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Honda 2002 XR50R Service Manual

Honda 2002 XR50R
197 pages
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Table of Contents

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Honda 2002 XR50R Specifications

General IconGeneral
Engine Type49cc air-cooled single-cylinder four-stroke
Bore and Stroke39.0mm x 41.4mm
Compression Ratio10.0:1
Valve TrainSOHC; two-valve
Carburetion13mm piston-valve
IgnitionCDI
Final DriveChain
Front BrakeDrum
Rear BrakeDrum
Front Tire2.50-10
Rear Tire2.50-10
Seat Height21.6 inches
Fuel Capacity0.7 gallons
Transmission3-speed

Summary

1. General Information

General Safety

Safety precautions for operating the motorcycle.

Service Rules

Rules to follow during service procedures.

3. Maintenance

Maintenance Schedule

Recommended maintenance intervals and tasks.

Valve Clearance

Inspecting and adjusting valve clearance.

Engine Oil

Checking and changing engine oil.

Drive Chain

Inspecting, adjusting, and lubricating the drive chain.

Brake System

Inspecting and maintaining the brake system.

5. Fuel System

Air Screw Adjustment

Adjusting the air screw for optimal engine performance.

6. Engine Removal/Installation

Engine Removal

Step-by-step procedure for removing the engine.

Engine Installation

Step-by-step procedure for installing the engine.

7. Cylinder Head/Valves

Cylinder Compression

How to measure cylinder compression pressure.

Camshaft Removal

Procedures for removing the camshaft.

Cylinder Head Removal

Step-by-step removal of the cylinder head.

Cylinder Head/Valves Disassembly

Procedures for disassembling cylinder head components.

Valve Guide Replacement

Procedures for replacing valve guides.

Valve Seat Inspection/Refacing

Inspecting and refacing valve seats.

Valve Seat Refacing

Using valve seat cutters for refacing.

Camshaft Installation

Procedures for installing the camshaft.

8. Cylinder/Piston

Cylinder Removal

Step-by-step procedure for removing the cylinder.

Piston Removal

Procedures for removing the piston.

Cylinder/Piston Inspection

Inspecting cylinder bore and piston for wear.

Piston Ring Installation

Procedures for installing piston rings.

Piston Installation

Step-by-step procedure for installing the piston.

Cylinder Installation

Procedures for installing the cylinder.

9. Clutch/Gearshift Linkage

Clutch Removal

Step-by-step procedure for removing the clutch.

Clutch Disassembly

Disassembling clutch components.

Clutch Inspection

Inspecting clutch lifter bearing and components.

Clutch Assembly

Assembling clutch components.

Gearshift Linkage Removal

Procedures for removing the gearshift linkage.

Gearshift Linkage Installation

Procedures for installing the gearshift linkage.

10. Alternator/Cam Chain Tensioner

Flywheel/Stator Removal

Procedures for removing flywheel and stator.

Cam Chain Tensioner Removal

Step-by-step removal of the cam chain tensioner.

Cam Chain Tensioner Installation

Installing cam chain tensioner components.

Stator/Flywheel Installation

Procedures for installing stator and flywheel.

11. Crankshaft/Transmission/Kickstarter

Crankcase Separation

Procedures for separating the crankcase halves.

Crankshaft Removal

Step-by-step procedure for removing the crankshaft.

Crankshaft Inspection

Inspecting crankshaft bearings and runout.

Crankshaft Installation

Procedures for installing the crankshaft.

12. Front Wheel/Brake/Suspension/Steering

13. Rear Wheel/Brake/Suspension

14. Ignition System

Service Information

General information and precautions for ignition system service.

Troubleshooting

Diagnosing ignition system problems.

16. Troubleshooting

Engine Does Not Start or Is Hard to Start

Diagnosing and resolving starting issues.

Engine Lacks Power

Troubleshooting symptoms of low engine power.

Poor Performance at Low and Idle Speed

Diagnosing poor performance at low speeds.

Poor Performance at High Speed

Troubleshooting high-speed performance issues.

Poor Handling

Diagnosing and resolving handling problems.

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