User Manuals: Honda 2002 XR50R Off-road Motorcycle

Manuals and User Guides for Honda 2002 XR50R Off-road Motorcycle. We have 1 Honda 2002 XR50R Off-road Motorcycle manual available for free PDF download: Service Manual

Honda 2002 XR50R Service Manual (198 pages)

Brand: Honda | Category: Motorcycle | Size: 22 MB

Contents
3
Symbols
4
General Information
5
General Safety
5
Carbon Monoxide
5
Hot Components
5
Service Rules
6
Model Identification
7
Engine Serial Number
7
Frame Serial Number
7
Vehicle Identification Number (VIN)
7
Specifications
8
Lubrication System
10
Fuel System
10
Cylinder Head/Valves
10
Torque Values
14
Table of Contents
16
Tools
16
Lubrication & Seal Points
17
Cable & Harness Routing
18
Emission Control Systems
21
Source of Emissions
21
Exhaust Emission Control System
21
Crankcase Emission Control System
21
Emission Control Information Label
22
Frame/Body Panels/Exhaust System Service Information
23
Frame/Body Panels/Exhaust System Troubleshooting
23
Frame/Body Panels/Exhaust System Torque Values
23
Excessive Exhaust Noise
23
Seat Disassembly/Assembly
24
Seat Removal
24
Seat Installation
24
Number Plate
25
Front Fender
25
Fuel Tank
25
Exhaust System Removal
26
Exhaust System Installation
26
Side Stand Removal
27
Side Stand Installation
27
Maintenance
29
Maintenance Service Information
29
Maintenance Specifications
29
Maintenance Torque Values
30
Maintenance Tools
30
Maintenance Schedule
31
Fuel Strainer Screen
32
Fuel Line
32
Throttle Operation
32
Air Cleaner
33
Spark Plug Removal
34
Spark Plug Inspection
34
Reusing a Spark Plug
34
Replacing a Spark Plug
35
Valve Clearance Inspection
35
Engine Oil Level Inspection
36
Engine Oil Change
37
Recommended Engine Oil
37
Engine Oil Strainer Screen Cleaning
38
Engine Oil Centrifugal Filter Cleaning
38
Engine Idle Speed
39
Drive Chain Slack Inspection
40
Drive Chain Adjustment
40
Cleaning Inspection and Lubrication
40
Drive Chain Slider
42
Brake Shoe Wear
42
Front Brake
42
Rear Brake
43
Clutch System
44
Side Stand
44
Suspension
44
Front Suspension Inspection
44
Spark Arrester
45
Rear Suspension Inspection
45
Minimum Tread Depth
46
Wheels/Tires
46
Recommended Tire Pressure and Tire Size
46
Nuts, Bolts, Fasteners
46
Steering Head Bearings
47
Lubrication System Diagram
48
Lubrication System Service Information
49
Lubrication System Specifications
49
Lubrication System Torque Values
49
Lubrication System Troubleshooting
49
Oil Pump Removal
50
Oil Pump Disassembly
50
Oil Pump Inspection
50
Oil Pump Assembly
51
Fuel System Tool
55
Fuel System Torque Value
55
Fuel System Service Information
55
Fuel System Specifications
55
Fuel System Troubleshooting
56
Engine Won't to Start
56
Lean Mixture
56
Rich Mixture
56
Air Cleaner Housing Removal/Installation
57
Carburetor Removal
57
Throttle Valve
57
Carburetor Body
58
Carburetor Disassembly
59
Carburetor Assembly
60
Float Level Inspection
61
Carburetor Installation
62
Idle Speed
64
Air Screw Adjustment
64
Initial Opening
64
Idle Drop Procedure
64
Crankcase Breather
65
Engine Removal/Installation
66
Cylinder Head/Valves Service Information
73
Cylinder Head/Valves Specifications
73
Cylinder Head/Valves Torque Values
73
Cylinder Head/Valves Troubleshooting
74
Cylinder Head/Valves Tools
74
Excessive Smoke
74
Excessive Noise
74
Valve Spring Compressor 07757 - 0010000
74
- Seat Cutter, 20.5 MM
  74
- Flat Cutter, 24 MM
  74
- Flat Cutter, 21.5 MM
  74
- Cutter Holder, 5 MM 07781 - 0010400
  74
  - Cylinder Compression
    75
  - Camshaft Removal
    75
  - Compression Pressure
    75
  - Cylinder Head Removal
    76
  - Cylinder Head Disassembly
    77
  - Cylinder Head Inspection
    78
  - Rocker Arm
    79
  - Valve Spring
    79
  - Valve
    79
  - Valve Guide Replacement
    80
  - Valve Seat Inspection/Refacing
    81
Valve Guide Driver, 5.0 MM 07942
81
- Note 3
  81
- Valve Seat Refacing
  82
- Note
  82
- Note
  83
- Camshaft Installation
  87
- Note Note
  87
  - Cylinder/Piston
    90
  - Cylinder/Piston Service Information
    91
  - Cylinder/Piston Specifications
    91
  - Cylinder/Piston Torque Values
    91
  - Cylinder/Piston Troubleshooting
    92
  - Piston Sounds
    92
  - Cylinder Removal
    93
  - Piston Removal
    93
  - Cylinder/Piston Inspection
    94
  - Piston Ring Installation
    96
- Note
  96
  - Piston Installation
    97
  - Cylinder Installation
    97
  - Clutch/Gearshift Linkage
    100
  - Clutch/Gearshift Linkage Service Information
    101
  - Clutch/Gearshift Linkage Specifications
    101
  - Clutch/Gearshift Linkage Torque Values
    101
  - Clutch/Gearshift Linkage Tools
    101
  - Clutch/Gearshift Linkage Troubleshooting
    102
  - Clutch Slips When Accelerating
    102
  - Hard to Shift
    102
  - Transmission Jumps out of Gear
    102
  - Right Crankcase Cover Removal
    103
  - Clutch Removal
    104
  - Clutch Spring
    108
  - Clutch Disc
    108
  - Primary Drive Gear/Clutch Center Guide
    108
  - Crankshaft
    109
  - Drive Gear Outer/Clutch Center
    109
  - Gearshift Linkage Removal
    114
  - Clutch/Gearshift Linkage Inspection
    116
  - Clutch/Gearshift Linkage Installation
    116
  - Right Crankcase Cover Installation
    117
  - Alternator/Cam Chain Tensioner
    120
  - Alternator/Cam Chain Tensioner Service Information
    121
  - Alternator/Cam Chain Tensioner Specifications
    121
  - Alternator/Cam Chain Tensioner Tools
    121
  - Alternator/Cam Chain Tensioner Troubleshooting
    121
  - Flywheel/Stator Removal
    122
  - Cam Chain Tensioner
    124
  - Stator/Flywheel Installation
    126
  - Crankshaft/Transmission/Kickstarter
    131
- Crankshaft Itransmission/Kickstarter
  132
- Troubleshooting
  132
- Crankcase Separation
  133
  - Crankshaft Removal
    134
  - Crankshaft Inspection
    135
  - Crankshaft Installation
    136
  - Transmission Removal
    136
  - Transmission Disassembly
    137
  - Transmission Inspection
    137
  - Transmission Assembly
    138
  - Gearshift Drum Disassembly
    138
  - Shift Drum Assembly
    139
  - Transmission Bearing Replacement
    140
  - Transmission Installation
    142
  - Kickstarter Removal
    142
  - Kickstarter Disassembly
    142
  - Kickstarter Inspection
    143
  - Kickstarter Assembly
    143
  - Kickstarter Installation
    144
- Crankcase Assembly
  144
  - Front Wheel/Brake/Suspension/Steering
    146
  - Front Wheel/Brake/Suspension/Steering Service Information
    147
  - Front Wheel/Brake/Suspension/Steering Specifications
    147
  - Front Wheel/Brake/Suspension/Steering Torque Values
    147
  - Front Wheel/Brake/Suspension/Steering Troubleshooting
    148
  - Front Wheel/Brake/Suspension/Steering Tools
    148
  - Hard Steering
    148
  - Front Wheel Wobbling
    148
  - Handlebar Removal
    149
  - Handlebar Installation
    150
  - Front Wheel Removal
    151
  - Front Wheel Inspection
    152
  - Axle
    152
  - Wheel Bearing
    152
  - Wheel Rim Runout
    152
  - Wheel Center Adjustment
    154
  - Front Brake Removal
    156
  - Front Brake Inspection
    156
  - Front Brake Disassembly
    156
  - Front Brake Assembly
    157
  - Fork Disassembly
    158
  - Front Brake Installation
    158
  - Fork Inspection
    159
  - Fork Assembly
    159
  - Steering Stem Removal
    161
  - Steering Stem Bearing Replacement
    162
  - Steering Stem Installation
    163
  - Rear Wheel/Brake/Suspension
    166
  - Rear Wheel/Brake/Suspension Service Information
    167
  - Rear Wheel/Brake/Suspension Torque Values
    167
  - Rear Wheel/Brake/Suspension Specifications
    167
  - Rear Wheel/Brake/Suspension Tools
    167
  - Rear Wheel/Brake/Suspension Troubleshooting
    168
  - Soft Suspension
    168
  - Hard Suspension
    168
  - Rear Wheel Wobbling
    168
  - Rear Wheel Removal
    169
  - Rear Wheel Inspection
    170
  - Rear Wheel Disassembly
    171
  - Rear Wheel Assembly
    171
  - Wheel Bearing Removal
    171
  - Wheel Bearing Installation
    172
  - Rear Brake Removal
    174
  - Rear Brake Inspection
    174
  - Rear Brake Disassembly
    174
  - Rear Brake Assembly
    175
  - Shock Absorber Removal
    176
  - Shock Absorber Inspection
    177
  - Shock Absorber Installation
    177
  - Swingarm Removal
    178
  - Swingarm Inspection
    178
  - Swingarm Installation
    179
  - Brake Pedal Removal
    179
  - Brake Pedal Installation
    180
  - Ignition System Diagram
    182
  - Ignition System Service Information
    183
  - Ignition System Specifications
    183
  - Ignition System Torque Values
    183
  - Ignition System Tools
    183
  - Ignition System Troubleshooting
    184
  - No Spark at Spark Plug
    184
  - Ignition System Inspection
    185
  - Ignition Coil Primary Peak Voltage
    185
  - Ignition Pulse Generator Peal Voltage
    186
  - Alternator Exciter Coil Peak Voltage
    187
  - Ignition Coil Removal/Installation
    188
  - Ignition Control Module
    188
  - Engine Stop Switch/Ignition Switch Inspection
    189
  - Ignition Timing
    189
  - Wiring Diagram
    191
  - Troubleshooting
    193
  - Engine Does Not Start or Is Hard to Start
    193
  - Engine Lacks Power
    194
  - Poor Performance at Low and Idle Speed
    195
  - Poor Performance at High Speed
    196
  - Poor Handling
    196
  - Index
    197

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User Manuals: Honda 2002 XR50R Off-road Motorcycle

Honda 2002 XR50R Service Manual (198 pages)

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