In this article, we will discuss the step-by-step process of replacing the fuel tank mounting bolts on a Honda XR200R. This is a common maintenance task that can be easily done at home with the right tools and knowledge. We will walk you through the process and provide helpful tips along the way. By the end of this guide, you will have the confidence to tackle this job on your own.

What tools do I need for this task?

To replace the fuel tank mounting bolts on your Honda XR200R, you will need a set of metric sockets and wrenches, a ratchet, and some lubricating oil. It’s also a good idea to have a container to catch any fuel that may spill during the process. Make sure you have the right size sockets and wrenches for the job and always work in a well-ventilated area to avoid inhaling any fumes.

Before you begin, it’s a good idea to gather all the necessary tools and have them within reach. This will make the job go more smoothly and prevent any unnecessary interruptions.

How do I remove the old mounting bolts?

Start by locating the fuel tank mounting bolts on your XR200R. They are typically located near the top of the tank and are used to secure the tank to the frame of the motorcycle. Use your ratchet and the appropriate socket to loosen and remove the bolts. Be careful not to apply too much pressure, as you don’t want to strip the threads or damage the bolts.

Once the bolts are removed, carefully lift the fuel tank away from the frame and set it aside in a safe location. You may need to gently wiggle the tank to free it from any remaining pressure points.

How do I install the new mounting bolts?

Start by applying a small amount of lubricating oil to the threads of the new mounting bolts. This will help prevent them from seizing and make future removal easier. Carefully position the fuel tank back onto the frame, aligning the holes with the mounting points. Insert the new bolts and hand-tighten them to ensure they are properly seated.

Once the new bolts are in place, use your ratchet and socket to tighten them to the manufacturer’s recommended torque specifications. Be sure to check the owner’s manual for the correct torque values, as over-tightening can cause damage and under-tightening can lead to loose bolts.

Honda XR200R

Is there anything else I need to consider?

Before you start the engine or ride your XR200R, it’s important to double-check the tightness of the new fuel tank mounting bolts. Give each bolt a final turn with your ratchet to ensure they are secure. Additionally, inspect the surrounding area for any signs of fuel leakage or damage.

Finally, take a moment to appreciate the work you’ve done and the improved safety and stability of your motorcycle. Regular maintenance tasks like this one can help extend the life of your vehicle and ensure a smooth riding experience.


Replacing the fuel tank mounting bolts on your Honda XR200R is a simple and rewarding task. With the right tools and a little know-how, you can easily tackle this job at home. By following the steps outlined in this guide and taking the time to do the job correctly, you can ensure the safety and reliability of your motorcycle for years to come.Honda XR200R


Are there any special precautions I should take when working with fuel?

When working with the fuel tank, it’s important to work in a well-ventilated area and avoid any open flames or sparks. Additionally, it’s a good idea to have a container to catch any spilled fuel and to wear gloves to protect your hands. Always follow the manufacturer’s recommendations for handling and disposing of fuel.

Do I need to drain the fuel tank before starting this task?

It’s not necessary to drain the fuel tank for this particular task, as you will only be removing the tank temporarily to access the mounting bolts. However, if you plan to do additional work that requires the tank to be completely removed, it may be a good idea to drain the fuel to prevent spills and accidents.

How often should I replace the fuel tank mounting bolts?

It’s a good idea to inspect the condition of the fuel tank mounting bolts whenever you perform routine maintenance on your XR200R. If you notice any signs of wear or damage, it’s best to replace them as soon as possible to ensure the safety and integrity of the fuel tank. Otherwise, you can consider replacing them every few years as part of a preventative maintenance plan.

Can I use any type of lubricating oil on the new mounting bolts?

It’s best to use a lubricating oil that is specifically designed for use on metal fasteners. Avoid using too much oil, as this can attract dirt and debris and make the bolts more difficult to remove in the future. A small amount of oil applied to the threads before installation should be sufficient to prevent seizing.

Do I need to use a torque wrench to tighten the new mounting bolts?

While it’s possible to tighten the new mounting bolts by hand, it’s best to use a torque wrench to ensure they are tightened to the correct specification. This will help prevent over-tightening or under-tightening, which can lead to damage or safety issues down the road. Refer to the owner’s manual for the recommended torque values for your XR200R.


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