1986-1999 Honda XR200R Factory Service Manual

• Covers 1986–1999 Honda XR200R off-road motorcycles equipped with the 195 cc air-cooled SOHC single-cylinder engine
• Official 177-page factory-authorized publication detailing technical specifications, chassis data, and maintenance benchmarks
• Features 12 comprehensive wiring schematics and 15 torque value tables for accurate engine and chassis assembly

Manual Content

This official reference provides the technical framework required for comprehensive workshop overhauls. It covers the entire motorcycle. Chapters are grouped by location for fast bench reference. You get dedicated sections mapping out the fuel system, cylinder head, valve train, piston components, and electrical diagnostics. Each chapter includes detailed assembly illustrations and troubleshooting charts to streamline your workflow.

Engine and Chassis Specifications

Inside, you will find critical clearance limits, ignition timing curves, and fluid capacity values essential for precise rebuilds. The cylinder head specification table lists intake valve clearance at 0.05 mm and exhaust at 0.08 mm. A standard oil drain requires a 0.9-liter refill. Cylinder compression is rated at 1,373 kPa. When assembling the top end, cylinder head bolts follow a strict multi-stage torque sequence to prevent warping, with specific values mapped out for every major fastener.

Working on motorcycle internals requires precision and strict adherence to factory tolerances. Always cross-reference your measurements with the OEM parameters provided in this guide to ensure safe, reliable performance and structural integrity after reassembly.