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Workshopmanual-Xl75 - 1977-1979 - En-10022019-1103-San-Compressed 2

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0% found this document useful (0 votes)
2K views126 pages

Workshopmanual-Xl75 - 1977-1979 - En-10022019-1103-San-Compressed 2

Uploaded by

serge
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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_& HONDA SHOP MANU AL XL75 IMPORTANT SAFETY NOTICE Indicates a strong pesiblicy of severe persona injury or loss of le If tstrections are not followed. [CAUTION] Indicates a possibility of personal injury or equipment damage if instructions are not followed. Detailed descriotions of standard workshop procedures, safety principles and service operations are not included. Its important 10 note that this manual contains some warnings and cautions against some specific service methods whic) | could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand | that thore warnings could rot cover all conceivable ways in which service, whether or not recommended by Honda might bbe done or of the possible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. | Anyone using service procedures or too, whether or not recommended by Honda must satisfy himself thoroughly that | neither personal safety nor vehicie safety will be jeopardized by the service method or tools selected xXL80S This shop manual covers the following HONDA MODELS: ALL INFORMATION, ILLUSTRATIONS, DIREC- ‘TIONS AND SPECIFICATIONS INCLUDED IN THIS, PUBLICATION ARE BASED ON THE LATEST PRO- DUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHAT- EVER. NO PART OF THIS PUBLICATION MAY BE REPRO- DUCED WITHOUT WRITTEN PERMISSION. Dateof Sepierber, 1980, © Armercan Honds Motor Ce., Ine. 1980 - All Rights Reserves 1977-1979 XL75 and 1980-1981 XLB0S TABLE OF CONTENTS |. SERVICING PROCEDURES secon U1. INSPECTION AND ADJUSTMENT scerarecnsare Ill, ENGINE DISASSEMBLY CHART IV, ENGINE REMOVAL/INSTALLATION V. ENGINE ......... 1. CYLINDER HEAD a 2. CYLINDER AND PISTON . sc earenetimeeitiemeneeie OM 3. LUBRICATION SYSTEM . 6-6 4, CLUTCH, OIL PUMP AND GEARSHIFT MECHANISM . ol 5. A.C. GENERATOR .. a1 6. TRANSMISSION, CRANKSHAFT AND KICK STARTER a1 7. CARBURETOR ...........05 wawaceronseeeeres Tl vi. Eeecsrica asso W-1 . CHARGING SYSTEM . s 11 ; IGNITION SYSTEM zi Sa eebie 3. OTHER ELECTRICAL PARTS : falas Vil. FRAME... |. FRONT WHEEL, STEERING STEM, FRONT SHOCK ABSORBER 2, REAR WHEEL, REAR SHOCK ABSORBER 3. FUEL VALVE, REAR FENDER, TAILLIGHT VIII, ROUTING OF CABLES AND WIRES IX. SERVICE DATA Fife annesashpas amen bones SPECIALTOOLS ©... - 0c eee eee cece tence ee TORQUE SPECIFICATIONS SERVICE DATA SPECIFICATIONS TROUBLE SHOOTING 6. WIRING DIAGRAM %. 1978 XL75 ADDENDUM XI. 1979 XL75 ADDENDUM (USA and Cenada only) . XII. 1980 XL80S ADDENDUM XIIL. 1981 XL80S ADDENDUM. Date of las September 1950 © American Hone Motor Co, Ine. 1880. All Rights Rerorved © Always replace gaskets, O-rings and cotter pins when reassembling. COTTER PIN © Tighten fasteners, beginning with the center or larger dia. bolts to specs, where the sequence is not specified, ina X pattern, Se o~ “xX sen oi CQ © Wash al sliding surfaces when disassembling. isassembled parts in solvent. Lubricate their 1 I. SERVICING PROCEDURES ‘© Grease by costing oF filling where specified. ‘© After reassembling, check every part for proper installa tion, movernent or operation, partner. = ‘These symbols are used throughout the menual to show specific kinds of operation, sequence of service procedures ete —SYMBOLS— ©.@,@-~+ Indeates wecwerce of service opere- Indicates there is @ possibility of per- sonal injury. Indicates there is a possibility of damage to the motorcycle, Indicates points of particular interest for more efficient and convenient operation. Date of Issue: Feb. 1977 @ HONDA MOTOR CO., LTD. MM 2 xL75 II, INSPECTION AND ADJUSTMENT ————_ * Contact Breaker Point Gap, Ign Ignition timing should be checked after adjusted, n Timing ap has been © Contact Breaker Point Gap Adjustment (1) Rotate flywheel until contact breaker ligns with the highest point of the cam. Measure point gap with a thickness gauge. (2) To adjust, loosen locking serew and move breaker base plate. Point Thickness Gauge © Ignition Timing Inspection with a Lamp ” 2 a ay Connect one lead of primary windings to a GV 3W test lamp and the other to battery positive (+) termina. Ground Battery negative (—) terminal Rotate flywheel counterclockwise until the * mark aligns with the index mark. Timing is correct if lamp becomes dim when marks align If timing is incorrect, recheck contact breaker point 1989 and repeat step (2) above. Replace contact breaker if the standard point gap ‘cannot be achieved. 03-04 mm (0.012-0.016 in.) Locking Serew {Ignition Timing Inspection with Service Tester) "Idle engine st 1600 1pm. The “F"" mark stould be aligned with the index mark. ‘© Run engine at speeds above 3300 rpm. The index mark should be within the advance marks. Index Mark Date of Issue: Feb. 197 ‘© HONDA MOTOR CO.,LTD. HONDA, 2 xL75 INSPECTION AND ADJUSTMENT ‘© Valve Tappet Clearance Adjustment Valve tappet clearance should be checked when the engine is cold, Clearance (2) To adjust, loosen adjusting screw lock nut and turn adjusting screw so that valve clearance offers a slight resistance when the feeler gauge is inserted. Lock Nut (1) Align the “T"" mark on the flywheel with the index mark on the case with the piston st the ton of the compression stroke, © Carburetor Adjustment Do not perform this operation until the following items have been inspected or corrected: (dle Speed Adjustment) (1) Tum stop screw counterclockwise to get lowest steady engine rpm. (2) Turn air serew in or out to find highest engine rom. (3) Turn stop sorew to sun engine at idle speed (4) Turn air screw to see if the engine speed increases. (5) If engine speed increases, rapeat steps (3) and (4) to run engine at idle speed. (6) Do not back off air screw more than 1-1/2 rotations. Idle speed: 1500 rpm_ (Throttle Cable Adjustment) Check the throttle cable for proper free play and adjust by ‘turning the throttle cable adjuster (A) first, if necessary, tw —~s Replace throttle eable if i is not corrected.by turning the acjuster (B) Throttle cable adjuster (A) TO INCREASE Date of tsue: Feb, 1877 2. HONDA NOTOR CO.,LTD ed q , HONDA xXL75S INSPECTION AND ADJUSTMENT ‘© Cam Chain Adjustment Adjusting Bolt To increase tension Front Tensioner Locking Bolt 8 Locking Nut (1) Looten focking bolt A. (2) Turn adjusting bolt elockwise to find position where the chain cunequiatly. Tighten loaking bolt A, (3) If still noisy, stop the engine and loosen the tensioner locking nut. Loosen and tighten locking bolt B. (4) Recheck chain. tension. To loosen, turn adjusting bolt counterclockwise. © Oil Filter Screen Cleaning (1), Remove drain plug to drain oil from engine. (2) Remove muffler assembly. (3) Remove R-crankcase cover. j aly’ of aa kes et (4) Remove oil filter screen from the underside of the —— fieen l es = (6) Wath oil filter sereen in clean solvent. i Filter Screen 2-3 Date of ue: Fab. 1677 SHowDR HoTOR CO LTO. HONDA 2 xXL75 Clutch Adjustment INSPECTION AND ADJUSTMENT Adjust the clutch so that the clutch lever is in line with the lowest point of head of the & mm screw on the R-crankcaie cover as shown, To adjust the clutch, loosen the lock nut and turn the adjusting screw counterclockwise until the resistance is felt. Then turn the screw clockwise 1/8 to 1/4 turns. Then tighten the lock nut Free play should be 10-20 mm the clutch lever: sasured at the outer end of | After adjustment, start the engine and make sure that the motoreycle does not creep with the clutch isengaged. Reaciust the clutch if the engine stalls when shifting or if shifting is difficult. Date of Issue: Feb. 197 2 HONDA MOTOR CO, LTD “4 2 : HONDA xXL75 INSPECTION AND ADJUSTMENT © Air Cleaner Maintenance A) Remove the right side cover. (3) Remove the 6 mm nut and the element cap. Then (2) Remove the three wing nuts on the air cleaner cover slide the element of the cover. ‘and slide the air cleaner tube band back. Then slide off the turn signal relay suspension rubber from the air cleaner cover, and pull the air cleaner cover (4) Wash in clean stoddard solvent. (5) Dry (6) Soak in gear oil. (7) Squeeze out the excess ol (SAE 80-90) Do not use gasoline or low flash point solvents as these are highly flammable. © Engine Oil Level, Engine Oil Change © Engine Oil Level ‘© Engine Oil Change (1) Place motorcycle in an upright position. Change engine oil while (2) Shut of theengae (3) To check ol level. insert the engine stil warm ‘and check the oil Pets Saree ser (1) Drain engine oil by level after approx. removing the drain 3 minutes. plug. (2) Reinstall drain plug 4nd refill up to the upper level Upper Level Mark Lower Level Mark ¥ cit tea snouts be batweon thee mis. a fot seeciricarion Use HONDA 4 STROKE OIL or euvaent. AP! saree clasifenton SE Viseaty-Genera ll temp. SAE 10W/~40 [owe 1S°C/S0"F TED roraue: O°C/32°F-15°C/59°F | SAE 20 or SAE 20 200-300 kgem (14.5~21.7 ibs-ft) [below 0°C/32°F SAE 10W. 2 Date of ase: Feb, 1977 “5 @HONDAMOTOR CO. LTD. Drain Plug | Oil Capecity: 0.98 (0.95 at) | xXL75 \ TS eytinder Compression INSPECTION AND ADJUSTMENT (1) Do not perform this ope- @ 3) ration until the engine reaches normal operating & temperature. & Cylinder Compression 10.0-12.0 kg/cm? (142-171 PSI) © Common causes of loss of compression are: Poor valve contact jom piston ring lown-aut cylinder head gasket improper tappet clearance © Common causes of excessive cylinder compression we: ‘© Excessive accumulation of carbon on piston head ‘© Excessive accumulation of carbon in combustion chamber Tighten securely to prevent leaks. Dat of suo: Feb. 1977 @ HONDA MOTOR CO.,LTD. 2-6 1, full strokes until the gauge needle iz : HONDA XL75 INSPECTION AND ADJUSTMENT © Brake Adjustment 1. Front Brake Lever Free Play 2. Rear Brake Pedal Free Play If free play is not within specification, adjust as follows. If out of specs, adjust by adjusting nut. Minor front brake adjustments can be made by the ‘adjuster on the front brake lever. Major adjustments can be made with the adjusting nut (on the Front wheel 2-1 Date of Issuer Feb. 1977 HONDA MOTOR CO.,LTD. xXL75 \ « Front Fork Oil Change Place a pan under the fork to be drained. Remove the drain plug end allow the fork to drain. Work the suspension up and down several times to completely drain the fork. INSPECTION AND ADJUSTMENT € e Tora 350-450 kg-em (25.3-32.6 Ibs, Refill the fork and replace the filler a! bolt and torque. Repeat this opera: ton on the remaining fork lea. Fluid canacity after draining ATE 100-105 ce (3.4-3.5 02) each fork leg. Dateor sue: Feb, 1977 2 HONDA MOTOR Co, LTD “8 HONDA INSPECTION AND ADJUSTMENT xL765 & © Drive Chain Maintenance (1) Stop the engine and place the metoreyele on 2 support block to raise the rear whee! off the ground, (2). Check chain stack. (3) To adjust, remove cotter pin and loosen the rear axle nut. (4) Turn adjusting nuts on both right and left chain adjusters to increase or decrease chain tension. Align the index marks with side scale graduations on both sides of the reer fork (5) Tighten the axle nut and secure the nut with a new cotter pin. Specified torque: 180-250 kg-cm (93.0-18.1 Ibs-ft) Date of Issue: Feb. 1977 © HONDA MOTOR CO., LTD. 8 KICK PEDAL HONDA — 3 xXL75 Il, ENGINE DISASSEMBLY CHART CYLINDER HEAD COVER, Cam HOLDER CANSHAFT em ” [ MUFFLEA | FF oONFRAWESERVICE ay wiecting J) IP ONFRAMEsERVice "%y ROD a ~~. = 1-3 a ielet zm Seiko - CAM SPROCKET CAM CHAIN R-CRANKCASE COVER — =| B Kcr IGNITION COIL! GEAR SHIFT SPINDLE SPINDLE CHANGE PEDAL v KICK SPRING Date of Issue: Feb. 1977 3-1 © HONDA MOTOR ©O.., LTD. 4 W.ENGINE REMOVAL /INSTALLATION (3) Remove henger bolts (A), (B) and (C) in that oraer. Torque: 200-250 kg-em (14.5~18.1 Ibs-ft,) are) 4-1 Date of Issue: Feb. @ HONDA MOTOR CO, LTO 5 V .ENGINE 1. CYLINDER HEAD \ a Removal/installation (1) Cylinder Head Cover e ®@ More: 20-10 gem tesa7iet) (2) came Holter Ital wit the pston atthe top ofthe ® | sSroresan oe | AP Stier chan witha pn af ww @ x 1 ocazeny Jy roe trom dropping th ean fsonbi. poe 8-2 / > om (2) Cam Sprocket Page 5-2 for valve timing (4) Camshaft Page 5-3 for Valve Disassembly/ Assembly 100-140 kgem (7.3-10.1 Ibs.tt) (5) Adjusting Bolt CAM CHAIN ADJUSTMENT Page 2-3 (6) Cylinder Hesd Date of lave: Feb, 1977 SHONDAMOTOR C0, LTD. 5-1 5 . HONDA CYLINDER HEAD xL75 b. Disassembly/Assembly © Rocker Arm Shaft Disassembly Assembly (Cam Holder Exhaust Side Install with thresded end out. Intake Side © Valve Timing Alignment © Cam Sprocket Installation Install the cam sprocket with both bolt hole: down ward, 2) Position the punch markon the sprocket up- ward and align the two bolt hholes (A) with the cylinder head mating sur- face (3) cma. | Po « > &x 10mm Dowel Bott “10 the intake side SJ) Align the mark on SL the rotor with the index. <> mark on the let eso, 5 Date of sue: Feb. 1977 ee © HONDA MOTOR CO.,LTD. CYLINDER HEAD \ Valve and Valve Guide Disassembly /Astembly © sae sets compen iisacee ‘After assembly, make sure valve cotters are seated properly by tapping lightly with plastic mallet. Date of ase: Feb, 1077 HONDA MOTOR CO, LTD. 5-3 CYLINDER HEAD © Valve Guide Removal Valve Guide Remover No. 07942-3290100 (Not necessary) © Valve Guide Installation ‘Valve Guide Driver No.07942:3290200 = © Valve Guide Reaming eam to specified size after installing new Valve Guide Reamer No. 079840980000 5 Date of issue: Feb. 197 4 © HONDA MOTOR CO.,LTD. CLINDER HEAD Standard Service limit 1.0 rom (0.0394 in.) 15 mm (0.0800 in.) comet —T ‘Service limit 5.475—5.485 mm (0.2185-0.2159 in) 5,50 mm (0.2165 in.) 5.475—5.485 mm (0.2145-0.2181 in) folttee:o 2150 in) | 550mm (02186ind Stood Senice init 580-5406 man 5.42 mm (0.2134 in.) 430-6.445 mm (0.2137-0.2143 in) 8.40 mm (0.2128 in.) Datwof Issue: Feb. 1977 © HONDA MOTOR CO., LTD, 5-5 5 CYLINDER HEAD © Valve face width Standard Service limit 715mm 18mm (6,0433~0.0590 in) (0.0709 in) Rocker Arm ID, Standard Service limit 100-1015 mm TOA mim (0,3937~0:3943 in) (0.3078 in.) © Rocker Arm Wear or Damage Wear or damage 5-6 Date of Issue: Feb. 1977 © HONDA MOTOR CO., LTO. CYLINDER HEAD Standard Service limit T76-0.987 mm 9.17 mm (0.3928-0.3931 in) (03610. Cam Height ‘Standard Service init Ww | 27,098 mm 26.0 mm (7.0632) (1023610. 27.005 mm 260 mm © | (ossaiin) (02736) © Valve Spring Free Length Free Length é ‘Standard Servies limit 28.05 mm 275 mm Umer | (1.1043 1) (1.0886 in.) amma 33:7 mm Outer | (1.3701 ind (13267'ing Date of tssue: Feb, 1977 5 © HONDA MOTOR CO., LTD. = CYLINDER HEAD HONDA xXL75 Follow instructions given in manual provided with the grinder. ‘Then lap each valve and check to see if the valves are ‘making good contact, (1) Check contact surface between valve face and seat by applying a thin coat of red lead, (2) If contact is uneven or excessive, reface valve seat using the valve seat grinder. (3) Recheck contact surface. Third cut (63.6°) First cut (45°) Second cut (37.5%) Valve seat width 5-8 Date of Issue: Feb. 1977 © HONDA MOTOR CO.,LTD. 2. CYLINDER AND PISTON nsioner Page 2-3 for cam chain adjustment 6 . HONDA XxXL75 CYLINDER/PISTON a. Disassembly/Assembly Install with “IN marking toward the intake side. Place rag over erankease opening to prevent piston pin clips from drop: ping inside, © Piston Ring Disassembly/Assombly ‘Stagger ring end gaps 120° away from each other (Sectional View) (1) Top ring (2) 2ndiring (3) Oil ting ‘Check fit of ring in ring groove by rotating the ring around in the groove. ‘Check for clogged oil holes or carbon buildup in ring grooves. 6-2 Date of Issue: Feb. 1977 Pi © HONDA MOTOR CO.,LTD. CYLINDER/PISTON a Loosen adjusting bolt after valve timing has been adjusted correctly. “Tensioner Spring Hook the end of the tensioner spring on the cylinder as ilustrated, Cam Chain Tensioner cam chain after installing head. For adjustment, see pages 2~3, © Cylinder Assembly 10x 16 mm Dowel Pin 7.5 mm rubber gasket Meke sure the rubber gasket is seated properly, Cam Chain Guide Cylinder Heed Gasket Date of Issue: Feb. 1977 6-3 ©@HONDA MOTOR CO, LTD. ie 6 HONDA CYLINDER /PISTON xL75 b. Inspection or cjimtir Measure at al sx positions. Sandord | __ Sever tint, $8,00-48.01 mm 48.40 mm (reser iaeet in) | __ (raeerind Top cénter Botton Sandord Seve int “7.98547 900 mm 4780 mm (iaa3—1 3908 m) | (1819 In) FEEEEE seosure at point 10mm (0. in) from the bottom. «© Piston Ring Side Cesranca & >> Sender Seas in 315-045 mm 0.12 mm ___._ Ss teeny | (ode kd 6-4 Date of issue: Feb. 1977 HONDA MOTOR CO,, LTD. CYLINDER/PISTON © Piston Ring End Gap @ er roarision + Pon P00. Bon|faanacoeelm | Weeeny eae |e " (0.0976~-0.0982 in.) (0.0953 in.) Date of Issue: Feb, 1977 © HONDA MOTOR ©O., LTD. 6-5 : HONDA /> § XL75 3. LUBRICATION SYSTEM 6-6 Date of issue: Feb. 1977 © HONDA MOTOR CO., LTD. HONDA " 1 xXL75 . CLUTCH, OIL PUMP AND GEARSHIFT MECHANISM ‘© Bofore operation, drain oil from engine. © Disconnect clutch cables. sage Tube Do not forget to install, (8) Drum Stopper Plate Page 7-3 for assembly (2) 14mm Nut Page 72 for disessemby and assembly. ‘Make sure O-rings are seated properly at assembly | Torque: 350-450 kg-em (25.3~32.6 Ibs.) (10) Drum Stopper Page 7—3 for assembly Page 7-2 for disassembly ‘end assembly ‘Wash in clean engine oil when @ assembling. (8) Gearshift Spindle Page 7-3 for assembly Clutch Adjusting Lever (7) 20 mm Spline Washer (ooun @ “Srevaccnys pS (5) 20 mm Set Ring b (4) Clutch Lifter Plate ~ Clutch Lever (1) Rerankease (© Page 2-4 for adjustment Covet © Page 7—3 for assemly Date of sue: Feb. 1977 Mona oroR co. 70. 1 7 : HONDA CLUTCH/OIL PUMP GEARSHIFT MECHANISM xL7S a. Disassembly/Assembly © Drive Goar “a Clutch Holder No. 07923-10701 Use tool to prevent clutch from being turned while operating. © Oil Pump Rotate oil pump until bolts appear. ‘Align with cutout in inner rotor. Fit locating tab in recess. 7-2 Date of Issue: Feb. 1977 © HONDA MOTOR CO.,LTD. HONDA. CLUTCH/OIL PUMP. © xL75 GEARSHIFT MECHANISM ‘© Clutch Disassembly Assembly (Clutoh Center Friction Dise Clutch Plate Clutch Pressure Plate ‘When assembling new friction discs, apply oil on dise surfaces. © Clutch Arm Assembly, © Gearshift Spindle Installation (Clutch Litter Cam ‘Use care so that cam does not come off adjusting lever during assembly. Clutch Lever Return Spring ‘© Drum Stopper Assembly Oe waak SV iN\\ { Install stopper spring as shown, Date of Issue: Feb. 1977 ©HONDA MOTOR CO,, LTD. + Slide ends of return spring over return pin. Oo Check operation after assembling. Trego pee thet pies ennene ein bobs, propery. CLUTCH/OIL PUMP GEARSHIFT MECHANISM b, Inspection © Oo Pump Rotor Clearance Check rotors for signs of damage and replace if necessary. Standard Service limit ‘Standard ‘Service limit 0.15 mm 02 mm 0.15-0.20 mm, 0.25 mm (0.0058 in.) (0.0079 in.) (0.0059-0.0079 in.) (0.0098 in.) © Cuteh Spring Free Length © Clutch Friction Dise Thickness Check clutch facings for damage or burning and replace recon seara i Wik i Bam 263 mn a iniering {10368 ee me re Date of Issue: Feb. 1977 © HONDA MOTOR CO. LTD. € a SS 5. AC. GENERATOR Make sure key is property seated, Breaker Point Page 8-2 for disassembly and assembly (3) Stator Neutral Switeh Page 82 for installation of (2) Fiywheet Page 82 for disassembly and assembly © Make sure no bolts, screws, ete. are attracted to the magnets © Do not us a hammer on the flywheel (1) L-erankease Cover Date of ut: Feb 1977 @ HONDA MOTOR CO, LTD. 8-1 A.C. GENERATOR 2. Disassembly/Assembly © Flywheel (1) Removing 12 mm nut Fiywheet Holder No, 078250010000 © Contact Breaker Disassembly © After assembly, adjust bresker oint yap and ignition timing Page 2-1 for adjustment. (2) Removing flywheel Flywhee! Puller ‘No. 078330010000 © Neutral Switch Wire Installation ‘Spring Insert exposed end of wire while compressing the spring. Date of Issue: Feb. 1977 @ HONDA MOTOR CO., LTD. AC. GENERATOR X b. Inspection © Contact Breaker Point wT Se '* ‘Moisten with cleen point crease if dry. will © Wg point an J ‘Standard: mm (0.01: ™T] Use point file to remove irregularities oF high spots Normal Check the condenser if the points are excessively pitted. € Date of Issue: Fob. 1977 8-3 © HONDA MOTOR CO,, LTD. - (1) Spring Colter, Page 9-2 for assembly Kick Starter Spring (4) Kick Starter Assy. Page 9-2 for assembly (3) R-Crankcase (5) Shift Fork Guide Shaft, (8) ShiftDrum Page 93 for assembly. 7 (9) Transmission Page 9-2 for cisassembly and assembly i (6) RShift For\ (7) CShift Fork Timing Sprocket a Before disassembling, follow instructions given on page 9-3. during assembly. L-Crankcase Date of tsve: Feb. 197 9-1 @HONDAMOTOR CO, LTD. HONDA — 9 Ss TRANSMISSION /CRANKSHAFT xL7! AND KICK STARTER a. Disassembly/Assembly © Kick Starter (1) Align markings. Ratchot Starter Kick Starter Spindle (2) Set ratchet starter on guide plate in direction of arrow. (3) After putting right and left cases together, install soring onspindle. (4) Insert one end of spring in groove in spring guide and hhook the other end on the case boss. Guide Plate ‘After assembling, check kick starter operation © Transmission ‘When replacing a transmission shaft and gears simultaneously, be sure to apply a coat of molybdenum disulfide on all sliding surfaces on the shaft. (If engine is revved up rapidly after starting, in some cases not enouch lubrication may be provided.) ‘Apply on rotating parts. Low Gear TopGear Third Gear Second Gear @ 00 A ‘Main Shaft Dateot tse: Feb. 1977 GHONDAMOTOR Co, LTD. 9-2 HONDA TRANSMISSION /CRANKSHAFT xXL75 AND KICK STARTER © Shift Fork Assembly © Shift Drum Assembly + Install neutral switch rotor in direction of arrow. ‘Check that gears rotate freely by rotating ~ meinshatt. © Timing Sprocket + Disassembly + Assembly Using scriber, scribe @ line squarely against timing Install new timing sprocket so that bottom center sprocket through bottom center between any two testh between any two teeth aligns with the scribed line. ‘as shown, Line (about 2 cm (0.8 in) long) ‘Do not scribe line over surfaces other than shown or the oil seal may be damaged. Date of Issue: Feb. 1977 © HONDA MOTOR CO.,LTD. € b. Inspection © Goarshift Fork LD. © Gearshift Fork Guide 0.D. TRANSMISSION /CRANKSHAFT AND KICK STARTER Standard ‘Sorvice limit 12.000—12.018 mm 12.08 mm (0.4724-0.4731 in) (0.4744 in.) Standard ‘Serviee limit 4.93-5.00 mm 470mm (0.1941--0.1968 in) (0.1850 in.) Standard Service limit 11.876-11.994 mm 11,96 mm (0.4716_0.4722 in.) (0.4709 in.) Date of Issue: Fed. 1977 @ HONDA MOTOR CO.,LTD. HONDA AND KICK STARTER ‘© Connecting Rod Small End I.D. TRANSMISSION/CRANKSHAFT XLT Standard Service limit 13.016-13,034 mm 13.08 mm (0.5124-0.5131 in.) (0.5160 in.) Service limit | ‘Standard 0.10.35 mm. 0.8 mm (0.0039-0.0138 in.) (0.0236 in.) Standard ‘Service limit 0.015 mm O.t mm (0.0006 i.) (0.0039 in.) Date of Issue: Feb, 1977 @ HONDA MOTOR CO., LTD. HONDA " 9 XL75 TRANSMISSION /CRANKSHAF E AND KICK STARTER ‘© Connecting Rod Big End Radial Play Measure at two points in arrow directions. ‘Stendard Service limit 00.012 mm 0.05 mm (0-0.0005 in.) (0.0020 in.) © Crankeshaft Ball Bearing Rattle © Kick Starter Pinion 11D. Rattle Radiat Axial direction direction (Replaced Standard Sorvicn limit {eptact 18,020—18.041 mm 18.07 mm (0.7004-0.7102 in.) (0.7114 in.) Date of Issue: Feb. 197 9 HONDA MOTOR Co.,LTD. +6 10 7. CARBURETOR '@ Set fuol valve in OF F position. © Drain fuel from the carburetor by removing carburetor drain plug. © Keep open flame or sparks away. (2) Throttle Valve Page 10-2 for disassembly and (1) Fust Tube anit ‘Check for deterioration or [a re ese es | before | fetanen, mormon oF sven bon | (2) Tube Band ong [check tor weaken Stop Surew POO* 2-2 for idle speed adjustment (4) Carburetor Body | Cee in eet and blow a ols an Qo hitsens See acm Float Page 103 for disassembly and assembly (5) Float Chamber ‘Carburetor Jet Page 10-23 for disassombly Drain Plug and assembly ull the throttle valve with the groove on the right ‘Align lugs on carburetor top with recesses in carburetor side. body, 1 0-1 Date of Issue; Feb. 1977 ‘© HONDA MOTOR CO., LTD. 10 CARBURETOR a. Disassombly/Assombly © Carburstor Top/Throtile Valve oe a { Needle Cap ‘Set properly in bottom at assembly Throttle Valve Jet Needle Remove cable end from groove in throttle valve. Needle Grip set Neate Replace needle and needle jet as « set when replacing + Turn adjuster all the way in at assembly + Make sure outer and of cable seats in adjuster Fully + Install rubber cap property Throttle Valve © Float Valve Pull flost pin out to separate float from the float valve | ‘At asvembly, check to see thet valve and seat ‘are not worn oF clogged. BNONDA oTOR 6O, LD. 10-2 10 CARBURETOR © Carhuretor Jets e— Main Jt o- ain Jet Holder Jet Needle Holder Slow Jot Float Valve "© Carefully handle jets and neces. © Clean in solvent and airdry. Make sure al jets are rot clagged. ae Roplace needle jet and jet needle as b. Inspection © Float Height Float Arm Tip © Carefully bend float arm tin to adjust float level Date of Issue: Fab. 1977 @ HONDA MOTOR CO.,LTD. 10 CARBURETOR { aaa Item XL75 agua | oes & Main jet #78 see = aha ¢ @ et needle setting 2nd notch (Std.) * = Air screw opening 2.1/2 (Standard) oo Idle speed 1,500 rpm Daw of tut: Feb. 1977 S HONDA MOTOR CO. LTD. 10-4 1 VI. ELECTRICAL HONDA xL75 |. CHARGING SYSTEM Azz — Engine Stop Switeh Primary Coil Charging/Lamp Coit AC. Generate Page 8—1 for removal © Electric Wiring Diagram whitey Scan Recttier Ww & AC. Flywheel Generator Headlight 6V151 Meter Taillight’ Meter evi7W 6v5.aW GVI.7W 11-1 Date of Issue: Feb, 1977 © HONDA MOTOR CO.,LTD, Charging Test Perform atter engine is fully warmed up. ey (4aH) Specific Gravity of Battery Electrolyte (1.260-1.280) 20°C (68°F) Raise engine speed gradually while observing volt meter indicator. Do not rev up engine rapidly. If continuity exists the stator is grounded. Replace. 11 CHARGING SYSTEM. Check battery, generaror and/or rectifier if out of specs: Initial eharsing | 4090 rpim| 8000 rom ‘Main switch in oN 1600 | 1.00.34 | 1.8:0.44 (Testing with stator mounted) © Continuity test of stator coil Black/White Radio Tester (Rectifier) ‘© Normal if continuity exists only in direction of arrow. © Replace if there is continuity in reverse polerity Date of fssue: Feb. 1977 © HONDA MOTOR CO.,LTD. 11-2 11 HONDA xXL75 CHARGING SYSTEM © Specific Gravity. Battery Maintenance 1.260~1.280 (at 20°C/08"F): Fully charged Below 1,200 = Charging necessary 9) PL Hydrometor 1 Electrolyte \ \ © Charging Battory Charger pesitive (+) terminal to battery Connecting | positive (+ terminal WD et hacer nate terminal ote negative (~) terminal ‘ep away spats |p ‘and open tiames| |Chersing |g 2p ville charging. | [surent | Charge battery until $.G. (Specific gravi- ‘Avoid quick-charg'|| charging {Y) becomes 1.26~1.28 (at 20°C/6EF) ing if possi Bubbles will be produced at end of the charg. Cherging | 12—13 hours for batteries with SG. time below 1.22 (20°C/68°F). © Battory Relationship between S.G. and Electrolyte Temperature m2 ‘© Replace battery if sulfation is observed. © Replace battery if paste has settled at the bottom, FT Date of tssue: Feb. 1977 3 © HONDA MOTOR CO.. LTD. 1 2. IGNITION SYSTEM Condenser (Black/White) Primary Coil Condenser Contact Breaker Ignition Coil Inspection © SPoint Spark Test Ground Ground CCl is normal if spark jumps at least 7 mm electrode-gap on tester. (0-2 mm (0-9.079 in.) Connect in accordance with instructions provided ‘with service tester, 3rd electrode Date of sue: Fob. 18 OHONDA MOTOR €0.-LTD. 11-4 1 IGNITION SYSTEM. © Continuity Test ‘Check for continuity per instructions given below. Reference: Resistonces for A and B are 4-5 kS? ‘Spark Plug Inspection jd 06-07 mm (0.024-0.028 in.) 1 sigsctae Seisenatbon oa Chack for Wear ‘Clean with spark plug Gap loaner or bristle wire brush, Fouling | ‘Accumulation T of carbon b =F To install, tighten finger tight then turn 1/2 to 3/4 sure 11-5 Date of tisue: Feb. 1977 © HONDA MOTOR CO.,LTD. 11 IGNITION SYSTEM Condenser Inspection Condenser e ca i Capscity| — 0.21-0.26uF Discharge by shorting before capacity. me @ MEMO Date of Issue: Feb. 1977 1 1-6 © HONDA MOTOR CO,, LTD. 11 : HONDA XL75 3. OTHER ELECTRICAL PARTS Main Switch Taal 7 1 © 1 gar] HO ‘Switch is normal if the yntinuity in clits (O-O). Black WireCotor _[BI@6K/ | Green | Red | Black OFF S&S 6 ON a | | fot Turn Signal Switeh Terminal wfleRif[e Wire Cotor Gray | Blue | Orange — a — eee _ = > ta fH Tk 11-7 Scare HONDA 11 xL75 Headlight Dimmer Switch OTHER ELECTRICAL PARTS Terminal ue | WireCotor [WRT | white | Blue Engine Stop Switen Terminal iG E Wire Color Godes | BieckAWmite | Green OFF os _~—~«| RUN | orF o—}—s Date of tssue: Feb. 1977 11-8 © HONDA MOTOR CO., LTD. | . HONDA xXL75S OTHER ELECTRICAL PARTS ‘Chock for continuity with tester. Switch is normal if stop light comes on when pedal is Pull on the switch to check for continuity, depressed 20-30 mm (0.8-1.2 in.) Switch ean be adjusted, 11-9 Date se: Feb, 1977 SMoNDAMOTOR CO. LTO 1 Horn inspection MEMO SMoNDA MOTOR 69. LD 11-10 12 Wi. FRAME |. FRONT WHEEL, STEERING STEM, FRONT SHOCK ABSORBER Note direction of installation. With punch marks backward, {ighten forward bolts first, C @e (6) Stoaring Stem Page 12—3 for disassembly and asiembly. (1) Front Wheet Page 12-3 for disassembly and assembly. Axle Nut i Torque: 400-500 kg-em (28.9-362 Ibs.) em, Toraue: 180-260 ka-om ~ (13.0-18.1 Ibs-tt) Position the hendiebsr so ‘that the punch mark is in line with the top of the holder. 12-1 Date of Issue: Feb. 1977 © HONDA MOTOR CO., LTD. FRONT WHEEL / 12 STEERING STEM, FRONT SHOCK ABSORBER FRONT WHEEL & Do not slow gene or oll to wore im Contact with beeke thoy or ide of brake an Brake Panel Align punch marks. \ (No, 07945-8150000) ‘Drive bearing squarely into place in hub, Date of Issue: Feb. 1977 12 HONDA MOTOR CO., LTD 2, " oan, Tae STEERING / FRONT SHOCK ABSORBER a. Disassembly/Assembly ‘STEERING STEM fa Torque ts. 600700 kg-cm (42.4506 ibs.) 238 mm Fin Spanner x No. 07902-2400000 Taam iS 80-120 ke-cm S (58-87 Ibs-tt) RX ~S ny Torque: SS Cre 10 tn Lr heny (1) Fork Top Bridge Screw in tightly frst, then back out about 1/8 tums, Make sure steering © Te) Hand Top Theat stem rotates freely without ratte, Stila ‘Top Ball Race Bottom Ball Race Ball Race Driver ‘No. 07944.1160001 (3) Steering Stem Toraue: 180-250 kg-em [13.0-18.1 Ibs-ft.) R 12 Date of sue: Feb. 1977 “3 HONDA MOTOR CO, LTD, HONDA — FRONT WHEEL / 12 STEERING STEM/ xL75 FRONT SHOCK ABSORBER a. Disassembly/ Assembly FRONT SHOCK ABSORBER Remove 37 mm snap ring before dsassonbling front sock beorbor Ss Oring Oo a e Fromt Fork Pipe —=sS (3) Separate fork pipe 4 Rak Sorin Fork Bolt fram bottom case by e os coeumae Tas 1a teen (25.3-28.9 lbs4t) (1), Loosen fork bolt enough to set tool up an fork Front Fork Pipe pie. ‘No, 07959-2680000 Front Fork e Bottom Case CQ Seal Cover SH Fm Sep Ring ‘é SQ-1 (2) Install bottom ease to tool. Fork Seal Driver No, 07947-1180001, Ss 1io-115ce(98-3900) ‘tor disety > Ar smn, check fr epernton anno of tet pa a Pour specified amount of ATF into fork pipe. © Wipe off excess oil from around pipe and bottom Date of tue: Fob. 1977 12 HONDA MOTOR 00. LTD. “4 STEERING STEM/ xXL75S 12 FRONT WHEEL / HONDA @ FRONT SHOCK ABSORBER b. Inspection - Measurement (Front Axle Runout) (Front Whee! Runout) 0.05 mm “0.2mm (Replace) (0.002 in.) (0.008 in.) ‘Standard | Service limit Radial runout 0:5 mm (0.0197 in.) Surface runout 0.6 mm (0.0197 in) ‘Service imit| 2.0mm (Replace) (0.0787 in) 2.0 mm (Replace) (0.0787 in) 12-5 Date of Issue: Feb. 1977 © HONDA MOTOR CO., LTD, HONDA FRONT WHEEL/ 12 STEERING STEM, %L75 eront SHOCK ABSORBER ‘(Ball Bearing Rattle} ing Thickness) Standard Service fimit 39-41mm 20mm (0.1635-0.1614 in) (0.0787 in.) (Front Fork Piston 0.0.) Standard Service limit 30927-30960 mm 30.90 mm 110mm Timm (1.2176-1.2189 in.) (1.2165 in.) (4.3307 in) 14.3700 in.) fa (Front Fork Pipe) Check for bending, scratches or scores (Front Shock Absorber Spring Free Length) = “Sean | (Front Shack Absorber Spring Free Length) 397.7.mm 370 mm Standard Service tit (15.657 in) (14556891 31.025—31.064 mm 3iAmm= (1.2215-1.2230 In) (1.2244 in) Date of Ise: Feb. 1977 12 © HONDA NOTOR CO.,LTD, “6 13 : HONDA XL75 2. REAR WHEEL, REAR SHOCK ABSORBER (2) Rear Wheel (1) Drive Chain BER overs ren stown Torque: 400-500 ka-cmn 7 - (28.8-36.2 tbs) ‘After disassembling, check the following items: 1, Rear brake . -Pase 2-7 2. Drive chain tens Page 2-9 3, Stop light switeh -- 2.2... Page 11-9 13-1 Date of Issue: Feb, 1977 4 © HONDA MOTOR CO., LTD, REAR WHEEL / REAR SHOCK ABSORBER REAR WHEEL, WEED sce sre san ia property | ‘seats in wheel hub groove at assembly. "© Wipe wheel hub interior clean at disassembly. © Donot apply grease to interior of whee! hub. (28.9-36.2 Ibs-tt) Driving Ball Bearing HE corm assembly. No. 07948.0370100 Drive bearing squarely into] place in hub. Date of isu: Fab. 1977 GHONDA MOTOR CO.,LTD. 13-2 1 3 HONDA REAR WHEEL / 75 REAR SHOCK ABSORBER =e a. Disassembly/Assembly REAR SHOCK ABSORBER, @ ta Torque: _— EE Sogn (21.7-28.9 Ibs-ft) sora DO, (1) 4 stopper BE icine Lowe oe m : 150-250 kg-cm = % {(10.8—18.1 ibs.-ft.) Lock nut (Disassembling Rear Shock Absorber) | ROTE Install with narrow pitch end up. Rear Shock Absorber ‘No, 07959-3290000 Torque: ‘300400 kgscm (21.7-28.9 bs-ft) (2) Rear Damper: @ ial installing, check the oper ation of the rear shock ab sorters. 13-3 Date of lesue: Fob, 1077 @HONDA MOTOR CO, LTD. & XL REAR WHEEL / 75 REAR SHOCK ABSORBER bb Inspoction - Measurement (Gall Bearing Rate) (Rear Wheel Axle Runout) ‘Standard Service limit 0.05 mm 02mm (0.002 in.) {0.008 in) =e beens A > wei! a (ta so hk ‘ioe Tan a TET ma i sei ie Wide Stowena | aoe nd ‘Check for damage or embedded nails inthe tire (Rear Wheel Oe A Standard Service tinit Spoke Loosenes 0.5 mm 2.0 mm Retighten spoke nipples or repair. (0.0197 in) (0.0787 in.) ss ” oe Date of tsue: Feb, 197 13-4 © HONDA MOTOR CO., LTD. HONDA REAR WHEEL / XL75S REAR SHOCK ABSORBER (Final Drivon Sprocket Wese) Good No good So x DAY DAY (Rear Shock Absorber Spring Free Length) Standard Serves in WE oo sive pcr ma aivernan ant —s [_ wear ate ame ime, (Rear Fork Pivot Bolt-to-Bushing Clearance) Standard ‘Service limit ‘02-03 mm. (0,0078-0.0118 in) Dsmm (0.0197 in) 13-5 Date of Issue: Feb. 1977 © HONDA MOTOR CO.,LTD, HONDA — 14 xL75S 3. FUEL VALVE, REAR FENDER, TAILLIGHT FUEL VALVE [Clean in solvent and blow drv. _——— (3) Filter Screen (2) Lock Nut Ss cA Fuel Tube Check for deterioration or cracking. Dateot sue CHONDA MOTORCO, LTO 141 14 FUEL VALVE/ REAR FENDER/TAILLIGHT a. Disassembly/Assembly REAR FENDER/TAILLIGHT Do not overtighten or lens damage may result. © Check lamps for operation after axsembling. 14-2 Date of Issue: Feb. 1977 i © HONDA MOTOR CO,, LTD. Front Brake Cable Front Stop Switch Wire Ss Throttle Cable — Date of Issue: Feb, 197 © HONDA MOTOR CO., LTD. W xXL7TS ROUTING OF CABLES AND WIRE Wire Harness Routing ‘Turn Signal Relay (mounted on the Fight side of the motorcycle.) To \ To inside of headlight case ‘ » and main switeh \ ae Gipewaee E> \\ Rear stop switch Fuse (7a) ‘Te Battery positive (9) terminal 15. Dateot sue: Feb, 1977 +2 @HONDAMOTOR CO,, LTD HONDA xL75 Engine ‘Clutch Holder (Tool No. 07923-10701) Flywheel Holder (Toot No, 07025-00100) (Cylinder Head) Valve Spring Compressor (Tool No. 07957-329001) = ve Guide Drivor (Toot No. 07842-3290200) 16 IK, SERVICE DATA 1. SPECIAL TOOLS Clutch Holder (Too! No. 07923-10701) Flywheel Puller (Tool No, 07933-0010000) (Too! No. 07984-0980000) Date of Issue: Feb. 1977 © HONDA MOTOR CO.,LTD. 16-1 16 . HONDA SPECIAL TOOLS xL75 Frame (Front/Rear Ball Bearings) (Steering Stem) Cn "26 mm Pin Spanoer ‘(Tool No. 07902.0010000) eS cern Drier NF Meo! No. 07945-8150000) (Top Bottom Race) PS \ Ball Raco Driver (Teo! No. 07944.1150001) (Front Fork) (Rear Shock Absorber) > | es s Fork Seal Driver = (Too! No, 07947-1180001) Disassembling Tool (Too! No, 07969:3290000) 16- Date of sue: Feb 1977 2 SHeNDAMOTOR CO, LTD SPECIAL TOOLS 16 ft to | Deserition Too! No 1 36 mm Pin Spanner 07902-00100 2 Tappet Adjusting Wrench 07908.0010900 2 Fiywher Holder 07828-0010000 4 Fyne! Puller 07933-0010000 5 Valve Guide Oriver 07942-3290200 6 Valve Guide Remover 07942.290100 7 Ball Race Driv 07948-1150001 ° Searing Driver 07945.8150000 8 Fotk Seal Driver 07947-1180001 10 Valve Sarina Compressor 07987 2200001 " 5.48 mm Valve Guide Reamer 107988-0980000 2 Special Too! Case 07737-2920300 Optional Speci! Toole 1 Front Fork Ditassembling Tool 07965.2860000 2 Rear Shock Absorber Disatsambling Too! 07989 3290000 2 Spring Attachment Holder 07967-1150000 Date of Issue: Feb. 1977 © HONDA MOTOR CO.,LTD. 16-3 11 HONDA xXL7S 2. TORQUE SPECIFICATIONS {eosine) aie : I Torque . no. ‘ghtening paint = ” mains me = kg-em Ibs-ft 1 | comahal holder wut 4 6 90-120 54 2 | ace mvnaat ine 1 2 400-500 a4 3. | crankcase (cover) sow ° 70-10 4 | comsorosket bot 2 100-140 = i | -tamsanenpnet 2 70-110 54 © | orve gear nut 1 i“ 360-40 | asam0 | 74 = . Tota Ne. Tightaring point avy | Teed ae oe on a | csheeaneeintaue 1 22 00-700 | 434-806 | 128 2. | rentop brn ri 2 10 300-400 | 217280 | 128 3. | steting lock tow 1 w-0 | oae7 | — 4 | Hance holder boi 4 6 so-120 | sa-e7 | 129 | Front ork botom Gage bate 2 8 190-250 130481 | 129 8 | Front fork axe nat 1 12 400-200 | 209-202 7. | Engine hanger bot 6 8 200-260 | 146-18: | smear ede 1 12 200800 | 289-262 | 194 2 Rear breke torque link nut |o4 a 180-250 130-181 134 10. | ‘uae shock absotber unser dad tower outs | 4 10 so0-400 | 217-209 | 199 11 | ‘step bar tote 4 8 200-250 | sie | 44 12. | Change peda an ick are bat 1 10 20-120 | 58-87 13 | ad tok pen tae 1 10 so0-400 | 217289 | 134 14 | Side stand pivot bor 1 10 soo400 | zi72zas | a1 Torque specifications listed above are important tightening paints. Other should be torqued to standard torque below. Standard Tightening Torques ' Wo Ve Tar 1 ine aslo 90-110 ( 65-87) 2 8 mm bot 100-140 ( 7.3-10.1) 3 Simm bot 200-250 (14.6-18.1) 4 Omm bot 300-400 (21.7-28.9) 1 1 Date of Issue: Feb. 1977 ‘l © HONDA MOTOR CO.,LTD. HONDA 18 xL75 3. SERVICE DATA XQ Unie mim in} No. Trem Siandord Service Limi Page 1 | Sytinder 10. 48.00 48.01 (1,8897-1.8901) | 48.10 (1.8937) | 64 & 2 | Piston 0.0, 47.965-47.290 (1.8809-1.6094) | 47.80 1.8819) | 64 [3 | Pision Pin 00. 12.994-13.00 (08115-05118) | 12,98 (0.8110) | 66 4 | Piston Pin Hole LB. ¥3:002-13.008 (08119-06121) | 13.086(05139) | 65 | Piston Ring Ené Gap | Top. sacona 018-035 _(00088-0.0137) | 060 (0.0197) | 65 e Ci 15-0.35 _(0.0089-0.0137)_| 0.80 (0.0197) 65 € | Piston Ring Side | Top, ascona 0.18.048 (0.0080.0.0177) | 0.12 (0.0047) 6 | eal ou 018-048 (0.0089-00177) | 012 (0.0047) | 6-4 7'| Piston Ring Thickness | Top, second 1.180-1.195 —(0.0465-0.0470) 1.12 (0.0441) 65 | oi 2480-2495 _(0.0976-0.0982) e053 | 66 @ | Vaive 0.0. w 5450-5465 (02145 -0.2161) ais | 88 54305.445 (0.2137-0.2143) | 840 (0.2126) | 55 3 | Valve Guide 1.0 N 5475-6405 (0.2185-0.2159) | 650 (0.2165) | 55 mK 5A75.5.485 (0.2185.0.2160) | 660 (0.2168) | 55 10 | Valve te Valve Guide N ©.010-0.039 (0.0004-0.0013) | 0.08 (0.0031) - e@ X 0030-0055 (0.0012-0.0022)_| 01 (0.0039) & 71 | Waive Spring Free length | Outer | 34.8 (1.4703) 33.7 (1.9268) a7 Toner | 28.05 (1083) 27.6 (1.0866) | 57 Outer | 20.65/13.0kg == 7 Toner | 25.65/5.25 ky = 57 12 | Valve Face Width W 18 (0.0433-0.0590) | 18 (0.0709) 56 % W418 (00433-00800 [18 (0700 | 5-6 18 | Valve Seat Wiat | IW 10 (0.0388) 15 (0.0580) | 55 x 10 (0.0394) 15 (0.0590) 55 | 14 | Clutch Dise Thickness ° (0.1181) 26 (0102) | 74 © trp erna Te ate hype Ei & 27.008 (1-0832) 28.0 (1.0236) | 57 16 | Gutch Spring Free length 24 (ret) 26.3 (1.0354) TA As installed lead) . fength 16-19k9/18 mm _ 17 | Crankshaft Runout W/L 0.015 (0.0008) 21 (0.0039) 95 18 | Conrecting Rod Small End 19 19.016 13.084 (0.8124.05733) | 12.08 (0.6150) | 9-8 18 | Connecting Red Big End Side Gearance [01-035 (.0039-00738) | 06 (0.0236) | as 20 | Connecting Rod Big End Beating Clearance | 00.012 (0-0.0008) 0.05 (0.0020) 36 21_| Rocker Arm Shatt 0.0. 9978-8.987 (0.3930.0.3833) | 981 (0.3902) 57 & 22 | Rocker Arm 10. 70.00-10.015 (0.3037-0.3943) | 10.1 (0.9876 |, 86 Dats of le: Feb, 1977 18-1 (ONDA MOTOR CO., LTD. HONDA 18 SERVICE DATA xL75 Unit: mm (in) Tes Tem Sianaera sevice Unt [Page 23 | Oil Pump | Rolortovotorclowrance 0.15 (0.0058), a2 (00079) | 74 Ouer roorio-bedy ceance | 0.16020 (00050-00079) | 0.25 0.0088) | 7-4 24 | Shiv Fon 1 72000-12018 (oa7ze 0.4701) | 12.08 (0474) | o4 25 | Shift Fork Gude Shalt 00. 11976-11994 (04716-04722) | 11.9(0<70) | 94 26 | Shift Fork Thickness 4935.00 (0.1941-0.1968) 4.70 (0.1850) 94 27_[ hick Stree Pion 6 70020 18041 (0708607102) | Vao7(o7i1) | — Unit: mm (in) We Sands ae 1 00s 0.0020) @2 (0008) | 125 2 ¢ Wheel Hub 1D. 110 (4.3307) 141 (4.3700) | 1268 3 | Front Rear Brake Uning Thikness 3o41@asas-ore14) | 20 ore | 126 4 | Rim Runout O58 (0.0197) - 20 (0.0787) 12-5 & | Front Fork Spring Free tenath 397.7 (15.657) 370 (14,5669) 12-6 @ | Rew Fork Prot Bato bushing Coasnes [0203 @ooroor | 08 Ooren | 198 7 | Rear Shock Absorber Spring Fee Leng | 2260 e298) 7 135 | & | Front Fork Bottom Case 1.0. 31,025-31,064 (1.2215-1.2230) 31.1 (1.2244) 12-6 [re | Front Fom Piston 00. 20,927-80.960 (1.2176-1.2189) [3090 (12106) | 126 18-2 Date of Issue: Feb, 1977 © HONDA MOTOR CO.,LTD. 19 4. SPECIFICATIONS Meine Dimension 1710mm 67.3 in 70 mim 27.9 In 240mm 37.0 in 1110 487 In Seat height TO mm 280 in Foot peg height 260 mm 102 In Ground clearance 180mm 75 In Dry weight 73ko 161 Ibs Frame Two Diamond fame F. sapension, wave) Telescopic fork warel 128 mm (4.96in,) — A, suspension, wavel Swing orm, vavel 85 mm (3.74in. F. tire siza, pressure 2,60-16 (4PR). 26 psi (1.75 ka/sa-em) A. ee ane. pressure 3.00.14 (APR), 28 pl (2.0049 [email protected]) F ing area internal expanding shoes, swept area 86.4 em (7.74 eqn) broke, ining are Internal expanding shoes, swopt ares 86.4 om? (7.74 san) Fuel capacity 6.01, 1.8 USoal_ | 1.37 imp ga. Fuel reserve copaciy 10. 27 usya | 0221p. od. Coser angle WBaogroe Trail fenath 88.3 mm ___2.68in Engi Tyee Air cooled, 4stroke ONC engine Cylinder arrangement ‘Single cylinder 12° inclined trom vertical Bore and stroke 48x41.4 mm 4.889% 1.623 in. Displacement 7a.9e0 487 eu: Compression ratio o0:F Valve iain ‘Chain riven over head camshatt Oil capacity Ooi 96 US qt. | 0.88 Imp. ar, Lubrication system Foreed and wet sump. Cylinder hoad compression pressure 12 ka/aa-em 170 psi Opens BTDC 5° Intake valve Closes ‘ABDC 15° Opens Exhaust valve Closes Valve tappet clearance 0.002, 1,500 ram, Date of Issue: Feb. 1977 © HONDA MOTOR CO.,LTD. 19-1 19 HONDA xXL7S SPECIFICATIONS Mewie English 1 Diive Wain Ghutch ‘Wet, multi plates | Transmission 4-speed constant mesh - [7 Primary eeduction 4437 Gear ratio | 3088 ratio Ih 1882 oar ratio ti 1.333 Geer ratio 1V 1082 Final reduction 2.571 Drie sprocket 147, eriven sprocket 36T Goar shift pattern {Left foot operated return system Eectical anion ‘Magneto and ignition coil Staring system Primary kick sterer il Alternator ‘AG. generatar Spark plug NGK C 7HS o ND U 22FS 19-2 Date of Issue: Feb. 1977 © HONDA MOTOR CO. LTD. NX c 1] Fue reaching Fuel not reaching carburetor 20 5. TROUBLE SHOOTING Couss of trouble (AD No fuel in fue! tank FF Clogged tuet pipe trom tank to arourotor SSS eee ‘Sparks aro weak or 2| sparks jumps 6 rot jump at al T Clogged tue! valve TS Breather hole in ol tank cap clogged (—® Detective spark plug [2 Fouled spa plug 3r poInt gap [5 Detective condenser ion oer oF no com reasuring foree nah when Kick Tf High tension cable broken or shorted [> Ignition ail open ‘or short sircuited [28 Detective main switch [AS Improper ignition timing shat) Enai Stops 0% 4] Engine does not fire os cease T= Blown Out evindar hen gasket [ap Blows or seSles tn eval heed EE Sik rent wave impede vate tm 0 Carburetor choke excessively open F8 Extoureor sr scrcw eneneatony Spon 5] Plug dry Plug wet F=@ Air sucked in cast manifold [a ignition ‘ting’ out Of proper adjustment a Excartive tse of choke, causing wot spark plug Date of Issue: Feb. 1977 @ HONDA MOTOR CO., LTD. 20-1 20 B. Engine lacks power HONDA TROUBLE SHOOTING xL75 Inspection - Adjustment Cause of trouble b Brake deagain Worn sr damages wneet bearing 1 [Wheet spins fresly Wheel does rat spin smoothly 2) Whee! bearng needs lubeieation (6 Dave chain to0 tight 1 Tice pressure is to9| Punetured tire Defective tie valve [© Clutch sipping due to improper adjustment [2 Worn elutch facing CS Ciateh ‘teeing distorted or warped 4 Carburetor choke closed ‘Ar cloaner clogged sli restrcte LE Clogged fuel tube C8 Clogged mutts 2 low while shift {How to! ecord geet 4 [enaing tae go [Enoine does nat when while whe sve ing cluteh lk Engine vicks up | [Engine doesnot pick 4 | speed up speed = (Test ride on Mat paved roma) {Check ignition tint ‘oie timing | i ! [ ition timing = |] [Teniton timing 5| 8 . Weowec Engine out of ignition timing Improper tappet clearance 6 [Tapper clearance is] [Tepper cle cha spas amrsoe hora not corse ria 7 valve senty omve not {chock syinder com . _-jpresson by operat! iIng kick pedal (Use| [—< Veive not seated on vaive west propeity = Worn pion ri 7 Supe is [Compression is feu} ——————_ 38 fi ons 5 ‘3 [3 impreperleniton timing 20-2 Date of Issue: Feb, 1977 © HONDA NOTOR CO.,LTD. cH XL75 20 TROUBLE SHOOTING | Carburetor i not ] [Carburetor is slogged clogged 1 9g Piug is not toured | | Pius is touted or br discolored discolored — ‘check it level by! ip atk. Also check! fil for costamina:| ‘Level is too low oF toa high Clogged oil pipe 11 yatsin i] [Yaew rain wets | 19 logged camaro passage [il © Excessive carbon deposits in combustion 12) Eaaire nee) [Engine cover chamber Sruteted westea Lp un stoping [3 faite 000 aah Woin pissin and vlindse 13[ Faage #0 70] [Era none F9 Misture tco ton. & excsete ceroon apelin oraee LL faition ‘timing 100 early X a L Date of tse: Feb. 1877 © HONDA MOTOR CO.,LTD. 20-3 20 HONDA xL75 TROUBLE SHOOTING C. Oil-up (Excessive exhaust smoke) Cause of trouble ‘eap engine ranniig} F=2 Worn cvnder and piston ing FF Olt tevel in oit pan too high Exhaust smoke not] [Excessive white or ot ae “@ Piston rings fitted upside down noperent biack smoke emicud) }—@ Piston or cylinder scored or scratched r Ug Flaws or eracks in cylinder or heed | Clase throttle grip | quickly ‘Ne white smoke | [White smoke omit] enitted. ted immediately after closing throttle < exhaust valve stom anv Exhaust smote not| [White smoke emit-] oe " a folurad ied fied exhust valve 4 NOTE: White smoke will persist if exhaust muffler Is not cleaned although above measures are ta D. Clutch out of operation Symptom Testing Cause of trouble ° ke [ Clutch spring weakened ‘Gluten slipping @ Clutch plate worn or warped r Clutch friction dss worn or warped Disengege 1 { shift into ge 1 rev up engine | 1 Clutch dragging, Eausing motor Clutch plate oF friction aise distorted sgining, metereete 19 nave eluth sping tension 20-4 Date of Issue: Feb. 1977 © HONDA MOTOR CO... LTD. € HONDA xXL75 © E. Improper shifting ‘Symptom 20 TROUBLE SHOOTING {Clutch normal) © Broken protrusion of shift fork & Broken shift arm paw! Hard shifting [

‘ODOMETER READING [NOTE (2)) ~ FREQUENCY | COMES FIRST Sa + rem | every ENGINE OIL. YEAR R ee ae 28 * | ENGINE OIL FILTER SCREEN L i [| AIRCLEANER NOTE (1) c o 7 | FUEL Lines 1 1 sank PLUG Tee “| VALVE CLEARANCE 1 I q * | CONTACT BREAKER POINTS “Tod 1 1 “IGNITION TIMING C 1 1 r "| CAM CHAIN TENSION A A * | THROTTLE OPERATION Ti Li i 1 *|_ CARBURETOR IDLE SPEED * |_CARBURETOR CHOKE m [oot NOTE(3) | INSPECT EVERY 600 mi. (1, ‘MONTH t ' BRAKE SHOE WEAR | BRAKE FREE PLAY t «| BRAKE LIGHT SWITCH 1 L 1 1 i : i [HEADLIGHT Ai fee CLUTCH FREE PLAY To a i 1 i i SIDE STAND ‘SUSPENSION * | SPARK ARRESTOR NUTS, BOLTS, FASTENERS i WHEELS/SPOKES 7 i ‘STEERING HEAD BEARING 1 | |: INSPECTION, CLEAN, ADJUST, OR REPLACE IF NECESSARY. c: CLEAN R: REPLACE A: ADJUST “*IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED. HONDA DEALER, * SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED, NOTES: (1) More frequent service may be required when riding in dusty orens (2) For higher odometer readings, repeat at the frequency interval established here (3) Initia service period 200 miles. [nw 22-8 Page 12-4, 13-3 | Pom 22-6 | Dsteof tse: Jy, 1977 SHONDA MOTOR CO. LTD. 1977 22-3 22 4. SPECIFICATIONS ADDENDUM SHEET XL75 78 tiem T Metric Dimension | _Overal lenath ih with =I Ground clearance Dry weight Frame a “Telescopic fork, travel 126 rm (4.96 in) Travel 98 mm (3.74 1.) [50-16 (@PR), 25 psi (1.78 kalo) 3.00—14 (4PR), 28 psi (2.00 kg/sarem) internal expanding shoes, swept area 88.4 em? (7.74 win) lining ee internal expanding shoes, swept ares 86.4 em (7.74 39.) [Fuel capacty 801i 1.6_US gl. 7.34 imp. wl Fuel reserve capasity TOT (0.27 US oil. 022 imo. so. ‘Gaster angle G3deqree “Trail iength Simm T LEVI Engine Type [_ Air cooled, 4 stroke ONC engine Gylinder arrangement Single evinder 12" inclined from vertical ‘Dore and stroke 48x AA mm 1.880% 1.620 in: Displacement 49 ce 457 exin, Compression ratio. ao7 Valvo train ‘Chin driven overhead camshaft Gil capacity ait, | __ 0.95 USqt__[ 0.78 1mn at Lubrication system Forced and wet sump Cylinder head compression pressure Y2ka/sa.cm | 170 psi Intake valve ‘Opens _ se pyDG | Closes 18° ABOC ~ Opens 15° BEDC Extwustvelve Closes |_5° ATDC ‘Valve tappet clearance 0.06 mm —I 0.002 in, | _ Idle speed 1.500 rpm Drive wai [__Clutch [Wet malt plates “Transmission “speed constant mesh Primary reduction — 4437 7] ‘Gear ratioT sas ——= Gear ratio N 1.882 7 Gear ratio Wi 1.333 Gear ratio IV 101 7 Final reduction [571 Drive sprocket 147, driven sprocket 36T Gear shitt pattern ‘Lett foot operated return system Electrical —|_Tgnition Magneto and ignition coil Starting system Primary Kick starter Alternetor ‘AG. generator ——_ ‘Spark plug NGK C7HS or ND U22FS (US.A. model) MGL CR7HS or ND U22FSR.L (Canada model) 22-4 Date of Issue: July, 1977 © HONDA MOTOR CO., LTD. 1977 xXL7S ADDENDUM SHEET XL75 ‘78 To _ , WIRING DIAGRAM fishes i iz [ soi Date of Issue: July, 1977 @HONDA MOTOR CO., LTD. 1977 22-5 22 6. INSPECTION © Choke Operation + Operate the choke lever and check for smooth operation ‘© Brake Shoes Inspection (Front/Fear) Replace the shoes if the arrow mark on the brake arm aligns with the index mark on the brake panel, on full application of the brake. © Headlight CAUTION ‘Adjust the headlight beam os speciied by local laws and regulations + Vertical adjustment is made by pivoting the headlight ‘ease on its mounting bolts Horizontal adjustment is made by turning the adjusting screw, Side Stand CGheck the rubber pad for deterioration or wear Repace if wear extends t0 wear line as shown. heck side stond spring for damage and loss of tension, and side stand assembly for freedom of Repair as necessary © Spark Arrestor |1), Remove the spark arrestor trom the muffler outte. 2} Start the engine and expel accumulated carton from the muffler by momentarily revving up the engine, 3). Clean the spark arrestor of carbon. |4) Stop the engine ané reinstall the spark arrestor and mounting bolt. Do not perform this operation immediately after the ‘engine has beon run besause the exhautt 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. + Weer eve protection. ADDENDUM SHEET XL75 ‘78 Weir tine “SZ 22-6 Date of Issue: July, 1977 © HONDA MOTOR CO,, LTD. 1977 xXL75 INTRODUCTION ‘This addendum contains mendatory emissions maintenance for XL75's manufactured after December 31, 1977. (USA only) Follow the Maintenance Schedule recommendations (Page 6) to ensure that the vehicle is always in peek operating Condition and the emission levels are within the standards set by US, Environmental Protection Agency. Performing ‘the frst scheduled maintenance is very important, It compensates for the initial wear that ocours during the break-in period Refer to the base XL75 Shop Manual for service terns not described in this addendurn. ALL INFORMATION, ILLUSTRATIONS, DIREC. ‘TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PROD- UCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD, RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRO- DUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD. Service Publications O XI. °79 ADDENDUM CONTENTS |. SPECIFICATIONS . sasnennsase@—@ I. EMISSION CONTROL SYSTEM (USA only) ..2..2-66:002e0082 29-4 CONTROL SYSTEM 2 .22.--:002040 EMISSION CONTROL INFORMATION LABEL (USA only} 6... 23-5 IIL, MAINTENANCE SCHEDULE ... 2-6 IV. INSPECTION AND ADJUSTMENT 23-7 ENGINE OIL -essscssseeseesseeesee 2867 ENGINE OIL FILTER SCREEN . 2-8 CRANKCASE BREATHER (USA only) .... 23- 9 AIR CLEANER . 23-9 FUEL LINE saben B10 SPARK PLUG 23-10 VALVE CLEARANCE : 231 IGNITION TIMING/CONTACT POINTS... 23-11 IGNITION TIMING ADVANCE + 23-13 CAM CHAIN TENSION... 0-0 .0s¢00r00 28-19 THROTTLE OPERATION 2314 CARBURETOR CHOKE 23-14 CARBURETOR IDLE SPEED 2-14 DRIVE CHAIN, 23-15 BATTERY ....... 23-16 BRAKE SHOE WEAR .... B47 BRAKE SYSTEM............ 23-17 BRAKE LIGHT SWITCH ... 23-19 HEADLIGHT AIM . . 23-19 CLUTCH FREE PLAY 23-20 SIDE STAND. Fs 23-20 SUSPENSION ....... 23-20 SPARK ARRESTER 23-21 NUTS, BOLTS, FASTENERS ....-...... 23-22 WHEELS 2:4! asp auvasapiarscewaiers PBR STEERING HEAD BEARING s+ 33423 V. CARBURETOR .....2.00060.0005 23-24 CARBURETOR SPECIFICATIONS .........23-24 DISASSEMBLY AND ASSEMBLY ........ 23-24 ‘AIR SCREW ADJUSTMENT ...... 23-24 HIGH ALTITUDE ADJUSTMENT se 225 Vi. BREATHER SYSTEM (USA only)... 23-26 Vil. TROUBLESHOOTING ......00000002),4 28-27 Date of Issue: September 1978 © HONDA MOTOR CO., LTD. 23-1 HONDA xXL75 I. SPECIFICATIONS [ Tom Metric English Dimension | _ Overall length 1.710 mm. 67.3in (Overall width 710 men 29in Overall hight ‘950 mm 37.0 in ‘Wheel base 1,110 mm 44.0 in - Seat height | 710 mm 28.0in Foot pag height 260 mn TO2in “round cleeraned 490 mm Tam : _ [bev weight 73 ks 161 bs Frame | Type Diamond frame - F. suspension, travel ‘Teletcopic fork, travel 126 mm (6.0 in) R. suspension, travel Swing arm, travel 86 rm (3.74 inh F. tive size, pressure 2.5016 (4PR), 24 psi (1.75 ko'sa'em) A. tie size, pressure 300-14 (4PR), 28 psi (2.00 ka/sc-em) F, brake, lining ares Internal expanding shoes, swept area 86.4 cm? (13.4 sq-in) R. brake, lining area | Internal expanding shoes, swept area 86.4 em? [13.4 sa) Fuel capacity s5it | 1.5 USoal 121 imp wat | Fuel reserve capacity 10 it 0.26 US onl (0.22 Imp gol Castor angle degree 7 Sinn 27 in Engine ys Ar cooled, 4stvoke ONG enine tinder arrangement Single cylinder 12° in clined from vertical ~ "Bore and stroke 41.4 mm 1889 x 1.62919 Displacement 75cc 487 cuin Compression ratio = 90:1 Chain driven over head camshaft 7 0.9 it 0.95 US at (0.88 Imp at [Lubrication system Forced and wet sump _—_ (ylinder heed compression pressure 12 ko/acper TO psi hin BE ATDG (at 1 mm lift, 42° ATOG (at 0 it) loses 15° ABDC (at T mm lift), 82° ABDC (at 0 it) Opens 15° BBDC (at 1 mm lift), 65° BBDC (at Ott) Extowstvalve | Closes | _ 6° BTDC (at 1 mm lift), 60° BTOC at 0 tit = Valve clearance 0.05 mm 0.002in Ile speed 1,500 109 rom Dey weight 163ke Wa 23-2 Daw of Issue: September 1978 © HONDA MOTOR CO.,LTD. "79 ADDENDUM Mettic English Wet multi plots “speed constant mesh a 3.083 1882 1333 1.042 Final reduction 2571 Gear shift pattern Laft foot operated return system Drive chein IK 4205 or D1D420 94 links Beciticat Ignition Magneto and ignition coit Ignition advance “F” mark 15° BTOC, Static and idle speed [Full advence mark «|= 8.1.5 BTOC RPM from "F tomax. xlvance 1800-3260 rem Oo Starting system Kick starter ‘Alternator ‘AC. generator, 58 W/5,000 rpm Battery capacity 6V-4 AH Fuse capacity 10A ‘Spark plug (USA) side | cold climate =, arna\| alow s°c-41?F) someon | NGK eH c7HS CoH —_ ND _W20FS u22Fs U20e8 Spark plug (for Canada) NGK _|_o.__ ‘Spark plug sap 06-0.7 (00024-0.078 in} ‘Condenser capacity (021-026 uF Date of Issue: September 1978 © HONDA MOTOR CO., LTD. 23-3 HONDA xXL75S II. EMISSION CONTROL SYSTEM CONTROL SYSTEM (USA only) XL75's Manufactured after December 31, 1977 are equipped with two Emission Control Systems. (© Exhaust Emission Control System The exhaust emission control system is composed of a factory pre-set carburetor. No adjustment should be made except idle speed with the throttle stop screw. ‘This system is separate from the crankcase emission control system, © Crankease Emission Control System Blow by gar is returned to the combustion chamber through the air cleaner and the carburetor Crankease Emission Control System Carburetor Intake Pipe j +}— Drain Tube ~~ brain Plug Transparent Section < FRESH AIR —— Blowsy cas 23 Date of Issue: September 1978 4 ® HONDA MOTOR CO.,LTD. ‘79 ADDENDUM. EMISSION CONTROL INFORMATION LABEL (USA only) XL75's manufectured after Docomber 31, 1977 have an Emission Contro! Information Label on the frame at shown. Iteontains basie tune-up specifications c s © EMISSION INFORMATION LABEL Dateot ave: Senember 1978 OHGNDA MCTOR CO, LTD, 23-5 xXL7S Il. MAINTENANCE SCHEDULE Perform the PRE-RIDE INSPECTION in the Owner's Manual at each maintenance period, 1: INSPECT, CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. c: CLEAN R: REPLACE ‘A; ADJUST L: LUBRICATE | WHICHEVER ODOMETER READING NOTE (4) FREQUENCY | COMES —> ~ ae | FIRST &%e, SESE Lge 6S OS teren } ew | every [ASAE TENS to ENGINE OIL YEAR m | sbeeecmeuetey | rages 7 g | 7 ENGINE O1L FILTER SCREEN = ‘CRANKCASE BREATHER (USA ONLY) NOTE (1) € a AIR CLEANER NOTE (2) =e ELS Fuet ines 1 4 ‘SPARK PLUG = H 2 |= vauve cLeanance EI 3 [= IGNivion Timine/conTAGT POINTS Tot B ‘CAM CHAIN TENSION L A A 2 | * THROTTLE OPERATION en [5 cansureTor ince sPeED 1 1 CARBURETOR CHOKE 1 DRIVE CHAIN NOTE (S)_| 1, C EVERY 300 mi. gi satreny MONTH 1 ay # BRAKE SHOE WEAR i 6 BRAKE SYSTEM Lo aOR E | onake icwrswircw Ti val 3 [7 HEADLIGHT Al i Ven @ t (ee | ea Page 23-20, é 1 1 Poge 23-20 & [= suspension aa Page 28-20 5 [> _ SPARK ARRESTER (USA ONLY) cp. Page 23:21 2 [= _NUTS, BOLTS, FASTENERS “| NOTES) i t U Page 23-22 2 [= WHEELs/spoKes nore [1 | 4 [4 Page 23:22 STEERING HEAD BEARING _ I 1 Page 23-23 * SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND ‘SERVICE DATA AND IS MECHANICALLY QUALIFIED. HONDA DEALER. NOTES: (1) Service more frequently when t (2) Series more frequently when (3) Service more frequently when riding OFF-ROAD. IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED (4) For higher odometer readings. repeat at the frequency interval established here 23-6 Date of fssue: September 1978 ‘© HONDA MOTOR CO., LTD. HONDA xXL75 — IV. INSPECTION AND ADJUSTMENT ENGINE OIL. © ENGINE OIL LEVEL CHECK Support the motoreycle upright on level Bos111202 OIL FILLER CAP. ground, and remove the oll filler eap/dipstick and wipe it clean. Insert the dipstick and check the oil level NoTE UPPER LEVEL MARK not sefow in the diphick MARK making this check, Roan OL LEVEL SHOULD BE BETWEEN THESE LimiTs 1f the oil level is below the lower level mark, fill to the upper level mark with the recom: mended oi © ENGINE OIL CHANGE Remove the oil filler cap and drain plug after the engine is warm, and drain the oil. Install the Grain plug. and make sure that the sealing wsher is In good condition, TORQUE: 2-3 kgm (15-22 feb} Fl the crankcase with the recommended oil OIL CAPACITY: 0.9 lt (0.95 US qt) [RecommeNceDONM: ———SSSCSCS~*SY Us HONDA +STRORE OIL oF equiva API SERVICE CLASSIFICATION: SE ‘scosr ‘Sen prt SAE 10H—€0 Atwnete Ahov CTE saz S — Tae Wer -wrens'e-is'cier | SAE iow CREF SAE OW — OIL SPECIFICATION ee Install the oi filer ep ==» ron Stop the engine, and make sure that the oi! level is at the upper level mark with the earn” Date of Issue: September 1978 23 © HONDA MOTOR CO,, LTD. “1 79 ADDENDUM ENGINE OIL FILTER CLUTCH CABLE SCREEN Drain the engine ol. Turn the fuel valve lever “OFF” Loosen the carburetor drain sorew and drain the float chamber, then retighten the screw. Remove the kick starter pedal and the right foot pes, and disconnect the clutch cable from the clutch arm, FOOT PEG ™~ ~ ‘Snr crankcase coven Rove thei ranks coe. Fors onder el er sen. poppe esta etches (ra Foes FILTER SCREEN Install the kick starter pedal and clutch cable, ‘Adjust the clutch cable. Fill with the specified engine cil, turn the fuel 23 8 Date of Issue: September 1978 _ © HONDA MOTOR CO., LTD. Ox CRANKCASE BREATHER (USA only) Remove the drain plug from the drain tube, ‘and drain deposits. Install the drain plug. ‘79 ADDENDUM DRAIN PLUG NOTE ‘Service more frequently when driven in rain or at full throttle or if the deposit level can be seen in the tansparent section of the drain tube. AIR CLEANER Remove the right side cover, Remove the turn signal relay. Remove the air cleaner cover attaching nuts and cover Pull out the air cleaner element retainer and ‘element. Wash the element in nonflammable or high flash point solvent and allow to dey. Soak the air cleaner element in clean gear oil {SAE 80-90), and squeeze out the excess. Install the air cleaner element and re Install the air cleaner cover, turn signal relay, and right side cover. excess solvent Gear Atowtodry (SAE 80-90) Squeeze out excess oil, Date of issue: September 1978 23-9 © HONDA MOTOR CO., LTD. p '79 ADDENDUM FUEL LINE rn Replace wor, damaged or leaking any parts. ras SPARK PLUG Disconnect the spark plug cap, and remove the spark plug. Visually inspect the spark plug electrodes for = ae ‘The center electrode should have square edges {GOA- 0428 in) SIDE ELECTRODE chipped. If the spark plug deposits can be removed by sandblasting the spark plug can be reused. Adjust the spark plug gap by bending the side electrode, SPARK PLUG GAP: 0.6-0.7 mm (0.024-0.028 in) RECOMMENDED SPARK PLUG USA model - Usoge |For cold climate For extended high Man itacarae— (below 5°C) Standied ‘peed riding ND ‘U20Fs U22Fs u24Fe NGK con c7us on CANADA model ND: U22FSR-L NGK: CR7HS Manufacturer: ND: Nippondenso Co,, Ltd. NGK: NGK Spark PlugCo,, Led. Install the spark plug, tighten it by hand, then tighten with a spark plug wrench, Connect the spark plug cap. 23-10 Date of Issue: September 1978 © HONDA MOTOR CO,, LTD ‘79 ADDENDUM VALVE CLEARANCE wore Vien dan eliatent Ta bF performed while the engine is cold, © Bates cas Remove the left crankcase cover and oylinder hnoad cover Rotate the flywheel counterclockwise and align the “T" mark on the flywheel with the g index mark on the left crankcase. The piston ‘must be at T.D.C. of the compression stroke. Measure the Intake and exhaust valve Glearances with a 0.05 mm (0.002 in} feeler ‘gauge. Incort the gauge botwoon the valve adjusting serew and valve stor. ‘Adjust by loosening the valve adjusting screw lock nut and turning the screw until there is a slight drag on the feeler gauge. € Hold the adjusting screw and tighten the lock rut. Recheck the clearance. Install the left crankcase cover and cylinder head cover, IGNITION TIMING / aS a @ GONTACT POINTS q se REPAIR OR REPLACE ‘Remove the left crankcase cover. ONE SIDE CONTACT BURNED Inspect the contact point surfaces. If they are BADLY WORN fares coe e tens ey Soot eee ees el tor Nese lt wa wes Siar wieoseae. Se ee ee replaced. . ale @'HONDAMOTON CO. LTO. 23-11 ‘79 ADDENDUM Disconnect the A.C. generator wires. Connect 2 continuity light to the black/white lead and to a battery positive terminal. Connect the negative battery ter convenient frame or engine ground. Rotate the flywheel counterctockwise and align the flywheel “F* and crankcase index marks. ‘The timing is correct ifthe light becomes dim ‘when both marks align. If ignition timing is incorrect, loosen the ‘contact breaker locking screw and adjust the breaker point gap. Increasing te gap will advance ignition timing. Decreasing the gap will retard ignition timing Tighten the locking screw and recheck the ignition timing. NOTE Replace the contact breaker point: iF the timing cannot be correctly adjusted while maintaining a minimum point gap 0f0.3-0.4 mm (0.012 -0.016 in). Batery Index Mark Locking Serew Conneet the A.C. generator wires. Install the left crankcase cover. ae ’ NN Poin Fer Si @ 93.04 nm (0.012=0016 in) YES Locking Serew 23-12 Date of Issue: September 1978 © HONDA MOTOR CO., LTD. xXL7S5 '79 ADDENDUM = DYNAMIC TIMING © Using a Strobosepic Timing Light NOTE ‘Adjust the contact breaker point gap é€ before this adjustment. Connect 2 tachometer and a timing Hight. Start the engine and make sure thatthe engine idle spaed i 1,500 # 100 rpm. The timing f correct, ifthe "F mark on the flywhee! aligns with the index mark on the @ left crankcase cover. ‘Adjust the timing, uting the same procedures 4 forthe continuity light IGNITION TIMING ADVANCE NOTE Betore performing this test, check and) adjust the ignition timing, 1. Connect » tachometer and a timing light. € 2. Start the engine, Increase engine speed to 3,400 rpm. FULL ADVANCE: 3400 rpm. Check that the index mark aligns with the advance marks, at 3,400 rpm as shown. If the index mark does ‘not align between the advance marks, check the spark advance mechanism, Replace if necessary, Start te enna tite oer ei cai tone tose i ane seu Foe, ‘wnover. will atoraticly postion ait povotin crac onson, ‘Taher coh Sun rae ae ne ~ NOTE When tightening the lock nut, hold the adjusting bolt to prevent it from turning ‘with the lock nut. Date of Issue: September 1978 © HONDA MOTOR CO., LTD. HONDA xL75S ‘79 ADDENDUM THROTTLE OPERATION Inspect the throttle cable for deterioration, damage or kinks, and measure the throttle rip free play at the flange. THROTTLE GRIP FREEPLAY: 2-6 mm (1/8-1/4 in) 2-6 mm (8-1/4 ind Check for smooth throttle grip rotation from fully open to automatic full closing in all steering positions. Adjust or replace as | UPPER — - necessary. ADJUSTER. ADJUSTMENT: Throtte grip fee play can be adjusted at cither end of the throttle cable. Minor adjustments can be made by the adjuster at the right handleber. Loosen the lock not and turn the adjuster, Tighten the Lock nut. Recheck the operation of the throttle grip. CARBURETOR CHOKE Operate the: operation, woke lever andl check for smooth CARBURETOR IDLE SPEED NOTE Check the idle speed after all other maintenance items have been performed. ‘Support the vehicle in an upright position. Warm up the engine. Tum the throtile stop screw 95 required 10 obtain an idle spoed of 1,600 + 100 rpm. NOTE + The engine must be warm for b ‘accurate idle speed adjustment. Stop and go driving for tn minutes is sufficient. Motorcycles manufactured after Decemoer 31, 1977 have the air screw factory preset. Do not adjust unless the carburetor is overhauled. 23-14 Date of Issue: September 1978 © HONDA MOTOR CO.,LTD. HONDA “) xL75 ‘78 ADDENDUM DRIVE CHAIN NOTE Perform ths maintenance with the ignition switch off. © DRIVE CHAIN FREE PLAY Place the vehicle on its side stand and shift the transmission into neutral Measure the drive chain fee play midway between sprockets on the lower chain run, FREEPLAY: 15-25 mm (5/81 in) © ADJUSTMENT Remove the cotter pin from the rear axle nut and loosen the nut. Tum nuts on both adjusters as required until the correct free play is obtained. NOTE ‘Be sure that the index mark aligns with the same scale graduation on both sides. Tighten the axle nut and install @ new cotter pin, TORQUE: 4.0-5.0 kg-m (23-36 feb) Lubricate the drive chain, * CLEANING/LUBRICATION When the drive chain becomes extremely dirty, it should be removed and cleaned prior to lubrication, Remove the master link retaining eip. NOTE Do not bend or twist the clip, Remove the master link. Remove the drive chain. Clean the chain with nontlammable or hhigh flash point solvent and brush, and allow 10 dry. Inspect the drive chain for possible wear or damage. Replace any chain that ie damaged or excessively worn. Inspect the sprocket teeth for excessive wear oF damage. Replace if necessary, worn sprockets or a worn chain on new sprockets. Both chain and sprockets must be ia good condition, or the new replacement chain or sorockets will wear rapidly. + Aerosol type drive chain lubricants recommended. LUBRICANT Date of Issue: September 1978 ‘© HONDA MOTOR CO.,LTD. 23-15 "79 ADDENDUM Lubricate the drive chain. Saturate each chain Tink joint. Install the drive chain and the master link. Install the master link retaining clip 40 that the closed end feces the direction (of forward wheel rotation. Master links are reusable if they remain in excallent condition, ‘but itis recommended thet anew master link bbe installed whenever the drive chain is reassembled. ‘Adjust the drive chain (See page 23~-15). BATTERY Remove the left side cover: Remove the battery band bolt and remove the battery. Inspect the battery fluid level Wher the fluid nears the lower level, refill With distilled water to the upper level. NOTE a ‘Add distitied water only. Tap water will shorten the service life of the battory ‘The battery electrolyte contains sulfuric oid, Protect your eyes, skin and clothing. In ease of contact, flush thoroughly with water and call a doctor if your eves were exposed, Route the battery breather tube as shown in the diagram. FILLER CAPS DISTILLED WATER ‘| ELECTROLYTE LEVEL t CARB ‘OVER FLOW TUBE BATTERY BREATHER TUBE 23-16 Date of Issue: September 1978 © HONDA MOTOR CO.,LTD. HONDA xXL7S ‘ 79 ADDENDUM * BRAKE SHOE WEAR FRONT Replace the brake shoes if the arrow on the Levene nee eenaneir ec tee pe een e é&< BRAKE SYSTEM © FRONT BRAKE LEVER FREE 10~20 mmm (3/8~2/4 in) PLAY Measure the brake lever free play at the lever end € FREEPLAY: 10-20 mm (3/8-3/4 in) Make major adjustments with the adjuster ea Tee tates Jock nut and turn the adjusting nut. @ wae ia | NOTE INCREASE “Turn in the upper edjuster on the bra evar before adjusting at the wheel hub, ADJUSTING NUT STHONDA MOTOR CO. LTD. 23-17 Make minor adjustments with the upper ‘adjuster located on the brake levar Loosen the lock nut and turn the adjuster. Recheck the brake operation. Tighten the lock nut. © REAR BRAKE FREE PLAY Check the brake pedal free play. FREEPLAY: 20-30 mm (3/4—1-1/4 in} If adjustment is necessary, turn the rear brake adjusting nut, ‘79 ADDENDUM HONDA xXL7TS INCREASE INCREASE ADJUSTING NUT 23-18 Date of Isue: September 1978 ‘© HONDA MOTOR CO.,LTD. HONDA XL75 ‘79 ADDENDUM © BRAKE LINKAGE Check the brake rodicable and brake lever/pedal for loose connections, excessive play, bending or damage, Replace or repair if ‘necessary. Inspect the brake and stopper arms for loose connections or damage. Check that the cotter pin is installed property. Co BRAKELIGHT SWITCH Adjust the brake light switch so that the light will come on when the brake padal i depressed 20 mm (3/4 in), where the brake 18 engagement. Adjust by turning the ‘switch adjusting nut. HEADLIGHT AIM ‘The headlight beam can be adjusted vertically and horizontally Adjust vertically by loosening the headlight ‘mounting bolts. Adjust the horizontal beam with the beam adjusting screw shown, NOTE ‘Adjust the headlight bear as specified ‘An improperly adjusted headlight may | ADIUSTING. ‘Blind oncoming drivers, orit may fail 1o | __ SCREW light the road fora safe distance. SHONDAMOTON GO” LTD. 23-19 '79 ADDENDUM. CLUTCH FREE PLAY © INSPECTION Check that the engine starts easily without the elutah slipping. Check that clutch operation is emooth and light when changing gears, especially when down shifting to neutral. * ADJUSTMENT Loosen the adjusting screw lock nut. Slowly turn the adjusting screw ‘counterclockwise until a resistance i felt. Then tum the adjusting screw clockwise 1/8-1/4 turn, and tighten the lock nut. SIDE STAND Check the rubber pad for deterioration or wear. Roplace if waar extends to the wear line, ae shown, CCheck the spring for damage or loss of tension check the enter assembly for freedom of movement and bending. NoTE When replacing the pad use one wit the mark “BELOW 259 Ibs ONLY’ Spring tension is correct if, the measurements fall within 2-3. kg (4.4-66 Ib) whon pulling the sido sand lower end using a spring scale. SUSPENSION MI Do mot ride @ vehicle with fauly suspension. Loose, worn or damaged suspension components may impair vehicle stability, safety and rider contro, * FRONT Check the action of the front forks by compressing them several times. Check the entire fork assembly for signs of leaks, or damage. Replace any components which aro uneepairable. Tighten ail bolts and nuts (See page 17-1). dost weak ne ‘ wee Goo / 23-20 Date of tsue: September 1978 @ HONDA MOTOR CO.,LTD. HONDA xXL7TS ‘79 ADDENDUM @ REAR J} REAR SUSPENTION Place the vehicle on its side stand. Move the rar wheel sideways with force to see if the swing arm bushings are wor. Replace if excessively worn. ‘Check the entire suspension assembly to see if itis sxcurely mounted, damaged or bent SPARK ARRESTER ‘Do not perform this maintenance immediately after the engine has been ran because the exhaust system becomes very hot. + Because of the fire hazard ensure ‘that there are no combustible ‘materials near by. + Exhaust gases contain poisonous ‘carbon monoxide. Perform this ‘operation only in a well ventilated ‘area. Wear eye protection. Remove the spark arrester mounting bolt and spark arrester. Start the engine and remove carbon from the mutfier by momentarily increasing engine speed. Clean the spark arrester with 2 wire brush Install the spark arrester and mounting bolt. aes 23-21 HONDA xXL7T5 ‘78 ADDENDUM NUTS,BOLTS, FASTENERS (Check that all chassis nuts, bolts and fasteners are tightened 0 their correct torque values (See page 17-1), WHEELS © TIRE PRESSURE Check the tires for cuts, imbedded nails, or other sharp objects. NOTE Tite pressure should be checked when the tires are COLD. Cold tire pressure |_Front: 1.75 (24) kglem? (psi) | Rear: 2.0 (28) Vehicle capacity toad timit kglibe)_|_ 100 (220) Front: 250-164PR Rear: 3.00-144PR Replace tire: when tread depth becomes less than 3 mm (1/8. © WHEEL SPOKE RETIGHTENING Tighten the wheel spokes periodically. TORQUE: 0.15-0:30 kgm (1.1-2.2 fttb) Tire size NIPPLE SPANNER (Check front and rear wheel trueness. 23-22 StonDA woTOR CO, LTD. ‘78 ADDENDUM STEERING HEAD BEARING NoTE Check that the contvel cables do not interfere with handlebar movernent. Raise the front wheel off the ground. Check that the handlebar moves freely. 1f the handlebar moves unevenly, binds or has vertical movement, adjust the steering head bearing by tuming the steering head adjusting ‘nut with a pin spanner. Dateot er 1978 SHONDAMOTOR CO, LTD. 23-23 V. CARBURETOR ——————______. CARBURETOR SPECIFICATIONS Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in High ate tude see seam (1.500 m 5,000 vind enitcaion Maino on a (options Jt needle nark | 178 eee Float heh | 20mm 374m) | ——— {ae somd | 11600' 100 rpm | = DISASSEMBLY AND ASSEMBLY Refer to the base XL75 Shop Manual for carburetor disassembly and assembly. pro: When disassembling jue system parts, ote the locations of the Orings Replace them with new ones on reassembly. The float bow! hes drain plug that can be loossned to drain residual gasoline. AIR SCREW ADJUSTMENT NOTE Tho air erow le fectory preset Adjustment is not necessary unless the ‘carburetor is overhauled or a high altitude main jet is installed. ‘Turn the air screw clockwise until it seats lightly and back it out 2-1/8 turns. This is 3 preliminary setting prior to the final Air Serow Adjustment. [caution] ‘Darnage 10 the air serew seat will occur ifthe air crew is tightened against te 23-24 Date of Issue: September 1978 © HONDA MOTOR CO.,LTD. ‘19 ADDENDUM Warm up the engine to operating temperature, Stop and go driving for ten minutes is sufficient. Attach a tachomoter [Adjust the idle speed with the throttle stop IDLE SPEED: 1,500 + 100 rpm Screw the sir screw in gradually until the engine stops. Tum the air screw 1 tum out from this position, Start the engine and readjust the throttte stop screw, if necessary. HIGH ALTITUDE ADJUSTMENT ‘The carburetor must be adjusted for high altitude riding (above 2000 m 6500 ft) STANDARD SETTING: 2000 m (6500 ft) ‘maximum HIGH ALTITUDE SETTING: 1500 m (6000 ft) minimum Turn the fuel valve “OFF. Remove the carburetor and drain the float chamber. Remove the flost chamber. Remove the standard main jet (No. 78) and install the high altitude main jet (No. 72). Install the float chamber. Tur the air screw counterclockwise 1/2 turn from the factory pre-set position. Install the carburetor. Start the engine ond adjust the idle speed to 1,800 + 100 rpm. NOTE * Adjust the idle speed at high altitude to ensure proper high ati: titude operation * Readjust the air screw if the engine idles rough, misses, or stalls, according to the instructions on page 23-24. CAUTION) ‘Sustained operation at altitudes lower ‘than 1,500 m (5,000 ft) with the high altitude wpecifications may cause engine verheating and damage. Install the standard main jet and turn the air screw 1/2 tum clockwise when operating the vehicle below 1,500m (5,000 ft) MAIN JET. Date of Issue: September 1978 © HONDA MOTOR CO.,LTD. 23-25

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