Honda PCX150 2016 - HYDRAULIC BRAKE

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COMPONENT LOCATION

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19-2

PAD/DISC

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INFORMATION······

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19-3

TROUBLESHOOTING

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19-4

CBS MASTER CYLINDER···

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19-16

BRAKE FLUID REPLACEMENT/

BRAKE CALIPER .. ···

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AIR BLEEDING · .. · · ...... · · · · · · · · · · .... · · · · · .... · 19-5

Main Page

Ho to Use this Manual3
Contents5
General Information7
Service Rules8
Abbreviation8
Model Identification9
Serial Numbers9
Labels10
General Specifications12
Cylinder/Piston Specifications15
Standard Torque Values17
Engine & Frame Torque Values17
General Information20
Lubrication and Seal Points23
Cable and Harness Routing Diagrams - '13 Model25
Cable and Harness Routing Diagrams - after '13 Model31
Technical Feature - after '13 Model40
Fuel Pump System with a Fuel Filter Blockage Reminder Function40
Crankcase Emission Control Systems41
Exhaust Emission Control Systems42
Evaporative Emission Control System - Except after '13 Model CM Type42
Fuel Permeation Emission Control System42
Noise Emission Control System42
Frame, Body Panels, Exhaust System43
Frame, Body Panels, Exhaust System Service Information44
Frame, Body Panels, Exhaust System Torque Values44
Frame, Body Panels, Exhaust System Troubleshooting44
Body Panel Locations - '13 Model45
Body Panel Removal Chart - '13 Model45
Body Panel Locations - after '13 Model46
Body Panel Removal Chart - after '13 Model46
Front Fender Removal/Installation47
Front Grille Removal/Installation47
Meter Visor Removal/Installation48
Front Meter Panel Removal/Installation49
Floor Mat Removal/Installation49
Side Cover Removal/Installation50
Under Cover Removal/Installation51
Seat Removal/Installation52
Center Cover Removal/Installation52
Meter Panel Cover Removal/Installation53
Right Inner Maintenance Lid Removal/Installation53
Left Inner Outer Cover Removal/Installation54
Right Inner Outer Cover Removal/Installation54
Inner Cover Removal/Installation55
Handlebar Front Cover Removal/Installation56
Rear Meter Panel Removal/Installation56
Front Cover Removal/Installation57
Front Lower Cover Removal/Installation59
Plug Maintenance Lid Removal/Installation60
Floor Step Removal/Installation61
Grab Rail Cover Removal/Installation62
Grab Rail Removal/Installation63
Body Cover Removal/Installation65
Luggage Box Removal/Installation67
Battery Box Removal/Installation68
Rear Fender Removal/Installation69
Exhaust Pipe/Muffler Removal/Installation70
Centerstand Removal/Installation70
Maintenance73
Maintenance - Service Information74
Maintenance - Specifications74
Maintenance Schedule76
Fuel Line78
Throttle Operation78
Air Cleaner79
Crankcase Breather80
Spark Plug81
Valve Clearance Inspection82
Engine Oil Level Check83
Engine Oil Strainer Screen84
Oil Change84
Engine Idle Speed85
Radiator Coolant85
Cooling System86
Evaporative Emission Control System Maintenance87
Drive Belt87
Final Drive Oil Level Check/Change88
Brake Fluid89
Front Brake Line89
CBS Brake Line89
Front Disc Brake Pads89
Brake System90
Rear Drum Brake Shoes90
Front Disc Brake90
Rear Drum Brake90
Cbs91
Rear Brake Light Switch92
Front Brake Light Switch92
Brake Lock Operation93
Headlight Aim94
Clutch Shoes Wear95
Sidestand95
Suspension95
Nuts, Bolts, Fasteners96
Wheels/Tires96
Steering Head Bearings97
PGM-FI System99
PGM-FI System Location Diagram100
PGM-FI System Diagram102
PGM-FI System Service Information104
PGM-FI System Specifications104
PGM-FI Symptom Troubleshooting105
PGM-FI Connector Location107
PGM-FI Troubleshooting108
DTC - Diagnostic Trouble Code108
MIL Blink Pattern108
MIL Check108
MCS Tester Information109
DTC Readout109
Pgm-Fi System109
Erasing DTC110
Inspection at ECM Connector110
PGM-FI Troubleshooting - after '13 Model111
System Description111
DTC Index - '13 Model113
DTC Index - after '13 Model114
DTC Troubleshooting - '13 Model115
DTC 1-2 - MAP Sensor High Voltage117
DTC 7-1 - ECT Sensor Low Voltage118
DTC 7-2 - ECT Sensor High Voltage119
DTC 8-1 - TP Sensor Low Voltage120
DTC 8-2 - TP Sensor High Voltage122
DTC 9-1 - IAT Sensor Low Voltage123
DTC 9-2 IAT Sensor High Voltage124
DTC 12-1 Fuel Injector125
Pgm-Fi System125
DTC 21-1 O2 Sensor127
Dtc 29-1 Iacv128
DTC 52-1 - CKP Sensor130
Sensor Unit Power Line Inspection - after '13 Model131
Before DTC Troubleshooting131
DTC Troubleshooting - after '13 Model132
DTC 1-1 - MAP Sensor Low Voltage132
DTC 7-1 ECT Sensor Low Voltage134
DTC 7-2 ECT Sensor High Voltage135
DTC 8-1 TP Sensor Low Voltage136
DTC 8-2 TP Sensor High Voltage137
DTC 9-1 IAT Sensor Low Voltage138
DTC 9-2 - IAT Sensor High Voltage139
DTC 12-1 - Fuel Injector140
Dtc 33-2 - Eeprom144
DTC 52-1 CKP Sensor144
MIL Circuit Inspection - '13 Model145
MIL Circuit Inspection - after '13 Model146
ECM Removal/Installation147
ECM Inspection148
ECT Sensor Removal/Installation150
ECT Sensor Inspection150
O2 Sensor Removal151
O2 Sensor Installation152
O2 Removal/Installation - after '13 Model153
Ignition System155
Ignition System Location Diagram156
Ignition System Diagram157
Ignition System Service Information158
Ignition System Specifications158
Ignition System Troubleshooting159
Ignition System Inspection160
Ignition Coil Primary Peak Voltage160
Ignition Coil Removal/Installation161
Ignition Timing161
Electrical Starter163
Electrical Starter System Location Diagram164
Electrical Starter System Diagram165
Electrical Starter Service Information166
Torque Value166
Electrical Starter Troubleshooting167
Starter/Charging Relay Removal/Installation170
Starter/Charging Relay Operation Inspection170
Relay Switch Line Inspection171
Relay Coil Line Inspection171
Continuity Inspection172
Starter System Inspection173
CKP Sensor Line Inspection173
Stator Inspection173
Starter Switch Line Inspection174
Sidestand Switch Removal/Installation175
Sidestand Switch Inspection175
Fuel System177
Fuel System Component Location Diagram178
Fuel System Service Information180
Fuel System Specifications180
Torque Values180
Fuel System - Tools Needed181
Fuel Line Inspection182
Fuel Pressure Relieving182
Quick Connect Fitting Removal182
Quick Connect Fitting Installation183
Fuel Pressure Normalization183
Fuel Pressure Test184
Fuel Supply Test - after '13 Model185
Fuel Flow Inspection185
Fuel Pump Unit Inspection186
Fuel Pump Unit Removal186
Fuel Filter Replacement187
Fuel Pump Installation188
Fuel Tank Removal/Installation189
Air Cleaner Housing Removal/Installation189
Throttle Body Removal191
Throttle Body Disassembly192
Throttle Body Cleaning193
Throttle Body Assembly193
Throttle Body Installation195
TP Sensor Reset Procedure197
IACV Removal/Installation198
IACV Inspection199
Fuel Injector Removal200
Fuel Injector Installation200
Intake Pipe Removal201
Intake Pipe Installation201
EVAP Purge Control Solenoid Valve Removal/Installation203
EVAP Purge Control Solenoid Valve Inspection203
EVAP Canister Removal/Installation204
Lubrication System205
Lubrication System Diagram206
Lubrication System Service Information207
Lubrication System Specifications207
Lubrication System Troubleshooting208
Oil Pump Removal209
Oil Pump Inspection210
Right Crankshaft Oil Seal Inspection/Replacement211
Right Crankshaft Oil Seal Installation211
Cooling System Flow Pattern214
Cooling System Service Information215
Cooling System Specifications215
Cooling System Troubleshooting215
Cooling System Testing216
Radiator Cap/System Pressure Inspection216
Coolant Replacement/Air Bleeding217
Radiator Removal/Installation218
Radiator Reserve Tank Removal/Installation219
Water Pump/Thermostat220
Mechanical Seal Inspection220
Water Pump/Thermostat Removal/Disassembly220
Thermostat Inspection221
Cooling System Assembly/Installation222
Cylinder Head/Valves225
Cylinder Head/Valves Component Location Diagram226
Cylinder Head/Valves Service Information227
Cylinder Head/Valves Specifications227
Cylinder Head/Valves - Tools Needed228
Cylinder Head/Valves Troubleshooting229
Cylinder Compression Test230
Cylinder Head Cover Removal230
Cylinder Head Cover Installation231
Camshaft Removal232
Camshaft Inspection233
Camshaft Installation234
Cylinder Head Removal237
Cylinder Head Disassembly238
Cylinder Head Inspection239
Valve Spring Inspection239
Valve/Valve Guide Inspection239
Cam Chain Guide Check240
Valve Guide Replacement241
Valve Seat Inspection/Refacing242
Seat Width242
Cylinder Head Assembly244
Cylinder Head Installation246
Cam Chain Tensioner Lifter Removal247
Cam Chain Tensioner Lifter Inspection247
Cam Chain Tensioner Lifter Installation247
Cylinder/Piston249
Cylinder/Piston Component Location Diagram250
Cylinder/Piston Service Information251
Cylinder/Piston Specifications251
Cylinder/Piston Troubleshooting252
Cylinder Removal253
Cylinder Inspection253
Stud Bolt Replacement254
Installation254
Piston Removal255
Piston Inspection256
Piston Installation257
Drive Pulley/Driven Pully/Clutch259
Drive Pulley/Driven Pully/Clutch Component Location Diagram260
Drive Pulley/Driven Pully/Clutch Service Information261
Drive Pulley/Driven Pully/Clutch Specifications261
Drive Pulley/Driven Pully/Clutch - Tools Needed262
Drive Pulley/Driven Pully/Clutch Troubleshooting263
Left Crankcase Cover Removal264
Bearing Inspection/Replacement264
Left Crankcase Cover Installation266
Drive Belt Replacement266
Drive Pulley Removal267
Drive Pully Disassembly/Assembly267
Drive Pulley Inspection268
Drive Pulley Face Check268
Drive Pulley Installation269
Weight Roller Check269
Drive Face Boss Check269
Movable Drive Face Check269
Clutch/Driven Pulley Removal270
Clutch/Driven Pulley Disassembly271
Clutch/Driven Pulley Inspection272
Driven Face Spring Check273
Driven Face Check273
Movable Driven Face Check273
Drive Pulley/Driven Pulley/Clutch273
Driven Face Bearing Replacement274
Clutch/Driven Pulley Assembly275
Clutch/Driven Pulley Installation278
Final Reduction279
Final Reduction Component Location280
Final Reduction Service Information281
Final Reduction Specifications281
Final Reduction - Tools Needed282
Final Reduction Troubleshooting283
Final Reduction Case Separation284
Final Reduction Inspection284
Gear/Shaft285
Driveshaft Check285
Counter Gear/Countershaft/Final Gear Shaft285
Final Reduction Bearing Replacement286
Left Crankcase286
Driveshaft287
Final Reduction Case289
Final Reduction Case Assembly290
Alternator/Starter291
Alternator/Starter Component Location292
Alternator/Starter Service Information293
Alternator/Starter Removal294
Alternator/Starter Installation296
Crankcase/Crankshaft299
Crankcase/Crankshaft Component Location300
Crankcase/Crankshaft Service Information301
Crankcase/Crankshaft Specifications301
Crankcase/Crankshaft - Tools Needed302
Crankcase/Crankshaft Troubleshooting302
Crankcase Separation303
Crankshaft Inspection305
Crankcase Assembly306
Cam Chain Tensioner Slider Inspection306
Engine Removal/Installation311
Engine Removal/Installation - Component Location312
Engine Removal/Installation Service Information313
Engine Removal/Installation Specifications313
Engine Removal314
Engine Removal/Installation315
Engine Hanger Link Removal/Installation316
Engine Hanger Link Inspection316
Engine Installation317
Front Wheel/Suspension/Steering321
Front Wheel/Suspension/Steering Component Location322
Front Wheel/Suspension/Steering Service Information323
Front Wheel/Suspension/Steering Specifications323
Front Wheel/Suspension/Steering - Tools Needed324
Front Wheel/Suspension/Steering Troubleshooting325
Front Wheel Removal326
Front Wheel Inspection326
Front Wheel Disassembly/Assembly327
Wheel Bearing Replacement327
Front Wheel Installation328
Fork Removal328
Fork Disassembly329
Fork Inspection332
Fork Spring Check332
Fork Pipe/Slider/Piston Check332
Fork Assembly333
Fork Pipe Bushing/Back-Up Ring Check333
Fork Installation336
Handlebar Removal337
Handlebar Installation340
Handlebar Post Removal/Installation343
Steering Stem Removal344
Steering Stem Bearings Replacement345
Steering Stem Installation347
Rear Wheel/Brake/Suspension349
Rear Wheel/Brake/Suspension Component Location350
Rear Wheel/Brake/Suspension Service Information351
Rear Wheel/Brake/Suspension Specifications351
Rear Wheel/Brake/Suspension - Tools Needed351
Rear Wheel/Brake/Suspension Troubleshooting352
Rear Wheel/Swingarm Removal353
Rear Wheel/Swingarm Installation354
Wheel Inspection355
Swingarm Bearing Inspection/Replacement355
Rear Drum Brake Inspection356
Rear Drum Brake Disassembly356
Rear Drum Brake Assembly358
Rear Shock Absorber Removal/Installation360
Rear Shock Absorber Inspection360
Hydraulic Brake361
Hydraulic Brake Component Location362
Hydraulic Brake Service Information363
Hydraulic Brake Specifications363
Hydraulic Brake Troubleshooting364
Brake Fluid Replacement/Air Bleeding365
Brake Fluid Draining365
Hydraulic Brake366
Brake Fluid Filling/Air Bleeding367
Brake Pad/Disc370
Brake Pad Replacement370
Brake Disc Inspection371
Brake Master Cylinder Removal372
Brake Master Cylinder Disassembly372
Brake Master Cylinder Inspection373
Brake Master Cylinder Assembly374
Brake Master Cylinder Installation375
CBS Master Cylinder Removal376
CBS Master Cylinder Disassembly377
CBS Master Cylinder Inspection379
CBS Master Cylinder Assembly379
CBS Master Cylinder Installation382
Brake Caliper Removal383
Brake Caliper Disassembly383
Brake Caliper Inspection384
Brake Caliper Assembly385
Brake Caliper Installation386
Battery/Charging System387
Battery/Charging System Location Diagram388
Battery/Charging System Diagram389
Battery/Charging System Service Information390
Battery Charging390
Battery Testing390
Battery/Charging System Specifications391
Battery/Charging System Troubleshooting392
Battery Removal/Installation393
Voltage Inspection394
Current Leakage Test394
Charging Voltage Inspection395
Charging Line Inspection395
Starter/Charging Relay Inspection396
Lights/Meters/Switches397
Electrical System Location Diagram398
Lights/Meters/Switches Service Information400
Lights/Meters/Switches Specifications400
Lights/Meters/Switches Torque Values401
Headlight - '13 Model402
Bulb Removal/Installation402
Headlight Inspection402
Headlight Removal/Installation402
Combination Light Removal/Installation/Inspection - after '13 Model403
Turn Signal Light - '13 Model403
Tail/Brake Light - '13 Model404
Turn Signal Light Unit Removal/Installation404
License Light Bulb Replacement405
License Light Unit Removal/Installation405
Speedometer Removal/Installation - '13 Model406
License Light Unit Inspection406
Speedometer Disassembly/Assembly - '13 Model406
Speedometer Inspection407
Combination Meter Inspection - after '13 Model408
Serial Communication Line Inspection409
Combination Meter Removal/Installation410
Combination Meter Disassembly/Assembly410
Fuel Gauge Inspection - after '13 Model411
Average Fuel Mileage Inspection - after '13 Model411
VS Sensor Removal/Installation412
VS Sensor Inspection413
Coolant Temperature Indicator Inspection414
System Inspection414
Fuel Meter/Fuel Level Sensor Inspection415
Fuel Level Sensor Removal/Installation416
Float Position416
Ignition Switch - Fuel Lid/Seat Opener Removal/Installation417
Ignition Switch Removal417
Ignition Switch Installation418
Ignition Switch Inspection418
Handlebar Switch Inspection420
Brake Light Switch Inspection421
Horn Removal/Installation421
Accessory Socket Removal/Installation - after '13 Model422
Horn Inspection422
Main Relay Removal/Installation423
Main Relay Continuity Inspection423
Turn Signal Light Relay Inspection - '13 Model424
LED Control Unit Removal/Installation - after '13 Model424
Input Voltage Inspection425
Output Voltage Inspection425
Wiring Diagram '13 Model431
Wiring Diagram after '13 Model433
Index435

Honda PCX150 2016 - HYDRAULIC BRAKE

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