Honda XL125L Manual Download Page 92

Page: 92 / 117

Tyre Puncture

Removing Wheels

continued

ou
bles

hoo

ting

❙

Rear Wheel

Removal

Place your motorcycle on its side stand on
a firm, level surface.

Raise the rear wheel off the ground using
a maintenance stand or a hoist.

Remove the rear brake adjusting nut.

Disconnect the brake rod from the brake
arm.

Loosen the drive chain lock nuts and drive
chain adjusting nuts on both sides of the
swingarm.

Remove the rear axle nut.

Remove the drive chain from the rear
wheel sprocket by pushing the rear wheel
forward.

Remove the rear axle shaft, rear axle
washer, side collars and rear wheel from
the swingarm.

Brake rod

Rear brake
adjusting
nut

Rear axle nut

Rear axle
washer

Drive chain
lock nut

Drive chain adjusting nut

Brake arm

Drive chain
adjusting nut

Drive chain lock nut

Rear axle shaft

Drive chain

Summary of Contents for XL125L

Page 1: ...he latest production information available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publica...

Page 2: ...this owner s manual carefully Follow all recommendations and procedures contained in this manual Pay close attention to safety messages contained in this manual and on the motorcycle The following co...

Page 3: ...taining a motorcycle You must use your own good judgement You will find important safety information in a variety of forms including Safety labels on the motorcycle Safety Messages preceded by a safet...

Page 4: ...Contents Motorcycle Safety P 2 Operation Guide P 18 Maintenance P 35 Troubleshooting P 82 Information P 97 Specifications P 108 Index P 111...

Page 5: ...portant information for safe riding of your motorcycle Please read this section carefully Safety Guidelines P 3 Image Labels P 6 Safety Precautions P 10 Riding Precautions P 11 Accessories Modificatio...

Page 6: ...e that you are physically fit mentally focused and free of alcohol and drugs Check that you and your passenger are both wearing an approved motorcycle helmet and protective apparel Instruct your passe...

Page 7: ...o use good judgement and ride safely Alcohol and riding don t mix Even one alcoholic drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additi...

Page 8: ...ers brakes and wheels Ride slowly and cautiously Your motorcycle may have suffered damage that is not immediately apparent Have your motorcycle thoroughly checked at a qualified service facility as so...

Page 9: ...re is a specific symbol on each label The meanings of each symbol and label are as follows Read instructions contained in Owner s Manual carefully Read instructions contained in Shop Manual carefully...

Page 10: ...people to touch a battery unless they understand proper handling and hazards of the battery very well Handle the battery electrolyte with extreme care as it contains dilute sulfuric acid Contact with...

Page 11: ...L Cold tyre pressure Driver only Front 150 kPa 1 50 kgf cm2 22 psi Rear 150 kPa 1 50 kgf cm2 22 psi Driver and passenger Front 150 kPa 1 50 kgf cm2 22 psi Rear 225 kPa 2 25 kgf cm2 33 psi Tyre size Fr...

Page 12: ...L For your protection always wear helmet protective apparel FUEL LABEL Unleaded petrol only DRIVE CHAIN LABEL Keep chain adjusted and lubricated 20 to 30 mm 0 8 to 1 2 in Freeplay CARGO LIMIT LABEL Do...

Page 13: ...d road conditions Helmet Safety standard certified high visibility correct size for your head Must fit comfortably but securely with the chin strap fastened Face shield with unobstructed field of visi...

Page 14: ...lmet and eye protection we recommend off road motorcycle boots and gloves riding trousers with knee and hip pads a jersey with elbow pads and a chest shoulder protector Riding Precautions During the f...

Page 15: ...t use of the brakes to reduce speed For full braking effectiveness operate both the front and rear brakes together Engine Braking Engine braking helps slow your motorcycle down when you release the th...

Page 16: ...lowly lean the motorcycle to the left until its weight rests on the side stand 4 Turn the handlebar fully to the left u Turning the handlebar to the right reduces stability and may cause the motorcycl...

Page 17: ...your motorcycle illegal to operate on public roads and highways Before deciding to install accessories on your motorcycle be certain the modification is safe and legal Do not pull a trailer with or a...

Page 18: ...nd on another motorcycle so that you can assist each other in case of trouble Familiarity with your motorcycle is critically important should a problem occur far from help Never ride beyond your abili...

Page 19: ...re of the motorcycle Do not place objects near the lights or the muffler Also follow these guidelines when you ride off road on rough terrain Do not carry a passenger Keep cargo small and light weight...

Page 20: ...Motorcycle Safety 17...

Page 21: ...tion Apply throttle gradually Obey the speed limit How to use basic features Instruments P24 Switches P26 Steering Lock P27 Starting the Engine P29 Start and warm the engine Avoid revving the engine S...

Page 22: ...ave applied the brakes Parking P12 Park on a firm level surface Use the stand and lock the steering Stopping If pulling off the road signal early enough to show traffic that you are pulling over and p...

Page 23: ...peration Guide Parts Location XL125LEK Front brake lever P63 Throttle grip P79 Engine oil fill cap dipstick P58 Seat P53 Fuel fill cap P32 Kickstarter P29 Rear brake pedal P65 Spark plug P56 Headlight...

Page 24: ...eration Guide Battery P55 Side stand P70 Fuel valve P28 Clutch lever P76 Crankcase breather P80 Drive chain P72 Engine oil drain bolt P59 Fuse box P95 Choke lever P29 Shift lever P31 Helmet holder P34...

Page 25: ...Continued Operation Guide Except XL125LEK Front brake fluid reservoir P61 Throttle grip P79 Engine oil fill cap dipstick P58 Seat P53 Fuel fill cap P32 Kickstarter P29 Rear brake pedal P65 Spark plug...

Page 26: ...on Guide Battery P55 Side stand P70 Fuel valve P28 Clutch lever P76 Crankcase breather P80 Drive chain P72 Engine oil drain bolt P59 Fuse box P95 Choke lever P29 Shift lever P31 Helmet holder P34 Main...

Page 27: ...pmeter Distance ridden since tripmeter was reset Speedometer This shows your speed in kilometer per hour km h Odometer Total distance ridden High beam indicator Neutral indicator Comes on when the tra...

Page 28: ...25 Operation Guide Tripmeter reset knob The tripmeter reset knob is used to reset the tripmeter to zero 0 by turning the knob in the direction shown in the illustration...

Page 29: ...26 Operation Guide Switches Horn button Turn signal switch u Pressing the switch turns the turn signal off Headlight dimmer switch High beam Low beam Start button...

Page 30: ...ignition switch to the LOCK position u Jiggle the handlebar if the lock is difficult to engage c Remove the key Unlocking Insert the key and turn the ignition switch to the OFF position Ignition Swit...

Page 31: ...three way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor ON normal position for riding OFF for parking storing or transportation RES ON OFF RES for extra fuel to g...

Page 32: ...eater Your carburetor is suitable for use in cold regions Cold Engine a The fuel valve is ON b Turn the ignition switch to the ON position c Shift the transmission to Neutral indicator comes on Altern...

Page 33: ...uous motion f Immediately after the engine starts push the choke lever down to the halfway position g Warm up the engine by opening and closing the throttle slightly h Continue warming up the engine u...

Page 34: ...n Guide Shifting Gears Your motorcycle transmission has five forward gears in a one down four up shift pattern If you put the motorcycle in gear with the side stand down the engine will shut off XR150...

Page 35: ...ll Cap Open the lock cover insert the ignition key and turn it clockwise to open the fuel fill cap Closing the Fuel Fill Cap a After refuelling push the fuel fill cap closed until it locks b Remove th...

Page 36: ...the seat Tool kit is in the tool box behind the left side cover Removing the Seat P53 u Insert the ignition key and turn it counterclockwise to unlock Document bag Rear carrier Never exceed the maxim...

Page 37: ...older pin and push it in to lock b Remove the ignition key u Use the helmet holder only when parked Holder pin Helmet holder Ignition key 3WARNING Riding with a helmet attached to the holder can inter...

Page 38: ...e data Importance of Maintenance P 36 Maintenance Schedule P 37 Maintenance Fundamentals P 41 Tool kit P 52 Removing Installing Body Components P 53 Seat P 53 Side Cover P 54 Battery P 55 Spark Plug P...

Page 39: ...se in performing maintenance Only you can decide whether or not you should perform a given task Follow these guidelines when performing maintenance Stop the engine and remove the key Place your motorc...

Page 40: ...s all of these requirements Keep an accurate record of maintenance to help ensure that your motorcycle is properly maintained Make sure that whomever performs the maintenance completes this record All...

Page 41: ...or replace if necessary Replace Lubricate Clean Items Pre ride Check 2 P 41 Odometer Reading 1 Annual Check Regular Replace Referto page 1 000 km 1 4 8 12 16 20 24 1 000 mi 0 6 2 5 5 7 5 10 12 5 15 F...

Page 42: ...al Check Regular Replace Referto page 1 000 km 1 4 8 12 16 20 24 1 000 mi 0 6 2 5 5 7 5 10 12 5 15 Engine Idle Speed Secondary Air Supply System 2 Secondary Air Supply Pair Filter 5 3 Years Drive Chai...

Page 43: ...ce Referto page 1 000 km 1 4 8 12 16 20 24 1 000 mi 0 6 2 5 5 7 5 10 12 5 15 Side Stand XR150LEK NZ type Only 70 Side Stand Except XR150LEK NZ type 70 71 Suspension Nuts Bolts Fasteners 4 Wheels Tyres...

Page 44: ...evel Add engine oil if necessary Check for leaks 2 P 58 Drive chain Check condition and slack adjust and lubricate if necessary 2 P 72 Brakes Check operation Front and Rear check shoes wear 2 P 68 and...

Page 45: ...l name colour and code mentioned on the colour label The colour label is attached to the right side of the frame Replacing Parts Colour label 3WARNING Installing non Honda parts may make your motorcyc...

Page 46: ...ery Terminals 1 Remove the battery 2 P 55 2 If the terminals are starting to corrode and are coated with a white substance wash with warm water and wipe clean Battery NOTICE Your battery is a maintena...

Page 47: ...cal circuits on your motorcycle If something electrical on your motorcycle stops working check for and replace any blown fuses 2 P 95 Inspecting and Replacing Fuses Turn off the ignition switch to rem...

Page 48: ...non Honda engine oil check the label to make sure that the oil satisfies all of the following standards JASO T 903 standard 1 MA SAE standard 2 10W 30 API classification 3 SG or higher 1 The JASO T 9...

Page 49: ...he chain does not move smoothly makes strange noises has damaged rollers or loose pins or missing O rings or kinks have the chain inspected by your dealer Also inspect the front sprocket and rear whee...

Page 50: ...ner chain cleaner or lubricant NOT designed specifically for O ring chains as these can damage the rubber O ring seals Avoid getting lubricant on the brakes or tyres Avoid applying excess chain lubric...

Page 51: ...ok low Always check air pressure when your tyres are cold If you decide to adjust the tyre pressure for a particular off road riding condition make changes a little at a time Inspecting for Damage Ins...

Page 52: ...mmediately For safe riding you should replace the tyres when the minimum tread depth is reached Wear indicator location mark 3WARNING Riding on tyres that are excessively worn or improperly inflated c...

Page 53: ...alents of the same size construction speed rating and load range Remember to replace the inner tube whenever you replace a tyre The old tube will probably be stretched and it could fail if installed i...

Page 54: ...rcycle is equipped with a viscous type air cleaner element Air blow cleaning or any other cleaning can degrade the viscous element performance and cause the intake of dust Do not perform the maintenan...

Page 55: ...can perform some roadside repairs minor adjustments and parts replacement with the tools contained in the kit Spark plug wrench 10 12 mm Open end wrench 14 17 mm Open end wrench No 2 Phillips screwdr...

Page 56: ...P 54 2 Remove the bolts and collars 3 Pull the seat back and up Installation 1 Align the front recesses to the front hooks and rear recess to the rear hook 2 Slide the seat into position 3 Install th...

Page 57: ...The right and left side covers must be removed for remove the seat The right and left side covers can be removed in the same way Removal 1 Remove the bolt and collar 2 Remove the prongs from the gromm...

Page 58: ...rom the battery 5 Disconnect the positive terminal from the battery 6 Remove the battery taking care not to drop the terminal nuts Installation Install the parts in the reverse order of removal Always...

Page 59: ...ean any dirt from around the spark plug base 3 Remove the spark plug using the spark plug wrench provided in the tool kit 4 Inspect the electrodes and centre porcelain for deposits erosion or carbon f...

Page 60: ...plug is good 1 8 turn after it seats If installing a new plug tighten it twice to prevent loosening 9 Reinstall the spark plug cap Take care avoid pinching any cables or wires The gap should be 0 80...

Page 61: ...Place your motorcycle in an upright position on a firm level surface 4 Remove the oil fill cap dipstick and wipe it clean 5 Insert the oil fill cap dipstick until it seats but don t screw it in Check...

Page 62: ...objects enter the oil filler opening uWipe up any spills immediately 2 Securely reinstall the oil fill cap dipstick For the recommended oil and oil selection guidelines see Maintenance Fundamentals 2...

Page 63: ...sher to drain the oil uDiscard the oil at an approved recycling centre 6 Install a new sealing washer onto the drain bolt Tighten the drain bolt 7 Fill the crankcase with the recommended oil 2 P 45 an...

Page 64: ...al and that the fluid level is above the LOWER level mark If the brake fluid level in the reservoir is below the LOWER level mark or the brake lever freeplay becomes excessive inspect the brake pads f...

Page 65: ...indicators The pads need to be replaced if a brake pad is worn to the bottom of the indicator 1 Inspect the brake pads from in front of the brake caliper If necessary have the pads replaced by your d...

Page 66: ...ke lever before the starts to take hold Check the brake cable for kinks or signs of wear If necessary have it replaced by your dealer Lubricate the brake cable with a commercially available cable lubr...

Page 67: ...usting the freeplay If proper adjustment cannot be obtained by this method see your dealer 1 Adjust by turning the front brake adjusting nut a half turn at a time 2 Apply the brake several times and c...

Page 68: ...topper bolt is provided to allow adjustment of the pedal height 1 Place your motorcycle on its side stand on a firm level surface 2 Loosen the lock nut and turn the stopper bolt 3 Tighten the lock nut...

Page 69: ...efore the starts to take hold Make sure the brake rod brake arm spring and fastener are in good condition Adjusting the Rear Brake Pedal Freeplay Make sure the cut out on the adjusting nut is seated o...

Page 70: ...r free wheel rotation after the brake pedal is released 3 Push the brake arm to confirm that there is a gap between the rear brake adjusting nut and brake arm pin After adjustment confirm the freeplay...

Page 71: ...Brake Shoe Wear The front and rear brake are equipped with a brake wear indicator The rear brake is equipped with a brake wear indicator XL125LEK Except XL125LEK Arrow Reference mark XL125LEK Front B...

Page 72: ...f the brake the brake shoes must be replaced See your dealer for this service When the brake service is necessary see your dealer Use only Honda Genuine Parts or its equivalent Adjusting the Brakeligh...

Page 73: ...70 Maintenance Side Stand Side stand spring Except XR150LEK NZ type Side stand spring XR150LEK NZ type...

Page 74: ...se the side stand 4 Start the engine pull the clutch lever in and shift the transmission into gear 5 Lower the side stand all the way The engine should stop as you lower the side stand If the engine d...

Page 75: ...e your motorcycle on its side stand on a firm level surface 2 Stop the engine Place the transmission in Neutral 3 Check the slack in the lower half of the drive chain midway between the sprockets uDo...

Page 76: ...lack adjusted by your dealer 1 Place your motorcycle on its side stand on a firm level surface 2 Stop the engine Place the transmission in Neutral 3 Loosen the rear axle nut 4 Loosen the lock nuts on...

Page 77: ...edge of the adjusting slots Both marks should correspond If the axle is misaligned turn the right or left adjusting nuts until the marks are aligned and recheck chain slack 7 Tighten the rear axle nut...

Page 78: ...n adjusted to the proper slack the chain is excessively worn and must be replaced If necessary have the drive chain replaced by your dealer Checking the Drive Chain Slider Check the condition of the d...

Page 79: ...er freeplay Check the clutch cable for kinks or signs of wear If necessary have it replaced by your dealer Lubricate the clutch cable with a commercially available cable lubricant to prevent premature...

Page 80: ...t adjustment with the upper clutch cable adjuster first 1 Pull back the rubber dust cover 2 Loosen the upper lock nut 3 Turn the upper adjuster until the freeplay is 10 to 20 mm 0 4 to 0 8 in 4 Tighte...

Page 81: ...sen the lower lock nut 3 Turn the lower adjusting nut until the clutch lever freeplay is 10 to 20 mm 0 4 to 0 8 in 4 Tighten the lower lock nut and check the clutch lever freeplay 5 Start the engine p...

Page 82: ...hly from fully closed to fully open in all steering positions and throttle freeplay is correct If the throttle does not move smoothly close automatically or if the cable is damaged have the motorcycle...

Page 83: ...nkcase Breather Cleaning the Crankcase Breather 1 Remove the crankcase breather tube plug from the tube 2 Drain deposits into a suitable container 3 Install the crankcase breather tube plug Crankcase...

Page 84: ...justing the Headlight Aim You can adjust vertical aim of the headlight for proper alignment Turn the screw using a Phillips screwdriver provided in the tool kit 2 P 52 in or out as necessary Obey loca...

Page 85: ...Troubleshooting Engine Will Not Start P 83 Tyre Puncture P 84 Electrical Trouble P 91 Battery Goes Dead P 91 Burned out Light Bulb P 91 Blown Fuse P 95...

Page 86: ...heck that there is petrol in the fuel tank Starter Motor Does Not Operate Check the following items Check for a blown fuse 2 P 95 Check for a loose battery connection or battery terminal corrosion 2 P...

Page 87: ...are riding If you need to make a temporary repair by patching a tube or using an aerosol sealant ride cautiously at reduced speed and have the tube replaced before you ride again Anytime a tube is re...

Page 88: ...hoist 3 Remove the speedometer cable set screw and disconnect the speedometer cable 4 Remove the rubber cap and front axle nut 5 Remove the front axle shaft front wheel side collar and speedometer gea...

Page 89: ...er cap onto the front axle nut 6 After installing the wheel apply the brake lever several times and then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not...

Page 90: ...aintenance stand or a hoist 3 Remove the speedometer cable by pushing the tab 4 Remove the front brake adjusting nut and remove the front brake cable from the brake arm 5 Remove the rubber cap and fro...

Page 91: ...en the front axle nut 5 Install the rubber cap onto the front axle nut 6 Adjust the front brake lever freeplay 2 P 64 7 After installing the wheel apply the brake lever several times and then check if...

Page 92: ...m 5 Loosen the drive chain lock nuts and drive chain adjusting nuts on both sides of the swingarm 6 Remove the rear axle nut 7 Remove the drive chain from the rear wheel sprocket by pushing the rear w...

Page 93: ...orarily tighten the rear axle nut 6 Connect the brake rod to the brake arm 7 Adjust the drive chain slack 2 P 73 8 Adjust the rear brake pedal freeplay 2 P 66 9 Tighten the rear axle nut 10 After inst...

Page 94: ...ot recover after recharging contact your dealer Burned out Light Bulb Follow the procedure below to replace a burned out light bulb Turn the ignition switch to the OFF or LOCK position Allow the bulb...

Page 95: ...nector 3 Remove the dust cover 4 Press the pin down and pull out the bulb without turning it 5 Install a new bulb and parts in the reverse order of removal Do not touch the glass surface with your fin...

Page 96: ...thout turning it 4 Install a new bulb and parts in the reverse order of removal Brake Tail light bulb 1 Remove the taillight lens by removing the screws 2 Slightly press the bulb in and turn it counte...

Page 97: ...bulb and parts in the reverse order of removal uUse only the amber bulb License Plate Light Bulb 1 Remove the nuts A washers and license plate bracket 2 Remove the nuts B license light cover and licen...

Page 98: ...acing Fuses 2 P 44 Fuse Box Fuses 1 Remove the left side cover 2 P 54 2 Open the fuse box cover 3 Pull out the fuses and check for a blown fuse Always replace a blown fuse with a spare of the same rat...

Page 99: ...t and check for a blown fuse Always replace a blown fuse with a spare of the same rating uSpare main fuse is provided in the starter magnetic switch 4 Install the parts in the reverse order of removal...

Page 100: ...98 Instruments Controls Other Features P 99 Fuels Containing Alcohol P 100 Caring for Your Motorcycle P 101 Storing Your Motorcycle P 104 Transporting Your Motorcycle P 105 You the Environment P 106 S...

Page 101: ...re key in a safe location To make a duplicate take the spare key or the key number to your dealer If you lose all keys and the key number the ignition switch assembly will probably have to be removed...

Page 102: ...drain the battery Do not turn the key while riding The owner s manual registration and insurance information can be stored in the plastic document bag located under the seat The odometer returns to 0...

Page 103: ...r motorcycle Ethanol ethyl alcohol up to 10 by volume u Petrol containing ethanol may be marketed under the name Gasohol The use of petrol containing more than 10 ethanol may Damage the painting of th...

Page 104: ...er plastic components with extra care to avoid scratching them Avoid directing water into the air cleaner muffler and electrical parts 3 Thoroughly rinse your motorcycle with plenty of clean water and...

Page 105: ...es rust in the muffler Dry the brakes u Water adversely affects braking effectiveness After washing apply the brakes intermittently at low speed to help dry them Do not direct water under the seat u W...

Page 106: ...ns use diluted detergent and rinse thoroughly with plenty of water Avoid getting petrol brake fluid or detergents on the instruments panels or headlight When the exhaust pipe and muffler are painted d...

Page 107: ...es with rust inhibiting oil Lubricate the drive chain Place your motorcycle on a maintenance stand and position a block so that both tyres are off the ground After rain remove the body cover and allow...

Page 108: ...ransported it should be carried on a motorcycle trailer or a flatbed truck or trailer that has a loading ramp or lifting platform and motorcycle tie down straps Never try to tow your motorcycle with a...

Page 109: ...er Put oil and other toxic wastes in approved containers and take them to a recycling centre Call your local or state office of public works or environmental services to find a recycling centre in you...

Page 110: ...quired in order to register your motorcycle They may also be required when ordering replacement parts The frame number is stamped on the right side of the steering head The engine number is stamped on...

Page 111: ...0 mm 10 2 in Caster angle XR125LEK XR150LEK 27 0 XL125LEK 26 8 Trail XR125LEK XR150LEK 104 mm 4 1 in XL125LEK 103 mm 4 1 in Curb weight XL125LEK 127 kg 280 lb XR125LEK 128 kg 282 lb XR150LEK 129 kg 28...

Page 112: ...P Tyre type Bias ply tube Recommended Tyres Front XR125LEK XR150LEK CHENG SHIN C6559F XL125LEK CHENG SHIN CM 704 Rear XR125LEK XR150LEK CHENG SHIN C6559 XL125LEK CHENG SHIN CM 705 Tyre air pressure Dr...

Page 113: ...3 US qt 1 1 Imp qt Recommended brake fluid Except XL125LEK Honda DOT 3 or DOT 4 Brake Fluid Recommended drive chain lubricant Drive chain lubricant designed specifically for O ring chains If not avai...

Page 114: ...adlight 92 License Plate Light 94 Position Light 93 C Caring for Your Motorcycle 101 Choke Lever 29 Clutch System 76 Colour Label 42 D Drive Chain 46 72 E Electrical Trouble 91 Engine Number 107 Oil 4...

Page 115: ...stem Side Stand 70 Ignition Key 98 Ignition Switch 27 99 Image Labels 6 Indicators 24 Instruments 24 K Kickstarter 29 L Load Limits 16 Loading Guidelines 16 M Maintenance Fundamentals 41 Importance 36...

Page 116: ...Seat 53 Serial Numbers 107 Shifting Gears 31 Side Cover 54 Side Stand 70 Specifications 108 Start Button 26 Starting the Engine 29 Steering Lock 27 Storage Document Bag 33 99 Equipment 33 Owner s Manu...

Page 117: ...114 Index Tyres Air Pressure 48 Puncture 84 Replacing 48 84 W Washing Your Motorcycle 101 Weight Limit 16 108 Wheels Front Removal 85 87 Rear Removal 89...

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Honda XL125L, Manual

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