Honda RS150R 2016 Owner'S Manual Download Page 75

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Clutch

Checking the Clutch

Checking the Clutch Lever Freeplay

Check the clutch lever freeplay.

Freeplay at the clutch lever:

10 - 20 mm (0.4 - 0.8 in)

Check the clutch cable for kinks or signs of

wear. If necessary have it replaced by your

dealer.

Lubricate the clutch cable with a

commercially available cable lubricant to

prevent premature wear and corrosion.

NOTICE

Improper freeplay adjustment can cause

premature clutch wear.

20160628185719_32K56E000_eng_BOOK Page 74 Tuesday, June 28 2016 18:59:29 JST

Maintenance

Freeplay

Clutch lever

Summary of Contents for RS150R 2016

Page 1: ......

Page 2: ...able before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written...

Page 3: ...riding pleasure Read this owner s manual carefully Follow all recommendations and procedures contained in this manual Pay close attention to safety messages contained in this manual and on the motorc...

Page 4: ...r own good judgement You will find important safety information in a variety of forms including Safety labels on the motorcycle Safety Messages preceded by a safety alert symbol and one of three signa...

Page 5: ...s Motorcycle Safety P 2 Operation Guide P 14 Maintenance P 31 Troubleshooting P 76 Information P 94 Specifications P 106 Index P 109 20160628185719_32K56E000_eng_BOOK Page 4 Tuesday June 28 2016 18 59...

Page 6: ...ions P 8 Accessories Modifications P 12 Loading P 13 20160628185719_32K56E000_eng_BOOK Page 5 Tuesday June 28 2016 18 59 29 JST This section contains important information for safe riding of your moto...

Page 7: ...pparel 2 P 7 Before Riding Make sure that you are physically fit mentally focused and free of alcohol and drugs Check that you and your passenger are both wearing an approved motorcycle helmet and pro...

Page 8: ...y to use good judgement and ride safely Don t Drink and Ride Alcohol and riding don t mix Even one alcoholic drink can reduce your ability to respond to changing conditions and your reaction time gets...

Page 9: ...ontinue riding first turn the ignition switch to the OFF position and evaluate the condition of your motorcycle Inspect for fluid leaks check the tightness of critical nuts and bolts and check the han...

Page 10: ...ever run your motorcycle inside a garage or other enclosure 3WARNING Running the engine of your motorcycle while in an enclosed or even partially enclosed area can cause a rapid build up of toxic carb...

Page 11: ...isibility correct size for your head Must fit comfortably but securely with the chin strap fastened Face shield with unobstructed field of vision or other approved eye protection 3WARNING Not wearing...

Page 12: ...ility u Where possible reduce speed before turning otherwise you risk sliding out Exercise caution on low traction surfaces u The tyres slip more easily on such surfaces and braking distances are long...

Page 13: ...speed when descending long steep slopes Wet or Rainy Conditions Road surfaces are slippery when wet and wet brakes further reduce braking efficiency Exercise extra caution when braking in wet conditi...

Page 14: ...and or Centre Stand 1 Stop the engine 2 Using the side stand Push the side stand down Slowly lean the motorcycle to the left until its weight rests on the side stand Using the centre stand To lower th...

Page 15: ...g lower octane petrol will result in decreased engine performance Do not use fuels containing a high concentration of alcohol 2 P 104 Do not use stale or contaminated petrol or an oil petrol mixture A...

Page 16: ...nstall accessories on your motorcycle be certain the modification is safe and legal 3WARNING Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed Follow...

Page 17: ...ght capacity 2 P 106 Tie all luggage securely evenly balanced and close to the centre of the motorcycle Do not place objects near the lights or the muffler 3WARNING Overloading or improper loading can...

Page 18: ...Operation Guide 14 Fuse boxes P 92 Battery P 48 Spark plug P 54 Throttle grip P 73 Coolant reserve tank P 61 Rear brake fluid reservoir P 63 Engine oil fill cap dipstick P 57 Right cowl P 51 Front bra...

Page 19: ...ST Operation Guide 15 Clutch lever P 71 Crankcase breather P 74 Fuel fill cap P 27 Tool kit Document bag P 30 Drive chain P 67 Side stand P 66 Shift lever P 26 Seat P 29 Centre lower cowl P 50 Seat lo...

Page 20: ...engine in the tachometer red zone Excessive engine speed can adversely affect engine life Tachometer red zone excessive engine rpm range Display Check When the ignition switch is turned on all the mo...

Page 21: ...If the fuel gauge indicator flashes in a repeat pattern or turns off P 80 Odometer TOTAL Tripmeter TRIP Speedometer Gear position indicator Shows 1st to 6th gear position u appears when the transmissi...

Page 22: ...Programmed Fuel Injection malfunction indicator lamp MIL High coolant temperature indicator Comes on briefly when the ignition switch is turned to ON position If it comes on while riding P 78 If one o...

Page 23: ...ng_BOOK Page 22 Tuesday June 28 2016 18 59 29 JST Operation Guide 19 continued Headlight dimmer switch High beam Low beam u Pressing the switch turns the turn signal off Turn signal switch Start butto...

Page 24: ...59 29 JST Operation Guide 20 Switches Continued ON Turns electrical system on for starting riding OFF Turns engine off Locks steering Lock Ignition Switch Switches the electrical system on off locks...

Page 25: ...left or right b Push the key down and turn the ignition switch to the Lock position u Jiggle the handlebar if the lock is difficult to engage c Remove the key Unlocking Insert the key push it in and t...

Page 26: ...manually Close a Remove the ignition key from the ignition switch b Align the projection of the shutter key with the slot of the shutter and turn the shutter key counterclockwise c Remove the key Open...

Page 27: ...to the ON position b Shift the transmission to Neutral N indicator comes on c Using the start button Press the start button with the throttle completely closed Release the start button as soon as the...

Page 28: ...ckstarter u Fold up the kickstarter after the kickstarter is returned to the pedal stop d If you cannot start the engine open the throttle slightly about 3 mm without freeplay 20160628185719_32K56E000...

Page 29: ...seconds then follow steps a b again Using the kickstarter a Turn the ignition switch to the OFF position b Open the throttle fully and crank the engine several times with the kickstarter c Turn the ig...

Page 30: ...Shifting Gears Your motorcycle transmission has 6 forward gears in a one down five up shift pattern 20160628185719_32K56E000_eng_BOOK Page 29 Tuesday June 28 2016 18 59 29 JST Operation Guide 26...

Page 31: ...l Refuelling and Fuel Guidelines P 11 Opening the Fuel Fill Cap a Open the seat P 29 b Turn the fuel fill cap counterclockwise until it stops and remove the cap Do not fill with fuel above the lower e...

Page 32: ...s aligned b Close the seat 3WARNING Petrol is highly flammable and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel o...

Page 33: ...ted under the seat u Use the helmet holders only when parked 3WARNING Riding with a helmet attached to the holder can interfere with your ability to safely operate the motorcycle and could lead to a c...

Page 34: ...torage compartment under the seat The owner s manual and other documents are stored in the document bag Opening the Seat P 29 20160628185719_32K56E000_eng_BOOK Page 33 Tuesday June 28 2016 18 59 29 JS...

Page 35: ...r P 53 Spark Plug P 54 Engine Oil P 57 Coolant P 61 Brakes P 63 Side Stand P 66 Drive Chain P 67 Clutch P 71 Throttle P 73 Crankcase Breather P 74 Other Adjustments P 75 Adjusting the Headlight Aim P...

Page 36: ...d schedules in this owner s manual Maintenance Safety Always read the maintenance instructions before you begin each task and make sure that you have the tools parts and skills required We cannot warn...

Page 37: ...e to help ensure that your motorcycle is properly maintained Make sure that whomever performs the maintenance completes this record All scheduled maintenance is considered a normal owner operating cos...

Page 38: ...r Coolant 4 3 Years 61 Cooling System Maintenance Level Maintenance Legend Intermediate We recommend service by your dealer unless you have the necessary tools and are mechanically skilled Procedures...

Page 39: ...Horn Clutch System 71 Side Stand 66 Suspension Nuts Bolts Fasteners Wheels Tyres 43 Steering Head Bearings Notes 1 At higher odometer readings repeat at the frequency interval established here 2 Servi...

Page 40: ...and full closing in all steering positions 2 P 73 Engine oil level Add engine oil if necessary Check for leaks 2 P 57 Coolant level Add coolant if required Check for leaks 2 P 61 Drive chain Check co...

Page 41: ...Honda parts may make your motorcycle unsafe and cause a crash in which you can be seriously hurt or killed Always use Honda Genuine Parts or equivalents that have been designed and approved for your m...

Page 42: ...ip is removed 3WARNING The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you Wear prote...

Page 43: ...ery and possibly damaging the system Fuses Fuses protect the electrical circuits on your motorcycle If something electrical on your motorcycle stops working check for and replace any blown fuses 2 P 9...

Page 44: ...isfies all of the following standards JASO T 903 standard 1 MA SAE standard 2 10W 30 API classification 3 SG or higher 1 The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle eng...

Page 45: ...larly Inspect the chain more frequently if you often ride on bad roads ride at high speed or ride with repeated fast acceleration 2 P 67 If the chain does not move smoothly makes strange noises has da...

Page 46: ...losion could result Avoid getting lubricant on the brakes or tyres Avoid applying excess chain lubricant to prevent spray onto your clothes and the motorcycle Recommended Coolant Use only genuine HOND...

Page 47: ...pressure gauge to measure the air pressure at least once a month or any time you think the tyres look low Always check air pressure when your tyres are cold Inspecting for Damage Inspect the tyres fo...

Page 48: ...h is reached 3WARNING Riding on tyres that are excessively worn or improperly inflated can cause a crash in which you can be seriously hurt or killed Follow all instructions in this owner s manual reg...

Page 49: ...this motorcycle Excessive heat build up can cause the tube to burst Use only tubeless tyres on this motorcycle The rims are designed for tubeless tyres and during hard acceleration or braking a tube...

Page 50: ...w cleaning or any other cleaning can degrade the viscous element performance and cause the intake of dust Do not perform the maintenance Should be serviced by your dealer 20160628185719_32K56E000_eng_...

Page 51: ...some roadside repairs minor adjustments and parts replacement with the tools contained in the kit 10 14 mm Open end wrench Spark plug wrench 5 mm Hex wrench Standard Phillips screwdriver Screwdriver h...

Page 52: ...P 53 2 Remove the harness band clip from the battery cover 2 P 52 3 Disconnect the negative terminal from the battery 4 Disconnect the positive terminal from the battery 5 Remove the bolt 201606281857...

Page 53: ...der of removal Always connect the positive terminal first Make sure that bolts and nuts are tight For proper handling of the battery see Maintenance Fundamentals 2 P 38 Battery Goes Dead 2 P 87 201606...

Page 54: ...t cowl u Carefully release the tabs 4 Remove the centre lower cowl Installation Install the parts in the reverse order of removal 20160628185719_32K56E000_eng_BOOK Page 53 Tuesday June 28 2016 18 59 2...

Page 55: ...tre pin 2 Insert the clip into the hole 3 Press down on the centre pin to lock the clip Right Cowl 20160628185719_32K56E000_eng_BOOK Page 54 Tuesday June 28 2016 18 59 29 JST Removing Installing Body...

Page 56: ...e the turn signal light wires from the guides and disconnect the connectors Installation Install the parts in the reverse order of removal Harness Band Clip Removal Pull the harness band clip while pr...

Page 57: ...sing the prongs from the grommets Installation Install the parts in the reverse order of removal 20160628185719_32K56E000_eng_BOOK Page 56 Tuesday June 28 2016 18 59 29 JST Removing Installing Body Co...

Page 58: ...oper heat range can cause engine damage 1 Remove the centre lower cowl 2 P 50 2 Remove the right cowl 2 P 51 3 Remove the radiator mounting bolt collar 4 Move the radiator to the left side and remove...

Page 59: ...electrodes and centre porcelain for deposits erosion or carbon fouling u If the erosion or deposit is heavy replace the plug u Clean a carbon or wet fouled plug with a plug cleaner otherwise use a wi...

Page 60: ...wice to prevent loosening a First tighten the plug NGK 1 2 turn after it seats DENSO 3 4 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats NOTICE An impr...

Page 61: ...evel surface 4 Remove the oil fill cap dipstick and wipe it clean 5 Insert the oil fill cap dipstick until it seats but don t screw it in 6 Check that the oil level is between the upper level and lowe...

Page 62: ...vel mark u Make sure no foreign objects enter the oil filler opening u Wipe up any spills immediately 2 Securely reinstall the oil fill cap dipstick NOTICE Overfilling with oil or operating with insuf...

Page 63: ...on its centre stand on a firm level surface 4 Place a drain pan under the drain bolt 5 Remove the oil fill cap dipstick drain bolt and sealing washer to drain the oil u Discard the oil at an approved...

Page 64: ...the oil fill cap dipstick Required oil When changing oil 1 1 L 1 2 US qt 1 0 Imp qt 8 Check the oil level 2 P 57 9 Check that there are no oil leaks 20160628185719_32K56E000_eng_BOOK Page 63 Tuesday J...

Page 65: ...olant level is dropping noticeably or the reserve tank is empty you likely have a serious leak Have your motorcycle inspected by your dealer Adding Coolant If the coolant level is below the lower leve...

Page 66: ...Install the reserve tank maintenance lid 3WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out potentially scalding you Always let the engine and radiator cool...

Page 67: ...level and UPPER level marks If the brake fluid level in either reservoir is below the L mark or LOWER level mark or the brake lever and pedal freeplay becomes excessive inspect the brake pads for wea...

Page 68: ...per 2 Rear Inspect the brake pads from the rear right of the motorcycle If necessary have the pads replaced by your dealer Always replace both left and right brake pads at the same time 20160628185719...

Page 69: ...turn the adjusting nut in the direction A if the switch operates too late or turn the nut in the direction B if the switch operates too soon 20160628185719_32K56E000_eng_BOOK Page 68 Tuesday June 28 2...

Page 70: ...smoothly If the side stand is stiff or squeaky clean the pivot area and lubricate the pivot bolt with clean grease 2 Check the spring for damage or loss of tension 20160628185719_32K56E000_eng_BOOK Pa...

Page 71: ...lace your motorcycle on its centre stand on a firm level surface 3 Check the slack in the lower half of the drive chain midway between the sprockets Drive chain slack 25 35 mm 1 0 1 4 in u Do not ride...

Page 72: ...stand on a firm level surface 3 Loosen the rear axle nut 4 Loosen the lock nuts on both sides of the swingarm 20160628185719_32K56E000_eng_BOOK Page 71 Tuesday June 28 2016 18 59 29 JST Drive Chain u...

Page 73: ...lots Both marks should correspond If the axle is misaligned turn the right or left adjusting nut until the marks are aligned and recheck chain slack 7 Tighten the rear axle nut Torque 59 N m 6 0 kgf m...

Page 74: ...ed to the furthest limit of adjustment the drive chain is worn and must be replaced Chain RK 428HSB If necessary have the drive chain replaced by your dealer 20160628185719_32K56E000_eng_BOOK Page 73...

Page 75: ...for kinks or signs of wear If necessary have it replaced by your dealer Lubricate the clutch cable with a commercially available cable lubricant to prevent premature wear and corrosion NOTICE Improper...

Page 76: ...into gear Make sure the engine does not stall and the motorcycle does not creep Gradually release the clutch lever and open the throttle Your motorcycle should move smoothly and accelerate gradually I...

Page 77: ...g positions and throttle freeplay is correct If the throttle does not move smoothly close automatically or if the cable is damaged have the motorcycle inspected by your dealer Freeplay at the throttle...

Page 78: ...e crankcase breather tube 2 Remove the crankcase breather tube plug from the tube 3 Drain deposits into a suitable container 4 Install the crankcase breather tube plug 20160628185719_32K56E000_eng_BOO...

Page 79: ...aim of the headlight for proper alignment To move the headlight case loosen the bolt Tighten the bolt after adjustment Obey local laws and regulations 20160628185719_32K56E000_eng_BOOK Page 78 Tuesday...

Page 80: ...Malfunction Indicator Lamp MIL P 79 Other Warning Indications P 80 Fuel Gauge Failure Indication P 80 Tyre Puncture P 81 Electrical Trouble P 87 Battery Goes Dead P 87 Burned out Light Bulb P 87 Blow...

Page 81: ...is on contact your dealer as soon as possible Starter Motor Does Not Operate Check the following items Check the correct engine starting sequence 2 P 23 Check for a blown fuse 2 P 92 Check for a loos...

Page 82: ...at the radiator fan is operating and then turn the ignition switch to the OFF position If the fan is not operating Suspect a fault Do not start the engine Transport your motorcycle to your dealer If t...

Page 83: ...ator Lamp MIL If the indicator comes on while riding you may have a serious problem with the PGM FI system Reduce speed and have your motorcycle inspected by your dealer as soon as possible 2016062818...

Page 84: ...on If the fuel system has an error the fuel gauge indicators will be displayed as shown in the illustration If this occurs see your dealer as soon as possible 20160628185719_32K56E000_eng_BOOK Page 83...

Page 85: ...pair kit Riding your motorcycle with a temporary tyre repair is very risky Do not exceed 50 km h 30 mph Have the tyre replaced by your dealer as soon as possible 3WARNING Riding your motorcycle with a...

Page 86: ...a maintenance stand or a hoist 4 Remove the front axle shaft front wheel and side collars u Avoid getting grease oil or dirt on the disc or pad surfaces u Do not pull the brake lever while the front w...

Page 87: ...xle nut Torque 59 N m 6 0 kgf m 44 lbf ft 4 After installing the wheel apply the brake lever several times then check if the wheel rotates freely Recheck the wheel if the brake drags or if the wheel d...

Page 88: ...aximum drive chain slack 3 Remove the rear axle nut and washer 4 Remove the drive chain from the driven sprocket by pushing the rear wheel forward 5 Remove the rear axle shaft and washer 2016062818571...

Page 89: ...e rear wheel reverse the removal procedure u Take care to prevent the brake caliper from scratching the wheel during installation NOTICE When installing the brake caliper into position carefully fit t...

Page 90: ...wheel rotates freely Recheck the wheel if the brake drags or if the wheel does not rotate freely If a torque wrench was not used for installation see your dealer as soon as possible to verify proper a...

Page 91: ...g using an automobile battery is not recommended as this can damage your motorcycle s electrical system Burned out Light Bulb Follow the procedure below to replace a burned out light bulb Turn the ign...

Page 92: ...b 1 Open the seat 2 P 29 2 Turn the socket counterclockwise and pull it out 3 Slightly press the bulb in and turn it counterclockwise 20160628185719_32K56E000_eng_BOOK Page 91 Tuesday June 28 2016 18...

Page 93: ...gular projection 5 Close the seat Front Rear Turn Signal Bulb 1 Remove the screw and turn signal light lens 2 Turn the socket counterclockwise and pull it out 3 Pull the bulb out without turning it 20...

Page 94: ...ntil the mark is aligned with the triangular projection u Use only the amber bulb Position Light Bulb 1 Turn the socket counterclockwise and pull it out 2 Pull the bulb out without turning it 20160628...

Page 95: ...angular projection License Plate Light Bulb 1 Remove the screws 2 Remove the license plate light cover and packing 3 Pull the bulb out of the socket without turning it 4 Install a new bulb and parts i...

Page 96: ...e of the same rating u Spare fuses are provided on back side of the battery cover 2 P 48 4 Close the fuse box covers 5 Reinstall parts in the reverse order of removal NOTICE If a fuse fails repeatedly...

Page 97: ...mittently while riding Even if this symptom occurs you can continue to ride your motorcycle If unstable engine operation occurs even if sufficient fuel is available have your motorcycle inspected by y...

Page 98: ...orcycle P 97 Storing Your Motorcycle P 100 Transporting Your Motorcycle P 101 You the Environment P 102 Serial Numbers P 103 Fuels Containing Alcohol P 104 Catalytic Converter P 105 20160628185719_32K...

Page 99: ...ake the spare key or the key number to your dealer If you lose all keys and the key number the ignition switch assembly will probably have to be removed by your dealer to determine the key number A me...

Page 100: ...stops the engine and fuel pump if the motorcycle falls over To reset the sensor you must turn the ignition switch to the OFF position and back to the ON position before the engine can be restarted Hig...

Page 101: ...owel with mild cleaner to remove road grime u Clean the headlight lens panels and other plastic components with extra care to avoid scratching them Avoid directing water into the air cleaner muffler a...

Page 102: ...t starting and causes rust in the muffler Dry the brakes u Water adversely affects braking effectiveness After washing apply the brakes intermittently at low speed to help dry them Do not direct water...

Page 103: ...ove stubborn stains use diluted detergent and rinse thoroughly with plenty of water Avoid getting petrol brake fluid or detergents on the instruments panels or headlight Exhaust Pipe and Muffler When...

Page 104: ...e on its centre stand and position a block so that both tyres are off the ground After rain remove the body cover and allow the motorcycle to dry Remove the battery 2 P 48 to prevent discharge Charge...

Page 105: ...er that has a loading ramp or lifting platform and motorcycle tie down straps Never try to tow your motorcycle with a wheel or wheels on the ground NOTICE Towing your motorcycle can cause serious dama...

Page 106: ...proved containers and take them to a recycling centre Call your local or state office of public works or environmental services to find a recycling centre in your area and to get instructions on how t...

Page 107: ...may also be required when ordering replacement parts To check the frame number open the seat 2 P 29 and pull out the rubber prongs You should record these numbers and keep them in a safe place 201606...

Page 108: ...ol may be marketed under the name Gasohol The use of petrol containing more than 10 ethanol may Damage the painting of the fuel tank Damage the rubber tubes of the fuel line Cause corrosion of the fue...

Page 109: ...ollution and can impair your engine s performance A replacement unit must be an original Honda part or equivalent Follow these guidelines to protect your motorcycle s catalytic converter Always use un...

Page 110: ...inimum turning radius 1 9 m 6 2 ft 1 Including rider passenger all luggage and accessories Displacement 149 16 cm3 9 099 cu in Bore x stroke 57 300 x 57 843 mm 2 2559 x 2 2773 in Compression ratio 11...

Page 111: ...ls marked as Energy Conserving or Resource Conserving SAE 10W 30 JASO T 903 standard MA Engine oil capacity After draining 1 1 L 1 2 US qt 1 0 Imp qt After disassembly 1 3 L 1 4 US qt 1 1 Imp qt Recom...

Page 112: ...12V 5W x 2 License plate light 12V 5W Fuses Main fuse 20A Other fuses 10A Torque Specifications Engine oil drain bolt 24 N m 2 4 kgf m 18 lbf ft Rear axle nut 59 N m 6 0 kgf m 44 lbf ft Front axle nu...

Page 113: ...ar Turn Signal 89 C Caring for Your Motorcycle 97 Clip 51 Clutch Freeplay 72 Clutch System 71 Coolant 42 61 Crankcase Breather 74 Crash 5 D Document Bag 30 96 Drive Chain 41 67 E Electrical Trouble 87...

Page 114: ...eam Indicator 18 96 High Coolant Temperature Indicator 18 78 Horn Button 19 I Ignition Cut off System Banking Sensor 96 Ignition Key 95 Ignition Switch 19 23 96 Indicators 18 Instruments 16 Instrument...

Page 115: ...ant 42 Engine Oil 40 Fuel 27 Refuelling 27 Removal Battery 48 Centre Lower Cowl 50 Clip 51 Harness Band Clip 52 Right Cowl 51 Right Side Cover 53 Repair Kit 81 Riding Precautions 8 Right Cowl 51 Right...

Page 116: ...ool Kit 30 Transporting Your Motorcycle 101 Tripmeter 96 Troubleshooting 76 Turn Signal Indicator 18 Turn Signal Switch 19 Tyres Air Pressure 43 Puncture 81 Replacing 43 81 W Warning Indicators On or...

Page 117: ......

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Honda RS150R 2016, Owner'S Manual

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