Honda XLR200R XR200R Motorcycle Service Manual 1986-2002

• 188-page factory publication covering 1986–2002 Honda XLR200R and XR200R models
• Primary reference document detailing the MD29E engine variant and KCN frame series
• Contains 12 exploded-view mechanical diagrams and 5 torque specification tables
• Features 3 electrical component layouts and 2 wiring harness routing schematics
• Official Honda Motors Japan publication serving as an authorized baseline for mechanical maintenance

Engine and Transmission Breakdown

Get a clear look inside the gasoline 4-stroke MD29E engine. The publication walks through core maintenance data for the lubrication system, fuel delivery, and top-end components. Whether you are reviewing valve train clearances or piston specifications, the documentation lays out the exact factory requirements. You will find specific tolerances for the clutch assembly alongside gearshift linkage torque settings, giving you the baseline numbers needed for a complete rebuild or routine bench work.

Chassis and Electrical Reference

Beyond the engine, the documentation outlines front and rear suspension configurations. This includes factory stroke limits and tire pressure baselines. You can trace faults using the detailed wiring schematics and charging system specifications, while starter clutch parameters and ignition timing data are clearly mapped out. Please note that working on motorcycle electrical and fuel systems involves inherent physical risks; always ensure you are familiar with workshop safety standards before utilizing these parameters, as this overview describes the manual's contents rather than providing direct diagnostic instruction.

Specification and Reference Data

Service metrics are broken down by system to streamline your maintenance operations. The manual highlights standard values and maximum wear limits, such as a valve clearance of 0.10±0.02 mm and cylinder compression specs hitting 13.5 kg/cm². You get the exact multi-stage sequence for cylinder head bolt torque, plus essential engine assembly figures like the 8.5 kg-m lock nut requirement for the oil filter rotor. Lubrication parameters are strictly defined, noting the precise 1.2-liter total oil volume requirement to prevent premature wear.