XL2 0 0

15.
SERVICE INFORMATION 15-1
TROUBLESHOOTING 15-2
BATTERY 15-3
CHARGING SYSTEM INSPECTION 15-5
REGULATOR/RECTIFIER 15-6
ALTERNATOR 15-7
SERVICE INFORMATION
GENERAL
t
A lw ays turn off the ignition sw itch before disconnecting any electrical com ponent.
h
For extended storage, rem ove the battery, give it a full charge, and store it in a cool, dry space. For m axim um service life,
charge the stored battery every tw o w eeks.
For a battery rem aining in a stored m otorcycle, disconnect the negative battery cable from the battery term inal.
The battery can be dam aged if overcharged our undercharged, or of left to discharge for long periods. These sam e
conditions contribute to shorting the life spanof the battery. Even under norm al use, the perform ance of the battery
deteriorates after 2-3 years.
B attery voltage m ay recover after battery charging, but under heavy load, battery voltage w ill drop quickly and eventually die
out. For this reason, the charging system is often suspected to be the problem . B attery overcharge often results from
problem in the battery itself., w hich m ay appear to be an overcharge sym ptom . If one of the battery cells is shorted and
battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. U nder these conditions, the
electrolyte level goes dow n quickly.
B efore troubleshooting the charging system , check for proper use and m aintenance of the battery. C heck if the battery is
frequently under heavy load, such as having the headlight and taillight O N for long periods of tim e w ithout riding the
m otorcycle.
The battery w ill self-discharge w hen the m otorcycle is not in use. For this reason, charge the battery every tw o w eeks to
prevent sulfation from form ing.
Filling a new battery w ith electrolyte w ill produce som e voltage, but in order to achieve its m axim um perform ance, alw ays
charge the battery, A lso, the battery life is lengthened w hen it is initial-charged.
W hen checking the charging system , alw ays follow the steps in the troubleshooting flow chart.
For charging system com ponent locations, see page 15-0.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition
switch is ON and current is present.
The battery gives off explosive gases; keep sparks, flam es, and cigarettes aw ay. Provide adequate ventilation w hen
charging or using the battery in an enclosed space.
The battery contains sulfuric acid (electrolyte). C ontact w ith your skin or eyes m ay cause severe burns. W ear protective
clothing and a face shield.
If electrolyte gets on your skin, flush w ith w ater.
If electrolyte gets in your eyes, flush w ith w ater for at least 15 m inutes call a physician inm ediately.
Eletrolyte is poisonous. If sw allow ed, drink large quantities of w ater or m ilk of m agnesia or vegetable oil and call a
physician. K EEP O U T O F R EA C H O F C H ILD R EN .
151
BATTERY/CHARGING
SYSTEM
15
XL2 0 0 B A TTER Y/C H A R G IN G SYSTEM
15-0
(2) REGULATOR/RECTIFIER
Y YELLOW
P PINK
G GREEN
R RED
B BLACK
(1) IGNITION
SWITCH
(5) ALTERNATOR
(4) MAIN FUSE 15A
R
R
B
G
Y
P
P G B R Y
(3) BATTERY
XL2 0 0
15-2
B A TTER Y/C H A R G IN G SYSTEM
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
Faulty battery
2. Install the battery (page 15-3).
C heck the battery current leakage (Leak test
page 15-5).
STANDARD: 0.01 mA max
D isconnect the regulator/rectifier 4P connector and
recheck the battery current leakage.
3. C heck the alternator charging coil (page 15-7).
STANDARD:
0.1 1.0 (20
O
C/68
O
F)
Shorted w ire harness
Faulty ignition sw itch
Faulty charging coil
C harging system is norm al
Faulty regulator/rectifier
4. R em ove the battery (page 15-3).
M easure and record the battery voltage using
digital m ultim eter (15-4).
Install the battery (page 15-3).
Start the engine.
M easure the charging voltage (page 15-4).
C om pare the m easurem ent to result of the
follow ing calculation.
STANDARD:
MEASURED BATTERY VOLTAGE <
MEASURED CHARGING VOLTAGE <
15.5 V at 5.000 min-
1
(rpm)
C heck the regulator/rectifier connector voltage and
resistance (page 15-6).
Faulty regulator/rectifier
Incorrect
C orrect
O pen circuit in related w ire
Loose or poor contacts of related term inal
Shorted w ire harness
C orrect
Incorrect
Incorrect
Incorrect
Incorrect
C orrect
C orrect
Incorrect C orrect
1. R em ove the battery (page 15-6).
C heck the battery condition using the
recom m ended battery tester.
RECOMMENDED BATTERY TESTER:
BM-210-AH ar BM-210
BATTERY MATE or equivalent
C orrect
XL2 0 0 B A TTER Y/C H A R G IN G SYSTEM
15-3
BATTERY
REMOVAL/INSTALLATION
R em ove the left side cover.
D isconnect the negative cable first from the battery, then
disconnect the positive cable.
R em ove the battery holder band and rem ove the battery.
Installation is in the reverse order of rem oval.
N O TE
Follow the instructions on the batterys C A U TIO N label.
M ake sure that the breather tube is correctly positioned,
and not kinked, trapped or bent in such a w ay as to obstruct
the passage of air.
INSPECTION
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C heck the level of each cell by the U PPER and LO W ER level
lines inscribed on the side of the battery.
If levels are approaching the LO W ER level line, rem ove the
battery, take off the filter caps and refill to the U PPER level w ith
distilled w ater.
h
A fter refilling, replace each of the filler caps firm ly.
Always refill batteries with distilled water. Tap water contains
minerals that will shorten the life of the battery.
Filling the battery above the UPPER level mark may cause
spillage while riding and subsequent corrosion of vehicle
parts.
D o not allow battery fluid (sulfuric acid) to com e into contact
w ith the skin, eyes or clothes as it w ill cause burning. If acid
is spilled on you, be sure to w ash off quickly w ith large
am ounts of w ater. If battery fluid enters the eyes, w ash w ith
w ater and consult a physician.
XL2 0 0
15-4
M easure the specific gravity of each cell w ith hidrom eter.
Fully charged: 1.27-1.29
Need charging: Below 1.23
N O TE
M ake sure that term inal conditions are not loose. If corrosion is
evident, w ash rust w ith w arm w ater and use a w ire brush to
rem ove com pletely.
CHARGING
C onnect the charger positive (+ ) cable to the battery positive (+ )
term inal.
C onnect the charger negative (-) cable to the battery negative (-)
term inal.
A fter charging, recheck the battery specific gravity and recharge
the battery if necessary.
R eplace the battery w ith a new one if the battery specific gravity
below 1.23.
t
The battery gives of explosive gases; keep sparks, flam es,
and cigarettes aw ay. Provide adequate ventilation w hen
charging or using the battery in an enclosed space.
If the difference in specific gravity betw een cells exceeds
0.01, re-charge the battery. If the difference in specific
gravity is excessive, replace the battery.
B A TTER Y/C H A R G IN G SYSTEM
C harging current C harging tim e
Standard 0.4 A 5 hours
M axim um 4.0 A 30 m inutes
(1) BATTERY
BATTERY
XL2 0 0 B A TTER Y/C H A R G IN G SYSTEM
15-5
CHARGING SYSTEM INSPECTION
LEAKAGE TEST
Turn the ignition sw itch off, and disconnect the ground (-) cable
from the battery.
C onnect the am m eter (+ ) probe to the ground cable and the
am m eter (-) probe to the battery (-) term inal.
W ith the ignition sw itch off, check for current leakage.
N O TE
Specified current leakage: 0.01mA max.
If current leakage exceeds the specified value, a shorted circuit
is likely.
Locate the short by disconnecting connectors one by one and
m easuring the current.
W hen m easuring the current using a tester, set it to a high
range, and then bring the range dow n to an appropriate
level. C urrent flow larger than the range selected m ay blow
out the fuse in the tester.
W hile m easuring current, do not turn the ignition sw itch O N .
A sudden surge of current m ay blow out the fuse in tester.
REGULATED VOLTAGE/AMPERAGE INSPECTION
t
NOTE
Start the engine and w arm it up to operating tem perature, then
turn the ignition sw itch O FF.
C onnect the m ultim eter betw een the battery term inals.
Start the engine and increase the engine speed gradually, and
m easure the voltage.
Regulated voltage 13.5 - 14.5 V/5.000 r.p.m.
B efore perform ing this test, be sure the battery is fully
charged and that the specific gravity is greater than 1.27
(20C /38F)
If the engine m ust be running to do som e w ork, m ake sure
the area is w ell-ventilated. N ever run the engine in an
enclosed are.
The exhaust contains poisonous carbon m onoxide gas that
m ay cause loss of consciousness and lead to death.
(1) NEGATIVE TERMINAL
(2) BATTERY
(3) NEGATIVE
CABLE
(2) MAIN FUSE 15A
(3) STARTER RELAY SWITCH
(1) CONNECTOR
CONNECTOR
CONNECTOR
REGULATOR/RECTIFIER
XL2 0 0
15-6
REGULATOR/RECTIFIER
SYSTEM INSPECTION
R em ove the fuel tank.
D isconnect the regulator/rectifier 4P connector.
C heck the connector for loose or corroded term inals.
M easure the follow ing betw een the connector term inals of the
w ire harness side.
If any one item does not m eet the standard, test the individual
com ponent and replace the part, or repair open or short circuit in
the w ire harness, or poor ground.
If the above item s are all O K , check the regulator/rectifier.
Provided the circuit on the w ire harness side is norm al and there
are no loose connections at the connector, inspect the
regulator/rectifier unit by m easuring the resistance betw een the
term inals.
R eplace the regulator/rectifier unit if the resistance value
betw een the term inal is abnorm al.
B A TTER Y/C H A R G IN G SYSTEM
Item Term inals Standard
B attery charging R ed (+ ) B attery voltage
line A nd G reen () should resister
G round line G reen and C ontinuity
B ody ground
C harging coil Pink and 0,11,0
line Yellow (20C /68F)
Lighting coil line Yellow and 0,10,8
G reen (20C /68F)
CONNECTOR
CONNECTOR
CONNECTOR REGULATOR/RECTIFIER
XL2 0 0 B A TTER Y/C H A R G IN G SYSTEM
15-7
REMOVAL
R em ove the fuel tank.
D isconnect the regulator/rectifier connector.
R em ove the bolt and regulator/rectifier unit.
Installation is in the reverse order of rem oval.
M easure the resistance betw een the pink and yellow w ire
term inals.
Standard:
White Green: 0.1 - 1.0 (20C/68F)
Yellow Pink: 0.1 - 1.0 (20C/68F)
If the resistance is not w ithin the specification, replace the stator
(page 9-3).
ALTERNATOR
R em ove the left side cover.
D isconnect the alternator 6P connector.
G EN ER A L IN FO R M A TIO N
HOW TO USE THIS MANUAL
This service m anual describes the service
procedure for the XL200.
Throughout the m anual, the follow ing
abbreviations are used to identify individual
m odels.
Follow the M aintenance Schedule (Section 3)
recom m endations to ensure that the vehicle is in
peak operation condition.
Perform ing the first scheduled m aintenance is very
im portant. It com pensates for the initial w ear that
occurs during the break-in period.
Section 1 through 3 apply to the w hole m otorcycle,
w hile section 4 through 18 describe parts of the
m otorcycle, grouped according to location.
Find the section you w ant on this page, then turn to
the table of contents on page 1 of that section.
M ost sections start w ith an assem bly or system
illustration, service inform ation and troubleshooting
for the section, the subsequent pages give detailed
procedures.
If you dont know the source of the trouble, go to
section 20 TR O U B LESH O O TIN G .
A ll inform ation, illustrations, directions and
specifications included in this publication are
based on the latest product inform ation available
at the tim e of approval for printing. M O TO
H O N D A D A A M A Z N IA LTD A . R eserves the
right to m ake changes at any tim e w ithout notice
and w ithout incurring any oblication w hatever.
N ot part of this publication m ay be reproduced
w ithout w ritten perm ission.
CONTENTS
G EN ER A L IN FO R M A TIO N
1
LU B R IC A TIO N
2
M A IN TEN A N C E
3
FU EL SYSTEM
4
EN G IN E R EM O VA L/IN STA LLA TIO N
5
C YLIN D ER H EA D /VA LVES
6
C YLIN D ER /PISTO N
7
C LU TC H /G EA R SH IFT LIN K A G E
8
A LTER N A TO R /STA R TER C LU TC H
9
C R A N K SH A FT/K IC K STA R TER /
TR A N SM ISSIO N
10
FR O N T W H EEL/SU SPEN SIO N /STEER IN G
11
R EA R W H EEL/SU SPEN SIO N
12
H YD R A U LIC B R A K E
13
FA IR IN G /EXH A U ST SYSTEM
14
C H A R G IN G SYSTEM
15
IG N ITIO N SYSTEM
16
ELEC TR IC STA R TER
17
LIG H TS/M ETER S/SW ITC H ES
E
L
E
C
T
R
I
C

S
T
A
R
T
E
R
F
R
A
M
E
E
N
G
I
N
E
18
W IR IN G D IA G R A M
19
TR O U B LESH O O TIN G
20
C ode A rea (type)
D K G eneral Type
2LA Latin A m erica