cylinder head
Contents
1. VALVE GUIDE REAMER After driving in the valve guide ream it with a valve guide reamer NOTE e Use cutting oil on the reamer during this operation e Always rotate the reamer clockwise never counterclockwise Clean the cylinder head thoroughly to remove any metal particles Reface the valve seat VALVE SEAT INSPECTION REFACING VALVE SEAT INSPECTION Clean the intake and exhaust valves thoroughly to remove the carbon deposits Apply light coating if Prussian Blue to the valve seats Lap the valves and seats using a rubber hose or other hand lapping tool Remove the tool and inspect the width of each valve seat STANDARD 1 1 1 3mm 0 04 0 05 in SERVICE LIMIT 1 5 mm 0 06 in 4 SEAT WIDTH If the valve seat is too wide too narrow or has low spots the seat must be ground ATTENTION e The valve cannot be ground If 8 valve face is burned or badly worn or it contact the seat unevenly replace the valve 6 10 XL200 VALVE SEAT GRINDING Honda Valve Seat Cutters a grinder or equivalent valve seat refacing equipament are recommended to correct a worn valve seat NOTE e Follow the refacer manufacturer s operating instructions Use a 45 degree cutter to remove ant roughness or irregularities from the seat NOTE CYLINDER HEAD VALVES 60 32 45 e Reface the valve seat with a 45 degree cut2. and inner valve springs spring seats inlet and exhaust valve NOTE e Mark all disassembled parts to ensure correct reassembly Remove the carbon deposits from the combustion chamber Clean off any gasket materials from the cylinder head surface INSPECTION CYLINDER HEAD Check the spark plug hole and valve area for cracks Check the cylinder head for warpage with a straight edge and a feeler gauge SERVICE LIMIT 0 10 mm 0 004 in CYLINDER HEAD VALVES PIVOT BOLT WASHER SOCKET BOLT CAM CHAIN TENSIONER INSULATOR SPRING COMPRESSOR VALVE SPRING SEAT INNER SPRING 2 STEM SEAL OUTERSPRING SPRING RETAINER CYLINDER HEAD VALVES VALVE Inspect the valve for trueness burning scratches or abnormal stem wear Measure the valve stem O D SERVICE LIMIT In 5 44 mm 0 214 in Ex 5 42 mm 0 213 in Insert each valve into the valve guide and check the valve movement in the guide VALVE GUIDE NOTE e Ream the valve guide to remove the carbon build up before checking the valve guide e Always rotate the reamer clockwise never couterclockwise when installing removing and reaming Measure and record each valve guide I D with a ball gauge or inside micrometer SERVICE LIMIT IN EX 5 50 mm 0 217 in Calculate the stem to guide clearance SERVICE LIMIT IN 0 06 mm 0 002 in EX 0 08 mm 0 003 in NOTE If the stem to guide clearance exceeds the ser
3. 3 38 0 1 50 OUTER 44 85 1 766 43 5 1 71 Valve stem O D IN 5 450 5 465 0 2146 0 2152 5 44 0 214 EX 5 430 5 445 0 2138 0 2144 5 42 0 213 Valve guide I D IN 5 475 5 485 0 2156 0 2159 5 50 0 217 EX 5 475 5 485 0 2156 0 2159 5 50 0 217 Stem to guide clearance IN 0 010 0 035 0 0004 0 0014 0 06 0 002 EX 0 030 0 055 0 0012 0 0022 0 08 0 003 Valve seat width 1 1 1 3 0 043 0 051 1 5 0 06 6 1 CYLINDER HEAD VALVES XL200 27 N m 2 7 kg m 20ft Ib 10 N m 1 0 kg m 7ft lb 9 9 af SI 15 N m 1 5 kg m 11 ft lb 12 N m 1 2 kg m 9ft Ib 4N m 0 4 kg m 3ft Ib ONTE a a k 7 amp A A ea D 12 N m 1 2 kg m 9ft lb WA 3 10 N m 1 0 kg m 7ft Ib een N m 0 8 kg m 6ft Ib 6 N m 0 6 kg m 41 10 NOx P NU Q D OY CYLINDER HEAD VALVES TORQUE VALUES Valve adjusting hole cap 15N m Valve adjusting screw lock nut 14 N m 27 N m 10 N m 12 N m Cylinder head cover 8 mm cap nut Cylinder head cover 6 mm socket bolt Cam sprocket bolt Cam chain tensioner lifter mounting bolt 12 N m Cam chain tensioner lifter sealing screw 4N m Timing hole cap 6 N m Crankshaft hole cap 8 N m TOOLS Valve guide reamer 5 485 mm Valve guide driver 5 5 mm Valve spring compressor TROUBLESHOOTING XL200 1 5 kg m 11 ft lb 1 4 kg m 10 ft lb 2 7 kg m 20 ft lb 1 0 kg m
4. 7 ft lb 1 2 kg m 9 ft lb 1 2 kg m 9 ft lb 0 4 kg m 3 ft lb 0 6 kg m 4 ft lb 0 8 kg m 6 ft lb 07984 0980001 07742 0010100BR 07757 0010000BR Engine top end problems usually affect engine performance These can be diagnosed by a compression or leak down test or by tracing noises to the top end with a sounding rod or stethoscope If the performance is poor at low speeds check for white smoke in the crankcase breather tube If the tube is smoky check for a seized piston ring Compression too low hard starting or poor per formance at low speed e Valves Incorrect valve adjustment Burned or bent valves Incorrect valve timing Broken valve spring Weak valve spring e Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head e Faulty cylinder piston Section 7 Compression too high overheating or knocking Excessive carbon build up in cylinder or on top of piston 6 2 Excessive smoke e Worn valve stem or valve guide Damaged stem seal e Faulty cylinder or piston Section 7 Excessive noise Incorrect valve clearance e Sticking valve or broken valve spring e Worn or damaged push rod e Loose or worn cam chain e Worn or damaged cam chain tensioner e Worn cam sprocket teeth e Worn rocker arm and or shaft e Faulty cylinder or piston Section 7 Rough idle e Low cylinder compression 5 Intake air leak XL200 CYLINDER HEAD
5. COVER CAMSHAFT REMOVAL Remove the following starter motor crankshaft timing hole caps Remove the bolts cam chain tensioner lifter and gasket Align the T mark on the flywheel with the index mark on the left crankcase cover by turning the crankshaft counterclockwise Remove the valve adjusting hole caps and make sure the piston is at T D C on the compression stroke by checking for clearance at both rocker arms If the piston is not at T D C on the compression stroke rotate the crankshaft 360 degrees counterclockwise and recheck Remove the cam sprocket cover Remove the cam sprocket bolts by holding the crankshaft Remove the cam sprocket from the camshaft flange then remove the cam chain from the sprocket NOTE e Suspend the cam chain with a piece of wire to prevent it from falling into the crankcase CYLINDER HEAD VALVES CAM CHAIN TENSIONER INDEX MARK a MARK CAM SPROCKET COVER CAM SPROCKET CAM CHAIN 6 3 CYLINDER HEAD VALVES Remove the engine hanger plate Remove the cylinder head cover cap nuts sealing washers and flange bolts in a gradual crisscross pattern Remove the cylinder head cover Remove the camshaft Remove the dowel pins NOTE e Itis not necessary to force them out Remove the rubber plug do not lose it Clean off any sealant material from the head cover and cylinder head mating surface CAMSHAFT INSPECTION Turn th
6. CYLINDER XL200 s HEAD VALVES SERVICE INFORMATION 6 1 VALVE GUIDE REPLACEMENT 6 9 TROUBLESHOOTING 6 2 VALVE SEAT INSPECTION REFACING 6 10 CYLINDER HEAD COVER CAMSHAFT CYLINDER HEAD ASSEMBLY 6 13 REMOVAL 6 3 CYLINDER HEAD INSTALLATION 6 14 CYLINDER HEAD REMOVAL 6 6 CAMSHAFT CYLINDER HEAD COVER CYLINDER HEAD DISASSEMBLY 6 7 INSTALLATION 6 15 SERVICE INFORMATION GENERAL e This section covers service procedure for the cylinder head and valves The engine must be removed to service the camshaft cylinder head valves and rocker arms e Camshaft and rocker arm lubrication oil is fed through an oil passage Be sure the passage is not clogged Clean all disassembled parts with clean solvent and dry them by blowing them off with compressed air before inspection e Pour clean engine oil into the oil pockets in the cylinder head during assembly to lubricate the camshaft lobes SPECIFICATIONS UNIT mm in ITEM STANDARD SERVICE LIMIT Cylinder compression 1 350 kPa 13 5 kg cm 192 psi Cam lobe height IN 31 579 31 739 1 243 1 249 31 30 1 232 EX 31 419 31 579 1 236 1 243 31 20 1 228 Cylinder head warpage 0 10 0 004 Rocker arm 12 000 12 018 0 4724 0 4731 12 05 0 474 Shaft O D 11 977 11 995 0 4715 0 4722 11 93 0 470 Arm to shaft clearance 0 005 0 041 0 0002 0 0016 0 08 0 003 Valve spring free length INNER 39 2 1 54
7. ELECTRIC STARTER CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS METERS SWITCHES WIRING DIAGRAM TROUBLESHOOTING as
8. ICE LIMIT 12 05 mm 0 474 in Measure the O D of each rocker arm shaft SERVICE LIMIT 11 93 mm 0 470 in Calculate the rocker arm to shaft clearance SERVICE LIMIT 0 08 mm 0 003 in CYLINDER HEAD VALVES TENSIONER LIFTER PLATE SCREW ROCKER ARM SHAFT ROCKER ARM 6 mm BOLT ROCKER ARM ROCKER ARM SHAFT 6 5 CYLINDER HEAD VALVES CYLINDER HEAD REMOVAL Remove the following cylinder head cover engine from the frame cylinder head socket bolt washer cylinder head cam chain guide gasket dowel pins Clean off any gasket material from the cylinder head and cylinder mating surfaces Remove the cam chain tensioner Check the cam chain tensioner for excessive wear or damage Check the cam chain guide for excessive wear or damage XL200 CYLINDER HEAD SOCKET BOLT WASHER GASKET DOWEL PIN CAM CHAIN GUIDE CAM CHAIN TENSIONER CAM CHAIN GUIDE XL200 CYLINDER HEAD DISASSEMBLY Remove the cam chain tensioner pivot bolt washer and cam chain tensioner Remove the socket bolts and carburetor insulator While compressing the valve spring with a valve spring compressor remove the valve cotters ATTENTION e To prevent loss of tension do not compress the valve spring more than necessary to remove the cotters TOOL Valve spring compressor Loosen the valve spring compressor and remove the following spring retainers outer
9. ant It compensates for the initial wear that occurs during the break in period Section 1 through 3 apply to the whole motorcycle while section 4 through 18 describe parts of the motorcycle grouped according to location Find the section you want on this page then turn to the table of contents on page 1 of that section Most sections start with an assembly or system illustration service information and troubleshooting for the section the subsequent pages give detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING GENERAL INFORMATION CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE ENGINE REMOVAL INSTALLATION CYLINDER HEAD VALVES CYLINDER PISTON CLUTCH GEARSHIFT LINKAGE ALTERNATOR STARTER CLUTCH CRANKSHAFT KICKSTARTER TRANSMISSION All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing MOTO HONDA DA AMAZONIA LTDA Reserves the right to make changes at any time without notice and without incurring any oblication whatever Not part of this publication may be reproduced without written permission FRAME FRONT WHEEL SUSPENSION STEERING REAR WHEEL SUSPENSION HYDRAULIC BRAKE FAIRING EXHAUST SYSTEM
10. e outer races of camshaft bearings with your finger The bearings should turn smoothly and quietly Also check that the inner races fit tightly on the camshaft Measure the height of each cam lobe and inspect it for wear or damage SERVICE LIMIT Intake 31 30 mm 1 232 in Exhaust 31 20 mm 1 228 in XL200 CAP NUT SEALING WASHER HEAD COVER BOLTS CAMSHAFT DOWEL PIN XL200 TENSIONER LIFTER INSPECTION Remove the cam chain tensioner lifter sealing bolt and O ring Check the lifter operation the tensioner shaft should not go into the body unless it is pushed When it turned clockwise with a screwdriver the tensioner shaft shoud be pulled into the body The shaft should spring out of the body as soon as the screwdriver is released Make a tensioner shaft stopper tool out of a thin piece of steel 0 8 mm thick using the diagram 15mm 19 mm 0 8 mm thick CYLINDER HEAD COVER DISASSEMBLY Remove the rocker arm shaft plate by removing the setting screw Remove the rocker arm shafts by screwing a 6 mm bolt into the threaded ends as shown Remove the rocker arms ROCKER ARM SHAFT INSPECTION Inspect the rocker arm slipper surfaces for excessive wear Inspect the rocker arms and shafts for wear or damage NOTE e If the rocker arms require servicing or replacement inspect the cam lobes for scoring chipping or flat spots Measure the I D of each rocker arm SERV
11. head gasket surface of any gasket materials NOTE e Do not allow dust and dirt to enter the engine Install the dowel pins new O ring and new cylinder head gasket Install the cylinder head Install a new sealing washer and the tensioner pivot bolt through the tensioner hole Tighten the bolt to the specified torque TORQUE 10 N m 1 0 kg m 7 ft lb CAMSHAFT CYLINDER HEAD COVER INSTALLATION CYLINDER HEAD COVER ASSEMBLY Apply oil to the rocker arm shafts Install the rocker arms and rocker arm shafts in the cylinder head cover With the rocker arm shaft reliefs on the inside install the rocker arm shaft plate Tighten the setting screw securely CAMSHAFT CYLINDER HEAD COVER INSTALLATION Install the dowel pins and rubber plug CYLINDER HEAD VALVES DOWEL PIN GASKET x y SOCKET BOLT WASHER ROCKER ARM ROCKER ARM SHAFT SCREW PLATE CYLINDER HEAD VALVES Apply oil to the cam lobes and camshaft bearings Install the camshaft in the cylinder head positioning the cam lobes down as shown Pour fresh oil into the oil pocket in the cylinder head until the cams are submerged Apply sealant to the mating surface of the cylinder head cover ATTENTION e Do not apply sealant to the oil passage Install the head cover onto the cylinder head Apply oil to the cap nut threads Install the new sealing washers cap nuts and flange bolts Tighten the cap nu
12. lifter mounting bolts TORQUE 12 N m 1 2 kg m 9 ft lb Remove the wire holder piece from the tensioner lifter Install and tighten the screw with a new O ring Tighten the screw to the specified torque TORQUE 4 N m 0 4 kg m 3 ft lb Rotate the crankshaft counterclockwise a few times and recheck the valve timing Install a new gasket and O ring onto the sprocket cover Install the sprocket cover with its oil pocket facing down as shown Install and tighten the cover bolts securely Apply clean engine oil to the O rings of the adjusting hole caps Install and tighten the cap bolts TORQUE 15 N m 1 5 kg m 11 ft lb Install and tighten the timing hole cap and crankshaft hole cap TORQUE Timing hole cap 6 N m 0 6 kg m 4 ft lb Crankshaft hole cap 8 N m 0 8 kg m 6 ft lb Install the following starter motor engine 6 18 XL200 CYLINDER HEAD VALVES NOTAS 6 19 HOW TO USE THIS MANUAL This service manual describes the service procedure for the XL200 e Throughout the manual the following abbreviations are used to identify individual models Code Area type DK General Type 2LA Latin America Follow the Maintenance Schedule Section 3 recommendations to ensure that the vehicle is in peak operation condition Performing the first scheduled maintenance is very import
13. ne oil Insert the intake and exhaust valve into the valve guides Install the valve spring seats springs and retainers NOTE e Install the valve springs with the narrow pitch end facing the combustion chamber Compress the valve spring and install the valve cotters ATTENTION e To prevent loss of tension do not compress the valve spring more than necessary TOOL Valve spring compressor CYLINDER HEAD VALVES VALVE SPRING SEAT INNER SPRING STEM SEAL OUTER SPRING SPRING RETAINER SPRING COMPRESSOR 6 13 XL200 CYLINDER HEAD VALVES Tap the stems gently with a plastic hammer to firmly seat the cotters ATTENTION e Support the cylinder head above the work bench surface to prevent valve damage Check the insulator O ring is in good condition replace if necessary Tighten the insulator socket bolt securely Install the cam chain tensioner washer and pivot bolt Tighten the pivot bolt to the specified torque TORQUE 10 N m 1 0 kg m 7 ft lb CYLINDER HEAD INSTALLATION Place the bottom end of the cam chain guide into the groove in the left crankcase and its bosses in the grooves in the cylinder upper surface NOTE e Make sure that the cam chain is properly installed on the timing sprocket as shown 6 14 INSULATOR PIVOT BOLT WASHER SOCKET BOLT CAM CHAIN TENSIONER CAM CHAIN GUIDE XL200 Clean the cylinder
14. t in a crisscross pattern in 2 3 steps TORQUE 27 N m 2 7 kg m 20 ft lb Tighten the flange bolts and setting bolt in a gradual crisscross pattern TORQUE 10 N m 1 0 kg m 7 ft lb Align the T mark on the flywheel with the index mark on the left crankcase cover by turning the crankshaft counterclockwise 6 16 CAMSHAFT XL200 XL200 Install the cam sprocket with its timing marks facing out Install the cam chain over the sprocket as shown NOTE e If it is difficult to install the chain over the sprocket make sure the chain is set properly on the timing sprocket Align the timing marks on the cam sprocket with the mating surface of the cylinder head and cover without rotating the crankshaft Apply oil to the cam sprocket bolts and install them Tighten the bolts to the specified torque TORQUE 12 N m 1 2 kg m 9 ft lb Turn the tensioner shaft clockwise with a small screwdriver to retract the tensioner and hold it in the fully retracted position NOTE e The tensioner will forced out by the spring when it is released Wedge the tensioner shaft with a piece of wire to hold the tensioner Install a new gasket on the cam chain tensioner lifter and install it CYLINDER HEAD VALVES CAM SPROCKET BOLTS TIMING MARK TENSIONER LIFTER SCREWDRIVER GASKET TENSIONER LIFTER CYLINDER HEAD VALVES Tighten the cam chain tensioner
15. ter when a valve guide is replaced Using 32 degree cutter remove 1 4 of the exiting valve seat material 32 6 11 CYLINDER HEAD VALVES Using 60 degree cutter remove the bottom 1 4 of the oil seat Remove the cutter and inspect the area you have just removed Install a 45 degree finish cutter and cut the seat to proper width Make sure that all pitting and irregularities are removed Refinish if necessary STANDARD SEAT WIDTH 1 1 1 3 mm 0 04 0 05 in Apply thin coat of Prussian Blue to the valve seat Press the valve through the valve guide and onto the seat to make a clear pattern NOTE XL200 60 The location of the valve seat in relation to the valve face is very important for good sealing If the contact area is too high on the valve the seat must be lowered using a 32 degree flat cutter If the contact area is too low on the valve the seat must be raised using a 60 degree inner cutter 6 12 XL200 Refinish the seat to specifications using a 45 degree finish cutter After cutting the seat apply lapping compound to the valve face and lap the valve using light pressure After lapping wash all residual compound off the cylinder head and valve CYLINDER HEAD ASSEMBLY Install the inner and outer valve spring seats and new valve stem seals Lubricate each valve stem with engi
16. vice limit determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace the guides as necessary and ream to fit e If the stem to guide clearance still exceeds the service limit with new guides replace the valve guide reamers e Reface the valve seat whenever new valve guides are installed VALVE GUIDE REAMER XL200 XL200 CYLINDER HEAD VALVES VALVE SPRING Measure the valve spring free length SERVICE LIMIT Inner 38 0 mm 1 50 in Outer 43 5 mm 1 71 in VALVE GUIDE REPLACEMENT Chill valve guides in the freezer section of a refrigerator for about an hour Heat the cylinder head to 100 C with a hot plate or oven e To avoid burns wear heavy gloves when handling the heated cylinder head e Do not use a torch to heat the cylinder head it may cause warping Support the cylinder head and drive out the valve guide from the valve port with a valve guide driver ATTENTION e Avoid damaging the cylinder head TOOL Valve guide driver 5 5 mm Place a new O ring on the new valve guide Install a valve guide from the top of the cylinder head ATTENTION e When installing a valve guide take care not to damage the cylinder head TOOL Valve guide driver 5 5 mm VALVE GUIDE DRIVER VALVE GUIDE DRIVER CYLINDER HEAD VALVES XL200
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