Honda XR150 2018 Owner'S Manual Download Page 75

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Adjusting the Clutch Lever

Freeplay

Upper Adjustment

Attempt adjustment with the upper clutch

cable adjuster first.

Pull back the rubber dust cover.

Loosen the upper lock nut.

Turn the upper clutch cable adjuster until

the freeplay is 10 - 20 mm (0.4 - 0.8 in).

Tighten the upper lock nut and check the

freeplay again.

Install the rubber dust cover.

20171023164032_32KRHH100_eng_BOOK Page 74 Monday, October 23 2017 17:21:44 JST

Clutch

Adjusting the Clutch Lever Freeplay

Maintenance

Continued

Rubber dust cover

Upper lock nut

Upper clutch cable adjuster

Summary of Contents for XR150 2018

Page 1: ......

Page 2: ...ble 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: ...roduct To ensure your safety and riding pleasure Read this owner s manual carefully Follow all recommendations and procedures contained in this manual Pay close attention to safety messages contained...

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

Page 5: ...Motorcycle Safety P 2 Operation Guide P 14 Maintenance P 30 Troubleshooting P 76 Information P 89 Specifications P 101 Index P 104 20171023164032_32KRHH100_eng_BOOK Page 4 Monday October 23 2017 17 2...

Page 6: ...essories Modifications P 11 Off Road Safety P 12 Loading P 13 20171023164032_32KRHH100_eng_BOOK Page 5 Monday October 23 2017 17 21 44 JST This section contains important information for safe riding o...

Page 7: ...free of alcohol and drugs Check that you and your passenger are both wearing an approved motorcycle helmet and protective apparel Instruct your passenger on holding onto the grab rail or your waist le...

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: ...ntinue 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 hand...

Page 10: ...ver 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 carbo...

Page 11: ...ity protective clothing Ride defensively in response to weather and road conditions Helmet Safety standard certified high visibility correct size for your head Must fit comfortably but securely with t...

Page 12: ...s and gloves riding pants with knee and hip pads a jersey with elbow pads and a chest shoulder protector Riding Precautions Running in Period During the first 500 km 300 miles of running follow these...

Page 13: ...with intermittent use of the brakes to reduce speed when descending long steep slopes Wet or Rainy Conditions Road surfaces are slippery when wet and wet brakes further reduce braking efficiency Exer...

Page 14: ...l 5 Turn the ignition switch to the LOCK position and remove the key 2 P 20 6 Turn the fuel valve to the OFF position Refuelling and Fuel Guidelines Follow these guidelines to protect the engine fuel...

Page 15: ...stall 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 16: ...Familiarity with your motorcycle is critically important should a problem occur far from help Never ride beyond your ability and experience or faster than conditions warrant If you are not familiar w...

Page 17: ...he lights or the muffler Also follow these guidelines when you ride off road on rough terrain Do not carry a passenger Keep cargo small and light weight Make sure it cannot easily be caught on brush o...

Page 18: ...Page 17 Monday October 23 2017 17 21 44 JST Operation Guide 14 Kickstarter P 22 Seat P 49 Spark plug P 51 Throttle grip P 73 Fuel fill cap P 26 Rear brake pedal P 58 Engine oil fill cap dipstick P 53...

Page 19: ...r 23 2017 17 21 44 JST Operation Guide 15 Clutch lever P 70 Main fuse P 88 Battery P 48 Helmet holder P 29 Drive chain P 64 Side stand P 63 Shift lever P 25 Fuel valve P 21 Fuse box P 87 Engine oil dr...

Page 20: ...uide 16 Speedometer This shows your speed in kilometer per hour km h Odometer Total distance ridden Tripmeter Distance ridden since tripmeter was reset Tripmeter reset knob The tripmeter reset knob is...

Page 21: ...onday October 23 2017 17 21 44 JST Operation Guide 17 Turn signal indicator High beam indicator Neutral indicator Comes on when the transmission is in Neutral If one of these indicators does not come...

Page 22: ...032_32KRHH100_eng_BOOK Page 21 Monday October 23 2017 17 21 44 JST Operation Guide 18 Headlight dimmer switch High beam Low beam u Pressing the switch turns the turn signal off Turn signal switch Star...

Page 23: ...17 17 21 44 JST Operation Guide 19 Continued Ignition switch Switches the electrical system on off locks the steering u Key can be removed when in the OFF or LOCK position ON Turns electrical system o...

Page 24: ...left b Push the key down and turn the ignition switch to the LOCK position u Jiggle the handlebar if the lock is difficult to engage c Remove the ignition key Unlocking Insert the key and turn the ign...

Page 25: ...rom the fuel tank to the carburetor ON normal position for riding OFF for parking storing or transportation RES for extra fuel to get to a gas station for refuelling 20171023164032_32KRHH100_eng_BOOK...

Page 26: ...0 seconds before trying to start the engine again to recover battery voltage Extended fast idling and revving the engine can damage the engine and the exhaust system Normal Air Temperature 10 35 C 50...

Page 27: ...lly off i If idling is unstable open the throttle slightly High Air Temperature 35 C 95 F or Above a Do not use the choke b Using the start button With the throttle slightly open press the start butto...

Page 28: ...the choke lever is at fully off If the engine does not start a Turn the ignition switch to the OFF position b Push the choke lever down all the way to fully off c Open the throttle fully d Crank the e...

Page 29: ...Shifting Gears Your motorcycle transmission has 5 forward gears in a one down four up shift pattern 20171023164032_32KRHH100_eng_BOOK Page 28 Monday October 23 2017 17 21 44 JST Operation Guide 25...

Page 30: ...64 Imp gal Reserve capacity 3 5 L 0 92 US gal 0 77 Imp gal The tank should be refilled as soon as possible after switching to reserve and the fuel valve should be returned to the ON position after ref...

Page 31: ...ignition key and close the lock cover u The ignition key cannot be removed if the fuel fill cap is not locked 3WARNING Petrol is highly flammable and explosive You can be burned or seriously injured...

Page 32: ...Removing the Seat P 49 u Insert the ignition key and turn it counterclockwise to unlock 20171023164032_32KRHH100_eng_BOOK Page 31 Monday October 23 2017 17 21 44 JST Operation Guide 28 Document bag R...

Page 33: ...met holder only when parked 3WARNING Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed Us...

Page 34: ...3 Brakes P 56 Side Stand P 63 Drive Chain P 64 Wheels P 69 Clutch P 70 Throttle P 73 Crankcase Breather P 74 Other Adjustments P 75 Adjusting the Headlight Aim P 75 20171023164032_32KRHH100_eng_BOOK P...

Page 35: ...ns and schedules in this owner s manual Maintenance Safety Always read the maintenance instructions before you begin each task and make sure that you have the tools parts and skills required We cannot...

Page 36: ...nance 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...

Page 37: ...e Speed Secondary Air Supply System 2 Secondary Air Supply Pair Filter 5 3 Years Maintenance Level Maintenance Legend Intermediate We recommend service by your dealer unless you have the necessary too...

Page 38: ...Clutch System 70 Side Stand 63 Suspension Nuts Bolts Fasteners 4 Wheels Tyres 4 43 69 Steering Head Bearings Notes 1 At higher odometer reading repeat at the frequency interval established here 2 Serv...

Page 39: ...ricate if necessary 2 P 64 Brakes Check operation Front check brake fluid level and pads wear 2 P 56 2 P 57 Rear check shoes wear and freeplay adjust if necessary 2 P 61 2 P 58 Lights and horn Check t...

Page 40: ...t have to check the battery electrolyte level or add distilled water Clean the battery terminals if they become dirty or corroded Do not remove the battery cap seals There is no need to remove the cap...

Page 41: ...in thoroughly using water Electrolyte splashes into your mouth u Rinse mouth thoroughly with water and do not swallow 3WARNING The battery gives off explosive hydrogen gas during normal operation A sp...

Page 42: ...y glasses 4 After cleaning reinstall the battery The battery has a limited life span Consult your dealer about when you should replace the battery Always replace the battery with another maintenance f...

Page 43: ...ses If a fuse is blown replace with a fuse of the same rating For fuse ratings see Specifications 2 P 103 NOTICE Replacing a fuse with one that has a higher rating greatly increases the chance of dama...

Page 44: ...rd 1 MA SAE standard 2 10W 30 API classification 3 SG or higher 1 The JASO T 903 standard is an index for engine oils for 4 stroke motorcycle engines There are two classes MA and MB For example the fo...

Page 45: ...ct the chain more frequently if you often ride on bad roads ride at high speed or ride with repeated fast acceleration 2 P 64 If the chain does not move smoothly makes strange noises has damaged rolle...

Page 46: ...l and benzene abrasive cleaner chain cleaner or lubricant NOT designed specifically for O ring chains as these can damage the rubber O ring seals Avoid getting lubricant on the brakes or tyres Avoid a...

Page 47: ...you decide to adjust the tyre pressure for a particular off road riding condition make changes a little at a time Inspecting for Damage Inspect the tyres for cuts slits or cracks that exposes fabric o...

Page 48: ...ir positions A tilted valve stem indicates the tube is slipping inside the tyre or the tyre is slipping on the rim See your dealer 3WARNING Riding on tyres that are excessively worn or improperly infl...

Page 49: ...place the inner tube whenever you replace a tyre The old tube will probably be stretched and it could fail if installed in a new tyre 3WARNING Installing improper tyres on your motorcycle can adversel...

Page 50: ...cleaning or any other cleaning can degrade the viscous element performance and cause the intake of dust Do not perform the maintenance Should be serviced by your dealer 20171023164032_32KRHH100_eng_B...

Page 51: ...s and parts replacement with the provided tools Spark plug wrench 10 12 mm Open end wrench 14 17 mm Open end wrench No 2 Phillips screwdriver No 2 Screwdriver Screwdriver handle Extension bar 24 mm Bo...

Page 52: ...from the battery 6 Remove the battery taking care not to drop the terminal nuts Installation Install the parts in the reverse order of removal Always connect the positive terminal first Make sure that...

Page 53: ...ks and rear recess to the rear hook 2 Slide the seat into position 3 Install the collars and tighten the bolts securely 4 Install both side covers 20171023164032_32KRHH100_eng_BOOK Page 52 Monday Octo...

Page 54: ...move the prongs from the grommets 3 Remove the side cover Installation Install the parts in the reverse order of removal 20171023164032_32KRHH100_eng_BOOK Page 53 Monday October 23 2017 17 21 44 JST R...

Page 55: ...plug base 3 Remove the spark plug using provided spark plug wrench 2 P 47 u Use the open end wrench provided in the tool kit to remove the spark plug 4 Inspect the electrodes and centre porcelain for...

Page 56: ...ighten it twice to prevent loosening a First tighten the plug 1 2 turn after it seats b Then loosen the plug c Next tighten the plug again 1 8 turn after it seats NOTICE An improperly tightened spark...

Page 57: ...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 58: ...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 59: ...ck drain bolt and sealing washer to drain the oil u Discard the oil at an approved recycling centre 6 Install a new sealing washer onto the drain bolt Tighten the drain bolt Torque 30 N m 3 1 kgf m 22...

Page 60: ...level mark If the brake fluid level in the reservoir is below the LOWER level mark or the brake lever freeplay becomes excessive inspect the brake pads for wear If the brake pads are not worn you mos...

Page 61: ...icator 1 Inspect the brake pads from in front of the brake caliper If necessary have the pads replaced by your dealer Always replace both left and right brake pads at the same time 20171023164032_32KR...

Page 62: ...r Brake Pedal Freeplay 1 Place your motorcycle on its side stand on a firm level surface 2 Measure the distance the rear brake pedal moves before the brake takes hold Freeplay at the tip of the brake...

Page 63: ...Adjust by turning the rear brake adjusting nut a half turn at a time 2 Apply the brake several times and check for free wheel rotation after the brake pedal is released 20171023164032_32KRHH100_eng_B...

Page 64: ...y of the brake pedal Make sure the brake rod brake arm spring and fastener are in good condition NOTICE Do not turn the adjuster beyond its natural limits 20171023164032_32KRHH100_eng_BOOK Page 63 Mon...

Page 65: ...w aligns with the reference mark on full application of the brake the brake shoes must be replaced See your dealer for this service When the brake service is necessary see your dealer Use only Honda G...

Page 66: ...urn 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 20171023164032_32KRHH100_eng_BOOK Page 65 Monday October 23...

Page 67: ...ease 2 Check the spring for damage or loss of tension Checking the Rubber Pad Check the rubber pad for deterioration and wear Replace if wear extends to any point of the wear line If necessary have th...

Page 68: ...e your motorcycle on its side stand on a firm level surface 3 Check the slack in the lower half of the drive chain midway between the sprockets Drive chain slack 20 30 mm 0 8 1 2 in u Do not ride your...

Page 69: ...side stand on a firm level surface 3 Loosen the rear axle nut 4 Loosen the lock nuts on both sides of the swingarm 20171023164032_32KRHH100_eng_BOOK Page 68 Monday October 23 2017 17 21 44 JST Drive...

Page 70: ...eft adjusting nuts until the marks are aligned and recheck chain slack 7 Tighten the rear axle nut Torque 93 N m 9 5 kgf m 69 lbf ft 8 Tighten the drive chain adjusting nuts lightly then hold the adju...

Page 71: ...on the label after the chain has been adjusted to the proper slack the chain is excessively worn and must be replaced Chain CHOHO 428 HO If necessary have the drive chain replaced by your dealer 2017...

Page 72: ...to be replaced if a chain slider is worn to the wear limit point If necessary have the drive chain slider replaced by your dealer 20171023164032_32KRHH100_eng_BOOK Page 71 Monday October 23 2017 17 2...

Page 73: ...the recommended service in the Maintenance Schedule However information for wheel removal is provided for emergency situations 2 P 78 1 Inspect the wheel rims and spokes for damage 2 Tighten any loos...

Page 74: ...or 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 75: ...Turn the upper clutch cable adjuster until the freeplay is 10 20 mm 0 4 0 8 in 4 Tighten the upper lock nut and check the freeplay again 5 Install the rubber dust cover 20171023164032_32KRHH100_eng_B...

Page 76: ...m 0 4 0 8 in 4 Tighten the lower lock nut and check the clutch lever freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycle doe...

Page 77: ...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: ...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 20171023164032_32KRHH100_eng_BOOK...

Page 79: ...ical aim of the headlight for proper alignment Turn the screw in or out as necessary using provided Phillips screwdriver 2 P 47 Obey local laws and regulations 20171023164032_32KRHH100_eng_BOOK Page 7...

Page 80: ...Start P 77 Tyre Puncture P 78 Electrical Trouble P 83 Battery Goes Dead P 83 Burned out Light Bulb P 83 Blown Fuse P 87 20171023164032_32KRHH100_eng_BOOK Page 79 Monday October 23 2017 17 21 44 JST T...

Page 81: ...Not Operate Check the following items Check the correct engine starting sequence 2 P 22 Check for a blown fuse 2 P 87 Check for a loose battery connection 2 P 48 or battery terminal corrosion 2 P 36...

Page 82: ...ching a tube or using an aerosol sealant ride cautiously at reduced speed and have the tube replaced before you ride again Anytime a tube is replaced the tyre should be carefully inspected as describe...

Page 83: ...move the front axle nut 5 Remove the front axle shaft front wheel side collar and speedometer gearbox u Avoid getting grease oil or dirt on the disc or pad surfaces u Do not pull the brake lever while...

Page 84: ...earbox 4 Tighten the front axle nut Torque 44 N m 4 5 kgf m 32 lbf ft 5 After installing the wheel apply the brake lever several times and then check if the wheel rotates freely Recheck the wheel if t...

Page 85: ...ear axle nut 6 Remove the drive chain from the driven sprocket by pushing the rear wheel forward 7 Remove the rear axle shaft rear axle washer side collars and rear wheel from the swingarm 20171023164...

Page 86: ...e chain slack 2 P 65 8 Adjust the rear brake pedal freeplay 2 P 59 9 Tighten the rear axle nut Torque 93 N m 9 5 kgf m 69 lbf ft 10 After installing the wheel apply the brake pedal several times then...

Page 87: ...ng using an automobile battery can damage your motorcycle s electrical system and is not recommended Burned out Light Bulb Follow the procedure below to replace a burned out light bulb Turn the igniti...

Page 88: ...l a new bulb and parts in the reverse order of removal Do not touch the glass surface with your fingers If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol 20171023...

Page 89: ...taillight lens by removing the screws 2 Slightly press the bulb in and turn it counterclockwise 3 Install a new bulb and parts in the reverse order of removal u After putting back the lens packing in...

Page 90: ...emove the nuts A washers and license plate bracket 2 Remove the nuts B license light cover and license light lens 3 Slightly press the bulb in and turn it counterclockwise 4 Install a new bulb and par...

Page 91: ...he fuses one by one to check for a blown fuse Always replace a blown fuse with a spare fuse of the same rating 4 Close the fuse box cover 5 Install the parts in the reverse order of removal 2017102316...

Page 92: ...Spare main fuse is provided in the starter magnetic switch 4 Install the parts in the reverse order of removal NOTICE If a fuse fails repeatedly you likely have an electrical problem Have your motorc...

Page 93: ...otorcycle P 92 Storing Your Motorcycle P 95 Transporting Your Motorcycle P 96 You the Environment P 97 Serial Numbers P 98 Fuels Containing Alcohol P 99 Catalytic Converter P 100 20171023164032_32KRHH...

Page 94: ...the spare key or the key number to your dealer If you lose all ignition keys and the key number the ignition switch assembly will probably have to be removed by your dealer to determine the key number...

Page 95: ...odometer returns to 0 when the read out exceeds 99 999 9 Tripmeter The tripmeter returns to 0 0 when the read out exceeds 999 9 Document Bag The owner s manual registration and insurance information c...

Page 96: ...ts with extra care to avoid scratching them Avoid directing water into the air cleaner muffler and electrical parts 3 Thoroughly rinse your motorcycle with plenty of clean water and dry with a soft cl...

Page 97: ...low speed to help dry them Do not direct water under the seat u Water in the under seat compartment can damage your documents and other belongings Do not direct water at the air cleaner u Water in th...

Page 98: ...o prevent scratches and blemishes Wash gently using a soft sponge and plenty of water To remove stubborn stains use diluted detergent and rinse thoroughly with plenty of water Avoid getting petrol bra...

Page 99: ...ance stand and position a block so that both tyres are off the ground After rain remove the body cover and allow the motorcycle to dry Remove the battery 2 P 48 to prevent discharge Fully charge the b...

Page 100: ...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 101: ...n approved containers and take them to a recycling centre Call your local or state office of public works or environmental services to find a recycling centre in your area and to get instructions on h...

Page 102: ...ired in order to register your motorcycle They may also be required when ordering replacement parts You should record these numbers and keep them in a safe place 20171023164032_32KRHH100_eng_BOOK Page...

Page 103: ...l may be marketed under the name Gasohol The use of petrol containing more than 10 ethanol may Damage the painting of the fuel tank Damage the rubber tubes of the fuel line Cause corrosion of the fuel...

Page 104: ...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 converters Always use u...

Page 105: ...inimum turning radius 2 10 m 6 88 ft 1 Including rider passenger all luggage and accessories Displacement 149 15 cm3 9 098 cu in Bore x stroke 57 300 x 57 838 mm 2 2559 x 2 2771 in Compression ratio 9...

Page 106: ...oil Honda 4 stroke motorcycle oil API Service Classification SG or higher excluding oils marked as Energy Conserving or Resource Conserving SAE 10W 30 JASO T 903 standard MA Engine oil capacity After...

Page 107: ...12 V 5 W License plate light 12 V 5 W Fuses Main fuse 15 A Other fuse 10 A Torque Specifications Engine oil drain bolt 30 N m 3 1 kgf m 22 lbf ft Rear wheel axle nut 93 N m 9 5 kgf m 69 lbf ft Front w...

Page 108: ...ng for Your Motorcycle 92 Catalytic Converter 100 Choke Lever 22 Clutch System 70 D Drive Chain 41 64 E Electrical Trouble 83 Engine Number 98 Oil 40 53 Starting 22 Environment 97 F Flooded Engine 22...

Page 109: ...delines 13 M Maintenance Fundamentals 35 Importance 31 Safety 31 Schedule 32 Maximum Weight Capacity 13 101 Modifications 11 N Neutral Indicator 17 O Odometer 16 91 Off Road Safety 12 Oil Engine 40 53...

Page 110: ...Bag 28 91 Equipment 28 Owner s Manual 28 91 Tool Kit 28 47 Storing Your Motorcycle 95 Switches 18 T Throttle 73 Tool Kit 28 47 Transporting Your Motorcycle 96 Tripmeter 16 91 Troubleshooting 76 Turn S...

Page 111: ......

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