Shrader valve on

the bottom of the reservoir and charge it with 14


psi.
Attach the hose to the reservoir with new sealing
washers, then fill the reservoir with the recommend

ed oiL
RECOMMENDED O il : ATF , BetRay LT-56, Golden Spectra Light or equivalent shock oil.
Now, place the reservoir upright and disconnect
the hose.

SEALING

WASH !~RS

AND SO L T

Connect the hose to the shock using new sealing


washers.
NOTE

Make sure that you're installing the hose in


the right direction. See page 132 1.

1323

REAR WHEEL/BRAKE/
SUSPENSION

Dip the reservoir-end of the hose into a container

filled with the type of shock oil you're using.


Very slowly compress the damper rod until bubbles
disappear, then slowly pull the rod out. Repeat this
unti l all air has been bled from the hose and shock.
Remove the hose from the oil and keep the shock

upright and the open hose end elevated to avoid


losing any shock oil.

VERY SLOWLY

PUMPING

Top off the reservoir with ATF to t he top of the


threads; this excess oil will be forced out when you
install the hose fitting.

Connect the hose to the reservoir.


Wipe off any excess oil and check for oil leaks.

Release the 14 psi that was in the reservoir.


Fill the reservoir with 10 kg/cm2 (14 2.2 psi) of
nitrogen.

Use only nitrogen to pressurize the shock


absorber. The use of an unstable gas can cause
a fire or explosion.
Install the valve cap.

1324

REAR WHEEL/BRAKE!
SUSPENSION

Install the spring and spring seat.


Turn the lower shock mount so that the rebound
adjuster is on the same side of the shock as the
reservoir hose outlet.

Tighten the spring adjuster nut until the spring


length is as specified.

LOCK NUT

NOTE
One turn of the adjuster nut changes the
spring length by 1.5 mm /0.06 in),

STANDARD SPR ING LENGTH :


199.5 mm (7.85 in)
Use this standard spring preload length just as a

baseline . See the Owner's Manual for detailed instructions on adjusting preload for rider weight and
setting damping for riding conditions and rider skill.

A: DECREASE THE SPR ING LENGTH


B: INCREASE THE SPRING LENGTH

INSTALLATION

Raise the rear wheel off the ground by placing iii


jack or block under the engine.
Install the rear shock absorber to the shock arm.
TorQue the lower bolt.
TORQUE: 40-50 N'm f4.0- S.0 kg -m , 29- 36 ft -Ib)

1325

REAR WHEEL/BRAKE/
SUSPENSION

UPPER MOUNT BOLT

Apply molybdenum disulfjed (MoS2) paste (con


taining more than 40% of MoS21 to the upper
mount bushings.

NOTE

Use MoS2 paste (containing more than 40% of


MoS2) as fo llows:

Molykote G-n Paste manufactured by


Dow Corning U.S.A.
Aocol Paste manufactured by Sumico

Lubricant Co., Ltd., Japan.


Other lubricants of equivalent quality.
Attach the shock absorber to the frame and torque
the upper bolt.

TORQUE : 40-50 N'm (4.5-5.0 kg-m. 29-36 ftlb)

Use only the correCl bolts. Do not SUbSfihlfe

other fasteners, since they may - not have


adequate strength and may fail during opera
tion.

Install the air cleaner (Page 4-5).

Route the reservoir hose properly (Page 1- 11 ) and


position the reservoir on the bracket aligning its
locating pin wi th the hole in the bracket.
Install the reservoir clamps and tighten thei r screws.
Install the followings.
- side covers.
- seat.

Check the operation of the shock absorber.

I
1326

REAR WHEEL/BRAKE!
SUSPENSION

SWING ARM/ SHOCK LINKAGE


REMO VA L
Raise the rear wheel off the ground by placing a
work stand or box under the engine.
Remore the rear wheel.
Remo ve the brake pedal return spr ing.

RETURN SPRING
Remove the shock linkage pillot bolts.
Remove the swing arm pivot bolt and the swing arm
from the frame.

SHOCK LI NKAGE PIVOT BO LTS

Remove the shock linkage pivot bolt and the lower


shock mount bolt.
Remove the shock linkage.

1327

REAR WHEEL! BRAKE!


SUSPENSION

CHA IN "U'Uo

D ISASSEMB LY
Remove the chain slider, chain guide and mudgard
from the swing arm.

Remove the dust seal and pivot collar.

DUST

CHAIN SUDER

Install the bearing remover into the swing arm pivot


BEARING REMOVER, 20 mm
No.
10600

hole and expand the tool behind the bearing.

Drive the bearing out with the slide hammer.


NOTE
If the swing arm bearings are removed, t hey

should be replaced with new ones.

0"136- 3710100

SWIN G

SWING ARM INSPECT ION

DUST SEA LS

SWING ARM

Inspect the collars, bearings, and t hrust bush ings.

Replace them if they have score marks, scratches,


or excessive or abnormal wear.
Apply molybdenum disulfied (MaSl) paste (contai ning more than 40% of MoSz) to the insides of the

bushings and dust seal lips.


NOTE

Use MoS 2 paste {containing more than 40%

of MoSz I as follows:
Molykote G-n Paste manufactured by
Dow Corning U.S.A.

Rocol Paste manufactured by Sumico


Lubricant Co., LTD. , Japan.
Other lubricants of equivalent quality.

1328

COL L AR

BUSHIN G

COLLAR BUSHING

REAR WHEEl/ BRAKE/


SUSPENSION

SHOCK LINKAGE INSPECTION


Inspect the collars, and bushings.
Apply molybdenum disulfied (MoS2 ) paste (containing more than 40% MoS2 ) to the pivot collars
and lip of the dust seals.

NOTE
Some sources of paste grease with 40% or more
molybdenum afe:
Molykote G'n Paste manufactured by Dow
Corning. U.S.A.

locol Paste manufactured


lubricant, Japan.

by

Bel-Ray Moly-Lube NIC-B, U.S.A.

Sumico

Any other manufacturer's paste grease equivalent the above may also be used.

0 '

to

ASSEMB LY

Q:g

~
cto

~1?,;1

SHOCK LINK

~@

SHOCK ARM

I.!.JI

ARM

1329

REAR WHEEL/BRAKE/
SUSPENSION
ASSEMBLY
Clean the bearings, then lubricate them with grease,
and carefully drive the needle bearings into the
swing arm with the special tool below the edge of
the hole.
Drive the thrust bushings into the swing arm with

the same tool.


NOTE
1

Install the bearings with the marks facing out

Lubricate the bearings with grease after installation.

AT'CA7'~~~T,

32 x

mm

PILOT, 20 mm 07746-0040500
Install the pivot collar and dust seals.
Install the chain guide, chain slider and mudguard.

Install the arm onto the lower shock absorber


mount.
TORQUE: 40- 60 N'm (4.0 -5.0 kg-m, 29- 36 ftlbj
Install the shock link with the connecting rod pivot
bolt.
TORQUE: 40-50 N'm (4.0-5.0 kg-m, 29-36 ftlbl

1330

_..;,CHA IN GUIDE

REAR WHEEL/ BRAKE/


SUSPENSION

Install the swingarm and torque the pillot bolt.

TORQUE : 80- 100 Nm


(8- 10 kg -m , 58- 72 ft lbl
Install the shock arm onto the swingarm.

TORQUE : 80- 100 Nm (8-10 kg.m, 58- 72 ftlb)


Install the shock link to the shock arm.

TORQUE : 40- 50 N-m 14- 5 kg -m , 29 - 36 ft lbl

Ap ply grease to the swingarm pivot through t he


grease fitting.
Apply molybdenum disulf ied (MoS2) paste to the
linkage bushings th rough the grease fitt ings o n the
lin kage piYots.

BRAKE PEDAL
REM OVAL
Pull the brake arm pin holder forward and disconnec t the brake rod from the brake arm.

1331

REAR WHEE LIBRAKE!


SUSPENSION

Remove the brake pedal return spring.


Remove t he brake pedal mount bolt.

Remove the brake pedal pivot and remove the brake

pedal.

Remolle the pivot rubber seals.

BRAKE PEDAL PIVOT

INSTA LLATI ON
When assembling, apply grease to the brake pedal
pillot bolt and pivot rubbe r seals.
Install the brake pedal in the reverse order of removal.
j

BRAKE PEDAL

SPRING

1332

MEMO

HYDRAULIC BRAKE
XR: 250R

20-30 N'm

(2 .0 - 3 .0 kg-m ,
14-22 ft -Ib)

20 - 25 N'm

(2 .0- 2.5 kg-m,

~
4 _ ' B ft'b)
/

15- 20 N-m
14 ft .lb)
(1.5- 2.0 kg-m. 11 ()

~o

14-0

14. HYDRAULIC BRAKE


SERVICE INFORMATION

14 -

TROUBLESHOOTING

14-

BRAKE FLUIO REPLACEMENT/AIR BLEEDING

14-

BRAKE PAD/DISC

14-

MASTER CYLINDER

14-

BRAKE CALIPER

14- 10

SERVICE INFORMATION
GENERAL

Use DOT-4 brake fluid .


Bleed the hydraulic system if it is disassembled or if the brake feels spongy.
00 not allow foreign material to enter the system when filling the reservoir.
Avoid spilling brake fluid on painted surfaces or instrument lenses, as severe damage can result .
Always check brake operation before riding the motorcycle.

SPECIFICATIONS
STANDARD

Front disc thickness

3.5 mm (0,14 in)

SERVICE LIMIT
3.0 mm (0. , 2

in)

0.30 mm (0.012 in)

Front disc runout

Front master cylinder to.

12.700-12.743 mm (0.5000-0.5017 in)

12.755 mm (0.5022 in)

Front master piston 0.0.

12.657-12.684 mm (0.4983-0.4994 in)

12.640 mm (0.4976 in)

Front caliper cylinder 1.0.

25.400- 25,405 mm (1.0000 - 1.0002 inl

25.45 mm (1.002 inl

Front caliper piston 0 .0 .

25.318- 25.368 mm (0.9968- 0.9987 in)

25.30 mm (0.996 in)

T ORQUE VALUES
Front brake caliper bolt
Pad pin
Caliper bracket pin

20-30 Nm 12.0-3.0 kg -m, 14 - 22 ft-Ib)


15 - 20 Nm 11.5 - 2.0 kg-m. 11 - 14 ft-Ibi
20 - 25 N'm 12.0-2.5 kg -m . 14 - 1 8 ft-Ibl

TOOL
SPECIAL
Snap ring pliers

07914 - 3230001 (Commercially available in U.S.A.)

141

HYDRAULIC BRAKE

TROUBLESHOOTING
Brake Lever Soft or Spongy
1. Air in hydraulic system.
2. Low fluid level.
3. Hydraulic system leaking.

Brakes Grab or Pull to One Side


1. Pads contaminated.
2. Oisc or wheel misaligned.

Brake l ever Too Herd


1. Sticking pistonls)
2. Clogged hydraulic system.
3. Pads glazed or worn excessively.

Brake Chatter or Squeal


1. Pads contaminated.
2. Excessive disc runout .
3. Caliper installed incorractly .
4. Disc or wheel misaligned.

Brakes Drag
1. Hydraulic system Slicking.
2. Sticking piston/51
3. Incorrect rear brake pedal adjustment.

142

HYDRAULIC BRAKE

BRAKE FLUID REPLACEMENT /


AIR BLEEDING
Check the fluid level with the master cylinder
paraUel to the ground .
CAUTION

irIS/ali the maSler cylinder cover when


operating the brake fever. Failure to do so
wiff aI/ow brake fluid (0 squirt OUI oj Ihe

during brake operation.


A void spilling fluid on painted surfaces.

reser~oir

BRAKE FLUID DRAINING


Connect a bleed hose to the bleed valve.
Loosen the caliper bleed valve and pump the brake

lever. Stop operating the lever when fluid stops


flowing out of the bleed valve .

contaminated brak~ disc or pad reduces stop


ping power. Discard contaminated pads and
clean Q contaminated disc with Q high quality
brake

(3/4 in) SPACER

BRAKE FLUID FILLING


NOTE
Do not mix different types of fluid since they
are not compatible.

Close the bleed valve, fill the master cylinder. and


install the cover.
To prevent piston overtravel and brake fluid seepage, keep a 20 mm (3/4 in) spacer between the
handleber grip and Jever when bleeding the front
brake system. Pump up the system pressure with
the lever until there are no air bubbles in the fluid
flowing out of the reservoir small hole and lever
resistance is felt .

143

HYDRAULIC BRAKE

BLEEDING
NOTE

Check Ihe fluid level often while bleeding


the brakes to prevent air from being

pumped into the system.


Use only DOT 4 brake fluid from 8 sealed
containsr.
Do nOI mi)( brake fluid types and never
reuse the contaminated fluid which has
been pumped out during brake bleeding.
because this will impair the efficiency of

the brake system.


When using 8 brake bleeding tool, follow
the manufacturer' s instructions.
Pump the brake lever to bring the caliper pads in
contact with the disc.
Remove the master cylind er covel and fill it t o near
full.
Connect the Mityvac Brake Bleeder No. 6860 or
equivalent to the bleed valve.

Pump 1M brake bleeder and loosen the bleed valve.


Add fluid when the fluid level in the master cylinder
is low.
Repeat the above procedures until no air bubbles
appear in the plastic hose .

NOTE
If air is entering the bleeder from around the
bleed valve threads, seal the threads with
teflon tape .
If Ihe brake bleeder is not available, perform the
following precedure.

11

Squeeze the brake lever, then open the


bleed valve 1/2 turn and close the valve.

NOTE
00 nol release the brake lever until the bleed
valve has been closed .
21

Release the brake lever slowly end weit


several seconds after it leaches the end of
ils travel.

Repeat steps 1 and 2 until bubbles cease to appear


in the fluid at the end of the hose,

144

, MI"#-Yv";,i

oqAKE
u.
BLEEDER
OR EQUIVALENT

HYDRAULIC BRAKE

Fill the fluid reservoir to near full.

A contaminated brake disc or pad reduces stopping po ...er. Discard contaminated pads and
dean Q COn/aminated disc with
brake degretuing agent.

high quality

BRAKE PAD/ DISC


PAD REPLACEMANT
NOTE

Alwavs replace the brake pads in pairs t o


assure even disc pressure.
Remove the pad pin plugs and loosen the pad pins.

Remove the caliper bolts, caliper and bracket from


the left fork leg.

CA W 't" BOLTS

Pull the pad pins out of caliper.

145

HYDRAULIC BRAKE

Position the pad springs in the caliper as shown.


Push the caliper pistons in all the way .

Install new pads in the caliper .


Install the pad pins, one pad pin first, then install the
other pin by pushing the pads against the caliper to
depress the pad spring.

.......;. SI LICONE
Make sure the pad spring on the caliper bracket is in

place.
Apply silicone grease to the caliper bracket pins.

Assemble the caliper and bracket as shown.

146

HYDRAULIC BRAKE
PAD PI N PLUGS

Tighten the pad pins.


TORQUE : 15-20 Nm
(1.5-2.0 kg-m. 11-14 ftlb)

CALIPER BO LTS
Install the caliper so that the b rake disc is positioned
between the pads, making sure not to damage the
pads and tighten the caliper bolts.
TORQUE: 20-30 N-m
(2.a - 3.a kg -m. 15- 22 ft -Ib)

Install the pad pin plugs.

DISC TH ICKNESS
Measure the thickness of disc.
SERVICE lEMIT : 3.0 mm 10.12 In)

147

HYDR A ULIC BR AK E

BRAKE DISC WARPAGE


Measure the brake disc for warpage on a surface

plate .
SERVICE LIMIT: 0.30 mm {0.0 12Inl

MASTER CYLINDER
DISASSEMBLY
Drain brake fluid from the hydraulic system.
Remove the brake lever from the master cylinder.
Disconnect the brake hose.
CAUTION

Avoid spill;ng broke fluid on pointed sur/aces.


PfQCf' Q fag over the fuel lank whenever the
brake system is serviced.
NOTE
When removing the brake hose bolt, cover the
end of the hose to prevent contamination.
Secure the hose to prevent fluid from leaking

out.
Remove the master cylinder.
Remove the piston boot and the circtip from the
master cylinder body_

148

SNAP RING PLIERS


079143230001

HYDRAULIC BRAKE

Remov e the secondary cup and


remove the primary cup and spring.

piston. Then

PISTON

Clean the inside of the master cylinder and reservoir


with brake fluid .
SECONDARY

..,

c~~J'i8'~
I' e 3

PRIMARY CUP - - - -

c:

~~@

INSPECTION
Measure the master cylinder 1.0.
SERVICE LIMIT: 12.755 mm (0.5022 in)
Check the master cylinder for scores, scratches
nicks.

Of

Measure the masler cylinder piston 0.0.


SERVICE LIMIT: 12.640 mrn (0.4976 in)
Check the primary and secondary cups for damage
before assembly.

149

HYDRAULIC BRAKE

BRAK E FLUID

ASSEMBLY
CAUTION

Handle the milster cylinder piston, cylinder and

spring as a set.

~:l

Assemble the master cylinder. Coat all parts with

clean brake fluid before assembly.


spring and primary cup together.

Install the

Dip the piston cup in brake fluid before assembly.


CAUTION

When installing the cups, do not affo", the lips


to turn inside OUI. Be cerlain [he circlip is seated
firmly in the groove.
Install the piston clip and boot.

I
I

Place the master cylinder on the handlebar and install the holder with the two mount ing bolts.

Tighten the top bolt first.


Tighten the brake hose to the specified torque.

TOROUE : 12- 15 Nm
11 .2- 1.5 kgm, 9- 11 fttb)
Install the brake lever.
Fill t he master cylinder to near full and bleed the
brake system according to page 14-4 .

BRAKE CALIPER
REMOVAL
Place a clean container under the caliper and
disconnect the brake hose from the caliper.
CAUTION

A void spilling brake fluid on painled surfaces.


Remove the caliper bolts, caliper and bracket.

CA I_IP'''' ,,01 TS

1410

HYDRAULIC BRAKE

DISASSEMBLY
Remove the following:
-caliper bracket.

- pads and pad springs.


- caliper pivot boots.
- pistons from the caliper.

If necessary, apply compressed air to the caliper

fluid inlet to get the piston out . Place a shop rag


under the caliper to cushion the piston when it is expelled. Use the air in short spurts.

Examine the pistons and cylinders for scoring.


scratches or other damage and replace if necessary.

Push the piston seals in, lift them out and discard
them .
Clean the brake piston seal grooves with brake fluid .
CAUTION

Be careful not to damage the piston sliding surfaces when removing the seals.

1411

HYDRAULIC BRAKE

PISTON INSPECTION
Check th e pistons for scoring. scretches or other

damage. Measure the piston diameter with a micrometer.


SERVICE LIMIT: 25.30 mm (0 .996 Inl

CYLINDER INSPECTION
Check the caliper cylinder bore for scoring. scratches or other faults. Messure the caliper cylinder

bore.
SERVICE LIMIT: 25.45 mm 11.002 Inl

INGS

ASSEMBLY
If the piston boots are hardened Of deteriorated,
replace them with new ones. The piston seals must
be replaced with new ones whenever they are
removed.
Coal the seals with silicone grease or brake fluid
before assembly.

Install new oil seals and piston boots.

Inslall the pistons with the insulated ends toward


the pads.

Ins tall the boots making s ure thai the boots are
sealed in the caliper grooves properly.
InSlellths pad springs and pads.

1412

HYDRAULIC BRAKE
SILI CONE
Apply silicone grease to the caliper bracket pins and
assemble the caliper and bracket .

PADS,:!~~...

CALIPER BRACKE T
Install the caliper on the fork leg and tighten the
caliper bolts.

TORQUE: 20-30 N'm

12 .0-3.0 kgm, 15 - 22 ft -Ib)


Tighten the pad pins and install the pad pin plugs.
Connect the brake hose.
Tighten the hose joint bolt.
TORQUE : 30-40 Nm
(3,0-4 .0 kg-m, 22-29 ft -Ibl
Fill the master cylinder and bleed the brake system
(Page 14-4).

1413

MEMO

15. REAR FENDER/EXHAUST PIPE


REAR FENDER

15- 1

EXHAUST PIPE

15-2

REAR FENDER
REMOVAL
Remove the seat and the left side cover.
Disconnect the taillight wire connectors and clamp.
Remove the two bolts attaching the taillight and the
taillight.

Remove the three nuts attaching the tool bag and


the tool bag.
Remove the two bolts mounting the rear fender and
the rear fender.

INSTALLAT ION
Install the fender in the reverse order of removal.

'~71''';,~ NUTS

BOLTS

RE"R' f'ENIDER BO LTS

151

REAR FENDER I
EXHAUST PIPE

EXHAUST PIPE
Do not service the exhaust pipes while they
are h OI.

REMOVAL
Remove the seat.
Remove the right side cover.
Remove the muffler mounting bolts.
Loosen the exhaust pipe clamp bolts and remove
the muffler .

Remove the exhaust pipe joint nuts and the exhaust


pipe.

MUFFLER
GASKET

~""--

MUF FLEF\~

LID

18- 25 N' m
(1.8- 2.5 kg-m , 13- 18 fttb)

GASKET

'"
~

18- 25 Nm
( 1.8 - 2.5 kg-m, 13- 18 ft .lb)

152

COLLAA

MAFFLER PLATE

"F

EXHAUST PIPE

8- 12 Nm
(0.8- 1.2 kg-m,
6- 9 ft-lb)

MEMO

IGNITION SYSTEM

~--./-- ---

GENERATOR

IGN ITION SYSTEM


ENGINE STOP
SWITCH

SPARK

PLUG
0

PULSE

GENERATOR

:),

-L

COIL

CO l
101

HEADLIGHT

AC REGULATOR

CDI UNIT

IGNITON

16-0

~ 'E'h

- ALTERNATOR

TAllliG HT

16. IGNITION SYSTEM


SERVICE INFORMATION

16- 1

TROUBLESHOOTING

16- 1

IGNITION COIL

16-2

ALTERNATOR

16-2

COl UNIT

16- 3

PULSE GENERATOR

16- 4

IGNITION TIMING

16-5

ENGINE STOP SWITCH

16-5

SERVICE INFORMATION
GENERAL
Ignition timing cannot be adjusted since the COl (Capacitive Discharge Ignition) unit is non-adjustable. If ignition timing is
incorrect, check. the COl unit, pulse generator and alternator and replace the faulty parts.
For spark plug gap inspection and adjustment procedure , see page 3-8.
For alternator removal and instal lation, see section 9.

SPECIF ICATIONS
XR200R

ITEM
Spark plug

Standard

DPR9Z (NGK) or X27GPRU (NO)

For cold climate

DPR8Z (NGK) or X24GPR-U (NO)

Plug gap
Ignition timing

XR250R

0.6 0.7 mm (0.02 0.03 in)


0

Initial

BTDC 8 at 1900 rpm

Full advance

STDC 28 at 4300 rpm

Alternator output

BOw/5OO0 rpm

TOOLS
SPEC IAL
KS-AHM 32-003
Sanwa electric tester 07308-0020000 or [
TH-5 H

TROUBLESHOOTING
No Spark at Plug
, . Engine Stop switch "OFF"
2. Poorly connected, broken or shorted wires
- Between alternator and ignition coil

- Between CO l unit and engine stop switch


- Between ignit ion coil and plug

- Between pulse generator and COl unit


3. Faulty ignition coil

4 . Faulty COl unit


5. Alternator faulty
6. Faulty pulse generator

Engine Starts but Runs Poorly


1. Ignition primary circuit
- Fau lty ignition coil

- loose or bare wires


- Faulty pulse generator
2. Secondary ci rcuit
- Alternator faulty
- COl unit faulty

- Faulty pulse generator

161

IGNITION SYSTEM

IGNITION COIL
REMOVAL
Remove the seat and fuel tank.

Disconnect the wire leads.


Remove the ignition coil.

INSPECTION

BLACK

Measure the resistance of the primary and secondary


ooil.

PRIMARY :

0.16-0.19 n

SECONDARY: 3.69-4.51 Kf2

INSTALLATION
Install the ignition coil in the reverse order of
removal.

GREEN

(SECONDARY)

ALTERNATOR
NOTE
It is not necessary to remove the stator coil to
make this test.

LIGHTING COl L INSPECTION


The lamp coil is correct if there is continuity
between the blue wire and ground.

EXCITER COIL INSPECTION


The exciter coil is normal if there is continuity
between the black /red wire and ground.

RESISTANCE:

162

50-200

IGNITION SYSTEM

_..;C
;;;D
;;' UNIT

COl UNIT
REMOVAL
Remove the seat and fuel tank
Disconnect the connector.
Remove the COL

BlACK/WHITE

INSPECTION

BLACK/ RED

GREEN/WHITE

'84:

Disconnect the wires and check continuity of the


COl terminals. Replate the COl unit if the readings
are not within the limits shown in the appropriate
on the following page.

NOTE

The COl unit is fully transistorized.


For accurate testing, it is necessary to use a
specified electric tester, Use of an improper
tester may give false readins.

Use a Sanwa Electric Tester (PIN 073080020000) or Kowa Electric Tester (TH-5H)
or KS-AHM-32-003 Kowa Digital Multi-

meter

BLACK

After '84:
BLACK/YEllOW

BLACK/WHITE

BLUE/ YELLOW

GREEN

BLACK/ RED
REEN! YELlOW

16 3

IGNITION SYSTEM

'84:

Range:
SANWA:
KOWA:

Green

Blue/Yellow

Green/White

Black / Red
Black/White

Black

50 500

5 500

Green
Blue/Yellow

0.5-59

Green/White

5 500

BIKk/ RIId

1.0-100

Black/White

Black

50 1000
~

1.0- 100

Bl ACK/vVHITE
BLACK/ RED

Range:
SANWA:
KOWA :

Black/White

------

BLUE/ YE LLOW
GREEN
GREEN/WHITE

Black/ Aed

Blue/ Yellow

50

0 .5 - Sa

500

1.0 - 100

INSPECTION
Disconnect the pulse generator wire connector.
Measure the resistance between the green/white
and blue/vellow wire terminals.

Green
GreenIWhite

50

x lOOn

500

~
~

xkn

Black/ Yellow

5 - 500

PULSE GENERA TOR

RESISTANCE : 468-572

1000

1.0 - 100

BLACK!Y ELlOW

164

-----------

After '84:

xkn
x lOOn

500
1000

5000
~

500 - 5000

IGNITI ON SYST EM

IGNITION TIMING

INDEX NOTCH

INDEX NOTCH

ADVANCER ROTOR INSPECTION


Remove the l iming hole cap.
Connect a tac hometer and a timing light.

Start the engine and allow it to idle.


IDLE SPEED: 1,300 100 rpm

The timing is normal if the "F" mark aligns with the


index notch.

The index notch should be between the advance


marks at 4,000 rmp,

ENGINE STOP SWITCH


Re move the headlight and disconnect the terminals .
Check the switch for continuity between the
black /white and black/green terminals with the
switch OFF.

PUSH

Bkl W

BklG

FREE

165

MEMO

17. TECHNICAL FEATURES


R.F.V.C. ENGINE

17 - 1

DUAL CARBURETORS

17 - 3

RFVC (Radial Four Valve Combustion) ENGINE


The RFVC IRadial Four Valve Combustion) engine incorporates a cylinder head which has in two intake and two exhaust
valves arranged radially . This design allows the largest possible valves to be used which maximizes intake and exhaust ef
fic iency.
The radial valve arrangement also enables a shallow hemispherical combustion chamber with a centralized spark plug location
10 be formed. This shape provides a high compression ratio and promotes rapid combustion, both of which increase horse
power end torque.

171

1
T ECHNICAL FEATURES
To ensure positive and reliable valve operation, sub-rocker arms are used in conjunction with conventional rocker arms to open
the radiallv arranged valves,

The subrocker arms minim ize side loads on the valve stems during operation.

SUB-ROCKER ARM

17-2

TECHNICAL FEATURES

DUAL CARBURETORS
This model has dual carburetors and an interport reed valve to provide smooth, precise throttle response at low speed and
maximum power delivery at high speed. From low speed to mid-range, the primary carburetor opens and supplies t he fuel
air mixture to the engine while the secondary carburetor remains closed, This ensures high air velocity through the primary
carburetor to provide smooth throttle response at low speeds. The reed valve between the two intake ports is also open at

this time allowing fuel-air mixture to enter the combustion chamber through both intake ports. From mid-range to full throttle,
the secondary carburetor opens causing the feed valve to close. The primary and secondary carburetors the n supply the engine
w ith the fuel air mi)!;ture through the two intake ports. Because both carburetors are open, a large volume of fu elair mixture
can be drawn into the engine to provide maximum power.

REED
VALVE

lOW/ mid-range flow

High-range flow

17-3

MEMO

18. TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START

18-1

ENGINE LACKS POWER

18-2
18-3

POOR PERFORMANCE AT LOW AND IDLE SPEEDS

18-4
18-4

POOR PERFORMANCE AT HIGH SPEED


POOR HANDLING

ENGINE DOES NOT START OR IS HARD TO START


Probable Gause:
1. Check if fuel is getting to the

carburetor
GE TIING TO CARBURETOR

2. Try spark test


SPARKS JUMP

NOT GETTING TO - - - - - - . 111 No fuel in fuel tank


CARBURETOR
121 Clogged fuel tube or fuel
strainer
131 Clogged float valve
141 Clogged fuel tank cap
breather tube.

WEAK OR NO SPARK - - - - - . 111 Faulty spark plug


121 Fouled spark plug
131 Faulty COl unit
141 Broken or shorted high
tension cord

151 Faulty alternator


161 Broken or shorted ignition
coil

171 Faulty engine stop switch


181 Faulty pulse generator
191 Poorly connected, broken
or shorted wires;
3. TEST CYLINDER COMPRESS ION

LOW COMPRESSION

COM PRESSION NORMAL

111 Insufficient valve clearance


121 Valve stuck open
131 Worn cylinder and piston
rings

141 Damaged cylinder head gasket


151 Improper valve timing
161 Improperly adjusted decom
pression mechanism

171 Seized valve


4 . Start by following normal starting
procedure

ENGINE FIRES BUT


SOON STOPS

( 1) Choke excessively open

121 Carburetor pilot screw


excessively closed

ENGINE DOES NOT FIRE

131 Air leaking past inta ke manifold


141 Improper ignition timing

j
5. Remove spark plug

(CO l unit or pulse


generator faulty)
WET PLUG

(1) Carburetor flooded

121 Carburetor choke excessively

DRY

closed

131 Throttle valve excessively


open

6. STAR T WI TH CHOKE APPLIED

181

lEI

TROUBLESHOOTING

ENGINE LACKS POWER


Probable Cause:

1. Raise wheels off ground dnd spin


by hand

WHEEL DOES NOT SPIN

FREELY

111 Brake dragging


121 Worn or damaged wheel
bearing

131 Wheel bearing needs

WHEEl SPINS FREelY

lubrication

141 Drille chain too tight


151 Rear axle nut excessively
tightened
2. Check tire pressure with tire
gauge

PRESSURE TOO lOW

111 Punctured fire


121 Faulty tire \I.I\le

ENGINE SPEED DOES NOT

111 Clutch slipping


121 Worn clutch disc/plate
13) Warped clutch disc/plate

11 1
121
13)
141

PRESSURE NORMAL

3 . Try rapid acceleration from low to


second

CHANGE WHEN CLUTCH IS

RELEASED
ENGINE SPEED LOWERED WHEN
CLUTCH IS RELEASED

4. Lightly accelerate engine

ENGINE SPEED DOES NOT

INCREASE SUFFICIENTLY
ENGINE SPEED INCREASE

j
S. Check ignition timing

Carburetor choke closed

Clogged air cleaner


Restricted fuel flow
Clogged fuel tank breather
tu,,"

151 Clogged muHler


INCORRECT

11) Faulty CO l unit


121 Faulty pulse generator

INCORRECT

111 Improper velve adjustment


121 Worn velve seat

TOOL LOW

111 Valve stuck open


12) Worn cylinder and piston

CORRECT

6 . Check valve clearance


CORRECT

7 . Test cylinder compression


using compression gauge

rings

(3) Le~k ing head gasket


(4) Improper valve timing
151 Improperly adjusted

NORMAL

8 . Check carburetor for clogging

decompression mechanism
CLOGGED

.. (1) Carburetor not serviced

frequently enough
NOT CLOGGED

9 . Remove 5park plug


NOT FOULED OR DISCOLORED

I
182

FOULED OR DISCOLORED

111 Plug not replaced frequently


enough

121 Use of plug with improper


heat range

TROUBLESHOOTI NG
10. Remove o il level gauge and check

OIL lEVElINCOAREcr------ - (11 Oil level too high


(2) Oillel/el too low

oil level.
CORRECT

j
11 . Remove cyli nder head cover and
inspect lubr ication

VALVE TRAIN NOT - - - - - - - ( 1) Clogged oil passage


LUBRICATED PROPERLY
(2) Clogged oil control orifice
(3) Contaminated oil

VA LVE TRAIN LUBR ICATED


PROPERLY

12. Check if engine overheats

OVEAHEATED' -------~

in combustion cham ber

NORMAL

12) Improper quality fu el


13) Clut ch slipping
14) Fuel air mixture too lean

j
13. Accelerate or run at high speed

11) Excessive carbon build-up

ENGINE KNOCKS - - - - - -.

ENGINE DOES NOT KNOCK

11) Worn piston and cyl inder


12) Fuel/air mixture too lean
13) Use of improper grade of
fuel
14) Excessive carbon build-up
in combustion cham ber

15) Ignitio n timing too advanced


(Faulty COl unit)

POOR PERFORMANCE AT LOW AND IDLE SPEEDS


Probable Cause :

1. Check ignition t iming and valve


clearance

INCORRECT----------- (1) Improper valve clearance


(2) Improper ignition timing
(Faulty COl unit)

CORRECT

2. Check carburetor pilot screw


adjustment
CORRECT

3. Check if air is leaking past

I NCOARECT----------. 11) Fuelair mixture too lean


(To correct , screw out)
12) Fuel air mixture too rich
(To correct, screw i n)
LEAKING

11) Deteriorated insulator


Ori ng

manifold

12) Loose carburetor


NOT LEAKING

4 . Try spark test

GOOD SPARK

WEAK OR INTERMITTENT SPARK -

(11 Faulty , carbon or wet


fou led spark plug
(2) Faulty COl unit
(3) Alternator faulty
(4 1 Faulty ignition coil
(51 Faulty pulse generator

183

TROUBLESHOOTING

POOR PERFORMANCE AT HIGH SPEED


Probable Cause:
1. Check ignition timing and valve

INCORRECT - - - - - - - - 111 Improper valve clearance

clearance

121 Faulty CDI unit


131 Faulty pu lse generator

CORRECT

2. Disconnect fuel line at carburetor

FUEL FLOW RESTRICTED - - -.

FUEl flOWS FREELY

111 Lack of fuel in tank


121 Clogged fuel line
131 Clogged fuel tank breather
"be

14) Clogged fuel valve

3. Rem ove carburetor and check for

ClOGGED----------.
111 Clean

clogged jet(s)
NOT CLOGGeD

INCORRECT"---------__ (1) Cam sprocket not installed


properly

4. Check valve timing


CORRECT

5. cieck valve spring tension

W E A K - - - - - - - - - - - - . (1) Faulty spring

NOT WEAKENED

POOR HANDLlNG,- - - - Check tire pressure


Probable Cause:
1. If steering is heavy

----------------------+

111 Steering head adjuster too


tight

12) Damaged steering bearing(s)

2. If either wheel is wobbling - - - - - - - - - - - - - - - - - - - _ 111 Excessive wheel bearing play


12) Bent rim
13) Improperly laced wheel
hub

(4) Swing arm pivot bushing


excessively worn

15) Bent frame


16) Loose swing arm pivot bolt
3. If the motorcycle pulls to one side - - - - - - - - - - - - - - - -_

184

Front and rear wheels not


aligned
12) Bent front fork
13) Bent swing arm
14) Bent frame

(1)