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Honda CB300F, Service Manual

The Honda CB300F Service Manual is available for download for free on manualshive.com. This comprehensive manual provides detailed instructions and information on maintaining and servicing your Honda CB300F motorcycle. Download the manual today to ensure your motorcycle stays in top condition for years to come.

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Summary of Contents for CB300F

Page 1: ......

Page 2: ...in each section according to the malfunction or sympton In case of an each trouble refer to PGM FI section troubleshooting first Your safety and the safety of others is very important To help you mak...

Page 3: ...ent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mits...

Page 4: ...t t CYLINDER HEADNALVES w t CYLINDER PISTON c t w CLUTCH GEARSHIFT LINKAGE z t ALTERNATOR STARTER CLUTCH z t w CRANKCASE CRANKSHAFT TRANSMISSION BALANCER ENGINE REMOVAL INSTALLATION FRONT WHEEL SUSPEN...

Page 5: ...MEMO j...

Page 6: ...1 GENERAL INFORMATION _ SERVICE RULES 1 2 LUBRICATION SEAL POINTS 1 17 MODEL IDENTIFICATION 1 3 CABLE HARNESS ROUTING 1 19 SPECIFICATIONS 1 6 EMISSION CONTROL SYSTEMS 1 40 TORQUE VALUES 1 12 1 1...

Page 7: ...d Harness Routing page 1 19 9 Do not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bind ABBREVIATION Throughout this manual the following abbreviations...

Page 8: ...300RA shown CB300FA shown This manual covers following models CBR300R Conventional Brake CBR300RA ABS CB300F Conventional Brake CB300FA ABS Be sure to refer to the procedure for the appropriate model...

Page 9: ...The throttle body identification number 1 is stamped on the lower left side of the throttle body LABEL The Safety Certicication Label 1 is located on left side of the frame The color label 1 is attac...

Page 10: ...GENERAL INFORMATION The Emission Control Information Label 1 is attached on the rear fender U S A Canada type 1 Canada type only 2 1 5...

Page 11: ...120mm 44 1 in CB300F FA 1 045mm 41 1 in 1 380 mm 54 3 in 785 mm 30 9 in 333 mm 13 1 in CBR300R RA 145 mm 5 7 in CB300F FA 150 mm 5 9 in CBR300R 162 kg 357 lbs CBR300RA 165 kg 364 lbs CB300F 158 kg 348...

Page 12: ...pe only IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATION Spark plug SIMR8A9 NGK Spark plug gap 0 8 0 9 mm 0 031 0 035 in Ignition coil peak voltage 100 V minimum CKP sensor peak voltage 0 7 V minimum...

Page 13: ...IN EX 0 90 1 10 0 035 0 043 1 50 0 059 Valve spring Free length Inner 35 24 1 387 33 61 1 323 Outer 39 85 1 569 37 85 1 488 Rocker arm Arm 1 0 IN EX 10 000 10 015 0 3937 0 3943 10 10 0 398 rocker arm...

Page 14: ...0 909 C2 25 000 25 021 0 9843 0 9851 25 04 0 986 C3 C4 28 000 28 021 1 1024 1 1032 28 04 1 104 Bushing 0 0 M5 M6 22 959 22 980 0 9039 0 9047 22 91 0 902 C1 22 984 23 005 0 9049 0 9057 22 47 0 885 C2 2...

Page 15: ...Size link I DID DID520VF 1 OSLE I RK RK520KL0 1 OSLE Slack 20 30 O S 1 2 HYDRAULIC BRAKE SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT4 Brake pad wear indicator...

Page 16: ...n 1 rpm Charging coil resistance 20 C 68 F 0 1 1 0 0 LIGHTS METERS SWITCHES SPECIFICATIONS ITEM SPECIFICATION Bulbs Headlight I CBR300R RA 12 v 55 w x 2 I CB300F FA 12 v 60 55 w Brake tail light 12V 2...

Page 17: ...2 3 17 Pillion step bolt 4 8 27 2 8 20 Exhaust pipe joint nut 2 8 18 1 8 13 Exhaust pipe stud bolt 2 8 Front reflector mounting nut 1 6 1 5 0 2 1 1 MAINTENANCE ITEM Q TY THREAD TORQUE DIA mm N m kgf m...

Page 18: ...5 3 4 0 3 2 5 Injector joint mounting bolt 2 5 5 1 0 5 3 8 Fuel pump setting plate nut 6 6 12 1 2 9 See page 7 9 Air cleaner cover screw 10 5 1 1 0 1 0 8 PAIR check valve cover bolt 2 5 5 2 0 5 3 8 Th...

Page 19: ...REMARKS DIA mm N m kgf m lbf ft Starter clutch socket bolt 6 8 30 3 1 22 Apply locking agent to the threads Flywheel bolt 1 12 128 13 0 94 Apply engine oil to the threads and seating surface Stator m...

Page 20: ...2 3 3 24 Brake hose mounting bolt 1 6 10 1 0 7 Apply locking agent to the ABS type only threads Clutch lever pivot bolt 1 6 1 0 0 1 0 7 Apply molybdenum disulfide grease to the sliding surface Front b...

Page 21: ...aster cylinder mounting bolt 2 6 12 1 2 9 Rear master cylinder push rod lock nut 1 8 17 1 7 13 Rear master cylinder hose joint screw 1 4 1 5 0 2 1 1 Apply locking agent to the threads Rear reservoir m...

Page 22: ...e countershaft water pump Molybdenum oil solution a Valve stem sliding surface mixture of 1 2 engine oil and Camshaft lobes and journal 1 2 molybdenum disulfide Rocker arm shaft outer surface grease R...

Page 23: ...ing sliding area Brake pedal pivot sliding area Each dust seal lips Each 0 ring Silicone grease Brake pad hunger pin 0 ring Brake caliper and bracket pins sliding surface 0 4 g 0 01 oz minimum Brake c...

Page 24: ...CABLES 1 RIGHT l HANDLE E 7 SWITCH THROTTLE CABLES FRONT BRAKE HOSE CLUTCH CABLE GENERAL INFORMATION CLUTCH SWITCH WIRE BAND ENDS SHALL NOT PROTRUDE BEYOND TOP BRIDGE IGNITION SWITCH WIRE FRONTWHEEL...

Page 25: ...GENERAL INFORMATION CBR300R RIGHT HANDLEBAR SWITCH WIRE 200 L 1 20 FRONT BRAKE HOSE CLUTCH CABLE BAND ENDS SHALL NOT PROTRUDE BEYOND TOP BRIDGE IGNITION SWITCH WIRE...

Page 26: ...SWITCH 9P BROWN CONNECTOR TO BE RUSHED AGAINST THE STOPPER GENERAL INFORMATION FRONT BRAKE LIGHT SWITCH WIRES LEFT HANDLEBAR SWITCH 9P BLACK 1 AND 3P BLACK CONNECTORS UP goo t FRONT WHEEL SPEED SENSO...

Page 27: ...URN SIGNAL LIGHT WIRE RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH 9P BROWN CONNECTOR CB300F FA LEFT HANDLEBAR SWITCH WIRE CLUTCH CABLE FRONT i 1 22 MAIN WIRE HARNESS FRONT BRAKE LIGHT SWITCH WI...

Page 28: ...FRONT SUB HARNESS 9P BLACK CONNECTOR LEFT TURN SIGNAL LIGHT WIRE CBR300R RA MAIN WIRE HARNESS COMBINATION METER 20P CONNECTOR HEADLIGHT 2P CONNECTORS CLUTCH CABLE TURN SIGNAL LIGHT WIRE GENERAL INFORM...

Page 29: ...L INFORMATION GENERA AC type PURGE CONTROL SOLENOID VALVE HOSE AIR TUBE ECM 33P BLACK CONNECTOR ROUND POINT 0 2SENSOR G 1 24 FUEL TANK BREATHER TUBE RIGHT SIPHON HOSE CLUTCH CABLE El RIGHT...

Page 30: ...t e Except AC YP ECM 33P BLACK CONNECTOR FUEL TANK E BREATHER TUB GROUND POINT 02SENSOR t RIGHT GENERAL INFORMATION THROTTLE CABLES SIPHON HOSE JJB t RIGHT 1 1 25...

Page 31: ...CH WIRE FRONT BRAKE HOSE LEFT HANDLEBAR SWITCH WIRE MAIN WIRE HARNESS TURN SIGNAL RELAY FAN CONTROL RELAY t 0 FRONT SPEED SENSOR 2P BLUE CONNECTOR ECT SENSOR 3P CONNECTOR MAIN WIRE HARNESS TURN SIGNAL...

Page 32: ...TCH WIRE SIPHON HOSE CLUTCH CABLE GENERAL INFORMATION FUEL PUMP RELAY FRONT BRAKE PIPES MAIN WIRE HARNESS PAIR CONTROL SOLENID VALVE FAN MOTOR 2P BLACK CONNECTOR FRONT BRAKE HOSE TO ABS MODULATOR FRON...

Page 33: ...GENERAL INFORMATION CB300FA CB300F 1 28 RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE TO ABS MODULATOR RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE...

Page 34: ...CB300F FA GENERAL INFORMATION LEFT HANDLEBAR SWITCH WIRE CLUTCH CABLE IGNITION SWITCH WIRE 1 29...

Page 35: ...AR SWITCH WIRE IGNITION SWIRCH WIRE BANK ANGLE SENSOR FUEL TANK DRAIN TUBE FUEL PUMP 5P CONNECTOR RIGHT HANDLEBAR SWITCH 9P BROWN CONNECTOR 1 30 PAIR CONTROL SOLENID VALVE 2P CONNECTOR IGNITION SWITCH...

Page 36: ...IRE LEFT HANDLEBAR SWITCH WIRE IGNITION SWIRCH WIRE FUEL TANK DRAIN TUBE PAIR CONTROL SOLENID VALVE 2P CONNECTOR BANK ANGLE SENSOR FUEL PUMP 5P CONNECTOR GENERAL INFORMATION RIGHT HANDLEBAR SWITCH 9P...

Page 37: ...ORMATION CB300FA TURN SIGNAL RELAY WIRE FUEL PUMP WIRE 1 32 IGNITION SWITCH 3P BLACK CONNECTOR CLUTCH CABLE FRONT BRAKE HOSE PUSH TO IGNITION STAY IGNITION SWITCH WIRE FRONT BRAKE PIPE FROM FRONT MAST...

Page 38: ...ELAY FUEL PUMP RELAY WIRE TURN SIGNAL RELAY WIRE FUEL PUMP WIRE IGNITION SWITCH 3P BLACK CONNECT R CLUTCH CABLE GENERAL INFORMATION SIPHON HOSE I I I I I I I I I I I I I I I I I THROTILE CABLES IGNITI...

Page 39: ...REAR SPEED SENSOR 2P ORANGE CONNECTOR REAR BRAKE RESERVOIR REAR BRAKE HOSE REAR BRAKE HOSE REAR SPEED SENSOR WIRE 1 34 REAR STOP SWITCH WIRES REAR BRAKE LIGHT SWITCH 0 2SENSOR GROUND POINT ECM 33P BLA...

Page 40: ...without ABS type REAR BRAKE RESERVOIR REAR BRAKE HOSE TO BRAKE CALIPER REAR STOP SWITCH WIRES 0 2SENSOR GROUND POINT GENERAL INFORMATION ECM 33P BLACK CONNECTOR SIPHON HOSE 1 35...

Page 41: ...TUBE AIR CLEANER DRAIN TUBE MAIN WIRE HARNESS GROUND TERMINALS FUEL TANK DRAIN TUBE MAIN WIRE HARNESS FUEL TANK DRAIN TUBE 1 36 FUEL TANK BREATHER TUBE FUEL FEED HOSE AIR CLEANER DRAIN TUBE SIDESTAND...

Page 42: ...ANISTOR DRAIN TUBE FUEL TANK DRAIN TUBE Back side of crankcase view FUEL TANK DRAIN TUBE AIR CLEANER DRAIN TUBE GENERAL INFORMATION AIR CLEANER DRAIN TUBE SIPHON HOSE OVER FLOW HOSE 0 2SENSOR EARTH WI...

Page 43: ...DER REAR BRAKE PIPE TO REAR BRAKE CALIPER IACV 4P BLACK CONNECTOR 1 38 ABS MODULATOR REAR SPEED SENSOR WIRE REAR BRAKE HOSE REAR SPEED SENSOR WIRE REAR BRAKE HOSE FRONT BRAKE PIPE FROM FRONT MASTER CY...

Page 44: ...GENERAL INFORMATION REAR LIGHT CONNECTORS LICENSE LIGHT WIRE MAIN WIRE HARNESS BATTERY POSITIVE CABLE STARTER MOTERA WIRE 1 39...

Page 45: ...Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect SOURCE OF EMISSIONS The combustion process produces carbon monoxide CO oxides of nitrogen NOx...

Page 46: ...he PAIR control valve is operated by the solenoid valve The solenoid valve is controlled by the PGM FI unit and the fresh air passage is opened closed according to running condition ECT IAT TP MAP sen...

Page 47: ...of 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any vehicle for the purpose of...

Page 48: ...14 REMOVAL CHART 2 3 FRONT FENDER 2 16 PASSENGER SEAT 2 5 DRIVE SPROCKET COVER 2 16 SINGLE SEAT 2 5 DRIVE CHAIN COVER 2 16 GRAB RAIL 2 6 REAR UNDER COVER 2 17 REARVIEW MIRROR 2 6 REAR COWL 2 18 MIDDLE...

Page 49: ...the exhaust pipe gasket with new ones after removing the exhaust pipe from the engine When installing the exhaust system loosely install all of the exhaust pipe fasteners Always tighten the exhaust pi...

Page 50: ...ront Fender page 2 16 14 Under Cowl page 2 14 This chart shows removal order of frame covers by means of arrow 18 Rear Under Cover 1 1 Rear Fender A 1 Passenger Seat 9 Grab Rail 2 Single Seat 3 Side C...

Page 51: ...Cowl page 2 15 13 Drive Sprocket Cover page 2 16 14 Drive Chain Cover page 2 16 This chart shows removal order of frame covers by means of arrow 16 Rear Under Cover 9 Rear Fender A 1 Passenger Seat 7...

Page 52: ...ary Install the passenger seat by inserting the hooks 3 into the seat retainers 4 Push the passenger seat down to lock it SINGLE SEAT REMOVAL INSTALLATION Remove the passenger seat page 2 5 Remove the...

Page 53: ...BR300R RA 2 6 Remove the mounting socket bolts 1 and rearview mirror 2 Install the rearview mirror and mounting socket bolts Tighten the mounting socket bolts to the specified torque _ TORQUE 5 2 N m...

Page 54: ...im clips pin head 1 and the socket bolts 2 Remove the middle cowl 3 by releasing its snap fit clips 4 and tabs 5 NOTE Be careful not to damage the snap fit clips and slits Disconnect the turn signal l...

Page 55: ...t turn signal light mounting nut 1 and turn signal light 2 from the middle cowl 3 Remove the screws 4 wire clamp 5 and middle panel 6 from the middle cowl Assembly is in the reverse order of disassemb...

Page 56: ...7 Remove the socket bolt 1 Release the bosses 2 and rib 3 _ Remove the side cover 4 CB300F FA Remove the single seat page 2 5 Remove the five socket bolts 1 Release the bosses 2 and rib 3 Remove the...

Page 57: ...over in the reverse order of removal CB300F FA Remove the side covers page 2 9 Remove the socket bolts 1 Remove the fuel tank cover 2 by releasing its bosses 3 from the fuel tank grommets Install the...

Page 58: ...Remove the upper cowl 3 by releasing its bosses 4 from the frame grommets 5 Disconnect the front sub harness 9P Black connector 6 Install the upper cowl in the reverse order of removal CB300F FA Remov...

Page 59: ...bolt 5 washers 6 and windscreen 7 Assembly is in the reverse order of disassembly CB300F FA Remove the four screws 1 and head light unit 2 Remove the nuts 3 plates 4 and righUleft turn signal lights...

Page 60: ...from the frame grommets 4 Install the meter panel in the reverse order of removal METER PANEL STAY CB300F FA REMOVAL INSTALLATION Remove the upper cowl page 2 11 Remove the clips 1 and bolt 2 Remove...

Page 61: ...e t II the meter pane Ins a LS EXHAUST SYSTEM removal UNDER COWL AL INSTALLATION REMOV CBR300R RA e 2 7 ve the middle cowls pag d under cowl 2 by Remo b Its 1 an 3 e the socket o frame bosses Remov 1...

Page 62: ...R RA Remove the socket bolt 1 and separate the right and left under cowls 2 Assembly is in the reverse order of disassembly NOTE Assemble the right and left under cowls by aligning its tabs with the s...

Page 63: ...Install the front fender in the reverse order of removal TORQUE Front reflector mounting nut 1 5 N m 0 2 kgf m 1 1 lbMt DRIVE SPROCKET COVER REMOVAL INSTALLATION Remove the bolts 1 and drive sprocket...

Page 64: ...FRAME BODY PANELS EXHAUST SYSTEM REAR UNDER COVER REMOVAL INSTALLATION Remove the trim clips 1 and rear under cover 2 Install the rear under cover in the reverse order of removal 2 2 17...

Page 65: ...age 2 6 Rear under cover page 2 17 Disconnect the seat lock cable 1 Disconnect the brake tail light 2P connector 2 and tail light connector 3 Remove the trim clips 4 bolts 5 and collars 6 Release tabs...

Page 66: ...brake tail light assembly 5 and rear center lower cowl 6 Remove the clip 7 cable guide 8 and seat lock 9 Remove the screws 1 OJ and rear cover from the rear cowl 11 Assembly is in the reverse order o...

Page 67: ...page 2 17 Disconnect the license light connectors 1 Remove the rear turn signal lights page 21 5 Remove the number plate bracket nuts 1 collars 2 bolts 3 and number plate bracket assembly 4 Remove the...

Page 68: ...lector mounting nut 4 and reflector 5 Remove the license light mounting nuts 6 collars 7 rubber 8 and license light Remove the nuts 9 and side reflectors 1 O Remove the hole plug 11 Assemble is in the...

Page 69: ...r housing page 7 11 Battery page 20 5 Release the fuse box 1 1 and starter relay switch 2 from the rear fender B 3 ABS type Release the fuse box 2 4 from the rear fender B 2 22 Release the clips 5 fro...

Page 70: ...washer bolt and nut and loosely tighten it Tighten the muffler band bolt first then tighten the mounting nut to the specified torque TORQUE Muffler band bolt 22 5 N m 2 3 kgf m 17 lbHt NOTE If the bo...

Page 71: ...haust pipe flanges onto the stud bolts and screw all the fasteners in fully Tighten the joint nuts first to the specified torque then tighten the mounting bolt TORQUE Exhaust pipe joint nut 18 N m 1 8...

Page 72: ...E IDLE SPEED 3 12 RADIATOR COOLANT 3 12 COOLING SYSTEM 3 13 SECONDARY AIR SUPPLY SYSTEM 3 13 3 MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM AC type only 3 14 DRIVE CHAIN 3 14 BRAKE FLUID 3 17 BRAKE...

Page 73: ...allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may...

Page 74: ...ARY AIR SUPPLY SYSTEM NOTE 4 I I I EVAPORATIVE EMISSION CONTROL SYSTEM AC type only I I Cf IDRIVE CHAIN EVERY 500 mi 800 Km I L BRAKE FLUID NOTE 5 I I R I I R w t BRAKE PADS WEAR I I I I I I 0 BRAKE S...

Page 75: ...ary page 7 8 THROTTLE OPERATION 3 4 Check for any deterioration or damage to the throttle cable Check the throttle grip for smooth operation Check that the throttle opens and automatically closes in a...

Page 76: ...ock nut to the specified torque while holding the adjuster TORQUE 3 0 N m 0 3 kgf m 2 2 lbMt Recheck the throttle operation Install the right side cover page 2 9 AIR CLEANER REMOVAL INSTALLATION Remov...

Page 77: ...ain hose and drain the deposits into a suitable container Reinstall the drain plug securely SPARK PLUG REMOVAL INSTALLATION Clean around the spark plug base with compressed air before removing the spa...

Page 78: ...eplace the plug if the center electrode 1 is rounded specified spark as shown in the illustration plugs on this motorcycle SPECIFIED SPARK PLUG To prevent damaging the iridium center electrode use a w...

Page 79: ...ench 3 07709 0010001 Rotate the crankshaft counterclockwise and align the T mark 4 on the flywheel with the index notch 5 on the left crankcase cover Make sure that the outside index lines IN 1 and EX...

Page 80: ...equation available from the below thinnest 1 200 mm thickness shim to the thickest 2 900 mm thickness shim in increments of 0 025mm A B C D A New shim thickness B Recorded valve clearance C Specified...

Page 81: ...sition Start the engine and let it idle for 3 5 minutes Stop the engine and wait 2 3 minutes Check the oil level through the inspection window If the level is below the lower level line 1 remove the o...

Page 82: ...US qt 1 2 Imp qt at draining 1 5 liters 1 6 US qt 1 3 Imp qt at oil filter change 1 8 liters 1 9 US qt 1 6 Imp qt at disassembly Install the oil filler cap 1 Check the oil level page 3 10 Make sure th...

Page 83: ...dle speed adjustment compared to previous designs Turn the ignition switch ON and engine stop switch O Start the engine and let it idle Check the idle speed IDLE SPEED 1 400 100 rpm If the idle speed...

Page 84: ...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 Inspect the water hoses for cracks or...

Page 85: ...es are not kinked pinched or cracked Check the hoses between the fuel tank intake manifold EVAP canister 1 EVAP purge control solenoid valve 2 for deterioration damage or loose connections Check the E...

Page 86: ...ON Clean the drive chain 1 with a chain cleaner designed specifically for 0 ring chains or a neutral detergent Use a soft brush if the drive chain is dirty NOTICE Do not use a steam cleaner high press...

Page 87: ...procket nut 2 75 N m 7 6 kgf m 55 lbf ft Install the drive sprocket cover page 2 16 REPLACEMENT This motorcycle uses a drive chain with a staked master link Loosen the drive chain page 3 15 1 2 When u...

Page 88: ...0 228 in RK 5 25 5 65 mm 0 207 0 222 in A drive chain with a After staking check the staked area of the master link clip type master link for cracks must not be used If there is any cracking replace t...

Page 89: ...KE Support the motorcycle on a level surface and check the rear brake fluid level Check the brake fluid level If the level is near the LOWER level line 1 fill the recommended brake fluid Remove the fo...

Page 90: ...isc pressure 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 If the lever or pedal feels soft or spongy w...

Page 91: ...ically by turning the vertical aim as specified by beam adjusting screw 1 local laws and A clockwise rotation moves the beam up and regulations counterclockwise rotation moves the beam down Adjust the...

Page 92: ...clutch lever Loosen the lock nut 1 and turn the adjuster 2 If the adjuster is threaded out near its limit and the correct freeplay cannot be obtained turn the adjuster all the way in and back out one...

Page 93: ...e should stop as the sidestand is lowered If there is a problem with the system check the sidestand switch page 21 22 REMOVAL INSTALLATION Support the motorcycle upright on a level surface Remove the...

Page 94: ...ssis nuts screws and bolts are tightened to their correct torque values page 1 12 Check that all cotter pins safety clips hose clamps and cable stays are in place and properly secured WHEELS TIRES Sup...

Page 95: ...MEMO...

Page 96: ...4 4 PGM FI TROUBLESHOOTING INFORMATION 4 6 PGM FI SYMPTOM TROUBLESHOOTING 4 9 OTC INDEX 4 10 4 PGM FI SYSTEM SENSOR UNIT POWER LINE INSPECTION 4 11 OTC TROUBLESHOOTING 4 12 MIL CIRCUIT TROUBLESHOOTING...

Page 97: ...tion carefully page 4 6 and inspect and troubleshoot according to the OTC A faulty PGM FI system is often related to poorly connected or corroded connectors Check those connections before proceeding U...

Page 98: ...PGM FI SYSTEM LOCATION CBR300RA shown ENGINE STOP SWITCH IGNITION SWITCH SENSOR UNIT MAP SENSOR IAT SENSOR TP SENSOR 0 2SENSOR FUEL PUMP CKP SENSOR PGM FI SYSTEM DLC 4 3...

Page 99: ...ER RELAY SWITCH G R 12 23 RN 81 R FAN FUSE 10 A 81 W IGNITION SWITCH ENGINE STOP SWITCH RN 81 R Fl IGN FUSE 10 A 81 Bu 8 1 G METER TAIL ____ FU fS E 10A 81 81 8 G 81 R FUEL PUMP UNIT FUEL PUMP RELAY 2...

Page 100: ...W RELAY SWITCH G R 12 23 ECM 33P BLACK CONNECTOR ECM srde of the male terminals PGM FI SYSTEM 8 F AN FU SE 1 0A 8 IMI _____________ BllR METER TAIL ______ F Ur SE 10A 81 BUBu BrlR Bl 9 FUEL PUMP UNIT...

Page 101: ...e sub code they detail the specific symptom of the component or function failure For example in the case of the TP sensor OTC 08 1 TP sensor voltage lower than the specified value OTC 08 2 TP sensor v...

Page 102: ...p switch O and check the MIL Start the engine and check the MIL If the engine will not start turn the starter motor for more than 10 seconds and check that the MIL blinks If the MIL blinks connect the...

Page 103: ...ghts If not the MIL will go off and stay on unsuccessful pattern In that case turn the ignition switch OFF and try again Note that the self diagnostic memory cannot be erased if the ignition switch is...

Page 104: ...page 7 22 Contaminated deteriorated fuel 3 Inspect the fuel supply system page 7 9 Intake air leak 4 Inspect the battery charging system Faulty MAP sensor page 20 6 Restricted fuel tank breather hose...

Page 105: ...uit malfunction 4 19 IAT sensor circuit high voltage more than 4 922 V Engine operates normally 9 2 Loose or poor contact of the sensor unit connector 4 19 IAT sensor or its circuit malfunction VS sen...

Page 106: ...rn the ignition switch ON and engine stop switch o Measure the voltage at the wire harness side Connection Yellow red Green white Standard 4 75 5 25 V If the voltage within 4 75 5 25 V YES Turn the ig...

Page 107: ...sensor with the MCS Is about 0 Vindicated YES GO TO STEP 2 NO Intermittent failure 2 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 4 11 Is the sensor unit power li...

Page 108: ...t MAP sensor OTC 1 2 MAP SENSOR HIGH VOLTAGE 1 MAP Sensor System Inspection 1 Turn the ignition switch ON and engine stop switch Check the MAP sensor with the MCS Is about 5 Vindicated YES GO TO STEP...

Page 109: ...loose or poor contact on the ECT sensor 3P connector and recheck the MIL blinking 5V ECT SENSOR _L L Y Bu G W J_ Probable cause Open or short circuit in Yellow blue wire between the ECT sensor and EC...

Page 110: ...eplace the ECM with a known good one and recheck DTC 7 2 ECT SENSOR HIGH VOLTAGE 1 ECT Sensor System Inspection 1 Turn the ignition switch ON and engine stop switch o Check the ECT sensor with the MCS...

Page 111: ...SENSOR 2 5V _J Open circuit in Yellow red wire between the sensor unit and ECM Open or short circuit in Yellow wire between the sensor unit and ECM Open circuit in Green white wire between the sensor...

Page 112: ...ensor unit with a known good one page 7 1 S Connect the sensor unit 5P and ECM 33P Black connectors Erase the DTC s page 4 8 Turn the ignition switch ON and engine stop switch O Check the TP sensor wi...

Page 113: ...sconnect the sensor unit 5P connector 1 Turn the ignition switch ON and engine stop switch 110 Measure the voltage at the sensor unit 5P connector of the wire side Connection Yellow red Green white St...

Page 114: ...Inspection Check for continuity between the sensor unit 5P connector 1 of the wire side and ground Connection Gray blue Ground Is there continuity YES Short circuit in Gray blue wire NO Replace the EC...

Page 115: ...switch OFF Disconnect the ECM 33P Black connector 1 Check for continuity between the ECM 33P Black connector and sensor unit 5P connector 2 of the wire side Connection Gray blue Gray blue TOOL Test pr...

Page 116: ...ion switch ON and engine stop switch o Measure the voltage at the ECM 33P Black connector of the wire side Connection White red Ground TOOL Test probe 2 pack 07ZAJ RDJA110 Slowly turn the rear wheel b...

Page 117: ...e between the injector 2P Gray connector of the wire side and ground Connection Black blue Ground Standard Battery voltage Does the standard voltage exist YES GO TO STEP 3 NO Open or short circuit in...

Page 118: ...wire OTC 21 02 SENSOR NOTE 2 1 P W Before starting the inspection check for loose or poor contact on the 0 2 sensor 1P Black connector or 0 2 sensor cap and recheck the MIL blinking ECM 0 2SENSOR Pro...

Page 119: ...y between the ECM 33P Black connector 1 and 0 2 sensor cap terminal 2 of the wire side Connection 02 sensor cap terminal Black white TOOL Test probe 2 pack Is there continuity YES GO TO STEP 4 07ZAJ R...

Page 120: ...tch ON and engine stop switch O Check the IACV with the MCS Is the DTC 29 1 indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the IACV 4P Black connector 2 IACV Short Circuit...

Page 121: ...witch OFF 07ZAJ RDJA110 Blue white or Brown Brown black or Blue Disconnect the IACV 4P Black connector 1 page 7 22 Measure the resistance at the IACV side connector Connection A Blue black D Blue whit...

Page 122: ...54 1 BANK ANGLE SENSOR LOW VOLTAGE 1 Recheck OTC Erase the DTC s page 4 8 Turn the ignition switch ON and engine stop switch o Check the bank angle sensor with the MCS Is the DTC 54 1 indicated YES G...

Page 123: ...d blue TOOL Test probe 2 pack Is there continuity YES GO TO STEP 5 07ZAJ RDJA110 NO Open circuit in Red blue wire 5 Bank Angle Sensor Inspection 1 R Bu Replace the bank angle sensor with a known good...

Page 124: ...Red blue wire MIL CIRCUIT TROUBLESHOOTING NOTE 1 R Bu Before starting the inspection check the speedometer power input line page 21 7 With The Ignition Switch ON The MIL Does Not Come On PGM FI SYSTE...

Page 125: ...3P Black connector 1 of the wire side and ground CONNECTION Blue Ground STANDARD No continuity TOOL Test probe 2 pack 07ZAJ RDJA110 If there is continuity check for short circuit in the Blue wire betw...

Page 126: ...constant for 3 minutes before testing A sudden change of temperature will result in incorrect readings Do not let the thermometer 2 or ECT sensor touch the pan CONNECTION A B Temperature 20 C 68 F 80...

Page 127: ...INSTALLATION Do not use an impact wrench while removing or ll ii installing the 0 2sensor 1 or it may be damaged Install and hand tighten the 0 2 sensor to the exhaust pipe 4 32 Tighten the 0 2sensor...

Page 128: ...s in the reverse order of removal Refer to procedure for the 0 2sensor cap installation page 4 32 BANK ANGLE SENSOR REMOVAL INSTALLATION Remove the upper cowl page 2 14 Remove the bank angle sensor mo...

Page 129: ...arness by connecting each connector page 5 5 ECM ignition coils Place the bank angle sensor 1 horizontal Start the engine Incline the bank angle sensor approximately 60 to the left or right The bank a...

Page 130: ...ion Black blue Ground Standard Battery voltage TOOL Test probe 2 pack 07ZAJ RDJA110 Does the standard voltage exist YES GO TO STEP 2 NO Open or short circuit in Black blue wire Faulty ignition switch...

Page 131: ...MEMO...

Page 132: ...SERVICE INFORMATION 5 2 TROUBLESHOOTING 5 3 SYSTEM LOCATION 5 4 SYSTEM DIAGRAM 5 4 5 IGNITION SYSTEM IGNITION SYSTEM INSPECTION 5 5 IGNITION TIMING 5 7 IGNITION COIL 5 7 5 1...

Page 133: ...current is present A faulty ignition system is often related to poorly connected or corroded connections Check those connections before proceeding Make sure the battery is adequately charged Using th...

Page 134: ...dy ground at the ECM connector or loosen ECM connection 4 An open circuit or loose connection in Green black wire at the ECM 5 An open circuit or loose connection in Light green wire between the ignit...

Page 135: ...A BATTERY Bl R 0 Bl G IGNITION COIL SPARK _fr_ PLUG 5 4 CKP SENSOR IGNITION SWITCH ENGINE STOP SWITCH W Y Bu Y Bl Bu Bl Bu Lg SUB FUSE 10 A SIDESTAND SWITCH BANK ANGLE SENSOR l Bl Bu I R L ECM SIDEST...

Page 136: ...ose connectors can cause incorrect readings If the system is disconnected incorrect peak voltage might be measured Check the cylinder compression and check that the spark plug is installed correctly i...

Page 137: ...probe 2 pack 07ZAJ RDJA110 CONNECTION Blue yellow White yellow Shift the transmission into neutral Turn the ignition switch ON and engine stop switch O Bu Y 2 Crank the engine with the starter motor a...

Page 138: ...on the left crankcase cover Apply engine oil to a new 0 ring 1 and install it to the timing hole cap Apply engine oil to the timing hole cap 2 threads Install and tighten the timing hole cap to the sp...

Page 139: ...IGNITION SYSTEM 5 8 Remove the bolts 1 spacers 2 and ignition coil 3 from the ignition coil stay Install the removed parts in the reverse order of removal 3 1 2...

Page 140: ...SERVICE INFORMATION 6 2 TROUBLESHOOTING 6 2 SYSTEM LOCATION 6 4 SYSTEM DIAGRAM 6 4 6 ELECTRIC STARTER STARTER MOTOR 6 5 STARTER RELAY SWITCH 6 8 NEUTRAL DIODE 6 10 DIODE 6 10 6 1...

Page 141: ...ub fuse 10 A IGN PUMP Fl SOLENOID Is the fuse blown YES Replace the fuse NO GO TO STEP 2 2 Battery Inspection Make sure the battery is fully charged and in good condition page 20 5 Is the battery in g...

Page 142: ...starter relay switch connector NO Faulty starter relay switch The starter motor turns when the transmission is in neutral but does not turn with the transmission in any position except neutral with t...

Page 143: ...TRAL SWITCH 1 To NEUTRAL INDICATOR G R SIDESTAND SWITCH STARTER RELAY SWITCH R W BATTERY STARTER RELAY SWITCH IGNITION SWITCH Y R1 IGN PUMP Fl SOLENOID 10 A DIODE SWITCH Bl G l NGINESTOP Bl Bu 0 i 9P...

Page 144: ...h lifter arm 4 Remove the cam chain tensioner lifter page 11 9 Release the rubber cap 1 Remove the starter motor terminal nut 2 and starter motor cable 3 Remove the stater motor mounting bolts 4 and g...

Page 145: ...lbMt 6 6 ARMATURE Align the index lines on the covers and motor case INSPECTION Check the oil seal 1 of the front cover for deterioration or damage Check the bearing 2 and needle bearing 3 for wear or...

Page 146: ...er motor as an assembly if necessary Check for continuity between pair of commutator bars 1 There should be continuity Check for continuity between each individual commutator bar 1 and the armature sh...

Page 147: ...k the bushing 1 of the rear cover for wear or damage Replace the starter motor as an assembly if necessary STARTER RELAY SWITCH INSPECTION 6 8 Remove the single seat page 2 5 Shift the transmission in...

Page 148: ...ed connector and ground If the battery voltage appears only when the starter switch is pushed with the ignition switch ON and engine stop switch O the starter relay input voltage is normal OPERATION C...

Page 149: ...ere is continuity a small resistance value will register If there is continuity in direction shown by the arrow the neutral diode is normal INSPECTION Remove the left side cover page 2 9 Remove the di...

Page 150: ...HOUSING 7 11 COMPONENT LOCATION 7 3 THROTTLE BODY 7 15 FUEL LINE INSPECTION 7 4 INJECTOR 7 20 FUEL TANK 7 7 IACV 7 22 FUEL PUMP UNIT 7 8 SECONDARY AIR SUPPLY SYSTEM 7 23 FUEL PUMP RELAY 7 10 EVAP PURG...

Page 151: ...dirt and debris from entering the throttle bore and air passages after the throttle body has been removed Clean them using a compressed air if necessary Do not loosen or tighten the white painted nut...

Page 152: ...FUEL SYSTEM COMPONENT LOCATION 7 3...

Page 153: ...TING REMOVAL NOTE Do not bend or twist fuel feed hose 1 Relieve the fuel pressure page 7 4 2 Check the fuel quick connect fitting 1 for dirt and clean if necessary Place a shop towel over the quick co...

Page 154: ...2 locks with a CLICK NOTE Align the quick connect fitting with the pipe If it is hard to connect put a small amount of engine oil on the pipe end 2 Make sure the connection is secure check visually an...

Page 155: ...07406 004000C 07AMJ HW3A100 07AAJ S6MA200 07AMJ K26A100 Temporarily connect the battery negative cable and fuel pump 5P connector Turn the ignition switch ON and engine stop switch O Start the engine...

Page 156: ...el to the fuel tank when the first fuel is flowed Amount of fuel flow 69 2 cm3 2 34 US oz 2 44 Imp oz minimum 10 seconds at 12 V If fuel flow is less than specified inspect the following Fuel pump uni...

Page 157: ...n STANDARD Battery voltage There should be standard voltage for a few seconds If there is standard voltage replace the fuel pump unit If there is no standard voltage inspect the following Main fuse 30...

Page 158: ...e replace it if necessary INSTALLATION Always replace the Install a new packing 1 onto the fuel pump unit 2 packing with a new one Be careful not to pinch the dirt and debris between the fuel pump uni...

Page 159: ...aligning its paint mark with bosses of filter Install the fuel tank page 7 7 FUEL PUMP RELAY INSPECTION 7 10 Remove the left middle cowl page 2 7 Remove the fuel relay cover Remove the fuel pump relay...

Page 160: ...ther hose 1 from the hose clamp 2 AC type only Disconnect the vacuum hose 3 from the hose joint 4 Disconnect the EVAP purge control solenoid valve 2P connector 5 Disconnect the secondary air supply ho...

Page 161: ...Remove the bolts 1 and air cleaner housing Disconnect the air cleaner housing drain hose 2 Installation is in the reverse order of removal NOTE After installing the air cleaner housing make sure the...

Page 162: ...rew 6 Remove the resonator 7 by releasing its tab 8 from the air cleaner cover 9 slit Remove the screw 1 O and hose clamp 11 Remove the following Air cleaner cover screws Air cleaner cover Packings 12...

Page 163: ...9 slit Disconnect the canister to EVAP purge control solenoid valve hose 10 from the canister 11 Remove the screw 12 EVAP purge control solenoid valve 13 and stay 14 Remove the canister from the air c...

Page 164: ...connector 1 and injector 2P Gray connector 2 Release the clamp 3 from the clamper stay Loosen the throttle cable A adjuster lock nut 1 and adjusting nut 2 then disconnect the throttle cable A 3 from...

Page 165: ...tighten the white painted nut and screw 1 of the throttle body Loosening or tightening it can cause throttle valve and idle control failure Always clean around the throttle body before each sensor rem...

Page 166: ...the idle air will leak When installing the sensor unit 2 to the throttle body and engine idle speed will be unstable align the following Clip of the TP sensor with the boss of the throttle valve IAT...

Page 167: ...he tab of the cylinder head with the groove of the throttle body insulator Tighten the insulator band screws to the specified torque TORQUE 4 2 N m 0 4 kgf m 3 1 lbMt After tightening the insulator ba...

Page 168: ...E FULLY CLOSED POSITION RESET PROCEDURE NOTE If the sensor unit is removed reset the throttle valve fully closed position as following 1 Erase the DTC s page 4 8 2 Turn the ignition switch OFF 3 Remov...

Page 169: ...IL OFF RESET RECEIVING PATTERN SUCCESSFUL PATTERN If the MIL stays lit the throttle valve fully closed position is not reset repeat the reset procedure from step 1 9 Turn the ignition switch OFF 10 Co...

Page 170: ...njector 1 into the injector joint 2 being careful not to damage the 0 ring NOTE Align the injector body with the injector joint tab 3 as shown Be careful not to Install the injector assembly 1 to the...

Page 171: ...t the IACV 4P Black connector 1 Remove the IACV setting plate torx screws 2 and setting plate 3 Remove the IACV 4 and 0 ring 5 Check the IACV 1 for wear or damage The IACV operation can be checked vis...

Page 172: ...until the coolant temperature is 80 C 176 F Stop the engine Disassemble the air cleaner housing page 7 11 Check that the secondary air intake port 1 of the element holder is clean and free of carbon...

Page 173: ...solenoid valve page 7 24 Check that air does not flow A to B when the 12 V battery is connected to the PAIR control solenoid valve terminals Air should flow A to B when there is no voltage applied to...

Page 174: ...ype REMOVAL INSTALLATION EVAP PURGE CONTROL SOLENOID VALVE Remove the fuel tank page 7 7 Disconnect the following EVAP purge control solenoid valve 2P connector 1 Vacuum hose 2 Canister to EVAP purge...

Page 175: ...attery is connected to the EVAP purge control solenoid valve terminal Measure the resistance at the EVAP purge control solenoid valve 2P connector solenoid valve side STANOARD 30 34 n 20 C 68 F If the...

Page 176: ...ORMATION 8 2 RADIATOR COOLING FAN 8 8 TROUBLESHOOTING 8 3 WATER PUMP 8 11 B SYSTEM FLOW PATTERN 8 4 RADIATOR RESERVE TANK 8 14 SYSTEM TESTING 8 5 FAN CONTROL RELAY 8 15 COOLANT REPLACEMENT 8 5 WATER P...

Page 177: ...the reserve tank Do not remove the radiator cap except to refill or drain the system All cooling system services can be done with the engine installed in the frame Avoid spilling coolant on painted s...

Page 178: ...Faulty cooling fan motor Faulty fan control relay Faulty water pump Engine temperature too low Faulty temperature gauge or ECT sensor Thermostat stuck open Faulty fan control relay Coolant leak Fault...

Page 179: ...COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR WATER HOSE THERMOSTAT WATER HOSE SIPHON HOSE RESERVE TANK WATER PIPE WATER PUMP 8 4...

Page 180: ...I 2 Excessive pressure can damage the cooling system components Do not exceed 122 6 kPa 1 25 kgflcm2 17 8 psi Repair or replace components if the system will not hold the specified pressure for at le...

Page 181: ...urface RECOMMENDED ANTIFREEZE Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate free corrosion inhibitors STANDARD COOLANT CONCENTRATION 1 1 mixture wit...

Page 182: ...ermostat align the tab of the seal ring 3 with the groove of the thermostat cover Fill and bleed the cooling system page 8 5 INSPECTION Visually inspect the thermostat 1 for damage Check the seal ring...

Page 183: ...dle cowls page 2 7 Disconnect the fan motor 2P Black connector 1 Disconnect the siphon hose 1 from the radiator Loosen the water hose band screw and disconnect the lower water hose 2 Loosen the water...

Page 184: ...k the rubber 1 from the radiator tabs 2 then damage the remove the radiator assembly radiator fins Installation is in the reverse order of removal Tighten the hose band screw to the specified range Fi...

Page 185: ...nto the fan motor shaft by aligning the flat surfaces Apply locking agent to the cooling fan nut 2 threads Install and tighten the cooling fan nut to the specified torque TORQUE 1 1 N m 0 1 kgf m 0 8...

Page 186: ...the mechanical seal page 8 12 If oil leaks through the bleed hole replace the oil seal page 8 12 Make sure that there are no continuous coolant leakage from the bleed hole while operating the engine...

Page 187: ...uter surface Hold the water pump shaft and tighten the water pump impeller to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbMt Install a new 0 ring to the water pump cover Install and tighten the b...

Page 188: ...ply grease to a new oil seal 1 lips Install the oil seal to the right crankcase cover as shown Drive in a new Drive in new bearings 1 into the right crankcase cover bearing squarely using the special...

Page 189: ...F KR10101 RADIATOR RESERVE TANK REMOVAL INSTALLATION Remove the shock linkage page 17 12 Drain the coolant from the reserve tank page 8 5 Remove the bolts 1 and reserve tank 2 Disconnect the overflow...

Page 190: ...ntinuity only when 12 V battery is connected If there is no continuity only when the 12 V battery is connected replace the fan control relay WATER PIPE REMOVAL INSTALLATION Drain the coolant page 8 5...

Page 191: ...MEMO...

Page 192: ...9 LUBRICATION SYSTEM SERVICE INFORMATION 9 2 ENGINE OIL STRAINER SCREEN 9 4 TROUBLESHOOTING 9 2 OIL PUMP 9 4 LUBRICATION SYSTEM DIAGRAM 9 3 PRESSURE RELIEF VALVE 9 7 9 1...

Page 193: ...to enter the engine If any portion of the oil pump is worn beyond the specified service limits replace the oil pump as an assembly After the oil pump has been installed check that there are no oil le...

Page 194: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFT ROCKER ARM OIL FILTER OIL STRAINER SCREEN COUNTERSHAFT 9 3...

Page 195: ...low dry it with compressed air to clean completely Before installing the strainer it should be examined closely for damage and make sure the sealing rubber is good condition Install the oil strainer s...

Page 196: ...er rotor 5 and washer 6 Remove the dowel pins 1 from the oil pump body 2 Remove the oil pump body 1 and dowel pins 2 Remove the 0 ring 3 from the oil pump body INSPECTION OIL PUMP DRIVEN GEAR OIL PUMP...

Page 197: ...OTE Measure e h large t ac clearan s reading to c ce at several P Tempocahly tall pacethe 9cviceo taod the pump shaft into th e outer rotor M e 011 pum inner rot easuce the 1 P covec aod oil ip cleara...

Page 198: ...2 while aligning the flats of the oil pump driven gear and oil pump shaft Install the right crankcase cover page 12 9 PRESSURE RELIEF VALVE REMOVAL INSTALLATION Remove the oil pump page 9 4 Remove th...

Page 199: ...ve by removing the snap ring 2 Remove the washer 1 spring 2 and piston 3 Check the piston for wear sticking or damage Check the spring for fatigue or damage Assemble the pressure relief valve in the r...

Page 200: ...0 CYLINDER HEADNALVES SERVICE INFORMATION 10 2 TROUBLESHOOTING 10 3 COMPONENT LOCATION 10 5 CYLINDER COMPRESSION 10 6 CYLINDER HEAD COVER 10 6 CAMSHAFT 10 7 ROCKER ARM 10 13 El CYLINDER HEAD 10 15 10...

Page 201: ...sed air before inspection Camshaft and rocker arm lubricating oil is fed through oil passage in the cylinder head stud bolt hole and camshaft holder Clean the oil passage before assembling them TOOLS...

Page 202: ...performance is poor at low speeds check for white smoke in the crankcase breather hose If the hose is smoky check for a seized piston rings Compression too low hard starting or poor performance al lo...

Page 203: ...e spring Worn or damaged camshaft Worn rocker arm and or shaft Worn rocker arm and valve stem end Worn cam sprocket teeth Worn and loose cam chain Worn or damaged cam chain tensioner Faulty cylinder p...

Page 204: ...CYLINDER HEADNALVES COMPONENT LOCATION 10 N m 1 0 kgf m 7 lbf ft 12 N m 1 2 kgf m 9 lbf ft 45 N m 4 6 kgf m 33 lbf ft 4 2 N m 0 4 kgf m 3 1 lbf ft 10 5...

Page 205: ...STANDARD 1 294 kPa 13 2 kgf cm2 188 psi at 490 min 1 rpm Low compression can be caused by Blown cylinder head gasket Improper valve adjustment Valve leakage Worn piston ring or cylinder High compress...

Page 206: ...nstall and tighten the cylinder head cover bolts 1 to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbf ft Install the following PAIR check valve page 7 24 Spark plug cap page 3 6 CAMSHAFT REMOVAL Th...

Page 207: ...n guide B 2 the cam chain guide bolts fall into the crankcase Be careful not to let Remove the bolts 1 and camshaft holders 2 the cam camshaft holder bolts fall into NOTE the crankcase From outside to...

Page 208: ...h for wear or damage Check the oil holes in the camshaft for clogging Measure the height of each cam lobe SERVICE LIMITS IN 30 911 mm 1 2170 in EX 30 819 mm 1 2133 in CAMSHAFT HOLDERS Check the camsha...

Page 209: ...l to the camshaft holder mounting bolt 1 threads and seating surface and install them NOTICE Failure to tighten the camshaft holder in a crisscross pattern might cause a camshaft holder to break Tight...

Page 210: ...Install the shims 1 in their original locations on the the shims fall into valve retainer the crankcase Lower the rocker arms 2 Each camshaft has an identification mark 1 IN mark intake camshaft EX ma...

Page 211: ...EX mark exhaust side 1 Apply engine oil to the camshaft holder mounting bolt 7M 1 1 threads and seating surface and install them Iii NOTICE Failure to tighten the camshaft holder in a crisscross patte...

Page 212: ...ioner lifter plug 2 to the specified torque TORQUE 4 2 N m 0 4 kgf m 3 1 lbMt Install the cylinder head cover page 10 6 ROCKER ARM NOTE The rocker arm can be serviced with the engine installed in the...

Page 213: ...m shaft NOTE The rocker arms are identified by the stamped marks IN mark Intake rocker arm 4 EX mark Exhaust rocker arm 5 Install a new sealing washer 1 and bolt 2 Install the camshafts page 10 11 INS...

Page 214: ...following Dowel pins 1 Gasket 2 Cam chain guide A 3 DISASSEMBLY Remove the following Spark plug page 3 6 Rocker arm page 10 13 Remove the valve spring cotters 1 using the special tools TOOLS To preven...

Page 215: ...et edge and feeler gauge surface 10 16 SERVICE LIMIT 0 05 mm 0 002 in VALVE SPRING Check the valve springs for fatigue or damage Measure the free length of the inner valve spring 1 and outer valve spr...

Page 216: ...guides are replaced page 10 18 CAM CHAIN GUIDE A CYLINDER HEADNALVES 1 Inspect the cam chain guide A for excessive wear or damage replace it if necessary VALVE GUIDE REPLACEMENT NOTE Refinish the valv...

Page 217: ...ert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise e 1 1 2 Clean the cylinder head thoroughly to remove any metal particles after reaming and reface the...

Page 218: ...ities from the seat 2 Use a 32 flat cutter remove the top 1 4 of the existing valve seat material 3 Use a 60 interior cutter remove the bottom 1 4 of the existing valve seat material 4 Using a 45 seat...

Page 219: ...lean the cylinder head assembly with solvent and blow through all oil passages with compressed air Install the spring seats 1 and new valve stem seals 2 Apply molybdenum oil solution to each valve ste...

Page 220: ...r arm page 10 13 INSTALLATION Do not allow dust Clean any gasket material from the cylinder mating and dirt to enter the surfaces crankcase Install the following Dowel pins 1 New gasket 2 Cam chain gu...

Page 221: ...MEMO...

Page 222: ...SERVICE INFORMATION 11 2 TROUBLESHOOTING 11 2 COMPONENT LOCATION 11 3 11 CYLINDER PISTON CYLINDER PISTON 11 3 CAM CHAIN TENSIONER LIFTER 11 9 11 1...

Page 223: ...eaning solvent before inspection use compressed air to dry the parts TOOL Tensioner stopper O OMG 0010100 or 07AMG 001A100 U S A only TROUBLESHOOTING Compression too low hard starting or poor performa...

Page 224: ...ft the cylinder 1 and remove it being careful not to damage the piston with the stud bolts NOTE Attach a piece of wire to the cam chain to prevent it from falling into the crankcase Do not strike the...

Page 225: ...revent the piston pin clips from falling into the crankcase 11 4 Push the piston pin 1 out of the piston 2 and connecting rod and remove the piston Spread each piston ring 1 and remove it by lifting u...

Page 226: ...imum reading to determine the cylinder wear SERVICE LIMIT 76 04 mm 2 994 in Check the top of the cylinder for warpage with a straight edge and feeler gauge across the stud and bolt holes SERVICE LIMIT...

Page 227: ...their 11 6 set grooves without catching Push in the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring ta ring groove clearance using a feeler gauge...

Page 228: ...s onto the stud bolt 1 and tighten them together and use a wrench on them to turn the stud bolt out Install new stud bolts into the crankcase as shown After installing the stud bolts check that the le...

Page 229: ...not confuse the top ring 2 and second ring 3 To install the oil ring 4 install the spacer 5 first then install the side rails 6 Stagger the piston ring end gaps 120 apart from each other Stagger the...

Page 230: ...he cylinder 1 inner surface and piston 2 sliding surface Route the cam chain 3 through the cylinder and install the cylinder over the piston while compressing the piston rings with your fingers Instal...

Page 231: ...ain tensioner lifter plug 3 to the specified torque TORQUE 4 2 N m 0 4 kgf m 3 1 lbf ft INSPECTION Check the cam chain tensioner lifter 1 operation The cam chain tensioner lifter shaft should not go i...

Page 232: ...CH GEARSHIFT LINKAGE SERVICE INFORMATION 12 2 TROUBLESHOOTING 12 3 COMPONENT LOCATION 12 4 RIGHT CRANKCASE COVER 12 5 CLUTCH 12 10 GEARSHIFT LINKAGE 12 17 GEARSHIFT PEDAL 12 20 PRIMARY DRIVE GEAR 12 2...

Page 233: ...engine oil level before servicing the clutch system TOOLS Clutch center holder 07724 0050002 pr o i 0 0 or equivalent commercially available in U S A Bearing remover shaft 15 mm 07936 KC10100 0 Not av...

Page 234: ...ps Clutch lifter sticking Worn clutch discs Weak clutch springs No clutch lever freeplay Engine oil level too low or oil additive used Hard to shift Misadjusted clutch cable Damaged or bent shift fork...

Page 235: ...HIFT LINKAGE COMPONENT LOCATION 12 N m 1 2 kgf m 9 lbf ft 7 108 N m 11 0 kgf m 80 lbf ft 108 N m 11 0 kgf m 80 lbf ft 10 N m 1 0 kgf m 7 lbf ft 12 4 Replace the clutch outer and primary drive gear as...

Page 236: ...water hose band screw and disconnect the water hose 1 Loosen the right crankcase cover bolts 1 in a crisscross pattern in 2 or 3 steps and remove the bolts Be careful not to let Remove the right cran...

Page 237: ...BLY Remove the return spring 1 from the right crankcase cover Remove the clutch lifter arm 1 from the right crankcase cover INSPECTION Check the oil seal 1 for fatigue or damage Check the needle beari...

Page 238: ...fit loosely in the right crankcase cover For crankshaft bearing replacement page 12 7 BEARING REPLACEMENT CRANKSHAFT BEARING Remove the crankshaft bearing 1 using the special tool TOOLS Remover weight...

Page 239: ...over 12mm Remover weight 07936 16601 OA 07936 371020A Install the bearing remover head 1 to the pilot collar 2 as shown TOOLS Bearing remover head 10 mm 07746 0050200 Pilot collar 16 mm 07PAF 0010620...

Page 240: ...ht crankcase cover by aligning the spring short end with the hole of the clutch lifter arm and long end with the groove of the right crankcase cover INSTALLATION Be careful not to Clean any gasket mat...

Page 241: ...cable to the clutch lifter arm 1 Install the clutch cable guide 2 and bolts 3 Tighten the bolts securely Install the water pipe page 8 15 Adjust the clutch lever freeplay page 3 21 Fill the engine wit...

Page 242: ...haft threads Hold the clutch center 1 with the special tool and loosen the clutch center lock nut 2 TOOL Clutch center holder 3 07724 0050002 or equivalent commercially available in U S A Remove the c...

Page 243: ...r race fits loosely in the Iifter plate Never install the old Drive in a new bearing 1 squarely with its marked side bearing once the facing up bearings have been removed the TOOLS bearings must be Dr...

Page 244: ...iscoloration discs and plates as Check the clutch plate for warpage on a surface plate a set using a feeler gauge SERVICE LIMIT 0 3 mm 0 01 in Warped clutch plates prevent the clutch from disengaging...

Page 245: ...clutch outer assembly is replaced be sure to select the outer guide according to the selective fit table by selecting same color codes of the mainsfaft and clutch outer guide The color codes position...

Page 246: ...the mainshaft Apply molybdenum oil solution to the clutch outer guide 2 inner surface and install it to the mainshaft Apply engine oil to the needle bearing 3 rotating area and install it to the clutc...

Page 247: ...Hold the clutch center 1 with the special tool and tighten the lock nut 2 to the specified torque TOOL Clutch center holder 3 07724 0050002 or equivalent commercially available in U S A TORQUE 108 N m...

Page 248: ...springs 2 and bolts 3 Tighten the clutch lifter plate bolts to the specified torque in a crisscross pattern in 2 or 3 steps TORQUE 12 N m 1 2 kgf m 9 lbf ft Install the right crankcase cover page 12 9...

Page 249: ...mage replace them if necessary Check the gearshift spindle for wear or bend Check the spindle arm for wear damage or deformation Replace the gearshift spindle as an assembly if necessary GEARSHIFT SPI...

Page 250: ...spring at the stopper arm groove Install and tighten the bolt to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbMt Check the stopper arm for proper operation Move the stopper arm 1 out of the way u...

Page 251: ...crankcase by aligning the return spring ends with the spring pin Install the gearshift arm 1 onto the gearshift spindle while aligning its slit with the punch mark Install and tighten the pinch bolt 2...

Page 252: ...e punch mark Install and tighten the gearshift pedal mounting bolt 2 and gearshift arm pinch bolt 3 securely PRIMARY DRIVE GEAR NOTE Replace the clutch outer and primary drive gear as an assembly REMO...

Page 253: ...ar lock nut 2 threads and seating surface and install it Temporarily install the washer 1 clutch outer guide 2 needle bearing 3 and clutch outer 4 Insert the gear holder 5 between the primary drive an...

Page 254: ...13 ALTERNATOR STARTER CLUTCH SERVICE INFORMATION 13 2 TROUBLESHOOTING 13 2 COMPONENT LOCATION 13 3 LEFT CRANKCASE COVER 13 4 STATOR CKP SENSOR 13 5 FLYWHEEL 13 6 STARTER CLUTCH 13 8 13 1...

Page 255: ...ection page 20 7 For CKP sensor inspection page 5 6 For starter motor service page 6 5 TOOLS Flywheel holder 07725 0040001 TROUBLESHOOTING Flywheel puller 07733 0020001 or 07933 3950000 U S A only Sta...

Page 256: ...ALTERNATOR STARTER CLUTCH COMPONENT LOCATION 128 N m 13 0 kgf m 94 lbf ft 13 3...

Page 257: ...itch wire connector 1 The left crankcase Loosen the left crankcase cover bolts 2 in a crisscross cover stater is pattern in 2 or 3 steps and remove the bolts and left magnetically crankcase cover 3 at...

Page 258: ...wheel be careful during installation Route the wire Connect the following properly page 1 Alternator 3P connector 1 19 CKP sensor neutral switch 6P connector 2 Install the following Under cowl page 2...

Page 259: ...cking agent 6 5 1 0 mm from the tip of the threads to the CKP sensor mounting socket bolts 3 Install and tighten the bolts to the specified torque TORQUE 10 N m 1 0 kgf m 7 lbf ft Install the left cra...

Page 260: ...emove the needle bearing 1 Remove the woodruff key 2 Check the needle bearing for wear or damage INSTALLATION Apply molybdenum oil solution to the needle bearing 1 rotating area Install the needle bea...

Page 261: ...e NOTE Set the holding block 3 of the flywheel holder 4 avoiding the flywheel reluctors TOOL Flywheel holder 07725 0040001 TORQUE 128 N m 13 0 kgf m 94 lbf ft Apply molybdenum oil solution to the star...

Page 262: ...e the starter one way clutch 3 from the starter clutch outer INSPECTION Check the starter driven gear teeth for wear or damage Check the roller contact surface for wear or damage Measure the starter d...

Page 263: ...UTCH OUTER l STARTER ONE WAY CLUTCH 13 10 Apply engine oil to the starter one way clutch sprag Install the starter one way clutch 1 to the starter clutch outer 2 Install the starter clutch assembly 1...

Page 264: ...ified torque TOOL Flywheel holder 2 07725 0040001 TORQUE 30 N m 3 1 kgf m 22 lbf ft Apply engine oil to the starter driven gear 1 sliding surface Install the starter driven gear while turning it count...

Page 265: ...MEMO...

Page 266: ...BALANCER SERVICE INFORMATION 14 2 TROUBLESHOOTING 14 4 COMPONENT LOCATION 14 5 CRANKCASE SEPARATION 14 6 CRANKSHAFT 14 7 MAIN JOURNAL BEARING 14 9 TRANSMISSION 14 13 BALANCER 14 18 BEARING REPLACEMENT...

Page 267: ...page 21 20 Starter motor page 6 5 Engine page 15 4 Be careful not to damage the crankcase mating surfaces when servicing Clean the oil passages before assembling the crankcase halves Prior to assembl...

Page 268: ...tal installer set 070MF KYJ0100 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER Pilot 20 mm 07746 0040500 Attachment 37 x 40 mm 07746 0010200 Driver 30 x 36 mm 07HMF KR10101 Y j Attachment 45 x 50 mm 07946...

Page 269: ...ing Hard to shift Bent shift fork Bent shift fork shaft Damaged shift drum guide groove Damaged shift fork guide pin Bent shift fork claw Damaged gearshift spindle Loose shift drum stopper arm bolt Tr...

Page 270: ...CRANKCASE CRANKSHAFT TRANSMISSION BALANCER COMPONENT LOCATION 14 5...

Page 271: ...ner for excessive wear or damage replace it if necessary Install an 0 0 3 mm pin 1 into the hole 2 of the balancer driven gear assembly 3 Insert the gear holder 1 between the balancer drive gear 2 and...

Page 272: ...y with the right crankcase down Do not pry the Carefully separate the left crankcase 1 from the right crankcase halves crankcase 2 while tapping them at several locations with a screwdriver with a pla...

Page 273: ...END SIDE CLEARANCE Measure the side clearance of the connecting rod big end with feeler gauge SERVICE LIMIT 0 85 mm 0 033 in BIG END RADIAL CLEARANCE Measure the radial clearance of the connecting rod...

Page 274: ...st be installed in their original locations or the correct bearing oil clearance may not be obtained resulting in engine damage BEARING INSPECTION Remove the following Crankshaft page 14 7 Transmissio...

Page 275: ...nce exceeds the service limit select the main journal bearing page 14 10 BEARING SELECTION Remove the following Crankshaft page 14 7 Transmission page 14 13 Balancer shaft page 14 18 Set a special too...

Page 276: ...een t O S F Yellow 0 S G Pink Middle A Blue B Black C Brown Thin BEARING SUPPORT 1 D 38 000 38 006 mm 1 4961 1 4963 in 38 006 38 012 mm 1 4963 1 4965 in 38 012 38 018 mm 1 4965 1 4968 in 38 018 38 024...

Page 277: ...s 1 and special tools assembly on inside of the crankcase fitting the bearing edge in the crankcase main journal Align the mating line of the bearings with the index mark on the crankcase as shown Set...

Page 278: ...OVAL DISASSEMBLY Separate the crankcase halves page 14 6 Pull the shift fork shaft 1 and remove it from the shift forks Remove the shift forks 2 and shift drum 3 Remove the mainshaft assembly 1 and co...

Page 279: ...4 27 95 mm 1 100 in Calculate the gear to bushing clearance SERVICE LIMITS M5 M6 C1 C2 C3 C4 0 10 mm 0 004 in Measure the l D of each bushing SERVICE LIMITS M5 C1 20 05 mm 0 789 in C2 22 07 mm 0 869 i...

Page 280: ...he shift drum journal l D at left crankcase SERVICE LIMIT 14 06 mm 0 554 in Calculate the shift drum to shift drum journal clearances SERVICE LIMIT 0 08 mm 0 003 in SHIFT FORK Check the shift forks fo...

Page 281: ...he gear bushing entire surface M5 C1 C2 C3 gear bushing outer surface M6 C4 to ensure initial lubrication Assemble all parts into their original positions NOTE Install the washers and snap rings 1 wit...

Page 282: ...edom of movement or rotation on each shaft Each gear teeth Apply engine oil to the transmission gear teeth Engage the mainshaft assembly 1 and countershaft assembly 2 Install the mainshaft assembly 1...

Page 283: ...tion to the shift drum 2 journal outer surface and grooves then install it while aligning the shift fork guide pins with the guide grooves Apply molybdenum oil solution to the shift fork shaft 1 outer...

Page 284: ...the balancer gear springs into the balancer driven gear 7 Install the balancer driven sub gear with its OUT mark 8 facing out NOTE Align the holes of the balancer driven and sub gear Install the follo...

Page 285: ...ools TOOLS Bearing remover set 17 mm 2 07936 3710300 Remover handle 07936 3710100 Remover weight 3 07741 0010201 or 07936 371020A U S A only Drive in new bearings into the right crankcase until they a...

Page 286: ...50 mm 3 07946 6920100 Pilot 20 mm 4 07746 0040500 After installation apply engine oil to each bearing rotating area Apply locking agent to the mainshaft bearing setting plate bolt 1 threads page 1 17...

Page 287: ...if are fully seated using the special tools TOOLS Mainshaft needle bearing 1 Driver 2 07749 0010000 Attachment 28 x 30 mm 3 07946 1870100 Pilot 17 mm 4 07746 0040400 Countershaft bearing 5 marked sid...

Page 288: ...Apply a light but through coating of sealant Three bond 12078 1215 or equivalent to left crankcase mating surface except the oil passage area Apply engine oil to a new 0 ring 1 Install the dowel pins...

Page 289: ...ul not to Install the woodruff key 1 onto the balancer shaft damage the key groove and balancer shaft 14 24 Align the balancer driven gear 1 and balancer driven sub gear 2 holes and install a 3 mm pin...

Page 290: ...s OUT mark 4 facing out Align the punch marks of the balancer drive gear and balancer driven gear Insert the gear holder 1 between the balancer drive gear 2 and balancer driven gear 3 TOOL Gear holder...

Page 291: ...chain over the timing sprocket 2 Apply locking agent to the cam chain tensioner pivot bolt 3 threads page 1 17 Install the cam chain tensioner 4 collar 5 and cam chain tensioner pivot bolt Tighten th...

Page 292: ...15 ENGINE REMOVAUINSTALLATION SERVICE INFORMATION 15 2 ENGINE REMOVAL 15 4 COMPONENT LOCATION 15 3 ENGINE INSTALLATION 15 6 El 15 1...

Page 293: ...ke the torque or sequence loosen all mounting fasteners then tighten them again to the specified torque in the correct sequence The following components can be serviced with the engine installed in th...

Page 294: ...ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 45 N m 4 6 kgf m 33 lbMt 45 N m 4 6 kgf m 33 lbMt 45 N m 4 6 kgf m 33 lbMt 45 N m 4 6 kgf m 33 lbf ft 10 N m 1 0 kgf m 7 lbMt 15 3...

Page 295: ...tch cable guide 2 then disconnect the clutch cable 3 from the clutch lifter arm 4 Release the rubber cap 5 Remove the starter motor terminal nut 6 and starter motor cable 7 Remove the starter motor mo...

Page 296: ...or 3P connector 1 CKP sensor neutral switch 6P connector 2 VS sensor 3P connector 3 ECT sensor 3P Gray connector 4 Release the VS sensor wire from the wire guides 5 Support the engine using a jack or...

Page 297: ...r hose wires and cables All the engine mounting bolts and nuts loosely install then tighten the bolts and nuts to the specified torque in the specified sequence Route the water hose wires and cables p...

Page 298: ...e spark plug cap 1 Connect the water hoses 1 and tighten the water hose band screws 2 to the specified range page 8 9 Install the drive chain 1 over the drive sprocket 2 Install the drive sprocket to...

Page 299: ...4 Tighten the terminal nut securely and reposition the rubber cap 5 properly on the starter motor terminal Connect the clutch cable 6 to the clutch lifter arm 7 Install clutch cable guide 8 and bolts...

Page 300: ...16 FRONT WHEEUSUSPENSION STEERING SERVICE INFORMATION 16 2 TROUBLESHOOTING 16 3 COMPONENT LOCATION 16 5 HANDLEBAR 16 7 FRONT WHEEL 16 16 FORK 16 21 STEERING STEM 16 29 CLUTCH LEVER 16 37 16 1...

Page 301: ...front wheel installation check the brake operation by applying the brake lever Use only tires marked TUBELESS and tubeless valves on rim marked TUBELESS TIRE APPLICABLE For brake system information pa...

Page 302: ...ers to one side or does not track straight Bent fork pipe Bent axle Worn wheel bearing Unequal fork fluid quantity in each fork pipe Faulty steering head bearing Bent frame Faulty wheel bearing Weak f...

Page 303: ...pension Incorrect fork fluid viscosity Bent fork pipe Clogged fork fluid passage Damaged fork pipe and or fork slider Fork pipe binds High tire pressure Front suspension noisy Insufficient fork fluid...

Page 304: ...FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION CBR300RA shown 103 N m 10 5 kgf m 76 lbMt 22 N m 2 2 kgf m 16 lbMt 59 N m 6 0 kgf m 44 lbMt 16 5...

Page 305: ...FRONT WHEEL SUSPENSION STEERING CB300FA shown 103 N m 10 5 kgf m 76 lbf ft 22 Nm 2 2 kgf m 16 lbf ft 30 N m 3 1 kgf m 22 lbf ft CB300F shown I 59 N m 6 0 kgf m 44 lbf ft 16 6...

Page 306: ...bolts 3 Bracket holder 4 Clutch lever bracket 5 Two screws 1 Left handlebar switch housings 2 2 Screw 3 while holding the handlebar weight 4 securely Handlebar weight Left handlebar grip 5 Stopper rin...

Page 307: ...air from entering Master cylinder holder 3 the hydraulic Front master cylinder 4 system Two screws 1 Upper right handlebar switch housing 2 Stopper ring 1 Pinch bolt 2 loosen Right handlebar 3 Thrott...

Page 308: ...holder 4 clutch lever bracket 5 screws 1 left handlebar switch housings 2 2 screw 3 while holding the handlebar weight 4 securely handlebar weight from both sides of the handlebar left handlebar grip...

Page 309: ...rottle grip INSTALLATION CBR300R RA LEFT HANDLEBAR Install the left handlebar 1 over the fork tube aligning the boss with the groove in the top bridge Be sure the handlebar holder is fully seated on t...

Page 310: ...r Tighten the upper screw first 2 then tighten the lower screw 3 to the specified torque TORQUE 2 5 N m 0 3 kgf m 1 8 lbf ft Align the edge of Install the clutch lever bracket 1 and holder 2 with the...

Page 311: ...ning the locating pin with the hole in the handlebar Install the upper right handlebar switch housing Tighten the upper screw first 2 then tighten the lower screw 3 to the specified torque TORQUE 2 5...

Page 312: ...the rear bolts 4 to the of the top bridge specified torque TORQUE 27 N m 2 8 kgf m 20 lbf ft Install the lower right handlebar switch housing 1 by aligning the locating pin with the hole in the handle...

Page 313: ...for even application of the adhesive Install the handlebar weight 3 and tighten the screw 4 while holding the weight securely Install the left handlebar switch housings 1 by aligning the locating pin...

Page 314: ...ole 4 the handlebar weight to the rubber cushions SJ for easy removal Remove the screw 1 handlebar weight 2 retainer ring 3 and rubber cushions 4 from the inner weight 5 Install the rubber cushions an...

Page 315: ...move any deposits Check the sensor tip for deformation or damage e g chipped pulser ring teeth Replace the front wheel speed sensor if necessary Loosen the front axle nut 3 Support the motorcycle usin...

Page 316: ...er 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 Remove and discard the bearings if the races do not...

Page 317: ...st area If the wheel is balanced it will not stop consistently in the same position To balance the wheel install a new balance weight on the lightest side of the rim on the side opposite the chalk mar...

Page 318: ...ollar and drive out the other bearing TOOLS Bearing remover head 15 mm 07746 0050400 Bearing remover shaft 07746 0050100 ASSEMBLY Install each dust seal with the flat side facing out so that it is flu...

Page 319: ...00 07746 0010300 07746 0040300 Install the front wheel between the fork legs so that the brake disc is positioned between the pads NOTE Be careful not to damage the brake pads Install the front axle 1...

Page 320: ...ket assembly from the brake hose Do not twist the brake hose Remove the wire bands 1 from both fork pipes Remove the stopper rings 2 from both fork pipes Loosen the handlebar pinch bolts 3 and remove...

Page 321: ...Remove the following Fork bolt 1 0 ring 2 Spring collar 3 Spring seat 4 Remove the fork spring 1 Drain the fork fluid by pumping the fork pipe several times Do not remove the Remove the fork piston 1...

Page 322: ...he fork piston Remove the fork socket bolt 2 and sealing washer 3 turns with the socket bolt temporarily install the fork spring spring seat spring collar and fork bolt Using quick successive motions...

Page 323: ...rk piston 1 piston ring 2 and oil lock piece 3 for wear or damage Check the rebound spring 4 for fatigue or damage Replace any components that are worn or damage GUIDE BUSHING SLIDER BUSHING BACK UP R...

Page 324: ...EAL FORK PIPE FORK PISTON RING STOPPER 6 1telo1L FORK PISTON BACK UP RING j REBOUND SPRING cw INGWASHER 20 N m 2 0 kgf m 15 lbf ft Do not open the Install the slider bushing 1 being careful not to dam...

Page 325: ...nto the fork slider 4 Set the fork slider in a vise with a piece of wood or soft jaws to avoid damage Install a new sealing washer 1 to the fork socket bolt 2 Apply locking agent to the fork socket bo...

Page 326: ...d into the fork pipe RECOMMENDED FORK FLUID Pro Honda Suspension Fluid SS 8 10W FORK FLUID CAPACITY CBR300R RA 331 2 5 cm3 11 2 0 08 US oz 11 7 0 09 Imp oz CB300F FA 311 2 5 cm3 10 5 0 08 US oz 10 9 0...

Page 327: ...ning index line of fork pipe with the top cables properly surface of top bridge page 1 19 CBR300RIRA Tighten the bottom bridge and top bridge pinch bolts to the specified torque TORQUE Bottom bridge p...

Page 328: ...2 8 kgf m 20 lbMt Install the stopper rings 3 to the grooves of both fork pipes Install the wire bands 4 to the both fork pipes NOTE Route the wire properly page 1 19 Install the front brake caliper b...

Page 329: ...r wire guide 2 and brake hose joints 3 CBR300R RA Remove the wire bands 1 from both fork pipes Remove the stopper rings 2 from both fork pipes Loosen the handlebar pinch bolts 3 and remove the handleb...

Page 330: ...m cap 1 Loosen the steering stem nut 2 Remove the fork legs page 16 21 Remove the following top bridge pinch bolt 3 stem nut washer 4 top bridge 5 Straighten the lock washer 1 tabs Remove the steering...

Page 331: ...t 2 Remover weight 3 U S A TOOL 07JAC PHSOOOO 07JAC PH80100 07JAC PH80200 07741 0010201 Adjustable bearing remover 25 40 07736 A01000B mm Remove the lower bearing outer race using the special tool and...

Page 332: ...ew lower inner race 2 using a hydraulic press and special tool TOOL Attachment 30 mm l D 3 07746 0030300 Drive in a new upper outer race 1 using the special tools TOOLS Driver 2 Attachment 42 x 47 mm...

Page 333: ...ly specified grease page 1 18 to a new steering head bearing dust seal lips Install the bearings 1 in the lower inner race and upper outer race Install the steering stem 2 upper inner race 3 and dust...

Page 334: ...adjusting nut Install the lock nut 2 until it contacts with the lock washer Further tighten the lock nut within 90 to align its grooves with the tabs of the lock washer Bend up the long lock washer t...

Page 335: ...QUE Bottom bridge pinch bolt 1 32 N m 3 3 kgf m 24 lbMt Top bridge pinch bolt 2 22 N m 2 2 kgf m 16 lbMt Install the handlebars and tighten the handlebar pinch bolts 1 to the specified torque TORQUE 2...

Page 336: ...page 3 4 STEERING HEAD BEARING PRE LOAD Jack up the motorcycle to raise the front wheel off the ground Position the steering stem to the straight ahead position Make sure that Hook a spring scale to...

Page 337: ...Apply molybdenum disulfide grease to the clutch lever pivot bolt 1 sliding surface Install and tighten the clutch lever pivot bolt to the specified torque TORQUE 1 0 N m 0 1 kgf m 0 7 lbMt Install and...

Page 338: ...17 REAR WHEEUSUSPENSION SERVICE INFORMATION 17 2 TROUBLESHOOTING 17 3 COMPONENT LOCATION 17 4 REAR WHEEL 17 5 SHOCK ABSORBER 17 10 SHOCK LINKAGE 17 12 SWINGARM 17 15 17 1...

Page 339: ...marked TUBELESS and tubeless valves on rim marked TUBELESS TIRE APPLICABLE Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting point For brake system information page 1...

Page 340: ...Bent frame or swingarm Axle not tightened properly Unbalanced tire and wheel Insufficient tire pressure Wheel hard to turn Brake drag Faulty wheel bearing Faulty driven flange bearing Bent axle Drive...

Page 341: ...REAR WHEEL SUSPENSION COMPONENT LOCATION ABS type shown 36 N m 3 7 kgf m 27 lbf ft 88 N m 9 0 kgf m 65 lbf ft 75 N m 7 6 kgf m 55 lbf ft 36 N m 3 7 kgf m 2 75 N m 7 6 kgf m 55 lbf ft 17 4...

Page 342: ...l forward Derail the drive chain 4 from the driven sprocket Remove the axle nut and adjusting plate 5 Do not operate the Remove the axle 6 adjusting plate and rear wheel brake pedal after removing the...

Page 343: ...ts tightly in the wheel hub and driven flange Replace the Remove and discard the bearings if the races do not turn smoothly quietly or if they fit loosely in the wheel hub bearings as a set and driven...

Page 344: ...e loosen the driven sprocket nuts 3 in a crisscross pattern in 2 or 3 steps before removing the driven flange from the left wheel hub Remove the damper rubbers 1 Remove the driven sprocket bolts 1 nut...

Page 345: ...07746 0050100 Remove the distance collar and drive out the other bearing ASSEMBLY Install each dust seal with the flat side facing out so that it is flush with the hub and driven flange end surfaces I...

Page 346: ...side bearing 6 squarely with its marked side facing up until it is seated on the distance collar TOOLS Driver Attachment 37 x 40 mm Pilot 17 mm 07749 0010000 07746 0010200 07746 0040400 Drive in a ne...

Page 347: ...ighten the rear axle nut 2 to the specified torque TORQUE 88 N m 9 0 kgf m 65 lbf ft Adjust the drive chain slack page 3 15 ABS type Install the rear wheel speed sensor 1 and bolts 2 Tighten the bolts...

Page 348: ...7 6 kgf m 55 lbMt INSPECTION Remove the bolt 1 and nut 2 Visually inspect the shock absorber for wear or damage Check the following Damper rod 1 for bend or damage Damper unit for deformation or oil...

Page 349: ...nd nut 6 Shock linkage assembly 7 Installation is in the reverse order of removal NOTE Install the shock linkage assembly with its arrow mark 8 facing forward TORQUE Shock absorber mounting nut 36 N m...

Page 350: ...shock absorber for damage abnormal wear oil leakage or bend damper unit pivot bushing needle bearings BEARING REPLACEMENT SHOCK ARM Remove the needle bearings 1 using the special tools TOOLS Bearing r...

Page 351: ...otating area Install the needle bearings 1 with the marked side facing up using a hydraulic press and special tools as shown TOOLS Driver 2 Attachment 22 x 24 mm 3 Pilot 17 mm 4 ASSEMBLY 07749 0010000...

Page 352: ...OVAL Remove the following Drive chain cover page 17 17 Rear wheel page 17 5 Remove the rear brake hose guide mounting screw 1 and brake hose guide 2 Release the brake hose and rear wheel speed sensor...

Page 353: ...PENSION 17 16 Remove the shock absorber lower mounting bolt 1 and nut 2 Remove both swingarm pivot caps 1 Remove the swingarm pivot nut 1 pivot bolt 2 and swingarm 3 Installation is in the reverse ord...

Page 354: ...LAR PIVOT COLLAR DUST SEAL a lllllljjilll Check the collars for wear damage or fatigue Check the needle bearing 4 for damage or loose fit replace it if necessary page 17 17 Check the drive chain slide...

Page 355: ...MJ00100 Apply grease to a new needle bearing rotating area Install the needle bearing 1 into the swingarm with the marked side facing up using a hydraulic press and special tools as shown TOOLS Drive...

Page 356: ...a thin coat of grease to the swingarm pivot bolt 1 outer surface Set the drive chain onto the swingarm 2 and install the swingarm to the frame Install the swingarm pivot bolt from the left side Instal...

Page 357: ...ose guide 2 Install and tighten a new rear brake hose guide mounting screw 3 to the specified torque TORQUE 1 3 N m 0 1kgf m 1 0 lbf ft Install the following Rear wheel page 17 9 Drive chain cover pag...

Page 358: ...18 11 TROUBLESHOOTING 18 2 FRONT BRAKE CALIPER WITHOUT ABS TYPE 18 13 COMPONENT LOCATION 18 3 FRONT BRAKE CALIPER BRAKE FLUID REPLACEMENT ABS TYPE 18 14 AIR BLEEDING 18 5 REAR BRAKE CALIPER 18 16 BRAK...

Page 359: ...servicing the system Do not mix different types of fluid they may not be compatible Always check brake operation before riding the motorcycle This section covers service of the brake components of th...

Page 360: ...e N1T LOCATION COMPON ABS type shown f m 25 lbMt 34N m 3 5kg without ABS type 34 N m 3 5 kg f m 25 lbMt HYDRAULIC BRAKE k f m g lbMt 12Nm 1 2 g I 34 N m 3 5 kg f m 25 lbMt 30N m 3 1 kg f m 22 lbMt 18...

Page 361: ...HYDRAULIC BRAKE ABS type shown 34 N m 3 5 kgf m 25 lbMt 10 N m 1 0 kgf m 7 lbMt 27 N m 2 8 kgf m 20 lbMt 34 N m 3 5 kgf m 25 lbMt 17 N m 1 7 kgf m 13 lbMt 18 4...

Page 362: ...ervoir cap 2 Set plate 3 Diaphragm 4 For rear brake Remove the mounting bolt 1 and reservoir 2 from the stay Take care not to spill the fluid out of the reservoir Remove the following Two screws 3 Res...

Page 363: ...l all the way and loosen the bleed valve 1 4 of a turn brake lever or pedal Wait several seconds and then close it until the bleed valve 2 Release the brake lever pedal slowly and wait several seconds...

Page 364: ...e lever after Install new brake pads to the brake caliper so their ends removing the brake seat against the retainer pads NOTE Make sure that the retainer and pad spring 2 are installed to the brake c...

Page 365: ...installed in position Be sure the stopper ring 2 on the pad pin 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 th...

Page 366: ...holes in the pads and caliper body Tighten the pad pin to the specified torque TORQUE 17 N m 1 7 kgf m 13 lbMt Operate the brake pedal to seat the caliper piston against the pads BRAKE DISC INSPECTIO...

Page 367: ...age 18 6 DISASSEMBLY ASSEMBLY 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 gr...

Page 368: ...pin 1 joint pin 2 and master cylinder from the brake pedal Remove the master cylinder mounting bolts 1 and master cylinder 2 from the right main step holder assembly Installation is in the reverse or...

Page 369: ...PUSH ROD 0 10 g 0 004 oz When the push rod has been disassembled adjust the push rod length so that the distance from the center of the master cylinder lower mounting bolt hole to the center of the jo...

Page 370: ...when tightening the oil bolt TORQUE Front brake caliper mounting bolt 30 N m 3 1 kgf m 22 lbMt Oil bolt 34 N m 3 5 kgf m 25 lbMt DISASSEMBLY ASSEMBLY For brake pad removal installation page 18 7 Mark...

Page 371: ...cessary FRONT BRAKE CALIPER ABS TYPE REMOVAL INSTALLATION Drain the brake fluid from the hydraulic system page 18 5 Remove the bolts 1 and front wheel speed sensor 2 Remove the brake pads page 18 8 Wh...

Page 372: ...the fluid inlet Install the pistons with the opening toward the pads 0 4 g 0 01 oz ca CALIPER PIN 22 N m 2 2 kgf m 16 lbf ft BLEED VALVE 5 4 N m 0 6 kgf m 4 0 lbf ft 0 RING BRAKE PAD PIN 17 N m 1 7 k...

Page 373: ...against the caliper body when tightening the oil bolt TORQUE Oil bolt 34 N m 3 5 kgf m 25 lbMt Fill and bleed the rear brake hydraulic system page 18 6 DISASSEMBLY ASSEMBLY When removing the caliper p...

Page 374: ...pedal Remove and discard the brake pedal joint cotter pin 2 Remove the joint pin 3 and disconnect the push rod lower joint from the brake pedal 4 Remove the snap ring 5 washer 6 return spring 7 and b...

Page 375: ...r 2 and snap ring 3 Connect the brake pedal to the push rod lower joint with the joint pin 4 Install a new cotter pin 5 Install the brake light switch spring 6 to the brake pedal Install the right mai...

Page 376: ...A SERVICE INFORMATION 19 2 SYSTEM LOCATION 19 3 SYSTEM DIAGRAM 19 4 ABS TROUBLESHOOTING INFORMATION 19 5 OTC INDEX 19 9 ABS INDICATOR CIRCUIT TROUBLESHOOTING 19 11 ABS TROUBLESHOOTING 19 13 WHEEL SPEE...

Page 377: ...til the ignition switch is turned OFF ordinary self diagnosis When the ABS control unit detects a problem it stops the ABS function and switches back to the conventional brake operation and the ABS in...

Page 378: ...ANTI LOCK BRAKE SYSTEM ABS CBR300RA CB300FA SYSTEM LOCATION CBR300RA shown REAR WHEEL SPEED SENSOR 19 3...

Page 379: ...LATOR 8 1 BLS IG 6 1 6 2 IND 13 r i PUMP MOTOR 18 MR B 5 4 5 1 GND SOLENOID VALVE 3 1 3 2 3 3 3 4 W BI G 1 G Bu 17 FVW S I 1 1 1 2 1 5 W Bu FRONT WHEEL r 1 i SPEED SENSOR 0 FRONT PULSER RING 2 1 OTC f...

Page 380: ...notify the rider of the problem The self diagnosis is also made while the motorcycle is running and the ABS indicator blinks when a problem is detected When the ABS indicator blinks the cause of the p...

Page 381: ...shooting erase the OTC and perform the pre start self diagnosis procedure to be sure that there is no problem in the ABS page 19 5 Do not apply the brake during OTC readout Connect the MCS to the DLC...

Page 382: ...OTC Example 2 3 Pattern repeated When the OTC is not stored 2 sec 3 6 sec ABS ON INDICATOR OFF ERASING STORED OTC NOTE The stored OTC can not be erased by simply disconnecting the battery negative ca...

Page 383: ...or by pressing it straight at the area as shown arrow until the lock tab clicks Make sure the connector is locked securely Always clean arouQd and keep any foreign material away from the connector bef...

Page 384: ...N fuse 10 A Front wheel speed sensor circuit malfunction Stops ABS operation 1 1 open circuit 0 0 19 13 Wheel speed sensor or related wires Front wheel speed sensor malfunction Stops ABS operation Whe...

Page 385: ...S MAIN fuse 10 A 19 20 Power circuit over voltage 0 Stops ABS operation 6 2 Input voltage too high 0 Tire malfunction 0 Stops ABS operation 7 1 19 21 Tire size ABS control unit Stops ABS operation 8 1...

Page 386: ...itch OFF Check for continuity between the wire harness side ABS modulator 18P Black connector 1 terminal and ground TOOL Test probe 2 pack 07ZAJ RDJA110 CONNECTION 13 Ground Is there continuity YES Sh...

Page 387: ...the White black wire Faulty combination meter if the Orange blue wire is OK 3 Modulator Ground Line Open Circuit Inspection Turn the ignition switch OFF Check for continuity between the wire harness...

Page 388: ...se specified All connector diagrams in the troubleshooting are viewed from the terminal side Use a fully charged battery Do not diagnose with a charger connected to the battery When the ABS modulator...

Page 389: ...sensor 2P Blue connector 1 and ground CONNECTION White Ground Blue Ground Is there continuity YES Faulty front wheel speed sensor NO GO TO STEP 4 1 Terminal side of the front wheel speed sensor 4 Fro...

Page 390: ...0 km h 19 mph check that the ABS indicator operates normally page 19 5 If the OTC 4 3 is indicated check the front brake for drag 1 Speed Sensor Air Gap Inspection Measure the air gap between the spee...

Page 391: ...ulator 18P Black 111 connector page 19 8 Check for continuity between each terminal of the wire harness side rear wheel speed sensor 2P Orange connector 1 and ground CONNECTION Pink white Ground Green...

Page 392: ...witch OFF Disconnect the front wheel speed sensor 2P Blue connector page 19 21 Check for continuity between each terminal of the sensor side front wheel speed sensor 2P Blue connector 1 and ground CON...

Page 393: ...wheel speed sensor 4 Rear Wheel Speed Sensor Line Short Circuit Inspection Check for continuity between each terminal of the wire harness side rear wheel speed sensor 2P Orange connector 1 and ground...

Page 394: ...onnector NO Intermittent failure Replace the ABS M fuse 30 A with a new one and recheck 3 Motor Power Input Line Open Circuit Inspection Install the ABS M fuse 30 A Disconnect the ABS modulator 18P Bl...

Page 395: ...NO Intermittent failure Replace the ABS MAIN fuse 10 A with a new one and recheck 3 Power Input Line Open Circuit Inspection Install the ABS MAIN fuse 10 A Turn the ignition switch ON with the engine...

Page 396: ...the motorcycle above 30 km h 19 mph Recheck the OTC page 19 6 Is the DTC 8 1 indicated YES Faulty ABS modulator NO ABS control unit is normal intermittent failure WHEEL SPEED SENSOR AIR GAP INSPECTIO...

Page 397: ...NSOR REMOVAL INSTALLATION Remove the following Left middle cowl page 2 7 Front wheel page 16 16 Remove the front wheel speed sensor 2P Blue connector 1 from the frame and disconnect the connector Remo...

Page 398: ...e front fender mounting bolt threads TORQUE Front reflector mounting nut 1 5 N m 0 2 kgf m 1 1 lbMt REAR WHEEL SPEED SENSOR REMOVAL INSTALLATION Remove the following Right side cover page 2 9 Drive ch...

Page 399: ...the rear wheel speed sensor mounting bolts 4 Remove the rear wheel speed sensor 1 from the caliper bracket Clean around the mounting area of the caliper bracket thoroughly and be sure that no foreign...

Page 400: ...e brake fluid from the lever pedal brake line hydraulic systems page 18 5 Remove the ABS modulator cover A and B page 19 24 Pull up the lock lever 1 and disconnect the ABS modulator 18P connector 2 Lo...

Page 401: ...MEMO...

Page 402: ...Y CHARGING SYSTEM SERVICE INFORMATION 20 2 TROUBLESHOOTING 20 3 SYSTEM LOCATION 20 4 SYSTEM DIAGRAM 20 4 BATTERY 20 5 CHARGING SYSTEM INSPECTION 20 6 ALTERNATOR CHARGING COIL 20 7 REGULATOR RECTIFIER...

Page 403: ...under heavy load battery voltage will drop quickly and eventually die out For this reason the charging system is often suspected as the problem Battery overcharge often results from problems in the ba...

Page 404: ...re harness Faulty ignition switch 4 CHARGING VOLTAGE INSPECTION Measure and record the battery voltage using a digital multimeter page 20 5 Start the engine Measure the charging voltage page 20 6 Comp...

Page 405: ...STEM SYSTEM LOCATION CBR300RA shown MAIN FUSE 30 A ALTERNATOR REGULATOR RECTIFIER SYSTEM DIAGRAM MAIN FUSE 30 A G R W Bl Bl Bl I I EB 8 BATTERY REGULATOR RECTIFIER 20 4 BATTERY ALTERNATOR Bl Black G G...

Page 406: ...der B For digital clock setting procedure page 21 10 VOLTAGE INSPECTION Measure the battery voltage using a commercially available digital multimeter VOLTAGE 20 C 68 F Fully charged 13 0 13 2 V Under...

Page 407: ...0 8 mA max If current leakage exceeds the specified value a shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION Rem...

Page 408: ...terminal of the alternator stator side connector and ground There should be no continuity Replace the alternator stator if the resistance is out of specification or if any wire has continuity to groun...

Page 409: ...ack 0 1 1 0 0 at 20 C 68 F Ground line Green and Continuity should ground exist If all components of the charging system are normal and there are no loose connections at the regulator rectifier connec...

Page 410: ...BAR SWITCH 21 19 TURN SIGNAL LIGHT 21 5 BRAKE LIGHT SWITCH 21 19 BRAKE TAIL LIGHT 21 6 NEUTRAL SWITCH 21 20 LICENSE LIGHT 21 6 SIDESTAND SWITCH 21 21 COMBINATION METER 21 6 CLUTCH SWITCH 21 22 SPEEDOM...

Page 411: ...Be sure to let it cool down before servicing Check the battery condition before performing any inspection that requires proper battery voltage Use an electric heating element to heat the water coolant...

Page 412: ...SYSTEM LOCATION CBR300RA shown METER COMBINATION CLUTCH SWITCH N SIGNAL RELAy TUR NEUTRAL SWITCH SIDESTAND SWITCH LIGHTS METERS SWITCHES VS SENSOR 21 3...

Page 413: ...nto the headlight unit groove Install the dust cover tightly against the headlight unit Connect the headlight 2P connector BULB REMOVAL INSTALLATION CB300F FA Remove the upper cowl page 2 11 2 3 4 I T...

Page 414: ...e turn signal light lens and screws Tighten the screws securely LIGHTS METERS SWITCHES 3 2 4 REAR TURN SIGNAL LIGHT REMOVAL INSTALLATION Remove the rear under cover page 2 17 Disconnect the rear turn...

Page 415: ...is installed in position and is in good condition replace it with a new one if necessary Install the license light cover and screws Tighten the screws securely COMBINATION METER SYSTEM INSPECTION CBR3...

Page 416: ...are OK replace the combination meter page 21 9 POWER GROUND LINES INSPECTION CBR300R RA Remove the upper cowl page 2 11 NOTE Check the following at the wire harness side connector of the combination m...

Page 417: ...te wire between the fuse box and starter relay switch 1 R POWER GROUND LINES INSPECTION CB300F FA 21 8 Remove the upper cowl page 2 11 NOTE Check the following at the wire harness side connector of th...

Page 418: ...lowing Open circuit in the Red wire Blown sub fuse 10 A CLOCK Blown main fuse 30 A Open circuit in Red white wire between the fuse box and starter relay switch LIGHTS METERS SWITCHES G BI 1 R REMOVAL...

Page 419: ...tion meter assembly page 21 9 DISASSEMBLY ASSEMBLY CB300F FA Remove the combination meter five screws then disassemble the combination meter 0 5 N m 0 1 kgf m 0 4 lbMt COMBINATION METER DIGITAL CLOCK...

Page 420: ...Press the SET button The minute digits start blinking 6 Press the SEL button until the desired minute is displayed 7 Press and hold to advance the minute fast 8 Press the SET button The clock is set N...

Page 421: ...ears replace the combination meter If pulse voliage does not appear check the following White red wire open circuit Black green wire open circuit If the wires are OK check the VS sensor page 21 13 SYS...

Page 422: ...emove the left side cover Check for loose or poor contact of the VS sensor 3P connector 1 Disconnect the VS sensor 3P connector Turn the ignition switch ON and engine stop switch O Measure the voltage...

Page 423: ...g this inspection check for combination meter system inspection page 21 6 Remove the upper cowl page 2 11 Remove the dust cover 1 Connect the peak voltage tester or peak voltage adaptor 1 probes to th...

Page 424: ...r system inspection page 21 7 Remove the upper cowl page 2 11 Remove the dust cover 1 Connect the peak voltage tester or peak voltage adaptor 1 probes to the combination meter 16P connector 2 terminal...

Page 425: ...ure gauge 1 blinks check for a short circuit in wire harness and the ECT sensor If the wire harness and ECT sensor are good replace the combination meter assembly page 21 9 SYSTEM INSPECTION Perform t...

Page 426: ...llustration Temperature 50 C 122 F 80 C 176 F Resistance 6 8 7 4 kQ 2 1 2 7 kQ Replace the ECT senor if it is out of specification by more than 10 at any temperature listed Install the ECT sensor page...

Page 427: ...e inspections are normal replace the combination meter with a known good one and recheck IGNITION SWITCH INSPECTION 21 18 Remove the fuel tank page 7 7 Disconnect the ignition switch 3P connector 1 Ch...

Page 428: ...RA page 22 2 CB300F FA page 22 3 BRAKE LIGHT SWITCH FRONT Disconnect the front brake light switch connectors 1 and check for continuity between the switch terminals There should be continuity with the...

Page 429: ...when the transmission is into gear If the continuity inspection is normal open circuit in Light green red wire between neutral switch wire connector and neutral indicator If the continuity inspection...

Page 430: ...e sidestand switch 3P Green connector 1 Check for continuity at the sidestand switch 3P Green connector of the switch side connector There should be continuity with the sidestand retracted and no cont...

Page 431: ...itch mounting bolt with a new one Installation is in the reverse order of removal NOTE Align the sidestand switch groove with the frame pin TORQUE 12 N m 1 2 kgf m 9 lbMt CLUTCH SWITCH 21 22 Remove th...

Page 432: ...the fuel pump 5P connector 1 Yellow white and Green black terminals Inspect the resistance of the float at the full and empty positions Float position FULL EMPTY Resistance 6 10 Q 180 186 Q Replace t...

Page 433: ...Black Green STANDARD Battery voltage There should be standard voltage If there is no standard voltage inspect the following Open circuit in Green wire Open circuit in Black or Black red wire between...

Page 434: ...Right turn signal light Gray Light blue Left turn signal light Gray Orange There should be continuity with the turn signal switch operated If there is no continuity inspect the following Open circuit...

Page 435: ...MEMO...

Page 436: ...22 WIRING DIAGRAMS WIRING DIAGRAM CBR300R RA 22 2 WIRING DIAGRAM CB300F FA 22 3 22 1...

Page 437: ...MEMO...

Page 438: ...NGINE IDLE SPEED 3 12 ENGINE INSTALLATION 15 6 ENGINE OIL 3 10 ENGINE OIL FILTER 3 11 ENGINE OIL STRAINER SCREEN 9 4 INDEX ENGINE REMOVAL 15 4 EVAP PURGE CONTROL SOLENOID VALVE CANISTER 7 25 EVAPORATI...

Page 439: ...11 STARTER CLUTCH 13 8 STARTER MOTOR 6 5 STARTER RELAY SWITCH 6 8 STATOR CKP SENSOR 13 5 STEERING HEAD BEARINGS 3 23 STEERING STEM 16 29 SUSPENSION 3 23 SWINGARM 17 15 SYSTEM DIAGRAM ABS BRAKE SYSTEM...

Page 440: ...CLOCK 6 10A ABS ECU I I I II I 1 1r _ a SENSOR 2P 3p 5 l 1111 J 00 fl CC f 6P iii iii iii3P SP i2 P I SENSOR UP DONN REGULATOR o o o Q o o_ Q ljQl I 1 1 FUEL RECTIFER I CD CD a i s CD iii s1 01 5 1l l...

Page 441: ..._ _ rn j EARTH g S 0 il 3 Q o fl 3 Gr SIDE SENSOR ALTERNATOR 1 en a s rn en CJ C J ii en ro STAND TSOR Pcsv TH I l lrnH l UJ I ll l J0Hl111 SWITCH YJ L J_ FUSE BOX LAa J EVAP 33P1 1 4P FUEL j FUSE BOX...

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