Honda NSR150SP Manual
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Honda NSR150SP Manual

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  • Page 1: Table Of Contents

    http://mototh.com...
  • Page 2 All information contained in this manual is based on the latest product information available at the time of printing. Honda Australia Motorcycle & Power Equipment Pty. Ltd., and Honda Motor Co. Ltd, Japan, reserve the rights to make changes at any time without notice.
  • Page 3 Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI#2 or equivalent). Example: Molykote ® G-n Paste manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use Silicone grease.

  • Page 4: General Safety

    NSR150SP General Information ______________________________________________ General Safety Torque Values 1-14 Service Rules Tools 1-17 Model Identification Lubrication & Seal Points 1-18 Specification Cable & Harness Routing 1-21 GENERAL SAFETY Carbon Monoxide If the engine must be running to do some work, make sure the area is well ventilated.
  • Page 5 NSR150SP General Information ______________________________________________ Coolant Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the engine ethylene glycol does ignite, you will not see any flame, but you can be burned.

  • Page 6: General Information

    ______________________________________________ SERVICE RULES Use genuine HONDA or HONDA-recommended parts and lubrications or their equivalents. Parts that do not meet HONDA's design specifications may damage the motorcycle. Use the special tools designed for this product. Use only metric tools when servicing this motorcycle. Metric bolts, nets and screws are not interchangeable with English fasteners.

  • Page 7: Model Identification

    NSR150SP General Information ______________________________________________ Model Identification ) FRAME SERIAL NUMBER (2) ENGINE SERIAL NUMBER The frame serial number is stamped The engine serial number is On the right side of the steering head. Stamped on the right crankcase (3) CARBURETTOR IDENTIFICATION NUMBER The carburettor identification number is stamped carburettor body.

  • Page 8: Specification

    NSR150SP General Information ______________________________________________ SPECIFICATIONS General ITEM SPECIFICATIONS Overall length 1,972mm (77.6 in) Overall width 683 mm (26.9 in ) DIMENSION Overall height 1,062mm (41.8 in ) Wheel base 1,337 mm (52.6 in ) Seat height 780 mm (30.7 in )
  • Page 9 NSR150SP General Information ______________________________________________ General (cont..) ITEM SPECIFICATIONS CARBURETTOR Carburettor type Piston Valve Throttle bore 30 mm (1.2 in) Clutch System Multi-plate, wet Clutch operation system Cable operating DRIVE TRAIN Transmission 6 speeds constant mesh Primary reduction 2.954 (65/22) Final reduction 2.857 (40/14)
  • Page 10 0.7 litre (0.73 US qt, 0.62 Imp, qt) capacity At disassembly 0.8 litre (0.85 US qt, 0.70 Imp, qt) Recommended transmission oil Honda 4-stroke oil or equivalent API Service Classification: SE,SF,or SG Viscosity: SAE 10W – 40 FUEL SYSTEM ITEM...
  • Page 11 NSR150SP General Information ______________________________________________ CYLINDER HEAD/CYLINDER/PISTON Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression 108kPa (11.0 kgf/cm , 156 psi at 400 min (rpm) Cylinder head warpage 0.05 (0.002) Cylinder I.D. Code A 59.010 – 59.015 (2.3232 – 2.3234) 59.05 (5.325)
  • Page 12 NSR150SP General Information ______________________________________________ CRANKSHAFT/TRANSMISSION Unit: mm (in) ITEM STANDARD SERVICE LIMIT Connecting rod big end Side clearance 0.3 – 0.7 (0.012 – 0.028) Radial 0.05(0.002) clearance Crankshaft runout 0.05(0.002) 0.03(0.001) Transmission gear I.D. M5, M6 22.020–22.041(0.8669–0.8678) 22.10(0.870) 20.020-20.041(0.7882-0.7890) 20.10(0.791) C2, C4 22.020–22.041(0.8669–0.8678)
  • Page 13 NSR150SP General Information ______________________________________________ FRONT WHEEL / SUSPENSION/STEERING ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 1.5 (0.06) Cold tire pressure Driver only 200kPa (2.00kgf/cm , 29psi) Driver & Passenger 200kPa (2.00kgf/cm , 29psi) Front axle runout 0.2 (0.008) Front wheel rim Radial 2.0 (0.08)
  • Page 14 NSR150SP General Information ______________________________________________ BRAKES ITEM STANDARD SERVICE LIMIT Brake fluid DOT 3 or 4 Brake pad wear indicator Indicator groove Brake disc thickness 3.8 – 4.2 (0.15 – 0.17) 3.0(0.12) Brake disc runout 0.3(0.01) Master cylinder I.D 10.957-10.984 (0.4314-0.4326) 10.945(0.4309)

  • Page 15: Torque Values

    NSR150SP General Information ______________________________________________ LIGHTS/METERS/SWITCHES ITEM SPECIFICATIONS Main fuse 20 A Fuse 10 A X 3 Headlight (high/low beam) 12 V – 60/55 W X 2 Tail/Brake Light 12 V – 5/18 W X 2 Front turn signal light 12 V – 10 W X 2 Rear turn signal light 12 V –...
  • Page 16 NSR150SP General Information ______________________________________________ ENGINE ITEM THREAD TORQUE REMARKS DIA (mm) N.m (kgf-m, lbf-ft) LUBRICANT SYSTEM Oil drain bolt 21 (2.1, 15 ) COOLANT SYSTEM Water Pump impeller 12 (1.2, 9) CYLINDER HEAD / CYLINDER /PISTON Spark Plug 20 (2.0, 14) Cylinder head nut 23 (2.3, 17)
  • Page 17 NSR150SP General Information ______________________________________________ FRAME ITEM THREAD TORQUE REMARKS DIA (mm) N.m (kgf-m, lbf-ft) FUEL SYSTEM Fuel valve nut 27 (2.8, 20) Fuel filler cap socket bolt 1.5 (0.15, 1.1) ENGINE HANGER Front engine hanger nut 55 (5.6, 41) Rear upper engine hanger nut 55 (5.6, 41)

  • Page 18: Tools

    NSR150SP General Information ______________________________________________ TOOLS Notes: 1. Equivalent commercially available 2. Alternative tools DESCRIPTION TOOL NUMBER APPLICABILITY REF. SEC Float level gauge 07401-0010000 Universal bearing puller 07631-0010000 Wrench, 20 x 24 mm 07716-0020100 Extension bar 07716-0020500 Gear holder 07724-0010100 Flywheel holder...

  • Page 19: Lubrication & Seal Points

    NSR150SP General Information ______________________________________________ LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Crankshaft Honda-2-stroke oil or • equivalent Connecting rod big end Small end • Right and left journal Cylinder bore inner surface Piston outer surface Piston pin outer surface...
  • Page 20 NSR150SP General Information ______________________________________________ LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Thermo unit threads Liquid sealant 4 + 1 mm Cylinder Right and left crankcase mating surface Example: Three Bond #1207B Reed valve manufactured by 3M, co, Ltd Right and left crankcase mating surface...
  • Page 21 NSR150SP General Information ______________________________________________ LUBRICATION & SEAL POINTS FRAME LOCATION MATERIAL REMARKS Rear axle nut threads and flange surface Recommended engine oil Caliper pin bolt sliding surface Silicone grease 0.4g Master cylinder push rod • Master piston contacting area Brake lever •...

  • Page 22: Cable & Harness Routing

    NSR150SP General Information ______________________________________________ CABLE & HARNESS ROUTING 1-21 http://mototh.com...
  • Page 23 NSR150SP General Information ______________________________________________ 1-22 http://mototh.com...
  • Page 24 NSR150SP General Information ______________________________________________ 1-23 http://mototh.com...
  • Page 25 NSR150SP General Information ______________________________________________ 1-24 http://mototh.com...
  • Page 26 NSR150SP General Information ______________________________________________ 1-25 http://mototh.com...

  • Page 27: Frame/Body Panels/Exhaust System

    NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ Service Information Side cover, Rear Cover, Tail Cover Troubleshooting Rear Fender Body Panel Location Upper Cowl, Rearview Mirror Air Guide Side Cowl, Lower Cowl Fuel Tank 2-12 Inner Panel, Grab Rail Exhaust Pipe/ Muffler 2-16...
  • Page 28 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ BODY PANEL LOCATION http://mototh.com...
  • Page 29 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ SEAT, PILLION SEAT Pillion Seat Removal Turn the ignition key and unhook the pillion seat from the set catch. Remove the pillion seat Installation Apply grease to the seat catch. Install the seat aligning the hooks on the seat with the frame.
  • Page 30 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ SIDE COWL, LOWER COWL SIDE COWL Removal/Installation Remove the screws and side cowl, Installation is in the reverse order of removal. NOTE • At installation, align the tabs on the side cowl with the grooves on the lower cowl and upper cowl.
  • Page 31 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ LOWER COWL Removal Remove the screws. Remove the tachometer cable from the tab on the lower cowl. NOTE • At tachometer cable removal, be careful not to damage the tab on the lower cowl. Remove the tube from the hole on the lower cowl and remove the lower cowl.
  • Page 32 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ INNER PANEL Removal / Installation Remove the screws and inner panel. Installation is in the reverse order of removal. GRAB RAIL Removal / Installation Remove the socket bolts and grab rail. Installation is in the reverse order of removal.
  • Page 33 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ RIGHT SIDE COVER Removal / Installation Remove the seat. (page 2-3) Loosen the bolt. Remove the screws, special bolt, collar and right side cover. Installation is in the reverse order of removal. NOTE: • At installation, align the tabs on the right side cover with the grooves on the rear cover.
  • Page 34 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ TAIL COVER Removal/Installation Remove the left or right side cover. (page 2-7) Remove the screws and tail cover. Installation is in the reverse order of removal. • NOTE: At installation, align the tab on the tail cover with the hole on the tail light lens.
  • Page 35 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ UPPER COWL, REARVIEW MIRROR, AIR GUIDE REARVIEW MIRROR Removal/Installation Remove the cap nut and rearview mirror. Installation is in the reverse order of removal. UPPER COWL Removal Disconnect the speedometer cable from the speedometer. http://mototh.com...
  • Page 36 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ Disconnect the headlight 3P connector and front turn signal connectors. Remove the speedometer cable form the hole on the upper cowl. Remove the screws and upper cowl. • NOTE: At removal, be careful not to damage the tabs on the cowls.
  • Page 37 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ Remove the tachometer cable from the hole on the right side air guide. Remove the bolts and right air guide. Remove the screws, right air guide and right air guide plate. Installation is in the reverse order of removal.
  • Page 38 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ FUEL TANK Removal Remove the seat. (page 2-3) • Gasoline is extremely flammable and is explosive under certain conditions. Disconnect the fuel unit 3P connector. NOTE: • Before disconnecting the fuel tube, turn fuel valve OFF.
  • Page 39 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ DISASSEMBLY Loosen the fuel tap nut and remove the fuel tap. Remove the fuel strainer screen and O-ring. Clean the fuel strainer screen. Remove the fuel unit wire from the clamp. Remove the nuts and remove the fuel unit.
  • Page 40 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ ASSEMBLY Install the fuel unit to the fuel tank. CAUTION • Be careful not to damage the fuel unit. Install and tighten the nuts securely. Install the fuel unit wire to the clamp. Install the new O-ring and fuel strainer screen to the fuel tank.
  • Page 41 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ INSTALLATION Install the fuel tank aligning its hooks to the rubber mounts on the frame. Install the fuel tank mounting bolt and washer. Install and tighten the fuel tank mounting bolt to the specified torque.
  • Page 42 NSR150SP Frame/Body Panels/Exhaust System ______________________________________________ EXHAUST PIPE/MUFFLER Removal/Installation • Do not service the exhaust system while it is hot. Remove the lower cowl. (page 2-5) Remove the exhaust pipe joint nuts. Remove the muffler mounting bolt, washer and nut. Remove the exhaust pipe mounting bolt and washer.

  • Page 43: Maintenance

    NSR150SP Maintenance ______________________________________________ Service Information Drive Chain Slider 3-19 Maintenance Schedule Battery 3-20 Fuel Line Brake Fluid 3-20 Fuel Strainer Screen Brake Pad Wear 3-21 Throttle Operation Brake System 3-22 Oil Pump and Oil Line Brake Light Switch 3-23 Air Cleaner...
  • Page 44 NSR150SP Maintenance ______________________________________________ ITEM SPECIFICATIONS Minimum tire depth Front 1.5mm Rear 2.0mm Tire Size Front 90/80 – 17 46S Rear 120/80 – 17 61S Tire Band Front NF46 Rear NR57 TORQUE VALUES Oil drain bolt 21N.m (2.1 kgf-m, 15 lbf-ft) Spark Plug 20N.m (2.0 kgf-m, 14 lbf-ft)
  • Page 45 Wheel / Tyres Steering Head Bearing Should be serviced by your authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. In the interest of safety, we recommend these items be serviced only by your authorized Honda dealer.
  • Page 46 NSR150SP Maintenance ______________________________________________ FUEL LINE Check the fuel lines for deterioration, damage or leakage. Replace the fuel lines if necessary. Route the tubes properly. (page 1-18) FUEL STRAINER SCREEN NOTE • Fuel strainer screen cleaning. FUEL CUP STRAINER Remove the fuel tank. (page 2-12) •...
  • Page 47 NSR150SP Maintenance ______________________________________________ THROTTLE OPERATION Check for any deterioration or damage to the throttle cables. Check the throttle grip for smooth operation. Check that the throttle grip returns from the full open to the full closed position smoothly and automatically in all steering positions.
  • Page 48 NSR150SP Maintenance ______________________________________________ OIL PUMP AND OIL LINE Check the engine oil lines for deterioration, damage or leakage. Replace the fuel lines if necessary. Bleed the oil pump and oil line if they have air bubbles in them (page 4-6).
  • Page 49 (page 4-6) OIL-TANK CAPACITY: 0.76 litres (0.83 us qt, 0.67 Imp gl) RECOMMENDED ENGINE OIL: Honda 2-stroke oil or equivalent Make sure that there are no oil leaks. http://mototh.com...
  • Page 50 NSR150SP Maintenance ______________________________________________ OIL PUMP CONTROL CABLE ADJUSTMENT NOTE The oil pump control cable should be adjusted after the throttle grip free play adjustment. Remove the right under cowl. Remove the bolts and oil pump cover. Loosen the oil control cable lock nut and open the throttle fully.
  • Page 51 NSR150SP Maintenance ______________________________________________ AIR CLEANER NOTE • The viscous paper element type air cleaner cannot be cleaned because the element contains a dust adhesive. If the motorcycle is used in wet or dusty areas, more frequent inspections are required. Remove the fuel tank. (page 2-12) Remove the screws and air cleaner housing cover.
  • Page 52 NSR150SP Maintenance ______________________________________________ Install the element to the air cleaner housing. Install the air cleaner housing cover and screws. Tighten the screws securely. Install the fuel tank. (page 2-14) SPARK PLUG Remove the side cowl Disconnect the spark plug cap and clean around the spark plug bases.
  • Page 53 NSR150SP Maintenance ______________________________________________ INSPECTION Check the following and replace if necessary (recommended spark plugs: (page 3-1) • Insulator for damage • Electrodes for wear • Burning condition, coloration; • dark to light brown indicates good condition. • excessive lightness indicates malfunctioning ignition system or learn mixture.
  • Page 54 NSR150SP Maintenance ______________________________________________ DECARBONIZING CYLINDER HEAD Remove the cylinder head cover. (page 8-3) Remove carbon deposits from the combustion chamber and clean off the head gasket surface. CAUTION • Avoid damaging the gasket surface. Check the spark plug hole for cracks.
  • Page 55 NSR150SP Maintenance ______________________________________________ MUFFLER Remove the muffler joint bolts, muffler mounting bolt and nut. Remove the muffler. Clean carbon deposits from the inner pipe and muffler. CAUTION • Do not heat or clean with solvent to remove the carbon from the muffler and inner pipe.
  • Page 56 NSR150SP Maintenance ______________________________________________ RADIATOR COOLANT LEVEL CHECK • Wait until the engine is cool before removing the radiator cap. Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding. • Radiator coolant is poisonous. Take care to avoid getting coolant in your eyes, on your skin, or on your clothes.
  • Page 57 NSR150SP Maintenance ______________________________________________ Straighten bent fins with a small, flat blade screwdriver and remove insects, mud or other obstructions with compressed air or low pressure water. Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.
  • Page 58 RECOMMENDED TRANSMISSION OIL: Honda 4-stroke oil or equivalent motor oil certified to meet APE service classification SE, SF or SG Viscosity: SAE 10W-40. NOTE •...
  • Page 59 NSR150SP Maintenance ______________________________________________ After draining the oil completely, check that the sealing washer on the drain bolt is in good condition and replace if necessary. Tighten the drain bolt to the specified torque. TORQUE: 21 N.m (2.1 kgf.m, 15 lbf-ft) Fill the crankcase with the recommended engine oil.
  • Page 60 NSR150SP Maintenance ______________________________________________ Raise the rear wheel off the ground by placing a support under the engine. Turn the bearing holder with the pin spanner provided in the tool kit until the correct drive chain slack is obtained. After adjustment, check the chain wear label on the rear caliper bracket.
  • Page 61 NSR150SP Maintenance ______________________________________________ Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or other wise appears unserviceable. Installing a new chain on badly worn sprockets will cause the new chain to wear quickly.
  • Page 62 NSR150SP Maintenance ______________________________________________ BATTERY The battery electrolyte contains sulfuric acid. Protect your eyes, skins and clothing. If electrolyte gets in your eyes; flush them thoroughly with water and get prompt medical attention. Remove the battery from the battery compartment (page 16-5).
  • Page 63 NSR150SP Maintenance ______________________________________________ FRONT BRAKE Turn the handlebar to the left side so that the reservoir is level and check the front brake reservoir level through the sight glass. If the level (float edge) is near the lower level mark, remove the screws, cover, set plate...
  • Page 64 NSR150SP Maintenance ______________________________________________ BRAKE PAD WEAR FRONT: Check the brake pad for wear. Replace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to page 15-6 for brake pad replacement. REAR: Check the brake pad for wear.
  • Page 65 NSR150SP Maintenance ______________________________________________ BRAKE LIGHT SWITCH CAUTION • Allowing the switch body to turn during adjustment can break the wires in the switch. NOTE • The brake light switch on the front brake lever cannot be adjusted. If the front brake light switch actuation and brake engagement are off, either replace the switch unit or the malfunctioning parts of the system.
  • Page 66 NSR150SP Maintenance ______________________________________________ Adjust as follows: Minor adjustments are made at the adjuster near the lever. Loosen the lock nut and turn the adjuster. Tighten the lock nut. CAUTION • The adjuster may be damaged if it is positioned too far out, leaving minimal thread engagement.
  • Page 67 NSR150SP Maintenance ______________________________________________ SUSPENSION Loose, worn, or damaged suspension parts impair motorcycle stability and control. Repair or replace any damaged components before riding. Riding a motorcycle with faulty suspension increases your risk of an accident and possible injury. FRONT Check the action of the forks by operating the front brakes and compressing the front suspension several times.
  • Page 68 NSR150SP Maintenance ______________________________________________ WHEELS / TYRES Making sure the fork is not allowed to move, raise the front wheel and check for play. Turn the wheel and check that it rotates smoothly with no usual noises. If faults are found inspect the wheel bearings.
  • Page 69 NSR150SP Maintenance ______________________________________________ STEERING HEAD BEARINGS NOTE • Check that the control cables do not interfere with handlebar rotation. Support the motorcycle securely and raise the front wheel off ground check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings.
  • Page 70 NSR150SP Lubrication System ______________________________________________ http://mototh.com...

  • Page 71: Lubrication System

    LIMIT Engine oil capacity 0.76 litre (0.83 US qt, 0.67 Imp qt) Recommended engine oil Used Honda 2-stroke oil or equivalent Transmission oil capacity 0.7 litre (0.73 US qt, 0.62 Imp qt) 0.8 litre (0.85 US qt, 0.70 Imp qt)
  • Page 72 NSR150SP Lubrication System ______________________________________________ TROUBLESHOOTING Excessive smoke and/or carbon on spark plug • Faulty oil pump (too much oil flow) • Low quality engine oil Overheating or seized piston • No oil in tank or clogged oil line • Air in oil lines or oil pump •...
  • Page 73 NSR150SP Lubrication System ______________________________________________ ENGINE OIL ENGINE OIL DRAINING AND OIL TANK REMOVAL Remove the left side cover. (Page 2-6) Disconnect the oil level sensor connectors. Remove the bolts and oil tank. Remove the oil tank cap and drain the engine oil.
  • Page 74 OIL TANK CAPACITY. 0.76 litre (0.83 US qt, 0.67imp qt) RECOMMENDED ENGINE OIL: Honda 2-stroke oil or equivalent Make sure that there are no oil leaks. OIL PUMP CAUTION •...
  • Page 75 NSR150SP Lubrication System ______________________________________________ Clamp the oil tube and oil pass tube to prevent oil from flowing out. Loosen the lock nut and disconnect the oil control cable from the oil pump drum. Remove the right crank case cover. (Page 10-3) Remove the snap ring and washer.
  • Page 76 Check the oil pump drum for smooth operation. AIR BLEEDING / INSTALLATION OIL TUBE AND OIL PUMP BLEEDING Remove the seat. (Page 2-3) Remove the oil tank cap and fill the tank with the recommended engine oil. RECOMMENDED ENGINE OIL: Honda 2-stroke oil or equivalent http://mototh.com...
  • Page 77 NSR150SP Lubrication System ______________________________________________ Place the shop towel around the oil pump. Let oil drip from the oil tube to expel any air that may be in the tube, and then connect the oil tube to the pump inlet. Remove the oil pump shaft while holding the oil pump its install surface facing up.
  • Page 78 NSR150SP Lubrication System ______________________________________________ OIL PUMP INSTALLING Clean the oil pump mating surface of the right crankcase cover. Install the new 0-ring to the oil pump groove. Apply transmission oil to the new 0-ring and then, install the oil pump/O-ring to the right crankcase cover.
  • Page 79 NSR150SP Lubrication System ______________________________________________ OIL PASS TUBE BLEEDING Disconnect the oil pass tube from the carburettor. Bend the oil pass tube into a 'U' from with both the ends parallel, and fill the oil pass tube with clean engine oil.
  • Page 80 NSR150SP Lubrication System ______________________________________________ Connect the oil pump control cables to the oil pump drum. Adjust the oil pump control cables. (Page 3-6) Install the oil pump cover. Install and tighten the bolts securely. Install the right side cowl and lower cowl.
  • Page 81 NSR150SP Fuel System ________________________________________________ http://mototh.com...

  • Page 82: Fuel System

    NSR150SP Fuel System ______________________________________________ Service Information Carburettor Troubleshooting Air Screw Adjustment 5-12 Air Cleaner Housing Reed Valve, Air Chamber 5-13 Throttle Valve SERVICE INFORMATION GENERAL Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.
  • Page 83 NSR150SP Fuel System ______________________________________________ SPECIFICATIONS ITEM STANDARD Carburettor identification number PE 74A Choke type Starting enrichment circuit system Main jet # 152 Slow jet # 42 Air screw initial opening 2 turns out Float level 19 mm (0.7 in) Idle speed 1,300 + 100 min –1 (rpm)
  • Page 84 NSR150SP Fuel System ______________________________________________ TROUBLESHOOTING Rich mixture • Starting enrichment valve ON Engine won't start • No fuel in tank • Float valve faulty • No fuel to carburettor • Float level too high • Fuel strainer clogged • Air jets clogged •...
  • Page 85 NSR150SP Fuel System ______________________________________________ AIR CLEANER HOUSING Remove the fuel tank (page 2-12) Remove the screws and air cleaner housing. Loosen the screw and connecting tube band. Disconnect the drain tubes, and crankcase breather tubes. Installation is in the reverse order of removal.
  • Page 86 NSR150SP Fuel System ______________________________________________ Remove the retainer, spring and jet needle from the throttle valve. INSPECTION Check the jet needle for stepped wear or damage. Check the throttle valve for wear or damage. Replace these parts if necessary. INSTALLATION Install the jet needle and spring to the throttle valve.
  • Page 87 NSR150SP Fuel System ______________________________________________ Install the carburettor top and tighten it securely. Check the throttle valve for smooth operation. Check the throttle lever free play. (page 3-4) Install the air cleaner housing. Install the fuel tank. (page 2-14) CARBURETTOR REMOVAL Gasoline is extremely flammable and is explosive under certain conditions.
  • Page 88 NSR150SP Fuel System ______________________________________________ Remove the screws, float chamber and 0- ring. Remove the float pin, float. Remove the float valve. CAUTION • Handle all jets with care. • Keep clean, thy can easily be blocked.. Remove the main jet, needle jet holder, needle jet and slow jet.
  • Page 89 NSR150SP Fuel System ______________________________________________ Remove the throttle stop screw control knob, spring and washer. INSPECTION FLOAT VALVE AND VALVE SEAT Check the float valve and valve seat for scoring, scratches, clogging or damage. Check the tip of the float valve where it contacts the valve seat, for stepped wear or contamination.
  • Page 90 NSR150SP Fuel System ______________________________________________ Clean the fuel strainer in the float valve using compressed air from the float valve seat side. ASSEMBLY Install the spring, washer and throttle stop screw. http://mototh.com...
  • Page 91 NSR150SP Fuel System ______________________________________________ Install the needle jet, needle jet holder, main jet and slow jet. Install the spring and air screw. • NOTE Install the air screw and return it to its original position as noted during removal. Perform air screw adjustment if new air screw is installed.
  • Page 92 NSR150SP Fuel System ______________________________________________ Install the new 0-ring into the float chamber groove. Install the float chamber. Install and tighten the screw securely. Connect the drain tube and fuel tube to the carburettor. INSTALLATION NOTE Route the wires and tubes properly (page 1-18) Install the SE valve to the carburettor and tighten the SE valve nut securely.
  • Page 93 NSR150SP Fuel System ______________________________________________ Install the carburettor aligning its lug with the groove on the insulator. Bleed the air from the oil pass tube. Connect the oil pass tube and carburettor breather tube to the carburettor. Tighten the insulator band screw securely.
  • Page 94 NSR150SP Fuel System ______________________________________________ Adjust the idle speed with the throttle stop control knob. IDLE SPEED: 1,300 ± 100 (rpm) Rev the engine up slightly from the idle speed and make sure that engine speed rises smoothly. Adjust the air screw by turning it in or out a 1/4 of a turn.
  • Page 95 NSR150SP Fuel System ______________________________________________ INSPECTION Check the carburettor insulator for damage or deterioration. Replace it if necessary. Check the reed valve for fatigue or damage. Check the reed valve seat for cracks or damage. Replace it as an assembly if necessary.
  • Page 96 NSR150SP Fuel System ______________________________________________ Install the carburettor insulator to the crankcase. Install the air chamber bracket. Install and tighten the bolts securely. Install the air chamber. Install the tube band. Install and tighten the bolt securely. Install the carburettor. (page 5-11) 5-15 http://mototh.com...
  • Page 97 NSR150SP Cooling System ______________________________________________ http://mototh.com...

  • Page 98: Cooling System

    NSR150SP Cooling System ______________________________________________ Service Information Coolant Troubleshooting Radiator System Flow Pattern Water Pump System Testing Radiator Reserve Tank 6-14 SERVICE INFORMATION GENERAL Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding.

  • Page 99: Troubleshooting

    NSR150SP Cooling System ______________________________________________ TORQUE VALUES Water pump impeller 12 N.m (1.2 kgf.m, 9 lbf.ft) TOOLS Pressure pump Equivalent commercially available Attachment, 24 X 26 mm 07746-0010700 Pilot, 10 mm 07746-0040100 Driver 07749-0010000 Bearing remover set, 10 mm 07936-GE00000 - Remover shaft...

  • Page 100: System Flow Pattern

    NSR150SP Cooling System ______________________________________________ SYSTEM FLOW PATTERN http://mototh.com...

  • Page 101: System Testing

    NSR150SP Cooling System ______________________________________________ SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the seat. (page 2-3) Remove the radiator tank cap. Check the coolant gravity using a hydrometer. Standard Coolant Concentration: 50% Look for contamination and replace the coolant if necessary. Coolant temp...
  • Page 102 NSR150SP Cooling System ______________________________________________ RADIATOR CAP/SYSTEM PRESSURE INSPECTION • The engine must be cool before removing the radiator cap or sever scalding may result. Remove the right air guide. Remove the radiator cap. • NOTE Before installing the cap in the tester, wet the sealing surface.
  • Page 103 NSR150SP Cooling System ______________________________________________ COOLANT REPLACEMENT Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. If any coolant gets in your eyes, rinse them with water and consult a doctor immediately. If any coolant is swallowed, induce vomiting, rinse and consult a physician immediately.

  • Page 104: Radiator

    NSR150SP Cooling System ______________________________________________ Disconnect the reserve tank overflow tube. Place a suitable container under the reserve tank. Remove the reserve tank cap from the reserve tank and drain the reserve coolant. Empty the coolant and rinse the inside of the reserve tank with water.
  • Page 105 NSR150SP Cooling System ______________________________________________ RADIATOR REMOVAL/INSTALLATION Remove the side cowl and lower cowl (page 2-4.) Drain the coolant (page 6-6) Loosen the screw and hose band. Disconnect the lower radiator hose. Remove the bolts. Disconnect the radiator breather tube. Remove the tabs on the radiator from the grommets on the frame.
  • Page 106 NSR150SP Cooling System ______________________________________________ WATER PUMP MECHANICAL SEAL INSPECTION Remove the lower cowl (page 2-5) Inspect the telltale hole for signs of coolant leakage. If there is leakage, the mechanical seal is defective and must be replaced (page 6-1) REMOVAL Remove the side cowl and lower cowl.
  • Page 107 NSR150SP Cooling System ______________________________________________ Remove the water pump driven gear and drive pin. Hold the water pump shaft using the spanner. CAUTION • To prevent the water pump gear for damage, hold the water pump shaft securely. Remove the water pump impeller by turning it counterclockwise.
  • Page 108 NSR150SP Cooling System ______________________________________________ Remove the water pump bearing from the right crankcase cover. TOOLS: • Bearing remover set, 10 mm 07936-GE00000 • Remover shaft 07936-GE00100 • Remover head 07936-GE00200 • Sliding weight 07741-0010201 Remove the water pump mechanical seal from the right crankcase cover.
  • Page 109 NSR150SP Cooling System ______________________________________________ Check the tachometer drive gear for wear or damage. Install the tachometer drive gear, washers and new dust seal. INSTALLATION Check the water pump shaft for wear or damage. Install the water pump shaft to the right crankcase cover.
  • Page 110 NSR150SP Cooling System ______________________________________________ Install the snap ring. Install the oil pump (page 4-6 ) Install the right crankcase cover (page 10-23) Install the dowel pin and new gasket. Install the water pump cover and bolts. Tighten the bolts securely.
  • Page 111 NSR150SP Engine Removal/Installation ________________________________________________ http://mototh.com...

  • Page 112: Engine Removal/Installation

    NSR150SP Engine Removal/Installation ______________________________________________ Service Information Engine Installation Drive Sprocket Removal Drive Sprocket Installation Engine Removal SERVICE INFORMATION GENERAL • During removal and installation, support the motorcycle using a safety stand or hoist. • A floor jack or other adjustable support is required to support and manoeuvre the engine.
  • Page 113 NSR150SP Engine Removal/Installation ______________________________________________ DRIVE SPROCKET REMOVAL Loosen the bearing holder pinch bolt. Raise the rear wheel off the ground by placing a support under the engine. Turn the bearing holder with the pin spanner, slacken the drive chain fully.
  • Page 114 NSR150SP Engine Removal/Installation ______________________________________________ Remove the drive sprocket setting plate bolts. Align the drive sprocket setting plate teeth and countershaft teeth, then remove the drive sprocket setting plate. Remove the drive sprocket. ENGINE REMOVAL NOTE Support the motorcycle using safety stand or a hoist.
  • Page 115 NSR150SP Engine Removal/Installation ______________________________________________ Disconnect the alternator 3P connector, ignition pulse generator 2P connector and neutral switch connector. Disconnect the servo motor 6P connector. Remove the bolts and servo motor. Disconnect the clutch cable, oil tube, radiator lower hose and tachometer cable (page 10-3).
  • Page 116 NSR150SP Engine Removal/Installation ______________________________________________ ENGINE INSTALLATION CAUTION • Carefully align the mounting points with the jack to prevent damage to engine, frame, wires and cables. NOTE All the engine mounting bolts and nuts should be loosely install, then tighten the bolts and nuts to the specified torque.
  • Page 117 NSR150SP Engine Removal/Installation ______________________________________________ Install the servo motor. Install and tighten the bolts securely. Connect the servo motor 6P connector. Connect the clutch cable, oil tube, radiator lower hose and tachometer cable. Connect the alternator 3P connector, ignition pulse generator 2P connector and neutral switch connector.
  • Page 118 NSR150SP Engine Removal/Installation ______________________________________________ Install the drive sprocket setting plate onto the counter shaft and align the bolt holes on the plate with the holes of the sprocket. Install and tighten the new drive sprocket setting plate bolts to the specified torque.
  • Page 119 NSR150SP Engine Removal/Installation ______________________________________________ Install the gearshift pedal link to the gearshift pedal. Install and tighten the gearshift pedal link pinch bolt securely Specified torque. TORQUE: N.m (-kgf-m lbf-ft) Adjust the drive chain slack. http://mototh.com...
  • Page 120 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ http://mototh.com...

  • Page 121: Cylinder Head/Cylinder/Piston

    NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Service Information Cylinder/Piston Selection 8-10 Troubleshooting Cylinder/Piston 8-10 Cylinder Compression Installation 8-10 Cylinder Head Removal Cylinder Head 8-14 Cylinder/Piston Removal Installation 8-14 SERVICE INFORMATION GENERAL • The cylinder head, cylinder and piston can be serviced with the engine in the frame.

  • Page 122: Troubleshooting

    NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ TORQUE VALUES Spark plug 20 N.m (2.0 kgf.m, 14 lbf-ft) Cylinder head nut 23 N.m (2.3 kgf.m, 17 ]bf-ft) Cylinder nut 23 N.m (2.3 kgf.m, 17 lbf-ft) Cylinder stud bolt 10 N.m (1.0 kgf.m, 7 lbf-ft)

  • Page 123: Cylinder Compression

    NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Cylinder Compression If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. Warm up the engine to normal operating temperature. Stop the engine and...

  • Page 124: Cylinder Head Removal

    NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ CYLINDER HEAD REMOVAL REMOVAL Remove the side cowl (Page 2-4). Remove the fuel tank (Page 2-4). Drain the coolant (Page 2-4). Remove the spark plug cap and spark plug. Remove the thermo sensor. Loosen the band screw and disconnect the upper radiator hose.

  • Page 125: Cylinder/Piston Removal

    NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ INSPECTION Remove the carbon deposits from the combustion chamber and clean off the head gasket surface. Clean the head gasket surface off any gasket material. CAUTION • Avoid damaging the gasket surface. Check for cracks around the spark plug and stud bolt holes.
  • Page 126 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Loosen the screw and hose band. Disconnect the water hose. Remove the cylinder nuts. NOTE • Loosen the nuts in a crisscross pattern in several steps. Remove the cylinder. CAUTION • Be careful not to damage the mating surface when the removing the cylinder.
  • Page 127 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Spread each piston ring and remove it by lifting it up at a point just opposite the gap. CAUTION • Do not damage the piston ring by spreading the ends too far. He careful not to damage the piston during piston ring removal Remove the expander.
  • Page 128 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Inspect the cylinder wall for scratches and wear. Measure and record the cylinder I.D. at three levels in both the X and Y axis. The maximum reading determines the cylinder wear. SERVICE LIMITS: Code A: 59.02 mm (2.325 in)

  • Page 129: Cylinder/Piston Selection

    NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Measure the I.D. of the connecting rod small end. SERVICE LIMIT: 20.03 mm (0.789 in) If the connecting rod I.D. is over the service limit, the crankshaft must be replaced. CYLINDER/PISTON SELECTION Record the piston O.D. code letter (A, C or no mark).
  • Page 130 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Lubricate the piston rings and ring grooves with clean 2-stroke oil. Install the expander on the piston. Install the top and second piston rings on the piston with the marks facing up. NOTE • Do not confuse the top and second rings. Be sure to install them in the proper grooves.
  • Page 131 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Clean off any gasket material from the engine case surface (Page 8-5). NOTE • Place a shop towel over the crankcase opening to prevent the piston pin clip from failing into the crankcase. Apply 2-stroke oil to the needle bearing and connecting rod small end.
  • Page 132 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Recheck and align each piston ring and gap with the location pins on the piston. Install the RC valve (Page 9-5). Apply 2-stroke oil to the cylinder wall, piston outer surface and piston rings. CAUTION •...
  • Page 133 NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ Align the tab on the servo motor pulley with the 'Hi' mark on the servo motor. Connect the front RC valve control cable to the RC valve timing pulley by compressing the control cable spring.

  • Page 134: Cylinder Head

    NSR150SP Cylinder Head/Cylinder Piston ________________________________________________ CYLINDER HEAD INSTALLATION Install the new gasket with the 'EX UP' mark facing the exhaust side and up. Install the cylinder head. Install and tighten the cylinder head nuts to the specified torque. NOTE •...
  • Page 135 NSR150SP RC Valve/Servo Motor ________________________________________________ http://mototh.com...

  • Page 136: Rc Valve/Servo Motor

    NSR150SP RC Valve/Servo Motor ________________________________________________ Service Information RC Valve Troubleshooting Servo Motor RC Valve Control Cable Adjustment SERVICE INFORMATION GENERAL • The RC valve and servo motor can be serviced with the engine in the frame. • Take care not to damage the cylinder wall and piston.
  • Page 137 NSR150SP RC Valve/Servo Motor ________________________________________________ TROUBLESHOOTING Engine starts, but RC valve does not operate Abnormal • RC valve control cable Check the RC valve control cable adjustment misadjusted • Sticking the RC valve control cable Normal Disconnect the RC valve control cable from Not smooth •...
  • Page 138 NSR150SP RC Valve/Servo Motor ________________________________________________ RC VALVE CONTROL CABLE ADJUSTMENT Remove the side cowl. Start the engine and let it idle. Check that the gap between the notch on the RC valve timing pulley and 'H' mark on the cylinder is within 0.3 mm (0.01 in).
  • Page 139 NSR150SP RC Valve/Servo Motor ________________________________________________ Remove the nut, washer, special washers and RC valve timing pulley. NOTE • The timing pulley nut has a left hand threads. Remove the dust seal. Remove the RC valve shaft and RC valves from the cylinder.
  • Page 140 NSR150SP RC Valve/Servo Motor ________________________________________________ INSPECTION Remove the carbon deposits from the RC valves, shaft and shaft sliding area in the cylinder. CAUTION • Be careful not to damage the RC valve and shaft. NOTE • If there is carbon on the RC valves and shaft, RC valve will not operate properly.
  • Page 141 NSR150SP RC Valve/Servo Motor ________________________________________________ Install the E-clip to the RC valve shaft. Apply 2-stroke engine oil to the RC valves and shaft. Install the RC valves to the cylinder. NOTE • At installation, align the punch marks as shown.
  • Page 142 NSR150SP RC Valve/Servo Motor ________________________________________________ Install the special washer to the RC valve shaft aligning the cut outs on the shaft and washer. Install the RC valve timing pulley to the RC valve shaft aligning the cut outs on the shaft and washer.
  • Page 143 NSR150SP RC Valve/Servo Motor ________________________________________________ SERVO MOTOR INSPECTION Remove the side cowl. Remove the air cleaner housing. Check the RC valve control cable for adjustment and sticking. Disconnect the RC valve control cable from the timing pulley and check the RC valve for smooth operation by turning the timing pulley using your hand.

  • Page 144: Installation

    NSR150SP RC Valve/Servo Motor ________________________________________________ Measure the resistance between the servo motor 6P connector terminals of the servo motor side. CONNECTION: Red/White - Light Green STANDARD: 0 - 6 k! CONNECTION: Green/Blue - Light Green STANDARD: 0-6k! If the resistance is ∞, turn the motor pully by your hand and measure the resistance again.
  • Page 145 NSR150SP RC Valve/Servo Motor ________________________________________________ Align the tab on the servo motor pulley with the 'Hi' mark on the servo motor. Connect the front RC valve control cable to the RC valve timing pulley by compressing the control cable spring.

  • Page 146: Clutch/Gearshift Linkage/Kickstarter

    NSR150SP Clutch/Gearshift Linkage/Kickstarter ______________________________________________ 10-0 http://mototh.com...

  • Page 147: Service Information

    NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Service Information 10-1 Kickstarter 10-11 Troubleshooting 10-2 Gearshift linkage 10-17 Right Crankcase Cover 10-2 Clutch Installation 10-21 Removal 10-3 Right Crankcase Cover Clutch Removal 10-6 Installation 10-23 Primary Drive Gear 10-9 SERVICE INFORMATION GENERAL • The clutch, gearshift linkage and kickstarter maintenance can be done with the engine in the frame.
  • Page 148 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ TORQUE VALUES Right crankcase cover bolt, (16 mm) 10 N.m (1.0 kgf.m, 7 lbf.ft) Right crankcase cover bolt, (8 mm) 26 N.m (2.7 kgf.m, 20 lbf.ft) Clutch cable adjuster lock nut 23 N.m (2.7 kgf.m, 20 lbf ft) Primary drive gear nut 66 N.m (6.7 kgf m, 48 lbf.ft)

  • Page 149: Troubleshooting

    NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ TROUBLESHOOTING Clutch lever too hard • Damaged, kinked or dirty clutch cable • Faulty clutch lifter plate bearing • Damaged clutch lifter mechanism • Improperly routed clutch cable Clutch will not disengage or motorcycle creeps with clutch disengaged •...

  • Page 150: Right Crankcase Cover

    NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ RIGHT CRANKCASE COVER REMOVAL Remove the side cowl and lower cowl. Remove the oil pump cover. Disconnect the oil tube and oil pass tube. Disconnect the oil control cable from the oil pump drum. Drain the transmission oil.
  • Page 151 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Remove the bolts and right crankcase cover. Remove the gasket and dowel pins. Clean off any gasket material from the right crankcase cover mating surface. CAUTION • Be careful not to damage the right crankcase cover mating surface.

  • Page 152: Clutch Removal

    NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ DISASSEMBLY Remove the oil pump. Remove the water pump shaft. Remove the tachometer drive gear. Remove the clutch lifter piece by turning the clutch lifter arm clockwise. Remove the clutch lifter arm and spring. INSPECTION Check the dust seal fatigue or damage or deterioration.
  • Page 153 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Hold the pressure plate with theclutch centre holder loosen the clutch centre lock nut. TOOLS: Wrench, 20 X 24 mm 07716-0020100 Extension bar 07716-0020500 Clutch centre holder 07923-KE10000 Remove the clutch centre lock nut and...
  • Page 154 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ INSPECTION LIFTER PLATE BEARING Check the lifter plate bearing for damage. Turn the bearing inner race with your finger. The bearing should turn smoothly and quietly without play. Also check that the bearing outer race fits in the plate.
  • Page 155 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ CLUTCH CENTER Cheek the clutch centre for nicks, indentations or abnormal wear made by the clutch plates. CLUTCH OUTER, CLUTCH OUTER GUIDE Check the clutch outer for nicks, indentations or abnormal wear made by the clutch discs.

  • Page 156: Primary Drive Gear

    NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ PRIMARY DRIVE GEAR REMOVAL Remove the clutch. Hold the primary drive gear with the gear holder and remove the primary drive gear nut and washer. TOOL: Gear holder 07724-0010100 Remove the primary drive gear, balancer drive gear and woodruff key from the crankshaft.

  • Page 157: Kickstarter

    NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the primary drive gear to the crankshaft aligning the cut out on the primary drive gear with the woodruff key and aligning the punch marks on the balancer drive gear and driven gear. Install the balancer drive gear to the...
  • Page 158 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ KICKSTARTER REMOVAL Remove the gear shift spindle. Unhook the kickstarter return spring from the hole on the crankcase. Remove the stopper plate bolt (10 mm). Remove the stopper plate bolt (8 mm) and stopper plate.
  • Page 159 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ DISASSEMBLY Remove the washer and pinion gear from the kickstarter spindle. Remove the rachet and rachet spring from the kickstarter spindle. Remove the spring retainer from the kickstarter spindle. Remove the return spring from the kickstarter spindle.
  • Page 160 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ INSPECTION KICKSTARTER Check the rachet spring and return spring for wear or damage. Check the teeth of the rachet and pinion gear for wear or damage. Measure the pinion gear I.D.. SERVICE LIMIT: ????? mm ( in) Check the spindle on the kickstarter spindle for wear or damage.
  • Page 161 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ COUNTERSHAFT Measure the countershaft O.D. at the kickstarter idle gear collar. SERVICE LIMIT: 16.96mm ( in) Install the washer and return to the kickstarter spindle. 10-15 http://mototh.com...
  • Page 162 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the return spring, aligning the spring end to the hole on the kickstarter spindle. Install the retainer, aligning the cut out in the retainer with the spring end. Install the washer. Install the rachet spring to the kickstarter spindle.

  • Page 163: Gearshift Linkage

    NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the kickstarter assembly. Install the dowel pin and stopper plate. Install and tighten the stopper plate bolts (8 mm and 10 mm) securely. Hook the return spring end to the crankcase. Install the gear shift spindle.
  • Page 164 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Remove the gearshift spindle from the crankcase. Remove the shifter collar from the guide plate. Remove the bolts. Remove the guide plate and drum shifter as an assembly. NOTE • Do not let the rachet pawls fall when removing the guide plate and drum shifter.
  • Page 165 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Remove the dowel pin. Remove the bolt, shift drum stopper arm and return spring. INSPECTION Check the gearshift spindle for wear or damage. Check the return spring for fatigue or damage. Check the each parts for wear or damage.
  • Page 166 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the return spring and shift drum stopper arm. Install and tighten the shift drum stopper arm bolt to the specified torque. TORQUE: 12 N. m (1.2 kgf.m, 9 lbf ft) Check the stopper arm for proper operation.

  • Page 167: Clutch Installation

    NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the collar to the guide plate. Install the gearshift spindle to the crankcase while aligning the spindle return spring ends with the shift return spring pin. Install the gearshift pedal link to the gearshift pedal.
  • Page 168 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Install the spring seat and judder spring on the clutch centre as shown. Coat the clutch discs and clutch plates with clean engine oil. Install the five clutch discs and four clutch plates alternately, starting with a clutch disc.

  • Page 169: Right Crankcase Cover Installation

    NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Apply transmission oil to the new clutch centre lock nut threads and flange surface. Install the washer and new clutch centre lock nut. Hold the pressure plate with the clutch centre holder. Tighten the clutch centre lock nut to the specified torque.
  • Page 170 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Align the clutch lifter arm slit and hole on the right crankcase cover by turning the clutch lifter arm clockwise. Apply grease to the clutch lifter piece. Install the clutch lifter piece. Install the water pump shaft.
  • Page 171 NSR150SP Clutch/Gearshift Linkage /Kickstarter _______________________________________________ Connect the lower water hose. Tighten the screw and hose band securely. Install the kickstarter and bolt. Tighten the bolt securely. Install the tachometer cable to the right crankcase. Install and tighten the bolt securely.
  • Page 172 NSR150SP Alternator/Balancer ______________________________________________ 11-0 http://mototh.com...

  • Page 173: Alternator/Balancer

    NSR150SP Alternator/Balancer ______________________________________________ Service Information 11-1 Balancer Removal 11-4 Troubleshooting 11-1 Balancer Installation 11-5 Stator Removal 11-2 Flywheel Installation 11-6 Flywheel Removal 11-3 Stator Installation 11-7 SERVICE INFORMATION GENERAL The alternator and balancer maintenance can be done with the engine in the frame.

  • Page 174: Stator Removal

    NSR150SP Alternator/Balancer ______________________________________________ STATOR REMOVAL NOTE Refer to page 10 for alternator (charging coil) inspection. Remove the drive sprocket cover. Remove the fuel tank Disconnect the alternator 3P connector and ignition pulse generator 2P connector. Remove the left crankcase cover bolts and left crankcase cover.

  • Page 175: Flywheel Removal

    NSR150SP Alternator/Balancer ______________________________________________ Remove the socket bolts and ignition pulse generator. Remove the bolts and stator. FLYWHEEL REMOVAL Remove the left crankcase cover. Remove the flywheel nut and washer while holding the flywheel with a flywheel holder. TOOL: Flywheel holder...

  • Page 176: Balancer Removal

    NSR150SP Alternator/Balancer ______________________________________________ BALANCER REMOVAL REMOVAL Remove the clutch. Remove the flywheel. Remove the set plate. Hold the balancer drive gear with the gear holder and remove the balancer drive gear nut and washer. TOOLS: Gear holder 07724-0010100 Wrench 20 X 24 mm...

  • Page 177: Balancer Installation

    NSR150SP Alternator/Balancer ______________________________________________ Check the balancer for bend, wear or damage. Replace the balancer driven if necessary. BALANCER INSTALLATION Apply transmission oil to the balancer sliding surfaces. Install the balancer to the left crankcase. Install the woodruff key to the groove on the balancer.

  • Page 178: Flywheel Installation

    NSR150SP Alternator/Balancer ______________________________________________ Hold the balancer drive gear with the gear holder and remove the balancer drive gear nut and washer. TOOL Gear holder 07724-0010100 Wrench 07716-0020100 Tighten the balancer drive gear nut to the specified torque. TORQUE: 54 N.m (5.5 kgf.m 40 lbf-ft) Install the flywheel (see below).

  • Page 179: Stator Installation

    NSR150SP Alternator/Balancer ______________________________________________ STATOR INSTALLATION Install the stator to the left crankcase cover. Install and tighten the stator bolts securely. Install the ignition pulse generator to the left crankcase cover. Clean and apply a locking agent to the ignition pulse generator socket bolt threads.
  • Page 180 NSR150SP Alternator/Balancer ______________________________________________ Clean and apply sealant to the wire grommets seating surface and install the grommets into the grooves in the left crankcase cover. Install the dowel pins and new gasket. Install the left crankcase cover. NOTE • The left crankcase cover (stator) is magnetically attached to the flywheel, be careful to installation.
  • Page 181 NSR150SP Crankshaft/Transmission ________________________________________________ 12-0 http://mototh.com...
  • Page 182 NSR150SP Crankshaft/Transmission ________________________________________________ Service Information 12-1 Crankshaft 12-10 Troubleshooting 12-3 Crankcase Bearing Crankcase Separation 12-4 Replacement 12-11 Transmission 12-4 Crankcase Assembly 12-16 SERVICE INFORMATION GENERAL • The crankcase halves must be separated to service the crankshaft, connecting rod and transmission (including the shift fork and shift drum). To service these parts, the engine must be removed from the engine (Section 7).
  • Page 183 NSR150SP Crankshaft/Transmission ________________________________________________ Unit: mm (in) ITEM STANDARD SERVICE LIMIT Gear-to-bushing M5, M6 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004) clearance 0.025 - 0.057 (0.0010 - 0.0022) 0.10 (0.004) 0.0 15 - 0.057 (0.0006 - 0.0022) 0.10 (0.004) 0.027 - 0.057 (0.0011 - 0.0022) 0.10 (0.004)
  • Page 184 NSR150SP Crankshaft/Transmission ________________________________________________ TROUBLESHOOTING Excessive noise • Worn connecting rod big end bearing • Bent connecting rod • Worn crankshaft main bearing • Worn transmission gear Hard to shift • Improper clutch adjustment • Improper clutch operation • Bent shift fork •...
  • Page 185 NSR150SP Crankshaft/Transmission ________________________________________________ CRANKCASE SEPARATION Remove the engine from the frame (Section 7). Refer to Service Information (page 12-1) for removal of necessary parts before disassembling the crankcase. Remove the crankcase bolts. NOTE • Loosen the left crankcase bolts in a crisscross pattern in several steps.
  • Page 186 NSR150SP Crankshaft/Transmission ________________________________________________ Remove the main shaft and countershaft from the right crankcase. NOTE • Do not forget to install the transmission end washer. DISASSEMBLY NOTE • Keep track of the disassembled parts (gears, bushings, washers and snap rings) by staking them on a toot or slipping them onto a piece of wire.
  • Page 187 NSR150SP Crankshaft/Transmission ________________________________________________ MAINSHAFT / COUNTERSHAFT Check the spline grooves and sliding surfaces for damage or abnormal wear. Measure the O.D. of the mainshaft and countershaft at the gear and bushing sliding areas. SERVICE LIMITS: Mainshaft: M5 gear bushing: > mm in)
  • Page 188 NSR150SP Crankshaft/Transmission ________________________________________________ Check the shift fork shaft for abnormal wear, damage or straightens. Measure the shift fork O.D. SERVICE LIMIT: 11.995 mm( in) SHIFT DRUM JOURNAL, SHIFT FORK JOURNAL Check the left and right crankcase shift fork journal for wear or damage.
  • Page 189 NSR150SP Crankshaft/Transmission ________________________________________________ MAINSHAFT COUNTERSHAFT 12-8 http://mototh.com...
  • Page 190 NSR150SP Crankshaft/Transmission ________________________________________________ INSTALLATION Apply transmission oil to the following parts. • Mainshaft • Countershaft • Each gear • Mainshaft bearing • Countershaft bearing • Shift drum bearing Install the mainshaft and countershaft to the left crankcase as an assembly.
  • Page 191 NSR150SP Crankshaft/Transmission ________________________________________________ Install the shift drum aligning the guide pins on the shift fork with the guide grooves of the shift drum. Apply transmission oil to the shift fork shaft. Install the shift fork shaft to the right crankcase.
  • Page 192 NSR150SP Crankshaft/Transmission ________________________________________________ INSPECTION Place the crankshaft on a stand or V-brocks. Set the indicator on the crankshaft as shown. Rotate the crankshaft two revolutions and read the runout. SERVICE LIMITS: 0.05 mm (0.002 in) 0.03 mm (0.001 in) Measure the side clearance between the connecting rod big end and crank weight using a feeler gauge.
  • Page 193 NSR150SP Crankshaft/Transmission ________________________________________________ LEFT CRANKCASE BEARING REPLACEMENT Remove the crankshaft oil seal, balancer oil seal, gearshift spindle oil seal and countershaft oil seal. Remove the balancer bearing and countershaft bearing out of the left crankcase. Remove the mainshaft bearing out of the left crankcase using special tools.
  • Page 194 NSR150SP Crankshaft/Transmission ________________________________________________ MAINSHAFT BEARING Apply transmission oil to the new bearing. Install the new bearing to the left crankcase using the following special tools. TOOLS: Driver 07749-0010000 Attachment, 42 X 47 mm 07746-0010300 NOTE • Drive in the new bearings squarely with the marking side facing up.
  • Page 195 NSR150SP Crankshaft/Transmission ________________________________________________ Install the new balancer oil seal, gearshift spindle oil seal and countershaft oil seal. RIGHT CRANKCASE BEARING REPLACEMENT Remove the crankshaft oil seal. Remove the bolts, shift drum bearing set plate and mainshaft bearing set plate. Remove the bolts, balancer shaft bearing set plate.
  • Page 196 NSR150SP Crankshaft/Transmission ________________________________________________ Remove the balancer bearing, mainshaft bearing countershaft bearing, shift drum bearing and crankshaft bearing out of the right crankcase. Mainshaft Bearing Install the new bearing to the right crankcase using the following tools. TOOLS: Driver 07749-0010000 Attachment, 42 x 47mm...
  • Page 197 NSR150SP Crankshaft/Transmission ________________________________________________ SHIFT DRUM BEARING Install the new bearing to the right crankcase using the following special tools. TOOLS: Driver 07749-0010000 Attachment, 42 X 47 mm 07746-0010300 Pilot, 25 mm 07746-0040600 NOTE • Drive in the new bearing squarely with the marking side facing up.
  • Page 198 NSR150SP Crankshaft/Transmission ________________________________________________ Install the new crankshaft oil seal (page 12-18). CRANKCASE ASSEMBLY Clean both crankcase mating surfaces before assembling and check for wear or damage. NOTE If there is minor roughness or irregularities on the crankcase mating surfaces, dress them with an oil stone.
  • Page 199 NSR150SP Crankshaft/Transmission ________________________________________________ Pack grease into the cavity between the left crankshaft oil seal lips. Press the left crankshaft oil seal into the left crankcase using the crank case assembly tool. TOOLS: Crank assembly collar 07964-MB00200 Crank assembly shaft 07965-VMOO200 •...
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  • Page 211: Front Wheel/Suspension/Steering

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  • Page 235: Rear Wheel/Suspension

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  • Page 266: Battery/Charging System

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  • Page 273: Ignition System

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  • Page 282 To print chapters, click on the printer icon and fill in the page range. General Information 5 - 26 Frame/Body panels/Exhaust system 27 - 42 Maintenance 43 - 69 Lubrication system 70 - 80 Fuel system 81 - 96 Cooling system 97 - 110 Engine removal/Installation 111 - 119...
  • Page 283 NSR150SP Spark Plug Application – Additional Information to SBMC0311 Ladies and Gentlemen, Please be advised that when servicing the NSR150SP, it is important to use the correct spark plug. The current specification is incorrect and in some cases may lead to severe engine damage.
  • Page 284 Oil Pump: The oil pump must be bled and the oil pump control cable should be adjusted correctly as per the service manual. Engine Oil: When filling the engine oil, please ensure only Honda 2-stroke oil or equivalent premium grade oil.
  • Page 285 GREG SNART National Motorcycle Service Manager PLEASE ENSURE ALL RELEVANT STAFF ARE AWARE OF THIS BULLETIN AND its CONTENTS. Service Manager Parts Manager Sales Manager Franchise Principle http://mototh.com...
  • Page 286 HONDA MPE MOTORCYCLE & POWER EQUIPMENT ACN.006 662 862 Service Bulletin Service Bulletin No: SBMC0311 All Motorcycle Franchises From Motorcycle Service Department Date: September 2003 Attention: Franchisee, Service Manager, Sales Manager and Relevant Staff Subject: NSR 150 Spark Plug Application...
  • Page 287 Important Service Tip Ladies and Gentlemen, Please be advised that when pre-delivering or servicing the NSR150SP make sure the correct amount of oil is placed in the gearbox. The most accurate way in doing this on pre-delivery inspection, is to DRAIN out ALL of the gearbox oil, and measure the specified amount (700mls) of good quality 10w-40 4 stroke engine oil, as recommended in the service manual.

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