2003-2012 Honda CRF150F Service & Repair Manual

HOW TO USE THIS MANUAL Th is servICe manua l descnOeS the :;erV1ce procedu res lor the CRFl50F Follow the Ma intenance Schedule ISect,on 3) recommendat>orlS 10 ensure 1M! the vehtde .s In peak opera~ng cond,hon and !he em ission levels are wlth,n the standard set by the U.S. EnvIronmental P'ole<;tlOl1 Agency (EPA) and Cal,forma Air Resoortes Board (CARB) Petform,"ll the f,rst sdleduled maintenance IS very important II compensates lor Ihe ,ml lal wear that occurs dUring lhe break· ,n penod Section:; 1 and 3 apply to lhe whole motorcycle SectIOn 2 II Iustra1es procedures for removal,l,nsl9l lahon ol cOrTlp<l<lenlS thai may be required to per10rrn service described In lhe 10110\'/'''9 sect.ons SectIon 4 through 23 describe paris of !he motorcyc l e, grouped accord ing 10 localKln Find the sectIon you want on Ih,s page, then IUff'l to tlla table at conlents on It!e f,rsl page 01 the sec\Jon Most sectlOllS sta,t ""In an assembly or system ,"us-lrahon. selVlC(l II1torma11On and Irool}l eshootll1g 10, the sectto~ The subsequent pages give delal1ed procedures I[ you oon'l krxow the source of the trouble, go to Sec~oo 25 TrOl.Jbfeshootong YOIJr safeI)', and the safely 01 others, is very Important. To help you make ,nformed decisions we have pml'Kled safety messages and other II110rmauon throughout this manual Of course, it is n<lt prnC\JC31 Of posMlle to warn you aboul all the IIazards associated w,lh servicing this vehicle YOl' must use your own good ludgement You "". lind Important salety II'lformatlOl1 in a ",nely of forms II1ciuding • Safety Labels - on lhe vehICle • Safety Messages - preceded by a safety alert symbol J and OM of three sigMI words, DANGER WARNING, or CAUTION These Signal wtlrds mean iN.bHMil You WILL be KILLED Of SERIOUSLY _ ••••• __ ._ HURT d 'fOU don't foflow ir'lslroctions ft'1 h1 i!.'! i N' eMI,u.g' You CAN be KILLED or SERIOUSLY HURT d you don't follow Instlllctions You CAN be HURT rt you (1on\ follow InstructIOnS • InstrlJCbons - how to servICe Uus valuele correctly aO<! safely As you read th iS manua l. you WI. hnd Informatoon that IS preceded by a JfO]eE symbo l. The purpose 01 th iS message IS to help prevent damage to your vehicle. othsr preperli', or the erlllironmeni z " go W > it o o z " w z '" z w III iii III " ::t: o ..J " !,1 a: .... o W ..J W CONTENTS GENERAL INFORMATION MAINTENANCE LUBRICATION SYSTEM (' 03 -' 05 model) LUBRICATION SYSTEM (After '05 model) FUEL SYSTEM ENGINE REMOVAUINSTALLATION CYLINDER HEADNALVES (' 03 - '05 model) CYLINDER HEADNALVES (After '05 model) CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ('03 - '05 model) CLUTCH/GEARSHIFT LINKAGE (After '05 model) ALTERNATOR ('03 - '05 model) ALTERNATOR (After ' 05 model) CRANKSHAFTfTRANSMISSION (After '05 model) FRONT WHEEUSUSPENSIONJSTEERING REAR WHEEUBRAKEISUSPENSION HYDRAULIC BRAKE ELECTRICAL SYSTEM (' 03 -' 05 model) BATTERY/CHARGING SYSTEM (After ' 05 model) IGNITION SYSTEM (After '05 model) ELECTRIC STARTER (After '05 model) WIRING DIAGRAMS TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it will be explained specifically in the text without the use of the symbols. tt r- , I- 7J ~--.. I I Replace the part(s) with new one(s) before assembly. -, t U,e ,ecommeoded e09ioe oil, oole" olhelWi,e ,pecilied, Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1). Use mUlti-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). - -+ - Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent. Example: Molykote® BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Milsubishi Oil, Japan --- Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide. NLGI #2 or equivalent. Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U,S.A. only) Roeol ASP manufactured by Roeol Limited. U.K. Roeol Paste manufactured by Sumico Lubricant. Japan Use s il icone grease, Apply a locking agent. Use a middle strength locking agent unless otherwise specified. - Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. - Use Fork or Suspension Fluid.

1. GENERAL INFORMATION SERVICE RULES · .. ·············· .. ······················1-2 MODEL IDENTIFICATION··························· 1-2 GENERAL SPECIFICATIONS ...................... 1-5 LUBRICATION SYSTEM SPECiFiCATiONS···································· ···1-7 FUEL SYSTEM SPECIFICATIONS·············· 1-7 CYLINDER HEADIV ALVES SPECiFiCATIONS···························· ···········1-8 CYLINDER/PISTON SPECIFICATIONS ...... 1-9 ALTERNATOR/STARTER CLUTCH SPECIFICATION (After '05 model) ············1-9 CLUTCH/GEARSHIFT LINKAGE SPECiFiCATIONS································ ·····1-10 CRANKSHAFT/TRANSMISSION/ KICKSTARTER SPECIFICATIONS ('03 - '05 model) ·······································1-10 CRANKSHAFT/TRANSMISSION SPECIFICATIONS (After '05 model) ········1-11 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS······································ 1- 12 REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS ..................................... 1-12 HYDRAULIC BRAKE SPECIFICATIONS··· 1-12 ELECTRICAL SYSTEM SPECIFICATIONS ('03 - '05 model) ....................................... 1-13 BATTERY/CHARGING SYSTEM SPECIFICATIONS (After '05 model)········ 1-13 IGNITION SYSTEM SPECIFICATIONS (After '05 model) ······································1-13 ELECTRIC STARTER SPECIFICATION (After '05 model) ······································1-13 STANDARD TORQUE VALUES··············· 1-14 ENGINE & FRAME TORQUE VALUES···· 1-14 LUBRICATION & SEAL POINTS ··············1-19 CABLE & HARNESS ROUTING ('03 - '05 model)······································· 1-22 CABLE & HARNESS ROUTING (After '05 model) ······································1-25 EMISSION CONTROL SYSTEMS ............ 1-29 1-1

GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda- recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the mo torcycl e. 2. Use the special tools designed for this pr oduct 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. Inslall new gaskets, O-rings, cOlier pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the l arger diamete r or inner bolt first. Then lighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubric ate any sliding surfaces before reassembly. 7. After reassembly. check all parts f or proper installat ion and operation. S. Route all electrical wires as shown in the Cable and Harness Routing (page 1-22). MODEL IDENTIFICATION '03 - '05 model : '06 - '07 model : 1-2

After ' 07 : SERIAL NUMBERS The Vehicle Identification Number {VIN} is stamped on the right side of the steering head. The engine seria l number is st amped on the lower left side of the crankcase. GENERAL INFORMATION 1-3

GENERAL INFORMATION The carbure tor identification number is stamped on the right side of the carburetor body. LABELS The name plate (U.S.A.) or Safety Certification Label (Canada) is - - attached on the frame down tube. r~ The color label is attached on the left rear frame behind the left side cover. When ordering color-coded parts, always specify the designated color code. I ' I ! , \ \ /- NAME PLATE (U.S.A.) ~ -'. c SAFE1YCERTlFlCATION A LABEL (Canada) COLOR LABEL The Emission Information Label is attached on the rear fender (U.S.A. 'EMISSION INFORMATION LABELS: type and After '07 Canada type). Aft" '07 Canada ~ / U.S.A. and / After '07 Canada 1-4

GENERAL SPECIFICATIONS '03 - '05 model: I DIMENSIONS ITEM Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance o _ _ _ f--,C~urb weight FRAME Frame type I ENGINE CARBURETOR DRIVE TRAIN ELECTRICAL Front suspension Front wheel travel Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Tire brand (Pirelli) FR/RR Front brake Rear brake Caster angle Trail length Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve Exhaust valve Lubrication system Oil pump type Cooling system Air filtration Engine dry weight Carburetor type Throttle bore Clutch system opens closes opens closes Clutch operation system Transmission Primary reduction Final reduction Gear ratio I Gearshift pattern 1 Ignition system at 1 mm (0.04 in) lift at I mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift ,,, 2nd 3,d 4th 5th GENERAL INFORMATION SPECIFICATION 1,936 mm (76.2 in) 799 mm (31.5 in) 1,120 mm (44.1 in) 1,323 mm (52.1 in) 825 mm (32.5 in) 338 mm (13.3 in) 270 mm (10.6 in) 103.3 kg (227.7 Ibs) Semi-double cradle Telescopic fork 207 mm (8.1 in) Swingarm 223.0 mm (8.78 in) Nitrogen gas filled damper 70/100·1942M 90/100·1651M MT18/MT18 Hydraulic single disc Mechanical drum (leading-trailing) 25° 45' 85 mm (3.3 in) 8.2 liters (2.17 US gal, 1.80 Imp gal) 1.5 liters {0.40 US gal, 0.33 Imp gal} Single cylinder inclined 15" from vertical 63.5 x 49.5 mm (2.50 x 1.95 in) 156 cm 3 (9.5 cu-in) 9.0: 1 Chain driven. OHC 2-valve with rocker arm 5° BTDC 30" ABDC 35° BBDC 5° ATDC Forced pressure and wet sump Trochoid Air cooled Oiled polyurethane foam 27.3 kg (60.2 Ibs) -- Piston valve 22 mm (0.9 in) Multi-plate, wet Cable operating 5 speeds 3.333 (60/18) 3.692 (48/13) 2.769 (36/13) 1.882 (32/17) 1.400 (28/20) 1.095 (23/21) 0.923 (24/26) Left foot operated return system. l-N-2-3-4-5 COl 1-5

GENERAL INFORMATION After '05: DIMENSIONS FRAME ENGINE CARBURETOR ITEM Overatllength Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Curb weight Frame type Front suspension Front wheel travel Rear suspension Rear whee l travel Rear damper Front tire size Rear tire size Tire brand (Pirelli) FR/RR Front brake Rear brake Caster angle Trail length Fuel tank capacity Fuel tank reserve capacity Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens lubrication syst em Oil pump type Cooling system Air filtration closes Engine dry weight Carburetor type Throttle bore DRIVE TR'''A''INCO-~-C;;I:C"~tch system ELECTRICAL 1-6 Clutch ope r ation system Transmission Primary reduction Final reduction Gear ratio Gearshift pattern Ignition system Starting system Charging system Reg u lato rlrect ifie r '06 - '07: After '07: '06 - '07: After '07: '06 - '07: After '07: '06 - '07: After '07: SPECIFICATION 1,945 mm (76.6 in) 799 mm (31.5 in) 786 mm (30.9 in) 1, III mm (43.7 in) 1,117 mm (44.0 in) 1,328 mm (52.3 in) 826 mm (32.5 in) 832 mm (32.8 in) 338 mm (13.3 in) 257 mm (10.1 in) 107.2 kg (227.7 Ibs) 106.1 kg (233.9 Ibs) . Semi-double cradle Telescopic fork 207 mm (8.1 in) Swingarm 227 mm (8.9 in) Nitrogen gas filled damper 70/100-1942M 90/100-1651M MT18/MT18 Hydraulic single disc Mechanical drum (leading - trailing) 26° 02' 88 mm (3.5 in) '06 - '07: 8.2 liters (2.17 US gal, 1.80 Imp gal) After '07: 7.0 lit ers (1.85 US gal, 1.54 Imp gall '06 - '07: 1.5 liters (OAO US gal, 0.33 Imp gal) After _ 'O~7~'_~ '~.6~liters (0.42 US gal, 0.35 Imp gal) Single cylinder inclined 15° f rom vertical 57.3 x 57.8 mm (2.26 x 2.28 in) 149 em' (9.1 cu-in) 9.5 : 1 at I mm (0.04 in) lift at 1 mm (0.04 in) lift at I mm (0.04 i n) lift at 1 mm (0.04 in) lift Chain driven, QHC 2·valve with rocker arm 10° BTDC 30 ABDC 35° BBDC 5° ATDC ," 2,d 'cd 4th 5th Forced pressure and wet sump Trochoid Air cooled Oiled polyurethane foam __ ~_2",7".8",kg (61.3 Ibs) Piston valve 22 mm (0.9 in) Multi·plate, wet Cable operating 5 speeds 3.350 (67/20) 3.615 (47/13) 2.786 (39/14) 1.875 (30116) 1.409 (31/22) 1.120 (28/25) 0.938 (30/32) Left foot operated return system, 1- N·2·3·4·5 DC·CDI Electric starter motor Single phase output alternator seR shorted single phase, half·wave rec- tification

GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS ' 03 - '05 model: ITEM Engine oil At draining capacity At disassembly Recommended engine oil Oil pump rotor Tip clearance Body clearance Side clearance Unit: mm (in) STANDARD ~ ERVICE LIMIT -====~1.0 liter (1.1 US qt, 0.9 Imp qt) _ 1.2 liter (1.3 US qt, 1.1 Imp qt) - --- ----+-~P~ro Honda GN4 4-stroke oil (U.S.A. and _ Canada) or equivalent motor oil 1 API service classification: SG or higher JASO T 903 standard: MA Viscosity: SAE lOW-30 __ ~~= 0.15 (0.006) _____ 0.20 (0.008) 0.15 0.21 {0.006 O.OOB} 0.35 (0.014) 0.03 0.12 (0.001 0.005) 0.15 (O.006) After '05: ITEM Engine oil At draining capacity At disassembly Recommended engine oil Unit: mm (in) STANDARD ___ + -"S ER VICE LIMIT I 1.0 liter (1.1 US qt, 0.9 Imp qt) ~ 1.2 liter (1.3 US qt. 1.1,~lm~p~q~t)~~;:;:;:::==- Pro Honda GN44-stroke oil (U.S.A. and 1 Canada) or equivalent motor oil API service classification: SG or higher JASO T 903 standard: MA Viscosity: SAE lOW-30 Oil pump rotor Tip clearance Body clearance Side clearance 0.15 (0.006) 0.20 (0.008) __ ~",0.,c.'8~- 0.23 (0.007 - 0.0'''09'''1----~---i OC;.2fii8iIOiC.iCo,i'i,i'-1 0.05 0.11 (0.002 - 0.004) 0.15 (0.006) FUEL SYSTEM SPECIFICATIONS '03 - '05 model : ITEM Carburetor identification number Main jet Slow jet Jet needle clip position Pilot screw opening Initial/final opening Float level Idle speed Throttle grip freeplay After ' 05: I High altitude adjustment ITEM SPECIFICATIONS PDD6A #98 #40 x #40 3rd groove from top See page 6·17 Seepage6·18 12.5 mm (O.49 in) 1,400 ± 100 rpm 2 - 6 mm (1/12 -1/4 in) SPE CIFICATIONS ~~ ________________ ~PDD6D +~'"-c~-- PDD6F I Carburetor identifica· U.S.A. type '06 '07 tion number After '07 t Canada type Main jet Slow jet Jet needle clip posi· U.S.A. type ·06 ·07 After '07 PDD6E PDD6F #95 #40 x #40 Lower groove tion Canada type I '06 '07 3rd groove from t~o2P ,-______ _ After '07 Lower groove ___ -iS~'~'~page 6·17 See page 6·18 Pilot screw Initial/final opening High altitude adjustment Float level 12.5 mm (0.49 in) t Idle speed , Throttle grip freeplay 1,400 ± 100 rpm 2 - 6 mm (1/12 - 1/4 in) 1-7

2003-2012 Honda CRF150F Service & Repair Manual

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