Download

Table Of Contents - Honda Elite CH 150 H Service Manual

Table Of Contents

Table of Contents

Advertisement

Table of Contents

General Information2

General Safety2

Model Identification3

Frame Serial Number3

Carburetor Identification Number3

Engine Serial Number3

Specifications4

Cable & Harness Routing8

Emission Control Systems13

Source Of Emissions13

Exhaust Emission Control System13

Crankcase Emission Control System13

Evaporative Emission Control System14

Noise Emission Control System14

Emission Control Information Label15

Emission Control Information Update Label15

Vacuum Hose Routing Diagram Label15

Lubrication Service Information17

Lubrication Troubleshooting17

Lubrication Specifications17

Lubrication Torque Values17

Engine Oil Level18

Engine Oil Change18

Engine Oil Filter Screen Cleaning18

Oil Pump Removal18

Oil Pump Disassembly19

Oil Pump Inspection19

Oil Pump Assembly20

Oil Pump Installation21

Transmission Oil Level Check22

Transmission Oil Change22

Lubrication Points23

Control Cables23

Maintenance Service Information24

Maintenance Specifications24

Maintenance Schedules25

Throttle Operation27

Crankcase Breather28

Recommended Spark Plugs28

Spark Plug Gap28

Valve Clearance29

Radiator Coolant30

Radiator Core30

Cooling System Hoses & Connections30

Carburetor - Idle Speed30

Evaporative Emission Control System (California Model Only)31

Ignition Timing31

Cylinder Compression32

Drive Belt Air Cleaner32

Brake Shoe Wear33

Brake Lock Lever34

Brake Lock Cable Adjustment34

Brake Light Switch/Starter Limiter Switch35

Headlight Aim35

Clutch Shoe Wear35

Front Suspension36

Rear Suspension36

Nut, Bolt, Fastener37

Steering Head Bearing37

Recommended Tires And Air Pressures37

Fuel System Service Information39

Fuel System Specifications39

Fuel System Torque Value39

Fuel System Tool39

Fuel System Troubleshooting40

Air Cut-Off Valve Inspection41

Air Cut-Off Valve Removal41

Air Cut-Off Valve Installation41

Auto Bystarter Inspection41

Auto Bystarter Removal42

Auto Bystarter Valve Inspection42

Auto Bystarter Installation42

Carburetor Removal43

Vacuum Chamber Disassembly43

Vacuum Chamber Assembly44

Pilot Screw Removal45

Pilot Screw Installation46

Float/Float Valve/Jets Disassembly46

Float/Float Valve/Jets Assembly48

Float Level Inspection48

Carburetor Installation49

Pilot Screw Adjustment49

Idle Drop Procedure (U.s.a. Only)49

High Altitude Adjustment (U.s.a. Only)50

Automatic Fuel Valve Inspection51

Fuel Strainer Cleaning51

Fuel Unit Removal52

Fuel Unit Installation52

Fuel Tank Removal52

Fuel Tank Installation53

Purge Control Valve Inspection (California Model)56

Engine Removal/Installation Service Information59

Engine Removal/Installation Specifications59

Engine Removal/Installation Torque Values59

Engine Removal/Installation Tool59

Engine Removal60

Engine Hanger Bracket Removal63

Engine Hanger Bracket Installation63

Engine Installation64

Cylinder Head/Valves Service Information66

Cylinder Head/Valves Specifications66

Cylinder Head/Valves Torque Values66

Cylinder Head/Valves Troubleshooting67

Cylinder Head/Valves Tools67

Cylinder Head Cover Removal68

Cylinder Head Cover Disassembly69

Camshaft Removal69

Rocker Arm Inspection69

Rocker Arm Shaft Inspection69

Camshaft Inspection70

Cylinder Head Removal71

Cylinder Head Disassembly72

Cylinder Head Inspection73

Valve Spring Free Length Inspection73

Valve Stem Inspection73

Valve Guide Inspection73

Valve Guide Replacement74

Valve Seat Inspection And Refacing75

Valve Seat Grinding75

Cylinder Head Assembly77

Cylinder Head Installation78

Camshaft Installation79

Cylinder Head Cover Assembly80

Cylinder Head Cover Installation80

Cylinder/Piston Service Information83

Cylinder/Piston Troubleshooting83

Cylinder/Piston Specifications83

Cylinder/Piston Torque83

Cylinder Removal84

Cylinder Inspection84

Piston Removal85

Piston Inspection85

Piston Ring Installation87

Piston Installation88

Cylinder Installation88

Drive Pulley/Clutch/Driven Pulley Service Information90

Drive Pulley/Clutch/Driven Pulley Specifications90

Drive Pulley/Clutch/Driven Pulley Torque Values90

Drive Pulley/Clutch/Driven Pulley Tools90

Drive Pulley/Clutch/Driven Pulley Troubleshooting91

Left Crankcase Cover Removal92

Left Crankcase Cover Installation92

Drive Pulley Removal92

Drive Pulley Inspection93

Drive Pulley Disassembly93

Drive Pulley Assembly95

Drive Pulley Installation96

Clutch/Driven Pulley Removal97

Clutch/Driven Pulley Inspection98

Clutch/Driven Pulley Disassembly98

Driven Pulley Face Bearing Replacement100

Clutch Disassembly101

Clutch Assembly103

Clutch Installation104

Final Reduction Service Information106

Final Reduction Troubleshooting106

Final Reduction Specifications106

Final Reduction Tools106

Final Reduction Disassembly107

Final Reduction Inspection107

Final Reduction Bearing Replacement108

Final Reduction Assembly110

Alternator/Starter Clutch Service Information113

Alternator/Starter Clutch Specifications113

Alternator/Starter Clutch Torque Values113

Alternator/Starter Clutch Tools113

Right Crankcase Cover Removal114

Stator Removal114

Flywheel Removal114

Starter Clutch Removal115

Starter Clutch Inspection116

Starter Clutch Disassembly116

Starter Clutch Assembly117

Starter Clutch Installation117

Flywheel Installation118

Stator Installation118

Right Crankcase Cover Installation118

Crankcase/Crankshaft Service Information121

Crankcase/Crankshaft Troubleshooting121

Crankcase/Crankshaft Specifications121

Crankcase/Crankshaft Torque Value121

Crankcase Separation122

Crankshaft Inspection124

Crankcase Assembly125

Cooling System Service Information128

Cooling System Troubleshooting128

Cooling System Specifications128

Cooling System Tools128

System Testing129

Coolant Replacement129

Radiator Cap Inspection129

Radiator Removal130

Radiator Disassembly131

Radiator Bracket Removal/Installation132

Radiator Assembly132

Radiator Installation132

Mechanical Seal Inspection133

Water Pump Removal133

Water Pump Shaft Removal134

Mechanical Seal Replacement134

Water Pump Impeller Installation136

Thermosensor Removal137

Thermosensor Installation137

Thermostat Removal137

Thermostat Inspection138

Thermostat Installation138

Frame Covers Service Information140

Left/Right Rear Cover Removal141

Left/Right Rear Cover Installation141

Frame Center Cover Removal141

Frame Center Cover Installation141

Front Cover Removal142

Front Cover Installation142

Radiator Grille Removal143

Radiator Grille Installation144

Floorboard Removal144

Floorboard Installation144

Side Rail Removal144

Steering/Front Wheel/Brake/Suspension Service Information147

Steering/Front Wheel/Brake/Suspension Specifications147

Steering/Front Wheel/Brake/Suspension Torque Values147

Steering/Front Wheel/Brake/Suspension Tools147

Steering/Front Wheel/Brake/Suspension Troubleshooting148

Handlebar Removal149

Handlebar Installation150

Front Wheel Removal152

Front Wheel Inspection152

Front Wheel Disassembly153

Front Wheel Assembly154

Front Wheel Installation154

Front Brake Inspection155

Brake Panel Disassembly156

Brake Panel Assembly157

Pivot Arm Removal158

Pivot Arm Inspection159

Pivot Arm Installation159

Front Shock Absorber Removal159

Front Shock Absorber Disassembly159

Shock Absorber Spring Inspection160

Front Shock Absorber Assembly160

Front Fork Removal161

Bottom Cone Race Replacement162

Ball Race Inspection162

Ball Race Replacement162

Front Fork Installation163

Rear Wheel/Brake/Suspension Service Information166

Rear Wheel/Brake/Suspension Troubleshooting166

Rear Wheel/Brake/Suspension Specifications166

Rear Wheel/Brake/Suspension Tools166

Exhaust Muffler Removal167

Exhaust Muffler Installation167

Rear Wheel Inspection168

Rear Wheel Bearing Replacement168

Rear Wheel Disassembly169

Rear Wheel Installation169

Rear Brake Inspection170

Rear Brake Disassembly171

Rear Brake Assembly171

Rear Brake Pedal/Brake Lock System172

Brake Lock Cable Removal172

Brake Cable/Pedal Removal173

Brake Lock Cable Installation173

Rear Shock Absorber Removal174

Rear Shock Absorber Disassembly174

Rear Shock Absorber Inspection174

Rear Shock Absorber Assembly175

Rear Shock Absorber Installation176

Electrical Equipment Service Information178

Electrical Equipment Specifications178

Electrical Equipment Troubleshooting179

Electrical Equipment Torque Values179

Battery Removal/Installation181

Battery Specific Gravity Test181

Battery Charging182

Charging System Charging Circuit182

Charging System Current Test183

Charging System Alternator Output Test183

Charging System Alternator Inspection183

Charging System Regulator/Rectifier Inspection184

Ignition System Circuit184

Ignition Coil Inspection185

Ignition Coil Replacement185

Exciter Coil Inspection185

Cdi Unit Inspection185

Pulse Generator Inspection186

Starting Circuit187

Starter Relay Inspection187

Starter Motor Removal188

Starter Motor Disassembly188

Starter Motor Inspection188

Starter Motor Assembly189

Starter Motor Installation190

Instruments Removal190

Instruments Disassembly192

Instruments Assembly/Installation192

Headlight Bulb Replacement192

Headlight Removal193

Front Turn Signal Light193

Rear Turn Signal Light193

Taillight Bulb Replacement194

Ignition Switch Inspection194

Ignition Switch Replacement194

Rear Brake Switch195

Handlebar Switches195

Front Brake Switch195

Engine Stop Switch195

Thermostatic Switch197

Thermosensor197

Temperature Gauge198

Retractable Headlight (Ch150D)199

Manual Headlight Opening Procedure199

Bulb Replacement199

Headlight Motor Removal200

Headlight Motor Final Gear Replacement201

Headlight Motor Installation201

Limit Switch Inspection203

Headlight Relay Inspection204

Timer Unit Inspection204

Headlight Motor Inspection204

Wiring Diagram205

After '85 Ch150D210

After '85 Ch150 Canada211

Troubleshooting213

Engine Does Not Start Or Is Hard To Start213

Engine Lacks Power214

Poor Performance At Low And Idle Speeds215

Poor Performance At High Speed215

Engine Noise216

Clutch, Drive And Driven Pulleys216

Poor Suspension Performance217

Poor Brake Performance217

Fuel Gauge Troubleshooting218

Pointer Does Not Register Correctly (Ignition Switch On)218

Pointer Fluctuates Or Swings (Ignition Switch On)218

Starter Motor Will Not Turn219

Starter Motor Turns Slowly219

Starter Motor Won't Stop Turning219

Technical Features220

Retractable Headlight (Ch150D) Construction And Operation220

Retracted Position To Lighting Position221

Lighting Position To Retracted Position221

Advertisement

Table of Contents

Troubleshooting