2004 Honda CBF150 Service Repair Manual (Free Preview)

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1-1 1 1. GENERAL INFORMATION SERVICE RULES ············································ 1-2 MODEL IDENTIFICATION······························ 1-2 GENERAL SPECIFICATIONS························· 1-4 LUBRICATION SYSTEM SPECIFICATIONS · 1-5 FUEL SYSTEM SPECIFICATIONS················· 1-5 CYLINDER HEAD/VALVES SPECIFICATIONS··········································· 1-5 CYLINDER/PISTON SPECIFICATIONS········· 1-6 CLUTCH/GEARSHIFT LINKAGE/ KICKSTARTER SPECIFICATIONS ················· 1-6 CRANKSHAFT/TRANSMISSION SPECIFICATIONS··········································· 1-7 FRONT WHEEL/SUSPENSION/ STEERING SPECIFICATIONS························ 1-8 REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS············································1-8 HYDRAULIC BRAKE SPECIFICATIONS·········1-8 BATTERY/CHARGING SYSTEM SPECIFICATIONS············································1-9 IGNITION SYSTEM SPECIFICATIONS ··········1-9 LIGHTS/METER/SWITCHES SPECIFICATIONS············································1-9 STANDARD TORQUE VALUES ···················1-10 ENGINE & FRAME TORQUE VALUES ········1-10 LUBRICATION & SEAL POINTS ··················1-14 CABLE & HARNESS ROUTING ···················1-17 EMISSION CONTROL SYSTEMS ················1-25

GENERAL INFORMATION 1-2 GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the 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 reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown on pages 1-17 through 1-24, Cable and Harness Routing. MODEL IDENTIFICATION

GENERAL INFORMATION 1-3 The frame serial number is stamped on the right side of the steering head. The engine serial number is stamped on the lower left side of the crankcase. The carburetor identification number is stamped on the left side of the carburetor body. The color label is attached as shown. When ordering color-coded parts, always specify the designated color code. FRAME SERIAL NUMBER ENGINE SERIAL NUMBER CARBURETOR IDENTIFICATION NUMBER COLOR LABEL

GENERAL INFORMATION 1-4 GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2,090 mm (82.3 in) Overall width 750 mm (29.5 in) Overall height 1,095 mm (43.1 in) Wheelbase 1,340 mm (52.7 in) Seat height 790 mm (31.1 in) Footpeg height 567 mm (22.3 in) Ground clearance 168 mm (6.6 in) Dry weight 126 kg (278 lbs) Curb weight 139 kg (306 lbs) Maximum weight capacity 170 kg (375 lbs) FRAME Frame type Diamond type Front suspension Telescopic fork Front wheel travel 130 mm (5.1 in) Rear suspension Swingarm Rear wheel travel 101 mm (4.0 in) Rear damper One side operation Front tire size 2.75-18 42P Rear tire size 3.00-18 52P Front tire brand MRF NYLOGRIP ZAPPER - FS Rear tire brand MRF NYLOGRIP ZAPPER Front brake Hydraulic single disc Rear brake Mechanical drum (leading-trailing) Caster angle 26° 00’ Trail length 97 mm (3.8 in) Fuel tank capacity 13.0 liter (3.43 US gal, 2.86 lmp gal) Fuel tank reserve capacity 1.0 liter (0.26 US gal, 0.22 lmp gal) ENGINE Cylinder arrangement Single cylinder inclined 17° from vertical Bore and stroke 57.3 x 57.8 mm (2.26 x 2.28 in) Displacement 149.2 cm 3 (9.10 cu-in) Compression ratio 9.1:1 Valve train Chain driven OHC with rocker arm Intake valve opens at 1 mm (0.04 in) lift 7° BTDC closes at 1 mm (0.04 in) lift 28° ABDC Exhaust valve opens at 1 mm (0.04 in) lift 27° BBDC closes at 1 mm (0.04 in) lift 3° ATDC Lubrication system Forced pressure and wet pump Oil pump type Trochoid Cooling system Air cooled Air filtration Paper filter Engine dry weight 27.2 kg (60.0 lbs) CARBURETOR Carburetor type Horizontal changable venturi Throttle bore 26 mm (1.02 in) DRIVE TRAIN Clutch system Multi-plate, wet Clutch operation system Cable operating Transmission 5 speeds Primary reduction 3.350 (67/20) Final reduction 2.800 (42/15) Gear ratio 1st 3.076 (40/13) 2nd 1.789 (34/19) 3rd 1.304 (30/23) 4th 1.090 (24/22) 5th 0.937 (30/32) Gearshift pattern Left foot operated return system 1 - N - 2 - 3 - 4 - 5 ELECTRICAL Ignition system DC – CDI Starting system Kickstarter Charging system Single phase output alternator Regulator/rectifier SCR shorted, single phase half-wave recti- fication

GENERAL INFORMATION 1-5 LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) FUEL SYSTEM SPECIFICATIONS CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engine oil capacity After draining 1.0 liter (1.1 US qt, 0.9 lmp qt) – After disassembly 1.2 liter (1.3 US qt, 1.1 lmp qt) – Recommended engine oil Honda 4-stroke oil or equivalent motor oil API service classification: SJ Viscosity: SAE 20W40 – Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 – 0.20 (0.006 – 0.008) 0.25 (0.010) Side clearance 0.05 – 0.11 (0.002 – 0.004) 0.15 (0.006) ITEM SPECIFICATIONS Carburetor identification number VK4FA Main jet #115 Slow jet #38 Pilot screw initial/final opening See page 5-19 Float level 13.0 mm (0.51 in) Idle speed 1,400 ± 100 min -1 (rpm) Throttle grip free play 2 – 6 mm (0.08 – 0.24 in) PAIR control valve specified vacuum 58.7 kPa (440 mm Hg) ITEM STANDARD SERVICE LIMIT Cylinder compression at 1,000 min -1 (rpm) 1,152 kPa (11.8 kgf/cm 2 , 167 psi) – Valve clearance IN 0.08 (0.003) – EX 0.12 (0.005) – Valve, valve guide Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.92 (0.194) EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193) Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.04 (0.198) Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.07 (0.003) EX 0.030 – 0.057 (0.0012 – 0.0022) 0.09 (0.004) Valve guide height IN/EX 16.8 – 17.0 (0.66 – 0.67) – Valve seat width IN/EX 0.9 – 1.1 (0.035 – 0.043) 1.5 (0.06) Valve spring Free length INNER 38.76 (1.526) 37.89 (1.492) OUTER 35.95 (1.415) 35.14 (1.383) Rocker arm Arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398) Shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390) Arm-to-shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004) Camshaft Cam lobe height IN 32.994 – 33.234 (1.2990 – 1.3084) 32.96 (1.298) EX 32.880 – 33.120 (1.2945 – 1.3039) 32.85 (1.293) Cylinder head warpage – 0.05 (0.002)

GENERAL INFORMATION 1-6 CYLINDER/PISTON SPECIFICATIONS Unit: mm (in) CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder I.D. 57.300 – 57.310 (2.2559 – 2.2563) 57.40 (2.260) Out-of-round – 0.10 (0.004) Taper – 0.10 (0.004) Warpage – 0.10 (0.004) Piston, piston pin, piston ring Piston O.D. at 10 (0.4) from bottom 57.280 – 57.295 (2.2551 – 2.2557) 57.20 (2.252) Piston pin hole I.D. 14.002 – 14.008 (0.5513 – 0.5515) 14.04 (0.553) Piston pin O.D. 13.994 – 14.000 (0.5509 – 0.5512) 13.96 (0.550) Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.04 (0.002) Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016) Second 0.10 – 0.25 (0.004 – 0.010) 0.40 (0.016) Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.85 (0.033) Piston ring-to-ring groove clearance Top 0.030 – 0.060 (0.0012 – 0.0024) 0.10 (0.004) Second 0.030 – 0.060 (0.0012 – 0.0024) 0.10 (0.004) Cylinder-to-piston clearance 0.005 – 0.030 (0.0002 – 0.0012) 0.09 (0.004) Connecting rod small end I.D. 14.010 – 14.028 (0.5516 – 0.5523) 14.06 (0.554) Connecting rod-to-piston pin clearance 0.010 – 0.034 (0.0004 – 0.0013) 0.10 (0.004) ITEM STANDARD SERVICE LIMIT Clutch lever free play 10 – 20 (0.4 – 0.8) – Clutch Spring free length 40.5 (1.59) 39.6 (1.56) Disc thickness 2.92 – 3.08 (0.115 – 0.121) 2.6 (0.10) Plate warpage – 0.20 (0.008) Clutch outer I.D. 23.000 – 23.021 (0.9055 – 0.9063) 23.08 (0.909) Clutch outer guide O.D. 22.959 – 22.980 (0.9039 – 0.9047) 22.93 (0.903) I.D. 16.991 – 17.009 (0.6689 – 0.6696) 17.04 (0.671) Mainshaft O.D. at clutch outer guide 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667) Kickstarter idle gear I.D. 20.500 – 20.521 (0.8071 – 0.8079) 20.58 (0.810) Kickstarter idle gear guide O.D. 20.459 – 20.480 (0.8055 – 0.8063) 20.43 (0.804) I.D. 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671) Countershaft O.D. at Kickstarter idle gear guide 16.966 – 16.984 (0.6680 – 0.6687) 16.94 (0.667) Kickstarter drive gear I.D. 16.016 – 16.034 (0.6305 – 0.6313) 16.06 (0.632) Kickstarter spindle O.D. at kickstarter drive gear 15.966 – 15.984 (0.6286 – 0.6293) 15.94 (0.628)

GENERAL INFORMATION 1-7 CRANKSHAFT/TRANSMISSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Runout – 0.03 (0.001) Connecting rod big end radial clearance 0 – 0.008 (0 – 0.0003) 0.05 (0.002) Connecting rod big end side clearance 0.10 – 0.35 (0.004 – 0.014) 0.80 (0.032) Transmission Gear I.D. M4, M5 20.000 – 20.021 (0.7874 – 0.7882) 20.05 (0.789) C1 20.500 – 20.521 (0.8071 – 0.8079) 20.55 (0.809) C2 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908) C3 23.025 – 23.046 (0.9065 – 0.9073) 23.07 (0.908) Bushing O.D. M4, M5 19.959 – 19.980 (0.7858 – 0.7866) 19.91 (0.784) C1 20.459 – 20.480 (0.8055 – 0.8063) 20.41 (0.804) C2, C3 22.984 – 23.005 (0.9049 – 0.9057) 22.95 (0.904) Gear-to-bushing clearance M4, M5, C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004) C2 0.015 – 0.057 (0.0006 –0.0022) 0.10 (0.004) C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004) Bushing I.D. M4, C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671) C2, C3 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790) Mainshaft / countershaft O.D. M4, C1 16.966 – 16.984 (0.6680 – 0.6687) 16.93 (0.667) C2 19.978 – 19.989 (0.7865 – 0.7870) 19.94 (0.785) C3 19.979 – 20.000 (0.7866 – 0.7874) 19.94 (0.785) Bushing-to-shaft clearance M4, C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004) C2 0.031 – 0.063 (0.0012 – 0.0025) 0.10 (0.004) C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004) Shift fork, shift fork shaft Shift fork shaft O.D. 9.986 – 9.995 (0.3931 – 0.3935) 9.93 (0.391) Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.05 (0.396) Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)

2004 Honda CBF150 Service Repair Manual (Free Preview)

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