1986-1999 Honda XR200R Service Manual

Honda XR200R technical guide detailing diagnostics, removal sequences, and maintenance for engine, chassis, and electrical systems. Includes part numbers like 07749-0010000.

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Document Details

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Document Number / Seller:
26151 / Melissa Morales
File Size:
20.11 MB
File Type:
PDF
Language:
English
Pages:
177
Printable:
Yes
Category:
Motorbike
Last updated / verified
Jul 23, 2025

Models Covered & Key Technical Specifications

Honda XR200R (1986-1999) Service Manual Service procedures are grouped by | Series Section. Container. Documented Assembly Torques: 15-22 N-m sets the primary tensioning requirements. Calibrated Liquid Volume: 0.9 liters specifies the engine oil capacity Framework. Authorized Maintenance Schedule: Every 1,600 km dictates routine service benchmarks. Maximum Engine Speed: 9,000 rpm dictates the peak operational speed Configuration. System Compression Pressure: 1,373 kPa signifies the standard cylinder compression Threshold. Principal Air Filter Type: Oiled polyurethane foam establishes the air intake filtration Parameters.

Professional Workshop Service Manual & Technical Specifications

OEM-Grade Workshop Manual: Honda XR200R Motorcycle Service Manual (1986-1999) Information-Suite

Procedure-Type: Service // Conceptual-Layout: Engine, Chassis, Electrical Logic // Model-Designation: Honda XR200R Metric Baseline Framework
Engine 27 kg Base Weight
Drive Chain Slack 35-45 mm Adjustment Range
Front Fork Oil 150 ml Standard Capacity
Front Brake Lever Play 25-30 mm Free Play Specification
Rear Shock Spring Length 190 mm Baseline Measurement
Idle Speed 1,400 rpm Target RPM

Service procedures are grouped by system and procedure. This manual provides comprehensive information on disassembly, installation, and maintenance for all major components.

Engine Systems

This manual details engine systems, including the cylinder head, valves, camshaft, and pistons. It covers disassembly, inspection, and reassembly procedures with specific torque values and service limits.

Drivetrain and Chassis Components

Procedures for the clutch, oil pump, gearshift linkage, drive chain, front wheel, rear wheel, brakes, suspension, and steering are thoroughly documented. Reliable maintenance practices are emphasized throughout.

Electrical System and Troubleshooting

Coverage includes the ignition system, lighting system, charging system, and troubleshooting for common issues. This manual is essential for maintaining your Honda XR200R. This manual documents torque specifications for engine and chassis components to ensure proper flange face sealing.

FAQ

What are the **correct** service interval parameters for the Honda XR200R? keyboard_arrow_down

1,600 km is the regular service interval specified for items like the drive chain, as detailed in the maintenance schedule.

What procedures are **documented** for the engine system architecture? keyboard_arrow_down

Engine systems, including cylinder head, valves, camshaft, and pistons, have documented procedures for disassembly, inspection, and reassembly.

Determine the **precise** tool requirements for front fork maintenance. keyboard_arrow_down

Specialized tools like the fork seal driver (07947-2730100) and fork tube attachment (07746-0010100) are required for front fork disassembly and reassembly.

What specifications are noted for **proper** ignition timing? keyboard_arrow_down

Proper ignition timing is specified as BTDC 10° at 1,400 ± 100 rpm for initial timing, and BTDC 30° at 3,500 ± 150 rpm for full advance.

Check the **standard** calibration settings for the carburetor pilot screw. keyboard_arrow_down

The standard pilot screw opening is 1-1/8 turns out, which is a critical setting for idle drop adjustment.

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This service manual is incredibly detailed and easy to follow. It helped me troubleshoot and repair my bike effectively. The download process was smooth, and I received a quick email with the link right after purchase. Highly recommend!