_& HONDA
SHOP MANU AL
XL75IMPORTANT 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 selectedxXL80S
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 XLB0STABLE 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.
MM2
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 edq , 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 “42 : 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 needleiz : 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 “8HONDA
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, LTO5
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. 5-15 . 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. 5-3CYLINDER 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,
5-55
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 adjustment6 . 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. ie6 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. 17 : 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. 8-1A.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. 9-2HONDA
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. +610
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. 10-210
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. 10-41
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.
11-211 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. 11-41
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 ScareHONDA 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. LTO1
Horn inspection
MEMO
SMoNDA MOTOR 69. LD 11-1012
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. “4STEERING 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, “613 : 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. 13-21 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 14114 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,, LTDHONDA
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.
16-116 . 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, LTDSPECIAL 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.
16-311 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.
19-119
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.
20-120
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. 20-320 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 22-322
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. 1977xXL7S
ADDENDUM SHEET XL75 ‘78
To _ , WIRING DIAGRAM
fishes
i
iz
[
soi
Date of Issue: July, 1977
@HONDA MOTOR CO., LTD. 1977 22-522
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. 1977xXL75
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.
23-1HONDA
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.
23-3HONDA
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, 23-5xXL7S
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. “179 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. 23-17Make 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 23-21HONDA
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. 23-23V. 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