Honda Zoomer Manuals

Manuals and User Guides for Honda Zoomer. We have 1 Honda Zoomer manual available for free PDF download: Service Manual

Honda Zoomer Service Manual (297 pages)

2003-2007

Brand: Honda | Category: Scooter | Size: 21 MB

General Information
2
Service Rules
2
Model Identification
2
Serial Numbers
3
Labels
4
General Specifications
5
Lubrication System Specifications
6
Fuel System Specifications
6
Cooling System Specifications
6
Cylinder Head/Valves Specifications
7
Kickstarter/Drive Pulley/Drive Pulley/Clutch Specifications
7
Final Reduction Specifications
7
Crankshaft/Piston/Cylinder Specifications
8
Rear Wheel/Brake/Suspension Specifications
8
Front Wheel/Brakes/Suspension/Steering Specifications
8
Battery/Charging System Specifications
9
Ignition System Specifications
9
Lights/Meters/Switches Specifications
9
Standard Torque Values
10
Engine & Frame Torque Values
10
Lubrication & Seal Points
13
Cable & Harness Routing
15
After 05 Model View
29
Source of Emissions
34
Crankcase Emission Control System
34
Exhaust Emission Control System
35
Secondary Air Supply System
35
Noise Emission Control System
36
Oxidation Catalytic Converter
36
Technical Features
37
PCV (Positive Crankcase Ventilation)
38
Frame/Body Panels/Exhaust System
39
Body Panel Locations
40
Frame/Body Panels/Exhaust System Service Information
41
Frame/Body Panels/Exhaust System Troubleshooting
41
Seat Removal
42
Seat Installation
42
Seat Rail Removal/Installation
43
Inner Cover Removal
43
Inner Cover Installation
43
Front Cover Removal/Installation
44
Floor Step Removal
45
Floor Step Installation
45
Under Cover Removal/Installation
46
Rear Fender Removal/Installation
46
Muffler Removal
47
Muffler Installation
47
Muffler Protector Removal/Installation
47
Maintenance
48
Maintenance Service Information
49
Maintenance Specifications
49
Maintenance Schedule
50
Fuel Line
51
Throttle Operation
51
Air Cleaner
52
Engine Breather
53
Spark Plug
53
Valve Clearance Inspection
55
Valve Clearance Adjustment
56
Engine Oil Level Check
57
Engine Oil Change
58
Engine Oil Strainer Screen
59
Engine Idle Speed
59
Radiator Coolant
60
Cooling System
60
Brake Shoes Wear
62
Brake System
63
Brake Lock Operation
63
Headlight Aim
64
Front Suspension
64
Rear Suspension
64
Nuts, Bolts, Fasteners
65
Wheels/Tires
65
Steering Head Bearings
66
Lubrication System
67
Lubrication System Diagram
68
Lubrication System Service Information
69
Lubrication System Troubleshooting
69
Oil Pump Removal
70
Oil Pump Disassembly
71
Oil Pump Inspection
71
Oil Pump Assembly
72
Oil Pump Installation
73
Fuel System
75
Fuel System Component Locations
76
Fuel System Service Information
77
Fuel System Tools
77
Fuel System Troubleshooting
78
Air Cleaner Housing Removal/Installation
79
Carburetor Removal
81
Carburetor Disassembly
82
Starting Enrichment (SE) Valve
83
Vacuum Chamber
83
Float Chamber
84
Carburetor Cleaning
85
Carburetor Assembly
86
Float Level Inspection
87
Carburetor Installation
89
Pilot Screw Adjustment
92
Idle Drop Procedure
92
High Altitude Adjustment
94
Input Voltage Inspection
95
Resistance Inspection
95
Operation Inspection
96
Secondary Air Supply System Inspection
96
Pair Control Valve Removal/Installation
97
PCV Control Solenoid Valve/Pcv Reed Valve Removal/Installation
98
Fuel Tank Removal/Installation
102
PCV Reed Valve
102
Cooling System Flow Pattern
105
Cooling System Service Information
106
Cooling System Troubleshooting
107
Coolant System Testing
108
Coolant (Hydrometer Test)
108
Coolant Specific Gravity Chart
108
Radiator Cap/System Pressure Inspection
109
Coolant Replacement Preparation
109
Coolant Replacement/Air Bleeding
110
Water Pump/Thermostat Removal
111
Thermostat Inspection
113
Thermostat Installation
113
Radiator Removal
115
Radiator Installation
116
Radiator Reserve Tank Removal/Installation
117
Engine Removal/Installation
119
Engine Removal/Installation Component Locations
120
Engine Removal/Installation Service Information
121
Engine Removal
122
Engine Installation
125
Cylinder Head/Valves
127
Cylinder Head/Valves Component Locations
128
Cylinder Head/Valves Service Information
129
Cylinder Head/Valves Tools
130
Cylinder Head/Valves Troubleshooting
131
Cylinder Compression Test
132
Cylinder Head Cover Removal
132
Camshaft/Rocker Arms Removal
133
Camshaft Inspection
135
Rocker Arm/Shaft Inspection
135
Side Spring Inspection
135
Cylinder Head Removal
136
Cam Chain Tensioner Lifter
136
Cylinder Head Disassembly
137
Cylinder Head Inspection
138
Valve Spring Inspection
138
Valve/Valve Guide Inspection
138
Valve Guide Replacement
139
Cam Chain Tensioner/Guide
139
Valve Seat Inspection/Refacing Inspection
140
Cylinder Head Assembly
143
Cylinder Head Installation
144
Camshaft/Rocker Arm Installation
145
Rocker Arm Holder Assembly
145
Cylinder Head Cover Installation
148
Kickstarter/Drive Pulley/Driven Pulley/Clutch
149
Kickstarter/Drive Pulley/Driven Pulley/Clutch Component Locations
150
Kickstarter/Drive Pulley/Driven Pulley/Clutch Service Information
151
Kickstarter/Drive Pulley/Driven Pulley/Clutch Tools
152
Kickstarter/Drive Pulley/Driven Pulley/Clutch Troubleshooting
153
Belt Case Cover Removal
154
Belt Case Cover Installation
154
Kickstarter Disassembly
154
Kickstarter Inspection
155
Kickstarter Assembly
156
Drive Pulley Removal
157
Drive Belt Inspection
158
Weight Roller Inspection
158
Movable Drive Face
159
Clutch/Driven Pulley Removal
160
Clutch/Driven Pulley Disassembly
160
Clutch/Driven Pulley Inspection
162
Clutch Outer
162
Clutch Shoe Lining
162
Driven Face Spring
162
Driven Face Bearing Replacement
163
Driven Face Bearing Assembly
164
Driven Face Bearing Installation
166
Final Reduction
167
Final Reduction Component Locations
168
Final Reduction Service Information
169
Final Reduction Tools
169
Final Reduction Troubleshooting
170
Final Reduction Oil Level Check
171
Final Reduction Disassembly
171
Transmission Disassembly
171
Driveshaft Removal
172
Driveshaft Inspection
173
Final Reduction Bearing Replacement
174
Final Reduction Assembly
175
Alternator/Starter
179
Alternator/Starter Component Locations
180
Alternator/Starter Service Information
181
Alternator/Starter Tools
181
Alternator/Starter Removal
182
Alternator/Starter Installation
183
Crankshaft/Piston/Cylinder
185
Crankshaft/Piston/Cylinder Component Locations
186
Crankshaft/Piston/Cylinder Service Information
187
Crankshaft/Piston/Cylinder Troubleshooting
188
Crankshaft/Piston/Cylinder Crankcase Separation
189
Crankshaft Removal
189
Piston Removal
190
Crankshaft Inspection
190
Piston/Cylinder Inspection
192
Piston Installation
194
Crankshaft Installation
194
Crankcase Assembly
195
Front Wheel/Brake/Suspension/Steering
197
Front Wheel/Brake/Suspension/Steering Component Locations
198
Front Wheel/Brake/Suspension/Steering Service Information
199
Front Wheel/Brake/Suspension/Steering Tools
200
Front Wheel/Brake/Suspension/Steering Troubleshooting
202
Front Wheel Removal
203
Front Wheel Inspection
203
Front Wheel Disassembly
204
Front Wheel Assembly
205
Front Wheel Installation
206
Front Brake Removal
207
Front Brake Inspection
207
Front Brake Disassembly
207
Front Brake Assembly
209
Front Brake Installation
210
Fork Removal
211
Fork Disassembly
211
Fork Inspection
212
Fork Assembly
213
Fork Installation
214
Handlebar Removal
215
Handlebar Installation
217
Steering Stem Removal
219
Steering Stem Bearing Replacement
220
Steering Stem Installation
222
Rear Wheel/Brake/Suspension
224
Rear Wheel/Brake/Suspension Component Locations
225
Rear Wheel/Brake/Suspension Service Information
226
Rear Wheel/Brake/Suspension Troubleshooting
226
Rear Wheel Inspection
227
Rear Wheel Removal
227
Rear Wheel Installation
227
Rear Brake Inspection
227
Rear Brake Disassembly
228
Rear Brake Assembly
229
Rear Shock Absorber Removal
230
Rear Shock Absorber Inspection
231
Rear Shock Absorber Installation
231
Battery/Charging System
232
Battery/Charging System Diagram
233
Battery/Charging System Service Information
234
Battery/Charging System Tools
235
Battery/Charging System Troubleshooting
236
Battery Removal/Installation
237
Battery Voltage Inspection
237
Charging System Inspection
238
Battery Testing
238
Battery Charging (U.S.A. Only)
238
Current Leakage Test
238
Charging Voltage Inspection
239
Alternator Charging Coil Inspection
239
Engine Control Module (ECM) System Inspection
240
Regulator/Rectifier Circuit Inspection
240
Ignition Switch Circuit Inspection
241
Main Relay System Inspection
242
Operating Inspection
243
Ignition System
244
Ignition System Diagram
245
Ignition System Service Information
246
Ignition System Tools
246
Ignition System Troubleshooting
247
Ignition System Inspection
248
Ignition Coil Primary Peak Voltage
248
Ignition Pulse Generator Peak Voltage
249
Ignition Coil Removal/Installation
250
Ignition Timing
250
Throttle Position Sensor System Inspection
251
Throttle Position Sensor Removal/Installation
252
Data Reset
253
Electric Starter
254
Electric Starter System Diagram
255
Electric Starter Service Information
256
Electric Starter Troubleshooting
257
Starter Relay Removal/Installation
259
Starter Relay Operation Inspection
259
Starter Relay Circuit Inspection
259
Ground Line
260
Starter Circuit Inspection
260
Engine Control Module (ECM)
261
Starter Switch Circuit Inspection
261
Angle Sensor Circuit Inspection
261
Lights/Meters/Switches
262
Lights/Meters/Switches System Location
263
Lights/Meters/Switches Service Information
264
Headlight Bulb Replacement
265
Headlight Inspection
265
Headlight Removal/Installation
267
Turn Signal Light Bulb Replacement
267
Turn Signal Light Inspection
267
Turn Signal Light Removal/Installation
268
Brake/Tail Light Bulb Replacement
269
Brake/Tail Light Inspection
269
Brake/Tail Light Removal/Installation
270
Turn Signal Indicator Bulb Replacement
271
High Beam Indicator Bulb Replacement
271
Speedometer Bulb Replacement
272
Speedometer Removal/Installation
272
Fuel Reserve Indicator/Fuel Reserve Sensor
273
Led Drive Unit Battery/Ground Line Inspection
273
Fuel Reserve Sensor Removal
275
Fuel Reserve Sensor Installation
275
Coolant Temperature Indicator/Ect Sensor
276
ECT Sensor Inspection
278
Fuel Pump System Inspection
279
Fuel Pump Removal/Installation
281
Ignition Switch Inspection
281
Ignition Switch Removal/Installation
281
Handlebar Switches
282
Brake Light Switch
283
Left Handlebar Switch
283
Right Handlebar Switch
283
Load Cut Relay
284
Horn Inspection
284
Wiring Diagrams
285
03-05 Model Wiring Diagram
286
After 05 Model Wiring Diagram
287
Troubleshooting
288
Engine Does Not Start or Is Hard to Start
289
Engine Lacks Power
290
Poor Performance at Low and Idle Speed
292
Poor Performance at High Speed
293
Poor Handling
294
Index
295

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Honda Zoomer Service Manual (297 pages)

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