Question about Honda XR 200 Motorcycles
Just got two 1984 honda xr200's they're in imaculate condition the only problem is that they haven't been started in just under 2 years and i was wondering how i would going about the start up procedure. I'm pretty good at mechanics but i'm not familiar with the dual carb setup on the 84's..
if you could help me with this it would be greatly appreciated
First, change the spark plug and oil. The stock plug is NGK DPR8Z and 10w40 motor oil is what you need. There is no oil filter. Changing the oil acts as the "filter". Lubricate the chain. be sure it has no kinks in it. If kinks, then get a new 520 chain. The stock sprockets are 50 tooth and 13 tooth. Lubricate the control cables with liquid graphite, ( Lock Eze ). Make sure the tires have adequate pressure. Check the spokes and snug up any that are lose.
The carbs will be your only problem area. The bike has four valves and a primary/secondary carb set up. The dual carb setup makes the bike more responsive. The set up does mean twice the effort to clean the carbs and twice the likelihood something will go sour. Sitting for two years is not a good thing. The gas in the carbs evaporates and leaves varnish to gum up the jets and passageways. If the fuel petcock (gas valve) was left open, you can really have a problem. Remove the gas tank. Dump out the gas tank and inspect it. Is there rust in the drained gas? If so, remove the petcock and put a LOT of large nuts into the tank and shake the tank well to let the abrasive action of the nuts break away the loose rust. Flush the tank well. You may want to consider a tank liner. This will solve the rust problem forever. Google “ kreem fuel tank liner “ or go to
Disassemble and clean the petcock. Now install an in-line fuel filter and make sure the fuel line is clear. On the bottom of the carb(s) is a drain plug. Remove the plug and and hope it is clean. Open the gas valve and see if gas is flowing past the float valve. If you lucked out and the plug was pretty clean and WITHOUT RUST, go ahead and install the plug, turn on the gas and see if it will start up. If the bike runs poorly after warming up, your next project is to clean the carbs.
FOR EACH carb > Remove the float bowl and clean the entire carb with a spray carb cleaner from the auto parts store. Wear protective goggles to avoid getting spray in your eyes. Spray into all the little airways and fittings in the carb. Remove the idle screw and the air screw on the outside of the carb and spray into the screw holes as well.
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Be sure to put these two screws back in the same hole they came out of. IMPORTANT > do not tighten these two adjusters down. Only screw these in until they LIGHTLY seat. Now turn each adjuster one and one half turns outward. Put the rest of the carb back together and install the carb. Clean or replace the air filter. Let the float bowl fill then start the engine. This process should get you back on the road.
Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock.
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Posted on May 24, 2009
Dual carb setups are easier than you think. The most important thing to remember is that the gas in these bikes has probably varnished. Drain the gas out of the tank by unhooking the line from both of the petcocks and opening the valves. It's also a really good idea to drain the carb bowls since the same bad gas has been sitting in there, too. There's probably a screw underneath each carb bowl (the lowest part of the carb) you can unscrew to drain them. I personally would take the bowls off and clean them up real good with carb cleaner. There's usually deposits sitting in there that are not good for the fuel system. While they're off, you can inspect the floats of the carb to ensure they are still free-floating. Try not to bend them or you'll change the ratio of gas the bike uses and it might become a nightmare. A stuck float will either flood the bike or starve it. Make sure when the float goes up, that the needle above it is moving properly. After you have done all this, check your oil and other fluids before you fire the bike up. Seafoam is also a great additive to gas for something that has been sitting a long time. Plugs, plug wires, fresh battery, etc. Hope this helps!
Posted on May 24, 2009
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Posted on Jan 02, 2017
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