Banjo Bolt Washers Cbr F4i

Connection: Black/White {+) - Black/Green (-) Standard: Battery voltage

Battery voltage

Open circuit in O? sensor Black/Green wires.

No voltage

Replace the ECM and inspect again.

Measure the voltage at the Ch sensor wire harness side connector terminal and ground.

Cbr1000rr 2006 Diagram

Connection: Black/White 1+) - Ground H Standard: Battery voltage

Rattery voltage

Turn the ignition switch to "OFF".

No voltage

• 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 harness to the wire harness connectors.

Measure the voltage at the test harness terminals.

No voltage

Open circuit in Black/Green wire between the ECM connector and O2 sensor 4P conncctor.

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Connection: B6 (♦) - A5 {-} Standard: Battery voltage

Battery voltage

Replace the ECM and inspect again.

PGM-FI MIL 33 BLINKS (E2-PROM)

Turn the ignition switch to "OFF".

1

Disconnect the ECM connectors. Check for louse or poor contact of the ECM connectors.

Disconnect the ECM connectors. Check for louse or poor contact of the ECM connectors.

Connect the ECM connectors.

Short the service check connector with a jumper wire (page 5-6).

Turn the ignition switch to "ON" and check that the MIL blinks. I_ _

i' Except 33 blinks

Remove the jumper wire from the service check connector (page 5 6).

33 blinks

Reset the self-diagnosis memory data (page 5-7). Turn the ignition switch to "ON" and check that the MIL blinks.

Blinks

| 33 blinks Replace the ECM.

Turn the ignition switch to "ON" and check that -

the MIL blinks.

33 blinks

Does not blink 33 tines

Does not blink 33 tines

No problem.

Turn the ignition switch to "OFF".

1

Does not blink 33 times

Short the service check connector with a jumper wire (paye 5-6).

Turn the ignition switch to "ON" and check that the MIL blinks.

1

' 33 blinks

Does not blink 33 times

Reset the self-diagnosis memory data (page 5-

Turn the ignition switch to "ON" and check that the MIL blinks.

No problem.

No problem.

33 blinks

33 blinks

No problem.

No problem.

Replace the ECM.

FUEL LINE INSPECTION

FUEL PRESSURE INSPECTION NOTICE

• Before disconnecting the fuel Iwses, release the fuel pressure by loosening the service check bolt at the fuel tank.

' Always replace the sealing washers when the scr vice check holt is removed or loosened.

Remove the seat (page 2-2).

Remove the ECM holder band and remove the ECM

from the battery cover.

Unhook the battery cover retainers, then open the battery cover.

Disconnect the hattery negative cable from the battery terminal.

Construction Plans
BAND

Lih if.e fuel ian< Support the front end of fuel tank (page 3-4).

slowly, Deing cnremi not to Disconnect the pressure regulator vacuum hose and overoxtend :ne p|ug thc vacuum hose.

fuel nose.

Cover the service check bolt with a rag or shop towel.

Slowly loosen thc scrvice check bolt and drain the remaining fuel into an approved gasoline container.

NEGATIVE TERMINAL

BATTERY

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PRESSURt REGUI ATOR

•nowlIM HOSE

Remove the service check bolt and attach the fuel pressure gauge.

TOOL:

Fuel pressure gauge

07406-0040003 or 0740f>-0040002

Connect the battery negative cable. Start the engine.

Read the fuel pressure at jdle speed.

Always replocc the sealing washer when the service check bolt r$ removed or loosened.

IDLE SPEED: 1,300 2 100 rpm STANDARD: 343 kPa (3.5 kgf/cm2. 50 psi)

If the fuel pressure is higher than specified, inspect the following:

- Pinched or clogged fuel return hose Pressure regulator

If the fuel pressure is lower than specified, inspect the following:

- Fuel line leaking

- Clogged fuel filter

- Pressure regulator

After inspection, remove the fuel pressure gauge and reinstall and tighten the service check bolt using the new sealing washer.

Connect the pressure regulator vacuum hose.

Install the removed parts in the reverse order of removal.

FUEL PRESSURE GAUGF

FUEL PRESSURE GAUGF

SERVICE CHECK BOLT SEALING WASHER

PRESSURE REGULATOR

VACUUM HOSE

FUEL FLOW INSPECTION

Remove the rear cowl (page 2-2). Support the front end of fuel tank (page 3-4).

Disconnect the fuel cut-off relay connector.

FUEl CUT-OFF RELAY

FUEl CUT-OFF RELAY

Honda F4i Relay Fuel

Jump the Brown and Black/White wire terminals of the wire harness side using a jumper wire.

• When the fuel return hose is disconnected, gasoline may spill out from the hose. Place a approved gasoline container under the hose and drain the gasoline.

• Wipe off any spilled out gasoline.

FUEL CUT-OFF RELAY

FUEL CUT-OFF RELAY

Cbr 600 Conecting Feul Tank

Disconnect the fuel return hose at the fuel tank and plug the fuel tank inlet joint.

Turn the ignition switch to "ON" for 10 seconds. Measure the amount of fuel flow.

Amount of fuel flow: Minimum 188 cm3 (6.4 US oz, 6.6 Imp oz) for 10 seconds at 12 V

If the fuel flow is less than specified, inspect the following:

Pinched or clogged fuel hose and fuel return hose

- Clogged fuel filter

- Pressure regulator

FUEL RETURN HOSE

FUEL RETURN HOSE

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After inspection, connect the fuel return hose. Start the engine and check for leak.

FUEL RETURN HOSE

FUEL RETURN HOSE

FUEL PUMP

INSPECTION

Turn the ignition switch to "ON" and confirm that the fuel pump operates for a few seconds.

If the fuel pump does not operate, inspect as follows:

Support the front end of fuel tank (page 3-4).

Disconnect the fuel pump 3P (Black) connector.

Turn the ignition switch to "ON" and measure the voltage between the terminals.

There should be battery voltage for a few seconds.

If there is battery voltage, replace the fuel pump. If there is no battery voltage, inspect the following:

- Main fuse 30A

- Sub fuse 10A

- Engine stop switch (page 19 19)

- Engine slop relay (page 5-84)

REMOVAL I NOTICE

• Before disconnecting the fuel hose, release the fuel pressure by loosening the service check bolt at the fuel tank.

• Always replace the sealiny washers when the service check bolt is removed or loosened.

Remove the fuel tank (page 5-55).

Remove the fuel pump mounting nuts.

3P (BLACK) CONNECTOR +

FUEL FILTER REPLACEMENT

Disconnect the fuel hoses from the Fuel filter. Remove the screws and fuel filter.

Note the direction Install the fuel filler in the reverse order of removal.

of the fuel filter.

SCREW

SCREW

FUEL HOSES

FUEL FILTER

FUEL HOSES

FUEL FILTER

INSTALLATION

Always replace Place a new packing onto the fuel tank. the packing with a u/ie. install the fuel pump being careful not to damage the fuel pump wire.

FUEL PUMP ASSEMBLY

FUEL PUMP ASSEMBLY

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Install and tighten the fuel pump mounting nuts in the sequence shown.

FUEL PUMP

FUEL PUMP

NUTS

FUEL CUT RELAY

INSPECTION

Remove the rear cowl (page 2-2).

Disconnect the fuel cut-off relay 4P connector, remove the fuel cul-uff («lay.

FUEL CUT-OFF RELAY

Connect the ohmmeter to the fuel cut-off relay connector terminals.

CONNECTION: Black/White - Brown

Connect the 12-V battery to the following fuel cut-off relay connector terminals.

CONNECTION: Brown/Black - Black/White

There should be continuity only when the 12-V battery is connected.

If there is no continuity when the 12-V battery is connected, replace the fuel cut-off relay.

FUEL TANK

REMOVAL

Remove the air duct cover (page 2-7).

Remove the fuel tank front mounting bolts and washers.

FUEt CUT-OFF RELAY BATTERY

FUEt CUT-OFF RELAY BATTERY

BOLTS/WASHERS

SUITABLE SUPPORT (250 mm)

Lit: the fuel Tank Support the front end of fuel tank and support it using slowly, being a suitable support (250 mm).

careful not to overextend the Re|ease the fue| pressure (page 5-50).

fuei tank.

SUITABLE SUPPORT (250 mm)

Disconnect the fuel pump/reserve sensor 3P (Black) connector.

3P (BLACK) CONNECTOR *

Disconnect the fuel tank air vent hose and overflow hose.

AIR VENT HOSE

OVERFLOW HOSE

AIR VENT HOSE

OVERFLOW HOSE

Hold the fuel pipe nut and remove the fuel hose sealing nut and sealing washers, then disconnect the fuel hose.

NOTICE

Do not apply excessive force to the fuel pipe. Always hold thc fuel pipe nut while removing the fuel huse sealing nut.

Temporarily install a 12 x 30 mm bolt (pitch 1.25) and sealing washers to the fuel hose banjo, then tighten the sealing nut.

Disconnect the fuel return hose at the pressure regulator.

NOTICE

Do not apply excessive force to the fuel pipe.

Close the fuel tank. Remove the fuel tank rear mounting bolts, seat bracket and fuel tank.

FUEL HOSE

SEALING NUT

FUEL RETURN HOSE

FUEL RETURN HOSE

BOLTS \

SEAT BRACKET

l-UEL TANK

Place the fuel tank upside down. Be careful not to damage the fuel tank.

Disconnect the fuel return hose from the fuel pump. Remove the fuel hose banjo bolt and sealing washers, then remove the fuel hose from the fuel pump.

Refer to page 5-53 for fuel pump removal.

FUEL RETURN HOSE

BANJO BOLT

FUEL RETURN HOSE

BANJO BOLT

FUEL HOSE

FUEL HOSE

INSTALLATION

FUEL TANK

FUEL TANK

Syst Pair Avec Sol

AIR VENT HOSE

OVERFLOW HOSE

AIR VENT HOSE

OVERFLOW HOSE

Align the fuel Connect the fuel hose to the fuel pump with new seal-nose eyeie: joint ing washers. with the stopper on the fuel pump. ,nsta,| anri tighten the fuel hose banjo bolt to the spec ified torque.

Connect the fuel return hose to the fuel pump.

FUEL RFTIJRN HOSE BANJO BOLT

FUEL RFTIJRN HOSE BANJO BOLT

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Install the fuel tank onto the frame.

Install the seat bracket and fuel tank rear mounting bolts.

Connect the fuel return hose to the pressure regulator.

NOTICE I

Do not apply excessive forcc to the fuel pipe.

Connect thc fuel hose banjo to the throttle body with new sealing washers.

While pushing the fuel hose banjo stopper to the throttle body, install and tighten the sealing nut to the specified torque.

NOTICE

• Do not apply excessive force to the fuel pipe.

• Always hold the fuel pipe nut while tightening the fuel hose sealing nut.

BOLTS

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SEAT BRACKET

FUEL TANK

BOLTS

SEAT BRACKET

FUEL TANK

FUEL RETURN HOSE

FUEL RETURN HOSE

SEALING WASHERS

SEALING NUT

FUEL HOSE

Connect the fuel pump/reserve sensor 3P (Black) con nector.

Remove the support and close the fuel lank.

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Install the fuel tank front mounting bolts and washers, then tighten the front and rear fuel tank mounting bolts.

BOLTS/WASHERS

BOLTS/WASHERS

3P (BLACK) CONNECTOR

AIR CLEANER HOUSING

REMOVAL

Remove the air cleaner element {page 3-5).

Disconnect the MAP sensor connector and vacuum hose.

Disconnect the PAIR control valve air suction hose and intake vacuum hoses from the air clcancr housing.

JUM HOSES

Disconnect the crankcase breather hose from the air cleaner housing.

CRANKCASE BREATHER HOSE

Remove the air funnel/air cleaner housing mounting screws, then remove the air funnels.

Remove the air cleaner housing.

AIR CLEANER HOUSING

SCREWS

AIR CLEANER HOUSING

SCREWS

AIR FUNNELS

INSTALLATION

Install the air cleaner housing onto the throttle body. Install the air funnels in their proper locations. Install and tighten thc air funnel/air cleaner housing mounting screws.

Connect the crankcasc breather hose to the air cleaner housing.

CRANKCASE BREATHER HOSE

Connect the PAIR control valve air suction hose and intake vacuum hoses to the air cleancr housing.

AIR SUCTION HOSE

Connect thc MAP sensor connector and vacuum hose. Install the air cleaner element (page 3-5).

AIR SUCTION HOSE

VACUUM HOSE

THROTTLE BODY

REMOVAL

■ Before disconnecting the fuel hose, release the fuel pressure by loosening the service check bolt. • Always replace the sealing washer when the service check bolt is removed or loosened.

Drain the coolant from the cooling system (page 6-4).

Remove the following:

- Air cleaner housing (page 5-60)

Do not snap the throttle valve from fully open to full y closed after the throttle cable has been removed. It nay cause incorrect idle operation.

Remove the throttle cable bracket mounting bolts. Disconnect the throttle cable ends from the throttle drum.

Remove the throttle stop screw knob from the clamp.

Disconnect the throttle body sub-harness 10P (Gray) connector.

California rype Disconnect the throttle body-to-EVAP purge control only: solenoid valve hose.

AIR HOSE

CARLE GUIDE BRACKET

BOLTS ?

THROTTLE STOP SCREW

THROTTLE STOP SCREW

10P (GRAY) CONNECTOR

10P (GRAY) CONNECTOR

Loosen the engine side insulator band screws using a long type phillips screwdriver through the frame hole.

Remove the throttle body from the cylinder head.

NOTICE

Do not hold the fuel pipe on the throttle body while removing the throttle body.

Loosen the hose band screws and disconnect the fast idle wax unit water hoses from the wax unit. Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been removed.

THROTTLE BODY^

Disconnect the TP sensor connector and injector connectors, then remove the throttle body sub-harness.

SUB-HARNESS INJECTOR CONNECTORS

SUB-HARNESS INJECTOR CONNECTORS

TP SENSOR CONNECTOR

Do not snap the throttle valve from fully open to fully dosed after the throttle cable has been removed. It may couso incorrect idle operation.

Remove the insulators from the throttle body.

INSULATORS

NOTICE

• Do not damage the throttle body, this may cause incorrect throttle and idle valve synchronization. ' The throttle body is factory pre-set, do not disassemble it in a way other than shown in this manual. ' Do not loosen or tighten the white painted bolts and screws of the throttle body. Loosening or tightening them can cause throttle and idle valve synchronization failure.

TOP VIEW:

TOP VIEW:

REAR VIEW.

STARTER VALVE LINK VIEW:

WHITE PAINTED

Truck Pictures Color

THROTTLE DRUM VIEW: RIGHT SIDE VIEW:

THROTTLE LINK VIEW:

WHITE PAINTED

STARTER VALVE LINK VIEW:

WHITE PAINTED

WHITE PAINTED

WHITE PAINTED

1 N-m (0.0Ü kgf-m, 0.7 lbf-ft)

WHITE PAINTED

THROTTLE BODY VACUUM HOSE ROUTING

Vacuum Cbr 1100Suzuki Bandit 600 Frame Manual

Except California type:

California type:

INSTALLATION

Check the insulator band angle.

Install the insulators onto the throttle body.

Tighten the throttle body side insulator band so that the insulator band distance is 7 ± 1 mm (0.3 = 0.04 in).

Apply oil to the insulator inside surfaces for case of throttle body installation.

Route the throttle body sub-harness properly and SUB-HARNESS INJECTOR CONNECTORS connect the injector connectors and TP sensor connector.

TP SENSOR CONNECTOR

Connect the fast idle wax unit water hoses to the unit, then tighten the hose bands securely.

Install the throttle body onto the cylinder head.

NOTICE

Do not hold the fuel pipe on the throttle body while installing thc throttle body.

Tighten the cylinder head side insulator band so that the insulator band distance is 4 ± 1 mm (0.2 ± 0.04 in).

Route the injector sub-harness referring the cable and harness routing (page 1-23).

Connect the throttle body sub harness 10P (Gray) connector.

10P (GRAY) CONNECTOR

10P (GRAY) CONNECTOR

California type Connect the throttle body-to-EVAP purge control sole-ooly. noid valve hose.

AIR HOSE

Route the throttle stop control cable properly, install ^ \ the control knob to the clamp on the bypass hose.

THROTTLE STOP SCREW

Connect the throttle cable ends to the throttle drum. Install the throttle cable guide bracket to the throttle body, then tighten the bolts to the specified torque.

Install the removed parts in the reverse order of removal.

THROTTLE STOP SCREW

INJECTOR

INSPECTION

Start the engine and let it idle.

Confirm proper injector operation with a sounding rod or stethoscope.

If the injector does not operate properly, replace it.

REMOVAL

Remove the throttle body (page 5 62). Remove the bolts and fuel pipe assembly.

Remove the injectors from the fuel pipe.

BOLTS

BOLTS

Cbr 600 F4i Throttle Stop Screw
FUEL PIPE ASSEMBLY

Replace the sea! ring, cushion ring ana O-ring with new ones as a set.

Remove the seal ring, 0 ring and cushion ring. INSTALLATION

Apply oil to the new O-ring.

Install the new seal ring, cushion ring and O-ring, being careful not to damage the O-ring.

CUSHION RING

O-RING

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Responses

  • sarah
    Where is a diagnostic connector for a 2000 honda cbr 600 f4i?
    3 years ago
  • mario
    How connect the hose sensor on cbr?
    2 years ago
  • MACEY
    How to remove banjo bolt f4i?
    2 years ago

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