FRONT WHEEL. Honda CBR125R 430 Pages
The Honda CBR125R is a lightweight and powerful motorcycle designed for both beginners and experienced riders. It features a liquid-cooled, single-cylinder engine with PGM-FI fuel injection, delivering reliable performance. The CBR125R also boasts a modern design with sleek bodywork and a comfortable riding position. This manual provides comprehensive service procedures, maintenance schedules, and troubleshooting information for the CBR125R, ensuring optimal performance and safety.
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FRONT WHEEL/SUSPENSION/STEERING
Install the inner weight assembly into the handlebar.
Turn the inner weight and hook the weight retainer tab with the tab locking hole in the handlebar.
TAB HOLE
FRONT WHEEL
REMOVAL
Support the motorcycle using a safety stand or hoist, raise the front wheel off the ground.
Disconnect the speedometer cable while pushing the tab of the cable.
Remove the axle nut.
Do not operate the brake lever after removing the front wheel.
Remove the axle and front wheel.
INNER WEIGHT
RETAINER RING
HANDLEBAR WEIGHT
TAB
Remove the side collar.
NUT/AXLE
SIDE COLLAR
SPEEDOMETER CABLE
Remove the speedometer gear box.
GEAR BOX
13-13
FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
AXLE
Place the axle on V-blocks.
Turn the axle and measure the runout using a dial indicator.
Actual runout is 1/2 of the total indicator reading.
SERVICE LIMIT: 0.2 mm (0.01 in)
WHEEL RIM
Check the wheel rim runout by placing the wheel in a truing stand.
Spin the wheel by hand and measure the runout using a dial indicator.
Actual runout is 1/2 of the total indicator reading.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Replace the bearings in pairs.
WHEEL BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the outer race fits tightly in the wheel hub.
Remove and discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the wheel hub.
13-14
FRONT WHEEL/SUSPENSION/STEERING
WHEEL BALANCE
• Carefully check balance before installing the wheel.
• Mount the tire with the arrow mark facing in the direction of rotation.
• The wheel balance must be checked when the tire is remounted.
• For optimum balance, the tire balance mark (light mass point: a paint dot on the side wall) must be located next to the valve stem. Remount the tire if necessary.
ROTATING
DIRECTION MARK
BALANCE MARK
VALVE STEM
Mount the wheel, tire and brake disc assembly on an inspection stand.
Spin the wheel, allow it to stop, and mark the lowest
(heaviest) part of the wheel with chalk.
Do this 2 or 3 times to verify the heaviest area.
If the wheel is balanced, it will not stop consistently in the same position.
To balance the wheel, install a new balance weight on the lightest side of the rim, on the side opposite the chalk marks. Add just enough weight so the wheel will no longer stop in the same position when it is spun.
Do not add more than 60 g to the wheel.
DISASSEMBLY
Remove the dust seal from the right wheel hub.
Loosen the brake disc mounting bolts in a crisscross pattern in 2 or 3 steps, and remove the bolts and brake disc.
DUST SEAL BRAKE DISC
BOLTS
Remove the dust seal and speedometer retainer from the left wheel hub.
DUST SEAL
RETAINER
13-15
FRONT WHEEL/SUSPENSION/STEERING
Install the bearing remover head into the bearing.
From the opposite side, install the bearing remover shaft and drive out the bearing from the wheel hub.
Remove the distance collar and drive out the other bearing.
TOOLS:
Bearing remover head, 12 mm 07746-0050300
Bearing remover shaft 07746-0050100
REMOVER SHAFT
REMOVER HEAD
ASSEMBLY
42 N·m (4.3 kgf·m, 31 lbf·ft)
BEARING (6301UU)
BRAKE DISC
DUST SEAL
DISTANCE COLLAR
RETAINER
DUST SEAL
SPEEDOMETER
GEAR BOX
BEARING (6301UU)
SPEEDOMETER GEAR
Never install the old bearing, once the bearing has been removed, the bearing must be replaced with new ones.
Drive in a new right side bearing squarely with its marked side facing up until it is fully seated.
Install the distance collar.
Drive in a new left side bearing squarely with its marked side facing up until it is seated on the distance collar.
TOOLS:
Driver
Attachment, 37 x 40 mm
Pilot, 12 mm
07749-0010000
07746-0010200
07746-0040200
SHIM
DRIVER
DISTANCE
COLLAR
PILOT
ATTACHMENT BEARINGS
13-16
FRONT WHEEL/SUSPENSION/STEERING
Install the speedometer retainer to the left wheel hub, while aligning the tabs on the retainer with the slots on the hub.
RETAINER
Align
Apply grease to a new dust seal lips.
Install the dust seal until it is fully seated to the left wheel hub.
DUST SEAL
Install the brake disc with the stamped mark
"MIN.TH. 3.5 mm" facing outside.
Install and tighten new brake disc bolts to the specified torque in a crisscross pattern in 2 or 3 steps.
TORQUE: 42 N·m (4.3 kgf·m, 31 lbf·ft)
Do not get grease on the brake disc or stopping power will be reduced.
Apply grease to a new dust seal lips.
Install the dust seal until it is flush with the wheel hub surface to the right wheel hub.
MARK
INSTALLATION
Apply grease to the speedometer gear teeth, gear
inner surface and shaft outer surface (page 1-17).
Install the speedometer gear box into the left wheel hub while aligning the tabs with the slots.
DUST SEAL
GEAR BOX
BRAKE DISC
BOLTS
Align
13-17
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Key Features
- Liquid-cooled engine
- PGM-FI fuel injection
- Sleek design
- Lightweight
- Powerful
- Comfortable riding position
- Comprehensive service manual
Frequently Answers and Questions
What type of engine oil is recommended for the CBR125R?
What is the recommended tire pressure for the CBR125R?
What kind of brake fluid should I use for the CBR125R?
Related manuals
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Table of contents
- 3 1
- 3 2
- 3 3
- 3 4
- 3 5
- 3 6
- 3 7
- 3 8
- 3 9
- 3 10
- 3 11
- 3 12
- 3 13
- 3 14
- 3 15
- 3 16
- 3 17
- 3 18
- 3 19
- 3 20
- 3 21
- 3 22
- 6 SERVICE RULES
- 6 ABBREVIATION
- 6 MODEL IDENTIFICATION
- 6 EXCEPT CM AND U model shown:
- 7 SERIAL NUMBERS
- 8 LABELS
- 9 GENERAL SPECIFICATIONS
- 11 LUBRICATION SYSTEM SPECIFICATIONS
- 11 FUEL SYSTEM (PGM-FI) SPECIFICATIONS
- 11 COOLING SYSTEM SPECIFICATIONS
- 12 CYLINDER HEAD/VALVES SPECIFICATIONS
- 12 CYLINDER/PISTON SPECIFICATIONS
- 12 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS
- 13 ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
- 13 CRANKSHAFT/BALANCER/TRANSMISSION SPECIFICATIONS
- 14 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS
- 14 REAR WHEEL/SUSPENSION SPECIFICATIONS
- 14 HYDRAULIC BRAKE SPECIFICATIONS
- 15 BATTERY/CHARGING SYSTEM SPECIFICATIONS
- 15 IGNITION SYSTEM SPECIFICATIONS
- 15 ELECTRIC STARTER SPECIFICATION
- 15 LIGHTS/METERS/SWITCHES SPECIFICATIONS
- 16 STANDARD TORQUE VALUES
- 16 ENGINE & FRAME TORQUE VALUES
- 20 LUBRICATION & SEAL POINTS
- 20 ENGINE
- 21 FRAME
- 22 CABLE & HARNESS ROUTING
- 34 EMISSION CONTROL SYSTEMS (Except CM type)
- 34 SOURCE OF EMISSIONS
- 34 CRANKCASE EMISSION CONTROL SYSTEM
- 35 EXHAUST EMISSION CONTROL SYSTEM
- 35 THREE-WAY CATALYTIC CONVERTER
- 35 NOISE EMISSION CONTROL SYSTEM (Except U type)
- 35 NOISE EMISSION CONTROL SYSTEM (U type only)
- 36 EMISSION CONTROL SYSTEMS (CM type only)
- 36 EXHAUST EMISSION REQUIREMENT
- 36 NOISE EMISSION REQUIREMENT
- 36 WARRANTY COMPLIANCE
- 36 SOURCE OF EMISSIONS
- 36 CRANKCASE EMISSION CONTROL SYSTEM
- 37 EXHAUST EMISSION CONTROL SYSTEM
- 37 THREE-WAY CATALYTIC CONVERTER
- 37 NOISE EMISSION CONTROL SYSTEM
- 40 BODY PANEL LOCATIONS
- 40 EXCEPT CM AND U TYPE shown:
- 41 SERVICE INFORMATION
- 41 GENERAL
- 41 TORQUE VALUES
- 41 TROUBLESHOOTING
- 42 PILLION SEAT
- 42 REMOVAL/INSTALLATION
- 42 SINGLE SEAT
- 42 REMOVAL/INSTALLATION
- 43 GRAB RAIL
- 43 REMOVAL/INSTALLATION
- 43 REAR COWL
- 43 REMOVAL/INSTALLATION
- 44 DISASSEMBLY/ASSEMBLY
- 44 FUEL TANK COVER
- 44 REMOVAL/INSTALLATION
- 45 INNER COWL
- 45 REMOVAL/INSTALLATION
- 46 LOWER COWL
- 46 REMOVAL/INSTALLATION
- 46 DISASSEMBLY/ASSEMBLY
- 47 MIDDLE COWL
- 47 REMOVAL/INSTALLATION
- 48 UPPER COWL
- 48 REMOVAL/INSTALLATION
- 49 FRONT FENDER
- 49 REMOVAL/INSTALLATION
- 50 REAR FENDER
- 50 REMOVAL/INSTALLATION
- 51 DISASSEMBLY/ASSEMBLY
- 51 EXHAUST PIPE/MUFFLER
- 51 REMOVAL
- 53 DISASSEMBLY/ASSEMBLY
- 54 INSTALLATION
- 55 STUD BOLT REPLACEMENT
- 58 SERVICE INFORMATION
- 58 GENERAL
- 58 SPECIFICATIONS
- 59 TORQUE VALUES
- 59 TOOLS
- 60 MAINTENANCE SCHEDULES
- 60 Except CM type
- 61 CM type only
- 62 FUEL LINE
- 62 FUEL TANK LIFTING
- 62 INSPECTION
- 62 FUEL TANK LOWERING
- 63 THROTTLE OPERATION
- 64 AIR CLEANER
- 64 REMOVAL/INSTALLATION
- 64 CLEANING
- 65 CRANKCASE BREATHER
- 65 SPARK PLUG
- 65 REMOVAL
- 66 INSPECTION
- 66 INSTALLATION
- 67 VALVE CLEARANCE
- 67 INSPECTION
- 68 ADJUSTMENT
- 69 ENGINE OIL
- 69 OIL LEVEL INSPECTION
- 70 ENGINE OIL CHANGE
- 70 ENGINE OIL STRAINER SCREEN
- 70 REMOVAL/INSTALLATION
- 71 RADIATOR COOLANT
- 71 COOLING SYSTEM
- 72 DRIVE CHAIN
- 72 DRIVE CHAIN SLACK INSPECTION
- 72 ADJUSTMENT
- 73 CLEANING AND LUBRICATION
- 73 SPROCKET INSPECTION
- 74 REPLACEMENT
- 77 BRAKE FLUID
- 77 FRONT BRAKE
- 78 REAR BRAKE
- 78 BRAKE PADS WEAR
- 78 FRONT BRAKE PADS
- 78 REAR BRAKE PADS
- 79 BRAKE SYSTEM
- 79 INSPECTION
- 79 BRAKE PEDAL HEIGHT ADJUSTMENT
- 79 BRAKE LIGHT SWITCH
- 80 CLUTCH SYSTEM
- 80 HEADLIGHT AIM
- 81 SIDESTAND
- 81 SUSPENSION
- 81 FRONT SUSPENSION INSPECTION
- 81 REAR SUSPENSION INSPECTION
- 82 NUTS, BOLTS, FASTENERS
- 82 WHEELS/TIRES
- 83 STEERING HEAD BEARINGS
- 86 LUBRICATION SYSTEM DIAGRAM
- 87 SERVICE INFORMATION
- 87 GENERAL
- 87 SPECIFICATIONS
- 87 TORQUE VALUE
- 87 TROUBLESHOOTING
- 88 OIL PUMP
- 88 REMOVAL
- 88 DISASSEMBLY
- 89 INSPECTION
- 89 OIL PUMP DRIVEN GEAR/OIL PUMP SHAFT/LOCK PIN
- 89 OIL SEAL
- 89 OIL PUMP
- 90 ASSEMBLY
- 92 INSTALLATION
- 94 COMPONENT LOCATION
- 95 SERVICE INFORMATION
- 95 GENERAL
- 95 SPECIFICATIONS
- 95 TORQUE VALUES
- 96 TOOLS
- 97 PGM-FI SYMPTOM TROUBLESHOOTING
- 98 PGM-FI SYSTEM LOCATION
- 99 PGM-FI SYSTEM DIAGRAM
- 100 PGM-FI CONNECTOR LOCATIONS
- 102 PGM-FI TROUBLESHOOTING INFORMATION
- 102 GENERAL TROUBLESHOOTING
- 102 Intermittent Failure
- 102 Opens and Shorts
- 102 If the MIL has come on
- 102 If the MIL did not stay on
- 102 SYSTEM DESCRIPTION
- 102 SELF-DIAGNOSIS SYSTEM
- 102 FAIL-SAFE FUNCTION
- 102 DTC
- 103 MIL Blink Pattern
- 103 MIL Check
- 103 CURRENT DTC/FREEZE DTC
- 103 HDS POCKET TESTER INFORMATION
- 103 How to connect the HDS pocket tester
- 103 ECM reset
- 104 DTC READOUT
- 104 Reading DTC with the MIL
- 104 CLEARING DTC
- 104 How to clear the DTC with SCS connector
- 105 CIRCUIT INSPECTION
- 105 INSPECTION AT ECM CONNECTOR
- 105 TEST HARNESS CONNECTION
- 105 TEST HARNESS TERMINAL LAYOUT
- 106 DTC INDEX
- 107 SENSOR UNIT POWER LINE INSPECTION
- 107 BEFORE DTC TROUBLRESHOOTING
- 107 1. Sensor Unit Power Input Voltage Inspection
- 107 2. Sensor Unit Input Voltage Line Short Circuit Inspection
- 107 3. Sensor Unit Power Line Open Circuit Inspection
- 108 BEFORE MIL TROUBLESHOOTING
- 108 1. Sensor Unit Power Input Voltage Inspection 1
- 108 2. Sensor Unit Power Input Voltage Inspection 2
- 108 3. Sensor Unit Input Voltage Line Short Circuit Inspection
- 109 4. Sensor Unit Input Voltage Line Open Circuit Inspection
- 109 DTC TROUBLESHOOTING
- 109 DTC 1-1 (MAP SENSOR LOW VOLTAGE)
- 109 1. MAP Sensor System Inspection
- 109 2. Sensor Unit Power Line Inspection
- 109 3. MAP Sensor Output Voltage Inspection
- 110 4. MAP Sensor Output Line Short Circuit Inspection
- 110 5. MAP Sensor Inspection
- 110 DTC 1-2 (MAP SENSOR HIGH VOLTAGE)
- 110 1. MAP Sensor System Inspection 1
- 110 2. Sensor Unit Power Line Inspection
- 111 3. MAP Sensor System Inspection 2
- 111 4. MAP Sensor Output Line Open Circuit Inspection
- 111 DTC 7-1 (ECT SENSOR LOW VOLTAGE)
- 111 1. ECT Sensor System Inspection
- 111 2. ECT Sensor Inspection
- 112 3. ECT Sensor Resistance Inspection
- 112 4. ECT Sensor Short Circuit Inspection
- 112 DTC 7-2 (ECT SENSOR HIGH VOLTAGE)
- 112 1. ECT Sensor System Inspection
- 113 2. ECT Sensor Inspection
- 113 3. ECT Sensor Open Circuit Inspection
- 113 DTC 8-1 (TP SENSOR LOW VOLTAGE)
- 113 1. TP Sensor System Inspection
- 113 2. Sensor Unit Power Line Inspection
- 114 3. TP Sensor Output Line Short Circuit Inspection
- 114 4. TP Sensor Output Line Open Circuit Inspection
- 114 5. TP Sensor Inspection
- 114 DTC 8-2 (TP SENSOR HIGH VOLTAGE)
- 114 1. TP Sensor System Inspection
- 115 2. Sensor Unit Power Line Inspection
- 115 3. TP Sensor Resistance Inspection
- 115 DTC 9-1 (IAT SENSOR LOW VOLTAGE)
- 115 1. IAT Sensor System Inspection
- 115 2. Sensor Unit Power Line Inspection
- 115 3. IAT Sensor Inspection
- 116 4. IAT Sensor Voltage Input Line Short Circuit Inspection
- 116 DTC 9-2 (IAT SENSOR HIGH VOLTAGE)
- 116 1. IAT Sensor System Inspection
- 116 2. Sensor Unit Power Line Inspection
- 116 3. IAT Sensor Inspection
- 117 4. IAT Sensor Voltage Input Line Open Circuit Inspection
- 117 DTC 12-1 (INJECTOR)
- 117 1. Injector System Inspection
- 117 2. Injector Input Voltage Inspection
- 118 3. Injector Signal Line Short Circuit Inspection
- 118 4. Injector Resistance Inspection
- 118 5. Injector Signal Line Open Circuit Inspection
- 119 DTC 21-1 (O
- 119 1. O
- 119 2. O
- 119 3. O
- 120 4. O
- 120 DTC 29-1 (IACV)
- 120 1. Recheck DTC
- 120 2. IACV Short Circuit Inspection
- 121 3. IACV Open Circuit Inspection
- 121 4. IACV Resistance Inspection
- 121 DTC 33-2 (EEPROM)
- 121 1. Recheck DTC
- 122 DTC 54-1 (BANK ANGLE SENSOR LOW VOLTAGE)
- 122 1. Recheck DTC
- 122 2. Bank Angle Sensor Power Input Voltage Inspection
- 122 3. Bank Angle Sensor Input Voltage Line Short Circuit Inspection
- 123 4. Bank Angle Sensor Output Line Short Circuit Inspection
- 123 5. Bank Angle Sensor Inspection
- 123 DTC 54-2 (BANK ANGLE SENSOR HIGH VOLTAGE)
- 123 1. Recheck DTC
- 124 2. Bank Angle Sensor Power Input Voltage Inspection
- 124 3. Bank Angle Sensor Input Voltage Line Open Circuit Inspection
- 124 4. Bank Angle Sensor Output Line Open Circuit Inspection
- 125 MIL TROUBLESHOOTING
- 125 MIL 1 BLINK (MAP SENSOR)
- 125 1. Sensor Unit Power Line Inspection
- 125 2. MAP Sensor Output Voltage Inspection
- 125 3. MAP Sensor Output Line Open Circuit Inspection 1
- 125 4. MAP Sensor Output Line Short Circuit Inspection
- 126 5. MAP Sensor Output Line Open Circuit Inspection 2
- 126 MIL 7 BLINKS (ECT SENSOR)
- 126 1. ECT Sensor Input Voltage Inspection
- 126 2. ECT Sensor Short Circuit Inspection
- 127 3. ECT Sensor Resistance Inspection
- 127 4. ECT Sensor Open Circuit Inspection
- 127 5. ECT Sensor Output Voltage Inspection
- 128 MIL 8 BLINKS (TP SENSOR)
- 128 1. Sensor Unit Power Line Inspection
- 128 2. TP Sensor Output Voltage
- 128 3. TP Sensor Output Line Short Circuit Inspection
- 128 4. TP Sensor Voltage Input Line Open Circuit Inspection
- 129 MIL 9 BLINKS (IAT SENSOR)
- 129 1. Sensor Unit Power Line Inspection
- 129 2. IAT Sensor Output Voltage Inspection 1
- 129 3. IAT Sensor Output Voltage Inspection 2
- 129 4. IAT Sensor Voltage Input Line Short Circuit Inspection
- 130 5. IAT Sensor Voltage Input Line Open Circuit Inspection
- 130 6. IAT Sensor Resistance Inspection
- 130 MIL 12 BLINKS (INJECTOR)
- 130 1. Injector Input Voltage Inspection
- 131 2. Injector Signal Line Short Circuit Inspection
- 131 3. Injector Resistance Inspection
- 131 4. Injector Signal Line Open Circuit Inspection
- 132 MIL 21 BLINKS (O
- 132 1. O
- 132 2. O
- 132 3. O
- 133 4. O
- 133 MIL 29 BLINKS (IACV)
- 133 1. IACV Resistance Inspection
- 133 2. IACV Short Circuit Inspection
- 134 3. IACV Open Circuit Inspection
- 134 MIL 54 BLINKS (BANK ANGLE SENSOR)
- 134 1. Bank Angle Sensor Power Input Voltage Inspection
- 134 2. Bank Angle Sensor Input Voltage Line Short Circuit Inspection
- 135 3. Bank Angle Sensor Input Voltage Line Open Circuit Inspection
- 135 4. Bank Angle Sensor Output Line Short Circuit Inspection
- 135 5. Bank Angle Sensor Output Line Open Circuit Inspection
- 136 MIL CIRCUIT TROUBLESHOOTING
- 136 FUEL LINE INSPECTION
- 136 FUEL PRESSURE RELIEVING/QUICK CONNECT FITTING REMOVAL
- 138 QUICK CONNECT FITTING INSTALLATION
- 139 FUEL PRESSURE TEST
- 140 FUEL FLOW INSPECTION
- 140 FUEL PUMP UNIT
- 140 INSPECTION
- 141 REMOVAL
- 142 INSPECTION
- 142 INSTALLATION
- 143 FUEL TANK
- 143 REMOVAL/INSTALLATION
- 144 AIR CLEANER HOUSING
- 144 REMOVAL/INSTALLATION
- 144 THROTTLE BODY
- 144 REMOVAL
- 145 DISASSEMBLY
- 146 IACV REMOVAL/INSPECTION
- 146 SENSOR UNIT REMOVAL
- 147 ASSEMBLY
- 147 SENSOR UNIT INSTALLATION
- 148 IACV INSTALLATION
- 148 INSTALLATION
- 150 THROTTLE VALVE FULLY CLOSED POSITION RESET PROCEDURE
- 151 INJECTOR
- 151 QUICK CONNECT FITTING REMOVAL
- 152 REMOVAL
- 153 INSTALLATION
- 153 QUICK CONNECT FITTING INSTALLATION
- 154 ENGINE IDLE SPEED
- 155 ECT SENSOR
- 155 REMOVAL/INSTALLATION
- 155 BANK ANGLE SENSOR
- 155 REMOVAL/INSTALLATION
- 156 INSPECTION WITH HDS POCKET TESTER
- 157 INSPECTION WITH ECM TEST HARNESS
- 157 ECM
- 157 REMOVAL/ INSTALLATION
- 158 ECM POWER/GROUND LINE INSPECTION
- 158 1. ECM Power Input Voltage Inspection
- 158 2. ECM Ground Line Inspection
- 159 O
- 159 REMOVAL
- 160 INSTALLATION
- 162 SYSTEM FLOW PATTERN
- 163 SERVICE INFORMATION
- 163 GENERAL
- 163 SPECIFICATIONS
- 163 TORQUE VALUES
- 164 TOOLS
- 164 TROUBLESHOOTING
- 165 SYSTEM TESTING
- 165 COOLANT (HYDROMETER TEST)
- 166 RADIATOR CAP/SYSTEM PRESSURE INSPECTION
- 166 COOLANT REPLACEMENT
- 166 PREPARATION
- 167 REPLACEMENT/AIR BLEEDING
- 168 THERMOSTAT
- 168 REMOVAL
- 168 INSPECTION
- 169 INSTALLATION
- 169 THERMOSTAT HOUSING
- 169 REMOVAL/INSTALLATION
- 170 RADIATOR
- 170 REMOVAL
- 171 DISASSEMBLY
- 172 ASSEMBLY
- 173 INSTALLATION
- 175 WATER PUMP
- 175 SEALS INSPECTION
- 175 REMOVAL/DISASSEMBLY
- 177 ASSEMBLY/INSTALLATION
- 179 RADIATOR RESERVE TANK
- 179 REMOVAL/INSTALLATION
- 180 FAN CONTROL RELAY
- 180 INSPECTION
- 182 COMPONENT LOCATION
- 183 SERVICE INFORMATION
- 183 GENERAL
- 183 SPECIFICATIONS
- 183 TORQUE VALUES
- 184 ENGINE REMOVAL
- 186 ENGINE INSTALLATION
- 190 COMPONENT LOCATION
- 191 SERVICE INFORMATION
- 191 GENERAL
- 191 SPECIFICATIONS
- 191 TORQUE VALUES
- 192 TOOLS
- 193 TROUBLESHOOTING
- 194 CYLINDER COMPRESSION
- 194 CYLINDER HEAD COVER
- 194 REMOVAL
- 195 INSTALLATION
- 196 CAMSHAFT
- 196 REMOVAL
- 197 INSPECTION
- 197 CAMSHAFT BEARING
- 197 CAM LOBE
- 198 INSTALLATION
- 200 CAMSHAFT HOLDER
- 200 REMOVAL
- 200 DISASSEMBLY
- 201 INSPECTION
- 201 ROCKER ARM/ROCKER ARM SHAFT
- 201 ASSEMBLY
- 202 INSTALLATION
- 203 CYLINDER HEAD
- 203 REMOVAL
- 203 DISASSEMBLY
- 204 INSPECTION
- 204 CYLINDER HEAD
- 205 VALVE SPRING
- 205 VALVE
- 205 VALVE GUIDE
- 206 VALVE GUIDE REPLACEMENT
- 207 VALVE SEAT INSPECTION
- 208 VALVE SEAT REFACING
- 210 ASSEMBLY
- 212 INSTALLATION
- 214 COMPONENT LOCATION
- 215 SERVICE INFORMATION
- 215 GENERAL
- 215 SPECIFICATIONS
- 215 TORQUE VALUE
- 215 TROUBLESHOOTING
- 216 CYLINDER/PISTON
- 216 CYLINDER REMOVAL
- 217 PISTON REMOVAL
- 218 INSPECTION
- 218 CAM CHAIN GUIDE
- 218 CYLINDER
- 219 PISTON/PISTON RING
- 220 CONNECTING ROD
- 220 CAM CHAIN TENSIONER LIDFTER
- 220 STUD BOLT REPLACEMENT
- 221 PISTON INSTALLATION
- 222 CYLINDER INSTALLATION
- 226 COMPONENT LOCATION
- 227 SERVICE INFORMATION
- 227 GENERAL
- 227 SPECIFICATIONS
- 227 TORQUE VALUES
- 227 TOOLS
- 228 TROUBLESHOOTING
- 229 RIGHT CRANKCASE COVER
- 229 REMOVAL
- 230 DISASSEMBLY
- 230 INSPECTION
- 231 ASSEMBLY
- 232 INSTALLATION
- 233 CLUTCH
- 233 REMOVAL
- 235 INSPECTION
- 235 CLUTCH LIFTER BEARING
- 235 CLUTCH SPRING
- 235 CLUTCH CENTER
- 236 CLUTCH DISC
- 236 CLUTCH PLATE
- 236 CLUTCH OUTER/OUTER GUIDE
- 236 MAINSHAFT
- 237 INSTALLATION
- 239 GEARSHIFT LINKAGE
- 239 REMOVAL
- 240 INSPECTION
- 240 INSTALLATION
- 242 GEARSHIFT PEDAL
- 242 REMOVAL
- 242 DISASSEMBLY/ASSEMBLY
- 243 INSTALLATION
- 244 PRIMARY DRIVE GEAR
- 244 REMOVAL
- 245 INSTALLATION
- 246 PRIMARY DRIVE GEAR SELECTION
- 248 COMPONENT LOCATION
- 249 SERVICE INFORMATION
- 249 GENERAL
- 249 SPECIFICATIONS
- 249 TORQUE VALUES
- 249 TOOLS
- 249 TROUBLESHOOTING
- 250 LEFT CRANKCASE COVER
- 250 REMOVAL
- 251 INSTALLATION
- 252 STATOR/CKP SENSOR
- 252 REMOVAL
- 252 INSTALLATION
- 253 FLYWHEEL REMOVAL
- 254 STARTER CLUTCH
- 254 REMOVAL
- 255 DISASSEMBLY
- 255 INSPECTION
- 256 ASSEMBLY
- 257 INSTALLATION
- 257 FLYWHEEL INSTALLATION
- 260 COMPONENT LOCATION
- 261 SERVICE INFORMATION
- 261 GENERAL
- 261 SPECIFICATIONS
- 262 TOOLS
- 263 TROUBLESHOOTING
- 264 CRANKCASE SEPARATION
- 266 CRANKSHAFT/BALANCER
- 266 REMOVAL
- 266 CRANKSHAFT INSPECTION
- 266 CRANKSHAFT RUNOUT
- 266 BIG END SIDE CLEARANCE
- 267 BIG END RADIAL CLEARANCE
- 267 TIMING SPROCKET
- 267 CRANKSHAFT BEARING
- 267 BALANCER BEARING
- 268 BALANCER DISASSEMBLY
- 268 BALANCER ASSEMBLY
- 269 BALANCER DRIVEN GEAR SELECTION
- 269 INSTALLATION
- 270 TRANSMISSION
- 270 REMOVAL/DISASSEMBLY
- 271 INSPECTION
- 271 GEARS/BUSHINGS
- 272 MAINSHAFT/COUNTERSHAFT
- 272 SHIFT DRUM/DRUM JOURNAL
- 272 SHIFT FORK
- 273 SHIFT FORK SHAFT
- 273 TRANSMISSION BEARING
- 273 ASSEMBLY/INSTALLATION
- 274 MAINSHAFT
- 274 COUNTERSHAFT
- 276 BEARING REPLACEMENT
- 276 CRANKSHAFT BEARING
- 277 BALANCER/TRANSMISSION BEARING
- 277 RIGHT CRANKCASE SIDE
- 278 LEFT CRANKCASE SIDE
- 279 CRANKCASE ASSEMBLY
- 284 COMPONENT LOCATION
- 285 SERVICE INFORMATION
- 285 GENERAL
- 285 SPECIFICATIONS
- 285 TORQUE VALUES
- 286 TOOLS
- 287 TROUBLESHOOTING
- 288 HANDLEBARS
- 288 REMOVAL
- 290 INSTALLATION
- 294 INNER WEIGHT REPLACEMENT
- 295 FRONT WHEEL
- 295 REMOVAL
- 296 INSPECTION
- 296 AXLE
- 296 WHEEL RIM
- 296 WHEEL BEARING
- 297 WHEEL BALANCE
- 297 DISASSEMBLY
- 298 ASSEMBLY
- 299 INSTALLATION
- 300 FORK
- 300 REMOVAL
- 301 DISASSEMBLY
- 303 INSPECTION
- 303 FORK SPRING
- 303 FORK PIPE/SLIDER/PISTON
- 304 ASSEMBLY
- 307 INSTALLATION
- 309 STEERING STEM
- 309 REMOVAL
- 310 BEARING REPLACEMENT
- 311 INSTALLATION
- 313 CLUTCH LEVER
- 313 REMOVAL/INSTALLATION
- 316 COMPONENT LOCATION
- 317 SERVICE INFORMATION
- 317 GENERAL
- 317 SPECIFICATIONS
- 317 TORQUE VALUES
- 318 TOOLS
- 318 TROUBLESHOOTING
- 319 REAR WHEEL
- 319 REMOVAL
- 319 INSPECTION
- 319 AXLE
- 320 WHEEL RIM
- 320 WHEEL AND DRIVEN FLANGE BEARINGS
- 320 WHEEL BALANCE
- 320 DRIVEN SPROCKET
- 320 DISASSEMBLY
- 322 ASSEMBLY
- 324 INSTALLATION
- 325 SHOCK ABSORBER
- 325 REMOVAL
- 326 INSPECTION
- 326 INSTALLATION
- 326 SWINGARM
- 326 REMOVAL
- 328 DISASSEMBLY
- 329 ASSEMBLY
- 330 INSTALLATION
- 334 COMPONENT LOCATION
- 335 SERVICE INFORMATION
- 335 GENERAL
- 335 SPECIFICATIONS
- 335 TORQUE VALUES
- 336 TOOL
- 336 TROUBLESHOOTING
- 337 BRAKE FLUID REPLACEMENT/AIR BLEEDING
- 337 BRAKE FLUID DRAINING
- 338 BRAKE FLUID FILLING/AIR BLEEDING
- 340 BRAKE PAD/DISC
- 340 FRONT BRAKE PAD REPLACEMENT
- 341 REAR BRAKE PAD REPLACEMENT
- 342 BRAKE DISC INSPECTION
- 343 FRONT MASTER CYLINDER
- 343 REMOVAL
- 343 DISASSEMBLY
- 344 INSPECTION
- 345 ASSEMBLY
- 347 INSTALLATION
- 347 REAR MASTER CYLINDER
- 347 REMOVAL
- 348 DISASSEMBLY
- 349 INSPECTION
- 350 ASSEMBLY
- 351 INSTALLATION
- 352 FRONT BRAKE CALIPER
- 352 REMOVAL
- 353 DISASSEMBLY
- 353 INSPECTION
- 354 ASSEMBLY
- 355 INSTALLATION
- 355 REAR BRAKE CALIPER
- 355 REMOVAL
- 355 DISASSEMBLY
- 356 INSPECTION
- 357 ASSEMBLY
- 358 INSTALLATION
- 358 BRAKE PEDAL
- 358 REMOVAL
- 359 INSTALLATION
- 362 SYSTEM LOCATION
- 362 SYSTEM DIAGRAM
- 363 SERVICE INFORMATION
- 363 GENERAL
- 363 BATTERY CHARGING
- 363 BATTERY TESTING
- 363 SPECIFICATIONS
- 364 TROUBLESHOOTING
- 364 1. BATTERY TEST
- 364 2. CURRENT LEAKAGE TEST
- 364 3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTOR
- 364 4. CHARGING VOLTAGE INSPECTION
- 364 5. ALTERNATOR CHARGING COIL INSPECTION
- 364 6. REGULATOR/RECTIFIER SYSTEM INSPECTION
- 365 BATTERY
- 365 REMOVAL/INSTALLATION
- 365 VOLTAGE INSPECTION
- 365 BATTERY TESTING
- 366 CHARGING SYSTEM INSPECTION
- 366 CURRENT LEAKAGE INSPECTION
- 366 CHARGING VOLTAGE INSPECTION
- 367 ALTERNATOR CHARGING COIL
- 367 INSPECTION
- 367 REGULATOR/RECTIFIER
- 367 SYSTEM INSPECTION
- 368 REMOVAL/INSTALLATION
- 370 SYSTEM LOCATION
- 370 SYSTEM DIAGRAM
- 371 SERVICE INFORMATION
- 371 GENERAL
- 371 SPECIFICATIONS
- 371 TORQUE VALUE
- 371 TOOLS
- 372 TROUBLESHOOTING
- 373 IGNITION SYSTEM INSPECTION
- 373 IGNITION COIL PRIMARY PEAK VOLTAGE
- 374 CKP SENSOR PEAK VOLTAGE
- 375 IGNITION TIMING
- 376 IGNITION COIL
- 376 REMOVAL/INSTALLATION
- 378 SYSTEM LOCATION
- 378 SYSTEM DIAGRAM
- 379 SERVICE INFORMATION
- 379 GENERAL
- 379 SPECIFICATION
- 380 TROUBLESHOOTING
- 380 1. Fuse Inspection
- 380 2. Battery Inspection
- 380 3. Starter Relay Switch Operation
- 380 4. Starter Motor Inspection
- 380 5. Relay Coil Ground Lines Inspection
- 380 6. Starter Relay Input Voltage Inspection
- 381 7. Starter Relay Switch Continuity Inspection
- 381 1. Clutch Switch Inspection
- 381 2. Sidestand Switch Inspection
- 382 STARTER MOTOR
- 382 REMOVAL
- 382 DISASSEMBLY/INSPECTION
- 386 ASSEMBLY
- 389 INSTALLATION
- 390 STARTER RELAY SWITCH
- 390 INSPECTION
- 390 GROUND LINE
- 390 STARTER RELAY INPUT VOLTAGE
- 390 OPERATION CHECK
- 391 REMOVAL/INSTALLATION
- 391 DIODE
- 391 INSPECTION
- 394 SYSTEM LOCATION
- 395 SERVICE INFORMATION
- 395 GENERAL
- 395 SPECIFICATIONS
- 395 TORQUE VALUES
- 396 HEADLIGHT
- 396 BULB REPLACEMENT
- 396 REMOVAL/INSTLATION
- 396 POSITION LIGHT
- 396 BULB REPLACEMENT
- 397 TURN SIGNAL LIGHTS
- 397 BULB REPLACEMENT
- 397 REMOVAL/INSTALLATION
- 397 FRONT
- 398 REAR
- 398 BRAKE/TAIL LIGHT
- 398 BULB REPLACEMENT
- 399 LICENSE LIGHT
- 399 BULB REPLACEMENT
- 399 REMOVAL/INSTALLATION
- 400 COMBINATION METER
- 400 BULB REPLACEMENT
- 401 REMOVAL/INSTALLATION
- 402 DISASSEMBLY/ASSEMBLY
- 403 TACHOMETER
- 403 INSPECTION
- 404 COOLANT TEMPERATURE GAUGE/ ECT SENSOR
- 404 GAUGE INSPECTION
- 404 The coolant temperature is too high, but the gauge needle does not moves
- 404 The coolant temperature is low, but the gauge needle moves
- 405 ECT SENSOR INSPECTION
- 405 IGNITION SWITCH
- 405 INSPECTION
- 406 REMOVAL/INSTALLATION
- 406 HANDLEBAR SWITCHES
- 406 RIGHT HANDLEBAR SWITCH
- 406 STARTER SWITCH:
- 406 ENGINE STOP SWITCH: (CM and U type)
- 407 LEFT HANDLEBAR SWITCHS
- 407 DIMMER SWITCH:
- 407 TURN SIGNAL SWITCH:
- 407 HORN SWITCH:
- 408 BRAKE LIGHT SWITCHES
- 408 FRONT
- 408 REAR
- 409 NEUTRAL SWITCH
- 409 INSPECTION
- 409 REMOVAL
- 410 INSTALLATION
- 411 SIDESTAND SWITCH
- 411 INSPECTION
- 411 REMOVAL/INSTALLATION
- 412 CLUTCH SWITCH
- 412 FUEL GAUGE/FUEL LEVEL SENSOR
- 412 INSPECTION
- 412 FUEL GAUGE
- 413 FUEL LEVEL SENSOR
- 413 HORN
- 413 INSPECTION
- 413 REMOVAL/INSTALLATION
- 414 TURN SIGNAL RELAY
- 414 INSPECTION
- 414 1. Recommended Inspection
- 414 2. Turn Signal Circuit Inspection
- 414 REMOVAL/INSTALLATION
- 414 MAIN RELAY
- 418 E, F, II G type
- 419 CM type
- 420 U type
- 422 ENGINE DOES NOT START OR IS HARD TO START
- 422 1. Spark Plug Inspection
- 422 2. Spark Test
- 422 3. Fuel Pump Inspection
- 422 4. PGM-FI System Inspection
- 422 5. Cylinder Compression
- 422 6. Engine Starting Condition
- 423 ENGINE LACKS POWER
- 423 1. Drive Train Inspection
- 423 2. Tire Pressure Inspection
- 423 3. Clutch Inspection
- 423 4. Engine Performance Inspection
- 423 5. Spark Plug Inspection
- 423 6. Engine Oil Inspection
- 424 7. Ignition Timing Inspection
- 424 8. Cylinder compression Inspection
- 424 9. Fuel Pump Inspection
- 424 10. PGM-FI system Inspection
- 424 11. Lubrication Inspection
- 424 12. Over Heating Inspection
- 424 13. Engine Knocking Inspection
- 425 POOR PERFORMANCE AT LOW AND IDLE SPEED
- 425 1. Spark Plug Inspection
- 425 2. Ignition Timing Inspection
- 425 3. Fuel Pump Inspection
- 425 4. PGM-FI System Inspection
- 425 5. IACV Inspection
- 425 6. Intake Pipes Leaking Inspection
- 426 POOR PERFORMANCE AT HIGH SPEED
- 426 1. Ignition Timing Inspection
- 426 2. Fuel Pump Inspection
- 426 3. PGM-FI System Inspection
- 426 4. Valve Timing Inspection
- 426 5. Valve Spring Inspection
- 426 6. Camshaft Inspection
- 427 POOR HANDLING
- 429 A
- 429 B
- 429 C
- 429 D
- 429 E
- 429 F
- 429 G
- 429 H
- 429 I
- 429 L
- 429 M
- 429 N
- 429 O
- 429 P
- 429 R
- 430 S
- 430 T
- 430 U
- 430 V
- 430 W