1986-2002 Honda XLR200R, XR200R Motorcycle Service Manual

Complete service and repair manual for Honda XLR200R and XR200R motorcycles (1986-2002). Covers all systems and components, Publication C4085-91017.

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Document Details

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Document Number / Seller:
29710 / Daniel Parker
File Size:
74.45 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Motorbike
Last updated / verified
Nov 16, 2025

Models Covered & Key Technical Specifications

1986-2002 Honda XLR200R, XR200R Motorcycle Service Manual: Precision Maintenance & Troubleshooting Transmission-Guide Honda XLR200R, XR200R (C4085-91017) - 1986-2002. Structured Automotive Briefing | Honda Package.

  • Designated Storage Capacity: 9.0 liters dictates the maximum fuel reserve Requirements.
  • Verified Tolerance Values: 0.10-0.02 mm specifies the engine oil clearance Benchmarks.
  • Nominal Consumption Data: 1.2 liters is the standard engine oil volume Threshold.
  • Defined Heat Dissipation: 14.5 km/h is the standard braking distance Baseline.
  • Key Footprint Data: 26 is the standard caster setting Sequences.
  • Essential Tank Capacity: 2.0 kg-m signifies the torque for the starter clutch bolts Threshold.

Professional Workshop Service Manual & Technical Specifications

Unified Performance Diagnostic Manual: Honda Genuine Factory XLR200R, XR200R Repair Manual (1986-2002) - Precision Maintenance & Troubleshooting Transmission-Guide

Technical-Scope: Motorcycle // Maintenance-Category: Motorcycle / Engine Logic // Technical-Scope: Repair and Maintenance Procedures.

Specification Rating Validation-Data
Engine Oil Volume 1.0 liter 0.10-0.02 mm
Fuel Tank Capacity 9.0 liters 1.400 +/- 100 rpm
Valve Clearance 0.10 mm 20-30 mm
Drive Chain Slack 25-35 mm 10.5 kg-m

Featuring a modular arrangement of chapters covering all aspects of motorcycle maintenance and repair. This manual provides essential information for ensuring your Honda XLR200R or XR200R operates at peak performance.

Clearancemeasurements are addressed for all critical engine components, ensuring proper assembly and function.

Special procedures are addressed for the front and rear brake systems, including pad replacement and caliper service.

Verification procedures are included for the ignition system, covering spark plugs, ignition coils, and pulse generators.

Repair information is provided for the suspension systems, including fork and rear shock absorber maintenance.

The document includes coverage of electrical system components, such as the battery, AC generator, and regulator/rectifier.

This manual documents torque specifications for critical fasteners to ensure proper pivot-point integrity.

FAQ

Assess the **critical** calibration settings for optimal performance. keyboard_arrow_down

1.2 liters is the standard engine oil volume for the Honda XLR200R/XR200R, with a 1.0 liter replacement volume, ensuring proper lubrication.

What components **required** clearance measurements are detailed? keyboard_arrow_down

0.10-0.02 mm is the specified valve clearance for both intake and exhaust valves, crucial for engine timing.

Confirm the **specified** torque specifications for engine assembly. keyboard_arrow_down

10.5 kg-m is the torque specification for the swing arm pivot bolt, ensuring secure and stable suspension.

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Reviews (3)

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Rated 4 out of 5 stars
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I appreciate the comprehensive details on engine specifications and maintenance. The diagrams are clear, and the download process was quick and smooth. Highly recommend!
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This manual has been a game changer for my motorcycle maintenance. The layout is user-friendly, making it easy to find what I need. Plus, the troubleshooting section is incredibly helpful!