Manual de Taller HONDA XR150L MANUAL TALLER 2014

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20. XR125/150LEK, XL125LEK ADDENDUM

A Few Words About Safety ·················· 20-2

INTRODUCTION·································· 20-3

SERVICE RULES································· 20-4

MODEL IDENTIFICATION ····················· 20-4

SPECIFICATIONS································ 20-6

TORQUE VALUES ······························20-13

LUBRICATION & SEAL POINTS ···········20-18

CABLE & HARNESS ROUTING ············20-20

SIDE SHROUD ···································20-25

FRONT VISOR ···································20-25

FRONT FENDER ································20-26

MAINTENANCE SCHEDULE ················20-27

STARTER MOTOR (XR150LEK)············20-28

PILOT SCREW ADJUSTMENT··············20-28

RESONATOR·····································20-29

CYLINDER HEAD (XR150LEK) ·············20-30

PRIMARY DRIVE GEAR/BALANCER

DRIVE GEAR (XR150LEK) ···················20-30

BALANCER DRIVEN GEAR

(XR150LEK)·······································20-31

BALANCER (XR150LEK) ·····················20-35

COMBINATION METER ·······················20-35

TURN SIGNAL RELAY ························20-36

WIRING DIAGRAMS ···························20-37

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XR125/150LEK, XL125LEK ADDENDUM

A Few Words About Safety

Service Information

The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting

service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the

vehicle or create an unsafe condition.

This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures

require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service

procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of

the vehicle.

If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend

that you do not use replacement parts of inferior quality.

For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while

servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety

practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge

of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.

Some of the most important general service safety precautions are given below. However, we cannot warn you of every

conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should

perform a given task.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing 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, drill, grind, pry or work around

pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.

• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe

burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,

make sure that it is always securely supported. Use jack stands.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will

help eliminate several potential hazards:

• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine

• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.

• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.

Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when

working around gasoline or batteries.

• Use only a nonflammable solvent, not gasoline, to clean parts.

• Never drain or store gasoline in an open container.

• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

Improper service or repairs can create an unsafe

condition that can cause your customer to be

seriously hurt or killed.

Follow the procedures and precautions in this

manual and other service materials carefully.

Failure to properly follow instructions and

precautions can cause you to be seriously hurt or

killed.

Follow the procedures and precautions in this

manual carefully.

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XR125/150LEK, XL125LEK ADDENDUM

INTRODUCTION

This addendum contains information for XR125/150LEK and XL125LEK-E.

Refer to XR125LK/125LEK and XL125LK SHOP MANUAL (No.62KRHM0) for service procedures and data not included in this

addendum.

As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help

prevent damage to your vehicle, other property, or the environment.

SERVICE PUBLICATION OFFICE

Date of Issue: February, 2014

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.

You will find important safety information in a variety of forms including:

• Safety Labels – on the vehicle

• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE

BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda

Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT

INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT

WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF

MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.

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XR125/150LEK, XL125LEK ADDENDUM

SERVICE RULES

1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design

specifications may cause damage to the motorcycle.

2. Use the special tools designed for this product to avoid damage and incorrect assembly.

3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English

fasteners.

4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.

5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in

incremental steps unless a particular sequence is specified.

6. Clean 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 following types of XR125/150 and XL125 models; be sure to refer to the procedure for the appropriate version.

MODEL CODE REGION Wheel size

(Front/Rear)

Front

brake

type

Air cut-

off valve

Carburetor

heater

Sidestand

switch

XR125LEK DK Common export 19/17 in Disc O – –

III LA Latin America 19/17 in Disc O – –

SA South Africa 19/17 in Disc O O –

XR150LEK DK Common export 19/17 in Disc O – –

III LA Latin America 19/17 in Disc O – –

CO Colombia 19/17 in Disc O – –

PH Philippines 19/17 in Disc O – –

SA South Africa 19/17 in Disc O O –

I LA Latin America 19/17 in Disc O O –

NZ New Zealand,

Ukraine

19/17 in Disc O O O

AG Argentina 19/17 in Disc O O –

PE Peru 19/17 in Disc O – –

MX Mexico 19/17 in Disc O – –

XL125LEK II SA South Africa 21/18 in Drum O O –

XR150LEK shown:

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XR125/150LEK, XL125LEK ADDENDUM

The frame serial number [1] is stamped on the right side of

the steering head.

The carburetor identification number [1] is stamped on the

right side of the carburetor body.

The registered number plate [1] is attached on the front side

of the frame.

The engine serial number [1] is stamped on the lower left side

of the crankcase.

The color label [1] is attached as shown. When ordering

color-coded parts, always specify the designated color code.

[1]

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XR125/150LEK, XL125LEK ADDENDUM

SPECIFICATIONS

GENERAL SPECIFICATIONS

ITEM SPECIFICATION

DIMENSIONS

(XR125/150LEK)

Overall length 2,091 mm (82.3 in)

Overall width 811 mm (31.9 in)

Overall height 1,125 mm (44.3 in)

Wheelbase XR125LEK 1,358 mm (53.5 in)

XR150LEK 1,362 mm (53.6 in)

Seat height 825 mm (32.5 in)

Ground clearance 243 mm (9.6 in)

Curb weight XR125LEK 128 kg (282 lbs)

XR150LEK 129 kg (284 lbs)

Maximum weight capacity 155 kg (341 lbs)

DIMENSIONS

(XL125LEK)

Overall length 2,107 mm (83.0 in)

Overall width 827 mm (32.6 in)

Overall height 1,125 mm (44.3 in)

Wheelbase 1,358 mm (53.5 in)

Seat height 849 mm (33.4 in)

Ground clearance 263 mm (10.4 in)

Curb weight 127 kg (280 lbs)

Maximum weight capacity 155 kg (341 lbs)

FRAME (XR125/

150LEK)

Frame type Semi double cradle

Front suspension Telescopic fork

Front wheel travel 160 mm (6.3 in)

Rear suspension Swingarm

Rear wheel travel XR125LEK 151 mm (5.9 in)

XR150LEK 152 mm (6.0 in)

Front tire size 90/90 – 19 M/C 52P

Rear tire size 110/90 – 17 M/C 60P

Front tire brand C6559F (CHENG SHIN)

Rear tire brand C6559 (CHENG SHIN)

Front brake Hydraulic single disc

Rear brake Mechanical leading trailing

Caster angle 27°

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)

FRAME

(XL125LEK)

Frame type Semi double cradle

Front suspension Telescopic fork

Front wheel travel 159 mm (6.3 in)

Rear suspension Swingarm

Rear wheel travel 148 mm (5.8 in)

Front tire size 70/100 – 21 M/C 44P

Rear tire size 100/90 – 18 M/C 56P

Front tire brand CM-704 (CHENG SHIN)

Rear tire brand CM-705 (CHENG SHIN)

Front brake Mechanical leading trailing

Rear brake Mechanical leading trailing

Caster angle 26.8°

Trail length 103 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)

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XR125/150LEK, XL125LEK ADDENDUM

IGNITION SYSTEM SPECIFICATIONS

ENGINE

(XR125LEK/

XL125LEK)

Bore and stroke 52.4 x 57.8 mm (2.06 x 2.28 in)

Displacement 124.7 cm

(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

closes at 1 mm (0.04 in) lift 30° ABDC

Exhaust valve opens at 1 mm (0.04 in) lift 30° BBDC

closes at 1 mm (0.04 in) lift 0° TDC

Lubrication system Forced pressure and wet sump

Oil pump type Trochoid

Cooling system Air cooled

Air filtration Paper element (Viscous type)

Engine dry weight 28.5 kg (62.8 lbs)

ENGINE

(XR150LEK)

Bore and stroke 57.3 x 57.8 mm (2.26 x 2.28 in)

Displacement 149.2 cm

(9.10 cu-in)

Valve train Chain driven, OHC 2-valve with rocker arm

Compression ratio 9.5 : 1

Intake valve opens at 1 mm (0.04 in) lift 5° BTDC

closes at 1 mm (0.04 in) lift 25° ABDC

Exhaust valve opens at 1 mm (0.04 in) lift 30° BBDC

closes at 1 mm (0.04 in) lift - 5° ATDC

Lubrication system Forced pressure and wet sump

Oil pump type Trochoid

Cooling system Air cooled

Air filtration Paper element (Viscous type)

Engine dry weight 29.2 kg (64.4 lbs)

CARBURETOR Carburetor type Piston valve

Throttle bore 20 mm (0.8 in)

DRIVE TRAIN Clutch system Multi-plate, wet

Clutch operation system Cable operating

Transmission Constant mesh, 5-speeds

Primary reduction 3.350 (67/20)

Final reduction XR125LEK/XL125LEK 3.187 (51/16)

XR150LEK 2.882 (49/17)

Gear ratio 1st 2.785 (39/14)

2nd 1.875 (30/16)

3rd 1.409 (31/22)

4th 1.120 (28/25)

5th 0.937 (30/32)

Gearshift pattern Left foot operated return system

1 - N - 2 - 3 - 4 - 5

ELECTRICAL Ignition system DC-CDI

Starting system Electric starter motor with kickstarter

Charging system Single phase output alternator

Regulator/rectifier SCR shorted, single phase half-wave

rectification

Lighting system Alternator

ITEM SPECIFICATION

ITEM SPECIFICATIONS

Spark plug XR125LEK/

XL125LEK

Standard CPR7EA-9 (NGK)

For extended high

speed riding

CPR8EA-9 (NGK)

XR150LEK Standard CPR8EA-9 (NGK)

For extended high

speed riding

CPR9EA-9 (NGK)

Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in)

Ignition coil primary peak voltage 100 V minimum

Ignition pulse generator peak voltage 0.7 V minimum

Ignition timing ("F" mark) 8° BTDC at idle

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XR125/150LEK, XL125LEK ADDENDUM

ELECTRIC STARTER SPECIFICATION

Unit: mm (in)

LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm (in)

FUEL SYSTEM SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT

Starter motor brush length 10.00 – 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 standard: MA

–

Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)

Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.25 (0.010)

Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)

ITEM SPECIFICATIONS

Carburetor

identification

number

XR125LEK (SA)/XL125LEK (II SA) PDN2H

XR125LEK (DK/III LA) PDN2J

XR150LEK (DK/III LA/PE/PH) PDN2M

XR150LEK (SA/I LA/NZ/AG) PDN2P

XR150LEK (CO/MX) @

Main jet XR125LEK/XL125LEK #100

XR150LEK (Except CO/MX) #105

XR150LEK (CO/MX) #@

Slow jet Except CO/MX #35

CO/MX #@

Pilot screw initial opening See page 6-12

Float level 14 mm (0.6 in)

Carburetor

heater

resistance

XR125LEK (SA)/XL125LEK (II SA) 8.2 – 12.3 Ω (25°C/77°F)

XR150LEK (I LA/SA/AG/NZ) 11.4 – 17.0 Ω (25°C/77°F)

PAIR control

valve specified

vacuum

XR125LEK/XL125LEK 330 mm Hg

XR150LEK 340 mm Hg

Idle speed XR125LEK/XL125LEK 1,500 ± 100 min

-1

(rpm)

XR150LEK 1,400 ± 100 min

-1

(rpm)

Throttle grip free play 2.0 – 6.0 mm (0.08 – 0.24 in)

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XR125/150LEK, XL125LEK ADDENDUM

CYLINDER HEAD/VALVES SPECIFICATIONS

Unit: mm (in)

CYLINDER/PISTON SPECIFICATIONS (XR125LEK/XL125LEK)

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder compression at 300 min

-1

(rpm) 1,275 kPa (13.0 kgf/cm

, 185 psi) –

Valve clearance IN 0.08 ± 0.02 (0.003 ± 0.001) –

EX 0.12 ± 0.02 (0.005 ± 0.001) –

Valve,

valve guide

Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.92 (0.194)

EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)

Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.04 (0.198)

Stem-to-guide

clearance

IN 0.010 – 0.037 (0.0004 – 0.0015) 0.07 (0.003)

EX 0.030 – 0.057 (0.0012 – 0.0022) 0.09 (0.004)

Valve seat width IN/EX 0.9 – 1.1 (0.035 – 0.043) 1.5 (0.06)

Valve spring Free length INNER 38.76 (1.526) 37.89 (1.492)

OUTER 35.95 (1.415) 35.14 (1.383)

Rocker arm Arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)

Shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)

Arm-to-shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004)

Camshaft Cam lobe height IN 32.9935 – 33.2335 (1.29895 – 1.30840) 32.96 (1.298)

EX 32.8804 – 33.1204 (1.29450 – 1.30395) 32.85 (1.293)

Cylinder head warpage – 0.05 (0.002)

ITEM STANDARD SERVICE LIMIT

Cylinder I.D. 52.400 – 52.410 (2.0630 – 2.0634) 52.50 (2.067)

Out-of-round – 0.10 (0.004)

Taper – 0.10 (0.004)

Warpage – 0.10 (0.004)

Piston,

piston pin,

piston ring

Piston O.D. at 10 mm (0.4 in) from

bottom

52.370 – 52.390 (2.0618 – 2.0626) 52.3 (2.059)

Piston 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 (0.004)

Second 0.030 – 0.065 (0.0012 – 0.0026) 0.10 (0.004)

Cylinder-to-piston clearance 0.010 – 0.040 (0.0004 – 0.0016) 0.10 (0.004)

Connecting rod small end I.D. 13.016 – 13.034 (0.5124 – 0.5131) 13.04 (0.513)

Connecting rod-to-piston pin clearance 0.016 – 0.034 (0.0006 – 0.0013) 0.10 (0.004)

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XR125/150LEK, XL125LEK ADDENDUM

CYLINDER/PISTON SPECIFICATIONS (XR150LEK)

Unit: mm (in)

CLUTCH/GEARSHIFT LINKAGE/BALANCER GEAR SPECIFICATIONS

Unit: mm (in)

ALTERNATOR/STARTER CLUTCH SPECIFICATION

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder I.D. 57.300 – 57.310 (2.2559 – 2.2563) 57.40 (2.260)

Out-of-round – 0.10 (0.004)

Taper – 0.10 (0.004)

Warpage – 0.10 (0.004)

Piston,

piston pin,

piston ring

Piston O.D. at 10 mm (0.4 in) from

bottom

57.280 – 57.295 (2.2551 – 2.2557) 57.20 (2.252)

Piston pin hole I.D. 14.002 – 14.008 (0.5513 – 0.5515) 14.04 (0.553)

Piston pin O.D. 13.994 – 14.000 (0.5509 – 0.5512) 13.96 (0.550)

Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.04 (0.002)

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 – 0.060 (0.0012 – 0.0024) 0.10 (0.004)

Second 0.030 – 0.060 (0.0012 – 0.0024) 0.10 (0.004)

Cylinder-to-piston clearance 0.005 – 0.030 (0.0002 – 0.0012) 0.09 (0.004)

Connecting rod small end I.D. 14.010 – 14.028 (0.5516 – 0.5523) 14.06 (0.554)

Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.10 (0.004)

ITEM STANDARD SERVICE LIMIT

Clutch lever free play 10 – 20 (0.4 – 0.8) –

Clutch Spring free length 40.5 (1.59) 39.6 (1.56)

Disc thickness Disc A 2.80 – 2.90 (0.110 – 0.114) 2.6 (0.10)

Disc B 2.80 – 2.90 (0.110 – 0.114) 2.6 (0.10)

Plate warpage – 0.20 (0.008)

Clutch outer I.D. 23.000 – 23.021 (0.9055 – 0.9063) 23.08 (0.909)

Clutch outer guide O.D. 22.959 – 22.980 (0.9039 – 0.9047) 22.93 (0.903)

I.D. 16.991 – 17.009 (0.6689 – 0.6696) 17.04 (0.671)

Mainshaft O.D. at clutch outer guide 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667)

Kickstarter idle gear I.D. 20.500 – 20.521 (0.8071 – 0.8079) 20.58 (0.810)

Kickstarter idle gear bushing O.D. 20.459 – 20.480 (0.8055 – 0.8063) 20.43 (0.804)

I.D. 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)

Countershaft O.D. at kickstarter idle gear 16.966 – 16.984 (0.6680 – 0.6687) 16.94 (0.667)

Kickstarter drive gear I.D. 16.016 – 16.034 (0.6305 – 0.6313) 16.06 (0.632)

Kickstarter spindle O.D. at kickstarter drive gear 15.966 – 15.984 (0.6286 – 0.6293) 15.94 (0.628)

ITEM STANDARD SERVICE LIMIT

Starter driven gear boss O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.60 (1.795)

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XR125/150LEK, XL125LEK ADDENDUM

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SPECIFICATIONS

Unit: mm (in)

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS (XR125/150LEK)

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Crankshaft Connecting rod big end radial

clearance

0 – 0.008 (0 – 0.0003) 0.05 (0.002)

Connecting rod big end side

clearance

0.10 – 0.35 (0.004 – 0.014) 0.80 (0.032)

Runout – 0.08 (0.003)

Transmission Gear I.D. M4 20.000 – 20.018 (0.7874 – 0.7881) 20.04 (0.789)

M5 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)

C1 20.500 – 20.521 (0.8071 – 0.8079) 20.55 (0.809)

C2 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)

C3 23.025 – 23.046 (0.9065 – 0.9073) 23.07 (0.908)

Bushing O.D. C1 20.459 – 20.480 (0.8055 – 0.8063) 20.41 (0.804)

C2 22.984 – 23.005 (0.9049 – 0.9057) 22.95 (0.904)

C3 22.984 – 23.005 (0.9049 – 0.9057) 22.95 (0.904)

Bushing I.D. C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)

C2 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790)

C3 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790)

Gear-to-bushing

clearance

C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)

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) 0.10 (0.004)

M5 0.020 – 0.050 (0.0008 – 0.0020) 0.10 (0.004)

Bushing-to-shaft

clearance

C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004)

C2 0.031 – 0.063 (0.0012 – 0.0025) 0.10 (0.004)

C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)

Shift fork, shift

fork shaft

Shift fork shaft O.D. 9.986 – 9.995 (0.3931 – 0.3944) 9.93 (0.391)

Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.05 (0.396)

Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)

ITEM STANDARD SERVICE LIMIT

Minimum tire thread depth – 3.0 (0.12)

Cold tire pressure Driver only 150 kPa (1.50 kgf/cm

, 22 psi) –

Driver and passenger 150 kPa (1.50 kgf/cm

, 22 psi) –

Axle runout – 0.20 (0.008)

Wheel rim runout Radial – 2.0 (0.08)

Axial – 2.0 (0.08)

Fork Spring free length 594.5 (23.41) 582.6 (22.94)

Pipe runout – 0.20 (0.008)

Recommended fluid Honda ULTRA CUSHION OIL 10W or

equivalent

–

Fluid level 179 (7.0) –

Fluid capacity 180 ± 2.5 cm

(6.1 ± 0.08 US oz, 6.3 ±

0.09 lmp oz)

–

Steering head bearing pre-load 11.8 – 17.7 N (1.2 – 1.8 kgf, 2.6 – 4.0 lbf) –

20-12

dummyheaddummyhead

XR125/150LEK, XL125LEK ADDENDUM

FRONT WHEEL/BRAKE/SUSPENSION/STEERING SPECIFICATIONS (XL125LEK)

Unit: mm (in)

REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS

Unit: mm (in

HYDRAULIC BRAKE SPECIFICATIONS (XR125/150LEK)

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Minimum tire thread depth – 3.0 (0.12)

Cold tire pressure Driver only 150 kPa (1.50 kgf/cm

, 22 psi) –

Driver and passenger 150 kPa (1.50 kgf/cm

, 22 psi) –

Axle runout – 0.20 (0.008)

Wheel rim runout Radial – 2.0 (0.08)

Axial – 2.0 (0.08)

Fork Spring free length 605.5 (23.84) 593.4 (23.36)

Pipe runout – 0.20 (0.008)

Recommended fluid Honda ULTRA CUSHION OIL 10W or

equivalent

–

Fluid level 194 (7.6) –

Fluid capacity 180 ± 2.5 cm

(6.1 ± 0.08 US oz, 6.3 ±

0.09 lmp oz)

–

Brake Drum I.D. 130 (5.1) 131 (5.2)

Brake lever free play 10 – 20 (0.4 – 0.8) –

Steering 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

XR125/

150LEK

Driver only 150 kPa (1.50 kgf/cm

, 22 psi) –

Driver and passenger 200 kPa (2.00 kgf/cm

, 29 psi) –

XL125LEK Driver only 150 kPa (1.50 kgf/cm

, 22 psi) –

Driver and passenger 225 kPa (2.25 kgf/cm

, 33 psi) –

Axle runout – 0.20 (0.008)

Wheel rim runout Radial – 2.0 (0.08)

Axial – 2.0 (0.08)

Drive chain Size/link 428/130 –

Slack 20 – 30 (0.8 – 1.2) –

Brake Drum I.D. 110 (4.3) 111 (4.4)

Brake pedal free play 15 – 25 (0.6 – 1.0) –

ITEM STANDARD SERVICE LIMIT

Specified brake fluid DOT 3 or DOT 4 –

Brake pad wear indicator – To groove

Brake disc thickness 4.0 (0.16) 3.5 (0.14)

Brake disc runout – 0.30 (0.012)

Master cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022)

Master piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)

Caliper cylinder I.D. 27.000 – 27.050 (1.0630 – 1.0650) 27.060 (1.0654)

Caliper piston O.D. 26.918 – 26.968 (1.0598 – 1.0617) 26.91 (1.059)

20-13

dummyheaddummyhead

XR125/150LEK, XL125LEK ADDENDUM

BATTERY/CHARGING SYSTEM SPECIFICATIONS

LIGHTS/METER/SWITCHES SPECIFICATIONS

TORQUE VALUES

For standard torque values (page 1-10).

ENGINE & FRAME TORQUE VALUES

FRAME/BODY PANELS/EXHAUST SYSTEM

ITEM SPECIFICATIONS

Battery Type YTX5L-BS

Capacity 12 V – 4 Ah (10 HR)

Current leakage 0.01 mA max.

Voltage

(20°C/68°F)

Fully charged Above 12.8 V

Needs charging Below 12.3 V

Charging

current

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 – 5 W

Brake/taillight 12 V – 21/5 W

License light 12 V – 5 W

Front turn signal light 12 V – 10 W x 2

Rear turn signal light 12 V – 10 W x 2

Instrument light 12 V – 1.7 W

Turn signal indicator 12 V – 3.4 W

High beam indicator 12 V – 1.7 W

Neutral indicator 12 V – 1.7 W

Fuse Main fuse 15 A

Sub fuse 10 A

ITEM Q'TY THREAD TORQUE REMARKS

DIA. (mm) N·m (kgf·m,

lbf·ft)

Exhaust pipe joint nut 2 8 18 (1.8, 13)

Exhaust pipe protector bolt 2 6 14 (1.4, 10)

Muffler rear mounting nut 2 8 26 (2.7, 19)

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

20-14

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XR125/150LEK, XL125LEK ADDENDUM

MAINTENANCE

IGNITION SYSTEM

ELECTRIC STARTER

FUEL SYSTEM

LUBRICATION SYSTEM

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 cap 1 32 15 (1.5, 11) Apply grease to the threads.

Timing hole cap 1 14 10 (1.0, 7)

Engine oil drain bolt 1 12 30 (3.1, 22)

Oil filter rotor cover screw 3 5 4.0 (0.4, 3.0)

Rear axle nut 1 16 93 (9.5, 69) U-nut

Drive sprocket fixing plate bolt 2 6 12 (1.2, 9)

Driven sprocket nut 6 8 32 (3.3, 24) U-nut

Sidestand pivot bolt 1 10 10 (1.0, 7)

Sidestand pivot nut 1 10 39 (4.0, 29) U-nut

Front spoke 36 BC3.2 3.7 (0.4, 2.7)

Rear spoke 36 BC3.2 3.7 (0.4, 2.7)

ITEM Q'TY THREAD TORQUE REMARKS

DIA. (mm) N·m (kgf·m,

lbf·ft)

Timing hole cap 1 14 10 (1.0, 7)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m,

lbf·ft)

Starter motor case bolt 2 – 4.9 (0.5, 3.6)

ITEM Q'TY THREAD TORQUE REMARKS

DIA. (mm) N·m (kgf·m,

lbf·ft)

Carburetor drain screw 1 – 1.5 (0.2, 1.1)

Carburetor heater

(I LA/SA/IISA/AG/NZ types)

1 – 4.9 (0.5, 3.6)

Choke lever set plate screw 1 4 2.1 (0.2, 1.5)

Slow jet 1 – 1.8 (0.2, 1.3)

Needle jet holder 1 – 2.5 (0.3, 1.8)

Main jet 1 – 2.1 (0.2, 1.5)

Float chamber screw 3 4 2.1 (0.2, 1.5)

Air cut-off valve cover screw 2 4 2.1 (0.2, 1.5)

Fuel valve 1 18 23 (2.3, 17)

Insulator socket bolt 2 6 12 (1.2, 9)

Shock absorber lower mounting nut 1 10 44 (4.5, 32) U-nut

PAIR check valve cover screw 2 4 2.1 (0.2, 1.5)

ITEM Q'TY

THREAD TORQUE

REMARKS

DIA. (mm) N·m (kgf·m,

lbf·ft)

Oil pump cover screw 1 4 3.0 (0.3, 2.2)

20-15

dummyheaddummyhead

XR125/150LEK, XL125LEK ADDENDUM

CYLINDER HEAD/VALVES

CYLINDER/PISTON

CLUTCH/GEARSHIFT LINKAGE/BALANCER GEAR

ALTERNATOR/STARTER CLUTCH

ITEM Q'TY THREAD TORQUE REMARKS

DIA. (mm) N·m (kgf·m,

lbf·ft)

Rocker arm shaft bolt 2 5 5.0 (0.5, 3.7)

Cylinder head cover bolt 2 6 10 (1.0, 7)

Cam sprocket bolt 2 5 9.0 (0.9, 6.6)

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

DIA. (mm) N·m (kgf·m,

lbf·ft)

Clutch center lock nut 1 14 74 (7.5, 55) Apply engine oil to the threads and

seating surface.

Clutch lifter plate bolt 4 6 12 (1.2, 9)

Oil filter rotor lock nut 1 14 64 (6.5, 47) Apply engine oil to the threads and

seating surface.

Oil filter rotor cover screw 3 5 4.0 (0.4, 3.0)

Gearshift cam bolt 1 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

Shift drum stopper arm bolt 1 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

Gearshift spindle return spring pin 1 8 22 (2.2, 16) Apply locking agent to the threads.

Coating width: 6.5 ± 1.0 mm (0.26 ±

0.04 in) from tip

Gearshift pedal pinch bolt 1 6 12 (1.2, 9)

Kickstarter arm bolt 1 8 26 (2.7, 19)

Balancer driven gear lock nut

(XR150LEK)

1 14 64 (6.5, 47) Apply engine oil to the threads and

seating surface.

ITEM Q'TY THREAD TORQUE REMARKS

DIA. (mm) N·m (kgf·m,

lbf·ft)

Flywheel nut 1 14 74 (7.5, 55) Apply engine oil to the threads and

seating surface.

Starter clutch bolt 6 6 16 (1.6, 12) Apply locking agent to the threads.

Coating width: 6.5 ± 1.0 mm (0.26 ±

0.04 in) from tip

Stator mounting bolt 3 6 12 (1.2, 9)

Ignition pulse generator mounting

bolt

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

Alternator stator wire guide bolt 1 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

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