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Honda xl 125 v1 Shop Manual
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Honda xl 125 v1 Shop Manual

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Marcos
July 6, 2025

No quadro de XL 125 CC pode acoplar um motor de 200 CC?

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Summary of Contents for Honda xl 125 v1

  • Page 2 Please understand th at th ose warnings cou Id not cover ali conceivable ways in which service, whether or not rec­ ommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investi gate ali such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoroughly that neither persona! safety nor vehicle safety will be jeopardized by the service methods or tools selected.
  • Page 3 VARADERO 125 VALVE CLEARANCES Remove fuel tank 2-8 Remove front inner fairing 2-6 Drain coolant 6-5 Remove radiator 6-8 Remove ai.r cleaner housing 6-4 Remove cylinder head covers 9-5 CHECK CLEARANCES 3-8 Refit cylinder head covers 9-25 Refit air cleaner housing 6-4 Refit radiator 6-12 Refit front inner fairing 2-6 Refit fuel tank 2-8...
  • Page 4 TIONS AND SPECIFICATIONS INCLUDED IN THIS BRAKE SYSTEM PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA CHARGING SYSTEM/ ALTERNA TOR MO TOR CO., L TD. RESERVES THE RIGHT TO MAKE CHANGES A T ANY TIME WITHOUT IGNITION SYSTEM NOTICE AND WITHOUT INCURRING ANY OBLIG­...
  • Page 5 Use molybdenum disulfide paste (containing more than molybdenum disulfide, NLGI or equivalent). Example: Molykote• G-n Paste manufactured by Dow corning, U.S.A. � Honda Moly (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan � Use silicone grease.
  • Page 6 1. GENERAL INFORMATION GENERAL SAFETY TOOLS 1-16 SERVICE RULES LUBRICATION & SEAL POINTS 1-18 MODEL IDENTIFICATION CABLE & HARNESS ROUTING 1-20 SPECIFICATIONS EMISSION CONTROL SYSTEMS 1-27 TORQUE VALUES 1-13 GENERAL SAFETY CARBON MONOXIDE USED ENGINE Oll If the engine must be running to do some work, make sure the area is weil ventilated.
  • Page 7 GENERAL INFORMATION SERVICE RULES Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that do not meet HONDA's design specifications may damage the motorcycle. Use the special tools designed for this product. Use only metric tools when servicing this motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners.
  • Page 8 GENERAL INFORMATION MODEL IDENTIFICATION ENGINE SERIAL NUMBER The frame seriai number is stamped on the right side of The engine seriai number is stamped on the left side the steering head. of the crankcase. CARBURETOR IDENTIFICATION NUMBER seriai number is stamped the left side carburetor the carburetor body as shown.
  • Page 9 GENERAL INFORMATION SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall length 2,150 mm (84.6 in) Overall width 850 mm (33.5 in) Overall height 1,250 mm (4.9.2 in) 1,450 mm (57.1 in) Wheelbase Seat height 802 mm (31.6 in) 190 mm (7 .5 Ground clearance Dry weight 154 kg (339.51bs) Cu rb weight...
  • Page 10 GENERAL INFORMATION GENERAL (C t'd} ITEM SPECIFICATIONS CARBURETOR Carburetor Type CV (Constant Velocity) dual carburetor Throttle bore 22 mm (0.9 in) DRIVE TRAIN Clutch system Multi-plate, wet Clutch operation system Mechanical type Transmission Constant mesh, 5-speed Primary reduction 3.722 (67/18) 3.142 (44/14) Final reduction Gear ratio...
  • Page 11 GENERAL INFORMATION Unit: mm (in) LUBRICATION SYSTEM ITEM STANDARD SERVICE LIMIT Engine oil capacity at draining 1.1 liter (1.2 US qt, 1.0 lmp qt) at disassembly 1.5 liter (1.6 US qt, 1.3 lmp qt) 1.21iter(1.3 USqt,1.1lmp qt) at filter change DA 4-stroke oil or equivalent Recommended engine oil motor oïl...
  • Page 12 GENERAL INFORMATION · Unit: mm (in) CLUTCH SVSTEM/GEARSHIFT LINKAGE ITEM STANDARD SERVICE LI Clutch lever free play 10-20 (3/8-13/16) Clutch spring free length 42.1 (1.66) 41.2 (1.62) Clutch dise thickness 2.92-3.08 (0.115-0.121) 2.6 (0.10) 2.92-3.08 (0.115-0.121) 2.6 (0.10) Clutch plate warpage 0.30 (0.012) 1.0.
  • Page 13 GENERAL INFORMATION Unit" (in) CYLINDER/PISTON ITEM STANDARD SERVICE LIMIT Cylinder t.D. 42.00-42.01 (1.654-1.654) 42.10 (1.657) Out of round 0.06 (0.002) Taper 0.06 (0.002) Warpage 0.05 (0.002) Piston, Piston mark direction "IN" mark facing toward the intake side piston rings Piston O.D. 41.97-41.99 (1.652-1.653) 41.90 (1.650) Piston O.D.
  • Page 14 GENERAL INFORMATION Unit: mm (in) CRANKCASE/TRANSMISSION/CRANKSHAFT ITEM STANDARD SERVICE LIMIT Gear I.D. Transmission M4, M5, C1, C2 23.000-23.021 (0.9055-0.9063) 23.04 (0.907) 25.06 (0.987) 25.020- 25.041 (0.9850-0.9859) Bushing O.D. M4, M5, C1, C2 22.959-22.980 {0.9039-0.9047) 22.94 (0.903) 24.979-25.000 (0.9834- 0.9843) 24.96 (0.983) 20.06 (0.790) Bushing I.D.
  • Page 15 GENERAL INFORMATION Unit: mm {in) FRONT WHEEL/SUSPENSION/STEERING ITÈM STANDARD SERVICE LIMIT Minimum tire tread depth 1.5 (0.06) Cold tire pressure Driver only 200 kPa (2.0 kgf/cm•, 29 psi) Driver and passenger 200 kPa (2.0 kgf/cm•, 29 psi) Axle runout 0.20 (0.008) Wheel rim runout Radial 1.0 (0.04)
  • Page 16 GENERAl INFORMATION Unit: (in) BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT Front Speeified brake fluid DOT3 or DOT4 Brake pad wear indicator To groove Bral<e dise thiekness 3.8-4.2 (0.15-0.17) 3.5 (0.13) Brake dise runout 0.1 (0.004) Master eylinder I.D. 11.000- 11.043 (0.4331 0.4348) 11.055 (0.4352) Master piston...
  • Page 17 GENERAL INFORMATION Unit· mm (in) IGNITION SYSTEM SPECIFICATIONS Spark plug DENSO Standard CR8EH-9 (NGK) U24FER-9 (DENSO) Spark plug gap 0.8-0.9 mm (0.031 -0.035 in) Ignition co il primary peak voltage 100 V minimum Ignition pulse generator peak voltage 0.7 V minimum Ignition timing "F"...
  • Page 18 GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ftl lbf·ftl N·m lkgf·m, 5 mm boit and nut 5 (0.5, 3.6) screw 4 (0.4, 2.9) 6 mm boit and nut (lnclude SH 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5) flange boit) flange boit and nut (lnclude...
  • Page 19 GENERAL INFORMATION ENGINE (C t'd) THREAD TORQUE ITEM Q'TV RE MARKS DIA. (mm) N·m (kgf.m, lbf·ftl CYLINDER HEAD/VALVE: Cylinder head side cover boit 10 (1.0, 7) Cylinder head cover boit 10 (1.0, 7) Cam sprocket boit 20 (2.0, 14) NOTE 2 Cylinder head flange nut: 8 mm (0.3 in) NOTES...
  • Page 20 GENERAL INFORMATION FRAME (C t'd) THREAO TORQUE ITEM Q'TV RE MARKS (mm) DIA. N.m (kgf.m, lbf.ftl REAR WHEEL/SUSPENSION: Rear axle nut 88 (9.0, 65) NOTE9 Driven sprocket nut 64 (6.5, 47) NOTE9 Rear brake dise boit NOTE 10 42 (4.3, 31) Shock absorber upper mounting nut 44 (4.5, 33) NOTE 9...
  • Page 21 GENERAL INFORMATION TOOLS NOTES: 1. Alternative tool. 2. Newly provided tool. DESCRIPTION TOOLNUMBER REMARKS REF.SEC. Attachment, 22 24 mm 077 46-001 0800 Attachment, 24 26 mm 077 46-0010700 Attachment, 28 30 m m 07746-1870100 Attachment, 32 07746-0010100 11, 13,6 Attachment, 42 077 46-001 0300 11, 12, 13 Bea ring installer 37.42...
  • Page 22 GENERAL INFORMATION t'd) DESCRIPTION TOOLNUMBER REMARKS REF.SEC. 07984-MA6000 1 Valve guide rea mer 07757-0010000 Valve spring compresser 07959-KM30101 Valve spring compresser attachment Valve seat cutter 24.5 (45. IN) 07780-0010100 Seat cutter, 07780-0010701 (45. EX) Seat cutter, (32.1N) 07780-0012000 Flat cutter, 07780-0012601 (32.
  • Page 23 Cam chain tensioner tighting boit threads Gearshift cam plate boit threads Mainshaft bea ring set plate boit threads Gearshift drum bearing set plate boit threads Fan motor shaft threads Cam sprocket boit threads Honda Bond A or Cylinder head cover gasket equivalent 1-18...
  • Page 24 Final driven flange boit threads locking agent Rear caliper nut threads Front caliper pin threads Front caliper nut threads Fork socket boit th reads Honda band or Cemedine Handle grip rubber inside surfaces #540 Fork fluid Front fork inside 1-19...
  • Page 25 GENERAL INFORMATION CABLE & HARNESS ROUTING THROTILE GABLES LEFT HANDLEBAR SWITCHWIRE BRAKE HOSE COMBINATION METER WIRE RIGHTFRONT LEFTFRONT TURN SIGNAL WIRE TURN SIGNAL WIRE TURN SIGNAL RELAYWIRE 1-20...
  • Page 26 GENERAL INFORMATION THROTTLE GABLES ENGINE STOP SWITCHWIRE AIR INJECTION HOSE MAIN WIRE HARNESS LEFT HANDLEBAR SWITCH WIRE RADIA TOR RESERVE TANK OVER FLOW TUBE FUEL TUBE SPEED SENSOR WIRE SIPHON TUBE 1-21...
  • Page 28 GENERAL INFORMATION SPEEDOMETER S IPHON TUBE FAN MOTOR SWITCHWIRE BRAKE HOSE CLUTCH CABLE WATER HOSE 1-23...
  • Page 29 GENERAL INFORMATION REAR BRAKE LIGHT SWITCH WIRE REAR SPAAK PLUG WIRE AIR SUPPL HOSE FRONTSPARK PLUG WIRE WATERTUBE STARTING ENRICHMENT DRAIN TUBE (SE) VALUE CABLES 1-24...
  • Page 30 GENERAL INFORMATION REAR BRAKE LIGHT SWITCH WIRE (ICM) IGNITION CONTROL MODULE WIRE MAIN WIRE HARNESS BATTERY NEGATIVE WIRE BA TTERY POSITIVE WIRE STARTER RELAY SWITCHWIRE 1-25...
  • Page 31 GENERAL INFORMATION TAIL/BRAKE LIGHTWIRE RIGHT REAR TURN SIGNALWIRE LEFT REAR TURN SIGNAL WIRE 1-26...
  • Page 32 Carbon monoxide does not react in the same way, but it is toxic. Honda Moter Co., Ltd. utilizes lean carburetor settings as weil as other systems, to reduce carbon monoxide and hydro­ carbons.
  • Page 33 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM) The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust bases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system.