Honda XL125, XL185, XL200, XR185, XR200, TLR200 Repair Manual 1979-2003

• Honda XL125S, 1979-1982, 1984-1985
• Honda XL185S, 1979-1983
• Honda XL200R, 1983-1984
• Honda XR185, 1979
• Honda XR200, 1980-1984
• Honda XR200R, 1981-1983, 1986-1988, 1990-2003
• Honda TLR200, 1986-1987

All models covered in this book are equipped with an air-cooled, 4-stroke, single cylinder engine with a single overhead camshaft.

The crankshaft is supported by 2 main ball bearings. The camshaft is chain-driven from the timing sprocket on the left-hand side of the crankshaft and operates rocker arms that are individually adjustable.

Engine lubrication is by wet sump with the oil pump located on the right-hand side of the engine adjacent to the clutch. The oil pump delivers oil under pressure throughout the engine and is gear driven off of the crankshaft.

The engine used in the various models is the same basic unit with different compression ratios and different bore and stroke dimensions to achieve varying displacements.

This chapter contains information for removal, inspection, service and reassembly of the engine. Table 1 provides complete specifications for the engine and Table 2 lists all of the engine torque specifications. Table 1 and Table 2 are located at the end of this chapter.

Tire pressure should be checked and adjusted to maintain the smoothness of the tire, good traction and handling and to get the maximum life out of the tire.

A simple, accurate gauge (Figure 3) can be purchased for a few dollars and should be carried in your motorcycle tool kit. The appropriate tire pressures are shown in Table 2.

The tires take a lot of punishment, so inspect them periodically for excessive wear, cuts, abrasions, etc. If you find a nail or other object in the tire, mark its location with a light crayon prior to removing it. This will help locate the hole for repair. Refer to Chapter Eight for tire changing and repair information.

Check local traffic regulations concerning minimum tread depth. Measure the tread depth at the center of the tire tread using a tread depth gauge (Figure 4) or small ruler.

Honda recommends tire replacement when the front or rear tread depth is 8 mm (1/8 in.) or less. Replace the tire(s) at this point.

Tap each spoke with a wrench. The higher the pitch of sound it makes, the tighter the spoke. The lower the sound frequency, the looser the spoke. A "ping" is good; a "klunk" says the spoke is too loose. If one or more spokes are loose, tighten them as described under Wheels in Chapter Eight.

• General Information
• Troubleshooting
• Lubrication, Maintenance and Tune-up
• Engine
• Clutch and External Gearshift Linkage
• Transmission and Internal Shift Mechanism
• Fuel and Emission Systems
• Exhaust System
• Electrical System
• Wheels, Tires and Drive Chain
• Front Suspension and Steering
• Rear Suspension
• Brakes
• Body and Frame
• Wiring Diagrams