Honda 2000 XR50R Service Manual Download Page 1

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Summary of Contents for 2000 XR50R

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Page 3: ...may be required to perform service described in the following sections Section 4 through 14 describe parts ofthe motorcycle grouped according to location Find the section you want on this page then tu...

Page 4: ...num disulfide grease containing more than 3 molybdenum disulfide Nl GI 2 or equivalent Example Molykotetl BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil J...

Page 5: ...ine is extremftJy flammable and is explosive under certain conditions KEEP OUT OF REACH OF CHILDREN TOOLS LUBRICATION SEAL POINTS CABLE HARNESS ROUTING EMISSION CONTROL SYSTEMS EMISSION CONTROL INFORM...

Page 6: ...not interchangeable with English fasteners 4 Install new gaskets D rings cotter pins and lock plates when reassembling 5 When tightening bolts or nuts begin with the larger diameter or inner bolt fir...

Page 7: ...or body as shown GENERAL INFORMATION FRAME SERIAL NUMBER 111 The frame serial number is stamped on the left side of the steering head 3 The Vehicle Identification Number VIN is located on right side o...

Page 8: ...10 33J Tire brand CHENG SHIN Front Rear C 183A Front brake Internal expanding shoe Rear brake Internal expanding shoe Caster angle 25 30 Trail length 35 mm 1 4 in Fuel tank capacity 3 0 II 0 79 US gal...

Page 9: ...Multi plate wet Clutch operation system Automatic centrifugal Transmission 3 speed Primary reduction 4 058 69 17 Final reduction 2 642 37 14 Gear ratio 3 272 36 2nd 1 667 25 15 3 d 1 190 25 21 Gearsh...

Page 10: ...SYSTEM ITEM Carburetor identification number Main et Slow at Jet needle eli osition Air screw initial 0 enin Float level Idle seed Throttle ri free la SPECIFICATIONS PA42A 58 35x 35 2nd rcove from to...

Page 11: ...AM CHAIN TENSIONER ITEM STANDARD STANDARD 2 52 2 68 O a9S 0 106 3 32 3 48 0 131 0 137 22 4 0 88 21 000 21 021 0 8268 0 8276 16 988 17 006 0 6688 0 6695 20 930 20 950 0 8240 0 8248 16 966 16 98410 6680...

Page 12: ...GENERAL INFORMATION CRANKSHAFT TRANSMISSION KICKSTARTER ITEM STANDARD SERVICE LIMIT I I 1 8...

Page 13: ...rim te hub distance Wheel rim runout Radia Axial Drive chain Size link Stack Brake Brake dal free I Brake drum 1 0 Brake lining thickness IGNITION SYSTEM ITEM plug 100kPa 1 0k ffern2 15 si 6 3 1 0 0...

Page 14: ...gf m Ibf ft REMARKS MAINTENANCE Spark plug 1 10 12 1 2 9 Oil drain bolt 1 12 25 2 5 18 Valve adjuster hole cap 2 30 12 1 2 9 NOTE 1 Valve adjuster lock nut 2 5 9 0 9 6 5 Clutch adjuster lock nut 1 8 1...

Page 15: ...witch thronle hounsing screw 2 5 3 0 3 2 2 Brake lever pivot bolt 1 5 3 0 3 2 2 Brake lever pivot nut 1 5 310 3 2 2 Spoke nipple 28 BC2 3 2 0 2 1 4 Front axle nut 1 12 47 4 8 35 NOTE 3 Front brake arm...

Page 16: ...ot 17 mm 07746 0040400 Bearing remover shaft 07746 0050100 NOTE 1 12 13 Bearing remover head 12 mm 07746 0050300 NOTE 1 12 13 Driver 07749 0010000 11 12 13 Valve spring compressor 07757 0010000 7 Valv...

Page 17: ...g surface gear teeth and shifter groove Shift drum outer surface Kickstarter spindle sliding surface Other rotating and sliding area Each bearing rotating area Each oil seal lips Each O rinn r FRAME L...

Page 18: ...RMATION CABLE HARNESS ROUTING THROTTLE CABLE BRAKE CABLE ENGINE STOP SWITCH WIRE FUEL TANK BREATHER TUBE AIR CLEANER HOUSING FUEL TUBE WIRE BANDS FUEL TUBE THROTTLE CABLE BRAKE CABLE ENGINE STOP SWITC...

Page 19: ...ROTTLE CABLE SPIIRKPLUG WIRE CARBURETOR AIR VENT TUBE THROTTLE CABLE CUP 5 1Qmm CLAMP IGNlnON SWITCH WIRE IGNITION 1 ENGINE STOP SWITCH WIRE SWITCH WIRE CRANKCASE BREATHER STORAGE TANK o CRANKCASE BRE...

Page 20: ...GENERAL INFORMATIO N _____________________ IGNITION CONTROL MODULE leM o o CLAMP MAIN WIRE HARNESS 1 16...

Page 21: ...s toxic Honda Motor Co Ltd utiliz es lean carburetor senings as well as other systems to reduce carbon monoxide and hydrocarbons EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is...

Page 22: ...ORMATION EMISSION CONTROL INFORMATION LABEL Except Canada type 1 18 The Vehicle Emission Control Information Label is attached on the reverse side of the left fuel tank shroud EMISSION CONTROL INFORMA...

Page 23: ...and exhaust system Always replace the exhaust pipe gasket after removing the exhaust system from the engine When installing the exhaust system loosely install all of the fasteners Always tighten the...

Page 24: ...and remove it INSTALLATION Install the seat assembly by inserting the prongs into the retainers on the frame Install the bolts and screws and tighten them Install the trim clips and lock them by push...

Page 25: ...er and collar For fuel strainer Remove the fuel tank service see page 3 4 Installation is in the reverse order of removal BREATHER BOLT AND COLLAR t FUEL TANK BREATHEATUBE NUMBER PLATE NUMBER PlATE Re...

Page 26: ...exhaust pipe joint gasket INSTALLATION Install a new joint gasket into the exhaust port Set the exhaust pipe onto the engine by aligning the exhaust pipe flange with the cylinder head studs then insta...

Page 27: ...t pivot bolt side stand INSTALLAnON Apply grease to the side stand pivot and sliding surfaces Install the side stand with the pivot bolt Tighten the pivot bott TORQUE 10 N m 1 0 kgf m 7Ibf ft Loosen t...

Page 28: ...MEMO...

Page 29: ...TIRES 3 18 STEERING HEAD BEARINGS 3 19 Gasoline s extremely flammable and is explosive undflr cBrtain conditions Work in well ventilated rea Smoking or allowing flames or sparks in the work area or wh...

Page 30: ...PECIFICATIONS 1 6 i 10 6 US at 0 51mo at moa on SF 0 SG l00 om B 1f nl i mm 10 02 0 001 Inl 13 16 nl I If3J ont sl 100 Pe 11 0 I 1 Fcont 3 0 mm 10 12 Inl 9 N m 0 9 kgf m 6 5 Ibf ft 12 N m 1 2 kgf m 9I...

Page 31: ...y C Clean A Replace A Adjust L lubricate H I z I I MAINTENANCE Refer to page 3 12 3 17 Should be serviced by your Honda dealer unless the owner has proper tools and service data and is mechanically qu...

Page 32: ...as drained completely remove the two bolts and collars and remove the fuel valve and strainer screen Wash the fuel strainer screen in non flammable or high flash solvent Check the a ring is in good co...

Page 33: ...on AIR CLEANER Remove the two screws and the air cleaner housing cover Remove the air cleaner element holder and element from the housing Wash the element in non flammable or high flash point solvent...

Page 34: ...ect or replace as described in the maintenance schedule page 3 3 INSPECTION Check the following and replace if necessary rec ommended spark plug page 3 1 Insulator for damage Electrodes for wear Burni...

Page 35: ...1 2 of a turn after the sealing washer contacts the seat of the plug hole Install the spark plug cap VALVE CLEARANCE INSPECTION Inspect and adjust Remove the valve adjuster hole caps the valve clearan...

Page 36: ...A only TORQUE 9 N m 0 9 kgf m 6 5 Ibf ft Recheck the valve clearance Check the valve adjuster hole cap O ring is in good condition replace if necessary Coat the O rings with clean engine oil and insta...

Page 37: ...k ENGINE OIL CHANGE When the engin8 must b running to do some work make sure the area is well ventilsted Never run the engine in an enclosBd area The exhaust contains poisonous carbon monoxidiJ gas th...

Page 38: ...the engine and let it idle for 2 to 3 minutes Stop the engine and recheck the oil level Make sure there are no oil leaks ENGINE OIL STRAINER SCREEN CLEANING Remove the right crankcase cover page 9 3 R...

Page 39: ...ed Th fJxh ust contillns poisonous carbon monoxide g85 that mey cause lass ofconsciousness and lead to death Run the engine in 8n o n area or with an exhaust evacuation system In an enclosttd rllll NO...

Page 40: ...ct drive chain slack is obtained Make sure th index marks on both adjusters are aligned with the index lines on the swingarm Tighten the rear axle nut to the specified torque TORQUE 47 N m 4 8 kgf m 3...

Page 41: ...ain on badly worn sprockets will cause the new chain to wear quickly Inspect the drive and driven sprocket teeth for wear or damage Replace if necessary Never use a new drive chain on worn sprockets B...

Page 42: ...shoes and brak drum jf the arrow on the indicator plate aligns with the A mark on the brake panel when the brake lever is applied Refer to page 12 10 or 13 8 for brake shoe and brake drum inspection B...

Page 43: ...djusting nut adjusting nul is S6ated on the joint pin REAR BRAKE Check the brake pedal free play FREE PLAY 10 20 mm 3 8 13 16 in Make sure he Adjust the brake pedal free play by turning the ad cutout...

Page 44: ...Check the sjd stand spring for damage or loss of tension Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary SUSPENSION 3 16 Loose worn or damaged su...

Page 45: ...ted Also check the pivot bushings for wear or damage Check the action of the shock absorber by compres sing it several times Check the entire shock absorber assembly for signs of leaks damage or loose...

Page 46: ...y clips cramps and cable stays are in place and properly secured WHEELS TIRES Tire pressure RECOMMENDED TIRE PRESSURE AND TIRE SIZE should be checked when the tires are COLD 3 18 FRONT REAR Tire press...

Page 47: ...INGS Ch8ck that the Support the motorcycle securely and raise the front control cables do wheel off the ground not interfere with handlebar Check that the handlebar moves freely from side to rotation...

Page 48: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ROCKERAAM CAMSHAFT PISTON nf t PUMP Oil THROUGH CRANKSHAFT OIL FILTER ROTOR COUNTERSHAFT I J t l lr OIL STRAINER KICKSTAATER 4 0...

Page 49: ...talled in the frame The service procedures in this section must be performed with the engine oil drained When removing and installing the oil pump use care not to allow dust or dirt to enter the engin...

Page 50: ...then remove the inner and outer rotors from the oil pump body INSPECTION If My portion of Temporarily install the outer and inner rotors into the oil pump is the oil pump body worn beyond the Install...

Page 51: ...8 in ASSEMBLY OUTER ROTOR OIL PUMP SHAFT INNER ROTOR Oil PUMP COVER Install the inner and outer rotors into the oil pump body Install the oil pump shaft aligning the flat surfaces of the shaft and inn...

Page 52: ...Install the rotor shaft collar into the crankcase Install a new gasket onto the oil pump body Install the oil pump into the crankcase while align ing the pump shaft groove with the cam chain guide spi...

Page 53: ...MEMO...

Page 54: ...FUELSVSTEM 1 N m 0 1 kgf m 0 7 Ibf ft 5 0...

Page 55: ...ation of the O rings Replace them with new ones on reassembly Before disassembling the carburetor place the suitable container under the carburetor drain tube loosen the screw and drain the carburetor...

Page 56: ...r in CLOSE position Float valve faulty Float level too high Air jets clogged Air cleaner element contaminated Flooded carburetor 5 2 Engine stall hard to start rough idling Fuel line restricted Igniti...

Page 57: ...sem bly Ar instal ation Installation is in the reverse order of remova l secure the ground eyelat with the air clesner housing mounting bolt CARBURETOR REMOVAL Gasoline i extremely flammable snd is ex...

Page 58: ...e under cflrtain conditions Work in B well ventilated Brea Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause II fire or explosion Loosen the drain screw a...

Page 59: ...the float valve Remove the following Main jet Needle jet Throttle stop screw and spring Turn the air screw in and carefully count the number of turns until it seats lightly Make a note of this to use...

Page 60: ...with compressed air Install the following Throttle stop screw and spring Needle jet Main jet CAUTION Handle alfjets with care They can easily be scored or scratched Install the air screw w ith the sp...

Page 61: ...ith the main jet With the float valve seated and the float arm just touching the valve measure the float level with the special toot as shown FLOAT LEVEL 12 7 mm 0 50 in TOOL Carburetor float level ga...

Page 62: ...leaner connecting tube and the insulator between the manifold and carburetor then install the mounting botts Tighten the connecting mounting bolts TORQUE tube band screw and Connecting tube 1 N m 0 1...

Page 63: ...dition replace if necessary Install the throttle valve spring onto the throttle cable Connect the throttle cable to the throttle valve while compressing the throttle valve spring Install the throttle...

Page 64: ...achometer with graduations of 50 rpm or smaller that will accurately indicate 50 rpm change 1 Turn the air screw clockwise until it seats lightly and then back it out to the specification given CAUTIO...

Page 65: ...rankcase breather lube plug and empty any deposits if the deposit level can be seen in the breather tube Install the crankcase breather tube plug and secure it with the clip securely CRANKCASE BREATHE...

Page 66: ...ENGINE REMOVAL INSTALLATION 12 N m 1 2 91bf ft 31 N m 3 2 kgf m IbUt 6 0...

Page 67: ...engine installed in the frame Alternator cam chain tensioner Section 10 Clutch Section 9 Cylinder piston Section 8 Cylinder head valves Section 7 Gearshift linkage Section 9 Oil pump Section 4 The cra...

Page 68: ...Remove the following exhaust system page 2 5 left crankcase cover page 10 2 Disconnect the following spark plug cap ignition pulse generator and exciter coil connectors crankcase breather tube Remove...

Page 69: ...s to loosen the drive chain page 3 12 Remove the following fixing plate bolts fixing plate drive sprocket intake manifold bolts C ring brake peda return spring Supporl the four bolts and footpeg bar m...

Page 70: ...s All bolts are Installed from left side The jack height must be continually adjusted to relieve stress from the hanger boilS Tighten the hanger nuts to the specified torque TORQUE 31 N m 3 2 kgf m 23...

Page 71: ...MEMO...

Page 72: ...CYLINDER HEAD VALVES 12 N m 1 2 kgf m 9 11 N m 1 1 kgf m albf n 9 N m 0 9 6 5Ibf ft 7 0...

Page 73: ...original locations Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection Camshaft lubricating oit is fed through oil passages in the...

Page 74: ...crankcase breather tube If the tube is smoky check for a seized piston ring Section 8 Compression too low hard starting or poor performance at low speed Valves Incorrect valve clearance Burned or ben...

Page 75: ...on chamber or on piston head CAMSHAFT REMOVAL Drain the engine oil page 3 9 Remove the following valv8 adjuster hole cap page 3 7 left crankcase cover page 10 2 sealing bolt tensioner spring and tensi...

Page 76: ...shaft bearing with your finger The outer race should turn smoothly and quietly Also check that the bearing inner race fits tightly on the camshaft Replace the camshaft assembly jf the outer race does...

Page 77: ...bolt and cylin der head Remove the followi ng Gasket Dowel pins Collar O ring DISASSEMBLY Remove the spark plug Remove the bolts and cover cylinder head right side Temporarily install a 8 mm bolt to...

Page 78: ...cotters Mark all parts Remove the following during Spring retainer dlssssembly so Valve spring they can be placed Valve back in their Stem seal origina locations Valve spring seat INSPECTIQN CYLINDER...

Page 79: ...t the rocker arm shafts for wear or damage Measure the 0 0 of the rocker arm shaft SERVICE LIMIT IN EX 9 91 mm 0 390 in VALVE SPRING Measure the free length of the inner and outer valve springs SERVIC...

Page 80: ...ver detemermine if a new guide with standard dimen the valve guides siens would bring the clearance within tolerance If are rep aced so replace any guides as necessary and ream to fit page 9 If the st...

Page 81: ...on the reamer during this operation Clean the cylinder head thoroughly to remove any metal particles Reface the valve seat see below VALVE SEAT INSPECTION REFACING Clean the intake and exhaust valves...

Page 82: ...a 45 dsgree cutter to remove any roughness or wilha45 degree irregularities from the seat cutler whenever a valve guide is replaced 7 10 Use a 32 degree IN 30 cutter to remove the top 1 4 of the exis...

Page 83: ...he valve through the valve guide and onto the seat to make a clear pattern NOTE The location of the valve seat in relation to the valve face is very important for good sealing If the contact areB is t...

Page 84: ...M O RING VALVE GUIDE iQ STEM SEAL VALVE SPRING SPRING RETAINER VALVE COTTERS Clean the cylinder head assembly with solvent and blow through all oil passages with compressed air SPRING SEAT Install the...

Page 85: ...as shown to seat the cotters firmly CAUTION Support the cylinder hBad above the work bench 50 that the valve hll ds will not contact anything that cause damage Apply engine oil to the rocker arm inne...

Page 86: ...nder sur face Install the follqwing New O ring Collar Dowel pins New gasket Route the cam chain through the cylinder head and install the cylinder head Ins all the cylinder Install a new gasket onto t...

Page 87: ...he cylinder was removed tighten the cylinder mounting bolt Install a new a ring into the groov9 in the intake manifold Install and tighten the intake manifold botts Install the following Spark plug pa...

Page 88: ...he cam sprocket bolts to the specified torque TORQUE 9 N m 0 9 kgf m I 6 5 Ibf ft Install the cyljnder head left side cover onto the cylinder head with a new gasket Set the tab on the side cover again...

Page 89: ...Install the tensioner push rod spring and sealing bolt page 10 5 Adjust the valve clearance page 3 7 Pour the recommended engine oil page 3 9 CYLINDER HEAD VALVES 7 17...

Page 90: ...CYLINDER PISTON 10 N m 1 0 kgf m 7 Ibf ft 8 0...

Page 91: ...vice can be done with the engine installed in the frame Camshaft lubrication oil is fed to the cylinder head through an orifice in the cylinder head cylinder and crankcase Be sure that this orifice is...

Page 92: ...engine is hard to start Blown cylinder head gasket Worn stuck or broken piston ring Worn or damaged cylinder or piston Cylinder compression is too high or engine overheats or knocks Carbon depositas o...

Page 93: ...ing bolt and cylinder Remove the following Rubber packing Gasket Dowel pins PISTON REMOVAL Do nollet the Remove the piston pin clip with pliers piston pin clips fall into the cranKcase Press the pisto...

Page 94: ...aper and out of round at three levels in X and Y axis Take the maximum reading to determine them SERVICE UMITS Taper 0 10 mm 0 004 in Out of round 0 10 mm 0 004 in The cylinder must be rebored and an...

Page 95: ...nd 0 12 mm D OOS in Inspect the piston for wear or damage Measure the diameter of the piston at 8 mm 0 3 in from the bottom and 90 degrees to the piston pin hole SERVICE LIMIT 38 90 mm 1 531 in Measur...

Page 96: ...inder 8 6 SERVICE LIMITS Top Second 0111 100 ail 0 5 mm 0 02 in 0 5 mm 0 02 in 1 1 mm 0 04 in PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings NOTE Apply...

Page 97: ...n clips fall into the crankcase CYLINDER INSTALLATION Clean off any gasket materials from the crankcase surface Install the dowel pins new gasket and new rubber packing Coat the cylinder bore piston o...

Page 98: ...all the cam chain guide railer new sealing washer and pin bolt Tighten the cam chain guide roller pin bolt to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Install the cylinder mounting bolt b...

Page 99: ...MEMO...

Page 100: ...CLUTCH GEARSHIFT LINKAGE 17 N m 1 7 12Ibf ft 13 N m 1 3 9Ibf ft 42 N m 4 3 kgf m 31 9 0...

Page 101: ...disengage or the motorcycle creeps with clutch disengaged inspect the transmission oil level before servicing the clutch system SPECIFICATIONS disc TOROUE VALUES Clutch outer cover screw Clutch lock...

Page 102: ...rect clutch adjustment Clutch plate warped Faulty clutch lifter Faulty clutch weight Incorrect engine oil weight 9 2 Hard to shift Incorrect clutch adjustment loose stopper plate bolt Damaged stopper...

Page 103: ...pedal Unhook the brake pedal return spring Loosen the rear brake pedal adjusting nut and lower the brake pedal Remove the eight bolts and right crankcase cover Remove the gasket and dowel pins Remove...

Page 104: ...arter oil seal for damage replace if necessary REMOVAL Remove the ball retainer and spring Remove the clutch lifter lever Remove the oiJ through and spring Remove the clutch lifter cam plate Remove th...

Page 105: ...tools as shown TOOLS Flywheel hold 07725 0040000 Equivalent com mercially available in U S A Lock nut wrench 20 X 24 mm 07716 0020100 Extension bar 07716 0020500 Equivalent com mercially available in...

Page 106: ...imary driven gear from the mainshaft Remove the collar from the crankshaft DISASSEMBLY Remove the following Set ring Clutch plate 8 Clutch disc A Clutch disc B Clutch disc A Free springs Clutch plate...

Page 107: ...rings ASSEMBLY Remove the clutch weight stopper ring CLUTCH WEIGHT CENTER RING Remove the clutch weight center ring INSPECTION BEARING Clutch lifter bearing Turn the inner face of the lifter bearing w...

Page 108: ...3 mm 0 09 in Clutch disc B 3 0 mm 0 12 in Clutch plate Check each disc plate for warpage on a surface plate using a feeler gauge SERVICE LIMIT 0 20 mm 0 008 in Primary drive gear clutch center guide...

Page 109: ...mm 0 665 in Drive gear outer clutch center Check the drive gear outer and clutch center for excessive wear or damage ASSEMBLY CLUTCH OUTER CLUTCH cEN TER CLUTCH PLATE A CLUTCH GEARSHIFT LINKAGE WEIGH...

Page 110: ...plate groove CLLJTCJY WEI GHT I ENITER RING Install the clutch springs onto the dutch outer holes DRIVE PLATE Install the drive plate assembly into the clutch outer ASSEMBLY aligning its bosses with t...

Page 111: ...tch disc A Clutch plate 8 NOTE Install the clutch disc A with its flat surface facing the clutch disc 8 Install the clutch plate 8 with its chamfered side facing the clutch disc A Install the clutch s...

Page 112: ...gear onto the mainshaft and secure it with the snap ring Apply engine oil to the clutch canter guide and install it onto the crankshaft Install the primary drive gear Install the clutch assembly onto...

Page 113: ...n U S A locknutwrench 20 x 24mm 07716 0020100 Extension bar 07716 0020500 Equivalent com mercially available in U S A TORQUE 42 N m 4 3 kgf m 31Ibf ft If the lock nut groove does not align with the lo...

Page 114: ...fter cam plate Install the oil through spring and oil through Install the spri ng ball retainer and clutch lifter lever Install the right crankcase cover page 9 17 GEARSHIFT LINKAGE REMOVAL Remove the...

Page 115: ...er arm and return spring Pull down the gearshift arm then pull oul the gearshift spindle from the crankcase Remove the I olt and shift cam plate Remove the dowel pins and gearshift drum pins CLUTCH GE...

Page 116: ...rshift drum pins and two dowel pins Install the cam plate and tighten the bolt to the specified torque TORQUE 17 N m 1 7 kgf m 12 Ibf ft Install the gearshift spindle into the crankcase by aligning th...

Page 117: ...the pinch bolt end tighten it Install the primary driven gear and clutch assembly page 9 12 RIGHT CRANKCASE COVER INSTALLA TION Install the clutch lifter plate adjusting bolt into the right crankcase...

Page 118: ...ht cover bolts in a crisscross pattern several steps Install the kic starter pedal as shown and tighten the bolt Hook the return spring to the brake pedal and spring holding pin as shown Install the f...

Page 119: ...MEMO...

Page 120: ...ALTERNATOR CAM CHAIN TENSIONER 16 N m 1 6 kgf m 12Ibf ft 23 N m 2 3 kgf m 17 Ibf ft 41 N m 4 2 kgf m 30 Ibf ft 10 0...

Page 121: ...Push rod 0 0 11 985 12 000 0 4718 0 724 11 94 0 470 S rin free len th 111 3 4 38 100 3 9 I TORQUE VALUES Flywheel nul Cam chain tensioner sealing bolt Cam chain tensioner pivot bolt TOOLS Universal ho...

Page 122: ...t the alternator and ignition pulse genera tor connectors Remove the bolt and gearshift pedal Remove the three bolts and left crankcase cover Hold the flywheel using the universal holder and remove th...

Page 123: ...Flywheel puller Remove the woodruff key 07933 GEOOOOO Not available in U S A 07933 0010000 U S A only Remove the bolt and wire clamp Release the wire grommet from the crankcase groove Remove the four...

Page 124: ...il page 3 9 Remove the screws and stator base Remove the O rings CAM CHAIN TENSLONER REMOVAL 10 4 Remove the stator base page 10 2 Remove the sealing bolt tensioner spring and push rod Remove the pivo...

Page 125: ...Install the cam chain tensioner roller tensioner arm and pivot bolt Tighten the pivot bolt to the specified torque TORQUE 16 N m 1 6 kgf m 12Ibf ft Check the sealing washer is in good condition replac...

Page 126: ...ll the seating washer and bolt Tighten the bolt securely STATOR FLYWHEEL INSTALLATION 10 6 Check the stator base oil seat for damage replace if necessary Apply engine oil to the lip of the oil seal Ap...

Page 127: ...ire grommet into the crankcase groove Install the wire clamp and tighten the bolt Clean any oil from the tapered portion of the crankshaft and flywheel Install the woodruff key into the crankshaft Ins...

Page 128: ...fied torque TOOL Universal holder 07725 0030000 TORQUE 41 N m 4 2 kgf m 30 tbf ft Install the left crankcase cover and tighten the three bolts Install the gearshift pedal so that it is same height as...

Page 129: ...MEMO...

Page 130: ...CRANKSHAFTITRANSMISSION KICKSTARTER 12 9Ibf ft 11 0...

Page 131: ...must be separated to service the crankshaft transmission and kickstarter The following parts must be removed before separating the crankcase Alternator cam chain tensioner Section 10 Clutch gearshift...

Page 132: ...adjustment Bent shift fork Bent fork claw Damaged shift drum cam groove Incorrect transmission oil weight Transmission Jumps out of gear Worn gear dogs and slots Bent fork shaft Broken shift drum stop...

Page 133: ...arts before separating the crankcase Remove the snap ring from the kickstarter spindle Unhook the return spring and remove the retainer and return spring Remove the rubber cap Remove the shift drum bo...

Page 134: ...th the left side down Separate the right and left crankcase halves Remove the gasket and dowel pins CRANKSHAFT REMOVAL 11 4 Remove the crankshaft from the left cran kcase If necessary remove the cam c...

Page 135: ...ical points as shown SERVICE LIMIT 0 05 mm 0 002 in Turn the outer race of the crankshaft bearing with your finger The bearing should turn smoothly and quietly Also check that the inner race of the be...

Page 136: ...the guide sprocket and guide spindle Pour 1 2 cm of engine oil into the connecting rod big end bearing Install the crankshaft into the left crankcase being careful not to interfere the connecting rod...

Page 137: ...the 1 0 and 0 0 of C1 gear bushing SERVICE LIMITS 0 0 22 93 mm 0 903 in 1 0 20 08 mm 0 791 in Calculate the C1 gear ta bushing clearance SERVICE UMIT 0 10 mm 0 004 in Check the shifter groolle of the...

Page 138: ...d shifter groove C3 GEAR 25T C2 G EAR 25T GEAR 36T COUNTERSHAFT M3 GEAR 21T M2 GEAR 15T MAINSHAFT Ml l1TJ GEARSHIFT DRUM DISASSEMBLY SHIFT Remove the guide pin clips Remove the guide pins then remove...

Page 139: ...he shift fork 1 0 SERVICE UMIT 34 14 mm 1 344 in Measure the shift fork claw thickness SERVICE UMIT 4 60 mm 0 181 in SHIFT DRUM ASSEMBLY SHIFT DRUM CRANKSHAFTITRANSMISSION KICKSTARTER SHIFT FORK GUIDE...

Page 140: ...emoved install a new washer and bend the tab to lock the washer TRANSMISSION BEARING REPLACE MENT Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Als...

Page 141: ...haft bearing out of the left crankcase Drive new bearings into the crankcases using the special tools as shown TOOLS Driver Attachment 37 X 4ij mm Pilot 17 mm 07749 0010000 07746 0010200 07746 0040400...

Page 142: ...aft and shift drum as shown Install the mainshaft countershaft and shift drum as an assembly into the left crankcase Rotate the shift drum to check the transmission operation Install the kickstarter s...

Page 143: ...k the kickstarter spindle for bending Check the friction spring for fatigue Check each part for wear or damage replace if necessary ASSEMBLY Assembly is in the reverse order of disassembly SNAP RING P...

Page 144: ...bling NOTE Dress the surfaces with an oil stone jf necessary to correct any minor roughness or irregularities Install the dowel pins and a new gasket onto the left crankcase Make sura that the Instal...

Page 145: ...Install the return spring and retainer onto the kickstarter spindle Temporarily install the kickstarter pedal Install the spring ends onto the retainer and crankcase lug as shown and press the retain...

Page 146: ...FRONT WHEEL BRAKE SUSPENSION STEERING 74 N m 7 5 54Ibf ft N m 2 0 kgf m 14Ibf ft 47 N m 4 8 kgf m 35 Ibf ft 10 N m 1 0 kgf m 7 Ibf ft 12 0...

Page 147: ...port the motorcycle using a safety stand or hoist SPECIFICATIONS ITEM runcut TORQUE VALUES Handlebar mounting nut Engine stop switch holder screw Brake lever pivot bolt Brake lever pivot nut Spoke nip...

Page 148: ...t rim Worn front wheel bearings Faulty tire Unbalanced tire and wheel 12 2 07701 0020100 Commercially available in U S A 07746 0050100 T Commercially available in U S A 07746 0050300 07749 0010000 077...

Page 149: ...her tube from the number plate and the number plate from the steering stem nut Remove the wire bands Remove the two screws and engine slop switch throttle housing from the handlebar Disconnect the thr...

Page 150: ...grip and to the outside surface of the left handlebar Wait 3 5 minutes and install the grip Rotate the grip for even application of the adhesive NOTE Allowthe adhesive to dry for an hour before using...

Page 151: ...contaminated brake drum or shOll rsducfls stopping power Discard contaminated shoss and c tlBn a contaminated drum with 8 high quality brake degre sing 89ftnt Support the motorcycle securely using a...

Page 152: ...Also check that the bearing outer race fits tightly in the hub Always replaca Ifle Remove and discard the bearings if they do not bearings in paJrs turn smoothly quietly or if they fit loosely in the...

Page 153: ...able in U S A 07746 0050100 Equivalent commercially available in U s A RIGHT WHEEL BEARING 6201U DUST SEAL CAUTION Never Insta the old bearings Once th bearings have been removed the bearings must be...

Page 154: ...left end surface to the side of rim is 6 3 mm 0 25 0 04 in as shown TOOL Spoke wrench 4 1 X 4 5 mm 07701 0020100 Equivalent com merCially available in U S A TORQUE 2 N m 0 2 kgf m 1 4Ibf ft Check the...

Page 155: ...arily tighten the axle nut Install the spring and joint pin and connect the brake cable Install the adjusting nut Adjust the front brake lever free play page 3 14 With the frol t brake applied pump th...

Page 156: ...front wheel page 12 5 INSPECTION Measure the front brake drum 1 0 SERVICE LIMIT 80 5 mm 3 17 in Measure the brake lining thickness SERVICE LIMIT 2 0 mm 0 08 in DISASSEM BLV Remove the spring and brake...

Page 157: ...se to th e brake cam spindle Install the brake cam into the brake panel Apply oil to a new dust seal and install it onto the brake panel Install the wear indicator onto the brake cam by aligning its w...

Page 158: ...brake cam sliding surfaces SHOES Install the brake shoes and spring as shown Wipe any excess grease of the brake cam and anchor pin INSTALLATION Install the front wheel page 12 8 DISASSEMBLY Remove t...

Page 159: ...lders slider piston slider guide back up ring stopper ring dust seal INSPECTION Visually inspect each part for excessive wear or damage Measure the fork spring free length SERVICE LIMIT 158 3 mm 6 23...

Page 160: ...rk slider and spring holder so that the locating pin on the upper spring holder is facing inside of the fork slider and drive the spring pin to secure them using a 4 mm pin driver Be sure that the spr...

Page 161: ...ghtening the cable nut Install the front wheel page 12 10 STEERING STEM REMOVAL Remove the following Number plate page 2 3 Handlebar page 12 3 Front wheel page 12 5 Front fender page 2 3 Steering stem...

Page 162: ...e stem to prevent the threads from being damaged when removing the lower bearing inner race from the stem Remove the lower bearing inner race with a chisel or equivalent tool being careful not to dama...

Page 163: ...e to upper and lower bearings and races Install the lower bearing onto the lower bearing race Insert the steering slem into the steering head pipe Install upper bearing inner race and top thread Hold...

Page 164: ...cified torque TORQUE 3 N m 10 3 kgf m 2 2 Ibf ft Install the top bridge Install the stem nut and fork top bolts with the washers and tighten them TORQUE Stem nut 74 N m 0 5 kgf m 54Ibf ft Make sure th...

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Page 166: ...REAR WHEEL BRAKE SUSPENSION 47 N m 4 8 kgf m 35lbf ft 13 0 34 N m 3 5 kgf m 25 Ibf ft 34 N m 3 5 kgf m 25Ibf ft 39 N m 4 0 kgf m 29Ibf ft...

Page 167: ...en sprocket nut Rear brake arm pinch bolt Swingarm pivot nut ITEM Shock absorber mounting nut Drive chain slider nut TOOLS Spoke wrench 4 1 x 4 5 mm Bearing remover shaft Bearing remover head 12 mm Dr...

Page 168: ...heel bearings Tire pressure too low Faulty tire Unbalanced tire and wheel Hard suspension Tire pressure too low Bent damper rod Faulty swingarm pivot bushings Damaged swingarm pivot bushings Bent swin...

Page 169: ...e the joint pin and spring l oosen the drive chain adjuster lock nuts and adjusting nuts Remove the axle nut and left chain adjuster Push the fear w heel forward and derail the drive chain from the dr...

Page 170: ...sely in the hub 13 4 Wheel rim runout Check the rim runout by placing the wheel in a turn ing stand Spin the wheel slowly and read the runout using a dial indicator Actual runout is 1 2 the total indi...

Page 171: ...emover shaft and drive the bearing out of the wheel hub Remove the distance collar and drive out the other bearing TOOLS Bearing rem oYer head 12 mm 07746 0050300 Equivalent commercially avail Bearing...

Page 172: ...drive in a new left bearing using the same tools Wheel center 8 djustment Place the rim on the work bench Place the hub with the left side down and begin lacing with new spokes Adjust the hub position...

Page 173: ...ar wheel into the swingarm by aligning the brake panel groove with the swingarm boss Install the drive chain over the driven sprocket Apply thin layer of grease to the axle Install the axle with the r...

Page 174: ...justing nut Adjust the drive chain slack page 3 12 REAR BRAKE REMOVAL 13 8 Remove the brake panel from the rear wheel page 13 3 INSPECTION Measure the rear brake drum I D SERVICE LIMIT 80 5 mm 3 17 in...

Page 175: ...nut bolt and brake arm Remove the indicstor plate dust seal and brake cam COVER ASSEMBLY BRAKE SHOES SPRING Apply grease to the brake cam spindle Install the brake cam Into the brake panel BRAKE CAM R...

Page 176: ...the specified torque TOROUE 6 N m 0 6 kgf m 4 3 Ibf tt Install the brake arm cover onto the arm Apply grease to the anchor pin and brake cam sliding surfaces Assemble the brake shoes and spring as sho...

Page 177: ...mation or oil leaks Bump rubber for wear or damage Mounting bushings for damage Replace the shock absorber assembly if necessary INSTALLATION Install the shock absorber into the frame and swingarm Ins...

Page 178: ...e chain cover Remove the bolts nuts and drive chain guard Remove the shock absorber lower mounting nut and bolt Remove the 5wingarm pivot nut bolt and swing arm Remove the 0Vl and bolt and the drive c...

Page 179: ...e seating surface of the 5wingarm pivot nut Instafl and tighten the nuts to the specified torque TORQUE Swingarm 39 N m 14 0 kgf m 29 Ibf tt Shock absorber 34 N m 3 5 kgf m 25 Ibf tt Install the drivt...

Page 180: ...ook the brake pedal return spring from the spring holding pin Remove the cotter pin washer and brake pedal INSTALLA TION Apply grease to the pivot groove and install the brake pedal Install the washer...

Page 181: ...into the brake arm Install the rod to the brake arm with the adjusting nut Connect the brake rod to the pedal with the joint pin and secure it with a new cotter pin Adjust the brake pedal free play pa...

Page 182: ...ROL MODULE leM IGNITIC N CDIL EXCITER COIL IGNITION PULSE GENERATOR _8vw cc J BIfW 8L ONTINUITY SWITCH C ENGINE STOP IGNITION SW SW IG E I I E UN ON OFF OFF 81 Black R Red Y Yellow W Whit 8u 81u G Gre...

Page 183: ...he connector is disconnected when current is flowing the excessive voltage may damage the module A faulty ignition system is often related to poor connections Check those connections before proceeding...

Page 184: ...aulty ignition switch or engine stop switch 4 Loose or poorly connected ICM connectors 5 Open circuit or poor connection in ground wire green of the ICM 6 Faulty peak voltage adaptor 7 Faulty exciter...

Page 185: ...er or use the peak voltage tester U S A only TOOLS Peak voltage tester U S A only or Peak voHage adaptor 07HGJ 0020100 not available in U S A with commercially availa ble digital multimeter impedance...

Page 186: ...eshooting chart page 14 21 IGNITION PULSE GENERATOR PEAK VOLTAGE NOTE Check cylinder compression and check that the spark plug is installed correctly Remove the seat assembly page 2 2 Disconnect the 4...

Page 187: ...checks described in the troubleshooting chart page 14 2 ALTERNATOR EXCITER COIL PEAK VOLTAGE Avoid touching the sp rk plug nd tester probes to prevent electric shock NOTE Check cylinder compression an...

Page 188: ...and the one measured at the alternator exciter coil is normal the wire harness has an open circuit or loose connection If both peak voltages are abnormal follow the checks described in the troublesho...

Page 189: ...sonous carbon moncxidB glJs that may CBuse loss ofconsciousness Bnd lead to death Run the engine In Itn open rsa or with 8n exhaust evacuation system in an enclosed af Warm up the engine Stop the engi...

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Page 191: ...SWITCH CONTINUITY ENGINE STOP SW IG E IGNITION SW IG E RUN ON IGNITION CONTROL MODULE f H OFF BI Black Y Yellow Bu Blue R Red W White G Green SPARK PLUG IGNITION COIL G 8u Y BVR BulY BIIA IGNITION PU...

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Page 193: ...oken or shorted spark plug wire 3 Remove and inspect spark plug I Good condition j faulty ignition pulse generator Faulty engine stop switch or ignition switch Loose or disconnected ignition sys temwi...

Page 194: ...s not Choke valve closed increase Clogged air cleaner Restricted fuel flow Clogged muffler Pinched fuel tank breather tube Incorrect Faulty ignition control module Faulty ignition pulse generator Inco...

Page 195: ...fuel mixture POOR PERFORMANCE AT LOW AND IDLE SPEED Check carburetor air screw adjustment I Correct I Possible cause Incorrect See section 5 2 Check for leaking intake pipe leaking loose carburetor m...

Page 196: ...orrect j Incorrect Cam sprocket not installed properly Incorrect Faulty ignition control module Faulty ignition pulse generator 5 Check valve spring Weak Faulty spring j Not weak POOR HANDLING Possibl...

Page 197: ...BER PLATE 2 4 NUTS BOLTS FASTENERS 3 18 Oil PUMP 4 2 PISTON INSTALLATION 8 7 PISTON REMOVAL 8 3 17 INDEX REAR BRAKE 13 8 REAR FENDER 2 4 REAR WHEEL 13 3 RIGHT CRANKCASE COVER INSTALLATION 9 17 RIGHT C...

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Honda 2000 XR50R, Service Manual

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