Table Of Contents - Honda CB HORNET 160R 2015 Shop Manual

Table of Contents

Important Safety Precautions2
How To Use This Manual3
Contents3
Symbols4
General Information Contents5
Service Rules5
Abbreviation5
Table Of Contents5
Model Identification6
Serial Numbers7
Color Label7
General Specifications8
Lubrication System Specifications9
Fuel System Specifications9
Cylinder Head/Valves Specifications9
Cylinder/Piston Specifications10
Clutch/Gearshift Linkage Specifications10
Alternator/Starter Clutch Specifications10
Crankcase Crankshaft/ Transmission/Kickstarter Specifications11
Front Wheel/Suspension/ Steering Specifications11
Rear Wheel/Suspension Specifications12
Brake System Specifications12
Battery/Charging System Specifications12
Electrical Starter Specification13
Ignition System Specifications13
Lights/Meter/Switches Specifications13
Standard Torque Values14
Engine And Frame Torque Values14
Frame16
Lubrication And Seal Points17
Cable And Harness Routing19
Cbs Type21
Std Type22
Emission Control System26
Source Of Emissions26
Crankace Emission Control System26
Exhaust Emission Control System27
Secondary Air Supply System27
Oxidation Catalytic Converter27
Noise Emission Control System27
Evaporative Emission Control System28
Frame/Body Panels/Exhaust System Contents29
Service Information29
Torque Values29
Troubleshooting29
Cover Headlight Rr30
Front Cowl Disassembly30
Seat31
Right Side Cover31
Left Side Cover31
Fuel Tank Assembly31
Fuel Tank Center Cover32
Fuel Tank Left And Right Side Cover32
Fuel Tank32
Front Fender33
Rear Grip34
Rear Garnish Set34
Rear Cowl35
Rear Fender35
Sari Guard36
Side Stand36
Exhaust Pipe/Muffler36
Muffler Protector37
Stud Bolt Replacement37
Maintenance Contents39
Tools40
Maintenance Schedule41
Fuel Line42
Fuel Strainer Screen42
Throttle Operation43
Choke Operation43
Minor/Major Adjustment43
Air Cleaner Element44
Torque44
Crankcase Breather45
Spark Plug45
Valve Clearance46
Engine Oil48
Oil Level Inspection48
Recommended Engine Oil48
Engine Oil Change49
Engine Oil Strainer Screen50
Engihne Oil Centrifugal Filter50
Engine Idle Speed52
Drive Chain Slack Inspection54
Battery56
Brake Fluid56
Sprocket56
Front Brake Fluid Level Inspection57
Rear Brake Fluid Level Inspection57
Brake Pad Wear58
Front Brake Pads58
Rear Brake Free Play Adjustment58
Brake System59
Front/Rear Brake Pads59
Rear Brake Shoes59
Front Brake59
Brake Light Switch60
Headlight Aim60
Clutch System60
Rear Brake60
Front/Rear Suspension Inspection61
Nuts, Bolts, Fasteners62
Wheels/Tires62
Front/Rear Wheel62
Steering Head Bearings63
Recommended Tire Pressure And Tire Size63
Lubrication System Diagram64
Lubrication System Contents65
Oil Pump66
Oil Pump Assembly69
Component Location72
Fuel System Components73
Air Cleaner Housing75
Starting Enrichment Valve77
Carburetor78
Throttle Cable Stay79
Vacuum Chamber79
Float80
Jets81
Starting Enrichment Valve Cover81
Carburetor Assembly82
Carburetor Cleaning82
Pilot Screw Adjustment87
Adjustment By Concentration Measurement88
Idle Drop Procedure90
System Inspect91
Pair Check Valve Inspection91
Pair Control Valve92
One Way Valve92
Canister Component93
Fuel Strainer94
Engine Removal/Installation97
Cylinder Head/Valves105
Cylinder Compression108
Cylinder Head Cover108
Camshaft110
Camshaft Bearing112
Cam Lobe112
Cylinder Head Removal114
Rocker Arm115
Cylinder Head Disassembly/Assembly116
Valve Spring117
Cylinder Head117
Valve117
Valve Guide117
Valve Guide Replacement118
Valve Seat Inspection119
Valve Seat Refacing120
Assembly122
Cylinder Head Installation123
Cam Chain Tensioner Lifter125
Cylinder/Piston Contents129
Cylinder Removal130
Cylinder Inspection130
Piston Removal131
Piston Inspection132
Piston Installation134
Cylinder Installation135
Clutch/Gearshift Linkage Contents139
Right Crankcase Cover141
Clutch144
Clutch Lifter Bearing146
Clutch Spring146
Clutch Center146
Friction Disc146
Clutch Plate147
Clutch Outer/Outer Guide147
Gearshift Linkage150
Primary Drive Gear152
Balancer Drive Gear153
Alternator Contents155
Left Crankcase Cover156
Flywheel158
Starter Clutch160
Starter Motor162
Stator/Ignition Pulse Generator170
Crankcase/Transmission/Kickstarter Contents173
Crankcase Separation176
Balancer Gear Removal176
Balancer Gear Inspection177
Transmission178
Gears179
Mainshaft/Countershaft179
Crankshaft180
Shift Fork180
Shift Fork Shaft180
Crankshaft Runout180
Crankshaft/Balancer Bearing Inspection181
Big End Side Clearance181
Big End Radial Clearance181
Timing Sprocket181
Oil Passages Inspection183
Right/Left Crankcase183
Bearing Replacement Of Crankshaft184
Mainshaft186
Countershaft187
Crankcase Assembly189
Kickstarter193
Front Wheel/Suspension/Steering Contents197
Handlebar200
Front Wheel205
Axle206
Wheel Bearing206
Wheel Rim207
Brake Disc207
Fork210
Fork Spring213
Fork Pipe/Slider213
Fork Piston/Rebound Spring/Oil Lock Piece213
Fork Assembly214
Guide Bushing/Slider Bushing/Back-Up Ring214
Steering Stem218
Ball Race Replacement220
Bottom Cone Race Replacement220
Steering Stem Assembly221
Steering Bearing Preload223
Rear Wheel/Suspension Contents225
Rear Wheel228
Disc Type228
Drum Type228
Wheel Bearing Removal229
Wheel Balance230
Assembly Of Disc Brake231
Assembly Of Drum Brake231
Driven Flange233
Driven Sprocket233
Driven Flange Baring234
Driven Flange Assembly235
Shock Absorber236
Swingarm237
Cbs Front/Rear Brake244
Brake System Contents245
Brake Fluid Line247
Brake Fluid Replacement/Air Bleeding247
Brake Fluid Draining Front Disc Brake247
Combi Brake System248
Cbs Brake Line248
Rear Brake Line248
Brake Fluid Filling/Air Bleeding Front Brake248
Cbs Brake250
Brake Pad/Disc251
Front Brake Pad Replacement251
Front Brake Disc Inspection252
Front Master Cylinder253
Installation Of Master Cylinder257
Front Brake Caliper258
Cbs Front Brake258
Cbs Front Brake Assembly259
Non Cbs Front Brake260
Front Brake (Non Cbs) Assembly262
Rear Disk Brake Pad Replacement263
Rear Brake Disc Inspection264
Rear Master Cylinder (Cbs)265
Rear Master Cylinder Assembly266
Brake Pedal Height267
Rear Brake Caliper268
Rear Brake Caliper Assembly270
Brake Pedal271
Rear Drum Brake274
Rear Drum Brake Assembly275
Battery/Charging System Contents279
Battery Testing Procedure281
Voltage Inspection281
Battery Load Test282
Battery Charging283
Battery Test Result283
Indication Table For Mf Battery Charger285
System Inspection285
Current Leakage Inspection285
Alternator Charging Coil286
Charging Voltage Inspection286
Regulator/Rectifier287
Ignition System Diagram288
Ignition System Contents289
Ignition System Inspection291
Ignition Coil Primary Peak Voltage291
Ignition Pulse Generator Peak Voltage292
Ignition Timing293
Ignition Coil294
Cdi294
Throttle Position Sensor295
Input Voltage295
Initialization Procedure296
Lights/Meters/Switches Contents301
Headlight302
Bulb Replacement302
Brake/Tail Light303
Headlight Unit303
Led Unit Replacement303
Number Plate Light Bulb303
Turn Signal Lights304
Bulbs Replacement304
Combination Meter305
Power/Ground Line Inspection305
Power Input Line305
Back-Up Voltage Line305
Combination Meter Assembly306
Speedometer Vs Sensor307
Vehicle Speed Sensor307
Tachometer308
Digital Meter Reset Procedure309
Tripmeter309
Digital Clock309
Combination Switch310
Handlebar Switches311
Left Handlebar Switch311
Neutral Switch312
Fuel Gauge/Fuel Level Sensor314
Horn316
Passing Relay316
Turn Signal Relay317
Fuse Box318
Electric Starter Component320
Electric Starter System Contents321
Starter Relay Switch323
Operation Inspection323
Circuit Inspection323
Ground Line323
Neutral Diode324
Function Inspection324
Clutch Switch325
Right Handlebar Switches325
Wiring Diagram327
Troubleshooting Contents328
Engine Does Not Start Or Is Hard To Start328
Engine Lacks Power329
Poor Performance At Low And Idle Speed331
Poor Performance At High Speed332
Poor Handling332
Index334