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Honda CRF150R 2020 Owner'S Manual & Competition Handbook Download Page 73

Piston/Piston Rings/Piston Pin

(cont’d)

Servicing Your Honda

67

5. Apply clean engine oil to the cylinder wall, 

piston outer surface and piston rings.
Route the cam chain (3) through the cylinder 
(4).
Install the cylinder over the piston rings by 
hand while compressing the piston rings (5).

NOTICE

Do not damage the piston rings and cylinder wall.

6. Install the cam chain guide (6) and fit the cam 

chain guide tabs (7) in the cylinder cut-outs 
(8).
Push the guide until it bottoms in the crankcase 
guide hole.

1. Install the dowel pins (1) and a new cylinder 

head gasket (2).

NOTICE

Do not let the dowel pins fall into the crankcase.

(3) cam chain

(5) piston rings

(4) cylinder

(4)

(3)

(5)

(6) cam chain guide
(7) cam chain guide tabs
(8) cylinder cut-outs

(6)

(7)

(8)

(8)

Cylinder Head Installation

(1) dowel pins
(2) cylinder head gasket

(2)

(1)

31KSE7100_NA.book  67 ページ  ２０１９年４月９日　火曜日　午後１時１３分

Summary of Contents for CRF150R 2020

Page 1: ...Black Pantone 186C CRF150R RB L PRINTED IN XXXX XXXX 2019 XX L 00X31 KSE 7100 31KSE710 2020 2020 CRF150R RB ...

Page 2: ...IENCED RIDERS NO PASSENGERS This motorcycle is designed as an operator only vehicle and for use by experienced riders only The load limit and seating configuration do not safely permit the carrying of a passenger This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold All information in this publication is based on the latest prod...

Page 3: ...2020 Honda CRF150R RB OWNER S MANUAL COMPETITION HANDBOOK 31KSE7100_NA book 3 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 4: ...manual before you ride It s full of facts instructions safety information and helpful tips To make it easy to use the manual contains a table of contents a detailed list of topics at the beginning of each section and an index at the back of the book As you read this manual you will find information that is preceded by a symbol This information is intended to help you avoid damage to your Honda oth...

Page 5: ...ual Safety Messages are preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean Of course it is not practical or possible to warn you about all hazards associated with operating or maintaining a motorcycle You must use your own good judgment You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY...

Page 6: ...4 Engine Oil 36 Transmission Oil 39 Coolant 41 Air Cleaner 43 Crankcase Breather 45 Engine Throttle 46 Engine Idle Speed 48 Clutch System 49 Hot Start Lever 51 Spark Plug 52 Valve Clearance 53 Piston Piston Rings Piston Pin 62 Chassis Suspension 70 Brakes 75 Wheels 79 Tires Tubes 80 Drive Chain 82 Exhaust Pipe Muffler 85 Additional Maintenance Procedures 88 Appearance Care 90 ADJUSTMENTS FOR COMPE...

Page 7: ...lp you ride your CRF safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your CRF Important Safety Information 2 Important Safety Precautions 2 Important Message to Parents 2 Accessories Modifications 3 Safety Labels 4 31KSE7100_NA book 1 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 8: ... additional drink So don t drink and ride and don t let your friends drink and ride either Keep your Honda in Safe Condition Maintaining your CRF properly is critical to your safety A loose bolt for example can cause a breakdown in which you can be seriously injured Your child s safely is very important to Honda That s why we urge you to read this message before you let any young person ride this ...

Page 9: ...e its design or operation could seriously impair your CRF s handling stability and braking making it unsafe to ride Accessories Modifications WARNING 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 modifications and accessories 31KSE7100_NA book 3 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 10: ...Motorcycle Safety Read this label carefully and don t remove it If the label comes off or becomes hard to read contact your dealer for replacement For Canada Safety Labels 31KSE7100_NA book 4 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 11: ...perating Controls 5 Instruments Controls Read this section carefully before you ride It presents the location of the basic controls on your CRF Operation Component Locations 6 31KSE7100_NA book 5 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 12: ...erating Controls Operation Component Locations clutch lever hot start lever front brake lever engine stop button throttle grip choke knob fuel valve shift lever kickstarter rear brake pedal 31KSE7100_NA book 6 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 13: ...elp get you prepared this section discusses how to evaluate your riding readiness and what items you should check on your CRF For information about suspension carburetor and other adjustments see page 93 Are You Ready to Ride 8 Is Your Motorcycle Ready to Ride 9 Pre ride Inspection 9 31KSE7100_NA book 7 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 14: ...ments see page 93 Whether you re preparing for competition or for practice always make sure you are In good physical and mental condition Free of alcohol and drugs Wearing an approved helmet eye protection and other appropriate riding gear Although complete protection is not possible wearing the proper gear can reduce the chance or severity of injury when you ride WARNING Not wearing a helmet incr...

Page 15: ...tion 88 Carburetor throttle operation 46 Tires for damage or improper inflation pressure 80 Spokes for looseness 79 Rim locks for looseness 79 Front and rear suspension for proper operation 70 71 Front and rear brakes check operation 75 Drive chain for correct slack and adequate lubrication 82 Drive chain sliders and drive chain rollers for damage or wear 82 83 Exhaust pipe Muffler inspection 85 E...

Page 16: ...10 Before Riding 31KSE7100_NA book 10 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 17: ...asic information on how to start and stop your engine as well as break in guidelines Safe Riding Precautions 12 Starting Stopping the Engine 13 Preparation 13 Starting Procedure 13 Flooded Engine 13 How to Stop the Engine 14 Shifting Gears 15 Break in Guidelines 16 31KSE7100_NA book 11 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 18: ...rage Your CRF s exhaust contains poisonous carbon monoxide gas which can collect rapidly in an enclosed area and cause illness or death Safe Riding Precautions WARNING Running the engine of your vehicle while in an enclosed or even partially enclosed area can cause a rapid build up of toxic carbon monoxide gas Breathing this colorless odorless gas can quickly cause unconsciousness and lead to deat...

Page 19: ...continuous motion Do not open the throttle As the carburetor is equipped with an accelerator pump excessive fuel will be charged into the engine and the spark plug will be fouled if the throttle is opened and closed repeatedly Excessive fuel in the engine makes kickstarting difficult 6 About a minute after the engine starts push the choke knob all the way to fully OFF If idling is unstable open th...

Page 20: ...imes and then close it 4 Push and hold the engine stop button 2 until the engine stops completely Failure to close the fuel valve may cause the carburetor to overflow result in hard starting Emergency Engine Stop To stop the engine in an emergency push and hold the engine stop button How to Stop the Engine 1 throttle 2 engine stop button 1 2 31KSE7100_NA book 14 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 21: ...ttains a moderate speed close the throttle pull in the clutch lever and shift to 2nd gear by raising the shift lever 5 This sequence is repeated to progressively shift to 3rd 4th 5th top gear Raise the shift lever to shift to a higher gear and depress it to downshift Each stroke of the shift lever engages the next gear in sequence The shift lever automatically returns to the horizontal position wh...

Page 22: ...a attention to how you ride during the first operating day or 15 miles 25 km During this period avoid full throttle starts and rapid acceleration This same procedure should be followed each time when piston is replaced piston rings are replaced cylinder is replaced crankshaft or crank bearings are replaced 31KSE7100_NA book 16 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 23: ...your dealer s parts department Before You Service Your Honda The Importance of Maintenance 18 Maintenance Safety 19 Important Safety Precautions 19 Maintenance Schedule 20 General Competition Maintenance 22 Before After Competition Maintenance 26 Between Motos Practice Maintenance 26 After Competition Maintenance 26 Service Preparations Maintenance Component Locations 28 Seat 29 Fuel Tank 30 Subfr...

Page 24: ...our CRF is designed to be ridden in off road competition Remember proper maintenance is your responsibility Be sure to inspect your CRF before each ride and follow the Maintenance Schedule in this section WARNING Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection and main...

Page 25: ...t system cool before touching Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin and make sure you have the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using an optional workstand or a maintenance stand to provide support To reduce the possibility of a fire or explosion be c...

Page 26: ...ing hours To avoid overlooking required service we urge you to develop a convenient way to record the number of races and or hours you ride If you do not feel capable of performing a given task or need assistance remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only Honda Genuine Parts or their equivale...

Page 27: ...t 7 5 hours Every 6 races or about 15 0 hours Every 9 races or about 22 5 hours Ref Page THROTTLE OPERATION I 46 HOT STARTER I 51 AIR FILTER NOTE 1 C 43 CRANKCASE BREATHER I 45 SPARK PLUG I 52 VALVE CLEARANCE DECOMPRESSOR SYSTEM NOTE 4 I 53 ENGINE OIL NOTE 3 R 36 ENGINE OIL FILTER NOTE 3 R 37 ENGINE IDLE SPEED I 48 PISTON AND PISTON RINGS R 62 PISTON PIN R 64 TRANSMISSION OIL NOTE 5 I R 39 RADIATO...

Page 28: ...heir equivalent when servicing your CRF Clean parts in non flammable high flash point cleaning solvent such as kerosene when disassembling Lubricate any sliding surface O rings and seals before reassembling Grease parts by coating or filling where specified After any engine disassembly always install new gaskets O rings cotter pins piston pin clips snap rings etc when reassembling After reassembly...

Page 29: ...a Foam Filter Oil or an equivalent Be sure to grease the air cleaner flange where it contacts the air cleaner housing Pro Honda White Lithium Grease or an equivalent is handy for this because any dirt that penetrates this sealing area will show up clearly page 43 Use the Honda Genuine air cleaner or an equivalent air cleaner specified for your model Using the wrong Honda air cleaner or a non Honda...

Page 30: ...General Competition Maintenance 24 Servicing Your Honda 31KSE7100_NA book 24 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 31: ...General Competition Maintenance Servicing Your Honda 25 31KSE7100_NA book 25 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 32: ...ork air pressure release screws 2 to release the built up pressure in excess of normal atmospheric pressure 0 psi 0 kPa 0 kgf cm2 in the fork tubes This pressure is caused by normal fork action while riding If you are riding at altitude remember that fork pressure of 0 at sea level will increase as elevation increases It is important to the long term performance of your CRF to practice a consisten...

Page 33: ...rushes are available from variety drug food and hardware stores Some of these brushes are extremely useful in removing dirt from the many tight contours of the metal pieces of your CRF Avoid using stiff abrasive brushes on the plastic or rubber parts If your CRF was exposed to sea air or salt water rinse it as soon as possible after the event dry it and apply a spray lubricant to all metal parts I...

Page 34: ...ne oil drain bolt throttle stop screw engine idle speed engine oil filter engine oil fill cap dipstick air cleaner rear brake caliper rear brake fluid reservoir rear suspension rebound damping adjuster transmission oil fill cap rear brake pedal transmission oil check bolt front suspension compression damping adjuster rear suspension compression damping adjuster front suspension rebound damping adj...

Page 35: ...1 with the seat bracket 2 and rear prong 3 with the tab 4 of the frame 2 Install the side covers 5 and tighten the side cover bolts 6 3 Install and tighten the seat mounting bolts 7 to the specified torque 19 lbf ft 26 N m 2 7 kgf m 1 seat mounting bolt 3 side cover 2 side cover bolt 4 seat 3 2 1 4 1 front prong 3 rear prong 2 seat bracket 4 tab 5 side cover 7 seat mounting bolt 6 side cover bolt ...

Page 36: ...e 6 7 Unhook the fuel tank band 7 8 Remove the fuel tank bolts washers 8 9 Remove the fuel tank 1 fuel valve 2 shroud A bolt collar 3 shroud B bolts 4 shroud 1 4 2 3 5 breather tube 6 fuel line 7 fuel tank band 8 fuel tank bolts washers 5 7 6 8 WARNING Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame...

Page 37: ...6 Install the seat page 29 7 Install the left shroud tab 5 under the crankcase breather tube 6 8 Install the shrouds 7 and shroud B bolts 8 9 Install and tighten the shroud A bolts collars 9 10 Tighten the shroud B bolts 1 fuel tank bolts washers 2 fuel tank band 3 fuel line 4 breather tube 4 2 3 1 5 left shroud tab 6 crankcase breather tube 7 shroud 8 shroud B bolts 9 shroud A bolt collar 6 5 7 9...

Page 38: ... cleaner housing 5 Loosen the screw 3 on the air cleaner connecting tube clamp 4 6 Remove the subframe lower mounting bolts 5 and upper mounting bolt 6 Then remove the subframe 7 by pulling it straight backward 1 crankcase breather tube 2 transmission breather tube 3 screw 4 air cleaner connecting tube clamp 2 1 4 3 5 subframe lower mounting bolts 6 subframe upper mounting bolt 7 subframe 6 7 5 31...

Page 39: ...or tab 4 aligns with the air cleaner connecting tube groove 5 3 Tighten the connecting tube clamp screw 6 so the gap between the tabs of the clamp is 0 1 0 04 in 3 1mm 4 Connect the crankcase breather tube 7 5 Route the transmission breather tube 8 into the air cleaner housing 6 Install the seat page 29 7 Install the muffler page 86 1 subframe 2 subframe upper mounting bolt 3 subframe lower mounti...

Page 40: ...sts consult your dealer Never use stale or contaminated gasoline Avoid getting dirt dust or water in the fuel tank Fuel Tank Capacity 1 14 US gal 4 3 ℓ 1 To open the fuel fill cap 1 pull the breather tube 2 out of the steering stem nut 3 Turn the fuel fill cap counterclockwise and remove it 2 Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be ...

Page 41: ...nk page 30 3 Remove the fuel valve 1 from the fuel tank by removing the bolts collars 2 4 Wash the fuel filter 3 in high flash point cleaning solvent 5 Make sure the O ring 4 is in good condition and install it onto the fuel valve 6 Install the fuel valve in the fuel tank by tightening the bolts collars to the specified torque 7 lbf ft 10 N m 1 0 kgf m 7 Install the fuel tank page 31 and refill th...

Page 42: ... service label Your CRF does not need oil additives Use the recommended oil Do not use API SH or higher 4 stroke engine oils displaying the circular API energy conserving or resource conserving service label on the container They may affect lubrication Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range Oil Recom...

Page 43: ... the recommended oil until it reaches the upper level mark Do not overfill Reinstall the engine oil fill cap dipstick Repeat steps 1 5 6 Reinsert the engine oil fill cap dipstick 7 Check for oil leaks 1 Run the engine at idle for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the engine oil fill cap dipstick 1 from the left crankcase cover 4 Place a...

Page 44: ...pecified for your model NOTICE If the oil filter is not installed properly it will cause serious engine damage 11 Apply engine oil to the new O ring and install it to the oil filter cover 12 Install the oil filter cover being careful not to damage the O ring then tighten the oil filter cover bolts to the specified torque 7 lbf ft 10 N m 1 0 kgf m 13 Fill the crankcase with the recommended oil 14 I...

Page 45: ... not use oils with graphite or molybdenum additives They may adversely affect clutch operation Do not use API SH or higher 4 stroke engine oils displaying the circular API energy conserving or resource conserving service label on the container They may affect lubrication and clutch performance Other viscosities shown in the following chart may be used when the average temperature in your riding ar...

Page 46: ...evel or adding oil tighten the oil check bolt to the specified torque Oil Check Bolt 7 lbf ft 10 N m 1 0 kgf m 6 Install the transmission oil fill cap securely 1 Run the engine at idle for 3 minutes then shut it off 2 Support the CRF in an upright position on a level surface 3 Remove the transmission oil fill cap 1 from the right crankcase cover 4 Place an oil drain pan under the engine to catch t...

Page 47: ...rosion protection Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additional protection against freezing Check the cooling system frequently during freezing weather Refer to Safety Precautions on page 19 1 With the engine cold remove the radiator cap 1 and check...

Page 48: ...er seal or the oil seal Both seals should be replaced at the same time Refer to Safety Precautions on page 19 Coolant should be replaced by your dealer unless you have the proper tools and service data and are mechanically qualified Refer to the Honda Service Manual page 148 To properly dispose of drained coolant refer to You the Environment page 130 NOTICE Improper disposal of drained fluids is h...

Page 49: ...cleaner maintenance can cause poor performance and premature engine wear 1 Remove the seat page 29 2 Remove the air cleaner retaining bolt 1 and air cleaner assembly 2 3 Remove the air cleaner element 3 from the air cleaner holder 4 4 Wash the air cleaner element in clean non flammable cleaning solvent Then wash in hot soapy water rinse well and allow to dry thoroughly The air cleaner element is m...

Page 50: ... air cleaner holder tabs 10 10 Install and tighten the air cleaner retaining bolt 1 NOTICE Improper installation of the air cleaner assembly may allow dirt and dust to enter the engine and cause rapid wear of the piston rings and cylinder 11 Install the seat page 29 1 air cleaner retaining bolt 8 air cleaner element tab 9 air cleaner element stay boss 10 air cleaner holder tabs 1 8 9 10 31KSE7100_...

Page 51: ...r often at full throttle Service the breather if you can see deposits in the transparent section of the drain tube 1 Remove the crankcase breather tube plug 1 from the tube 2 and drain deposits into a suitable container 2 Reinstall the crankcase breather tube plug Draining 1 crankcase breather tube plug 2 tube 1 2 31KSE7100_NA book 45 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 52: ...one turn Tighten the lock nut to the specified torque 3 0 lbf ft 4 0 N m 0 4 kgf m Install the dust cover and make the adjustment with the lower adjuster Lower Adjustment The lower adjuster is used for major freeplay adjustment such as after replacing the throttle cables or removing the carburetor It is also used if you cannot get the proper adjustment with the upper adjuster 1 Pull the dust cover...

Page 53: ...l steering positions If there is a problem see your dealer 3 Inspect the condition of the throttle cables from the throttle grip down to the carburetor If the cable is kinked or chafed have it replaced 4 Check the cables for tension or stress in all steering positions 5 Lubricate the cables with a commercially available cable lubricant to prevent premature rust and corrosion Throttle Inspection 1 ...

Page 54: ... speed adjustment The best way to assure proper carburetion is to see your dealer for regularly scheduled servicing including carburetor adjustment 1 If the engine is cold start it and warm it up 3 minutes and then shut it off 2 Connect a tachometer to the engine 3 Shift the transmission into neutral and start the engine 4 Keep the motorcycle in an upright position 5 Adjust idle speed with the thr...

Page 55: ...djuster Integral Cable Adjustment The integral cable adjuster is used if the cable end adjuster is threaded out near its limit or the correct freeplay cannot be obtained 1 Turn the cable end adjuster in direction until it seats lightly and then turn it out one turn 2 Loosen the lock nut 1 3 Turn the integral cable adjuster 2 to obtain the specified freeplay 4 Tighten the lock nut Check the freepla...

Page 56: ...s of wear If necessary have it replaced Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion 1 Check for smooth clutch lever operation If necessary lubricate the clutch lever pivot or clutch cable 2 Check the clutch cable for deterioration kinks or damage Other Inspections Lubrication 1 end of the holder 2 punch mark Clutch Operation 1 2 ...

Page 57: ...ts can be made with the cable adjuster Loosen the lock nut 1 and turn the adjuster 2 Turning the adjuster clockwise will increase freeplay and turning it counterclockwise will decrease freeplay After adjustment tighten the lock nut Hot Start Lever Freeplay 1 hot start lever 2 hot start lever freeplay 2 1 1 lock nut increase freeplay 2 adjuster decrease freeplay 2 1 31KSE7100_NA book 51 ページ ２０１９年４月...

Page 58: ...f you re using a new plug ride for at least 10 minutes before taking a plug reading a brand new plug will not show color initially If the electrodes appear burnt or the insulator is white or light gray lean or the electrodes and insulator are black or fouled rich there is a problem elsewhere page 122 Check the carburetor fuel system and ignition timing 9 With the sealing gasket attached thread the...

Page 59: ...ngine is cold The valve clearance will change as engine temperature rises Before inspection clean the engine thoroughly to keep dirt from entering the engine 1 Remove the seat and fuel tank page 29 30 2 Remove the spark plug page 52 3 Disconnect the breather tube 1 4 Remove the cylinder head cover bolts 2 and cylinder head cover 3 5 Remove the spark plug hole packing 1 Remove the crankshaft hole c...

Page 60: ...the piston is on the compression stroke If they are tight and the valves are open rotate the primary drive gear bolt 360 and realign the punch mark with the index mark 1 Measure the intake valve clearance by inserting a feeler gauge 1 between the valve lifters 2 and intake cam lobes 3 2 Measure the exhaust valve clearance by inserting a feeler gauge 1 between the exhaust rocker arms 4 and exhaust ...

Page 61: ...tensioner stopper fully to hold the stopper in the fully retracted position 5 Remove the bolt 6 stopper plate 7 return spring 8 and decompressor weight 9 NOTICE Do not let the bolt stopper plate return spring and decompressor weight fall into the crankcase 6 Remove the cam sprocket bolts 10 and cam sprocket 11 then attach a piece of wire to the cam chain 12 to prevent it from falling into the cran...

Page 62: ...e lifters and the shims separate so you can easily identify the originally installed location such as intake or exhaust right or left NOTICE Do not let the valve lifters and shims fall into the crankcase 8 Remove the valve lifters 15 9 Remove the O ring 16 10 Remove the shims 17 Keep the shims separate so you can easily identify the originally installed location such as intake or exhaust right or ...

Page 63: ...mm 3 Calculate the new shim thickness using the equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness Make sure of the correct shim thickness by measuring the shim with a micrometer Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2 450 mm Reface the exhaust valve seat if carbon deposits resul...

Page 64: ...um disulfide additive to the surface of the cam lobes Install the camshaft holder assembly onto the cylinder head aligning the index line 8 on the camshaft flange with the index mark 9 on the camshaft holder as illustrated above Apply oil to the camshaft holder assembly bolt threads and seating surface Align the camshaft holder assembly bolt holes 10 with the rocker arm shaft cut outs 11 Tighten t...

Page 65: ... sprocket bolts 18 alternately to the specified torque 15 lbf ft 20 N m 2 0 kgf m NOTICE Do not let the bolts fall into the crankcase 10 Install the decompressor weight 19 and return spring 20 as illustrated below 11 Clean and apply locking agent to the bolt threads coating width 0 26 0 04 in 6 5 1 mm from tip 12 Install the stopper plate 21 and tighten the bolt 22 to the specified torque 7 lbf ft...

Page 66: ...alve clearance by inserting a feeler gauge 26 Valve Clearance 17 Coat a new O ring 27 with oil and install it onto the crankshaft hole cap 28 Apply grease to the crankshaft hole cap threads Install and tighten the crankshaft hole cap to the specified torque 11 lbf ft 15 N m 1 5 kgf m 23 tensioner stopper 24 sealing washer 25 cam chain tensioner lifter cover bolt 23 25 24 2 punch mark 3 index mark ...

Page 67: ...ead cover packing into the groove of the cylinder head cover 3 3 Check the rubber seal 4 is in good condition replace them if necessary Install the rubber seals onto the cylinder head cover with their UP marks 5 facing up 4 Install the cylinder head cover 3 and tighten the cylinder head cover bolts 6 to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 Connect the breather tube 7 6 Install the spar...

Page 68: ...ug page 52 7 Remove the cylinder head cover page 53 8 Remove the camshaft holder assembly page 55 9 Remove the radiator grills 1 10 Loosen the water hose clamp screws and disconnect the water hoses 2 11 Disconnect the radiator overflow hose 3 Note the direction of the hose clamp Be careful not to damage the radiator core 12 Remove the radiator mounting bolts washers 4 and radiators 5 Cylinder Head...

Page 69: ... three steps NOTICE Do not let the nuts washers and cam chain fall into the crankcase 16 Remove the dowel pins 10 cylinder head gasket 11 and cam chain guide 12 NOTICE Do not let the dowel pins and cam chain fall into the crankcase 6 cylinder head bolts 7 cylinder bolt 7 6 8 cylinder head nuts washers 9 cylinder head 8 9 10 dowel pins 12 cam chain guide 11 cylinder head gasket 11 12 10 31KSE7100_N...

Page 70: ... pliers 3 Press the piston pin 2 out of the piston 3 and remove the piston Under racing conditions the piston should be replaced after 15 0 hours of running Replace the piston pin after 15 0 hours of running Spread each piston ring 1 and remove by lifting it up at a point just opposite the gap Under racing conditions the piston rings should be replaced after 15 0 hours of running NOTICE Do not dam...

Page 71: ...ston ring installation To install the oil ring install the spacer first then install the side rails Install the top ring on the piston with the marking side facing up 3 After installing the rings they should rotate freely without sticking Space the ring end gaps 180 degrees apart between top ring and upper side rail Space the ring end gaps 90 degrees apart between upper side rail spacer and lower ...

Page 72: ...on pin clips fall into the crankcase Do not align the piston pin clip end gap with the piston cut out 6 1 Clean off any gasket material from the gasket surface of the crankcase being careful not to let any material fall into the crankcase Be careful not to remove any metal from the gasket surface 2 Remove the shop towel Do not let any gasket debris fall into the crankcase being careful not to let ...

Page 73: ...s and cylinder wall 6 Install the cam chain guide 6 and fit the cam chain guide tabs 7 in the cylinder cut outs 8 Push the guide until it bottoms in the crankcase guide hole 1 Install the dowel pins 1 and a new cylinder head gasket 2 NOTICE Do not let the dowel pins fall into the crankcase 3 cam chain 5 piston rings 4 cylinder 4 3 5 6 cam chain guide 7 cam chain guide tabs 8 cylinder cut outs 6 7 ...

Page 74: ...s in a crisscross pattern in two or three steps to the specified torque 21 lbf ft 29 N m 3 0 kgf m NOTICE Do not let the washers and nuts fall into the crankcase 4 Install the cylinder bolt 5 and cylinder head bolts 6 and tighten them to the specified torque 7 lbf ft 10 N m 1 0 kgf m 5 Install the radiators 7 and tighten the radiator mounting bolts washers 8 3 cylinder head 4 cylinder head nuts wa...

Page 75: ... 11 Install the cylinder head cover page 61 12 Install the spark plug and direct ignition coil page 52 13 Install the exhaust pipe page 87 14 Install the carburetor page 116 15 Install the fuel tank page 31 and seat page 29 16 Pour a fresh recommended coolant mixture page 41 Check for the following compression leaks abnormal engine noise secondary air leaks coolant leaks 9 radiator overflow hose 1...

Page 76: ...and foreign materials Check the oil for any contamination Refer to Suspension Adjustment Guidelines page 107 Make all rebound and compression damping adjustments in 1 4 turn increments Adjusting 1 2 or more turns at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment settings return to the standard position and start over If...

Page 77: ... pass over the best adjustment Test ride after each adjustment If the rear suspension is too stiff soft adjust it by turning both the compression and rebound damping adjusters in 1 4 turn increments until the suspension feels approximately right Turning just one adjuster rather than both may cause a loss of balance between compression and rebound damping After adjusting both adjusters simultaneous...

Page 78: ...e 4 Raise the fork tube 2 and cover the top of the tube with your hand Compress the fork tube fully then release your hand Use your other hand to secure the fork tube Repeat this procedure three times 5 Pour the remaining fork oil into the piston rod until a little oil flows out of the top of the rod Pump the piston rod slowly eight ten times through a stroke of 10 in 25 cm Gently slide the fork t...

Page 79: ...city 7 43 in 188 7 mm 10 27 US oz 303 7 cm3 Slightly softer as it nears full compression Standard oil level capacity 5 02 in 127 5 mm 11 95 US oz 353 2 cm3 Maximum oil level capacity 5 02 in 127 5 mm 11 95 US oz 353 2 cm3 Slightly stiffer as it nears full compression Minimum oil level capacity 7 61 in 193 4 mm 10 14 US oz 299 9 cm3 Slightly softer as it nears full compression 1 coil at both ends f...

Page 80: ...l level capacity 5 16 in 131 0 mm 11 84 US oz 350 1 cm3 Slightly stiffer as it nears full compression Minimum oil level capacity 7 63 in 193 7 mm 10 13 US oz 299 4 cm3 Slightly softer as it nears full compression Standard oil level capacity 5 34 in 135 7 mm 11 71 US oz 346 3 cm3 Maximum oil level capacity 4 95 in 125 7 mm 11 99 US oz 354 4 cm3 Slightly stiffer as it nears full compression Minimum ...

Page 81: ...r to the handgrip turn the adjuster counterclockwise 3 While holding the adjuster tighten the lock nut to the specified torque 4 4 lbf ft 5 9 N m 0 6 kgf m 4 Apply the brake release it then spin the wheel and check that it rotates freely Repeat this procedure several times 5 Check freeplay by pulling in slowly on the front brake lever until the brake starts to engage Freeplay LESS THAN 13 16 in 20...

Page 82: ...ke bleeding Rear Brake Fluid Level Check With the motorcycle in an upright position check the fluid level It should be above the LOWER mark 1 If the level is at or below the LOWER mark check the brake pads for wear page 78 Worn brake pads should be replaced If the pads are not worn have your brake system inspected for leaks If the brake pedal freeplay exceeds 1 2 in 30 mm there is probably air in ...

Page 83: ...nted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap make sure the reservoir is horizontal first Always use fresh DOT 4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not be compatible The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent 1 Remove the rear brake reser...

Page 84: ...ads 1 from the rear side of the caliper to determine the pad wear If either pad is worn anywhere to a thickness of 0 04 in 1 mm both pads must be replaced Check that the brake lever and pedal assemblies are positioned properly and the securing bolts are tight Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Brake Pad Wear 1 brake pads 3 brake disc 2 fr...

Page 85: ... to perform the recommended service in the Maintenance Schedule page 21 However information for wheel removal is provided for emergency situations 1 Inspect the wheel rims 1 and spokes 2 for damage 2 Tighten any loose spokes and rim locks 3 to the specified torque Spokes 2 7 lbf ft 3 7 N m 0 4 kgf m Rim Locks 9 lbf ft 12 4 N m 1 3 kgf m 3 Check wheel rim runout If runout is noticeable see the Hond...

Page 86: ...tch the recommended cold pressures the tires will be underinflated The correct cold tire pressures are If you decide to adjust tire pressures for a particular riding condition make changes a little at a time Take time to inspect your tires and wheels before you ride Inspect carefully for bumps or bulges in the side of the tire or the tread Replace any tire that has a bump or bulge Look closely for...

Page 87: ...acement WARNING Installing improper tires on your motorcycle can affect handling and stability This can cause a crash in which you can be seriously hurt or killed Always use the size and type of tires recommended in this owner s manual Front AC 70 100 17 40M DUNLOP MX71F CM 70 100 17 40M BRIDGESTONE M23 Rear AC 90 100 14 49M DUNLOP MX71 CM 90 100 14 49M BRIDGESTONE M22 Tire type bias ply tube Fron...

Page 88: ...hand 1 3 8 1 3 4 in 35 45 mm 3 Check drive chain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the chain will often eliminate binding and kinking NOTICE Excessive chain slack may allow the drive chain to damage the engine cases 4 Inspect the drive chain for damaged rollers loose pins dry or rusted links kinked ...

Page 89: ...he specified torque 65 lbf ft 88 N m 9 0 kgf m 4 Recheck chain slack and adjust as necessary 5 Turn the adjusting bolts counterclockwise until it touches the axle plates lightly Then tighten the chain adjuster lock nut to the specified torque while holding the adjusting bolt with a wrench 20 lbf ft 27 N m 2 8 kgf m Commercially prepared drive chain lubricants may be purchased at most motorcycle sh...

Page 90: ...n held taut and any kinked joints straightened measure the distance between a span of 21 pins from pin center to pin center If the measurement exceeds the service limit replace the chain After the chain is measured shift the transmission into neutral again before proceeding with inspection and service 6 Lubricate the drive chain page 83 7 Pass the chain over the sprockets and join the ends of the ...

Page 91: ...ne performance 1 Remove the seat mounting bolt 1 side cover bolt 2 and right side cover 3 2 Loosen the muffler clamp bolt 4 3 Remove the muffler 5 by removing the muffler mounting bolts 6 and washer 7 Exhaust Pipe Muffler Inspection Muffler Removal 1 seat mounting bolt 3 right side cover 2 side cover bolt 1 3 2 4 muffler clamp bolt 5 muffler 6 muffler mounting bolts 7 washer 5 7 4 6 31KSE7100_NA b...

Page 92: ... torque 15 lbf ft 21 N m 2 1 kgf m 7 Tighten the muffler mounting bolts 8 to the specified torque 24 lbf ft 32 N m 3 3 kgf m 8 Install the right side cover 11 and side cover bolt 12 9 Install the seat mounting bolt 13 and tighten to the specified torque 19 lbf ft 26 N m 2 7 kgf m Muffler Installation 1 muffler clamp 3 cut out 2 tab 4 muffler 5 gasket new 7 muffler 6 exhaust pipe 4 3 2 1 7 6 5 8 mu...

Page 93: ... 86 but do not tighten the bolts yet 4 Tighten the exhaust pipe joint nuts to the specified torque 8 lbf ft 11 N m 1 1 kgf m 5 Tighten the muffler clamp bolt and muffler mounting bolts page 86 6 Installation can be done in the reverse order of removal Exhaust Pipe Removal 1 exhaust pipe joint nuts 2 exhaust pipe 3 gasket old 1 3 2 Exhaust Pipe Installation 1 exhaust pipe gasket new 2 exhaust pipe ...

Page 94: ...stment procedures or see your dealer 1 Check the handlebar 1 for bends or cracks 2 Check that the handlebar has not moved from its proper position by inspecting the punch mark 2 3 Check the torque of the handlebar upper holder bolts 3 16 lbf ft 22 N m 2 2 kgf m Tighten the front bolts first Periodically disconnect the throttle clutch and hot start cables at their upper ends Thoroughly lubricate th...

Page 95: ...heck bolt 7 10 1 0 6 Cylinder bolt 7 10 1 0 7 Oil filter cover bolts 7 10 1 0 8 Cylinder head bolts 7 10 1 0 9 Drive sprocket bolt 10 13 1 3 10 Transmission oil drain bolt 16 22 2 2 11 Engine oil drain bolt 16 22 2 2 1 cylinder head cover bolts 2 exhaust pipe joint nuts 3 coolant drain bolt 4 crankshaft hole cap 5 transmission oil check bolt 5 1 2 4 3 6 cylinder bolt 7 oil filter cover bolts 8 cyl...

Page 96: ...igh pressure water or air can damage certain parts of your CRF You may use Pro Honda Hondabrite a multi surface cleaner degreaser to remove both dirt and petroleum based grime from paint alloy plastic and rubber surfaces Wet any heavy deposits with water first Then spray on Pro Honda Hondabrite and rinse with a low pressure garden hose Stubborn deposits may require a quick wipe with a sponge 1 Rin...

Page 97: ... Be sure the chain is wiped clean and is dry before applying the chain lube Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins The exhaust pipe and muffler are stainless steel but may become stained by mud or dust To remove mud or dust use a wet sponge and a liquid kitchen abrasive then rinse well wi...

Page 98: ...92 Servicing Your Honda 31KSE7100_NA book 92 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 99: ...ed by installing the optional fork springs of a similar rate Front Suspension Adjustments 94 Front Suspension Air Pressure 94 Front Suspension Oil Level 94 Front Suspension Damping 100 Fork Springs 101 Rear Suspension Adjustments 102 Rear Suspension Spring Pre Load 102 Rear Suspension Damping 103 Rear Suspension Race Sag 104 Suspension Adjustments for Track Conditions 106 Suspension Adjustment Gui...

Page 100: ...lease screws The front wheel should be off the ground before you release the pressure The air pressure should be adjusted according to the altitude and outside temperature 1 Place an optional workstand under the engine so that the front wheel is off the ground Do not adjust air pressure with the front wheel on the ground as this will give false pressure readings 2 Remove the fork air pressure rele...

Page 101: ... both the fork tube and slider pipe when removing the fork cap 9 Record the rebound damping adjuster position and turn the adjuster screw 12 counterclockwise until it stops 10 Hold the fork tube 10 then remove the fork cap 2 from the fork tube Gently slide the fork tube down onto the lower end of the slider pipe 13 NOTICE When removing the fork cap be careful not to damage the damping force adjust...

Page 102: ...83 in 122 8 mm 12 07 US oz 357 0 cm3 Slightly stiffer as it nears full compression Minimum oil level capacity 7 43 in 188 7 mm 10 27 US oz 303 7 cm3 Slightly softer as it nears full compression Standard oil level capacity 5 02 in 127 5 mm 11 95 US oz 353 2 cm3 Maximum oil level capacity 5 02 in 127 5 mm 11 95 US oz 353 2 cm3 Slightly stiffer as it nears full compression Minimum oil level capacity ...

Page 103: ...il level capacity 5 55 in 141 0 mm 11 57 US oz 342 0 cm3 Maximum oil level capacity 5 16 in 131 0 mm 11 84 US oz 350 1 cm3 Slightly stiffer as it nears full compression Minimum oil level capacity 7 63 in 193 7 mm 10 13 US oz 299 4 cm3 Slightly softer as it nears full compression Standard oil level capacity 5 34 in 135 7 mm 11 71 US oz 346 3 cm3 Maximum oil level capacity 4 95 in 125 7 mm 11 99 US ...

Page 104: ... mechanic s wire up through the spring Angle the fork spring and slowly slide it down into the fork using a gentle rocking motion 23 Reaching through the two adjacent coils near the oil lock valve hold the spring guide 22 with your finger Remove the mechanic s wire and hand tighten the lock nut 16 to the spring guide 22 24 Set the adjuster screw 12 to 0 06 in 1 5mm from the fork cap 2 top then ins...

Page 105: ...pecified torque 5 2 lbf ft 7 N m 0 7 kgf m 36 Clean the surfaces where the front axle shaft and axle clamps contact each other 37 Install the left and right side collars into the wheel hub 38 Insert the front axle shaft 4 through the wheel hub from the right side Make sure the axle shaft is seated firmly onto the left fork leg clamp inner surface 39 Install the front axle nut 3 40 Align the brake ...

Page 106: ...ill no longer turn lightly seats This is the full hard position 2 Turn the adjuster counterclockwise 1 1 4 turn This is the standard position 3 Make sure that both fork legs are adjusted to the same position Rebound Damping Rebound damping effects how quickly the fork rebounds The rebound damping adjuster has 3 turns or less Always start with the full hard position when adjusting damping To adjust...

Page 107: ...mum oil level When adjusting oil levels bear in mind that the air in the fork will increase in pressure while riding therefore the higher the oil level the higher the eventual pressure of any air in the fork Fork Springs Minimum oil level CRF150R Standard Spring 7 43 in 188 7 mm Softer Spring 7 61 in 193 4 mm Stiffer Spring 7 64 in 194 1 mm Minimum oil level CRF150RB Standard Spring 7 63 in 193 7 ...

Page 108: ...complete turn of the adjuster nut changes the spring length by 0 06 in 1 5 mm 4 After adjustment hold the adjusting nut and tighten the lock nut to the specified torque 32 lbf ft 44 N m 4 5 kgf m To increase spring pre load Loosen the lock nut with the optional pin spanners 3 and turn the adjusting nut to shorten the spring length 4 Do not shorten to less than 8 7 in 222 mm CRF150R 8 9 in 226 mm C...

Page 109: ...ns with the reference mark 3 on the shock absorber Rebound Damping The rebound damping adjuster 1 is located at the lower end of the shock absorber The rebound damping adjuster has 3 turns or less To increase damping turn the adjuster screw clockwise To decrease damping turn the adjuster screw counterclockwise To adjust to the standard position 1 Turn the adjuster clockwise until it will no longer...

Page 110: ...wearing your riding apparel Ask one helper to steady your CRF perfectly upright so you can put both feet on the pegs Bounce your weight on the seat a couple of times to help the suspension overcome any situation and settle to a good reference point Ask the other helper to measure the loaded with rider dimension Example 4 Calculate the race sag dimension To do this subtract the loaded with rider di...

Page 111: ...add excessive spring pre load to get the right race sag and as a result the rear end of the motorcycle is raised This can cause the rear wheel to unload too much in the air and top out as travel rebounds The rear end may top out from light braking or kick sideways over lips and square edged terrain It may even top out when you dismount your CRF Because of the great absorption quality of the shock ...

Page 112: ...fer aftermarket springs front and rear may help especially if you are heavier than the average rider Your CRF may be undersprung because of the added weight of the clinging mud This additional weight may compress the suspension too much and affect traction Hard Surface For a fast hard track with no large jumps you can probably run the same spring as normal but run softer damping both ways compress...

Page 113: ...s Middle travel too soft Front end dives when cornering If suspension isn t stiff in initial travel Test stiffer compression damping adjustments in 1 4 turn increments If initial travel becomes stiff because of the above adjustment Reduce the rebound damping in 1 4 turn increments Test softer compression damping adjustments in 1 4 turn increments If that doesn t solve the problem install the optio...

Page 114: ...iff Test stiffer compression damping adjustments in 1 4 turn increments This should produce smooth fork action from initial to middle travel If initial and middle travel is stiff Test softer compression damping adjustments in 1 4 turn increments Reduce the rebound damping in 1 4 turn increments Final travel too stiff Doesn t bottom on landings but feels stiff Stiff on large bumps especially downhi...

Page 115: ...4 turn increments Install the optional stiff spring Adjustments for Too Soft Stiff Suspension Symptom Action Rear end kicks up on deep bumps on sand track Test stiffer compression and rebound damping adjustments in 1 4 turn increments until the rear end does not kick up and or the suspension becomes stiff Then test softer compression damping adjustments in 1 4 turn increments Suspension bottoms an...

Page 116: ...en a cold engine is being started When the choke knob 1 is pulled out fuel is metered by the starter jet 2 and is mixed with air from the air passage 3 located above the throttle valve 4 to provide a rich mixture for starting The mixture discharges through the orifice 5 into the cylinder Hot Start Circuit A lean mixture must be delivered to the cylinder when a hot engine is being started When the ...

Page 117: ...ir passage 2 The mixture enters the venturi through the bypass 3 and pilot outlet 4 that has been metered by the pilot screw 5 Main Circuit Fuel is metered by the main jet 1 jet needle 2 and needle jet 3 It is then mixed with air coming from the air jet 4 and enters the venturi past the needle jet Baffle Plate The baffle plate 5 prevents foaming of fuel or abnormal fuel level around the main jet F...

Page 118: ...lockwise to lean the mixture If the engine surges lean exiting a corner turn the pilot screw counterclockwise to richen the mixture The minimum to maximum range of pilot screw adjustment is 1 1 2 to 2 1 4 turns out from the lightly seated position If you exceed 2 1 4 turns out the next larger slow jet is needed If you are under 1 1 2 turns out the next smaller slow jet is needed Leak jet The small...

Page 119: ...ll the dust cover 9 back 10 Remove the throttle drum cover bolt 10 and throttle drum cover 11 11 Loosen the lock nuts 12 adjuster 13 and disconnect the throttle cables 14 from the throttle drum 15 12 Remove the hot start cable holder 16 2 insulator band screw 3 connecting tube clamp screw 4 tabs 5 grooves 2 5 5 3 4 6 wire band 7 clamp 8 throttle position sensor connector 9 dust cover 10 throttle d...

Page 120: ...ew threads 4 Remove the throttle valve 5 5 Remove the floating valve 7 and roller 8 from the throttle valve When installing the floating valve 7 onto the throttle valve 5 make sure the floating valve s flat side faces out and the hole 9 faces down Carburetor Disassembly Assembly 1 cable clamp 2 carburetor top screws 3 carburetor top 4 jet needle holder assembly 5 throttle valve 1 3 2 4 5 5 throttl...

Page 121: ...lace 10 Measure the float level 25 with the float level gauge 26 while the float tab is just contacting the float valve and the carburetor intake 27 is facing up The float level should be 0 28 in 7 0 mm If the float level is out of specification adjust it by bending the float tab carefully 11 Remove the leak jet 28 from the float bowl 16 Clean the leak jet 10 accelerator pump cover screws 11 accel...

Page 122: ... kgf m throttle cable lock nut 3 0 lbf ft 4 0 N m 0 4 kgf m leak jet 0 2 lbf ft 0 3 N m 0 03 kgf m main jet 1 1 lbf ft 1 5 N m 0 2 kgf m slow jet 1 1 lbf ft 1 5 N m 0 2 kgf m Route the throttle cables 1 hot start cable 2 and throttle position sensor wire correctly After installing the carburetor adjust the throttle grip freeplay and hot start lever freeplay After installing the carburetor check th...

Page 123: ...ary All jetting recommendations are based on standard jetting with an unmodified engine The following conditions can affect the fuel mixture Standard Tuning Recommendations Adjustment Standard settings Pilot screw opening 2 1 8 turns out Slow jet 38 Jet needle NMQT Needle clip position 3rd groove Main jet 140 Float level 0 28 in 7 0 mm Identification number FCR08D Adjustments for Altitude Temperat...

Page 124: ... Tips Your CRF dose not conform to AMA noise emission regulation for 2019 year If you use optional AMA noise emission regulation conformed muffler you should change the carburetor settings Optional Muffler Settings 31KSE7100_NA book 118 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 125: ...s blocked or restricted exhaust or fuel systems or a dirty air cleaner Before adjusting carburetor settings check the following air cleaner air leaks float level clogged carburetor jets spark plug fouling improper heat range or other cause freshness of fuel owner modifications such as exhaust system holes in the air cleaner housing etc ignition timing compression If the above check out adjust the ...

Page 126: ...standard setting or corrected jetting page 117 and spark plug Note engine acceleration and other engine conditions in relation to throttle opening Verify carburetion by removing the spark plug and reading its firing end page 122 It may take more than two or three laps to get a good spark plug reading with a new spark plug 5 Change carburetor settings or select suitable carburetor jets taking into ...

Page 127: ...lip position of jet needle or jet needle as required 17 Reinstall the jet needle holder assembly and tighten it to the specified torque 1 3 lbf ft 1 8 N m 0 18 kgf m 18 Reinstall the carburetor top cable clamp and carburetor top screws Tighten the carburetor top screws to the specified torque 1 5 lbf ft 2 1 N m 0 2 kgf m 19 Rotate the carburetor and align the tabs 14 on the carburetor with the gro...

Page 128: ...ever in to release the clutch 3 Coast to a stop 4 Remove the spark plug 5 Use a magnifying glass to inspect the spark plug The porcelain insulator 1 around the center electrode 2 should appear clean and colorless with a gray ring around the center electrode where it exits the porcelain Metallic specks indicate lean jetting that is removing metal from the piston Black sooty streaks on the porcelain...

Page 129: ...ion of the fork tubes in the clamps is not adjustable Align the groove in the outer tube with the top surface of the upper fork clamp Standard Position Align the groove 1 in the outer tube with the top surface of the upper fork clamp 2 Adjusting your CRF s wheelbase can offer subtle changes in overall handling You may adjust wheelbase by adding or removing links on the drive chain If you change th...

Page 130: ...anges from good to great and back to good and possibly ends the day with a slick rock hard consistency Ideally your gearing should be adjusted to suit all these conditions Wet and slippery or sandy conditions use a higher gear less teeth to keep engine rpm down and avoid unwanted wheelspin The engine may bog in certain corners so you ll need to slip the clutch to compensate downshifting may be too...

Page 131: ... be less acceptable in other circumstances For example an aggressive mud tire will give excellent grip on wet loamy terrain but less impressive grip on a hard surface If you choose a tire with a sticky compound for added traction remember that it may transfer additional loads to the transmission because it grips so well especially when riding in situations that normally place unusual demands on th...

Page 132: ...rapid access but not so close that either is depressed when sitting or standing comfortably on your CRF Position the handlebar so that both gripping the bar and operating the controls is comfortable while both seated and standing while riding straight ahead and turning Tighten the forward bolts first Be sure to check control cable and wiring harness routing after the adjustment Handlebar width can...

Page 133: ...d store your Honda as well as three troubleshooting flow charts Transporting Your Motorcycle 128 Storing Your Honda 129 Preparation for Storage 129 Removal from Storage 129 You the Environment 130 Troubleshooting 131 31KSE7100_NA book 127 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 134: ...rail Attach the lower ends of two straps to the tie down hooks on your CRF Attach the upper ends of the straps to the handlebar one on the right side the other on the left close to the fork Check that the tie down straps do not contact any control cables or electrical wiring Tighten both straps until the front suspension is compressed about half way Too much pressure is unnecessary and could damag...

Page 135: ...equivalent to raise both tires off the ground 9 Stuff a rag into the muffler outlet Then tie a plastic bag over the end of the muffler to prevent moisture from entering 10 Store your CRF in an unheated area free of dampness away from sunlight with a minimum of daily temperature variation 11 Cover your CRF with a porous material Avoid using plastic or similar non breathing coated materials that res...

Page 136: ...away see the following guidelines for proper disposal Recycle Wastes It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline and cleaning solvents contain poisons that can hurt refuse workers and contaminate our drinking water lakes rivers and oceans Before changing your oil make sure you have the proper containers Put oil and other toxic wa...

Page 137: ...ew out P 120 Fuel air mixture too rich Turn the pilot screw in P 120 4 Check carburetor jets and accelerator pump for clogs Contaminants in the fuel Not cleaned frequently enough P 112 5 Try spark test Faulty carbon or wet fouled spark plug P 52 Faulty ignition control module Faulty exciter coil Faulty engine stop button Faulty direct ignition coil Broken or shorted direct ignition coil wire Loose...

Page 138: ...132 Tips 31KSE7100_NA book 132 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 139: ...ntains dimensions capacities and other technical data Vehicle Identification 134 Specifications 135 Torque Specifications 137 Oxygenated Fuels 140 Competition Logbook 141 Optional Parts List 143 Spare Parts Equipment 145 Wiring Diagram 146 31KSE7100_NA book 133 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 140: ... when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle identification number 1 is stamped on the right side of the steering head RIGHT SIDE 1 VIN The engine number 2 is stamped on the left crankcase LEFT SIDE Serial Numbers 2 engine number 1 2 31KSE7100_NA book 134 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 141: ... inclined from vertical Bore and stroke 2 60 x 1 72 in 66 0 x 43 7 mm Displacement 9 13 cu in 149 7 cm3 Compression ratio 11 7 1 Valve clearance Intake 0 006 0 001 in 0 16 0 03 mm Exhaust 0 010 0 001 in 0 26 0 03 mm Engine oil capacity 0 59 US qt 0 56 ℓ After draining After draining and oil filter change 0 62 US qt 0 59 ℓ After disassembly 0 74 US qt 0 70 ℓ Transmission oil capacity 0 60 US qt 0 5...

Page 142: ...9 inclined from vertical Bore and stroke 2 60 x 1 72 in 66 0 x 43 7 mm Displacement 9 13 cu in 149 7 cm3 Compression ratio 11 7 1 Valve clearance Intake 0 006 0 001 in 0 16 0 03 mm Exhaust 0 010 0 001 in 0 26 0 03 mm Engine oil capacity 0 59 US qt 0 56 ℓ After draining After draining and oil filter change 0 62 US qt 0 59 ℓ After disassembly 0 74 US qt 0 70 ℓ Transmission oil capacity 0 60 US qt 0 ...

Page 143: ... 7 10 1 0 4 Crankshaft hole cap 11 15 1 5 NOTE 5 5 Transmission oil check bolt 7 10 1 0 6 Cylinder bolt 7 10 1 0 7 Oil filter cover bolts 7 10 1 0 8 Cylinder head bolts 7 10 1 0 9 Drive sprocket bolt 10 13 1 3 10 Transmission oil drain bolt 16 22 2 2 NOTE 3 11 Engine oil drain bolt 16 22 2 2 NOTE 3 NOTES 1 U nut 2 UBS nut 3 Apply oil to the threads and seating surface 4 Alock bolt 5 Apply grease t...

Page 144: ... 34 3 5 10 Middle engine mounting nut 47 64 6 5 11 Shock absorber 32 44 4 5 NOTE 1 12 Swingarm pivot nut 61 83 8 5 13 Rear shock arm nuts swingarm side 32 44 4 5 NOTE 1 shock link side 32 44 4 5 NOTE 1 14 Rear shock link nuts frame side 32 44 4 5 NOTE 1 15 Shock spring lock nut 32 44 4 5 16 Kickstarter arm bolt 28 38 3 9 17 Throttle cable adjuster lock nut 3 0 4 0 0 4 18 Brake lever adjuster lock ...

Page 145: ...cap lock nut 15 19 7 2 0 29 Fork protector bolts 5 2 7 0 7 NOTE 4 30 Muffler mounting bolts 24 32 3 3 31 Muffler clamp bolt 15 21 2 1 32 Driven sprocket nuts 24 32 3 3 NOTE 1 33 Seat mounting bolts 19 26 2 7 34 Front brake reservoir cap screws 1 1 1 5 0 2 35 Rear brake reservoir cap bolts 1 1 1 5 0 2 36 Fork air pressure release screw 1 0 1 3 0 1 37 Fuel valve bolts 7 10 1 0 NOTES 1 U nut 2 UBS nu...

Page 146: ...ing ethanol may be marketed under the name Gasohol METHANOL methyl or wood alcohol up to 5 by volume You may use gasoline containing up to 15 methanol by volume as long as it contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of yo...

Page 147: ...engine running time on suspension components Timekeeping This Manual lists maintenance intervals for every so many races or every so many hours of running Because all races are not the same the most effective way to schedule maintenance is by the hours you have run your CRF An official guesstimate is close enough for our timekeeping purposes You may choose to record your time the same way aircraft...

Page 148: ...Information Date Running Time Location Event Comments Jetting Suspension Settings Gearing Chassis Adjustments Maintenance Performed etc Make several photocopies of this page for future use 31KSE7100_NA book 142 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 149: ...S ø2 765 mm NMRS ø2 765 mm standard needle NMQT ø2 775 mm NMRT ø2 775 mm NMQU ø2 785 mm NMRU ø2 785 mm Lean NMQV ø2 795 mm NMRV ø2 795 mm MARK CARBURETOR Remarks Fuel flow amount Leak jet number decrease 75 70 65 standard 60 increase 55 MUFFLER Remarks AMA Noise Emission Regulation Conformed Muffler Using an optional muffler change the carburetor settings See page 118 for more details FRAME Remark...

Page 150: ... Standard 291 2 lbf in 51 0 N mm Stiffer 302 6 lbf in 53 0 N mm White mark No mark Black mark FRAME Remarks Fork springs CRF150R Softer 17 9 lbf in 3 14 N mm Standard 19 0 lbf in 3 33 N mm Stiffer 20 2 lbf in 3 53 N mm CRF150RB Softer 19 0 lbf in 3 33 N mm Standard 20 2 lbf in 3 53 N mm Stiffer 21 3 lbf in 3 73 N mm 2 coils at one end 1 coil at other end 1 coil at both ends 1scribe mark 1 coil at ...

Page 151: ...ex Allen wrench spoke torque wrench metric scale click stop style pliers standard needle nose channel lock set hammer plastic head syringe with adjustable stop tire pressure gauge tire irons tire pump or air tank feeler gauge set vernier caliper metric pressure vacuum testing equipment USA only Any special tools for your CRF purchased from your dealer Spoke Wrench 07701 0020300 Tensioner Stopper 0...

Page 152: ...Wiring Diagram 146 Technical Information Wiring Diagram 31KSE7100_NA book 146 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 153: ...147 Consumer Information This section contains information about contacting Honda and how to get an official Honda Service Manual Authorized Manuals 148 Contacting Honda 149 Your Honda Dealer 150 31KSE7100_NA book 147 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 154: ...r s Manual and Service Manual can help you prepare your Honda motorcycle scooter ATV and SxS for winter storage These Honda manuals are written for the professional technician but most mechanically capable owners should find them helpful if they have the proper tools and skills Special Honda tools are necessary for some procedures Order online www helminc com Order Toll Free 1 888 CYCLE93 1 888 29...

Page 155: ...ou wish to comment on your experiences with your Honda or with your dealer please send your comments to the following address Motorcycle Division American Honda Motor Co Inc P O Box 2200 Torrance CA 90509 2200 mailstop 100 4C 7B telephone 866 784 1870 Canada Honda Canada Inc Customer Relations Dept 180 Honda Boulevard Markham Ontario L6C 0H9 telephone 888 946 6329 facsimile 877 939 0909 E mail hon...

Page 156: ...nda Genuine Parts Pro Honda products Honda Genuine Accessories USA only and Honda accessories and products Canada only The same quality that went into your Honda can be found in Honda Genuine replacement parts You ll also find comparable quality in the accessories and products available from the parts department Your dealer can inform you about competition events in your area We re sure you ll be ...

Page 157: ...Consumer Information 151 31KSE7100_NA book 151 ページ ２０１９年４月９日 火曜日 午後１時１３分 ...

Page 158: ...ments 120 optional muffler settings 118 care appearance 90 chain drive 82 chassis adjustments 123 choke knob 13 cleaner air 43 cleaning appearance care 90 clutch system adjustment 49 competition logbook 141 consumer information 147 contacting Honda 149 controls operating 5 coolant 41 customer service 149 cylinder system 62 damping adjustments front 100 rear 103 dealer your Honda 150 diagram wiring...

Page 159: ...ompetition 26 between motos practice 26 component locations 28 general competition 22 importance 18 safety 19 schedule 20 manual service 148 modifications 3 oil engine 36 fork 72 transmission 39 operating controls 5 instructions 11 operation component locations 6 optional muffler settings 118 parts list 143 sprockets 124 oxygenated fuels 140 pads brake 78 parts optional 143 personal fit adjustment...

Page 160: ...pension 102 starting engine 13 troubleshooting 131 steering stem inspection 88 stopping engine 14 storage 129 subframe 32 suspension front 70 94 rear 71 102 suspension adjustment front 94 rear 102 for track conditions 106 guidelines 107 transmission oil 39 tuning tips 110 throttle freeplay 46 inspection 47 tires air pressure 80 flat 80 selection 81 tools 145 torque specifications carburetor 116 en...

Page 161: ...items listed on the Pre ride inspection checklist each time before you ride page 9 Fuel Capacity unleaded gasoline pump octane number of 91 or higher tank 1 14 US gal 4 3 ℓ Engine Oil Capacity Pro Honda GN4 4 stroke oil USA Canada or Honda 4 stroke oil or an equivalent motorcycle oil 0 62 US qt 0 59 ℓ after draining and oil filter change 0 59 US qt 0 56 ℓ after draining Transmission Oil Capacity P...

Page 162: ... are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle 31KSE7100_NA book 157 ペー...

Page 163: ...Black Pantone 186C CRF150R RB L PRINTED IN XXXX XXXX 2019 XX L 00X31 KSE 7100 31KSE710 2020 2020 CRF150R RB ...

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