HONDA NSR150SP NSR 150 SP* Factory Service / Repair/ Workshop Manual !

NSR150SP General Information CONTENTS

NSR150SP General Information ______________________________________________ 1-1 HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the motorcycle is in peak operating condition. Performing the first schedule maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 through 3 apply to the whole unit, while sections 4 through 19 describe parts of the unit, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to section 20, TROUBLESHOOTING. All information contained in this manual is based on the latest product information available at the time of printing. Honda Australia Motorcycle & Power Equipment Pty. Ltd., and Honda Motor Co. Ltd, Japan, reserve the rights to make changes at any time without notice. Apart from criticism or reviews permitted under the Copyright Act 1968, no part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying or recording or otherwise, without the prior written permission of Honda Motorcycle & Power Equipment Pty. Ltd., and/or Honda Motor Co Ltd. Japan. This includes test, figures and tables. HONDA MOTOR CO., LTD Service Publications Office IMPORTANT SAFETY NOTICE Indicate a strong possibility of severe personal injury or death if instructions are not followed. CAUTION Indicate a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by HONDA, must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardised by the service methods or tools selected.

NSR150SP General Information ______________________________________________ 1-2 SYMBOL The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use to the symbols. Replace the part (s) with new one (s) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1) Use multi-purpose grease (lithium based multi-purpose grease NLGI#2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI#2 or equivalent). Example: Molykote ® BR-2 plus manufactured by Dow Corning, U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil Japan. Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI#2 or equivalent). Example: Molykote ® G-n Paste manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use Silicone grease. Apply a locking agent. Use a middle strength-locking agent unless otherwise specified. Apply sealant. Use brake fluid, DOT 4. Use the recommended brake fluid, unless otherwise specified. Use Fork or Suspension Fluid.

NSR150SP General Information ______________________________________________ 1-3 General Safety 1-3 Torque Values 1-14 Service Rules 1-5 Tools 1-17 Model Identification 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. 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. Hot Components Used Engine / Transmission Oil Brake Dust Never use an air hose or dry brush to clean brake assemblies. Brake Fluid CAUTION: • Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN.

NSR150SP General Information ______________________________________________ 1-4 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. 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. 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 • Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flame. • Coolant (ethylene glycol) can cause some skin irritation and is poisonous if swallowed, KEEP OUT OF REACH OF CHILDREN. • Keep out of reach of pets. Some pets are attracted to the smell and taste of coolant and can die if they drink it. • Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. • Use only nitrogen to pressurize the shock absorb. The use of an unstable gas can cause a fire or explosion resulting in serious injury. • The shock absorber contains nitrogen under high pressure. Allowing fire or heat near the shock absorber could lead to and explosion that could result in serious injury. • Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explosion and serious injury if it is heated or pierced. - The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. - The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and face Shield. - If electrolyte gets on your skin, flush with water. - If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician If swallowed, drink large quantities of water or milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN.

NSR150SP General Information ______________________________________________ 1-5 SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubrications or their equivalents. Parts that do not meet HONDA's design specifications may damage the motorcycle. 2. Use the special tools designed for this product. 3. Use only metric tools when servicing this motorcycle. Metric bolts, nets and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motorcycle. 4. Install new gaskets, 0-rings, cotter pins, lock plates, etc. When reassembling. 4. When tightening a series of bolts or nuts, begin with the larger-diameter of inner bolts first, and tighten to specified torque diagonally, in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before re-assembly. 7. After assembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown on pages 1-22 through 1-27, Cable and Harness Routing.

NSR150SP General Information ______________________________________________ 1-6 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.

NSR150SP General Information ______________________________________________ 1-7 SPECIFICATIONS General ITEM SPECIFICATIONS Overall length 1,972mm (77.6 in) Overall width 683 mm (26.9 in ) 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 (289.7 lb ) DIMENSION Maximum Weight capacity 118kg (260.1 lb ) Frame Type Diamond Front Suspension Telescopic fork Fork Inner tube diameter 35 mm (1.4 in) Fork fluid capacity (per leg) 322 cm 3 (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 2 , 142psi) Pressurized gas material Nitrogen Front tyre size 90/80-17 46S Rear tyre size 120/80-17 61S Front brake Hydraulic single disc Rear brake Hydraulic single disc Caster angle 25 O 36’ Trail 91 mm (3.6 in) Fuel Tank capacity 10.5 litre (2.8 US gal, 2.3 Imp gal) FRAME 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 3 (9.1 cu-in) Compression ratio 108 kPa (11.0kgf cm 2 ,156 psi) at 400min- 1 (rpm) Port timing intake open Reed valve controlled Port timing intake close Reed valve controlled Port timing exhaust open - Hi 97.6 O BBDC - Low 73.9 O BBDC Port timing exhaust close - Hi 97.7 O ABDC Low 74.0 O ABDC Port timing scavenge open 62.6 O BBDC Port timing scavenge close 62.8 O ABDC Lubrication system Oil automatically mixed with gasoline Oil pump type Plunger type Cooling system Liquid cooled Air filtration Urethane form Crankshaft type Assembly type ENGINE Engine weight 23.9kg (52.7lb)

NSR150SP General Information ______________________________________________ 1-8 General (cont..) ITEM SPECIFICATIONS Carburettor type Piston Valve CARBURETTOR Throttle bore 30 mm (1.2 in) Clutch System Multi-plate, wet Clutch operation system Cable operating Transmission 6 speeds constant mesh Primary reduction 2.954 (65/22) Final reduction 2.857 (40/14) Gear ratio 1 st 2.916 (35/12) Gear ratio 2 nd 1.937 (31/16) Gear ratio 3 rd 1.470 (25/17) Gear ratio 4 th 1.210 (23/19) Gear ratio 5 th 1.043 (24/23) Gear ratio 6 th 0.916 (22/24) DRIVE TRAIN Gearshift pattern Left foot operated return system (1N-2-3-4-5-6) Ignition system DC-CDI Charging system Triple phase output alternator Alternator /capacity 188 W/5,000 min 1 (rpm) Regulator/rectifier type Semi conductor type ELECTRICAL Lighting system Battery

NSR150SP General Information ______________________________________________ 1-9 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 At draining 0.7 litre (0.73 US qt, 0.62 Imp, qt) Transmission oil capacity At disassembly 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 10W – 40 FUEL SYSTEM ITEM STANDARD Carburettor identification number PE74A Choke type Starting enrichment circuit system Main jet #152 Slow jet #42 Air screw initial opening 2 turns out Float level 19mm (0.7 in) Idle speed 1,300 + 100 min 1 (rpm) Throttle grip free play 2 – 6mm (0.08 – 0.24in) COOLING SYSTEM ITEM STANDARD Radiator and engine 1.2 Litre (1.27US qt, 1.06 Imp qt) Cooling capacity Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4kgf/cm 2 , 16-21 psi) Standard coolant concentration 50% mixture with soft water

HONDA NSR150SP NSR 150 SP* Factory Service / Repair/ Workshop Manual !

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