Honda Xl125 Xl200 Xr125 Xr200 1979-1987 Service Repair Manual

Regular price: $16.99
Sale price: $16.99
Regular price
Unit price: per

This manual covers the XL125, XL200, XR125, and XR200 models produced between 1979 and 1987. These versatile motorcycles, featuring 125cc and 200cc engine variants, were designed for a range of...

16 people are viewing this right now

Type: Motorcycle

Vendor:

Sku: 104814

Tags: 1979 1980 1981 1982 1983 1984 1985 1986 1987 B Models Honda Marine Motorcycle Outboard Engines Xl125 Xl200 Xr125 Xr200

Product variants

Description

This manual covers the XL125, XL200, XR125, and XR200 models produced between 1979 and 1987. These versatile motorcycles, featuring 125cc and 200cc engine variants, were designed for a range of uses including trail riding, commuting, and light off-road adventures. The legacy in the motorcycle industry is built on engineering prowess, reliability, and innovation, and these models exemplify that heritage, offering capable and durable performance. The XL and XR lines have a strong lineage in the dual-sport and off-road segments, providing riders with dependable machines for various conditions. This comprehensive service repair manual provides detailed information essential for the maintenance, troubleshooting, and repair of your motorcycle. It covers a wide array of systems, including engine service, fuel system maintenance, transmission overhauls, suspension and brake servicing, and electrical system diagnostics. With factory repair procedures, detailed specifications, and abundant illustrations and diagrams, this manual is an invaluable resource for owners and technicians alike. It empowers users to perform everything from routine maintenance, such as oil changes and valve adjustments, to complete engine and transmission rebuilds, ensuring the longevity and optimal performance of your vehicle.

🏷️ Basic Information

Identification

Make:

Honda

Model:

XL125, XL200, XR125, XR200

Engine Variants:

125cc, 200cc (specific designations may vary by market and sub-model)

Model Years Covered:

1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987

Codes

Chassis Codes Likely Covered:

PD03 (XR200R), JD01 (XL200R), PD04 (XR200), MB01 (XL125S), MB04 (XL125R), MB06 (XR125L) - *Note: Specific chassis codes should be verified against the manual's internal indexing.*

Engine Codes Likely Covered:

P03E (XL125S/R), P05E (XL200R), PE04E (XR200), PE06E (XR125) - *Note: Specific engine codes should be verified against the manual's internal indexing.*

👋 Introduction

Market Position

Target Audience:

Owners of Honda XL125, XL200, XR125, and XR200 motorcycles from 1979-1987 seeking to perform their own maintenance, repairs, or restorations.

Value Proposition:

Provides dealer-level diagnostic and repair information, enabling cost savings on labor and ensuring proper maintenance and repair procedures are followed.

Competitive Analysis

Comparative Advantage:

Offers a single, comprehensive source for multiple related models, consolidating information that might otherwise be scattered or unavailable.

Key Features

Illustrations:

Abundant Illustrations, Lots of Pictures & Diagrams included to aid comprehension.

Procedures:

Factory Repair Procedures and Detailed Specifications ensure accuracy and adherence to manufacturer standards.

📋 Manual Details

Coverage Areas

Primary Coverage:

North America, Europe, Asia (general service information applicable globally)

Page Count

Estimated Page Count:

Likely between 300-600 pages (typical for comprehensive factory service manuals of this era).

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete Engine Service, Engine Firing Order, Engine Rebuild Procedures, Carburetor Servicing, Valve Adjustment, Camshaft Timing, Piston and Cylinder Diagnosis, Crankshaft and Connecting Rod Inspection.

Fuel System:

Fuel System Service, Carburetor Disassembly, Cleaning, and Reassembly, Fuel Tank Inspection and Cleaning, Fuel Petcock Operation and Service.

Transmission:

Gearbox Service, Removal and Installation, Gear Selection Mechanism, Clutch Removal and Installation, Clutch Adjustment, Transmission Component Inspection.

Suspension:

Front Suspension Service, Rear Suspension (Shock Absorbers/Swingarm) Service, Fork Seal Replacement, Spring and Damper Specifications.

Brakes:

Brake Servicing Procedures, Front and Rear Brake System Maintenance, Brake Pad Replacement, Brake Shoe Adjustment, Brake Drum/Disc Inspection, Hydraulic System Bleeding (if applicable).

Electrical:

Wiring Diagrams (comprehensive), Lighting System Service, Ignition System Diagnosis, Charging System (Stator, Regulator/Rectifier) Testing, Battery Maintenance, Horn, Turn Signals, Brake Lights.

Bodywork:

Bodywork Inspection and Repair, Seat Removal, Fender and Panel Fitting, Exhaust System Service and Removal/Installation.

Procedures Included

Maintenance:

Factory Maintenance Schedules, Oil Change Procedures, Air Filter Cleaning/Replacement, Spark Plug Replacement, Chain Adjustment and Lubrication, General Lubrication Points.

Troubleshooting:

Fault Finding Guides, Diagnostic Procedures for Common Issues, Symptom-Based Troubleshooting.

Repair:

Component Repair and Overhaul, Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Electrical System Troubleshooting and Repair.

Restoration:

Procedures for refurbishing and restoring components to original specifications.

Technical Depth

Depth:

Comprehensive (suitable for DIY enthusiasts and professional mechanics), covering everything from basic maintenance to complete engine and transmission rebuilds.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable if properly created OCR (Optical Character Recognition) was applied.

Print Quality

Quality:

High-resolution, designed for clear viewing of text, diagrams, and illustrations.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, Air-Cooled (typically OHC - Overhead Camshaft)

Bore X Stroke 125Cc Approx:

53.0 mm x 53.0 mm (example, specific engines may vary)

Bore X Stroke 200Cc Approx:

65.0 mm x 59.0 mm (example, specific engines may vary)

Compression Ratio Approx:

9.0:1 to 10.0:1 (varies by specific model and year)

Performance

Horsepower 125Cc Approx:

10-14 HP (at RPM)

Horsepower 200Cc Approx:

15-18 HP (at RPM)

Torque Approx:

Not specified, but torque figures would be provided for engine speed ranges in the manual.

Fuel System

Carburetor Type Common:

Keihin or similar, single carburetor, constant velocity (CV) type likely for some models.

Fuel Type:

Unleaded gasoline (Octane rating specified in manual)

Fuel Capacity Liters:

Typically 8-12 Liters (approx. 2.1-3.2 US Gallons), specific to each model.

🔧 Transmission

Standard

Type:

5-speed or 6-speed manual transmission (varies by model and year)

Drive Type:

Chain Drive

Clutch Type:

Wet, Multi-plate Clutch

Features

Gear Ratios:

Specific gear ratios for each speed will be detailed in the manual.

Transmission Fluid Spec:

Engine oil (e.g., SAE 10W-30 or 20W-40 API SE or SF classification) is typically used for the transmission and clutch lubrication in these bikes. Specifics in manual.

📐 Dimensions

Exterior

Overall Length:

Varies by model, typically around 2100-2200 mm.

Overall Width:

Varies by model, typically around 800-900 mm.

Overall Height:

Varies by model, typically around 1150-1250 mm.

Weights

Dry Weight Kg:

Approximately 100-130 kg (varies significantly by model and equipment).

Wet Weight Kg:

Approximately 110-140 kg (varies significantly by model and equipment).

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety ratings from government bodies like NHTSA were not standard practice during this era).

Active Features

Braking System:

Drum brakes front and rear on many base models, some higher trims may have disc brakes. Manual covers inspection and adjustment.

Lighting:

Headlight, Taillight, Brake Light, Turn Signals (where equipped).

Passive Features

Frame Construction:

Steel diamond frame.

💡 Technology Features

Infotainment

Infotainment Features:

None (This era of motorcycles predates modern infotainment systems).

Driver Assistance

Assistance Features:

None (No electronic rider aids or driver assistance systems).

Connectivity

Connectivity Features:

None (No wireless or digital connectivity features).

🔧 Maintenance

Service Intervals

Oil Change Interval Km:

Typically every 2,000 - 4,000 km or annually, as specified in the manual.

Air Filter Cleaning Interval:

Regular inspection, cleaning every 1,000-2,000 km, depending on riding conditions.

Spark Plug Replacement Interval:

Typically every 6,000 - 12,000 km, or based on condition.

Valve Clearance Check Interval:

Often around every 4,000 - 6,000 km, critical for engine performance and longevity.

Fluid Specifications

Engine Oil Type:

API SE or SF classification, SAE 10W-30 or 20W-40 motorcycle-specific oil recommended.

Engine Oil Capacity Liters:

Approximately 1.0 - 1.5 Liters (including filter change), specific to model.

Brake Fluid Type:

DOT 3 or DOT 4 (if hydraulic brakes are equipped), specification to be confirmed in the manual.

Known Issues

Common Wear Items:

Clutch wear, carburetor gumming due to infrequent use or fuel degradation, aging electrical connections, suspension seal leaks.

Potential Failures:

Stator failure (affecting charging system), regulator/rectifier issues, cam chain tensioner wear on some models.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Honda is renowned for its engineering prowess, reliability, and innovation in the motorcycle industry, with a strong history in dual-sport and off-road segments.

Model Evolution

Lineage:

The XL and XR lines represent Honda's successful foray into the dual-sport and off-road motorcycle markets, evolving from earlier models to offer increased performance and versatility.

Positioning:

These models were positioned as versatile, capable, and relatively affordable motorcycles for trail riding, commuting, and light off-road adventure.

Production

Manufacturing Era:

Produced during a significant period of growth and development for the dual-sport motorcycle category.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

While specific awards for these individual models are not readily cataloged, Honda's XL and XR series were widely recognized for their durability, performance, and market impact in the dual-sport segment during their production years.