cbhornet160r2015

SHOPMANUALCBHORNET160RCBHORNET160RFailuretoproperlyfollowinstructionsandprecautionscancauseyoutobeseriouslyhurtorkilled.Followtheproceduresandprecautionsinthismanualcarefully.AFewWordsAboutSafetyServiceinformationTheserviceandrepairinformationcontainedinthismanualisintendedforusebyqualified,professionaltechnicians.Attemptingserviceorrepairswithoutthepropertraining,tools,andequipmentcouldcauseinjurytoyouorothers.Itcouldalsodamagethevehicleorcreateanunsafecondition.Thismanualdescribesthepropermethodsandproceduresforperformingservice,maintenance,andrepairs.Someproceduresrequiretheuseofspeciallydesignedtoolsanddedicatedequipment.Anypersonwhointendstouseareplacementpart,serviceprocedureoratoolthatisnotrecommendedbyHonda,mustdeterminetheriskstotheirpersonalsafetyandthesafeoperationofthevehicle.Ifyouneedtoreplaceapart,usegenuineHondapartswiththecorrectpartnumberoranequivalentpart.Westronglyrecommendedthatyoudonotusereplacementpartsofinferiorquality.Improperserviceorrepairscancreateanunsafeconditionthatcancauseyourcustomerorotherstobeseriouslyhurtorkilled.Followtheproceduresandprecautionsinthismanualandotherservicematerialscarefully.ForYourCustomer’sSafetyProperserviceandmaintenanceareessentialtothecustomer’ssafetyandthereliabilityofthevehicle.Anyerrororoversightwhileservicingavehiclecanresultinfaultyoperation,damagetothevehicle,orinjurytoothers.ForYourSafetyBecausethismanualisintendedfortheprofessionalservicetechnician,wedonotprovidewarningsaboutmanybasicshopsafetypractices(e.g,.Hotparts–weargloves).Ifyouhavenotreceivedshopsafetytrainingordonotfeelconfidentaboutyourknowledgeofsafeservicingpractice,werecommendedthatyoudonotattempttoperformtheproceduresdescribedinthismanual.Someofthemostimportantgeneralservicesafetyprecautionsaregivenbelow.However,wecannotwarnyouofeveryconceivablehazardthatcanariseinperformingserviceandrepairprocedures.Onlyyoucandecidewhetherornotyoushouldperformagiventask.ImportantSafetyPrecautionsMakesureyouhaveaclearunderstandingofallbasicshopsafetypracticesandthatyouarewearingappropriateclothingandusingsafetyequipment.Whenperforminganyservicetask,beespeciallycarefulofthefollowing:•Readalloftheinstructionsbeforeyoubegin,andmakesureyouhavethetools,thereplacementorrepairparts,andtheskillsrequiredtoperformthetaskssafelyandcompletely.•Protectyoureyesbyusingpropersafetyglasses,gogglesorfaceshieldsanytimeyouhammer,drill,grind,pryorworkaroundpressurizedairorliquids,andspringsorotherstored-energycomponents.Ifthereisanydoubt,putoneyeprotection.•Useotherprotectivewearwhennecessary,forexampleglovesorsafetyshoes.Handlinghotorsharppartscancausesevereburnsorcuts.Beforeyougrabsomethingthatlookslikeitcanhurtyou,stopandputongloves.•Protectyourselfandotherswheneveryouhavethevehicleupintheair.Anytimeyouliftthevehicle,eitherwithahoistorajack,makesurethatitisalwayssecurelysupported.Usejackstands.Makesuretheengineisoffbeforeyoubeginanyservicingprocedures,unlesstheinstructiontellsyoutodootherwise.Thiswillhelpeliminateseveralpotentialhazards:•Carbonmonoxidepoisoningfromengineexhaust.Besurethereisadequateventilationwheneveryouruntheengine.•Burnsfromhotpartsorcoolant.Lettheengineandexhaustsystemcoolbeforeworkinginthoseareas.•Injuryfrommovingparts.Iftheinstructiontellsyoutoruntheengine,besureyourhands,fingersandclothingareoutoftheway.Gasolinevaporsandhydrogengasesfrombatteriesareexplosive.Toreducethepossibilityofafireorexplosion,becarefulwhenworkingaroundgasolineorbatteries.•Useonlyanonflammablesolvent,notgasoline,tocleanparts.•Neverdrainorstoregasolineinanopencontainer.•Keepallcigarettessparksandflamesawayfromthebatteryandallfuel-relatedparts.HOWTOUSETHISMANUALThisservicemanualdescribestheserviceproceduresfortheCBF160MG.FollowtheMaintenanceSchedule(Section3)recommendationstoensurethatthevehicleisinpeakoperatingcondition.Performingthefirstscheduledmaintenanceisveryimportant.Itcompensatesfortheinitialwearthatoccursduringthebreak-inperiod.Sections1and3applytothewholevehicle.Section2illustratesproceduresforremoval/installationofcomponentsthatmayberequiredtoperformservicedescribedinthefollowingsections.Section4through18describepartsofthevehicle,groupedaccordingtolocation.Findthesectionyouwantonthispage,thenturntothetableofcontentsonthefirstpageofthesection.Mostsectionsstartwithanassemblyorsystemillustration,serviceinformationandtroubleshootingforthesection.Thesubsequentpagesgivedetailedprocedures.Ifyoudon’tknowthesourceofthetrouble,gotosection20Troubleshooting.CONTENTSENGINEGENERALINFORMATIONFRAME/BODYPANELS/EXHAUSTSYSTEMMAINTENANCELUBRICATIONSYSTEMCYLINDER/PISTONCLUTCH/GEARSHIFTLINKAGEFUELSYSTEMENGINEREMOVAL/INSTALLATIONCYLINDERHEAD/VALVESALTERNATORMonthofIssue:November,2015©HondaMotorCo.,Ltd.CRANKCASE/TRANSMISSION/KICKSTARTERBATTERY/CHARGINGSYSTEMREARWHEEL/SUSPENSIONCHASSISFRONTWHEEL/SUSPENSION/STEERINGBRAKESYSTEMELECTRICALINDEXWIRINGDIAGRAMTROUBLESHOOTINGIGNITIONSYSTEMLIGHTS/METERS/SWITCHESELECTRICSTARTERSYSTEM123467891011121314151617181920215Yoursafety,andthesafetyofothers,isveryimportant.Tohelpyoumakeinformeddecisionsweha