Honda CRF150R 2020 Owner's Manual & Competition Handbook
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Honda CRF150R 2020 Owner's Manual & Competition Handbook

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2020
2020
CRF150R/RB

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Summary of Contents for Honda CRF150R 2020

  • Page 1 2020 2020 CRF150R/RB...
  • Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when it is resold. All information in this publication is based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd.
  • Page 3 2020 Honda CRF150R/RB OWNER’S MANUAL & COMPETITION HANDBOOK...
  • Page 4 This information is intended to help you avoid damage When you own a Honda, you’re part of a to your Honda, other property, or the environment. worldwide family of satisfied customers — people who appreciate Honda’s reputation for building Unless you are mechanically qualified and have quality into every product.
  • Page 5 A Few Words About Safety A Few Words About Safety Your safety, and the safety of others, is very important. And operating this motorcycle safely is an important responsibility. To help you make informed decisions about safety, this manual contains a section devoted to Motorcycle Safety, as well as a number of Safety Messages throughout the manual.

  • Page 6: Table Of Contents

    Important Safety Information ......2 Fluids & Filters Transporting Your Motorcycle...... 128 Fuel System............34 Important Safety Precautions ......2 Storing Your Honda ........129 Engine Oil ............36 Important Message to Parents ....... 2 You & the Environment ........ 130 Transmission Oil..........39 Accessories &...

  • Page 7: Motorcycle Safety

    Motorcycle Safety Motorcycle Safety This section presents some of the most important Important Safety Information ......2 information and recommendations to help you ride Important Safety Precautions......2 your CRF safely. Please take a few moments to Important Message to Parents......2 read these pages. This section also includes Accessories &...

  • Page 8: Important Safety Information

    Alcohol and riding don’t mix. Even one drink can reduce your ability to respond to changing Your child's safely is very important to Honda. Your CRF can provide many years of pleasure, if conditions, and your reaction time gets worse with That’s why we urge you to read this message...

  • Page 9: Accessories & Modifications

    Accessories & Modifications Accessories & Modifications Accessories & Modifications Installing non-Honda accessories, removing original equipment, or modifying your CRF in any way that would change its design or operation, could seriously impair your CRF’s handling, stability, and braking, making it unsafe to ride.

  • Page 10: Safety Labels

    Safety Labels Safety Labels Read this label carefully and don’t remove it. If the label comes off or becomes hard to read, contact your dealer for replacement. (For Canada) Motorcycle Safety...

  • Page 11: Operating Controls

    Instruments & Controls Operating Controls Read this section carefully before you ride. It Operation Component Locations .......6 presents the location of the basic controls on your CRF. Operating Controls...

  • Page 12: Operation Component Locations

    Operation Component Locations Operation Component Locations hot start lever front brake lever clutch lever engine stop button throttle grip kickstarter choke knob rear brake pedal fuel valve shift lever Operating Controls...

  • Page 13: Before Riding

    Before each ride, you need to make sure you and Are You Ready to Ride? ........8 your Honda are both ready to ride. To help get you Is Your Motorcycle Ready to Ride? ....9 prepared, this section discusses how to evaluate Pre-ride Inspection.........9...

  • Page 14: Are You Ready To Ride

    Are You Ready to Ride? Are You Ready to Ride? Before riding your CRF for the first time, we WARNING strongly recommend that you read this owner’s manual, make sure you understand the safety Not wearing a helmet increases the messages, and know how to operate the controls.

  • Page 15: Is Your Motorcycle Ready To Ride

    Is Your Motorcycle Ready to Ride? Is Your Motorcycle Ready to Ride? Competitive riding can be tough on a motorcycle, Pre-ride Inspection so it’s important to inspect your CRF and correct any problems you find before each ride. Check the Check the following before each ride: following items (page numbers are at the right): •...
  • Page 16 Before Riding...

  • Page 17: Basic Operating Instructions

    Basic Operating Instructions Basic Operating Instructions This section gives basic information on how to Safe Riding Precautions ......12 start and stop your engine as well as break-in Starting & Stopping the Engine ......13 guidelines. Preparation ..........13 Starting Procedure ........13 Flooded Engine ...........13 How to Stop the Engine ......14 Shifting Gears ..........15 Break-in Guidelines .........16...

  • Page 18: Safe Riding Precautions

    Basic Operating Instructions Basic Operating Instructions Safe Riding Precautions Before riding your CRF for the first time, please review the Important Safety Precautions begininng on page 2 and the previous section, titled Before Riding. For your safety, avoid starting or operating the engine in an enclosed area such as a garage.

  • Page 19: Starting & Stopping The Engine

    Starting & Stopping the Engine Starting & Stopping the Engine Always follow the proper starting procedure Check the engine oil, transmission oil and coolant Warm Engine Starting 1. Turn the fuel valve ON. described below. levels before starting the engine (pages 37, 40, 41). 2.

  • Page 20: How To Stop The Engine

    Starting & Stopping the Engine How to Stop the Engine (1) throttle (2) engine stop button Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle (1) two or three times, and then close it.

  • Page 21: Shifting Gears

    Break-in Guidelines Shifting Gears NOTICE Improper shifting may damage the engine, transmission, and drive train. NOTICE Downshifting can help slow your motorcycle, especially on downhills. However, downshifting when engine rpm is too high can cause engine damage. NOTICE 1. After the engine has been warmed up, the motorcycle is ready for riding.

  • Page 22: Break-In Guidelines

    Basic Operating Instructions Break-in Guidelines Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: •...

  • Page 23: Servicing Your Honda

    Fuel Tank ............30 Appearance Care ..........90 on this motorcycle; consequently, routine ignition Subframe ............32 timing adjustment is unnecessary. If you want to check the ignition timing, refer to the Honda Service Procedures Service Manual (page 148). Fluids & Filters Fuel System............34 An optional tool kit may be available.

  • Page 24: The Importance Of Maintenance

    Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual. Servicing Your Honda...

  • Page 25: Maintenance Safety

    Be sure there is adequate ventilation whenever you operate the engine. Burns from hot motorcycle parts. Let the engine and exhaust system cool before touching. Injury from moving parts. Do not run the engine unless instructed to do so. Servicing Your Honda...

  • Page 26: Maintenance Schedule

    If you do not feel capable of performing a given task or need assistance, remember that your Honda dealer knows your CRF best and is fully equipped to maintain and repair it. If you decide to do your...
  • Page 27 NOTE: 1. Clean after every moto for dusty riding conditions. 2. Replace every 2 years. Replacement requires mechanical skill. 3. Replace after the first break-in ride. 4. Inspect after the first break-in ride. 5. Replace the transmission oil, if the clutch discs and plates are replaced. Servicing Your Honda...

  • Page 28: General Competition Maintenance

    Use Honda Genuine Parts or their equivalent when servicing your CRF. Clean parts in non-flammable (high flash point) cleaning solvent (such as kerosene) when disassembling.
  • Page 29 Follow the servicing instructions in the Maintenance section. Use Pro Honda Foam Filter Oil or an equivalent. Be sure to grease the air cleaner flange where it contacts the air cleaner housing. Pro Honda White Lithium...
  • Page 30 General Competition Maintenance Servicing Your Honda...
  • Page 31 General Competition Maintenance Servicing Your Honda...

  • Page 32: Before & After Competition Maintenance

    This will ensure that the rear wheel is in proper alignment and allow maximum (2) fork air pressure release screw performance from the rear disc brake. Maintaining proper wheel alignment will also extend brake pad wear. Servicing Your Honda...
  • Page 33 If your CRF was exposed to sea air or salt water, rinse it as soon as possible after the event, dry it, and apply a spray lubricant to all metal parts. If you decide to wash your CRF or use cleaners, refer to Appearance Care (page 90). Servicing Your Honda...

  • Page 34: Maintenance Component Locations

    (engine idle speed) Servicing Your Honda...

  • Page 35: Seat

    2. Remove the seat (4) by sliding it backward. cover bolts (6). 3. Install and tighten the seat mounting bolts (7) to the specified torque: 19 lbf·ft (26 N·m, 2.7 kgf·m) (4) seat (5) side cover (7) seat mounting bolt (6) side cover bolt Servicing Your Honda...

  • Page 36: Fuel Tank

    2. Remove the shroud A bolts/collars (2). 3. Remove the shroud B bolts (3) and shrouds (4). (5) breather tube (6) fuel line (7) fuel tank band (8) fuel tank bolts/washers (2) shroud A bolt/collar (3) shroud B bolts (4) shroud Servicing Your Honda...
  • Page 37 9. Install and tighten the shroud A bolts/collars (9). 10. Tighten the shroud B bolts. (1) fuel tank bolts/washers (2) fuel tank band (3) fuel line (4) breather tube (7) shroud (8) shroud B bolts (9) shroud A bolt/collar Servicing Your Honda...

  • Page 38: Subframe

    2. Remove the seat (page 29). connecting tube clamp (4). (5) subframe lower mounting bolts (6) subframe upper mounting bolt (1) crankcase breather tube (7) subframe (2) transmission breather tube (3) screw (4) air cleaner connecting tube clamp Servicing Your Honda...
  • Page 39 4. Connect the crankcase breather tube (7). 5. Route the transmission breather tube (8) into the air cleaner housing. (1) subframe (2) subframe upper mounting bolt (3) subframe lower mounting bolts (7) crankcase breather tube (8) transmission breather tube Servicing Your Honda...

  • Page 40: Fuel System

    Type Unleaded Pump Octane Number 91 (or higher) Use only unleaded fuel in your Honda. If you ride your Honda in a country where leaded fuel might be available, take precautions to use only unleaded fuel. Your engine is designed to use any unleaded...
  • Page 41 Turn the fuel valve ON; check for leaks. approved gasoline container. 2. Remove the fuel tank (page 30) 3. Remove the fuel valve (1) from the fuel tank by removing the bolts/collars (2). (3) fuel filter (4) O-ring (1) fuel valve (2) bolts/collars Servicing Your Honda...

  • Page 42: Engine Oil

    SAE 10W-30 insufficient oil can cause serious damage to the (weight) engine. JASO T 903 standard suggested oil* Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil, or an NOT RECOMMENDED RECOMMENDED equivalent motorcycle oil. Suggested 4-stroke engine oils are equal...
  • Page 43 (Do not (1) engine oil fill cap/dipstick (2) engine oil drain bolt overfill.) (3) sealing washer Reinstall the engine oil fill cap/dipstick. Repeat steps 1–5. 6. Reinsert the engine oil fill cap/dipstick. 7. Check for oil leaks. (cont’d) Servicing Your Honda...
  • Page 44 (9) facing out, away from the engine. You should see the “OUT-SIDE” mark (10) on the filter body, near the seal. Use a new Honda Genuine oil filter or a filter of equal quality specified for your model. NOTICE...

  • Page 45: Transmission Oil

    JASO T903 standard others without friction modifiers as molybdenum additives suggested oil* Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil. NOT RECOMMENDED RECOMMENDED Suggested 4-stroke engine oils are equal...
  • Page 46 NOTICE tighten the oil check bolt to the specified torque: Improper disposal of drained fluids is harmful to Oil Check Bolt: 7 lbf·ft (10 N·m, 1.0 kgf·m) the environment. 6. Install the transmission oil fill cap securely. Servicing Your Honda...

  • Page 47: Coolant

    Coolant Recommendation Checking & Adding Coolant 2. Add coolant up to the filler neck if the level is Use Pro Honda HP Coolant or an equivalent high low. Refer to Safety Precautions on page 19. quality ethylene glycol antifreeze containing Inspect the coolant level before each outing.
  • Page 48 (4) for leakage. Check for signs of seal leakage. A small amount of “weeping” from Always let the engine and radiator cool the bleed hole is normal. See the Honda down before removing the radiator cap. Service Manual or consult your dealer for replacing the water seal or the oil seal.

  • Page 49: Air Cleaner

    Using the wrong air cleaner may result in premature engine wear. Proper air cleaner maintenance can prevent 7. Apply 0.09 – 0.11 oz (2.6 – 3.0 g) of Pro Honda premature engine wear or damage, expensive White Lithium Grease or an equivalent to the...
  • Page 50 11. Install the seat (page 29). 10. Install and tighten the air cleaner retaining bolt (1). (10) (1) air cleaner retaining bolt (8) air cleaner element tab (9) air cleaner element stay boss (10) air cleaner holder tabs Servicing Your Honda...

  • Page 51: Crankcase Breather

    Draining 1. Remove the crankcase breather tube plug (1) from the tube (2) and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plug. (1) crankcase breather tube plug (2) tube Servicing Your Honda...

  • Page 52: Throttle

    6. Install the dust cover. (–) If you can’t get the freeplay within the specified range, contact your dealer. (1) dust cover (+) increase freeplay (2) lock nut (–) decrease freeplay (3) adjuster Servicing Your Honda...
  • Page 53 (1) throttle housing (2) punch mark 2. Check for smooth rotation of the throttle (3) from fully open to fully closed in all steering positions. If there is a problem, see your dealer. (3) throttle Servicing Your Honda...

  • Page 54: Engine Idle Speed

    5. Adjust idle speed with the throttle stop screw The best way to assure proper carburetion is to see (1). your dealer for regularly scheduled servicing, Idle speed: including carburetor adjustment. 2,100 ± 100 rpm (1) throttle stop screw Servicing Your Honda...

  • Page 55: Clutch System

    If you can’t get proper adjustment, or the clutch does not work properly, the cable may be kinked or worn, or the clutch discs may be worn. See your dealer or refer to the Honda Service Manual (page 148). Servicing Your Honda...
  • Page 56 Clutch Operation 1. Check for smooth clutch lever operation. If necessary, lubricate the clutch lever pivot or clutch cable. 2. Check the clutch cable for deterioration, kinks, or damage. Servicing Your Honda...

  • Page 57: Hot Start Lever

    (1) hot start lever (2) hot start lever freeplay Inspection (1) lock nut (+) increase freeplay Check freeplay: (2) adjuster (–) decrease freeplay Freeplay: 1/16 – 1/8 in (2 – 3 mm) If necessary, adjust to the specified range. Servicing Your Honda...

  • Page 58: Spark Plug

    (5) sealing gasket (6) spark plug gap damaged. (7) side electrode 11. Connect the direct ignition coil. Take care to avoid pinching any cables or wires. 12. Connect the direct ignition coil connector. 13. Install the dust cover. Servicing Your Honda...

  • Page 59: Valve Clearance

    The valve clearance will change as engine temperature rises. (1) crankshaft hole cap 2. Remove the spark plug (page 52). (1) breather tube (2) cylinder head cover bolts (3) cylinder head cover 5. Remove the spark plug hole packing. (cont’d) Servicing Your Honda...
  • Page 60 Camshaft Holder Assembly Removal (page 55) and select the correct shim for each valve. (2) primary drive gear bolt (4) index mark (1) feeler gauge (3) punch mark (2) valve lifters (3) intake cam lobes Servicing Your Honda...
  • Page 61 Do not let the bolt, stopper plate, return spring and decompressor weight fall into the crankcase. (6) bolt (8) return spring (3) cam chain tensioner lifter cover bolt (7) stopper plate (9) decompressor weight (4) sealing washer (cont’d) Servicing Your Honda...
  • Page 62 (15) valve lifters (16) O-ring NOTICE Do not let the valve lifters and shims fall into the crankcase. (13) (17) shims (14) (13) camshaft holder assembly bolts (14) camshaft holder assembly Servicing Your Honda...
  • Page 63 2. Measure the shim thickness with a micrometer and record it. Sixty-nine different thickness shims (2) are available from the thinnest (1.200 mm thickness) shim to the thickest (2.900 mm thickness) in intervals of 0.025 mm. (2) shim Servicing Your Honda...
  • Page 64 (11) rocker arm shaft cut-outs Tighten the camshaft holder assembly bolts (12) in a crisscross pattern in two or three steps to the specified torque: 10 lbf·ft (13 N·m, 1.3 kgf·m) (4) shims (5) valve spring retainers Servicing Your Honda...
  • Page 65 (22) to the specified torque: (18) cam sprocket bolts 7 lbf·ft (10 N·m, 1.0 kgf·m) (17) (14) (22) (13) cam chain (16) “ ” marks (21) (14) cam sprocket (17) “OUT” mark (15) timing marks (21) stopper plate (22) bolt (cont’d) Servicing Your Honda...
  • Page 66 (28) crankshaft hole cap IN: 0.006 ± 0.001 in (0.16 ± 0.03 mm) EX: 0.010 ± 0.001 in (0.26 ± 0.03 mm) (24) (26) (25) (24) sealing washer (25) cam chain tensioner lifter cover bolt (26) (26) feeler gauge Servicing Your Honda...
  • Page 67 (7) breather tube 6. Install the spark plug and direct ignition coil (1) spark plug hole packing (page 52). (2) cylinder head cover packing 7. Install the fuel tank and the seat (pages 31, 29). (3) cylinder head cover Servicing Your Honda...

  • Page 68: Piston/Piston Rings/Piston Pin

    7. Remove the cylinder head cover (page 53). 8. Remove the camshaft holder assembly (page 55). 9. Remove the radiator grills (1) (4) radiator mounting bolts/washers (5) radiators (2) water hoses (3) radiator overflow hose (1) radiator grills Servicing Your Honda...
  • Page 69 Do not let the nuts, washers and cam chain fall into the crankcase. (12) (11) (6) cylinder head bolts (7) cylinder bolt (10) (10) dowel pins (12) cam chain guide (11) cylinder head gasket (8) cylinder head nuts/washers (9) cylinder head Servicing Your Honda...
  • Page 70 2. Remove the dowel pins (3) and cylinder gasket (4). (1) piston ring NOTICE (1) piston pin clip (3) piston (2) piston pin Do not let the dowel pins fall into the crankcase. (3) dowel pins (4) cylinder gasket Servicing Your Honda...
  • Page 71 3. After installing the rings they should rotate freely, without sticking. Space the ring end gaps 180 degrees apart between top ring and upper side rail. Space the ring end gaps 90 degrees apart between upper side rail, spacer and lower side rail. Servicing Your Honda...
  • Page 72 (5) piston pin clip (6) piston cut-out (1) dowel pins (2) cylinder gasket 4. Clean any gasket material off the cylinder. (1) piston (4) piston pin (2) “IN” mark (5) piston pin clip (3) large valve recesses Servicing Your Honda...
  • Page 73 Do not damage the piston rings and cylinder wall. (6) cam chain guide (7) cam chain guide tabs (8) cylinder cut-outs (1) dowel pins (2) cylinder head gasket (3) cam chain (5) piston rings (4) cylinder (cont’d) Servicing Your Honda...
  • Page 74 21 lbf·ft (29 N·m, 3.0 kgf·m) (7) radiators NOTICE (8) radiator mounting bolts/washers (5) cylinder bolt (6) cylinder head bolts Do not let the washers and nuts fall into the crankcase. (3) cylinder head (4) cylinder head nuts/washers Servicing Your Honda...
  • Page 75 (page 29). (10) 16. Pour a fresh recommended coolant mixture (page 41). Check for the following: – compression leaks – abnormal engine noise (9) radiator overflow hose – secondary air leaks (10) water hoses – coolant leaks Servicing Your Honda...

  • Page 76: Suspension

    Replace the wear ring if it is 0.06 in (1.5 mm) or flat with the outer tube (4). Remove the fork leg when replacing the wear ring (page 94). Install the wear ring with its end gap (5) facing rearward. Servicing Your Honda...

  • Page 77: Rear Suspension Inspection

    If there is, have the in 1/4 turn increments. bearings replaced by your dealer. • If you have a problem finding an acceptable adjustment, return to the standard position and begin again. Servicing Your Honda...

  • Page 78: Recommended Fork Oil

    10 in (25 cm). Gently slide the fork tube down onto the lower end of the slider pipe (3). Wait about 5 minutes. (1) piston rod (1) piston rod (3) lower end of the slider (2) fork tube pipe Servicing Your Honda...
  • Page 79 Slightly stiffer as level 127.5 mm it nears full [capacity] 11.95 US oz compression. (353.2 cm Minimum oil 7.61 in Slightly softer as level 193.4 mm it nears full [capacity] 10.14 US oz compression. (299.9 cm (5) syringe (cont’d) Servicing Your Honda...
  • Page 80 4.95 in Slightly stiffer as level 125.7 mm it nears full [capacity] 11.99 US oz compression. (354.4 cm Minimum oil 7.42 in Slightly softer as level 188.4 mm it nears full [capacity] 10.27 US oz compression. (303.7 cm Servicing Your Honda...

  • Page 81: Brakes

    If they are not worn beyond the recommended limit (page 78), there is probably air in the brake system. Refer to the Honda Service (1) lock nut (3) piston (–)
  • Page 82 Refer to the Honda Service Manual or see If the brake lever freeplay exceeds 0.8 in (20 mm), your dealer for brake bleeding.
  • Page 83 • The recommended brake fluid is Pro Honda • The recommended brake fluid is Pro Honda DOT 4 brake fluid or an equivalent. DOT 4 brake fluid or an equivalent.
  • Page 84 (1) brake pads (3) brake disc (2) front brake caliper Make sure there are no fluid leaks. Check for deterioration or cracks in the hoses and fittings. Servicing Your Honda...

  • Page 85: Wheels

    During the first few rides, spokes will 3. Check wheel rim runout. If runout is loosen more rapidly due to the initial seating of the noticeable, see the Honda Service Manual for parts. Excessively loose spokes may result in inspection instructions.

  • Page 86: Tires & Tubes

    Make sure the valve stem caps are secure. If necessary, install new caps. Servicing Your Honda...
  • Page 87 Tire type bias – ply, tube CRF150RB 70/100 – 19 42M DUNLOP MX71F Front 70/100 – 19 42M BRIDGESTONE 90/100 – 16 52M DUNLOP MX71 Rear 90/100 – 16 52M BRIDGESTONE Tire type bias – ply, tube Servicing Your Honda...

  • Page 88: Drive Chain

    Lubricate the drive chain (page 83) if it appears dry or shows signs of rust. Lubricate any kinked or (2) chain guide slider (3) wear inspection window binding links and work them free. Adjust chain slack if needed (page 83). Servicing Your Honda...
  • Page 89 2. Measure the outer diameter of the drive chain turn the adjusting bolts (3) counterclockwise to be used in preference to motor oil. Pro Honda HP roller and replace it if below the service limit. decrease slack or clockwise to increase slack.
  • Page 90 21 pins, from pin center to pin center. If the measurement exceeds the service limit, replace the chain. After the chain is measured, shift the transmission into neutral again before proceeding with inspection and service. Servicing Your Honda...

  • Page 91: Exhaust Pipe/Muffler

    1. Remove the seat mounting bolt (1), side cover bolt (2) and right side cover (3). (4) muffler clamp bolt (5) muffler (6) muffler mounting bolts (7) washer (1) seat mounting bolt (3) right side cover (2) side cover bolt Servicing Your Honda...
  • Page 92 (8) muffler mounting bolts 3. Install a new gasket (5) to the exhaust pipe (6). (9) washer (10) muffler clamp bolt 4. Install the muffler (7) to the exhaust pipe. (5) gasket (new) (7) muffler (6) exhaust pipe Servicing Your Honda...
  • Page 93 4. Tighten the exhaust pipe joint nuts to the specified torque: 8 lbf·ft (11 N·m, 1.1 kgf·m) 5. Tighten the muffler clamp bolt and muffler mounting bolts (page 86). 6. Installation can be done in the reverse order of removal. Servicing Your Honda...

  • Page 94: Additional Maintenance Procedures

    Refer to the Control Cables Honda Service Manual for replacement or adjustment procedures, or see your dealer. Periodically, disconnect the throttle, clutch and hot start cables at their upper ends. Thoroughly lubricate the cable pivot points with a commercially-available cable lubricant.
  • Page 95 (3) coolant drain bolt (8) cylinder head bolts Transmission oil drain (4) crankshaft hole cap bolt (9) drive sprocket bolt (5) transmission oil check bolt (10) transmission oil drain bolt Engine oil drain bolt (11) engine oil drain bolt Servicing Your Honda...

  • Page 96: Appearance Care

    This will help dry the penetrate the dust seals of the suspension pivot brakes and restore normal braking You may use Pro Honda Hondabrite, a multi- points and steering head bearings-driving dirt performance. surface cleaner/degreaser, to remove both dirt and inside and needed lubrication out.
  • Page 97 Be sure the chain is wiped clean and is dry before applying the chain lube. Follow the suggestions given in the pages of this manual for lubricating items such as the brake and clutch lever pivot points and footpeg pivot pins. Servicing Your Honda...
  • Page 98 Servicing Your Honda...

  • Page 99: Adjustments For Competition

    Adjustments for Competition Adjustments for Competition This section tells you how to fine tune your CRF Front Suspension Adjustments ......94 for maximum competition performance. Front Suspension Air Pressure.....94 Front Suspension Oil Level ......94 Initial suspension adjustments should be Front Suspension Damping......100 performed after a minimum of 2 hours of easy Fork Springs..........101 break-in time.

  • Page 100: Front Suspension Adjustments

    Front Suspension Adjustments Front Suspension Adjustments Refer to Safety Precautions on page 19. The air pressure should be adjusted according to Front Suspension Oil Level the altitude and outside temperature. The front suspension can be adjusted for the rider’s • If your CRF is brand-new, put enough part- weight and riding conditions by using one or more 1.
  • Page 101 Front Suspension Adjustments 4. Remove the front axle nut (3). 7. Loosen the fork bridge lower pinch bolts (7), 10. Hold the fork tube (10), then remove the fork cap (2), from the fork tube. Gently slide the 5. Pull the front axle shaft (4) out of the wheel then pull the fork legs down and out.
  • Page 102 Front Suspension Adjustments 13. Pour the recommended fork oil into the piston Fork Oil Level (CRF150R) Optional Stiffer 20.2 lbf/in (3.53 N/mm) Fork Spring rod (15) until a little oil flows out of the top of Standard 19.0 lbf/in (3.33 N/mm) Fork Spring the piston rod.
  • Page 103 Front Suspension Adjustments Fork Oil Level (CRF150RB) Optional Stiffer 21.3 lbf/in (3.73 N/mm) Fork Spring 16. Inspect both ends of the fork spring. If you find any roughness or burred edge on the end of Standard 20.2 lbf/in (3.53 N/mm) Fork Spring either spring, smooth the roughness with a file 2 scribe mark and some emery cloth.
  • Page 104 Front Suspension Adjustments 17. Clean the spring and spring seat thoroughly 22. Install the fork spring (17) as follows: NOTICE with a high flash point solvent to remove all – With the fork spring held upright on its metal particles and dirt. marked end, feed the mechanic’s wire up When installing the fork cap, be careful not to 18.
  • Page 105 Front Suspension Adjustments 28. Align the groove (23) in the fork tube (10) with 33. Clean the threads of the fork protector bolts 40. Align the brake caliper (6) with the left fork the top surface of the upper fork clamps (24). and axle holder thoroughly.

  • Page 106: Front Suspension Damping

    Front Suspension Adjustments 44. With the front brake applied, pump the fork up Rebound Damping Front Suspension Damping Rebound damping effects how quickly the fork and down several times to seat the axle and rebounds. check front brake operation. Compression Damping The rebound damping adjuster has 3 turns or less.

  • Page 107: Fork Springs

    Front Suspension Adjustments When adjusting oil levels, bear in mind that the air Fork Springs in the fork will increase in pressure while riding; therefore, the higher the oil level, the higher the If the fork is too hard on big bumps, turn the eventual pressure of any air in the fork.

  • Page 108: Rear Suspension Adjustments

    Min. (Stiffer, 291.2 lbf/in (51.0 N/mm)): equipped with the proper tools, safety equipment 8.9 in (226 mm) (CRF150RB) and the official Honda Service Manual. Spring preload length (Standard spring) Standard: 9.21 in (234.0 mm) If your CRF is new, put enough part-throttle break- Min.

  • Page 109: Rear Suspension Damping

    Rear Suspension Adjustments Rebound Damping Rear Suspension Damping The rebound damping adjuster (1) is located at the lower end of the shock absorber. Compression Damping The rebound damping adjuster has 3 turns or less. Compression damping can be adjusted with the adjuster located on the rear shock absorber's To increase damping, turn the adjuster screw reservoir.

  • Page 110: Rear Suspension Race Sag

    Rear Suspension Adjustments 4. Calculate the race sag dimension. REAR FENDER MOUNTING BOLT Rear Suspension Race Sag To do this, subtract the loaded with rider dimension (step 3) from the unloaded Setting the proper race sag (ride height) is very dimension (step 2).
  • Page 111 Rear Suspension Adjustments 6. Calculate the free sag dimension. Because of the great absorption quality of the To do this, subtract the loaded without rider shock bumper rubber, it may be difficult for you to dimension (step 5) from the unloaded notice when your CRF’s suspension is bottoming.

  • Page 112: Suspension Adjustments For Track Conditions

    Suspension Adjustments for Track Conditions Suspension Adjustments for Track Conditions Soft Surface On soft ground, sand, and especially mud, consider increasing compression damping front and rear. Sand often requires a bit more rebound damping to minimize rear end kick. Although sand bumps are usually larger, there’s more distance between them, giving the shock more time to recover.

  • Page 113: Suspension Adjustment Guidelines

    Suspension Adjustment Guidelines Follow the procedures described below to accurately adjust your CRF, using the methods described on pages 94 – 103. Remember to make all adjustments in 1/4 turn increments. Test ride after each adjustment. Front Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard setting.
  • Page 114 Suspension Adjustment Guidelines Symptom Action Stiff suspension Initial travel too stiff: – Test softer compression damping adjustments in 1/4 turn increments. • Stiff on small bumps while riding at full throttle in a straight line. – Reduce the rebound damping adjustments in 1/4 turn increments. •...
  • Page 115 Suspension Adjustment Guidelines Rear Suspension Adjustment Adjustments for Type of Track Hard-surfaced track Begin with the standard settings. If the suspension is too stiff/soft, adjust according to the chart below. Sand track Lower the rear end (to improve front wheel stability) by increasing Race Sag (reduce spring pre-load). Example: –...

  • Page 116: Carburetor Adjustments & Tuning Tips

    Carburetor Adjustments & Tuning Tips The carburetor used on your CRF should perform Hot Start Circuit Carburetor Components A lean mixture must be delivered to the cylinder suitably with the standard recommended settings when a hot engine is being started. When the hot under average load, climatic, and barometric Cold Start Circuit start lever is pulled back, the hot start valve (1)
  • Page 117 Carburetor Adjustments & Tuning Tips Accelerator Pump Circuit Slow Circuit Main Circuit The accelerator pump circuit operates when the Fuel is metered by the slow jet (1) and mixed with Fuel is metered by the main jet (1), jet needle (2) throttle is opened.

  • Page 118: Carburetor Circuit Functions

    If you are under 1 1/2 turns out, the next smaller desired jetting is obtained. Because Honda jet size slow jet is needed. numbers do not correspond with other carburetor Leak jet manufacturer’s jet size numbers, use only Honda...
  • Page 119 Carburetor Adjustments & Tuning Tips 4. Tighten the drain screw. Release the throttle sensor wire from the wire 11. Loosen the lock nuts (12), adjuster (13) and 5. Loosen the insulator band screw (2) and band (6) and clamp (7). disconnect the throttle cables (14) from the connecting tube clamp screw (3).

  • Page 120: Carburetor Disassembly/Assembly

    Carburetor Adjustments & Tuning Tips 3. Remove the link arm torx screw (6). When installing the floating valve (7) onto the Carburetor Disassembly/Assembly When installing the link arm torx screw, apply throttle valve (5), make sure the floating a locking agent to the link arm torx screw valve’s flat side faces out and the hole (9) faces 1.
  • Page 121 Carburetor Adjustments & Tuning Tips 6. Remove the accelerator pump cover screws 8. Remove the holder screw (17), throttle stop 10. Measure the float level (25) with the float level (10) and accelerator pump cover (11). screw holder (18), float bowl screws (19), hose gauge (26) while the float tab is just contacting guides (20), float bowl (16) and O-ring (21).
  • Page 122 Carburetor Adjustments & Tuning Tips To assemble, reverse the disassembly procedures. • Route the throttle cables (1), hot start cable (2) To install the carburetor, reverse the removal and throttle position sensor wire correctly. procedures. • After installing the carburetor, adjust the throttle grip freeplay and hot start lever Tighten the following parts to the specified torque.

  • Page 123: Standard Tuning Recommendations

    Carburetor Adjustments & Tuning Tips Standard Tuning Recommendations For the following recommendations to be accurate, you must use the standard settings as a baseline. Also, don’t change any of the settings until you’ve determined what changes are necessary. Adjustment Standard settings Pilot screw opening 2 1/8 turns out Slow jet...

  • Page 124: Optional Muffler Settings

    Carburetor Adjustments & Tuning Tips Optional Muffler Settings Your CRF dose not conform to AMA noise emission regulation for 2019 year. If you use optional AMA noise emission regulation conformed muffler, you should change the carburetor settings. Adjustments for Competition...

  • Page 125: Special Tuning Conditions

    Carburetor Adjustments & Tuning Tips Once you’ve adjusted the carburetor for Special Tuning Conditions Pre-Adjustment Checks temperature and altitude, it shouldn’t need major readjustment unless race conditions change There are some unique atmospheric conditions or Before adjusting carburetor settings, check the drastically.

  • Page 126: Carburetor Minor Adjustments

    Carburetor Adjustments & Tuning Tips WARNING Carburetor Minor Adjustments Gasoline is highly flammable and The standard carburetor settings are ideal for the explosive. You can be burned or seriously following conditions: sea level altitude, and 68°F injured when handling fuel. (20°C) air temperature.
  • Page 127 Carburetor Adjustments & Tuning Tips 11. Change the main jet (5) and slow jet (6) as 13. Rotate the carburetor to the right and remove 19. Rotate the carburetor and align the tabs (14) required. the carburetor top screws (7), cable clamp (8) on the carburetor with the grooves (15) on the Main jet;...

  • Page 128: Spark Plug Reading

    Carburetor Adjustments & Tuning Tips 21. Tighten the insulator band screw (17) so the NOTICE Spark Plug Reading gap between the tabs of the clamp is 0.3 ± 0.04 in (7 ± 1 mm). An improperly tightened spark plug can damage Refer to Spark Plug on page 52.

  • Page 129: Chassis Adjustments

    Chassis Adjustments The following suggestions may improve a specific Fork Height/Angle Wheelbase concern. Subtle changes in overall handling may also be noted. The position of the fork tubes in the clamps is not Adjusting your CRF’s wheelbase can offer subtle adjustable.

  • Page 130: Gearing

    Unless you have the required mechanical appraisal of the gearing change. “Seat-of-the- down, and avoid unwanted wheelspin. The knowhow, tools, and an official Honda Service pants” feelings can’t be trusted. Eliminating engine may bog in certain corners so you’ll Manual, sprocket changing should be done by your wheelspin with a gearing change can make you need to slip the clutch to compensate;...

  • Page 131: Tire Selection For Track Conditions

    Tire Selection for Track Conditions Tire Selection for Track Conditions Choosing the correct tire tread pattern and rubber If you choose a tire with a sticky compound for compound can affect your placing in competition. added traction, remember that it may transfer The tires on your CRF offer a “happy medium”...

  • Page 132: Personal Fit Adjustments

    Make sure that the bolts are torqued securely enough to prevent slippage during normal operation. Apply Pro Honda Hondalock or an equivalent to Handlebar Position, Width & Shape the threads of these bolts prior to adjustment to help ensure the correct torque is retained.

  • Page 133: Tips

    Tips Tips Here’s helpful advice on how to transport and store your Honda, as well as three troubleshooting flow charts. Transporting Your Motorcycle...... 128 Storing Your Honda ........129 Preparation for Storage......129 Removal from Storage ......129 You & the Environment ........ 130 Troubleshooting..........

  • Page 134: Transporting Your Motorcycle

    Transporting Your Motorcycle If you use a truck or motorcycle trailer to transport To secure your CRF, brace the front wheel against your Honda, we recommend that you follow these the front of the truck bed or trailer rail. guidelines: Attach the lower ends of two straps to the tie-down •...

  • Page 135: Storing Your Honda

    Removal from Storage as during the winter, thoroughly inspect your bolt/sealing washer (1) at the water pump (2) to Honda and correct any problem before storing it. drain coolant. 1. Uncover and clean your CRF. That way, needed repairs won’t be forgotten and it...

  • Page 136: You & The Environment

    You & the Environment You & the Environment Owning and riding a motorcycle can be enjoyable, NOTICE but you must do your part to protect nature. When you show respect for the land, wildlife, and other Improper disposal of drained fluids is harmful to people, you also help preserve the sport of off road the environment.

  • Page 137: Troubleshooting

    The items that require use of the CHECK POSSIBLE CAUSES 1. Disconnect fuel line FUEL FLOW Honda Service Manual are followed by an asterisk • Lack of fuel in tank (P.34) at carburetor and RESTRICTED • Clogged fuel line (P.34) INCORRECT 1.
  • Page 138 Tips...

  • Page 139: Technical Information

    Technical Information Technical Information This section contains dimensions, capacities, and Vehicle Identification........134 other technical data. Specifications..........135 Torque Specifications ........137 Oxygenated Fuels...........140 Competition Logbook ........141 Optional Parts List .........143 Spare Parts & Equipment.......145 Wiring Diagram ..........146 Technical Information...

  • Page 140: Vehicle Identification

    Vehicle Identification Vehicle Identification The VIN (vehicle identification number) (1) is Serial Numbers stamped on the right side of the steering head. RIGHT SIDE The VIN and engine serial number are required when you register your CRF. They may also be required when ordering replacement parts.

  • Page 141: Specifications

    Specifications Specifications CRF150R Item English Metric Item English Metric Item English Metric Engine Drive train Dimension Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type Overall length 72.1 in 1,832 mm Transmission 5-speed, constant mesh Single 19° inclined from Cylinder arrangement Overall width 30.3 in 770 mm...
  • Page 142 Specifications Specifications CRF150RB Item English Metric Item English Metric Item English Metric Engine Drive train Dimension Type Liquid cooled, 4-stroke Clutch type Wet, multi-plate type Overall length 74.8 in 1,900 mm Transmission 5-speed, constant mesh Single 19° inclined from Cylinder arrangement Overall width 30.3 in 770 mm...

  • Page 143: Torque Specifications

    Torque Specifications ENGINE Nuts, Bolts, Fasteners Torque Item Remarks lbf•ft N•m kgf•m Check and tighten nuts, bolts, and fasteners before every outing. Cylinder head cover bolts Engine Exhaust pipe joint nuts RIGHT SIDE Coolant drain bolt Crankshaft hole cap NOTE 5 Transmission oil check bolt Cylinder bolt...
  • Page 144 Torque Specifications FRAME Frame Torque Item Remarks lbf•ft N•m kgf•m Steering stem nut 13.1 Fork bridge upper pinch bolts Fork bridge lower pinch bolts Handlebar upper holder bolts Front axle nut NOTE 1 Rear axle nut NOTE 1 Chain adjuster lock nuts NOTE 2 Front engine hanger bracket nuts (10 mm)
  • Page 145 Torque Specifications FRAME Frame Torque Item Remarks lbf•ft N•m kgf•m Brake hose bolts Brake caliper mounting bolts NOTE 4 Brake disc bolts NOTE 4 Brake pedal pivot bolt Spokes Rim locks 12.4 Subframe upper/lower mounting bolts Fork cap Fork cap lock nut 19.7 Fork protector bolts NOTE 4...

  • Page 146: Oxygenated Fuels

    Oxygenated Fuels Oxygenated Fuels Some conventional gasolines are being blended If you notice any undesirable operating symptoms, with alcohol or an ether compound. These try another service station or switch to another gasolines are collectively referred to as oxygenated brand of gasoline. fuels.

  • Page 147: Competition Logbook

    Competition Logbook Any serious competition effort relies heavily on Tuning & Adjustment Records Racing Records the knowledge gained and compiled from previous Keep track of the settings and adjustments that Information worth recording for this section of racing events. The best way to organize the many worked best at a particular location.
  • Page 148 Competition Logbook Date Running Location/Event Comments (Jetting, Suspension Settings, Gearing, Chassis Adjustments, Maintenance, Time Performed, etc.) (Make several photocopies of this page for future use) Technical Information...

  • Page 149: Optional Parts List

    Optional Parts List Optional Parts List These parts and tools may be ordered from your CARBURETOR Remarks FRAME Remarks authorized dealer. Fuel flow amount Leak jet number < >: Drive chain links 49T, Aluminum <120> decrease CARBURETOR Remarks CRF150R 50T, steel <120> (standard) 50T, Aluminum <120>...
  • Page 150 Specifications Optional Parts List FRAME Remarks FRAME Remarks FRAME Remarks CRF150R CRF150RB CRF150R Shock Shock Fork springs springs springs 2 coils at White mark 17.9 lbf/in 268.4 lbf/in 279.8 lbf/in Red mark Softer Softer Softer one end; (49.0 N/mm) (3.14 N/mm) (47.0 N/mm) 1 coil at other end...

  • Page 151: Spare Parts & Equipment

    SAE 80 or 90 gear oil Spare Parts wrenches: open end & box HP Fork Oil, SS-19 wrenches: hex (Allen) Pro Honda DOT 4 Brake Fluid spark plugs wrench, spoke Pro Honda HP Chain Lube air cleaner (clean & oiled, sealed in a plastic bag)

  • Page 152: Wiring Diagram

    Wiring Diagram Wiring Diagram Technical Information...

  • Page 153: Consumer Information

    Consumer Information Consumer Information This section contains information about contacting Authorized Manuals........148 Honda and how to get an official Honda Service Contacting Honda ..........149 Manual. Your Honda Dealer ........150 Consumer Information...

  • Page 154: Authorized Manuals

    Authorized Manuals The Service Manual used by your authorized dealer is available from your Honda dealer or Helm, Inc. (USA only, Canada: See your dealer to order authorized manuals.) Also available but not necessary to service your model is the Honda Common Service Manual which explains theory of operation and basic service information for various systems on Honda motorcycles, scooters, and ATV.

  • Page 155: Contacting Honda

    If you wish to comment on your experiences with your Honda or with your dealer, please send your comments to the following address: Motorcycle Division, American Honda Motor Co., Inc., P.O.

  • Page 156: Your Honda Dealer

    Your Honda Dealer Once you purchase your new Honda, get familiar Your dealer can inform you about competition with the organization of your Honda dealer so you events in your area. can utilize the full range of services available. We’re sure you’ll be as pleased with the service...
  • Page 157 Consumer Information...

  • Page 158: Index

    ........141 oil..............37 front suspension.......... 94 consumer information ........147 flooded engine, starting ........13 tires ............. 80 contacting Honda ...........149 fork, appearance care ..........90 controls, operating..........5 front suspension adjustment ....... 94 authorized manuals........148 coolant..............41 front suspension inspection ......
  • Page 159 ....... 102 general competition........22 pre-ride inspection ..........9 importance ..........18 protective apparel ..........2 safety............19 handlebar inspection........88 schedule ............20 Honda, manual, service ..........148 contacting ..........149 modifications............3 service manual.......... 148 your dealer..........150 oil, engine............36 identification, vehicle ........134 fork..............72...
  • Page 160 Index suspension, front............70,94 rear ............71,102 rear suspension maintenance ......71 washing your motorcycle ........ 90 suspension adjustment, riding, wheels .............. 79 front.............94 basic operation..........11 wiring diagram..........146 rear ............102 before............7 for track conditions ........106 important safety information......2 guidelines ..........107 safety precautions........

  • Page 161: Quick Reference

    91 or higher tank: 1.14 US gal (4.3 ℓ Engine Oil/Capacity Pro Honda GN4 4-stroke oil (USA & Canada), or Honda 4-stroke oil, or an equivalent motorcycle oil. 0.62 US qt (0.59 ℓ ) after draining and oil filter change ℓ...
  • Page 162 California Proposition 65 Warning WARNING: Operating, servicing and maintaining a passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your hands frequently when servicing your vehicle.
  • Page 163 31KSE710 XXXX.2019.XX.L 00X31-KSE-7100 PRINTED IN XXXX...

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