Complete repair service manual for Honda Motorbikes CBR125, CBR150, CBR250, CBR400, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Honda Motorcyles CBR125-150-250-400workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
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PRODUCT DETAILS:
Total Pages: 2,415 pages
File Format: PDF
Language: English
Honda CBR125RW Shop Manual….2
TYPE CODE….2
Service Information….3
For Your Customer’s Safety….3
For Your Safety….3
Important Safety Precautions….3
CONTENTS….4
1….4
2….4
3….4
4….4
5….4
6….4
7….4
8….4
9….4
10….4
11….4
12….4
13….4
14….4
15….4
16….4
17….4
18….4
19….4
20….4
21….4
22….4
SYMBOLS….5
1. GENERAL INFORMATION….6
SERVICE RULES….7
ABBREVIATION….7
MODEL IDENTIFICATION….7
EXCEPT CM AND U model shown:….7
SERIAL NUMBERS….8
LABELS….9
GENERAL SPECIFICATIONS….10
LUBRICATION SYSTEM SPECIFICATIONS….12
FUEL SYSTEM (PGM-FI) SPECIFICATIONS….12
COOLING SYSTEM SPECIFICATIONS….12
CYLINDER HEAD/VALVES SPECIFICATIONS….13
CYLINDER/PISTON SPECIFICATIONS….13
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS….13
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS….14
CRANKSHAFT/BALANCER/TRANSMISSION SPECIFICATIONS….14
FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS….15
REAR WHEEL/SUSPENSION SPECIFICATIONS….15
HYDRAULIC BRAKE SPECIFICATIONS….15
BATTERY/CHARGING SYSTEM SPECIFICATIONS….16
IGNITION SYSTEM SPECIFICATIONS….16
ELECTRIC STARTER SPECIFICATION….16
LIGHTS/METERS/SWITCHES SPECIFICATIONS….16
STANDARD TORQUE VALUES….17
ENGINE & FRAME TORQUE VALUES….17
LUBRICATION & SEAL POINTS….21
ENGINE….21
FRAME….22
CABLE & HARNESS ROUTING….23
EMISSION CONTROL SYSTEMS (Except CM type)….35
SOURCE OF EMISSIONS….35
CRANKCASE EMISSION CONTROL SYSTEM….35
EXHAUST EMISSION CONTROL SYSTEM….36
THREE-WAY CATALYTIC CONVERTER….36
NOISE EMISSION CONTROL SYSTEM (Except U type)….36
NOISE EMISSION CONTROL SYSTEM (U type only)….36
EMISSION CONTROL SYSTEMS (CM type only)….37
EXHAUST EMISSION REQUIREMENT….37
NOISE EMISSION REQUIREMENT….37
WARRANTY COMPLIANCE….37
SOURCE OF EMISSIONS….37
CRANKCASE EMISSION CONTROL SYSTEM….37
EXHAUST EMISSION CONTROL SYSTEM….38
THREE-WAY CATALYTIC CONVERTER….38
NOISE EMISSION CONTROL SYSTEM….38
2. BODY PANELS/EXHAUST SYSTEM….40
BODY PANEL LOCATIONS….41
EXCEPT CM AND U TYPE shown:….41
SERVICE INFORMATION….42
GENERAL….42
TORQUE VALUES….42
TROUBLESHOOTING….42
PILLION SEAT….43
REMOVAL/INSTALLATION….43
SINGLE SEAT….43
REMOVAL/INSTALLATION….43
GRAB RAIL….44
REMOVAL/INSTALLATION….44
REAR COWL….44
REMOVAL/INSTALLATION….44
DISASSEMBLY/ASSEMBLY….45
FUEL TANK COVER….45
REMOVAL/INSTALLATION….45
INNER COWL….46
REMOVAL/INSTALLATION….46
LOWER COWL….47
REMOVAL/INSTALLATION….47
DISASSEMBLY/ASSEMBLY….47
MIDDLE COWL….48
REMOVAL/INSTALLATION….48
UPPER COWL….49
REMOVAL/INSTALLATION….49
FRONT FENDER….50
REMOVAL/INSTALLATION….50
REAR FENDER….51
REMOVAL/INSTALLATION….51
DISASSEMBLY/ASSEMBLY….52
EXHAUST PIPE/MUFFLER….52
REMOVAL….52
DISASSEMBLY/ASSEMBLY….54
INSTALLATION….55
STUD BOLT REPLACEMENT….56
3. MAINTENANCE….58
SERVICE INFORMATION….59
GENERAL….59
SPECIFICATIONS….59
TORQUE VALUES….60
TOOLS….60
MAINTENANCE SCHEDULES….61
Except CM type….61
CM type only….62
FUEL LINE….63
FUEL TANK LIFTING….63
INSPECTION….63
FUEL TANK LOWERING….63
THROTTLE OPERATION….64
AIR CLEANER….65
REMOVAL/INSTALLATION….65
CLEANING….65
CRANKCASE BREATHER….66
SPARK PLUG….66
REMOVAL….66
INSPECTION….67
INSTALLATION….67
VALVE CLEARANCE….68
INSPECTION….68
ADJUSTMENT….69
ENGINE OIL….70
OIL LEVEL INSPECTION….70
ENGINE OIL CHANGE….71
ENGINE OIL STRAINER SCREEN….71
REMOVAL/INSTALLATION….71
RADIATOR COOLANT….72
COOLING SYSTEM….72
DRIVE CHAIN….73
DRIVE CHAIN SLACK INSPECTION….73
ADJUSTMENT….73
CLEANING AND LUBRICATION….74
SPROCKET INSPECTION….74
REPLACEMENT….75
BRAKE FLUID….78
FRONT BRAKE….78
REAR BRAKE….79
BRAKE PADS WEAR….79
FRONT BRAKE PADS….79
REAR BRAKE PADS….79
BRAKE SYSTEM….80
INSPECTION….80
BRAKE PEDAL HEIGHT ADJUSTMENT….80
BRAKE LIGHT SWITCH….80
CLUTCH SYSTEM….81
HEADLIGHT AIM….81
SIDESTAND….82
SUSPENSION….82
FRONT SUSPENSION INSPECTION….82
REAR SUSPENSION INSPECTION….82
NUTS, BOLTS, FASTENERS….83
WHEELS/TIRES….83
STEERING HEAD BEARINGS….84
4. LUBRICATION SYSTEM….86
LUBRICATION SYSTEM DIAGRAM….87
SERVICE INFORMATION….88
GENERAL….88
SPECIFICATIONS….88
TORQUE VALUE….88
TROUBLESHOOTING….88
OIL PUMP….89
REMOVAL….89
DISASSEMBLY….89
INSPECTION….90
OIL PUMP DRIVEN GEAR/OIL PUMP SHAFT/LOCK PIN….90
OIL SEAL….90
OIL PUMP….90
ASSEMBLY….91
INSTALLATION….93
5. FUEL SYSTEM (PGM-FI)….94
COMPONENT LOCATION….95
SERVICE INFORMATION….96
GENERAL….96
SPECIFICATIONS….96
TORQUE VALUES….96
TOOLS….97
PGM-FI SYMPTOM TROUBLESHOOTING….98
PGM-FI SYSTEM LOCATION….99
PGM-FI SYSTEM DIAGRAM….100
PGM-FI CONNECTOR LOCATIONS….101
PGM-FI TROUBLESHOOTING INFORMATION….103
GENERAL TROUBLESHOOTING….103
Intermittent Failure….103
Opens and Shorts….103
If the MIL has come on….103
If the MIL did not stay on….103
SYSTEM DESCRIPTION….103
SELF-DIAGNOSIS SYSTEM….103
FAIL-SAFE FUNCTION….103
DTC….103
MIL Blink Pattern….104
MIL Check….104
CURRENT DTC/FREEZE DTC….104
HDS POCKET TESTER INFORMATION….104
How to connect the HDS pocket tester….104
ECM reset….104
DTC READOUT….105
Reading DTC with the MIL….105
CLEARING DTC….105
How to clear the DTC with SCS connector….105
CIRCUIT INSPECTION….106
INSPECTION AT ECM CONNECTOR….106
TEST HARNESS CONNECTION….106
TEST HARNESS TERMINAL LAYOUT….106
DTC INDEX….107
SENSOR UNIT POWER LINE INSPECTION….108
BEFORE DTC TROUBLRESHOOTING….108
1. Sensor Unit Power Input Voltage Inspection….108
2. Sensor Unit Input Voltage Line Short Circuit Inspection….108
3. Sensor Unit Power Line Open Circuit Inspection….108
BEFORE MIL TROUBLESHOOTING….109
1. Sensor Unit Power Input Voltage Inspection 1….109
2. Sensor Unit Power Input Voltage Inspection 2….109
3. Sensor Unit Input Voltage Line Short Circuit Inspection….109
4. Sensor Unit Input Voltage Line Open Circuit Inspection….110
DTC TROUBLESHOOTING….110
DTC 1-1 (MAP SENSOR LOW VOLTAGE)….110
1. MAP Sensor System Inspection….110
2. Sensor Unit Power Line Inspection….110
3. MAP Sensor Output Voltage Inspection….110
4. MAP Sensor Output Line Short Circuit Inspection….111
5. MAP Sensor Inspection….111
DTC 1-2 (MAP SENSOR HIGH VOLTAGE)….111
1. MAP Sensor System Inspection 1….111
2. Sensor Unit Power Line Inspection….111
3. MAP Sensor System Inspection 2….112
4. MAP Sensor Output Line Open Circuit Inspection….112
DTC 7-1 (ECT SENSOR LOW VOLTAGE)….112
1. ECT Sensor System Inspection….112
2. ECT Sensor Inspection….112
3. ECT Sensor Resistance Inspection….113
4. ECT Sensor Short Circuit Inspection….113
DTC 7-2 (ECT SENSOR HIGH VOLTAGE)….113
1. ECT Sensor System Inspection….113
2. ECT Sensor Inspection….114
3. ECT Sensor Open Circuit Inspection….114
DTC 8-1 (TP SENSOR LOW VOLTAGE)….114
1. TP Sensor System Inspection….114
2. Sensor Unit Power Line Inspection….114
3. TP Sensor Output Line Short Circuit Inspection….115
4. TP Sensor Output Line Open Circuit Inspection….115
5. TP Sensor Inspection….115
DTC 8-2 (TP SENSOR HIGH VOLTAGE)….115
1. TP Sensor System Inspection….115
2. Sensor Unit Power Line Inspection….116
3. TP Sensor Resistance Inspection….116
DTC 9-1 (IAT SENSOR LOW VOLTAGE)….116
1. IAT Sensor System Inspection….116
2. Sensor Unit Power Line Inspection….116
3. IAT Sensor Inspection….116
4. IAT Sensor Voltage Input Line Short Circuit Inspection….117
DTC 9-2 (IAT SENSOR HIGH VOLTAGE)….117
1. IAT Sensor System Inspection….117
2. Sensor Unit Power Line Inspection….117
3. IAT Sensor Inspection….117
4. IAT Sensor Voltage Input Line Open Circuit Inspection….118
DTC 12-1 (INJECTOR)….118
1. Injector System Inspection….118
2. Injector Input Voltage Inspection….118
3. Injector Signal Line Short Circuit Inspection….119
4. Injector Resistance Inspection….119
5. Injector Signal Line Open Circuit Inspection….119
DTC 21-1 (O….120
1. O….120
2. O….120
3. O….120
4. O….121
DTC 29-1 (IACV)….121
1. Recheck DTC….121
2. IACV Short Circuit Inspection….121
3. IACV Open Circuit Inspection….122
4. IACV Resistance Inspection….122
DTC 33-2 (EEPROM)….122
1. Recheck DTC….122
DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE)….123
1. Recheck DTC….123
2. Bank Angle Sensor Power Input Voltage Inspection….123
3. Bank Angle Sensor Input Voltage Line Short Circuit Inspection….123
4. Bank Angle Sensor Output Line Short Circuit Inspection….124
5. Bank Angle Sensor Inspection….124
DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE)….124
1. Recheck DTC….124
2. Bank Angle Sensor Power Input Voltage Inspection….125
3. Bank Angle Sensor Input Voltage Line Open Circuit Inspection….125
4. Bank Angle Sensor Output Line Open Circuit Inspection….125
MIL TROUBLESHOOTING….126
MIL 1 BLINK (MAP SENSOR)….126
1. Sensor Unit Power Line Inspection….126
2. MAP Sensor Output Voltage Inspection….126
3. MAP Sensor Output Line Open Circuit Inspection 1….126
4. MAP Sensor Output Line Short Circuit Inspection….126
5. MAP Sensor Output Line Open Circuit Inspection 2….127
MIL 7 BLINKS (ECT SENSOR)….127
1. ECT Sensor Input Voltage Inspection….127
2. ECT Sensor Short Circuit Inspection….127
3. ECT Sensor Resistance Inspection….128
4. ECT Sensor Open Circuit Inspection….128
5. ECT Sensor Output Voltage Inspection….128
MIL 8 BLINKS (TP SENSOR)….129
1. Sensor Unit Power Line Inspection….129
2. TP Sensor Output Voltage….129
3. TP Sensor Output Line Short Circuit Inspection….129
4. TP Sensor Voltage Input Line Open Circuit Inspection….129
MIL 9 BLINKS (IAT SENSOR)….130
1. Sensor Unit Power Line Inspection….130
2. IAT Sensor Output Voltage Inspection 1….130
3. IAT Sensor Output Voltage Inspection 2….130
4. IAT Sensor Voltage Input Line Short Circuit Inspection….130
5. IAT Sensor Voltage Input Line Open Circuit Inspection….131
6. IAT Sensor Resistance Inspection….131
MIL 12 BLINKS (INJECTOR)….131
1. Injector Input Voltage Inspection….131
2. Injector Signal Line Short Circuit Inspection….132
3. Injector Resistance Inspection….132
4. Injector Signal Line Open Circuit Inspection….132
MIL 21 BLINKS (O….133
1. O….133
2. O….133
3. O….133
4. O….134
MIL 29 BLINKS (IACV)….134
1. IACV Resistance Inspection….134
2. IACV Short Circuit Inspection….134
3. IACV Open Circuit Inspection….135
MIL 54 BLINKS (BANK ANGLE SENSOR)….135
1. Bank Angle Sensor Power Input Voltage Inspection….135
2. Bank Angle Sensor Input Voltage Line Short Circuit Inspection….135
3. Bank Angle Sensor Input Voltage Line Open Circuit Inspection….136
4. Bank Angle Sensor Output Line Short Circuit Inspection….136
5. Bank Angle Sensor Output Line Open Circuit Inspection….136
MIL CIRCUIT TROUBLESHOOTING….137
FUEL LINE INSPECTION….137
FUEL PRESSURE RELIEVING/QUICK CONNECT FITTING REMOVAL….137
QUICK CONNECT FITTING INSTALLATION….139
FUEL PRESSURE TEST….140
FUEL FLOW INSPECTION….141
FUEL PUMP UNIT….141
INSPECTION….141
REMOVAL….142
INSPECTION….143
INSTALLATION….143
FUEL TANK….144
REMOVAL/INSTALLATION….144
AIR CLEANER HOUSING….145
REMOVAL/INSTALLATION….145
THROTTLE BODY….145
REMOVAL….145
DISASSEMBLY….146
IACV REMOVAL/INSPECTION….147
SENSOR UNIT REMOVAL….147
ASSEMBLY….148
SENSOR UNIT INSTALLATION….148
IACV INSTALLATION….149
INSTALLATION….149
THROTTLE VALVE FULLY CLOSED POSITION RESET PROCEDURE….151
INJECTOR….152
QUICK CONNECT FITTING REMOVAL….152
REMOVAL….153
INSTALLATION….154
QUICK CONNECT FITTING INSTALLATION….154
ENGINE IDLE SPEED….155
ECT SENSOR….156
REMOVAL/INSTALLATION….156
BANK ANGLE SENSOR….156
REMOVAL/INSTALLATION….156
INSPECTION WITH HDS POCKET TESTER….157
INSPECTION WITH ECM TEST HARNESS….158
ECM….158
REMOVAL/ INSTALLATION….158
ECM POWER/GROUND LINE INSPECTION….159
1. ECM Power Input Voltage Inspection….159
2. ECM Ground Line Inspection….159
O….160
REMOVAL….160
INSTALLATION….161
6. COOLING SYSTEM….162
SYSTEM FLOW PATTERN….163
SERVICE INFORMATION….164
GENERAL….164
SPECIFICATIONS….164
TORQUE VALUES….164
TOOLS….165
TROUBLESHOOTING….165
SYSTEM TESTING….166
COOLANT (HYDROMETER TEST)….166
RADIATOR CAP/SYSTEM PRESSURE INSPECTION….167
COOLANT REPLACEMENT….167
PREPARATION….167
REPLACEMENT/AIR BLEEDING….168
THERMOSTAT….169
REMOVAL….169
INSPECTION….169
INSTALLATION….170
THERMOSTAT HOUSING….170
REMOVAL/INSTALLATION….170
RADIATOR….171
REMOVAL….171
DISASSEMBLY….172
ASSEMBLY….173
INSTALLATION….174
WATER PUMP….176
SEALS INSPECTION….176
REMOVAL/DISASSEMBLY….176
ASSEMBLY/INSTALLATION….178
RADIATOR RESERVE TANK….180
REMOVAL/INSTALLATION….180
FAN CONTROL RELAY….181
INSPECTION….181
7. ENGINE REMOVAL/INSTALLATION….182
COMPONENT LOCATION….183
SERVICE INFORMATION….184
GENERAL….184
SPECIFICATIONS….184
TORQUE VALUES….184
ENGINE REMOVAL….185
ENGINE INSTALLATION….187
8. CYLINDER HEAD/VALVES….190
COMPONENT LOCATION….191
SERVICE INFORMATION….192
GENERAL….192
SPECIFICATIONS….192
TORQUE VALUES….192
TOOLS….193
TROUBLESHOOTING….194
CYLINDER COMPRESSION….195
CYLINDER HEAD COVER….195
REMOVAL….195
INSTALLATION….196
CAMSHAFT….197
REMOVAL….197
INSPECTION….198
CAMSHAFT BEARING….198
CAM LOBE….198
INSTALLATION….199
CAMSHAFT HOLDER….201
REMOVAL….201
DISASSEMBLY….201
INSPECTION….202
ROCKER ARM/ROCKER ARM SHAFT….202
ASSEMBLY….202
INSTALLATION….203
CYLINDER HEAD….204
REMOVAL….204
DISASSEMBLY….204
INSPECTION….205
CYLINDER HEAD….205
VALVE SPRING….206
VALVE….206
VALVE GUIDE….206
VALVE GUIDE REPLACEMENT….207
VALVE SEAT INSPECTION….208
VALVE SEAT REFACING….209
ASSEMBLY….211
INSTALLATION….213
9. CYLINDER/PISTON….214
COMPONENT LOCATION….215
SERVICE INFORMATION….216
GENERAL….216
SPECIFICATIONS….216
TORQUE VALUE….216
TROUBLESHOOTING….216
CYLINDER/PISTON….217
CYLINDER REMOVAL….217
PISTON REMOVAL….218
INSPECTION….219
CAM CHAIN GUIDE….219
CYLINDER….219
PISTON/PISTON RING….220
CONNECTING ROD….221
CAM CHAIN TENSIONER LIDFTER….221
STUD BOLT REPLACEMENT….221
PISTON INSTALLATION….222
CYLINDER INSTALLATION….223
10. CLUTCH/GEARSHIFT LINKAGE….226
COMPONENT LOCATION….227
SERVICE INFORMATION….228
GENERAL….228
SPECIFICATIONS….228
TORQUE VALUES….228
TOOLS….228
TROUBLESHOOTING….229
RIGHT CRANKCASE COVER….230
REMOVAL….230
DISASSEMBLY….231
INSPECTION….231
ASSEMBLY….232
INSTALLATION….233
CLUTCH….234
REMOVAL….234
INSPECTION….236
CLUTCH LIFTER BEARING….236
CLUTCH SPRING….236
CLUTCH CENTER….236
CLUTCH DISC….237
CLUTCH PLATE….237
CLUTCH OUTER/OUTER GUIDE….237
MAINSHAFT….237
INSTALLATION….238
GEARSHIFT LINKAGE….240
REMOVAL….240
INSPECTION….241
INSTALLATION….241
GEARSHIFT PEDAL….243
REMOVAL….243
DISASSEMBLY/ASSEMBLY….243
INSTALLATION….244
PRIMARY DRIVE GEAR….245
REMOVAL….245
INSTALLATION….246
PRIMARY DRIVE GEAR SELECTION….247
11. ALTERNATOR/STARTER CLUTCH….248
COMPONENT LOCATION….249
SERVICE INFORMATION….250
GENERAL….250
SPECIFICATIONS….250
TORQUE VALUES….250
TOOLS….250
TROUBLESHOOTING….250
LEFT CRANKCASE COVER….251
REMOVAL….251
INSTALLATION….252
STATOR/CKP SENSOR….253
REMOVAL….253
INSTALLATION….253
FLYWHEEL REMOVAL….254
STARTER CLUTCH….255
REMOVAL….255
DISASSEMBLY….256
INSPECTION….256
ASSEMBLY….257
INSTALLATION….258
FLYWHEEL INSTALLATION….258
12. CRANKSHAFT/BALANCER/TRANSMISSION….260
COMPONENT LOCATION….261
SERVICE INFORMATION….262
GENERAL….262
SPECIFICATIONS….262
TOOLS….263
TROUBLESHOOTING….264
CRANKCASE SEPARATION….265
CRANKSHAFT/BALANCER….267
REMOVAL….267
CRANKSHAFT INSPECTION….267
CRANKSHAFT RUNOUT….267
BIG END SIDE CLEARANCE….267
BIG END RADIAL CLEARANCE….268
TIMING SPROCKET….268
CRANKSHAFT BEARING….268
BALANCER BEARING….268
BALANCER DISASSEMBLY….269
BALANCER ASSEMBLY….269
BALANCER DRIVEN GEAR SELECTION….270
INSTALLATION….270
TRANSMISSION….271
REMOVAL/DISASSEMBLY….271
INSPECTION….272
GEARS/BUSHINGS….272
MAINSHAFT/COUNTERSHAFT….273
SHIFT DRUM/DRUM JOURNAL….273
SHIFT FORK….273
SHIFT FORK SHAFT….274
TRANSMISSION BEARING….274
ASSEMBLY/INSTALLATION….274
MAINSHAFT….275
COUNTERSHAFT….275
BEARING REPLACEMENT….277
CRANKSHAFT BEARING….277
BALANCER/TRANSMISSION BEARING….278
RIGHT CRANKCASE SIDE….278
LEFT CRANKCASE SIDE….279
CRANKCASE ASSEMBLY….280
13. FRONT WHEEL/SUSPENSION/STEERING….284
COMPONENT LOCATION….285
SERVICE INFORMATION….286
GENERAL….286
SPECIFICATIONS….286
TORQUE VALUES….286
TOOLS….287
TROUBLESHOOTING….288
HANDLEBARS….289
REMOVAL….289
INSTALLATION….291
INNER WEIGHT REPLACEMENT….295
FRONT WHEEL….296
REMOVAL….296
INSPECTION….297
AXLE….297
WHEEL RIM….297
WHEEL BEARING….297
WHEEL BALANCE….298
DISASSEMBLY….298
ASSEMBLY….299
INSTALLATION….300
FORK….301
REMOVAL….301
DISASSEMBLY….302
INSPECTION….304
FORK SPRING….304
FORK PIPE/SLIDER/PISTON….304
ASSEMBLY….305
INSTALLATION….308
STEERING STEM….310
REMOVAL….310
BEARING REPLACEMENT….311
INSTALLATION….312
CLUTCH LEVER….314
REMOVAL/INSTALLATION….314
14. REAR WHEEL/SUSPENSION….316
COMPONENT LOCATION….317
SERVICE INFORMATION….318
GENERAL….318
SPECIFICATIONS….318
TORQUE VALUES….318
TOOLS….319
TROUBLESHOOTING….319
REAR WHEEL….320
REMOVAL….320
INSPECTION….320
AXLE….320
WHEEL RIM….321
WHEEL AND DRIVEN FLANGE BEARINGS….321
WHEEL BALANCE….321
DRIVEN SPROCKET….321
DISASSEMBLY….321
ASSEMBLY….323
INSTALLATION….325
SHOCK ABSORBER….326
REMOVAL….326
INSPECTION….327
INSTALLATION….327
SWINGARM….327
REMOVAL….327
DISASSEMBLY….329
ASSEMBLY….330
INSTALLATION….331
15. HYDRAULIC BRAKE….334
COMPONENT LOCATION….335
SERVICE INFORMATION….336
GENERAL….336
SPECIFICATIONS….336
TORQUE VALUES….336
TOOL….337
TROUBLESHOOTING….337
BRAKE FLUID REPLACEMENT/AIR BLEEDING….338
BRAKE FLUID DRAINING….338
BRAKE FLUID FILLING/AIR BLEEDING….339
BRAKE PAD/DISC….341
FRONT BRAKE PAD REPLACEMENT….341
REAR BRAKE PAD REPLACEMENT….342
BRAKE DISC INSPECTION….343
FRONT MASTER CYLINDER….344
REMOVAL….344
DISASSEMBLY….344
INSPECTION….345
ASSEMBLY….346
INSTALLATION….348
REAR MASTER CYLINDER….348
REMOVAL….348
DISASSEMBLY….349
INSPECTION….350
ASSEMBLY….351
INSTALLATION….352
FRONT BRAKE CALIPER….353
REMOVAL….353
DISASSEMBLY….354
INSPECTION….354
ASSEMBLY….355
INSTALLATION….356
REAR BRAKE CALIPER….356
REMOVAL….356
DISASSEMBLY….356
INSPECTION….357
ASSEMBLY….358
INSTALLATION….359
BRAKE PEDAL….359
REMOVAL….359
INSTALLATION….360
16. BATTERY/CHARGING SYSTEM….362
SYSTEM LOCATION….363
SYSTEM DIAGRAM….363
SERVICE INFORMATION….364
GENERAL….364
BATTERY CHARGING….364
BATTERY TESTING….364
SPECIFICATIONS….364
TROUBLESHOOTING….365
1. BATTERY TEST….365
2. CURRENT LEAKAGE TEST….365
3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTOR….365
4. CHARGING VOLTAGE INSPECTION….365
5. ALTERNATOR CHARGING COIL INSPECTION….365
6. REGULATOR/RECTIFIER SYSTEM INSPECTION….365
BATTERY….366
REMOVAL/INSTALLATION….366
VOLTAGE INSPECTION….366
BATTERY TESTING….366
CHARGING SYSTEM INSPECTION….367
CURRENT LEAKAGE INSPECTION….367
CHARGING VOLTAGE INSPECTION….367
ALTERNATOR CHARGING COIL….368
INSPECTION….368
REGULATOR/RECTIFIER….368
SYSTEM INSPECTION….368
REMOVAL/INSTALLATION….369
17. IGNITION SYSTEM….370
SYSTEM LOCATION….371
SYSTEM DIAGRAM….371
SERVICE INFORMATION….372
GENERAL….372
SPECIFICATIONS….372
TORQUE VALUE….372
TOOLS….372
TROUBLESHOOTING….373
IGNITION SYSTEM INSPECTION….374
IGNITION COIL PRIMARY PEAK VOLTAGE….374
CKP SENSOR PEAK VOLTAGE….375
IGNITION TIMING….376
IGNITION COIL….377
REMOVAL/INSTALLATION….377
18. ELECTRIC STARTER….378
SYSTEM LOCATION….379
SYSTEM DIAGRAM….379
SERVICE INFORMATION….380
GENERAL….380
SPECIFICATION….380
TROUBLESHOOTING….381
1. Fuse Inspection….381
2. Battery Inspection….381
3. Starter Relay Switch Operation….381
4. Starter Motor Inspection….381
5. Relay Coil Ground Lines Inspection….381
6. Starter Relay Input Voltage Inspection….381
7. Starter Relay Switch Continuity Inspection….382
1. Clutch Switch Inspection….382
2. Sidestand Switch Inspection….382
STARTER MOTOR….383
REMOVAL….383
DISASSEMBLY/INSPECTION….383
ASSEMBLY….387
INSTALLATION….390
STARTER RELAY SWITCH….391
INSPECTION….391
GROUND LINE….391
STARTER RELAY INPUT VOLTAGE….391
OPERATION CHECK….391
REMOVAL/INSTALLATION….392
DIODE….392
INSPECTION….392
19. LIGHTS/METERS/SWITCHES….394
SYSTEM LOCATION….395
SERVICE INFORMATION….396
GENERAL….396
SPECIFICATIONS….396
TORQUE VALUES….396
HEADLIGHT….397
BULB REPLACEMENT….397
REMOVAL/INSTLATION….397
POSITION LIGHT….397
BULB REPLACEMENT….397
TURN SIGNAL LIGHTS….398
BULB REPLACEMENT….398
REMOVAL/INSTALLATION….398
FRONT….398
REAR….399
BRAKE/TAIL LIGHT….399
BULB REPLACEMENT….399
LICENSE LIGHT….400
BULB REPLACEMENT….400
REMOVAL/INSTALLATION….400
COMBINATION METER….401
BULB REPLACEMENT….401
REMOVAL/INSTALLATION….402
DISASSEMBLY/ASSEMBLY….403
TACHOMETER….404
INSPECTION….404
COOLANT TEMPERATURE GAUGE/ ECT SENSOR….405
GAUGE INSPECTION….405
The coolant temperature is too high, but the gauge needle does not moves….405
The coolant temperature is low, but the gauge needle moves….405
ECT SENSOR INSPECTION….406
IGNITION SWITCH….406
INSPECTION….406
REMOVAL/INSTALLATION….407
HANDLEBAR SWITCHES….407
RIGHT HANDLEBAR SWITCH….407
STARTER SWITCH:….407
ENGINE STOP SWITCH: (CM and U type)….407
LEFT HANDLEBAR SWITCHS….408
DIMMER SWITCH:….408
TURN SIGNAL SWITCH:….408
HORN SWITCH:….408
BRAKE LIGHT SWITCHES….409
FRONT….409
REAR….409
NEUTRAL SWITCH….410
INSPECTION….410
REMOVAL….410
INSTALLATION….411
SIDESTAND SWITCH….412
INSPECTION….412
REMOVAL/INSTALLATION….412
CLUTCH SWITCH….413
FUEL GAUGE/FUEL LEVEL SENSOR….413
INSPECTION….413
FUEL GAUGE….413
FUEL LEVEL SENSOR….414
HORN….414
INSPECTION….414
REMOVAL/INSTALLATION….414
TURN SIGNAL RELAY….415
INSPECTION….415
1. Recommended Inspection….415
2. Turn Signal Circuit Inspection….415
REMOVAL/INSTALLATION….415
MAIN RELAY….415
20. WIRING DIAGRAMS….418
E, F, II G type….419
CM type….420
U type….421
21. TROUBLESHOOTING….422
ENGINE DOES NOT START OR IS HARD TO START….423
1. Spark Plug Inspection….423
2. Spark Test….423
3. Fuel Pump Inspection….423
4. PGM-FI System Inspection….423
5. Cylinder Compression….423
6. Engine Starting Condition….423
ENGINE LACKS POWER….424
1. Drive Train Inspection….424
2. Tire Pressure Inspection….424
3. Clutch Inspection….424
4. Engine Performance Inspection….424
5. Spark Plug Inspection….424
6. Engine Oil Inspection….424
7. Ignition Timing Inspection….425
8. Cylinder compression Inspection….425
9. Fuel Pump Inspection….425
10. PGM-FI system Inspection….425
11. Lubrication Inspection….425
12. Over Heating Inspection….425
13. Engine Knocking Inspection….425
POOR PERFORMANCE AT LOW AND IDLE SPEED….426
1. Spark Plug Inspection….426
2. Ignition Timing Inspection….426
3. Fuel Pump Inspection….426
4. PGM-FI System Inspection….426
5. IACV Inspection….426
6. Intake Pipes Leaking Inspection….426
POOR PERFORMANCE AT HIGH SPEED….427
1. Ignition Timing Inspection….427
2. Fuel Pump Inspection….427
3. PGM-FI System Inspection….427
4. Valve Timing Inspection….427
5. Valve Spring Inspection….427
6. Camshaft Inspection….427
POOR HANDLING….428
22. INDEX….430
A….430
B….430
C….430
D….430
E….430
F….430
G….430
H….430
I….430
L….430
M….430
N….430
O….430
P….430
R….430
S….431
T….431
U….431
V….431
W….431
Honda CBR150R Shop Manual 2002-2009….432
CONTENTS….432
General Information….435
Frame/Body Panels/Exhaust System….461
Maintenance….468
Engine….432
Lubrication System….491
Diagram….490
Fuel System….498
Diagram….497
Cooling System….515
Diagram….514
Engine Removal/Installation….530
Clutch/Gearshift Linkage….539
Diagram….538
Alternator/Starter Clutch….554
Diagram….553
Cylinder Head/Valves….563
Diagram….562
Cylinder/Piston….587
Diagram….586
Transmission….597
Diagram….596
Crankshaft/Balancer….612
Diagram….611
Chassis….432
Front Wheel/Suspension/Steering….618
Diagram….617
Rear Wheel/Suspension….642
Diagram….641
Brake System….657
Diagram….656
Electrical….432
Charging System….681
Diagram….680
Ignition System….690
Diagram….689
Electric Starter….698
Diagram….697
Lights/Meters/Switches….710
Diagram….709
Wiring Diagram….727
Troubleshooting….728
Index A-S….732
Index S-W….733
Print Chapter….734
Honda CBR250FOUR_R_RR (G~R) Service Manual (EN)….735
Honda CBR250R, CBR250RA (MC41) Shop Manual 2010-2014….1209
General Information….1210
Frame/Body Panels/Exhaust System….1259
Maintenance….1281
Lubrication System….1311
Fuel System….1320
Cooling System….1381
Engine Removal/Installation….1399
Cylinder Head/Valves….1408
Cylinder/Piston….1432
Clutch/Gearshift Linkage….1443
Alternator/Starter Clutch….1467
Crankcase/Crankshaft/Transmission/Balancer….1478
Front Wheel/Suspension/Steering….1506
Rear Wheel/Suspension….1543
Hydraulic Brake….1567
Anti-Lock Brake System (ABS)….1609
Battery/Charging System….1639
Ignition System….1649
Electric Starter….1659
Lights/Meters/Switches….1675
Wiring Diagrams….1697
Troubleshooting….1700
Honda CBR250R, CBR250RR Service Manual….1708
Honda CBR400RR (NC23 Tri-Arm), CBR400RR (NC29 Gull-Arm, FireBlade) 1990-1999 Service Repair Manual….2179
Front Cover….2179
Preface….2181
Contents….2182
Introduction….2184
Chapter 01….2195
Chapter 02….2220
Chapter 03….2277
Chapter 04….2285
Chapter 05….2301
Chapter 06….2307
Chapter 07….2332
Chapter 08….2352
Chapter 09….2358
Reference….2386
Back Cover….2434
Honda CBR400RR NC29 1991-1995 Repair Manual….2435
Honda Motorcyles CBR125-150-250-400 Service Repair Manuals
