Honda Xr 125 L Service Manual

							
18
1
2005.10.01     E
• Bulk part number of fuel hose, general purpose hose and vinyl hose.
(Example)
9 5 0 0 1 - 7 5 0 0 1 - 5 0 M
Bulk part number: Refers to the bulk part.
Marking code (hose type): (fuel hose and general purpose hose)
Change code (for added hose): (Vinyl hose)• Indicates number mark or change sequence, however, the code for the bulk part must be strictly 
0 (zero).
Types of code:
• Fuel hose 2: Red outside braid     (3 mm inside dia. only)
5: Black inside braid
3: Red (3 mm inside dia. only)
4: Ash gray with red stripe
    (3 mm inside dia. only)
6: Black • Vinyl hose 1: Clear
2: Black
3: Light red
6: Light red
7: Pale black • General hose 1: Ash gray
2: Ash gray
3: Black
5: Black
Lengths:  001: 1 m (standard) 003: 3 m
008: 8 m
I.D code: (fuel hose and general purpose hose) 30: 3.0 mm 11: 11 mm
35: 3.5 mm 91: 12 mm (outside dia. 15) mm
45: 4.5 mm 92: 12 mm (outside dia. 16) mm
50: 5.0 mm 12: 12 mm (outside dia. 17) mm
55: 5.3 mm, 5.5 mm 14: 14 mm
65: 6.5 mm 17: 17 mm
70: 7.0 mm
75: 7.3 mm, 7.5 mm
80: 8.0 mm
ID./OD. code: (vinyl hose) 01: ID. 2.9, OD. 6.8 mm 14: ID.   6.0, OD.   9.0 mm 37: ID. 11.0, OD. 15.0 mm
03: ID. 3.0, OD. 6.0 mm 17: ID.   7.0, OD.   9.0 mm 38: ID. 12.0, OD. 13.0 mm
05: ID. 3.5, OD. 6.5 mm 19: ID.   7.0, OD. 11.0 mm 39: ID. 12.0, OD. 14.0 mm
07: ID. 4.0, OD. 7.0 mm 21: ID.   8.0, OD.   9.0 mm 40: ID. 12.0, OD. 16.0 mm
08: ID. 4.5, OD. 6.5 mm 23: ID.   8.0, OD. 12.0 mm 43: ID. 13.0, OD. 15.0 mm
09: ID. 4.5, OD. 8.0 mm 25: ID.   9.0, OD. 11.0 mm 45: ID. 14.0, OD. 18.0 mm
12: ID. 5.0, OD. 7.0 mm 27: ID.   9.0, OD. 13.0 mm 50: ID. 16.0, OD. 19.0 mm
10: ID. 5.0, OD. 8.0 mm 33: ID. 10.0, OD. 14.0 mm 55: ID. 17.5, OD. 20.5 mm
11: ID. 5.0, OD. 9.0 mm 36: ID. 11.0, OD. 13.0 mm 60: ID. 22.0, OD. 27.0 mm
Hose type: 1: Fuel hose 3: Vinyl hose
5: General hose
C 2 
						

							
19
1
2005.10.01     E
 
Flat rate service time (FRT) means the standard time required to 
service a MC, which is listed in this manual to help the dealers 
control the actual working process  and calculate the service charge 
by using  it as a guide.
* Float time is set by multiplyin g the net service time by a given 
coefficient.
FLAT RATE SERVICE TIME
Net service time
FRT setting system
Removal, Disassembly/reassembly, Installation
Diagnosis/troubleshooting (Electric system)Completion inspection
Inspection, Measurement, Adjustment, Confirmation
Float time Preparation  
(Process check, Confirma tion arrangement for 
necessary tools)
Related work (Transfer of vehicles)
Editorial style
The service items shown in the te xt are listed with the exchange 
work time for the repair sales parts as the subject. Other 
representative service items not  using repair parts (removal/
installation, adjustment, inspection/measuring, and other work) are 
listed collectively in the list in the preface, classified according to the 
work.
FRT setting standard
• Decimal system (in unit of 0.1)  is adopted to set FRT as it is 
convenient to calculate the wage.  
Example: (0.1) 6 minutes,  (0.2) 12 minutes  
[Labor cost per hour] x [FRT] = [Wage]
• FRT is set with a hand tool.
• Service items and FRT can be subject to change depending on  development of tools and service equipment and improvement in 
service procedure.
C 3 
						

							
20
1
2005.10.01     E
Work procedure
• As the work procedure is set with the work time according to the 
method in the separate Service Manual, refer to this Manual as 
required.
• Work methods permitting servicin g in the shortest time still 
permitting assurance of safe work and product warranty are used 
for the setting of service items not listed in the Service Manual.
• Work basically is to be performed by one person, and when two or  more people are required, setting is done as the total time for the 
number of people.
• The set value for the technological level of the workers uses a  person with three years of experience in the repair of Honda 
vehicles as the standard.
• Special tools and service equipment used to set FRT are those  specified or recommended in Service Manual. Service item whose FRT is not presented
• Accessories and service parts that are not listed to use in this 
manual.
• Locations with little aging deteri oration or breakage during normal 
use.
• Service work that can be finished by one touch.
• Service work that is seldom done  (i.e. extremely small causes of 
trouble and service frequency).
* When FRT is not presented, plea se calculate wages based on ap-
propriate actual work time
Operation not included of FRT
• Oil and coolant water draining, Waiting time for warming up  operation and etc..
• Additional operation that involves removal/installation of standard  exterior equipment.
• Indirect time spent for service by  visiting the customer, trade-in, 
and delivery of a MC.
• Indirect time required for ordering and delivery of parts.
• Cost for grease, adhesive agent, etc. used for service work.
C 4 
						

							
21
1
2005.10.01     E
Explanation of FRT by using an example 
(The example may differ from the actual presented items)
Reference No. of the illustration of part that shows location 
of the replacement work.
FRT is an abbreviation of Flat  Rate Time indicating the 
standard service time required for the replacement.
LON is an abbreviation of Labor Operation Number, and it 
is a classification of the service items by the work unit code.  
 
The same operation code is used regardless of the models.  
 
Standard operation is indicated with 6 digits code, and 
additional operation is indicated with 7 digits code.
Indicating the camshaft replacement and  FRT4.5.
Indicating FRT1.0 that will be added when additional 
operation (replace rocker arm)  is done in association with 
camshaft replacement.
Ref. L.O.N. (Relative ref. Number)
F.R.T.No.
Description
(1, 3, 4, 7)
2 111118 CAMSHAFT • • • • • • • • • • • • • • 4.5
• Includes: Valve clearance adjustment
111118A  Replace rocker arm add  
• • • • • • • • • • • • • • • • • • • • • • • • • 1.0
Indicating work contents that are included in the service 
item.
Indicating a reference No. whose operation and time are 
the same as FRT4.5 for the camshaft.  
 
(The application range is limited to the service items 
without an LON setting within a same block.)
How to refer to the servic e item by using the sample  
(camshaft replacement)
Open to the page of the block where the camshafts 
spare part illustra tion is shown.
Look for the camshaft illustra tion, and refer to the ser-
vice item and FRT that agree with the reference No.
C 5 
						

							
22
1
2005.10.01     E
Indication mark for the listing of service items that continues to 
the following page
Indication of the block with no setting of FRT
• LON code systemRef.
L.O.N.(Relative ref. Number)
F.R.T.No.
Description
NO INFORMATION • • • • • • • • • • • • • • • • • • •
Ref. L.O.N.(Relative ref. Number)
F.R.T.No.
Description
2 111118 CAMSHAFT  • •  •  •  •  •  •  •  •  •  •  •  •  •  • 4.5
•••
•••
+
Mark indicated at the last line.
a
a) Category code.....................  Engine
111118A
bcde
b) Location/function code ........  Engine upper
c) Operation code....................  Replace
d) Operation sequence number (Unit code can be shown with alphabet)
.........................  camshaft  
 (No regular rule of code)
e) Additional code ...................  replace rocker arm  
 (No regular rule of code)
a
111118A
c
a) Category codes and classification
c) Operation codes and classification
Code  Category
1Engine
2 Transmission
3 Fuel & Exhaust
4 Frame & Body
5 Steering/Suspension
6 Electrical
7 Wheels/Brakes
8 Controls/instrument
9-
0-
Code  Operation category
1 Replace, Removal/Installation, Change
2 Overhaul
3 Adjust, Balance
4 (Paint-related work: Top-coat)
5 Test, Inspect/diagnos e, Measurment, Check
6 (Overhaul-related work: Rebore)
7 (Overhaul-related work: Reseal)
8 (Resurface)
9 (Paint-related work: Refinish)
0 Repair, Cleaning, Air bleeding
C 6 
						

							
23
1
2005.10.01     E
Major service items without using spare parts
(1) Removal/Installation, (2) Adjustment, (3) Inspection/
Measurement, (4) Overhaul, (5) Other work
* OPERATIONS OTHER THAN REPLACING PARTS
(1) Removal and installation  
Set for the configuration with the parts removed from the vehicle.
(2) Adjustment LON DESCRIPTION FRT
E
1101E5
TILTING ENGINE ASSEMBLY-
 
REMOVAL/INSTALLATION  
INCLUDES: All necessary adjustment 1.8
1111K0 CYLINDER HEAD ASSEMBLY-
 
REMOVAL/INSTALLATION 1.5
3111D6 CARBURETOR ASSEMBLY-
 
REMOVAL/INSTALLATION 0.4
1101E6 CRANKCASE SEPARATION
 
INCLUDES: Engine removal and installation 3.6
LON DESCRIPTION FRT
E3113A0
CARBURETOR IDLE-ADJUSTMENT 0.1
2123A0 CLUTCH-ADJUSTMENT
 
INCLUDES: Clutch lever adjustment 0.1
6143A1 SPARK PLUG-ADJUSTMENT/CLEANING 0.1
1113A0 VALVE CLEARANCE-ADJUSTMENT
 
NOTE: For 1 vehicle 0.4
F 6163A0
HEADLIGHT-AIMING 0.1
2133A0 DRIVE CHAIN-ADJUSTMENT 0.1
7113A1 REAR BRAKE-ADJUSTMENT
 
EXCLUDES: Rear brake shoe adjustment 0.1
3113A3 THROTTLE OPERATION-ADJUSTMENT 0.1
E: Engine, F: Frame
(3) Inspection, Measurement
(4) Overhaul 
Work condition: The required  Measurements, inspections, 
adjustments, and cleaning/washing of each part are performed, 
including the main body removal/installation work and the 
replacement of defective parts.
(5) Other work LON DESCRIPTION FRT
E
1115A0
COMPRESSION PRESSURE-MEASUREMENT 0.1
3115A0 CARBURETOR FLOAT LEVEL-
 
MEASUREMENT  
NOTE: For 1 vehicle 0.5
1135A0 ENGINE OIL-INSPECTION
 
EXCLUDES: Oil change 0.1
F 7115A0
BRAKE OPERATION-TEST 0.1
6105A0 BATTERY-CHECKING OF ELECTROLYTE 
LEVEL & GRAVITY 0.2
LON DESCRIPTION FRT
E 311200CARBURETOR-OVERHAUL
 
INCLUDES: All necessary adjustment 0.6
LON DESCRIPTION FRT
E 1130A1
OIL FILTER SCREEN-CLEANING 0.1
F 3120A0
CLEANER ELEMENT-CLEANING 0.2
7110A0 FRONT BRAKE-AIR BLEEDING 0.2
C 7 
						

							
24
2005.10.01 E
2
ENGINE GROUP
E-1
CYLINDER HEAD COVER (XR125L3)
D 1E-1-1
CYLINDER HEAD COVER (XR125L4,5,6)
D 2E-2
CYLINDER HEAD
D 3
E-3
CAMSHAFT/VALVE
D 4E-4
CYLINDER
D 6E-5
RIGHT CRANKCASE COVER
D 7
E-6
CLUTCH
D 8E-7
OIL PUMP
D 9E-8
LEFT CRANKCASE COVER
D10
C 8 
						

							
2005.10.01 E
25
  
 
ENGINE GROUP 
2
E-9
GENERATOR
D11E-10
STARTING CLUTCH
D12E-11
STARTING MOTOR
D13
E-12
CRANKCASE
D14E-13
CRANKSHAFT/PISTON
D16E-14
TRANSMISSION
E 1
E-15
GEARSHIFT DRUM
E 3E-16
CARBURETOR
E 4EOP-1
GASKET KIT A
E 6
C 9 
						

							
26
2005.10.01 E
  
 
ENGINE GROUP 
2
EOP-2
GASKET KIT B
E 7
C10 
						

							
2005.10.01 E
27
3
FRAME GROUP
F-1
HEADLIGHT
F 1F-2
METER
F 2F-3
HANDLE LEVER/SWITCH/CABLE
F 3
F-4
FR. BRAKE MASTER CYLINDER
F 5F-5
HANDLE PIPE/TOP BRIDGE
F 6F-6
STEERING STEM
F 7
F-7
FRONT FENDER
F 8F-8
FRONT FORK
F 9F-9
FRONT BRAKE CALIPER
F11
C11