Honda CB HORNET 160R 2015 Manuals

Honda CB HORNET 160R 2015 Manuals

Manuals and User Guides for Honda CB HORNET 160R 2015. We have 1 Honda CB HORNET 160R 2015 manual available for free PDF download: Shop Manual

Honda CB HORNET 160R 2015 Shop Manual

Honda CB HORNET 160R 2015 Shop Manual (337 pages)

Brand: Honda | Category: Motorcycle | Size: 28.85 MB

Table of Contents

Important Safety Precautions
2
How to Use this Manual
3
Contents
3
Symbols
4
General Information Contents
5
Service Rules
5
- Table of Contents
  5
- Abbreviation
  5
Model Identification
6
Color Label
7
Serial Numbers
7
General Specifications
8
Lubrication System Specifications
9
Fuel System Specifications
9
Cylinder Head/Valves Specifications
9
Clutch/Gearshift Linkage Specifications
10
Cylinder/Piston Specifications
10
Alternator/Starter Clutch Specifications
10
Crankcase Crankshaft/ Transmission/Kickstarter Specifications
11
Front Wheel/Suspension/ Steering Specifications
11
Rear Wheel/Suspension Specifications
12
Brake System Specifications
12
Battery/Charging System Specifications
12
Electrical Starter Specification
13
Ignition System Specifications
13
Lights/Meter/Switches Specifications
13
Engine and Frame Torque Values
14
Standard Torque Values
14
- Frame
  16
- Lubrication and Seal Points
  17
- Cable and Harness Routing
  19
- CBS Type
  21
- STD Type
  22
- Crankace Emission Control System
  26
- Emission Control System
  26
- Source of Emissions
  26
- Exhaust Emission Control System
  27
- Noise Emission Control System
  27
- Oxidation Catalytic Converter
  27
- Secondary Air Supply System
  27
- Evaporative Emission Control System
  28
- Frame/Body Panels/Exhaust System Contents
  29
- Service Information
  29
- Torque Values
  29
- Troubleshooting
  29
- Cover Headlight RR
  30
- Front Cowl Disassembly
  30
- Fuel Tank Assembly
  31
- Left Side Cover
  31
- Right Side Cover
  31
- Seat
  31
  - Fuel Tank
    32
  - Fuel Tank Center Cover
    32
  - Fuel Tank Left and Right Side Cover
    32
- Front Fender
  33
- Rear Garnish Set
  34
- Rear Grip
  34
- Rear Cowl
  35
- Rear Fender
  35
- Exhaust Pipe/Muffler
  36
- Sari Guard
  36
- Side Stand
  36
- Muffler Protector
  37
  - Stud Bolt Replacement
    37
  - Maintenance Contents
    39
  - Tools
    40
  - Maintenance Schedule
    41
- Fuel Line
  42
- Fuel Strainer Screen
  42
- Choke Operation
  43
- Minor/Major Adjustment
  43
- Throttle Operation
  43
  - Air Cleaner Element
    44
  - Torque
    44
- Crankcase Breather
  45
- Spark Plug
  45
- Valve Clearance
  46
- Engine Oil
  48
  - Oil Level Inspection
    48
  - Recommended Engine Oil
    48
  - Engine Oil Change
    49
  - Engihne Oil Centrifugal Filter
    50
- Engine Oil Strainer Screen
  50
- Engine Idle Speed
  52
- Secondary Air Supply System
  52
- Evaporative Emission Control System
  53
- Drive Chain Slack Inspection
  54
- Battery
  56
- Brake Fluid
  56
  - Sprocket
    56
  - Front Brake Fluid Level Inspection
    57
  - Rear Brake Fluid Level Inspection
    57
  - Brake Pad Wear
    58
  - Front Brake Pads
    58
  - Rear Brake Free Play Adjustment
    58
- Brake System
  59
  - Front Brake
    59
  - Front/Rear Brake Pads
    59
  - Rear Brake Shoes
    59
- Brake Light Switch
  60
- Clutch System
  60
- Headlight Aim
  60
  - Rear Brake
    60
  - Front/Rear Suspension Inspection
    61
- Side Stand
  61
- Front/Rear Wheel
  62
- Nuts, Bolts, Fasteners
  62
- Wheels/Tires
  62
- Recommended Tire Pressure and Tire Size
  63
- Steering Head Bearings
  63
  - Lubrication System Diagram
    64
  - Lubrication System Contents
    65
  - Oil Pump
    66
  - Oil Pump Assembly
    69
  - Component Location
    72
  - Fuel System Components
    73
  - Air Cleaner Housing
    75
  - Starting Enrichment Valve
    77
  - Carburetor
    78
  - Throttle Cable Stay
    79
  - Vacuum Chamber
    79
  - Float
    80
  - Jets
    81
  - Starting Enrichment Valve Cover
    81
  - Carburetor Assembly
    82
  - Carburetor Cleaning
    82
  - Pilot Screw Adjustment
    87
  - Adjustment by Concentration Measurement
    88
  - Idle Drop Procedure
    90
  - Pair Check Valve Inspection
    91
  - System Inspect
    91
  - One Way Valve
    92
  - Pair Control Valve
    92
  - Canister Component
    93
  - Fuel Strainer
    94
  - Engine Removal/Installation
    97
  - Cylinder Head/Valves
    105
  - Cylinder Compression
    108
  - Cylinder Head Cover
    108
  - Camshaft
    110
  - Cam Lobe
    112
  - Camshaft Bearing
    112
  - Cylinder Head Removal
    114
  - Rocker Arm
    115
  - Cylinder Head Disassembly/Assembly
    116
  - Cylinder Head
    117
  - Valve
    117
  - Valve Guide
    117
  - Valve Spring
    117
  - Valve Guide Replacement
    118
  - Valve Seat Inspection
    119
  - Valve Seat Refacing
    120
  - Assembly
    122
  - Cylinder Head Installation
    123
  - Cam Chain Tensioner Lifter
    125
  - Cylinder/Piston Contents
    129
  - Cylinder Inspection
    130
  - Cylinder Removal
    130
  - Piston Removal
    131
  - Piston Inspection
    132
  - Piston Installation
    134
  - Cylinder Installation
    135
  - Clutch/Gearshift Linkage Contents
    139
  - Right Crankcase Cover
    141
  - Clutch
    144
  - Clutch Center
    146
  - Clutch Lifter Bearing
    146
  - Clutch Spring
    146
  - Friction Disc
    146
  - Clutch Outer/Outer Guide
    147
  - Clutch Plate
    147
  - Gearshift Linkage
    150
  - Primary Drive Gear
    152
  - Balancer Drive Gear
    153
  - Alternator Contents
    155
  - Left Crankcase Cover
    156
  - Flywheel
    158
  - Starter Clutch
    160
  - Starter Motor
    162
  - Stator/Ignition Pulse Generator
    170
  - Crankcase/Transmission/Kickstarter Contents
    173
  - Balancer Gear Removal
    176
  - Crankcase Separation
    176
  - Balancer Gear Inspection
    177
  - Transmission
    178
  - Gears
    179
  - Mainshaft/Countershaft
    179
  - Crankshaft
    180
  - Crankshaft Runout
    180
  - Shift Fork
    180
  - Shift Fork Shaft
    180
  - Big End Radial Clearance
    181
  - Big End Side Clearance
    181
  - Crankshaft/Balancer Bearing Inspection
    181
  - Timing Sprocket
    181
  - Oil Passages Inspection
    183
  - Right/Left Crankcase
    183
  - Bearing Replacement of Crankshaft
    184
  - Mainshaft
    186
  - Countershaft
    187
  - Crankcase Assembly
    189
  - Kickstarter
    193
  - Front Wheel/Suspension/Steering Contents
    197
  - Handlebar
    200
  - Front Wheel
    205
  - Axle
    206
  - Wheel Bearing
    206
  - Brake Disc
    207
  - Wheel Rim
    207
  - Fork
    210
  - Fork Pipe/Slider
    213
  - Fork Piston/Rebound Spring/Oil Lock Piece
    213
  - Fork Spring
    213
  - Fork Assembly
    214
  - Guide Bushing/Slider Bushing/Back-Up Ring
    214
  - Steering Stem
    218
  - Ball Race Replacement
    220
  - Bottom Cone Race Replacement
    220
  - Steering Stem Assembly
    221
  - Steering Bearing Preload
    223
  - Rear Wheel/Suspension Contents
    225
  - Disc Type
    228
  - Drum Type
    228
  - Rear Wheel
    228
  - Wheel Bearing Removal
    229
  - Wheel Balance
    230
  - Assembly of Disc Brake
    231
  - Assembly of Drum Brake
    231
  - Driven Flange
    233
  - Driven Sprocket
    233
  - Driven Flange Baring
    234
  - Driven Flange Assembly
    235
  - Shock Absorber
    236
  - Swingarm
    237
  - CBS Front/Rear Brake
    244
  - Brake System Contents
    245
  - Brake Fluid Draining Front Disc Brake
    247
  - Brake Fluid Line
    247
  - Brake Fluid Replacement/Air Bleeding
    247
  - Brake Fluid Filling/Air Bleeding Front Brake
    248
  - CBS Brake Line
    248
  - Combi Brake System
    248
  - Rear Brake Line
    248
  - CBS Brake
    250
  - Brake Pad/Disc
    251
  - Front Brake Pad Replacement
    251
  - Front Brake Disc Inspection
    252
  - Front Master Cylinder
    253
  - Installation of Master Cylinder
    257
  - CBS Front Brake
    258
  - Front Brake Caliper
    258
  - CBS Front Brake Assembly
    259
  - Non CBS Front Brake
    260
  - Front Brake (Non CBS) Assembly
    262
  - Rear Disk Brake Pad Replacement
    263
  - Rear Brake Disc Inspection
    264
  - Rear Master Cylinder (CBS)
    265
  - Rear Master Cylinder Assembly
    266
  - Brake Pedal Height
    267
  - Rear Brake Caliper
    268
  - Rear Brake Caliper Assembly
    270
  - Brake Pedal
    271
  - Rear Drum Brake
    274
  - Rear Drum Brake Assembly
    275
  - Battery/Charging System Contents
    279
  - Battery Testing Procedure
    281
  - Voltage Inspection
    281
  - Battery Load Test
    282
- Battery Charging
  283
  - Battery Test Result
    283
  - Current Leakage Inspection
    285
- Indication Table for MF Battery Charger
  285
- System Inspection
  285
- Alternator Charging Coil
  286
- Charging Voltage Inspection
  286
- Regulator/Rectifier
  287
- Ignition System Diagram
  288
- Ignition System Contents
  289
- Ignition Coil Primary Peak Voltage
  291
- Ignition System Inspection
  291
- Ignition Pulse Generator Peak Voltage
  292
- Ignition Timing
  293
- Ignition Coil
  294
- CDI
  294
- Throttle Position Sensor
  295
- Input Voltage
  295
- Initialization Procedure
  296
- Lights/Meters/Switches Contents
  301
- Headlight
  302
- Bulb Replacement
  302
- Brake/Tail Light
  303
- Headlight Unit
  303
- LED Unit Replacement
  303
- Number Plate Light Bulb
  303
- Turn Signal Lights
  304
- Bulbs Replacement
  304
- Back-Up Voltage Line
  305
- Power Input Line
  305
- Power/Ground Line Inspection
  305
- Combination Meter
  305
- Combination Meter Assembly
  306
- Speedometer VS Sensor
  307
- Vehicle Speed Sensor
  307
- Tachometer
  308
- Digital Meter Reset Procedure
  309
- Tripmeter
  309
- Digital Clock
  309
- Combination Switch
  310
- Handlebar Switches
  311
- Left Handlebar Switch
  311
- Neutral Switch
  312
- Fuel Gauge/Fuel Level Sensor
  314
- Horn
  316
- Passing Relay
  316
- Turn Signal Relay
  317
- Fuse Box
  318
- Electric Starter Component
  320
- Electric Starter System Contents
  321
- Starter Relay Switch
  323
- Operation Inspection
  323
- Circuit Inspection
  323
- Ground Line
  323
- Neutral Diode
  324
- Function Inspection
  324
- Right Handlebar Switches
  325
- Clutch Switch
  325
- Wiring Diagram
  327
- Troubleshooting Contents
  328
- Engine Does Not Start or Is Hard to Start
  328
- Engine Lacks Power
  329
- Poor Performance at Low and Idle Speed
  331
- Poor Performance at High Speed
  332
- Poor Handling
  332
- Index
  334

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