Honda CB 600F Hornet 2007 Shop Manual
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Honda CB 600F Hornet 2007 Shop Manual

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Table of Contents

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"'HONDA
SHOP MANUAL
CB600F/FA
CB600F/FA1
•

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Summary of Contents for Honda CB 600F Hornet 2007

  • Page 1 "'HONDA SHOP MANUAL CB600F/FA CB600F/FA1 •...
  • Page 2 TYPE CODE • Throughout this manual, the following abbreviations are used to identify individual model. CODE AREA TYPE U.K. France EUROPEAN DIRECT SALES (Belgium, Denmark, Germany, Greece, Italy, Luxemburg, Austria, Portugal, Finland, Sweden, Switzerland, Czech, Slovakia, Norway, Iceland, Russia, Poland, Slovenia, Croatia, Latvia, Macedonia, Romania, Bulgaria, Ukraine, Israel, Ireland) Spain, Hungary EUROPEAN DIRECT SALES II...
  • Page 3 Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.
  • Page 4 OUT INCURRING ANY OBLIGATION WHATSO­ EVER. NO PAR T OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PER· MISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS ATVS. Honda Motor Co., Ltd.
  • Page 5 Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan I• Use silicone grease.

  • Page 6: Table Of Contents

    1. GENERAL INFORMATION SERVICE RULES ········· · ······························· 1- 2 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATION S ···················· ················· 1 - 1 0 MODEL IDENTIFICATI ON ••··-- · ···················· 1- 3 REAR WHEEL/SUSPENSION SPECIFICATIONS ········ ·················· ··········· 1 -1 0 GENERAL SPECIFICATIO NS ·················· ···· 1-5 HYDRAULIC BRAKE SPECIFICATIONS •...

  • Page 7: Service Rules

    GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda' s design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.

  • Page 8: Model Identification

    GENERAL INFORMATION MODEL IDENTIFICATION CB600FA Shown: SERIAL NUMBERS The Vehicle Identification Number (V.1.N) is stamped on right side of the steering head. The registered number plate is located on left side of the frame tube.
  • Page 9 GENERAL INFORMATION The engine serial number is st amped on the right side of the upper crankcase. The throttle body identification number is stamped on the left side of the throttle body. LABEL The color label is attached on the sub-frame under the seat. When ordering color-coded parts.

  • Page 10: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,085 mm (82. 1 in) Overall width 760 mm (29.9 in) Overall height 1,090 mm (42.9 in) Wheelbase 1,435 mm (56.5 in) Seat height 800 mm (31.5 in) Ground clearance 135 mm (5.3 in) Curb weight CB600F: 198 kg (437 lbs)
  • Page 11 GENERAL INFORMATION SPECIFICATIONS ITEM ELECTRICAL Ignition system Computer-controlled digital transistorized with electric advance Electric starter motor Starting system Triple phase output alternator Charging system SCR shorted/triple phase, full wave rectifies- Regulator/rectifier tion Lighting system Battery...

  • Page 12: Fuel System (Pgm-Fi)

    2.8 liter (3.0 US qt, 2.5 Imp qt) After disassembly 3.5 liter (3.7 US qt, 3.1 Imp qt) Engine oil Suggested oil: Honda "4-stroke motorcycle oil" or an equivalent Oil recommendation: API classification: SG or higher (except oils labeled as energy con-...

  • Page 13: Cylinder Head/Valves

    GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) STANDARD SERVICE LIMIT ITEM 1,304 kPa (13.3 kgf/cm'. 189 psi) Cylinder compression at 350 min•' (rpm) Valve clearance 0.20 ± 0.03 (0.008 ± 0.001 ) 0.28 ± 0.03 (0.011 ± 0.001 ) Camshaft Cam lobe height 36.24 -36.32 (1.427 -1.430)
  • Page 14 GENERAL INFORMATION CRANKCASE/TRANSMISSION SPECIFICATIONS Unit· mm (in} ITEM STANDARD SERVICE LIMIT 1.0. Shift fork 12.000 -12.018 (0.4724-0.4731) 12.03 (0.474) Claw thickness 5.93 -6.00 (0.233 -0.236) 5.9 (0.23) Shift fork shaft 0.0. 11.957 -11.968 (0.4707 0.4712) 11.95 (0.470) Transmission Gear 1.0. M5,M6 28.000 -28.021 (1.1024 1.1032)
  • Page 15 60 g (2.1oz) max. Fork Spring free length 245.7 (9.67) 240.8 (9.48) Fork tube runout 0.20 (0.008) Recommended fork fluid Honda ULTRA CUSHION OIL 10W or equivalent Fluid level 70 (2.8) Fluid capacity ± cm• ( 16.7 ± 0.08 US oz, 17.4 ±...

  • Page 16: Specificatio Ns

    GENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS Unit· mm (In) ITEM STANDARD SERVICE LIMIT Specified brake fluid OOT4 � Front Brake disc thickness 4.3 -4.7 (0.17 -0.19) 3.5 (0.14) Brake disc runout 0.30 (0.012) Master cylinder I.D. 12.700-12.743 (0.5000-0.5017) 12.755 (0.5022) Master piston 0.0. 12.657 -12.684 (0.4983 -0.4994) 12.645 (0.4978) Caliper cylinder I.D.
  • Page 17 GENERAL INFORMATION LIGHTS/METERS/SWITCH ES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight 12 V-55W 12 V-55 W Position light 12V-5Wx2 Brake/tail light License light 12 V-5 W Turn signal light 12V-21 Wx4 Instrument light Turn signal indicator High beam indicator Neutral indicator Warning indicator Immobilizer system (HISS) indicator ABS indicator (CB600FA) Fuse...
  • Page 18 GENERAL INFORMATION STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N•m (kgf·m, lbf . ft) N-m (kgf•m, lbf•ft) 5 mm hex bolt and nut 5.2 ( 0.5, 3.8) 5 mm screw 4.2 ( 0.4, 3.1) 6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
  • Page 19 GENERAL INFORMATION CYLINDER HEAD/VALVES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf-m, lbf•ft) Cylinder head mounting bolt 47 (4.8, 35) Apply molybdenum oil solu- tion to the threads and seat- ing surface. Camshaft holder flange bolt 12 (1.2, 9) Apply engine oil to the threads and seating surface.
  • Page 20 GENERAL INFORMATION CRANKC ASE/TRANSMISSION THREAD TORQUE ITEM Q'TV REMARKS N-m (kgf•m, lbf·ft) DIA. (mm) 12 (1.2, 9) Apply a locking agent to the Mainshaft bearing set plate bolt threads. Shift drum bearing set bolt 12 (1.2, 9) Apply a locking agent to the threads.
  • Page 21 GENERAL INFORMATION FRAME FRAME/BODY PANELS/EXHAUST SYSTEM THREAD TORQUE REMARKS ITEM Q'TY N•m (kgf-m, !bf . ft) DIA. (mm) Exhaust pipe joint nut 12 (1.2, 9) 22 (2.2, 16) Exhaust pipe/muffler mounting Exhaust pipe/muffler protector 12(1.2,9) socket bolt 22 (2.2, 16) Muffler band bolt Grab rail socket bolt 27 (2.8, 201...

  • Page 22: Front Wheel/Suspension/Steering

    GENERAL INFORMATION FRON T WHEEL/SUSPENSION/STEERING THREAD TORQUE Q'TY ITEM REMARKS N·m (kgf•m, lbf.ft) DIA. (mm) Handlebar holder bolt 27 (2.8, 20) Clutch lever pivot bolt 1.0 (0.1, 0.7) Clutch lever pivot nut 6.0 (0.6, 4.4) Steering stem adjusting lock nut See page 13-37 Steering stem adjusting nut 26 (2.7, 19)
  • Page 23 GENERAL INFORMATION HYDRAULIC BRAKE THREAD TORQUE ITEM REMARKS Q'TV DIA. (mm) N•m (kgf•m, lbf•ft) Brake hose oil bolt 34 (35, 25) C8600FA: 34 (3.5, 25) C8600F: 30 (3.1, 22) ALOC bolt; replace with a new Front brake caliper mounting bolt one.
  • Page 24 GENERAL INFORMATION OTHERS THREAD TORQUE ITEM O'TY REMARKS DIA. (mm) N·m (kgf·m, lbf.ft) 15 (1.5, 11 Sidestand pivot bolt 39 (4.0, 29) Sidestand pivot nut Sidestand bracket socket bolt 55 (5.6, 41) Gearshift pedal link pivot bolt 27 (2.8, 20) Gearshift arm pinch bolt 20 (2.0, 15) Ignition coil stay mounting nut...

  • Page 25: Lubrication & Seal Points

    GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION REMARKS MATE.RIAL Liquid sealant Crankcase mating surface See page 11-15 (Three Bond 1207B or equiv- Oil pan mating surface See page 4-7 a lent) Right crankcase cover mating surface See page 9-25 Alternator cover mating surface See page 10-7 EOP switch threads...
  • Page 26 GENERAL INFORMATION LOCATION REMARKS MATERIAL ± Oil level finder plate bolt threads Coating width: 6.5 1 mm Locking agent ± Oil pump driven sprocket bolt threads Coating width: 6.5 1 mm ± Shift drum bearing setting bolt threads Coating width: 6.5 1 mm ±...
  • Page 27 Engine oil Cable lubricant Throttle cable A, B casing inside Clutch cable outer inside Handlebar grip rubber inside Honda bond A, Honda hand grip cement, Cemedine#540 or equivalent Silicone grease Brake caliper main and sub slide pin sliding surfaces Apply 0.4 g each...

  • Page 28: Cable & Harness Routing

    GENERAL INFORMATION CABLE & HARNESS ROUTING CB 600FA: LEFT HANDLEBAR BRAKE HOSE GUIDE RIGHT HANDLEBAR SWITCH WIRE SWITCH WIRE CB600F: LEFT HANDLEBAR RIGHT HANDLEBAR SWITCH WIRE SWITCH WIRE 1-23...
  • Page 29 GENERAL INFORMATION CB600FA: COMBINATION METER 20P CONNECTOR IGNITION SWITCH 2P IMMOBILIZER RECEIVER 4P .---t..(Brown) CONNECTOR (Natural) CONNECTOR -- - IMMOBILIZER HARNESS RECEIVE IGNITION SWITCH WIR FRONT BRAKE HOSE ENGINE STOP SWITCH WIRE IGNITION SWITCH CB600F: COMBINATION METER 20P CONNECTOR IGNITION SWITCH 2P IMMOBILIZER RECEIVER 4P (Brown) CONNECTOR...
  • Page 30 GENERAL INFORMATION ENGINE STOP SWITCH WIRE HEADLIGHT SUB WIRE HARNESS LEFT TURN SIGNAL LIGHT WIRE LEFT HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH 10P (Gray) CONNECTOR 14P (Blue) CONNECTOR CLUTCH CABLE 1-25...
  • Page 31 GENERAL INFORMATION CB600FA: FRONT TURN SIGNAL LIGHT 2P GUIDE CLAMP (Orange/Light blue) CONNECTORS FRONT BRAKE PIPE C CB600F: THROTTLE CABLES EADLIGHT SUB WIRE ARNESS BP (Gray) ONNECTOR FRONT TURN SIGNAL LIGHT 2P (Orange/Light blue) CONNECTORS BRAKE HOSE CLAMP 1-26...
  • Page 32 GENERAL INFORMATION CB60 0FA: CLAMP FRONT BRAKE HOSE B RONTWHEEL PEED SENSOR WIRE BRAKE HOSE 3WAY JOINT FRONT WHEEL SPEED SENSOR CB600F: FRONT BRAKE HOSE 1-27...
  • Page 33 GENERAL INFORMATION FRONT BRAKE PIPES (CB600FA only) FUEL FEE FUEL T ANK DRAIN HOSE FUEL TANK BREATH BLEED INJECTOR SUB-HARN 10P (White) CONNECTO View A WIRE INJECTOR SUB-HARNESS 10P (Black) FILLER NECK-TO­ CONNECTOR THERMOSTAT HOSE Hold the wire by the HORN alternator cover CKP SENSOR WIRE...
  • Page 34 GENERAL INFORMATION 02 SENSOR 4P (Black) REAR BRAKE LIGHT SWITCH CB60 0F A: CONNECTOR 2P (Black) CONNECTOR STARTER REA R WH EEL SPE ED SEN SOR \.__,.C() 2 P (Green) CLAMP REAR BRAKE SWITCH WIRE CLAMP O2SENSOR CBS00F : 02 SENSOR 4P (Black) CONNECTOR REAR BRAKE LIGHT SWITCH 2P (Black) CONNECTOR...
  • Page 35 GENERAL INFORMATION GUIDE CLAMP CLAMP EOP SWITCH FUEL CUT RELAY/FAN CONTROL RELAY HEADLIGHT RELAY/ENGINE STOP RELAY TURN SIGNAL RELAY FUSE STARTER MOTOR CABLE 1-30...
  • Page 36 GENERAL INFORMATION FRONT BRAKE PIPE (CB600FA only) MAIN ARNESS FUEL LEVEL SENSOR 2P (Nat ONNECTOR /.------ FUEL PUMP 2P (Black) PAIR AIR SUCTION HOSE (To cylinder head cover) CONNECTOR PAIR AIR SUCTION HOSE SUB-HARNESS 6P (Black) ECT SENSOR 3P (To air cleaner housing) CONNECTOR (Black) CONNECTOR RADIATOR RESERVE...
  • Page 37 GENERAL INFORMATION CLAMP: - RADIATOR SIPHON HOSE RADIATOR RESERVE TANK OVERFLOW HOSE -SIDESTAND SWITCH WIRE GUIDE: -AL TERNA TOR WIRE - FUEL TANK DRAIN HOSE -BATTERY NEGATIVE(-) CABLE RADIATOR RESERVE TANK OVERFLOW HOSE -SIDESTAND SWITCH WIRE -ALTERNATOR WIRE CLIPS FUEL TANK DRAIN HOSE RADIATOR RESERVE TANK OVERFLOW HOSE SIDESTAND SWITCH WIRE 1-32...
  • Page 38 GENERAL INFORMATION CYLINDER BLOCK-TO-WATER PUMP HOSE FUEL TANK HOSE � • y� :-,,_ View D {';)-. - � ViewB 0-45' RADIATOR RESERVE TANK OVERFLOW HOSE 1-33...
  • Page 39 GENERAL INFORMATION CB600FA: CRANKCASE BREATHER HOSE PAIR CONTROL SOLENOID VALVE THROTTLE CABLES FRONT WHEEL SPEED SENSOR 2P (Blue) CONNECTOR #4 SPARK PLUG WIRE CLUTCH C ..-;. .::;..� AIR CONTROL OLENOIDVALVE 2P lack) CONNECTOR PAIR AIR SUCTION HOSE (To air cleaner housing) PAIR AIR SUCTION HOSES (To cylinder head cover) BRAKE PIPES...
  • Page 40 GENERAL INFORMATION IACV DISTRIBUTION HOSES MAP SENSOR 3P (Black) CONNECTOR CK P SE NS OR 2P (R ed ) CON NECTO R IACV 4P (Black) CONNECT OR DRAIN HOSE INJECTOR 2P (Gray) CONNECTORS ECM 33P (Black) INJECTOR SUB-HARNESS CONNECTOR 10P (White) CONNECTOR INJECTOR SUB-HARNESS IAT SENSOR 2P (Gray) _.-.._ ,,__..
  • Page 41 GENERAL INFORMATION INJECTOR SUB-HARNESS INTAKE AIR DUCT DIAPHRAGM INTAKE AIR DUCT CONTROL VALVE 2P (Gray) CONNECTOR ONE-WAY VALVE VACUUM CHAMBER DRAIN HOSE INTAKE AIR DUCT VACUUM HOSE VS SENSOR 3P (Black) CONNECTOR SUB-HARNESS 6P (Black) CONNECTOR STARTER NEUTRAL SWITCH WIRE BATTERY NEGATIVE(-) CABLE NEUTRAL SWITCH 1-36...
  • Page 42 GENERAL INFORMATION CB6 00F A only : ABS CHECK 3P (Natural) CONNECTOR DELAY VALVE FRONT BRAKE PIPE A FRONT BRAKE PIPE B 1-37...
  • Page 43 GENERAL INFORMATION CB600FA: STARTER RELAY SWITCH BATTERY POSITIVE FUSE BOX (+) CABLE REAR WHEEL SPEED SENSOR BANK ANGLE SENSOR 3P _.._,�,,v 2P (Green) CO Green) CONNECTOR ALTERNATOR 3P CONNECTO REAR BRAKE LIGHT SWITCH BATTERY 2P (Black) CONNECTOR REGULAT /RECTIFI NK ANGLE NSOR RY NEGATIVE CABLE...
  • Page 44 GENERAL INFORMATION C 8600F A : REAR WHEEL SPEED SENSOR REAR BRAKE RESERVOIR TANK 2P (Green) CONNECTOR REAR BRAKE MASTER REAR BRAKE REAR WHEEL REAR WHEEL SPEED CYLINDER SENSOR WIRE HOSE B SPEED SENSOR C8600F: REAR BRAKE RESERVOIR TANK REAR BRAKE MASTER CYLINDER REAR BRAKE HOSE 1-39...
  • Page 45 GENERAL INFORMATION CONNECTOR: SEAT LOCK CABLE - LEFT TURN SIGNAL LIGHT 2P (Orange) RIGHT TURN SIGNAL LIGHT 2P (Light blue) � - BRAKE/TAIL LIGHT 3P (Natural) LICENSE LIGHT 2P (Natural) :::::::�;;::- ---- OPTION 6P (Natural) CONNECTOR LEFT TURN SIGNAL LIGHT WIRE LICENSE LIGHT WIRE RIGHT TURN SIGNAL LIGHT WIRE BRAKE/TAIL LIGHT UNIT...
  • Page 47 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a pulse secondary air supply system, a three-way catalytic convert er and PGM-FI system. No adjustment should be made for the exhaust emission control system. The exhaust emission control system is separa te from the crankcase emission control system.
  • Page 49 2. FRA ME/BODY PANELS/EXHAUST SYSTEM BO D Y P A N EL LO CA TIO NS ····· ····· ····· ·········2 -2 M ETER C O VER··········································· 2-5 S ER V I CE I N F O R M A TIO N ····· ····· ···· ····· ····· ···2 -3 REAR C O WL ••••••••••••••••••••••••••••...

  • Page 50: Bo D Y P A N El Lo Ca Tio

    FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS REAR COWL EXHAUST PIPE MUFFLER...

  • Page 51: S Er V I Ce I N F O R M A Tio

    FRAME/BODY PANELS/EXHAUST SYSTEM SE RV I CE IN FO RM A TI O N GE NER AL • wor k in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can ca us e a fir e or ex plo sio n.

  • Page 52: Side Cover

    FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL/INSTALLATION Unlock the seat with the ignition key. Remove the seat backward while releasing the seat hooks. Install the seat with inserting the hooks into the frame. Push the seat forward, then push down to lock it. After installation, make sure that the seat is installed properly by moving the seat.

  • Page 53: Fr Ont Cow L

    FRAME/BODY PANELS/EXHAUST SYSTEM FR ONT COW L REMO VAL/I NSTA LLATI ON UPPE R FRON T COW L Remove the clips. CLIPS Carefully release the tabs of the upper front cowl - � from the right/left front cowls, then remove the upper front cowl.

  • Page 54: Rear Cowl

    FRAME/BODY PANELS/EXHAUST SYSTEM REAR COWL REMOVAL Remove the seat (page 2-4). SOCKET BOLT B/COLLAR Remove the socket bolts A and washers. Remove the socket bolts B, collars and grab rails. �� 0 � - , .. ; ,:__ l / �...

  • Page 55: Ont Fe N Der

    FRAME/BODY PANELS/EXHAUST SYSTEM Remove the cowl screws. REAR CENTER SCREWS Carefully release the tabs of the right/left rear cowls LOWER COWL from the rear center lower cowl, then remove the rear cowls. • Assembly is in the reverse order of disassembly. While installi ng the ligh c um t.

  • Page 56: Rear Fender

    FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER REMOVAL Remove the following: - rear cowl (page 2-6) - battery (page 17-6) - bank angle sensor (page 5-94) - starter relay switch (page 19-16) Remove the fuse boxes. fan control/fuel cut relays, turn signal relay and engine stop/headlight relays from the rear fender.
  • Page 57 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the mounting bolts. Release the battery negative (-) cable clip from the rear fender. Release the main harness clip from the rear fender. Release the hook of the rear fender from the frame brace. Remove the rear fender backward.

  • Page 58: Seat Rail

    FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Installation is in the reverse order or removal. NOTE: • While installing the rear fender, route the wire harness properly (page 1-23). • When connecting the seat lock cable, apply grease to the cable end. SEAT LOCK CABLE CABLE CLIP RELAYS •...
  • Page 59 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the bolt and rear brake fluid reservoir. C8600fA o nly: Remove the delay valve mounting bolts. Release the ABS service check 3P (Natural) connec­ CB600FA only: from the PCV stay. CB600FA only: Release the rear wheel speed sensor 2P (Green) STAY 2P (Black) CONNECTOR from...
  • Page 60 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Installation is in the reverse order or removal. NOTE: While installing the seat rail, route the wire harness properly (page 1-23). SEAT RAIL DELAY VALVE � (CB600FA) RADIATOR RESERVOIR TANK BOLT � �== � :::.- BOLTS 39 N·m (4.0 kgf•m, 29 lbf·ft) Tighten the mounting nut and bolts to the specified torque.

  • Page 61: Ex Ha Ust System

    FRAME/BODY PANELS/EXHAUST SYSTEM EX HA UST SYSTEM REMOVAL MUFFLER Remove the socket bolt. Remove the muffler protector. releasing its slits off the stays. Remove the packing rubbers from the stays. Loosen the muffler band bolt. Remove the muffler mounting bolt/nut, washer and collar.
  • Page 62 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the exhaust pipe mounting bolts/nuts, washers and collars. Remove the exhaust pipe. Carefully release sensor wire from the frame. BOL TS/WASHERS/COLLA .!l, S/NUTS DISASSEMBLY/ ASSEMBLY Remove the socket bolts, washers and rear protec­ tor. SOCKET BOLT/WASHERS Remove the socket bolts, collars, rubbers and front protector.
  • Page 63 FRAME/BODY PANELS/EXHAUST SYSTEM Install the rear protector with the socket bolts and washers. Tighten the socket bolts to the specified torque. TORQUE: 12 N•m (1.2 kgf•m. 9 !bf.ft) SOCKET BOLT/WASHERS INSTALLATION SOCKET BOLTS 1? N·m (1.2 kgf-m. 9 lbf·ft) EXHAUST PIPE MOUNTING NUTS 22 N·m (2.2 kgf•m.
  • Page 64 FRAME/BODY PANELS/EXHAUST SYSTEM Install new gaskets to the exhaust ports. Always replace rhe gaskets with new ones GASKETS Route the 0 & sensor wire properly and install the r---,--:---=--.:::--,-r-:-::::-:-:-:::::-7:". Refer 'CABLE exhaust pipe. HARNESS ROUTING" (page 1- Temporarily install the exhaust pipe joint nuts, 23 ).
  • Page 65 FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER Install a new gasket onto the exhaust pipe. Install the muffler to the exhaust pipe. Install the muffler mounting bolt/nut, washer and collar. Tighten the muffler mounting nut to the specified torque. TORQUE: 22 N•m (2.2 kgf•m, 16 lbf•ft) Tighten the muffler band bolt to the specified torque.
  • Page 67 After oil filter change 2.8 liter (3.0 US qt, 2.5 Imp qt) Suggested oil: Engine oil Honda "4-stroke motorcycle oil" or an equivalent O il recommendation: API classification: SG or higher (except oils labeled as energy conserving on the circular API service label)
  • Page 69 3-30 STEERING HEAD BEARINGS 3-30 • Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechani­ cally qualified. *" In the interest of safety, we recommended these items be serviced only by an authorized Honda dealer Honda recommends that an authorized Honda dealer should road-test the motorcycle after each periodic maintenance is carried out.
  • Page 70 MAINTENANCE FUEL LINE Remove the following: seat (page 2-4) side covers (page 2-4) Remove the fuel tank front mounting bolts/washers and collars. Lift the fuel tank and support it using the equipped tools (eye wrench and handle) as shown. NOTE: •...
  • Page 71 MAINTENANCE Install the fuel tank front mounting bolts/washers BOL. TS/VVASHERS/COLLARS and collars. Tighten the fuel tank mounting bolts securely. Install the removed parts in the reverse order of � removal. THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closing in all steering positions.
  • Page 72 MAINTENANCE AIR CL EANER Remove the left side cover (page 2-4). Remove the air cleaner duct mounting screws. Remove the air cleaner duct without disconnecting the vacuum hose. Remove and inspect the air cleaner element in accordance with the maintenance schedule (page 3- 4 ) .
  • Page 73 MAINTENANCE SPARK PLUG REMOVAL Lift and support the fuel tank (page 3-5). Disconnect the spark plug caps from the spark Clean around rhe plugs. spark plug bases with compressed air before removing, and be sure that no debris is allowed to enter the combustion chamber.
  • Page 74 MAINTENANCE INSTALLATION Install the spark plugs by hand and tighten them to the specified torque with the spark plug wrench. TORQUE: 16 N-m (1.6 kgf•m, 12 lbf•ft) Install the spark plug caps. Install the removed parts in the reverse order. VALVE CLEARANCE INSPECTION NOTE:...
  • Page 75 MAINTENANCE Remove the timing hole cap and O-ring. Turn the crankshaft clockwise. align the "T" mark on the CKP sensor rotor with the index mark on the right crankcase cover. The timing marks ("IN" and "EX") on the cam sprockets must be flush with the cylinder head sur- _._,...
  • Page 76 MAINTENANCE Check the valve clearance for the No. 1 and No.3 cyl­ Record the No.3 INTAKE VALVES inder intake valves using a feeler gauge. c /(18rance for each •AJ/ v e for reference VALVE CLEARANCE: in shim selection rf IN: 0.20 0.03 (0.008 ±...
  • Page 77 MAINTENANCE Record the Check the valve clearance for the No.2 and No.4 cyl­ inder intake valves using feeler gauge. No.2 INTAKE VALVES clearance for each valve for reference VALVE CLEARANCE: in shim selection if ad1usrmenr is IN: 0.20 ± 0.03 mm (0.008 ±...
  • Page 78 MAINTENANCE Clean the valve shim contact area in the valve lifter VALVE LIFTER wi1h compressed air. "\ Measure the shim thickness and record it. Sixiy-nme different SHIM thickness shims are available from the 1.200 thinnest thickness shim to 2.900 the thickest mm thickness shim 0 025 in intervals of...
  • Page 79 MAINTENANCE Apply engine oil to the timing hole cap 0-ring. Check that the O­ Apply grease to the timing hole cap threads. ring 1s m good condmon. replace If Install and tighten the timing hole cap to the speci­ necessa,y fied torque.
  • Page 80 SUGGESTED OIL: ot he r vis co sit ies sho wn ,n the cha rr Honda "4-stroke motorcycle oil" or an equivalent ma y be us ed wh en OIL RECOMMENDATION: the average API classification: SG or higher (except oils labeled...
  • Page 81 MAINTENANCE Replace the sealing washer with a new one. Install and tighten the drain bolt to the specified torque. TORQUE: 30 N-m (3.1 kgf-m, 22 lbf-ft) Check that the oil filter boss protrusion from the crankcase is specified length as shown. SPECIAED LENGTH: 16.
  • Page 82 MAINTENANCE Fill the crankcase with recommended engine oil (page 3-15). OIL CAPACITY: 2.7 liter (2.9 US qt, 2.4 Imp qt) after draining 2.8 liter (3.0 US qt, 2.5 Imp qt} after oil filter change Check that the O-ring on the oil filler cap is in good condition, and replace it if necessary.
  • Page 83 MAINTENANCE Inspect the radiator hoses for cracks or deteriora­ tion, and replace if necessary. Check the tightness of all hose clamps and fasten­ ers. SECONDARY AIR SUPPL V SYSTEM • This model is equipped built-in secondary air supply system. The PAIR system is located on CYLINDER HEAD COVER the cylinder head cover.
  • Page 84 MAINTENANCE DRIV E CHAIN DRIVE CHAIN SLACK INSPECTION Nsvsr ,nspsct and Turn the ign i tion switch OFF, place the motorcycle acfJ v st rhe dnve on its sidestand and shift the transmission into neu­ cham while ths tral. engine rvnnmg.
  • Page 85 MAINTENANCE CLEANING AND LUBRICATION Clean the chain with non-flammable or high flash NON-FLAMMABLE OR HIGH point solvent and wipe it dry. FLASH POINT SOLVENT Be sure the chain has dried completely before lubri­ cating. Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable.
  • Page 86 MAINTENANCE Remove the crankcase rear cover (page 7-4). Check the attaching bolt and nuts on the drive and driven sprockets. Tighten the bolt or nut to the specified torque if nec­ essary. TORQUE: Drive sprocket bolt: 54 N,m (5.5 kg•m, 40 lbf-ft) Driven sprocket nut: 108 N•m (11.0 kgf•m.
  • Page 87 MAINTENANCE Locate the crimped p n ends of the master link from MASTER LINK the outside of the chain, and remove the link with the drive chain tool set. Remove the drive chain. Include the master Remove the excess drive chain links from the new link when drive chain with the drive chain tool set.
  • Page 88 MAINTENANCE Make sure that the master link pins are installed MASTER LINK PINS properly. Measure the master link pin length projected from the plate. STANDARD LENGTH: 1.15 - 1.55 mm (0.045 - 0.061 in) Stake the master link pins. Make sure that the pins are staked properly by mea­ SLIDE CALIPER suring the diameter of the staked area using a slide caliper.
  • Page 89 MAINTENANCE BRAKE FLUID NOTICE • Do not mix different types of fluid, as they are not compatible with each other. • Do not allow foreign material to enter the system when filling the reservoir. • Avoid spilling fluid on painted, plastic or rubber parts.
  • Page 90 MAINTENANCE REAR BRAKE Support the motorcycle upright on a level surface. Remove the right side cover (page 2-4). Check the fluid level in the rear brake fluid reservoir. If the level is near the "LOWER" level line, remove the mounting bolt and the reservoir cap, and fill the reservoir with DOT 4 brake fluid from a sealed con­...
  • Page 91 MAINTENANCE BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal, and check that no air has entered the system. If the lever or pedal feels soft or spongy when oper­ ated, bleed the air from the system. Inspect the brake hose and fittings for deterioration. cracks and signs of leakage.
  • Page 92 MAINTENANCE BRAKE LIGHT SWITCH The front brake Adjust the brake light switch so that the brake light "' BRAKE LIGHT SWITCH ltght switch does comes on just prior to the brake actually being not require engaged. adjustment. If the light fails to come on, adjust the switch so that the light comes on at the proper time.
  • Page 93 MAINTENANCE Major adjustment is performed at the clutch lifter � ... �., .. lever. Loosen the lock nut and turn the adjusting nut to adjust the freeplay. Tighten the lock nut while holding the adjusting nut. If proper freeplay cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch (page 9-6).
  • Page 94 MAINTENANCE Check for worn steering stem bearings by grabbing the front fork leg and attempting to move the front fork side 10 side. Replace the steering head bearings if any looseness is noted (page 13-31 ). REAR SUSPENSION INSPECTION Support the motorcycle using a hoist or equivalent tool and raise the rear wheel off the ground.
  • Page 95 MAINTENANCE NUTS,BOLTS,FASTENERS Check that all chassis nuts and bolts are tightened to their specified torque values (page 1-13). Check that all hose clamps and cable stays are in place and properly secured. WHEELS/TIRES Tire pressure should be checked when the tires are COLD.
  • Page 96 4. LUBRICATION SYSTEM LUBRICAT ION SYSTEM DIAGRAM ··········4 - 2 O IL STRAIN ER/ PRES SURE REL I EF V A L VE ········· ··············· 4-6 SER V ICE IN FO RMA T I ON ••••••••••••••••••••••• •••• 4-3 OI L PUMP •••••••••••••• ••••••••••••••••••••••••••••••••••••• 4-8 TR OUB L E SHOO T IN G ···················...
  • Page 97 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM EXHAUST CAM SHAFT CONNECTING ROD r OILORI OIL COOLER OIL FILTER CARTRIDGE RELIEF VALVE...
  • Page 98 2.8 liter (3.0 US qt, 2.5 Imp qt) After disassembly 3.5 liter (3.7 US qt, 3.1 Imp cit) Engine oil Suggested oil: Honda "4-stroke motorcycle oil" or an equivalent Oil recommendation: API classification: SG or higher (except oils labeled as energy con-...
  • Page 99 LUBRICATION SYSTEM TOOLS Oil pressure gauge Oil pressure gauge attachment 07506-3000001 07510-4220100 or equivalent commercially avail­ or equivalent commercially avail­ able able TROUBLE SHOOTING Oil level too low • Oil consumption • External oil leak • Worn piston rings • Improperly installed piston rings •...
  • Page 100 LUBRICATION SYSTEM OIL PRESSURE INSPECTION Remove the rubber cap from the EOP switch. ff ths pressure indicator lighe Remove the terminal bolt and disconnect the EOP remains on while switch wire. the engine Remove the EOP switch while holding the switch running, check the base.
  • Page 101 LUBRICATION SYSTEM Install and tighten the EOP switch to the specified torque. TORQUE: 12 N•m (1.2 kgf•m, 9 lbf•ft) Connect the EOP switch wire and tighten the termi­ nal bolt to the specified torque. TORQUE: 2.0 N•m (0.2 kgf•m, 1.5 lbf•ft) lnstal the rubber cap securely.
  • Page 102 LUBRICATION SYSTEM Remove the pressure relief valve and O-ring. E RELIEF VALVE ---- � ----� ..,,.,.,� - • � -r--. INSPECTION Check the operation of the pressure relief valve by pushing on the piston. PISTON Disassemble the pressure relief valve by removing the snap ring.
  • Page 103 LUBRICATION SYSTEM Clean the oil pan mating surface thoroughly. Apply sealant (Three Bond 12078 or an equivalent) Oonorapplymore to the mating surface. sealant than necessary. Install the oil pan onto the lower crankcase. Install the flange bolts. Tighten the bolts in a crisscross pattern in two or three steps.
  • Page 104 LUBRICATION SYSTEM Remove the bolts and oil pump assembly. Remove the dowel pins. Remove the bolts, oil pipe B and O-rings. Clean the oil pipe B thoroughly. DISASSEMBLY Remove the oil pump assembly bolts. ASSEMBLY BOLTS...
  • Page 105 LUBRICATION SYSTEM Remove the oil pump cover and dowel pins. OIL PUMP COVER DOWEL PINS Remove the thrust washer, drive pin, oil pump OUTER ROTOR shaft. outer rotor and inner rotor from the oil pump body. TWASHEA Clean all disassembly parts thoroughly. OIL PUMP HAFT DRIVE PIN...
  • Page 106 LUBRICATION SYSTEM Measure the side clearance using a straight edge SIDE CLEARANCE: and feeler gauge. SERVICE LIMIT: 0.17 mm (0.007 in) ASSEMBLY ASSEMBLY BOLTS 12 N-m (1.2 kgf-m, 9 lbf·ft) OIL PUMP SHAFT DRIVE PIN OIL PUMP COVER OIL PUMP BODY Dip all parts in clean engine oil.
  • Page 107 LUBRICATION SYSTEM Install the dowel pins into the oil pump cover. OIL PUMP C OVER Install the oil pump cover to the oil pump body. DOWEL PINS Install and tighten the oil pump assembly bolts to the specified torque. ASSEMBLY BOLTS TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Check the oil pump operation by turning the pump shaft.
  • Page 108 LUBRICATION SYSTEM Install the oil pump assembly onto the crankcase while aligning the oil pump shaft lug with the water pump shaft groove by turning the oil pump shaft. Tighten the bolts securely. Apply engine oil to new seal rings and install them onto the oil pipe A.
  • Page 109 LUBRICATION SYSTEM OIL COOLER REMOVAL Drain the engine oil (page 3-15). Drain the coolant from the system (page 6-7). Loosen the hose band screws and disconnect the oil cooler water hoses from the oil cooler. Remove the bolt, sealing washer and the oil cooler. Remove the O-ring from the oil cooler.
  • Page 110 LUBRICATION SYSTEM Apply engine oil to the oil cooler bolt threads and a new sealing washer seating surface. Install the sealing washer and oil cooler bolt. Hold the oil cooler by your hand and tighten the bolts to the specified torque. TORQUE: 59 N-m (6.0 kgf•m, 44 lbf.ft) Connect the oil cooler water hoses to the oil cooler and tighten the hose clamp screws securely.
  • Page 111 5. FUEL SYSTEM (PGM-FI} FUEL TANK ·············· .. ······ ......5-58 COMPONENT LOCATION ··················· ······· 5-2 AIR CLEANER HOUSING ..... ···· 5-61 SERVICE INFORMATION ......5-3 PGM - FI SYMPTOM THROTTLE BODY ........5-81 TRO UBLESHOOTIN G ........ . 5-5 IN J ECTOR ··························--····...

  • Page 112: Component Location

    FUEL SYSTEM (PGM-FI) COMPONENT LOCA TION 12 N•m (1.2 kgf·m, 9 lbf.ft) <:;) .Jh ­ � ' "', .. /��- · . &·�-· .::_ -_J,· --/. --·-_"- --,; er ·"...

  • Page 113: Service Information

    FUEL SYSTEM (PGM-FI) SERVICE INFORMATION GENERAL • Work in a we ventilated area. Smok ng or a owing flames or sparks in the work area or where gasoline s stored can cause a fire or explosion. • Before disconnect ng the fuel feed hose, relieve fuel pressure from the system by disconnecting the quick connect fit­ ting of the fuel tank.
  • Page 114 FUEL SYSTEM (PGM-FI) TOOLS Fuel pressure gauge Pressure gauge manifold Pressure gauge hose attachment C 07ZAJ-S5A0111 07ZAJ-S7C0100 07406-0040004 �•� ECM test harness 33P Pressure gauge hose attachment A Fuel attachment joint C 07ZAJ-S5A0120 07ZAJ-S7C0200 070MZ-MCA0100 �� �� � SCS connector Inspection test harness Test probe 070PZ-ZY30100...

  • Page 115: Pgm-Fi Symptom Troubleshooting

    FUEL SYSTEM (PGM-FI) PGM-FI SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms, check the DTC or MIL blinking, refer to the OTC index (page 5-16) and begin the appropriate troubleshooting procedure. If there are no OTC/MIL blinking stored in the ECM memory, do the diag­ nostic procedure for the symptom, in sequence listed below, until you find cause.

  • Page 116: Pgm-Fi System Location

    FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM LOCATION PAIR CONTROL SOLENOID VALVE MAP SENSOR INJECTO TPSEN CKPSENSOR 02SENSOR...

  • Page 117: Pgm-Fi System Diagram

    FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM DIAGRAM • tgnhton Switch f•se 10 A r:-- Engine Stop r-.-1ttin � "':":: " '• � �-� -,----- ��--- ---, fuse Switch Engin� Stop Acl.oy Fuso ◄ ::: A � 30A i!!!, ,__:::; :::'.::: ✓ ""...

  • Page 118: Pgm-Fi Connector Locations

    ¥1 FUEL SYSTEM (PGM-FI) PGM-FI CONNECTOR LOCATIONS NOTE 1: Remove the left side cover (page 2-4). IAT SENSOR 2P (Gray) CONNECTOR (NOTE 1) ECT SENSOR 3P (Black) CONNECTOR NOTE 2: lift and support the fuel tank (page 3-5). INJECTOR 2P (Gray) CONNECTORS (NOTE2) TPSENSOR 3P (Black) CONNECTOR...
  • Page 119 FUEL SYSTEM (PGM-FI) NOTE 3: Remove the air cleaner housing (page 5-61 ). MAP SENSOR 3P (Black I CONNECTOR (NOTE 3) � � IACV 4P (Black) CONNECTOR (NOTE 3) ECM 33P (Black) AND 33P (Light gray) CONNECTORS(NOTE2) . , : �; n 1 n u_ft f )fu1 n mt· , , B (light gray) A (Black) A 12...
  • Page 120 FUEL SYSTEM (PGM-FI) 02 SENSOR 4P (Black) CONNECTOR (NOTE 2) [] ffi Sensor side: Main harness side: VS SENSOR 3P (Black) CONNECTOR (NOTE 3) 5-10...

  • Page 121: Pgm-Fi Troubleshooting Information

    FUEL SYSTEM (PGM-FI) PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting. If the MIL was on, but then went out.
  • Page 122 FUEL SYSTEM (PGM-FI) MIL Blink Pattern • If the HDS pocket tester is not available, DTC can be read from the ECM memory by the MIL blink pattern. • The number of blinks is the equivalent the main code of the DTC {the sub code cannot be displayed by the MIL).
  • Page 123 FUEL SYSTEM (PGM-FI) HDS POCKET TESTER INFORMATION • The HOS can readout the DTC, freeze data, current data and other ECM condition. How to connect the HOS Pocket Tester Turn the ignition switch to OFF. Lift and support the fuel tank (page 3-5). Remove the dummy connector from the OLC.
  • Page 124 FUEL SYSTEM (PGM-FI) CLEARING OTC Connect the HDS Pocket Tester to the DLC (page 5-13). Clear the DTC with the HDS while the engine is stopped. To clear the OTC without HOS, refer to the following procedure. How to clear the OTC with SCS connector 1.
  • Page 125 FUEL SYSTEM (PGM-FI) Connect ECM test harness between the main wire harness and the r---------------------, ECM TEST HARNESS ECM. TOOL: ECM test harness 33P 070MZ-MCA0100 TEST HARNESS TERMINAL LAYOUT The ECM connector terminals are numbered as shown in this illustra• ECM 33P (Black) CONNECTOR tion.

  • Page 126: Otc Index

    FUEL SYSTEM (PGM-FI) OTC INDEX Refer Refer Function Failure Symptom/Fail-safe function (MIL blinks) (OTC) (MIL) 1-1 (1) MAP sensor circuit low voltage (less than 0.2 V) Engine operates normally 5-17 5-36 MAP sensor or its circuit malfunction Fail-safe value: 760 mmHg/ 1,013 hPa •...

  • Page 127: Otc Troubleshooting

    FUEL SYSTEM (PGM-FI) OTC TROUBLESHOOTING DTC 1-1 (MAP SENSOR LOW VOLTAGE) • Before starting the inspection, check for loose or poor contact on the MAP sensor 3P (Black) con­ nector and ECM 33P connectors, then recheck the OTC. 1. MAP Sensor System Inspection Turn the ignition switch ON and engine stop "0".
  • Page 128 FUEL SYSTEM (PGM-FI) 4. MAP Sensor Output Line Short Circuit Inspec­ tion Turn the ignition switch OFF. Check for continuity between the MAP sensor 3P (Black) connector terminal of the wire harness Light green/ side and ground. yellow CONNECTION: light green/yellow Ground Is there continuity7 - Short circuit in Light green/yellow wire...
  • Page 129 FUEL SYSTEM (PGM-FI) 2. MAP Sensor System Inspection 2 Turn the ignition switch OFF. 3P (Black) CONNECTOR Disconnect the MAP sensor 3P (Black) connec­ (Wire side/female terminals) tor. Connect the MAP sensor terminals at the wire JUMPER WIRE harness side with a jumper wire. CONNECTION: Light green/yellow - Green/ orange Turn the ignition switch ON and engine stop...
  • Page 130 FUEL SYSTEM (PGM-FI) OTC 2-1 (MAP SENSOR HOSE CONNECTION) • Before starting the inspection, check for loose or poor contact on the MAP sensor 3P (Black) con• nector and ECM 33P connectors, then recheck the OTC. 1. MAP Sensor System Inspection Turn the ignition switch ON and engine stop "O".
  • Page 131 FUEL SYSTEM (PGM-FI) OTC 7-1 (ECT SENSOR LOW VOLTAGE) • Before starting the inspection. check for loose or poor contact on the ECT sensor 3P (Black) con­ nector and ECM 33P connectors, then recheck the OTC. 1. ECT Sensor System Inspection Turn the ignition switch ON and engine stop "O".
  • Page 132 FUEL SYSTEM (PGM-FI) DTC 7-2 (ECT SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the ECT sensor 3P (Black) con­ nector and ECM 33P connectors, then recheck the OTC. 1. ECT Sensor System Inspection Turn the ignition switch ON and engine stop "O".
  • Page 133 FUEL SYSTEM (PGM-FI) OTC 8-1 (TP SENSOR LOW VOLTAGE) • Before starting the inspection, check for loose or poor contact on the TP sensor 3P (Black) connec­ tor and ECM 33P connectors, then recheck the OTC. 1. T P Sensor SyS1em Inspection Turn the ignition switch ON and engine stop "0".
  • Page 134 FUEL SYSTEM {PGM-FI) 5. TP Sensor Output Line Open Circuit lnspe<:tion Turn the ignition switch OFF. 33P (Light gray) CONNECTOR B Disconnect the ECM 33P (Light gray) connector. (Wire side/female terminals) Check for continuity at the Red/yellow wire between the TP sensor 3P (Black) connector ter­ minal and the ECM 33P (Light gray) connector.
  • Page 135 FUEL SYSTEM (PGM-FI) DTC 8-2 (TP SENSOR HIGH VOLTAGE) • Before starting the inspection, checlc for loose or poor contact on the TP sensor 3P (Black) connec­ tor and ECM 33P connectors. then recheck the OTC. 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch •...
  • Page 136 FUEL SYSTEM (PGM-FI) OTC 9-1 (IAT SENSOR LOW VOLT AGE) • Before starting the inspection, check for loose or poor contact on the IAT sensor 2P (Gray) connec­ tor and ECM 33P connectors, then recheck the OTC. 1. IAT Sensor System Inspection Turn the ignition switch ON and engine stop "0".
  • Page 137 FUEL SYSTEM (PGM-FI) OTC 9-2 (IAT SENSOR HIGH VOLTAGE) • Before starting the inspection. check for loose or poor contact on the IAT sensor 2P (Gray) connec­ tor and ECM 33P connectors, then recheck the OTC. 1. IAT Sensor System Inspection Turn the ignition switch ON and engine stop switch "...
  • Page 138 FUEL SYSTEM (PGM-FI) OTC 11-1 (VS SENSOR) • Before starting the inspection, check for loose or poor contact on the VS sensor 3P (Black) connec­ tor and ECM 33P connectors, then recheck the OTC. 1. VS Sensor System Inspection Support the motorcycle securely, raise the rear wheel off the ground.
  • Page 139 FUEL SYSTEM (PGM-FI) 5. VS Sensor Pulse line Short Circuit Inspection Check for continuity between the VS sensor 3P 3P (Black) CONNECTOR (Black) connector of the wire harness side and (Wire side/female terminal) body ground. CONNECTION: Pink/blue Ground Is there continuity? - Short circuit in Pink/blue wire - Faulty VS sensor Pink/blue...
  • Page 140 FUEL SYSTEM (PGM-FI) 3. Injector Resistance Inspection Turn the ignition switch OFF. Measure the resistance of the injector connector terminals. STANDARD: 11 - 13 (20 °C/68 °F) Is the resistance within 11 (20"C/68'F)7 - GO TO STEP 4. - Faulty injector 4.
  • Page 141 FUEL SYSTEM (PGM-FI) OTC 13-1 (No.2 INJECTOR) (page 5-29) OTC 14-1 (No.3 INJECTOR) (page 5-29) OTC 15-1 (No.4 INJECTOR) (page 5-29) DTC 21-1 (02 SENSOR) • Before starting the inspection, check for loose or poor contact on the 02 sensor 4P (Black) connec­ tor and ECM 33P connectors, then recheck the OTC.
  • Page 142 FUEL SYSTEM (PGM-FI) 3. Oz Sensor Short Circuit Inspection Connect the 02 sensor 4P (Black) connector. 33P (Light gray) CONNECTOR Check for continuity between the ECM 33P (Light (Wire side/female terminal) gray) connector of the wire harness side and ground. CONNECTION: B20 Ground TOOL:...
  • Page 143 FUEL SYSTEM (PGM-FI) 2. 02 Sensor Heater Resistance Inspection Turn the ignition switch OFF. 4P (Black) CONNECTOR Disconnect the 02 sensor 4P (Black) connector (Sensor side/female terminals) and measure the resistance at the 02 sensor con­ nector terminals of the sensor side. CONNECTION: White White Is the resistance within 10...
  • Page 144 FUEL SYSTEM (PGM-FI) DTC 29-1 (IACV) • Before starting the inspection, check for loose or poor contact on the IACV 4P (Black) connector and ECM 33P connectors, then recheck the OTC. 1. Recheck OTC Clear the ECM self-diagnosis memory data (page 5-14).
  • Page 145 FUEL SYSTEM (PGM-FI) 3. IACV Circuit Continuity Inspection Disconnect the ECM 33P (Black) connector. Check the continuities between the ECM 33P (Black) connector terminals and the IACV 4P (Black) connector terminals. 33P (Black) CONNECTOR CONNECTION: A 19 - Black/yellow (Wire side/female terminals) A2.7 Black/red A 16- Black/blue...

  • Page 146: Mil Troubleshooting

    FUEL SYSTEM (PGM-FI) MIL TROUBLESHOOTING MIL 1 BLINK (MAP SENSOR) • Before starting the inspection, check for loose or poor contact on the MAP sensor 3P (Black) con­ nector and ECM 33P connectors, then recheck the MIL blinking. 1. MAP Sensor Output Voltage Inspection Turn the ignition switch OFF.
  • Page 147 FUEL SYSTEM (PGM-FI) 4. MAP Sensor Output Line Short Circuit lnspec• tion Turn the ignition switch OFF. Check for continuity between the MAP sensor 3P (Black) connector terminal of the wire harness side and ground. Light green/ yellow CONNECTION: light green/yellow Ground Is there continuity? - Short circuit in Light green/yellow wire...
  • Page 148 FUEL SYSTEM (PGM-FI) 2. MAP Sensor Output Voltage Inspection Connect the ECM test harness to ECM connec­ tors (page 5-14). TEST HARNESS PIN BOX (A TERMINALS) Turn the ignition switch ON and engine stop "0". switch (89) Measure the voltage at the test harness termi­ nals.
  • Page 149 FUEL SYSTEM (PGM-FI) 2. ECT Sensor Input Voltage Inspection Turn the ignition switch OFF. 3P (Black) CONNECTOR Disconnect the ECT sensor 3P (Black) connector. (Wire side/female terminals) Turn the ignition switch ON and engine slop switch • Measure the voltage at the test harness terminal and ground.
  • Page 150 FUEL SYSTEM (PGM-FI) MIL 8 BLINKS (TP SENSOR) • Before starting the inspection. check for loose or poor contact on the TP sensor 3P (Black) connec­ tor and ECM 33P connectors. then recheck the MIL blinking. 1. TP Sensor Output Voltage Turn the ignition switch OFF.
  • Page 151 FUEL SYSTEM (PGM-FI) 3. ECM Output Voltage Inspection Turn the ignition switch ON and engine stop "O". switch TEST HARNESS PIN BOX Measure the voltage at the test harness termi­ (A TERMINALS) nals. CONNECTION: A9 l+)-A18 (-) fs the voltage within 4. 75 5.25 V7 - •...
  • Page 152 FUEL SYSTEM (PGM-FI) MIL 9 BLINKS (IAT SENSOR) • Before starting the inspection, check for loose or poor contact on the IAT sensor 2P (Gray) connec­ tor and ECM 33P connectors, then recheck the MIL blinking. 1. IAT Sensor Output Voltage Inspection Turn the ignition switch OFF.
  • Page 153 FUEL SYSTEM (PGM-FI) 4. IAT Sensor Open Circuit Inspection Turn the ignition switch OFF. Check for continuity at the Gray/blue and Green/ orange wires between the IAT sensor 2P (Gray) connector terminal and the test harness termi­ nals. CONNECTION: Gray/blue - B29 Green/orange - A 18 Are there continuities? YES - GO TO STEP 5.
  • Page 154 FUEL SYSTEM (PGM-FI) 2. Combination Meter Inspection Check for operation of combination meter. meter - Open or short circuit in Pink/blue wire Does the combination operate normally? between the VS sensor and ECM. - GO TO STEP 3. 3. VS Sensor Input Voltage Inspection Turn the ignition switch OFF.
  • Page 155 FUEL SYSTEM (PGM-FI) MIL 12 BLINKS (No. 1 INJECTOR) • Before starting the inspection, check for loose or poor contact on the injector 2P (Grey) connectors and ECM 33P connectors, then recheck the MIL blinking. SIGNAL SIGNAL INJEC- POWER INPUT LINE LINE AT ECM No.1...
  • Page 156 FUEL SYSTEM (PGM-FI) 3. Injector Signal Line Open Circuit Inspection Connect the ECM test harness to the ECM con­ INJECTOR 2P CONNECTORS nectors (page 5-14). (Wire side/female terminal): Connect the continuity between the test harness #4 INJECTOR 2P terminal and injector 2P (Gray) connector of the CONNECTOR wire harness side.
  • Page 157 FUEL SYSTEM (PGM-FI) MIL 21 BLINKS (02 SENSOR) • Before starting the inspection, check for loose or poor contact on the 02 sensor 4P {Black) connec­ tor and ECM 33P connectors. then recheck the MIL blinking. 1. O, Sensor System Inspection Start the engine and warm it up to coolant tem­...
  • Page 158 FUEL SYSTEM (PGM-FI) MIL 23 BLINKS (02 SENSOR HEATER) • Before starting the inspection, check for loose or poor contact on the Oz sensor 4P (Black) connec­ tor and ECM 33P connectors, then recheck the MIL blinking. 1. Oz Sensor Heater Resistance Inspection Turn the ignition switch OFF.
  • Page 159 FUEL SYSTEM (PGM-FI) 4. 02 Sensor Heater Short Circuit Inspection Check for continuity between the test harness terminals and ground. CONNECTION: 82 - Ground Is there continuity? (B2) - Short circuit in the Black/green wire - Replace the ECM with a known good one, and recheck;...

  • Page 160: Mil Circuit Troubleshooting

    FUEL SYSTEM (PGM-FI) 2. IACV Circuit Continuity Inspection Connect the ECM test harness to the ECM con­ nectors (page 5-14). Check the continuities between the test harness TEST HARNESS PIN BOX and the IACV 4P (Black) connector. (A TERMINALS) CONNECTION: A19 -Black/yellow A27 -Black/red A 16-Black/blue A29 - Black/orange...

  • Page 161: Fuel Line Inspection

    FUEL SYSTEM (PGM-FI) Ground the White/blue wire terminal of the wire ECM 33P (Black) CONNECTOR A harness side connector with a jumper wire. (Wire side/female terminal) White/blue TOOL: (A20) Test probe 07ZAJ-RDJA110 Turn the ignition switch to "ON", the MIL should come on.
  • Page 162 FUEL SYSTEM (PGM-FI) 7. Pull and release the rubber cap from the retainer. RUBBER CAP RETAINER TABS 8. Hold the connector with one hand and squeeze the retainer tabs with the other hand to release them from the locking pawls. Pull the connector off, then remove the rubber cap and retainer from the fuel joint.
  • Page 163 FUEL SYSTEM (PGM-FI) 2. Install the rubber cap and seat it onto the fuel RUBBER CAP joint flange as shown. Align the quick connect fitting with the fuel joint CONNECTOR and align the new retainer locking pawls with the connector grooves. Then press the quick connect fitting onto the fuel joint until both retainer pawls lock with a "CLICK".
  • Page 164 FUEL SYSTEM (PGM-FI) FUEL PRESSURE TEST Relieve the fuel pressure and disconnect the quick connect fitting (page 5-51 ). ( 1) Allach the fuel pressure gauge, attachments and manifold. TOOLS: (1 ): Fuel pressure gauge 0740 6- 0 040004 ( 2 ): Pressure gauge manifold 07ZAJ-S5A0111 (3 ): Pressure gauge hose attach- 07ZAJ-S5A0120 mentA...

  • Page 165: Fuel Pump

    FUEL SYSTEM (PGM-FI) Jump the Brown and Black/white wire terminals of the wire harness side using a jumper wire. JUMPER WIRE Black/white • Place an approved gasoline container and drain the gasoline. • Wipe off spilled out gasoline. RELAY TERMINALS Disconnect the quick connect fitting from the fuel ATTACHMENT joint (page 5-51 ).
  • Page 166 FUEL SYSTEM (PGM-FI) Turn the ignition switch ON and measure the volt­ 2P (Black) CONNECTOR age between the terminals. (Wire side/female terminals) CONNECTION: Brown Green Brown� Green There should be battery voltage for a few seconds. If there is battery voltage a few seconds, replace the ���...
  • Page 167 FUEL SYSTEM (PGM-FI) INSPECTION Check the fuel pump unit and chamber for wear or damage, replace them as an assembly if necessary. Clean the fuel strainer screen with non-flammable ���:-::: or high flash point solvent. FUEL STRAINER SCREEN INSTALLATION Install the fuel pump chamber, hooking its tab to the hole of fuel pump unit.

  • Page 168: Fuel Cut-Off Relay

    FUEL SYSTEM (PGM-FI) FUEL CUT-OFF RELAY INSPECTION Disconnect the fuel cut-off relay connector (page 5- BATTERY FUEL CUT-OFF RELAY 54). Connect the ohmmeter to the fuel cut-off relay con­ nector terminals. CONNECTION: A Connect the 12 V battery to the following fuel cut-off relay connector terminals.
  • Page 169 FUEL SYSTEM (PGM-FI) Remove the nut and fuel tank stopper cable. Remove the nut and pivot bolt, then remove the fuel FUEL TANK tank. INSTALLATION BOLTS FUEL TANK WASHERS STOPPER PIVOT BOLT 2P (Black) CONNECTOR 2P (Natural) CONNECTOR FUEL FEED HOSE 5-59...
  • Page 170 FUEL SYSTEM (PGM-FI) Install the fuel tank onto the frame, then install the FUEL TANK pivot bolt and nut. Hold the pivot bolt and tighten the nut to the speci­ fied torque. TORQUE: 12 N·m (1.2 kgf-m, 9 lbf·ft) Lift and support the fuel tank (page 3-5). Connect the fuel tank stopper cable through the stopper groove of stay.

  • Page 171: Air Cleaner Housing

    FUEL SYSTEM (PGM-FI) AIR CLEANER HOUSING REMOVAL Make the throttle cable freeplay at the handlebar side (page 3-6). Loosen the throttle cable nuts fully. Disconnect the throttle cables from the throttle pipe. Release the throttle cables from the clamp and r-r=====��...
  • Page 172 FUEL SYSTEM (PGM-FI) Release the IDC solenoid valve vacuum hose from the ECM. Release the connectors from the ECM stay. Disconnect the injector sub-harness 1 OP (Black) and 10P (White) connectors. and 02 sensor 4P (Black) connector. Remove the screws and ECM stay. Pull out the ECM from the air cleaner housing.
  • Page 173 FUEL SYSTEM (PGM-FI) Disconnect the #1/#4 ignition coil connectors. CONNECTORS Disconnect the crankcase breather hose from the air cleaner housing. Release the wires and hoses from the guides of air cleaner housing. Remove the screws and left air cleaner duct from the air cleaner housing.
  • Page 174 FUEL SYSTEM (PGM-FI) Disconnect the vacuum hose from the diaphragm. Remove the air cleaner element. Disconnect the ECT sensor 3P (Black) connector. 3P (Black) CONNECTOR Disconnect the sub-harness 6P (Black) connector. Disconnect the PAIR air suction hose from the air cleaner housing.
  • Page 175 FUEL SYSTEM (PGM-FI) Disconnect the #2/#3 ignition coil connectors. CONNECTORS Disconnect the PAIR control solenoid valve 2P (Black) connector. Remove the mounting bolt and collar. Loosen the throttle body insulator bands (cylinder head side}. 5-65...
  • Page 176 FUEL SYSTEM (PGM-FI) Release the starter motor/ground cable from the guide of air cleaner housing. Release the throttle cables from the frame, then pull out the air cleaner housing with the throttle body to the left side. NOTICE Be careful not to damage the harness and hoses. DISASSEMBLY Disconnect the IAT sensor 2P (Gray) connector.
  • Page 177 FUEL SYSTEM (PGM-FI) Disconnect the TP sensor 3P (Black) connector. Disconnect the MAP sensor 3P (Black) connector. Disconnect the vacuum hose from the MAP sensor. Remove the screw and MAP sensor from the air cleaner housing. Disconnect the quick connect fitting from the fuel rail (page 5-51 ).
  • Page 178 FUEL SYSTEM (PGM-FI) Release the CKP sensor 2P (Red) connector from the stay. Release the injector sub-harness from the guides. Disconnect the IACV 4P (Black) connector. Remove the injector sub-harness from the air cleaner housing. Disconnect the vacuum hoses and remove the screw and IDC solenoid valve.
  • Page 179 Remove the left air cleaner duct packing. Remove the right air cleaner duct packing. Remove the screws and upper air cleaner housing. UPPER AIR CLEANER HOUSING Remove the mesh screen from the upper air cleaner housing. Clean the mesh screen with compressed air. 5-69...
  • Page 180 FUEL SYSTEM (PGM-FI) Loosen the screws, then remove the air funnels and AIR FUNNELS throttle body from the lower air cleaner housing. Remove the rubber seals from the lower air cleaner RUBBER SEALS housing. ASSEMBLY 3.5 N•m (0.4 kgf•m, 2.6 lbf·tr) VACUUM CHAMBER MESH SCREEN...
  • Page 181 FUEL SYSTEM (PGM-FI) Install new rubber seals into the lower air cleaner RUBBER SEALS housing. Install the lower air cleaner housing onto the throt­ AIR FUNNELS tle body, then install the air funnels. Tighten the air funnel screws securely. Install the mesh screen by aligning with the guides of upper air cleaner housing.
  • Page 182 FUEL SYSTEM (PGM-FI) Install a new right air cleaner duct packing into the groove on the housing. Install a new left air cleaner duct packing into the groove on the housing. Install the crankcase breather drain hose with hose clamp. Install the vacuum chamber, aligning its boss with the hole of air cleaner housing.
  • Page 183 FUEL SYSTEM (PGM-FI) Tighten the vacuum chamber screw securely. Install the IDC solenoid valve and tighten the screw -�•-=::::;--;'1\li securely. Connect the vacuum hoses to the one-way valve. Refer to 'CABLE & Route the vacuum hoses and connect them to the HARNESS IDC solenoid valve and vacuum chamber.
  • Page 184 FUEL SYSTEM {PGM-FI) Install the fuel feed hose and connect the quick con• nect fitting to the fuel rail (page 5-52). Install the MAP sensor and tighten the screw securely. Connect the MAP sensor vacuum hose. Connect the MAP sensor 3P (Black) connector. Connect the TP sensor 3P (Black) connector.
  • Page 185 FUEL SYSTEM (PGM-FI) Install the IAT sensor with a new O-ring and tighten the screws securely. Connect the IAT sensor 2P {Gray) connector. INSTALLATION Refer to 'CABLE & Route the throttle cables to the frame properly, then HARNESS install the air cleaner housing with the throttle body from the left side.
  • Page 186 FUEL SYSTEM (PGM-FI) Install mounting bolt with the collar, then tighten the bolt securely. Connect the PAIR control solenoid valve 2P (Black) connector. Connect the #2/#3 ignition coil connectors. Connect the PAIR air suction hose to the air cleaner housing. 5-76...
  • Page 187 Connect the sub-harness 6P (Black) connector. Connect the ECT sensor 3P (Black) connector. 3P (Black) CONNECTOR Install the air cleaner element. Connect the vacuum hose to the diaphragm. Install the left air cleaner duct to the air cleaner housing. Tighten the screws securely. 5-77...
  • Page 188 FUEL SYSTEM (PGM-FI) Refer to 'CABLE & Route the wires and hoses to the guides of air OSES HARNESS cleaner housing. ROUTING' (page 1- 23 ) Connect the crankcase breather hose to the air cleaner housing. Connect the #1/#4 ignition coil connectors. CONNECTORS Route the IDC solenoid valve vacuum hose to the guide of air cleaner housing.
  • Page 189 FUEL SYSTEM (PGM-FI) Connect the ECM 33P (Black and Light gray) connec­ tors to the ECM. Install the ECM on the air cleaner housing. Install the ECM stay with the screws, then tighten the screws securely. Connect the injector sub-harness 1 OP (Black) and Route the wires 10P (White) connectors, and 02 sensor 4P (Black) properly (page...
  • Page 190 FUEL SYSTEM (PGM-FIJ Refer to 'CABLE & Route the wires to the guide of rear resonator. HARNESS ROUTING' (page 1- Install the right front resonator and tighten the RESONATOR screw securely. Route the fuel feed hose to the guide of front reso­ Refer to 'CABLE &...

  • Page 191: Throttle Body

    FUEL SYSTEM (PGM-FI) THROTTLE BODY REMOVAL Remove the throttle body from the air cleaner hous­ ing (page 5-66). Loosen the lock nuts and disconnect the throttle cables from the throttle drum. Loosen the insulator band screws and re.move the INSULATORS insulators.
  • Page 192 FUEL SYSTEM (PGM-FI) • Do not damage the throttle body. It may cause incorrect throttle and idle valve synchronization. • The throttle body is factory pre-set. Do not disas­ semble in a way other than shown in this man­ ual. •...
  • Page 193 FUEL SYSTEM (PGM-FI) Viewed from top and throt t le drum side: 2.1 N-m (0.2 kgf-m, 1 .5 I bf.ft) Do not loosen or Do not loosen or remove remove PAINTED WHITE Viewed from bottom: PAINTED WHITE Do not loosen or Do not loosen or tighten tighten...
  • Page 194 FUEL SYSTEM (PGM-FI) INSTALLATION Install each insulator onto the throttle body while aligning its groove with the lug on the throttle body. Align the hole on each insulator band with the boss on the insulator. Confirm the direction of the insulator band screws INSULATORS as shown.

  • Page 195: Injector

    FUEL SYSTEM (PGM-FI) INJECTOR INSPECTION Start the engine and let it idle. Confirm the injector operating sounds with a sound­ ing rod or stethoscope. SOUNDING ROD REMOVAL Remove the throttle body (page 5-81 }. VACUUM HOSES VACUUM HOSE Disconnect the MAP sensor vacuum hoses and IDC (MAP SENSOR} (IDC SOLENOID VALVE} solenoid valve vacuum hose.
  • Page 196 FUEL SYSTEM (PGM-FI) Remove the screw and joint plate. Do nor loosen rhe JOINT PLATE /ACV cover screws. Remove the IACV joints and O-rings. IACV JOINTS Remove the injectors from the fuel rail. FUEL RAIL INJECTORS Remove the seal ring and O-ring from each injector. INJECTOR 5-86...
  • Page 197 FUEL SYSTEM (PGM-FI) FUEL RAIL JOINT Remove the fuel rail joint. Remove the O-rings from the fuel rail joint. 0-RINGS INSTALLATION SCREWS 5.1 N-m 2.1 N·m (0.5 kgf-m, 3.8 lbf•ft) 11f •m, 1.5 l:�:L RAIL 5.1 N·m (0.5 kgf•m, 3.8 lbf,ft) 0-RINGS ..
  • Page 198 FUEL SYSTEM (PGM-FI) Apply small amount of engine oil to new seal rings and 0-rings. Install the seal ring and 0-ring to each injector. .�-:71!1 fiil ... _. SEAL RING INJECTOR Install the injectors to the fuel rail. FUEL RAIL INJECTORS Apply oil to new 0-rings and install them to the IACV JOINTS...
  • Page 199 FUEL SYSTEM (PGM-FI) Connect the IACV distribution hoses. HOSES Install the injectors with the fuel rail. FUEL RAIL Install and tighten the bolts to the specified torque. TORQUE: 5. 1 N•m (0.5 kgf•m, 3.8 lbf•ft) Connect the MAP sensor vacuum hoses and JDC VACUUM HOSE solenoid valve air hoses.

  • Page 200: Engine Idle Speeo

    FUEL SYSTEM (PGM-FI) ENGINE IDLE SPEED IDLE SPEED INSPECTION NOTE: • Inspect the idle speed after all other engine main­ tenance items have been performed and are within specifications. • Before checking the idle speed, inspect the fol­ lowing items. No OTC and MIL blinking.
  • Page 201 FUEL SYSTEM (PGM- FI) REMOVAL • Always clean the throttle body before the IACV removal to prevent dirt and debris from entering the IACV passage. Remove the throttle body (page 5-85}. Remove the screws and setting plate. Remove the IACV motor and O-ring. INSTALLATION Turn the slide valve clockwise until lightly seated on IACV.

  • Page 202: Map Sensor

    FUEL SYSTEM (PGM-FI) Install the setting plate while aligning the cut-out with the lug on the IACV motor. Install the screws and tighten them to the specified torque. TORQUE: 2.1 N·m (0.2 kgf·m, 1.5 lbf . ft) Install the throttle body (page 5-70). MAP SENSOR OUTPUT VOLT AGE INSPECTION Connect the test harness to the ECM connectors...

  • Page 203: Iat Sensor

    FUEL SYSTEM (PGM-FI) REMOVAL/INSTALLATION Remove the air cleaner housing (page 5-61 ). Disconnect the MAP sensor 3P (Black) connector. Disconnect the vacuum hose from the MAP sensor. Remove the screw and MAP sensor. Installation is in the reverse order of removal. IAT SENSOR REMOVAL/INSTALLATION Remove the left side cover (page 2-4).

  • Page 204: Ect Sensor

    FUEL SYSTEM (PGM-FI) ECT SENSOR REMOVAL/INSTALLATION Replace the ECT Drain the coolant from the system (page 6-7). ECT SENSOR sensor while the Disconnect the 3P (Black) connector from the ECT engine ,scold. sensor. Remove the ECT sensor and sealing washer. Install a new sealing washer and ECT sensor.

  • Page 205: Engine Stop Relay

    FUEL SYSTEM (PGM-FI) INSPECTION Remove the seat (page 2-4). Disconnect the bank angle sensor 3P (Green) con­ nector and connect the special tool between the connectors. Inspection test harness TOOL: 07GMJ-ML80100 Turn the ignition switch ON and engine stop switch ·...

  • Page 206: Ecm

    FUEL SYSTEM (PGM-FI) Connect the ohmmeter to the engine stop relay con­ ENGINE STOP RELAY BATTERY nector terminals. CONNECTION: A - B iiTI Connect a 12 V battery to the following engine stop relay connector terminals. CONNECTION: C (+) � There should be continuity only when the 12 V bat­...
  • Page 207 FUEL SYSTEM (PGM-FI) 2. ECM Ground Line Inspection Turn the ignition switch OFF. 33P (Black) 33P (Light gray) Check the continuity between the ECM CONNECTOR (Wire CONNECTOR (Wire (Black) connector terminals and ground. side/female terminals) side/female terminals) T OOL: Test probe 07ZAJ-RDJA 110 CONNECTION: A23 -Ground A24-Ground...

  • Page 208: Secondary Air Supply System

    FUEL SYSTEM (PGM-FI) SECONDARY AIR SUPPLY SYSTEM ..- - ii ; ��;�;�;�;;;;;;��;���::�---... SYSTEM INSPECTION Start the engine and warm until the coolant •c temperature is 80 (176 °F). Stop the engine. Lift and support the fuel tank (page 3-5). Disconnect the air supply hose from the air cleaner housing.
  • Page 209 FUEL SYSTEM (PGM-FI) Disconnect the PAIR control solenoid valve 2P (Black) connector. Pull the PAIR control solenoid valve out the stay. Installation is in the reverse order of removal. Inspection Remove the PAIR control solenoid valve. Check that air flows (A) to (BJ when the 12 v battery is connected to the PAIR control solenoid valve ter­...

  • Page 210: Intake Air Duct

    FUEL SYSTEM (PGM-FI) 02SENSOR REMOVAL/INSTALLATION • Handle the 02 sensor with care. • Do not get grease, oil or other materials in the 02 sensor air hole, or it may be damaged. • Do not service the 02 sensor while it is hot. Remove the exhaust pipe (page 2-13).
  • Page 211 FUEL SYSTEM (PGM-FI) Removal/Installation Remove the left intake air duct from the air cleaner housing (page 5-63). Disconnect the vacuum hose from the diaphragm. Turn the diaphragm counterclockwise and unhook the diaphragm rod rrom the duct valve. Installation is in the reverse order of removal. INTAKE AIR DUCT IDC SOLENOID VALVE Removal/Installation...
  • Page 212 FUEL SYSTEM (PGM-FI) Inspection Remove the IDC solenoid valve. Check that the air should flow (A) to (B). only when the 12 V battery is connected to the IDC solenoid valve terminals. CONNECTION: Battery(+) terminal Black/white terminal Battery(-) terminal - Yellow/black terminal Check the re sistance between the terminals of the IDC SOLENOID VALVE IDC solenoid valve.
  • Page 214 COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR RESERVE TANK FILLER NECK UPPER RADIATOR HOSE THERMOSTAT ECTSENSOR BYPASS HOSE LOWER RADIATOR HOSE OIL COOLER WATER HOSE...
  • Page 215 COOLING SYSTEM SERVICE INFORMATION GENERAL Removing the radiator cap while the engine is hot can allow the coolant to spray out. seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. NOTICE I Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage.
  • Page 216 COOLING SYSTEM TROUBLESHOOTING Engine temperature too high • Faulty temperature gauge or ECT sensor • Thermostat stuck closed • Faulty radiator cap • Insufficient coolant • Passage blocked in radiator,hoses or water jacket • Air in system • Faulty cooling fan motor •...
  • Page 217 COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Lift and support the fuel tank (page 3-5). Remove the radiator cap. Always let the engine and rad,aror cool down before removing the radiaror cap. Disconnect the #4 spark plug cap. Remove the bolt and pull out the filler neck. Test the coolant gravity using a hydrometer (see below for "Coolant gravity chart").
  • Page 218 COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (page 6-5). Before installing the C8p m the tester, Pressure test the radiator cap. wet the sealing Replace the radiator cap if it does not hold pressure, surfaces. or if relief pressure is too high too low. It must hold specified pressure for at least 6 sec­...
  • Page 219 COOLING SYSTEM REPLACEMENT/ AIR BLEEDING NOTE: • When filling the system or reserve tank with coolant, or checking the coolant level, place the motorcycle in a vertical position on a rial, level surface. Lift and support the fuel tank (page 3-5). Remove the radiator cap.
  • Page 220 COOLING SYSTEM Remove the radiator reserve tank cap and lill the FILLER CAP reserve tank to the upper level line. Bleed air from the system as follow: 1. Shift the transmission into neutral. Start the engine and let it idle for 2 3 minutes.
  • Page 221 COOLING SYSTEM Remove the bolts and thermostat housing cover. HOUSING COVER Remove the thermostat from the housing. THERMOSTAT HOUSING THERMOSTAT INSPECTION Wear insulated gloves and adequate eye protection. THERMOSTAT Keep flammable materials away from the electric heating element. Visually inspect the thermostat for damage. Check for damage of seal ring.
  • Page 222 COOLING SYSTEM INSTALLATION Align the direction of the thermostat stamp mark with the boss of housing. Install the thermostat into the housing by aligning the body with the groove of the housing. THERMOSTAT Install the thermostat housing cover to the housing HOUSING COVER by aligning the bosses of housing and cover.
  • Page 223 COOLING SYSTEM Refer to 'CABLE & Roule the water hose properly and connect the water hose to the filler neck. HARNESS Tighten the hose band screw securely. ROUTING'/page 1· Install the filler neck and tighten the bolt securely. Connect the #4 spark plug cap securely. Lower the fuel tank and install the front mounting bolts (page 3-5).
  • Page 224 COOLING SYSTEM Loosen the hose band screw and disconnect the lower radiator hose. Release the horn wire from the guide of fan motor -------,,,...­ shroud. Remove the lower mounting bolt, washer and mounting rubber. nor ro Remove the upper mounting bolts, washers and Be careful mounting rubbers, then remove the radiator assem­...
  • Page 225 COOLING SYSTEM DISASSEMBLY Release the hooks from the tabs on the radiator and RADIATOR GRILL remove the radiator grill. Remove the mounting bolts, washers cooling BOLTS/WASHERS ran motor assembly from the radiator. Remove the nut and cooling fan. COOLING FUN 6-13...
  • Page 226 COOLING SYSTEM ASSEMBLY RADIA T OR GRILL � 5. 0 N -m (0 . 5 kgf-m, 3 . 7 lb f . :� FAN MOTOR SHROUD (!$>© &? (© © 8.4 N·rn (0.9 kgf·rn, 6.2 lbf·ft) Install the fan motor onto the fan motor shroud and O T OR tighten the mounting bolts to the specified torque.
  • Page 227 COOLING SYSTEM Apply a locking agent to the cooling fan nut threads. Install and tighten the nut securely. Install the cooling fan motor assembly onto the radi­ BOLTS/WASHERS ator . Install the mounting bolts with washers and tighten the bolts to the specified torque. TORQUE: 8.4 N·m (0.9 kgf·m, 6.2 !bf.ft) Install the radiator grill while aligning the tabs to RADIATOR GRILL...
  • Page 228 COOLING SYSTEM Install the lower mounting bolt with mounting rub• ber and washer. Route the horn wire through the guide of fan motor ..----- .._.­ shroud. Connect the lower radiator hose and tighten the hose band screw (page 6-21 ). Connect the upper radiator hose and tighten the hose band screw (page 6-21 ).
  • Page 229 COOLING SYSTEM Connect the fan motor 2P (Black) connector. Lower the fuel tank and install the front mounting bolts (page 3-5). Fill the system with recommended coolant (page 6- RADIATOR RESERVE TANK REMOVAUINST ALLA TION Remove the rear cowl (page 2-6). Disconnect the siphon hose and overflow hose from the reserve tank.
  • Page 230 COOLING SYSTEM REMOVAL Drain the coolant (page 6-7). Remove the crankcase rear cover (page 7-4). Loosen the hose band screw and disconnect the lower radiator hose from the water pump cover. Loosen the hose band screw and disconnect the oil cooler water hose from the joint pipe.
  • Page 231 COOLING SYSTEM Remove the O-ring from the water pump body. INSTALLATION • �/II !iii O-RING CYLINDER BLOCK-TO­ WATER PUMP HOSE ASSEMBLY BOLTS� 12 N•m (1 . 2 kgf•m, 9 lbf . ft) WATER PUMP BODY � O-RING OIL COOLER WATER HOSE Apply engine oil to a new O-ring and install it onto the stepped portion of the water pump body.
  • Page 232 COOLING SYSTEM Align the mounting bolt holes in the water pum and crankcase and make sure the water pump 1s securely installed. Install a new O-ring into the groove in the water pump body. Install the water pump cover and assembly bolts. Tighten the bolts to the specified torque.
  • Page 233 COOLING SYSTEM Tighten the mounting bolts securely. Install the joint pipe to the water pump cover and tighten the bolt securely. Connect the lower radiator hose and oil cooler water hose. Tighten the hose band screws as shown. Install the crankcase rear cover (page 7-15). Fill the system with recommended coolant and bleed the air (page 6-7).
  • Page 234 7. ENGINE REMOVAL/INSTALLATION COM P O NENT LOCATION·························· 7 - 2 ENGINE REMOVAL ···················· ················ 7-4 - SERVICE INFORMATIO N ················· ······· · ·· 7-3 ENGINE INSTALLATIO N ················· ··········· 7-9 CRANKCASE REAR COVER INSTALLATIO N ····················· ··················· 7-15...

  • Page 235: Component Location

    ENGINE REMOVAUINSTALLA TION COMPONENT LOCATION 20 N•m (2.0 kgf . m, 15 lbf•ft) 59 N•m (6.0 kgf·m, 43 !bf.ft) 49 N·m (5.0 kgf•m, 36 lbf•ft) 59 N•m (6.0 kgf•m, 43 lbf•ft) 54 N•m (5.5 kgf•m, 40 lbf•ft)
  • Page 236 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL • A hoist or equivalent is required to support 'the motorcycle when removing and installing the engine. • A floor jack or other adjustable support is required to support and maneuver the engine. NOTICE Do not use the oil filter and oil cooler as a jacking point. •...

  • Page 237: Engine Removal

    ENGINE REMOVAL/INSTALLATION CRANKCASE REAR COVER REMOVAL Remove the crankcase rear cover A, releasing its bosses from the grommets of rear cover B. Remove the pinch bolt and disconnect the gearshift arm from the gearshift spindle. Rele11se the sidestand switch wire clip from the re11r -----­ cover B.
  • Page 238 ENGINE REMOVAL/INSTALLATION Disconnect the spark plug caps. Disconnect the PAIR air suction hoses from the cyl­ inder head cover. Remove the stay bolts. Disconnect the alternator 3P (Black) connector. Release the alternator wire from the clamps. Open the rubber cap, then remove the terminal nut and disconnect the starter motor cable from the starter motor.
  • Page 239 ENGINE REMOVAL/INSTALLATION Loosen the hose band screw and disconnect the water hose from the thermostat housing cover. Loosen the hose band screw and disconnect the air bleed hose from the hose joint on the cylinder head. Disconnect the horn wire connectors, then release the horn wire from the stay clamp.
  • Page 240 ENGINE REMOVAL/INSTALLATION Remove the bolt, clutch cable guide plate, then dis­ connect the clutch cable from the clutch lifter lever. Loosen the hose band screw and disconnect the lower radiator hose from the hose joint. Remove the radiator lower mounting bolt and washer.
  • Page 241 ENGINE REMOVAL/INSTALLATION Remove the right front engine mounting bolt and collar. Remove the left front engine hanger bracket bolts, washers and nuts. Remove the right front engine hanger bracket bolts, nuts and horn stay. Remove the front engine hanger bracket from the frame.

  • Page 242: Engine Installation

    ENGINE REMOVAL/INSTALLATION Remove the rear upper engine mounting bolt/nut and collar. Carefully lower the adjustable support, then remove the engine from the frame. ENGINE INSTALLATION • Note the direction of the mounting bolts/collars. • The jack height must be continually adjusted to relieve stress from the mounting fasteners.
  • Page 243 ENGINE REMOVAL/INSTALLATION Install the front engine hanger bracket to the frame. Install the right front engine hanger bracket bolts, horn stay and nuts. Install the left front engine hanger bracket bolts, washers and nuts. Install the right front engine mounting bolt and col­ lar.
  • Page 244 ENGINE REMOVAL/INSTALLATION Tighten the right and left front engine hanger bracket nuts to the specified torque. TORQUE: 49 N•m (5.0 kgf-m, 36 lbf.ft) Tighten the lower engine mounting nut to the speci­ fied torque. TORQUE: 59 N•m (6.0 kgf•m, 44 lbf•ft) Tighten the upper engine mounting nut to the spec­...
  • Page 245 ENGINE REMOVAL/INSTALLATION Mount the radiator with the mounting bolt and washer to the front engine hanger. Tighten the mounting bolt securely. Connect the lower radiator hose to the hose joint and tighten the hose band screw securely. Connect the clutch cable to the clutch lifter lever. Install the clutch cable guide plate, aligning its hole with the boss of right crankcase cover and tighten the bolt.
  • Page 246 ENGINE REMOVAL/INSTALLATION Install the horn and tighten the bolt securely. Route the horn wire through the stay clamp and connect the horn wire connectors to the horn. HORN CONNECTORS Connect the air bleed hose to the hose joint on the -�=:::11 cylinder head and tighten the hose band screw securely.
  • Page 247 ENGINE REMOVAL/INSTALLATION Secure the alternator wire with the clamps. Connect the alternator 3P (Black) connector. Install the regulator/rectifier and tighten the stay bolts securely. Connect the PAIR air suction hoses to the cylinder head cover. Connect the spark plug caps securely. Install the drive sprocket with its "15T"...

  • Page 248: Crankcase Rear Cover

    ENGINE REMOVAL/INSTALLATION CRANKCASE REAR COVER INSTALLATION Set the sidestand switch wire clip to the hole of rear cover B. Set the drive chain guide plate onto the rear cover Install the drive chain guide plate/rear cover B and tighten the bohs securely. Install the gearshift arm, aligning its slit with the punch mark on the gearshift spindle.
  • Page 249 ENGINE REMOVAL/INSTALLATION Install the rear cover A. aligning its bosses with the grommets of rear cover B. 7-16...
  • Page 250 8. CYLINDER HEAD/VALVES COMPONENT LOCATION·············· ············ 8-2 CYLINDER HEAD INSPECTION ••••••••••••••• 8-15 SERVICE IN FORMATION ··· ·· · · · · ·· · ···· ··· ··· · · ··· 8- 3 VALVE GUIDE REPLACEMENT ··· ·· · · ·· · · ··· · 8-18 TROUBLESHOOTING ··...

  • Page 251: Component Location

    CYLINDER HEAD/VALVES COMPONENT LOCATION 10 N·m (1.0 kgl•m, 7 lbMt) if .. � "' ef' ��� � 20 N·m (2.0 kgf•m,15 lbf . ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1 . 2 kgf•m, 9 lbf•ft)

  • Page 252: Service Information

    CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL • This section covers service of the cylinder head, valves and camshaft. • The camshaft and cylinder head services can be done with the engine installed in the frame. • When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca­ tions.
  • Page 253 CYLINDER HEAD/VALVES TOOLS Valve spring compressor Compression gauge attachment Tensioner stopper 07757-0010000 07RMJ-MY50100 070MG-0010100 or equivalent commercially avail­ able. Tappet hole protector Valve guide driver Valve spring compressor attach­ ment 07HMG-MR70002 07GMD-KD0100 07959 -KM30101 Valve guide driver Valve seat cutter, 29 mm (45 °...

  • Page 254: Troubleshooting

    CYLINDER HEAD/VALVES ° ° Interior cutter, 30 mm (60 Interior cutter, 24 mm (60 Cutter holder, 4.0 mm 07780-0014000 070PH-Z0D0100 07781-0010500 or equivalent commercially avail­ or equivalent commercially avail­ or equivalent commercially avail• able. able. able. TROUBLESHOOTING • Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or by tracing engine noises to the top-end with a sounding rod stethoscope.

  • Page 255: Cylinder Compression Test

    CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Warm the engine to normal operating temperature. 2P (Black) CONNECTOR Stop the engine and remove the all spark plug caps and spark plugs (page 3-8). Lift and support the fuel tank (page 3-5). Disconnect the fuel pump unit 2P (Black) connector. TOOL: Compression gauge 07RMJ-MV50100 or...

  • Page 256: Cylinder Head Cover

    CYLINDER HEAD/VALVES Disconnect the crankcase breather hose from the cylinder head cover. Remove the cylinder head cover bolts and washers. Remove the cylinder head cover from the cylinder head. CYLINDER HEAD COVER DISASSEMBLY Remove the cylinder head cover packing. PACKING Remove the bolts and PAIR check valve cover.

  • Page 257: Camshaft Removal

    CYLINDER HEAD/VALVES Remove the port plates from the cylinder head cover. CAMSHAFT REMOVAL Remove the cylinder head cover (page 8-6). Remove the timing hole cap and O-ring. Turn the crankshaft clockwise, align the "T" mark on the CKP sensor rotor with the index mark on the right crankcase cover.
  • Page 258 CYLINDER HEAD/VALVES Remove the cam chain tensioner lifter sealing bolt and sealing washer. Turn the cam chain tensioner lifter shaft fully in STOPPER TOOL (clockwise) and secure it using the special tool to prevent damaging the cam chain. TOOL: Tensioner stopper 070MG-0010100 If you plan to replace the camshaft and/or cam It ,s not necessary...
  • Page 259 CYLINDER HEAD/VALVES Remove the bolts and cam chain guide B. Loosen and remove the camshaft holder bolts/ Suspend the cam washers, then remove the camshaft holders and chain with piece camshafts. of wire to prevenr the chain from NO TE: inro falhng From outside to inside, loosen the bolts in a criss­...
  • Page 260 CYLINDER HEAD/VALVES Using a micrometer, measure each cam lobe height. SERVICE LIMITS: IN: 36.22 mm (1.426 in) EX: 35.40 mm (1.394 in) CAMSHAFT HOLDERS Inspect the bearing surface of the each camshaft CAMSHAFT HOLDER A holder for scoring, scratches, or evidence of insuffi­ cient lubrication.

  • Page 261: Cylinder Head Removal

    CYLINDER HEAD/VALVES Install the each camshaft holder to the correct loca­ Be svre the dowel SEALING WASHERS tions with the identification marks. pins m rhe cam shsfr holder sl,gn - No mark: right camshaft holder the holes ,n the � LI.2;. - "R"...
  • Page 262 CYLINDER HEAD/VALVES Remove the two 6 mm bolts. Loosen the 9 mm Remove the ten 9 mm bolts/washers. bolts ma crisscross Remove the cylinder head. parrern m three steps. LTS/ ASHERS Remove the gasket and dowel pins. DOWEL PINS Remove the following: - right crankcase cover (page 9-5) - starter clutch (page 9-17) Remove the bolt, washer and cam chain guide A.

  • Page 263: Cylinder Head Disassembly

    CYLINDER HEAD/VALVES CYLINDER HEAD DISASSEMBLY Remove the cylinder head (page 8-12). Remove the bolt, sealing washer and cam chain tensioner B from the cylinder head. Remove the bleeding joint, sealing washer from the cylinder head. Remove the spark plugs from the cylinder head. Install the tappet hole protector into the valve lifter bore.

  • Page 264: Cylinder Head Inspection

    CYLINDER HEAD/VALVES Remove the valve spring cotters using the special To prevent loss of VALVE SPRING COMPRESSOR tools as shown. tens,on, the valve compress TOOLS: spr,ngs more than Valve spring compressor 07757-0010000 necessary to Valve spring compressor remove the cotters. attachment 07959-KM30101 Remove the following:...
  • Page 265 CYLINDER HEAD/VALVES VALVE LIFTER BORE Inspect each valve lifter bore for scratches or abnor­ mal wear. Measure the each valve lifter bore I.D. SERVICE LIMIT: 26.04 mm (1.025 in) VALVE LIFTER Inspect each valve lifter for scratches or abnormal wear. Measure the each valve lifter O.D.
  • Page 266 CYLINDER HEAD/VALVES Inspect the cam chain tensioner B for excessive CAM CHAIN TENSIONER B wear or damage, replace it if necessary. CAM CHAIN TENSIONER LIFTER Check the cam chain tensioner lifter operation as SHAFT follows. The tensioner shaft should no go into the body when it is pushed.

  • Page 267: Valve Guide Replacement

    CYLINDER HEAD/VALVES Measure and record each valve guide I.D. SERVICE LIMITS: IN/EX: 4.04 mm (0.159 in) Subtract each valve stem O.D. from the correspond­ ing guide I.D. to obtain the stem-to-guide clearance. SERVICE LIMITS: IN: 0.075 mm (0.0030 in) EX: 0.085 mm (0.0033 in) If the stem-to-guide clearance is out of standard, Reface the valve determine if a new guide with standard dimensions...
  • Page 268 CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to the valve seats. Tap the valves and seats using a rubber hose or other hand-lapping tool. Remove the valve and inspect the valve seat face.
  • Page 269 CYLINDER HEAD/VALVES VALVE SEAT REFACING Valve seat cutters/grinders or equivalent valve seat Follow the refacing refacing equipment are recommended to correct manufacturer's worn va Ive seats. operating instructions. ° '- 32 If the contact area is too high on the valve, the seat CONTACT TOO HIGH OLD SEAT WIDTH must be lowered using a 32-degree flat cutter.
  • Page 270 CYLINDER HEADNALVES Use a 60-degree cutter to remove the bottom 1/4 of the old seat. TOOLS: Interior cutter, 30 mm (IN) 07780-0014000 Interior cutter, 24 mm (EX) 070PH-Z0D0100 Cutter holder, 07781-0010500 or 4.0 mm equivalent commer­ cially available so• / Using a 45-degree seat cutter, cut the seat to the proper width.

  • Page 271: Cylinder Head Assembly

    CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY � VALVE LIFTER ------� SHIM� COTTERS ----�cl SPRING RETAINER VALVE GUIDE INTAKE VALVE Blow through all oil passages in the cylinder head TAPPET HOLE PROTECTOR with compressed air. Install the tappet hole protector into the valve lifter bore.
  • Page 272 CYLINDER HEAD/VALVES Install the valve springs with the tightly wound coils The exhaust valve EXHAUSTVALVE INTAKE VALVE facing the combustion chamber. springs has green SPRING SPRING pain, marks and the Install the valve spring retainer. intake vtilve springs has gray pa,m marks COMB USTION CHAMBER SIDE Install the valve cotters using the special tool as...

  • Page 273: Cylinder Head Installation

    CYLINDER HEAD/VALVES Apply a locking agent to the cam chain tensioner B � -- pivot bolt threads. Install a new sealing washer, bolt and cam chain tensioner B as shown. Tighten the cam chain tensioner B pivot bolt to the specified torque.
  • Page 274 CYLINDER HEAD/\l Apply a locking a gent to the cam chain tensioner pivot bolt threads. Install the collar, cam chain tensioner A and bolt Tighten the cam chain guide A bolt to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 !bf . ft) Tighten the cam chain tensioner A pivot bolt to the specified torque .

  • Page 275: Camshaft Installation

    CYLINDER HEAD/VALVES Apply molybdenum disulfide oil solution to the threads and seating surface of the 9 mm bolts/wash­ ers and install them. Install the two 6 mm flange bolts. Tighten the 9 mm bolts in a crisscross pattern in two or three steps to the specified torque.
  • Page 276 CYLINDER HEAD/VALVES If the cam sprockets are removed, install the cam N0.1 CYLINDER CAM LOBES sprockets onto the camshafts. • Install the intake cam sprocket with the timing mark (IN) facing outward and the No. 1 cam lobes facing up and out as shown. •...
  • Page 277 CYLINDER HEAD/VALVES Install the cam chain over the cam sprockets and INTAKE CAMSHAFT then install the intake and exhaust camshafts. • Install the each camshaft to the correct locations with the identification marks. "FG": Intake camshaft "FG/EX": Exhaust camshaft • Make sure that the timing marks on the cam CYLINDER HEAD UPPER SURFACE sprockets are facing outward and flush with the...
  • Page 278 CYLINDER HEAD/VALVES Install the each camshaft holder onto the camshafts. Be sure to align the CAMSHAFT HOLDER dowel pins ,n the camshaft holder align properly with holes in the cylinder head properly. Apply engine oil to the threads and seating surfaces of the camshaft holder bolts.
  • Page 279 CYLINDER HEAD/VALVES In case the cam sprockets were removed, tighten the cam sprocket bolts to the specified torque. TORQUE: 20 N·m (2.0 kgf-m, 15 lbf·ft) Turn the crankshaft clockwise one full turn (360 ° and tighten the other cam sprocket bolts. Remove the stopper tool from the cam chain STOPPER TOOL tensioner lifter.

  • Page 280: Cylinder Head Cover

    CYLINDER HEAD/VALVES Install the PAIR check valves into the cylinder head cover. Install the PAIR check valve cover and tighten the bo l ts to the specified torque. TORQUE: 12 N•m (1.2 kgf•m, 9 lbf-ft) CYLINDER HEAD COVER INSTALLATION Install the cylinder head packing into the groove of PACKING the cylinder head cover.
  • Page 281 CYLINDER HEADNALVES Install the cylinder head cover onto the cylinder head. "UP" MARK Install the washers to the cylinder head cover with their "UP" mark facing up. Install and tighten the cylinder head cover bolts to the specified torque. TORQUE: 10 N·m (1.0 kgf•m. 7 lbf•ft) Connect the crankcase breather hose to the cylinder head cover.
  • Page 282 9. CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE CO MPONENT L OCATION ··················· ······ · 9-2 C LU T CH ······················································ 9 -6 SERVICE INFORM ATION ·········· ················· 9-3 ST ARTER CL UTCH ••••••• ••••••••••• •••••• ••••••• ••• • 9-17 TROU BLESHOOTING ··················· ·············· 9-4 GEARSHIFT L INKAGE ·····...

  • Page 283: Component Location

    CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION 20 N•m (2.0 kgf·m, 15 lbf·ft)

  • Page 284: Clutch

    CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL • This section covers service of the clutch, starter clutch and gearshift linkage. All service can be done with the engine installed in the frame. • Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motorcycle creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.
  • Page 285 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE TOOLS Clutch center holder Gear holder. M2.5 07724-0050002 07724-0010100 or equivalent commercially avail­ able TROUBLESHOOTING Clutch lever too hard to pull in • Damaged clutch lifter mechanism • Faulty clutch lifter bearing • Clutch lifter piece installed improperly Clutch slips when accelerating •...
  • Page 286 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-15). Remove the bolt and clutch cable guide plate, then disconnect the clutch cable end from the clutch lifter lever. Release the EOP switch wire from the clamp. Remove the right crankcase cover bolts and clamp.
  • Page 287 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Remove the dowel pins. Clean any sealant off from the right crankcase cover mating surfaces. NOTE: Do not turn the crankshaft counterclockwise after removing the right crankcase cover 10 prevent the starter reduction gear from damage. CLUTCH LIFTER LEVER Remove the clutch lifter lever, return spring and washer from the right crankcase cover.
  • Page 288 CLUTCH/ST ARTER CLUTCH/GEARSHIFT LINKAGE Remove the clutch spring bolts, springs in a criss­ cross pattern in two to three steps, then remove the pressure plate. Remove the clutch lifter piece from the lifter bear­ ing. Remove the following: - clutch disc A - six clutch discs seven clutch plates - clutch disc B...
  • Page 289 CLUTCH/ST ARTER CLUTCH/GEARSHIFT LINKAGE Remove the lock washer, thrust washer and clutch center. Remove the thrust washer. Remove the clutch outer guide and needle bearing. Remove the clutch outer.
  • Page 290 CLUTCH/ST ARTER CLUTCH/GEARSHIFT LINKAGE Remove the bolts, oil pump drive chain guide A and chain guide B. Remove the oil pump driven sprocket bolt and ------� ..washer. Remove the oil pump drive/driven sprocket and drive chain as an assembly. Remove the oil pump drive sprocket guide.
  • Page 291 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Clutch spring Measure the clutch spring free length. Replace the clucch springs as a set. SERVICE LIMIT: 47.2 mm (1.86 in) Clutch center Check the grooves of the clutch center for damage or wear caused by the clutch plates. Replace it if necessary.
  • Page 292 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Clutch plate Replace rhe clurch Check the plates for discoloration. Check the plate warpage on a surface plate using a discs Bnd pl8tes as feeler gauge. a set. SERVICE LIMIT: 0.30 mm (0.012 in) Judder spring/spring seat Check the judder spring and spring seat for defor­...
  • Page 293 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Oil pump drive sprocket guide Measure the 0.0. and 1.0. of the oil pump drive sprocket guide. SERVICE LIMITS: O.D.: 34.940 mm (1.3756 in) I.D.: 25.031 mm (0.9855 in) Oil pump drive sprocket Check the oil pump drive sprocket for abnormal wear or damage.
  • Page 294 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE INSTALLATION � DRIVE SPROCKET GUIDE CHAIN GUIDE B :2''/.r-�,__ , ..,,,,, NEEDLE BEARING CLUTCH OUTER GUIDE LOCK WASHER � LIFTER BEARING CLUTCH D JUDDER SPRING SPRING CLUTCH PLATES @@� THRUST WASHER IFTER PIECE ¢!� ----:7J! • LOCK NUT ..._.
  • Page 295 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Be careful not 10 Apply a locking agent to the oil pump drive chain drop the parts into guide mounting bolts threads. the oil pan . Install the oil pump drive chain guide A/8, aligning each hole with each boss of crankcase. Tighten the bolts securely.
  • Page 296 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Install the clutch center and thrust washer. Install the lock washer with its "OUT" mark facing out. Apply engine oil to the threads and seating surface of a new clutch center lock nut, then install it onto the mainshaft.
  • Page 297 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Coat the clutch discs and plates with clean engine CLUTCH DISC B oil. Install the clutch disc B (larger I.D. disc) into the clutch outer. Stack the six clutch discs, seven plates and clutch disc A alternately. CLUTCH DISC A CLUTCH PLATES Install the tabs of outside clutch disc A into the shal­...

  • Page 298: Starter Clutch

    CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Apply molybdenum oil solution to the starter idle gear shaft sliding surface. Install the starter idle gear and shaft. Install the right crankcase cover (page 9-25). STARTER CLUTCH REMOVAL Remove the clutch (page 9-6). Remove the starter reduction gear from the crank­ case.
  • Page 299 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Remove the thrust washer. INSPECTION Check the operation of the one-way clutch by turn­ ing the driven gear. You should be able to turn the driven gear clock­ wise smoothly, but the gear should not turn coun­ terclockwise.
  • Page 300 CLUTCH/ST ARTER CLUTCH/GEARSHIFT LINKAGE Check the starter clutch outer inner surface and one­ ONE-WAY CLUTCH way clutch for abnormal wear or damage and replace them if necessary. STARTER CLUTCH OUTER Check the starter driven gear for abnormal wear or damage. Measure the starter driven gear boss O.D.
  • Page 301 CLUTCH/ST ARTER CLUTCH/GEARSHIFT LINKAGE ASSEMBLY STARTER DRIVEN GEAR 83 N·m (8.5 kgf·m, 61 lbf-ft) Apply engine oil to the one-way clutch. PAINT MARK Install the one-way clutch into the starter clutch � ONE-WAY CLUTCH outer with its paint mark facing out. STARTER CLUTCH OUTER Install the snap ring into the starter clutch outer SNAP RING...
  • Page 302 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Install the starter driven gear into the starter clutch STARTER DRIVEN GEAR outer while turning the starter driven gear clock­ wise. Install the needle bearing into the starter clutch NEEDLE BEARIN outer. Recheck the one-way clutch operation (page 9-18). INSTALLATION Install the thrust washer into the crankshaft.

  • Page 303: Gearshift Linkage

    CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Apply engine oil to the starter clutch mounting bolt threads and seating surface. Install the washer and starter clutch mounting bolt. Temporarily install the following: oil pump drive sprocket guide oil pump drive sprocket clutch outer clutch outer guide clutch outer needle bearing Be C1Jreful Attach the gear holder between the primary drive...
  • Page 304 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Remove the bolt and setting plate. Pull the gearshift spindle assembly and thrust washer out of the crankcase. Remove the following: - stopper arm pivot bolt - stopper arm - return spring - washer shift drum center socket bolt - gearshift cam - dowel pin INSPECTION...
  • Page 305 CLUTCH/STARTER CLUTCH/GEARSHIFT LINK.AGE INSTALLATION Apply a locking agent to the stopper arm pivot bolt threads. Install the following: - washer - return spring - stopper arm - pivot bolt Tighten the stopper arm pivot bolt to the specified torque. TORQUE: 12 N-m (1.2 kgf,m, 9 lbf•ft) Install the dowel pin onto the shift drum.

  • Page 306: Right Crankcase Cover

    CLUTCH/ST ARTER CLUTCH/GEARSHIFT LINKAGE Apply a locking agent to the setting plate bolt threads. Install the setting plate and tighten the bolt securely. Install the gearshift arm to the gearshift spindle, aligning the arm slit with the punch mark on the gearshift spindle.
  • Page 307 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Install the dowel pins. Install the wave washer and thrust washer onto the starter idle gear. Install the right crankcase cover while turning the lifter lever clockwise to engage the lifter lever spin­ dle groove with the lifter piece flange. Install the right crankcase cover bolts with the clamp.
  • Page 308 CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Connect the clutch cable end to the clutch lifter 11111.,..__ ..,. lever. Install the clutch cable guide plate, aligning its hole with the boss of right crankcase cover. Tighten the bolt securely. Add the recommended engine oil (page 3-15). Adjust the clutch lever freeplay (page 3-27).
  • Page 309 ,,,. 10. AL TERNA TOR STATOR ···················································· 10-5 COMPONENT LOCATI ON ......10-2 SERV ICE INFO RMA TI ON ······· ······· ··········· 10-3 F L YWH EE L ················································ 10-6 ALTERNATOR COVER REMOVAL ··········· 10- 4 AL TERNATOR COVER INST AL L ATI ON •••••••••...

  • Page 310: Component Location

    ALTERNATOR COMPONENT LOCATION 12 N•m (1.2 kgf•m, - - 9 lbf.ft) � (T. </, 113 N·m (11 . 5 kgf•m, 83 lbf . ft) 12 N•m (1.2 kgf·m, 9 lbf.ft) 10-2...

  • Page 311: Service Information

    ALTERNATOR SERVICE INFORMATION GENERAL • This section covers service of the alternator stator and flywheel. All service can be done with the engine installed in the frame. • Refer to procedures for alternator stator inspection (page 17-8). • Refer to procedures for starter motor servicing (page 19-6).

  • Page 312: Alternator Cover Removal

    ALTERNATOR ALTERNATOR COVER REMOVAL Remove the following: - seat (page 2-4) - left side cover (page 2-4) - crankcase rear cover A (page 7-4) Remove the regulator/rectifier stay bolts. Disconnect the alternator 3P (Black} connector. Release the alternator wire from the clamps. Unhook the alternator wire from the guide.

  • Page 313: Installation

    ALTERNATOR Remove the dowel pins. Clean any sealant off from the alternator cover mat­ ing surfaces. STATOR REMOVAL Remove the bolt and stator wire clamp. GROMMET SOCKET BOLTS Remove the alternator wire grommet from the alter­ nator cover. Remove the socket bolts and stator. STATOR WIRE CLAMP INSTALLATION...
  • Page 314 ALTERNATOR Install the stator to the alternator cover. 4'· '1!:ru SOCKET BOLTS Install and tighten the socket bolts to the specified GROMMET torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply sealant to the wire grommet. then install it into the alternator cover groove securely. Install the wire clamp and tighten the flange bolt to the specified torque.
  • Page 315 ALTERNATOR Install the flywheel to the crankshaft. Apply engine oil to the flywheel bolt threads and seating surface. Install the washer and flywheel bolt. Hold the flywheel using the special tool, then .-------­ tighten the bolt to the specified torque. TOOL: 07725- 0 040001 or Flywheel holder...
  • Page 316 ALTERNATOR Install the dowel pins. Install the alternator cover. The afremaror cover (sratorJ is Install and tighten the bolts in a crisscross pattern in msgnerrcafly two or three steps securely. arrached 10 the flywheel. be careful during instsffat,on. Refer to 'CABLE & Route the alternator wire and hook the alternator GUIDE HARNESS wire on the guide.
  • Page 317 ALTERNATOR Connect the alternator 3P (Black) connector. Install the regulator/rectifier and tighten the bolts securely. Install the following: crankcase rear cover A (page 7-15) left side cover (page 2-4) seat {page 2-4) 10-9...
  • Page 319 CRANKCASE/TRANSMISSION COMPONENT LOCATION 39 N·m (4 . 0 kgf·m, 29 lbf . ft) 15 N•m (1 . 5 kgf•m, 11 lbf . tt)+ 120 ° 12 N•m ( 1.2 kgf•m, 9 lbf·ft) 24 N•m (2.4 kgf•m. 18 lbf-ft) 11-2...
  • Page 320 ,,.. CRANKCASE/TRANSMISSION SERVICE INFORMATION GENERAL • The crankcase must be separated to service the following: Transmission -Crankshaft (page 12-5) Piston/connecting rod/cylinder (page 12-14) • The following components must be removed before separating the crankcase: Engine (page 7-4) -Clutch (page 9-6) Gearshift linkage (page 9-22) Starter clutch (page 9-17) Flywheel (page...
  • Page 321 CRANKCASE/TRANSMISSION TOOLS Bearing remover set, 20 mm Remover weight Bearing remover handle 07936-3710600 07741-0010201 07936-3710100 _,.,,;'/ ,,-,/ /✓/ '� � � Driver Attachment. 42 x 47 mm Pilot, 20 mm 07949-3710001 07746-0010300 07746-0040500 ,../ ,,,,,,- ,/1/ �_,.. TROUBLESHOOTING Hard to shift •...
  • Page 322 CRANKCASE/TRANSMISSION CRANKCASE SEPARATION Refer to Service Information for removal of neces­ sary parts before separating the crankcase (page 11- Remove the bolt, oil level plate and oil level finder from the crankcase. Remove the bolts and sealing washers. Pl111.:e lite enyine up�ide down. Loosen the 10 mm bolt and 6 mm bolts in a criss­...
  • Page 323 CRANKCASE/TRANSMISSION Remove the dowel pins and oil orifices. OIL ORIFICES Clean any sealant off from the crankcase mating surface. DOWEL PINS SHIFT FORK/SHIFT DRUM/ TRANSMISSION REMOVAL/DISASSEMBLY Separate the crankcase halves (page 11-5). COUNTERS HAFT Remove the countershaft assembly. ie...:. Remove the dowel pin and countershaft bearing set DOWELPIN ring.
  • Page 324 CRANKCASE/TRANSMISSION Remove the fork shaft and shift forks. SHIFT FORKS Remove the shift drum and shift drum bearing. Remove the bolts and mainshaft bearing set plate. Remove the mainshaft bearing from the crankcase. Check the mainshaft bearing for smooth rotation, abnormal wear or damage.
  • Page 325 CRANKCASE/TRANSMISSION Remove the mainshaft assembly. Disassemble the mainshaft. Clean all disassembled parts in solvent thoroughly. SHIFT DRUM/SHIFT FORK INSPECTION Check the shift fork guide pin for abnormal wear or damage Measure the shift fork I.D. SERVICE LIMIT: 12.03 mm (0.474 in) Measure the shift fork claw thickness.
  • Page 326 CRANKCASE/TRANSMISSION TRANSMISSION INSPECTION Check the gear shifter groove for abnormal wear or damage. Check the gear dogs, dog holes and teeth for abnor­ mal wear or lack of lubrication. Measure the I.D. of each gear. SERVICE LIMITS: MS, M6: 28.04 mm (1.104 in) 2.
  • Page 327 CRANKCASE/TRANSMISSION Countershaft bearing Turn the outer race of countershaft bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the shaft. Replace the countershaft, collar. and bearing as an assembly, If the race does not turn smoothly, qui­...
  • Page 328 CRANKCAS E/TRANSMISSION -------:TTRRA A , rNJ lSSIMMISSION SSEMBLY Apply molybde I lion to the gear teeth, num oil so u sliding surface, s hifter grooves a nd bushings. Assem ble the mamshaft and countershaft. MAINSHAFT/M1 GEAR {12T) M5 GEAR {24T) M4/3 GEAR (23/18T) M2 GEAR ( 1 ST)
  • Page 329 CRANKCASE/TRANSMISSION Assemble the transmission gear and shafts. • Coat each gear with clean engine oil and check for smooth movement. • Align the lock washer tabs with the spline washer grooves. • Always install thrust washer and snap ring with the chamfered {rolled) edge facing away CORRECT INCORRECT from the th rust load.
  • Page 330 ,... CRANKCASE/TRANSMISSION INSTALLATION Apply molybdenum oil solution to the shift fork grooves in the M3/4, C5 and C6 gear. Install the mainshaft into the crankcase. Install rhe bear,ng Install the mainshaft bearing into the crankcase. mto che crenkcBss with the marked side fac,ng out.
  • Page 331 CRANKCASE/TRANSMISSION Install the shift drum and shift drum bearing into the crankcase. The shift forks have the following identification marks: - "L" for left - "R" for right "C" for center Install the shift forks into the shift drum guide grooves with the identification marks facing toward the right side of the engine and insert the fork shaft.
  • Page 332 CRANKCASE/TRANSMISSION Install the dowel pin in the upper crankcase hole. DOWEL PIN � Install the countershaft bearing set ring into the upper crankcase groove. Install the countershaft by aligning the countershaft BEARING COUNTERSHAFT bearing groove with the set ring on the crankcase, and bearing cap hole with the dowel pin.
  • Page 333 CRANKCASE/TRANSMISSION Install the oil orifices, aligning its cut-out with the 1!111! groove of upper crankcase. Install the dowel pins in the upper crankcase. • Tighten the crankcase 8 mm bolts (main journal ® bolts) using the Plastic Region Tightening � CRANKCASE 8 MM BOLTS Method described below.
  • Page 334 CRANKCASE/TRANSMISSION Tighten the 10 mm bolt to the specified torque. TORQUE: 39 N·m (4.0 kgf·m, 29 lbf·ft) 6 mm BOLTS/SEALING WASHERS � From the inside to outside, tighten the 6 mm bolts/ sealing washers to the specified torque. 6 mm BOLTS TORQUE: 12 N•m (1.2 kgf•m, 9 lbf•ft) 6 mm BOLTS Place the enqine with the lower side down.
  • Page 335 CRANKCASE/TRANSMISSION Install a new oil level finder into the crankcase When ,nstalhng a securely. new oil level fmder. do nor press the Apply a locking agent to the oil level plate bolt clear surface. threads. Install the oil level plate and tighten the bolt Align che or/ level securely.
  • Page 336 12. CRANKSHAFT /PISTON/CYLINDER CO MPONENT LOCATION ····················· ··· 12-2 M AIN JOURNAL BEARI N G ••••••••••••••••••••• 12-8 SER V ICE INFOR M ATI ON ··················· ······ 12-3 CRANK PIN BEARING ·················· ··········· 12-11 TRO UBLES H OOTING ········ ······················· 12-4 PISTON/CYLIND ER ········...
  • Page 337 CRANKSHAFT /PISTON/CYLINDER COMPONENT LOCATION 26 N m fm 19 lbf ft) 7 � 12-2...
  • Page 338 CRANKSHAFT /PISTON/CYLINDER SERVICE INFORMATION GENERAL • The crankcase must be separated to service the crankshaft, cylinder and piston/connecting rod. Refer to procedures for crankcase separation (page 1 1-5). • Mark and store the connecting rods, bearing caps and bearing inserts to be sure of their correct locations for reassem­ bly.
  • Page 339 CRANKSHAFT /PISTON/CYLINDER TROUBLESHOOTING Cylinder compression is too low. hard to starting or poor performance at low speed • Leaking cylinder head gasket • Worn. stuck or broken piston ring • Worn or damaged cylinder and piston Cylinder compression too high, overheating or knocking •...
  • Page 340 CRANKSHAFT /PISTON/CYLINDER CRANKSHAFT Separate the crankcase halves (page 11-5). SIDE CLEARANCE INSPECTION Measure the connecting rod side clearance. FEELER GAUGE SERVICE LIMIT: mm (0.014 0.35 If the clearance exceeds the service limit, replace the connecting rod. Recheck and if still out of limit, replace the crank­ shaft.
  • Page 341 CRANKSHAFT /PISTON/CYLINDER INSPECTION Support the crankshaft on both end journals. Set a dial gauge on the center main journal of the MEASURE POINT crankshaft. Rotate the crankshaft two revolutions and read the runout. SERVICE LIMIT: 0.05 mm (0.002 in) Check the primary drive gear teeth for abnormal wear or damage.
  • Page 342 CRANKSHAFT /PISTON/CYLINDER Apply molybdenum oil solution to the crankpin bearing sliding surfaces on the connecting rod bear­ ing caps. Install the connecting rod bearing caps by aligning the 1.0. code on the connecting rod and bearing cap. Be sure each part is installed in its original position, as noted during removal.
  • Page 343 CRANKSHAFT /PISTON/CYLINDER MAIN JOURNAL BEARING NOTICE Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the crankshaft (page 12-5). BEARING INSPECTION Inspect the main journal bearing inserts on the upper and lower crankcase halves for unusual wear or peeling.
  • Page 344 CRANKSHAFT /PISTON/CYLINDER PLASTIC REGION TIGHTENING METHOD: Install the crankcase 8 mm bolts (main journal 8 mm bolts). Loosely install all the crankcase bolts. Make sure the upper and lower crankcase are seated securely. Tighten the crankcase 8 mm bolts (main journal bolts) as follow: Tighten the crankcase 8 mm bolts (main journal bolts) in numerical order in the illustration in two to...
  • Page 345 CRANKSHAFT /PISTON/CYLINDER Cross reference the main journal and bearing sup­ port codes to determine the replacement bearing color code. MAIN JOURNAL BEARING SELECTION TABLE: BEARING SUPPORT LO.CODE 34.000- 34.006 mm 34.006 -34.012 34.012-34.018 mm (1.3386- 1.3388 in) (1.3388 -1.3391 in) (1.3391 -1.3393 MAIN JOURNAL 30.999 - 31.005 mm...
  • Page 346 CRANKSHAFT /PISTON/CYLINDER CRANKPIN BEARING NOTICE Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Remove the crankshaft (page 12-5). BEARING INSPECTION Check the bearing inserts for unusual wear or peel­...
  • Page 347 CRANKSHAFT /PISTON/CYLINDER Tighten the nuts in two or three steps alternately, then tighten the nuts to the specified torque. TORQUE: 26 N·m (2.7 kgf·m, 19 lbf.ft) Remove the bearing caps and measure the com­ pressed plastigauge at its widest point on the crankpin to determine the oil clearance.
  • Page 348 CRANKSHATT /PISTON/CYLINDER Cross-reference the connecting rod and crankpin codes to determine the replacement bearing color. CRANKPIN BEARING SELECTION TABLE: CONNECTING ROD 1.O.CODE 33.500 -33.508 mm 33.508-33.516 mm (1.3189 - 1.3192 in) ( 1.3192 -1.3195 in) CRANK PIN 0.D.CODE 30.995 -31.003 mm Yellow Green (1.2203-1.2206 in)
  • Page 349 CRANKSHAFT /PISTON/CYLINDER PISTON/CYLINDER PISTON/CONNECTING ROD REMOVAL NOTICE This motorcycle is equipped with aluminum cyl­ • inder sleeves. Before piston removal, place a clean shop towel around the connecting rod to prevent damaging the cylinder sleeve. • Do not try to remove the piston/connecting rod assembly from bottom of the cylinder;...
  • Page 350 CRANKSHAFT /PISTON/CYLINDER PISTON DISASSEMBLY Be careful not to Spread each piston ring ends and remove them by damage the piston lifting up at a point opposite the gap. ring by spreading the ends too far. Never use a wire Clean carbon deposits from the piston ring grooves brush;...
  • Page 351 CRANKSHAFT /PISTON/CYLINDER Measure the piston pin bore. SERVICE LIMIT: 16.02 mm (0.631 in) Measure the 0.0. of the piston pin. SERVICE LIMIT: 15.98 mm (0.629 in) Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.04 mm (0.002 Measure the diameter o'I the piston at 6 mm (0.2 in) from the bottom and 90 degrees to the piston pin hole.
  • Page 352 CRANKSHAFT /PISTON/CYLINDER CYLINDER INSPECTION Inspect the cylinder bore for wear or damage. Measure the cylinder 1.0. in X and Y axis at three levels. Take the maximum reading to determine the cylin­ der wear. SERVICE LIMIT: 67.10 mm (2.642 in) Calculate the piston-to-cylinder clearance.
  • Page 353 CRANKSHAFT /PISTON/CYLINDER PISTON ASSEMBLY Clean the piston ring grooves thoroughly and install the piston rings. • Apply engine oil to the piston rings. TOP RING SECOND RING • Avoid piston and piston ring damage during installation. • Install the piston rings with the marking (RE: top ring, RNE: second ring) facing up.
  • Page 354 CRANKSHAFT /PISTON/CYLINDER Coat the cylinder walls, pistons and piston rings PISTON RING COMPRESSOR with engine oil. Install the piston/connecting rod assemblies into the Install the piston/ cylinders using a commercially available piston ring connecting rod compressor tool. assembly wirh tho When reusing the connecting rods, they must be piston 'IN' mark installed in their original locations.
  • Page 355 13. FRONT WHEEL/SUSPENSION/STEERING C OM P ONENT LO C A TION · •······················13-2 F RONT WHEEL · · ······················ ··············· 13-14 SER V I CE INFORMA TION ··················· ······ 13-4 FOR K······················································· 13-21 TRO U B LESHOOTING ···················· ··········· 13-7 STEERING STEM••...

  • Page 356: Component Location

    FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION CB600FA: 27 N·m (2.8 kgf.m, 20 lbf-ft) N·m (10.5 kgf-m, 76 lbf-ft) " � 22 N•m (2.2 kgf•m, f•ft) 39 N·m (4.0 kgf-m, 29 lbf·ft) --=---- - 59 N•m (6.0 kgf-m,44 lbf-ft) 30 N-m (3.1 kgf•m, 22 lbf·ft) 22 N•m (2.2 kgf•m, 16 lbf•ft) 13-2...

  • Page 358: Service Information

    60 g (2.1oz) max. Fork Spring free length 245.7 (9.67) 240.8 (9.48) Pipe runout 0.20 (0.008) Recommended fork fluid Honda Ultra Cushion Oil 10W or equivalent Fluid level 70 (2.8) Fluid capacity ± (16.7 ± 0.08 US oz, 17.4 ±...
  • Page 359 FRONT WHEEL/SUSPENSION/STEERING TOOLS r-;;:aring remover shaft Bearing remover head, 20 mm Driver 07GGD-0010100 07746-0050600 07749-0010000 or 07746-0050100 Attachment, 42 X 47 mm Pilot, 20 mm Fork seal driver weight 07746-0010300 07746-0040500 07KM D-KZ30100 Stopper plate Oil seal driver attachment Spring collar holder 07RMn-MW40100 070MF-MR7C:110 070MF-MB7C1'.l0...
  • Page 360 FRONT WHEEL/SUSPENSION/STEERING Assembly base Driver shaft assembly Bearing remover, A f - j 07946-KM90301 07946-KM90401 07946-KM90600 � · ( 1 \) "-- ---� (" e� ,:-;: Bearing remover, B Driver attachment (upper) Driver attachment (lower) 07NMF-MD0110 070MF-MCJ0100 070MF-MCJ0200 (�\ � Steering stem driver 07946-MB00000 _/,,,�...

  • Page 361: Troubleshooting

    FRONT WHEEL/SUSPENSION/STEERING TROUBLESHOOTING Hard steering • Steering head bearing adjustment nut too tight • Faulty or damaged steering head bearings • Bent steering stem • Faulty tire • Insufficient tire pressure Steers to one side or does not track straight •...
  • Page 362 FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the rearview mirrors. REARVIEW MIRROR Remove the wire bands. Hold the handlebar weights and remove the screws, For inner weight HANDLEBAR WEIGHT then remove both handlebar weights from the han­ replacement, see dlebar. page 13-14 Disconnect the clutch switch wire connectors from LOCK NUT CABLE END...
  • Page 363 FRONT WHEEL/SUSPENSION/STEERING Remove the left handle grip and switch housing plate. GRIP PLATE Loosen the bolt and remove clutch lever bracket from the handlebar. CLUTCH LEVER BRACKET BOLT Disconnect the front brake light switch wire connec­ tors from the switch. <...
  • Page 364 FRONT WHEEL/SUSPENSION/STEERING Remove the right handlebar switch/thronle housing SWITCHfrHROTTLE HOUSING screws. Disconnect the thronle cable ends from the throttle pipe and remove the right handlebar switch/throttle housing. Remove the right handlebar grip/throttle pipe. Remove the bolts and handlebar upper holders. Remove the handlebar.
  • Page 365 FRONT WHEEL/SUSPENSION/STEERING Apply Honda Bond A, Honda hand grip cement or equivalent to the inside surface of the right handle­ bar grip and to the clean surfaces of the throttle pipe. Allow the adhesive Wait 3-5 minutes and install the grip. Rotate the...
  • Page 366 Tighten the bolt securely. Install the switch housing plate. Apply Honda Bond A, Honda hand grip cement or equivalent to the inside surface of the left handlebar grip and to the clean surfaces of the handlebar.
  • Page 367 FRONT WHEEL/SUSPENSION/STEERING Tighten the forward screw first, then the rear screw. Apply grease to the clutch cable end. LOCK NUT Connect the clutch cable end to the clutch lever and tighten the lock nut. Connect the clutch switch wire connectors. Install both handlebar weights onto the inner weights, aligning each cut-out of the weights.
  • Page 368 =RONT WHEEL/SUSPENSION/STEERING Secure the handlebar switch wires with the wire REARVIEW MIRROR bands. Install the rearview mirrors. Check the following: throttle operation and grip freeplay (page 3-6) clutch operation and lever freeplay (page 3-27) HANDLEBAR INNER WEIGHT REPLACEMENT Remove the left handlebar grip and throttle grip. HOLE Straighten the retainer tab with a screwdriver or punch.
  • Page 369 FRONT WHEEL/SUSPENSION/STEERING Remove the axle bolt and loosen the right axle pinch bolt. Support the motorcycle securely using a hoist or equivalent and raise the front wheel off the ground. Loosen the left axle pinch bolt. Pull the front axle out and remove the front wheel. CB600FA: Be careful nor to NOTE:...
  • Page 370 RONT WHEEL/SUSPENSION/STEERING Wheel bearing Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if they do not turn Replace the smoothly, quietly, or if they fit loosely in the hub.
  • Page 371 FRONT WHEEL/SUSPENSION/STEERING Mount the wheel, tire and brake disc (and pulser ring; CB600FA) assembly on an inspection stand. Spin the wheel, allow it to stop, and mark the lowest (heaviest) part of the wheel with chalk. Do this two or three times to verify the heaviest area.
  • Page 372 =RONT WHEEL/SUSPENSION/STEERING Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft and drive the bearing out or the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover head, 20 mm 07746-0050600 07GGO-0010100 or Bearing remover shaft 07746-0050100...
  • Page 373 FRONT WHEEL/SUSPENSION/STEERING Do not get grease Install the brake discs with the arrow mark facing in AKE DI �� �'---. illiiiliiiiii. on the brake discs the normal rotating direction. • or stopping power Install and tighten new mounting bolts to the speci­ will be reduced.
  • Page 374 =RONT WHEEUSUSPENSION/STEERING Hold the axle and tighten the axle bolt to the speci­ fied torque. TORQUE: 59 N·m (6.0 kgf·m. 44 lbf . ft) Tighten the right axle pinch bolt to the specified torque. TORQUE: 22 N·m (2.2 kgf•m, 16 lbf.ft) Install the left brake caliper and tighten new mount­...
  • Page 375 FRONT WHEEL/SUSPENSION/STEERING FORK REMOVAL Remove the following: front wheel (page 13-14) - front brake calipers CB600FA (page 15-33) CB600F (page 15-37) - front fender (page 2-7) Loosen the fork top bridge pinch bolt. If it is necessary to disassemble the front fork, loosen the fork bolt at this moment.
  • Page 376 :RONT WHEEL/SUSPENSION/STEERING Insert the stopper plate between the nut and the FORK BOLT spring collar. O-RING TOOL: Stopper plate 070MF-MBZC130 Loosen the lock nut with holding the front fork bolt. Remove the front fork bolt and O-ring. 'NUT SPRING COLLAR STOPPER PLATE Remove the spring collar and fork spring from the SPRING COLLAR...
  • Page 377 FRONT WHEEL/SUSPENSION/STEERING Remove the fork damper from the fork slider. FORK SLIDER FORK DAMPER Remove the dust seal. DUST SEAL Do not scratch the Remove the stopper ring. STOPPER RING fork tube sliding surface. Pull the fork tube out until you feel resistance from FORK TUBE the slider bushing.
  • Page 378 =RONT WHEEL/SUSPENSION/STEERING Remove the oil seal, back-up ring and slider bushing BACK-UP RING from the fork tube. SLIDER BUSHING OIL SEAL Carefully remove the fork tube bushing by prying Do not remove the the slit with a screwdriver until the bushing can be fork tube bushing pulled off by hand.
  • Page 379 FRONT WHEEL/SUSPENSION/STEERING Check the oil lock valve for wear or damage. Replace the fork damper, if components is dam­ aged. OIL LOCK VALVE Place the fork tube in V-block and measure the run out. Actual runout is 1/2 of the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) Fork tube.
  • Page 380 =RONT WHEEL/SUSPENSION/STEERING ASSEMBLY 20 N·m (2.0 kgf·m, LOCK NUT 15 lbf·ft) 34 N·m (3.5 kgf·m, FORK BOLT FORK TUBE 25 lbf•ft) � �r-; ---, FORK TUBE BUSHING SLIDER BUSHING �s,._ BACK-UP RING �0-RING � � � -=- ..OIL SEAL STOPPER RING ��...
  • Page 381 FRONT WHEEL/SUSPENSION/STEERING Drive the oil seal in using the special tools. DRIVER WEIGHT OIL SEAL TOOLS: Forte seal driver weight 07KMD-KZ30100 Oil seal driver attachment 07RMD-MW40100 ATTACHMENT Install the stopper ring into the fork slider groove STOPPER RING securely. Install the dust seal. DUST SEAL Install the fork damper into the fork slider.
  • Page 382 07 YMB-MCF0101 TORQUE: 20 N-m (2.0 kgf•m, 15 lbf•ft) Pour the specified amount of recommended fork fluid into the fork slider. RECOMMENDED FORK FLUID: Honda Ultra Cushion Oil 10W or equivalent FORK FLUID CAPACITY: 494±2.5 cm• (16.7 ± 0.08 US oz, 17.4 ±...
  • Page 383 FRONT WHEEL/SUSPENSION/STEERING Pull the fork damper rod up and install the fork TAPERED END spring with the tapered end facing up into the fork slider. FORK SPRING Attach the fork damper holder to the fork damper. FORKDAMPER TOOL: HOLDER Fork damper holder 070MF-MBZC120 Install the fork spring collar.
  • Page 384 RONT WHEEL/SUSPENSION/STEERING Install the front fork bolt to the fork slider. FORK SLIDER INSTALLATION Install the fork leg through the steering stem and top bridge. Align the top end of the fork slider with the upper surface of the top bridge. Tighten the bottom bridge pinch bolt to the speci­...

  • Page 385: Steering Stem

    FRONT WHEEL/SUSPENSION/STEERING STEERING STEM REMOVAL -...- Remove the following: NNECTOR - headlight unit (page 20-6) - combination meter (page 20-10) - front wheel (page 13-14) Release the immobilizer receiver 4P (Natural) and ignition switch 2P (Blown) connectors from the meter stay, then disconnect the connectors. Release the engine stop switch wire clip from the meter stay.
  • Page 386 RONT WHEEL/SUSPENSION/STEERING Remove the bolt and front brake hose from the CB600F only· steering stem. Remove the handlebar (page 1 3 - 8). STEM NUT TOP BRIDGE Remove the steering stem nut. Loosen the fork top bridge pinch bolts and remove the top bridge.
  • Page 387 FRONT WHEEL/SUSPENSION/STEERING Remove the following: dust seal - upper bearing inner race upper bearing steering stem lower bearing OUTER RACE REPLACEMENT C8600FA only: Release the clutch cable from the guide. GUIDE only: Remove the bolt and separate the brake pipe Joint. CB600FA careful not to Remove the mounting bolt and stay.
  • Page 388 RONT WHEEL/SUSPENSION/STEERING Replace the races using the special tools as ,/ways replace rhe described in the following procedure. ,earings and races TOOLS: (1 l Driver attachment (upper) 070MF-MCJ0100 (2) Driver attachment (lower) 070MF-MCJ0200 (3) Driver shaft assembly 07946-KM90301 (4) Bearing remover, A 07946-KM90401 (5) Bearing remover, B 07NMF-MT70110...
  • Page 389 FRONT WHEEL/SUSPENSION/STEERING Install the special tools into the steering head as Note the mstaliat,on DRIVER shown and remove the lower outer race using the direct10n of rhe DRIVER SHAFT ATTACHMENT same procedure as for the upper outer race. assembly base; the (upper) large I.
  • Page 390 RONT WHEEUSUSPENSION/STEERING Remove any burrs from the outer race installation surface of the steering head. NUT A Install new lower outer race with the special tools ote the installation as shown. d1rect,on of the Hold the driver shaft with wrench and turn the nut ssembty base.
  • Page 391 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION STEERING STEM NUT : BEARINGS : BEARING RACE 103 N-m (10.5 kgf-m, LOCK NUT : DUST SEAL 76 lbf·ft) ..$� METER STAY LOCK WASHER <� ADJUSTMENT NUT 26 N-m {2.7 kgf-m, lbf•ft) ER DUST SEAL CB600F ONLY HEADLIGHT STAY Apply grease to upper and lower bearings and bear­...
  • Page 392 ' RONT WHEEUSUSPENSION/STEERING Move the steering stem right and left, lock-to-lock, STEERING STEM five times to seat the bearings. Make sure that the steering stem moves smoothly, without play or binding. Retighten the bearing adjusting nut to the specified torque. TOOL: Steering stem socket 07916-3710101...

  • Page 393: H A N Dl Eb A R

    FRONT WHEEL/SUSPENSION/STEERING Install the top bridge and steering stem nut. STEM NUT TOP BRIDGE Install the fork legs (page 13-30). Tighten the steering stem nut to the specified torque. STEM NUT/WASHER TORQUE: 103 N•m (10.5 kgf•m, 76 lbf•ft) Install the handlebar (page 13-10). Install the front brake hose with a new bolt and CB600F only·...
  • Page 394 FRONT WHEEL/SUSPENSION/STEERING Install the meter stay and tighten the bolts securely. CLUTCH BRAKE HOSE GUIDE Route the clutch cable to the guide of meter stay. (CB600FA only) CABLE GUIDE Route the front brake hose to the guide of meter CB600FA only: stay.
  • Page 395 14. REAR WHEEL/SUSPENSION COM P ONENT LO C ATION ·· ··················· ··· 14-2 REAR W HEEL ············································ 14-7 SER VICE IN FORMATION······················· ·· 14-3 SHO CK ABSORBER ···················· ············ 14-14 T RO UBLESHO OTIN G··············· ················ 14-6 S W ING ARM ············································ 14-18 1111 14-1...
  • Page 396 REAR WHEEL/SUSPENSION COMPONENT LOCATION 42 N-m (4.3 kgf·m, 31 lbf•ft) (0.4 kgf-m, 3.1 lbf·ft) 37 N-m (3.8 kgf•m, 98 N-m (10.0 kgf·m, 72 lbf·ft) 12 N·m (1.2 kgf-m. 9 lbf·ft) 14-2...
  • Page 397 • When servicing the rear wheel and suspension, support the motorcycle using a safety stand or hoist. • Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE". • Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting point. • Refer to the brake system information (page 15-4).
  • Page 398 REAR WHEEL/SUSPENSION TOOLS Bearing remover shaft Bearing remover head, 20 mm Driver 07749-0010000 07GGD-0010100 07746-0050600 . / � �/.7/ ,,,.1/ or 07746-0050100 �/ Attachment, 32 X 35 mm Attachment, 42 X 47 mm Attachment, 52 X 55 mm 07746-0010400 07746-0010100 07746-0010300 �-�...
  • Page 399 REAR WHEEL/SUSPENSION Attachment, 22 X 24 mm Bearing remover shaft, 20 mm Remover shaft handle 07936-3710600 07936-3710100 07746-0010800 � Remover weight Needle bearing remover attachment Outer driver attachment 07741-0010201 07HMC-MR70100 07ZMD-MBW0200 Pilot, 28 mm Attachment. 37 X 40 mm 07746-0010200 07JAD-PH80400 14-5...
  • Page 400 REAR WHEEL/SUSPENSION TROUBLESHOOTING Soft suspension • Weak shock absorber spring • Incorrect suspension adjustment • Oil leakage from damper unit • Insufficient tire pressure Stiff suspension • Incorrect suspension adjustment • Damaged rear suspension pivot bearings • Bent damper rod •...
  • Page 401 REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Loosen the rear axle nut. Support the motorcycle using a safety stand or a hoist, raise the rear wheel off the ground. Adjust the drive chain slack fully (page 3-19). Remove the axle nut and washer. Push the rear wheel forward.
  • Page 402 REAR WHEEi/SUSPENSiON Wheel bearing Turn the inner race of each bearing with your nnger. Bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not Replace rhe wheel turn smoothly and quietly, or if they fit loosely In the bearings in pa,rs.
  • Page 403 REAR WHEEUSUSPENSION Remove the bolts and brake disc. Remove the right dust seal. Remove the left dust seal. If you will be disassemble the dr,ven flange, loosen the driven sprocket nuts before removing the dr,ven flange from rhe wheel hub. Remove the driven flange assembly from the left wheel hub.
  • Page 404 REAR WHEEUSUSPENSION Remove the nuts and driven sprocket. DRIVEN SPROCKET Remove the driven flange collar. Drive out the driven flange bearing using the special tool. TOOLS: Driver 07749-0010000 Att achment, 42 X 47 mm 07746-0010300 Pilot. 22 mm 07746-0041000 ATTACHMENT/PILOT Install the bearing remover head into the bearing.
  • Page 405 REAR WHEEL/SUSPENSION ASSEMBLY Fully seated .� DRIVEN FLANGE DRIVEN FLANGE COLLAR BEARING (63/22) ..108N·m(11.0kgf• 80 Ibf-fl) Be f l ush with the wheel hub 7.0 N-m (0.7 kgf-m, RIGHT DUST SEAL � 5.2 lbf-ft) �� ,p,. DRIVEN SPROCKET PULSER RING (CB600FAJ �...
  • Page 406 REAR WHEEL/SUSPENSION Drive the driven flange bearing/collar into the driven flange using the special tools. TOOLS: Driver 07749-0010000 Attachment, 52 X 55 mm 07746-0010400 Pilot,20 mm 07746-0040500 Install the driven sprocket and tighten the nuts tem­ DRIVEN SPROCKET porarily. � NUTS Install the wheel damper rubbers into the wheel Replace the...
  • Page 407 REAR WHEEUSUSPENSION If the driven sprocket was removed, tighten the nuts to the specified torque. TORQUE: 108 N•m (11.0 kgf•m, 80 lbf•ftl Apply grease to the dust seal lips and install the dust seal until it is nush with the driven flange. Install the brake disc with its rotating direction mark facing out.
  • Page 408 REAR WHEEL/SUSPENSION Install the rear brake caliper bracket onlo the guide CALIPER BRACKET of the swingarm. Coat the axle surface with thin layer of grease. Be ci,reful not to damage the brake Place the rear wheel in the swingarm so the brake pads and speed disc is positioned between the brake pads.
  • Page 409 REAR WHEEL/SUSPENSION Release the drive chain case slit from the boss of swingarm. Remove the shock absorber lower mounting bolt/ nut. Remove the shock absorber upper mounting bolt/ nut and lhe shock absorber. INSPECTION Check the damper unit for leakage or other damage. Check the upper bushing for wear or damage.
  • Page 410 REAR WHEEL/SUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the damper case to mark the drilling point. Wrap the shock absorber inside a plastic bag. Support the shock absorber upright in a vise as shown. Through the open end of the bag, insert a drill motor with a sharp 2 (5/64 1/8 in) drill bit.
  • Page 411 REAR WHEEL/SUSPENSION Make sure the needle rollers in the bearing are in position. Apply grease to new dust seal lips. Install the dust seals with the flat surface facing out until they are flush with the lower pivot surface. Install the pivot collar. COLLAR ..
  • Page 412 REAR WHEEL/SUSPENSION Install the rear brake fluid reservoir and tighten the boll to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf.ft) Install the following: - rear wheel (page 14-13) - side covers (page 2-4) SWINGARM REMOVAL Support the motorcycle using a safety stand or a hoist, raise the rear wheel off the ground.
  • Page 413 REAR WHEEL/SUSPENSION Remove the shock absorber lower mounting bolt/ nut. Loosen the pivot bracket nuts. Remove the swingarm pivot nut and washer. Slightly pull the pivot bracket outward. Remove the swingarm pivot bolt and swingarm. DISASSEMBLY /INSPECTION Remove the bolts, washers and drive chain slider. SN/ASHERS Check the drive chain slider for wear or damage.
  • Page 414 REAR WHEEL/SUSPENSION Remove the pivot collar and dust seals from the swingarm left pivot. Check the dust seals and collar for damage or fatigue. Check the needle bearing for damage. DUST SEALS Remove the pivot collars and dust seals from the swingarm right pivot.
  • Page 415 REAR WHEEUSUSPENSION Remove the right pivot radial ball bearings out using the special tool. TOOLS: Bearing remover shaft. 20 mm 07936-3710600 07936-3710100 Remover shaft handle BEARING Remover weight 07741-0010201 REMOVER BALL BEARINGS Press the left pivot needle bearing out using the DRIVER SHAFT special tools and a hydraulic press.
  • Page 416 REAR WHEEL/SUSPENSION Install the snap ring into the right swingarm pivot groove securely. ASSEMBLY �� r� � DUST SEAL RIGHT PIVOT BEARINGS (20X37X91 � � PIVOTCOL SNAP RING PIVOT COLLAR 8 ► .r-uml' DUST SEAL �--umt' DUSTSEAL ... �� ��...
  • Page 417 REAR WHEEL/SUSPENSION Make sure the needle rollers in the bearing are in position. Apply grease to new dust seal lips. Install the dust seals with the flat surface facing out until they are flush with the pivot outer surface. Install the pivot collar. DUST SEALS Install the drive chain slider, aligning the slit with BOSSES/HOLES...
  • Page 418 REAR WHEEL/SUSPENSION Install the washer and swingarm pivot nut. Tighten the pivot bracket nuts to the specified torque. TORQUE: 69 N-m (7.0 kgf-m, 51 lbf•ft) Tighten the swingarm pivot nut to the specified torque. TORQUE: 98 N-m 110.0 kgf-m. 72 lbf-ftl Move the swingarm up and down several times and make sure it moves smoothly.
  • Page 419 REAR WHEEL/SUSPENSION Install the brake hose clamps and tighten the screws to the special torque. TORQUE: 4.2 N•m (0.4 kgf•m, 3.1 lbf·ft) Install the drive chain case aligning its slit with the DRIVE CH boss on the swingarm. Tighten the drive chain case bolts to the specified torque.
  • Page 420 15. HYDRAULIC BRAKE FRONT MASTER CYLINDER · · ····· ····· · ··· · · 15 -21 SYSTEM CO MPONENTS ·· ···· · . . •••••••••••••• .. 15- 2 SERVICE INFORMATION · · ···· ········ ··········· 15 - 4 REAR MASTER CYLINDER/ BRAKE PEDAL ··...
  • Page 421 HYDRAULIC BRAKE SYSTEM COMPONENTS 12 N·m (1.2 kgf·m, 9 lbf.ft) 34N·m (3 . 5 kgf•m, 25 !bf.ft) CB600FA: CB600F: 34 N•m (3.5 kgf•m, 34 N•m (3.5 kgf•m, 25 lbf-ft) �, � @'® 17 N-m "''•�, I� 2.5 N·m (0.3 kgf-m, 1 .8 lbf·ft) 17 N·m (1.7 kgf•m, 13 lbf .
  • Page 422 HYDRAULIC BRAKE C8600F: C8600FA: 17 N-m (1.7 kgf-m, 34 N•m (3.5 kgf-m, 13 lbf·ft) 25 lbf•ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) � \o/t 22 N•m (2.2 kgf-m, 16 lbf·ft) 15-3...
  • Page 423 HYDRAULIC BRAKE SERVICE INFORMATION GENERAL ACAUTION Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush clean brake assemblies. Use and OSHA-approved vacuum cleaner. NOTICE Spilled brake fluid will severely damage instrument lenses and painted surfaces.
  • Page 424 HYDRAULIC BRAKE TORQUE VALUES Brake hose oil bolt 34 N·m (3.5 kgf-m, 25 lbf·ft) Front brake caliper mounting bolt 30 N•m (3.1 kgf,m, 22 lbf·ft) ALOC bolt; replace with a new one. Caliper bleed valve 5.4 N-m (0.6 kgf,m, 4.0 lbf•ft) Brake pad pin 17 N·m (1.7 kgf•m, 13 lbf·ft) Pad pin plug (CB600F)
  • Page 425 HYDRAULIC BRAKE TROUBLESHOOTING Brake lever/pedal soft or spongy • Air in hydraulic system • Leaking hydraulic system • Contaminated brake pad/disc • Worn caliper piston seals • Worn master cylinder piston cups • Worn brake pad/disc • Contaminated caliper • Contaminated master cylinder •...

  • Page 426: Brake Fluid Replacement

    HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/ AIR BLEEDING (CB600FA) BRAKE FLUID DRAINING NOTICE $pilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. NOTE: • Do not allow foreign material to enter the system when filling the reservoir.
  • Page 427 HYDRAULIC BRAKE Pedal (Combined) Brake Line: Remove the right side cover (page 2·4). Remove the reservoir mounting bolt. Remove the reservoir cap, set plate and diaphragm. Secure the reservoir with the mounting bolt. Connect a bleed hose to the right front caliper cen­ ter bleed valve.
  • Page 428 HYDRAULIC BRAKE Connect a commercially available brake bleeder to the left caliper bleed valve. Operate the brake bleeder and loosen the bleed valve. NOTE: • If an automatic refill system is not used, add brake fluid when the fluid level in the reservoir is low.
  • Page 429 HYDRAULIC BRAKE 1. Squeeze the brake lever, open the bleed valve 1/4 of a turn and then close it. 2. Release the brake lever slowly and wait several seconds after it reaches the end of its travel. • Do not release the lever until the bleed valve has been closed.
  • Page 430 HYDRAULIC BRAKE Install the diaphragm and set plate. SCREWS Install the reservoir cap and tighten the screws to the specified torque. TORQUE: 1.5 N•m (0.2 kgf•m, 1.1 lbf•ft) REAR (COMBINED) BRAKE FLUID FILLING/ AIR BLEEDING Brake Fluid Feeding: Add fluid and bleed any air from the pedal brake .---..,,.,.,,.,.,,...,..__ line in the sequence as follow: 1.

  • Page 431: Air Bleeding (Cb600F A )

    HYDRAULIC BRAKE If a brake bleeder is not available, perform the fol­ lowing procedure. Connect a bleed hose to the right front caliper cen­ ter bleed valve. 1. Pump the brake pedal several (5 times quickly, then push the brake pedal all the way down, loosen the right front caliper center bleed valve 1/4 of a turn.

  • Page 432: Brake Fluid Replacement

    HYDRAULIC BRAKE After there are no more air bubbles in the fluid, repeat the air bleeding procedure about two or three times at each bleed valve. Make sure the bleed valves are closed and operate the brake pedal. If it still feels spongy, bleed the sys­ tem again.
  • Page 433 HYDRAULIC BRAKE BRAKE FLUID FILLING/ AIR BLEEDING Close the bleed valve. Fill the reservoir with DOT 4 brake fluid from a sealed container. Connect a commercially available brake bleeder to the bleed valve. Operate the brake bleeder and loosen the bleed valve.

  • Page 434: Brake Pad/Disc

    HYDRAULIC BRAKE Fill the front brake reservoir to the upper level line UPPER LEVEL LINE (casting ledge) with DOT 4 brake fluid. (CASTING LEDGE) Install the diaphragm, set plate and reservoir cap, then tighten the screws to the specified torque. TORQUE: 1.5 N•m (0.2 kgf•m, 1.1 lbf•ft) Fill the rear brake reservoir to the upper level line with DOT 4 brake fluid.
  • Page 435 HYDRAULIC BRAKE Loosen the pad pin. Pull the pad pin out of the caliper body while hold­ ing the brake pads. Remove the brake pads. Make sure that the pad spring is in place. Install new brake pads into the caliper so their ends Always replace the rest into the pad retainer on the bracket properly.
  • Page 436 HYDRAULIC BRAKE Remove the pad pin plug. Remove the pad pin and brake pads. Make sure that the pad spring is in place. Always replace the Install the new brake pads. brake p;;ds in p;;irs Push the brake pads against the pad spring, then to assure even disc install the pad pin.
  • Page 437 HYDRAULIC BRAKE Loosen the pad pin. Remove the caliper mounting bolt. Pull the pad pin out of the caliper body while hold­ ing the brake pads. Pivot the caliper up. Remove the brake pads. Make sure that the pad spring is in place. rhe Install new brake pads into the caliper so their ends Always replace rest into the pad retainer on the bracket properly.
  • Page 438 HYDRAULIC BRAKE REAR BRAKE PAD REPLACEMENT (CB600F) Push the caliper piston all the way in to allow instal­ Check the brake lation of new brake pads by pushing the caliper • - • --'"'­ flu1d level m the body inward. reservo,r 1h,s operation causes...
  • Page 439 HYDRAULIC BRAKE Tighten the pad pin to the specified torque. TORQUE: 17 N-m (1.7 kgf-m, 13 lbf-ft) Operate the brake pedal to seat the caliper piston against the pads. BRAKE DISC INSPECTION Visually inspect the disc for damage or cracks. Measure the brake disc thickness at several points.

  • Page 440: Front Master Cylinder

    HYDRAULIC BRAKE FRONT MASTER CYLINDER REMOVAL NOTE: • Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. Drain the brake fluid from the front brake hydraulic SEALING WASHERS OIL BOLT system (page 15-7).
  • Page 441 HYDRAULIC BRAKE Remove the screw and brake light switch. SCREW SWITCH Remove the boot. BOOT Remove the snap ring from the master cylinder body using the special tool. TOOL: 07914-SA50001 Snap ring pliers Remove the master piston and spring. MASTER CYLINDER Clean the inside or the master cylinder, reservoir and the master piston in clean brake fluid.
  • Page 442 HYDRAULIC BRAKE INSPECTION Check the piston cups and boot for wear, deteriora­ tion or damage. Check the spring for fatigue or damage. Check the master cylinder and piston for scoring, scratches or damage. Measure the master cylinder I.D. SERVICE LIMIT: 12.755 mm (0.5022 in) Measure the master piston O.D.
  • Page 443 HYDRAULIC BRAKE Install the snap ring into the groove in the master Make sure rhe snap cylinder. rmg ,s seated f1tm/y m the groove. TOOL: Snap ring pliers 07914-SA50001 Apply silicone grease inside the boot. Install the boot into the master cylinder and the pis­ ton groove.
  • Page 444 HYDRAULIC BRAKE Apply silicone grease to the brake lever pivot bolt � PIVOT BOLT sliding surface. Install the brake lever and pivot bolt, and tighten it. TORQUE: 1.0 N•m (0.1 kgf•m, 0.7 lbf•ft) Install the nut and tighten it while holding the pivot bolt.
  • Page 445 HYDRAULIC BRAKE Release the rear brake light switch wire from the clamp of footpeg bracket. Remove the oil bolt and sealing washers. Remove the muffler mounting bolt/nut, washer and collar. Loosen the rear master cylinder mounting bolts. Remove the bolts and footpeg bracket. Remove the rear master cylinder mounting bolts.

  • Page 446: Brake Pedal

    HYDRAULIC BRAKE Remove the return springs. Remove the rear brake light switch. Remove the cotter pin. RETURN SPRINGS COTTER PIN Remove the joint pin and rear master cylinder. MASTER CYLINDER JOINT PIN Remove the snap ring, washer and brake pedal. BRAKE PEDAL SNAP RING MASTER CYLINDER DISASSEMBLY...
  • Page 447 HYDRAULIC BRAKE Pull the boot out of the master cylinder and remove the snap ring using the special tool. TOOL: Snap ring pliers 07914-SA50001 Remove the push rod. master piston, primary cup and spring. SNAP RING INSPECTION Clean inside of the master cylinder and the master CB600FA: piston with clean brake fluid.
  • Page 448 HYDRAULIC BRAKE Measure the master cylinder I.D. CB600F: CB600F· SERVICE LIMIT: 12.755 mm (0.5022 in) Measure the master piston O.D. SERVICE LIMIT: 12.645 mm (0.4978 in) MASTER CYLINDER ASSEMBLY C8600FA shown: ,,,,,--- · RESERVOIR HOSE JOINT RESERVOIR CBFG00F: SPRING -------- SPRING MASTER Pl �...
  • Page 449 HYDRAULIC BRAKE Apply silicone grease to the piston contacting sur­ CB600F only: face of the push rod. PUSH ROD ASSEMBLY C8600F only: MASTER PISTON Coat the master piston and piston cups with clean CB600F: brake fluid. SPRING C8600F: Install the spring onto the master piston. Install the spring/master piston with the push rod 10 into the master cylinder.
  • Page 450 HYDRAULIC BRAKE Coat a new O-ring with brake fluid and install it onto the reservoir hose joint. Install the hose joint into the master cylinder. Apply a locking agent to the hose joint screw threads. Install the screw and tighten it to the specified torque.
  • Page 451 HYDRAULIC BRAKE Secure the master cylinder with a new cotter pin. Install the rear brake light switch into the stay on the bracket. Install the switch spring and brake pedal return spring in the direction as shown..$� RETURN SPRINGS COTTER PIN Install the rear master cylinder mounting bolts.
  • Page 452 HYDRAULIC BRAKE Secure the brake light switch wire with the clamp. Connect the rear brake light switch 2P (black) con­ nector. Fill and bleed the hydraulic system: - CB600FA (page 15-7) - CB600F (page 15-13) FRONT BRAKE CALIPER (CBG00FA) REMOVAL Drain the brake fluid from the hydraulic system ---------w (page 15-7).
  • Page 453 HYDRAULIC BRAKE Remove the mounting bolts and brake caliper. DISASSEMBLY Remove the caliper bracket from the caliper body. CALIPER BODY Remove the pad spring and bracket pin boot from the caliper body. Remove the caliper pin boot from the caliper bracket.
  • Page 454 HYDRAULIC BRAKE INSPECTION Check the caliper cylinders and pistons for scoring, scratches or damage. Measure each caliper cylinder I.D. SERVICE LIMIT: 22.710 mm (0.8941 in) Measure each caliper piston O.D. SERVICE LIMIT: 22.560 mm (0.8882 in) ASSEMBLY BLEED VALVES o,:::;;:' 4.0 lbf .
  • Page 455 HYDRAULIC BRAKE Coat new piston seals with clean brake fluid and PISTON SEALS install them into the seal grooves in the caliper. Coat new dust seals with silicone grease and install 5 � � �- them into the seal grooves in the caliper. DUST SEALS Coat the caliper pistons with clean brake fluid and Install the shone,...

  • Page 456: Front Brake Caliper (Cb600Fa)

    HYDRAULIC BRAKE Connect the brake hoses to the caliper with the oil bolts and new sealing washers. Push the stopper or the brake hose eyelet joint against the caliper body, then tighten the oil bolts to the specified torque. TORQUE: 34 N•m (3.5 kgf-m, 25 lbf•ft) Install the brake pads (page 15-15).
  • Page 457 HYDRAULIC BRAKE Remove the caliper pin boot from the caliper CALIPER BRACKET bracket. If the caliper pin boot is hard or deteriorated, replace it with a new one. BOOT Remove the pad spring and bracket pin boot from the caliper body. BOOT If the bracket pin boot is hard or deteriorated, replace it with a new one.
  • Page 458 HYDRAULIC BRAKE INSPECTION Check the caliper cylinders and pistons for scoring, scratches or damage. Measure each caliper cylinder I.D. SERVICE LIMIT: 25.460 mm (1.0024 in) Measure each caliper piston O.D. SERVICE LIMIT: 25.310 mm (0.9965 in) ASSEMBLY PAD REATAINER BLEED VALVE ...-6 5.4 N·m (0.6 kgf·m, PISTONS...
  • Page 459 HYDRAULIC BRAKE Coat new piston seals with clean brake fluid and install them into the seal grooves in the caliper. Coat new dust seals with silicone grease and Install them into the seal grooves in the caliper. Coat the caliper pistons with clean brake fluid and install them into the caliper cylinders with the open­...

  • Page 460: Rear Brake Caliper (Cb600Fa)

    HYDRAULIC BRAKE INSTALLATION Install the brake caliper with new mounting bolts. Tighten the mounting bolts to the specified torque. TORQUE: 30 N•m (3.1 kgf-m, 22 lbf-ft) Hold rhe brake Connect the brake hose to the caliper with the oil hose in the stopper bolt and new sealing washers.
  • Page 461 HYDRAULIC BRAKE DISASSEMBLY Remove the slide pin boot from the caliper bracket. If the boot is hard, damaged or deteriorated, replace it with a new one. Remove the pad spring, collar and bracket pin boot BOOT COLLAR from the caliper body. If the boot is hard, damaged or deteriorated, replace it with a new one.
  • Page 462 HYDRAULIC BRAKE INSPECTION Check the caliper cylinders and pistons for scoring, scratches or damage. Measure each caliper cylinder I.D. SERVICE LIMIT: 38.24 mm (1.506 in) Measure each caliper piston O.D. SERVICE LIMIT: 38.09 mm (1.500 in) ASSEMBLY s� �..m ���...
  • Page 463 HYDRAULIC BRAKE Apply silicone grease to the inside of bracket pin COLLAR boot. � Install the boot and collar into the caliper body. BOOT Install the pad spring onto the caliper body properly as shown. CALIPER BODY PAD SPRING Check that the pad retainer is in place on the caliper .--- ..-----u­ bracket.

  • Page 464: Rear Brake Caliper (Cb600F)

    HYDRAULIC BRAKE REAR BRAKE CALIPER (CB600F) REMOVAL Drain the rear brake hydraulic system (page 15-13). Remove the rear brake pads (page 15-19). Remove the oil bolt and sealing washers. Remove the rear wheel (page 14-7). Remove the rear brake caliper with the caliper bracket.
  • Page 465 HYDRAULIC BRAKE Push the dust seal and piston seal in and lift them Be careful not to PISTON SEAL out. damage the p,sron sliding surface Clean the seal grooves, caliper cylinder and piston with clean brake fluid. DUST SEAL INSPECTION Check the caliper cylinder and piston for scoring, scratches or damage.
  • Page 466 HYDRAULIC BRAKE ASSEMBLY PAD SPRING PAD RETAINER � CALIPER BRACKET BLEED VALVE 5.4 N·m (0.6 kgf·m, 4.0 lbf . ft) CALIPER a PISTON SEAL PAD SPRING �· ®" Coat a new piston seal with clean brake fluid and install it in the seal groove in the caliper. PISTON SEAL Coat a new dust seal with silicone grease and install it in the seal groove in the caliper.
  • Page 467 HYDRAULIC BRAKE Install the boot into the caliper. Install the pad spring onto the caliper body properly as shown. PAD SPRING Apply silicone grease to the inside of the boots and the slide pins. BRACKET Install the caliper bracket over the caliper body. PAD SPRING CALIPER BODY INSTALLATION...
  • Page 468 16. ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA} ABS TROUBLESHOOTING ··· · ··· · ········ ..1 6- 11 ABS SYSTEM LOCATION ················ ····· · ·· 16-2 ABS SYSTEM DIAGRAM •••••• •• •• •• ••••••• •• •• •• 1 6- 3 ABS INDICATOR CIRCU I T TRO UBL ESHO OTI NG •·······...

  • Page 469: Abs System Location

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) ABS SYSTEM LOCATION FRONT WHEEL SPEED SENSOR 2P (Blue) CONNECTOR ABS MODULATOR 25P CONNECTOR REAR WHEEL SPEED SENSOR 2P (Green) CONNECTOR ABS MODULATOR REAR WHEEL SPEED SENSOR ABS SERVICE CHECK CONNECTOR 16-2...

  • Page 470: Abs System Diagram

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) ABS SYSTEM DIAGRAM ......ABS Indicator Me1er Fuse Bl/Br Brake Switches 4 STOP LAMP SW Electronic Control Unit (ABS-ECU) ABS Main Ignition R/81 Fuso WARN IND 7 R/Br 61 /62 16 IGN POWER ABS Motor Pump Fuse 51/52/53...

  • Page 471: Service Information

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) SERVICE INFORMATION GENERAL • This section covers service of the Anti-lock Brake System (ABS). For conventional brake service, see page 15-2. • When the ABS control unit detects a problem, it stops the ABS function and switches back to the conventional brake operation.

  • Page 472: Abs Connector Locations

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) ABS CONNECTOR LOCATIONS NOTE 1: Lift and support the fuel tank (page 3-5). FRONT WHEEL SPEED SENSOR 2P (Blue) CONNECTOR (NOTE 1) Sensor side: W rn Main harness side: NOTE 2: Remove the seat (page 2-4). ABS FUSE BOX 4P CONNECTOR (NOTE 2) I LJ l...
  • Page 473 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) ABS MODULATOR 25P CONNECTOR (NOTE 2) NOTE 3: Remove the right side cover (page 2-4). REAR WHEEL SPEED SENSOR 2P (Green) CONNECTOR (NOTE3} Sensor side: Main harness side: 16-6...

  • Page 474: Abs Troubleshooting Information

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) ABS TROUBLESHOOTING INFORMATION SYSTEM DESCRIPTION ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When there is any abnormality, the problem and the problematic part can be detected by outputting the problem code. When the vehicle speed is approximately 6 km/h (4 mph) or more, the wheel speed sensor signal is sent to the ABS control unit, then the pre-start self-diagnosis system operates the pump motor (inside the modulator) and detects whether the hydraulic operation is normal, and it completes the pre-start self-diagnosis.
  • Page 475 ANTI-LOCK BRAKE SYSTEM (ABS; C8600FA) PROBLEM CODE INDICATION PATTERN • The ABS indicator indicates the problem code by blinking a specified number of times. The indicator has two types of blinks. a long blink and short blink. The long blink lasts for 1.3 sec­ onds, the short blink lasts for 0.3 seconds.
  • Page 476 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) Turn the ignition switch to "ON". The ABS indica­ Do not apply the tor should come on 2 seconds (start signal) (then fronr or rear brake goes off 3.6 seconds) and starts problem code during reroeval. indication.

  • Page 477: Abs Problem Code Index

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) ABS PROBLEM CODE INDEX NOTE: • The ABS indicator might blink in the following cases. Correct the faulty part. Incorrect tire pressure. - Tires not recommended for the motorcycle were installed (incorrect tire size). - Deformation of the wheel or tire. •...

  • Page 478: Abs Troubleshooting

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) ABS TROUBLESHOOTING NOTE: • Perform inspection with the ignition switch turned to "OFF", unless otherwise specified. • Refer to the ABS Connector Locations (page 16· 5). All connector diagrams in the troubleshooting are viewed from the terminal side. •...
  • Page 479 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) 3. Speed Sensor Line Short Circuit Inspection (at control unit side) Lift and support the fuel tank (page 3-5). MODULATOR 25P CONNECTOR Disconnect the ABS modulator 25P connector (Wire side/female terminals) and the speed sensor 2P (Blue) connector. Check for continuity between the Yellow/black wire terminal of the connector and ground, and between the Green/orange #3 wire terminal of...
  • Page 480 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) 6. Failure Reproduction with a New Speed Sensor Replace the front wheel speed sensor with a new ,--------------------. ABS INDICATOR one (page 16-24). Connect the ABS modulator 25P connector. Erase the problem code (page 16-9). Perform the pre-start self-diagnosis and check «:/ �...
  • Page 481 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) 3. Speed Sensor Line Short Circuit Inspection (at control unit side) Remove the following: MODULATOR 25P CONNECTOR - seat (page 2-4) (Wire side/female terminals) - right side cover (page 2-4) Disconnect the ABS modulator 25P connector and the speed sensor 2P (Green) connector.
  • Page 482 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) 6. Failure Reproduction with a New Speed Sensor Replace the rear wheel speed sensor with new ABS INDICATOR one (page 16-24). ¼ Connect the ABS modulator 25P connector. Erase the problem code (page 16-9). Perform the pre-start self-diagnosis and check the ABS indicator (page 16-7).
  • Page 483 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) 2. Motor Power Input Line Short Circuit Inspection Disconnect the ABS modulator 25P connector. MODULATOR 25P CONNECTOR Check for continuity between the Red wire termi­ (Wire side/the female terminals) nal of the 25P connector and ground with "ABS MOTOR"...
  • Page 484 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) 5. Failure Reproduction Connect the ABS modulator 25P connector. Erase the problem code {page 16-9). Perform the pre-start self-diagnosis (page 16-7). Retrieve the problem code {page 16-8). Does the indicator indicate the code "51, 52, or 53"7 - Faulty ABS modulator.
  • Page 485 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) 3. Relay Power Input Line Open Circuit Inspection (at control unit side) Install the "ABS FAIL-SAFE RELAY" fuse. MODULATOR 25P CONNECTOR Disconnect the ABS modulator 25P connector. (Wire side/female terminals) Measure the voltage between Black wire termi­ nal (+) of the 25P connector and ground (-).
  • Page 486 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) PROBLEM CODE 61 or 62 (Power Circuit) 1. Fuse Inspection Remove the seat (page 2-4). Check the "'ABS MAIN" fuse (10A) in the ABS main fuse box for blown. Is the fuse blown? - GO TO STEP 2. - GO TO STEP 3.
  • Page 487 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) 4. Failure Reproduction Connect the ABS modulator 25P connector. Erase the problem code (page 16-9). Perform the pre-start self-diagnosis (page 16-7). Retrieve the problem code (page 16-8). Does the indicator indicate the code "61 or 62"7 - Faulty ABS modulator.

  • Page 488: Abs Indicator Circuit

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) ABS INDICATOR CIRCUIT TROUBLESHOOTING ABS INDICATOR DOES NOT COME ON (when the ignition switch turned to "ON") 1. Combination Meter Power/Ground Line Inspection Check the combination meter power and ground lines (page 20-12). Are the wires normal? GO TO STEP 2.
  • Page 489 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA} 2. Power Input Line Short Circuit Inspection Disconnect the ABS modulator 25P connector. MODULATOR 25P CONNECTOR Check. for continuity between the Red/brown (Wfro ,;d,Ifomal "mio,lsl wire terminal of the 25P connector and body ground with "ABS MAIN" fuse removed. T OOL: Test probe 07ZAJ-RDJA 110...
  • Page 490 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA} 5. Indicator Operation Inspection Remove the meter cover (page 2-5). Remove the dust cover. With the connector connected, short the Red/ black wire terminal of the combination meter 20P connector and ground with a jumper wire. Check the ABS indicator with the ignition switch turned to "ON".

  • Page 491: Wheel Speed Sensor

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) WHEEL SPEED SENSOR AIR GAP INSPECTION Support the motorcycle securely using a hoist or ron • t· equivalent and raise the wheel off the ground. Measure the clearance (air gap) between the sensor and pulser ring at several points by turning the wheel slowly.
  • Page 492 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) • Release the sensor wire clips. Remove the wheel speed sensor mounting bolts and guide. Remove the wheel speed sensor from the caliper bracket. Clean around the mounting area of the caliper bracket thoroughly, and be sure that no foreign material is allowed to enter the mounting hole.

  • Page 493: Abs Modulator

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) Release the sensor wire clips from the caliper bracket. Remove the wheel speed sensor mounting bolts and guide. Remove the wheel speed sensor from the caliper bracket. Clean around the mounting area of the caliper bracket thoroughly, and be sure that no foreign material is allowed to enter the mounting hole.
  • Page 494 ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) Remove the modulator side mounting bolt/washer. Remove the modulator lower mounting bolts. Remove the ABS modulator from the stay (so the Be careful not to modulator is not interfere with the brake pipes). bend or damage the brake pipes durmg removal.

  • Page 495: Pcv

    ANTI-LOCK BRAKE SYSTEM (ABS; CB600FA) Installation is in the reverse order of removal by loosely tightening all the fasteners. NOTE: • Apply brake fluid to the brake pipe joint nut threads. Tighten the modulator lower mounting bolt and side mounting bolt/washer securely. Tighten the brake pipe joint nuts to the specified torque.
  • Page 496 17. BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM ···················· ·············· l7-2 CHARGING SYSTEM INSPECTION • • ······· l 7-7 SERVICE INFORMATIO N ···················· ···· • 17-3 ALTERNATO R CHARGING COIL ············· l 7- 8 TROU B LESHOOTING ························ ······· 17-5 REGU LATOR /REC T I F IE R ·········· ···· ·········· · 17- 8 B ATTERY ·····...

  • Page 497: System Diagram

    BATTERY /CHARGING SYSTEM SYSTEM DIAGRAM MAIN FUSE (30 A) r-.o- BATTERY REGULATOR/RECTIFIER R ..RED ALTERNATOR Y ..YELLOW ..GREEN 17-2...
  • Page 498 BATTERY /CHARGING SYSTEM SERVICE INFORMATION GENERAL A.WARNING • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
  • Page 499 BATTERY /CHARGING SYSTEM SPECIFICATIONS SPECIFICATIONS ITEM Capacity 12V-8.6Ah Battery 2.0 mA max. Current leakage Voltage 13.0-13.2 V Fully charged c168 ° ° Below 12.3 V Needs charging Charging current Normal 0.8 A/5-10 h 4.5 A/1 h Quick Alternator Capacity 0.333 kW/5,000 min•• (rpm) Charging coil resistance (20 C/68 0.1-1.on...
  • Page 500 BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. BATTERY TEST Remove the battery {page 17-6). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210 or BATTERY MATE or equivalent Is the battery in good condition? - GO TO STEP 2.
  • Page 501 BATTERY /CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the seat (page 2-4). Always rum the 19nit1on switch OFF Unhook the battery holder band and remove the before removing rubber cover. the battery Remove the negative terminal screw, then discon- �� ... --� nect the negative cable from the battery negative terminal.

  • Page 502: Charging System Inspection

    BATTERY /CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the seat (page 2-4). Do not disconnect Turn the ignition switch and disconnect the the battery or any negative battery cable from the battery. cable 1n the Connect the ammeter (+) probe to the negative charging system cable and the ammeter H probe to the battery H without f,rst...

  • Page 503: Alternator Charging Coil

    BATTERY /CHARGING SYSTEM ALTERNATOR CHARGING COIL INSPECTION is nor necessary Disconnect the alternator 3P (Black) connector (page remove the 17-9). stator coil to make Check the resistance between all three Yellow termi­ th,s test nals. STANDARD: 0.1 (at 20 C/68 °...
  • Page 504 BATTERY /CHARGING SYSTEM REMOVAL/INSTALLATION Remove the seat (page 2-4). Remove the stay bolts. Disconnect the regulator/rectifier 2P (Black) and alternator 3P (Black) connectors. Remove the mounting bolts. washers. collars, nuts and regulator/rectifier from the stay. Install the regulator/rectifier in the reverse order of removal.
  • Page 505 18. IGNITION SYSTEM SYSTEM DIAGRAM• .. ···· ......18-2 C K P S E NS OR ············································ 18-7 IGNITION COIL · · ··· ·································· ·· 18-7 TRO UBLESHOO TING ······················ ········· 18-4 IGNITION TIM ING ·· ················ ·················· 18-7 18-1...
  • Page 506 IGNITION SYSTEM SYSTEM DIAGRAM IGNITION SWITCH ENGINE STOP SWITCH FUSE BOX/DIODE BATTERY IGNITION NEUTRAL SWITCH SIDESTAND SWITCH �-------� SIOESTANO SWITCH ENGINE STOP RELAY UP � � ENGINE STOP l SVl�TCH DONN� CLUTCH SW ITCH PGM•fl W /8I FUSE T o Ban� angle (20A) S l.
  • Page 507 IGNITION SYSTEM SERVICE INFORMATION GENERAL NOTICE • The ECM may be damaged if dropped. Also if the connector disconnected when current flowing, the excessive volt­ age may damage the module. Always turn off the Ignition switch before servicing. Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine. •...
  • Page 508 IGNITION SYSTEM TROUBLESHOOTING • Inspect the following before diagnosing the system. Faulty spark plug - Loose spark plug cap connection Loose ignition coil connectors Water got into the spark plug cap (shorting the ignition coil secondary voltage) • there is no spark at any cylinder, temporarily exchange the ignition coil with the other good one and perform the spark test.
  • Page 509 IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark at any plug, check all connec• tions for loose or poor contact before measuring each peak voltage. • Use recommended digital multimeter or com­ mercially available digital multimeter with an impedance of 10 MO/DCV minimum.
  • Page 510 IGNITION SYSTEM Avoid rouching rhe Turn the ignition switch ON and engine stop switch Check for initial voltage at this time. "0 ". spark plugs and T he battery voltage should be measured. tester probes to If the initial voltage cannot be measured, check the prevenr electric power supply circuit {refer to the troubleshooting, shock.
  • Page 511 IGNITION SYSTEM CKP SENSOR REPLACEMENT Remove the right crankcase cover (page 9-S). CKP SENSOR Remove the wire grommet from the cover. Remove the bolts and CKP sensor. Install the new CKP sensor and tighten the mount­ ing bolts securely. Route the CKP sensor wire into the groove of the right crankcase cover.
  • Page 512 IGNITION SYSTEM Connect the timing light to the No.1 spark plug wire. Read the instructions for timmg light operation. Start the engine and let it idle. IDLE SPEED: 1,300 ± 100 min•' (rpm) The ignition timing is correct if the "F" mark on the r-�Pl CKP sensor rotor aligns with the index notch on the right crankcase cover at idle.
  • Page 513 19. ELECTRIC STARTER SYSTEM D IAG RAM ······················· ··········· 19-2 STARTER MO TOR ························ ············ 19-6 SER V ICE IN FORMA T ION ·················· ······· 19-3 STARTER RELAY S WITCH ················· ···· 19-15 TRO UBLESHOOTING ······················ ········· 19-4 D IO D E ······················································ 19-17 19-1...
  • Page 514 ELECTRIC STARTER SYSTEM DIAGRAM ENGINE STOP SWITCH STARTER SWITCH """ STARTER RELAY SWITCH/MAIN FUSE 30A FUSE BOX/DIODE BATTERY SIDESTAND SWITCH STARTER RELAY SWITCH STARTER MAIN MOTOR BATTERY FUSE (30AI i '" , �-� IGNITION SWITCH FUSE 10 A CLUTCH � �...
  • Page 515 ELECTRIC ST ARTER SERVICE INFORMATION GENERAL NOTICE If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged. • Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.
  • Page 516 ELECTRIC ST ARTER TROUBLESHOOTING Starter motor does not turn 1. Fuse Inspection Check for blown main fuse or sub fuse. Did the fuse blow? - Replace the fuse - GO TO STEP 2. 2. Battery Inspection Make sure the battery is fully charged and in good condition. Is the battery in good condition? - GO TO STEP 3.
  • Page 517 ELECTRIC STARTER 7. Starter Relay Switch Continuity Inspection Disconnect the starter relay switch 4P connector. Connect a fully charged 12 V battery positive wire to the relay switch Yellow/red wire terminal and negative wire to the Green/red wire terminal. Check the continuity between the starter relay switch large terminals while the battery connected. Is there continuity? - Loose or poor contact of the starter relay switch 4P connector - Faulty starter relay switch...
  • Page 518 ELECTRIC ST ARTER STARTER MOTOR REMOVAL • With the ignition switch OFF, remove the nega­ tive cable at the battery before servicing the starter motor. Remove the following: - air cleaner housing (page 5-61) thermostat (page 6-8) Remove the bolts, water hose joint and O-ring. Open the rubber cap, then remove the terminal nut and starter motor cable from the starter motor.
  • Page 519 ELECTRIC STARTER DISASSEMBL V Remove the starter motor case bolts. CASE BOLTS Remove the front cover and seal ring. SEAL RING FRONT COVER STARTER M OR CASE Remove the starter motor case and seal ring. REAR COVER Remove the armature from the rear cover. ARMATURE SEAL RING Remove the brushes and springs from the brush...
  • Page 520 ELECTRIC STARTER Check for continuity between starter motor cable Continuity: terminal and positive brushes. There should be continuity. POSITIVE BRUSHES Check for continuity between positive brushes (ter- No continuity: NEGATIVE BRUSHES minal bolt side) and rear cover. There should be no continuity. Check for continuity between positive and negative brushes.
  • Page 521 ELECTRIC ST ARTER Remove the washer, insulator, terminal stopper and TERMINAL STOPPER 0-ring from the rear cover. WASHER INSULATOR 0-RING Remove the brush holder assembly from the rear TERMINAL BOLT cover. Release the brush plate from the brush holder by turning the terminal bolt.
  • Page 522 ELECTRIC STARTER Check the commutator for damage or abnormal ARMATURE wear. Check the commutator bar for discoloration. Do not use emery or sand paper on Clean the metallic debris off between commutator bars. the commutator. Replace the armature with a new one if necessary. COMMUTATOR Check for continuity between pairs of commutator Continuity:...
  • Page 523 ELECTRIC STARTER • Chee k the bushing of the rear co ver for wear or BUSHING damage. ASSEMBLY �� CASE BOLTS 0-RING POSITIVE BRUSHES PR� ARMATURE TERMINAL BOLT � SCREW/WASHER NEGATIVE BRUSHES ..� 0-RING INSULATOR TERM INAL STOPPER Assem h holder, positive ble the brus brushes and...
  • Page 524 ELECTRIC ST ARTER Lock the brush plate to the brush holder by turning TERMINAL BOLT the terminal bolt. Install the brush holder assembly into the rear cover. BRUSH HOLDER Install a new O-ring, terminal stopper, insulator and TERMINAL STOPPER REAR COVER washer.
  • Page 525 ELECTRIC STARTER Install the brush springs to the brush holder. SPRINGS Set the brushes to the brush holder. BRUSHES Install the armature to the rear cover. Install a new seal ring to the starter motor case. Install the starter motor case with its groove with �...
  • Page 526 ELECTRIC ST ARTER Install a new seal ring to the starter motor case. Install the front cover to the starter motor case. � SEAL RING NOTE: When installing the front cover, take care to prevent damaging the oil seal lip with the armature shaft. FRONT COVER Align the index marks on the front cover, starter motor case and rear cover.
  • Page 527 ELECTRIC ST ARTER Install the starter motor into the crankcase. Install the ground cable and mounting bolts, and Roura rho w,ros 1- tighten the bolts securely. properly (page Install the starter motor cable, then tighten the ter­ 23 ) minal nut to the specified torque. TORQUE: 10 N•m (1.0 kgf-m, 7 lbf•ft) Install the rubber cap securely.
  • Page 528 ELECTRIC STARTER ST ARTER RELAY VOLT AGE INSPECTION Connect the starter relay switch 4P connector. Shift the transmission into neutral. Measure the voltage between the Yellow/red wire terminal (+) and body ground(-). If the battery voltage appears only when the starter switch is pushed with the ignition switch ON and "0", engine stop switch...
  • Page 529 ELECTRIC ST ARTER DIODE REMOVAL/INSTALLATION Remove the seat (page 2-4). Open the fuse box and remove the diode. Install the diode in the reverse order of removal. INSPECTION Check for continuity between the diode terminals. When there is continuity, a small resistance value will register.
  • Page 530 20. LIGHTS/METER/SWITCHES SYSTEM LOCATION ··············· ················ ·· 20-2 ENGINE OIL PRESSURE INDICATOR/ EOP SWITCH ·········································· 20-16 SERVICE IN F ORMAT ION •••••••• ••••• •••••••••••• 20-3 FUEL LEVEL INDICATOR ················ ······· 20-17 TRO UBLESHOOT ING ······················· ········ 20-5 FUEL LEVEL SENSOR ················· ··········· 20-18 HEADLIG HT ···············································...

  • Page 531: System Location

    LIGHTS/METER/SWITCHES SYSTEM LOCATION IGNITION SWITCH FRONT BRAKE LIGHT SWITCH LEFT HANDLEBAR SWITCH EOPSWITCH CLUTCH SWITCH SIDESTAND SWITCH 20-2...

  • Page 532: Service Information

    LIGHTS/METER/SWITCHES SERVICE INFORMATION GENERAL NOTICE • A halogen headlight bulb becomes very hot while the headlight is ON, and remain hot for a while after it is turned OFF. Be sure to let it cool down before servicing. • Note the following when replacing the halogen headlight bulb. - Wear clean gloves while replacing the bulb.
  • Page 533 LIGHTS/METE R/SWITCHES TOOLS Imrie dia gnoStic tester { model 625) k volta p tor oo fi,� g 0 7 H G J- • Y available d • • with commerci multimeter(' im p ed nce 10 MJ��� minimum) 20-4...

  • Page 534: Troubleshooting

    LIGHTS/METER/SWITCHES TROUBLESHOOTING VS SENSOR/SPEEDOMETER The speedometer and odometer/trip meter indicates "- - -". Faulty EEPROM in ECM The odometer/trip meter operate normally, but the speedometer does not operate Faulty speedometer in combination meter The speedometer operate normally, but the odometer/trip meter does not operate Faulty odometer/trip meter in combination meter The speedometer operates abnormally 1.

  • Page 535: Headlight

    LIGHTS/METER/SWITCHES HEADLIGHT REMOVAL/INSTALLATION Remove the front cowl (page 2-5). (Gray) 14P (Blue) Remove the mounting bolts. CONNECTOR CONNECTOR Disconnect the headlight (Gray) connector and release the right handlebar switch 14P (Blue) con­ SOCKET BOLT/ nector clip from the headlight unit. WASHER Remove the socket bolt, washer and headlight unit.

  • Page 536: Position Light

    LIGHTS/METER/SWITCHES Install the headlight bulb aligning its tab with the groove in the headlight unit. If you touch the bulb with your bare hands, clean it with cloth moistened with denatured alcohol to pre­ vent early bulb failure. NOTICE Avoid touching the halogen headlight bulb. Finger prints can create hot spots that cause a bulb to break.

  • Page 537: Turn Signal Light

    LIGHTS/METER/SWITCHES TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw. Remove the turn signal lens and seal rubber. While pushing in, turn the bulb counterclockwise to remove it and replace with a new one. Check the seal rubber for fatigue or damage and replace it if necessary.

  • Page 538: Brake/Tail Light

    LIGHTS/METER/SWITCHES REAR TURN SIGNAL LIGHT Remove the rear cowl (page 2-6). Disconnect the rear turn signal light 2P connector. Remove the mounting nut, setting plate and turn signal unit. Installation is in the reverse order of removal. Tighten the mounting nut to the specified torque. TORQUE: 5.0 N·m (0.5 kgf•m, 3.7 lbf·ft) BRAKE/TAIL LIGHT INSPECTION...

  • Page 539: Combination Meter

    LIGHTS/METER/SWITCHES Do not rum the bulb Pull out the license light bulb and replace it with a while removing ir. new one. Install the license light case in the reverse order of removal. Tighten the screws to the specified torque. TORQUE: 1.7 N•m (0.2 kgf•m.
  • Page 540 LIGHTS/METER/SWITCHES Remove the combination meter assembly screws. SCREWS Disassemble the combination meter to the upper, CIRCUIT BOARD lower case and the circuit board. ASSEMBLY Assemble the combination meter in the reverse order of disassembly. LOWER CASE CIRCUIT BOARD UPPER METER COVER SOCKET BOLTS 0.5 N-m (0.1 kgf-m, 0.4 lbf·ft)
  • Page 541 LIGHTS/METER/SWITCHES POWER/GROUND LINE INSPECTION If any indication in the combination meter is abnor­ mal, check the following item. Remove the meter cover (page 2-5). Remove the dust cover. Check the following at the wire harness side con­ nector terminals of the combination meter. Power input line Measure the voltage between lhe Black/brown wire ,----------- -------- -...

  • Page 542: Vs Sensor

    LIGHTS/METER/SWITCHES VS SENSOR SYSTEM INSPECTION Check that the indicators function properly. If they do not function, perform the power and ground line inspection of the combination meter (page 20-12). Remove the meter cover (page 2-5). Remove the dust cover. Support the motorcycle securely using a safety stand or hoist, and raise the rear wheel off the ground.

  • Page 543: Tachometer

    LIGHTS/METER/SWITCHES REMOVAL/INSTALLATION Remove the air cleaner housing (page 5-61 ). Disconnect the VS sensor 3P (Black) connector. Remove the bolt and VS sensor. Check the O-ring is in good condition, replace if nec­ essary. Installation is in the reverse order of removal. TACHOMETER SYSTEM INSPECTION When the ignition switch is turned ON, check that...

  • Page 544: Engine Coolant Temperature

    LIGHTS/METER/SWITCHES Connect the peak voltage adaptor or Imrie diagnos­ tic tester probe to the combination meter 20P con­ Green/black nector Yellow/green Green/black (-) terminals. TOOLS: Imrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with commercially available digital multimedia (impedance 10 Mn/OCV minimum) CONNECTION: Yellow/green (+)

  • Page 545: Engine Oil Pressure Indicator

    LIGHTS/METER/SWITCHES Turn the ignition switch to "ON" and check the WARNING INDICATOR engine coolant temperature and warning indicators. '" \./, \�,.) • If the engine coolant temperature and warning '�\' indicators light as over heat (shown in the right illustration), inspect the ECT sensor (page 20-16). •...

  • Page 546: Fuel Level Indicator

    LIGHTS/METER/SWITCHES Remove the rubber cap, and disconnect the EOP switch wire by removing the terminal bolt. Start the engine, check that the engine oil pressure and warning indicators. • If the indicators come on, check the following. Short circuit the EOP switch (Blue/red) wire - Faulty combination meter •...

  • Page 547: Fuel Level Sensor

    LIGHTS/METER/SWITCHES SHORT CIRCUIT IN THE FUEL LEVEL SYSTEM If the fuel level indicator indicates the right illustra­ tion (full fuel level) in spite of an empty fuel level, check the fuel level system for short circuit. � El,. FUEL LEVEL INDICATOR (FULL POSITION) Lift and support the fuel tank (page 3-5).

  • Page 548: Ignition Switch

    LIGHTS/METER/SWITCHES INSPECTION Check the fuel level sensor and arm for damage. FUEL RESERVE Measure the resistance at the fuel level sensor 2P • ---- SENSOR (Natural) connector terminal with moving the float at the top "F" and bottom "E" position. TOP''F"...

  • Page 549: Handlebar Switches

    LIGHTS/METER/SWITCHES REMOVAL/INSTALLATION Remove the headlight unit (page 20-6). Release the immobilizer receiver 4P (Natural) and ignition switch 2P (Blown) connectors from the meter stay. Disconnect the ignition switch 2P (Brown) connec­ tor. Remove the bolts and ignition switch. Install the ignition switch to the top bridge. Tighten new ignition switch mounting bolts to the specified torque.
  • Page 550 LIGHTS/METER/SWITCHES RIGHT HANDLEBAR SWITCH Check for right handle switch continuity between the wire terminals of the handlebar switch connec­ tor. Continuity should exist between the terminals as follows: RIGHT HANDLEBAR SWITCH: ENGINE STOP SWITCH STARTER SWITCH HAZARD SWITCH COLOR B1/W COLOR Y/R B1/W B1/R Bu/W COLOR Gr LEFT HANDLEBAR SWITCH...

  • Page 551: Brake Light Switch

    LIGHTS/METER/SWITCHES BRAKE LIGHT SWITCH FRONT Disconnect the front brake light switch connectors and check for continuity between the terminals. There should be continuity with the brake lever applied, and there should be no continuity with the brake lever is released. REAR Remove the right side cover (page 2-4).

  • Page 552: Neutral Switch

    LIGHTS/METER/SWITCHES NEUTRAL SWITCH INSPECTION Disconnect the neutral switch connector from the switch. Shift the transmission into neutral and check for continuity between the neutral switch terminal and ground. There should be continuity with the transmission is in neutral, and no continuity when the transmission is into gear.
  • Page 553 LIGHTS/METER/SWITCHES Check for continuity between the wire terminals of the sidestand switch 2P (Green) connector. Continuity should exist only when the sidestand is REMOVAL/INSTALLATION Remove the left side cover (page 2-4). Disconnect the sidestand switch 2P (Green) connec• tor. Release the sidestand switch wire from the clamp. Remove the crankcase rear cover A.

  • Page 554: Horn

    LIGHTS/METER/SWITCHES HORN INSPECTION Disconnect the wire connectors from the horn. Connect the 12V battery to the horn terminal directly and check the horn sound. REMOVAL/INSTALLATION Disconnect the wire connectors from the horn. Remove the nut and horn. Installation is in the reverse order of removal. TURN SIGNAL RELAY INSPECTION 1.
  • Page 555 LIGHTS/METER/SWITCHES 2. Turn Signal Circuit Inspection Remove the rear cowl (page 2-6). Disconnect the turn signal 4P connector and short the Gray and White/green terminals of the wire harness side connector with a jumper wire. Turn the ignition switch ON and check the turn signal light by turning the turn signal switch on.
  • Page 556 21. IMMOBILIZER SYSTEM (HISS) TROU BLES HO OTIN G• ····· · · ········· ·············· 21-9 COMPONENT LOCATION ····················· ··· 2 1- 2 IMMOBILIZER INDICATOR · · ·· · · ·· ············ 2 1- 1 2 SYSTEM DIAGRAM ························· ········· 21 - 2 ECM ·························································...
  • Page 557 IMMOBILIZER SYSTEM (HISS) COMPONENT LOCATION ENGINE STOP SWITCH SYSTEM DIAGRAM R ..RED Bl ..BLACK FUSE (10 A) IGNITION SWITCH Bu ..BLUE Y ..YELLOW BVB� R/81----0------❖---- R -� G ..GREEN Fl FUSE l20 A) W ..WHITE 0 ..
  • Page 558 SERVICE INFORMATION GENERAL • HISS is the abbreviation of Honda Ignition Security System. • When checking the immobilizer system (HISS), follow the steps in the troubleshooting (page 21-9). • Keep the immobilizer key away from the other vehicle's immobilizer key when using it. The jamming of the key code signal may occur and the proper operation of the system will be obstructed.
  • Page 559 IMMOBILIZER SYSTEM (HISS) KEY REGISTRATION PROCEDURES When the key has been lost, or additional spare key is required: 1. Obtain a new transponder key. 2. Grind the key in accordance with the shape of the original key. 3. Apply 12 V battery voltage to the CKP sensor lines of the ECM using the special tool (page 21-7). 4.
  • Page 560 IMMOBILIZER SYSTEM (HISS) When the ignition switch is faulty (ignition switch replacement): 1. Obtain a new ignition switch and two new transponder keys. 2. Remove the ignition switch (page 20-19). 3. Apply 12 V battery voltage to the CKP sensor lines of the ECM using the special tool (page 21-7). 4.
  • Page 561 IMMOBILIZER SYSTEM (HISS) 16.Turn the ignition switch to "ON" with a second new key. (Never use the key registered in step 9.) The indicator comes on for two seconds then it blinks four times repeatedly. • The second key is registered in the ECM. •...
  • Page 562 IMMOBILIZER SYSTEM (HISS) HISS DIAGNOSTIC INFORMATION Lift and support the fuel tank (page 3-5) . Disconnect the CKP sensor 2P (Red) connector. Connect the inspection adaptor to the wire harness side connector. TOOLS: 07XMZ-MBW0101 Inspection harness 070MZ-MEC0101 Test harness adaptor Connect the Red clip of the adaptor to the 12 V bat·...
  • Page 563 IMMOBILIZER SYSTEM (HISS) When the system (ECM) enters the diagnostic mode from the registration mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE Re91stration is The key is Use a new key or overlapped. a I ready reg is­ cancelled key. tered properly. Code signals Communication Follow the trouble­...
  • Page 564 IMMOBILIZER SYSTEM (HISS) TROUBLESHOOTING The immobilizer indicator comes on for approx. two seconds then it goes off, when the ignition switch is turned to "ON" with the properly registered key and the immobilizer system (HISS) functions normally. If there is any problem or the properly registered key is not used, the indicator will remains on. Immobilizer indicator does not come on when the ignition switch is turned to "ON"...
  • Page 565 IMMOBILIZER SYSTEM (HISS) Immobilizer indicator remains on with the ignition switch to "ON" 1. Immobilizer Receiver Jamming Inspection Check that there is any metal obstruction or the other vehicle's transponder key near the immobilizer receiver and key. any metal obstruction or other transponder key? there Remove it and recheck.
  • Page 566 IMMOBILIZER SYSTEM (HISS) .r---utn Diagnostic code is indicated (Code signals cannot send or receive) 1. Immobilizer Receiver Power Input Line Inspection Check the power input line (Yellow/red) at the immobilizer receiver connector (page 21-14). Is there approx. 5 V7 - GO TO STEP 2. - Open or short circuit in the Yellow/red wire.
  • Page 567 IMMOBILIZER SYSTEM {HISS) IMMOBILIZER INDICATOR Remove the meter cover (page 2-5). Perform the following inspections with the combi­ nation meter 20P connector connected. POWER INPUT LINE INSPECTION Measure the voltage between the Black/brown (+) Viewed from harness side/ and Green/black wire terminals.
  • Page 568 IMMOBILIZER SYSTEM (HISS) Lift and support the fuel tank (page 3-5). Pull out the ECM from the stay (page 5-96). Disconnect the ECM 33P (Black and Light gray) con­ nectors. Perform the following inspections at the wire har­ ness side connector. TOOL: 07ZAJ-RDJA 110 Test probe...
  • Page 569 IMMOBILIZER SYSTEM (HISS) CKP SENSOR LINE INSPECTION Disconnect the CKP sensor 2P (Red) connector. 2P (Red) Check the Yellow wire for continuity between the CONNECTOR ECM and CKP sensor connectors. (Wire side/male Also check the White/yellow wire for continuity terminals) between the ECM and CKP sensor connectors There should be continuity between the same color wire terminals.
  • Page 570 IMMOBILIZER SYSTEM (HISS) SIGNAL LINE INSPECTION Measure the voltage between the Pink wire terminal 4P (Natural) CONNECTOR (+) and ground (-). (Wire side/female terminals) There should be approx. S V when the ignition switch is turned to "ON". Pink Disconnect the ECM 33P (Light gray) connector 4P (Natural) CONNECTOR (page 21-13).
  • Page 571 IMMOBILIZER SYSTEM (HISS) REQUIRED PARTS FOR PROBLEM � Replacement parts Problem Transponder Immobilizer Ignition "Accessory receiver switch lock and key One key has been lost, or addi- tional spare key is required All key have been lost, or ECM is faulty Immobilizer receiver is faulty Ignition switch is faulty...
  • Page 572 22. WIRING DIAGRAMS CB600FA ••••••••••••• ••••••••••••••••••••••••••••••••••••••• 22-3 CB600F •••••••••••••••••••••••••• •••••••••••••••••••••••••••• 22-4 22-1...
  • Page 573 WIRING DIAGRAMS CB600FA �FU�r.n�v.u.&T �I " a,,,._ .., �� • " 0030Z-MFG-D200 22-3...
  • Page 574 WIRING DIAGRAMS CB600F "1 " " .' ,,.,.,. � 'II" "" '. ' ' ". ' \ J!i(• • � 1,l l l� ' I l l � - - � ��- � " ,__. •• ' """ W,fftllJ' lllflSGIW.t..00 �...
  • Page 576 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 1. Spark Plug Inspection Remove and inspect spark plugs. Are the spark plugs in good condition? - GO TO STEP 2. - • Incorrect spark plug heat range • Incorrect spark plug gap •...
  • Page 577 TROUBLESHOOTING ENGINE LACKS POWER 1. Drive Train Inspection Raise wheel off the ground and spin by hand. Did the wheel spin freely? - GO TO STEP 2. - • Brake dragging • Worn or damaged wheel bearings 2. Tire Pressure Inspection Check the tire pressure.
  • Page 578 TROUBLESHOOTING 8. Cylinder compression Inspection Test the cylinder compression (page 8-6). Is the compression as specified? - GO TO STEP 9. - • Valve clearance too small • Worn cylinder and piston rings • Damaged cylinder head gasket • Improper valve timing 9.
  • Page 579 TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Spark Plug Inspection Remove and inspect spark plugs. Are the spark plugs in good condition? GO TO STEP 2. - • Plugs not serviced frequently enough • Incorrect spark plug heat range •...
  • Page 580 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1. Ignition Timing Inspection Check the ignition timing. Is the ignition timing as specified? - GO TO STEP 2. - • Faulty ECM • Faulty CKP sensor • Faulty VS sensor • Improper valve timing 2.
  • Page 582 INDEX IMMO BILIZE R RECEI VER ···················· .. •••••••••• •••••••••• 21-14 MAINTENANCE ............3.2 INJECTOR ..............5-85 REAR WHEE L/SUS PENS ION •········· ·············· .. • ..14.3 INTAKE AIR DUCT ............ 5-100 SERVICE RULES •••••••• · ••••••••••••• ........1 . 2 KEY REGISTRATION PROCEDURES ......
  • Page 583 :H:ON'D.A. The Power of Dreams Published by Honda Motor Co.,Ltd © Honda Motor Co., Lid 2007 @(DSP2007.03 62MFG00 Printed in Belgium...

This manual is also suitable for:

Cb 600f hornet 2008Cb 600fa hornet 2007Cb 600fa hornet 2008

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