~HONDA "f SHOP MANUAL
Contents
1. Master piston O D Cali per cylinder 10 957 10 984 0 4314 0 4324 25 400 25 450 1 0000 1 0020 10 945 0 4309 25 460 1 0024 Caliper piston O D 25 335 25 368 0 9968 0 9987 25 31 0 996 Specified brake fluid DOTS3 or DOT4 Brake pad wear indicator To groove Brake disc thickness 3 8 42 0 15 0 17 3 5 0 13 Brake disc runout 0 1 0 004 Master cylinder 12 700 12 743 0 5000 0 5017 12 755 0 5022 Master piston O D Caliper cylinder 12 657 12 684 0 4983 0 4994 32 030 32 080 1 2610 1 2630 12 654 10 4978 32 090 1 2634 Caliper piston O D 31 948 31 998 1 2578 1 2598 31 94 1 257 CHARGING SYSTEM ALTERNATOR ITEM SPECIFICATIONS Battery Capacity 12V 6Ah Current leakage 1 0 mA max Voltage 20 C 68 F Fully charged 13 0 13 2 V Needs charging Below 12 3 V Charging current Normal 0 6 A 5 10 h Quick 3 0 A 1 h max Alternator Capacity 260 VV 5 000 mm rpm Charging coil resistance 20 C 68 F 0 1 0 50 1 11 GENERAL INFORMATION Unit mm in IGNITION SYSTEM ITEM Standard Spark plug gap Ignition coil primary peak voltage Ignition pulse generator peak voltage SPECIFICATIONS Spark plug CR8EH 9 NGK U24FER 9 DENSO 0 8 0 9 mm 02. HONDA SHOP MANUAL XL 125 V1 IMPORTANT SAFETY NOTICE YIN indicates a strong possibility of severe personal injury or death if instructions are not followed CAUTION indicates a possibility of equipment damage if instructions are not followed NOTE Gives helpful information Detailed descriptions of standard workshop procedures safety principles and service operations are not included It is important to note that this manual contains some warnings and cautions against some specific service meth ods which could cause PERSONAL NJURY to service personnel or could damage a vehicle or render it unsafe Piease understand that those warnings could not cover all 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 investigate all such ways Anyone using service procedures or tools whether or not recommended by Honda must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected TYPE CODE Throughout this manual the following addreviations are used to identify individual model FRANCE GERMANY TYPE Il VARADERO 125 VALVE CLEARANCES Remove fuel tank 2 8 Remove front inner fairing 2 6 Drain coolant 6 5 Remove radiator 6 8 Remove air cleaner housing 5 4 Remove cylinder head covers 9 5 CHECK CLEARANCES 3 8 Refit cyli
3. 2 FRAME BODY PANELS EXHAUST SYSTEM SERVICE INFORMATION 2 1 COVER REAR FENDER 2 4 TROUBLESHOOTING 2 1 REAR INNER FENDER BATTERY BOX 2 5 SEAT 2 2 FRONT COWL 2 6 SIDE COVER 2 2 FUEL TANK 2 8 FRONT FENDER 2 3 MUFFLER EXHAUST PIPE 2 9 REAR CARRIER SERVICE INFORMATION GENERAL A WARNING Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated area Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion Engine and exhaust system parts become very hot and remain hot for some time after the engine is run Wear insu lated gloves or wait until the engine and exhaust system have cooled before handling these parts If the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area This section covers removal and installation of the body panels fuel tank and exhaust system Always replace the exhaust pipe gasket when removing the exhaust pipe from the engine When installing the exhaust system loosely install all of the exhaust pipe fasteners Always tighten the exhaust clamps first then tighten the mounting fasteners If you tighten the mounting fasteners fir
4. Cylinder head side cover bolt Cylinder head cover bolt Cam sprocket bolt Cylinder head flange nut 8 mm 0 3 in 6 mm 0 2 in 10 1 0 7 10 1 0 7 20 2 0 14 32 3 3 24 12 1 2 9 12 1 2 9 5 0 5 3 6 12 1 2 9 4 0 4 2 9 Camshaft holder bolt Rocker arm shaft Cam chain tensioner lifter bolt Cam chain tensioner lifter plug CRANKCASE TRANSMISSION CRANKSHAFT Mainshaft bearing setting plate bolt Shift drum bearing setting plate bolt CHARGING SYSTEM ALTERNATOR Flywheel nut 64 6 5 47 Stator mounting bolt 12 1 2 9 Ignition pulse generator mounting bolt 5 0 5 3 6 Stator Ignition pulse generator wire clamp bolt 5 0 5 3 6 IGNITION SYSTEM Engine coolant temperature ECT sensor 23 2 3 17 ELECTRIC STARTER STARTER CLUTCH Starter motor terminal nut 6 12 1 2 9 Starter motor front cover boit 5 0 5 3 6 Primary drive gear lock nut 88 9 0 65 OTHERS Neutral switch 12 1 2 9 Neutral switch terminal nut 2 0 2 1 4 NPP HP DROP m m N 10 1 0 7 10 1 0 7 FRAME THREAD TORQUE DIA mm N m kgf m REMARKS FRAME BODY PANELS EXHAUST SYSTEM Muffler band bolt 8 20 2 0 14 Exhaust pipe joint nut 4 8 18 1 8 13 Muffler mounting bolt 2 8 32 3 3 24 ENGINE REMOVAL INSTALL ATION Front engine mounting nut 1 10 39 4 0 29 Rear upper engine mounting nut 1 10 39 4 0 29 Rear lower engine mounting n
5. MODEL IDENTIFICATION ENGINE SERIAL NUMBER The frame serial number is stamped on the right side of The engine serial number is stamped on the left side the steering head of the crankcase CARBURETOR IDENTIFICATION NUMBER The carburetor serial number is stamped on the left side of the carburetor body as shown 1 3 GENERAL INFORMATION SPECIFICATIONS GENERAL Overall length Overall width Overall height Wheelbase Seat height Ground clearance Dry weight Curb weight Maximum weight capacity Frame type Front suspension Front wheel travel Rear suspension Rear wheel travel Front tire size Rear tire size Front tire brand Rear tire brand Front brake Rear brake Caster angle Trail length Fuel tank capacity Fuel tank reserve capacity ENGINE Bore and stroke Displacement Compression ratio Valve train Intake valve Exhaust vaive Lubrication system Oil pump type Cooling system Air filtration Engine dry weight opens closes opens closes SPECIFICATIONS 2 150 mm 84 6 850 mm 33 5 in 1 250 mm 49 2 in 1 450 mm 57 1 in 802 mm 31 6 in 190 mm 7 5 in 154 kg 339 5 Ibs 167 kg 368 2 Ibs 180 kg 396 8 Ibs Double cradle Telescopic fork 132 mm 5 2 in Swingarm 150 mm 5 9 in 100 90 18 56P 130 80 17 65P BRIDGESTONE PIRELLI BRIDGESTONE PIRELLI Hydraulic single disc Hydraulic single disc 28 00 97 mm 3 8 in 17 5 liter 4 62 US gal 3 85 Imp
6. 031 0 035 in 100 V minimum 0 7 V minimum 12 1 BTDC at 1 500 100 rpm BTDC 38 Ignition timing F mark Full advance ELECTRIC STARTER STARTER CLUTCH ITEM STANDARD SERVICE LIMIT Starter motor brush length 10 00 10 05 0 394 0 396 350014 000 Starter clutch gear O D 45 657 45 673 1 7975 1 7981 45 64 1 797 Starter clutch outer 62 317 62 347 2 4534 2 4546 62 33 2 454 LIGHTS METERS SWITCHES ITEM SPECIFICATIONS Headlight High low beam 12 V 35 35 W x 2 Position light 12V 5Wx2 8rake tail license light 12 21 5W Front turn signat light 12V 10W x2 Rear turn signal light 12V 10W x2 Instrument light 12V 17W x3 Turn signal indicator 12V 2Wx2 High beam indicator 12V 12W Neutral indicator 12V 2W 12V 17W Temp indicator Fuse Main fuse INE Thermo ae 112 118 C 234 444 F Below 108 C 226 F 1 12 GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE TORQ UE FASTENER TYPE Ibf ft FASTENER kgf m 5 mm bolt and nut 5 0 5 3 6 5 mm screw 4 0 4 2 9 6 mm bolt and nut include SH 10 1 0 7 6 mm screw 9 0 9 6 5 flange bolt 6 mm flange boit and nut Include 12 1 2 9 8mm bolt and nut 22 2 2 16 NSHF 10 mm boit and nut 34 3 5 25 8 mm flange bolt and nut 26 2 7 20 12 mm boit and nut 54 5
7. 1 654 Unit mm in SERVICE LIMIT 42 10 1 657 0 06 0 002 0 06 0 002 0 05 0 002 41 90 1 650 Cytinder Piston Piston mark direction piston rings Piston O D IN mark facing toward the intake side D 41 97 41 99 1 652 1 653 Piston O D measurement point 14 0 0 55 from bottom of skirt 13 002 13 008 0 5119 0 5121 13 04 0 513 Piston pin O O 12 994 13 000 0 5116 0 5118 12 98 0 511 0 002 0 014 0 0001 0 0006 0 04 0 002 0 080 0 0031 Second 0 015 0 05 0 0006 0 002 0 080 0 0031 Piston ring end gap Top 0 05 0 15 0 002 0 006 0 30 0 012 Second 0 20 0 35 0 008 0 014 0 50 0 020 Oil side rail 0 10 0 60 0 004 0 024 0 80 0 031 a Ee Cylinder to piston clearance 0 010 0 040 0 0004 0 0016 0 10 0 004 Connecting rod small end 1 0 13 016 13 034 0 5124 0 5131 13 044 0 5135 Connecting rod to piston pin clearance 0 010 0 040 0 0004 0 0016 0 06 0 002 Piston to piston pin clearance Piston ring to ring groove clearance 1 8 CRANKCASE TRANSMISSION CRANKSHAFT Transmission Shift fork Shift fork shaft Crankshaft ITEM Gear D Bushing O D Bushing I D M4 M5 C1 C2 j M4 M5 C1 C2 GENERAL INFORMATION STANDARD 23 000 23 021 0 9055 0 9063 25 020 25
8. 5 40 10 mm flange bolt and nut 39 4 0 29 Torque specifications listed below are for important fasteners Others should be tightened to standard torque values listed above NOTES 1 Apply sealant to the threads 2 Apply locking agent to the threads 3 Apply molybdenum disulfide oil to the threads and flange surface 4 Left hand threads 5 Stake 6 Apply oil to the threads and flange surface 7 Apply clean engine oil to the O ring 8 UBS bolt 9 U nut 10 ALOC bolt ENGINE QTY THREAO TORQUE DIA mm kgf m Ibf ft MAINTENANCE Spark plug 10 12 1 2 9 Crankshaft hole cap 15 1 5 11 Timing hole cap 10 1 0 7 Valve adjusting screw lock nut 17 1 7 12 Oil drain bolt 25 2 5 18 LUBRICATION SYSTEM Oil pump mounting boit 14 1 4 10 FUEL SYSTEM Caburetor insutator band screw 5 5 0 5 3 6 PAIR check valve cover bolt 5 0 5 3 6 COOLING SYSTEM Water pump drain bolt Water pump impeller Cooling fan nut ENGINE REMOVAL INSTALLATION Drive sprocket setting plate bolt CLUTCH GEARSHIFT LINKAGE Clutch center lock nut Clutch pressure plate bolt Gear shift stopper arm pivot bolt Gear shift cam plate bolt 13 1 3 9 12 1 2 9 1 0 1 0 7 12 1 2 9 108 11 80 NOTE 5 6 12 1 2 9 12 1 2 9 NOTE 6 23 2 3 17 NOTE 2 1 13 GENERAL INFORMATION ENGINE Cont d ITEM THREAD TORQUE Ka DIA mm N m kgf m Ibf ft CYLINDER HEAD VALVE
9. fender Installation is in the reverse order of removal 2 5 FRAME BODY PANELS EXHAUST SYSTEM FRONT COWL WINDSHIELD SCREEN SIRE VES WASHERS WINDSHIELD SCREEN CAUTION Do not scratch and damage the windshield screen Remove the screws washers and windshield screen Remove the setting nut Installation is in the reverse order of removal SETTING NUT INNER CENTER COWL Remove the lower bolts of the front cowl assembly Remove the trim crips and inner center piece Remove the trim crips and inner center cowl Installation is in the reverse order of removal INNER ENTER PIECE TRIM CRIPS INNER CENTER COWL FRAME BODY PANELS EXHAUST SYSTEM FRONT COWL ASSEMBLY REMOVAL TRIM CRIPS METER LID Remove the inner center piece and inner center cowl page 2 6 Remove the trim crips and meter lid Remove the combination meter page 18 6 FRONT COWL ASSEMBLY UPPER BOLTS COLLARS Remove the upper boits collars socket bolts and front cow assembly NOTE Be careful not to damage the front cow assembly Disconnect the head light position light 4P connector and Left and right turn signal light 2P connectors SOCKET BOLTS DISASSEMBLY Remove the windscreen page 2 6 Remove the bolts and headlight HEADLIGHT BOLT Remove the trim crips screws and meter panel Remove the left and right front cowls Remove the screws and turn signal lights Installation is in the reverse order of rem
10. 041 0 9850 0 9859 22 959 22 980 0 9039 0 9047 24 979 25 000 0 9834 0 9843 C3 20 020 20 041 0 7882 0 7890 18 000 18 018 0 7087 0 7094 20 000 20 021 0 7874 0 7882 Unit mm in SERVICE LIMIT 23 04 0 907 25 06 0 987 22 94 0 903 24 96 0 983 20 06 0 790 18 04 0 710 20 04 0 789 22 000 22 021 0 8661 0 8670 22 04 0 868 Gear to bushing clearance Mainshaft O D Countershaft O D M4 M5 C1 C2 C3 M4 bushing 0 020 0 062 0 0008 0 0024 19 959 19 980 0 7858 0 7866 0 10 0 004 C1 bushing C2 bushing Bushing to shaft clearance Claw thickness O D Shift drum O D atleft side journal 17 966 17 984 0 7073 0 7080 19 974 19 987 0 7864 0 7869 C3 bushing 21 959 21 980 0 8645 0 8654 M4 0 040 0 082 0 0016 0 0032 0 016 0 052 0 0006 0 0020 19 94 0 785 17 95 0 707 19 95 0 785 21 94 0 864 0 10 0 004 0 08 0 003 0 013 0 047 0 0005 0 0019 0 08 0 003 Connecting rod big end side clearance Connecting rod big end radial clearance gd 0 020 0 062 0 0008 0 0024 12 000 12 018 0 4724 0 4731 4 930 5 000 0 1941 0 1969 11 957 11 968 0 4707 0 4712 13 966 13 984 0 5498 0 5506 0 05 0 70 0 002 0 028 0 09 0 004 ex GENERAL I
11. 25 mm Pilot screw wrench Plate 200 x 300 x 20 Snap ring pliers Driver handle Steering stem driver Driver attachment Steering stem cap nut wrench Steering stem socket wrench Universal bearing puller Vacuum gauge attachment Valve guide driver 5 mm 07746 0010800 07746 00 10700 07746 1870100 07746 0010100 077 46 0010300 07XMF KGB0100 07 0200 07746 0050400 07936 GE00200 07936 KC10200 07936 GE00100 07936 KC10100 07746 0050100 07741 0010201 07401 0010000 07724 0050002 07965 VM00100 07965 VM00200 07749 0010000 07946 MJ00100 07725 0040000 07KMC HE00100 07747 0010100 07947 KA20200 07724 0010200 07945 4150400 07PMD KBP0100 07HGJ 0020100 07746 0040100 07746 0040200 07746 0040300 07746 0040400 07746 0040500 07746 0040600 07908 4730002 07XMF KGBO0300 07914 SA50001 07953 MJ 10200 07946 MB00000 07953 MJ10100 07716 0020400 07916 3710101 07631 0010000 07510 3000100 07942 MA60000 REMARKS REF SEC 11 12 13 11 11 11 1 16 GENERAL INFORMATION Cont d Valve guide reamer 07984 60001 Valve spring compressor 07757 0010000 Valve spring compressor attachment 07959 KM30101 Valve seat cutter Seat cutter 24 5 mm 45 IN 07780 0010100 Seat cutter 22 mm 45 EX 07780 0010701 Flat cutter 25 mm 32 IN 07780 0012000 Flat cutter 22 mm 32 EX 07780 0012601 Interior cutter 22 mm 60 IN EX 07780 0014202 Cutter holder
12. 4 0 785 CYLINDER HEAD VALVE Unit mm in ITEM STANDARD SERVICE LIMIT Cylinder compression 1 304 kPa 13 3 kgf cm 189 psi at 500 min7 rpm Cylinder head warpage 0 05 0 002 Valve valve Vaive clearance 0 15 0 02 0 006 0 001 guide 0 24 0 02 0 009 0 001 Valve stem O D 4 975 4 990 0 1959 0 1965 4 965 0 1955 Valve guide 5 000 5 012 0 1969 0 1973 5 03 0 198 5 000 5 012 0 1969 0 1973 5 03 0 198 Stem to guide clearance 0 010 0 037 0 0004 0 0015 0 065 0 0026 FE 080 110 10035 00 150008 Valve spring free length IN 38 00 1 496 36 5 1 44 bsc MNA Camshaft Cam lobe height iN 28 8527 29 0927 1 13593 1 14538 28 82 1 135 28 8849 29 1249 1 13720 1 14665 28 85 1 136 Identification marks Front F Rear R Rocker arm shaft O D 9 972 9 987 0 3926 0 3932 9 92 0 391 Rocker arm to rocker arm shaft clearance 0 013 0 043 0 0005 0 0017 0 10 0 004 CLUTCH SYSTEM GEARSHIFT LINKAGE ITEM Clutch lever free play Clutch spring free length Clutch disc thickness Clutch plate warpage Clutch outer guide Mainshaft O D at clutch outer guide GENERAL INFORMATION TEE en CYLINDER PISTON ITEM 4200 42 07 17 654
13. 5 mm 07781 0010400 1 17 GENERAL INFORMATION LUBRICATION amp SEAL POINTS ENGINE Camshaft camsurffjournals Molybdenum Valve stem valve guide sliding surface stem end disulfide oil a mixture of Rocker arm slipper surface 1 2 engine oil and 1 2 Rocker arm shaft sliding surface molybdenum disulfide Connecting rod small end inner surface grease Clutch outer sliding surface M 3 C 4 C 5 gear shift fork grooves Clutch outer guide surface Gear engaging and bearing portion Piston pin outer surface Gear shift fork inner surface and shaft Piston pin hole and outer cylindrical surface Piston ring whole surface Primary drive gear lock nut threads and seating surface Flywheel lock nut threads and seating surface Clutch disk lining surface Cylinder stud bolt threads Valve adjusting nut threads Cam chain whole surface Connecting rod bearing surface Ciutch center lock nut threads and seating surface Oil pump inner rotor Cylinder inner surface Camshaft holder bolt threads and seating surface Clutch lifter piece outer surface Clutch lifter arm shaft outer surface Starter clutch sliding area Each ball needle bearing sliding area Each O ring Gearshift spindle shaft outer surface Oil strainer screen rubber frame Scavenging pipe rubber parts Right and left crankcase mating surface Sealant 222 A gt Thermo switch threads Alternator and ignition pulse generator grom
14. ERS BOLTS CARRIER Remove the seat page 2 2 Remove the bolts Remove the rear carrier washers and collars installation is in the reverse order of removal COLLARS 2 3 FRAME BODY PANELS EXHAUST SYSTEM TAIL COVER REAR FENDER MES REMOVAL Remove the seat page 2 2 Remove the rear carrier page 2 3 Remove the bolts Disconnect the tail brake light and rear turn signal connectors Remove the tail cover rear fender Installation is in the reverse order of removal DISASSEMBLV Remove the screws bolts and rear tail cover from the rear fender TAIL COVER BOLTS Remove the screws and turn signal lights Installation is in the reverse order of removal TURN SIGNAL LIGHT TAIL COVER REAR FENDER SCREW REAR FENDER FRAME BODY PANELS EXHAUST SYSTEM IGNITION CONTROL REGULATOR RECTIFIER MODULE REAR INNER FENDER BATTERY BOX Remove the foltowing Seat page 2 2 Left side cover page 2 2 Battery page 15 4 Regulator rectifier page 15 7 Ignition control module page16 9 Starter relay switch page 17 16 BATTERY STARTER RELAY SWITCH e BATTERY CASE OFF LY soi MOUNT BOLTS 2 S ACT SOZ AD CN BATTERY CASE KEY CYLINDER WIRE REAR FENDER MOUNT BOLTS COLLARS Remove the battery mount bolts and battery case Disconnect the wire and remove the key cylinder Remove the mount bolts collars and rear inner
15. ING ANY OBLIG ATION WHATEVER NO PART OF THIS PUBLICA TION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWL EDGE OF MAINTENANCE ON HONDA MOTORCY CLES MOTOR SCOOTERS OR ATVS HONDA MOTOR CO LTD SERVICE PUBLICATION OFFICE CONTENTS GENERAL INFORMATION FRAME BODY PANELS EXHAUST SYSTE MAINTENANCE Bee LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL INSTALLATION 7 CLUTCH GEARSHIFT LINKAGE CYLINDER HEAD VALVE CYLINDER PISTON CRANKCASE TRANSMISSION CRAN FRONT WHEEL SUSPENSION STEERING REAR WHEEL SUSPENSION ENGINE AND DRIVE TRAIN A esch HASSIS BRAKE SYSTEM C CHARGING SYSTEM ALTERNATOR IGNITION SYSTEM ECTRIC STARTER STARTER CLUTCH LIGHT METER SWITCHES m 17 ELECTRICAL WIRING DIAGRAM TROUBLESHOOTING N N SYMBOLS The symbols used throughout this manual show specific service procedures If supplementary information is required pertaining to these symbols it would be explained specifically in the text without the use of the symbols Replace the part s with new one s before assembly Use recommended engine oil unless otherwise specified Use molybdenum oil solution mixture of the engine oil and molybde
16. NFORMATION FRONT WHEEL SUSPENSION STEERING ECH ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 1 5 0 06 Cold tire pressure 200 kPa 20 kale 28 Driver and passenger 200 kPa 2 0 kgf cm 29 psi 0 20 0 008 Axle runout Wheel rim runout Radiat 1 0 0 04 Axial er OT Wheel balance weight 60 g 2 1 oz max Fork Spring free length 470 6 18 53 461 18 15 Tube runout 0 20 0 008 Recommended fluid Fork fiuid Fluid capacity 346 2 5 11 7 0 08 US oz 12 2 0 09 Imp oz Steering head bearing pre load 0 10 0 15 kgf 0 220 0 330 Ibf REAR WHEEL SUSPENSION SERVICE UMT Minimumtre weed 2 _ 225 kPa 2 25 33 psi 0 008 0 20 Radial 1 0 0 04 Wheel weight Pee 60 g 2 1 oz max Axle runout Wheel runout 60 2308 Drive chain link 520V6 520 SMOZ2 REGINA 135 ORNV2 DID Drive chain size 1 10 BRAKE SYSTEM Front Rear GENERAL INFORMATION Unit mm in ITEM STANDARD SERVICE LIMIT Specified brake fluid DOT3 or DOT4 Brake pad wear indicator To groove Brake disc thickness 3 8 4 2 0 15 0 17 3 5 0 13 Brake disc runout 0 1 0 004 Master cylinder LD 11 000 11 043 0 4331 0 4348 11 055 0 4352
17. RTER MOTOR WIRE WIRE 1 22 GENERAL INFORMATION ut EG SIPHON AES EM Gegen 5 i FAN MOTOR SWITCH WIRE SPARK PLUG WIRE CLUTCH CABLE WATER HOSE 1 23 GENERAL INFORMATION LIGHT SWITCH WIRE REAR BRAKE AIR SUPPLY HOSE REAR SPARK PLUG WIRE x lt Dn o 2 Q LL PLUG WIRE WATER TUBE STARTING ENRICHMENT SE VALUE CABLES DRAIN TUBE 1 24 GENERAL INFORMATION LIGHT SWITCH REAR BRAKE WIRE N NS d PERS ES Dr gt lt N N REAR BRAKE HOSE IGNITION CONTROL MODULE ICM WIRE MAIN WIRE HARNESS V 5 26 OIA GE L3 p wi E ON E ees Get Eat ZA MeL KA a gt Za p STARTER RELAY BATTERY POSITIVE WIRE SWITCH WIRE BATTERY NEGATIVE WIRE 1 25 TURN SIGNAL WIRE GY iS YAS GENERAL INFORMATION EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons Controlling hydrocarbon emission is very important because under certain conditions they react to form photochemical smog when subjected to suniight Carbon monoxide does not react in the same way but it is toxic Honda Moter Co Ltd utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydro carbons CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent di
18. SG Viscosity SAE 10W 40 Oil pump rotor Tip clearance 0 15 0 006 0 20 0 008 Body clearance 0 15 0 21 0 006 0 008 0 25 0 010 0 03 0 11 0 001 0 004 0 15 0 006 Carburetor identification number Main jet 2 88 438 FUEL SYSTEM Slow jet Jet needle number C12B fnitial final opening See page 5 18 13 7 mm 0 54 in Front cylinder 2 1 500 gt 100 min rpm 280 mm Hg 11 02 in Hg 2 6 mm 1 16 1 4 in Rear Pilot screw Float level Base carburetor for synchronization Idle speed PAIR control valve specified vacuum Throttle grip free play COOLING SYSTEM ITEM SPECIFICATIONS Coolant capacity Radiator and engine 1 03 liter 1 08 US qt 0 95 Imp qt Reserve tank 0 24 liter 0 25 US qt 0 21 Imp qt Radiator cap relief pressure 108 1 1 kgf cm 16 psi Thermostat Begin to open 81 84 C 178 183 F Fully open 95 C 203 F Valve lift 4 5 mm 0 18 in minimum Standard coolant concentration 50 mixture with soft water GENERAL INFORMATION 10 20 3 8 13 16 42 1 166 2 92 3 08 0 115 0 121 2 92 3 08 0 115 0 121 Unit mm in SERVICE LIMIT WEE 2 6 0 10 0 30 0 012 20 010 20 035 0 7878 0 7888 20 05 0 789 25 959 25 980 1 0220 1 0228 25 94 1 021 19 959 19 980 0 7858 0 7866 19 9
19. at page 2 2 Remove the side covers page 2 2 Loosen the muffler band bolt Remove the muffler mounting bolts and muffler Loosen the rear exhaust pipe band bolt and remove the rear exhaust pipe joint nuts gasket and rear exhaust pipe Remove the front exhaust joint nuts gasket and front exhaust pipe FRAME BODY PANELS EXHAUST SYSTEM MUFFLER MUFFLER MOUNTING BOLTS MUFFLER BAND BOLT GASKET REAR EXHAUST PIPE EXHAUST REAR EXHAUST BAND BOLT PIPE PIPE JOINT NUTS w FRONT EXHAUST FRONT EXHAUST PIPE PIPE JOINT NUTS 2 9 FRAME BODY PANELS EXHAUST SYSTEM INSTALLATION GASKET REAR EXHAUST PIPE JOINT NUTS Q MUFFLER E wr S MUFFLER A Y MOUNTING BOLT GASKET 2 GASKETS BAND FRONT FRONT BOLT EXHAUST EXHAUST PIPE PIPE JOINT NUT Replace the gaskets with new ones installation is in the reverse order of removal Tighten the boits and nuts to their specified torque TORQUE Exhaust pipe joint nut 18 N m 1 8 kgf m 13 Ibf ft Muffler band bolt 20 12 0 kgf m 14 Ibf ft Muffler mounting bolt 32 N m 3 3 kgf m 24 Ibf ft 2 10
20. gal 2 0 liter 0 53 US gal 0 44 Imp gal 42 0 x 45 0 mm 1 65 x 1 77 in 125 cm 7 6 cu in 11 8 1 Silent multi link chain driven SOHC with rocker arms 6 BTDC 24 ABDC 31 BBDC 9 ATDC Forced pressure dry sump Trochoid Liquid cooled Viscous paper element 40 5 kg 89 29 Ibs CARBURETOR DRIVE TRAIN ELECTRICAL GENERAL Cont d Carburetor Type Throttle bore Clutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio Gearshift pattern Ignition system Starting system Charging system Regulator rectifier Lighting system GENERAL INFORMATION SPECIFICATIONS CV Constant Velocity dual carburetor 22 mm 0 9 in Multi plate wet Mechanical type Constant mesh 5 speed 3 722 67 18 3 142 44 14 3 083 37 12 1 933 29 15 1 428 30 21 1 173 27 23 1 000 25 25 Left foot operated return system 1 2 3 4 5 Full transistor digital ignition Electric starter motor Tripte phase output alterator SCR shorted triple phase full wave rectification Battery GENERAL INFORMATION LUBRICATION SYSTEM Unit mm in ITEM STANDARD SERVICE LIMIT Engine oil capacity at draining 1 1 liter 1 2 US qt 1 0 Imp qt at disassembly 1 5 liter 1 6 US qt 1 3 imp qt at filter change 1 2 liter 1 3 US qt 1 1 Imp qt Recommended engine oil HONDA 4 stroke oil or equivalent motor oi API service classification SE SF or
21. inder pistons and cups Rear caliper piston sliding surface DOT 3 or DOT 4 brake fluid Throttle cable casting inside Clutch cable casing inside Caliper piston seal sliding surface Caliper pin sliding surface Final driven flange bolt threads Rear caliper nut threads Front caliper pin threads Front caliper nut threads Fork socket boit threads Handle grip rubber inside surfaces Front fork inside Silicone grease Locking agent Honda band A or Cemedine 540 Fork fluid cO GENERAL INFORMATION CABLE amp HARNESS ROUTING THROTTLE CABLES CLUTCH CABLE C i m YL A 7 1 X b YL Vay f 7 7 LEFT HANOLEBAR SWITCHWIRE BRAKE HOSE 4 COMBINATION METER WIRE RIGHT FRONT TURN SIGNAL WIRE LEFT FRONT TURN SIGNAL WIRE TURN SIGNAL RELAY WIRE 1 20 GENERAL INFORMATION THROTTLE CABLES ENGINE STOP SWITCHWIRE 5 Xy Tp AIR INJECTION HOSE z MAIN WIRE HARNESS 22 LEFT HANDLEBAR SWITCH WIRE RADIATOR RESERVE TANK OVER FLOW TUBE pes dts 7 22 CX e J FUEL TUBE SPEED SENSOR WIRE SIPHON TUBE 1 21 GENERAL INFORMATION MAIN WIRE THERMO SWITCH WIRE ENGINE COOLANT THROTTLE CABLES HARNESS TEMPLATURE SENSOR WIRE L NP SIDE STAND SWITCHWIRE SPEED SENSOR WIRE IIG TYPE ONLY GROUND NEUTRAL SWITCH WIRE WIRE ALTERNATOR STA
22. liper pad pin 1 18 1 8 13 Front caliper pad pin plug 1 2 0 2 1 4 Rear brake reservoir tank bolt 1 12 1 2 9 Rear brake oil boit 2 34 3 5 25 Rear master cylinder mounting bolt 2 12 1 2 9 Rear master cylinder push rod nut 1 17 1 7 12 Rear master cylinder cover screw 2 2 0 2 1 4 Rear caliper pin 1 17 1 7 12 Rear caliper pad pin 1 17 1 7 12 Rear caliper pad pin plug 1 2 0 2 1 4 LIGHTS METERS SWITCHES Thermo switch 18 1 8 13 OTHER FASTENERS Side stand pivot boit 10 1 0 7 Side stand lock nut 29 3 0 22 NOTE 9 Side stand switch bott 10 1 0 7 1 15 GENERAL INFORMATION TOOLS NOTES 1 Alternative tool 2 Newly provided tool DESCRIPTION TOOL NUMBER Attachment 22 x 24 mm Attachment 24 x 26 mm Attachment 28 x 30 mm Attachment 32 x 35 mm Attachment 42 x 47 mm Bearing installer 37 42 Bearing installer 37 5 Bearing remover head Bearing remover head Bearing remover head Bearing remover shaft Bearing remover shaft Bearing remover shaft Bearing remover weight Carburetor float level gauge Clutch center holder Crank shaft assembly collar Crankshaft assembly shaft Driver Driver shaft Flywheel holder Flywheel puller Fork seat driver body Fork seai driver attachment Gear hoider Mechanical seal driver attachment Mechanical seal driver Peak voltage adapter Pilot 10 mm Pilot 12 mm Pilot 15 mm Pilot 17 mm Pilot 20 mm Pilot
23. mets Water pump mechanical seal flange Cam chain tensioner tighting bolt threads Locking agent Gearshift cam plate bolt threads Mainshaft bearing set plate bolt threads Gearshift drum bearing set plate bolt threads Fan motor shaft threads Cam sprocket bolt threads Engine oil Cylinder head cover gasket Honda Bond A or equivalent 1 18 GENERAL INFORMATION FRAME LOCATION Clutch lever pivot sliding surface Throttle grip pipe rolled up portion Rear brake pedal pivot sliding surface Gearshift pedal pivot sliding surface Side stand pivot sliding surface Front wheel dust seal lip area Rear wheel dust seal lip area Rear wheel O ring whole Final driver flange gap with rear hub Final driver flange dust seal lip area Steering head upper bearing Steering head lower bearing Steering head dust seal lips Rear caliper pin bolt Rear master cylinder push rod contact area Front brake lever pivot and piston contact area Front brake lever pivot sliding area Front fork oil seal lips Swingarm pivot dust seal lips Swingarm pivot bearing and center collar sliding surface Swingarm pivot bush and collar sliding surface Speedometer gear box inside Speedometer gear sliding portion Steering top threads Front engine hanger bolt threads Rear engine hanger bolt threads Upper engine hanger bolt threads MATERIAL REMARKS Multi purpose grease Grease Engine oil Brake master cyl
24. nder head covers 9 25 Refit air cleaner housing 5 4 Refit radiator 6 12 Refit front inner fairing 2 6 Refit fuel tank 2 8 Refill coolant and bieed system 6 6 HOW TO USE THIS MANUAL This service manual describes the service procedures for the XL125V Follow the Maintenance Schedule Section 3 recom mendations to ensure that the vehicle is in peak oper ating condition Performing the first scheduled maintenance is very important It compensates for the initial wear that occurs during the break in period Sections 1 and 3 apply to the whole motorcycle Section 2 illustrates procedures for removal installa tion of components that may be required to perform Service described in the following sections Sections 4 through 20 describe parts of the motorcycle grouped according to location Find the section you want on this page then turn to the table of contents on the first page of the section Most sections start with an assembly or system illus tration service information and troubleshooting for the section The subsequent pages give detailed procedure if you don t know the source of the trouble go to sec tion 21 Troubleshooting ALL INFORMATION ILLUSTRATIONS DIREC TIONS 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 INCURR
25. num grease in a ratio of 1 1 Use multi purpose grease Lithium based multi purpose grease NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste containing more than 40 motybdenum disulfide NLGI 2 or equivalent Example Molykote Paste manufactured by Dow corning U S A Honda Moly 60 U S A only Rocol ASP manufactured by Rocoi Limited U K Rocol Paste manufactured by Sumico Lubricant Japan Use silicone grease Apply a locking agent Use a middle strength locking agent unless otherwise specified Apply sealant Use DOT 4 brake fluid Use the recommended brake fluid unless otherwise specified Use Fork or Suspension Fluid 1 GENERAL INFORMATION TOOLS LUBRICATION amp SEAL POINTS CABLE amp HARNESS ROUTING EMISSION CONTROL SYSTEMS GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES GENERAL SAFETY CARBON MONOXIDE the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area A WARNING The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death Run the engine in an open area or wi
26. othing and a face shield ff electrolyte gets on your skin flush with water ff electrolyte gets in your eyes flush with water for at least 15 minutes and call a physician immediately Electrolyte is poisonous swallowed drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician KEEP OUT OF REACH OF CHILDREN GENERAL INFORMATION SERVICE RULES 1 Use genuine HONDA HONDA recommended parts and lubricants or their equivatents Parts that 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 The use of incorrect tools and fasteners may damage the motorcycle Install new gaskets O rings cotter pins lock plates etc when reassembling When tightening a series of bolts or nuts begin with the larger diameter of inner bolts first and tighten to the speci fied torque diagonally in incremental steps unless a particular sequence is specified Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly After assembly check all parts for proper installation and operation Route all electrical wires as show on pages 1 through 1 Cable and Harness Routing 1 2 GENERAL INFORMATION
27. oval METER RIGHT FRONT COWL PANEL TURN SIGNAL LIGHT LEFT FRONT COWL 2 7 FRAME BODY PANELS EXHAUST SYSTEM FUEL TANK REMOVAL BREATHER TUBE FUEL TANK BOLT COLLAR 707 Gasoline is extremely flammable is explosive under certain conditions Work in a well ventilated area Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire explosion CAUTION Do not damage the front cow assembly and fuel tank Remove the seat page 2 2 Turn the fuel valve OFF Disconnect the fuel tube from the fuel joint NOTE At removal be careful not to damage the fuel sensor 2P connector and wire Remove the lower bolts and socket bolts from the front cowl assembly SOCKET FUEL JOINT BREATHER BOLT TUBE Remove the boit collar and fuel tank Disconnect the breather tube DISASSEMBLY PARR Loosen the fuel valve nut and remove the fuel valve Remove the strainer screen and O ring Check the fuel strainer screen for clogs or damage and clean or replace if necessary Install the new O ring to the fuel strainer screen Attach the fuel strainer screen to the fuel valve and install to the fuel tank STRAINER NOE SCREEN Always replace the O ring with new one Tighten the fuel valve nut securely O RING FUEL VALVE FUEL VALVE NUT MUFFLER EXHAUST PIPE REMOVAL fr Do not service the exhaust system while it is hot Remove the se
28. scharging crankcase emissions into the atmospher Blow by gas is returned to the combustion chamber through the air cleaner and carburetor AIR CLEANER CASE CARBURETOR BLOW BY GAS ex FRESH AIR 1 27 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 puise in the exhaust system This charge of fresh air promotes burning of the unburned exhaust gases and changes a consid erable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor This model has the pulse secondary air injection PAIR control valve and PAIR check valve Pair check valve prevents reverse air flow through the system The PAIR control valve reacts to high intake manifold vacuum and will cut off the supply of the fresh air during engine deceleration thereby preventing afterburn in the exhaust system No adjustment to the pulse secondary air injection system should be made although periodic inspection of the compo nents is recommended AIR CLEANER PULSE SECONDARY AIR INJECTION PAIR CHECK VALVE 3 per TIT 22712212117 PULSE SECONDARY AIR INJECTION PAIR CONTROL VALVE CARBURETOR EXHAUST PORT 1 28
29. st the exhaust pipe may not seat properly Always inspect the exhaust system for leaks after installation TORQUE VALUES Muffler band bolt 20 N m 2 0 kgf m 14 Ibf ft Exhaust pipe joint nut 18 1 8 kgf m 13 Ibf ft Muffler mounting boit 32 N m 3 3 kgf m 24 Ibf ft TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler 2 1 FRAME BODY PANELS EXHAUST SYSTEM SEAT REMOVAL Unlock the seat with the ignition key Pull the seat back and remove it INSTALLATION Install the seat by inserting the groove to the prong on the fuel tank and the catches into the hooks of the frame Push the seat forward then down to lock it SIDE COVER Remove the seat see above NOTE Be careful not to damage the bosses of the side cover Remove the bolt and screw Remove the boss of the side cover from the grommet and remove the side cover Installation in the reverse order of removal SIDE COVER BOSS GROMMET SEAT IGNITION KEY BOLT SIDE COVER BOSS GROMMET FRAME BODY PANELS EXHAUST SYSTEM SPEED SENSOR CABLE GROMMET FRONT FENDER FRONT FENDER Remove the speed sensor cable grommet Remove the bolts brake hose cramp front fender and front fender stay Installation is in the reverse order of removal BOLTS BRAKE HOSE FRONT CRAMP FENDER STAY REAR REAR CARRIER WASH
30. th an exhaust evacuation system in an enclosed area GASOLINE Work in a well ventilated area Keep cigarettes flames or sparks away from the work area or where gasoline is stored ENS 10D Gasoline is extremely flammable and is explosive under certain conditions KEEP OUT OF REACH OF CHILDREN HOT COMPONENTS A WARNING Engine and exhaust system parts become very hot and remain hot for some time after the engine is run Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts USED ENGINE OIL E 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 stil advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil KEEP OUT OF REACH OF CHIL DREN BRAKE FLUID CAUTION Spilling fluid on painted plastic or rubber pasts will damage them Place a clean shop towel over these parts whenever the system is serviced KEEP OUT OF REACH OF CHILDREN BATTERY HYDROGEN amp ELECTROLYTE The battery gives off explosive gases keep sparks flames and cigarettes away Provide adequate venti lation when charging or using the battery in an enclosed space The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns Wear protective cl
31. ut 2 10 39 4 0 29 Engine hanger bracket bolt 1 8 18 1 8 13 FRONT WHEEL SUSPENSION STEERING Fork bolt 2 28 22 2 2 16 Fork socket bolt 2 8 20 2 0 14 NOTE 2 Handlebar holder bolt 4 8 24 2 4 17 Steering stem nut 1 24 103 10 5 76 Steering top thread 1 26 See page 12 26 Top bridge pinch bolt 2 8 26 2 7 20 Bottom bridge pinch 4 8 34 3 5 25 Front axle bolt 1 14 66 6 7 48 Front axle pinth bolt 1 8 22 2 2 16 Front brake disc bolt 4 8 42 4 3 31 NOTE 10 Throttle housing screw 5 4 0 4 2 9 1 14 GENERAL INFORMATION FRAME Cont d THREAD TORQUE QTV oa mm kgf m Ibt ft REMARKS REAR WHEEL SUSPENSION Rear axle nut 1 88 9 0 65 NOTE 9 Driven sprocket nut 6 64 6 5 47 NOTE 9 Rear brake disc bolt 4 42 4 3 31 NOTE 10 Shock absorber upper mounting nut 1 44 4 5 33 NOTE 9 Shock absorber lower mounting nut 1 44 4 5 33 Swingarm pivot nut 1 88 9 0 65 NOTE 9 Chain slider screw 2 3 0 3 2 2 Chain adjuster lock nut 2 10 1 0 7 BRAKE SYSTEM Front brake oil 2 34 3 5 25 Front master cylinder holder bolt 2 12 1 2 9 Front master cylinder cover screw 2 2 0 2 1 4 Front brake light switch screw 1 1 0 1 0 7 Brake lever pivot nut 1 6 0 6 4 3 Brake lever pivot bolt 1 1 0 1 0 7 Front brake caliper mounting bolt 1 30 3 1 22 NOTE 10 Front caliper pin bolt main 1 18 1 8 13 Front caliper pin bolt sub 1 23 2 3 17 Front ca
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