Honda 2014 CBR650F/FA Manual

How To Use This Manual

This set-up and pre-delivery manual describes the service procedures for the CBR650F/FA, CB650F/FA.
Follow the complete sequence of steps as shown. Do not short-cut any steps. The sequence has been established to ensure the unit is properly assembled.

Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including:

• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION. These signal words mean:
  
  You CAN be KILLED or SERIOUSLY HURT if you don't follow instructions.
  
  You CAN be HURT if you don't follow instructions.
• Instructions – how to service this vehicle correctly and safely.

As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment.

Modifications and Accessories

Modifications which you may have made, or should make in the future, to any Honda product, shall be deemed by our company to have been performed at your sole risk and responsibility, and without our company's or the manufacturer's approval, or consent, implied or expressed. We further disclaim any and all liability, obligation, or responsibility for any defects of modified parts or of the modified product, and for any claims, demands, or causes of action for damage to property or for personal injuries resulting from the modification of said Honda product.
Throughout this manual, the following codes are used to identify individual models:
ED European direct sales
U Australia, New Zealand
MA Malaysia
RU Russia, Ukraine
KO Korea

CBR650F/FA: SPORT
CB650F/650FA: NAKED

SET-UP SECTION

CRATE COVER

Cut the strap [1] and remove the carton cover [2].

PARTS CARTON

CBR650F/FA, CB650F/FA
Remove loose parts carton [1] from left side of the crate by cutting the two straps.
Place the side stand [2] in the down position as shown.

CRATE FRAME REMOVAL

Remove four nuts [1] from handlebar stay.

• Carefully remove crate frame with at least two people.
• Take care not to damage the motorcycle while removaing the crate frame.

Remove the six bolts [1] and [2] from both side and three cross braces [2] from the top of the crate frame.

Remove the two bolts [1] from the rear wheel support at the left crate frame.
Then remove the left crate frame by removal the nine bolts [2] and carefully lower it to the floor.

Remove the two bolts [1] from the rear wheel support on right crate frame.

• The motorcycle is supported only by the sidestand. Do not pushor lean the motorcycle as it may fall and damaged.

Remove the one bolt [2] from rear crate frame [3] and carefully lower the rear crate frame to the floor.
Remove the right crate frame by removal the nine bolts and carefully lower it to the floor.

Remove one bolt [1] from the front crate frame [2] and carefully lower it to the floor and remove plastic cover off the motorcycle.

• The motorcycle is supported only by the sidestand. Do not pushor lean the motorcycle as it may fall and damaged.

Remove the nut [1] and then the brace [2] from the handgrip.
Remove the protective cover [3] from the handgrip.

Tilt the rear wheel support [1] and wheel chock [2] as shown and then remove the wheel chock [2] by sliding it to the left.
Remove the rear wheel support [1] and insulator [3].

Route slings around the handgrips [1] and rear passenger footpeg [2].
Lift the slings and motorcycle just enough to remove crate base [3] and then move the crate base away from the motorcycle.
Place the motorcycle on its wheels and slide stand on a firm, level surface.

Do not roll the motorcycle off the crate from case base as it will damage the motorcycle.
Remove the headlight cloth cover [4] from the headlight.

SET-UP PARTS

SET UP PARTS

Unpack the remaining loose parts and check them against this illustration and list.

MIRROR INSTALLATION

CBR650F/FA
Remove the two socket bolts [1] and rearview mirror [2].
Installation is in the reverse order of removal.

NOTE:

• 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)

CB650F/FA
Slide the boot [1] off from the lock nut [2].
Loosen the lock nut (left-hand threads) and remove the rearview mirror [3].
Remove the mirror adaptor [4].
Installation is in the reverse order of removal.

TORQUE:
Rearview mirror lock nut:
20 N·m (2.0 kgf·m, 15 lbf·ft)
Rearview mirror adaptor:
20 N·m (2.0 kgf·m, 15 lbf·ft)

KEY

The keys [1] with key number plate are in the ignition switch.

OWNER'S MANUAL AND TOOL KIT

Unhook the seat with the ignition key [1].
Remove the seat [2] by pulling it rearward.

Confirm that tool kit [1] are inside its plastic bag and placed inside the space under the seat.

Secure the bag and manual [2]/[3] with the retaining clips on the bottom of the seat.

BRAKE DISCS

Clean the front and rear discs with brake cleaner and a clean shop towel.

PRE-DELIVERY

BATTERY INSTALLATION

The battery used in this motorcycle is a pre-charged, maintenance free type.
The electrolyte has already been added to the battery.
Remove the seat.
Ensure the ignition switch is in the OFF position.
Release the battery band and remove the battery.
Remove the protective cap from the positive (+) battery cable first and then the negative cable (-) battery cable.
Follow the instructions as below:

• Be sure to recharge the battery.
• Up to over 13.0V
• Be sure to measure terminal voltage about one hour after the battery has been recharged.

Set the battery [1] into its compartment.
Connect the positive battery cable [2] to the positive (+) battery terminal using the terminal bolt.
Tighten the bolt securely, and pull the red cover over the positive terminal.
Connect the negative (-) battery cable [3] to the negative (-) battery terminal using the terminal bolt.
Tighten the bolt securely.
Verify the correct routing of the battery cables.
Attach the battery band [4].
Reinstall the seat.

NOTE:

• Connect the positive (+) cable first, then connect the negative (-)cable.
• Be sure to install the cable clip [5] on the battery (-) cable to the battery housing.

DIGITAL CLOCK SETTING PROCEDURE

Turn the ignition switch ON.

1. Press and hold the SEL and SET buttons until the hour digits starts flashing.
2. Press SEL button to select "12hr" or "24hr". Press SET button. The time format is set, and then the display moves to the clock adjustment.
3. Press the SEL button until the desired hour is displayed (press and hold to advance the hour fast).
4. Press the SET button. The minute digits start flashing.
5. Press the SEL button until the desired minute is displayed (press and hold to advance the minute fast).
6. Press the SET button. The clock is set, and then the display moves to the backlight brightness adjustment ("ooo" – "o" is indicated).
   Turn the ignition switch OFF.

NOTE:

• The control is automatically switched from the setting mode to the ordinary display if the button is not pressed for about 30 seconds.

FRONT BRAKE

Park the motorcycle on a level surface.
Turn the handlebar so the reservoir is level and check the front master cylinder reservoir through the inspection window.
If the level is near the "LOWER" level line [1], fill the brake fluid as follows.
Add fresh DOT 4 brake fluid or equivalent from a sealed container to bring the level up to the upper level.

• Brake fluid can cause irritation; avoid contact with the eyes and skin.
• Handle brake fluid with care as it can cause damage to paint andplastics.

Reinstall the diaphragm, set plate and reservoir cover, and tighten the two screws to the specified torque.

TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf.ft)

REAR BRAKE

Park the motorcycle on a level surface.
Check the fluid level of the rear brake master cylinder reservoir.
If the level is near the "LOWER" level line [1], add fresh DOT 4 brake fluid or equivalent from a sealed container to bring the level up to the upper level.

Loosen the reservoir stay bolt [1].
Slightly pull the reservoir [2] upward and turn it counterclockwise.
Align the groove with the tab, then temporarily tighten the reservoir stay bolt.
Remove the two screws [3], reservoir cap [4], set plate [5] and diaphragm [6].
Fill the reservoir with DOT 4 brake fluid from a sealed container to the upper level line [7].
Install the diaphragm [6], set plate [5], reservoir cap [4] and tighten the two screws [3] to the specified torque.

TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

Loosen the reservoir stay bolt [1] and set the reservoir [2] in position.
Attach the stopper of the reservoir stay [3] against the groove surface, then tighten the reservoir stay bolt securely.

ENGINE OIL

Before starting the engine, remove the anti-rust coating from the engine and exhaust system using a mild detergent and water.
Rinse with clean water.
Support the motorcycle in an upright position on a firm level surface.
Check the oil filler cap/dipstick and check the dipstick to make sure the engine has oil.
Reinstall the oil filler cap/dipstick.
Start the engine and let it idle for 3 – 5 minutes.
Stop the engine and wait 2 – 3 minutes.
Remove the oil filler cap/dipstick and wipe off the oil with a clean cloth.
Reinstall the oil filler cap/dipstick, but do not screw it in, remove it and check the oil level.
If the level is below or near the lower level [2] on the dipstick, fill the recommended engine oil to the upper level [3].
Apply engine oil to the O-ring and reinstall the oil filter cap/dipstick.

RECOMMENDED ENGINE OIL:
Honda "4-stroke motorcycle oil" or an equivalent
API classification: SG or higher
(except oils labeled as energy conserving on the circular API service label)
JASO T 903 standard: MA
Viscosity: SAE 10W-30

DRIVE CHAIN

Turn the ignition switch OFF, support the motorcycle on its side stand and shift the transmission into neutral.
Check the slack in the drive chain lower run midway between the sprockets.
DRIVE CHAIN SLACK: 25 – 35 mm (1.0 – 1.4 in)

Excessive chain slack, 50 mm (2.0 in) or more, may damage the frame.

Amputation hazard. Never inspect or adjust the drive chain while the engine running.

ADJUSTMENT
Loosen the rear axle nut [1].
Loosen the locknut [2] and turn the adjusting bolts [3] an equal number of a turn until the correct drive chain slack is obtained.
Make sure the scales [4] on both swingarm end are aligned with the end face of the adjusting plates [5].
Tighten the axle nut to the specified torque.

TORQUE: 98 N·m (10.0 kgf·m, 72 lbf·ft)
Hold the adjusting nuts [3] and tighten the locknuts [2] to the specified torque.
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)
Recheck the drive chain slack and free wheel rotation.

RADIATOR COOLANT LEVEL

• Using coolant with silicate corrosion inhibitors may causepremature wear of the water pump seal or blockage of radiator passages.
• Using tap water may cause engine damage.
• Do not spill coolant on the painted or plastic surfaces as it may damage the finish.
• Mix only distilled, low mineral water with the antifreeze

Hold the motorcycle in an upright position.
Check the coolant level f the reserve tank.
The level should be between the "UPPER" [1] and "LOWER" [2] level lines with the motorcycle in an upright position on a level surface.

If necessary, add recommended coolant as follows:

RECOMMENDED ANTIFREEZE:
High quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors (Mix the distilled water and antifreeze in the ratio of 1:1)
Mix the distilled water and antifreeze in the ratio of 1:1.
Remove the reserve tank cap [3] and fill the tank to the "UPPER" level line with a 1:1 mixture of distilled water and antifreeze.
Reinstall the reserve tank cap.

THROTTLE OPERATION

INSPECTION
Check for smooth operation of the throttle and that it returns automatically to the fully closed position from any open position and from any steering position.
Measure the throttle grip freeplay at the throttle grip flange.
FREEPLAY: 2 – 6 mm (0.1 – 0.2 in)

ADJUSTMENT
Adjusted the freeplay by loosing the lock nit and turning the adjuster.
Slide the boot [1] to remove it from the adjuster [2].
Loosen the lock nut [3] and turn the adjuster as required.
Tighten the lock nut to the specified torque while holding the adjuster.

TORQUE: 3.8 N·m (0.4 kgf·m, 2.8 lbf·ft)
Install the boot over the adjuster properly.

CLUTCH LEVEL FREEPLAY

INSPECTION
Measure the clutch lever freeplay at the end of the clutch lever.
FREEPLAY: 10 – 20 mm (0.4 – 0.8 in)

ADJUSTMENT
Minor adjustment is made with the upper adjuster at the clutch lever.
Loosen the lock nut [1] and turn the adjuster [2] as required.
If the adjuster is threaded out near its limit and the correct freeplay cannot be obtained, turn the adjuster all the way in and back out one turn, then perform the adjustment at major adjuster as follows.
Tighten the lock nut while holding the adjuster.
Recheck the clutch lever freeplay.

Major adjustment is made with the lower adjusting nut [1] at the clutch lifter arm.
Loosen the lock nut [2] and turn the adjusting nut [1]as required.
Tighten the lock nut while holding the adjusting nut.

TIRE PRESSURE

Check the cold tire pressure with a tire pressure gauge.

RECOMMENDED TIRE PRESSURE:
FRONT: 250 kPa (2.50 kgf/cm², 36 psi)
REAR: 290 kPa (2.90 kgf/cm², 42 psi)

LICENSE PLATE HARDWARE

ED TYPE
Install the plug hole [1] to rear fender [2] then install two washers [3] and tighten two bolts [4] to license plate [5].

NOTE:
The bolts [4]/ washers [3] and plug hole [1] are not including in set up parts.

ED TYPE (GERMANY)
Install the plug hole [1] and collar [2] to rear fender [3] then install three washer [4] and tighten three bolts [5] through license plate [6] to rear fender.

NOTE:
The bolts [5]/ washer [4]/ collar [2] and plug hole [1] are not including in set up parts.

PRE-DELIVERY SERVICE CHECKLIST

NOTE:
Check all items listed on the following Pre-Delivery Service Checklist. Refer to owner's manual or shop manual for specifications and detailed procedures.
Always test ride the unit to make sure that it is functioning properly.

• Check for front and rear brake operation.
• Fill front and rear brakes and clutch master cylinder reservoirs with DOT 4 brake fluid, and bleed brake and clutch systems, if necessary.
• Check the engine oil level and fill crankcase with recommended engine oil if necessary. When exchanging engine oil, refer to Shop Manual.
• Check coolant level and cooling system for leaks. When exchanging coolant, refer to the Shop Manual. When exchanging coolant, refer to Shop Manual.
• Check throttle grip freeplay, cable routing, and operation in all steering positions.
• Check for clutch operation.
• Check tire pressure.
• Inspect all electrical components for proper operation and adjustment.
• Check and tighten all nuts, bolts and other fasteners.
• Check to ensure that all applicable recall and product update campaigns are complied with as of this date.
• TEST RIDE: Check performance, handling and operation.
  Transmission and clutch: Ease of shifting, clutch operation, etc.
  Acceleration: Smoothness, etc.
  Cruising: Smoothness, etc.
  Handling: Stability and cornering.
  Brakes: Smoothness and stopping power.
  Idling: Smoothness, throttle response, return to idle.
  Speedometer and Tachometer: Proper operation.
  Upon completion of test ride, check for fuel, oil or coolant leaks; check fan operation.

A Few Words About Safety

Service Information

The set-up and pre-delivery service information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing set-up and pre-delivery. Some procedures require the use of specially designed tools and dedicated equipment. 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.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.

For Your Customer's Safety

Proper set-up and pre-delivery are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

Improper set-up or pre-delivery service can create an unsafe condition that can cause your customer to be seriously hurt or killed.
Follow the procedures and precautions in this manual and the service manual carefully.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing set-up and pre-delivery procedures. Only you can decide whether or not you should perform a given task.

Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed.
Follow the procedures and precautions in this manual carefully.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following:

• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards:

• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.

Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries.

• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.