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Honda XR125LEK User Manual

Honda XR125LEK
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How to use this manual
How to use this manual
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.

Table of Contents

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Honda XR125LEK Specifications

General IconGeneral
Compression Ratio9.2:1
Fuel SystemCarburetor
Ignition SystemCDI
StarterElectric and kick
Transmission5-speed
Final DriveChain
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDrum
Length2, 100 mm
Width820 mm
Height1, 126 mm
Seat Height825 mm
Fuel Capacity12 liters
Engine TypeAir-cooled, 4-stroke, single-cylinder
Displacement124 cc
Front Tire90/90-19
Rear Tire110/90-17
Bore x Stroke56.5 mm x 49.5 mm

Summary

Safety Information

Service Information

General safety advice for professional technicians performing service and repairs on the vehicle.

For Your Safety

Important general service safety precautions and advice for performing service and repair procedures.

Important Safety Precautions

Key safety guidelines to ensure safe practices when performing any service task on the vehicle.

Safety Messages

Explanation of safety alert symbols (DANGER, WARNING, CAUTION) and their meanings.

How to Use This Manual

Manual Structure Overview

Description of the manual's structure, sections, and how to find information.

Symbols

Service Symbols Reference

Explanation of symbols used throughout the manual to indicate specific service procedures.

General Information

Service Rules

Guidelines for performing service and repairs using genuine parts and tools.

Model Identification

Information on identifying different models covered by the manual.

Specifications

Technical data and specifications for various motorcycle components.

Torque Values

Standard torque values for fasteners used in engine, frame, and other systems.

Lubrication & Seal Points

Locations and types of lubricants and sealants required for various components.

Cable & Harness Routing

Diagrams illustrating the correct routing of cables and wiring harnesses.

Emission Control Systems

Source of Emissions

Explanation of emission sources and their impact on the environment.

Pulse Secondary Air Injection System (XR125LK/LEK)

Details on the PAIR system for controlling exhaust emissions.

Frame, Body Panels, and Exhaust System

Seat Removal/Installation

Steps for removing and installing the motorcycle seat.

Side Cover Removal/Installation

Steps for removing and installing the side covers.

Rear Carrier Removal/Installation

Steps for removing and installing the rear carrier.

Rear Cowl Removal/Installation

Steps for removing and installing the rear cowl.

Number Plate Bracket Removal/Installation

Steps for removing and installing the number plate bracket.

Side Shroud Removal/Installation

Steps for removing and installing the side shroud.

Fuel Tank Removal/Installation

Steps for removing and installing the fuel tank.

Front Visor Removal/Installation

Steps for removing and installing the front visor.

Front Fender Removal/Installation

Steps for removing and installing the front fender.

Drive Sprocket Cover Removal/Installation

Steps for removing and installing the drive sprocket cover.

Exhaust Pipe/Muffler Removal/Installation

Steps for removing and installing the exhaust pipe and muffler.

Maintenance

Maintenance Schedule

Detailed schedule for periodic maintenance tasks based on mileage or time.

Fuel Strainer Screen Service

Procedure for cleaning the fuel strainer screen.

Throttle Operation Check

Checking throttle grip operation and free play.

Air Cleaner Servicing

Procedure for inspecting and replacing the air cleaner element.

Spark Plug Service

Inspection, removal, and installation of the spark plug.

Valve Clearance Adjustment

Procedure for inspecting and adjusting valve clearance.

Engine Oil Level Inspection and Change

Procedure for checking engine oil level and performing an oil change.

Drive Chain Adjustment and Maintenance

Steps for adjusting drive chain slack, cleaning, and lubricating.

Brake Fluid and Pad/Shoe Wear Checks

Procedures for checking brake fluid level and brake pad/shoe wear.

Clutch System Inspection

Procedure for inspecting and adjusting clutch lever free play.

Wheels and Tires Check

Inspection of wheel bearings, tires, and spoke tension.

Steering Head Bearings Check

Procedure for checking the condition of steering head bearings.

Ignition System

Component Location

Visual identification of ignition system components on the motorcycle.

System Diagram

Electrical schematic illustrating the ignition system's connections.

Troubleshooting Ignition System

Step-by-step guide for diagnosing and resolving ignition system problems.

Ignition System Inspection Procedures

Methods for inspecting ignition coil primary peak voltage and system connections.

Ignition Timing Check

Procedure for checking the engine's ignition timing using a timing light.

Electric Starter

Component Location

Visual identification of electric starter system components.

System Diagram

Electrical schematic of the electric starter system.

Troubleshooting Electric Starter

Step-by-step guide for diagnosing and resolving electric starter problems.

Starter Motor Inspection

Procedures for inspecting the starter motor for wear and damage.

Starter Relay Inspection

Checking starter relay operation, circuits, and connections.

Neutral Diode Inspection

Procedure for inspecting the neutral indicator diode.

Fuel System

System Components Overview

Visual overview of the motorcycle's fuel system components.

Service Information

General notes and precautions for servicing the fuel system.

Troubleshooting Fuel System

Common fuel system problems and their potential causes and solutions.

Air Cleaner Housing Service

Steps for removing and installing the air cleaner housing.

Carburetor Service

Procedures for carburetor removal, disassembly, and assembly.

Pilot Screw Adjustment

Procedure for adjusting the pilot screw for optimal idle operation.

Lubrication System

Lubrication System Diagram

Diagram illustrating the flow of lubricating oil throughout the engine.

Troubleshooting Lubrication

Common problems related to engine oil level, consumption, and contamination.

Oil Pump Service

Procedures for removing, installing, disassembling, and inspecting the oil pump.

Cylinder Head and Valves

System Components Overview

Visual overview of the cylinder head, valves, camshaft, and related parts.

Service Information

General notes and precautions for servicing the cylinder head and valve train.

Troubleshooting Cylinder Head/Valves

Diagnosing problems related to compression, smoke, noise, and idle.

Cylinder Compression Test

Procedure for performing a cylinder compression test.

Cylinder Head Cover Service

Steps for removing and installing the cylinder head cover.

Camshaft Service

Procedures for camshaft removal, inspection, and installation.

Camshaft Holder Service

Procedures for removing, disassembling, and assembling the camshaft holder.

Cylinder Head Removal/Installation

Steps for removing and installing the cylinder head.

Cylinder Head Disassembly

Steps for disassembling the cylinder head, including valve removal.

Valve Guide Replacement

Procedures for replacing valve guides.

Valve Seat Refacing

Procedures for refacing valve seats.

Cylinder and Piston

System Components Overview

Visual overview of cylinder and piston components.

Service Information

General notes and precautions for cylinder and piston servicing.

Troubleshooting Cylinder/Piston

Common cylinder and piston issues like low compression or noise.

Cylinder Removal and Installation

Steps for removing and installing the cylinder.

Piston Removal and Installation

Steps for removing and installing the piston and piston rings.

Clutch and Gearshift Linkage

System Components Overview

Visual overview of clutch, gearshift linkage, and kickstarter components.

Service Information

General notes on clutch, gearshift, and kickstarter servicing.

Troubleshooting Clutch/Gearshift

Common problems related to clutch operation and gear shifting.

Right Crankcase Cover Service

Steps for removing and installing the right crankcase cover.

Clutch Service

Procedures for clutch removal, installation, and assembly.

Gearshift Linkage Service

Procedures for gearshift linkage removal, inspection, and installation.

Primary Drive Gear Service

Steps for removing and installing the primary drive gear.

Alternator and Starter Clutch

System Components Overview

Visual overview of alternator, starter clutch, and related components.

Troubleshooting Starter Motor

Diagnosing issues when the starter motor turns but the engine does not.

Left Crankcase Cover Service

Steps for removing and installing the left crankcase cover.

Stator and Ignition Pulse Generator Service

Procedures for removing and installing the stator and ignition pulse generator.

Flywheel and Starter Clutch Service

Procedures for removing and installing the flywheel and starter clutch.

Starter Clutch Disassembly/Assembly

Steps for disassembling and assembling the starter clutch.

Crankshaft, Transmission, and Kickstarter

System Components Overview

Visual overview of crankshaft, transmission, and kickstarter components.

Service Information

General notes and precautions for servicing the crankshaft and transmission.

Troubleshooting Crankshaft/Transmission

Diagnosing problems related to noise, shifting, and gear jumping.

Crankcase Separation and Assembly

Steps for separating and assembling the crankcase halves.

Transmission Disassembly and Assembly

Procedures for disassembling and assembling the transmission.

Crankshaft Service

Procedures for crankshaft removal, installation, and bearing replacement.

Kickstarter Idle Gear Service

Steps for removing and installing the kickstarter idle gear.

Kickstarter Service

Procedures for kickstarter removal, installation, and disassembly.

Engine Removal and Installation

System Components Overview

Visual overview of components and torques related to engine removal/installation.

Service Information

General notes and precautions for engine removal and installation.

Engine Removal Procedure

Detailed steps for safely removing the engine from the motorcycle frame.

Engine Installation Procedure

Steps for correctly installing the engine into the motorcycle frame.

Front Wheel, Brake, Suspension, and Steering

System Components Overview

Visual overview of front wheel, brake, suspension, and steering components.

Service Information

General notes on servicing and safety precautions for front systems.

Troubleshooting Front Systems

Diagnosing problems with steering, wheel, suspension, and front brake.

Handlebar Service

Procedures for removing and installing the handlebar.

Front Wheel Service

Steps for removing and installing the front wheel.

Front Drum Brake Service

Procedures for disassembling and assembling the front drum brake.

Fork Service

Procedures for fork removal, disassembly, and assembly.

Steering Stem Service

Procedures for removing, installing, and replacing steering stem components.

Steering Bearing Preload Adjustment

Procedure for measuring and adjusting steering bearing preload.

Rear Wheel, Brake, and Suspension

System Components Overview

Visual overview of rear wheel, brake, and suspension components with torques.

Service Information

General notes on servicing and safety precautions for rear systems.

Troubleshooting Rear Systems

Diagnosing problems with rear wheel, suspension, and brake.

Rear Wheel Removal and Installation

Steps for removing and installing the rear wheel.

Wheel Bearing Replacement

Procedures for replacing rear wheel bearings.

Rear Drum Brake Disassembly/Assembly

Steps for disassembling and assembling the rear drum brake.

Brake Pedal Service

Procedures for removing and installing the brake pedal.

Shock Absorber Service

Procedures for removing the shock absorber and replacing needle bearings.

Swingarm Service

Procedures for removing, disassembling, and assembling the swingarm.

Hydraulic Brake (XR125LK/LEK)

System Components Overview

Visual overview of hydraulic brake components with torques.

Service Information

General notes on servicing hydraulic brake system and safety.

Troubleshooting Hydraulic Brake

Diagnosing common hydraulic brake problems like soft levers or drag.

Brake Fluid Replacement and Air Bleeding

Steps for draining, filling, and bleeding the hydraulic brake system.

Brake Pad Replacement

Steps for removing and installing brake pads.

Master Cylinder Service

Procedures for removing, installing, disassembling, and assembling the master cylinder.

Brake Caliper Service

Procedures for removing, installing, disassembling, and assembling the brake caliper.

Battery and Charging System

Component Location

Visual identification of battery and charging system components.

System Diagram

Electrical schematic of the battery and charging system.

Service Information

General notes on battery care, charging, and system servicing safety.

Troubleshooting Battery/Charging

Step-by-step guide for diagnosing battery and charging system issues.

Battery Service

Procedures for battery removal, installation, testing, and charging.

Charging System Inspection

Methods for inspecting current leakage and charging voltage.

Regulator/Rectifier Service

Procedures for inspecting and replacing the regulator/rectifier.

Alternator Charging Coil Inspection

Procedure for measuring the resistance of the alternator charging coil.

Lights, Meters, and Switches

Component Location

Visual identification of lighting, meter, and switch components.

Service Information

General notes on servicing lights, meters, and switches, including safety.

Lighting System Inspection

Procedures for inspecting lighting circuits and components.

Bulb Replacement

Steps for replacing headlight, position, brake, tail, license, and turn signal bulbs.

Combination Meter Service

Procedures for removing, installing, disassembling, and assembling the combination meter.

Ignition Switch Service

Procedures for inspecting, removing, and installing the ignition switch.

Handlebar Switches Inspection

Procedure for inspecting handlebar switches for continuity.

Brake Light Switch Service

Checking the operation of front and rear brake light switches.

Neutral Switch Service

Procedures for inspecting, removing, and installing the neutral switch.

Sidestand Switch (NZ Type) Inspection

Procedure for inspecting the sidestand switch for continuity.

Turn Signal Relay Inspection

Steps for inspecting the turn signal relay and circuit.

Wiring Diagrams

XR125LEK (DK, I LA TYPES) Wiring Diagram

Detailed wiring diagram for XR125LEK models (DK, I LA types).

XR125LEK (III LA, CO TYPES) Wiring Diagram

Detailed wiring diagram for XR125LEK models (III LA, CO types).

XR125LEK (NZ TYPE) Wiring Diagram

Detailed wiring diagram for XR125LEK models (NZ type).

XR125LK (DK TYPE) Wiring Diagram

Detailed wiring diagram for XR125LK models (DK type).

XR125LK (III LA TYPE) Wiring Diagram

Detailed wiring diagram for XR125LK models (III LA type).

XL125LK Wiring Diagram

Detailed wiring diagram for the XL125LK model.

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