2004 xr200 service manual pdf free download

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Honda Cbrf Fireblade Download. Honda Cbrxx Super Blackbird Download. Honda Cbx RC17 Download. Honda Cg Download. Honda Cms Cms Download. Honda Cx Download. Honda Gl Gl Goldwing Download. Honda Gl Goldwing Download. Inspect the oil filler cap O-ring for cracks or other damage and replace the O-ring if necessary. Next reinstall the oil filler cap and be sure the cap is fully seated. Check your service manual for the recommended oil and filter change intervals for motorcycles operated in moderate climates.

If the motorcycle is operated in heavy dust, mud, water or other conditions, the oil should be changed more frequently. If manufacturer recommend brand oils are not available then use manufacturer recommended oil alternatives. Follow the viscosity recommendations applicable to your model oil. Always try and use the same brand of oil at each change and check your service manual for the correct oil viscosity to use in anticipated ambient temperatures, not engine oil temperature.

Using oil additives. Overfilling may cause clutch malfunctioning. The transmission oil also lubricates the clutch, primary drive chain and sprockets. Your manual will list the recommended transmission oil inspection intervals.

When checking the transmission oil level, do not allow any dirt or debris to enter the transmission case opening. If the motorcycle has been operated recently, wait approximately ten minutes before checking the oil to allow the oil to settle in the case. Park the motorcycle on a level surface and have an assistant support it so that it is standing straight. This procedure is for a fork oil change. If the fork has been disassembled for service, refer to correct chapter for fork oil refilling and specifications and the lists of recommended fork oil change intervals.

Lubricate the control cables with a cable lubricant at the intervals in your manual or when they become stiff or sluggish. When lubricating the control cables, inspect each cable for fraying and cable sheath damage.

Always Replace damaged cables promptly. To remove and install the throttle grip, refer to the Throttle and Idle Cable Replacement section in your manual book.

Lubricate the throttle control grip where it contacts the handlebar with graphite. Inspect the front brake lever pivot pin see diagrams for help at the intervals in service maintenance section. If the pin is dry, lubricate it with a lightweight oil. To service the pivot pin, refer to the Front Master Cylinder in appropriate chapter. Perform the services listed at the intervals section in your motorcycle manual.

If the motorcycle is exposed to harsh conditions then perform the services more frequently. Check and adjust the drive chain at the intervals specified in your manual. If the motorcycle is operated at sustained high speeds or if it is repeatedly accelerated very hard, inspect the drive chain adjustment more often.

When adjusting the chain, check the free play at several places along its length by rotating the rear wheel. The chain rarely wears uniformly and as a result will be tighter at some places than others.

Measure the chain free play halfway between the sprockets. Make sure the chain free play at the tightest place on the chain is not less than the specs or specifications given. Check drive belt deflection to see if the drive belt is severely worn, or if it is wearing incorrectly, if after inspection you find sever wear or damage then follow the replacement procedures.

Inspect the brake pads for damage. Measure the thickness of each brake pad lining on the front caliper s and rear caliper. Replace the brake pad if its thickness is worn to the minimum thickness as listed in your specifications. NOTE: It may be necessary to dismount the caliper in the following steps if there is not sufficient access to the brake pads. Inspect the front and rear brake discs for scoring, cracks or other damage.

Measure the brake disc thickness and service the brake discs as described in your repair guide. Check the brake lines between each master cylinder and each brake caliper. If there are any leaks, tighten the connections and bleed the brakes as described in the book.

To change brake fluid, follow the brake bleeding procedure in and continue adding new fluid to the master cylinder until the fluid leaving the caliper is clean and free of contaminants and air bubbles.

Front Brake Adjustment — The front brake does not require periodic adjustment on most motorcycles. Inspect the throttle cables from the grip to the carburetor. Make sure they are not kinked or chafed and replace them if necessary. Make sure the throttle grip rotates smoothly from fully closed to fully open.

Check with the handlebar at the center, full left and full right positions. There are two different throttle cables.