Honda XR125LK Owner's Manual
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How to use this manual

A Few Words About Safety
How to use this manual

Service Information

The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also
damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service
procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer to be
seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
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Summary of Contents for Honda XR125LK

  • Page 1: How To Use This Manual

    Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.
  • Page 2 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 3 Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: • Molykote® G-n Paste manufactured by Dow Corning U.S.A. • Honda Moly 60 (U.S.A. only) • Rocol ASP manufactured by Rocol Limited, U.K. • Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease.
  • Page 4: Table Of Contents

    CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE IGNITION SYSTEM ELECTRIC STARTER FUEL SYSTEM LUBRICATION SYSTEM CYLINDER HEAD/VALVES CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKSHAFT/TRANSMISSION/KICKSTARTER ENGINE REMOVAL/INSTALLATION FRONT WHEEL/BRAKE/SUSPENSION/STEERING REAR WHEEL/BRAKE/SUSPENSION HYDRAULIC BRAKE (XR125LK/LEK) BATTERY/CHARGING SYSTEM LIGHTS/METER/SWITCHES WIRING DIAGRAMS INDEX...
  • Page 5 dummyhead dummyhead MEMO...
  • Page 6: General Information

    1. GENERAL INFORMATION SERVICE RULES ··········································1-2 LUBRICATION & SEAL POINTS ··············· 1-14 MODEL IDENTIFICATION ····························1-2 CABLE & HARNESS ROUTING (XR125LK/ LEK) ···························································· 1-16 SPECIFICATIONS ·········································1-3 CABLE & HARNESS ROUTING (XL125LK) ·· 1- TORQUE VALUES ······································1-10 EMISSION CONTROL SYSTEMS ·············· 1-30...
  • Page 7: General Information

    SERVICE RULES GENERAL INFORMATION 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.
  • Page 8: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2,100 mm (82.7 in) (XR125LK/LEK) Overall width 820 mm (32.3 in) Overall height 1,126 mm (44.3 in) Wheelbase 1,361 mm (53.6 in) Seat height 825 mm (32.5 in)
  • Page 9 GENERAL INFORMATION ITEM SPECIFICATION FRAME Frame type Semi double cradle (XR125LK/LEK) Front suspension Telescopic fork Front wheel travel 160 mm (6.3 in) Rear suspension Swingarm Rear wheel travel 151 mm (5.9 in) Front tire size 90/90 – 19 M/C 52P Rear tire size 110/90 –...
  • Page 10: Ignition System Specifications

    See page 6-13 Float level 14 mm (0.6 in) 8.2 – 12.3 Ω (25°C/77°F) Carburetor heater resistance (except III LA, CO types) PAIR control valve specified vacuum (XR125LK/LEK) 330 mm Hg Idle speed 1,500 ± 100 min (rpm) Throttle grip free play...
  • Page 11 dummyhead dummyhead GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression at 300 min (rpm) 1,275 kPa (13.0 kgf/cm , 185 psi) – Valve clearance 0.08 ± 0.02 (0.003 ± 0.001) – 0.12 ± 0.02 (0.005 ± 0.001) –...
  • Page 12 Fork Spring free length 594.5 (23.41) 582.6 (22.94) Pipe runout – 0.20 (0.008) Recommended fluid Honda ULTRA CUSHION OIL 10W or – equivalent Fluid level 179 (7.0) – Fluid capacity 180 ± 2.5 cm (6.1 ± 0.08 US oz, 6.3 ±...
  • Page 13 Fork Spring free length 605.5 (23.84) 593.4 (23.36) Pipe runout – 0.20 (0.008) Recommended fluid Honda ULTRA CUSHION OIL 10W or – equivalent Fluid level 194 (7.6) – Fluid capacity 180 ± 2.5 cm (6.1 ± 0.08 US oz, 6.3 ±...
  • Page 14 Headlight (High/Low beam) 12 V – 35/35 W Position light 12 V – 4 W Brake/taillight 12 V – 21/5 W License light (XR125LK/LEK) 12 V – 5 W Front turn XR125LK/LEK 12 V – 16 W x 2 signal light XL125LK 12 V –...
  • Page 15: Frame/Body Panels/Exhaust System

    dummyhead dummyhead GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm hex bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
  • Page 16 2.5 (0.3, 1.8) Main jet 2.1 (0.2, 1.5) Float chamber screw 2.1 (0.2, 1.5) Air cut-off valve cover screw 2.1 (0.2, 1.5) (XR125LK/LEK) Fuel valve 27 (2.8, 20) Insulator socket bolt 12 (1.2, 9) Shock absorber lower mounting nut 44 (4.5, 32)
  • Page 17 dummyhead dummyhead GENERAL INFORMATION ALTERNATOR/STARTER CLUTCH THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Flywheel nut 74 (7.5, 55) Apply engine oil to the threads and seating surface. Starter clutch bolt 16 (1.6, 12) Apply locking agent to the threads. Coating width: 6.5 ±...
  • Page 18 Shock absorber lower mounting nut 44 (4.5, 32) U-nut Drive chain slider screw 6.0 (0.6, 4.4) Swingarm pivot nut 88 (9.0, 65) U-nut HYDRAULIC BRAKE (XR125LK/LEK) THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Master cylinder reservoir cap screw 1.5 (0.2, 1.1)
  • Page 19: Lubrication & Seal Points

    dummyhead dummyhead GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Sealant (ThreeBond 1215 or Crankcase mating area equivalent) Alternator wire grommet seating surface Engine oil Oil pump rotors Oil filter rotor lock nut threads and seating surface Oil through sliding area Rocker arm shaft whole surface Rocker arm inner surface and roller surface Rocker arm valve adjusting nut threads...
  • Page 20 Silicone grease Brake lever pivot sliding surface (XR125LK/LEK) Brake caliper pin sliding surface (XR125LK/LEK) Brake caliper bracket pin sliding surface (XR125LK/LEK) Brake caliper piston dust seal (XR125LK/LEK) Brake lever push rod contact surface (XR125LK/LEK) DOT 3 or DOT 4 brake fluid...
  • Page 21 GENERAL INFORMATION CABLE & HARNESS ROUTING (XR125LK/LEK) FRONT BRAKE HOSE THROTTLE CABLE FRONT TURN SIGNAL LIGHT WIRE RIGHT FRONT TURN SIGNAL LIGHT WIRE IGNITION RIGHT SWITCH WIRE HANDLEBAR CLUTCH CABLE SWITCH WIRE SPEEDOMETER WIRE SPEEDOMETER WIRE RIGHT FRONT...
  • Page 22 dummyhead dummyhead GENERAL INFORMATION RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLE PAIR SUB AIR FILTER-TO- CONTROL VALVE HOSE SPEEDOMETER CABLE SPARK PLUG WIRE CLUTCH CABLE PAIR CONTROL VALVE-TO-CYLINDER HEAD COVER HOSE 1-17...
  • Page 23 dummyhead dummyhead GENERAL INFORMATION RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR CLUTCH CABLE SWITCH WIRE MAIN WIRE HARNESS HORN WIRE FRONT BRAKE HOSE PAIR CONTROL VALVE VACUUM HOSE AIR INLET COVER RESONATOR 1-18...
  • Page 24 dummyhead dummyhead GENERAL INFORMATION THROTTLE CABLE CONNECTOR BOOT: - NEUTRAL SWITCH WIRE CONNECTOR - ALTERNATOR 2P CONNECTOR - IGNITION PULSE GENERATOR WIRE CONNECTOR PAIR SUB AIR - THERMO SWITCH 2P CONNECTOR (EXCEPT III LA, CO TYPES) FILTER-TO-CONTROL VALVE HOSE CARBURETOR HEATER WIRE (EXCEPT III LA, CO TYPES) CARBURETOR AIR VENT HOSE...
  • Page 25 dummyhead dummyhead GENERAL INFORMATION XR125LEK: STARTER MOTOR CABLE (XR125LEK) REAR BRAKE LIGHT SWITCH IGNITION CONTROL 2P (BLACK) CONNECTOR MODULE (ICM) SIDESTAND SWITCH 3P (GREEN) CONNECTOR (NZ TYPE) FUEL HOSE HORN WIRE CLUTCH CABLE STARTER RELAY SWITCH (XR125LEK) NEUTRAL SWITCH WIRE SIDESTAND SWITCH WIRE (NZ TYPE) CRANKCASE BREATHER...
  • Page 26 GENERAL INFORMATION XR125LK: IGNITION CONTROL MODULE (ICM) REAR BRAKE LIGHT SWITCH 2P (BLACK) CONNECTOR FUEL HOSE FUSE BOX HORN WIRE BATTERY (+) CABLE CLUTCH CABLE BATTERY (–) CABLE NEUTRAL SWITCH WIRE ALTERNATOR WIRE CRANKCASE BREATHER DRAIN HOSE 1-21...
  • Page 27 dummyhead dummyhead GENERAL INFORMATION CONNECTOR BOOT (XR125LEK): - DIODE - SIDESTAND DIODE (NZ TYPE ONLY) CONNECTOR BOOT: - BRAKE/TAIL LIGHT 3P CONNECTOR - REAR TURN SIGNAL LIGHT WIRE CONNECTORS - LICENSE LIGHT WIRE CONNECTORS RIGHT REAR TURN SIGNAL LIGHT WIRE LEFT REAR TURN SIGNAL LIGHT WIRE LICENSE LIGHT WIRE...
  • Page 28 dummyhead dummyhead GENERAL INFORMATION AIR INLET COVER Left PAIR CONTROL VALVE 45° Left VACUUM HOSE 45° VACUUM HOSE CLIP CLIP (PAIR SUB AIR FILTER-TO-CONTROL VALVE HOSE) PAIR SUB AIR FILTER PAIR CONTROL PAIR CONTROL VALVE VALVE-TO-CYLINDER HEAD COVER HOSE PAIR SUB AIR FILTER-TO-CONTROL VALVE HOSE HOSE CLAMP...
  • Page 29: Cable & Harness Routing (Xl125Lk)

    dummyhead dummyhead GENERAL INFORMATION CABLE & HARNESS ROUTING (XL125LK) FRONT BRAKE CABLE RIGHT FRONT TURN RIGHT SPEEDOMETER SIGNAL LIGHT WIRE HANDLEBAR WIRE SWITCH WIRE CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE LEFT FRONT TURN SIGNAL LIGHT WIRE TURN SIGNAL RELAY HEADLIGHT/ POSITION LIGHT 4P CONNECTOR IGNITION SWITCH WIRE...
  • Page 30 dummyhead dummyhead GENERAL INFORMATION RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE CABLE LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLE SPARK PLUG WIRE SPEEDOMETER CABLE CLUTCH CABLE 1-25...
  • Page 31 dummyhead dummyhead GENERAL INFORMATION LEFT HANDLEBAR THROTTLE CABLE SWITCH WIRE CLUTCH CABLE RIGHT HANDLEBAR SWITCH WIRE MAIN WIRE HARNESS FRONT BRAKE CABLE HORN WIRE SPEEDOMETER CABLE 1-26...
  • Page 32 dummyhead dummyhead GENERAL INFORMATION CONNECTOR BOOT: - NEUTRAL SWITCH WIRE CONNECTOR THROTTLE CABLE - ALTERNATOR 2P CONNECTOR - IGNITION PULSE GENERATOR WIRE CONNECTOR - THERMO SWITCH 2P CONNECTOR CARBURETOR HEATER WIRE CARBURETOR AIR VENT HOSE REAR BRAKE LIGHT SWITCH WIRE CLUTCH CABLE CRANKCASE CRANKCASE BREATHER...
  • Page 33 dummyhead dummyhead GENERAL INFORMATION IGNITION CONTROL MODULE (ICM) REAR BRAKE LIGHT SWITCH 2P (BLACK) CONNECTOR FUEL HOSE FUSE BOX HORN WIRE BATTERY (+) CABLE CLUTCH CABLE BATTERY (–) CABLE NEUTRAL SWITCH WIRE ALTERNATOR WIRE CRANKCASE BREATHER DRAIN HOSE 1-28...
  • Page 34 dummyhead dummyhead GENERAL INFORMATION CONNECTOR BOOT: - BRAKE/TAIL LIGHT 3P CONNECTOR - REAR TURN SIGNAL LIGHT WIRE CONNECTORS RIGHT REAR TURN SIGNAL LIGHT WIRE FUSE BOX REAR BRAKE LIGHT SWITCH 2P (BLACK) CONNECTOR LEFT REAR TURN SIGNAL LIGHT WIRE MAIN WIRE HARNESS 1-29...
  • Page 35: Emission Control Systems

    Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.
  • Page 36: Frame/Body Panels/Exhaust System

    dummytext 2. FRAME/BODY PANELS/EXHAUST SYSTEM SEAT······························································2-2 FUEL TANK ·················································· 2-4 SIDE COVER ·················································2-2 FRONT VISOR ·············································· 2-4 REAR CARRIER············································2-2 FRONT FENDER··········································· 2-5 REAR COWL ·················································2-3 DRIVE SPROCKET COVER ························· 2-5 NUMBER PLATE BRACKET ························2-3 EXHAUST PIPE/MUFFLER ·························· 2-6 SIDE SHROUD ··············································2-4...
  • Page 37: Side Cover

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SEAT FRAME/BODY PANELS/EXHAUST SYSTEM REMOVAL/INSTALLATION Remove the side cover (page 2-2). Remove the bolts [1] and collars [2] from both sides of the seat [3]. Remove the seat rearward. Align the hooks of the frame with the holes of the seat and install the seat.
  • Page 38: Rear Cowl

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR COWL REMOVAL/INSTALLATION Remove the following: – Side covers (page 2-2) – Seat (page 2-2) – Rear carrier (page 2-2) Remove the bolts [1]. Remove the rear cowl [2] by releasing its rubber [3] from the number plate bracket [4]. Installation is in the reverse order of removal.
  • Page 39: Fuel Tank

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SIDE SHROUD REMOVAL/INSTALLATION Remove the side cover (page 2-2). Remove the screw [1] and bolts [2]. Remove the side shroud [3] while releasing its hole from the hook [4] on the fuel tank. Installation is in the reverse order of removal. FUEL TANK REMOVAL/INSTALLATION Remove the following:...
  • Page 40: Front Fender

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws [1] and plates [2], then separate the visor [3], headlight rubber [4], inner visor [5] and headlight [6]. Assembly is in the reverse order of disassembly. FRONT FENDER REMOVAL/INSTALLATION Remove the bolts [1]. Remove the front fender [2], headlight aim adjuster holder [3] and collars [4].
  • Page 41: Exhaust Pipe/Muffler

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE/MUFFLER REMOVAL/INSTALLATION Remove the right side cover (page 2-2). Loosen the muffler band bolt [1]. Remove the following: – Front mounting bolt [2] and washer [3] – Rear mounting bolt [4] and nut [5] –...
  • Page 42: Maintenance

    DRIVE CHAIN SLIDER ······························· 3-11 THROTTLE OPERATION······························3-3 BRAKE FLUID (XR125LK/LEK) ················· 3-12 AIR CLEANER···············································3-4 BRAKE SHOES/PADS WEAR ··················· 3-12 AIR CLEANER SUB FILTER (XR125LK/LEK) ·· BRAKE SYSTEM ········································ 3-13 BRAKE LIGHT SWITCH ····························· 3-14 CRANKCASE BREATHER ···························3-5 HEADLIGHT AIM ········································ 3-15 SPARK PLUG················································3-5...
  • Page 43: Maintenance Schedule

    * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by a dealer. Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: 1.
  • Page 44: Throttle Operation

    dummyhead dummyhead MAINTENANCE FUEL STRAINER SCREEN Turn the fuel valve [1] "OFF". Remove the fuel strainer cup [2] and drain the contents of the cup into a suitable container. Remove the O-ring [3] and fuel strainer screen [4]. Wash the fuel strainer screen and cup in clean non- flammable high flash point solvent.
  • Page 45: Air Cleaner

    Air cleaner element screw: 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft) Air cleaner case cover screw: 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft) AIR CLEANER SUB FILTER (XR125LK/ LEK) Remove the following: – Side shroud (page 2-4) – Fuel tank (page 2-4) Check the air cleaner sub filter [1] and replace if necessary.
  • Page 46: Crankcase Breather

    dummyhead dummyhead MAINTENANCE CRANKCASE BREATHER • Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or overturned. Service if the deposits level can be seen in the transparent section of the breather drain hose. Remove the drain plug [1] from the breather drain hose [2] and drain deposits into a suitable container.
  • Page 47: Valve Clearance

    dummyhead dummyhead MAINTENANCE VALVE CLEARANCE INSPECTION Remove the cylinder head cover (page 8-4). Inspect and adjust the valve clearance Remove the timing and crankshaft hole caps. while the engine is Rotate the crankshaft counterclockwise and align the cold (below 35°C/ "T"...
  • Page 48: Engine Oil

    If the level is below or near the lower mark [2] on the dipstick, fill the crankcase with recommended oil to the upper level [3]. RECOMMENDED ENGINE OIL: Honda "4-stroke motorcycle oil" or an equivalent API classification: SG or higher (except oils labeled as energy conserving on the circular API service label)
  • Page 49: Engine Idle Speed

    dummyhead dummyhead MAINTENANCE ENGINE OIL CENTRIFUGAL FILTER Remove the right crankcase cover (page 10-4). Remove the following: – Screws [1] – Oil filter rotor cover [2] – Gasket [3] Clean the oil filter rotor cover and inside of the oil filter rotor using a clean lint-free cloth.
  • Page 50: Drive Chain

    MAINTENANCE SECONDARY AIR SUPPLY SYSTEM (XR125LK/LEK) • The secondary air supply system introduces filtered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system.
  • Page 51: Cleaning And Lubrication

    dummyhead dummyhead MAINTENANCE ADJUSTMENT Loosen the rear axle nut [1]. Loosen the lock nuts [2] and turn the adjusting nuts [3] until the correct drive chain slack is obtained. Make sure that the index marks on both adjusters are aligned with the rear edges of the axle slots in the swingarm.
  • Page 52: Drive Chain Slider

    dummyhead dummyhead MAINTENANCE SPROCKET INSPECTION Remove the drive sprocket cover (page 2-5). Inspect the drive and driven sprocket teeth for wear [1] or damage [2], replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition [3], or new replacement chain will wear rapidly.
  • Page 53: Brake Fluid (Xr125Lk/Lek)

    [2] on the brake panel, inspect the brake drum. Replace the brake shoes if the drum I.D. is within the service limit (page 1-8). FRONT BRAKE PADS (XR125LK/LEK) Check the brake pads for wear. Replace the brake pads [1] if wear limit groove [2] of either pad is worn out (page 16-6).
  • Page 54: Brake System

    Replace the brake shoes if the drum I.D. is within the service limit (page 1-8). BRAKE SYSTEM HYDRAULIC BRAKE(XR125LK/LEK) Firmly apply the brake lever and check that no air has entered the system. If the lever feels soft or spongy when operated, bleed air from the system (page 16-4).
  • Page 55: Brake Pedal Height

    dummyhead dummyhead MAINTENANCE BRAKE PEDAL FREEPLAY Check the brake pedal free play. Perform the free play adjustment FREEPLAY: 15 – 25 mm (0.6 – 1.0 in) after adjusting pedal height. 15 – 25 mm (0.6 – 1.0 in) Adjust the freeplay by turning the adjusting nut [1]. Make sure the cutout of the rear brake adjusting nut is seated on the joint pin [2].
  • Page 56: Headlight Aim

    dummyhead dummyhead MAINTENANCE HEADLIGHT AIM • Adjust the headlight beam as specified by local laws and regulations. Place the motorcycle on a level surface. Adjust the headlight beam vertically by turning the adjusting screw [1]. CLUTCH SYSTEM Inspect the clutch cable for kinks or damage, and lubricate the cable if necessary.
  • Page 57: Nuts, Bolts, Fasteners

    dummyhead dummyhead MAINTENANCE SIDESTAND Check the sidestand spring [1] for damage or loss of tension. Check the sidestand [2] operation for freedom of movement and lubricate the sidestand pivot if necessary. Check that the sidestand pivot bolt and lock nut are tightened.
  • Page 58: Steering Head Bearings

    MAINTENANCE Check the cold tire pressure. Tire pressure should be checked RECOMMENDED TIRE PRESSURE AND TIRE SIZE: when the tires are XR125LK/LEK XL125LK cold. FRONT REAR FRONT REAR Driver only 150 (1.5, 22) 150 (1.5, 22) 150 (1.5, 22) 150 (1.5, 22)
  • Page 59 dummyhead dummyhead MEMO...
  • Page 60: Ignition System

    dummytext 4. IGNITION SYSTEM COMPONENT LOCATION ····························4-2 IGNITION SYSTEM INSPECTION ················ 4-4 SYSTEM DIAGRAM ······································4-2 IGNITION TIMING ········································· 4-5 SERVICE INFORMATION ·····························4-3 IGNITION COIL ············································· 4-6 TROUBLESHOOTING···································4-3 ICM (IGNITION CONTROL MODULE)·········· 4-6...
  • Page 61: Component Location

    dummyhead dummyhead IGNITION SYSTEM COMPONENT LOCATION IGNITION SYSTEM IGNITION SWITCH IGNITION COIL SPARK PLUG IGNITION CONTROL MODULE (ICM) IGNITION PULSE GENERATOR SYSTEM DIAGRAM IGNITION SWITCH MAIN FUSE (15 A) NZ TYPE shown: ... Black ... Red ... Green ... White ...
  • Page 62: Troubleshooting

    dummyhead dummyhead IGNITION SYSTEM SERVICE INFORMATION GENERAL • When servicing the ignition system, always follow the steps in the troubleshooting sequence on (page 4-3). • The ignition timing cannot be adjusted since the Ignition Control Module (ICM) is factory preset. •...
  • Page 63: Ignition System Inspection

    dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark at the plug, check all connections for loose or poor contact before measuring the peak voltage. • Use a commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum. •...
  • Page 64: Ignition Timing

    dummyhead dummyhead IGNITION SYSTEM IGNITION PULSE GENERATOR PEAK VOLTAGE • Check the cylinder compression and check that the spark plug is installed correctly in the cylinder head. Disconnect the ICM 4P connector. Connect the peak voltage adaptor [1] or tester probes to the ignition pulse generator wire terminal of the 4P connector [2] and body ground.
  • Page 65: Ignition Coil

    dummyhead dummyhead IGNITION SYSTEM The ignition timing is correct if the "F" mark [1] on the flywheel aligns with the index notch [2] on the left crankcase cover. Coat a new O-ring [1] with engine oil and install it onto the timing hole cap [2].
  • Page 66: Electric Starter

    dummytext 5. ELECTRIC STARTER COMPONENT LOCATION ····························5-2 STARTER MOTOR ······································· 5-5 SYSTEM DIAGRAM ······································5-2 STARTER RELAY········································· 5-7 SERVICE INFORMATION ·····························5-3 NEUTRAL DIODE ········································· 5-8 TROUBLESHOOTING···································5-3...
  • Page 67 dummyhead dummyhead ELECTRIC STARTER COMPONENT LOCATION ELECTRIC STARTER STARTER SWITCH IGNITION SWITCH CLUTCH SWITCH DIODE FUSE BOX/SUB FUSE (10 A) STARTER RELAY SWITCH/ MAIN FUSE (15 A) BATTERY STARTER MOTOR NEUTRAL SWITCH SIDESTAND SWITCH (NZ TYPE) SYSTEM DIAGRAM STARTER MAIN BATTERY MOTOR FUSE...
  • Page 68 dummyhead dummyhead ELECTRIC STARTER SERVICE INFORMATION GENERAL If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged. • Always turn the ignition switch to OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.
  • Page 69 dummyhead dummyhead ELECTRIC STARTER 6. Starter Motor Inspection Connect the starter motor terminal to the battery positive (+) terminal directly. (A large amount of current flows, so do not use a thin wire.) Does the starter motor turn? – Faulty starter relay switch. –...
  • Page 70: Starter Motor

    dummyhead dummyhead ELECTRIC STARTER STARTER MOTOR REMOVAL Disconnect the negative (–) cable from the battery (page 17-5). Slide the rubber cap [1] off and remove the starter motor terminal nut [2], and then disconnect the starter motor cable [3]. Remove the mounting bolts [4], battery (–) cable [5] and [2]/[3] starter motor [6] from the crankcase.
  • Page 71 dummyhead dummyhead ELECTRIC STARTER INSPECTION Check the following: – Bushing in the motor case for wear or damage – Oil seal in the front cover for deterioration, wear or damage – Commutator bars of the armature for discoloration Check continuity in each part of the starter motor as follows: –...
  • Page 72: Starter Relay

    dummyhead dummyhead ELECTRIC STARTER STARTER RELAY REMOVAL/INSTALLATION Disconnect the negative (–) cable from the battery (page 17-5). Disconnect the starter relay switch 4P (Red) connector [1]. Remove the nuts [2], battery cable [3] and starter motor cable [4] from the starter relay switch [5]. Remove the starter relay switch from the stays of the air cleaner housing.
  • Page 73: Neutral Diode

    dummyhead dummyhead ELECTRIC STARTER FUNCTION INSPECTION Remove the starter relay switch (page 5-7). Connect an ohmmeter [1] to the starter relay switch [2] cable terminals. Connect the fully charged 12 V battery [3] to the relay switch connector terminals. CONNECTIONS: Battery (+) terminal – Yellow/red Battery (–) terminal –...
  • Page 74: Fuel System

    6. FUEL SYSTEM SYSTEM COMPONENTS······························6-2 CARBURETOR ············································· 6-5 SERVICE INFORMATION ·····························6-2 CARBURETOR HEATER (EXCEPT CO, III LA TYPES)························································ 6-10 TROUBLESHOOTING···································6-3 PILOT SCREW ADJUSTMENT ·················· 6-12 AIR CLEANER HOUSING·····························6-4 SECONDARY AIR SUPPLY SYSTEM (XR125LK/LEK) ·········································· 6-13...
  • Page 75: System Components

    dummyhead dummyhead FUEL SYSTEM SYSTEM COMPONENTS FUEL SYSTEM 44 N·m (4.5 kgf·m, 32 lbf·ft) SERVICE INFORMATION GENERAL • Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind, resulting in loss of vehicle control.
  • Page 76 dummyhead dummyhead FUEL SYSTEM TROUBLESHOOTING Engine cranks but won’t start • No fuel in tank • No fuel to carburetor – Clogged fuel strainer – Clogged fuel line – Clogged fuel tank breather hose • Too much fuel getting to the engine –...
  • Page 77: Air Cleaner Housing

    dummyhead dummyhead FUEL SYSTEM AIR CLEANER HOUSING REMOVAL/INSTALLATION Raise the rear wheel off the ground by placing a box or work stand under the engine. Remove the following: – Side covers (page 2-2) – Seat (page 2-2) – Muffler (page 2-6) –...
  • Page 78 dummyhead dummyhead FUEL SYSTEM CARBURETOR REMOVAL THROTTLE VALVE Remove the following: – Side cover (page 2-2) – Side shroud (page 2-4) Loosen the carburetor top [1]. Be careful not to damage the jet needle [1] when removing the throttle valve [2] from the carburetor body. Remove the carburetor top and throttle valve/jet needle.
  • Page 79 dummyhead dummyhead FUEL SYSTEM Remove the screw [1] and carburetor heater cover [2]. Except CO, III LA types: Disconnect the carburetor heater connector [1] and Except CO, III LA ground wire connector [2]. types: Release the carburetor heater wire from the clamp [3]. Loosen the connecting boot band screw [1].
  • Page 80 DRAIN SCREW VALVE 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft) 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) AIR CUT-OFF VALVE REMOVAL/INSTALLATION (XR125LK/LEK) Remove the two screws [1]. Hold the air cut-off valve cover, or the compression spring will jump out of the...
  • Page 81 dummyhead dummyhead FUEL SYSTEM Remove the air cut-off valve cover [1], spring [2], diaphragm [3] and O-ring [4]. Check the following: – Diaphragm for pin holes, deterioration or damage – O-ring for damage – Spring for deterioration – Needle of diaphragm for wear –...
  • Page 82 dummyhead dummyhead FUEL SYSTEM Connect the carburetor heater connector [1] and ground Except CO, III LA wire connector [2]. types: Secure the carburetor heater wire with the wire clamp [3]. Install the carburetor heater cover [1] and tighten the Except CO, III LA screw [2] securely.
  • Page 83: Carburetor Heater (Except Co, Iii La Types)

    dummyhead dummyhead FUEL SYSTEM Install the throttle valve spring [1] onto the throttle cable [2]. Connect the throttle cable to the throttle valve [3] while compressing the throttle valve spring. Be careful not to damage the jet needle when installing the throttle valve [1] into the carburetor body.
  • Page 84 dummyhead dummyhead FUEL SYSTEM Remove the carburetor heater [1] and ground terminal [2]. Installation is in the reverse order of removal. TORQUE: CARBURETOR HEATER: 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) INSPECTION Measure the resistance at the carburetor heater [1] terminals. STANDARD: 8.2 –...
  • Page 85: Pilot Screw Adjustment

    • Use a tachometer with graduations of 50 min (rpm) or smaller that will accurately indicate a 50 min (rpm) change. IDLE DROP PROCEDURE (XR125LK/ LEK) 1. Turn the pilot screw clockwise until it is lightly seated then back it out the specification given.
  • Page 86: System Inspection

    FINAL OPENING: 5/8 turns in from the position obtained in step 6 8. Readjust the idle speed with the throttle stop screw. SECONDARY AIR SUPPLY SYSTEM (XR125LK/LEK) SYSTEM INSPECTION Start the engine and warm it up to normal operating temperature.
  • Page 87 dummyhead dummyhead FUEL SYSTEM Disconnect the PAIR control valve vacuum hose [1] from the insulator and plug it to keep air from entering. Connect the vacuum pump to the PAIR control valve. TOOL: [2] Vacuum pump Commercially available Start the engine and open the throttle slightly to be certain that air is sucked in through the air cleaner sub filter-to-PAIR control valve hose [3].
  • Page 88 dummyhead dummyhead FUEL SYSTEM Disconnect the PAIR control valve-to-cylinder head cover hose [1] and sub air filter-to-PAIR control valve hose [2]. Remove the nuts [3] and PAIR control valve [4]. Installation is in the reverse order of removal. AIR SUCTION PIPE REMOVAL/ INSTALLATION Remove the PAIR control valve (page 6-14).
  • Page 89 dummyhead dummyhead MEMO...
  • Page 90: Lubrication System

    dummytext 7. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ············7-2 TROUBLESHOOTING ·································· 7-3 SERVICE INFORMATION ·····························7-3 OIL PUMP ····················································· 7-3...
  • Page 91: Lubrication System Diagram

    dummyhead dummyhead LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM ROCKER ARM CAMSHAFT OIL FILTER ROTOR CRANKSHAFT OIL PUMP OIL STRAINER SCREEN MAINSHAFT COUNTERSHAFT...
  • Page 92: Oil Pump

    dummyhead dummyhead LUBRICATION SYSTEM SERVICE INFORMATION GENERAL Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil.
  • Page 93 dummyhead dummyhead LUBRICATION SYSTEM DISASSEMBLY/ASSEMBLY Disassemble and assemble the oil pump as following illustration. PUMP BODY ROTOR SHAFT OIL PUMP COVER OUTER ROTOR INNER ROTOR SCREW 3.0 N·m (0.3 kgf·m, 2.2 lbf·ft) INSPECTION Disassemble the oil pump (page 7-4). TIP CLEARANCE: •...
  • Page 94: Cylinder Head/Valves

    dummytext 8. CYLINDER HEAD/VALVES SYSTEM COMPONENTS······························8-2 CAMSHAFT··················································· 8-5 SERVICE INFORMATION ·····························8-2 CAMSHAFT HOLDER ·································· 8-8 TROUBLESHOOTING···································8-3 CYLINDER HEAD ······································· 8-11 CYLINDER COMPRESSION·························8-3 CAM CHAIN TENSIONER LIFTER············· 8-17 CYLINDER HEAD COVER····························8-4...
  • Page 95 CYLINDER HEAD/VALVES SYSTEM COMPONENTS CYLINDER HEAD/VALVES 10 N·m (1.0 kgf·m, 7 lbf·ft) XR125LK/LEK shown: 32 N·m (3.3 kgf·m, 24 lbf·ft) 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft) 16 N·m (1.6 kgf·m, 12 lbf·ft) 4.0 N·m (0.4 kgf·m, 3.0 lbf·ft)
  • Page 96: Cylinder Compression

    dummyhead dummyhead CYLINDER HEAD/VALVES TROUBLESHOOTING • Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. • If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, check for a seized piston ring.
  • Page 97: Cylinder Head Cover

    CYLINDER HEAD/VALVES CYLINDER HEAD COVER REMOVAL/INSTALLATION Remove the following (XR125LK/LEK only): [1]/[2] – PAIR control valve (page 6-14) – Air suction pipe (page 6-15) Remove the side shrouds (page 2-4). Remove the cylinder head cover special bolts [1], mounting rubbers [2] and cylinder head cover [3].
  • Page 98 dummyhead dummyhead CYLINDER HEAD/VALVES Install the cylinder head cover [1] onto the cylinder [2]/[3] head. Install the cylinder head cover bolts [2] with the Install the mounting mounting rubbers [3]. rubbers onto the cylinder head cover Tighten the cylinder head cover bolts to the specified with their "UP"...
  • Page 99 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the cam sprocket bolts [1]. Be careful not to let Remove the cam sprocket [2] off the camshaft flange the sprocket bolts and cam chain [3]. fall into the Attach a piece of wire to the cam chain to prevent it crankcase.
  • Page 100 dummyhead dummyhead CYLINDER HEAD/VALVES Instal retainer plate [1] and bolt [2], then tighten the bolt securely. Rotate the crankshaft counterclockwise and align the Be careful not to “T” mark [1] on the flywheel with the index notch [2] on jam the cam chain. the left crankcase cover.
  • Page 101: Camshaft Holder

    dummyhead dummyhead CYLINDER HEAD/VALVES Coat new O-rings [1] with engine oil and install them onto the timing hole cap [2] and crankshaft hole cap [3]. Apply grease to the crankshaft hole cap threads. Install the crankshaft hole cap and tighten it. TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft) Install the timing hole cap and tighten it.
  • Page 102 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the rocker arm shafts [1] and rocker arms [2] from the holder. ASSEMBLY : molybdenum oil solution to cam lobes ROCKER ARMS ROCKER ARM SHAFT BOLTS 5 N·m (0.5 kgf·m, 3.7 lbf·ft) CAMSHAFT ROCKER ARM SHAFT CAMSHAFT HOLDER ROCKER ARM SHAFT RETAINER PLATE...
  • Page 103 dummyhead dummyhead CYLINDER HEAD/VALVES Set the rocker arms [1] in the camshaft holder, then Note the directions install the rocker arm shafts [2] into the camshaft holder of the bolt holes in through the rocker arms. the rocker arm shafts. Align the bolt holes in the camshaft holder and rocker arm shafts [1] using a screwdriver, and install the rocker arm shaft bolts [2].
  • Page 104 dummyhead dummyhead CYLINDER HEAD/VALVES INSTALLATION Install the camshaft holder [1] onto the cylinder head by aligning the pins [2] with the holes [3]. Align Apply engine oil to the threads and seating surfaces of [1]/[2] the camshaft holder special nuts [1]. Install the washers [2] and camshaft holder special nuts, then tighten the nuts to the specified torque.
  • Page 105 dummyhead dummyhead CYLINDER HEAD/VALVES Route the cam chain [1] through the cylinder head and install the cylinder head [2] onto the cylinder. Loosely install the cylinder head bolts [3]. Install the spark plug [4] and tighten it. TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft) Install the following: –...
  • Page 106 dummyhead dummyhead CYLINDER HEAD/VALVES ASSEMBLY RETAINER VALVE COTTERS STEM SEAL VALVE SPRINGS CLIP SPRING SEAT VALVE GUIDE INTAKE VALVE EXHAUST VALVE Clean the cylinder head assembly with solvent and blow through all oil passage with compressed air. Install the spring seats [1] and new valve stem seals [2]. Lubricate each valve stem with molybdenum oil solution.
  • Page 107 dummyhead dummyhead CYLINDER HEAD/VALVES Compress the valve spring and install the valve cotters [1]. TOOL: [2] Valve spring compressor 07757-0010000 Tap the stems [1] gently with a bar and hammer to Support the cylinder firmly seat the cotters. head above the work bench surface to prevent valve damage.
  • Page 108: Valve Guide Replacement

    dummyhead dummyhead CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. Heat the cylinder head to 130°C – 140°C (275°F – Wear insulated 290°F) with a hot plate or oven. Do not heat the cylinder gloves to avoid head beyond 150°C (300°F).
  • Page 109 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the valve and inspect the width of each valve The valve cannot seat. be grounded. If the valve face is burned The valve seat contact should be within the specified or badly worn or if it width and even all around the circumference.
  • Page 110: Cam Chain Tensioner Lifter

    dummyhead dummyhead CYLINDER HEAD/VALVES CAM CHAIN TENSIONER LIFTER REMOVAL/INSTALLATION Remove the sealing plug [1] and O-ring [2] from the cam chain tensioner lifter. Turn the cam chain tensioner lifter shaft [1] clockwise fully and secure it using the special tool. TOOL: [2] Tensioner stopper 070MG-0010100...
  • Page 111 dummyhead dummyhead CYLINDER HEAD/VALVES Install a new gasket [1] and cam chain tensioner lifter [2] onto the cylinder. Install the two mounting bolts [1] and tighten them. Remove the tensioner stopper from the tensioner lifter. Coat a new O-ring [2] with engine oil and install it into the tensioner lifter groove.
  • Page 112: Cylinder/Piston

    dummytext 9. CYLINDER/PISTON SYSTEM COMPONENTS······························9-2 CYLINDER ···················································· 9-4 SERVICE INFORMATION ·····························9-3 PISTON ························································· 9-5 TROUBLESHOOTING···································9-3...
  • Page 113 dummyhead dummyhead CYLINDER/PISTON SYSTEM COMPONENTS CYLINDER/PISTON...
  • Page 114 dummyhead dummyhead CYLINDER/PISTON SERVICE INFORMATION GENERAL • The cylinder and piston services require engine removal. • Take care not to damage the cylinder wall and piston. • Be careful not to damage the mating surfaces when removing the cylinder. Do not strike the cylinder too hard during removal. •...
  • Page 115 dummyhead dummyhead CYLINDER/PISTON CYLINDER REMOVAL Remove the following: – Cam chain tensioner lifter if necessary (page 8-17) – Cylinder head (page 8-11) – Cam chain guide [1] Lift the cylinder [2] and remove it, being careful not to Do not strike the damage the piston.
  • Page 116 dummyhead dummyhead CYLINDER/PISTON STUD BOLT REPLACEMENT Thread two 8 mm nuts onto the stud bolt [1] and tighten 113.4 – 115.4 mm them together, and use a wrench on them to turn the (4.46 – 4.54 in) stud bolt out. Install new stud bolts into the crankcase and tighten them TORQUE: 11 N·m (1.1 kgf·m, 8 lbf·ft)
  • Page 117 dummyhead dummyhead CYLINDER/PISTON INSTALLATION Carefully install the piston rings into the piston ring grooves with the markings facing up. • Do not damage the piston ring by spreading the ends too far. • Be careful not to scratch the piston surface. •...
  • Page 118: Clutch/Gearshift Linkage

    dummytext 10. CLUTCH/GEARSHIFT LINKAGE SYSTEM COMPONENTS····························10-2 CLUTCH ······················································ 10-7 SERVICE INFORMATION ···························10-3 GEARSHIFT LINKAGE ····························· 10-10 TROUBLESHOOTING·································10-3 PRIMARY DRIVE GEAR ··························· 10-13 RIGHT CRANKCASE COVER ····················10-4 10-1...
  • Page 119 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE SYSTEM COMPONENTS CLUTCH/GEARSHIFT LINKAGE 22 N·m (2.2 kgf·m, 16 lbf·ft) 26 N·m (2.7 kgf·m, 19 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 4.0 N·m (0.4 kgf·m, 3.0 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 10-2...
  • Page 120 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL • This section covers service of the clutch, gearshift linkage and kickstarter. These services can be performed with the engine installed in the frame. • Engine oil viscosity, oil level and the use of oil additives have an effect on clutch operation. Oil additives of any kind are specifically not recommended.
  • Page 121: Right Crankcase Cover

    dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-7). Remove the bolt [1] and kickstarter pedal [2]. When removing the kickstarter pedal, mark the pedal position to ensure the original position. Remove the brake pedal return spring [1]. Disconnect the brake rod from the brake arm (page 15- 4), then lower the brake pedal down.
  • Page 122 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Install the right crankcase cover [1] and bolts [2]. [3]/[4] Connect the clutch cable to the clutch lifter arm, then install the clutch cable stay [3] and two bolts [4]. Tighten the bolts in a crisscross pattern in 2 or 3 steps. Install the brake pedal return spring [1].
  • Page 123 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Remove the kickstarter spindle dust seal [1]. Remove the clutch lifter arm [2] and dust seal [3]. Check the lifter piece and arm for wear or damage. Check the return spring for fatigue or damage. Replace them if necessary. ASSEMBLY Apply grease to lip of a new kickstarter spindle dust seal and install it into the right crankcase cover as...
  • Page 124 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE CLUTCH REMOVAL Remove the following: – Right crankcase cover (page 10-4) – Oil pump driven gear [1] – Screws [2] – Oil filter rotor cover [3] and gasket [4] Install the gear holder between the primary drive and driven gears, and loosen the oil filter rotor lock nut [1].
  • Page 125 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Remove the following: [3]/[4] – Washer [1] – Clutch center [2] – Clutch discs [3]/clutch plates [4] – Pressure plate [5] – Thrust washer [6] – Clutch outer [7] – Clutch outer guide [1] INSTALLATION Apply molybdenum oil solution to the outer surface of the clutch outer guide and install it onto the mainshaft.
  • Page 126 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Install the clutch center assembly [1] into the clutch Install the tabs of outer [2]. clutch disc A (out side) into the shallow slots [3] in the clutch outer. Apply engine oil to the threads and seating surface of the clutch center lock nut [1].
  • Page 127: Gearshift Linkage

    dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Apply engine oil to the threads and seating surface of the oil filter rotor lock nut [1], and then install it. Install the gear holder between the primary drive and driven gears, and tighten the oil filter rotor lock nut. TOOLS: [2] Gear holder 07724-0010200...
  • Page 128 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Pull the gearshift spindle [1] out of the crankcase being careful not to damage the oil seal lip, and remove the thrust washer [2] from the spindle. Remove the following: – Gearshift cam bolt [1] – Gearshift cam [2] –...
  • Page 129 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE INSTALLATION Apply locking agent to the stopper arm bolt threads. Install the return spring [1], washer [2], stopper arm [3] and bolt [4], while holding the spring end to the groove on the stopper arm. Tighten the stopper arm bolt to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Hook Install the dowel pins [1] into the shift drum holes.
  • Page 130: Primary Drive Gear

    dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE Install the spindle [1] over the spring pin by aligning the Be careful not to return spring ends with the spring pin. damage the oil seal Align lip in the left crankcase. Install the clutch (page 10-8) Install the gearshift pedal [1] in the original position as noted during removal.
  • Page 131 dummyhead dummyhead MEMO...
  • Page 132: Alternator/Starter Clutch

    dummytext 11. ALTERNATOR/STARTER CLUTCH SYSTEM COMPONENTS····························11-2 STATOR/IGNITION PULSE GENERATOR 11-4 TROUBLESHOOTING·································11-2 FLYWHEEL/STARTER CLUTCH ··············· 11-4 LEFT CRANKCASE COVER ······················11-3 11-1...
  • Page 133 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH SYSTEM COMPONENTS ALTERNATOR/STARTER CLUTCH 74 N·m (7.5 kgf·m, 55 lbf·ft) TROUBLESHOOTING Starter motor turns, but engine does not turn • Faulty starter clutch • Damaged starter motor pinion gear, starter reduction gear or shaft 11-2...
  • Page 134: Left Crankcase Cover

    dummyhead dummyhead ALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-7). [1]/[2] Remove the following: – Left side cover (page 2-2) – Drive sprocket cover (page 2-5) Disconnect the alternator 2P connector [1] and ignition pulse generator (Blue/yellow) wire connector [2] from the connector boot.
  • Page 135: Stator/Ignition Pulse Generator

    dummyhead dummyhead ALTERNATOR/STARTER CLUTCH STATOR/IGNITION PULSE GENERATOR REMOVAL Remove the left crankcase cover (page 11-3). Remove the following from the left crankcase cover: – Socket bolt [1] and wire guide [2] – Socket bolts [3] and ignition pulse generator [4] –...
  • Page 136 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Remove the flywheel [1] using the special tool. TOOL: [2] Flywheel puller 07933-KM10000 Remove the woodruff key [1] and needle bearing [2]. Be careful not to damage the crankshaft. INSTALLATION Apply engine oil to the needle bearing and install it onto the crankshaft.
  • Page 137 dummyhead dummyhead ALTERNATOR/STARTER CLUTCH Apply engine oil to the starter reduction gear shaft [1]. Install the starter reduction gear [2], collar [3] and shaft. Install the left crankcase cover (page 11-3). STARTER CLUTCH DISASSEMBLY/ ASSEMBLY Disassemble and assemble the starter clutch as following illustration.
  • Page 138: Crankshaft/Transmission/Kickstarter

    dummytext 12. CRANKSHAFT/TRANSMISSION/KICKSTARTER SYSTEM COMPONENTS····························12-2 TRANSMISSION ········································· 12-8 SERVICE INFORMATION ···························12-3 CRANKSHAFT ·········································· 12-13 TROUBLESHOOTING·································12-3 KICKSTARTER IDLE GEAR ···················· 12-14 CRANKCASE SEPARATION/ASSEMBLY·12-4 KICKSTARTER ········································· 12-15 12-1...
  • Page 139 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER SYSTEM COMPONENTS CRANKSHAFT/TRANSMISSION/KICKSTARTER 10 N·m (1.0 kgf·m, 7 lbf·ft) 12-2...
  • Page 140 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER SERVICE INFORMATION GENERAL • The crankcase halves must be separated to service the transmission and crankshaft. To service these parts, the engine must be removed from the frame (page 13-3). • Be careful not to damage the crankcase mating surfaces when servicing. •...
  • Page 141 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER CRANKCASE SEPARATION/ ASSEMBLY Remove the following: – Engine (page 13-3) – Cylinder head (page 8-11) – Cylinder and piston (page 9-4) – Oil pump (page 7-3) – Clutch (page 10-7) – Kickstarter (page 12-15) – Primary drive gear (page 10-13) –...
  • Page 142 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER Loosen the thirteen left crankcase bolts [1] in a crisscross pattern in 2 or 3 steps, and remove them. Place the crankcase assembly with the right side down. Carefully separate the left crankcase [1] from the right Do not ply the crankcase [2] while tapping them at several locations crankcase halves.
  • Page 143 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them. Apply liquid sealant to the mating surface (shadowed area) of the left crankcase except the oil passage area as shown. Install the two dowel pins [1]. Install the left crankcase over the right crankcase.
  • Page 144 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER Install the bearing retainer plates [1] and bolts [2]. When installing the retainer plate, pull Tighten the bolts securely. Hook the crankshaft [3] and hook the plate tab to the crankshaft bearing groove as shown. Apply molybdenum oil solution to the push plug entire surface.
  • Page 145 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER TRANSMISSION DISASSEMBLY Separate the crankcase halves (page 12-4). Remove the shift fork shafts [1]. Remove the shift forks [2] and shift drum [3]. Remove the mainshaft [1] and countershaft [2] as an assembly. Disassemble the mainshaft [1] and countershaft [2]. Keep track of the disassembled parts (gears, bushings, washers, and snap rings) by stacking them on a tool or slipping them onto a piece of wire.
  • Page 146 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER MAINSHAFT : Gear and bushing sliding surfaces SNAP RING SPLINE WASHER M4 GEAR (25T) M1 GEAR (14T) THRUST WASHER MAINSHAFT M3 GEAR (22T) M2 GEAR (16T) M5 GEAR (32T) THRUST WASHER SPLINE WASHER SNAP RING THRUST WASHER THRUST WASHER M3 GEAR (22T) M2 GEAR (16T)
  • Page 147 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER COUNTERSHAFT C3 GEAR (31T) THRUST WASHER : Gear and bushing sliding surfaces/shifter gear grooves C3 BUSHING C4 GEAR (28T) SPLINE WASHER SNAP RING C1 GEAR (39T) THRUST WASHER C1 BUSHING THRUST WASHER THRUST WASHER C2 BUSHING C2 GEAR (30T) THRUST WASHER C5 GEAR (30T) COUNTERSHAFT...
  • Page 148 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER Apply molybdenum oil solution to the gear shifter grooves. Apply clean engine oil to the gear teeth and engage the mainshaft and countershaft gears. Install the mainshaft [1] and countershaft [2] assemblies as a set into the left crankcase. Each shift fork has an identification marks;...
  • Page 149 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER Apply engine oil to the shift fork shafts [1] and insert them through the shift forks into the right crankcase. Assemble the crankcase (page 12-4). TRANSMISSION BEARING REPLACEMENT RIGHT CRANKCASE Remove the bolts [1] and mainshaft bearing setting [1]/[2] plates [2] from the crankcase.
  • Page 150 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER LEFT CRANKCASE BEARING REPLACEMENT Drive the countershaft bearing [1] out of the crankcase. Remove the mainshaft bearing [2] from the crankcase using the special tools. TOOLS: [3] Remover head, 12 mm 07936-1660110 Remover shaft, 12 mm 07936-1660120 Remover weight 07741-0010201 Apply engine oil to new bearings [1].
  • Page 151: Kickstarter Idle Gear

    dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER Lubricate crankcase bearing with molybdenum oil solution. Press the crankcase bearing into the crankcase using the special tools. TOOLS: [2] Driver 07749-0010000 [3] Attachment, 52 x 55 mm 07746-0010400 [4] Pilot, 30 mm 07746-0040700 Install a new crankcase bearing inner race. KICKSTARTER IDLE GEAR REMOVAL Remove the clutch assembly (page 10-7).
  • Page 152 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER KICKSTARTER REMOVAL Remove the right crankcase cover (page 10-4). Unhook the return spring [1] from the crankcase. Remove the following: – Kickstarter assembly [1] – Ratchet spring [2] – Washer [3] INSTALLATION Apply engine oil to the kickstarter drive gear teeth. Install the ratchet spring and washer to the spindle.
  • Page 153 dummyhead dummyhead CRANKSHAFT/TRANSMISSION/KICKSTARTER Remove the following: – Snap ring [1] – Washer A [2] – Kickstarter drive gear [3] – Washer B [4] ASSEMBLY Install the following: – Washer B – Kickstarter drive gear – Washer A – Snap ring Install the ratchet gear [1].
  • Page 154: Engine Removal/Installation

    dummytext 13. ENGINE REMOVAL/INSTALLATION SYSTEM COMPONENTS····························13-2 ENGINE REMOVAL ···································· 13-3 SERVICE INFORMATION ···························13-2 ENGINE INSTALLATION···························· 13-5 13-1...
  • Page 155 ENGINE REMOVAL/INSTALLATION SYSTEM COMPONENTS ENGINE REMOVAL/INSTALLATION 26 N·m (2.7 kgf·m, 19 lbf·ft) XR125LK/LEK shown: 60 N·m (6.1 kgf·m, 44 lbf·ft) 35 N·m (3.6 kgf·m, 26 lbf·ft) 60 N·m (6.1 kgf·m, 44 lbf·ft) 35 N·m (3.6 kgf·m, 26 lbf·ft) 35 N·m (3.6 kgf·m, 26 lbf·ft)
  • Page 156 – Side covers (page 2-2) – Fuel tank (page 2-4) – Exhaust pipe (page 2-6) – Carburetor (page 6-5) – PAIR control valve (XR125LK/LEK) (page 6-14) – Resonator tank/air inlet cover (XR125LK/LEK) (page 6-15) – Spark plug cap – Clutch cable (page 10-4) –...
  • Page 157 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the following: [1]/[2]/[3] – Alternator 2P connector [1] – Ignition pulse generator wire connector [2] – Neutral switch wire connector [3] – Starter motor cable [1] (by removing the rubber cap [2] and terminal nut [3]) –...
  • Page 158: Engine Installation

    • Use the correct bolts in their proper positions. • Note the direction of the hanger bolts and the location of the collars (page 13-2). XR125LK/LEK only: • The hanger plates are identified by the marks. Install with the marked side facing out; "R": right / "L": left.
  • Page 159 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Hang the tab of each rubber caps [1] onto the hanger plate [2] and install them over the upper engine hanger plate bolts [3]. Install the drive chain onto the drive sprocket [1]. Install the drive sprocket onto the countershaft. Install the fixing plate [2] to the countershaft while aligning their teeth.
  • Page 160: Front Wheel/Brake/Suspension/Steering

    dummytext 14. FRONT WHEEL/BRAKE/SUSPENSION/ STEERING SYSTEM COMPONENTS····························14-2 FRONT WHEEL ·········································· 14-9 SERVICE INFORMATION ···························14-3 FRONT DRUM BRAKE (XL125LK) ·········· 14-13 TROUBLESHOOTING·································14-3 FORK························································· 14-13 HANDLEBAR ··············································14-4 STEERING STEM ····································· 14-22 14-1...
  • Page 161 FRONT WHEEL/BRAKE/SUSPENSION/STEERING SYSTEM COMPONENTS FRONT WHEEL/BRAKE/SUSPENSION/STEERING XR125LK/LEK: 26 N·m (2.7 kgf·m, 19 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 26 N·m (2.7 kgf·m, 19 lbf·ft) 32 N·m (3.3 kgf·m, XL125LK: 24 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 44 N·m (4.5 kgf·m,...
  • Page 162 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING SERVICE INFORMATION GENERAL Frequent inhalation of brake shoe or pad dust, regardless of material composition could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. •...
  • Page 163 Remove the wire bands [1]. Remove the rearview mirrors [2]. Remove the front visor [2] (page 2-4). Disconnect the front brake light switch connectors [1]. XR125LK/LEK: Remove the bolts [1], master cylinder holder [2] and XR125LK/LEK: master cylinder [3]. Remove the bolts [1], holder [2] and brake lever bracket XL125LK: [3].
  • Page 164 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the screws [1] and throttle housing cover [2]. Disconnect the throttle cable end [3] from the throttle pipe and remove the throttle housing. Remove the throttle cable guide [4]. Remove the throttle grip from the handlebar. Remove the right handlebar switch housing screws [1].
  • Page 165 Align TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft) Apply Honda Bond A [1] or an equivalent to the inside of Allow the adhesive the grip [2] and the clean surfaces of the left handlebar to dry for an hour and throttle grip.
  • Page 166 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the left handlebar switch housing screws [1] and tighten the forward screw first, then the rear screw. Install the clutch lever bracket [1] and holder [2] to the handlebar. Align the slit of the bracket with the punch mark [3] on the handlebar.
  • Page 167 Install the throttle housing cover screws [7], and tighten the forward screw first, then the rear screw. Install the master cylinder [1] and holder [2] with the XR125LK/LEK: "UP" mark [3] on the holder facing up. Install the master cylinder holder bolts [4].
  • Page 168: Front Wheel

    FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the wire bands [1]. Install the rearview mirrors [2]. FRONT WHEEL REMOVAL (XR125LK/LEK) Raise and support the motorcycle using safety stand or Do not operate the a hoist. front brake lever after removing the Remove the screw [1] and speedometer cable [2] from front wheel.
  • Page 169 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the wheel assembly onto the fork legs so that the brake disc is positioned between the pads, being careful not to damage the pads. Align the groove on the speedometer gear box with the lug on the right fork leg as shown. Install the front axle [1] from the right side.
  • Page 170 [4] and adjusting nut [5]. Connect the speedometer cable [6]. Adjust the front brake lever freeplay and check the brake operation (page 3-13). [1]/[2] DISASSEMBLY/ASSEMBLY XR125LK/LEK: Remove/install the following: – Dust seals [1] – Retainer [2] – Nuts [3] – Brake disc [4] –...
  • Page 171 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING XL125LK: Remove/install the following: – Dust seal [1] – Wheel bearings [2] – Distance collar [3] • Replace the bearings and dust seals with new ones. • Apply grease to the dust seal lips and bearing cavities.
  • Page 172: Front Drum Brake (Xl125Lk)

    • Adjust the front brake lever freeplay (page 3-13). FORK REMOVAL Remove the front wheel (page 14-9). Remove the following (XR125LK/LEK left fork only): Support the caliper so it does not hang – Brake hose clamp cover [1] from the brake –...
  • Page 173 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the following (XL125LK left fork only): – Bolts [1] – Brake cable guide [2] Loosen the top bridge pinch bolt [1]. Loosen the fork cap [2]. Do not remove the fork cap yet. Loosen the fork bottom bridge pinch bolts [1] while holding the fork.
  • Page 174 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the fork spring [1]. Pour the fork fluid from the fork leg by pumping the fork 8 – 10 times. Hold the fork slider in a vise with a piece of wood or soft jaws to avoid damage. Loosen and remove the fork socket bolt [1] and sealing washer from the fork slider.
  • Page 175 Remove the fork piston [1] and rebound spring [2] from the fork pipe [3]. INSPECTION FORK SPRING Measure the fork spring free length on a flat surface. SERVICE LIMIT: XR125LK/LEK: 582.6 mm (22.94 in) XL125LK: 593.4 mm (23.36 in) 14-16...
  • Page 176 Check the back-up ring; replace it if there is any distortion at the points indicated by arrows on the figure. COPPER SURFACE CHECK POINTS ASSEMBLY FORK CAP XR125LK/LEK shown: PISTON RING FORK SPRING DUST SEAL 22 N·m (2.2 kgf·m, FORK 16 lbf·ft)
  • Page 177 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the rebound spring [1] to the fork piston [2]. Install the fork piston into the fork pipe [3]. Install the oil lock piece [1] onto the fork piston [2] end. Apply fork fluid to the fork slider bushing [3], and install the fork pipe [4] into the fork slider [5].
  • Page 178 Apply fork oil to the lip of a new dust seal [2] and install Pour half of the required amount of the recommended fork fluid into the fork pipe. RECOMMENDED FORK FLUID: Honda ULTRA CUSHION OIL 10W or equivalent FORK FLUID CAPACITY: FLUID 180 ± 2.5 cm (6.1 ±...
  • Page 179 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Apply fork fluid to new O-ring [1] and install it to the fork Tighten the fork cap cap [2]. after installing the Install the fork cap into the fork pipe. fork pipe into the fork bridge. Install the dust boot with its breathing hole [1] facing XL125LK only: Right fork leg shown:...
  • Page 180 Tighten the boot band screw [2]. Seat Install the brake caliper [1] with new mounting bolts [2], XR125LK/LEK: and then tighten the bolts to the specified torque. TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft) Install the brake hose clamps [3], cover [4] and bolts [5].
  • Page 181: Steering Stem

    dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the brake cable guide [1] and route the brake XL125LK: cable [2]. Install and tighten the bolts [3] securely. Install the front wheel (page 14-11). STEERING STEM REMOVAL Remove the following: – Front wheel (page 14-9) –...
  • Page 182 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Hold the steering stem and remove the steering stem adjusting nut [1] with the special tool. TOOL: [2] Steering stem socket wrench 07916-KA50100 Remove the upper dust seal [3]. Remove the upper bearing inner race [1] and upper bearing [2].
  • Page 183 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the stem nut [1] onto the stem to prevent the threads from being damaged when removing the lower bearing inner race from the stem. Remove the lower bearing inner race [2] with a chisel or an equivalent tool without damaging the stem.
  • Page 184 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING INSTALLATION UREA BASED GREASE WITH EXTREME PRESSURE AGENT STEERING STEM CAP STEM ADJUSTING NUT STEERING STEM NUT WASHER UPPER DUST SEAL UPPER INNER RACE TOP BRIDGE UPPER BEARING UPPER BEARING OUTER RACE LOWER BEARING OUTER RACE LOWER BEARING LOWER BEARING INNER RACE...
  • Page 185 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Apply urea based multi-purpose grease (page 1-15) to lip of a new upper dust seal [1] and install it. Install the steering stem adjusting nut [2]. Tighten the steering stem adjusting nut to the specified torque. TOOL: [3] Steering stem socket wrench 07916-KA50100 TORQUE: 5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)
  • Page 186 dummyhead dummyhead FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the steering stem cap [1]. Make sure that the steering stem moves smoothly, not loosely or tightly. Install the meter holder and two bolts. Install the turn signal lights [1] and top bridge pinch bolts [2]. Connect the turn signal light connectors [1].
  • Page 187 dummyhead dummyhead MEMO...
  • Page 188: Rear Wheel/Brake/Suspension

    dummytext 15. REAR WHEEL/BRAKE/SUSPENSION SYSTEM COMPONENTS····························15-2 REAR DRUM BRAKE ································· 15-7 SERVICE INFORMATION ···························15-3 BRAKE PEDAL ··········································· 15-9 TROUBLESHOOTING·································15-3 SHOCK ABSORBER ································ 15-11 REAR WHEEL ·············································15-4 SWINGARM ·············································· 15-13 15-1...
  • Page 189 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION SYSTEM COMPONENTS REAR WHEEL/BRAKE/SUSPENSION 88 N·m (9.0 kgf·m, 65 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 93 N·m (9.5 kgf·m, 69 lbf·ft) 15-2...
  • Page 190 • A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contaminated drum with a high quality brake degreasing agent. • Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. • Refer to page 3-9 for drive chain information.
  • Page 191 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Support the motorcycle securely with a hoist or an equivalent and raise the rear wheel off the ground. Remove the rear brake adjusting nut [1] and disconnect the rear brake rod [2] from the brake arm [3]. Remove the joint pin [4] and spring [5].
  • Page 192 • Replace the bearings and dust seal with new ones. • Apply grease to the dust seal lip and bearing cavities. Refer to procedures for bearing replacement (page 15-6). XR125LK/LEK shown: 32 N·m (3.3 kgf·m, 24 lbf·ft) [8] (6303U) [6] (6203UU)
  • Page 193 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION WHEEL BEARING REPLACEMENT Install the remover head into the bearing. From the opposite side of the wheel, install the bearing remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing.
  • Page 194: Rear Drum Brake

    dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Apply grease to the rear axle [1]. Insert the rear axle through the left drive chain adjuster, left side collar, rear wheel, brake panel and right chain adjuster. Install the drive chain [2] onto the driven sprocket. Install the axle plate [1] and axle nut [2], then tighten the nut to the specified torque.
  • Page 195 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION ASSEMBLY Apply grease to lips of new dust seals [1]. Install the dust seals with the flat surface facing out until they are seated. Install the lock washer [2], aligning its tabs with the lug [3] on the brake panel. Apply grease to the spindle groove in the brake cam [1].
  • Page 196: Brake Pedal

    dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION BRAKE PEDAL REMOVAL Remove the following: – Brake adjusting nut [1] – Brake rod [2] (from the joint pin) – Rod spring [3] – Joint pin [4] – Pedal return spring [1] – Brake light switch spring [2] –...
  • Page 197 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION – Cotter pin [1] – Pivot pin [2] (to separate the brake rod and pedal) INSTALLATION Install the brake pedal in the reverse order of removal. – Brake adjusting nut [1] – Brake rod [2] – Spring [3] –...
  • Page 198: Shock Absorber

    dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION SHOCK ABSORBER REMOVAL Support the motorcycle securely with a hoist or an equivalent. Remove the following: – Seat (page 2-2) – Left side cover (page 2-2) – Rear wheel (page 15-4) Remove the shock absorber lower mounting bolt [1] and nut [2].
  • Page 199 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Apply multi-purpose grease to needle rollers of a new bearing [1]. Press the needle bearings into the shock arm lower Press the needle 7.8 – 8.2 mm mount so that the needle bearing surface is lower 7.8 – bearing on the (0.31 –...
  • Page 200 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION SWINGARM REMOVAL Remove the drain plug [1] from the crankcase breather hose [2]. Remove the breather hose and carburetor drain hose [3] from the guide [4]. Remove the rear wheel (page 15-4). [2]/[3] Unhook the rear brake return spring [1]. Remove the shock absorber lower mount bolt [2] and nut [3].
  • Page 201 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Remove the swingarm pivot nut [1]. [1]/[2] Remove the pivot bolt [2] from the left side and remove the swingarm [3]. DISASSEMBLY/ASSEMBLY Disassemble and assemble the swingarm as following illustration. – Drive chain adjuster [1] – Screw [2] –...
  • Page 202 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION NEEDLE BEARING REPLACEMENT Remove the drive chain guard bolts, collars and drive chain guard (page 15-14). Remove the needle bearing [1] form the swingarm using the special tools. TOOL: [2] Bearing remover set, 20 mm 07936-3710600 [3] Bearing remover weight 07741-0010201 Bearing remover handle...
  • Page 203 dummyhead dummyhead REAR WHEEL/BRAKE/SUSPENSION Install the drive chain adjusters [1]. Install the rear wheel (page 15-6). [1]/[2] Install the shock absorber lower mount bolt [1] and nut [2]. Hook the rear brake return spring [3]. Install the carburetor drain hose [1] and crankcase breather hose [2] through the guide [3].
  • Page 204: Hydraulic Brake (Xr125Lk/Lek)

    16. HYDRAULIC BRAKE (XR125LK/LEK) SYSTEM COMPONENTS····························16-2 BRAKE PAD/DISC ······································ 16-6 SERVICE INFORMATION ···························16-3 MASTER CYLINDER ·································· 16-7 TROUBLESHOOTING·································16-3 BRAKE CALIPER ······································· 16-9 BRAKE FLUID REPLACEMENT/AIR BLEEDING···················································16-4 16-1...
  • Page 205 HYDRAULIC BRAKE (XR125LK/LEK) SYSTEM COMPONENTS HYDRAULIC BRAKE (XR125LK/LEK) 12 N·m (1.2 kgf·m, 9 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 17.2 N·m (1.8 kgf·m, 13 lbf·ft) 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft)
  • Page 206 HYDRAULIC BRAKE (XR125LK/LEK) SERVICE INFORMATION GENERAL Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
  • Page 207: Brake Fluid Replacement/Air Bleeding

    HYDRAULIC BRAKE (XR125LK/LEK) BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING Turn the handlebar until the reservoir is parallel to the ground before removing the reservoir cap. Remove the screws [1], reservoir cap [2], set plate [3] and diaphragm [4].
  • Page 208 HYDRAULIC BRAKE (XR125LK/LEK) If the brake bleeder is not available, perform the following procedure. Pump up the system pressure with the brake lever [1] until the lever resistance is felt. Connect a bleed hose [1] to the bleed valve [2] and...
  • Page 209: Brake Pad Replacement

    HYDRAULIC BRAKE (XR125LK/LEK) BRAKE PAD/DISC BRAKE PAD REPLACEMENT Remove the pad pin plug [1] and loosen the pad pin [2]. Remove the pad pin [1] while holding the brake pads [2], then remove the brake pads. Make sure the pad spring is installed in position.
  • Page 210: Brake Disc Inspection

    HYDRAULIC BRAKE (XR125LK/LEK) BRAKE DISC INSPECTION Visually inspect the brake disc [1] for damage or crack. Measure the brake disc thickness at several points. SERVICE LIMIT: 3.5 mm (0.14 in) Replace the brake disc if the smallest measurement is less than service limit.
  • Page 211 HYDRAULIC BRAKE (XR125LK/LEK) DISASSEMBLY/ASSEMBLY Disassemble and assemble the master cylinder as following illustration. - Nut [1] - Brake lever pivot bolt [2] - Brake lever [3] - Screw [4] - Brake light switch [5] - Boot [6] - Snap ring [7]...
  • Page 212: Brake Caliper

    HYDRAULIC BRAKE (XR125LK/LEK) BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake fluid (page 16-4). Remove the following: – Oil bolt [1]/brake hose [2]/sealing washers [3] – Mounting bolts [4] – Brake caliper [5] Installation is in the reverse order of removal.
  • Page 213 dummyhead dummyhead MEMO...
  • Page 214: Battery/Charging System

    dummytext 17. BATTERY/CHARGING SYSTEM COMPONENT LOCATION ··························17-2 BATTERY ···················································· 17-5 SYSTEM DIAGRAM ····································17-2 CHARGING SYSTEM INSPECTION ·········· 17-6 SERVICE INFORMATION ···························17-3 REGULATOR/RECTIFIER ·························· 17-7 TROUBLESHOOTING·································17-4 ALTERNATOR CHARGING COIL ·············· 17-7 17-1...
  • Page 215 dummyhead dummyhead BATTERY/CHARGING SYSTEM COMPONENT LOCATION BATTERY/CHARGING SYSTEM IGNITION SWITCH REGULATOR/RECTIFIER ALTERNATOR BATTERY SYSTEM DIAGRAM MAIN FUSE (15 A) To Lights REGULATOR/ RECTIFIER BATTERY ALTERNATOR ..Black ..Red ..Green ..White ..Yellow 17-2...
  • Page 216 dummyhead dummyhead BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
  • Page 217 dummyhead dummyhead BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. BATTERY TEST Remove the battery (page 17-5). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210 or equivalent Is the battery in good condition? – Faulty battery. –...
  • Page 218: Voltage Inspection

    (+) cable [5]. Remove the battery [6]. Install the battery in the reverse order of removal. • Connect the positive terminal first and then the negative cable. XR125LK, XL125LK: VOLTAGE INSPECTION Measure the battery voltage using a commercially available digital multimeter. VOLTAGE: Fully charged: Above 12.8 V...
  • Page 219: Charging System Inspection

    dummyhead dummyhead BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the left side cover (page 2-2). With the ignition switch turned to "OFF", disconnect the negative (–) cable from the battery. Connect the ammeter (+) probe to the negative (–) cable and the ammeter (–) probe to the battery (–) terminal.
  • Page 220: Alternator Charging Coil

    dummyhead dummyhead BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER SYSTEM INSPECTION Remove the fuel tank (page 2-4). Check the regulator/rectifier 4P connector [1] for loose contact or corroded terminals. If the charging voltage reading (page 17-6) is out of the specification, check the following at the wire harness side connector.
  • Page 221 dummyhead dummyhead MEMO...
  • Page 222: Lights/Meter/Switches

    BRAKE LIGHT SWITCHES ························ 18-8 HEADLIGHT/POSITION LIGHT ··················18-4 CLUTCH SWITCH ······································· 18-9 BRAKE/TAIL LIGHT····································18-4 NEUTRAL SWITCH ···································· 18-9 LICENSE LIGHT (XR125LK/LEK) ··············18-5 SIDESTAND SWITCH (NZ TYPE) ············ 18-10 TURN SIGNAL LIGHTS ······························18-5 TURN SIGNAL RELAY ····························· 18-11 COMBINATION METER······························18-6 HORN ························································ 18-11...
  • Page 223 dummyhead dummyhead LIGHTS/METER/SWITCHES COMPONENT LOCATION LIGHTS/METER/SWITCHES CLUTCH SWITCH FRONT BRAKE LIGHT SWITCH IGNITION SWITCH LEFT HANDLEBAR SWITCH STARTER SWITCH TURN SIGNAL RELAY HORN REAR BRAKE LIGHT SWITCH NEUTRAL SWITCH SIDESTAND SWITCH (NZ TYPE) SERVICE INFORMATION GENERAL • A halogen headlight bulb becomes very hot while the headlight is "ON", and remains hot for a while after it is turned "OFF". Be sure to let it cool down before servicing.
  • Page 224: Lighting System Inspection

    dummyhead dummyhead LIGHTS/METER/SWITCHES LIGHTING SYSTEM INSPECTION HEADLIGHT DOES NOT COME ON OR IS WEAK Standard Inspection Check the following: – Burned out bulb or bulb with unspecified wattage – Loose connector – Dimmer switch If the above items are normal, check as follows: Lighting Circuit Inspection Remove the front visor (page 2-4).
  • Page 225: Headlight/Position Light

    dummyhead dummyhead LIGHTS/METER/SWITCHES HEADLIGHT/POSITION LIGHT BULB REPLACEMENT Remove the two bolts [1] and headlight aim adjusting screw [2]. Remove the dust cover [1]. Unhook the bulb retainer [2]. Push the headlight bulb [3] in, turn it counterclockwise and remove it. Install the headlight bulb in the reverse order of removal.
  • Page 226: License Light (Xr125Lk/Lek)

    LIGHTS/METER/SWITCHES LICENSE LIGHT (XR125LK/LEK) REMOVAL/BULB REPLACEMENT Remove the nuts [1], collars [2] and license light assembly. Remove the license light nuts [3], lens cover [4] and lens [5]. Push the bulb [6] in, turn it counterclockwise and remove it.
  • Page 227: Combination Meter

    dummyhead dummyhead LIGHTS/METER/SWITCHES COMBINATION METER REMOVAL/INSTALLATION Remove the front visor (page 2-4). Disconnect the combination meter 9P connector [1]. Disconnect the speedometer cable [1]. Remove the nuts [2], washers [3] and combination meter assembly [4]. Installation is in the reverse order of removal. [2]/[3] DISASSEMBLY/ASSEMBLY Disassemble and assemble the combination meter as following illustration.
  • Page 228: Ignition Switch

    dummyhead dummyhead LIGHTS/METER/SWITCHES IGNITION SWITCH INSPECTION Remove the front visor (page 2-4). Disconnect the ignition switch 2P connector [1]. Check for continuity between the connector terminals in each switch position according to the chart (page 19-2). REMOVAL/INSTALLATION Disconnect the ignition switch connector (page 18-7). Remove the two mounting bolts [1] and the ignition switch [2].
  • Page 229: Brake Light Switches

    LIGHTS/METER/SWITCHES BRAKE LIGHT SWITCHES FRONT (XR125LK/LEK) Disconnect the front brake light switch connectors [1]. There should be continuity with the brake lever [1] applied, and there should be no continuity when the brake lever is released. FRONT (XR125LK) Remove the front visor (page 2-4).
  • Page 230: Neutral Switch

    dummyhead dummyhead LIGHTS/METER/SWITCHES CLUTCH SWITCH Disconnect the clutch switch connectors [1]. There should be continuity with the clutch lever [1] applied, and there should be no continuity when the clutch lever is released. NEUTRAL SWITCH INSPECTION Remove the right side cover (page 2-2). Disconnect the neutral switch wire connector [1].
  • Page 231: Sidestand Switch (Nz Type)

    dummyhead dummyhead LIGHTS/METER/SWITCHES Release the neutral switch wire [1] from the ribs on the left crankcase cover. Remove the bolts [2] and neutral switch [3]. Remove the pin [1] and spring [2] from the shift drum. Installation is in the reverse order of removal. •...
  • Page 232: Turn Signal Relay

    dummyhead dummyhead LIGHTS/METER/SWITCHES TURN SIGNAL RELAY INSPECTION 1. Recommended Inspection Check the following: – Battery condition – Burned out bulb or non-specified wattage – Burned fuse – Ignition switch and turn signal switch function – Loose connector Check for the above items. Are the above items in good condition? –...
  • Page 233 dummyhead dummyhead MEMO...
  • Page 234: Wiring Diagrams

    19. WIRING DIAGRAMS XR125LEK (DK, I LA TYPES)·····················19-2 XR125LK (DK TYPE) ·································· 19-5 XR125LEK (III LA, CO TYPES)···················19-3 XR125LK (III LA TYPE) ······························ 19-6 XR125LEK (NZ TYPE) ································19-4 XL125LK ····················································· 19-7 19-1...
  • Page 235: Xr125Lek (Dk, I La Types)

    dummyhead dummyhead WIRING DIAGRAMS XR125LEK (DK, I LA TYPES) WIRING DIAGRAMS 19-2...
  • Page 236: Xr125Lek (Iii La, Co Types)

    dummyhead dummyhead WIRING DIAGRAMS XR125LEK (III LA, CO TYPES) 19-3...
  • Page 237: Xr125Lek (Nz Type)

    dummyhead dummyhead WIRING DIAGRAMS XR125LEK (NZ TYPE) 19-4...
  • Page 238: Xr125Lk (Dk Type)

    WIRING DIAGRAMS XR125LK (DK TYPE) 19-5...
  • Page 239: Xr125Lk (Iii La Type)

    WIRING DIAGRAMS XR125LK (III LA TYPE) 19-6...
  • Page 240 dummyhead dummyhead WIRING DIAGRAMS XL125LK 19-7...
  • Page 241 dummyhead dummyhead MEMO...
  • Page 242: Index

    INDEX AIR CLEANER ································································3-4 IGNITION SYSTEM INSPECTION ································· 4-4 AIR CLEANER HOUSING ··············································6-4 IGNITION TIMING ·························································· 4-5 AIR CLEANER SUB FILTER (XR125LK/LEK)················3-4 KICKSTARTER··························································· 12-15 ALTERNATOR CHARGING COIL ································17-7 KICKSTARTER IDLE GEAR ······································ 12-14 BATTERY······································································17-5 LEFT CRANKCASE COVER········································ 11-3 BRAKE CALIPER··························································16-9 LICENSE LIGHT (XR125LK/LEK) ································...
  • Page 243: Torque Values ······································1

    XR125LEK (DK, I LA TYPES) ·································· 19-2 CRANKCASE/CRANKSHAFT/TRANSMISSION····· 12-3 XR125LEK (III LA, CO TYPES)································ 19-3 CYLINDER HEAD/VALVES······································· 8-3 XR125LEK (NZ TYPE) ············································· 19-4 CYLINDER/PISTON ·················································· 9-3 XR125LK (DK TYPE) ··············································· 19-5 ELECTRIC STARTER ··············································· 5-3 XR125LK (III LA TYPE) ············································ 19-6 20-2...

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