2007-2009 Honda Crf150r Service & Repair Manual

HOW TO USE THIS MANUAL A Few Words About Safety Service Information The service and repair information contained in thiS manual is Intended for use by qualified, professional technicians. Attempting service or repai rs without the proper training, loo ls. and equipment could cause injury to you or others II could also damage the vehicle or create an unsafe condition. This manual descnbes the proper methods and procedures for perfonning service, maintenance and repairs. Some procedures req uire the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a 1001 that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the ve hicle. If you need to replace a part. use Honda Genuine parts with the correct part number or an eqUivalenl part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer's Safety Proper servIce and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error Of oversight while servicing a vehicle can result in faul ty operation, damage to the vehicle, Of injury to others. For Your Safety AWARNING Improper service and repairs can create an unsafe condition that can cause your customer to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. Because this manual is intended fo r the professional service techniCian, we do not provide warnings about many basic shop safety practices (e.g ., Hot parts-wear gloves). If you have nol received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manua l. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard thai can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. AWARNING Failure to properly follow instructi ons and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in thiS manual carefully. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wea ri ng appropriate clothi ng and uSing safety equipment. When performing any service task, be especially careful of the following: Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. Protect your eyes by USing proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe bums or cuts. Before you grab something that looks like II can hurt you, stop and put on gloves. Protect yourself and others whenever you have Ihe vehicle up in the air. Any time you lift the vehicle, either with a hoist or a Jack, make sure Ihat it is always securely supported. Use jack stands. Make sure the engine IS off before you begin any servicing procedures, unless the instruction tells you to do othelWise. This will help eliminate several potential hazards: Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engi ne Burns from hot parts or coolant. let the engine and exhaust system cool before working in those areas. Injury from moving parts. If the lnstruction tells you to run the engine , be sure your hands, fingers and clothing are out of Ihe way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the POSSibi lity of a fire or explOS ion, be careful when working around gasoline or batteries. Use only a nonflammable solvent, not gasoline, to d ean parts. Never drain or store gasoline in an open container. Keep all Cigarettes, sparks and flames away from the battery and all fuel-related parts.

HOW TO USE THIS MANUAL How To Use This Manual This manual describes the service procedures for the CRF150R/RB. Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removallinstallation of components that may be required to perform service described in the following sections. Section 4 through 15 describe parts of the motorcycle, grouped according to location. Follow the Maintenance Schedule recommendations to ensure thai the vehicle is in peak operating condition and the emission levels are within the standards set by Ihe U.S. Environmental Protection Agency (EPA) and California Air Resources Board (CARB) and Transport Canada. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. If you don't know the source of the trouble, go to Troubleshooting section 17 . Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: Safety Labels - on the vehicle • Safety Messages - preceded by a safety alert symbol ! and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean: f1.tHH3ji You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions. t1iwJjWWfI You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions. t!''b''U.g. You CAN be HURT if you don't follow instructions. • Instructions - how to service this vehicle correctly and safely. As you read this manual, you will find information that IS preceded by a ~ symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment.

HOW TO USE THIS MANUAL SYMBOLS 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 of the symbols. I Replace Ihe par1(s) with new one(s) before assembly . Use the recommend engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1). Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NlGI #2 or equivalent). Example: • Molykote® BR-2 plus manufactured by Dow Coming U.S.A. +- ' Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent), Example : Molykote® G-n Paste manufactured by Dow Corning U.S.A Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, UK +-_~ R~ ocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a medium 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.

z ~ I- W > i< o o z " w z a z w CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEADNALVES CYLINDER/PISTON CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER FRONT WHEEL/SUSPENSION/STEERING ~ F===~================================ :il REAR WHEEL/SUSPENSION ~ F===~~================================== U HYDRAULIC BRAKE ELECTRICAL SYSTEM WIRING DIAGRAM TROUBLESHOOTING INDEX

SERVICE RULES ··········································1·2 MODEL IDENTIFICATION .. .......................... 1·2 GENERAL SPECIFICATIONS ...................... 1-4 LUBRICATION SYSTEM SPECIFICATIONS ...... · .... · .. · ...... · .. ··· .... · .... · .... 1·6 FUEL SYSTEM SPECIFICATIONS .............. ·1·6 COOLING SYSTEM SPECIFICATIONS .... · .. 1·6 CYLINDER HEAD/ VALVES SPECIFICATIONS .......................... 1·7 CYLINDER/PISTON SPECIFICATIONS ...... ·1·7 CLUTCH/KICKSTARTER/ GEARSHIFT LINKAGE SPECIFICATlONS"1·8 CRANKCASE/CRANKSHAFT/ TRANSMISSION SPECIFICATIONS ............ 1·8 1. GENERAL INFORMATION FRONT WHEEUSUSPENSION/STEERING SPECIFICATIONS ........ · .. ·.......................... · .. 1·9 REAR WHEEUSUSPENSION SPECIFICATIONS .... · ........ · .. · ........ · ........ · .. ·· 1·10 HYDRAULIC BRAKE SPECIFICATIONS """"""" """"""""""",,, 1·11 ELECTRICAL SYSTEM SPECIFICATIONS .... · .. ·· .......... .. .... · ............ · 1·11 STANDARD TORQUE VALUES ................ · 1·12 ENGINE & FRAME TORQUE VALUES ...... 1·12 LUBRICATION & SEAL POINTS .............. ·1·1 6 CABLE & HARNESS ROUTlNG .............. .. ·1·18 OPTIONAL PARTS .................................... ·1·22 1-1

GENERAL INFORMATION SERVICE RULES 1. Use Honda genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to Ihe motorcycle. 2. Use Ihe special tools designed for this producllo avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuls and screws are nol interchangeable with English fastener . 4. Install new gaskets. O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolls or nuts, begin with the larger diameter or inner boll firs!. Then tighten to Ihe specified torque diagonally in incremental sleps 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. Roule all electrical wires as shown in the Cable and Harness Routing (page 1-18). MODEL IDENTIFICATION 1-2

The Vehicle Identification Number (VIN) is stamped on the right side of the steering head. GENERAL INFORMATION '<\/~ '4JJr~~ > ~~j~/=--1' ,'- I C"~ ' " 'L~ ~~"~'J ~- e \ -¥'Jy ~~~~i ~ '--' "'(.! ~ --C:?r-X .-.,"(- '. VEHICLE IDENTIFICATION NUMBER (VIN) ___ '-.... ---. 1 The engine serial number is stamped on the left side of the lower :================~ crankcase. The carburetor identification number is stamped on the left side of the carburetor body. 1-3

GENERAL INFORMATION GENERAL SPECIFICATIONS CRF150R: DIMENSIONS Overall length Overall width Overall height Wheelbase ITEM' --- Seat heigl'll Footpeg heigl'll Ground clearance FRAME -r Frame type Front suspension Front suspension axle travel Front suspension cushion stroke Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Tire brand Front brake Front brake swept area Rear brake Rear brake swept area Casler angle Trail length _--====;:::;::;:;:~ SPECIFICATION 1,832 mm (72.1 in) 770 mm (30.3 in) 1,133 mm (44.6 in) 1,260 mm (49.6 in) 832 mm (32.8 in) 379 mm (14.9 in) 301 mm (11.9 in) -----~S~e~m~;~dio~uble cradle Telescopic fork 241.3 mm (9.50 in) 275 mm (10.83 in) Pro-Link U.S.A. type: Canada type: 272.4 mm (10.72 in) Decarbon type with nitrogen gas filled damper 70/100-17 40M 90/100-1449M DUNLOP Front K490G IRear: K695 BRIDGESTONE Front: M23 / Rear: M22 Hydraulic single disc 358.1 cm 1 (55.5 inl) Hydraulic single disc 300.7 cm~ (46.6 in 2) 27"02' 78 mm (3 .07 in) 1 i ENGINE __ +~ F ~u"e:l tank capac"ityL _______ _ Bore and stroke 4.31119r (1.14 US gal. O.9Slmp gal) 66,0 x 43.7 mm (2.60 x 1.72 in) 149.7 em] (9 .13 cu-in) Displacement Compression ratio Valve train Intake valve ('07-'11) Inlake valve (After '11) Exhaust valve Lubrication system Oil pump type Cooling system Air filtration Crankshaft type Engine dry weigl'll opens closes opens closes opens closes at 1 mm (0.04 in) lift at 1 mm (0.04 in) hft atl mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift atl mm (0.04 in) lift 11.7 : 1 Chain drive and OHC with rocker arm 15° BlOC 48° ABDC 15° BTDC 49° ABDC 50· BBDC 25" ATDe Forced pressure and wet sump Trochoid liquid cooled Oiled polyurethane foam Assembled type 20.2 kg (44 .5Ibs) ,--t-~Cylinder arrangeme~ ol '___ _ ___ _ CARBURETOR Carburetor type Venturi diameter Single cylinder, inclined 19° from vertical Piston valve type DRIVE TRAIN ELECTRICAL 1-4 Clutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio Gearshift pattern Ignition system lSi 'od 3,d 4th 5th 32 mm (1.3 in) Multi-plate, wet Cable operated Constant mesh, 5-speed 4.117 (70/17) 3.333 (50115) 2.214 (31/14) 1.647 (28/17) 1.318 (29122) 1.105(21119) 0.956 (22J23) Left fool operated return system, ~ l-N-2-3-4·5 __ ---"--'C~ D~I-'(C ,apacitive Discharged Ignition

You're Reading a Preview

2007-2009 Honda Crf150r Service & Repair Manual

Description

Reviews

Q&A

Recently Viewed