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Honda Manuals
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PCX150 2013
Service manual
Table Of Contents - Honda PCX150 2013 Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Advertisement
Table of Contents
Ho To Use This Manual
3
Contents
5
General Information
7
Service Rules
8
Abbreviation
8
Model Identification
9
Serial Numbers
9
Labels
10
General Specifications
12
Cylinder/Piston Specifications
15
Standard Torque Values
17
Engine & Frame Torque Values
17
Lubrication And Seal Points
23
Cable And Harness Routing Diagrams - '13 Model
25
Cable And Harness Routing Diagrams - After '13 Model
31
Technical Feature - After '13 Model
40
Fuel Pump System With A Fuel Filter Blockage Reminder Function
40
Crankcase Emission Control Systems
41
Exhaust Emission Control Systems
42
Evaporative Emission Control System - Except After '13 Model Cm Type
42
Fuel Permeation Emission Control System
42
Noise Emission Control System
42
Frame, Body Panels, Exhaust System
43
Frame, Body Panels, Exhaust System Service Information
44
Frame, Body Panels, Exhaust System Torque Values
44
Frame, Body Panels, Exhaust System Troubleshooting
44
Body Panel Locations - '13 Model
45
Body Panel Removal Chart - '13 Model
45
Body Panel Locations - After '13 Model
46
Body Panel Removal Chart - After '13 Model
46
Front Fender Removal/Installation
47
Front Grille Removal/Installation
47
Meter Visor Removal/Installation
48
Front Meter Panel Removal/Installation
49
Floor Mat Removal/Installation
49
Side Cover Removal/Installation
50
Under Cover Removal/Installation
51
Seat Removal/Installation
52
Center Cover Removal/Installation
52
Meter Panel Cover Removal/Installation
53
Right Inner Maintenance Lid Removal/Installation
53
Left Inner Outer Cover Removal/Installation
54
Right Inner Outer Cover Removal/Installation
54
Inner Cover Removal/Installation
55
Handlebar Front Cover Removal/Installation
56
Rear Meter Panel Removal/Installation
56
Front Cover Removal/Installation
57
Front Lower Cover Removal/Installation
59
Plug Maintenance Lid Removal/Installation
60
Floor Step Removal/Installation
61
Grab Rail Cover Removal/Installation
62
Grab Rail Removal/Installation
63
Body Cover Removal/Installation
65
Luggage Box Removal/Installation
67
Battery Box Removal/Installation
68
Rear Fender Removal/Installation
69
Exhaust Pipe/Muffler Removal/Installation
70
Centerstand Removal/Installation
70
Maintenance
73
Maintenance - Service Information
74
Maintenance - Specifications
74
Maintenance Schedule
76
Fuel Line
78
Throttle Operation
78
Air Cleaner
79
Crankcase Breather
80
Spark Plug
81
Valve Clearance Inspection
82
Engine Oil Level Check
83
Engine Oil Strainer Screen
84
Oil Change
84
Engine Idle Speed
85
Radiator Coolant
85
Cooling System
86
Evaporative Emission Control System Maintenance
87
Drive Belt
87
Final Drive Oil Level Check/Change
88
Brake Fluid
89
Front Brake Line
89
Cbs Brake Line
89
Front Disc Brake Pads
89
Brake System
90
Rear Drum Brake Shoes
90
Front Disc Brake
90
Rear Drum Brake
90
Cbs
91
Rear Brake Light Switch
92
Front Brake Light Switch
92
Brake Lock Operation
93
Headlight Aim
94
Clutch Shoes Wear
95
Sidestand
95
Suspension
95
Nuts, Bolts, Fasteners
96
Wheels/Tires
96
Steering Head Bearings
97
Pgm-Fi System
99
Pgm-Fi System Location Diagram
100
Pgm-Fi System Diagram
102
Pgm-Fi System Service Information
104
Pgm-Fi System Specifications
104
Pgm-Fi Symptom Troubleshooting
105
Pgm-Fi Connector Location
107
Pgm-Fi Troubleshooting
108
Dtc - Diagnostic Trouble Code
108
Mil Blink Pattern
108
Mil Check
108
Mcs Tester Information
109
Dtc Readout
109
Erasing Dtc
110
Inspection At Ecm Connector
110
Pgm-Fi Troubleshooting - After '13 Model
111
System Description
111
Dtc Index - '13 Model
113
Dtc Index - After '13 Model
114
Dtc Troubleshooting - '13 Model
115
Dtc 1-2 - Map Sensor High Voltage
117
Dtc 7-1 - Ect Sensor Low Voltage
118
Dtc 7-2 - Ect Sensor High Voltage
119
Dtc 8-1 - Tp Sensor Low Voltage
120
Dtc 8-2 - Tp Sensor High Voltage
122
Dtc 9-1 - Iat Sensor Low Voltage
123
Dtc 9-2 Iat Sensor High Voltage
124
Dtc 12-1 Fuel Injector
125
Dtc 21-1 O2 Sensor
127
Dtc 29-1 Iacv
128
Dtc 52-1 - Ckp Sensor
130
Sensor Unit Power Line Inspection - After '13 Model
131
Before Dtc Troubleshooting
131
Dtc Troubleshooting - After '13 Model
132
Dtc 1-1 - Map Sensor Low Voltage
132
Dtc 7-1 Ect Sensor Low Voltage
134
Dtc 7-2 Ect Sensor High Voltage
135
Dtc 8-1 Tp Sensor Low Voltage
136
Dtc 8-2 Tp Sensor High Voltage
137
Dtc 9-1 Iat Sensor Low Voltage
138
Dtc 9-2 - Iat Sensor High Voltage
139
Dtc 12-1 - Fuel Injector
140
Dtc 33-2 - Eeprom
144
Dtc 52-1 Ckp Sensor
144
Mil Circuit Inspection - '13 Model
145
Mil Circuit Inspection - After '13 Model
146
Ecm Removal/Installation
147
Ecm Inspection
148
Ect Sensor Removal/Installation
150
Ect Sensor Inspection
150
O2 Sensor Removal
151
O2 Sensor Installation
152
O2 Removal/Installation - After '13 Model
153
Ignition System
155
Ignition System Location Diagram
156
Ignition System Diagram
157
Ignition System Service Information
158
Ignition System Specifications
158
Ignition System Troubleshooting
159
Ignition System Inspection
160
Ignition Coil Primary Peak Voltage
160
Ignition Coil Removal/Installation
161
Ignition Timing
161
Electrical Starter
163
Electrical Starter System Location Diagram
164
Electrical Starter System Diagram
165
Electrical Starter Service Information
166
Torque Value
166
Electrical Starter Troubleshooting
167
Starter/Charging Relay Removal/Installation
170
Starter/Charging Relay Operation Inspection
170
Relay Switch Line Inspection
171
Relay Coil Line Inspection
171
Continuity Inspection
172
Starter System Inspection
173
Ckp Sensor Line Inspection
173
Stator Inspection
173
Starter Switch Line Inspection
174
Sidestand Switch Removal/Installation
175
Sidestand Switch Inspection
175
Fuel System
177
Fuel System Component Location Diagram
178
Fuel System Service Information
180
Fuel System Specifications
180
Torque Values
180
Fuel System - Tools Needed
181
Fuel Line Inspection
182
Fuel Pressure Relieving
182
Quick Connect Fitting Removal
182
Quick Connect Fitting Installation
183
Fuel Pressure Normalization
183
Fuel Pressure Test
184
Fuel Supply Test - After '13 Model
185
Fuel Flow Inspection
185
Fuel Pump Unit Inspection
186
Fuel Pump Unit Removal
186
Fuel Filter Replacement
187
Fuel Pump Installation
188
Fuel Tank Removal/Installation
189
Air Cleaner Housing Removal/Installation
189
Throttle Body Removal
191
Throttle Body Disassembly
192
Throttle Body Cleaning
193
Throttle Body Assembly
193
Throttle Body Installation
195
Tp Sensor Reset Procedure
197
Iacv Removal/Installation
198
Iacv Inspection
199
Fuel Injector Removal
200
Fuel Injector Installation
200
Intake Pipe Removal
201
Intake Pipe Installation
201
Evap Purge Control Solenoid Valve Removal/Installation
203
Evap Purge Control Solenoid Valve Inspection
203
Evap Canister Removal/Installation
204
Lubrication System
205
Lubrication System Diagram
206
Lubrication System Service Information
207
Lubrication System Specifications
207
Lubrication System Troubleshooting
208
Oil Pump Removal
209
Oil Pump Inspection
210
Right Crankshaft Oil Seal Inspection/Replacement
211
Right Crankshaft Oil Seal Installation
211
Cooling System Flow Pattern
214
Cooling System Service Information
215
Cooling System Specifications
215
Cooling System Troubleshooting
215
Cooling System Testing
216
Radiator Cap/System Pressure Inspection
216
Coolant Replacement/Air Bleeding
217
Radiator Removal/Installation
218
Radiator Reserve Tank Removal/Installation
219
Water Pump/Thermostat
220
Mechanical Seal Inspection
220
Water Pump/Thermostat Removal/Disassembly
220
Thermostat Inspection
221
Cooling System Assembly/Installation
222
Cylinder Head/Valves
225
Cylinder Head/Valves Component Location Diagram
226
Cylinder Head/Valves Service Information
227
Cylinder Head/Valves Specifications
227
Cylinder Head/Valves - Tools Needed
228
Cylinder Head/Valves Troubleshooting
229
Cylinder Compression Test
230
Cylinder Head Cover Removal
230
Cylinder Head Cover Installation
231
Camshaft Removal
232
Camshaft Inspection
233
Camshaft Installation
234
Cylinder Head Removal
237
Cylinder Head Disassembly
238
Cylinder Head Inspection
239
Valve Spring Inspection
239
Valve/Valve Guide Inspection
239
Cam Chain Guide Check
240
Valve Guide Replacement
241
Valve Seat Inspection/Refacing
242
Seat Width
242
Cylinder Head Assembly
244
Cylinder Head Installation
246
Cam Chain Tensioner Lifter Removal
247
Cam Chain Tensioner Lifter Inspection
247
Cam Chain Tensioner Lifter Installation
247
Cylinder/Piston
249
Cylinder/Piston Component Location Diagram
250
Cylinder/Piston Service Information
251
Cylinder/Piston Troubleshooting
252
Cylinder Removal
253
Cylinder Inspection
253
Stud Bolt Replacement
254
Installation
254
Piston Removal
255
Piston Inspection
256
Piston Installation
257
Drive Pulley/Driven Pully/Clutch
259
Drive Pulley/Driven Pully/Clutch Component Location Diagram
260
Drive Pulley/Driven Pully/Clutch Service Information
261
Drive Pulley/Driven Pully/Clutch Specifications
261
Drive Pulley/Driven Pully/Clutch - Tools Needed
262
Drive Pulley/Driven Pully/Clutch Troubleshooting
263
Left Crankcase Cover Removal
264
Bearing Inspection/Replacement
264
Left Crankcase Cover Installation
266
Drive Belt Replacement
266
Drive Pulley Removal
267
Drive Pully Disassembly/Assembly
267
Drive Pulley Inspection
268
Drive Pulley Face Check
268
Drive Pulley Installation
269
Weight Roller Check
269
Drive Face Boss Check
269
Movable Drive Face Check
269
Clutch/Driven Pulley Removal
270
Clutch/Driven Pulley Disassembly
271
Clutch/Driven Pulley Inspection
272
Driven Face Spring Check
273
Driven Face Check
273
Movable Driven Face Check
273
Drive Pulley/Driven Pulley/Clutch
273
Driven Face Bearing Replacement
274
Clutch/Driven Pulley Assembly
275
Clutch/Driven Pulley Installation
278
Final Reduction
279
Final Reduction Component Location
280
Final Reduction Service Information
281
Final Reduction Specifications
281
Final Reduction - Tools Needed
282
Final Reduction Troubleshooting
283
Final Reduction Case Separation
284
Final Reduction Inspection
284
Gear/Shaft
285
Driveshaft Check
285
Counter Gear/Countershaft/Final Gear Shaft
285
Final Reduction Bearing Replacement
286
Left Crankcase
286
Driveshaft
287
Final Reduction Case
289
Final Reduction Case Assembly
290
Alternator/Starter
291
Alternator/Starter Component Location
292
Alternator/Starter Service Information
293
Alternator/Starter Removal
294
Alternator/Starter Installation
296
Crankcase/Crankshaft
299
Crankcase/Crankshaft Component Location
300
Crankcase/Crankshaft Service Information
301
Crankcase/Crankshaft Specifications
301
Crankcase/Crankshaft - Tools Needed
302
Crankcase/Crankshaft Troubleshooting
302
Crankcase Separation
303
Crankshaft Inspection
305
Crankcase Assembly
306
Cam Chain Tensioner Slider Inspection
306
Engine Removal/Installation
311
Engine Removal/Installation - Component Location
312
Engine Removal/Installation Service Information
313
Engine Removal/Installation Specifications
313
Engine Removal
314
Engine Hanger Link Removal/Installation
316
Engine Hanger Link Inspection
316
Engine Installation
317
Front Wheel/Suspension/Steering
321
Front Wheel/Suspension/Steering Component Location
322
Front Wheel/Suspension/Steering Service Information
323
Front Wheel/Suspension/Steering Specifications
323
Front Wheel/Suspension/Steering - Tools Needed
324
Front Wheel/Suspension/Steering Troubleshooting
325
Front Wheel Removal
326
Front Wheel Inspection
326
Front Wheel Disassembly/Assembly
327
Wheel Bearing Replacement
327
Front Wheel Installation
328
Fork Removal
328
Fork Disassembly
329
Fork Inspection
332
Fork Spring Check
332
Fork Pipe/Slider/Piston Check
332
Fork Assembly
333
Fork Pipe Bushing/Back-Up Ring Check
333
Fork Installation
336
Handlebar Removal
337
Handlebar Installation
340
Handlebar Post Removal/Installation
343
Steering Stem Removal
344
Steering Stem Bearings Replacement
345
Steering Stem Installation
347
Rear Wheel/Brake/Suspension
349
Rear Wheel/Brake/Suspension Component Location
350
Rear Wheel/Brake/Suspension Service Information
351
Rear Wheel/Brake/Suspension Specifications
351
Rear Wheel/Brake/Suspension - Tools Needed
351
Rear Wheel/Brake/Suspension Troubleshooting
352
Rear Wheel/Swingarm Removal
353
Rear Wheel/Swingarm Installation
354
Wheel Inspection
355
Swingarm Bearing Inspection/Replacement
355
Rear Drum Brake Inspection
356
Rear Drum Brake Disassembly
356
Rear Drum Brake Assembly
358
Rear Shock Absorber Removal/Installation
360
Rear Shock Absorber Inspection
360
Hydraulic Brake
361
Hydraulic Brake Component Location
362
Hydraulic Brake Service Information
363
Hydraulic Brake Specifications
363
Hydraulic Brake Troubleshooting
364
Brake Fluid Replacement/Air Bleeding
365
Brake Fluid Draining
365
Brake Fluid Filling/Air Bleeding
367
Brake Pad/Disc
370
Brake Pad Replacement
370
Brake Disc Inspection
371
Brake Master Cylinder Removal
372
Brake Master Cylinder Disassembly
372
Brake Master Cylinder Inspection
373
Brake Master Cylinder Assembly
374
Brake Master Cylinder Installation
375
Cbs Master Cylinder Removal
376
Cbs Master Cylinder Disassembly
377
Cbs Master Cylinder Inspection
379
Cbs Master Cylinder Assembly
379
Cbs Master Cylinder Installation
382
Brake Caliper Removal
383
Brake Caliper Disassembly
383
Brake Caliper Inspection
384
Brake Caliper Assembly
385
Brake Caliper Installation
386
Battery/Charging System
387
Battery/Charging System Location Diagram
388
Battery/Charging System Diagram
389
Battery/Charging System Service Information
390
Battery Charging
390
Battery Testing
390
Battery/Charging System Specifications
391
Battery/Charging System Troubleshooting
392
Battery Removal/Installation
393
Voltage Inspection
394
Current Leakage Test
394
Charging Voltage Inspection
395
Charging Line Inspection
395
Starter/Charging Relay Inspection
396
Lights/Meters/Switches
397
Electrical System Location Diagram
398
Lights/Meters/Switches Service Information
400
Lights/Meters/Switches Specifications
400
Lights/Meters/Switches Torque Values
401
Headlight - '13 Model
402
Bulb Removal/Installation
402
Headlight Inspection
402
Headlight Removal/Installation
402
Combination Light Removal/Installation/Inspection - After '13 Model
403
Turn Signal Light - '13 Model
403
Tail/Brake Light - '13 Model
404
Turn Signal Light Unit Removal/Installation
404
License Light Bulb Replacement
405
License Light Unit Removal/Installation
405
Speedometer Removal/Installation - '13 Model
406
License Light Unit Inspection
406
Speedometer Disassembly/Assembly - '13 Model
406
Speedometer Inspection
407
Combination Meter Inspection - After '13 Model
408
Serial Communication Line Inspection
409
Combination Meter Removal/Installation
410
Combination Meter Disassembly/Assembly
410
Fuel Gauge Inspection - After '13 Model
411
Average Fuel Mileage Inspection - After '13 Model
411
Vs Sensor Removal/Installation
412
Vs Sensor Inspection
413
Coolant Temperature Indicator Inspection
414
System Inspection
414
Fuel Meter/Fuel Level Sensor Inspection
415
Fuel Level Sensor Removal/Installation
416
Float Position
416
Ignition Switch - Fuel Lid/Seat Opener Removal/Installation
417
Ignition Switch Removal
417
Ignition Switch Installation
418
Ignition Switch Inspection
418
Handlebar Switch Inspection
420
Brake Light Switch Inspection
421
Horn Removal/Installation
421
Accessory Socket Removal/Installation - After '13 Model
422
Horn Inspection
422
Main Relay Removal/Installation
423
Main Relay Continuity Inspection
423
Turn Signal Light Relay Inspection - '13 Model
424
Led Control Unit Removal/Installation - After '13 Model
424
Input Voltage Inspection
425
Output Voltage Inspection
425
Wiring Diagram '13 Model
431
Wiring Diagram After '13 Model
433
Index
435
Previous
Page
1
...
436
437
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Table of Contents
Troubleshooting
Frame, Body Panels, Exhaust System Service Information
44
PGM-FI symptom troubleshooting
105
PGM-FI troubleshooting
108
PGM-FI troubleshooting - after '13 model
111
DTC troubleshooting - '13 model
115
Sensor unit power line inspection - after '13 model
131
DTC troubleshooting - after '13 model
132
Ignition System Troubleshooting
159
Electrical starter troubleshooting
167
Lubrication System Troubleshooting
208
Cooling system service information
215
Cylinder Head/Valves Troubleshooting
229
Cylinder/Piston Troubleshooting
252
Drive Pulley/Driven Pully/Clutch Troubleshooting
263
Final Reduction Troubleshooting
283
Crankcase/Crankshaft - Tools Needed
302
Front Wheel/Suspension/Steering Troubleshooting
325
Rear wheel/Brake/Suspension Troubleshooting
352
Hydraulic brake troubleshooting
364
Battery/charging system troubleshooting
392
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Honda NSS300
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Honda 2008 Metropolitan CHF50
PCX Table Of Contents
Honda PCX
This manual is also suitable for:
Pcx150 2014
Pcx150 2016
Pcx150 2015
Pcx150 2017
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