Honda CBR1000S1 2016 Shop Manual
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Honda CBR1000S1 2016 Shop Manual

Honda CBR1000S1 2016 Shop Manual

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Table of Contents

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SHOP MANUAL
CBR1000RR/RA/S1/S2
CBR1000RR/RA/S1/S2
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Summary of Contents for Honda CBR1000S1 2016

  • Page 1 SHOP MANUAL CBR1000RR/RA/S1/S2 CBR1000RR/RA/S1/S2...

  • Page 2: How To Use This Manual

    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/STARTER CLUTCH/GEARSHIFT LINKAGE ALTERNATOR CRANKCASE/TRANSMISSION/BALANCER CRANKSHAFT/PISTON/CYLINDER ENGINE REMOVAL/INSTALLATION FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 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 ································· 1-21 MODEL IDENTIFICATION ····························1-3 CABLE & HARNESS ROUTING················· 1-23 SPECIFICATIONS ·········································1-5 EMISSION CONTROL SYSTEMS ·············· 1-52 TORQUE VALUES ······································1-13 TECHNICAL FEATURES···························· 1-55 LUBRICATION & SEAL POINTS················1-19...

  • Page 8: Service Rules

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

  • Page 9: Model Identification

    dummyhead dummyhead GENERAL INFORMATION MODEL IDENTIFICATION CBR1000RR/RA CBR1000S1/S2 SERIAL NUMBERS/LABELS The Vehicle Identification Number (VIN) [1] is stamped on the The engine serial number [1] is stamped on the front side of right side of the steering head as shown. the lower crankcase.
  • Page 10 dummyhead dummyhead GENERAL INFORMATION The emission control information label [1] (BR/KO types) is attached on the left side of the swingarm. TYPES Electric Lithium-ion Model Destination code Quick shifter EVAP suspension battery CBR1000RR GS/IIGS – – – – – CBR1000RA IIBR –...

  • Page 11: General Specifications

    dummyhead dummyhead GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,065 mm (81.3 in) Overall width 720 mm (28.3 in) Overall height 1,125 mm (44.3 in) Wheelbase Except CH/FO: 1,405 mm (55.3 in) CH/FO: 1,415 mm (55.7 in) Seat height CBR1000RR/RA 832 mm (32.8 in)

  • Page 12: Pgm-Fi Specifications

    dummyhead dummyhead GENERAL INFORMATION ITEM SPECIFICATIONS ENGINE Cylinder arrangement 4 cylinders in-line, inclined 27.6° from vertical Bore and stroke 76.0 x 55.1 mm (2.99 x 2.17 in) Displacement 1,000 cm (61.0 cu-in) Compression ratio 13.0 : 1 Valve train Chain driven, DOHC Intake valve opens at 1 mm (0.04 in) lift...
  • Page 13 2.7 liters (2.9 US qt, 2.4 Imp qt) – After disassembly 3.4 liters (3.6 US qt, 3.0 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 90 kPa (0.92 kgf/cm...

  • Page 14: Service Limit

    dummyhead dummyhead GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression 1,299 kPa (13.25 kgf/cm , 188 psi) – at 300 min (rpm) Valve clearance 0.16 ± 0.03 (0.006 ± 0.001) – 0.30 ± 0.03 (0.012 ± 0.001) –...

  • Page 15: Crankcase/Transmission/Balancer Specifications

    dummyhead dummyhead GENERAL INFORMATION CRANKCASE/TRANSMISSION/BALANCER SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Shift fork, fork Fork I.D. 14.000 – 14.018 (0.5512 – 0.5519) – shaft Fork shaft O.D. 13.957 – 13.975 (0.5495 – 0.5502) – Claw thickness 5.93 – 6.00 (0.233 – 0.236) 5.83 (0.230) Transmission Gear I.D.

  • Page 16: Rear Wheel/Suspension Specifications

    Wheel balance weight 60 g (2.1 oz) max. – Fork Spring free length 230.7 (9.08) 226.1 (8.90) Recommended fork fluid Honda Ultra Cushion Oil SS-47 (10W) or – equivalent Fluid level 84 (3.3) – Fluid capacity 515 ± 2.5 cm –...

  • Page 17: Hydraulic Brake Specifications

    dummyhead dummyhead GENERAL INFORMATION CBR1000S1/S2 Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cold tire pressure 290 kPa (2.90 kgf/cm , 42 psi) – Axle runout – 0.1 (0.004) Wheel rim Radial – 0.3 (0.012) runout Axial – 0.3 (0.012) Wheel balance weight 60 g (2.1 oz) max.
  • Page 18 dummyhead dummyhead GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight Position light Brake/taillight License light Turn signal light Except CH 12 V – 21 W x 4 Instrument light Turn signal indicator High beam indicator Neutral indicator HISS indicator Low fuel indicator ABS indicator (CBR1000RA/S1/S2) HESD indicator Low oil pressure indicator...

  • Page 19: Standard Torque Values

    dummyhead dummyhead GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt (Include SH flange bolt) 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
  • Page 20 dummyhead dummyhead GENERAL INFORMATION PGM-FI SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Bank angle sensor mounting nut 5.2 (0.5, 3.8) ECT sensor 23 (2.3, 17) sensor 24.5 (2.5, 18) IAT sensor mounting screw 1.1 (0.1, 0.8) APS mounting screw 2.0 (0.2, 1.5) Shift drum angle sensor bolt...
  • Page 21 dummyhead dummyhead GENERAL INFORMATION CYLINDER HEAD/VALVES THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Cylinder head nut – See page 10-24 Camshaft holder bolt 12 (1.2, 9) Apply oil to the threads and seating surface. Cylinder head cover bolt 10 (1.0, 7) Cam sprocket bolt 20 (2.0, 15)
  • Page 22 dummyhead dummyhead GENERAL INFORMATION ENGINE REMOVAL/INSTALLATION THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Drive sprocket bolt 54 (5.5, 40) Front engine hanger bolt 64 (6.5, 47) Upper engine hanger adjusting bolt 10 (1.0, 7) Upper engine hanger lock nut 54 (5.5, 40) Upper engine hanger nut 64 (6.5, 47)
  • Page 23 dummyhead dummyhead GENERAL INFORMATION HYDRAULIC BRAKE (ABS type) THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Front master cylinder bleed valve 6.0 (0.6, 4.4) Front brake caliper bleed valve 8.0 (0.8, 5.9) (CBR1000RR/RA) Front brake caliper bleed valve 13 (1.3, 10) (CBR1000S1/S2) Rear brake caliper bleed valve...
  • Page 24 dummyhead dummyhead GENERAL INFORMATION Water hose band: Hose diameter 19 mm, 21 mm: 1 mm (0.04 in) maximum Hose diameter 29.8 mm: 2 mm (0.08 in) maximum Water hose clamp: 0 – 1 mm (0 – 0.04 in) 1-18...

  • Page 25: Lubrication & Seal Points

    dummyhead dummyhead GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Liquid sealant Crankcase mating surface See page 13-5 (Three Bond 1207B or Oil pan mating surface See page 9-6 equivalent) Right crankcase cover mating surface See page 11-5 Alternator cover mating surface See page 12-4 Cylinder head semi-circular cut-out...
  • Page 26 Shock absorber spherical bearing (CBR1000RR/RA) Shock absorber dust seal lips (CBR1000RR/RA) Cable lubricant Clutch cable inside EGCA cable inside Honda bond A or equivalent Handlebar grip rubber inner surface adhesive Silicone grease Front brake push rod-to-master piston contact surface Front brake push rod tip...

  • Page 27: Special Tool List

    dummyhead dummyhead GENERAL INFORMATION SPECIAL TOOL LIST TITLE TOOL No TOOL NAME MAINTENANCE 070MG-0010100 Tensioner stopper 07HAA-PJ70101 Oil filter wrench 07HMH-MR10103 Drive chain tool set PGM-FI SYSTEM 070PZ-ZY30100 SCS short connector 07ZAJ-RDJA110 Test probe IGNITION SYSTEM 07HGJ-0020100 Peak voltage adaptor 07ZAJ-RDJA110 Test probe FUEL SYSTEM...
  • Page 28 dummyhead dummyhead GENERAL INFORMATION TITLE TOOL No TOOL NAME REAR WHEEL/SUSPENSION 07749-0010000 Driver 07746-0010500 Attachment, 62 x 68 mm 07746-0041100 Pilot, 28 mm 07746-0050900 Bearing remover head, 28 mm 07GGD-0010100 Bearing remover shaft 07746-0010400 Attachment, 52 x 55 mm 07746-0041100 Pilot, 28 mm 07949-3710001 Driver...

  • Page 29: Cable & Harness Routing

    dummyhead dummyhead GENERAL INFORMATION CABLE & HARNESS ROUTING COMBINATION METER 32P (Gray) CONNECTOR MAIN WIRE HARNESS HEADLIGHT LEFT FRONT TURN LED TURN SIGNAL RELAY SIGNAL LIGHT WIRE (Except CH shown) RIGHT FRONT TURN SIGNAL LIGHT WIRE GUIDE HEADLIGHT 8P (Black) CONNECTOR MAIN WIRE HARNESS BANK ANGLE SENSOR (Route into the groove in the headlight)
  • Page 30 dummyhead dummyhead GENERAL INFORMATION JH2SC77A3HK001627~ LEFT INTAKE AIR DUCT WIRE BAND AIR DUCT COVER LEFT INTAKE AIR DUCT AIR DUCT COVER WIRE BAND AIR DUCT COVER MAIN WIRE HARNESS WIRE BAND MAIN WIRE HARNESS WIRE BAND WIRE HARNESS CLIP (Set into the hole in the left intake air duct) MAIN WIRE HARNESS LEFT INTAKE AIR DUCT...

  • Page 31: Clutch Cable

    dummyhead dummyhead GENERAL INFORMATION CBR1000RR: CLUTCH CABLE IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR SWITCH WIRES RIGHT TURN SIGNAL LIGHT CONNECTORS MAIN WIRE HARNESS HORN WIRE CLAMP (Clamp wire at white paint) FRONT BRAKE HOSE FRONT WHEEL SPEED SENSOR WIRE 1-25...
  • Page 32 dummyhead dummyhead GENERAL INFORMATION CBR1000RA: CLUTCH CABLE IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR SWITCH WIRES RIGHT TURN SIGNAL LIGHT CONNECTORS MAIN WIRE HARNESS FRONT BRAKE HOSE A HORN WIRE CLAMP FRONT BRAKE HOSE D FRONT WHEEL SPEED SENSOR WIRE 1-26...
  • Page 33 dummyhead dummyhead GENERAL INFORMATION CBR1000S1/S2: REBOUND DAMPING ADJUSTER WIRE CLUTCH CABLE IMMOBILIZER RECEIVER WIRE RIGHT HANDLEBAR SWITCH WIRES RIGHT TURN SIGNAL LIGHT CONNECTORS MAIN WIRE HARNESS FRONT BRAKE HOSE A HORN WIRE CLAMP FRONT BRAKE HOSE D FRONT WHEEL SPEED SENSOR WIRE 1-27...
  • Page 34 dummyhead dummyhead GENERAL INFORMATION CBR1000RR: CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE LEFT FRONT TURN SIGNAL LIGHT CONNECTORS LEFT HANDLEBAR SWITCH WIRE (To horn) LEFT HANDLEBAR SWITCH WIRE (To horn) WIRE BAND LEFT COOLING FAN MOTOR MAIN WIRE HARNESS 2P (Black) CONNECTOR FRONT WHEEL SPEED SENSOR WIRE...
  • Page 35 dummyhead dummyhead GENERAL INFORMATION CBR1000RA/S1/S2: CBR1000RA shown: CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE A LEFT HANDLEBAR SWITCH WIRE (To horn) LEFT FRONT TURN SIGNAL LIGHT CONNECTORS LEFT HANDLEBAR SWITCH WIRE (To horn) WIRE BAND MAIN WIRE HARNESS LEFT COOLING FAN MOTOR 2P (Black) CONNECTOR FRONT BRAKE PIPE B...
  • Page 36 dummyhead dummyhead GENERAL INFORMATION CBR1000RR/RA: LEFT HANDLEBAR SWITCH WIRE ECM 33P (Blue) CONNECTOR ECM 33P (Black) CONNECTOR ECM 33P (Gray) CONNECTOR IGNITION SWITCH WIRE SPINDLE SWITCH RESISTOR CLUTCH CABLE APS 6P (Black) CONNECTOR CLUTCH SWITCH DIODE RIGHT HANDLEBAR SWITCH 6P (Blue) CONNECTOR IMMOBILIZER RECEIVER 4P (Black) CONNECTOR IMMOBILIZER...
  • Page 37 dummyhead dummyhead GENERAL INFORMATION CBR1000S1/S2: COMPRESSION DAMPING REBOUND DAMPING ADJUSTER 4P (Black) ADJUSTER 4P (Gray) LEFT HANDLEBAR SWITCH WIRE CONNECTOR CONNECTOR ECM 33P (Blue) CONNECTOR ECM 33P (Black) CONNECTOR ECM 33P (Gray) IGNITION CONNECTOR SWITCH WIRE SPINDLE SWITCH MAIN WIRE HARNESS RESISTOR CLUTCH CABLE APS 6P (Black)
  • Page 38 dummyhead dummyhead GENERAL INFORMATION CBR1000S1/S2 shown: IMMOBILIZER RIGHT HANDLEBAR RECEIVER WIRE SWITCH WIRE LEFT HANDLEBAR SWITCH WIRES APS WIRE CBR1000S1/S2 only: IGNITION SWITCH WIRE MAIN WIRE HARNESS (To fork damping adjusters) Except CH: LEFT HANDLEBAR LEFT HANDLEBAR SWITCH SWITCH 6P (Blue) CONNECTOR 8P (Black) CONNECTOR CH: LEFT HANDLEBAR SWITCH 8P (Blue) CONNECTOR...
  • Page 39 dummyhead dummyhead GENERAL INFORMATION Except KO: MAP SENSOR 3P No. 2 LOWER INJECTOR TP SENSOR 6P 2P (Gray) CONNECTOR (Black) CONNECTOR (Black) CONNECTOR No. 1 LOWER INJECTOR No. 3 LOWER INJECTOR ENGINE SUB-WIRE 1P 2P (Gray) CONNECTOR 2P (Gray) CONNECTOR (White) CONNECTOR No.
  • Page 40 dummyhead dummyhead GENERAL INFORMATION MAP SENSOR 3P No. 2 LOWER INJECTOR TP SENSOR 6P 2P (Gray) CONNECTOR (Black) CONNECTOR (Black) CONNECTOR No. 1 LOWER INJECTOR No. 3 LOWER INJECTOR ENGINE SUB-WIRE 1P 2P (Gray) CONNECTOR 2P (Gray) CONNECTOR (White) CONNECTOR EVAP PURGE HOSE (Fuel tank-to-EVAP canister) No.
  • Page 41 dummyhead dummyhead GENERAL INFORMATION Except KO shown: Direct the shift spindle switch wire within this range. SHIFT SPINDLE SWITCH WIRE EVAP PURGE HOSE ** (Solenoid valve-to-throttle body) · CKP SENSOR 2P (Red) CONNECTOR EVAP PURGE CONTROL · STROKE SENSOR 3P (Black) CONNECTOR SOLENOID VALVE** VS SENSOR SIPHON HOSE...
  • Page 42 dummyhead dummyhead GENERAL INFORMATION HESD HESD 2P (Brown) CONNECTOR PAIR CONTROL SOLENOID CRANKCASE VALVE 2P (Black) CONNECTOR BREATHER HOSE MAIN WIRE HARNESS CMP SENSOR 3P (Blue) PAIR SUPPLY HOSE CONNECTOR IGNITION COIL SUB- IGNITION COIL SUB-WIRE CMP SENSOR 3P (Blue) WIRE HARNESS HARNESS 6P (Black) CONNECTOR CONNECTOR...
  • Page 43 dummyhead dummyhead GENERAL INFORMATION No. 2 DIRECT IGNITION COIL 0 – 20° PAIR SUPPLY HOSE 90° 90° 90° PAINT MARKS PAIR CONTROL SOLENOID VALVE IGNITION COIL SUB-WIRE CLUTCH CABLE HARNESS 6P (Black) CONNECTOR CMP SENSOR RIGHT COOLING FAN MOTOR 2P (Black) CONNECTOR 1-37...
  • Page 44 dummyhead dummyhead GENERAL INFORMATION CBR1000RR/RA (Except KO): CKP SENSOR 2P (Red) CONNECTOR STROKE SENSOR 3P (Black) CONNECTOR 60° ALTERNATOR WIRE 10° SIDESTAND SWITCH 2P (Black) CONNECTOR SENSOR 4P (Black) CONNECTOR NEUTRAL SWITCH SHIFT DRUM ANGLE SENSOR SIDESTAND SWITCH SENSOR 30 – 50 mm (1.2 –...
  • Page 45 dummyhead dummyhead GENERAL INFORMATION CBR1000RR/RA shown: CKP SENSOR 2P (Red) CONNECTOR ALTERNATOR WIRE STROKE SENSOR 3P (Black) CONNECTOR 60° FUEL TANK SIPHON HOSE DRAIN HOSE 10° SENSOR 4P (Black) EVAP CANISTER ALTERNATOR WIRE CONNECTOR NEUTRAL SWITCH SHIFT DRUM SIDESTAND ANGLE SENSOR SWITCH 2P (Black) CONNECTOR...
  • Page 46 dummyhead dummyhead GENERAL INFORMATION CBR1000S1/S2 (Except KO): CKP SENSOR 2P (Red) CONNECTOR STROKE SENSOR 3P (Black) CONNECTOR 60° ALTERNATOR WIRE 10° SIDESTAND SWITCH 2P (Black) CONNECTOR SENSOR 4P (Black) CONNECTOR NEUTRAL SWITCH STROKE SENSOR SHIFT DRUM ANGLE SENSOR SIDESTAND SWITCH SENSOR 30 –...
  • Page 47 dummyhead dummyhead GENERAL INFORMATION SIPHON HOSE MAIN WIRE HARNESS WATER HOSE MAIN WIRE HARNESS (Thermostat-to-filler neck) CLUTCH CABLE SIPHON HOSE WATER HOSE CLUTCH CABLE (Thermostat-to-filler neck) ENGINE SUB-WIRE EOP SWITCH 1-41...
  • Page 48 dummyhead dummyhead GENERAL INFORMATION CBR1000RR: ALTERNATOR WIRE ALTERNATOR WIRE BATTERY GROUND CABLE REAR FENDER B IMU STAY STARTER RELAY SWITCH FUSE/RELAY BOX STARTER MOTOR CABLE BATTERY (+) CABLE MAIN WIRE HARNESS BATTERY MAIN WIRE HARNESS MAIN WIRE HARNESS (To regulator/ rectifier) 12P JOINT CONNECTOR This end should be placed...
  • Page 49 dummyhead dummyhead GENERAL INFORMATION CBR1000RA/S1/S2: CBR1000S1/S2 shown: REAR BRAKE LIGHT SWITCH WIRE REAR SHOCK ABSORBER DAMPING ADJUSTER SUB-WIRE HARNESS* REAR BRAKE PIPE C REAR WHEEL SPEED SENSOR WRIE MAIN WIRE REAR BRAKE LIGHT HARNESS SWITCH WIRE (To IMU) WIRE HARNESS PROTECTOR REAR WHEEL SPEED SENSOR WRIE...
  • Page 50 dummyhead dummyhead GENERAL INFORMATION CBR1000RA/S1/S2: CBR1000S1/S2 shown: SUSPENSION CONTROL UNIT WIRE* ALTERNATOR WIRE REAR FENDER B SUSPENSION CONTROL UNIT 34P (Black) CONNECTOR* BATTERY ABS MODULATOR WIRE BATTERY (+) CABLE REAR SHOCK ABSORBER FUSE/ DAMPING ADJUSTER MAIN WIRE HARNESS RELAY BOX SUB-WIRE HARNESS* MAIN WIRE HARNESS...
  • Page 51 dummyhead dummyhead GENERAL INFORMATION CBR1000RR/RA: LICENSE LIGHT FAN CONTROL RELAYS 2P (Black) CONNECTOR MAIN WIRE HARNESS BRAKE/TAILLIGHT 3P (Black) CONNECTOR REAR TURN SIGNAL LIGHT CONNECTOR HOLDER OPTION CONNECTOR CBR1000S1/S2: LICENSE LIGHT FAN CONTROL RELAYS 2P (Black) CONNECTOR MAIN WIRE HARNESS BRAKE/TAILLIGHT 3P (Black) CONNECTOR REAR TURN SIGNAL LIGHT...

  • Page 52: Evap Canister

    dummyhead dummyhead GENERAL INFORMATION LICENSE LIGHT BRAKE/TAILLIGHT FAN CONTROL RELAYS 3P (Black) CONNECTOR 2P (Black) CONNECTOR REGULATOR/RECTIFIER 2P (Black) CONNECTOR LEFT REAR TURN SIGNAL LIGHT 2P (Orange) CONNECTOR RIGHT REAR TURN SIGNAL LIGHT 2P (Light blue) CONNECTOR ALTERNATOR 2P (Black) CONNECTOR CBR1000RA (Except GS/IN/KO/RU/U) shown: SIPHON HOSE OVERFLOW HOSE...
  • Page 53 dummyhead dummyhead GENERAL INFORMATION CBR1000RR REAR BRAKE LIGHT REAR BRAKE HOSE SWITCH WIRE REAR WHEEL SPEED SENSOR WIRE REAR BRAKE HOSE 40 mm (1.6 in) 45 mm REAR BRAKE HOSE (1.8 in) REAR WHEEL SPEED SENSOR WIRE EGCA CABLE A EGCA CABLE B REAR WHEEL SPEED SENSOR WIRE...
  • Page 54 dummyhead dummyhead GENERAL INFORMATION CBR1000RA: REAR BRAKE HOSE D REAR WHEEL SPEED SENSOR WIRE REAR BRAKE PIPE B 40 mm (1.6 in) 45 mm REAR BRAKE HOSE A (1.8 in) REAR BRAKE HOSE D REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE PIPE C REAR WHEEL SPEED SENSOR REAR BRAKE HOSE A...
  • Page 55 dummyhead dummyhead GENERAL INFORMATION CBR1000S1/S2: REAR BRAKE HOSE D REAR WHEEL SPEED SENSOR WIRE REAR SHOCK ABSORBER DAMPING ADJUSTER WIRES 40 mm (1.6 in) 45 mm (1.8 in) REAR BRAKE PIPE B REAR BRAKE HOSE A REAR WHEEL SPEED SENSOR WIRE REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE PIPE C...
  • Page 56 dummyhead dummyhead GENERAL INFORMATION CBR1000S1/S2: REAR SHOCK ABSORBER DAMPING ADJUSTER SUB-WIRE HARNESS REAR BRAKE HOSE D REAR WHEEL SPEED SENSOR WIRE REAR BRAKE PIPE C REAR SHOCK ABSORBER DAMPING ADJUSTER WIRES CONNECTOR COVER REAR SHOCK ABSORBER REBOUND DAMPING ADJUSTER 4P (Gray) CONNECTOR REAR SHOCK ABSORBER COMPRESSION DAMPING ADJUSTER 4P (Black) CONNECTOR REAR SHOCK ABSORBER...
  • Page 57 dummyhead dummyhead GENERAL INFORMATION Water hose clamp position: MARK MARK MARK 30° ± 22.5° 0° ± 22.5° 30° ± 22.5° 0° ± 22.5° 0° ± 22.5° MARK MARK 0° ± 22.5° 30° ± 22.5° 0° ± 22.5° MARK MARK 20° ± 22.5° MARK MARK MARK...
  • Page 58 dummyhead dummyhead GENERAL INFORMATION Water hose clamp position: Upper side Upper side 90° ± 10° Right side Right side 0° ± 10° MARK 70° ± 22.5° MARK 60° ± 22.5° 23.5° ± 5° MARK + 22.5° 45° – 10° Front side Front side MARK MARK...

  • Page 59: Source Of Emissions

    Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes various system (page 1-54) 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 60: Three Way Catalytic Converter

    dummyhead dummyhead GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) The exhaust emission control system is composed of a pulse secondary air supply system, a three-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. Fresh air is drawn into the exhaust port by the function of the PAIR control valve.

  • Page 61: Noise Emission Control System

    dummyhead dummyhead GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (Except GS/IN/RU/U) Fuel vapor from the fuel tank is routed into the EVAP canister where it is absorbed and stored while the engine is stopped. When the engine is running and the EVAP purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn into the engine. FUEL TANK THROTTLE BODY EVAP PURGE CONTROL...

  • Page 62: Technical Features

    dummyhead dummyhead GENERAL INFORMATION TECHNICAL FEATURES Grip APS Grip APS overview of construction With the TBW (Throttle By Wire) that requires no cables employed for the purpose of weight reduction, the layout around the handlebars of this model is made simpler and more innovative. When the throttle is opened right after the ignition is turned on that is before the engine starts, the throttle valves are driven by the motor to open and close.

  • Page 63: Valve Gear

    dummyhead dummyhead GENERAL INFORMATION Throttle body overview of construction As for the throttle body assembly, when the throttle body receives a signal from the ECM, the motor for driving the throttle valves is activated. Output from the motor is transferred to the valve gear via the pinion gear and idle gear, and then drives the coaxially arranged throttle valve shaft to open the throttle valves.
  • Page 64 GENERAL INFORMATION Honda Selectable Torque Control System The torque control system limits the engine torque by reducing the fuel supply to control the rotational speed of the rear wheel when opening the throttle rapidly or riding in rain.
  • Page 65 dummyhead dummyhead GENERAL INFORMATION Indicators When the torque control is active, the torque control indicator blinks. When the torque control system fails, the system is stops and the torque control indicator comes on. The following figures show the indication status before the pre-start self-diagnosis is completed with the ignition switch turned ON. The torque control indicator stays on at this time.
  • Page 66 dummyhead dummyhead GENERAL INFORMATION Quick Shifter System Overview Quick shifter is a system that enables clutchless upshifts under acceleration and blipping on downshifts under acceleration/ deceleration by systematically utilizing input of sensor information and output of control information. It allows the rider to upshift and downshift only using the shift pedal. There is no need to touch either the clutch lever or throttle grip. In the traditional way of gear shifting, the rider disengages the clutch to reduce transmission torque.
  • Page 67 dummyhead dummyhead GENERAL INFORMATION Mechanisms of disengagement of dog (gear) due to reduction in transmission torque and gear change Downshifting under deceleration: Engine min (rpm) is increased as ECM Gear is shifted by controls electronic shift pedal operation. throttle opening. Stationary Sliding gear...

  • Page 68: Rear Wheel Speed Sensor

    dummyhead dummyhead GENERAL INFORMATION ABS WITH IMU (Inertia Measurement Unit) The ABS of CBR1000RA/S1/S2 consists of the ABS modulator, IMU, and front and rear wheel speed sensors. The IMU constantly measures the vehicle inertia force and sends the data to the ABS modulator. The ABS modulator detects and calculates the vehicle attitude (include bank angle) based on the signals from the IMU.
  • Page 69 GENERAL INFORMATION ÖHLINS Smart EC ÖHLINS Smart EC system has been adopted for CBR1000S1/S2 in joint cooperation between the HONDA and ÖHLINS. It provides the pre-programmed damping characteristics optimized for every situation, for more enjoyable ride. The front and rear suspensions constantly determine the riding conditions as the SCU receives signals from the different control units.

  • Page 70: Lithium Ion Battery

    dummyhead dummyhead GENERAL INFORMATION BANK ANGLE ESTIMATION SYSTEM The IMU measure the vehicle behavior using the 5-axis inertia information (3-axis acceleration sensor and 2-axis gyro sensor) and sends this information to the ABS modulator. The ABS modulator converts this information to the longitudinal, side and vertical accelerations, and the roll and yaw behaviors, and then estimates the bank angle of the vehicle.
  • Page 71 dummyhead dummyhead GENERAL INFORMATION OBD (On-Board Diagnostic) SYSTEM (European Market) This motorcycle 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 72 DTC, freeze data and 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 4-10) for each DTC and troubleshooting detail.

  • Page 73: Frame/Body Panels/Exhaust System

    dummytext 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION ·····························2-2 SEAT RAIL ·················································· 2-12 TROUBLESHOOTING···································2-2 FRONT LOWER COVER ···························· 2-13 BODY PANEL LOCATIONS ·························2-3 MIDDLE COWL ··········································· 2-13 MAIN SEAT ···················································2-4 INTAKE AIR DUCT ····································· 2-14 PILLION SEAT/SEAT BELT REARVIEW MIRROR ·································· 2-16 (CBR1000RR/RA only) ·································2-4 WINDSCREEN ············································...

  • Page 74: Service Information

    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, exhaust system and seat rail. • Always replace the exhaust pipe gaskets with new ones after removing the exhaust pipe from the engine. •...

  • Page 75: Body Panel Locations

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS [10] [11] [25] [24] [23] [22] [21] [20] [19] [18] [17] [16] [15] [14] [13] [12] Middle cowl (page 2-13) [14] Rear fender C (page 2-12) Rearview mirror (page 2-16) [15] Rear under cowl (page 2-8) Windscreen (page 2-17) [16] Seat rail (page 2-12)
  • Page 76 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM MAIN SEAT REMOVAL/INSTALLATION Remove the socket screws [1] and washers [2]. [1]/[2] Remove the main seat [3] by sliding it rearward. Install the main seat by inserting the prongs [4] under the frame. Install the washers and screws, and tighten screws securely.
  • Page 77 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SINGLE SEAT COWL (CBR1000S1/S2) REMOVAL/INSTALLATION Unlock the single seat cowl [1] using the ignition key [2] and remove it by pulling it forward Install the single seat cowl by inserting the prong [3] under the rear frame, and push the front of the cowl down to lock it.

  • Page 78: Top Shelter

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM TOP SHELTER REMOVAL/INSTALLATION Remove the following: – IMU cover (page 2-5) – Socket screws [1] – Top shelter [2] Installation is in the reverse order of removal. • Hook the retainers [3] onto the frame properly. DISASSEMBLY/ASSEMBLY LEFT AIR CLEANER SIDE COVER COLLARS B...
  • Page 79 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR UPPER COWL REMOVAL/INSTALLATION Remove the following: – Main seat (page 2-4) – CBR1000RR/RA: Pillion seat/seat belt (page 2-4) – CBR1000S1/S2: Single seat cowl (page 2-5) – Two trim clips [1] – Four special screws [2] Release the tabs of the upper cowl [3] from the rear under cowl.
  • Page 80 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM SEAT LOCK REMOVAL/ INSTALLATION Remove the following from the cross upper plate: Align – Setting spring [1] – Seat lock cylinder [2] – Seat lock washer [3] – Bolt [4] – Seat catch hook [5] Installation is in the reverse order of removal.

  • Page 81: Rear Fender A

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REGULATOR COVER REMOVAL/INSTALLATION Remove the following: – Rear under cowl (page 2-8) – Cross upper plate (page 2-7) – Two trim clips [1] – Four tapping screws [2] – Regulator cover [3] Installation is in the reverse order of removal. REAR FENDER A REMOVAL/INSTALLATION Remove the regulator cover (page 2-7).
  • Page 82 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY RIGHT REAR TURN SIGNAL LIGHT TURN SIGNAL MOUNTING RUBBER LICENSE LIGHT COVER TURN SIGNAL COLLARS LEFT REAR TURN SIGNAL LIGHT 5 mm WASHERS 5 mm SPECIAL BOLTS RUBBER WASHERS LICENSE LIGHT COVER LICENSE LIGHT MOUNTING RUBBERS REAR FENDER A RUBBER WASHERS...

  • Page 83: Rear Fender B

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER B REMOVAL/INSTALLATION Remove the following: – Regulator cover (page 2-7) – DLC from the stay (page 4-7) – Fuel tank (page 7-8) – Battery (page 20-6) – Regulator/rectifier (page 20-8) – CBR1000RA/S1/S2: ABS modulator/IMU (page 19- –...

  • Page 84: Rear Fender C

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER C REMOVAL/INSTALLATION Remove the two socket screws [1], rear fender C [2] and washer [3] from the swingarm. Installation is in the reverse order of removal. PILLION STEP HOLDER (CBR1000RR/ RA only) REMOVAL/INSTALLATION Remove the two flange bolts [1] and the pillion step holder [2] from the seat rail.

  • Page 85: Front Lower Cover

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT LOWER COVER REMOVAL/INSTALLATION Remove the four trim clips [1]. Release the two tabs [2] from the inner middle cowls. Release the hook [3] from the front cowl, and remove the front lower cover [4]. Installation is in the reverse order of removal.

  • Page 86: Intake Air Duct

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the following from the middle cowl [1]: – Two trim clips [2] – Shroud [3] – Two tapping screws [4] – Inner middle cowl [5] Assembly is in the reverse order of disassembly. INTAKE AIR DUCT REMOVAL/INSTALLATION Remove the middle cowl (page 2-13).
  • Page 87 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY • The intake air duct and triangular resonator have identification mark. – Left side: LH – Right side: RH AIR DUCT COVER INTAKE AIR DUCT TRIM CLIPS RESONATOR TUBE A RESONATOR TUBE B CYLINDRICAL RESONATOR TRIANGULAR RESONATOR Install resonator tube A [1] into the air duct [2] and resonator tube B [3] into the cylindrical resonator [4].

  • Page 88: Rear View Mirror

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM REARVIEW MIRROR REMOVAL/INSTALLATION Pull the connector boot out of the stay and disconnect the turn signal light 1P and 2P connectors [1]. Remove the cap nuts [2] and pull the wires out of the stay carefully to remove the rearview mirror [3]. Installation is in the reverse order of removal.
  • Page 89 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM WINDSCREEN REMOVAL/INSTALLATION Remove the left and right rearview mirrors (page 2-16). Remove the two 5 x 14 mm special bolts [1], 5 x 16 mm special bolts [2], four plastic washers [3] and rubber washers [4]. Slightly press the windscreen [5] inward to release the Be careful not to two grommets [6] from the bosses [7] and remove...
  • Page 90 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT COWL REMOVAL/INSTALLATION Remove the following: – Middle cowls (page 2-13) – Windscreen (page 2-17) Release the air duct cover tabs from the front cowl. Remove the two socket screws [1] and front cowl assembly [2] by releasing the two bosses [3] from the grommets [4].
  • Page 91 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the following: – Screws/washers [1] – Headlight [2] – Collars [3] – Except CH: LED turn signal relay stay [4] with the LED turn signal relay – CH: Turn signal relay stay [4] with the turn signal relay and headlight relay –...

  • Page 92: Under Cowl

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM UNDER COWL REMOVAL/INSTALLATION Remove the eight special bolts [1] and two socket screws [2]. Release the right tabs from the right middle cowl. Release the left tabs from the left middle cowl and boss [3] from the grommet [4], and remove the under cowl [5].

  • Page 93: Left Rear Cover

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM RIGHT REAR UNDER COVER (CH/FO/ TH only) REMOVAL/INSTALLATION Remove the following: – Under cowl (page 2-20) – Special bolt [1] – Socket screw [2] – Right rear under cover [3] Installation is in the reverse order of removal. TORQUE: Special bolt: 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)

  • Page 94: Frame Side Cover

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRAME SIDE COVER REMOVAL/INSTALLATION Remove the following: Align – Socket screw [1] – Frame side cover [2] Installation is in the reverse order of removal. • Align the cover tab with the frame slot. SIDESTAND REMOVAL/INSTALLATION Support the motorcycle securely using a hoist or equivalent.

  • Page 95: Front Fender

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the following: – Front wheel (page 16-15) – Bolt [1], wire clamp [2] and brake hose 3-way joint [3] – Cap nut [4] and brake hose clamp [5] – Four mounting screws [6] –...
  • Page 96 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER REMOVAL/INSTALLATION Remove the following: – Under cowl (page 2-20) – Nuts [1] – Bolts [2] – Valve guide cover [3] Loosen the lock nuts [4] and remove the cable joints [5] from the valve guide body of the muffler. Disconnect EGCA cable B [6] from the valve cable guide [7].

  • Page 97: Exhaust Pipe

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Straighten the lock washer [1] tabs. Remove the following: – Nut [2] – Lock washer – Valve cable guide [3] – Return spring [4] Assembly is in the reverse order of disassembly. • Hook the return spring ends to the muffler tab [5] and valve cable guide groove [6] as shown.
  • Page 98 dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM Loosen the exhaust pipe mounting bolt [1]. Remove the following: – Eight joint nuts [2] – Stay bolt [3] – Exhaust pipe assembly [4] – Four gasket [5] – Mounting bolt – Washer [6] – Mounting collar [7] –...

  • Page 99: Stud Bolt Replacement

    dummyhead dummyhead FRAME/BODY PANELS/EXHAUST SYSTEM STUD BOLT REPLACEMENT Remove the exhaust pipe (page 2-25). EXHAUST PIPE STUD BOLT Thread two nuts onto the stud and tighten them together, and use a wrench on them to turn the stud bolt out. Install a new stud bolt [1] into the cylinder head.
  • Page 100 dummyhead dummyhead MEMO...

  • Page 101: Maintenance

    dummytext 3. MAINTENANCE SERVICE INFORMATION ·····························3-2 DRIVE CHAIN ············································· 3-17 MAINTENANCE SCHEDULE························3-2 DRIVE CHAIN SLIDER ······························· 3-20 FUEL LINE·····················································3-4 BRAKE FLUID ············································ 3-20 THROTTLE OPERATION······························3-5 BRAKE PADS WEAR ································· 3-21 AIR CLEANER···············································3-5 BRAKE SYSTEM ········································ 3-21 SPARK PLUG················································3-6 BRAKE LIGHT SWITCH ····························· 3-22 VALVE CLEARANCE····································3-8 HEADLIGHT AIM ········································...

  • Page 102: Service Information

    * 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 your motorcycle after each periodic maintenance is carried out. NOTES: 1.
  • Page 103 * 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 104 dummyhead dummyhead MAINTENANCE FUEL LINE FUEL TANK LIFTING/LOWERING Remove the top shelter (page 2-6). Disconnect the fuel tank drain hose [1] from the fuel tank tray BR/CH/ED/FO/KO/TH: Disconnect the fuel tank-to- canister hose [2] from the breather joint. GS/IN/RU/U: Disconnect the fuel tank breather hose [2] from the breather joint.

  • Page 105: Throttle Operation

    dummyhead dummyhead MAINTENANCE INSPECTION Lift and support the fuel tank (page 3-4) Check the fuel lines [1] for deterioration, damage or leakage. Replace the fuel lines if necessary. Also check the fuel line fittings for leakage. Lower the fuel tank (page 3-4) THROTTLE OPERATION Check for smooth operation of the throttle grip [1] and that it returns automatically to the fully closed position...

  • Page 106: Spark Plug

    dummyhead dummyhead MAINTENANCE ED/U: Clean the air cleaner element using compressed air from the throttle body side any time it is excessively dirty. Except ED/U: Replace the air cleaner element in accordance with the maintenance schedule or any time it is excessively dirty or damage. •...
  • Page 107 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 108: Valve Clearance

    dummyhead dummyhead MAINTENANCE VALVE CLEARANCE • Inspect and adjust the valve clearance while the engine is cold (below 35°C/95°F). INSPECTION Remove the cylinder head cover (page 10-4). Remove the bolt [1] and sealing washer [2] from the cam chain tensioner lifter. [1]/[2] Turn the tensioner lifter shaft fully in (clockwise) and secure it using the special tool.
  • Page 109 dummyhead dummyhead MAINTENANCE Make sure the following: • The inside punch mark [1] of the intake cam sprocket [2] must be flush with the cylinder head upper surface. • The outside timing marks ("IN" and "EX") [3] of the intake cam sprocket and exhaust cam sprocket [4] must be flush with the cylinder head upper surface and facing outward as shown.
  • Page 110 Adjust the valve clearance if necessary (page 3-10). ADJUSTMENT Use genuine Honda parts for the shims replacement. In case of the wrong shims usage, its material may damage to the intake valve titanium surface. Remove the valve lifters and shims (page 10-6).
  • Page 111 dummyhead dummyhead MAINTENANCE Measure the thickness of the shim [1] and record it. Calculate the new shim thickness using the equation Sixty-five different below. thickness shims are A = (B – C) + D available from the A: New shim thickness thinnest 1.200 mm B: Recorded valve clearance thickness shim to...

  • Page 112: Engine Oil

    [3] and add the recommended engine oil to the upper level line [4] through the oil filler hole. RECOMMENDED ENGINE OIL: Honda "4-stroke motorcycle oil" or an equivalent motor oil API service classification: SG or higher JASO T903 standard: MA...

  • Page 113: Engine Oil Filter

    dummyhead dummyhead MAINTENANCE ENGINE OIL FILTER Remove the under cowl (page 2-20). Drain the engine oil (page 3-12). Remove the oil filter cartridge [1] using the special tool. TOOL: Oil filter wrench [2] 07HAA-PJ70101 Check that the oil filter boss [1] protrusion from the 6.5 ±...

  • Page 114: Engine Idle Speed

    RECOMMENDED ANTIFREEZE: Except IN/TH: High quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors IN/TH: Honda PRE-MIX Coolant RECOMMENDED MIXTURE (Except IN/TH): 1:1 mixture with distilled water Remove the reserve tank filler cap [4] and fill to the "UPPER" level line.

  • Page 115: Cooling System

    dummyhead dummyhead MAINTENANCE COOLING SYSTEM Remove the middle cowls (page 2-13). Check the radiator air passages for clogging or damage. Straighten bent fins with a small, blade screwdriver and remove insects, mud or other obstructions with compressed air or low water pressure. Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.

  • Page 116: Cable Adjustment

    dummyhead dummyhead MAINTENANCE EGCA CABLE OPERATING INSPECTION Remove the following: – Under cowl (page 2-20) – Nuts [1] – Bolts [2] – Valve guide cover [3] Short the DLC terminals using the special tool (page 4- Turn the ignition switch ON and engine stop switch " ". The EGCA operates and the index line [1] on the valve cable guide tab should be aligned with the index projection [2] of the valve guide body.

  • Page 117: Drive Chain Slack Inspection

    dummyhead dummyhead MAINTENANCE DRIVE CHAIN Amputation hazard. Never inspect or adjust the drive chain while the engine is running. DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF, place the motorcycle on its sidestand and shift the transmission into neutral. Check the slack in the drive chain lower run midway between the sprockets.

  • Page 118: Recommended Lubricant

    dummyhead dummyhead MAINTENANCE CLEANING AND LUBRICATION Clean the drive chain [1] with a chain cleaner designed specifically for O-ring chains. 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 119 dummyhead dummyhead MAINTENANCE REPLACEMENT This motorcycle uses a drive chain with a staked master link. Fully slacken the drive chain (page 3-17). Remove the drive chain using the special tool. When using the special tool, follow 1 LINK TOOL: the manufacturer's Drive chain tool set 07HMH-MR10103 instruction.

  • Page 120: Drive Chain Slider

    dummyhead dummyhead MAINTENANCE DRIVE CHAIN SLIDER Inspect the drive chain slider [1] for excessive wear or damage. If it is worn to the wear indicators [2], replace the drive chain slider (page 17-17). BRAKE FLUID Spilled fluid can damage painted, plastic or rubber parts.

  • Page 121: Brake Pads Wear

    dummyhead dummyhead MAINTENANCE BRAKE PADS WEAR Check the brake pads for wear. FRONT: REAR: Replace the brake pads if either pad is worn to the bottom of wear limit groove [1]. For brake pad replacement (page 18-8). BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal, and check that no air has entered the system.

  • Page 122: Brake Light Switch

    dummyhead dummyhead MAINTENANCE BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut [1] and turn the push rod [2] until the correct pedal height is obtained. When adjusting the push rod length, do not extend it more than 5.5 mm (0.22 in). After adjustment, tighten the lock nut [1] to the specified torque.

  • Page 123: Headlight Aim

    dummyhead dummyhead MAINTENANCE HEADLIGHT AIM • Adjust the headlight aim as specified by local laws and regulations. Place the motorcycle on a level surface. Adjust the headlight aim vertically by turning the vertical beam adjusting screw [1]. A clockwise rotation moves the beam up and counterclockwise rotation moves the beam down.

  • Page 124: Front Suspension Inspection

    dummyhead dummyhead MAINTENANCE Major adjustment is performed at the clutch lifter lever. Loosen the lock nut [1] and turn the adjusting nut [2] to adjust the freeplay. Tighten the lock nut securely while holding the adjusting nut. If proper freeplay cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch (page 11-6).
  • Page 125 dummyhead dummyhead MAINTENANCE COMPRESSION AND REBOUND DAMPING ADJUSTERS Do not turn the adjusters more than the given positions or the adjusters may be damaged. The compression and rebound damping can be To adjust both adjusted by turning the adjusters. sides equally, set the right and left DIRECTION H: Increase the damping force (harder) damping adjusters...

  • Page 126: Rear Suspension Inspection

    dummyhead dummyhead MAINTENANCE Adjust the spring pre-load by turning the adjuster [1] To adjust both sides equally, set TURN CLOCKWISE: the right and left Increase the spring pre-load pre-load adjusters TURN COUNTERCLOCKWISE: to the same Decrease the spring pre-load position PRE-LOAD ADJUSTER STANDARD POSITION: 4 turns clockwise from softest position Connect the 4P connector and install it onto the stay.
  • Page 127 dummyhead dummyhead MAINTENANCE COMPRESSION AND REBOUND DAMPING ADJUSTERS Do not turn the adjusters more than the given positions or the adjusters may be damaged. The compression and rebound damping can be adjusted by turning the adjusters. DIRECTION H: Increase the damping force DIRECTION S: Decrease the damping force Turn the compression damping adjuster [1] clockwise until...

  • Page 128: Nuts, Bolts, Fasteners

    dummyhead dummyhead MAINTENANCE COMPRESSION AND REBOUND DAMPING ADJUSTERS The compression and rebound damping forces can be adjusted using the FUNCTION menu in the SETTING mode of the combination meter. For meter setting mode (page 21-11). FRONT FORK OIL (CBR1000S1/S2 only) For front fork oil replacement, contact ÖHLINS (service) in each region.

  • Page 129: Pgm-Fi System

    dummytext 4. PGM-FI SYSTEM SERVICE INFORMATION ·····························4-2 SHIFT DRUM ANGLE SENSOR ················· 4-78 PGM-FI SYSTEM LOCATION ·······················4-3 SHIFT STROKE SENSOR ·························· 4-79 PGM-FI SYSTEM DIAGRAM·························4-4 SHIFT SPINDLE SWITCH··························· 4-81 PGM-FI TROUBLESHOOTING CLUTCH SWITCH ······································· 4-81 INFORMATION··············································4-6 MAP SENSOR············································· 4-82 PGM-FI SYMPTOM TROUBLESHOOTING···································4-9 IAT SENSOR···············································...

  • Page 130: Service Information

    dummyhead dummyhead PGM-FI SYSTEM SERVICE INFORMATION PGM-FI SYSTEM GENERAL • Use an electric heating element to heat the water for the ECT sensor inspection, keep flammable materials away from the electric heating element. Wear protective clothing, insulated gloves, and eye protection. •...

  • Page 131: Pgm-Fi System Location

    dummyhead dummyhead PGM-FI SYSTEM PGM-FI SYSTEM LOCATION SECONDARY INJECTOR TP SENSOR MAP SENSOR IAT SENSOR MOTOR EVAP PURGE CLUTCH CONTROL FUEL PUMP SWITCH SOLENOID VALVE FUSE/ RELAY BOX BANK ANGLE SENSOR PAIR CONTROL SOLENOID VALVE CMP SENSOR IGNITION COIL FRONT WHEEL SPEED PRIMARY...

  • Page 132: Pgm-Fi System Diagram

    dummyhead dummyhead PGM-FI SYSTEM PGM-FI SYSTEM DIAGRAM CBR1000RR: METER/IMU/ILLUMI MAIN FUSE 30 A FUSE 10 A FI FUSE 15 A FI/IGN/START FUSE 10 A R/Bl IGNITION MAIN RELAY SWITCH Bl/Bu ENGINE STOP SWITCH ENGINE STOP RELAY Bl/Bu Bl/G FAN (R) MOTOR RELAY BATTERY FAN (L) MOTOR RELAY FAN (R) FUSE 20A...
  • Page 133 dummyhead dummyhead PGM-FI SYSTEM Except CBR1000RR: METER/IMU/ILLUMI MAIN FUSE 30 A FUSE 10 A FI FUSE 15 A FI/IGN/START FUSE 10 A R/Bl IGNITION MAIN RELAY SWITCH Bl/Bu ENGINE STOP SWITCH ENGINE STOP RELAY Bl/Bu Bl/G FAN (R) MOTOR RELAY BATTERY FAN (L) MOTOR RELAY FAN (R) FUSE 20A...

  • Page 134: Pgm-Fi Troubleshooting Information

    MIL circuit (page 4-73). DTC (Honda code) • The DTC (Honda code) is composed of a main code and a sub code and it is displayed as a hyphenated number when retrieved from the ECM with the MCS.

  • Page 135: Dtc Readout

    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 Turn the ignition switch OFF. CBR1000RR/RA: Remove the pillion seat (page 2-4). CBR1000S1/S2: Remove the single seat cowl (page 2-5).

  • Page 136: Erasing Dtc

    DTC index (page 4-10). • The main code of Honda code (the number in front of hyphen) can be indicated as MIL blinking. • The MIL has two types of blinks, a long blink and short blink. The long blinking lasts for 1.3 seconds, the short blinking lasts for 0.5 seconds.

  • Page 137: Pgm-Fi Symptom Troubleshooting

    dummyhead dummyhead PGM-FI SYSTEM PGM-FI SYMPTOM TROUBLESHOOTING When the motorcycle has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 4-10) and begin the appropriate troubleshooting procedure. If there are no DTC/MIL blinking stored in the ECM memory, do the diagnostic procedure for the symptom, in sequence listed below, until you find the cause.

  • Page 138: Dtc Index

    PGM-FI SYSTEM DTC INDEX • If the MCS is not used, perform all of the inspection on the corresponding main code (digits in front of hyphen) of the Honda code. • The main code of Honda code (the number in front of hyphen) can be indicated as MIL blinking.
  • Page 139 PGM-FI SYSTEM Refer (Honda Function Failure Symptom/Fail-safe function code) (page) sensor heater circuit malfunction • Engine operates normally P0135 • Loose or poor contact of the O sensor heater 4-27 (23-1) connector • O sensor heater or its circuit malfunction...
  • Page 140 PGM-FI SYSTEM Refer (Honda Function Failure Symptom/Fail-safe function code) (page) TP sensor 2 low voltage • Vehicle speed limit: approximately 120 P0222 • TP sensor 2 or its circuit malfunction km/h (75 mph) 4-45 (72-1) • Quickshifter does not operate •...
  • Page 141 PGM-FI SYSTEM Refer (Honda Function Failure Symptom/Fail-safe function code) (page) No.1 ignition coil circuit malfunction • No.1 Injector and ignition coil shut down P0351 • Loose or poor contact of the ignition coil • Quickshifter does not operate...

  • Page 142: Dtc Troubleshooting

    dummyhead dummyhead PGM-FI SYSTEM DTC TROUBLESHOOTING • Before starting the inspection, check for loose or poor contact on the sensor connector and ECM connectors, then recheck the DTC. DTC P0107 (MAP SENSOR LOW VOLTAGE) 1. MAP Sensor System Inspection Check the MAP sensor with the GST or MCS. Is about 0 V indicated? –...
  • Page 143 dummyhead dummyhead PGM-FI SYSTEM 5. MAP Sensor Inspection Replace the MAP sensor with a known good one (page 4-82). Connect the ECM 33P connectors. Erase the DTC (page 4-8). Check the MAP sensor with the GST or MCS. Is DTC P0107 indicated? –...
  • Page 144 dummyhead dummyhead PGM-FI SYSTEM 4. MAP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Black) connector (page 4-73). Check for continuity between the wire harness side 3P (Black) [1] and 33P (Black) [2] connectors terminals.
  • Page 145 dummyhead dummyhead PGM-FI SYSTEM DTC P0117 (ECT SENSOR LOW VOLTAGE) 1. ECT Sensor System Inspection Check the ECT sensor with the GST or MCS. Is about 0 V indicated? – GO TO STEP 2. – Intermittent failure 2. ECT Sensor Inspection Turn the ignition switch OFF.
  • Page 146 dummyhead dummyhead PGM-FI SYSTEM 3. ECT Sensor Line Open Circuit Inspection Turn the ignition switch OFF. Remove the jumper wire. Disconnect the ECM 33P (Black) connector [1] and ECM 33P (Gray) connector [2] (page 4-73). Check for continuity between the wire harness side 3P (Gray) [3] and ECM connectors terminals.
  • Page 147 dummyhead dummyhead PGM-FI SYSTEM DTC P0113 (IAT SENSOR HIGH VOLTAGE) 1. IAT Sensor System Inspection Check the IAT sensor with the GST or MCS. Is about 5 V indicated? – GO TO STEP 2. – Intermittent failure 2. IAT Sensor Inspection Turn the ignition switch OFF.
  • Page 148 dummyhead dummyhead PGM-FI SYSTEM 2. VS Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the VS sensor 3P (Black) connector (page 4-77). Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the wire harness side 3P (Black) connector [1] terminals.

  • Page 149: Signal Line

    dummyhead dummyhead PGM-FI SYSTEM DTC P0201/P0202/P0203/P0204/P21CF/ P21D0/P21D1/P21D2 (PRIMARY/SECONDARY INJECTOR) INJECTOR POWER INPUT LINE SIGNAL LINE SIGNAL AT ECM P0201 No.1 Primary Yellow Light blue P0202 No.2 Primary Yellow Green P0203 No.3 Primary Yellow Pink P0204 No.4 Primary Yellow Black P21CF No.1 Secondary Yellow Gray...
  • Page 150 dummyhead dummyhead PGM-FI SYSTEM 4. Injector Signal Line Open Circuit Inspection Disconnect the ECM 33P (Gray) and ECM 33P PRIMARY: (Blue) connectors (page 4-73). Check for continuity between the wire harness side 2P (Gray) [1], 33P (Gray) [2] and 33P (Blue) [3] connectors terminals.
  • Page 151 dummyhead dummyhead PGM-FI SYSTEM DTC P0340 (CMP SENSOR) 1. CMP Sensor System Inspection 1 Erase the DTC (page 4-8). Check the CMP sensor with the GST or MCS. Crank the engine for ten seconds or more. Is DTC P0340 indicated? –...
  • Page 152 dummyhead dummyhead PGM-FI SYSTEM DTC P0335 (CKP SENSOR) 1. CKP Sensor Peak Voltage Inspection Turn the ignition switch OFF. Disconnect the CKP sensor 2P (Red) connector. Turn the ignition switch ON. Crank the engine and measure the CKP sensor peak voltage between the sensor side 2P (Red) connector [1] terminals.
  • Page 153 dummyhead dummyhead PGM-FI SYSTEM DTC P0131 SENSOR LOW VOLTAGE) 1. Recheck DTC Erase the DTC (page 4-8). Warm the engine until the coolant temperature is 80°C (176°F). Stop the engine. Check the O sensor with the GST or MCS. Is the DTC P0131 indicated? –...
  • Page 154 dummyhead dummyhead PGM-FI SYSTEM DTC P0132 SENSOR HIGH VOLTAGE) 1. Recheck DTC Erase the DTC (page 4-8). Warm the engine until the coolant temperature is 80°C (176°F). Stop the engine. Check the O sensor with the GST or MCS. Is the DTC P0132 indicated? –...
  • Page 155 dummyhead dummyhead PGM-FI SYSTEM DTC P0135 SENSOR HEATER) 1. O Sensor System Inspection Erase the DTC (page 4-8). Start the engine and check the O sensor heater with the GST or MCS. Is DTC P0135 indicated? – GO TO STEP 2. –...
  • Page 156 dummyhead dummyhead PGM-FI SYSTEM 5. O Sensor Heater Short Circuit Inspection Check for continuity between the wire harness side 4P (Black) connector [1] terminal and ground. Connection: Light blue – Ground Is there continuity? – Short circuit in the Light blue wire –...
  • Page 157 dummyhead dummyhead PGM-FI SYSTEM 3. ECV POT Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Gray) connector (page 4- 73). Check for continuity between the wire harness side 6P (Black) [1] and 33P (Gray) [2] connectors terminals. TOOL: Test probe 07ZAJ-RDJA110...
  • Page 158 dummyhead dummyhead PGM-FI SYSTEM DTC P0478 (ECV POT HIGH VOLTAGE) 1. ECV POT System Inspection Check the ECV POT with the GST or MCS. Is about 5 V indicated? – GO TO STEP 2. – • Intermittent failure 2. ECV POT Resistance Inspection Turn the ignition switch OFF.
  • Page 159 dummyhead dummyhead PGM-FI SYSTEM DTC P0475 (EGCA LOCK) 1. EGCA Operating Inspection Disconnect the EGCA cable from the EGCA pulley (page 4-85). Turn the ignition switch ON. Check the EGCA pulley rotation when shorting the DLC with the SCS connector (page 4-8). Does the EGCA pulley operate correctly? –...
  • Page 160 dummyhead dummyhead PGM-FI SYSTEM 2. Shift Drum Angle Sensor Input Voltage Inspection Turn the ignition switch OFF. Disconnect the shift drum angle sensor/neutral switch 4P (Black) connector (page 4-78). Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the wire harness side 4P (Black) connector [1] terminals.
  • Page 161 dummyhead dummyhead PGM-FI SYSTEM 5. Shift Drum Angle Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side 4P (Black) connector [1] terminal and ground. Connection: Yellow – Ground Is there continuity? – Short circuit in Yellow wire –...
  • Page 162 dummyhead dummyhead PGM-FI SYSTEM 3. Shift Drum Angle Sensor Inspection Replace the shift drum angle sensor with a known good one (page 4-78). Erase the DTC (page 4-8). Check the shift drum angle sensor with the GST or MCS. Is DTC P1703 indicated? –...
  • Page 163 dummyhead dummyhead PGM-FI SYSTEM 4. Bank Angle Sensor Signal Line Short Circuit Inspection Check for continuity between the wire harness side 2P (Black) connector [1] terminal and ground. Connection: Red – Ground Is there continuity? – Short circuit in the Red wire –...
  • Page 164 dummyhead dummyhead PGM-FI SYSTEM DTC P2158 (REAR WHEEL SPEED SENSOR) Except CBR1000RR: 1. DTC Recheck Erase the DTC (page 4-8). Test-ride the motorcycle above 17.6 km/h (11 mph). Stop the engine. Check the DTC with the GST or MCS. Is DTC P2158 indicated? –...
  • Page 165 dummyhead dummyhead PGM-FI SYSTEM 5. ECM Inspection Replace the ECM with a known good one (page 4- 73). Connect the ABS modulator 18P (Black) connector. Erase the DTC (page 4-8). Test-ride the motorcycle above 17.6 km/h (11 mph). Stop the engine. Check the DTC with the GST or MCS.
  • Page 166 dummyhead dummyhead PGM-FI SYSTEM 4. Rear Wheel Speed Sensor Line Open Circuit Inspection Short the wire harness side 32P (Gray) connector [1] terminals with a jumper wire [2]. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: Light blue – White Check for continuity at the wire harness side 2P (Black) connector [3].
  • Page 167 dummyhead dummyhead PGM-FI SYSTEM 8. ECM Inspection Replace the ECM with a known good one (page 4- 73). Erase the DTC (page 4-8). Test-ride the motorcycle above 17.6 km/h (11 mph). Stop the engine. Check the DTC with the GST or MCS. Is DTC P2158 indicated? –...
  • Page 168 dummyhead dummyhead PGM-FI SYSTEM 4. Front Wheel Speed Sensor Signal Output Line Short Circuit Inspection Check for continuity between the wire harness side 33P (Gray) connector [1] terminal and ground. TOOL: Test probe 07ZAJ-RDJA110 Connection: D22 – Ground Is there continuity? –...
  • Page 169 dummyhead dummyhead PGM-FI SYSTEM 3. Front Wheel Speed Sensor Line Short Circuit Inspection Disconnect the combination meter 32P (Gray) connector (page 21-9). Check for continuity between each terminal of the wire harness side 2P (Orange) connector [1] and ground. CONNECTION: Violet – Ground Yellow –...
  • Page 170 dummyhead dummyhead PGM-FI SYSTEM 6. Front Wheel Speed Sensor Signal Output Line Short Circuit Inspection Check for continuity between the wire harness side 33P (Gray) connector [1] terminal and ground. TOOL: Test probe 07ZAJ-RDJA110 Connection: D22 – Ground Is there continuity? –...
  • Page 171 dummyhead dummyhead PGM-FI SYSTEM DTC P0122 (TP SENSOR 1 LOW VOLTAGE) 1. TP Sensor 1 System Inspection Erase the DTC (page 4-8). Check the TP sensor with the GST or MCS. Is about 0 V indicated? – GO TO STEP 2. –...
  • Page 172 dummyhead dummyhead PGM-FI SYSTEM DTC P0123 (TP SENSOR 1 HIGH VOLTAGE) 1. TP Sensor 1 System Inspection Erase the DTC (page 4-8). Check the TP sensor with the GST or MCS. Is about 5 V indicated? – GO TO STEP 2. –...
  • Page 173 dummyhead dummyhead PGM-FI SYSTEM DTC P0222 (TP SENSOR 2 LOW VOLTAGE) 1. TP Sensor 2 System Inspection Erase the DTC (page 4-8). Check the TP sensor with the GST or MCS. Is about 0 V indicated? – GO TO STEP 2. –...
  • Page 174 dummyhead dummyhead PGM-FI SYSTEM DTC P0223 (TP SENSOR 2 HIGH VOLTAGE) 1. TP Sensor 2 System Inspection Erase the DTC (page 4-8). Check the TP sensor with the GST or MCS. Is about 5 V indicated? – GO TO STEP 2. –...
  • Page 175 dummyhead dummyhead PGM-FI SYSTEM DTC P2135 (TP SENSOR 1 and 2 VOLTAGE CORRELATION FAILURE) DTC P2135 (TP SENSOR 1 and 2 SHORT CIRCUIT) 1. TP Sensor System Inspection Erase the DTC (page 4-8). Check the TP sensor with the GST or MCS. Is the DTC P2135 or P2135 indicated? –...
  • Page 176 dummyhead dummyhead PGM-FI SYSTEM DTC P2122 (APS 1 LOW VOLTAGE) 1. APS 1 System Inspection Erase the DTC (page 4-8). Check the APS 1 sensor with the GST or MCS. Is about 0 V indicated? – GO TO STEP 2. –...
  • Page 177 dummyhead dummyhead PGM-FI SYSTEM 5. APS 1 Inspection • If the APS 1 is faulty, replace the grip APS. Replace the grip APS (page 4-75). Connect the ECM and APS connectors. Erase the DTC (page 4-8). Check the APS 1 with the GST or MCS. Is DTC P2122 indicated? –...
  • Page 178 dummyhead dummyhead PGM-FI SYSTEM DTC P2127 (APS 2 LOW VOLTAGE) 1. APS 2 System Inspection Erase the DTC (page 4-8). Check the APS 2 with the GST or MCS. Is about 0 V indicated? – GO TO STEP 2. – Intermittent failure 2.
  • Page 179 dummyhead dummyhead PGM-FI SYSTEM 5. APS 2 Inspection • If the APS 2 is faulty, replace the grip APS. Replace the grip APS (page 4-75). Connect the ECM and APS connectors. Erase the DTC (page 4-8). Check the APS 2 with the GST or MCS. Is DTC P2127 indicated? –...
  • Page 180 dummyhead dummyhead PGM-FI SYSTEM DTC P2138 (APS 1 and 2 VOLTAGE CORRELATION FAILURE) 1. APS System Inspection Erase the DTC (page 4-8). Open the throttle and check the APS with the GST or MCS. Is the DTC P2138 indicated? – GO TO STEP 2. –...
  • Page 181 dummyhead dummyhead PGM-FI SYSTEM DTC P1684 (TBW RETURN SPRING FAILURE) 1. Throttle Valve and Return Spring Inspection • Be careful not to damage the throttle valves. • The return spring cannot be replaced. If the return spring is faulty, replace the throttle body/ TBW unit assembly.
  • Page 182 dummyhead dummyhead PGM-FI SYSTEM DTC P2118 (TBW MOTOR FAILURE) 1. TBW Motor System Inspection Erase the DTC (page 4-8). Check the TBW motor with the GST or MCS. Is the DTC P2118 indicated? – GO TO STEP 2. – Intermittent failure 2.
  • Page 183 dummyhead dummyhead PGM-FI SYSTEM DTC P2101 (TBW SYSTEM CONTROL CORRELATION FAILURE) 1. TBW Control System Inspection • The TBW motor cannot be replaced. If the TBW unit is faulty, replace the throttle body/TBW unit assembly. Erase the DTC (page 4-8). Check the TBW control system with the GST or MCS.
  • Page 184 dummyhead dummyhead PGM-FI SYSTEM 2. TBW Relay Input Voltage Inspection Turn the ignition switch OFF. Remove the TBW relay (page 21-21). Measure the voltage at the TBW relay [1] terminal and ground. Connection: Brown/white (+) – Green (–) Br/W Is about 12 V indicated? –...
  • Page 185 dummyhead dummyhead PGM-FI SYSTEM DTC P0443 (EVAP PURGE CONTROL SOLENOID VALVE) 1. EVAP Purge Control Solenoid Valve System Inspection Erase the DTC (page 4-8). Check the EVAP purge control solenoid valve with the GST or MCS. Is the DTC P0443 indicated? –...
  • Page 186 dummyhead dummyhead PGM-FI SYSTEM 5. EVAP Purge Control Solenoid Valve Resistance Inspection Measure the resistance between the solenoid valve side 2P (Black) connector [1] terminals. Is the resistance within 30 – 34 Ω (20°C/68°F)? – Replace the ECM with a known good one (page 4-73) and recheck.
  • Page 187 dummyhead dummyhead PGM-FI SYSTEM 4. PAIR Control Solenoid Valve Signal Line Short Circuit Inspection Check for continuity between the wire harness side 2P (Black) connector [1] and ground. CONNECTION: Light green – Ground Is there continuity? – Short circuit in Light green wire –...
  • Page 188 dummyhead dummyhead PGM-FI SYSTEM 3. Ignition Coil Primary Circuit Ground Line Open Circuit Inspection Turn the ignition switch OFF. No.1 ignition coil: Disconnect the ECM 33P (Blue) connector (page 4- 73). Check the continuity between the wire harness side 2P (Black) [1] and 33P (Blue) [2] connectors terminals.
  • Page 189 dummyhead dummyhead PGM-FI SYSTEM 5. Ignition Coil Inspection Replace the ignition coil with a known good one (page 3-6). Erase the DTC (page 4-8). Check the ignition coil with the GST or MCS. Is DTC P0351, P0352, P0353 or P0354 indicated? –...
  • Page 190 dummyhead dummyhead PGM-FI SYSTEM DTC U0001 (CAN) 1. CAN System Inspection Erase the DTC (page 4-8). Check the CAN with the GST or MCS. Is DTC U0001 indicated? – GO TO STEP 2. – Intermittent failure 2. CAN Line Open Circuit Inspection Turn the ignition switch OFF.
  • Page 191 dummyhead dummyhead PGM-FI SYSTEM 3. CAN Line Short Circuit Inspection Check for continuity between the wire harness side 33P (Gray) connector [1] terminals and ground. Connection: D10 – Ground D11 – Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? – • Short circuit in the Red wire •...
  • Page 192 dummyhead dummyhead PGM-FI SYSTEM DTC U0155 (CAN_METER) 1. CAN System Inspection Erase the DTC (page 4-8). Check the CAN with the GST or MCS. Is DTC U0155 indicated? – GO TO STEP 2. – Intermittent failure 2. CAN Line Open Circuit Inspection Turn the ignition switch OFF.
  • Page 193 dummyhead dummyhead PGM-FI SYSTEM 4. Combination meter Inspection Replace the combination meter with a known good one. Connect the following: – IMU 4P (Black) connector (page 4-75) – ECM 33P (Gray) connector (page 4-73) – Combination meter 32P (Gray) connector (page 21-9) –...
  • Page 194 dummyhead dummyhead PGM-FI SYSTEM 3. CAN Line Short Circuit Inspection Check for continuity between the wire harness side 33P (Gray) connector [1] terminals and ground. Connection: D10 – Ground D11 – Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? – • Short circuit in the Red wire •...
  • Page 195 dummyhead dummyhead PGM-FI SYSTEM 2. CAN Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the following: – IMU 4P (Black) connector (page 4-75) – ECM 33P (Gray) connector [1] (page 4-73) – Combination meter 32P (Gray) connector (page 21-9) –...
  • Page 196 dummyhead dummyhead PGM-FI SYSTEM 4. ABS modulator Inspection Replace the ABS modulator with a known good one. Connect the following: – IMU 4P (Black) connector (page 4-75) – ECM 33P (Gray) connector (page 4-73) – Combination meter 32P (Gray) connector (page 21-9) –...
  • Page 197 dummyhead dummyhead PGM-FI SYSTEM 4. Shift Stroke Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the ECM 33P (Blue) connector. Check for continuity between the wire harness side 3P (Black) [1] and 33P (Blue) [2] connectors terminals.
  • Page 198 dummyhead dummyhead PGM-FI SYSTEM 2. Shift Stroke Sensor Input Voltage Inspection Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the wire harness side 3P (Black) connector terminals. Connection: Red (+) – Gray (–) Is the voltage within 4.75 –...
  • Page 199 dummyhead dummyhead PGM-FI SYSTEM 3. Shift Spindle Switch Inspection Replace the shift spindle switch with a known good one. Erase the DTC (page 4-8). Test-ride the motorcycle and shift up more than three times. Check the shift spindle switch with the GST or MCS. Is DTC P1708 indicated? –...
  • Page 200 dummyhead dummyhead PGM-FI SYSTEM 4. Shift Spindle Switch Inspection 2 Replace the shift spindle switch with a known good one. Erase the DTC (page 4-8). Test-ride the motorcycle and shift down without clutch operation and hold the shift pedal in the down position for one second, more than three times.

  • Page 201: Mil Circuit Troubleshooting

    dummyhead dummyhead PGM-FI SYSTEM MIL CIRCUIT TROUBLESHOOTING When The Engine Starts But The MIL Does Not Come On Check that the MIL comes on a few 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 power/ground line inspection (page 21-9).

  • Page 202: Power Input Line

    dummyhead dummyhead PGM-FI SYSTEM POWER/GROUND LINE INSPECTION Disconnect the ECM 33P (Blue) connector (page 4-73). POWER INPUT LINE Measure the voltage between the wire harness side ECM 33P (Blue) connector [1] and ground. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: A11 (+) – Ground (–) A22 (+) –...
  • Page 203 dummyhead dummyhead PGM-FI SYSTEM REMOVAL/INSTALLATION Remove the IMU cover (page 2-5). [1]/[2] Remove the socket bolts [1]/nuts [2] and IMU [3]. Rear Disconnect the IMU 4P (Black) connector [4]. • Do not drop the IMU. • Never use the dropped IMU. •...
  • Page 204 dummyhead dummyhead PGM-FI SYSTEM 2. APS 1 and 2 System Inspection Erase the DTC (page 4-8). Check the APS 1 and 2 with the MCS. Note the APS 1 and 2 output voltage. Calculate the 5 V / input voltage x output voltage. Standard (at throttle opened): APS 1: 4.433 –...
  • Page 205 dummyhead dummyhead PGM-FI SYSTEM Remove the screws [1] and throttle housing cover [2]. Loosen the screw [3] and remove the throttle housing [4]. Remove the screws [1] and APS [2]. Installation is in the reverse order of removal. Route the wire properly (page 1- 3 mm 23).
  • Page 206 dummyhead dummyhead PGM-FI SYSTEM SHIFT DRUM ANGLE SENSOR REMOVAL/INSTALLATION Remove the fuel tank (page 7-8). Disconnect the shift drum angle sensor/neutral switch 4P (Black) connector [1]. Remove the bolt [1] and shift drum angle sensor [2]. Remove the bolt [3] and shift dram angle sensor base [4].
  • Page 207 dummyhead dummyhead PGM-FI SYSTEM SHIFT STROKE SENSOR INSPECTION • If the gear position indicator blinks between gear position and "–" in alternate shifts, perform the below troubleshooting. • Before the troubleshooting check the following: – Tire air pressure – Tire size –...
  • Page 208 dummyhead dummyhead PGM-FI SYSTEM REMOVAL/INSTALLATION Remove the sift pedal assembly (page 11-23). Remove the following: – Bolt [1] – Nut [2] – Arm [3] – Shift pedal [4] – Lock nut [5] – Lock nut (left-hand thread) [6] – Rod [7] –...

  • Page 209: Clutch Switch

    dummyhead dummyhead PGM-FI SYSTEM Shift the transmission to the neutral position then do not Do not operate the touch the pedal. throttle grip. Wait for the display shows the message that "INITIALIZE SUCCEEDED" then turn the ignition switch OFF and remove the SCS short connector. If the display shows the message that "INITIALIZE FAILURE", check the mounting conditions of the shift stroke and shift drum angle sensors, then restart the...

  • Page 210: Map Sensor

    dummyhead dummyhead PGM-FI SYSTEM MAP SENSOR REMOVAL/INSTALLATION Remove the air cleaner housing (page 7-10). Remove the screw [1] and MAP sensor [2] from the air cleaner housing. Installation is in the reverse order of removal. IAT SENSOR REMOVAL/INSTALLATION Lift and support the fuel tank (page 7-8). Disconnect the IAT sensor 2P (Black) connector [1].

  • Page 211: Cmp Sensor

    dummyhead dummyhead PGM-FI SYSTEM CMP SENSOR REMOVAL/INSTALLATION Remove the air cleaner housing (page 7-10). Disconnect the CMP sensor 3P (Blue) connector [1]. Remove the bolt [2], CMP sensor [3] and O-ring [4] from the cylinder head cover. Installation is in the reverse order of removal. •...
  • Page 212 dummyhead dummyhead PGM-FI SYSTEM SYSTEM INSPECTION Connect the MCS (page 4-7). 70° BANK ANGLE POSITION Remove the bank angle sensor (page 4-83). Connect the bank angle sensor 2P (Black) connector. Place the bank angle sensor horizontally as shown. Turn the ignition switch ON and engine stop switch " ". Read the voltage with the MCS.
  • Page 213 dummyhead dummyhead PGM-FI SYSTEM EGCA REMOVAL/INSTALLATION Remove the IMU cover (page 2-5). Disconnect the EGCA 6P (Black) connector [1]. Remove the socket bolt [1] and EGCA cover [2]. Loosen the lock nut [1] and adjuster [2]. Remove the bolt [3], collar [4] and EGCA [5]. [3]/[4] Turn the EGCA pulley [1] and disconnect the EGCA cables [2] from the EGCA pulley.
  • Page 214 dummyhead dummyhead PGM-FI SYSTEM WHEEL SPEED SENSOR (CBR1000RR) AIR GAP INSPECTION Support the motorcycle securely using a hoist or Front: equivalent and raise the wheel off the ground. Measure the air gap at several points by turning the wheel slowly. –...

  • Page 215: Rear Wheel Speed Sensor

    dummyhead dummyhead PGM-FI SYSTEM Remove the wire clips [1] and release the sensor wire from the clamp [2]. Remove the bolt [3] and wire clamp [4]. [3]/[4] Remove the following: – Bolts [1] – Wire guide [2] – Front wheel speed sensor [3] Installation is in the reverse order of removal.
  • Page 216 dummyhead dummyhead PGM-FI SYSTEM Release the sensor wire from the clamp [1] and remove the wire clip [2]. Remove the wire clip [3] from the brake hose and release the sensor wire from the clamps [4]. Remove the following: [2]/[3] –...

  • Page 217: Ignition System

    dummytext 5. IGNITION SYSTEM SYSTEM DIAGRAM ······································5-2 IGNITION SYSTEM INSPECTION ················ 5-4 SERVICE INFORMATION ·····························5-3 IGNITION TIMING ········································· 5-6 TROUBLESHOOTING···································5-3...

  • Page 218: System Diagram

    dummyhead dummyhead IGNITION SYSTEM SYSTEM DIAGRAM IGNITION SYSTEM ENGINE STOP SWITCH FUSE/ IGNITION SWITCH RELAY BOX MAIN FUSE (30 A) CLUTCH SWITCH CMP SENSOR BANK ANGLE SENSOR DIRECT IGNITION COIL ECT SENSOR CKP SENSOR NEUTRAL SWITCH SIDESTAND SWITCH MAIN FUSE 30 A FI/IGN/START FUSE 10 A R/Bl...

  • Page 219: Service Information

    dummyhead dummyhead IGNITION SYSTEM SERVICE INFORMATION 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 220: Ignition System Inspection

    dummyhead dummyhead IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark at any plug, check all connections for loose or poor contact before measuring each peak voltage. • Use recommended digital multimeter commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum.

  • Page 221: Ckp Sensor Peak Voltage

    dummyhead dummyhead IGNITION SYSTEM CKP SENSOR PEAK VOLTAGE • Check all system connections before inspection. If the system is disconnected, incorrect peak voltage might be measured. • Check cylinder compression and check that the spark plugs are installed correctly. Lift and support the fuel tank (page 7-8). Disconnect the ECM 33P (Black) connector [1] from the ECM.

  • Page 222: Ignition Timing

    dummyhead dummyhead IGNITION SYSTEM IGNITION TIMING Warm up the engine. Stop the engine and remove the timing hole cap [1]. Connect the timing light [1] to the No.1 direct ignition Read the coil connector wire. instructions for timing light Start the engine, let it idle and check the ignition timing. operation.

  • Page 223: Electric Starter

    dummytext 6. ELECTRIC STARTER SERVICE INFORMATION ·····························6-2 STARTER MOTOR ······································· 6-4 TROUBLESHOOTING···································6-2 STARTER RELAY SWITCH ························· 6-7 SYSTEM DIAGRAM ······································6-3 DIODE ··························································· 6-8...
  • Page 224 dummyhead dummyhead ELECTRIC STARTER SERVICE INFORMATION ELECTRIC STARTER GENERAL If current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged. • Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. •...
  • Page 225 dummyhead dummyhead ELECTRIC STARTER SYSTEM DIAGRAM STARTER RELAY SWITCH DIODE STARTER SWITCH IGNITION FUSE/ SWITCH RELAY BOX CLUTCH SWITCH DIODE STARTER MOTOR NEUTRAL BATTERY SWITCH SIDESTAND SWITCH STARTER RELAY SWITCH BATTERY STARTER MOTOR MAIN RELAY MAIN FUSE 30 A NEUTRAL SWITCH R/Bl FI FUSE 15 A...

  • Page 226: Starter Motor

    dummyhead dummyhead ELECTRIC STARTER STARTER MOTOR REMOVAL/INSTALLATION • With the ignition switch OFF, disconnect the battery negative (–) cable before servicing the starter motor (page 20-6). KO only: Remove the EVAP canister (page 7-22). KO only: Open the rubber cap [1], then remove the terminal nut [2] and starter motor cable [3] from the starter motor.
  • Page 227 dummyhead dummyhead ELECTRIC STARTER DISASSEMBLY/ASSEMBLY The coil may be damaged if the magnet pulls the armature against the motor case. 3.9 N·m (0.4 kgf·m, 2.9 lbf·ft) FRONT COVER MOTOR CASE ARMATURE TERMINAL BOLT POSITIVE BRUSHES TERMINAL STOPPER 3.7 N·m (0.4 kgf·m, 2.7 lbf·ft) WASHER NEGATIVE BRUSHES BRUSH HOLDER...

  • Page 228: Front Cover

    dummyhead dummyhead ELECTRIC STARTER INSPECTION FRONT COVER Check the oil seal [1] in the front cover for deterioration, wear, or damage. Turn the inner race of the bearing [2] in the front cover with your finger. The bearing should turn smoothly and quietly. Also check that the outer race fits tightly in the front cover.

  • Page 229: Starter Relay Switch

    dummyhead dummyhead ELECTRIC STARTER STARTER RELAY SWITCH REMOVAL/INSTALLATION Remove the main seat (page 2-4). [4]/[5] Turn the ignition switch OFF. Remove the starter relay switch cover [1]. Disconnect the battery negative (–) cable [2] (page 20- Disconnect the starter relay switch 4P (Black) connector [3].

  • Page 230: Continuity Inspection

    dummyhead dummyhead ELECTRIC STARTER CONTINUITY INSPECTION Remove the starter relay switch (page 6-7). Connect an ohmmeter to the starter relay switch large terminals. Connect a fully charged 12 V battery positive (+) wire to the starter relay switch Pink terminal and negative (–) wire to the Orange terminal.
  • Page 231 dummyhead dummyhead ELECTRIC STARTER INSPECTION Check for continuity between the diode [1] terminals. When there is continuity, a small resistance value will 3 terminals: register. If there is continuity in one direction, the diode is normal. 2 terminals:...
  • Page 232 dummyhead dummyhead MEMO...

  • Page 233: Fuel System

    dummytext 7. FUEL SYSTEM SERVICE INFORMATION ·····························7-2 THROTTLE BODY ······································ 7-13 COMPONENT LOCATION ····························7-3 PRIMARY INJECTOR ································· 7-15 FUEL LINE INSPECTION······························7-4 SECONDARY INJECTOR··························· 7-16 FUEL TANK···················································7-8 SECONDARY AIR SUPPLY SYSTEM ······· 7-17 FUEL PUMP UNIT ·········································7-9 EVAP ··························································· 7-21 AIR CLEANER HOUSING···························7-10...
  • Page 234 dummyhead dummyhead FUEL SYSTEM SERVICE INFORMATION FUEL SYSTEM GENERAL • 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. • Before disconnecting the fuel feed hose, relieve fuel pressure from the system (page 7-4). •...

  • Page 235: Component Location

    dummyhead dummyhead FUEL SYSTEM COMPONENT LOCATION 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) CH/TH/FO only 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)

  • Page 236: Fuel Line Inspection

    dummyhead dummyhead FUEL SYSTEM FUEL LINE INSPECTION FUEL PRESSURE RELIEVING • Before disconnecting the fuel hose, relieve pressure from the system as follows. 1. Turn the ignition switch OFF. Lift and support the fuel tank (page 3-4). Remove the quick connect fitting cover [1] (fuel pump side only).

  • Page 237: Quick Connect Fitting Installation

    dummyhead dummyhead FUEL SYSTEM 6. To prevent damage and keep foreign matter out, cover the disconnected connector and fuel joint with plastic bags [1]. QUICK CONNECT FITTING INSTALLATION • Always replace the retainer of the quick connect fitting when the fuel hose is disconnected. •...

  • Page 238: Fuel Pressure Normalization

    dummyhead dummyhead FUEL SYSTEM 3. Make sure the connection is secure and that the pawls are firmly locked into place; check visually and by pulling the connector [1]. 4. Make sure the rubber damper [2] is in place (between the flange [3] and retainer tab [4]). FUEL PRESSURE NORMALIZATION 1.

  • Page 239: Fuel Pressure Test

    dummyhead dummyhead FUEL SYSTEM FUEL PRESSURE TEST Relieve the fuel pressure (page 7-4). Disconnect the quick connect fitting (fuel pump side) (page 7-4). Attach the special tools between the fuel pump joint and fuel feed hose. TOOLS: Fuel pressure gauge [1] 07406-0040004 Pressure gauge manifold [2] 07ZAJ-S5A0111...
  • Page 240 dummyhead dummyhead FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Relieve the fuel pressure (page 7-4) and disconnect the quick connect fitting from the fuel tank. Disconnect the fuel reserve sensor 2P (Black) connector [1]. Remove the support, fuel tank pivot bolts [2], collars [3] and fuel tank [4].

  • Page 241: Fuel Pump Unit

    dummyhead dummyhead FUEL SYSTEM FUEL PUMP UNIT INSPECTION Turn the ignition switch ON and engine stop switch " " and confirm that the fuel pump operates for a few seconds. If the fuel pump does not operate, inspect as follows: Turn the ignition switch OFF.

  • Page 242: Installation

    dummyhead dummyhead FUEL SYSTEM INSPECTION Check the fuel pump unit for wear or damage, replace it if necessary. Clean the fuel strainer screen [1] with non-flammable or high flash point solvent. INSTALLATION Place new packings [1] onto the fuel pump unit [2]. Always replace the old packing with new ones.
  • Page 243 dummyhead dummyhead FUEL SYSTEM CH/TH/FO only: Remove the air cleaner rear rubber [1] from the bosses [2] of the upper housing. Disconnect the following: – Except CH: Left handlebar switch 6P (Blue) connector [1] – CH only: Left handlebar switch 8P connector [1]. –...
  • Page 244 dummyhead dummyhead FUEL SYSTEM Remove the intake air duct (page 2-14). Remove the screws [1] and air funnels [2]. Remove the screws [3] and air cleaner element [4]. Disconnect the MAP sensor 3P (Black) connector [1] and vacuum hose [2]. Disconnect the PAIR air suction hose [3] from the lower housing.

  • Page 245: Throttle Body

    dummyhead dummyhead FUEL SYSTEM 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) UPPER HOUSING 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) LOWER HOUSING AIR CLEANER ELEMENT 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) AIR FUNNELS Installation is in the reverse order of removal. TORQUE: Air cleaner housing screw: 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) Air cleaner element screw:...
  • Page 246 dummyhead dummyhead FUEL SYSTEM Loosen the insulator band screws [1] using a long type phillips screwdriver. Remove the throttle body [2] from the cylinder head. When removing the throttle body, do not • Seal the cylinder head intake ports with tape or a hold it by the fuel clean cloth to keep dirt and debris from entering the rail.
  • Page 247 dummyhead dummyhead FUEL SYSTEM PRIMARY INJECTOR REMOVAL/INSTALLATION Remove the fuel tank (page 7-8). Disconnect the quick connect fitting [1] (page 7-4). Disconnect the primary injector 2P (Gray) connectors [2]. Release the hooks [3]. Remove the bolts [1] and fuel rail assembly [2]. Remove the injectors [1] from the fuel rail [2].
  • Page 248 dummyhead dummyhead FUEL SYSTEM Remove the fuel rails [1] and O-rings [2] from the fuel rail joint [3]. Installation is in the reverse order of removal. • Apply oil to new O-rings and install them. TORQUE: Fuel rail mounting bolts: 5.1 N·m (0.5 kgf·m, 3.8 lbf·ft) SECONDARY INJECTOR REMOVAL/INSTALLATION...

  • Page 249: System Inspection

    dummyhead dummyhead FUEL SYSTEM Remove the retainers [1] and injectors [2] from the fuel rail. Remove the seal ring [1] and O-ring [2]. Remove the fuel rails [1] and O-rings [2] from the fuel rail joint [3]. Installation is in the reverse order of removal. •...

  • Page 250: Exhaust Port

    dummyhead dummyhead FUEL SYSTEM PAIR CHECK VALVE INTAKE PORT PAIR CONTROL SOLENOID VALVE FRESH AIR EXHAUST GAS EXHAUST PORT PAIR CONTROL SOLENOID VALVE REMOVAL/INSTALLATION Remove the air cleaner housing (page 7-10). Pull up the front of heat guard rubber [1]. 7-18...
  • Page 251 dummyhead dummyhead FUEL SYSTEM Remove the direct ignition coil wire harness clip [1] from the PAIR control solenoid valve [2]. Disconnect the PAIR control solenoid valve 2P (Black) connector [3]. Disconnect the PAIR air suction hoses [4]. Installation is in the reverse order of removal. INSPECTION Remove the PAIR control solenoid valve.
  • Page 252 dummyhead dummyhead FUEL SYSTEM Remove the PAIR check valves [1] from the cylinder head cover. Check the PAIR check valve for wear or damage, replace if necessary. Remove the baffle plates [1] from the cylinder head cover. Installation is in the reverse order of removal. •...
  • Page 253 dummyhead dummyhead FUEL SYSTEM EVAP EVAP PURGE CONTROL SOLENOID VALVE REMOVAL/INSTALLATION Remove the fuel tank (page 7-8). BR/ED/CH/TH/FO: Disconnect the following: – EVAP purge control solenoid valve 2P (Black) connector [1]. – EVAP purge control solenoid valve-to-throttle body hose [2] –...
  • Page 254 dummyhead dummyhead FUEL SYSTEM EVAP CANISTER REMOVAL/ INSTALLATION (BR/ED/CH/TH/FO) Support the motorcycle and raise the rear wheel off the ground. Remove the shock absorber lower mounting nut [1] and Support the rear bolt [2]. wheel securely. Move the shock absorber [3] rearward. [1]/[2] Disconnect the following: [10]...
  • Page 255 dummyhead dummyhead FUEL SYSTEM Pull the canister [1] then disconnect the fuel tank breather hose (to fuel tank) [2] and canister-to-purge control solenoid valve hose [3]. Remove the canister assembly. Remove the bolts [1], washers [2], grommets [3], collars [4], stay [5] and canister [6]. Installation is in the reverse order of removal.
  • Page 256 dummyhead dummyhead MEMO...

  • Page 257: Cooling System

    dummytext 8. COOLING SYSTEM SERVICE INFORMATION ·····························8-2 THERMOSTAT ·············································· 8-6 TROUBLESHOOTING···································8-2 RADIATOR/COOLING FAN·························· 8-7 SYSTEM FLOW PATTERN···························8-3 WATER PUMP ············································ 8-11 SYSTEM TESTING········································8-4 RADIATOR RESERVE TANK····················· 8-12 COOLANT REPLACEMENT ·························8-4...

  • Page 258: Service Information

    dummyhead dummyhead COOLING SYSTEM SERVICE INFORMATION COOLING SYSTEM GENERAL Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages.

  • Page 259: System Flow Pattern

    dummyhead dummyhead COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR CAP RADIATOR RESERVE TANK RADIATOR THERMOSTAT OIL COOLER WATER PUMP...

  • Page 260: System Testing

    dummyhead dummyhead COOLING SYSTEM SYSTEM TESTING RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the right middle cowl (page 2-13). Remove the radiator cap [1]. Wet the sealing surfaces of the cap, then install the cap onto the tester [1]. Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low.
  • Page 261 dummyhead dummyhead COOLING SYSTEM Fill the system with the recommended coolant through the filler opening up to filler neck [1]. Remove the radiator reserve tank cap [1] and fill the reserve tank to the upper level line [2]. Bleed air from the system as follows: 1.
  • Page 262 dummyhead dummyhead COOLING SYSTEM THERMOSTAT • For ECT sensor removal/installation (page 4-82). REMOVAL/INSTALLATION Drain the coolant (page 8-4). Remove the fuel tank (page 7-8). Disconnect the water hose [1]. Cut off and remove the hose clamps [2] then disconnect the water hoses [3]. Disconnect the ECT sensor 3P (Gray) connector [1].

  • Page 263: Radiator/Cooling Fan

    dummyhead dummyhead COOLING SYSTEM INSPECTION Visually inspect the thermostat [1] for damage. Replace the thermostat if the valve stays open at room temperature. Check for damage of the seal ring [2]. Heat a container of water with an electric heating Do not let the element for 5 minutes.
  • Page 264 dummyhead dummyhead COOLING SYSTEM Disconnect the right fan motor 2P (Black) connector [1]. Cut off and remove the hose clamp [1] then disconnect the water hose [2]. Cut off and remove the hose clamp [1] then disconnect the right radiator hose [2]. Remove the radiator lower mounting bolt [1] and washer [2].
  • Page 265 dummyhead dummyhead COOLING SYSTEM Remove the radiator upper mounting bolt [1]. Release the radiator upper grommet [2] from the frame Be careful not to boss to remove the radiator. damage the radiator fins. Release the clutch cable [3] from the cable guide of the right heat guard plate [4].
  • Page 266 dummyhead dummyhead COOLING SYSTEM DISASSEMBLY/ASSEMBLY RIGHT COOLING FAN RIGHT FAN MOTOR RIGHT SHROUD LEFT FAN MOTOR LEFT COOLING FAN RADIATOR LEFT SHROUD • Install the cooling fan to the fan motor shaft by aligning the flat surfaces. • Apply locking agent to the cooling fan mounting nut threads.

  • Page 267: Water Pump

    dummyhead dummyhead COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Remove the Under cowl (page 2-20). Check the bleed hole [1] of the water pump [2] for signs of coolant leakage. • A small amount of coolant weeping from the bleed hole is normal.

  • Page 268: Radiator Reserve Tank

    dummyhead dummyhead COOLING SYSTEM Installation is in the reverse order of removal. • Apply oil to a new O-ring [1] and install it onto the Align stepped portion of the water pump body. • Install the water pump body into the crankcase while aligning the water pump shaft groove with the oil pump shaft end by turning the water pump impeller.

  • Page 269: Lubrication System

    dummytext 9. LUBRICATION SYSTEM SERVICE INFORMATION ·····························9-2 OIL PRESSURE INSPECTION ····················· 9-4 TROUBLESHOOTING···································9-2 OIL PUMP ····················································· 9-4 LUBRICATION SYSTEM DIAGRAM ············9-3 OIL COOLER ················································ 9-7...

  • Page 270: Service Information

    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 271 dummyhead dummyhead LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFTS PISTON OIL JET PIPE CRANKSHAFT BALANCER EOP SWITCH MAINSHAFT OIL COOLER OIL JET PIPE OIL PUMP COUNTERSHAFT OIL FILTER CARTRIDGE OIL STRAINER PRESSURE RELIEF VALVE...

  • Page 272: Lubrication System Diagram

    dummyhead dummyhead LUBRICATION SYSTEM OIL PRESSURE INSPECTION Remove the EOP switch (page 21-15). If the oil pressure indicator remains Install the oil pressure gauge attachment [1] to the on while the engine switch base. is running, check Connect the oil pressure gauge [2] to the oil pressure the indicator system gauge attachment.
  • Page 273 dummyhead dummyhead LUBRICATION SYSTEM Remove the oil strainer [1] and seal ring [2]. Align Remove the oil pipe mounting bolts [1], oil pipe [2] and seal rings [3]. Clean the oil pipe in solvent thoroughly and check for damage. Remove the oil pump driven sprocket bolt [1], washer [2] and oil pump driven sprocket [3].
  • Page 274 dummyhead dummyhead LUBRICATION SYSTEM Remove the dowel pins [1]. Installation is in the reverse order of removal. • Replace the seal rings with new ones and coat them with engine oil. • Install the driven sprocket [1] with its “OUT” mark [2] facing out by aligning the flat surfaces.

  • Page 275: Oil Cooler

    dummyhead dummyhead LUBRICATION SYSTEM OIL COOLER REMOVAL/INSTALLATION Drain the engine oil (page 3-12). Remove the exhaust pipe (page 2-25). Loosen the hose clamp screws and disconnect the water hoses [1] from the oil cooler. Remove the bolt [2], sealing washer [3], oil cooler [4] and O-ring [5].
  • Page 276 dummyhead dummyhead MEMO...

  • Page 277: Cylinder Head/Valves

    dummytext 10. CYLINDER HEAD/VALVES SERVICE INFORMATION ···························10-2 CAMSHAFT REMOVAL······························ 10-6 TROUBLESHOOTING·································10-2 CAMSHAFT INSTALLATION ··················· 10-10 COMPONENT LOCATION ··························10-3 CYLINDER HEAD ····································· 10-14 CYLINDER COMPRESSION·······················10-4 CAM CHAIN TENSIONER LIFTER··········· 10-25 CYLINDER HEAD COVER REMOVAL/ INSTALLATION···········································10-4 10-1...
  • Page 278 dummyhead dummyhead CYLINDER HEAD/VALVES SERVICE INFORMATION CYLINDER HEAD/VALVES GENERAL • This section covers service of the cylinder head, valves and camshaft. • The camshaft services can be done with the engine installed in the frame. The cylinder head service requires engine removal. •...

  • Page 279: Component Location

    dummyhead dummyhead CYLINDER HEAD/VALVES COMPONENT LOCATION 10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 20 N·m (2.0 kgf·m, 15 lbf·ft) 16 N·m (1.6 kgf·m, 12 lbf·ft) 74 N·m (7.5 kgf·m, 55 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 10-3...

  • Page 280: Cylinder Compression

    dummyhead dummyhead CYLINDER HEAD/VALVES CYLINDER COMPRESSION Warm up the engine to normal operating temperature. Stop the engine, disconnect the all direct ignition coils/ spark plug caps and remove the spark plugs (page 3-6). Connect the ignition switch 2P (Black) and right handlebar switch 6P (Blue) connectors.
  • Page 281 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the cylinder head cover [1] from the cylinder head. Remove the cylinder head cover packing [1]. Remove the bolts [2] and breather plate [3]. Installation is in the reverse order of removal. • Apply locking agent to the breather plate mounting bolt threads.

  • Page 282: Camshaft Removal

    dummyhead dummyhead CYLINDER HEAD/VALVES CAMSHAFT REMOVAL Remove the following: [1]/[2] – Cylinder head cover (page 10-4) – CH, TH, FO only: Right rear under cover (page 2-21) Remove the timing hole cap [1] and O-ring [2]. Remove the crankshaft hole cap [3] and O-ring [4]. [3]/[4] Turn the crankshaft clockwise and align the “T”...
  • Page 283 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the cam chain tensioner lifter bolt [1] and sealing washer [2]. [1]/[2] Turn the tensioner lifter shaft fully in (clockwise) and secure it using the tensioner stopper to prevent damaging the cam chain. TOOL: Tensioner stopper [1] 070MG-0010100 Remove the cam sprocket bolts [1] from the intake and exhaust camshafts.

  • Page 284: Valve Specifications

    dummyhead dummyhead CYLINDER HEAD/VALVES If you plan to replace the camshaft and/or CMP sensor rotor [1], loosen the CMP sensor rotor bolts [2]. Loosen and remove the camshaft holder bolts [1], Suspend the cam [1]/[2] washers [2], then remove the camshaft holders [3] and chain with a piece camshafts [4].
  • Page 285 dummyhead dummyhead CYLINDER HEAD/VALVES CAMSHAFT OIL CLEARANCE Wipe any oil from the journals of the camshaft, cylinder Do not rotate the head and camshaft holders. camshaft when Lay a strip of plastigauge [1] lengthwise on top of each using plastigauge. camshaft journal.

  • Page 286: Camshaft Installation

    dummyhead dummyhead CYLINDER HEAD/VALVES CAMSHAFT INSTALLATION Apply molybdenum oil solution to the sliding surface of each valve lifter [1]. Install the shims [2] and valve lifters to the cylinder Install the shims head. and valve lifters in their original locations. Each camshaft has an identification mark.
  • Page 287 dummyhead dummyhead CYLINDER HEAD/VALVES Apply molybdenum oil solution to the camshaft journal of the cylinder head. Install the intake and exhaust camshafts. Each camshaft has an identification mark. • “IN” [1]: Intake camshaft • “EX” [2]: Exhaust camshaft Coat new O-rings [1] with oil and install them into the grooves in the camshaft holders.
  • Page 288 dummyhead dummyhead CYLINDER HEAD/VALVES Install each camshaft holder [1] onto the camshafts. Be sure to align the dowel pins in the camshaft holder with the holes in the cylinder head. Apply oil to the threads and seating surfaces of the [1]/[2] camshaft holder bolts [1].
  • Page 289 dummyhead dummyhead CYLINDER HEAD/VALVES Apply locking agent to the cam sprocket bolts [1] threads. Tighten the cam sprocket bolts to the specified torque. TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft) Turn the crankshaft clockwise one full turn (360°) and tighten the other cam sprocket bolts. Install the cam chain guide B [2], and tighten the bolts [3].
  • Page 290 dummyhead dummyhead CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL Remove the following: – Engine (page 15-4) – Thermostat housing (page 8-6) – Cam chain tensioner lifter (page 10-25) – Camshaft (page 10-6) Remove the bolts [1]. Remove the cylinder head nuts [1] and washers [2]. Loosen the nuts in [1]/[2] a crisscross pattern...
  • Page 291 dummyhead dummyhead CYLINDER HEAD/VALVES DISASSEMBLY Remove the cylinder head (page 10-14). Remove the bolts [1], insulators [2] and O-rings [3]. Remove the bolt [1], sealing washer [2] and cam chain tensioner B [3] from the cylinder head. [1]/[2] Remove the spark plugs from the cylinder head. Install the tappet hole protector into the valve lifter bore.

  • Page 292: Combustion Chamber

    dummyhead dummyhead CYLINDER HEAD/VALVES Remove the following: Mark all parts during disassembly – Spring retainer [1] so they can be – Inner [2]/outer [3] valve springs (IN) placed back in their – Except CBR1000S2: Inner [4]/outer [5] valve springs original locations. (EX) Except –...

  • Page 293: Valve Guide Replacement

    dummyhead dummyhead CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. Heat the cylinder head to 100 – 150°C (212 – 302°F) Do not use a torch with a hot plate or oven. to heat the cylinder To avoid burns, wear heavy gloves when handling the head;...
  • Page 294 dummyhead dummyhead CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING Disassemble the cylinder head (page 10-15). Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to the valve seats. Tap the valves and seats using a rubber hose or other hand-lapping tool [1].
  • Page 295 dummyhead dummyhead CYLINDER HEAD/VALVES EXHAUST SIDE: After cutting the exhaust seat, apply lapping compound to the exhaust valve face, and lap the exhaust valve using light pressure. After lapping, wash all residual compound off the cylinder head and valve. • Excessive lapping pressure may deform or damage the seat.
  • Page 296 dummyhead dummyhead CYLINDER HEAD/VALVES Install the valve spring seats [1]. Install new stem seals [2]. Lubricate the valve stems with molybdenum oil solution. Insert the valve [3] into the valve guide while turning it slowly to avoid damage to the stem seal. Install the valve springs with the tightly wound coils facing the combustion chamber.
  • Page 297 dummyhead dummyhead CYLINDER HEAD/VALVES Install the valve cotters using the special tool as shown. Grease the cotters to ease installation. To prevent loss of tension, do not compress the valve spring more than necessary. TOOLS: Valve spring compressor 07757-0010000 Valve spring compressor attachment 07959-KM30101 Tap the valve stems gently with hammer and shaft [1]...
  • Page 298 dummyhead dummyhead CYLINDER HEAD/VALVES INSTALLATION Install the timing sprocket [1] by aligning the wide teeth Align between the crankshaft and sprocket. Install the collar [1] to the cam chain guide A [2]. Apply locking agent to the cam chain guide A bolt/ washer [3] threads.
  • Page 299 dummyhead dummyhead CYLINDER HEAD/VALVES Install the dowel pins [1] and a new cylinder head gasket [2] as shown. Check that the cylinder stud bolt height from the bolt head to cylinder gasket surface is within specification. Except CBR1000S2: 72.5 ± 1 mm 69.0 ±...
  • Page 300 dummyhead dummyhead CYLINDER HEAD/VALVES Install the cylinder head onto the cylinder block while aligning the cam chain tensioner A [1] and B [2] as shown. Apply oil to the stud bolt [1] threads. Apply oil to the washers [2] and install them. Apply oil to the cylinder head nut [3] threads and seating surface and install them.

  • Page 301: Cam Chain Tensioner Lifter

    dummyhead dummyhead CYLINDER HEAD/VALVES 5. Tighten the cylinder head nuts [1] to the specified Tightening sequence: torque in the specified sequence as shown. TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft) 6. Further tighten the cylinder head nuts to the specified torque in the specified sequence as shown.
  • Page 302 dummyhead dummyhead CYLINDER HEAD/VALVES Remove the cam chain tensioner lifter [1] and gasket [2]. Installation is in the reverse order of removal. • Note the installation direction of the gasket. INSPECTION Check the cam chain tensioner lifter [1] operation: – The cam chain tensioner lifter shaft should not go into the lifter body when it is pushed.

  • Page 303: Clutch/Starter Clutch/Gearshift Linkage

    dummytext 11. CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION ···························11-2 CLUTCH ······················································ 11-6 TROUBLESHOOTING·································11-2 STARTER CLUTCH ·································· 11-16 COMPONENT LOCATION ··························11-3 GEARSHIFT LINKAGE ····························· 11-19 RIGHT CRANKCASE COVER ····················11-4 GEARSHIFT PEDAL ································· 11-23 11-1...

  • Page 304: Service Information

    dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE GENERAL • This section covers service of the clutch, starter clutch and gearshift linkage. All service can be done with the engine installed in the frame. • Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motorcycle creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.

  • Page 305: Component Location

    dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION 12 N·m (1.2 kgf·m, 9 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 186 N·m (19.0 kgf·m, 137 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) CH, TH, FO only CH, TH, FO only 115 N·m (11.7 kgf·m, 85 lbf·ft)

  • Page 306: Right Crankcase Cover

    dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL/INSTALLATION Remove the following: – Right middle cowl (page 2-13) – CH, TH, FO only: Right rear under cover (page 2-21) – Except CH, TH, FO: Under cowl (page 2-20) Remove the bolt [1] and clutch cable guide plate [2], then disconnect the clutch cable [3] end from the clutch lifter lever [4].

  • Page 307: Clutch Lifter Lever

    dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Remove the four dowel pins [1]. Clean off any sealant from the right crankcase cover mating surfaces. • Do not turn the crankshaft counterclockwise after removing the right crankcase cover to prevent the starter reduction gear from damage. Installation is in the reverse order of removal.
  • Page 308 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Check the oil seal [1] and needle bearings [2] for wear or damage. Install the clutch lifter lever [1] and return spring [2] to the right crankcase cover as shown. • Align the return spring end with the clutch lifter lever groove.
  • Page 309 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Remove the starter idle gear [1] and shaft [2]. Loosen the set plate bolts [1] in a crisscross pattern in 2 [1]/[3] or 3 steps, and remove the bolts, set plate [2], and clutch springs [3]. Remove the following: –...
  • Page 310 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Install special tools and loosen the clutch center lock nut [1] while holding the clutch center with the special tool. TOOLS: Clutch center holder [2] 07724-0050002 Lock nut wrench 30 x 40 mm [3] 07916-9690000 Remove the lock nut.
  • Page 311 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Remove the starter reduction gear [1] from the crankcase. Remove the bolt [1] and oil pump drive chain guide [2]. Be careful not to drop the parts into the oil pan. Remove the oil pump drive sprocket guide [1]. Remove the oil pump drive sprocket [1] and chain [2].

  • Page 312: Clutch/Gearshift Linkage Specifications

    dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE 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. Check the following of the clutch center [1] for scratches, damage, abnormal wear and deformation.
  • Page 313 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE NEEDLE BEARING SELECTION The primary driven gear has I.D. code paint [1]. The clutch outer guide has O.D. code marks [1] as shown. Cross-reference the primary driven gear and clutch outer guide codes to determine the replacement needle bearing.
  • Page 314 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE INSTALLATION 186 N·m (19.0 kgf·m, 137 lbf·ft) : Each clutch discs Install the oil pump drive sprocket [1] and drive chain [2]. Apply molybdenum oil solution to the oil pump drive sprocket guide [1] sliding surface and install it to the mainshaft.
  • Page 315 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Apply locking agent to the oil pump drive chain guide Be careful not to mounting bolt [1] threads (page 1-19). drop the parts into the oil pan. Install the oil pump drive chain guide [2] by aligning its hole with the crankcase tab and tighten the bolt to the Align specified torque.
  • Page 316 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Install the thrust washer [1]. Apply engine oil to a new clutch center lock nut threads and seating surface. Install the clutch center lock nut [1] onto the mainshaft. Install special tools and tighten the clutch center lock nut to the specified torque by holding the clutch center with the special tool.
  • Page 317 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Apply molybdenum oil solution to the entire surface of judder spring seat and judder spring. 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] and plate B [5] onto the clutch center.

  • Page 318: Starter Clutch

    dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Install the clutch springs [1], set plate [2] and set plate bolts [3]. Tighten the set plate bolts in a crisscross pattern in 2 or [1]/[3] 3 steps. Apply molybdenum oil solution to the starter idle gear shaft sliding surface.
  • Page 319 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Remove the starter clutch assembly [1]. Remove the thrust washer [1]. Installation is in the reverse order of removal. • Install the starter clutch assembly [1] to the crankshaft while aligning the wide teeth of the crankshaft with the starter clutch assembly.
  • Page 320 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE DISASSEMBLY/ASSEMBLY 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 should turn counterclockwise. Remove the starter driven gear by turning it clockwise. STARTER DRIVEN GEAR SNAP RING ONE-WAY CLUTCH...

  • Page 321: Gearshift Linkage

    dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Apply oil to the one-way clutch [1] sliding surface. Install the one-way clutch into the starter clutch outer [2] with its paint mark [3] facing out. Install the snap ring [1] into the starter clutch outer [2] After installing the groove securely.
  • Page 322 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Remove the bolt [1] and setting plate [2]. Pull the gearshift spindle [1] and thrust washer [2] out of the crankcase. Remove the following: Be careful not to drop the parts into – Stopper arm pivot bolt [1] the oil pan.

  • Page 323: Installation

    dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE INSPECTION Check the gearshift spindle [1] for wear, damage or bending. Check the return spring [2] for fatigue or damage. INSTALLATION Install the needle bearing [1] into the crankcase. Apply grease to a new oil seal [2] lips, then install it into the crankcase securely.
  • Page 324 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE Tighten a new shift drum center bolt [1] to the specified torque. TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft) Install the thrust washer [1] and gearshift spindle [2] into the crankcase while aligning the spring ends with the stopper pin [3].

  • Page 325: Gearshift Pedal

    dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE GEARSHIFT PEDAL REMOVAL/INSTALLATION KO only: Remove the EVAP canister (page 7-22). CBR1000S1/S2: Disconnect the shift stroke sensor 3P (Black) connector [1] and remove the harness clamp [2]. Remove the pinch bolt [1] and gearshift arm [2] from the gearshift spindle.
  • Page 326 dummyhead dummyhead CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE ADJUSTMENT When adjusting the gearshift pedal height, perform the procedure as follows: CBR1000RR/ Loosen the lock nuts [1]. The upper lock nut has left hand Adjust the tie-rod [2] length so that the distance threads. between the ball joint ends is standard length as shown.

  • Page 327: Alternator

    dummytext 12. ALTERNATOR SERVICE INFORMATION ···························12-2 STATOR ······················································ 12-5 COMPONENT LOCATION ··························12-2 FLYWHEEL ················································· 12-5 ALTERNATOR COVER·······························12-3 12-1...

  • Page 328: Service Information

    dummyhead dummyhead ALTERNATOR SERVICE INFORMATION ALTERNATOR GENERAL • This section covers service of the stator and flywheel. All service can be done with the engine installed in the frame. • For stator inspection (page 20-7). COMPONENT LOCATION 123 N·m (12.5 kgf·m, 91 lbf·ft) 12-2...

  • Page 329: Alternator Cover

    dummyhead dummyhead ALTERNATOR ALTERNATOR COVER REMOVAL/INSTALLATION Remove the following: – Fuel tank (page 7-8) – Left middle cowl (page 2-13) – Left rear cover (page 2-21) – Regulator cover (page 2-9) – KO only: EVAP canister (page 7-22) – Except CBR1000RR: ABS modulator (page 19-24) Disconnect the alternator 3P (Black) connector [1].
  • Page 330 dummyhead dummyhead ALTERNATOR Installation is in the reverse order of removal. Cover side: • Apply sealant (TB 1207B or equivalent) to the mating surface of the alternator cover. • Apply sealant (TB 1207B or equivalent) to the crankcase mating surface area [1] of the crankcase. •...
  • Page 331 dummyhead dummyhead ALTERNATOR STATOR REMOVAL/INSTALLATION 14 N·m (1.4 kgf·m, 10 lbf·ft) Do not damage to wire harness. CLAMP • Apply locking agent to the stator mounting bolt. TORQUE: Stator mounting bolt: 14 N·m (1.4 kgf·m, 10 lbf·ft) FLYWHEEL REMOVAL/INSTALLATION Remove the alternator cover (page 12-3). [2]/[3] Hold the flywheel [1] using the special tool then remove the flywheel bolt [2] and washer [3].
  • Page 332 dummyhead dummyhead ALTERNATOR Remove the flywheel using the special tool. TOOL: Rotor puller [1] 07733-0020001 Remove the woodruff key [1] from the crankshaft. Installation is in the reverse order of removal. • Clean any oil from the tapered area of the crankshaft Align and flywheel thoroughly.

  • Page 333: Crankcase/Transmission/Balancer

    dummytext 13. CRANKCASE/TRANSMISSION/BALANCER SERVICE INFORMATION ···························13-2 CRANKCASE ·············································· 13-4 TROUBLESHOOTING·································13-2 SHIFT FORK/SHIFT DRUM/ TRANSMISSION ········································· 13-8 COMPONENT LOCATION ··························13-3 BALANCER··············································· 13-16 13-1...

  • Page 334: Troubleshooting

    dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER SERVICE INFORMATION CRANKCASE/TRANSMISSION/BALANCER GENERAL • The crankcase must be separated to service the following: – Transmission – Crankshaft (page 14-4) – Piston (page 14-13) – Balancer (page 13-16) – Cylinder (page 14-13) • The following components must be removed before separating the crankcase: –...
  • Page 335 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER COMPONENT LOCATION MAIN JOURNAL BOLT: 8 mm BOLT: 24 N·m (2.4 kgf·m, 18 lbf·ft) 20 N·m (2.0 kgf·m, 15 lbf·ft) + 150° 10 mm BOLT: 39 N·m (4.0 kgf·m, 29 lbf·ft) 7 mm BOLT: 18 N·m (1.8 kgf·m, 13 lbf·ft) 14 N·m (1.4 kgf·m, 10 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 13-3...
  • Page 336 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER CRANKCASE SEPARATION For Service Information for removal of necessary parts before separating the crankcase (page 13-2). Cut off and remove the hose clamp [1] then disconnect the water hose [2]. Remove the bolts [3], water hose joint [4] and O-ring [5]. Remove the 7 mm bolts [1].
  • Page 337 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Remove the dowel pins [1], oil orifice A [2], oil orifice B [3] and oil orifice C [4]. Clean any sealant off from the crankcase mating surface. Clean the oil orifices in solvent thoroughly. Check the oil orifice A [1], oil orifice B [2] and oil orifice C [3] for clogs, and replace them if necessary.
  • Page 338 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Install the oil orifice A [1], oil orifice B [2] and oil orifice C [3] in the upper crankcase. Install the dowel pins [4]. Install the lower crankcase onto the upper crankcase while aligning the crankshaft balancer drive gear white paint mark [1] with between the balancer gear [2] index lines [3] as shown.
  • Page 339 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER PLASTIC REGION TIGHTENING METHOD: Make sure the upper and lower crankcase are seated securely. Tighten the crankcase main journal bolts [1] as follows: Tighten the crankcase main journal bolts in numerical order as shown in the illustration in two or three steps to the specified torque.

  • Page 340: Shift Fork/Shift Drum/ Transmission

    dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Pinch the ear portion of the water hose band [1] with a pincher until the pinched area clearance is 1 mm (0.04 in) or 2 mm (0.08 in) maximum as shown to secure water hose. TOOL: Pincher [2] Oetiker 1098 or equivalent Install the removed parts in the reverse order of removal.
  • Page 341 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Remove the fork shaft [1] and shift forks [2]. • Mark all shift forks direction to ensure correct reassembly in their original locations. Remove the mainshaft bearing [1] from the crankcase. Remove the mainshaft assembly [1]. Disassemble the mainshaft assembly. Clean all disassembled parts in solvent thoroughly.

  • Page 342: Mainshaft Bearing Replacement

    dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Remove the oil jet pipe [1] and O-ring [2]. Clean the oil jet pipe in solvent thoroughly. MAINSHAFT BEARING REPLACEMENT Remove the following: – Crankshaft (page 14-4) – Countershaft (page 13-8) – Mainshaft (page 13-8) Remove the mainshaft bearing [1] using the special tools as shown.
  • Page 343 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER INSPECTION Inspect the following parts for scratches, damage, abnormal wear, or deformation. – Transmission gears – Transmission bushings – Transmission bearings – Shift drum/bearing – Shift forks – Shift fork shafts – Oil jet pipe Measure each part according to CRANKCASE/ TRANSMISSION SPECIFICATIONS (page 1-9).
  • Page 344 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER COUNTERSHAFT: C1 GEAR (32T) C5 GEAR (34T) C4 GEAR (32T) C3 GEAR (33T) C6 GEAR (33T) COUNTERSHAFT C2 GEAR (32T) • Apply engine oil to the gear teeth, sliding surface and bushings. • Apply molybdenum oil solution to the shift fork grooves.

  • Page 345: Installation

    dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Assemble the transmission gears and shafts. Align • Coat each gear with clean engine oil and check for smooth movement. • Align the lock washer tabs with the spline washer grooves. • Always install the thrust washers and snap rings [1] with the chamfered (rolled) edge facing away from the thrust load.
  • Page 346 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Install the mainshaft assembly [1] into the crankcase. Install the mainshaft bearing [1] into the crankcase. Install the bearing into the crankcase with the marked side facing out. The shift forks have the following identification marks: – “RL” [1] for right/left –...
  • Page 347 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Install the shift forks [1] into the shift drum guide grooves and insert the fork shaft [2]. • Face the shift fork marks as follows: – “RL” marks to the outside – “C” mark to the right side (clutch side) •...
  • Page 348 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER BALANCER REMOVAL/INSTALLATION Separate the crankcase halves (page 13-4). Loosen the balancer shaft pinch bolt [1]. Remove the bolt [2] and balancer shaft holder [3]. Remove the sealing bolt [4] and sealing washer [5]. Pull the balancer shaft [1] out and remove the balancer weight assembly [2] from the lower crankcase.
  • Page 349 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER DISASSEMBLY/ASSEMBLY WASHER B NEEDLE BEARINGS BALANCER WEIGHT RUBBER DAMPERS BALANCER GEAR WASHER A BALANCER SHAFT HOLDER Apply grease to the damper rubber fitting area. Align Install the damper rubbers into the balancer gear. Assemble the balancer gear [1] and weight [2] while aligning the marks.
  • Page 350 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Apply oil to a new O-ring [1] and install it to the balancer shaft [2] groove. INSPECTION Check each needle bearing [1] for wear or damage, Replace the replace if necessary. balancer weight, balancer shaft, needle bearing as a Check the balancer weight [1] and gear [2] for wear or damage.
  • Page 351 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER Reference the balancer weight I.D. code letters to determine the replacement bearing [1] color. Refer to the selection table below for bearing selection. BALANCER BEARING SELECTION TABLE: BALANCER WEIGHT I.D. CODE 26.996 – 27.000 mm 26.991 – 26.996 mm 26.987 –...
  • Page 352 dummyhead dummyhead CRANKCASE/TRANSMISSION/BALANCER FINAL BACKLASH ADJUSTMENT Warm up the engine and let it idle. If the balancer gear noises are excessive, adjust the balancer backlash as follows: Turn the balancer gear shaft [1] counterclockwise until the gears begin to make a “whining” noise. Then turn the gear shaft clockwise until the gear “whining”...

  • Page 353: Crankshaft/Piston/Cylinder

    dummytext 14. CRANKSHAFT/PISTON/CYLINDER SERVICE INFORMATION ···························14-2 MAIN JOURNAL BEARING························ 14-8 TROUBLESHOOTING·································14-2 CRANKPIN BEARING ······························ 14-10 COMPONENT LOCATION ··························14-3 PISTON/CYLINDER ·································· 14-13 CRANKSHAFT ············································14-4 14-1...

  • Page 354: Service Information

    dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER SERVICE INFORMATION CRANKSHAFT/PISTON/CYLINDER GENERAL • The crankcase must be separated to service the following: – Crankshaft (page 14-4) – Piston (page 14-13) – Cylinder (page 14-13) • Mark and store the connecting rods, bearing caps and bearing inserts to be sure of their correct locations for reassembly. •...

  • Page 355: Component Location

    dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER COMPONENT LOCATION 27.5 N·m (2.8 kgf·m, 20 lbf·ft) + 90° 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 14-3...

  • Page 356: Side Clearance Inspection

    dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER CRANKSHAFT Separate the crankcase halves (page 13-4). SIDE CLEARANCE INSPECTION Measure the connecting rod side clearance. SERVICE LIMIT: 0.35 mm (0.014 in) If the clearance exceeds the service limit, replace the connecting rod. Recheck and if still out of limit, replace the crankshaft. REMOVAL •...
  • Page 357 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER INSPECTION Support the crankshaft on both end journals. Set a dial gauge on the center main journal of the crankshaft. Rotate the crankshaft two revolutions and read the runout at the measurement point [1]. SERVICE LIMIT: 0.05 mm (0.002 in) Check the primary drive gear and balancer drive gear teeth for abnormal wear or damage.
  • Page 358 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Apply locking agent to the oil jet pipe mounting bolts [1] threads (page 1-19) and tighten them to the specified torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply molybdenum oil solution to the main journal bearing sliding surfaces on the upper crankcase and crankpin bearing sliding surfaces on the connecting rods.
  • Page 359 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Apply molybdenum oil solution to the crankpin bearing Align sliding surfaces on the crankpin bearing caps. Install the crankpin bearing caps, aligning the dowel pins with the holes in the connecting rods. Be sure each part is installed in its original position, as noted during removal.

  • Page 360: Main Journal Bearing

    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. Remove the crankshaft (page 14-4). BEARING INSPECTION Inspect the main journal bearing inserts [1] on the upper and lower crankcase halves for unusual wear or peeling.

  • Page 361: Bearing Selection

    dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER PLASTIC REGION TIGHTENING METHOD: Install the crankcase main journal bolts [1]. Make sure the upper and lower crankcase are seated securely. Tighten the crankcase main journal bolts as follows: Tighten the crankcase main journal bolts in numerical order in the illustration in two or three steps to the specified torque.

  • Page 362: Bearing Installation

    dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Cross reference the main journal and bearing support codes to determine the replacement bearing color code [1]. BEARING THICKNESS: Brown: Thickest Green: Yellow: Pink: Red: Thinnest After selecting new bearings, recheck the clearance with a plastigauge. Incorrect clearance can cause severe engine damage.
  • Page 363 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER BEARING INSPECTION Check the bearing inserts [1] for unusual wear or peeling. Check the bearing tabs for damage. OIL CLEARANCE INSPECTION Clean off any oil from the bearing inserts and crankpins. Carefully install the crankshaft onto the upper crankcase.
  • Page 364 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER BEARING SELECTION Record the connecting rod I.D. code [1] (1, 2 or 3) or Numbers (1, 2 or 3) measure the I.D. with the crankpin bearing cap installed on the connecting without bearing inserts. rods are the connecting rod I.D.
  • Page 365 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER BEARING INSTALLATION Clean the bearing outer surfaces, crankpin bearing cap and connecting rod. Install the crankpin bearing inserts [1] onto the bearing cap and connecting rod, aligning each tab with each groove. PISTON/CYLINDER PISTON/CONNECTING ROD/ CYLINDER REMOVAL •...

  • Page 366: Piston Ring Removal

    dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Remove the bolts [1] and cylinder [2]. Remove the gasket [1] and dowel pins [2]. PISTON REMOVAL Remove the piston pin clip [1] with pliers. Push the piston pin [2] out of the piston and connecting rod, and remove the piston [3]. PISTON RING REMOVAL Spread each piston ring ends and remove them by Be careful not to...

  • Page 367: Crankshaft/Piston/Cylinder Specifications

    dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER INSPECTION Inspect the following parts for scratches, damage, abnormal wear, or deformation. – Cylinder – Piston – Piston rings – Piston pin – Connecting rod small end Measure each part and calculate the clearance according CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS (page 1-9). Replace any part if it is out of service limit.
  • Page 368 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Apply molybdenum oil solution to the connecting rod [1] small end inner surfaces and piston pin sliding surfaces. Assemble the piston and connecting rod with the journal bearing tab [2] facing to the piston “IN” mark [3]. Apply molybdenum oil solution to the piston pin [1] sliding surface.
  • Page 369 dummyhead dummyhead CRANKSHAFT/PISTON/CYLINDER Coat the cylinder walls, pistons and piston rings with engine oil. Install the piston/connecting rod assemblies into the Install the piston/ cylinders using a commercially available piston ring connecting rod compressor tool [2]. assembly with the When reusing the connecting rods, they must be piston punch mark installed in their original locations.
  • Page 370 dummyhead dummyhead MEMO...

  • Page 371: Engine Removal/Installation

    dummytext 15. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ···························15-2 ENGINE REMOVAL ···································· 15-4 COMPONENT LOCATION ··························15-3 ENGINE INSTALLATION···························· 15-8 15-1...

  • Page 372: Service Information

    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. •...

  • Page 373: Component Location

    dummyhead dummyhead ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION 54 N·m (5.5 kgf·m, 40 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 84 N·m (8.6 kgf·m, 62 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 15-3...
  • Page 374 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 3-12). Drain the coolant from the system (page 8-4). Remove the following: – Under cowl (page 2-20) – Middle cowls (page 2-13) – CH/TH/FO only: Right rear under cover (page 2-21) –...
  • Page 375 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the VS sensor 3P (Black) [1], CKP sensor 2P (Red) [2], shift spindle switch 1P (Black) [3] and shift drum angle sensor/neutral switch 4P (Black) [4] connectors. BR/ED/CH/TH/FO: Disconnect the EVAP canister-to- purge control solenoid valve hose [5] Disconnect the sidestand switch 2P (Black) connector [1].
  • Page 376 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Disconnect the CMP sensor 3P (Blue) connector [1]. Support the engine using a jack or other adjustable Right side: Left side: support. Remove the right front engine hanger bolt [1] and collar [2]. Remove the left front engine hanger bolt [3]. Remove the upper engine hanger nut [1] while holding the engine hanger bolt [2].
  • Page 377 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Turn the upper engine hanger adjusting bolt [1] counterclockwise fully by turning the upper engine hanger bolt [2]. Remove the lower engine hanger nut [1] and washer [2] while holding the engine hanger bolt [3]. Support the engine using a jack or other adjustable support to ease removal of the engine hanger bolts.
  • Page 378 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION UPPER ENGINE HANGER BOLT UPPER ENGINE HANGER LOCK NUT UPPER ENGINE HANGER FRONT ENGINE ADJUSTING BOLT HANGER BOLT UPPER ENGINE HANGER NUT COLLARS LOWER ENGINE HANGER BOLT FRONT ENGINE LOWER ENGINE HANGER BOLT WASHER HANGER NUT •...
  • Page 379 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Install the upper engine hanger adjusting bolt [1] fully from the inside of the frame [2]. OUTSIDE INSIDE Carefully install the engine into the frame. Install the collar [1] and lower engine hanger bolt [2] from the right side. Install the upper engine hanger bolt [1] from the right side.
  • Page 380 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Tighten the upper engine hanger adjusting bolt to the specified torque by turning the upper engine hanger bolt [1]. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Install the upper engine hanger lock nut [1]. Hold the adjusting bolt by holding the hanger bolt and tighten the lock nut to the indicated below torque.
  • Page 381 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Tighten the front engine hanger bolts [1] to the specified RIGHT SIDE: LEFT SIDE: torque. TORQUE: 64 N·m (6.5 kgf·m, 47 lbf·ft) KO only: Install the battery negative (–) cable [1] and Route the wires KO only: [1]/[2]/[3] [1]/[2] Except KO:...
  • Page 382 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Pinch the ear portion of the water hose band [1] with a pincher until the pinched area clearance is 1 mm (0.04 in) or 2 mm (0.08 in) maximum as shown to secure water hose. TOOL: Pincher [2] Oetiker 1098 or equivalent Pinched Area...
  • Page 383 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION Connect the alternator 3P (Black) connector [1]. Connect the clutch cable end [1] to the clutch lifter lever [2]. Install the clutch cable guide plate [3] by aligning its hole with the right crankcase cover boss and tighten the bolt [4] securely.
  • Page 384 dummyhead dummyhead MEMO...

  • Page 385: Front Wheel/Suspension/Steering

    dummytext 16. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION ···························16-2 FRONT WHEEL ········································ 16-15 TROUBLESHOOTING·································16-2 FORK························································· 16-20 COMPONENT LOCATION ··························16-3 HESD ························································· 16-29 HESD TROUBLESHOOTING······················16-5 STEERING STEM ····································· 16-30 HANDLEBARS ············································16-7 16-1...

  • Page 386: Service Information

    dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION FRONT WHEEL/SUSPENSION/STEERING GENERAL • When servicing the front wheel, fork or steering stem, support the motorcycle using a safety stand or hoist. • 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 387: Component Location

    dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION CBR1000RR/RA (Except BR/IN/KO/TH shown): 22 N·m (2.2 kgf·m, 16 lbf·ft) 137 N·m (14.0 kgf·m, 101 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)
  • Page 388 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING CBR1000S1/S2 (Except BR/IN/KO/TH shown): 22 N·m (2.2 kgf·m, 16 lbf·ft) 137 N·m (14.0 kgf·m, 101 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 40 N·m (4.1 kgf·m, 30 lbf·ft)
  • Page 389 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING HESD TROUBLESHOOTING • The HESD system is equipped with a Self-Diagnostic System that is linked to the PGM-FI system (page 4- 10). If the MIL lights, follow the DTC troubleshooting to remedy the problem (page 16-6). The HESD system is also equipped with a Function Test Mode to check the HESD under maximum damping characteristics.
  • Page 390 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING DTC TROUBLESHOOTING Refer Causes Symptoms • Loose or poor contact on • Engine operates normally rear wheel speed sensor • HESD does not function P2158 connector – ECM does not control the linear solenoid 4-36 (66-1) •...
  • Page 391 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING 3. Linear Solenoid Short Circuit Inspection Check for continuity between the wire harness side 33P (Black) connector [1] and ground. Connection: C11 – Ground C22 – Ground TOOL: Test probe 07ZAJ-RDJA110 Is there continuity? – Short circuit in the White/green or White/ blue wire –...
  • Page 392 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Loosen the holder screw [1] of the right handlebar switch/APS. Remove the screw [1], left handlebar weight [2] and grip [3] from the handlebar. Disconnect the wire connectors [1] from the clutch switch. Remove the screws [2] and left handlebar switch housing [3].
  • Page 393 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the screw [1] and steering damper cover [2] by releasing the tab [3]. Remove the nut [1] by holding the second arm joint [2] and disconnect the second arm from the top bridge. Remove the washer [3] from the second arm. CBR1000S1/S2 only: Slide the connector cover [1] off the damping adjuster 4P connector [2].

  • Page 394: Installation

    dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the cap [1], steering stem nut [2] and top bridge [3] with immobilizer receiver and ignition switch wire connector connected. Remove the handlebars [4] from the fork sliders. Remove the clutch lever bracket and right handlebar switch/APS from the handlebars.
  • Page 395 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the steering stem nut [1] and tighten it to the specified torque. TORQUE: 137 N·m (14.0 kgf·m, 101 lbf·ft) Install the steering stem cap [2]. Tighten the top bridge pinch bolts [1] to the specified torque.
  • Page 396 TORQUE: 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) Connect the wire connectors [3] to the clutch switch securely. Apply Honda Bond A or equivalent adhesive to the inner surface of the grip [1] and to the clean surfaces of the left handlebar [2].
  • Page 397 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the left handlebar weight [1] and a new screw [2], and tighten the screw to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Align the holder boss of the right handlebar switch/APS Align with the hole in the handlebar, and tighten the holder screw [1] securely.
  • Page 398 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the right handlebar weight [1] and a new screw [2], and tighten the screw to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) HANDLEBAR WEIGHT REPLACEMENT Remove the left grip and right handlebar switch/APS from the handlebars (page 16-7).

  • Page 399: Right Side

    dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL REMOVAL Remove the bolts [1] and brake calipers [2]. Support the brake caliper with a piece of wire so that it Do not operate the does not hang from the brake hose. Do not twist the brake lever after the brake hose.

  • Page 400: Wheel Balance

    dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INSPECTION Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the outer race fits tightly in the wheel hub. Inspect the following parts for damage, abnormal wear, deformation, or bend.
  • Page 401 7.5 mm (0.3 in) 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 402: Wheel Bearing Replacement

    dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING WHEEL BEARING REPLACEMENT Install the bearing remover head [1] into the bearing [2]. From the opposite side, install the bearing remover shaft [3] and drive the bearing out of the wheel hub. TOOLS: Bearing remover head, 25 mm 07746-0050800 Bearing remover shaft 07GGD-0010100...
  • Page 403 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Install the right and left side collars [1]. RIGHT SIDE: LEFT SIDE: 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.
  • Page 404 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Tighten the left axle holder bolts [1] to the specified torque. TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) FORK REMOVAL Remove the following: – Intake air duct (page 2-14) – Front wheel (page 16-15) – Front fender (page 2-23) CBR1000S1/S2 only: Slide the connector cover [1] off the damping adjuster 4P connector [2].
  • Page 405 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY (CBR1000RR/RA only) Turn the spring pre-load adjuster [1] counterclockwise to the softest position (be sure to record the number of turns from the starting position). Remove the collars [2] if necessary. Remove the stopper ring [1] being careful not to scratch the outer tube.
  • Page 406 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING – Spring collar B [1] – Fork spring [2] – Spring collar A [1] (pour out the fork fluid by pumping the slide pipe up and down several times) – Dust seal [1] Be careful not to –...
  • Page 407 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the following from the slide pipe: – Slider bushing [1] – Guide bushing [2] – Back-up ring [3] – Oil seal [4] – Stopper ring [5] – Dust seal [6] Loosen the piston rod nut [1] while holding the fork cap Take care not to [2] with the special tool.
  • Page 408 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY (CBR1000RR/RA only) OUTER TUBE PISTON RING B 27.5 N·m (2.8 kgf·m, 20 lbf·ft) STOPPER RING SLIDER BUSHING O-RING FORK CAP GUIDE BUSHING 35 N·m (3.6 kgf·m, 26 lbf·ft) O-RING BACK-UP RING INNER ROD PIPE OIL SEAL ROD GUIDE CASE 90 N·m (9.2 kgf·m, 66 lbf·ft) STOPPER RING...
  • Page 409 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Cover the slide pipe end with a plastic wrap [1] or equivalent to avoid damaging the seals on the edges. Apply fork fluid to the lips of a new dust seal [2] and a oil seal [3]. Install the following onto the slide pipe: –...
  • Page 410 RECOMMENDED FORK FLUID: total amount of fluid Honda ULTRA CUSHION OIL SS-47 (10W) as described in the or equivalent later step. FORK FLUID CAPACITY: 515 ± 2.5 cm (17.4 ±...
  • Page 411 TORQUE: 90 N·m (9.2 kgf·m, 66 lbf·ft) Fill the rod guide case with the remaining fork fluid. RECOMMENDED FORK FLUID: Honda ULTRA CUSHION OIL SS-47 (10W) or equivalent Hold the fork cap [1] down, then pump the outer tube [2] 84 mm several times to remove any trapped air completely.
  • Page 412 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Install the fork leg into the bottom bridge, handlebar and Route the wires, Front top bridge. cables and hose properly (page 1- CBR1000RR/RA: Align the top of the outer tube with 23). the upper surface of the top bridge and parallel the adjusters on the fork cap [1] to the top bridge (rider can be read characters) as shown, then tighten the bottom bridge pinch bolt to determine the fork position.
  • Page 413 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING HESD REMOVAL Remove the air cleaner housing (page 7-10). Remove the nut [1] by holding the second arm joint [2] and disconnect the second arm from the top bridge. Remove the washer [3] from the second arm joint. Disconnect the HESD 2P (Brown) connector [1].

  • Page 414: Steering Stem

    dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the washer [1] to the second arm joint and connect the second arm to the top bridge. Install the nut [2] and tighten it to the specified torque by holding the second arm joint [3]. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the air cleaner housing (page 7-10).
  • Page 415 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove the following: – Dust seal [1] – Upper bearing inner race [2] – Upper bearing [3] – Steering stem [4] – Lower bearing [5] OUTER RACE REPLACEMENT Replace the outer races using the following: TOOLS: Bearing remover [1] 07NMF-MT70110 Driver attachment [2]...
  • Page 416 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Install the special tools into the steering head as shown and r TOOLS: Bearing remover [1] 07NMF-MT70110 Driver attachment [2] 07NMF-MT70120 (2 required) Driver shaft assembly 07946-KM90301 – Driver shaft [3] – Nut A [4] – Nut B [5] Assembly base [6] 07946-KM90600 Remove the lower outer race [7] using the same...
  • Page 417 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Remove any burrs from the outer race installation surface of the steering head. Install a new lower outer race [1] with the special tools as shown. TOOLS: Driver attachment [2] 07NMF-MT70120 (2 required) Driver shaft assembly 07946-KM90301 –...

  • Page 418: Lock Washer

    dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING INSTALLATION LOCK NUT : Lock washer, bearing, races and dust seals LOCK WASHER Apply specified grease to the bearings, races, dust ADJUSTING NUT UPPER DUST SEAL seal lips and adjusting nut threads. UPPER INNER RACE UPPER BEARING UPPER OUTER RACE 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft) LOWER OUTER RACE...
  • Page 419 dummyhead dummyhead FRONT WHEEL/SUSPENSION/STEERING Move the steering stem [1] right and left, lock-to-lock, five times to seat the bearings. Retighten the steering stem adjusting nut [1] to the specified torque. TOOL: Steering stem socket [2] 07HMA-MR70100 TORQUE: 37 N·m (3.8 kgf·m, 27 lbf·ft) Recheck that the steering stem moves smoothly without play or binding.
  • Page 420 dummyhead dummyhead MEMO...

  • Page 421: Rear Wheel/Suspension

    dummytext 17. REAR WHEEL/SUSPENSION SERVICE INFORMATION ···························17-2 SUSPENSION LINKAGE ···························· 17-9 TROUBLESHOOTING·································17-2 SHOCK ABSORBER (CBR1000RR/RA) ····································· 17-11 COMPONENT LOCATION ··························17-3 SHOCK ABSORBER (CBR1000S1/S2) ······································· 17-14 REAR WHEEL ·············································17-5 SWINGARM ·············································· 17-16 17-1...

  • Page 422: Service Information

    • After the rear wheel installation, check the brake operation by applying the brake pedal. • Use Honda genuine replacement bolts and nuts for all suspension pivot and mounting point. • The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber.

  • Page 423: Component Location

    dummyhead dummyhead REAR WHEEL/SUSPENSION COMPONENT LOCATION CBR1000RR/RA 44 N·m (4.5 kgf·m, 32 lbf·ft) 124 N·m (12.6 kgf·m, 91 lbf·ft) 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 135 N·m (13.8 kgf·m, 100 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 17-3...
  • Page 424 dummyhead dummyhead REAR WHEEL/SUSPENSION CBR1000S1/S2 44 N·m (4.5 kgf·m, 32 lbf·ft) 124 N·m (12.6 kgf·m, 91 lbf·ft) 4.2 N·m (0.4 kgf·m, 3.1 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 135 N·m (13.8 kgf·m, 100 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 17-4...
  • Page 425 dummyhead dummyhead REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Support the motorcycle securely and raise the rear wheel off the ground using a hoist or safety stand. Fully slacken the drive chain (page 3-17). Remove the rear axle nut [1], washer [2] and right adjusting plate [3].
  • Page 426 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 outer race fits tightly in the wheel hub. Inspect the following parts for damage, abnormal wear, deformation or bends.
  • Page 427 dummyhead dummyhead REAR WHEEL/SUSPENSION DRIVEN FLANGE BEARING REPLACEMENT Press the collar [1] out of the driven flange bearing [2]. Press the bearing [1] out of the driven flange [2]. Press the driven flange collar [1] into a new driven flange bearing [2] until it is fully seated. Press the driven flange bearing/collar into the driven flange until it is fully seated using the special tools.

  • Page 428: Installation

    dummyhead dummyhead REAR WHEEL/SUSPENSION WHEEL BEARING REPLACEMENT Install the bearing remover head [1] into the bearing. From the opposite side, install the bearing remover shaft [2] and drive the bearing [3] out of the wheel hub. Remove the distance collar and drive out the other bearing.

  • Page 429: Suspension Linkage

    dummyhead dummyhead REAR WHEEL/SUSPENSION Apply a thin coat of grease to the outer surface of the rear axle [1]. Install the left adjusting plate [2] and rear axle. Install the drive chain [3] over the driven sprocket. Install the right adjusting plate [1], washer [2] and rear axle nut [3].
  • Page 430 dummyhead dummyhead REAR WHEEL/SUSPENSION Press the needle bearings out of the shock link using [2]/[3] the special tools. TOOLS: Driver [1] 07949-3710001 Attachment, 22 x 24 mm [2] 07746-0010800 Pilot, 17 mm [3] 07746-0040400 Attachment, 30 mm I.D. [4] 07746-0030300 Pack new needle bearings with molybdenum disulfide Press the needle [3]/[4]...

  • Page 431: Bearing Replacement

    dummyhead dummyhead REAR WHEEL/SUSPENSION SHOCK ABSORBER (CBR1000RR/RA) REMOVAL Remove the suspension linkage (page 17-9). Remove the shock absorber upper mounting nut [1] and bolt [2], then remove the shock absorber [3] downward. INSPECTION Visually inspect the shock absorber for damage. Check the following: –...
  • Page 432 dummyhead dummyhead REAR WHEEL/SUSPENSION Press the spherical bearing [1] out of the upper mount using the special tools. TOOLS: Bearing driver 07GMD-KT80100 (Use only 17 mm collar [2]) Attachment, 30 mm I.D. [3] 07746-0030300 Press a new spherical bearing [1] into the upper mount Drive the bearing in using the special tool.

  • Page 433: Lower Bearing

    dummyhead dummyhead REAR WHEEL/SUSPENSION LOWER BEARING Remove the collar [1] dust seals [2]. Press the needle bearing out of the lower mount using [2]/[3] the special tools. TOOLS: Driver [1] 07949-3710001 Attachment, 22 x 24 mm [2] 07746-0010800 Pilot, 17 mm [3] 07746-0040400 Attachment, 25 mm I.D.
  • Page 434 dummyhead dummyhead REAR WHEEL/SUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE • Before disposal of the shock absorber, release the nitrogen from the reservoir. • Put on safety glasses. Release the nitrogen from the reservoir by pushing and dropping the packing [1] from the reservoir cap [2] using a 2 mm (0.07 in) shaft [3].
  • Page 435 dummyhead dummyhead REAR WHEEL/SUSPENSION Remove the wire clip [1] and connector cover [2], and slide the cover off the damping adjuster 4P (Black) connector [3] and 4P (Gray) connector [4]. Remove the connectors from the stay and disconnect them. Remove the clamp [5] and adjuster wire clips [6]. Remove the upper mounting nut [1] and bolt [2].
  • Page 436 dummyhead dummyhead REAR WHEEL/SUSPENSION SWINGARM REMOVAL Remove the following: – Drive sprocket cover (page 2-21) – Rear fender C (page 2-12) – Rear wheel (page 17-5) – Shock absorber – CBR1000RR/RA (page 17-11) – CBR1000S1/S2 (page 17-14) – Special screws [1] –...
  • Page 437 dummyhead dummyhead REAR WHEEL/SUSPENSION DISASSEMBLY/ASSEMBLY DUST SEAL 12 N·m (1.2 kgf·m, 9 lbf·ft) SNAP RING NEEDLE BEARING BALL BEARING DISTANCE COLLAR NEEDLE BEARING DUST SEAL DRIVE CHAIN CASE PIVOT COLLAR NEEDLE BEARING :DUST SEAL DUST SEAL :BEARING 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft) Install the drive chain slider by aligning its tab with the groove in the swingarm.
  • Page 438 dummyhead dummyhead REAR WHEEL/SUSPENSION PIVOT BEARING REPLACEMENT Remove the snap ring [1] from the swingarm right pivot. Press the right pivot needle bearing [1] and ball bearing [4]/[5] [2] out of the swingarm pivot using the special tools. TOOLS: Driver [3] 07949-3710001 Attachment, 28 x 30 mm [4] 07946-1870100...
  • Page 439 dummyhead dummyhead REAR WHEEL/SUSPENSION Pack a new needle bearing [1] with molybdenum disulfide grease. Press the needle bearing into the swingarm right pivot Press the needle until it is fully seated using the special tools. bearing with the marked side facing TOOLS: out.
  • Page 440 dummyhead dummyhead REAR WHEEL/SUSPENSION Pack a new needle bearing [1] with molybdenum [3]/[4] disulfide grease. 5.5 – 6.0 mm Press the needle bearing into the swingarm so that the (0.22 – 0.24 in) needle bearing surface is 5.5 – 6.0 mm (0.22 – 0.24 in) below the end of the swingarm using the special tools.

  • Page 441: Hydraulic Brake

    dummytext 18. HYDRAULIC BRAKE SERVICE INFORMATION ···························18-2 BRAKE PAD/DISC ······································ 18-8 TROUBLESHOOTING·································18-2 FRONT MASTER CYLINDER ··················· 18-10 COMPONENT LOCATION ··························18-3 REAR MASTER CYLINDER ····················· 18-12 BRAKE FLUID REPLACEMENT/ FRONT BRAKE CALIPER ························ 18-17 AIR BLEEDING ···········································18-5 REAR BRAKE CALIPER ·························· 18-19 18-1...

  • Page 442: Service Information

    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 443 dummyhead dummyhead HYDRAULIC BRAKE COMPONENT LOCATION FRONT: 12 N·m (1.2 kgf·m, 9 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) CBR1000RR/RA: 45 N·m (4.6 kgf·m, 33 lbf·ft) CBR1000S1/S2: 40 N·m (4.1 kgf·m, 30 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 18-3...
  • Page 444 dummyhead dummyhead HYDRAULIC BRAKE REAR: 34 N·m (3.5 kgf·m, 25 lbf·ft) 18 N·m (1.8 kgf·m, 13 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 37 N·m (3.8 kgf·m, 27 lbf·ft) 18-4...

  • Page 445: Brake Fluid Replacement/Air Bleeding

    dummyhead dummyhead HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING Front brake only: Turn the handlebar so the reservoir is FRONT: level. Remove the following: – Screw [1] – Stopper plate [2] – Reservoir cap [3] – Set plate [4] –...
  • Page 446 dummyhead dummyhead HYDRAULIC BRAKE BRAKE FLUID FILLING/AIR BLEEDING FRONT BRAKE Fill the front reservoir to the upper level line with DOT 4 brake fluid from a sealed container. Connect a commercially available brake bleeder to the front master cylinder bleed valve [1]. Operate the brake bleeder and loosen the bleed valve.
  • Page 447 dummyhead dummyhead HYDRAULIC BRAKE Connect a bleed hose [1] to the front brake caliper bleed valve [2]. Repeat the steps 1 through 3 at the caliper bleed valve. After bleeding the system completely, tighten the brake caliper bleed valve to the specified torque. TORQUE: CBR1000RR/RA: 8.0 N·m (0.8 kgf·m, 5.9 lbf·ft) CBR1000S1/S2: 13 N·m (1.3 kgf·m, 10 lbf·ft)

  • Page 448: Brake Pad/Disc

    dummyhead dummyhead HYDRAULIC BRAKE If the brake bleeder is not available, use the following procedure. Connect a bleed hose [1] to the rear brake caliper bleed valve [2]. Pump up the system pressure with the brake pedal until the lever resistance is felt. 1.
  • Page 449 dummyhead dummyhead HYDRAULIC BRAKE Push the caliper pistons all the way in to allow Do not operate the installation of new brake pads by pushing the bake brake lever after pads with a screwdriver or equivalent. removing the pads. Slide the one pad [1] inward to release its tabs [2] from the grooves in the caliper body, and remove it.

  • Page 450: Brake Disc Inspection

    dummyhead dummyhead HYDRAULIC BRAKE Be sure the stopper ring [1] on the pad pin [2] is in good condition, and replace it with a new one if necessary. Coat the stopper ring with silicone grease. Install the pads [3] so that their ends are rest on the pad retainer properly.

  • Page 451: Specifications

    dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY • Use special tool to remove and install the snap ring. TOOL: Snap Ring Pliers 07914-SA50001 • Do not allow the piston cup lips to turn inside out. • Install the snap ring with the chamfered edge facing the thrust load side and be certain it is firmly seated in the groove.

  • Page 452: Rear Master Cylinder

    dummyhead dummyhead HYDRAULIC BRAKE REAR MASTER CYLINDER REMOVAL Drain the brake fluid from the rear brake hydraulic system (page 18-5). Remove the brake hose oil bolt [1], sealing washers [2] When removing the and brake hose eyelet joint [3]. oil bolt, cover the end of the brake hose to prevent contamination.
  • Page 453 dummyhead dummyhead HYDRAULIC BRAKE Remove the following: [1]/[2]/[3] – Nuts [1] – Collar [2] – Bolts [3] – Step guard [4] – Step guard stay [5] – Master cylinder [6] [1]/[3] – Brake pedal return spring [1] – Snap ring [2] –...
  • Page 454 dummyhead dummyhead HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY • Use special tool to remove and install the snap ring. TOOL: Snap Ring Pliers 07914-SA50001 • Install the snap ring with the chamfered edge facing the thrust load side and be certain it is firmly seated in the groove.
  • Page 455 dummyhead dummyhead HYDRAULIC BRAKE INSTALLATION 10 N·m (1.0 kgf·m, 7 lbf·ft) SEALING WASHERS REAR BRAKE 34 N·m (3.5 kgf·m, 25 lbf·ft) COLLAR STEP GUARD STAY LIGHT SWITCH REAR MASTER CYLINDER ASSEMBLY STEP GUARD COTTER PIN PUSH ROD JOINT PIN 10 N·m (1.0 kgf·m, 7 lbf·ft) SWITCH RETURN SPRING PEDAL RETURN...
  • Page 456 dummyhead dummyhead HYDRAULIC BRAKE Install the washer [1] and snap ring [2]. Install the brake pedal return spring [3] by hooking its ends to the pedal and main step bracket as shown. Install the following: [4]/[5]/[6] – Master cylinder [1] –...

  • Page 457: Front Brake Caliper

    dummyhead dummyhead HYDRAULIC BRAKE Install the right main step bracket assembly [1] onto the Except frame. CBR1000RR: Fit the clip [2] onto the Install the bolts [3] and tighten them to the specified rear brake pipe. torque. TORQUE: 37 N·m (3.8 kgf·m, 27 lbf·ft) Install the EGCA cables into the cable guides of the Route the cables step guard stay.
  • Page 458 PISTON SEAL B DUST SEAL B PISTON SEAL B DUST SEAL B PISTONS B *Apply Honda Bond A or equivalent to the seating surface. INSPECTION Check the following parts for scoring, scratches, deterioration or damage. – Caliper cylinders – Caliper pistons Measure the parts according to HYDRAULIC BRAKE SPECIFICATIONS (page 1-11).

  • Page 459: Rear Brake Caliper

    RETAINER* PISTON SEAL BLEED VALVE CAP BRACKET PIN BOOT CALIPER PISTON CALIPER BRACKET CALIPER PIN BOOT CALIPER PIN 27 N·m (2.8 kgf·m, 20 lbf·ft) REAR BRAKE CALIPER PAD SPRING *Apply Honda Bond A or equivalent to the seating surface. 18-19...
  • Page 460 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 1-11). Replace any part if it is out of service limit. 18-20...

  • Page 461: Anti-Lock Brake System (Abs) (Except Cbr1000Rr)

    dummytext 19. ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) SERVICE INFORMATION ···························19-2 ABS INDICATOR CIRCUIT TROUBLESHOOTING ································ 19-9 SYSTEM LOCATION···································19-2 DTC TROUBLESHOOTING ······················ 19-11 SYSTEM DIAGRAM ····································19-3 WHEEL SPEED SENSOR ························ 19-21 ABS TROUBLESHOOTING INFORMATION············································19-4 ABS MODULATOR ··································· 19-24 DTC INDEX··················································19-7 19-1...

  • Page 462: Service Information

    dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) SERVICE INFORMATION ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 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 463: System Diagram

    dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) SYSTEM DIAGRAM MAIN FUSE (30 A) FI/IGN/START FUSE (10 A) FI FUSE (10 A) METER/IMU/ILLUMI FUSE (10 A) IGNITION MAIN RELAY SWITCH ABS MAIN FUSE (10 A) STOP/HORN FUSE (10 A) DIODE FRONT BRAKE LIGHT SWITCH BATTERY...

  • Page 464: Abs Troubleshooting Information

    dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 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 465: Dtc Readout

    dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) DTC READOUT • The DTC is not erased by turning the ignition switch OFF while the DTC is being output. Note that turning the ignition switch ON again does not indicate the DTC. To show the DTC again, repeat the DTC readout procedures from the beginning. •...

  • Page 466: Inspection At Abs Modulator Connector

    dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) How to erase the DTC without MCS 1. Connect the SCS short connector to the DLC (page 4-8). 2. While squeezing the brake lever, turn the ignition switch ON with the engine stop switch to " ". The ABS indicator should come on for 2 seconds and go off.

  • Page 467: Dtc Index

    dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 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). –...
  • Page 468 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) Detection Refer Function failure Symptom/Fail-safe function Power circuit over voltage • Stops ABS operation • Input voltage (too high) 19-18 • ABS MAIN fuse (10 A) • ABS MOTOR fuse (30 A) Tire malfunction •...

  • Page 469: Abs Indicator Circuit Troubleshooting

    dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 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 21-9). 1. Indicator Operation Inspection Turn the ignition switch OFF.

  • Page 470: Yes - Go To Step

    dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 2. Indicator Signal Line Open Circuit Inspection Short the wire harness side 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 471: Dtc Troubleshooting

    dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 6. Power Input Line Open Circuit Inspection Install the ABS MAIN fuse (10 A). Turn the ignition switch ON with the engine stop switch " ". Measure the voltage between the wire harness side 18P (Black) connector [1] and ground.
  • Page 472 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 2. Speed Sensor Condition Inspection Inspect the area around the front 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.
  • Page 473 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 5. Front Wheel Speed Sensor Line Open Circuit Inspection Short the wire harness side 18P (Black) connector [1] terminals with a jumper wire [2]. Connection: 8 – 17 Check for continuity between the wire harness side 2P (Orange) connector [3] terminals.
  • Page 474 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 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.
  • Page 475 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 5. Rear Wheel Speed Sensor Line Open Circuit Inspection Short the wire harness side 18P (Black) connector [1] terminals with a jumper wire [2]. Connection: 6 – 15 Check for continuity between the wire harness side 2P (Black) connector [3] terminals.
  • Page 476 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 2. Motor Power Input Line Short Circuit Inspection Disconnect modulator (Black) connector (page 19-6). With the ABS MOTOR fuse (30 A) removed, check for continuity between the wire harness side 18P (Black) connector [1] and ground. Connection: 9 –...
  • Page 477 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) DTC 5-4 (Fail-safe Relay) 1. Fuse Inspection Turn the ignition switch OFF. Remove the main seat (page 2-4). Remove the fuse/relay box cover. Check the ABS FSR fuse (30 A) for blown. Is the fuse blown? –...
  • Page 478 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) DTC 6-1 or 6-2 (Power Circuit) 1. Fuse Inspection Turn the ignition switch OFF. Remove the main seat (page 2-4). Remove the fuse/relay box cover. Check the ABS MOTOR fuse (30 A) for blown. Is the fuse blown? –...
  • Page 479 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) – Power circuit is normal (intermittent failure) DTC 7-1 (Tire Size) • Check the following and correct the faulty part. – Incorrect tire pressure. – Tires not recommended for the motorcycle were installed (incorrect tire size).
  • Page 480 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 2. IMU Input Voltage Inspection Turn the ignition switch OFF. Disconnect the IMU 4P (Black) connector (page 4- 75). Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the 4P (Black) connector [1] terminals.
  • Page 481 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 3. IMU Inspection Replace the IMU with a known good one (page 4- 75). Erase the DTC (page 19-5). Test-ride the motorcycle above 30 km/h (19 mph). Recheck the DTC (page 19-5). Is the DTC 8-5 indicated? –...
  • Page 482 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) Remove the wire clips [1] and release the sensor wire from the clamps [2]. Remove the bolt [3] and wire clamp [4]. [3]/[4] Remove the following: – Bolts [1] – CBR1000RA only: Wire guide [2] –...
  • Page 483 dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) Release the sensor wire from the clamp [1] and remove the wire clips [2]. Remove the wire clips [3] from the brake hose and release the sensor wire from the clamps [4]. Remove the following: [2]/[3] –...

  • Page 484: Abs Modulator

    dummyhead dummyhead ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) ABS MODULATOR REMOVAL/INSTALLATION Drain the brake fluid from the brake hydraulic systems (page 18-5). Remove the fuel tank (page 7-8). Disconnect the ABS modulator 18P (Black) connector [1] (page 19-6). Loosen the brake pipe joint nuts [2] to disconnect the brake pipes.

  • Page 485: Battery/Charging System

    dummytext 20. BATTERY/CHARGING SYSTEM SERVICE INFORMATION ···························20-2 BATTERY ···················································· 20-6 TROUBLESHOOTING·································20-3 CHARGING SYSTEM INSPECTION ·········· 20-6 SYSTEM LOCATION···································20-5 ALTERNATOR CHARGING COIL ·············· 20-7 SYSTEM DIAGRAM ····································20-5 REGULATOR/RECTIFIER ·························· 20-8 20-1...

  • Page 486: Service Information

    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 487: Troubleshooting

    dummyhead dummyhead BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. BATTERY TEST Remove the battery (page 20-6). Check the battery condition using the recommended battery tester. Recommended battery tester: BM210 or BATTERY MATE or equivalent Is the battery in good condition? –...
  • Page 488 dummyhead dummyhead BATTERY/CHARGING SYSTEM ELECTRICAL SYSTEM DOES NOT TURNED ON WHEN THE IGNITION SWITCH IS TURNED ON OR STARTER MOTOR CANNOT BE TURNED (CBR1000S1/S2 only) 1. ELECTRICAL SYSTEM INSPECTION Remove the battery (page 20-6). Connect a fully charged 12 V battery and turn the ignition switch ON. Is the electrical system turned ON? –...

  • Page 489: System Location

    dummyhead dummyhead BATTERY/CHARGING SYSTEM SYSTEM LOCATION MAIN FUSE (30 A) REGULATOR/RECTIFIER ALTERNATOR BATTERY SYSTEM DIAGRAM MAIN FUSE (30 A) REGULATOR/RECTIFIER BATTERY ALTERNATOR G: Green R: Red Y: Yellow 20-5...

  • Page 490: Charging System Inspection

    dummyhead dummyhead BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the main seat (page 2-4). Always turn the ignition switch OFF Disconnect the negative (–) cable [1] and then the before removing the positive (+) cable [2]. battery. Remove the battery holder band [3] and battery [4]. Install the battery in the reverse order of removal.

  • Page 491: Charging Voltage Inspection

    dummyhead dummyhead BATTERY/CHARGING SYSTEM CHARGING VOLTAGE INSPECTION Be sure the battery is in good condition before performing this test. Warm the engine to normal operating temperature and stop the engine. Remove the main seat (page 2-4). Connect the multimeter between the positive terminal [1] and negative terminal [2] of the battery.

  • Page 492: System Inspection

    dummyhead dummyhead BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER SYSTEM INSPECTION Remove the regulator cover (page 2-9). Slide the connector cover [1] off the regulator/rectifier 2P (Black) connector [2] and disconnect the connector. Check the connector for loose contact or corroded terminals. Measure the voltage between the wire harness side connector and ground.

  • Page 493: Lights/Meters/Switches

    dummytext 21. LIGHTS/METERS/SWITCHES SERVICE INFORMATION ···························21-2 FUEL RESERVE SENSOR ······················· 21-16 SYSTEM LOCATION···································21-2 IGNITION SWITCH···································· 21-16 HEADLIGHT ················································21-3 HANDLEBAR SWITCHES ························ 21-17 TURN SIGNAL LIGHT/LED TURN SIGNAL BRAKE LIGHT SWITCH ··························· 21-18 RELAY (Except CH)····································21-5 CLUTCH SWITCH ····································· 21-18 TURN SIGNAL LIGHT (CH) ························21-8 NEUTRAL SWITCH ··································...
  • Page 494 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. • The following color codes are used throughout this section. Be = Beige Bl = Black Br = Brown...

  • Page 495: Yes - Go To Step

    dummyhead dummyhead LIGHTS/METERS/SWITCHES HEADLIGHT SYSTEM INSPECTION • If any LED in the headlights [1] does not turn on, replace the headlight unit (page 2-18). • The headlights are controlled by the combination meter. They are turned on after the engine is started.
  • Page 496 dummyhead dummyhead LIGHTS/METERS/SWITCHES 3. Headlight Unit Inspection Turn the ignition switch OFF. Disconnect the combination meter 32 P (Gray) connector (page 21-9). Ground the wire harness side 32 P (Gray) connector [1] with the jumper wire. TOOL: Test probe 07ZAJ-RDJA110 Connection: Black –...
  • Page 497 dummyhead dummyhead LIGHTS/METERS/SWITCHES High beam indicator does not come on with the headlight high beam on Disconnect combination meter (Gray) connector (page 21-9). Temporarily connect the headlight unit 8P (Black) connector. Turn the ignition switch ON and dimmer switch to " ".
  • Page 498 dummyhead dummyhead LIGHTS/METERS/SWITCHES Turn signal lights do not operate at all when the turn signal switch or hazard switch is operated with the ignition switch turned ON 1. LED Turn Signal Relay Ground Line Open Circuit Inspection Disconnect the LED turn signal relay 12P (Black) connector.
  • Page 499 dummyhead dummyhead LIGHTS/METERS/SWITCHES 4. Turn Signal Switch/Hazard Switch Power Input Line Open Circuit Inspection Push the hazard switch. Measure the voltage between the wire harness side 12P (Black) connector [1] and ground. Connection: Gray (+) – Ground (–) Yellow (+) – Ground (–) Is there Battery voltage? Y (+) Gr (+)

  • Page 500: Bulb Replacement

    dummyhead dummyhead LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT (CH) BULB REPLACEMENT FRONT Remove the screw [1] and turn the rearview mirror for ease removal of the front cover [2] as shown. Release the front cover tabs in the specified sequence Be careful not to as shown and remove the front cover.

  • Page 501: Combination Meter

    dummyhead dummyhead LIGHTS/METERS/SWITCHES BRAKE/TAILLIGHT INSPECTION Turn the ignition switch ON, and check the taillight operation. Check that all LED in the brake/taillight unit [1] illuminate with the front brake lever and/or rear brake pedal applied. If any LED does not turn on, replace the brake/taillight (page 21-9).
  • Page 502 dummyhead dummyhead LIGHTS/METERS/SWITCHES POWER INPUT LINE Measure the voltage between the wire harness side 32P (Gray) connector [1] and ground. TOOL: Test probe 07ZAJ-RDJA110 Connection: Blue (+) – Ground (–) There should be battery voltage with the ignition switch Bu (+) turned ON.

  • Page 503: Date & Time Setting Procedure

    dummyhead dummyhead LIGHTS/METERS/SWITCHES DISASSEMBLY/ASSEMBLY • The combination meter on this model is equipped with the automatic brightness control system. Be careful not to damage the lens [1] of the upper case [2] for the photosensor. Remove the following: – Four tapping screws [3] –...
  • Page 504 dummyhead dummyhead LIGHTS/METERS/SWITCHES SPEEDOMETER SYSTEM INSPECTION Except CBR1000RR: 1. ABS DTC Check Check the ABS DTC (page 19-5). Does the ABS modulator have any DTC? – Follow the ABS DTC index (page 19-7). – GO TO STEP 2. 2. Rear Wheel Speed Sensor Signal Input Line Open Circuit Inspection Turn the ignition switch OFF.
  • Page 505 dummyhead dummyhead LIGHTS/METERS/SWITCHES CBR1000RR: 1. Rear Wheel Speed Sensor Short Circuit Inspection Turn the ignition switch OFF. Disconnect the rear wheel speed sensor 2P (Black) connector (page 4-87). Check for continuity between the sensor side 2P (Black) connector [1] and ground. Connection: White –...
  • Page 506 dummyhead dummyhead LIGHTS/METERS/SWITCHES TACHOMETER SYSTEM INSPECTION If the tachometer does not operate properly, check that the ECM stores the DTC 19-1, DTC 103-1 or DTC 103- 2 (page 4-7). If the ECM stores DTC, follow the DTC troubleshooting (page 4-10). If the ECM does not store DTC, replace the meter assembly (page 21-11).

  • Page 507: Engine Oil Pressure Indicator/ Eop Switch

    dummyhead dummyhead LIGHTS/METERS/SWITCHES ENGINE OIL PRESSURE INDICATOR/ EOP SWITCH INSPECTION • The oil pressure indicator should come on when the ignition switch is turned ON and go off when the engine is started. Engine oil pressure indicator does not come on when the ignition switch is turned ON Remove the EOP switch wire terminal (page 21-15).

  • Page 508: Fuel Reserve Sensor

    dummyhead dummyhead LIGHTS/METERS/SWITCHES FUEL RESERVE SENSOR INSPECTION • When the fuel level in the fuel tank is low, the low fuel indicator comes on and information display [1] appears. Turn the ignition switch ON and check the low fuel indicator. If the indicator is blinking, check the following: –...

  • Page 509: Handlebar Switches

    dummyhead dummyhead LIGHTS/METERS/SWITCHES Disconnect immobilizer receiver (Black) connector [1], and remove the wire band [2] and wire clip [3]. Remove the mounting bolts [1] and ignition switch [2]. • Use a drill or an equivalent tool when removing the mounting bolts. Install the ignition switch and new mounting bolt onto the top bridge, and tighten bolts to the specified torque.
  • Page 510 dummyhead dummyhead LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH FRONT Disconnect the wire connectors [1] from the front brake light switch and check for continuity between the switch terminals. There should be continuity with the brake lever squeezed, and there should be no continuity with the brake lever is released.

  • Page 511: Neutral Switch

    dummyhead dummyhead LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Disconnect the wire connectors [1] from the clutch switch. Remove the mounting screw [2] and clutch switch [3] while squeezing the clutch lever. Squeeze the clutch lever and install the clutch switch by aligning the lug with the groove in the bracket. Install a new mounting screw and tighten it to the specified torque.

  • Page 512: Sidestand Switch

    dummyhead dummyhead LIGHTS/METERS/SWITCHES SIDESTAND SWITCH INSPECTION Remove the left middle cowl (page 2-13). Remove the sidestand switch 2P (Black) connector [1] from the stay and disconnect it. Check for continuity between the switch side 2P (Black) connector terminals. Continuity should exist only when the sidestand is retracted.

  • Page 513: Control Relay

    dummyhead dummyhead LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Disconnect the horn wire connectors (page 21-20). Remove the mounting bolt [1] and horn [2]. Installation is in the reverse order of removal. Route the wire properly (page 1- 23). • Align the edges of the horn stay and steering stem properly.
  • Page 514 dummyhead dummyhead LIGHTS/METERS/SWITCHES RELAY INSPECTION Remove the relay (page 21-21). Connect an ohmmeter to the relay [1] terminals as shown. Connect a 12 V battery [2] to the relay terminals as shown. There should be continuity only when the 12 V battery is connected.
  • Page 515 dummyhead dummyhead LIGHTS/METERS/SWITCHES HEADLIGHT RELAY (CH only) For relay inspection (page 21-22). SYSTEM INSPECTION • Check the following before troubleshooting: – HEADLIGHT fuse (10 A) – Headlight switch 1. Headlight Relay Coil Ground Line Open Circuit Inspection Disconnect the headlight relay 4P connector [1]. Check for continuity between the wire harness side 4P connector [1] and ground Connection: Green –...

  • Page 516: Self-Diagnosis System

    dummyhead dummyhead LIGHTS/METERS/SWITCHES ELECTRIC SUSPENSION SYSTEM (CBR1000S1/S2 only) SELF-DIAGNOSIS SYSTEM The electric suspension system is equipped with the self-diagnosis system. When any abnormality occurs in the system, the SCU displays the electric suspension system failure information [1] on the combination meter and stores a DTC in its erasable memory.
  • Page 517 dummyhead dummyhead LIGHTS/METERS/SWITCHES DTC INDEX Refer Causes Symptoms • SCU power input circuit voltage too low • Electric suspension 21-26 system does not function • SCU power input circuit too high • Electric suspension 21-26 system does not function CAN communication malfunction •...
  • Page 518 dummyhead dummyhead LIGHTS/METERS/SWITCHES SCU POWER/GROUND LINE INSPECTION • If the suspension setting indicator (S) [1] blinks "–", check the SCU power/ground lines. • Check that the ABS MAIN fuse (10 A) is in good condition before inspection. Disconnect the SCU 34P (Black) connector (page 21- 36).
  • Page 519 dummyhead dummyhead LIGHTS/METERS/SWITCHES 2. DTC Recheck Read the DTC (page 21-24). Is the DTC S1 or S2 indicated? – GO TO STEP 3. – Follow the DTC index (page 21-25). 3. Charging System Inspection Perform the charging system troubleshooting (page 20-3).
  • Page 520 dummyhead dummyhead LIGHTS/METERS/SWITCHES DTC S4 or S7 (CAN COMMUNICATION MALFUNCTION TO SCU FROM ECM) • Before starting the troubleshooting, check for loose or poor contact on the SCU 34P (Black) connector. • Make sure that the MIL does not light with the ignition switch ON.
  • Page 521 dummyhead dummyhead LIGHTS/METERS/SWITCHES 2. DTC Recheck Read the DTC (page 21-24). Is the DTC S5 or S8 indicated? – GO TO STEP 3. – Follow the DTC index (page 21-25). 3. SCU-to-ABS Control Unit CAN Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the following: –...
  • Page 522 dummyhead dummyhead LIGHTS/METERS/SWITCHES DTC S11, S12, S13 or S14 (DAMPING ADJUSTER DRIVER CIRCUIT TEMPERATURE TOO HIGH) 1. Failure Information Recheck Turn the ignition switch OFF and cool the SCU. Turn the ignition switch ON and check that the electric suspension system failure information is displayed (page 21-24).
  • Page 523 dummyhead dummyhead LIGHTS/METERS/SWITCHES DTC S30 (FORK COMPRESSION DAMPING ADJUSTER MALFUNCTION) • Before starting the troubleshooting, check for loose or poor contact on the SCU 34P (Black) connector and fork compression damping adjuster 4P (Black) connector. 1. Failure Information Recheck Turn the ignition switch OFF. Turn the ignition switch ON and check that the electric suspension system failure information is displayed (page 21-24).
  • Page 524 dummyhead dummyhead LIGHTS/METERS/SWITCHES 4. Fork Compression Damping Adjuster Line Short Circuit Inspection Check for continuity between the wire harness side 4P (Black) connector [1] and ground Connection: Blue/red – Ground Blue – Ground Bu/R Blue/black – Ground Blue/white – Ground Bu/Bl Bu/W Are there continuity?
  • Page 525 dummyhead dummyhead LIGHTS/METERS/SWITCHES 3. Fork Rebound Damping Adjuster Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the following: – SCU 34P (Black) connector (page 21-36) – Fork rebound damping adjuster 4P (Gray) Br/Bu 6 (Br/Bu) connector (right side) (page 3-25) Br/R 15 (Br/R) Check for continuity between the wire harness side...
  • Page 526 dummyhead dummyhead LIGHTS/METERS/SWITCHES 2. DTC Recheck Read the DTC (page 21-24). Is the DTC S32 indicated? – GO TO STEP 3. – Follow the DTC index (page 21-25). 3. Shock Absorber Compression Damping Adjuster Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the following: –...
  • Page 527 dummyhead dummyhead LIGHTS/METERS/SWITCHES DTC S33 (SHOCK ABSORBER REBOUND DAMPING ADJUSTER MALFUNCTION) • Before starting the troubleshooting, check for loose or poor contact on the SCU 34P (Black) connector, sub-wire harness 4P (Gray) connector and shock absorber rebound damping adjuster 4P (Gray) connector.
  • Page 528 dummyhead dummyhead LIGHTS/METERS/SWITCHES 4. Shock Absorber Rebound Damping Adjuster Line Short Circuit Inspection Check for continuity between the sub-wire harness side 4P (Gray) connector [1] and ground Connection: Black/green – Ground Black/blue – Ground Bl/Bu Bl/G Black – Ground Black/yellow – Ground Bl/Y Are there continuity? –...

  • Page 529: Immobilizer System (Hiss)

    dummytext 22. IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION ···························22-2 TROUBLESHOOTING ································ 22-7 SYSTEM LOCATION···································22-2 HISS INDICATOR ······································· 22-9 SYSTEM DIAGRAM ····································22-3 ECM ····························································· 22-9 KEY REGISTRATION PROCEDURES ·······22-3 IMMOBILIZER RECEIVER·························· 22-9 DIAGNOSTIC CODE INDICATION ·············22-6 22-1...

  • Page 530: 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 22-7). • 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 531: System Diagram

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) SYSTEM DIAGRAM CLOCK/TURN FUSE (10 A) MAIN FUSE (30 A) FI/IGN/START FUSE (10 A) R/Bl FI FUSE (15 A) IGNITION MAIN RELAY SWITCH BATTERY Bl: Black Br: Brown IMMOBILIZER Bu: Blue RECEIVER G: Green Gr: Gray Lg: Light green O/Bu O: Orange...
  • Page 532 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) • The new key or spare key is registered in the ECM. • If there is any problem in the registration, the system will enter the diagnostic mode and the indicator will remain on for approx. ten seconds, then it will indicate the diagnostic code (page 22-7).
  • Page 533 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 16.Turn the ignition switch ON with a second new key. (Never use the key registered in previous step.) The indicator comes on for two seconds, then it blinks four times repeatedly. • The second key or spare key is registered in the ECM. •...

  • Page 534: Diagnostic Code Indication

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) DIAGNOSTIC CODE INDICATION KO only: Remove the EVAP canister (page 7-22). Disconnect the CKP sensor 2P (Red) connector [1]. Connect the special tools to the wire harness side 2P (Red) connector [1]. TOOLS: Inspection adaptor [2] 07XMZ-MBW0101 Adaptor, test harness [3] 070MZ-MEC0101...

  • Page 535: Blinking Pattern

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) When the system (ECM) enters the diagnostic mode from the registration mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE Registration is The key is Use a new key or overlapped. already cancelled key. registered properly. Code signals Communication Follow the cannot send or...
  • Page 536 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) 2. First Transponder Key Inspection Turn the ignition switch ON with the spare transponder key and check the HISS indicator. The indicator should come on for 2 seconds then go off. Does the indicator go off? –...

  • Page 537: Hiss Indicator

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) HISS INDICATOR POWER INPUT LINE INSPECTION Inspect the combination meter power/ground line (page 21-9) HISS INDICATOR LINE INSPECTION Check that the ECM stores the DTC 103-2 (page 4-7). If the ECM stores DTC, follow the DTC troubleshooting (page 4-10).

  • Page 538: Signal Line Inspection

    dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) GROUND LINE INSPECTION Check for continuity between the wire harness side 4P (Black) connector [1] and ground. Connection: Gray – Ground There should be continuity at all times. Gray SIGNAL LINE INSPECTION Turn the ignition switch ON and engine stop switch " ". Measure the voltage between the wire harness side 4P (Black) connector [1] and ground.
  • Page 539 dummyhead dummyhead IMMOBILIZER SYSTEM (HISS) REMOVAL/INSTALLATION Lift and support the fuel tank (page 3-4). Disconnect immobilizer receiver (Black) connector [1], and remove the wire band [2] and wire clip [3]. Remove the mounting screws [1] and immobilizer receiver [2]. Installation is in the reverse order of removal. Route the immobilizer receiver wire properly (page...
  • Page 540 dummyhead dummyhead MEMO...

  • Page 541: Wiring Diagram

    dummytext 23. WIRING DIAGRAM WIRING DIAGRAM······································23-2 23-1...
  • Page 542 dummytext WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM FRONT REAR SENSOR EGCA PRIMARY INJECTORS SECONDARY INJECTORS (ABS) WHEEL WHEEL (SP only) (SP only) TP SENSOR FUEL ABS MODULATOR FUEL LEVEL SPEED SPEED SHOCK PUMP SENSOR SENSOR SENSOR ABSORBER UNIT COMPRESSION VS SENSOR DAMPING CAN Lo CAN Hi...
  • Page 543 dummytext MEMO...

  • Page 544: Index

    INDEX dummytext INDEX ABS INDICATOR CIRCUIT TROUBLESHOOTING ·····19-9 ABS MODULATOR ·····················································19-24 IMMOBILIZER SYSTEM (HISS) ······························ 22-9 ABS TROUBLESHOOTING INFORMATION················19-4 PGM-FI SYSTEM····················································· 4-73 AIR CLEANER ································································3-5 ECT SENSOR AIR CLEANER HOUSING ············································7-10 LIGHTS/METERS/SWITCHES ······························ 21-14 ALTERNATOR CHARGING COIL ································20-7 PGM-FI SYSTEM····················································· 4-82 ALTERNATOR COVER REMOVAL EGCA ···········································································...
  • Page 545 dummytext INDEX NUTS, BOLTS, FASTENERS ······································ 3-28 SINGLE SEAT COWL (CBR1000S1/S2)························ 2-5 SENSOR ································································· 4-84 SPARK PLUG ································································· 3-6 OIL COOLER·································································· 9-7 SPECIAL TOOL LIST ··················································· 1-21 OIL PRESSURE INSPECTION ······································ 9-4 SPECIFICATIONS ·························································· 1-5 OIL PUMP ······································································ 9-4 SPEEDOMETER/VS SENSOR ·································· 21-12 PGM-FI SYMPTOM TROUBLESHOOTING···················...
  • Page 546 Honda Motor Co., Ltd. 2016 Published by Honda Motor Co., Ltd. Book number : 62MKF00 Printed in Japan 2016.12.H...

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