Fuel Reserve Sensor Inspection

Connect the fuel reserve sensor 3P (Black) connector. Turn the ignition switch is ON and make sure the fuel reserve indicator comes ON. If,the fuel reserve indicator does not indicate properly, check for the following Disconnect the fuel reserve sensor 3P (Black) connector. Short the wire harness side connector Brown Black and Green Black terminals with a jumper wire. Turn the ignition switch is ON and make sure the fuel reserve indicator comes ON. If the indicator come ON, replace the fuel...

Main Journal Bearing

Inspect the main journal bearing inserts for damage or separation. Wipe the oil from the bearing inserts and journals. Reinstall the upper crankcase's main journal bearing inserts, then carefully lower the crankshaft in place. Put a piece of plastigauge on each journals. NOTE Do not put the plastigauge over the oil hole in the main bearing journal of the crankshaft. Do not rotate the crankshaft during inspection. Tighten the 9 mm bolts to the specified torque. TORQUE 37 N-m (3.8 kgf-m , 27...

Input Voltage Inspection

Disconnect the EVAP CAV solenoid valve 2P (Black) connector. Turn the ignition switch ON and measure the voltage between the terminals. CONNECTION Black Brown ( + ) Green ( ) STANDARD Battery voltage If there is battery voltage, replace the EVAP CAV solenoid valve. If there is no battery voltage, check the wire harness. Install the tubes to the EVAP CAV solenoid valve and connect the 2P (Black) connector.

Rear Balancer Removal

Separate the crankcase (Section 11) and remove the crankshaft and transmission. Remove the balancer idle gear shaft holder bolt. Loosen the pinch bolt and remove the holder. Remove the balancer idle gear shaft stopper bolt washer. Rotate the balancer shaft and place the punch mark on the shaft facing up. The balancer idle Pull out the balancer idle gear shaft and remove the gear shaft will distance collar and idle gear. only come out from one particular position. Rotate it until it comes out...

Carburetor Installation

Coat the inside of the carburetor insulators with clean engine oil for ease of installation. Install the carburetor assembly onto the cylinder head. Tighten the engine side insulator screws so that the band ends clearance is 11 13 mm (0.4 0.5 in). Connect the throttle cable ends to the throttle drum and install the throttle cables on to the cable holder. Connect the choke cable end to the starting enrichment valve arm. Connect the throttle sensor connector.

Cylinder Compression Test

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. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in enclosed area. Warm up the engine to normal operating temperature. Stop the engine and remove the all spark plug caps and remove the one spark plug at a time. To measure the cylinder...

Cam Chain Guide

Install the dowel pins and a new cylinder head gasket as shown. If using the new bolt, remove anti-rust additive from the bolt. Apply molybdenum disulfide oil to the threads and seating surface of the 10 mm bolts washers and in stall them. Tighten the 10 mm bolts in a crisscross pattern in 2 3 steps to the specified torque. TORQUE 67 N-m (6.8 kgf-m , 49 Ibf-ft) Tighten the 6 mm flange bolts to the specified torque. TORQUE 10 N m (1.0 kgf-m , 7 Ibf-ft)

Clutch Outer Guide

Do not try to remove the countershaft bearing from the shaft. If the bearing is worn or damaged, replace the countershaft as an assembly. Turn the outer race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the shaft. Remove and discard the mainshaft bearing, if the race does not turn smoothly, quietly, or fits loosely on the mainshaft. Replace the countershaft, collar, and bearing as an assembly, if the race...

High Altitude Adjustment

This adjustment When the vehicle is to be operated continuously must be made at above 2,000 m (6,500 feet), the carburetors must be high altitude to readjusted as follows to improve diveability and ensure proper high decrease exhaust emissions. altitude operation. Warm up the engine to operating temperature. Stop and go riding for 10 minutes is sufficient. Turn each pilot screw clockwise 3 4 turn. Adjust the idle speed with the throttle stop screw. IDLE SPEED 1,100 100 rpm Attach a Vehicle...

Forktube Forktube Bushing

Before assembly, wash all parts with a high flash or non-flammable solvent and wipe them dry. Install a new fork tube bushing if the bushing has been removed. Install the oil seal Install the slider bushing, back-up ring and a new with its marked oil seal. side facing up. Apply fork fluid to the oil seal lips. Install the fork tube into the fork slider. Drive the oil seal in using the special tools. TOOLS Slider weight Oil seal driver Fork seal driver 07947-KA50100 07947 - KA40200 07NMD KZ3010A...

Right Handlebar Removal

Remove the screw and the handlebar grip end. Disconnect the front brake switch wires connectors from the switch. Remove the master cylinder holder bolts, holder and master cylinder assembly. Remove the right handlebar switch throttle housing screws. Disconnect the throttle cable ends from the throttle Remove the throttle pipe from the right handlebar.

Washir

07724 0050002

Install the thrust washer. Install the lock washer with its OUTSIDE mark facing out. Hold the clutch center with the clutch center holder, then tighten the lock nut to the specified torque using the tool as shown. 07724-0050002 Equivalent commercially available in U.S.A. TORQUE 127 N m 13.0 kgf-m , 94 Ibf ft Stake lock nut into the mainshaft groove with a punch. Coat the clutch discs and plates with clean engine oil. Install the spring seat and judder spring onto the...

Awarning

Idle Screw Honda Cbr 600

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. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in enclosed area. Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications. The engine must be warm for accurate idle speed...

Oil Viscosities

Change the engine oil with the engine warm and the motorcycle on level ground to assure complete draining. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. Stop the engine and remove the oil filler cap and drain bolt. Remove...

Cylinder Head Cover Removal

Air cleaner housing page 5-4 Remove the spark plug caps. Disconnect the crankcase breather tube. Disconnect the PAIR control valve air tube, vacuum tube and remove the PAIR control valve assembly. Remove the SH bolts and PAIR check valve covers from the cylinder head cover. Remove the cylinder head cover bolts and washers. Remove the cylinder head cover rearward. J1' Mill ij illlMliiillliillilM . iMii. W ,1' JP

Engine Removal

Support the motorcycle securely on its center stand. Drain the engine oil page3-14 . Drain the coolant page6-4 . Disconnect the following connectors Alternator 3P White connector Ignition pulse generator 2P Red connector Speed sensor 3P White connector Side stand switch 3P Green connector Engine sub-harness 3P Black connector Disconnect the air tubes from the PAIR check valve cover and disconnect the vacuum tube from the intake port. Remove the PAIR control valve assembly. Disconnect the air...

Outer Rotor Inner Rotor

Install and tighten the assembly bolt to the speci TORQUE 13 N-m 1.3 kgf-m , 9 lbf-ft Check the oil pump operation by turning the pump shaft. If necessary, reassemble the oil pump. Install the oil pressure relief valve with its smal O.D. side facing the spring. Install the spring and spring seat.

Exhaust Emission Control System Pulse Secondary Air Injection System

The exhaust emission control system uses a lean carburetor setting and no adjustment should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and...

Lock Nut Wrench

Turn the adjusting bolt with the engine hanger bolt counterclockwise to release the adjusting bolt from the engine. Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal. Remove the right engine hanger bolt and distance collar. Remove the left engine hanger bolts.

Secondary Air Supply System

This model is equipped built-in secondary air supply system. The pulse secondary air supply system is located on the cylinder head cover. The secondary air supply system introduces filtered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system. This charged secondary air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into...

Evap Purge Control Valve Inspection

The EVAP purge control valve should be inspected if hot restart is difficult. Remove the EVAP purge control valve from the air cleaner housing. Connect the vacuum pump to the No. 5 tube fitting output port that goes to the carburetors. Apply the specified vacuum to the EVAP purge control valve. SPECIFIED VACUUM 250 mm Hg 9.8 in Hg The specified vacuum should maintained. Replace the EVAP purge control valve if vacuum is not maintained.

Purge Control Valve

Remove the vacuum pump and connect it to the No. 11 tube fitting vacuum port that goes to the No. 3 carburetor. Apply the specified vacuum to the EVAP purge control valve. SPECIFIED VACUUM 250 mm Hg 9.8 in Hg The specified vacuum should maintained. Replace the EVAP purge control valve if vacuum is not maintained. Connect a pressure pump to the No. 4 tube fitting input port that goes to EVAP canister. Damage to the EVAP purge control valve may result from use of a high pressure air source. Use a...

Bolts

Loosen the rear upper engine hanger adjusting bolt lock nut using the special tool. Turn the adjusting bolt with the engine hanger bolt counterclockwise to release the adjusting bolt from the engine. Loosen the rear lower engine hanger adjusting bolt lock nut using the special tool.

Diaphragmvacuum Piston

Check the condition of the O-ring on the jet needle holder, replace if necessary. Apply oil to the O-ring. Install the washer, jet needle and spring into the vacuum piston. Press the jet needle holder into the vacuum piston until you feel a click indicating that the O-ring is seated into the groove in the vacuum piston. Install the diaphragm vacuum piston in the carburetor body by aligning the diaphragm tab with the groove of the carburetor body. Hold the vacuum piston almost full open so the...

System Inspection

Valve Vacuum Control

Start the engine and warm it up to normal operating temperature. Remove the air cleaner element page 3-5 . Check that the secondary air intake ports are clean and free carbon deposits. If the ports are carbon fouled, check the pulse secondary air injection PAIR control valve. Disconnect the air cleaner housing-to-PAIR control valve tube No. 15 from the air cleaner housing. Disconnect the PAIR control valve vacuum tube from the control valve and plug it to keep air from entering. Connect the...

Siphon Tube

Disconnect the fan motor switch 3P White connector. Release the air guide hooks from the oil cooler hoses. Remove the upper mounting bolt and collar. Release the radiator from the lower bracket. Lower the left side of the radiator down and slide the radiator rightward, then release the grommet from the frame boss. Remove the radiator and air guide as an assembly. CAUTION Be careful not to damage the radiator core.

Replacementair Bleeding

The engine must be cool before servicing the cooling system, or severe scalding may result. When filling the system or reserve tank with a coolant checking coolant level , place the motorcycle in a vertical position on a flat, level surface. Remove the drain bolt on the water pump cover and drain the system coolant. Reinstall the drain bolt with the new sealing washer. Disconnect the siphon tube from the radiator. Drain the reserve tank coolant. Empty the coolant and rinse the inside of the...

Cleaning And Lubrication

Clean the chain with non-flammable or high flash point solvent and wipe it dry. Be sure the chain has dried completely before lubricating. Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. Inspect and replace sprocket as necessary. Lubricate the drive chain with 80 90 gear oil or Pro Honda chain lube...

Evap Cav Solenoid Valve

Exhaust Solenoid Valve Honda Cbr 600f4i

Connect a pressure pump to the No. 6 tube fitting that goes to carburetor. Damage to the EVAP CAV solenoid valve may result from use of high pressure air source. Use a hand oprated air pump only. With the ignition switch OFF, pump air through the No. 6 tube fitting. Make sure the air flow out from No. 4 fitting, and does not flow out from No. 7 fitting. Turn the ignition switch ON, pump air through the No. 6 tube fitting. Make sure the air flow out from No. 7 fitting, and does not flow out from...

Radiator Coolant

Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the UPPER and LOWER level lines. If necessary, add recommended coolant. Remove the seat page 2-2 . Remove the reserve tank filler cap and fill to the UPPER level line with 50 50 mixture of distilled water and antifreeze. Reinstall the filler cap.

Right Upper Cowl Cover Right Inner Panel

Align the inner panel with the frame boss and lower edge of the fuel tank, then install the boss into the fuel tank gromment. Install the both upper cowl cover. NOTE Align the upper cowl covers with the meter panel bosses. Temporarily install the special bolts. Install the upper ends of the windscreen special bolts cap nuts. Tighten the cap nuts while holding the special bolts. Tighten the special bolts.

Oil Level Inspection

Honda Oil Level Dipstick

Start the engine and let it idle for 2 3 minutes. Turn off the engine and support the motorcycle on its center stand. Remove the oil level dipstick wipe it clean. Reinstall the oil level dipstick, but do not screw it. Remove the oil level dipstick and check the oil level. If the level is below the lower mark on the dipstick, fill the crankcase with recommended oil. Fill the recommended engine oil up to the upper level mark. HONDA GN4 4-stroke oil or equivalent motor oil API service...

Breather Tube

Route the fuel level reserve sensor unit wire. Remove the fuel tank support and lower the fuel tank. Be careful not to damage the inner panel bosses. Connect the fuel level reserve sensor 3P Black connector. Install and tighten the fuel tank mounting bolts. nner panel bosses into the fuel tank i

Lower Bracket

Cbr1100 Timing Marks

Remove the crankshaft hole cap and O-ring. Turn the crankshaft clockwise, align the T mark on the ignition pulse generator rotor with the index mark on the ignition pulse generator rotor cover. The timing marks IN and EX on the cam sprockets must be flush with the cylinder head surface and facing outward as shown. If the timing marks on the cam sprocket facing inward, turn the crankshaft clockwise one full turn 360 and realign the timing marks with the cylinder head surface so they are facing...

Idle Drop Procedure

Pilot Screw Wrench 07kma Mn90100

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. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in enclosed area. Make sure the carburetor synchronization is within specification before pilot screw adjustment page 3-16 . The pilot screws are factory pre-set. Adjustment is not necessary...

Brake Fluid

Do not mix different types of fluid, as they are not compatible with each other. Do not allow foreign material to enter the system when filling the reservoir. Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. When the fulid level is low, check the brake pads for wear see next page . A low fluid level may be due to wear of the brake pads. If the brake pads are worn, the caliper piston is pushed out, and this accounts for a...

Float And Jets

They can easily be scored or scratched. Install the pilot screw and return it to its original position as noted during removal. Perform the pilot screw adjustment procedure if a new pilot screw is installed page 5-21 . Install the float and float valve in the carburetor body, then install the float pin through the body and float.

Oil Pressure Inspection

Yamaha Vmax Oil Pressure Gauge

If the oil pressure indicator light remains on a few seconds, check the indicator system before checking the oil pressure. Warm up the engine to normal operating temperature approximately 176 F 80 C . Stop the engine and disconnect the oil pressure switch wire connector from the switch. Remove the oil pressure switch and connect an oil pressure gauge and attachment to the switch hole. Oil pressure gauge 07506 3000000 Equivalent commercially available in U.S.A. Oil pressure gauge attachment...

Evaporative Emission Control System California Type Only

Cbr 1100 Carbs

This model complies with California Air Resources Board evaporative emission requirements. Fuel vapor from the fuel tank and carburetors is routed into the evaporative emission EVAP canister where it is absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission EVAP purge control valve is open, fuel vapor in the EVAP canister is drawn into the engine through the carburetor. At the same time, the EVAP carburetor air vent CAV solenoid valve is open...

Clutch Fluid

Do not mix different types of fluid, as they are not compatible with each other. Do not allow foreign material to enter the system when filling the reservoir. Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. When the fluid level is low, check entire system for leaks. Turn the handlebar to the right so that the reservoir is level and check the clutch fluid reservoir level through the sight glass. rHQRI2 . ft E fl BE AM DjjOS...

Carburetor Synchronization

Synchronize the carburetors with the engine at normal operating temperature, transmission is in neutral and the motorcycle supported securely on a level surface. Remove the following Fuel tank page 2-2 Lower cowl page 2-7 Remove the vacuum plugs from the engine intake ports. Screw the adaptors in the intake ports. Install the 3-way joint to the fuel valve vacuum tube. Connect the fuel tube and vacuum tube to the fuel Connect the vacuum gauge tubes to the adaptors and 3-way joint.

Master Link

Staking Chain Links

Remove the excess drive chain links from the new drive chain with the drive chain tool set. Include the master link when you count the drive chain links. STANDARD LINKS 110 links REPLACEMENT CHAIN DID DID50ZVS-120ZB RK RK50LFOZ1-12QLJ-FZ Never reuse the oil drive chain, master link, master link plate and O-rings. Assemble the new master link, O-rings and plate. caution Insert the master link from the inside of the drive chain, and install the plate with the identification mark facing the...