Honda CBR150R Manual
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HOW TO USE THIS MANUAL
CONTENTS
This service manual describes the service procedures
for the
CBR150R.
Follow the Maintenance Schedule (Section 3) recom-
mendations to ensure that the vehicle is in peak oper-
ating condition and the emission levels are within the
standards.
Performing the first scheduled maintenance is very
important. It compensates for the initial wear that oc-
curs during the break-in period.
Sections 1 and
3
apply to the whole motorcycle.
Section 2 illustrates procedures for removal/installa-
tion of components that may be required to perform
service described in the following sections.
Section 4 through 21 describe parts of the motorcycle,
grouped according t o location.
Find the section you want on this page, then turn to
the table
of
contents on the first page of the section.
Most sections start with an assembly or system illus-
tration, service information and troubleshooting for the
section. The subsequent pages give detailed procedure.
If you don't know the source of the trouble, go to sec-
tion 22 TROUBLESHOOTING.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS
AND SPECIFICATIONS INCLUDED IN THIS PUBLICA-
TION ARE BASED ON THE LATEST PRODUCT IN-
FORMATION AVAILABLE AT THE TIME OF AP-
PROVAL 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 REPRODUCED WITHOUT
WRITEN PERMISSION. THIS MANUAL IS WRITEN
FOR PERSONS WHO HAVE ACQUIRED BASIC
KNOWLEDGE
OF
MAINTENANCE ON Honda MO-
TORCYCLES, MOTOR SCOOTERS OR ATVS.
Honda Motor Co., Ltd.
SERVICE PUBLICATION OFFICE
GENERAL INFORMA TlON
FRAMElBODY PANELSlEXHAUST
SYSTEM
MAINTENANCE
FUEL SYSTEM
COOLING SYSTEM
z
ENGINE REMOV ALlINSTALLATlON
CLUTCHlGEARSHlFT LINKAGE
ALTERNATORlSTARTER CLUTCH
k
Lu
2
n
W
E
CYLINDER HEADlVALVES
0
CYLlNDERlPlSTON
TRANSMISSION
CRANKSHAFTlBALANCER
FRONT WHEELlSUSPENSIONI
V,
STEERING
v)
8
REAR WHEELlSUSPENSION
r
BRAKE SYSTEM
CHARGING SYSTEM
2
IGNITION SYSTEM
0
ELECTRIC STARTER
LIGHTSlMETERSlSWITCHES
WIRING DIAGRAM
2
TROUBLESHOOTING
Date of Issue: February, 2002
Q
Honda Motor Co., Ltd.

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Summary of Contents for Honda CBR150R

  • Page 66 FUEL SYSTEM...
  • Page 67: Fuel System

    5. FUEL SYSTEM SERVICE INFORMATION CARBURETOR DISASSEMBLY TROUBLESHOOTING CARBURETOR ASSEMBLY FUEL TANK CARBURETOR INSTALLATION 5-13 AIR CLEANER HOUSING PILOT SCREW ADJUSTMENT 5-14 SUB-AIR CLEANER SECONDARY AIR SUPPLY SYSTEM 5-15 CARBURETOR REMOVAL SERVICE INFORMATION GENERAL • Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. •...
  • Page 68: Troubleshooting

    FUEL SYSTEM TROUBLESHOOTING Engine cranks but won’t start Engine stalls, hard to start, rough idling • No fuel in tank • Restricted fuel line • No fuel to carburetor • Fuel mixture too lean/rich — Clogged fuel strainer • Contaminated/deteriorated fuel —...
  • Page 69: Fuel Tank

    FUEL SYSTEM FUEL TANK FUEL TANK BOLT REMOVAL/INSTALLATION Remove the driver seat (page 2-2). Remove the bolt and collar. Raise the rear of fuel tank while releasing the bosses of the rear cowl from the grommets of the fuel tank. Pull the fuel tank backward and support it.
  • Page 70: Air Cleaner Housing

    FUEL SYSTEM AIR CLEANER HOUSING REMOVAL/INSTALLATION Remove the fuel tank (page 5-3). FUEL OVERFLOW TUBE Disconnect the crankcase breather, crankcase breather drain and fuel overflow tubes. Loosen the caburetor connecting tube band screw and dis- connect the connecting tube from the carburetor. Remove the air cleaner mounting bolts and air cleaner housing.
  • Page 71 FUEL SYSTEM Loosen the throttle cable adjusting nut and disconnect the throttle cable end from the throttle drum. ADJUSTING NUT Loosen the nut and remove the starting enrichment (SE) valve and washer from the carburetor body. VALVE/WASHER Loosen the insurator band screw. Remove the carburetor.
  • Page 72: Carburetor Disassembly

    FUEL SYSTEM CARBURETOR DISASSEMBLY COVER VACUUM CHAMBER Remove the two screws and vacuum chamber cover. NOTE: As the compression spring is very long, it will jump out of the carburetor when the cover is removed. SCREWS Remove the compression spring and diaphragm/vacuum DIAPHRAGM/ SPRING piston from the carburetor body.
  • Page 73 FUEL SYSTEM Throttle cable stay STAY SCREWS Remove the two screws and throttle cable stay. Air cut-off valve O-RING SCREWS Remove the two screws. Remove the valve cover, spring, O-ring and diaphragm. NOTE: The air cut-off valve cover is under spring pressure. Check the following: —...
  • Page 74 FUEL SYSTEM Remove the float pin, float and float valve. FLOAT Check the float for damage or fuel in the float. Check the following: — valve and valve seat for scoring, scratches, clogging or damage. — tip of the float valve, where it contacts the valve seat, for stepped wear or contamination.
  • Page 75: Carburetor Cleaning

    FUEL SYSTEM CARBURETOR CLEANING Remove the following: — diaphragm/vacuum piston — main jet, needle jet and slow jet — pilot screw — air cut-off valve CAUTION: Cleaning the air and fuel passages with a piece of wire will damage the carburetor body. Blow open all air and fuel passages in the carburetor body with compressed air.
  • Page 76 FUEL SYSTEM Hang the float valve onto the float arm lip. FLOAT Install the float valve, float and float pin. FLOAT VALVE FLOAT LEVEL INSPECTION NOTE: Set the float level gauge so that it is perpendicular to the float chamber face at the highest position of the float. With the float valve seated and the float arm just touching the valve, measure the float level with the float level gauge.
  • Page 77 FUEL SYSTEM Starting enrichment (SE) valve cover COVER Install a new O-ring to the valve cover. Install the valve cover to the carburetor body. O-RING Install and tighten the two screws/washers securely. SCREWS Air cut-off valve SCREWS COVER Install the diaphragm to the carburetor body. O-RING Install a new O-ring, spring and cover.
  • Page 78 FUEL SYSTEM VACUUM CHAMBER DIAPHRAGM/VACUUM PISTON Install the jet needle with washer into the vacuum piston. Install the spring onto the needle holder and set the needle JET NEEDLE holder into the vacuum piston. HOLDER SPRING WASHER Install the needle holder by aligning the cut-out of the DIAPHRAGM/ ALIGN holder and boss of the vacuum piston.
  • Page 79: Carburetor Installation

    FUEL SYSTEM CARBURETOR INSTALLATION FUEL TUBE Connect the fuel, air vent and fuel drain tubes. AIR VENT TUBE DRAIN TUBE Install the carburetor into the insulator by aligning the ALIGN carburetor boss with insulator boss. Tighten the insulator band screw. SCREW Check the starting enrichment (SE) valve for scoring, WASHER...
  • Page 80: Pilot Screw Adjustment

    FUEL SYSTEM Connect the air injection hose to the cylinder head cover. BOLT Install the PAIR control valve and tighten the bolt. Install the following: — air cleaner housing (page 5-4) — fuel tank (page 5-3) Adjust the throttle grip free-play (page 3-4). PAIR CONTROL VALVE AIR INJECTION HOSE PILOT SCREW ADJUSTMENT...
  • Page 81: System Inspection

    FUEL SYSTEM 6. Start the engine and adjust the idle speed with the throttle stop screw. ± –1 TENTATIVE IDLE SPEED: 1,400 100 min (rpm) 7. Turn the pilot screw in or out slowly to obtain the high- est engine speed. 8.
  • Page 82 FUEL SYSTEM PAIR CHECK VALVE INSPECTION BOLT Remove the following: — fuel tank (page 5-3) — air cleaner housing (page 5-4) Remove the bolt and PAIR control valve with the tubes connected. Disconnect the air injection hose from PAIR check valve cover.
  • Page 303 To print chapters, click on the printer icon and fill in the page range. General Information 4 - 28 Frame/Body panels/Exhaust system 29 - 36 Maintenance 37 - 58 Lubrication system 59 - 65 Fuel system 66 - 82 Cooling System 83 - 98 Engine removal/Installation 99 - 106...

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2002 cbr150r

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