Ta200 Owner Manual
Ta200 Owner Manual
Ta200 Owner Manual
this motorcycle)
If the Pre-ride Inspe9tion (page 35) is not performed,
severe personal injury or vehicle damage may result.
SUSPENSION
Each shock absorber (1) has 5 adjustment positions for
different load or riding conditions.
Use a pin spanner (2) to adjust 'the' rear shocks.
Position 1 and 2 is for light loads and smooth road conditions.
Positions 4 to 5 increase spring preload for a stiffer rear
suspension, and can be used when the motorcycle is heavily
loaded. Be certain to adjust both shock absorbers to the same
position.
Standard position: 3
BRAKES
Both the front and rear brakes are the hydraulic disc types. Check that the fluid level is above the LOWER level mark (1)
As the brake pads wear, the brake fluid level drops. with the motorcycle in an upright position.
There are no adjustments to perform, but fluid level and pad Brake fluid must be added to the reservoir whenever the fluid
wear must be inspected periodically. The system must be level begins to reach the LOWER level mark (1). Remove the
inspected frequently to ensure there are no fluid leaks. If the screws (2), reservoir cover (3), diaphragm plate (4), and
control lever or pedal free travel becomes excessive and the diaphragm (5). Fill the reservoir with DOT 3 or DOT 4 BRAKE
brake pads are not worn beyond the recommended limit FLUID from a sealed container up to the upper level mark (6).
(page 67), there is probably air in the brake system and it Reinstall the diaphragm, diaphragm plate, and cover. Tighten
must be bled. See your Honda dealer for this service. the screws securely.
Other Checks:
Make sure there are no fluid leaks. Check for deterioration or
Front Brake cracks in the hoses and fittings.
Brake Fluid Level:
Other Checks:
Make sure there are no fluid leaks. Check for deterioration or
cracks in the hoses and fittings.
Clutch adjustment may be required if the motorcycle stalls 1. Loosen the lock nut (2) and turn the adjuster (3). Tighten the
when shifting into gear or tends to creep; or if the clutch slips, lock nut (2) and check the adjustment.
causing acceleration to lag behind engine speed. Minor 2. If the adjuster is threaded out near its limit or if the correct
adjustments can be made with the clutch cable adjuster (3) at free play cannot be obtained, loosen the lock nut (2) and turn
the lever (1). Normal clutch lever free play is: in the cable adjuster (3) completely. Tighten the lock nut (2).
NOTE:
If proper adjustment cannot be obtained or the clutch
does not work correctly, see your Honda dealer.
Other Checks:
Check the clutch cable for kinks or signs of wear that could
cause sticking or failure. Lubricate the clutch cable with a
commercially available cable lubricant to prevent premature
wear and corrosion.
(1)
Front NF52/TL
TUBELESS
ONLY Rear NR66/TL
Check the tyres for cuts, embedded nails or other sharp Tyre Repair/Replacement:
objects. Check the rims for dents or deformation. If there is See your Honda Dealer.
any damage, see your Honda dealer for repair, replacement,
and balancing.
The use of tyres other than those listed on the tyre
information label may adversely affect handling.
Do not install tube-type tyres on tubeless rims. The
beads may not seat and the tyres could slip on the
rims, causing tyre deflation that may result in a loss of
Improper tyre inflation will cause abnormal tread wear vehicle control.
and create a safety hazard. Under inflation may result Do not install a tube inside a tubeless tyre. Excessive
in the tyre slipping on, or coming off of the rim causing heat build-up may cause the tube to burst resulting in
tyre deflation that may result In a loss of vehicle rapid tyre deflation that may result in a loss of vehicle
control. control.
Operation with excessively worn tyres is hazardous Replace the tyre if the sidewall is punctured or
and will adversely affect traction and handling. damaged. Sidewall flexing may cause repair failure
and tyre deflation that may result in a loss of vehicle
Replace tyres before tread depth at the center of the tyre control.
reaches the following limit:
(1)
(2)
HELMET HOLDER SIDE COVER
The helmet holder (1) is on the left side below the seat. To remove the right side cover (1) and left side cover (2),
Insert the ignition key (2) and turn it counterclockwise to remove the screw and pull out the side covers.
unlock. Hang your helmet on the holder pin (3) and push it in
to lock. Remove the key.
To move the headlight case (1), loosen the bolts (2) and nuts If the Pre-ride Inspection Is not performed, severe'
(3). personal injury or vehicle damage may result.
Tighten the bolts (2) and nuts (3) after adjustment. Inspect your motorcycle every day before you ride it. The
Obey local laws and regulations. items listed here will only take a few minutes to inspect, and in
the long run they can save time, expense, and possibly your
life.
Preparation
Before starting, insert the key, turn the ignition switch ON and
confirm the following:
The transmission is, in NEUTRAL (neutral indicator
light ON).
The engine stop switch is at RUN.
The fuel cock is ON.
Starting Procedure
Cold Engine: (1) Choke knob
1. Pull the choke knob (1) out all the way to Fully ON (A).
2. With the throttle closed, press the starter button. (A) Fully ON (B) Fully OFF
NOTE:
Do not open the throttle when starting the engine with the
choke ON. This will lean the mixture, resulting in hard
starting.
3. When engine speed begins to pick up operate the choke
Warm Engine:
1. Do not use the choke. 2. Open the throttle slightly. 3. Start RIDING
the engine.
RUNNING-IN 3. Slowly release the clutch lever and at the same time
Help assure your motorcycle's future reliability and gradually increase engine speed by opening the throttle.
performance by paying extra attention to how you ride during Coordination of the throttle and clutch lever will assure a
the first 500 km (300 miles). smooth positive start. .
During this period, avoid full-throttle starts and rapid
acceleration. 4. When the motorcycle attains a moderate speed, close the
throttle, pull in the clutch lever and shift to 2nd gear by
raising the gearshift pedal.
This sequence is repeated to progressively shift to 3rd,
4th, 5th and 6th (top) gear.
5. Coordinate the throttle and brakes for smooth
deceleration.
6. Both front and rear brakes should be used at the same
Do not downshift when traveling at a speed that would force
time and should not be applied strongly enough to lock the
the engine to over-rev in the next lower gear; the rear wheel
wheel, or braking effectiveness will be reduced and control
may lose traction, resulting in a possible loss of vehicle
of the motorcycle be difficult.
control.
CAUTION:
Do not shift gears without disengaging the clutch and
closing the throttle. The engine and drive train could be
damaged by over speed and shock.
Do not tow the motorcycle or coast for long distances
while the engine is off. The transmission will not be
properly lubricated and damage may result.
Do not ride over a curb or rub the wheel against an
obstacle, as wheel damage may result.
NOTE:
AIR CLEANER
CAUTION:
Do not use oils with graphite or molybdenum additives:
they will adversely affect clutch operation.
(1) Screws (2) Spark plug gap 6. With the plug washer attached, thread the spark plug in by
2. Disconnect the spark plug cap (3) from the spark plug. hand to prevent cross threading.
3. Clean any dirt from around the spark plug bases. Remove 7. Tighten a new spark plug 1/2 turn with a spark plug wrench
the spark plug using the plug wrench (4) furnished in the to compress the washer. If you are reusing a plug, it should
tool kit. only take 1/8-1/4 turns after the plug seats.
4. Inspect the electrodes and center porcelain for deposits, 8. Reinstall the spark plug cap, right front side cover and
erosion or carbon & fouling. If the erosion or deposit is screws.
heavy, replace the plug. Clean a carbon or wet fouled plug, CAUTION:
with a plug cleaner, otherwise use a wire brush. The spark plug must be securely tightened. An
5. Check the spark plug gap (3) using a wire-type feeler improperly tightened plug can become very hot and
gauge. (4) Plug wrench J (3) Side electrode If adjustment is possibly damage the engine.
necessary, bend the side electrode (4) carefully. Never use a spark plug with an improper heat range.
Severe engine damage could result.
THROTTLE OPERATION NOTE:
(Refer to the maintenance precautions. on page 50). Do not attempt to compensate for faults in other systems
1. Check for smooth rotation of the throttle grip from the fully by adjusting idle speed. See your Honda dealer for
open to the fully closed position at both full steering regularly scheduled carburetor adjustments, including
positions. individual carburetor adjustment and synchronization.
2. Measure the throttle grip free play at the throttle grip flange. 1. Warm up the engine, shift to neutral and
The standard free play should be approximately:
2-6 mm (0.08-0.24 in) place the motorcycle on its side stand.
To adjust the free play, loosen the lock nut (1) and turn the 2. Connect a tachometer to the engine.
adjuster (2).
3. Adjust idle speed with the throttle stop screw (1).
IDLE SPEED
(Refer to the maintenance precautions on page 50).
The engine must be at normal operating temperature for
accurate idle speed adjustment. Ten minutes of stop-and-go
riding is sufficient.
(1)
Adjustment: 3. Loosen the lock nuts (2) on both adjusting nuts (3).
Drive chain slack should be checked and adjusted, if 4. Turn both adjusting nuts (3) an equal number of turns until
necessary, every 1,000 km (600 miles). When operated at the correct drive chain slack is obtained. Turn the adjusting
sustained high speed or under conditions of frequent rapid nuts clockwise to tighten the chain, or counterclockwise to
acceleration, the chain may require more frequent provide more slack. Adjust the chain slack at a point midway
adjustment. between the drive sprocket and the rear wheel sprocket.
Rotate the rear wheel and recheck slack at other sections of
the chain.
Chain slack should be: 20-30 mm (0.8-1.2 in)
7. Tighten the adjusting nuts lightly, then tighten the lock nuts
by holding theadjusting nuts with a spanner.
8. Recheck drive chain slack.
CAUTION:
The drive chain on this motorcycle is equipped with
small O-rings between the link plates. These O-rings
retain grease inside the chain to improve its service
life. However, special precautions must be taken
when adjusting, lubricating, washing, and replacing
the chain.
Installation Notes:
To install the front wheel assembly, install the brake disc
between the brake pads taking care not to damage the
brake pads and insert, the axle through the left fork leg. .
Make sure that the lugs (5) on the fork I leg is conta8ting the
lugs on the speedometer gear box. Tighten the axle nut to (5) Lugs
specified torques.
Axle nut torque:
59 Nm (6.0 kgf.m . 43 Ibf.ft)
Rear Wheel Removal
1. Raise the rear wheel off the ground by placing a support
block under the engine.
2. Loosen the rear axle nut.
3. Loosen the locknuts (2),
4. Loosen the drive chain adjusting nuts (3).
5. Remove the rear axle nut.
6. Remove the drive chain (4) from the driven sprocket by
pushing the rear wheel forward. (1)
7. Remove the axle shaft (5) side collar and rear wheel from
the swing arm.
Installation:
To install the rear wheel, reverse the removal procedure.
Torque the axle nut to the specified torque.
Axle nut torque: 88 N.m (9.0 kgf.m , 65 Ibf.ft)
CAUTION:
When installing the wheel, carefully (fit the brake disc
between the brake), pads to avoid damaging the pads.
(1) Rear axle nut (2) Lock nuts (3) Drive chain adjusting nuts After installing the wheel, apply the brake, several times
and then check if the wheel can rotate freely. Recheck the
NOTE: wheel if the brake drags or if the wheel does not rotate
freely,
Do not depress the brake pedal while the wheel is off the If a torque wrench was not used for installation, see your
motorcycle. The caliper pistons will be forced out of the Honda dealer as soon as possible to verify proper
cylinders with subsequent loss of brake fluid, If this occurs, assembly. Improper assembly may lead to loss of braking
servicing the brake system will be necessary, See your Honda capacity.
dealer for this service: (4)
BATTERY If electrolyte gets on your skin, flush with water.
(Refer to the maintenance precautions on page 50). If electrolyte gets in your eyes, flush with water for at
It is not necessary to check the battery electrolyte level or add least 15 minutes and call a physician immediately.
distilled water as the battery is a maintenance-free (sealed)
type. If your battery seems weak add/or is leaking electrolyte Electrolyte is poisonous.
(causing hard starting or other electrical troubles), contact
your Honda dealer. If swallowed, drink large quantities of water or milk and
follow with milk of magnesia or vegetable oil and call a
CAUTION: physician.
Removing the battery cap strip can damage the cap strip -
and result In leaks and eventual battery damage. KEEP OUT OF REACH OF CHILDREN.
When the motorcycle is to be stored for an extended
period of 'time, remove the battery from, the' motorcycle
and charge it fully. Then store it in a cool, dry place. If the
battery is to be left in the motorcycle, disconnect the
negative cable from the battery terminal.
FUSE REPLACEMENT
(Refer to the maintenance precaution on page 50). When
frequent fuse failure occurs, it (usually indicates a short circuit
or an overload in the electrical system. See your Honda
dealer for repair.
CAUTION:
Turn the ignition switch OFF before checking or
replacing fuses to prevent accidental short-circuiting.
Blown fuse
Main fuse:
The main fuse (1) is located behind the right side cover. The STOPLIGHT SWITCH ADJUSTMENT
specified fuse is: (Refer to the maintenance precautions on page 50).
15A Check the operation of the stoplight switch (1) at the right side
1. Remove the right side cover (page 31). 2. Disconnect the behind the engine from time to time. Adjustment is done by
wire connector (2) of the stater magnetic switch (3). turning the adjusting nut (2). Turn the nut in the direction (A) if
3. Pull out the fuse. If the fuse is blown install a new fuse. The the switch operates too late and in direction (B) if the switch
spare main fuse (4) is located near the starter magnetic operates too soon.
switch.
4. Reconnect the wire connector and install the right side
cover.
CAUTION:
Do not put finger prints on the headlight bulb, as they
may create hot spots on the bulb and cause it to
break. 5. Remove the socket (5) from headlight by slightly pressing
Wear clean gloves while replacing the bulb. the socket and turning it counterclockwise.
If you touch the bulb with your bare hands, clean it 6. Remove the bulb (6).
with a cloth moistened with alcohol to prevent its 7. Install a new bulb in the reverse order of removal.
early failure.
NOTE:
Be sure to turn the ignition switch OFF when replacing the
bulb.
Do not use bulbs other than that specified.
After installing a new bulb, check that the light operates
properly.
2. Dry the motorcycle, start the engine, and let it run for
several minutes.
STORAGE GUIDE safe place. Do not connect the spark plug to the spark plug
Extended storage, such as for winter, requires that you take cap.
certain steps to reduce the effects of deterioration from Pour a - tablespoon (15-20 cm3) of clean engine oil into
non-use of the motorcycle. In addition, necessary repairs the cylinder and cover the spark plug hole with a piece of
should be made BEFORE storing the motorcycle; otherwise, cloth,
these repairs may be forgotten by the time the motorcycle is Crank the engine several times to distribute the oil.
removed from storage. Reinstall the spark plug and spark plug cap.
STORAGE
1. Change the engine oil. 4. Remove the battery. Store in an area protected from
2. Empty the fuel tank into an approved petrol container using freezing temperatures and direct sunlight.
a commercially available hand siphon or an equivalent Slow charge the battery once a month.
method. Spray the inside of the tank with aerosol
rust-inhibiting oil. 5. Wash and dry the motorcycle. Wax all painted surfaces.
Reinstall the fuel fill cap on the tank. Coat chrome with rust inhibiting oil.
6. Lubricate the drive chain (page 65)
NOTE:
If storage will last more than one month, carburetor 7. Inflate the tyres to their recommended' pressures. Place
draining is very important, to assure proper performance the motorcycle on blocks to raise both tyres off the ground.
after storage.
8. Cover the motorcycle (don't use plastic or other coated
materials) and store in an unheated area, free of
dampness with a minimum of daily temperature variation.
Petrol is extremely flammable and is explosive under
certain conditions. Perform this operation in a Do not store the motorcycle in direct sunlight.
well-ventilated area with the engine stopped. Do not
smoke or allow flames or sparks in the area where
petrol is drained or stored and where the fuel tank is
refueled.
3. Drain any excess aerosol rust inhibiting oil from the fuel
WEIGHT
tank. Fill, the fuel tank with fresh petrol.
Dry weight 140 kg (308 Ibs)
4. Perform all Pre-ride inspection checks (page 35).
CAPACITIES 1.0L
Engine oil (After draining) 1.2L
Test rides the motorcycles at low speeds in a safe riding area
(After disassembly) 11.2 L
away from traffic.
Fuel tank 2.68 L
Fuel reserve
Passenger capacity Operator and one passenger
Maximum weight capacity 126 kg (277 Ibs)
ENGINE ELECTRICAL
Bore and stroke 63.5 x 62.2 mm (2.49 x 2.44 in) MF Battery 12V - 3.5Ah
Compression ratio 9.0: 1 Generator 130W/5000 min (rpm)
Displacement 196.9 cm3
Spark plug
Standard DPR8EA 9 (NGK) or
X24EPR U9 (DENSO) LIGHTS
Headlight 12V - 30/30W
Spark plug cap 0.80 - 0.90 mm (0.031 - 0.035 in) Tail/brake light 12V - 5/18W
Idle speed 1,400 100 min (rpm) Turn signal light Front 12V - 15W x 2
Rear 12V - 15W x 2
Instrument light 12V - 1 .7W x 2
CHASSIS AND SUSPENSION License light bulb 12V - 5W
Caster 31010' Neutral indicator light 12V - 1 .7W
Trail 117 mm (4.6 in) Turn signal indicator light 1 2V - 1 .7W
Tyre size, front 90/90 - 17 49P High beam indicator light 1 2V - 1 .7W
Tyre size, rear 130/90 - 15 M/C 66P
POWER TRANSMISSION
Primary reduction 3.090 FUSE
Gear ratio, 1st 2.545 Main fuse 15A
2nd 1.687
3rd 1.280
4th 1.041
5th 0.903
6th 0.814
Final reduction 3.154
CATALYTIC CONVERTER
A defective catalytic converter contributes to air pollution and
This motorcycle is equipped with a catalytic converter. can impair your engine's performance. Follow these
guidelines to protect your motorcycle's catalytic converter.
The catalytic converter contains precious metals that serve as
catalysts, promoting chemical reactions to convert the
exhaust gasses without affecting the metals. Always use unleaded petrol. Even a small amount of
leaded petrol can contaminate the catalyst metals, making
The catalytic converter acts on HC, CO, and NOx: A the catalytic converter ineffective.
replacement unit must be an original Honda part or its
equivalent. Keep the engine tuned-up.
The catalytic converter must operate at a high temperature for
the chemical reactions to take place. It can set on fire any Have your motorcycle diagnosed and replaced if it is
combustible materials that come near it. Park your motorcycle misfiring, backfiring, stalling or otherwise not running
away from high grasses, dry leaves, or other flammables. properly.