Table Of Contents - Honda XL 125 V1 Shop Manual

Table of Contents

Important Safety Notice2
Country Codes2
Contents3
Symbols4
General Information5
General Safety5
Carbon Monoxide5
Gasoline5
Service Rules6
Model Identification7
Frame Serial Number7
Engine Serial Number7
Carburetor Identification Number7
Specifications8
Torque Values17
Tools20
Lubrication & Seal Points22
Cable & Harness Routing24
Emission Control Systems31
Source Of Emissions31
Crankcase Emission Control System31
Exhaust Emission Control System32
Frame/Body Panels/Exhaust System Service Information33
Frame/Body Panels/Exhaust System Torque Values33
Frame/Body Panels/Exhaust System Troubleshooting33
Seat Removal34
Seat Installation34
Side Cover34
Front Fender35
Rear Carrier35
Tail Cover/Rear Fender Removal36
Tail Cover/Rear Fender Disassembly36
Rear Inner Fender/Battery Box37
Front Cowl38
Windshield Screen38
Inner Center Cowl38
Front Cowl Assembly Removal39
Front Cowl Assembly Disassembly39
Fuel Tank Removal40
Fuel Tank Disassembly40
Muffler/Exhaust Pipe Removal41
Muffler/Exhaust Pipe Installation42
Maintenance Service Information43
Maintenance Specifications43
Maintenance Schedule45
Fuel Line46
Throttle Operation46
Carburetor Choke47
Starting Enrichment (Se) Valve47
Air Cleaner48
Spark Plug48
Spark Plugs Inspection49
Reusing A Spark Plug49
Replacing A Spark Plug49
Valve Clearance Inspection50
Rear Cylinder Head50
Front Cylinder Head50
Valve Clearance Adjustment51
Engine Oil/Oil Filter Inspection51
Engine Oil Change52
Oil Filter Change53
Carburetor Synchronization54
Engine Idle Speed55
Radiator Coolant Level Check55
Cooling System56
Secondary Air Supply System57
Drive Chain Slack Inspection58
Drive Chain Adjustment58
Drive Chain Cleaning And Lubrication58
Sprockets Inspection59
Drive Chain Replacement59
Drive Chain Slider61
Brake Fluid62
Front Brake62
Rear Brake62
Front Brake Pad62
Brake System63
Rear Brake Pad63
Inspection For Air In System63
Brake Pedal Height63
Brake Light Switch64
Headlight Aim64
Clutch System65
Side Stand66
Front Suspension66
Rear Suspension67
Nuts, Bolts, Fasteners67
Wheels/Tires68
Steering Head Bearings68
Lubrication System Diagram70
Lubrication System Service Information71
Lubrication System Specifications71
Lubrication System Troubleshooting72
Lubrication System Torque Values72
Oil Pump Removal73
Oil Pump Disassembly73
Oil Pump Inspection73
Oil Pump Assembly74
Oil Pump Installation75
Fuel System Service Information77
Fuel System Specifications78
Fuel System Torque Values78
Fuel System Troubleshooting79
Air Cleaner Housing Removal/Installation80
Carburetor Base Removal/Installation80
Carburetor Removal82
Carburetor Separation83
Carburetor Disassembly85
Vacuum Chamber85
Float Chamber86
Carburetor Assembly87
Carburetor Cleaning87
Float Level Inspection88
Carburetor Combination90
Carburetor Installation92
Choke System94
Pilot Screw Adjustment94
Idle Drop Procedure94
Secondary Air Supply System Inspection95
Pair Check Valve Inspection96
System Flow Pattern98
Cooling System Service Information99
Cooling System Specifications99
Cooling System Troubleshooting100
Cooling System Torque Values100
Cooling System Tools100
System Testing Coolant (Hydrometer Test)101
Radiator Cap/System Pressure Inspection102
Coolant Replacement Preparation102
Radiator Cap/System Pressure Replacement/Air Bleeding103
Thermostat Removal104
Thermostat Inspection104
Thermostat Installation105
Radiator/Cooling Fan Removal106
Radiator/Cooling Fan Disassembly107
Radiator/Cooling Fan Installation110
Radiator Reserve Tank Removal/Installation111
Water Pump Mechanical Seal Inspection111
Water Pump Removal111
Water Pump Disassembly113
Water Pump Assembly114
Water Pump Installation116
Engine Removal/Installation Service Information121
Engine Removal/Installation Specifications122
Engine Removal123
Drive Sprocket Removal123
Engine Installation125
Drive Sprocket Installation125
Clutch/Gearshift Linkage Service Information129
Clutch/Gearshift Linkage Specifications129
Clutch/Gearshift Linkage Torque Values129
Clutch/Gearshift Linkage Tools129
Clutch/Gearshift Linkage Troubleshooting130
Clutch Lifter Arm Removal131
Clutch Lifter Arm Inspection131
Clutch Lifter Installation131
Clutch Removal132
Clutch Inspection133
Clutch Installation136
Gearshift Linkage Removal138
Gearshift Linkage Inspection139
Gearshift Linkage Installation139
Cylinder Head/Valves Service Information143
Cylinder Head/Valves Specifications143
Cylinder Head/Valves Torque Values144
Cylinder Head/Valves Tools144
Cylinder Head/Valves Troubleshooting145
Valve Timing145
Cylinder Compression146
Cylinder Head Side Cover Removal/Installation147
Cylinder Head Cover Removal Front/Rear147
Camshaft Removal148
Camshaft Holder Disassembly150
Camshaft Runout151
Cam Lobe Height151
Cylinder Head Removal152
Rocker Arm, Rocker Arm Shaft152
Cylinder Head Disassembly153
Cylinder Head Inspection153
Valve Spring154
Valve Guide Replacement155
Valve Seat Inspection/Refacing156
Cylinder Head Assembly159
Cylinder Head Installation161
Camshaft Installation162
Camshaft Service For Both Cylinder162
Rear Cylinder Camshaft Service Only162
Front Cylinder Camshaft Service Only163
Cylinder Head Cover Installation Front/Rear167
Cylinder/Piston Service Information171
Cylinder/Piston Specifications171
Cylinder/Piston Troubleshooting172
Cylinder Removal173
Cylinder Inspection174
Piston Removal175
Piston Inspection176
Crankcase Stud Bolt Inspection177
Piston Installation178
Cylinder Installation179
Crankcase/Transmission/Crankshaft Service Information183
Crankcase/Transmission/Crankshaft Specifications183
Crankcase/Transmission/Crankshaft Troubleshooting184
Crankcase/Transmission/Crankshaft Tools184
Crankcase Separation185
Transmission Removal/Disassembly186
Transmission Inspection187
Mainshaft/Countershaft188
Shift Fork, Shift Fork Shaft188
Transmission Assembly189
Shift Drum189
Shift Fork Shaft Journal189
Transmission Bearing189
Transmission Installation192
Crankshaft Removal193
Crankshaft Inspection193
Crankshaft Installation194
Crankcase Bearing/Dust Seal Location195
Camshaft Bearing195
Crankcase Assembly198
Front Wheel/Suspension/Steering Service Information203
Front Wheel/Suspension/Steering Specifications203
Front Wheel/Suspension/Steering Troubleshooting204
Front Wheel/Suspension/Steering Torque Values204
Front Wheel/Suspension/Steering Tools204
Handlebar Removal205
Handlebar Installation207
Front Wheel Removal211
Front Wheel Inspection211
Front Wheel Balance212
Front Wheel Disassembly213
Front Wheel Bearing Replacement213
Front Wheel Assembly214
Front Wheel Installation216
Fork Removal216
Fork Disassembly217
Fork Inspection219
Fork Spring219
Fork Tube/Slider/Fork Piston219
Fork Tube Bushing220
Fork Installation224
Steering Stem Removal225
Steering Bearing Race Replacement226
Steering Stem Assembly228
Steering Stem Installation230
Steering Bearing Preload231
Rear Wheel/Suspension Service Information233
Rear Wheel/Suspension Specifications233
Rear Wheel/Suspension Torque Values233
Rear Wheel/Suspension Troubleshooting234
Rear Wheel/Suspension Tools234
Rear Wheel Removal235
Rear Wheel Inspection235
Rear Wheel Bearing236
Rear Wheel Balance236
Rear Wheel Driven Sprocket236
Rear Wheel Disassembly237
Rear Wheel Assembly238
Rear Wheel Bearing Removal238
Rear Wheel Driven Flange Bearing Removal238
Rear Wheel Bearing Installation239
Rear Wheel Driven Flange Bearing Installation239
Rear Wheel Installation241
Shock Absorber Removal242
Shock Absorber Inspection242
Needle Bearing Replacement242
Shock Absorber Installation243
Shock Absorber Disposal244
Swingarm Removal244
Swingarm Disassembly245
Swingarm Assembly246
Swingarm Installation248
Brake System Service Information251
Brake System Specifications251
Brake System Troubleshooting252
Brake System Torque Values252
Brake Fluid Replacement/Air Bleeding253
Brake Fluid Draining253
Brake Fluid Filling/Bleeding254
Front Brake Pad Replacement255
Rear Brake Pad Replacement257
Brake Disc Inspection258
Front Master Cylinder Removal258
Front Master Cylinder Disassembly258
Front Master Cylinder Inspection260
Front Master Cylinder Assembly260
Front Master Cylinder Installation262
Rear Master Cylinder Removal263
Rear Master Cylinder Disassembly263
Rear Master Cylinder Inspection264
Rear Master Cylinder Assembly265
Front Brake Caliper Removal267
Front Brake Caliper Disassembly268
Front Brake Caliper Inspection269
Front Brake Caliper Assembly269
Front Brake Caliper Installation270
Rear Brake Caliper Removal271
Rear Brake Caliper Disassembly271
Rear Brake Caliper Inspection272
Rear Brake Caliper Assembly273
Rear Brake Caliper Installation274
Brake Pedal Removal274
Brake Pedal Installation275
Charging System/Alternator System Diagram276
Charging System/Alternator Service Information277
Charging System/Alternator Specifications278
Charging System/Alternator Torque Values278
Charging System/Alternator Tools278
Charging System/Alternator Battery Testing278
Charging System/Alternator Troubleshooting279
Battery Removal280
Battery Installation280
Battery Inspection281
Battery Charging281
Charging System Inspection282
Current Leakage Test282
Charging Voltage Inspection282
Regulator/Rectifier283
Wire Harness Inspection283
Battery Line283
Regulator/Rectifier Installation284
Charging Line284
Alternator Removal285
Left Crankcase Cover Removal285
Pulse Generator Removal286
Stator Removal286
Flywheel Removal286
Flywheel Installation287
Stator Installation288
Ignition Pulse Generator Installation288
Left Crankcase Cover Installation288
Ignition System Diagram290
Ignition System Service Information291
Ignition System Troubleshooting292
Ignition System Specifications292
Ignition System Torque Values292
No Spark At Spark Plugs293
Ignition System Inspection294
Ignition Primary Voltage Inspection294
Ignition Pulse Generator Peak Voltage296
Ignition Coil Removal/Installation297
Ignition Timing298
Engine Coolant Temperature (Ect) Sensor Inspection299
Electric Starter/Starter Clutch System Diagram300
Electric Starter/Starter Clutch Service Information301
Electric Starter/Starter Clutch Specifications301
Electric Starter/Starter Clutch Torque Values301
Electric Starter/Starter Clutch Troubleshooting302
Starter Motor Removal304
Starter Motor Disassembly304
Starter Motor Inspection306
Brush Holder Disassembly306
Starter Motor Assembly308
Starter Motor Installation310
Primary Drive Gear/Starter Clutch Removal311
Primary Drive Gear/Starter Clutch Assembly312
Starter Clutch Outer312
One-Way Clutch312
Starter Clutch Disassembly313
Starter Clutch Inspection313
Starter Clutch Gear313
Starter Clutch Installation314
Starter Relay Switch Removal/Installation316
Starter Relay Switch Inspection316
Ground Line316
Starter Relay Voltage316
Clutch Diode Inspection317
Lights/Meters/Switches System Diagram318
Lights/Meters/Switches Service Information319
Lights/Meters/Switches Specifications320
Lights/Meters/Switches Torque Values320
Lights/Meters/Switches Trouble Shooting320
Lights/Meters/Switches Troubleshooting321
Headlight Bulb Replacement322
Turn Signal Light Bulb Replacement322
Brake/Taillight Bulb Replacement322
Indicator And Meter Light Bulb Replacement323
Combination Meter Inspection323
Combination Meter Removal/Installation324
Combination Meter Disassembly324
Speed Sensor Inspection325
Tachometer Inspection325
Ignition Switch Inspection326
Ignition Switch Removal/Installation327
Handlebar Switches327
Right Handlebar Switch327
Left Handlebar Switch328
Front Brake Light Switch328
Rear Brake Light Switch328
Clutch Switch329
Neutral Switch329
Horn329
Fan Motor Switch Inspection330
Fan Motor Switch Removal/Installation330
Fan Motor Does Not Stop330
Fan Motor Does Not Start330
Coolant Temperature Indicator Thermo Switch System Inspection331
The Indicator Does Not Come On331
The Indicator Come On331
Thermo Switch Inspection332
Turn Signal Relay Inspection333
Side Stand Switch Inspection333
Side Stand Switch Removal/Installation334
Speed Sensor (Iig Type Only) Inspection334
Wiring Diagram335
Troubleshooting337
Engine Does Not Start Or Is Hard To Start337
Engine Lacks Power338
Poor Performance At Low And Idle Speed339
Poor Performance At High Speed340
Poor Handling340
Index341