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The vehicle pictured in this owner’s manual may not match your actual
vehicle.
Welcome
Congratulations on your purchase of a new ● The following code in this manual indicates
Honda motorcycle. Your selection of a Honda the country.
makes you part of a worldwide family of
satisfied customers who appreciate Honda’s Country Codes
reputation for building quality into every Code Country
product. GL150
PH Philippines
To ensure your safety and riding pleasure:
● Read this owner’s manual carefully.
● Follow all recommendations and
procedures contained in this manual.
● Pay close attention to safety messages
contained in this manual and on the
motorcycle.
18 GL150 (PH)-32KYAD200.book Page 3 Monday, September 11, 2017 5:38 PM
Contents
Motorcycle Safety P. 2
Operation Guide P. 12
Maintenance P. 27
Troubleshooting P. 72
Information P. 87
Specifications P. 98
Index P. 101
18 GL150 (PH)-32KYAD200.book Page 2 Monday, September 11, 2017 5:38 PM
Motorcycle Safety
This section contains important information for safe riding of your motorcycle.
Please read this section carefully.
Safety Guidelines
Safety Guidelines that you and your passenger are both wearing
an approved motorcycle helmet and protective
Motorcycle Safety
Follow these guidelines to enhance your safety: apparel. Instruct your passenger on holding onto
● Perform all routine and regular inspections the grab rail or your waist, leaning with you in
specified in this manual. turns, and keeping their feet on the footpegs,
● Stop the engine and keep sparks and flame even when the motorcycle is stopped.
away before filling the fuel tank.
● Do not run the engine in enclosed or partly
enclosed areas. Carbon monoxide in exhaust Take Time to Learn & Practice
gases is toxic and can kill you. Even if you have ridden other motorcycles,
practice riding in a safe area to become familiar
with how this motorcycle works and handles, and
Always Wear a Helmet to become accustomed to the motorcycle’s size
It’s a proven fact: helmets and protective apparel and weight.
significantly reduce the number and severity of
head and other injuries. So always wear an
approved motorcycle helmet and protective Ride Defensively
apparel. 2 P. 6 Always pay attention to other vehicles around
you, and do not assume that other drivers see
you. Be prepared to stop quickly or perform an
Before Riding evasive maneuver.
Make sure that you are physically fit, mentally
focused and free of alcohol and drugs. Check
continued 3
18 GL150 (PH)-32KYAD200.book Page 4 Monday, September 11, 2017 5:38 PM
Safety Guidelines
wearing bright reflective clothing, positioning maintained and in safe riding condition.
yourself so other drivers can see you, signaling Inspect your motorcycle before every ride and
before turning or changing lanes, and using your perform all recommended maintenance. Never
horn when necessary. exceed load limits (2 P. 11), and do not modify
your motorcycle or install accessories that would
make your motorcycle unsafe (2 P. 10).
Ride within Your Limits
Never ride beyond your personal abilities or
faster than conditions warrant. Fatigue and If You are Involved in a Crash
inattention can impair your ability to use good Personal safety is your first priority. If you or
judgement and ride safely. anyone else has been injured, take time to assess
the severity of the injuries and whether it is safe
to continue riding. Call for emergency assistance
Don’t Drink and Ride if needed. Also follow applicable laws and
Alcohol and riding don’t mix. Even one alcoholic regulations if another person or vehicle is
drink can reduce your ability to respond to involved in the crash.
changing conditions, and your reaction time gets
worse with every additional drink. Don’t drink If you decide to continue riding, first turn the
and ride, and don’t let your friends drink and ride ignition switch to the (OFF) position, and
either. evaluate the condition of your motorcycle.
4
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Safety Guidelines
Motorcycle Safety
control levers, brakes, and wheels. Ride slowly Running the engine of your motorcycle
and cautiously. while in an enclosed or even partially
Your motorcycle may have suffered damage that
enclosed area can cause a rapid build-up
is not immediately apparent. Have your
of toxic carbon monoxide gas.
motorcycle thoroughly checked at a qualified
service facility as soon as possible.
Breathing this colourless, odorless gas
can quickly cause unconsciousness and
Carbon Monoxide Hazard lead to death.
Exhaust contains poisonous carbon monoxide, a
colourless, odorless gas. Breathing carbon Only run your motorcycle's engine when
monoxide can cause loss of consciousness and it is located in a well ventilated area
may lead to death. outdoors.
5
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Safety Precautions
Riding Precautions
Motorcycle Safety
Running-in Period and braking distances are longer.
● Avoid continuous braking.
During the first 500 km (300 miles) of running,
u Repeated braking, such as when
follow these guidelines to ensure your
descending long, steep slopes can seriously
motorcycle’s future reliability and performance.
overheat the brakes, reducing their
● Avoid full-throttle starts and rapid
effectiveness. Use engine braking with
acceleration.
intermittent use of the brakes to reduce
● Avoid hard braking and rapid down-shifts.
speed.
● Ride conservatively.
● For full braking effectiveness, operate both the
front and rear brakes together.
Brakes
Observe the following guidelines:
● Avoid excessively hard braking and
downshifting.
u Sudden braking can reduce the
motorcycle’s stability.
u Where possible, reduce speed before
turning; otherwise you risk sliding out.
continued 7
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Riding Precautions
8
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Riding Precautions
Slowly lean the motorcycle to the left until its 3. Turn the handlebar fully to the left.
weight rests on the side stand. u Turning the handlebar to the right reduces
Motorcycle Safety
stability and may cause the motorcycle to
Using the centre stand fall.
To lower the centre stand, stand on the left 4. Turn the ignition switch to the (LOCK)
side of the motorcycle. Hold the left handle position (2 P. 17) and remove the key and
grip and the grab rail. Press down on the tip of close the shutter. 2 P. 18
the centre stand with your right foot and,
simultaneously, pull up and back.
Refuelling and Fuel Guidelines
Left handle grip Grab rail
Follow these guidelines to protect the engine,
fuel system and catalytic converter:
● Use only unleaded petrol.
● Use recommended octane number. Using
lower octane petrol will result in decreased
Centre stand engine performance.
● Do not use fuels containing a high
concentration of alcohol. 2 P. 96
● Do not use stale or contaminated petrol or an
oil/petrol mixture.
● Avoid getting dirt or water in the fuel tank.
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Loading
Loading 3 WARNING
Motorcycle Safety
● Carrying extra weight affects your Overloading or improper loading can
motorcycle’s handling, braking and stability. cause a crash and you can be seriously
Always ride at a safe speed for the load you
hurt or killed.
are carrying.
● Avoid carrying an excessive load and keep
Follow all load limits and other loading
within specified load limits.
Maximum weight capacity / Maximum guidelines in this manual.
luggage weight 2 P. 98
● Tie all luggage securely, evenly balanced and
close to the centre of the motorcycle.
● Do not place objects near the lights or the
muffler.
11
Operation Guide
Parts Location
Battery (P44)
Main fuse (P85)
Operation Guide
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Operation Guide
Fuel valve (P19)
Headlight (P46)
Fuse holders (P84)
Tool (P26)
Document bag (P26)
Seat
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Instruments
Speedometer
Fuel gauge
Operation Guide
Odometer Tachometer
Total distance ridden Tripmeter NOTICE
Distance ridden since tripmeter was reset. Do not operate the engine in
the tachometer red zone.
Excessive engine speed can
adversely affect engine life.
Indicators
If one of these indicators does not come on when it should, have your dealer check for problems.
Operation Guide
Left turn signal Right turn signal
indicator indicator
Neutral indicator
Comes on when the
transmission is in Neutral.
Gear position indicators
Shows 1st to 5th gear position.
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Switches
Headlight switch
• : Headlight, taillight,
Operation Guide
Operation Guide
(OFF)
u Key can be removed when in the (OFF) or
Turns engine off.
(LOCK) position.
(LOCK)
Locks steering.
Steering Lock
Lock the steering when parking to help # Locking
prevent theft. !a Turn the handlebar all the way to the left.
A U-shaped wheel lock or similar device is also
!b Push the key down, and turn the ignition
recommended.
switch to the (LOCK) position.
!b Push u Jiggle the handlebar if the lock is difficult
Turn to engage.
!a
!c Remove the key.
# Unlocking
Insert the key and turn the ignition switch to
the OFF position.
Ignition key
continued 17
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Switches (Continued)
Shutter # Close
The ignition switch for this motorcycle is !a Remove the ignition key from the ignition
equipped with a shutter. After parking the switch.
Operation Guide
motorcycle, close the shutter for theft !b Align the projection of the shutter key with
prevention. the slot of the shutter, and turn the shutter
key counterclockwise.
Close u You can also close the shutter by moving
the knob downward without the shutter
key.
Knob !c Remove the key.
# Open
Open Align the projection of the shutter key with the
slot of the shutter, and turn the shutter key
Shutter key Ignition
key clockwise.
Slot Projection
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Fuel Valve
The three-way fuel valve is used to control the
flow of fuel from the fuel tank to the
carburetor.
Operation Guide
(ON) (OFF) (RES)
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!b !e
!g
(B)
!a
(A)
!d !f
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Cold Engine:
!a The fuel valve is (ON).
!b Turn the ignition switch to the (ON)
position.
!c Shift the transmission to Neutral (
Operation Guide
indicator comes on).
!d Pull the choke lever back all the way to fully
ON (A).
!e With the throttle slightly open, press the start
button.
!f Warm up the engine by opening and closing
the throttle slightly.
!g Continue warming up the engine until it runs
smoothly and responds to the throttle, when
the choke lever is at fully OFF (B).
continued 21
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“Cold Engine”.
22
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Shifting Gears
Your motorcycle transmission has 5 forward
gears, five-down shift pattern.
Operation Guide
23
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Refuelling
Fuel type: Unleaded petrol only Lower edge of
Fuel octane number: Your motorcycle is filler neck
designed to use Research Octane Number
Operation Guide
(RON) 91 or higher.
Tank capacity: 10.3 litres (2.72 US gal,
2.27 Imp gal)
Reserve capacity: 2.0 litres (0.53 US gal,
0.44 Imp gal)
Fuel fill
# Refuelling and Fuel Guidelines (P9) cap
Opening the Fuel Fill Cap
Open the lock cover, insert the ignition key,
and turn it clockwise to open the cap.
Ignition key Lock cover
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Operation Guide
cap into the filler neck until it snaps closed
and locks.
!b Remove the key and close the lock cover.
u The key cannot be removed if the fuel fill
cap is not locked.
3 WARNING
Petrol is highly flammable and explosive.
You can be burned or seriously injured
when handling fuel.
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Storage Equipment
Rear Carrier Tool/Document Bag
Never exceed the maximum weight limit. The document bag and the tool kit are in the
Maximum Weight: 3.0 kg (6.6 lb) compartment box behind the left side cover.
Operation Guide
Rear Carrier
Document bag
Compartment box
Tool kit
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Maintenance
Importance of Maintenance
Maintenance is the owner’s responsibility. Be that can arise in performing maintenance. Only
sure to inspect your motorcycle before each ride, you can decide whether or not you should
and perform the periodic checks specified in the perform a given task.
Maintenance Schedule. 2 P. 29
Follow these guidelines when performing
3 WARNING maintenance.
Improperly maintaining your motorcycle ● Stop the engine and remove the key.
or failing to correct a problem before ● Place your motorcycle on a firm, level surface
using the side stand, centre stand or a
you ride can cause a crash in which you
maintenance stand to provide support.
can be seriously hurt or killed.
● Allow the engine, muffler, brakes, and other
high-temperature parts to cool before
Always follow the inspection and servicing as you can get burned.
maintenance recommendations and ● Run the engine only when instructed, and do
schedules in this owner’s manual. so in a well-ventilated area.
28
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Maintenance Schedule
The maintenance schedule specifies the All scheduled maintenance is considered a
maintenance requirements necessary to normal owner operating cost and will be
ensure safe, dependable performance, and charged to you by your dealer. Retain all
proper emission control. receipts. If you sell the motorcycle, these
receipts should be transferred with the
Maintenance
Maintenance work should be performed in motorcycle to the new owner.
accordance with Honda’s standards and
specifications by properly trained and Honda recommends that your dealer should
equipped technicians. Your dealer meets all of road test your motorcycle after each periodic
these requirements. Keep an accurate record maintenance is carried out.
of maintenance to help ensure that your
motorcycle is properly maintained.
Make sure that whomever performs the
maintenance completes this record.
continued 29
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Maintenance Schedule
Pre-ride Frequency *1
Annual Regular Refer to
Items Check × 1,000 km 1 4 8 12 16 20 24
Check Replace page
2 P. 32 × 1,000 mi 0.6 2.5 5 7.5 10 12.5 15
Fuel Line I I I I I I I –
Fuel Level I –
Maintenance
Maintenance Schedule
Pre-ride Frequency *1
Annual Regular Refer to
Items Check × 1,000 km 1 4 8 12 16 20 24
Check Replace page
2 P. 32 × 1,000 mi 0.6 2.5 5 7.5 10 12.5 15
Maintenance
Brake System I I I I I I I I I 54
Brakelight Switch I I I I I I I 60
Headlight Aim I I I I I I I 71
Lights/Horn I –
Clutch System I I I I I I I I I 66
Side Stand I I I I I I I 61
Suspension I I I I I I I –
Nuts, Bolts, Fasteners I I I I I –
Wheels/Tyres I I I I I I I I I 39
Steering Head Bearings I I I I –
Notes:
*1 : At higher odometer reading, repeat at the frequency interval established here.
*2 : Service more frequently when riding in unusually wet or dusty areas.
*3 : Service more frequently when riding in rain or at full throttle.
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Maintenance Fundamentals
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Maintenance Fundamentals
Maintenance
Installing non-Honda parts may make corroded.
your motorcycle unsafe and cause a Do not remove the battery cap seals. There is no
need to remove the cap when charging.
crash in which you can be seriously hurt
or killed. NOTICE
Your battery is a maintenance-free type and can be
Always use Honda Genuine Parts or permanently damaged if the cap strip is removed.
equivalents that have been designed NOTICE
and approved for your motorcycle. An improperly disposed of battery can be harmful to the
environment and human health.
Always confirm local regulations for proper battery
disposal instruction.
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Maintenance Fundamentals
for at least 15 minutes. Using water under A spark or flame can cause the battery to
pressure can damage your eyes. explode with enough force to kill or
● Electrolyte splashes onto your skin: seriously hurt you.
u Remove affected clothing and wash your
skin thoroughly using water. Wear protective clothing and a face
● Electrolyte splashes into your mouth: shield, or have a skilled mechanic do the
u Rinse mouth thoroughly with water, and do
battery servicing.
not swallow.
# Cleaning the Battery Terminals
1. Remove the battery. 2 P. 44
2. If the terminals are starting to corrode and are
coated with a white substance, wash with
warm water and wipe clean.
34
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Maintenance Fundamentals
Maintenance
# Inspecting and Replacing Fuses
Turn the ignition switch to the (off) position to
remove and inspect fuses. If a fuse is blown,
replace with a fuse of the same rating. For fuse
ratings, see “Specifications.” 2 P. 100
4. After cleaning, reinstall the battery.
Blown fuse
The battery has a limited life span. Consult your
dealer about when you should replace the
battery. Always replace the battery with another
maintenance-free battery of the same type.
NOTICE NOTICE
Installing non-Honda electrical accessories can overload Replacing a fuse with one that has a higher rating greatly
the electrical system, discharging the battery and possibly increases the chance of damage to the electrical system.
damaging the system.
continued 35
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Maintenance Fundamentals
If a fuse fails repeatedly, you likely have an *1. The JASO T 903 standard is an index for engine
electrical fault. Have your motorcycle inspected oils for 4-stroke motorcycle engines. There are
by your dealer. two classes: MA and MB. For example, the
following label shows the MA classification.
Engine Oil
Engine oil consumption varies and oil quality Oil code
Maintenance
36
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Maintenance Fundamentals
Maintenance
acceleration. 2 P. 62
continued 37
18 GL150 (PH)-32KYAD200.book Page 38 Monday, September 11, 2017 5:38 PM
Maintenance Fundamentals
recommended lubricant.
Recommended lubricant:
Drive chain lubricant Never use petrol or low flash point solvents for
cleaning the drive chain.
If not available, use SAE 80 or 90 gear oil.
A fire or explosion could result.
Avoid getting lubricant on the brakes or tyres.
Avoid applying excess chain lubricant to prevent
spray onto your clothes and the motorcycle.
38
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Maintenance Fundamentals
Maintenance
tube. embedded in the side
If the drain tube overflows, the air filter may of the tyre or the
become contaminated with engine oil causing tread. Also inspect for
poor engine performance. 2 P. 70 any unusual bumps or bulges in the side walls of
the tyres.
continued 39
18 GL150 (PH)-32KYAD200.book Page 40 Monday, September 11, 2017 5:38 PM
Maintenance Fundamentals
killed.
Wear indicator
location mark
40
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Maintenance Fundamentals
Maintenance
which you can be seriously hurt or killed.
● Use the recommended tyres or equivalents of
the same size, construction, speed rating, and
load range. Always use the size and type of tyres
● Remember to replace the inner tube recommended in this owner’s manual.
whenever you replace a tyre. The old tube will
probably be stretched, and it could fail if
installed in a new tyre.
41
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Maintenance Fundamentals
Air Cleaner
This motorcycle is equipped with a viscous type
air cleaner element.
Air blow cleaning or any other cleaning can
degrade the viscous element performance and
Maintenance
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Tool
The tool kit is in the compartment box behind
the left side cover. 2 P. 26
Maintenance
with the provided tools.
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Battery # Removal
Make sure the ignition switch is in the (off)
position.
Negative terminal 1. Remove the right side cover. 2 P. 48
Screw 2. Remove the fuse holder from the battery
Maintenance
Positive terminal
Screw holder.
3. Disconnect the negative - terminal from
the battery.
4. Disconnect the positive + terminal from
the battery.
5. Remove the battery holder by removing
the bolts.
6. Remove the battery taking care not to drop
Bolts the terminal nuts.
u Pull out the battery and battery holder
Battery holder Battery Fuse holder together from motorcycle.
44
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# Installation
Install the parts in the reverse order of
removal. Always connect the positive +
terminal first. Make sure that bolts and nuts
are tight.
Maintenance
For proper handling of the battery, see
“Maintenance Fundamentals.” 2 P. 33
“Battery Goes Dead.” 2 P. 79
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Connector
46
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Maintenance
# Installation
1. Align the bosses with the grommets.
2. Push the side cover into position while
turning the ignition key clockwise.
Bosses
47
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# Installation
1. Align the bosses with the grommets.
2. Push the bosses into position.
3. Install the screw.
Bosses
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Spark Plug
Maintenance
Use only the recommended type of spark plug
in the recommended heat range.
NOTICE
Using a spark plug with an improper heat range can cause
engine damage.
1. Disconnect the spark plug cap from the
spark plug. Spark plug wrench
2. Clean any dirt from around the spark plug
base. 4. Inspect the electrodes and centre porcelain
3. Remove the spark plug using provided for deposits, erosion or carbon fouling.
spark plug wrench. 2 P. 43 u If the erosion or deposit is heavy,
replace the plug.
u Clean a carbon or wet-fouled plug with
a plug cleaner, otherwise use a wire
brush.
continued 49
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5. Check the spark plug gap using a wire-type 8. Tighten the spark plug:
feeler gauge. ● If the old plug is good:
u If adjustment is necessary, bend the side NGK: 1/8 turn after it seats.
electrode carefully. ● If installing a new plug, tighten it twice to
50
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Engine Oil
Maintenance
position and wait for 2 to 3 minutes.
3. Place your motorcycle on its centre stand Upper level
on a firm, level surface.
4. Remove the oil fill cap/dipstick and wipe it
clean.
5. Insert the oil fill cap/dipstick until it seats,
but don’t screw it in. Lower level
6. Check that the oil level is between the
upper level and lower level marks on the oil
fill cap/dipstick.
7. Securely install the oil fill cap/dipstick.
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52
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3. Place your motorcycle on its centre stand 6. Install a new sealing washer onto the drain
on a firm, level surface. bolt. Tighten the drain bolt.
4. Place a drain pan under the drain bolt. Torque: 30 N·m (3.1 kgf·m, 22 lbf·ft)
5. Remove the oil fill cap/dipstick, drain bolt
and sealing washer to drain the oil. 7. Fill the crankcase with the recommended
Maintenance
u Discard the oil at an approved oil (2 P. 36, 99) and install the oil fill cap/
recycling centre. dipstick.
Sealing washer Required oil
When changing oil:
1.0 litres (1.06 US qt, 0.88 Imp qt)
Drain bolt
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Brakes
Inspecting the Front Brake Check the brake cable for kinks or signs of
wear. If necessary have it replaced by your
Lever Freeplay dealer.
1. Place your motorcycle on its centre stand Lubricate the brake cable with a commercially
on a firm, level surface. available cable lubricant to prevent premature
Maintenance
2. Measure the distance the front brake lever wear and corrosion.
moves before the brake takes hold. Make sure the brake arm, spring and fastener
are in good condition.
Freeplay at the tip of the brake lever:
10 to 20 mm (0.4 to 0.8 in)
Freeplay
54
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Maintenance
# Upper Adjustment Make sure the cut-out on the adjusting nut is
Attempt adjustment with upper brake cable seated on the brake arm pin when adjusting
adjuster first. the freeplay.
1. Pull back the rubber dust cover. Adjusting nut Brake arm pin
2. Loosen the upper lock nut.
3. Turn the front brake cable adjuster until the
freeplay is 10 to 20 mm (0.4 to 0.8 in).
4. Tighten the upper lock nut and check the
freeplay again.
5. Install the rubber dust cover.
Upper lock nut
+
If proper adjustment cannot be obtained by
this method, see your dealer.
-
Upper brake
cable adjuster
continued 55
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Brake arm
Adjusting
nut
Push
Maintenance
56
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Adjusting the Rear Brake Pedal Inspecting the Rear Brake Pedal
Height Freeplay
The stopper bolt is provided to allow 1. Place your motorcycle on its centre stand
adjustment of the pedal height. on a firm, level surface.
Maintenance
2. Measure the distance the rear brake pedal
1. Place your motorcycle on its centre stand moves before the brake takes hold.
on a firm, level surface. Freeplay at the tip of the brake pedal:
2. Loosen the lock nut and turn the stopper 20 to 30 mm (0.8 to 1.2 in)
bolt.
3. Tighten the lock nut and check the Rear brake pedal
freeplay.
Brake pedal
Freeplay
Lock nut
Stopper bolt Make sure the brake rod, brake arm, spring
and fastener are in good condition.
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the freeplay.
Adjusting nut Brake arm pin Decrease
Freeplay
Adjusting Increase
nut Freeplay
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3. Push the brake arm to confirm that there is Inspecting the Brake Shoe Wear
a gap between the rear brake adjusting nut
and brake arm pin. The front and rear brake are equipped with a
Brake arm brake wear indicator.
Front Arrow Brake panel
Maintenance
Push
Brake arm
After adjustment, confirm the freeplay of the
rear brake pedal.
Make sure the brake rod, brake arm, spring
and fastener are in good condition.
NOTICE
Do not turn the adjuster beyond its natural limits.
continued 59
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Side Stand
Checking the Side Stand 1. Check that the side stand operates
smoothly. If the side stand is stiff or
Side stand spring
squeaky, clean the pivot area and lubricate
the pivot bolt with clean grease.
2. Check the spring for damage or loss of
Maintenance
tension.
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Drive Chain
62
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Maintenance
engine.
2. Place your motorcycle on its centre stand
on a firm, level surface.
3. Loosen the rear axle nut.
4. Loosen the lock nuts on both sides of the Drive chain adjuster Lock nut
drive chain adjusters.
Adjusting nut Scale graduations 5. Turn both adjusting nuts an equal number
of turns until the correct drive chain slack
is obtained. Turn the adjusting nuts
Lock nut clockwise to tighten the chain. Turn the
adjusting nuts counterclockwise and push
the rear wheel toward the front to provide
more slack.
Rear axle nut
Drive chain adjuster
continued 63
18 GL150 (PH)-32KYAD200.book Page 64 Monday, September 11, 2017 5:38 PM
Adjust the slack at a point midway 7. Tighten the rear axle nut.
between the drive sprocket and the driven Torque: 68 N·m (6.9 kgf·m, 50 lbf·ft)
sprocket.
Check the drive chain slack. 2 P. 62 8. Hold the adjusting nuts and tighten the
6. Check rear axle alignment by making sure lock nuts.
Maintenance
the end of the drive chain adjuster aligns 9. Recheck drive chain slack.
with the scale graduations on both sides 10. Rear brake pedal freeplay is affected
of the swingarm. when repositioning the rear wheel to
Both marks should correspond. If the axle adjust drive chain slack. Check rear brake
is misaligned, turn the right or left pedal freeplay and adjust as necessary.
adjusting nut until the marks are aligned 2 P. 57
and recheck chain slack.
If a torque wrench was not used for
installation, see your dealer as soon as
possible to verify proper assembly.
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18 GL150 (PH)-32KYAD200.book Page 65 Monday, September 11, 2017 5:38 PM
Maintenance
Chain:
HUZHOU SHUANSHI 428H
KMC 428HDF
65
18 GL150 (PH)-32KYAD200.book Page 66 Monday, September 11, 2017 5:38 PM
Clutch
wear.
10 to 20 mm (0.4 to 0.8 in)
66
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-
# Upper Adjustment
Attempt adjustment with the upper clutch
Maintenance
cable adjuster first.
1. Pull back the rubber dust cover.
+
2. Loosen the upper lock nut.
3. Turn the upper clutch cable adjuster until
the freeplay is 10 to 20 mm (0.4 to 0.8 in).
Upper lock nut Rubber dust cover
4. Tighten the upper lock nut and check the
freeplay again.
5. Install the rubber dust cover.
continued 67
18 GL150 (PH)-32KYAD200.book Page 68 Monday, September 11, 2017 5:38 PM
68
18 GL150 (PH)-32KYAD200.book Page 69 Monday, September 11, 2017 5:38 PM
Throttle
Maintenance
freeplay is correct. If the throttle does not
move smoothly, close automatically, or if the
cable is damaged, have the motorcycle
inspected by your dealer.
Freeplay at the throttle grip flange:
2 to 6 mm (0.1 to 0.2 in).
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Crankcase Breather
70
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Other Adjustments
Maintenance
(2 P. 43).
Obey local laws and regulations.
Screw
Raise
Lower
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Troubleshooting
Troubleshooting
● Check for a loose battery connection
(2 P. 44) or battery terminal corrosion
(2 P. 34).
● Check the condition of the battery. 2 P. 79
If the problem continues, have your
motorcycle inspected by your dealer.
73
18 GL150 (PH)-32KYAD200.book Page 74 Monday, September 11, 2017 5:38 PM
Tyre Puncture
Repairing a puncture or removing a wheel
requires special tools and technical expertise.
3 WARNING
We recommend you have this type of service Riding your motorcycle with a temporary
performed by your dealer. tyre or tube repair can be risky. If the
After an emergency repair, always have the temporary repair fails, you can crash and
tyre inspected/replaced by your dealer. be seriously injured or killed.
Troubleshooting
74
18 GL150 (PH)-32KYAD200.book Page 75 Monday, September 11, 2017 5:38 PM
Troubleshooting
removing the screw.
4. Remove the front brake adjusting nut and Front brake
remove the front brake cable from the adjusting nut Front brake cable
brake arm.
5. Remove the front axle nut.
6. Remove the front axle shaft, front wheel, Front axle shaft
and side collar.
continued 75
18 GL150 (PH)-32KYAD200.book Page 76 Monday, September 11, 2017 5:38 PM
3. Make sure that the lug on the left fork leg is Slot
located in the slot of the brake panel.
4. Tighten the front axle nut.
Torque: 59 N·m (6.0 kgf·m, 44 lbf·ft)
Troubleshooting
arm
arm.
4. Disconnect the brake stopper arm from the
Brake
brake panel by removing the cotter pin, stopper
brake stopper arm nut, washer and rubber Rear brake Cotter pin arm
grommet. adjusting nut Brake stopper arm nut
5. Loosen the drive chain lock nuts and drive
chain adjusting nuts on both sides of the 6. Remove the rear axle nut while holding the
swingarm. rear axle shaft at the other end with a
wrench.
7. Remove the drive chain from the driven
sprocket by pushing the rear wheel
forward.
continued 77
18 GL150 (PH)-32KYAD200.book Page 78 Monday, September 11, 2017 5:38 PM
8. Remove the rear axle shaft, drive chain 3. Tighten the brake stopper arm nut.
adjusters, side collars and rear wheel from Torque: 22 N·m (2.2 kgf·m, 16 lbf·ft)
the swingarm.
Drive chain adjuster 4. Adjust the rear brake pedal freeplay. 2 P. 58
5. Adjust the drive chain slack. 2 P. 63
Rear axle Drive chain 6. After installing the wheel, apply the brake
shaft lock nut pedal several times, then check if the wheel
Troubleshooting
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18 GL150 (PH)-32KYAD200.book Page 79 Monday, September 11, 2017 5:38 PM
Electrical Trouble
Troubleshooting
charger, as these can overheat a motorcycle Do not use bulbs other than those specified.
battery and cause permanent damage. Check the replacement bulb for correct
If the battery does not recover after operation before riding.
recharging, contact your dealer.
NOTICE For the light bulb wattage, see
Jump starting using an automobile battery can damage “Specifications.” 2 P. 100
your motorcycle's electrical system and is not
recommended.
continued 79
18 GL150 (PH)-32KYAD200.book Page 80 Monday, September 11, 2017 5:38 PM
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Troubleshooting
Bulb
Screws
continued 81
18 GL150 (PH)-32KYAD200.book Page 82 Monday, September 11, 2017 5:38 PM
# Front and Rear Turn Signal Bulb 1. Remove the turn signal assembly by
removing the screw A.
Screws B 2. Remove the turn signal lens and lens
Turn signal assembly
packing by removing the screws B.
3. Remove the bulb by slightly pressing the
Turn signal lens
bulb and turn it counterclockwise.
4. Install a new bulb and parts in the reverse
Troubleshooting
order of removal.
u Use only the amber bulb.
Bulb
Screw A
Lens packing
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Troubleshooting
Socket
Bulb
83
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Blown Fuse Do not pry the clips open to get a fuse out;
you could bend them and cause poor contact
Before handling fuses, see “Inspecting and with the new fuse. A loose fuse could cause
Replacing Fuses.” 2 P. 35 damage to the electrical system and even start
a fire.
# Fuse Holders
1. Remove the left side cover. 2 P. 47
Troubleshooting
# Main Fuse
Fuse holder
Fuse holder
Main fuse
Clips
Troubleshooting
Battery
holder
Spare main fuse
Clips
3. Open the fuse holder and lift out the main
1. Remove the right side cover. 2 P. 48
fuse with the clips.
2. Remove the fuse holder from the battery
4. Slide the main fuse out of the clips. If the
holder.
fuse is blown, discard it.
continued 85
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86
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Information
Keys .............................................................. P. 88
Instruments, Controls, & Other Features... P. 89
Caring for Your Motorcycle ....................... P. 90
Storing Your Motorcycle............................ P. 93
Transporting Your Motorcycle .................. P. 93
You & the Environment ............................. P. 94
Serial Numbers............................................ P. 95
Fuels Containing Alcohol ........................... P. 96
18 GL150 (PH)-32KYAD200.book Page 88 Monday, September 11, 2017 5:38 PM
Keys
Keys
Ignition key
Be sure to record the key number provided with
the original keys and record it in this manual.
Store the spare key in a safe location.
To make a duplicate, take the spare key or the
key number to your dealer.
If you lose all keys and the key number, the
Information
88
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Information
Do not turn the key while riding.
Tripmeter
The tripmeter returns to 0 when the read-out
exceeds 999.9.
Odometer
The odometer returns to 0 when the read-out
exceeds 99,999.9.
89
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Caring for Your Motorcycle 3. Thoroughly rinse your motorcycle with plenty
of clean water and dry with a soft, clean cloth.
Frequent cleaning and polishing is important to 4. After the motorcycle dries, lubricate any
ensure the life of your Honda. A clean moving parts.
motorcycle makes it easier to spot potential u Make sure that no lubricant spills onto the
problems. brakes or tyres. Brake discs, pads, drum or
In particular, seawater and salts used to prevent shoes contaminated with oil will suffer
ice on roads promote the formation of corrosion. greatly reduced braking effectiveness and
Always wash your motorcycle thoroughly after can lead to a crash.
Information
riding on coastal or treated roads. 5. Lubricate the drive chain immediately after
washing and drying the motorcycle.
6. Apply a coat of wax to prevent corrosion.
Washing u Avoid products that contain harsh
Allow the engine, muffler, brakes, and other detergents or chemical solvents. These can
high-temperature parts to cool before washing. damage the metal, paint, and plastic on
1. Rinse your motorcycle thoroughly using a low your motorcycle.
pressure garden hose to remove loose dirt. Keep the wax clear of the tyres and brakes.
2. If necessary, use a sponge or a soft towel with u If your motorcycle has any mat painted
mild cleaner to remove road grime. parts, do not apply a coat of wax to the mat
u Clean the headlight lens, panels, and other painted surface.
plastic components with extra care to avoid
scratching them. Avoid directing water into
the air cleaner, muffler, and electrical parts.
90
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Information
u Water in the muffler can prevent starting water or ice accumulated inside the
and causes rust in the muffler. lens(es), have your vehicle inspected by
● Dry the brakes: your dealer.
u Water adversely affects braking ● Do not use wax or polishing compounds on
effectiveness. After washing, apply the mat painted surface:
brakes intermittently at low speed to help u Use a soft cloth or sponge, plenty of water,
dry them. and a mild detergent to clean mat painted
● Do not direct water under the seat:
surfaces. Dry with a soft clean cloth.
u Water in the under seat compartment can
damage your documents and other
belongings.
● Do not direct water at the air cleaner:
u Water in the air cleaner can prevent the
engine from starting.
continued 91
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92
18 GL150 (PH)-32KYAD200.book Page 93 Monday, September 11, 2017 5:38 PM
Information
● Lubricate the drive chain. 2 P. 38
● Place your motorcycle on its centre stand and NOTICE
position a block so that both tyres are off the Towing your motorcycle can cause serious damage to the
transmission.
ground.
● After rain, remove the body cover and allow
the motorcycle to dry.
● Remove the battery (2 P. 44) to prevent discharge.
Fully charge the battery and then place it in a
shaded, well-ventilated area.
u If you leave the battery in place, disconnect
the negative - terminal to prevent discharge.
After removing your motorcycle from storage,
inspect all maintenance items required by the
Maintenance Schedule.
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You & the Environment drain or on the ground. Used oil, petrol, and
cleaning solvents contain poisons that can hurt
Owning and riding a motorcycle can be refuse workers and contaminate drinking water,
enjoyable, but you must do your part to protect lakes, rivers, and oceans.
the environment.
Recycle Wastes
Put oil and other toxic wastes in approved
containers and take them to a recycling centre.
Call your local or state office of public works or
environmental services to find a recycling centre
in your area, and to get instructions on how to
dispose of non-recyclable wastes. Do not place
used engine oil in the trash, or pour it down a
94
18 GL150 (PH)-32KYAD200.book Page 95 Monday, September 11, 2017 5:38 PM
Serial Numbers
Serial Numbers
The frame and engine serial numbers uniquely
identify your motorcycle and are required in
order to register your motorcycle. They may also
be required when ordering replacement parts.
You should record these numbers and keep
them in a safe place.
Information
Frame number
Engine number
95
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Fuels Containing Alcohol The use of petrol containing more than 10%
ethanol may:
Some conventional fuels blended with alcohol ● Damage the painting of the fuel tank.
are available in some locales to help reduce ● Damage the rubber tubes of the fuel line.
emissions to meet clean air standards. If you plan ● Cause corrosion of the fuel tank.
to use blended fuel, check that it is unleaded and ● Cause poor drivability.
meets the minimum octane rating requirement. NOTICE
Use of blended fuels containing higher than approved
The following fuel blends can be used in your percentages can damage metal, rubber, plastic parts of
Information
96
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Catalytic Converter
Information
A defective catalytic converter contributes to air
pollution and can impair your engine’s
performance. A replacement unit must be an
original Honda part or equivalent.
97
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Specifications
Specifications
98
18 GL150 (PH)-32KYAD200.book Page 99 Monday, September 11, 2017 5:38 PM
Specifications
Specifications
(Driver and passenger) HUZHOU SHUANSHI 428H
Standard drive
225 kPa (2.25 kgf/cm2, 33 psi) KMC 428HDF
chain
Minimum tread Front 1.5 mm (0.06 in) No. of links 120
depth Rear 2.0 mm (0.08 in) Standard Drive sprocket 15T
(standard) CPR8EA-9 (NGK) sprocket size Driven sprocket 43T
(For extend
high speed CPR9EA-9 (NGK)
Spark plug
riding)
(For cold
CPR7EA-9 (NGK)
climate)
Spark plug gap 0.8 to 0.9 mm (0.03 to 0.04 in)
Idle speed 1,400 ± 100 rpm
99
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Specifications
■ Fuses
Main fuse 20 A
Other fuse 10 A
Specifications
100
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Index
Index
A D
Accessories .............................................................10 Drive Chain ...................................................... 37, 62
B E
Battery ...............................................................33, 44 Electrical Trouble .................................................. 79
Brakelight Switch ..................................................60 Engine
Brakes Number ................................................................ 95
Shoe Wear ...........................................................59 Oil ................................................................... 36, 51
Braking ....................................................................... 7 Starting ................................................................. 20
Bulb Environment ........................................................... 94
Brakelight/Taillight .............................................81
Front and Rear Turn Signal ..............................82 F
Headlight ..............................................................80 Flooded Engine ..................................................... 22
Index
Position Light .......................................................83 Frame Number ...................................................... 95
Fuel
C Gauge ................................................................... 14
Caring for Your Motorcycle ...............................90 Recommended ................................................... 24
Catalytic Converter ...............................................97 Remaining ............................................................ 14
Choke Lever ............................................................20 Reserve Capacity ................................................ 24
Clutch System ........................................................66 Tank Capacity ..................................................... 24
Compartment Valve ..................................................................... 19
Document Bag .............................................26, 89 Fuels Containing Alcohol ................................... 96
Tool .................................................................26, 43 Fuses .................................................................. 35, 84
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G Fundamentals ..................................................... 32
Gasohol ....................................................................96 Importance .......................................................... 28
Gear Position Indicators .....................................15 Safety .................................................................... 28
Schedule ............................................................... 29
H Modifications ......................................................... 10
Headlight Aim ........................................................71
Headlight Dimmer Switch ..................................16 N
Headlight Switch ...................................................16 Neutral Indicator .................................................. 15
High Beam Indicator ............................................15
Horn Button ............................................................16 O
Odometer ............................................................... 14
I Oil
Ignition Key .............................................................88 Engine ............................................................ 36, 51
Index
Index
Shutter ......................................................................18 Tyres
Side Stand ...............................................................61 Air Pressure .................................................. 39, 99
Specifications .........................................................98 Puncture ............................................................... 74
Speedometer ..........................................................14 Replacing ...................................................... 39, 74
Start Button .....................................................16, 20
Starting the Engine ..............................................20 W
Steering Lock .........................................................17 Washing Your Motorcycle ................................. 90
Storage Wheels
Compartment ......................................................26 Front Removal .................................................... 75
Document Bag .............................................26, 89 Rear Removal ...................................................... 77
103
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