1986 Honda XR200R Repair Manual

The 1986 Honda XR200R is a lightweight, air-cooled four-stroke trail motorcycle featuring a 195cc single-cylinder engine, 5-speed transmission, front and rear drum brakes, and rugged off-road suspension. This repair manual covers complete maintenance, troubleshooting, and repair procedures for engine, transmission, electrical system, chassis, and all major components. Below are key sections for specifications, maintenance schedules, engine repair, transmission service, electrical systems, and troubleshooting.

1. Specifications 2. Maintenance Schedule 3. Engine Repair 4. Transmission Service 5. Electrical System 6. Chassis & Suspension 7. Carburetor Service 8. Brake System 9. Troubleshooting 10. Torque Specifications 11. Wiring Diagrams

Specifications

Complete technical specifications for the 1986 Honda XR200R motorcycle.

Component	Specification
Engine Type	Air-cooled 4-stroke single cylinder OHC
Displacement	195cc
Bore x Stroke	65.5mm x 57.8mm
Compression Ratio	10.0:1
Carburetor	24mm Keihin piston valve
Ignition System	CDI (Capacitor Discharge Ignition)
Transmission	5-speed constant mesh
Final Drive	#520 chain
Front Suspension	Telescopic fork, 7.1 inches travel
Rear Suspension	Pro-Link single shock, 6.7 inches travel
Front Brake	Drum, 110mm
Rear Brake	Drum, 110mm
Fuel Capacity	2.4 gallons (9.0 liters)
Dry Weight	229 lbs (104 kg)

Maintenance Schedule

Regular maintenance intervals for optimal performance and longevity.

Engine Oil Change: Every 600 miles or 6 months
Oil Filter Cleaning: Every 1,200 miles
Air Filter Service: Every 300 miles (more often in dusty conditions)
Spark Plug Replacement: Every 3,000 miles
Valve Clearance Check: Every 1,500 miles
Chain Adjustment: Every 300 miles
Brake Inspection: Every 600 miles
Wheel Bearing Check: Every 2,400 miles

WARNING! Always use genuine Honda parts and recommended lubricants for best performance.

Engine Repair

Complete engine disassembly, inspection, and reassembly procedures.

Engine Removal: Disconnect battery, drain coolant, remove exhaust and intake systems
Cylinder Head: Remove camshaft, check valve clearances, inspect combustion chamber
Cylinder & Piston: Measure cylinder bore, inspect piston and rings
Crankshaft & Connecting Rod: Check bearing clearance, inspect crankpin
Engine Reassembly: Follow torque specifications, use new gaskets

CAUTION! Engine components are precision parts; handle with care and use proper tools.

Transmission Service

Transmission disassembly, gear inspection, and shift mechanism service.

Transmission Removal: Split engine cases after engine removal
Gear Inspection: Check for worn teeth, pitting, or damage
Shift Forks: Inspect for bending or wear
Shift Drum: Check for wear on cam grooves
Reassembly: Ensure proper gear engagement and shift mechanism operation

Electrical System

Complete electrical system diagnosis and repair procedures.

Components: CDI ignition, alternator, voltage regulator, battery, lighting system.

Testing Procedures: Use multimeter to check resistance and voltage outputs. Ignition coil primary resistance: 0.1-0.3 ohms. Alternator output: 13.5-15V at 5000 RPM. Battery voltage: 12.6V fully charged.

Chassis & Suspension

Frame inspection, suspension service, and steering head maintenance.

Frame Inspection: Check for cracks, bends, or damage
Front Fork Service: Oil change, seal replacement, spring inspection
Rear Shock: Nitrogen pressure check, seal replacement
Steering Head: Bearing adjustment and lubrication
Wheels: Spoke tension, rim runout check

Tip: Always use a torque wrench for chassis fasteners to prevent over-tightening.

Carburetor Service

Keihin carburetor disassembly, cleaning, and adjustment procedures.

Carburetor Removal: Disconnect fuel line, throttle cable, and vent lines
Disassembly: Remove float bowl, jets, needle valve
Cleaning: Use carburetor cleaner, compressed air
Adjustments: Float level 12.5mm, pilot screw 1-3/4 turns out
Reinstallation: Synchronize throttle operation

WARNING! Use only approved carburetor cleaners; avoid damaging rubber components.

Brake System

Drum brake service, cable adjustment, and lining replacement.

Component	Service Procedure
Front Brake	Adjust cable free play to 10-20mm
Rear Brake	Adjust pedal height and free play
Brake Shoes	Replace when lining wears to wear limit
Brake Drums	Clean and inspect for scoring or wear
Cables	Lubricate regularly, replace if frayed

Troubleshooting

Common problems and their solutions for the XR200R.

Symptom	Possible Cause	Corrective Action
Hard starting	Clogged pilot jet, incorrect valve clearance	Clean carburetor, adjust valves to 0.002" intake, 0.003" exhaust
Poor performance	Worn piston rings, clogged air filter	Compression test, replace rings if below 120 psi, clean air filter
Transmission slipping	Worn clutch plates, weak springs	Replace clutch plates and springs
Electrical failure	Bad CDI, stator failure	Test stator output, replace CDI if no spark
Oil consumption	Worn valve guides, piston rings	Engine overhaul, replace worn components

Torque Specifications

Critical torque values for engine and chassis components.

Cylinder Head Nuts: 20 ft-lbs (27 Nm)
Spark Plug: 13 ft-lbs (18 Nm)
Engine Mount Bolts: 25 ft-lbs (34 Nm)
Axle Nuts: 65 ft-lbs (88 Nm)
Sprocket Bolts: 17 ft-lbs (23 Nm)
Oil Drain Plug: 18 ft-lbs (24 Nm)

Wiring Diagrams

Complete electrical schematics for troubleshooting and repair.

Color-coded wiring diagrams showing: Ignition system, charging circuit, lighting system, CDI unit connections, handlebar switches, and ground points. Refer to diagram for proper wire routing and connector identification.

Service Support: For technical assistance contact Honda Customer Service or authorized Honda dealership.