Lightsmetersswitches

SYSTEM LOCATION

19-0

COOLING FAN MOTOR SWITCH

19-15

SERVICE INFORMATION

19-1

OIL PRESSURE SWITCH

19-16

TROUBLESHOOTING

19-3

FUEL RESERVE SENSOR

19-17

HEADLIGHT

19-4

IGNITION SWITCH

19-18

TURN SIGNAL

19-6

HANDLEBAR SWITCHES

19-19

TAIL/BRAKE LIGHT

19-7

BRAKE LIGHT SWITCH

19-20

LICENSE LIGHT

19-7

CLUTCH SWITCH

19-20

COMBINATION METER

19-8

NEUTRAL SWITCH

19-20

SPEEDOMETER/VEHICLE SPEED

SIDE STAND SWITCH

19-21

SENSOR

19-11

HORN

19-22

TACHOMETER

19-13

TURN SIGNAL RELAY

19-23

COOLANT TEMPERATURE GAUGE/

SENSOR

19-14

GENERAL

NOTICE

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 put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail.

- If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.

- Be sure to install the dust cover after replacing the bulb.

Check the battery condition before performing any inspection that requires proper battery voltage.

A continuity test can he made with the switches installed on the motorcycle.

The following color codes are used throughout this section.

SPECIFICATIONS

ITEM

SPECIFICATIONS

Bulbs

Headlight

Hi

12V - 55 W

lo

12V - 55 W

Brake/tail light

12V - 21/5 W x 2

Tront turn signal/running light

12V-32/3 CP (23/8 W) x 2

Rear turn signal light

12V-32 CP (23 W) x 2

License light

12V-4 CP (5 W)

Instrument light

LED

Turn signal indicator

LED

High beam indicator

LED

Neutral indicator

LED

Oil pressure indicator

LED

PGM-FI warning indicator

LED

Low fuel indicator

LED

Fuse

Main fuse

30 A

PGM-FI fuse

20 A

Sub fuse

10 A x 6

Tachometer peak voltage

10.5 V minimum

Fan motor

Start to close (ON)

98- 102 'C (208- 216 eF)

switch

Stop to open

93-97 *C (199-207 eF)

Coolant temperature/ECT sensor Side stand switch bolt Ignition switch mounting bolt Fan motor switch Oil pressure switch

Oil pressure switch wire terminal bolt/washer Neutral switch

23 N-m (2.3 kgf-m. 17 lbf-ft) 10 N-m (1.0 kgf-m, 7 lbf-ft) 25 N-m (2.5 kgf-m, 18 lbf-ft) 18 N-m (1.8 kgf-m, 13 lbf-ft) 12 N-m (1.2 kgf-m, 9 lbf-ft) 2 N-m (0.2 kgf-m, 1.4 lbf-ft) 12 N-m (1.2 kgf-m, 9 lbf-ft)

ALOC bolt; replace with a new one.

Apply sealant to the threads. Apply sealant to the threads.

TROUBLESHOOTING

SPEED SENSOR/SPEEDOMETER

The odometer/trip meter operate normally, but the speedometer does not operate

• Faulty speedometer

The speedometer operate normally, but the odometer/trip meter does not operate

• Faulty odometer/trip meter

The speedometer operate is abnormal

• Check for the following before diagnosing.

- Blown main or sub fuses

- Loose or corroded terminals of llie connectors

- Discharged battery

Check for loose or poor contact of the speed sensor 3P (Natural! connector. With the ignition switch turned to "ON" and measure the voltage at the speed sensor connector.

Abnormal

Loose or poor contact of related terminals. Open circuit in Black/Brown or Grccn/Black wires between the battery and speed sensor.

Normal

Abnormal

Check for loose or poor contact of the combina-------> • Loose or poor contact of related terminals.

tion meter multi-connectors. • Open circuit in Black/Brown or Green/Black

With the ignition switch turned to "ON" and wires between the battery and speedometer, measure the voltage at the bottom of the speedometer terminals.

Normal

With the ignition switch turned to "OFF", check for continuity of the Pink/Green wire between the terminals of the speed sensor and speedometer.

Abnormal

Open circuit or loose connection in Pink/Green wire.

Normal

Support the motorcycle using a hoist or other support to rise the rear wheel off the ground. Measure the output voltage (sensor signal) at the speedometer with the ignition switch is turned to "ON" while slowly turning the rear wheel by your hand.

Abnormal

• Loose speed sensor mounting bolts.

Normal

HEADLIGHT

BULB REPLACEMENT

Remove the air duct cover (page 2-91.

Release the resonator chamber from the hook arm.

Disconnect the headlight bulb connectors. Remove the dust cover.

Avoid touching Unhook the bulb retainer and remove the headlight thehaluyen hand- bulb/socket. light bulb. Finger prints am create |f y0LI touch the bulb with your hare hands, clean it not spots the!t wjth c|Qth m0jStcnccj with denatured alcohol to precise o buib to . . . .. . .,

. . vent early bulb failure.

Remove the headlight bulb from the socket. Install a new bulb into the socket.

SOCKt I

SOCKt I

Install the new headlight bulb/socket aligning its tabs with the groove in the headlight unit.

RETAINER

RETAINER

BLJLB

Install the dust cover tightly against the headlight unit with its arrow mark facing up.

Connect the headlight connectors.

Hook the resonator chamber to the hook joint. Install the air duct cover «.page 2-12).

REMOVAL/INSTALLATION

Remove the upper cowl (page 2-7).

Disconnect the turn signal/running light connectors. Remove the four screws and headlight unit.

Install the headlight unit in the reverse order of removal.

ARROW MARK

DUST COVER

HOOK JOINT

RtSONAI OR

HOOK JOINT

RtSONAI OR

SCREWS

HEADLIGHT UNIT

Install Cbr 600 F4i Idle Screw

SCREWS

HEADLIGHT UNIT

TURN SIGNAL

BULB REPLACEMENT

Remove Ihe screw and turn signal lens.

While pushing in the bulb, turn it counterclockwise, remove it and replace with a new one.

Install the turn signal lens in the reverse order of removal.

REMOVAL/INSTALLATION

Tor front turn signal unit removal, see upper cowl removal (page 2-9).

For rear turn signal removal, remove the seat/rear cowl (page 2-2)

Disconnect the turn signal connector.

Remove the turn signal mounting nut.

Release the turn signal wiie and remove the turn signal unit.

Route Hie turn Install the turn signal unit in the reverse order of signs' wire prop- re m ova I. eriy {page 1-24).

TURN SIGNAL UNIT

TURN SIGNAL UNIT

TURN SIGNAL LENS

SCREW

TURN SIGNAL LENS

SCREW

Install Cbr 600 F4i Idle Screw
TURN SIGNAL CONNECTORS

TAIL/BRAKE LIGHT

BULB REPLACEMENT

Remove the pillion seat (page 2-2).

Disconnect the tail/brake light connectors.

Turn the hulh socket counterclockwise, then remove the bulb socket.

While pushing in the bulb, turn them counterclockwise, remove them and replace with new ones.

Install the tail/brake light sockets in the reverse order of removal.

REMOVAL/INSTALLATION

Remove the rear cowl (page 2-9).

Remove the two nuts, wire clamps and toil/brake light unit.

Installation is in the reverse order of removal.

TAILVBRAKE LIGHT UNIT

qprW/

V Pk

WIRE CLAMP

NUTS

LICENSE LIGHT

BULB REPLACEMENT

Remove the license light bracket bolts and the license light assembly.

/ LICENSE LIGHT

/ LICENSE LIGHT

BOLTS

BOLTS

BULB

CONNECTORS

BULB

Remove the screws, license light cover and lens.

While pushing in the bulb, turn it counterclockwise, remove it and replace with a new one.

Install the license light assembly in the reverse order of removal.

COMBINATION METER [IP

REMOVAL

Remove the upper cowl (page 2-7).

Disconnect the combination meter 9P (Natural) and 9P (Black) connectors.

Remove the combination meter mounting screws and combination meter.

DISASSEMBLY

Remove the screws and combination meter harness connector lid.

(NATURAL) CONNECTOR

F4i Combination Meter

(BLACK) CONNECTOR

(NATURAL) CONNECTOR

(BLACK) CONNECTOR

SCREWS

COMBINATION MTTPR

Install Cbr 600 F4i Idle Screw

SCREWS

SCREWS

Disconnect the combination meter sub-harness connectors.

Remove the screws and combination meter rear cover.

SCREWS

REAR COVER

Remove the combination meter print board assembly from the front cover.

ASSEMBLY

Install the print board assembly into the front cover.

PRINT BOARD

FRONT COVER

PRINT BOARD

FRONT COVER

F4i Combination Meter

Install the rear cover and tighten the screws securely.

SCREWS

SCREWS

REAR COVER

CONNECTORS

Connect the combination meter sub-harness to the print board.

Install the harness connector lid while installing the .^^SBIHK®^^^ CONNtCTOR I ID

grommct into the grooves of the rear cover and har- ^^Sifc, ness lid. ra WSSe. V ^JJ i4H ¿7,

INSTALLATION

Install the combination meter onto the bracket aligning the bosses with the grommets on the bracket.

Install and tighten the mounting screws.

Connect the combination meter 9P (Natural) and 9P (Black) connectors.

Install the upper cowl (paye 2-9).

9P (NATURAL) CONNECTOR

9P (NATURAL) CONNECTOR

F4i Combination Meter
9P (BLACK) CONNECTOR

CONNECT OR

SCREWS

SCREWS

COMBINATION METER

POWER/GROUND LINE INSPECTION

Disconnect the combination meter multi-connector. Check the following at the wire harness side connector terminals of the combination meter.

Power input line

Measure the voltage between the Black/Brown wire terminal (+) and Ground (-).

There should he battery voltage with the ignition switch turned to "ON".

If there is no voltage, check for an open circuit in Black/Brown wire.

Back-up voltage line

Measure the voltage between the Red/Green wire terminal (+) and Ground (-). There should be battery voltage at all times. If there is no voltage, check for an open circuit in Red/Green wire.

Honda Cbr600rr Manual 2012

Sensor ground line

Check for continuity between the Green/Black wire terminal (+) and Ground ( ).

There should be battery voltage at all limes.

If there is no voltage, check for an open circuit in

Green/Black wire.

SPEEDOMETER/VEHICLE SPEED SENSOR |~iF

SYSTEM INSPECTION

Check that the tachometer and coolant temperature meter function properly.

• If they do not function, perform the power and ground line inspection of the combination meter (see above).

• If they function, shift the transmission into neutral, disconnect the combination meter combination meter 9P (Natural) and 9P (Black) connectors and turn the ignition switch to "ON". Qp Measure the voltage between the Pink/Green (-t) and Green/Black (-) wire terminals of the wire harness side connector. Slowly turn the rear wheel by hand. There should be 0 to 5 V pulse voltage.

- If no pulse voltage appears, replace the combination meter print circuit board.

- If pulse voltage does not appear, check for an open or short circuit in Pink/Green wire. If the Pink/Green wire is OK, check for the speed sensor (page 19-12).

(NATURAL) CONNECTOR

(BLACK) CONNECTOR

(NATURAL) CONNECTOR

(BLACK) CONNECTOR

SPEED SENSOR INSPECTION

Remove the throttle body (page 5-62).

Disconncct the speed sensor 3P (Black) connector and check for loose or poor contact of the connector. Also check for loose or poor contact of the engine sub-harness 12P (Gray) connector.

3P (BLACK) CONNECTOR

3P (BLACK) CONNECTOR

nf ih

Connect the engine sub harness 12P (Gray) connector and speed sensor 3P (Black) connector.

Turn the ignition switch is to "ON" and measure the voltage at the 3P (Black) connector with the connector connected.

Connection: Black (+) - Green (-) Standard: Battery voltage

If there is no voltage, check for an open circuit in the Black and Green wires and loose contact of the wire harness connectors.

Support the motorcycle securely and place the rear wheel off the ground.

Shift the transmission into neutral.

Measure the voltage at the sensor connector terminals with the ignition switch is turned to "ON" while slowly turning the rear wheel by hand.

CONNECTION: Pink (+) - Green H STANDARD: Repeat 0 to 5V

It the measurement is out of specification, replace the speed sensor.

REMOVAL/INSTALLATION

Remove the throttle body (page 5-62).

Disconnect the speed sensor 3P (Black) connector from the engine sub-harness.

Remove the bolts and speed sensor.

Tacho Sensor Cbr 1100

3P (BLACK> CONNECTOR

Check that the O-ring is in good condition, replace if necessary.

Install the speed sensor into the upper crankcase.

F4i Combination Meter

Install and tighten the mounting bolts securely. Route the sensor wire.

Connect the speed sensor 3P (Black) connector.

TACHOMETER

SYSTEM INSPECTION

Turn the ignition switch to "ON" and check that the tachometer needle move to full scale and then returns to zero.

If the needle does not show initial function, check for combination meter power input line (page 19-11).

Disconnect the combination meter 9P (Natural) and 9P (Black) connectors (page 19-11). Connect the peak voltage adaptor to the tachometer Yellow/Green (+) terminal and Green (-).

TOOLS:

Peak voltage tester (U.S.A. only) or Peak voltage adaptor 07HGJ-0020100

(not available in U.S.A.) with commercially available digital multimeter (impedance 10 MQ/DCV minimum)

Start the engine and measure the tachometer input peak voltage.

PEAK VOLTAGE: 10.5 V minimum

If the value is normal, replace the tachometer.

If the measured value is below 10.5 V, replace the

ECM.

BOLTS

PEAK VOLTAGE ADAPTOR

Honda Cbr 230

O-RING

SPEED SENSOR

Conector Ecu Honda Cbr 600

If the value is 0 V, check for continuity between the combination meter 9P (Black) connectors terminal and the ECM multi-connector Yellow/Green terminals. If there :s no continuity, check the wire harness and combination meter sub-harness for an open circuit. If there is continuity, replace the combination meter printed circuit board (page 19-8).

COOLANT TEMPERATURE GAUGE/SENSOR

THERMO SENSOR UNIT INSPECTION

Drain the coolant (page 6-3).

Disconnect the wire connector from the ECT/thermo sensor and remove the sensor.

Suspend the ECTAhermo sensor in a pan of coolant (1:1 mixture) on an electric heating element and measure the resistance through the sensor as the coolant heats up.

• Soak the ECT/thermo sensor in coolant up to its threads with at least 40 mm (1.6 in) from the bottom of the pan to the bottom of the sensor.

• Keep the temperature constant for 3 minutes before testing. A sudden change of temperature will result in incorrect readings. Do not let the thermometer or ECTAhermo sensor touch the pan.

Replace the sensor if it is out of specification by more than 10% at any temperature listed.

Temperature

80'C (68°F)

120'C (248°F)

Resistance

2.1-2.6 kü

0.65-0.73 kn

ECT,THERMO SENSOR CONNECTOR

Always repiacc Install and tighten the ECTAhermo sensor to the specie sealing wash- jfjed torque.

er with a new one■ TORQUE: 23 N-m (2.3 kgf-m, 17 Ibf-ft)

Connect the ECTAhermo sensor connector. Fill the system and bleed the air (page 6-4).

COOLING FAN MOTOR SWITCH

INSPECTION

Remove the following:

Check for a blown fuse before inspection.

Fan motor does not stop Turn the ignition switch to "OFF", disconnect the connector from the fan motor switch and turn the ignition switch to "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.

Fan motor does not start

Before testing, warm up the engine to operating tcm perature.

Disconnect the connector from the fan motor switch and ground the connector to the body with a jumper wire.

Turn the ignition switch to "ON" and check the fan motor.

If the motor starts, check the connection at the tan motor switch terminal.

If it is OK, replace the fan motor switch.

SEALING

Honda 998 Motorcycle Engine Diagram

SEALING

ECT/THERMO SENSOR CONNECTOR

If the motor does not start, check for voltage between the fan motor switch connector and ground. It battery vnltage is measured, replace the fan motor. If there is no battery voltage, check for poor connec tion of the connector or a damaged wire harness.

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