Page 1 ( 718 頁 ) CBR650RA CB650RA Honda Motor Co., Ltd. 2014 CBR650RA CB650RA Published by Honda Motor Co., Ltd. Honda Motor Co., Ltd. 2014 Honda Motor Co., Ltd. 2014 Book number : 60MJS00 OWNER’ S/SERVICE MANUAL Published by Honda Motor Co., Ltd.
Page 2 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 3 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
Page 4 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. • Pro Honda M-77 Assembly Paste (Moly) (U.S.A. only) • Rocol ASP manufactured by Rocol Limited, U.K. • Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease.
Page 5: Table Of Contents
dummyhead dummyhead CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE PGM-FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM CYLINDER HEAD/VALVES CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH ALTERNATOR CRANKCASE/TRANSMISSION CRANKSHAFT/PISTON/CYLINDER ENGINE REMOVAL/INSTALLATION FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE ANTI-LOCK BRAKE SYSTEM (ABS) BATTERY/CHARGING SYSTEM LIGHTS/METERS/SWITCHES IMMOBILIZER SYSTEM (HISS)
Page 6 dummyhead dummyhead MEMO...
Page 7: General Information
dummytext 1. GENERAL INFORMATION SERVICE RULES··································· 1-2 SPECIAL TOOL LIST ··························· 1-20 MODEL IDENTIFICATION ······················· 1-3 CABLE & HARNESS ROUTING ············· 1-22 SPECIFICATIONS·································· 1-5 EMISSION CONTROL SYSTEMS ··········· 1-48 TORQUE VALUES ······························· 1-11 TECHNICAL FEATURE ························ 1-51 LUBRICATION & SEAL POINTS ············ 1-17...
Page 8 SERVICE RULES GENERAL INFORMATION 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not 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 9 GENERAL INFORMATION MODEL IDENTIFICATION CBR650RA: ED model shown: CB650RA: ED model shown: This manual covers following models: Turn Front sensor/ sensor/ Destination signal/ Front licence Type EVAP code position reflector plate sensor sensor light stay CBR650RA ED, IIED, –...
Page 10 GENERAL INFORMATION SERIAL NUMBERS/LABELS CBR650RA shown: ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER (V.I.N) CBR650RA shown: ED, IIED, IIIED, IVED, FO, IIFO models: REGISTERED NUMBER PLATE THROTTLE BODY IDENTIFICATION NUMBER KO, IIKO models: SAFETY CERTIFICATION LABEL U, IIU models: COMPLIANCE PLATE...
Page 11 128 mm (5.0 in) Front tire size 120/70ZR17M/C (58W) Rear tire size 180/55ZR17M/C (73W) Front tire brand CBR650RA, CB650RA Include ED, D214F Z (DUNLOP) IIIED models CB650RA ED, IIIED models ROADTEC 01 (METZELER) Rear tire brand CBR650RA, CB650RA Include ED,...
Page 12 dummyhead dummyhead GENERAL INFORMATION ITEM SPECIFICATION ENGINE Cylinder arrangement 4 cylinders in-line, inclined 30° from vertical Bore and stroke Except TH, IITH, IN, BR, IIBR models 67.0 x 46.0 mm (2.64 x 1.81 in) IN, TH, IITH, BR, IIBR models 67.000 x 46.000 mm (2.6378 x 1.8110 in) Displacement...
Page 13 ED, IIED, IIIED, IVED, KO, IIKO, U, High quality ethylene glycol antifreeze containing silicate-free antifreeze IIU,BR, IIBR models corrosion inhibitors (Mix the distilled water and antifreeze in the ratio of 1:1) TH, IITH, IN, FO, IIFO, MA, IIMA, IN Honda PRE-MIX COOLANT or equivalent models...
Page 14 2.6 liters (2.7 US qt, 2.3 Imp qt) – At disassembly 3.0 liters (3.2 US qt, 2.6 Imp qt) – Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent motor oil API service classification: SG or higher – JASO T903 standard: MA Viscosity: SAE 10W-30 Oil pressure at EOP switch 490 kPa (5.0 kgf/cm...
Page 15 dummyhead dummyhead GENERAL INFORMATION CRANKCASE/TRANSMISSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Transmission Gear I.D. M5, M6, C1 28.000 – 28.021 (1.1024 – 1.1032) – C2, C3, C4 33.000 – 33.025 (1.2992 – 1.3002) – Bushing O.D. M5, M6 27.959 –...
Page 16 dummyhead dummyhead GENERAL INFORMATION REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cold tire pressure Driver only 290 kPa (2.90 kgf/cm , 42 psi) – Driver and passenger 290 kPa (2.90 kgf/cm , 42 psi) – Axle runout –...
Page 17 GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATION Bulbs Headlight Position light (CBR650RA), (CB650RA: IN model) Turn signal/position light (CB650RA: Except IN model) Turn signal light (CBR650RA), (CB650RA: IN model) Brake/taillight License light Instrument light Turn signal indicator High beam indicator...
Page 18: Frame/Body Panels/Exhaust System
1.8 (0.2, 1.3) Self-lock nut (Except TH, IITH, IN, BR, IIBR models) Windscreen special bolt (CBR650RA) 0.42 (0.04, 0.3) Middle cowl special bolt (CBR650RA) 0.42 (0.04, 0.3) Front cowl stay mounting nut 27 (2.8, 20) (CBR650RA) Shroud A mounting bolt (CB650RA) 0.42 (0.04, 0.3)
Page 19: Pgm-Fi System
dummyhead dummyhead GENERAL INFORMATION PGM-FI SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) MAP sensor mounting screw 3.4 (0.3, 2.5) ECT sensor 12 (1.2, 9) IAT sensor screw 1.2 (0.1, 0.9) A/F sensor (ED, IIED, IIIED, IVED, FO, 24.5 (2.5, 18) IIFO, KO, IIKO models) sensor...
Page 20: Cylinder Head/Valves
dummyhead dummyhead GENERAL INFORMATION CYLINDER HEAD/VALVES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Cylinder head cover bolt 10 (1.0, 7) Camshaft holder bolt 12 (1.2, 9) Apply engine oil to the threads and seating surface. Cam sprocket bolt 20 (2.0, 15) Apply locking agent to the threads.
Page 21: Crankshaft/Piston/Cylinder
45 (4.6, 33) ALOC bolt; replace with a new one. Fork cap – 35 (3.6, 26) Bottom bridge pinch bolt (CBR650RA) 42 (4.3, 31) Bottom bridge pinch bolt (CB650RA) 27 (2.8, 20) Fork rod lock nut 18 (1.8, 13) Steering bearing adjustment nut 31 (3.2, 23)
Page 22: Hydraulic Brake
dummyhead dummyhead GENERAL INFORMATION HYDRAULIC BRAKE THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Brake caliper bleed valve 5.4 (0.6, 4.0) Front master cylinder reservoir cap 1.5 (0.2, 1.1) screw Rear brake reservoir cap screw 1.5 (0.2, 1.1) Front brake caliper mounting bolt 45 (4.6, 33) ALOC bolt;...
Page 23 dummyhead dummyhead GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Sealant (TB1207B Oil pan mating surface See page 9-7 manufactured by ThreeBond Right crankcase cover mating area (cover side) See page 11-4 or an equivalent) Crankcase mating area (right side of the case) See page 11-4 Left crankcase cover mating area (cover side) See page 12-3...
Page 24 dummyhead dummyhead GENERAL INFORMATION MATERIAL LOCATION REMARKS Medium strength locking PAIR check valve cover bolt threads Coating width: 6.5 mm (0.26 in) agent (TB1322N or TB2415 except 2 mm (0.1 in) from tip manufactured by ThreeBond, Engine oil filter boss threads Coating width: 6.5 mm (0.26 in) LOCTITE 648 or DL-200 from tip...
Page 25 Fork fluid (viscosity: 10W) or Fork oil seal lips equivalent Fork dust seal lips Fork cap O-ring Honda Bond A or equivalent Left handlebar grip inner surface ThreeBond 1521 or an Rear brake pad retainer mating surface equivalent Drive chain lubricant...
Page 26 dummyhead dummyhead GENERAL INFORMATION SPECIAL TOOL LIST TITLE TOOL No TOOL NAME MAINTENANCE 07HAA-PJ70101 Oil filter wrench 07HMH-MR10103 Drive chain tool set PGM-FI SYSTEM 070MZ-0010300 SCS short connector 07ZAJ-RDJA110 Test probe IGNITION SYSTEM 07HGJ-0020100 Peak voltage adaptor 07ZAJ-RDJA110 Test probe (2 pack) FUEL SYSTEM 07406-0040004 Fuel pressure gauge...
Page 27: Anti-Lock Brake System (Abs)
dummyhead dummyhead GENERAL INFORMATION TITLE TOOL No TOOL NAME REAR WHEEL/SUSPENSION 07746-0050600 Bearing remover head, 20 mm 07GGD-0010100 Bearing remover shaft 07749-0010000 Driver 07746-0010300 Attachment, 42 x 47 mm 07746-0040500 Pilot, 20 mm 07746-0010800 Attachment, 22 x 24 mm 07946-1870100 Attachment, 28 x 30 mm 07746-0010400 Attachment, 52 x 55 mm...
Page 28 GENERAL INFORMATION CABLE & HARNESS ROUTING CBR650RA: COMBINATION METER THROTTLE CABLE A 20P (Gray) CONNECTOR THROTTLE CABLE B CLUTCH SWITCH FRONT BRAKE LIGHT SWITCH WIRE CONNECTORS WIRE CONNECTORS LEFT HANDLEBAR RIGHT HANDLEBAR SWITCH WIRE SWITCH WIRE CLUTCH CABLE...
Page 29 GENERAL INFORMATION CBR650RA: THROTTLE CABLE A CLUTCH CABLE THROTTLE CABLE B LEFT HANDLEBAR RIGHT HANDLEBAR SWITCH WIRE SWITCH WIRE THROTTLE CABLE A THROTTLE CABLE B LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR CLUTCH CABLE SWITCH WIRE 1-23...
Page 30 GENERAL INFORMATION CBR650RA: LEFT SIDE: FRONT SUB HARNESS LEFT HANDLEBAR SWITCH LEFT FRONT TURN 12P (Black) CONNECTOR 10P (Gray) CONNECTOR SIGNAL LIGHT WIRE FRONT SUB HARNESS 12P (Gray) CONNECTOR LEFT FRONT TURN SIGNAL LIGHT WIRE LEFT HANDLEBAR SWITCH...
Page 31 GENERAL INFORMATION CBR650RA: RIGHT SIDE: RIGHT HANDLEBAR SWITCH FRONT WHEEL SPEED SENSOR 6P (Gray) CONNECTOR 2P (Black) CONNECTOR MAIN WIRE HARNESS AIR BLEED HOSE RADIATOR SIPHON HOSE RIGHT FRONT TURN AIR BLEED HOSE SIGNAL LIGHT WIRE RADIATOR SIPHON HOSE...
Page 32 dummyhead dummyhead GENERAL INFORMATION CB650RA: FRONT BRAKE LEFT HANDLEBAR HOSE SWITCH WIRE RIGHT HANDLEBAR FRONT FRONT SWITCH WIRE CLUTCH CABLE COMBINATION METER FRONT BRAKE LIGHT 20P (Gray) CONNECTOR SWITCH WIRE CLUTCH CABLE CONNECTORS FRONT BRAKE HOSE CLUTCH SWITCH WIRE CONNECTORS LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLE A...
Page 33 dummyhead dummyhead GENERAL INFORMATION CB650RA: THROTTLE CABLE A COMBINATION METER THROTTLE CABLE B 20P (Gray) CONNECTOR LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR LEFT FRONT TURN SWITCH WIRE SIGNAL LIGHT WIRE RIGHT FRONT TURN CLUTCH CABLE SIGNAL LIGHT WIRE HEADLIGHT 8P (Black) CONNECTOR COMBINATION METER FRONT BRAKE HOSE...
Page 34 dummyhead dummyhead GENERAL INFORMATION CB650RA: THROTTLE CABLE A THROTTLE CABLE B FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE RIGHT FRONT TURN SIGNAL LIGHT 7P (Green) CONNECTOR HEADLIGHT 8P (Black) CONNECTOR COMBINATION METER 20P (Gray) CONNECTOR LEFT HANDLEBAR SWITCH WIRE LEFT FRONT TURN SIGNAL LIGHT 7P (Black) CONNECTOR CLUTCH CABLE 1-28...
Page 35 dummyhead dummyhead GENERAL INFORMATION CB650RA: LEFT FRONT TURN SIGNAL LIGHT 7P (Black) CONNECTOR THROTTLE CABLE B THROTTLE CABLE A CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLE A RIGHT HANDLEBAR CLUTCH CABLE SWITCH WIRE THROTTLE CABLE A THROTTLE CABLE B THROTTLE CABLE B CLUTCH CABLE 1-29...
Page 36 dummyhead dummyhead GENERAL INFORMATION CB650RA: Except IN model: LEFT HANDLEBAR TORQUE CONTROL SWITCH SWITCH 14P (Gray) CONNECTOR 3P (Black) CONNECTOR IN model: LEFT HANDLEBAR SWITCH 10P (Gray) CONNECTOR HORN WIRE FAN MOTOR WIRE HORN WIRE HORN WIRE HORN WIRE 1-30...
Page 37 dummyhead dummyhead GENERAL INFORMATION CB650RA: AIR BLEED HOSE MAIN WIRE HARNESS MAIN WIRE AIR BLEED HOSE RIGHT FRONT TURN SIGNAL HARNESS LIGHT 7P (Green) CONNECTOR FRONT BRAKE HOSE MAIN WIRE HARNESS AIR BLEED HOSE HEADLIGHT 8P (Black) CONNECTOR CLUTCH CABLE RIGHT HANDLEBAR SWITCH 5P (Gray) CONNECTOR...
Page 38 GENERAL INFORMATION CBR650RA, CB650RA: ED model shown: FRONT BRAKE HOSE FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE HOSE [1]: FRONT BRAKE HOSE [2]: FRONT WHEEL SPEED SENSOR WIRE TH, IITH, IN, BR, IIBR models: Except TH, IITH, IN, BR, IIBR models:...
Page 39 GENERAL INFORMATION CBR650RA, CB650RA: CB650RA shown: TP SENSOR 3P (Blue) CONNECTOR FRAME GROUND POINTS SIDESTAND SWITCH 2P (Black) CONNECTOR CKP SENSOR 3P (Black) GEAR POSITION CONNECTOR (ED, IIED, SWITCH 8P (Black) IIIED, IVED, FO, IIFO, CONNECTOR KO, IIKO models)
Page 40 GENERAL INFORMATION CBR650RA, CB650RA: CB650RA shown: IGNITION COIL PRIMARY (Black/blue) WIRE IGNITION COIL PRIMARY IAT SENSOR 2P (Black) (Pink/blue) WIRE CONNECTOR IMMOBILIZER RECEIVER 4P (Black) CONNECTOR IGNITION SWITCH 2P (Brown) CONNECTOR IGNITION COIL 1 LEFT IMMOBILIZER RECEIVER IGNITION COIL 2...
Page 41 GENERAL INFORMATION CBR650RA, CB650RA: PAIR CONTROL SOLENOID VALVE 2P (Black) CONNECTOR FRONT WHEEL SPEED No.3 SENSOR WIRE SPARK PLUG WIRE CLUTCH CABLE FRONT LEFT THROTTLE CABLE A No.4 SPARK PLUG WIRE No.2 THROTTLE CABLE B SPARK PLUG WIRE No.1...
Page 42 GENERAL INFORMATION CBR650RA, CB650RA: CLUTCH DIODE IAT SENSOR 2P (Black) CONNECTOR NEUTRAL DIODE MAIN RELAY DIODE (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models) AIR BLEED HOSE IMMOBILIZER RECEIVER 4P (Black) EOP SWITCH 1P (Black) CONNECTOR CONNECTOR...
Page 43 GENERAL INFORMATION CBR650RA, CB650RA: CRANKCASE BREATHER HOSE · Connect the hose to the air cleaner lid until it is fully seated · Align the paint mark of the hose with the center of the air cleaner lid rib...
Page 44 GENERAL INFORMATION CBR650RA, CB650RA: EVAP PURGE HOSES MAP SENSOR IACV 4P (Black) VACUUM HOSES CONNECTOR ABS MODULATOR 18P (Black) CONNECTOR OPTIONAL 2P (Blue) CONNECTOR INJECTOR SUB HARNESS 6P (Black) CONNECTOR TURN SIGNAL RELAY 8P (Gray) CONNECTOR RADIATOR MAP SENSOR 3P...
Page 45 CONNECTOR CONNECTOR EVAP CANISTER-to-EVAP CONTROL SOLENOID VALVE HOSE CBR650RA, CB650RA (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models): EVAP PURGE CONTROL SOLENOID VALVE 2P (Black) CONNECTOR (TH, IITH, BR, IIBR models) Left SIDESTAND SWITCH CKP SENSOR 2P (Black)
Page 46 GENERAL INFORMATION CBR650RA, CB650RA: Viewed from the upper side: Front Left INSULATOR BAND Front Left Viewed from the upper side: INSULATOR BAND 1-40...
Page 47 GENERAL INFORMATION CBR650RA, CB650RA: WATER PUMP-to- A/F SENSOR 4P (Black) CONNECTOR CYLINDER HEAD HOSE (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO CKP SENSOR 3P (Black) models) CONNECTOR (ED, IIED, SENSOR 4P (Black) CONNECTOR IIIED, IVED, FO, IIFO,...
Page 48 GENERAL INFORMATION CBR650RA, CB650RA: LOWER RADIATOR HOSE B LOWER RADIATOR HOSE A Identification mark 0°± 15° Identification mark 0°± 15° Identification mark Left 0°± 15° Same direction 90° ± 15° Opposite direction Identification mark AIR BLEED HOSE WATER PUMP-to-...
Page 49 GENERAL INFORMATION CBR650RA, CB650RA (Except MA, IIMA, IN, U, IIU models): FUEL TANK DRAIN HOSE White paint mark 15° 15° 15° 15° FUEL TANK-to-EVAP FUEL FEED HOSE CANISTER HOSE White paint mark EVAP CANISTER-to-EVAP FUEL TANK-to-EVAP CONTROL SOLENOID...
Page 50 GENERAL INFORMATION CBR650RA, CB650RA (MA, IIMA, IN, U, IIU models): FUEL TANK FUEL FEED HOSE DRAIN HOSE White paint mark 15° 15° 15° FUEL TANK 15° BREATHER HOSE White paint mark REAR WHEEL SPEED SENSOR WIRE Left RADIATOR...
Page 51 GENERAL INFORMATION CBR650RA, CB650RA: REAR WHEEL SPEED SENSOR 2P REAR BRAKE LIGHT (Black) CONNECTOR SWITCH 2P (Black) STARTER MOTOR CABLE CONNECTOR REAR BRAKE LIGHT STARTER MOTOR CABLE SWITCH 2P (Black) CONNECTOR REAR BRAKE MASTER CYLINDER RESERVOIR HOSE REAR WHEEL SPEED SENSOR WIRE...
Page 52 GENERAL INFORMATION CBR650RA, CB650RA: FUEL PUMP 3P (Black) CONNECTOR FUEL PUMP WIRE REGULATOR/ RECTIFIER 3P (Gray) CONNECTOR FRAME BODY REGULATOR/ RECTIFIER 3P (Black) BATTERY NEGATIVE (–) CONNECTOR TERMINAL BATTERY POSITIVE (+) TERMINAL INSIDE BOOT CONNECTORS: · BRAKE/TAIL LIGHT 3P ·...
Page 53 GENERAL INFORMATION CBR650RA, CB650RA LICENSE LIGHT WIRE RIGHT REAR TURN SIGNAL LIGHT WIRE LEFT REAR TURN SIGNAL LIGHT WIRE BRAKE/TAIL LIGHT WIRE LEFT REAR TURN SIGNAL LIGHT WIRE RIGHT REAR TURN SIGNAL LIGHT WIRE LICENSE LIGHT WIRE RIGHT REAR TURN...
Page 54 Carbon monoxide does not react in the same way, but it is toxic. Uncontrolled fuel evaporation also releases hydrocarbons to the atmosphere. Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Page 55 dummyhead dummyhead GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a pulse secondary air supply system, 3-way catalytic converter and PGM-FI system. SECONDARY AIR SUPPLY SYSTEM The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port [1]. Fresh air is drawn into the exhaust port by the function of the PAIR control solenoid valve [2].
Page 56 dummyhead dummyhead GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM Fuel vapor from the fuel tank [1] is routed into the evaporative emission (EVAP) canister [2] where is it absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission (EVAP) purge control solenoid valve [3] is open, fuel vapor in the EVAP canister is drawn into the engine through the intake pipe.
Page 57 dummyhead dummyhead GENERAL INFORMATION TECHNICAL FEATURE OBD (On-Board Diagnostic) SYSTEM This vehicle complies with the emission limits of Euro 4 and OBD stage 1 regulation. Existing PGM-FI system already equips the self-diagnostic system that detects the PGM-FI system malfunction, and that malfunction data can be read by MCS (Motorcycle Communication System) as the DTCs or freeze data.
Page 58 ECM data reading. The DTCs read by GST are standardized by ISO standard, those are different code system from existing Honda code system read by MCS. Refer to DTC INDEX (page 4-12) for each DTC and troubleshooting detail.
Page 59 dummyhead dummyhead GENERAL INFORMATION OBD2 (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models) This motorcycle complies with OBD2. Comparison of OBD1 and OBD2: ITEMS OBD1 OBD2 Threshold diagnosis (Diagnosis of deterioration) Function diagnosis or Function diagnosis Diagnostic Threshold diagnosis (Diagnosis of deterioration)/ method Circuit diagnostics For items that can not be function diagnosed,...
Page 60 dummyhead dummyhead MEMO...
Page 61 DRIVE SPROCKET COVER··················· 2-15 UPPER INNER PANEL (CBR650RA)········· 2-8 DRIVE CHAIN COVER/MUD GUARD ······ 2-16 METER PANEL (CBR650RA)··················· 2-8 SIDESTAND ······································· 2-16 FRONT COWL (CBR650RA)···················· 2-9 FOOTPEG BRACKET··························· 2-17 FRONT LOWER COWL (CBR650RA)········ 2-9 EXHAUST PIPE/MUFFLER···················· 2-17 FRONT COWL STAY (CBR650RA) ··········· 2-9...
Page 62 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM GENERAL • This section covers removal and installation of the body panels and exhaust system. • When disassembling, mark and store the mounting fasteners to ensure that they are reinstalled in their original locations. •...
Page 63 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS/REMOVAL CHART CBR650RA [14] [17] [13] [16] [10] [20] [18] [15] [19] [11] [12] [1] Rearview mirror (page 2-5) [8] Meter panel (page 2-8) [15] Side cover (page 2-12) [2] Front fender (page 2-5)
Page 64 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM CB650RA IN model shown: [13] [12] [10] [11] [1] Rearview mirror (page 2-5) [6] Pillion seat (page 2-12) [11] Drive sprocket cover (page 2-15) [2] Front fender (page 2-5) [7] Side cover (page 2-12) [12] Drive chain cover/mud guard (page 2-16) [3] Tank cover (page 2-7) [8] Rear cowl (page 2-12) [13] Front license plate stay (page 2-15)
Page 65 FRAME/BODY PANELS/EXHAUST SYSTEM REARVIEW MIRROR REMOVAL/INSTALLATION CBR650RA Remove the socket bolts [1] and rearview mirror [2]. Installation is in the reverse order of removal. • Install with the reference mark [3] facing the rear side. TORQUE: Rearview mirror mounting socket bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft)
Page 66 FRAME/BODY PANELS/EXHAUST SYSTEM WINDSCREEN (CBR650RA) REMOVAL/INSTALLATION Remove the following: – Four special bolts [1] – Four plastic washers [2] – Four rubber washers [3] – Windscreen [4] – Four well nuts [5] Installation is in the reverse order of removal.
Page 67 FRAME/BODY PANELS/EXHAUST SYSTEM MIDDLE COWL (CBR650RA) REMOVAL/INSTALLATION Remove the following: – Three trim clips (pin head) [1] – Three trim clips [2] – Two special bolts [3] – Two socket bolts A (Black) [4] – Two socket bolts A (Silver) [5] –...
Page 68 FRAME/BODY PANELS/EXHAUST SYSTEM INTAKE AIR DUCT (CBR650RA) REMOVAL/INSTALLATION Remove the middle cowl (page 2-7). Left side shown: Release the harness clip [1] and front sub harness 12P Left side: (Black) [2] and 12P (Gray) [3] connectors from the intake air duct [4].
Page 69 – Two collars [3] Installation is in the reverse order of removal. • Align the lugs [4] of the headlight with the locating ridges on the front cowl. FRONT LOWER COWL (CBR650RA) REMOVAL/INSTALLATION Remove the following: – Front cowl (page 2-9) –...
Page 70 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SHROUD (CB650RA) REMOVAL/INSTALLATION Remove the trim clip [1] and two socket bolts [2]. Release the duct [3] and remove the shroud [4]. Remove the two connector clips [5] from the shroud. Right side: Remove the connector clip from the shroud. Left side: Installation is in the reverse order of removal.
Page 71 FRAME/BODY PANELS/EXHAUST SYSTEM UNDER COWL (CBR650RA) REMOVAL/INSTALLATION Release the hoses [1] from the under cowl [2]. Remove the following: Align – Four trim clips [3] – Two socket bolts A (Silver) [4] – Two socket bolts B [5] –...
Page 72 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM PILLION SEAT REMOVAL/INSTALLATION Unhook the seat with the ignition key [1]. Remove the pillion seat [2] by pulling it rearward. Install the pillion seat by inserting the prongs [3] under the frame. Push down the rear of the seat securely to lock it. SIDE COVER REMOVAL/INSTALLATION Remove the main seat (page 2-11).
Page 73 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER STAY REMOVAL/INSTALLATION Remove the rear cowl (page 2-12). Disconnect the following connectors [1]: – Rear turn signal light 2P (left: Orange, right: Light blue) – Brake/tail light 3P – License light 2P Remove the bolts [2] and rear fender stay [3] by pulling the wires out from the holes [4] of the rear fender B.
Page 74 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER B REMOVAL/INSTALLATION Remove the following: – Fuel tank (page 7-7) – Battery (page 20-5) – Brake/tail light unit (page 21-5) – Regulator/rectifier (page 20-7) – USB charger unit (Except KO, IIKO, U, IIU, BR, II BR models) (page 21-25) Release the following from the rear fender B [1]: –...
Page 75 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT LICENSE PLATE STAY REMOVAL/INSTALLATION IN model Remove the following: [3]/[4]/[5]/[6]/[7] – Headlight (page 21-3) – Socket bolts [1] – Front license plate stays [2] – Bolts [3]/nuts [4]/washers [5] – Collars [6]/mounting rubbers [7] Installation is in the reverse order of removal.
Page 76 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DRIVE CHAIN COVER/MUD GUARD REMOVAL/INSTALLATION Remove the following: – Three socket bolts [1] – Bolt [2] – Drive chain cover/mud guard [3] Installation is in the reverse order of removal. DISASSEMBLY/ASSEMBLY Remove the following: – Three tapping screws [1] –...
Page 77 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FOOTPEG BRACKET REMOVAL/INSTALLATION • For right rider footpeg bracket removal/installation, refer to following: – Brake pedal (page 18-16) – Rear master cylinder (page 18-12) LEFT RIDER FOOTPEG BRACKET Remove the two socket bolts [1] and footpeg bracket [2].
Page 78 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REMOVAL/INSTALLATION Remove the drive sprocket cover (page 2-15). Pull down the radiator (page 8-7). Disconnect the A/F sensor 4P (Black) connector [1] and ED, IIED, IIIED, remove the A/F sensor wire [2] out of the frame. IVED, FO, IIFO, KO, IIKO models Disconnect the O...
Page 79 dummytext 3. MAINTENANCE SERVICE INFORMATION························ 3-2 EVAPORATIVE EMISSION CONTROL SYSTEM (Except MA, IIMA, IN, U, IIU models) ······ 3-14 MAINTENANCE SCHEDULE ··················· 3-2 DRIVE CHAIN ····································· 3-15 FUEL LINE ··········································· 3-4 DRIVE CHAIN SLIDER ························· 3-17 THROTTLE OPERATION ························ 3-4 BRAKE FLUID ····································...
Page 80 * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by a dealer. Honda recommends that a dealer should road test the motorcycle after each periodic maintenance is carried out. NOTES: 1.
Page 81 * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by a dealer. Honda recommends that a dealer should road test the motorcycle after each periodic maintenance is carried out. NOTES: 1.
Page 82 If the throttle grip does not return properly, lubricate and overhaul the throttle grip housing. – CBR650RA: page 16-5 – CB650RA: page 16-9 If the throttle grip still do not return properly, replace the throttle cables.
Page 83 dummyhead dummyhead MAINTENANCE Throttle grip freeplay can be adjusted at either end of the throttle cable. Major adjustment is made with the lower adjuster on the throttle body. Remove the air cleaner housing (page 7-12). Loosen the lock nut [1] and turn the adjuster [2] as required.
Page 84 dummyhead dummyhead MAINTENANCE Remove the two tapping screws [1] and air cleaner element [2]. Replace the air cleaner element in accordance with the maintenance schedule (page 3-2) or any time it is excessively dirt or damaged. Clean the inside of the air cleaner lid and housing. Make sure the rubber seals in the housing and lid is in position and in good condition.
Page 85 dummyhead dummyhead MAINTENANCE INSPECTION Check the insulator [1] for cracks or damage, and the This motorcycle's electrodes [2]/[3] for wear, fouling or discoloration. spark plug is Replace the spark plug with the specified one if equipped with an necessary. iridium center electrode.
Page 86 dummyhead dummyhead MAINTENANCE VALVE CLEARANCE INSPECTION • Inspect and adjust the valve clearance while the engine is cold (below 35°C/95°F). Remove the following: – Cylinder head cover (page 10-4) – Timing hole cap and O-ring Rotate the crankshaft clockwise slowly and align the "T" mark [1] with the index notch [2] in the crankcase cover.
Page 87 dummyhead dummyhead MAINTENANCE Turn the crankshaft clockwise 1/2 turn (180°), align the "T" mark on the CKP sensor rotor with the index mark on the right crankcase cover. Check the valve clearance for the No.2 and No.4 Record the cylinder intake valves using feeler gauge. clearance for each valve for reference VALVE CLEARANCE:...
Page 88 If the level is below or near the lower level [2] on the dipstick, fill the recommended engine oil to the upper level [3]. RECOMMENDED ENGINE OIL: Honda "4-stroke motorcycle oil" or an equivalent API classification: SG or higher Viscosity: SAE 10W-30 JASO T 903 standard: MA Check that the O-ring [4] is in good condition, replace it if necessary.
Page 89 dummyhead dummyhead MAINTENANCE ENGINE OIL & FILTER CHANGE Warm up the engine. Stop the engine and remove the oil filler cap/dipstick. Remove the oil drain bolt [1] and sealing washer [2] to drain the engine oil. Remove the oil filter cartridge [3] using the special tool. TOOL: Oil filter wrench 07HAA-PJ70101...
Page 90 dummyhead dummyhead MAINTENANCE ENGINE IDLE SPEED • Inspect the idle speed after all other engine maintenance items have been performed and are within specifications. • Before checking the idle speed, inspect the following items: – No MIL blinking – Throttle operation and throttle grip freeplay (page 3-4) •...
Page 91 Replace the radiator if the air flow is restricted over more than 20% of the radiating surface. Remove the following: – Middle cowls (page 2-7) (CBR650RA) – Under cowl (page 2-11) (CBR650RA) – Shroud (page 2-10) (CB650RA) Check for any coolant leakage from the water hoses and hose joints.
Page 92 dummyhead dummyhead MAINTENANCE SECONDARY AIR SUPPLY SYSTEM Remove the air cleaner housing (page 7-12). Check the air supply hoses [1] between the air cleaner housing, PAIR control solenoid valve [2] and cylinder head cover for deterioration, damage or loose connections. Also, check that the hoses are not kinked or pinched.
Page 93 dummyhead dummyhead MAINTENANCE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF. Never inspect and adjust the drive Place the motorcycle on its sidestand and shift the chain while the transmission into neutral. engine is running. Check the slack in the drive chain lower run midway between the sprockets.
Page 94 dummyhead dummyhead MAINTENANCE CLEANING AND LUBRICATION Clean the drive chain [1] with a chain cleaner designed specifically for O-ring chains or a neutral detergent. Use a soft brush if the drive chain is dirty. Do not use a steam cleaner, high pressure cleaner, wire brush, volatile solvent such as gasoline and benzene, abrasive cleaner or a chain cleaner NOT designed specifically for O-ring chains to clean the drive chain.
Page 95 dummyhead dummyhead MAINTENANCE Insert a new master link [1] with new O-rings [2] from Never reuse the old the inside of the drive chain, and install a new plate [3] drive chain, master and O-rings with the identification mark facing out. link, master link plate and O-rings.
Page 96 dummyhead dummyhead MAINTENANCE BRAKE FLUID Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. • Do not mix different types of fluid, as they are not compatible with each other. •...
Page 97 dummyhead dummyhead MAINTENANCE REAR BRAKE Support the motorcycle upright position on a level surface and check the rear brake fluid level. If the level is near the "LOWER" level line [1], fill the brake fluid as follows. Remove the following: Take care not to spill the fluid out of –...
Page 98 dummyhead dummyhead MAINTENANCE BRAKE PADS WEAR FRONT BRAKE PADS Check the brake pads for wear. Replace the brake pads if either pad is worn to the wear Always replace the limit groove [1]. brake pads as a set to assure even disc For brake pad removal/installation (page 18-8).
Page 99 dummyhead dummyhead 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 operated, bleed the air from the system (page 18-5). Inspect the brake hoses [1], pipes and fittings for deterioration, cracks, damage and signs of leakage.
Page 100 MAINTENANCE HEADLIGHT AIM • Adjust the headlight aim as specified by local laws CBR650RA: and regulations. Support the motorcycle in an upright position on a level surface. Adjust the headlight aim vertically by turning the pinion [1]. A counterclockwise rotation moves the beam up and clockwise rotation moves the beam down.
Page 101 dummyhead dummyhead MAINTENANCE CLUTCH SYSTEM Inspect the clutch cable for kinks or damage, and CB650RA shown: lubricate the cable if necessary. Measure the clutch lever freeplay at the end of the clutch lever. FREEPLAY: 10 – 20 mm (0.4 – 0.8 in) 10 –...
Page 102 dummyhead dummyhead MAINTENANCE SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brake and compressing them several times. Check the entire fork assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all fasteners.
Page 103 dummyhead dummyhead MAINTENANCE WHEELS/TIRES Support the motorcycle using a hoist or equivalent and raise the front wheel off the ground. Hold the front fork leg and move the front wheel sideways with force to see if the wheel bearings are worn. For front wheel service (page 16-15).
Page 104 dummyhead dummyhead MEMO...
Page 105 dummytext 4. PGM-FI SYSTEM SERVICE INFORMATION························ 4-2 ECM ·················································· 4-76 SYSTEM LOCATION ······························ 4-4 MAP SENSOR····································· 4-79 SYSTEM DIAGRAM ······························· 4-5 ECT SENSOR ····································· 4-79 PGM-FI TROUBLESHOOTING IAT SENSOR ······································ 4-79 INFORMATION ····································· 4-7 A/F SENSOR (ED, IIED, IIIED, IVED, PGM-FI SYMPTOM FO, IIFO, KO, IIKO models)···················...
Page 106 dummyhead dummyhead PGM-FI SYSTEM SERVICE INFORMATION PGM-FI SYSTEM GENERAL • This section covers electrical system service of the PGM-FI system. For other service and fuel supply system, see Fuel System section (page 7-2). • The PGM-FI system is equipped with the Self-Diagnostic System (page 4-7). If the MIL lights or blinks, follow the Self-Diagnostic Procedures to remedy the problem.
Page 107 dummyhead dummyhead PGM-FI SYSTEM ECM-to-COMBINATION METER TWO-WAY SERIAL COMMUNICATION This motorcycle is equipped with the ECM-to-combination meter two-way serial communication system. The ECM sends the following information to the combination meter. – Torque control indicator signal – Coolant temperature gauge signal –...
Page 108 dummyhead dummyhead PGM-FI SYSTEM SYSTEM LOCATION IGNITION COIL 1 IAT SENSOR IGNITION COIL 2 MAIN RELAY IACV DIODE EVAP PURGE CONTROL MAP SENSOR SOLENOID VALVE (Except MA, IIMA, IN, U, IIU, models) ECT SENSOR BANK ANGLE SENSOR FUSE/RELAY BOX – MAIN FUSE (30 A) –...
Page 109 FUEL PUMP ENG STOP SWITCH MAIN (30A) (7.5 A) Bl/R R/Bl FUEL (20 A) W/Bl FAN (15 A) Bl/R Y/R Bl/W CBR650RA: Br/W METER/HORN/TAIL CB650RA: Bl/Br /TURN (7.5 A) Bl/Br CBR650RA: G/R G/Bl COMBINATION METER BATTERY CB650RA: G M-TXD/RXD Bl/Bu...
Page 110 SWITCH SWITCH MAIN (30A) (7.5 A) Bl/R R/Bl Bl/Y FUEL (20 A) W/Bl FAN (15 A) Bl/R Bl/W METER/HORN/TAIL CBR650RA: Br/W /TURN (7.5 A) CB650RA: Bl/Br Bl/Br G/Bl COMBINATION METER CBR650RA: G/R BATTERY CB650RA: G M-TXD/RXD Bl/Bu CBR650RA: W Bl/Bu...
Page 111 dummyhead dummyhead PGM-FI SYSTEM 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, the original problem may be intermittent.
Page 112 dummyhead dummyhead PGM-FI SYSTEM GST (General Scan Tool) INFORMATION • The GST can readout the DTC, freeze data, current data and other ECM condition. How to connect the GST Remove the main seat (page 2-11). Turn the ignition switch OFF. Remove the dummy connector [1] from the DLC.
Page 113 dummyhead dummyhead PGM-FI SYSTEM DTC READOUT Start the engine and check the MIL. • If the engine will not start, turn the starter motor for more than 10 seconds and check that the MIL. If the MIL turns on, connect the MCS or GST to the DLC, read the DTC, freeze data and follow the troubleshooting index. –...
Page 114 dummyhead dummyhead PGM-FI SYSTEM CIRCUIT INSPECTION INSPECTION AT ECM CONNECTOR • Always clean around and keep any foreign material away from the ECM 33P connectors before disconnecting it. • A faulty PGM-FI system is often related to poorly connected or corroded connections.
Page 115 dummyhead dummyhead PGM-FI SYSTEM PGM-FI SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms, check the MIL blinking, refer to the DTC index (page 4-46) and begin the appropriate troubleshooting procedure. If there are no DTC stored in the ECM memory, do the diagnostic procedure for the symptom, in sequence listed below, until you find cause.
Page 116 dummyhead dummyhead PGM-FI SYSTEM DTC INDEX (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models) • When using GST or MCS, check the lighting or blinking state of the MIL, and then refer to DTC index. • If GST or MCS is not used, perform all of the inspection on the MIL blinks. •...
Page 117 dummyhead dummyhead PGM-FI SYSTEM Detected Refer to DTC name blinks (Driving page Cycle) CKP Sensor Variation Not Learned P0315* 4-29 (Crankshaft Position System Variation Not Learned) Ignition Coil 1 Primary Control Circuit Open P0351 (No.1, 4 (No.1, No.4 Cylinder) Ignition Coil Circuit Malfunction) 4-30 Ignition Coil 2 Primary Control Circuit Open P0352...
Page 118 dummyhead dummyhead PGM-FI SYSTEM DTC TROUBLESHOOTING (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models) PRIOR DIAGNOSIS Before processing the DTC troubleshooting, check as follows: • Check for loose or poor contact on the DTC related connectors (each sensor, solenoid, unit etc.), then recheck the DTC.
Page 119 dummyhead dummyhead PGM-FI SYSTEM DTC P0031/DTC P0032 Probable cause: • Faulty A/F sensor heater or its related circuit • Faulty ECM Symptom/Fail-safe function: • Fuel consumption deterioration • Detected value feedback stops 1. A/F Sensor Heater Line Open Circuit Inspection Disconnect the ECM 33P (Gray) connector (page 4- 76).
Page 120 dummyhead dummyhead PGM-FI SYSTEM 4. A/F Sensor Inspection Replace the A/F sensor with a new one. Connect the disconnected connector(s). Erase the DTC (page 4-9). Start the engine and wait for a minute. Check the DTC with GST or MCS. Is same DTC indicated? –...
Page 121 dummyhead dummyhead PGM-FI SYSTEM DTC P0106 Probable cause: • Faulty MAP sensor or its related circuit • Contaminated intake manifold or throttle bore • Faulty ECM Symptom/Fail-safe function: • Rough idling • Driveability deterioration 1. MAP Sensor Inspection Replace the MAP sensor with a new one. Erase the DTC (page 4-9).
Page 122 dummyhead dummyhead PGM-FI SYSTEM 3. MAP Sensor Signal Line Short Circuit Inspection Check for continuity between the wire harness side MAP sensor 3P (Black) connector [1] and ground. CONNECTION: Light green/black – Ground Is there continuity? – Short circuit in the Light green/black wire Lg/Bl –...
Page 123 dummyhead dummyhead PGM-FI SYSTEM DTC P0112/DTC P0113 Probable cause: • Faulty IAT sensor or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine operates normally 1. IAT Sensor Output Line Open Circuit Inspection Disconnect the ECM 33P (Gray) connector (page 4- 76).
Page 124 dummyhead dummyhead PGM-FI SYSTEM 4. IAT Sensor Inspection Replace the IAT sensor with a new one. Erase the DTC (page 4-9). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS. Is same DTC indicated? –...
Page 125 dummyhead dummyhead PGM-FI SYSTEM 2. ECT Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side ECT sensor 2P (Blue) connector [1] and ground. CONNECTION: Pink/yellow – Ground Is there continuity? – Short circuit in the Pink/yellow wire –...
Page 126 dummyhead dummyhead PGM-FI SYSTEM DTC P011B Probable cause: • Faulty ECT sensor or its related circuit • Insufficient coolant • Faulty thermostat • Faulty water pump • Clogged coolant passage • Faulty IAT sensor or its related circuit • Faulty ECM Symptom/Fail-safe function: •...
Page 127 dummyhead dummyhead PGM-FI SYSTEM DTC P0122/DTC P0123 Probable cause: • Faulty TP sensor or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine operates at idle speed 1. TP Sensor Input Voltage Inspection Disconnect the TP sensor 3P (Blue) connector (page 7-13).
Page 128 dummyhead dummyhead PGM-FI SYSTEM 4. TP Sensor Inspection Replace the throttle body (TP sensor) with a known good one (page 7-13). Connect the disconnected connector(s). Erase the DTC (page 4-9). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS.
Page 129 dummyhead dummyhead PGM-FI SYSTEM DTC P0131/DTC P0132 Probable cause: • Faulty A/F sensor or its related circuit • Faulty ECM Symptom/Fail-safe function: • Fuel consumption deterioration • Detected value feedback stops 1. A/F Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the A/F sensor 4P (Black) connector (page 4-80).
Page 130 dummyhead dummyhead PGM-FI SYSTEM 4. A/F sensor Inspection Replace the A/F sensor with a new one. Connect the disconnected connector(s). Erase the DTC (page 4-9). Start the engine and wait for a minute. Stop the engine. Check the DTC with GST or MCS. Is same DTC indicated? –...
Page 131 dummyhead dummyhead PGM-FI SYSTEM DTC P0201/DTC P0202/DTC P0203/ DTC P0204 Probable cause: • Faulty fuel injector • Faulty ECM Symptom/Fail-safe function: • Engine does not start (Fuel injectors, fuel pump and ignition shut down) 1. Fuel Injector Input Voltage Inspection Disconnect the fuel injector 2P (Black) connector (page 7-16).
Page 132 dummyhead dummyhead PGM-FI SYSTEM 4. Fuel Injector Inspection Replace the fuel injector with a new one. Connect the disconnected connector(s). Erase the DTC (page 4-9). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS. Is same DTC indicated? –...
Page 133 dummyhead dummyhead PGM-FI SYSTEM DTC P0315 Probable cause: • Faulty CKP sensor • Faulty crank pulse initialize learning • Faulty ECM Symptom/Fail-safe function: • Engine operates normally • This DTC is erased at the 1 D/C (driving cycle) after detecting the system normally. 1.
Page 134 dummyhead dummyhead PGM-FI SYSTEM DTC P0351/DTC P0352 Probable cause: • Faulty Ignition coil or its related circuit • Faulty ECM Symptom/Fail-safe function: • Fuel injector and ignition coil shut down 1. Ignition Coil Primary Coil Input Voltage Inspection Disconnect the ignition coil wire connector (page 5- Turn the ignition switch ON.
Page 135 dummyhead dummyhead PGM-FI SYSTEM 3. Ignition Coil Primary Coil Signal Line Short Circuit Inspection Check for continuity between the wire harness side ignition coil wire connector [1] and ground. CONNECTION: Ignition coil 1: Pink/blue – Ground Ignition coil 2: Pink/black – Ground Is there continuity? –...
Page 136 dummyhead dummyhead PGM-FI SYSTEM DTC P0412 Probable cause: • Faulty PAIR control solenoid valve or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine operates normally 1. PAIR Control Solenoid Valve Input Voltage Inspection Disconnect the PAIR control solenoid valve 2P (Black) connector (page 7-19).
Page 137 dummyhead dummyhead PGM-FI SYSTEM 4. PAIR Control Solenoid Valve Inspection Replace the PAIR control solenoid valve with a new one. Connect the disconnected connector(s). Erase the DTC (page 4-9). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS. Is same DTC indicated? –...
Page 138 dummyhead dummyhead PGM-FI SYSTEM 3. EVAP Purge Control Solenoid Valve Signal Line Short Circuit Inspection Check for continuity between the wire harness side EVAP purge control solenoid valve 2P (Black) connector [1] and ground. CONNECTION: Blue/white – Ground Is there continuity? Bu/W –...
Page 139 dummyhead dummyhead PGM-FI SYSTEM DTC P0500 Probable cause: • Faulty front wheel speed sensor or its related circuit • ABS modulator has DTC (CAN lines included) • Faulty ECM Symptom/Fail-safe function: • Engine operates normally • When other DTC is displayed, together with P0500, troubleshoot it first.
Page 140 dummyhead dummyhead PGM-FI SYSTEM DTC P0511 Probable cause: • Faulty IACV or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine stalls, hard to start, rough idling 1. IACV Line Open Circuit Inspection Disconnect the following: – ECM 33P (Black) connector (page 4-76) –...
Page 141 dummyhead dummyhead PGM-FI SYSTEM DTC P0519 Probable cause: • Faulty IACV or its related parts • Faulty ECM Symptom/Fail-safe function: • Engine stalls, hard to start, rough idling 1. IACV Inspection Replace the IACV with a new one. Erase the DTC (page 4-9). Perform the test ride.
Page 142 dummyhead dummyhead PGM-FI SYSTEM DTC P0600 Probable cause: • Faulty combination meter or its related circuit • Blown CLOCK 7.5 A fuse • Blown METER/HORN/TAIL/TURN 7.5 A fuse • Faulty ECM Symptom/Fail-safe function: • Engine operates normally 1. Combination Meter Serial Communication Output Voltage Inspection...
Page 143 Measure the voltage at the combination meter 20P (Gray) connector [1] of the wire harness side and ground. CONNECTION: CBR650RA: White (+) – Ground (–) CB650RA: Red/blue (+) – Ground (–) Does the voltage repeat 0 V to 8 V or more at intervals of 5 seconds? –...
Page 144 dummyhead dummyhead PGM-FI SYSTEM DTC P064D Probable cause: • Loose or poor contact of the ECM connector Symptom/Fail-safe function: • Engine operates normally 1. A/F Sensor IC Circuit Input Voltage line Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Gray) connector (page 4- 76).
Page 145 dummyhead dummyhead PGM-FI SYSTEM 2. Gear Position Switch Inspection Disconnect the gear position switch 8P (Black) connector (page 4-81). Check for continuity between the gear position Bl/Y switch 8P (Black) connector [1] terminals at the switch side and ground. It is normal if there is continuity at each gear position as follows and no continuity at other gear position.
Page 146 dummyhead dummyhead PGM-FI SYSTEM 2. Bank Angle Sensor Signal Line Open Circuit Inspection Disconnect the ECM 33P (Gray) connector (page 4- 76). Check for continuity between the wire harness side bank angle sensor 2P (Black) connector [1] and ECM 33P (Gray) connector [2] terminals. CONNECTION: Blue/red –...
Page 147 dummyhead dummyhead PGM-FI SYSTEM DTC P1100 Probable causes: • Faulty fuel pump • Faulty fuel injector • Faulty throttle body • Faulty A/F sensor Symptom/Fail-safe function: • Engine operates at restricted speed • Driveability deterioration • When other DTC is displayed, together with P0300, troubleshoot it first.
Page 148 dummyhead dummyhead PGM-FI SYSTEM DTC P2158 Probable cause: • Faulty rear wheel speed sensor or its related circuit • ABS modulator has DTC (CAN lines included) • Faulty ECM Symptom/Fail-safe function: • Engine operates normally • When other DTC is displayed, together with P0500, troubleshoot it first.
Page 149 dummyhead dummyhead PGM-FI SYSTEM DTC P2195/DTC P2196 Probable cause: • Faulty A/F sensor or its related circuit • Faulty fuel injector or its fuel pressure too low • Faulty ECT sensor • Faulty ECM Symptom/Fail-safe function: • Hard to start at a low temperature •...
Page 150 dummyhead dummyhead PGM-FI SYSTEM DTC INDEX (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models) • If the MCS or GST is not used, perform all of the inspection on the corresponding main code (digits in front of hyphen) of the DTC.
Page 151 dummyhead dummyhead PGM-FI SYSTEM Refer Function Failure Symptom/Fail-safe function Bank angle sensor circuit low voltage (less than 0.020 • Engine operates normally • Engine stop function does not operate P1000 • Loose or poor contact of the bank angle sensor 4-64 (54-1) connector...
Page 152 dummyhead dummyhead PGM-FI SYSTEM DTC TROUBLESHOOTING (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models) P0107 (MAP SENSOR LOW VOLTAGE) 1. MAP Sensor System Inspection Check the MAP sensor with the MCS or GST. Is about 0 V indicated? –...
Page 153 dummyhead dummyhead PGM-FI SYSTEM 5. MAP Sensor Inspection Replace the MAP sensor with a known good one (page 4-79). Connect the ECM 33P connectors. Erase the DTC (page 4-9). Check the MAP sensor with the MCS or GST. Is P0107 indicated? –...
Page 154 dummyhead dummyhead PGM-FI SYSTEM 4. MAP Sensor Signal Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Gray) connector (page 4- 76). Check for continuity between the wire harness side MAP sensor 3P (Black) connector [1] and ECM 33P (Gray) connector [2] terminals.
Page 155 dummyhead dummyhead PGM-FI SYSTEM P0117 (ECT SENSOR LOW VOLTAGE) 1. ECT Sensor System Inspection Check the ECT sensor with the MCS or GST. Is about 0 V indicated? – GO TO STEP 2. – Intermittent failure 2. ECT Sensor System Inspection with Connector Disconnected Turn the ignition switch OFF.
Page 156 dummyhead dummyhead PGM-FI SYSTEM 3. ECT Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Black) and 33P (Gray) connectors (page 4-76). Check for continuity between the wire harness side ECT sensor 2P (Blue) connector [1] and ECM 33P (Black) [2] and 33P (Gray) [3] connector terminals.
Page 157 dummyhead dummyhead PGM-FI SYSTEM 3. TP Sensor Input Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Black) connector (page 4-76). Check for continuity between the wire harness side TP sensor 3P (Blue) connector [1] and ECM 33P (Black) connector [2] terminals.
Page 158 dummyhead dummyhead PGM-FI SYSTEM P0123 (TP SENSOR HIGH VOLTAGE) 1. TP Sensor System Inspection Check the TP sensor with the MCS or GST. Is about 5 V indicated? – GO TO STEP 3. – GO TO STEP 2. 2. TP Sensor System Inspection with throttle operated Check that the TP sensor voltage increases continuously when moving the throttle from fully...
Page 159 dummyhead dummyhead PGM-FI SYSTEM P0112 (IAT SENSOR LOW VOLTAGE) 1. IAT Sensor System Inspection Check the IAT sensor with the MCS or GST. Is about 0 V indicated? – GO TO STEP 2. – Intermittent failure 2. IAT Sensor System Inspection with Connector Disconnected Turn the ignition switch OFF.
Page 160 dummyhead dummyhead PGM-FI SYSTEM 3. IAT Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Black) and 33P (Gray) connectors (page 4-76). Check for continuity between the wire harness side IAT sensor 2P (Black) connector [1] and ECM 33P (Black) [2]/33P (Gray) [3] connector terminals.
Page 161 dummyhead dummyhead PGM-FI SYSTEM 2. Fuel Injector Input Voltage Inspection Turn the ignition switch OFF. Lift the fuel tank and support it (page 3-4). Disconnect the fuel injector 2P (Black) connector. Turn the ignition switch ON with the engine stop switch "...
Page 162 dummyhead dummyhead PGM-FI SYSTEM 5. Fuel Injector Signal Line Short Circuit Inspection Check for continuity between the wire harness side injector 2P (Black) connectors [1] terminal and ground. CONNECTION: No. 1: P/W No. 1: Pink/white – Ground No. 2: P/G No.
Page 163 dummyhead dummyhead PGM-FI SYSTEM P0132 (O SENSOR HIGH VOLTAGE) • Before starting the inspection, check for loose or poor contact on the O sensor 4P (Black), ECM 33P (Black) and 33P (Gray) connectors, and recheck the DTC. 1. Recheck DTC Erase the DTC (page 4-9).
Page 164 dummyhead dummyhead PGM-FI SYSTEM P0135 (O SENSOR HEATER) • Before starting the inspection, check for loose or poor contact on the O sensor 4P (Black) and ECM 33P (Gray) connectors, and recheck the DTC. 1. Recheck DTC Erase the DTC (page 4-9). Start the engine and check the O sensor heater with the MCS or GST.
Page 165 dummyhead dummyhead PGM-FI SYSTEM 5. O Sensor Heater Line Short Circuit Inspection Check the continuity between the wire harness side sensor 4P (Black) connector [1] terminal and ground. CONNECTION: Black – ground Is there continuity? – Short circuit in Black wire –...
Page 166 dummyhead dummyhead PGM-FI SYSTEM 4. IACV Line Open Circuit Inspection Disconnect the ECM 33P (Black) connector (page 4-76). Check for continuity between the wire harness side ECM 33P (Black) connector [1] and IACV 4P (Black) connector [2] terminals. TOOL: Gr/R Test probe (2 required) 07ZAJ-RDJA110 Lg/Bl...
Page 167 dummyhead dummyhead PGM-FI SYSTEM P0914 (GEAR POSITION SWITCH) 1. Gear Position Switch System Inspection Erase the DTC (page 4-9). Check the gear position switch with the MCS or GST. Is the DTC P0914 indicated? – GO TO STEP 2. – Intermittent failure 2.
Page 168 dummyhead dummyhead PGM-FI SYSTEM 3. Gear Position Switch Inspection Disconnect the gear position switch 8P (Black) connector (page 4-81). Check for continuity between the gear position Bl/Y switch 8P (Black) connector [1] terminals at the switch side and ground. It is normal if there is continuity at each gear position as follows and no continuity at other gear position.
Page 169 dummyhead dummyhead PGM-FI SYSTEM 3. Bank Angle Sensor Signal Line Open Circuit Inspection Disconnect the ECM 33P (Gray) connector (page 4- 76). Check for continuity between the wire harness side bank angle sensor 2P (Black) connector [1] and ECM 33P (Gray) connector [2] terminals. TOOL: Test probe 07ZAJ-RDJA110...
Page 170 dummyhead dummyhead PGM-FI SYSTEM P2158 (REAR WHEEL SPEED SENSOR SIGNAL) 1. DTC Recheck Erase the DTC (page 4-9). Test-ride the motorcycle above 20 km/h (12 mph) for more than 20 seconds. Stop the engine. Check the DTC with the GST or MCS. Is P2158 indicated? –...
Page 171 dummyhead dummyhead PGM-FI SYSTEM 5. ECM Inspection Replace the ECM with a known good one (page 4- 76). Connect the ABS modulator 18P (Black) connector. Erase the DTC (page 19-26). Test-ride the motorcycle above 20 km/h (12 mph) for more than 20 seconds. Stop the engine.
Page 172 dummyhead dummyhead PGM-FI SYSTEM 4. Front Wheel Speed Sensor Signal Output Line Short Circuit Inspection Check for continuity between the wire harness side ECM 33P (Gray) connector [1] and ground. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: White/blue – Ground W/Bu Is there continuity? –...
Page 173 PGM-FI SYSTEM P0600 (SERIAL COMMUNICATION) • Before starting the inspection, check the following connectors for loose or poor contact. – Front sub harness 12P (Black) (CBR650RA) – ECM 33P (Gray) – Combination meter 20P (Gray) 1. Recheck DTC Erase the DTC (page 4-9).
Page 174 Measure the voltage at the combination meter 20P (Gray) connector [1] of the wire harness side and ground. CONNECTION: CBR650RA: White (+) – Ground (–) CB650RA: Red/blue (+) – Ground (–) STANDARD: 8 V or more (Every 5 seconds)
Page 175 dummyhead dummyhead PGM-FI SYSTEM P0443 (EVAP PURGE CONTROL SOLENOID VALVE) • Before starting the inspection, check for loose or poor contact on the EVAP purge control solenoid valve 2P (Black) connector and ECM 33P (Black) connector, then recheck the DTC. 1.
Page 176 dummyhead dummyhead PGM-FI SYSTEM 4. EVAP Purge Control Solenoid Valve Signal Line Open Circuit Inspection Disconnect the ECM 33P (Black) connector (page 4-76). Check the continuity between the EVAP purge control solenoid valve 2P (Black) connector [1] and ECM 33P (Black) connector [2] of the wire harness side.
Page 177 dummyhead dummyhead PGM-FI SYSTEM 2. PAIR Control Solenoid Valve Input Voltage Inspection Turn the ignition switch OFF. Disconnect the PAIR control solenoid valve 2P (Black) connector (page 7-19). Turn the ignition switch ON and engine stop switch Bl/Bu " ". Measure the voltage between the PAIR control solenoid valve 2P (Black) connector [1] of the wire harness side and ground.
Page 178 dummyhead dummyhead PGM-FI SYSTEM 5. PAIR Control Solenoid Valve Signal Line Short Circuit Inspection Check for continuity between the PAIR control solenoid valve 2P (Black) connector [1] and ground with the ECM 33P (Black) connector disconnected. CONNECTION: Yellow/blue – Ground Y/Bu Is there continuity? –...
Page 179 dummyhead dummyhead PGM-FI SYSTEM 3. Ignition Coil Primary Circuit Signal Line Open Circuit Inspection Disconnect the ECM 33P (Black) connector (page Ignition coil 1: 4-76). Check the continuity between the ignition coil wire connector [1] and ECM 33P (Black) connector [2] of the wire harness side.
Page 180 dummyhead dummyhead PGM-FI SYSTEM MIL CIRCUIT TROUBLESHOOTING Check that the MIL [1] comes on for 2 seconds and goes off when the ignition switch is turned ON with the engine stop switch " ". • If the MIL and digital display do not function at all, refer to combination meter initial operation check (page 21-6).
Page 181 dummyhead dummyhead PGM-FI SYSTEM Turn the ignition switch OFF. Pull out the ECM [1] from the ABS modulator tray, then disconnect the ECM 33P (Black) [2] and 33P (Gray) [3] connectors. Installation is in the reverse order of removal. • ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models: If the ECM is replaced, perform the following Procedure: –...
Page 182 dummyhead dummyhead PGM-FI SYSTEM GROUND LINE Check for continuity between the wire harness side ECM 33P (Black) [1] and 33P (Gray) [2] connector ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models: terminals and ground. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: Green – Ground There should be continuity at all times.
Page 183 dummyhead dummyhead PGM-FI SYSTEM MAP SENSOR REMOVAL/INSTALLATION Lift the fuel tank and support it (page 3-4). Disconnect the MAP sensor 3P (Black) connector [1]. Remove the screw [2] and MAP sensor [3]. Remove the O-ring [4] from the MAP sensor. Installation is in the reverse order of removal.
Page 184 dummyhead dummyhead PGM-FI SYSTEM A/F SENSOR (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models) REMOVAL/INSTALLATION • Do not get grease, oil or other materials in the A/F sensor air hole. • The A/F sensor may be damaged if dropped. Replace it with a new one, if dropped.
Page 185 dummyhead dummyhead PGM-FI SYSTEM GEAR POSITION SWITCH REMOVAL/INSTALLATION Remove the drive sprocket cover (page 2-15). Disconnect the gear position switch 8P (Black) connector [1] and remove the wire clip [2]. Remove the socket bolt [3] and gear position switch [4]. Remove the O-ring [5] from the gear position switch.
Page 186 dummyhead dummyhead PGM-FI SYSTEM INSPECTION SYSTEM INSPECTION WITH MCS Remove the bank angle sensor without disconnecting its connector (page 4-81). Connect the MCS to the DLC (page 4-8). Check the output voltage at each position of the sensor with the MCS. STANDARD: Horizontal Position: 7.0 –...
Page 187 dummyhead dummyhead PGM-FI SYSTEM CKP SENSOR LINE INSPECTION Disconnect the CKP sensor 3P (Black) connector [1]. POWER INPUT/GROUND LINE INSPECTION Turn the ignition switch ON with the engine stop switch " ". Measure the voltage at the CKP sensor 3P (Black) connector [1] of the wire harness side.
Page 188 dummyhead dummyhead PGM-FI SYSTEM CRANK PULSE LEARNING • If you done the following works, perform the crank pulse learning reset procedure and crank pulse initialize learning procedure. Perform the crank pulse learning reset procedure first, and then the crank pulse initialize learning procedure.
Page 189 dummyhead dummyhead PGM-FI SYSTEM MAIN RELAY CIRCUIT INSPECTION (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models) For relay inspection (page 21-24). Remove the main relay (page 21-24). RELAY COIL POWER INPUT LINE Measure the voltage between the main relay 4P connector [1] terminal and ground.
Page 190 dummyhead dummyhead PGM-FI SYSTEM CIRCUIT INSPECTION (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models) For relay inspection (page 21-24). Remove the main relay (page 21-24). RELAY COIL POWER INPUT LINE Measure the voltage between the main relay 4P connector [1] terminal and ground.
Page 191 dummyhead dummyhead PGM-FI SYSTEM MAIN RELAY DIODE INSPECTION Remove the air cleaner housing (page 7-12). Remove the rubber cap [1] and main relay diode [2]. Installation is in the reverse order of removal. Check for continuity between the diode terminals. When there is continuity, a small resistance value will register.
Page 192 dummyhead dummyhead MEMO...
Page 193 dummytext 5. IGNITION SYSTEM SERVICE INFORMATION························ 5-2 IGNITION SYSTEM INSPECTION ············· 5-7 TROUBLESHOOTING ···························· 5-3 IGNITION TIMING ································ 5-10 SYSTEM LOCATION ······························ 5-5 IGNITION COIL ··································· 5-11 SYSTEM DIAGRAM ······························· 5-5 CKP SENSOR (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models) ································...
Page 194 dummyhead dummyhead IGNITION SYSTEM SERVICE INFORMATION IGNITION SYSTEM GENERAL • The ECM may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive voltage may damage the module. Always turn off the ignition switch before servicing. •...
Page 195 dummyhead dummyhead IGNITION SYSTEM TROUBLESHOOTING • Inspect the following before diagnosing the system. – Faulty spark plug – Loose spark plug cap or spark plug wire connection – Water got into the spark plug cap (Leaking the ignition coil secondary current) •...
Page 196 dummyhead dummyhead IGNITION SYSTEM MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models No spark at spark plug Unusual condition Probable cause (Check in numerical order) Ignition coil No initial voltage with the ignition 1. An open circuit in the Black/blue wire between the main primary voltage switch turned ON and engine stop relay and ignition coil.
Page 197 dummyhead dummyhead IGNITION SYSTEM SYSTEM LOCATION ENGINE STOP SWITCH IGNITION COIL 2 (No. 2, 3) IGNITION SWITCH FUSE/RELAY BOX IGNITION COIL 1 – MAIN FUSE (30 A) (No. 1, 4) – ENG STOP FUSE (7.5 A) – FI FUSE (10 A) –...
Page 198 dummyhead dummyhead IGNITION SYSTEM MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models FI FUSE (10 A) MAIN FUSE (30 A) Bu/R Lg/W Bl/Bu P/Bl P/Bu Bu/Y BATTERY Bl/Bu ENG STOP FUSE IGNITION SWITCH (7.5 A) Bl/R R/Bl ENGINE STOP SWITCH BANK ANGLE...
Page 199 dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark at the plug, check all connections for loose or poor contact before measuring the peak voltage. • Use a commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum. •...
Page 200 dummyhead dummyhead IGNITION SYSTEM IGNITION COIL PRIMARY PEAK VOLTAGE • Check all system connections before performing this inspection. Loose connectors can cause incorrect readings. • Check the cylinder compression and check that the spark plugs are installed correctly in the cylinder head.
Page 201 dummyhead dummyhead IGNITION SYSTEM CKP SENSOR PEAK VOLTAGE (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models) • Check the cylinder compression and check that the spark plugs are installed correctly in the cylinder head. Disconnect the ECM 33P (Black) and 33P (Gray) connectors (page 4-76).
Page 202 • The ignition timing cannot be adjusted since the ECM is factory preset. Remove the following: – Left middle cowl (page 2-7) (CBR650RA) – Left shroud (page 2-10) (CB650RA) Start the engine, warm it up to normal operating temperature and stop it.
Page 203 dummyhead dummyhead IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Disconnect the spark plug caps (page 3-6). Ignition coil 1 shown: Disconnect the ignition coil wire connectors [1] Remove the socket bolts [2] and release the ignition coil stay assembly [3] from the frame. Remove the bolts [4], spacers [5] and ignition coil [6].
Page 204 dummyhead dummyhead MEMO...
Page 205 dummytext 6. ELECTRIC STARTER SERVICE INFORMATION························ 6-2 STARTER MOTOR································· 6-5 TROUBLESHOOTING ···························· 6-3 STARTER RELAY SWITCH ····················· 6-7 SYSTEM LOCATION ······························ 6-4 DIODE ················································· 6-9 SYSTEM DIAGRAM ······························· 6-4...
Page 206 dummyhead dummyhead ELECTRIC STARTER SERVICE INFORMATION ELECTRIC STARTER GENERAL If the current is kept flowing through the starter motor turn it while the engine is not cranking over, the starter motor may be damaged. • The starter motor can be serviced with the engine installed in the frame. •...
Page 207 dummyhead dummyhead ELECTRIC STARTER TROUBLESHOOTING • Make sure the battery is fully charged and in good condition. • Check for a blown main fuse (30 A) and sub fuse (ENG STOP; 7.5 A). (Check for a short circuit in the related wires if the fuse is blown again) •...
Page 208 dummyhead dummyhead ELECTRIC STARTER SYSTEM LOCATION ENGINE STOP SWITCH STARTER SWITCH IGNITION SWITCH CLUTCH SWITCH STARTER RELAY SWITCH CLUTCH DIODE NEUTRAL DIODE FUSE/RELAY BOX – MAIN FUSE (30 A) – ENG STOP FUSE (7.5 A) STARTER MOTOR SIDESTAND SWITCH BATTERY GEAR POSITION SWITCH SYSTEM DIAGRAM Bl: Black...
Page 209 dummyhead dummyhead ELECTRIC STARTER STARTER MOTOR REMOVAL/INSTALLATION Disconnect the negative (–) cable from the battery [2]/[3] (page 20-5). Release the terminal cap [1]. Remove the terminal nut [2] and disconnect the starter motor cable [3]. Remove the two mounting bolts [4] and negative (–) cable [5].
Page 210 dummyhead dummyhead ELECTRIC STARTER • Install the armature [1] into the motor case from the case groove [2] side so the commutator bars facing to the rear side. • When installing the rear cover [3], align the tab with the groove (the index lines [4] are aligned). •...
Page 211 dummyhead dummyhead ELECTRIC STARTER ARMATURE Clean the metallic debris off the commutator bars [1]. Do not use emery or sand paper on Check the commutator bars for discoloration. the commutator. Check for continuity on the armature as follows: – Between pair of commutator bars; there should be continuity.
Page 212 dummyhead dummyhead ELECTRIC STARTER GROUND LINE Turn the ignition switch OFF. Disconnect the starter relay switch 2P (Black) connector [1]. Check for continuity between the 2P (Black) connector terminal and ground. CONNECTION: Green/red – Ground There should be continuity when the transmission is in neutral or when the clutch lever is squeezed with the sidestand retracted (There is a slight resistance due to the diode).
Page 213 dummyhead dummyhead ELECTRIC STARTER Remove the starter relay switch [1] from the stays [2]. Release the terminal covers [3], and remove the nuts [4] to disconnect the cables. Installation is in the reverse order of removal. TORQUE: Starter relay switch cable nut: 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) DIODE REMOVAL/INSTALLATION...
Page 214 dummyhead dummyhead ELECTRIC STARTER INSPECTION Check for continuity between the turn signal light diode [1] terminals. When there is continuity, a small resistance value will register. (–) If there is continuity in one direction, the turn signal light diode is normal. 6-10...
Page 215 dummytext 7. FUEL SYSTEM SERVICE INFORMATION························ 7-2 INSULATOR ······································· 7-16 COMPONENT LOCATION ······················· 7-3 FUEL INJECTOR ································· 7-16 FUEL LINE INSPECTION ························ 7-4 IACV·················································· 7-17 FUEL TANK ·········································· 7-7 FUEL PUMP RELAY ···························· 7-19 FUEL FILLER CAP ································ 7-8 SECONDARY AIR SUPPLY SYSTEM······ 7-19 FUEL PUMP UNIT··································...
Page 216 dummyhead dummyhead FUEL SYSTEM SERVICE INFORMATION FUEL SYSTEM GENERAL • Bending or twisting the control cable will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control. • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.
Page 217 dummyhead dummyhead FUEL SYSTEM COMPONENT LOCATION ED model shown: 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft) 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft) Except MA, IIMA, IN, U, IIU models...
Page 218 dummyhead dummyhead FUEL SYSTEM FUEL LINE INSPECTION FUEL PRESSURE RELIEVING • Before disconnecting fuel feed hose, relieve pressure from the system as follows. 1. Turn the ignition switch OFF. 2. Lift the fuel tank and support it (page 3-4). 3. Remove the wire band [1]. 4.
Page 219 dummyhead dummyhead FUEL SYSTEM 7. To prevent damage and keep foreign matter out, cover the disconnected connector and pipe end with the plastic bags. QUICK CONNECT FITTING INSTALLATION • Do not bent or twist the fuel feed hose. 1. Press the connector [1] onto the fuel pump joint/fuel injector joint until the retainer [2] locks with a "CLICK".
Page 220 dummyhead dummyhead FUEL SYSTEM FUEL PRESSURE TEST • Check the fuel tank breather hose on the frame (MA, IIMA, IN, U, IIU models) or fuel tank-to-EVAP canister hose (Except MA, IIMA, IN, U, IIU models) for pinches or clogs when the fuel tank is lifted. Disconnect the quick connect fitting from the fuel pump (page 7-4).
Page 221 dummyhead dummyhead FUEL SYSTEM FUEL FLOW INSPECTION • Check the fuel tank breather hose on the frame (MA, IIMA, IN, U, IIU models) or fuel tank-to-EVAP canister hose (Except MA, IIMA, IN, U, IIU models) for pinches or clogs when the fuel tank is lifted. Disconnect the fuel injector side quick connect fitting (page 7-4).
Page 222 dummyhead dummyhead FUEL SYSTEM FUEL FILLER CAP REMOVAL/INSTALLATION Remove the following: – Three socket bolts [1] – Fuel filler cap [2] – Breathe seal [3] A pressure release can be heard when opening the fuel cap, but this is not blockage of the passage. If checking for clog in the passage of the fuel tank side is necessary, apply air pressure to the breather hose end with the fuel filler cap opened.
Page 223 dummyhead dummyhead FUEL SYSTEM CB650RA ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models Turn the ignition switch ON with the engine stop switch " ". Measure the voltage between the terminals of the wire harness side fuel pump 3P (Black) connector [1]. CONNECTION: Yellow/red (+) –...
Page 224 dummyhead dummyhead FUEL SYSTEM DISASSEMBLY/INSPECTION Remove the screws [1], Black wire terminals [2] and stoppers [3]. Disconnect the Pink wire connector [4] and Blue wire connector [5]. Remove the fuel pump unit assembly [1] and O-ring [2] from the fuel pump stay [3]. Remove the chamber [1].
Page 225 dummyhead dummyhead FUEL SYSTEM Remove the pressure regulator/O-ring [1] from the fuel filter [2]. ASSEMBLY Replace the fuel filter [1] with a new one if necessary. Install a new pressure regulator/O-ring [2]. Install a new O-ring [1] to the fuel pump [2]. Install the fuel pump.
Page 226 REMOVAL/INSTALLATION Remove the following: – Fuel tank (page 7-7) – Air cleaner lid (page 3-5) – Intake air duct (page 2-8) (CBR650RA) – Shroud (page 2-10) (CB650RA) Release the following: – Optional 2P (Black) connector [1] from the air cleaner housing [2] –...
Page 227 dummyhead dummyhead FUEL SYSTEM Loosen the six screws [1] fully and remove the intake ducts [2]. Remove the air cleaner housing [3]. Remove the O-rings [1] from the air cleaner housing. Installation is in the reverse order of removal. • Replace the O-rings with new ones. THROTTLE BODY REMOVAL/INSTALLATION •...
Page 228 dummyhead dummyhead FUEL SYSTEM – EVAP vacuum hose [1] from the hose joint [2] Except MA, IIMA, IN, U, IIU models: Loosen the four insulator band screws (throttle body side) [1]. Slide the throttle body assembly upward and release it off of the insulators.
Page 229 dummyhead dummyhead FUEL SYSTEM DISASSEMBLY/ASSEMBLY • The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual. • Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle operation.
Page 230 dummyhead dummyhead FUEL SYSTEM INSULATOR REMOVAL/INSTALLATION Remove the following: – Throttle body (page 7-13) – Cam chain tensioner lifter (page 10-20) Loosen the band screws [1] and remove the insulators [2]. Installation is in the reverse order of removal. • Align the insulator grooves with the tabs of the cylinder head.
Page 231 dummyhead dummyhead FUEL SYSTEM – Fuel rails [1] – Fuel rail joint [2] – O-rings [3] Check each part for wear or damage and replace it if necessary. Installation is in the reverse order of removal. • Replace the O-rings and seal rings with new ones and coat them with engine oil.
Page 232 dummyhead dummyhead FUEL SYSTEM REMOVAL Remove the air cleaner housing (page 7-12). Disconnect the IACV 4P (Black) connector [1]. Remove the following: – Two screws [2] – Setting plate [3] – IACV [4] – O-ring [5] INSTALLATION Replace the O-ring [1] with a new one (do not apply oil). Align Turn the slide valve [2] clockwise until it is seated lightly and install the IACV [3] by aligning the long slot with the...
Page 233 dummyhead dummyhead FUEL SYSTEM FUEL PUMP RELAY CIRCUIT INSPECTION For relay inspection (page 21-24). Remove the fuel pump relay (page 21-24). RELAY SWITCH/COIL POWER INPUT LINE Measure the voltage between each fuel pump relay 4P connector [1] terminal and ground. CONNECTION: B (+) –...
Page 234 dummyhead dummyhead FUEL SYSTEM Start the engine and open the throttle slightly to be certain that air is sucked in through the disconnected air supply hose. If the air is not drawn in, check the air supply hoses [1] for clogs and PAIR control solenoid valve [2] (page 7- 21).
Page 235 dummyhead dummyhead FUEL SYSTEM PAIR CONTROL SOLENOID VALVE INSPECTION Remove the PAIR control solenoid valve (page 7-20). Check that air flows (A) to (B) when the 12 V battery is connected to the PAIR control solenoid valve terminals. Air should not flow (A) to (B) when the battery is disconnected.
Page 236 dummyhead dummyhead FUEL SYSTEM PAIR CHECK VALVE INSPECTION Remove the PAIR check valves (page 7-21). Check the reed [1] of the PAIR check valve for damage or fatigue. Replace if necessary. Replace the PAIR check valve if the rubber seat [2] is cracked, deteriorated or damaged, or if there is clearance between the reed and seat.
Page 237 EVAP CANISTER (Except MA, IIMA, IN, U, IIU models) REMOVAL/INSTALLATION Release the EVAP canister drain hose [1] from under CBR650RA: CBR650RA shown: cowl [2] and harness clip [3]. Release the EVAP canister drain hose from hose clamp CB650RA: and harness clip.
Page 238 dummyhead dummyhead MEMO...
Page 239 dummytext 8. COOLING SYSTEM SERVICE INFORMATION························ 8-2 RADIATOR/COOLING FAN ····················· 8-7 TROUBLESHOOTING ···························· 8-2 RADIATOR RESERVE TANK··················· 8-9 SYSTEM FLOW PATTERN······················ 8-3 WATER PUMP ···································· 8-10 SYSTEM TESTING································· 8-4 WATER HOSE JOINT B························ 8-11 COOLANT REPLACEMENT ···················· 8-4 THERMOSTAT CASE ASSEMBLY ········· 8-12 THERMOSTAT ······································...
Page 240 • Use only genuine Honda PRE-MIX COOLANT containing corrosion inhibitors, specifically recommended for aluminium engines when adding or replacing the coolant. Genuine Honda PRE-MIX COOLANT is excellent at preventing corrosion and overheating. The effects last for up to 2 years. • The coolant should be inspected and replaced properly by following the maintenance schedule.
Page 241 dummyhead dummyhead COOLING SYSTEM SYSTEM FLOW PATTERN SIPHON HOSE AIR BLEED HOSE RADIATOR CAP LOWER RADIATOR HOSE A RADIATOR AIR BLEEDING JOINT CYLINDER BLOCK-TO- WATER PUMP HOSE LOWER RADIATOR HOSE B THERMOSTAT RADIATOR OIL COOLER RESERVE TANK WATER PUMP WATER PUMP-TO- CYLINDER HEAD HOSE OVERFLOW HOSE...
Page 242 SYSTEM TESTING RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the following: – Right middle cowl (page 2-7) (CBR650RA) – Right shroud (page 2-10) (CB650RA) – Radiator cap [1] Wet the sealing surfaces of the cap [1], then install the cap onto the tester [2].
Page 243 dummyhead dummyhead COOLING SYSTEM Remove the water pump drain bolt [1] and sealing washer [2], then drain the coolant. Reinstall the drain bolt with new sealing washer. Tighten the drain bolt to the specified torque. TORQUE: Water pump drain bolt: 13 N·m (1.3 kgf·m, 10 lbf·ft) Disconnect the siphon hose [1] from the radiator reserve tank.
Page 244 Check that there are no coolant leaks. Install the following: – Under cowl (page 2-11) (CBR650RA) – Intake air duct (page 2-8) (CBR650RA) – Shroud (page 2-10) (CB650RA) THERMOSTAT REMOVAL/INSTALLATION Drain the coolant (page 8-4).
Page 245 – Radiator (page 8-8) – Exhaust pipe/muffler (page 2-17) – Front wheel speed sensor (page 19-23) Remove the following: – Middle cowl (page 2-7) (CBR650RA) – Under cowl (page 2-11) (CBR650RA) – Shroud (page 2-10) (CB650RA) – Radiator lower mounting bolt [1] –...
Page 246 COOLING SYSTEM REMOVAL/INSTALLATION Drain the coolant (page 8-4). CBR650RA shown: Pull down the radiator (page 8-7). Disconnect the fan motor 2P (Black) connector [1]. Disconnect the siphon hose [1]. Disconnect lower radiator hose A [1] and lower hose B [2], then remove the radiator.
Page 247 COOLING SYSTEM DISASSEMBLY/ASSEMBLY Disassemble and assemble the radiator as following illustration. RADIATOR CBR650RA shown: RADIATOR CAP Align the cut outs. Release the wire clip. FAN MOTOR SHROUD COOLING FAN NUT 2.7 N·m (0.3 kgf·m, 2.0 lbf·ft) COOLING FAN FAN MOTOR NUT 5.1 N·m (0.5 kgf·m, 3.8 lbf·ft)
Page 248 COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Remove the under cowl (page 2-11) (CBR650RA). Check the bleed hole [1] of the water pump for signs of coolant leakage. • A small amount of coolant weeping from the bleed hole is normal.
Page 249 dummyhead dummyhead COOLING SYSTEM Remove the O-ring [1] from the water pump cover groove and replace it a new one. • Do not apply engine oil to the cover O-ring. Installation is in the reverse order of removal. Align TORQUE: Water pump mounting bolt: 12 N·m (1.2 kgf·m, 9 lbf·ft) Water pump cover bolt:...
Page 250 dummyhead dummyhead COOLING SYSTEM THERMOSTAT CASE ASSEMBLY REMOVAL/INSTALLATION Remove the following: – Radiator (page 8-8) – Exhaust pipe/muffler (page 2-18) Disconnect the following from the thermostat case joint: – Lower radiator hose A [1] – Lower radiator hose B [2] –...
Page 251 dummytext 9. LUBRICATION SYSTEM SERVICE INFORMATION························ 9-2 OIL PUMP ············································ 9-4 TROUBLESHOOTING ···························· 9-2 PRESSURE RELIEF VALVE ···················· 9-6 LUBRICATION SYSTEM DIAGRAM·········· 9-3 OIL STRAINER······································ 9-6 OIL PRESSURE INSPECTION ················· 9-4 OIL COOLER ········································ 9-8...
Page 252 dummyhead dummyhead LUBRICATION SYSTEM SERVICE INFORMATION LUBRICATION SYSTEM GENERAL Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil.
Page 253 dummyhead dummyhead LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models shown: EXHAUST CAM SHAFT INTAKE CAM SHAFT PISTON CONNECTING ROD CRANKSHAFT OIL ORIFICE OIL COOLER MAINSHAFT EOP SWITCH COUNTERSHAFT OIL PUMP OIL FILTER CARTRIDGE OIL STRAINER RELIEF VALVE...
Page 254 dummyhead dummyhead LUBRICATION SYSTEM OIL PRESSURE INSPECTION • If the engine oil pressure indicator remains on while the engine is running, check the indicator system before checking the oil pressure (page 21-12). Remove the EOP switch (page 21-13). Install the oil pressure gauge attachment [1] to the switch base.
Page 255 dummyhead dummyhead LUBRICATION SYSTEM Installation is in the reverse order of removal. • Align the oil pump shaft end with the water pump shaft groove. Align DISASSEMBLY/ASSEMBLY Disassemble and assemble the oil pump as following illustration. OIL PUMP BODY DRIVE PIN WASHER OIL PUMP PLATE OUTER ROTOR...
Page 256 dummyhead dummyhead LUBRICATION SYSTEM PRESSURE RELIEF VALVE REMOVAL/INSTALLATION Remove the oil pump (page 9-4). Remove the oil pressure relief valve [1] and O-rings [2]. Apply engine oil to a new O-rings. Install the O-rings to the oil pressure relief valve grooves.
Page 257 dummyhead dummyhead LUBRICATION SYSTEM Remove the oil strainer [1] and seal ring [2]. Clean the oil strainer screen [3] and check for damage. INSTALLATION Clean any gasket material from the mating surfaces of Be careful not to the oil pan. damage the mating surfaces.
Page 258 dummyhead dummyhead LUBRICATION SYSTEM OIL COOLER REMOVAL/INSTALLATION Drain the engine oil (page 3-11). Drain the coolant from the system (page 8-4). Remove the bolt [1], sealing washer [2] and oil cooler [3]. Disconnect the oil cooler water hoses [4] from the oil cooler.
Page 259 dummytext 10. CYLINDER HEAD/VALVES SERVICE INFORMATION······················ 10-2 CYLINDER HEAD COVER····················· 10-4 TROUBLESHOOTING ·························· 10-2 CAMSHAFT ········································ 10-5 COMPONENT LOCATION ····················· 10-3 CYLINDER HEAD ······························· 10-11 CYLINDER COMPRESSION TEST·········· 10-4 CAM CHAIN TENSIONER LIFTER ········· 10-20 10-1...
Page 260: Service Information
dummyhead dummyhead CYLINDER HEAD/VALVES SERVICE INFORMATION CYLINDER HEAD/VALVES GENERAL • This section covers service of the cylinder head, valves and camshafts. • All the services covered in this section 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 locations. •...
Page 261: Component Location
dummyhead dummyhead CYLINDER HEAD/VALVES COMPONENT LOCATION 12 N·m (1.2 kgf·m, 9 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 47 N·m (4.8 kgf·m, 35 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 10-3...
Page 262: Cylinder Compression Test
– Carbon deposits in combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL/INSTALLATION • The cylinder head cover can be serviced with the CBR650RA: engine installed in the frame. Disconnect the spark plug caps from the spark plugs (page 3-6). Remove the following: –...
Page 263: Camshaft
dummyhead dummyhead CYLINDER HEAD/VALVES Remove the cylinder head cover bolts [1] and mounting [1]/[2] rubbers [2]. Remove the cylinder head cover [3] from the cylinder head. • Do not forcibly remove the dowel pins from the cylinder head cover. Remove the cylinder head cover packing [1] from the cylinder head cover.
Page 264 dummyhead dummyhead CYLINDER HEAD/VALVES If you replace the camshaft and/or cam sprocket, Be careful not to let loosen the cam sprocket bolts [1]. the cam chain guide bolts fall into • Turn the crankshaft clockwise one full turn (360°), the crankcase. loosen the other cam sprocket bolts, then reset the No.1 piston to the TDC (Top Dead Center) on the compression stroke (page 3-8).
Page 265 dummyhead dummyhead CYLINDER HEAD/VALVES CAMSHAFT OIL CLEARANCE Wipe any oil from the journals of the camshaft, cylinder head and camshaft holders. Install the camshafts onto the cylinder head. Lay a strip of plastigauge [1] lengthwise on top of each camshaft journal avoiding the oil hole. •...
Page 266 dummyhead dummyhead CYLINDER HEAD/VALVES INSTALLATION Apply molybdenum oil solution to the outer surface of each valve lifter [1]. Install the shims [2] on the retainers and valve lifters Install the shims into the valve lifter bores. and valve lifters in their original locations.
Page 267 dummyhead dummyhead CYLINDER HEAD/VALVES Apply molybdenum oil solution to the camshaft journals, lobes and thrust surfaces. Install the cam chain [1] over the cam sprockets of the intake [2] and exhaust [3] camshafts, making sure that the timing marks [4] on the cam sprockets are flush with the top surface [5] of the cylinder head.
Page 268 dummyhead dummyhead CYLINDER HEAD/VALVES Apply engine oil to the camshaft holder bolt [1] threads [1]/[2] and seating surface. Install the camshaft holder bolts with new sealing washers [2]. Failure to tighten the camshaft holder in a crisscross pattern may cause the camshaft holder to break. From inside to outside tighten the camshaft holder bolts gradually until the camshaft holders seats on the cylinder head.
Page 269: Cylinder Head
dummyhead dummyhead CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL Remove the following: – Exhaust pipe/muffler (page 2-18) – Throttle body (page 7-13) – Camshaft (page 10-5) Disconnect the ECT sensor 2P (Blue) connector [1] and bleeding hose [2]. Remove the bolts [1] and water hose joint A [2] from the cylinder head.
Page 270 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the starter clutch (page 11-14). [2]/[3] Remove the cam chain guide A [1]. Remove the washer bolt [2], collar [3] and cam chain tensioner [4]. Remove the cam chain [5] and timing sprocket [6] from the crankshaft.
Page 271 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the valve spring cotters [1] using the special To prevent loss of tools as shown. tension, do not compress the valve TOOLS: springs more than [2] Valve spring compressor 07757-0010000 necessary to [3] Valve spring compressor remove the cotters.
Page 272 dummyhead dummyhead CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Disassemble the cylinder head (page 10-12). Chill new valve guides in a freezer for about 1 hour. • Be sure to wear heavy gloves to avoid burns when handling the heated cylinder head. •...
Page 273 dummyhead dummyhead CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING INSPECTION Disassemble the cylinder head (page 10-12). Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coat of Prussian Blue to the valve seats. Tap the valve against the valve seat several times using a hand-lapping tool [1], without rotating the valve to make a clear pattern.
Page 274 dummyhead dummyhead CYLINDER HEAD/VALVES REFACING Reface the valve seat using the following tools. TOOLS: Cutter holder, 4.5 mm 07781-0010600 Seat cutter, 27.5 mm (IN, 45°) 07780-0010200 Seat cutter, 24 mm (EX, 45°) 07780-0010600 Flat cutter, 28 mm (IN, 32°) 07780-0012100 Flat cutter, 24 mm (EX, 32°) 07780-0012500 Interior cutter, 26 mm (IN, 60°)
Page 275 dummyhead dummyhead CYLINDER HEAD/VALVES ASSEMBLY VALVE LIFTER VALVE COTTERS AIR BLEEDING JOINT 12 N·m (1.2 kgf·m, 9 lbf·ft) SHIM VALVE SPRING RETAINER VALVE SPRING VALVE STEM SEAL VALVE SPRING SEAT SEALING WASHER VALVE GUIDE EXHAUST VALVE INTAKE VALVE Clean the cylinder head assembly with solvent and blow through all oil passages with compressed air.
Page 276 dummyhead dummyhead CYLINDER HEAD/VALVES Place a suitable tool [1] onto the valve stem [2]. Support the cylinder head above the Tap the tool gently to seat the valve cotters firmly using work bench surface a hammer. to prevent valve damage. Apply a locking agent to the air bleeding joint [1] threads (page 1-17).
Page 277 dummyhead dummyhead CYLINDER HEAD/VALVES Install the dowel pins [1] and a new gasket [2]. Route the cam chain through the cylinder head and install the cylinder head [1] onto the cylinder. Clean the cylinder head 9 mm washer-bolts [2] in solvent, and dry them thoroughly.
Page 278: Cam Chain Tensioner Lifter
dummyhead dummyhead CYLINDER HEAD/VALVES CAM CHAIN TENSIONER LIFTER REMOVAL/INSTALLATION • The cam chain tensioner lifter can be serviced with the engine installed in the frame. Remove the sealing bolt [1] and sealing washer [2]. Turn the cam chain tensioner lifter shaft fully in (clockwise) and secure it using the special tool.
Page 279 dummytext 11. CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH SERVICE INFORMATION······················ 11-2 CLUTCH ············································ 11-6 TROUBLESHOOTING ·························· 11-2 STARTER CLUTCH ···························· 11-14 COMPONENT LOCATION ····················· 11-3 GEARSHIFT LINKAGE ························ 11-19 RIGHT CRANKCASE COVER ················ 11-4 11-1...
Page 280 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH SERVICE INFORMATION CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH GENERAL • This section covers service of the clutch, gearshift linkage and starter clutch. 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 281 83 N·m (8.5 kgf·m, 61 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 15 N·m (1.5 kgf·m, 11 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 128 N·m (13.1 kgf·m, 94 lbf·ft) (CBR650RA only) 12 N·m (1.2 kgf·m, 9 lbf·ft) 11-3...
Page 282 Remove the bolt [1] and clutch cable holder [2], then disconnect the clutch cable [3] from the clutch lifter arm [4]. Align Remove the following: – Right crankcase cover bolts [1] – Under cowl stay (CBR650RA only) [2] – Right crankcase cover [3] 11-4...
Page 283 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Remove the dowel pins [1]. Clean any sealant off from the right crankcase cover Be careful not to mating surfaces. damage the mating surfaces. Installation is in the reverse order of removal. TORQUE: Right crankcase cover bolt: 12 N·m (1.2 kgf·m, 9 lbf·ft) •...
Page 284 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Remove the oil seal [1] from the right crankcase cover. Check the needle bearings [2] for wear or damage, replace them if necessary. Assembly is in the reverse order of disassembly. • Apply grease to a new oil seal lips. •...
Page 285 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Remove the following: [10] – Clutch pressure plate [1] – Clutch spring seats [2] – Clutch lifter pin [3] – Clutch discs B [4] (2 pcs) – Clutch plate B [5] – Clutch disc C [6] –...
Page 286 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Loosen the oil pump driven sprocket washer-bolt [1], but do not remove it yet. Remove the thrust washer [2] and clutch outer [3]. Remove the needle bearing [1]. Remove the bolt [1] and oil pump drive chain guide [2]. Remove the oil pump driven sprocket washer-bolt [1].
Page 287 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Remove the clutch outer guide [1]. INSPECTION Check the following of the clutch pressure plate [1] for scratches, damage, abnormal wear and deformation. – Cam areas [2] – Grooves – Disc sliding surface – Bearing [3] Replace the clutch pressure plate if necessary.
Page 288 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Inspect the following parts for scratch, damage, abnormal wear and deformation. – Clutch lifter bearing – Clutch lifter pin – Clutch springs – Spring seats – Judder spring – Clutch discs/plates – needle bearing – Clutch outer guide –...
Page 289 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Install the oil pump drive chain guide [1] by aligning the Be careful not to hole with boss of crankcase. drop the parts into Tighten the bolt [2] securely. the oil pan. Align Apply engine oil to the rotating area of the needle bearing [1].
Page 290 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Install the clutch center [1] and thrust washer [2]. Install the lock washer [3] with its "OUT" mark [4] facing out. Apply engine oil to the threads and seating surface of a new clutch center lock nut [1], then install it onto the mainshaft.
Page 291 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Install the judder spring seat [1] and judder spring [2] onto the clutch center [3] as shown. Apply engine oil to the entire surface of clutch discs. Install the clutch disc B [4] onto the clutch center. Install the clutch plates A [5] (4 pcs) and discs A [6] (3 pcs) alternately, starting with the plate A.
Page 292 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Install the clutch springs [1], set plate [2] and set plate bolts [3]. Tighten the set plate bolts in a crisscross pattern in two or three steps. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply molybdenum oil solution to the starter idle gear shaft [1] outer surface.
Page 293 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Remove the starter clutch outer assembly [1]. MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models shown: Remove the thrust washer [1]. DISASSEMBLY Check the operation of the one-way clutch by turning the driven gear [1]. You should be able to turn the driven gear clockwise smoothly, gear...
Page 294 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH INSPECTION Inspect the following parts for scratch, damage, abnormal wear and deformation. – Starter driven gear – Starter reduction gear – Starter clutch outer – Starter one-way clutch Measure each part according to CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH SPECIFICATIONS (page 1-8).
Page 295 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Install the starter driven gear [1] into the starter clutch outer while turning the starter driven gear clockwise. Apply engine oil to the rotating area of the needle bearing [1]. Install the needle bearing into the starter clutch outer. Recheck the one-way clutch operation (page 11-15).
Page 296 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Apply engine oil to the starter clutch outer mounting bolt MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models shown: [1] threads and seating surface. Install the washer [2] and starter clutch mounting bolt. Temporarily install the following: MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models shown: –...
Page 297 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH GEARSHIFT LINKAGE REMOVAL Remove the clutch (page 11-6). Remove the pinch bolt [1] and disconnect the gearshift arm [2] from the gearshift spindle. Remove the bolt [1] and setting plate [2]. Pull the gearshift spindle assembly [1] and thrust washer [2] out of the crankcase.
Page 298 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH INSPECTION Inspect the following parts for scratch, damage, abnormal wear and deformation. – Shift drum stopper plate – Shift drum stopper arm – Shift drum stopper arm return spring Replace if necessary. Check the gearshift spindle [1] for wear, damage or bending.
Page 299 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Install the dowel pin [1] onto the shift drum. Hold the stopper arm [2] using a screwdriver as shown. Align the dowel pin Align on the shift drum Install the gearshift cam [3] while aligning its slot with with the wide the dowel pin.
Page 300 dummyhead dummyhead CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH Install the gearshift arm [1] to the gearshift spindle by aligning the arm slit with the punch mark on the gearshift spindle. Install and tighten the pinch bolt [2]. Install the clutch (page 11-10). Align GEARSHIFT PEDAL REMOVAL/ INSTALLATION Remove the pinch bolt [1] and gearshift arm [2] from the...
Page 301 dummytext 12. ALTERNATOR SERVICE INFORMATION······················ 12-2 STATOR ············································ 12-4 COMPONENT LOCATION ····················· 12-2 FLYWHEEL ········································ 12-5 LEFT CRANKCASE COVER·················· 12-3 12-1...
Page 302 – MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models (page 5-9) COMPONENT LOCATION ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models shown: 113 N·m (11.5 kgf·m, 83 lbf·ft) CBR650RA only: 12 N·m (1.2 kgf·m, 9 lbf·ft) 12-2...
Page 303 Support the motorcycle in an upright position on a level surface. Remove the following: – Left middle cowl (page 2-7) (CBR650RA) – Under cowl (page 2-11) (CBR650RA) Lift the fuel tank and support it (page 3-4). Disconnect the alternator 3P (Gray) connector [1].
Page 304 dummyhead dummyhead ALTERNATOR Installation is in the reverse order of removal. Cover side: TORQUE: Do not apply liquid sealant Left crankcase cover bolt: to the grommet area 12 N·m (1.2 kgf·m, 9 lbf·ft) • Apply sealant (TB1207B manufactured ThreeBond or an equivalent) to the mating areas of crankcase cover and crankcase as shown.
Page 305 dummyhead dummyhead ALTERNATOR FLYWHEEL REMOVAL Remove the left crankcase cover (page 12-3). ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models Hold the flywheel [1] using the special tool and loosen shown: the flywheel bolt [2]. • Set the holding block [3] of the flywheel holder [4] avoiding the flywheel reluctors [5].
Page 306 dummyhead dummyhead ALTERNATOR Install the flywheel [1] while aligning the woodruff key ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models on the crankshaft with flywheel keyway. shown: Align Apply engine oil to the flywheel bolt [1] threads and ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models seating surface.
Page 307 dummytext 13. CRANKCASE/TRANSMISSION SERVICE INFORMATION······················ 13-2 CRANKCASE······································ 13-4 TROUBLESHOOTING ·························· 13-2 TRANSMISSION·································· 13-7 COMPONENT LOCATION ····················· 13-3 13-1...
Page 308 dummyhead dummyhead CRANKCASE/TRANSMISSION SERVICE INFORMATION CRANKCASE/TRANSMISSION GENERAL • The crankcase must be separated to service the following: – Transmission – Crankshaft (page 14-4) – Piston/connecting rod/cylinder (page 14-13) • The following components must be removed before separating the crankcase: – Engine (page 15-4) –...
Page 309 dummyhead dummyhead CRANKCASE/TRANSMISSION COMPONENT LOCATION 24 N·m (2.4 kgf·m, 18 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 15 N·m (1.5 kgf·m, 11 lbf·ft) + 120° 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 13-3...
Page 310 dummyhead dummyhead CRANKCASE/TRANSMISSION CRANKCASE SEPARATION Refer to Service Information for removal of necessary parts before separating the crankcase (page 13-2). Remove the crankcase 6 x 50 mm bolt [1] on the upper side of the crankcase. Remove the bolt [2] and wire stay [3] on the lower side of the crankcase.
Page 311 dummyhead dummyhead CRANKCASE/TRANSMISSION ASSEMBLY Clean the upper and lower crankcase mating surfaces thoroughly, being careful not to damage them. Check the crankcase oil passages for clogs, and clean them if necessary. Apply sealant (TB1207B manufactured by ThreeBond or an equivalent) to the crankcase mating surface as shown.
Page 312 dummyhead dummyhead CRANKCASE/TRANSMISSION Apply molybdenum oil solution to the main journal bearing sliding surfaces on the lower crankcase. Install the lower crankcase onto the upper crankcase. Install new crankcase main journal bolts [1]. • Tighten the crankcase main journal bolts using the Plastic Region Tightening Method.
Page 313 dummyhead dummyhead CRANKCASE/TRANSMISSION TRANSMISSION REMOVAL Separate the crankcase halves (page 13-4). Remove the countershaft assembly [1] and dowel pin [2]. Remove the shift drum bearing setting washer-bolts [1]. Remove the shift fork shaft [1] and shift forks [2]. Remove the shift drum [1]/bearing [2] assembly. Remove the shift drum bearing from the shift drum.
Page 314 dummyhead dummyhead CRANKCASE/TRANSMISSION Remove the bolts [1] and mainshaft bearing setting plate [2]. Slide the mainshaft assembly [1] off the upper crankcase and remove the right mainshaft bearing [2]. Remove the mainshaft assembly. INSPECTION Inspect the following parts for scratch, damage, abnormal wear and deformation.
Page 315 dummyhead dummyhead CRANKCASE/TRANSMISSION Apply engine oil to a new main shaft bearing [1]. Drive in a new bearing squarely Drive a new bearing into the crankcase until it is fully with the marking seated using the special tools. side facing down. TOOLS: [2] Driver 07949-3710001...
Page 316 dummyhead dummyhead CRANKCASE/TRANSMISSION COUNTERSHAFT : Gear teeth THRUST WASHER THRUST WASHER SNAP RING Rotating gear inner surface NEEDLE BEARING C2 bushing entire surface SPLINE WASHER C3, C4 bushing outer surface C5, C6 gear inner spline surface C4 GEAR BUSHING C5, C6 gear shifter groove C4 GEAR (39T) C1 needle bearing rotating area LOCK WASHER...
Page 317 dummyhead dummyhead CRANKCASE/TRANSMISSION Apply locking agent to the mainshaft bearing setting plate bolts [1] threads (page 1-17). Install the mainshaft bearing setting plate [2] and setting plate bolts. Tighten the setting plate bolts to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply engine oil to the shift drum bearing [1] and shift drum [2] journal outer surface.
Page 318 dummyhead dummyhead CRANKCASE/TRANSMISSION Apply locking agent to the shift drum bearing setting washer-bolt [1] threads (page 1-17). Install and tighten the shift drum bearing setting washer-bolts to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the dowel pin [1] onto the upper crankcase hole. Install the countershaft [2] by aligning the following: –...
Page 319 dummytext 14. CRANKSHAFT/PISTON/CYLINDER SERVICE INFORMATION······················ 14-2 MAIN JOURNAL BEARING ··················· 14-7 TROUBLESHOOTING ·························· 14-2 CRANKPIN BEARING ························· 14-10 COMPONENT LOCATION ····················· 14-3 PISTON/CYLINDER ···························· 14-13 CRANKSHAFT ···································· 14-4 14-1...
Page 320 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER SERVICE INFORMATION CRANKSHAFT/PISTON/CYLINDER GENERAL • The crankcase must be separated to service the crankshaft, cylinder, piston/connecting rod and piston oil jet. Refer to procedures for crankcase separation (page 13-4). • Mark and store the connecting rods, bearing caps and bearing inserts to be sure of their correct locations for reassembly. •...
Page 321 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER COMPONENT LOCATION 35.2 N·m (3.6 kgf·m, 26 lbf·ft) 14-3...
Page 322 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER CRANKSHAFT SIDE CLEARANCE INSPECTION Separate the crankcase halves (page 13-4). Measure the connecting rod side clearance. SERVICE LIMIT: 0.25 mm (0.010 in) If the clearance exceeds the service limit, replace the connecting rod (page 14-4). Recheck and if still out of limit, replace the crankshaft (page 14-4).
Page 323 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER INSPECTION Support the crankshaft [1] on both end journals. Set a dial gauge on the center main journal of the crankshaft avoiding the oil groove and hole. Rotate the crankshaft two revolutions (720°) and read the runout. SERVICE LIMIT: 0.05 mm (0.002 in) INSTALLATION Apply molybdenum oil solution to the main journal...
Page 324 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Clean the mating surface of the connecting rods and crankpin bearing caps with solvent and blow them with compressed air. Apply molybdenum oil solution to the crankpin bearing [1] sliding surfaces on the crankpin bearing caps [2]. Install the crankpin bearing caps by aligning the I.D.
Page 325 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER MAIN JOURNAL BEARING 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. BEARING INSPECTION Remove the crankshaft (page 14-4). Check the main journal bearing inserts [1] for unusual wear or peeling.
Page 326 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Install the lower crankcase onto the upper crankcase. Clean the crankcase main journal bolts (reuse) in solvent, and dry them thoroughly. Apply engine oil to the crankcase main journal bolt threads and seating surfaces. Install the crankcase main journal bolts [1]. Make sure the upper and lower crankcase are seated securely.
Page 327 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Cross-reference the main journal and bearing support codes to determine the replacement bearing color code [1]. MAIN JOURNAL BEARING THICKNESS: A: Black: Thickest B: Brown: C: Green: D: Yellow: E: Pink: Thinnest MAIN JOURNAL BEARING SELECTION TABLE: BEARING SUPPORT I.D.
Page 328 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER CRANKPIN BEARING 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. BEARING INSPECTION Remove the crankshaft (page 14-4). Check the crankpin bearing inserts [1] for unusual wear or peeling.
Page 329 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Install the crankpin bearing caps [1] by aligning the I.D. code number on the connecting rod and bearing cap. Align Be sure to install each part in its original position, as noted during removal. Apply engine oil to the crankpin bearing cap nut [1] threads and seating surfaces.
Page 330 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER If you are replacing the crankshaft, record the Letters (A, B or C) corresponding crankpin O.D. code letter [1]. on the crank weight are the crankpin If you are reusing the crankshaft, measure the crankpin O.D. codes from left O.D.
Page 331 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER PISTON/CYLINDER PISTON/CONNECTING ROD REMOVAL • 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; the assembly will get stuck in the gap between the cylinder liner and the upper crankcase.
Page 332 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Clean carbon deposits from the piston ring grooves with a ring that will be discarded. • Never use a wire brush; it will scratch the groove. INSPECTION Inspect the following parts for scratch, damage, abnormal wear, deformation, burning or clogs in oil passages.
Page 333 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER PISTON INSTALLATION Install the crankpin bearings in the original locations (page 14-5). Apply engine oil to the piston pin hole inner surface. Apply molybdenum oil solution to the connecting rod small end inner surface. Assemble the piston [1] and connecting rod [2] with the oil passage hole [3] facing to the piston "IN"...
Page 334 dummyhead dummyhead MEMO...
Page 335 dummytext 15. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION······················ 15-2 ENGINE REMOVAL ····························· 15-4 COMPONENT LOCATION ····················· 15-3 ENGINE INSTALLATION ······················ 15-7 15-1...
Page 336 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE REMOVAL/INSTALLATION 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. Do not use the oil filter as a jacking point.
Page 337 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models shown: 40 N·m (4.1 kgf·m, 30 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 49 N·m (5.0 kgf·m, 36 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 12 N·m...
Page 338 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 3-11). MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models shown: Drain the coolant (page 8-4). Fully slacken the drive chain (page 3-15). Remove the following: – Drive sprocket cover (page 2-15) –...
Page 339 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the alternator 3P (Gray) connector [1]. Release the alternator wire clip [1]. Remove the alternator wire [2] out of the frame. Release the terminal cap [1]. Remove the terminal nut [2] and disconnect the starter motor cable [3].
Page 340 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Remove the drive sprocket bolt [1], washer [2] and drive sprocket [3]. Support the motorcycle securely with a hoist or equivalent. Place a floor jack or other adjustable support under the Do not use the oil engine.
Page 341 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION Place the engine in the frame, then loosely install all the bolts, collars and nuts. During engine installation, hold the engine securely • Place the jack or other adjustable support under the engine. and be careful not •...
Page 342 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Install the removed parts in the reverse order of removal. • Install the drive sprocket [1] with its marked [2] side facing out. • Align the clutch cable holder hole with the right crankcase cover boss. TORQUE: Drive sprocket bolt: 54 N·m (5.5 kgf·m, 40 lbf·ft)
Page 343 dummytext 16. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION······················ 16-2 FRONT WHEEL·································· 16-15 TROUBLESHOOTING ·························· 16-2 FORK ··············································· 16-21 COMPONENT LOCATION ····················· 16-3 STEERING STEM ······························· 16-38 HANDLEBAR ······································ 16-5 16-1...
Page 344 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION FRONT WHEEL/SUSPENSION/STEERING GENERAL • A hoist or equivalent is required to support the motorcycle when servicing the front wheel, fork and steering stem. • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
Page 345 FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION CBR650RA 103 N·m 22 N·m (10.5 kgf·m, 76 lbf·ft) (2.2 kgf·m, 16 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) Except TH, IITH, IIBR models: TH, IITH, IIBR models: 42 N·m (4.3 kgf·m, 31 lbf·ft) 45 N·m...
Page 346 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING CB650RA Except IN model shown: 103 N·m (10.5 kgf·m, 76 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 22 N·m TH, IN, BR models: (2.2 kgf·m, 16 lbf·ft) Except TH, IN, BR models: 27 N·m (2.8 kgf·m, 20 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 45 N·m...
Page 347 FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL (CBR650RA) Remove the following: – Ignition switch cover (page 21-14) – Clutch switch connectors [1] – Two bolts [2] – Bracket holder [3] – Clutch lever bracket [4] – Two screws [1] – Left handlebar switch housings [2] –...
Page 348 Remove the following: – Cap [1] – Steering stem nut [2] [2]/[3] – Washer [3] – Top bridge [4] Remove the handlebars [5] from the fork sliders. INSTALLATION (CBR650RA) Make sure the stopper ring [1] is installed in position. 16-6...
Page 349 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the handlebars [1] onto the fork sliders. Align Install the top bridge [2] while aligning its holes with the handlebar stopper pins. Align Install the washer [1] and steering stem nut [2]. Temporarily tighten the top bridge pinch bolts [3] until Do not fully tighten the seating surfaces contact with each other.
Page 350 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the right handlebar switch housings [1] by aligning the locating pin with the hole in the handlebar. Tighten the upper screw first [2], then tighten the lower screw [3] to the specified torque. TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) Align Install the master cylinder [1] and holder [2] with the Align the edge of...
Page 351 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING REMOVAL (CB650RA) Remove the following: – Rearview mirrors (page 2-5) – Handlebar weights (page 16-13) – Bolt caps [1] – Clutch switch connectors [1] – Two bolts [2] – Bracket holder [3] – Clutch lever bracket [4] –...
Page 352 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING – Two screws [1] – Right handlebar switch housing [2] – Two screws [1] – Rear throttle housing [2] – Four socket bolts [1] – Handlebar upper holder [2] – Handlebar [3] – Throttle grip/housing assembly [1] (from the handlebar [2]) 16-10...
Page 353 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INSTALLATION (CB650RA) Apply grease to the cable groove and roll-up area of the throttle grip [1]. Install the throttle grip/housing assembly onto the handlebar [2]. Install the handlebar [1] and upper holder [2]. Tighten Align the punch the front socket bolts [3] first, then tighten the rear mark with the edge socket bolts [4] to the specified torque.
Page 354 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the master cylinder [1] and holder [2] with the Align the edge of Align "UP" mark [3] facing up. Tighten the upper bolt [4] first, the master cylinder then the lower bolt [5] to the specified torque. with the punch mark on the TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Page 355 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR LOWER HOLDER REMOVAL/INSTALLATION (CB650RA) Loosen the handlebar lower holder nuts [1]. Remove the Bolt caps [2], handlebar mounting socket bolts [3], handlebar upper holder [4] and handlebar [5] (page 16-9). Remove the lower holder nuts, washers [6], handlebar lower holders [7] and lower mount rubbers [8].
Page 356 FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR INNER WEIGHT REPLACEMENT CBR650RA Remove the left handlebar grip and throttle grip (page 16-15). Straighten the retainer tab [1] with a screwdriver or punch. Temporarily install the handlebar weight [3] with the Apply soapy water...
Page 357 Clean the inside surface of the handlebar grip and outside surface of the handlebar and throttle pipe. Apply Honda bond A or equivalent to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe.
Page 358 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the right and left side collars [1]. RIGHT SIDE: LEFT SIDE: INSPECTION 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. Replace the bearings if they do not turn smoothly, quietly, or if they fit loosely in the hub.
Page 359 Do not add more than 60 g (2.1 oz) to the wheel. Press the weights by your hands firmly and make sure they are not come off the rim. • Stick-type balance weights should be used on this motorcycle. Use genuine Honda balance weights. – Before installing weights,...
Page 360 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY/ASSEMBLY Disassemble and assemble the front wheel as following illustration. • Install each dust seal with the flat side facing out so that it is flush with the wheel hub. • Install the brake disc with the rotation mark (arrow) facing out.
Page 361 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Drive in a new left side bearing squarely with the marked side facing up until it is fully seated. Install the distance collar. Drive in a new right side bearing squarely with the marked side facing up until it is fully seated. TOOLS: [1] Driver 07749-0010000...
Page 362 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the front wheel between the fork legs. Be careful not to damage the pulser Apply a thin layer of grease to the front axle surface. ring. Install the front axle [1] from the right side. Install the axle bolt [1].
Page 363 FRONT WHEEL/SUSPENSION/STEERING FORK REMOVAL (CBR650RA) Remove the following: TH model shown: – Front wheel (page 16-15) – Front fender (page 2-5) Remove the bolts [1] and front wheel speed sensor Left side only: guard [2] from the left fork.
Page 364 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION (CBR650RA) When the fork is disassembled: Insert the fork leg [1] into the bottom bridge, handlebar, top bridge and temporarily tighten the pinch bolt [2]. Tighten the fork cap to the specified torque using the special tools.
Page 365 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the front wheel speed sensor guard [1] and new Left side only: TH model shown: mounting bolts [2] onto the left fork. • Always replace the front wheel speed sensor guard mounting bolts with new ones. Install the wire clip [3] onto the left fork (TH, IITH IIBR models).
Page 366 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING If it is necessary to disassemble the fork leg, perform the following procedure: – Remove the handlebar (page 16-9) Keep the master – Loosen the pinch bolt of the top bridge (page 16-23) cylinder reserve tank upright to While holding the fork leg, loosen the bottom bridge prevent air from pinch bolts [1].
Page 367 – Front turn signal light (page 21-4) – Handlebar (page 16-11) DISASSEMBLY RIGHT SIDE Remove the stopper ring [1] being careful not to scratch the outer tube (CBR650RA). Remove the fork cap [2] with the special tool. TOOL: Fork cap wrench 070MA-MGP0100 Push the outer tube [1] slowly down, and gently seat the dust seal [2] onto the axle holder [3].
Page 368 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the stopper ring [1] from the groove in the fork pipe. Pull up and remove the fork rod assembly [1]. Remove the fork spring [1] and spring collar [2]. Pour out the fork fluid by pumping the outer tube [3] several times.
Page 369 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Pull the slide pipe assembly [1] out until you feel resistance from the slider bushing. Then move it in and out, tapping the bushing lightly until the outer tube [2] separates from the slide pipe assembly. The guide bushing will be forced out by the slider bushing.
Page 370 FRONT WHEEL/SUSPENSION/STEERING LEFT SIDE Remove the stopper ring [1] being careful not to scratch the outer tube (CBR650RA). Remove the fork cap [2] with the special tool. TOOL: Fork cap wrench 070MA-MGP0100 Push the outer tube [1] slowly down, and gently seat the dust seal [2] onto the axle holder [3].
Page 371 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Loosen the lock nut [1] while holding the fork cap [2], then remove the fork cap. Remove the O-ring [3] from the fork cap groove. Remove the spring seat [4] and rebound spring [5]. Remove the fork spring [1]. Remove the spring collar [1].
Page 372 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Pull the slide pipe assembly [1] out until you feel resistance from the slider bushing. Then move it in and out, tapping the bushing lightly until the outer tube [2] separates from the slide pipe assembly. The guide bushing will be forced out by the slider bushing.
Page 373 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY RIGHT SIDE Before assembly, wash all parts with a high flash point or non-flammable solvent and wipe them off completely. LOCK NUT 18 N·m (1.8 kgf·m, 13 lbf·ft) FORK CAP O-RING STOPPER RING 35 N·m (3.6 kgf·m, 26 lbf·ft) STOPPER SEAT SLIDE PIPE REBOUND...
Page 374 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Apply fork fluid to new dust seal and oil seal lips. Install the dust seal [1], stopper ring [2] and oil seal [3]. Install the oil seal with its marked side Install the back-up ring [4] and guide bushing [5]. facing toward the Install the slider bushing [6] and piston B ring [7] if they axle holder.
Page 375 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Pour the specified amount of recommended fork fluid. RECOMMENDED FORK FLUID: Fork fluid (viscosity: 10W) FORK FLUID CAPACITY: 465 ± 2.5 cm (15.7 ± 0.08 US oz, 16.3 ± 0.09 Imp oz) Slowly push the outer tube [1] and pump the fork pipe several times to remove the trapped air from the lower portion of the fork pipe.
Page 376 Install and tighten the fork cap [1] into the outer tube. Install the stopper ring [2] being careful not to scratch the outer tube (CBR650RA). Tighten the fork cap to the specified torque after installing the fork leg into the steering stem (page 16- 21).
Page 377 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING LEFT SIDE Before assembly, wash all parts with a high flash point or non-flammable solvent and wipe them off completely. FORK CAP STOPPER RING 35 N·m (3.6 kgf·m, 26 lbf·ft) SPRING SEAT SLIDE PIPE ASSEMBLY LOCK NUT REBOUND SPRING 18 N·m (1.8 kgf·m, 13 lbf·ft) FORK SPRING...
Page 378 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Apply fork fluid to new dust seal and oil seal lips. Install the dust seal [1], stopper ring [2] and oil seal [3]. Install the oil seal with its marked side Install the back-up ring [4] and guide bushing [5]. facing toward the Install the slider bushing [6] if it is removed.
Page 379 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the spring collar [1]. Install the fork spring [2] into the slide pipe assembly with the tightly wound side facing down. Down Tighten the lock nut [1] until it stops. Install the rebound spring [2] to the fork rod. Install the spring seat [3] in the shown direction.
Page 380 Install and tighten the fork cap [1] into the outer tube. Install the stopper ring [2] being careful not to scratch the outer tube (CBR650RA). Tighten the fork cap to the specified torque after installing the fork leg into the steering stem (page 16- 21).
Page 381 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Loosen the steering bearing adjustment nut [1] using the special tool. TOOL: [2] Steering stem socket 07916-3710101 While holding the steering stem, remove the adjustment nut. Remove the following: – Steering stem [1] – Upper dust seal [2] –...
Page 382 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the stem nut [1] onto the steering stem [2] to prevent the threads from being damaged when removing the lower inner race [3]. Remove the lower inner race with a chisel or equivalent tool, being careful not to damage the stem. Remove the lower dust seal [4].
Page 383 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION LOCK NUT CBR650RA shown: ADJUSTMENT NUT LOCK WASHER UPPER DUST SEAL LOWER OUTER RACE UPPER INNER RACE LOWER STEERING BEARING UPPER STEERING BEARING LOWER INNER RACE LOWER DUST SEAL UPPER OUTER RACE STEERING STEM • Use urea based multi-purpose extreme pressure...
Page 384 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Apply engine oil to the threads of the adjustment nut [1]. Install the adjusting nut. Tighten the adjustment nut to the specified torque using the special tool while holding the steering stem. TOOL: [2] Steering stem socket 07916-3710101 TORQUE: 31 N·m (3.2 kgf·m, 23 lbf·ft) Turn the steering stem [1] left and right, lock-to-lock five...
Page 385 FRONT WHEEL/SUSPENSION/STEERING Clean the threads of the stem with a degreasing agent. CB650RA: Install the following: CBR650RA: – Handlebars (page 16-5) – Fork legs (page 16-21) Make sure the steering stem moves smoothly, without play or binding. Install the top bridge [1], washer [2] and steering stem CB650RA: nut [3].
Page 386 dummyhead dummyhead MEMO...
Page 387 dummytext 17. REAR WHEEL/SUSPENSION SERVICE INFORMATION······················ 17-2 REAR WHEEL····································· 17-4 TROUBLESHOOTING ·························· 17-2 SHOCK ABSORBER ···························· 17-8 COMPONENT LOCATION ····················· 17-3 SWINGARM······································· 17-10 17-1...
Page 388 • Do not operate the brake pedal after removing the rear wheel. • After the rear wheel installation, check the brake operation by applying the brake pedal. • Use only genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. • For brake system service (page 18-2).
Page 389 dummyhead dummyhead REAR WHEEL/SUSPENSION COMPONENT LOCATION Except MA, IIMA, IN, U, IIU shown: 103 N·m (10.5 kgf·m, 76 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 98 N·m (10.0 kgf·m, 72 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 17-3...
Page 390 dummyhead dummyhead REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL/INSTALLATION Loosen the axle nut [1]. Support the motorcycle using a hoist or equivalent and raise the rear wheel off the ground. Loosen the lock nuts [2] and turn the adjusting bolts [3] so the wheel can be moved forward all the way. Remove the axle nut, washer [4] and right adjusting Support the caliper plate [5].
Page 391 dummyhead dummyhead REAR WHEEL/SUSPENSION INSPECTION 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. Replace the bearings if they do not turn smoothly, quietly, or if they fit loosely in the hub. Inspect the following parts for damage, abnormal wear, deformation or bend.
Page 392 dummyhead dummyhead REAR WHEEL/SUSPENSION BEARING REPLACEMENT WHEEL BEARING Install the bearing remover head [1] into the bearing. From the opposite side of the wheel, install the bearing remover shaft [2] and drive the bearing out of the wheel hub. TOOLS: Bearing remover head, 20 mm 07746-0050600 Bearing remover shaft...
Page 393 dummyhead dummyhead REAR WHEEL/SUSPENSION Place a new bearing [1] with the marked side facing down. Install the driven flange collar [2] into the bearing until it is fully seated. TOOLS: [3] Driver 07749-0010000 [4] Attachment, 28 x 30 mm 07946-1870100 [5] Pilot, 20 mm 07746-0040500 Drive in the driven flange bearing/collar squarely with...
Page 394 dummyhead dummyhead REAR WHEEL/SUSPENSION SHOCK ABSORBER REMOVAL/INSTALLATION Remove the drive chain cover/mud guard (page 2-16). Lift the fuel tank and support it (page 3-4). Remove the shock absorber upper mounting nut [1] and bolt [2]. Remove the shock absorber lower mounting nut [1] and bolt [2].
Page 395 dummyhead dummyhead REAR WHEEL/SUSPENSION Press the spherical bearing [1] out of the shock absorber using the special tools. TOOL: [2] Spherical Bearing Installer 07HMF-HC00100 10 x 19 Apply molybdenum disulfide grease to the spherical bearing rotating area. Install the spherical bearing [1] into the shock absorber until it is fully seated using a hydraulic press and special tools as shown.
Page 396 dummyhead dummyhead REAR WHEEL/SUSPENSION SWINGARM REMOVAL/INSTALLATION Remove the following: – Drive chain cover/mud guard (page 2-16) – Rear wheel (page 17-4) – EVAP canister (Except MA, IIMA, IN, U, IIU models) (page 7-23) Remove the bolt [1], brake pipe stay [2] and brake pipe [3].
Page 397 dummyhead dummyhead REAR WHEEL/SUSPENSION DISASSEMBLY/ASSEMBLY Disassemble and assemble the swingarm as following illustration. • Install each dust seal with the flat side facing out so that it is flush with the pivot end surface. SWINGARM NEEDLE BEARING DUST SEAL RIGHT PIVOT COLLAR (27.6 mm) DUST SEAL...
Page 398 dummyhead dummyhead REAR WHEEL/SUSPENSION SWINGARM PIVOT BEARING REPLACEMENT RIGHT SIDE Remove the snap ring [1]. Press the ball bearing [1] and needle bearing [2] out of the right pivot using the special tools. TOOLS: [3] Driver, 15 x 280L 07949-3710001 [4] Attachment, 24 x 26 mm 07746-0010700 [5] Pilot 20 mm...
Page 399 dummyhead dummyhead REAR WHEEL/SUSPENSION Install the snap ring [1] into the right pivot groove securely. • Do not reuse worm snap ring which could easily spin in the groove. • Make sure that the snap ring is firmly seated in the groove.
Page 400 dummyhead dummyhead MEMO...
Page 401 dummytext 18. HYDRAULIC BRAKE SERVICE INFORMATION······················ 18-2 FRONT MASTER CYLINDER················ 18-10 TROUBLESHOOTING ·························· 18-2 REAR MASTER CYLINDER·················· 18-12 COMPONENT LOCATION ····················· 18-3 FRONT BRAKE CALIPER ···················· 18-14 BRAKE FLUID REPLACEMENT/ REAR BRAKE CALIPER······················ 18-15 AIR BLEEDING ··································· 18-5 BRAKE PEDAL ·································· 18-16 BRAKE PAD/DISC ·······························...
Page 402 dummyhead dummyhead HYDRAULIC BRAKE SERVICE INFORMATION HYDRAULIC BRAKE GENERAL 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 to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Spilling brake fluid will severely damage instrument lenses and painted surface.
Page 403 HYDRAULIC BRAKE COMPONENT LOCATION FRONT: CBR650RA shown: 34 N·m (3.5 kgf·m, 25 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft) 18-3...
Page 404 dummyhead dummyhead HYDRAULIC BRAKE REAR: 34 N·m (3.5 kgf·m, 25 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 17 N·m (1.7 kgf·m, 13 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 18-4...
Page 405 dummyhead dummyhead HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING Turn the handlebar so the reservoir is level. For front brake: Remove the following: – Two screws [1] – Reservoir cap [2] – Set plate [3] – Diaphragm [4] Remove the bolt [1] and reservoir [2] from the stay.
Page 406 dummyhead dummyhead HYDRAULIC BRAKE BRAKE FLUID FILLING/AIR BLEEDING Fill the reservoir to the upper level line [1] with DOT 4 Front: Rear: brake fluid from a sealed container. Connect a commercially available brake bleeder to the bleed valve [2]. Operate the brake bleeder and loosen the bleed valve. If an automatic refill system is not used, add fluid when Check the fluid level the fluid level in the reservoir is low.
Page 407 dummyhead dummyhead HYDRAULIC BRAKE Install the diaphragm [1], set plate [2], reservoir cap [3] For front brake: and tighten the screws [4] to the specified torque. TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) Carefully remove the reservoir [1] from the stay by For rear brake: removing the mounting bolt [2].
Page 408 dummyhead dummyhead HYDRAULIC BRAKE BRAKE PAD/DISC BRAKE PAD REMOVAL/ INSTALLATION • Always replace the brake pads in pairs to ensure even disc pressure. • Check the fluid level in the reservoir as this operation causes the fluid level to rise. FRONT Remove the brake caliper mounting bolts [1] and brake Do not operate the...
Page 409 dummyhead dummyhead HYDRAULIC BRAKE Slide the one pad [1] inward to release its tabs [2] from the grooves in the caliper body, and remove it. Remove the other pad in the same manner. Remove the pad spring [3]. Clean the inside of the caliper body especially around the caliper pistons.
Page 410 BRAKE SPECIFICATIONS (page 1-10) and replace if necessary. FRONT MASTER CYLINDER REMOVAL/INSTALLATION Drain the brake fluid from the front brake hydraulic CBR650RA shown: system (page 18-5). Remove the following: When removing the oil bolt, cover the – Brake light switch connectors [1] end of the brake –...
Page 411 dummyhead dummyhead HYDRAULIC BRAKE – Two bolts [1] Align – Master cylinder holder [2] – Master cylinder [3] Installation is in the reverse order of removal. • Replace the sealing washers with new ones. • Install the master cylinder holder with the "UP" mark [4] facing up.
Page 412 dummyhead dummyhead HYDRAULIC BRAKE REAR MASTER CYLINDER REMOVAL/INSTALLATION Drain the brake fluid from the rear brake hydraulic system (page 18-5). Remove the stay bolt [1] and rear brake reservoir [2]. Disconnect the brake hose [1] by removing the oil bolt When removing the [2] and sealing washers [3].
Page 413 dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY Disassemble and assemble the rear master cylinder as following illustration. • Adjust the push rod length between the center of the lower mounting bolt hole and center of the joint pin hole when installing the push rod joint. •...
Page 414 dummyhead dummyhead HYDRAULIC BRAKE FRONT BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake fluid from the front brake hydraulic ED model left side shown: system (page 18-5). Remove the following: – Oil bolt [1] When removing the – Sealing washers [2] oil bolt, cover the –...
Page 415 Installation is in the reverse order of removal. • Replace the sealing washers with new ones. • If the pad retainer [6] was removed, apply Honda Bond A or equivalent to the retainer seating surface. • Apply silicone grease to the sliding area of the caliper pin bolt.
Page 416 dummyhead dummyhead HYDRAULIC BRAKE INSPECTION Check the following parts for scoring, scratches, deterioration or damage. – Caliper cylinder – Caliper piston Measure the parts according to HYDRAULIC BRAKE SPECIFICATIONS (page 1-10) and replace if necessary. BRAKE PEDAL REMOVAL/INSTALLATION Support the right rider footpeg bracket [1] securely and remove the bracket socket bolts [2].
Page 417 dummytext 19. ANTI-LOCK BRAKE SYSTEM (ABS) SERVICE INFORMATION······················ 19-2 ABS INDICATOR CIRCUIT TROUBLESHOOTING ························· 19-12 SYSTEM LOCATION ···························· 19-3 ABS TROUBLESHOOTING ·················· 19-14 SYSTEM DIAGRAM ····························· 19-4 WHEEL SPEED SENSOR ···················· 19-23 ABS TROUBLESHOOTING INFORMATION···································· 19-6 ABS MODULATOR ····························· 19-26 DTC INDEX········································19-10 19-1...
Page 418 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) SERVICE INFORMATION ANTI-LOCK BRAKE SYSTEM (ABS) GENERAL • The ABS modulator may be damaged if dropped. Also if a connector is disconnected when current is flowing, the excessive voltage may damage the control unit. Always turn off the ignition switch before servicing. •...
Page 419 ANTI-LOCK BRAKE SYSTEM (ABS) SYSTEM LOCATION CBR650RA shown: BATTERY REAR WHEEL SPEED SENSOR FRONT PULSER RING FRONT WHEEL SPEED SENSOR ABS MODULATOR REAR PULSER RING 19-3...
Page 420 Bl/R R/Bl ABS MAIN (7.5 A) Bl/R Bl/Br METER/HORN/TAIL/TURN (7.5 A) BATTERY FRONT BRAKE LIGHT SWITCH REAR BRAKE LIGHT SWITCH CBR650RA: Br/W CB650RA: Bl/Br R/Bl O/Bl INDICATOR (6-1, 6-2) COMBINATION METER CBR650RA: G/R TIRE SIZE CB650RA: G CBR650RA: W (7-1)
Page 421 Bl/R R/Bl ABS MAIN (7.5 A) Bl/R Bl/Br METER/HORN/TAIL/TURN (7.5 A) BATTERY FRONT BRAKE LIGHT SWITCH REAR BRAKE LIGHT SWITCH CBR650RA: Br/W CB650RA: Bl/Br R/Bl O/Bl INDICATOR (6-1, 6-2) COMBINATION METER CBR650RA: G/R TIRE SIZE CB650RA: G CBR650RA: W (7-1)
Page 422 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING INFORMATION SYSTEM DESCRIPTION SUMMARY OF 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 associated part can be detected by reading the DTC. When the motorcycle is running, pulse signals generated at the front and rear wheel speed sensors are sent to the ABS control unit.
Page 423 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) MCS INFORMATION • The MCS can read out and erase the DTC. How to connect the MCS Remove the main seat (page 2-11). Turn the ignition switch OFF. Remove the dummy connector [1] from the DLC. Connect the MCS to the DLC.
Page 424 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) DTC INDICATION PATTERN • The ABS indicator indicates the DTC by blinking a specified number of times. The indicator has two types of blinking, a long blink and short blink. The long blink lasts for 1.3 seconds, the short blink lasts for 0.3 seconds. For example, when one long blink is followed by two short blinks, the DTC is 1-2 (one long blink = 1 blink, plus two short blinks = 2 blinks).
Page 425 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) CIRCUIT INSPECTION INSPECTION AT ABS MODULATOR CONNECTOR Remove the ABS modulator cover (page 4-76). Disconnect: Connect: Turn the ignition switch OFF. Disconnecting procedure: Turn the lock lever [1] to this side while pressing the lock tab [2] to release it. Be sure the lock lever is turned all the way and disconnect the ABS modulator 18P (Black) connector [3].
Page 426 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) DTC INDEX • 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 427 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) Detection Refer Function failure Symptom/Fail-safe function Power circuit under voltage • Stops ABS operation • Input voltage (too low) • ABS MAIN fuse (7.5 A) 19-21 Power circuit over voltage • Stops ABS operation •...
Page 428 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR CIRCUIT TROUBLESHOOTING ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON) • Before starting this inspection, check the initial operation of the combination meter (page 21-6). 1. Indicator Operation Inspection Turn the ignition switch OFF.
Page 429 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 2. Indicator Signal Line Open Circuit Inspection Short the wire harness side ABS modulator 18P (Black) connector [1] terminal to the ground with a jumper wire [2]. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: 13 – Ground Turn the ignition switch ON with the engine stop switch "...
Page 430 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 5. Power Input Line Short Circuit Inspection With the ABS MAIN fuse (7.5 A) removed, check for continuity between the wire harness side ABS modulator 18P (Black) connector [1] and ground. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: 7 –...
Page 431 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 1. Speed Sensor Air Gap Inspection Measure the air gap between the speed sensor and pulser ring (page 19-23). Is the air gap correct? – GO TO STEP 2. – Check each part for deformation and looseness correct accordingly.
Page 432 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 5. Front Wheel Speed Sensor Line Open Circuit Inspection Short the wire harness side ABS modulator 18P (Black) connector [1] terminals with a jumper wire [2]. CONNECTION: 8 – 17 Check for continuity between the wire harness side front wheel speed sensor 2P (Black) connector [3] terminals.
Page 433 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 2. Speed Sensor Condition Inspection Inspect the area around the rear wheel speed sensor: Check that there is iron or other magnetic deposits between the pulser ring [1] and wheel speed sensor [2], and the pulser ring slots for obstructions. Check the installation condition of the pulser ring or wheel speed sensor for looseness.
Page 434 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 5. Rear Wheel Speed Sensor Line Open Circuit Inspection Short the wire harness side ABS modulator 18P (Black) connector [1] terminals with a jumper wire [2]. CONNECTION: 6 – 15 Check for continuity between the wire harness side rear wheel speed sensor 2P (Black) connector [3] terminals.
Page 435 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 2. Motor Power Input Line Short Circuit Inspection Disconnect modulator (Black) connector (page 19-9). With the ABS MOTOR fuse (30 A) removed, check for continuity between the wire harness side ABS modulator 18P (Black) connector [1] terminal and ground.
Page 436 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) DTC 5-4 (Fail Safe Relay) 1. Fuse Inspection Turn the ignition switch OFF. Remove the main seat (page 2-11). Remove the fuse/relay box cover [1] and check the FSR fuse (30 A) [2] for blown. Is the fuse blown? –...
Page 437 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 4. Failure Reproduction Turn the ignition switch OFF. Connect the ABS modulator 18P (Black) connector. Erase the DTC (page 19-8). Test-ride the motorcycle above 30 km/h. Recheck the DTC (page 19-7). Is the DTC 5-4 indicated? –...
Page 438 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) 4. Failure Reproduction Turn the ignition switch OFF. Connect the ABS modulator 18P (Black) connector. Erase the DTC (page 19-8). Test-ride the motorcycle above 30 km/h. Recheck the DTC (page 19-7). Is the DTC 6-1 or 6-2 indicated? –...
Page 439 – Front pulser ring (page 16-18) – Rear pulser ring (page 17-5) REMOVAL/INSTALLATION FRONT WHEEL SPEED SENSOR Pull down the radiator (page 8-7). CBR650RA: CB650RA: Remove the front wheel (page 16-15). Release the front wheel speed sensor 2P (Black) CBR650RA: connector [1] from the right intake air duct and disconnect it.
Page 440 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) Remove the bolt [1] and front wheel speed sensor wire ED model shown: guide [2]. Release the front wheel speed sensor wire [3] from the clamp [4]. Remove the wire clip [5]. Remove the front wheel speed sensor guard bolts [1]. Remove the bolt [2] and front wheel speed sensor [3] from wheel speed sensor guard [4].
Page 441 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) Remove the bolt [1] and brake pipe stay [2]. Release the rear wheel speed sensor wire [3] from the stay [4] and clamp [5]. Remove the following: – Bolts [1] – Clamp [2] – Sensor bolt [3] –...
Page 442 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) ABS MODULATOR REMOVAL/INSTALLATION Drain the brake fluid from the rear brake hydraulic systems (page 18-5). Remove the following: – Throttle body (page 7-13) – ABS modulator cover (page 4-76) Disconnect the ABS modulator 18P (Black) connector (page 19-9). Pull the ECM [1] upward as shown.
Page 443: 20. Battery/Charging System
dummytext 20. BATTERY/CHARGING SYSTEM SERVICE INFORMATION······················ 20-2 BATTERY··········································· 20-5 TROUBLESHOOTING ·························· 20-3 CHARGING SYSTEM INSPECTION ········ 20-6 SYSTEM LOCATION ···························· 20-4 ALTERNATOR CHARGING COIL ··········· 20-7 SYSTEM DIAGRAM ····························· 20-4 REGULATOR/RECTIFIER ····················· 20-7 20-1...
Page 444 dummyhead dummyhead BATTERY/CHARGING SYSTEM SERVICE INFORMATION BATTERY/CHARGING SYSTEM GENERAL • 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 445 dummyhead dummyhead BATTERY/CHARGING SYSTEM TROUBLESHOOTING Battery is damaged or weak 1. Battery Test Remove the battery (page 20-5). 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? –...
Page 446 dummyhead dummyhead BATTERY/CHARGING SYSTEM SYSTEM LOCATION REGULATOR/RECTIFIER FUSE/RELAY BOX – MAIN FUSE (30 A) ALTERNATOR BATTERY SYSTEM DIAGRAM MAIN FUSE (30 A) BATTERY REGULATOR/RECTIFIER Bl: Black G: Green ALTERNATOR R: Red W: White 20-4...
Page 447 dummyhead dummyhead BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the main seat (page 2-11). Turn the ignition switch OFF. Disconnect the negative (–) cable [1] first and then disconnect the positive (+) cable [2] by removing the terminal bolts. Remove the rubber strap [3] and the battery [4]. Installation is in the reverse order of removal.
Page 448 dummyhead dummyhead BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE TEST Remove the main seat (page 2-11). Turn the ignition switch OFF. Remove the terminal bolt and disconnect the negative (–) cable [1] from the battery. Connect the ammeter (+) probe to the negative (–) (–) cable and ammeter (–) probe to the battery negative (–) terminal [2].
Page 449 dummyhead dummyhead BATTERY/CHARGING SYSTEM ALTERNATOR CHARGING COIL INSPECTION Lift the fuel tank and support it (page 3-4). Disconnect the alternator 3P (Gray) connector [1] from the regulator/rectifier. Check the connector for loose contacts or corroded terminals. Measure the resistance between the Black wire terminals of the alternator side 3P (Gray) connector.
Page 450 dummyhead dummyhead BATTERY/CHARGING SYSTEM Remove the following: – Two nuts [1] – Two socket bolts [2] – Two washers [3] – Regulator/rectifier [4] Installation is in the reverse order of removal. [1]/[2]/[3] 20-8...
Page 451: 21. Lights/Meters/Switches
CLUTCH SWITCH······························· 21-18 LICENSE LIGHT ·································· 21-5 SIDESTAND SWITCH·························· 21-18 COMBINATION METER ························ 21-6 HORN ··············································· 21-19 SPEEDOMETER ·································21-10 HSTC (Honda Selectable Torque Control) SYSTEM ··········································· 21-20 TACHOMETER···································21-11 TURN SIGNAL RELAY ························ 21-21 COOLANT TEMPERATURE GAUGE/ECT SENSOR ···········································21-11 CONTROL RELAY ······························ 21-24...
Page 452 dummyhead dummyhead LIGHTS/METERS/SWITCHES SERVICE INFORMATION LIGHTS/METERS/SWITCHES GENERAL • Check the battery condition before performing any inspection that requires proper battery voltage. • A continuity test can be made with the switches installed on the motorcycle. • Use an electric heating element to heat the coolant for the ECT sensor inspection. Keep flammable materials away from the electric heating element.
Page 453 LIGHTS/METERS/SWITCHES HEADLIGHT REMOVAL/INSTALLATION CBR650RA: Remove the upper inner panel (page 2-8). Remove the front lower cowl (page 2-9). Disconnect the headlight 6P (Black) connector [1]. Remove the following. – Three bolts [2] – Headlight [3] – Three collars [4] Installation is in the reverse order of removal.
Page 454 LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT FRONT TURN SIGNAL LIGHT REMOVAL/INSTALLATION CBR650RA: Remove the following: – Middle cowl (page 2-7) – Screw [1] – Turn signal holder [2] – Front turn signal light [3] Installation is in the reverse order of removal.
Page 455 dummyhead dummyhead LIGHTS/METERS/SWITCHES BRAKE/TAIL LIGHT BRAKE/TAIL LIGHT UNIT REMOVAL/ INSTALLATION Remove the rear fender stay (page 2-13). Disconnect the brake/tail light 3P connector [1]. Release the bosses [1] and lower the rear fender B [2]. Remove the two nuts [1], washers [2], wire clip [3] and [1]/[2] brake/tail light unit [4].
Page 456 POWER INPUT LINE Measure the voltage between the combination meter 20P (Gray) connector [1] terminal and ground. CONNECTION: CBR650RA: Brown/white – Ground CB650RA: Black/brown – Ground CBR650RA: Br/W CB650RA: Bl/Br There should be battery voltage with the ignition switch turned ON.
Page 457 LIGHTS/METERS/SWITCHES GROUND LINE Check for continuity between the combination meter 20P (Gray) connector [1] terminal and ground. CONNECTION: CBR650RA: Green/Red – Ground CBR650RA: G/R CB650RA: Green – Ground CB650RA: G There should be continuity at all times. If there is no continuity, check for open circuit in the CBR650RA: Green/red or Green wire.
Page 458 CBR650RA: W Gray) connector [2] terminals. CB650RA: R/Bu TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: CBR650RA: Red/blue – White CB650RA: Red/blue – Red/blue Is there continuity? R/Bu – Loose or poor contact on the related connectors. MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models: –...
Page 459 dummyhead dummyhead LIGHTS/METERS/SWITCHES CB650RA: Remove the headlight (page 21-3) (Except IN model). Remove the front license plate stay (page 2-15) (IN model only). Remove the dust cover [1] and disconnect the 20P (Gray) connector [2]. Release the main wire harness band bosses [3] from the cable guide.
Page 460 dummyhead dummyhead LIGHTS/METERS/SWITCHES DISASSEMBLY/ASSEMBLY Remove the following: – Six tapping screws [1] – Upper case [2] – Key tops [3] – Tapping screw [4] – Meter assembly [5] – Lower case [6] Assembly is in the reverse order of disassembly. DIGITAL CLOCK SETTING PROCEDURE Turn the ignition switch ON.
Page 461 dummyhead dummyhead LIGHTS/METERS/SWITCHES TACHOMETER SYSTEM INSPECTION If the tachometer does not operate, check the following: • Combination meter initial operation (page 21-6) • Combination meter indication when the serial communication line is abnormal (page 4-3) • CKP sensor – ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models (page 4-83) –...
Page 462 dummyhead dummyhead LIGHTS/METERS/SWITCHES ENGINE OIL PRESSURE INDICATOR/ EOP SWITCH SYSTEM INSPECTION When the system is normal, the engine oil pressure indicator [1] comes on when the ignition switch is turned ON with the engine stop switch " ", and then goes off when the engine is started.
Page 463 – CBR650RA (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models): Pink or Red/black wire – CBR650RA (MA, IIMA, TH, IITH, U, IIU, IIBR models): Pink or Yellow/white wire –...
Page 464 – CBR650RA: ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models (page 23-2) – CBR650RA: MA, IIMA, TH, IITH, U, IIU, IIBR models (page 23-3) – CB650RA: ED, IIIED, FO, KO models (page 23-4) – CB650RA: MA, IN, TH, U, BR models (page 23-5)
Page 465 dummyhead dummyhead LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the tank cover (page 2-7). Remove the two clips [1] and ignition switch cover [2]. Disconnect immobilizer receiver (Black) connector [1]. Remove the dust cover [2] and disconnect the ignition switch 2P (Brown) connector [3]. Remove the wire clip [4] Remove the following: –...
Page 466 LIGHTS/METERS/SWITCHES HANDLEBAR SWITCH LEFT HANDLEBAR SWITCH CBR650RA: Remove the left middle cowl (page 2-7). Disconnect the left handlebar switch 10P (Gray) connector [1]. Check for continuity between the switch side 10P (Gray) connector terminals in each switch position according to the continuity chart.
Page 467 – MA, IN, TH, U, BR models (page 23-5) BRAKE LIGHT SWITCH FRONT Disconnect the brake light switch connectors [1] and CBR650RA shown: check for continuity between the switch terminals. There should be continuity with the brake lever squeezed, and no continuity when the brake lever is released.
Page 468 LIGHTS/METERS/SWITCHES CLUTCH SWITCH Disconnect the clutch switch connectors [1] and check CBR650RA shown: for continuity between the switch terminals. There should be continuity with the clutch lever squeezed, and no continuity when the clutch lever is released. SIDESTAND SWITCH INSPECTION Remove the throttle body (page 7-13).
Page 469 LIGHTS/METERS/SWITCHES HORN INSPECTION Remove the left middle cowl (page 2-7) (CBR650RA). CBR650RA shown: Disconnect the connectors [1] from the horn [2]. Connect a 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V battery is connected across the horn terminals.
Page 470 TORQUE CONTROL CAN NOT BE TURNED OFF BY PRESSING THE TORQUE CONTROL SWITCH Check the following: – CBR650RA: Green/white wire between the torque control switch and ECM for open or short circuit. – CB650RA: Yellow/red wire between the torque control switch and ECM for open or short circuit.
Page 471 dummyhead dummyhead LIGHTS/METERS/SWITCHES CB650RA: Remove the left shroud (page 2-10). Disconnect the Torque control switch 3P (Black) connector [1]. Check for continuity between the switch side 3P (Black) connector terminals in each switch position according to the continuity chart. – ED, IIIED, FO, KO models (page 23-4) –...
Page 472 BRAKE LIGHT SWITCH LINE OPEN CIRCUIT INSPECTION Disconnect the following: CBR650RA: – Right handlebar switch 6P (Gray) connector (page 21-16) (CBR650RA) – Right handlebar switch 5P (Gray) connector (page 21-16) (CB650RA) – Rear brake light switch 2P (Black) connector (page 21-17) –...
Page 473 dummyhead dummyhead LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH LINE SHORT CIRCUIT INSPECTION Disconnect the ABS modulator 18P (Black) connector (page 19-9). Check for continuity between the ABS modulator 18P (Black) connector [1] terminal and ground. CONNECTION: Green/yellow – Ground There should be no continuity. If there is continuity, check for short circuit in Green/ yellow wire.
Page 474 [2] by pulling it up. – Main relay [3] – Fan control relay [4] – Fuel pump relay [5] Installation is in the reverse order of removal. ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models: CBR650RA: Br CB650RA: Y/R Bl/R Bl/Bu Br/R Bl/Bu...
Page 475 dummyhead dummyhead LIGHTS/METERS/SWITCHES USB CHARGER UNIT (Except KO, IIKO, U, IIU, BR, IIBR) INSPECTION Remove the main seat (page 2-11). Turn the ignition switch OFF. Disconnect the USB charger unit 2P (Black) connector [1]. Turn the ignition switch ON. Measure the voltage between the connector terminals. CONNECTION: Light green/black (+) –...
Page 476 dummyhead dummyhead MEMO...
Page 477: Immobilizer System (Hiss)
dummytext 22. IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION······················ 22-2 KEY REGISTRATION PROCEDURES (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models) ············································· 22-7 SYSTEM LOCATION ···························· 22-2 DIAGNOSTIC CODE INDICATION ········· 22-11 SYSTEM DIAGRAM ····························· 22-3 TROUBLESHOOTING ························· 22-13 KEY REGISTRATION PROCEDURES (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models) ································...
Page 478: Service Information
dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION IMMOBILIZER SYSTEM (HISS) GENERAL • When checking the immobilizer system (HISS), follow the steps in the troubleshooting flow chart (page 22-13). • 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 479: System Diagram
O: Orange P: Pink IMMOBILIZER R: Red RECEIVER W: White Y: Yellow Br: Brown CBR650RA: G/R CBR650RA: W CBR650RA: R/W CB650RA: R/Bu Lg: Light green CB650RA: G CB650RA: R/G MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models CLOCK...
Page 480: Key Registration Procedures
dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) KEY REGISTRATION PROCEDURES (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models) 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.
Page 481 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) When the ignition switch is faulty: 1. Obtain a new ignition switch assembly. 2. Remove the ignition switch (page 21-14). 3. Connect the SCS short connector to the DLC (page 22-11). 4. Set the original (registered) key near the immobilizer receiver so that the transponder in the key can communicate with the receiver.
Page 482 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 18.Turn the ignition switch ON (with the first new key registered in step 13). The HISS indicator comes on and it remains on. • The code of the first new key is recognized by the ECM. •...
Page 483: Key Registration Procedures
dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) When the ECM is faulty: 1. Obtain a new ECM and two new transponder keys. 2. Grind the keys in accordance with the shape of the original key. 3. Replace the ECM with a new one (page 4-76). 4.
Page 484 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 7. Turn the ignition switch ON with a new key or the spare key (Never use the key registered in previous steps). The indicator comes on for two seconds then it blinks four times repeatedly. 2 sec.
Page 485 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 9. Turn the ignition switch ON with a first new key. The indicator comes on for two seconds then it blinks four times repeatedly. 2 sec. • The first key is registered in the ECM. •...
Page 486 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 7. Turn the ignition switch OFF and remove the second key. • The system will not enter the normal mode unless the two keys are registered in ECM. • The third new key cannot be continuously registered. When it is necessary to register the third key, follow the procedures "When the key has been lost, or additional key is required"...
Page 487: Diagnostic Code Indication
dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) DIAGNOSTIC CODE INDICATION ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models Turn the ignition switch OFF. Remove the main seat (page 2-11). Remove the dummy connector [1] from the DLC [2] and short DLC terminals using the special tool.
Page 488 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) DIAGNOSTIC CODE When the system (ECM) enters the diagnostic mode from the normal mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE ECM data is Faulty ECM Replace the ECM. abnormal. 10 sec. Code signals Faulty immobilizer Follow the troubleshooting (page cannot send or receiver or wire 22-13).
Page 489: Troubleshooting
dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) TROUBLESHOOTING The immobilizer indicator comes on for approx. two seconds then it goes off, when the ignition switch is turned ON with the properly registered key with the engine stop switch turned " " and the immobilizer system (HISS) functions normally.
Page 490: Immobilizer Receiver
dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) Diagnostic code is indicated (Code signals cannot send or receive) 1. Immobilizer Receiver Power Input Line Inspection Check the immobilizer receiver power input line (page 22-15). Is the input line normal? – GO TO STEP 2. –...
Page 491 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) POWER INPUT LINE INSPECTION Turn the ignition switch ON with the engine stop switch " ". Measure the voltage between the immobilizer receiver 4P (Black) connector [1] terminal of the wire harness side and ground. CONNECTION: Yellow/red (+) –...
Page 492 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) Disconnect the ECM 33P connector (page 4-76). ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models: Check for continuity between the ECM 33P (Black) ED, IIED, IIIED, connector [1] and immobilizer receiver 4P (Black) IVED, FO, IIFO, KO, connector [2] terminals of the wire harness side.
Page 493: Replacement Parts For Problem
dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) REPLACEMENT PARTS FOR PROBLEM Replacement Parts Ignition Problem Transponder Immobilizer *Accessory switch Key set receiver lock and key assembly One key has been lost, or additional spare key is required All keys have been lost ECM is faulty Immobilizer receiver is faulty...
Page 494 dummyhead dummyhead MEMO...
Page 495 23. WIRING DIAGRAMS CBR650RA: ED, IIED, IIIED, IVED, CB650RA: ED, IIIED, FO, KO models ····· 23-4 FO, IIFO, KO, IIKO models···················· 23-2 CB650RA: MA, IN, TH, U, BR models ····· 23-5 CBR650RA: MA, IIMA, TH, IITH, U, IIU, IIBR models ······························ 23-3...
Page 496: Wiring Diagrams
WIRING DIAGRAMS CBR650RA: ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models WIRING DIAGRA MS STARTER ENGINE STOP No. 3 FUEL No. 1 FUEL INJECTOR INJECTOR FUEL FUEL LEVEL SWITCH SWITCH PUMP SENSOR No. 4 FUEL No. 2 FUEL...
Page 497 WIRING DIAGRAMS CBR650RA: MA, IIMA, TH, IITH, U, IIU, IIBR models No. 3 FUEL No. 1 FUEL TH,IITH,IIBR models STARTER ENGINE STOP INJECTOR INJECTOR SWITCH SWITCH FUEL FUEL LEVEL No. 4 FUEL No. 2 FUEL PUMP INJECTOR INJECTOR SENSOR...
Page 498 dummytext WIRING DIAGRAMS CB650RA: ED, IIIED, FO, KO models STARTER ENGINE STOP No. 3 FUEL No. 1 FUEL INJECTOR INJECTOR SWITCH SWITCH IMMOBILIZER No. 4 FUEL No. 2 FUEL FRONT FUEL FUEL LEVEL INJECTOR INJECTOR RECEIVER FRONT REAR ENGINE BRAKE SENSOR PUMP SENSOR...
Page 499 dummytext WIRING DIAGRAMS CB650RA: MA, IN, TH, U, BR models No. 3 FUEL No. 1 FUEL TH,BR models STARTER ENGINE STOP INJECTOR INJECTOR SWITCH SWITCH FUEL FUEL LEVEL No. 4 FUEL No. 2 FUEL PUMP SENSOR SENSOR INJECTOR INJECTOR SENSOR FRONT REAR IMMOBILIZER...
Page 500: Index
HEADLIGHT AIM ················································ 3-22 HYDRAULIC BRAKE········································ 18-3 HORN····························································· 21-19 REAR WHEEL/SUSPENSION···························· 17-3 HSTC CONTROL RELAY ············································ 21-24 (Honda Selectable Torque Control) SYSTEM ·········· 21-20 COOLANT REPLACEMENT ····································8-4 IACV································································· 7-17 COOLANT TEMPERATURE GAUGE/ IAT SENSOR ····················································· 4-79 ECT SENSOR ·················································· 21-11 IGNITION COIL ··················································...
Page 501 TURN SIGNAL RELAY ······································· 21-21 IGNITION SYSTEM ··········································· 5-2 UNDER COWL (CBR650RA) ·································2-11 IMMOBILIZER SYSTEM (HISS) ························· 22-2 UPPER INNER PANEL (CBR650RA)························ 2-8 LIGHTS/METERS/SWITCHES ·························· 21-2 USB CHARGER UNIT (Except KO, IIKO, U, IIU, LUBRICATION SYSTEM ···································· 9-2 BR, IIBR) ························································· 21-25 MAINTENANCE················································...
Page 502 INDEX WINDSCREEN (CBR650RA) ···································2-6 CBR650RA (ED, IIED, IIIED, IVED, FO, IIFO, WIRING DIAGRAM KO, IIKO models) ············································ 23-2 CB650RA (ED, IIIED, FO, KO models) ················· 23-4 CBR650RA (MA, IIMA, IN, TH, IITH, U, CB650RA (MA, IN, TH, U, BR models)················· 23-5 IIU, IIBR models) ·············································...
Page 503 ( 718 頁 ) ( 718 頁 ) Honda Motor Co., Ltd. 2014 CB1100/A/S/SA/SAD [EBL-SC65] Published by Honda Motor Co., Ltd. Honda Motor Co., Ltd. 2014 Honda Motor Co., Ltd. 2021 Book number : 60MJS00 OWNER’ S/SERVICE MANUAL Published by Honda Motor Co., Ltd.

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