Honda CBR150R, CBR150R (2002) User Manual

HOW

TO USE

THIS

MANUAL

CONTENTS

This service manual describes the service procedures

CBR150R.

for the

Follow the Maintenance Schedule (Section
mendations to ensure that the vehicle is

ating condition and the emission levels are within the

standards.
Performing the first scheduled maintenance is very

important.
curs during the break-in period.

Sections
Section
tion of components that may be required to perform
service described in the following sections.
Section
grouped according to location.

Find the section you want on this page, then turn to
the table

Most sections start with an assembly or system illus­tration, 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

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS
AND SPECIFICATIONS INCLUDED IN THIS PUBLICA­TION ARE BASED ON THE LATEST PRODUCT IN­FORMATION AVAILABLE AT THE TIME OF AP­PROVAL FOR PRINTING.
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
FOR PERSONS WHO HAVE ACQUIRED BASIC
KNOWLEDGE
TORCYCLES, MOTOR SCOOTERS

It

compensates for the initial wear that oc-

1

and 3 apply to the whole motorcycle.

2

illustrates procedures for removal/installa-

4

through

21

describe parts of the motorcycle,

of

contents on the first page of the section.

22

TROUBLESHOOTING.

Honda Motor

OF

MAINTENANCE ON Honda MO-

SERVICE PUBLICATION OFFICE

Honda Motor Co.,

OR

3)

in

peak oper-

Co..

IS

WRITEN

ATVS.

recom-

Ltd.

Ltd.

GENERAL INFORMA TlON
FRAMElBODY PANELSlEXHAUST

SYSTEM

MAINTENANCE

FUEL SYSTEM
COOLING SYSTEM

z

ENGINE REMOV ALlINSTALLATlON

k

Lu

CLUTCHlGEARSHlFT LINKAGE

2

n

ALTERNATORlSTARTER CLUTCH

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

2

LIGHTSlMETERSlSWITCHES

Date of Issue: February,

Q

Honda Motor

Co.,

Ltd.

WIRING DIAGRAM
TROUBLESHOOTING

2002

IMPORTANT SAFETY NOTICE

Indicates a strong possibility of severe personal injury or death if instructions are not followed.

CAUTION:

NOTE:
Detailed descriptions of standard workshop procedures, safety principles and service operations are not

included.
service methods which could cause
render
whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each
conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or
whether or not recommended by Honda, must satisfy himself thoroughly that neither personal safety nor
vehicle safety will be jeopardized by the service methods or

Indicates a possibility of equipment damage if instructions are not followed.

Gives helpful information.

It

is important to note that this manual contains some warnings and cautions against some specific

it

unsafe. Please understand that those warnings could not cover all conceivable ways in which service,

PERSONAL INJURY

to service personnel or could damage a vehicle or

tools,

tools

selected.

SYMBOLS

The symbols used throughout this manual show specific service procedures. If supplementary information is required

pertaining to these symbols,

-3

it

would be explained specifically in the text without the use of the symbols.

Replace the part(s) with new one(s) before assembly.

~~

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a

1:l)

ratio of

Use multi-purpose grease (Lithium based multi-purpose grease NLGl

Use molybdenum disulfide grease (containing more than
NLGl#2 or equivalent.
Example: Molykote'

Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan

Use molybdenum disulfide paste (containing more than
NLGl#2 or equivalent.
Example: Molykote' G-n Paste manufactured by Dow Corning U.S.A.

Honda Moly
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan

Use silicone grease.

~

BR-2

plus manufactured by Dow Corning U.S.A.

60

(U.S.A. only)

3%

40%

#2

or equivalent)

molybdenum disulfide,

molybdenum disulfide,

Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

Apply sealant.

Use DOT

Use Fork or Suspension Fluid.

4

brake fluid. Use the recommended brake fluid unless otherwise specified.

1.

GENERAL

INFORMATION

GENERAL SAFETY 1-1 TOOLS 1-14

&

SERVICE RULES
MODEL IDENTIFICATION
SPECIFICATIONS
TORQUE VALUES

1-2 LUBRICATION
1-3 CABLE

&

1-4 EMISSION CONTROL SYSTEMS
1-12

SEAL POINTS

HARNESS ROUTING

1-17

1-24

GENERAL SAFETY

I

CARBON MONOXIDE

If

the engine must be running to
sure the area is well ventilated. Never run the engine in
an enclosed area.

The exhaust contains poisonous carbon monoxide gas
that can cause loss of consciousness and may lead to

death.

Run

the engine in an open area orwith an exhaust evacu-

ation system in an enclosed area.

GASOLINE

Work in a well ventilated area. Keep cigarettes, flames
or sparks away from the work area or where gasoline is
stored.

Gasoline is extremely flammable and is explosive un­der certain conditions. KEEP OUT
DREN.

HOT COMPONENTS

Engine and exhaust system parts become very hot and
remain hot for some time after the engine is run. Wear
insulated gloves or wait until the engine and exhaust
system have cooled before handling these parts.

do

some work, make

OF

REACH OF CHIL-

USED ENGINE OIL

Used engine oil may cause skin cancer if repeatedly left

in contact with the skin for prolonged periods. Although

this is unlikely unless you handle used oil on a daily ba-

sis,

it

is still advisable to thoroughly wash your hands

with soap and water as soon as possible after handling

used oil. KEEP OUT

BRAKE FLUID

CAUTION:

Spilling fluid on painted, plastic or rubber parts
age them. Place a clean shop towel over these parts

whenever the system is serviced. KEEP OUT

OF

CHILDREN.

~

BATTERY HYDROGEN GAS & ELECTROLYTE

The battery gives
flames and cigarettes away. Provide adequate venti­lation when charging.
The battery contains sulfuric acid felectrolyte). Con­tact with skin

protective clothing and a face shield.

-If electrolyte gets on your skin, flush with water.

-If

electrolyte gets in your eyes, flush with water
for at least
diately.

Electrolyte is poisonous.

-

Ifswallowed, drinklarge quantities of water or milk
and follow with milk of magnesia or vegetable oil
and call a physician. KEEP OUT
DREN.

OF

REACH

OF

CHILDREN.

will

OF

REACH

off

explosive gases; keep sparks,

or

eyes may cause severe burns. Wear

15

minutes and call a physician imme-

OF

REACH

OF

dam-

CHIL-

1-1

GENERAL

INFORMA

TION

SERVICE

1.

Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet
design specifications may cause damage to the motorcycle.

2.

Use the special tools designed for this product to avoid damage and incorrect assembly.

3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with
English fasteners.

4.

Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.

5.

When tightening
diagonally in incremental steps unless a particular sequence is specified.

6.

Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.

7. After reassembly, check all parts for proper installation and operation.

8.

Route all electrical wires as show on pages 1-17 through 1-23, Cable and Harness Routing.

RULES

bolts

or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque

HONDA's

1-2

GENERAL INFORMA TlON

MODEL

IDENTIFICATION

FRAME

SERIAL

NUMBER

The frame serial number is stamped on the right side
the steering head.

CARBURETOR IDENTI

The carburetor identification number is stamped on the

of

left side

the carburetor body.

”

Fl

CAT1 ON NUMBER

of

ENGINE SERIAL NUMBER

The engine serial number is stamped on the lower left side

of

the crankcase.

I/

/

1-3

GENERAL INFORMA TlON

SPEC

IF I CAT1 0 N

-

GENERAL

DIMENSIONS

FRAME

ENGINE

S

Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Dry weight
Curb weight

Frame type
Front suspension
Front axle travel
Rear suspension

Rear axle travel
Rear damper
Front tire size

Rear tire size
Tire brand

Front brake

Rear brake

Caster angle
Trail length

Fuel tank capacity

Bore and stroke

Displacement

Compression ratio

Valve train

Intake valve

Exhaust valve opens

Lubrication system
Oil pump type
Cooling system
Air filtration

Crankshaft type

Engine dry weight

Cvlinder arranaement

ITEM

closes

SPECIFICATIONS

1,910 mm (75.2 in)
552

mm

(25.7 in)

1,065

mm

(41.9

(4.29 in)

in)

US

mm

in)

gal, 2.2 Imp gal)

(2.50 x 1.86 in)

1,286 mm (50.6 in)
776 mm (30.6 in)
312 mm (12.3 in)
172 mm (6.8 in)
115 kg (253.53 Ibs)
123 kg (271.17 Ibs)

Diamond type
Telescopic fork
190

mm

Swingarm
120 mm (4.72in)
Single effected tube type
80/90-17M/C 44P
100/80-17M/C 52P
FronVRear: IRC
Hydraulic disc brake
Hydraulic disc brake
25"
88 mrn (3.46

10.0 liter (2.64

63.5 x 47.2

149.4 cm3 (9.1 cu-in)

11.0:

1

Multi link chain drive and DOHC

5"

BTDC
35" ABDC
30" BBDC

0"

ATDC

Forced pressure and wet sump

Trochoid

Liquid cooled
Paper filter
Assembled type

26.1 kg (57.55 Ibs)
Sinale cvlinder inclined 40" from vertical

1-4

GENERAL INFORMA TlON

GENERAL

ZARBURETOR

3RIVE

TRAIN

ZLECTRICAL

(Cont'd)

Earburetor type
Venturi dia.

Clutch system
Clutch operation system
Transmission
Primary reduction
Final reduction
Gear ratio

Gearshift pattern
Ignition system

Starting system
Charging system
Regulator/rectifier
Lighting system

ITEM

~~ ~

SPECIFICATIONS

CV (Constant velocity) type

(0.98

25 rnm
Multi-plate, wet

Mechanical type
Constant mesh, 6-speed

3.260 (75/23)

2.933 (44/15)

1st

3.083 (37/12)

2nd

1.941 (33/17)

3rd

1.500 (30/20)

4th

1.227 (27/22)

1.041 (25/24)

5th
6th

0.923 (24/26)
Left

Condenser Discharged Ignition (CDI)

Electric starter motor

Single phase output alternator
SCR shorted/single phase, half wave rectification

Alternator

in) or equivalent

foot

operated return system

1-N-2-3-4-5-6

1-5

GENERAL INFORMA

Engine oil capacity

Oil pump rotor Tip clearance

TlON

ITEM STANDARD SERVICE LIMIT

At draining
At disassembly

Body clearance
Side clearance

1.0

liter

(1.06

US qt,

0.88

Imp qt)

1.3

liter

(1.37

US

qt,

1.14

Imp qt)

Honda 4-stroke oil or equivalent

motor oil
API service classification
Viscositv: SAE

IOW-30

SE,

-

1

0.150 - 0.210 (0.0059 - 0.0083)

1

0.050 - 0.100 (0.0020

-

0.0040)

SF

or

SG

1

0.20

(0.008)

1

0.26 (0.010)

1

0.15 (0.006)

Carburetor identification number
Main jet
Slow iet
Pilot screw opening
Float level
Idle speed
Throttle grip free play

Coolant capacity

I

Radiator cap relief pressure

Thermostat Begin

-

CLUTCHGEARSHIFT LINKAGE

Clutch Lever free play

Radiator and engine
Reserve tank

Fully open
Valve lift

ITEM STANDARD SERVICE LIMIT

Spring free length
Disc thickness A

Plate warpage
Outer guide

I

I

Outer

I.D.

Mainshaft

0.0.

at clutch outer wide

to

open

B

OD.

1

I.D.

VK6AA

#I15

#35

See

page

5-14

13

mm

(0.5

in)

1,400 + 100
2 - 6

1

0.76

liter

(0.20

US qt,

I

0.24

liter

(0.06

US

at,

108

kPa

(1.1

kgf/cm2,

69.5-72.5"C (157.1 - 1625°F)
80°C

(176°F)

3.5

mm

(0.14

in) minimum

10-20(3/8-13/16)

37.6 (1.48)

3.5 - 3.6 (0.138 - 0.1421

2.92 -3.08 (0.115 -0.121) 2.60 (0.102)

__

1

22.959 - 22.980 (0.9039 - 0.9047)

1

16.991 - 17.009 (0.6689 - 0.6696)

I

23.000 - 23.013 (0.9055 - 0.9060)

1

16.996 - 16.984 (0.6680 - 0.6687)

rnm

0.17

0.05

16

min-' (rpm)

(1/12 - 1/4

Imp qt)

imp

psi)

at)

in)

-

36.6 (1.44)

3.1 (0.121

10.2 (0.008)

I

22.93 (0.903)

1

17.04 (0.671)

I

23.06 (0.908)

I

16.935 (0.6667)

-

I

1-6

Cylinder compression

Cylinder head warpage
Valve,

valve guide

Valve spring free length
Valve lifter

Camshaft Cam

I

Valve clearance

Valve stem

Valve guide I.D.
Stem-to-guide clearance

Valve guide projection
above cylinder head

Valve seat width

O.D.

Bore

Runout

Camshaft holder

Camshaft
Camshaft-to-camshaft

holder clearance (right side)

ITEM

I.D.

lobe

O.D.

height

O.D.

I.D.

I

IN
EX

IN
EX
IN/EX
IN
EX
IN
EX

IN/EX

I

IN/EX

IN

EX

IN/EX
INEX
lN/EX

STANDARD

1,370

kpa

(13.9

at

680

kgf/cm2,

min-’ (rpm)

197.7

-

0.16 f 0.03 (0.006 f 0.001)

0.25 f 0.03 (0.010 f 0.001)

psi)

SERVICE LIMIT

-

0.05 (0.002)

-

-

3.775 - 3.790 (0.1486 - 0.1492) 3.7 (0.15)

3.765-3.780 (0.1482 - 0.1488) 3.7 (0.15)

3.800 -3.812 (0.1496-0.1501) 3.89 (0.153)

0.010 - 0.037 (0.0004- 0.0015) 0.075 (0.0029)

0.020 - 0.047 (0.0008 - 0.0019) 0.085 (0.0033)

15.5 (0.61)

13.1 (0.52)

1.2

-

1.6 10.05 - 0.06) 1.9 (0.07)

-

-

39.7 (1.56) 38.5 (1.52)

22.478

22.510

-

22.493 (0.8850 - 0.8855)

-

22.526 (0.8862 - 0.8869)

22.47 (0.885)

22.5 (0.89)

35.12-35.20(1.383- 1.386) 35.073 (1.3808)

-

34.79 (1.367 - 1.370) 34.662 (1.3646)

34.71

-

17.000 - 17.018 (0.6693- 0.6700)

-

16.966- 16.984 (0.6680

0.6687)

0.016- 0.052 (0.0006- 0.0020)

0.02 (0.001)

17.02 (0.6703)

16.960 (0.6677)

0.067 (0.0026)

Cylinder-to-piston clearance

Connecting rod small end

Connecting rod small end-to-piston pin clearance

I.D.

0.01 - 0.04 (0.0004 - 0.0016)

-

15.028 (0.5909 - 0.5917)

15.010

-

0.034 (0.0004 - 0.0013)

0.010

0.90 (0.035)

15.09 (0.594)

0.075 (0.0030)

1-7

7

TRANSMISSION

Transmission

Shift fork

ITEM

c1
c2
C3. C4

Bushing

Bushing

Gear-to-bushing clearance

Countershaft O.D.

Gear-to-shaft clearance I M5
Bushing-to-shaft clearance

Shaft

Fork

Fork claw thickness

Shift drum journal (R.crankcase)

Mainshaft

O.D.

I.D.

I.D.

O.D.

O.D.

c1 15.000- 15.018 (0.590-0.591) 15.1 (0.59)
c2 20.020 - 20.041 (0.7882 - 0.7890)
c1 17.969 - 17.980 (0.7074- 0.7079) 17.9 (0.70)
c2
C1
c2

I

M5

C1

gear bushing I 14.966 - 14.984 (0.5892 - 0.5899)

C2 aear bushino

I I

C1 0.016 - 0.052 (0.0001 - 0.0020) 0.10 (0.004)
c2 0.031 - 0.063 (0.0012 - 0.0025)

I

18.000 - 18.021 (0.7087 - 0.7095)

23.020

22.020 - 22.041 (0.8669 - 0.8678)

22.984 - 23.005 (0.9049 - 0.9057) 22.9 (0.90)

1

0.020 - 0.052 (0.0008 - 0.0020) 0.10 (0.004)

I

0.036 - 0.057 (0.0014 - 0.0022)

I

16.966 - 16.984 (0.6680 - 0.6687)

1

19.978 - 19.989 (0.7866 - 0.7870)

\

0.032 - 0.068 (0.0012 - 0.0027)

9.986 - 9.995 (0.3931 - 0.3935)

10.000

4.93 - 5.00 (0.194 - 0.197)

I

26.000 - 26.021 (1.0236 - 1.0244)

STANDARD

-

23.041 (0.9063 - 0.9071)

-

10.018 (0.3937 - 0.3944)

Unit:

I

SERVICE LIMIT

18.07 (0.71 1)

23.09 (0.909)

22.1 (0.87)

20.10 (0.791)

I

0.10

(0.004)

I

16.93 (0.667)

I

14.90 (0.587)

I

19.92 (0.784)

1

0.10 (0.004)

0.10 (0.004)

9.93 (0.391)

10.03 10.395)

1

4.90 (0.193)

I

25.08 (0.987)

rnrn

(in)

1

]

1

Connecting rod

Crankshaft runout

Big end side clearance
Big end radial clearance

STANDARD

-

-

-

SERVICE LIMIT

0.6 (0.02)

0.05 (0.002)

0.03 (0.001)

1-8

ITEM STANDARD

Minimum tire tread depth
Cold tire pressure Driver only 200 kPa

Driver and passenger
Axle runout
Wheel rim runout

Wheel balancer weight
Fork Spring free length

Radial 2.0 (0.08)

Axial

Spring direction

200

kPa (2.00 kgf/cm2, 29 psi)

412.4 (16.24) 404.1 (15.91)

With the tightly wound end facing

-

(2.00

kgf/cm2, 29 psi)

-

__
__

-

SERVICE LIMIT

To

the indicator

-

__

0.20

(a.aoa

2.0

(0.08)

60

g

(2.1

02)

-

max.

Pipe runout

I

Recommended fork fluid I Honda Ultra Cushion Oil No.10

Fluid level

Fluid capacity

tlEM

Minimum tire tread depth
Cold tire pressure

Axle runout
Wheel

rim

runout

Wheel balancer weiaht
Drive chain Size/link

Driver only 200 kPa (2.00 kgf/cm2, 29 psi)

Driver and passenger

Radial

Axial

Slack 25-35(1.0-1.4)

131 (5.2)
206 f 2.5 crn3 (7.0

0.09 Imp

225

1

oz)

STANDARD

kPa

(2.25

DID428V13-124LE

-

?

0.08

US oz,7.3

-

kgf/cm2, 33 psi)

__

-

-

-

I

0.20

(0.008)

I- I

-

f

-

SERVICE LIMIT

To

the indicator

-

-

0.20

(0.008)

2.0

(0.08)

2.0

(0.08)

60

II

(2.1

02)

-

-

max.

1-9

Specified brake fluid Front DOT 3 or DOT

4

-

Rear

Battery

Alternator

Brake disc thickness
Brake disc runout
Master cvlinder I.D.
Master piston O.D.
Caliper cylinder I.D.
CaliDer Diston
Specified brake fluid
Brake pad wear indicator
Brake disc thickness

I

Brake disc runout
Master cylinder I.D.

Master piston O.D.
Calioer cvlinder

1

Caliper piston

Capacity
Current leakane

Specific gravity

Charging current

Capacity
Charging coil resistance
Linhtina coil resistance

Fully

Needs charging Below
Normal
Quick

O.D.

I.D.

O.D.

charged

(2OoC/68"F)

(2OoC/68"F)

3.8- 4.2 (0.15-0.17) 3.0 (0.12)

-

12.700

-

12.743 (0.5000 - 0.5017)

12.657 - 12.684 (0.4983 - 0.4994)

-

25.405

(1.0000

-

25.400

25.318

-

25.368 (0.9968 - 0.9987)

DOT

3

or

DOT

4

1.0002)

-

3.8 - 4.2 (0.15 - 0.17) 3.0 (0.12)

I

12.700

-

12.657

-

32.030

-

I

31.948-31.998 (1.2578- 1.2598)

-

12.743 (0.5000 - 0.5017)

12.684 (0.4983 - 0.4994)

32.080 (1.2610 - 1.2630)

12

V

-

5

0.1

mA max

13.0 - 13.2

12.3

0.5

AX

5-

2.5

Ax

0.2

-

1.0

0.1 - 0.8

rnin-' (rpm)

155 WI5,OOO

Ah

1

10

h

n

C2

V

V

h

0.1 (0.004)

12.755 (0.5022)

12.640 (0.4976)

25.450 (1.0020)

25.300 10.9960)

To groove

I

0.1 10.004)

12.755 (0.5022)

12.645 (0.4978)

32.090 (1.2634)

1

31.94 (1.257)

-

1-10

Spark plug

Standard

ODtional
Spark plug gap
Ignition coil peak voltage
Ignition pulse generator peak voltage

I

Ignition timing

I

Starter motor brush lenath

NGK

CR8E
CR9E

0.7 - 0.8
100 V

0.7 V minimum

120 BTDC

I

10.00 - 10.05 (0.393 - 0.396)

at

mm

(0.028 -0.032

minimum

1,400 f 100

DENS0

U24ESR

U27ESR - N

min~’ (rpm)

I

3.5 (0.14)

-

in)

N

I

I

Bulbs

Fuse

Thermosensor
resistance

Headlight (Hi/low beam)

Bra ke/tai

I

light
License IiQht
Front turn signal light
Rear turn signal light
Instrument liaht

Turn signal indicator

High-beam indicator
Neutral indicator
Main

Sub

50°C (122°F)

1200c

(2480Fl

12 V- 18/18 W x 2

12

v-

10/5 wx2

12V-5W

12

v-

10 wx2

12

v-

10 wx2

12 V- 1.7

133.9 - 178.9

WX4

12V-1.7W

12v-1.7w
12V- 1.7W

20

A

10Ax2

14.9

-

17.3

Q

Q

1-1

1

GENERAL INFORMA

TlON

TORQUE VALUES

-

STANDARD

FASTENER TYPE

5

mm bolt and nut

6

mm bolt and nut (Include

flange bolt)

8

mm

bolt and nut

10

mm

bolt and

12

mrn

bolt and

-

ENGINE

MAINTENANCE:

Spark plug
Crankshaft hole cap
Timing hole cap
Oil drain bolt

LUBRICATION SYSTEM:

Oil pump bolt

COOLING SYSTEM:

Water pump impeller

CYLINDER HEADlV ALVE:

Cylinder head cover bolt
Cylinder head nut
Cylinder head bolt
Cam sprocket bolt
Cam chain tensioner plug
Camshaft holder bolt

CLUTCHlGEARSHlFT LINKAGE:

Clutch center lock nut
Primary drive
Gearshift cam plate bolt
Shift drum stopper arm bolt

ACTERNATORlSTARTER CLUTCH:

Flywheel nut
Stator bolt
Ignition pulse generator bolt
Starter clutch bolt

OTHER FASTENERS:

Reed valve cover bolt

nut

nut

gear

lock

SH

ITEM

nut

TORQUE

(kgfvn. Ibf.ft)

N.m

5 (0.5.3.6) 5

10

(1.0.7)

22 (2.2, 16)
34 (3.5.25)
54 (5.5.40)

FASTENER TYPE

mm

screw

6

mm

screw

6

mm flange bolt and
NSHF)
8

mm

flange bolt and

10

rnm

flange bolt and

QTY

-

THREAD

DIA.

1

1

1
1

3

1

2
4
2
2

1

8

1

1

1
1

1

3
3
3

2

-

(rnrnl

10

30

14
12

5

7

6
8

12

5
6
6

14
14

6

6

12

6

5

8

nut

(Include

nut

nut

TORQUE

U.m

(kgfm

Ibf.ftl

12 (1.2,9)

7.9 (0.8, 5.8)

5.9 (0.6, 4.3)
25 (2.5’18)

5.2

(0.53,3.8)

10

(1.0,7)

10

(1.0,7)

30 (3.1,22)
32 (3.3.24)

8.8 (0.9. 6.5)

4.2 (0.43,3.1)
12 (1.2.9)

74 (7.5,54)
64 (6.5,47)

12 (1.2.9)
12 (1.2.9)

64 (6.5,47)

10 (1.0,7)

5.2 (0.53, 3.8)
30 (3.1,22)

5.2 (0.53.3.8)

TORQUE

(kgfm Ibf.ft)

N.m

4 (0.4,2.9)

9 (0.9, 6.5)

12 (1.2,9)

26 (2.7.20)
39 (4.0,29)

REMARKS

NOTE
NOTE
NOTE
NOTE

NOTE
NOTE

NOTE
NOTE
NOTE
NOTE

1

3

1

1
1

3

1

3
3
3

1-12

.

FRAME

ITEM

FRAMEIBODY PANELSIEXHAUST SYSTEM:

Muffler mounting nut
Exhaust pipe cover volt

ENGINE REMOV ALIINSTALLATION:

Engine hanger nut
Drive sprocket fixing plate bolt

WHEELISUSPENSlONISTEERI":

FRONT

Steering stem nut

Top thread

Handlebar pinch bolt

Top bridge pinch bolt

Bottom bridge pinch bolt
Front axle nut
Fork bolt
Fork socket bolt
Front brake disk bolt
Grip end screw

REAR WHEELISUSPENSION:

Rear axle
Driven sprocket nut
Rear brake disc bolt
Shock absorber upper mounting bolt
Shock absorber lower mounting nut
Swingarm pivot nut

BRAKE

Brake hose bolt
Front master cylinder cover screw
Front brake light switch screw
Brake lever pivot nut
Front brake caliper mounting bolt
Brake caliper pad pin
Bleed valve
Rear brake reservoir cover screw
Rear master cylinder mounting bolts
Rear master cylinder push rod nut
Main step holder mounting bolt

OTHER FASTENERS:

Chain slider screw

nut

SYSTEM:

GENERAL

TORQUE

N.m

(kafm,

1
3

3
2

1
1
2
2
2
1
2
2
8
2

1
4
4
1
1
1

1
2
1
1
2
1
2
2
2
1
4

2

6
6

10

6

24
26

8
8

8
12
27

8

6

6

12

10

8
10
10
12

10

4

4

6

8

8

8

4

6

8

8

6

13 (1.3, 9)
13 (1.3,9)

(6.0,

59

10 (1.0,7)

88 (9.65)

See page

27 (2.8, 20)
23 (2.3, 17)
26 (2.7,20)
59 (6.0,43)
23 (2.3,17)
20 (2.0,14)
42 (4.3,31)

8.8 (0.9,6.5)
59 (6.0,

64 (6.5, 47)
42 (4.3,31)
39 (4.0.29)
44 (4.5,33)
88 (9.0.65)

34 (3.5,25)

1.5 (0.15, 1.1)

1.2 (0.12. 0.9)

5.9 (0.6, 4.3)
30 (3.1,22)

17 (1.7, 12)

5.4 (0.6, 4)

1.5 (0.15, 1.1)
12 (1.2,9)

17 (1.7, 12)
27 (2.8,20)

5.9 (0.6, 4.3)

IbfW

43)

14-22

43)

INFORMA

REMARKS

NOTE

3

NOTE

7

NOTE

3

NOTE

8

NOTE

7

NOTE

7

NOTE

8

NOTE

7

NOTE

7

NOTE

8

TlON

1-13

GENERAL INFORMA TlON

TOOLS

NOTES: 1. Eauivalent commerciallv available.

2. Alternative tool.

DESCRIPTION

Float level gauge
Universal bearing puller
Lock nut wrench,
Flywheel holder

Bearing remover weight

Attachment,
Attachment, 37
Attachment, 42
Attachment, 72

Pilot, 12 mm

15

mm

Pilot,
Pilot, 17

mm

Pilot, 20

mm

Pilot, 35

mm
Bearing remover shaft
Bearing remover head,
Fork seal driver
Fork seal driver attachment
Oil seal remover
Driver
Valve spring compressor
Valve seat cutter

Seat cutter,
Seat cutter, 24
Flat cutter,
Flat cutter, 27
Interior cutter,
Interior cutter, 26 mm
Cutter holder, 3.8 mm

Snap ring pliers
Steering stem socket
Bearing remover head,
Bearing remover shaft
Bearing remover shaft
Bearing remover head, 15
Attachment, 36
Steering stem driver
Assembly collar
Assembly shaft
Clutch center holder

Ball race remover

Valve guide driver

Peak voltage adaptor
Valve spring compressor attachment
Tapet hole protector
Valve guide reamer

Rotor puller

20 x 24

32 x 35

x

40

x

47

x

75

27.5

mm

mm

24

mm

mm

30 mm (60"

mm

mm

mm

rnm

mm

rnm

12

(45"

(45" EX)
(32" IN)
(32" EX)

(60"EX)

12

mm

IN)

IN)

mm

mm

TOOL NUMBER

07401 - 0010000

-

0010000

07631
07716 -0020100
07725-0040000

-

0010201

07741

-

0010100

07746

-

0010200

07746

-

0010300

07746
07746

-

0010600

-

0040200

07746

-

0040300

07746

-

0040400

07746
07746-0040500

-

0040800

07746
07746-0050100
07746

-

0050300

07747 -0010100

-

0010300

07747
07748-0010001
07749-0010000
07757-0010000

07780-0010200
07780-0010600
07780-0012500
07780-0013300
07780-0014000
07780-0014500

-

07JMH

07965 -VMOOlOO
07965

07GMB

07GMD

07GMD

07HGJ

07JME
07JMG
07JMH-KV20100
07KMC

KV20200

-

SA50001

07914
07916-3710101
07936- 1660110
07936-1660120

-

KClOlOO

07936

-

KC10200

07936
07945-4150400
07946-4300101

-

VM00200

-

KT70101

-

KS40100

-

KT70100

-

0020100

-

KV20100

-

KV20100

-

HEOOIOO

REMARKS

VOTE 1

NOTE

2:

lmrie diagnostic tester
[model

625)

REF. SEC.

5
13
8
9

12
12,13

12, 13, 14, 15

12,14
13
13, 14, 15
12
12
12
13
14,15
14,15
14
14
14
12, 13, 14, 15
10
10

16

14
12
12
12
12
6
14
13
13
8
14
10
18
10
10
10
9

1-14

GENERAL INFORMA TlON

LUBRICATION

&

SEAL

POINTS

ENGINE

LOCATION

lalve stem (valve guide sliding surface)
:lutch outer guide outer surfaces
'iston pin outer surface
:onnecting rod small end inner surface
jhift fork shaft
rransmission gear rotating surfaces
rransmission gear shift fork grooves
:1, C2 gear bushing
3alancer driven gear inner surface
Zlutch lifter arm spindle
;earshift spindle outer surface
jhift drum journal outer surface
:amshaft

:am chain
:amshaft holder bolt threads and seating surface
'iston outer surface
'iston rings
zylinder head nut threads and seating surface
Jalve lifter sliding surfaces
3lutch disc lining surface
3lutch center lock nut threads and seating surface
Zlutch lifter piece
:ran kshaft thrust surfaces
'rimary drive gear nut threads and seating surface
'lywheel
Shift drum grooves
Starter clutch rolling surface
Starter reduction gear
3il
Each bearing rotating area
Each O-ring whole surface
Each oil seal lip
Water pump shaft

Each oil seal lip

liming hole cap threads
Crankshaft hole cap threads

Gearshift cam plate bolt threads
Ignition pulse generator bolt threads
Mainshaft bearing setting plate bolt threads
Starter clutch bolt threads
Camsprocket bolt threads

Alternator/ignition pulse generator wire grommet
seating surface

R./L.

except the oil passage area.

nut

threads and seating surface

pump inner and outer rotor

(clutch lifter arm spindle, gearshift spindle)

Crankcase mating surface

MATERIAL

Molybdenum oil solution

a mixture of 1/2 engine oil

nnd

1/2 molybdenum

jisulfide grease)

oil

Engine

Multi-purpose grease

Locking agent

Liquid sealant

REMARKS

1-15

GENERAL INFORMA

-

FRAME

Steering head bearing sliding surface
Steering head bearing dust seal lips
Front fork oil seal lips

Front wheel dust seal lips
Rear wheel duat seal lips
Rear wheel hub O-ring
Clutch lever pivot bolt sliding surface
Speedometer gear and pinion gear teeth

Speedometer gear/pinion sliding surface

Side stand pivot surface
Throttle grip sliding surface
Speedometer outer cable inside

Seat lock sliding surface

Brake pad pin sliding surface

Brake caliper pin bolt

Brake lever pivot bolt sliding surface

Brake lever-to-master piston contacting area

Rear brake master piston-to-push rod contacting area
Throttle cable inside

Clutch inner cable surface

Choke inner cable surface

Fork socket bolt threads

Cooling fan motor shaft threads

Handle grip rubber inside

Brake master piston and cups

Brake caliper piston and piston seals

Brake caber dust seal

Fork inside

Air cleaner housing tube ioint

TION

LOCATION

~~

I

Silicone grease

---r

Molybdenum compound oil

Locking agent

or

Honda Bond A

DOT

3

or 4 brake fluid

Honda Ultra Cushion Oil
Sealant

eauivalent

No.10

I
I

I

1

1-16

GENERAL INFORMA TlON

CABLE & HARNESS

THROTTLE CAB

IGNITION SWITCH WIRE

MAIN WIRE HARNESS

ROUTING

FRONT BRAKE HOSE

RIGHT HANDLE6
SWITCH WIRE

CLUTCH CABLE

I

HORN WIRE

TACHOMETER

2P

CONNECTOR

1-17

GENERAL INFORMA TlON

CLUTCH

CABLE

1-18

IGNITION CONTROL MODULE IICM)

GENERAL INFORMA TlON

IGNITION COIL

\

FUEL TUBE

I

NEUTRAL SWITCH
CONNECTOR

FUEL UNIT

3P

CONNECTOR

RADIATOR OVERFLOW TUBE

”\

CARBURETOR DRAIN TUBE

\

1-19

GENERAL INFORMA TlON

LEFT HANDLEBAR

SWITCH 9P CONNECTOR

CHOKE CABLE

FUEL AUTO VALVE
VACUUMTUBE

-

LEFT HANDLEBAR SWITCH

2P

CONNECTOR

\

RIGHT HANDLEBAR SWITCH

3P

CONNECTOR

I

PAIR CONTROL VALVE

/

FUEL TUBE

CARBURETOR AIR

VENT TUBE

1

-

THROlTLE CABLE

\

THERMO SENSOR
WIRE

\

/

SUB-AIR CLEANER

b.

REAR BRAKELIGHT
SWITCH

2P

CONNECTOR

1-21

GENERAL

INFORMA

TlON

REGULATOR/RECTIFIER

I

DIODE

REAR BRAKELIGHT SWITCH

2P

CONNECTOR

I

1-22

GENERAL INFORMA TlON

SPARE FUSE 10A

RADIATOR RESERVE TANK CAP

/

SPARE FUSE

STARTER RELAY SWITCH/
MAIN FUSE 20A

20A

1-23

GENERAL INFORMA TlON

EMISSION CONTROL SYSTEMS

SOURCE

The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emission is very
important because, under certain conditions, they react to form photochemical smog when subjected to sunlight.
Carbon monoxide does not react

Honda Moter Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and
hydrocarbons.

CRANKCASE EMISSION CONTROL

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmospher.

Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.

OF

EMISSIONS

in

the same way, but

SYSTEM

it

is toxic.

a

1

1-24

:

FRESH

:

BLOW-BY

AIR

GAS

GENERAL INFORMA TlON

EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDAR Y AIR INJECTION SYSTEM)

The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the
exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse

in

the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a consid-

erable amount
This model has the pulse secondary air injection (PAIR) control valve and PAIR check valve. Pair check valve prevents

reverse air flow through the system. The PAIR control valve reacts to high intake manifold vacuum and will cut

supply of the fresh air during engine deceleration, thereby preventing afterburn

No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the com-

ponents is recommended.

of

hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.

in

the exhaust system.

PULSE SECONDARY

off

the

1-25

FRAMElBODY P ANELSlEXHAUST SYSTEM

BODY

PANEL LOCATIONS

2-0

2.

FRAME/BODY PANELS/EXHAUST SYSTEM

BODY PANEL LOCATIONS
SERVICE INFORMATION
TROUBLESHOOTING

PASSENGER SEAT
DRIVER SEAT
GRAB RAIL
REAR COWL

SERVICE

GENERAL

Serious burns may result

*

This section covers removal and installation of the body panels and exhaust system.

*

Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine.

Always inspect the exhaust system for leaks after installation.

TORQUE VALUES

Muffler mounting
Exhaust pipe cover bolt

INFORMATION

if

the exhaust system is not allowed

nut

2-0

REAR FENDER
2-1 UNDER COWL
2-1 MIDDLE COWL
2-2 FRONT FENDER

2-2

UPPER COWL

2-2

EXHAUST SYSTEM

2-2

13

Nm

(1.3 kgfm, 9 Lbf.ft)

13 Nm (1.3 kgfm,

9

to

cool before components are removed or serviced.

Ibf.ft)

2-3
2-3

2-4

2-4
2-5

2-5

I

lh

1

I

TROUBLESHOOTING

Excessive exhaust noise

*

Broken exhaust system

-

Exhaust gas leak

Poor

performance

-

Deformed exhaust system

-

Exhaust gas leak

*

Clogged muffler

2-

I