Caution

First, disconnect the negative battery lead, and then the positive battery lead. For connecting, reverse the disconnection procedure. Cylinder identification sensor coupler For connecting reverse the disconnection Removing the parts in the order listed. Place a suitable stand under the frame and Refer to INSTALLING THE ENGINE. Use the pivot shaft wrench and adapter to loosen the engine mounting adjust bolts. For installation, reverse the removal

Engine

Remove the parts in the order listed. Refer to COWLINGS in chapter 3. Refer to ADJUSTING THE DRIVE CHAIN in chapter 3. For installation, reverse the removal procedure. Bottom cowling Side cowlings Muffler Exhaust pipe assembly Exhaust pipe gasket Remove the parts in the order listed. Refer to COWLINGS in chapter 3. For installation, reverse the removal procedure. Air filter case Throttle body assembly Battery negative lead Battery positive lead Disconnect the parts in the order listed. Refer to...

Front 01 mm 0004 in Rear 015 mm 0006 in

Place the motorcycle on a suitable stand so that the wheel is elevated. b. Before measuring the front brake disc deflection, turn the handlebars to the left or right to ensure that the front wheel is stationary. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the deflection 2 3 mm (0.08 0.12 in) below the edge of the brake disc. 3. Measure brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification Replace.

Adjusting The Engine Idling Speed Adjusting The Throttle Cable Free Play

Turn the throttle stop screw in direction or until the specified engine idling speed is obtained. 5. Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play (at the flange of the throttle grip) 6 - 8 mm (0.24 - 0.31 in) ADJUSTING THE THROTTLE CABLE FREE PLAY Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Check throttle cable free play Out of specification Adjust. Throttle cable free...

Electrical

CHECKING SWITCH CONTINUITY 8-3 CHECKING THE BULBS AND BULB SOCKETS TYPES OF CHECKING THE CONDITION OF THE CHECKING THE CONDITION OF THE BULB SOCKETS 8-7 CHECKING THE LEDs 8-9 ELECTRIC STARTING CIRCUIT STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 8-15 CHECKING THE STARTER MOTOR 8-21 ASSEMBLING THE STARTER MOTOR 8-22 8-24 CHECKING THE LIGHTING SIGNALING SYSTEM CIRCUIT CHECKING THE SIGNALING SYSTEM 8-43 FUEL PUMP CIRCUIT FUEL PUMP CHECKING THE FUEL SELF-DIAGNOSIS STARTING ENGINE FUEL ELECTRICAL...

Nm 06 mkg 43 fWb

Install a new brake pad shim onto each new brake pad 6. Install rear brake caliper (front) Below the minimum level mark Add the recommended brake fluid to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3. Soft or spongy feeling Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3. Remove the parts in the order listed. Refer to CHANGING THE BRAKE FLUID in chapter 3. Brake fluid reservoir diaphragm holder For installation, reverse the removal...

Adjusting The Rear Brake Checking The Brake Fluid Level

Adjust rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH. 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure the motorcycle is upright. 2. Check brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level.

Lubrication Points And Lubricant Types

Steering bearings and bearing races upper and lower Front wheel oil seal right and left Sidestand pivoting point and metal-to-metal moving parts Link and sidestand switch contact point Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Relay arm, connecting rod and rear shock absorber collar Swingarm head pipe end, oil seal and bush Oil seal relay arm, connecting arm and rear shock absorber Engine mount bolts rear upper and...

Checking The Connections

Check the leads, couplers, and connectors for stains, rust, moisture, etc. Moisture Dry with an air blower. Rust stains Connect and disconnect several times. Loose connection Connect properly. If the pin on the terminal is flattened, bend it up. Make sure all connections are tight. If there is no continuity, clean the terminals. When checking the wire harness, perform steps 1 to 3 . As a quick remedy, use a contact revitalizer available at most part stores.

Features

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber. Despite the same volume of intake air, the fuel volume requirement...

Synchronizing The Throttle Bodies Note

Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE Place the motorcycle on a suitable stand. Refer to AIR FILTER CASE. 3. Remove synchronizing hose onto the synchronizing hose digital tachometer near the spark plug Refer to AIR FILTER CASE. 6. Start the engine and let it warm up for several minutes. Refer to ADJUSTING THE ENGINE IDLING...

Checking The Spark Plugs Measuring The Compression Pressure

spark plug gap with a wire Thickness gauge Out of specification Regap. Spark plug gap 0.6 0.7 mm 0.0236 0.0276 in Spark plug gap 0.6 0.7 mm 0.0236 0.0276 in spark plug IX113 Nm 1.3 m kg, 9.4 fHb Before installing the spark plug, clean the spark plug and gasket surface. Refer to AIR FILTER CASE. The following procedure applies to all of the cylinders. Insufficient compression pressure will result in a loss of performance. Out of specification Adjust. Refer to ADJUSTING THE VALVE CLEARANCE. 2....

General Tightening Torque Specifications

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature. A...

Chassis Specifications

250 kPa 2.5 kgf cm2, 2.5 bar, 35.6 psi 250 kPa 2.5 kgf cm2, 2.5 bar, 35.6 psi 250 kPa 2.5 kgf cm2, 2.5 bar, 35.6 psi 250 kPa 2.5 kgf cm2, 2.5 bar, 35.6 psi Tire pressure cold 0 90 kg 0 198 lb 90 193 kg 198 426 lb USA except for CAL 90 192 kg 198 423 lb CAL High-speed riding Min. tire tread depth 180 55 ZR17 M C 73W Pilot SPORT B MICHELIN D208L DUNLOP 250 kPa 2.5 kgf cm2, 2.5 bar, 35.6 psi 290 kPa 2.9 kgf cm2, 2.9 bar, 41.3 psi 290 kPa 2.9 kgf cm2, 2.9 bar, 41.3 psi 250 kPa 2.5 kgf cm2, 2.5 bar,...

Checking The Engine Oil Level Changing The Engine

At 5 C 40 F or higher A Yamalube 4 20W40 or SAE 20W40 type SE motor oil At 15 C 60 F or lower B Yamalube 4 10W30 or SAE 10W30 type SE motor oil Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. Before checking the engine oil level, wait a few minutes until the oil has settled. 1. Start the engine, warm it up for several minutes, and then turn it off....

Adjusting The Throttle Cable Free Play

Yamaha Throttle Cable Free Play

Adjust throttle cable free play When the throttle is opened, the accelerator cable is pulled. b. Turn the adjusting nut in direction or to take up any slack on the decelerator cable. Throttle cable free play is increased. Throttle cable free play is decreased. If the specified throttle cable free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side. b. Turn the adjusting nut 2 in direction or until the specified throttle cable free play...

Engine Specifications

Standard compression pressure at sea level Liquid-cooled, 4-stroke, DOHC 600 cm3 36.61 cu.in Forward-inclined parallel 4-cylinder 65.5 x 44.5 mm 2.58 x 1.75 in 12.4 1 1,550 kPa 15.50 kg cm2,15.50 bar, 220.46 psi at 400 r min Recommended fuel Fuel tank capacity Total including reserve Reserve only 17 L 3.74 Imp gal, 4.49 US gal 3.5 L 0.77 Imp gal, 0.92 US gal Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure Engine oil temperature...

Cable Routing

Honda Cbr Coolant

Right handlebar switch lead Clutch cable Main switch lead and left handlebar switch lead Throttle cable return side Throttle cable pull side Front brake hoses Throttle cables Joint A Pass the right handlebar switch lead inside the front brake hoses and over the throttle cables. B Install the throttle cables to the hook so that the pulling side of the throttle cables is routed downward. O Pass the clutch cable through the guide. 0 Plastic locking tie shall be positioned at 10 mm 0.39 in. below...

Special Tools

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. For U.S.A. and Canada, use part number starting with YM-, YU-, or ACC-. For others, use part number starting with...