SOP UAL XL 125 ViIMPORTANT SAFETY NOTICE CREME tretcatas a strong possibility of severe personal injury or death if instructions sre not followed. CAUTION: — Indicates a possibility of equipment damage if instructions are not followed. NOTE: Gives helpful information. Detaited descriptions of standard workshop procedures, safety principles and service operations are not included, Itis important to note that this manual contains some warnings and cautions egainst some specific service meth- ‘ods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not reo- ‘ommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor ‘could Honda invastigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoroughly that neitner personal safety nor vohicle safety will be jeopardized by the service methods or tools selected. ‘TYPE CODE + Throughout this manual, the following addreviations are used to identify individual model. CODE ‘AREA TYPE =D EUROPEAN DIRECT SALES E UK F FRANCE SW. ‘SWITZERLAND NG. (GERMANY (TYPE II)HOW TO USE THIS MANUAL ‘This service manual describes the servico procedures forthe XL128V. Follow the Maintenance Schedule (Section 3) racom- ‘mendations to ensure that the vehicle Is in peak oper ating condition. important. It compenss occurs during the bre: Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/ installe- tlon of components that may be required to perform service described in the following sections, Sections ‘4 through 20 describe perts of the motorcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illus- tration, sorvice information and troubleshooting for the section, ‘The subsequent pages give detailed procedure. Ifyou dan’t know the source of the trouble, go to sec- tion 21 Troubleshooting. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS 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 OBLIG- ATION WHATEVER. NO PART OF THIS PUBLICA- ‘TION MAY BE REPRODUCED WITHOUT WRITTEN. PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWL- EDGE OF MAINTENANCE ON HONDA MOTORCY- CLES, MOTOR SCOOTERS OR ATVS. HONDA MOTOR CO., LTD. ‘SERVICE PUBLICATION OFFICE CONTENTS GENERAL INFORMATION E I EXHAUST Ny DY PANELS/I MAINTENANCE ENGINE AND DRIVE TRAIN, Cuawrence LUBRICATION SYSTEM COOLING SYSTEM KE 6 | CLUTCH/GEARSHIFT LINKAGE El CRANKCA: ELTRAl ISMISSION/ CRANKSHA! CHASSIS Eiohng SU | 12 | REAR WHEEL/SUSPENSION I 3 | BRAKE SYSTEM E E 7 ELECTRICAL CHARGING SYSTEM/ALTERNATOR E 15 | ERGTER Glaren™ ia “wenconcram «iE TROUBLESHOOTING E a INDEX Ei ISYMBOLS The symbols used throughout this manual show specific service procedures. If supplementar portaining to these symbols, it would be explained specifically in the txt without the use of the symbol required Replace the part(s) with now onets} before assembly. Use recommended engine oil, unioss otherwise specified, of 1:1), Use molybdenum oil solution (mixture of the engine oil and molybdenum great ina ratio Use multi-purpose grease (Lithium based multi-purpose grees NLGI #2 or equivalent). #2 or equivalent Example: Molykoto® BR-2 plus manufactured by Dow corning, U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan, Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent Example: Molykote” G-n Paste manufactured by Dow corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K, Rocol Paste manufactured by Sumico Lubricant, Use molybdenum disulfide paste (containing more then 40% molybdenum disulfide, NLGI Use licone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. hater a a Rhoale Use Fork or Suspension Fluid.1, GENERAL INFORMATION GENERAL SAFETY 141 TOOLS 116 SERVICE RULES 1-2 LUBRICATION & SEAL POINTS 118 MODEL IDENTIFICATION 1-3 CABLE & HARNESS ROUTING 1:20 SPECIFICATIONS 1-4 EMISSION CONTROL SYSTEMS 127 TORQUE VALUES 1-13 GENERAL SAFETY ‘CARBON MONOXIDE USED ENGINE OL ifthe engine must be running to do seme work, make ‘suro the area is well ventilated. Never run the engine in SN ‘an enclosed eres, The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may leed to death, Run the engine in an open area or with an exhaust ‘evacuation system in an enclosed area GASOLINE Work in a woll ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is, stored. Wm Gasoline is extremely flammable and is explosive under certain conditions, KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS Engine and exhaust system parts become vary hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust ‘system have cooled bofore handling these parts. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used off on ‘# daily basis, 1¢ is still advisable to thoroughly wash your hands with soap and water 2s soon as possible after handling used oll. KEEP OUT OF REACH OF CHit- DREN. BRAKE FLUID CAUTION: Spilling fluid on painted, plastic or rubber parts will damage them. Place @ clean shop towal over these arts whenever the system is serviced. KEEP OUT OF ‘REACH OF CHILDREN. BATTERY HYDROGEN & ELECTROLYTE. + The battery givas off explosive gases; keep sparks, flames and cigarettes away. Provide adequate venti- Jation when charging or using tha battery in an ‘enclosed space. + The battery contains sulfurie acid (electrolyto). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. — Melectrolyte gets on your skin, flush with water. — electrolyte gets in your ayes, flush with water for at least 15 minutes and calla physician immodietoly. and follow with milk of magnesia or vegetable oif ‘and call a physician, KEEP QUT OF REACH OF CHILDREN, 1-1GENERAL INFORMATION 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 damage the motorcycle. 2, Use the special tools designed for this product, 3. Use only metric tools whan servicing this motorcyele. Metric bolts, nuts and screws are not interchangeable with English fasteners. The usa of incorrect tools and fasteners may damage the motoreycle. 4, Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembting, 5. When tightening a series of bolts or nuts, begin with the larger-diameter of inner bolts first, and tighten to the spect- fied torque diagonally, in incremental steps unless @ particular sequence is specified. ‘6. Cloan parts in cleaning solvent upon disassembly, Lubricate eny sliding surfaces bofore reassembly. 7. After assembly, check all parts for proper installation and operation. £8 Route all electrical wires as show on pages 1- through 1- , Cable and Harness Routing, 1-2GENERAL INFORMATION MODEL IDENTIFICATION ENGINE SERIAL NUMBER The frame serial number is stamped on the right side of The engine serial number is stamped on the left side the steoring head. of the crankcase. CARBURETOR IDENTIFICATION NUMBER ‘The carburetor serial number is stamped an the lett side of the carburetor body as shown. 1-3GENERAL INFORMATION SPECIFICATIONS GENERAL TEM SPECIFICATIONS: DIMENSIONS | Overall longth 2,150 mm (84.6) £850 mm (33.5 in) 4,280 mmn (48.2 in} 1,450 men (87.1 in) 802 mm (31.8 in) Ground clearance 190 mm (75 in) Dry woight 154 kg (839 5 Ibs) Curb weight 167 kg (988.2 Ibe) Maximum weight capacity 180 kg (298.8 be) FRAME Frame type Double cradle Front suspension Telescopie fork Front whos! travel 432 mm (6.2 in) Roar suspension Swingarm Rear whool travel 160 mn (6.9 in) Front tre size +100/20-18 56P eer tte size 130/80-17 65P Front tie brand BRIDGESTONE, PIRELLI Reartire brand BRIDGESTONE, PIRELLI Front brake Hydraule single dise Rear brake Hydraulic single dise Castor angle 28°00" Trait ongth 87 mm (38 inh Fuel tank capacity 17.5 liter (4,62 US gal, 3.85 Imp gal) Fuel tank reserve capacity 2.0 liter (0.63 US gal, 0.44 Imp gal ENGINE Bore and stroke 42.0 45.0 mm (1.65 x 1.77 in} Displacement 426 om (7.8 cu in) Compression ratio 18:1 Silent mult-tink chain diven SOHC with rocker arms ‘opens | 8° BTOC closes | 24° ABDC Exhaust valve ‘pans | 31° BBDC closes | 9° ATOC Lubrication system Forced pressure (dry sump) Oil pump type Trochoid Cooling system Liquid cooled Air filtration Viscous paper element Engine dry weight 40.5 kg (88.28 Ibs)GENERAL INFORMATION yr GENERAL (Cont'd) TEM, ‘SPECIFICATIONS: CARBURETOR | Carburetor Type CV {Constant Velocity) dual carburetor Throttle bore 22 men {0.9 in) DRIVETRAIN | Clutch system Multi-piate, wet Clutch operation system Mechanical type ‘Transmission Constant mash, 5-speed Primary reduction, 3.722 (67/18) Final reduction 3.142 (aayte) Gear ratio ast | 3.083 (87/12) and | 1,933 (29/16) 3rd | 1.428 (0/21) ath | 1.173 (27/23) ssth | 1.000 (25/25) Gearshift pattern Laft foot oparated return eystem, 1-N-2-3-4-5 ELECTRICAL | ignition system Full transistor digital ignition Starting system Electric starter motor Charging system Triple phase output alterator Regulator/rectifier SCR shortedatriple phase, full wave rectification Lighting system BatteryGENERAL INFORMATION — LUBRICATION SYSTEM Lait rom (nh TEM ‘STANDARD SERVICE LIMIT Engine oil capacity at draining 1.1 liter (1.2 US at, 1.0 Imp qt) = ‘at disassembly 115 liter (1.6 US at, 1.3 Imp at) —_ at fiker change 7.2 titer (1.3 US at. 1.1 imp at) — Recommended engine oll HONDA é-stroe oll or equivalent API service classification SE, SF or SG ~~ Viscosity: SAE 10W - 40 Oil pump rotor Tip clearence (0.20 (0.008) Body clearance 0.16 -0.21 (0.006 0.008) 0.2510.070) Side clearance 0.03-0.11 (0.001 0.008 0.18 0.008), rp FUEL SYSTEM TEM ‘SPECIFICATIONS Carburetor identification number VPUZA Main jot Front #82 Re #88 ‘Slow jet #38 Jet needle number Front Ciak Rear cre Pilot screw Initiative! opening See page 5:18 Float lavel 18:7 mm (054 in) Base corburator for aynchronization) Front oylindor (#2) Tale speed 77500 = 100 min” (eprad PAIR control vaive specified vacuum 280 mm Hg (11.02 in Hg) Throttle rip free play 2-6mm (V/16-V4ind ~ COOLING SYSTEM TEM ‘SPECIFICATIONS Coolant capacity Fadiator and engine 1108 Iter (1.08 US at 0.95 Imp a Reserve tank 024 iter 0.25 US at 0.21 Imp ad Radiator cap relief pressure 108 kpa (1.1 kgffcm’, 16 psi} Thermostat Beginto open 81 88°C (178 16377) Fully open 95° 200) Vaive if 4B mam (018 in) minimum ‘Standard coolant concentration ‘50% mixture with soft water 1-6GENERAL INFORMATION ~ CLUTCH SYSTEM/GEARSHIFT LINKAGE vente TEM STANDARD SERVICE UMIT Clutch lever free play 70-20 (a8 19/16) = latch spring free length a1 (1.88) ETO Clute dis thickness A 292-308 (0116-012 2610.10) B 2,923.08 10.115~ 0.120) 2.8 (010) Clutch plate warpage =_— 0.30 10.012) Clutch outer guide WD. 20.010 20.036 (0.7678 0.7688) | 20.05 (0.789) 0D. 25,959 ~ 25.980 (1.0220 - 1.0228) 25.94 (1.021) Malnshaft 0. at cluteh outer guide 79.960 10.900 (0.785-0.7866) | 10.94 (0.705) > CYLINDER HEAD/VALVE Unit: mn ih Trem STANDARD SERVICE UMIT Cylinder compression 1.304 KPa (18.3 Kae, 189 psi at _ 500 min pen) Cylinder head warpege = 0.05 10002) Valve, valve | Valve clearance in [6x6 0.02 (0008 2 0.000 — guide EX] 024 + 0.02 0.009 « 0.001) = Valve stem OD. In | 4875~ 4.990 (0.1959 - 0.1985) 2866 (0.1086) EX 4.955 ~ 4.970 (0.1951 - 0.1957) 4.945 (0.1947) Valve guide LD, IN 6.000 - 6.012 (0,1969 - 0.1973) 6.03 (0.198) EX] 5000 - 5.012 0.1969 6.187) 5.03 (0.1981 Storto-gide clearance IN [010 - 0.037 (0:0008-0.0015) 0.068 (0.0026) ex | 0.030 6.067 (0.012 0.0022) 0.085 (0.0088) Valve guide projection above [IN| 12.1010.476) = cylinder head EX] 12.10 (0476) = Valve seat width IN/EX | 0.90 - 1.10 (0.035 - 0.043) 1.5 (0.06) Valve spring fee length iN [38.00 (1.486) 36.5 (1.44) EX | 38.06 (1.496) 365 (14a) Camshaft] Cam lobe height IN| 28.8527 ~ 29.0927 (1.19500 ~ 114688) | 26.2 (1.196) EX | 28.8849 29.1249 (1.19790 ~ 1.14665) | 78.95 (1.136) Runaut 0.080 (0.0012) 0.050 0.0020) Identification marks Front *F” Roar "7 — Rocker arm iD. TWAEX | 10.000 10.015 (0.3067 0.3848) | 1005 10.306) Rocker atm shaft O.D. IWex | 6972 -0.987 (0.9926 - 0.3922) 3.92 0290) Rocker arm-t0-rockar arm shaft laarance 0.013 0,048 10,0005 - 0.0017) 0.10 (0.008) 1-7GENERAL INFORMATION > CYLINDER/PISTON nie sn (nt (TEM STANDARD ‘SERVICE LIMIT Cylinder [0 00-4207 (1.654 - 1.85) a0 (16s) Out of round — 0.06 0.0029 Taper = 0.060.002) Worpege = 0.05 0.002) Piston, Piston mark direction “IN” mark facing toward the intake side — Fistonrings Tpigton 0.0. 4157 — 41.99 (1.652 - 1.689 4.80 1.650) Piston 0.D. measurement point 16.0 (058) from bottom of skirt — 73.002 - 73.006 (05119-06720) | Ta0ai0sTa) 12.994 ~ 13,000 (0.5116 ~ 0.5118) 12,98 (0.511) Fiston-to-bston pin clearance 0.002 - 0.074 (0.000 - 0.0006), 0.0¢ 10.0021 jon tingto-ring | Top 0.015 ~0.05 (0.0008 - 0.002) 0.080 0.003) aroove clearance | Second 0.075 ~ 0.05 0.0006 - 0.002) 0.080 (0.0087) Piston ring ead gep | Top 0.05 - 0.16 (0.002 - 0.008) 0.300.012) Second 0:20-0.26 (0.008 -0.014) 0.500.020) Oiliside rai) | 0.10 -0,60 (0,004 - 0.024) 0.0/0.3 Piston ing mark | Top “RY mark = Second AN’ mark a Gylindorto piston clearance 0.010 - 0.040 (0.0008 - 00076) 0.700.008) Connecting rod amall end LD. Va018- 14094 (05124-05991) | 13.044 (05735) Connecting rae-te-platon pin clearance {0.010 0.040 (0.0004 - 0.0016) 0.06 0.002) 1-8GENERAL INFORMATION ~ CRANKCASE/TRANSMISSION/CRANKSHAFT Unit mom nh (TEM ‘STANDARD ‘SERVICE LIMIT Transmission | Gear 1D Wid, ME, C1, C2_| 28.600 25.021 09065-09065 __| 28104 0.907 o 725.020 26.041 (0.8850 - 09868) | 2606 0.87) Bushing OD. MA M5, C3, €2 | 22.959 - 22.980 (0.9930- 0.9047) | 22.84(0.903) @ 24.978 25.000(0.9634-09643) | 24.96 (0989) Bushing 1D, Me 20.020 20.041 (0.7862 0.7600) | 20.06 (0.790) c 78.000 - 16.016 0.7087 - 0.7094) | 18040710) cz 20.000 - 20.021 (0.7874 - 0.7882) 20.04 (0.789) a 22,000 22.021 (0.8661 -08870) | 22.04 (0.868) Gearto-bushing | MA, M5, 0.020 6.082 10,0008 - 0.0024) 0.10 10.004) cleerance 1,02, ¢3 Mainshatt OD. Ma bushing | 19.960. Te.980 (0785807866) __| 10.84 (0.785) Countershatt 0 Ct bushing | 17.966 - 17.964 0.7073-0.7080) _| 17.95 0.707) C2 bushing | 19.974 19.967 (07864-07868) | 19:95 (0.785) Cabushing | 21.989 -27.960 (0.8645-0.8858) | 27.96 (0.868) Bushingtoshatt | Me (0.040 = 0.82 (0.0016 - 0.0032) 6.10 (0.008) clearance Gl (0.016 - 0052 (0.0006 0.0020) 0.08 (0.0031 c2 10.013 0.047 (0,0005 0.0018) 0.06 (0.0091 ca 0,020 0,062 (0.0008 - 0.0020) 0.090.008) Shitfok | 1D. 12000 12.018 (0.4724 - 04731) | 12.0 (047A) Claw thickness 14.990 ~ 5.000 (0.1941 - 0.1969) 49 (0.19) Shift fork shaft O.D. 11957 11.988 (04707-04712) __| 11.95 0.470) Shift drum 0.0. (at lef side journal) 79.966 19.984 (05498-05606) | 18.94(0.549) Crankshaft | Connecting od big end side clearance _| 0.05~0.70 0.002-0.028) 0.80 0.030) Connecting rod big end radial clearance — 6.020 (0.0008) Runout = 0.06 (0.0029