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Honda NSR150SP (TYPE 1), Manual, Page: 12 / 287

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Honda NSR150SP (TYPE 1) Manual Download Page 12

NSR150SP                   General Information 

______________________________________________

 

 

1-11 

 

CRANKSHAFT/TRANSMISSION 

 

 

 

 

 

 

 

 

 

 

 

Unit:   mm (in) 

ITEM STANDARD 

SERVICE 

LIMIT 

Side clearance 

0.3 – 0.7 (0.012 – 0.028) 

 

Connecting rod big end 

Radial 
clearance 

 0.05(0.002) 

A  

0.05(0.002) 

Crankshaft runout 

B  

0.03(0.001) 

M5, M6 

22.020–22.041(0.8669–0.8678) 

22.10(0.870) 

C1 20.020-20.041(0.7882-0.7890) 

20.10(0.791) 

C2, C4 

22.020–22.041(0.8669–0.8678) 

22.10(0.870) 

Transmission gear I.D. 

C3 25.020-25.041(0.9850-0.9859) 

25.10(0.988) 

M5, M6 

21.979-22.000(0.8653-0.8661) 

21.90(0.862) 

C1 19.984-19.995(0.7868-0.7872) 

19.90(0.783) 

C2 21.984-22.005(0.8655-0.8663) 

21.90(0.862) 

Transmission gear  
bushing O.D. 

C3 24.984-24.993(0.9836-0.9840) 

24.90(0.980) 

M5, M6 

20.000-20.021(0.7874-0.7882) 

20.01(0.791) 

C1 17.016-17.034(0.6700-0.6706) 

17.10(0.673) 

C2 20.020-20.041(0.7882-0.7890) 

20.10(0.791) 

Transmission gear  
bushing I.D. 

C3 22.020–22.041(0.8669–0.8678) 

22.10(0.870) 

M5, M6 

0.020-0.062(0.0008-0.0024) 

0.10(0.004) 

C1 0.025-0.057(0.0010-0.0022) 

0.10(0.004) 

C2 0.015-0.057(0.0006-0.0022) 

0.10(0.004) 

Gear-to-bushing clearance 

C3 0.027-0.057(0.0011-0.0022) 

0.10(0.004) 

M5 19.959-19.980(0.7858-0.7866) 

19.92(0.784) 

Mainshaft O.D. 

Right Crankcase 
journal 

16.966-16.984(0.6683-0.6687) 16.95(0.667) 

C1 16.975-16.984(0.6683-0.6687) 

16.95(0.667) 

C2 19.974-19.984(0.7863-0.7867) 

19.94(0.785) 

Countershaft O.D. 

C3, C4 

21.959-21.980(0.8645-0.8653) 

21.09(0.830) 

Gear-to-shaft clearance 

C4 

0.040-0.082(0.0016-0.0032) 0.10(0.004) 

M5, M6 

0.020-0.062(0.0001-0.0024) 

0.10(0.004) 

C1 0.032-0.059(0.0013-0.0023) 

0.10(0.004) 

C2 0.033-0.067(0.0013-0.0026) 

0.10(0.004) 

Gear bushing-to-shaft 
clearance 

C3 0.040-0.082(0.0016-0.0032) 

0.10(0.004) 

Shift fork claw thickness 

4.93-5.00(0.194-0.197) 

4.80(0.189) 

Shift fork I.D. 

12.041-12.056(0.4741-0.4746) 

12.65(0.475) 

Shift fork shaft O.D 

11.983-11.994(0.4718-0.4722) 

11.973(0.4714) 

 

http://mototh.com

Summary of Contents for NSR150SP (TYPE 1)

Page 1: ...ST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL INSTALLATION CYLINDER HEAD CYLINDER PISTON RC VALVE SERVO MOTOR CLUTCH GEARSHIFT LINKAGE KICKSTARTER ALTERNATOR BALAN...

Page 2: ...ced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying or recording or otherwise without the prior written permission of Honda Motorcycle Power Equ...

Page 3: ...ase NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2...

Page 4: ...or rubber parts will damage them Place a clean shop towel over these parts whenever the system is serviced KEEP OUT OF REACH OF CHILDREN The exhaust contains poisonous carbon monoxide gas that can ca...

Page 5: ...the coolant to ignite and burn without a visible flame Coolant ethylene glycol can cause some skin irritation and is poisonous if swallowed KEEP OUT OF REACH OF CHILDREN Keep out of reach of pets Som...

Page 6: ...steners The use of incorrect tools and fasteners may damage the motorcycle 4 Install new gaskets 0 rings cotter pins lock plates etc When reassembling 4 When tightening a series of bolts or nuts begin...

Page 7: ...on 1 FRAME SERIAL NUMBER 2 ENGINE SERIAL NUMBER The frame serial number is stamped The engine serial number is On the right side of the steering head Stamped on the right crankcase 3 CARBURETTOR IDENT...

Page 8: ...908 kPa 10kgf cm2 142psi Pressurized gas material Nitrogen Front tyre size 90 80 17 46S Rear tyre size 120 80 17 61S Front brake Hydraulic single disc Rear brake Hydraulic single disc Caster angle 25O...

Page 9: ...reduction 2 954 65 22 Final reduction 2 857 40 14 Gear ratio 1st 2 916 35 12 Gear ratio 2nd 1 937 31 16 Gear ratio 3rd 1 470 25 17 Gear ratio 4th 1 210 23 19 Gear ratio 5th 1 043 24 23 Gear ratio 6th...

Page 10: ...da 4 stroke oil or equivalent API Service Classification SE SF or SG Viscosity SAE 10W 40 FUEL SYSTEM ITEM STANDARD Carburettor identification number PE74A Choke type Starting enrichment circuit syste...

Page 11: ...n to piston pin clearance 0 002 0 021 0 0001 0 0008 0 04 0 002 Piston ring to ring groove clearance 0 12 0 05 Top 0 38 0 53 0 015 0 021 0 65 0 026 Ring end gap Second 0 38 0 53 0 015 0 021 0 65 0 026...

Page 12: ...0 20 10 0 791 Transmission gear bushing I D C3 22 020 22 041 0 8669 0 8678 22 10 0 870 M5 M6 0 020 0 062 0 0008 0 0024 0 10 0 004 C1 0 025 0 057 0 0010 0 0022 0 10 0 004 C2 0 015 0 057 0 0006 0 0022 0...

Page 13: ...Recommended fork oil Fork oil level 125 4 9 Fork oil capacity 322 cm3 10 9 US oz 11 3 Imp oz Steering bearing preload 1 0 1 5 N m 0 1 0 15 kgf m REAR WHEEL SUSPENSION ITEM STANDARD SERVICE LIMIT Minim...

Page 14: ...y cup side 12 657 12 684 0 4983 0 4994 12 645 0 4978 Caliper cylinder I D 25 40 250 45 0 999 1 002 25 46 1 002 REAR Caliper piston O D 25 335 25 368 0 9974 0 9987 25 300 0 9960 BATTERY CHARGING SYSTEM...

Page 15: ...0 5 3 6 6 mm screw 9 0 9 6 5 6 mm hex bolt and nut 10 1 0 7 6 mm flange bolt 8mm head 9 0 9 6 5 8 mm hex bolt and nut 22 2 2 16 6 mm flange bolt 10mm head and nut 10 mm hex bolt and nut 34 3 5 25 12...

Page 16: ...se cover bolt 6mm 10 8 10 1 0 7 8mm 1 8 26 2 7 20 Clutch cable adjuster lock nut 1 8 23 2 3 17 Primary drive gear nut 1 12 66 6 7 48 Note 6 Clutch lifter plate bolt 4 6 12 1 2 9 Clutch centre lock nut...

Page 17: ...screw 4 6 5 1 0 52 3 8 Shock absorber upper mounting bolt 1 10 44 4 5 33 Shock absorber lower mounting bolt 1 10 44 4 5 33 Note 9 BRAKE SYSTEM Front brake disc bolt 6 8 42 4 3 31 Note 2 Rear brake di...

Page 18: ...46 0040400 12 Pilot 20mm 07746 0040500 12 Pilot 25mm 07746 0040600 12 Pilot 40mm 07746 0040900 14 Pilot 22mm 07746 0041000 12 Bearing remover shaft 07746 0050100 13 Bearing remover head 15mm 07746 005...

Page 19: ...ing sliding area and tooth Kickstarter spindle Spline area Rotating sliding area and tooth Water pump shaft rotating sliding area and tooth Clutch lever sliding surface Primary drive gear nut threads...

Page 20: ...ads Cylinder Right and left crankcase mating surface Reed valve Right and left crankcase mating surface Liquid sealant Example Three Bond 1207B manufactured by 3M co Ltd 4 1 mm Crankcase bolt threads...

Page 21: ...cleaner housing and connecting tube matching surface Locking agent Brake caliper piston sliding surface Master cylinder piston cap Master cylinder piston sliding surface DOT 4 brake fluid Front and r...

Page 22: ...CABLE HARNESS ROUTING http mototh com Throttle Cable Meter 9P BIO ck Connector Combination Meter 3P BI ackV Connector Turn Signal Connectors 3P Connector Tachometer Front Brake S I itc h Wires Front B...

Page 23: ...NSR150SP General Information ______________________________________________ 1 22 http mototh com...

Page 24: ...Left Crankcase Breather Tube Battery Breather Tube Brake Hose Left Handle Switch 4P Connector Left Handle Switch 9P Connector Ignition Switch 2P Connector Crankc Tube Main Wire Harness Rear Brake Lig...

Page 25: ...___________________________________________ 1 24 http mototh com Crankcase Breather Tub Left Handle Switch 4P Red Connector Left Handle Switch 9P Connector Ignition Switch 2P Connector 71n ft jf _l Ai...

Page 26: ...ion ______________________________________________ 1 25 http mototh com Fuel Unit 3P Connector Oil Leve nnector Sensor 0 Ignition I Module Contro k Hose Rear Bra e Brake Rear Hose Reservoir _ __ r Rea...

Page 27: ...t system and all fasteners loosely Always tighten the exhaust clamps first then tighten the mounting fasteners first the exhaust pipe may not seat properly This section covers removal and installation...

Page 28: ...50SP Frame Body Panels Exhaust System ______________________________________________ 2 2 BODY PANEL LOCATION http mototh com Left Air Guide page 2 11 Seat page 2 3 Upper Cowl page 2 9 Rear Cover page...

Page 29: ...n Apply grease to the seat catch Install the seat aligning the hooks on the seat with the frame Lock the pillion seat securely SEAT Removal Remove the pillion seat see above Operate the set lever and...

Page 30: ...WER COWL SIDE COWL Removal Installation Remove the screws and side cowl Installation is in the reverse order of removal NOTE At installation align the tabs on the side cowl with the grooves on the low...

Page 31: ...left lower cowl right lower cowl and centre lower cowl Assembly Assembly is in the reverse order of removal Installation NOTE At tachometer cable removal be careful not to damage the tab on the lower...

Page 32: ..._ 2 6 INNER PANEL Removal Installation Remove the screws and inner panel Installation is in the reverse order of removal GRAB RAIL Removal Installation Remove the socket bolts and grab rail Installati...

Page 33: ...llar and left side cover Installation is in the reverse order of removal NOTE At installation align the tabs on the right side cover with the grooves on the rear cover At installation align the tabs o...

Page 34: ...the seat lock operation using the ignition key REAR FENDER Removal Installation Remove the side cover rear cover and tail cover page 2 8 Remove the ICM page 17 1 Remove the screw and ICM bracket Disc...

Page 35: ..._________________ 2 9 UPPER COWL REARVIEW MIRROR AIR GUIDE REARVIEW MIRROR Removal Installation Remove the cap nut and rearview mirror Installation is in the reverse order of removal UPPER COWL Remova...

Page 36: ...e upper cowl with the tabs on the frame Install the speedometer cable to the hole on the upper cowl Connect the headlight 3P connector and front turn signal connectors Connect the speedometer cable to...

Page 37: ...d right air guide Remove the screws right air guide and right air guide plate Installation is in the reverse order of removal LEFT AIR GUIDE Remove the bolts and left air guide Remove the screws left...

Page 38: ...the fuel unit 3P connector Disconnect the fuel tube from the fuel valve Remove the bolt cap fuel tank mounting bolt and washer Remove the fuel tank hooks from the rubber mounts Remove the fuel tank Ga...

Page 39: ...__ 2 13 DISASSEMBLY Loosen the fuel tap nut and remove the fuel tap Remove the fuel strainer screen and O ring Clean the fuel strainer screen Remove the fuel unit wire from the clamp Remove the nuts a...

Page 40: ...el tank CAUTION Be careful not to damage the fuel unit Install and tighten the nuts securely Install the fuel unit wire to the clamp Install the new O ring and fuel strainer screen to the fuel tank In...

Page 41: ...its hooks to the rubber mounts on the frame Install the fuel tank mounting bolt and washer Install and tighten the fuel tank mounting bolt to the specified torque Install the bolt cap Connect the fue...

Page 42: ...and nut Remove the exhaust pipe mounting bolt and washer Remove the gasket and muffler exhaust pipe assembly Install the new gasket Install the muffler exhaust pipe assembly Temporarily install the al...

Page 43: ...eering Head Bearings 3 27 Drive Chain 3 17 SERVICE INFORMATION Specification ITEM SPECIFICATION Throttle grip free play 2 6mm 0 08 0 24 NGK NIPPONDENSO Standard B9ES W27ES U Spark Plug For Cold climat...

Page 44: ...ICATIONS Front 1 5mm Minimum tire depth Rear 2 0mm Front 90 80 17 46S Tire Size Rear 120 80 17 61S Front NF46 Tire Band IRC Rear NR57 TORQUE VALUES Oil drain bolt 21N m 2 1 kgf m 15 lbf ft Spark Plug...

Page 45: ...ir Cleaner Note 2 C C C Spark Plug I R I Decarbonizing C Engine Idle Speed I I I I Radiator Coolant Note 3 I Cooling System I Transmission Oil R Drive Chain I L Every 1 000km 600ml Drive Chain Slider...

Page 46: ...iner screen cleaning FUEL CUP STRAINER Remove the fuel tank page 2 12 Remove the fuel cup 0 ring and fuel cup strainer Wash the cup strainer and cup in clean non flammable high flash point solvent Rei...

Page 47: ...lubricant or a light weight oil If the throttle grip still does not return properly replace the throttle cables With the engine idling turn the handlebar all the way to the right and left to ensure th...

Page 48: ...r deterioration damage or leakage Replace the fuel lines if necessary Bleed the oil pump and oil line if they have air bubbles in them page 4 6 Route the tubes properly ENGINE OIL STRAINER SCREEN Remo...

Page 49: ...oil strainer with compressed air Install the oil strainer to the strainer joint Install the strainer joint to the oil tank Fill the oil tank with the recommended engine oil and bleed the air from the...

Page 50: ...fully Check that the aligning mark on the oil pump drum is aligned with the index mark projection on the oil pump body Adjust if necessary by turning the adjusting nut CAUTION An adjustment within 1...

Page 51: ...ctions are required Remove the fuel tank page 2 12 Remove the screws and air cleaner housing cover Remove the element from the air cleaner housing Wash the element in non flammable or high flash point...

Page 52: ...stall the fuel tank page 2 14 SPARK PLUG Remove the side cowl Disconnect the spark plug cap and clean around the spark plug bases NOTE Clean around the spark plug base with compressed air before remov...

Page 53: ...n the center and side electrodes with a wire type feeler gauge If necessary adjust the gap by bending the side electrodes carefully SPARK PLUG GAP 0 7 0 8mm 0 028 0 031in CAUTION To prevent damage to...

Page 54: ...bustion chamber and clean off the head gasket surface CAUTION Avoid damaging the gasket surface Check the spark plug hole for cracks CYLINDER EXHAUST PORT Remove the cylinder Remove the RC valve Clean...

Page 55: ...fler mounting bolt ENGINE IDLE SPEED NOTE Inspect and adjust idle speed after all other engine adjustments are within specification Engine must be warm for accurate adjustment Ten minutes of stop and...

Page 56: ...lant level decreases very rapidly If the reserve tank becomes completely empty there is a possibility of air getting into the cooling system Be sure to remove all air from the cooling system as descri...

Page 57: ...mps are tight TRANSMISSION OIL OIL LEVEL INSPECTION NOTE The oil level cannot be correctly measured if the motorcycle is not supported perfectly upright on a level surface As the oil is gradually cons...

Page 58: ...shown in the chart may be used when the average temperature in your riding area is within the indicated range Reinstall the oil filler cap For engine oil change see below OIL CHANGE NOTE Change the en...

Page 59: ...mp qt Install the oil filler cap Start the engine and re check the oil level Make sure that there are no oil leaks Install the lower cowl DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Turn the ignition swi...

Page 60: ...h bolt to the specified torque TORQUE 73 N m 7 4 kgf m 54 lbf ft Re check chain slack and free wheel rotation Lubricate the drive chain with 80 90 gear oil Wipe off the excess chain oil CLEANING INSPE...

Page 61: ...pect the drive and driven sprocket teeth for damage or wear Replace if necessary Never use a new drive chain on worn sprockets Both chain and sprockets must be in good condition or the new replacement...

Page 62: ...terial to enter the system when filling the reservoir Avoid spilling fluid on painted plastic or rubber parts Place a rug over these parts whenever the system is serviced NOTE When the fluid level is...

Page 63: ...nd fill the reservoir to the casting ledge with DOT 3 or 4 brake fluid from a sealed container REAR BRAKE Remove the right side cover page 2 7 Place the motorcycle on a level surface and support it up...

Page 64: ...pads if either pad is worn to the bottom of wear limit groove Refer to page 15 9 for brake pad replacement BRAKE SYSTEM Firmly apply the brake lever or pedal and check that no air has entered the syst...

Page 65: ...the light Adjust the rear brake light switch so that the brake light comes on just prior to the brake actually being engaged If the light fails to come on adjust the switch so that the light comes on...

Page 66: ...justment as described below Remove the side cowl and lower cowl Major adjustment is performed at the clutch arm Loosen the lock nut and turn the adjusting nut to adjust free play Hold the adjusting nu...

Page 67: ...ings if any looseness is noted Check the action of the shock absorbers by compressing them several times Check the entire shock absorber assembly for signs of leaks damage or loose fasteners Replace d...

Page 68: ...e swingarrn pivot is included in this check be sure to confirm the location of the play i e from the wheel bearings or the swingarm pivot NOTE Tire pressure should be checked when tires are COLD Check...

Page 69: ...k that the control cables do not interfere with handlebar rotation Support the motorcycle securely and raise the front wheel off ground check that the handlebar moves freely from side to side If the h...

Page 70: ...NSR150SP Lubrication System ______________________________________________ 4 0 http mototh com Oil Level Sensor Oil Pass Tube...

Page 71: ...e to prevent oil from flowing out The oil pump control cable should be adjusted after the throttle grip free play is adjusted For oil indicator inspection refer to section 18 of this manual For engine...

Page 72: ...essive smoke and or carbon on spark plug Faulty oil pump too much oil flow Low quality engine oil Overheating or seized piston No oil in tank or clogged oil line Air in oil lines or oil pump Faulty oi...

Page 73: ...ver Page 2 6 Disconnect the oil level sensor connectors Remove the bolts and oil tank Remove the oil tank cap and drain the engine oil Remove the joint band and oil strainer from the oil tank Remove t...

Page 74: ...sure that there are no oil leaks OIL PUMP CAUTION Air in oil system will block or restrict oil flow and may result in severe engine damage Bleed air from the oil lines whenever the oil lines pump have...

Page 75: ...tube to prevent oil from flowing out Loosen the lock nut and disconnect the oil control cable from the oil pump drum Remove the right crank case cover Page 10 3 Remove the snap ring and washer Remove...

Page 76: ...o not attempt to disassemble the oil pump Check the oil pump body for damage Check the oil pump oil seal for wear or damage Check the oil pump drum for smooth operation AIR BLEEDING INSTALLATION OIL T...

Page 77: ...outlet Wait until there are no air bubbles in the oil coming out of the oil pump shaft hole then reinstall the oil pump shaft Turn the oil pump with its installing surface on level ground Remove the...

Page 78: ...ll the new 0 ring to the oil pump groove Apply transmission oil to the new 0 ring and then install the oil pump O ring to the right crankcase cover Install and tighten the bolts securely Install the d...

Page 79: ...ed with fuel oil mixture 25 50 parts fuel to 1 part oil Start the engine and allow it to idle with the oil control lever in the fully open position making sure that oil is flowing out of the oil pass...

Page 80: ..._______________ 4 10 Connect the oil pump control cables to the oil pump drum Adjust the oil pump control cables Page 3 6 Install the oil pump cover Install and tighten the bolts securely Install the...

Page 81: ...NSR150SP Fuel System ________________________________________________ 5 0 http mototh com...

Page 82: ...with a shop towel or cover them with a piece of tape to prevent any foreign material from dropping into the engine Be sure to remove the cover when reinstalling the carburettor When disconnecting the...

Page 83: ...ng enrichment circuit system Main jet 152 Slow jet 42 Air screw initial opening 2 turns out Float level 19 mm 0 7 in Idle speed 1 300 100 min 1 rpm Throttle grip free play 2 6 mm 0 08 0 24 in TORQUE V...

Page 84: ...ow Fuel line restricted Intake air leak Throttle valve faulty Rich mixture Starting enrichment valve ON Float valve faulty Float level too high Air jets clogged Air cleaner element contaminated Floode...

Page 85: ...isconnect the drain tubes and crankcase breather tubes Installation is in the reverse order of removal THROTTLE VALVE REMOVAL Remove the air cleaner housing page 5 4 Remove the carburettor top and pul...

Page 86: ...e retainer to the throttle valve aligning the grooves on the retainer and throttle valve Install the throttle valve spring and washer to the carburettor top Compress the throttle valve spring against...

Page 87: ...air cleaner housing Remove the throttle valve page 5 4 Disconnect the oil pass tube from the carburettor Clamp the oil pass tube to prevent oil from flowing out Disconnect the carburettor breather tu...

Page 88: ...n easily be blocked Remove the main jet needle jet holder needle jet and slow jet CAUTION Damage to the air screw seat will occur if the air screw is tightened against the seat Turn the air screw in a...

Page 89: ...lve does not seat properly and will eventually flood the carburettor JETS Check each jets for wear or blockage Clean the jets with non flammable or high flash solvent and blow open with compressed air...

Page 90: ...all the spring washer and throttle stop screw http mototh com Carburett Throttle Cable SPrin a washer g Retainer Spring JetNeedJe Throttle Valve Air Screw Throttle Stop Control Knob Float Carburettor...

Page 91: ...arm lip Be sure that the float valve tip is securely in contact with the valve seat Make sure the float level with the float level gauge TOOL Float level gauge 07401 0010000 FLOAT LEVEL 19 mm 0 7 in...

Page 92: ...he float chamber groove Install the float chamber Install and tighten the screw securely Connect the drain tube and fuel tube to the carburettor INSTALLATION Install the SE valve to the carburettor an...

Page 93: ...on turn the fuel valve ON and check the fuel line for leakage AIR SCREW ADJUSTMENT CAUTION Damage to the air screw seat will occur if the air screw is tightened against the seat Warm the engine up to...

Page 94: ...air screw by turning it in or out a 1 4 of a turn If the engine cannot be adjusted by turning the air screw within a 1 4 turn check for other engine problems REED VALVE AIR CHAMBER REMOVAL Remove the...

Page 95: ...fatigue or damage Check the reed valve seat for cracks or damage Replace it as an assembly if necessary INSTALLATION Apply a light coating of sealant to the crankcase as shown Install the new gasket t...

Page 96: ...___ 5 15 Install the carburettor insulator to the crankcase Install the air chamber bracket Install and tighten the bolts securely Install the air chamber Install the tube band Install and tighten the...

Page 97: ...NSR150SP Cooling System ______________________________________________ 6 0 http mototh com 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1...

Page 98: ...r servicing the system check for leaks with a cooling system tester Refer to Section 18 for thermo sensor inspection SPECIFICATIONS ITEM STANDARD Cooling capacity Radiator and engine 1 2 litre 1 27 US...

Page 99: ...ng weight 07741 0010201 Mechanical seal driver 07PMD KBP0100 TROUBLESHOOTING Engine temperature too high Faulty temperature gauge or thermo sensor Section 18 Faulty radiator cap Insufficient coolant P...

Page 100: ...NSR150SP Cooling System ______________________________________________ 6 3 SYSTEM FLOW PATTERN http mototh com Radiator Reserve Tank _ Lower Radiator Hose Engine Feed...

Page 101: ...009 1 007 1 005 15 1 025 1 027 1 026 1 025 1 024 1 022 1 020 1 018 1 016 1 014 1 012 20 10 36 1 035 1 034 1 033 1 031 1 029 1 027 1 025 1 023 1 021 1 019 25 1 045 1 044 1 043 1 042 1 040 1 038 1 036 1...

Page 102: ...6 19 9 psi Pressurise the radiator engine and hoses and check for leaks CAUTION Excessive pressure can damage the cooling system components Do not exceed 137 kPa 1 4 kgf cm 2 19 9 psi Check the follo...

Page 103: ...ion on a flat level surface Remove the right air guide page 2 11 Remove the radiator cap Remove the lower cowl page 2 5 Remove the drain bolt and seating washer Drain the coolant Reinstall and tighten...

Page 104: ...e tank to the upper level line Bleed air from the system as follows NOTE Remove the filler cap before starting 1 Shift the transmission into neutral Start the engine and let it idle for 2 3 minutes 2...

Page 105: ...the lower radiator hose Remove the bolts Disconnect the radiator breather tube Remove the tabs on the radiator from the grommets on the frame Loosen the screw and hose band Disconnect the upper radia...

Page 106: ...coolant leakage If there is leakage the mechanical seal is defective and must be replaced page 6 1 REMOVAL Remove the side cowl and lower cowl Drain the coolant Loosen the screw and hose band Disconne...

Page 107: ...old the water pump shaft securely Remove the water pump impeller by turning it counterclockwise Remove the washer and water pump shaft Check the water pump shaft bushing in the right crankcase for wea...

Page 108: ...weight 07741 0010201 Remove the water pump mechanical seal from the right crankcase cover Install the new water pump mechanical seal to the right crankcase cover using the following tools TOOLS Mechan...

Page 109: ...the water pump shaft to the right crankcase cover Install the washer and water pump impeller Hold the water pump shaft using the spanner Tighten the water pump impeller to the specified torque TORQUE...

Page 110: ...Tighten the bolts securely Connect the lower radiator hose to the water pump cover Tighten the hose band screw securely Fill and bleed the cooling system page 6 6 Install the side cowl and lower cowl...

Page 111: ...NSR150SP Engine Removal Installation ________________________________________________ 7 0 http mototh com 55Nm 56 kgf m 41 Ibf ft 55 N m 56 k gf m 41 Ibf ft...

Page 112: ...tion 11 17 Carburettor Section 5 Oil pump Section 4 Clutch gearshift linkage kickstarter Section 10 RC valve servo motor Section 9 Cylinder head cylinder piston Section 8 Water pump Section 6 The foll...

Page 113: ...ngine Turn the bearing holder with the pin spanner slacken the drive chain fully Remove the gearshift pedal link pinch bolt and gearshift pedal link Remove the bolts and drive sprocket cover Remove th...

Page 114: ...hoist Turn the ignition switch OFF and disconnect the battery ground cable A floor jack or other adjustable support is required to support and manoeuvre the engine The jack height must be continually...

Page 115: ...d neutral switch connector Disconnect the servo motor 6P connector Remove the bolts and servo motor Disconnect the clutch cable oil tube radiator lower hose and tachometer cable page 10 3 CAUTION Duri...

Page 116: ...emporarily install the drive chain over the gearshift spindle Use a floor jack or other adjustable support to carefully manoeuvre the engine into place Carefully align the bolt holes in the frame and...

Page 117: ...connector Connect the radiator upper hose spark plug cap and thermo sensor connector Install the followings Reed valve page 5 14 Carburettor page 5 1 1 Fuel tank page 2 12 Drive sprocket page 7 3 Exha...

Page 118: ...ounter shaft and align the bolt holes on the plate with the holes of the sprocket Install and tighten the new drive sprocket setting plate bolts to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbf f...

Page 119: ...____________________________________ 7 8 Install the gearshift pedal link to the gearshift pedal Install and tighten the gearshift pedal link pinch bolt securely Specified torque TORQUE N m kgf m lbf...

Page 120: ...NSR150SP Cylinder Head Cylinder Piston ________________________________________________ 8 0 http mototh com...

Page 121: ...pression 108 kPa 1 1 0 kgf cm2 156 psi at 400 min 1 rpm Cylinder head warpage 0 05 0 002 Code A 59 010 59 015 2 3232 2 3234 59 05 2 325 No mark 59 005 59 010 2 3230 2 3232 59 05 2 325 Cylinder I D Cod...

Page 122: ...ed Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose spark plug Leaking cylinder head gasket Worn stuck or broken piston rings Worn or damaged cylinder and pi...

Page 123: ...he maximum reading is usually reached within 4 7 seconds STANDARD 108 kPa 11 0 kgf cm2 156 psi at 400 min 1 rpm If compression is high it indicates that carbon deposits have accumulated on the combust...

Page 124: ...2 4 Remove the spark plug cap and spark plug Remove the thermo sensor Loosen the band screw and disconnect the upper radiator hose Remove the nut and clutch cable guide Remove the cylinder head nuts...

Page 125: ...or cracks around the spark plug and stud bolt holes Check the cylinder head for warpage with a straight edge and a feeler gauge SERVICE LIMIT 0 05mm 0 002 in CYLINDER PISTON REMOVAL CYLINDER REMOVAL R...

Page 126: ...cylinder CAUTION Be careful not to damage the mating surface when the removing the cylinder Remove the gasket and dowel pins Clean off any gasket material from the cylinder lower surface CAUTION Be ca...

Page 127: ...val Remove the expander Clean carbon deposits from the piston NOTE Clean carbon deposits from the piston ring grooves with a ring that will be discarded Never use a wire brush it will scratch the groo...

Page 128: ...n Measure the cylinder for taper at three levels in an X and Y axis Take the maximum reading to determine the taper SERVICE LIMIT 0 05 mm 0 002 in PISTON Inspect the piston for cracks or other damage...

Page 129: ...e crankshaft must be replaced CYLINDER PISTON SELECTION Record the piston O D code letter A C or no mark Record the cylinder I D code letter A C or no mark Use the cylinder and piston with the same I...

Page 130: ...on the piston with the marks facing up NOTE Do not confuse the top and second rings Be sure to install them in the proper grooves Align the piston ring end gaps with the location pins on the piston Ch...

Page 131: ...earing to the connecting rod small end Install the piston with the IN mark facing the intake side Apply 2 stroke oil to the piston pin and install it to the piston pin hole Install the new piston pin...

Page 132: ...not to damage the piston rings and cylinder wall When installing the cylinder do not rotate the cylinder since this may cause the piston rings to snag a cylinder port and break Install the cylinder o...

Page 133: ...mark on the cylinder by turning the adjuster hold the outer tube to prevent it from being twisted Tighten the lock nut securely Recheck that the tab on the servo motor pulley is aligned with the H mar...

Page 134: ...head nuts to the specified torque NOTE Tighten the nuts in a crisscross pattern in several steps TOROUE 23 N m 2 3 kgf m 17 lbf ft Install the clutch cable guide Install and tighten the nut securely...

Page 135: ...NSR150SP RC Valve Servo Motor ________________________________________________ 9 0 http mototh com...

Page 136: ...nd piston Clean all disassembled parts with clean solvent and dry them using compressed air before inspection Coat all sliding surfaces with clean 2 stroke oil before assembly For engine control modul...

Page 137: ...lty servo motor Bent valve shaft Excessive carbon build up on the RC valve Damaged RC valve Poor performance at high speed Exhaust valve do not open fully Improper installation Faulty servo motor Exce...

Page 138: ...nut and adjust the gap by turning the adjuster NOTE While turning the adjuster hold the cable tube to prevent the tube from being twisted Tighten the lock nut securely After adjustment start the engin...

Page 139: ...__________ 9 4 Remove the nut washer special washers and RC valve timing pulley NOTE The timing pulley nut has a left hand threads Remove the dust seal Remove the RC valve shaft and RC valves from the...

Page 140: ...the RC valve and shaft NOTE If there is carbon on the RC valves and shaft RC valve will not operate properly Inspect the RC valves for wear scores or damage Inspect the RC valve shaft for bend or dama...

Page 141: ...e RC valve shaft Apply 2 stroke engine oil to the RC valves and shaft Install the RC valves to the cylinder NOTE At installation align the punch marks as shown Install the RC valve shaft to the cylind...

Page 142: ...aligning the cut outs on the shaft and washer Install the washer and timing pulley nut to the RC valve shaft NOTE The timing pulley nut has left hand threads Align the hole in the cylinder with the cu...

Page 143: ...h operation by turning the timing pulley using your hand CAUTION Before this inspection disconnect the ICM 2P Black 4P 1Black connector to prevent the ICM from damage Disconnect the ICM 2P Black 4P Bl...

Page 144: ...ion replace the servo motor assembly Check the open circuit between the ICM and servo motor If there is open circuit replace the wire harness REMOVAL Remove the side cowl Loosen the RC valve control c...

Page 145: ...tch on the RC valve timing pulley and H mark on the cylinder by turning the adjuster holding the outer tube to prevent it from being twisted Tighten the lock nut securely Recheck the tab on the servo...

Page 146: ...NSR150SP Clutch Gearshift Linkage Kickstarter ______________________________________________ 10 0 http mototh com I 64N m 64k f 9 om 47 Ibf ft 0 N m 67 k f 9 om 48 Ibf ft 0 22Nm2 Sr I 2 kg om 16Ibf_ft...

Page 147: ...ge the crankcase cover mating surface when servicing When removing or servicing the clutch gearshift linkage and kickstarter use care not to allow dust or dirt to enter the engine The crankcase must b...

Page 148: ...nut 66 N m 6 7 kgf m 48 lbf ft Apply oil to the threads and flange surface Clutch lifter plate bolt 12 N m 1 2 kgf m 9 lbf ft Clutch centre lock nut 64 N m 6 5 kgf m 47 lbfft Shift drum centre pin 22...

Page 149: ...g Worn clutch discs Weak clutch springs No clutch lever free play Hard to shift Improper clutch operation or incorrect clutch adjustment Bent or damaged shift forks Section 12 Bent shift fork shaft Se...

Page 150: ...ube and oil pass tube Disconnect the oil control cable from the oil pump drum Drain the transmission oil Drain the coolant Remove the water pump cover Remove the bolt and cable holder Disconnect the c...

Page 151: ...r Remove the gasket and dowel pins Clean off any gasket material from the right crankcase cover mating surface CAUTION Be careful not to damage the right crankcase cover mating surface Remove the wash...

Page 152: ...y Check the needle bearings for wear damage or loose fit Replace needle bearing if necessary NOTE If the dust seal replacement is required press the dust seal to the case surface Check the clutch lift...

Page 153: ...tre lock nut TOOLS Wrench 20 X 24 mm 07716 0020100 Extension bar 07716 0020500 Clutch centre holder 07923 KE10000 Remove the clutch centre lock nut and washer Remove the clutch centre spring seat and...

Page 154: ...f necessary CLUTCH SPRING Measure the clutch spring free length SERVICE LIMIT 33 6 mm 1 32 in NOTE Replace the clutch springs as a set CLUTCH DISC Check the clutch discs for signs of scoring or discol...

Page 155: ...tations or abnormal wear made by the clutch discs Check the serrated teeth of the primary driven gear for wear or damage Measure the clutch outer I D SERVICE LIMIT 23 06 mm 0 908 in Measure the clutch...

Page 156: ...drive gear balancer drive gear and woodruff key from the crankshaft NOTE When woodruff key removal be careful not to damage the key groove or crankshaft Do not loose the woodruff key INSPECTION Check...

Page 157: ...Install the balancer drive gear to the crankshaft aligning the cut out on the balancer drive gear with the woodruff key Apply oil to the primary drive gear nut threads and flange surface Install the w...

Page 158: ...KICKSTARTER REMOVAL Remove the gear shift spindle Unhook the kickstarter return spring from the hole on the crankcase Remove the stopper plate bolt 10 mm Remove the stopper plate bolt 8 mm and stoppe...

Page 159: ...EMBLY Remove the washer and pinion gear from the kickstarter spindle Remove the rachet and rachet spring from the kickstarter spindle Remove the spring retainer from the kickstarter spindle Remove the...

Page 160: ...ear for wear or damage Measure the pinion gear I D SERVICE LIMIT mm in Check the spindle on the kickstarter spindle for wear or damage Measure the kickstarter spindle O D SERVICE LIMIT mm in KICKSTART...

Page 161: ...starter _______________________________________________ 10 15 COUNTERSHAFT Measure the countershaft O D at the kickstarter idle gear collar SERVICE LIMIT 16 96mm in Install the washer and return to th...

Page 162: ...the spring end Install the washer Install the rachet spring to the kickstarter spindle Install the rachet to the kickstarter spindle aligning the wide groove in the rachet with the punch mark on the s...

Page 163: ...topper plate bolts 8 mm and 10 mm securely Hook the return spring end to the crankcase Install the gear shift spindle Temporally install the kickstarter pedal onto the kickstatter spindle and check th...

Page 164: ...gearshift spindle from the crankcase Remove the shifter collar from the guide plate Remove the bolts Remove the guide plate and drum shifter as an assembly NOTE Do not let the rachet pawls fall when r...

Page 165: ...PECTION Check the gearshift spindle for wear or damage Check the return spring for fatigue or damage Check the each parts for wear or damage Replace the damaged parts with a new one if necessary INSTA...

Page 166: ...nstall the dowel pin into the shift drum Move the stopper arm out of the way using a screwdriver Align the shift drum centre hole with the dowel pin and slip it into place Install and tighten the shif...

Page 167: ...n spring ends with the shift return spring pin Install the gearshift pedal link to the gearshift pedal Install and tighten the bolt securely Move the gearshift pedal and check the shift mechanism for...

Page 168: ...oil Install the five clutch discs and four clutch plates alternately starting with a clutch disc When installing the outside clutch disc align the end grooves in the clutch outer with the tabs of the...

Page 169: ...Extension bar 07716 0020500 TORQUE 64 N m 6 5 kgf m 47 lbf ft Remove the clutch centre holder and stake the lock nut into the mainshaft groove CAUTION Be careful not to damage the mainshaft threads I...

Page 170: ...Install the clutch lifter piece Install the water pump shaft Install the oil pump and bleed the oil pump tube and pass tube INSTALLATION Install the washer water pump oil pump drive gear shaft and wa...

Page 171: ...se Install and tighten the bolt securely Connect the clutch cable and install the cable holder and bolt TORQUE 10 N m 1 0 kgf m 7 lbf ft Install the water pump cover Fill and bleed the cooling system...

Page 172: ...NSR150SP Alternator Balancer ______________________________________________ 11 0 http mototh com 64 N m 6 5 kgf m 47Ibf ft 54 N m 5 5 kgf m 40 I tt...

Page 173: ...e done with the engine in the frame Refer to section 16 for alternator inspection and to section 17 for ignition pulse generator inspection TORQUE VALUES Timing hole cap 3 N m 0 3 kgf m 2 2 lbf ft Fly...

Page 174: ...nnect the alternator 3P connector and ignition pulse generator 2P connector Remove the left crankcase cover bolts and left crankcase cover NOTE Loosen the left crankcase cover bolts in a crisscross pa...

Page 175: ...ve the left crankcase cover Remove the flywheel nut and washer while holding the flywheel with a flywheel holder TOOL Flywheel holder 07725 0040000 Remove the flywheel using the flywheel puller TOOL F...

Page 176: ...balancer drive gear nut and washer TOOLS Gear holder 07724 0010100 Wrench 20 X 24 mm 07716 0020100 Remove the balancer driven gear and woodruff key NOTE When woodruff key removal be careful not to da...

Page 177: ...er sliding surfaces Install the balancer to the left crankcase Install the woodruff key to the groove on the balancer NOTE When woodruff key installation be careful not to damage the key groove or bal...

Page 178: ...STALLATION Wipe any oil off the mating surface of the crankshaft Install the woodruff key to the groove on the crankshaft NOTE When woodruff key installation be careful not to damage the key groove or...

Page 179: ...se cover Install and tighten the stator bolts securely Install the ignition pulse generator to the left crankcase cover Clean and apply a locking agent to the ignition pulse generator socket bolt thre...

Page 180: ...d new gasket Install the left crankcase cover NOTE The left crankcase cover stator is magnetically attached to the flywheel be careful to installation Install and tighten the left crankcase cover bolt...

Page 181: ...0SP Crankshaft Transmission ________________________________________________ 12 0 http mototh com 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1...

Page 182: ...to damage the crankcase mating surface When disassembling mark and store the disassembled parts to ensure that they are reinstalled in their original locations SPECIFICATIONS Unit mm in ITEM STANDARD...

Page 183: ...026 0 10 0 004 Gear bushing to shaft clearance C3 0 040 0 082 0 0016 0 0032 0 10 0 004 Shift fork claw thickness 4 93 5 00 0 194 0 197 4 80 0 189 Shift fork I D 12 041 12 056 0 4741 0 4746 12 65 0 475...

Page 184: ...n bearing Worn transmission gear Hard to shift Improper clutch adjustment Improper clutch operation Bent shift fork Bent shift fork shaft Bent shift spindle Damaged shift drum cam grooves Incorrect tr...

Page 185: ...o the left crankcase and separate the crankcase halves NOTE Separate the right and left crankcase from each other while tapping them at several locations with a soft hammer CAUTION Do not pry the cran...

Page 186: ...for removal To remove a snap ring expand the soap ring and pull it off using the gear behind it Disassemble the main shaft and countershaft INSPECTION GEAR Check the gear dogs dog holders and teeth fo...

Page 187: ...g mm in Calculate the clearance by subtracting mainshaft countershaft O D from gear bushing I D SERVICE LIMITS M5 mm in C1 mm in C2 mm in C3 mm in Calculate the clearance by subtracting gear bushing O...

Page 188: ...ts in solvent Apply transmission oil to the gear and bushing sliding su face and shift fork grooves to ensure initial lubrication Assemble all parts into their original positions NOTE Check the gears...

Page 189: ...MAINSHAFT COUNTERSHAFT http mototh com M5 Gear 23T M6 Gear 24T M3 M4 Gear 17 19T Snap Ring I Washer O 6om i SnaLSpline waf I p g M6 Gear Bushing M5 Gear Bushing SplineWashe M2 Gear 16T MainshaftlM1 Ge...

Page 190: ...ntershaft to the left crankcase as an assembly NOTE Do not forget to install the transmission end washer When mainshaft and countershaft installation be careful not to damage the countershaft oil seal...

Page 191: ...ft to the right crankcase After installing check for smooth transmission operation Assemble the crankcase page 12 17 CRANKSHAFT REMOVAL Separate the crankcase page 12 4 Remove the transmission page 12...

Page 192: ...ight using a feeler gauge STANDARD 0 3 0 7 mm 0 012 0 028 in Measure the radial clearance in both X and Y directions SERVICE LIMIT mm in INSTALLATION Install the crankshaft page 12 17 CRANKCASE BEARIN...

Page 193: ...of the left crankcase using special tools TOOLS Remover head 16 mm 07936 MK50100 Remover shaft 15 mm 07936 KC10100 Sliding weight 07741 0010201 Clean the crankcase with high flash point solvent and c...

Page 194: ...X 47 mm 07746 0010300 Pilot 20 mm 07746 0040500 NOTE Drive in the new bearing squarely with the marking side facing up CRANKSHAFT BEARING NOTE At crankcase bearing installation install the bearing to...

Page 195: ...ll the new balancer oil seal gearshift spindle oil seal and countershaft oil seal RIGHT CRANKCASE BEARING REPLACEMENT Remove the crankshaft oil seal Remove the bolts shift drum bearing set plate and m...

Page 196: ...Drive in the new bearing squarely with the marking side facing up Countershaft Bearing Install the new bearing to the right crankcase using the following special tools TOOLS Driver 07749 0010000 Atta...

Page 197: ...apply locking agent to the bolt threads Install the mainshaft bearing set plate and shift drum bearing set plate Install and tighten the bolts to the specified torque TORQUE 10 N m 1 0 kgf m 7 tbfft C...

Page 198: ...aces dress them with an oil stone Before assembly lubricate the transmission bearings with the clean transmission oil Install the crankshaft into the left crankcase using the special tools TOOLS Crank...

Page 199: ...f the left crankcase Pack grease into the cavity between the right crankshaft oil seal lips Press the right crankshaft oil seal into the right crankcase using the crank case assembly tool TOOLS Crank...

Page 200: ...P Front Wheel Suspension Steering 13 0 http mototh com NSR150SP Front Wheel Suspension Steering 22 N m 2 2 kgf m 16Ibf lb 27 N m 2 8 kgf m 20 Ibf ft 30 N m 3 1 kgf m 22 Ibf ft 59 N m 6 0 kgf m 43 Ibf...

Page 201: ...rkfluid 125 4 9 322 cm3 10 9US oz 11 31 Imp oz 0 1 5Nm 10 1 0 15 k d m 13 1 http mototh com NSR150SP Front Wheel Suspension Steering SERVICE INFORMATION GENERAL A contaminated brake disc or pad reduce...

Page 202: ...ns hard Faultywheel bearings Bent front axle Brake drug Faultyspeedometergear 13 2 http mototh com NSR150SP Front Wheel Suspension Steering TORQUE VALUES Front axle nut Front brake disc bolt 59 Nm 6 0...

Page 203: ...hrottle cables from the throttle pipe Removethe throttle housing from the handlebar 13 3 http mototh com NSR150SP Front Wheel Suspension Steering HANDLEBAR RIGHT HANDLEBAR REMOVAL Remove the master cy...

Page 204: ...ove on the fork tube Loosen the handlebar pinch bolt and removethe right handlebar 13 4 http mototh com NSR150SP Front Wheel Suspension Steering Remove the screw handlebar weight and throttle grip fro...

Page 205: ...emovethe screw and handlebar weight Removethe left handlebar grip from the handlebar 13 5 http mototh com NSR150SP Front Wheel Suspension Steering LEFT HANDLEBAR REMOVAL Remove the bolts and clutch le...

Page 206: ...top ring to the groove on the fork tube Tighten the handlebar pinch bolt securely 13 6 http mototh com NSR150SP Front Wheel Suspension Steering Remove the stop ring from the groove on the fork tube Lo...

Page 207: ...llthe throttle housing aligningthe pin on the housingwith the hole in the handlebar 13 7 http mototh com NSR150SP Front Wheel Suspension Steering Apply grease to the throttle grip inner surface and ri...

Page 208: ...the fork tube aligningthe stopper on the Handlebarwith the grove in the top bridge 13 8 http mototh com NSR150SP Front Wheel Suspension Steering Apply grease to the throttle cable ends and connect th...

Page 209: ...rweight with the slit of the handlebar Installand tighten the new screw securely 13 9 http mototh com NSR150SP Front Wheel Suspension Steering Install the stop ring to the groove on the fork tube Tigh...

Page 210: ...the handlebar Tighten the upper bolt first then tighten the lower bolt securely 13 10 http mototh com NSR150SP Front Wheel Suspension Steering Install the left handlebar switch aligning the pin on th...

Page 211: ...d front wheel Remove the speedometergear box from the left side of the front wheel 13 1 1 http mototh com NSR150SP Front Wheel Suspension Steering FRONT WHEEL con n1ln brake disc or pad reduces stoppi...

Page 212: ...E LIMITS Radial 2 0 m m 0 08 in Axial 2 0 mm 0 08 in Check the spokes for loose or damage 13 12 http mototh com NSR150SP Front Wheel Suspension Steering Remove the side collar from the right side of t...

Page 213: ...0 07746 0050400 NOTE Replacethe wheel bearingin pairs Do not fe sue old bearings 13 13 http mototh com NSR150SP Front Wheel Suspension Steering DISASSEMBLY Remove the right and left dust seals from th...

Page 214: ...ke disc bolt threads Install and tighten the brake disc bolts to the specifiedtorque TORQUE 42 N m 4 3 kgf m 31 Ibft 13 14 http mototh com NSR150SP Front Wheel Suspension Steering ASSEMBLY t ront Hrak...

Page 215: ...pply grease to the left dust seal lip Installthe left dust seal on the left wheel 13 15 http mototh com NSR150SP Front Wheel Suspension Steering WHEEL BALANCE I Wheel balance directly affects the stab...

Page 216: ...pads Apply thin coat of grease to the front axle shaft Installthe front axle shaft 13 16 http mototh com NSR150SP Front Wheel Suspension Steering Apply grease to the right dust seal lip Install the ri...

Page 217: ...om the brake hose Do not twist the brake hose Remove the bolts screw and front fender 13 17 http mototh com NSR150SP Front Wheel Suspension Steering Align the tab on the speedometer gear box with the...

Page 218: ...is under spring pressure Use care when removing it and wear eye and face protection 13 18 http mototh com NSR150SP Front Wheel Suspension Steering Remove the wire band Remove the handlebar from the fo...

Page 219: ...emporarily install the fork spring spring joint plate spring collar and fork cap 13 19 http mototh com NSR150SP Front Wheel Suspension Steering Remove the spring collar Remove the spring joint plate a...

Page 220: ...e fork tube out of the fork slider Remove the oil lock piece from the fork slider 13 20 http mototh com NSR150SP Front Wheel Suspension Steering Remove the fork piston and rebound spring NOTE Do not r...

Page 221: ...re marks and excessive or abnormal wear Replace the component if necessary 13 21 http mototh com NSR150SP Front Wheel Suspension Steering Remove the oil seal back up ring and slider bushing from The f...

Page 222: ...ion at the points shown Back up Ring Copper Surfaces 13 22 http mototh com NSR150SP Front Wheel Suspension Steering Check the fork piston ring for wear or damage Check the rebound spring for fatigue o...

Page 223: ...Steering ASSEMBLY Before assembly wash all parts with a high flash point or non flammable solvent and wipe them off completely Dust Seal Fork P ston pring _______ I I Stopper Rin J I O S Back up rin9...

Page 224: ...emporarily installthe fork spring spring joint plate spring collar and fork cap 13 24 http mototh com NSR150SP Front Wheel Suspension Steering Install the oil lock piece onto the fork tube end Coat th...

Page 225: ...fork tube and installthe fork spring with the tapered side facing down 13 25 http mototh com NSR150SP Front Wheel Suspension Steering Drive in the new oil seal into the fork tube until stopper ring g...

Page 226: ...TORQUE 27 N m 2 8 kgf m 20 Ibf ft Installthe handlebar right page 13 6 left 13 8 13 26 http mototh com NSR150SP Front Wheel Suspension Steering Install the spring joint plate and spring collar Apply...

Page 227: ...Disconnectthe ignition switch 2P connector Removethe steering stem nut and washer 13 27 http mototh com NSR150SP Front Wheel Suspension Steering Install the wire band Install the front fender Install...

Page 228: ...aring inner race and upper bearing Steel balls NOTE Do not loosethe steel balls 13 28 http mototh com NSR150SP Front Wheel Suspension Steering Remove the fork page 13 17 Remove the top bridge Remove t...

Page 229: ...l being careful not to damage the stem Removethe dust seal and washer 13 29 http mototh com NSR150SP Front Wheel Suspension Steering Re move the steering stem and lower bearing steel balls NOTE Do not...

Page 230: ...sing the following tools TOOLS Driver attachment 07946 3290000 Driver 07749 0010000 13 30 http mototh com NSR150SP Front Wheel Suspension Steering Apply grease to the new dust seal lip and install it...

Page 231: ...P Front Wheel Suspension Steering Top Bridge Steering Stem Nut vvasher Steering Top Thread __ Upper Bearing Inner Race r cL __ _ Upper Bearing 1 _ Steel Balls J f _ Horn Stay Dust seal Lower Bearing O...

Page 232: ...16 3710101 TORQUE 1 N m 0 1 kgf m 0 7 Ibf ft Connect the ignition switch 2P connector 13 32 http mototh com NSR150SP Front Wheel Suspension Steering Install the steering top thread and tighten it to t...

Page 233: ...in the reverse order of removal NOTE Routethe cables and wire harnessproperly 13 33 http mototh com NSR150SP Front Wheel Suspension Steering Install the brake hose to the clamp on the steering stem I...

Page 234: ...http mototh com NSR150SP Rear Wheel Suspension 44 N m 4 5 kgf m 33 Ibf ft 44 N m 4 5 kgf m 33 Ibf ft 73 N m 7 4 kgf m 54 Ibf ft 10B N m 11 0kgf m BO Ibf ft 14 0...

Page 235: ...arm Bearing Holder Driven SERVICE INFORMATION GENERAL i A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean contaminated disc with a high quality brake degreasi...

Page 236: ...ingarm pivot bearing Rear suspension noisy Faulty rear shock absorber Loose fasteners 14 2 http mototh com NSR150SP TORQUE VALUES Rear wheel nut Rear axle nut Rear brake disc nut Driven sprocket nut B...

Page 237: ...same position when it is spun Do not add more than 60 grams 2 1 oz to the rear wheel http mototh com NSR150SP Rear Wheel Suspension REAR WHEEL A contaminated brake disc or pad reduces stopping power...

Page 238: ...e 15 11 Removethe final driven flange assembly and rear axle brakedisc assembly 14 4 http mototh com NSR150SP Rear Wheel Suspension INSTALLATION Clean and apply grease to the rear axle and wheel matin...

Page 239: ...le FINAL DRIVEN FLANGE Remove the snap ring from the groove on the final driven flange 14 5 http mototh com NSR150SP Rear Wheel Suspension Remove the snap ring and washer Remove the bearing holder and...

Page 240: ...ide of the bearing holder Removethe dust seal from the left side of the bearing holder 14 6 http mototh com NSR150SP Rear Wheel Suspension Remove the driven sprocket and final driven hub from the fina...

Page 241: ...if they fit loosely in the bearing holder NOTE Replacethe holder bearingsin pairs 14 7 http mototh com NSR150SP Rear Wheel Suspension Remove the dust seal from the right D Se side of the bearing holde...

Page 242: ...earing groove Installthe new needle bearing with its dust seal end facing inside 14 8 http mototh com NSR150SP Rear Wheel Suspension FINAL DRIVEN FLANGE Check the damper rubber for wear or damage Repl...

Page 243: ...ar Brake Disc Final Driven Needle Bearing 14 9 http mototh com NSR150SP Rear Wheel Suspension Press the new needle bearing in the right side of the bearing holder using AMCImiIiiI the special tools TO...

Page 244: ...lip Installthe new dust seal to the right side of the bearing holder 14 10 http mototh com NSR150SP Rear Wheel Suspension BEARING HOLDER Sto p Ring Install the stop ring to the right side of the bear...

Page 245: ...Tightenthe driven sprocket nutsafter installing the driven flange to the frame 14 11 http mototh com NSR150SP Rear Wheel Suspension Install the collar to the left side of the bearing holder REAR AXLE...

Page 246: ...ackets to the tab on the swingarm Installthe bearing holderto the swingarm 14 12 http mototh com NSR150SP Rear Wheel Suspension Install the driven sprocket and final Spt QIl t lHl lb drive hub to the...

Page 247: ...holder pinch bolt to the specifiedtorque TORQUE 73 N rn 7 4 kgf m 54 Ibf ft 14 13 http mototh com _ _ _ _ _ _ NSR150SP Rear Wheel Suspension Install the washer and snap ring Install the rear axle bra...

Page 248: ...necessary deformationor oil Check the bushingfor wear or damage and replace if necessary 14 14 http mototh com NSR150SP Rear Wheel Suspension SHOCK ABSORBER shock absorber contains nitrogen under hig...

Page 249: ...Drilling Point Installthe battery case page 16 6 Installthe side cover page 2 7 14 15 http mototh com NSR150SP Rear Wheel Suspension SHOCK ABSORBER rnSPOSAL PROCEDURE Center punch the shock absorber...

Page 250: ...drive chain cover Removethe brake hose from the guide and clamp Remove the bolt 14 16 http mototh com NSR150SP SWINGARM REMOVAL Remove the rear wheel page 14 3 Remove the rear brake caliper page 15 1...

Page 251: ...ivot covers Removethe swingarm pivot nut Removethe swingarm pivot bolt and swingarm 14 17 http mototh com NSR150SP Remove the bolts and drive chain cover Remove the swingarm pivot covers Remove the sw...

Page 252: ...ssivewear Replace the drive chain slider if it is worn to wear indicator page3 19 14 18 http mototh com NSR150SP Rear Wheel Suspension DISASSEMBLV Remove the bearing holder and driven flange page 14 5...

Page 253: ...ry Check the swingarm for deformation cracks or other damage and replace if necessary 14 19 http mototh com NSR150SP Remove the right pivot collar and dust seal Remove the dust seal left pivot collar...

Page 254: ...46 0010100 NOTE Pressthe needle bearing in with the stamped side facing out 5 5rnm 0 22 i n d 14 20 http mototh com NSR150SP Rear Wheel Suspension BEARING REPLACEMENT REMOVAL Remove the snap ring from...

Page 255: ...Chain Slider 5 1 N 3 8 lbf ft Left Swingarm Pivot Collar Left Dust Seal Needle Bearing Ball Bearine f Collar Right Dust 6 Drive ChaiA Guard Right Swing Arm Pivot C h a r 14 21 http mototh com NSR150SP...

Page 256: ...n the swingarm Installthe tabs on the chain slider to the holes on the swingarm 14 22 http mototh com _ _ _ _ NSR150SP Rear Wheel Suspension Install the sWingarm pivot collar left pivot collar and dus...

Page 257: ...the swingarm pivot nut to the specified torque TORQUE 88 N m 9 0 kgfm 65 Ibf ft 14 23 http mototh com NSR150SP Rear Wheel Suspension Install the collars and drive chain slider screws Tighten the drive...

Page 258: ...Install and tighten the bolt securely Installthe brake hose to the guide and clamp 14 24 http mototh com NSR150SP Rear Wheel Suspension Install the swingarm pivot covers Install the drive chain cover...

Page 259: ...33 Ibf ft Installthe rear brake caliper page 15 20 Installthe rear wheel page 14 4 14 25 http mototh com NSR150SP Install the brake hose cover aligning the its tabs to the grooves on the drive chain...

Page 260: ...llow W White RegulatorIRectifier 4 4 G I R 16 0 http mototh com NSR150SP BatteryI Charging System SYSTEM DIAGRAM Main Fuse 20 A Regulator Rectifier Ba ery I 6 I Regulator Rectifier I I RIW IBattery I...

Page 261: ...t ON for long periods of time without riding the motorcycle BATTERYlCHARGING SYSTEM 16 1 http mototh com NSR150SP BatteryI Charging System SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING BATTERY SE...

Page 262: ...PECIFlCAT1ONS ITEM SPECIFICATIONS I Alternator rated outwt I 180 W 5 000 min 1 h r n l 16 2 http mototh com NSR150SP BatteryI Charging System Battery Charging System The battery will self discharge wh...

Page 263: ...aulty regulator rectifier Correct Correct Faulty regulatorhedifier 16 3 http mototh com NSR150SP BatteryICharging System TROUBLESHOOTING BATTERY UNDERCHARGING VOLTAGE NOT RAISED TO REGULATED VOLTAGE M...

Page 264: ...nected connectors 16 4 http mototh com NSR150SP BatteryI Charging System BATTERY OVERCHARGING REGULATED VOLTAGE TOO HIGH Measure the charging voltage with the battery fully charged and in good conditi...

Page 265: ...gital multimeter Voltage Fully charged 11 13V Under charged Below 1OV RwL EL 16 5 http mototh com NSR150SP BatteryI Charging System BATTERY REMOVAL NOTE Always turn the ignition switch OFF before remo...

Page 266: ...he reverse order of removal NOTE Route the tubes and wire harnesses properly page1 18 16 6 http mototh com NSR150SP Battery Charging System BATTERY CHARGING The battery gives off explosive gases keep...

Page 267: ...rise cannot be checked as it varies with the temperature and loads of the generator 16 7 http mototh com NSR150SP BatteryI Charging System CHARGING SYSTEM INSPECTION NOTE Measuring circuits with a lar...

Page 268: ...ections one by one and measuring the current 16 8 http mototh com NSR150SP BatteryI Charging System A frequently discharges battery is an indication that it is deteriorated even if it proves normal in...

Page 269: ...68 OF If the charging coil reading is out of specification check the alternator page 16 10 16 9 http mototh com NSR150SP BatteryI Charging System REGULATOR I RECTIFIER WIRE HARNESS INSPECTION Remove t...

Page 270: ...re is continuity between the 5P connector and ground check the alternator page 16 10 16 10 http mototh com NSR150SP BatteryI Charging System Check for continuity between the 5P connector terminals and...

Page 271: ...there is continuity between the 3P connector and ground replace the stator page 11 2 16 11 http mototh com NSR150SP Battery Charging System REMOVAL INSTALLATION Remove the right side cover page 2 6 Di...

Page 272: ...f there is continuity between the 3P connector and ground replace the stator page 11 2 16 12 http mototh com NSR150SP BatteryICharging System Remove the fuel tank page 2 12 Disconnect the alternator 3...

Page 273: ...se Generator BI BLACK G GREEN Bu BLUE Lg LIGHT GREEN R RED w WHITE Y YELLOW 17 0 http mototh com NSR150SP Ignition System SYSTEM DIAGRAM Engine Stop Switch BI BLACK G GREEN Bu BLUE Lg LIGHT GREEN R RE...

Page 274: ...nstallation see section 13 19 For ignition switch inspection see section 13 19 17 1 http mototh com NSR150SP Ignition System SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING 17 0 17 1 17 3 IGNITION...

Page 275: ...SO W27ES U For cold climate below NGK B8ES 5 C 41 OF NIPPONDENSO W24ES U Ignition timing F mark BTDC 12 3 0 200 min 1 jr pm Advance I Start 1 900 200min 1 rpm I Stop 3 500 200 min 1 rpm Full advance B...

Page 276: ...No 1 3 are normal 1 Faulty peak voltage adaptor 2 Faulty ignition pulse generator 17 3 http mototh com NSR150SP Ignition System TROUBLESHOOTING Inspect the following before diagnosing the system Faul...

Page 277: ...the spark plug to the cylinder as done in a spark test Remove the fuel tank page 2 12 17 4 http mototh com NSR150SP Ignition System IGNITION SYSTEM INSPECTION NOTE If there is no spark at the plug che...

Page 278: ...tal multimeter impedance I OM R DCV minimum CONNECTION GreedWhite Green 17 5 http mototh com NSR150SP Connect the peak voltage adaptor or Imrie tester to the ignition coil primary terminal NOTE Do not...

Page 279: ...ION Remove the fuel tank page 2 12 Disconnect the spark plug cap from the spark plug 17 6 http mototh com NSR150SP Ignition System Turn the ignition switch ON and engine stop switch to RUN Shift the t...

Page 280: ...e engine Stop the engine Remove the side cowl and lower cowl page 2 4 Remove the timing hole cap 17 7 http mototh com NSR150SP Ignition System Disconnect the ignition coil primary wires from the termi...

Page 281: ...orque TORQUE 3 N m 0 3 kgf m 2 2 Ibf ft Install the side cowl and lower cowl page 2 4 5 17 8 http mototh com NSR150SP Connect a timing light to the spark plug wire Start the engine and let it idle IDL...

Page 282: ...96 6 Cooling system 97 110 7 Engine removal Installation 111 119 8 Cylinder head Cylinder Piston 120 134 9 RC Valve Servo motor 135 145 10 Clutch Gearshift linkage Kickstarter 146 171 11 Alternator Ba...

Page 283: ...nt plug for this model is the B 9ECS as marked on the fuel tank sticker Please ensure owners are made aware of this This part is currently in stock and can be ordered through the normal parts ordering...

Page 284: ...he oil pump must be bled and the oil pump control cable should be adjusted correctly as per the service manual Engine Oil When filling the engine oil please ensure only Honda 2 stroke oil or equivalen...

Page 285: ...EG SNART National Motorcycle Service Manager PLEASE ENSURE ALL RELEVANT STAFF ARE AWARE OF THIS BULLETIN AND its CONTENTS Service Manager Parts Manager Sales Manager Franchise Principle http mototh co...

Page 286: ...re listed in the current parts list as the replacement plugs for this model These are incorrect and must not be used The correct replacement plug for this model is the B 9ECS as marked on the fuel tan...

Page 287: ...is on pre delivery inspection is to DRAIN out ALL of the gearbox oil and measure the specified amount 700mls of good quality 10w 40 4 stroke engine oil as recommended in the service manual CHECKING TH...

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