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Table Of Contents - Honda CBR600F4I 2001 Service Manual

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Table of Contents

Table Of Contents

Contents2................................................................................................................................................................
Symbols3................................................................................................................................................................
General Information4................................................................................................................................................................
Service Rules4................................................................................................................................................................
Model Identification4................................................................................................................................................................
Frame Serial Number5................................................................................................................................................................
Vehicle Identification Number (vin)5................................................................................................................................................................
Color Label5................................................................................................................................................................
Engine Serial Number5................................................................................................................................................................
Specifications6................................................................................................................................................................
Torque Values15................................................................................................................................................................
Insulator Clamp (throttle Body Side)17................................................................................................................................................................
Insulator Clamp (cylinder Head Side)17................................................................................................................................................................
Exhaust Pipe Stud Bolt17................................................................................................................................................................
Tools20................................................................................................................................................................
Lubrication & Seal Points22................................................................................................................................................................
Cable & Harness Routing26................................................................................................................................................................
Emission Control Systems41................................................................................................................................................................
Crankcase Emission Control System41................................................................................................................................................................
Exhaust Emission Control System (pulse Secondary Air Supply System)42................................................................................................................................................................
Evaporative Emission Control System43................................................................................................................................................................
Noise Emission Control System43................................................................................................................................................................
Emission Control Information Labels (u.s.a. Only)44................................................................................................................................................................
Vacuum Hose Routing Diagram Label (california Type Only)44................................................................................................................................................................
Body Panel Locations45................................................................................................................................................................
Frame/body Panels/exhaust System Service Information46................................................................................................................................................................
Frame/body Panels/exhaust System Troubleshooting46................................................................................................................................................................
Seat Removal47................................................................................................................................................................
Seat Installation47................................................................................................................................................................
Pillion Seat/rear Cowl Removal47................................................................................................................................................................
Pillion Seat/rear Cowl Installation48................................................................................................................................................................
Lower Cowl Removal49................................................................................................................................................................
Lower Cowl Installation50................................................................................................................................................................
Upper Cowl Removal52................................................................................................................................................................
Upper Cowl Installation54................................................................................................................................................................
Front Fender Removal57................................................................................................................................................................
Front Fender Installation57................................................................................................................................................................
Rear Fender Removal58................................................................................................................................................................
Rear Fender Installation59................................................................................................................................................................
Seat Rail Removal61................................................................................................................................................................
Seat Rail Installation62................................................................................................................................................................
Muffler/exhaust Pipe Removal64................................................................................................................................................................
Muffler/exhaust Pipe Installation65................................................................................................................................................................
Maintenance Service Information70................................................................................................................................................................
Maintenance Specifications71................................................................................................................................................................
Maintenance Schedule72................................................................................................................................................................
Fuel Line73................................................................................................................................................................
Throttle Operation73................................................................................................................................................................
Air Cleaner74................................................................................................................................................................
Spark Plug Removal75................................................................................................................................................................
Spark Plug Inspection76................................................................................................................................................................
Valve Clearance Inspection78................................................................................................................................................................
Valve Clearance Adjustment81................................................................................................................................................................
Engine Oil/oil Filter83................................................................................................................................................................
Engine Oil Level Inspection83................................................................................................................................................................
Engine Oil & Filter Change84................................................................................................................................................................
Engine Idle Speed86................................................................................................................................................................
Radiator Coolant86................................................................................................................................................................
Cooling System86................................................................................................................................................................
Secondary Air Supply System87................................................................................................................................................................
Evaporative Emission Control System (california Type Only)88................................................................................................................................................................
Drive Chain Slack Inspection88................................................................................................................................................................
Drive Chain Slack Adjustment88................................................................................................................................................................
Drive Chain Cleaning And Lubrication89................................................................................................................................................................
Drive Chain Sprockets Inspection89................................................................................................................................................................
Drive Chain Replacement90................................................................................................................................................................
Front Brake Fluid92................................................................................................................................................................
Rear Brake Fluid92................................................................................................................................................................
Front Brake Pads Wear93................................................................................................................................................................
Rear Brake Pads Wear93................................................................................................................................................................
Brake System Inspection93................................................................................................................................................................
Brake Lever Adjustment93................................................................................................................................................................
Brake Light Switch94................................................................................................................................................................
Headlight Aim94................................................................................................................................................................
Brake Pedal Height Adjustment94................................................................................................................................................................
Clutch System95................................................................................................................................................................
Side Stand95................................................................................................................................................................
Front Suspension Inspection96................................................................................................................................................................
Front Suspension Adjustment96................................................................................................................................................................
Rear Suspension Inspection97................................................................................................................................................................
Compression And Rebound Damping Adjusters97................................................................................................................................................................
Compression Adjuster Standard Position97................................................................................................................................................................
Rear Suspension Adjustment98................................................................................................................................................................
Nuts, Bolts, Fasteners99................................................................................................................................................................
Wheels/tires99................................................................................................................................................................
Recommended Tire Pressure And Tire Size99................................................................................................................................................................
Minimum Tread Depth99................................................................................................................................................................
Steering Head Bearings100................................................................................................................................................................
Lubrication System Diagram101................................................................................................................................................................
Lubrication System Service Information102................................................................................................................................................................
Lubrication System Specifications102................................................................................................................................................................
Lubrication System Troubleshooting103................................................................................................................................................................
Oil Pressure Inspection104................................................................................................................................................................
Oil Strainer/pressure Relief Valve Removal104................................................................................................................................................................
Oil Strainer/pressure Relief Valve Inspection105................................................................................................................................................................
Oil Pump Removal106................................................................................................................................................................
Oil Pump Disassembly107................................................................................................................................................................
Oil Pump Inspection107................................................................................................................................................................
Oil Pump Assembly108................................................................................................................................................................
Oil Pump Installation109................................................................................................................................................................
Oil Cooler Removal109................................................................................................................................................................
Oil Cooler Inspection110................................................................................................................................................................
Oil Cooler Installation110................................................................................................................................................................
Fuel System (programmed Fuel Injection)113................................................................................................................................................................
Fuel System (programmed Fuel Injection) Service Information114................................................................................................................................................................
Fuel System (programmed Fuel Injection) Specifications115................................................................................................................................................................
Fuel System (programmed Fuel Injection) Troubleshooting116................................................................................................................................................................
System Location117................................................................................................................................................................
System Diagram118................................................................................................................................................................
Pgm-fi (programmed Fuel Injection) System119................................................................................................................................................................
Self-diagnostic Procedures119................................................................................................................................................................
Self-diagnosis Reset Procedure120................................................................................................................................................................
Peak Voltage Inspection Procedure121................................................................................................................................................................
Test Harness Connection121................................................................................................................................................................
Test Harness Terminal Layout122................................................................................................................................................................
Pgm-fi Self-diagnosis Malfunction Indicator Lamp (mil) Failure Codes123................................................................................................................................................................
Pgm-fi Mil 1 Blink (map Sensor)125................................................................................................................................................................
Pgm-fi Mil 2 Blinks (map Sensor)127................................................................................................................................................................
Pgm-fi Mil 7 Blinks (ect Sensor)129................................................................................................................................................................
Pgm-fi Mil 8 Blinks (tp Sensor)131................................................................................................................................................................
Pgm-fi Mil 9 Blinks (iat Sensor)135................................................................................................................................................................
Pgm-fi Mil 11 Blinks (vehicle Speed Sensor)137................................................................................................................................................................
Pgm-fi Mil 12 Blinks (no.1 Injector)139................................................................................................................................................................
Pgm-fi Mil 13 Blinks (no.2 Injector)142................................................................................................................................................................
Pgm-fi Mil 14 Blinks (no. 3 Injector)145................................................................................................................................................................
Pgm-fi Mil 15 Blinks (no. 4 Injector)148................................................................................................................................................................
Pgm-fi Mil 18 Blinks (cam Pulse Generator)151................................................................................................................................................................
Pgm-fi Mil 19 Blinks (ignition Pulse Generator)153................................................................................................................................................................
Pgm-fi Mil 21 Blinks (o2 Sensor/california Type Only)155................................................................................................................................................................
Pgm-fi Mil 23 Blinks (o2 Sensor Heater/california Type Only)157................................................................................................................................................................
Pgm-fi Mil 33 Blinks (e2-prom)161................................................................................................................................................................
Fuel Line Inspection163................................................................................................................................................................
Fuel Pressure Inspection163................................................................................................................................................................
Fuel Flow Inspection165................................................................................................................................................................
Fuel Pump Inspection166................................................................................................................................................................
Fuel Pump Removal166................................................................................................................................................................
Fuel Filter Replacement167................................................................................................................................................................
Fuel Pump Installation167................................................................................................................................................................
Fuel Cut Relay Inspection167................................................................................................................................................................
Fuel Tank Removal168................................................................................................................................................................
Fuel Tank Installation170................................................................................................................................................................
Air Cleaner Housing Removal173................................................................................................................................................................
Air Cleaner Housing Installation174................................................................................................................................................................
Throttle Body Removal175................................................................................................................................................................
Throttle Body Top View177................................................................................................................................................................
Throttle Body Rear View177................................................................................................................................................................
Throttle Drum View178................................................................................................................................................................
Throttle Link View178................................................................................................................................................................
Right Side View178................................................................................................................................................................
Starter Valve Link View178................................................................................................................................................................
Throttle Body Vacuum Hose Routing179................................................................................................................................................................
Injector Inspection182................................................................................................................................................................
Injector Removal182................................................................................................................................................................
Injector Installation182................................................................................................................................................................
Pressure Regulator Removal/installation183................................................................................................................................................................
Fast Idle Wax Unit Disassembly184................................................................................................................................................................
Fast Idle Wax Unit Inspection185................................................................................................................................................................
Fast Idle Wax Unit Assembly185................................................................................................................................................................
Starter Valve Disassembly186................................................................................................................................................................
Starter Valve Assembly188................................................................................................................................................................
Starter Valve Synchronization190................................................................................................................................................................
Output Voltage Inspection192................................................................................................................................................................
Map Sensor Removal/installation192................................................................................................................................................................
Iat Sensor Removal/installation193................................................................................................................................................................
Ect Sensor Removal/installation193................................................................................................................................................................
Cam Pulse Generator Removal/installation194................................................................................................................................................................
Tp Sensor Inspection195................................................................................................................................................................
Back Angle Sensor Inspection196................................................................................................................................................................
Continuity Inspection196................................................................................................................................................................
Back Angle Sensor Removal/installation197................................................................................................................................................................
Engine Stop Relay Inspection198................................................................................................................................................................
Ecm (engine Control Module) Removal/installation198................................................................................................................................................................
Power/ground Line Inspection198................................................................................................................................................................
Pair Solenoid Valve Removal/installation199................................................................................................................................................................
Pair Solenoid Valve Inspection199................................................................................................................................................................
Evap Purge Control Valve (california Type Only) Removal200................................................................................................................................................................
Evap Purge Control Valve (california Type Only) Inspection200................................................................................................................................................................
O2 Sensor Removal201................................................................................................................................................................
System Flow Pattern203................................................................................................................................................................
Cooling System Service Information204................................................................................................................................................................
Cooling System Specifications205................................................................................................................................................................
Cooling System Troubleshooting205................................................................................................................................................................
Cooling System Testing206................................................................................................................................................................
Coolant (hydrometer Test)206................................................................................................................................................................
Coolant Gravity Chart206................................................................................................................................................................
Coolant Replacement207................................................................................................................................................................
Radiator Cap/system Pressure Inspection207................................................................................................................................................................
Radiator Cap Relief Pressure207................................................................................................................................................................
Replacement/air Bleeding207................................................................................................................................................................
Thermostat Removal209................................................................................................................................................................
Thermostat Inspection209................................................................................................................................................................
Thermostat Housing Removal210................................................................................................................................................................
Thermostat Housing Installation210................................................................................................................................................................
Thermostat Installation210................................................................................................................................................................
Radiator Removal211................................................................................................................................................................
Radiator Disassembly212................................................................................................................................................................
Radiator Assembly213................................................................................................................................................................
Radiator Installation214................................................................................................................................................................
Mechanical Seal Inspection216................................................................................................................................................................
Water Pump Removal216................................................................................................................................................................
Water Pump Installation217................................................................................................................................................................
Radiator Reserve Tank Removal218................................................................................................................................................................
Radiator Reserve Tank Installation219................................................................................................................................................................
Engine Removal/installation222................................................................................................................................................................
Engine Removal/installation Service Information223................................................................................................................................................................
Shock Link Lower Bracket Removal224................................................................................................................................................................
Engine Removal226................................................................................................................................................................
Engine Installation231................................................................................................................................................................
Shock Link Lower Bracket Installation237................................................................................................................................................................
Cylinder Head/valves Service Information242................................................................................................................................................................
Cylinder Head/valves Specifications243................................................................................................................................................................
Cylinder Head/valves Troubleshooting244................................................................................................................................................................
Cylinder Compression Test245................................................................................................................................................................
Cylinder Head Cover Removal245................................................................................................................................................................
Cylinder Head Cover Disassembly246................................................................................................................................................................
Camshaft Removal247................................................................................................................................................................
Camshaft Inspection250................................................................................................................................................................
Camshaft Holder250................................................................................................................................................................
Cam Chain Guide B251................................................................................................................................................................
Camshaft Oil Clearance251................................................................................................................................................................
Cylinder Head Removal252................................................................................................................................................................
Cylinder Head Disassembly253................................................................................................................................................................
Cylinder Head Inspection254................................................................................................................................................................
Valve Lifter Bore255................................................................................................................................................................
Valve Lifter255................................................................................................................................................................
Valve Spring255................................................................................................................................................................
Cam Chain Tensioner/cam Chain Guide255................................................................................................................................................................
Valve/valve Guide256................................................................................................................................................................
Valve Guide Replacement257................................................................................................................................................................
Valve Seat Inspection/refacing257................................................................................................................................................................
Valve Seat Refacing258................................................................................................................................................................
Cylinder Head Assembly260................................................................................................................................................................
Cylinder Head Installation262................................................................................................................................................................
Camshaft Installation264................................................................................................................................................................
Cylinder Head Cover Assembly268................................................................................................................................................................
Cylinder Head Cover Installation269................................................................................................................................................................
Cam Chain Tensioner Lifter Removal270................................................................................................................................................................
Cam Chain Tensioner Lifter Installation271................................................................................................................................................................
Clutch/gearshift Linkage Service Information274................................................................................................................................................................
Clutch/gearshift Linkage Specifications274................................................................................................................................................................
Clutch/gearshift Linkage Troubleshooting275................................................................................................................................................................
Right Crankcase Cover Removal276................................................................................................................................................................
Clutch Lifter Lever277................................................................................................................................................................
Clutch Removal277................................................................................................................................................................
Clutch Inspection279................................................................................................................................................................
Clutch Lifter Bearing279................................................................................................................................................................
Clutch Center280................................................................................................................................................................
Clutch Lifter Piece280................................................................................................................................................................
Clutch Disc280................................................................................................................................................................
Clutch Plate280................................................................................................................................................................
Clutch Outer Needle Bearing Replacement281................................................................................................................................................................
Clutch Outer/clutch Outer Guide281................................................................................................................................................................
Mainshaft281................................................................................................................................................................
Clutch Installation282................................................................................................................................................................
Gearshift Linkage Removal285................................................................................................................................................................
Gearshift Linkage Inspection286................................................................................................................................................................
Gearshift Linkage Installation286................................................................................................................................................................
Right Crankcase Cover Installation288................................................................................................................................................................
Alternator/starter Clutch Service Information292................................................................................................................................................................
Alternator/starter Clutch Specifications292................................................................................................................................................................
Alternator/starter Clutch Troubleshooting292................................................................................................................................................................
Alternator Cover Removal293................................................................................................................................................................
Stator Removal293................................................................................................................................................................
Flywheel Removal294................................................................................................................................................................
Alternator Cover Installation294................................................................................................................................................................
Starter Clutch Inspection296................................................................................................................................................................
Starter Clutch Disassembly296................................................................................................................................................................
Starter Clutch Assembly297................................................................................................................................................................
Flywheel Installation298................................................................................................................................................................
Crankcase/transmission Service Information302................................................................................................................................................................
Crankcase/transmission Specifications302................................................................................................................................................................
Crankcase/transmission Troubleshooting303................................................................................................................................................................
Crankcase Separation304................................................................................................................................................................
Shift Fork/shift Drum Removal305................................................................................................................................................................
Shift Drum/shift Fork Inspection306................................................................................................................................................................
Shift Drum/shift Form Installation306................................................................................................................................................................
Transmission Removal/disassembly307................................................................................................................................................................
Mainshaft Bearing Replacement309................................................................................................................................................................
Mainshaft Bearing Assembly310................................................................................................................................................................
Mainshaft Bearing Installation312................................................................................................................................................................
Crankcase Assembly313................................................................................................................................................................
Crankshaft/piston/cylinder Service Information318................................................................................................................................................................
Crankshaft/piston/cylinder Specifications318................................................................................................................................................................
Crankshaft/piston/cylinder Troubleshooting319................................................................................................................................................................
Crankshaft Side Clearance Inspection320................................................................................................................................................................
Crankshaft Removal320................................................................................................................................................................
Crankshaft Inspection320................................................................................................................................................................
Crankshaft Primary Drive Sub-gear Removal320................................................................................................................................................................
Primary Drive Sub-gear Installation321................................................................................................................................................................
Starter Clutch Needle Bearing Replacement321................................................................................................................................................................
Starter Clutch Needle Bearing Installation322................................................................................................................................................................
Main Journal Bearing Inspection323................................................................................................................................................................
Oil Clearance Inspection323................................................................................................................................................................
Main Journal Bearing Selection324................................................................................................................................................................
Main Journal Bearing Installation325................................................................................................................................................................
Crankpin Bearing Inspection325................................................................................................................................................................
Crankpin Bearing Selection326................................................................................................................................................................
Crankpin Bearing Installation327................................................................................................................................................................
Piston/cylinder328................................................................................................................................................................
Piston/connecting Rod Removal328................................................................................................................................................................
Piston Removal328................................................................................................................................................................
Piston Disassembly328................................................................................................................................................................
Piston Inspection329................................................................................................................................................................
Connecting Rod Inspection330................................................................................................................................................................
Cylinder Inspection330................................................................................................................................................................
Piston Assembly331................................................................................................................................................................
Piston Installation332................................................................................................................................................................
Front Wheel/suspension/steering Service Information336................................................................................................................................................................
Front Wheel/suspension/steering Specifications336................................................................................................................................................................
Front Wheel/suspension/steering Troubleshooting337................................................................................................................................................................
Handlebar Removal338................................................................................................................................................................
Handlebar Installation340................................................................................................................................................................
Handlebar Weight Replacement341................................................................................................................................................................
Front Wheel Removal344................................................................................................................................................................
Front Wheel Inspection345................................................................................................................................................................
Axle345................................................................................................................................................................
Wheel Bearing345................................................................................................................................................................
Wheel Rim Runout345................................................................................................................................................................
Front Wheel Disassembly346................................................................................................................................................................
Front Wheel Assembly347................................................................................................................................................................
Front Wheel Installation348................................................................................................................................................................
Fork Removal349................................................................................................................................................................
Fork Disassembly350................................................................................................................................................................
Fork Inspection353................................................................................................................................................................
Fork Spring353................................................................................................................................................................
Fork Tube/slider/damper353................................................................................................................................................................
Fork Assembly354................................................................................................................................................................
Fork Tube Bushing354................................................................................................................................................................
Fork Installation358................................................................................................................................................................
Steering Stem Removal359................................................................................................................................................................
Bearing Replacement361................................................................................................................................................................
Steering Stem Installation366................................................................................................................................................................
Steering Head Bearing Pre-load369................................................................................................................................................................
Rear Wheel/suspension Service Information372................................................................................................................................................................
Rear Wheel/suspension Specifications372................................................................................................................................................................
Rear Wheel/suspension Troubleshooting373................................................................................................................................................................
Rear Wheel Removal374................................................................................................................................................................
Rear Wheel Inspection374................................................................................................................................................................
Rear Wheel Disassembly375................................................................................................................................................................
Driven Sprocket375................................................................................................................................................................
Driven Flange Bearing Removal376................................................................................................................................................................
Rear Wheel Assembly377................................................................................................................................................................
Wheel Bearing Removal377................................................................................................................................................................
Wheel Bearing Installation378................................................................................................................................................................
Driven Flange Bearing Installation378................................................................................................................................................................
Rear Wheel Installation379................................................................................................................................................................
Shock Absorber Removal380................................................................................................................................................................
Shock Absorber Inspection381................................................................................................................................................................
Needle Bearing Replacement381................................................................................................................................................................
Shock Absorber Disposal Procedure382................................................................................................................................................................
Shock Absorber Installation383................................................................................................................................................................
Suspension Linkage Removal383................................................................................................................................................................
Shock Line Bearing Replacement384................................................................................................................................................................
Shock Line Bearing Installation385................................................................................................................................................................
Swingarm Removal385................................................................................................................................................................
Swingarm Disassembly/inspection387................................................................................................................................................................
Pivot Bearing Replacement388................................................................................................................................................................
Shock Link Plate Bearing Replacement390................................................................................................................................................................
Swingarm Assembly392................................................................................................................................................................
Swingarm Installation393................................................................................................................................................................
Hydraulic Brake Front397................................................................................................................................................................
Hydraulic Brake Rear398................................................................................................................................................................
Hydraulic Brake Service Information399................................................................................................................................................................
Hydraulic Brake Specifications399................................................................................................................................................................
Hydraulic Brake Troubleshooting400................................................................................................................................................................
Brake Fluid Replacement/air Bleeding401................................................................................................................................................................
Brake Fluid Draining401................................................................................................................................................................
Brake Fluid Filling402................................................................................................................................................................
Brake Bleeding403................................................................................................................................................................
Front Brake Pad Replacement404................................................................................................................................................................
Rear Brake Pad Replacement405................................................................................................................................................................
Brake Disc Inspection407................................................................................................................................................................
Front Master Cylinder Removal407................................................................................................................................................................
Front Master Cylinder Disassembly408................................................................................................................................................................
Front Master Cylinder Inspection409................................................................................................................................................................
Front Master Cylinder Assembly410................................................................................................................................................................
Rear Master Cylinder Removal412................................................................................................................................................................
Rear Master Cylinder Disassembly413................................................................................................................................................................
Rear Master Cylinder Inspection414................................................................................................................................................................
Rear Master Cylinder Assembly414................................................................................................................................................................
Rear Master Cylinder Installation416................................................................................................................................................................
Front Brake Caliper Removal416................................................................................................................................................................
Front Brake Caliper Disassembly417................................................................................................................................................................
Front Brake Caliper Inspection418................................................................................................................................................................
Front Brake Caliper Assembly418................................................................................................................................................................
Front Brake Caliper Installation419................................................................................................................................................................
Rear Brake Caliper Removal420................................................................................................................................................................
Rear Brake Caliper Disassembly420................................................................................................................................................................
Rear Brake Caliper Inspection421................................................................................................................................................................
Rear Brake Caliper Assembly422................................................................................................................................................................
Rear Brake Caliper Installation423................................................................................................................................................................
Brake Pedal Removal423................................................................................................................................................................
Brake Pedal Installation424................................................................................................................................................................
Battery/charging System Diagram427................................................................................................................................................................
Battery/charging System Service Information428................................................................................................................................................................
Battery/charging System Specifications429................................................................................................................................................................
Battery/charging System Troubleshooting430................................................................................................................................................................
Battery Removal/installation432................................................................................................................................................................
Battery Voltage Inspection432................................................................................................................................................................
Battery Testing432................................................................................................................................................................
Battery Charging433................................................................................................................................................................
Charging System Inspection434................................................................................................................................................................
Current Leakage Inspection434................................................................................................................................................................
Charging Voltage Inspection435................................................................................................................................................................
Alternator Charging Coil Inspection435................................................................................................................................................................
Regulator/rectifier System Inspection436................................................................................................................................................................
Regulator/rectifier Removal/installation436................................................................................................................................................................
Ignition System Diagram437................................................................................................................................................................
Ignition System Service Diagram438................................................................................................................................................................
Ignition System Specifications438................................................................................................................................................................
Ignition System Troubleshooting440................................................................................................................................................................
Ignition System Inspection441................................................................................................................................................................
Ignition Coil Primary Peak Voltage441................................................................................................................................................................
Ignition Pulse Generator Peak Voltage442................................................................................................................................................................
Ignition Pulse Generator Removal443................................................................................................................................................................
Ignition Pulse Generator Installation444................................................................................................................................................................
Ignition Timing445................................................................................................................................................................
Electric Starter System Diagram447................................................................................................................................................................
Electric Starter Service Information448................................................................................................................................................................
Electric Starter Specification448................................................................................................................................................................
Electric Starter Troubleshooting449................................................................................................................................................................
Starter Motor Removal451................................................................................................................................................................
Starter Motor Disassembly451................................................................................................................................................................
Starter Motor Inspection452................................................................................................................................................................
Starter Motor Assembly454................................................................................................................................................................
Starter Motor Installation456................................................................................................................................................................
Starter Relay Switch Operation Inspection457................................................................................................................................................................
Starter Relay Switch Ground Line Inspection457................................................................................................................................................................
Starter Relay Voltage Inspection457................................................................................................................................................................
Starter Relay Switch Continuity Inspection458................................................................................................................................................................
Diode Removal458................................................................................................................................................................
Diode Inspection458................................................................................................................................................................
Diode Installation458................................................................................................................................................................
Lights/meters/switches System Location459................................................................................................................................................................
Wiring Diagram460................................................................................................................................................................
Lights/meters/switches Service Information461................................................................................................................................................................
Lights/meters/switches Specifications462................................................................................................................................................................
Lights/meters/switches Troubleshooting463................................................................................................................................................................
Headlight Bulb Replacement464................................................................................................................................................................
Headlight Removal/installation465................................................................................................................................................................
Turn Signal Bulb Replacement466................................................................................................................................................................
Turn Signal Removal/installation466................................................................................................................................................................
Tail/brake Light Bulb Replacement467................................................................................................................................................................
Tail/brake Light Removal/installation467................................................................................................................................................................
License Light Bulb Replacement467................................................................................................................................................................
Combination Meter Removal468................................................................................................................................................................
Combination Meter Disassembly468................................................................................................................................................................
Combination Meter Assembly469................................................................................................................................................................
Combination Meter Installation470................................................................................................................................................................
Speedometer/vehicle Speed Sensor System Inspection471................................................................................................................................................................
Speed Sensor Inspection472................................................................................................................................................................
Speed Sensor Removal/installation472................................................................................................................................................................
Tachometer System Inspection473................................................................................................................................................................
Coolant Temperature Gauge/sensor474................................................................................................................................................................
Thermo Sensor Unit Inspection474................................................................................................................................................................
Cooling Fan Motor Switch Inspection475................................................................................................................................................................
Cooling Fan Motor Switch Removal/installation476................................................................................................................................................................
Oil Pressure Switch Inspection476................................................................................................................................................................
Oil Pressure Switch Removal/installation477................................................................................................................................................................
Fuel Reserve Sensor Inspection477................................................................................................................................................................
Ignition Switch Inspection478................................................................................................................................................................
Ignition Switch Removal/installation478................................................................................................................................................................
Handlebar Switches479................................................................................................................................................................
Brake Light Switch Front480................................................................................................................................................................
Brake Light Switch Rear480................................................................................................................................................................
Clutch Switch480................................................................................................................................................................
Neutral Switch480................................................................................................................................................................
Side Stand Switch Inspection481................................................................................................................................................................
Side Stand Switch Removal481................................................................................................................................................................
Side Stand Switch Installation481................................................................................................................................................................
Horn482................................................................................................................................................................
Turn Signal Relay Inspection483................................................................................................................................................................
Technical Feature485................................................................................................................................................................
Fuel Reserve Trip Indicator485................................................................................................................................................................
Function486................................................................................................................................................................
Troubleshooting487................................................................................................................................................................
Engine Does Not Start Or Is Hard To Start487................................................................................................................................................................
Engine Lacks Power488................................................................................................................................................................
Poor Performance At Low And Idle Speed489................................................................................................................................................................
Poor Performance At High Speed490................................................................................................................................................................
Poor Handling490................................................................................................................................................................
Index491................................................................................................................................................................

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Cbr600f4i 2002Cbr600f4i 2003

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