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Honda 2003 XR50R Service Manual

Honda 2003 XR50R
197 pages
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Table of Contents

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Honda 2003 XR50R Specifications

General IconGeneral
Engine Type49cc air-cooled single-cylinder four-stroke
Bore and Stroke39.0mm x 41.4mm
Compression Ratio10.0:1
Induction13mm piston-valve carburetor
IgnitionCDI
Final DriveChain
Front BrakeDrum
Rear BrakeDrum
Front Tire2.50-10
Rear Tire2.50-10
Wheelbase36.0 inches
Seat Height21.6 inches
Curb Weight110 pounds
Fuel Capacity0.7 gallons
TransmissionThree-speed
Front SuspensionInverted telescopic fork; 3.5 inches travel
Rear SuspensionSingle shock; 2.8 inches travel

Summary

General Information

General Safety Precautions

Crucial safety precautions for operating and maintaining the vehicle.

Torque Values

Essential torque specifications for critical fasteners during assembly and maintenance.

Maintenance Procedures

Maintenance Schedule Overview

Recommended service intervals and tasks for optimal vehicle performance.

Spark Plug Service Guide

Guide for inspecting, removing, and reusing the spark plug.

Valve Clearance Adjustment

Detailed instructions for checking and adjusting valve clearance.

Engine Oil Service Procedures

Procedures for checking and changing the engine oil, including strainer and filter.

Clutch System Service

Guide for adjusting and servicing the motorcycle's clutch system.

Lubrication System

Oil Pump Service Procedures

Detailed instructions for removing, inspecting, and assembling the oil pump.

Fuel System

Carburetor Service Procedures

Procedures for air cleaner housing, carburetor removal, disassembly, and assembly.

Air Screw Adjustment

Guide for adjusting the carburetor's air screw for optimal engine idle.

Engine Removal and Installation

Engine Removal Steps

Step-by-step guide for safely removing the engine from the motorcycle frame.

Engine Installation Procedure

Instructions for reinstalling the engine into the motorcycle frame.

Cylinder Head and Valves

Cylinder Compression Testing

Procedure for measuring engine compression to diagnose performance issues.

Camshaft Removal and Installation

Detailed steps for removing and reinstalling the camshaft assembly.

Cylinder Head Disassembly and Inspection

Instructions for disassembling the cylinder head and inspecting its components.

Cylinder and Piston

Cylinder and Piston Removal

Step-by-step guide for removing the cylinder and piston assembly.

Cylinder and Piston Inspection

Methods for inspecting cylinder bore, piston diameter, and warpage.

Piston and Cylinder Installation

Procedures for installing the piston into the cylinder and the cylinder onto the crankcase.

Clutch and Gearshift Linkage

Clutch Service Procedures

Detailed procedures for clutch removal, disassembly, inspection, and assembly.

Alternator and Cam Chain Tensioner

Flywheel and Stator Removal

Steps to remove the flywheel and stator assembly.

Stator and Flywheel Installation

Instructions for installing the stator and flywheel components.

Crankshaft, Transmission, and Kickstarter

Crankcase Separation Procedure

Steps to split the crankcase halves for internal access.

Crankshaft Service Guide

Procedures for crankshaft removal, inspection, and installation.

Transmission Service Procedures

Steps for transmission disassembly, inspection, assembly, and installation.

Front Wheel, Brake, Suspension, and Steering

Front Brake Service Procedures

Steps for inspecting, disassembling, and assembling the front brake system.

Front Fork Service Guide

Detailed guide for disassembling, inspecting, and assembling the front fork components.

Rear Wheel, Brake, and Suspension

Rear Brake Service Procedures

Steps for inspecting, disassembling, and assembling the rear brake system.

Ignition System

Ignition System Troubleshooting

Diagnosing ignition system issues like no spark or low voltage.

Wiring Diagram

Ignition System Wiring Diagram

Comprehensive electrical system schematic showing component connections and wire colors.

Troubleshooting Guide

Engine Starting Problems

Diagnostic flowcharts for engine starting problems.

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