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Service manual
Honda Zoomer Service Manual
2003-2007
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Table Of Contents
297
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297
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297
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
General Information
Service Rules
Model Identification
Serial Numbers
Labels
General Specifications
Lubrication System Specifications
Fuel System Specifications
Cooling System Specifications
Cylinder Head/Valves Specifications
Kickstarter/Drive Pulley/Drive Pulley/Clutch Specifications
Final Reduction Specifications
Crankshaft/Piston/Cylinder Specifications
Rear Wheel/Brake/Suspension Specifications
Front Wheel/Brakes/Suspension/Steering Specifications
Battery/Charging System Specifications
Ignition System Specifications
Lights/Meters/Switches Specifications
Standard Torque Values
Engine & Frame Torque Values
Lubrication & Seal Points
Cable & Harness Routing
After 05 Model View
Source of Emissions
Crankcase Emission Control System
Exhaust Emission Control System
Secondary Air Supply System
Noise Emission Control System
Oxidation Catalytic Converter
Technical Features
PCV (Positive Crankcase Ventilation)
Frame/Body Panels/Exhaust System
Body Panel Locations
Frame/Body Panels/Exhaust System Service Information
Frame/Body Panels/Exhaust System Troubleshooting
Seat Removal
Seat Installation
Seat Rail Removal/Installation
Inner Cover Removal
Inner Cover Installation
Front Cover Removal/Installation
Floor Step Removal
Floor Step Installation
Under Cover Removal/Installation
Rear Fender Removal/Installation
Muffler Removal
Muffler Installation
Muffler Protector Removal/Installation
Maintenance
Maintenance Service Information
Maintenance Specifications
Maintenance Schedule
Fuel Line
Throttle Operation
Air Cleaner
Engine Breather
Spark Plug
Valve Clearance Inspection
Valve Clearance Adjustment
Engine Oil Level Check
Engine Oil Change
Engine Oil Strainer Screen
Engine Idle Speed
Radiator Coolant
Cooling System
Brake Shoes Wear
Brake System
Brake Lock Operation
Headlight Aim
Front Suspension
Rear Suspension
Nuts, Bolts, Fasteners
Wheels/Tires
Steering Head Bearings
Lubrication System
Lubrication System Diagram
Lubrication System Service Information
Lubrication System Troubleshooting
Oil Pump Removal
Oil Pump Disassembly
Oil Pump Inspection
Oil Pump Assembly
Oil Pump Installation
Fuel System
Fuel System Component Locations
Fuel System Service Information
Fuel System Tools
Fuel System Troubleshooting
Air Cleaner Housing Removal/Installation
Carburetor Removal
Carburetor Disassembly
Starting Enrichment (SE) Valve
Vacuum Chamber
Float Chamber
Carburetor Cleaning
Carburetor Assembly
Float Level Inspection
Carburetor Installation
Pilot Screw Adjustment
Idle Drop Procedure
High Altitude Adjustment
Input Voltage Inspection
Resistance Inspection
Operation Inspection
Secondary Air Supply System Inspection
Pair Control Valve Removal/Installation
PCV Control Solenoid Valve/Pcv Reed Valve Removal/Installation
Fuel Tank Removal/Installation
PCV Reed Valve
Cooling System Flow Pattern
Cooling System Service Information
Cooling System Troubleshooting
Coolant System Testing
Coolant (Hydrometer Test)
Coolant Specific Gravity Chart
Radiator Cap/System Pressure Inspection
Coolant Replacement Preparation
Coolant Replacement/Air Bleeding
Water Pump/Thermostat Removal
Thermostat Inspection
Thermostat Installation
Radiator Removal
Radiator Installation
Radiator Reserve Tank Removal/Installation
Engine Removal/Installation
Engine Removal/Installation Component Locations
Engine Removal/Installation Service Information
Engine Removal
Engine Installation
Cylinder Head/Valves
Cylinder Head/Valves Component Locations
Cylinder Head/Valves Service Information
Cylinder Head/Valves Tools
Cylinder Head/Valves Troubleshooting
Cylinder Compression Test
Cylinder Head Cover Removal
Camshaft/Rocker Arms Removal
Camshaft Inspection
Rocker Arm/Shaft Inspection
Side Spring Inspection
Cylinder Head Removal
Cam Chain Tensioner Lifter
Cylinder Head Disassembly
Cylinder Head Inspection
Valve Spring Inspection
Valve/Valve Guide Inspection
Valve Guide Replacement
Cam Chain Tensioner/Guide
Valve Seat Inspection/Refacing Inspection
Cylinder Head Assembly
Cylinder Head Installation
Camshaft/Rocker Arm Installation
Rocker Arm Holder Assembly
Cylinder Head Cover Installation
Kickstarter/Drive Pulley/Driven Pulley/Clutch
Kickstarter/Drive Pulley/Driven Pulley/Clutch Component Locations
Kickstarter/Drive Pulley/Driven Pulley/Clutch Service Information
Kickstarter/Drive Pulley/Driven Pulley/Clutch Tools
Kickstarter/Drive Pulley/Driven Pulley/Clutch Troubleshooting
Belt Case Cover Removal
Belt Case Cover Installation
Kickstarter Disassembly
Kickstarter Inspection
Kickstarter Assembly
Drive Pulley Removal
Drive Belt Inspection
Weight Roller Inspection
Movable Drive Face
Clutch/Driven Pulley Removal
Clutch/Driven Pulley Disassembly
Clutch/Driven Pulley Inspection
Clutch Outer
Clutch Shoe Lining
Driven Face Spring
Driven Face Bearing Replacement
Driven Face Bearing Assembly
Driven Face Bearing Installation
Final Reduction
Final Reduction Component Locations
Final Reduction Service Information
Final Reduction Tools
Final Reduction Troubleshooting
Final Reduction Oil Level Check
Final Reduction Disassembly
Transmission Disassembly
Driveshaft Removal
Driveshaft Inspection
Final Reduction Bearing Replacement
Final Reduction Assembly
Alternator/Starter
Alternator/Starter Component Locations
Alternator/Starter Service Information
Alternator/Starter Tools
Alternator/Starter Removal
Alternator/Starter Installation
Crankshaft/Piston/Cylinder
Crankshaft/Piston/Cylinder Component Locations
Crankshaft/Piston/Cylinder Service Information
Crankshaft/Piston/Cylinder Troubleshooting
Crankshaft/Piston/Cylinder Crankcase Separation
Crankshaft Removal
Piston Removal
Crankshaft Inspection
Piston/Cylinder Inspection
Piston Installation
Crankshaft Installation
Crankcase Assembly
Front Wheel/Brake/Suspension/Steering
Front Wheel/Brake/Suspension/Steering Component Locations
Front Wheel/Brake/Suspension/Steering Service Information
Front Wheel/Brake/Suspension/Steering Tools
Front Wheel/Brake/Suspension/Steering Troubleshooting
Front Wheel Removal
Front Wheel Inspection
Front Wheel Disassembly
Front Wheel Assembly
Front Wheel Installation
Front Brake Removal
Front Brake Inspection
Front Brake Disassembly
Front Brake Assembly
Front Brake Installation
Fork Removal
Fork Disassembly
Fork Inspection
Fork Assembly
Fork Installation
Handlebar Removal
Handlebar Installation
Steering Stem Removal
Steering Stem Bearing Replacement
Steering Stem Installation
Rear Wheel/Brake/Suspension
Rear Wheel/Brake/Suspension Component Locations
Rear Wheel/Brake/Suspension Service Information
Rear Wheel/Brake/Suspension Troubleshooting
Rear Wheel Inspection
Rear Wheel Removal
Rear Wheel Installation
Rear Brake Inspection
Rear Brake Disassembly
Rear Brake Assembly
Rear Shock Absorber Removal
Rear Shock Absorber Inspection
Rear Shock Absorber Installation
Battery/Charging System
Battery/Charging System Diagram
Battery/Charging System Service Information
Battery/Charging System Tools
Battery/Charging System Troubleshooting
Battery Removal/Installation
Battery Voltage Inspection
Charging System Inspection
Battery Testing
Battery Charging (U.S.A. Only)
Current Leakage Test
Charging Voltage Inspection
Alternator Charging Coil Inspection
Engine Control Module (ECM) System Inspection
Regulator/Rectifier Circuit Inspection
Ignition Switch Circuit Inspection
Main Relay System Inspection
Operating Inspection
Ignition System
Ignition System Diagram
Ignition System Service Information
Ignition System Tools
Ignition System Troubleshooting
Ignition System Inspection
Ignition Coil Primary Peak Voltage
Ignition Pulse Generator Peak Voltage
Ignition Coil Removal/Installation
Ignition Timing
Throttle Position Sensor System Inspection
Throttle Position Sensor Removal/Installation
Data Reset
Electric Starter
Electric Starter System Diagram
Electric Starter Service Information
Electric Starter Troubleshooting
Starter Relay Removal/Installation
Starter Relay Operation Inspection
Starter Relay Circuit Inspection
Ground Line
Starter Circuit Inspection
Engine Control Module (ECM)
Starter Switch Circuit Inspection
Angle Sensor Circuit Inspection
Lights/Meters/Switches
Lights/Meters/Switches System Location
Lights/Meters/Switches Service Information
Headlight Bulb Replacement
Headlight Inspection
Headlight Removal/Installation
Turn Signal Light Bulb Replacement
Turn Signal Light Inspection
Turn Signal Light Removal/Installation
Brake/Tail Light Bulb Replacement
Brake/Tail Light Inspection
Brake/Tail Light Removal/Installation
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General Specifications
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Table of Contents
Troubleshooting
Frame/Body Panels/Exhaust System Service Information
41
Lubrication System Service Information
69
Fuel System Troubleshooting
78
Cooling System Troubleshooting
107
Cylinder Head/Valves Troubleshooting
131
Kickstarter/Drive Pulley/Driven Pulley/Clutch Troubleshooting
153
Final Reduction Troubleshooting
170
Crankshaft/Piston/Cylinder Troubleshooting
188
Front Wheel/Brake/Suspension/Steering Troubleshooting
202
Rear Wheel/Brake/Suspension Service Information
226
Battery/Charging System Troubleshooting
236
Ignition System Troubleshooting
247
Electric Starter Troubleshooting
257
Troubleshooting
288
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