Honda CB HORNET 160R 2015 User Manual

Honda CB HORNET 160R 2015

336 pages

To Next Page

To Next Page

Page #1 background image

Loading...

Page #1 background image

SHOP MANUAL

CB HORNET 160R

CB HORNET 160R

Table of Contents

Important Safety Precautions2
How to Use this Manual3
Contents3
Symbols4
General Information Contents5
Service Rules5
- Table of Contents5
- Abbreviation5
Model Identification6
Color Label7
Serial Numbers7
General Specifications8
Lubrication System Specifications9
Fuel System Specifications9
Cylinder Head/Valves Specifications9
Clutch/Gearshift Linkage Specifications10
Cylinder/Piston Specifications10
Alternator/Starter Clutch Specifications10
Crankcase Crankshaft/ Transmission/Kickstarter Specifications11
Front Wheel/Suspension/ Steering Specifications11
Rear Wheel/Suspension Specifications12
Brake System Specifications12
Battery/Charging System Specifications12
Electrical Starter Specification13
Ignition System Specifications13
Lights/Meter/Switches Specifications13
Engine and Frame Torque Values14
Standard Torque Values14
- Frame16
- Lubrication and Seal Points17
- Cable and Harness Routing19
- CBS Type21
- STD Type22
- Crankace Emission Control System26
- Emission Control System26
- Source of Emissions26
- Exhaust Emission Control System27
- Noise Emission Control System27
- Oxidation Catalytic Converter27
- Secondary Air Supply System27
- Evaporative Emission Control System28
- Frame/Body Panels/Exhaust System Contents29
- Service Information29
- Torque Values29
- Troubleshooting29
- Cover Headlight RR30
- Front Cowl Disassembly30
- Fuel Tank Assembly31
- Left Side Cover31
- Right Side Cover31
- Seat31
  - Fuel Tank32
  - Fuel Tank Center Cover32
  - Fuel Tank Left and Right Side Cover32
- Front Fender33
- Rear Garnish Set34
- Rear Grip34
- Rear Cowl35
- Rear Fender35
- Exhaust Pipe/Muffler36
- Sari Guard36
- Side Stand36
- Muffler Protector37
  - Stud Bolt Replacement37
  - Maintenance Contents39
  - Tools40
  - Maintenance Schedule41
- Fuel Line42
- Fuel Strainer Screen42
- Choke Operation43
- Minor/Major Adjustment43
- Throttle Operation43
  - Air Cleaner Element44
  - Torque44
- Crankcase Breather45
- Spark Plug45
- Valve Clearance46
- Engine Oil48
  - Oil Level Inspection48
  - Recommended Engine Oil48
  - Engine Oil Change49
  - Engihne Oil Centrifugal Filter50
- Engine Oil Strainer Screen50
- Engine Idle Speed52
- Secondary Air Supply System52
- Evaporative Emission Control System53
- Drive Chain Slack Inspection54
- Battery56
- Brake Fluid56
  - Sprocket56
  - Front Brake Fluid Level Inspection57
  - Rear Brake Fluid Level Inspection57
  - Brake Pad Wear58
  - Front Brake Pads58
  - Rear Brake Free Play Adjustment58
- Brake System59
  - Front Brake59
  - Front/Rear Brake Pads59
  - Rear Brake Shoes59
- Brake Light Switch60
- Clutch System60
- Headlight Aim60
  - Rear Brake60
  - Front/Rear Suspension Inspection61
- Side Stand61
- Front/Rear Wheel62
- Nuts, Bolts, Fasteners62
- Wheels/Tires62
- Recommended Tire Pressure and Tire Size63
- Steering Head Bearings63
  - Lubrication System Diagram64
  - Lubrication System Contents65
  - Oil Pump66
  - Oil Pump Assembly69
  - Component Location72
  - Fuel System Components73
  - Air Cleaner Housing75
  - Starting Enrichment Valve77
  - Carburetor78
  - Throttle Cable Stay79
  - Vacuum Chamber79
  - Float80
  - Jets81
  - Starting Enrichment Valve Cover81
  - Carburetor Assembly82
  - Carburetor Cleaning82
  - Pilot Screw Adjustment87
  - Adjustment by Concentration Measurement88
  - Idle Drop Procedure90
  - Pair Check Valve Inspection91
  - System Inspect91
  - One Way Valve92
  - Pair Control Valve92
  - Canister Component93
  - Fuel Strainer94
  - Engine Removal/Installation97
  - Cylinder Head/Valves105
  - Cylinder Compression108
  - Cylinder Head Cover108
  - Camshaft110
  - Cam Lobe112
  - Camshaft Bearing112
  - Cylinder Head Removal114
  - Rocker Arm115
  - Cylinder Head Disassembly/Assembly116
  - Cylinder Head117
  - Valve117
  - Valve Guide117
  - Valve Spring117
  - Valve Guide Replacement118
  - Valve Seat Inspection119
  - Valve Seat Refacing120
  - Assembly122
  - Cylinder Head Installation123
  - Cam Chain Tensioner Lifter125
  - Cylinder/Piston Contents129
  - Cylinder Inspection130
  - Cylinder Removal130
  - Piston Removal131
  - Piston Inspection132
  - Piston Installation134
  - Cylinder Installation135
  - Clutch/Gearshift Linkage Contents139
  - Right Crankcase Cover141
  - Clutch144
  - Clutch Center146
  - Clutch Lifter Bearing146
  - Clutch Spring146
  - Friction Disc146
  - Clutch Outer/Outer Guide147
  - Clutch Plate147
  - Gearshift Linkage150
  - Primary Drive Gear152
  - Balancer Drive Gear153
  - Alternator Contents155
  - Left Crankcase Cover156
  - Flywheel158
  - Starter Clutch160
  - Starter Motor162
  - Stator/Ignition Pulse Generator170
  - Crankcase/Transmission/Kickstarter Contents173
  - Balancer Gear Removal176
  - Crankcase Separation176
  - Balancer Gear Inspection177
  - Transmission178
  - Gears179
  - Mainshaft/Countershaft179
  - Crankshaft180
  - Crankshaft Runout180
  - Shift Fork180
  - Shift Fork Shaft180
  - Big End Radial Clearance181
  - Big End Side Clearance181
  - Crankshaft/Balancer Bearing Inspection181
  - Timing Sprocket181
  - Oil Passages Inspection183
  - Right/Left Crankcase183
  - Bearing Replacement of Crankshaft184
  - Mainshaft186
  - Countershaft187
  - Crankcase Assembly189
  - Kickstarter193
  - Front Wheel/Suspension/Steering Contents197
  - Handlebar200
  - Front Wheel205
  - Axle206
  - Wheel Bearing206
  - Brake Disc207
  - Wheel Rim207
  - Fork210
  - Fork Pipe/Slider213
  - Fork Piston/Rebound Spring/Oil Lock Piece213
  - Fork Spring213
  - Fork Assembly214
  - Guide Bushing/Slider Bushing/Back-Up Ring214
  - Steering Stem218
  - Ball Race Replacement220
  - Bottom Cone Race Replacement220
  - Steering Stem Assembly221
  - Steering Bearing Preload223
  - Rear Wheel/Suspension Contents225
  - Disc Type228
  - Drum Type228
  - Rear Wheel228
  - Wheel Bearing Removal229
  - Wheel Balance230
  - Assembly of Disc Brake231
  - Assembly of Drum Brake231
  - Driven Flange233
  - Driven Sprocket233
  - Driven Flange Baring234
  - Driven Flange Assembly235
  - Shock Absorber236
  - Swingarm237
  - CBS Front/Rear Brake244
  - Brake System Contents245
  - Brake Fluid Draining Front Disc Brake247
  - Brake Fluid Line247
  - Brake Fluid Replacement/Air Bleeding247
  - Brake Fluid Filling/Air Bleeding Front Brake248
  - CBS Brake Line248
  - Combi Brake System248
  - Rear Brake Line248
  - CBS Brake250
  - Brake Pad/Disc251
  - Front Brake Pad Replacement251
  - Front Brake Disc Inspection252
  - Front Master Cylinder253
  - Installation of Master Cylinder257
  - CBS Front Brake258
  - Front Brake Caliper258
  - CBS Front Brake Assembly259
  - Non CBS Front Brake260
  - Front Brake (Non CBS) Assembly262
  - Rear Disk Brake Pad Replacement263
  - Rear Brake Disc Inspection264
  - Rear Master Cylinder (CBS)265
  - Rear Master Cylinder Assembly266
  - Brake Pedal Height267
  - Rear Brake Caliper268
  - Rear Brake Caliper Assembly270
  - Brake Pedal271
  - Rear Drum Brake274
  - Rear Drum Brake Assembly275
  - Battery/Charging System Contents279
  - Battery Testing Procedure281
  - Voltage Inspection281
  - Battery Load Test282
- Battery Charging283
  - Battery Test Result283
  - Current Leakage Inspection285
- Indication Table for MF Battery Charger285
- System Inspection285
- Alternator Charging Coil286
- Charging Voltage Inspection286
- Regulator/Rectifier287
- Ignition System Diagram288
- Ignition System Contents289
- Ignition Coil Primary Peak Voltage291
- Ignition System Inspection291
- Ignition Pulse Generator Peak Voltage292
- Ignition Timing293
- Ignition Coil294
- CDI294
- Throttle Position Sensor295
- Input Voltage295
- Initialization Procedure296
- Lights/Meters/Switches Contents301
- Headlight302
- Bulb Replacement302
- Brake/Tail Light303
- Headlight Unit303
- LED Unit Replacement303
- Number Plate Light Bulb303
- Turn Signal Lights304
- Bulbs Replacement304
- Back-Up Voltage Line305
- Power Input Line305
- Power/Ground Line Inspection305
- Combination Meter305
- Combination Meter Assembly306
- Speedometer VS Sensor307
- Vehicle Speed Sensor307
- Tachometer308
- Digital Meter Reset Procedure309
- Tripmeter309
- Digital Clock309
- Combination Switch310
- Handlebar Switches311
- Left Handlebar Switch311
- Neutral Switch312
- Fuel Gauge/Fuel Level Sensor314
- Horn316
- Passing Relay316
- Turn Signal Relay317
- Fuse Box318
- Electric Starter Component320
- Electric Starter System Contents321
- Starter Relay Switch323
- Operation Inspection323
- Circuit Inspection323
- Ground Line323
- Neutral Diode324
- Function Inspection324
- Right Handlebar Switches325
- Clutch Switch325
- Wiring Diagram327
- Troubleshooting Contents328
- Engine Does Not Start or Is Hard to Start328
- Engine Lacks Power329
- Poor Performance at Low and Idle Speed331
- Poor Performance at High Speed332
- Poor Handling332
- Index334

Questions and Answers:

Need help?

Do you have a question about the Honda CB HORNET 160R 2015 and is the answer not in the manual?

Honda CB HORNET 160R 2015 Specifications

General

Brand	Honda
Model	CB HORNET 160R 2015
Category	Motorcycle
Language	English

Related product manuals

Preview: Honda CB Hornet 160R

Honda CB Hornet 160R

Preview: Honda CB Hornet 2016

Honda CB Hornet 2016

Preview: Honda CB 600F Hornet 2007

Honda CB 600F Hornet 2007

Honda CB 600F Hornet 2008

Preview: Honda CB 900-F

Preview: Honda CB TWISTER

Honda CB TWISTER

Preview: Honda CB 1100 2017

Honda CB 1100 2017

Honda Nighthawk CB 750 1993

Honda Nighthawk CB 750 1998

Honda Nighthawk CB 750 1995

Honda Nighthawk CB 750 1992

Preview: Honda CB UNICORN DAZZLER 2010

Honda CB UNICORN DAZZLER 2010