Honda CRF150L Owner'S Manual Download

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Throttle

Checking the Throttle

With the engine off, check that the throttle

rotates smoothly from fully closed to fully

open in all steering positions and throttle

freeplay is correct. If the throttle does not

move smoothly, close automatically, or if the

cable is damaged, have the motorcycle

inspected by your dealer.

Freeplay at the throttle grip flange:

2 - 6 mm (0.1 - 0.2 in)

20170928113120_32K84A000_eng_BOOK Page 73 Thursday, September 28 2017 11:34:27 JST

Maintenance

Freeplay

Flange

Summary of Contents for CRF150L

Page 1: ......

Page 2: ...le before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission The vehicle pictured in this owner s manual may not match your actual vehicle 2017 Honda Motor Co Ltd 20170928113120_32K84A000_eng_BOOK Page 1 Thursday September 28 2017 11 34 27 JST ...

Page 3: ...wner s manual carefully Follow all recommendations and procedures contained in this manual Pay close attention to safety messages contained in this manual and on the motorcycle The following codes in this manual indicate each country The illustrations here in are based on the CRF150L PH type Country Codes Code Country CRF150L IN Indonesia PH Philippines The specifications may vary with each locale...

Page 4: ...own good judgement You will find important safety information in a variety of forms including Safety labels on the motorcycle Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean 3DANGER You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions 3WARNING You CAN be KILLED or SERIOUSLY HURT if you don t follow i...

Page 5: ...Motorcycle Safety P 2 Operation Guide P 16 Maintenance P 31 Troubleshooting P 73 Information P 91 Specifications P 103 Index P 106 20170928113120_32K84A000_eng_BOOK Page 4 Thursday September 28 2017 11 34 27 JST ...

Page 6: ...ssories Modifications P 12 Off Road Safety P 13 Loading P 14 20170928113120_32K84A000_eng_BOOK Page 5 Thursday September 28 2017 11 34 27 JST This section contains important information for safe riding of your motorcycle Please read this section carefully Motorcycle Safety ...

Page 7: ...ee of alcohol and drugs Check that you and your passenger are both wearing an approved motorcycle helmet and protective apparel Instruct your passenger on holding onto the seat strap or your waist leaning with you in turns and keeping their feet on the footpegs even when the motorcycle is stopped Take Time to Learn Practice Even if you have ridden other motorcycles practice riding in a safe area t...

Page 8: ... to use good judgement and ride safely Don t Drink and Ride Alcohol and riding don t mix Even one alcoholic drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink Don t drink and ride and don t let your friends drink and ride either Keep Your Honda in Safe Condition It s important to keep your motorcycle properly maintained and...

Page 9: ...tinue riding first turn the ignition switch to the Off position and evaluate the condition of your motorcycle Inspect for fluid leaks check the tightness of critical nuts and bolts and check the handlebar control levers brakes and wheels Ride slowly and cautiously Your motorcycle may have suffered damage that is not immediately apparent Have your motorcycle thoroughly checked at a qualified servic...

Page 10: ...er run your motorcycle inside a garage or other enclosure 3WARNING Running the engine of your motorcycle while in an enclosed or even partially enclosed area can cause a rapid build up of toxic carbon monoxide gas Breathing this colourless odorless gas can quickly cause unconsciousness and lead to death Only run your motorcycle s engine when it is located in a well ventilated area outdoors 2017092...

Page 11: ...ty correct size for your head Must fit comfortably but securely with the chin strap fastened Face shield with unobstructed field of vision or other approved eye protection 3WARNING Not wearing a helmet increases the chance of serious injury or death in a crash Make sure that you and any passenger always wear an approved helmet and protective apparel Gloves Full finger leather gloves with high abra...

Page 12: ...ill need more serious off road gear In addition to your helmet and eye protection we recommend off road motorcycle boots and gloves riding pants with knee and hip pads a jersey with elbow pads and a chest shoulder protector 20170928113120_32K84A000_eng_BOOK Page 11 Thursday September 28 2017 11 34 27 JST Safety Precautions Motorcycle Safety 8 ...

Page 13: ... Where possible reduce speed before turning otherwise you risk sliding out Exercise caution on low traction surfaces u The tyres slip more easily on such surfaces and braking distances are longer Avoid continuous braking u Repeated braking such as when descending long steep slopes can seriously overheat the brakes reducing their effectiveness Use engine braking with intermittent use of the brakes ...

Page 14: ...while riding at low speed to help them dry Parking Park on a firm level surface If you must park on a slight incline or loose surface park so that the motorcycle cannot move or fall over Make sure that high temperature parts cannot come into contact with flammable materials Do not touch the engine muffler brakes and other high temperature parts until they cool down To reduce the likelihood of thef...

Page 15: ...e key 2 P 24 Refuelling and Fuel Guidelines Follow these guidelines to protect the engine fuel system and catalytic converter Use only unleaded petrol Use recommended octane number Using lower octane petrol will result in decreased engine performance Do not use fuels containing a high concentration of alcohol 2 P 101 Do not use stale or contaminated petrol or an oil petrol mixture Avoid getting di...

Page 16: ...tall accessories on your motorcycle be certain the modification is safe and legal 3WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding accessories and modifications Do not pull a trailer with or attach a sidecar to your motorcycle Your motorcycle was not designed for these attachments ...

Page 17: ...Familiarity with your motorcycle is critically important should a problem occur far from help Never ride beyond your ability and experience or faster than conditions warrant If you are not familiar with the terrain ride cautiously Hidden rocks holes or ravines could spell disaster A muffler is required in most off road areas Don t modify your exhaust system Remember that excessive noise bothers ev...

Page 18: ...muffler Also follow these guidelines when you ride off road on rough terrain Do not carry a passenger Keep cargo small and light weight Make sure it cannot easily be caught on brush or other objects and that it does not interfere with your ability to shift position to maintain balance and stability 3WARNING Overloading or improper loading can cause a crash and you can be seriously hurt or killed F...

Page 19: ...20170928113120_32K84A000_eng_BOOK Page 18 Thursday September 28 2017 11 34 27 JST Motorcycle Safety 15 ...

Page 20: ...ge 19 Thursday September 28 2017 11 34 27 JST Operation Guide 16 Throttle grip P 70 Rear brake fluid reservoir P 58 Engine oil fill cap dipstick P 54 Front brake fluid reservoir P 58 Kickstarter pedal P 25 Spark plug P 52 Seat P 49 Right side cover P 50 ...

Page 21: ... 2017 11 34 27 JST Operation Guide 17 Clutch lever P 67 Fuel fill cap P 28 Fuse box P 89 Drive chain P 62 Side stand P 61 Shift lever P 27 Battery P 48 Left side cover P 50 Crankcase breather P 71 Helmet holder P 29 Tool box Tool kit P 30 Engine oil drain bolt P 56 ...

Page 22: ...tember 28 2017 11 34 27 JST Operation Guide 18 SEL button Display Check When the ignition switch is turned to the On position all the mode and digital segments will show If any part of these displays does not come on when it should have your dealer check for problems ...

Page 23: ...urns off P 76 Speedometer Odometer TOTAL Tripmeter TRIP A B SEL button switches between the odometer and tripmeters Odometer Total distance ridden Tripmeter Distance ridden since tripmeter was reset press and hold SEL button to reset to 0 0 km at the tripmeter display Remaining fuel when only 1st E segment starts flashing When is displayed go to your dealer for service When is displayed go to your...

Page 24: ...s in Neutral Comes on briefly when the ignition switch is turned to the On position If it comes on while engine is running P 75 Neutral indicator PGM FI Programmed Fuel Injection malfunction indicator lamp MIL If one of these indicators does not come on when it should have your dealer check for problems High beam indicator Turn signal indicator ...

Page 25: ...20170928113120_32K84A000_eng_BOOK Page 24 Thursday September 28 2017 11 34 27 JST Operation Guide 21 ...

Page 26: ...button u Pressing the switch turns the turn signal off Headlight dimmer switch Passing light control switch Low beam Turn signal switch High beam Flashes the high beam headlight Start button Should normally remain in the run position Engine stop switch u In an emergency switch to the Stop position to stop the engine ...

Page 27: ...4 27 JST Operation Guide 23 Continued Ignition switch Switches the electrical system on off locks the steering u Key can be removed when in the Off or Lock position Steering Lock P 24 On Turns electrical system on for starting riding Lock Off Turns engine off Locks steering ...

Page 28: ... left b Push the key down and turn the ignition switch to the Lock position u Jiggle the handlebar if the lock is difficult to engage c Remove the ignition key Unlocking Insert the key and turn the ignition switch to the Off position 20170928113120_32K84A000_eng_BOOK Page 27 Thursday September 28 2017 11 34 27 JST Operation Guide 24 Switches Continued Push Turn Ignition key ...

Page 29: ...n to recover battery voltage Extended fast idling and revving the engine can damage the engine and the exhaust system a Make sure the engine stop switch is in the Run position b Turn the ignition switch to the On position c Shift the transmission to Neutral N indicator to come on d Using the start button Press the start button with the throttle completely closed 20170928113120_32K84A000_eng_BOOK P...

Page 30: ...hrottle fully and press the start button for 5 seconds b Repeat the normal starting procedure c If the engine starts open the throttle slightly if idling is unstable d If the engine does not start wait 10 seconds before trying steps a b again Using the kick starter a Turn the ignition switch to the Off position b Open the throttle fully c Crank the engine several times with the kickstarter d Repea...

Page 31: ...ing Gears Your motorcycle transmission has 5 forward gears in a one down four up shift pattern 20170928113120_32K84A000_eng_BOOK Page 30 Thursday September 28 2017 11 34 27 JST Operation Guide 27 2 3 4 5 1 N ...

Page 32: ...ling align the fuel cap latch with the slot in the filler neck Push the fuel fill cap into the filler neck until it snaps closed and locks b Remove the ignition key and close the lock cover u The ignition key cannot be removed if the fuel fill cap is not locked 3WARNING Petrol is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat ...

Page 33: ...on key u Use the helmet holder only when parked 3WARNING Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed Use the helmet holder only while parked Do not ride with a helmet secured by the holder 20170928113120_32K84A000_eng_BOOK Page 32 Thursday September 28 2017 11 34 27 JST Operation Gu...

Page 34: ...r Removing the left side cover P 50 Owner s manual The owner s manual is located storage compartment 20170928113120_32K84A000_eng_BOOK Page 33 Thursday September 28 2017 11 34 27 JST Operation Guide 30 Storage Equipment Continued Tool box Tool kit Owner s manual Storage compartment ...

Page 35: ... Brakes P 58 Side Stand P 61 Drive Chain P 62 Wheels P 66 Clutch P 67 Throttle P 70 Crankcase Breather P 71 Other Adjustments P 72 Adjusting the Headlight Aim P 72 20170928113120_32K84A000_eng_BOOK Page 34 Thursday September 28 2017 11 34 27 JST Please read Importance of Maintenance and Maintenance Fundamentals carefully before attempting any maintenance Refer to Specifications for service data Ma...

Page 36: ...s and schedules in this owner s manual Maintenance Safety Always read the maintenance instructions before you begin each task and make sure that you have the tools parts and skills required We cannot warn you of every conceivable hazard that can arise in performing maintenance Only you can decide whether or not you should perform a given task Follow these guidelines when performing maintenance Sto...

Page 37: ...to help ensure that your motorcycle is properly maintained Make sure that whomever performs the maintenance completes this record All scheduled maintenance is considered a normal owner operating cost and will be charged to you by your dealer Retain all receipts If you sell the motorcycle these receipts should be transferred with the motorcycle to the new owner Honda recommends that your dealer sho...

Page 38: ...trifugal Filter Engine Idle Speed Maintenance Level Maintenance Legend Intermediate We recommend service by your dealer unless you have the necessary tools and are mechanically skilled Procedures are provided in an official Honda Shop Manual Inspect clean adjust lubricate or replace if necessary Lubricate Replace Clean Technical In the interest of safety have your motorcycle serviced by your deale...

Page 39: ...Clutch System 67 Side Stand 61 Suspension Nuts Bolts Fasteners 4 Wheels Tyres 4 43 66 Steering Head Bearings Notes 1 At higher odometer reading repeat at the frequency interval established here 3 Service more frequently when riding in rain or at full throttle 2 Service more frequently when riding in unusually wet or dusty areas 4 Service more frequently when riding OFF ROAD 5 Replacement requires ...

Page 40: ...lubricate if necessary 2 P 62 Brakes Check operation Front and Rear check brake fluid level and pads wear 2 P 58 2 P 59 Lights and horn Check that lights indicators and horn function properly Engine stop switch Check for proper function 2 P 22 Clutch Check operation Adjust freeplay if necessary 2 P 67 Wheels and tyres Check condition air pressure and adjust if necessary 2 P 43 Before riding off ro...

Page 41: ...d distilled water Clean the battery terminals if they become dirty or corroded Do not remove the battery cap seals There is no need to remove the cap when charging NOTICE Your battery is a maintenance free type and can be permanently damaged if the cap strip is removed This symbol on the battery means that this product must not be treated as household waste NOTICE An improperly disposed of battery...

Page 42: ...hly with water and do not swallow 3WARNING The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you Wear protective clothing and a face shield or have a skilled mechanic do the battery servicing Cleaning the Battery Terminals 1 Remove the battery 2 P 48 2 If the terminals are starting to c...

Page 43: ...ibly damaging the system Fuses Fuses protect the electrical circuits on your motorcycle If something electrical on your motorcycle stops working check for and replace any blown fuses 2 P 89 Inspecting and Replacing Fuses Turn the ignition switch to the Off position to remove and inspect fuses If a fuse is blown replace with a fuse of the same rating For fuse ratings see Specifications 2 P 105 NOTI...

Page 44: ...fies all of the following standards JASO T 903 standard 1 MA SAE standard 2 10W 30 API classification 3 SG or higher 1 The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB For example the following label shows the MA classification 2 The SAE standard grades oils by their viscosity 3 The API classification specifies the quality and perf...

Page 45: ...nspect the chain more frequently if you often ride on bad roads ride at high speed or ride with repeated fast acceleration 2 P 62 If the chain does not move smoothly makes strange noises has damaged rollers has loose pins or kinks have the chain inspected by your dealer Also inspect the drive sprocket and driven sprocket If either has worn or damaged teeth have the sprocket replaced by your dealer...

Page 46: ...A fire or explosion could result Avoid getting lubricant on the brakes or tyres Avoid applying excess chain lubricant to prevent spray onto your clothes and the motorcycle Crankcase Breather Service more frequently when riding in rain at full throttle or after the motorcycle is washed or overturned Service if the deposit level can be seen in the transparent section of the drain tube If the drain t...

Page 47: ...ou decide to adjust the tyre pressure for a particular off road riding condition make changes a little at a time Inspecting for Damage Inspect the tyres for cuts slits or cracks that exposes fabric or cords or nails or other foreign objects embedded in the side of the tyre or the tread Also inspect for any unusual bumps or bulges in the side walls of the tyres Inspecting for Abnormal Wear Inspect ...

Page 48: ...r positions A tilted valve stem indicates the tube is slipping inside the tyre or the tyre is slipping on the rim See your dealer 3WARNING Riding on tyres that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual regarding tyre inflation and maintenance 20170928113120_32K84A000_eng_BOOK Page 47 Thu...

Page 49: ...lace the inner tube whenever you replace a tyre The old tube will probably be stretched and it could fail if installed in a new tyre 3WARNING Installing improper tyres on your motorcycle can adversely affect handling and stability and can cause a crash in which you can be seriously hurt or killed Always use the size and type of tyres recommended in this owner s manual 20170928113120_32K84A000_eng_...

Page 50: ...cleaning or any other cleaning can degrade the viscous element performance and cause the intake of dust Do not perform the maintenance Should be serviced by your dealer 20170928113120_32K84A000_eng_BOOK Page 49 Thursday September 28 2017 11 34 27 JST Maintenance Fundamentals Maintenance 46 ...

Page 51: ...e roadside repairs minor adjustments and parts replacement with the provided tools Phillips screwdriver 10 14 mm Open end wrench 5 mm Hex wrench Fuse puller Spark plug wrench 20170928113120_32K84A000_eng_BOOK Page 50 Thursday September 28 2017 11 34 27 JST Maintenance 47 ...

Page 52: ...ve terminal from the battery 7 Remove the battery taking care not to drop the terminal nuts Installation Install the parts in the reverse order of removal Always connect the positive terminal first Make sure that bolts and nuts are tight For proper handling of the battery see Maintenance Fundamentals 2 P 37 Battery Goes Dead 2 P 83 20170928113120_32K84A000_eng_BOOK Page 51 Thursday September 28 20...

Page 53: ...hooks with the guides and insert the prongs into the front stays and rear recess to the rear stay 2 Install the collars onto the bolts 3 Tighten the bolts securely 20170928113120_32K84A000_eng_BOOK Page 52 Thursday September 28 2017 11 34 27 JST Removing Installing Body Components u Seat Maintenance 49 Bolt Collar Tab Rear recess Front stay Seat Rear stay Collar Front recess Bolt Prong Prong Hook ...

Page 54: ...8113120_32K84A000_eng_BOOK Page 53 Thursday September 28 2017 11 34 27 JST Removing Installing Body Components u Side Cover Maintenance 50 Left side Tabs Screw Prong Prong Grommet Grommet Right side Grommets Prongs Bolt ...

Page 55: ...he prongs from the grommets Right side 1 Remove the bolt 2 Remove the prongs from the grommets Installation Install the parts in the reverse order of removal 20170928113120_32K84A000_eng_BOOK Page 54 Thursday September 28 2017 11 34 27 JST Removing Installing Body Components u Side Cover Maintenance 51 ...

Page 56: ...ark plug base 3 Remove the spark plug using provided spark plug wrench 2 P 47 u Use the open end wrench provided in the tool kit to remove the spark plug 4 Inspect the electrodes and centre porcelain for deposits erosion or carbon fouling u If the erosion or deposit is heavy replace the plug u Clean a carbon or wet fouled plug with a plug cleaner otherwise use a wire brush 20170928113120_32K84A000...

Page 57: ...revent loosening a First tighten the plug NGK 1 2 turn after it seats DENSO 3 4 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats NOTICE An improperly tightened spark plug can damage the engine If a plug is too loose a piston may be damaged If a plug is too tight the threads may be damaged 9 Install the parts in the reverse order of removal u When rei...

Page 58: ...urface 4 Remove the oil fill cap dipstick and wipe it clean 5 Insert the oil fill cap dipstick until it seats but don t screw it in 6 Check that the oil level is between the upper level and lower level marks on the oil fill cap dipstick 7 Securely install the oil fill cap dipstick 20170928113120_32K84A000_eng_BOOK Page 57 Thursday September 28 2017 11 34 27 JST Maintenance 54 Oil fill cap dipstick...

Page 59: ...el mark u Make sure no foreign objects enter the oil filler opening u Wipe up any spills immediately 2 Securely reinstall the oil fill cap dipstick NOTICE Overfilling with oil or operating with insufficient oil can cause damage to your engine Do not mix different brands and grades of oil They may affect lubrication and clutch operation For the recommended oil and oil selection guidelines see Maint...

Page 60: ...r motorcycle on a firm level surface 4 Place a drain pan under the drain bolt 5 Remove the oil fill cap dipstick drain bolt and sealing washer to drain the oil u Discard the oil at an approved recycling centre 6 Install a new sealing washer onto the drain bolt Tighten the drain bolt Torque 30 N m 3 1 kgf m 22 lbf ft 20170928113120_32K84A000_eng_BOOK Page 59 Thursday September 28 2017 11 34 27 JST ...

Page 61: ...e oil fill cap dipstick Required oil When changing oil 1 0 L 1 1 US qt 0 9 Imp qt 8 Check the oil level 2 P 54 9 Check that there are no oil leaks 20170928113120_32K84A000_eng_BOOK Page 60 Thursday September 28 2017 11 34 27 JST Engine Oil u Changing Engine Oil Maintenance 57 ...

Page 62: ...WER level and UPPER level marks If the brake fluid level in either reservoir is below the LOWER level mark or the brake lever and pedal freeplay becomes excessive inspect the brake pads for wear If the brake pads are not worn you most likely have a leak Have your motorcycle inspected by your dealer 20170928113120_32K84A000_eng_BOOK Page 61 Thursday September 28 2017 11 34 27 JST Maintenance 58 Fro...

Page 63: ...er 2 Rear Inspect the brake pads from the rear right of the motorcycle If necessary have the pads replaced by your dealer Always replace both left and right brake pads at the same time 20170928113120_32K84A000_eng_BOOK Page 62 Thursday September 28 2017 11 34 27 JST Brakes u Inspecting the Brake Pads Maintenance 59 Front Rear Pads Wear indicator Disc Pads Wear indicator Disc Wear indicator Wear in...

Page 64: ...rn the adjusting nut in the direction A if the switch operates too late or turn the nut in the direction B if the switch operates too soon 20170928113120_32K84A000_eng_BOOK Page 63 Thursday September 28 2017 11 34 27 JST Brakes u Adjusting the Brakelight Switch Maintenance 60 Brakelight switch Adjusting nut B A ...

Page 65: ...oothly If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with clean grease 2 Check the spring for damage or loss of tension 20170928113120_32K84A000_eng_BOOK Page 64 Thursday September 28 2017 11 34 27 JST Maintenance 61 Side stand spring ...

Page 66: ... your motorcycle on its side stand on a firm level surface 3 Check the slack in the lower half of the drive chain midway between the sprockets Drive chain slack 20 30 mm 0 8 1 2 in u Do not ride your motorcycle if the slack exceeds 50 mm 2 0 in 4 Roll the motorcycle forward and check that the chain moves smoothly 5 Inspect the sprockets 2 P 41 6 Clean and lubricate the drive chain 2 P 42 201709281...

Page 67: ...our motorcycle on its side stand on a firm level surface 3 Loosen the rear axle nut 4 Loosen the lock nuts on both sides of the swingarm 20170928113120_32K84A000_eng_BOOK Page 66 Thursday September 28 2017 11 34 27 JST Drive Chain u Adjusting the Drive Chain Slack Maintenance 63 Continued Adjusting nut Lock nut Rear axle nut Adjusting nut Lock nut Rear edge of adjusting slot Index marks ...

Page 68: ...g slots Both marks should correspond If the axle is misaligned turn the right or left adjusting nuts until the marks are aligned and recheck chain slack 7 Tighten the rear axle nut Torque 93 N m 9 5 kgf m 69 lbf ft 8 Tighten the drive chain adjusting nuts lightly then hold the adjusting nuts and tighten the lock nuts 9 Recheck drive chain slack If a torque wrench was not used for installation see ...

Page 69: ...ipper Check the condition of the drive chain slider and slipper The drive chain slider and slipper will need to be replaced if the chain slider and slipper are worn to the wear limit indicator If necessary have the drive chain slider and slipper replaced by your dealer 20170928113120_32K84A000_eng_BOOK Page 68 Thursday September 28 2017 11 34 27 JST Drive Chain u Checking the Drive Chain Slider Sl...

Page 70: ...the recommended service in the Maintenance Schedule However information for wheel removal is provided for emergency situations 2 P 77 1 Inspect the wheel rims and spokes for damage 2 Tighten any loose spokes 3 Rotate the wheel slowly to see if it appears to wobble If it does the rim is out of round or not true If the wobble is noticeable see your dealer for inspection 20170928113120_32K84A000_eng_...

Page 71: ...r kinks or signs of wear If necessary have it replaced by your dealer Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion NOTICE Improper freeplay adjustment can cause premature clutch wear 20170928113120_32K84A000_eng_BOOK Page 70 Thursday September 28 2017 11 34 27 JST Maintenance 67 Clutch lever Freeplay ...

Page 72: ...ut 3 Turn the upper clutch cable adjuster until the freeplay is 10 20 mm 0 4 0 8 in 4 Tighten the upper lock nut and check the freeplay again 5 Install the rubber dust cover 20170928113120_32K84A000_eng_BOOK Page 71 Thursday September 28 2017 11 34 27 JST Clutch u Adjusting the Clutch Lever Freeplay Maintenance 68 Rubber dust cover Upper lock nut Upper clutch cable adjuster ...

Page 73: ...utch lever freeplay is 10 20 mm 0 4 0 8 in 4 Tighten the lower lock nut and check the clutch lever freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your motorcycle should move smoothly and accelerate gradually If proper adjustment cannot be obtained...

Page 74: ...positions and throttle freeplay is correct If the throttle does not move smoothly close automatically or if the cable is damaged have the motorcycle inspected by your dealer Freeplay at the throttle grip flange 2 6 mm 0 1 0 2 in 20170928113120_32K84A000_eng_BOOK Page 73 Thursday September 28 2017 11 34 27 JST Maintenance 70 Freeplay Flange ...

Page 75: ...table container under the crankcase breather tube 2 Remove the crankcase breather tube and drain deposits 3 Reinstall the crankcase breather tube 20170928113120_32K84A000_eng_BOOK Page 74 Thursday September 28 2017 11 34 27 JST Maintenance 71 Crankcase breather tube ...

Page 76: ...f the headlight for proper alignment Turn the pinion using a Phillips screwdriver provided in the tool kit 2 P 47 in or out as necessary Obey local laws and regulations 20170928113120_32K84A000_eng_BOOK Page 75 Thursday September 28 2017 11 34 27 JST Maintenance 72 Lower Raise ...

Page 77: ...Other Warning Indications P 76 Fuel Gauge Failure Indication P 76 Tyre Puncture P 77 Electrical Trouble P 83 Battery Goes Dead P 83 Burned out Light Bulb P 83 Blown Fuse P 89 Unstable Engine Operation Occurs Intermittently P 90 20170928113120_32K84A000_eng_BOOK Page 76 Thursday September 28 2017 11 34 27 JST Troubleshooting ...

Page 78: ... on u If the indicator lamp is on contact your dealer as soon as possible Starter Motor Does Not Operate Check the following items Check the correct engine starting sequence 2 P 25 Check for a blown fuse 2 P 89 Check for a loose battery connection 2 P 48 or battery terminal corrosion 2 P 37 Check the condition of the battery 2 P 83 If the problem continues have your motorcycle inspected by your de...

Page 79: ...p MIL If the indicator comes on while riding you may have a serious problem with the PGM FI system Reduce speed and have your motorcycle inspected by your dealer as soon as possible 20170928113120_32K84A000_eng_BOOK Page 78 Thursday September 28 2017 11 34 27 JST Troubleshooting 75 ...

Page 80: ... If the fuel system has an error the fuel gauge indicators will be displayed as shown in the illustration If this occurs see your dealer as soon as possible 20170928113120_32K84A000_eng_BOOK Page 79 Thursday September 28 2017 11 34 27 JST Troubleshooting 76 ...

Page 81: ...a tube or using an aerosol sealant ride cautiously at reduced speed and have the tube replaced before you ride again Anytime a tube is replaced the tyre should be carefully inspected as described 3WARNING Riding your motorcycle with a temporary tyre or tube repair can be risky If the temporary repair fails you can crash and be seriously injured or killed If you must ride with a temporary tyre or t...

Page 82: ... a hoist 4 Remove the front axle shaft right and left side collars and wheel u Avoid getting grease oil or dirt on the disc or pad surfaces u Do not pull the brake lever while the front wheel is removed 20170928113120_32K84A000_eng_BOOK Page 81 Thursday September 28 2017 11 34 27 JST Tyre Puncture u Removing Wheels Troubleshooting 78 Front axle nut Right side collar Front axle shaft Left side coll...

Page 83: ...en the pads to avoid scratching them 3 Install and tighten the front axle nut Torque 69 N m 7 0 kgf m 51 lbf ft 4 After installing the wheel apply the brake lever several times and then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely If a torque wrench was not used for installation see your dealer as soon as possible to verify proper as...

Page 84: ...e moved all the way forward for maximum drive chain slack 4 Remove the rear axle nut and axle washer 5 Remove the drive chain from the driven sprocket by pushing the rear wheel forward 6 Remove the rear axle shaft and axle washer 20170928113120_32K84A000_eng_BOOK Page 83 Thursday September 28 2017 11 34 27 JST Tyre Puncture u Removing Wheels Troubleshooting 80 Adjusting nut Axle washer Lock nut Re...

Page 85: ... pedal while the rear wheel is removed Installation 1 To install the rear wheel reverse the removal procedure u Take care to prevent the brake caliper from scratching the wheel during installation NOTICE When installing a wheel or caliper into original position carefully fit the brake disc between the pads to avoid scratching them 20170928113120_32K84A000_eng_BOOK Page 84 Thursday September 28 201...

Page 86: ...eral times then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely If a torque wrench was not used for installation see your dealer as soon as possible to verify proper assembly Improper assembly may lead to loss of braking capacity 20170928113120_32K84A000_eng_BOOK Page 85 Thursday September 28 2017 11 34 27 JST Tyre Puncture u Removing W...

Page 87: ...l system and is not recommended Burned out Light Bulb Follow the procedure below to replace a burned out light bulb Turn the ignition switch to the Off or Lock position Allow the bulb to cool before replacing it Do not use bulbs other than those specified Check the replacement bulb for correct operation before riding For the light bulb wattage see Specifications 2 P 105 Do not touch the glass surf...

Page 88: ...adlight assembly then remove the prongs from the slots 4 Disconnect the connector 20170928113120_32K84A000_eng_BOOK Page 87 Thursday September 28 2017 11 34 27 JST Electrical Trouble u Burned out Light Bulb Troubleshooting 84 Number plate bracket Bolt A Bolt A IN type only Brake hose guide Headlight assembly Connector Bolt B Bolt B Slots Prongs ...

Page 89: ...ll and tighten the bolts A Torque 21 N m 2 1 kgf m 15 lbf ft Do not touch the glass surface with your fingers If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol 20170928113120_32K84A000_eng_BOOK Page 88 Thursday September 28 2017 11 34 27 JST Electrical Trouble u Burned out Light Bulb Troubleshooting 85 Continued Dust cover Bulb Pin ...

Page 90: ...of removal Brakelight Taillight Bulb 1 Remove the seat 2 P 49 2 Remove the rear fender by removing the bolts A and rear stay 3 Remove the prong from the grommet 4 Remove the rear fender 20170928113120_32K84A000_eng_BOOK Page 89 Thursday September 28 2017 11 34 27 JST Electrical Trouble u Burned out Light Bulb Troubleshooting 86 Bulb Socket Prong Grommet Rear fender Bolts A Rear stay ...

Page 91: ...clockwise 9 Install a new bulb and parts in the reverse order of removal 10 Install and tighten the bolts B Torque 4 5 N m 0 5 kgf m 3 3 lbf ft 20170928113120_32K84A000_eng_BOOK Page 90 Thursday September 28 2017 11 34 27 JST Electrical Trouble u Burned out Light Bulb Troubleshooting 87 Continued Brakelight Taillight Bolts B Grommet Slot Bulb Socket ...

Page 92: ... 1 Remove the screws license light cover and license light cover packing 2 Pull out the bulb without turning it 3 Install a new bulb and parts in the reverse order of removal 4 Install and tighten the screws Torque 1 0 N m 0 1 kgf m 0 7 lbf ft 20170928113120_32K84A000_eng_BOOK Page 91 Thursday September 28 2017 11 34 27 JST Electrical Trouble u Burned out Light Bulb Troubleshooting 88 Turn signal ...

Page 93: ...ne check for a blown fuse Always replace a blown fuse with a spare of the same rating 4 Close the fuse box cover 5 Install the left side cover NOTICE If a fuse fails repeatedly you likely have an electrical problem Have your motorcycle inspected by your dealer 20170928113120_32K84A000_eng_BOOK Page 92 Thursday September 28 2017 11 34 27 JST Electrical Trouble u Blown Fuse Troubleshooting 89 Fuse b...

Page 94: ...ttently while riding Even if this symptom occurs you can continue to ride your motorcycle If unstable engine operation occurs even if sufficient fuel is available have your motorcycle inspected by your dealer as soon as possible 20170928113120_32K84A000_eng_BOOK Page 93 Thursday September 28 2017 11 34 27 JST Troubleshooting 90 ...

Page 95: ...orcycle P 94 Storing Your Motorcycle P 97 Transporting Your Motorcycle P 98 You the Environment P 99 Serial Numbers P 100 Fuels Containing Alcohol P 101 Catalytic Converter P 102 20170928113120_32K84A000_eng_BOOK Page 94 Thursday September 28 2017 11 34 27 JST Information ...

Page 96: ...ake the spare key or the key number to your dealer If you lose all keys and the key number the ignition switch assembly will probably have to be removed by your dealer to determine the key number A metal key holder may cause damage to the area surrounding the ignition switch 20170928113120_32K84A000_eng_BOOK Page 95 Thursday September 28 2017 11 34 27 JST Keys Information 92 ...

Page 97: ...battery Odometer The display locks at 999 999 when the read out exceeds 999 999 Tripmeter The tripmeters return to 0 0 when each read out exceeds 9 999 9 Owner s manual The owner s manual registration and insurance information can be stored in the storage compartment 2 P 30 Ignition Cut off System A banking lean angle sensor automatically stops the engine and fuel pump if the motorcycle falls over...

Page 98: ...recting water into the air cleaner muffler and electrical parts 3 Thoroughly rinse your motorcycle with plenty of clean water and dry with a soft clean cloth 4 After the motorcycle dries lubricate any moving parts u Make sure that no lubricant spills onto the brakes or tyres Brake discs pads drum or shoes contaminated with oil will suffer greatly reduced braking effectiveness and can lead to a cra...

Page 99: ...gings Do not direct water at the air cleaner u Water in the air cleaner can prevent the engine from starting Do not direct water near the headlight u The headlight s inside lens may fog temporarily after washing or while riding in the rain This does not impact the headlight function u Any condensation inside the headlight should dissipate after a few minutes of running the engine with the headligh...

Page 100: ...e stubborn stains use diluted detergent and rinse thoroughly with plenty of water Avoid getting petrol brake fluid or detergents on the instruments panels or headlight Exhaust Pipe and Muffler When the exhaust pipe and muffler are painted do not use a commercially available abrasive kitchen cleaning compound Use a neutral detergent to clean the painted surface on the exhaust pipe and muffler If yo...

Page 101: ...nce stand and position a block so that both tyres are off the ground After rain remove the body cover and allow the motorcycle to dry Remove the battery 2 P 48 to prevent discharge Fully charge the battery and then place it in a shaded well ventilated area u If you leave the battery in place disconnect the negative terminal to prevent discharge After removing your motorcycle from storage inspect a...

Page 102: ... that has a loading ramp or lifting platform and motorcycle tie down straps Never try to tow your motorcycle with a wheel or wheels on the ground NOTICE Towing your motorcycle can cause serious damage to the transmission 20170928113120_32K84A000_eng_BOOK Page 101 Thursday September 28 2017 11 34 27 JST Transporting Your Motorcycle Information 98 ...

Page 103: ... approved containers and take them to a recycling centre Call your local or state office of public works or environmental services to find a recycling centre in your area and to get instructions on how to dispose of non recyclable wastes Do not place used engine oil in the trash or pour it down a drain or on the ground Used oil petrol and cleaning solvents contain poisons that can hurt refuse work...

Page 104: ...ed in order to register your motorcycle They may also be required when ordering replacement parts You should record these numbers and keep them in a safe place 20170928113120_32K84A000_eng_BOOK Page 103 Thursday September 28 2017 11 34 27 JST Serial Numbers Information 100 Frame number Engine number ...

Page 105: ... may be marketed under the name Gasohol The use of petrol containing more than 10 ethanol may Damage the painting of the fuel tank Damage the rubber tubes of the fuel line Cause corrosion of the fuel tank Cause poor drivability NOTICE Use of blended fuels containing higher than approved percentages can damage metal rubber plastic parts of your fuel system If you notice any undesirable operating sy...

Page 106: ...lution and can impair your engine s performance A replacement unit must be an original Honda part or equivalent Follow these guidelines to protect your motorcycle s catalytic converter Always use unleaded petrol Leaded petrol will damage the catalytic converter Keep the engine in good running condition Have your motorcycle serviced if your engine is misfiring backfiring stalling or otherwise not r...

Page 107: ...urning radius 2 1 m 6 9 ft 1 Including rider passenger all luggage and accessories Displacement 149 15 cm3 9 098 cu in Bore x stroke 57 300 x 57 840 mm 2 2559 x 2 2772 in Compression ratio 9 5 1 Fuel Unleaded petrol Recommended 88 RON or higher Fuel containing alcohol ETHANOL up to 10 by volume Tank capacity 7 2 L 1 90 US gal 1 58 Imp gal Battery GTZ5S 12 V 3 5 Ah 10 HR Gear ratio 1st 3 076 2nd 1 ...

Page 108: ...mmended engine oil Honda 4 stroke motorcycle oil API Service Classification SG or higher excluding oils marked as Energy Conserving or Resource Conserving SAE 10W 30 JASO T 903 standard MA Engine oil capacity After draining 1 0 L 1 1 US qt 0 9 Imp qt After disassembly 1 2 L 1 3 US qt 1 1 Imp qt Recommended brake fluid Honda DOT 4 Brake Fluid Recommended drive chain lubricant Drive chain lubricant ...

Page 109: ...rque Specifications Engine oil drain bolt 30 N m 3 1 kgf m 22 lbf ft Rear axle nut 93 N m 9 5 kgf m 69 lbf ft Front axle nut 69 N m 7 0 kgf m 51 lbf ft Number plate bracket bolt 21 N m 2 1 kgf m 15 lbf ft Taillight mounting bolt 4 5 N m 0 5 kgf m 3 3 lbf ft License light cover screw 1 0 N m 0 1 kgf m 0 7 lbf ft 20170928113120_32K84A000_eng_BOOK Page 108 Thursday September 28 2017 11 34 27 JST Spec...

Page 110: ...aring for Your Motorcycle 94 Clutch Freeplay 68 Crankcase Breather 71 Crash 5 D Drive Chain 41 62 E Electrical Trouble 83 Engine Idle Speed 34 Number 100 Oil 40 54 Starting 25 Stop Switch 22 93 Stopping 93 Will Not Start 74 F Flooded Engine 25 Frame Number 100 Fuel Gauge 19 Recommended 28 Tank Capacity 28 Fuses 39 89 20170928113120_32K84A000_eng_BOOK Page 109 Thursday September 28 2017 11 34 27 JS...

Page 111: ...20 Instruments Controls Other Features 93 K Keys 92 L Load Limits 14 Loading Guidelines 14 M Maintenance Fundamentals 36 Importance 32 Safety 32 Schedule 33 Maximum Weight Limit 14 Modifications 12 N Neutral Indicator 20 O Odometer 19 93 Oil Engine 40 54 Owner s Manual 30 93 P Parking 10 Parts Location 16 Petrol 28 20170928113120_32K84A000_eng_BOOK Page 110 Thursday September 28 2017 11 34 27 JST ...

Page 112: ...l Numbers 100 Shifting Gears 27 Side Stand 61 Spark Plugs 52 Specifications 103 Speedometer 19 Start Button 22 Starting the Engine 25 Steering Lock 24 Stopping Engine 93 Storage Equipment 29 Tool Kit 30 Storing 97 Switches 22 T Throttle 70 Transporting 98 Tripmeter 19 93 Troubleshooting 73 Turn Signal Indicator 20 Turn Signal Switch 22 Tyres Air Pressure 43 Puncture 77 Replacing 43 77 201709281131...

Page 113: ...W Washing 94 Weight Limit 14 103 Wheels Front Removal 78 Rear Removal 80 Rims Spokes 66 20170928113120_32K84A000_eng_BOOK Page 112 Thursday September 28 2017 11 34 27 JST Index 109 ...

Page 114: ...20170928113120_32K84A000_eng_BOOK Page 113 Thursday September 28 2017 11 34 27 JST ...

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Honda CRF150L, Owner'S Manual

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