Honda Cbr150r 2002-2009

TTRROOUUBBLLEESSHHOOOOTTIINNGG

PPOOOORR PPEERRFORMANCEAATTHHIIGH SSPPEEED

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

cchheecckkffuueell ffllooww • CClologgggeeddffuueellttaannkkbbrreeaatthheerr

II
FFuueell fflloowwssffrreeeellyy
CCaarrbbuurreettoorr nnoottsseerrvviicceeddffrreeqquueennttllyy
+t ------I..-...2. RReemmoovveetthhee ccaarrbbuurreettoorraanndd cchheecckkffoorr ~- - CCllooggggeedd
ccllooggggiinngg eennoouugghh

+•II -------I.....IInnccorrect CCaamm sspprroocckkeettss nnoott iinnssttaalled pprroopp-

NNoott ccllooggggeedd eerrllyy..

3. CChheeck vvaallvvee ttiimmiinng

II

CCoorrrreecctt ------I...-...Incorrect FFaauullttyy iiggnniittiioonn ccoonntrol mmooddulee ((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 addjjuussttiinngg nutt too tight
• DDaammaaggeeddsteeeerriinngg hheeaadd bearings
EExxcceessssiivveewwhheeeell bbeeaarriinngg ppllaayy
-22.. IIff eeiitthheer wwhheeeell iiss wwoobbbblliinngg - - - - - - - - - - - - - - - . - . . . . •
• BBeenntt rriimm

• IImmpprrooppeerr iinnssttaalllleedd wwhheeeell hhuubb

• SSwwiinnggaarrmm ppiivvoot bbuusshhiinngg eexxcceessssiivveellyy

wwoorrnn

• BBeennttffrraammee

33.. IIfftthheemmoottoorrccyycclleeppuullleeddttoo oonneessiiddee - - - - - - - - - - - - - 1 . . .*. • FFaauullttyy sshhoocckkaabbssoorrbbeerr

• FFrroonnttaannddrreeaarr wwhheeeell nnoottaalliiggnneedd
• BBeennt tffoorrkk
• BBeennttsswwiinnggaarrmm
• BBeennttaaxxllee

2222--44 http://www.motorcycle.in.th

23.. INDEX

AIR CLEANER .............................................................. 3-5 HANDLEBAR .......................................................................................................................... 14-3
HANDLEBAR SWITCHES ................................................... 20-8
AIR CLEANER HOUSING ........................................... 5-4 HEADLIGHT AIM................................................................................................... 3-19
HORN ................:........................................................................ 20-13
ALTERNATOR/STATOR .............................................. 9-2 IGNITION COIL ............................................................................... 18-5
IGNITION CONTROL MODULE (lCM) .......................................... 18-5
ALTERNATOR INSPECTION ..................................... 17-7
IGNITION SWiTCH .................................................... 20-7
BATTERY ................................................................... 17-4 IGNITION SYSTEM INSPECTION ............................ 18-3

BODY PANEL LOCATIONS ......................................... 2-0 IGNITION TIMING ..................................................... 18-6

BRAKE FLUiD ............................................................ 3-17 LEFT CRANKCASE COVER INSTALLATION ............. 9-8

BRAKE FLUID REPLACCEEMMEENNTT//AAIIRRBLEEDING ...... 16-3 LEFT CRANKCASE COVER REMOVAL ...................... 9-2
BRAKEE LIGHT SWITCH .................................................... 3-18
BRAKEE LIGHT SWITCH (SYSTEM INSPECTION) ..... 20-8 LUBRICATION & SEAL POINTS ............................... 1-15
BRAKKEE PADD WEAR ........................................................................... 3-18
BRAKKEE PEDALL.............................................................. 16-22 LUBRICATION SYSTEM DIAGRAM ........................... 4-0

BRAKE PAD/DISC ...................................................... 16-5 MAINTENANCE SCHEDULE ...................................... 3-3
BRAKE SYSTEM ....................................................... 3-18
MIDDLE COWL ............................................................ 2-4
BULB REPLACEMENT .............................................. 20-3
CABLE & HARNESS ROUTING ................................ 1-17 MODEL IDENTIFICATION ........................................... 1-3

CARBURETOR ASSEMBLy ........................................ 5-9 NUTS, BOLTS, FASTENERS .................................... 3-21

CARBURETORR CHOKE .............................................................. 3-5 OIL PUMP .................................................................... 4-2

CARBURETORR DIiSASSEMMBBLLYy ................................................ 5-6 PASSEN GEAR SEAT .................................................. 2-2

CARBURETOORR INSTALLATION ........................................ 5-13 PILOT SCREW ADJUSTMENT ................................. 5-14

CARBURETOR REMOVAL .......................................... 5-4 PISTON INSTALLATION ........................................... 11-7
PISTON REMOVAL ................................................... 11-4
CHARGGIINNGG SYSTEEMM INSPEECCTTIIOONN.................................... 17-5
CLUTTCCHH.............................................................................. 8-4 POOR HANDLING ..................................................... 22-4

CLUTCH/NEUTRRAALL DIODE ..................................... 19-11 POOR PERFORMANCE AT HIGH SPEED ................ 22-4
CLUTCH SWiTCH .................................................... 20-16 POOR PERFOORRMMAANNCCEE AT LOW

CLUTCH SYSTEM .................................................... 3-19 AND IDLEE SPEEEEDD .................................................................................... 22-3

COMBINATION METER ...............•............................ 20-5 PRIMARY DRIVE GEAR ............................................ 8-12
RADIATOR COOLANT .............................................. 3-13
COOLANT REPLACCEEMMEENNTT................................................................................ 6-4 RADIATOR/COOLING FAN ......................................... 6-8
R ADIATOR RESERVE TANK ..................................... 6-12
COOLANT TEMPERATUURREE RREAR BRAKE CALIPER ........................................... 16-19
REAR COWL ................................................................ 2-2
GAUGE/THHEERRMMOOSSEENNSSOORR......................... 20-15 REAR FENDER ............................................................ 2-3

COOLING FAN MOTOR SWiTCH ........................... 20-14 REAR MASTER CyLINDER ........................................................ 16-12

COOLING SySTEM ................................................... 3-14 REAR WHEEL ............................................................ 15-3

..CRANKKCCAASSEE ASSEMMBBLLYy ...................................... 12-13 REGULATOR/RECTI FIRE .......................................... 17-8

CRANNKKCCAASSEE BREATHHEERR ........................................... 3-6 RIGHT CRANKCASE COVER INSTALLATION ......... 8-13

CRANKSHAFT INSTALLATION ................................ 13-5 RIGGHHTT CRAANNKKCCAASSEECOVEERR REMMOOVVAALL ...................................... 8-3

CRANKKSSHHAAFFTT REMOOVVAALL ........................................... 13-2 SECOONNDDAARRYYAIR SUPPPLLYY SYSTEMM

.CYLINDEERR INSTALLATTIOONN ...................................... 11-8 (MAINNTTEENNAANNCCEE)) ............................................................... 3-14

CYLINDER REMOVAL ............................................... 11-3 SECONDARY AIR SUPPPLLYY SYSTEEMM

CYLINDER COMPRESSION ...................................... 10-3 (SYSTTEEMM INSPECCTTIIOONN))................................................................ 5-1155

CYLINDEERR HEAADD ASSEMBLYy ................................................. 100--1177 SERVICE INFORMATION

CYLINDER HEAD DiSASSEMBLy ............................ 10-8 (ALTERNATOR/STARTER CLUTCH) ......................... 9-1
CYLINDER HEAD INSTALLATION ......................... 10-19
(COOLING SYSTEM) ................................................ 6-1
CYLINDER HEAD REMMOOVVAALL........................................... 10-4
(CHARGING SYSTEM) ........................................... 17-'
DRIVE CHAIN ............................................................ 3-15
(BRAKE SYSTEM) ................................................... 16-1
DRIVER SEAT .............................................................. 2-2
(CLUTCH/GEARSHIFT LINKAGE) ............................ 8-'
ENGINE IDLE SPEED ................................................ 3-12
(CRANKSHAFT/BALANCER) .................................. 13-1
ENGINE LACKS POWER .......................................... 22-2
(CYYLLIINNDDEERR HEEAADD/NVALLVVEESS))....................................... 10-1
ENGINE OIL ............................................................... 3-10
(CYLINDER/PISTON) ............................................... 11-1
ENGINE OIL STRAINER SCREEN ............................ 3-12
(ENGINE REMOVAL/INSTALLATION) ...................... 7-1
ENGINE INSTALLATION ............................................ 7-4 (ELECTRIC STARTER) ............................................. 19-1

ENGINE REMOVAL ..................................................... 7-2 (FRAME/BODY PANELS/EXHAUST SySTEM) ........ 2-1

EXHAUST SYSTEM .................................................... 2-5 (FRONT WHEEL/SUSPENSION/STEERING) ......... 14-'

FLYWHEEL INSTALLATION ........................................ 9-7 (FUEL SYSTEM) ........................................................ 5-1

FLYWHEEL REMOVAL ................................................ 9-3 I:!:'I(IGNITION SYSTEM) .............................................. 18-1

FORK ...................................................................... 14-12 (LIGHTS/METERS/SWITCHES) .............................. 20-1 ~

FRONT BRAKE CALIPER ........................................ 16-16 (LUBRICAT!ON SySTEM) ......................................... 4-1

FRONT FENDER .......•.................................................. 2-4 (MAINTENANCE) ...................................................... 3-'
(REAR WHEEL/SUSPENSION) ............................... 15-'
FRONT MASTER CYLINDER .................................... 16-8
(TRANSMiSSiON) ................................................... 12-'
FRONT WHEEL ......................................................... 14-8
SERVICE RULES ................................................................................ 11--22
FUEL LINE ................................................................... 3-4
SSHHOOCCKK AABBSSOORRBBEER .................................................. 15-9
FUEL METER/FUEL UNIT ....................................... 20-11
SSIIDDEE SSTTAANNDD....................................................................... 3-20
FUEL TANK .................................................................................................................. 5--33

GEARSHIFT LINKAGE .............................................. 8-10

GENERAL SAFETY ..................................................... 1-1

GRAB RAIL .................................................................. 2-2

http://www.motorcycle.in.th 233--11

INDDEEXX

SSPPAARRKKPPLLUUGG.............................................................................................................................. 33--66
SSPPEECCIIFFIICCAATTIIOONNSS................................................................................................................ 11--44
SSTTAARRTTEERR CCLLUUTTCCHH............................................................... 9-4
SSTTAARRTTEERR MMOOTTOORR ............................................................. 19-4
SSTTAARRTTEERR RREELLAAYYSSWWIITTCCHH .......................................................................... 1199--1100

STEERING HEAD BEARINGS ................................... 3-22
STEERING STEM .................................................... 14-19

SUB-AIR CLEANER .......................................................................................................... 55--44

SUSPENSION ........................................................... 3-20
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 ..........................................................•............................................................... 6-66

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

TORQUEE VALUUEESS ................................................................ 1-12

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

TRANNSSMMIISSSSIIOONN DiISASSEMBLYy ........................................................ 12--33

TROUBBLLEESSHHOOOOTTIINNGG

(ALTERRNNAATTOORR//SSTTAARRTTEERRCLUTTCCHH)).............................. 9-1
(COOOLLIINNGG SYSTEMM) ............................................................................ 6-2
(CHAARRGGIINNGG SYSTEM) ...................................................................................... 17-3
{(BRRAAKKEE SYySSTTEEMM)) ...................................................................................................... 166--22

...(CLUUTTCCHH//GGEEAARRSSHHIFIFTTLINKAGGEE)) ............................ 8-2
(CRANNKKSSHHAAFFTT//BBAALLAANNCCEERR))............................................. 13-1
(CYLINDER HEADNNAALLVVEESS)J................................................. 10-2
(CYLINNDDEERR//PPIISSTTOONN)).............................................................................................. 11-2

(ELEECCTTRRIICCSTAARRTTEERR))......................................................199--22
(FRAME/BOODDYY PANELS/EXHAUST SySTEM) ................ 2-11
(FRONNTTWHEEULJSSUUSSPPEENNSSIOIONN/S/STTEEEERRI"IN) G) .................. 14-2
(FUEL SYSTEM) .................................................................. 5-2
(IGNITION SYSTEEMM)) .................................................. 18-2

(LIGHTS/MMEETTEERRSS//SSWWIITCHES) .............................. 20-2

(LUBRICATIOONN SYySSTEM) .................................................................................. 4-11
(REARR WHEELUJSSUUSSPPEENSION) .............................................................. 15-2

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

TURN SIGNAL RELAAYy ................................................ 20-13
UNDER COWL ........................................................................................................ 2-3

UPPER COWL .............................................................. 2-5

VALVEE CLEARANCE ........................................................................................................ 33--88

VALVE GUIDE REPLACEEMMEENNTT .............................. 10-13

VALVE SEAT INSPECTTIIOONN ............................................ 10-14
VALVE SEAT REFACINNGG .................................................................................. 10-15

WATER PUMP ........................................................... 6-12
WHEELS/TIRES ......................................................... 3-21

23--22 http://www.motorcycle.in.th

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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

http://www.motorcycle.in.th