XR125LEK/XL125LEK/XR150LEK

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1 XR25LEK/XL25LEK/XR50LEK XR25LEKE XL25LEKE XR50LEKE KRHE0 Honda Motor Co., Ltd. 204

2 FOREWORD INDEX ENGINE GROUP 2 FRAME GROUP PART NUMBER INDEX 4 PART NAME INDEX 5

3

4 B Instruction for use of parts catalogue CONTENTS Address Page This parts catalogue has been created as of February 0, 204. Instruction for use of parts catalogue... How to refer to the part information... 2 B B 2 Since this date, the sales practice for repair parts may have been changed or the parts may have been eliminated (listed for those not for sale). Part catalogue structure... When the parts were revised... 5 Abbreviations used in the parts catalogue... 5 B B 5 B 5 The modified information is reflected on the latest Electronic Parts Catalogue (EPC). Also, refer to the parts catalogue news for any change. Part block and serial number check... 6 Color label attachment position check... 6 Models, parts catalogue codes and applicable serial numbers... 7 B 6 B 6 B 7 See the parts catalogue news for any revision that is made after February 0, 204. Color label... 8 Color chart... 9 B 8 B 9 Always specify the part number when ordering a part. Fuel hose, general purpose hoses and vinyl hose... 9 C Check the model, type, serial numbers, color, maker, and the size as needed before ordering a part. Note that the illustrations (part drawings) can differ from the actual parts in shape. They are given just to help you to refer to the parts. FLAT RATE SERVICE TIME... 2 Illustrated index ENGINE GROUP... 6 FRAME GROUP PART NO. INDEX... 2 PART NAME INDEX... 7 C 7 C2 E G K L When modifications or additions to this parts catalogue are made, a revised edition will be issued at an appropriate time, with successively progressing revision numbers on the cover. We recommend obtaining such revisions in order to keep your parts catalogue up-to-date at all times. To check whether a parts catalogue revision has been issued, please contact your Honda distributor. Initial version issue date February 0, 204 Honda Motor Co., Ltd.

5 B 2 How to refer to the part information Reference with Illustrated index Reference with Part number index Reference with Part name index 2

6 B Part catalogue structure Address number Address is provided (in place of the page ) to help you refer to the part with the part or part name. Block title Block number Service item/flat rate time Reference number Title number marked with the parenthesis or parentheses indicates that it continues from the previous page. Part number Honda color code Assemblies Sections framed with broken lines in the exploded view drawings are available as complete assemblies. (Their individual parts can also be obtained.) Color description Note Notes are shown with the parentheses in the part name column. Required quantity shown in the parenthesis or parentheses indicates the optional part. marked with N indicates the optional part that should be selected as needed. indicates the number of the part used in the block. Serial number When the parts catalogue code column is blank, it indicates that the part is applicable to all codes.

7 B Parts enclosed within a dotted line are covered in a different block. A hollow arrow indicates the block for the parts enclosed within a dotted line. A solid arrow indicates the block the part in question is connected to. 8 Replacement Identification Information for Designated Part 9 Location of Replacement Identification Information for Designated Part If an arrow mark is indicated in 9, the part is incompatible with a different part Make sure to order the part of the same manufacture, including the component part. To make an order, indicate the part, which includes the symbol displayed on the applicable section of the part to be replaced. 4

8 B 5 When the parts were revised Be sure to check the serial number!! Abbreviations used in the parts catalogue RIGHT is abbreviated as R. L. stands for LEFT * L. or R. in the description of a part stands for the LEFT hand side or the RIGHT hand side. Determine the left or right as if you were in the motorcycle seat. The number has been used from the initial model without revision. When shown at the left side, it is applicable to the models of and the subsequent numbers. When shown at the right side, it is applicable to the models up to The parts listed with "###" at the end of the parts name have limited supply period (parts not for sale). The following abbreviations are used in this parts catalogue. A... Ampere ABS... Anti-lock brake system A.C.... Alternating current A.M.... Attaching mark ASSY.... Assembly C.D.I.... Capacitive discharge ignition COMP.... Complete D.C.... Direct current EX.... Exhaust FR.... Front G... Gram HEX.... Hexagonal IN.... Inlet KPH... Kilometers per hour L....Left L (00L).Link (00 Links) L.E.D....Light emitted diode MM...Millimeter MPH...Miles per hour R....Right RR....Rear STD....Standard T (22T)...Tooth (22 Teeth) TCS...Traction control system T.M....Transcript mark V...Volt W...Watt WL...With labelling WOL...Without labelling 5

9 B 6 Part block Part block and serial number check Engine parts Carburetor parts Frame parts E-~ E-22 F-~ Color label attachment position check Colored parts Required serial number Engine serial number Carburetor serial number Frame serial number Color label Check point

10 B 7 Models, parts catalogue codes and applicable serial Nos. given in this parts catalogue can be identified as follows. Parts with parts catalogue codes are exclusive for models destined for countries designated. If no area codes are listed, parts are for common use. Model Area code Models, parts catalogue codes and applicable serial numbers Type Applicable engine serial Applicable frame serial Applicable carburetor identification XR25LEKE LA DK Latin America General export (KPH) PDN2J A SA South Africa PDN2H A XL25LEKE 2SA South Africa PDN2H A XR50LEKE LA LA DK Latin America General export (KPH) PDN2P A PDN2M A NZ SA New Zealand South Africa PDN2P A * Of carburetor/throttle body identification numbers, only the portions underlined in the example below are used for registration. PDN2J KC 7

11 B 8 Color label When ordering parts, check the model name, main color, and code by observing the COLOR LABEL on the vehicle. When ordering a colored part, use the color chart in the instruction for use of parts catalogue. VFR800FIW R-57 R57 8

12 B 9 Color chart When ordering a colored part, refer to the chart below and use a part number consisting of the relevant basic part number to which has been added a part color code. XR25LEK (XR25LEKE) LA MODEL XR25LEKE COLOR CODE Fighting red Black Ross white R-4 NH- NH-96 Name of colored parts Basic part R4 NH NH96 Applicable model Initial applicable model Final applicable model Applicable block BODY COMP., FRAME 5000-KRH-A00 ZB ZB ZB F-9 2 BRIDGE COMP., FORK TOP 500-KRH-660 ZA ZA ZA F-7 7 CARRIER COMP., RR KRH-780 ZA ZA ZA F COVER SET, R. SIDE 850-KRH-900 ZB ZB ZB F-24 5 COVER, L. FR. SIDE 860-KRH-900 ZA ZA ZA F COVER, L. SIDE 8600-KRH-900 ZB ZB ZB F COVER, R. FR. SIDE 850-KRH-900 ZA ZA ZA F-24 8 COWL SET, RR KRH-900 ZB ZB ZB F FENDER, FR. 600-KRH-660 ZA ZC ZB F-0 0 HUB SUB ASSY., RR KRH-780 ZA ZA ZA F LABEL, DRIVE CAUTION KYY-600 ZB ZB ZB F MARK, FR. 65-KRH-900 ZC ZC ZC F-50 2 MARK, RR. 60-KRH-900 ZC ZC ZC F-50 4 PANEL COMP., RR. BRAKE 400-KRH-900 ZA ZA ZA F PIPE, STEERING HANDLE 500-KRH-900 ZA ZA ZA F PROTECTOR, EX. PIPE 845-KRH-900 ZA ZA ZA F

13 B0 XR25LEK (XR25LEKE) LA MODEL COLOR CODE Fighting red Black Ross white R-4 NH- NH-96 Name of colored parts Basic part R4 NH NH96 XR25LEKE Applicable model Initial applicable model Final applicable model Applicable block 7 SEAT COMP., DOUBLE KRH-780 ZB ZB ZB F SHROUD SET, L. TANK 9200-KRH-620 ZC ZB ZA F-2 9 SHROUD SET, R. TANK 900-KRH-620 ZC ZB ZA F STRIPE A, L. TANK SHROUD 8692-KRH-660 ZC ZB ZA F STRIPE A, R. TANK SHROUD 869-KRH-660 ZC ZB ZA F STRIPE B, L. TANK SHROUD 8694-KRH-620 ZC ZB ZA F STRIPE B, R. TANK SHROUD 869-KRH-620 ZC ZB ZA F SWINGARM SUB ASSY., RR KRH-780 ZA ZA ZA F TANK COMP., FUEL 750-KRH-900 ZA ZA ZA F VISOR SET, FR. 600-KRH-660 ZA ZA ZA F- 27 WHEEL SUB ASSY., RR KRH-A00 ZA ZA ZA F

14 B XR25LEK (XR25LEKE) DK,SA MODEL COLOR CODE Fighting red Black Ross white R-4 NH- NH-96 Name of colored parts Basic part R4 NH NH96 XR25LEKE Applicable model Initial applicable model Final applicable model Applicable block BODY COMP., FRAME 5000-KRH-A00 ZB ZB ZB F-9 2 BRIDGE COMP., FORK TOP 500-KRH-660 ZA ZA ZA F-7 7 CARRIER COMP., RR KRH-780 ZA ZA ZA F COVER SET, R. SIDE 850-KRH-900 ZB ZB ZB F-24 5 COVER, L. FR. SIDE 860-KRH-900 ZA ZA ZA F COVER, L. SIDE 8600-KRH-900 ZB ZB ZB F COVER, R. FR. SIDE 850-KRH-900 ZA ZA ZA F-24 8 COWL SET, RR KRH-900 ZB ZB ZB F FENDER, FR. 600-KRH-660 ZA ZC ZB F-0 0 HUB SUB ASSY., RR KRH-780 ZA ZA ZA F LABEL, DRIVE CAUTION KYY-600 ZB ZB ZB F LABEL, RR. CARRIER 8220-KV8-860 ZA ZA ZA F-49 MARK, FR. 65-KRH-900 ZC ZC ZC F MARK, RR. 60-KRH-900 ZC ZC ZC F-50 5 PANEL COMP., RR. BRAKE 400-KRH-900 ZA ZA ZA F PIPE, STEERING HANDLE 500-KRH-900 ZA ZA ZA F PROTECTOR, EX. PIPE 845-KRH-900 ZA ZA ZA F SEAT COMP., DOUBLE KRH-780 ZB ZB ZB F-2 2

15 B2 XR25LEK (XR25LEKE) DK,SA MODEL COLOR CODE Fighting red Black Ross white R-4 NH- NH-96 Name of colored parts Basic part R4 NH NH96 XR25LEKE Applicable model Initial applicable model Final applicable model Applicable block 9 SHROUD SET, L. TANK 9200-KRH-620 ZC ZB ZA F-2 20 SHROUD SET, R. TANK 900-KRH-620 ZC ZB ZA F STRIPE A, L. TANK SHROUD 8692-KRH-660 ZC ZB ZA F STRIPE A, R. TANK SHROUD 869-KRH-660 ZC ZB ZA F STRIPE B, L. TANK SHROUD 8694-KRH-620 ZC ZB ZA F STRIPE B, R. TANK SHROUD 869-KRH-620 ZC ZB ZA F SWINGARM SUB ASSY., RR KRH-780 ZA ZA ZA F TANK COMP., FUEL 750-KRH-900 ZA ZA ZA F VISOR SET, FR. 600-KRH-660 ZA ZA ZA F- 28 WHEEL SUB ASSY., RR KRH-A00 ZA ZA ZA F

16 B XL25LEK (XL25LEKE) MODEL COLOR CODE Fighting red Ross white R-4 NH-96 Name of colored parts Basic part R4 NH96 XL25LEKE Applicable model Initial applicable model Final applicable model Applicable block BODY COMP., FRAME 5000-KRH-640 ZA ZA F-9 2 BRIDGE COMP., FORK TOP 500-KRH-660 ZA ZA F-7 7 CARRIER COMP., RR KRH-780 ZA ZA F COVER SET, R. SIDE 850-KRH-900 ZB ZB F-24 5 COVER, L. FR. SIDE 860-KRH-900 ZA ZA F COVER, L. SIDE 8600-KRH-900 ZB ZB F COVER, R. FR. SIDE 850-KRH-900 ZA ZA F-24 8 COWL SET, RR KRH-900 ZB ZB F FENDER, FR. 600-KRH-660 ZA ZB F-0 0 HUB SUB ASSY., FR KRH-780 ZA ZA F HUB SUB ASSY., RR KRH-780 ZA ZA F MARK, FR. 65-KRH-900 ZC ZC F-50 2 MARK, RR. 60-KRH-900 ZC ZC F-50 4 PANEL COMP., RR. BRAKE 400-KRH-900 ZA ZA F PANEL SUB COMP., FR. BRAKE 4500-KRH-780 ZA ZA F- 7 6 PIPE, STEERING HANDLE 500-KRH-640 ZA ZA F PROTECTOR, EX. PIPE 845-KRH-900 ZA ZA F SEAT COMP., DOUBLE KRH-780 ZB ZB F-2 2

17 B4 XL25LEK (XL25LEKE) MODEL COLOR CODE Fighting red Ross white R-4 NH-96 Name of colored parts Basic part R4 NH96 XL25LEKE Applicable model Initial applicable model Final applicable model Applicable block 9 SHROUD SET, L. TANK 9200-KRH-640 ZB ZA F-2 20 SHROUD SET, R. TANK 900-KRH-640 ZB ZA F STRIPE, L. TANK SHROUD 8692-KRH-640 ZB ZA F STRIPE, R. TANK SHROUD 869-KRH-640 ZB ZA F-50 2 SWINGARM SUB ASSY., RR KRH-780 ZA ZA F TANK COMP., FUEL 750-KRH-900 ZA ZA F VISOR SET, FR. 600-KRH-660 ZA ZA F- 26 WHEEL SUB ASSY., FR KRH-780 ZA ZA F WHEEL SUB ASSY., RR KRH-780 ZA ZA F

18 B5 XR50LEK (XR50LEKE) LA,LA MODEL COLOR CODE Fighting red Black Ross white R-4 NH- NH-96 Name of colored parts Basic part R4 NH NH96 XR50LEKE Applicable model Initial applicable model Final applicable model Applicable block BODY COMP., FRAME 5000-KRH-A00 ZB ZB ZB F-9 2 BRIDGE COMP., FORK TOP 500-KRH-660 ZA ZA ZA F-7 7 CARRIER COMP., RR KRH-780 ZA ZA ZA F COVER SET, L. SIDE 8650-KRH-660 ZA ZA ZA F COVER SET, R. SIDE 8550-KRH-660 ZA ZA ZA F COVER, L. FR. SIDE 860-KRH-900 ZA ZA ZA F COVER, R. FR. SIDE 850-KRH-900 ZA ZA ZA F-24 8 COWL SET, RR KRH-900 ZB ZB ZB F FENDER, FR. 600-KRH-660 ZA ZC ZB F-0 0 HUB SUB ASSY., RR KRH-650 ZA ZA ZA F LABEL, DRIVE CAUTION KYY-600 ZB ZB ZB F MARK, FR. 65-KRH-900 ZC ZC ZC F-50 2 MARK, RR. 60-KRH-900 ZC ZC ZC F-50 4 PANEL COMP., RR. BRAKE 400-KRH-900 ZA ZA ZA F PIPE, STEERING HANDLE 500-KRH-900 ZA ZA ZA F PROTECTOR, EX. PIPE 845-KRH-900 ZA ZA ZA F SEAT COMP., DOUBLE KRH-780 ZB ZB ZB F SHROUD SET, L. TANK 9200-KRH-660 ZC ZB ZA F-2 5

19 B6 XR50LEK (XR50LEKE) LA,LA MODEL COLOR CODE Fighting red Black Ross white R-4 NH- NH-96 Name of colored parts Basic part R4 NH NH96 XR50LEKE Applicable model Initial applicable model Final applicable model Applicable block 9 SHROUD SET, R. TANK 900-KRH-660 ZC ZB ZA F STRIPE A, L. TANK SHROUD 8692-KRH-660 ZC ZB ZA F STRIPE A, R. TANK SHROUD 869-KRH-660 ZC ZB ZA F STRIPE B, L. TANK SHROUD 8694-KRH-660 ZC ZB ZA F STRIPE B, R. TANK SHROUD 869-KRH-660 ZC ZB ZA F STRIPE, L. SIDE COVER 8682-KRH-660 ZA ZA ZA F STRIPE, R. SIDE COVER 868-KRH-660 ZA ZA ZA F SWINGARM SUB ASSY., RR KRH-780 ZA ZA ZA F TANK COMP., FUEL 750-KRH-900 ZA ZA ZA F VISOR SET, FR. 600-KRH-660 ZA ZA ZA F- 29 WHEEL SUB ASSY., RR KRH-650 ZA ZA ZA F

20 C XR50LEK (XR50LEKE).DK,NZ,SA MODEL COLOR CODE Fighting red Black Ross white R-4 NH- NH-96 Name of colored parts Basic part R4 NH NH96 XR50LEKE Applicable model Initial applicable model Final applicable model Applicable block BODY COMP., FRAME 5000-KRH-A00 ZB ZB ZB F-9 2 BODY COMP., FRAME 5000-KRH-A40 ZB ZB ZB F-9 BRIDGE COMP., FORK TOP 500-KRH-660 ZA ZA ZA F CARRIER COMP., RR KRH-780 ZA ZA ZA F COVER SET, L. SIDE 8650-KRH-660 ZA ZA ZA F COVER SET, R. SIDE 8550-KRH-660 ZA ZA ZA F COVER, L. FR. SIDE 860-KRH-900 ZA ZA ZA F COVER, R. FR. SIDE 850-KRH-900 ZA ZA ZA F-24 9 COWL SET, RR KRH-900 ZB ZB ZB F FENDER, FR. 600-KRH-660 ZA ZC ZB F-0 HUB SUB ASSY., RR KRH-650 ZA ZA ZA F LABEL, DRIVE CAUTION KYY-600 ZB ZB ZB F-49 6 LABEL, RR. CARRIER 8220-KV8-860 ZA ZA ZA F-49 4 MARK, FR. 65-KRH-900 ZC ZC ZC F MARK, RR. 60-KRH-900 ZC ZC ZC F-50 6 PANEL COMP., RR. BRAKE 400-KRH-900 ZA ZA ZA F PIPE, STEERING HANDLE 500-KRH-900 ZA ZA ZA F PROTECTOR, EX. PIPE 845-KRH-900 ZA ZA ZA F

21 C 2 XR50LEK (XR50LEKE).DK,NZ,SA MODEL COLOR CODE Fighting red Black Ross white R-4 NH- NH-96 Name of colored parts Basic part R4 NH NH96 XR50LEKE Applicable model Initial applicable model Final applicable model Applicable block 9 SEAT COMP., DOUBLE KRH-780 ZB ZB ZB F SHROUD SET, L. TANK 9200-KRH-660 ZC ZB ZA F-2 2 SHROUD SET, R. TANK 900-KRH-660 ZC ZB ZA F STRIPE A, L. TANK SHROUD 8692-KRH-660 ZC ZB ZA F STRIPE A, R. TANK SHROUD 869-KRH-660 ZC ZB ZA F STRIPE B, L. TANK SHROUD 8694-KRH-660 ZC ZB ZA F STRIPE B, R. TANK SHROUD 869-KRH-660 ZC ZB ZA F STRIPE, L. SIDE COVER 8682-KRH-660 ZA ZA ZA F STRIPE, R. SIDE COVER 868-KRH-660 ZA ZA ZA F SWINGARM SUB ASSY., RR KRH-780 ZA ZA ZA F TANK COMP., FUEL 750-KRH-900 ZA ZA ZA F VISOR SET, FR. 600-KRH-660 ZA ZA ZA F- WHEEL SUB ASSY., RR KRH-650 ZA ZA ZA F

22 C Fuel hose, general purpose hoses and vinyl hose The standard part fuel hose, general purpose hose and vinyl hose may be substituted by the coiled bulk part. When ordering the standard part fuel hose, general purpose hose and vinyl hose use the bulk part number written in the parts catalogue in brackets ( ) underneath the part name, or use the catalogue below. (The bulk part standard length is m, however, those displayed in the catalogue < > are available in m and 8 m lengths.) When exchanging the hose, cut and use at the specified length as mentioned in the part name. (For the method of cutting the bulk part, and method of filling out orders etc., please refer to the service manual and the instructions issued with the bulk part.) The list below is a catalogue of the standard part numbers and bulk part numbers. Note that those numbers are applicable to the listed replacement parts only. Standard part Fuel hoses/tubes Bulk part Bulk part Inner diameter (mm) Length (m) xxx-2x M xxx-x M xxx-4x M xxx-2x xxx-x xxx-4x xxx-5x xxx-6x xxx-2x xxx-x xxx-4x xxx-5x xxx-6x xxx-2x M < M> M < M> M < M> M < M> M < M> M < M> M < M> < M> M < M> < M> M < M> M < M> < M> M < M> < M> Standard part xxx-x xxx-4x xxx-5x xxx-6x xxx-2x xxx-x xxx-4x xxx-5x xxx-6x Fuel hoses/tubes Bulk part M < M> < M> M < M> < M> M < M> < M> M < M> < M> M < M> M < M> < M> M < M> < M> M < M> M < M> < M> Bulk part Inner diameter (mm) xxx-2x M xxx-x M xxx-4x M xxx-5x M xxx-6x M Length (m)

23 C 4 Vinyl tube Vinyl tube Vinyl tube Standard part Bulk part Inner dia- meter (mm) Bulk part Outer dia-meter (mm) Length (m) Standard part Bulk part Inner dia- meter (mm) Bulk part Outer dia-meter (mm) Length (m) Standard part Bulk part Inner dia- meter (mm) Bulk part Outer dia-meter (mm) Length (m) xxx-x M < M> xxx M < M> xxx-x M < M> xxx M < M> M xxx-x < M> < M> M xxx-60 < M> < M> M xxx-x < M> < M> M xxx-20 < M> < M> M xxx-x < M> < M> M xxx-60 < M> < M> M xxx-7x < M> < M> M xxx-x < M> < M> xxx-x M < M> xxx M < M> xxx-x M < M> M xxx-20 < M> xxx-x M < M> xxx M < M> M 9500-xxx-x < M> < M> M 9500-xxx-60 < M> < M> M xxx-x < M> < M> M xxx-20 < M> < M> xxx-x M < M> xxx M < M> xxx-x M < M> xxx-x M < M> M xxx-x < M> < M> M xxx-20 < M> < M> M xxx-x < M> < M> M xxx-60 < M> < M> xxx-x M < M> xxx M < M> xxx-x M < M> xxx M < M> M xxx-x < M> < M> M xxx-60 < M> < M> xxx-x M < M> xxx M < M> xxx-x M < M> M xxx-7x < M> xxx-x M < M> xxx M < M> xxx-x M < M> xxx M < M> 9500-xxx-x M < M> 9500-xxx M < M> M xxx-x < M> < M> M xxx-20 < M> < M> xxx-x M M> xxx M < M> xxx-x M < M> xxx M < M> xxx-x M < M> xxx M < M> xxx M < M> xxx-x M < M> xxx M < M> M xxx-x < M> < M> M xxx-20 < M> < M> M xxx-x < M> < M> M xxx-20 < M> < M> xxx-x M < M> xxx M < M> M xxx-x < M> xxx-x M < M> xxx M < M> xxx-x M < M> xxx M < M> xxx-x M < M> xxx M < M>

24 C 5 Standard part General purpose hoses Bulk part Bulk part Inner diameter (mm) Length (m) xxx-x M xxx-5x M xxx-x M < M> xxx-2x M xxx-x M xxx-5x M xxx-x M xxx-2x M < M> xxx-x M xxx-5x M xxx-x M xxx-2x M xxx-x M xxx-5x M xxx-x M xxx-5x M xxx-x M < M> < M> xxx-2x M xxx-x M xxx-4x M < M> < M> xxx-5x M xxx-x M < M> < M> xxx-2x M xxx-x M Standard part xxx-4x M < M> < M> xxx-5x M xxx-x M < M> xxx-5x M xxx-x xxx-2x xxx-4x xxx-x M < M> < M> M < M> M < M> < M> M < M> NOTE: X is displayed to represent the omitted numerals and letters of the roman alphabet xxx-2x M xxx-x M < M> xxx-5x M xxx-x General purpose hoses Bulk part M < M> xxx-2x M xxx-x M < M> xxx-2x M xxx-x M xxx-5x M xxx-x M xxx-5x M xxx-x M xxx-5x M Bulk part Inner diameter (mm) Length (m) CAUTION: It is DANGEROUS to confuse the fuel hose with the general purpose hose or vinyl hose. Never use a general purpose hose or vinyl hose in place of a fuel hose or vice versa. Always use the correct bulk part in the parts catalogue, according to the service manual or the instructions issued with the bulk part. 2

25 C 6 Bulk part number of fuel hose, general purpose hose and vinyl hose. (Example) 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 ( mm inside dia. only) 5: Black inside braid : Red ( mm inside dia. only) 4: Ash gray with red stripe ( mm inside dia. only) 6: Black Vinyl hose : Clear 2: Black : Light red 6: Light red 7: Pale black General hose : Ash gray 2: Ash gray : Black 5: Black Lengths: 00: m (standard) 00: m 008: 8 m I.D code: (fuel hose and general purpose hose) 0:.0 mm : mm 5:.5 mm 9: 2 mm (outside dia. 5) mm 45: 4.5 mm 92: 2 mm (outside dia. 6) mm 50: 5.0 mm 2: 2 mm (outside dia. 7) mm 55: 5. mm, 5.5 mm 4: 4 mm 65: 6.5 mm 7: 7 mm 70: 7.0 mm 75: 7. mm, 7.5 mm 80: 8.0 mm ID./OD. code: (vinyl hose) 0: ID. 2.9, OD. 6.8 mm 4: ID. 6.0, OD. 9.0 mm 7: ID..0, OD. 5.0 mm 0: ID..0, OD. 6.0 mm 7: ID. 7.0, OD. 9.0 mm 8: ID. 2.0, OD..0 mm 05: ID..5, OD. 6.5 mm 9: ID. 7.0, OD..0 mm 9: ID. 2.0, OD. 4.0 mm 07: ID. 4.0, OD. 7.0 mm 2: ID. 8.0, OD. 9.0 mm 40: ID. 2.0, OD. 6.0 mm 08: ID. 4.5, OD. 6.5 mm 2: ID. 8.0, OD. 2.0 mm 4: ID..0, OD. 5.0 mm 09: ID. 4.5, OD. 8.0 mm 25: ID. 9.0, OD..0 mm 45: ID. 4.0, OD. 8.0 mm 2: ID. 5.0, OD. 7.0 mm 27: ID. 9.0, OD..0 mm 50: ID. 6.0, OD. 9.0 mm 0: ID. 5.0, OD. 8.0 mm : ID. 0.0, OD. 4.0 mm 55: ID. 7.5, OD mm : ID. 5.0, OD. 9.0 mm 6: ID..0, OD..0 mm 60: ID. 22.0, OD mm Hose type: : Fuel hose : Vinyl hose 5: General hose 22

26 C 7 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. FRT setting system FLAT RATE SERVICE TIME Net service time Removal, Disassembly/reassembly, Installation Inspection, Measurement, Adjustment, Confirmation Diagnosis/troubleshooting (Electric system) Completion inspection Float time Preparation (Process check, Confirmation arrangement for necessary tools) Related work (Transfer of vehicles) * Float time is set by multiplying the net service time by a given coefficient. Editorial style The service items shown in the text 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.) is adopted to set FRT as it is convenient to calculate the wage. Example: (0.) 6 minutes, (0.2) 2 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. 2

27 C 8 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 servicing 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 deterioration 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, please calculate wages based on appropriate 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. 24

28 Explanation of FRT by using an example (The example may differ from the actual presented items) (Relative ref. Number) L.O.N. F.R.T. (,, 4, 7) 2 8 CAMSHAFT 4.5 C 9 Indicating work contents that are included in the service item. Indicating a reference 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.) 8A Includes: Valve clearance adjustment Replace rocker arm add.0 How to refer to the service item by using the sample (camshaft replacement) Open to the page of the block where the camshaft's spare part illustration is shown. Reference 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. Look for the camshaft illustration, and refer to the service item and FRT that agree with the reference 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 FRT.0 that will be added when additional operation (replace rocker arm) is done in association with camshaft replacement. 25

29 C0 Indication mark for the listing of service items that continues to the following page Indication of the block with no setting of FRT L.O.N. L.O.N. LON code system (Relative ref. Number) (Relative ref. Number) NO INFORMATION F.R.T. 2 8 CAMSHAFT a Mark indicated at the last line. 8 A b c d e a) Category code... Engine b) Location/function code... Engine upper c) Operation code... Replace F.R.T. 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) 8 A a c a) Category codes and classification Code Category Engine 2 Transmission Fuel & Exhaust 4 Frame & Body 5 Steering/Suspension 6 Electrical 7 Wheels/Brakes 8 Controls/instrument c) Operation codes and classification Code Operation category Replace, Removal/Installation, Change 2 Overhaul Adjust, Balance 4 (Paint-related work: Top-coat) 5 Test, Inspect/diagnose, Measurement, Check 6 (Overhaul-related work: Rebore) 7 (Overhaul-related work: Reseal) 8 (Resurface) 9 (Paint-related work: Refinish) 0 Repair, Cleaning, Air bleeding 26

30 C Major service items without using spare parts () Removal/Installation, (2) Adjustment, () Inspection/Measurement, (4) Overhaul, (5) Other work E: Engine, F: Frame * OPERATIONS OTHER THAN REPLACING PARTS () Removal and installation Set for the configuration with the parts removed from the vehicle. E LON DESCRIPTION FRT TILTING ENGINE ASSEMBLY- 0E5 REMOVAL/INSTALLATION.8 INCLUDES: All necessary adjustment D6 CARBURETOR ASSEMBLY- REMOVAL/INSTALLATION 0.5 0E6 CRANKCASE SEPARATION INCLUDES: Engine removal and installation.6 (2) Adjustment E F LON DESCRIPTION FRT A0 CARBURETOR IDLE-ADJUSTMENT 0. 22A0 CLUTCH-ADJUSTMENT INCLUDES: Clutch lever adjustment 64A SPARK PLUG-ADJUSTMENT/CLEANING 0. A0 VALVE CLEARANCE-ADJUSTMENT NOTE: For vehicle 66A0 HEADLIGHT-AIMING 0. 2A0 DRIVE CHAIN-ADJUSTMENT 0. 7A0 7A FRONT BRAKE-ADJUSTMENT EXCLUDES: Front brake shoe adjustment REAR BRAKE-ADJUSTMENT EXCLUDES: Rear brake shoe adjustment () Inspection, Measurement E F LON DESCRIPTION FRT 5A0 COMPRESSION PRESSURE-MEASUREMENT 0. 5A0 (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 CARBURETOR FLOAT LEVEL- MEASUREMENT 645A0 IGNITION TIMING-INSPECTION A0 BATTERY-CHECKING OF ELECTROLYTE LEVEL & CHARGE LON DESCRIPTION FRT E 200 CARBURETOR-OVERHAUL INCLUDES: All necessary adjustment LON DESCRIPTION FRT E 0A OIL FILTER SCREEN-CLEANING 0.6 F 70A0 FRONT BRAKE-AIR BLEEDING A THROTTLE OPERATION-ADJUSTMENT 0. 27

31 ENGINE GROUP C2 E- CYLINDER HEAD COVER E E-2 CYLINDER HEAD E 2 E- CAMSHAFT/VALVE E 4 2 E-4 CAM CHAIN/TENSIONER E 5 E-5 CYLINDER E 6 E-6 RIGHT CRANKCASE COVER E 7 E-8 CLUTCH E 8 E-9 STARTING CLUTCH E 9 E-0 LEFT CRANKCASE COVER E0 28

32 ENGINE GROUP C E- GENERATOR E E- STARTER MOTOR E2 E-4 OIL PUMP E E-5 CRANKCASE E4 E-6 CRANKSHAFT/PISTON(XR/XL25LEK) E5 E-6- CRANKSHAFT/PISTON(XR50LEK) E6 2 E-7 TRANSMISSION F 2 E-9 GEARSHIFT DRUM F 4 E-20 KICK STARTER SPINDLE F 5 29

33 ENGINE GROUP C4 E-22 CARBURETOR F 6 2 0

34 FRAME GROUP C5 F- HEADLIGHT G F-2 METER G 2 F- MIRROR G 4 F-4 HANDLE LEVER/SWITCH/CABLE(DISK BRAKE) G 5 F-4- HANDLE LEVER/SWITCH/CABLE(DRUM BRAKE) G 7 F-5 FRONT BRAKE MASTER CYLINDER G 9 F-7 HANDLE PIPE/TOP BRIDGE G0 F-9 STEERING STEM G F-0 FRONT FENDER G2

35 FRAME GROUP C6 F- FRONT FORK(XR25LEK/XR50LEK) G F-- FRONT FORK(XL25LEK) G5 F-2 FRONT BRAKE CALIPER H F- FRONT BRAKE PANEL H 2 F-4-0 FRONT WHEEL(XL25LEK) H F-4-20 FRONT WHEEL(XR25LEK/XR50LEK) H 4 F-8 REAR BRAKE PANEL H 6 F-9-0 REAR WHEEL H 7 F-2 FUEL TANK H 9 2

36 FRAME GROUP D F-2 SEAT H F-24 SIDE COVER H2 F-25 AIR CLEANER H F AIR SUCTION VALVE H5 F-27 EXHAUST MUFFLER I F-29 PEDAL I F-0 STEP I 4 F- STAND I 5 F-2 SWINGARM I 6

37 FRAME GROUP D 2 F- REAR CUSHION I 8 F-4 REAR FENDER I 9 F-5 WINKER I F-6 TAILLIGHT I2 F-7 BATTERY I F-8 WIRE HARNESS I4 F-9 FRAME BODY I5 F-48 TOOLS J F-49 CAUTION LABEL(XR25LEK/XR50LEK) J 2 4

38 FRAME GROUP D F-49- CAUTION LABEL(XL25LEK) J F-50 MARK/STRIPE J 4 5

39 E- CYLINDER HEAD COVER E L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 6

40 E-2 CYLINDER HEAD E 2 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 7

41 E-2 CYLINDER HEAD E 2 Part Serial 8

42 E- CAMSHAFT/VALVE E 4 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 9

43 E-4 CAM CHAIN/TENSIONER E 5 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 40

44 E-5 CYLINDER E 6 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 4

45 E-6 RIGHT CRANKCASE COVER E 7 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 42

46 E-8 CLUTCH E 8 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 4

47 E-9 STARTING CLUTCH E 9 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 44

48 E-0 LEFT CRANKCASE COVER E0 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 45

49 E- GENERATOR E L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 46

50 E- STARTER MOTOR E2 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 47

51 E-4 OIL PUMP E L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 48

52 E-5 CRANKCASE E4 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 49

53 E-6 CRANKSHAFT/PISTON(XR/XL25LEK) E5 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 50

54 E-6- CRANKSHAFT/PISTON(XR50LEK) E6 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 5

55 E-6- CRANKSHAFT/PISTON(XR50LEK) F 2 Part Serial 52

56 E-7 TRANSMISSION F 2 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 5

57 E-7 TRANSMISSION F (Relative ref. Number) L.O.N. F.R.T. 2 Part Serial 54

58 E-9 GEARSHIFT DRUM F 4 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 55

59 E-20 KICK STARTER SPINDLE F 5 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 56

60 E-22 CARBURETOR F 6 L.O.N. (Relative ref. Number) F.R.T. 2 Part Serial 57

61 E-22 CARBURETOR F 7 2 Part Serial 58

62 F- HEADLIGHT G L.O.N. (Relative ref. Number) F.R.T. Part Serial 59

63 F-2 METER G 2 L.O.N. (Relative ref. Number) F.R.T. Part Serial 60

64 F-2 METER G Part Serial 6

65 F- MIRROR G 4 L.O.N. (Relative ref. Number) F.R.T. Part Serial 62

66 F-4 HANDLE LEVER/SWITCH/CABLE(DISK BRAKE) L.O.N. G 5 (Relative ref. Number) F.R.T. Part Serial 6

67 F-4 HANDLE LEVER/SWITCH/CABLE(DISK BRAKE) G 6 Part Serial 64

68 F-4- HANDLE LEVER/SWITCH/CABLE(DRUM BRAKE) G 7 L.O.N. (Relative ref. Number) F.R.T. Part Serial 65

69 F-4- HANDLE LEVER/SWITCH/CABLE(DRUM BRAKE) G 8 Part Serial 66

70 F-5 FRONT BRAKE MASTER CYLINDER L.O.N. (Relative ref. Number) G 9 F.R.T. Part Serial 67

71 F-7 HANDLE PIPE/TOP BRIDGE G0 L.O.N. (Relative ref. Number) F.R.T. Part Serial 68

72 F-9 STEERING STEM G L.O.N. (Relative ref. Number) F.R.T. Part Serial 69

73 F-0 FRONT FENDER G2 L.O.N. (Relative ref. Number) F.R.T. Part Serial 70

74 F- FRONT FORK(XR25LEK/XR50LEK) L.O.N. (Relative ref. Number) G F.R.T. Part Serial 7

75 F- FRONT FORK(XR25LEK/XR50LEK) G4 Part Serial 72

76 F-- FRONT FORK(XL25LEK) G5 L.O.N. (Relative ref. Number) F.R.T. Part Serial 7

77 F-- FRONT FORK(XL25LEK) G6 Part Serial 74

78 F-2 FRONT BRAKE CALIPER H L.O.N. (Relative ref. Number) F.R.T. Part Serial 75

79 F- FRONT BRAKE PANEL H 2 L.O.N. (Relative ref. Number) F.R.T. Part Serial 76

80 F-4-0 FRONT WHEEL(XL25LEK) L.O.N. (Relative ref. Number) H F.R.T. Part Serial 77

81 F-4-20 FRONT WHEEL(XR25LEK/XR50LEK) H 4 L.O.N. (Relative ref. Number) F.R.T. Part Serial 78

82 F-4-20 FRONT WHEEL(XR25LEK/XR50LEK) H 5 Part Serial 79

83 F-8 REAR BRAKE PANEL H 6 L.O.N. (Relative ref. Number) F.R.T. Part Serial 80

84 F-9-0 REAR WHEEL L.O.N. (Relative ref. Number) H 7 F.R.T. Part Serial 8

85 F-9-0 REAR WHEEL H 8 Part Serial 82

86 F-2 FUEL TANK H 9 L.O.N. (Relative ref. Number) F.R.T. Part Serial 8

87 F-2 FUEL TANK H0 Part Serial 84

88 F-2 SEAT H L.O.N. (Relative ref. Number) F.R.T. Part Serial 85

89 F-24 SIDE COVER H2 L.O.N. (Relative ref. Number) F.R.T. Part Serial 86

90 F-25 AIR CLEANER H L.O.N. (Relative ref. Number) F.R.T. Part Serial 87

91 F-25 AIR CLEANER H4 Part Serial 88

92 F AIR SUCTION VALVE H5 L.O.N. (Relative ref. Number) F.R.T. Part Serial 89

93 F AIR SUCTION VALVE H6 Part Serial 90

94 F-27 EXHAUST MUFFLER I L.O.N. (Relative ref. Number) F.R.T. Part Serial 9

95 F-27 EXHAUST MUFFLER I 2 Part Serial 92

96 F-29 PEDAL I L.O.N. (Relative ref. Number) F.R.T. Part Serial 9

97 F-0 STEP I 4 L.O.N. (Relative ref. Number) F.R.T. Part Serial 94

98 F- STAND I 5 L.O.N. (Relative ref. Number) F.R.T. Part Serial 95

99 F-2 SWINGARM I 6 L.O.N. (Relative ref. Number) F.R.T. Part Serial 96

100 F-2 SWINGARM I 7 Part Serial 97

101 F- REAR CUSHION I 8 L.O.N. (Relative ref. Number) F.R.T. Part Serial 98

102 F-4 REAR FENDER I 9 L.O.N. (Relative ref. Number) F.R.T. Part Serial 99

103 F-4 REAR FENDER I0 Part Serial 00

104 F-5 WINKER I L.O.N. (Relative ref. Number) F.R.T. Part Serial 0

105 F-6 TAILLIGHT I2 L.O.N. (Relative ref. Number) F.R.T. Part Serial 02

106 F-7 BATTERY I L.O.N. (Relative ref. Number) F.R.T. Part Serial 0

107 F-8 WIRE HARNESS I4 L.O.N. (Relative ref. Number) F.R.T. Part Serial 04

108 F-9 FRAME BODY I5 L.O.N. (Relative ref. Number) F.R.T. Part Serial 05

109 F-9 FRAME BODY I6 Part Serial 06

110 F-48 TOOLS J L.O.N. (Relative ref. Number) F.R.T. Part Serial 07

111 F-49 CAUTION LABEL(XR25LEK/XR50LEK) L.O.N. J 2 (Relative ref. Number) F.R.T. Part Serial 08

112 F-49- CAUTION LABEL(XL25LEK) J L.O.N. (Relative ref. Number) F.R.T. Part Serial 09

113 F-50 MARK/STRIPE J 4 L.O.N. (Relative ref. Number) F.R.T. 0 Part Serial

114 F-50 MARK/STRIPE J 5 Part Serial

115 PART NO. INDEX K 4 2 Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page

116 PART NO. INDEX K 2 Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page 4

117 PART NO. INDEX K 4 4 Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page

118 PART NO. INDEX K 4 Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page 5 4

119 PART NO. INDEX K Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page Part Number Address Page

120 PART NAME INDEX L Part name Address Page Part name Address Page Part name Address Page 7 5

121 PART NAME INDEX L Part name Address Page Part name Address Page Part name Address Page

122 PART NAME INDEX L Part name Address Page Part name Address Page Part name Address Page 9 5

123 PART NAME INDEX L Part name Address Page Part name Address Page Part name Address Page

124 PART NAME INDEX L 5 Part name Address Page Part name Address Page Part name Address Page 2 5

125 PART NAME INDEX L Part name Address Page Part name Address Page Part name Address Page

126

127 FOREWORD INDEX 2 ENGINE GROUP FRAME GROUP 4 PART NUMBER INDEX 5 PART NAME INDEX

128 E Published by Honda Motor Co., Ltd. Printed in Japan