NSR150$P General Information

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTENTS
GENERAL INFORMATION 1
FRAME/BODY PANELS/EXHAUST SYSTEM 2
MAINTENANCE 3
LUBRICATION SYSTEM 4
FUEL SYSTEM 5
COOLING SYSTEM 6
Lu ENGINE REMOVAL/INSTALLATION 7
E CYLINDER HEAD/CYLINDER/PISTON 8
Lu RC VALVE/SERVO MOTOR 9
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER 1 0
ALTERNATOR/BALANCER 1 1
CRANKSHAFT/TRANSMISSION 12
9 FRONT WHEEL/SUSPENSION/STEERING 13
g REAR WHEEL/SUSPENSION 14
5 1 5
a: BATTERY/CHARGING SYSTEM 16
E IGNITION SYSTEM 17
E 18
_l
I" 1 9
20

 

 

 

NSR 1 SOSP Ge ne ral 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 iniormation contained in this manual is based on the latest product information available at the time of pri ing.
Honda Australia Motorcycle 8. 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 iorm by any means, electronic. mechanical, photocopying or
recording or otherwise, without the prior written permission of Honda Motorcycle 8. Power Equipment Pty. Ltd.. andlor
Honda Motor Co Ltd. Japan.

This includes test. figures and tables.
HONDA MOTOR 00., LTD
Service Publications Office

 

 

 

 

 

IMPORTANT SAFETY NOTICE

 

mm

A Indicate a strong possibility of severe personal injury or death it instructions are not followed.
CAUTION Indicate a possibility of personal injury or equipment damage if instructions are not followed.
NOTE: Gives helplul inlormation

Detailed descriptions of standard workshop procedures, salety 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 satist himself thoroughly that neither personal salety nor vehicle safety will be jeopardised by the
service methods or tools selected.

 

1-1

 

NSR 1 SOSP

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.

 

9:"

Replace the part (5) with new one (s) before assembly.

 

"7|

Use recommended engine oil, unless otherwise specified.

 

75

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 NLG|#2 or
equivalent).

 

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide,

NLG|#2 or equivalent).

Example: Molykote ® BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-Z manufactured by Mitsubishi Oil Japan.

 

Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide,
NLG|#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, UK.

Rocol Paste manufactured by Sumico Lubricant, Japan

 

Use Silicone grease.

 

Apply a locking agent. Use a middle strength-locking agent unless othenlvise
specified.

 

Apply sealant.

 

Use brake fluid, DOT 4. Use the recommended brake fluid, unless othenlvise
specified.

 

 

 

Use Fork or Suspension Fluid.

 

1-2

 

NSRIBOSP General Information

 

 

 

 

 

 

 

 

 

 

 

General Salety 1-3 Torque Values 1-14

Service Rules 1-5 Tools 1-17

Model Identilication 1-6 Lubrication & Seal Points 1-18

Specification 1-7 Cable & Harness Routing 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 ol 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 pans become very hot and remain hot tor some time alter the engine is run. Wear insulated
gloves or wait until the engine and exhaust system have cooled belore handling these parts.

 

 

Used Engine / Transmission Oil

Used engine oil may cause skin cancer il repeatedly left in contact with the skin lor 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 alter handling used oil. KEEP our 0F REACH OF CHILDREN.

 

 

 

Brake Dust
Never use an air hose or dry brush to clean brake assemblies.

Warning

  

 

Inhaled asbeslos libers have been found to cause respiralory disease and cancel.

 

 

 

Brake Fluid

CAUTION:
. Spilling tluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these
parts whenever the system is serviced. KEEP our 0F REACH OF CHILDREN.

1—3

NSR 1 SOSP Ge ne ral 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.

Warning

  

 

. 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 tlame.

. Coolant (ethylene glycol) can cause some skin
REACH OF CHILDREN.

. Keep out ol reach or pets. Some pets are attracted to the smell and taste ol 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.

 

ation and is poisonous if swallowed, KEEP OUT OF

 

 

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 ol an unstable gas can cause a tire or explosion
resulting in serious injury.

. The shock absorber contains nitrogen under h'gh pressure. Allowing fire or heat hear the shock absorber
could lead to and explosion that could result in serious injury.

. Failure to release the pressure from a shock absorber belore disposing ol it may lead to a possible explosion
and serious injury 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

a The battery gives off explosive gases; keep sparks. flames and cigarettes away. Provide adequate ventilation
when charging.

a The battery cont hs sulluric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear
protective clothing and face Shield.

7 ll electrolyte gets on your skin, llush with water. - If electrolyte gets in your eyes, llush 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 our OF REACH OF CHILDREN.

 

 

1-4

NSR 1 SOSP Ge ne ral 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, O-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

NSR 1 SOSP General Information

 

Model Identification

 

(1) FRAME SERIAL NUMBER (2) ENGINE SERIAL NUMBER
The frame serial number is stamped The engine serial number is
On the right side of the steering head. Stamped on the right crankcase.

 

(3) CARBURETTOR IDENTIFICATION NUMBER
The carburettor identification number is stamped
carburettor body.

 

NSR 1 SOSP

General Information

 

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

General
ITEM SPECIFICATIONS
Overall length 1,972mm (77.6 in)
Overall width 683 mm (26.9 in )
DIMENSION Overall height 1,062mm (41.8 in )

Wheel base 1,337 mm (52.6 in )
Seat height 780 mm (30.7 in )
Foot peg height 325 mm (12.8 in)
Ground clearance 142 mm (5.6 in)
Dry Weight 122.4kg (269.8 lb)
Curb Weight 131 .4kg (239.7 lb)
Maximum Weight capacity 118kg (260.1 lb)
Frame Type Diamond
Front Suspension Telescopic fork

FRAME Fork Inner tube diameter 35 mm (1.4 in)
Fork fluid capacity (per leg) 322 cm (10.9 US oz, 11.3 Imp oz)
Front wheel travel 117 mm (4.6 in)
Steering head bearing Ball Bearing
Rear suspension Swingarm
Rear wheel travel 125 mm (4.9 in)
Rear damper Both side operation tube type
Damper / reservoir gas pressure 908 kPa (10kgf/cm , 142psi)
Pressurized gas material Nitrogen
Front tyre size 90/80—17 465
Rear tyre size 120/80-17 61 S
Front brake Hydraulic single disc
Rear brake Hydraulic single disc
Caster angle 25U 36’
Trail 91 mm (3.6 in)
Fuel Tank capacity 10.5 litre (2.8 US gal, 2.3 Imp gal)
Fuel Tank reserve capacity 2.7 litre (0.7 US gal, 0.6 Imp gal)
Bore and Stroke 59 mm x 54.5 mm (2.3 in x 2.1 in)
Displacement 149 cm (9.1 cu—in)

ENGINE Compression ratio 108 kPa (1 1 .0kgf cm ,156 psi) at

400min-‘ (rpm)

 

Port timing intake open

Reed valve controlled

 

Port timing intake close

Reed valve controlled

 

 

 

 

 

 

 

 

 

 

 

Port timing exhaust open - Hi 97.6U BBDC
- Low 73.9U BBDC
Port timing exhaust close - Hi 97.7U ABDC
Low 74.0U ABDC
Port timing scavenge open 62.6U BBDC
Port timing scavenge close 62.8U ABDC
Lubrication system Oil automatically mixed with gasoline
Oil pump type Plunger type
Cooling system Liquid cooled
Air filtration Urethane form
Crankshaft type Assemny type

 

 

Engine weight

 

23.9kg (52.7lb)

 

1-7

 

NSR 1 SOSP

General Information

 

General (cont..)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM SPECIFICATIONS

CARBURETTOR Carburettor type Piston Valve

Throttle bore 30 mm (1.2 in)

Clutch System Multi-plate, wet

Clutch operation system Cable operating
DRIVE TRAIN Transmission 6 speeds constant mesh

Primary reduction 2.954 (65/22)

Final reduction 2.857 (40/14)

Gear ratio 15‘ 2.916 (35/12)

Gear ratio 2"d 1.937 (31/16)

Gear ratio 3“1 1.470 (25/17)

Gear ratio 4‘h 1.210 (23/19)

Gear ratio 5‘h 1.043 (24/23)

Gear ratio 6‘" 0.916 (22/24)

Gearshift pattern Left foot operated return system

(1 N-2—3-4-5—6)

Ignition system DC—CDI

Charging system Triple phase output alternator
ELECTRICAL Alternator /capacity 188 W/5,000 min1 (rpm)

 

Regulator/rectifier type

Semi conductor type

 

 

Lighting system

 

Batte ry

 

1-8

 

NSR 1 SOSP

General Information

 

LUBRICATION SYSTEM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Unit: mm (in)
ITEM STANDARD SERVICE
LIMIT

Engine Oil Capacity 0.76 litre (0.83 US qt, 0.67 Imp, qt)
Recommended engine oil Honda 2—stroke oil or equivalent
Transmission oil At draining 0.7 litre (0.73 US qt, 0.62 Imp, qt)
capacity At disassemny 0.8 litre (0.85 US qt, 0.70 Imp, qt)
Recommended transmission oil Honda 4—stroke oil or equivalent API

Service Classification: SE,SF,or SG

Viscosity: SAE 10W740
FUEL SYSTEM

ITEM STANDARD

Carburettor identification number PE74A
Choke type Starting enrichment circuit system
Main yet #152
Slow )et #42
Air screw initial opening 2 turns out
Float level 19mm (0.7 in)
Idle speed 1,300 1100 min1 (rpm)
Throttle grip free play 2 7 6mm (0.08 7 0.24in)

 

 

 

COOLING SYSTEM

 

ITEM

STANDARD

 

Cooling capacity

Radiator and engine

1.2 Litre (1 .27US qt, 1.06 Imp qt)

 

 

 

Radiator cap relief pressure

1037137 kPa (1.171.4kgf/cm,16-21 psi)

 

 

Standard coolant concentration

 

 

50% mixture with soft water

 

1-9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NSR 1 50SP Ge ne ral Information
CYLINDER HEAD/CYLINDERIPISTON
Unit: mm (in)
ITEM STANDARD SERVICE
LIMIT
Cylinder compression 108kPa (11.0 kgf/cm , 156 psi
at 400 min'1 (rpm)
Cylinder head warpage 0.05 (0.002)
Cylinder ID. Code A 59.010 7 59.015 (2.3232 7 2.3234) 59.05 (5.325)
No mark 59.005 7 59.010 (2.3230 7 2.3232) 59.05 (5.325)
Code C 59.000 7 59.005 (2.3228 7 2.3230) 59.05 (5.325)
Cylinder out of round 0.05 (0.002)
Cylinder warpage 0.05 (0.002)
Piston mark direction “IN” mark facing toward the intake side
Piston pin O.D. Code A 58.965 7 58.970 (2.3215 7 2.3216) 58.92 (5.320)
Code B 58.960 7 58.965 (2.3213 7 2.3215) 58.92 (5.320)
Code C 58.955 7 58.960 (2.3211 7 2.3213) 58.92 (5.320)
Piston O.D. measurement point 12mm (0.5in) from the bottom
Piston pin hole |.D. 16.002 7 16.015 (0.6300 7 0.6305) 16.03 (0.631)
Cylinder-to-pision clearance 0.040 7 0.050 (0.0016 7 0.0019) 0.080 (0.0031)
Piston pin O.D. 15.994 7 16.000 (0.6927 7 0.6299) 15.98 (0.629)
Piston-to—piston pin clearance 0.002 7 0.021 (0.0001 7 0.0008) 0.04 (0.002)
Piston ring-io-ring groove clearance 0.12 (0.05)
Ring end gap Top 0.38 7 0.53 (0.015 7 0.021) 0.65 (0.026)
Second 0.387053 (0.01570.021) 0.65 (0.026)
Ring mark Top 3R
Second 4R
Connecting rod small end |.D. 20.002 7 20.014 (0.7875 7 0.7880) 20.03 (0.789)
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER
Unit: mm (in)
ITEM STANDARD SERVICE
LIMIT
Clutch lever free play 10-20 (0.4—0.8) -
Clutch outer guide O.D. 22.930 7 22.950 (0.9028 7 0.9035) 22.80 (0.898)
|.D. 16.988 717.010 (0.6688 7 0.6697) 17.04 (0.671)
Clutch outer |.D. 23.000 7 23.021 (0.9055 7 0.9063) 23.06 (0.908)
Mainshaft CD. at clutch outer guide 16.966 716.984 (0.6680 7 0.6687) 16.95 (0.667)
Clutch spring free length 35.76 (1.408) 33.6 (1 32)
Clutch disc thickness A 2.9-3.08 (011570.121) 2.5(0 0.98)
B 2.627278 (010370.109) 2.2 (0 086)
Clutch plate warpage 0.20 (0.01 )
Pinion gear |.D. 16.016 716.034 (0.6305 7 0.6313) 16.07 (0 633)
Kickstarter spindle O.D. 15.966 715.984 (0.6286 7 0.6293) 15.94 (0 628)
Kickstarter idle gear |.D. 20.020 7 20.041 (0.7882 7 0.7890) 20.10 (0 791)
Idle gear bushing O.D. 19.984 719-995 (0.7868 7 0.7872) 19.90 (0 783)
ID. 17.010 717.035 (0.6697 7 0.6707) 17.10 (0.673)

 

 

 

 

1-10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NSR 1 SOSP Ge ne ral Information
CRANKSHAFTITRANSMISSION
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Connecting rod big end Side clearance 0.3 7 0.7 (0.012 7 0.028)
Radial 0.05(0.002)
clearance
Crankshaft runout A 0.05(0.002)
B 0.03(0.001)
Transmission gear |.D. M5, M6 22.02%22041(08669708678) 22.10(O.870)
C1 20.020-20.041(07882-07890) 20.10(0.791)
C2, C4 22020722041(03669708678) 22.10(0.870)
C3 25020-25041(03850-09859) 25.10(0.988)
Transmission gear M5, M6 21 .979-22.000(0.8653-0.8661) 21 .90(0.862)
bushing O.D. C1 19.984-19.995(0.7868-0.7872) 19.90(0.783)
C2 21.984-22.005(0.8655-0.8663) 21.90(0.862)
C3 24.984-24.993(0.9836-0.9840) 24.90(0.980)
Transmission gear M5, M6 20000-20021(07874-07882) 20.01(0.791)
bushing |.D. C1 17.016-17.034(0.6700-0.6706) 17.10(0.673)
C2 20.020-20.041(07882-07890) 20.10(0.791)
C3 22020722041(08669708678) 22.10(0.870)
Gear—to-bushing clearance M5, M6 0.020-0.062(0.0008—0.0024) 0.10(0.004)
C1 0.025—0.057(0.0010-0.0022) O.10(0.004)
C2 0.015—0.057(0.0006-0.0022) O.10(0.004)
C3 0.027—0.057(0.0011-0.0022) O.10(0.004)
Mainshaft OD. M5 19.959-19.980(0.7858-0.7866) 19.92(0.784)
Right Crankcase 16.966-16.984(0.6683-0.6687) 16.95(0.667)
journal
Countershaft O.D. C1 16.975-16.984(0.6683-0.6687) 16.95(0.667)
C2 19.974-19.984(0.7863-0.7867) 19.94(0.785)
C3, C4 21 .959-21 .980(0.8645-0.8653) 21.09(O.830)
Gear—to-shaft clearance C4 0.040—0.082(0.0016-0.0032) 0.10(0.004)
Gear bushing—to-shaft M5, M6 0.020-0.062(0.0001-0.0024) O.10(0.004)
clearance C1 0.032—0.059(0.0013-0.0023) O.10(0.004)
C2 0.033—0.067(0.0013-0.0026) O.10(0.004)
C3 0.040—0.082(0.0016-0.0032) O.10(0.004)
Shift fork claw thickness 4.93-5.00(0.194-0.197) 4.80(0.189)
Shift fork |.D. 12.041—12.056(0.4741-0.4746) 12.65(O.475)
Shift fork shaft O.D 11.983—11.994(0.4718-0.4722) 11.973(0.4714)

 

 

 

1-11

 

NSR 1 50SP

General Information

 

FRONT WHEEL l SUSPENSION/STEERING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM STANDARD SERVICE
LIMIT
Minimum tire tread depth 1.5 (0.06)
Cold tire pressure Driver only 200kPa (2.00kgf/cm , 29psi)
Driver & Passenger 200kPa (2.00kgf/cm , 29psi)
Front axle runout 0.2 (0.008)
Front wheel rim Radial 2.0 (0.08)
run out Axial 2.0 (0.08)
Wheel balance weight Max 609
Fork spring free length 310.4 (12.22) 304.2 (11.98)
Fork spring installed direction Tapered side facing down
Fork lube runout 0.2 (0.008)
Recommended fork oil
Fork oil level 125 (4.9)
Fork oil capacity 322 cm (10.9 US 02, 11.3 Imp oz)
Steering bearing preload 1.0 71.5 N.m (0.1 r 0.15 kgf.m)
REAR WHEELISUSPENSION
ITEM STANDARD SERVICE
LIMIT
Minimum tire tread depth 2.0 (0.08)
Cold tire pressure Driver only 200kPa (2.00kgf/cm , 29psi)
Driver & Passenger 200kPa (2.00kgf/cm , 29psi)
Rear wheel rim Radial 2.0 (0.08)
run out Axial 2.0 (0.08)
Wheel balance weight Max 609
Drive chain slack 35 mm
Drive chain link 108
Drive chain size DID 525VCS
RK 520MOZ9
Damper/reservoir gas pressure 980 kPa (10 kgf/cm , 142psi)
Pressurize gas material Nitrogen
Damper rod compressed force at 10mm 272 kg

(0.4in) compressed

 

 

Damper/reservoir gas release drilling point

 

See page 14-15

 

 

1-12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NSR 1 SOSP Ge ne ral Information
BRAKES
ITEM STANDARD SERVICE LIMIT
Brake fluid DOT 3 or 4
Brake pad wear indicator Indicator groove
Brake disc thickness 3.8742 (0.157017) 3.0(0.12)
5 Brake disc runout 0.3(0.01)
a Master cylinder |.D 10957—10984 (04314-04326) 10.945(0.4309)
u. Master cylinder CD on secondary 10957—10984 (04314-04326) 10.945(0.4309)
cup side
Caliper cylinder |.D. 25.40—25.45(0.999-1.002) 25.46(1.002)
Caliper piston O.D. 25.335—25.368(09974-09987) 25.300(0.9960)
Brake fluid DOT 3 or 4
Brake pad wear indicator Indicator groove
Brake disc thickness 3.8-4.2 (0.15-0.17) 3.0(0.12)
1: Brake disc runout 0.3(0.01)
E Master cylinder |.D 12.700—12.743(05000-05017) 12.755(0.5022)
M

Master cylinder CD on secondary
cup side

12.657—12.684(0.4983-0.4994)

12.645(0.4978)

 

Caliper cylinder |.D.

25.40-250.45(0.999-1.002)

25.46(1.002)

 

 

Caliper piston O.D.

 

25335—25.368(0.9974-0.9987)

 

25.300(0.9960)

 

BATTERY/CHARGING SYSTEM

 

ITEM

SPECIFICATIONS

 

Alternator rated output

180 W/5,000 min‘ (rpm)

 

Alternator charging coil resistance (At 20°C / 68°F)

0.171.0®

 

Regulator/rectifier: regulated voltage (At 20°C / 68°F)

14.7 1 0.5V at 5,000 min1 (rpm)

 

Current leakage

1mA maximum

 

 

 

 

 

 

 

 

 

 

Battery capacity 12V 7 3A
Battery type YB3L-A
Battery charging rate Normal 0.3A/ 10h
Quick 3A / 0.5h
IGNITION SYSTEM
ITEM SPECIFICATIONS

Standard NGK BQES
Spark Plug Nippondenso W27ES-U

For cold NGK BSES

climate riding Nippondenso W24ES-U

 

 

 

 

 

Ignition timing *F‘ mark

BTDC 12 :3”/1,200 :200 min‘

 

 

 

 

(rpm)
Advance Start 1,900 1 200 min‘ (rpm)
Stop 3,500 1 200 min‘ (rpm)
Full advance BTDC 35 1 3”

 

Ignition cut-out revolution

13,000 i 200 min1 (rpm)

 

Ignition coil Peak Voltage

100V minimum

 

 

Ignition Pulse generator peak voltage

0.7 V minimum

 

 

 

1-13

 

 

 

 

NSR 1 SOSP Ge ne ral Information
LIGHTS/METERSISWITCHES
ITEM SPECIFICATIONS
Main fuse 20 A
Fuse 10 A X 3

 

 

Headlight (high/low beam)

12V760/55WX2

 

Tail/Brake Light

12V75/18WX2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Frontturn signal light 12Vr10WX2
Rear turn signal light 12 V r 10 W X 2
Instruments light 12 V71.7WX2
Oil pressure warning indicator LED
High beam indicator 12 V r 1.7 W
Turn signal indicator 12 V 71.7 W
Neutral indicator 12 V r 3.4 W
TORQUE VALUES
STANDARD
FASTENERS TYPE TORQUE FASTENERS TYPE TORQUE
N.m (kgfm, Ibf.ft) N.m (kgf.m,
|bf.ft)
5 mm hex bolt and nut 5 (0.5, 3.6) 6 mm screw 9 (0.9, 6.5)
6 mm hex bolt and nut 0 (1.0 , 7) 6 mm flange bolt 9 (0.9, 6.5)
(8mm head)
8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt
(10mm head and nut)
10 mm hex bolt and nut 34 (3.5 , 25) 12 (1.2, 9)
12 mm hex bolt and nut 54 (5.5 , 40) 8 mm flange bolt and nut 26 (2.7, 20)
5 mm screw 4 (0.4 , 2.9) 10mm flange bolt and nut 9 (4.0, 29)

 

 

 

 

Torque specifications listed below are for important fasteners. Others should be
tightened to standard torque values listed above.

NOTES:

Apply sealant to the treads

Apply a locking agent to the threads

Apply molybdenum disulfide oil to the threads and flange surfaces
Left hand threads

Stake

Apply clean engine oil to the O-ring

UBS bolts
U-nut

0. ALOC bolt; Replace with a new one

1-14

1
2
3
4
5.
6. Apply oil to the threads and flange surface
7
8
9
1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NSR 1 SOSP Ge ne ral Information
ENGINE
ITEM QTY THREAD TORQUE REMARKS
DIA (mm) N.m (kgf—m, lbf-ft)
LUBRICANT SYSTEM
Oil drain bolt 1 8 21 (2.1, 15)
COOLANT SYSTEM
Water Pump impeller 1 7 12 (1.2, 9)
CYLINDER HEAD I CYLINDER [PISTON
Spark Plug 1 14 20 (2.0, 14)
Cylinder head nut 6 8 23 (2.3, 17)
Cylinder nut 4 8 23 (2.3, 17)
Cylinder stud bolt 4 8 10 (1.0, 7)
RC VALVE
RC valve timing pulley nut l 1 6 l 9 (0.9, 6.5) Note 4
CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER
Right crankcase cover bolt 6mm 10 8 10 (1.0, 7)
8mm 1 8 26 (2.7, 20)
Clutch cable adyuster lock nut 1 8 23 (2.3, 17)
Primaw drive gear nut 1 12 66 (6.7, 48) Note 6
Clutch lifter plate bolt 4 6 12 (1.2, 9)
Clutch centre lock nut 1 14 64 (6.5, 47) Note 6
Shift drum centre pin 1 8 22 (2.2, 16)
Shift return spring pin 1 8 22 (2.2, 16) Note 2
Shift drum stopper arm bolt 1 6 12 (1.2, 9)
ALTERNATOR/BALANCER
Timing hole cap 1 14 3 (0.3, 2.2)
Flywheel nut 1 12 64 (6.5, 47)
Balancer driven gear nut 1 14 54 (5.5, 40)
Ignition pulse generator socket bolt 2 6 10 (1 .0, 7) Note 2
CRANKCASEICRANKSHAFTITRANSMISSION
Crank case bolt 12 6 10 (1.0, 7)
Bearing set plate bolt 6 6 10 (1.0 7) Note 2
OTHER FASTERNERS
Neutral Switch l 1 10 l 16 (1.6, 12)

 

1-15

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NSR 1 SOSP Ge ne ral Information
FRAME
ITEM QTY THREAD TORQUE REMARKS
DIA (mm) N.m (kgf—m, lbf-ft)
FUEL SYSTEM
Fuel valve nut 1 18 27 (2.8, 20)
Fuel filler cap socket bolt 7 4 1.5 (0.15, 1.1)
ENGINE HANGER
Front engine hanger nut 1 10 55 (5.6, 41)
Rear upper engine hanger nut 1 10 55 (5.6, 41)
Rear lower engine hanger nut 1 10 76 (7.8, 56)
FRONT WHEELISUSPENSIONISTEERING
Front axle nut 1 14 59 (6.0, 43)
Steering stem nut 1 24 88 (9.0, 65) Note 9
Steering top thread 1 26 1 (0.1, 1.7) See Pg 13
Top bridge pinch bolt 1 8 22 (2.2, 16)
Bottom bridge pinch bolt 2 8 27 (2.8, 20)
Fork cap 2 32 22 (2.2, 16)
Fork socket bolt 2 8 20 (2.0, 14) Note 2
REAR WHEEL I SUSPENSION
Rear wheel nut 1 12 108 (11.0, 80)
Rear axle nut 1 30 226 (23.0, 166) Note 6
Driven sprocket nut 5 8 30 (3.1, 22) Note 9
Bearing holder pinch bolt 1 16 73 (7.4, 54)
Swingarm pivot nut 1 14 88 (9.0, 65)
Drive chain slider screw 4 6 5.1 (0.52, 3.8)
Shock absorber upper mounting 1 10 44 (4.5, 33)
bolt
Shock absorber lower mounting 1 10 44 (4.5, 33) Note 9
bolt
BRAKE SYSTEM
Front brake disc bolt 6 8 42 (4.3, 31) Note 2
Rear brake disc bolt 4 8 34 (3.5, 25) Note 9
Brake oil bolt 4 10 34 (3.5, 25)
Pad pin 4 1o 7(1.7, 12)
Pad pin plug 4 10 2.5 (0.25, 1.8)
Caliper bleeder 2 8 5.4 (0.55, 4.0)
Brake lever pivot nut 1 6 5.9 (0.60, 4.3)
Front brake light switch screw 1 4 1.2 (0.12, 0.9)
Front master cylinder cover screw 2 4 1.5 (0.15, 1.1)
Front caliper bracket bolt 2 8 30 (3.1, 22) Note 2
Front caliper pin bolt 1 8 17 (1.7, 12)
Front caliper torque nut 1 8 22 (2.2, 16) Note 2
Rear master cylinder cover screw 2 4 1.5 (0.15, 1.1)
Rear master cylinderjoint screw 1 4 1.5(0.15, 1.1)
Rear master cylinder lowerJoint 1 8 8 (1.8, 13)
nut
Rear caliper holder bolt 1 8 26 (2.7, 20) Note 10
Rear caliper pin bolt 1 8 17 (1.7, 12)
Rear caliper torque nut 1 8 22 (2.2, 16) Note 2
Rear caliper hanger pin 2 10 17 (1 .7, 12)
OTHERS
Side stand pivot nut 1 10 45 (4.6, 33)
Right and left footpeg holder bolt 4 8 32 (3.3, 24)
Ignition coil mounting bolt 2 6 12 (1.2, 9)

 

 

 

 

 

1-16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NSR 1 SOSP Ge ne ral Information
TOOLS
Notes: 1. Equivalent commercially available
2. Alternative tools

DESCRIPTION TOOL NUMBER APPLICABILITY REF. SEC
Float level gauge 07401-0010000 5
Universal bearing puller 07631-0010000 12
Wrench, 20 x 24 mm 07716-0020100 10
Extension bar 07716-0020500 10
Gear holder 07724-0010100 10
Flywheel holder 07725-0040000 11
Sliding weight 07741-0010201 12
Attachment 32x35mm 07746-0010100 14
Attachment 37x40mm 07746-0010200 12,14
Attachment 42x47mm 07746-0010300 12,13
Attachment 52x55mm 07746-0010400 12,14
Attachment 62x67mm 07746-0010500 12,14
Attachment 24x26mm 07746-0010700 6
Pilot, 10mm 07746-0040100 6
Pilot, 15mm 07746-0040300 12,13,14
Pilot, 17mm 07746-0040400 12
Pilot, 20mm 07746-0040500 12
Pilot, 25mm 07746-0040600 12
Pilot, 40mm 07746-0040900 14
Pilot, 22mm 07746-0041000 12
Bearing remover shaft 07746-0050100 13
Bearing remover head, 15mm 07746-0050400 13
Fork seal driver 07747-0010100 13
Driver 077490010000 6,12,13,14
Steering stem socket 07916-3710101 13
Clutch center holder 07923KE10000 10
Bearing remover set, 10mm 07936-GE00000 6
Remover shaft 07936-GE00100
Remover head 07936-GE00200
Sliding weight 07741-0010201
Bearing remover head, 16mm 07936MK50100 12
Remover shaft, 15mm 07936KC10100 12
Driver attachment 07946-3290000 13
Steering stem driver 07946-4300001 13
Driver shaft 07946-MJ00100 14
Fork seal driver attachment 07947-KA20200 13
Crank assembly collar 07964MB00200 12
Crank assembly shaft 07965VM00200 12
Flywheel puller 07KMC-HE00100 11
Bearing remover attachment 07LMC—KV30200 14
Mechanical seal driver 07PMD—KBP0100 6
Case puller 07SMC-0010001 12

 

 

 

 

1-17

 

NSR 1 SOSP

General Information

 

LUBRICATION 8. SEAL POINTS

ENGINE

 

LOCATION

MATERIAL

 

Crankshaft

0 Connecting rod big end
Small end

0 Right and left journal

Cylinder bore inner surface

Piston outer surface

Piston pin outer surface

Piston ring outer surface

Right and left crankshaft bearing

Honda-2—stroke oil or
equivalent

 

Connecting rod big end

Molybdenum disulfide oil
solution (Mixture of the engine
oil and molybdenum diulfide
grease with the ration 1:1)

 

Mainshaft

o Spline area

0 Rotating, sliding area and tooth
Countershaft

o Spline area

0 Rotating, sliding area and tooth
Kickstarter spindle

o Spline area

0 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

0 Right and left mainshaft bearing
Right and left countershaft bearing
Shift drum bearing

Water pump shaft bearing

Clutch outer needle bearing
Balancer shaft bearing

ach transmission gear tooth

rn

Recommended transmission
oil

 

 

Clutch lifter arm sliding surface
Each oil seal lip

0 Right and left crankshaft oil seal
0 Countershaft oil seal

0 Water pump shaft oil seal
0 Flap valve shaft oil seal

0 Balancer shaft oil seal

0 Kickstart shaft oil seal

0 Gearshift spindle oil seal
0 Clutch lifter arm oil seal
Oil pump O-ring

 

Multipurpose grease;
(Litium based grease)

 

 

1-18

REMARKS

 

NSR 1 SOSP

General Information

 

LUBRICATION 8. SEAL POINTS

 

 

 

 

ENGINE

LOCATION MATERIAL REMARKS
Thermo unit threads Liquid sealant 4 :1 mm
Cylinder
Right and left crankcase mating surface Example: Three Bond #1207B
Reed valve manufactured by 3M, co, Ltd
Right and left crankcase mating surface

Locking agent 6.5 :1 mm

 

Ignition pulse generator socket bolt
Kickstarter stopper plate bolt

Shaft return spring pin

Bearing set plate bolt

 

 

 

1-19

 

NSR 1 SOSP

General Information

 

LUBRICATION 8. SEAL POINTS

 

 

 

FRAME

LOCATION MATERIAL REMARKS
Rear axle nut threads and flange surface Recommended engine oil
Caliper pin bolt sliding surface Silicone grease 0.4g

Master cylinder push rod

0 Master piston contacting area
Brake lever

. Master piston contacting area
. Pivot bolt sliding surface
Junction box and boot inner surface

 

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

Fork fluid

 

 

Clutch lever pivot bolt sliding surface

 

 

Brake grease

 

1-20

 

NSR 1 SOSP

General Information

 

CABLE 8- HARNESS ROUTING

Front Brake

Throttle Cable Swit h Wires

Comb inalio
Meier 9P (Bl ck)
Connector ,

Comb inalion
Meier 3P (Black
Connector

Turn Signal
Connectors \

Headlight
3P Connector

Tachometer C: e

Turn Signal
Relay

clutch Cable

@

 

Lefl Handle Switch Wire

 

 

 

199399
Speedometer Cable
\>
O
\> <> -
~> <> Horn ere
¢<><2<><Z

From Brake Hose

1-21

NSR 1 SOSP Ge neral Information

 

        
     
   
 

Front Brake

 

‘
d Tao ometer
Cable

Left Hand
wltch ere

Tachometer

 

Speedometer
Cahle

NSR 1 SOSP Ge neral Information

 

Le" HandlE Switch 4? Connector
Len Hurdle Swilch 9P Connector
Ignnion Switch 2? Connector

      

Anemrhor WC"! VA

Ignition Pulse
Generator ‘ ire

LE“ crankcase
Breather Tube

R

an
Brako Hose

NSR 1 SOSP Ge ne ral Information

 

 
 
 
 
 
 
  
 
 
 
 
  
 
   
 

Lefl Handle Switch
4P (Red) Connedor
Lefl Handle Switch
9P Co nneflor

lg nition Switch

2P Co nneflor

Spark Plug Wire

Choke
Cable

RC Valve
Control Cable

Grankcase
Brealher Tub

O

   
 

O

    
  
 
  
   
  
   

Air Cleaner Housing

0
Breather Tube

Le" Crankcase
Breather Tube

Throflle
Cable

Fuel Tube

c“"’“'°"°' Bre‘me' “be Air Cleaner Housing Drain Tube

1-24

NSR 1 SOSP Ge neral Information

 

Main Wire
Harness

      
   
   
 
 
 
  
   
   
  
 
  

Fuel Unil 3P

Conneclor 0" Lew.

Sensor Connector

    

Rear Brake Hose

Igniiion
Conlrol Module

Rear Brake
Reservoir Hose

REar Bréke’ \
Light Switch

 

 

 

Regulalor/
Rectifier

Rear Brake
Hose

NSRIBOSP
Frame /B0dy Panels/Exhaust System

 

 

 

 

 

 

 

 

Service Information 2-1 Side cover, Rear Cover, Tail 2-6
Cover

Troubleshooting 2-1 Rear Fender 2-8

Body Panel Location 2-2 Upper Cowl, Ftearview Mirror 2-9
Air Guide

Side Cowl, Lower Cowl 2-4 Fuel Tank 2-12

Inner Panel, Grab Flail 2-6 Exhaust Pipe/ Muffler 2-16

 

 

 

 

SERVICE INFORMATION
General

 

 

. Gasoline is extremely llammable and is explosive under certain condition.
. Serious burns may result if the exhaust system is not allowed to cool berare components are
removed or serviced.

 

 

0 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.

o 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.

a This section covers removal and installation of the frame body panels, fuel tank
and exhaust system.

a 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
0 Broken exhaust system
a Exhaust gas leak

Poor Performance

o Deformed exhaust system
0 Exhaust gas leak

. Clogged muffler

2—1

NSR 1 SOSP
Frame / Body Panels/ Exhaust System

 

BODY PANEL LOCATION
Right Side
c ¢  2.1) Grab Rail
mm P e / (page 2-5) Egg)“ Upper Cowl

      
   
  
   
    
  

“use 241)

Right Ail Guide
(Page 2-10?

Seal (page 2-3)

P H 5 Real Cover
, i ion eal (Page 2.8,
 
(page 2-1 1 )

(page 24)

Fender
(page 2-5)

NSR 1 SOSP
Frame / Body Panels] Exhaust System

 

ffim
SEAT, PILLION SEAT Seat Catch
Ignition Key

        

Pillian Seat

Removal
Turn the ignition key and unhook
the pillion seat from the set catch.

Remove the pillion seat llllon 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

NSR 1 SOSP
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.

0 At installation, be careful not to damage the tabs on the side cowl.

NSR 1 SOSP

Frame / Body Panels/ Exhaust System

 

LOWER COWL

Removal

Remove the screws.

Remove the tachometer cable
from the tab on the lower cowl.

NOTE
0 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

0 At assembly, be carerul not to
damage the tabs on the cowls.

Installation

NOTE

. Route the tubes and cables properly.

 

Side Cowl

 

a At tachometer cable installation, be careful not to damage the tab on the lower cowl.

0 At installation, align the grooves on the lower cowl with the tabs on the side cowl.

NSR 1 SOSP
Frame / Body Panels] Exhaust System

 

INNER PANEL %.——Screws\% Inner

Removal I Installation
Remove the screws and inner panel.

Installation is in the reverse order of removal.

GRAB RAIL

Removal I Installation
Remove the socket bolts and grab rail.

Installation is in the reverse order of removal.

SIDE COVER / REAR COVER l TAIL COVER

 

 

NSR 1 SOSP

Frame / Body Panels] Exhaust System

 

RIGHT SIDE COVER

Removal I 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.

0 A! installation, be careful not to damage
the tabs on the right side cover.

LEFT SIDE COVER

Removal I 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 leit side
cover with the grooves on the rear cover.

. At installation, align the tabs on the leit side
cover with the grommets on the frame.

0 At installation, be careful not to damage the
tabs on the side cover.

2-7

Screws

 

 

  

Left Side Cover

NSR 1 SOSP

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.

u NOTE: Be careful not to damage the rear
fenderY tubes. cables and wire harnesses.

Installation is in the reverse order of
removal.

. NOTE: Route the tubes, cables and
harnesses properly. (page1-1B)

. Be careful not to damage the rear render,
tubes. cables and wire harnesses.

2-8

  
    
     

Ta i I Cover

Screws

Con actors

NSR 1 SOSP
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.

 

U PPER COWL

Removal
Disconnect the speedometer cable from
the speedometer.

    

\
Speedometer Cable

NSR 1 SOSP

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.

. more: At removal. be carerul not to damage
the tabs on the cowls. (page 1-13)

Installation

NOTE:
. Route the cables and wires properly.

0 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 29)

Disconnect the tachometer cable from the
tachometer.

2-10

 

Speedometer

NSR 1 SOSP

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:

0 The len air guide removal I 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

 

Right 1
Air Guide ,1 -

    
  

, Tachometer
[' Cable

   

Gulde Plate

 

    

Left Air Guide

Guide Plale

NSR 1 SOSP
Frame / Body Panels] Exhaust System

 

FUEL TANK FuelTank

Cap

    

Removal
Remove the seat. (page 2-3)

  

mung

. Gasoline is extremely
flammable and is explosive
under certain conditions.

   

"Z‘i \\
l
Disconnect the fuel unitSP 3P con “or
connector.

NOTE:
o Before disconnecting the fuel
tube, tum 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

NSR 1 SOSP
Frame / Body Panels] Exhaust System

 

DISASSEMBLY

Loosen the fuel tap nut and remove the fuel tap.

 

Slral ner
Screen

   

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.

NSR 1 SOSP
Frame / Body Panels] Exhaust System

 

ASSEMBLY

Fuel
Strainer
Screen

 

Fuel Unlt

 

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

NSR 1 SOSP
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.

Fuel Tank

 

2-15

NSR 1 SOSP

Frame / Body Panels/ Exhaust System

EXHAUST PIPE/MUFFLER

Removal/Installation

   
 
 

  

Do not service the exhaust system while i! 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.

     
  

G\éske
Mounting

Joint
Boll/Nut

Nuts

Exhaust Pipe/Muffler

2-16

NSR 1 SOSP

Maintenance

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Service Information 3-1 Drive Chain Slider 3-19
Maintenance Schedule 3-3 Battery 3-20
Fuel Line 3-4 Brake Fluid 3-20
Fuel Strainer Screen 3-4 Brake Pad Wear 3-21
Throttle Operation 3-5 Brake System 3-22
Oil Pump and Oil Line 3-6 Brake Light Switch 3-23
Air Cleaner 3-9 Headlight Aim 3-23
Spark Plug 3-10 Clutch System 3-23
Decarbonizing 3-12 Side Stand 3-24
Engine Idle Speed 3-13 Suspension 3-25
Radiator Coolant 3-14 Nuts, Bolts, Fasteners 3-25
Cooling System 3-14 Wheels / Tyres 3-26
Transmission Oil 3-15 Steering Head Bearings 3-27
Drive Chain 3-17

 

 

 

 

SERVICE IN FORMATION

Specification

 

 

 

 

 

ITEM SPECIFICATION
Throttle grip free play 2 7 6mm (0.08 7 0.24)
Spark Plug Standard NGK NIPPONDENSO
BQES W27ES—U
For Cold climate riding B8ES W24ES—U

 

 

Spark Plug gap

0.7 7 0.8 mm (0.028 7 0.031 in)

 

Engine oil capacity

0.76 litre (0.83 us qt, 0.67 Imp, qt)

 

Engine oil capacity Atdraining

0.7 litre (0.73 US qt, 0.62 Imp, qt)

 

At disassembly

0.8 litre (0.85 US qt, 0.70 Imp, qt)

 

Carburettor idle speed

1,300 :100 min1 (rpm)

 

 

 

 

 

 

 

 

 

 

 

 

Drive chain slack 35mm

Drive chain size DID 525VCS
RK 525MOZ9

Drive chain link 108

Clutch lever free play 10-20mm

Cold tire pressure Driver only Front 200kPa (2.00 kgf/cm , 29psi)

Rear 200kPa (2.00 kgf/cm , 29psi)

Driver and Front 200kPa (2.00 kgf/cm , 29psi)
passenger Rear 200kPa (2.00 kgf/cm , 29psi)

 

 

3-1

 

 

NSR 1 SOSP

Maintenance

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM SPECIFICATIONS
Minimum tire depth Front 1.5mm
Rear 2.0mm
Tire Size Front 90/80 7 17 468
Rear 120/80 717 618
Tire Band IRC Front NF46
Rear NR57
TORQUE VALUES
Oil drain bolt 21N.m (2.1 kgf—m, 15 Ibf-ft)
Spark Plug 20N.m (2.0 kgf—m, 14 Ibf-ft)
TOOLS

Drive chain tool set

07HMH-MR10103

3-2

 

NSR 1 SOSP Maintenance

 

Maintenance Schedule — NSP150$P

Perform the Pre-ride inspection in the Owner‘s Manual at each scheduled
maintenance period.

I: Inspect and clean, adjust, lubricate or replace if necessaw 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.

 

Whichever Odometer Reading - (Note 1)

 

FREQUENCY Comes x1000km 1 4 12

 

First x1000mi 0.6 2.5

 

ITEM 11 MONTH 6

 

Fuel Line

 

Fuel Strainer Screen

 

Throttle Operation

 

»»»»

Oil Pump and Oil Line

 

Air Cleaner Note 2

 

|
C
|
|
C
|

Spark Plug

 

Decarbonizing

 

Engine Idle Speed I I

 

Radiator Coolant Note 3

 

———omo——o—;um

Cooling System

 

Transmission Oil R

 

Drive Chain I, L: Every 1,000km (600ml)

 

Drive Chain Slider

 

Battery

 

Brake Fluid Note 3

 

Brake Pad Wear

 

Brake System I

 

* Brake Light Switch

 

* Headlight Aim

 

Clutch System I

 

Side Stand

 

Suspension

 

Nut, Bolt, Fastener I

 

" Wheel / Tyres I

 

 

 

 

 

 

 

 

 

" Steering Head Bearing I I

 

Should be sen/iced 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.

H

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

 

NSR 1 SOSP

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)

 

n Gasoline is exlremely flammable and is
explosive under certain condition.

 

 

 

Remove the fuel cup, O-ring and fuel cup strainer.

Wash the cup strainer and cup in clean non-

flammable high flash point solvent.

Reinstall the cup strainer, O-ring and cup in the fuel
tap, making sure that the O-ring is in place.

Tighten the fuel cup securely.

Install the fuel tank. (page 2-4)

3-4

 

Fue' @

Stralner é O'Ring

 

NSR 1 SOSP Maintenance

 

THROTTLE OPERATION ' 2-6mm (0.08-0.24in)
Check for any deterioration or damage to ’ r
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.

raw

Reusing a damaged or abnormally bent or
kinked throttle cable can prevent proper  . A
throttle side operation and may lead to a loss D
oi throttle control while riding.

 

   
   
 

 

 

 

Lock Nut

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.

Adi usler

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

NSR 1 SOSP Maintenance

 

OIL PUMP AND OIL LINE ’ _ -
Check the engine all 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.

 

NSR 1 SOSP Maintenance

 

Remove the joint band.

Remove the strainer joint from the
oil tank.

 

    

r M
Stralner ,_
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

NSR 1 SOSP 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 all 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
0 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

NSR 1 SOSP

Maintenance

 

AIR CLEANER

NOTE

0 The viscous paper element type air cleaner cannot
be cleaned because the element contains a dust
adhesive. lflhe motorcycle is used in wet or dusty
areas, more lrequent 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.

rmng

 

 

Never use gasoline or low flash point
solvents for cleaning (he air cleaner element.
A fire or explosion could result.

 

 

 

 

 
 
 
 

 

Ele ell!

l:

Squeeze Squeeze

25%?

"1 "0W. Soak
flammable solvent

Soak the element in gear 0” (SAE #30 - 40) and squeeze out oil.

3-9

NSR 1 SOSP Maintenance

 

Install the element to the air cleaner Ele em
housing.

’E

Screws

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

NSR 1 SOSP Maintenance

 

INSPECTION

Check the following and replace if necessaly
(recommended spark plugs: (page 3-1)
- Insulator for damage
- Electrodes for wear
- Burning condition, coloration;
a dark to light brown indicates
good condition.
a excessive lightness indicates malfunctioning
ignition system or learn mixture.
0 wet or black sooty deposit indicates over-
rich mixture.

 

Plug
Gap

 

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)

CAUTIDN
- To prevent damage to the cylinder head. hand-lighten the spark _\=L

plug beiore using a wrench to lighten lo 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 |bf.ft)

Connect the spark plug cap.

REPLACING A SPARK PLUG

 

Set the plug gap to specification with a wire-type feeler gauge

CAUTIDN
. Do not overtighlen the spark plug.

Install and tighten the new spark plug, then tighten it about 1/. of turn after sealing
washer contacts the seat of the plug hole.

3-11

NSR 1 SOSP Maintenance

 

DECARBONIZING Cylinder Head
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" Carbon

CAUTION
. Avoid damaging the cylinder bore.

RC Valve

Clean carbon deposits from the RC valve.

CAUTION
. Avoid damaging the RC valve.

3-12

NSR 1 SOSP Maintenance

 

MUFFLER I  M°'"‘""9

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
irom 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 Throttle stop
run the en ine in an enclosed area.

9 Control Knob

 

 

 

 

NOTE
e Inspect and adjust idle speed after all other engine
adjustments are within specification.

 

0 Engine must be warm [or 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 2100 min-‘ (rpm)

3-13

NSR 1 SOSP

Maintenance

 

RADIATOR COOLANT

LEVEL CHECK

  

Warning

 

 

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.

lr coolant gets in your eyes, flush
repeatedly with water and contact a doctor
immediately.

it coolant is accidentally swallowed. induce
vomiting and contact a doctor immediately.
KEEP our REACH OF CHILDREN.

 

 

 

I Lower level

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 antirreeze 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 rrorn the cooling ran. it may
start automatically, without warning.

 

 

Remove the radiator grill.

Check the radiator air passage for clogging

or damage.

3-14

 

NSR 1 SOSP

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

Warning

  

 

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 or the clutch may be etrecled.
Too little oil may cause engine overheating as well as premature wear to various pans.

I If a different brand or grade of oil or low quality oil i mixed when adding oilY 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

NSR 1 SOSP Maintenance

 

With the motorcycle upright on the level
ground, check the oil level through the
inspection window.

Lower Level Llne

. t m.) ’7’ WW

If the level is below or near the lower Flu" cap

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 $6 Viscosity: SAE 10W~40.

NOTE

 

0 other viscosities shown in the chart may be used
when the average temperature in your riding “WWW
area is within the indicated range.

 

Reinstall the oil filler cap.

 

 

For engine oil change, see below.

 

OIL CHANGE

NOTE

e Change the engine oil h the engine warm
and the motorcycle o de stand to assure
complete and rapid dra ng.

    

20 40 60 BO 100“F

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 we
and exhaust system have cooled before Flue" cal:

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

NSR 1 SOSP 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 kglm, 15 Ibf-fl)

Fill the crankcase with the recommended
engine oil.

CAPACITY:

0.7 Litres (0.73 US qt, 0.62 Imp q!)

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

mung

  

 

 

. 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

NSR 1 SOSP Maintenance

 

Bearing Holder

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.

  

Index Mark

    

Tighten the bearing holder pinch bolt to 4* ‘7‘
the specified torque.

TORQUE: 73 N.m (7.4 kylm, 54 lbf-fl)

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 things should not be treated to
the following cleaning and oiling procedure.
This treatment will cause degradation of the
o-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

NSR 1 SOSP

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

o If the chain slider becomes worn through to the
swingarnt, the chain will begin to wear against
the swingarm.

3-19

   
   

   

Pro-Honda
Chain Lube
or Equivalent

  

 

  
 

I Indicator

 

NSR 1 SOSP Maintenance

 

BATTERY

A

The battery electrolyte contains sulfuric acid.
Protect your eyes, skins and clothing. lf
electrolyte gets in your eyes; flush them
thoroughly with water and get prompt medical
attention.

 

 

 

 

 

 

Remove the battely from the battery
compartment (page 165).

NDTE

a Add only distilled water. Tap water will shorten the
service life of the battery.

e Inspect the battery fluid level in each cell.

When the fluid level near the lower level, refill k
with distilled water to the upper level.

 

BRAKE FLUID

 
   

Lower Level
CAUTIDN

. Do not remove the cover or cap unless the
reservo' 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.

0 Avoid spilling fluid on painted, plastic or rubber
parts. Place a rug over these parts whenever
the system is serviced.

NDTE
. When the fluid level is low. check the brake pads for wear (see below). A low fluid level may be due
to wear ofthe brake pads. lfthe brake pads are worn. the caliper piston is pushed out, and this
accounts for a low reservoir level. lfthe brake pads are not worn and the fluid level is low, check
entire system for leaks

I Do not remove the level float from the reservoir when filling with brake fluid.

3-20

NSR 1 SOSP 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.
Ifthe 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 Upper Level

Remove the right side cover.

(page 2-7)
9‘
Place the motorcycle on a level surface,

and support it upright. Check the rear
brake fluid resen/oir level.

Ifthe 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

NSR 1 SOSP Maintenance

 

BRAKE PAD WEAR Pads

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.

 

 

Grooves

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.

Pads

 

 

 

 

 

 

G oves

 

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

NSR 1 SOSP Maintenance

 

BRAKE LIGHT SWITCH

CAUTION

o Allowing the switch body to turn during adjustment
can break the wires in the switch.

NOTE

. The brake light switch on the from brake lever cannot be
adjusted. llthe from brake light switch actuation and
brake engagement are oil, either replace the switch unit or
the malfunctioning parts of the system.

0 Make all rear brake light switch adjustments after the
height adjustment and the brake pedal free play
adjustment have been made.

      

,n f) e \\/
Brake L g/ht Switch
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
0 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)

    

10-2Dmm(0.4 - 0.8 in)
- a.

3-23

NSR 1 SOSP 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

o The adjuster may be damaged 5
positioned too iar out, leaving minimal
thread engagement.

 

J t.

‘ I.
1“ Adlusler

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.

    

Side Stand
Bump Rubber

Ensure that the “bump” rubber is attached and in good condition.

3-24

NSR 1 5OSP Maintenance

 

SUSPENSION

Loose. worn, or damaged suspension parts
impair motorcycle stability and control. Repair
or replace any damaged components berore
riding. Riding a motorcycle with raulty
suspension increases your risk of an accident
and possible injury.

 

 

 

 

    

FRONT
Check the action of the forks by V r _ “
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 inten/al 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

NSR 1 SOSP 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.

lffaults 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

0 As the swingarrn pivot is included in this check,
be sure to confirm the location oflhe play; i.e.
from the wheel hearings or the swingarm pivot.

NOTE

0 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
Unit: kPa kgr/cm‘, psi)

 

 

 

 

 

 

 

 

 

Front Rear
Cold tire Driver Only 200 (2.00, 29) 200 (2.00, 29)
pressure Driver and passenger 200 (2.00, 29) 200 (2.00, 29)
Tire Size 90/80-17 468 120/80—17 61 S

 

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

NSR 1 SOSP Maintenance

 

STEERING HEAD BEARINGS

NOTE

0 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

NSR 1 SOSP Lubrication System

 

    
   
  

Oil Tank

Carburetlor

Oil Level Sensor

Oil Tube
Oil Pump

Oil Pass Tube

NSR 1 SOSP

Lubrication System

 

 

Service Information

4-1 Engine Oil 4-3

 

 

Troubleshooting

 

 

 

 

4-2 Oil Pump 4-4

 

SERVICE IN FORMATION

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 oi
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 airfrom the oil lines whenever the oil lines or pump have been removed or there is air in the oil
lines.

Bleed airfrom the oil inlet line first, then bleed air lrom 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.

 

O 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.
O 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
Unit: mm (in)
ITEM STANDARD SERVICE
LIMIT

 

Engine oil capacity

0.76 litre (0.83 us qt, 0.67 Imp qt)

 

Recommended engine oil

Used Honda 2-stroke oil or equivalent

 

Transmission oil capacity

0.7 litre (0.73 US qt, 0.62 Imp qt)

 

0.8 litre (0.85 US qt, 0.70 Imp qt)

 

 

Recommended transmission oil

Used Honda 4-stroke oil or equivalent
API Service Classification: SE, SF or 86
Viscosity: SAE 10W40

 

 

 

TORQUE VALUES

Oil drain bolt

21 N.m (2.1 kgr, 15lbf-ft)

4-1

 

 

NSR 1 SOSP Lubrication System

 

TROUBLESHOOTING
Excessive smoke and/or carbon on spark plug

a Faulty oil pump (too much oil flow)
a 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

NSR 1 SOSP 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.

 

Joint

4-3

NSR 1 SOSP 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
llow and may result in severe engine
damage.
. Bleed air lrom the oil lines whenever the
pump have been removed or
air in the oil line Bleed air from the
oil inlet line lirst, then bleed air from oil
outlet line.

    

   
  
 
 
 
  

 

NDTE
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.

NSR 1 SOSP Lubrication System

 

    
    
  
   

Clamp the oil tube and oil pass tube to prevent oil

from flowing out. Oil Pass ube

Tube Clamp

Conlrol Cable
Lock Nul

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.

NSR 1 SOSP

Lubrication System

 

Remove the bolts and oil pump from the right
crank case cover.

Remove the O-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 243)

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

Oil Pump

    

‘ Oil Pump _

Oil Seal

 

 

NSR 1 SOSP 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.

   

Pump Shaft

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 0" Tube %\ Bleed
ground. Bolt

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

NSR 1 SOSP Lubrication System

 

OIL PUMP INSTALLING

Clean the oil pump mating surface of the
right crankcase cover.

Install the new O-ring to the oil pump
groove.

Apply transmission oil to the new O-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.

 

   

c 

Drive Pin

NSR 1 SOSP 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).

Oil Pass

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 0' conscious and may lead to
death.

Oil Pass Tu

 

 

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

NSR 1 SOSP 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

NSRISOSP Fuel System

 

 

 

5-0

 

NSR 1 SOSP Fuel System

 

 

 

 

 

 

Service Information 5-1 Carburettor 5-6
Troubleshooting 5-3 Air Screw Adjustment 5-12
Air Cleaner Housing 5-4 Reed Valve, Air Chamber 5-13
Throttle Valve 5-4

 

 

 

 

 

SERVICE IN FORMATION
GEN ERAL

Warning

  

 

Gasoline ls extremely flammable and is explosive under certain conditions. KEEP our 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
olconsciousness 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.

 

0 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.

0 For fuel tank removal and installation, refer to Section 2.

0 Before disassembling the carburettor, place an approved gasoline container under the
carburettor drain tube, loosen the carburettor drain screw and drain the carburettor.

0 When disassembling the fuel system parts, note the locations of the O-rings, Replace
them with new ones on re-assembly.

0 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.

0 When disconnecting the oil outlet line tube, clamp or plug the tube to prevent oil from
flowing out.

o The oil pump control cable should be adjusted after the throttle grip free play is
adjusted.

 

NOTE

. llthe vehicle is to be stored for more than one month, drain the lloat bowls. Fuel leh in the
float bowls may cause clogged jets resulting in hard starting or poor driveability.

 

 

 

5-1

 

NSR 1 SOSP

Fuel System

 

SPECIFICATIONS

 

 

 

 

 

 

 

 

ITEM STANDARD
Carburettor identification number PE 74A
Choke type Starting enrichment circuit system
Main Jet # 152
Slow Jet # 42
Air screw initial opening 2 turns out
Float level 19 mm (0.7 in)
Idle speed 1,300 +100 min 71 (rpm)

 

 

Throttle grip free play

 

2 7 6 mm (0.08 7 0.24 in)

 

TORQU E VALUES

Fuel valve nut
Fuel filter cap socket bolt

TOOLS

Float level gauge

27 N.m (2.8 kgf.m, 20 ibf.ft)
1.5 N.m (0.15 kgf.m, 1.1 |bf.ft)

07401 -001 0000

5-2

 

NSR 1 SOSP

Fuel System

 

TROU BLESHOOTING

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)

Lean mixture

Fuel jets clogged
Float valve faulty
Float level too low
Fuel line restricted
Intake air leak
Throttle valve faulty

5-3

Rich mixture

Starting enrichment valve ON
Float valve faulty

Float level too high

Airjets 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
0 Lean mixture in slow circuit

Backfiring or misfiring during

acceleration

a Ignition system malfunction
(Section 17)

0 Fuel mixture too lean

Poor performance (driveability) and
poor fuel economy
0 Fuel system clogged
o Ignition system malfunction
(Section 17)

NSRISOSP Fuel System

 

AIR CLEANER HOUSING Air Cleaner

    

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.

Breather
Tube

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.

 

Throttle Vlve Throttle Cable
— 4

5-4

NSR 1 SOSP

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

0 Be sure that the throttle Valve cutaway is toward the
air cleaner housing side as it determines the Volume of
air for iuel mixture.

 

 

 

5-5

 

Th rotlle Valve
1

l
Jet Needle
I
‘1 ‘ Retainer

 

Throttle Valve

Spring”

    

Throttle Valve

 

Throttle Cable
— ,

 

NSR 1 SOSP

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)

CARBU RETTOR

REMOVAL

mung

 

 

Gasoline is extremely flammable and is
explosive under certain condilions.
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

Em.an Top

Throttle Valve Throttle Cable
— .

 

Fuel Tube

   

Drain Tube

Carbuvenor

NSRISOSP Fuel System

 

Remove the screws, float chamber and O-
ring.

Remove the float pin, float.
Remove the float valve.

CAUTION
.Handle all jets wilh care.
.Keep clean, thy can easily be blacked..

Remove the main jet, needle jet holder,
needle jet and slow jet.

 

e NOTE
The air screw is iactary pre-sel and should no! he
removed unless the carbureltar is overhauled.

 

 

 

 

CAUTION
. Damage to the air screw seal will occur iHhe air
screw is lightened againsi 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.

 

V‘Holder
Spring/V,

Alt screw” - "5'" 19'

5-7

NSR 1 SOSP

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 seal properly
and will eventually flood me 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 airand fuel passages with a piece of
wire will damage the carburelmr body.

Disassembled the carburettor (page 5-7).

Blow open all air and fuel passages in the
carburettor body with compressed air.

5-8

 

Throttle Slap ‘Conlrol Knob

Valve 5 e at

    

‘e\

V \

V ‘a
Main int

Air Screw , ‘e

 

NSRISOSP Fuel System

 

Clean the fuel strainer in the float valve
using compressed air from the float valve
seat side.

 

  
 
     
  

 

ASSEM B LY
Carburettor Body “91 Tube
Carburettor Top m! screw
Spring
I Needle let
M y ‘— Slow Iel
V
Needle Jet Holder
Washerx©
Retainer —> @
spring )E

]et Needle /U

/

Throttle Valve Floal Valve

Throttle Stop Control Knob

Install the spring, washer and throttle
stop screw.

 

Thfile'swfiflzonuol Knob

5-9

NSRISOSP Fuel System

 

     
    
  
 

Install the needle jet, needle jet holder, main & r b. Needle let
jet and slow jet.

 

 

 

 

Install the spring and air screw. Slaw let
. NOTE /
Install the air screw and return it to its original
position as noted during removal. §\ NM" 1"
Perform air screw adjustment if new air screw is A/Holder
installed. ( Page 5-12) 5 - /
Prms V
\‘\
Mnln [at

Air screw] ‘ e

Main int/Needle jet holderINeodle jet
.0

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.

 

I, Float level
III gauge

 

 

 

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 07401 -0010000

FLOAT LEVEL: 19 mm (0.7 in)

If the level is out of specification, replace the float.

5-10

NSR150$P Fuel System

 

Install the new O-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 Brain Tub.

carburettor.

INSTALLATION

 

NOTE
Rome the wires and tubes properly (page 1-13)

 

 

 

Install the SE valve to the carburettor and
tighten the SE valve nut securely.

 

5-11

NSRISOSP 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.

Cnrburenor 4

Install the throttle valve (page 56)

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.

 

NDTE
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

NSRISOSP Fuel System

 

Adjust the idle speed with the throttle

stop control knob. ”

IDLE SPEED: 1,300 1 100 (rpm) Thr°nle~$1°l2lc°ntr°| knob

 

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 114 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

NSRISOSP 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
as sure to replace the road valve as an assembly.
Disassembling or bending the read 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

NSR150$P 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

NSRISOSP Cooling System

 

 

6-0

NSR 1 SOSP Cooling System

 

 

 

 

 

 

 

 

 

 

Service Information 6-1 Coolant 6-5
Troubleshooting 6-2 Radiator 6-7
System Flow Pattern 6-3 Water Pump 6-9
System Testing 6-4 Radiator Reserve Tank 6-14

 

SERVICE IN FORMATION

GENERAL

mung

  

 

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

 

 

 

0 Use only distilled water and ethylene glycol in the cooling system. A 50-50
mixture is recommended for maximum corrosion protection. Do not use alcohol-
based antifreeze or an anti-freeze with self sealing properties.

0 Add coolant at the resen/e tank. Do not remove the radiator cap except to refill or
drain the system.

0 All cooling system services can be done with the engine in the frame.

0 Avoid spilling coolant on painted surfaces.

0 After servicing the system, check for leaks with a cooling system tester.

0 Refer to Section 18 for thermo sensor inspection.

 

 

 

 

 

 

SPECIFICATIONS
ITEM STANDARD
Cooling capacity I Radiator and engine 1.2 litre (1.27 US qt,1.06 Imp qt)
Radiator cap relief pressure 108 - 137 kPa (1.1 - 1.4 kgf/cmZ, 16-21 psi)
Standard coolant concentration 50 % mixture with soft water

 

6-1

 

NSR 1 SOSP

Cooling System

 

TORQU E VALUES

Water pump impeller 12 N.m (1.2 kgf.m, 9 |bf.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
O7PMD-KBP01OO

TROU BLESHOOTING

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 O-ring

Loose hose connection or clamp
Damaged or deteriorated hose
Faulty radiator cap

6-2

Cooling System

NSR 1 SOSP

 

SYSTEM FLOW PATTERN

Radiator Reserve Tank

Ox

6
\.

\\

3‘:

\

Upper Radiator Hose

/ Radialor Tube
1 /

\_/
\{Jy

  

Engine Feed

 

6-3

NSR 1 SOSP

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 0 5 10 15 20 25 30 35 40 45 50

(32) (41) (50) (59) (68) (77) (86) (95) (104) (113) (122)
Coolant mm

5 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.999 0,997
10 1.018 1.017 1.017 1.016 1.015 1.014 1.013 1.011 1.009 1.007 1.005
15 1.025 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012
20 10.36 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019
25 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025
30 1.053 1.052 1.051 1.049 1.047 1.045 1.043 1.041 1.038 1.035 1.032
35 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.040
40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047
45 1.080 1.078 1.076 1.074 1.072 1.069 1.066 1.063 1.060 1.057 1.054
50 1.086 1.084 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.059
55 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.075 1.073 1.070 1.067
60 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1,071

 

6-

4

 

NSRISOSP 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
Beiore 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: Tes‘er

108 -137 kPa (1.1 - 1.4 kgflml2,15.6 -19.9 psi)

Pressurise the radiator, engine and hoses,
and check for leaks.

CAUTION
. Excessive pressure can damage the cooling system
components. Do not exceed 137 kPa (1.4 kgtlcm’ 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 300""9 System

ester

6-5

NSRISOSP Cooling System

 

 

 

COOLANT
REPLACEMENT Ann-freeze
Radiator coolant is toxic. Keep it away from eyes, (Ethylene _
mouth. skin and clothes. Glyccl Base Low Mineral
- liany coolant gets in your eyes, rinse them 8 I r or
with water and consult a doctor immediately. ° " '0")

Distilled Water

- liany coolant is swallowed induce vein 9,
rinse and consult a physic n immedi ely.

e liany coolant gets on your skin or clothes. Coolant
rinse thoroughly with plenty of water.

7 KEEP our 0F REACH OF CHILDREN

 

 

 

NOTE

. The etiectiveness ol coolant decreases with the accumulation of rust or if there is a change in the
mixing proportion during usage. Therelore, ior best perlormance change the coolant regularly as
specified in the maintenance schedule.

. Mix only distilled, low mineral water with the anti-ireeze.

RECOMMENDED MIXTURE:
50-50 (Distilled water and anti-freeze)

REPLACEMENT/AIR BLEEDING

naming

  

 

 

The engine must be cool before removing the radiator
cap. or severe scalding may result.

 

 

NOTE

. When lilling the system or reserve tank with a coolant
(checking the coolant level), place the motorcycle in a
vertical position on a flat, level suriace.

Remove the right air guide (page 2-11)
Remove the radiator cap.

Remove the lower cowl (page 2-5) ‘ Drain Boll
Remove the drain bolt and seating washer. Sealing 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.

 

NSR15OSP Cooling System

 

Disconnect the reserve tank overflow tube.

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.

 

_ ( l\\fi ’ ‘

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. Shift the transmission into neutral.
Start the engine and let it idle for
2 » 3 minutes.

2. Snap the throttle 3 - 4 times to bleed air
from the system.

3. Stop the engine and add coolant up to
the filler neck. Reinstall the radiator
cap.

4. 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

NSRISOSP 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.

LOWE! Hadlator H052

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. F

NOTE '

At installation, align the tabs on the radiator with the
glam-nets on the frame.

 

 

 

 

Fill and bleed the cooling system. a,
(page 6-6). '

Radiator

6-8

NSR150$P 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

NSRISOSP 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 «or damage, hold the
water pump shaft securely.

Remove the water pump impeller by turning
it counterclockwise. 'mP°“°r
Remove the washer and water pump shaft.

Check the water pump shaft bushing in the
right crankcase for wear or damage.

/

\Washer
MECHANICAL SEAL REPLACEMENT

Remove the right crankcase cover

(page 10-3) Drive Gear

Remove the oil pump (page 4-3) Dust Seal
Remove the water pump shaft
(page 6-9) ,

c 
Remove the dust seal, washers and Washers

 

tachometer drive gear.

6-10

NSRISOSP Cooling System

 

Remove the water pump bearing from the right
crankcase cover.

TOOLS:
o Bearing remover
set, 10 mm 07936-GE00000
o Remover shaft 07936-GE00100
o Remover head 07936-GE00200
o Sliding weigh! 07741 41010201

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: Mechanlcal Seal
0 Mechanical seal driver
07PMD-KBP0100
0 Driver 07749-0010000

 

Install the new water pump bearing to
the right crankcase cover using the
following tools.
TOOLs: Mechanical Seal
0 Driver 07749-0010000
0 Attachment.

24 x 26 mm 07746-0010700
0 Pilot, 10 mm 07746-0040100

   

6-11

NSR150$P Cooling System

 

Drive Gear

    
 

Check the tachometer drive gear for wear or

damage. Dust eal

Install the tachometer drive gear, washers

and new dust seal. ' ’0 'mi @(‘g
Was er

INSTALLATION Impeller

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 |bf.ft)

Check the water pump driven gear for _
wear or damage. Dr'ver Gear
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

NSR150$P 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 I
(pass 243) '
Remove the battery case l -
(page 16-6) -
Drain the coolant x »‘\k‘ ‘ ‘
(page 16-6)

Disconnect the reserve tank overflow tube and siphon tube.
Installation is in the reverse order of removal.

     

6-13

NSR 1 SOSP Engine Re moval / Installation

 

 

 

 

 

 

7-0

NSR 1 SOSP

Engine Removal/ Installation

 

 

 

 

Service Information 7-1 Engine Installation 7-4
Drive Sprocket Removal 7-2 Drive Sprocket Installation 7-6
Engine Removal 7-3

 

 

 

 

 

 

SERVICE IN FORMATION

GENERAL

0 During removal and installation, support the motorcycle using a safety stand or

hoist.

o A floorjack or other adjustable support is required to support and manoeuvre the

engine.

a When removing/installing the engine, tape the frame about the engine beforehand

to protect the frame.

a 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 sen/ice.

- 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

SPECIFICATIONS

(page 3-22)
(page 3-15)
(page 3-4)

 

ITEM

SPECIFICATIONS

 

Engine dry weight

23.9 kg (52.7 lb)

 

Transmission oil capacity at disassembly

0.8 litre (0.85 US 02, 0..70 Imp oz)

 

 

Coolant capacity (radiator and engine)

 

 

Litre )US oz, Imp oz)

 

TORQU E VALUES

Front engine hanger nut
Rear upper engine hanger nut
Rear lower engine hanger nut

55 N.m (5.6 kgf.m, 41 Ibf—ft)
55 N.m (5.6 kgfm, 41 |bf.ft)
76 N.m (7.5 kgfm, 56 Ibf—ft)

7-1

NSRISOSP Engi

ne 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.

Pinch Half

an 

 
     
 

Bearing Holder '

,1)“ v
v L,

 

7-2

NSR 1 SOSP Engine Re moval/ 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

    

more
Support the motorcycle using safely stand or
a hoist. Turn the ignition switch OFF and
disconnect the battery ground (-) cable.
A iloor jack or other adjustable support is
required to support and manoeuvre the
engine. The jack height must be continually
adjusted to relieve stress lor 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

NSR 1 SOSP Engine Re moval/ Installation

 

Disconnect the alternator 3P connector,
ignition pulse generator 2P connector
and neutral switch connector.

3P Connector

Disconnect the servo motor 6P
connector.
Remove the bolts and sen/o 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 carelul not m damage
the frame and engine.

Remove the engine hanger bolts and
nuts.
Remove the engine.

 

NSR 1 SOSP Engine Re moval/ Installation

 

ENGINE INSTALLATION

CAUTION
. Carerully align the mounting points with the
jack to prevent damage to engine. rrame, wires
and cables.

more
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 |bf.ft)

Tighten the rear lower engine hanger nut
to the specified torque.

TORQUE: 76 N.m (7.8 kgf-m, 56 lbf-fl)
Tighten the front engine hanger nut to the
specified torque.

TORQUE: 55 N.m 5.6 kglm, 41 Ibf-fl)

 

7-5

NSR 1 SOSP Engine Re moval/ 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

-Lower cowl
-Side cowl

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

NSR 1 SOSP Engine Re moval/ 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: 1O N.m (1.0 kglm, 7 |bf.ft)

Install the drive chain guard to the
drive sprocket cover.

Install the drive-sprocket-cover and
tighten the bolts securely.

 

NSR 1 SOSP Engine Re moval/ 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 Ibf-ft)

Adjust the drive chain slack.

 

NSRISOSP Cylinder Head/ Cylinder Piston

 

 

23 N.m (2.3 kgf-m, 17 Ibf-ft

 

8-0

NSRISOSP Cylinder Head/ Cylinder Piston

 

 

 

 

 

 

 

 

 

Service Information 8-1 Cylinder/Piston Selection 8-10
Troubleshooting 8-2 Cylinder/Piston 8-10
Cylinder Compression 8-3 Installation 8-10
Cylinder Head Removal 8-4 Cylinder Head 8-14
Cylinder/Piston Removal 8-5 Installation 8-14

 

 

 

SERVICE INFORMATION

GENERAL

0 The cylinder head, cylinder and piston can be serviced with the engine in the frame.

0 Be careful not to damage the mating surfaces by using a screwdriver when
removing the cylinder head and cylinder.

0 Take care not to damage the cylinder wall and piston.

a Clean all disassembled parts with clean solvent and dry them using compressed air

before inspection.

a Coat a" sliding surfaces with clean 2-stroke oil before assembly.
0 Refer to Section 9 for RC valve information.

SPECIFICATIONS

Unit: mm (in)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM STANDARD SERVICE LIMIT
Cylinder compression 108 kPa (1 1.0 kgf/cm , 156 psi) at -
400 min" (rpm)
Cylinder head warpage - 0.05 (0.002)
Cylinder ID. Code A 59.010 - 59.015 (2.3232 - 2.3234) 59.05 (2.325)
No mark 59.005 - 59.010 (2.3230 - 2.3232) 59.05 (2.325)
Code C 59.000 - 59.005 (2.3228 - 2.3230) 59.05 (2.325)
Cylinder out of round - 0.05 (0.002)
Cylinder warpage - 0.05 (0.002)
Piston mark direction 'IN' mark facing toward the intake side -
Piston O.D. Code A 58.965 - 58.970 (2.3215 - 2.3216) 58.92 (2.320)
Code B 58.960 - 58.965 (2.3213 - 2.3215) 58.92 (2.320)
Code C 58.955 - 58.960 (2.3211 - 2.3213) 58.92 (2.320)
Piston O.D. measurement point 12 mm (0.5 in) from the bottom
Piston pin hole |.D 16.002 - 16.015 (0.6300 - 0.6305) 16.03 (0.631)
Cylinder—to-piston clearance 0.040 - 0.050 (0.0016 - 0.0019) 0.080 (0.0031)
Piston pin O.D. 15.994 - 16.000 (0.6927 - 0.6299) 15.98 (0.629)
Piston-to-piston pin cIearance 0.002 - 0.021 (0.0001 - 0.0008) 0.04 (0.002)
Piston ring~to-ring groove clearance 0.12 (0.05)
Ring end gap Top 0.38 — 0.53 (0.015 — 0.021) 0.65 (0.026)
Second 0.38 - 0.53 (0.015 - 0.021 0.65 (0.026)
Ring mark Top 3R
Second 4R
Connecting rod small end |.D. 20.002 - 20.014 (0.7875 - 0.7880 20.03 (0.789)

 

8-1

 

NSRISOSP Cylinder Head/ Cylinder Piston

 

TORQUE VALUES

Spark plug
Cylinder head nut
Cylinder nut
Cylinder stud bolt

TROU BLESHOOTING

20 N.m
23 N.m
23 N.m
10 N.m

2.0 kgfm, 14 Ibf-ft)
2.3 kgfm, 17 ]bf—ft)
2.3 kgf.m, 17 Ibf-ft)
1.0 kgfm, 7 lbf-ft)

Compression too low, hard starting or poor performance at low speed

0 Cylinder head

- Leaking or damaged cylinder head gasket
- Warped or cracked cylinder head

0 Loose spark plug

a Leaking cylinder head gasket

0 Worn, stuck or broken piston rings

a Worn or damaged cylinder and piston

o Leaking crankcase primary compression
- Blown crankcase gasket
- Damaged crankshaft oil seal

Compression too high, overheating or knocking
0 Excessive carbon build-upon piston or combustion chamber

Excessive noise

a Worn cylinder and piston

o Worn piston pin or piston pin hole
a Worn connecting rod small end

Rough idle

a Low cylinder compression

8-2

NSRISOSP 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.

- - —
/ ompression Gauge Attachment

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 me gauge reading stops
rising. The maximum reading is usually reached
within 4 - 7 seconds.

 

STANDARD:
108 kPa (11.0 kgr/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.

7 \
Kickstarler Pedal

    

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

NSRISOSP Cylinder Head] Cylinder Piston

 

CYLINDER HEAD REMOVAL » ’ -
Upper Radiator Hose

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.

 

NSR15OSP 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.

CAUTIDN
. 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)

CYLINDERIPISTON REMOVAL
CYLINDER REMOVAL

Remove the exhaust pipe (Page 245).
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

 

    

Control Cable
Timing Pulley

Control

NSRISOSP Cylinder Head] Cylinder Piston

 

Loosen the screw and hose band.
Disconnect the water hose.

Remove the cylinder nuts.

NOTE
. Loosen the nuls in a crisscross paltern in
several steps.

Remove the cylinder.

CAUTION
. Be careiul nol lo damage the maling
surface when lhe removing the cylinder.

Remove the gasket and dowel pins.

Clean off any gasket material from the
cylinder lower surface.

CAUTION
. Be careiul nol lo damage the gasket
surface.

PISTON REMOVAL

NOTE

. Place a shop lowel over lhe crankcase
opening to prevenl the pislon pin clip lrom
railing inlo lhe crankcase.

Remove the piston pin clip, piston pin,
needle bearing and piston.

 

8-6

NSR150$P Cylinder Head] Cylinder Piston

 

Spread each piston ring and remove it
by lifting it up at a point just opposite the
gaps

CAUTION

. Do not damage tire piston ring by spreading

tile ends too [art He careful not to damage the
piston during piston ring removal

Remove the expandert

 

Plllon
Clean carbon deposits from the piston
NOTE
. Clean Carbon deposits lrom the piston ring grooves with a ring

that will ha discardndt Never use a wire brush: it will scratch the
groovnt

INSPECTION

CYLINDER
Inspect the cylinder bore for wear or damage
Remove the carbon deposits from the exhaust port.

 

CAUTION ollimlar
. Be careful not to damage tire plating on tho Cylinderwallt

II

    

Check the cylinder for warpage by placing a straight
edge and a feeler gauge. Emu-tam

SERVICE LIMIT: 0.05 mm (0.002.in)

 

8-7

NSR15OSP Cylinder Head] Cylinder Piston

 

Inspect the cylinder wall for scratches and wear.
Measure and record the cylinder ID. 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.ir|)

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
- Take measurements 12 mm (0.5 in) from (he bonom. 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 ID. in an X and Y
axis. Take the maximum reading to determine
|.D..

SERVICE LIMIT: 16.08 mm (0.83 in)

 

 

 

8-8

NSR15OSP Cylinder Head] Cylinder Piston

 

Measure the ID. of the connecting rod small
end.

SERVICE LIMIT: 20.03 mm (0.789 in)

If the connecting rod ID. is over the service
limit, the crankshaft must be replaced.

 

CYLINDERIPISTON SELECTION

Record the piston O.D. code letter
(A, C or no mark).

 

 

 

 

 

Cylinder
Record the cylinder |.D. code letter (A, C

or no mark) .

Use the cylinder and piston with the same
ID. and OD. codes when the replacing
the cylinder and piston as a set.

 

 

 

 

 

 

Cylinder ID. code A No mark C
Piston O.D. code
A O
No mark 0
C O

 

 

 

 

 

Pislon
CYLINDERIPISTON INSTALLATION

PISTON INSTALLATION

Clean the piston ring grooves.

 

Fling

8-9

NSRISOSP Cylinder Head] Cylinder Piston

 

Top Ring
Expander ‘

I
A/ um

fl Séond
Rin
pin ‘ V Ex rider 9
\ Pis on

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

0 Do not confuse ma tap and second rins. Ba
sum in install mm in the pmpnr groans.

 

Align the piston ring end gaps with the Piston
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. Locmion

Pin

 

8-10

NSR150$P Cylinder Head] Cylinder Piston

 

Clean off any gasket material from the
engine case surface (Page 8-5).

NOTE

0 Place a shop towel over the crankcase opening to
prevent the piston pin clip lrom 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 and gap with the piston
cut-out.

 

IS >20 mm [0.6 «0.8 in)

CYLINDER INSTALLATION

Apply a light but through coating of sealant to
crankcase as shown.

Install the dowel pins and new gasket.

 

 

 

 

8-11

NSR15OSP 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 Ibf-ft)

Connect the lower water hose.

Tighten the screw and hose band.

 

8-12

NSRl SOSP Cylinder Head/Cylinder Piston

 

Align the tab on the servo motor pulley with the 'Hi' mark
on the servo motor.

 
       
     
 
    

    

«aw-'3

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 50 to 100 in several 1
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.

kc
E5“.
‘3.—

  

It 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).

"HI" Mark

8—13

NSRl 5OSP 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 me nuts in a crisscross panern in
several steps.

TOROUE: 23 N.m (2.3 kgf.m, 17 Ibf-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

NSR 1 SOSP RC Valve / Se rvo Motor

 

9 N.m (0.9 kgf-m, 6.5 lbf-ft)

 

NSR 1 SOSP

RC Valve/ Servo Motor

 

 

 

 

 

 

 

 

 

 

 

l

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Service Information 9-1 RC Valve 9-3
Troubleshooting 9-2 Servo Motor 9-6
RC Valve Control Cable
Adjustment
SERVICE INFORMATION
GENERAL
0 The RC valve and sen/o motor can be serviced with the engine in the frame.
0 Take care not to damage the cylinder wall and piston.
0 Clean all disassembled parts with clean solvent and dry them using
compressed air before inspection.
0 Coat all sliding surfaces with clean 2-stroke oil before assembly.
0 For engine control module (ICM) inspection and removal/installation
see section 17.
0 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 lbfft)
Battery Servo Motor
A l1 le ICM
Main Fuse En ins l I
20 A Stgp mm: B” RIW Lg
Switch 1 ma |—'—‘—J
Ignition GM WIBI
Switch Lg
RIBI men _ WW
I—MBI G
Fuse 10 A WEI _
W
G: Green Y: Yellow
R: Red Bu: Blue
W: White Lg: Light Green
Bl: Black

9-1

NSR 1 SOSP

RC Valve/ Servo Motor

 

TROU BLESHOOTING

Engine starts, but RC valve does not operate

 

 

Check the RC valve control cable adjustment

— Abnormal

 

 

Normal

 

- RC valve control cable
misadjusted

. Sticking the RC valve
control cable

 

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 smooths 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,
RedNVhite, Light green and White).

— Abnormal - Faulty servo motor

 

 

Normal

 

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

I Open circuit between ICM and servo motor

I Faulty the ICM 2P (black), 4P (black),
servo motor 6P connector

I Faulty ICM

NSR 1 SOSP 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).

   

_ _ Timing \
If the gap exceeds 0.3 mm (0.01 In), adjust the Pulley , LL/
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

NSR 1 SOSP RC Valve [Servo Motor

 

Remove the nut, washer, special Nut/w-
washers and RC valve timing pulley.

NOTE
- The liming pulley nut has a In“ hand threads.

     
  
  
    

unfilg Pulley

Remove the dust seal. Dual seal

Q

Cylinder

Remove the RC valve shaft and RC RC Val“
valves from the cylinder.

Shalt /

Remove the E-clip from the RC valve

“‘3”- 

NSR 1 SOSP RC Valve [Servo Motor

 

INSPECTION

FlC Valves
Remove the carbon deposits from the RC /\
valves, shaft and shaft sliding area in the
cylinder.
CAUTION

o Be careful not to damage the RC valve and shaft.

NOTE
. Inhere is carbon on the RC valves and shaft.
RC valve will not operate properly.

 

Sh afl

Inspect the RC valves for wear, scores or ¢

damage. 7 -
Inspect the RC valve shaft for bend or damage. W
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.

   

Cylinder
FlC Valve Shaft

E-Clip

RC Valve
Timing Pulley @\

    

Special Washers
©®

«Ii/“RC Valve Timing Pulley Nut

9 N.m (0.9 kgf-m, 6.5 lbf-ft)

 

9-5

NSR 1 SOSP RC Valve [Servo Motor

 

Install the E-clip to the RC valve shaft. E-Clip

/

iii _,_.,, .
' \Sh...

w.—

Apply 2-stroke engine oil to the RC valves cylinder

and shaft.
Install the RC valves to the cylinder.

Shift

 

«9

NOTE
- At installalion. align (he punch marks as shown.

Install the RC valve shaft to the cylinder.

 

 

‘

  
 

Apply transmission oil to the new oil seal lip. Du“ 593'

Install the new oil seal to the cylinder.

Q

9-6

NSR 1 SOSP RC Valve [Servo Motor

 

Install the special washer to the RC valve
shaft aligning the cutouts on the shaft
and washer. 5M“

   
  
  
   

Install the RC valve timing pulley to the
RC valve shaft aligning the cutouts on
the shaft and washer.

Timing Pulley

Install the special washer to the RC valve
shaft aligning the cutouts on the shaft
and washer.

Install the washer and timing pulley nut to
the RC valve shaft.

NOTE
. The timing pulley nut has lefl 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 Ibf-ft)

   

Cylinder

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) 0.1-D.3mm(0.mn.0linl

   

9-7

NSR 1 SOSP RC Valve [Servo Motor

 

SERVO MOTOR Control Cabin-

    

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

. Berore this inspection, disconnectthe ICM 2P
(Black), 4P 1Black) connector to prevent the ICM
from damage.

Disconnect the ICM 2P (Black), 4P (Black)
connector.

6P Connector

Disconnect the servo motor 6P connector.

Measure the resistance between the servo
motor 6P connector terminals of the servo
motor side.

 

 

CONNECTION: Red/White-GreenlBlue
STANDARD: 4 - 6 k®
CONNECTION: White - White/Black
STANDARD: 8 - 15 k8

 

 

 

 

 

If out of specification, replace the servo motor
assembly.

 

 

 

9-8

NSR15OSP RC Valve/Servo Motor

 

 

Measure the resistance between the servo
motor 6P connector terminals of the servo
motor side.

6P Connector

 

 

5©fl

 

 

 

 

CONNECTION: Red/White - Light Green
STANDARD: 0 - 6 k8

CONNECTION: Green/Blue - Light Green
STANDARD: 0-6k®

 

 

It the resistance is 00, 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

NSR 1 SOSP RC Valve / Se rvo 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 5° to 10° 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

NSR 1 SOSP
Clutch / Gearshift Linkage / Kickstarter

 

    
 
   

25 N.m (2.1 kgl-m. 25 Ibt-IMBS /

‘ a  //
 \

0/
ID N.m 1.0 k l-m,7 lbl-ll 1' rx
( 9 33¢“ a 5 m N.m(1.0 kgl-m,1 lbl-II)
K -

-- a

10-0

NSR150SP Clutch] Gearshift Linkage

 

 

 

 

 

 

 

 

/ Kickstarter
Service Information 10-1 Kickstarter 10-11
Troubleshooting 10-2 Gearshift linkage 10-17
Right Crankcase Cover 10-2 Clutch Installation 10-21
Removal 10-3 Right Crankcase Cover
Clutch Removal 10-6 Installation 10-23
Primary Drive Gear 10-9

 

 

 

 

 

SERVICE IN FORMATION
GEN ERAL

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 sen/icing 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 sen/icing 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 STANDARD SERVICE LIMIT
Clutch lever free pla 10 - 20 (0.4 - 0.8)
Clutch outer guide O.D. 22.930 - 22.950 (0.9028 - 0.9035 22.80 (0.898)
|.D. 16.988 - 17.010 (0.6688 - 0.6697 17.04 (0.671)

 

Clutch outer I.D.

(23.06 (0.903)

 

Marnshaft CD. at clutch outer guide

)
)
23.000 - 23.021 (0.9055 - 0.9063)
16.966 - 16.984 (0.6680 - 0.6687)

16.95 (0.667)

 

 

 

 

 

 

 

 

 

 

 

 

 

Clutch sprrng free length 35.76 (1.408) 33.6 (1.32)
Clutch dlsc thickness A 2.92 - 3.08 (0.1150 - 0.1213) 2.5 (0.098)

B 2.62 - 2.73 (0.1031 - 0.1094) 2.2 (0.086)
Clutch plate warpage 0.20 (0.01)
Pinron gear l.D. 16.016 - 16.034 (0.6305 - 0.6313) 16.07 (0.633)
Kickstarter spindle O.D. 15.966 - 15.984 (0.6286 - 0.6293) 15.94 (0.628)
Kickstarter Idle gear |.D. 20.020 - 20.041 (0.7882 - 0.7890) 20.10 (0.791)
Idle gear bushlng 0.0. 19.934 - 19.995 (0.7868 - 0.7372) 19.92 (0.733)

|.D. 17.010 - 17.035 (0.6697 - 0.6707) 17.10 (0.673)

 

10-1

 

NSRISOSP Clutch] Gearshift Linkage

/ Kickstarter

 

TORQU E 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
TOOLS
Wrench, 20 X 24 mm
Extension bar

Gear holder
Clutch centre holder

10 N.m (1.0 kgf.m, 7 mm)

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 mm)

64 N.m (6.5 kgf—m, 47 Ibfft)

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)

07716-0020100
07716-0020500
07724-0010100
07923-KE10000

10-2

NSR1 SOSP 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 leverfree 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

NSR1 SOSP 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 all 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. W3

   

Tachometer Cable

Remove the bolt and kickstarter.

Loosen the screw and hose band.
Disconnect the lower water hose.

 

10-4

NSR1 SOSP 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 no! to damage the right
crankcase cover mating surface.

Remove the washer, water pump/oil
pump drive gear, shaft and washer.

 

Drive G ea r

Check the teeth of the water pump/oil pump 7
drive gear for wear or damage.
/Shlll
w share \

10-5

NSR1 SOSP 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
. lnlre dust seal replacement is required, press
the dust seal lo the case surface.

 

Check the clutch lifter arm for damage or bending.
Check the spring for fatigue or damage.
Replace these parts if necessary.

Lifllr Arm

Apply grease to the clutch lifter arm sliding
surface.
Apply grease to the dust seal lips and needle
bearing.
Gm

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

NSR1 SOSP Clutch] Gearshift Linkage
/ Kickstarter

 

Hold the pressure plate with theclutch centre Q'R’l‘fixs

TOOLS:
Wrench, 20 X 24 mm 077164020100
Extension bar 07716-0020500

Clutch centre holder 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

  

NSRl 5OSP 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.

Disc
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

NSR 1 5OSP Clutch / Gearshift Linkage
/Kickstarter

 

Clutch Oonhr

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 |.D..
SERVICE LIMIT: 23.06 mm (0.908 in)

Measure the clutch outer guide.

 

SERVICE LIMITS:
0.0.: 22.80 mm ( 03??)
D.: 17.04 mm (0.671 in)

MAINSHAFI'
Measure the mainshaft CD. 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. -

Judthr amid/Q

10—9

NSR1 SOSP 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 woodrufl key removal. he carelul
nor to damage me key groove ar
crankshalt.
. Do nol loose me waadruff key.

INSPECTION

Check the teeth of the primary drive
gear for wear or damage.

Check the teeth of the balancer drive Balance Drive Gaar
gear for wear or damage.

 

M '

.\

Woodrul‘l K9

INSTALLATION

Install the woodruff key to the cut out on
the crankshaft.

NOTE
. When woodrufl key lnslallallon, be careful
nor to damage me key groove ar
crankshalt.

 

10-10

   
 

NSR15OSP Clutch] Gearshift Linkage

 

 
   

/ Kickstarter
Install the primary drive gear to the ’y Align > R. 35:56:“: .
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 Ibf ft)

Install the clutch.

 

10-11

NSR1 SOSP 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

NSR1 SOSP Clutch] Gearshift Linkage
/ Kickstarter

 

DISASSEMBLY Pinion Gear

    
  

Remove the washer and pinion gear from
the kickstarter spindle.

Remove the rachet and rachet spring from
the kickstarter spindle.

 

Remm Spring

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

NSR15OSP Clutch] Gearshift Linkage

 

/ Kickstarter
INSPECTION Rum spring
KICKSTARTER l V.
Check the rachet spring and return spring
for wear or damage.
Return Spring
Rachel

Check the teeth of the rachet and pinion
gear for wear or damage.

Measure the pinion gear |.D..

SERVICE LIMIT: ????? mm ( in)

Check the spindle on the kickstarter
spindle for wear or damage.
Measure the kickstarter spindle O.D..

SERVICE LIMIT: 7???’??mm ( in)

KICKSTARTER IDLE GEAR

Check the teeth of the kickstarter idle gear
for wear or damage.
Measure the kickstarter idle gear |.D.

SERVICE LIMIT: ????mm ( in)
Measure the kickstarter idle gear collar.

SERVICE LIMITS: O.D.: mm ( in)

|.D.: mm (in)

10-14

 

Pinion Gear

 

. p

NSR1 SOSP Clutch] Gearshift Linkage
/ Kickstarter

 

COUNTERSHAFT

Measure the countershaft CD. at the
kickstarter idle gear collar.

SERVICE LIMIT: 16.96mm ( in)

Kickstarter Spindle

 

Pi ian Gear

Kickstartsr
Return Spring

\ J

  

 

Washer

 

 

 

 

I, Splndln

    

Install the washer and return to the kickstarter
spindle.

Washer

10-15

NSR1 SOSP Clutch] Gearshift Linkage
/ Kickstarter

 

Install the return spring, aligning the spring Imam. spring
end to the hole on the kickstarter spindle. 

    
   

Allan
Install the retainer, aligning the cutout in the
retainer with the spring end.

Punch mm VWide Groove

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.

Ram-r Spun“
“- Rachel

Pinion Gear

    

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

NSR1 SOSP Clutch] Gearshift Linkage
/ Kickstarter

 

Install the kickstarter assembly. chkstarter Asseth .A

g .

Install the dowel pin and stopper plate.
Install and tighten the stopper plate bolts
(8 mm and 10 mm) securely.

    

Stopper Plan ‘

Hook

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 ?’.7???’.7??
Remove the clutch.

Remove the bolt and gearshift pedal
linkage.

 

10-17

NSR1 SOSP 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 no! la! the rachel pawls fall when
removing the guide plate and drum shifter.

Remove the shift drum centre pin and
shift drum centre.

 

10-18

NSR1 SOSP 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.

Guide Plate

Drum Shift-r

 

Plunger

N 6
A flDali-chm PIWI

§
Wu
W

10-19

NSR1 SOSP 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 Ibf 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,16lbf.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.

Guido PlalaIDrum Shin-r

 

10-20

NSR1 SOSP 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.

\J - um Lining.
‘

;.

Move the gearshift pedal and check the
shift mechanism for smooth operation.

Install the clutch (see below)

CLUTCH INSTALLATION

Apply molybdenum 0” solution to the
clutch outer guide outer surface.

Install the clutch outer guide and clutch
outer to the mainshaft.

 

10-21

NSR1 SOSP Clutch] Gearshift Linkage
/ Kickstarter

 

    
  
 
   

Install the spring seat and judder spring on the clutch centre as Spring Seat

shown.

 

Jufldcl Spring

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.

Clutc Disc 5

Clutch Dlsc A
Clutch Plate

    

Clutch centre

 
 
 

Clutch 0 [er Guide

   

Install the washer pressure plate, clutch
discs, clutch plates, judder spring, spring
seat and clutch centre as a set to the
clutch outer.

 

NSR1 SOSP 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 07923-KE10000
Wrench, 20 X 24 mm 0771641020100

Extension bar 07716-0020500

TORQUE: 64 N.m (6.5 kglm, 47 Ibf ft)

Remove the clutch centre holder and
stake the lock nut into the mainshaft
groove.

CAUTION

- Be careful not to damage the mainshafl
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 kglm, 9 Ibf.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

NSR1 SOSP 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: 10 N.m (1.0 kgfm, 7 Ibf ft)
8mm: 26 N.m (2.7 kgfm, 20 Ibf n)

 

10-24

NSR1 SOSP 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 O kgf-m, 7 Ibf.ft) - chometer Cable
\

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.

 

NSR 1 SOSP Alternator / Balancer

 

 

11-0

 

 

 

 

 

NSR150$P Alternator / Balancer
Service Information 11-1 Balancer Removal 11-4
Troubleshooting 11 -1 Balancer Installation 11 -5
Stator Removal 11 -2 Flywheel Installation 11 -6
Flywheel Removal 11-3 Stator Installation 11-7

 

 

 

 

 

 

SERVICE IN FORMATION

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.

TORQU E VALUES

Timing hole cap
Flywheel nut

Balancer driven gear nut
Starter socket bolt

Ignition pulse generator socket bolt

Apply a locking agent to the threads

TOOLS

Flywheel holder
Flywheel puller
Gear holder

3 N.m (0.3 kgf.m, 2.2 Ibf-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 Ibf-ft)
10 N.m (1.0 kgf.m, 7 lbf-ft)

07725-0040000
O7KMC-HE01000
07724-0010100

11-1

NSR 1 SOSP

Alternator / Balancer

 

STATOR REMOVAL

NOTE
Reier 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 lert crankcase cover (stator) is magnetically
attached to the llywheel. be carelul
to removal.

Remove the gasket and dowel pins.

Remove the grommet from the left
crankcase cover.

11-2

/ 2P Conn-ch)!

 

 

NSRISOSP Alternator / Balancer

 

Remove the socket bolts and
ignition pulse generator.
Remove the bolts and stator.

‘-
Suck at Bolts

   
   

Ignlflon Pulse
E [Generator 

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 O7KMC-HEO1000

< F_lywhael Pullar

Remove the woodruff key.

NOTE
. When woodmff key removal, be careful not to damage the key groove or crankshafl.
. Do not loose the woodmff key.

11-3

NSRISOSP Alternator / Balancer

BALANCER REMOVAL . . NuuWashe ' /'
~ Gear Holder
REMOVAL ' 4
. _ _1

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 07724-0010100
Wrench 20 X 24 mm

07716-0020100

Remove the balancer driven gear
and woodruff key.

 

NOTE

. When woodrufl key removal, he carer-u no! lo
damage the key groove or halancnr.

. Do not loose ma woodrufl' key.

Remove the balancer from the left
crankcase.

 

INSPECTION
Driven Gur

Check the balancer driven gear for wear

or damage.

Replace the balancer driven gear if

necessary.

 

11-4

NSR1 SOSP Alternator / Balancer

 

Check the balancer for bend, wear or
damage.
Replace the balancer driven if necessary.

Balancer

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

NSR150$P Alternator / Balancer

 

Hold the balancer drive gear with the
gear holder and remove the balancer
drive gear nut and washer.

TOOL
Gear holder 07724-0010100
Wrench 07716-0020100

Tighten the balancer drive gear nut to

the specified torque.

 

TORQUE: 54 N.m (5.5 kgf.m 40 Ibf-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 woodluff key installation, be
careful not to damage the key groove or
crankshaft.

Flywheel

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.

N uthu hor

 

TORQUE: 64 N.m (6.5 kgf.m 47 Ibffl)

11-6

NSR150$P Alternator / Balancer

 

STATOR INSTALLATION

Ignition Pulse Generator Socket Bolt
10 w (1.0 kgf-m 7|bf—ft)
I

    
  
 

Stator Socket
Bolt

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: 1O N.m (1.0 kgf.m 7 Ibffl)

 

11-7

NSR15OSP 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 left crankcase cover.

NOTE

. The lefl crankcase cover (stator) is magnetically
altached 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

NSRISOSP Crankshaft / Transmission

 

 

12-0

 

 

 

 

 

NSR150$P Crankshaft / Transmission
Service Information 12-1 Crankshaft 12-10
Troubleshooting 12-3 Crankcase Bearing
Crankcase Separation 12-4 Replacement 12-11
Transmission 12-4 Crankcase Assembly 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 STANDARD SERVICE LIMIT

Connecting rod big Side clearance 0.3 - 0.7 (0.012 - 0.028)

end Radial clearance 0.05 (0.002)

Crankshaft runout A 0.05 (0.002)

B 0.03 (0.001)

Transmission gear |.D. M5, M6 22.020 - 22.041 (0.8669 - 0.8678) 22.10 (0.870)

20.020 - 20.041 (0.7882 - 0.7890) 20.10 (0.791)

CZ, C4 22.020 - 22.041 (0.8669 - 0.8678) 22.10 (0.870)

C3 25.020 - 25.041 (0.9850 - 0.9859) 25.10 (0.988)

Transmission gear M5, M6 21.979 - 22.000 (0.8653 - 0.8661) 21.90 (0.862)

bushing O.D. C1 19.984 - 19.995 (0.7868 - 0.7872) 19.90 (0.783)

C2 21.984 - 22.005 (0.8655 - 0.8663) 21.90 (0.862)

C3 24.984 - 24.993 (0.9836 - 0.9840) 24.90 (0.980)

Transmission gear M5, M6 20.000 - 20.021 (0.7874 - 0.7882) 20.10 (0.791)

bushing |.D. C1 17.016 - 17.034 (0.6700 - 0.6706) 17.10 (0.673)

C2 20.020 - 20.041 (0.7882 - 0.7890) 20.10 (0.791)

C3 22.020 - 22.041 (0.8669 - 0.8678) 22.10 (0.870)

 

 

 

 

12-1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NSR 150SP Crankshaft / Transmission
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Gear—to-bushing M5, M6 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance C1 0.025 - 0.057 (0.0010 - 0.0022) 0.10 (0.004)
C2 0.0 15 - 0.057 (0.0006 - 0.0022) 0.10 (0.004)
C3 0.027 - 0.057 (0.0011 - 0.0022) 0.10 (0.004)
Mainshafl O.D. M5 19.959 — 19.980 (0.7858 — 0.7866) 0.10 (0.004)
Right crankcase 16.966 — 16.984 (0.6679 — 0.6686) 19.92 (0.784)
journal
Countershaft O.D. C1 16.975 - 16.984 (0.6683 — 0.6687) 16.95 (0.667)
C2 19.974 - 19.984 (0.7863 — 0.7867) 16.95 (0.667)
C3, C4 21.959 - 21.980 (0.8645 - 0.8653) 19.94 (0.785)
Gear—to-shaft C4 0.040 - 0.082 (0.0016 - 0.0032) 21.09 (0.830)
clearance
Gear bushing—to- M5, M6 0.020 - 0.062 (0.0001 - 0.0024) 0.10 (0.004)
shaft clearance C1 0.032 - 0.059 (0.0013 - 0.0023) 0.10 (0.004)
C2 0.033 - 0.067 (0.0013 - 0.0026) 0.10 (0.004)
C3 0.040 - 0.082 (0.0016 - 0.0032) 0.10 (0.004)
Shift fork claw 4.93 - 5.00 (0.194 - 0.197) 4.80 (0.189)
thickness
Shift fork |.D 12.041 — 12.056 (0.4741 — 0.4746) 12.65 (0.475)

 

 

 

Shift fork shaft O.D

 

11.983 — 11.994 (0.4718 — 0.4722)

 

11.973 (0.4714)

 

TORQUE VALUES

Crankcase bolt
Bearing set plate bolt

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

10 N.rn (1.0 kgfm, 7 Ib-ft)
10 N.rn (1.0 kgf.m, 7 lb-ft)
Apply a locking agent to the threads

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-KCIOIOO
07964-M300200
07965-VM00200

07SMC-0010001

12-2

 

NSR150$P Crankshaft / Transmission

 

TROU BLESHOOTING

Excessive noise
a Worn connecting rod big end bearing
a Bent connecting rod
0 Worn crankshaft main bearing
a Worn transmission gear

Hard to shift
a Improper clutch adjustment
0 Improper clutch operation
a Bent shift fork
o Bent shift fork shaft
0 Bent shift spindle
o Damaged shift drum cam grooves
o Incorrect transmission on weight

Transmission jumps out of gear
a Worn gear dogs or slots Bent fork shaft
0 Broken shift drum stopper
0 Worn or bent shift forks
a Broken shift linkage return spring

12-3

NSR ISOSP 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 balls in a crisscross
paltern in several steps.

Attach the case puller to the left crankcase an. Fuller
and separate the crankcase halves.

NOTE
. Separate the right and left crankcase from each
other while lapping 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
5e calaful 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

NSR 1 SOSP

Crankshaft [Transmission

 

Remove the main shaft and countershaft
from the right crankcase.

NOTE
o 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
ror 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 ID. of each gear.

SERVICE LIMITS:

M5, M6: 22.10 mm (0.870 in)
C1:

C2, C4: 22.10 mm (0.870 in)
cs: 25.10 mm (0.988 in)
BUSHING

Check the bushings for damage or
excessive wear.
Measure the OD. of each bushing.

SERVICE LIMITS:

M5, M6: mm in)

C1: 19.90 mm (in)
C2: (in)

CS: 24.90 mm ( in),,

Measure the ID. of each bushing.

 

Countershaft

SERVICE LIMITS:

M5, M6: mm in)

C1: 19.10 mm (in)

C2: 20.40 mm (in)
CS: 22.10 mm ( in),,

12-5

NSR ISOSP Crankshaft [Transmission

 

MAINSHAFT I COUNTERSHAFT
Check the spline grooves and sliding
surfaces for damage or abnormal wear.
Measure the OD. of the mainshaft and

countershaft at the gear and bushing
sliding areas.

SERVICE LIMITS: a

Mainshaft: M5 gear bushing: > mm in)

Case journal:

Countershaft: C1 gear bushing: mm (in)
C2 gear bushing: mm (in)
C3 gear bushing: mm (in)
C4 gear bushing: mm (in)

Calculate the clearance by subtracting mainshaft/countershaft O.D. from gear bushing
|.D..

SERVICE LIMITS:
M5: mm (in)

C1: mm (in)
C2: mm (in)
C3: mm (in)

Calculate the clearance by subtracting gear bushing CD. from gear |.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 ID. and claw thickness.

SERVICE LIMITS: I —
|.D.:12.65 mm (in),
Claw thickness: 4.20 mm in)

12-6

NSR ISOSP 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 w
journal for wear or damage. I
Check the left crankcase shift drum journal for Fm“ J°“"“' :
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 ior freedom oimovement or rotation on the shalt.

. 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 'n the grooves.

. Check that the snap rings are seated in the grooves. Align their end gaps with the grooves oi the spline.
. install the lock washer aligning its tabs with the grooves in the spline washer.

12-7

NSRISOSP Crankshaft / Transmission

 

MAI NSHAFT

MG Gear (241)

M5 5°” (23” WIS/M4 Gear (17Il9'r) Snap Ring Washer

MainshafllM1 Gear (127)

          

Spline Washer

M5 Gear Bushing Spline Waelle S R. M2 Gear (1ST)
“a” '"9 M6 Gear Bushing

 

 

 

COU NTERSHAFT

Spline Washer

c1 Gear (351i

  
  
   

c5 Gear (2")
Spline Washer

Em @
“9 c ear(25T)

Washer

Washer

 

c2 4 mm

c2 Ge r Bushing

(:1 Gear alluring
Washer

Countershan

(Bi

 

 

 

 

12-8

NSR ISOSP Crankshaft [Transmission

 

INSTALLATION

Malnshal't

Apply transmission oil to the following
parts.
0 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 countershafl installation,

be careful not to damage the countershaft oil cwn‘shafl
seal

  
 

.
W' Fl" -. --.
"R" Mark "L" Mark
NOTE
- Each shift fork has an identification mark: 'R' *- ‘
is for the right shift forkY 'L' is for the left shift
fork and 'C' is for the center shift fork. .
"0" Mark

Install the shift forks to the grooves of
the shifter gear with their marks facing
up (right crankcase side).

 

12-9

NSR 1 SOSP

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 -001 0000

 

 
   
  

Crankshaft

-= ‘7. want c nkcase

   
    

Unlversal

Holder\

 

 

 

 

12-10

NSRISOSP 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: 0.05 mm (0.002 in)
B: 0.03 mm (0.001 in)

 

 

 

leeIGauge
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)

05
kg“

0N6.

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

NSR 1 50SP

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.

TO0LS..

Remover head, 16 mm
O7936-MK50100
Remover shaft, 15 mm
O7936-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

Countshan
Oil Sui

Bahnoerall Seal

   
    

  

.“
Cnnkliufl
‘0!

on Sui ~~ , , 
. l V Gearshift Spindle OIISBOI
LE"

Balanner Bearing“

‘ _

D river

. Install in the new media bearing squarely with the marking side racing up.

12-12

NSR ISOSP 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 “WT”:
.Drive in the new bearings squarely with the marking
side facing up.
COU NTERSHAFT BEARING
Apply transmission oil to the new bearing. DflV"

Install the new bearing to the left

 

crankcase using the following special
tools.

 

 

Ci |

 

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 surlace.

. Crankshalt 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

NSRISOSP Crankshaft] Transmission

 

Install the new balancer 0” seal, gearshift aflmflrou s... Counuhaft
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

NSR 150$P Crankshaft] Transmission

 

Remove the balancer bearing, mainshaft .
bearing countershaft bearing, shift drum Shin D""" 59"“9 c ‘ M‘iMhm Enring
bearing and crankshaft bearing out of the ' ’
right crankcase.

        
    
  

 

Mainshaft Bearing
Install the new bearing to the right
crankcase using the following tools.

  

“var r . .
07749—0010000 °°“"‘°,'9"‘" Beafing; ! Grammy, Bearing
Attachment, 42 x 47mm
07746-0010300
Pilot, 17mm

07746-0040400

  

 

 

 

NOTE:
. Drive in the new bearing squarely with the
marking side racing 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

 

 

 

 

s.
b

we i . 

- Drive in the new bearing squarely with the iAflachmlml pllm

marking side racing up.

Balancer Bearing
Install the new bearing to the right crankcase using the following special tools.

TOOLS: -—-—— ——-~r ——~ ‘3
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. 7*
Muchmsnl I Pllot

12-15

NSR ISOSP 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. Install the balancer shaft bearing set
plate.

Install and tighten the bolts to the specified
torque.

TORQUE: 1O N.m (1.0 kgf.m, 7 Ibfjt)

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: 1o N.m (1.0 kgf.m, 1 tbfft)

CRANKSHAFT BEARING

NOTE

. At crankcase bearing installation, install the bearing to
the specified depth from the crankcase mating surface.

. Crankshafl bearing must be installed in a parallel
manner.

     

Amhmcnl]

Prlpt

 

 

 

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 07749-0010000
Attachment, 52 X 55 mm 07746-0010400
Pilot, 22 mm 07746-0041000
NOTE

0 Drive in the new beating squarely with the marking side racing up.

12-16

NSR ISOSP 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

ll 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-M500200
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 O7964-MBOOZOO
Crank assembly shaft 07965-VM00200

     

Crank Assembly
Collar

 

Dowel Plns

 

NSR ISOSP 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 07964-M300200 \
Crank assembly shaft 07965-VM00200
. NOTE on Seal
Install the crankshaft oil seal into me left crankcase lo l/Il/ll/l/ll/l/Il/ll/l/ _
before the surface onhe left crankcase. \  ~ /-\9/

rank Assembly
Pack grease into the cavity between the right crankshaft collar

oil seal lips. Null Assembly snarl
§/\\

Press the right crankshaft oil seal into the right crankcase \ \\\q
using the crank case assembly tool. ‘

  

 

TOOLS:

Crank assembly collar 07964-M306200
Crank assembly shaft 07965-VM00200
NOTE

o Install the crankshaft oil seal into the light crankcase to '2’? '2’? 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 |bf.ft)

Install the engine to the frame (Section 7).

 

12-18

NSRISOSP
Front Wheel / Suspension] Steering

 

 

59 N.m (6.0 kgi-m 43 Inf-fl)

13-0

NSR1 SOSP
Front Wheel / Suspension] Steering

 

SERVICE INFORMATION

GENERAL

 

A contaminated brake din: or pad reduces nopplng mar. Discard contaminated pads and clean
contaminated also wltll I lllgll quality brake dogmulllg I961“.
fildlng on damaged rlms or spam lmpaln “to operation at the vehlele.

Wheel balance directly Ill-cu up mummy, handling and ovmll may at in. llwtoreyclo. carefully chock
balance before rah-stalling the wheel

0 When servicing the front wheel, support the motorcycle securely using a safety
stand or hoist.

0 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
Unll: mm (in)
ITEM STANDARD SERVICE
LIMIT
Minimum tire tread depth 1.5 (0.06)
Cold tire pressure Driver 0m 200 kPa (2.00 kgf/cm , 29 psi)
Driver and 200 kPa (2.00 kgf/cm’, 29 psi)
passenger
Front axle runout 0.2 (0.008)
Front wheel rim run out Radial 2.0 (0.08)
Axial 2.0 (0.08)
Wheel balance weight Max 60 g
Fork spring free length 3104 (12.22) 304.2
(11.98)
Fork spring installed direction Tapered side facing down
Fork tube runout 0.2 (0.008)
Recommended fork oil Fork fluid
Fork oil level 125 (4.9)
Fork oil capacity 322 crll’(10.9 US oz, 11.31 Imp oz)
Steering bearing preload D » 15 Nm (0,1 - 0.15 kgtm)

 

13-1

 

NSRl SOSP

Front Wheel / Suspension] Steering

 

TORQUE VALUES
Front axle nut
Front brake disc bolt

Steering stem nut
Steering top thread

Top bridge pinch bolt
Bottom bridge pinch bolt
Fork cap

Fork socket bolt

Front caliper bracket bolt

TOOLS

Attachment, 42 X 47 mm
Pilot, 15 mm

Driver

Bearing remover shalt

Bearing remover head, 15 mm

Fork seal driver

Fork seal driver attachment
Steering stem socket
Driver attachment

Steering stem driver

TROUBLESHOOTING

Hard steering
Steering top thread too tight

59 Nm (6‘0 kgf*m, 43 |bf*ft)
42 Nm (4.3 kgf‘m, 31 lbf'ft)

88 Bin (9.0mm, 65 rpm)
1 Nm (0.1 kgf*m, 0.7 lbf‘ft)
22 Nm (2.2 kgf‘m, 16 |bl*ft)
27 Nm (2.8 kgf*m, 20 lbf*ft)
22 Nm (2.2 kgf‘m, 1e |bf*ft)
20 Nm (2.0 kgf’m, 14 lbf'ft)

30 Nm (3.1 kgf"m, 22 mm)

07746-001 0300
07746-0040300
07749—001 0000
07746-00501 00
07746—0050400
07747-001 0100
07947-KA20200
07916-3710101

07946-3290000
079464300001

Faulty steering head bearings
Damaged steering head bearings

Faulty lire
Insufficient tire pressure

Steers to one side or does not track straight

Bent fork

Faulty steering head bearings
Damaged steean head bearings
Unevenly adjusted right and left forks

Bent frame
Worn wheel bearings
Bent front axle

Worn swingarrn pivot component

Front wheel wobbling
Bent rim

Worn wheel bearings
Faulty tire

Unbalanced tire and wheel

13-2

U—nut
Apply a locking agent
to the threads

Apply a locking agent
to the threads
Apply a locking agent
to the threads

Soft Suspension
Weak fork spring

Low fluid level In fork
Insufficient fluid in fork
Low tire pressure

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

NSRl SOSP

Front Wheel / Suspension] Steering

 

HANDLEBAR

RIGHT HANDLEBAR REMOVAL
Remove the master cylinder
(page 15-11).

CAUTION
- Do not amount the hyannlo Ilm.

NOTE
- The master cylinder upright to prevent air "om
entaian the hydraullc synem.

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

    

I Malt-r eyumm

 

 

NSRISOSP
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.

   

HIndloBar

13-4

NSR150SP
Front Wheel / Suspension/ Steering

 

LEFI' 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

NSR1 SOSP
Front Wheel / Suspension] 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

NSRI SOSP
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

NSRISOSP
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.

 

Engine Stop Snatch Hmng
Install the engine stop switch, aligning ‘
the its mating surface with the punch
mark on me handlebar.
Tighten the forward screw first, then
tighten the rear screw securely.

 

Install the master cylinder (page 15-16).

    

LEFT HANDLEBAR INSTALLATION "mm-j V

Install the right handlebar onto the fork
tube, aligning the stopper on the
Handlebar with the grove in the top
bridge.

13-8

NSRISOSP
Front Wheel / Suspension] Steering

 

Install the stop 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 III. adhesive to dry lor an hour More uslng.

Install the handlebar weight to the
handlebar aligning the tab on the
handlebar weight with the slit oi the
handlebar.

install and tighten the new screw securely.

 

13-9

NSR150SP
Front Wheel / Suspension/ 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 “UP” "up" Mart:
mark lacing 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

NSR1 508?
Front Wheel / Suspension] Steering

 

FRONT WHEEL

 

A oonlnmlnaled brake also oi pad reduces
slopplng powet. Dilcard eonmmlnalod pad: and
clean eonhmlnated also with I high qufllly brake
dogmasan 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. Axle sum

Remove the speedometer gear box
from the left side of the front wheel.

 

13-11

NSR1 SOSP

Front Wheel / Suspension] Steering

 

Remove the side collar from the right side 01
the tram wheel.

INSPECTION

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 ‘/2 the total indicator
reading.

SERVICE LIMIT: 0.2 mm (0.003 In)
WHEEL BEARING

Turn the inner race of each bearing with
your finger. The

Bearings should tum 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

Smootth and quietly, if they fit loosely in the
hub.

NOTE:
Replace the wheel beefing: In pure.

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 V2 the total indicator
reading.

SERVICE LIMITS:
Radial: 2.0 mm (0.08 In)
Axial: 2.0 mm (0.08 in)

Check the spokes for loose or damage.

13-12

 

 

   

Axl- 8M"

Front Wheel

NSRISOSP
Front Wheel / Suspension] Steering

 

DISASSEMBLV

Remove the right and Ielt 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
077450050100
Bearing remover head, 15 mm 3"“ R'M‘W" “"fl

077450050400

    

NOTE:
Replace the wheel bearing In pars. Do not re-we old bearings.

13-13

NSR1 SOSP
Front Wheel / Suspension] Steering

 

ASSEMBLY

PTO"! Brake DISC BO"
42 N.m (4‘3 kgf.m,31 let)

      
  

Le“ Wmel Beafing Speedometer Gear Retainer

l®© k Left Dust Seal

Front Brake Disc

ight 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
07749-001 0000

Attachment, 42 X 47 mm
07746-0010300

Pilot, 15 mm
077460040300

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, a1 lbl't)

13-14

NSRISOSP
Front Wheel / Suspension] Steering

 

WHEEL BALANCE

 

0 Wind balance dlreclly Iflecll [M “filmy, handling and ovlnll
solely at the molovcycle. carefully check balance before
veinshlllng the thII.

NOTE:

e The wheel balance must be checked when the tire I:

o Remountod.

- For optimum balance, the ter mvk (I paint dot

o On "In slde wall) must be located flux! to the valve stem.
n Remounl the tire ll‘ neceuury.

 

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 verily 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 he ’ ‘
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.
Cur Rum-h. r
.-
1

  

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

NSRISOSP
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 me
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

NSRISOSP
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.lt)

Connect the speedometer cable.
Install and tighten the screw securely.

FORK
Spooflotmohr Cutl-
REMOVAL -

   

Remove the front wheel (page 13-11).
Remove the front brake caliper (15-17) (right
side only).

CAUTION

Q Do not suspend the bran caliper flolll the brake
hole.

. Do not leal Ihl links home.

Remove the bolts, screw and front fender.
From Bull: Iltpnv

  

13-17

NSRl SOSP
Front Wheel / Suspension] Steering

 

Remove. the wire band.

 

Remove the handlebar from the fork tube (page 13-3).

Loosen the top bridge pinch bolt. I
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 0-ring from the
fork tube.

   

The lurk cap is under eprlng plenum. U0. we
when removing it and woe! eye and In»
protection.

13-18

NSRISOSP
Front Wheel / Suspension] Steering

 

Remove the spring collar.
Swing Cull-r
\

  

Jon Flak

Remove the spring joint plate and fork spring.

 

Pourout the fork oil from the fork leg by
pumping the fork 8-10 times.

 

CAUTION
Do not om llglllen m. but:ka

Hold the brake caliper
bracket of the fork slider in
a vice with a piece of
wood or soft jaws to avoid
damage.

Sock-t desc-llnv with" sum 30“!me Washer

    

Loosen and remove the
fork socket bolt and
sealing washer from the
fork slidert

If the fork piston turns with the socket bolt. temporarily install the fork spring, spring
joint plate, spring collar and fork cap.

13-19

NSRISOSP
Front Wheel / Suspension / Steering

 

Remove the fork piston and rebound

spring. -
NOTE rm Pinon .
0 Do not remove the fork plnlon rlng, miles: It In -

mull-y to "place wllh n nuw one. \

inbound Sprung

Remove the dust seal.
Remove the stopper n‘ng from the Du"
groove of the fork slider.

CAUTION
0 Do not scratch lhe Inner fork lube s|ldlng
surface,

NOTE
cheek um the lork tub. movu onloome In
lhs lork tilde! I! It does not, check the folk
lube lor bending of damage. Ind bushlng:
for wear or damage.

Using quid< successive motions, pull
the fork tube out of the fork slider.

Remove the oil lock piece from the fork
slider.

 

13-20

NSRl SOSP

Front Wheel / Suspension/ Steering

 

Remove the oil seal, back~up ring
and slider bushing from
The fork tube.

NOTE

0 Do not remove the fork lube bushing
unless It Is
. Necessary to nplnes 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 (11.93 in)

FORK TUBE, SLIDER, FORK
PISTON

Check the fork tube, slider and fork
piston for score mams, and excessive
or abnormal wear.

Replace the component it necessary.

Sllfllng Bushing

13-21

   

Oil
Seal

 

. a; 3,.t‘tx’172‘i'f:

Fork Tub-

 

NSRlSOSP
Front Wheel / Suspension] Steering

 

Check the fork piston ring for wear or

damage.

Check the rebound spring for fatigue

or damage. Piston Rlng\

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 rouu the lork lube It It cannot be
perleclly malgmanod with mlnlmll man.

FORK TUBE BUSHING . .
Visually inspect the slider and fork B"5“'"9 Back-UP Rlng
tube bushings.

Replace the bushings if there is K '/
excessive soonng or scratching, or if \
the tetlon is worn so that the copper

C ck Points

surface appears on more 3/4 of the
entire surface.

Check the backup ring; replace it if
there is any distortion at the points
shown.

Copper Surfaces

13-22

NSR1 50S?

Front Wheel / Suspension] Steering

 

ASSEMBLY

Before assembly, wash all parts wim a high flash point or non-flammable solvent and

wipe them olf completelyi

Dust Seal , FOM'sfon Sgrlng V
\ I = II .

Stopper Rin9\_ ®
on Seal Q»

Back up rin9\\:~§

Bushing

  
 
    

 

Fork

Slider \

F ks k I Rebou d .
or 00 G ' /
Bolt 9" Spnng "
uu.m[z.WJr-\IN<:I\ sealing

Washer

Install a new fork tube bushing if the
tube bushing has been
Removed.

CAUTION

o Be careful no! lo damage the lovk lube
buthlng emlng.

o no nolopen malorktube bushing more than
necessity.

NOTE

. Remove the burn from the bushing matlng
surface.

. Being careful no! lo peel on Iha coating.

Install the slider bushing and back-up
ring to the fork tube.

Apply the oil to the new oil seal Iip.
Install the new oil seal to the fork tube
with it marking side lacing up.

13-23

   
  
  
   

 

 

 

K:—

Sliding Batting

j % Fork Cap
 z n m [2,2 W! n.
s Q\ n m.)
O-Ring
\ Spring

Collar

\Spring Joint

Plate

 

, Fork Spran
Fork Tube Bushing

   
   

Fork Tub. Bushing

Fork Tun-

Back-up Ring

on sea.

NSR1 50SP

Front Wheel / Suspension/ Steering

 

Install the oil lock piece onto me fork
tube end.

Coat the lonk 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 tlghtm me bracket.

Hold the brake caliper bracket of the
fork slider in a vice with a piece of wood
or soft iaws 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.

Tighten the fork socket bolt to the
specified torque.

TORQUE: 20 N.m (2.0 kgf‘m, 14 lbf'tt)

If the fork piston turns with the socket
bolt, temporarily install the fork spring,
spring joint plate, spring collar and fork
cap.

13-24

Rebound Spring

Fort Piston

 

“ A Oil Lock Plec-

 

 

Fort Tub.

Snlln Washer

Furl Socket Bolt

Soclm WHIII‘IO Washer

 

NSRISOSP
Front Wheel / Suspension [Steering

 

Drive in the new oil seal into me fork tube until
stopper n'ng groove is visible, using the special
tools.

TOOLS:
Fork seal driver
07747410101 00
Fork seal driver attachment
O7947-KA20200

 

 

 

 

 

Stoppw
Ring
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.

" K, Dust
Seal

 

Pour half the required amount of the
recommended fork oil in the fork tube.

 

 

RECOMMENDED FORK OIL:
Foflt fluid
OIL CAPACITY:
322 cm’ (10.9 US oz, 11.3 Imp oz)

 

 

 

 

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.

 

. Spring
Measure the ori level from the top of the
fork tube. \
OlL LEVEL: 125mm (4.9m) ’

Pull the fork tube and install the fork
spring with the tapered side facing
down.

Dawn

13-25

NSRISOSP
Front Wheel / Suspension] Steering

 

Install the spring joint plate and spring collar. M,“ PM.

 

O-R’
Apply fork oil and install the new O-ring and In.
install the new O-ring to the fork cap.

Install the fork cap into the fork tube.

NOTE
o Tighten the tork cap after running nu rm tub» Into the
lork bridge.

   

INSTALLATION

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 bn'dge pinch bolt to the specified torque.

TORQUE: 27 N.m (2.3 mm, 20 Ibf.ft)

Tighten the fork cap to the torque.

TORQUE: 22 N.m (2.2 kgtm, 16 Ibm)

Tighten the top bridge pinch bolt to the
specified torque.

TORQUE: 21 N.m (2.8 kgtm, 20 |bt.l't)

Install the handlebar (right: page 13-6,
left 13-8).

 

13-26

NSRISOSP
Front Wheel / Suspension] Steering

 

Install the wire band.

—- n. .
ern Bunch

 

Install the front fender.
install and tighten the bolts and
screws securely.

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 212).
Remove handlebar (page 1343).
Remove the front wheel (page 134 1).
Remove the horn connector (page 18-
17)

Disconnect the ignition switch 2P
connector.

 

Remove the steering stern nut and
washer

 

13-27

NSRl SOSP

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 079164710101

Remove the upper bearing inner race
and upper bearing
Steel balls.

NOTE
. Do no! loose the steel balls.

 

 
   

Top This“!

 

NSRISOSP
Front Wheel / Suspension] Steering

 

Re move the steering stem and
lower bearing steel balls.

NOTE
o Do not loos. (It. “0d bllll.

Check the steering bearing steel
balls, inner and outer races for
wear or damage.

STEERING STEM BEARINGS
REPLACEMENT

NOTE

0 Always "pl-o. the burlan ltd new
as a uh

Remove the upper and lower
bearing outer races.

 

Remove the bolts and hom stay.

 

Inner Race

Slam Nut

Install the stern 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 raoe ,,.

with a chisel or equivalent tool, being ’

careful not to damage the stem. Dust summer

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.

San-ring Slam

Sharing sum

TOOL:
Steering stem driver » "um Run
079464300001

 

Install the horn stay to the
steering stern.

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 077490010000
Driver attachment 0794643290000

13-30

NSRlsosP
Front Wheel / Suspension] Steering

 

- steering Stem Nut Steering Top
Top Bridge
7 @/ Washer [/f/ Thread
,/

//"' Upper Bearing

,,/"/ @ Inner Race
/ / Upper Bearing

/ m
/’ steel Balls

g

   
  

\ v
\ Dust Seal '
\\ .. - Lower Bearmg
’\ Outer Race
\\  Lower Bea ring
\\ & Steel Balls
\ Q Lower Bearing

Inner Race

   

 

Steering Stern

NOTE

. Number nl head bearing steel balls:
. Upper: 18

. Lower: 13

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.

 

 
   

Sbll Bllh

Apply grease to the new upper bearing
steel balls and upper inner race.

Install the new steel balls and upper inner
race.

13-31

NSRl SOSP
Front Wheel / Suspension] Steering

 

Top "rand

Install the steering top thread and
tighten it to the specified
Torque.

TOOL:
Steering stem socket 079164710101

ronous: 27 MM (2.3 kgf.m, 20 rbm)

Turn the steering stern 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 079153710101 _ ‘ . Connector

TORQUE: 1 N.m (0.1 kgf.m, 0.7 lbtlt)

Connect the ignition switch 2P
connector.

 

13-32

NSRlSOSP
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.

TORGUE: as N.m (9.0 kgt‘.m, 65 1111.11)

Make sure that the steering stern 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 steenng stem just starts to move.

 

STEERING BEARING PRELOAD:
1.0 - 1.5 MM (0.1 - 0.15 kgf.m)

lithe readings do not fall within the limits, read just the steering top thread.

Install the removed parts in the reverse order of removal.

NOTE 1
D Home the tables and win hum property

13-33

NSR1 SOSP Rear Wheel / Suspension

 

44 N.m (4.5 kgf.m,33 lbf-ft)

    

73 N.m(7.4 kgf.m,54 [bf-ft)

108 N.m(11.0kgf.m,80 Ibf-ft)

14-0

 

 

 

 

NSR1508P Rear Wheel/ Suspension
Service lnfonnation 14-1 Flange 14—4
Troubleshooting 14-2 Shock Absorber 14—14
Rear Wheel 14-3 Swingarm 14—16
Bearing Holder/Driven

 

 

 

 

 

SERVICE INFORMATION

GENERAL

A contaminated brake also or we reduces stopplng power. Dlecard conumlnated pods and clean
oonumlnahd dlsc wlth a hlgh quality brake degreeelng agent.
The shock absorber eonwns nitrogen under high pressure. Do not allow fire or heel near the 98 containing

shock absorber.

Before dlapoeal oi the gas conhlnlng shock absorber, release the nllrogen gal (see page u—s).

CAUTION

- 'Io avoid damnglng the rlm when uslng the tire lever, always we rim protectors.

0 When servicing the rear wheel, suspension linkage, swingarm or shock absorber,
support the motorcycle using a safety stand or hoists

o 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.

e Flefer to Section 15 for brake system information.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE
LIMIT
Minimum tire tread depth 20 (0.08)
Gold tire pressure Driver only 200 kPa (2,00 kgf/cmz, 29 psi)
Driver and 200 kPa (2,00 kgf/cmz, 29 psi)
passenger
Rear wheel rim run out Radial 20 (0,08)
Axial 2.0 (0.08)
Wheel balance weight Max 60 9
Drive chain slack 35 (14)
Drive chain link 108
Drive chain size DID 525V05
RK 520M029
Damper/reservoir gas pressure 980 kPa (10 kgf/cmz, 142 psi)
Pressurize gas material | Nitrogen

 

Damper rod compressed force at 10 mm
(0.4 in) compressed

272 kg

 

 

Damper Ireservoir gas release drilling point

 

See page 14—15

 

 

14-1

 

 

Rear Wheel] Suspension

NSR1 SOSP

 

TORQUE VALUES

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

108 N.m (11.0 kgfm, 80 Ibf.ft)
226 N.m (23.0 kgfm, 166 lbttft)
Apply oil to the threads and flange
surface

34 N.m 93.5(kgfm, 25 Ibf.fl) U-nut
30 N.m (3.1 kgf.m, 22 Ibf.ft) U~nut
73 N.m (7.4 kgt.m, 54 Ith)

88 N.m (9.0 kgf.m, 65 Ibf.ft)

5.1 N.m (0.52 kgtm, 3.8 lbfjt)

44 N.m (4.5 kgfm, 331bf.ft)

44 Nm (4.5 kgf.m, 33 lbf.ft) U—nut

TOOLS

Attachment, 32 X 35 mm 07746-0010100
Attachment, 37 X 40 mm 07746-0010200
Attachment, 52 X 55 mm 07746-001040!)
Attachment, 62 X 67 mm 07746-0010500
Pilot, 15 mm 077460040300
Pilot, 40 mm 077460040900
Driver 07749-0010000
Driver shaft 07946-MJ00100

Bearing remover attachment

TROUBLESHOOTING

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

Wheel turns hard
Faulty rear axle holder bearings
Bent rear axle
Brake drug

Rear suspension noisy
Faulty rear shock absorber
Loose fasteners

14-2

07LMC-KV30200

Soft suspension
Weak spring
Oil and gas leakage from
Damper unit
Low tire pressure

Hard suspension
Bent damper rod
High tire pressure
Damaged swingarm pivot
bearing

NSR1 50SP Rear Wheel] Suspension

 

HEAR WHEEL

 

o A contaminated brake also or pad reduces
otopplng power. Disoud contaminated pad:
and clean Contaminated also with a high quality
brake daglolllng agent.

REMOVAL

Loosen the rear wheel nuts.

Raise the rear wheel olf the ground using
a safety stand or hoist.

Remove the rear wheel nuts.

Remove the rear wheel;

INSPECTION
WHEEL FllM

Check the rim runout by placing the wheel in a
tuming stand.
Spin the wheel slowly and read the runout using a
dial indicator.
Actual runout is ‘/2 the total indicator reading.

   
  
  
  
 
  
   
 
  
  
 

SERVICE LIMITS
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)

WHEEL BALANCE
Wheel wane. directly meets the mbllny. handling and overall

nloty o! the motorcycle. Cuehllly check balance baton
relnlhlllng "to wheel.

 

NOTE
I The wheel balance must bi checked when “1- “I. h
Remounled.

For optimum balance, the ter ltd-loo mark (a pint dot
on the slde wall) must be located next h) the villa stem.
Hemount Ch! tire it 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) pan 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. I
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 z ‘ ~ -

position when it is spun. . '«
Do not add more than 60 grams (2.1 oz) to '“

the rear wheels

14-3

NSRISOSP Rear Wheel/ Suspension

INSTALLATION ‘.
Clean and apply grease to the rear arde and f 
wheel mating surface. ‘

 

Nuts

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 M!!! (11.0 kgf-m, 80 Ibf-fl) 
fit

BEARING HOLDER/DRIVEN FLANGE

  

A wnhmlnlt-d brake dllc or pod "due-I flopplng power. Discard cont-mutated pads and clan
contamlnlled am with a hlgh quality brake «greasing gent

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 Dunn Fun“.
and rear axle/brake disc assembly.

   

Axle I Huh Dbl:

14-4

NSRl SOSP Rear Wheel / Suspension

 

Remove the snap ring and washert

Remove the bearing holder and bracket.

DISASSEMBLV

REAR AXLE/BRAKE DISC
Remove the rear brake disc nuts and bolts.

Remove the rear brake disc from the rear
axle.

FINAL DFIIVEN FLANGE

Remove the snap ring from the groove
on the final driven flange

 

NSRISOSP Rear Wheel/ Suspension

 

Remove the driven sprocket and final
driven hub from the final driven flange.

    
  

Omen Fang.

Remove the nuts, washers and driven
sprocket from the final driven hub.

BEARING HOLDER
Remove the collar item the left side of
the bearing holder.

Burhu Holder
‘ .

Dual Seal

Remove the dust seal from the left
side of the bearing holder.

 

14-6

NSRISOSP Rear Wheel/ Suspension

 

Remove the dust seal from the right Dull 5m
side of the bearing holder.

 

Burma Holder

Remove the stop ring from the left side

of the bearing holder. Stop ng

    

Remove the stop ring from the right
side of the bearing holder.

Slop ng

Bearing replacement (page 14—8).

INSPEC110N
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 raoe fits tightly in the bearing holder.

Remove and discard the bearings if the races do
not turn smoothly and quietly, it they fit loosely in
the bearing holder.

NOTE
. Roping the holder hearings in pain.

 

14-7

NSRISOSP Rear Wheel/ Suspension

 

FINAL DRIVEN FLANGE Rum.”
Check the damper mbber for wear or damage.
Replace if necessary.

NOTE
- new». the damper rubber u . m

 

HOLDER BEARlNG REPLACEMENT

REMOVAL

Remove the ball bearing from the left side
of the bearing holder using the special
tools‘

TOOLS:

Driver WAS-0010000
Attachment, 37 X 40 mm 07746-001020!)
Pilot, 40 mm 077460040900

Remove the needle bearing from the right
side of the bearing holder using the special
tools.

TOOLS:
Driver 0774941010000
Attachment, 52 X 55 mm 077460010400

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

NSR15OSP Rear Wheel/sfispension

 

Press the new needle bearing in the

 

 

 

 

 

 

 

right side of the bearing holder using on... ,1 mum."
the special tools. 1
TOOLS: I
Driver 07749-001000!) 59mm!
Attachment, 62 X 67 mm 077450010500 Inn-w a

W _.

Install the new ball bearing tolhe left
side of the bearing holder using the

 

special tools.

TOOLS:

Drlver 077490010000
Attachment, 62 X 67 mm 07746-001050!)
Pilot, 40 mm 077460040900
ASSEMBLY

Bearing Holder Plnch Bol‘
RearAxIe an Bracket

73 Mm 1.4 kgr—m, 54 Ihl-f!)

226 Mm (23.0 kgf-m. 166 lb!!!)

    
 
  
 
 
 
 
     
    
   

o /
Driven Sprocket ’

Snap Rlng
Rear Brake Dlsc Bolts
Rear Brake Disc

Rear Axle

Sprocket Nuts
Rear Brake m um.
34 «.m (35 lira. 25 mm)

so N.m(3l1 kgf-mJZ

Flnal Driven
Flange

 

Ball Bearing Rluhl Dust Seal

 

 

 

 

 

Beiran Holder
Slap Rlng
Needle Bearing

14-9

NSRl SOSP

Rear Wheel] Suspension

 

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.

 

Slop Ring

    

/ '
Burma Hold:

Stop Ring

Burqu Holder

Dust Seal

1

Bearing Holder

 

14-10

NSR1 SOSP Rear Wheel] Suspension

 

Install the collar to the left side of the
bearing holdert 00""

REAR AXLE/BRAKE DISC

Install the rear brake disc with its
marking side facing the right side.

Install the rear brake disc bolls and
nuts.

Install and tighten the rear brake disc
nuts to the specified torque.

TORQUE: a4 N—m -
(3.5 kgf.m, 25 let)

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
.Tlghtan the driven splat:in nut: any Installan
the driven flange lo Ilia fume.

 

NSRISOSP Rear Wheel] Suspension

 

Install the driven sprocket and final Swanuflw
drive hub to the final driven flange.

Install the snap ring to the groove on
the final driven flange.

INSTALLATION

Install the bracket to the swingan'n
aligning the groove onto brackets to the
tab on the swingarm.

Install the bearing holder to the
swingarmt

 

14-12

NSRISOSP Rear Wheel / Suspension

 

lnstall 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 Mm (23.0 kglm, 166 lel)

 

Stake the rear axle nut.
Install the final driven flange assembly to the rear axle.

ll driven sprocket is removed from the final driven hub, tighten the driven sprocket
nuts to the specified torque.

TORQUE:
so N.m (3.1 mm, -22 lbf-fl)

Install the rear wheel (page 14—4).
Adiust the drive chain slack (page 3~1 7).

Tighten the bearing holder pinch bell to the specified torque.

TORQUE:
73 N.rn (7.4 kgf—m, 54 Ibt-fl)

14-13

NSR1 SOSP Rear Wheel] Suspension

 

SHOCK ABSORBER

   

u

The shock abwrbsr contain: nltrogon under high
pressure. Do not allow fire or heal nu! the can
containan shock absorber,

REMOVAL

Remove the side cover (page 26).
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 absorber upper
mounting bolt.

Remove the shock absorber.

 

Do not try to dluuomble the shock absorber or more. V
s'hocu Absorber

 

INSPECTION
Shock Absorber

Check the damper unit for defamation or oil

leakage and replace it 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 il necessary.

Bum-nu:

We 9 

14-14

NSRISOSP Rear Wheel / Suspension

 

SHOCK ABSORBER - DISPOSAL s"°‘“”’°"’°’
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.

 

 

e Using a dull drill bit Illows I bullddip ol‘ excessive heat
and pressure Inside the damper which may cause ll

 

 

 

 

 

explosion.
. The thock absorber contains nitrogen one and under
high pressure. Drilling larther into the damper on. .F-.-
than specified can puncture the all chamber. Oil 35".“
“unplug under high pressure may cause urlom
'"W'Y- :I: Drilling Point

- Always wear eye protection to avoid getting metal
shawng In your eyes when gas pressure It released.

 

 

 

NOTE
» ‘nie plutlc 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 kgt'.m, 33 lht-t't)
Install the shock absorber lower mounting bolt
and nut.

Tighten the lower mounting bolt to the specified
torque.

TORQUE: 44 N.m (4.5 mm, as lbflt)

Install the battery case (page 16-6).
Install the side cover (page 2—7).

 

14-15

NSRl SOSP

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

0 Do not suspend the bran callpor Iron- we
broke [woe-Do not lwlll the hub Mu.

NOTE

Do not operate the bloke pedal I'M removlng flue
cfllw Ind rear wheel. To do so wlll can"
dmlcnlly In fining the brake dllo WI.“ the huh
pods.

Remove the shock absorber lower
mounting nut/bolt.

Remove the screws and brake hose
cover.

 

NOTE
BI careful not to damage "I. Dbl all me In“.
hose cover and groove: on the dvlvo ehnln cover.

Remove the brake hose from the guide
and clamp.

 

Remove the bolt.

 

14-16

NSR1 SOSP Rear Wheel/ Suspension

 

Remove the bolts and drive chain
cover.

Remove the swingarrn pivot covers.

Remove the swingarrn pivot nut.

Remove the swingarrn pivot bolt and
swingarrn.

 

14-17

NSRISOSP Rear Wheel / Suspension

 

DISASSEMBLY our» sun!

Remove the bearing holder and driven
flange (page 14-5).
Remove the bolts and chain guard.

 

Sena-Icahn
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 swingarrn.
Remove the drive chain slider.

Chain slid"

Inspect the drive chain slider for
excessive wear.

Replace the drive chain slider if it is
worn to wear indicator (page 3- 19 ).

Srlnum

14-18

NSRISOSP Rear Wheel] Suspension

 

Remove the right pivot collar and
dust seal.

 

Pivot Collar

  

Remove the dust seal, left pivot
collar and swingann pivot collar.

is"

m Plvcl Colby

INSPECTION

Check the pivot collars for wear or
damage and replace it necessary.
Cheek the dust seals for wear or

damage and replace it necessary.

 

Phat Colar
Check the needle and ball bearings
for damage or loose fit
and replace if necessary.
Check the swingarm lor
deformation, cracks or other
damage and replace if necessary.

   

uh Du sun

\ UHPNMCOIII

   

14-19

NSR1 5081’ 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 toolst

TOOLS:
Driver shaft 07946-MJ00100

Remove the left pivot needle bearing using
the special tools.

TOOLS:

Driver shafl 07946-MJ00100
Bearing remover attachment
07LMC-KV30200

INSTALLATION

Apply grease to the new left pivot needle
bearing.

Press the new left pivot needle bean’ng into
the swingann so

that the needle bearing outer surface is 55
mm (0.22 in)

below the outer edge of the swingarm pivot
bearing cavityt

 

 

 

TOO LS:

Driver 0774943010000

Attachment, 32 X 35 mm

0774eomo1oo 5.5mm (0.22 int},
J

NOTE

Pm: the needle hearing In wnh the stumped old. T

hclng out.

 

 

 

14-20

NSR150SP Rear Wheel/ Suspension

 

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:

Driver 0774943010000
Attachment, 32 X 35mm
07746-0010100

Pilot, 15mm 07746-004034”

 

 

 

 

 

 

 

 

 

NOTE
o Press the ball bolting: Ill wlih In.
stamped side in:an out.

Snap Ring
Install the snap ring to the pivot
grooves of the swingarm.

 

9"“ Chain Drive Chain Slider

5'1 N' La" Swingarm Pivot Collar
Leit Dust Seal

Needle Bearing

Swing Arm
/ Ball Bearing

Snap Ring

   
 
   
     

Swingarm Pivot

Collar Right Dust 395’

Right Swing Arm Pivot Collar

Drive Chain Guard

 

14-2 1

NSR1 SOSP Rear Wheel/ Suspension

 

Install the swingarm pivot collar, left
pivot collar and dust seal.

lnstall the dust seal and tight pivot
collar.

Install the dn‘ve 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

NSRlSOSP Rear Wheel/ Suspension

 

Install the collars and drive chain
slider screws.

Tighten the drive chain slider screws
to the specified torque.

Scat-[Icahn

TORQUE: 5.1 MM
(0.52 kgf.m,3.8lbf.1t)

Chain Guild

Install the chain guard.
Install and tighten the bolts securely.

Install the bearing holder
(page 1442).

INSTALLATION

NOTE
oRouia the tubes and wins properly (pigs 1-10;

Install the swingarrn.

Apply thin coat of grease to the
swingarrn pivot bolt.

Install the swingarm pivot bolt.

 

Install and tighten the swingarm pivot
nut to the specified torque.

TORQUE: ss N.m (9.0 kgrm, es lbt—l't)

m Prvol Nut
7' m
V

   

NSR15OSP Rear Wheel/ Suspension

 

Install the swingarm pivot covers.

Install the drive chain cover.
Install and tighten the bolls securely. V ‘

 

Install and tighten the bolt securely.

 

Install the brake hose to the guide
and clamp.

 

NSR1 SOSP Rear Wheel/ Suspension

 

Install the brake hose cover
aligning the its tabs to the
grooves on the drive chain
cover.

NOTE
. Be careful Ml to during. the lib.
on "I. broke hon cow and
groom on the drlvs choln cover.

Install and tighten the screws
securely.

 

Install the shock absorber lower ~x
mounting nut/bolt. '
Tighten the lower mounting bolt
to the specified torque.

TORQUE: 44 N.m
(4.5 kgtni, 33 Ibt.ft)

Install the rear brake caliper
(page 15-20).

Install the rear wheel

(page 14—4).

 

14-25

NSRISOSP Battery / Charging System

 

SYSTEM DIAGRAM

‘ Maln Fuse 20 A

 
 
  

RegulatorlRacmier

  

Alternator

 

 

I .
rel—(Li RM, Regulator/Reamer

 

 

 

 

 

 

 

 

 

 

V
v g
(cm:

AI

 

16-0

NSRISOSP Battery / Charging System

 

 

 

 

 

SYSTEM DIAGRAM 16-0 CHARGING SYSTEM INSPECTION 15-6
SERVICE INFORMATION 18-1 REGULATORIRECTIFIER 16-9
TROUBLESHOOTING 16-3 ALTERNATOR INSPECTION 16-10
BATTERY 16»5

SERVICE INFORMATION

GENERAL

 

'amlnn

. The baitery gives an explosive gases; keep sparks. llames and cigarettes away. Provide adequate
ventilation when charging or using the battery in an enclosed space.

a The halter contains sulluric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective
clothing and a race shield.
Il electrolyte gets o your skin. linen with water.

a ll electrolyte gets on your eyes. flush with water lor at least 15 minutes and call a physician immediately.

- Electrolyte is poisonous.
Il swallowed, drlnk large quantities or water or milk and iollow with milk or magnesia or vegetable oil and call a
physician.

- KEEP our or: REACH on CHILDREN

 

- Always turn off the ignition switch before disconnecting any electrical component.

CAUTION

- Some electrical components may be damaged iI lerrninals or connectors are connected or disconnect while the
ignition switch ls ON and a current is present.

e For extended storage, remove the battery, give it a full charge and store it in a cool, dry
space.

0 For battery remaining in a stored motorcycle, disconnect the negative battery cable from the
battery terminal.

CAUTION
. rap water wlll shorten ihe service lire of the emery,

- Immediately wash off any spilled electrolyte using a mixture baking soda and water.

CAUTION

- Avoid filling the battery shove the UPPER LEVEL line to prevent an electrolyte overflow which could corrode ihe
engine or nearby pans.

- The battery can be damaged it 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.

e 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 shoned 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 It 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.

 

BATTERY/CHARGING SYSTEM

16-1

NSRISOSP

Battery / Charging System

 

Battery Charging System

- 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.

o 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.

a When checking the charge system, always follow the steps in the troubleshooting flow chart

(page 16—3)

0 Alternator servicing may be done with the engine in the frame.

SPECIFICATIONS

 

ITEM

SPECIFICATIONS

 

Alternator rated output

180 W/5,000 min-1 (rpm)

 

Alternator charging coil resistance (At 20 °C/68 °F)

0.1—1‘09

 

Regulator/rectifier: regulated voltage (At 20 D0/68 °F)

14.7:o.5v at 5,000 min-1 (rpm)

 

Current leakage

1 mA maximum

 

 

 

 

 

 

 

Battery capacity 12 V -3A

Battery type YB3L-A

Battery charging rate Normal 0.3A/10h
Quick 3N0.5h

 

 

16-2

NSRISOSP Battery / Charging System

 

TROUBLESHOOTING

BATTERY UNDERCHARGING (VOLTAGE NOT RAISED T0 REGULATED VOLTAGE).

 

 

 

 

 

 

 

 

Measure the charging voltage
w'm "‘5 balmy {UHV Charged and Correct Check the batten/ current leakage
in good condition (page 16-5) (leak'estl page 153)
Correct
Incorrect
Faulty Battery

Standard regulated voltage is not reached
when the engine speed increase,

 

Disconnect the regulator/rectifier
4P connector and recheck the
battery current leakage

 

 

 

 

Correct
Incorrect
shorted Wire harness
Faulty ignition switch
Faulty regulatorl
rectifier
Check me VOItage between "‘9 Incorrect Shorted wire harness

battery line and ground line ofthe
regulator/rectifier 4P connector
(page 16-8)

Poorly connected connectors

 

 

 

Correct

 

Check the resistance of the charging
coil at the charging coil line of the

 

 

 

incorrect shorted Wire hamess
regulator/rectifier 3P connector Faulty charging coil
ipage 16-9)
Correct

Faulty regulator/rectifier

16-3

NSRISOSP Battery / Charging System

 

BATI'ERY OVERCHARGING (REGULATED VOLTAGE T00 HIGH).

Measure the charging voltage with the battery fully 1 Correct Faulty Battery
charged and In good condition ( age 16-5) l

 

     

Regulated voltage greatly exceeds the standard value

Check the continuity between the ground line and
frame of the regulator/rectifier 4P connector (page Incorred Open circuit inwire harness

16—8) Poorly connected connectors

 

Correct

Faulty regulator/rectifier
Poorly connected connectors

16-4

NSRISOSP Battery / Charging System

 

BATI'ERY
RE MOVAL

 

 

 

NOTE

- Always turn the ignition switch OFF before removing or
installlng the battery

. tr you disconnectthe battery terminal, all memories or
the tnp 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.

lNSTALLATION

Installation is in the reverse order Of removal.

NOTE
. Apply clean grease to Ihe battety terminals,
- Pull the cover over the positive terminal.

 

INSPECTION

Measure the battery voltage using a
commercially available
Digital multimeter

Voltage: Fully charged: 11-13V
Under charged: Below 10V

 

16-5

NSRISOSP Battery / Charging System

 

BATTERY CHARGING

. The battery glves of! explosive gases,- keep sparks,
llames and clgamttes away. Prov/do adequate venn'lation
when charging.

- rhe hattery contains sulfuric acid (electrolyte), ooh-
tact with skin or eyes ma cause severe burns. Wear
protective clothing and a face shield.
all electrolyte gets on your skin, lluslt with water

it electrolyte gets on your eyes, flush WM! water her
at least 15 minutes and cell a physician,

. Electrolyte is poisonous lfswallawud. drink large
quantities of water or milk and follow with milk of
magnesia or vegetaht. oil and call a physician.

. Tum power ON/OFF at the charger, not at the battery
terminals.

Remove the battery (page 16-5)

Connect the charger positive (+) cable to the
battery positive (+) terminal.

Connect the charger negative (+) cable to the
battery negative (+) terminal.

Charging current/time
Standard: 0.3A/1oh
Quick: 3N0.5h

CAUTION

« Quick-charging should only he done in an emergency;
slow charging is preferred.

- Fol battery charging, do not exceed the charging cur-
rent and time specilled on the battery. Using excesslve
current or extending the charging time may damage
the battery,

BATTERY CASE REMOVAUINSTALLATION
Remove the battery (page 16-5).

Remove the bolts and battery case.

Remove the battery breathertube from the
clamp on the battery case.

installation is in the reverse order of removal.

NOTE

 

- Routethe tubes one wire harnesses properly ipage 1-18).

16-6

NSRISOSP Battery / Charging System

 

CHARGING SYSTEM INSPECTION

NOYE

. Measunng circuits with a large capacity that exceeds the capacity of the tester may cause damageto the tester.
aerore starting each test. set the tester at the high capacity range first. the gradually down to low capacity ranges in
oroer to ensure that you have the correct range and do not damage the tester.

- When measuring smart capacity circuits. keep the ignition switch off. lrthe switch is suddenly turned on during a test.
the tester lose my blow.

REGULATED VOLTAGE INSPECTION

. ii the engine must be running to do some work, nuke
sure the area is weir-venuiatad. Never run the engine in
an enclosed area.

. The exhaust contains poisonous carbon monoxide gas

that may cause loss 0! consciousness and may lead to
death.

Remove the battery (page16-5) and install the
fully 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.

 

cwnorv

. 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 of! the Igni-
tion switch, Failure to follow this precaution can dam-
age the tester or electrical components.

With the headlight ON (Lo beam), restart the engine.
Measure the voltage on the multitester when the engine runs
at 5.000 min-1 (rpm).

Regulated voltage: 14.7 :r 0.5VI5.000 min-1 (rpm)

The battery is normal if the voltage reads the regulated volt-
age on the tester,

NOTE

. The speed at which voltage starts to rise cannot be
checked as it varies with the temperature and loads or
the generator.

16-7

NSRlSOSP Battery / Charging System

 

A frequently discharges battery is an N°mmhmm W”.

indication that it is deteriorated even if it 2

proves normal in the regulated voltage  ' ’ mt:
inspection.

The charging circuit may be abnormal it 3

any of the followmg symptoms IS wings

encountered:

1. Voltage not raised to regulated
voltage (page 16-3) 7
- Open or shorted circuit in the charging

system wire hamess or poorly —~——|—E~nml——F

connected connector
. Open or shorted of the alternator
. Faulty regulator/rectifier

 

2. Regulated voltage too high " Abnormal Charging Voltage

(page16-4)

e Poorly grounded voltage
regulator/rectifier

- Faulty battery

- Faulty regulator/rectifier

{w sermon ‘

 

 

EnginL Speed 3m...»

CURRENT LEAKAGE TEST

Remove the battery cover (page 16-5).

 

k. Animator

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 6 e

- When measuring current using .5 tester, set it to a hlgh
range, and then hung the range down to an appropriate
level. Current flow higherthan the range selected my
blow out the ruse in the testere on: d Cable
. While measuring current. do not turn the ignition on. A
sudden surge at current may blow out the his. lntne
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

NSR150$P Battery / Charging System

 

REGULATOR] RECTIFIER

WIRE HARNESS INSPECTION

Remove the side cover (page 2-6).

Disconnect the regulator/rectifier 5P connector.

Checkthe 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:

 

 

 

 

 

 

 

 

Item Termlnals Specification
Battery Red (+) and Battery voltage
charging ground 1-) should register
IIne
Ground Green and Continuity eXIsts
IIne ground “e. 'RN.‘
V 59 Cmtm , I

CHARGING LINE

NOYE

- It is necessary to remove the stator coil to complete
this test.

Measure the resistance between the 5P connector
terminals and ground.

Connection: Yellow and Yellow
Standard: 0.1 - 1.0 Q (20 was °F)

 

It the charging coil reading is out of specification, check the alternator (page 16-10).

16-9

NSRISOSP 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).
It 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
groundi check the alternator (page 16-10]

 

16-10

NSRlSOSP Battery / Charging System

 

REMOVAL INSTALLATION . |\ a

5’ Crmzlm

Remove the right side cover (page 2—6)

Disconnect the regulator/rectifier 5P connector,

Remove the bolts and regulator/rectifier unit,
Installation Is in the reverse order of removal.
Remove the bolts and regulator/rectifier unite

Installation is in the reverse order of removal.

more
- Route the wire harness properly anger-19).

 

ALTERNATOR INSPECTION

NOTE
0 Refer to section 11 altematol removal/installation.

we 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

    

:9 :mr'mnm
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 continuityv

if the there is continuity between the 3P connector and
ground. replace the stator (page 11-2).

16-11

NSRISOSP 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 0c 68° F)

If the charging coil reading is out of specification,
replace the stator (page 11-2).

Check for continuity between the 3P connector
terminals and ground
There should be no continuity.

I1 there is continuity between the 3P connector and
ground replace the stator (page 11-2}

    

‘ i
a. JP Commie:
c .M

16-12

NSRISOSP Ignition System

 

SYSTEM DIAGRAM

mum" swim Engine Slop Switch
A Mall: Fun 20A

A

I//

7 9&1

  

erfibfd?“

EJBI
|—o\0—B|—o\

Fuse 10A O

Engine Slop Swlwh Ignition Pulse Generator

 

 

 

 

 

 

 

 

 

3'16?

 

Bl‘ BLACK

G: GREEN

Bu: BLUE

Lg: LIGHT GREEN
R. RED

w: WHITE

Y: YELLOW

1 7-0

 

NSRlSOSP Ignition System

 

SYSTEM DIAGRAM 11-0 IGNI110N 116
SERVICE INFORMATION 17~1 ICM REMOVAL/INSTALLATION 17-7
TROUBLESHOOTING 17-3 IGNITION 17-7
IGNITION SYSTEM INSPECTION 114

 

 

SERVICE INFORMATION

GENERAL

 

 

l I! the engine must be running to do some work, make sun the am It well-ventflaied Navll run (It!
enylne In an enclosed ma. The exhaust com-ins poisonous carbon monoxide gas that may esuse ioss
of the consciousness andnlay iead lo death. Run tin ongan in In upln em or with an exhaust
evacuatlon system in an enclosed em.

 

CAUTION

- some electrlcal components may be damaged ii rem/nets or commuters are connected or dlsconnocnd
while the Ignition switch is oN and. alumni is present.

 

0 When checking the ignition system. always follow the steps in the troubleshooting
(page 173).

- Ignition timing cannot be adjusted since the Ignition Control Module (ICM) is non-
actjustable. It ignition timing is incorrect, check the system components and
replace any faulty parts.

- The lCM may be damaged ifdropped. Also. ifthe connector is disconnected when
current is flowing, the resulting excessive voltage may damage the unit. Always
turn off the ignition switch before servicing

o 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 motorwith 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 removal/installation see section 19.

For engine stop switch inspection and removalfinstallation see section 13,19.

For ignition switch inspection see section 13. 19.

17-1

NSRlSOSP

Ignition System

 

SPECIFICATIONS

 

 

 

 

 

ITEM SPECIFICATIONS
Spark plug Standard NGK BQES
NIPPONDENSO W27ES.U
For cold climate/below NGK BBES
(5 “0/41 °F)
NIPPONDENSO w24ES-U

 

 

 

Ignition timing "F" mark

BTDC 12 i 3 °l 1‘ 200 min-1 (rpm)

 

 

 

 

Advance star! 1,900 1 200 min-1 (rpm)
Slop 3,500 1 200 min-1 (rpm)
Full advance BTDC 35 i 3 °

 

Ignition cut-out revolution

13,000 i 200 min-1 (rpm)

 

Ignition coil Peak voltage

100 V minimum

 

 

Ignition pulse generator peak voltage

0.7 V minimum

 

 

TORQUE VALUES
Timing hole cap

Ignition pulse generator socket bolt

Ignition coil mounting bolt

TOOLS

Peak voltage adaptor
Imrie diagnostic tester (model 625)

3 Mn (0.3 kgf~m, 2.2 mm)

10 Nm (1.0 kgI~m, 7 Ibfrft)
Apply a locking agent to the threads

12 N-m (1.2kgf~m, 9 lbf~tt)

07HGJ-020100

17-2

 

NSRISOSP Ignition System

 

TROUBLESHOOTING

0 Inspect the following before diagnosing the system.
7 Faulty spark plug
7 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

 

 

Unusual condition Probable cause (Check In numerical order)
Ignition coil Low peak 1, Incorrect peak voltage adaptor connections
primary voltage 2, Multimeter impedance is too low: below 10 MQ/DCV
volt- 3, Cranking speed is too slow (Operating force of the
399 kickstarter is weak)

4' 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)

5 Poorly connected connectors or an open circuit in ignition
system

6. Faulty side stand switch or neutral switch

. Faulty ignition coil

8 Faulty ignition control module (ICM) (in cases when above
No. 1-7 are normal)

\r

 

_.

No peak voltage t Incorrect peak voltage adaptor connectors

2. Faulty ignition switch or engine stop switch

. No voltage at the power source wire between BlAN (4-) and
ground (-) of the ICM, or loose or poorly connected ICM
connectors

V Poor connection or open circuit in G wire of the ICM

V Faulty neutral switch

4
S
6' Faulty peak voltage adaptor
7
8

t.)

V Faulty ignition pulse generator
V Faulty 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
sparkjumps at 2. Faulty ignition coil

 

 

Plug
Ignition Low peak 1, Multimeter impedance is too low; below 10 Mfl/DCV
pulse voltage 2. Cranking speed is too slow (Operating force of the
generator kickstaiter 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 . Faulty peak voltage adaptor

2, Faulty ignition pulse generator

 

 

 

17-3

 

NSR1508P

Ignition System

 

IGNITION SYSTEM INSPECTION
NOTE

0 If thus is no spark It the plug, :hlEk I“ connmlons '0'
loose or poor Contact baton measuring each peak voltage.

. Use the recommended digital multimeter or commercially
available digital multimuer with an impedance 0!

a 10 Min/Dov minimum.

a The display value diners depending upon the internal
impedance or the multimeter.

| If using Imrie dagnostlc tester (model 625), follow the
manufacturer's operating instructlonst

Connect the peak voltage adaptor to the digital
multimeter,
or use the lmrie diagnostic tester.

TOOLS:

Imrie diagnostic tester (model 625) or

Peak voltage adaplor 07HGJ-
0020100 with

Commercially available digital multimeter
(impedance

10MMDC minimum)

IGNITION PRIMARY VOLTAGE INSPECTION

NOTE

. Check all system connection before the inspection

    

,' ““““ " \ nlqitaluummtcr
\

 

 

 

Sim swirl

. II the system is disconnected, an incorrect peak voltage will register.
0 Check cylinder compression at each cylinder and check Illa! 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

 

NSRISOSP Ignition System

 

Connect the peak voltage adaptor or lmrie
tester to the ignition coil primary terminal.

NOTE
0 Do not disconnect the ignition coil primary wires.

 

 

 

 

TOOLS:
Imrie diagnostic tester (model 625) or
Peak voltage adaptor

07HGJ-0020100 with
Commercially available digital multimeter
(impedance) 10MQ/DCV minimum)

 

 

 

CONNECTION: Black/Yellow (-9) - Body ground (-l

Turn the ignition switch “ON” and engine stop switch to “RUN”.
Shift the transmission into neutral.
Crank the engine with the kickstalter and read the ignition coil primary voltage.

PEAK VOLTAGE: 100 V minimum

Pillio seat

- Ava/d louchlng the spark plug and taster woes to prev-m
electric shock.

if the peak voltage is lower than the standard value,
follow the checks described in the troubleshooting on
page 174:.

IGNITION PULSE GENERATOR PEAK VOLTAGE
INSPECTION

 

Remove the pillion seal (page 2-3).

NOTE
I check all system connection before the inspection If the

system is disconnected, an incorrect peak voltage will /
register. I Q

- 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 adaptorto the 4P
connector wire harness side.

 

 

 

 

 

 

 

TOOLS:

lmrie diagnostic tester (model 625) or

Peak voltage adaptor 07HGJ-
0020100 with

Commercially available digital multimeter (impedance 10M Q DCV minimum)

CONNECTION: GreenlWhite (+) . Green H

17-5

NSRISOSP Ignition System

 

Turn the ignition switch “ON” and engine stop switch to
“RUN”.

Shifl the transmission into neutral.

Crank the engine with the kickstarter and read the ignition
pulse generator peak voltage.

r‘ . le um
PEAK VOLTAGE: 0.7 V mlnlmum ‘
:‘w y

- Avoid touching the spark plug and tester probes to prevent
doctric 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 slop 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: Green/White (+) — Blue/Yellow (-i
PEAK VOLTAGE: 0.1 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 generatorwires -

c 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 1713.

IGNITION COIL

 

REMOVAL/INSTALLATION
Remove the fuel tank (page 2-12).

Disconnect the spark plug cap from the spark plug.

1 7-6

NSRISOSP Ignition System

 

Disconnect the ignition coil primary wires from the terminals.
Remove the bolts and ground wire eyelet.
Remove the ignition coil.

l'ulll-u rein

    

Installation is in the reverse order of removal.

TORQUE: 12N.m(1.2kgv~m. 9 mm)

NOTE
- Route the spark plug wires properly (page 1-13).

ICM REMOVAL [INSTALLATION

Remove the pillion seat (page 2-3).
Disconnect the ICM 2P and 4P connectors.
Disconnect the lCM 2P (Black) and AP
(Black) connectors.

Remove the ICM from the bracket.

installation is in the reverse order of removal, ""

IGNITION TIMING

- mn- engine nnrsr be running to do some work, mire sun the me Is well-Ventilated Never run the
engine In an enclosed use. The exhaust comalns poisonous urban monoxide yes am my cause loss
oltne consciousness .no my lend to darn. Run II" mglne In an open area or with an exneust
:vlcualion system In an enclosed nun.

 

NOTE
- Reno the manuhctuver’s operating instructions {or the filming right,

Warm up the engine.
Stop the engine.

Remove the side cowl and lower cowl (page 2-4).

Remove the timing hole cap.

 

17-7

NSRISOSP Ignition System

 

Connect a timing light to the spark plug wire
Start the engine and let it idle.

IDLE SPEED: 1,300 1 100 min“ (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 NM (0.3 kgl-m. 2.2 le!)

 

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. General Information 5 - 26
2. Frame/Body panels/Exhaust system 27 - 42
3. Maintenance 43 - 69
4. Lubrication system 70 - 80
5. Fuel system 81 - 96
6. Cooling system 97 - 110
7. Engine removal/Installation 111 - 119
8. Cylinder head/Cylinder/Piston 120 - 134
9. RC Valve/Servo motor 135 - 145
10. Clutch/Gearshift linkage/Kickstarter 146 - 171
11. Alternator/Balancer 172 - 180
12. Crankshaft/Transmission 181 - 199
13. Front Wheel/Suspension/Steering 200 - 234
14. Rear Wheel/Suspension 235 - 260
16. Battery/Charging system 261 - 273
17. Ignition System 274 - 281

 

 

 

 

 

 

HONDA® MPE

MOTORCYCLE & POWER EQUIPMENT ACN.006 662 862

Service Bulletin

 

Service Bulletin No: SBMCO549

 

 

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 SBM60311

 

Ladies and Gentlemen,

Please be advised that when servicing the NSRl EOSP, 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-QES 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
NSR15OSP from the Honda MPE spare parts department, please ensure that P/N: 98079-
59812 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 NSR15OSP.***

GREG SNART
National Motorcycle Service Manager

@0/

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 I. POWER EQUIPMENT acmoos 662 862

Service Bulletin

 

Service Bulletin No: SBM00312

 

 

To: All Motorcycle Franchises
From Motorcycle Service Department
Date: September 2003

Attention: Franchisee, Service Manager, Sales Manager and Relevant Staff

Subject: NSFi 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 Insgection.

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 Oil and the correct oil viscosity
of 10wr40 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 27stroke oil or equivalent
premium grade oil,

L/H Hand Grip: It may also be necessary on some units to secure the UH 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 2-
stroke 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 ils CONTENTS.

 

Service Manager

Parts Manager

Sales Manager

Franchise Principle

 

 

 

 

 

 

 

 

 

HONDA® MPE

MOTORCYCLE t. POWER EQUIPMENT ACN.006 662 862

Service Bulletin

 

Service Bulletin No: SBM0031 1

 

 

To: All Motorcycle Franchises
From Motorcycle Service Department
Date: September 2003

Attention: Franchisee, Service Manager, Sales Manager and Relevant Staff

Subject: NSFl 150 Spark Plug Application

 

Ladies and Gentlemen,

Please be advised that when servicing the NSFt 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 BP8ES and the BVQES 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: SBMCOZOQ

 

 

To: All Motorcycle Franchises
From Motorcycle Service Department
Date: 6'“ April 2002

Attention: Franchisee, Service Manager, Sales Manager and Relevant Staff

Subject: Important Service Tip

 

Ladies and Gentlemen,

Please be advised that when Dre-delivering or servicing the NSR15OSP 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 low-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