2004-2006 Honda CBR 125 & CBR 125R Service & Repair Manual

TYPE CODE Throughout this manual, the following abbreviations are used to identify individual model. CODE AREA TYPE E U.K. (Ireland) F France ED EUROPEAN DIRECT SALES (Austria, Switzerland, Belgium, Germany, Portugal, Italy, Spain, Israel) U Australia II G Germany II CM Canada

A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer’s Safety Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: • Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. • Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. • Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. • Never drain or store gasoline in an open container. • Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts. Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully. • Use only a non-flammable solvent, not gasoline, to clean parts. • Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.

Date of Issue: March, 2007 ©Honda Motor Co., Ltd. HOW TO USE THIS MANUAL This service manual describes the service procedures for the CBR125RW. Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Section 4 through 19 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 illustration, 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 section 21 Troubleshooting. Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: • Safety Labels – on the vehicle • Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. • Instructions – how to service this vehicle correctly and safely. As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LAT- EST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI- GATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITH- OUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTE- NANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE CONTENTS GENERAL INFORMATION BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM (PGM-FI) COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKSHAFT/BALANCER/TRANSMISSION FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION 14 13 12 11 10 9 8 7 6 5 4 2 3 1 HYDRAULIC BRAKE BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER 18 17 16 15 ENGINE CHASSIS ELECTRICAL LIGHTS/METERS/SWITCHES WIRING DIAGRAMS TROUBLESHOOTING INDEX 19 20 21 22

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 the recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #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. Apply locking agent. Use a medium 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.

1-1 1 1. GENERAL INFORMATION SERVICE RULES ········································· 1-2 MODEL IDENTIFICATION··························· 1-2 GENERAL SPECIFICATIONS······················ 1-5 LUBRICATION SYSTEM SPECIFICATIONS········································ 1-7 FUEL SYSTEM (PGM-FI) SPECIFICATIONS········································ 1-7 COOLING SYSTEM SPECIFICATIONS ······ 1-7 CYLINDER HEAD/VALVES SPECIFICATIONS········································ 1-8 CYLINDER/PISTON SPECIFICATIONS ······ 1-8 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS········································ 1-8 ALTERNATOR/STARTER CLUTCH SPECIFICATIONS········································ 1-9 CRANKSHAFT/BALANCER/TRANSMISSION SPECIFICATIONS········································ 1-9 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS······································ 1-10 REAR WHEEL/SUSPENSION SPECIFICATIONS ····································· 1-10 HYDRAULIC BRAKE SPECIFICATIONS··· 1-10 BATTERY/CHARGING SYSTEM SPECIFICATIONS ····································· 1-11 IGNITION SYSTEM SPECIFICATIONS ···· 1-11 ELECTRIC STARTER SPECIFICATION····· 1-11 LIGHTS/METERS/SWITCHES SPECIFICATIONS ····································· 1-11 STANDARD TORQUE VALUES··············· 1-12 ENGINE & FRAME TORQUE VALUES ···· 1-12 LUBRICATION & SEAL POINTS ·············· 1-16 CABLE & HARNESS ROUTING ··············· 1-18 EMISSION CONTROL SYSTEMS (Except CM type) ····································· 1-30 EMISSION CONTROL SYSTEMS (CM type only)·········································· 1-32

2004-2006 Honda CBR 125 & CBR 125R Service & Repair Manual

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