Honda SL125 - Shop Manual

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Contents3
Procedure of Performing the Work5
Special Tools6
Special Tools for CB125S, CD125S and SL1258
Maintenance Operations9
Tappet Adjustment9
Carburetor Adjustment9
Breaker Point and Ignition Timing Adjustment10
Clutch Adjustment11
Spark Plug Inspection11
Engine Oil Change12
Oil Filter Cleaning12
Oil Pump Screen Cleaning12
Cam Chain Adjustment13
Fuel System Inspection13
Air Cleaner Element Servicing13
Brake Adjustment14
Drive Chain Adjustment15
Battery Electrolyte Inspection15
Front Fork Oil Replacement15
Cylinder Compression Check16
Engine Construction17
Work Which Can be Performed Without Removing the Engine18
Engine Removal18
Engine Reinstallation19
Cylinder, Cylinder Head and Piston Disassembly19
Direction of Rotation19
Camshaft Removal19
Cylinder, Cylinder Head and Piston Inspection20
Cylinder Removal20
Piston Pin Removal20
Cylinder Bore Measurement20
Cylinder, Cylinder Head and Piston Reassembly21
Piston Diameter Measurement21
Piston Gap Measurement21
Piston Installation21
Camshaft Installation22
Valve Timing Procedure22
Advance Installation23
Valve Removal24
Valve Disassembly24
Valve Inspection24
Valve Stem Clearance Measurement24
Valve Reassembly25
Valve Seat Dressing25
Oil Pump and Oil Filter26
Lubrication System26
Lock Nut Removal27
Oil Pump Drive Gear Removal27
Oil Pump Body Removal27
Oil Pump Disassembly27
Oil Pump and Oil Filter Reassembly28
Lock Nut Tightening28
Clutch Disassembly29
Clutch Removal29
Clutch Inspection30
Clutch Reassembly30
Clutch Outer Removal30
Spline Washer Installation30
Gear Shift Mechanism31
Circlip Removal32
Pin Alignment32
Spindle Installation32
Cam Chain Tensioner and A.C. Generator Disassembly33
Rotor Removal33
Cam Chain Tensioner and A.C. Generator Reassembly34
Crankshaft34
Cam Chain Tensioner Installation34
Generator Installation34
Crankshaft Disassembly35
Crankshaft Inspection35
Crankcase Disassembly35
Crankshaft Runout Measurement35
Transmission and Primary Kick Starter36
Crankshaft Reassembly36
Crankcase Tightening36
Transmission and Primary Kick Starter Disassembly37
Transmission and Primary Kick Starter Reassembly38
Kick Starter Installation38
Direction of Drum Installation38
Carburetor39
Float Level Adjustment39
Carburetor Setting Table40
Chassis41
Front Brake and Front Wheel Disassembly41
Front Wheel Removal41
Brake Shoe Removal41
Front Brake and Front Wheel Inspection42
Rim Runout Measurement42
Front Brake Drum Measurement42
Spoke Retightening42
Front Brake and Front Wheel Reassembly43
Tire Assembly43
Front Brake Wire Adjustment43
Brake Lever Play43
Rear Brake and Rear Wheel Disassembly44
Drive Chain Disassembly44
Rear Wheel Removal44
Rear Brake and Rear Wheel Inspection45
Rear Brake Drum Measurement45
Brake Lining Measurement45
Rear Brake and Rear Wheel Reassembly46
Final Driven Sprocket Assembly46
Brake Stopper Arm Installation46
Chain Slack and Brake Pedal Play46
Steering Unit Disassembly47
Clutch Cable Removal47
Emergency Switch Removal47
Handle Bar Removal47
Steering Unit Inspection48
Steering Unit Reassembly48
Steering Stem Removal48
Front Suspension49
Brake Cable Play Adjustment49
Clutch Cable Play Adjustment49
Front Suspension Construction50
Front Suspension Disassembly50
Front Fork Removal50
Front Suspension Inspection51
Front Suspension Reassembly51
Spring Gree Length Measurement51
Front Fork Assembly51
Rear Suspension Disassembly52
Rear Shock Absorber Disassembly52
Rear Suspension Inspection53
Rear Suspension Reassembly53
Rear Fork Assembly53
Rear Shock Absorber Assembly53
Frame Body Construction54
Frame Body Disassembly54
Seat and Fuel Tank Removal54
Air Cleaner and Tool Box Removal54
Frame Body Inspection55
Stand Removal55
Ball Race Removal55
Air Cleaner Element Cleaning55
Front Body Reassembly56
Electrical57
Generating System57
A.C. Generating Specifications57
Charging System58
Charging Test58
Ignition System59
Charging System Inspection59
Stator Coil Test59
Selenium Rectifier Continuity Test59
Battery Construction60
Ignition Coil Test60
Condenser Test60
Battery Inspection and Servicing61
Battery Charging61
Auxiliary Electrical Equipment Inspection62
Troubleshooting65
Periodical Maintenance70
Maintenance Schedule70
Technical Data71
Wiring Diagram (CB100)73
Wiring Diagram (CL100)74
Wiring Diagram (SL100)75
Wiring Diagram (CB125S)76
Wiring Diagram (CD125S)77
Wiring Diagram (SL125)78
TL125 Special Tools79
Tapper Clearance Adjustment81
Air Cleaner Maintenance82
Clutch Wire Adjustment83
Front Brake Adjustment84
Rear Brake Adjustment84
Brake Pedal Height Adjustment85
Gear Change Pedal Height Adjustment85
Front Suspension Spring Adjustment85
Front Fork Oil Change85
Cylinder Compression Inspection86
Chassis Brake Arm91
Handlebar91
Cables and Lead Wires91
Electrical System94
A.C. Generator95
Inspection of Electrical Accessories96
Main Switch96
A.C. Generator Removal96
A.C. Generator Starter Inspection96
Table of Optional Parts97
Specifications99
TL 125 Wiring Diagram100
Index101

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