Honda Atc 125m Service Repair Manual 1986-1987

B6-B7 ATC125

.--------- IMPORTANT SAFETY NOTICE ----------, Ind icQles a strong possibility 0/ sel'ut! personal injuf}' or loss 0/ life if instruttions are nOI follo .... ed. CAUTION: Indicates (J possibility oj lH?fSOnol injury or eqU/pmen/ damage if instructions aft! not follo .... ed. NOTE: Gives helpful information. Detailed descrlpttons of standa rd workshop procedures, safety principles and se rvice oper ations are not included. It IS important to note that this manual contains some warnings and cautions against some specifIC service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe . Please understand that those warnings could not cover all conceivable ways In which service, whether or not recommended by Honda might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tool s, whether or not recommended by Honda must sstisfy himself thoroughly that neither personal safety not vehicle safety will be jeopardized by the service method or tools selected.

HOW TO USE THIS MANUAL Sections 1 through 3 apply to the whole ATC , while sections 4 through 17 describe parts of the ATC, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sec t ions start with an assembly or system illustration and all the required specifications. torque values, general instructions. tools and troubleshooting for th e section. The subsequent pages give detailed procedures. If you there is a problem with the ATC and don ' t know the source of the trouble. see section lB . TROUBLESHOOT ING . CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION ~ ~~~~~==: " CYLINDER/PISTON ~ ~======================== .... <I CLUTCH/GEARSHIFT LINKAGE RECOIL STARTER/ALTERNATOR TRANSMISSION/CRANKSHAFT IGNITION SYSTEM '-' BATTERY/CHARGING SYSTEM a: >- bl STARTER SYSTEM .... w LIGHTS/SWITCHES TROUBLESHOOTING INDEX

1. GENERAL INFORMATION GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS GENERAL SAFETY i ;1 . 1-1 1-1 1-2 1-3 l Ithe engine must be running to do some work, make sure the area is ... tll-~'entifated. Nel'u run the engine in a closed area. The txhaust COn/ains poi sonous carbon monoxide gas. The batter)' generates h) 'droge" gas which con be highly ('xpfo- sil't. Do nor smoke or allow flames or sparks near the baUer)'. especially while charging it. SERVICE RULES TORQUE VALUES TOOLS CABLE & HARNESS ROUTING NOISE EMISSION CONTROL SYSTEM 1-5 1-7 1-9 1- 13 Gasolin,;s extremel), flammable and; s exp!osil't' under certain conditions. Do 1I0r smoke or allow flames or sparks in J'OUf work area, Thl' ballery eleclrofJ'U contains SUlfuric acid, Protect )'OUT tyn , ski" and clothing. In case 0/ contact, flush thoroughl y with .... ater and call a doctor 1/ elulrolyle gelS in your e}'es. 1. Use genuine HONDA or HONDA -recommended parts and lubricants or their equivalents. Parts t hat don 't meet HONDA 's design specifications may cause damage to the ATC. 2. Use the speci al tools designed for this product to avoid damage and incorre ct assembly. 3. Use only metric tools when servicing this ATC . Metric bolts, nu ts and screws are not interchangeable with English fasten- ers. 4 . Install new gaskets. O-rings cotter pins. and lock plates when reassembling . 5. When tig hten ing bolts or nuts. begin With the larger-diameter or inner bolt first . Then tighten to the specified torque diago- nally in 1 -5 steps, unless a particular sequence is specified. 6. Clean parts in non-flammable or high flash point solvent upon disassembly. 7. lubricate any sliding surfaces before reassembly. 8. After reassembly, check all parts for proper installation and operation. 1-1

GENERAL INFORMATION MODEL INDENTIFICATION The frame serial number is stamped on the steering head right side. The carburetor identification number is on the carburetor body left side. 1-2 The engine serial number is stamped on the crankcase lower l eft side.

GENERAL INFORMATION SPECIFICATIONS • DIMENSIONS Overall length 1,660 mm (65.4 in) Overall width 990 mm (38.9 in) Overall height 965 mm (37.9 in) Wheelbase 1,085 mm (42.7 in) Rear tread 720 mm (28.3 in) Seat height 680 mm (26.8 in) Fo ot peg height 245 mm (9. 6 in) Ground clearance 115 mm (4.5 in) Dry weight '25 kg (276 Ib) FRAME Type Semi double credle Rim size Front 22 x 11.0 -8 Rear 22 x 11.0 -8 Front tire size, pressure 0.15 kg/cm 2 12.2 psi, 15 kPa) Rear tire size, pressure 0.15 kg/cm2 (2.2 psi, 15 kPa) Front brake Internal expanding shoe Rear brake Internal expanding shoe Fuel tank capacity 8.5 liters (2.2 US gal, 1.9 Imp gall Fuel reserve capacity 1.4 liters (0.4 US gal, 0.3 Imp gal) Caster angle ,," Trail length 16 mm (0.63 in) ENGINE Type Gasoline, air-cooled 4~sttoke Cylinder arrangement Single cylinder, 25 0 inclined from vertical Bore x stroke 54 x 54 .5 mm !2. 12 x 2.14 in! Displacement 124 cc !4.9 cu in! Compression ratio 9.0 : 1 Valve train Overhead camshaft chain driven Maximum horse power 9.3 BHP/7,5OD rpm Maximum torQue 0.96 kg-m/ 6,000 rpm /16.9 1t -lb/6.ODO rpm! Oil capacity 1.3 liters! 1.4 US qt, 1.1 Imp Qt! at draining Lubrication system Forced pressure and wet sump Cylinder compression 13.3 j: '.0 kg/cm~ (189 ± 14.2 psi, 1,330 ± 100 kPa) Intake valve OPENS 0 0 STDC CLOSES 30° ABDC } at 1 mm lift Exhaust valve OPENS 30 0 BBDC CLOSES 0 0 ATDC Valve clearance Intake 0.08 mm 10.003 in) (Cold) Exhaust 0.08 mm (0.003 inl Idle speed 1.500 ± 100 rpm CARBURETOR Type Piston valve Ma in jet No. #95 Slow jet No. #35 - #35 Pilot screw opening 2 turns out Jet needle 3rd groove Float level 10.7 mm (0.42 in) 1-3

GENERAL INFORMATION DRIVE TRAIN Clutch Wet mUlti-plate automatic Transmission 5-speed constant-mesh with reverse Primary reduction 3,737 Gear ratio I 3.250 II 2. 188 III 1.550 IV 1.167 V 0.923 Reverse 4.593 Final reduction 4.000 Gearshift pattern Left foot operated return system, Forward: N-S /L- 1- 2-3-4 Reverse: N - R ELECTRICAL Ignition COl Ignition timing In iti al 10°:l:. 2° BTCD at idle Full advance 28° ::t 2° BTDC at 4 ,000 rpm Alternator Capacity 130W/5,DOO rpm Battery 12V - l0AH Spark plug NGK ORBES -l NO X24ESA·U Spark plug gap 0.6 - 0.7 mm (0.024-0.028 in) Headlight 12V-45W/ 45W Taillight 12V- 5W Neutral indicator 12V· 3W Reverse indicator 12V-3W 1-4

GENERAL INFORMATION TORQUE VALUES ENG INE Item C'tv Thread dia. N·m kg·m ft-lb Remark {mm) Cylinder head cap nut • 8 28 - 30 2.8 - 3.0 20 - 22 - Apply oil to cap nut Spark plug 1 12 12- 19 1.2- 1.9 9- 14 Valve adjusting hole cover 2 36 9- 15 0.9-1.5 6.5- 11 Valve adjuster lock nut 2 6 15- 18 1.5 - 1.8 11 - 13 Apply oil to lock nut Cam sprocket bolt 2 1 18 - 20 , .8-2.0 13- 15 - Apply oil to bolt Cam chain tensioner sealing bolt 1 6 8- 12 0.8-1.2 5.8- 9 T ensioner pivot bolt 1 6 10 - 14 1,0 - 1.4 7.2 - 10 Centrifugal clutch lock nut 1 16 70 - 80 7.0 - 8.0 51 - 58 , Apply oil to lock nut L left hand thread Manua l clutch lock nut 1 16 50 - 60 5.0-6.0 36 - 43 - Ap ply oil to lock nut Clutch adjuster lock nut 1 8 19- 25 , .9-2.5 14 - 18 Gearshift return spring pin 1 8 24 - 30 2.4 - 3.0 17- 22 Starter driven pulley bolt 1 8 40 - 50 4.0-5.0 29 - 36 - Apply oil to bolt Drum plate center bolt 1 6 10 - 14 1.0-1.4 7.2 - 10 Pulse generator mount screw 2 5 8- 12 0.8-1.2 5.8- 9 Timing hole cap 1 I. 10 - 14 1. 0-1.4 7.2- 10 Oil drain bolt 1 12 35 - 40 3.5-4.0 25 - 29 Intake pipe attaching bolt 2 6 6- 9 0.6-0.9 4.3- 6.5 Cylinder head bolt 1 6 10 - 14 1.0-1.4 7.2-10 Sterter dutch bolt 3 8 26 - 30 2.6-3.0 19- 22 Alternator stator bolt 3 6 7- 11 0.7 - 1. 1 5. 1- 8 1-5

GENERAL INFORMATION FRAME Item Q'ty Thread dia. /mm) N·m kg-m ft -Ib Remark s Handlebar holder bolt 4 8 18- 30 1 .8- 3.0 13- 22 Handlebar holder nut 2 10 40 - 50 4.0 -5.0 29 - 36 Fork bridge bolt 2 12 50 - 70 5.0 - 7.0 36 - 51 Steering stem nut 1 22 50 - 70 5.0- 7.0 36 - 51 Bearing adjusting nut 1 22 20 - 30 2.0-3.0 15 - 22 r- Initial 7- 8 0.7-0.8 5.1 - 5.8 r- Final Eng ine hanger bolt 5 8 30 - 36 3.0 - 3.6 22- 26 2 10 70 - 80 7.0- 8.0 51 - 58 Drive sprocket bolt 1 8 24- 30 2.4-3.0 17 - 22 Gearshift pedal bolt 1 6 14 - 18 1.4-1.8 10- 13 Footpeg bolt 4 12 80 - 100 8.0 - 10.0 58 - 72 Seat/rear fender mount nut 4 6 6- 9 0.6 - 0.9 4.5- 6.5 Mud guard bolt 10 6 6- 9 0.6 - 0.9 4 .5- 6 .5 Front wheel hub nut 4 10 50 - 60 5.0 - 6.0 36 - 43 Wheel rim nut 12 10 30 - 40 3.0-4.0 22 - 29 Front a)(le nut 1 14 70 - 110 7.0-11.0 51 - 80 Rear wheel hub nut 4 10 50 - 60 5. 0-6.0 36 - 43 Rear axle nut 2 18 80 - 100 8.0 - 10.0 58 - 72 Rear brake drum nut 30 40 - 50 4.0-5.0 29- 36 - Inner 140 - 150 14.0-15.0 101 - 108 - Outer Driven sprocket nut 4 8 28- 32 2.8 - 3.2 20 - 23 Rear axle bearing holder bolt 4 12 50 - 70 5.0 - 7.0 36 - 51 .. Torque specifications hsted above are for the most Important tightening pOints. If a torque specificatIOn IS not listed, follow the standards given below . STANDARO TORQUE VA LUES Item Torque N'm (kg·m , h-Ib) Item Torque N'm (kg·m, ft · lb ) 5 mm bolt, nut 4.5- 610.45 - 0.6, 3- 4) 5 mm screw 3.5 - 510.35 - 0.5 , 2- 4) 6 mm bolt, nut S- 12 10. S-1.2,6-9) 6 mm sc rew , 6 mm 7- 11 (0.7-1. 1, 5-S) flange bolt with S mm head S mm bolt, nut 1S - 2511.S - 2.5,13 - 1S) 6 mm flange bolt, nut 10- 1411.0 - 1.4,7 - 10) 10 mm bolt, nut 30 - 40 (3.0- 4.0, 22 - 29) S mm flange bolt, nut 24 - 30 (2.4 - 3.0, 17- 22) , 2 mm bolt, nut 50 - 60 15.0-6.0, 36-43) 10 mm flange bolt , nut 35 - 45 (3 . 5-4.5, 25 - 33) 1-6

GENERAL INFORMA nON TOOLS SPECIAL Description Number Alternative Ref. Page Cylinde r compression gauge attachment 0751Q-MBOO1Dl Equivalent commercially available in U.S.A. 3-15 Valve guide reamer, 5.48 mm 07984 - 0980000 6~9 Bearing remover set, 12 mm 07936 - 1660001 B~3 - bearing remover shaft assy, 12mm 07936-1660100 B~3 - remover we ight 07741-0010201 8-3,10-8 Bearing remover, 15 mm 07936-KC10000 10-8 - remover assy, 15 mm 07936-KC10500 10-8 - remover shaft, 15 mm 07936 - KC10100 10-8 - remover head, 15 mm 07936 - KC10200 10-8 Clutch cente r holder 07923 - 9580000 8-9,12 Attachment, 45 x 50 mm 07946 - 6920100 10-9 Spanne r wrench, 41 mm 07916 - 9580200 07916 - 958020A 12-4,9 Wrench set, 41 mm 07916 - 9580300 Not available in U.S.A. 12-4, 9 ~ wrench attachment, 41 mm 07916 ~ 9580400 07916 - 958010A 12-4, 9 Ball race remover 07944 - 1150001 M9360 - 277 - 91774 (U,S .A. only I 11-18 Steering stem driver 07946-GC40000 11 - 18 Shaft protector 07960-' 8701 00 Equivalent commercially available B~7 in U.S.A. 1-7

Honda Atc 125m Service Repair Manual 1986-1987

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