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Honda XL125LK, Owner'S Manual

The Honda XL125LK Owner's Manual is available for free download on our website. This comprehensive manual provides detailed instructions and information for users of the Honda XL125LK motorcycle. Get the most out of your riding experience by downloading the manual from manualshive.com.

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INDEX

A

AIR CLEANER ································································3-4
AIR CLEANER HOUSING ··············································6-4
AIR CLEANER SUB FILTER (XR125LK/LEK)················3-4
ALTERNATOR CHARGING COIL ································17-7

B

BATTERY······································································17-5
BRAKE CALIPER··························································16-9
BRAKE FLUID (XR125LK/LEK) ····································3-12
BRAKE FLUID REPLACEMENT/AIR BLEEDING ········16-4
BRAKE LIGHT SWITCH ···············································3-14
BRAKE LIGHT SWITCHES ··········································18-8
BRAKE PAD/DISC ························································16-6
BRAKE PEDAL ·····························································15-9
BRAKE SHOE/PAD WEAR···········································3-12
BRAKE SYSTEM ··························································3-13
BRAKE/TAIL LIGHT······················································18-4

C

CABLE & HARNESS ROUTING

XL125LK ···································································1-24
XR125LK/LEK ··························································1-16

CAM CHAIN TENSIONER LIFTER·······························8-17
CAMSHAFT ····································································8-5
CAMSHAFT HOLDER ····················································8-8
CARBURETOR ·······························································6-5
CARBURETOR HEATER (EXCEPT CO, III LA TYPES) ··6-
10
CHARGING SYSTEM INSPECTION ····························17-6
CLUTCH········································································10-7
CLUTCH SWITCH ························································18-9
CLUTCH SYSTEM························································3-15
COMBINATION METER ···············································18-6
COMPONENT LOCATION

BATTERY/CHARGING SYSTEM ·····························17-2
ELECTRIC STARTER ················································5-2
IGNITION SYSTEM ····················································4-2
LIGHTS/METER/SWITCHES ···································18-2

CRANKCASE BREATHER ·············································3-5
CRANKCASE SEPARATION/ASSEMBLY ···················12-4
CRANKSHAFT····························································12-13
CYLINDER ······································································9-4
CYLINDER COMPRESSION ··········································8-3
CYLINDER HEAD ·························································8-11
CYLINDER HEAD COVER ·············································8-4

D

DRIVE CHAIN ·································································3-9
DRIVE CHAIN SLIDER ·················································3-11
DRIVE SPROCKET COVER···········································2-5

E

EMISSION CONTROL SYSTEMS ································1-30
ENGINE IDLE SPEED ····················································3-8
ENGINE INSTALLATION··············································13-5
ENGINE OIL····································································3-7
ENGINE OIL CENTRIFUGAL FILTER····························3-8
ENGINE OIL STRAINER SCREEN ································3-7
ENGINE REMOVAL······················································13-3
EXHAUST PIPE/MUFFLER ············································2-6

F

FLYWHEEL/STARTER CLUTCH ·································11-4
FORK ··········································································14-13
FRONT DRUM BRAKE (XL125LK)·····························14-13
FRONT FENDER ····························································2-5
FRONT VISOR································································2-4
FRONT WHEEL ····························································14-9
FUEL STRAINER SCREEN············································3-3
FUEL TANK ····································································2-4

G

GEARSHIFT LINKAGE ···············································10-10

H

HANDLEBAR ································································14-4
HANDLEBAR SWITCHES ············································18-7
HEADLIGHT AIM ··························································3-15
HEADLIGHT/POSITION LIGHT····································18-4
HORN··········································································18-11

I

ICM (IGNITION CONTROL MODULE) ···························4-6
IGNITION COIL·······························································4-6
IGNITION SWITCH ·······················································18-7

IGNITION SYSTEM INSPECTION ································· 4-4
IGNITION TIMING ·························································· 4-5

K

KICKSTARTER··························································· 12-15
KICKSTARTER IDLE GEAR ······································ 12-14

L

LEFT CRANKCASE COVER········································ 11-3
LICENSE LIGHT (XR125LK/LEK) ································ 18-5
LIGHTING SYSTEM INSPECTION ······························ 18-3
LUBRICATION & SEAL POINTS·································· 1-14
LUBRICATION SYSTEM DIAGRAM ······························ 7-2

M

MAINTENANCE SCHEDULE ········································· 3-2
MASTER CYLINDER···················································· 16-7
MODEL IDENTIFICATION ············································· 1-2

N

NEUTRAL DIODE··························································· 5-8
NEUTRAL SWITCH······················································ 18-9
NUMBER PLATE BRACKET·········································· 2-3
NUTS, BOLTS, FASTENERS······································· 3-16

O

OIL PUMP ······································································ 7-3

P

PILOT SCREW ADJUSTMENT···································· 6-12
PISTON ·········································································· 9-5
PRIMARY DRIVE GEAR ············································ 10-13

R

REAR CARRIER····························································· 2-2
REAR COWL ·································································· 2-3
REAR DRUM BRAKE··················································· 15-7
REAR WHEEL ······························································ 15-4
REGULATOR/RECTIFIER ··········································· 17-7
RIGHT CRANKCASE COVER ····································· 10-4

S

SEAT ·············································································· 2-2
SECONDARY AIR SUPPLY SYSTEM (XR125LK/LEK)

FUEL SYSTEM ························································ 6-13
MAINTENANCE ························································· 3-9

SERVICE INFORMATION

BATTERY/CHARGING SYSTEM ···························· 17-3
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER ·· 10-3
CRANKCASE/CRANKSHAFT/TRANSMISSION ····· 12-3
CYLINDER HEAD/VALVES ······································· 8-2
CYLINDER/PISTON··················································· 9-3
ELECTRIC STARTER················································ 5-3
ENGINE REMOVAL/INSTALLATION ······················ 13-2
FRONT WHEEL/SUSPENSION/STEERING ··········· 14-3
FUEL SYSTEM ·························································· 6-2
HYDRAULIC BRAKE ··············································· 16-3
IGNITION SYSTEM ··················································· 4-3
LIGHTS/METER/SWITCHES··································· 18-2
LUBRICATION SYSTEM ··········································· 7-3
REAR WHEEL/BRAKE/SUSPENSION···················· 15-3

SERVICE RULES ··························································· 1-2
SHOCK ABSORBER ·················································· 15-11
SIDE COVER ································································· 2-2
SIDE SHROUD······························································· 2-4
SIDESTAND ································································· 3-16
SIDESTAND SWITCH (NZ TYPE) ····························· 18-10
SPARK PLUG································································· 3-5
SPECIFICATIONS·························································· 1-3
STARTER MOTOR························································· 5-5
STARTER RELAY ·························································· 5-7
STATOR/IGNITION PULSE GENERATOR·················· 11-4
STEERING HEAD BEARINGS····································· 3-17
STEERING STEM ······················································ 14-22
SUSPENSION ······························································ 3-16
SWINGARM································································ 15-13
SYSTEM COMPONENTS

ALTERNATOR/STARTER CLUTCH························ 11-2
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER ·· 10-2
CRANKCASE/CRANKSHAFT/TRANSMISSION ····· 12-2
CYLINDER HEAD/VALVES ······································· 8-2
CYLINDER/PISTON··················································· 9-2
ENGINE REMOVAL/INSTALLATION ······················ 13-2
FRONT WHEEL/SUSPENSION/STEERING ··········· 14-2
FUEL SYSTEM ·························································· 6-2

INDEX

Summary of Contents for XL125LK

Page 1: ...aring appropriate clothing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields any time you hammer dri...

Page 2: ...vironment Honda Motor Co Ltd SERVICE PUBLICATION OFFICE Date of Issue May 2012 Your safety and the safety of others is very important To help you make informed decisions we have provided safety messages and other information throughout this manual Of course it is not practical or possible to warn you about all the hazards associated with servicing this vehicle You must use your own good judgement ...

Page 3: ... 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 molybdenum disulfide NLGI 2 or equivalent Example Molykote G n Paste manufactured by Dow Corning U S A Honda Moly 60 ...

Page 4: ...VALVES 8 CYLINDER PISTON 9 CLUTCH GEARSHIFT LINKAGE 10 ALTERNATOR STARTER CLUTCH 11 CRANKSHAFT TRANSMISSION KICKSTARTER 12 ENGINE REMOVAL INSTALLATION 13 FRONT WHEEL BRAKE SUSPENSION STEERING 14 REAR WHEEL BRAKE SUSPENSION 15 HYDRAULIC BRAKE XR125LK LEK 16 BATTERY CHARGING SYSTEM 17 LIGHTS METER SWITCHES 18 WIRING DIAGRAMS 19 INDEX ENGINE DRIVE TRAIN ELECTRICAL CHASSIS FRAME ELECTRICAL ...

Page 5: ...MEMO dummyhead dummyhead ...

Page 6: ... INFORMATION SERVICE RULES 1 2 MODEL IDENTIFICATION 1 2 SPECIFICATIONS 1 3 TORQUE VALUES 1 10 LUBRICATION SEAL POINTS 1 14 CABLE HARNESS ROUTING XR125LK LEK 1 16 CABLE HARNESS ROUTING XL125LK 1 24 EMISSION CONTROL SYSTEMS 1 30 ...

Page 7: ...ean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly 7 After reassembly check all parts for proper installation and operation 8 Route all electrical wires as show in the Cable and Harness Routing page 1 24 9 Do not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bind MODEL IDENTIFICATION This manual covers fo...

Page 8: ... color code 1 1 1 1 ITEM SPECIFICATION DIMENSIONS XR125LK LEK Overall length 2 100 mm 82 7 in Overall width 820 mm 32 3 in Overall height 1 126 mm 44 3 in Wheelbase 1 361 mm 53 6 in Seat height 825 mm 32 5 in Ground clearance 243 mm 9 6 in Dry weight 119 kg 262 lbs Curb weight 129 kg 284 lbs Maximum weight capacity 159 kg 351 lbs DIMENSIONS XL125LK Overall length 2 065 mm 81 3 in Overall width 827...

Page 9: ...anical leading trailing Caster angle 26 9 Trail length 104 mm 4 1 in Fuel tank capacity 12 0 liter 3 17 US gal 2 64 lmp gal Fuel tank reserve capacity 3 5 liter 0 92 US gal 0 77 lmp gal ENGINE Bore and stroke 52 4 x 57 8 mm 2 06 x 2 28 in Displacement 124 7 cm3 7 61 cu in Valve train Chain driven OHC 2 valve with rocker arm Compression ratio 9 2 1 Intake valve opens at 1 mm 0 04 in lift 5 BTDC clo...

Page 10: ... 05 0 394 0 396 6 5 0 26 ITEM STANDARD SERVICE LIMIT Engine oil capacity After draining 1 0 liter 1 1 US qt 0 9 lmp qt After disassembly 1 2 liter 1 3 US qt 1 1 lmp qt Recommended engine oil Honda 4 stroke motorcycle oil or an equivalent motor oil API service classification SG or higher except oils labeled as energy conserving on the circular API service label Viscosity SAE 10W 30 JASO T 903 stand...

Page 11: ...iston pin hole I D 13 002 13 008 0 5119 0 5121 13 04 0 513 Piston pin O D 12 994 13 000 0 5116 0 5118 12 96 0 510 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 02 0 001 Piston ring end gap Top 0 10 0 25 0 004 0 010 0 40 0 016 Second 0 10 0 25 0 004 0 010 0 40 0 016 Oil side rail 0 20 0 70 0 008 0 028 0 85 0 033 Piston ring to ring groove clearance Top 0 030 0 065 0 0012 0 0026 0 10 0 ...

Page 12: ...04 C2 0 015 0 057 0 0006 0 0022 0 10 0 004 C3 0 020 0 062 0 0008 0 0024 0 10 0 004 Mainshaft O D at M4 19 968 19 980 0 7861 0 7866 19 93 0 785 at M5 16 968 16 980 0 6680 0 6685 16 93 0 667 Countershaft O D at C1 16 966 16 984 0 6680 0 6687 16 93 0 667 at C2 19 978 19 989 0 7865 0 7870 19 94 0 785 at C3 19 979 20 000 0 7866 0 7874 19 94 0 785 Gear to shaft clearance M4 0 020 0 050 0 0008 0 0020 0 1...

Page 13: ...teering head bearing pre load 11 8 17 7 N 1 2 1 8 kgf 2 6 4 0 lbf ITEM STANDARD SERVICE LIMIT Minimum tire thread depth 3 0 0 12 Cold tire pressure XR125LK LEK Driver only 150 kPa 1 50 kgf cm2 22 psi Driver and passenger 200 kPa 2 00 kgf cm2 29 psi XL125LK Driver only 150 kPa 1 50 kgf cm2 22 psi Driver and passenger 225 kPa 2 25 kgf cm2 33 psi Axle runout 0 20 0 008 Wheel rim runout Radial 2 0 0 0...

Page 14: ... 5 10 h Quick 4 0 A 0 5 h XR125LEK Normal 0 5 A 5 10 h Quick 5 0 A 0 5 h Alternator Capacity 0 12 kW 5 000 min 1 rpm Charging coil resistance 20 C 68 F 0 2 1 2 Ω ITEM SPECIFICATIONS Bulbs Headlight High Low beam 12 V 35 35 W Position light 12 V 4 W Brake taillight 12 V 21 5 W License light XR125LK LEK 12 V 5 W Front turn signal light XR125LK LEK 12 V 16 W x 2 XL125LK 12 V 15 W x 2 Rear turn signal...

Page 15: ...Muffler front mounting bolt 2 8 26 2 7 19 Muffler band bolt 1 8 20 2 0 15 Exhaust pipe stud bolt 2 8 11 1 1 8 See page 2 6 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Air cleaner case cover screw 4 5 1 1 0 1 0 8 Air cleaner element screw 4 5 1 1 0 1 0 8 Spark plug 1 10 16 1 6 12 Valve adjusting lock nut 2 6 14 1 4 10 Apply engine oil to the threads and seating surface Crankshaft hole c...

Page 16: ...surface Tensioner lifter sealing plug 1 6 4 0 0 4 3 0 Camshaft holder special nut 4 8 32 3 3 24 Apply engine oil to the threads and seating surface Timing hole cap 1 14 10 1 0 7 Apply grease to the threads Crankshaft hole cap 1 32 15 1 5 11 Spark plug 1 10 16 1 6 12 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Cylinder stud bolt 4 8 11 1 1 8 See page 9 5 ITEM Q TY THREAD TORQUE REMARKS ...

Page 17: ...Apply locking agent to the threads Coating width 6 5 1 0 mm 0 26 0 04 in from tip ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Mainshaft bearing setting plate bolt Right crankcase side 2 6 12 1 2 9 Apply locking agent to the threads Coating width 6 5 1 0 mm 0 26 0 04 in from tip Push plug plate bolt 1 6 10 1 0 7 Apply locking agent to the threads Coating width 6 5 1 0 mm 0 26 0 04 in fr...

Page 18: ...6 5 9 0 6 4 4 Front brake arm nut XL125LK 1 6 10 1 0 7 Front brake hose clamp bolt XR125LK LEK 1 6 12 1 2 9 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Driven sprocket nut 6 10 32 3 3 24 U nut Rear axle nut 1 16 93 9 5 69 U nut Rear brake arm nut 1 6 10 1 0 7 U nut Shock absorber upper mounting bolt 1 10 44 4 5 32 ALOC bolt replace with new one Shock absorber lower mounting nut 1 10 44...

Page 19: ...denum disulfide oil a mixture of 1 2 engine oil and 1 2 molybdenum disulfide grease Valve stem sliding surface and stem end Camshaft cam whole surface Piston pin outer surface Clutch outer guide outer surface Crankshaft connecting rod big end needle bearing Drip 1 2 cm3 Crankshaft connecting rod small end inner surface Crankshaft bearing push plug whole surface Right crankshaft bearing rotating su...

Page 20: ... Rear brake cam and shaft Apply each 0 2 0 3 g Rear brake panel anchor pin Apply 0 2 0 3 g Rear brake cam dust seal lip Apply 0 2 0 3 g Front wheel dust seal lip Rear wheel dust seal lip Shock absorber needle bearing Shock absorber dust seal lip Swingarm pivot needle bearing Swingarm pivot dust seal cap lip Sidestand pivot Rear brake pedal pivot sliding surface Throttle grip pipe cable rolling are...

Page 21: ...GHT WIRE RIGHT HANDLEBAR SWITCH 6P CONNECTOR HEADLIGHT POSITION LIGHT 4P CONNECTOR SPEEDOMETER CABLE THROTTLE CABLE MAIN WIRE HARNESS LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE RIGHT FRONT TURN SIGNAL LIGHT WIRE RIGHT HANDLEBAR SWITCH WIRE SPEEDOMETER WIRE IGNITION SWITCH WIRE FRONT TURN SIGNAL LIGHT WIRE THROTTLE CABLE FRONT BRAKE HOSE CLUTCH CABLE ...

Page 22: ...INFORMATION RIGHT HANDLEBAR SWITCH WIRE PAIR SUB AIR FILTER TO CONTROL VALVE HOSE PAIR CONTROL VALVE TO CYLINDER HEAD COVER HOSE SPEEDOMETER CABLE SPARK PLUG WIRE CLUTCH CABLE FRONT BRAKE HOSE LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLE ...

Page 23: ...ummyhead dummyhead GENERAL INFORMATION FRONT BRAKE HOSE CLUTCH CABLE HORN WIRE RESONATOR AIR INLET COVER PAIR CONTROL VALVE VACUUM HOSE MAIN WIRE HARNESS LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE ...

Page 24: ...PES CONNECTOR BOOT NEUTRAL SWITCH WIRE CONNECTOR ALTERNATOR 2P CONNECTOR IGNITION PULSE GENERATOR WIRE CONNECTOR THERMO SWITCH 2P CONNECTOR EXCEPT III LA CO TYPES CRANKCASE BREATHER HOSE CRANKCASE BREATHER DRAIN HOSE CARBURETOR DRAIN HOSE PAIR CONTROL VALVE TO CYLINDER HEAD COVER HOSE PAIR SUB AIR FILTER TO CONTROL VALVE HOSE THROTTLE CABLE ...

Page 25: ...N WIRE CLUTCH CABLE NEUTRAL SWITCH WIRE ALTERNATOR WIRE SIDESTAND SWITCH WIRE NZ TYPE STARTER RELAY SWITCH XR125LEK REAR BRAKE LIGHT SWITCH 2P BLACK CONNECTOR SIDESTAND SWITCH 3P GREEN CONNECTOR NZ TYPE IGNITION CONTROL MODULE ICM FUEL HOSE CRANKCASE BREATHER DRAIN HOSE XR125LEK ...

Page 26: ...RAL INFORMATION BATTERY CABLE BATTERY CABLE ALTERNATOR WIRE FUSE BOX IGNITION CONTROL MODULE ICM REAR BRAKE LIGHT SWITCH 2P BLACK CONNECTOR HORN WIRE CLUTCH CABLE NEUTRAL SWITCH WIRE FUEL HOSE CRANKCASE BREATHER DRAIN HOSE XR125LK ...

Page 27: ...T 3P CONNECTOR REAR TURN SIGNAL LIGHT WIRE CONNECTORS LICENSE LIGHT WIRE CONNECTORS SIDESTAND SWITCH WIRE NZ TYPE MAIN WIRE HARNESS LICENSE LIGHT WIRE LEFT REAR TURN SIGNAL LIGHT WIRE RIGHT REAR TURN SIGNAL LIGHT WIRE CONNECTOR BOOT XR125LEK DIODE SIDESTAND DIODE NZ TYPE ONLY ...

Page 28: ...P PAIR CONTROL VALVE TO CYLINDER HEAD COVER HOSE CLIP PAIR SUB AIR FILTER TO CONTROL VALVE HOSE VACUUM HOSE CLIP PAIR CONTROL VALVE TO CYLINDER HEAD COVER HOSE PAIR SUB AIR FILTER TO CONTROL VALVE HOSE PAIR CONTROL VALVE VACUUM HOSE PAIR SUB AIR FILTER PAIR CONTROL VALVE 45 Left Up ...

Page 29: ...BAR SWITCH WIRE LEFT FRONT TURN SIGNAL LIGHT WIRE TURN SIGNAL RELAY CLUTCH CABLE FRONT BRAKE CABLE RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLE SPEEDOMETER CABLE HEADLIGHT POSITION LIGHT 4P CONNECTOR RIGHT FRONT TURN SIGNAL LIGHT WIRE SPEEDOMETER WIRE IGNITION SWITCH WIRE MAIN WIRE HARNESS ...

Page 30: ...1 25 dummyhead dummyhead GENERAL INFORMATION SPARK PLUG WIRE RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE CABLE THROTTLE CABLE LEFT HANDLEBAR SWITCH WIRE CLUTCH CABLE SPEEDOMETER CABLE ...

Page 31: ...1 26 dummyhead dummyhead GENERAL INFORMATION RIGHT HANDLEBAR SWITCH WIRE SPEEDOMETER CABLE THROTTLE CABLE LEFT HANDLEBAR SWITCH WIRE MAIN WIRE HARNESS HORN WIRE CLUTCH CABLE FRONT BRAKE CABLE ...

Page 32: ...E THROTTLE CABLE CARBURETOR HEATER WIRE CARBURETOR AIR VENT HOSE REAR BRAKE LIGHT SWITCH WIRE CONNECTOR BOOT NEUTRAL SWITCH WIRE CONNECTOR ALTERNATOR 2P CONNECTOR IGNITION PULSE GENERATOR WIRE CONNECTOR THERMO SWITCH 2P CONNECTOR CARBURETOR DRAIN HOSE CRANKCASE BREATHER DRAIN HOSE ...

Page 33: ...GENERAL INFORMATION BATTERY CABLE BATTERY CABLE ALTERNATOR WIRE FUSE BOX IGNITION CONTROL MODULE ICM REAR BRAKE LIGHT SWITCH 2P BLACK CONNECTOR HORN WIRE CLUTCH CABLE NEUTRAL SWITCH WIRE FUEL HOSE CRANKCASE BREATHER DRAIN HOSE ...

Page 34: ... INFORMATION FUSE BOX REAR BRAKE LIGHT SWITCH 2P BLACK CONNECTOR RIGHT REAR TURN SIGNAL LIGHT WIRE LEFT REAR TURN SIGNAL LIGHT WIRE MAIN WIRE HARNESS CONNECTOR BOOT BRAKE TAIL LIGHT 3P CONNECTOR REAR TURN SIGNAL LIGHT WIRE CONNECTORS ...

Page 35: ...on chamber through the air cleaner and carburetor EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a pulse secondary air injection system and lean carburetor settings no adjustment should be made except idle speed adjustment with the throttle stop screw PULSE SECONDARY AIR INJECTION SYSTEM XR125LK LEK The pulse secondary air injection PAIR system introduces filter...

Page 36: ...ME BODY PANELS EXHAUST SYSTEM SEAT 2 2 SIDE COVER 2 2 REAR CARRIER 2 2 REAR COWL 2 3 NUMBER PLATE BRACKET 2 3 SIDE SHROUD 2 4 FUEL TANK 2 4 FRONT VISOR 2 4 FRONT FENDER 2 5 DRIVE SPROCKET COVER 2 5 EXHAUST PIPE MUFFLER 2 6 ...

Page 37: ...e bolts and collars on both sides then tighten the bolts SIDE COVER REMOVAL INSTALLATION Remove the bolt 1 and collar 2 Remove the bosses 3 of the side cover 4 from the grommets of the frame then remove the side cover Installation is in the reverse order of removal REAR CARRIER REMOVAL INSTALLATION Remove the seat page 2 2 Remove the following Bolts 1 Collars 2 Mount rubbers 3 Rear carrier 4 Insta...

Page 38: ...RACKET REMOVAL INSTALLATION Remove the following Side covers page 2 2 Seat page 2 2 Rear carrier page 2 2 Rear cowl page 2 3 Disconnect the brake tail light 3P connector 1 Remove the bolts 2 collars 3 clamps 4 and mount rubbers 5 Remove the number plate bracket 6 Installation is in the reverse order of removal DISASSEMBLY ASSEMBLY Remove the license light page 18 5 Remove the screws 1 mount rubber...

Page 39: ...fuel valve OFF Disconnect the fuel hose from the fuel valve Remove the bolt 1 collar 2 and mount rubber 3 Remove the fuel tank 4 while releasing it from the rubber mounts 5 Installation is in the reverse order of removal FRONT VISOR REMOVAL INSTALLATION Remove the following Two bolts 1 setting nuts 2 Headlight aim adjusting screw 3 washer 4 Mount rubber 5 Collar 6 Nut 7 Headlight aim adjuster 8 Di...

Page 40: ...he reverse order of disassembly FRONT FENDER REMOVAL INSTALLATION Remove the bolts 1 Remove the front fender 2 headlight aim adjuster holder 3 and collars 4 Installation is in the reverse order of removal DRIVE SPROCKET COVER REMOVAL INSTALLATION Remove the bolts 1 then remove the drive sprocket cover 2 and drive chain guide 3 Installation is in the reverse order of removal 6 1 1 2 3 4 5 1 2 3 4 1...

Page 41: ...sket with new ones Temporarily install the exhaust pipe and muffler in the reverse order of removal by loosely installing all the fasteners Tighten the exhaust pipe joint nuts first then tighten the muffler band bolt muffler mounting bolt and nut After installation inspect the exhaust system for leaks When replacing the stud bolt 1 check that the stud length is within specification as shown 9 6 5 ...

Page 42: ...INE OIL 3 7 ENGINE OIL STRAINER SCREEN 3 7 ENGINE OIL CENTRIFUGAL FILTER 3 8 ENGINE IDLE SPEED 3 8 SECONDARY AIR SUPPLY SYSTEM XR125LK LEK 3 9 DRIVE CHAIN 3 9 DRIVE CHAIN SLIDER 3 11 BRAKE FLUID XR125LK LEK 3 12 BRAKE SHOES PADS WEAR 3 12 BRAKE SYSTEM 3 13 BRAKE LIGHT SWITCH 3 14 HEADLIGHT AIM 3 15 CLUTCH SYSTEM 3 15 SIDESTAND 3 16 SUSPENSION 3 16 NUTS BOLTS FASTENERS 3 16 WHEELS TIRES 3 16 STEERI...

Page 43: ...res mechanical skill 6 Replace the PAIR air filter every 3 years or 24 000 km 15 000 mi Replacement requires mechanical skill FREQUENCY NOTE ODOMETER READING NOTE 1 REFER TO PAGE x 1 000 km 1 4 8 12 ITEMS x 1 000 mi 0 6 2 5 5 7 5 FUEL LINE I I I FUEL STRAINER SCREEN C C C 3 3 THROTTLE OPERATION I I I 3 3 AIR CLEANER DK TYPE AND XL125LK NOTE 2 EVERY 12 000 km 7 500 mi R 3 4 AIR CLEANER EXCEPT DK TY...

Page 44: ...the throttle grip for smooth operation Check that the throttle opens and automatically closes in all steering positions If the throttle grip does not return properly lubricate the throttle cable and throttle housing For cable lubrication Disconnect the throttle cable at its upper end Thoroughly lubricate the cable and its pivot points with a commercially available cable lubricant or a light weight...

Page 45: ...der of removal AIR CLEANER SUB FILTER XR125LK LEK Remove the following Side shroud page 2 4 Fuel tank page 2 4 Check the air cleaner sub filter 1 and replace if necessary When replacing the sub filter remove the following Disconnect the air cleaner sub filter to PAIR control valve hose 2 Disconnect the air cleaner sub filter to three way joint hose 3 and remove the air cleaner sub filter Installat...

Page 46: ...er head and then tighten the spark plug to the specified torque Connect the spark plug cap INSPECTION Check the following and replace if necessary Insulator for damage Center electrode and side electrode for wear Burning condition coloration Dark to light brown indicates good condition Excessive lightness indicates malfunctioning ignition system or lean mixture Wet or black sooty deposit indicates...

Page 47: ...er toward the outside Check the clearances of the intake and exhaust valves by inserting the feeler gauge 1 between the adjusting screw and valve stem Adjust by loosening the lock nut 1 and turning the adjusting screw 2 until there is a slight drag on the feeler gauge Apply engine oil to the lock nut Hold the adjusting screw and tighten the lock nut After tightening the lock nut recheck the valve ...

Page 48: ... onto the drain bolt Install the drain bolt with a new sealing washer and tighten it to the specified torque Fill the crankcase with the recommended engine oil Check the oil level Make sure there are no oil leaks ENGINE OIL STRAINER SCREEN Remove the right crankcase cover page 10 4 Remove the oil strainer screen 1 out of the crankcase Wash the strainer screen thoroughly in non flammable or high fl...

Page 49: ... with the clip Check that the oil through operates freely without binding Install the rotor cover 1 with a new gasket 2 and tighten the three screws Install the right crankcase cover page 10 4 ENGINE IDLE SPEED Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications Engine must be warm for accurate adjustment Ten minutes of stop ...

Page 50: ...injection hoses between the air cleaner sub filter 1 PAIR control valve 2 and cylinder head cover for deterioration damage or loose connections Make sure that the hoses are not cracked Check the PAIR hoses 1 between the air cleaner sub filter and air inlet cover for deterioration damage or loose connections Make sure that the hoses are not kinked pinched or cracked Check the vacuum hose 2 between ...

Page 51: ...N Clean the drive chain 1 with a chain cleaner designed specifically for O ring chains or a neutral detergent Use a soft brush if the drive chain is dirty Do not use a steam cleaner high pressure cleaner wire brush volatile solvent such as gasoline and benzene abrasive cleaner or a chain cleaner NOT designed specifically for O ring chains to clean the drive chain Inspect the drive chain for possib...

Page 52: ...r rapidly Check the attaching bolts and nuts on the drive and driven sprockets If any are loosen torque them Install the drive sprocket cover page 2 5 DRIVE CHAIN SLIDER Remove the drive sprocket cover page 2 5 Check the drive chain slider 1 for wear or damage Replace the drive chain slider if it is worn up to the wear limit Refer to procedure for swingarm removal installation page 15 13 2 3 1 TOR...

Page 53: ...rake pads for wear page 3 12 A low fluid level may be due to worn brake pads If the brake pads are worn the caliper pistons are pushed out and this causes a low reservoir level If the brake pads are not worn and the fluid level is low check entire system for leaks page 3 13 BRAKE SHOES PADS WEAR FRONT BRAKE SHOES XL125LK Check the wear indicator position when the brake lever is applied If the arro...

Page 54: ...ystem If the lever feels soft or spongy when operated bleed air from the system page 16 4 Inspect the brake hose 1 and fittings for deterioration cracks damage and signs of leakage Tighten any loose fittings Replace hose and fittings as required BRAKE LEVER FREEPLAY XL125LK Inspect the brake cable for kinks or damage and lubricate the cable if necessary Measure the brake lever freeplay at the end ...

Page 55: ...1 and turn the adjusting bolt 2 to obtain the pedal height After adjustment tighten the lock nut Adjust the pedal free play page 3 14 BRAKE LIGHT SWITCH Adjust the rear brake light switch after adjusting the brake pedal free play The front brake light switch does not adjusting Adjust the rear brake light switch 1 so that the brake light will come on when the brake pedal is pushed down 15 mm 0 6 in...

Page 56: ...the lock nut and install the dust cover The adjuster may be damaged if it is positioned too far out leaving minimal thread engagement If the adjuster is threaded out near the limit and the correct free play cannot be obtained turn the adjuster all the way in and back out one turn Tighten the lock nut and make major adjustments as described below Major adjustments are made with the lower adjusting ...

Page 57: ... motorcycle securely Check for worn swingarm by grabbing the swingarm and attempting to move the wheel side to side NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values page 1 10 Check that all cotter pins safety clips hose clamps and cable stays are in place and properly secured WHEELS TIRES Check for worn wheel bearings by grabbing the front and...

Page 58: ... or box under the engine Check that the handlebar moves freely from side to side Make sure the control cables do not interfere with the handlebar rotation If the handlebar moves unevenly binds or has vertical movement inspect the steering head bearings page 14 22 XR125LK LEK XL125LK FRONT REAR FRONT REAR Tire pressure kPa kgf cm2 psi Driver only 150 1 5 22 150 1 5 22 150 1 5 22 150 1 5 22 Driver a...

Page 59: ...MEMO dummyhead dummyhead ...

Page 60: ...mytext 4 IGNITION SYSTEM COMPONENT LOCATION 4 2 SYSTEM DIAGRAM 4 2 SERVICE INFORMATION 4 3 TROUBLESHOOTING 4 3 IGNITION SYSTEM INSPECTION 4 4 IGNITION TIMING 4 5 IGNITION COIL 4 6 ICM IGNITION CONTROL MODULE 4 6 ...

Page 61: ...GNITION PULSE GENERATOR SPARK PLUG IGNITION PULSE GENERATOR IGNITION COIL SPARK PLUG SIDESTAND SWITCH NEUTRAL SWITCH CLUTCH SWITCH BATTERY IGNITION SWITCH IGNITION CONTROL MODULE ICM Bl R G W Y Bu Lg Black Red Green White Yellow Blue Light Green NZ TYPE shown Bu Y Bl Y G R R W R Bl Bl G R G W G 2P 4P Bu Y Bl Y R Bl G W Lg R G Up Down MAIN FUSE 15 A ...

Page 62: ...The sampling time of the tester and measured pulse were not synchronized System is normal if measured voltage is over the standard voltage at least once 4 Poorly connected connectors or an open circuit in the ignition system 5 Faulty ignition coil 6 Faulty ignition control module ICM in case when above No 1 5 are normal No peak voltage 1 Incorrect peak voltage adapter connections 2 Faulty ignition...

Page 63: ...nnect the spark plug cap from the spark plug Connect a known good spark plug 1 to the spark plug cap and ground it to the cylinder head as done in a spark test With the ignition coil primary wire connected connect the peak voltage adaptor 1 or tester probes to the ignition coil primary terminal 2 and body ground Shift the transmission into neutral Turn the ignition switch to ON Crank the engine wi...

Page 64: ...or side connector and body ground In the same manner as at the ICM connector measure the peak voltage and compare it to the voltage measured at the ICM connector If the peak voltage measured at the ICM is abnormal and the one measured at the ignition pulse generator is normal the wire harness has an open or short circuit or loose connection If both peak voltages are abnormal follow the checks desc...

Page 65: ...move the fuel tank page 2 4 Disconnect the spark plug cap from the spark plug Disconnect the primary wire connector 1 and ground wire connector 2 from the ignition coil Remove the bolts 3 and ignition coil 4 Installation is in the reverse order of removal ICM IGNITION CONTROL MODULE REMOVAL INSTALLATION Remove the left side cover page 2 2 Disconnect the ICM 4P connector 1 Remove the ICM 2 from the...

Page 66: ...5 1 5 dummytext 5 ELECTRIC STARTER COMPONENT LOCATION 5 2 SYSTEM DIAGRAM 5 2 SERVICE INFORMATION 5 3 TROUBLESHOOTING 5 3 STARTER MOTOR 5 5 STARTER RELAY 5 7 NEUTRAL DIODE 5 8 ...

Page 67: ...H STARTER RELAY SWITCH MAIN FUSE 15 A BATTERY CLUTCH SWITCH FUSE BOX SUB FUSE 10 A DIODE STARTER MOTOR STARTER RELAY SWITCH MAIN FUSE 15 A IGNITION SWITCH BATTERY R W Bl Br G R Lg R R STARTER SWITCH SUB FUSE 10 A CLUTCH SWITCH DIODE NEUTRAL SWITCH Bl Bl G W G Bl Bl R R Bl Y R G R SIDESTAND SWITCH NZ type DOWN UP Bl R G W Y Br Lg Black Red Green White Yellow Brown Light Green ...

Page 68: ...l or when the clutch lever is squeezed Starter motor does not turn 1 Fuse Inspection Check for blown main fuse 15 A or sub fuse 10 A Is the fuse blown YES Replace the fuse NO GO TO STEP 2 2 Battery Inspection Make sure the battery is fully charged and in good condition Is the battery in good condition YES GO TO STEP 3 NO Charge or replace the battery page 17 5 3 Battery Cable Inspection Check the ...

Page 69: ...e of the starter relay switch page 5 7 Is the power input line normal YES GO TO STEP 9 NO Faulty ignition switch page 18 7 Faulty starter switch page 18 7 Loose or poor contact of the related connector terminal Open circuit in the wire harness 9 Starter Relay Switch Inspection Check the function of the starter relay switch page 5 8 Does the starter relay switch function properly NO Faulty starter ...

Page 70: ...BLY The coil may be damaged if the magnet pulls the armature against the motor case Disassemble and assemble the starter motor as following illustration When disassembling record the location and number of shims to ensure correct reassembly in their original locations Align the rear cover tab with the motor case groove 4 2 3 1 5 6 MOTOR CASE BOLT O RINGS FRONT COVER INSULATED PLATES NUT MOTOR CASE...

Page 71: ...etween the brush and rear cover should be continuity Between the cable terminal and rear cover should be NO continuity Inspect the brushes for damage and measure the brush length INSTALLATION Coat a new O ring 1 with clean engine oil and install it into the groove of the starter motor 2 Install the starter motor to the crankcase Install the mounting bolts 1 with the battery cable 2 as shown and ti...

Page 72: ...n t hear the switch click inspect the relay switch circuits page 5 7 CIRCUIT INSPECTION Remove the left side cover page 2 2 Inspect the starter relay circuit as follows GROUND LINE Turn the ignition switch to OFF Disconnect the starter relay switch 4P Red connector 1 Check for continuity between the Green red wire terminal of the wire harness side connector and ground If there is continuity when t...

Page 73: ...page 2 3 Remove the neutral diode 1 from the connector boot EXCEPT NZ TYPE Check for continuity between the diode terminals When there is continuity a small resistance value will register If there is continuity in one direction the neutral diode is normal Install the neutral diode in the reverse order of removal NZ TYPE Check for continuity between the diode terminals When there is continuity a sm...

Page 74: ...TEM SYSTEM COMPONENTS 6 2 SERVICE INFORMATION 6 2 TROUBLESHOOTING 6 3 AIR CLEANER HOUSING 6 4 CARBURETOR 6 5 CARBURETOR HEATER EXCEPT CO III LA TYPES 6 10 PILOT SCREW ADJUSTMENT 6 12 SECONDARY AIR SUPPLY SYSTEM XR125LK LEK 6 13 ...

Page 75: ...tem parts note the locations of the O rings Replace them with new ones on reassembly Before removing the carburetor place an approved gasoline container under the carburetor drain hose loosen the drain screw and drain the carburetor After removing the carburetor wrap the intake port of the engine with a shop towel or cover it with pieces of tape to prevent any foreign material from dropping into t...

Page 76: ... valve Rich mixture Choke valve closed Clogged air jets Faulty float valve Float level too high Dirty air cleaner Worn jet needle or needle jet Engine stalls hard to start rough idling Restricted fuel line Fuel mixture too lean rich Contaminated deteriorated fuel Clogged jets Intake air leak Misadjusted idle speed Restricted fuel tank breather hose Dirty air cleaner Misadjusted pilot screw Faulty ...

Page 77: ...module ICM page 4 6 Starter relay switch 1 Fuse box 2 Loosen the connecting boot band screw 1 Disconnect the crankcase breather hose 2 and carburetor air vent hose 3 Remove the shock absorber lower mounting bolt 1 and nut 2 Remove the air cleaner housing mounting bolts 3 and washer 4 Remove the air cleaner housing 5 to the backward Installation is in the reverse order of removal 1 2 1 2 3 TORQUE S...

Page 78: ...r top and throttle valve jet needle Remove the throttle cable 3 from the throttle valve while compressing the throttle valve spring 4 Turn the jet needle retainer 1 counterclockwise Remove the jet needle retainer and jet needle 2 from the throttle valve 3 Remove the spring 4 from the jet needle retainer Check the throttle valve and jet needle for scratches wear or damage CARBURETOR BODY Turn the f...

Page 79: ...Except CO III LA types Disconnect the carburetor heater connector 1 and ground wire connector 2 Release the carburetor heater wire from the clamp 3 Loosen the connecting boot band screw 1 Remove the carburetor mounting nuts 2 and wire clamp 3 then remove the carburetor 4 from the insulator 1 2 1 2 3 2 1 3 2 4 ...

Page 80: ... off valve cover or the compression spring will jump out of the carburetor Remove the two screws 1 2 1 N m 0 2 kgf m 1 5 lbf ft 2 1 N m 0 2 kgf m 1 5 lbf ft O RING BAFFLE PLATE 1 5 N m 0 2 kgf m 1 1 lbf ft 2 1 N m 0 2 kgf m 1 5 lbf ft 1 8 N m 0 2 kgf m 1 3 lbf ft 2 5 N m 0 3 kgf m 1 8 lbf ft FLOAT VALVE SETTING PLATE DRAIN SCREW CHOKE LEVER MAIN JET NEEDLE JET HOLDER NEEDLE JET FLOAT CHAMBER FLOAT...

Page 81: ...seated and the float arm just touching the valve measure the float level with the special tool as shown The float cannot be adjusted Replace the float assembly if the float level is beyond the specified limit INSTALLATION CARBURETOR BODY Install a new O ring 1 into the groove of the carburetor body Install the carburetor 1 to the carburetor connecting boot Install the carburetor mounting nuts 2 wi...

Page 82: ...eater cover 1 and tighten the screw 2 securely Connect the fuel hose 1 to the fuel valve After installing the carburetor check the following Throttle grip free play page 3 3 Engine idle speed page 3 8 Pilot screw adjustment page 6 12 THROTTLE VALVE Install the spring 1 into the jet needle retainer 2 Install the jet needle 3 and retainer to the throttle valve 4 Turn the jet needle retainer clockwis...

Page 83: ...e valve while aligning its cut out 2 with the throttle stop screw 3 Tighten the carburetor top securely Install the following Right side cover page 2 2 Right side shroud page 2 4 After installing the throttle valve check the following Throttle grip free play page 3 3 Engine idle speed page 3 8 CARBURETOR HEATER EXCEPT CO III LA TYPES CARBURETOR HEATER REMOVAL INSTALLATION Remove the screw 1 and ca...

Page 84: ...n replace the carburetor heater THERMO SWITCH INSPECTION Remove the right side cover page 2 2 Remove the thermo switch from the connector boot 1 Disconnect the thermo switch 2P connector 1 Check for continuity between the terminals If thermo switch is out of specification replace the switch TORQUE CARBURETOR HEATER 4 9 N m 0 5 kgf m 3 6 lbf ft 1 2 STANDARD 8 2 12 3 Ω 25 C 77 F 1 1 STANDARD Above 2...

Page 85: ...tes sufficient 3 Stop the engine and connect a tachometer according to the tachometer manufacturer s instructions 4 Disconnect the PAIR control valve vacuum hose 1 then connect the vacuum pump 2 and plug the vacuum port Apply the specified vacuum to the PAIR control valve vacuum hose more than 330 mm Hg 5 Start the engine and adjust the idle speed with the throttle stop screw 1 6 Turn the pilot sc...

Page 86: ...ot screw inward or outward slowly to obtain the highest engine speed 6 Lightly open the throttle 2 3 times then adjust the idle speed with the throttle stop screw 7 Turn the pilot screw inward to the final opening 8 Readjust the idle speed with the throttle stop screw SECONDARY AIR SUPPLY SYSTEM XR125LK LEK SYSTEM INSPECTION Start the engine and warm it up to normal operating temperature Remove th...

Page 87: ...ng air and that the vacuum does not bleed If the air drawn in or if the specified vacuum is not maintained install a new PAIR control valve PAIR CHECK VALVE INSPECTION Remove following PAIR control valve page 6 14 Two screws 1 Valve cover 2 PAIR check valve 3 Check the valve reed for fatigue or damage replace if necessary Replace the PAIR check valve if the seat rubber is cracked deteriorated or d...

Page 88: ...Remove the bolts 1 and air suction pipe 2 Remove the O ring 3 from the cylinder head cover Installation is in the reverse order of removal RESONATOR TANK AND AIR INLET COVER REMOVAL INSTALLATION Remove the side shroud page 2 4 Disconnect the air inlet cover to three way joint hose 1 Remove the bolt 2 and air inlet cover 3 Disconnect resonator tank to three way joint hose 4 Remove the bolt 5 and re...

Page 89: ...MEMO dummyhead dummyhead ...

Page 90: ...7 1 7 dummytext 7 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 7 2 SERVICE INFORMATION 7 3 TROUBLESHOOTING 7 3 OIL PUMP 7 3 ...

Page 91: ...7 2 dummyhead dummyhead LUBRICATION SYSTEM LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM OIL STRAINER SCREEN OIL PUMP CAMSHAFT OIL FILTER ROTOR COUNTERSHAFT ROCKER ARM MAINSHAFT CRANKSHAFT ...

Page 92: ...ks Worn valve guide or stem seal Worn piston rings or incorrect piston ring installation Worn cylinder Engine oil contamination Oil not changed often enough Clogged oil strainer Oil centrifugal filter not cleaned often enough Worn piston rings OIL PUMP REMOVAL Remove the right crankcase cover page 10 4 Remove the oil pump driven gear 1 Remove the two mounting bolts 2 and oil pump 3 Remove the dowe...

Page 93: ... cover as an assembly Temporarily install the outer rotor inner rotor and oil pump shaft into the oil pump body TIP CLEARANCE Measure the tip clearance BODY CLEARANCE Measure the body clearance SIDE CLEARANCE Remove the oil pump shaft Measure the side clearance using a straight edge and feeler gauge Assemble the oil pump page 7 4 PUMP BODY INNER ROTOR OIL PUMP COVER ROTOR SHAFT OUTER ROTOR SCREW 3...

Page 94: ...CYLINDER HEAD VALVES SYSTEM COMPONENTS 8 2 SERVICE INFORMATION 8 2 TROUBLESHOOTING 8 3 CYLINDER COMPRESSION 8 3 CYLINDER HEAD COVER 8 4 CAMSHAFT 8 5 CAMSHAFT HOLDER 8 8 CYLINDER HEAD 8 11 CAM CHAIN TENSIONER LIFTER 8 17 ...

Page 95: ...the cylinder head cover and cylinder head too hard during removal When disassembling mark and store the disassembled parts to ensure that they are reinstalled in their original locations Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection Camshaft and rocker arm lubricating oil is fed through oil passages in the cylinder head an...

Page 96: ...seat Worn or damaged camshaft Worn rocker arm and or shaft Worn rocker arm and valve stem end Worn cam sprocket teeth or cam chain Worn or damaged cam chain tensioner Cylinder piston problem page 9 3 Rough idle Low cylinder compression CYLINDER COMPRESSION Warm up the engine to normal operating temperature Stop the engine and remove the spark plug Install the compression gauge 1 into the spark plu...

Page 97: ... Remove the gasket 1 from the cylinder head cover 2 Remove the O ring 3 Remove the dowel pin 1 and O ring 2 from the camshaft holder Clean the oil passage and air passage of the cylinder head cover using compressed air Install the dowel pin into the camshaft holder Coat a new O ring with engine oil and install it onto the dowel pin Install a new gasket 1 into the cylinder head cover groove Coat a ...

Page 98: ... T mark 1 on the flywheel with the index notch 2 on the left crankcase cover Make sure the piston is at TDC Top Dead Center on the compression stroke This position can be confirmed by checking for slack in the rocker arms If there is no slack rotate the crankshaft counterclockwise one full turn and align the T mark with the index notch again Remove the sealing plug and O ring from the cam chain te...

Page 99: ...e bearings should turn smoothly and quietly Also check that the bearing inner race fits tightly on the camshaft Replace the camshaft assembly if the bearing does not turn smoothly quietly or if they fit loosely on the camshaft Measure the height of each cam lobe Inspect the cam lobes for damage or excessive wear Check the rocker arm if each cam lobe are worn or damaged INSTALLATION Lubricate the c...

Page 100: ...cylinder head Install the cam sprocket onto the camshaft flange Install the cam sprocket bolts 4 and tighten them Remove the tensioner stopper from the cam chain tensioner lifter Turn the crankshaft counterclockwise one full turn 360 Be sure that the index line on the cam sprocket aligns with the upper surface of the cylinder head when the T mark on the flywheel is aligned with the index notch on ...

Page 101: ...ming hole cap and tighten it Install the cylinder head cover page 8 4 CAMSHAFT HOLDER REMOVAL Remove the cam sprocket page 8 5 Loosen the cylinder head bolts 1 Remove the camshaft holder nuts 2 washers 3 and the camshaft holder 4 DISASSEMBLY Remove the bolt 1 and camshaft retainer plate 2 Remove the camshaft 3 from the camshaft holder Remove the rocker arm shaft bolts 1 TORQUE 15 N m 1 5 kgf m 11 ...

Page 102: ... the holder ASSEMBLY Apply engine oil to the rocker arm 1 inner surfaces rollers and rocker arm shaft 2 entire surfaces 1 2 ROCKER ARMS ROCKER ARM SHAFT ROCKER ARM SHAFT CAMSHAFT CAMSHAFT HOLDER RETAINER PLATE ROCKER ARM SHAFT BOLTS molybdenum oil solution to cam lobes 5 N m 0 5 kgf m 3 7 lbf ft 1 2 ...

Page 103: ...holes in the camshaft holder and rocker arm shafts 1 using a screwdriver and install the rocker arm shaft bolts 2 Tighten the rocker arm shaft bolts Lubricate the camshaft bearings 1 with engine oil Apply molybdenum oil solution to the cam lobes 2 Install the camshaft 1 into the camshaft holder with its tab 2 facing up Install the camshaft retainer plate 3 and bolt 4 then tighten the bolt securely...

Page 104: ... nuts to the specified torque Tighten the cylinder head bolts 3 Install the cam sprocket page 8 6 CYLINDER HEAD REMOVAL INSTALLATION Remove the following Engine page 13 3 Camshaft holder page 8 8 Spark plug 1 Two cylinder head bolts 2 and cylinder head 3 Remove the cylinder head gasket 1 and two dowel pins 2 Clean the mating surfaces of the cylinder head and cylinder Install the dowel pins and a n...

Page 105: ... of tension do not compress the valve spring more than necessary to remove the cotters While compressing the valve spring with a valve spring compressor remove the valve cotters 1 Mark all disassembled parts to ensure correct reassembly Remove the following Spring retainers 1 Inner and outer valve springs 2 Intake and exhaust valves 3 Stem seals 4 Spring seats 5 Remove the carbon deposits from the...

Page 106: ...stem with molybdenum oil solution Insert the intake and exhaust valves 3 into the valve guides Install the inner and outer valve springs 4 with the tightly wound coils facing the combustion chamber Install the spring retainers 5 RETAINER VALVE COTTERS SPRING SEAT STEM SEAL VALVE GUIDE INTAKE VALVE EXHAUST VALVE CLIP VALVE SPRINGS To avoid damage to the seal turn the valve slowly when inserting 5 4...

Page 107: ...and always rotate the reamer clockwise Measure each valve guide I D and record it Calculate the stem to guide clearance If the stem to guide clearance exceeds the service limit determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace the guides as necessary and ream to fit If the stem to guide clearance still exceeds the service limit with a new gu...

Page 108: ... cool to room temperature Take care not to tilt or lean the reamer in the guide while reaming Use cutting oil on the reamer during this operation Ream the new valve guides Insert the reamer from the combustion chamber side of the cylinder head and always rotate the reamer clockwise Clean the cylinder head thoroughly to remove any metal particles after reaming and inspect and reface the valve seats...

Page 109: ...nded to correct a worn valve seat Using 45 degree cutter and cut the seat to the proper width Make sure that all pitting and irregularities are removed Refinish if necessary After cutting the seat apply lapping compound to the valve face and lap the valve using light pressure Change the angle of lapping tool 1 frequently to prevent uneven seat wear After lapping wash any residual compound off the ...

Page 110: ...he cylinder Remove the tensioner stopper from the tensioner lifter Check the cam chain tensioner lifter operation The tensioner lifter shaft should not go into the body when it is pushed When it is turned clockwise with a screwdriver the tensioner lifter shaft should be pulled into the body The shaft should spring out of the body as soon as the screwdriver is released Turn the cam chain tensioner ...

Page 111: ...lifter 2 onto the cylinder Install the two mounting bolts 1 and tighten them Remove the tensioner stopper from the tensioner lifter Coat a new O ring 2 with engine oil and install it into the tensioner lifter groove Install the plug 3 and tighten it 1 2 TORQUE 4 0 N m 0 4 kgf m 3 0 lbf ft 3 1 2 ...

Page 112: ...9 1 9 dummytext 9 CYLINDER PISTON SYSTEM COMPONENTS 9 2 SERVICE INFORMATION 9 3 TROUBLESHOOTING 9 3 CYLINDER 9 4 PISTON 9 5 ...

Page 113: ...9 2 dummyhead dummyhead CYLINDER PISTON CYLINDER PISTON SYSTEM COMPONENTS ...

Page 114: ...lean the oil passage before installing cylinder TROUBLESHOOTING Compression too low hard starting or poor performance at low speed Leaking cylinder head gasket Worn stuck or broken piston ring Worn or damaged cylinder and piston Compression too high overheating or knocking Excessive carbon built up on piston or combustion chamber Excessive smoke Worn cylinder piston or piston rings Improper instal...

Page 115: ...wo dowel pins and a new gasket Apply engine oil to the cylinder wall piston outer surface and piston rings Route the cam chain 1 through the cylinder 2 and install the cylinder over the piston 3 while compressing the piston rings 4 with your fingers Insert the cam chain guide 1 into the cylinder and crankcase grooves 2 Install the cylinder head page 8 11 Do not strike the cylinder too hard and do ...

Page 116: ...height if necessary PISTON REMOVAL Place a clean shop towel over the crankcase to prevent the possibility of the clip falling into the crankcase Remove the piston pin clip 1 using the pair of pliers Push the piston pin 2 out of the piston and connecting rod and remove the piston Do not damage the piston ring by spreading the ends too far Spread each piston ring 1 and remove it by lifting it up at ...

Page 117: ... connecting rod small end inner surface Apply engine oil to the piston pin hole 1 Install the piston 2 with its IN mark 3 toward the intake side and insert the piston pin 4 through the piston and connecting rod Place a shop towel over the crankcase opening to prevent piston pin clips from falling into the crankcase Install new piston pin clips 1 into the grooves in the piston pin hole Make sure th...

Page 118: ...10 1 10 dummytext 10 CLUTCH GEARSHIFT LINKAGE SYSTEM COMPONENTS 10 2 SERVICE INFORMATION 10 3 TROUBLESHOOTING 10 3 RIGHT CRANKCASE COVER 10 4 CLUTCH 10 7 GEARSHIFT LINKAGE 10 10 PRIMARY DRIVE GEAR 10 13 ...

Page 119: ...TCH GEARSHIFT LINKAGE SYSTEM COMPONENTS 22 N m 2 2 kgf m 16 lbf ft 12 N m 1 2 kgf m 9 lbf ft 4 0 N m 0 4 kgf m 3 0 lbf ft 64 N m 6 5 kgf m 47 lbf ft 74 N m 7 5 kgf m 55 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft 26 N m 2 7 kgf m 19 lbf ft ...

Page 120: ... 4 TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the freeplay Clutch lever difficult to pull in Damaged kinked or dirty clutch cable Improperly routed clutch cable Damaged clutch lifter mechanism Faulty clutch lifter plate bearing Clutch will not disengage or motorcycle creeps with clutch disengaged Excessive clutch lever free play Clutch plate warped Oil level too ...

Page 121: ...lutch cable stay 2 then disconnect the clutch cable Loosen the right crankcase cover bolts 3 in a crisscross pattern in 2 or 3 steps Remove the bolts and right crankcase cover 4 Remove the two dowel pins 1 and gasket 2 INSTALLATION Clean off any gasket material from the right crankcase and cover mating surfaces Install the dowel pins and a new gasket When removing the kickstarter pedal mark the pe...

Page 122: ...n the original position as noted during removal and tighten the bolt 2 Fill the crankcase with the recommended engine oil page 3 7 Adjust the brake pedal freeplay page 3 14 DISASSEMBLY Remove the right crankcase cover page 10 4 Remove the clutch lifter piece 1 by turning the lifter arm clockwise slightly Drive the spring pin 2 into the clutch lifter arm 3 until the pin end is flush with the lifter...

Page 123: ...the right crankcase cover as specified Apply engine oil to the clutch lifter arm sliding surface and install it into the right crankcase cover Install the return spring 1 onto the lifter arm end From the opposite side drive the spring pin 2 until it projects as specified using the pin driver Install the lifter piece 1 into the lifter arm groove while turning the lifter arm 2 clockwise slightly Ins...

Page 124: ...lock nut washer 4 and oil filter rotor 5 Loosen the clutch lifter plate bolts 1 in a crisscross pattern in several steps Remove the bolts lifter plate 2 and clutch springs 3 Attach the clutch center holder 1 to the pressure plate using the four clutch lifter plate bolts to hold the clutch center and then loosen the lock nut 2 Remove the lock nut then the clutch center holder 4 2 3 1 TOOLS 2 Gear h...

Page 125: ...ter surface of the clutch outer guide and install it onto the mainshaft Apply engine oil to the primary driven gear teeth Install the clutch outer 1 and thrust washer 2 Coat the clutch discs with engine oil Install the clutch disc A 1 four clutch plates 2 and three discs B 3 alternately and clutch disc A onto the clutch center 4 Install the pressure plate 5 onto clutch center by aligning the o mar...

Page 126: ...ll the lock nut onto the mainshaft Attach the clutch center holder to the pressure plate using four clutch lifter plate bolts to hold the clutch center and then tighten the lock nut Install the clutch springs 1 lifter plate 2 and bolts 3 Tighten the bolts in a crisscross pattern in several steps Install the oil filter rotor 1 and washer 2 onto the crankshaft 1 2 3 TOOL 2 Clutch center holder 07GMB...

Page 127: ...lter rotor cover 1 and screws 2 Tighten screws to the specified torque Install the oil pump driven gear 3 Install the right crankcase cover page 10 4 GEARSHIFT LINKAGE REMOVAL INSPECTION Remove the clutch page 10 7 Remove the bolt 1 and gearshift pedal 2 Clean the left end of the gearshift spindle TOOLS 2 Gear holder 07724 0010200 3 Lock nut wrench 07716 0020100 TORQUE 64 N m 6 5 kgf m 47 lbf ft 1...

Page 128: ...emove the thrust washer 2 from the spindle Remove the following Gearshift cam bolt 1 Gearshift cam 2 Dowel pins 1 Stopper arm bolt 2 Stopper arm 3 Washer 4 Return spring 5 Inspect the gearshift spindle oil seal 1 for deterioration or damage replace if necessary If replacing the oil seal install it as specified 1 2 1 2 1 2 3 4 5 0 5 1 0 mm 0 02 0 04 1 ...

Page 129: ...driver and install the gearshift cam 3 by aligning its holes 4 with the dowel pins Apply locking agent to the gearshift cam bolt threads Install the gearshift cam bolt 1 and tighten it Check the gearshift spindle 1 for wear or bend Check the spindle plate 2 for wear damage or deformation Check the return spring 3 for fatigue or damage Apply engine oil to the gearshift spindle journals Install the ...

Page 130: ...emoval Install the pinch bolt 2 and tighten it PRIMARY DRIVE GEAR REMOVAL INSTALLATION Remove the clutch page 10 7 Remove the primary drive gear 1 spacer 2 and woodruff key 3 Install the woodruff key into the crankshaft key groove Apply engine oil to the primary drive gear teeth Install the spacer and primary drive gear onto the crankshaft by aligning the key groove 4 with the woodruff key Install...

Page 131: ...MEMO dummyhead dummyhead ...

Page 132: ...11 1 11 dummytext 11 ALTERNATOR STARTER CLUTCH SYSTEM COMPONENTS 11 2 TROUBLESHOOTING 11 2 LEFT CRANKCASE COVER 11 3 STATOR IGNITION PULSE GENERATOR 11 4 FLYWHEEL STARTER CLUTCH 11 4 ...

Page 133: ...R STARTER CLUTCH ALTERNATOR STARTER CLUTCH SYSTEM COMPONENTS TROUBLESHOOTING Starter motor turns but engine does not turn Faulty starter clutch Damaged starter motor pinion gear starter reduction gear or shaft 74 N m 7 5 kgf m 55 lbf ft ...

Page 134: ... the flywheel be careful during removal Loosen the left crankcase cover bolts in a crisscross pattern in several steps Remove the bolts 1 and left crankcase cover 2 Remove the dowel pins 3 and gasket 4 INSTALLATION Clean any gasket material from the mating surfaces of the left crankcase and cover Install the dowel pins and a new gasket Install the left crankcase cover and bolts and tighten the bol...

Page 135: ...e grommet seating surface and install it into the cover groove Apply locking agent to the threads of the ignition pulse generator bolt and wire guide bolt Install the wire guide and ignition pulse generator onto the cover Install the bolts and tighten them to the specified torque Install the left crankcase cover page 11 3 FLYWHEEL STARTER CLUTCH REMOVAL Remove the left crankcase cover page 11 3 Re...

Page 136: ... key into the crankshaft key groove Clean any oil from the tapered portions of the crankshaft and flywheel Install the flywheel 1 by aligning the key way with the key on the crankshaft Apply engine oil to the flywheel nut threads and seating surface Install the washer 2 and flywheel nut 3 Hold the flywheel with the special tool and tighten the flywheel nut 1 TOOL 2 Flywheel puller 07933 KM10000 1 ...

Page 137: ...ll the left crankcase cover page 11 3 STARTER CLUTCH DISASSEMBLY ASSEMBLY Disassemble and assemble the starter clutch as following illustration When loosening and tightening the starter clutch bolts 1 hold the flywheel using the special tool 1 2 3 TOOL 2 Flywheel holder 07725 0040001 1 2 DRIVEN GEAR FLYWHEEL CLUTCH OUTER BOLTS SPRAG CLUTCH 16 N m 1 6 kgf m 12 lbf ft ...

Page 138: ... CRANKSHAFT TRANSMISSION KICKSTARTER SYSTEM COMPONENTS 12 2 SERVICE INFORMATION 12 3 TROUBLESHOOTING 12 3 CRANKCASE SEPARATION ASSEMBLY 12 4 TRANSMISSION 12 8 CRANKSHAFT 12 13 KICKSTARTER IDLE GEAR 12 14 KICKSTARTER 12 15 ...

Page 139: ...12 2 dummyhead dummyhead CRANKSHAFT TRANSMISSION KICKSTARTER CRANKSHAFT TRANSMISSION KICKSTARTER SYSTEM COMPONENTS 10 N m 1 0 kgf m 7 lbf ft ...

Page 140: ... the crankcase Clean the oil passages before assembling the crankcase halves TROUBLESHOOTING Excessive noise Worn sized or chipped transmission gear Worn or damaged transmission bearing Worn or damaged connecting rod bearing Worn connecting rod small end Worn crankshaft bearing Hard to shift Bent shift fork Bent shift fork shaft Damaged shift drum guide groove Damaged shift fork guide pin Transmis...

Page 141: ... 3 Clutch page 10 7 Kickstarter page 12 15 Primary drive gear page 10 13 Gearshift linkage page 10 10 Flywheel page 11 4 Starter motor page 5 5 Neutral switch page 18 9 Two bolts 1 and cam chain guide setting plate 2 Cam chain guide 3 Cam chain 4 Bolt 1 and push plug plate 2 Spring 3 and push plug 4 Three bolts 1 and crankshaft bearing setting plates 2 Right crankcase bolt 1 1 2 3 4 1 2 3 4 1 2 1 ...

Page 142: ...th the right side down Carefully separate the left crankcase 1 from the right crankcase 2 while tapping them at several locations with a soft hammer Remove the dowel pins 1 Remove the countershaft oil seal 1 from the left crankcase Apply grease to new gearshift spindle oil seal and countershaft oil seal lips and install them into the left crankcase 1 Do not ply the crankcase halves 2 1 1 1 ...

Page 143: ...m Apply liquid sealant to the mating surface shadowed area of the left crankcase except the oil passage area as shown Install the two dowel pins 1 Install the left crankcase over the right crankcase Install the thirteen left crankcase bolts 1 and tighten them in a crisscross pattern in 2 or 3 steps Install the right crankcase bolt 1 and tighten it 1 1 1 ...

Page 144: ...aring outer race 3 Apply locking agent to the push plug plate bolt threads Install the push plug plate 1 and bolt 2 and then tighten the bolt to the specified torque Install the cam chain 1 and cam chain guide 2 Install the setting plate 3 with the two bolts 4 and tighten the bolts Install the following Neutral switch page 18 9 Starter motor page 5 6 Flywheel page 11 5 Gearshift linkage page 10 12...

Page 145: ...to a piece of wire Clean disassembled parts in solvent thoroughly ASSEMBLY Apply molybdenum oil solution to the gear and bushing sliding surfaces Assemble all parts into their original positions Check the gears for freedom of movement or rotation on the shaft Do not reuse worn snap ring which could easily spin in the groove Always install the thrust washers and snap ring with the chamfered rolled ...

Page 146: ...AINSHAFT Gear and bushing sliding surfaces M5 GEAR 32T M2 GEAR 16T M4 GEAR 25T SNAP RING M3 GEAR 22T THRUST WASHER SPLINE WASHER MAINSHAFT M1 GEAR 14T SPLINE WASHER SNAP RING M4 GEAR 25T M5 GEAR 32T THRUST WASHER M2 GEAR 16T M3 GEAR 22T THRUST WASHER THRUST WASHER ...

Page 147: ...30T C2 BUSHING C5 GEAR 30T C4 GEAR 28T C3 BUSHING C3 GEAR 31T THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER COUNTERSHAFT Gear and bushing sliding surfaces shifter gear grooves C1 GEAR 39T C3 GEAR 31T C2 GEAR 30T SNAP RING SPLINE WASHER THRUST WASHERS THRUST WASHERS C2 BUSHING C3 BUSHING C5 GEAR 30T C4 GEAR 28T C1 BUSHING THRUST WASHER ...

Page 148: ...ft 2 assemblies as a set into the left crankcase Each shift fork has an identification marks R L marks 1 for right and left shift forks and C mark 2 for center shift fork Install the shift forks 1 into the shifter gear grooves with the marks facing up left crankcase side Apply engine oil to the shift drum journals and guide grooves in the and install the shift drum 2 Install the shift fork guide p...

Page 149: ...tershaft bearing 4 out of the crankcase Apply engine oil to rolling area of new mainshaft bearing 1 and countershaft bearing Drive the bearings in the crankcase with the marked side facing up using the special tools Apply locking agent to the setting plate bolt threads Install the mainshaft bearing setting plates 1 and bolts 2 and tighten the bolts 1 1 2 3 4 TOOLS 2 Driver 07749 0010000 3 Attachme...

Page 150: ...he right crankcase Apply 1 2 cm3 of molybdenum oil solution to the connecting rod big end bearing Install the crankshaft 1 into the right crankcase CRANKSHAFT BEARING REPLACEMENT Remove the crankcase bearing inner race 1 Press the crankshaft bearing 2 out of the crankcase TOOLS 3 Remover head 12 mm 07936 1660110 Remover shaft 12 mm 07936 1660120 Remover weight 07741 0010201 1 2 3 TOOLS Mainshaft b...

Page 151: ...move the clutch assembly page 10 7 Remove the snap ring 1 washer 2 and kickstarter idle gear 3 Remove the bushing 1 and washer 2 INSTALLATION Apply molybdenum oil solution to the bushing Install the washer and bushing Apply engine oil to the kickstarter idle gear teeth Install the idle gear 1 washer 2 and snap ring 3 Install the clutch assembly page 10 8 TOOLS 2 Driver 07749 0010000 3 Attachment 5...

Page 152: ...ng Kickstarter assembly 1 Ratchet spring 2 Washer 3 INSTALLATION Apply engine oil to the kickstarter drive gear teeth Install the ratchet spring and washer to the spindle Install the kickstarter assembly Hook the return spring 1 to the crankcase Install the right crankcase cover page 10 4 DISASSEMBLY Remove the following Collar 1 Return spring 2 Starter ratchet gear 3 1 3 2 1 Hook 1 1 2 3 ...

Page 153: ...tarter drive gear 3 Washer B 4 ASSEMBLY Install the following Washer B Kickstarter drive gear Washer A Snap ring Install the ratchet gear 1 Hook the return spring 1 to the hole of the spindle Install the collar 2 to the return spring aligning the cut out of the collar with the spring 4 2 1 2 3 4 1 1 Hook 2 Align ...

Page 154: ...13 1 13 dummytext 13 ENGINE REMOVAL INSTALLATION SYSTEM COMPONENTS 13 2 SERVICE INFORMATION 13 2 ENGINE REMOVAL 13 3 ENGINE INSTALLATION 13 5 ...

Page 155: ...ape the frame around the engine beforehand for frame protection The following components require engine removal for service Crankshaft page 12 13 Transmission page 12 8 35 N m 3 6 kgf m 26 lbf ft 12 N m 1 2 kgf m 9 lbf ft 26 N m 2 7 kgf m 19 lbf ft 35 N m 3 6 kgf m 26 lbf ft 35 N m 3 6 kgf m 26 lbf ft 35 N m 3 6 kgf m 26 lbf ft 60 N m 6 1 kgf m 44 lbf ft 60 N m 6 1 kgf m 44 lbf ft 12 N m 1 2 kgf m...

Page 156: ...R125LK LEK page 6 14 Resonator tank air inlet cover XR125LK LEK page 6 15 Spark plug cap Clutch cable page 10 4 Pinch bolt 1 Gearshift pedal 2 Drive sprocket cover bolts 3 Drive sprocket cover 4 drive chain guide 5 Fixing plate bolts 1 Fixing plate 2 by aligning the splines of the plate and countershaft Drive sprocket 3 pull it off the countershaft and remove from the drive chain Brake adjusting n...

Page 157: ... Battery negative cable 4 by removing the motor mounting bolt 5 Remove the rubber caps 1 from the upper engine hanger plates Remove each engine hanger plate hanger bolt and nut Two upper engine hanger plate nuts 2 bolts 3 Upper engine hanger nut 4 and bolt 5 Hanger plates 6 and collar 7 Rear upper engine hanger nut 1 and bolt 2 Rear upper engine hanger plate bolts 3 Hanger plate 4 Crankcase breath...

Page 158: ...ly align the bolt holes in the frame and engine then install all the engine hanger plates hanger bolts and nuts After installing all the engine mounting fasteners tighten them to the specified torque During engine removal hold the engine securely and be careful not to damage the frame and engine 5 3 4 9 10 11 6 7 1 2 8 During engine installation hold the engine securely and be careful not to damag...

Page 159: ... and align the bolt holes Install and tighten the drive sprocket fixing plate bolts 3 alternately to the specified torque Install the gearshift pedal 1 on its original position as marked during removal Install and tighten the pinch bolt 2 to the specified torque Install the removed parts in the reverse order of removal Fill the crankcase with recommended engine oil page 3 7 Check the following Clu...

Page 160: ...mmytext 14 FRONT WHEEL BRAKE SUSPENSION STEERING SYSTEM COMPONENTS 14 2 SERVICE INFORMATION 14 3 TROUBLESHOOTING 14 3 HANDLEBAR 14 4 FRONT WHEEL 14 9 FRONT DRUM BRAKE XL125LK 14 13 FORK 14 13 STEERING STEM 14 22 ...

Page 161: ...N STEERING SYSTEM COMPONENTS 22 N m 2 2 kgf m 16 lbf ft 32 N m 3 3 kgf m 24 lbf ft 26 N m 2 7 kgf m 19 lbf ft 44 N m 4 5 kgf m 32 lbf ft 30 N m 3 1 kgf m 22 lbf ft XL125LK XR125LK LEK 22 N m 2 2 kgf m 16 lbf ft 26 N m 2 7 kgf m 19 lbf ft 44 N m 4 5 kgf m 32 lbf ft 32 N m 3 3 kgf m 24 lbf ft ...

Page 162: ... bearings Bent frame Worn wheel bearings Bent front axle Worn swingarm pivot component Front wheel wobbling Bent rim Worn wheel bearings Faulty tire Unbalanced tire and wheel Soft suspension Weak fork spring Low fluid level in fork Insufficient fluid in fork Low tire pressure Hard suspension High tire pressure Bent fork High fluid level in fork Incorrect fluid weight Clogged fluid passage Front su...

Page 163: ... bands 1 Remove the rearview mirrors 2 Remove the front visor 2 page 2 4 Disconnect the front brake light switch connectors 1 XR125LK LEK Remove the bolts 1 master cylinder holder 2 and master cylinder 3 XL125LK Remove the bolts 1 holder 2 and brake lever bracket 3 1 2 XR125LK LEK 1 2 3 2 1 1 2 3 ...

Page 164: ... and remove the throttle housing Remove the throttle cable guide 4 Remove the throttle grip from the handlebar Remove the right handlebar switch housing screws 1 Remove the right handlebar switch housing 2 from the handlebar Disconnect the clutch switch connectors 1 from the clutch switch Remove the clutch lever holder screws 1 bracket 2 and holder 3 4 3 2 1 1 2 1 1 3 2 ...

Page 165: ...the upper holders with the punch marks 4 facing forward Install the handlebar holder bolts and tighten the front bolts first then the rear bolts Allow the adhesive to dry for an hour before using Apply Honda Bond A 1 or an equivalent to the inside of the grip 2 and the clean surfaces of the left handlebar and throttle grip Wait 3 5 minutes to install the grip Rotate the grip to spread the adhesive...

Page 166: ...lit of the bracket with the punch mark 3 on the handlebar Install the clutch lever holder screws 4 and tighten the forward screw first then rear screw Connect the clutch switch connectors 1 to the clutch switch Install the right handlebar switch housing 1 by aligning its locating pin 2 with the hole 3 in the handlebar Install the right handlebar switch housing screws 4 and tighten the forward scre...

Page 167: ... 7 and tighten the forward screw first then the rear screw XR125LK LEK Install the master cylinder 1 and holder 2 with the UP mark 3 on the holder facing up Install the master cylinder holder bolts 4 Align the end of the master cylinder with the punch mark 5 on the handlebar and tighten the upper bolt first then lower bolt XL125LK Install the brake lever bracket 1 and holder 2 with the UP mark 3 o...

Page 168: ...and speedometer cable 2 from the speedometer gear box Remove the rubber cap Remove the axle nut 1 and pull out the axle 2 Remove the front wheel Remove the speedometer gear box 1 and side collar 2 INSTALLATION XR125LK LEK Install the side collar and speedometer gear box 1 2 Do not operate the front brake lever after removing the front wheel To do so will cause difficulty in fitting the brake disc ...

Page 169: ...ubber cap 2 to the axle nut Connect the speedometer cable 1 to the gear box and secure it with the set screw 2 With the front brake applied pump the fork up and down several times to seat the axle and check the front brake operation REMOVAL XL125LK Raise and support the motorcycle using safety stand or a hoist Release the tab 1 while pushing it and disconnect the speedometer cable 2 Remove the adj...

Page 170: ...l and connect it with the joint pin 4 and adjusting nut 5 Connect the speedometer cable 6 Adjust the front brake lever freeplay and check the brake operation page 3 13 DISASSEMBLY ASSEMBLY XR125LK LEK Remove install the following Dust seals 1 Retainer 2 Nuts 3 Brake disc 4 Wheel bearings 5 Distance collar 6 Replace the bearings and dust seals with new ones Apply grease to the dust seal lips Refer ...

Page 171: ...f the wheel hub Remove the distance collar and drive out the other bearing Pack new bearing cavities with grease Drive in a new left side bearing 1 squarely with the sealed side facing up until it is fully seated Coat a distance collar with grease and install it Drive in a new right side bearing with the sealed side facing up until it is seated on the distance collar 7 5 1 0 mm 0 30 0 04 2 6301U 2...

Page 172: ... 3 g Inner 0 2 0 3 g Sliding surface 0 2 0 3 g Shoe contact area 0 2 0 3 g Align the wide tooth on the indicator plate with the wide groove on the brake cam 2 2 3 14 6 Align the punch marks on the brake arm and brake cam Insert the end of the return spring into the hole on the brake panel 8 9 1 10 12 4 10 N m 1 0 kgf m 7 lbf ft 13 11 5 7 Brake panel 1 Brake shoes 2 Brake shoe springs 3 Nut 4 Brake...

Page 173: ...osen the fork bottom bridge pinch bolts 1 while holding the fork Remove the fork from the steering stem DISASSEMBLY Loosen the boot band screw and remove the dust boot from the fork XL125LK only Remove the fork cap 1 and O ring 2 from the fork pipe 1 2 Do not remove the fork cap yet 2 1 1 The fork cap is under spring pressure Wear an eye protector and a face protector while removing the cap 1 2 ...

Page 174: ...der If the fork piston turns with the socket bolt temporarily install the fork spring washer spring spacer and fork cap Remove the dust seal 1 from the fork slider Remove the stopper ring 2 from the groove of the fork slider Check that the fork pipe moves smoothly in the fork slider If not check the fork pipe for bending or damage and bushings for wear or damage Pull the fork pipe 1 out of the for...

Page 175: ... seal remover Remove the back up ring 1 from the fork slider Remove the fork piston 1 and rebound spring 2 from the fork pipe 3 INSPECTION FORK SPRING Measure the fork spring free length on a flat surface TOOL 2 Oil seal remover 07748 0010001 1 2 1 1 2 3 SERVICE LIMIT XR125LK LEK 582 6 mm 22 94 in XL125LK 593 4 mm 23 36 in ...

Page 176: ...it is exceeded or it has scratches or nicks that will cause fork fluid to leak out of the seals FORK PIPE BUSHING Visually inspect the slider bushing Replace the fork slider if they are worn or if the Teflon coating is worn and 3 4 or over of the copper surface appears Check the back up ring replace it if there is any distortion at the points indicated by arrows on the figure ASSEMBLY SERVICE LIMI...

Page 177: ...hten the fork slider Hold the axle holder of the fork slider in a vise with a piece of wood or soft jaws to avoid damage Clean the fork socket bolt threads and apply a locking agent to them Install the fork socket bolt 1 in the fork piston with a new sealing washer 2 Tighten the fork socket bolt to the specified torque Install the back up ring 1 into the fork slider 2 1 3 1 2 3 4 5 If the fork pis...

Page 178: ... fork pipe slowly several times to remove trapped air Pour additional fluid up to the specified capacity and repeat the above step Compress the fork leg fully Measure the fluid level from the top of the fork pipe Wipe fluid off the spring thoroughly with a clean cloth Install the fork spring with the tightly wound coil side facing down TOOLS 3 Fork seal driver 07747 0010100 4 Driver attachment 31 ...

Page 179: ... the fork cap 2 Install the fork cap into the fork pipe XL125LK only Install the dust boot with its breathing hole 1 facing rearward Set the boot band screw 2 as shown in the illustration INSTALLATION Install the fork pipe 1 into the bottom bridge 2 Align the top end of the fork pipe with the upper surface of the top bridge as shown 1 2 2 1 FRONT REARWARD Right fork leg shown 1 2 Align ...

Page 180: ...end of the boot 1 on the bottom bridge Tighten the boot band screw 2 XR125LK LEK Install the brake caliper 1 with new mounting bolts 2 and then tighten the bolts to the specified torque Install the brake hose clamps 3 cover 4 and bolts 5 Tighten the bolts securely Install the front wheel page 14 9 TORQUE 32 N m 3 3 kgf m 24 lbf ft 1 TORQUE 22 N m 2 2 kgf m 16 lbf ft TORQUE 22 N m 2 2 kgf m 16 lbf ...

Page 181: ... 14 11 STEERING STEM REMOVAL Remove the following Front wheel page 14 9 Front visor page 2 4 Combination meter page 18 6 Handlebar page 14 4 Disconnect the turn signal light Green Orange Light blue wire connectors 1 Remove the top bridge pinch bolts 1 and turn signal lights 2 Remove the steering stem cap 1 stem nut 2 and washer 3 Remove the top bridge 4 Remove the forks page 14 13 2 1 3 1 1 2 1 2 ...

Page 182: ... stem 1 from the steering head pipe Remove the lower bearing 2 Check the steering bearings inner and outer races for wear or damage STEERING BEARING RACE REPLACEMENT Always replace the bearings and races in pairs Remove the upper bearing outer race 1 and lower bearing outer race 2 with the following tools TOOL 2 Steering stem socket wrench 07916 KA50100 1 2 3 1 2 1 2 TOOLS 3 Ball race remover shaf...

Page 183: ... new dust seal 1 Install the dust seal Install the new lower bearing inner race 2 with the following tool and a hydraulic press Drive the new upper bearing outer race 1 into the head pipe with the following tools Drive the new lower bearing outer race 1 into the head pipe with the following tools 2 3 1 Do not damage the steering stem during installation TOOL 3 Steering stem driver 07946 4300101 1 ...

Page 184: ...ead pipe Apply urea based multi purpose grease page 1 15 to a new upper bearing 1 Install the upper bearing Install the upper bearing inner race 2 STEERING STEM STEERING STEM NUT WASHER TOP BRIDGE STEM ADJUSTING NUT UPPER DUST SEAL UPPER INNER RACE LOWER DUST SEAL STEERING STEM CAP LOWER BEARING INNER RACE LOWER BEARING LOWER BEARING OUTER RACE UPPER BEARING OUTER RACE UPPER BEARING UREA BASED GRE...

Page 185: ...es to seat the bearings Loosen the steering stem adjusting nut completely Retighten the adjusting nut to the specified torque Install the top bridge 1 Temporarily install the front fork page 14 20 Install the steering stem nut 2 and washer 3 Tighten the steering stem nut to the specified torque with a special tool TOOL 3 Steering stem socket wrench 07916 KA50100 TORQUE 5 0 N m 0 5 kgf m 3 7 lbf ft...

Page 186: ...lebar page 14 6 Front wheel page 14 9 STEERING BEARING PRELOAD Raise the front wheel off the ground Position the steering stem to the straight ahead position Hook a spring scale to the fork tube between the fork top and bottom bridges Make sure that there is no cable or wire harness interference Pull the spring scale keeping the scale at a right angle to the steering stem Read the scale at the poi...

Page 187: ...MEMO dummyhead dummyhead ...

Page 188: ...1 15 dummytext 15 REAR WHEEL BRAKE SUSPENSION SYSTEM COMPONENTS 15 2 SERVICE INFORMATION 15 3 TROUBLESHOOTING 15 3 REAR WHEEL 15 4 REAR DRUM BRAKE 15 7 BRAKE PEDAL 15 9 SHOCK ABSORBER 15 11 SWINGARM 15 13 ...

Page 189: ... 2 dummyhead dummyhead REAR WHEEL BRAKE SUSPENSION REAR WHEEL BRAKE SUSPENSION SYSTEM COMPONENTS 44 N m 4 5 kgf m 32 lbf ft 88 N m 9 0 kgf m 65 lbf ft 44 N m 4 5 kgf m 32 lbf ft 93 N m 9 5 kgf m 69 lbf ft ...

Page 190: ...roperly Wheel turns hard Brake drag Faulty wheel bearings Bent axle Drive chain too tight page 3 9 Soft suspension Incorrect suspension adjustment Weak shock absorber springs Oil leakage from damper unit Low tire pressure Hard suspension Incorrect suspension adjustment Bent shock absorber damper rod Damaged suspension or swingarm pivot bearings Bent swingarm pivot or frame High tire pressure Steer...

Page 191: ...ing nut 1 and disconnect the rear brake rod 2 from the brake arm 3 Remove the joint pin 4 and spring 5 Loosen the left and right drive chain lock nuts 6 and adjusting nuts 7 Remove the rear axle nut 8 and axle plate 9 Push the rear wheel forward Derail the drive chain 1 Remove the rear axle 2 from the left then the rear wheel Remove the brake panel 1 Remove the side collar 1 9 8 6 7 1 2 3 4 5 1 2 ...

Page 192: ...n so that the distance from the left end surface of the hub center to the side of rim is 18 0 1 0 mm 0 71 0 04 in as shown Tighten the spokes in 2 or 3 progressive steps Dust seal 1 Nuts 2 Washers 3 Bolts 4 Driven sprocket 5 Right wheel bearing 6203UU 6 Distance collar 7 Left wheel bearing 6303U 8 XR125LK LEK shown 32 N m 3 3 kgf m 24 lbf ft 1 2 3 4 5 6 6203UU 7 8 6303U TOOL Spoke wrench 5 8 x 6 1...

Page 193: ...w bearing cavities with grease Drive in a new left side driven sprocket side bearing 1 with the sealed side facing up until it is fully seated INSTALLATION Install the side collar 1 Install the brake panel 2 into the wheel hub Place the rear wheel in the swingarm by aligning the brake panel groove with the swingarm boss TOOLS 1 Bearing remover head 17 mm 07746 0050500 2 Bearing remover shaft 07746...

Page 194: ...ring 3 onto the brake rod Connect the brake rod 4 to the brake arm 5 with the joint pin 6 and adjusting nut 7 Adjust the drive chain slack page 3 9 Adjust the brake pedal free play page 3 14 REAR DRUM BRAKE DISASSEMBLY Remove the rear wheel page 15 4 Disassemble the brake panel as following illustration 2 1 TORQUE 93 N m 9 5 kgf m 69 lbf ft 1 2 7 4 5 6 3 Brake shoes 1 Shoe springs 2 Brake arm cove...

Page 195: ...ll the indicator plate 3 by aligning the wide tooth with the wide groove in the brake cam Install the brake arm 1 by aligning the punch marks 2 Install the bolt 3 from the punch mark side and tighten the nut 4 Install the arm cover 5 over the brake arm as shown Apply grease to the anchor pin 1 and brake cam 2 sliding surfaces Assemble the brake shoes 3 and springs 4 as shown Install the shoe assem...

Page 196: ...SPENSION BRAKE PEDAL REMOVAL Remove the following Brake adjusting nut 1 Brake rod 2 from the joint pin Rod spring 3 Joint pin 4 Pedal return spring 1 Brake light switch spring 2 Cotter pin 1 Washer 2 Brake pedal 1 Dust seals 2 1 2 4 3 1 2 1 2 1 2 ...

Page 197: ...st seal lips Install the dust seals 1 with the lip facing the swingarm side same direction Apply grease to the groove in the pedal pivot and install the brake pedal 1 2 Brake adjusting nut 1 Brake rod 2 Spring 3 Joint pin 4 Brake pedal return spring 5 Brake light switch spring 6 Cotter pin 7 Washer 8 Brake pedal 9 Dust seals 10 Cotter pin 11 Pivot pin 12 Brake arm cover 13 13 10 11 12 9 8 7 6 5 4 ...

Page 198: ... for deformation or oil leaks Upper mount bush for wear or damage Do not disassemble the shock absorber Replace the shock absorber if any component is damaged Installation is in the reverse order of removal NEEDLE BEARING REPLACEMENT Remove the collar 1 from the shock absorber Remove the dust seals 2 Press the needle bearing 1 out using the special tools and a hydraulic press Replace the shock abs...

Page 199: ...h could cause a build up of excessive heat and pressure inside the damper leading to explosion and severe personal injury The shock absorber contains nitrogen gas and oil under high pressure Do not drill any further down the damper case than the measurement given above or you may drill into the oil chamber oil escaping under high pressure may cause serious personal injury Always wear an eye protec...

Page 200: ...emove the breather hose and carburetor drain hose 3 from the guide 4 Remove the rear wheel page 15 4 Unhook the rear brake return spring 1 Remove the shock absorber lower mount bolt 2 and nut 3 Remove the drive chain adjusters 1 Remove the drive chain cover bolts 1 and collars 2 Remove the drive chain cover 3 1 2 3 4 1 2 3 1 1 2 3 ...

Page 201: ...bolt 2 from the left side and remove the swingarm 3 DISASSEMBLY ASSEMBLY Disassemble and assemble the swingarm as following illustration 1 2 3 Drive chain adjuster 1 Screw 2 Collar 3 Chain slider 4 Dust seals 5 Distance collar 6 Needle bearings 7 Swingarm 8 5 1 2 3 4 5 6 8 7 6 0 N m 0 6 kgf m 4 4 lbf ft ...

Page 202: ...ss INSTALLATION Install the swingarm 1 onto the frame Install the swingarm pivot bolt 2 to the frame from the left side Install and tighten the swingarm pivot nut 3 to the specified torque Install the drive chain cover 1 on the swingarm Install the drive chain cover collars 2 and bolts 3 then tighten the bolts TOOL 2 Bearing remover set 20 mm 07936 3710600 3 Bearing remover weight 07741 0010201 Be...

Page 203: ...ters 1 Install the rear wheel page 15 6 Install the shock absorber lower mount bolt 1 and nut 2 Hook the rear brake return spring 3 Install the carburetor drain hose 1 and crankcase breather hose 2 through the guide 3 Install the drain plug 4 to the breather drain hose 1 3 1 2 4 2 1 3 ...

Page 204: ...ummytext 16 HYDRAULIC BRAKE XR125LK LEK SYSTEM COMPONENTS 16 2 SERVICE INFORMATION 16 3 TROUBLESHOOTING 16 3 BRAKE FLUID REPLACEMENT AIR BLEEDING 16 4 BRAKE PAD DISC 16 6 MASTER CYLINDER 16 7 BRAKE CALIPER 16 9 ...

Page 205: ...LIC BRAKE XR125LK LEK HYDRAULIC BRAKE XR125LK LEK SYSTEM COMPONENTS 30 N m 3 1 kgf m 22 lbf ft 2 5 N m 0 3 kgf m 1 8 lbf ft 17 2 N m 1 8 kgf m 13 lbf ft 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft 12 N m 1 2 kgf m 9 lbf ft ...

Page 206: ...ore riding the motorcycle TROUBLESHOOTING Brake lever soft or spongy Air in hydraulic system Leaking hydraulic system Contaminated brake pad disc Worn caliper piston seal Worn master cylinder piston cups Worn brake pad disc Contaminated caliper Contaminated master cylinder Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped deformed brake disc Sticking worn caliper pist...

Page 207: ...FLUID FILLING AIR BLEEDING Fill the reservoir to the casting ledge 1 with DOT 3 or DOT 4 brake fluid from a sealed container Connect a commercially available brake bleeder 1 to the bleed valve 2 Operate the brake bleeder and loosen the bleed valve If an automatic refill system is not used add fluid when the fluid level in the reservoir is low Perform the bleeding procedure until the system is comp...

Page 208: ...leed valve 1 2 of a turn Wait several seconds and then close the bleed valve 2 Release the brake lever slowly and wait several seconds after it reaches the end of its travel 3 Repeat the steps 1 and 2 until there are no air bubbles in the bleed hose After bleeding the system completely tighten the bleed valve Fill the reservoir to the casting ledge 1 with DOT 3 or DOT 4 brake fluid from a sealed c...

Page 209: ...talled in position Install the brake pads 1 so that their ends rest on the pad retainer 2 on the caliper bracket properly Install the pad pin 1 by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper Tighten the pad pin Install and tighten the pad pin plug 2 Operate the brake lever to seat the caliper pistons against the pads 1 2 1 2 2 1 TORQUE 17 2 N m 1 8 kg...

Page 210: ...1 by removing the oil bolt 2 and sealing washers 3 Disconnect the front brake light switch connectors 4 Remove the master cylinder holder bolts 5 holder 6 and master cylinder 7 Install the master cylinder holder and holder bolts Align the end of the master cylinder with the punch mark 9 on the handlebar and tighten the upper bolt first then tighten the lower bolt Connect the brake light switch con...

Page 211: ...urn inside out Be sure that the snap ring is firmly seated in the groove Remove and install the snap ring 1 using the special tool Nut 1 Brake lever pivot bolt 2 Brake lever 3 Screw 4 Brake light switch 5 Boot 6 Snap ring 7 Master piston 8 Spring 9 Piston cups 10 Reservoir cap 11 Set plate 12 Diaphragm 13 Screws 14 14 13 11 12 10 9 8 7 6 5 4 3 2 1 1 0 N m 0 1 kgf m 0 7 lbf ft 1 2 N m 0 1 kgf m 0 9...

Page 212: ...s 3 page 16 6 Pad spring 4 Caliper bracket 5 pad retainer 6 Bracket pin boot 7 Caliper pin boot 8 Bleed valve 9 cap 10 Position the caliper body 11 with the pistons down and apply small squirts of air pressure to the fluid inlet 12 to remove the pistons 13 Remove the dust seals 14 and piston seals 15 Assembly is in the reverse order of disassembly TORQUE Brake caliper mounting bolt 30 N m 3 1 kgf ...

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Page 214: ...t 17 BATTERY CHARGING SYSTEM COMPONENT LOCATION 17 2 SYSTEM DIAGRAM 17 2 SERVICE INFORMATION 17 3 TROUBLESHOOTING 17 4 BATTERY 17 5 CHARGING SYSTEM INSPECTION 17 6 REGULATOR RECTIFIER 17 7 ALTERNATOR CHARGING COIL 17 7 ...

Page 215: ...YSTEM BATTERY CHARGING SYSTEM COMPONENT LOCATION SYSTEM DIAGRAM ALTERNATOR REGULATOR RECTIFIER IGNITION SWITCH BATTERY Bl R G W Y Black Red Green White Yellow ALTERNATOR BATTERY R G Y W G REGULATOR RECTIFIER To Lights G R W W W G MAIN FUSE 15 A ...

Page 216: ...he battery Check if the battery is frequently under heavy load such as having the headlight and taillight ON for long periods of time without riding the motorcycle The battery will self discharge when the motorcycle is not in use For this reason charge the battery every 2 weeks to prevent sulfation from occurring When checking the charging system always follow the steps in the troubleshooting flow...

Page 217: ...ALTERNATOR CHARGING COIL INSPECTION Check the alternator charging coil page 17 7 Is the alternator charging coil resistance within 0 2 1 2 Ω 20 C 68 F NO Faulty charging coil YES GO TO STEP 5 5 CHARGING VOLTAGE INSPECTION Measure and record the battery voltage using a digital multimeter page 17 6 Start the engine Measure the charging voltage page 17 6 Compare the measurements to the results of the...

Page 218: ...ly be done in an emergency slow charging is preferred For battery charging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time may damage the battery Remove the battery page 17 5 Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal 6 4 3 5 2 1 X...

Page 219: ...nt leakage exceeds the specified value a shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION Remove the left side cover page 2 2 Be sure the battery is in good condition before performing this test Warm up the engine to normal operating temperature Connect the multimeter between the battery positive and negative t...

Page 220: ...tor rectifier 4P connector 1 Remove the bolts 2 and regulator rectifier 3 from the frame Install the regulator rectifier in the reverse order of removal ALTERNATOR CHARGING COIL INSPECTION Remove the left side cover page 2 2 Disconnect the alternator 2P connector 1 Measure the resistance between each wire terminal of the alternator Replace the alternator stator if resistance is out of specificatio...

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Page 222: ...TION 18 3 HEADLIGHT POSITION LIGHT 18 4 BRAKE TAIL LIGHT 18 4 LICENSE LIGHT XR125LK LEK 18 5 TURN SIGNAL LIGHTS 18 5 COMBINATION METER 18 6 IGNITION SWITCH 18 7 HANDLEBAR SWITCHES 18 7 BRAKE LIGHT SWITCHES 18 8 CLUTCH SWITCH 18 9 NEUTRAL SWITCH 18 9 SIDESTAND SWITCH NZ TYPE 18 10 TURN SIGNAL RELAY 18 11 HORN 18 11 ...

Page 223: ... clean gloves while replacing the bulb Do not put finger prints on the headlight bulb as they may create hot spots on the bulb and cause is to fail If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure Be sure to install the dust cover after replacing the bulb Check the battery condition before performing any inspection that requires p...

Page 224: ... to Hi position Check the continuity between the Blue terminal of the headlight 4P connector 2 and Yellow terminal of the regulator rectifier 4P connector 3 Turn the dimmer switch to Lo position Check the continuity between the White terminal of the headlight 4P connector and Yellow terminal of the regulator rectifier 4P connector If there is continuity check the following Ground Inspection Check ...

Page 225: ...remove it Install the headlight bulb in the reverse order of removal Remove the position light bulb socket 1 Push the position light bulb 2 in turn it counterclockwise and remove it Install the position light bulb in the reverse order of removal BRAKE TAIL LIGHT BULB REPLACEMENT Remove the screws 1 and the brake tail light lens 2 Push the bulb 3 in turn it counterclockwise and remove it Install th...

Page 226: ...wise and remove it Install the bulb in the reverse order of removal TURN SIGNAL LIGHTS BULB REPLACEMENT XR125LK LEK Remove the screw 1 and turn the signal light lens 2 Pull out the bulb 3 without turning Install the bulb in the reverse order of removal BULB REPLACEMENT XL125LK Remove the screw 1 and turn the signal light lens 2 Turn the bulb 3 counterclockwise and remove it Install the bulb in the...

Page 227: ...nector 1 Disconnect the speedometer cable 1 Remove the nuts 2 washers 3 and combination meter assembly 4 Installation is in the reverse order of removal DISASSEMBLY ASSEMBLY Disassemble and assemble the combination meter as following illustration 1 2 3 1 4 HARNESS BAND TRIPMETER RESET KNOB UPPER CASE BULBS SOCKETS HARNESS BAND SCREWS SPEEDOMETER LOWER CASE ...

Page 228: ...nition switch connector page 18 7 Remove the two mounting bolts 1 and the ignition switch 2 Install the ignition switch in the reverse order of removal HANDLEBAR SWITCHES Remove the front visor page 2 4 Disconnect the right handlebar switch 6P connector 1 Disconnect the left handlebar switch 9P Black connector 2 and wire connector 3 Check for continuity between the connector terminals in each swit...

Page 229: ... XR125LK Remove the front visor page 2 4 Remove the brake light switch wire connectors 1 from the boot and disconnect them There should be continuity with the brake lever applied and there should be no continuity when the brake lever is released REAR Remove the left side cover page 2 2 Disconnect the rear brake light switch 2P connector 1 There should be continuity with the brake pedal applied and...

Page 230: ...WITCH INSPECTION Remove the right side cover page 2 2 Disconnect the neutral switch wire connector 1 Shift the transmission gear into neutral Check for continuity between the Light Green Red terminal and body ground There should be continuity REMOVAL INSTALLATION Remove the following Right side cover page 2 2 Drive sprocket cover page 2 5 Remove the neutral switch Light green red wire connector 1 ...

Page 231: ...itch 3P Green connector 1 and check for continuity There is continuity when the sidestand is raised and there is no continuity when the sidestand is put down REMOVAL INSTALLATION Remove the left side cover page 2 2 Disconnect the sidestand 3P connector Remove the bolts 1 and sidestand switch cover 2 Remove the sidestand switch bolt 3 and sidestand switch 4 Installation is in the reverse order of r...

Page 232: ...Black connector 1 from the turn signal relay 2 Short the Black brown and Gray terminals of the turn signal relay connector with a jumper wire Start the engine and check the turn signal light by turning the switch ON Is the light come on YES Faulty turn signal relay Poor connection of the connector NO Broken wire harness HORN REMOVAL INSTALLATION Disconnect the connectors 1 from the horn 2 Remove t...

Page 233: ...MEMO dummyhead dummyhead ...

Page 234: ...19 1 19 dummytext 19 WIRING DIAGRAMS XR125LEK DK I LA TYPES 19 2 XR125LEK III LA CO TYPES 19 3 XR125LEK NZ TYPE 19 4 XR125LK DK TYPE 19 5 XR125LK III LA TYPE 19 6 XL125LK 19 7 ...

Page 235: ... Bl Br Bu Br Bu G Bl Br SWITCH CONTINUITY TURN SIGNAL SWITCH TURN SIGNAL RELAY DIMMER SWITCH HORN SWITCH CLUTCH SWITCH STARTER SWITCH IGNITION SWITCH COLOR COMB GROUND MARKING REGULATOR RECTIFIER 4P Bl 2P 4P WPC 4P R 2P HORN DIODE TURN SIGNAL DIMMER HORN SWITCH SPEEDOMETER TURN SIGNAL INDICATOR 12V 3 4W NEUTRAL INDICATOR 12V 3 4W HIGH BEAM INDICATOR 12V 3 4W METER ILLUMINATION 12V 1 7W RIGHT REAR ...

Page 236: ... Bl Bl G R Lg R Bl Bl R R SWITCH CONTINUITY TURN SIGNAL SWITCH TURN SIGNAL RELAY DIMMER SWITCH HORN SWITCH CLUTCH SWITCH STARTER SWITCH IGNITION SWITCH COLOR COMB GROUND MARKING REGULATOR RECTIFIER 4P Bl 2P 4P WPC 4P R 2P HORN DIODE TURN SIGNAL DIMMER HORN SWITCH SPEEDOMETER TURN SIGNAL INDICATOR 12V 3 4W NEUTRAL INDICATOR 12V 3 4W HIGH BEAM INDICATOR 12V 3 4W METER ILLUMINATION 12V 1 7W RIGHT REA...

Page 237: ...Bl R R SWITCH CONTINUITY TURN SIGNAL SWITCH TURN SIGNAL RELAY DIMMER SWITCH HORN SWITCH CLUTCH SWITCH STARTER SWITCH IGNITION SWITCH COLOR COMB GROUND MARKING REGULATOR RECTIFIER 4P Bl 2P 4P WPC 4P R 2P 10W 2P WPC UP DOWN HORN DIODE DIODE THERMO SWITCH CARBURETOR HEATER TURN SIGNAL DIMMER HORN SWITCH SPEEDOMETER TURN SIGNAL INDICATOR 12V 3 4W NEUTRAL INDICATOR 12V 3 4W HIGH BEAM INDICATOR 12V 3 4W...

Page 238: ... Bl Bl Bl Bl Br Bu Br Bu G Bl Br SWITCH CONTINUITY TURN SIGNAL SWITCH TURN SIGNAL RELAY DIMMER SWITCH HORN SWITCH IGNITION SWITCH COLOR COMB GROUND MARKING REGULATOR RECTIFIER 4P Bl 2P 4P WPC HORN TURN SIGNAL DIMMER HORN SWITCH SPEEDOMETER TURN SIGNAL INDICATOR 12V 3 4W NEUTRAL INDICATOR 12V 3 4W HIGH BEAM INDICATOR 12V 3 4W METER ILLUMINATION 12V 1 7W RIGHT REAR TURN SIGNAL LIGHT 12V 16W LEFT REA...

Page 239: ...Y Gr Bl Y R Bl Bu Y G Y G Y Bl Br G Y Bl Bl SWITCH CONTINUITY TURN SIGNAL SWITCH TURN SIGNAL RELAY DIMMER SWITCH HORN SWITCH IGNITION SWITCH COLOR COMB GROUND MARKING REGULATOR RECTIFIER 4P Bl 2P 4P WPC HORN TURN SIGNAL DIMMER HORN SWITCH SPEEDOMETER TURN SIGNAL INDICATOR 12V 3 4W NEUTRAL INDICATOR 12V 3 4W HIGH BEAM INDICATOR 12V 3 4W METER ILLUMINATION 12V 1 7W RIGHT REAR TURN SIGNAL LIGHT 12V 1...

Page 240: ...Y Bl Bl Bl Bl Br Bu Br Bu G Bl Br SWITCH CONTINUITY TURN SIGNAL SWITCH TURN SIGNAL RELAY DIMMER SWITCH HORN SWITCH IGNITION SWITCH COLOR COMB GROUND MARKING REGULATOR RECTIFIER 4P Bl 2P 4P WPC HORN TURN SIGNAL DIMMER HORN SWITCH SPEEDOMETER TURN SIGNAL INDICATOR 12V 3 4W NEUTRAL INDICATOR 12V 3 4W HIGH BEAM INDICATOR 12V 3 4W METER ILLUMINATION 12V 1 7W RIGHT REAR TURN SIGNAL LIGHT 12V 15W LEFT RE...

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Page 242: ...ROL MODULE 4 6 IGNITION COIL 4 6 IGNITION SWITCH 18 7 IGNITION SYSTEM INSPECTION 4 4 IGNITION TIMING 4 5 K KICKSTARTER 12 15 KICKSTARTER IDLE GEAR 12 14 L LEFT CRANKCASE COVER 11 3 LICENSE LIGHT XR125LK LEK 18 5 LIGHTING SYSTEM INSPECTION 18 3 LUBRICATION SEAL POINTS 1 14 LUBRICATION SYSTEM DIAGRAM 7 2 M MAINTENANCE SCHEDULE 3 2 MASTER CYLINDER 16 7 MODEL IDENTIFICATION 1 2 N NEUTRAL DIODE 5 8 NEU...

Page 243: ...AGE KICKSTARTER 10 3 CRANKCASE CRANKSHAFT TRANSMISSION 12 3 CYLINDER HEAD VALVES 8 3 CYLINDER PISTON 9 3 ELECTRIC STARTER 5 3 FRONT WHEEL SUSPENSION STEERING 14 3 FUEL SYSTEM 6 3 HYDRAULIC BRAKE 16 3 IGNITION SYSTEM 4 3 LUBRICATION SYSTEM 7 3 REAR WHEEL BRAKE SUSPENSION 15 3 TURN SIGNAL LIGHTS 18 5 TURN SIGNAL RELAY 18 11 V VALVE CLEARANCE 3 6 W WHEELS TIRES 3 16 WIRING DIAGRAMS XL125LK 19 7 XR125...

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