Honda TL 125 Motorcycle Owner's Manual

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IMPORTANT NOTICE
FIFA SAS SA SOA EEE EEE EA ESA LEA AAA EEE AAA EEES IIA IAS IIIIIIAA.ADATIIIIID ADA A
e FOR OFF THE ROAD USE ONLY.
This vehicle is designed and manufactured for off-
the-road use only. It does not comform to feddral
motor vehicle safety standards and operation on
public streets, roads, or highways is illegal.
e OPERATOR ONLY.
This motorcycle is designed and constructed as an
operator only model. The seating configuration
does not safely permit the carrying of a passenger.
e READ OWNER'S MANUAL CAREFULLY.
FILS SI ISLS ISLS ILL ELL ES LS SISSIES LLL SLL SESSILIS ILS SSSI LISTS LS LSS LLL ELSI SILLS ISLS ISLS SIS ILIS SSSI SEIS SS ISLS
11.
ALLLILLIDOLODODFICEELEEEDEEZDEEZ ETE: :O.:ZÓÓ:K)S
It is with great pleasure that we welcome
you as a new owner of the HONDA TL125.
Thank you for selecting a HONDA product.
The TL125 features a quiet engine and
light weight construction, and has been
designed for easy handling.
This Owner's Manual is a guide for the
proper operation and servicing of your
TL125. Read it thoroughly so that you
will be able to maintain your TL125 in the
best condition for the utmost in riding
pleasure.
Your HONDA dealer will provide you with
complete periodic inspection and is always
happy to give you assistance in case you
PREF ACE~
have any problem. We wish you many
miles of safe and happy riding.
In this manual statements preceded by the
following words are of special signifi-
cance:
“WARNING” means that there is the pos-
sibility of personal injury to yourself and
others.
“CAUTION” means that there is the pos-
sibility of damage to the vehicle.
“NOTE” indicates points of particular
interest for more efficient and convenient
operation.
We recommend that you take particular
notice of these items when reading this
manual.
A motorcycle is only as safe as its oper-
ator.
The safe rider will spend much time
learning to ride and developing his riding
skills in an uncongested off-road area free
of obstacles before venturing into areas
of varied terrain.
1.
Always obey local off-road riding laws
and regulations and show respect for
private property by obeying posted
signs.
Always preserve nature and watch for
fire hazards such as dry grass condi-
tions, etc.
Clean up trash and do not litter.
When off-road riding, ride in the
company of a friend on another motor-
cycle so that you can be of mutual as-
sistance to each other in the event of
trouble.
Remember to always wear protective
apparel including a safety helmet, eye
OFF-ROAD SAFETY:
protection, gloves, boots, and heavy
clothing.
Familiarity with your motorcycle is
critically important in off-road riding.
NEVER ride beyond your ability and
experience.
. Know the terrain on which you are
riding. Always ride so that your visi-
bility is sufficient to give adequate
warning of upcoming hazards.
NEVER ride faster than conditions
warrant.
Don’t modify your exhaust system. Re-
member that excessive noise antogo-
nizes everyone and creates a bad image
for motorcycles.
10. This motorcycle is not legally equipped
to be ridden on the highway. Re-
member to walk an off-road motorcycle
when crossing the public highways,
roads or streets.
CONTENTS
SERIAL NUMBER LOCATION. «i coc civ vs sso sss sss nmms vasnss §6sssseesses 6
CONTROL LOCATIONS : =5 ex mos re y mo me y 255 1 nave e ae y Y a mre fre snes gouges 7
OPERATING INSTRUCTIONS. .............eeeresconorocsnotareaceren.. 10
en SWIC ws sm où à om wiv à 08 à 00 à SR 5 515 & 518 В ОВ à A0 à RE à БЫ Дл В В НВ e A 10
He ¿ WIN - === à ge 1 00 à 0e В E vom € RE 5 NS RE NEE 10
Rear Shock Absorbers.............eeeeeeeerrcorooerocróereoereem.. 11
Document Compartment «à ar à ae à ane à 200 à A6 à 60 6 à à 4/0 à 50 3 UN | 07 # 558 & ВО e Une 12
FUEL AND OIL, 5 ее к wos wes вто 5 60 mes rula sa 20 ae 6 us ae « de « ace f eye ave à e y ene 13
Fuel Valve..........eeee.ececsocorecococrererereceoe ao nerecere en 13
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Engine Oil Recommendation. : se « ss i se s sms pw ss vies sw 310 ee e me: e fe ¢ oi 15
VisCOSIity........r_eoorrecorrraoacrroracorocaacrraaacrroo)acoorecraoa 15
PRE-RIDING INSPECTION. .......ñ.ññe..0e0mmasareavaranecareecoeanrec., 16
TIRE RECOMMENDATION io: коз в вв в соб обоя о ой вой в mss e a masa eee E a 17
STARTING THE ENGINE @ à в: к ва к это в вое e une 5 576 5 908 5 058 5.000 5.0/8 Ne | a als $0.8 #8 17
Starting a Cold Engine... sw. sus vos 5s s ve à eve a we PR о п в 9 TOO В 17
Starting in Extremely Cold Weather..............e_eoceceevecrororeroo 19
Starting a Warm Engine ¿== mes vea ves ss re à 100 § 916 § 9190 e HE № 19
RIDING THE MOTORCYCLE ................... 00000... .000coaroeooe e 20
BARKING 55.5005 5705 505 550 5155 0% § 300 5 505 rend wane omen wre $188 S006 SIETE MUA y META SIE € SID $ 22
TOOL KIT 25 eu maes mu me y me y Ub à 6578 à С В ОЙ В ой Se es eee ace vs e ANA: Y wide 3 23
MAINTENANCE SCHEDULE ................ee_eo0sso0orocacosacerecereo 24
MAINTENANCE OPERATIONS. ...............eoweoeroovcdoc0reaseacervoo 28
Engine JN LBV. seves as РУБЛ ras me REG SER HEN NELAR ESA 1 EN LES ama 28
Engine Oil Change...............oeeeesccosocoroccrnocoeecenecaroo 28
ON Filter Cleaning =: ==: == 5 565 5 5:6 6.5% 5.50 Soe wide somes muses y me ¿UA «NY a TUTO 30
ON Filter Rotor Cleaning . === «== à == 1 e are Dane 7575 570.6 576.3 578 5 516 À da one wi 30
Spark Plug Replacement and Adjustment................eeeeeeec... 31
Contact Breaker Point Gap Adjustment.............._.e_.eeocoroceoo 32
Ignition Timing Adjustment................e_er.ecercorccorocacoaro 33
Valve Tappet Clearance Adjustment. .............._...oooeoesccooco 34
Cam Chain Adjustment..............e_.eee0esrcororodorsoocoraorerero. 36
Air Cleaner Maintenance............ñoreorccoesoooonoceeocorecero 37
Spark Arrestor Maintenance .............ooereresoeccsoccssorocececa 38
Carburetor Adjustment. ............e_._e._eeesoscorocccecocorecveroroo 39
Throttle Cable Inspection..............ñ.e_m_ee0.eeeseccsrcesrccerenco, 40
Throttle Cable Adjustment................... 2... e. LL 41
Fuel Filter Maintenance. .................. e eooenoa anecoeec, 42
Clutch Adjustment ..................... e eeaaoooadarerie con, 43
Drive Chain Maintenance. .......................e=svsriei0rí.eea, 45
Front Brake Adjustment.....................00000 0. . .. hocecocooooo 48
Rear Brake Adjustment.................. 00000000000 euericioa, 49
Brake Wear Indicator:. - us em à are à 555 5 678 d'eux à ae ao na e mío e mala e 51
Front Suspension Inspection ..........e......0. 00000000 eaeneciceo, 52
Front Fork Oil Change ................000000 0 eechoeaoerecon 52
Rear Suspension Inspection... an aan 53
Front Wheel Removal ...............e.eooeeoccocorecoorbecaceoceaao 54
Rear Wheel Removal.................. ee rioeaaaoo a neneereoo 55
Headlight Beam Adjustmemt........................... [SA o 56
Headlight and Taillight Bulb Replacement.......................... 56
SPECIFICATIONS © vs cre cms 5m 5 505 5 515 5 506 8 50» so En 58
WIRING DIAGRAM. . oi 60
"MPA
The frame serial number © is stamped
on the left of the steering head. The
engine serial number © is located on
the lower left side of the engine. These
numbers are required when registering the
@ Frame serial number
6
motorcycle. Refer to the frame or engine
serial number when ordering replacement
parts to ensure that you will obtain the
correct parts for your model series.
@ Engine serial number
© Front brake lever ® Rear brake pedal switch
® Throttle grip ® Foot peg ® Headlight switch
® Ignition switch @ Clutch lever © Fuel tank cap
O Kick starter pedal Headlight dimmer @ Gear change pedal
O Fuel valve
O Choke lever
1
® Gear change pedal
O Drive chain adjuster
O Drive chain adjuster O Rear brake pedal ® Kick starter pedal
ssn QPERATING INSTRUCTIONS ee
Ignition Switch _
The three position ignition switch @ is
located on center of the handlebar. In
the “RUN” position (center) the ignition
circuit is complete and the engine oper-
ates. In the “OFF” position (either side
of center) the ignition circuit is open and
the engine will not operate.
(O) Ignition switch
10
Headlight Switch
The headlight switch © and the headlight
dimmer switch O) are located at the left
handlebar grip.
Move the headlight switch O up to turn
the headlight and taillight on, and down
to turn off.
Move the headlight dimmer switch © to
the “Hi” position to select high beam and
to the “Lo” position to select low beam.
The lights will only operate when engine
is running.
@ Headlight switch
@ Headlight dimmer switch
Rear Shock Absorbers
The rear shock absorbers @ are adjustable
in five increments to meet different road
or riding conditions.
Position | is suitable for smooth roads
and light rider weight. Shock absorber
spring tension should be increased to
prevent the rear suspension from bottom-
ing when heavily laden or when traveling
on rougher roads.
Shock absorber spring tension is progres-
© Rear shock absorber |
sively increased by turning the adjuster
to position Il, III, IV, or V.
Use a pin spanner @ to adjust the rear
shock absorbers. Be certain to adjust both
right and left shock absorbers to identical
positions.
@ Pin spanner
11
Document Compartment
A vinyl bag is attached to the inside of
the left side cover for storing an owner's
manual and/or other documents.
When washing the motorcycle, take care
not to direct a blast of water over this
area.
12
5”
@ Vinyl bag
Fuel Valve
The fuel valve is mounted under the left
side of the fuel-tank.
“OFF” position:
When the fuel valve lever () is turned to
the “OFF” position, fuel cannot flow from
the fuel tank to the carburetor. Set the
valve in this position whenever the motor-
cycle is not in use.
“ON” position:
When the fuel valve lever is turned to
the “ON” position, fuel will flow from
the main fuel supply to the carburetor.
Set the valve in this position when the
engine is to be operated from the main
fuel supply.
“RES” position:
When the fuel valve lever is turned to
the “RES” position fuel will flow from the
reserve . fuel supply to the carburetor.
The fuel valve lever should be set in this
position only after the main fuel supply
has been consumed. The reserve fuel
supply is 0.57 (0.13 U.S. gal:). Switching to
the reserve fuel supply serves as a warning
to the rider that it is time to refill the
fuel tank.
NOTE: Do not operate the machine with
the fuel valve in the reserve position after
refuelling, or you will defeat the purpose
of the reserve fuel supply.
® Fuel valve lever
13
Fuel Tank
Fuel tank capacity is 4.5¢ (1.19U.S. gal.)
including 0.54 (0.13 U.S. gal.) in the reserve
supply. The fuel tank cap O) is removed
by twisting counterclockwise. Use low-
lead or regular gasoline with a Research
Octane number of 91 or higher, or a
Pump Octane number of 86 or higher.
When refueling, take care to exclude dirt,
water or other contaminants from the fuel
tank.
NOTE: Pump Octane is the octane for-
mula specified by the Cost of Living
Council.
WARNING:
* Gasoline is extremely flammable and is
explosive under certain conditions.
Refuel in a well ventilated area with
engine stopped. Do not smoke or allow
open flames or sparks in the area where
the motorcycle is refueled or where
gasoline is stored.
14
* Do not overfill the tank (there should
be no fuel in the filler neck). After
refueling, make sure the filler cap is
closed securely.
* Gasoline is harmful or fatal is swallowed.
Avoid repeated or prolonged contact
with skin or breathing of vapor. Keep
out of reach of children. If gasoline
is swallowed, do not induce vomiting.
Call a physician immediately.
® Fuel tank cap
Engine Oil Recommendation
Use only high detergent, premium quality
motor oil certified to meet or exceed US
automobile manufacturer's requirements
for Service Classification SE. Motor oils
intended for Service SE will show this
designation on the container.
The regular use of special oil additives is
unnecessary and will only increase operat-
ing expenses.
Engine oil should be changed at the inter-
vals prescribed in the maintenance sched-
ule on page 25.
CAUTION: Engine oil is a major factor
affecting the performance and service life
of the engine. Non-detergent and low
quality oils are specifically not recom-
mended.
Viscosity
Viscosity selection should be based on the
average atmospheric temperature in your
riding area. Change to the proper viscos-
ity oil whenever the average atmospheric
temperature changes substantially.
Recommended oil viscosity:
General, all temperatures
SAE 10W-30 or SAE 10W-40
Alternate:
Above 59°F SAE 30
32° to 59°F SAE 20 or 20W
Below 32°F SAE 10W
15
WARNING:
Take care not to let water enter the muf-
fler or the brake system when washing
the motorcycle. Water in the muffler may
cause poor starting and wet brakes may
reduce brake efficiency.
At the start of each riding day, perform
a general inspection to be certain the
motorcycle is in good, safe operating con-
dition. This inspection will require only
a few minutes and can save you much
time and expense in the long run. Check
the following items and adjust or service
if necessary. Refer to the appropriate
section of this manual for detailed main-
tenance instructions.
1. ENGINE OIL LEVEL—Measure oil level
and add oil if necessary (page 28).
2. FUEL—Check fuel level and fill tank if
low (page 13).
16
~PRE-RIDING INSPECTION
4. TIRE PRESSURE—Check with a
3. BRAKES—Check operation of front and
rear brakes. Adjust free play if neces-
sary (pages 48~50).
tire
pressure gauge (page 17).
5. DRIVE CHAIN—Check condition of
chain and measure chain slack. Adjust
if drive chain tension is incorrect.
Lubricate if drive chain appears dry.
Replace if drive chain is badly worn or
damaged (pages 45~47).
6. THROTTLE—Check throttle operation in
all steering positions. Adjust, if free
play is incorrect. Replace or correct
cable routing if throttle does not
operate freely in all steering positions
(page 40).
wn TIRE RECOMMENDATION vss
Check tire pressure frequently, and main-
tain pressure within a range of 0.5~1.5
kg/cm? (7~21 psi), which will provide the
best handling characteristics and traction
for your riding conditions.
WARNING:
* Improper tire inflation will cause ab-
normal tread wear or other damage and
create a safety hazard.
* Check tire pressures frequently and ad-
just if necessary.
* It is recommended that the tires are
replaced when the tread depth at the
center of the tire is less than 3mm
(0.12 in.).
* Operation with excessively worn tires
is very hazardous and will adversely
affect traction, steering and handling.
wire STARTING THE ENGINE
WARNING: Ensure that the transmission
is in neutral before starting the motor-
cycle. Attempting to start the engine with
the transmission in gear might result in
injury to the rider or damage to the
motorcycle.
Starting a Cold Engine
1. Turn the fuel valve to the “ON” posi-
tion (page 13)
o Choke lever
17
Turn the ignition switch to the “RUN”
position (page 10).
Raise the choke lever to the fully closed
position O.
Shift the transmission into neutral (the
engine can be started in gear with the
clutch disengaged, but it is recom-
mended that starting be performed in
neutral.).
Unhook the foot peg holding spring ©
from its anchor pin @ on the right rear
fork, and hook the spring to the right
ÿ
foot peg ©. The right foot peg must
be raised to allow full kick starter travel
(limited kick starter travel, with foot
peg down, is sufficient when restarting
a warm engine).
6. Open the throttle about ‘/s turn, and
operate the kick starter with the right
foot, starting from the top of the stroke
and following through to the bottom
with a rapid and continuous kick.
Operate several times until engine
starts.
CAUTION: Do not allow the kick starter
to snap back freely against the pedal stop
as engine case damage could result.
If the engine fails to start after several
repeated attempts, it may have become
flooded with excess fuel. To clear
the engine, turn off the ignition switch
and lower the choke lever to the full
open position ®, open the throttle fully
and crank the engine several times
using the kick starter pedal.
After the cylinder has been cleared of
O Anchor pin | ym Eas ‚
@ Foot peg holding spring @ Right foot peg excess fuel turn the ignition switch to
18.
the “RUN” position, and follow the
starting procedure outlined in steps 1
through 4; however, at this time the
use of the choke is not necessary.
7. After starting, warm up the engine until
the engine properly responds to the
throttle with the choke fully open (lever
down).
8. Unhook the foot peg holding spring
from the right foot peg, and hook it
on the rear fork anchor pin.
Starting in Extremely Cold Weather
Prime the engine before starting by crank-
ing several times with the kick starter
pedal. The ignition switch should be
“OFF”, the choke fully closed (raised up)
and the throttle opened slightly. Follow
with the starting procedure for a cold
engine.
Starting a Warm Engine
When the engine is to be re-started while
still warm, proceed with cold engine
starting procedure; however, do not use
the choke. Limited kick starter travel, with
foot peg down, is usually sufficient for
starting a warm engine. If the engine
fails to start, follow the same procedures
as for the cold engine starting given above.
WARNING: Exhaust contains poisonous
carbon monoxide gas. Avoid inhalation
of exhaust gases. Never run the engine
in a closed garage or confined area.
SIS I La BR E AK-IN PROCEDURE YILEDLIDID.
During the first week of operation, operate
your new TL125 so the engine neither
pulls: laboriously nor exceeds 80% of the
maximum rpm in any gear. Avoid full
throttle operation, and select your gear
changes to spare the engine undue stress.
Careful break-in operation during the
initial mileage will measurably extend the
service life of the engine.
19
CEPI PPPPPP PFET
WARNING:
+ Exhaust pipe and muffler become very
hot during operation and remain suffi-
ciently hot to inflict burns if touched,
even after shutting off the engine. Wear
clothing which will completely cover
the legs while riding and avoid any
contact with unshielded portions of the
exhaust system.
- Do not wear loose clothing which may
catch on control levers, kick starter, foot
pegs, drive chain, wheels, and tires.
1. After the engine has been warmed up,
the motorcycle is ready for riding.
2. While the engine is idling, pull in the
clutch lever and depress the gear
change pedal to shift into low (1st)
gear.
WARNING: Ensure that the side stand is
fully retracted before riding the motor-
cycle. Failure to retract the stand may
20
«RIDING THE MOTORCYCLE ~~
interfere with an attempted left turn and
cause serious control problems.
3. Slowly release the clutch lever and at
the same time gradually increase engine
speed by opening the throttle ; coordi-
nation of the throttle and clutch lever
will assure a smooth start.
4. When the motorcycle attains a moder-
ate speed, close the throttle, pull in
the clutch lever and shift to 2nd gear
by raising the gear change pedal.
CAUTION: When changing gears, the
clutch must be disengaged and the throttle
momentarily closed to avoid over-revving
the engine and over-stressing the drive
train components.
5. This sequence is repeated to progres-
sively shift to 3rd, 4th and 5th gear.
6. When decelerating the motorcycle,
coordination of the throttle and the
front and rear brakes is important.
will, under most conditions, assure
good control and stability during de-
celeration. As speed is reduced, it is
common practice to downshift the
transmission into the gear appropriate
for the speed of the motorcycle. This
assures maximum control through bet-
ter braking effectiveness and better
acceleration when necessary.
The smooth gradual application of both
the front and rear brakes together
with the required throttle coordination
Shifting pattern
8. For maximum deceleration and braking
close the throttle, apply both the front
and rear brakes simultaneously, and as
the motorcycle comes to a stop, disen-
gage the clutch. This maneuver re-
quires smooth coordination of the
controls.
Both front and rear brakes should be
applied equally. Independent use of
only the front or rear brake reduces
stopping performance. Excessive brake
application may cause either wheel to
lock, reducing control of the motorcycle.
Avoid locking the wheels. If excessive
brake application causes either wheel
to lock, reduce applied pressure on
the brake pedal or lever
WARNING:
- When riding on wet terrain or when
riding in rainy conditions, the frictional
contact between the tires and the road
is greatly reduced, therefore extreme
caution should be exercised during
2]
operation including braking, accelera-
tion and turning.
* When descending a steep grade, down-
shift and use engine compression to-
gether with intermittent applications of
both brakes to slow the motorcycle
down. Avoid continuous use of the
brakes which may result in overheating
and reduction of braking efficiency.
CAUTION: Donot coast for a long dis-
tance with the engine off, and do not tow
the motorcycle a long distance. Even with
gears in neutral, the transmission is only
properly lubricated when the engine is
running. Inadequate lubrication may dam-
age the transmission.
22
WARNING: Park the motorcycle on firm,
level ground. Failure to do so could re-
sult in injury or damage to the machine.
When parking the motorcycle, turn the
ignition switch to the “OFF” position.
Turn the fuel valve to the “OFF” position.
y9100000000000000000000000000007 » TOOL KIT 77727777
The tool kit O is located in a compart- Listed below are the items included in the
ment in the center of the motorcycle tool kit.
directly behind the left side cover. Minor + Spark plug wrench
adjustment and parts replacement can be « Wrench handle
performed with the tools contained in the - 24 mm wrench: for oil filter cap re-
kit. Adjustments or repairs which cannot moval
be performed with the tools in the kit - 10mm box wrench: for air filter element
should be performed by your HONDA removal
dealer. | * No. 3 Phillips screwdriver
- Handle grip: for screwdriver
+ Tool bag
(1) Tool kit
23
The maintenance intervals shown in the
following schedule are based upon average
riding conditions. Machines subjected to
severe use, or ridden in unusually dusty
areas, require more frequent servicing.
Items marked* should be serviced by an
authorized Honda dealer, unless the owner
has proper tools and is mechanically pro-
ficient.
Other maintenance items are simple to
24
perform and may be serviced by the
owner.
CAUTION: To maintain the safety and
reliability of your HONDA motorcycle,
do not modify the motorcycle and use
genuine HONDA parts when servicing or
repairing. The use of other replacement
parts which are not of equivalent quality
may impair the operation of your motor-
cycle.
INITIAL
SERVICE
PERIOD
FIRST WEEK
OF
OPERATION
NOTE
Change front
fork fluid
initially after
30 operating
days and once
a year
thereafter
® ENGINE OIL—Change.
e*CONTACT POINTS AND IGNI-
TION TIMING—Clean, check,
and adjust or replace if neces-
sary.
@*VALVE TAPPET CLEARANCE—
Check and adjust if necessary.
e*CAM CHAIN TENSION—Adjust.
@*CARBURETOR—Check and ad-
just if necessary.
OPERATION—
Check and ad-
® THROTTLE
Inspect cable.
just free play.
e*CLUTCH—-—Check operation and
adjust if necessary.
® DRIVE CHAIN—Check, lubri-
cate, and adjust if necessary.
® BRAKE CONTROL LINKAGE—
Check linkage and adjust if
necessary.
e*WHEELS, RIMS, AND SPOKES—
Check. Tighten spokes and true
wheels if necessary.
e TIRES—Inspect and check air
pressure.
e FRONT
and refill.
e FRONT AND REAR SUSPEN-
SION—Check operation.
® ALL NUTS, BOLTS, AND OTHER
FASTENERS—Check security and
tighten if necessary.
FORK FLUID—Drain
25
REGULAR
SERVICE
PERIOD
EVERY
30
OPERATING
DAYS
NOTE
Change oil
every 30
operating days
or
every 3 months,
whichever
occurs first.
® ENGINE OIL—Change.
® SPARK PLUG—Clean and adjust
gap, or replace if necessary.
e*CONTACT POINTS AND IGNI-
TION TIMING—Clean, check,
and adjust or replace if neces-
sary.
e*VALVE TAPPET CLEARANCE—
Check and adjust if necessary.
e POLYURETHANE FOAM AIR
FILTER ELEMENT—Clean and oil.
Service more frequently if oper-
ated in dusty areas.
® SPARK ARRESTOR—Purge
@*CARBURETOR—Check and ad-
just it necessary.
@*CAM CHAIN TENSION—Adjust
® THROTTLE OPERATION—
Inspect cable. Check and ad-
just free play.
e*CLUTCH—Check operation and
adjust if necessary.
e DRIVE CHAIN—Check, lubri-
cate, and adjust if necessary.
e BRAKE CONTROL LINKAGE—
Check linkage and adjust if
necessary.
e*WHEELS, RIMS, AND SPOKES—
Check. Tighten spokes and tire
wheels if necessary.
e TIRES—Inspect and check air
pressure.
e FRONT AND REAR SUSPEN-
SION—Check operation.
® REAR FORK BUSHING—Check
for excessive looseness.
® SIDE STAND—Check installa-
tion, operation, deformation,
damage and wear.
® ALL NUTS, BOLTS, AND OTHER
FASTENERS—Check security and
tighten if necessary.
26
EVERY YEAR
e*CENTRIFUGAL OIL FILTER—Clean.
® OIL FILTER SCREEN—Clean.
e FUEL FILTER SCREEN—Clean.
e FUEL LINE—Check.
e*BRAKE SHOES—Inspect and replace if worn.
® FRONT FORK FLUID—Drain and refill.
e*STEERING HEAD BEARINGS—Adjust.
27
mer 177 MAINTENANCE OPERATIONS гонт comes
Engine Oil Level
Check engine oil level at the start of each and the oil filler cap touching the surface
day the motorcycle is to be operated. of the filler opening but not screwed in.
The oil filler cap © is located on the right
crankcase cover and contains a dipstick @ Engine Oil Change
for measuring oil level. Oil level must be Engine oil should be changed in accord-
maintained between the upper ® and ance with the maintenance schedule on
lower © oil level marks on the dipstick. page 25~27. Use only motor oil of the
Oil level must be checked with the motor- grade and viscosity recommended on page
cycle standing upright on level ground 14. When changing oil, drain the used oil
OA
© Oil filler cap _
28
O Dipstick O Upper oil level mark @ Lower oil level mark
from the crankcase while the engine is
warm. This will ensure complete and
rapid draining.
1.
2.
Remove the oil filler cap © (page 28)
from the right crankcase cover.
Place an oil drain pan under the engine
to catch the oil, and then remove the
oil filter cap © with a 24mm wrench
provided in the tool kit.
After the oil stops draining from the
crankcase, operate the kick starter
several times to drain any oil which
may be left in the engine.
When the oil has been completely
drained, reinstall the oil filter cap mak-
ing sure that the “O” ring seal used
on the cap is in good condition.
Thoroughly clean dirt and dust off the
oil filter cap threads and tighten the
filter cap properly.
Fill the crankcase through the oil filler
orifice with approximately 1.08 (1.1
U.S. gt.) of recommended grade oil.
Make sure that the oil level is between
the upper O and lower O oil level
marks (page 28).
CAUTION:
- Check the oil level frequently.
- If the oil level is below the lower level
mark on the dipstick, fill to the upper
level mark before operating the engine.
- When operating the motorcycle in un-
usually dusty conditions, the oil changes
must be performed at more frequent
intervals than those specified in the
maintenance schedule.
o | ой filter cap
29
Oil Filter Cleaning
Engine oil from the crankcase sump flows
through a metal filter screen and is pump-
ed through a centrifugal oil filter to engine
components. The filtering process purifies
the oil to minimize engine wear. Both
filters should be cleaned yearly to ensure
efficient operation.
1. Drain the engine oil (page 29).
2. Remove the filter screen O and spring
O and wash them in clean solvent, and
then reinstall.
O Filter screen © Spring |
30
Oil Filter Rotor Cleaning
1. Drain the engine oil.
2. Remove the kick starter pedal.
3. Disconnect the clutch cable from the
clutch lever.
4. Remove the right crankcase cover.
5. Remove the oil filter rotor cover.
6. Clean any sludge from the center of
the oil filter rotor @. Reassemble the
filter.
@ Oil filter rotor cover e) Oil filter rotor
Spark Plug Replacement and
Adjustment
The standard spark plug for this model is
the NGK D8ES-L or the ND X24ES.
Be sure to clean mud and sand from
around the spark plug before removing it.
1. Detach the spark plug lead and remove
the spark plug with the spark plug
wrench provided in the tool kit.
2. Inspect the electrodes and center por-
celain of the spark plug for deposits,
eroded electrodes, or carbon fouling.
If the spark plug deposits are heavy,
or the electrodes appear to be eroded
excessively, replace the spark plug with
a new one. If the spark plug is carbon
or wet fouled, the plug can sometimes
be cleaned with a stiff wire brush.
3. Adjust the spark plug gap © to 0.6-0.7
mm (0.024-0.028in.). The gap can be
measured with a wire gauge. The
adjustment is made by bending the side
(grounded) electrode @.
® Spark plug gap
@ Side electrode
Before installing the spark plug, clean
any oil or dirt from the spark plug seat
in the cylinder head.
Install the spark plug by hand until
finger tight. Then use the spark plug
wrench to tighten the plug an additional
1/2 to 3/4 turn or until the sealing
gasket is compressed.
CAUTION:
+ Spark plug must be securely tightened.
31
An improperly tightened plug can be-
come very hot and possibly cause
damage to the engine.
* Never use a spark plug with a heat
range that is not recommended for this
motorcycle.
* Do not attempt to dry or remove soot
from the spark plug by burning the tip.
Contact Breaker Point Gap
Adjustment
1. Remove the index mark cover D and
generator rotor cover ©.
2. Remove the point cover.
© Index mark cover
@ Generator rotor cover
32
“® Contact breaker points
@ Contact braker locking screws
® Contact breaker plate
Open the contact breaker points ®
with your finger or small screw driver
blade and check for pitting. If pitted or
burned, the points should be replaced
and the condenser checked. A gray
discoloration is normal and can be re-
moved with a point file. Filing should
be done carefully and kept to a mini-
mum. Clean the point contacts after
filing with a clean piece of unwaxed
paper such as a business card.
Rotate the generator rotor counterclock-
wise to find the point where the breaker
point gap is at maximum and check
=
with a feeler gauge.
The standard gap is 0.3~0.4 mm (0.012
Ignition Timing Adjustment
Do not perform this operation until point
gaps have been adjusted.
—0.016 in.). 1. Rotate the generator rotor fixing bolt
5. When adjustment is necessary, loosen O in the counterclockwise direction
the contact breaker plate locking screws and align the “F” mark O with the index
O and move the contact breaker plate mark ©. At this time, the contact
®to achieve correct gap. When proper- breaker points should just start to open.
ly gapped, retighten the locking screws. 2. To adjust the timing loosen the two
base plate locking screws @ and move
‘ ® Generator
@ “F” mark
rotor fixing bolt
® Index mark
@ Base plate locking screws
6) Breaker base plate
33
the contact breaker base plate ®. Mov-
ing the plate in the clockwise direction
will advance the timing.
3. After performing the ignition timing
adjustment, recheck the contact breaker
point gap ® (refer to page 32) to be
sure that it has not changed.
Static ignition timing is relatively accu-
rate and will give satisfactory engine
performance; however, the use of a
stroboscopic timing light will provide
more precise timing. y
When using the stroboscopic timing
light to check the timing, idle the engine
at 1,300 rpm'
Perform the adjustment in the same
manner as described above.
CAUTION: This ignition timing adjust-
ment procedure must be made with care
as advanced or retarded timing may cause
engine damage. For best results, consult
your Honda Dealer.
34
Valve Tappet Clearance Adjustment
Excessive valve tappet clearance will cause
tappet noise, and little or no clearance
will cause valve damage and loss of power.
Therefore, valve tappet clearance should
be properly maintained.
NOTE: The checking or adjusting of the
tappet clearance should be performed
while the engine is cold. The clearance
may tend to increase as the temperature
rises.
1. Turn the fuel valve lever to “OFF”
position and remove the fuel tank.
@ cope mark ©) Index mark
2. Remove the index and generator rotor
covers as shown on page 32.
Remove the tappet adjusting hole caps.
Rotate the generator rotor counter-
clockwise until the “T” mark © on the
generator rotor lines up with the index
mark O on the left crankcase cover.
In this position, the piston may be
either on the compression or the ex-
haust stroke.
The adjustment is made with the piston
at the top of the compression stroke
when both the intake and exhaust
valves are closed. This condition can be
determined by moving the tappets with
the fingers through the tappet adjusting
holes. If the tappets are free, it is an
indication that the valves are closed
and that the piston is on the compres-
sion stroke. If the tappets are tight
and the valves are open, rotate the
generator rotor 360% and realign the
“T” mark to the timing index mark.
Check the clearance of both valves by
inserting a 0.05 тт (0.002 in.) feeler
gauge between the adjusting screw and
the valve stem.
If it is necessary to make an adjust-
ment, loosen the adjusting screw lock
nut ® and turn the adjusting screw Y
so that the valve clearance offers slight
resistance when the feeler gauge ® is
inserted. After completing the adjust-
ment, tighten the adjusting screw lock
nut while holding the adjusting screw
to prevent it from turning. Finally,
recheck the clearance to make sure that
the adjustment has not been disturbed.
@® Adjusting screw
Cam Chain Adjustment
If the cam chain is excessively noisy during
engine operation, the tension of the cam
chain is improper and requires adjustment.
1. Start the engine and set the idling
speed to 1,300rpm.
2. Remove the rubber cap and loosen the
cam chain adjuster O (not the 6mm
sealing bolt @). This will automatically
apply the proper tension to the cam
chain.
3. After completing the adjustment, tighten
the adjuster securely.
a) Cam chain adjuster
@ 6 mm sealing bolt
36
Air Cleaner Maintenance
If the air cleaner is clogged, it affects engine
performance and, therefore, should be
cleaned periodically.
1.
2.
® Air filter mounting nuts @) Air filter case
Remove the right side cover.
Unscrew the three air cleaner mounting
nuts D with the 10mm box wrench
contained in the tool kit and remove
the air cleaner case O.
Remove the air cleaner element ® from
the case.
Wash the air cleaner element in clean
stoddard solvent and allow to dry
thoroughly.
5. Soak the air cleaner element in clean
gear oil (SAE 80-SAE 90) until saturated
then squeeze out excess oil.
6. Reinstall the air cleaner element.
7. Reinstall the right side cover
WARNING: Gasoline or low flash point
solvents are explosive and highly flam-
mable and must not be used to clean the
air cleaner element. Fire or explosion
could result.
"® Polyurethane foam air filter element
37
Spark Arrestor Maintenance
The exhaust system spark arrestor must
be purged of accumlated carbon periodi-
cally.
1. Remove the spark arrestor mounting
bolt O.
2. Remove the spark arrestor from the
muffler outlet.
3. Start the engine and purge accumulated
carbon from the muffler by moment-
arily revving up the engine.
@® Mounting bolt
38
4. Clean the spark arrestor of carbon.
5. Stop the engine and reinstall the spark
arrestor and mounting bolt.
WARNING:
- Do not perform this operation immedi-
ately after the engine has been run
because the exhaust system becomes
very hot.
Because of the increased fire hazard
ensure that there are no combustible
materials in the area when purging the
spark arrestor.
Exhaust gases contain poisonous carbon
monoxide. Perform this operation only
in a well ventilated area.
- Wear eye protection.
Carburetor Adjustment
NOTE: Before making adjustments to the
carburetor, be sure the ignition system is
functioning properly and the engine has
good compression. Do not attempt to
compensate for other faults by carburetor
adjustment.
The carburetor should be adjusted only
after the engine has attained operating
temperature.
1. Adjust the idle speed screw © until
the engine idles at approximately 1,300
R.P.M. Turn the idle speed screw clock-
wise to increase idle speed or counter-
clockwise to decrease idle speed.
2. Turn the air screw ® clockwise until
you hear the engine miss or decrease
in speed, then counterclockwise until
the engine again misses or decreases in
speed. Set the air screw exactly between
these two extreme positions. Turning
the air screw clockwise creates a richer
fuel mixture, while turning the air screw
O) Idle speed screw
counterclockwise creates a leaner fuel
mixture. Usually the correct setting
(between extremes of richness and
leanness)will be found to be 11/14 turns
open from a fully closed position.
If idle speed changes after adjusting
fuel mixture, readjust the idle speed
screw.
O) Air screw
39
Throttle Cable Inspection
WARNING: For safe operation and posi-
tive engine response, the throttle cable
must be properly adjusted.
Check for smooth rotation of the throttle
grip from the fully open to the fully closed
position. Check both when at full left
and full right steering positions. Inspect
the condition of throttle cable © from the
throttle grip down to the carburetor. If
the cable is kinked, chafed or improperly
routed, it shoud be replaced and/or re-
routed. Recheck cable for tension or
stress at both full left and full right steer-
ing positions.
@ Throttle cable
40
Throttle Cable Adjustment
Standard throttle grip free play is approx-
imately 10-15° of grip rotation. This free
play can be adjusted at the grip free
play upper adjuster © and also with the
grip free play lower adjuster ®. Major
free play adjustments are made with the
lower adjuster ® (after replacing a throttle
cable or removing the carburetor). Minor
free play adjustments are made with the
Grip free play upper adjuster @ Lock nut
upper adjuster D. To adjust free play,
loosen the lock nut and turn the adjuster.
Tighten the lock nut after adjustment.
Check for smooth rotation and closing
tension of the throttle grip in all steering
positions.
Inspect the throttle cable for kinks, chaf-
ing or improper routing.
(3) Grip free play lower adjuster
41
Fuel Filter Maintenance
The fuel filter is incorporated in the fuel 2. Unscrew the fuel filter cap ©. Wipe
valve which is mounted on the bottom all sediment from the inside of the cap.
of the fuel tank at the left side. Accumu- 3. Remove the “O” ring seal © and the
lation of dirt in the filter will restrict the filter screen O. Clean the filter screen.
flow of the fuel and cause the carburetor 4. Reinstall the filter screen, “O” ring,
to malfunction, therefore, the fuel filter and cap.
should be serviced periodically. 5. Turn the fuel valve lever to the “ON”
1. Turn the fuel valve lever © to the position and check for leakage at the
“OFF” position. filter cap.
ee
(1) Fuel valve lever
42
® Fuel filter cap | ® Filter screen
O) “0” ring seal
Clutch Adjustment
The clutch should be adjusted so that
operating the clutch lever completely dis-
engages the transmission from the engine.
If the clutch does not completely diseng-
age, the engine will stall when shifting,
or the motorcycle will have the tendency
to creep even with the clutch disengaged.
On the other hand, if the clutch does not
fully engage, the clutch will slip, and the
motorcycle will not accelerate in response
to the acceleration of the engine. In order
for full engine output to be delivered to
the rear wheel, it is necessary to have the
clutch properly adjusted.
1. The normal clutch lever D free play is
10~20 mm (0.4~0.8 in.) at the lever end
before the clutch starts to disengage.
2. Clutch lever free play can be adjusted
at either end of the clutch cable. Major
adjustments (after replacing the clutch
cable) should be made at the lower
adjuster ® (page 44).
Minor adjustment should be made at
the upper adjuster ® (page 44).
The adjustment procedure is similar
for using either the upper or lower
adjuster
® Clutch lever @ Clutch lever free play |
43
Loosen the lock nut (® lower or ®
upper), turn the adjuster (® lower or
® upper) to provide the correct clutch
lever free play, then retighten the
adjuster. Turning the adjuster in direc-
tion @ will decrease free play and
turning the adjuster in the opposite
direction will increase free play.
After the adjustment has been made,
check to see that the clutch is not
he
slipping or that the clutch is properly
disengaging according to the following
procedure. After the engine starts, pull
in the clutch lever and shift into gear,
and make sure that the engine does
not stall, nor the motorcycle start to
creep. Gradually release the clutch
lever and open the throttle, the motor-
cycle should start smoothly and accel-
erate gradually.
® Clutch cable lower adjuster a Lock nut (5) Lock nut © Clutch cable upper adjuster
44
Drive Chain Maintenance
Proper tensioning and lubrication will
help to extend the service life of the
drive chain and ensure smooth power
transmission to the rear wheel. Under
severe usage, or when the motorcycle is
ridden in unusually dusty areas, more
frequent maintenance is necessary.
Tension Adjustment:
1. Place the motorcycle on a support
block to raise the rear wheel off the
ground. Shift the transmission into
neutral.
2. Check vertical movement of the lower
length of the drive chain at a point
midway between the sprockets. Move
the chain up and down with your
fingers and observe the amount of
slack. Drive chain tension should be
adjusted to allow approximately 20 mm
vertical movement at this point.
Rotate the rear wheel and check drive
chain tension throughout its length.
® Drive chain
Drive chain tesion should remain con-
stant as the wheel is rotated.
If the chain is found to be slack in
one segment of its length and taut in
another, this indicates that some of
the links are either worn or kinked
and binding. Kinking and binding can
frequently be eliminated by lubrication.
45
3. If the drive chain is found to require
adjustment, proceed as follows:
a. Remove the cotter pin @.
b. Loosen the rear axle nut ®.
c. Pull back on the rear wheel, and
turn the left drive chain adjuster ©
to a setting which will produce 20
mm of drive chain slack. Turn the
right drive chain adjuster to the
same setting.
d. With both adjusters seated firmly
against their stopper pins ®, tighten
the rear axle nut, and secure the
nut with a new cotter pin.
e. Recheck drive chain slack.
f. Rear brake pedal free play is
affected when repositioning the rear
wheel to adjust drive chain slack.
Check rear brake pedal free play
and adjust as necessary (page 49~
50).
CAuTION: Always
pins with new ones.
46
replace used cotter
Lubrication:
Commercially prepared drive chain lubri-
cants may be purchased at most motor-
cycle shops and should be used in prefer-
ence to motor oil or other lubricants.
Saturate each chain link joint so that the
lubricant will penetrate the space between
adjacent surfaces of link plates and rollers.
Removal and Cleaning:
When the drive chain becomes extremely
dirty, it should be removed and cleaned
prior to lubrication.
——
@ Drive chain adjuster
® Adjuster stopper pin
@ Cotter pin
3 Rear axle nut
Carefully remove the master link re-
taining clip with pliers. Do not bend
or twist the clip. Remove the master
link. Remove the drive chain from the
motorcycle.
Clean the drive chain in solvent and
allow to dry. Inspect the drive chain
for possible wear or damage. Replace
any chain that has damaged rollers,
loose fitting links, or otherwise appears
unserviceable.
Inspect the sprocket teeth for possible
wear or damage. Replace if necessary.
Never use a new drive chain on badly
worn sprockets. Both chain and
sprockets must be in good condition,
or the new replacement chain or
sprocket will wear rapidly.
Lubricate the drive chain.
Install the master link retaining clip ®
so that the closed end of the clip will
face the direction of forward wheel
rotation.
The master link is the most critical
part affecting the security of the drive
chain. It is recommended that a new
master link be installed whenever
the drive chain is reassembled.
6. Adjust the drive chain to the proper
tension, following the instructions on
page 46.
CAUTION: Never install a new drive
chain on badly worn sprockets, or use
new sprockets with a badly worn drive
chain. Both chain and sprockets must be
in good condition, or the new replace-
ment chain or sprocket will wear rapidly.
® Retaining clip
47
Front Brake Adjustment
1.
Raise the front wheel off the ground
by placing a support block under the
engine, spin the front wheel by hand
and measure the distance the front
brake lever © must be moved before
the brake starts to engage.
Free play at the end of the brake lever
should be 20—30 mm (0.8—1.2 in).
(1) Front brake lever
48
Major adjustments should be made
using the adjuster located at the front
wheel.
Loosen the lock nut © and then turn
the front brake adjusting nut ®.
Turning the nut in direction O will
decrease the brake lever free play, and
turning the nut in direction ® will
increase the free play.
@ Lock nut
@ Front brake adjusting nut
3. Minor adjustments can be made with
the front brake cable adjuster on the
front brake lever.
Loosen the lock nut @ and turn the
front brake cable adjuster ®. Turning
the adjuster in direction @ will de-
crease the brake lever free play, and
turning the adjuster in direction ® will
increase the free play.
@ Lock nut o Front brake cable adjuster
Rear Brake Adjustment
Rear brake pedal free play, measured at
the tip of the rear brake pedal (), should
be maintained at 20-30 mm (0.8—1.2 in).
Free ay is the distance the brake pedal
moves before the brake starts to engage.
| ко
® Rear brake pedal
49
1. Brake pedal height can be adjusted to
suit the rider.
To adjust, loosen the lock nut O), and
turn the stopper blot ®. Retighten the
lock nut after the pedal is adjusted to
the desired height.
> al
>”
2 Lock nut (3) Stopper bolt
50
o
Adjust the pedal free play by turning
the rear brake adjusting nut O. Turn-
ing the adjusting nut in direction ® will
decrease the brake pedal free play and
turning the nut in direction ® will in-
crease the free play.
Brake Wear Indicator
On the TL125, the wear indicator is pro-
vided in the front and rear brakes. When
the brake is applied, a arrow O), adjacent
to the brake arm ®, moves toward a
reference mark O) on the brake panel O.
The distance between the arrow and the
reference mark, on full application of the
brake, indicates brake lining thickness.
If the arrow aligns with the reference
make on full application of the brake,
o Brake panel @ Arrow
@ Reference mark @ Brake arm
replace the brake shoes.
NOTE: When brake service is necessary,
or when brake adjustment is impossible
(refer to pages 48~50), see your authorized
Honda motorcycle dealer. When replac-
ing brake shoes, install only genuine
Honda parts.
51
Front Suspension Inspection
Check front fork action by locking the
front brake and pumping the forks up and
down several times. The suspension should
function smoothly, with no oil leakage from
the fork legs. Damaged, binding, or leak-
ing front forks should be repaired before
the motorcycle is operated. Check security
of all front fork and handlebar mounting
bolts illustrated below.
WARNING: Contact your Honda dealer
for repair of any steering or front suspen-
sion wear or damage.
52
Do not operate the motorcycle with loose,
worn, or damaged steering or front sus-
pension, as handling will be adversely
affected.
Front Fork Oil Change
To maintain good riding characteristics and
increase fork service life, the oil in the
front fork should be changed periodically.
1. Remove drain plugs © from each fork
leg and pump the forks several times
to ensure complete draining.
2. Reinstall drain plugs and block up the
front of the motorcycle.
@ Front fork drain plug
3. Remove the rubber cap O.
4. While pushing down the spring upper
seat O with the tip of a screwdriver,
remove the snap ring ( using snap
ring pliers. Then remove the spring
upper seat.
CAUTION: When removing the snap
ring, the spring upper seat may acciden-
tally jump out by means of the force of
shock absorber spring.
5. Fill each fork leg with 130~140cc (4.4~
4.7 ozs) of premium quality Automatic
e) Rubber cap @ Spring upper
@ Snap ring
Transmission Fluid (ATF).
6. Installation is the reverse order of re-
moval.
NOTE: Securely set the snap ring in the
ring groove in the front fork.
Rear Suspension inspection
Check the rear suspension periodically by
careful visual examination. Note the fol-
lowing items.
1. Rear fork bushing—this can be checked
by pushing hard against the side of
the rear wheel while the motorcycle
is on a support block and feeling for
looseness of the fork bushings.
2. Check the side stand spring for damage.
3. Check all suspension components at-
tachment points for security of their
respective fasteners.
WARNING: If any suspension components
appear worn or damaged, consult your
HONDA dealer for further inspection.
53
Front Wheel Removal
1. Place a wood block under the engine
and raise the front wheel off the ground.
2. Remove the cotter pin ® and disconnect
the front brake cable O from the brake
arm.
Unscrew the brake cable lock nut and
disconnect the front brake cable from
the brake panel.
3. Remove the cotter pin O, the front
axle nut O and remove the front axle.
The front wheel can then be removed.
4. To install the front wheel, follow the
reverse of removal procedure outlined
in steps 1 through 3.
Be sure to tighten the axle nut to 350-
500kg-em (26-31 Ibs-ft).
CAUTION: Always replace used cotter
pins with new ones.
54
| @ Cotter pin
@ Front brake cable
® Cotter pin
@ Front axle nut
Rear Wheel Removal
1.
Place a wood block under the engine
to raise the rear wheel off the ground.
Remove the cotter pin ©, loosen the
rear axle nut ®, and disconnect the
drive chain.
Remove the rear brake adjusting nut ®
and rear brake rod from the brake arm.
Remove the rear torque arm bolt @ at
the rear brake backing plate.
Pull out the rear axle ®, and the rear
wheel can be removed from the frame.
To install the rear wheel, follow the
reverse of removal procedure outlined
in steps 1 through 5.
Be sure to tighten the axle nut to 400-
550kg-cm (29-39 Ibs-ft)
CAUTION: Always replace used cotter
pins with new ones.
® Cotter pin o Torque arm bolt
@ Rear axle nut 6) Rear axle
(3) Rear brake adjusting nut
55
Headlight Beam Adjustment Headlight and Taillight Bulb
Vertical adjustment is made by pivoting Replacement
the headlight case on its mounting bolts Headlight Bulb Replacement
O. 1. Remove the headlight attaching screw
and remove the headlight from the
headlight case.
2. Remove the headlight socket ® by
pushing down the socket and twisting
counterclockwise to unhook from the
reflector.
|
(1) Headlight socket
(A) Headlight ounting bolts
@ Headlight attaching screw
56
3. Pull the bulb © out and replace.
@ Headlight bulb
Taillight Bulb Replacement
1. Remove the two screws retaining the
taillight lens.
2. Press the bulb @ inward and twist to
the left, and the bulb can be removed.
3. When installing the taillight lens, do
not overtighten the screws.
CAUTION: If either light burns out, turn
the headlight switch off immediately and
replace the bulb, or the other bulb will
burn out.
WARNING: The lighting equipment is not
legal for highway use. Do not operate
on public streets, roads or highways.
© Taillight bulb
58
SPECIFICATIONS ~~ RE
Item
DIMENSIONS
Overall length 1,995 mm (78.7 in.)
Overall width 840 mm (33.1in.)
Overall height 1,095 mm (43.1 in.)
Wheel base 1,280 mm (50.4 in.)
WEIGHT
Dry weight 88 kg (194 lbs.)
CAPACITIES
Engine oil 1.0 € (1.1 U.S. qt.)
Fuel tank 4.5 8 (1.19 U.S. gal.)
Fuel reserve tank
Front forkoil
Passenger capacity
0.5¢ (0.13 U.S. gal.)
145~155 cc (4.9~5.3 075)
Operator only
ENGINE
Bore and stroke
Compression ratio
56.5 x 49.5 mm (2.224 x 1.949 in.)
8.0:1
Item
Displacement
Contact breaker point gap
Spark plug gap
Valve tappet clearance
124 cc (7.57 cu-in.)
0.3~0.4 mm (0.012~0.016 in.)
0.6~0.7 mm (0.024~0.028 in.)
0.05 mm (0.002 in.)
CHASSIS AND SUSPENSION
Caster 61°30
Trail 105 mm (4.13 in.)
Tire size 2.75-21 (4 PR)
Tire size 4.00-18 (4 PR)
POWER TRANSMISSION
Primary reduction 4.055
Final reduction 4.000
Gear ratio, 1st 2.769
2nd 2.125
3rd 1.450
4th 1.000
5th 0.724
59
TL 125 WIRING DIAGRAM
ENGINE STOP SWITCH
da si ss TAIL LIGHT
6V3W
HEADLIGHT
6V25/25W
CONTACT
SPARK BREAKER
PLUG 4
TL =
IGNITION COIL
LIGHTING DIMMER SWITCH
ALTERNATOR LIGHTING
(FLYWHEEL TYPE) C | TL | Hi | Lo
00303-355-7100.
60