NSR150SP General Information CONTENTS z NSR150SP General Information ______________________________________________ HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the motorcycle is in peak operating condition. Performing the first schedule maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 through 3 apply to the whole unit, while sections 4 through 19 describe parts of the unit, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to section 20, TROUBLESHOOTING. All information contained in this manual is based on the latest product information available at the time of printing. Honda Australia Motorcycle & Power Equipment Pty. Ltd., and Honda Motor Co. Ltd, Japan, reserve the rights to make changes at any time without notice. Apart from criticism or reviews permitted under the Copyright Act 1968, no part of this publication may be reproduced, 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 Equipment Pty. Ltd., and/or Honda Motor Co Ltd. Japan. This includes test, figures and tables. HONDA MOTOR CO., LTD Service Publications Office IMPORTANT SAFETY NOTICE Indicate a strong possibility of severe personal injury or death if instructions are not followed. CAUTION Indicate a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by HONDA, must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardised by the service methods or tools selected. 1-1 NSR150SP General Information ______________________________________________ SYMBOL The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use to the symbols. Replace the part (s) with new one (s) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1) Use multi-purpose grease (lithium based multi-purpose grease 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 manufactured by Mitsubishi Oil Japan. Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI#2 or equivalent). Example: Molykote ® G-n Paste manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use Silicone grease. Apply a locking agent. Use a middle strength-locking agent unless otherwise specified. Apply sealant. Use brake fluid, DOT 4. Use the recommended brake fluid, unless otherwise specified. Use Fork or Suspension Fluid. 1-2 NSR150SP General Information ______________________________________________ General Safety Service Rules Model Identification Specification 1-3 1-5 1-6 1-7 Torque Values Tools Lubrication & Seal Points Cable & Harness Routing 1-14 1-17 1-18 1-21 GENERAL SAFETY Carbon Monoxide If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. Gasoline Work in a well ventilated area. Keep cigarettes, flames or sparks from work area or where gasoline is stored. Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Hot Components Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. Used Engine / Transmission Oil Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. Brake Dust Never use an air hose or dry brush to clean brake assemblies. Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Brake Fluid CAUTION: • Spilling fluid on painted, plastic 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. 1-3 NSR150SP General Information ______________________________________________ Coolant Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the engine ethylene glycol does ignite, you will not see any flame, but you can be burned. • • • • Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause 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. Some pets are attracted to the smell and taste of coolant and can die if they drink it. Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. If it contacts your skin, wash the affected areas immediately with soap and water. If it contacts your eyes, flush them thoroughly with fresh water and get immediate medical attention. If it is swallowed, the victim must be forced to vomit then rinse mouth and throat with fresh water before obtaining medical attention. Because of these dangers, away from the reach of children. Recycle used coolant in an ecologically correct manner. NITROGEN PRESSURE For shock absorber with a gas-filled reservoir. • • • Use only nitrogen to pressurize the shock absorb. The use of an unstable gas can cause a fire or explosion resulting in serious injury. The shock absorber contains nitrogen under high pressure. Allowing fire or heat near the shock absorber could lead to and explosion that could result in serious injury. Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explosion and serious injury if it is heated or pierced. To prevent the possibility of an explosion, release the nitrogen by pressing the valve core. Then remove the valve stem from the shock absorber reservoir. Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve stem from the shock absorber. BATTERY HYDROGEN GAS & ELECTROLYTE - The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and face Shield. If electrolyte gets on your skin, flush with water. - If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician If swallowed, drink large quantities of water or milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN. 1-4 NSR150SP General Information ______________________________________________ SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubrications or their equivalents. Parts that do not meet HONDA's design specifications may damage the motorcycle. 2. Use the special tools designed for this product. 3. Use only metric tools when servicing this motorcycle. Metric bolts, nets and screws are not interchangeable with English fasteners. 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 with the larger-diameter of inner bolts first, and tighten to specified torque diagonally, in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before re-assembly. 7. After assembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown on pages 1-22 through 1-27, Cable and Harness Routing. 1-5 NSR150SP General Information ______________________________________________ Model Identification (1) FRAME SERIAL NUMBER (2) ENGINE SERIAL NUMBER The engine serial number is Stamped on the right crankcase. The frame serial number is stamped On the right side of the steering head. (3) CARBURETTOR IDENTIFICATION NUMBER The carburettor identification number is stamped carburettor body. 1-6 NSR150SP General Information ______________________________________________ SPECIFICATIONS General DIMENSION FRAME ENGINE ITEM Overall length Overall width Overall height Wheel base Seat height Foot peg height Ground clearance Dry Weight Curb Weight Maximum Weight capacity Frame Type Front Suspension Fork Inner tube diameter Fork fluid capacity (per leg) Front wheel travel Steering head bearing Rear suspension Rear wheel travel Rear damper Damper / reservoir gas pressure Pressurized gas material Front tyre size Rear tyre size Front brake Rear brake Caster angle Trail Fuel Tank capacity Fuel Tank reserve capacity Bore and Stroke Displacement Compression ratio Port timing intake open Port timing intake close Port timing exhaust open - Hi - Low Port timing exhaust close - Hi Low Port timing scavenge open Port timing scavenge close Lubrication system Oil pump type Cooling system Air filtration Crankshaft type Engine weight 1-7 SPECIFICATIONS 1,972mm (77.6 in) 683 mm (26.9 in ) 1,062mm (41.8 in ) 1,337 mm (52.6 in ) 780 mm (30.7 in ) 325 mm (12.8 in) 142 mm (5.6 in) 122.4kg (269.8 lb ) 131.4kg (289.7 lb ) 118kg (260.1 lb ) Diamond Telescopic fork 35 mm (1.4 in) 322 cm3 (10.9 US oz, 11.3 Imp oz) 117 mm (4.6 in) Ball Bearing Swingarm 125 mm (4.9 in) Both side operation tube type 908 kPa (10kgf/cm2, 142psi) Nitrogen 90/80-17 46S 120/80-17 61S Hydraulic single disc Hydraulic single disc 25O 36’ 91 mm (3.6 in) 10.5 litre (2.8 US gal, 2.3 Imp gal) 2.7 litre (0.7 US gal, 0.6 Imp gal) 59 mm x 54.5 mm (2.3 in x 2.1 in) 149 cm3 (9.1 cu-in) 108 kPa (11.0kgf cm2 ,156 psi) at 400min-1 (rpm) Reed valve controlled Reed valve controlled 97.6O BBDC 73.9O BBDC 97.7O ABDC 74.0O ABDC 62.6O BBDC 62.8O ABDC Oil automatically mixed with gasoline Plunger type Liquid cooled Urethane form Assembly type 23.9kg (52.7lb) NSR150SP General Information ______________________________________________ General (cont..) CARBURETTOR DRIVE TRAIN ELECTRICAL ITEM Carburettor type Throttle bore Clutch System Clutch operation system Transmission Primary reduction Final reduction Gear ratio 1st Gear ratio 2nd Gear ratio 3rd Gear ratio 4th Gear ratio 5th Gear ratio 6th Gearshift pattern Ignition system Charging system Alternator /capacity Regulator/rectifier type Lighting system 1-8 SPECIFICATIONS Piston Valve 30 mm (1.2 in) Multi-plate, wet Cable operating 6 speeds constant mesh 2.954 (65/22) 2.857 (40/14) 2.916 (35/12) 1.937 (31/16) 1.470 (25/17) 1.210 (23/19) 1.043 (24/23) 0.916 (22/24) Left foot operated return system (1N-2-3-4-5-6) DC-CDI Triple phase output alternator 188 W/5,000 min1 (rpm) Semi conductor type Battery NSR150SP General Information ______________________________________________ LUBRICATION SYSTEM ITEM Engine Oil Capacity Recommended engine oil Transmission oil At draining capacity At disassembly Recommended transmission oil STANDARD Unit: mm (in) SERVICE LIMIT 0.76 litre (0.83 US qt, 0.67 Imp, qt) Honda 2-stroke oil or equivalent 0.7 litre (0.73 US qt, 0.62 Imp, qt) 0.8 litre (0.85 US qt, 0.70 Imp, qt) Honda 4-stroke oil or equivalent API Service Classification: SE,SF,or SG Viscosity: SAE 10W – 40 FUEL SYSTEM ITEM Carburettor identification number Choke type Main jet Slow jet Air screw initial opening Float level Idle speed Throttle grip free play STANDARD PE74A Starting enrichment circuit system #152 #42 2 turns out 19mm (0.7 in) 1,300 + 100 min1 (rpm) 2 – 6mm (0.08 – 0.24in) COOLING SYSTEM Cooling capacity ITEM Radiator and engine STANDARD 1.2 Litre (1.27US qt, 1.06 Imp qt) 108 – 137 kPa (1.1 – 1.4kgf/cm2, 16-21 psi) 50% mixture with soft water Radiator cap relief pressure Standard coolant concentration 1-9 NSR150SP General Information ______________________________________________ CYLINDER HEAD/CYLINDER/PISTON ITEM STANDARD 108kPa (11.0 kgf/cm2, 156 psi at 400 min-1 (rpm) Cylinder compression Cylinder head warpage Cylinder I.D. Unit: mm (in) SERVICE LIMIT Code A No mark Code C Cylinder out of round Cylinder warpage Piston mark direction Piston pin O.D. Code A Code B Code C Piston O.D. measurement point Piston pin hole I.D. Cylinder-to-piston clearance Piston pin O.D. Piston-to-piston pin clearance Piston ring-to-ring groove clearance Ring end gap Top Second Ring mark Top Second Connecting rod small end I.D. 59.010 – 59.015 (2.3232 – 2.3234) 59.005 – 59.010 (2.3230 – 2.3232) 59.000 – 59.005 (2.3228 – 2.3230) “IN” mark facing toward the intake side 58.965 – 58.970 (2.3215 – 2.3216) 58.960 – 58.965 (2.3213 – 2.3215) 58.955 – 58.960 (2.3211 – 2.3213) 12mm (0.5in) from the bottom 16.002 – 16.015 (0.6300 – 0.6305) 0.040 – 0.050 (0.0016 – 0.0019) 15.994 – 16.000 (0.6927 – 0.6299) 0.002 – 0.021 (0.0001 – 0.0008) 0.38 – 0.53 (0.015 – 0.021) 0.38 – 0.53 (0.015 – 0.021) 3R 4R 20.002 – 20.014 (0.7875 – 0.7880) 0.05 (0.002) 59.05 (5.325) 59.05 (5.325) 59.05 (5.325) 0.05 (0.002) 0.05 (0.002) 58.92 (5.320) 58.92 (5.320) 58.92 (5.320) 16.03 (0.631) 0.080 (0.0031) 15.98 (0.629) 0.04 (0.002) 0.12 (0.05) 0.65 (0.026) 0.65 (0.026) 20.03 (0.789) CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER ITEM Clutch lever free play Clutch outer guide STANDARD O.D. I.D. Clutch outer I.D. Mainshaft O.D. at clutch outer guide Clutch spring free length Clutch disc thickness A B Clutch plate warpage Pinion gear I.D. Kickstarter spindle O.D. Kickstarter idle gear I.D. Idle gear bushing O.D. I.D. 10-20 (0.4-0.8) 22.930 – 22.950 (0.9028 – 0.9035) 16.988 – 17.010 (0.6688 – 0.6697) 23.000 – 23.021 (0.9055 – 0.9063) 16.966 – 16.984 (0.6680 – 0.6687) 35.76 (1.408) 2.9 - 3.08 (0.115 – 0.121) 2.62 – 2.78 (0.103 – 0.109) 16.016 – 16.034 15.966 – 15.984 20.020 – 20.041 19.984 – 19-995 17.010 – 17.035 1-10 (0.6305 – 0.6313) (0.6286 – 0.6293) (0.7882 – 0.7890) (0.7868 – 0.7872) (0.6697 – 0.6707) Unit: mm (in) SERVICE LIMIT 22.80 (0.898) 17.04 (0.671) 23.06 (0.908) 16.95 (0.667) 33.6 (1 32) 2.5 (0 0.98) 2.2 (0 086) 0.20 (0.01 ) 16.07 (0 633) 15.94 (0 628) 20.10 (0 791) 19.90 (0 783) 17.10 (0.673) NSR150SP General Information ______________________________________________ CRANKSHAFT/TRANSMISSION ITEM Connecting rod big end Crankshaft runout Transmission gear I.D. Transmission gear bushing O.D. Transmission gear bushing I.D. Gear-to-bushing clearance Mainshaft O.D. Countershaft O.D. Gear-to-shaft clearance Gear bushing-to-shaft clearance Shift fork claw thickness Shift fork I.D. Shift fork shaft O.D Side clearance Radial clearance A B M5, M6 C1 C2, C4 C3 M5, M6 C1 C2 C3 M5, M6 C1 C2 C3 M5, M6 C1 C2 C3 M5 Right Crankcase journal C1 C2 C3, C4 C4 M5, M6 C1 C2 C3 STANDARD 0.3 – 0.7 (0.012 – 0.028) Unit: mm (in) SERVICE LIMIT 0.05(0.002) 22.020–22.041(0.8669–0.8678) 20.020-20.041(0.7882-0.7890) 22.020–22.041(0.8669–0.8678) 25.020-25.041(0.9850-0.9859) 21.979-22.000(0.8653-0.8661) 19.984-19.995(0.7868-0.7872) 21.984-22.005(0.8655-0.8663) 24.984-24.993(0.9836-0.9840) 20.000-20.021(0.7874-0.7882) 17.016-17.034(0.6700-0.6706) 20.020-20.041(0.7882-0.7890) 22.020–22.041(0.8669–0.8678) 0.020-0.062(0.0008-0.0024) 0.025-0.057(0.0010-0.0022) 0.015-0.057(0.0006-0.0022) 0.027-0.057(0.0011-0.0022) 19.959-19.980(0.7858-0.7866) 16.966-16.984(0.6683-0.6687) 0.05(0.002) 0.03(0.001) 22.10(0.870) 20.10(0.791) 22.10(0.870) 25.10(0.988) 21.90(0.862) 19.90(0.783) 21.90(0.862) 24.90(0.980) 20.01(0.791) 17.10(0.673) 20.10(0.791) 22.10(0.870) 0.10(0.004) 0.10(0.004) 0.10(0.004) 0.10(0.004) 19.92(0.784) 16.95(0.667) 16.975-16.984(0.6683-0.6687) 19.974-19.984(0.7863-0.7867) 21.959-21.980(0.8645-0.8653) 0.040-0.082(0.0016-0.0032) 0.020-0.062(0.0001-0.0024) 0.032-0.059(0.0013-0.0023) 0.033-0.067(0.0013-0.0026) 0.040-0.082(0.0016-0.0032) 4.93-5.00(0.194-0.197) 12.041-12.056(0.4741-0.4746) 11.983-11.994(0.4718-0.4722) 16.95(0.667) 19.94(0.785) 21.09(0.830) 0.10(0.004) 0.10(0.004) 0.10(0.004) 0.10(0.004) 0.10(0.004) 4.80(0.189) 12.65(0.475) 11.973(0.4714) 1-11 NSR150SP General Information ______________________________________________ FRONT WHEEL / SUSPENSION/STEERING ITEM STANDARD Minimum tire tread depth Cold tire pressure Driver only Driver & Passenger Front axle runout Front wheel rim Radial run out Axial Wheel balance weight Fork spring free length Fork spring installed direction Fork tube runout Recommended fork oil Fork oil level Fork oil capacity Steering bearing preload SERVICE LIMIT 1.5 (0.06) 200kPa (2.00kgf/cm2, 29psi) 200kPa (2.00kgf/cm2, 29psi) 0.2 (0.008) 2.0 (0.08) 2.0 (0.08) Max 60g 310.4 (12.22) Tapered side facing down 304.2 (11.98) 0.2 (0.008) 125 (4.9) 322 cm3 (10.9 US oz, 11.3 Imp oz) 1.0 – 1.5 N.m (0.1 – 0.15 kgf.m) REAR WHEEL/SUSPENSION ITEM STANDARD Minimum tire tread depth Cold tire pressure Driver only Driver & Passenger Rear wheel rim Radial run out Axial Wheel balance weight Drive chain slack Drive chain link Drive chain size DID RK Damper/reservoir gas pressure Pressurize gas material Damper rod compressed force at 10mm (0.4in) compressed Damper/reservoir gas release drilling point SERVICE LIMIT 2.0 (0.08) 200kPa (2.00kgf/cm2, 29psi) 200kPa (2.00kgf/cm2, 29psi) 2.0 (0.08) 2.0 (0.08) Max 60g 35 mm 108 525VC5 520MOZ9 980 kPa (10 kgf/cm2, 142psi) Nitrogen 272 kg See page 14-15 1-12 NSR150SP General Information ______________________________________________ REAR FRONT BRAKES ITEM Brake fluid Brake pad wear indicator Brake disc thickness Brake disc runout Master cylinder I.D Master cylinder O.D on secondary cup side Caliper cylinder I.D. Caliper piston O.D. Brake fluid Brake pad wear indicator Brake disc thickness Brake disc runout Master cylinder I.D Master cylinder O.D on secondary cup side Caliper cylinder I.D. Caliper piston O.D. STANDARD DOT 3 or 4 3.8 – 4.2 (0.15 – 0.17) 10.957-10.984 (0.4314-0.4326) 10.957-10.984 (0.4314-0.4326) 25.40-25.45(0.999-1.002) 25.335-25.368(0.9974-0.9987) DOT 3 or 4 SERVICE LIMIT Indicator groove 3.0(0.12) 0.3(0.01) 10.945(0.4309) 10.945(0.4309) 25.46(1.002) 25.300(0.9960) 12.700-12.743(0.5000-0.5017) 12.657-12.684(0.4983-0.4994) Indicator groove 3.0(0.12) 0.3(0.01) 12.755(0.5022) 12.645(0.4978) 25.40-250.45(0.999-1.002) 25.335-25.368(0.9974-0.9987) 25.46(1.002) 25.300(0.9960) 3.8-4.2 (0.15-0.17) BATTERY/CHARGING SYSTEM ITEM Alternator rated output Alternator charging coil resistance (At 20OC / 68OF) Regulator/rectifier: regulated voltage (At 20OC / 68OF) Current leakage Battery capacity Battery type Battery charging rate Normal Quick SPECIFICATIONS 180 W/5,000 min1 (rpm) 0.1 – 1.0 : 14.7 + 0.5V at 5,000 min1 (rpm) 1mA maximum 12V – 3A YB3L-A 0.3A / 10h 3A / 0.5h IGNITION SYSTEM ITEM Standard Spark Plug For cold climate riding Ignition timing *F* mark Advance NGK Nippondenso NGK Nippondenso Start Stop Full advance Ignition cut-out revolution Ignition coil Peak Voltage Ignition Pulse generator peak voltage 1-13 SPECIFICATIONS B9ES W27ES-U B8ES W24ES-U BTDC 12 + 3O / 1,200 + 200 min1 (rpm) 1,900 + 200 min1 (rpm) 3,500 + 200 min1 (rpm) BTDC 35 + 3 O 13,000 + 200 min1 (rpm) 100V minimum 0.7 V minimum NSR150SP General Information ______________________________________________ LIGHTS/METERS/SWITCHES ITEM Main fuse Fuse Headlight (high/low beam) Tail/Brake Light Front turn signal light Rear turn signal light Instruments light Oil pressure warning indicator High beam indicator Turn signal indicator Neutral indicator SPECIFICATIONS 20 A 10 A X 3 12 V – 60/55 W X 2 12 V – 5/18 W X 2 12 V – 10 W X 2 12 V – 10 W X 2 12 V – 1.7 W X 2 LED 12 V – 1.7 W 12 V – 1.7 W 12 V – 3.4 W TORQUE VALUES STANDARD FASTENERS TYPE TORQUE N.m (kgf.m, lbf.ft) 5 mm hex bolt and nut 6 mm hex bolt and nut 5 (0.5, 3.6) 10 (1.0 , 7) 8 mm hex bolt and nut 22 (2.2 , 16) 10 mm hex bolt and nut 12 mm hex bolt and nut 5 mm screw 34 (3.5 , 25) 54 (5.5 , 40) 4 (0.4 , 2.9) FASTENERS TYPE 6 mm screw 6 mm flange bolt (8mm head) 6 mm flange bolt (10mm head and nut) 8 mm flange bolt and nut 10mm flange bolt and nut TORQUE N.m (kgf.m, lbf.ft) 9 (0.9, 6.5) 9 (0.9, 6.5) 12 (1.2, 9) 26 (2.7, 20) 39 (4.0, 29) Torque specifications listed below are for important fasteners. Others should be tightened to standard torque values listed above. NOTES: 1. Apply sealant to the treads 2. Apply a locking agent to the threads 3. Apply molybdenum disulfide oil to the threads and flange surfaces 4. Left hand threads 5. Stake 6. Apply oil to the threads and flange surface 7. Apply clean engine oil to the O-ring 8. UBS bolts 9. U-nut 10. ALOC bolt; Replace with a new one 1-14 NSR150SP General Information ______________________________________________ ENGINE ITEM QTY LUBRICANT SYSTEM Oil drain bolt 1 COOLANT SYSTEM Water Pump impeller 1 CYLINDER HEAD / CYLINDER /PISTON Spark Plug 1 Cylinder head nut 6 Cylinder nut 4 Cylinder stud bolt 4 RC VALVE RC valve timing pulley nut 1 CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Right crankcase cover bolt 6mm 10 8mm 1 Clutch cable adjuster lock nut 1 Primary drive gear nut 1 Clutch lifter plate bolt 4 Clutch centre lock nut 1 Shift drum centre pin 1 Shift return spring pin 1 Shift drum stopper arm bolt 1 ALTERNATOR/BALANCER Timing hole cap 1 Flywheel nut 1 Balancer driven gear nut 1 Ignition pulse generator socket bolt 2 CRANKCASE/CRANKSHAFT/TRANSMISSION Crank case bolt 12 Bearing set plate bolt 6 OTHER FASTERNERS Neutral Switch 1 1-15 THREAD DIA (mm) TORQUE N.m (kgf-m, lbf-ft) REMARKS 8 21 (2.1, 15 ) 7 12 (1.2, 9) 14 8 8 8 20 (2.0, 23 (2.3, 23 (2.3, 10 (1.0, 6 9 (0.9, 6.5) 8 8 8 12 6 14 8 8 6 10 (1.0, 7) 26 (2.7, 20) 23 (2.3, 17) 66 (6.7, 48) 12 (1.2, 9) 64 (6.5, 47) 22 (2.2, 16) 22 (2.2, 16) 12 (1.2, 9) 14 12 14 6 3 (0.3, 2.2) 64 (6.5, 47) 54 (5.5, 40) 10 (1.0, 7) Note 2 6 6 10 (1.0, 7) 10 (1.0, 7) Note 2 10 16 (1.6, 12) 14) 17) 17) 7) Note 4 Note 6 Note 6 Note 2 NSR150SP General Information ______________________________________________ FRAME ITEM QTY FUEL SYSTEM Fuel valve nut 1 Fuel filler cap socket bolt 7 ENGINE HANGER Front engine hanger nut 1 Rear upper engine hanger nut 1 Rear lower engine hanger nut 1 FRONT WHEEL/SUSPENSION/STEERING Front axle nut 1 Steering stem nut 1 Steering top thread 1 Top bridge pinch bolt 1 Bottom bridge pinch bolt 2 Fork cap 2 Fork socket bolt 2 REAR WHEEL / SUSPENSION Rear wheel nut 1 Rear axle nut 1 Driven sprocket nut 5 Bearing holder pinch bolt 1 Swingarm pivot nut 1 Drive chain slider screw 4 Shock absorber upper mounting 1 bolt Shock absorber lower mounting 1 bolt BRAKE SYSTEM Front brake disc bolt 6 Rear brake disc bolt 4 Brake oil bolt 4 Pad pin 4 Pad pin plug 4 Caliper bleeder 2 Brake lever pivot nut 1 Front brake light switch screw 1 Front master cylinder cover screw 2 Front caliper bracket bolt 2 Front caliper pin bolt 1 Front caliper torque nut 1 Rear master cylinder cover screw 2 Rear master cylinder joint screw 1 Rear master cylinder lower joint 1 nut Rear caliper holder bolt 1 Rear caliper pin bolt 1 Rear caliper torque nut 1 Rear caliper hanger pin 2 OTHERS Side stand pivot nut 1 Right and left footpeg holder bolt 4 Ignition coil mounting bolt 2 THREAD DIA (mm) TORQUE N.m (kgf-m, lbf-ft) REMARKS 18 4 27 (2.8, 20) 1.5 (0.15, 1.1) 10 10 10 55 (5.6, 41) 55 (5.6, 41) 76 (7.8, 56) 14 24 26 8 8 32 8 59 (6.0, 43) 88 (9.0, 65) 1 (0.1, 1.7) 22 (2.2, 16) 27 (2.8, 20) 22 (2.2, 16) 20 (2.0, 14) 12 30 8 16 14 6 10 108 (11.0, 80) 226 (23.0, 166) 30 (3.1, 22) 73 (7.4, 54) 88 (9.0, 65) 5.1 (0.52, 3.8) 44 (4.5, 33) 10 44 (4.5, 33) Note 9 8 8 10 10 10 8 6 4 4 8 8 8 4 4 8 42 (4.3, 31) 34 (3.5, 25) 34 (3.5, 25) 17 (1.7, 12) 2.5 (0.25, 1.8) 5.4 (0.55, 4.0) 5.9 (0.60, 4.3) 1.2 (0.12, 0.9) 1.5 (0.15, 1.1) 30 (3.1, 22) 17 (1.7, 12) 22 (2.2, 16) 1.5 (0.15, 1.1) 1.5 (0.15, 1.1) 18 (1.8, 13) Note 2 Note 9 8 8 8 10 26 (2.7, 17 (1.7, 22 (2.2, 17 (1.7, 10 8 6 45 (4.6, 33) 32 (3.3, 24) 12 (1.2, 9) 1-16 20) 12) 16) 12) Note 9 See Pg 13 Note 2 Note 6 Note 9 Note 2 Note 2 Note 10 Note 2 NSR150SP General Information ______________________________________________ TOOLS Notes: 1. Equivalent commercially available 2. Alternative tools DESCRIPTION Float level gauge Universal bearing puller Wrench, 20 x 24 mm Extension bar Gear holder Flywheel holder Sliding weight Attachment 32x35mm Attachment 37x40mm Attachment 42x47mm Attachment 52x55mm Attachment 62x67mm Attachment 24x26mm Pilot, 10mm Pilot, 15mm Pilot, 17mm Pilot, 20mm Pilot, 25mm Pilot, 40mm Pilot, 22mm Bearing remover shaft Bearing remover head, 15mm Fork seal driver Driver Steering stem socket Clutch center holder Bearing remover set, 10mm Remover shaft Remover head Sliding weight Bearing remover head, 16mm Remover shaft, 15mm Driver attachment Steering stem driver Driver shaft Fork seal driver attachment Crank assembly collar Crank assembly shaft Flywheel puller Bearing remover attachment Mechanical seal driver Case puller TOOL NUMBER 07401-0010000 07631-0010000 07716-0020100 07716-0020500 07724-0010100 07725-0040000 07741-0010201 07746-0010100 07746-0010200 07746-0010300 07746-0010400 07746-0010500 07746-0010700 07746-0040100 07746-0040300 07746-0040400 07746-0040500 07746-0040600 07746-0040900 07746-0041000 07746-0050100 07746-0050400 07747-0010100 077490010000 07916-3710101 07923KE10000 07936-GE00000 07936-GE00100 07936-GE00200 07741-0010201 07936MK50100 07936KC10100 07946-3290000 07946-4300001 07946-MJ00100 07947-KA20200 07964MB00200 07965VM00200 07KMC-HE00100 07LMC-KV30200 07PMD-KBP0100 07SMC-0010001 1-17 APPLICABILITY REF. SEC 5 12 10 10 10 11 12 14 12,14 12,13 12,14 12,14 6 6 12,13,14 12 12 12 14 12 13 13 13 6,12,13,14 13 10 6 12 12 13 13 14 13 12 12 11 14 6 12 NSR150SP General Information ______________________________________________ LUBRICATION & SEAL POINTS ENGINE LOCATION Crankshaft • Connecting rod big end Small end • Right and left journal Cylinder bore inner surface Piston outer surface Piston pin outer surface Piston ring outer surface Right and left crankshaft bearing MATERIAL Honda-2-stroke oil or equivalent Connecting rod big end Mainshaft • Spline area • Rotating, sliding area and tooth Countershaft • Spline area • Rotating, 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 and flange surface Each Bearing • Right and left mainshaft bearing • Right and left countershaft bearing • Shift drum bearing • Water pump shaft bearing • Clutch outer needle bearing • Balancer shaft bearing Each transmission gear tooth Clutch lifter arm sliding surface Each oil seal lip • Right and left crankshaft oil seal • Countershaft oil seal • Water pump shaft oil seal • Flap valve shaft oil seal • Balancer shaft oil seal • Kickstart shaft oil seal • Gearshift spindle oil seal • Clutch lifter arm oil seal Oil pump O-ring Molybdenum disulfide oil solution (Mixture of the engine oil and molybdenum diulfide grease with the ration 1:1) Recommended transmission oil Multipurpose grease; (Litium based grease) 1-18 REMARKS NSR150SP General Information ______________________________________________ LUBRICATION & SEAL POINTS ENGINE LOCATION Thermo unit threads Cylinder Right and left crankcase mating surface Reed valve Right and left crankcase mating surface MATERIAL Liquid sealant Crankcase bolt threads Locking agent REMARKS 4 + 1 mm Example: Three Bond #1207B manufactured by 3M, co, Ltd Ignition pulse generator socket bolt Kickstarter stopper plate bolt Shaft return spring pin Bearing set plate bolt 1-19 6.5 + 1 mm NSR150SP General Information ______________________________________________ LUBRICATION & SEAL POINTS FRAME LOCATION Rear axle nut threads and flange surface MATERIAL Recommended engine oil REMARKS Caliper pin bolt sliding surface Master cylinder push rod • Master piston contacting area Brake lever • Master piston contacting area • Pivot bolt sliding surface Junction box and boot inner surface Silicone grease 0.4g Rear caliper torque nut threads Fork socket bolt Throttle grip pipe and handle grip matching surface Left handle grip inner surface Air 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 rear wheel dust seal lip Speedometer gear box inside Speedometer gear tooth and inner dia Steering head bearing and cone race Swingarm pivot bearing Swingarm dust seal lip Throttle grip pipe sliding surface Rear brake pedal pivot surface Speedometer cable O-ring Change pedal pivot surface Tie rod sliding surface Side stand pivot surface Seat catch and lever sliding surface Kick arm joint sliding surface Multipurpose grease; (Litium based grease) Front fork oil seal lip Clutch lever pivot bolt sliding surface Fork fluid Brake grease 1-20 NSR150SP General Information ______________________________________________ CABLE & HARNESS ROUTING 1-21 NSR150SP General Information ______________________________________________ 1-22 NSR150SP General Information ______________________________________________ 1-23 NSR150SP General Information ______________________________________________ 1-24 NSR150SP General Information ______________________________________________ 1-25 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ Service Information 2-1 Troubleshooting Body Panel Location 2-1 2-2 Side Cowl, Lower Cowl Inner Panel, Grab Rail 2-4 2-6 Side cover, Rear Cover, Tail Cover Rear Fender Upper Cowl, Rearview Mirror Air Guide Fuel Tank Exhaust Pipe/ Muffler 2-6 2-8 2-9 2-12 2-16 SERVICE INFORMATION General • • • • • • • Gasoline is extremely flammable and is explosive under certain condition. Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. Work in a well ventilated area. Smoking or allowing flames or sparks in the working area or where gasoline is stored can cause a fire or explosion. When installing the exhaust pipe, install the exhaust 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 of the frame body panels, fuel tank and exhaust system. Always replace the exhaust pipe gaskets when removing the exhaust pipe from the engine. Always inspect the exhaust system for leaks after installation. TORQUE VALUES TROUBLESHOOTING Excessive exhaust noise • Broken exhaust system • Exhaust gas leak Poor Performance • Deformed exhaust system • Exhaust gas leak • Clogged muffler 2-1 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ BODY PANEL LOCATION 2-2 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ SEAT, PILLION SEAT Pillion Seat Removal Turn the ignition key and unhook the pillion seat from the set catch. Remove the pillion seat Installation 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 unhook the seat from the set catch bar. Remove the seat. Installation Apply grease to the seat catch. Install the seat aligning the hooks on the seat with the frame. Lock the seat securely. Install the pillion seat (see above) 2-3 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ SIDE COWL, LOWER 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 lower cowl and upper cowl. • At installation, be careful not to damage the tabs on the side cowl. 2-4 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ LOWER COWL Removal Remove the screws. Remove the tachometer cable from the tab on the lower cowl. NOTE • At tachometer cable removal, be careful not to damage the tab on the lower cowl. Remove the tube from the hole on the lower cowl and remove the lower cowl. Disassembly Remove the screws, left lower cowl, right lower cowl and centre lower cowl. Assembly Assembly is in the reverse order of removal. NOTE • At assembly, be careful not to damage the tabs on the cowls. Installation NOTE • Route the tubes and cables properly. • At tachometer cable installation, be careful not to damage the tab on the lower cowl. • At installation, align the grooves on the lower cowl with the tabs on the side cowl. 2-5 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ 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. Installation is in the reverse order of removal. SIDE COVER / REAR COVER / TAIL COVER 2-6 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ RIGHT SIDE COVER Removal / Installation Remove the seat. (page 2-3) Loosen the bolt. Remove the screws, special bolt, collar and right 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 on the right side cover with the grommets on the frame. • At installation, be careful not to damage the tabs on the right side cover. LEFT SIDE COVER Removal / Installation Remove the seat. (page 2-3) Loosen the bolt. Remove the screws, special bolt, collar and left side cover. Installation is in the reverse order of removal. NOTE: • At installation, align the tabs on the left side cover with the grooves on the rear cover. • At installation, align the tabs on the left side cover with the grommets on the frame. • At installation, be careful not to damage the tabs on the side cover. 2-7 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ TAIL COVER Removal/Installation Remove the left or right side cover. (page 2-7) Remove the screws and tail cover. Installation is in the reverse order of removal. • NOTE: At installation, align the tab on the tail cover with the hole on the tail light lens. REAR COVER Removal/Installation Remove the right and left side cover. (page 2-7) Remove the bolts. Unhook the key cylinder hook from the seat catch hook and remove the rear cover. Installation is in the reverse order of removal. After installation, check 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. Disconnect the tail light 3P (black) connector and rear turn signal connectors. Remove the wire harnesses from the clamps on the rear fender. • NOTE: Be careful not to damage the rear fender, tubes, cables and wire harnesses. Installation is in the reverse order of removal. • • NOTE: Route the tubes, cables and harnesses properly. (page1-18) Be careful not to damage the rear fender, tubes, cables and wire harnesses. 2-8 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ 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 Removal Disconnect the speedometer cable from the speedometer. 2-9 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ Disconnect the headlight 3P connector and front turn signal connectors. Remove the speedometer cable form the hole on the upper cowl. Remove the screws and upper cowl. • NOTE: At removal, be careful not to damage the tabs on the cowls. (page 1-18) Installation NOTE: • Route the cables and wires properly. • At installation, be careful not to damage the tabs on the cowls. Install the upper cowl aligning the holes on the 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 the speedometer. AIR GUIDE Right Air Guide Remove the upper cowl. (page 2-9) Disconnect the tachometer cable from the tachometer. 2-10 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ Remove the tachometer cable from the hole on the right side air guide. Remove the bolts and 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 NOTE: • The left air guide removal / installation can be done without upper cowl removal. Remove the bolts and left air guide. Remove the screws, left air guide and left air guide plate. Installation is in the reverse order of removal. 2-11 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ FUEL TANK Removal Remove the seat. (page 2-3) • Gasoline is extremely flammable and is explosive under certain conditions. Disconnect the fuel unit 3P connector. NOTE: • Before disconnecting the fuel tube, turn fuel valve OFF. 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. 2-12 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ 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 and remove the fuel unit. CAUTION • Be careful not to damage the fuel unit. 2-13 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ ASSEMBLY Install the fuel unit to the fuel 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. Install the fuel tap into the fuel tank. Tighten the fuel tap nut to the specified torque. TORQUE: 27N.m (28 kgf-m, 20 lbf-ft) 2-14 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ INSTALLATION Install the fuel tank aligning 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 fuel unit 3P connector. Install the seat. (page 2-3) After installation, turn the fuel tap ON and check the fuel line for leakage. 2-15 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ EXHAUST PIPE/MUFFLER Removal/Installation • Do not service the exhaust system while it is hot. Remove the lower cowl. (page 2-5) Remove the exhaust pipe joint nuts. Remove the muffler mounting bolt, washer 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 all bolts and nuts. Tighten the exhaust pipe joint nuts securely. Tighten the exhaust pipe mounting bolt securely. Tighten the muffler mounting bolt securely. Install the lower cowl. 2-16 NSR150SP Maintenance ______________________________________________ Service Information Maintenance Schedule Fuel Line Fuel Strainer Screen Throttle Operation Oil Pump and Oil Line Air Cleaner Spark Plug Decarbonizing Engine Idle Speed Radiator Coolant Cooling System Transmission Oil Drive Chain 3-1 3-3 3-4 3-4 3-5 3-6 3-9 3-10 3-12 3-13 3-14 3-14 3-15 3-17 Drive Chain Slider Battery Brake Fluid Brake Pad Wear Brake System Brake Light Switch Headlight Aim Clutch System Side Stand Suspension Nuts, Bolts, Fasteners Wheels / Tyres Steering Head Bearings 3-19 3-20 3-20 3-21 3-22 3-23 3-23 3-23 3-24 3-25 3-25 3-26 3-27 SERVICE INFORMATION Specification ITEM Throttle grip free play Spark Plug Standard For Cold climate riding Spark Plug gap Engine oil capacity Engine oil capacity At draining At disassembly Carburettor idle speed Drive chain slack Drive chain size DID RK Drive chain link Clutch lever free play Cold tire pressure Driver only Driver and passenger Front Rear Front Rear 3-1 SPECIFICATION 2 – 6mm (0.08 – 0.24) NGK NIPPONDENSO B9ES W27ES-U B8ES W24ES-U 0.7 – 0.8 mm (0.028 – 0.031in) 0.76 litre (0.83 US qt, 0.67 Imp, qt) 0.7 litre (0.73 US qt, 0.62 Imp, qt) 0.8 litre (0.85 US qt, 0.70 Imp, qt) 1,300 + 100 min1 (rpm) 35mm 525VC5 525MOZ9 108 10-20mm 200kPa (2.00 kgf/cm2, 29psi) 200kPa (2.00 kgf/cm2, 29psi) 200kPa (2.00 kgf/cm2, 29psi) 200kPa (2.00 kgf/cm2, 29psi) NSR150SP Maintenance ______________________________________________ ITEM Minimum tire depth Tire Size Tire Band IRC Front Rear Front Rear Front Rear SPECIFICATIONS 1.5mm 2.0mm 90/80 – 17 46S 120/80 – 17 61S NF46 NR57 TORQUE VALUES Oil drain bolt Spark Plug 21N.m (2.1 kgf-m, 15 lbf-ft) 20N.m (2.0 kgf-m, 14 lbf-ft) TOOLS Drive chain tool set 07HMH-MR10103 3-2 NSR150SP Maintenance ______________________________________________ Maintenance Schedule – NSP150SP Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period. I: Inspect and clean, adjust, lubricate or replace if necessary C: Clean R: Replace A: Adjust L: Lubricate The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools. Consult your authorised Honda Dealer. FREQUENCY ITEM * Fuel Line * Fuel Strainer Screen * Throttle Operation * Oil Pump and Oil Line * Air Cleaner Spark Plug ** Decarbonizing * Engine Idle Speed Radiator Coolant Cooling System Transmission Oil Drive Chain Drive Chain Slider Battery Brake Fluid Brake Pad Wear Brake System * Brake Light Switch * Headlight Aim Clutch System Side Stand * Suspension * Nut, Bolt, Fastener ** Wheel / Tyres ** Steering Head Bearing * ** Whichever Comes x 1000km First x 1000mi Ø MONTH Note 2 Note 3 Note 3 Odometer Reading - (Note 1) 1 4 8 12 0.6 2.5 5 7.5 6 12 18 I I I C C C I I I I I I C C C I R I C I I I I I I R I, L: Every 1,000km (600ml) I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I Should be serviced by your authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. In the interest of safety, we recommend these items be serviced only by your authorized Honda dealer. NOTES: 1. At higher odometer reading, repeat at the frequency interval established here. 2. Service more frequently when riding in unusually wet or dusty areas. 3. Refer to Common Service Manual. 3-3 NSR150SP Maintenance ______________________________________________ FUEL LINE Check the fuel lines for deterioration, damage or leakage. Replace the fuel lines if necessary. Route the tubes properly. (page 1-18) FUEL STRAINER SCREEN NOTE • Fuel strainer screen cleaning. FUEL CUP STRAINER Remove the fuel tank. (page 2-12) • Gasoline is extremely flammable and is explosive under certain condition. Remove the fuel cup, 0-ring and fuel cup strainer. Wash the cup strainer and cup in clean nonflammable high flash point solvent. Reinstall the cup strainer, 0-ring and cup in the fuel tap, making sure that the 0-ring is in place. Tighten the fuel cup securely. Install the fuel tank. (page 2-4) 3-4 NSR150SP Maintenance ______________________________________________ THROTTLE OPERATION Check for any deterioration or damage to the throttle cables. Check the throttle grip for smooth operation. Check that the throttle grip returns from the full open to the full closed position smoothly and automatically in all steering positions. If the throttle grip does not return properly, lubricate the throttle cable, overhaul and lubricate the throttle grip housing. For cable lubrication: Disconnect the throttle cables at their upper ends Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil. If the throttle grip still does not return properly, replace the throttle cables. Reusing a damaged or abnormally bent or kinked throttle cable can prevent proper throttle side operation and may lead to a loss of throttle control while riding. With the engine idling, turn the handlebar all the way to the right and left to ensure that idle speed does not change. If idle speed increases, check the throttle grip free play and the throttle cable connection. Measure the throttle grip free play at the throttle grip flange. FREE PLAY: 2 - 6 mm (0.08 - 0.24 in) Throttle grip free play can be adjusted at the upper adjuster of the throttle cable. Loosen the lock nut and turn the adjuster to obtain the free play. After adjustment, tighten the lock nut securely and reposition the boot securely. 3-5 NSR150SP Maintenance ______________________________________________ OIL PUMP AND OIL LINE Check the engine oil lines for 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 Remove the left side cover. Remove the bolts and disconnect the oil level sensor connector. Drain the engine oil. 3-6 NSR150SP Maintenance ______________________________________________ Remove the joint band. Remove the strainer joint from the oil tank. Remove the oil strainer from the strainer joint. Clean the 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 oil pump and oil line. (page 4-6) OIL-TANK CAPACITY: 0.76 litres (0.83 us qt, 0.67 Imp gl) RECOMMENDED ENGINE OIL: Honda 2-stroke oil or equivalent Make sure that there are no oil leaks. 3-7 NSR150SP Maintenance ______________________________________________ OIL PUMP CONTROL CABLE ADJUSTMENT NOTE The oil pump control cable should be adjusted after the throttle grip free play adjustment. Remove the right under cowl. Remove the bolts and oil pump cover. Loosen the oil control cable lock nut and open the throttle 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 mm (0.04 in) of index mark on the open side is acceptable. However, the aligning mark must never be on the closed side on the index mark, otherwise engine damage will occur because of insufficient lubrication. Tighten the control cable lock nut and install the oil pump cover. Install and tighten the bolts securely. 3-8 NSR150SP Maintenance ______________________________________________ AIR CLEANER NOTE • The viscous paper element type air cleaner cannot be cleaned because the element contains a dust adhesive. If the motorcycle is used in wet or dusty areas, more frequent inspections 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 cleaning solvent. Squeeze out the solvent thoroughly, and allow to dry. Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result. Soak the element in gear oil (SAE #30 - 40) and squeeze out oil. 3-9 NSR150SP Maintenance ______________________________________________ Install the element to the air cleaner housing. Install the air cleaner housing cover and screws. Tighten the screws securely. Install 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 removing, and be sure that no debris is allowed to enter the combustion chamber. Remove the spark plug using the spark plug wrench. Inspect or replace as described in the maintenance schedule. 3-10 NSR150SP Maintenance ______________________________________________ INSPECTION Check the following and replace if necessary (recommended spark plugs: (page 3-1) • Insulator for damage • Electrodes for wear • Burning condition, coloration; • dark to light brown indicates good condition. • excessive lightness indicates malfunctioning ignition system or learn mixture. • wet or black sooty deposit indicates overrich mixture. REUSING A SPARK PLUG Clean the spark plug electrodes with a wire brush or spark plug cleaner. Check the gap between 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 the cylinder head, hand-tighten the spark plug before using a wrench to tighten to the special torque Reinstall the spark plug in the cylinder head and hand tighten, then torque to specification. TORQUE: 20 N.m (2.0 kgf.m, 14 lbf.ft) Connect the spark plug cap. REPLACING A SPARK PLUG Set the plug gap to specification with a wire-type feeler gauge CAUTION • Do not overtighten the spark plug. Install and tighten the new spark plug, then tighten it about ¼ of turn after sealing washer contacts the seat of the plug hole. 3-11 NSR150SP Maintenance ______________________________________________ DECARBONIZING CYLINDER HEAD Remove the cylinder head cover. (page 8-3) Remove carbon deposits from the combustion 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 carbon deposits from the exhaust port area. CAUTION • Avoid damaging the cylinder bore. Clean carbon deposits from the RC valve. CAUTION • Avoid damaging the RC valve. 3-12 NSR150SP Maintenance ______________________________________________ MUFFLER Remove the muffler joint bolts, muffler mounting bolt and nut. Remove the muffler. Clean carbon deposits from the inner pipe and muffler. • CAUTION Do not heat or clean with solvent to remove the carbon from the muffler and inner pipe. Install the muffler. Install and tighten the muffler joint bolts and muffler mounting bolt. ENGINE IDLE SPEED If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. 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-go riding is sufficient. Warm up the engine and shift the transmission into neutral. Place the motorcycle on its side stand. Check the idle speed and adjust by turning the throttle stop control knob if necessary. IDLE SPEED: 1,300 ± 100 min-1 (rpm) 3-13 NSR150SP Maintenance ______________________________________________ RADIATOR COOLANT LEVEL CHECK • • • • • Wait until the engine is cool before removing the radiator cap. Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding. Radiator coolant is poisonous. Take care to avoid getting coolant in your eyes, on your skin, or on your clothes. If coolant gets in your eyes, flush repeatedly with water and contact a doctor immediately. If coolant is accidentally swallowed, induce vomiting and contact a doctor immediately. KEEP OUT REACH OF CHILDREN. Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the 'UPPER' and 'LOWER' level lines with the motorcycle in a vertical position on a flat, level surface. It necessary, remove the seat and reserve tank cap and fill to the 'UPPER' level line with a 50-50 mixture of distilled water and antifreeze / coolant mixture preparation. • • CAUTION Be sure to use the proper mixture of antifreeze and distilled water to protect the engine. Using distilled water Tap water may cause the engine to rust or corrode Check to see if there are any coolant leaks when the coolant 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 described on page 6-5. COOLING SYSTEM To prevent injury, keep your hands and clothing away from the cooling fan. It may start automatically, without warning. Remove the radiator grill. Check the radiator air passage for clogging or damage. 3-14 NSR150SP Maintenance ______________________________________________ Straighten bent fins with a small, flat blade screwdriver and remove insects, mud or other obstructions with compressed air or low pressure water. Replace the radiator if the air flow is restricted over more than 20% of the radiating surface. For radiator replacement, refer to (page 6-8). Remove the side cowl. (page 2-4) Remove the fuel tank. (page 2-12) Check for any coolant leakage from the water pump and water hoses. Make sure the hoses are in good condition; they should not show any sings of deterioration. Replace any hose that shows any sign of deterioration. Check that all hose clamps are tight. TRANSMISSION OIL OIL LEVEL INSPECTION If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. 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 consumed, it is necessary to periodically check the oil level and replenish the oil volume to its proper level. • If the oil level is too high, overall engine performance and the actuation of the clutch may be effected. Too little oil may cause engine overheating as well as premature wear to various parts. • If a different brand or grade of oil or low quality oil is mixed when adding oil, the lubricating function deteriorates. Start the engine and let it idle for a several minutes. Stop the engine and wait 2 - 3 minutes. 3-15 NSR150SP Maintenance ______________________________________________ With the motorcycle upright on the level ground, check the oil level through the inspection window. If the level is below or near the lower level line, remove the oil tiller cap and add the recommended oil up to the upper level line. RECOMMENDED TRANSMISSION OIL: Honda 4-stroke oil or equivalent motor oil certified to meet APE service classification SE, SF or SG Viscosity: SAE 10W-40. NOTE • Other viscosities 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 engine oil with the engine warm and the motorcycle on its side stand to assure complete and rapid draining. Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated groves or wait until the engine and exhaust system have cooled before handling these parts. Remove the lower cowl. Warm up the engine. Place an oil drain pan under the engine to catch the oil, then remove the oil drain bolt and oil filler cap. 3-16 NSR150SP Maintenance ______________________________________________ After draining the oil completely, check that the sealing washer on the drain bolt is in good condition and replace if necessary. Tighten the drain bolt to the specified torque. TORQUE: 21 N.m (2.1 kgf.m, 15 lbf-ft) Fill the crankcase with the recommended engine oil. CAPACITY: 0.7 Litres (0.73 US qt, 0.62 Imp 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 • Inspecting the drive chain while the engine is running can result in serious hand or finger injury. DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF, place the motorcycle on its side stand and shift the transmission in neutral. Check the slack in the drive chain lower run midway between the sprockets. DRIVE CHAIN SLACK: 35mm Lubricate the drive chain ADJUSTMENT Loosen the bearing holder pinch bolt. 3-17 NSR150SP Maintenance ______________________________________________ Raise the rear wheel off the ground by placing a support under the engine. Turn the bearing holder with the pin spanner provided in the tool kit until the correct drive chain slack is obtained. After adjustment, check the chain wear label on the rear caliper bracket. If the red zone on the label reaches the outside index mark of the swingarm, replace the drive chain with the new one. Tighten the bearing holder pinch 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, INSPECTION AND LUBRICATION DRIVE CHAIN CAUTION • Chains with 0-rings should not be treated to the following cleaning and oiling procedure. This treatment will cause degradation of the 0-rings and loss of grease, thus shortening chain life not use steam or high pressure water washing. Use a chain spray containing a cleaning agent or use gasoline to clean the chain. Clean the chain with suitable detergent and wipe it dry. Be sure the chain has dried completely before lubricating. 3-18 NSR150SP Maintenance ______________________________________________ Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or other wise appears unserviceable. Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. Inspect and replace sprockets as necessary. Lubricate the drive chain with #80 - 90 gear oil. Wipe off the excess chain oil. SPROCKET Inspect 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 chain wilt wear rapidly. Check the attachment bolt and nuts on the drive and driven sprockets. If any are loose, torque them. REPLACEMENT Remove the swingarm and replace the drive chain. DRIVE CHAIN SLIDER Check the drive chain slider for wear or damage. Replace the drive chain slider if it is worn to the indicator. CAUTION • If the chain slider becomes worn through to the swingarm, the chain will begin to wear against the swingarm. 3-19 NSR150SP Maintenance ______________________________________________ BATTERY The battery electrolyte contains sulfuric acid. Protect your eyes, skins and clothing. If electrolyte gets in your eyes; flush them thoroughly with water and get prompt medical attention. Remove the battery from the battery compartment (page 16-5). NOTE • Add only distilled water. Tap water will shorten the service life of the battery. • Inspect the battery fluid level in each cell. When the fluid level near the lower level, refill with distilled water to the upper level. BRAKE FLUID CAUTION • Do not remove the cover or cap unless the reservoir is level because fluid may spilt out. • Do not mix different types of fluid, as they are not compatible with each other. • Do not allow foreign material 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 low, check the brake pads for wear (see below). A low fluid level may be due to wear of the brake pads. If the brake pads are worn, the caliper piston is pushed out, and this accounts for a low reservoir level. If the brake pads are not worn and the fluid level is low, check entire system for leaks • Do not remove the level float from the reservoir when filling with brake fluid. 3-20 NSR150SP Maintenance ______________________________________________ FRONT BRAKE Turn the handlebar to the left side so that the reservoir is level and check the front brake reservoir level through the sight glass. If the level (float edge) is near the lower level mark, remove the screws, cover, set plate and diaphragm and 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 upright. Check the rear brake fluid reservoir level. If the level is near the lower level mark, remove the screws, cover, set plate and diaphragm and fill the reservoir to the upper level mark with DOT 3 or 4 brake fluid from a sealed container. Refer to page 15-5 for brake fluid replacement/bleeding procedures. 3-21 NSR150SP Maintenance ______________________________________________ BRAKE PAD WEAR FRONT: Check the brake pad for wear. Replace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to page 15-6 for brake pad replacement. REAR: Check the brake pad for wear. Replace the brake 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 system. If the lever or pedal feels soft or spongy when operated, bleed air from the system. Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. Refer to page 15-5 for brake bleeding procedures. 3-22 NSR150SP Maintenance ______________________________________________ BRAKE LIGHT SWITCH CAUTION • • Allowing the switch body to turn during adjustment can break the wires in the switch. NOTE The brake light switch on the front brake lever cannot be adjusted. If the front brake light switch actuation and brake engagement are off, either replace the switch unit or the malfunctioning parts of the system. • Make all rear brake light switch adjustments after the height adjustment and the brake pedal free play adjustment have been made. Check the brake light switch operation and adjustment by applying the brakes. Visually inspect for any damage and make sure the reflector plate is clean within 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 at the proper time. Turn the adjusting nut on the brake light switch and not the switch body and wires to make switch actuation adjustments. Be sure to hold the switch body firmly while turning the adjusting nut. After adjustment, recheck to be sure the brake light comes on at the proper time. HEADLIGHT AIM An improperly adjusted headlight may blind oncoming drivers, or it may fail to light the road for a safe distance. NOTE • Adjust the headlight beam as specified by local laws and regulation. Adjust the headlight beam by turning the screw at the under of the upper cowl. CLUTCH SYSTEM Measure the clutch free play at the end of the clutch lever. FREE PLAY: 10 - 20 mm 0.4 - 0.8 in) 3-23 NSR150SP Maintenance ______________________________________________ Adjust as follows: Minor adjustments are made at the adjuster near the lever. Loosen the lock nut and turn the adjuster. Tighten the lock nut. CAUTION • The adjuster may be damaged if it is positioned too far out, leaving minimal thread engagement. If the adjuster is threaded out near its limit and the correct free play cannot be obtained, turn the adjuster all the way in and back out one turn. Tighten the lock nut and make a major adjustment 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 nut securely while tightening the lock nut. If proper free play cannot be obtained, or the clutch slips during the test ride, disassemble and inspect the clutch. SIDE STAND Support the motorcycle on a level surface. Check the side stand spring for damage or loss of tension. Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary. Make sure that the side stand is not bent. Bump Rubber Ensure that the “bump” rubber is attached and in good condition. 3-24 NSR150SP Maintenance ______________________________________________ SUSPENSION Loose, worn, or damaged suspension parts impair motorcycle stability and control. Repair or replace any damaged components before riding. Riding a motorcycle with faulty suspension increases your risk of an accident and possible injury. FRONT Check the action of the forks by operating the front brakes and compressing the front suspension several times. Check the entire fork assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to section 13 for front fork service. REAR Support the motorcycle securely using safety stand or hoist and raise the rear wheel off the ground. Check for worn swingarm bearings by grabbing the rear wheel and attempting to move the wheel side to side. Replace the bearings 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 damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to section 14 for shock absorber service. NUTS, BOLTS, FASTENERS Check that all chassis nuts, bolts and screws are tightened to their correct torque values at the interval shown in the Maintenance Schedule. Check that all cotter pins, slip clips, hose clamps and cable stays are in place and properly secured. 3-25 NSR150SP Maintenance ______________________________________________ WHEELS / TYRES Making sure the fork is not allowed to move, raise the front wheel and check for play. Turn the wheel and check that it rotates smoothly with no usual noises. If faults are found inspect the wheel bearings. Support the motorcycle securely and raise the rear wheel off the ground. Check for play in either the wheel or the swingarm pivot. Turn the wheel and check that it rotates smoothly with no unusual noises. If abnormal conditions are suspected, check the rear wheel bearings. NOTE • As the 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 the pressure of each tire with a pressure gauge. Recommended tire pressure and tire size Cold tire pressure Tire Size Driver Only Driver and passenger Unit: kPa (kgf/cm2, psi) Front Rear 200 (2.00, 29) 200 (2.00, 29) 200 (2.00, 29) 200 (2.00, 29) 90/80-17 46S 120/80-17 61S Check the tires for cuts, embedded nails, or other damage. Check the front and rear wheels for trueness. (Section 11-12) Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the following limits. MINIMUM TREAD DEPTH: Front: 1.5 mm (0.06 in) Rear: 2.0 mm (0.08 in) 3-26 NSR150SP Maintenance ______________________________________________ STEERING HEAD BEARINGS NOTE • Check 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 handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings. 3-27 NSR150SP Lubrication System ______________________________________________ 4-0 NSR150SP Lubrication System ______________________________________________ Service Information Troubleshooting 4-1 4-2 Engine Oil Oil Pump 4-3 4-4 SERVICE INFORMATION GENERAL If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in enclosed area. 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 or pump have been removed or there is air in the oil lines. • Bleed air from the oil inlet line first, then bleed air from oil outlet line. • • • • • • • • The engine must be removed from the frame before servicing the oil pump. When removing and installing the oil pump use care not to allow dust or dirt to enter the engine. Do not attempt to disassemble the oil pump. Fill the oil outlet line with oil whenever the oil outlet line is disconnected. When disconnecting the oil outlet line tube, clamp or plug the tube 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 oil strainer cleaning, refer to page 3-5. SPECIFICATIONS ITEM STANDARD Engine oil capacity Recommended engine oil 0.76 litre (0.83 US qt, 0.67 Imp qt) Used Honda 2-stroke oil or equivalent Transmission oil capacity Recommended transmission oil 0.7 litre (0.73 US qt, 0.62 Imp qt) 0.8 litre (0.85 US qt, 0.70 Imp qt) Used Honda 4-stroke oil or equivalent API Service Classification: SE, SF or SG Viscosity: SAE 10W-40 TORQUE VALUES Oil drain bolt 21 N.m (2.1 kgf, 15 lbf-ft) 4-1 Unit: mm (in) SERVICE LIMIT NSR150SP Lubrication System ______________________________________________ TROUBLESHOOTING Excessive 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 oil pump (too little oil flow) Clogged oil strainer Clogged oil tank cap breather hole 4-2 NSR150SP Lubrication System ______________________________________________ ENGINE OIL ENGINE OIL DRAINING AND OIL TANK REMOVAL Remove the left side cover. (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 the oil tank. Clean the oil strainer. (Page 3-5) ENGINE OIL REFILLING AND OIL TANK INSTALLATION Install the oil strainer to the strainer joint. 4-3 NSR150SP Lubrication System ______________________________________________ Install the strainer joint to the oil tank. Install the joint band. Install the oil tank. Install and tighten the bolts securely. Connect the oil level sensor connectors. Fill the oil tank with the recommended engine oil and bleed the air from the oil pump and oil line. OIL TANK CAPACITY. 0.76 litre (0.83 US qt, 0.67imp qt) RECOMMENDED ENGINE OIL: Honda 2-stroke oil or equivalent Make 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 been removed or there is air in the oil line Bleed air from the oil inlet line first, then bleed air from oil outlet line. NOTE When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. REMOVAL Remove the right side cowl and lower cowl. (Page 2-4) Drain the transmission oil. Remove the bolts and oil pump cover. (Page 3-14) Remove the mount rubbers. Disconnect the oil tube and oil pass tube from the oil pump. 4-4 NSR150SP Lubrication System ______________________________________________ Clamp the oil tube and oil pass 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 the oil pump drive gear from the oil pump shaft. Remove the drive pin from the oil pump shaft. 4-5 NSR150SP Lubrication System ______________________________________________ Remove the bolts and oil pump from the right crank case cover. Remove the 0-ring from the oil pump. INSPECTION CAUTION • Do 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 TUBE AND OIL PUMP BLEEDING Remove the seat. (Page 2-3) Remove the oil tank cap and fill the tank with the recommended engine oil. RECOMMENDED ENGINE OIL: Honda 2-stroke oil or equivalent 4-6 NSR150SP Lubrication System ______________________________________________ Place the shop towel around the oil pump. Let oil drip from the oil tube to expel any air that may be in the tube, and then connect the oil tube to the pump inlet. Remove the oil pump shaft while holding the oil pump its install surface facing up. Check that the oil flows out of the 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. NOTE When installing the oil pump shaft use care not to allow dust or dirt to enter the oil pump Turn the oil pump with its installing surface on level ground. Remove the bleed bolt ' and refill the oil from the bleed bolt hole until the oil flows out of the bleed bolt hole. Check that oil flows out of the outlet. Wait until there are no air bubbles in the oil coming out of the oil hole, then retighten the bleed bolt. 4-7 NSR150SP Lubrication System ______________________________________________ OIL PUMP INSTALLING Clean the oil pump mating surface of the right crankcase cover. Install 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 drive pin to the oil pump shaft. Install the oil pump drive gear to the oil pump shaft. Install the washer and snap ring. Install the right crankcase cover. 4-8 NSR150SP Lubrication System ______________________________________________ OIL PASS TUBE BLEEDING Disconnect the oil pass tube from the carburettor. Bend the oil pass tube into a 'U' from with both the ends parallel, and fill the oil pass tube with clean engine oil. Connect the oil pass tube to the oil pump. Drain the fuel from the carburettor. Turn the fuel valve off and disconnect the fuel tube from the fuel valve. Connect the fuel tube to the container filled 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 tube. Perform this operation in a well ventilated area. Exhaust contains poisonous carbon monoxide gas that can cause loss of conscious and may lead to death. CAUTION • Run the engine at lowest necessary rpm level to avoid possible engine damage if oil flow is restricted. Stop the engine and again bleed air from the oil tube and oil pump if oil does not flow out within one minute. Then recheck oil flow. Connect the oil pass tube to the carburettor. 4-9 NSR150SP Lubrication System ______________________________________________ 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 right side cowl and lower cowl. (Page 2-4, 2-5) 4-10 NSR150SP Fuel System ________________________________________________ 5-0 NSR150SP Fuel System ______________________________________________ Service Information Troubleshooting Air Cleaner Housing Throttle Valve 5-1 5-3 5-4 5-4 Carburettor Air Screw Adjustment Reed Valve, Air Chamber 5-6 5-12 5-13 SERVICE INFORMATION GENERAL Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. Bending or twisting the control cables will impair smooth operation and could cause the cable to stick or bind, resulting in loss of vehicle control. • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. CAUTION • Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms might be damaged. • For fuel tank removal and installation, refer to Section 2. • Before disassembling the carburettor, place an approved gasoline container under the carburettor drain tube, loosen the carburettor drain screw and drain the carburettor. • When disassembling the fuel system parts, note the locations of the 0-rings, Replace them with new ones on re-assembly. • After removing the carburettor, wrap the intake ports of the engine 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 oil outlet line tube, clamp or plug the tube to prevent oil from flowing out. • The oil pump control cable should be adjusted after the throttle grip free play is adjusted. NOTE • If the vehicle is to be stored for more than one month, drain the float bowls. Fuel left in the float bowls may cause clogged jets resulting in hard starting or poor driveability. 5-1 NSR150SP Fuel System ______________________________________________ SPECIFICATIONS ITEM Carburettor identification number Choke type Main jet Slow jet Air screw initial opening Float level Idle speed Throttle grip free play STANDARD PE 74A Starting enrichment circuit system # 152 # 42 2 turns out 19 mm (0.7 in) 1,300 + 100 min –1 (rpm) 2 – 6 mm (0.08 – 0.24 in) TORQUE VALUES Fuel valve nut Fuel filter cap socket bolt 27 N.m (2.8 kgf.m, 20 ibf.ft) 1.5 N.m (0.15 kgf.m, 1.1 lbf.ft) TOOLS Float level gauge 07401-0010000 5-2 NSR150SP Fuel System ______________________________________________ TROUBLESHOOTING Engine won't start • No fuel in tank • No fuel to carburettor • Fuel strainer clogged • Fuel valve stuck • Fuel line clogged • Fuel tank breather clogged • Float level faulty • Too much fuel getting to the engine • Air cleaner clogged • Flooded carburettor • Intake air leak • Fuel contaminated/deteriorated • Jet clogged • Improper starting enrichment valve operation • Clogged fuel filter • Slow circuit or starting enrichment valve circuit clogged • Improper throttle operation • No spark at plug (ignition system faulty) Rich mixture • Starting enrichment valve ON • Float valve faulty • Float level too high • Air jets clogged • Air cleaner element contaminated • Flooded carburettor Engine stalls, hard to start, rough idling • Fuel line restricted • Ignition system malfunction • Fuel mixture too lean/rich • Fuel contaminated/deteriorated • Jetclogged • Intake air leak • Idle speed misadjusted • Float level misadjusted • Fuel tank breather clogged • Air screw misadjusted • Slow circuit or starting enrichment valve circuit clogged Afterburn when engine braking is used • Lean mixture in slow circuit Lean mixture • Fuel jets clogged • Float valve faulty • Float level too low • Fuel line restricted • Intake air leak • Throttle valve faulty Backfiring or misfiring during acceleration • Ignition system malfunction (Section 17) • Fuel mixture too lean Poor performance (driveability) and poor fuel economy • Fuel system clogged • Ignition system malfunction (Section 17) 5-3 NSR150SP Fuel System ______________________________________________ AIR CLEANER HOUSING Remove the fuel tank (page 2-12) Remove the screws and air cleaner housing. Loosen the screw and connecting tube band. Disconnect 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 pull out the throttle valve from the carburettor. Compress the throttle valve spring against the carburettor top, slide the throttle cable end side ways remove the throttle valve. Remove the washer. 5-4 NSR150SP Fuel System ______________________________________________ Remove the retainer, spring and jet needle from the throttle valve. INSPECTION Check the jet needle for stepped wear or damage. Check the throttle valve for wear or damage. Replace these parts if necessary. INSTALLATION Install the jet needle and spring to the throttle valve. Install the 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 the carburettor top. Insert the throttle cable end into the throttle valve and slide it sideways. Install the throttle valve aligning the groove on the throttle valve with the tab on the carburettor body. NOTE • Be sure that the throttle valve cutaway is toward the air cleaner housing side as it determines the volume of air for fuel mixture. 5-5 NSR150SP Fuel System ______________________________________________ Install the carburettor top and tighten it securely. Check the throttle valve for smooth operation. Check the throttle lever free play. (page 3-4) Install the air cleaner housing. Install the fuel tank. (page 2-14) CARBURETTOR REMOVAL Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Remove the fuel tank. (page 2-12) Remove the 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 tube from the carburettor. Loosen the screw and insulator tube band. Remove the carburettor. Loosen the SE valve nut and remove it from the carburettor. DISASSEMBLY Disconnect the drain tube and fuel tube from the carburettor. 5-6 NSR150SP Fuel System ______________________________________________ Remove the screws, float chamber and 0ring. Remove the float pin, float. Remove the float valve. CAUTION • Handle all jets with care. • Keep clean, thy can easily be blocked.. Remove the main jet, needle jet holder, needle jet and slow jet. • NOTE The air screw is factory pre-set and should not be removed unless the carburettor is overhauled. CAUTION • Damage to the air screw seat will occur if the air screw is tightened against the seat. Turn the air screw in and record the number of the turns it takes before it seats lightly. Remove the air screw and spring. 5-7 NSR150SP Fuel System ______________________________________________ Remove the throttle stop screw control knob, spring and washer. INSPECTION FLOAT VALVE AND VALVE SEAT Check the float valve and valve seat for scoring, scratches, clogging or damage. Check the tip of the float valve where it contacts the valve seat, for stepped wear or contamination. NOTE • A worn or contaminated valve 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. AIR PILOT SCREW Check the air screw for stepped wear or damage. Check the spring for damage. Replace these parts if necessary. CARBURETOR BODY CLEANING CAUTION • Cleaning the air and fuel passages with a piece of wire will damage the carburettor body. Disassembled the carburettor (page 5-7). Blow open all air and fuel passages in the carburettor body with compressed air. 5-8 NSR150SP Fuel System ______________________________________________ Clean the fuel strainer in the float valve using compressed air from the float valve seat side. ASSEMBLY Install the spring, washer and throttle stop screw. 5-9 NSR150SP Fuel System ______________________________________________ Install the needle jet, needle jet holder, main jet and slow jet. Install the spring and air screw. • NOTE Install the air screw and return it to its original position as noted during removal. Perform air screw adjustment if new air screw is installed. ( Page 5-12) Fit the float valve onto the float arm lip. Install the float valve with the float in the carburettor body, then install the float pin through the body and float. FLOAT LEVEL Set the carburettor so that the float valve just NOTE Check the float level after checking the float valve and float.. Set the float level gauge so that it is perpendicular to the float chamber face and in line with the main jet. contacts the float 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 FLOAT LEVEL: 07401-0010000 19 mm (0.7 in) If the level is out of specification, replace the float. 5-10 NSR150SP Fuel System ______________________________________________ Install the new 0-ring into the float chamber groove. Install the float chamber. Install and tighten the screw securely. Connect the drain tube and fuel tube to the carburettor. INSTALLATION NOTE Route the wires and tubes properly (page 1-18) Install the SE valve to the carburettor and tighten the SE valve nut securely. 5-11 NSR150SP Fuel System ______________________________________________ Install the carburettor aligning its lug with the groove on the insulator. Bleed the air from the oil pass tube. Connect the oil pass tube and carburettor breather tube to the carburettor. Tighten the insulator band screw securely. Install the throttle valve (page 5-6) Install the air cleaner housing. Install the fuel tank Perform the following inspections and adjustment. – • Throttle operation (page 3-4) • Carburettor choke (page 3- ) • Engine idle speed (page 3-11) • Air screw adjustment • Oil pump control cable adjustment After installation, turn the fuel valve ON and check the fuel line for leakage. AIR SCREW ADJUSTMENT If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of the consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. CAUTION • Damage to the air screw seat will occur if the air screw is tightened against the seat. NOTE The air screw is factory pre-set and should not be removed unless the carburettor is overhauled. Warm the engine up to operating temperature. Turn the air screw clockwise until it seats tightly, then back it out to the specification given. AIR SCREW OPENING: 2 turns out 5-12 NSR150SP Fuel System ______________________________________________ Adjust the idle speed with the throttle stop control knob. IDLE SPEED: 1,300 ± 100 (rpm) Rev the engine up slightly from the idle speed and make sure that engine speed rises smoothly. Adjust the 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 carburettor (page 5-7) Remove the bolt and tube band. Remove the air chamber. Remove the bolts and air chamber bracket. Remove the carburettor insulator from the crankcase. Remove the reed valve from the crankcase. Remove the gasket from the crankcase. 5-13 NSR150SP Fuel System ______________________________________________ INSPECTION Check the carburettor insulator for damage or deterioration. Replace it if necessary. Check the reed valve for fatigue or damage. Check the reed valve seat for cracks or damage. Replace it as an assembly if necessary. NOTE Be sure to replace the reed valve as an assembly. Disassembling or bending the reed stopper will cause engine trouble. INSTALLATION Apply a light coating of sealant to the crankcase as shown. Install the new gasket to the crankcase. Install the reed valve to the crankcase. 5-14 NSR150SP Fuel System ______________________________________________ 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 bolt securely. Install the carburettor. (page 5-11) 5-15 NSR150SP Cooling System ______________________________________________ 6-0 NSR150SP Cooling System ______________________________________________ Service Information Troubleshooting System Flow Pattern System Testing 6-1 6-2 6-3 6-4 Coolant Radiator Water Pump Radiator Reserve Tank 6-5 6-7 6-9 6-14 SERVICE INFORMATION GENERAL Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding. Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. • If any coolant gets in your eyes rinse them with water and consult a doctor immediately. • If any coolant is swallowed induce vomiting rinse and consult a physician immediately. • If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. • KEEP OUT OF REACH OF CHILDREN • Use only distilled water and ethylene glycol in the cooling system. A 50-50 mixture is recommended for maximum corrosion protection. Do not use alcoholbased antifreeze or an anti-freeze with self sealing properties. • Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. • All cooling system services can be done with the engine in the frame. • Avoid spilling coolant on painted surfaces. • After servicing the system, check for leaks with a cooling system tester. • Refer to Section 18 for thermo sensor inspection. SPECIFICATIONS ITEM Cooling capacity Radiator and engine Radiator cap relief pressure Standard coolant concentration 6-1 STANDARD 1.2 litre (1.27 US qt,1.06 lmp qt) 108 - 137 kPa (1.1 - 1.4 kgf/cm2, 16-21 psi) 50 % mixture with soft water NSR150SP Cooling System ______________________________________________ TORQUE VALUES Water pump impeller 12 N.m (1.2 kgf.m, 9 lbf.ft) TOOLS Pressure pump Attachment, 24 X 26 mm Pilot, 10 mm Driver Bearing remover set, 10 mm - Remover shaft - Remover head - Sliding weight Mechanical seal driver Equivalent commercially available 07746-0010700 07746-0040100 07749-0010000 07936-GE00000 07936-GE00100 07936-GE00200 07741-0010201 07PMD-KBP0100 TROUBLESHOOTING Engine temperature too high • Faulty temperature gauge or thermo sensor (Section 18) • Faulty radiator cap • Insufficient coolant • Passages blocked in radiator, hoses or water jacket • Air in system • Faulty water pump • Thermostat stuck closed Engine temperature too low • Faulty temperature gauge or thermo sensor (Section 18) • Thermostat stuck open Coolant leaks • Faulty water pump mechanical seal • Deteriorated 0-ring • Loose hose connection or clamp • Damaged or deteriorated hose • Faulty radiator cap 6-2 NSR150SP Cooling System ______________________________________________ SYSTEM FLOW PATTERN 6-3 NSR150SP Cooling System ______________________________________________ SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the seat. (page 2-3) Remove the radiator tank cap. Check the coolant gravity using a hydrometer. Standard Coolant Concentration: 50% Look for contamination and replace the coolant if necessary. Coolant temp Coolant ratio 5 10 15 20 25 30 35 40 45 50 55 60 0 (32) 5 (41) 10 (50) 15 (59) 20 (68) 25 (77) 30 (86) 35 (95) 40 (104) 45 (113) 50 (122) 1.009 1.018 1.025 10.36 1.045 1.053 1.063 1.072 1.080 1.086 1.095 1.100 1.009 1.017 1.027 1.035 1.044 1.052 1.062 1.070 1.078 1.084 1.093 1.098 1.008 1.017 1.026 1.034 1.043 1.051 1.060 1.068 1.076 1.082 1.091 1.095 1.008 1.016 1.025 1.033 1.042 1.049 1.058 1.066 1.074 1.080 1.088 1.092 1.007 1.015 1.024 1.031 1.040 1.047 1.056 1.064 1.072 1.077 1.085 1.089 1.006 1.014 1.022 1.029 1.038 1.045 1.054 1.062 1.069 1.074 1.082 1.086 1.005 1.013 1.020 1.027 1.036 1.043 1.052 1.059 1.066 1.071 1.079 1.083 1.003 1.011 1.018 1.025 1.034 1.041 1.049 1.056 1.063 1.068 1.075 1.080 1.001 1.009 1.016 1.023 1.031 1.038 1.046 1.053 1.060 1.065 1.073 1.077 0.999 1.007 1.014 1.021 1.028 1.035 1.043 1.050 1.057 1.062 1.070 1.074 0.997 1.005 1.012 1.019 1.025 1.032 1.040 1.047 1.054 1.059 1.067 1.071 6-4 NSR150SP Cooling System ______________________________________________ RADIATOR CAP/SYSTEM PRESSURE INSPECTION • The engine must be cool before removing the radiator cap or sever scalding may result. Remove the right air guide. Remove the radiator cap. • NOTE Before installing the cap in the tester, wet the sealing surface. Pressure test the radiator cap. Replace the radiator cap if does not hold pressure, or if relief pressure is too high or too low. It must hold specified pressure for at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: 108 - 137 kPa (1.1 - 1.4 kgf/ml2,15.6 - 19.9 psi) Pressurise the radiator, engine and hoses, and check for leaks. CAUTION • Excessive pressure can damage the cooling system 2 components. Do not exceed 137 kPa (1.4 kgf/cm 19.9 psi). Check the following components if the system will not hold specified pressure for at least 6 seconds. All hoses and connections Water pump cover installation Water pump cover gasket (for leakage) Water pump seal (for leakage) Deformed radiator filler neck 6-5 NSR150SP Cooling System ______________________________________________ COOLANT REPLACEMENT Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. If any coolant gets in your eyes, rinse them with water and consult a doctor immediately. If any coolant is swallowed, induce vomiting, rinse and consult a physician immediately. If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. KEEP OUT OF REACH OF CHILDREN NOTE • The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usage. Therefore, for best performance change the coolant regularly as specified in the maintenance schedule. • Mix only distilled, low mineral water with the anti-freeze. RECOMMENDED MIXTURE: 50-50 (Distilled water and anti-freeze) REPLACEMENT/AIR BLEEDING The engine must be cool before removing the radiator cap, or severe scalding may result. NOTE • When filling the system or reserve tank with a coolant (checking the coolant level), place the motorcycle in a vertical position 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 the drain bolt securely with a new sealing washer. Remove the right side cover. (page 2-7) Remove the battery case. (page 16-6) Remove the bolts. 6-6 NSR150SP Cooling System ______________________________________________ Disconnect the reserve tank overflow tube. Place a suitable container under the reserve tank. Remove the reserve tank cap from the reserve tank and drain the reserve coolant. Empty the coolant and rinse the inside of the reserve tank with water. Reconnect the reserve tank overflow tube. Install the reserve tank. Install and tighten the bolts securely. Completely fill the system with the recommended coolant through the filler neck. Remove the reserve tank cap and fill the reserve tank to the upper level line. Bleed air from the system as follows: • NOTE: Remove the filler cap before starting. 1. 2. 3. 4. Shift the transmission into neutral. Start the engine and let it idle for 2 - 3 minutes. Snap the throttle 3 - 4 times to bleed air from the system. Stop the engine and add coolant up to the filler neck. Reinstall the radiator cap. Check the level of coolant in the reserve tank and fill to the upper level if it is low. RADIATOR CAUTION • Be careful not to damage the radiator grills. RADIATOR GRILL REMOVAL/INSTALLATION Remove the side cowl and lower cowl. (page 2-4). Remove the screws. Remove the tabs on the radiator grill from the holes on the radiator. Remove the radiator grill. Installation is in the reverse order of removal. 6-7 NSR150SP Cooling System ______________________________________________ RADIATOR REMOVAL/INSTALLATION Remove the side cowl and lower cowl (page 2-4.) Drain the coolant (page 6-6) Loosen the screw and hose band. Disconnect 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 radiator hose. Remove the radiator. Installation is in the reverse order of removal. NOTE At installation, align the tabs on the radiator with the grommets on the frame. Fill and bleed the cooling system. (page 6-6). 6-8 NSR150SP Cooling System ______________________________________________ WATER PUMP MECHANICAL SEAL INSPECTION Remove the lower cowl (page 2-5) Inspect the telltale hole for signs of 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. Disconnect the lower radiator hose. Remove the bolts and water pump cover. Remove the dowel pin. Remove the gasket. Remove the right crankcase cover (page 10-3) Remove the snap ring. 6-9 NSR150SP Cooling System ______________________________________________ Remove the water pump driven gear and drive pin. Hold the water pump shaft using the spanner. CAUTION • To prevent the water pump gear for damage, hold 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 wear or damage. MECHANICAL SEAL REPLACEMENT Remove the right crankcase cover (page 10-3) Remove the oil pump (page 4-3) Remove the water pump shaft (page 6-9) Remove the dust seal, washers and tachometer drive gear. 6-10 NSR150SP Cooling System ______________________________________________ Remove the water pump bearing from the right crankcase cover. TOOLS: • Bearing remover set, 10 mm 07936-GE00000 • Remover shaft 07936-GE00100 • Remover head 07936-GE00200 • Sliding 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: • Mechanical seal driver 07PMD-KBP0100 • Driver 07749-0010000 Install the new water pump bearing to the right crankcase cover using the following tools. TOOLS: • Driver • Attachment. 24 x 26 mm • Pilot, 10 mm 07749-0010000 07746-0010700 07746-0040100 6-11 NSR150SP Cooling System ______________________________________________ Check the tachometer drive gear for wear or damage. Install the tachometer drive gear, washers and new dust seal. INSTALLATION Check the water pump shaft for wear or damage. Install 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: 12 N.m (1.2 kgf-m, 9 lbf.ft) Check the water pump driven gear for wear or damage. Install the drive pin to the water pump shaft hole. Install the water pump driven gear to the pump shaft aligning the groove on the pump gear with the drive pin. 6-12 NSR150SP Cooling System ______________________________________________ Install the snap ring. Install the oil pump (page 4-6 ) Install the right crankcase cover (page 10-23) Install the dowel pin and new gasket. Install the water pump cover and bolts. 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 2-4, 2-5) RADIATOR RESERVE TANK Remove the side cover (page 2-6) Remove the battery case (page 16-6) Drain the coolant (page 16-6) Disconnect the reserve tank overflow tube and siphon tube. Installation is in the reverse order of removal. 6-13 NSR150SP Engine Removal/Installation ________________________________________________ 7-0 NSR150SP Engine Removal/Installation ______________________________________________ Service Information Drive Sprocket Removal Engine Removal 7-1 7-2 7-3 Engine Installation Drive Sprocket Installation 7-4 7-6 SERVICE INFORMATION GENERAL • • • • - During removal and installation, support the motorcycle using a safety stand or hoist. A floor jack or other adjustable support is required to support and manoeuvre the engine. When removing/installing the engine, tape the frame about the engine beforehand to protect the frame. The following components can be serviced with the engine installed in the frame. Alternator/balancer Ignition pulse generator Carburettor Oil pump Clutch/gearshift linkage/kickstarter RC valve/servo motor Cylinder head/cylinder/piston Water pump (Section 11) (Section 11, 17) (Section 5) (Section 4) (Section 10) (Section 9) (Section 8) (Section 6) The following components require engine removal for service. - Crankshaft - Shift fork, shift drum and shift spindle - Transmission (Section 12) (Section 12) (Section 12) After engine installation. adjust the followings. - Clutch cable - Drive chain - Throttle cable (page 3-22) (page 3-15) (page 3-4) SPECIFICATIONS ITEM Engine dry weight Transmission oil capacity at disassembly Coolant capacity (radiator and engine) SPECIFICATIONS 23.9 kg (52.7 lb) 0.8 litre (0.85 US oz, 0..70 lmp oz) Litre )US oz, lmp oz) TORQUE VALUES Front engine hanger nut Rear upper engine hanger nut Rear lower engine hanger nut 55 N.m (5.6 kgf.m, 41 lbf-ft) 55 N.m (5.6 kgfm, 41 lbf.ft) 76 N.m (7.8 kgfm, 56 lbf-ft) 7-1 NSR150SP Engine Removal/Installation ______________________________________________ DRIVE SPROCKET REMOVAL Loosen the bearing holder pinch bolt. Raise the rear wheel off the ground by placing a support under the engine. 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 the drive chain guard from the drive sprocket cover. Check the drive chain guard for wear or damage. If the drive chain guard is excessively worn or damaged, replace the drive sprocket cover with a new one. 7-2 NSR150SP Engine Removal/Installation ______________________________________________ Remove the drive sprocket setting plate bolts. Align the drive sprocket setting plate teeth and countershaft teeth, then remove the drive sprocket setting plate. Remove the drive sprocket. ENGINE REMOVAL NOTE Support the motorcycle using safety stand or a 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 adjusted to relieve stress for ease of bolt removal. Drain the coolant Remove the following: -Side cowl (page 2-4) -Lower cowl (page 2-5) -Exhaust pipe/muffler (page 2-15) -Drive sprocket (page 7-3) -Fuel tank (page 2-12) -Carburettor (page 5-6) -Reed valve (page 5-13) Disconnect the radiator upper hose, spark plug cap and thermo sensor connector. 7-3 NSR150SP Engine Removal/Installation ______________________________________________ Disconnect the alternator 3P connector, ignition pulse generator 2P connector and 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 • During engine removal, hold the engine securely and be careful not to damage the frame and engine. Remove the engine hanger bolts and nuts. Remove the engine. 7-4 NSR150SP Engine Removal/Installation ______________________________________________ ENGINE INSTALLATION CAUTION • Carefully align the mounting points with the jack to prevent damage to engine, frame, wires and cables. NOTE All the engine mounting bolts and nuts should be loosely install, then tighten the bolts and nuts to the specified torque. At engine installation, temporarily 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 engine. Temporally install all engine hanger bolts and nuts. Tighten the rear upper engine hanger nut to the specified torque. TORQUE: 55 N.m 5.6 kgf-m, 41 lbf.ft) Tighten the rear lower engine hanger nut to the specified torque. TORQUE: 76 N.m (7.8 kgf-m, 56 lbf-ft) Tighten the front engine hanger nut to the specified torque. TORQUE: 55 N.m 5.6 kgf.m, 41 lbf-ft) 7-5 NSR150SP Engine Removal/Installation ______________________________________________ Install the servo motor. Install and tighten the bolts securely. Connect the servo motor 6P connector. Connect the clutch cable, oil tube, radiator lower hose and tachometer cable. Connect the alternator 3P connector, ignition pulse generator 2P connector and neutral switch connector. Connect the radiator upper hose, spark plug cap and thermo sensor connector. Install the followings: -Reed valve -Carburettor -Fuel tank -Drive sprocket -Exhaust pipe/muffler -Lower cowl -Side cowl (page 5-14) (page 5-1 1) (page 2-12) (page 7-3) (page 2-15) (page 2-5) (page 2-4) Fill and bleed the cooling system (page 6-6). Fill and bleed the engine oil line (page 4-6). Connect the battery ground cable. DRIVE SPROCKET INSTALLATION Install the drive chain to the drive sprocket. Install the drive sprocket to the countershaft with its marking side facing out. 7-6 NSR150SP Engine Removal/Installation ______________________________________________ Install the drive sprocket setting plate onto the counter 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.ft) Install the drive chain guard to the drive sprocket cover. Install the drive-sprocket-cover and tighten the bolts securely. 7-7 NSR150SP Engine Removal/Installation ______________________________________________ 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-ft) Adjust the drive chain slack. 7-8 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ 8-0 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Service Information Troubleshooting Cylinder Compression Cylinder Head Removal Cylinder/Piston Removal 8-1 8-2 8-3 8-4 8-5 Cylinder/Piston Selection Cylinder/Piston Installation Cylinder Head Installation 8-10 8-10 8-10 8-14 8-14 SERVICE INFORMATION GENERAL • The cylinder head, cylinder and piston can be serviced with the engine in the frame. • Be careful not to damage the mating surfaces by using a screwdriver when removing the cylinder head and cylinder. • Take care not to damage the cylinder wall and 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. • Refer to Section 9 for RC valve information. SPECIFICATIONS ITEM Cylinder compression Cylinder head warpage Cylinder I.D. Cylinder out of round Cylinder warpage Piston mark direction Piston O.D. Code A No mark Code C Code A Code B Code C Piston O.D. measurement point Piston pin hole I.D Cylinder-to-piston clearance Piston pin O.D. Piston-to-piston pin clearance Piston ring~to-ring groove clearance Ring end gap Top Second Ring mark Top Second Connecting rod small end I.D. STANDARD 108 kPa (1 1.0 kgf/cm2, 156 psi) at 400 min-1 (rpm) 59.010 - 59.015 (2.3232 - 2.3234) 59.005 - 59.010 (2.3230 - 2.3232) 59.000 - 59.005 (2.3228 - 2.3230) 'IN' mark facing toward the intake side 58.965 - 58.970 (2.3215 - 2.3216) 58.960 - 58.965 (2.3213 - 2.3215) 58.955 - 58.960 (2.3211 - 2.3213) 12 mm (0.5 in) from the bottom 16.002 - 16.015 (0.6300 - 0.6305) 0.040 - 0.050 (0.0016 - 0.0019) 15.994 - 16.000 (0.6927 - 0.6299) 0.002 - 0.021 (0.0001 - 0.0008) 0.38 - 0.53 (0.015 - 0.021) 0.38 - 0.53 (0.015 - 0.021 3R 4R 20.002 - 20.014 (0.7875 - 0.7880 8-1 Unit: mm (in) SERVICE LIMIT 0.05 (0.002) 59.05 (2.325) 59.05 (2.325) 59.05 (2.325) 0.05 (0.002) 0.05 (0.002) 58.92 (2.320) 58.92 (2.320) 58.92 (2.320) 16.03 (0.631) 0.080 (0.0031) 15.98 (0.629) 0.04 (0.002) 0.12 (0.05) 0.65 (0.026) 0.65 (0.026) 20.03 (0.789) NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ TORQUE VALUES Spark plug Cylinder head nut Cylinder nut Cylinder stud bolt 20 N.m (2.0 kgf.m, 14 lbf-ft) 23 N.m (2.3 kgf.m, 17 ]bf-ft) 23 N.m (2.3 kgf.m, 17 lbf-ft) 10 N.m (1.0 kgf.m, 7 lbf-ft) TROUBLESHOOTING Compression too low, hard starting or poor performance at low speed • 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 piston • Leaking crankcase primary compression - Blown crankcase gasket - Damaged crankshaft oil seal Compression too high, overheating or knocking • Excessive carbon build-upon piston or combustion chamber Excessive noise • Worn cylinder and piston • Worn piston pin or piston pin hole • Worn connecting rod small end Rough idle • Low cylinder compression 8-2 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Cylinder Compression If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. Warm up the engine to normal operating temperature. Stop the engine and remove the fuel tank (Page 2-12) Disconnect the spark plug cap and spark plug. Shift the transmission into neutral. Install a the commercially available compression gauge attachment in the spark plug hole. Connect the compression gauge to the attachment. Open the throttle all the way and crank the engine with the kickstarter. NOTE • Crank the engine until the gauge reading stops rising. The 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 combustion chamber and/or the piston crown. If compression is low, pour 3 - 5 cc (0.1 - 0.2 oz) of clean engine oil into the cylinder through the spark plug hole and recheck the compression. If the compression increases from the previous value, check the cylinder, piston and piston rings. • Leaking cylinder head gasket • Worn piston ring • Worn cylinder and piston If the compression is the same as the previous value, check the values for leakage. 8-3 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ CYLINDER HEAD REMOVAL REMOVAL Remove the side cowl (Page 2-4). Remove the fuel tank (Page 2-4). Drain the coolant (Page 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. NOTE: • Loosen the nuts in a crisscross pattern in several steps. Remove the cylinder head. CAUTION: • Be careful not to damage the mating surface when removing the cylinder head. Remove the gasket. 8-4 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ INSPECTION Remove the carbon deposits from the combustion chamber and clean off the head gasket surface. Clean the head gasket surface off any gasket material. CAUTION • Avoid damaging the gasket surface. Check for 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 Remove the exhaust pipe (Page 2-15). Remove the cylinder head (Page 8-14). Disconnect the front RC valve control cable from the RC valve timing pulley by compressing the control cable spring. Loosen the lock nut and disconnect the rear RC valve control cable from the RC valve timing pulley. 8-5 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Loosen the screw and hose band. Disconnect the water hose. Remove the cylinder nuts. NOTE • Loosen the nuts in a crisscross pattern in several steps. Remove the 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 careful not to damage the gasket surface. PISTON REMOVAL NOTE • Place a shop towel over the crankcase opening to prevent the piston pin clip from failing into the crankcase. Remove the piston pin clip, piston pin, needle bearing and piston. 8-6 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Spread each piston ring and remove it by lifting it up at a point just opposite the gap. CAUTION • Do not damage the piston ring by spreading the ends too far. He careful not to damage the piston during piston ring removal 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 groove. INSPECTION CYLINDER Inspect the cylinder bore for wear or damage. Remove the carbon deposits from the exhaust port. CAUTION • Be careful not to damage the plating on the cylinder wall. Check the cylinder for warpage by placing a straight edge and a feeler gauge. SERVICE LIMIT: 0.05 mm (0.002.in) 8-7 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Inspect the cylinder wall for scratches and wear. Measure and record the cylinder I.D. at three levels in both the X and Y axis. The maximum reading determines the cylinder wear. SERVICE LIMITS: Code A: 59.02 mm (2.325 in) No mark: 59.02 mm (2.325 in) Code C: 59.02 mm (2.325 in) Measure the cylinder for out of round at the upper and lower levels in an X and Y axis. Take the maximum reading to determine the out of round. SERVICE LIMIT: 0.05 mm (0.002.in) 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. Inspect the ring grooves for excessive wear and carbon build-up. Measure the piston O.D.. NOTE O • Take measurements 12 mm (0.5 in) from the bottom, and 90 to the piston pin hole. SERVICE LIMITS: Code A: 58.92 mm (2.320 in) Code B: 58.92 mm (2.320 in) Code C: 58.92 mm (2.320 in) Calculate the piston-to-cylinder clearance. Take the maximum reading to determine the clearance. SERVICE LIMIT: 0.080 mm (0.0031 in) Measure the piston pin hole I.D. in an X and Y axis. Take the maximum reading to determine I.D.. SERVICE LIMIT: 16.08 mm (0.83 in) 8-8 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Measure the I.D. of the connecting rod small end. SERVICE LIMIT: 20.03 mm (0.789 in) If the connecting rod I.D. is over the service limit, the 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.D. and O.D. codes when the replacing the cylinder and piston as a set. Cylinder I.D. code Piston O.D. code A No mark C A No mark C O O O CYLINDER/PISTON INSTALLATION PISTON INSTALLATION Clean the piston ring grooves. 8-9 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Lubricate the piston rings and ring grooves with clean 2-stroke oil. Install the expander on the piston. Install the top and second piston rings 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. Check the fit of each ring in its groove by pressing the ring into the groove. Make sure that it is flush with the piston at several points around the ring. Align each piston ring end gap with the location pins on the piston. 8-10 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Clean off any gasket material from the engine case surface (Page 8-5). NOTE • Place a shop towel over the crankcase opening to prevent the piston pin clip from failing into the crankcase. Apply 2-stroke oil to the needle bearing and connecting rod small end. Install the needle bearing 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 clips. CAUTION • Always use new piston pin clips. Reinstalling used piston pin clips may lead to serious engine damage. NOTE • Set the piston pin clip in the groove properly. • Do not align the clips end gap with the piston cut-out. CYLINDER INSTALLATION Apply a light but through coating of sealant to crankcase as shown. Install the dowel pins and new gasket. 8-11 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Recheck and align each piston ring and gap with the location pins on the piston. Install the RC valve (Page 9-5). Apply 2-stroke oil to the cylinder wall, piston outer surface and piston rings. CAUTION • Be careful 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 over the piston rings by hand while compressing the piston rings. Install and tighten the cylinder nuts to the specified torque. NOTE • Tighten the nuts in a crisscross pattern in several steps. TORQUE: 23 N.m (2.3 kgf.m, 17 lbf-ft) Connect the lower water hose. Tighten the screw and hose band. 8-12 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Align the tab on the servo motor pulley with the 'Hi' mark on the servo motor. Connect the front RC valve control cable to the RC valve timing pulley by compressing the control cable spring. Connect the rear RC valve control cable to the RC valve timing pulley. Align the notch on the RC valve timing pulley and 'H' 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' mark on the servo motor. Turn the RC valve timing pulley 5O to 10 O in several steps. When the tab on the servo motor pulley aligns with the 'Hi' mark on the servo motor, the notch on the RC valve timing pulley should align with the 'H' mark on the cylinder. If not adjust again. Check the RC valve control cable (Page 9-3). Install the expansion chamber (Page 1-15). Install the cylinder head.(Page 8-15). 8-13 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ CYLINDER HEAD INSTALLATION Install the new gasket with the 'EX UP' mark facing the exhaust side and up. Install the cylinder head. Install and tighten the cylinder 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. Connect the upper radiator hose and tighten the band screw securely. Connect the thermo sensor connector. Install the spark plug cap. Fill and bleed the cooling system (Page 6-6). Install the fuel tank (Page 2-14). Install the side cowl (Page 2-4). 8-14 NSR150SP RC Valve/Servo Motor ________________________________________________ 9-0 NSR150SP RC Valve/Servo Motor ________________________________________________ Service Information Troubleshooting RC Valve Control Cable Adjustment 9-1 9-2 RC Valve Servo Motor SERVICE INFORMATION GENERAL • The RC valve and servo motor can be serviced with the engine in the frame. • Take care not to damage the cylinder wall and 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 module (ICM) inspection and removal/installation see section 17. • Adjust the RC valve system only when The valves don't operate properly The linkage is removed Related parts are removed or replaced. TORQUE VALUES RC valve timing pulley nut 9 N.m (0.9 kgf m, 6.5 lbf ft) G: R: W: Bl: Green Red White Black Y: Bu: Lg: Yellow Blue Light Green 9-1 9-3 9-6 NSR150SP RC Valve/Servo Motor ________________________________________________ TROUBLESHOOTING Engine starts, but RC valve does not operate Check the RC valve control cable adjustment Abnormal • RC valve control cable misadjusted • Sticking the RC valve control cable Normal Disconnect the RC valve control cable from the timing pulley. Check the RC valve for smooth operation by turning the timing pulley using your hand. Not smooth • Excessive carbon build-up on the Operation RC valve • Burned RC valve Normal Disconnect the servo motor 6P connector. Disconnect the ICM 2P (black), 4P (black) connector. Check the continuity and resistance between The ICM 2P (black), 4P (black) connector wire Harness side and servo motor 6P connector wire harness side (White/Black, Green/Blue, Red/White, Light green and White). Abnormal • Faulty servo motor Normal ● Open circuit between ICM and servo motor ● Faulty the ICM 2P (black), 4P (black), servo motor 6P connector ● Faulty ICM Poor performance at low speed • Exhaust valve do not close fully - Improper adjustment - Faulty 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 • Excessive carbon build-up on the RC valve • Damaged RC valve 9-2 NSR150SP RC Valve/Servo Motor ________________________________________________ RC VALVE CONTROL CABLE ADJUSTMENT Remove the side cowl. Start the engine and let it idle. Check that the gap between the notch on the RC valve timing pulley and 'H' mark on the cylinder is within 0.3 mm (0.01 in). If the gap exceeds 0.3 mm (0.01 in), adjust the valve timing as followings: Loosen the lock 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 engine and make sure that the gap is within 0.3 mm (0.01 in). RC VALVE Check the RC valve for smooth operation by turning the timing pulley using your hand. If RC valve operation is not smooth, remove the cylinder head and RC valve and inspect them. REMOVAL Remove the cylinder. Align the hole in the cylinder with the cut out on the timing pulley with the dowel pin (0 6 mm). 9-3 NSR150SP RC Valve/Servo Motor ________________________________________________ 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 cylinder. Remove the E-clip from the RC valve shaft. 9-4 NSR150SP RC Valve/Servo Motor ________________________________________________ INSPECTION Remove the carbon deposits from the RC valves, shaft and shaft sliding area in the cylinder. CAUTION • Be careful not to damage 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 damage. Install the RC valves to the shaft and check the clearance of the valves and shaft if the clearance is more than 0.3 mm (0.01 in), replace the valves and shaft with a new ones. 9 N.m (0.9 kgf-m, 6.5 lbf-ft) 9-5 NSR150SP RC Valve/Servo Motor ________________________________________________ Install the E-clip to the 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 cylinder. Apply transmission oil to the new oil seal lip. Install the new oil seal to the cylinder. 9-6 NSR150SP RC Valve/Servo Motor ________________________________________________ Install the special washer to the RC valve shaft aligning the cut outs on the shaft and washer. Install the RC valve timing pulley to the RC valve shaft aligning the cut outs on the shaft and washer. Install the special washer to the RC valve shaft 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 cut out on the timing pulley with the dowel pin (0 6 mm). Tighten the RC valve timing pulley nut to the specified torque. TORQUE: 9 N.m (0.9 kgf m, 6.5 lbf-ft) Check the clearance between the RC valves and cylinder when the notch on the timing pulley aligns with the 'H' mark on the cylinder. STANDARD: 0.1 - 0.3 mm (0.004 - 0.01 in) 9-7 NSR150SP RC Valve/Servo Motor ________________________________________________ SERVO MOTOR INSPECTION Remove the side cowl. Remove the air cleaner housing. Check the RC valve control cable for adjustment and sticking. Disconnect the RC valve control cable from the timing pulley and check the RC valve for smooth 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 (Black) connector. Disconnect the servo motor 6P connector. Measure the resistance between the servo motor 6P connector terminals of the servo motor side. CONNECTION: STANDARD: CONNECTION: STANDARD: Red/White-Green/Blue 4 - 6 k: White - White/Black 8 - 15 k: If out of specification, replace the servo motor assembly. 9-8 NSR150SP RC Valve/Servo Motor ________________________________________________ Measure the resistance between the servo motor 6P connector terminals of the servo motor side. CONNECTION: STANDARD: CONNECTION: STANDARD: Red/White - Light Green 0 - 6 k! Green/Blue - Light Green 0-6k! If the resistance is ∞, turn the motor pully by your hand and measure the resistance again. If out of specification, 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 cable lock nut. Turn the adjuster and disconnect the RC valve control cables from the RC valve timing pulley. Remove the air cleaner housing. Disconnect the servo motor 6P connector. Remove the bolts and servo motor. INSTALLATION NOTE • Route the wires and harness properly. Install the servo motor. Install and tighten the bolts securely. Connect the servo motor 6P connector. 9-9 NSR150SP RC Valve/Servo Motor ________________________________________________ Align the tab on the servo motor pulley with the 'Hi' mark on the servo motor. Connect the front RC valve control cable to the RC valve timing pulley by compressing the control cable spring. Connect the rear RC valve control cable to the RC valve timing pulley. Align the notch 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 motor pulley is aligned with the mark on the servo motor. Turn the RC valve timing pulley 5O to 10 O in several steps. When the tab on the servo motor pulley aligns with the 'Hi' mark on the servo motor, the notch on the RC valve timing pulley aligns with the 'H' mark on the cylinder. If not so, reinstall again. Check the RC valve control cable. 9-10 NSR150SP Clutch/Gearshift Linkage/Kickstarter ______________________________________________ 10-0 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Service Information Troubleshooting Right Crankcase Cover Removal Clutch Removal Primary Drive Gear 10-1 10-2 10-2 10-3 10-6 10-9 Kickstarter Gearshift linkage Clutch Installation Right Crankcase Cover Installation 10-11 10-17 10-21 10-23 SERVICE INFORMATION GENERAL • The clutch, gearshift linkage and kickstarter maintenance can be done with the engine in the frame. • Transmission oil viscosity and level, and the use of oil additives have an effect on clutch disengagement. Oil additives of kind are not recommended. When the clutch does not disengage or the motorcycle creeps with the clutch dis/engaged, inspect the transmission oil viscosity and level before servicing the clutch system. • Clean off any gasket material from the right crankcase cover surface. • Be careful not to damage 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 be separated when the transmission requires service (Section 12). SPECIFICATIONS Unit: mm (in) ITEM Clutch lever free play Clutch outer guide O.D. I.D. Clutch outer I.D. Mainshaft O.D. at clutch outer guide Clutch spring free length Clutch disc thickness A B Clutch plate warpage Pinion gear I.D. Kickstarter spindle O.D. Kickstarter idle gear I.D. Idle gear bushing O.D. I.D. STANDARD 10 - 20 (0,4 - 0.8) 22.930 - 22.950 (0.9028 - 0.9035) 16.988 - 17.010 (0.6688 - 0.6697) 23.000 - 23.021 (0.9055 - 0.9063) 16.966 - 16.984 (0.6680 - 0.6687) 35.76 (1.408) 2.92 - 3.08 (0.1150 - 0.1213) 2.62 - 2.78 (0.1031 - 0.1094) 16.016 - 16.034 (0.6305 - 0.6313) 15.966 - 15.984 (0.6286 - 0.6293) 20.020 - 20.041 (0.7882 - 0.7890) 19.984 - 19.995 (0.7868 - 0.7872) 17.010 - 17.035 (0.6697 - 0.6707) 10-1 SERVICE LIMIT 22.80 (0.898) 17.04 (0.671) (23.06 (0.908) 16.95 (0.667) 33.6 (1.32) 2.5 (0.098) 2.2 (0.086) 0.20 (0.01) 16.07 (0.633) 15.94 (0.628) 20.10 (0.791) 19.92 (0.783) 17.10 (0.673) NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ TORQUE VALUES Right crankcase cover bolt, (16 mm) Right crankcase cover bolt, (8 mm) Clutch cable adjuster lock nut Primary drive gear nut Clutch lifter plate bolt Clutch centre lock nut Shift drum centre pin Shift return spring pin Shift drum stopper arm bolt 10 N.m (1.0 kgf.m, 7 lbf.ft) 26 N.m (2.7 kgf.m, 20 lbf.ft) 23 N.m (2.7 kgf.m, 20 lbf ft) 66 N.m (6.7 kgf m, 48 lbf.ft) Apply oil to the threads and flange surface 12 N.m (1.2 kgf.m, 9 lbf.ft) 64 N.m (6.5 kgf-m, 47 lbfft) 22 N.m (2.2 kgf.m, 16 lbfft) 22 N.m (2.2 kgf.m, 16 fbf.ft) Apply a locking agent to the threads 12 N.m (1.2 kgfm, 9 lbfft) TOOLS Wrench, 20 X 24 mm Extension bar Gear holder Clutch centre holder 07716-0020100 07716-0020500 07724-0010100 07923-KE10000 10-2 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ TROUBLESHOOTING Clutch lever too hard • Damaged, kinked or dirty clutch cable • Faulty clutch lifter plate bearing • Damaged clutch lifter mechanism • Improperly routed clutch cable Clutch will not disengage or motorcycle creeps with clutch disengaged • Too much clutch ever freeplay • Warped clutch plates • Loose clutch centre lock nut • Engine oil too high, improper oil viscosity Clutch slips • Clutch lifter sticking • 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 (Section 12) • Bent or damaged gearshift spindle • Damaged shift drum cam grooves Transmission jumps out of gear • Worn gear dogs or slots • Bent shift fork shaft (Section 12) • Broken shift drum stopper arm • Worn or bent shift forks (Section 12) • Broken shift linkage return spring Kickstarter slips • Worn or damaged rachet teeth of the starter rachet and/or starter pinion • Broken rachet spring Kickstarter pedal does not return • Weak or damaged kickstarter return spring • Return spring hook out of place 10-3 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ RIGHT CRANKCASE COVER REMOVAL Remove the side cowl and lower cowl. Remove the oil pump cover. Disconnect the oil tube 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 clutch cable from the clutch lifter arm. Remove the bolt and tachometer cable from the right crankcase. Remove the bolt and kickstarter. Loosen the screw and hose band. Disconnect the lower water hose. 10-4 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Remove the bolts and right crankcase cover. 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 washer, water pump/oil pump drive gear, shaft and washer. Check the teeth of the water pump/oil pump drive gear for wear or damage. 10-5 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ DISASSEMBLY Remove the oil pump. Remove the water pump shaft. Remove the tachometer drive gear. Remove the clutch lifter piece by turning the clutch lifter arm clockwise. Remove the clutch lifter arm and spring. INSPECTION Check the dust seal fatigue or damage or deterioration. Replace dust seal if necessary. 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 lifter arm for damage or bending. Check the spring for fatigue or damage. Replace these parts if necessary. Apply grease to the clutch lifter arm sliding surface. Apply grease to the dust seal lips and needle bearing. CLUTCH REMOVAL Remove the right crankcase cover. Loosen the clutch lifter plate bolts in a crisscross pattern in 2 or 3 steps. Remove the lifter plate/bearing and clutch springs. 10-6 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Hold the pressure plate with theclutch centre holder loosen the clutch centre lock nut. TOOLS: Wrench, 20 X 24 mm Extension bar Clutch centre holder 07716-0020100 07716-0020500 07923-KE10000 Remove the clutch centre lock nut and washer, Remove the clutch centre, spring seat and judder spring. Remove the seven clutch discs and six clutch plates. Remove the pressure plate. Remove the clutch outer guide and clutch outer. Remove the washer. 10-7 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ INSPECTION LIFTER PLATE BEARING Check the lifter plate bearing for damage. Turn the bearing inner race with your finger. The bearing should turn smoothly and quietly without play. Also check that the bearing outer race fits in the plate. Replace the bearing if 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 discoloration. Measure the thickness of the discs. SERVICE LIMITS: A: 2.5 mm (0.098 in) B: 2.2 mm (0.086 in) NOTE • Replace the discs and plates as a set. CLUTCH PLATE Check the plate for excessive warpage or discoloration. Check the plate warpage on a surface plate using a feeler gauge. SERVICE LIMIT: 0.20 mm (0.?? in) NOTE • Replace the discs and plates as a set. 10-8 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ CLUTCH CENTER Cheek the clutch centre for nicks, indentations or abnormal wear made by the clutch plates. CLUTCH OUTER, CLUTCH OUTER GUIDE Check the clutch outer for nicks, indentations 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 outer guide. SERVICE LIMITS: O.D.: 22.80 mm ( 0.8??) I.D.: 17.04 mm (0.671 in) MAINSHAFT Measure the mainshaft O.D. at the clutch outer guide. SERVICE LIMIT: 16.45 mm (0.667 in) JUDDER SPRING, SPRING SEAT Check the spring seat and judder spring for distortion, wear or damage. 10-9 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ PRIMARY DRIVE GEAR REMOVAL Remove the clutch. Hold the primary drive gear with the gear holder and remove the primary drive gear nut and washer. TOOL: Gear holder 07724-0010100 Remove the primary 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 the teeth of the primary drive gear for wear or damage. Check the teeth of the balancer drive gear for wear or damage. INSTALLATION Install the woodruff key to the cut out on the crankshaft. NOTE • When woodruff key installation, be careful not to damage the key groove or crankshaft. 10-10 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the primary drive gear to the crankshaft aligning the cut out on the primary drive gear with the woodruff key and aligning the punch marks on the balancer drive gear and driven gear. 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 washer and primary drive gear nut. Hold the primary drive gear with the gear holder and remove the primary drive gear nut and washer. TOOL: Gear holder 07724-0010100 Tighten the primary drive gear nut to the specified torque. TORQUE: 66 N.m (6.7 kgf-m, 48 lbf ft) Install the clutch. 10-11 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ 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 stopper plate. Remove the kickstarter assembly. Remove the kickstarter idle gear and collar. 10-12 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ DISASSEMBLY 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 return spring from the kickstarter spindle. Remove the washer from the kickstarter spindle. 10-13 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ INSPECTION KICKSTARTER Check the rachet spring and return spring for wear or damage. Check the teeth of the rachet and pinion gear 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) KICKSTARTER IDLE GEAR Check the teeth of the kickstarter idle gear for wear or damage. Measure the kickstarter idle gear I.D. SERVICE LIMIT: ????mm ( in) Measure the kickstarter idle gear collar. SERVICE LIMITS: O.D.: mm I.D.: mm ( in) (in) 10-14 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ COUNTERSHAFT Measure the countershaft O.D. at the kickstarter idle gear collar. SERVICE LIMIT: 16.96mm ( in) Install the washer and return to the kickstarter spindle. 10-15 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the return spring, aligning the spring end to the hole on the kickstarter spindle. Install the retainer, aligning the cut out in the retainer with 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 spindle. Install the pinion gear and washer to the kickstarter spindle. INSTALLATION Apply transmission oil to the kickstarter idle gear and collar. Install the idle gear collar to the countershaft. Install the idle gear to the countershaft. 10-16 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the kickstarter assembly. Install the dowel pin and stopper plate. Install and tighten the stopper 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 the kickstarter operation. Remove the kickstarter pedal. Install the clutch. GEARSHIFT LINKAGE REMOVAL Remove the lower cowl ???????? Remove the clutch. Remove the bolt and gearshift pedal linkage. 10-17 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Remove the 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 removing the guide plate and drum shifter. Remove the shift drum centre pin and shift drum centre. 10-18 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Remove the dowel pin. Remove the bolt, shift drum stopper arm and return spring. INSPECTION 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. INSTALLATION Apply clean transmission oil to the rachet pawls, springs and plungers. Assemble the drum shifter, springs, plungers and rachet pawls in the guide plate as shown. 10-19 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the return spring and shift drum stopper arm. Install and tighten the shift drum stopper arm bolt to the specified torque. TORQUE: 12 N. m (1.2 kgf.m, 9 lbf ft) Check the stopper arm for proper operation. Install 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 shift drum center pin to the specified torque. TORQUE: 22 N. m (2.2 kgf m, 16 lbf.ft) Position the drum centre in a gear other than neutral. Holding the rachet pawls in place in the guide plate, and drum shifter, install the assembly onto the shift drum centre pin. Install and tighten the bolts securely. 10-20 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the collar to the guide plate. Install the gearshift spindle to the crankcase while aligning the spindle return 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 smooth operation. Install the clutch (see below) CLUTCH INSTALLATION Apply molybdenum oil solution to the clutch outer guide outer surface. Install the clutch outer guide and clutch outer to the mainshaft. 10-21 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the spring seat and judder spring on the clutch centre as shown. Coat the clutch discs and clutch plates with clean engine 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 disc. Install the pressure plate/judder spring/spring seat to the clutch centre. Install the washer pressure plate, clutch discs, clutch plates, judder spring, spring seat and clutch centre as a set to the clutch outer. 10-22 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Apply transmission oil to the new clutch centre lock nut threads and flange surface. Install the washer and new clutch centre lock nut. Hold the pressure plate with the clutch centre holder. Tighten the clutch centre lock nut to the specified torque. TOOLS: Clutch centre holder Wrench, 20 X 24 mm Extension bar 07923-KE10000 07716-0020100 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. Install the clutch springs and lifter plate/bearing. Install and tighten the clutch lifter plate bolts in a crisscross pattern in several steps. TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft) Install the right crankcase cover (see below). RIGHT CRANKCASE COVER INSTALLATION ASSEMBLY Apply grease to the needle bearing. Apply grease to the clutch lifter arm sliding surfaces and slit. Install the clutch lifter arm and spring. 10-23 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Align the clutch lifter arm slit and hole on the right crankcase cover by turning the clutch lifter arm clockwise. Apply grease to the clutch lifter piece. 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 washer. Install the dowel pins and new gasket. Install the right crankcase cover. Install and tighten the right crankcase cover bolts in a crisscross pattern in several steps. TORQUE: 6 mm: 8mm: 10 N.m (1.0 kgfm, 7 lbf ft) 26 N.m (2.7 kgfm, 20 lbf ft) 10-24 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Connect the lower water hose. Tighten the screw and hose band securely. Install the kickstarter and bolt. Tighten the bolt securely. Install the tachometer cable to the right crankcase. 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. Fill the transmission oil. Connect the oil tube and oil pass tube to the oil pump. Bleed the air from the oil line. Connect the oil control cable to the oil pump drum. Adjust the oil pump control cable Install the oil pump cover. Install the side cowl and lower cowl. 10-25 NSR150SP Alternator/Balancer ______________________________________________ 11-0 NSR150SP Alternator/Balancer ______________________________________________ Service Information Troubleshooting Stator Removal Flywheel Removal 11-1 11-1 11-2 11-3 Balancer Removal Balancer Installation Flywheel Installation Stator Installation 11-4 11-5 11-6 11-7 SERVICE INFORMATION GENERAL The alternator and balancer maintenance can be 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 Flywheel nut Balancer driven gear nut Starter socket bolt Ignition pulse generator socket bolt 3 N.m (0.3 kgf.m, 2.2 lbf-ft) 64 N.m (6.5 kgf.m, 47 lbf-ft) 54 N.m (5.5 kgf.m, 40 lbf-ft) 12 N.m (1.2 kgf.m, 9 lbf-ft) 10 N.m (1.0 kgf.m, 7 lbf-ft) Apply a locking agent to the threads TOOLS Flywheel holder Flywheel puller Gear holder 07725-0040000 07KMC-HE01000 07724-0010100 11-1 NSR150SP Alternator/Balancer ______________________________________________ STATOR REMOVAL NOTE Refer to page 10 for alternator (charging coil) inspection. Remove the drive sprocket cover. Remove the fuel tank Disconnect 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 pattern in several steps. • The left crankcase cover (stator) is magnetically attached to the flywheel, be careful to removal. Remove the gasket and dowel pins. Remove the grommet from the left crankcase cover. 11-2 NSR150SP Alternator/Balancer ______________________________________________ Remove the socket bolts and ignition pulse generator. Remove the bolts and stator. FLYWHEEL REMOVAL Remove 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: Flywheel puller 07KMC-HE01000 Remove the woodruff key. NOTE • When woodruff key removal, be careful not to damage the key groove or crankshaft. • Do not loose the woodruff key. 11-3 NSR150SP Alternator/Balancer ______________________________________________ BALANCER REMOVAL REMOVAL Remove the clutch. Remove the flywheel. Remove the set plate. Hold the balancer drive gear with the gear holder and remove the balancer drive gear nut and washer. TOOLS: Gear holder Wrench 07724-0010100 20 X 24 mm 07716-0020100 Remove the balancer driven gear and woodruff key. NOTE • When woodruff key removal, be careful not to damage the key groove or balancer. • Do not loose the woodruff key. Remove the balancer from the left crankcase. INSPECTION Check the balancer driven gear for wear or damage. Replace the balancer driven gear if necessary. 11-4 NSR150SP Alternator/Balancer ______________________________________________ Check the balancer for bend, wear or damage. Replace the balancer driven if necessary. BALANCER INSTALLATION Apply transmission oil to the balancer 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 balancer. Install the balancer driven gear to the balancer aligning the punch marks on the balancer drive gear and driven gear. Align the cut out on the balancer driven gear with the woodruff key in the balancer. 11-5 NSR150SP Alternator/Balancer ______________________________________________ Hold the balancer drive gear with the gear holder and remove the balancer drive gear nut and washer. TOOL Gear holder Wrench 07724-0010100 07716-0020100 Tighten the balancer drive gear nut to the specified torque. TORQUE: 54 N.m (5.5 kgf.m 40 lbf-ft) Install the flywheel (see below). Install the clutch. FLYWHEEL INSTALLATION 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 crankshaft. Wipe any oil off the mating surface of the flywheel. Install the flywheel to the crankshaft aligning the key groove of the flywheel with the woodruff key on the crankshaft. Hold the flywheel with a flywheel holder. TOOL: Flywheel holder 07725-0040000 Install the washer. Install and tighten the flywheel nut to the specified torque. TORQUE: 64 N.m (6.5 kgf.m 47 lbf.ft) 11-6 NSR150SP Alternator/Balancer ______________________________________________ STATOR INSTALLATION Install the stator to the left crankcase 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 threads. Install and tighten the ignition pulse generator socket bolts to the specified torque. TORQUE: 10 N.m (1.0 kgf.m 7 lbf.ft) 11-7 NSR150SP Alternator/Balancer ______________________________________________ Clean and apply sealant to the wire grommets seating surface and install the grommets into the grooves in the left crankcase cover. Install the dowel pins and 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 bolts securely in a crisscross pattern in several steps. NOTE • Route the wire harness properly. Connect the alternator 3P connector and ignition pulse generator 2P connector. Install the fuel tank. Install the drive sprocket cover. 11-8 NSR150SP Crankshaft/Transmission ________________________________________________ 12-0 NSR150SP Crankshaft/Transmission ________________________________________________ Service Information Troubleshooting Crankcase Separation Transmission 12-1 12-3 12-4 12-4 Crankshaft Crankcase Bearing Replacement Crankcase Assembly 12-10 12-11 12-16 SERVICE INFORMATION GENERAL • The crankcase halves must be separated to service the crankshaft, connecting rod and transmission (including the shift fork and shift drum). To service these parts, the engine must be removed from the engine (Section 7). • The following parts must be removed before separating the crankcase: Oil pump (Section 4) Water pump (Section 6) Cylinder head, Cylinder, piston (Section 8) Clutch, gearshift linkage,and kickstarter (Section 10) Alternator, flywheel (Section 1 1) Neutral switch (Section 18) • Be careful not 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 Connecting rod big end Crankshaft runout Transmission gear I.D. Transmission gear bushing O.D. Transmission gear bushing I.D. Side clearance Radial clearance A B M5, M6 C2, C4 C3 M5, M6 C1 C2 C3 M5, M6 C1 C2 C3 STANDARD 0.3 - 0.7 (0.012 - 0.028) 22.020 - 22.041 (0.8669 - 0.8678) 20.020 - 20.041 (0.7882 - 0.7890) 22.020 - 22.041 (0.8669 - 0.8678) 25.020 - 25.041 (0.9850 - 0.9859) 21.979 - 22.000 (0.8653 - 0.8661) 19.984 - 19.995 (0.7868 - 0.7872) 21.984 - 22.005 (0.8655 - 0.8663) 24.984 - 24.993 (0.9836 - 0.9840) 20.000 - 20.021 (0.7874 - 0.7882) 17.016 - 17.034 (0.6700 - 0.6706) 20.020 - 20.041 (0.7882 - 0.7890) 22.020 - 22.041 (0.8669 - 0.8678) 12-1 SERVICE LIMIT 0.05 (0.002) 0.05 (0.002) 0.03 (0.001) 22.10 (0.870) 20.10 (0.791) 22.10 (0.870) 25.10 (0.988) 21.90 (0.862) 19.90 (0.783) 21.90 (0.862) 24.90 (0.980) 20.10 (0.791) 17.10 (0.673) 20.10 (0.791) 22.10 (0.870) NSR150SP Crankshaft/Transmission ________________________________________________ Unit: mm (in) ITEM Gear-to-bushing clearance Mainshaft O.D. Countershaft O.D. Gear-to-shaft clearance Gear bushing-toshaft clearance M5, M6 C1 C2 C3 M5 Right crankcase journal C1 C2 C3, C4 C4 M5, M6 C1 C2 C3 Shift fork claw thickness Shift fork I.D Shift fork shaft O.D STANDARD 0.020 - 0.062 (0.0008 - 0.0024) 0.025 - 0.057 (0.0010 - 0.0022) 0.0 15 - 0.057 (0.0006 - 0.0022) 0.027 - 0.057 (0.0011 - 0.0022) 19.959 - 19.980 (0.7858 - 0.7866) 16.966 - 16.984 (0.6679 - 0.6686) 16.975 19.974 21.959 0.040 - 16.984 (0.6683 - 0.6687) - 19.984 (0.7863 - 0.7867) - 21.980 (0.8645 - 0.8653) - 0.082 (0.0016 - 0.0032) 0.10 (0.004) 0.10 (0.004) 0.10 (0.004) 0.10 (0.004) 4.80 (0.189) 12.041 - 12.056 (0.4741 - 0.4746) 11.983 - 11.994 (0.4718 - 0.4722) 12.65 (0.475) 11.973 (0.4714) 10 N.m (1.0 kgfm, 7 lb-ft) 10 N.m (1.0 kgf.m, 7 lb-ft) Apply a locking agent to the threads TOOLS Universal bearing puller Sliding weight Attachment, 37 X 40 mm Attachment, 42 X 47 mm Attachment, 52 X 55 mm Attachment, 62 X 67 mm Pilot, 15 mm Pilot, 17 mm Pilot, 20 mm Pilot, 25 mm Pilot, 22 mm Driver Bearing remover head, 16 mm Remover shaft, 15 mm Crank assembly collar Crank assembly shaft Case puller 16.95 (0.667) 16.95 (0.667) 19.94 (0.785) 21.09 (0.830) 0.020 - 0.062 (0.0001 - 0.0024) 0.032 - 0.059 (0.0013 - 0.0023) 0.033 - 0.067 (0.0013 - 0.0026) 0.040 - 0.082 (0.0016 - 0.0032) 4.93 - 5.00 (0.194 - 0.197) TORQUE VALUES Crankcase bolt Bearing set plate bolt SERVICE LIMIT 0.10 (0.004) 0.10 (0.004) 0.10 (0.004) 0.10 (0.004) 0.10 (0.004) 19.92 (0.784) 07631-0010000 07741-0010201 07746-0010200 07746-0010300 07746-0010400 07746-0010500 07746-0040300 07746-0040400 07746-0040500 07746-0040600 07746-0041000 07749-0010000 07936-MK50100 07936-KClOlOO 07964-MB00200 07965-VMOO200 07SMC-0010001 12-2 NSR150SP Crankshaft/Transmission ________________________________________________ TROUBLESHOOTING Excessive noise • Worn connecting rod big end bearing • Bent connecting rod • Worn crankshaft main 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 transmission oil weight Transmission jumps out of gear • Worn gear dogs or slots Bent fork shaft • Broken shift drum stopper • Worn or bent shift forks • Broken shift linkage return spring 12-3 NSR150SP Crankshaft/Transmission ________________________________________________ CRANKCASE SEPARATION Remove the engine from the frame (Section 7). Refer to Service Information (page 12-1) for removal of necessary parts before disassembling the crankcase. Remove the crankcase bolts. NOTE • Loosen the left crankcase bolts in a crisscross pattern in several steps. Attach the case puller to 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 crankcase halves apart with a screwdriver. TOOL: Case puller 07SMC-0010001 Remove the gasket and dowel pins. Clean off any gasket material from the crankcase mating surface. CAUTION Be careful not to damage the crankcase mating surface. TRANSMISSION REMOVAL Separate the crankcase (see above). Remove the shift fork shafts from the shift forks. Remove the shift drum and shift forks. 12-4 NSR150SP Crankshaft/Transmission ________________________________________________ Remove the main shaft and countershaft from the right crankcase. NOTE • Do not forget to install the transmission end washer. DISASSEMBLY NOTE • Keep track of the disassembled parts (gears, bushings, washers and snap rings) by staking them on a toot or slipping them onto a piece of wire. • Do not expand the snap ring more than necessary 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 for damage or excessive wear. Measure the I.D. of each gear. SERVICE LIMITS: M5, M6: 22.10 mm (0.870 in) C1: C2, C4: 22.10 mm (0.870 in) C3: 25.10 mm (0.988 in) BUSHING Check the bushings for damage or excessive wear. Measure the O.D. of each bushing. SERVICE LIMITS: M5, M6: mm in) C1: 19.90 mm (in) C2: (in) C3: 24.90 mm ( in),, SERVICE LIMITS: M5, M6: mm in) C1: 19.10 mm (in) C2: 20.40 mm (in) C3: 22.10 mm ( in),, Measure the I.D. of each bushing. 12-5 NSR150SP Crankshaft/Transmission ________________________________________________ MAINSHAFT / COUNTERSHAFT Check the spline grooves and sliding surfaces for damage or abnormal wear. Measure the O.D. of the mainshaft and countershaft at the gear and bushing sliding areas. SERVICE LIMITS: Mainshaft: M5 gear bushing: > mm Case journal: Countershaft: C1 gear bushing: C2 gear bushing: C3 gear bushing: C4 gear bushing: in) mm mm mm mm (in) (in) (in) (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.D. from gear I.D.. SERVICE LIMITS: M5,M6: mm (in) C1: mm (in) C2: mm (in) C3: mm (in) SHIFT DRUM Inspect the shift drum for scoring, scratches or evidence of insufficient lubrication. Check the shift drum grooves for abnormal wear or damage. SHIFT FORK, SHIFT FORK SHAFT Check the shift fork for abnormal wear or deformation. Measure the shift fork I.D. and claw thickness. SERVICE LIMITS: I.D.:12.65 mm (in), Claw thickness: 4.20 mm in) 12-6 NSR150SP Crankshaft/Transmission ________________________________________________ Check the shift fork shaft for abnormal wear, damage or straightens. Measure the shift fork O.D. SERVICE LIMIT: 11.995 mm( in) SHIFT DRUM JOURNAL, SHIFT FORK JOURNAL Check the left and right crankcase shift fork journal for wear or damage. Check the left crankcase shift drum journal for wear or damage. ASSEMBLY Clean all parts 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 for freedom of movement or rotation on the shaft. Install the washers and snap rings with the chamfered edges facing the thrust load side. Do not reuse worn snap rings which could easily spin in the grooves. Check that the snap rings are seated in the grooves. Align their end gaps with the grooves of the spline. Install the lock washer aligning its tabs with the grooves in the spline washer. 12-7 NSR150SP Crankshaft/Transmission ________________________________________________ MAINSHAFT COUNTERSHAFT 12-8 NSR150SP Crankshaft/Transmission ________________________________________________ INSTALLATION Apply transmission oil to the following parts. • Mainshaft • Countershaft • Each gear • Mainshaft bearing • Countershaft bearing • Shift drum bearing Install the mainshaft and countershaft 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 NOTE • Each shift fork has an identification mark; 'R' is for the right shift fork, 'L' is for the left shift fork and 'C' is for the center shift fork. Install the shift forks to the grooves of the shifter gear with their marks facing up (right crankcase side). 12-9 NSR150SP Crankshaft/Transmission ________________________________________________ Install the shift drum aligning the guide pins on the shift fork with the guide grooves of the shift drum. Apply transmission oil to the shift fork shaft. Install the shift fork shaft 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 12-4). Remove the crankshaft from the right crankcase using a hydraulic press as shown. If the crankshaft bearing is removed with the crankshaft, remove the bearing using the bearing puller and discard the bearing. TOOL: Universal bearing puller 07631-0010000 12-10 NSR150SP Crankshaft/Transmission ________________________________________________ INSPECTION Place the crankshaft on a stand or V-brocks. Set the indicator on the crankshaft as shown. Rotate the crankshaft two revolutions and read the runout. SERVICE LIMITS: A: B: 0.05 mm (0.002 in) 0.03 mm (0.001 in) Measure the side clearance between the connecting rod big end and crank weight 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 BEARING REPLACEMENT Remove the followings: Crankshaft (page 12-10) Transmission (page 12-4) Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the crankcase. Replace the bearings if the races does not turn smoothly and quietly, or if they fit loosely in the crankcase. 12-11 NSR150SP Crankshaft/Transmission ________________________________________________ LEFT CRANKCASE BEARING REPLACEMENT Remove the crankshaft oil seal, balancer oil seal, gearshift spindle oil seal and countershaft oil seal. Remove the balancer bearing and countershaft bearing out of the left crankcase. Remove the mainshaft bearing out 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 check for crack or damage. BALANCER BEARING Apply transmission oil to the new needle bearing. Press the new needle bearing into the left crankcase using the following special tools. TOOLS: Driver 07749-0010000 Attachment 35 X 40 mm 07746-0010200 NOTE • Install in the new needle bearing squarely with the marking side facing up. 12-12 NSR150SP Crankshaft/Transmission ________________________________________________ MAINSHAFT BEARING Apply transmission oil to the new bearing. Install the new bearing to the left crankcase using the following special tools. TOOLS: Driver 07749-0010000 Attachment, 42 X 47 mm 07746-0010300 NOTE • Drive in the new bearings squarely with the marking side facing up. COUNTERSHAFT BEARING Apply transmission oil to the new bearing. Install the new bearing to the left crankcase using the following special tools. TOOLS: Driver 07749-0010000 Attachment, 42 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 the specified depth from the crankcase mating surface. • Crankshaft bearing must be installed in a parallel manner. Install the snap ring into the left crankcase groove. Apply transmission oil to the new bearing. Install the new bearing into the left crankcase so that the bearing outer surface is 25.55 – 25.60 mm 1.006-1.008 in) below the mating surface of the left crankcase). TOOLS: Driver 07749-0010000 Attachment, 62 X 67 mm 07746-0010500 Pilot, 25 mm 07746-0040600 NOTE • Drive in the new bearing squarely with the marking side facing up. 12-13 NSR150SP Crankshaft/Transmission ________________________________________________ Install 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 mainshaft bearing set plate. Remove the bolts, balancer shaft bearing set plate. 12-14 NSR150SP Crankshaft/Transmission ________________________________________________ Remove the balancer bearing, mainshaft bearing countershaft bearing, shift drum bearing and crankshaft bearing out of the right crankcase. Mainshaft Bearing Install the new bearing to the right crankcase using the following tools. TOOLS: Driver 07749-0010000 Attachment, 42 x 47mm 07746-0010300 Pilot, 17mm 07746-0040400 NOTE: • Drive in the new bearing squarely with the marking side facing up. Bearing Countershaft Bearing Install the new bearing to the right crankcase using the following special tools. TOOLS: Driver 07749-0010000 Attachment, 42 x 47mm 07746-0010300 Pilot, 17mm 07746-0040400 NOTE: • Drive in the new bearing squarely with the marking side facing up. Balancer Bearing Install the new bearing to the right crankcase using the following special tools. TOOLS: Driver 07749-0010000 Attachment, 42 x 47mm 07746-0010300 Pilot, 17mm 07746-0040400 NOTE: • Drive in the new bearing squarely with the marking side facing up. 12-15 NSR150SP Crankshaft/Transmission ________________________________________________ SHIFT DRUM BEARING Install the new bearing to the right crankcase using the following special tools. TOOLS: Driver 07749-0010000 Attachment, 42 X 47 mm 07746-0010300 Pilot, 25 mm 07746-0040600 NOTE • Drive in the new bearing squarely with the marking side facing up. Clean and apply locking agent to the bolt threads. lnstall the balancer shaft bearing set plate. Install and tighten the bolts to the specified torque. TORQUE: 10 N.m (1.0 kgf.m, 7 lbf.ft) Clean and 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) CRANKSHAFT BEARING NOTE • At crankcase bearing installation, install the bearing to the specified depth from the crankcase mating surface. • Crankshaft bearing must be installed in a parallel manner. Apply transmission oil to the new bearing. Install the new bearing into the right crankcase so that the bearing outer surface is 26.00-26.05 mm(1.024-1.026 in)below them at TOOLS: Driver Attachment, 52 X 55 mm Pilot, 22 mm 07749-0010000 07746-0010400 07746-0041000 NOTE • Drive in the new beating squarely with the marking side facing up. 12-16 NSR150SP Crankshaft/Transmission ________________________________________________ Install the new crankshaft oil seal (page 12-18). CRANKCASE ASSEMBLY Clean both crankcase mating surfaces before assembling and check for wear or damage. NOTE If there is minor roughness or irregularities on the crankcase mating surfaces, 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 assembly collar 07964-MB00200 Crank assembly shaft 07965-VM00200 Install the transmission (page 12-9). Install the dowel pins and new gasket. Place the right crankcase onto the left crankcase using the crank case assembly tool. TOOLS: Crank assembly collar Crank assembly shaft 07964-MB00200 07965-VM00200 12-17 NSR150SP Crankshaft/Transmission ________________________________________________ Pack grease into the cavity between the left crankshaft oil seal lips. Press the left crankshaft oil seal into the left crankcase using the crank case assembly tool. TOOLS: Crank assembly collar Crank assembly shaft 07964-MB00200 07965-VMOO200 • NOTE Install the crankshaft oil seal into the left crankcase to /////////////////////// before the surface of 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 assembly collar Crank assembly shaft • 07964-MB06200 07965-VMOO200 NOTE Install the crankshaft oil seal into the right crankcase to ?? ?? below the surface of the right crankcase. Clean and apply a locking agent to the crankcase bolt threads as shown. Install and tighten the crankcase bolts in a crisscross pattern in several steps. TORQUE: 10 N.m (1.0 kgf.m, 7 lbf. ft) Install the engine to the frame (Section 7). 12-18 NSR150SP Front Wheel / Suspension/Steering 13-0 NSRl50SP Front Wheel / Suspension/Steering SERVICE INFORMATION GENERAL A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean contaminated disc with a high quality brake degreasing agent. Riding on damaged rims or spokes impairs safe operation of the vehicle. Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Carefully check balance before reinstalling the wheel When servicing the front wheel, support the motorcycle securely using a safety stand or hoist. Do not operate the brake lever after removing the caliper and front wheel. To do so will cause difficulty in fitting the brake disc between the brake pads. Use only tires marked 'TUBELESS' and tubeless valves on rims marked 'TUBELESS TIRE APPLICABLE'. Refer to Section 15 for brake system information. SPECIFICATIONS ITEM STANDARD 1 SERVICE 1 LIMIT Minimum tire tread depth Cold tire pressure Front axle runout Front wheel rim run out 1.5 (0.06) Driver only Driver and passenger 200 kPa (2.00 kgf/cm2,29 psi) 200 kPa (2.00 kgf/cm2,29 psi) 0.2 (0.008) 2.0 (0.08) 2.0 (0.08) Radial Axial Wheel balance weight Fork spring free length Max 60 g 310.4 (12.22) Fork spring installed direction Fork tube runout Recommended fork oil Fork oil level Fork oil capacity Steerina bearina Dreload Tapered side facing down 304.2 (11.98) zyx zyxwv 0.2 (0.008) Fork fluid 125 (4.9) 322 cm3(10.9US oz, 11.31 Imp oz) 0 -1 . 5 N m 10 1 - 0 15 k d m \ 13-1 NSRl50SP Front Wheel / Suspension/Steering TORQUE VALUES Front axle nut Front brake disc bolt 59 Nm (6.0 kgVm, 43 Ibf*ft) 42 Nm (4.3 kgf*m, 31 Ibf*ft) Steering stem nut Steering top thread Top bridge pinch bolt Bottom bridge pinch bolt Fork cap Fork socket bolt 88 8m (Q.Okgf*rn, 65 Ibf*ft) 1 Nm (0.1 kgf*m, 0.7 Ibf*ft) 22 Nm (2.2 kgf*m, 16 Ibf*ft) 27 Nm (2.8 kgf*m, 20 Ibf*ft) 22 Nm (2.2 kgf*m, 16 Ibf*ft) 20 Nm (2.0 kgf*m, 14 Ibf*ft) Front caliper bracket bolt 30 Nm (3.1 kgf*m, 22 Ibf*ft) TOOLS Attachment, 42 X 47 mm Pilot, 15 mm Driver Bearing remover shaft Bearing remover head, 15 mm Fork seal driver Fork seal driver attachment Steering stem socket Driver attachment Steering stem driver U-nut Apply a locking agent to the threads Apply a locking agent to the threads Apply a locking agent to the threads 07746-0010300 07746-0040300 07749-0010000 07746-0050100 07746-0050400 07747-0010100 07947-KA20200 07916-3710101 07946-3290000 07946-4300001 TROUBLESHOOTING Hard steering Steering top thread too tight Faulty steering head bearings Damaged steering head bearings Faulty tire Insufficient tire pressure Soft Suspension Weak fork spring Low fluid level In fork Insufficient fluid in fork Low tire pressure Steers to one side or does not track straight Bent fork Faulty steering head bearings Damaged steering head bearings Unevenly adjusted right and left forks Bent frame Worn wheel bearings Bent front axle Worn swingarm pivot component Hard suspension High tire pressure Bent fork High fluid level in fork Incorrect fluid weight Clogged fluid passage Front Suspension Noisy Loose fork fasteners Insufficient fluid in fork Wheel turns hard Faulty wheel bearings Bent front axle Brake drug Faulty speedometer gear zy Front wheel wobbling Bent rim Worn wheel bearings Faulty tire Unbalanced tire and wheel 13-2 NSRlSOSP Front Wheel / Suspension/Steering HANDLEBAR RIGHT HANDLEBAR REMOVAL Remove the master cylinder (page 15-11). CAUTION Do not disconnect the hydraulic line. NOTE The master cylinder upright to prevent air from entering the hydraulic system. Remove the screws and engine stop switch housing. Remove the screws and throttle housing cover from the handlebar. Remove the throttle, cable guide and disconnect the throttle cables from the throttle pipe. Remove the throttle housing from the handlebar. 13-3 NSR150SP Front Wheel / Suspension/Steering Remove the screw, handlebar weight and throttle grip from the handlebar. Remove the throttle pipe from the handlebar. Remove the stop ring from the groove on the fork tube. Loosen the handlebar pinch bolt and remove the right handlebar. 13-4 NSRl50SP Front Wheel / Suspension/Steering LEFT HANDLEBAR REMOVAL Remove the bolts and clutch lever bracket holder from the left handlebar. Remove the clutch lever bracket from the left handlebar. Remove the screws and left handlebar switch from the left handlebar. Remove the screw and handlebar weight. Remove the left handlebar grip from the handlebar. 13-5 NSR150SP Front Wheel / Suspenslon/Steering Remove the stop ring from the groove on the fork tube. Loosen the handlebar pinch bolt and remove the left handlebar. RIGHT HANDLEBAR INSTALLATION Install the right handlebar onto the fork tube, aligning the stopper on the handlebar with the groove in the top bridge. Install the stop ring to the groove on the fork tube. Tighten the handlebar pinch bolt securely. 13-6 -~ ~ zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA NSRl50SP Front Wheel / Suspension/Steering Apply grease to the throttle grip inner surface and right handlebar sliding surface. Install the throttle grip. Install the handlebar weight to the handlebar aligning the tab on the handlebar weight with the slit of the handlebar. Install and tighten the new screw securely. Install the throttle housing, aligning the pin on the housing with the hole in the handlebar. 13-7 NSRl50SP Front Wheel / Suspension/Steering Apply grease to the throttle cable ends and connect them to the throttle grip. Install the throttle housing cover to the throttle housing. Install and tighten the forward screw first, then tighten the rear screw securely. Install the engine stop switch, aligning the its mating surface with the punch mark on the handlebar. Tighten the forward screw first, then tighten the rear screw securely. Install the master cylinder (page 15-16). LEFT HANDLEBAR INSTALLATION Install the right handlebar onto the fork tube, aligning the stopper on the Handlebar with the grove in the top bridge. 13-8 NSR150SP Front Wheel / Suspension/Steering Install thestop ring to the groove on the fork tube. Tighten the handlebar pinch bolt securely. Clean the inside surface of the left handlebar grip and the outside surface of the handlebar. Apply Honda Bond A or equivalent to the inside surface of the left handlebar grip and outside surface of the handlebar. Wait 3 - 5 minutes and install the grip. Rotate the grip for even application of adhesive. NOTE - Allow the adhesive to dry for an hour before using. Install the handlebar weight to the handlebar aligning the tab on the handlebar weight with the slit of the handlebar. Install and tighten the new screw securely. 13-9 NSR150SP Front Wheel / Suspenslon/Steering Install the left handlebar switch, aligning the pin on the housing with the hole in the handlebar. Tighten the forward screw first, then tighten the rear screw. Install the clutch lever bracket and holder with the YJP” mark facing up. Align mating surface of the clutch lever bracket holder with the punch mark on the handlebar. Tighten the upper bolt first, then tighten the lower bolt securely. 13-10 NSR15OSP Front Wheel / Suspension/Steering FRONT WHEEL A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean contaminated disc with a high quality brake degreasing agent. REMOVAL Remove the screw and disconnect the speedometer cable. Loosen the front axle nut. NOTE - Only loosen the front axle nut. Support the motorcycle securely using a safety stand or hoist. Remove the front axle nut. Remove the front axle shaft and front wheel. Remove the speedometer gear box from the left side of the front wheel. 13-11 NSRl50SP Front Wheel / Suspenslon/Steering Remove the side collar from the right side of the front wheel. INS PECTl0N AXLE Set the front axle shaft in V-blocks and measure the runout. Turn the front axle shaft and measure using a dial indicator. Actual runout is ?hthe total indicator reading. SERVICE LIMIT: 0.2 m m (0.008 in) WHEEL BEARING Turn the inner race of each bearing with your finger. The Bearings should turn smoothly and quietly. Also check that the bearing Outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn Smoothly and quietly, if they fit loosely in the hub. NOTE: Replace the wheel bearings in pairs. WHEEL RIM Check the rim runout by placing the wheel in a truing stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is ?h the total indicator reading. SERVICE LIMITS: 2.0 m m (0.08 in) Radial: Axial: 2.0 m m (0.08 in) Check the spokes for loose or damage. 13-12 /-\ Front Wheel NSRl50SP Front Wheel / Suspension/Steering DISASSEMBLY Remove the right and left dust seals from the each side of the front wheel. Remove the speedometer gear retainer. Remove the brake disc mounting bolts and brake disc. Install the bearing remover head into the bearing. From opposite side install the bearing remover shaft and Drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover shaft 07746-0050100 Bearing remover head, 15 mm 07746-0050400 NOTE: Replace the wheel bearing in pairs. Do not fe-sue old bearings. 13-13 NSRl50SP Front Wheel / Suspension/Steering ASSEMBLY kront Brake UISC Bolt 42 N.m (4.3 kgf.m,31 Ibf.ft) Speedometer Gear Retainer Left Dust Seal a \Front Wheel kight Wheel Bearing ight Dust Seal Drive in a new right bearing (6302 U) squarely with the marking Side facing up until it is fully seated. Install the distance collar. Drive in a new left bearing (6302 U) squarely with the marking Side facing up until it is fully seated. TOOLS: Driver 07749-0010000 Attachment, 42 X 47 mm 07746-0010300 Pilot, 15 mm 07746-0040300 Install the brake disc with the marked side facing out. Clean and apply a locking agent to the brake disc bolt threads. Install and tighten the brake disc bolts to the specified torque. TORQUE: 42 N.m (4.3 kgf-m, 31 Ibft) 13-14 NSRl50SP Front Wheel / Suspension/Steering WHEEL BALANCE Wheel balance directly affects the stabilitv. handlina and overall safety of the motorcycle. Carefully check balance before reinstalling the wheel. NOTE: The wheel balance must be checked when the tire is Remounted. For optimum balance, the tire mark (a paint dot On the side wall) must be located next to the valve stem. Remount the tire if necessary. Mount the wheel, tire and brake disc assembly on an inspection stand. Spin the wheel, allow it to stop, and mark the lowest (heaviest) part of the wheel with chalk. Do this two or three times to verify the heaviest area. If the wheel is balanced, it will not stop consistently in the same position. To balance the wheel, install balance weights on the lightest side of rim, the side opposite the chalk marks. Add just enough weight so the wheel will no longer stop in the same position when it is spun. Do not add more than 60 grams (2.1 oz) to the front wheel. I I zyxwvut Install the speedometer gear retainer to the wheel hub aligning the tangs on the retainer with the slots on the hub. Apply grease to the left dust seal lip. Install the left dust seal on the left wheel. 13-15 NSRl50SP Front Wheel / Suspension/Steering Apply grease to the right dust seal lip Install the right dust seal to the right wheel. INSTALLATION Apply grease to the inside of the speedometer gear box, and install the washer and speedometer gear. Install the speedometer gear box into the right side of the front wheel. Install the side collar into the left wheel. Install the front wheel between the fork legs so that the brake disc is positioned between the pads, being careful not to damage the pads. Apply thin coat of grease to the front axle shaft. Install the front axle shaft. 13-16 NSRl50SP Front Wheel / Suspension/Steering Align the tab on the speedometer gear box with the groove on the fork leg. Install and tighten the front axle nut to the specified torque. TORQUE: 59 N.m (6.0 kgf.m, 43 Ibf.ft) Connect the speedometer cable. Install and tighten the screw securely. FORK REMOVAL Remove the front wheel (page 13-11). Remove the front brake caliper (15-17) (right side only). CAUTION Do not suspend the brake caliper from the brake hose. Do not twist the brake hose. Remove the bolts, screw and front fender. 13-17 NSR150SP Front Wheel / Suspension/Steering Remove. the wire band. Remove the handlebar from the fork tube (page 13-3). Loosen the top bridge pinch bolt. When the fork is ready to be disassembled, loosen the fork cap, but do not remove it. Loosen the bottom bridge pinch bolt while holding the fork. Remove the fork from the top bridge and steering stem. DISASSEMBLY Remove the fork cap and O-ring from the fork tube. The fork cap is under spring pressure. Use care when removing it and wear eye and face protection. 13-18 NSRl50SP Front Wheel / Suspension/Steering Remove the spring collar. Remove the spring joint plate and fork spring. Pour out the fork oil from the fork leg by pumping the fork 8-10 times. CAUTION Do not over tighten the bracket Hold the brake caliper bracket of the fork slider in a vice with a piece of wood or soft jaws to avoid damage. Loosen and remove the fork socket bolt and sealing washer from the fork slider. If the fork piston turns with the socket bolt, temporarily install the fork spring, spring joint plate, spring collar and fork cap. 13-19 NSR150SP Front Wheel / Suspension/Steering Remove the fork piston and rebound spring. NOTE Do not remove the fork piston ring, unless it is necessary to replace with a new one. Remove the dust seal. Remove the stopper ring from the groove of the fork slider. CAUTION Do not scratch the inner fork tube sliding surface. NOTE Check that the fork tube moves smoothly in the fork slider if it does not, check the fork tube for bending or damage, and bushings for wear or damage. Using quick successive motions, pull the fork tube out of the fork slider. Remove the oil lock piece from the fork slider. 13-20 NSRl50SP Front Wheel / Suspension/Steering Remove the oil seal, back-up ring and slider bushing from The fork tube. NOTE Do not remove the fork tube bushing unless it is Necessary to replace it with a new one. Carefully remove the fork tube bushing by prying the slot with a screwdriver until the bushing can be pulled off by hand. INSPECTION FORK SPRING Measure the fork spring free length by placing the spring on a flat surface. SERVICE LIMIT: 304.2 mm (11.98 in) FORK TUBE, SLIDER, FORK PISTON Check the fork tube, slider and fork piston for score marks, and excessive or abnormal wear. Replace the component if necessary. 13-21 NSR150SP Front Wheel / Suspension/Steering Check the fork piston ring for wear or damage. Check the rebound spring for fatigue or damage. Replace the component if necessary. Set the fork tube in V-blocks and measure the fork tube runout by rotating it with a dial indicator reading. SERVICE LIMIT: 0.2 mm(0.008 in) Replace if the service limit is exceeded, or there are scratches or nicks that will allow fork oil to leak past the seals. NOTE Do not reuse the fork tube if it cannot be perfectly straightened with minimal effort. zyxwvuts FORK TUBE BUSHING Visually inspect the slider and fork tube bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon is worn so that the copper surface appears on more 3/4 of the entire surface. Back-up Ring Check the back-up ring; replace it if there is any distortion at the points shown. Copper Surfaces 13-22 NSRl50SP Front Wheel / Suspension/Steering ASSEMBLY Before assembly, wash all parts with a high flash point or non-flammable solvent and wipe them off completely. Install a new fork tube bushing if the tube bushing has been Removed. CAUTION Be careful not to damage the fork tube bushing coating. Do not open the fork tube bushing more than necessary. NOTE Remove the burrs from the bushing mating surface. Being careful not to peel off the coating. Install the slider bushing and back-up ring to the fork tube. Apply the oil to the new oil seal lip. Install the new oil seal to the fork tube with it marking side facing up. 13-23 NSRl50SP Front Wheel / Suspension/Steering Install the oil lock piece onto the fork tube end. Coat the fork tube bushing with the fork oil and install the Fork tube into the fork slider. Install the rebound spring to the fork piston. Install the fork piston into the fork tube. CAUTION s Do not over tighten the bracket. Hold the brake caliper bracket of the fork slider in a vice with a piece of wood or soft jaws to avoid damage. Replace the sealing washer with a new one. Clean and apply a locking agent to the fork socket bolt threads and install the fork socket bolt with the new sealing washer into the fork piston. zyxwvutsr Tighten the fork socket bolt to the specified torque. TORQUE: 20 N.m (2.0 kgPm, 14 IbfVt) If the fork piston turns with the socket bolt, temporarily install the fork spring, spring joint plate, spring collar and fork cap. 13-24 NSRl50SP zyxw Front Wheel / Suspension/Steering Drive in the new oil seal into the fork tube until stopper ring groove is visible, using the special tools. zyxwvu TOOLS: Fork seal driver 07747-0010100 Fork seal driver attachment 07947-KA20200 Install the stopper ring in the fork slider. Apply fork oil to the lip of the new dust seal and install the dust seal to the fork slider. Pour half the required amount of the recommended fork oil in the fork tube. zyxwvuts RECOMMENDEDFORK OIL: Fork fluid OIL CAPACITY: 322 cm3 (10.9 US 02, 11.3 Imp 02) Slowly pump the fork tube several times to remove trapped air. Pour additional oil up to the specified capacity and repeat the above step. Compress the fork leg fully. Measure the oil level from the top of the fork tube. OIL LEVEL: 125mm (4.9in) Pull the fork tube and install the fork spring with the tapered side facing down. 13-25 NSRl50SP Front Wheel / Suspension/Steering Install the spring joint plate and spring collar. zyxwvutsrq Apply fork oil and install the new O-ring and install the new O-ring to the fork cap. Install the fork cap into the fork tube. NOTE 0 Tighten the fork cap after installing the fork tube into the fork bridge. I NSTALLATI0N Install the fork into the bottom and top bridge. Align the second groove on the fork tube with the upper surface of the top bridge. Tighten the bottom bridge pinch bolt to the specified torque. TORQUE: 27 N.m (2.8 kgf.m, 20 Ibf.ft) Tighten the fork cap to the torque. TORQUE: 22 N.m (2.2 kgf.m, 16 Ibf.ft) Tighten the top bridge pinch bolt to the specified torque. TORQUE: 27 N.m (2.8 kgf.m, 20 Ibf.ft) Install the handlebar (right: page 13-6, left 13-8). 13-26 NSRl50SP Front Wheel / Suspension/Steering Install the wire band. Install the front fender. Install and tighten the bolts and screws secu rely. Install the front brake caliper (page 15-20) (right side only). Install the front wheel (page 13-16). STEERING STEM REMOVAL Remove the fuel tank (page 2-12). Remove handlebar (page 13-3). Remove the front wheel (page 13-1 1). Remove the horn connector (page 1817) Disconnect the ignition switch 2P connector. Remove the steering stem nut and washer 13-27 NSRl50SP Front Wheel / Suspension/Steering Remove the fork (page 13-17). Remove the top bridge. Remove the brake hose from the clamp on the steering stem. Remove the steering top thread using following tool. TOOL: Steering stem socket 07916-3710101 Remove the upper bearing inner race and upper bearing Steel balls. NOTE Do not loose the steel balls. 13-28 NSR150SP Front Wheel / Suspension/Steering Re move the steering stem and lower bearing steel balls. NOTE Do not loose the steel balls. Check the steering bearing steel balls, inner and outer races for wear or damage. STEERING STEM BEARINGS REPLACEMENT NOTE Always replace the bearings and races as a set. Remove the upper and lower bearing outer races. Remove the bolts and horn stay. Install the stem nut onto the stem to prevent the threads from being damage when removing the lower bearing inner race from the stem. Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the stem. Remove the dust seal and washer. 13-29 NSR150SP Front Wheel / Suspension/Steering Apply grease to the new dust seal lip and install it to the steering stem. Install the new lower bearing inner race using the following tool and hydraulic press. TOOL: Steering stem driver 07946-4300001 Install the horn stay to the steering stem. Install and tighten the bolts securely. Drive the new upper and lower bearing outer race into the Head pipe using the following tools. TOOLS: Driver Driver attachment 07749-0010000 07946-3290000 13-30 NSRl50SP Front Wheel / Suspension/Steering Steering Stem Nut NOTE Number of head bearing steel balls: Upper: 18 Lower: 18 Apply grease to the new lower bearing steel balls. Install the new steel balls onto the steering stem. Install the steering stem into the head pipe. Apply grease to the new upper bearing steel balls and upper inner race. Install the new steel balls and upper inner race. 13-31 NSRl50SP Front Wheel / Suspension/Steering Install the steering top thread and tighten it to the specified Torque. TOOL: Steering stem socket 07916-3710101 TORQUE: 27 N.m (2.8 kgf.m, 20 Ibf.ft) Turn the steering stem right and left, lock to lock at least five times to seat bearings. Make sure that the steering stem moves smoothly, without play or binding. Loosen the steering top thread. Install the fork (page 13-26). Install the front wheel (page 13-16). Tighten the steering top thread to the specified torque while Front wheel is grounded. TOOL: Steering stem socket 07916-3710101 TORQUE: 1 N.m (0.1 kgf.m, 0.7 Ibf.ft) Connect the ignition switch 2P connector. 13-32 NSR150SP Front Wheel / Suspension/Steering Install the brake hose to the clamp on the steering stem. Install the top bridge, washer and steering stem nut. Tighten the steering stem nut to the specified torque. TORQUE: 88 N.m (9.0 kgf.m, 65 Ibf-ft) Make sure that the steering stem moves smoothly, without play or binding. Install the horn connectors (page 18-17). Install the handlebar (right: page 13-6, left: 13-8). STEERING BEARING PRELOAD Raise the front wheel off the ground. Position the steering stem to straight ahead position. Hook a spring scale to fork tube between the fork tube between the fork top and bottom bridges. Make sure that there is no cable or wire harness interference. Pull the spring scale keeping the scale at a right angle to the steering stem. Read the scale at the point where the steering stem just starts to move. STEERING BEARING PRELOAD: 1.0 1.5 N.m (0.1 0.15 kgf.m) - - If the readings do not fall within the limits, read just the steering top thread. Install the removed parts in the reverse order of removal. NOTE : Route the cables and wire harness properly 13-33 NSR150SP Service Information Troubleshooting Rear Wheel Bearing HoldedDriven Rear Wheel/ Suspension 14-1 14-2 14-3 Flange Shock Absorber Swingarm 14-4 14-14 14-16 SERVICE INFORMATION GENERAL A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean contaminated disc with a high quality brake dkreasing agent. The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the gas containing shock absorber. Before disposal of the gas containing shock absorber, release the nitrogen gas (see page 14-5). CAUTION To avoid damaging the rim when using the tire lever, always use rim protectors. 0 0 zyxw When servicing the rear wheel, suspension linkage, swingarm or shock absorber, support the motorcycle using a safety stand or hoist. Do not operate the brake pedal after removing the caliper and rear wheel. To do so will cause difficulty in fitting the brake disc between the brake pads. Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points. Refer to Section 15 for brake system information. SPECIFICATIONS I ITEM I STANDARD (0.4 in) compressed Damper /reservoir gas release drilling point I See page 14-15 14-1 Unit: m m (in) I SERVICE I Rear Wheel/ Suspension NSR150SP TORQUE VALUES 108 N.m (11.O kgf.m, 80 Ibf.ft) 226 N.m (23.0 kgf.m, 166 Ibf.ft) Apply oil to the threads and flange su dace 34 N.m 93.5(kgf.m, 25 Ibf.ft) U-nut 30 N.m (3.1 kgf.m, 22 Ibf.ft) U-nut 73 N.m (7.4 kgf.m, 54 Ibf.ft) 88 N.m (9.0 kgf.m, 65 Ibf.ft) 5.1 N.m (0.52 kgf.m, 3.8 Ibf.ft) 44 N.m (4.5 kgf.m, 33 Ibf.ft) 44 N.m (4.5 kgf.m, 33 Ibf.ft) U-nut Rear wheel nut Rear axle nut Rear brake disc nut Driven sprocket nut Bearing holder pinch bolt Swingarm pivot nut Drive chain slider screw Shock absorber upper mounting bolt Shock absorber lower mounting nut TOOLS Attachment, 32 X 35 mm Attachment, 37 X 40 mm Attachment, 52 X 55 mm Attachment, 62 X 67 mm Pilot, 15 mm Pilot, 40 mm Driver Driver shaft Bearing remover attachment 07746-0010100 07746-0010200 07746-0010400 07746-0010500 07746-0040300 07746-0040900 07749-0010000 07946-MJ00100 07LMC-KV30200 TROUBLESHOOTING Soft suspension Weak spring Oil and gas leakage from Damper unit Low tire pressure Rear wheel wobbles Bent rim Worn rear axle holder bearings Bent rear axle Faulty tire Unbalanced tire or wheel Low tire pressure Faulty swingarm pivot bearings Hard suspension Bent damper rod High tire pressure Damaged swingarm pivot bearing Wheel turns hard Faulty rear axle holder bearings Bent rear axle Brake drug Rear suspension noisy Faulty rear shock absorber Loose fasteners 14-2 NSR150SP Rear Wheel/Suspension REAR WHEEL A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean Contaminated disc with a high quality brake degreasing agent. REMOVAL Loosen the rear wheel nuts. Raise the rear wheel off the ground using a safety stand or hoist. Remove the rear wheel nuts. Remove the rear wheel. I NSPECTlON WHEEL RIM Check the rim runout by placing the wheel in a turning stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is '/2 the total indicator reading. zyxwvut SERVICE LIMITS Radial: 2.0 m m (0.08 in) Axial: 2.0 mm (0.08 in) WHEEL BALANCE Emil Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Carefully checkbalance before reinstalling the wheel. NOTE The wheel balance must be checked when the tire is Remounted. For optimum balance, the tire balance mark (a paint dot On the side wall) must be located next to the valve stem. Remount the tire if necessary. Mount the wheel, tire and brake disc assembly on an inspection stand. Spin the wheel, allow it to stop, and mark the lowest (heaviest) part of the wheel with chalk. Do this two or three times to verify the heaviest area. If the wheel is balanced, it will not stop consistently in the same position. To balance the wheel, install balance weights on the lightest side of rim, the side opposite the chalk marks. Add just enough weight so the wheel will no longer stop in the same position when it is spun. Do not add more than 60 grams (2.1 oz) to the rear wheel. Rear Wheel/Suspension NSR150SP INSTALLATION Clean and apply grease to the rear axle and wheel mating surface. Install the rear wheel to the rear axle. Install the washers and rear wheel nuts. Tighten the rear wheel nuts to the specified torque. TORQUE: 108 N.m (11.0 kgf-m, 80 Ibf-ft) BEARING HOLDER/DRIVEN FLANGE Em A contaminated brake disc or pad reduces stopping power. Discard contaminatedpads and clean contaminated disc with a high-qualitybrake degreasing agent. ~~ ~~ REMOVAL Loosen the bearing holder pinch bolt and turn the holder to loosen the drive chain. Remove the rear wheel (page 14-3). Remove the drive chain from the drive sprocket. When the final driven flange assembly is ready to be disassembled, loosen the driven sprocket nuts, but do not remove them. Unstake and loosen the rear axle nut. Remove the rear axle nut and washer. Remove the rear brake caliper (page 15-11). Remove the final driven flange assembly and rear axle/brake disc assembly. 14-4 NSR150SP Rear Wheel/ Suspension Remove the snap ring and washer. Remove the bearing holder and bracket. DISASSEMBLY REAR AXLUBRAKE DISC Remove the rear brake disc nuts and bolts. Remove the rear brake disc from the rear axle. FINAL DRIVEN FLANGE Remove the snap ring from the groove on the final driven flange. 14-5 NSRl50SP Rear Wheel/Suspension Remove the driven sprocket and final driven hub from the final driven flange. Remove the nuts, washers and driven sprocket from the final driven hub. BEARING HOLDER Remove the collar from the left side of the bearing holder. Remove the dust seal from the left side of the bearing holder. 14-6 NSRl50SP Rear Wheel/Suspension Remove the dust seal from the right side of the bearing holder. Remove the stop ring from the left side of the bearing holder. Remove the stop ring from the right side of the bearing holder. Bearing replacement (page 14-8). INSPECTlON BEARING HOLDER Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the bearing holder. Remove and discard the bearings if the races do not turn smoothly and quietly, if they fit loosely in the bearing holder. NOTE Replace the holder bearings in pairs. 14-7 NSR150SP Rear Wheel/Suspension FINAL DRIVEN FLANGE Check the damper rubber for wear or damage. Replace if necessary. NOTE Replace the damper rubber as a set. HOLDER BEARING REPLACEMENT REMOVAL Remove the ball bearing from the left side of the bearing holder using the special tools. TOOLS: Driver 07749-0010000 Attachment, 37 X 40 mm 07746-0010200 Pilot, 40 mm 07746-0040900 Remove the needle bearing from the right side of the bearing holder using the special tools. TOOLS: Driver 07749-0010000 Attachment, 52 X 55 mm 07746-0010400 INSTALLATION Apply grease to the new dust seal lips. Install the new dust seal to the needle bearing groove. Install the new needle bearing with its dust seal end facing inside. 14-8 NSR150SP Rear Wheel/Suspension Press the new needle bearing in the right side of the bearing holder using the special tools. TOOLS: Driver 07749-0010000 Attachment, 62 X 67 mm 07746-0010500 Bearing Install the new ball bearing to the left side of the bearing holder using the special tools. TOOLS: Driver 07749-0010000 Attachment, 62 X 67 mm 07746-0010500 Pilot, 40 mm 07746-0040900 ASSEMBLY Bearing Holder Pinch Bolt racket Rear Axle Nut 226 N.m (23.0 kgf-m, 166 Ibf.ft) ear Brake Disc Final Driven Needle Bearing 14-9 zy Rear Wheel/ Suspension NSRl50SP BEARING HOLDER Install the stop ring to the right side of the bearing holder. Install the stop ring to the left side of the bearing holder. Apply grease to the new dust seal lip. Install the new dust seal to the left side of the bearing holder. Apply grease to the new dust seal lip. Install the new dust seal to the right side of the bearing holder. 14-10 NSRl50SP Rear Wheel/Suspension Install the collar to the left side of the bearing holder. REAR AXLUBRAKE DISC Install the rear brake disc with its marking side facing the right side. Install the rear brake disc bolts and nuts. Install and tighten the rear brake disc nuts to the specified torque. TORQUE: 34 N-m (3.5 kgf.m, 25 Ibf.ft) FINAL DRIVEN FLANGE Install the driven sprocket to the final driven hub with its marking side facing out. Install the washers and driven sprocket nuts. NOTE *Tighten the driven sprocket nuts after installing the driven flange to the frame. 14-11 NSR150SP Rear Wheel/Suspension Install the driven sprocket and final drive hub to the final driven flange. Install the snap ring to the groove on the final driven flange. INSTA LLATlON Install the bracket to the swingarm aligning the groove onto brackets to the tab on the swingarm. Install the bearing holder to the swingarm. 14-12 NSR150SP Rear Wheel/Suspension Install the washer and snap ring. Install the rear axle/brake disc assembly and final driven flange assembly to the bearing holder. Install the rear brake caliper (page 15-20). Apply oil to the new rear axle nut threads and flange surface. Install the washer and new rear axle nut. Tighten the rear axle nut to the specified torque . TORQUE: 226 N.m (23.0 kgf.m, 166 1bf.ft) Stake the rear axle nut. Install the final driven flange assembly to the rear axle. If driven sprocket is removed from the final driven hub, tighten the driven sprocket nuts to the specified toque. TORQUE: 30 N.m (3.1 kgf.rn, -22 Ibf-ft) Install the rear wheel (page 14-4). Adjust the drive chain slack (page 3-17). Tighten the bearing holder pinch bolt to the specified torque. TORQUE: 73 N.rn (7.4 kgf-m, 54 Ibf-ft) 14-13 NSRl50SP Rear Wheel/Suspension SHOCK ABSORBER mI The shock absorber contains nitrogen under high pressure. Do not allow fire or heatnear the gas containing shock absorber. REMOVAL Remove the side cover (page 2-6). Remove the battery case (page 16-6). Raise the rear wheel off the ground using a safety stand or hoist. Remove the shock absorber lower mounting nut/bolt. Remove the shock absotber upper mounting bolt. Remove the shock absotber. Em Do not try to disassemble the shock absorber or more. INSPECTlON Check the damper unit deformation or oil leakage and replace if necessary. Check the damper rod for straightens. Also check for stepped wear and replace if necessary. Check the bushing for wear or damage and replace if necessary. 14-14 NSR150SP Rear Wheel/Suspension SHOCK ABSORBER - DISPOSAL PROCEDURE Center punch the shock absorber to mark the drilling point. Place the shock absorber inside a plastic bag and it upright in a visa. Through the open end of the bag, insert a drill motor with a sharp 2 - 3 mm (5/64- 1/8 in) drill bit. Warp the bag around the drill and hold it closed. Use a sharp drill bit to minimize heat. Build up. mu Using a dull drill bit allows a build-up of excessive heat and pressure inside the damper which may cause an explosion. The shock absorber contains nitrogen gas and under high pressure. Drilling farther into the damper case than specified can puncture the oil chamber. Oil escaping under high pressure may cause serious injury. Always wear eye protection to avoid getting metal shaving in your eyes when gas pressure is released. NOTE - The plastic bag is only intended to shield you from the escaping gas. Briefly run the drill motor inside the bag; this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start. INSTALLATION Install the shock absorber. Install and tighten the shock absorber upper mounting bolt to the specified torque. TORQUE: 44 N.m (4.5 kgf.m, 33 Ibf-ft) Install the shock absorber lower mounting bolt and nut. Tighten the lower mounting bolt to the specified torque. TORQUE: 44 N.m (4.5 kgf-m, 33 Ibfft) Install the battery case (page 16-6). Install the side cover (page 2-7). 14-15 Shock Absorber B5m Drilling Point NSRl50SP Rear Wheel/Suspension SWINGARM REMOVAL Remove the rear wheel (page 14-3). Remove the rear brake caliper (page 15-10). Remove the drive chain from the driven sprocket. CAUTION Do not suspend the brake caliper from the brake hose.Do not twist the brake hose. NOTE Do not operate the brake pedal after removing the caliper and rear wheel. To do so will cause difficulty in fitting the brake disc between the brake pads. Remove the shock absorber lower mounting nutlbolt. Remove the screws and brake hose cover. NOTE Be careful not to damage the tabs on the brake hose cover and grooves on the drive chain cover. Remove the brake hose from the guide and clamp. Remove the bolt. 14-16 Rear Wheel/Suspension NSR150SP Remove the bolts and drive chain cover. Remove the swingarm pivot covers. Remove the swingarm pivot nut. Remove the swingarm pivot bolt and swingarm. 14-17 Rear Wheel/ Suspension NSR150SP DISASSEMBLY Remove the bearing holder and driven flange (page 14-5). Remove the bolts and chain guard. Remove the screws and collars. Remove the tabs on the drive chain slider from the holes on the swingarm. Remove the hole on the drive chain slider from the tab on the swingarm. Remove the drive chain slider. Inspect the drive chain slider for excessive wear. Replace the drive chain slider if it is worn to wear indicator (page 3- 19 ). 14-18 NSR150SP Rear Wheel/Suspension Remove the right pivot collar and dust seal. Remove the dust seal, left pivot collar and swingarm pivot collar. INSPECTlON Check the pivot collars for wear or damage and replace if necessary. Cheek the dust seals for wear or damage and replace if necessary. Check the needle and ball bearings for damage or loose fit and replace if necessary. Check the swingarm for deformation, cracks or other damage and replace if necessary. 14-19 NSRl50SP Rear Wheel/Suspension BEARING REPLACEMENT REMOVAL Remove the snap ring from the pivot groove of the swingarm. Remove the right pivot ball bearings using the special tools. TOOLS: Driver shaft 07946-MJ00100 Remove the left pivot needle bearing using the special tools. Driver Shaft TOOLS: Driver shaft 07946-MJ00100 Bearing remover attachment 07LMC- KV3020O INSTALLATION Apply grease to the new left pivot needle bearing. Press the new left pivot needle bearing into the swingarm so that the needle bearing outer surface is 5.5 mm (0.22 in) below the outer edge of the swingarm pivot bearing cavity. TOOLS: Driver 07749-001OOOO Attachment, 32 X 35 mm 07746-0010100 NOTE Press the needle bearing in with the stamped side facing out. 14-20 Bearing 5.5rnm (0.22 i n d Rear Wheel/Suspension NSRl50SP Apply grease to the new right pivot ball bearings. Press the new right pivot ball bearings into the swingarm one at a time until they are fully seated. TOOLS: zyxwvut Driver 07749-0010000 Attachment, 32 X 35mm 07746-0010100 Pilot, 15mm 07746-0040300 NOTE Press the ball bearings in with the stamped side facing out. Install the snap ring to the pivot grooves of the swingarm. Drive Chain 5.1 N.@ (3.8 lbf.ft) t Drive Chain Slider Left Swingarm Pivot Collar Left Dust Seal Needle Bearing zyx zyxw Ball Bearine Collar Right Dust 6 f Right Swing Arm Pivot C h a r Drive ChaiA Guard 14-21 NSRl50SP Rear Wheel/Suspension ~~ install the swingarm pivot collar, left pivot collar and dust seal. Install the dust seal and tight pivot collar. Install the drive chain slider aligning the hole on the chain slider with the tab on the swingarm. Install the tabs on the chain slider to the holes on the swingarm. 14-22 Rear Wheel/Suspension NSR150SP Install the collars and drive chain slider screws. Tighten the drive chain slider screws to the specified torque. TORQUE: 5.1 N.m (0.52 kgf.m, 3.8 Ibf.ft) Install the chain guard. Install and tighten the bolts securely. Install the bearing holder (page 14-12). zyxwvutsrq INSTALLATION NOTE .Route the tubes and wires properly (page 1-18). Install the swingarm. Apply thin coat of grease to the swingarm pivot bolt. Install the swingarm pivot bolt. Install and tighten the swingarm pivot nut to the specified torque. TORQUE: 88 N.m (9.0 kgfm, 65 Ibf-ft) 14-23 NSR150SP Rear Wheel/ Suspension Install the swingarm pivot covers. Install the drive chain cover. Install and tighten the bolts securely. Install and tighten the bolt securely. Install the brake hose to the guide and clamp. 14-24 NSRl50SP Rear Wheel/Suspension Install the brake hose cover aligning the its tabs to the grooves on the drive chain cover. zyxwvutsrqp NOTE Be careful not to damage the tabs on the brake hose cover and grooves on the drive chain cover. Install and tighten the screws securely. Install the shock absorber lower mounting nut/bolt. Tighten the lower mounting bolt to the specified torque. TORQUE: 44 N.m zyxwvut (4.5 kgf.ni, 33 Ibf.ft) Install the rear brake caliper (page 15-20). Install the rear wheel (page 14-4). 14-25 Battery/Charging System NSR15OSP SYSTEM DIAGRAM zyxwvu 4=4 zyxwvut RegulatorIRectifier zyxwvutsrq I R - G: Green R: Red Y: Yellow W: White G - 16-0 Battery/Charging System NSR150SP SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING BAlTERY 16-0 16-1 16-3 16-5 CHARGING SYSTEM INSPECTION REGUIATOWRECTlFlER ALTERNATOR INSPECTION zyxw 16-6 16-9 16-10 SERVICE INFORMATION GENERAL The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an enclosed space. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. If electrolyte gets o your skin, flush with water. If electrolyte gets on your eyes, flush with water for at least 15 minutes and call a physician immediately. Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN zyxwvutsr ~ ~ Always turn off the ignition switch before disconnecting any electrical component. CAUTION zyxwvut zyxwvuts Some electrical components may be damaged if terminals or connectors are connected or disconnect while the ianition switch i s ON and a current is oresent. For extended storage, remove the battery, give it a full charge and store it in a cool, dry space. For battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal. . CAUTION Tap water will shorten the service life o f the battery. Immediately wash off any spilled electrolyte using a mixture baking soda and water. CAUTION Avoid filling the battery above the UPPER LEVEL line to prevent an electrolyte overflow which could corrode the engine or nearby parts. The battery can be damaged if overcharged or undercharges, or if left to discharge for long periods. These same conditions contribute to shortening the life-span of the battery. Even under normal use, the performance of the battery deteriorates after 2-3 years. Battery voltage may recover after battery charging, but under a heavy load, battery voltage will drop quickly and eventually the battery will be completely discharged. For this reason, the charging system is often suspected to be the problem. Battery overcharge often results in problems in the battery itself, which may appear to be an overcharge symptom. If one of the battery cells is shorted and the battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level drops quickly. Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is frequently under a heavy load, such as having the headlight and tail light ON for long periods of time without riding the motorcycle. BATTERYlCHARGING SYSTEM 16-1 Battery/Charging System NSR150SP Battery Charging System z The battery will self-discharge when the motorcycle is not use. For this reason, charge the battery every two weeks to prevent sulfation from forming. Filling a new battery with electrolyte will produce some voltage, but in order to achieve maximum performance, always charge the battery. Also, the battery life is lengthened when it is initial-charges. When checking the charge system, always follow the steps in the troubleshooting flow chart (page 16-3). Alternator servicing may be done with the engine in the frame. S PECI FlCAT1ONS ITEM zyxwv SPECIFICATIONS I Alternator rated outwt Alternator charging coil resistance (At 20 OW68 O F ) Regulatorhectifier: regulated voltage (At 20 "C/68O F ) Current leakage Battery capacity Battery type Battery charging rate Normal Quick 16-2 I 180 W/5.000 min-1 h r n l 0.1-1.oa 14.7k0.5V at 5,000 min-I (rpm) 1 mAmaximum 12 V -3A YB3L-A 0.3A/lOh 3N0.5h Battery/Charging System NSR150SP TROUBLESHOOTING BATTERY UNDERCHARGING (VOLTAGE NOT RAISED TO REGULATED VOLTAGE). Measure the charging voltage with the battery fully charged and in good condition (page 16-5). Check the battery current leakage (leak test, page 16-8) Correct Correct Incorrect Faulty Battery Standard regulated voltage is not reached when the engine speed increase. 4P connector and recheck the battery current leakage. Correct Incorrect Shorted wire harness Faulty ignition switch Faulty regulator/ rectifier Check the voltage between the battery line and ground line of the regulatorhectifier 4P connector (page 16-8) Incorrect Shorted wire harness Poorly connected connectors Incorrect Shorted wire harness Faulty charging coil Correct Check the resistance of the charging coil at the charging coil line of the regulator/rectifier 3P connector (page 16-9) Correct Faulty regulatorhedifier 16-3 zy NSR150SP Battery/Charging System BATTERY OVERCHARGING (REGULATED VOLTAGE TOO HIGH). Measure the charging voltage with the battery fully charged and in good condition (page 16-5). , ~ Correct Faulty Battery j Regulated voltage greatly exceeds the standard value 16-8). Poorly connected connectors I Correct Faulty regulatorlrectifier Poorly connected connectors 16-4 NSR150SP Battery/Charging System BATTERY REMOVAL . NOTE Always turn the ignition switch OFF before removing or installing the battery. If you disconnect the battery terminal, all memories of the trip meter are erased. Remove the right side cover (page 2-6). Remove the band and battery cover. NOTE Disconnect the battery negative cable first, then positive cable from the battery. Remove the bolt and battery negative cable Remove the positive cable cover. Remove the bolt and battery positive cable. Disconnect the battery breather tube. Remove the battery. INSTALLATION Installation is in the reverse order of removal. - NOTE Apply clean grease to the battery terminals. Pull the cover over the positive terminal. INSPECTlON Measure the battery voltage using a commercially available Digital multimeter Voltage: Fully charged: 11-13V Under charged: Below 1OV 16-5 -----‘RwL%EL- z NSR150SP BATTERY CHARGING . zy zyxwvuts Battery / Charging System The battery gives off explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation when charging. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes ma cause severe burns. Wear protective clothing and a face shield. if electrolyte gets on your skin, flush with water If electrolyte gets on your eyes, flush with water for at least 15 minutes and call a physician. Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. Turn power ON/OFF at the charger, not at the battery terminals. zyxwvutsrq Remove the battery (page 16-5) Con nect the charger positive (+) cable to the battery positive (+) terminal Connect the charger negative (+) cable to the battery negative (+) terminal. Charging c urrentltime Standard: 0.3AAOh Quick: 3Al0.5h CAUTION Quick-charging should only be done in an emergency; slow charging is preferred. For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery. BATTERY CASE REMOVALANSTALLATION Remove the battery (page 16-5). Remove the bolts and battery case. Remove the battery breather tube from the clamp on the battery case. Installation is in the reverse order of removal. NOTE Route the tubes and wire harnesses properly (page 1-18). 16-6 NSR150SP Battery/Charging System CHARGING SYSTEM INSPECTION NOTE Measuring circuits with a large capacity that exceeds the capacity of the tester may cause damage to the tester. Before starting each test, set th e tester at the high capacity range first, the gradually down to low capacity ranges in order to ensure that you have the correct range and do not damage the tester. When measuring small capacity circuits, keep the ignition switch off. If the switch is suddenly turned on during a test, the tester fuse may blow. REGULATED VOLTAGE INSPECTION If the engine must be running to do some work, make sure the area i s well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Remove the battery (pagel6-5) and install the fu Ily charged battery. Start the engine and warm it up to the operating temperature; stop the engine. Connect the multimeter between the positive and negative terminals of the battery. zyxwvutsrqpon CA U TlON To prevent short, make absolutely certain which are the positive and negative terminals or cable. Do not disconnect the battery or any cable in the charging system without first switching o f f the ignition switch. Failure to follow this precaution can damage the tester or electrical components. zyxwvu With the headlight ON (Lo beam), restart the engine. Measure the voltage on the multitester when the engine runs at 5,000 min-I (rpm). Regulated voltage: 14.7 k OSV15,OOO min-I (rpm) The battery is normal if the voltage reads the regulated voltage on the tester. NOTE zyxwvutsr The speed at which voltage starts to rise cannot be checked as it varies with the temperature and loads of the generator. 16-7 NSR150SP Battery/Charging System A frequently discharges battery is an indication that it is deteriorated even if it proves normal in the regulated voltage inspecti on. The charging circuit may be abnormal if any of the following symptoms is encountered I .... Normal Charging Voltage zyxwvuts zyxwvutsrqponmlkjihgfedcbaZ 2 Control Voltage - ~ zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGF Battery Voltage 2W 0 a 1. Voltage not raised to regulated voltage (page 16-3) > F - Open or shorted circuit in the charging system wire harness or poorly I 0 2. Regulated voltage too high (page 16 -4) 0 -I Abnormal Charging Voltage Poorly grounded voltage regulator/rectifier Faulty battery Faulty regulatorhectifier i CURRENT LEAKAGE TEST Remove the battery cover (page 16-5). Turn the ignition switch off, and disconnect the ground (-) cable from the battery. Connect the ammeter (+) probe to the battery ground cable and the ammeter (-) probe to the battery (-) terminal. With the ignition switch off, check for current leakage. NOTE When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range selected may blow out the fuse in the tester. While measuring current, do not turn the ignition on. A sudden surge of current may blow out the fuse in the tester. Specified current leakage: 1 mA max. If current leakage exceeds the specified value, a shorted circuit is likely. Locate the short by disconnecting connections one by one and measuring the current. 16-8 I zyxwvuts Battery/ Charging System NSR150SP REGULATOR I RECTIFIER WIRE HARNESS INSPECTION Remove the side cover (page 2-6). Disconnect the regulator/rectifier 5P connector. Check the connector for loose or corroded terminals. BATTERY LINE Make sure the battery voltage between Red (+) and Green (-). If there are no voltage, measure the followings: 1 I Item Battery charging line Ground line I Terminals I Red (+) and ground.(-) Green and around 1 I Specification I Battery voltage should regist& Continuity exists CHARGING LINE NOTE It is necessary to remove the stator coil to complete this test. zyxwvu Measure the resistance between the 5P connector terminals and ground. Connection: Yellow and Yellow Standard: 0.1 - 1.0 R (20 "C168 OF) If the charging coil reading is out of specification, check the alternator (page 16-10). 16-9 NSR150SP zyxwvu Battery / Charging System Check for continuity between the 5P connector terminals and ground. There should be no continuity. If there is continuity between the 5P connector and ground, check the alternator (page 16-10). If the charging coil reading is out of specification, check the alternator (page 16-10) Check for continuity between the 5P connector terminals and ground There should be no continuity. If there is continuity between the 5P connector and ground, check the alternator (page 16-10). 16-10 Battery/Charging System NSR150SP REMOVAL INSTALLATION zyxwvut Remove the right side cover (page 2-6) Disconnect the regulatorhectifier 5P connector Remove the bolts and regulatorhectifier unit Installation is in the reverse order of removal Remove the bolts and regulator/rectifier unit. Installation is in the reverse order of removal. NOTE Route the wire harness properly (pagel-18). ALTERNATOR INSPECTION NOTE Refer to section 11 alternator rernovallinstallation. ove the fuel tank (page 1-12). Disconnect the alternator 3P connector. Measure the resistance between the 3P connector terminals and ground. Connection: Yellow and Yellow If the charging coil reading is out of specification, replace the stator (page 11-12). Check for continuity between the 3P connector terminals and ground. There should be no continuity. If the there is continuity between the 3P connector and ground, replace the stator (page 11-2). 16-11 NSR150SP Battery/ Charging System Remove the fuel tank (page 2-12) Disconnect the alternator 3P connector. Measure the resistance between the 3P connector terminals and ground. Connection: Yellow and Yellow Standard: 0.1 - 1.0 ohms (20 OC 68' F) If the charging coil reading is out of specification, replace the stator (page 11-2). zyxwvu Check for continuity between the 3P connector terminals and ground. There should be no continuity. If there is continuity between the 3P connector and ground replace the stator (page 11-2). 16-12 Ignition System NSR15OSP SYSTEM DIAGRAM Ignition Switch Engine Stop Switch A Fuse 10A zyxwvut - Engine Stop Switch 0 zyxwvutsrqp BI: BLACK Ignition Pulse Generator G: GREEN Bu: BLUE Lg: LIGHT GREEN R: RED w: WHITE Y: YELLOW 17-0 Ignition System NSR15OSP SYSTEM DIAGRAM 174 IGNITION 17-6 SERVICE INFORMATION 17-1 ICM REMOVAUINSTALLATION 17-7 TROUBLESHOOTING 17-3 IGNITION 17-7 IGNITION SYSTEM INSPECTION 17-4 SERVICE INFORMATION GENERAL If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of the consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system i n an enclosed area. Some electrical components may be damaged If terminals or connectors are connected or disconnected while the ignition switch is ON and a current is present. When checking the ignition system, always follow the steps in the troubleshooting (page 17-3). Ignition timing cannot be adjusted since the Ignition Control Module (EM) is nonadjustable. If ignition timing is incorrect, check the system components and replace any faulty parts. The ICM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the resulting excessive voltage may damage the unit. Always turn off the ignition switch before servicing. A faulty ignition system is often related to poorly connected or corroded connectors. Check those connections before proceeding. Make sure the battery is adequately charged. Using the starter motor with a week battery results in a slower engine cranking speed as well as no spark at the spark plugs. Use spark plugs of the correct heat range. Using a spark plug of an incorrect heat range can damage the engine. For ignition pulse generator removal/installation see section 16. For neutral switch inspection and removaI/installation see section 19. For engine stop switch inspection and removaMnstallation see section 13,19. For ignition switch inspection see section 13, 19. zyxw 17-1 Ignition System NSR150SP SPECIFICATIONS zyxwv TORQUE VALUES Timing hole cap 3 N.m (0.3 kgf.m, 2.2 Ibf4t) Ignition pulse generator socket bolt 10 N.m (1 .O kgf.m, 7 Ibf4t) Apply a locking agent to the threads Ignition coil mounting bolt 12 N.m (1.2kgf.m, 9 Ibf.ft) TOOLS Peak voltage adaptor 07HGJ-020100 lmrie diagnostic tester (model 625) 17-2 NSR15OSP TROUBLESHOOTING 0 zyxwvu Ignition System Inspect the following before diagnosing the system. Faulty spark plug Loose spark cap or spark plug wire connections Water got into the spark plug cap (Leaking to the ignition coil secondary voltage) If there is no spark at either cylinders, temporarily exchange the ignition coil with the other good one and perform the spark test. If there is a spark, the exchanged ignition coil is faulty. NO SPARK AT SPARK PLUG Unusu condition Ignition coil Low peak primary voltage voltage Probable cause (Check in numerical order) 1 . Incorrect peak voltage adaptor connections 2. Multimeter impedance is too low; below 10 MWDCV 3. Cranking speed is too slow (Operating force of the kickstarter is weak) 4. The sample timing of the tester and measured pulse were Ignition pulse generator not synchronized (system is normal if measured voltage is over the specifications at least once) 5. Poorly connected connectors or an open circuit in ignition system 6. Faulty side stand switch or neutral switch 7. Faulty ignition coil 8. Faulty ignition control module (ICM) (in cases when above No. 1-7 are normal) No peak voltage 1. Incorrect peak voltage adaptor connectors 2. Faulty ignition switch or engine stop switch 3. No voltage at the power source wire between B I N (+) and ground (-) of the ICM, or loose or poorly connected ICM connectors 4. Poor connection or open circuit in G wire of the ICM 5. Faulty neutral switch 6. Faulty peak voltage adaptor 7. Faulty ignition pulse generator 8. Faultv ICM (in cases when above No. 1-7 are normal) Peak voltage is 1. Faulty spark plug or leaking ignition coil secondary current normal, but no ampere spark jumps at 2. Faulty ignition coil Plug Low peak 1. Multimeter impedance is too low; below 10 MWDCV voltage 2. Cranking speed is too slow (Operating force of the kickstarter is weak) 3. The sample timing of the tester and measured pulse were not synchronized (System is normal if measured voltage is over the specifications at least once) 4. Faulty ignition pulse generator (in cases when above No.1 -3 are normal) No peak voltage 1. Faulty peak voltage adaptor 2. Faulty ignition pulse generator zyx 17-3 Ignition System NSR150SP IGNITION SYSTEM INSPECTION ,,'- - - - - - - , 7 NOTE . If there i s n o spark at the plug, check all connections for loose or poor contact before measuring each peak voltage. Use the recommended digital multimeter or commercially available digital multimeter with an impedance of 10 MQlDCV minimum. The display value differs depending upon the internal impedance of the multimeter. If using lmrie diagnostic tester (model 625), follow the manufacturer's operating instructions. Connect the peak voltage adaptor to the digital multimeter, or use the lmrie diagnostic tester. TOOLS: lmrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ0020100 with Commercially available digital multimeter (imped ance 1OMWDC minimum) IGNITION PRIMARY VOLTAGE INSPECTION NOTE Check all system connection before the inspection. If the system is disconnected, an incorrect peak voltage will register. Check cylinder compression at each cylinder and check that the spark plugs are installed correctly in each cylinder. Support the motorcycle using the side stand. Disconnect the spark plug cap from the spark plug on the cylinder head (page 17-6). Connect a good known spark plug to the spark plug cap and ground the spark plug to the cylinder as done in a spark test. Remove the fuel tank (page 2-12). 17-4 z DlgitalMultitester NSR150SP Ignition System Connect the peak voltage adaptor or lmrie tester to the ignition coil primary terminal. NOTE Do not disconnect the ignition coil primary wires. TOOLS: lmrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with Commercially available digital multimeter (impedance) 1OMWDCV minimum) CONNECTION: - BlacklYellow (+) Body ground (-) Turn the ignition switch “ON” and engine stop switch to “RUN”. Shift the transmission into neutral. Crank the engine with the kickstarter and read the ignition coil primary voltage. PEAK VOLTAGE: 100 V minimum Avoid touching the spark plug and tester probes to prevent electric shock. If the peak voltage is lower than the standard value, follow the checks described in the troubleshooting on page 17-3. IGNITION PULSE GENERATOR PEAK VOLTAGE INSPECTlON Remove the pillion seal (page 2-3). NOTE Check all system connection before the inspection. If the system is disconnected, an incorrect peak voltage will register. Check cylinder compression at each cylinder and check that the spark plugs are installed correctly in each cylinder. Disconnect the ICM 4P connector. Connect the peak voltage adaptor to the 4P connector wire hamess side. TOOLS: zyxw lmrie diagnostic tester (model 625) or 07HGJPeak voltage adaptor 0020100 with Commercially available digital multimeter (impedance IOM R DCV minimum) CONNECTION: - GreedWhite (+) Green (-) 17-5 Ignition System NSR15OSP Turn the ignition switch “ON” and engine stop switch to “RUN”. Shift the transmission into neutral. Crank the engine with the kickstarter and read the ignition pulse generator peak voltage. PEAK VOLTAGE: 0.7 V minimum Avoid touching the spark plug and tester probes to prevent electric shock. If the peak voltage is lower than standard value, perform the following procedure. Remove the fuel tank (page 2-12). Disconnect the ignition pulse generator 2P connector. Turn the ignition switch “ON” and engine stop switch to RUN . Shift the transmission into neutral. Crank the engine with the kickstarter and measure the peak voltage at the 2P connector ignition pulse generator side and record it. “ ” - CONNECTION: Greenwhite (+) BluelYellow (-) PEAK VOLTAGE: 0.7 V minimum Compare their values at the ICM 4P connector and the ignition pulse generator 2P connector. If the value at the ignition pulse generator is normal, but abnormal at the ICM: Open circuit in the ignition pulse generator wires Loosen connection in the ignition pulse generator connector If both values are abnormal: The ignition pulse generator is likely to be faulty. Check and perform troubleshooting on page 17-3. IGNITION COIL REMOVALANSTALLATION Remove the fuel tank (page 2-12). Disconnect the spark plug cap from the spark plug. 17-6 zyxw zy Ignition System NSR15OSP Disconnect the ignition coil primary wires from the terminals. Remove the bolts and ground wire eyelet. Remove the ignition coil. Installation is in the reverse order of removal. TORQUE: 12N.m(l.2kgf-m, 9 Ibf-ft) NOTE Route the spark plug wires properly (page 1-18). ICM REMOVAL /INSTALLATION Remove the pillion seat (page 2-3). Disconnect the ICM 2P and 4P connectors. Disconnect the ICM 2P (Black) and 4P (Black) connectors. Remove the ICM from the bracket. Installation is in the reverse order of removal. IGNITION TIMING 2P (Black) and 4P (Blac If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of the consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. NOTE Read the manufacturer’s operating instructions for the timing light. Warm up the engine. Stop the engine. Remove the side cowl and lower cowl (page 2-4). Remove the timing hole cap. 17-7 Ignition System NSR15OSP zyxwvut Connect a timing light to the spark plug wire. Start the engine and let it idle. IDLE SPEED: 1,300 k 100 m i d (rpm) The timing is correct if the “F” mark on the flywheel aligns with the index mark on the left crankcase cover. Increase the engine speed by rotating the throttle stop control knob. The timing is correct if the advance marks on the flywheel aligns with the index mark on the left crankcase cover. Coat the new O-ring with engine oil and install it in the timing hole cap groove. Apply molybdenum disulfide oil to the timing hole cap threads and flange surface. Install and tighten the timing hole cap to the specified torque. 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 To print chapters, click on the printer icon and fill in the page range. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 16. 17. General Information Frame/Body panels/Exhaust system Maintenance Lubrication system Fuel system Cooling system Engine removal/Installation Cylinder head/Cylinder/Piston RC Valve/Servo motor Clutch/Gearshift linkage/Kickstarter Alternator/Balancer Crankshaft/Transmission Front Wheel/Suspension/Steering Rear Wheel/Suspension Battery/Charging system Ignition System 5 - 26 27 - 42 43 - 69 70 - 80 81 - 96 97 - 110 111 - 119 120 - 134 135 - 145 146 - 171 172 - 180 181 - 199 200 - 234 235 - 260 261 - 273 274 - 281 HONDA MPE MOTORCYCLE & POWER EQUIPMENT ACN.006 662 862 Service Bulletin Service Bulletin No: SBMC0549 To: All Motorcycle Franchises From Motorcycle Service Department Date: December 2005 Attention: Franchisee, Service Manager, Sales Manager and Relevant Staff Subject: NSR150SP Spark Plug Application – Additional Information to SBMC0311 Ladies and Gentlemen, Please be advised that when servicing the NSR150SP, it is important to use the correct spark plug. The current specification is incorrect and in some cases may lead to severe engine damage. The B-8ES and the B-9ES are 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 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 channels. It is also important to note that the spark plug must be removed, inspected and the spark plug gap adjusted at 2,000 klm intervals and the plug replaced at 4,000 klm intervals. *** Additional Information: When ordering the correct replacement spark plug for the NSR150SP from the Honda MPE spare parts department, please ensure that P/N: 9807959812 is used. This spark plug has a removable cap that will need to be removed to fit the standard spark plug caps that come fitted to the NSR150SP.*** GREG SNART National Motorcycle Service Manager PLEASE ENSURE ALL RELEVANT STAFF ARE AWARE OF THIS BULLETIN AND IT’S CONTENTS. Service Manager Parts Manager Sales Manager Franchise Principle HONDA MPE MOTORCYCLE & POWER EQUIPMENT ACN.006 662 862 Service Bulletin Service Bulletin No: SBMC0312 To: All Motorcycle Franchises From Motorcycle Service Department Date: September 2003 Attention: Franchisee, Service Manager, Sales Manager and Relevant Staff Subject: NSR 150 SP Important Service Information. Ladies and Gentlemen, The following information has been revised and updated for the Pre Delivery and Scheduled Servicing of the NSR 150 SP. Pre Delivery Inspection. Transmission Oil: To ensure the correct level is obtained, the transmission oil must be drained completely and refilled. Please ensure the correct amount oil of 0.7l and the correct oil viscosity of 10w-40 rated SE, SF or SG are used. Oil Pump: The 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 equivalent premium grade oil. L/H Hand Grip: It may also be necessary on some units to secure the L/H hand grip Scheduled Servicing. Maintenance should be carried out as per the service schedule with the following exception. The spark plug must be removed, inspected and the spark plug gap adjusted at 2,000 klm intervals and the plug replaced at 4,000 klm intervals. It is important to understand that the NSR 150 SP, is a motorcycle that requires a higher maintenance schedule, due to the nature of the single cylinder, 2-stroke design. Please ensure all of your NSR 150 customers are aware of the need to run a premium quality 2stroke engine oil and the shorter service intervals, required for this model. GREG 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 HONDA MPE MOTORCYCLE & POWER EQUIPMENT ACN.006 662 862 Service Bulletin Service Bulletin No: SBMC0311 To: All Motorcycle Franchises From Motorcycle Service Department Date: September 2003 Attention: Franchisee, Service Manager, Sales Manager and Relevant Staff Subject: NSR 150 Spark Plug Application Ladies and Gentlemen, Please be advised that when servicing the NSR 150 SP, it is important to use the correct spark plug. The current specification is incorrect and in some cases may lead to severe engine damage. The B-8ES and the B-9ES are 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 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 channels. It is also important to note that the spark plug must be removed, inspected and the spark plug gap adjusted at 2,000 klm intervals and the plug replaced at 4,000 klm intervals. GREG SNART National Motorcycle Service Manager PLEASE ENSURE ALL RELEVANT STAFF ARE AWARE OF THIS BULLETIN AND IT’S CONTENTS. Service Manager Parts Manager Sales Manager Franchise Principle HONDA MPE MOTORCYCLE & POWER EQUIPMENT ACN.006 662 862 Service Bulletin Service Bulletin No: SBMC0209 To: All Motorcycle Franchises From Motorcycle Service Department Date: 6th April 2002 Attention: Franchisee, Service Manager, Sales Manager and Relevant Staff Subject: Important Service Tip Ladies and Gentlemen, Please be advised that when pre-delivering or servicing the NSR150SP make sure the correct amount of oil is placed in the gearbox. The most accurate way in doing this 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 THE OIL LEVEL THROUGH THE SIGHT GLASS CAN GIVE AN INACCURATE OIL LEVEL READING, AS THE OIL TAKES A WHILE TO SETTLE. Make sure a measured 700ml of oil is put in the gearbox, and you should have no problem with correct gearbox oil levels. Thank you for your co-operation. GREG SNART National Motorcycle Service Manager PLEASE ENSURE ALL RELEVANT STAFF ARE AWARE OF THIS BULLETIN AND IT’S CONTENTS. Service Manager Parts Manager Sales Manager Franchise Principle