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 with the motorcycle upright on a level surface.

If the level is low, remove the right side fairing (page 2-4) and the reserve tank cap, and fill the tank to the "UPPER" level line with a 50/50 mixture of distilled water and antitreeze (coolant preparation: page 6-4).

RECOMMENDED ANTIFREEZE:

Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors CAUTION:

Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage.

Check to see if there are any coolant leaks when the coolant level decreases very rapidly.

If reserve tank becomes completely empty, there is a possibility of air getting into the cooling system. Be sure to remove all air from the cooling system (page 6-4).

UPPER

UPPER

Radiator Coolant Honda

COOLING SYSTEM

Remove the side fairings (page 2-4),

Check for any coolant leakage from the water pump, water hoses and hose joints.

Check the water hoses for cracks or deterioration and replace if necessary.

Check that all hose clamps are tight.

WATER

Check the radiator air passage for clogging or damage.

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 airflow is restricted over more than 20% of the radiating surface.

Install the side fairings (page 2-4).

WATER

Secondary Air Injection Honda Cbr 250

SECONDARY AIR SUPPLY SYSTEM

Check the air supply hoses between the pulse secondary air injection (PAIR) control valve and PAIR check valves for damage or loose connections Check the air supply hoses for cracks or deterioration.

If the hoses show any signs of heat damage, inspect the PAIR check valves (page 5-38).

Check the vacuum tube between the No. 4 cylinder head vacuum joint and PAIR control valve for doteri oration, damage or loose connections. Also check that the tube is not kinked or pinched.

For PAIR control valve inspection, see page 5-37.

PAIR CHECK VALVE

PAIR CHECK VALVE

Coolant System Honda F4i Diagram

AIR SUPPLY HOSES PAIR CONTROL VALVE

EVAPORATIVE EMISSION CONTROL SYSTEM (California type only)

Check the evaporative emission (EVAP) canister for cracks or damage.

Tl mm

Check the tubes between the fuel tank, EVAP canister, EVAP purge control valve, EVAP carburetor air vent (CAV) solenoid valve and carburetors for deterioration, damage or loose connections. Also check that the tubes are not kinked or pinched.

Refer to the Vacuum Hose Routing Diagram Label and Cable & Harness Routing (page 1-18) for tube connections and routing.

DRIVE CHAIN

CHAIN SLACK INSPECTION

EVAP CAV SOLENOID VALVE

EVAP PURGE CONTROL VALVE

EVAP CAV SOLENOID VALVE

EVAP PURGE CONTROL VALVE

Yamaha Xjr 1300
EVAP CANISTER

AWARNING

Never inspect and adjust the drive chain while the engine is running.

Turn the ignition switch OFF, place the motorcycle on its side stand and shift the transmission into neutral.

Check the slack in the drive chain lower run midway between the sprockets.

Checkpoint Loose Wheel Nut Indicators
25-35 mm {1-1 3/8 in)

ADJUSTMENT

Loosen the rear axle nut.

Turn both adjusting bolts an equal number of turn until the correct drive chain slack is obtained. Make sure the index marks on both adjusters are aligned with the index lines on the swingarm. Tighten the rear axle nut.

INDEX MARKS

INDEX MARKS

ADJUSTING BOLT

Recheck the drive chain slack and free wheel rotation.

Check the drive chain wear indicator label attached on the left drive chain adjuster. If the red zone of the indicator label reaches the index line on the swingarm, replace the drive chain with a new one (page 3-18).

CLEANING AND INSPECTION

Clean the chain with a soft brush using a non-flammable or high flash point solvent and wipe it dry. Re sure the chain has dried completely hefore 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 the sprockets as necessary.

LUBRICATION

Lubricate the drive chain with #80 — 90 gear oil or equivalent chain lubricant designed for specifically for use on O-ring chains.

Some commercially available chain lubricants may contain solvents which could damage the O-rings. Wipe off the excess chain lube.

NO KINKING OR BINDING

NO KINKING OR BINDING

SPROCKET INSPECTION

Inspect the drive and driven sprocket teeth for damage or wear. Replace if necessary. Never use a worn chain on new sprockets. Both chain and sprockets must be in good condition, or the new replacement parts will wear rapidly.

Check the attachment bolt and nuts on the drive and driven sprockets. If any are loose, torque them.

WORN

WORN

07hmh Mr10103

REPLACEMENT

This motorcycle uses a drive chain with a staked master link.

Loosen the drive chain. Assemble the special tool.

TOOL:

Drive chain tool set 07HMH-MR10103 or

07HMH-MR1Q1QB (U.S.A. only)

NOTE:

When using the special tool, follow the manufacturer's instruction.

07hmh Mr10103

Locate the crimped pin ends of the master link from the outside of the chain and remove the link with the drive chain tool set.

Remove the drive chain.

Cbr 600 Drive Chain 2000

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.

SPECIFIED LINKS: 110 links REPLACEMENT CHAIN: DID525HV RK525ROZ1

Remove the drive sprocket cover (page 7-4). Install the new drive chain on the sprockets over the drive and driven sprockets.

Assemble the new master link, O-rings and master link plate with the drive chain tool set.

NOTE:

Insert the master link from the inside of the drive chain, and install the plate with the identification mark facing the outside.

Measure the master link pin length projected from the plate.

SPECIFIED LENGTH: DID: 1.15-1.55 mm (0.045-0.061 in) RK: 1.20-1.40 mm (0.047-0.055 in)

Stake the master link pins with the drive chain tool set.

1 LINK

MASTER LINK

MASTER LINK

SPECIFIED LINKS

SPECIFIED LINKS

07hmh Mr10103

MASTER LINK

DRIVE CHAIN CUTTER

MASTER LINK

DRIVE CHAIN CUTTER

MASTER LINK

MASTER LINK

07hmh Mr10103
DRIVE CHAIN CUTTER

Make sure that the maser link pins are staked properly by measuring the diameter of the staked area.

DIAMETER OF THE STAKED AREA: DID: 5.50-5.80 mm (0.217-0.228 in) RK: 5.55-5.85 mm (0.219-0.230 in)

Make sure that the maser link pins are staked properly by measuring the diameter of the staked area.

DIAMETER OF THE STAKED AREA: DID: 5.50-5.80 mm (0.217-0.228 in) RK: 5.55-5.85 mm (0.219-0.230 in)

After staking, check the staked area of the master link for cracks.

If there is any cracking, replace the master link, O-rings and plate.

CAUTION.

A drive chain with a clip-type master link must not be used.

Install the drive sprocket cover (page 7-8).

CRACKS

o

X

GOOD

NO GOOD

DRIVE CHAIN SLIDER INSPECTION

Check the drive chain slider for wear. Replace the chain slider if it is worn to the wear limit line.

Refer to section 14 for drive chain slider replacement.

BRAKE FLUID

CAUTION:

• 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.

NOTE:

When the fluid level is low, check the brake pads for wear (page 3-21). A low fluid level may be. due to wear of the brake pads. If the brake pads are worn, the caliper pistons are pushed out, and this accounts for a low reservoir level. If the brake pads are not worn and the fluid level is low, check entire system for leaks (page 3-21).

Cbr 600 Sight Glass

FRONT BRAKE

Turn the handlebar to the left side so that the reservoir is level and check the fluid level through the sight glass.

If the level is near the lower level mark, remove the reservoir cap, set plate and diaphragm, and fill the reservoir with DOT 4 brake fluid from a sealed container to the casting ledge.

Install the diaphragm, set plate and reservoir cap and tighten the cap screws.

REAR BRAKE

Place the motorcycle on a level surface and support it upright.

Check the fluid level in the rear brake reservoir.

If the level is near the lower level line, remove the reservoir mounting bolt and the reservoir cap. and fill the reservoir with DOT 4 brake fluid from a sealed container to the upper level line. Install the reservoir cap.

Install the reservoir onto the stay with the mounting bolt.

F4i Coolant Reserve
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Responses

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