Starter Motor

With the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor. Remove the left engine hanger plate (page 7-4). Remove the motor mounting bolts and ground cable. Remove the starter motor. L Record the location and number of shims. Check for continuity between the cable terminal and case. There should be no continuity. Check for continuity between the cable terminal and brush. There should be continuity Check for continuity between (+) and (-)...

Service Information

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. Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and a current is present. When checking the ignition system, always follow the steps in the troubleshooting (page 16-3). The...

Cylinder Head Disassembly

Honda Cylinder Head Lifters

Mark all parts during disassembly so that they can be placed back in their original locations for installation. Install the tappet hole protector into the valve lifter sliding surface. Tappet hole protector 07HMG - MR70002 An equivalent tool can easily be made from a plastic 35 mm film container by using the measurements as shown. Install the valve spring compressor onto the valve and compress the valve spring. Compressing the valve springs more than necessary will cause loss of valve spring...

Cylinder Head Installation

Honda Cbr 600 Fork Seal Installation

Clean any gasket material from the cylinder mating surfaces. Install the dowel pins and new gasket. < 2> ' -I VALVE SPRING COMPRESSOR Install the cylinder head onto the cylinder. Apply molybdenum oil solution to the cylinder head bolt threads and seating surface. Install and tighten the cylinder head bolts in a crisscross pattern in 2 - 3 steps. Torque 48 N m (4.8 kg-m, 35 Ib-ft) Connect the thermosensor connector. Connect the water hoses to the cylinder head. Install the cam chain...

Fan Motor Switch

Fan motor does not stop Turn the ignition switch OFF, disconnect the connector from the fan motor switch and turn the ignition switch ON again. If the fan motor does not stop, check for a shorted wire between the fan motor and switch. If the fan motor stops, replace the fan motor switch. Before testing, warm up the engine to operating temperature. Disconnect the connector from the fan motor switch and ground the connector to the body with a jumper wire. Turn...

Rear Master Cylinder

Drain the brake fluid from the rear hydraulic system (page Avoid spilling brake fluid on painted, plastic or rubber parts. Place a rag or shop towel over these parts whenever the system is serviced. When removing the oil bolt, cover the end of the hose to prevent contamination . Disconnect the brake hose from the master cylinder by removing the oil bolt and sealing washers. Loosen the rear master cylinder mounting bolts. Remove the footpeg holder bolts and footpeg holder assembly. Remove the...

Air Vent Solenoid Valve 49 state Canada type

Disconnect the No.4, 6, 7 tubes from the air vent solenoid valve. Connect the pressure pump to the No.4 tube fitting. Tool Pressure pump ST - AH - 255 - MC7 (U.S.A. only) Damage to the air vent solenoid valve may result from use of high pressure air source. Use a hand operated air pump only. With the ignition switch OFF, pump air through the No.6 tube fitting. Connect the pressure pump to the No.7 tube fitting. With the ignition switch ON, pump air through the No.6 tube Remove the drive...

Camshaft Installation

Honda Cbr 600f Timing Marks

Apply molybdenum disulfide oil to the valve lifters. Install the shims and valve lifters. Align the T mark (notch mark) with the index mark on the ignition pulse generator rotor cover by turning the crankshaft clockwise. Apply molybdenum disulfide oil (a 50 50 mixture of engine oil and molybdenum disulfide grease) to the camshaft journals of the cylinder head and camshaft holders. Install the camshafts onto the cylinder head with the cam lobes for the No.1 cylinder facing upas shown., Install...

Steering Stem

Honda 07916 3710101

Disconnect the ignition switch connector and remove the wire from the clamps (page 18-12). Remove the steering stem nut and washer. - handlebar (page 12-3). fork legs (page 12-14). Always replace the bearings and races as a set. Remove the upper bearing outer race. 07953-MJ10000 or 07953 - MJ1000A or 07953-MJ1000B Loosen the steering bearing adjustment nut by holding the steering stem and remove the adjustment nut. Steering stem socket 07916 - 3710101 or Straighten the lock washer tabs, and...

Right Handlebar Installation

Install the right handlebar aligning the stopper on the handlebar with the groove in the top bridge. Tighten the handlebar pinch bolt. Torque 27 N m (2.7 kg-m, 20 Ib-ft) Install the stopper ring into the fork groove. Apply grease to the throttle grip inner surface and flange groove. Install the handlebar weight aligning its boss with the handlebar. Clean and apply a locking agent to the screw threads. Tighten the screw. Connect the throttle cables to the throttle grip flange. Install the...

Battery

Always turn the ignition switch OFF before removing or installing the battery. Remove the battery cover bolts and cover. Remove the battery positive cable cover. Disconnect the battery negative cable first, then the positive Remove the tool kit and the battery. Installation is in the reverse order of removal. Apply clean grease to the battery terminals. Pull the cover over the positive terminal. Measure the battery voltage using a digital multimeter. The battery gives off explosive gases keep...

Clutch Removal

Xtz750 Clutch Spring Plate

Drain the engine oil (page 3-11). Remove the clutch cable holder bolt and disconnect the Remove the oil filler cap dip stick. Remove the bolts and right crankcase cover. FILLER CAP DIP STICK (4) RIGHT CRANKCASE COVER Loosen the clutch lifter plate bolts in a crisscross pattern in 2 (1) BOLTS or 3 steps. Remove the bolts, lifter plate, springs and lifter rod. Be careful not damage the mainshaft threads. Unstake the clutch center lock nut. Hold the pressure...

Poor Performance At Low And Idle Speeds

Check ignition timing and valve-Incorrect- 2. Check carburetor pilot screw-Incorrect- 3. Check if air is leaking past intake pipe Excessive carbon build-up on the piston Excessive carbon build-up on the piston (Faulty ignition control module or ignition (Faulty ignition control module or ignition Fuel-air mixture too lean Fuel-air mixture too rich Deteriorated intake pipe O-ring Loose carburetor Damaged intake pipe Faulty, carboned or wet-fouled spark plug Go to page 16-3

Brake Fluid Replacement Air Bleeding

A brake disc or pad contaminated with brake fluid reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. 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. For the front brake, turn the handlebar to the left until the reservoir is level before removing the reservoir cap. For the...

Coolant Temperature Gauge

1995 Honda Hatchback Coolant Sensor

Disconnect the connector from the thermosensor and short it to body ground. Turn the ignition switch ON. The coolant temperature gauge needle should move all the way to H. If the gauge does not move, check the sub fuse (15A) and wires for a loose connection or an open circuit if normal, replace the gauge with a new one. Wear insulated gloves and adequate eye protection. Keep flammable materials away from the electric heating element. Drain the coolant (page 6-4). Remove the carburetor page...

Cylinder Head Assembly

Install the outer spring seats, inner spring seats and new stem seals. Install the tappet hole protector into the valve lifter sliding surface. Tappet hole protector 07HMG - MR70002 Lubricate each valve stem with molybdenum oil solution and insert the valves into the valve guides. To avoid damage to the stem seal, turn the valve slowly when installing. Install the valve springs and retainers. The springs' tightly wound coils should face toward the combustion chamber. < 2> ' -I VALVE SPRING...

Transmission Assembly

Apply molybdenum oil solution to the gear and bushing sliding surface and shift fork grooves to ensure initial lubrication. Assemble all parts into their original positions. NOTE Check the gears for freedom of movement or rotation on the shaft. Install the washers and snap rings with the chamfered edges facing the thrust load side. Do not reuse worn snap rings which could easily spin in the groove. Check that the snap rings are seated in the grooves. Align their end gaps with the grooves of the...

Ignition Switch

Cbr 600 Repsol Wiring Ignition

Disconnect the ignition switch 3P connector. Check for continuity between the terminals. Continuity should exist between the color coded wire as shown in chart. Remove the upper fairing (page 2-4). Disconnect the ignition switch 3P connector. Release the ignition switch wire from the clamp, band and Remove the bolts and ignition switch. Torx bit (T40) 07703 - 0010100 or equivalent commercially available in U.S.A. Install the ignition switch in the reverse...

Crankcase Separation

Cam And Dowel Connectors

Refer to Service Information (page 10-1) for removal of necessary parts before disassembling the crankcase. Remove the bolt, collar and cam chain guide. Remove the cam chain and cam chain drive sprocket. Remove the screw and oil pressure switch terminal. Disconnect the neutral switch connector. Remove the bolts and speed sensor. CAUTION ( Remove the speed sensor before separating the crank-case. Do not separate or assemble the crankcase with the speed sensor installed. Remove the upper...

Valve Seat Inspectionrefacing

Clean all intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to each valve face. Tap the valve against the valve seat several times using a hand-lapping tool, without rotating the valve, to make a clear pattern. Remove the valve and inspect the valve seat face. NOTE _ The valve cannot be ground. If the valve face is burned or badly worn or if it contacts the seat unevenly, replace the valve. Bent or collapsed valve stem Replace the valve and...

Ignition Timing

Cbr600 F4i Ignition Timing

Stop the engine and connect a timing light to the spark plug wire. Read the manufacturer's instructions for the timing light before operating. - Right side fairing (page 2-3) - Ignition pulse generator rotor cover cap. The timing is correct if the F mark (three punch marks) align with the index mark on the ignition pulse generator rotor cover. Increase the engine speed by rotating the throttle stop screw and make sure the F mark begins to move counterclockwise at approximately 1,500 rpm. The...

Side Stand Switch

Remove Honda Timing Inspection Cap

Disconnect the side stand switch 3P mini connector. Check for continuity between each of the terminals as below. There should be continuity between the O O positions on the chart below. Disconnect the side stand switch 3P mini connector (Green) and remove the bolt and side stand switch . Install the side stand switch aligning the pin on the switch Secure the side stand switch with the bolt. Install the removed parts in the reverse order of removal.

Turn Signal Relay

Blinker Relay 1995 Heritage Softail

Remove the turn signal relay from the frame and disconnect the connector. Remove the suspension rubber holder from the relay. Installation is in the reverse order of removal. Remove the turn signal relay see page 18-16). Check for turn signal circuit connection before testing. Connect the terminals as described below Black Brown DC 12 V Positive (+) Green DC 12 V Negative (-) Gray Turn signal wire of one side connect other If the turn signal relay fails this...

Inspection

Remove Camshaft Cbr600

Inspect the camshaft journal surfaces for scoring or evidence of insufficient lubrication. Measure the O.D. of each camshaft journal. Service limit 24.955 mm (0.9825 in) Clean off any oil from the journals of the camshaft holders, head and camshafts. Put the camshaft onto the cylinder head and lay a strip of plastigauge lengthwise on top of each camshaft journal. Do not block any oil holes with the plastigauge. Do not rotate the camshaft during inspection. Apply engine oil to the camshaft...

Cylinder Compression

Pressure Valve Sportster

Warm up the engine to normal operating temperature. Stop the engine, disconnect the spark plug caps and remove one spark plug at a time. To measure the cylinder compression of each cylinder, remove only one plug at a time. Shift the transmission into neutral and turn the engine stop switch ON. Insert the compression gauge. Open the throttle all the way and crank the engine with the starter motor. Crank the engine until the gauge reading stops rising. The maximum reading is usually reached...

Fuel Pump

Starting Circuit Cutoff Relay Yamaha

Remove the side cover (page 2-2) and disconnect the fuel cut-off relay connector. Check for battery voltage between the Black (+) terminal and ground (-). There should be battery voltage with the ignition switch ON. If there is no voltage, check for an open circuit or loose connection in the Blue Yellow wire. If there is battery voltage, check for continuity in the Black Blue wire. Check for continuity, between the Black Blue wire and ground. If there is continuity, replace the fuel cut-off...

Nuts Bolts Fasteners

Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-13). Check that all cotter pins, safety clips, hose clamps and cable stays are in place and properly secured. Refer to section 13 for shock absorber service. Check the action of the shock absorbers by compressing them several times. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts.

Suspension Linkage

Honda Cbr Shock And Link Bolt

Raise the rear wheel off the ground and support the motorcycle using a hoist. Remove the shock link bolt and nut (frame side). Install the reservoir tank aligning the hose end with the cut off of the stay. Install the reservoir holder and hose band. Install the reservoir hose to the clamp. Remove the lower shock absorber mounting bolt and nut. Remove the shock arm bolt and nut (swingarm side). (1) LOWER SHOCK ABSORBER MOUNTING BOLT NUT Remove the shock link shock arm assembly. Remove the shock...

Wiring Diagrams

Honda Cbr 600 Wiring Diagram

T njsc 10* > > L (T.p, 5sits J 2 use 10* f UNTION STMT01 FXL . SO.EMD WU.VE ) 3 *U1E IS ( TVH1 SljMi-'FtKHT. BEAR BtUKC* HCfll'NETER TJUL ) E SM STWCCAT0 F T ,l i HlHtL rOCAIC* ITLBK stanL-mOM hopBA --CW-VETER-HL ' ll HTUM-ST W TER HJ-L SCCOWtl ML ) MUCUCHT ITLBK stanL-mOM hopBA --CW-VETER-HL ' ll HTUM-ST W TER HJ-L SCCOWtl ML ) MUCUCHT fOWTW 12V1.TV KM IMUCATOft IZVI.TMT WtSJJK U(XT 1JVI.7W fwwxon i2VI.ni a BUC< f wwv l> < B.UE L> IBM BLU 4 Wt Li Llixr h BCD P PWC UTE fr GM

Rear Brake Light Switch

Remove the left side fairing (page 2-3). Disconnect the brake light 2P (White) connector and check for continuity at the switch side connector terminals. There should be continuity with the brake applied and no continuity with it released. Disconnect the right handlebar connectors and single lead connector.

Valve Seat Refacing

Valve Seat Contact

Follow the tool manufacturer's operating instruc-tions. Be careful not to grind the seat more than necessary. If the contact area is too high on the valve, the seat must be lowered using a 32* flat cutter. If the contact area is too low on the valve, the seat must be raised using a 60' inner cutter. Refinish the seat to specifications, using a 45* finish cutter. Using a 45' cutter, remove any roughness or irregularities from the seat. Valve seat cutter, 27.5 mm (45' IN) Valve seat cutter, 24.5...

Ignition Pulse Generator

Suckerpunchsallysmotorcycles

It is not necessary to remove the ignition pulse generator from the engine. Disconnect the ignition control module 16P connector. Measure the resistance of the ignition pulse generator at the ignition control module 16P connector. If the measurement is out of specified range, perform the following procedures Disconnect the ignition pulse generator 2P (Red) connector. Measure the resistance of the ignition pulse generator at the ignition pulse generator 2P (Red) connector. Connect the primary...

Oil Pressure Switch

Disconnect the oil pressure switch wire from the switch by removing the terminal screw (page 4-3). Short it to ground using a jumper wire. Turn the ignition switch ON. The oil pressure warning indicator should come on. If the light dose not come on, check the sub-fuse (10 A) and wires for a loose connection or an open circuit. Start the engine and make sure that the light gose out. If the light dose not go out, check the oil pressure (page 4-3). If the oil pressure is normal, replace the oil...

Cylinder Head Removal

Remove the exhaust system (page 2-10). Remove the carburetor (page 5-5). Remove the radiator (page 6-8). Remove the thermostat (page 6-6). Remove the PAIR control valve (California type only page 5-38). Remove the cylinder head 6 mm bolts. Remove the cap nut and sealing washer. Remove the cam chain tensioner slider. Disconnect the water hoses to the cylinder head. Disconnect the thermosensor connector. Disconnect the PAIR control valve hose from the cylinder head (California type only). Loosen...

Flywheelstarter Clutch

Honda Cbr 150 Starter Assembly

Remove the left crankcase cover (page 15-9). Loosen the flywheel bolt while holding the flywheel with a flywheel holder. Flywheel holder 07925 - ME90000 or equivalent commercially available in the U.S.A. Remove the flywheel bolt with the washer. Remove the flywheel using the rotor puller. Tool Rotor puller 07733 - 0020001 or Remove the starter idle gear shaft and idle gear. Remove the starter driven gear by turning it counterclockwise. Remove the starter clutch bolts while holding the flywheel...

Starter Relay Switch

Shift the transmission into neutral. Turn the ignition switch ON and depress the starter switch button. The coil is normal if the starter relay switch clicks. If you don't hear the switch CLICK, inspect the relay switch using the procedure below. Disconnect the relay switch connector. Check for continuity between the Green Red wire (ground If there is continuity when the transmission is in neutral or when the clutch is disengaged and the side stand switch is up, the...

Clutch Installation

Xtz750 Clutch Spring Plate

Apply molybdenum oil solution to the clutch outer needle bearing. Install the clutch outer onto the mainshaft by positioning the projections of the crankcase between the teeth of the primary driven gears. Line up the gear teeth of the primary driven gears with a 5 mm pin or suitable tool . Apply molybdenum oil solution to the clutch outer guide. Install the clutch outer guide with the ribbed side facing out. Install the clutch outer, aligning the clutch outer holes with the oil pump driven...

Connecting Rod Bearing Selection

Record the connecting rod I.D. code numbers on the rods. NOTE Numbers 1 or 2 on the connecting rods are the codes for the connecting rod I.D.s. Record the crankpin O.D. code letters from the crank weight. NOTE Letters A or B on the left side of the crank weight are the codes for the crankpin O.D.s from left to right. Cross reference the crankpin and rod codes to determine the rep acement bearing color code. 34.000-34.008 mm lt 1.3386-1.3389 in 34.008-34.016 mm lt 1.3389-1.3392 in 31.492 -...

Ignition System Inspection

Peak Voltage Tester Honda

If there is no spark at either plug, check all connections for loose or poor contact before measuring each peak voltage. Use the recommended digital multimeter or commercially available digital multimeter with an impedance of 10 Mil DCV minimum. The display value differs depending upon the internal impedance of the multimeter. If using an Imrie diagnostic tester model 625 , follow the manufacturer's instructions. Connect the peak voltage adaptor to the digital multimeter, or use the Imrie...

Combination Meter

When checking the speedometer and speed sensor, follow the steps in the troubleshooting flow chart page 18- Remove the upper fairing page 2-4 . Remove the bulb socket by turning it counterclockwise. Remove the bulb and replace with a new one. Install it in the reverse order of removal. Remove the upper fairing page 2-4 . Remove the rubber cap from the combination meter. Remove the meter mounting bolts and collars. Raise the combination meter and disconnect the connectors. Remove the meter...

Clutch Diode

Remove the tape and diode. Check for continuity between the diode terminals. B and A - No continuity B and C - No continuity A and B - Continuity C lt and BH Continuity When there is continuity, a small resistance value will register. If there is abnormal, replace the diode.

Engine Does Not Start Or Is Hard To Start

Remove and inspect spark plug Spark jump 4. Test cylinder compression Compression normal 5. Start by following normal procedure-Engine starts, then stops- No fuel in tank Sticking float valve Clogged float valve Clogged fuet tank vent tube Valve clearance too small Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Seized valve Improper valve timing Improper valve and seat contact Carburetor pilot screw excessively closed Faulty ignition control module or ignition

Throttle Position Sensor

Reset Tps Speed Triple

Disconnect the throttle position sensor 3P connector. Check the connector for loose or corroded terminals. Connect the inspection adaptor between the throttle position sensor connectors. Inspection adaptor 07GMJ - ML80100 Measure and record the input voltage at the inspection adaptor terminals using a digital multimeter. Connection Red clip - Green clip - Standard 4.5 - 5.5 V If the measurement is out of the specification, check the following - Loosn connection ignition control module 16P...

R r

Within 30 mmHg 1.2 inHg Base carburetor No3 Sparkplug 12 N m 1.2 kg-m, 9 Ib-ft Cylinder head cover bolt 10 N m 1.0 kg-m, 7 Ib-ft Camshaft holder bolt 12 N-m 1.2 kg-m, 9 Ib-ft Apply oil to the threads. Ignition pulse generator cover cap 18 N-m 1.8 kg-m, 13 Ib-ft Apply grease to the threads. Oil drain bolt 30 N m 3.0 kg-m, 22 Ib-ft Oil filter cartridge 10 N m 1.0 kg-m, 7 Ib-ft Drive chain adjuster lock nut 22 N m 2.2 kg-m, 16 Ib-ft Rear axle nut 95 N m 9.5 kg-m, 69 Ib-ft Side stand pivot bolt 10...

Installation

Apply engine oil to a new O-ring and install it onto the stepped portion of the water pump. Install the water pump into the crankcase while aligning the water pump shaft groove with the oil pump shaft end. Align the mounting bolt holes in the water pump and crankcase and make sure the water pump is securely installed. Install a new O-ring into groove in the water pump. Install the water pump cover and tighten the bolts. Torque CT bolt 13 N m 1.3 kg-m, 9 Ib-ft Install the water hoses and tubes...

Valve Guide Replacement

Chill the valve guides in the freezer section of a refrigerator for about an hour. Wear insulated gloves to avoid burns when handling the heated cylinder head. Heat the cylinder head to 130'C - 140'C 275'F - 290'F with a hot plate or oven. Do not heat the cylinder head beyond 150C 300F . Use temperature indicator sticks, available from welding supply stores, to be sure the cylinder head is heated to the proper temperature. Using a torch to heat the cylinder head may cause warping. Support the...

Oil Cooler

Drain the engine oil page 3-11 . Drain the coolant page 6-4 . Remove the pulse secondary air injection PAIR control valve California type only page 5-38 . Remove the oil cooler mounting bolts. Remove the oil cooler assembly and O-ring. Remove the O-rings and joint collars from the-crankcase.

Relief Valve Check

Check the operation of the pressure relief valve by pushing on the piston. Remove the relief valve snap ring and disassemble the relief valve. Check the piston for wear, sticking or damage. Check the spring and piston for wear or damage. Check the valve for clogging or damage. Clean the remaining parts and assemble the relief valve in the reverse order of disassembly.

Carburetor Removal

Remove the air cleaner base page 5-4 . Disconnect the No.15 tube California type only from the air chamber. Disconnect the sub-air cleaner tube from the sub-air cleaner. Disconnect the No.6 tube from the tube joint. Disconnect the fuel tube from the tube joint. Disconnect the throttle position sensor connector. Remove the throttle stop screw from the clamp. Disconnect the No.5 and No.11 tubes from the EVAP purge control valve California type only . Disconnect the carburetor heater tube from the...

Engine Installation

Carefully align mounting points with the jack to prevent damage to engine, frame, wires and cables. Use a floor jack or other adjustable support to carefully maneuver the engine into place. Carefully align the bolt holes in the frame and engine then insert the rear lower mounting bolt from the left side. Loosely install the rear lower mounting nut. Install the collar short and right front mounting bolt. Loosely install the right front mounting nut. Install the collar and rear upper mounting...

R

Connect the turn signal connectors and headlight socket. Install the upper fairing, aligning its bosses with the grom-mets. Engage the windscreen tabs with the upper fairing slots securely as shown. Install the upper fairing assembly and windscreen. Install the upper fairing mounting bolts. Install the screw and fuse box cover page 18-18 . Install the upper fairing lower cover page 18-5 . Install the left seat rubber with the mark MT4-L facing out. Install the left seat rubber plate with the...

Specifications

No. 1 4 carburetor 135, No.2 3 carburetor 138 Carburetor float level gauge Vacuum Pressure pump Vacuum pump Pressure pump Pilot screw wrench Pilot elbow wrench Pilot screw wrench or U.S.A. only Pilot screw wrench Adjustable guide 07KMA - MS60101 with-p 49 state, California type

High Altitude Adjustment Usa only

When the vehicle is to be operated continuously above 6,500 feet 2,000 m , the carburetor must be readjusted as follows to improve driveability and decrease exhaust emissions. Remove the screws, float cambers an O-rings. Replace the standard main jet with the high altitude type. Assemble and install the carburetor page 5-19 . 6,500 feet 6,500 feet 2,000 m 2,000 m 6,500 feet 6,500 feet 2,000 m 2,000 m Warm up the engine to operating temperature. Stop and go riding for 10 minutes is sufficient....

Cbr Sub Air Cleaner Problems

Air vent tube clogged or restricted EVAP CAV solenoid valve faulty California type only, page 5-281. Air vent tube clogged or restricted EVAP CAV solenoid valve faulty California type only, page 5-28 . Engine stalls, rough idling at warm engine Air vent solenoid valve faulty see next page Incorrect air vent tube connections Engine stalls, rough idling in a strong wind Outer air vent tube out of connection Sub-air cleaner clogged or restricted Air vent tube clogged or restricted Sub-air cleaner...

Side Stand

Support the motorcycle on a level surface. Check the side stand spring for damage or loss of tension. Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary. Make sure that the side stand is not bent. Check the side stand ignition cut-off system - Sit astride the motorcycle and raise the side stand. - Start the engine with the transmission in neutral, then shift the transmission into gear, with the clutch lever squeezed. - Move the side stand fully...

Radiator Capsystem Pressure Inspection

The engine must be cool before removing the radiator cap, or severe scalding may result. Remove the upper fairing page 2-4 . Remove the radiator cap. Before installing the cap in the tester, wet the sealing surfaces. Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low. It must hold specified pressure for at least 6 seconds. 108 -137 kPa 1.1 - 1.4 kg cm , 15.6 - 19.9 psi Pressure the radiator, engine and hoses, and...

Coolant Replacement

1995 Yamaha Vmax 600 Water Pump Diagram

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, gargle and consult a physician immediately. - If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usage. Therefore, for best...

Air Vent Solenoid Valve Relay 49 state Canada type

AIR VENT SOLENOID VALVE RELAY VOLTAGE Remove the upper fairing page 2-4 . Check for loose or poor connection of the connector. Turn the ignition switch ON and measure the voltage between the connector terminals at the air vent solenoid valve relay connector. Connection Orange Black - ground - Standard Battery voltage Connection Black 1 - ground - Standard Battery voltage Connection Black 2 - ground - Standard Battery voltage

Troubleshooting

IT When checking the direct air intake system, follow the steps in the procedure on page 5-26. -Fuel tank breather tube restricted, 49 state Canada type - Evaporative emission tube No.1 restricted California type Too much fuel getting to the engine -Air cleaner clogged Fuel contaminated deteriorated Improper starting enrichment valve operation Starting enrichment valve circuit clogged Improper throttle operation No spark at plug ignition system faulty Emission control system faulty California...

Evap Cav Solenoid Valve California type Operation Check

Evap Canister Vent Valve Solenoid

Disconnect the No.4, 8 tubes from the EVAP CAV solenoid valve. Connect the pressure pump to the No.4 tube fitting goes to EVAP canister. Pressure pump ST - AH - 255 - MC U.S.A. only Damage to the air vent solenoid valve may result from use of high pressure air source. Use a hand operated air pump only IGNITION SWITCH OFF 1 gt N0 4 TUBE fitting IGNITION SWITCH OFF 1 gt N0 4 TUBE fitting With the ignition switch OFF, pump air through the No.4 tube fitting goes to air vent solenoid valve. Connect...

Evaporative Emission Evap Purge Control Valve

Cbr 600 Vacuum

Remove the EVAP purge control valve from the frame stay. Disconnect the No.11, No.5 and No.4 tube from their connections. Installation is in the reverse order of removal. The EVAP purge control valve should be inspected if hot restart is difficult. Remove the EVAP purge control valve see above . Connect a 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. Vacuum Pressure pump A937X - 041- XXXXX or Vacuum...

Air Cleaner Housingdirect Air Intake Dai Duct

Xjr 1300 Air Induction System

Remove the air cleaner housing cover and air cleaner page 3-5 . Disconnect the cylinder head cover breather tube and remove the air cleaner base. Disconnect the sub-air cleaner tube and air vent tube from the direct air intake D.A.I. duct. Remove the trim clips. Remove the radiator mounting bolts and D.A.I, duct mounting screws. Disconnect the fan motor connector. Remove the upper fairing page 2-4 . Release the grommet on the left side radiator top from the boss. Release the hook on the filler...

Pulse Secondary Air Injection Pair Control Valve

Bootleg Control Valves

Disconnect the PAIR control valve control tube and No.15 hose from the PAIR control valve. Disconnect the air injection hoses from the PAIR control valve. Remove the three bolts and PAIR control valve. Remove the four nuts and air injection pipes. Remove the air injection pipe gasket. Installation is in the reverse order of removal. Start the engine and warm it to operating temperature. Stop the engine and remove the air cleaner page 3-5 . Check the No.15...

Idle Drop Procedure

Pilot Screw Wrench 07908 4220201

Make sure the carburetor synchronization is within specification before pilot screw adjustment. The pilot screws are factory pre-set and no adjustment is necessary unless the pilot screws are replaced. Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change. U.S.A. only Pilot screw wrench Adjustable guide 07MMA - MT3010A with 07PMA - MZ2011A 1. Turn each pilot screw clockwise until it seats lightly, then back it out to the specification given. This...

Carburetor Assembly

Cbr600 Choke Spring

Install the new O-rings, air jet and air cut-off valve assembly 1 O-RINGS to the carburetor body. -- Install the screw and connect the vacuum tube. Install the pilot screws and return them to their original position as noted during removal. Perform pilot screw adjustment if new pilot screws are installed. Install the needle jet holder, main jet and slow jet. Hang the float valve onto the float arm lip. Install the float valve with float in the carburetor body, then install the float pin through...

Carburetor Disassembly

Cbr Carburetor Disassembled

vacuum chambers, float chambers and pilot screws can be serviced without separating the carburetors. Keep each carburetor's parts separate from the other's so you can install the parts in their original positions. Bend up the lock plate tabs and remove the screws. Remove the air chamber and air funnel assembly. Remove the O-rings. Disconnect the sub-air cleaner tube and air vent tubes from the carburetor. Disconnect the No.5 tube joint California type only from the vacuum tubes. Remove the...

Carburetor Installation

Throttle Cables Yamaha Dragstar 650

Note the cables and tubes properly page 1-20 . Connect the throttle cable ends to the throttle drum and install the throttle cables into the cable holder. Install the carburetor assembly onto the cylinder head. Tighten each insulator band screw alternately. Install the right engine hanger plate and collar. Install and tighten the hanger plate bolts. Torque 10 mm bolt 45 N m 4.5 kg-m, 33 Ib-ft Connect the carburetor heater tube to the thermostat valve. Connect the carburetor heater tube to the...

Oil Pressure Check

Oil Pressure Sender Yamaha 1100 Classic

NOTE If the engine is cold, the pressure reading will be abnormally high. Warm up the engine to normal operating temperature before starting this test. Remove the switch cover and disconnect the oil pressure switch wire by removing the screw. Remove the oil pressure switch and connect an oil pressure gauge attachment and gauge to the pressure switch hole. Oil pressure gauge attachment 07510 - 4220100 Oil pressure gauge 07506 - 3000000 or equivalent...

How To Replace Timing Belts On A Cbr 250

1996 Softail Transmission Drain Plug

Check the valve clearance for the No.1 and No.3 cylinder intake valves using a feeler gauge. Insert the feeler gauge between the valve lifter and the cam lobe. Valve clearance IN 0.16 0.03 mm 0.006 0.001 in Record the clearance for each valve in case shim selection is required for adjustment. Turn the crankshaft clockwise 1 2 turn 180 and make sure the index line on the ignition pulse generator rotor is facing straight up as shown not aligned with the index mark . Check the valve clearance for...

Cbr 600 95 Battery Manual

Softail Oil Line Diagram

5 FAN MOTOR SWITCH FAN MOTOR WIRE 5 FAN MOTOR SWITCH FAN MOTOR WIRE 6 PULSE SECONDARY AIR INJECTION PAIR CONTROL VALVE AIR INTAKE HOSE CALIFORNIA TYPE ONLY PULSE SECONDARY AIR INJECTION PAIR CONTROL VALVE TUBE CALIFORNIA TYPE ONLY 6 PULSE SECONDARY AIR INJECTION PAIR CONTROL VALVE AIR INTAKE HOSE CALIFORNIA TYPE ONLY PULSE SECONDARY AIR INJECTION PAIR CONTROL VALVE TUBE CALIFORNIA TYPE ONLY lt 3 gt IGNITION PULSE I GENERATOR 2P RED 2 SIDE STAND SWITCH 3P GREEN CONNECTOR 4 REAR BRAKE LIGHT...