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2002 CBR150R
User Manuals: Honda 2002 CBR150R Sport motorcycle
Manuals and User Guides for Honda 2002 CBR150R Sport motorcycle. We have
1
Honda 2002 CBR150R Sport motorcycle manual available for free PDF download: Manual
Honda 2002 CBR150R Manual (304 pages)
Brand:
Honda
| Category:
Motorcycle
| Size: 13 MB
Table of Contents
Table of Contents
1
Important Safety Notice
2
Symbols
3
General Information
4
General Safety
4
Service Rules
5
GENERAL INFORMA Tlon
6
Model Identification
6
Specifications
7
Torque Values
15
General Information
19
Cable & Harness Routing
20
Crankcase Emission Control System
27
Emission Control Systems
27
Source of Emissions
27
Exhaust Emission Control System (Pulse Secondary Air Injection System)
28
Body Panel Locations
29
Frame/Body Panels/Exhaust System
29
Driver Seat
31
Grab Rail
31
Passenger Seat
31
Rear Cowl
31
Rear Fender
32
Under Cowl
32
Front Fender
33
Middle Cowl
33
Exhaust System
34
Upper Cowl
34
Disassembly/Assembly
35
Maintenance
37
Maintenance Schedule
39
Fuel Line
40
Throttle Operation
40
Air Cleaner
41
Carburetor Choke
41
Crankcase Breather
42
Spark Plug
42
Reusing a Spark Plug
43
Replacing a Spark Plug
44
Valve Clearance
44
Engine Oil
46
Oil Level Inspection
46
Engine Oil Change
47
Engine Idle Speed
48
Engine Oil Strainer Screen 3-1
48
Level Check
49
Radiator Coolant 3-1
49
Cooling System
50
Secondary Air Supply System
50
Drive Chain Slack Inspection
51
Cleaning and Lubrication
52
Sprockets Inspection
52
Brake Fluid 3-1
53
Front Brake
53
Rear Brake
53
Brake Light Switch 3-1
54
Brake Pad Wear 3-1
54
Brake System 3-1
54
Front/Rear Brake Pad
54
Clutch System 3-1
55
Headlight Aim 3-1
55
Front Suspension Inspection
56
Rear Suspension Inspection
56
Side Stand
56
Suspension
56
Nuts, Bolts, Fasteners
57
Wheels/Tires
57
Steering Head Bearings
58
Lubrication System Diagram
59
Oil Pump
61
Fuel System
66
Fuel System
67
Service Information
67
Troubleshooting
68
Fuel Auto Valve Inspection
69
Fuel Tank
69
Air Cleaner Housing
70
Carburetor Removal
70
Sub-Air Cleaner
70
Carburetor Disassembly
72
Vacuum Chamber
72
Air Cut-Off Valve
73
Float Chamber
73
Starting Enrichment (SE) Valve Cover
73
Throttle Cable Stay
73
Carburetor Assembly
75
Carburetor Cleaning
75
Float Level Inspection
76
Carburetor Installation
79
Idle Drop Procedure
80
Pilot Screw Adjustment
80
Secondary Air Supply System
81
System Inspection
81
Pair Check Valve Inspection
82
System Flow Pattern
83
Cooling System
84
Coolant (Hydrometer Test)
86
System Testing
86
Coolant Replacement
87
Radiator Cap/System Pressure Inspection
87
Replacement/Air Bleeding
88
Thermostat
89
Radiator/Cooling Fan
91
Mechanical Seal Inspection
95
Radiator Reserve Tank
95
Water Pump
95
Water Pump Cover Removal/Installation
95
Engine Removal/Installation
99
ENGINE REMOV Allinstallatlon
100
Engine Installation
102
Clutch/Gearshift Linkage
107
Right Crankcase Cover Removal
110
Clutch
111
Clutch Lifter Arm
111
Clutch Lifter Bearing
112
Clutch Disc
113
Clutch Plate
113
Clutch Spring
113
Clutch Center
114
Clutch Outer
114
Clutch Outer Guide
114
Judder Spring, Spring Seat
114
Gearshift Linkage
117
Primary Drive Gear
119
Clutch Lifter Arm Installation
120
Right Crankcase Cover Installation
120
Alternator/Starter Clutch
122
System Diagram
122
Alternator/Stator
124
Left Crankcase Cover Removal
124
Stator Removal
124
Flywheel Removal
125
Stator Installation
125
Starter Clutch
126
Flywheel Installation
129
Left Crankcase Cover Installation
130
Cylinder Head/Valves
131
Cylinder Compression
134
Cylinder Head Cover Removal
135
Cylinder Head Removal
135
Camshaft Removal
136
Cam Chain Tensioner Lifter
138
Cylinder Head Disassembly
139
Camshaft/Camshaft Holder
141
Valve Lifter
142
Valve Spring
142
Cylinder Head
143
Valve
143
Valve Guide
143
Valve Guide Replacement
144
Valve Seat Inspection
145
Valve Seat Refacing
146
Cylinder Head Assembly
148
Camshaft Installation
150
Cylinder Head Installation
150
Cylinder Head Cover Installation
153
Cylinder/Piston
155
Cylinder Removal
158
Piston Removal
159
Piston Installation
162
Cylinder Installation
163
Transmission
165
Transmission
166
Transmission Disassembly
168
Bushings
170
Gears
170
Inspection
170
Mainshaft/Countsrshaft
170
Shift Drum/Drum Journal
171
Shift Fork
171
Shiftfork Shaft
172
Transmission Bearing
172
Transmission Bearing Replacement
173
Left Crankcase
174
Right Crankcase
174
Mainshaft
175
Transmission Assembly
175
Countershaft
176
Washer and Snap Ring Direction
176
Crankcase Assembly
178
Crankshaft/Balancer
180
13. Crankshaftlbalancer
181
Big End Side Clearance
182
Crankshaft Removal
182
Crankshaft Runout
182
Balancer Gear
183
Big End Radial Clearance
183
Crankshaft/Balancer Bearing
183
Crankshaft/Balancer Bearing Replacement
184
Crankshaft Installation
185
Front Wheel/Suspension/Steering
186
FRONT Wheellsuspensioni STEERING
187
Handlebar
189
Axle
194
Front Wheel
194
Wheel Bearing
194
Wheel Bearing Replacement
195
Wheel Rim
195
Fork
198
Fork Pipe/Slider/Piston
201
Fork Spring
201
Steering Stem
205
Bearing Race Replacement
206
Bottom Cone Race Replacement
207
Steering Bearing Preload
209
Rear Wheel/Suspension
210
REAR Wheellsuspension
211
Rear Wheel
213
Wheel Rim Runout
213
Driven Sprocket
214
Driven Flange Bearing Removal
216
Wheel Bearing Removal
216
Wheel Bearing Installation
217
Driven Flange Installation
218
Wheel Assembly
218
Shock Absorber
219
Swingarm
220
Brake System
225
Brake System
226
Brake Fluid Draining
228
Brake Fluid Filling/Bleeding
228
Brake Fluid Replacement/Air Bleeding
228
Brake Pad/Disc
230
Front Brake Pad Replacement
230
Rear Brake Pad Replacement
231
Brake Disc Inspection
232
Front Master Cylinder
233
Rear Master Cylinder
237
Front Brake Caliper
241
Brake System Assembly
243
Rear Brake Caliper
244
Brake Pedal
247
Charging System
249
System Diagram
249
17. Charging System
250
Battery Is Damaged or Weak
252
Troubleshooting
252
Battery
253
Battery Charging
254
Charging System Inspection
254
Charging Voltage Inspection
254
Alternator Inspection
256
Current Leakage Inspection
256
Regulator/Rectifier
257
Ignition System
258
18. Ignition System
259
Nospark at Plug
260
Ignition Coil Primary Peak Voltage
261
Ignition System Inspection
261
Ignition Pulse Generator Peak Voltage
262
Ignition Coil
263
Ignition Control Module (ICM)
263
Ignition Timing
264
Electric Starter: System Diagram
266
Starter Motor
270
Starter Relay Switch
276
Clutch/Neutral Diode
277
Lights/Meters/Switches
278
System Location
278
Bulb Replacement
281
Front Turn Signal Light
281
Headlight
281
Rear Turn Signal and Tail/Brake Light and License Light
281
License Light
282
Rear Turn Signal Light
282
Tail/Brake Light
282
Combination Meter
283
Ignition Switch
285
Brake Light Switch
286
Front
286
Handlebar Switches
286
Neutral Indicator/Switch
287
Rear
287
Fuel Meter Inspection
289
Fuel Meter/Fuel Unit
289
Fuel Unit Inspection
289
Fuel Unit Installation
290
Horn
291
Turn Signal Relay
291
Cooling Fan Motor Switch
292
Fan Motor Does Not Start
292
Fan Motor Does Not Stop
292
Coolant Temperature Gauge/Thermosensor
293
Clutch Switch
294
Thermosensor Inspection
294
Tachometer
295
Wiring Diagram
296
22. Troubleshooting
297
Engine Does Not Start or Is Hard to Start
297
Engine Lacks Power
298
Poor Performance at Low and Idle Speed
299
Poor Handling
300
Poor Performance at High Speed
300
Index
301
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