Indicator Switch Honda Cbr 600

Disconnect the fan motor switch connector and remove the switch. Install a new 0-ring onto the fan motor switch. Apply sealant to the fan motor switch threads. Install and tighten the fan motor switch. TOROUE 18 N-m (1.8 kgf-m, 13 Ibf.ft) Install the removed parts in the reverse order of removal. If the oil pressure warning indicator stays on while the engine is running, check the engine oil level before inspection. Make sure the oil pressure warning indicator come on with the ignition switch...

Primary Drive Subgear Installation

Install the stopper pins and gear springs onto the primary drive gear as shown. Apply molybdenum oil solution to the sub-gear sliding surface and friction spring sliding surface. Temporarily install the sub-gear by aligning the punch mark with the hole in the primary drive gear. Install the friction spring onto the sub-gear. Install the sub-gear onto the primary drive gear so it evenly touches the primary drive gear by prying the sub-gear with a 5-rnm pin ot screwdriver is the stoppers on the...

Powerground Line Inspection

Connect the test harness between the main wire harness and ECM (page 5-8). Check for continuity between the ECM test harness connector A9 terminal and ground, between the A20 terminal and ground, and between the B12 terminal and ground. There should be continuity at all times. If there is no continuity, check for an open circuit in Turn the ignition switch to ON with the engine stop switch in the RUN position. Measure the voltage between the ECM test harness connector BB terminal (+) and...

Removal

Remove the throttle body (page 5-62). Remove the cam chain tensioner sealing bolt and sealing washer. Turn the tensioner shaft fully in (clockwise) and secure it using the stopper tool to prevent damaging the cam chain. See page 8-7 for detail of the tool. Remove the bolts and cam chain tensioner lifter. Remove the gasket.

Engine Removal

Remove the following Fuel tank (page 5-55) - Lowei bracket (page 7-3) Disconncct the PAIR air suction hoses from the reed valve covers. Disconnect the ignition coil connectors, then remove the direct ignition coils. Remove the wire band and release the brake light wire from the seat rail. Disconncct the brake light switch 2P (Black) connector Disconnect the lower radiator hose from the water pump cover. Disconnect the oil cooler water hose from the oil cooler. Disconnect the air bleed hose and...

Valve Seat Inspectionrefacing

Clean the intake and exhaust valves thoroughly to remove any carbon deposits. Apply a light coat of Prussian Blue to the valve seats. Tap the valves and seats using a rubber hose or another hand-lapping tool. Remove the valve and inspect the valve seat face. The valve seat contact should he within the specified width and even all around the circumference. STANDARD 0.90 -1.10 mm (0.035 - 0.043 in) SERVICE LIMIT 1.5 mm (0.06 in) If the seat width is not within specification, reface the valve seat...

Alternator Cover Removal

Disconnect the alternator 3P (Natural) connector. The alternator Remove the alternator cover SH bolts and alternator cover (stator) is cover. magnetically The engine oil will run out when the alternator cover is removed. Set a clean oil pan under the engine and add the recommended oil to the specified level after installation.

Cylinder Head Assembly

SHIM COTTERS SPRING RETAINER EXHAUST VALVE SPRING INTAKE VALVE SPRING (INNER) VALVE SPRING (OUTER) Blow out all oil passages in the cylinder head with compressed air. Install the tappet hole protector into the valve lifter bore. Install the valve spring seats. Install the new stem seals. Lubricate the valve stems with molybdenum oil solution. Insert the valve into the valve guide while turning it slowly to avoid damage to the stem seal. Install the valve spring with the tightly wound coils...

Right Crankcase Cover Removal

Change Road Star Right Cranckcase Cover

Hemove the lower cowl (page 2 4). Disconnect the ignition pulse generator 2P (Red ) connector. Remove the bolts and clutch cable guide, then disconnect the clutch cable end from the clutch lifter lever. The Hfter arm Remove the right crankcase cover SH holts. spindle is Remove the right crankcase cover while turning the engaged with the clutch lifter arm counterclockwise to disengage the clutch lifter piece )ifter arm spir iCj e from the lifter piece. Clean off...

Valve Seat Refacing

Follow the retac- Valve seat cutlers grinders or equivalent valve seat ing manufactur- refacing equipment are recommended to correct ore operating worn vajve scats. 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' interior cutter. Re face me sea with u 4b-degree cutter whenever a valve guide is replaced. Use a 4b-degree cutter to remove any roughness or irregularities...

Shock Link Lower Bracket Removal

- Muffler exhaust pipe (page 2-19) Disconnect the side stand switch 2P (Green) connector. Remove the gearshift arm pinch bolt then remove the gearshift arm from the gearshift spindle. Remove the shock link lower brackeVside stand bracket mounting bolt nut. Remove the bolt and side stand bracket assembly. Remove the two bolts, drive sprocket cover and guide plate. California type Remove the bolt and EVAP canister bracket assembly only from the shock link bracket. Disconnect the EVAP purge...

Crankcase Assembly

Install the swingarm pivot collars into the lower crankcase. Apply a light, but thorough, coating of liquid sealant to the crankcase mating surface. Do not apply sealant to the main bearing journal bolt (lower crankcase bolt, 8 mm) area and the oil passage area as shown. Install oil orifices aligning their cut-outs with the groove in the upper crankcase. Install the lower crankcase onto the upper crankcase. Clean the new crankcase 8-mrn bolts thoroughly with solvent and blow them dry. Apply oil...

Removal Of Engine Head From Honda Cbr 600

Remove the lower cowl and inner half cowl (page 2-4). Remove the air duct cover mounting two screws. Be csrehtf not to Carefully release the air intake duct cover boss and damage the raos. hook from the fuel tank. Remove the air duct cover while releasing the hook from the upper cowl groove. Remove the socket bolts, plastic and rubber washers, then remove the windscreen. Remove the rearview mirror mounting sockct bolts and rearview mirror. Be careful not lo Disconnect the front sub-harness...

Lightsmetersswitches

Install Cbr 600 F4i Idle Screw

A halogen headlight bulb becomes very hot while the headlight is on, and remains hot for a while after it is turned off. Be sure to let it cool down before servicing. Use an electric heating element to heat the coolant for the fan motor switch inspection. Keep flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye protection. Note the following when replacing the halogen headlight bulb. - Wear clean gloves while replacing the bulb. Do not...

Banjo Bolt Washers Cbr F4i

Suzuki Bandit 600 Frame Manual

Connection Black White +) - Black Green (-) Standard Battery voltage Open circuit in O sensor Black Green wires. Measure the voltage at the Ch sensor wire harness side connector terminal and ground. Connection Black White 1+) - Ground H Standard Battery voltage Turn the ignition switch to OFF. Open circuit in Black White wire between the O2 sensor and the engine stop relay. Connect the O2 sensor 4P connectors. Connect the O2 sensor 4P connectors. Disconnect the ECM connectors. Connect the test...

Hydraulic Brake

Primary Piston Brakes Honda

Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use and OSHA-approved vacuum cleaner. A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake digreasing agent. Check the brake system by applying the brake lever or pedal after the air bleeding. Spilled hrake fluid...

Technical Feature

F4i Combination Meter

This motorcycle is equipped with a fuel residual quantity indicator that indicate a residual fuel quantity according to the mileage incrementally. The fuel reserve trip indicator is controlled by a fuel reserve sensor (thermisler), ECM (engine revolution), vehicle speed sensor, side stand switch and ignition switch. First the fuel reserve sensor detects a low fuel condition, the combination meter reserve indicator and four segments of the fuel reserve trip indicators all light up (Fig. 1). As...

Batterycharging System

Position Regulator Bandit 600

SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING CHARGING SYSTEM INSPECTION 16-7 ALTERNATOR CHARGING COIL 16-8 The battery gives off explosive gases keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may causc severe burns. Wear protective clothing and a facc shield. - If electrolyte gets on your skin, flush with water. - If electrolyte gets in your eyes, flush with water tor at least...

Hepace the Ect Removalinstallation

Drajn the coolant from the system page 6-5 . Remove the throttle body page 5-62 . Disconnect the ECT sensor connector from the sensor. Remove the ECT sensor and sealing washer. Remove the screws and IAT sensor from the air cleaner housing cover. Installation is in the reverse order of removal. Always replace a Install the new sealing washer and ECT sensor. sealing washer Tighten the ECT sensor to the specified torque. TORQUE 23 N-m 2.3 kgf m, 17 lbf-ft Fill the cooling system...

Camshaft Removal

Cbr 600 Cam Chain Replacement

Remove the cylinder head cover page 8-4 . Avoid damaging Remove the bolt and cam pulse generator from the generator while removing the camshafts. Turn the crankshaft clockwise, align the T mark on the ignition pulse generator rotor with the index mark on the right crankcase cover. Make sure the No.1 piston is at TDC Top Dead Center on the compression stroke. Remove the cam chain tensioner lifter sealing bolt and sealing washer. Turn the tensioner lifter shaft fully in clockwise and secure it...

Tools

Bearing remover shaft Bearing remover head, 20 mm Driver Driver head Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachment, 52 x 55 mm Attachment, 24 x 26 mm Attachment, 22 x 24 mm Pilot, 17 mm Pilot, 20 mm Pilot, 25 mm Pilot, 28 mm Attachment. 28 x 30 mm Lock nut wrench Bearing remover handle Bearing remover head Remover weight Driver Attachment, 34 mm Attachment, 37 mm Bearing remover set 07949-3710001 or 07946-MJ00100 07ZMD-MBW0100 072MD-MBW0200 07LMC-KV30100...

Ignition System

SYSTEM DIAGRAM 17-0 IGNITION SYSTEM INSPECTION 17-4 SERVICE INFORMATION 17-1 IGNITION PULSE GENERATOR 17-6 TROUBLESHOOTING 17-3 IGNITION TIMING 17-8 Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is turned to ON and current is present. When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 17-3. This motorcycle's Ignition Control Module ICM is built into the Engine Control...

Cylinder Compression Test

Fo avoid discharging V e battery, do not oocotc the srader motor Tor more then 7 seconds. Warm up the engine to normal operating temperature. Stop the engine and remove all the direct ignition coil spark plug caps and spark pluys page 3-6 . Support the front end of fuel tank page 3-4- . Disconnect the fuel pump reserve sensor 3P Black connector. Install a compression gauge into the spark plug hole. TOOL Compression gauge attachment 07RMJ-MY50100 equivalent commercially available in U.S.A. Open...

Electric Starter

Yamaha 600 Motorcycle Cable Diagrams

SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING STARTER MOTOR STARTER RELAY SWITCH DIODE Always turn the ignition switch to OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. When checking the starter system, always follow the steps in the troubleshooting flow chart page 18-2 . A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. If the current is kept flowing through the starter motor to turn...

Harness For F4i 600cc And Connection

Crank Shaft Connection

Apply molybdenum oil solution to the main journal bearing sliding surfaces on the upper crankcase and the crankpin bearing sliding surfaces on the connecting rods. Apply molybdenum oil solution to the thrust surfaces of the crankshaft as shown. Lower all of the pistons to top dead center to ovoid damaging the crankpin with the connecting rod bolts. Carefully install the crankshaft onto the upper crankcase. Set the connecting rods onto the crankpins. Apply molybdenum oil solution to the crankpin...

Bearing Selection

Record the crankcase bearing support I.D. code letters from the left side of the upper crankcase as shown Numbers 1, 7 or 3 on we crank weight are the codes for the main journal U.U.s from left to right Record the corresponding main journal O.D. code numbers from the crank weight. Cross reference the main journal and bearing support codes to determine the replacement bearing color code. MAIN JOURNAL BEARING SELECTION TABLE BEARING THICKNESS A Black Thick B Brown A C Green D Yellow T E Pink Thin

Replacementair Bleeding

Remove the drain holt on the water pump cover and drain the coolant. Remove the cylinder drain bolt and drain the coolant from the cylinder. Reinstall the drain bolt with the new sealing washer. Tighten the water pump drain bolt to the specified torque. TORQUE 12 N-m 1.2 kgf-m, 9 Ibf-ft Remove the right air duct page 2-7 Disconnect the siphon hose from the radiator. Empty the coolant and rinse the inside of the reserve Fill the system with the recommended coolant through the filler opening up...

Gearshift Linkage Installation

Tighten the stopper arm socket holt to the specified torque. TORQUE 12 N-m 1.2 kgf-m, 9 Ibf-ft Align the dowel pin on tne shift drum center with the wide groove on the gearshift cam. Install the dowel pin onto the shift drum. Install the gearshift cam while holding the stopper Apply a locking agent to the gearshift cam socket bolt threads. Install and tighten the socket bolt to the specified torque. TORQUE 23 N-m 2.3 kgf-m, 17 lbt-ft Install the thrust washer and gearshift spindle assembly into...

Cylinder Head Removal

Cylinder Block Drain Coolant

Remove the following - Camshaft page 8 6 Remove the cylinder drain bolt and sealing washer. Drain the coolant from the cylinder head and cylinder block. Check the scaling washer is in good condition, replace if necessary. Reinstall the sealing washer and drain bolt. Remove the socket bolts, sealing washers and cam chain tensioner lifter and gasket. Loosen the y mm bolts in a crisscross pattern in two or three steps. Remove the two 6-mm flange bolts. Remove the ten 9-rnm bolts, washers. Remove...

Cylinder Head Disassembly

Remove the spark plugs from the cylinder head. Install the tappet hole protector into the valve lifter bore. Tappet hole protector 07HMG-MR70002 An equivalent tool can easily be made from a 35-mm plastic film container as shown. Remove the valve spring cottcrs using the special tools as shown. Valve spring compressor 07757-0010000 Valve spring compressor attachment

Honda Cbr600rr Swingarm Dust Seal

Lipped Brake Disc

Place the axle in V-blocks and measure the runout. Actual runout is 1 2 the total indicator reading. Turn the inner race of each bearing with your finger. Bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Replace the Hemove and discard the bearings if the races do not wheef bearings in turn smoothly and quietly, or if they fit luosely in the Pairs, hub. Check the rim runout by placing the wheel in a true-ing stand. Spin the wheel slowly...

Honda Cbr 600 F4i Idling Valves

Honda Cbr 600 Wax Unit

Install the fuel injectors into the fuel pipe, being careful not to damage the O-ring and cushion ring. Install the fuel pipe assembly onto the throttle body, being careful not to damage the seal rings. Do not apply excessive force to the fuel pipe. Hold the fuel pipe securely, remove the pressure regulator mounting bolts., then remove the pressure regulator. Install and tighten the fuel pipe mounting bolls. Install the throttle body page 5 66 . Disconnect the vacuum hose from the pressure...

Assembly

Wax Unit Honda Cbr 600 F4i

Install the three collars and starter valve shaft. Install the starter valve assembly into the valve hole. Tighten the starter valve lock nut to the specified torque. TORQUE 2 N-m 0.18 kgf-m, 1.3 Ibf.ft Compress the thrust spring and install the No.3 4 starter valve arm onto the starter valves. Install and tighten the starter valve arm mounting sciews to the specified torque. TORQUE 1 N-m 0.09 kgf-m, 0.7 lbf-ft Install the No.1 2 starter valve arm to the starter valves. Install and tighten the...

NOTICE i

Honda Cbr 600 Del 2000

Always start with the adjusters fully turned in when adjusting the damping. Dn not turn the adjuster screws more than the given positions or the adjusters may be damaged. The compression and rebound damping can be adjusted by turning the adjusters. DIRECTION H Increase the damping force DIRECTION S Decrease the damping force Turn the compression adjuster clockwise until it stops, then turn the adjuster counterclockwise. COMPRESSION ADJUSTER STANDARD POSITION 1-1 2 turns out from fully turned...

Starter Valve Synchronization

Nsr 250 Engine Hose Diagram

Synchronize the starter valve with the engine at the normal operating temperature and with the transmission in neutral. Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate 50 rpm change. Support the front end of fuel tank page .1-4 . Remove the No.1 and No.4 vacuum hoses from the air Disconnect the pressure regulator vacuum hoses at Connect the hoses to the vacuum gauge. Disconncct the PAIR air suction hoses from the reed valve covers and plug the cover. Start...

Map Sensor Removalinstallation

Support the front end of fuel tank paye 3-4 . Disconnect the MAP sensor connector. Disconnect the vacuum hose from the MAP sensor. Remove the air cleaner housing page 5-60 . Remove the screw and MAP sensor from the air cleaner housing. Installation is in the reverse order of removal.

Inspection

Honda Cbr 600 Del 2000

Check the operation of the pressure relief valve by pushing on the piston. Disassemble the lelief valve by removing the snap ring. Inspect the piston for wear, unsmooth movement or damage. Inspect the spring for fatigue or damage Assemble the relief valve iri the reverse order of disassembly. Apply oil to the new packing and install it onto the oil strainer. Install the oil strainer into the crankcase while align- ing its boss with the groove in the crankcase. Apply oil to the new O-ring and...

Torque Values

Oil main gallery sealing bolt Oil pressure switch Oil pressure switch wire terminal bolt washer Oil pump driven sprocket bolt washer 29 N-m 3.0 kgf-m, 22 lbf-ft 12 N-m 1.2 kgf-m, 9 lbf-ft 2 N-m 0.2 kgf-m, 1.4 lbf-ft 8 N-m 0.8 kyf-rn, 5.8 lbf-ft R4 N-m 6.5 kgt-m, 47 lbf-ft 29 N-m 3.0 kgf-m, 22 lbf-ft 15 N-m 1.5 kgf-m, 11 lbf-ft Apply a locking agent to the threads. Apply sealant to the threads. Apply oil to the threads and flange surface. Apply oil to the threads and flange surface and O-ring....

Selfdiagnosis Reset Procedure

Yamaha Xvs650 Dragstar Ignition Wiring

1.Turn the engine stop switch to RUN and the ignition switch to OFF. 2. Short the service check connector of the PGM-FI system using a jumper wire. 3.Turn the ignition switch to ON. 4. Remove the jumper wire from the service chcck connector. 5. The MIL lights about 5 seconds. While the indicator lights, short the service check connector again with the jumper wire. Self diagnosis memory data is erased if the MIL turns off and then starts blinking. The scrvicc check connector must be jumped while...

Emission Control Systems

Environmental Protection Agency, California Air Resources Board CARB and Transport Canada require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 3,730 miles 6,000 km after the time of sale to the ultimate purchaser, when operated...

Peak Voltage Inspection Procedure

Use this procedure for the ignition pulse generator and cam pulse generator inspection. Check ail system connections before inspection. If the system is disconnected, incorrect peak voltage might be measured. Check cylinder compression and check that all spark plugs are installed correctly. Use the recommended digital multimeter or a commercially available digital multimeter with an impedance of 10 MQ DCV minimum. If the Peak Voltage Tester U.S.A. only is used, follow the manufacturer's...

Adjustment

Honda Chain Adjustment

Turn both adjusting bolts until the correct drive chain slack is obtained. Make sure the index marks on both adjusting plates are aligned with the end of the swingarm. Tighten the rear axle nut to the specified torque. TORQUE 93 N-m 9.5 kgf-m, 69 lbf-ft Recheck the drive chain slack arid free wheel rotation. Lubricate the drive chain with 80 - 90 gear oil or Pro Honda chain lube designed specifically for use with O-ring chains. Wipe off any excess oil or chain lubricant. Check the drive chain...

Cbr 1100 Speed Sensor

Cbr Speedometer Sensor Location

Light green Yellow - Green Orange - Standard 4.75 - 5.25 V Turn the ignition switch to OFF. Connect the MAP sensor 3P connector. Open or short circuit in Light green,'Yellow wire. Loose or poor contact on the ECM connectors. Disconnect the ECM connectors. Connect the test harness to ECM connectors. Turn the ignition switch to ON. Disconnect the ECM connectors. Connect the test harness to ECM connectors. Turn the ignition switch to ON. Measure the voltage at the test harness terminals page 5-9 ....

Failure Codes

Injection Pgm Cbr 1100

The PGM-FI MIL denotes the failure codes the number of blinks from 0 to 33 . When the indicator lights for 1.3 seconds it is equivalent to 10 blinks For example, a 1.3 second illumination and two blinks 0.5 second X 2 of the indicator equals 12 blinks. Follow code 12 on page 5-26. When more than one failure occurs, the MIL shows the blinks in the order of lowest number to highest number. For example, if the indicator blinks once, then two times, two failures have occurred. Follow codes 1 and 2...

L

Honda Cbr 600 F4i Connectors

Connect the speed sensor 3P connector. Connect the test harness to the wire harness Connect the test harness to the wire harness Support the motorcycle securely and place the rear wheel off the ground. Shift the transmission into 1st gear. Measure the voltage at the test harness terminals with the ignition switch is turned to ON while slowly turning the rear wheel by hand. CONNECTION Pink Green - Ground - STANDARD Repeat 0 to 5V Open or short circuit in Pink wire of the engine sub-harness. Open...

Notice

The adjuster may be damaged if it is positioned too far out, leaving minimal thread engagement. If the adjuster is threaded out near its limit and the correct free play cannot be obtained, turn the adjuster all the way in and back out one turn. Tighten the lock nut and make a major adjustment as described as follow. Major adjustments are performed at the clutch arm. Loosen the lock nut and turn the adjusting nut to adjust the free play. Hold the adjusting nut securely while tightening the lock...

Selfdiagnostic Procedures

Honda Cbr Indicator Connectors Type

The me function indicator lamp MIL will star blinking only with i ie side stand down and with the engine off engine stop switch turned to run or engine revs are below 5.000 rpm. In any other conditions, the MIL wili illuminate and stay on. Place the motorcycle on its side stand. Start the engine and let it idle. If the malfunction indicator lamp MIL does not light or blink, the system has no memory of problem data. If the malfunction indicator blinks, note how many times the MIL blinks, and...

Service Information

Be sure to relieve the fuel pressure with the engine off. Bending or twisting the control cables will impair smooth operation and could causc the cables to stick or bind, resulting in loss of vehicle control. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. Do not apply commercially available carburetor cleaners to the inside uf the throttle bore, which is coated with molybdc num. Do not snap the...

Noise Emission Control System

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal, state and local law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use 2 the use of the vehicle after such device or element of design has...

Troubleshooting

Fuel contaminated deteriorated Pinched or clogged fuel hose Clogged fuel injector filter Sticking fuel injector needle Faulty fuel pump operating system Engine stall, hard to start, rough idling Fuel contaminated deteriorated Pinched or clogged fuel hose Starter valve synchronization misadjusted 23 N-m 2.3 kgf-m, 17 lbf-ft See page 1-14. 3 N-m 0.35 kgf-m, 2.5 lbf-ft 1 N-m 0.09 kgf-m, 0.7 lbf-ft 5 N-m 0.5 kgf-m, 3.6 lbf-ft 10 N-m 1.0 kgf-m. 7 lbf-ft 2 N-m 0.2 kgf-m, 1.4 lbf-ft 15 N-m 1.5 kyf-m,...

Fuel Line

Line Diagram For Cbr F4i

Remove the air duct covers page 2-7 . Remove the fuel tank front mounting bolts. Lift the fuel tank Open and support the front end of the fuel tank using slowly, being suitahle support 250-mm as shown. corcfui not to ov amp raxT amp n amp d the ue hose. Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary. Install the fuel tank in the reverse order of removal.

How To Replace Spark Plugs On Honda Cbr 600

Be careful nut Lu damage the radiator fins. Remove the lower cowl and inner half cowl page 2-4 . Disconnect the fan motor sub-harness P Black connector. Remove the radiator lower mounting bolt, nut and washer. Remove the radiator upper mounting bolt and UPPER MOUNTING BOLT WASHER washer. Remove the radiator grommet from the frame boss by moving it to the right, then move the radiator forward. Clean around the spark plug bases with compressed air b9fore removing the spark piuys, and be curc that...

Oil Level Inspection

Oil Change Honda Cbr600f4i

Start the engine and let it idle for 2 - 3 minutes. Turn off the engine and support the motorcycle on a level surface. Check the oil level through the inspection window. If the level is below the lower line, remove the oil filler cap and fill the crankcasc with the recommended oil to the upper level line. Add the recommended engine oil until the oil level is to the upper level line. Othei viscosities RECOMMENDED ENGINE OIL shown in The chart may be used when the average tcmpcro tu re in your...

How To Use This Manual

This service manual describes the service procedures for the CBR600F41. Follow the Maintenance Schedule Section 3 recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency, California Air Resources Board and Transport Canada. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply...

Cooling System

1996 Honda Accord Coolant Flow Route

Remove the lower r.owl and inner half cowl page 2-4 . Check the radiator air passages for clogs or damage. Straighten any bent fins, and remove insects, mud or other obstructions with compressed air or low water pressure. Replace the radiator if the air flow is restricted over more than 20 of the radiating surface. Inspect the radiator hoses for cracks or deterioration, and replacc if necessary. Check the tightness of all hose clamps and fasteners.

Honda Cbr 600 F4i Pgm-fi System

Install Starter 1991 Cbr 600

Coat a new O-ring with engine oil and install it into the oil cooler groove. Install the oil cooler aligning its guide groove with the lug on the c.rankcase. Apply oil lo the oil cooler bolt threads and seating cur face. install the lock Install the lock washer and oil cooler bolt. washer with its concave side o mark facing the Make sure the oil Tighten the oil cooler bolt to thft specified torque. slides inside the TORQUE 64 N m 6.5 kgf.m, 47 Ibf-ft Connect the oil cooler water hoses and...

Rear Suspension Inspection

Support the motorcycle securely and raise the rear wheel off the ground. Hold the swingarm and move the rear wheel sideways with force to see if the wheel bearings ore worn. Check for worn swingarm bearings by grahbing the rear swingarm and attempting to move the swingarm side to side. Replace the bearings if any looseness is noted. Check the action of the shock absorber by compressing it several times. Check the entire shock absorber assemhly for signs of leaks, damage or loose fasteners....

Oil Pressure Inspection

If the of pressure indicator light remains on a few scconds, check the indicator system before checking the oii pressure. Warm up The engine to normal operating temperature approximately 8CTC 176T . Stop the engine and remove the oil main gallery sealing bolt. Connect an oil pressure gauge and attachment to the Oil pressure gauge set 07506-3000000 equivalent commercially available in U.S.A. 07510-MJ10100 equivalent commercially available in U.S.A. Start the engine and increase engine speed to...

Throttle Operation

Cbr600 Throttle Grip Assembly

Check for smooth throttle grip full opening and automatic full closing in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged. Lubricate the throttle cables, if throttle operation is not smooth. Measure the free play at the throttle grip flange. FREE PLAY 2 - 6 mm 1 16 - 1 4 in Throttle grip tree play can he adjusted at either end of the throttle cable. Minor adjustments are made with the upper adjuster. Adjust the free play by...

Brake Fluid

Do not mix different types of fluid, as they are not compatible with cach other. Do not allow foreign material lo enter the system when filling the reservoir. Avoid spilling fluid on painted, plastic or rubber parts. Place a raq over these parts whenever the system is serviced. When the fluid 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. It the brake pads are worn, the caliper piston is pushed out, and this accounts for a...

Headlight

Adjust the head- Place the motorcycle on a level surface. specified by local Adjust the headlight beam vertically by turning the lows and rcgulo vcrtica beam adjuster. A clockwise rotation moves the beam up and counterclockwise rotation moves the beam down. Adjust the headlight beam horizontally by turning the horizontal beam adjuster A clockwise rotation moves the beam toward the right side of the rider.

Cbr 600 Exhaust

Install Exhaust Gasket Fazer 1000

Always replace Install the new exhaust pipe gaskets onto the exhaust the exhaust pipe ports of the cylinder head. Install the mounting rubbers and collar into the exhaust pipe mounting bracket. install the washer. Install the exhaust pipe, temporarily install the holt find nut exhaust pipe joint nuts, mounting washer and mount-properly. ing bolt nut. Tighten the exhaust pipe joint nuts to the specified torque. TORQUE 12 N-m 1.2 kgf-m. 9 Ibf.ft Tighten the exhaust pipe mounting bolt nut. Install...

Secondary Air Supply System

Secondary Air Supply System Honda

This model is equipped with a built-in secondary air supply system. The pulse secondary air supply sys tern 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 purl 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...

Steering Head Bearings

Honda F4i Schematics

Check that the control cables do not interfere with handlebar rotation. Support the motorcycle securely and raise the front wheel off the ground. Check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings Section 13 .

Side Stand

Motorcycle Side Stand

Support the motorcycle on a level surface. Check the side stand spring for fatigue or damage. Check the side stand assembly tor movement and lubricate the side stand pivot if necessary. Check the side stand ignition cut-off system - vSit 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. - The engine should stop as the side stand is lowered. If there is a problem with the...

Brake Light Switch

The front brake Adjust the brake light switch so the brake light comes light switch does on just prior to the brake actually being engaged. not require adjust- if the light fails to come on, adjust the switch so the light comes on at the proper time. Hold the switch body and turn the adjuster. Do not turn the switch body.

Front Suspension Adjustment

Spring pre-load can be adjusted by turning the adjuster. Increase the spring pre-load TURN COUNTERCLOCKWISE Decrease the spring pre-load PRE LOAD ADJUSTER ADJUSTABLE RANGE 6-21 mm 0.2 - 0.8 in from the top of the fork bolt PRE-LOAD ADJUSTER STANDARD POSITION 4th groove from the top of the fork bolt

Where Is The Masterlink On A Honda F4i

07hmh Mr10103

Never reuse the old drive chain, master link, master link plate and O-rings. Insen the master Assemble the new master link, O-rings and plate. link from the inside of the drive chain, and install the jiate with the identification mark facing out. Assemble and install the drive chain tool set. 07HMH-MR10103 or 07HMH-MR1010A U.S.A. only Make sure the master link pins are installed properly. Measure the master link pin length projected from the plate. STANDARD LENGTH DID 1.15 - 1.55 mm 0.045 -...

Ni i

Set the lower cowl onto the frame and install the lower cowl boss into the air duct cover grommet. lns al the 4-mm Install the six screws. Correct location 3s Tighten the upper cowl to lower cowl screws to the TORQUE 2 N-m 0.1b kgf-m, 1.1 lbf-tt Install the inner half cowl-to-lower r.owl two trim clips and four screws. Tighten the screws to the specified torque. TORQUE 2 N-m 0.15 kgf-m, 1.1 lbf-ft Install the two trim clips into the bottom of the lower cowl.

Installation

F4i Fuel Tank Installation

Route the turn signal wire into the upper cowl, inner middle cowl and setting plate. Install and tighten the nut securely. Conncct the turn signal running light connectors. Install the front air duct covers into the upper cowl and tighten the screw securely. Install the resonator onto the air duct and secure it with a trim clip. Install the air duct into the air cleaner intake duct. Hook the resonator chamber stays to the chambers. Install the upper cowl onto the upper cowl stay while aligning...

Evaporative Emission Control System California Type Only

Check the hoses between the fuel tank, EVAP canister, EVAP purge control solenoid valve for deterioration, damage or loose connections. Cheek the EVAP canister for cracks or other damage. Refer to the Vacuum Hose Routing Diagram Label page 1 41 and Cable amp Harness Routing page 1-23 for hose connections.

Sprockets Inspection

Honda Cbr 600 Del 2000

Inspect the drive and driven sprocket teeth for wear or damage, replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition, or the new replacement chain will wear rapidly. NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT Check the attaching bolts and nuts on the drive and Drive sprocket bolt 54 N-m 5.5 kgf-m, 40 lbf-ft Driven sprocket nut 64 N-m 6.5 kgf-m, 47 lbf-ft When using the special too ,...

Hondabond On F4i Waterpump

Liquid sealant Three Bond 1207B or equivalent Do not apply sealant to the thread head 3-4 mm 0.1 - 0.2 in . Connecting rod small end inner surface Camshaft lobes journals and thrust surface Valve stem valve guide sliding surface Water pump shaft spline and thrust washer sliding surface Clutch outer piimary driven year sliding surface M3 4, C5. C6 shifter gear shift fork grooves Starier reduction gear shaft outer surface Primary sub-gear friction spring sliding surface Molybdenum disulfide oil a...

Radiator Coolant

Check the coolant level in the reserve tank with the engine running at normal operating temperature. The level should be between the UPPER and LOWER level lines. It necessary, add the recommended coolant. RECOMMENDED ANTIFREEZE Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors. Remove the reserve tank filler cap and fill to the UPPER level line with a 1 1 mixture of distilled water and antifreeze. Reinstall the filler cap.

Air Cleaner

Intake Air Temperature Sensor

Support the front end of fuel tank page 3-4 . Disconnect the IAT Intake Air Temperature sensor connector. Remove the screws and air cleaner housing cover. Remove and discard the air cleaner element in accordance with the maintenance schedule page 3-3 . Also replace the air cleaner element any time it is excessively dirty or damage. Install the removed parts in the reverse order of removal.

Cable Harness Routing

Iat Sensor Cbr 600

RIGHT HANDLEBAR SWITCH 9P BLACK CONNECTOR COMBINATION METER 9P BLACK CONNECTOR LEFT HANDLEBAR SWITCH 9P BLACK CONNECTOR IGNITION SWITCH 4P NATURAL CONNECTOR COMBINATION METER 9P BLACK CONNECTOR LEFT HANDLEBAR SWITCH 9P BLACK CONNECTOR IGNITION SWITCH 4P NATURAL CONNECTOR RIGHT HANDLEBAR SWITCH 9P BLACK CONNECTOR FRONT SUB-HARNESS 12P GRAY CONNECTOR COMBINATION METER 9P BLACK CONNECTOR COMBINATION METER DP NATURAL CONNECTOR FRONT SUB-HARNESS 12P GRAY CONNECTOR COMBINATION METER 9P BLACK...

Exhaust Emission Control System Pulse Secondary Air Supply System

Pulsed Secondary Air Injection

The exhaust emission control system is composed of a lean fuel injection setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcasc emis sion control system. 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 by the function of the Pulse Secondary...

Engine Oil Filter Change

Hero Honda Engine Oil Screw

Stop the engine and remove the oil filler cap. Remove the drain bolt and drain the oil completely. Remove and discard the oil filter cartridge using the special tool. OIL FILTER WRENCH OIL FILTER CARTRIDGE OIL FILTER WRENCH OIL FILTER CARTRIDGE Check that the sealing washer nn the drain bolt is in good condition and replacc if ncccssory. Install and lighten Ihe drain bolt. TORQUE 29 N-m 3.0 kgf-m. 22 lbf-ft Apply clean engine oil to the new oil filter O-ring. Install the now oil filter and...

Valve Clearance

Yamaha Sr250 Timing Marks

Inspect und adjust INSPECTION the valve clearance v hne the Remove the cylinder head cover page 8-4 bciow35'C 95'F . Remove the cam chain tensioner lifter sealing bolt and sealing washer. Turn the cam chain tensioner lifter shaft fully and secure it using the mechanic's tensioner stopper tool page 8-7 . Remove the timing hole cap and 0 ring. Turn the crankshaft clockwise and align the T mark on the ignition pulse generator rotor with the index mark on the right crankcase cover. The timing marks...

Model Identification

Numeros Serie Una Honda Cbr

1 The frame serial number is stamped on the right side of the steering head. 2 The engine serial number is stamped on the right side of the upper crankcase. 3 The Vehicle Identification Number VIN is located on left side of the main frame on the Safety Certification Labels. h IHHOTTLT BODY IDENTIFICATION NUMBER 4 The throttle body identification number is stomped on the intake side of the throttle body as shown. h IHHOTTLT BODY IDENTIFICATION NUMBER 4 The throttle body identification number is...

F4i Foot Peg Bracket Bolt

Honda F4i Left Front Bracket

Loosen the rear shock absorber reservoir tank band and remove the reservoir tank from the seat rail. Remove the brake light switch wire band. Remove the bolt nut and rear brake reservoir tank from the seat rail. Remove the regulator rectifier page 16-8 . Remove the muffler mounting bolt nut. Remove the holts and right pillion footpeg bracket. Remove the bolts and left pillion footpeg bracket. Remove the seat rail mounting holts nuts, coolant reservoir tank mounting collar washcr and seat roil....

Cbr600 F4i Radiator Removal

F4i Sensor

Remove the lower cowl and inner half cowl page 2-4 . California type Disconnect the o2 sensor 4P Natural connector. only Remove the o2 sensor wire from the frame. Remove the muffler mounting bolt nut and washer, then remove the muffler. Remove the radiator lower mounting bolt nut, then move the radiator forward. - Exhaust pipe mounting bolt nut Remove the collar and mounting rubbers from the exhaust pipe bracket.

California Type

Sr250 Wiring Diagram

TURN SIGNAL LICENSE LIGHT CONNECTORS REGULATOR RECTIFIER 6P BLACK CONNECTOR REAR SUB-HARNESS 14H GRAY CONNECTOR BRAKE LIGHT SWITCH 2P BLACK CONNECTOR TURN SIGNAL LICENSE LIGHT CONNECTORS REGULATOR RECTIFIER 6P BLACK CONNECTOR REAR SUB-HARNESS 14H GRAY CONNECTOR BRAKE LIGHT SWITCH 2P BLACK CONNECTOR

Did Did525hv-108le

Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clcarance Dry weight 49 States Canada type California type Curb weight 49 States Canada type California type Maximum weight capacity Frame type Front suspension Front axle travel Rear suspension Rear axle travel Front tire size Rear tire size Front tire brand Front brake Rear brake Caster angle Trail length Fuel tank capacity 2,041 mm 80.4 in 6R5 mm 27.0 in 1,135 mm 44.7 in 1,386 mm 54.6 in 810 mm 31.9 in...