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CBR600F4I 2001
Service manual
Table Of Contents - Honda CBR600F4I 2001 Service Manual
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Service manual
(492 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
Contents
2
Symbols
3
General Information
4
Service Rules
4
Model Identification
4
Frame Serial Number
5
Vehicle Identification Number (Vin)
5
Color Label
5
Engine Serial Number
5
Specifications
6
Torque Values
15
Insulator Clamp (Throttle Body Side)
17
Insulator Clamp (Cylinder Head Side)
17
Exhaust Pipe Stud Bolt
17
Tools
20
Lubrication & Seal Points
22
Cable & Harness Routing
26
Emission Control Systems
41
Crankcase Emission Control System
41
Exhaust Emission Control System (Pulse Secondary Air Supply System)
42
Evaporative Emission Control System
43
Noise Emission Control System
43
Emission Control Information Labels (U.s.a. Only)
44
Vacuum Hose Routing Diagram Label (California Type Only)
44
Body Panel Locations
45
Frame/Body Panels/Exhaust System Service Information
46
Frame/Body Panels/Exhaust System Troubleshooting
46
Seat Removal
47
Seat Installation
47
Pillion Seat/Rear Cowl Removal
47
Pillion Seat/Rear Cowl Installation
48
Lower Cowl Removal
49
Lower Cowl Installation
50
Upper Cowl Removal
52
Upper Cowl Installation
54
Front Fender Removal
57
Front Fender Installation
57
Rear Fender Removal
58
Rear Fender Installation
59
Seat Rail Removal
61
Seat Rail Installation
62
Muffler/Exhaust Pipe Removal
64
Muffler/Exhaust Pipe Installation
65
Maintenance Service Information
70
Maintenance Specifications
71
Maintenance Schedule
72
Fuel Line
73
Throttle Operation
73
Air Cleaner
74
Spark Plug Removal
75
Spark Plug Inspection
76
Valve Clearance Inspection
78
Valve Clearance Adjustment
81
Engine Oil/Oil Filter
83
Engine Oil Level Inspection
83
Engine Oil & Filter Change
84
Engine Idle Speed
86
Radiator Coolant
86
Cooling System
86
Secondary Air Supply System
87
Evaporative Emission Control System (California Type Only)
88
Drive Chain Slack Inspection
88
Drive Chain Slack Adjustment
88
Drive Chain Cleaning And Lubrication
89
Drive Chain Sprockets Inspection
89
Drive Chain Replacement
90
Front Brake Fluid
92
Rear Brake Fluid
92
Front Brake Pads Wear
93
Rear Brake Pads Wear
93
Brake System Inspection
93
Brake Lever Adjustment
93
Brake Light Switch
94
Headlight Aim
94
Brake Pedal Height Adjustment
94
Clutch System
95
Side Stand
95
Front Suspension Inspection
96
Front Suspension Adjustment
96
Rear Suspension Inspection
97
Compression And Rebound Damping Adjusters
97
Compression Adjuster Standard Position
97
Rear Suspension Adjustment
98
Nuts, Bolts, Fasteners
99
Wheels/Tires
99
Recommended Tire Pressure And Tire Size
99
Minimum Tread Depth
99
Steering Head Bearings
100
Lubrication System Diagram
101
Lubrication System Service Information
102
Lubrication System Specifications
102
Lubrication System Troubleshooting
103
Oil Pressure Inspection
104
Oil Strainer/Pressure Relief Valve Removal
104
Oil Strainer/Pressure Relief Valve Inspection
105
Oil Pump Removal
106
Oil Pump Disassembly
107
Oil Pump Inspection
107
Oil Pump Assembly
108
Oil Pump Installation
109
Oil Cooler Removal
109
Oil Cooler Inspection
110
Oil Cooler Installation
110
Fuel System (Programmed Fuel Injection)
113
Fuel System (Programmed Fuel Injection) Service Information
114
Fuel System (Programmed Fuel Injection) Specifications
115
Fuel System (Programmed Fuel Injection) Troubleshooting
116
System Location
117
System Diagram
118
Pgm-Fi (Programmed Fuel Injection) System
119
Self-Diagnostic Procedures
119
Self-Diagnosis Reset Procedure
120
Peak Voltage Inspection Procedure
121
Test Harness Connection
121
Test Harness Terminal Layout
122
Pgm-Fi Self-Diagnosis Malfunction Indicator Lamp (Mil) Failure Codes
123
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 Inspection
163
Fuel Pressure Inspection
163
Fuel Flow Inspection
165
Fuel Pump Inspection
166
Fuel Pump Removal
166
Fuel Filter Replacement
167
Fuel Pump Installation
167
Fuel Cut Relay Inspection
167
Fuel Tank Removal
168
Fuel Tank Installation
170
Air Cleaner Housing Removal
173
Air Cleaner Housing Installation
174
Throttle Body Removal
175
Throttle Body Top View
177
Throttle Body Rear View
177
Throttle Drum View
178
Throttle Link View
178
Right Side View
178
Starter Valve Link View
178
Throttle Body Vacuum Hose Routing
179
Injector Inspection
182
Injector Removal
182
Injector Installation
182
Pressure Regulator Removal/Installation
183
Fast Idle Wax Unit Disassembly
184
Fast Idle Wax Unit Inspection
185
Fast Idle Wax Unit Assembly
185
Starter Valve Disassembly
186
Starter Valve Assembly
188
Starter Valve Synchronization
190
Output Voltage Inspection
192
Map Sensor Removal/Installation
192
Iat Sensor Removal/Installation
193
Ect Sensor Removal/Installation
193
Cam Pulse Generator Removal/Installation
194
Tp Sensor Inspection
195
Back Angle Sensor Inspection
196
Continuity Inspection
196
Back Angle Sensor Removal/Installation
197
Engine Stop Relay Inspection
198
Ecm (Engine Control Module) Removal/Installation
198
Power/Ground Line Inspection
198
Pair Solenoid Valve Removal/Installation
199
Pair Solenoid Valve Inspection
199
Evap Purge Control Valve (California Type Only) Removal
200
Evap Purge Control Valve (California Type Only) Inspection
200
O2 Sensor Removal
201
System Flow Pattern
203
Cooling System Service Information
204
Cooling System Specifications
205
Cooling System Troubleshooting
205
Cooling System Testing
206
Coolant (Hydrometer Test)
206
Coolant Gravity Chart
206
Coolant Replacement
207
Radiator Cap/System Pressure Inspection
207
Radiator Cap Relief Pressure
207
Replacement/Air Bleeding
207
Thermostat Removal
209
Thermostat Inspection
209
Thermostat Housing Removal
210
Thermostat Housing Installation
210
Thermostat Installation
210
Radiator Removal
211
Radiator Disassembly
212
Radiator Assembly
213
Radiator Installation
214
Mechanical Seal Inspection
216
Water Pump Removal
216
Water Pump Installation
217
Radiator Reserve Tank Removal
218
Radiator Reserve Tank Installation
219
Engine Removal/Installation
222
Engine Removal/Installation Service Information
223
Shock Link Lower Bracket Removal
224
Engine Removal
226
Engine Installation
231
Shock Link Lower Bracket Installation
237
Cylinder Head/Valves Service Information
242
Cylinder Head/Valves Specifications
243
Cylinder Head/Valves Troubleshooting
244
Cylinder Compression Test
245
Cylinder Head Cover Removal
245
Cylinder Head Cover Disassembly
246
Camshaft Removal
247
Camshaft Inspection
250
Camshaft Holder
250
Cam Chain Guide B
251
Camshaft Oil Clearance
251
Cylinder Head Removal
252
Cylinder Head Disassembly
253
Cylinder Head Inspection
254
Valve Lifter Bore
255
Valve Lifter
255
Valve Spring
255
Cam Chain Tensioner/Cam Chain Guide
255
Valve/Valve Guide
256
Valve Guide Replacement
257
Valve Seat Inspection/Refacing
257
Valve Seat Refacing
258
Cylinder Head Assembly
260
Cylinder Head Installation
262
Camshaft Installation
264
Cylinder Head Cover Assembly
268
Cylinder Head Cover Installation
269
Cam Chain Tensioner Lifter Removal
270
Cam Chain Tensioner Lifter Installation
271
Clutch/Gearshift Linkage Service Information
274
Clutch/Gearshift Linkage Specifications
274
Clutch/Gearshift Linkage Troubleshooting
275
Right Crankcase Cover Removal
276
Clutch Lifter Lever
277
Clutch Removal
277
Clutch Inspection
279
Clutch Lifter Bearing
279
Clutch Center
280
Clutch Lifter Piece
280
Clutch Disc
280
Clutch Plate
280
Clutch Outer Needle Bearing Replacement
281
Clutch Outer/Clutch Outer Guide
281
Mainshaft
281
Clutch Installation
282
Gearshift Linkage Removal
285
Gearshift Linkage Inspection
286
Gearshift Linkage Installation
286
Right Crankcase Cover Installation
288
Alternator/Starter Clutch Service Information
292
Alternator/Starter Clutch Specifications
292
Alternator/Starter Clutch Troubleshooting
292
Alternator Cover Removal
293
Stator Removal
293
Flywheel Removal
294
Alternator Cover Installation
294
Starter Clutch Inspection
296
Starter Clutch Disassembly
296
Starter Clutch Assembly
297
Flywheel Installation
298
Crankcase/Transmission Service Information
302
Crankcase/Transmission Specifications
302
Crankcase/Transmission Troubleshooting
303
Crankcase Separation
304
Shift Fork/Shift Drum Removal
305
Shift Drum/Shift Fork Inspection
306
Shift Drum/Shift Form Installation
306
Transmission Removal/Disassembly
307
Mainshaft Bearing Replacement
309
Mainshaft Bearing Assembly
310
Mainshaft Bearing Installation
312
Crankcase Assembly
313
Crankshaft/Piston/Cylinder Service Information
318
Crankshaft/Piston/Cylinder Specifications
318
Crankshaft/Piston/Cylinder Troubleshooting
319
Crankshaft Side Clearance Inspection
320
Crankshaft Removal
320
Crankshaft Inspection
320
Crankshaft Primary Drive Sub-Gear Removal
320
Primary Drive Sub-Gear Installation
321
Starter Clutch Needle Bearing Replacement
321
Starter Clutch Needle Bearing Installation
322
Main Journal Bearing Inspection
323
Oil Clearance Inspection
323
Main Journal Bearing Selection
324
Main Journal Bearing Installation
325
Crankpin Bearing Inspection
325
Crankpin Bearing Selection
326
Crankpin Bearing Installation
327
Piston/Cylinder
328
Piston/Connecting Rod Removal
328
Piston Removal
328
Piston Disassembly
328
Piston Inspection
329
Connecting Rod Inspection
330
Cylinder Inspection
330
Piston Assembly
331
Piston Installation
332
Front Wheel/Suspension/Steering Service Information
336
Front Wheel/Suspension/Steering Specifications
336
Front Wheel/Suspension/Steering Troubleshooting
337
Handlebar Removal
338
Handlebar Installation
340
Handlebar Weight Replacement
341
Front Wheel Removal
344
Front Wheel Inspection
345
Axle
345
Wheel Bearing
345
Wheel Rim Runout
345
Front Wheel Disassembly
346
Front Wheel Assembly
347
Front Wheel Installation
348
Fork Removal
349
Fork Disassembly
350
Fork Inspection
353
Fork Spring
353
Fork Tube/Slider/Damper
353
Fork Assembly
354
Fork Tube Bushing
354
Fork Installation
358
Steering Stem Removal
359
Bearing Replacement
361
Steering Stem Installation
366
Steering Head Bearing Pre-Load
369
Rear Wheel/Suspension Service Information
372
Rear Wheel/Suspension Specifications
372
Rear Wheel/Suspension Troubleshooting
373
Rear Wheel Removal
374
Rear Wheel Inspection
374
Rear Wheel Disassembly
375
Driven Sprocket
375
Driven Flange Bearing Removal
376
Rear Wheel Assembly
377
Wheel Bearing Removal
377
Wheel Bearing Installation
378
Driven Flange Bearing Installation
378
Rear Wheel Installation
379
Shock Absorber Removal
380
Shock Absorber Inspection
381
Needle Bearing Replacement
381
Shock Absorber Disposal Procedure
382
Shock Absorber Installation
383
Suspension Linkage Removal
383
Shock Line Bearing Replacement
384
Shock Line Bearing Installation
385
Swingarm Removal
385
Swingarm Disassembly/Inspection
387
Pivot Bearing Replacement
388
Shock Link Plate Bearing Replacement
390
Swingarm Assembly
392
Swingarm Installation
393
Hydraulic Brake Front
397
Hydraulic Brake Rear
398
Hydraulic Brake Service Information
399
Hydraulic Brake Specifications
399
Hydraulic Brake Troubleshooting
400
Brake Fluid Replacement/Air Bleeding
401
Brake Fluid Draining
401
Brake Fluid Filling
402
Brake Bleeding
403
Front Brake Pad Replacement
404
Rear Brake Pad Replacement
405
Brake Disc Inspection
407
Front Master Cylinder Removal
407
Front Master Cylinder Disassembly
408
Front Master Cylinder Inspection
409
Front Master Cylinder Assembly
410
Rear Master Cylinder Removal
412
Rear Master Cylinder Disassembly
413
Rear Master Cylinder Inspection
414
Rear Master Cylinder Assembly
414
Rear Master Cylinder Installation
416
Front Brake Caliper Removal
416
Front Brake Caliper Disassembly
417
Front Brake Caliper Inspection
418
Front Brake Caliper Assembly
418
Front Brake Caliper Installation
419
Rear Brake Caliper Removal
420
Rear Brake Caliper Disassembly
420
Rear Brake Caliper Inspection
421
Rear Brake Caliper Assembly
422
Rear Brake Caliper Installation
423
Brake Pedal Removal
423
Brake Pedal Installation
424
Battery/Charging System Diagram
427
Battery/Charging System Service Information
428
Battery/Charging System Specifications
429
Battery/Charging System Troubleshooting
430
Battery Removal/Installation
432
Battery Voltage Inspection
432
Battery Testing
432
Battery Charging
433
Charging System Inspection
434
Current Leakage Inspection
434
Charging Voltage Inspection
435
Alternator Charging Coil Inspection
435
Regulator/Rectifier System Inspection
436
Regulator/Rectifier Removal/Installation
436
Ignition System Diagram
437
Ignition System Service Diagram
438
Ignition System Specifications
438
Ignition System Troubleshooting
440
Ignition System Inspection
441
Ignition Coil Primary Peak Voltage
441
Ignition Pulse Generator Peak Voltage
442
Ignition Pulse Generator Removal
443
Ignition Pulse Generator Installation
444
Ignition Timing
445
Electric Starter System Diagram
447
Electric Starter Service Information
448
Electric Starter Specification
448
Electric Starter Troubleshooting
449
Starter Motor Removal
451
Starter Motor Disassembly
451
Starter Motor Inspection
452
Starter Motor Assembly
454
Starter Motor Installation
456
Starter Relay Switch Operation Inspection
457
Starter Relay Switch Ground Line Inspection
457
Starter Relay Voltage Inspection
457
Starter Relay Switch Continuity Inspection
458
Diode Removal
458
Diode Inspection
458
Diode Installation
458
Lights/Meters/Switches System Location
459
Wiring Diagram
460
Lights/Meters/Switches Service Information
461
Lights/Meters/Switches Specifications
462
Lights/Meters/Switches Troubleshooting
463
Headlight Bulb Replacement
464
Headlight Removal/Installation
465
Turn Signal Bulb Replacement
466
Turn Signal Removal/Installation
466
Tail/Brake Light Bulb Replacement
467
Tail/Brake Light Removal/Installation
467
License Light Bulb Replacement
467
Combination Meter Removal
468
Combination Meter Disassembly
468
Combination Meter Assembly
469
Combination Meter Installation
470
Speedometer/Vehicle Speed Sensor System Inspection
471
Speed Sensor Inspection
472
Speed Sensor Removal/Installation
472
Tachometer System Inspection
473
Coolant Temperature Gauge/Sensor
474
Thermo Sensor Unit Inspection
474
Cooling Fan Motor Switch Inspection
475
Cooling Fan Motor Switch Removal/Installation
476
Oil Pressure Switch Inspection
476
Oil Pressure Switch Removal/Installation
477
Fuel Reserve Sensor Inspection
477
Ignition Switch Inspection
478
Ignition Switch Removal/Installation
478
Handlebar Switches
479
Brake Light Switch Front
480
Brake Light Switch Rear
480
Clutch Switch
480
Neutral Switch
480
Side Stand Switch Inspection
481
Side Stand Switch Removal
481
Side Stand Switch Installation
481
Horn
482
Turn Signal Relay Inspection
483
Technical Feature
485
Fuel Reserve Trip Indicator
485
Function
486
Troubleshooting
487
Engine Does Not Start Or Is Hard To Start
487
Engine Lacks Power
488
Poor Performance At Low And Idle Speed
489
Poor Performance At High Speed
490
Poor Handling
490
Index
491
Previous
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1
...
492
493
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Table of Contents
Troubleshooting
Frame/Body Panels/Exhaust System Service Information
46
Lubrication System Troubleshooting
103
Fuel System (Programmed Fuel Injection) Troubleshooting
116
Cooling System Specifications
205
Cylinder Head/Valves Troubleshooting
244
Clutch/Gearshift Linkage Troubleshooting
275
Alternator/Starter Clutch Service Information
292
Crankcase/Transmission Troubleshooting
303
Crankshaft/Piston/Cylinder Troubleshooting
319
Front Wheel/Suspension/Steering Troubleshooting
337
Rear Wheel/Suspension Troubleshooting
373
Hydraulic Brake Troubleshooting
400
Battery/Charging System Troubleshooting
430
Ignition System Troubleshooting
440
Electric Starter Troubleshooting
449
Lights/Meters/Switches Troubleshooting
463
Troubleshooting
487
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Cbr600f4i 2002
Cbr600f4i 2003
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