Index - Honda 2000 XR50R Service Manual

AIR CLEANER ...................................................... ·········3-5
AlA CLEANER HOUSING ······· .. · .. ····· .... ········· .... ···········5-3
AIR SCREW ADJUSTMENT ·········································5-10
BRAKE PEDAL ............................................................ 13-13
BRAKE SHOEWEAA ...................... , ............................. 3-14
BRAKE SYSTEM ................ ........................................... 3-14
CABLE & HARNESS ROUTING···································· 1-14
CAM CHAIN TENSIONER .......................................... 10-4
CAMSHAFT INSTALLATION ·······································7-15
CAMSHAFT REMOVAL····················.··········· ...... ······· .. · 7-3
CARBURETOR ASSEMBLy····· ...... ·· .. ··············· .... ···· .. · 5-6
CARBURETOR DiSASSEMBLy .... ··· .......... · ........ · .. ··· .. · 5-5
CARBURETOR INSTALLATION .... ··· .. · .. ··· .. ··· .......... ·· .. · 5-8
CARB URETOR REMOVAL ........................................ ... 5-3
CLUTCH ················ .. ··· .. ······ .. ··· .. · .... ··· .... · .. ······ .. ·· .. ······ .. · 9-4
CLUTCH SySTEM······ ........ ··· .. ········ .. ······ .. · .... ··· .. · ...... ··· 3-16
CRANKCASE ASSEMBLy·············· .. ······················ .. ·· 11 -14
CRANKCASE BREATHER .. ··· .. ········ .. ········· .... ·········· .. ··· 5-11
CRANKCASE SEPARATION··········· .. ·· .. ·· ...... ······ .... ···· 11-3
CRANKSHAFT · .. ·· .... · ...... ···· .. ······· .... ·· .............. · ...... ····11-4
CYLINDER/PISTON INSPECTION·· .. ······· .... ········· .... ···· 8-4
CYLINDER COMPRESSION ......................................... 7-3
CYLINDER HEAD·· .... · ...... ·············· .. ·· .. ·· .... ·· .. ···· ........ ··· 7-4
CYLINDER INSTALLATION .. ········· .... · .......... ······· .. · .... ·· 8-7
CYLINDER REMOVAL .................................................. 8-3
DRIVE CHAIN ................................................................ 3-12
DRIVE CHAIN SLIDER ..... ................... ·3·1 4
EMISSION CONTROL INFORMATION LABEL
(Except Canada type) ... ....................................... ·1 -18
EMISSION CONTROL SYSTEMS .. ·· .. ············· .. ········ .. · 1-17
ENGINE IDLE SPEED .... ····· .. ···· ...... ··· ........ ····· ...... ········· 3-11
ENGINE INSTALLATION .... ·· .. ······································ 6-4
ENGINE OIL·· ...... ·········· .... ····· ...... ··· .. ,········ .. ·· .. ·············3-8
ENGINE OIL CENTRIFUGAL FILTER ·· ........ ······· .. · .. ······ 3- 10
ENGINE OIL STRAINER SCREEN ................................ 3-10
ENGINE REMOVAL······· .... ···· .. ········ .. ···························6-2
ENGINE STOP SWITCH/IGNITION SWiTCH············· 14-7
EXHAUST SySTEM········ .. ····· .. · .. ··································2-4
FLYWHEEl/STATOR REMOVAL ............................... 10-2
FORK ····················· .... · .. ······ .... ···· .... ······ .... ······ .... ·········12-12
FRONT BRAKE······· .. ·· .... ···· .... ···· .... ···· .. · ...... ···· .......... ·· 12-10
FRONT FENDER ........................................................... 2-3
FRONT WHEEL ··· .... ·· .. ···· .............. ················· .. ·· .... ··· ·· 12-5
FUEL LINE··· .. ······· .. ············ .. ··· .... ················· ··· .. ········· .. ·3-4
FUEL TANK .. ····· ........ · .. ··· ...... · ........ ···· .. · .. ·· .. ···· .... ···•••·· .. 2-3
GEARSHIFT LINKAGE .... ··· .... ·· .. · ...... · ............ ·· ........ · .... 9-14
GENERAL SAFETY··········································· ············ 1-1
HANDLEBAR .......... .. ............................... . ..... 12-3
IGNITION COIL··················· .. ······································ 14-6
IGNITION CONTROL MODULE ···················· .. ···· ·······14-6
IGNITION SYSTEM INSPECTION .............................. 14-3
IGNITION TIMING .. ······· · .... ·· .. · .. ························ ········· 14-7
KICKSTARTER······· .. ·· .. ································· .. ····· .. ····· 11-12
LUBRICATION & SEAL POINTS .................................. 1-13
LUBRICATION SYSTEM DIAGRAM ............................ 4-0
MAINTENANCE SCHEDULE·· ...... ······················ .... ···· .. 3·3
MODEL IDE NTIFICATION .... · ...... ······•· .. ········ .. ·············1-3
NUMBER PLATE ······················· .. ··································2-4
NUTS, BOLTS, FASTENERS ·· ...... ·· .. ·· .......................... 3-18
Oil PUMP ......................................................... ············ 4-2
PISTON INSTALLATION .... ........ . , ......... , ...................... 8·7
PISTON REMOVAL· .. ·· ...... ····· ...... · .. · .. ·· .. ········ .. · .. · .. ······· 8-3
17. INDEX
REAR BRAKE· ........ ·· .. · .. · ........ · ........ · ...... · ........ · ........ 13-8
REAR FENDER .......................................................... 2-4
REAR WHEE L· .. · .......... ···· .. · .. ····· .... ··· .. · .. ···· .. ········ .... 13-3
RIGHT CRANKCASE COVER INSTALLATION ........ · 9-17
RIGHT CRANKCASE COVER REMOVAL .... .... ·9-3
SEAT······················ .. ···· ...... ···· .. ······ .. ····· .... · ................ 2-2
SERVICE INFORMATION
ALTERNATOR/CAM CHAIN TENSIONER .......... 10-1
ClUTCt-VGEARSHIFT LINKAGE ........................... 9- 1
CRANKSHAFT{TRANSMISSION/
KICKSTARTER·· .. · .. ··· ........ · ...... ···· .. ····· ............ ··· .. ',-,
CYLINDER HEADNALVES ...... ··· .. ······· .... · ........ ··· .. 7-1
CYLINDER/PISTON ............................................... 8· 1
ENGINE REMOVAl/INSTALLATION· .... ·· ........ ··· .. 6-1
FRAME/BODY PANELS/EXHAUST SySTEM ...... · 2·1
FRONT WHEEl/BRAKE/SUSPENSION}
STEERING ....... .................................................... 12-1
FUEL SySTEM .. ··· .... ·· .... · .. ·· .. · .. ··········· ...... • .... · .. ····· 5-1
IGNITION SYSTEM .. ·· ...... ····· .. ····· .... ····· .... · ...... · .. 14-1
LUBRICATION SYSTEM ...................................... 4-1
MAINTENANCE .. · .... ··· ...... ···· .. · .... · .... ····· .... · .. · ...... ·· 3-1
REAR WHEEl/BRAKElSUSPENSION ................. 13-1
SERVICE RULES ....................................................... 1-2
SHOCK ABSORBER ·· ...... · .. ·· .. ······ .... ·· .. · .. ······ .. ··· .... · 13-10
SIDE STAND ............................................................. 2-5
SIDE STAND .. ······ .... ·· ...... ····· .... ···· .... ··· .. · .... ·· .. ··· ··· ··· .. 3-16
SPARK ARRESTER· .. ·· .. · .. ·· .. · ...... ··· .... · ............ · .. ······ ·· 3- 17
SPARK PLUG .... ........................................................ 3-6
SPECiFiCATIONS· .. ··· .... ··············· .... · .... ······ .. ···· .. · ..... 1-4
STATOA/FlYWHEELINSTALLATION ................... 10-6
STEERING HEAD BEARINGS .... · ................ ····· ·3-19
STEERING STEM ···· .. ··· ................ ········ ........ · .... ······12-15
SUSPENSION ........................................................... 3-'6
SWINGARM -...... · ...... ···· ...... · ........ · .... ····· ...... · ...... ·· .. 13-12
SYSTEM DIAGRAM ......................................... ....... , 4-(1
THROTnE OPERATION······ .. ······ .. · ...... ··········· ........ · 3-4
TOOlS .. · ...... ·· .. · .. ············ ...... · ...... ········· ...... ·· .... ···· ... .. '-12
TORQUE VALUES ···· .. ····· .... · ...... ·········· .. · .. ···· .. ········ .. 1-10
TRANSMiSSiON· .... ···· .... ····· .. ······ .... ··.... . ..... ... 11 -6
TROUBLESHOOTING
Al TERNATORlCAM CHAI N TENSIONER .......... , 0-'
CLUTCH/GEARSHIFT LINKAGE ........................... 9-2
CRANKSHAFT{TRANSMISSION/
KICKSTARTER · .... ··· ................ ···· .. ····· .... ···· .. ····· .. · 11 -2
CYLINDER/PISTON ............................................... 8-2
CYLINDER HEADNALVES .... ··· .... · ...... · .. ··· .. ··· .. · .... 7-2
ENGINE DOES NOT START OR IS HARD TO
START· .. ··· ............ ·· ...... · .. ··· .... ··· .... ·· ........ ·· .. ·· .. · .... 16-1
ENGINE LACKS POWER·· .... ···· .... ·· .. · .. · .. ···· .. ····· .. 16-2
FRAME/BODY PANELS/EXHAUST SySTEM .... · .. 2-1
FRONT WHEEl/BRAKE/SUSPENSION/
STEERING ............................................ .. ...... 12-2
FUEL SySTEM·· .... · ...... · .. ··· .. ····· .... ··· .... ····· ...... · ...... 5-2
IGNITION SYSTEM ......... · ... ······· .. ····· .. · .. ······ .. ·· .. · 14-2
LUBRICATION SySTEM··· .. · .. ·· .. · .. ···· .... ···· .. ····· .. · .. 4-1
POOR HANDLING ·· .... ·· .. ··· .... ··· .. · .. ··· ...... ··· .. ·· .. ···· 16-4
POOR PERFORMANCE AT HIGH SPEED ........... 16-4
POOR PERFORMANCE AT lOW AND IDLE SPEED· .. · 16-3
REAR WHEEl/BRAKE/SUSPENSiON ................. 13-2
VALVE CLEARANCE ................................................. 3·7
WHEELS{TIRES .... ··· .. ···· .. · .... · ........ ···· .. ······ .......... ·· .. ·· 3-18
WIRING DIAGRAM ........................... ....... ............... 15-1
17-1