Table Of Contents - Honda 2000 XR50R Service Manual

Table of Contents

Contents3
Symbols4
General Information5
General Safety5
Carbon Monoxide5
Hot Components5
Service Rules6
Model Identification7
Engine Serial Number7
Frame Serial Number7
Vehicle Identification Number (Vin)7
Specifications8
Lubrication System10
Fuel System10
Cylinder Head/Valves10
Torque Values14
Tools16
Table Of Contents16
Lubrication & Seal Points17
Cable & Harness Routing18
Emission Control Systems21
Source Of Emissions21
Exhaust Emission Control System21
Crankcase Emission Control System21
Emission Control Information Label22
Frame/Body Panels/Exhaust System Service Information23
Frame/Body Panels/Exhaust System Troubleshooting23
Frame/Body Panels/Exhaust System Torque Values23
Excessive Exhaust Noise23
Seat Removal24
Seat Installation24
Seat Disassembly/Assembly24
Fuel Tank25
Number Plate25
Front Fender25
Exhaust System Removal26
Exhaust System Installation26
Side Stand Removal27
Side Stand Installation27
Maintenance29
Maintenance Service Information29
Maintenance Specifications29
Maintenance Torque Values30
Maintenance Tools30
Maintenance Schedule31
Fuel Line32
Throttle Operation32
Fuel Strainer Screen32
Air Cleaner33
Spark Plug Removal34
Spark Plug Inspection34
Reusing A Spark Plug34
Replacing A Spark Plug35
Valve Clearance Inspection35
Engine Oil Level Inspection36
Engine Oil Change37
Recommended Engine Oil37
Engine Oil Strainer Screen Cleaning38
Engine Oil Centrifugal Filter Cleaning38
Engine Idle Speed39
Drive Chain Slack Inspection40
Drive Chain Adjustment40
Cleaning Inspection And Lubrication40
Drive Chain Slider42
Brake Shoe Wear42
Front Brake42
Rear Brake43
Clutch System44
Side Stand44
Suspension44
Front Suspension Inspection44
Spark Arrester45
Rear Suspension Inspection45
Nuts, Bolts, Fasteners46
Wheels/Tires46
Recommended Tire Pressure And Tire Size46
Minimum Tread Depth46
Steering Head Bearings47
Lubrication System Diagram48
Lubrication System Service Information49
Lubrication System Specifications49
Lubrication System Torque Values49
Lubrication System Troubleshooting49
Oil Pump Removal50
Oil Pump Disassembly50
Oil Pump Inspection50
Oil Pump Assembly51
Fuel System Service Information55
Fuel System Specifications55
Fuel System Torque Value55
Fuel System Tool55
Fuel System Troubleshooting56
Engine Won't To Start56
Lean Mixture56
Rich Mixture56
Air Cleaner Housing Removal/Installation57
Carburetor Removal57
Throttle Valve57
Carburetor Body58
Carburetor Disassembly59
Carburetor Assembly60
Float Level Inspection61
Carburetor Installation62
Air Screw Adjustment64
Idle Drop Procedure64
Initial Opening64
Idle Speed64
Crankcase Breather65
Engine Removal/Installation66
Cylinder Head/Valves Service Information73
Cylinder Head/Valves Specifications73
Cylinder Head/Valves Torque Values73
Cylinder Head/Valves Troubleshooting74
Cylinder Head/Valves Tools74
Excessive Smoke74
Excessive Noise74
Valve Spring Compressor 07757 - 001000074
Seat Cutter, 20.5 Mm74
Flat Cutter, 24 Mm74
Flat Cutter, 21.5 Mm74
Cutter Holder, 5 Mm 07781 - 001040074
Cylinder Compression75
Camshaft Removal75
Compression Pressure75
Cylinder Head Removal76
Cylinder Head Disassembly77
Cylinder Head Inspection78
Rocker Arm79
Valve Spring79
Valve79
Valve Guide Replacement80
Valve Seat Inspection/Refacing81
Valve Guide Driver, 5.0 Mm 0794281
Note 381
Valve Seat Refacing82
Note82
Camshaft Installation87
Note Note87
Cylinder/Piston90
Cylinder/Piston Service Information91
Cylinder/Piston Specifications91
Cylinder/Piston Torque Values91
Cylinder/Piston Troubleshooting92
Piston Sounds92
Cylinder Removal93
Piston Removal93
Cylinder/Piston Inspection94
Piston Ring Installation96
Piston Installation97
Cylinder Installation97
Clutch/Gearshift Linkage100
Clutch/Gearshift Linkage Service Information101
Clutch/Gearshift Linkage Specifications101
Clutch/Gearshift Linkage Torque Values101
Clutch/Gearshift Linkage Tools101
Clutch/Gearshift Linkage Troubleshooting102
Clutch Slips When Accelerating102
Hard To Shift102
Transmission Jumps Out Of Gear102
Right Crankcase Cover Removal103
Clutch Removal104
Clutch Spring108
Clutch Disc108
Primary Drive Gear/Clutch Center Guide108
Crankshaft109
Drive Gear Outer/Clutch Center109
Gearshift Linkage Removal114
Clutch/Gearshift Linkage Inspection116
Clutch/Gearshift Linkage Installation116
Right Crankcase Cover Installation117
Alternator/Cam Chain Tensioner120
Alternator/Cam Chain Tensioner Service Information121
Alternator/Cam Chain Tensioner Specifications121
Alternator/Cam Chain Tensioner Tools121
Alternator/Cam Chain Tensioner Troubleshooting121
Flywheel/Stator Removal122
Cam Chain Tensioner124
Stator/Flywheel Installation126
Crankshaft/Transmission/Kickstarter131
Crankshaft Itransmission/Kickstarter132
Troubleshooting132
Crankcase Separation133
Crankshaft Removal134
Crankshaft Inspection135
Crankshaft Installation136
Transmission Removal136
Transmission Disassembly137
Transmission Inspection137
Transmission Assembly138
Gearshift Drum Disassembly138
Shift Drum Assembly139
Transmission Bearing Replacement140
Transmission Installation142
Kickstarter Removal142
Kickstarter Disassembly142
Kickstarter Inspection143
Kickstarter Assembly143
Kickstarter Installation144
Crankcase Assembly144
Front Wheel/Brake/Suspension/Steering146
Front Wheel/Brake/Suspension/Steering Service Information147
Front Wheel/Brake/Suspension/Steering Specifications147
Front Wheel/Brake/Suspension/Steering Torque Values147
Front Wheel/Brake/Suspension/Steering Troubleshooting148
Front Wheel/Brake/Suspension/Steering Tools148
Hard Steering148
Front Wheel Wobbling148
Handlebar Removal149
Handlebar Installation150
Front Wheel Removal151
Front Wheel Inspection152
Axle152
Wheel Bearing152
Wheel Rim Runout152
Wheel Center Adjustment154
Front Brake Removal156
Front Brake Inspection156
Front Brake Disassembly156
Front Brake Assembly157
Fork Disassembly158
Front Brake Installation158
Fork Inspection159
Fork Assembly159
Steering Stem Removal161
Steering Stem Bearing Replacement162
Steering Stem Installation163
Rear Wheel/Brake/Suspension166
Rear Wheel/Brake/Suspension Service Information167
Rear Wheel/Brake/Suspension Torque Values167
Rear Wheel/Brake/Suspension Specifications167
Rear Wheel/Brake/Suspension Tools167
Rear Wheel/Brake/Suspension Troubleshooting168
Soft Suspension168
Hard Suspension168
Rear Wheel Wobbling168
Rear Wheel Removal169
Rear Wheel Inspection170
Rear Wheel Disassembly171
Rear Wheel Assembly171
Wheel Bearing Removal171
Wheel Bearing Installation172
Rear Brake Removal174
Rear Brake Inspection174
Rear Brake Disassembly174
Rear Brake Assembly175
Shock Absorber Removal176
Shock Absorber Inspection177
Shock Absorber Installation177
Swingarm Removal178
Swingarm Inspection178
Swingarm Installation179
Brake Pedal Removal179
Brake Pedal Installation180
Ignition System Diagram182
Ignition System Service Information183
Ignition System Specifications183
Ignition System Torque Values183
Ignition System Tools183
Ignition System Troubleshooting184
No Spark At Spark Plug184
Ignition System Inspection185
Ignition Coil Primary Peak Voltage185
Ignition Pulse Generator Peal Voltage186
Alternator Exciter Coil Peak Voltage187
Ignition Coil Removal/Installation188
Ignition Control Module188
Engine Stop Switch/Ignition Switch Inspection189
Ignition Timing189
Wiring Diagram191
Engine Does Not Start Or Is Hard To Start193
Engine Lacks Power194
Poor Performance At Low And Idle Speed195
Poor Performance At High Speed196
Poor Handling196
Index197