Honda CBF150 2002 Manual
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Honda CBF150 2002 Manual

Honda CBF150 2002 Manual

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Summary of Contents for Honda CBF150 2002

  • Page 1 !"#$ &'($ " #$%&'($&') )$*+ ,-.'-/0 )$1 2&//&3*.( -44%15*-)*&.+ -%1 '+16 )& *61.)*27 *.6*5*6'-/ )7819 :;<= >?=> #@A= B< B.6*-...

  • Page 5: Table Of Contents

    1. GENERAL INFORMATION SERVICE RULES ············································ 1-2 REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS············································1-8 MODEL IDENTIFICATION······························ 1-2 HYDRAULIC BRAKE SPECIFICATIONS·········1-8 GENERAL SPECIFICATIONS························· 1-4 BATTERY/CHARGING SYSTEM SPECIFICATIONS············································1-9 LUBRICATION SYSTEM SPECIFICATIONS · 1-5 IGNITION SYSTEM SPECIFICATIONS ··········1-9 FUEL SYSTEM SPECIFICATIONS················· 1-5 LIGHTS/METER/SWITCHES CYLINDER HEAD/VALVES SPECIFICATIONS············································1-9 SPECIFICATIONS··········································· 1-5 STANDARD TORQUE VALUES ···················1-10 CYLINDER/PISTON SPECIFICATIONS ·········...

  • Page 8: General Specifications

    GENERAL INFORMATION 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...

  • Page 9: Lubrication System Specifications

    1.0 liter (1.1 US qt, 0.9 lmp qt) – capacity After disassembly 1.2 liter (1.3 US qt, 1.1 lmp qt) – Recommended engine oil Honda 4-stroke oil or equivalent motor – API service classification: SJ Viscosity: SAE 20W40 Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)

  • Page 10: Cylinder/Piston Specifications

    GENERAL INFORMATION CYLINDER/PISTON 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 O.D. at 10 (0.4) from bottom 57.280 –...

  • Page 11: Crankshaft/Transmission

    GENERAL INFORMATION CRANKSHAFT/TRANSMISSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Runout – 0.03 (0.001) Connecting rod big end radial clear- 0 – 0.008 (0 – 0.0003) 0.05 (0.002) ance Connecting rod big end side clear- 0.10 – 0.35 (0.004 – 0.014) 0.80 (0.032) ance Transmission...
  • Page 12 GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire thread depth – 1.5 (0.06) Cold tire Driver only 175 kPa (1.75 kgf/cm , 25 psi) – pressure Driver and passenger 175 kPa (1.75 kgf/cm , 25 psi) –...

  • Page 13: Specifications

    GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12 V – 2.5 Ah Current leakage 0.1 mA max. Specific grav- Fully charged 1.270 – 1.290 ity (20°C/68°F) Needs charging Below 1.230 Voltage Fully charged 12.7 – 12.9 V Needs charging Below 12.3 V Charging current Normal...
  • Page 15 GENERAL INFORMATION CYLINDER HEAD/VALVES THREAD TORQUE ITEM REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Cylinder head cover bolt 10 (1.0, 7) Rocker arm shaft bolt 5 (0.5, 3.7) Cam sprocket bolt 9 (0.9, 6.6) Cam shaft holder bolt 32 (3.3, 24) NOTE 1 Carburetor insulator bolt 12 (1.2, 9)

  • Page 17: Ignition System Specifications

    GENERAL INFORMATION FRAME FRAME/BODY PANELS/EXHAUST SYSTEM THREAD TORQUE ITEM REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Exhaust pipe stud bolt 11 (1.1, 8) page 1-12 ENGINE REMOVAL/INSTALLATION THREAD TORQUE ITEM REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Front engine hanger nut 26 (2.7, 19) Rear engine hanger nut 54 (5.5, 40) Fixing plate bolt...
  • Page 19 GENERAL INFORMATION LOCATION MATERIAL REMARKS Shift drum stopper arm bolt threads Locking agent Coating width: 6.5 ± 1.0 mm from tip Gear shift cam bolt threads Coating width: 6.5 ± 1.0 mm from tip Ignition pulse generator mounting bolt threads Coating width: 6.5 ±...
  • Page 20 1:1) Fork socket bolt threads Locking agent Ignition switch mounting bolt threads Fork cap O-ring Fork fluid Fork oil seal lips Handlebar grip inner surface Honda Bond A or equiva- lent 1-16...
  • Page 31 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION ······························ 2-2 FUEL TANK ·····················································2-4 TROUBLESHOOTING ···································· 2-2 FRONT FENDER··············································2-5 FRONT COWL ················································ 2-3 REAR GRIP ······················································2-6 WIND SCREEN··············································· 2-3 REAR COWL····················································2-6 REAR FENDER ················································2-8 SEAT······························································· 2-3 RIGHT SIDE COVER······································· 2-4 SAREE GUARD ···············································2-8 LEFT SIDE COVER ·········································...
  • Page 32 FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL • This section covers removal and installation of the body panels, fuel tank and exhaust system. • Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. • When installing the exhaust system, loosely install all fasteners, tighten the exhaust pipe joint nuts first, tighten the muffler band bolt, then tighten the muffler mounting bolts.
  • Page 41 3. MAINTENANCE SERVICE INFORMATION ······························ 3-2 DRIVE CHAIN················································3-15 MAINTENANCE SCHEDULE ························· 3-4 BATTERY·······················································3-19 FUEL LINE ······················································ 3-5 BRAKE FLUID················································3-20 FUEL STRAINER SCREEN····························· 3-5 BRAKE SHOES/PADS WEAR ······················3-20 BRAKE SYSTEM ···········································3-21 THROTTLE OPERATION································ 3-6 CHOKE OPERATION······································ 3-6 BRAKE LIGHT SWITCHES····························3-22 AIR CLEANER················································· 3-7 HEADLIGHT AIM ··········································3-22 CRANKCASE BREATHER ······························...
  • Page 42 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 10W-30 1,400 ± 100 min Engine idle speed...
  • Page 66 MEMO...
  • Page 67 4. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ············· 4-2 ENGINE OIL STRAINER SCREEN ··················4-4 SERVICE INFORMATION ······························ 4-3 OIL PUMP························································4-4 TROUBLESHOOTING ···································· 4-3...
  • Page 75 5. FUEL SYSTEM SYSTEM COMPONENTS ······························ 5-2 CARBURETOR ················································5-8 SERVICE INFORMATION ······························ 5-3 PILOT SCREW ADJUSTMENT·····················5-19 TROUBLESHOOTING ···································· 5-4 SECONDARY AIR SUPPLY SYSTEM ··········5-23 AIR CLEANER HOUSING ······························ 5-5 FUEL STRAINER ···········································5-24 STARTING ENRICHMENT (SE) VALVE········ 5-7...
  • Page 78 FUEL SYSTEM TROUBLESHOOTING Engine won’t start • Too much fuel getting to the engine – Air cleaner clogged – Flooded carburetor • Intake air leak • Fuel contaminated/deteriorated • No fuel to carburetor – Fuel strainer clogged – Fuel hose clogged –...
  • Page 101 6. ENGINE REMOVAL/INSTALLATION SYSTEM COMPONENTS ······························ 6-2 ENGINE REMOVAL ········································6-4 SERVICE INFORMATION ······························ 6-3 ENGINE INSTALLATION································6-6...
  • Page 110 MEMO...
  • Page 111 7. CYLINDER HEAD/VALVES SYSTEM COMPONENTS ······························ 7-2 CAMSHAFT HOLDER DISSASSEMBLY/ASSEMBLY ·····················7-11 SERVICE INFORMATION ······························ 7-3 CYLINDER HEAD DISSASSEMBLY/ASSEMBLY ·····················7-14 TROUBLESHOOTING ···································· 7-5 CAMSHAFT HOLDER/ CYLINDER COMPRESSION··························· 7-6 CYLINDER HEAD INSTALLATION···············7-23 CYLINDER HEAD COVER ······························ 7-6 CAM CHAIN TENSIONER LIFTER················7-25 CAMSHAFT HOLDER/ CYLINDER HEAD REMOVAL ························...
  • Page 113 CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL • This section covers service of the cylinder head, valves, rocker arms and camshaft. • The cylinder head and valves services can be done with the engine installed in the frame. • Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not strike the cylinder head cover and cylinder head too hard during removal.
  • Page 115 CYLINDER HEAD/VALVES TROUBLESHOOTING • Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. • If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, check for a seized piston ring (page 8-5).
  • Page 137 8. CYLINDER/PISTON SYSTEM COMPONENTS ······························ 8-2 TROUBLESHOOTING·····································8-3 SERVICE INFORMATION ······························ 8-3 CYLINDER/PISTON ········································8-4...
  • Page 147 9. CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SYSTEM COMPONENTS ······························ 9-2 GEARSHIFT LINKAGE ··································9-15 SERVICE INFORMATION ······························ 9-3 KICKSTARTER IDLE GEAR ··························9-17 TROUBLESHOOTING ···································· 9-4 KICKSTARTER ··············································9-18 RIGHT CRANKCASE COVER························· 9-5 PRIMARY DRIVE GEAR/ CRANKSHAFT COLLAR ·······························9-21 CLUTCH·························································· 9-8...
  • Page 149 CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SERVICE INFORMATION GENERAL • This section covers service of the clutch, gearshift linkage, kickstarter. All services can be done with the engine installed in the frame. • Transmission oil viscosity and level have an effect on clutch disengagement. when the clutch does not disengage or motorcycle creeps with clutch disengaged, inspect the transmission oil level before servicing the clutch system.
  • Page 151 CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the free play. Clutch lever difficult to pull in • Damaged, kinked or dirty clutch cable • Improperly routed clutch cable • Damaged clutch lifter mechanism • Faulty clutch lifter plate bearing Clutch will not disengage or motorcycle creeps with clutch disengaged •...
  • Page 170 CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER 9-24...
  • Page 171 10. ALTERNATOR/STARTER CLUTCH SYSTEM COMPONENTS ···························· 10-2 FLYWHEEL ····················································10-6 SERVICE INFORMATION ···························· 10-3 STATOR/IGNITION PULSE GENERATOR ··10-7 LEFT CRANKCASE COVER ························· 10-4 10-1...
  • Page 179 11. CRANKSHAFT/TRANSMISSION SYSTEM COMPONENTS ···························· 11-2 TRANSMISSION···········································11-7 SERVICE INFORMATION ···························· 11-3 CRANKSHAFT·············································11-16 TROUBLESHOOTING ·································· 11-5 CRANKCASE ASSEMBLY ··························11-18 CRANKCASE SEPARATION························ 11-6 11-1...
  • Page 181 CRANKSHAFT/TRANSMISSION SERVICE INFORMATION GENERAL • The following components must be removed before separating the crankcase: – engine (page 6-4) – flywheel (page 10-6) – cylinder head (page 7-6) – cylinder/piston (page 8-4) – oil pump (page 4-4) – clutch (page 9-8) –...
  • Page 200 CRANKSHAFT/TRANSMISSION 11-22...
  • Page 201 12. FRONT WHEEL/SUSPENSION/STEERING SYSTEM COMPONENTS ···························· 12-2 FRONT WHEEL ···········································12-12 SERVICE INFORMATION ···························· 12-3 FORK ···························································12-18 TROUBLESHOOTING ·································· 12-5 STEERING STEM········································12-26 HANDLEBAR ················································ 12-6 12-1...
  • Page 203 FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION GENERAL • When servicing the front wheel, fork or steering stem, support the motorcycle using a safety stand or hoist. • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
  • Page 232 MEMO...
  • Page 233 13. REAR WHEEL/BRAKE/SUSPENSION SYSTEM COMPONENTS ···························· 13-2 REAR DRUM BRAKE ··································13-17 SERVICE INFORMATION ···························· 13-3 PILLION STEP/BRAKE PEDAL ···················13-19 TROUBLESHOOTING ·································· 13-7 SHOCK ABSORBER····································13-23 REAR WHEEL ··············································· 13-8 SWINGARM ················································13-24 DRIVEN FLANGE ······································· 13-13 13-1...
  • Page 236 REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire thread depth – 2.0 (0.08) Cold tire pressure Driver only 225 kPa (2.25 kgf/cm , 33 psi) – Driver and passenger 280 kPa (2.80 kgf/cm , 41 psi) –...
  • Page 239 REAR WHEEL/BRAKE/SUSPENSION TROUBLESHOOTING Rear wheel wobbles • Bent rim • Worn or damaged rear wheel bearings • Worn or damaged driven flange bearing • Faulty rear tire • Loose or broken spokes • Worn or damaged swingarm bearings • Bent frame or swingarm •...
  • Page 264 MEMO...
  • Page 265 14. HYDRAULIC BRAKE SYSTEM COMPONENTS ···························· 14-2 BRAKE PAD/DISC·········································14-7 SERVICE INFORMATION ···························· 14-3 MASTER CYLINDER ·····································14-9 TROUBLESHOOTING ·································· 14-4 BRAKE CALIPER ·········································14-16 BRAKE FLUID REPLACEMENT/ AIR BLEEDING ············································· 14-5 14-1...
  • Page 268 HYDRAULIC BRAKE TROUBLESHOOTING Brake lever soft or spongy • Air in hydraulic system • Leaking hydraulic system • Contaminated brake pad/disc • Worn caliper piston seal • Worn master cylinder piston cups • Worn brake pad/disc • Contaminated caliper • Contaminated master cylinder •...
  • Page 283 15. BATTERY/CHARGING SYSTEM COMPONENT LOCATION ··························· 15-2 BATTERY·······················································15-6 SYSTEM DIAGRAM····································· 15-2 CHARGING SYSTEM INSPECTION·············15-8 SERVICE INFORMATION ···························· 15-3 ALTERNATOR COIL······································15-9 TROUBLESHOOTING ·································· 15-5 REGULATOR/RECTIFIER ···························15-10 15-1...
  • Page 286 BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12 V – 2.5 Ah Current leakage 0.1 mA max. Specific grav- Fully charged 1.270 – 1.290 ity (20°C/68°F) Needs charging Below 1.230 Voltage Fully charged 12.7 – 12.9 V Needs charging Below 12.3 V Charging current Normal 0.25 A/5 –...
  • Page 287 BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. BATTERY TEST Remove the battery (page 15-6). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210 or equivalent Is the battery in good condition? – Faulty battery. –...
  • Page 293 16. IGNITION SYSTEM COMPONENT LOCATION ··························· 16-2 IGNITION TIMING ········································16-7 SYSTEM DIAGRAM····································· 16-2 IGNITION COIL ·············································16-8 SERVICE INFORMATION ···························· 16-3 ICM (IGNITION CONTROL MODULE) ·········16-8 TROUBLESHOOTING ·································· 16-4 THROTTLE POSITION SENSOR ··················16-9 IGNITION SYSTEM INSPECTION ··············· 16-5 16-1...
  • Page 296 IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system. – Faulty spark plug – Loose spark plug cap or spark plug wire – Water got into the spark plug cap (Leaking the ignition coil secondary voltage) No spark at plug Unusual condition Probable cause (check in numerical order) Ignition coil...
  • Page 305 17. LIGHTS/METER/SWITCHES COMPONENT LOCATION ··························· 17-2 HANDLEBAR SWITCHES ···························17-10 SERVICE INFORMATION ···························· 17-3 BRAKE LIGHT SWITCHES··························17-12 HEADLIGHT·················································· 17-4 NEUTRAL SWITCH·····································17-12 BRAKE/TAIL LIGHT ····································· 17-5 FUEL GAUGE/FUEL LEVEL SENSOR ·······17-14 HORN ··························································17-16 TURN SIGNAL LIGHTS ······························· 17-6 COMBINATION METER······························· 17-6 PASSING RELAY ········································17-17 TACHOMETER ·············································...
  • Page 307 LIGHTS/METER/SWITCHES SERVICE INFORMATION GENERAL • A halogen headlight bulb becomes very hot while the headlight is "ON", and remains hot for a while after it is turned "OFF". Be sure to let it cool down before servicing. • Keep all flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye protection.
  • Page 324 LIGHTS/METER/SWITCHES 17-20...
  • Page 325 18. WIRING DIAGRAM WIRING DIAGRAM ······································ 18-3 18-1...
  • Page 328 19. TROUBLESHOOTING ENGINE DOES NOT START OR POOR PERFORMANCE AT LOW IS HARD TO START····································· 19-2 AND IDLE SPEED··········································19-5 ENGINE LACKS POWER ····························· 19-3 POOR PERFORMANCE AT HIGH SPEED ····19-6 POOR HANDLING·········································19-6 19-1...
  • Page 329 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 1. Fuel Line Inspection Check fuel flow to carburetor. Does fuel reach the carburetor? – • Clogged fuel hose or fuel strainer • Clogged fuel valve • Clogged fuel fill cap breather –...
  • Page 330 TROUBLESHOOTING ENGINE LACKS POWER 1. Drive Train Inspection Raise wheel off the ground and spin by hand. Does the wheel spin freely? – • Brake dragging • Worn or damaged wheel bearings • Bent axle – GO TO STEP 2. 2.
  • Page 331 TROUBLESHOOTING 7. Engine Oil Inspection Check oil level and condition. Is there correct level and good condition? – • Oil level too high • Oil level too low • Contaminated oil – GO TO STEP 8. 8. Spark Plug Inspection Remove and inspect spark plug.
  • Page 332 TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Pilot Screw Inspection Check carburetor pilot screw adjustment. Is the adjustment correct? – See page 5-19 – GO TO STEP 2. 2. Intake Air Leak Inspection Check for leaking carburetor insulator. Is there leaking? –...
  • Page 333 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1. Fuel Line Inspection Disconnect fuel line at carburetor. Does fuel flow freely? – • Clogged fuel line • Clogged fill cap breather • Faulty fuel valve • Clogged fuel strainer – GO TO STEP 2. 2.
  • Page 334 20. INDEX AIR CLEANER ·································································· 3-7 FUEL STRAINER SCREEN··············································· 3-5 AIR CLEANER HOUSING ················································ 5-5 FUEL SYSTEM SPECIFICATIONS··································· 1-5 ALTERNATOR COIL ······················································ 15-9 FUEL TANK ······································································ 2-4 BATTERY GEARSHIFT LINKAGE ··················································· 9-15 BATTERY/CHARGING SYSTEM ······························ 15-6 GENERAL INFORMATION ·············································· 1-2 MAINTENANCE ························································...
  • Page 335 INDEX SPARK PLUG ··································································· 3-8 TROUBLESHOOTING STANDARD TORQUE VALUES ···································· 1-10 BATTERY/CHARGING SYSTEM ·······························15-5 STARTING ENRICHMENT (SE) VALVE ·························· 5-7 CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER ········9-4 STATOR/IGNITION PULSE GENERATOR ···················· 10-7 CRANKSHAFT/TRANSMISSION ······························11-5 STEERING HEAD BEARINGS ······································· 3-25 CYLINDER HEAD/VALVES ··········································7-5 STEERING STEM························································· 12-26 CYLINDER/PISTON······················································8-3 SUSPENSION ································································...
  • Page 336 TYPE CODE CBF150M-5 ADDENDUM Throughout this manual, the following abbreviations are used to identify individual model. CODE AREA TYPE India...
  • Page 338 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 340 21. CBF150M-5 ADDENDUM MODEL IDENTIFICATION···························· 21-2 LUBRICATION & SEAL POINTS ················21-15 CABLE & HARNESS ROUTING ·················21-18 GENERAL SPECIFICATIONS······················· 21-4 LUBRICATION SYSTEM AIR CLEANER HOUSING ···························21-21 SPECIFICATIONS········································· 21-5 ENGINE REMOVAL/INSTALLATION FUEL SYSTEM SPECIFICATIONS··············· 21-5 SYSTEM COMPONENTS ···························21-23 CYLINDER HEAD/VALVES ALTERNATOR/STARTER CLUTCH SPECIFICATIONS·········································...

  • Page 341: Model Identification

    CBF150M-5 ADDENDUM MODEL IDENTIFICATION 21-2...

  • Page 343: General Specifications

    CBF150M-5 ADDENDUM GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2,078 mm (81.8 in) Overall width 749 mm (29.5 in) Overall height 1,092 mm (43.0 in) Wheelbase 1,337 mm (52.6 in) Seat height 790 mm (31.1 in) Footpeg height 295 mm (11.6 in) Ground clearance 164 mm (6.5 in) Dry weight...

  • Page 344: Specifications

    1.0 liter (1.1 US qt, 0.9 lmp qt) – capacity After disassembly 1.2 liter (1.3 US qt, 1.1 lmp qt) – Recommended engine oil Honda 4-stroke oil or equivalent motor – API service classification: SJ Viscosity: SAE 10W-30 Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)

  • Page 345: Cylinder/Piston Specifications

    CBF150M-5 ADDENDUM CYLINDER/PISTON 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 O.D. at 10 (0.4) from bottom 57.280 –...
  • Page 346 CBF150M-5 ADDENDUM CRANKSHAFT/TRANSMISSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Runout 0.03 (0.001) 0.08 (0.003) Connecting rod big end radial clear- 0 – 0.008 (0 – 0.0003) 0.05 (0.002) ance Connecting rod big end side clear- 0.10 – 0.35 (0.004 – 0.014) 0.80 (0.032) ance Transmission...
  • Page 347 CBF150M-5 ADDENDUM FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire thread depth – 1.5 (0.06) Cold tire Driver only 175 kPa (1.75 kgf/cm , 25 psi) – pressure Driver and passenger 175 kPa (1.75 kgf/cm , 25 psi) –...

  • Page 348: Electric Starter Specifications

    CBF150M-5 ADDENDUM BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12 V – 7 Ah Current leakage 0.1 mA max. Specific grav- Fully charged 1.270 – 1.290 ity (20° C/68° F) Needs charging Below 1.230 Voltage Fully charged 12.7 – 12.9 V Needs charging Below 12.3 V Charging current...

  • Page 349: Standard Torque Values

    CBF150M-5 ADDENDUM STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9) 6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5) (Include SH flange bolt) 6 mm flange bolt...
  • Page 350 CBF150M-5 ADDENDUM CYLINDER HEAD/VALVES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Cylinder head cover bolt 10 (1.0, 7) Rocker arm shaft bolt 5 (0.5, 3.7) Cam sprocket bolt 9 (0.9, 6.6) Cam shaft holder bolt 32 (3.3, 24) NOTE 1 Carburetor insulator bolt 12 (1.2, 9)

  • Page 352: Engine Removal/Installation

    CBF150M-5 ADDENDUM FRAME FRAME/BODY PANELS/EXHAUST SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Brake/tail light unit mount nut 5.1 (0.5, 3.8) Exhaust pipe stud bolt 11 (1.1, 8) page 21-12 ENGINE REMOVAL/INSTALLATION THREAD TORQUE ITEM Q'TY REMARKS DIA.
  • Page 353 CBF150M-5 ADDENDUM IGNITION SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Throttle position sensor screw 3.4 (0.4, 2.5) LIGHTS/METER/SWITCHES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Fuel level sensor mounting nut 10 (1.0, 7) 21-14...
  • Page 354 CBF150M-5 ADDENDUM LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Crankcase mating area Liquid sealant Alternator wire grommet seating surface Oil pump rotors Engine oil Oil through sliding area Oil pump drive gear teeth Rocker arm shaft entire surface Rocker arm inner surface and roller surface Camshaft lobes Cam chain entire surface Cylinder inner surface...
  • Page 355 CBF150M-5 ADDENDUM LOCATION MATERIAL REMARKS Shift drum stopper arm bolt threads Locking agent Coating width: 6.5 ± 1.0 mm from tip Gear shift cam bolt threads Coating width: 6.5 ± 1.0 mm from tip Starter clutch bolt threads Coating width: 6.5 ±...
  • Page 356 1:1) Fork socket bolt threads Locking agent Ignition switch mounting bolt threads Fork cap O-ring Fork fluid Fork oil seal lips Handlebar grip inner surface Honda Bond A or equiva- lent 21-17...
  • Page 373 CBF150M-5 ADDENDUM ELECTRIC STARTER SERVICE INFORMATION GENERAL • Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. • The starter motor can be serviced with the engine in the frame. •...

  • Page 374: Starter Motor

    CBF150M-5 ADDENDUM ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn 1. Fuse Inspection Check for blown fuse. Is the fuse blown? – Replace the fuse. – GO TO STEP 2. 2. Battery Inspection Make sure the battery is fully charged and in good condition. Is the battery in good condition? –...
  • Page 375 CBF150M-5 ADDENDUM 8. Relay Coil Power Input Line Inspection Check the power input line of the starter relay switch (page 21-45). Is the power input line normal? – GO TO STEP 9. – • Faulty ignition switch (page 17-9). • Faulty starter switch (page 21-47). •...

  • Page 387: Wiring Diagram

    CBF150M-5 ADDENDUM WIRING DIAGRAM 21-48...
  • Page 399 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 400 23. CBF 150M-5 ADDENDUM MODEL IDENTIFICATION ..........23-4 GENERAL SPECIFICATION ..........23-6 CABLE & HARNESS ROUTING FRONT COWL ..... 23-20 FRONT COWL / WIND SCREEN ........23-26 RIGHT SIDE COVER / LEFT SIDE COVER ....... 23-27 FRONT WHEEL ..............23-29 REAR WHEEL ..............
  • Page 403 SHOP MANUAL - ADDENDUM GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 2,095 mm (82.5 in) Overall width 750 mm (29.6 in) Overall height 1,100 mm (43.3 in) Wheelbase 1,340 mm (52.8 in) Seat height 798 mm (31.5 in) Footpeg heigh 301 mm (11.9 in) Ground clearance 179 mm (7.1 in)
  • Page 404 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 20W-40 Oil pump rotor Tip clearance 0.15 (0.006)
  • Page 405 SHOP MANUAL - ADDENDUM CYLINDER/PISTON SPECIFICATONS IT IT ITEM ITEM S T A N D A R D S T A N D A R D SERVICE LIMIT SERVICE LIMIT Cylinder I.D. 57.300 – 57.310 (2.2559 – 2.2563) 57.40 (2.260) Out-of-round –...
  • Page 406 SHOP MANUAL - ADDENDUM CRANKSHAFT/TRANSMISSION SPECIFICATIONS ITEM S T A N D A R D SERVICE LIMIT ER I Crankshaft Runout 0.03 (0.001) 0.08 (0.003) Connecting rod big end radial clearance 0 – 0.008 (0 – 0.0003) 0.05 (0.002) Connecting rod big end side clearance 0.10 –...
  • Page 407 Fork Spring free length 481 (18.94) 458 (18.0) Pipe runout – 0.20 (0.008) Recommended fluid Fork fluid (Honda ultra cusion oil) – Fluid level 165 (6.50) – Fluid capacity 158 ± 1.0 cm³ (5.23 ± 0.03 US oz, – 5.43 ± 0.04 lmp oz) Steering head bearing pre-load 0.7 –...
  • Page 408 SHOP MANUAL - ADDENDUM BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12 V – 7 Ah Current leakage 0.1 mA max. Specific gravity Fully charged 1.270 – 1.290 (20×C/68×F) Needs charging Below 1.230 Voltage Fully charged 12.7 – 12.9 V Needs charging Below 12.3 V Charging current...
  • Page 409 SHOP MANUAL - ADDENDUM STANDARD TORQUE VALUES FASTENER TYPE TORQUE FASTENER TYPE TORQUE N·m (kgf·m, lbf·ft) ·m ·m, N·m (kgf·m, lbf·ft) · lbf t 5 mm bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9) 6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5)
  • Page 410 SHOP MANUAL - ADDENDUM CYLINDER HEAD/VALVES CYLINDER HEAD/VALVES I DE ITEM Q'TY T T H R E A D TORQUE REMARKS D I DIA. (mm) N·m (kgf·m, lbf·ft) ·m, lbf t Cylinder head cover bolt 10 (1.0, 7) Rocker arm shaft bolt 5 (0.5, 3.7) Cam sprocket bolt 9 (0.9, 6.6)
  • Page 412 SHOP MANUAL - ADDENDUM FRAME FRAME/BODY PANELS/EXHAUST SYSTEM ITEM M ITEM Q'TY T T H R E A D TORQUE REMARKS Q'TY T R E T H R E A D TORQUE REMARKS D I DIA. (mm) N·m (kgf·m, lbf·ft) ·m, lbf t Brake/tail light unit mount nut 5.1 (0.5, 3.8)
  • Page 413 SHOP MANUAL - ADDENDUM CARBURETOR IT ITEM Q'TY T H R E A D TORQUE REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) · Throttle position sensor screw 3.4 (0.4, 2.5) LIGHTS/METER/SWITCHES IT IT ITEM Q'TY T H R E A D TORQUE REMARKS ITEM...
  • Page 415 SHOP MANUAL - ADDENDUM LOCATION MATERIAL REMARKS Shift drum stopper arm bolt threads Locking agent Coating width: 6.5 ± 1.0 mm from tip Gear shift cam bolt threads Coating width: 6.5 ± 1.0 mm from tip Starter clutch bolt threads Coating width: 6.5 ±...
  • Page 416 1:1) Fork socket bolt threads Locking agent Ignition switch mounting bolt threads Fork cap O-ring Fork fluid Fork oil seal lips Handlebar grip inner surface Honda Bond A or equivalent 23-19...

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