Table of Contents
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Chapters
Table of Contents
Related Manuals for Honda SH150
Summarization of Contents
1. General Information
Service Rules
Guidelines for proper service procedures, parts, lubricants, tools, and fasteners.
Model Identification
Information on identifying specific vehicle models, including VIN location.
General Specifications
Key technical specifications for dimensions, frame, engine, fuel, drive train, and electrical systems.
Standard Torque Values
List of specified torque values for various fasteners across different systems.
Lubrication & Seal Points
Diagrams and lists of lubrication points and sealants for engine and frame components.
Cable & Harness Routing
Diagrams illustrating the correct routing of cables and electrical harnesses.
Emission Control Systems
Explanation of crankcase and exhaust emission control systems and their functions.
2. Frame/Body Panels/Exhaust System
Service Information
General service guidelines for body panels and exhaust system removal/installation.
Body Panel Locations
Illustrated guide to the location and removal order of various body panels.
Exhaust System
Detailed procedures for the removal and installation of the exhaust system components.
3. Maintenance
Maintenance Schedule
Periodic maintenance intervals and required service actions based on mileage or time.
Engine Oil
Procedures for checking engine oil level, changing oil, and oil change indicator reset.
Brake Fluid
Instructions for checking, replacing, and bleeding brake fluid, including notices.
Wheels/Tires
Guidelines for checking tire pressure, condition, tread depth, and wheel trueness.
Steering Head Bearings
Procedure for inspecting steering head bearings for smooth movement and play.
4. Lubrication System
Service Information
General information on used oil handling, oil pump service, and oil change procedures.
Oil Pump
Detailed procedures for the removal, disassembly, inspection, and assembly of the oil pump.
5. Fuel System (Programmed Fuel Injection)
System Components
Exploded view of the fuel system components, showing parts and torque values.
PGM-FI Self-Diagnosis Information
Procedures for accessing and interpreting diagnostic trouble codes (DTCs) via MIL and HDS.
MIL Code Index
List of Malfunction Indicator Lamp (MIL) codes, their causes, symptoms, and refer pages.
Throttle Body
Procedures for the removal and installation of the throttle body assembly.
Injector
Step-by-step guide for removing and installing the fuel injector, including inspection.
6. Cooling System
Service Information
General precautions for handling hot coolant and system service notes.
Coolant Replacement
Detailed instructions for preparing, replacing, and bleeding coolant, including notices.
Water Pump
Instructions for inspecting and replacing the water pump mechanical seal.
7. Engine Removal/Installation
Engine Removal
Detailed steps and component lists for safely removing the engine from the frame.
Engine Installation
Procedures for reinstalling the engine, including mounting, alignment, and final checks.
8. Cylinder Head/Valves
Cylinder Compression Test
Procedure for performing a compression test to diagnose engine performance issues.
Valve Guide Replacement
Detailed instructions for replacing valve guides, including special tool usage and temperature control.
Valve Seat Inspection/Refacing
Procedures for inspecting valve seat contact and refacing using specialized tools.
Cylinder Head Assembly
Steps for reassembling the cylinder head, including valve springs, seals, and cotters.
9. Cylinder/Piston
Cylinder/Piston Inspection
Procedures for inspecting cylinder dimensions, taper, out-of-round, and piston ring clearances.
Piston/Cylinder Installation
Steps for installing piston rings, piston, and cylinder, including oil application and alignment.
10. Drive and Driven Pulleys/Clutch
Drive Belt
Inspection of the drive belt for wear and procedures for its removal and installation.
Drive Pulley
Steps for removing and inspecting the drive pulley face and components.
Clutch/Driven Pulley
Procedures for disassembly, inspection, and assembly of the clutch and driven pulley.
11. Final Reduction
Final Reduction Disassembly/Inspection
Steps for disassembling the final reduction case, inspecting gears, bearings, and oil seals.
Bearing Replacement
Detailed instructions for replacing bearings in the crankcase and final reduction case using special tools.
12. Alternator/Starter Clutch
Service Information
General notes on servicing flywheel, starter clutch, and CKP sensor, including torque values.
Flywheel/Starter Clutch
Detailed procedures for removing, disassembling, inspecting, and assembling the flywheel and starter clutch.
13. Crankcase/Crankshaft
Crankcase Separation
Detailed steps for separating the crankcase halves, including removing components and using special tools.
Crankshaft Inspection
Procedures for inspecting crankshaft runout, rod clearances, and bearings.
Crankcase Assembly
Steps for assembling crankcase halves, installing crankshaft bearings, and applying sealant.
14. Front Wheel/Suspension/Steering
Front Wheel
Procedures for removing, inspecting, and installing the front wheel, axle, and bearings.
Fork
Detailed steps for front fork removal, disassembly, inspection, and assembly, including fluid replacement.
Steering Stem
Steps for removing, replacing, and adjusting steering head bearings and steering stem.
15. Rear Wheel/Suspension
Rear Wheel
Procedures for removing, inspecting, and installing the rear wheel, including rim runout and brake drag.
Rear Shock Absorber
Procedures for removing, installing, and inspecting the rear shock absorber for wear and damage.
16. Brake System
Brake Fluid Replacement/Air Bleeding
Detailed instructions for draining, replacing, and bleeding brake fluid in the hydraulic system.
Brake Pad/Disc
Procedures for replacing brake pads, inspecting brake disc thickness and warpage.
Front Brake Caliper
Steps for disassembling, inspecting, and assembling the front brake caliper.
Rear Drum Brake
Procedures for removing, inspecting, and disassembling the rear drum brake shoes and drum.
17. Battery/Charging System
Battery
Procedures for battery removal, installation, voltage inspection, and charging.
Charging System Inspection
Inspection of charging voltage, current leakage, and alternator charging coil.
Alternator Charging Coil
Inspection of the alternator charging coil resistance and continuity.
18. Ignition System
Troubleshooting
Diagnosing no spark at plug, ignition coil issues, and CKP sensor problems.
Ignition System Inspection
Procedures for checking ignition system connections, peak voltage, and using diagnostic tools.
Ignition Coil
Steps for removing and installing the ignition coil, including wire band and connector checks.
Ignition Timing
Procedure for checking ignition timing using a timing light and ensuring correct marks align.
19. Electric Starter
Troubleshooting
Diagnosing starter motor issues: not turning, slow turning, engine not turning, or relay clicks.
Starter Motor
Procedures for starter motor removal, disassembly, inspection, and assembly.
Starter Relay Switch
Inspection of the starter relay switch operation, coil power, and ground lines.
20. Lights/Meters/Switches
Headlight
Procedures for replacing the headlight bulb and removing/installing the headlight assembly.
Combination Meter
Inspection of power, ground, and backup voltage lines for the combination meter.
Fuel Gauge/Fuel Level Sensor
System inspection and procedure for checking fuel level sensor resistance.
Coolant Temperature Gauge/ECT Sensor
Inspection of coolant temperature gauge operation and ECT sensor resistance and continuity.
Ignition Switch
Procedures for removing and installing the ignition switch, including continuity checks.
Handlebar Switch
Inspection of handlebar switches (starter, horn, dimmer, turn signal) for continuity.
Brake Light Switch
Inspection of brake light switch operation for continuity relative to brake lever engagement.
Main Relay
Inspection of the main relay's coil and switch lines, including functional tests.
Turn Signal Relay
Inspection of the turn signal relay operation and continuity checks.
22. Troubleshooting
Engine Does Not Start or Is Hard to Start
Troubleshooting guide for engine starting issues, covering spark, fuel, compression, and timing.
Engine Lacks Power
Diagnostic steps for engine power loss, including brake drag, tire pressure, clutch, and spark plug.
Poor Performance at High Speed
Diagnostic steps for poor high-speed performance, covering ignition, fuel, air cleaner, and valve timing.
Poor Handling
Troubleshooting guide for handling issues like heavy steering, wheel wobbles, and vehicle pulling.
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