Table Of Contents - Honda CBR150R Manual

Table of Contents

Table Of Contents1
Important Safety Notice2
Symbols3
General Information4
General Safety4
Service Rules5
Model Identification6
General Informa Tlon6
Specifications7
Torque Values15
Cable & Harness Routing20
Emission Control Systems27
Source Of Emissions27
Crankcase Emission Control System27
Exhaust Emission Control System (Pulse Secondary Air Injection System)28
Frame/Body Panels/Exhaust System29
Body Panel Locations29
Passenger Seat31
Driver Seat31
Grab Rail31
Rear Cowl31
Rear Fender32
Under Cowl32
Middle Cowl33
Front Fender33
Upper Cowl34
Exhaust System34
Disassembly/Assembly35
Maintenance37
Maintenance Schedule39
Fuel Line40
Throttle Operation40
Carburetor Choke41
Air Cleaner41
Crankcase Breather42
Spark Plug42
Reusing A Spark Plug43
Valve Clearance44
Replacing A Spark Plug44
Engine Oil46
Oil Level Inspection46
Engine Oil Change47
Engine Idle Speed48
Engine Oil Strainer Screen 3-148
Level Check49
Radiator Coolant 3-149
Cooling System50
Secondary Air Supply System50
Drive Chain Slack Inspection51
Cleaning And Lubrication52
Sprockets Inspection52
Front Brake53
Rear Brake53
Brake Fluid 3-153
Front/Rear Brake Pad54
Brake Pad Wear 3-154
Brake System 3-154
Brake Light Switch 3-154
Headlight Aim 3-155
Clutch System 3-155
Side Stand56
Suspension56
Front Suspension Inspection56
Rear Suspension Inspection56
Nuts, Bolts, Fasteners57
Wheels/Tires57
Steering Head Bearings58
Lubrication System Diagram59
Oil Pump61
Fuel System66
Service Information67
Troubleshooting68
Fuel Tank69
Fuel Auto Valve Inspection69
Air Cleaner Housing70
Sub-Air Cleaner70
Carburetor Removal70
Carburetor Disassembly72
Vacuum Chamber72
Float Chamber73
Throttle Cable Stay73
Air Cut-Off Valve73
Starting Enrichment (Se) Valve Cover73
Carburetor Cleaning75
Carburetor Assembly75
Float Level Inspection76
Carburetor Installation79
Pilot Screw Adjustment80
Idle Drop Procedure80
System Inspection81
Pair Check Valve Inspection82
System Flow Pattern83
System Testing86
Coolant (Hydrometer Test)86
Radiator Cap/System Pressure Inspection87
Coolant Replacement87
Replacement/Air Bleeding88
Thermostat89
Radiator/Cooling Fan91
Radiator Reserve Tank95
Water Pump95
Mechanical Seal Inspection95
Water Pump Cover Removal/Installation95
Engine Removal/Installation99
Engine Remov Allinstallatlon100
Engine Installation102
Clutch/Gearshift Linkage107
Right Crankcase Cover Removal110
Clutch Lifter Arm111
Clutch111
Clutch Lifter Bearing112
Clutch Spring113
Clutch Disc113
Clutch Plate113
Clutch Center114
Clutch Outer114
Clutch Outer Guide114
Judder Spring, Spring Seat114
Gearshift Linkage117
Primary Drive Gear119
Clutch Lifter Arm Installation120
Right Crankcase Cover Installation120
Alternator/Starter Clutch122
System Diagram122
Left Crankcase Cover Removal124
Alternator/Stator124
Stator Removal124
Stator Installation125
Flywheel Removal125
Starter Clutch126
Flywheel Installation129
Left Crankcase Cover Installation130
Cylinder Head/Valves131
Cylinder Compression134
Cylinder Head Removal135
Cylinder Head Cover Removal135
Camshaft Removal136
Cam Chain Tensioner Lifter138
Cylinder Head Disassembly139
Camshaft/Camshaft Holder141
Valve Lifter142
Valve Spring142
Cylinder Head143
Valve143
Valve Guide143
Valve Guide Replacement144
Valve Seat Inspection145
Valve Seat Refacing146
Cylinder Head Assembly148
Cylinder Head Installation150
Camshaft Installation150
Cylinder Head Cover Installation153
Cylinder/Piston155
Cylinder Removal158
Piston Removal159
Piston Installation162
Cylinder Installation163
Transmission165
Transmission Disassembly168
Inspection170
Gears170
Bushings170
Mainshaft/Countsrshaft170
Shift Drum/Drum Journal171
Shift Fork171
Shiftfork Shaft172
Transmission Bearing172
Transmission Bearing Replacement173
Right Crankcase174
Left Crankcase174
Transmission Assembly175
Mainshaft175
Countershaft176
Washer And Snap Ring Direction176
Crankcase Assembly178
Crankshaft/Balancer180
13. Crankshaftlbalancer181
Crankshaft Removal182
Crankshaft Runout182
Big End Side Clearance182
Big End Radial Clearance183
Balancer Gear183
Crankshaft/Balancer Bearing183
Crankshaft/Balancer Bearing Replacement184
Crankshaft Installation185
Front Wheel/Suspension/Steering186
Front Wheellsuspensioni Steering187
Handlebar189
Front Wheel194
Axle194
Wheel Bearing194
Wheel Bearing Replacement195
Wheel Rim195
Fork198
Fork Spring201
Fork Pipe/Slider/Piston201
Steering Stem205
Bearing Race Replacement206
Bottom Cone Race Replacement207
Steering Bearing Preload209
Rear Wheel/Suspension210
Rear Wheellsuspension211
Rear Wheel213
Wheel Rim Runout213
Driven Sprocket214
Driven Flange Bearing Removal216
Wheel Bearing Removal216
Wheel Bearing Installation217
Driven Flange Installation218
Wheel Assembly218
Shock Absorber219
Swingarm220
Brake System225
Brake Fluid Replacement/Air Bleeding228
Brake Fluid Draining228
Brake Fluid Filling/Bleeding228
Brake Pad/Disc230
Front Brake Pad Replacement230
Rear Brake Pad Replacement231
Brake Disc Inspection232
Front Master Cylinder233
Rear Master Cylinder237
Front Brake Caliper241
Brake System Assembly243
Rear Brake Caliper244
Brake Pedal247
Charging System249
17. Charging System250
Battery Is Damaged Or Weak252
Battery253
Battery Charging254
Charging System Inspection254
Charging Voltage Inspection254
Alternator Inspection256
Current Leakage Inspection256
Regulator/Rectifier257
Ignition System258
18. Ignition System259
Nospark At Plug260
Ignition System Inspection261
Ignition Coil Primary Peak Voltage261
Ignition Pulse Generator Peak Voltage262
Ignition Coil263
Ignition Control Module (Icm)263
Ignition Timing264
Electric Starter: System Diagram266
Starter Motor270
Starter Relay Switch276
Clutch/Neutral Diode277
Lights/Meters/Switches278
System Location278
Bulb Replacement281
Headlight281
Front Turn Signal Light281
Rear Turn Signal And Tail/Brake Light And License Light281
Rear Turn Signal Light282
Tail/Brake Light282
License Light282
Combination Meter283
Ignition Switch285
Handlebar Switches286
Brake Light Switch286
Front286
Rear287
Neutral Indicator/Switch287
Fuel Meter/Fuel Unit289
Fuel Meter Inspection289
Fuel Unit Inspection289
Fuel Unit Installation290
Horn291
Turn Signal Relay291
Cooling Fan Motor Switch292
Fan Motor Does Not Stop292
Fan Motor Does Not Start292
Coolant Temperature Gauge/Thermosensor293
Thermosensor Inspection294
Clutch Switch294
Tachometer295
Wiring Diagram296
Engine Does Not Start Or Is Hard To Start297
22. Troubleshooting297
Engine Lacks Power298
Poor Performance At Low And Idle Speed299
Poor Performance At High Speed300
Poor Handling300
Index301