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XL 125 V1
Honda XL 125 V1 Manuals
Manuals and User Guides for Honda XL 125 V1. We have
2
Honda XL 125 V1 manuals available for free PDF download: Shop Manual
Honda XL 125 V1 Shop Manual (344 pages)
Brand:
Honda
| Category:
Motorcycle
| Size: 50.06 MB
Table of Contents
Important Safety Notice
2
Country Codes
2
Contents
3
Symbols
4
General Information
5
General Safety
5
Carbon Monoxide
5
Gasoline
5
Service Rules
6
Model Identification
7
Frame Serial Number
7
Engine Serial Number
7
Carburetor Identification Number
7
Specifications
8
Torque Values
17
Tools
20
Lubrication & Seal Points
22
Cable & Harness Routing
24
Emission Control Systems
31
Source of Emissions
31
Crankcase Emission Control System
31
Exhaust Emission Control System
32
Frame/Body Panels/Exhaust System Service Information
33
Frame/Body Panels/Exhaust System Torque Values
33
Frame/Body Panels/Exhaust System Troubleshooting
33
Seat Removal
34
Seat Installation
34
Side Cover
34
Front Fender
35
Rear Carrier
35
Tail Cover/Rear Fender Removal
36
Tail Cover/Rear Fender Disassembly
36
Rear Inner Fender/Battery Box
37
Front Cowl
38
Windshield Screen
38
Inner Center Cowl
38
Front Cowl Assembly Removal
39
Front Cowl Assembly Disassembly
39
Fuel Tank Removal
40
Fuel Tank Disassembly
40
Muffler/Exhaust Pipe Removal
41
Muffler/Exhaust Pipe Installation
42
Maintenance Service Information
43
Maintenance Specifications
43
Maintenance Schedule
45
Fuel Line
46
Throttle Operation
46
Carburetor Choke
47
Starting Enrichment (SE) Valve
47
Air Cleaner
48
Spark Plug
48
Spark Plugs Inspection
49
Reusing a Spark Plug
49
Replacing a Spark Plug
49
Valve Clearance Inspection
50
Rear Cylinder Head
50
Front Cylinder Head
50
Valve Clearance Adjustment
51
Engine Oil/Oil Filter Inspection
51
Engine Oil Change
52
Oil Filter Change
53
Carburetor Synchronization
54
Engine Idle Speed
55
Radiator Coolant Level Check
55
Cooling System
56
Secondary Air Supply System
57
Drive Chain Slack Inspection
58
Drive Chain Adjustment
58
Drive Chain Cleaning and Lubrication
58
Sprockets Inspection
59
Drive Chain Replacement
59
Drive Chain Slider
61
Brake Fluid
62
Front Brake
62
Rear Brake
62
Front Brake Pad
62
Brake System
63
Rear Brake Pad
63
Inspection for Air in System
63
Brake Pedal Height
63
Brake Light Switch
64
Headlight Aim
64
Clutch System
65
Side Stand
66
Front Suspension
66
Rear Suspension
67
Nuts, Bolts, Fasteners
67
Wheels/Tires
68
Steering Head Bearings
68
Lubrication System Diagram
70
Lubrication System Service Information
71
Lubrication System Specifications
71
Lubrication System Troubleshooting
72
Lubrication System Torque Values
72
Oil Pump Removal
73
Oil Pump Disassembly
73
Oil Pump Inspection
73
Oil Pump Assembly
74
Oil Pump Installation
75
Fuel System Service Information
77
Fuel System Specifications
78
Fuel System Torque Values
78
Fuel System Troubleshooting
79
Air Cleaner Housing Removal/Installation
80
Carburetor Base Removal/Installation
80
Carburetor Removal
82
Carburetor Separation
83
Carburetor Disassembly
85
Vacuum Chamber
85
Float Chamber
86
Carburetor Assembly
87
Carburetor Cleaning
87
Float Level Inspection
88
Carburetor Combination
90
Carburetor Installation
92
Choke System
94
Pilot Screw Adjustment
94
Idle Drop Procedure
94
Secondary Air Supply System Inspection
95
Pair Check Valve Inspection
96
System Flow Pattern
98
Cooling System Service Information
99
Cooling System Specifications
99
Cooling System Troubleshooting
100
Cooling System Torque Values
100
Cooling System Tools
100
System Testing Coolant (Hydrometer Test)
101
Radiator Cap/System Pressure Inspection
102
Coolant Replacement Preparation
102
Radiator Cap/System Pressure Replacement/Air Bleeding
103
Thermostat Removal
104
Thermostat Inspection
104
Thermostat Installation
105
Radiator/Cooling Fan Removal
106
Radiator/Cooling Fan Disassembly
107
Radiator/Cooling Fan Installation
110
Radiator Reserve Tank Removal/Installation
111
Water Pump Mechanical Seal Inspection
111
Water Pump Removal
111
Water Pump Disassembly
113
Water Pump Assembly
114
Water Pump Installation
116
Engine Removal/Installation Service Information
121
Engine Removal/Installation Specifications
122
Engine Removal
123
Drive Sprocket Removal
123
Engine Installation
125
Drive Sprocket Installation
125
Clutch/Gearshift Linkage Service Information
129
Clutch/Gearshift Linkage Specifications
129
Clutch/Gearshift Linkage Torque Values
129
Clutch/Gearshift Linkage Tools
129
Clutch/Gearshift Linkage Troubleshooting
130
Clutch Lifter Arm Removal
131
Clutch Lifter Arm Inspection
131
Clutch Lifter Installation
131
Clutch Removal
132
Clutch Inspection
133
Clutch Installation
136
Gearshift Linkage Removal
138
Gearshift Linkage Inspection
139
Gearshift Linkage Installation
139
Cylinder Head/Valves Service Information
143
Cylinder Head/Valves Specifications
143
Cylinder Head/Valves Torque Values
144
Cylinder Head/Valves Tools
144
Cylinder Head/Valves Troubleshooting
145
Valve Timing
145
Cylinder Compression
146
Cylinder Head Side Cover Removal/Installation
147
Cylinder Head Cover Removal Front/Rear
147
Camshaft Removal
148
Camshaft Holder Disassembly
150
Camshaft Runout
151
Cam Lobe Height
151
Cylinder Head Removal
152
Rocker Arm, Rocker Arm Shaft
152
Cylinder Head Disassembly
153
Cylinder Head Inspection
153
Valve Spring
154
Valve Guide Replacement
155
Valve Seat Inspection/Refacing
156
Cylinder Head Assembly
159
Cylinder Head Installation
161
Camshaft Installation
162
Camshaft Service for both Cylinder
162
Rear Cylinder Camshaft Service Only
162
Front Cylinder Camshaft Service Only
163
Cylinder Head Cover Installation Front/Rear
167
Cylinder/Piston Service Information
171
Cylinder/Piston Specifications
171
Cylinder/Piston Troubleshooting
172
Cylinder Removal
173
Cylinder Inspection
174
Piston Removal
175
Piston Inspection
176
Crankcase Stud Bolt Inspection
177
Piston Installation
178
Cylinder Installation
179
Crankcase/Transmission/Crankshaft Service Information
183
Crankcase/Transmission/Crankshaft Specifications
183
Crankcase/Transmission/Crankshaft Troubleshooting
184
Crankcase/Transmission/Crankshaft Tools
184
Crankcase Separation
185
Transmission Removal/Disassembly
186
Transmission Inspection
187
Mainshaft/Countershaft
188
Shift Fork, Shift Fork Shaft
188
Transmission Assembly
189
Shift Drum
189
Shift Fork Shaft Journal
189
Transmission Bearing
189
Transmission Installation
192
Crankshaft Removal
193
Crankshaft Inspection
193
Crankshaft Installation
194
Crankcase Bearing/Dust Seal Location
195
Camshaft Bearing
195
Crankcase Assembly
198
Front Wheel/Suspension/Steering Service Information
203
Front Wheel/Suspension/Steering Specifications
203
Front Wheel/Suspension/Steering Troubleshooting
204
Front Wheel/Suspension/Steering Torque Values
204
Front Wheel/Suspension/Steering Tools
204
Handlebar Removal
205
Handlebar Installation
207
Front Wheel Removal
211
Front Wheel Inspection
211
Front Wheel Balance
212
Front Wheel Disassembly
213
Front Wheel Bearing Replacement
213
Front Wheel Assembly
214
Front Wheel Installation
216
Fork Removal
216
Fork Disassembly
217
Fork Inspection
219
Fork Spring
219
Fork Tube/Slider/Fork Piston
219
Fork Tube Bushing
220
Fork Installation
224
Steering Stem Removal
225
Steering Bearing Race Replacement
226
Steering Stem Assembly
228
Steering Stem Installation
230
Steering Bearing Preload
231
Rear Wheel/Suspension Service Information
233
Rear Wheel/Suspension Specifications
233
Rear Wheel/Suspension Torque Values
233
Rear Wheel/Suspension Troubleshooting
234
Rear Wheel/Suspension Tools
234
Rear Wheel Removal
235
Rear Wheel Inspection
235
Rear Wheel Bearing
236
Rear Wheel Balance
236
Rear Wheel Driven Sprocket
236
Rear Wheel Disassembly
237
Rear Wheel Assembly
238
Rear Wheel Bearing Removal
238
Rear Wheel Driven Flange Bearing Removal
238
Rear Wheel Bearing Installation
239
Rear Wheel Driven Flange Bearing Installation
239
Rear Wheel Installation
241
Shock Absorber Removal
242
Shock Absorber Inspection
242
Needle Bearing Replacement
242
Shock Absorber Installation
243
Shock Absorber Disposal
244
Swingarm Removal
244
Swingarm Disassembly
245
Swingarm Assembly
246
Swingarm Installation
248
Brake System Service Information
251
Brake System Specifications
251
Brake System Troubleshooting
252
Brake System Torque Values
252
Brake Fluid Replacement/Air Bleeding
253
Brake Fluid Draining
253
Brake Fluid Filling/Bleeding
254
Front Brake Pad Replacement
255
Rear Brake Pad Replacement
257
Brake Disc Inspection
258
Front Master Cylinder Removal
258
Front Master Cylinder Disassembly
258
Front Master Cylinder Inspection
260
Front Master Cylinder Assembly
260
Front Master Cylinder Installation
262
Rear Master Cylinder Removal
263
Rear Master Cylinder Disassembly
263
Rear Master Cylinder Inspection
264
Rear Master Cylinder Assembly
265
Front Brake Caliper Removal
267
Front Brake Caliper Disassembly
268
Front Brake Caliper Inspection
269
Front Brake Caliper Assembly
269
Front Brake Caliper Installation
270
Rear Brake Caliper Removal
271
Rear Brake Caliper Disassembly
271
Rear Brake Caliper Inspection
272
Rear Brake Caliper Assembly
273
Rear Brake Caliper Installation
274
Brake Pedal Removal
274
Brake Pedal Installation
275
Charging System/Alternator System Diagram
276
Charging System/Alternator Service Information
277
Charging System/Alternator Specifications
278
Charging System/Alternator Torque Values
278
Charging System/Alternator Tools
278
Charging System/Alternator Battery Testing
278
Charging System/Alternator Troubleshooting
279
Battery Removal
280
Battery Installation
280
Battery Inspection
281
Battery Charging
281
Charging System Inspection
282
Current Leakage Test
282
Charging Voltage Inspection
282
Regulator/Rectifier
283
Wire Harness Inspection
283
Battery Line
283
Regulator/Rectifier Installation
284
Charging Line
284
Alternator Removal
285
Left Crankcase Cover Removal
285
Pulse Generator Removal
286
Stator Removal
286
Flywheel Removal
286
Flywheel Installation
287
Stator Installation
288
Ignition Pulse Generator Installation
288
Left Crankcase Cover Installation
288
Ignition System Diagram
290
Ignition System Service Information
291
Ignition System Troubleshooting
292
Ignition System Specifications
292
Ignition System Torque Values
292
No Spark at Spark Plugs
293
Ignition System Inspection
294
Ignition Primary Voltage Inspection
294
Ignition Pulse Generator Peak Voltage
296
Ignition Coil Removal/Installation
297
Ignition Timing
298
Engine Coolant Temperature (ECT) Sensor Inspection
299
Electric Starter/Starter Clutch System Diagram
300
Electric Starter/Starter Clutch Service Information
301
Electric Starter/Starter Clutch Specifications
301
Electric Starter/Starter Clutch Torque Values
301
Electric Starter/Starter Clutch Troubleshooting
302
Starter Motor Removal
304
Starter Motor Disassembly
304
Starter Motor Inspection
306
Brush Holder Disassembly
306
Starter Motor Assembly
308
Starter Motor Installation
310
Primary Drive Gear/Starter Clutch Removal
311
Primary Drive Gear/Starter Clutch Assembly
312
Starter Clutch Outer
312
One-Way Clutch
312
Starter Clutch Disassembly
313
Starter Clutch Inspection
313
Starter Clutch Gear
313
Starter Clutch Installation
314
Starter Relay Switch Removal/Installation
316
Starter Relay Switch Inspection
316
Ground Line
316
Starter Relay Voltage
316
Clutch Diode Inspection
317
Lights/Meters/Switches System Diagram
318
Lights/Meters/Switches Service Information
319
Lights/Meters/Switches Specifications
320
Lights/Meters/Switches Torque Values
320
Lights/Meters/Switches Trouble Shooting
320
Lights/Meters/Switches Troubleshooting
321
Headlight Bulb Replacement
322
Turn Signal Light Bulb Replacement
322
Brake/Taillight Bulb Replacement
322
Indicator and Meter Light Bulb Replacement
323
Combination Meter Inspection
323
Combination Meter Removal/Installation
324
Combination Meter Disassembly
324
Speed Sensor Inspection
325
Tachometer Inspection
325
Ignition Switch Inspection
326
Ignition Switch Removal/Installation
327
Handlebar Switches
327
Right Handlebar Switch
327
Left Handlebar Switch
328
Front Brake Light Switch
328
Rear Brake Light Switch
328
Clutch Switch
329
Neutral Switch
329
Horn
329
Fan Motor Switch Inspection
330
Fan Motor Switch Removal/Installation
330
Fan Motor Does Not Stop
330
Fan Motor Does Not Start
330
Coolant Temperature Indicator Thermo Switch System Inspection
331
The Indicator Does Not Come on
331
The Indicator Come on
331
Thermo Switch Inspection
332
Turn Signal Relay Inspection
333
Side Stand Switch Inspection
333
Side Stand Switch Removal/Installation
334
Speed Sensor (IIG Type Only) Inspection
334
Wiring Diagram
335
Troubleshooting
337
Engine Does Not Start or Is Hard to Start
337
Engine Lacks Power
338
Poor Performance at Low and Idle Speed
339
Poor Performance at High Speed
340
Poor Handling
340
Index
341
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Honda XL 125 V1 Shop Manual (33 pages)
Brand:
Honda
| Category:
Motorcycle
| Size: 2.89 MB
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