Honda SH125 Owner's Manual
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Honda SH125 Owner's Manual

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Honda SH125/150CRF
OWNER'S MANUAL
Honda Motor Co., Ltd. 2009

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  • Page 1 09/08/05 17:20:31 32KTGC00_001 Honda SH125/150CRF OWNER’S MANUAL Honda Motor Co., Ltd. 2009...
  • Page 2 09/08/05 17:20:36 32KTGC00_002 IMPORTANT INFORMATION OPERATOR AND PASSENGER This scooter is designed to carry the operator and one passenger. ON-ROAD USE This scooter is designed to be used only on the road. READ THIS OWNER’S MANUAL CAREFULLY Pay special attention to the safety messages that appear throughout the manual. These messages are fully explained in the ‘‘A Few Words About Safety’’...
  • Page 3 OWNER’S MANUAL All information in this publication is based on the latest production 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.
  • Page 4 When service is required, remember that your Honda dealer knows your scooter best. If you have the required mechanical ‘‘know-how’’ and tools, your dealer can supply you with an Official Honda Shop Manual to help you perform many maintenance and repair tasks.
  • Page 5 09/08/05 17:20:51 32KTGC00_005 The following code in this manual indicates the country. Vietnam The specifications may vary with each locale.
  • Page 6 09/08/05 17:20:56 32KTGC00_006 A FEW WORDS ABOUT SAFETY Your safety, and the safety of others, is very important. And operating this scooter safely is an important responsibility. To help you make informed decisions about safety, we have provided operating procedures and other information on labels and in this manual.
  • Page 7 09/08/05 17:21:02 32KTGC00_007 You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. Safety Headings –– such as Important Safety Reminders or Important Safety Precautions. Safety Section ––...
  • Page 8 09/08/05 17:21:14 32KTGC00_008 OPERATION page page SCOOTER SAFETY ESSENTIAL INDIVIDUAL IMPORTANT SAFETY COMPONENTS INFORMATION IGNITION SWITCH PROTECTIVE APPAREL KEYS LOADING AND ACCESSORIES RIGHT HANDLEBAR CONTROLS LEFT HANDLEBAR CONTROLS PARTS LOCATION INSTRUMENTS AND INDICATORS MAJOR COMPONENTS (Information you need to operate this scooter) SUSPENSION BRAKES...

  • Page 9: Table Of Contents

    09/08/05 17:21:26 32KTGC00_009 page page FEATURES OPERATION (Not required for operation) PRE-RIDE INSPECTION STEERING LOCK STARTING THE ENGINE SEAT LOCK RUNNING-IN HELMET HOLDER RIDING DOCUMENT COMPARTMENT PARKING CENTER COMPARTMENT ANTI-THEFT TIPS SHOPPING HOOK FRONT COVER HEADLIGHT AIM VERTICAL ADJUSTMENT...
  • Page 10 09/08/05 17:21:44 32KTGC00_010 MAINTENANCE page page MAINTENANCE CLEANING THE IMPORTANCE OF MAINTENANCE STORAGE GUIDE MAINTENANCE SAFETY STORAGE SAFETY PRECAUTIONS REMOVAL FROM STORAGE MAINTENANCE SCHEDULE TOOL KIT TAKING CARE OF THE SERIAL NUMBERS UNEXPECTED AIR CLEANER BELT CASE AIR CLEANER SPECIFICATIONS CRANKCASE BREATHER ENGINE OIL CATALYTIC CONVERTER...
  • Page 11 09/08/05 17:21:54 32KTGC00_011 SCOOTER SAFETY IMPORTANT SAFETY INFORMATION Make Yourself Easy to See Your scooter can provide many years of Some drivers do not see scooters because service and pleasure if you take they are not looking for them. To make responsibility for your own safety and yourself more visible, wear bright reflective understand the challenges that you can...
  • Page 12 Never exceed load limits, and only use accessories that have been approved by Honda for this scooter. See page for more details. Not wearing a helmet increases the chance of serious injury or death in a crash.
  • Page 13 09/08/05 17:22:05 32KTGC00_013 Helmets and Eye Protection Additional Riding Gear Your helmet is your most important piece of In addition to a helmet and eye protection, riding gear because it offers the best we also recommend: protection against head injuries. A helmet Sturdy boots with non-slip soles to help should fit your head comfortably and protect your feet and ankles.
  • Page 14 09/08/05 17:22:12 32KTGC00_014 ALWAYS wear a helmet. You should also wear a face shield or goggles. Clothes should be close-fitting. Wear bright or reflective clothing. Wear gloves. Shoes should be close-fitting, have low heels and offer ankle protection.
  • Page 15 09/08/05 17:22:19 32KTGC00_015 LOADING AND ACCESSORIES Loading Your scooter has been designed to carry How much weight you put on your scooter, you and one passenger. When you carry a and how you load it, are important to your passenger, you may feel some difference safety.
  • Page 16 09/08/05 17:22:28 32KTGC00_016 Putting too much weight in individual storage compartments can also affect stability and handling. So be sure to stay within the limits given below: Maximum weight: in center compartment: 10 kg (22 lb) shopping hook: 1.5 kg (3.3 lb) rear carrier: 3.0 kg (6.6 lb) Rear carrier:...
  • Page 17 If you wish to carry more cargo, check with To prevent loose items from creating a your Honda dealer for advice, and be sure h a z a r d , m a k e s u r e t h e c e n t e r...
  • Page 18 09/08/05 17:22:42 32KTGC00_018 Accessories and Modifications Accessories Modifying your scooter or using non-Honda We strongly recommend that you use only accessories can make your scooter unsafe. Honda Genuine Accessories that have been B e f o r e y o u c o n s i d e r m a k i n g a n y...
  • Page 19 09/08/05 17:22:47 32KTGC00_019 Do not pull a trailer or sidecar with your Modifications scooter. This scooter was not designed We strongly advise you not to remove any for these attachments, and their use can original equipment or modify your scooter seriously impair your scooter’s handling.

  • Page 20: Parts Location

    09/08/05 17:22:52 32KTGC00_020 PARTS LOCATION Rear brake fluid reservoir Speedometer Front brake fluid reservoir Rearview mirror Coolant Fuel gauge Rearview mirror temperature gauge Front brake lever Rear brake lever Headlight dimmer switch Throttle grip Passing light control switch Headlight switch Turn signal switch Start button Horn button...
  • Page 21 09/08/05 17:22:57 32KTGC00_021 Helmet holder Shopping hook Center compartment Document bag Fuel fill cap Tool kit Coolant reserve tank Rear carrier Rear suspension spring preload adjuster Oil filler cap/dipstick Spark plug Passenger footpeg...
  • Page 22 09/08/05 17:23:02 32KTGC00_022 Helmet holder Fuse box Rear suspension spring preload adjuster Air cleaner Belt case air cleaner Battery Passenger footpeg Main fuse Engine oil drain plug Center stand Engine oil strainer screen...
  • Page 23 09/08/05 17:23:09 32KTGC00_023 INSTRUMENTS AND INDICATORS The indicators are contained in the instrument panel. Their functions are described in the tables on the following pages. (1) Left turn signal indicator (2) High beam indicator (3) PGM-FI malfunction indicator lamp (MIL) (4) Oil change indicator (13) (5) Right turn signal indicator...
  • Page 24 ON. If it comes on at any other time, reduce speed and take the scooter to your Honda dealer as soon as possible. Oil change indicator...
  • Page 25 09/08/05 17:23:35 32KTGC00_025 (Ref.No.) Description Function Fuel gauge Shows approximate fuel supply available (page CLOCK/OIL button This button is used to adjust the time (page This button is also used to reset the oil change indicator (page Speedometer Shows riding speed. Digital clock Shows hour and minute (page (10)
  • Page 26 09/08/05 17:23:41 32KTGC00_026 Coolant Temperature Gauge The coolant temperature gauge ( ) shows coolant temperature. When the needle begins to move above the C (Cold) mark ( ), the engine is warm enough for the scooter to be ridden. The normal operating temperature range is within the section between the H and C marks.
  • Page 27 09/08/05 17:23:47 32KTGC00_027 Fuel Gauge When the fuel gauge needle ( ) enters the red band ( ), fuel will be low and you should refill the tank as soon as possible. The amount of fuel left in the tank with the vehicle set upright when the fuel gauge n e e d l e e n t e r s t h e r e d b a n d i s approximately:...

  • Page 28: Digital Clock

    09/08/05 17:23:55 32KTGC00_028 Digital Clock Shows hour and minute. To adjust the time, Press the CLOCK/OIL button until the proceed as follows: desired time and AM/PM are displayed. The time is advanced by one minute, Turn the ignition switch ON. each time the button is pressed.

  • Page 29: Oil Change Indicator

    09/08/05 17:24:03 32KTGC00_029 If the oil is changed before the oil change Oil Change Indicator The oil change indicator ( ) lights when indicator appears, be sure to reset the oil the mileage on your scooter approaches the change indicator after changing the oil. The oil change interval specified on the indicator will appear for 2 seconds, then maintenance schedule (page...
  • Page 30 09/08/05 17:24:06 32KTGC00_030 The first oil change is at 1,000 km (600 miles), but in this case the indicator should not be reset. The indicator will start blinking after the scooter has covered approximately 4,000 km (2,500 miles). Therefore, after the second engine oil change, as described in the maintenance schedule (page ), remember to reset the...
  • Page 31 09/08/05 17:24:12 32KTGC00_031 MAJOR COMPONENTS (Information you need to operate this scooter) SUSPENSION Each shock absorber ( ) has 3 adjustment positions for different load or riding conditions. Use a handlebar ( ) to adjust the rear shocks. Always adjust the shock absorber position in sequence (1-2-3 or 3-2-1).
  • Page 32 See your Honda dealer for this service. For normal braking, apply both the front and rear brake lever to match your road speed.
  • Page 33 Worn pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is Honda DOT 3 or DOT 4 brake fluid from a sealed container, or an equivalent. Other Checks: Make sure there are no fluid leaks.
  • Page 34 Worn pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is Honda DOT 3 or DOT 4 brake fluid from a sealed container, or an equivalent. Other Checks: Make sure there are no fluid leaks.
  • Page 35 09/08/05 17:24:36 32KTGC00_035 COOLANT Use any genuine HONDA PRE-MIX Coolant Recommendation COOLANT without diluting with water. Use only genuine HONDA PRE-MIX COOLANT containing corrosion inhibitors, specifically recommended for aluminum engines when adding or replacing the Do not use non-ethylene glycol coolant, tap coolant.
  • Page 36 The reserve tank ( ) is behind the front loss is excessive, check for leaks and see cover ( ). your Honda dealer for repair. Check the coolant level in the reserve tank while the engine is at the normal operating temperature with the scooter in an upright position.
  • Page 37 09/08/05 17:24:52 32KTGC00_037 FUEL Fuel Tank The fuel tank is located under the seat. Fuel tank capacity is: 7.5 (1.98 US gal , 1.65 Imp gal) To open the fuel fill cap ( ), unlock and lift up the seat (page ), then remove the fuel fill cap by turning it counterclockwise.
  • Page 38 If ‘‘spark knock’’ or ‘‘pinking’’ occurs at a steady engine speed under normal load, change brands of petrol. If spark knock or pinking persists, consult your Honda dealer. Failure to do so is considered misuse, and damage caused by misuse is not covered by...
  • Page 39 Damage the painting of the fuel tank. is at least as high as that recommended by Damage the rubber tubes of the fuel line. Honda. There are two types of ‘‘gasohol’’: Cause corrosion of the fuel tank. one containing ethanol, and the other Cause poor drivability.
  • Page 40 09/08/05 17:25:12 32KTGC00_040 ENGINE OIL Reinstall the oil filler cap/dipstick. Check Engine Oil Level Check for oil leaks. Check the engine oil level each day before riding the scooter. The level must be maintained between the Running the engine with insufficient oil upper ( ) and lower ( ) level marks on the pressure may cause serious engine damage.
  • Page 41 09/08/05 17:25:18 32KTGC00_041 TUBELESS TYRES Air Pressure To safely operate your scooter, your tyres Keeping your tyres properly inflated must be the proper type and size, in good provides the best combination of handling, condition with adequate tread, and correctly tread life and riding comfort.
  • Page 42 09/08/05 17:25:26 32KTGC00_042 Always check air pressure when your tyres Inspection are ‘‘cold’’ when the scooter has been Whenever you check the tyre pressures, parked for at least three hours. If you check you should also examine the tyre treads and air pressure when your tyres are ‘‘warm’’...
  • Page 43 09/08/05 17:25:31 32KTGC00_043 Tread Wear Replace tyres before tread depth at the center of the tyre reaches the following limit: Minimum tread depth Front: 1.5 mm (0.06 in) Rear: 2.0 mm (0.08 in) (1) Wear indicator (2) Wear indicator location mark...
  • Page 44 09/08/05 17:25:36 32KTGC00_044 Even if a tyre is professionally repaired with Tyre Repair If a tyre is punctured or damaged, you a permanent internal patch plug, it will not should replace it, not repair it. As discussed be as good as a new tyre. You should not below, a tyre that is repaired, either exceed 60 km/h (40 mph) for the first 24 temporarily or permanently, will have lower...
  • Page 45 09/08/05 17:25:45 32KTGC00_045 The recommended tyres for your scooter Tyre Replacement The tyres that came on your scooter were are: designed to match the perf ormance Front: 100/80 16M/C 50P capabilities of your scooter and provide the DUNLOP best combination of handling, braking, D451 durability and comfort.
  • Page 46 09/08/05 17:25:49 32KTGC00_046 Important Safety Reminders Do not install a tube inside a tubeless tyre on this scooter. Excessive heat build-up can cause the tube to burst. Use only tubeless tyres on this scooter. The rims are designed for tubeless tyres, and during hard acceleration or braking, a tube-type tyre could slip on the rim and cause the tyre to rapidly deflate.
  • Page 47 09/08/05 17:25:57 32KTGC00_047 ESSENTIAL INDIVIDUAL COMPONENTS IGNITION SWITCH The ignition switch ( ) is on the right side below the steering stem. LOCK (1) Ignition switch Key Position Function Key Removal LOCK Steering is locked. Engine and lights cannot be Key can be (steering lock) operated.
  • Page 48 This scooter has two keys ( ) and a key have to replace a key. Store the plate in a number plate ( ). safe place. To reproduce keys, bring all keys, key number plate and scooter to your Honda dealer. (1) Keys (2) Key number plate...
  • Page 49 09/08/05 17:26:11 32KTGC00_049 RIGHT HANDLEBAR CONTROLS Headlight Switch The headlight switch ( ) has three positions; and OFF marked by a dot to the right of Headlight, taillight, position light, license light and meter lights on. Position light, taillight, license light and meter lights on.
  • Page 50 09/08/05 17:26:22 32KTGC00_050 LEFT HANDLEBAR CONTROLS Headlight Dimmer Switch ( ) Push the headlight dimmer sw it ch to (HI) t o select high be am or t o (LO) to select low beam. Passing Light Control Switch ( ) When this switch is pressed, the headlight flashes on to signal approaching cars or when passing.

  • Page 51: Features

    09/08/05 17:26:30 32KTGC00_051 FEATURES (Not required for operation) STEERING LOCK To lock To lock the steering, turn the handlebars all the way to the left, turn the key ( ) to LOCK while pushing in. Remove the key. To unlock the steering, turn the key to OFF while pushing in.

  • Page 52: Seat Lock

    09/08/05 17:26:36 32KTGC00_052 SEAT LOCK The seat lock is in the ignition switch. To open the seat, insert the ignition key ( ) and turn it to the OFF position while pushing in, then turn it counterclockwise to unlock. Pull the seat up. To lock the seat, lower and push down on it until it locks.

  • Page 53: Helmet Holder

    09/08/05 17:26:42 32KTGC00_053 HELMET HOLDER The helmet holders ( ) are on the left and right side below the seat. The helmet holders are designed to secure your helmet while parked. Open the seat (page Hang your helmet on the hooks at the seat hinge and lower the seat to lock.

  • Page 54: Document Compartment

    09/08/05 17:26:49 32KTGC00_054 DOCUMENT COMPARTMENT The document bag ( ) is in the document compartment ( ), located under the seat. Open the seat (page This owner’s manual and other documents should be stored in this compartment. When washing your scooter, be careful not to flood this area with water.

  • Page 55: Center Compartment

    09/08/05 17:26:56 32KTGC00_055 CENTER COMPARTMENT The center compartment ( ) is below the seat. Opening and closing: See ‘‘SEAT LOCK’’ (page MAXIMUM WEIGHT LIMIT: 10 kg (22 lb) Never exceed the maximum weight limit; handling and stability may be severely affected.
  • Page 56 09/08/05 17:27:02 32KTGC00_056 SHOPPING HOOK The shopping hook ( ) is provided below the handlebar. MAXIMUM WEIGHT LIMIT: 1.5 kg (3.3 lb) Do not attach large luggage to the hook that would hang out from the scooter and/or interfere with the movement of your feet. (1) Shopping hook...
  • Page 57 09/08/05 17:27:11 32KTGC00_057 FRONT COVER The front cover ( ) must be removed to service the coolant and fuse. Removal: Remove the screws ( ). Release the hooks ( ), then remove the front cover. Installation: Installation can be done in the reverse order of removal.
  • Page 58 09/08/05 17:27:16 32KTGC00_058 HEADLIGHT AIM VERTICAL ADJUSTMENT Vertical adjustment can be made by turning the screw ( ) in or out as necessary. Obey local laws and regulations. (1) Screw (A) Up (B) Down...
  • Page 59 If you detect any problem, be sure you take Coolant level add coolant if required. care of it, or have it corrected by your Check for leaks (pages Honda dealer. Front and rear brakes check operation; make sure there is no brake fluid leakage (pages...
  • Page 60 09/08/05 17:27:33 32KTGC00_060 Your scooter’s exhaust contains poisonous STARTING THE ENGINE Always follow the proper starting procedure carbon monoxide gas. High levels of carbon described below. monoxide can collect rapidly in enclosed areas such as a garage. Do not run the This scooter has an automatic fuel valve.
  • Page 61 09/08/05 17:27:39 32KTGC00_061 This scooter has a fuel-injected engine with an automatic choke. Follow the procedure indicated below. Place the scooter on its center stand. Squeeze the rear brake lever ( ). The electric starter will only work when the rear brake lever is pulled in.
  • Page 62 09/08/05 17:27:48 32KTGC00_062 Turn the ignition switch ( ) to ON. With the throttle completely closed, press the start button ( ). Confirm the following: The PGM-FI malfunction indicator lamp The engine will not start if the throttle is (MIL) is OFF. fully open (because the electronic control module cuts off the fuel supply).
  • Page 63 09/08/05 17:27:56 32KTGC00_063 Be sure to keep the throttle closed and Flooded Engine the rear brake lever applied while starting If the engine fails to start after repeated and warming up the engine. attempts, it may be flooded. Allow the engine to warm up before Open the throttle fully.
  • Page 64 09/08/05 17:28:01 32KTGC00_064 Ignition Cut Off RUNNING-IN Your scooter is designed to automatically Help assure your scooter’s future reliability stop the engine and fuel pump if the scooter and performance by paying extra attention is over-turned (a banking sensor cuts off the to how you ride during the first 500 km (300 ignition system).
  • Page 65 09/08/05 17:28:08 32KTGC00_065 RIDING Review Scooter Safety (pages before you ride. Make sure the throttle is closed and before moving the rear brake is applied the scooter off the center stand. The rear wheel must be locked when moving the scooter off the center stand or loss of control may result.
  • Page 66 09/08/05 17:28:14 32KTGC00_066 Stand on the left side of the scooter Mount the scooter f rom the left side and push it forward and off the center keeping at least one foot on the ground to stand. steady the scooter.
  • Page 67 09/08/05 17:28:20 32KTGC00_067 Unlock the rear wheel by releasing the Bef ore starting of f , indicate your rear brake lever ( ). direction with the turn signals, and check for safe traffic conditions. Grasp the handlebars firmly with both hands.
  • Page 68 09/08/05 17:28:26 32KTGC00_068 To accelerate, open the throttle ( ) gradually; the scooter will move forward. Do not ‘‘BLIP’’ the throttle (open and close rapidly) as the scooter will move CLOSE OPEN forward suddenly, causing possible loss of control. To decelerate, close the throttle.
  • Page 69 09/08/05 17:28:32 32KTGC00_069 When slowing down the scooter, coordination of the throttle ( ) and front and rear brakes ( ) is most important. Both front and rear brakes should be applied together. Independent use of only the front or rear brake reduces stopping performance.
  • Page 70 09/08/05 17:28:38 32KTGC00_070 When approaching a corner or turn, Af ter completing the turn, open the close the throttle ( ) fully, and slow the throttle gradually to accelerate the scooter down by applying both front and scooter. rear brakes ( ) at the same time. (2) Throttle (3) Front and rear brakes...
  • Page 71 09/08/05 17:28:44 32KTGC00_071 When descending a steep grade, close Avoid continuous use of the brakes, which the throttle ( ) fully and apply both may result in overheating and reduction of brakes ( ) to slow the scooter. braking efficiency. (2) Throttle (3) Front and rear brakes...
  • Page 72 09/08/05 17:28:50 32KTGC00_072 12. When riding on wet or loose surfaces, be especially cautious. When riding in wet or rainy conditions or on loose surfaces, the ability to maneuver and stop will be reduced. For your safety: Exercise extreme caution when braking, accelerating or turning.
  • Page 73 09/08/05 17:28:58 32KTGC00_073 Lock the steering to help prevent theft PARKING After stopping the scooter turn the (page ignition switch to the ‘‘OFF’’ position and remove the key. The exhaust pipe and muffler become Use the center stand to support the very hot during operation and remain scooter while parked.
  • Page 74 09/08/05 17:29:04 32KTGC00_074 ANTI-THEFT TIPS Always lock the steering and never leave the key in the ignition switch. This LOCK STEERING sounds simple but people do forget. Be sure the registration information for your scooter is accurate and current. Park your scooter in a locked garage whenever possible.
  • Page 75 MAINTENANCE If your scooter overturns or becomes THE IMPORTANCE OF MAINTENANCE involved in a crash, be sure your Honda A well-maintained scooter is essential for dealer inspects all major parts, even if you safe, economical and trouble-free riding. It are able to make some repairs.
  • Page 76 Wheel removal should normally be handled only by a Honda technician or other qualified mechanic; instructions are included in this manual only to assist in emergency service.
  • Page 77 To ensure the best quality and reliability, Injury from moving parts. Do not run the engine unless instructed use only new Honda Genuine Parts or their to do so. equivalents for repair and replacement. Read the instructions before you begin, and make sure you have the tools and skills required.

  • Page 78: Maintenance Schedule

    ) may require more technical information and tools. Consult your Honda dealer. Should be serviced by your Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. Refer to the Official Honda Shop Manual. In the interest of safety, we recommend these items be serviced only by your Honda dealer.
  • Page 79 09/08/05 17:29:39 32KTGC00_079 FREQUENCY WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST 1,000 km Refer 1,000 mi ITEM NOTE MONTH page FUEL LINE THROTTLE OPERATION AIR CLEANER NOTE (2) EVERY 8,000km(5,000mi):R CRANKCASE BREATHER NOTE (3) SPARK PLUG VALVE CLEARANCE ENGINE OIL ENGINE OIL STRAINER SCREEN ENGINE IDLE SPEED RADIATOR COOLANT...
  • Page 80 09/08/05 17:29:46 32KTGC00_080 FREQUENCY WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST 1,000 km Refer 1,000 mi ITEM NOTE MONTH page DRIVE BELT EVERY 8,000km (5,000mi):I EVERY 24,000km (15,000mi):R BELT CASE AIR CLEANER FINAL DRIVE OIL NOTE (4) BRAKE FLUID NOTE (4) 23, 24 BRAKE PADS WEAR 89, 90...
  • Page 81 09/08/05 17:29:57 32KTGC00_081 TOOL KIT T he tool kit ( ) is in the center compartment ( ). Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. 12 mm Open end wrench 14 mm Open end wrench 4 mm Hex wrench Spark plug wrench...
  • Page 82 09/08/05 17:30:05 32KTGC00_082 SERIAL NUMBERS The frame and engine serial numbers are The frame number ( ) is stamped on the required when registering your scooter. right side of the frame body. They may also be required by your dealer when ordering replacement parts.
  • Page 83 09/08/05 17:30:14 32KTGC00_083 AIR CLEANER Refer to the Safety Precautions on page Take out the air cleaner element ( ). Thoroughly clean the inside of the air The air cleaner should be serviced at cleaner housing ( ). regular intervals (page ).
  • Page 84 Air blow cleaning or any other cleaning can element specified for your model. Using degrade the viscous element performance the wrong Honda air cleaner element or a and cause the intake of dust. non-Honda air cleaner element which is Do not perform the maintenance.
  • Page 85 09/08/05 17:30:29 32KTGC00_085 BELT CASE AIR CLEANER Refer to the Safety Precautions on page Remove the screws ( ) and release the hook ( ). Disconnect the drain tube ( ). Remove the belt case air cleaner assembly ( ) by removing the bolts ( ). (4) Belt case air cleaner assembly (5) Bolts (1) Screws...
  • Page 86 09/08/05 17:30:39 32KTGC00_086 Remove the element cover ( ) by Wash the element in clean, nonflammable releasing the tab ( ). or high flash point solvent and let it dry Remove the element ( ). thoroughly. Never use petrol or low flash point solvents for cleaning the air cleaner.
  • Page 87 09/08/05 17:30:46 32KTGC00_087 CRANKCASE BREATHER Refer to the Safety Precautions on page Remove the crankcase breather tube plug ( ) from the tube and drain deposits into a suitable container. Reinstall the crankcase breather tube plug. Service more frequently when riding in rain, at full throttle, or after the scooter is washed or overturned.
  • Page 88 API service label Viscosity SAE 10W-30 JASO T 903 NOT RECOMMENDED standard Do not use non-detergent, vegetable, or castor based racing oils. Suggested Oil HONDA ‘‘4-STROKE GASOLINE ENGINE OIL’’ or equivalent.
  • Page 89 09/08/05 17:31:07 32KTGC00_089 JASO T 903 standard Viscosity: Viscosity grade of engine oil should be The JASO T 903 standard is an index for based on average atmospheric temperature engine oils for 4-stroke motorcycle engines. in your riding area. The following provides a There are two classes: MA and MB.
  • Page 90 Engine oil quality is the chief factor If you do not have it and the necessary skill, affecting engine service life. Change the we recommend that you have your Honda engine oil as specified in the maintenance dealer perform this service.
  • Page 91 09/08/05 17:31:22 32KTGC00_091 Place a drain pan under the crankcase. Clean the oil strainer screen. To drain the oil, remove the oil filler cap/ Check that the oil strainer screen, sealing dipstick ( ), oil drain plug ( ), O-ring rubber and drain plug O-ring are in good ( ), spring ( ) and oil strainer screen condition.
  • Page 92 09/08/05 17:31:27 32KTGC00_092 Install the oil strainer screen, spring and drain plug. Oil drain plug torque: 20 N·m (2.0 kgf·m , 14 lbf·ft) Fill the crankcase with the recommended grade oil; approximately: 0.9 (1.0 US qt , 0.8 Imp qt) Install the oil filler cap/dipstick.
  • Page 93 09/08/05 17:31:40 32KTGC00_093 SPARK PLUG Refer to the Safety Precautions on page Recommended plugs: Standard: CR8EH-9 (NGK) U24FER9 (DENSO) For extended high speed riding: CR9EH-9 (NGK) U27FER9 (DENSO) Never use a spark plug with an improper heat range. Severe engine damage could result.
  • Page 94 09/08/05 17:31:51 32KTGC00_094 Disconnect the spark plug cap ( ) from Inspect the electrodes and center the spark plug. porcelain for deposits, erosion or carbon Clean any dirt from around the spark plug fouling. If the erosion or deposit is heavy, base.
  • Page 95 09/08/05 17:31:58 32KTGC00_095 With the plug washer attached, thread the spark plug in by hand to prevent cross-threading. An improperly tightened spark plug can Tighten the spark plug: damage the engine. If a plug is too loose, a If the old plug is good: piston may be damaged.
  • Page 96 Refer to the Safety Precautions on page Coolant Replacement Removing the radiator cap while the Coolant should be replaced by a Honda engine is hot can cause the coolant to dealer, unless the owner has proper tools spray out, seriously scalding you.
  • Page 97 09/08/05 17:32:12 32KTGC00_097 THROTTLE OPERATION Refer to the Safety Precautions on page Check for smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions. Measure the throttle grip freeplay at the throttle grip flange.
  • Page 98 09/08/05 17:32:16 32KTGC00_098 FRONT AND REAR SUSPENSION INSPECTION Refer to the Safety Precautions on page Check the front fork assembly by locking the front brake and pumping the fork up and down vigorously. Suspension action should be smooth and there must be no oil leakage.
  • Page 99 (page Front Brake Check the wear indicator marks ( ) on each pad. If either pad is worn to the wear indicator mark, replace both pads as a set. See your Honda dealer for this service. (1) Wear indicator marks...
  • Page 100 Rear Brake Check the wear indicator grooves ( ) in each pad. If either pad is worn to the bottom of the grooves, replace both pads as a set. See your Honda dealer for this service. (2) Wear indicator grooves...
  • Page 101 (causing hard starting or A spark or flame can cause the battery other electrical troubles), contact your to explode with enough force to kill or Honda dealer. seriously hurt you. Wear protective clothing and a face shield, or have a skilled mechanic do Your battery is a maintenance-free type and the battery maintenance.
  • Page 102 09/08/05 17:32:42 32KTGC00_102 Removal: Make sure the ignition switch is OFF. Remove the maintenance lid (page Remove the battery holder ( ) by removing the screws ( ). Disconnect the negative ( ) terminal lead ( ) from the battery first, then disconnect the positive ( ) terminal lead ( ).
  • Page 103 Blown fuse usually indicates a short circuit or an overload in the electrical system. See your Honda dealer for repair. Never use a fuse with a different rating from that specified. Serious damage to the electrical system or a fire may result, causing a dangerous loss of lights or engine power.
  • Page 104 09/08/05 17:32:58 32KTGC00_104 Fuse Box: The fuse box is located behind the front cover. The specified fuses are: 15A, 10A Remove the front cover (page Open the fuse box cover ( ). Pull out the fuse with the fuse puller furnished in the tool kit (page ).
  • Page 105 09/08/05 17:33:07 32KTGC00_105 Main Fuse: The main fuse ( ) is located near the battery. The specified fuse is: Remove the maintenance lid (page Disconnect the wire connector ( ) of the starter magnetic switch ( ). Pull the fuse out. If the main fuse is blown, install a new main fuse.
  • Page 106 09/08/05 17:33:15 32KTGC00_106 BULB REPLACEMENT Refer to the Safety Precautions on page Be sure to turn the ignition switch OFF when replacing the bulb. The light bulb becomes very hot while the Do not use bulbs other than those light is ON, and remains hot for a while specified.
  • Page 107 09/08/05 17:33:24 32KTGC00_107 Headlight Bulb Pull up the dust covers ( ). Remove the right and left handle covers Loosen the lock nuts ( ) until they will ( ) by removing the screws A ( ). no longer turn. Remove the screws B ( ).
  • Page 108 09/08/05 17:33:31 32KTGC00_108 Remove the dust cover ( ). Disconnect the connector ( ). T u r n t h e b u l b h o l d e r counterclockwise and remove the bulb (10) ( ). Install a new bulb in the reverse order of removal.
  • Page 109 09/08/05 17:33:39 32KTGC00_109 Position Light Bulb Remove the front cover (page Remove the socket ( ). Pull out the position light bulb ( ) without turning. Install a new bulb in the reverse order of removal. (1) Socket (2) Bulb...
  • Page 110 09/08/05 17:33:45 32KTGC00_110 Brake/Tail Light Bulb Remove the taillight lens ( ) by removing the screws ( ). Slightly press the bulb ( ) and turn it counterclockwise. Install a new bulb in the reverse order of removal. (1) Taillight lens (3) Bulb (2) Screws...
  • Page 111 09/08/05 17:33:52 32KTGC00_111 Front Turn Signal Bulb The right and left turn signal bulbs replacement can be done in the same way. Remove the socket ( ) by turning it clockwise. Slightly press the bulb ( ) and turn it counterclockwise.
  • Page 112 09/08/05 17:34:01 32KTGC00_112 Rear Turn Signal Bulb The right and left turn signal bulbs replacement can be done in the same way. Remove the taillight lens (page Remove the rear turn signal lens ( ) by removing the screw ( ). Slightly press the bulb ( ) and turn it counterclockwise.
  • Page 113 09/08/05 17:34:09 32KTGC00_113 License Light Bulb Remove the license light cover ( ) by removing the screw ( ). Pull out the socket ( ). Pull out the bulb ( ) without turning. Install a new bulb in the reverse order of removal.
  • Page 114 09/08/05 17:34:19 32KTGC00_114 CLEANING Clean your scooter regularly to protect the Washing the scooter surface finishes and inspect for damage, Rinse the scooter thoroughly with cool wear, and oil, coolant or brake fluid leakage. water to remove loose dirt. Clean the scooter with a sponge or soft Avoid cleaning products that are not cloth using cool water.
  • Page 115 09/08/05 17:34:27 32KTGC00_115 Af ter cleaning, rinse the scooter Test the brakes before riding the scooter. thoroughly with plenty of clean water. Several applications may be necessary to Strong detergent residue can corrode restore normal braking performance. alloy parts. Dry the scooter, start the engine and let it Braking efficiency may be temporarily run for several minutes.
  • Page 116 09/08/05 17:34:34 32KTGC00_116 Finishing Touches Removing Road Salt After washing your scooter, consider using Seawater can be found on the road near the a commercially-available spray cleaner/ seaside. The salt in seawater causes rust. polish or quality liquid or paste wax to finish Wash your scooter as follows after it has the job.
  • Page 117 09/08/05 17:34:38 32KTGC00_117 Painted Aluminum Wheel Maintenance Clean the Mat Painted Surface Aluminum may corrode from contact with Using plenty of water, clean the mat painted dirt, mud, or road salt. Clean the wheels surface with a soft cloth or sponge. Dry af ter riding through any of these with a soft, clean cloth.
  • Page 118 Refuel only outdoors. Change the engine oil. Wipe up spills immediately. Make sure the cooling system is filled with a HONDA PRE-MIX COOLANT. Empty the fuel tank into an approved petrol container using a commercially available hand siphon or an equivalent method.
  • Page 119 09/08/05 17:34:52 32KTGC00_119 To prevent rusting in the cylinder, Remove the battery. Store in an area perform the following: protected from freezing temperatures Remove the spark plug cap from the and direct sunlight. spark plug. Using tape or string, secure Slow charge the battery once a month.
  • Page 120 09/08/05 17:34:58 32KTGC00_120 REMOVAL FROM STORAGE Uncover and clean the scooter. Change the engine oil if more than 4 months have passed since the start of storage. Charge the battery as required. Install the battery. Drain any excess aerosol rust-inhibiting oil from the fuel tank.
  • Page 121 Also, be sure to have your vehicle is involved in the crash. Honda dealer check the frame and suspension after any serious crash. If you decide that you are capable of riding safely, first evaluate the condition of your scooter.
  • Page 122 09/08/05 17:35:15 32KTGC00_122 SPECIFICATIONS DIMENSIONS Overall length 2,025 mm (79.7 in) Overall width 726 mm (28.6 in) Overall height 1,230 mm (48.4 in) Wheelbase 1,335 mm (52.6 in) CAPACITIES Engine oil After draining 0.9 (1.0 US qt , 0.8 Imp qt) After disassembly 1.0 (1.1 US qt , 0.9 Imp qt) Fuel tank...
  • Page 123 09/08/05 17:35:23 32KTGC00_123 ENGINE Bore and stroke 52.4 57.8 mm (2.06 2.28 in) … SH125CRF 58.0 57.8 mm (2.28 2.28 in) … SH150CRF Compression ratio 11.0 : 1 Displacement 124.6 cm (7.60 cu-in) … SH125CRF 152.7 cm (9.31 cu-in) … SH150CRF Spark plug Standard CR8EH-9 (NGK)
  • Page 124 09/08/05 17:35:32 32KTGC00_124 CHASSIS AND SUSPENSION Caster 27°00’ Trail 85.0 mm (3.35 in) Tyre size, front 100/80 16M/C 50P DUNLOP D451 SS 530F Tyre size, rear 120/80 16M/C 60P DUNLOP D451 SS 530R Tyre type bias ply, tubeless POWER TRANSMISSION Primary reduction V Belt Final reduction...
  • Page 125 09/08/05 17:35:43 32KTGC00_125 ELECTRICAL Battery 12V 6Ah Generator 0.30kW / 5,000 min (rpm) LIGHTS Headlight 12V 60/55W Brake/Tail light 12V 21/5W Turn signal light Front 12V 21W Rear 12V 21W Position light 12V 5W Speedometer lights 12V 1.7W Turn signal indicator 12V 3W High beam indicator 12V 1.7W...
  • Page 126 NOx. A replacement unit must be an the catalyst metals, making the catalytic original Honda part or its equivalent. converter ineffective. The catalytic converter must operate at a Keep the engine in good running high temperature for the chemical reactions condition.

This manual is also suitable for:

Sh150crf

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