Honda Cbr 125 Shop Manual
GOING OUT OF PRINT - LIMITED QUANTITY - The 2004-2007 Honda CBR125R DIY repair manual by Haynes, covers the following models:. Honda CBR125R-4, 2004. Honda CBR125R-5, 2005. Honda CBR125R-6, 2006-2007 These bikes are powered by 124.7cc SOHC, four-stoke, liquid-cooled, single-cylinder engines. Transmissions are 6-speed constant mech, with wet multi-plate clutch.
Power is transmitted to the rear wheel via a chain and sprocket. The CBR125R is the successor to the Honda NSR125R which keeps the sportbike image but with a much more suitable design aimed at beginner riders. The 4-stroke engine is also far more environmentally-friendly than that of the NSR125R model.
2005-2007 models were available — in addition to the regular colors — in a Repsol replica paint scheme. Note: This manual does not include the 2007 Honda R-7 model (fuel-injected). Book Excerpt: 2004-2007 Honda CBR125R Repair Manual ENGINE, CLUTCH AND TRANSMISSION CLUTCH INSPECTION.
After an extended period of service the clutch friction plates will wear and promote clutch friction, plates will wear and promote clutch slip. Measure the thickness of each friction plate using a Vernier caliper, noting that there is a difference in thickness of the outer (type A0 plate to the rest (see illustration). If any plate has worn to or beyond the service limits given in the Specifications at the beginning of the Chapter, or if any of plates small burnt or are glazed, the friction plates must be replaced with a new set. The plain plates should not show any signs of excess heating (bluing). Check for warpage using a flat surface and feeler gauges (see illustration).
If any plate exceeds the maximum permissible amount of warpage, or shows signs of bluing, all plain plates must be replaced with a new set. Measure the free length of each clutch spring using a Vernier caliper (see illustration). Place each spring upright on a flat surface and check it for bend by placing a ruler against it, or alternatively lay it against a set square.
If any spring is below the minimum free length specified or if the bend in any spring is excessive, replace all the springs as a set. Also check the anti-judder spring and spring seat for damage or distortion and replace them with new ones if necessary. Inspect the friction plates and the clutch housing for burrs and indentations on the edges of the protruding tabs on the plates and/or the slots in the housing (see illustration). Similarly check for wear between the inner teeth of the plain plates and the slots in the clutch center. (see illustration). Wear of this nature will cause clutch drag and slow disengagement during gear changes as the plates will snap when the pressure plate is lifted. With care a small amount of wear can be corrected by dressing with a fine file, but if this is excessive the worn components should be renewed.
Inspect the bearing surfaces of the clutch housing bush and on the clutch guide and input shaft (see illustration). Measure the internal diameter of the housing bush, the external and internal diameters of the guide and the external diameter of the input shaft where the guide sits, and compare the result to the specifications at the beginning of the Chapter. If there are any signs of wear, pitting or other damage the affected parts must be replaced with new ones. FUEL SYSTEM AND EXHAUST COMPONENT RENEWAL CONTROL VALVE. Remove the fuel tank (see Section 2). Release the clamps and detach the vacuum hose and the air hoses from the control valve (see illustration). Remove the valve from its bracket.
If required unscrew the bolt and remove the bracket. Installation is the reverse of removal. Make sure the hoses are pushed fully onto their unions and secured by their clamps (see illustration 8.9).
REED VALVE. Remove the fairing side panels (see Chapter 8). Release the clamp and detach the air hose from its union (see illustration).
Unscrew the bolts securing the reed valve cover and remove the cover (see illustration). Remove the reed valve, noting which way around it is fitted (see illustration). Installation is the reverse of removal. Make sure the reed valve and housing are clean and correctly fitted (see illustration). Tighten the cover bolts to the torque setting specified at the beginning of the Chapter. Subject: 2004, 2005, 2006, 2007 Honda CBR125R service, maintenance, repair.
ISBN-10: ISBN-13: 204 Haynes 4620.
Honda cbr150 r-service-manual-english. 1.
HOWTO USETHIS MANUAL CONTENTS This service manual describes the service procedures for the CBR150R. Follow the Maintenance Schedule (Section 3) recom- mendations to ensure that the vehicle is in peak oper- ating condition and the emission levels are within the standards. Performing the first scheduled maintenance is very important. It compensates for the initial wear that oc- curs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installa- tion of components that may be required to perform service described in the following sections. Section 4 through 21 describe parts of the motorcycle, grouped according to location.
Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illus- tration, service information andtroubleshooting for the section.The subsequent pagesgivedetailed procedure.
If you don’t know the source of the trouble, go to sec- tion 22 TROUBLESHOOTING. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONSINCLUDEDINTHIS PUBLICA- TION ARE BASED ON THE LATEST PRODUCT IN- FORMATION AVAILABLE AT THE TIME OF AP- PROVAL FOR PRINTING. Honda Motor Co. RESERVESTHE RIGHTTO MAKE CHANGESAT ANY TIMEWITHOUT NOTICEAND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITEN PERMISSION. THIS MANUAL ISWRITEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MO- TORCYCLES, MOTOR SCOOTERS OR ATVS.
Honda Motor Co., Ltd. SERVICE PUBLICATIONOFFICE GENERAL INFORMATlON FRAMElBODY PANELSlEXHAUST SYSTEM MAINTENANCE FUEL SYSTEM COOLING SYSTEM z ENGINE REMOV ALlINSTALLATlON CLUTCHlGEARSHlFT LINKAGE ALTERNATORlSTARTER CLUTCH k Lu 2n 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 LIGHTSlMETERSlSWITCHES WIRING DIAGRAM 2 TROUBLESHOOTING Date of Issue: February, 2002 Q Honda Motor Co., Ltd. HOW TO USE THIS MANUAL This service manual describes the service procedures for the CBR150R. Follow the Maintenance Schedule (Section 3) recom- mendations to ensure that the vehicle is in peak oper- ating condition and the emission levels are within the standards. Performing the first scheduled maintenance is very important.
It compensates for the initial wear that oc- curs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installa- tion of components that may be required to perform service described in the following sections.
Section 4 through 21 describe parts of the motorcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illus- tration, 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 22 TROUBLESHOOTING.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICA- TION ARE BASED ON THE LATEST PRODUCT IN- FORMATION AVAILABLE AT THE TIME OF AP- PROVAL FOR PRINTING. Honda Motor Co. 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 WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MO- TORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., ltd. SERVICE PUBLICATION OFFICE Date of Issue: February, 2002 © Honda Motor Co., Ltd.
CONTENTS GENERAL INFORMA TION III::::::::::::::::::::::;::;:::;;:::;:;::::::::::::::::::::::: FRAME/BODY PANELS/EXHAUST -=-S=Y=S=T=EM MAINTENANCE. LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM Z 0:: «iiii;;; ENGINE REMOV ALIINST ALLATION a: CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCHI Ir=C=Y=L=IN=D=E=R=H=E=A=D=/VA=LV=E=S;;;;; Zw. CYLINDER/PISTON '. ' ITRANSMISSIONII: CRANKSHAFT/BALANCER FRONT WHEEL/SUSPENSION/ en STEERING Ui:::::::::: REARWHEEL/SUSPENSION::: BRAKE SYSTEM CHARGING SYSTEM IGNITION SYSTEM 111:1 r. ,:.=.:., ELECTRIC STARTER !!! W.w LIGHTS/METERS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX til tU. IMPORTANTSAFETY NOTICE Indicates a strong possibility of severe personal injury or death if instructionsare not followed.
CAUTION: Indicates a possibility of equipment damage if instructionsare not followed. NOTE: Gives helpful information. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, 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 tools, 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 tools selected.-IMPORTANT SAFETY NOTICE -, '4'¥iii!N Indicates a strong possibility of severe personal injury or death if instructions are not followed.
CAUTION: Indicates a possibility of equipment damage if instructions are not followed. NOTE: Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, 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 tools, 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 tools selected. SYMBOLS The symbols used throughout this manual show specific service procedures.
If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.3 Replacethe 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 ratio of 1:l) Use multi-purpose grease (Lithium based multi-purpose grease NLGl #2 or equivalent) Use molybdenum disulfide grease (containingmore than 3% molybdenum disulfide, NLGl#2 or equivalent. Example: Molykote' BR-2plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGl#2 or equivalent. Example: Molykote' G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. Only) Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use Fork or Suspension Fluid. SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, 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 ratio of 1:1) -Ii Use multi-purpose grease (lithium based mUlti-purpose grease NLGI #2 or equivalent) Use molybdenum disulfide grease (containing more than 3% molybdenum disulfideNLGI #2 or equivalent. Example: Molykote' BR-2 plus manufactured by Dow Corning U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent. Example: Molykote' G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. Only) Rocol ASP manufactured by Rocol limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. LW Apply a locking agent. Use a middle strength locking agent unless otherwise specified. J1tmru Apply sealant. I Use DOT 4 brake fluid.
Use the recommended brake fluid unless otherwise specified. Use Fork or Suspension Fluid. GENERAL INFORMATION GENERAL SAFETY 1-1 TOOLS 1-14 SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES 1-17 1-2 LUBRICATION & SEAL POINTS 1-3 CABLE & HARNESS ROUTING 1-24 I1-4 EMISSION CONTROL SYSTEMS 1-12 GENERALSAFETY CARBON MONOXIDE If the engine must be running to do some work, make sure the area is well ventilated.
Never run the engine in an enclosed area. Theexhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Runthe engine inan open areaorwith 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.
Gasolineis extremely flammable and is explosive un- der certain conditions. KEEP OUT OFREACH OF CHIL- 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 theseparts. USED ENGINE OIL Usedengine oil may causeskin cancer if repeatedly left in contact withtheskinfor prolongedperiods.Although this is unlikely unless you handle used oil on a daily ba- sis, it is still advisable to thoroughly wash your hands with soapand wateras soonaspossible after handling used oil.
KEEP OUT OFREACH OF CHILDREN. BRAKE FLUID CAUTION: Spilling fluidonpainted, plasticor rubberparts willdam- age them. Place a clean shop towel over these parts whenever thesystem is serviced. KEEP OUT OFREACH OFCHILDREN. BATTERY HYDROGEN GAS & ELECTROLYTE The battery gives off explosive gases; keep sparks, flames and cigarettesaway.Provideadequate venti- lation when charging. Thebattery contains sulfuric acid felectrolyte). Con- tact with skin or eyes may causesevere burns.
Wear 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 15minutes and call a physician imme- diately. Electrolyte is poisonous.Ifswallowed, drinklargequantitiesof wateror milk and follow with milk of magnesiaor vegetable oil andcallaphysician. KEEP OUTOFREACHOFCHIL- DREN.
GENERAL INFORMATION GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES GENERAL SAFETY CARBON MONOXIDE 1-1 1-2 1-3 1-4 1-12 If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. '!i.§Uiiii' 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 or with 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.,.;ad' Gasoline is extremely flammable and is explosive un- der certain conditions. KEEP OUT OF REACH OF CHIL- 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.
TOOLS LUBRICATION & SEAL POINTS CABLE & HARNESS ROUTING EMISSION CONTROL SYSTEMS USED ENGINE OIL 1-14 1-15 1-17 1-24 Used engine oil may cause skin cancer ifrepeatedly left in contact with the skin for prolongedperiods. 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 afterhandling used oil. KEEP OUT OF REACH OF CHILDREN. BRAKE FLUID CAUTION: Spilling fluid onpainted, plasticorrubberparts will dam- age them.
Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OFREACH OF CHILDREN. BATTERY HYDROGEN GAS & ELECTROLYTE. The battery gives off explosive gases; keep sparks, flames and cigarettes away.
Honda Cbr 125 Price
Provide adequate venti- lation when charging. The battery contains sulfuric acid (electrolyte).
Con- tact with skin or eyes may cause severe burns. Wear 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 15 minutes and call a physician imme- diately. Electrolyte is poisonous.
Honda Cbr 125 Review
III - Ifswallowed, drinklarge quantities ofwater ormilk and follow with milk ofmagnesia or vegetable oil andcall a physician. KEEP OUTOFREACH OFCHIL- DREN. 1-1. GENERAL INFORMA TION SERVICE RULES 1. Use genuine Honda or Honda-recommendedpartsand lubricants or their equivalents.
Partsthat don't meet HONDA's 2. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the motorcycle.
Honda Cbr 125 Top Speed
Metric bolts, nuts and screws are not interchangeable with 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. When tightening bolts or nuts, begin with the larger diameter or inner boltfirst. Thentighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. Clean parts in cleaning solvent upon disassembly.
Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation. Route all electrical wires as show on pages 1-17through 1-23, Cable and Harness Routing. Design specifications may cause damage to the motorcycle. English fasteners. 1-2 GENERAL INFORMA liON SERVICE RULES 1.
Use genuine Honda or Honda-recommended parts and lubricants ortheir equivalents. Parts that don't meet HONDA's design specifications may cause damage to the motorcycle. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. When tightening bolts or nuts, begin with the larger diameter or inner bolt first.
Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation. Route all electrical wires as show on pages 1-17 through 1-23, Cable and Harness Routing. 1-2. GENERAL INFORMA TlON MODELIDENTIFICATION FRAMESERIAL NUMBER ” ENGINE SERIAL NUMBER I / / The frame serial number is stamped on the right side of The engine serial number is stamped on the lower left side the steering head.
Of the crankcase. CARBURETOR IDENTIFlCAT1ON NUMBER The carburetor identification number is stamped on the left side of the carburetor body. 1-3GENERAL INFORMA TION MODEL IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER The frame serial number is stamped on the right side of The engine serial number is stamped on the lower left side the steering head. Of the crankcase.
CARBURETOR IDENTIFICATION NUMBER The carburetor identification number is stamped on the left side of the carburetor body.