Honda-CBR150R-Service-Manual-English

TTRROOUUBBLLEESSHHOOOOTTIINNG

PPOOOORR PPEERRFORMANCEAATTHHIIGH SSPPEEED

-1. DDiissccoonnnneeccttffuueell ttuubbee aattccaarrbbuurreettoorraanndd -- FFuueel fflloowwrreessttrriicctted - PPoossssiibbleleccaauussee
• CClologgggeeddffuueell lilnineeaannddffuueell aauuttoovvaalvlvee

cchheecckkffuueell ffllooww • CClologgggeeddffuueellttaannkkbbrreeaatthheerr

+tII ------I.-... CCaarrbbuurreettoorr nnoottsseerrvviicceed ffrreeqquueennttllyy

FFuueell fflloowwss ffrreeeellyy
2. RReemmoovvee tthhee ccaarrbbuurreettoorr aanndd cchheecckkffoorr ~- - CCllooggggeedd

ccllooggggiinngg eennoouugghh

+•II -------I. ...IInnccorrect CCam sspprroocckkeettss nnot iinnstalled pprop-

NNoott ccllooggggeedd eerrllyy..

3. CChheeck vvaallvvee ttiimmiinng

II

CCoorrrreecctt ------I..-...Incorrect FFaauullttyy iiggnnittiioonn ccoontrol mmodule ((IlCM)

4 • FFaauullttyy iiggnniittiioonn ppuullssee ggeenneerraattoorr

44. CCheck ignition ttiiming
II

CCoorrrreecctt

1+ -------i.....Weak
* Faulty valve spring
5. CChheecckk vvaallvvee sspprriinngg

1i
NNoott wweeaakk

POOR HANDLINNGG

PPoossssiibblleecaussee

-11.. IIff sstteeeerriinngg iiss hheeaavvyy - - - - - - - - - - - - - - - - - - - . . • Stteeeerriinngg steemm aaddjjuussttiinngg nutt too tight
• DDaammaaggeeddsteeeerriinngg hheeaadd bearings
EExxcceessssiivveewwhheeeell bbeeaarriinngg ppllaayy
-22.. IIff eeiitthher wwhheeeell iiss wwoobbbblliinngg - - - - - - - - - - - - - - - . - . . . . •
• BBeenntt rriimm

• IImmpprrooppeerr iinnssttaalllleedd wwhheeeell hhuubb

• SSwwiinnggaarrmm ppiivvoot bbuusshhiinngg eexxcceessssiivveellyy

wwoorrnn

• BBeennttffrraammee

33.. IIfftthhee mmoottoorrccyycclleeppuullleeddttoo oonneessiiddee - - - - - - - - - - - - - 1 . . .*. • FFaauullttyy sshhoocckkaabbssoorrbbeerr

• FFrroonnttaannddrreeaarr wwhheeeell nnoottaalliiggnneedd
• BBeennt tffoorrkk
• BBeennttsswwiinnggaarrmm
• BBeennttaaxxllee

2222--44 http://mototh.com

23.. INDEX

AIR CLEANER . HANDLEBAR . ........................................ 14-3
........... 20-8
3-5 HANDLEBAR ............................................................. 14-3 LIGHT AIM............

AIR CLEANER HOUSING . ..................... 3-19
.............. 20-13
5-4 HANDLEBAR SWITCHES ......................................... 20-8 ........... 18-5

ALTERNATOR/STATOR .............................................. 9-2 HEADLIGHT AIM . ............... 3-19

ALTERNATOR INSPECTION ..................................... 17-7 HORN ................:. ............. 20-13 ........... 18-5

BATTERY .

B1R7A-4KE FLUIDIGRNEITPILOANCCEOMIELN...T../.A..I.R...B..L..E...E..D...I.N..G...............1..6..-..3.............. 18-5
BBORADKYEPLAINGEHLTLSOWCIATTCIHON. .S... ..... 3-18
B2R-0AKE LIGHIGTNSIWTIIOTNCHCO(SNYTROL MODULE (lCNM))......2..0..-.8............. 18-5
BBRRAAKKEE FPLAUDiDW.EAR ................................. 3-18
B3R-1A7KE PEDAIGL.N.I.TION SWiTCH .................................................... 20-7

BRAKEE PFALUDI/DDIRSCEPLACEMENT/AIR BLEEDING ...... 16-3 IGNITION SYSTEM INSPECTION . ........................... 18-3

BRAKE LIGHT SWITCH ............................................ 3-18 IGNITION TIMING . ............. 18-6

BRAKE LIGHT SWITCH (SYSTEM INSPECTION) ... 20-8 LEFT CRANKCASE COVER INSTALLATION . ............ 9-8

BRAKE PAD WEAR .

3-18 LEFT CRANKCASE COVER REMOVAL ...................... 9-2

CCB1RAA6ARR-2KBB2EUURRPEEETTDOOARRLL.CUDHBISROAIKCSEASTE..IM.O.BN..L.&Y....S..E....A...L....P....O..I.NTS ............................... 1-15
BCRAARKBEURPEATDO/DRISINCS. TALLATION ..........
16-5 LUBRICATION SYSTEM DIAGRAM ........................... 4-0

CBRHAAKREGSINYGSTSEYMST.EM INSPECTION............. 17-5
C3L-1U8TCH.....M..A..I.N..TENANCE SCHEDULE ...................................... 3-3
MIDDLE COWL ...................... 2-4
CBULULBTCRHE/PNLEAUCTERMAELNT .............................................. 20-3

CABLE & HARNESS ROUTING ................................ 1-17 PMOOODRELPEIDREFNOTRIFMICAANTCIEOANT...L.O1W-3
CARBURETOR ASSEMBLy .
AND IDLEE SPEEEEDD ...................................................................... 22-3

C5O-9MBINATINOUNTMS,EBTOERLT.S...,..F..A..S...T..E•.N..E...R..S......................................2..0..-.5............. 3P-2R1IMARY DRIVE GEAR . ............................................ 8-12
COAROBLUARNETTROERPCLAHCCOEEKMEMEE..NN..T.T.................................................................. 63-54
ORAILDPIAUTMOPR.C...O...O...L..A..N...T..............4..-..2................................. 3-13

CAOROBLUARNETTTOERMDPEiSRRAAASTTSUUERRMEEBLy .................................. 5-6 RPASDSIAETNOGRE/CAOROSLEINAGT .F..A..N.......2..-..2................................... 6-8
PRIALDOITATSOCRERWESAEDRJVUESTTAMNEKN.T...................................... 6-12
CARBUGRAEUTOGRE/TINHHSEETRRAMMLOLOASSTEEINONSNSOO..R.R.................................205-135
C...O...O...L..I.N..G....F...A..N....M...O...T..O...R....S...W...i.T...C..H..........................................205-14
REAR BRAKE CALIPER . ......... 16-19

COAROBLUINRGETSOyRSTREEMM.O...V..A...L............................................3-51-4 RPEISATRONCOINWSLT.A..L...L..A..T..I.O...N...........1..1..-.7.. 2-2
RPEISATROFNERNEDMEROV. A...L..................1..1..-.4.. 2-3
..CRHAANRNKGKCCINAAGSSEESYASSTSEEMMBINLLSYyP.E...C..T..I.O...N............................121-71-35
R ............ 16-12
CRLRUAATNNCKKHCCA.ASSEEBRREEAATTHHEERR ....

38-64 RPOEAORR MHASNTDELRINCGy.L..I.N..D...E..R..........................................162R-21-24
CCRRLUAATNNCKKHSS/HHNAAEFFUTTTIRRNEASMLTDAOLIVOLADALET.I..O..N.................................... 13-5
RREAR WHEEL . ........................... 15-3
.CC1RY9LA-1INN1KDSEHRAIFNTSPTROAEOLMRLOAPVTEIAORLFN.O..R...M...A..N...C..E....A..T...H...I.G..H....S...P..E1E3D-2...............RR. E2G2-U4LATOR/RECTI FIRE . ........ 17-8
CYLULITNCDHERSWINiTSCTHAL. LATION . RIGHT CRANKCASECOVER REMOVAL . ............ 8-3

.1..1..-.8......... 20-R16IGHT CRAPNOKOCRAPSEERCFOVREMRANINCSETALTLLAOTWION ......... S8E-1C3ONDARYAIR SUPPLY SYSTEM
CCYYLULLIITNNCDDHEERRSYHRSEETMAEDOMVA.A.S..LS...E..M...B...L..Y...................................................... 130--1197 (MAINTENANCE) ............
11-3 RIGHT CRANKCASE COVER REMOVAL ..................S. E8C-3ONDARY AIR SUPPLY SYSTEM

CYLINDER COMPRESSION . (SYSTEM INSPECTION)............... 5-15

........... 10-3 D RSEEMCOOVNADLA.R..Y..AIR SUPPLY SYSTEM

CYLINDER HEAD ASSEMBLy . ............................... 10-17 (MAINTENANCE) .......... 3-14

CYLINDER HEAD DiSASSEMBLy .

........... 10-8 SECONDARY AIR SUPPLY SYSTEM

CYLINDER HEAD INSTALLATION . ........................ 10-19 (SYSTEM INSPECTION)................................. 5-15

CYLINDER HEAD REMOVAL .

.............................. 10-4 SERVICE INFORMATION

DRIVE CHAIN . (CYLINDER HEADNALVES)...

3-15 (ALTERNATOR/STARTER CLUTCH) ......................... 9-1

DRIVER SEAT .

2-2 (COOLING SYSTEM) ................................................ 6-1

ENGINE IDLE SPEED .

3-12 (CHARGING SYSTEM) ........................................... 17-'

ENGINE LACKS POWER .......................................... 22-2 (BRAKE SYSTEM) .

........................................................................................ 16-1 I:!:'I(IGNITION SYSTEM) . .............................................. 18-1
ENGINE OIL .
(LIGHTS/METERS/SWITCHES) . .............. 20-1 ~
3-10 (CLUTCH/GEARSHIFT LINKAGE) ............................ (8LU-'BRICAT!ON SySTEM) . ......................................... 4-1

EFUNEGLINLEINOEIL. .S...T..R...A..I.N...E..R....S...C..R...E..E..N...............................................................33-1-42 ((CMRAAINNTKESNHAANFCTE/B)A..L..A..N...C..E...R..).........................................................................133--1'
EFNUEGLINMEEITNESRT/AFLULEALTUIONNIT......................................... 20-11
(REAR WHEEL/SUSPENSION) ............................... 15-'
F7U-4EL TANK .(.C..Y...L..I.N..D...E..R.......H.....E...A.....D..../..V....A....L...V.....E....S...)....................................................5.5.-.-3.3............ 10(-T1RANSMiSSiON) ................................................... 12-'
EGNEGARINSEHIRFETMLOINVKAALG. E .............................................. 8-10 SERVICE RULES ........................................................................ 11--22
G7E-2NERAL SA(FCEYTLYIN.D.E...R../..P..I.S..T...O...N..)...............................................................1..-.1............. 1SS1HH-1OOCCKKAABBSSOORRBBEER .................................................. 15-9
EGXRHAABURSATILS.Y..S...T..E...M.......................................................... 2-2 SIDDEE STTAANNDD..................................................................... 3-20
2-5 (ENGINE REMOVAL/INSTALLATION) ...................... 7-1

FLYWHEEL INSTALLATION ........................................ 9-7 (ELECTRIC STARTER) .

....................................................................................... 19-1 233--11

FLYWHEEL REMOVAL . http://mototh.com

9-3 (FRAME/BODY PANELS/EXHAUST SySTEM) ........ 2-1

INDDEEXX

SSPPAARRKKPPLLUUGG..................3..-..6............................................... 3-6
SSPPEECCIIFFIICCAATTIIOONNSS........................................................... 1-4
SSSSSSS..TTTTTTT.AAAE.AAA.RRRERR.R.TTTRTTT..EEEEEIE.NRRR.RRR.G.CMRCMR..HLEEOL.O.UELUL.TTAT.AATO.OYCD.YCR.RHSHSBW..W..E......A.I..I..T..T..1R...C...C-...I.4..NH...H...G........S............................................................................................................................................................................11..91399-9--12--140420

STEERING STEM ...................................................... 14-19

SSUUBS-PAEIRNSCILOENAN. ..E..R................................................................................................................................................3. -552--044

SWINGARM . ............................................................. 15-10
SYSTEM DIAGRAM

(CHARGING SYSTEM) . ........................................... 17-0
(IGNITION SYSTEM) . .............................................. 18-0
(ELECTRIC STARTER) . ............................................. 19-0
SYSTEM LOCATION ................................................... 20-0
SYSTEM TESTING . ....................................................... 6-3

...THERMOSTAT ............6..-.6.............•................................. 6-6

THROTTLE OPERATION . ............................................. 3-4
TOOLS .......................................................................... 1-14

TORQUEE VVAALLUUEESS .............................................................. 1-12

TRANSMISSION ASSEMBLy ................................. 12-10

TTRRAANNSSMMIISSSSIIOONN DDiISSAASSSSEEMMBBLLYy ............................................ 1122--33

TTRROOUUBBLLEESSHHOOOOTTIINNGG

(A(ALTLETRERNANTAOTOR/RS/TSATRATRETRERCCLULUTCTHC)H.)............................... 9-1
(C(COOOOLILNIGNGSSYYSSTETEMM) .) .................................................................. 6-2
(C(CHHAARRGGINIGNGSSYYSSTTEEMM) )......................................................................... 1177--33
{B(BRRAKAEKESSySYTSETMEM) .)...................................................................................... 1166--22

(C(CLULUTCTCH/HG/GEAERASRHSIHFTIFTLILNINKKAAGGEE) ).................................. 8-2
(C(CRRANANKSKHSAHFATF/TB/ABLAALNACNECRE)R.)............................................ 13-1
(((ECC(((CCELYYELYYLLCEIILLNNTCIINNDDRTDEDEIRCERREICRS/RPHST/HIEPASTEAIRATSADOTRTDENTNORNAE)N)AL.R)..VL..).....EV.........SE......).S........J.....................................................................................................................................................1111110919----2-2222
(F(FRRAAMMEE/B/OBODDYYPPAANNEELSLS/EXHAUST SySTEM) . .............. 22--11

(F(FRROONNT TWWHHEEEELJUSSUUSSPPEENNSSIOIONN/S/STTEEEERRINI"G) ) . ............... 1144--22
(F(UFUELELSSYYSSTETEMM) .).................................................................. 5-2
(I(GIGNNITITIOIONNSSYYSSTETEMM) ). .................................................... 18-2

(L(ILGIGHHTST/SM/METEETRESR/SS/WSWITCI HES) ................................. 20-2
(LUBRICATION SySTEM) . ........................................... 4-1

(R(LEUABRRWICHAETEILOJNSUSSYPSETNESMI)O..N..)....................................................... 154--21

(TRANSMISSION) . ..................................................... 12-2

T(URRENARSWIGHNEAELURSEULSAPyE. .N..S...I.O...N...)................................................ 201-51-32

UNDER COWL . .............................................................. 2-3

TUUPPRENRSCIGONWALL. .R...E..L..A...Y........................................................ 2-5
VUANLDVEERCCLOEAWRLANCE . ..................................................... 3-8
V..A.L.V..E...G..U..ID..E...R..E..P.L..A.C..E. MEN2T-3. ............................. 10-13
VALVEE CSELEAATRINASNPCEEC..T.ION .3..-...8................................ 10-14

VALVE GSEUAIDTERREEFAPCLIANCGE.M...E..N...T................................. 10-15

VWAALTVEERSPEUAMT PIN.S.P...E...C..T...I.O...N................................................ 6-12
VWAHLEVELSSE/TAIRTERSEF. .A...C..I.N...G.........................................................................130-2115

23--22 http://mototh.com

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1. General Information 4 - 28
2. Frame/Body panels/Exhaust system 29 - 36
3. Maintenance 37 - 58
4. Lubrication system 59 - 65
5. Fuel system 66 - 82
6. Cooling System 83 - 98
7. Engine removal/Installation 99 - 106
8. Clutch/Gearshift linkage 107 - 121
9. Alternator/Starter Clutch 122 - 130
10. Cylinder head/Valves 131 - 154
11. Cylinder/Piston 155 - 164
12. Transmission 165 - 179
13. Crankshaft/Balancer 180 - 185
14. Front wheel/Suspension/Steering 186 - 209
15. Rear wheel/Suspension 210 - 224
16. Brake system 225 - 248
17. Charging system 249 - 257
18. Ignition system 258 - 265
19. Electric starter 266 - 277
20. Lights/Meter/Switches 278 - 295
21. Wiring diagram
22. Troubleshooting 296
23. Index 297 - 300
301 - 302

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