TL125-TLR2OO Pe DAT SeHONDA TLI23-TLR200 HOW TO USE THIS MANUAL Sections 1 through 3 apply to the whole motor- cycle, while sections 4 through 15 describe parts of the motorcycle, grouped according to loca- tion, Find the section you want on this page, then ‘turn to the table of contents on page 1 of that section, Most sections start with an assembly or system illustration. and all the required specifications, torques, working practices, tools and trouble- shooting for the section. The subsequent pages give detailed procedures for the section. If you do not know what the source of the ‘trouble is, go to section 16 TROUBLESHOOT: ING. Following codes in this manual indicate each ‘country. ‘SW. Switzerland F France B Belgium ‘The specifications may vary with destinations, ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS IN: CLUDED 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 IN- CURRING ANY OBLIGATION WHATEVER. NOT PART OF HIT SPUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMIS- SION, HONDA MOTOR CO., LTD. Service Publications Office CONTENTS GNEEPAL INFORMATION | 1 LUBRICATION INSPECTION/ ADJUSTMENT FUEL SYSTEM ENGINE REIMOVAL7 INSTALLATION “isncaron i “werseriowaoiveTmen [va sveren A Ln a 5 [evawoermeron i [thicken PUMPOEARSHIET Lismore w 2 [ cvunper/Piston = ‘“ [| CLUTCH/OIL PUMP/GEARSHIFT LINKAGE A.C. GENERATOR/PULSE GENERATOR TRANSMISSION/CRANKSHAFT/ 6 KICK STARTER @ ] FRONT WHEEL/BRAKE/ 7 SUSPENSION/STEERING S [REAR WHEEL/BRAKE/ § | SUSPENSION’ J | BATTERY/CHARGING SYSTEM EE 3 E IGNITION SYSTEM E E a | switcHes EE TROUBLESHOOTING few)1.GENERAL INFORMATION @ 2725 GENERAL SAFETY 1 SERVICE RULES WW SPECIFICATIONS 12 TORQUE VALUES 14 TOOLS 16 WIRING DIAGRAM 16 CABLE AND HARNESS ROUTING Ww GENERAL SAFETY Tf the engine mast be running to do some work, make Gasoline is exiremely flammable and is explosere sure the area is well-ventilated. Never ran the engine under certain conditions. Do not smoke or get flamed in a clesed area. The exhaust contains poisonous cor spared in your working area. carbon monoxide ga. The bartery elecivolyre conains sulfuric acid. Protect | | The battery generaies Tydrogen gas which can be Your eves, skin and clothing. In case of contact, flusk| | highly exploseve. Do not smoke or get flamed or ‘throughly. with water and call a doctor if the| | sparked near the battery especially while charging it electrolyte gets into your eye. SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that do not meet HONDA’s design specifications may damage the motorcycle. 2. Use the spocial tools designed for thie vehicl 3. Install new gaskets, Oring, cotter pins, lock plate, 4. When torquing bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in 23 stops, unless a particular sequence is specified. 5. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 6. After reassembly, check all parts for proper installation and operation. 7. Use only metric tools when servicing this motoreycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motorcycleGENERAL INFORMATION | TL FLA 200 DIMENSIONS 2,080 mm (81.9 in} eee ‘ ‘B25 mm (32.5 in} ee Overall height 4,118 mm (439 in} —— ‘Wheel base 1,320 mm (52.0 in) 1,315 mm (51.8 in} ‘Seat height 800mm (31.6 in) 780 mm {30.7 in) Foot peg height 380mm (15.0 in) re Minimum ground clearance 300mm (11.8 in) Pee Se Dry weight 89kg (196.2 Ib) 90 kg [198.5 Ib) FRAME Type Diamond frame — Front suspension, travel | Taescopie’ 160 mm (6:3 in) ——— Rear suspension, travel ‘Swing arm 150 mm (5.9 in} ~~ Front tire size, pressure 2,75-21-4PR 1.5 kg/em? (21.3 psi) Pee Rear tire size, pressure: 4.00~18-4PR_ 1.5 kg/em* (21.3 psi) Pee Front brake Cable operated leading-traling shoes a Rear brake Fd operated leading trating shoos =———_ Fuel capacity 8. lit (1.72 US gal, 1-43 imp gal) ee Fuel reserve capacity 1.0 lit (0.26 US gal., 0.22 imp gal) eee Caster 26°30" — Trail £86 mm (3.4 in) cee Front fork oil capacity 20742.5 ce (12.720.2 Cuin) 2952.5 cc (18.1+0.2 Cun) ENGINE ‘Type Gasoline, air-cooled 4-stroke cycle —E Grinder arrangement Single cylinder inclined 15° a Bore x stroke 58.5 x 49.5mm (2.2 x1.9in) 655 x 57.8 mm (2.6 x2.3 in) 126 ee (757 eu in) 194 ce (11.87 Culn) Compression ratio 90:1 B2:1 Valve tain Overhead camshaft chain driven eee ‘Maximum hosepower 10.4 ps/8,000 rpm (DIN) 13.4 ps/6,500 rpm {DIN} Maximum coraue 11.04 kgen/4,500 rom 18 k-m/4,000 rom Otreapacity, 11 {1.2 US qt 1.0 Imp aed — Lubrication system Forced pressure and wot sump a Air filtration system Oiles pelyurethane foam eo Cylinder compression 12.0 kafem? (170.7 psi) 12.0 kgfem? (170.7 psid Intake valve" OPEN. ogra plciieb LAL Closes | 30° ABI ; Exhaust valve OPEN 36° BED = eel CLOSES oo ATDC Serer Valve clearance IN 0.05 mm (0.002 in} (Cold) — EX 0,05 mm {0.002 in) (Cold) eet i CARBURETOR | Type Piston valve type ———— ‘Main jet #90 #98 Pilot serew opening Factory preset eee Fon: level 20mm (0.8 in) 24 mm (0.9 in) ale speed 4,300#100 rom 4,3008100 rpm DRIVE TRAIN | Clutch Wt multiplote type <———— “Transmission S-apeed constant mash G-speed constant mech Primary eduction 4.085 3333, Geer ratio. | 2768 2769 Gear ratio 1! 2.125 2.062 Gear ratio It 1.450 41500 Gear ratio IV 1000 1.130 Gearatio V. 0.728 0.960, Gear ratio VI — ost Final reduction 3.886 3384 Gear shit pattern Left foot operated return system —(nS REAM TRIE GENERAL INFORMATION TL 126 TLR 200, ELECTRICAL | Ignition CDA. — Ignition timing initial 13° BTDC at 1,30021000 rem 7 BTDCat 1,300#100 rpm Full advance 28° BTDC at 2,700 100 rpm 33° BTDC at 3,000100 rom Alternator ‘A.C. generator a Battery capacity eV 2AH = Sp: For cold climate X22ESR-U ND — (Below 5°C, 41°F) DRIES NGK — Standard X24ESR-U ND =< DREESL NGK =< Forextended — X27ESR-U ND = High speed driving DRBES NG —— Spark plug gap 0.6-0.7 mm (0.024~-0.028 in) = Headlight ev 39/s6W =—— Tailfbrakeliaht 21W/5W = ‘Speedometer light aw = ‘Neutral indicator Ww — High beam indicator 1.2W —— Position light ev aw —— 1-3GENERAL INFORMATION TORQUE VALUES Ora TLI25-TLR200 ENGINE Tightening point ow Thread dia. (mm) Tightening Toraue Gylinder heed 4 8 28-30 Nw (2.8-3.0 kom, 20-22 feb) Flywheel (TL 125) 1 8 4553 Nm (4.55.3 kgm, 33-38 fib) Flywheel (TLR 200) 1 10 55-85 Nim (4.5-6.5 kgm, 40—47 fib) Giuteh outer 1 16 40-50 Nim (4.06.0 kgm, 20~36 feb) Oil iter rotor 1 16 40-50 Nim (4.06.0 kgm, 2-36 ft) Oil filter screen rotor 1 36 10-20 Nam (1.0-2.0 kgm, 714 felb) Cam chain adjust bolt 1 16 15-22 Nim (15-22 kam, 11—16 feb) FRAME Tightening point ay “Thread dia. (mim) “Tightening Torque Steering stem nut 1 22 0-120 Nim (8.0—12.0 kgm, 56-87 Felb) Front fork top bridge 2 8 20-25 Nam. (2.025 kg-m, 14-18 felb) Handle holder 4 8 20-25 Num (2.0-25 kgm, 14-18 feb) Front fork bottom bridge 2 8 30-40 Nim (3.0-4.0 kgm, 22-29 feb) Front fork batt 2 36 36-30 Num (1.8-3.0 kgm, 11-22 fib) Front fork socket bolt 2 6 18-25 Nim (18-25 kam, 11-18 ft) Front axle nut 1 2 60-80 Nim (6.0-8.0 korn, 43-58 ftib) Engine hanger bott (Upper) 3 8 31-37 Nam (3.13.7 kg-m, 22-27 feb) (Fron) a 8 31-37 Nam_ (3.13.7 kgm, 22-27 felb) (Rear) 2 10 45-60 Nm (4.58.0 kg-m, 93-43 ftb) ple (Front) 2.0-4.5 N.m(0.20-0.45 kor, 1.4~8.3 fib) (Rear) 256.0 Nm (0.25-0.60 kg-m,1.8-3.6 feb} 1 4 60-80 Nm (6.0-8.0 kgm, 43-58 ftib) ven sproket 4 10 55-65 Nm (55-6.5kam, 40-47 ftib) Rear shock absorber 4 6 10-14 Nam (1.0-1.4 kgm, 7-10 feb) Geashift pedal 1 6 B12Nm (O8—12kem, 6-9 feb) Keke arm 1 6 B212Nm (08-12 kgm, 6-9 fib) Swing atm pivot 1 u 60=80 Nim_(6:0-80 kom, 43-58 ft) “Torque specification listed above are for the most important tightening points. Ia torque specification isnot listed, follow the standards given below. STANDARD TORQUE VALUES [we SSCSTightening Torque ‘Simm bolt, nut 4.5-6.0 Nim (0.45-0.6 kg-m, 3.3—4.3 feb) Emm bolt, nut 8.0-12 Nim (0.8-1.2 kgm, 6-9 fetb) Bmm bolt, nut 18-25 Nam_(1.8-2.5 kgm, 13-18 feb) 10mm ott, nut 30-40 Nim (8.0~8.0 kgm, 22-29 Fetb) 12mm bolt, nut 50-80N.m_ (5.0~6.0 kam, 36—43 feb) 5mm screw 35-55 Nim (0.35-0.5 kgm, 2.5~3.6 felb) mm screw 7.0-11 Nm (0.7=1.1 kam, 5-8 felb) 6 mm flange bott, nut JO-14 Num (1.0-1.4 kgm, 710 feb) ‘8mm flange bolt, nut 24-30 Nam (243.0 kgm, 17-22 feb) 10 mm flange bolt, nut 30-40 Nam_(8.0-4.0 kgm, 22-29 feb)HONDA GENERAL INFORMATION TLI25-TLR2OO SPECIAL TOOLS Tool Name “Tool Number ‘Section Valve guide rearner ‘07984-09800 6 Clutch center holder 07923—1070001 8 Bearing remover (18 mm) 07938-10000 10 Slider weight 07741—0010201 10 Hollow set wrench (6 ram) 7917-32300 " Fork teal drivor attachment (TLR 200) 079471420200 n Ball race remover (07053 ~-3330000 u Ball race remover 07953—-K AS50000 W Driver attachment 1079483290000 in Steering stom driver 079884300101 a Bearing romovor (17 mm) (07936-3710300 12 Remover handle 07936-3710100 12 Slider weight 077410010201 2 COMMON TOOLS Tool Name Too! Number Section Fork seal driver attachment (TL. 128) 07747-0010501 ii Nipple wrench 8 (4.5 x 5.1 mm) 077010020200 2 Nipple wrench C (6.8 x 6.1 mm) 07010020300 2 Teppet adjusting wrench (10 x 12 mm) 07708--0030200 2 ‘Tappet adjuster A 07708—0030300 2 Float level gauge 07401—0010000 4 Valve spring compressor 07757-00100, 8 Valve guide remover {5.5 mm) 077420010100 6 Lock nut wrench (20 x 24mm) 07716—0020100 8 Extension bar 07716-0020500, 8 Universal holder (97725-0030000 8 Flywheel holder 07725~-0040000 8 Rotor puller 077330020001 8 Driver handle outer A 07748-0010000 10 Bearing driver outer (32 x 35 mm] 07746-0010100 10, 11, 12 Bearing driver pilot (12 mm) 07746-04020 40,11, 12 Bearing driver outer (42 x 47 mm) 07746-0010300 19 Bearing driver pilot (20 mm) (077460040500 10 Bearing driver outer (52 x 55 mm) 07746—0010400 10 Bearing driver pilot_(30 mm) (0748-0040700, 10 handle inner B 077460020100 10 Bearing driver inner (20mm) 077460020400 10 Driver handle inner 07746 -0030100 10 Bearing driver inner (30 mm) 077460030300 10 Bearing remover shaft 07746-0050100 1,12 Bearing remover head (12 mm) 07746-05030, 14,12 Fork seal driver body 07747-01010, W Lock nut wrench (30 x 32 mm) 077160020400 WwW Pin span 07702—0020000 u Bearing driver outer (37 x 40 mm) 077460010200 12 Shock absorber compressor (07959-3280001 12 VALVE SEAT CUTTER Flat cutter EX. (25mm) 07780-01200, 6 Flat cutter IN. (30 mm). 07780—0012200 6 Seat cutter EX, (24.5 mm) 0780~0010100 6 Seat cutter IN. (29mm) 07780—0010300 6 Interior cutter EX/IN, (30 mm) 07780—0014000 6 Gutterholder (5.5mm) 0781—0010101 6GENERAL INFORMATION E. 1-6 0029—zm—Zo0e00 SSS fs i i 2h Ex TLI2S-TLR2OO WIRING DIAGRAM =SCHALTPLAN SCHEMA DE CABLAGEHONDA TLI25-TLR2GD GENERAL INFORMATION CABLE AND HARNESS ROUTING ‘Note the following when routing cables and wire harnesses. + A loose wire, harness or cable can be a safety hazard, After clamping, check each wire to be sure itis secure. Cee coe ee eed ee A500 its clamp when a weld-on clamp is used + Secure wires and wire harnesses to the frame sith reper bands he Jad lection, ‘Tighten the bands so tat ony the oO 7 inated cane. comsc the es of te QQ roman Om + Route hamests 2 they ae nt pulled tat o have exces sack, O x + Protect wires and harnesses with: electrical tape or tube if they are contact a sharp edge or ‘corner. Clean the attaching surface thoroughly before applying tape. + Do not use wires or harnesses with @ broken me = : insulator. Repair by wrapping thom with a protective tape of replace them. + Route wire harnesses to avoid sharp edges or comers, + Also avoid the projected ends of bolts and + Keop wire harnesses away from the exhaust pipes and other hot parts. + Be sure grommets are seated in their grooves properly. + After clamping, check each harness to be certain that it is not interferring with any moving or sliding parts. + After routing, check that the wire harnesses are not twisted or kinked. * Wire harnesses routed along the handle bars should not be pulled taut, have excessive slack, be pinched, or interfer with adjacent or sur rounding parts in all steering positions.HONDA. GENERAL INFORMATION TLIZ5-TLR20O eer eee ee ee ee eee eee eee eee are (1) FRONT BRAKE CABLE (2) SPEEDOMETER CABLEHONDA GENERAL INFORMATION TLI2ZS-TLR2OO I ee (2) FRONT BRAKE CABLE (6) THROTTLE CABLE (9) A. C. GENERATOR HARNESS. (10) PULSE GENERATOR HARNESS (7) IGNITION COIL, (8) C.D.1, UNITGENERAL INFORMATION (2) BATTERY BREATHER (3) CABURETOR BREATHER TUBE TUBE (4) TAIL LIGHT HARNESS (6) BATTERY HARNESS (6) BRAKE LIGHT SWITCH HARNESS 1-10 28mines 2. LUBRICATION SERVICE INFORMATION TROUBLESHOOTING ENGLINE OIL ENGINE OIL FILTER SCREEN ENGINE OIL FILTER ROTOR LUBRICATION POINTS. 24 24 22 22 23 24 SERVICE INFORMATION GENERAL INSTRUCTIONS ‘This section describes how to inspect and replace the engine oil and clean the oll filter scre SPECIFICATIONS Oil capacity 41.1 liters (1.2 U.S.at, 1.0 Imp at) at disasesmbly 0.9 liters (0.95 U.S.qt, 0.8 Imp qt) at draining Recommended oil HONDA 4-stroke oil or equivalent API Service Classification — SE or SF VISCOSITY: SAE 10W—40 ® Single ‘rede ® Maiti grade 10-07-1020 -30 are 20406080 Td0F TORQUE VALUE Oil fittrsereen cap 1020 Nem (1.0-2.0 kgm 7—14 feb), TROUBLESHOOTING Oil level to0 low 1. Normat oil comsumption 2. External oil leaks 3. Worn piston rings Oil consumption 1, Oil not changed often enough 2. Faulty head gasketLUBRICATION HONDA. TL125-TLR2OO ENGINE OIL Place the mortorcycle on level ground, ‘Check the oil level with the oil evel gauge. If the oil level is below the lower level mark of the ‘gauge, fill the recommended oll up to the upper level mark. ENGINE OIL FILTER SCREEN NOTE Drain the engine oll while the engine warm. Remove the skid plate. Remove the oil fillar cap and oil filter soreen cap. NOTE ‘The oil filter soreen and spring will come out when the oil filter screen cap is removed. Operate the kick starter several times to drain residual oil completely. Clean the oil filter screen. ‘Make sure that the oil filter sereen, sealing rubber, screen cap and O-ring are in good condition. Install the ol filter screen, spring and sereen cap. Fill the crankcase with the recommended cil. ENGINE OIL CAPACITY: 0.9 liters (0.95 U.S.qt, 0.8 Imp qt) at draining Install the ofl filler cap. Install the skid plate. ‘Start the engine and idle it for 2:3 minutes. Stop the engine and meke sure that the engine oil level is at the upper level marie of the gauge and that there is no oil leaking. (1) O1L LEVEL GAUGE << (2) UPPER =< (3) LOWER, (1) skip PLATE (2) SCREEN CAP (3) OIL FILTER SCREEN (@) SPRINGLUBRICATION HONDA TL925-TLR2OO ENGINE O1L FILTER ROTOR Remove the skid plate and drain the engine oil. Remove the right crankcase cover. (Page 83) Revome the oil filter rotor cover and clean the oil filter rotor. Make sure that the gasket of the oil filter rotor ‘cover is in good condition. Install the ol filter rotor cover. {Install the dowel pins and the gasket. {Install the right crankcase cover. (Page 8-13) Install the brake pedal. Adjust the brake pedal free play. (Page 3-16) Connect the clutch cable, ‘Adjust the clutch lever free play. (Page 3-17) Install the kick arm. Fill the recommended engine oil. (1) KICK ARF (2) CLUTCH CABLE (4) RIGHT CRANKCASE. (5) SKID PLATE COVER (3) KICK ARM STOPPER (6) OIL FILTER ROTOR (7) GASKETHONDA. LUBRICATION TLI25-TLR200 LUBRICATION POINTS Use general purpose grease when no other specifica- tion is given, Apply oll or grease to any sliding sur- faces and cables not shown here. Sm (1) STEEL BALL (2) THROTTLE CONE RACE GRIP BALL RACE sam Rh (9) GEARSHIFT PEDAL (6) DRIVE CHAIN BALL JOINT (4) SWING ARM PIVOT BUSHING A \ (6) FRONT FORK — Samat (7) SPEEDOMETER GEAR — (14) BALL BEARING \ 74 \ (e) pace eeaninc | : ‘ Sas t (10) ENGINE (19) BRAKE caM | \ \ \ | Sasa (11) BRAKE PEDAL (42) SIDE STAND PIvor pivot (9) BRAKE CAM aa Sam@uonpa Q, WSPECTION/ 7125-18200 * ADJUSTMENT SERVICE INFORMATION 34 IGNITION TIMING 31 : MAINTENANCE SCHEDULE 33 DRIVE CHAIN 312 FUEL LINE 34 BATTERY 344 j THROTTLE OPERATION 34 BRAKE SHOE WEAR 314 qa CARBURETOR-CHOKE 35 BRAKE SYSTEM 315 Kk AIR CLEANER 36 BRAKE LIGHT SWITCH 3416 CRANKCASE BREATHER 37 HEADLIGHT AIM 3-17 SPARK PLUG 37 CLUTCH 317 VALVE CLEARANCE 38 SUSPENSION 3-18 STARTER DECOMPRESSOR (TLR200) 3-9 NUTS/BOLTS/FASTENERS 3-19 CAM CHAIN TENSION 3-10 WHEELS/SPOKES 3.20 3 CARBURETOR-IDLE SPEED 3-10 STEERING 3-20 CYLINDER COMPRESSION 341 SERVICE INFORMATION SPECIFICATIONS Ignition timing: Initial TL 128 13°BTDC at 1,300#100rpm TLR 200 _7°BTDCat 1,3002100;pm Full advance TL 125 28°BTDC at 2,708 100rpm TLR 200 33°BTDC at 3,000#100rpm i Spark plug: Spark plug gap 0.6-0.7 mm {0,024—-0,028 in} Recommended spark plugs: For cold climate For extended high Beflow 5°C (41°F) Standard speed driving ND NGK ND NGK_ ND NGK_ xazesr-u | pr7es | x2aesr-u | Drees. |x27EsR-u | DRBES Valve clearance: INTAKE 0.05 mm (0.002 in} EXHAUST 0.05 mm (0.002 in} ‘Throttle grip free play: 2-6 mm (1/8—1/4 in) Idle speed: TL125 — 1,3008100¢pm TLR 200 1,300!100rpm. Cylinder compression: TL125 10~14 kg/om?'(178 psi) TLR 200 10-14 kg/om? (178 pai) ‘Starter decompressor lever free play: TLR 200 1-2 mm (0,04-0.08 in)HONDA INSPECTION/ADJUSTMENT TL125-TLR20O Drive chain slack: 25-35 mm (1.01.4 in) Front brake lver free play: 10-20 mm {04-0.8 in) Rear brake pedal fre play: 20-30 mm (0.81.2 in) Clutet lever free play 10-20 mm (04-08 in) Tire sie: Front 2.75-21-40R Rear :00—18-4PR Pressure: Front 15 kg/cm? (2.3 ps) eer 15 kg/em? (21.3 ps)HONDA. TLI2Z5-TLR2OD INSPECTION/ADJUSTMENT MAINTENANCE SCHEDULE Perform PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period. 1: lnspect and Clean, Adjust, Lubricate or Replace if necessary. ©: Clean R: Replace “A: Adjust L: Lubricate WHICHEVER ODOMETER READING [NOTE (3]] —~ FREQUENCY | COMES roe ~ = = Bee rinst > / Se | §F é F/ ¢ & & g 8g 3 sx [es ITEM EVERY ey fe] rs 7] FUEL LINE 1 H H apa acne | REPLACE EVERY 36,000 fem (21,600 mi) = | THROTTLE OPERATION 1 f L = | CARBURETOR.CHOKE. H ! cfo ‘AIR CLEANER NOTE (1) c Gg c | Poce36 | (CRANKCASE BRATHER NOTE (2) ce c c SPARK PLUG o R | Page 87 = [VALVE CLEARANCE _ 7 1 1 t 1 _ | Page 38 REPLACE EVERY ENGINE OIL YEAR R Soa Beene Page 2-2 ENGINE OIL FILTER SCREEN YEAR c ipa Page 2.2 3,200 km (2,000 mid * | ENGINE OIL FILTER ROTOR c Page 23 | «| STARTER DECOMPRESSOR t te v = | CAN CHAIN TENSION A a A * | CARBURETORADLE SPEED v t i r Page 3-10 DRIVE CHAIN NOTE (2) IL EVERY 7,000 km (600 mi) Page 3-12 BATTERY MONTH U U 0 o Page 3-14 1 BREAKE SHOE WEAR v T 1 Page 3-14 1 BRAKE SYSTEM r t i 1 Page 3-18 + | BRAKE LIGHT SWITCH L L 1 1 Page 3-17 * | HEADLIGHT AIM t t i t ‘CLUTCH 1 1 T T Page 3-17 SIDE STAND oH T t o * | SUSPENSION t U i 1 Page 3-18 * |_NUTS, BOLTS, FASTENERS NOTE (2) v U q 1 2° | WHEELS/SPOKES NOTE (2) V t t 1 **| STEERING HEAD BEARING L 1 * SHOULD BE SERVICE BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED. “IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHO: RIZED HONDA DEALER, NOTE: (1) Service more fraquenty when riding in dusty areas. (2) Service more frequently when riding OFF-ROAD, "7 3- woHONDA. INSPECTION/ADJUSTMENT TL125-TLR200 FUEL LINE (yet une eee ee Replace any parts which show signs of deteriora eee 5 tion, damage or leaks. THROTTLE OPERATION Inspect the throttle cable for dterioration, damage, or kinks, and measure throttle grip free play at the throttle grip flange. THROTTLE GRIP FREE PLAY: 2.6mm (1/8-1/4 in) Check for smooth throttle grip operation from fully, ‘closed to fully open in all steering positions and that automatically returns to “fully closed” when released. & EsINSPECTION/ADJUSTMENT. THROTTLE GRIP FREE PLAY ADJUSTMENT Perform major adjustments by turning an adjuster con the carburator. Remove the seat, side cover and the fuel tank, Remove the rubber cap and adjust major free play bby turning the adjuster. Perform minor adjustment by turning an adjuster on ‘the handleber. Loosen the lock nut and adjust turning the adjuster. Tighten the lock nut securely. Free play by CARBURETOR-CHOKE Inspect the choke lever for smooth operation. | i (2) RUBBER CAP (3) Lock NUT 1 HONDA. TL125-TLR200 (1) ADJUSTER (4) ADJUSTER (1) CHOKE LEVERHONDA. INSPECTION/ADJUSTMENT TLI25-TLR2OO AIR CLEARER Remove the left side cover. Unscrew the air cleaner cover. (2) SET PLATE Remove the set plate of the air cleaner element and remove the element holder. Remove the ait cleaner element from the element holder. ELEMENT Wash the eloment in noniammable or high flash point solvent, squeeze out the solvent thoroughly, and dry it, NOTE Do not wash the element in gasoline or acid, alkaline or organic volatile oll. ‘Soak the element in gear oil (#80~90) and squeeze & ‘our the oil a ae ne Install the element into the element holder. 7 ° Install the element holder into the air cleaner case. Install the air cleaner cover. (a) WASH (5) SQUEEZE (6) GEAR OIL (7) SQUEEZE Install the left side cover. ‘AND DRYHONDA INSPECTION/ADJUSTMENT TLIZS-TLR2OO CRANKCASE BREATHER Squeeze the tube end and drain deposits, NOTE ‘Service more frequently when ridden in the rain or at full throttle, or if deposits can be seen in the transparent section of the drein tube. SPARK PLUG Remove the spark plug. Inspoct the spark plug for burn, dirt and deposits. Cleon the spark plug with a plug cleaner or wire brush if there are dirt and/or deposits. SPECIFIED PLUG; NNGK, DRBES-L — (DR7ES, DREES) ND, X24ESR-U (X22ESR-U, X27ESR-U) SPARK PLUG GAP; (0.6-0.7mm (0.024-0.028 in} NOTE Install the spark plug tightening it by hand and then with a spark plug wrench.INSPECTION/ADJUSTMENT VALVE CLEARANCE NOTE Inspect and adjust valve clearance while the engine is cold (below 35°C/96"F). Remove the seat and the side covers. Turn the fuel value “OFF” and disconnect the fuel tube. Remove the fuel tank. Remove the crankshaft hole cap and timing mark: hole cap. Rotate the crankshaft counterclockwise and align the “T"" mark on the gonerator rotor with the alin rmarkon the left crankcase cover. ‘The piston must be at T.0.C. (Top Dead Center) of ‘the compression storke. Inspect the intake and exhaust valve clearances by inserting the feler gauge between the adjusting sorew and valve stem. VALVE CLEARANCES; INTAKE: 0,05mm20.02mm (0.00240,0008 in) EXHAUST: 0.05mm20.02mm (0,0020.0008 in) Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge. Hold the adjusting screw and tighten the lock nut, Recheck the valve clearance. Install the valve adjuster covers. Install the timing hole cap and crankshaft hole cep. Install the fuel tank and the seat. Reconnect the fuel tube. 3-8 HONDA TLIZ5-TLR2OO (1) ALIGN MARK (2) TIMING MARK HOLE (3) "T" MARK (4) CRANKSHAFT HOLE (6) TAPPET ADJUSTER A 07708~0030300 a — (6) TAPPET ADJUSTING WRENCH (10 x 12) 07708-0030200 58INSPECTION/ADJUSTMENT STARTER DECOMPRESSOR (TLR200) Note Porform thi decompressor adjust after the valve clearance has been adjusted Remove the crankshaft hole cap and timing mark. hole cap. Rotate the crankshaft counterclockwise end align the "T” mark on the generator rotor with the Index ‘mark on the generator rotor with the index marie on the left crankcase cover. Be sure that the piston is at T.D.C. (Top Dead Center) of the compression stroke. Measure the free play at the tip of the valve lifter lover. FREE PLAY; 1.0-2.0mm (0.04-0.08 in) To adjust, loosen the lock nut and turn the adjuster. NOTE Excessive free play causes hard starting. In- sufficient free play may cause erratic engine idle and valve burning. Recheck the free play. Install the timing mark and crankshaft hole cap. HONDA. TL125-TLR2OO0 Oo :INSPECTION/ADJUSTMENT CAR CHAIN TENSION ‘Start the engine and idle it. Remove the rubber cap and loosen the cam chain tension adjusting bolt. When the cam chain tension adjusting bolt Is loosened, the tensioner will automatically position itself to provide the correct tension. Tighten the cam chain tension adjusting bolt and reinstall the eubber cap. TORQUE; 15-22N-m (1.5-2.2kg-m 11-16 fe-tb) NOTE Do not loosen the 6mm bolt. CARBURETOR-IDLE SPEED Warm up the engine. Turn the throttle stop screw to right ond left to ‘brain the low smooth idling speed, about 1,200 rmin-1{epm). Turn the air screw to right and left to obtain the hhighost idlespoed. Obtain the specified idle speed by turning the throttle stop screw t0 right and left. IDLE SPEED; 1,3002100rpm Check if the idle speed goes up by turning the ait screw to right and left. Ropeat the operatic speed goes up. mentioned above if the idle HORIDA TLIZS-TLRZGO (1) RUBBER CAP (2) 6mm BOLT (3) ADJUSTING BOLT (1) THROTTLE STOP SCREW (2) AIR SCREWINSPECTION/ADJUSTMENT TLI25-TLR200 CYLINDER COMPRESSION © See ee Warm up the engine ee as Stop the engine and remove the spark plug cap. = a ferment aaa 4 , Open the choke nob fully. ~ oh E Open the throttle grip fully. Operate the kick starter pedal several times. NOTE Note that the compression is not leaking at gauge connection, COMPRESSION: 980-1373 kPa (10-14 keg/em* 142-199 psi) Low compression can be caused by; Improper valve adjustment Valve leakage Biown cylinder head gasket Worn piston ring or evlinder High compression can be caused by; Carbon deposits in combusion chamber or piston head. IGNITION TIMING NOTE ‘The Capacitive Discharge Ignition (C.D.1.) system is factory preset and does not require adjustment. When ignition timing is wrong, inspect C.D.1. unit and the pulse gonarator and replace them if necessary. (Section 14) Warr up the engine. Remove the timing hole cap. Connect the timing light and a tachometer. HONDA. (2) COMPRESSION GAUGE ATTACHMENT (1) TIMING HOLE 64 il | | iq |@remne a INSPECTION/ADJUSTMENT ‘TLI23-TER2OO : ‘Start the engine and check the items below. ma BI ALIGN MARK 1,3004100rpm; If “F*" mark is within the range of 2mm from the align mark to both right and left, timing is correct. 2,7002100rpm (TL 126) '3,0002100rpm (TLR 200) If the align mark is within the range of advance mark, timing is correct. ies (oF MARK|: ae a Sis DRIVE CHAIN DRIVE CHAIN ADJUSTMENT Note Perform the following inspection and adjust ‘ment with the engine switch "OFF" transmis- sion in neutral, and the motoreyele on its side stand, Push the drive chain tensioner so that no tension is ‘transmitted to the drive chain, Measure the drive chain free play in the middle between sprockets on the lower chain run. 25-36 mm 7 Ko.984—1.37% CHAIN FREE PLAY; 25-36mm (0.984-1.378 = in) (1) DRIVE CHAIN TENSIONER (2) STOPPER PIN (3) AXLE NUT Adjust as follows. Adjust by loosening the axle nut and turning the adjuster on both sides. NOTE “The same position of both adjusters must gear with the stopper pin on the swing arm. hten the axle nut. TORQUE; 60-80 N-m 16.0-8.0kg-m 43-58 ft-Ib) NOTE Make sure to inspect the rear bral play after adjusting the drive chain. (Page 346) (4) ADJUSTER 3-12 66 1INSPECTION/ADJUSTMENT DRIVE CHAIN/SPROCKET INSPECTION Inspect the drive chain and sprockets for wear or damage. Remove the clip on the chain jointed point. Clean the drive chain in non-flammable or high flash point solvent and dry it, Inspect the drive chain for wear or damage and replace it if necessary. Measure the drive chain length of 41 pins (40 links) from a pin centor to pin, center and replace if it ‘exceeds the service limit. Inspect the drive sprocket and driven sprocket teeth for wear or damage, NOTE HONDA. TLI25S-TLR2GO SERVICE LIMITS; TL 125 618 mm (20.394 in) TLR 200 648 mm (25.472 in) (2) 41 PINs Replace both drive chain and sprockets to new ones if there is necessity for either drive chain or sprockets. Install the drive chain. (40 LINKS)”INSPECTION/ADJUSTMENT BATTERY Stand the motoreycle erect and inspect the battery fluid love. When the fluid level is near the lower level mark, fll ‘with the distilled water to the upper level mark. NOTE ‘Add only distilled water. Tap water will shorten the service life of the battery. Do not put the battery fluid on the other parts of the vehicle. The battery electrolyte contains sufturie acid. Protect your eyes, skin, and clothing. In case of contact, flush thoroughly with water and call « doctor if electrolyte gets in your eves. BRAKE SHOE WEAR BRAKE SHOE INSPECYION (FRONT BRAKE) Inspect the brake shoe for wear by squeezing a ‘brake lever to the full, Replace the brake shoe if an arrow on the brake arm aligns or comes over the aligning line with a mark on ‘the brake drum plate. (Page 11-10) Inspect the brake drum for wear or damage. Replace the front wheel if the brake drum is worn ‘ut or damaged beyond its service limit. (Page 116), (4) BATTERY BOX COVER (6) BATTERT BANDINSPECTION/ADJUSTMENT HONDA. ‘TLI2S-FLR200 BRAKE SHOE INSPECTION (REAR BRAKE) Inspect the brake shoo for wear or damage by stepping down the brake pedal all the way. Replace the brake shoe if an arrow on the brake atm aligns or comes over the aligning line with a mark on the bral drum plate. (Page 12-8) Inspect the brake drum for wear or damage. Replace the rear wheel to a new one if the brake drum is worn out or damaged beyond its service limit. (Page 123) BRAKE SYSTEM FRONT BRAKE BRAKE LEVER FREE PLAY Measure front lever free play at the tip of the brake lever. BRAKE LEVER FREE PLAY; 10-20mm (3/8-3/4 in) Inspect the brake cable for wear, damage or kink. Inspect the brake arm for smooth operation. Perform major adjustments with the lower adjuster ‘on the brake drum. ‘Adjust the brake lover free play byloosening the lock nut and turning the adjuster on the brake ‘drum. Perform minor adjustments with the upper adjuster ‘on the handlebers. ‘Adjust the brake lever free play by loosening the lock nut and turning the adjuster on the handlebars. NOTE Do not expose the screw of the adjuster more than 8mm (0.315 in}, Replace the brake cable if the spacifed free play of the brake lever or smooth operation of the brake arm are not obtained after te adjustments. (1) MARK (2) BRAKE ARM 10-20mm) G83 in) (4) ADJUSTER,HONDA. TLI2ZS-TLR2OO INSPECTION/ADJUSTMENT (1) Lock NUT REAR BRAKE F BRAKE PEDAL HEIGHT ADJUSTMENT ‘Adjust the brake pedal height by loosening the Tock nut and turning the stopper bolt. Tighten the lock nut. NOTE Cheek for the lighting timing of the stop light after adjusting brake pedal height. (Page 3 16) BRAKE PEDAL FREE PLAY NOTE ‘Adjust the brake pedal free play after edjust- ing the brake pedal height. Inspect for the brake pedal free pla QD : BRAKE PEDAL FREE PLAY; INCREASE FREE PLAY] 20-30mmn (3/4-1.1/4 in) 5 aj ne ete ps ue yy ung we Sera an Pen BRAKELIGHT SWITCH i switch adjustment should be done after adjusting the brake pedal height and the brake pedal free play. ‘Turn the adjust nut so that the brake light turns on when the brake pedal is stepped 20mm (3/4 in) down, 3-16 4HONDA. INSPECTION/ADJUSTMENT TLI2S-TLR2OO HEADLIGHT AIM NOTE Headlight ‘can be adjusted only vertically. ‘Adiust the headlight headlight munting bolt. im vertically by tuming the CLUTCH CLUTCH LEVER FREE PLAY clutch lever. 10-20 mam. CLUTCH LEVER FREE PLA’ _ (B/8-3/4 in) 10-20%nm (3/8-3/4 in) Saha: If the measured clutch lever free play is more than required, adjust It and inspect the clutch disk, Ingpect the clutch cable for wear, damage and kink. Turning the handlebars in all direction, inspect the clutch lever for smooth operation, (1) ADJUSTER (2) LOCK NUT Perform mejor adjustments with the lower adjuster - near the clutch. Loosen the lock nut on the elutch cable and turn the adjuster. Tighten the lock nut. (S) DECREASE EREE PLAY|INSPECTION/ADJUSTMENT Perform minor adjustments with the upper adjuster (on the cluich lever holder. Remove the cover, loosen the lock nut, and turn the adjuster. Tighten the lock nut. NOTE Do not expose the screw of the adjusters more ‘than 8mm (0.315 in}, Inspect the eluteh if the required free play can not be obtained by turning the adjusters. (Page 8-4) Inspect the clutch operation after the adjustments, SUSPENSION FRONT SUSPENSION COMPRESSION Remove the valve cap. Measure the front suspension compression with an air pressure gouge. COMPRESSION; 0-40 kPa {0-0.4 kg/om*, 0-5.7 psi) NOTE Pump sir by 8 hand pump gradually Do not compress more than 285 kPa (3 kglem?, 43 psi) not to damage the oil sea. Raise the front wheel off the ground when ‘measuring the compression. Use specified oir pressure gauge. Compression may drop slightly due to the air ing into the fork oil. 3-18 B HONDA TLI25-TER200 (1) Lock NUT (2) ADJUSTER Ss eeHONDA INSPECTION/ADJUSTMENT ‘TLI25-TLR2OO FRONT SUSPENSION INSPECTION Cheek the action of the front forks by compressing ‘hom soveral ti Check the entire fork assembly for signs of leaks or damage. Replace damaged components which cannot be repaired. Torque all nuts and bolts. Inspect the front wheel for bend. REAR SUSPENSION INSPECTION Place the motorcycle on a support to raise the reat ‘wheel off the ground, Move the reer suspension up and down to check the ‘operation and damage. Move the rear wheel sideways to see if the swingarm bushings are worn out. Check the entire suspension assembly. Be sure if itis securely mounted and not damaged or bent. Torque all nuts and bolts. NUTS/BOLTS/FASTENERS ‘Tighten bolts, nuts and fasteners at regular intorvals shown in the Maintenance Schedule. ‘Check that all chassis nuts and bolts are tightened to their correct torque values. (Page 1-4). Check all cotter pins and clips. 3-19 80HONDA TL125-TLR209 INSPECTION/ADJUSTMENT WHEELS/SPOKES Measure the tire pressure. NOTE Ti ie should be checked when the PRESSURES; Front (TL125) 147 kPa (1.5 kg/om, 21.3 (TLR 200) 147 kPa (1.5 kg/em, 21.3 psi) Rear (TL 125) 147 kPa (1.5 kg/em, 21.3 psi) (TLR 200) 147 kPa (1.5 keg/em, 21.3 psid 7 (1) AIR PRESSURE GAUGE (2) NIPPLE WRENCH (Check the tires for cuts, imbedded nails, or other shatp objects. Replace the tires if the depth of the center tread, falls below the specified values: CENTER TREAD DEPTH: Front/Rear: 3mm (1/8 in) TIRE SIZE; Front 2.75-21-4PR Rear 4,00-18-4PR Inspect sporks for looseness Tighten them to the specified torque if they are TORQUE; 25-85 N-m (25-45 keg-em, 1.8-3.3 ft-1b) STEERING NOTE ‘Cheek that the control wites do not interfere with the rotation of the handlebars. Raise the front wheel off the ground and make sure, that the handlebars rotate smoothly. If the handlebars move unevenly, bind or have vertical movement, inspect the steering stem top thread. (Page 11-18) 3-20 824. FUEL SYSTEM sonny SERVICE INFORMATION 44 TROUBLESHOOTING 42 THROTTLE VALVE 43 CARBURETOR REMOVAL 44 CARBURETOR DISASSEMBLY 45 CARBURETOR ASSEMBLY 47 FLOAT LEVER ADJUSTMENT 47 CARBURETOR INSTALLATION 47 FUEL TANK 43 AIR CLEANER 49 SERVICE INFORMATION GENERAL INSTRUCTIONS ‘Take precautions against fire whenever working with gasoline. Note the locations of the O-rings and replace them with new ones on reassembly. ‘The carburetor float bow! has a drain plug. Loosen it to drain the residual gasoline before disassembling SPECIFICATIONS TL125 TLR200 Tdenifcation mail POORT S06. Float level 20mm (0.790 in) ‘24mm (0.940 in) Main Jet #90. #8. Slow iet #35 40 Tet needle ing second ——— ‘Air screw opening 1718 turnings 1778 turnings Tale speed 773005100 rom —— “Throttle grip free play (2-6mm (178-174 in) ——— Fuel tank capacity 65 it (1.72 US gal, 1.48 Tap wall — Reserve capacity 1.0 lit. (0.26 US gal, 0.22 imp gal) ee TOOL Common too! Float level geuge 07401 - 0010000HONDA TLI25-TLR2OO TROUBLESHOOTING Engine cranks but won't start |. No fuel in tank No fuel to cylinder 3. Too much fuel getting to cylinder Alr cleaner clogged 3. Flat valve clogged Flost level adjustment incorrect Seasons Engine idles roughly, stalls, oF runs poorly 1. Idle speed incorrect 2. Ignition malfunction 3, Low compression 4, Rich mixture 5. Lean mixture 6. Air cleaner clogged 7. Fuel contaminated Rich mixture 1, Carburetor choke stuck closed 2, Float valve faulty 3, Float level too high 4, Air cleaner element clogged ‘Loan mixture Carburetor fuel jet clogged Breather tube clogged 3. Fuel filter clogged Ful line kinked or restricted . Float valve faulty Float level t00 low FUEL SYSTEM@ HONDA. FUEL SYSTEM 1L125-TLR200 THROTTLE WALVE (1) caRaURETOR Tor THROTTLE VALVE DISASSEMBLY Romove the seat and the fuel tank. Loosen carburetor top and remove it together with throttle valve, Remove the throttle cable from the throttle valve (3) THROTTLE CABLE (1) THROTTLE VALVE (2) NEEDLE JET (3) CLIP RETAINER THROTTLE VALVE INSPECTION Bbe Remove the needle clip retainer. Remove the needle jet and the needle Inspect the throttle valve and needle dirt, scratches or wear. surface for (4) NEEDLE CLIP (6) SPRINGFUEL SYSTEM HONDA. TLIZS-TLR2ZOO THROTTLE VALVE ASSEMBLY Install the needle clip on the needle jet. Install the needle jet and needle clip retainer. NOTE Make sure to install the needle the groove of the nee Install the throttle cable and the spring to the carburetor top. Connect the throttle cable to the throttle valve, THROTTLE VALVE INSTALLATION When installing the throttle valve, aligh the throttle valve groove with the throttle stop serew. Inspect the operation of the throttle valve after the Installation. CARBURETOR REMOVAL Remove the seat. Turn the fuel valve OFF and disconnect the fuel Hine. Remove the fuel tank. Loosen the drain screw and drain the gasoline. Loosen the screw securing the carburetor band and remove the carburetor setting nuts. Unscrew the carburetor top and pull the throttle valve out. Remove the carburetor, (1) NEEDLE CLIP 2) STANDARD: SD SECOND (3) NEEDLE JET (3) THROTTLE STOP SCRE! (2) THROTTLE VALVE (3) CARBURETOR BANDHONDA. FUEL SYSTEM FL125-TER20O CARBURETOR DISASSEMBLY (4) VAND. (5) CARBURETOR INSULATOR FLOAT AND FLOAT VALVE REMOVAL Remove the float chamber body. Remove the float pin so that the float and the float valve can be removed. u — (2) FLOAT 4-5 96FUEL SYSTEM HONDA TLI2S-TLR20O FLOAT AND FLOAT VALVE INSPECSION Inspect the float valve and the valve seat for wear or darnage. Inspect if the gasoline is not leaking into the float. JETS REMOVAL Remove the main jet, jet holder, jet needle holder ‘and the jet needle. Romove the stow jet. Remove the throttles stop screw. Check each part for wear or damage, Blow compressed sir through the pasiage of the carburetor body and make sure that it is not clogged. (1) VALVE SEAT (2) FLOAT VALVE (1) JET HOLDER (2) MAIN JET (3) SLOW JET (4) JET NEEDLE HOLDERHONDA FUEL SYSTEL TL125-TLR200 | Sl | (2) JET NEEDLE (3) CARBURETOR ASSEMBLY () JET NEEDLE == CHOLDER JET HOLDER Carburetor assembly is essentially the reverse order of desassembly. NOTE ‘O-rings should be replaced to the new ones whenever the carburetor is reassembled. Hnadle all jets and neadles with care. (4) THROTTLE {5) (6) SLOW JET (7) MAIN JET STOP SCREW AIR SCREW FLOAT LEVEL ADJUSTMENT Measure the float level with a float level gauge as shown below. To adjust the float level, bend the float arm until ‘the float tip contacts with the float valve, FLOAT LEVEL; TL 125 20mm (0.780 in) ‘TLR 200 24mm (0.940 in) (1) FLOAT LEVEL GAUGE 074010010000 CARBURETOR INSTALLATION Carburetor installation Is essentially the reverse order of removal. Adust the throttle grip free play after the installa- tion. (Page 3-4) NOTE ‘Make sure of the gasoline not leaking after the installation. 4-7 100 |HONDA FUEL SYSTEM TL125-TLR2OO FUEL TANK (1) FUEL TANK (2) FUEL STRAINER see crete Remove the seat and the side covers. ‘Turn the fuel value OFF. Disconnect the fuel tube and remove the fuel tank. Remove the fuel starainer. [Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once. ‘Check the fuel strainer, Replace to 2 new one clogged. Fuel tank installation is essentially the reverse order of its removal. itis (a) FUEL TANK CAP (3) BREATHER TUBE Sp ®e@ (6) FUEL STRAINER (g) FUEL STRAINER, SCREEN (5) FUEL TANK (7) FUEL VALVE NOTE Make sure there are no fuel leaks after the installation. Do not overtighten the fuel valve lock nut. 4-8 lozFUEL SYSTEM AIR CLEARER Air cleaner should be removed as shown below. Remove the seat and the side covers. Remove the rear wheel. (Page 12-3) Remove the rear exhaust pipe and the muffler. (Page 12-17) Remove three sir cleaner mounting bolts and the air cleaner. Clean the element, (Page 3-6) Alircleaner installation is essentially the reverse ordor of removal. (5) HEAT GUAR, (1) INLET DUCT (6) ELEMENT HOLDER HONDA. TLI25-TLR200@)itrzs e200 ENGINE REMOVAL/ INSTALLATION AUSBAU/EINBAU DES MOTORS DEPOSE/REPOSE DU MOTEURHONDA. TLIZS-TLR2OD ENGINE REMOVAL/INSTALLATION 18-25 Nem (1.8-2.5 kgm, 13-18 feb) 18-25 Num 137 Na t i (1.8-2.5 kgm, 13-18 ft1b) (3.1-3.7 kg-m, 22-27 fetb) 45-60 N.m (4.5-6.0 kgm, 33-43 fr-lb) 31-37 Nm 7 {31-37 kom, 22-27 fetb)B, ENGINE REMOVAL/ a INSTALLATION TL125-T1R200 SERVICE INFORMATION 5-1 ENGINE REMOVAL 52 i ENGINE INSTALLATION 54 SERVICE INFORMATION GENERAL INSTRUCTIONS ‘This section covers removal and installation of the enginé During removal and installation, support vehicle with suitable blocks. A jack or an adjustable support is required to maneuver the engine. ‘Jack height must be continuously adjusted during operation to prevent damage to the mounting threads, the wiring harnesses, ‘and the cables. Operations required engine removal; Cylinder head Section 6 Gylinder and piston Section 7 Crankshaft, transmission and kick starter Section 10 SPECIFICATIONS. Engine dry weight TL125 ——29.0kg (63.95Ib) TLR 200 _30.0kg (66.1511b) Engine oil capacity 1.10 liters (0.29 US gal, 0.24 Imp gal) at engine disassembly (0.90 liters (0.24 US gal, 0.20 Imp gal) at engine oil change TORQUE VALUES Engine hanger bolt 8mm bolt; 31-97 Nem (3.1-3.7kg-m, 22-27 ft-lb) 10mm bolt; ‘45-60 Nem (4.5-6.0kg-m, 33-43 ft-tb) Rear axle nut 60-80 N+m (6.0-8.0kg-m, 43-58 ft-Ib) Exhaust pipe joint nut 18-25 Nem (1.8-2.5k9-m, 13-18 ft-lb) Exhaust pipe clamp bolt 18-25 Nem (1.8-2.5kg-m, 13-18 ft-Ib) Skid plate mount bolt 8-12 Nem (0.8-1.2kq-m, 6-9 ft-lb) 5-1 108ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the seat, right and left side covers, and the fuel tank. ‘Remove the skid plate and drain the engine oil. Remove the exhaust pipe. Disconnect the clutch cable. amove the kick arm stopper. Flemove the spark plug eap. Remove the carburetor. Disconnect the A.C. geni generator wire coupler. Remove the gearshift arm. Remove the drive sprocket cover. Loosen the rear axle nut, and the loosen the drive chain adjuster. stor wire and the pulse ee (@) KICK ARM STOPPER (6) CARBURETOR WIRE (9) DRIVE STOROCKET COVER HONDA TL125-TLR20O (5) SKID PLATE (7) AC.GENERATOR (8) PULSE GENERATOR ‘COUPLER, (10) GEARSHIFT ARMHORIDA ENGINE REMOVAL/INSTALLATION TLI25-TLR2OO Ee (1) CHAIN RETAINING CLIP Romove the chain retaining clip. Remove the master link, and then remove the drive chain, Remove the front engine hanger bracket. Remove the rear engine hanger bolts. (3) FRONT ENGINE (4) REAR ENGINE HANGER BRACKET HANGER BOLT (6) COLLAR Remove the upper engine hanger bolt and the collar. Remove the engine. NOTE Take care not to damage the wiring harnesses ‘and the cables. Also take care not to sratch each part of the frame, bolts and nuts. (6) UPPER HANGER BOLTENGINE REMOVAL/INSTALLATION @ HONDA. ¥L125-TLR200 ENGINE INSTALLATION Engine installation should be performed essentially in reverse order of the engine removal NOTE Engine hanger bolts should be installed as shown below. Make sure to install the collar on the right side of the engine after installing the upper hanger bott. After installing all hanger bolts, tighten them to the specified torques. TORQUES; —Smm bolt (upper) 31-37 Nem (3.1-3.7kgem, 22-27 F-tb) Smm bolt (front) 31-37 Nem (3.1-3.7kg-m, 22-27 ft-lb) TOmm bolt (rear) 45-65 N-m (4.8-8.5kg-m, 33-47 ft-lb) Connect the wires and the harnesses correctly. (Page 1-6) Make sure that exhaust gas is not leaking through the exhaust pipe connection. (1) 8mm BOLT; TORQUE 31-37 Nem (3.1-8.7 kgm, 22-27 fb) (3) 10mm BOLT; TORQUE 45-65 Nem (45-65 kom, 33-47 feb) ae Ss a (4) 8mm BOLT; TORQUE 31-37 Nem (3.1-3.7 ket 1m, 22-27 Fb)HONDA. TL125-TLR200 CYLINDER HEAD/VALVES ZYLINDERKOPF/VENTILE CULASSE/SOUPAPES 6-0 8 |HONDA. TLI25-TLR2OO CYLINDER HEAD/VALVES nD 30 Nem kgm, 20-22 feb)6. VALVES CYLINDER HEAD/ HONDA TLI25-TLR200 SERVICE INFORMATION TROUBLESHOOTING CAMSHAFT REMOVAL CYLINDER HAED COVER REMOVAL CYLINDER HEAD REMOVAL CYLINDER HEAD DISASSEMBLY VALVE SEAT INSPECTION/REFACING CYLINDER HEAD ASSEMBLY CYLINDER HEAD INSTALLATION CYLINDER HEAD COVER INSTALLATION CAMSHAFT INSTALLATION 64 62 63 64 a7 67 6-10 6-14 6-15 6-16 6-17 SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers maintenance of the eylinder head, the valves, the camshaft, and the rocker arms. Every operation except for the camshaft operation should be done with the engine removed. Camshaft lubrication oll is fed to the cylinder head through an oil control orifice in the engine case. Make sure that the oil control orifice is not clogged and that the O-rings and the dowel pins are in the correct position before assembly. Before assembly, apply molybdenum diulfide grease to the camshaft bearings to provide initial lubrication. Pour clean engine oil into the oil pockets in the cylinder head to lubricate the cams. SPECIFICATIONS TEM ‘STANDARD SERVICE LIMIT ‘Compression 981-1,573 KPa {10-14 kglem?, 142-199 psi) [ Camshaft Cam Wife IN| “31.050—31.219 mm —_(1.2227—1.2201 in] [30.94 mm (218 Ta) EX. '30,657=30.817 mm _(1.2070—1.2133 in) | 30.53 mm_{1.202 in} Touraal OD) R__|19.967—10.980 mm (07861 0.7866 in) | 19.90 mm_(0.784 in} T 3.969=33.975 mm —(1.3370~1.4376 in)_| 33.00 mm_(1.395 in) ‘Cylinder head | Bearing 1D. R "20,005~20.026 mm _(0.7876-0.7884 in) | 20.05 mm (0.769 in) c 34,000=34,026 mm —(1.3386=1.3386 In)_|_34,05 mm_(1.341 in) Warpage = 0.10 mm (0.004 in} [Racker an 10- FA00OAT OTE mam O.AT2A-O.ATS 72.05 mm (0.474 in) Rocker Arm shaft O.D. 11,977=11.885 mm (0.4715-0.472: 11.93 mm (0.470 Rocker arm-to-shaft clearance 150.041 mm (0.0002—0.0016 in) | 0.08 mm (0.003, Valve spring | Free length Taner [39.4 mim (165 in J 35.50 mm (1.400 in) Guier [46.5 mm (1.79 in) a 47.00 mm (1.610 in) | Piéload Taner | 8.30.6 kg/S3.7 mm —_(18.3+1.31b/1.33 in) — i Outer [2141.5 kg/38.4 mm —_(46.3°9.31b/1.51 in) Vale, valve guide] Stern 0.0. IN| 8460-5.485 mm ___(0.2146-0.2182 in) EX 5.430-6.445 mm (0.2138-0.2144 in) Guide 1D. TN | 8.475=5.485 mm _(0.2158—0.2169 in) . EX $.475=5.85 mm (0.2166-0.2160 in} | 6,68 mm_(0.218 in) Stomto-guide | _IN (0.010-0.035 mm _(0.0004—0.0014 in) | 0.06 mm_(0.002 clearnace (ox 0,030=0.055 mm _(0.0012—0.0022 in) | 0.07 mm_ (0.003 Valve face width 4.7 mm (0.087 in) 2.0_mm_{(0.08 in) | T1=1.3 mm 1010433-0,0512 in) [1.5 mm_(0.059 in) 120HONDA. TLI25-TLR2GO CYLINDER HEAD/VALVES TORQUE VALUES Cylinder head nut Cylinder head socket bolt Cam sprocket bolt Carburetor maniforlé TOOLS ‘Special tools Valve Guide Reamer (6.48 mm) ‘Common tools Valve Guide Remover (5.5 mm) Valve Spring Compressor Valve Seat Cutter Flat cutter (32), EX IN Seat cutter (46) =x IN Interior cutter (60) Valve Seat Cutter Holder INEX TROUBLESHOOTING Low compression 1. Valve = Incorrect valve adjustment — Burned or bent valves — Incorrect valve timing — Broken valve spring 2, Oylinder head — Leaking or damaged head gasket — Warpod or cracked oylinder head 3. Cylinder and piston incorrect 4, Decompressor out of adjustment High compression 28-30 Nem (2.8-3.0 kgm, 20-22 ftb) 18-25 Nem (18-25 kgm, 13~18 feb) 8-12 Nem (0.8-1.2 kgm, 6-9 fb) 8-12 Nem (0.8-1.2 kgm, 6-9 fb) 079840980000 077420010100 07757~0010000 07780-0012000 07780-0012200 07780-0010100 07780-00100 07780~0014000 07781 ~0010100 1, Excessive carbon build up on piston head or combustion chamber Poor i 1, Compression too low Hard starting 1. Compression too low Excesseve exhaust White smoke during the engine brake 1, Inlet valve stem worn out 2. Inlet valve guide worn out 3, Inlet stem seal incorrect 4. Inlot valve stem installed incorrectly White smoke during engine speed 1, Exhaust valve stem worn out 2, Exhaust stem seal damaged 3, Exhaust valve stem installed incorrectly 4. Exhaust valve guide worn out Excessive Noise 1, Incorrect valve adjustment 2. Sticking vaive broken valve spring 3. Damaged or worn rocker arm or camshaft, 4, Loose or worn eam chain 5, Worn or damaged cam chain tensioner 6. Worn cam sprocker teeth 121 6-2CYLINDER HEAD/VALVES CARISHAFT REMOVAL Remove the cover. Remove the crankshaft hole eap and the timing hole cap. ‘Turn the crankshaft to bring the piston to TOC (Top Dead Center) of the compression stroke. Remove the cam sprocket bolts and then remove ‘the cam sprocket. NOTE “Take precaution not to drop @ cam sprocket bolt into the crankcase. (3) CAM SPROCKET BOLTS Remove the camshaft. NOTE ‘Suspend the cam chain with a piece of wire to prevent it from falling into the crankcase.CYLINDER HEAD/VALVES CAMSHAFT INSPECTION Measure the camshaft journal O.D, with @ microme- ter. SERVICE LIMITS; RIGHT 19.90mm (0.784 in} LEFT 33.90mm (7.335 in) Check the cam for crack or wear. Measure each cam helgit with a micrometer. SERVICE LIMITS; tN 30.94mm (1.218 in) EX 30.53mm (7.202 in) CYLINDER HEAD COVER REMOVAL AS cers oranda (TLR200) Remove the bolt and the decompressor cable set plate. Disconnect the decompressor cable. (3) BOLT HONDA. TLI25-TLR2OO (2) DECOMPRESSOR CABLE SET PLATECYLINDER HEAD/VALVES Remove the 6mm socket bolts, 8mm cap nuts, and the cylinder head cover. Remove the camshaft bushing. NOTE ‘The socket bolts should be loosened little by litele, twice of three times diagonally. Remove the rocker arm shafts and the rocker arms. Remove the rocker arm shaft and the rocker arm, NOTE ‘Screw @ mm bolt into the threaded end of ‘the rocker arm shaft to remove it. (TLR200) Remove the pin bolt, the valve lifter lever, and the spring, HONDA TL125-FLR200 | fe (1) LOCKER ARM SHAFT (2) SET PLATE (3) 6mm BOLT (4) PIN BOLT (5) VALVE LIFTER LEVER (6) SPRING 130HONDA CYLINDER HEAD/VALVES ‘TL125-TLR2OO ROCKER ARM INSPECTION Check the oil hole for clogging and the rocker arms for wear or damage, NOTE Inspect the cam lobes for scoring, chipping or flat spots in case of the rocker arms cracked and/or worn out. Measure the ILD. of each rocker arm. SERVICE LIMIT; 12.05mm (0.474 in) ROCKER ARM SHAFT INSPECTION Check the rocker arm shafts for wear or damage, Measure the O.D. with a micrometer, SERVICE LIMIT; 11.98mm (0.470 in) Calculate the rocker armto-shatto! SERVICE LIMIT; 0.08mm (0.003 in) (2) (RIGHT) (1) CAMSHAFT HOLDER CAMSHAFT BUSHING CAMSHAFT HOLDER/CAMSHAFT Q BUSHING INSPECTION Install the cylinder head cover with 8mm nuts. TORQUE; 28-30 N-m (2.8-3.0kg-m, 20-22 ft-tb) Measure both the camshaft holder ILD. and the bushing 1.0. SERVICE LIMITS; R (bushing) :20.05mm (0.789 in) L (camshaft holder) 34,05mm (7.341 in) Calculate the clearances of both camshaft-to- camshaft holder and camshaft-to-bushing. SERVICE LIMIT; 0.10mm (0.004 in) 6-6 132 \HONDA. CYLINDER HEAD/VALVES TLI25-TLR2OO CYLINDER HEAD REMOVAL (1) GAM CHAIN TENSIONER 80LT Remove the cam chain tensioner bolt. Remove the cylinder heed bolt. Remove the cylinder. ee (2) CYLINDER HEAD BOLT (1) VALVE SPRING COMPRESSOR 07757~0010000 CYLINDER HEAD, DISASSEMBLY Romove the valve eotters, the spring retainers, and the valve springs with a valve spring compressor. NOTE Do not compress the valve springs more than ocessary to remove the cotters. Marks all parts to ensure that they are reassembled in thelr original locations, Remove the carson deposits from the combustion ‘chamber. Clean off any gasket material from the eylinder head surface.HONDA CYLINDER HEAD/VALVES TLI25-TLR2OO CYLINDER HEAD INSPECTION Check the spark plug hole end the valve hole for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. SERVICE LIMIT; 0.10mm (0,002 in) VALVE SPRING INSPECTION ‘Meature the free length of the inner and the outer valve springs. SERVICE LIMITS; Inner 35.50mm (1.308 in) Outer 41.00mm, (1.614 in) VALVE/VALVE GUIDE INSPECTION ‘Check each valve for trueness, burning, scratches, or L ‘abnormal stom wear. Check the valve movement in the guide. ‘Measure each valve stem O.D. SERVICE Limits; IN 5.42mm (0.213 in) EX 5.4mm (0.213 in) 6-8 136 1CYLINDER HEAD/VALVES: HONDA TLI25-TLR2OO NOTE Ream the guide to remove the carbon deposits before measuring the valve guide. Measure each guide I.D. using a ball gauge or an inside micrometer. SERVICE LIMITS; IN 5.53mm (0.218 in) EX 653mm (0.218 in) ‘Stem-to-guide clearance is calculated by subtracting the valve stem O.D, from guide 1,D. SERVICE LIMITS; IN 0.06mnm (0.002 in) EX. 0.07mm (0.003 in) NOTE If the stem-to-guide clearance exceeds the service limit, determine if a new guide with standard dimensions would bring the clearance within tolerance. if so, replace guides to the new ones, If stem-to-guide clearance still exceeds the service limit when new guides are installed, replace both of the guides and valves to the new ones. NOTE Reface the valve seats whenever new valve ‘Guides ae installed. VALVE GUIDE REPLACEMENT ‘Support the cylinder head and take out the guide from the combustion chamber side, NOTE Do not damage the cylinder head during the guide removal. Install an Orting on the new valve guide. Drive the guide into the cylinder head. NOTE Ingpect the valve guide for damage. 138HONDA 1L125-TLR2OO 2YLINDER HEAD/VALVES (1) VALVE GUIDE REAMER 079840980000 Zeam the now valvo guide after the installation, NOTE Use cutting oil on the reamer during the ‘operation. Rotate the reamer when inserting and remov- ing it. slean the cylinder head thoroughly to remove any netal particles. Yeface the valve seat. VALVE SEAT INSPECTION/REFACING Clean all intake and exhaust valves thoroughiy to ‘emove carbon deposits. Apply a light coating of Prussian blue to cach valve seat. Lap each valve and seat using a rubber hose or other haneldapping tool. Remove the valve to inspect the valve face. NOTE “The valve cannot be ground. If the valve face Is burned or badly worn out, or if it contacts the seat uneventy, replace the valve. Measure the valve face width. SERVICE LIMIT; 200mm (0.079 in)CYLINDER HEAD/VALVES Inspect each valve seat. VALVE SEAT WIDTH STANDARD 1.20mm (0.047 in} SERVICE LIMIT —1.50mm (0.059 in) If the seat is t00 wide, too narrow, oF has tow spots, the seat must be refinished to seal properly. NOTE Valves cannot be ground. If the valve face is burned, badly worn out, or contacts the seat unevenly, replace the valve. VALVE SEAT GRINDING HONDA VALVE SEAT CUTTERS, grinder or equivalent valve seat refacing equipment are re- commended to correct a worn valve seat. NOTE Follow the refacer manufacturer's operating Instructions. HONDA TLI25-TLR200 (2) VALVE SEAT CUTTER VALVE SEAT CUTTER {3} FLAT CUTTER (4) SEAT CUTTER (6) INTERIOR CUTTER 4 V~. 4B — 4 \ \ EX 07780-0012000 (25 mm) EX _07780—0010100 (24.5 mm) EX/IN IN 0780~0012200 (30 mm) IN 07780—0010300 (29 mm) 9780—0014000 (80 mnt 6-11 vaCYLINDER HEAD/VALVES Use a 45 degree cutter 10 remove any roughness or ircegularities from the seat. NOTE Reface the seat with a 45 degree cutter when the valve guide is replaced. Use @ 32 degree cutter to remove 1/4 of the existing valve seat material. Use 2 60 degree cutter to remove the bottom 1/4 of the old seat. lemove the cutter and inspect the ares that is just removed. Install a 45 degree finish cutter and cut the seat to ‘the proper width. NOTE “Make sure that all pitting and irregularities are removed, Refinish if necessary. 6-12 HONDA. FLI25-TLR2OO (1) OLD SEAT WIDTH (2) OLD SEAT WIDTH “a 60" 1.11.3 mm (0.0433-0,0512 in} |CYLINDER HEAD/VALVES HONDA. TLi25-TLR2OO Apply a thin coating of Prussian blue to the valve seat. Press the valve through the valve seat to make @ clear pattern. ‘and on to the NOTE he location of the valve seat in relation to the valve face is very important for good sealing. If the contact area is too high on the valve, the seat must be lowered using a 32 degree flat cutter. If the contact area is too low on the valve, the seat ‘must be reised with a 60 degree inner cuter. ‘After cutting the seat, apply lapping compound to the valve face, and lap the valve with light pressure. ‘After lapping, wash all residual compound off the cylinder head and the valve. NOTE ‘Take precautions against the lapping com- pound not to enter the stem-to-guide clearance, (1) CONTACT AREA TOO HIGH (2) OLD SEAT WIDTH (3) CONTACT AREA TOO Low 146