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Honda CBF600N Service Manual Download Page 440

HYDRAULIC BRAKE

15-4

SERVICE INFORMATION

GENERAL

Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be
careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.

 • This section covers service of the conventional brake components of the brake system. For Anti-lock Brake System

(ABS) service, see page 16-4.

 • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc

with a high quality brake degreasing agent.

 • Never allow contaminates (e.g., dirt, water) to get into an open reservoir.
 • Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
 • Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of

fluid as they may not be compatible.

 • Always check brake operation before riding the motorcycle.

SPECIFICATIONS

Unit: mm (in)

Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health.
 • Avoid breathing dust particles.
 • Never use an air hose or brush to clean brake assemblies. Use and OSHA-approved vacuum cleaner.

ITEM

STANDARD

SERVICE LIMIT

Front

Specified brake fluid

DOT 4

–

Brake disc thickness

4.5 (0.18)

3.5 (0.14)

Brake disc runout

–

0.30 (0.012)

Master cylinder I.D.

12.700 – 12.743 (0.5000 – 0.5017)

12.755 (0.5022)

Master piston O.D.

12.657 – 12.684 (0.4983 – 0.4994)

12.645 (0.4978)

Caliper cylinder I.D.
(CBF600SA/NA)

Upper

22.650 – 22.700 (0.8917 – 0.8937)

22.712 (0.8942)

Middle

22.650 – 22.700 (0.8917 – 0.8937)

22.712 (0.8942)

Lower

22.650 – 22.700 (0.8917 – 0.8937)

22.712 (0.8942)

Caliper cylinder I.D.
(CBF600S/N)

Upper

25.400 – 25.450 (1.0000 – 1.0020)

25.460 (1.0023)

Lower

25.400 – 25.450 (1.0000 – 1.0020)

25.460 (1.0023)

Caliper piston O.D.
(CBF600SA/NA)

Upper

22.585 – 22.618 (0.8892 – 0.8905)

22.560 (0.8882)

Middle

22.585 – 22.618 (0.8892 – 0.8905)

22.560 (0.8882)

Lower

22.585 – 22.618 (0.8892 – 0.8905)

22.560 (0.8882)

Caliper piston O.D.
(CBF600S/N)

Upper

25.318 – 25.368 (0.9968 – 0.9987)

25.310 (0.9965)

Lower

25.318 – 25.368 (0.9968 – 0.9987)

25.310 (0.9965)

Rear

Specified brake fluid

DOT 4

–

Brake pedal height

67.5 (2.66)

–

Brake disk thickness

5.0 (0.20)

4.0 (0.16)

Brake disc runout.

–

0.30 (0.012)

Master cylinder I.D.(CBF600SA/NA)

15.870 – 15.913 (0.6248 – 0.6265)

15.925 (0.6270)

Master cylinder I.D. (CBF600S/N)

14.000 – 14.043 (0.5512 – 0.5529)

14.055 (0.5533)

Master piston O.D. (CBF600SA/NA)

15.827 – 15.854 (0.6231 – 0.6242)

15.815 (0.6226)

Master piston O.D. (CBF600S/N)

13.954 – 13.984 (0.5494 – 0.5510)

13.945 (0.5490)

Caliper cylinder I.D. 

38.180 – 38.230 (1.5031– 1.5051)

38.240 (1.5055)

Caliper cylinder O.D. 

38.098 – 38.148 (1.4999– 1.5019)

38.090 (1.4996)

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

email: [email protected]

Summary of Contents for CBF600N

Page 1: ...IRECT SALES Spain Holland Austria Portugal Belgium Denmark Greece Italy Macedonia Romania Burgaria Ukuraine Israel Finland Germany Sweden Island Russia Poland Slovenia Croatia Latvia Norway Swiss Luxemburug Hungary Czech Slovakia III ED Germany Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 2: ...lly careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields any time you hammer drill grind pry or work around pressurized air or liquids and springs or other stored energy compone...

Page 3: ...OUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instructions Instructions how to service this vehicle correctly and safely As you read this manual you will find information that is preceded by a symbol The purpose of this message is to help prevent damage to your vehicle other property or the envir...

Page 4: ...um disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NLGI 2 or equivalent Example Molykote G n Paste manufactured by Dow Corning U S A Honda Moly 60 U S A only Rocol ASP manufactured by Rocol Limited U K Rocol Paste manufacture...

Page 5: ...DER SPECIFICATIONS 1 10 FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS 1 11 REAR WHEEL SUSPENSION SPECIFICATIONS 1 11 HYDRAULIC BRAKE SPECIFICATIONS 1 12 BATTERY CHARGING SYSTEM SPECIFICATIONS 1 12 IGNITION SYSTEM SPECIFICATIONS 1 12 ELECTRIC STARTER SPECIFICATIONS 1 13 LIGHTS METERS SWITCHES SPECIFICATIONS 1 13 STANDARD TORQUE VALUES 1 14 ENGINE FRAME TORQUE VALUES 1 14 LUBRICATION SEAL POINTS 1 ...

Page 6: ...8 Route all electrical wires as show in the Cable and Harness Routing page 1 24 ABBREVIATION Throughout this manual the following abbreviations are used to identify the respective parts or systems Abbrev term Full term ABS Anti lock Brake System CKP sensor Crankshaft Position sensor DLC Data Link Connector DTC Diagnostic Trouble Code ECM Engine Control Module ECT sensor Engine Coolant Temperature ...

Page 7: ...GENERAL INFORMATION 1 3 MODEL IDENTIFICATION CBF600SA shown CBF600N shown Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 8: ...ame tube The engine serial number is stamped on the right side of the upper crankcase The throttle body identification number is stamped on the throttle body as shown VEHICLE IDENTIFICATION NUMBER REGISTERED NUMBER PLATE ENGINE SERIAL NUMBER THROTTLE BODY IDENTIFICATION NUMBER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 9: ...bel is attached to the frame under the seat When ordering color coded parts always specify the designated color code COLOR LABEL Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 10: ...AL E Bridgestone PILOT ROAD A Michelin Front brake Hydraulic double disc Rear brake Hydraulic single disc Caster angle 26 00 Trail length 110 mm 4 3 in Fuel tank capacity 20 liter 5 28 US gal 4 40 lmp gal Fuel reserve capacity 4 0 liter 1 06 US gal 0 88 lmp gal ENGINE Cylinder arrangement 4 cylinders in line inclined 30 from vertical Bore and stroke 67 0 X 42 5 mm 2 64 X 1 67 in Displacement 599 c...

Page 11: ... 23 5th 1 150 23 20 6th 1 041 25 24 Gearshift pattern 1 N 2 3 4 5 6 ELECTRICAL Ignition system Computer controlled digital transistorized with electric advance Starting system Electric starter motor Charging system Triple phase output alternator Regulator rectifier SCR shorted triple phase full wave rectification Lighting system Battery ITEM SPECIFICATIONS Manuals by Motomatrix www motomatrix co u...

Page 12: ...cation number GQ84A Idle speed 1 300 100 min 1 rpm Throttle grip freeplay 2 6 mm 1 16 1 4 in IAT sensor resistance at 20 C 68 F 1 4 kΩ ECT sensor resistance at 20 C 68 F 2 3 2 6 kΩ Fuel injector resistance at 20 C 68 F 11 13 Ω PAIR control solenoid valve resistance at 20 C 68 F 23 27 Ω CKP sensor peak voltage at 20 C 68 F 0 7 V minimum Fuel pressure at idle 343 kPa 3 5 kgf cm2 50 psi Fuel pump flo...

Page 13: ...alve seat width 0 90 1 10 0 035 0 043 1 5 0 06 Valve spring free length IN 40 19 1 582 39 4 1 55 EX 39 76 1 565 39 0 1 54 Cylinder head warpage 0 10 0 004 ITEM STANDARD SERVICE LIMIT Clutch lever freeplay 10 20 3 8 13 16 Clutch Spring free length 48 2 1 90 47 2 1 86 Disc thickness 2 92 3 08 0 115 0 121 2 6 0 10 Plate warpage 0 30 0 012 Clutch outer guide I D 24 993 25 003 0 9840 0 9844 25 013 0 98...

Page 14: ...ARD SERVICE LIMIT Crankshaft Connecting rod side clearance 0 15 0 30 0 006 0 012 0 35 0 014 Crankpin bearing oil clearance 0 028 0 052 0 0011 0 0020 0 06 0 002 Main journal bearing oil clearance 0 020 0 038 0 0008 0 0015 0 05 0 002 Runout 0 05 0 002 Piston piston rings Piston O D at 6 0 2 from bottom 66 965 66 985 2 6364 2 6372 66 90 2 634 Piston pin bore I D 16 002 16 008 0 6300 0 6302 16 02 0 63...

Page 15: ...0 008 Recommended fork fluid Honda Ultra Cushion Oil 10W or equivalent Fluid level 149 5 9 Fluid capacity 457 2 5 cm3 15 5 0 08 US oz 16 1 0 09 lmp oz Steering head bearing pre load 8 8 13 7 N 0 9 1 4 kgf 2 0 3 1 lbf ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 2 0 0 08 Cold tire pres sure Driver only 290 kPa 2 90 kgf cm2 42 psi Driver and passenger 290 kPa 2 90 kgf cm2 42 psi Axle runout ...

Page 16: ...cified brake fluid DOT 4 Brake pedal height 67 5 2 66 Brake disk thickness 5 0 0 20 4 0 0 16 Brake disc runout 0 30 0 012 Master cylinder I D CBF600SA NA 15 870 15 913 0 6248 0 6265 15 925 0 6270 Master cylinder I D CBF600S N 14 000 14 043 0 5512 0 5529 14 055 0 5533 Master piston O D CBF600SA NA 15 827 15 854 0 6231 0 6242 15 815 0 6226 Master piston O D CBF600S N 13 954 13 984 0 5494 0 5510 13 9...

Page 17: ... X 2 Instrument light LED 12V 1 7 W X 2 Turn signal indicator LED 12V 1 7 W X 2 High beam indicator LED Neutral indicator LED Low oil pressure indicator LED MIL LED Coolant temperature indicator LED Immobilizer system HISS indicator LED ABS indicator LED LED Fuse Main fuse 30 A Sub fuse 20 A X 3 10 A X 4 30 A X 2 20 A X 3 10 A X 5 20 A X 3 10 A X 4 30 A X 2 20 A X 3 10 A X 5 Tachometer peak voltag...

Page 18: ...oil filter cartridge 1 20 26 2 7 19 Apply engine oil to the threads and O ring Oil filter boss 1 20 See page 3 14 Apply a locking agent to the threads Engine oil drain bolt 1 12 30 3 1 22 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Oil pump assembly bolt 3 6 12 1 2 9 CT bolt Oil pump driven sprocket bolt 1 6 15 1 5 11 Apply a locking agent to the threads Oil pipe A mounting bolt 2 6 12...

Page 19: ...1 2 9 Apply a locking agent to the threads Exhaust pipe stud bolt 8 8 See page 2 11 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Clutch center lock nut 1 22 128 13 1 94 Apply engine oil to the threads and seating surface Stake Clutch spring bolt 5 6 12 1 2 9 Starter clutch outer mounting bolt 1 10 83 8 5 61 Apply engine oil to the threads and seating surface Shift drum center socket bol...

Page 20: ...5 11 120 See page 11 17 Replace with a new one 10 mm bolt 1 10 39 4 0 29 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Connecting rod bearing cap nut 8 7 26 2 7 19 Apply engine oil to the threads and seating surface ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Starter motor terminal nut 1 6 10 1 0 7 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft EOP switch 1 PT 1 8 12...

Page 21: ...TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Fuel tank rear mounting nut 1 6 12 1 2 9 Fuel filler cap mounting bolt 3 4 1 8 0 2 1 3 Fuel pump mounting nut 7 6 12 1 2 9 See page 5 57 Air cleaner housing screw 9 6 3 5 0 4 2 6 ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Radiator upper mounting bolt 2 6 3 5 0 4 2 6 Fan motor mounting bolt 3 5 5 0 0 5 3 7 Fan motor shroud mounting bolt ...

Page 22: ...C bolt replace with a new one Front brake hose clamp bolt CBF600S N 1 6 12 1 2 9 ALOC bolt replace with a new one Front brake hose bolt CBF600S N 2 6 10 1 0 7 Front brake hose bolt CBF600SA NA 4 6 10 1 0 7 Front pulser ring mounting bolt CBF600SA NA 3 5 7 0 0 7 5 2 ALOC bolt replace with a new one ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Drive chain case mounting bolt 2 6 12 1 2 9 R...

Page 23: ...nt brake light switch screw 1 4 1 2 0 1 0 9 Rear master cylinder mounting bolt 2 6 12 1 2 9 Rear master cylinder reservoir hose joint screw 1 4 1 5 0 2 1 1 Apply a locking agent to the threads Rear master cylinder push rod joint nut 1 8 17 1 7 13 Rear brake fluid reservoir mount ing bolt 1 6 10 1 0 7 Front brake hose clamp bolt CBF600SA NA 4 6 10 1 0 7 CBF600S N 1 6 12 1 2 9 ALOC bolt replace with...

Page 24: ...4 0 29 Sidestand bracket socket bolt 2 10 55 5 6 41 Gearshift pedal link pivot bolt 1 8 27 2 8 20 Gearshift arm pinch bolt 1 6 20 2 0 15 Ignition coil stay mounting nut 4 6 3 5 0 4 2 6 Pair solenoid valve stay mounting nut 2 6 3 5 0 4 2 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 25: ...er sliding surface Clutch outer primary driven gear sliding surface Clutch outer guide sliding surface Oil pump drive sprocket and collar sliding surface M3 4 C5 C6 shifter gear shift fork grooves Starter reduction gear shaft sliding surface Starter idle gear shaft sliding surface Water pump shaft thrust washer sliding surface Cylinder head mounting bolt threads and seating surface Engine oil Pist...

Page 26: ...lt threads Coating width 6 5 1 mm Cam chain tensioner B pivot bolt threads Coating width 6 5 1 mm Oil filter boss threads stud side Coating width 6 5 1 mm Oil pipe A B bolt threads Coating width 6 5 1 mm Oil pump chain guide A B bolt threads Coating width 6 5 1 mm Spindle plate bolt threads Coating width 6 5 1 mm Spindle set plate bolt threads Coating width 6 5 1 mm Shift drum stopper arm pivot bo...

Page 27: ... absorber spring adjuster cam sliding area Engine oil Steering head bearing adjusting nut threads Cable lubricant Throttle cable A B casing inside Clutch cable outer inside Honda bond A Honda hand grip cement Cemedine 540 or equivalent Handlebar grip rubber inside Silicone grease Brake caliper main and sub slide pin sliding surfaces Apply 0 4 g each Brake caliper pin boot inside Brake pad pin stop...

Page 28: ...NDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE CLUTCH SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE CLUTCH SWITCH WIRE BRAKE HOSE GUIDE CLUTCH CABLE THROTTLE CABLES FRONT BRAKE HOSE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 29: ...CH WIRE CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE RIGHTHANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLES CLUTCH CABLE FRONT BRAKE HOSE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 30: ...RONT BRAKE HOSE SPEEDOMETER 16P Black CONNECTOR Parallel Contact FRONT TURN SIGNAL LIGHT 2P Orange CONNECTOR HEAD LIGHT 4P Natural CONNECTOR THROTTLE CABLES SPEEDOMETER 16P Black CONNECTOR FRONT BRAKE HOSE Parallel Contact FRONT TURN SIGNAL LIGHT 2P Light blue CONNECTOR CLUTCH CABLE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 31: ...ER RECEIVER WIRE LEFT TURN SIGNAL WIRE RIGHT TURN SIGNAL WIRE 30 CLUTCH CABLE FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLES 30 IMMOBILIZER RECEIVER WIRE LEFT HANDLEBAR SWITCH WIRE RIGHT TURN SIGNAL WIRE LEFT TURN SIGNAL WIRE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 32: ...T HANDLEBAR SWITCH 6P Blue CONNECTOR HEAD LIGHT 3P Black CONNECTOR LEFT HANDLEBAR SWITCH 6P Black CONNECTOR COMBINATION METER 9P Natural CONNECTOR RIGHT HANDLEBAR SWITCH 9P Brown CONNECTOR RIGHT HANDLEBAR SWITCH 2P Natural CONNECTOR COMBINATION METER 9P BLACK CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 33: ...CABLE FRONT BRAKE PIPE B CBF600SA only FAN MOTOR 2P Black CONNECTOR FRONT WHEEL SPEED SENSOR 2P Blue CONNECTOR HEAD LIGHT 4P Natural CONNECTOR FRONT BRAKE PIPE B CBF600NA only MAIN WIRE HARNESS CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE FAN MOTOR 2P Black CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 34: ...t blue CONNECTOR RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE A FRONT BRAKE PIPE A THROTTLE CABLES FRONT BRAKE PIPE C FRONT TURN SIGNAL LIGHT 2P Light blue CONNECTOR CLAMP RIGHT HANDLEBAR SWITCH WIRE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 35: ...FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLES FRONT BRAKE PIPE A FRONT BRAKE PIPE C FRONT BRAKE HOSE A Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 36: ...ED SENSOR FRONT WHEEL SPEED SENSOR WIRE CLIP CLAMP FRONTBRAKE HOSE C BRAKE HOSE 3WAY JOINT FRONT BRAKE HOSE B FRONT BRAKE HOSE BRAKE HOSE 3WAY JOINT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 37: ... HOSE FUEL TANK BREATHER HOSE RADIATOR SIPHON HOSE FUEL FEED HOSE IDC SOLENOID VALVE VACUUM HOSE FRONT BRAKE PIPES CBF600SA NA only DLC C View C View B B A D View D View A Hold the wire by the clutch cover FUSE BOX STARTER RELAY SWITCH INJECTOR SUB HARNESS 10P White CONNECTOR UPPER RADIATOR HOSE HORN WIRE 45 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ema...

Page 38: ... WIRE HARNESS 8P Natural CONNECTOR OPTION 6P Natural CONNECTOR REAR WHEEL SPEED SENSOR 2P Red CONNECTOR FUSE BOX REAR BRAKE LIGHT SWITCH 2P Black CONNECTOR STARTER MOTOR CABLE CLUTCH CABLE O2 SENSOR 4P Black CONNECTOR REAR BRAKE LIGHT SWITCH CLAMP EOP SWITCH WIRE O2 SENSOR WIRE O2 SENSOR CKP SENSOR WIRE STARTER RELAY SWITCH OPTION 6P Natural CONNECTOR Manuals by Motomatrix www motomatrix co uk The...

Page 39: ...wire by the clutch cover EOP SWITCH CKP SENSOR WIRE GUIDE TURN SIGNAL RELAY FUSE BOX BATTERY BATTERY NEGATIVE CABLE BATTERYPOSITIVE CABLE SUB HARNESS 6P Natural CONNECTOR OPTION 6P Natural CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 40: ... FRONT BRAKE PIPE CBF600SA NA only ECT SENSOR 3P Black CONNECTOR IAT SENSOR 2P Gray CONNECTOR PAIR AIR SUCTION HOSE To cylinder head cover SUB HARNESS 6P Black CONNECTOR FAN MOTOR 2P Black CONNECTOR MAIN WIRE HARNESS FUEL LEVEL SENSOR 2P Blue or Green CONNECTOR TP SENSOR 3P Black CONNECTOR CKP SENSOR 2P Red CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded...

Page 41: ...IAT SENSOR 2P Gray CONNECTOR SIDESTAND SWITCH 2P Green CONNECTOR ALTERNATOR WIRE ABS CHECK 3P Natural CONNECTOR SUB HARNESS 6P Black CONNECTOR HEADLIGHTRELAY ENGINE STOP RELAY FUEL CUT RELAY FAN CONTROL RELAY BATTERY NEGATIVE CABLE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 42: ...NE STOP RELAY CONNECTORS REAR COMB LIGHT 9P Black LICENSE LIGHT 2P Natural BANK ANGLE SENSOR 3P Green CONNECTOR REGULATOR RECTIFIER ALTERNATOR 3P CONNECTOR BANK ANGLE SENSOR REGULATOR RECTIFIER 2P CONNECTOR FUEL CUT RELAY FAN CONTROL RELAY ENGINE STOP RELAY CONNECTORS REAR COMB LIGHT 9P Black LICENSE LIGHT 2P Natural Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded...

Page 43: ...E CLAMP RADIATOR SIPHON HOSE SIDESTAND SWITCH WIRE ALTERNATOR WIRE BATTERY NEGATIVE CABLE RADIATOR RESERVE TANK OVERFLOW HOSE SIDESTAND SWITCH NEUTRAL SWITCH CLIP RADIATOR SIPHON HOSE SIDESTAND SWITCH 2P Green CONNECTOR 15 25 mm Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 44: ...SA N NA A View A 45 B View B LOWER RADIATOR HOSE 0 45 CYLINDER BLOCK TO WATER PUMP HOSE BYPASS HOSE FUEL TANK DRAIN HOSE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 45: ...ROL SOLENOID VALVE 2P Black CONNECTOR 1 SPARK PLUG WIRE 4 SPARK PLUG WIRE CRANKCASE BREATHER HOSE BRAKE PIPES PAIR AIR SUCTION HOSES To cylinder head cover THROTTLE CABLES PAIR AIR SUCTION HOSE To air cleaner housing CLUTCH CABLE UPPER RADIATOR HOSE PAIR CONTROL SOLENOID VALVE 2 SPARK PLUG WIRE 3 SPARK PLUG WIRE PAIR CONTROL SOLENOID VALVE 2P Black CONNECTOR 1 SPARK PLUG WIRE 4 SPARK PLUG WIRE CRA...

Page 46: ...ES INJECTOR SUB HARNESS INTAKE AIR DUCT VACUUM HOSE INTAKE AIR DUCT VACUUM HOSE INTAKE AIR DUCT CONTROL VALVE 2P Gray CONNECTOR DLC IAT SENSOR 2P Gray CONNECTOR ECM 33P Black CONNECTOR INJECTOR SUB HARNESS 10P White CONNECTOR INTAKE AIR DUCT DIAPHRAGM INJECTOR SUB HARNESS 10P Black CONNECTOR O2 SENSOR 4P Black CONNECTOR ECM 33P Light gray CONNECTOR ECM Manuals by Motomatrix www motomatrix co uk Th...

Page 47: ...E DRAIN HOSE INTAKE AIR DUCT VACUUM HOSE INTAKE AIR DUCT CONTROL VALVE 2P Gray CONNECTOR SUB HARNESS 6P Black CONNECTOR STARTER MOTOR VS SENSOR 3P Black CONNECTOR NEUTRAL SWITCH BATTERY NEGATIVE CABLE VS SENSOR WIRE NEUTRAL SWITCHWIRE STARTER MOTOR CABLE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 48: ... 25P CONNECTOR FRONT BRAKE PIPE C REAR BRAKE PIPE D REAR BRAKE PIPE A DELAY VALVE REAR BRAKE PIPE B REAR BRAKE PIPE C FRONT BRAKE PIPE B FRONT BRAKE PIPE A Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 49: ...OX STARTER RELAY SWITCH FRONT BRAKE PIPE C REAR BRAKE PIPE D IDC SOLENOID VALVE VACUUM HOSE O2 SENSOR 4P Black CONNECTOR A View A INJECTOR SUB HARNESS 10P White CONNECTOR INJECTOR SUB HARNESS 10P Black CONNECTOR O2 SENSOR 4P Black CONNECTOR REAR BRAKE LIGHT SWITCH 2P Black CONNECTOR BATTERYPOSITIVE CABLE ECM FUSE BOX STARTER RELAY SWITCH OPTION 6P Natural CONNECTOR Manuals by Motomatrix www motoma...

Page 50: ... MASTER CYLINDER REARBRAKE HOSE B REAR BRAKE CALIPER REAR BRAKE HOSE A DELAY VALVE REAR BRAKE MASTER CYLINDER REAR BRAKE RESERVOIR HOSE REAR BRAKE RESERVOIR TANK REAR BRAKE HOSE REAR BRAKE CALIPER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 51: ...BF600S SA N NA BRAKE TAIL LIGHT UNIT LEFT TURN SIGNAL LIGHT WIRE RIGHT TURN SIGNAL LIGHT WIRE LICENSE LIGHT WIRE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 52: ... not react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere Blow by gas is returned to the combustion chamber through the air cleaner and throttle body AIR CLEA...

Page 53: ...f fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor The reed valve prevents reverse air flow through the system The 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 acc...

Page 54: ...orporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing of the muffler baffles header pipes ...

Page 55: ...5 FRONT FENDER 2 6 REAR FENDER 2 7 REAR VIEW MIRROR CBF600S SA 2 8 FRONT LEFT RIGHT COWL CBF600S SA 2 9 WINDSCREEN CBF600S SA 2 9 METER PANEL CBF600S SA 2 10 FRONT CENTER COWL CBF600S SA 2 10 MUFFLER 2 11 EXHAUST PIPE 2 11 MAIN STAND CBF600SA NA 2 13 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 56: ...LOCATIONS SEAT REAR COWL FRONT FENDER CBF600SA shown FRONT CENTER COWL FRONT LEFT RIGHT COWL WIND SCREEN SIDE COVER SEAT REAR COWL FRONT FENDER CBF600N shown SIDE COVER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 57: ...ays inspect the exhaust system for leaks after installation TORQUE VALUES TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler Exhaust pipe joint nut 12 N m 1 2 kgf m 9 lbf ft Muffler mounting nut 22 N m 2 2 kgf m 16 lbf ft Exhaust pipe mounting nut 22 N m 2 2 kgf m 16 lbf ft Muffler band bolt 22 N ...

Page 58: ... moving the seat SEAT BRACKET REMOVAL INSTALLATION Remove the four socket bolts Remove the seat bracket If you wish the seat position upward or downward you can choose low or high position There are three bolt holes each mounting point Middle bolt hole is standard position Install the seat bracket Install and tighten the socket bolt to the specified torque After installation make sure that the sea...

Page 59: ...de cover page 2 5 Remove the bolt caps Remove the socket bolts and grab rail Remove the socket bolts and rear center cowl Remove the socket bolts and special bolts collars Remove the trim clips Carefully release the tabs of the rear cowl from the grooves on the taillight unit then remove the right left rear cowl TORQUE 4 N m 0 4 kgf m 3 0 lbf ft GROMMETS SIDE COVER SOCKET BOLT TABS SOCKET BOLTS RE...

Page 60: ...age 13 15 Remove the front brake hose clamp bolts Remove the mounting bolts and front fender Installation is in the reverse order of removal Install and tighten the front fender mounting bolts to the specified torque Install and tighten a new front brake hose clamp bolts to the specified torque TORQUE 27 N m 2 8 kgf m 20 lbf ft SOCKET BOLTS REAR CENTER COWL BOLT CAPS GRAB RAIL SOCKET BOLTS CLAMP B...

Page 61: ...ck connector Remove the bolts and nuts washers Remove the tail brake light unit Remove the battery page 17 5 Remove the bolt and rear brake fluid reservoir BOLTS 9P Black CONNECTOR NUTS WASHERS TAIL BRAKE LIGHT UNIT 2P Natural CONNECTOR BOLT REAR BRAKE FLUID RESERVOIR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 62: ...BF600S SA REMOVAL INSTALLATION Remove the two socket bolts Remove the rear view mirror Install the rear view mirror Install the two socket bolts to the specified torque While installing the rear fender route the wire harness properly page 1 24 TABS BOLT WASHER COLLAR REAR FENDER FUSE BOX BOLTS TORQUE 14 N m 1 4 kgf m 10 lbf ft SOCKET BOLTS REAR VIEW MIRROR Manuals by Motomatrix www motomatrix co u...

Page 63: ...ves on the upper cowl Disconnect the turn signal 2P connector Installation is in the reverse order or removal WINDSCREEN CBF600S SA REMOVAL Remove the windscreen covers Remove the screws and windscreen GROOVE 2P CONNECTOR TABS GROOVES BOLT COLLAR CLIP BOSS SOCKET BOLT LONG SOCKETBOLT SHORT COVERS SCREWS WINDSCREEN Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Ke...

Page 64: ...removal FRONT CENTER COWL CBF600S SA REMOVAL INSTALLATION Remove the following Windscreen page 2 9 Front left right cowl page 2 9 Meter panel page 2 10 Rear view mirror page 2 8 Release the grooves of the front center cowl from the rear view mirror stay mounting boss Pull the front center cowl and remove its bosses from the grommets on the stay Disconnect the headlight 4P Natural connector Install...

Page 65: ...fler page 2 11 Remove the right side cover page 2 5 Disconnect the O2 sensor 4P Black connector Remove the exhaust pipe joint nuts Remove the exhaust pipe mounting nut washer and bolt Remove the exhaust pipe and gaskets Always replace the gasket with a new one TORQUE 22 N m 2 2 kgf m 16 lbf ft TORQUE 22 N m 2 2 kgf m 16 lbf ft BAND BOLT MUFFLER WASHER MOUNTING BOLT COLLAR GASKET NUT 4P Black CONNE...

Page 66: ...ust pipe joint nuts to the speci fied torque Tighten the exhaust pipe mounting nut to the speci fied torque Always replace the gaskets with new ones MOUNTING BOLT EXHAUST PIPE GASKETS JOINT NUTS WASHER NUT TORQUE 12 N m 1 2 kgf m 9 lbf ft JOINT NUTS TORQUE 22 N m 2 2 kgf m 16 lbf ft BOLT WASHER NUT EXHAUST PIPE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ...

Page 67: ...the main stand pivot nut washer Remove the pivot bolt washer then remove the main stand INSTALLATION Install the main stand Install the pivot bolt washer Hook the return springs PIVOT NUT RETURN SPRINGS PIVOT BOLT WASHER MAIN STAND PIVOT BOLT WASHER MAIN STAND RETURN SPRINGS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 68: ...her Install and tighten the nut to the specified torque After installation check the main stand operation TORQUE 29 N m 3 0 kgf m 21 lbf ft PIVOT NUT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 69: ... COOLING SYSTEM 3 17 SECONDARY AIR SUPPLY SYSTEM 3 18 DRIVE CHAIN 3 19 DRIVE CHAIN SLIDER 3 23 BRAKE FLUID 3 24 BRAKE PAD WEAR 3 25 BRAKE SYSTEM 3 26 BRAKE LIGHT SWITCH 3 27 HEADLIGHT AIM 3 27 CLUTCH SYSTEM 3 28 SIDESTAND 3 28 SUSPENSION 3 29 NUTS BOLTS FASTENERS 3 30 WHEELS TIRES 3 30 STEERING HEAD BEARINGS 3 31 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Key...

Page 70: ... 7 liter 2 9 US qt 2 4 Imp qt After oil filter change 2 8 liter 3 0 US qt 2 5 lmp qt Engine oil Suggested oil Honda 4 stroke motorcycle oil or an equivalent Oil recommendation API classification SG or higher except oils labeled as energy conserving on the circular API service label Viscosity SAE 10W 30 JASO T 903 standard MA Engine idle speed 1 300 100 min 1 rpm Drive chain slack 20 30 mm 1 0 1 2 ...

Page 71: ...bolt 54 N m 5 5 kgf m 40 lbf ft Driven sprocket nut 108 N m 11 0 kgf m 80 lbf ft Front master cylinder reser voir cap screw 1 5 N m 0 2 kgf m 1 1 lbf ft Rear brake fluid reservoir mounting bolt 10 N m 1 0 kgf m 7 lbf ft Rear master cylinder push rod joint nut 17 N m 1 7 kgf m 13 lbf ft Drive chain adjuster lock nut 21 N m 2 1 kgf m 15 lbf ft Tensioner stopper 070MG 0010100 Oil filter wrench 07HAA ...

Page 72: ...quently when riding in rain or at full throttle 4 Replace every 2 years or at indicated odometer interval whichever comes first Replacement requires mechanical skill FREQUENCY WHICHEVER COMES FIRST ODOMETER READING NOTE 1 REFER TO PAGE X1 000 km 1 6 12 18 24 30 36 X1 000 mi 0 6 4 8 12 16 20 24 ITEMS Months 6 12 18 24 30 36 FUEL LINE I I I 3 5 THROTTLE OPERATION I I I 3 6 AIR CLEANER NOTE2 I I 3 7 ...

Page 73: ...61 Check the fuel rails and injectors for damage or leakage replace them if necessary page 5 85 Check the fuel pump mounting area for leakage replace the fuel pump packing if necessary page 5 56 Remove a support tools then lower the fuel tank Route the hoses wires and harness properly page 1 24 Be careful not to damage the harness and hoses After installing the fuel tank make sure the drain breath...

Page 74: ...either end of the throttle cable Minor adjustment is made with the upper adjuster Adjust the freeplay by loosening the lock nut and turning the adjuster Major adjustment is made with the lower adjuster Lift and support the fuel tank page 3 5 Adjust the freeplay by loosening the lock nut and turning the adjuster After adjustment tighten the lock nut securely Remove the support tool then install and...

Page 75: ...ER Service more frequently when ridden in rain at full throttle or after the motorcycle is washed or overturned Service if the deposit level can be seen in the drain hose Remove the left side cover page 2 5 Remove the crankcase breather drain hose and drain the deposits into a suitable container then reinstall the drain hose with the hose clamp SCREWS DUCT Install the air cleaner element with its ...

Page 76: ...h a wire brush or special plug cleaner Check the gap between the center and side elec trodes with a wire type feeler gauge If necessary adjust the gap by bending the side electrodes carefully Clean around the spark plug bases with compressed air before removing and be sure that no debris is allowed to enter the combustion chamber SPARK PLUG CAP SPARK PLUG WRENCH SPARK PLUG SPECIFIED SPARK PLUG NGK...

Page 77: ...cylinder head cover page 8 6 Remove the cam chain tensioner lifter sealing bolt and sealing washer Failure to release the cam chain tensioner will result in inaccurate valve clearance reading Turn the cam chain tensioner lifter shaft fully in clockwise and secure it using the special tool to prevent damaging the cam chain TORQUE 16 N m 1 6 kgf m 12 lbf ft SPARK PLUG WRENCH SPARK PLUG SEALING WASHE...

Page 78: ...ce and facing outward as shown If the timing marks on the cam sprocket facing inward turn the crankshaft clockwise one full turn 360 and realign the timing marks with the cylin der head surface so they are facing outward Insert the feeler gauge between the valve lifter and the cam lobe TIMING HOLE CAP O RING INDEX MARK T MARK TIMING MARKS FEELER GAUGE Manuals by Motomatrix www motomatrix co uk The...

Page 79: ...er exhaust valves using a feeler gauge Turn the crankshaft clockwise 1 2 turn 180 align the T mark on the CKP sensor rotor with the index mark on the right crankcase cover Record the clearance for each valve for reference in shim selection if adjustment is required VALVE CLEARANCE IN 0 20 0 03 mm 0 008 0 001 in No 3 INTAKE VALVES No 1 INTAKE VALVES INDEX LINE VALVE CLEARANCE EX 0 28 0 03 mm 0 011 ...

Page 80: ...m the camshaft except when replacing the camshaft and or cam sprocket Remove the camshafts page 8 8 Remove the valve lifters and shims Shim may stick to the inside of the valve lifter Do not allow the shims to fall into the crankcase Mark all valve lifters and shims to ensure correct reassembly in their original locations The valve lifter can be easily removed with a valve lapping tool or magnet T...

Page 81: ...shim thickness by mea suring the shim by micrometer Reface the valve seat if carbon deposit result in a calculated dimension of over 2 900 mm Install the shims and valve lifters in their original locations Install the newly selected shim on the valve retainer Apply molybdenum disulfide oil to the valve lifters Install the valve lifters into the valve lifter holes Install the camshaft page 8 26 Rot...

Page 82: ...motorcycle on the level ground with its sidestand Start the engine and let it idle for 3 5 minutes Stop the engine and wait 2 3 minutes Hold the motorcycle in an upright position Check the oil level through the inspection window If the level is below the lower level line fill the crankcase with the recommended oil up to the upper level line as following procedures Remove the oil filler cap TORQUE ...

Page 83: ...iscard the oil filter cartridge using the special tool Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range SUGGESTED OIL Honda 4 stroke motorcycle oil or an equivalent OIL RECOMMENDATION API classification SG or higher except oils labeled energy conserving on the circular API service label Viscosity SAE 10W 30 JASO T 903 s...

Page 84: ... ring Install the new oil filter and tighten it to the specified torque TORQUE 30 N m 3 1 kgf m 22 lbf ft OIL DRAIN BOLT SEALING WASHER SPECIFIED LENGTH 16 0 17 0 mm 0 63 0 67 in 16 0 17 0 mm 0 63 0 67 in OIL FILTER BOSS OIL FILTER CARTRIDGE O RING TOOL Oil filter wrench 07HAA PJ70101 TORQUE 26 N m 2 7 kgf m 19 lbf ft OIL FILLER WRENCH OIL FILTER CARTRIDGE Manuals by Motomatrix www motomatrix co u...

Page 85: ...gging or dam age Remove the radiator grill page 6 11 Straighten bend fins with a small flat blade screw driver and remove insects mud or other obstruc tions with compressed air or low water pressure Replace the radiator if the air flow is restricted over more than 20 of the radiating surface Remove the rear cover A page 7 4 Inspect the radiator hoses for cracks or deteriora tion and replace if nec...

Page 86: ...ioxide and water Lift and support the fuel tank page 3 5 Check the PAIR air suction hoses between the PAIR control solenoid valve and cylinder head cover for deterioration damage or loose connections Make sure that the hoses are not cracked Check the PAIR air suction hose between the air cleaner housing and PAIR control solenoid valve for deterioration damage or loose connections Make sure that th...

Page 87: ... axle wash ers aligned with the index marks of the swingarm Tighten the both drive chain adjuster lock nuts to the specified torque Tighten the rear axle nuts to the specified torque Recheck the drive chain slack and free wheel rota tion Lubricate the drive chain with 80 90 gear oil or drive chain lubricant designed specifically for use with O ring chains Wipe off the excess oil or chain lubricant...

Page 88: ...icate the drive chain with 80 90 gear oil or drive chain lubricant designed specifically for use with O ring chains Wipe off the excess oil or chain lubricant SPROCKETS INSPECTION Inspect the drive and driven sprocket teeth for wear or damage replace if necessary Never use a new drive chain on worn sprockets Both chain and sprockets must be in good condi tion or the new replacement chain will wear...

Page 89: ... drive chain page 3 19 Assemble the special tool as shown TORQUE Drive sprocket bolt 54 N m 5 5 kg m 40 lbf ft Driven sprocket nut 108 N m 11 0 kgf m 80 lbf ft BOLT DRIVE SPROCKET Drive sprocket Driven sprocket DRIVEN SPROCKET NUT When using the special tool follow the manufacturer s instruction TOOL Drive chain tool set 07HMH MR10103 DRIVE CHAIN TOOL SET Manuals by Motomatrix www motomatrix co uk...

Page 90: ...old drive chain master link master link plate and O rings Insert a new master link with new O rings from the inside of the drive chain and install the new plate and O rings with the identification mark facing the outside Assemble and set the drive chain tool set MASTER LINK DRIVE CHAIN TOOL SET STANDARD LINKS 124 LINKS REPLACEMENT CHAIN DID DID525VM2 124LE 124 LINKS 1 LINK O RINGS PLATE MASTER LIN...

Page 91: ...of the master link for cracks If there is any cracking replace the master link O rings and plate DRIVE CHAIN SLIDER Remove the crankcase rear cover page 7 4 Inspect the drive chain slider for excessive wear or damage If it is worn to the wear indicator replace the drive chain slider page 14 20 STANDARD LENGTH 1 3 1 5 mm 0 05 0 06 in MASTER LINK PINS DIAMETER OF THE STAKED AREA 5 50 5 80 mm 0 217 0...

Page 92: ... reservoir level If the brake pads are not worn and the fluid level is low check entire system for leaks page 3 26 FRONT BRAKE Turn the handlebar to the left so the reservoir is level and check the front brake reservoir fluid level through the sight glass If the fluid level is near the LOWER level mark remove the reservoir cap set plate and diaphragm and fill the reservoir with DOT 4 brake fluid f...

Page 93: ...g bolt Install the right side cover page 2 5 BRAKE PAD WEAR FRONT BRAKE PADS Check the brake pad for wear Replace the brake pads if either pad is worn to the bottom of wear limit groove Refer to brake pad replacement CBF600SA NA page 15 15 CBF600S N page 15 16 REAR BRAKE PADS Check the brake pad for wear Replace the brake pads if either pad is worn to the bottom of wear limit groove Refer to brake...

Page 94: ...n be adjusted by turning the adjuster BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the master cylinder push rod to obtain the desired pedal height After adjustment hold the adjusting bolt and tighten the lock nut If the brake pedal is adjusted to the lower position make sure that the clearance between the lower end of the push rod and the brake pedal does not fall below 1 mm 0 04 in ...

Page 95: ...he beam toward the left side of the rider A clockwise rotation moves the beam toward the left and counterclockwise rotation moves the beam toward the right side of the rider CBF600N NA Place the motorcycle on a level surface Adjust the headlight aim vertically by turning the head light case assembly Loose the headlight case mounting bolts and adjust the vertical beam by moving the headlight case a...

Page 96: ...scribed as follow Major adjustment is performed at the clutch lifter lever Loosen the lock nut and turn the adjusting nut to adjust the freeplay Tighten the lock nut while holding the adjusting nut If proper freeplay cannot be obtained or the clutch slips during test ride disassemble and inspect the clutch page 9 6 SIDESTAND Support the motorcycle on a level surface Check the sidestand spring for ...

Page 97: ...igns of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts Refer to the fork service page 13 21 Check for worn steering stem bearings by grabbing the front fork leg and attempting to move the front fork side to side Replace the steering head bearings if any looseness is noted page 13 33 REAR SUSPENSION INSPECTION Support the motorcycle us...

Page 98: ...e 14 14 NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their specified torque values page 1 14 Check that all hose clamps and cable stays are in place and properly secured WHEELS TIRES Tire pressure should be checked when the tires are COLD RECOMMENDED TIRE PRESSURE AND TIRE SIZE FRONT AXLE BOLT FRONT REAR Tire pressure 250 kPa 2 50 kgf cm2 36 psi 290 kPa 2 90 kgf cm2 ...

Page 99: ...ere with handlebar rotation Support the motorcycle using a safety stand or hoist securely and raise the front wheel off the ground Check that the handlebar moves freely from side to side and there is any abnormal play at the steering head bearings If the handlebar moves unevenly binds or has ver tical movement inspect the steering head bearings page 13 33 MINIMUM TREAD DEPTH FRONT 1 5 mm 0 06 in R...

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Page 101: ...AGRAM 4 2 SERVICE INFORMATION 4 3 TROUBLE SHOOTING 4 4 OIL PRESSURE INSPECTION 4 5 OIL STRAINER PRESSURE RELIEF VALVE 4 6 OIL PUMP 4 8 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 102: ... CAM SHAFT CONNECTING ROD PISTON INTAKE CAM SHAFT CRANKSHAFT OIL FILTER CARTRIDGE OIL ORIFICE MAINSHAFT EOP SWITCH COUNTERSHAFT OIL PUMP OIL STRAINER RELIEF VALVE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 103: ... disassembly 3 5 liter 3 7 US qt 3 1 lmp qt Engine oil Suggested oil Honda 4 stroke motorcycle oil or an equivalent Oil recommendation API classification SG or higher except oils labeled as energy con serving on the circular API service label Viscosity SAE 10W 30 JASO T 903 standard MA Oil pressure at EOP switch 496 kPa 5 1 kgf cm2 72 psi at 6 000 min 1 rpm 80 C 176 F Oil pump Tip clearance 0 15 0...

Page 104: ...ive or driven sprocket Damaged oil pump Internal oil leak High oil pressure Oil pressure relief valve stuck closed Clogged oil filter gallery or metering orifice Incorrect oil being used Oil contamination Oil or filter not changed often enough Worn piston rings Oil emulsification Blown cylinder head gasket Leaky coolant passage Entry of water Oil pressure gauge 07506 3000001 or equivalent commerci...

Page 105: ...ry page 3 15 Warm the engine to normal operating temperature approximately 80 C 176 F and increase the engine speed to 6 000 min 1 rpm and read the oil pressure Stop the engine and remove the tools Apply a sealant to the EOP switch threads as shown TERMINAL BOLT EOP SWITCH RUBBER CAP TOOLS Oil pressure gauge set 07506 3000001 or equivalent commercially avail able Oil pressure gauge attach ment 075...

Page 106: ...ne the cause page 20 28 OIL STRAINER PRESSURE RELIEF VALVE REMOVAL Drain the engine oil page 3 15 Remove the exhaust pipe page 2 11 Remove the flange bolts and the oil pan Remove the oil strainer and packing Clean the oil strainer screen TORQUE 12 N m 1 2 kgf m 9 lbf ft EOP SWITCH TORQUE 2 0 N m 0 2 kgf m 1 5 lbf ft TERMINAL BOLT EOP SWITCH RUBBER CAP Loosen the bolts in a crisscross pattern in tw...

Page 107: ...ly INSTALLATION Apply engine oil to a new O ring and install it onto the pressure relief valve Install the pressure relief valve to the crankcase Apply engine oil to a new packing and install it onto the oil strainer flange Install the oil strainer to the oil pump while aligning the oil strainer boss with the groove of the oil pump PRESSURE RELIEF VALVE O RING WASHER PISTON SNAP RING RELIEF VALVE ...

Page 108: ...il page 3 15 After installation check that there are no oil leaks OIL PUMP REMOVAL Drain the engine oil page 3 15 Remove the following right crankcase cover page 9 5 oil pan oil strainer page 4 6 Remove the bolt washer and oil pump driven sprocket Remove the bolts oil pipe A and seal rings Clean the oil pipe A thoroughly Do not apply more sealant than necessary BOLTS OIL PAN DRIVEN SPROCKET BOLT W...

Page 109: ...the bolts oil pipe B and O rings Clean the oil pipe B thoroughly DISASSEMBLY Remove the oil pump assembly bolts BOLTS OIL PUMP DOWEL PINS OIL PIPE B BOLTS O RINGS ASSEMBLY BOLTS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 110: ...an assembly Temporarily install the outer and inner rotors into the oil pump body Temporarily install the drive pin and oil pump shaft Measure the rotor tip clearance Measure the pump body clearance DOWEL PINS OIL PUMP COVER OIL PUMP BODY INNER ROTOR OUTER ROTOR OILPUMP SHAFT THRUST WASHER DRIVE PIN SERVICE LIMIT 0 20 mm 0 008 in TIP CLEARANCE SERVICE LIMIT 0 35 mm 0 014 in BODY CLEARANCE Manuals ...

Page 111: ... and oil pump body Install the drive pin into the hole in the oil pump shaft and align the drive pin with the groove in the inner rotor Install the thrust washer SERVICE LIMIT 0 17 mm 0 007 in SIDE CLEARANCE DRIVE PIN INNER ROTOR OIL PUMP BODY OUTER ROTOR OIL PUMP SHAFT DOWEL PINS OIL PUMP COVER THRUST WASHER 12 N m 1 2 kgf m 9 lbf ft ASSEMBLY BOLTS INNER ROTOR OUTER ROTOR OILPUMP SHAFT THRUST WAS...

Page 112: ...ump INSTALLATION Apply engine oil to new O rings and install them onto the oil pipe B Apply a locking agent to the oil pipe B mounting bolt threads Install the oil pipe B and tighten the bolts securely Install the dowel pins to the crankcase DOWEL PINS OIL PUMP COVER OIL PUMP BODY TORQUE 12 N m 1 2 kgf m 9 lbf ft ASSEMBLY BOLTS O RINGS OIL PIPE B BOLTS DOWEL PINS Manuals by Motomatrix www motomatr...

Page 113: ... and drive chain Apply a locking agent to the oil pump driven sprocket bolt threads Install the driven sprocket with its OUT mark fac ing out Install and tighten the driven sprocket bolt washer to the specified torque Install the following oil pan oil strainer page 4 7 right crankcase cover page 9 25 After installation fill the crankcase with the recom mended oil page 3 15 Check the oil pressure p...

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Page 115: ... 36 MIL CIRCUIT TROUBLESHOOTING 5 50 FUEL LINE INSPECTION 5 51 FUEL PUMP 5 56 FUEL CUT OFF RELAY 5 58 FUEL TANK 5 59 AIR CLEANER HOUSING 5 61 THROTTLE BODY 5 81 INJECTOR 5 85 ENGINE IDLE SPEED 5 90 IACV 5 90 MAP SENSOR 5 92 IAT SENSOR 5 93 ECT SENSOR 5 94 BANK ANGLE SENSOR 5 94 ENGINE STOP RELAY 5 96 ECM 5 97 SECONDARY AIR SUPPLY SYSTEM 5 99 O2 SENSOR 5 101 INTAKE AIR DUCT 5 101 Manuals by Motomat...

Page 116: ...FUEL SYSTEM PGM FI 5 2 FUEL SYSTEM PGM FI COMPONENT LOCATION 16 N m 1 6 kgf m 12 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 117: ...embled Always replace the packing when the fuel pump is removed A faulty PGM FI system is often related to poorly connected or corroded connectors Check those connections before proceeding The VS sensor sends digital pulse signal to the ECM and computation Refer to procedures for VS sensor inspection DTC troubleshooting MIL troubleshooting When disassembling the fuel system parts note the location...

Page 118: ...ssure gauge hose attachment A 07ZAJ S5A0120 Fuel attachment joint C 07ZAJ S7C0200 ECM test harness 33P 070MZ MCA0100 SCS connector 070PZ ZY30100 Inspection test harness 07GMJ ML80100 Test probe 07ZAJ RDJA110 O2 sensor wrench 07LAA PT50101 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 119: ... idle speed 2 Check the IACV 3 Inspect the fuel supply system page 5 51 Restricted fuel feed hose Contaminated deteriorated fuel Intake air leak Faulty IACV Restricted fuel tank breather hose Faulty ignition system Afterburn when engine braking is used Check the PAIR system page 5 99 Faulty PAIR system Faulty PAIR control solenoid valve Faulty PAIR check valve Clogged hose of the PAIR system Fault...

Page 120: ...SOR PAIR CONTROL SOLENOID VALVE ECT SENSOR TP SENSOR FUEL PUMP DLC IDC SOLENOID VALVE ENGINE STOP RELAY FUEL CUT OFF RELAY VS SENSOR CKP SENSOR INJECTOR ECM IACV IGNITION SWITCH Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 121: ...PG1 IAT SENSOR ECT SENSOR IMMOBILIZER RECEIVER ECM 33P Black CONNECTOR A ECM side male terminals ECM 33P Light gray CONNECTOR B Bl Y Bu G R W Br O Lg P Gr Black Yellow Blue Green Red White Brown Orange Light green Pink Gray FI FI FI FI FI FI FI FI A21 A4 A12 A3 B28 A20 B12 A8 A6 A17 A7 B3 A22 A31 B17 B9 B2 B20 B31 B29 B13 A9 A18 B14 B32 A30 B19 B4 A24 A23 A16 A27 A29 A19 A32 B22 B27 B15 1 2 8 9 29...

Page 122: ...5 NOTE 2 Lift and support the fuel tank page 3 5 ECT SENSOR 3P Black CONNECTOR IAT SENSOR 2P Gray CONNECTOR NOTE 1 TP SENSOR 3P Black CONNECTOR INJECTOR 2P Gray CONNECTORS NOTE2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 123: ...R NOTE 3 IACV 4P Black CONNECTOR NOTE 3 ECM 33P Black AND 33P Light gray CONNECTORS NOTE 2 DLC 4P Red CONNECTOR NOTE 2 B1 B11 B12 B23 B33 A12 A1 A23 A33 A22 A11 B22 A Black B Light gray Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 124: ...5 10 Sensor side Main harness side O2 SENSOR 4P Black CONNECTOR NOTE 2 VS SENSOR 3P Black CONNECTOR NOTE 3 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 125: ... diagnosis function running capability is maintained by pre programed value in the simulated program map When any abnormality is detected in the injector s and or CKP sensor the fail safe function stops the engine to protect it from damage DTC Diagnostic Trouble Code The DTC is composed of a main code and a sub code and it is displayed as a hyphenated number when retrieved from the ECM with the HD...

Page 126: ... blinks When the ECM stores more than one DTC the MIL will indicate them by blinking in the order from the lowest number to highest number MIL Check When the ignition switch is turned ON and engine stop switch the MIL will stay on for a few seconds then go off If the MIL does not come on troubleshoot the MIL circuit page 5 50 CURRENT DTC FREEZE DTC The DTC is indicated in two ways according to the...

Page 127: ...he MIL blinks When the ignition switch is turned ON the MIL will stay on for a few seconds then go off If the MIL stays on or blinks connect the HDS Pocket Tester to the DLC page 5 13 Read the DTC freeze data and follow the troubleshooting index page 5 16 To read the DTC with the MIL blinking refer to the following proce dure Reading DTC with the MIL Turn the ignition switch to OFF Lift and suppor...

Page 128: ...s If not the MIL will not start blinking Note that the self diagnostic memory cannot be erased if the ignition switch is turned to OFF before the MIL starts blinking CIRCUIT INSPECTION INSPECTION AT ECM CONNECTOR Always clean around and keep any foreign material away from the ECM connector before disconnecting it A faulty PGM FI system is often related to poorly connected or cor roded terminals Ch...

Page 129: ... are same layout as for the ECM con nector terminals as shown ECM 33P Black CONNECTOR 33P Light gray CONNECTOR TOOL ECM test harness 33P 070MZ MCA0100 ECM TEST HARNESS ECM 33P Black CONNECTOR ECM side male terminals ECM 33P Light gray CONNECTOR ECM side male terminals A1 B1 A11 B11 A12 B12 A22 B22 A23 B23 A33 B33 TEST HARNESS PIN BOX A TERMINALS TEST HARNESS PIN BOX B TERMINALS Manuals by Motomatr...

Page 130: ...poor contact of the IAT sensor connec tor IAT sensor or its circuit malfunction Engine operates normally Fail safe value 35 C 95 F 5 27 11 1 11 VS sensor no signal Loose or poor contact of the VS sensor connector VS sensor or its circuit malfunction Engine operates normally 5 28 5 43 12 1 12 No 1 injector circuit malfunction Loose or poor contact of the injector connector Injector or its circuit m...

Page 131: ...tage within 4 75 5 25 V YES GO TO STEP 4 NO GO TO STEP 3 3 MAP Sensor Input Line Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector Check for continuity at the Yellow red wire between the MAP sensor 3P Black connector terminal and the ECM 33P Black connector Is there continuity YES Replace the ECM with a known good one and recheck refer to Key Registra tion Procedures p...

Page 132: ...1 indicated YES Replace the ECM with a known good one and recheck refer to Key Registra tion Procedures page 21 6 NO Faulty original MAP sensor DTC 1 2 MAP SENSOR HIGH VOLTAGE Before starting the inspection check for loose or poor contact on the MAP sensor 3P Black con nector and ECM 33P connectors then recheck the DTC 1 MAP Sensor System Inspection 1 Turn the ignition switch ON and engine stop sw...

Page 133: ...uit Inspec tion Disconnect the ECM 33P Light gray connector Check for continuity at the Light green yellow wire between the MAP sensor 3P Black connec tor terminal and the ECM 33P Light gray con nector Is there continuity YES Replace the ECM with a known good one and recheck refer to Key Registra tion Procedures page 21 6 NO Open circuit in Light green yellow wire CONNECTION Light green yellow Gre...

Page 134: ...switch OFF Check for connection and installation of the MAP sensor vacuum hose Is the MAP sensor vacuum hose connection cor rect YES GO TO STEP 3 NO Correct the hose installation 3 MAP Sensor System Inspection Replace the MAP sensor with a known good one page 5 93 Turn the ignition switch ON and engine stop switch Start the engine and check the MAP sensor with the HDS pocket tester at idle speed I...

Page 135: ...urn the ignition switch OFF Measure the resistance at the ECT sensor termi nals Is the resistance within 2 3 2 6 kΩ YES Replace the ECM with a new one and recheck refer to Key Registration Proce dures page 21 6 NO Faulty ECT sensor 4 ECT Sensor Short Circuit Inspection Turn the ignition switch OFF Check for continuity between the ECT sensor 3P Black connector terminal of the wire harness side and ...

Page 136: ...O GO TO STEP 3 3 ECT Sensor Output Line Inspection Turn the ignition switch OFF Remove the jumper wire Disconnect the ECM 33P connectors Check the continuity between the ECM connec tors and ECT sensor connector of the wire har ness side Are there continuities YES Replace the ECM with new one and recheck refer to Key Registration Proce dures page 21 6 NO Open circuit in Pink white wire Open circuit...

Page 137: ...sor 3P Black connector Turn the ignition switch ON and engine stop switch Measure the voltage at the wire harness side Is the voltage within 4 75 5 25 V YES GO TO STEP 5 NO GO TO STEP 4 4 TP Sensor Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Black connector Check the continuity at the Yellow red wire between the TP sensor 3P Black connector ter minal and the ECM 33P Blac...

Page 138: ...ES Short circuit in Red yellow wire NO GO TO STEP 7 7 TP Sensor Inspection Replace the throttle body page 5 81 Clear the ECM self diagnosis memory data page 5 14 Turn the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket tester Is DTC 8 1 indicated YES Replace the ECM with a known good one and recheck refer to Key Registra tion Procedures page 21 6 NO Faulty origina...

Page 139: ... 3 TP Sensor Resistance Inspection Turn the ignition switch OFF Disconnect the TP sensor 3P Black connector Measure the resistance at the TP sensor side Is the resistance within 0 5 1 5 kΩ YES GO TO STEP 4 NO Faulty TP sensor 4 TP Sensor Input Voltage Inspection Turn the ignition switch ON and engine stop switch Measure the voltage at the wire harness side Is the voltage within 4 75 5 25 V YES Rep...

Page 140: ...tion switch ON and engine stop switch Check the IAT sensor with the HDS pocket tester Is about 0 V indicated YES GO TO STEP 3 NO Faulty IAT sensor 3 IAT Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF Check for continuity between the IAT sensor 2P Gray connector terminal of the wire harness side and ground Is there continuity YES Short circuit in Gray blue wire NO Replace ...

Page 141: ... Output Line Inspection Turn the ignition switch OFF Disconnect the ECM 33P connectors Check the continuity at the Gray blue and Green orange wire between the IAT sensor 2P Gray connector terminals and the ECM 33P connec tors Are there continuities YES Replace the ECM with a known good one and recheck refer to Key Registra tion Procedures page 21 6 NO Open circuit in Gray blue wire Open circuit in...

Page 142: ...ector Turn the ignition switch ON and engine stop switch Measure the voltage at the VS sensor connector of the wire harness side Is there battery voltage YES GO TO STEP 4 NO Open or short circuit in the Yellow red wire Open circuit in the Green black wire 4 VS Sensor Pulse Line Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P Light gray connector Check the continuity bet...

Page 143: ...STEP 2 NO Intermittent failure 2 Injector Input Voltage Inspection Turn the ignition switch OFF Disconnect the injector 2P Gray connector Turn the ignition switch ON and engine stop switch Measure the voltage between the injector 2P Gray connector of the wire harness side and ground Is there battery voltage YES GO TO STEP 3 NO Open or short circuit in Black white wire CONNECTION Pink blue Ground 3...

Page 144: ...ctor 2P Gray connector and ground Is there continuity YES Short circuit in SIGNAL LINE wire NO Replace the ECM with a known good one and recheck refer to Key Registra tion Procedures page 21 6 STANDARD 11 13 Ω 20 C 68 F INJECTOR CONNECTION SIGNAL LINE SIGNAL LINE TOOL Test probe 07ZAJ RDJA110 INJECTOR 2P CONNECTORS Wire side female terminal 33P Black CONNECTOR Wire side female terminals 1 INJECTOR...

Page 145: ... O2 Sensor Open Circuit Inspection Turn the ignition switch OFF Disconnect the ECM 33P connectors and O2 sen sor 4P Black connector Check the continuity between the ECM 33P con nectors of the wire harness side and O2 sensor 4P Black connector of the wire harness side Are there continuities YES GO TO STEP 3 NO Open circuit in Green orange wire Open circuit in Orange white wire STANDARD 0 1 V 0 3 V ...

Page 146: ...ter Is the DTC 21 1 indicated YES Replace the ECM with a known good one and recheck refer to Key Registra tion Procedures page 21 6 NO Faulty original O2 sensor DTC 23 1 O2 SENSOR HEATER Before starting the inspection check for loose or poor contact on the O2 sensor 4P Black connec tor and ECM 33P connectors then recheck the DTC 1 O2 Sensor Heater System Inspection Clear the ECM self diagnosis mem...

Page 147: ...the wire harness side Is there continuity YES GO TO STEP 5 NO Open circuit in Black green wire 5 O2 Sensor Heater Short Circuit Inspection 2 Connect the ECM 33P Light gray connector Check for continuity between the O2 sensor heater 4P Black connector of the wire harness side and ground Is there continuity YES Short circuit in Black green wire NO Replace the ECM with a known good one and recheck re...

Page 148: ...ection Turn the ignition switch OFF Disconnect the IACV 4P Black connector Check for continuities between the IACV 4P Black connector and ground Are there continuities YES Short circuit in Black yellow or Black orange wire Short circuit in Black red or Black blue wire NO GO TO STEP 3 4P Black CONNECTOR CONNECTION Black yellow Ground Black red Ground Black blue Ground Black orange Ground Black yell...

Page 149: ...TC Clear the ECM self diagnosis memory data page 5 14 Turn the ignition switch ON and engine stop switch Recheck the ECM EEPROM Is the DTC 33 2 indicated YES Replace the ECM with new one and recheck refer to Key Registration Proce dures page 21 6 NO Intermittent failure CONNECTION A19 Black yellow A27 Black red A16 Black blue A29 Black orange TOOL Test probe 07ZAJ RDJA110 A27 4P Black CONNECTOR Wi...

Page 150: ... ON and engine stop switch Measure the voltage at the wire harness side Is the voltage within 2 7 3 1 V YES Faulty MAP sensor NO Open circuit in Light green yellow wire Open circuit in Green orange wire 3 MAP Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the MAP sensor 3P Black connec tor Turn the ignition switch ON and engine stop switch Measure the voltage at the wire h...

Page 151: ...O Open circuit in Yellow red wire MIL 2 BLINKS MAP SENSOR HOSE CONNECTION Before starting the inspection check for loose or poor contact on the MAP sensor 3P Black con nector and ECM 33P connectors then recheck the MIL blinking 1 MAP Sensor Hose Inspection Turn the ignition switch OFF Check the connection and installation of the MAP sensor vacuum hoses Is the MAP sensor hose connection correct YES...

Page 152: ...pection check for loose or poor contact on the ECT sensor 3P Black con nector and ECM 33P connectors then recheck the MIL blinking 1 ECT Sensor Output Voltage Inspection Turn the ignition switch OFF Connect the test harness to ECM 33P connectors page 5 14 Turn the ignition switch ON and engine stop switch Measure the voltage at the test harness termi nals Is the voltage within 2 7 3 1 V YES Interm...

Page 153: ...TO STEP 5 NO Open circuit in Pink white wire Open circuit in Green orange wire 5 ECT Sensor Short Circuit Inspection Check for continuity between the ECT sensor 3P Black connector of the wire harness side and ground Is there continuity YES Short circuit in Pink white wire NO Replace the ECM with a known good one and recheck refer to Key Registra tion Procedures page 21 6 CONNECTION Pink white Grou...

Page 154: ...V 0 6 X 4 75 5 0 0 57 V Thus the solution is 0 38 0 57 V with the throttle fully closed Replace 0 4 and 0 6 with 4 2 and 4 8 respec tively in the above equations to determine the throttle fully opened range Is there standard voltage YES Intermittent failure NO GO TO STEP 2 2 TP Sensor Input Voltage Inspection Turn the ignition switch OFF Disconnect the TP sensor 3P Black connector Turn the ignitio...

Page 155: ... side and the test harness terminal Is there continuity YES GO TO STEP 5 NO Open circuit in Red yellow wire 5 TP Sensor Output Line Short Circuit Inspection Check for continuity between the TP sensor 3P Black connector terminal of the wire harness side and ground Is there continuity YES Short circuit in Red yellow wire NO Faulty TP sensor CONNECTION A9 A18 TEST HARNESS PIN BOX A TERMINALS A18 A9 C...

Page 156: ...ector Turn the ignition switch ON and engine stop switch Measure the voltage at the wire harness side of IAT sensor connector Is the voltage within 4 75 5 25 V YES GO TO STEP 3 NO GO TO STEP 4 3 IAT Sensor Resistance Inspection Turn the ignition switch OFF Measure the resistance at the IAT sensor termi nals at 20 30 C 68 86 F Is the resistance within 1 4 kΩ YES GO TO STEP 4 NO Faulty IAT sensor CO...

Page 157: ...ck connec tor and ECM 33P connectors then recheck the MIL blinking 1 VS Sensor Pulse Inspection Turn the ignition switch OFF Connect the ECM test harness to the ECM con nectors page 5 14 Support the motorcycle securely raise the rear wheel off the ground Turn the ignition switch ON and engine stop switch Shift the transmission into gear Measure the voltage at the test harness termi nals while slow...

Page 158: ...he ignition switch OFF Check the continuity between the test harness terminal and VS sensor connector of the wire harness side Is there continuity YES GO TO STEP 5 NO Open circuit in Pink blue wire 5 VS Sensor Pulse Line Short Circuit Inspection Check for continuity between the VS sensor con nector and the ground Is there continuity YES Short circuit in the Pink blue wire NO Inspect the VS sensor ...

Page 159: ...P 2 NO Open circuit in Black white wire 2 Injector Resistance Inspection Turn the ignition switch OFF Measure the resistance of the injector connector terminals Is the resistance within 11 13 Ω 20 C 68 F YES GO TO STEP 3 NO Faulty injector MIL INJEC TOR POWER INPUT LINE SIGNAL LINE SIGNAL AT ECM 12 No 1 Black white Pink yellow A17 13 No 2 Black white Pink blue A6 14 No 3 Black white Pink green A8 ...

Page 160: ...O Replace the ECM with a known good one and recheck refer to Key Registra tion Procedures page 21 6 MIL 13 BLINKS No 2 INJECTOR page 5 45 MIL 14 BLINKS No 3 INJECTOR page 5 45 MIL 15 BLINKS No 4 INJECTOR page 5 45 CONNECTION SIGNAL LINE SIGNAL LINE INJECTOR 2P CONNECTORS Wire side female terminal TEST HARNESS PIN BOX A TERMINALS 1 INJECTOR 2P CONNECTOR 2 INJECTOR 2P CONNECTOR 3 INJECTOR 2P CONNECT...

Page 161: ...re Open circuit in Green orange wire 3 O2 Sensor Short Circuit Inspection Connect the O2 Sensor 4P Black connector Check for continuity between the test harness terminal and ground Is there continuity YES Short circuit in the Orange white wire NO GO TO STEP 4 4 O2 Sensor Inspection Replace the O2 sensor with a known good one page 5 101 Start the engine and warm it up until the coolant temperature ...

Page 162: ...r of the wire harness side Is there battery voltage YES GO TO STEP 3 NO Open circuit in Black white wire 3 O2 Sensor Heater Open Circuit Inspection 2 Turn the ignition switch OFF Connect the ECM test harness to the ECM con nectors page 5 14 Check the continuity between the test harness terminal and O2 sensor 4P Black connector of the wire harness side Is there continuity YES GO TO STEP 4 NO Open c...

Page 163: ...g 1 IACV Short Circuit Inspection Turn the ignition switch OFF Disconnect the IACV 4P Black connector Check for continuities between the IACV 4P Black connectors and ground Are there continuities YES Short circuit in Black yellow or Black orange wire Short circuit in Black red or Black blue wire NO GO TO STEP 2 CONNECTION B2 Ground TEST HARNESS PIN BOX B TERMINALS B2 CONNECTION Black yellow Ground...

Page 164: ...ed but the MIL does not come on when the ignition switch is turned ON and the engine stop switch is in check as follows Check for operation of the combination meter func tion properly If they do not function check the combination meter power input line page 20 21 If they function properly check as follows Pull out the ECM from the stay page 5 14 Turn the ignition switch to OFF disconnect the ECM 3...

Page 165: ...NG REMOVAL Before disconnecting fuel feed hose relieve pres sure from the system as following procedures 1 Turn the ignition switch OFF Lift and support the fuel tank page 3 5 2 Disconnect the fuel pump 2P Black connector 3 Start the engine and let it idle until the engine stalls 4 Turn the ignition switch OFF 5 Disconnect the battery negative cable page 17 5 6 Check the fuel quick connect fitting...

Page 166: ... tabs pressed down and alternately pull and push the connector until it comes of easily 9 To prevent damage and keep foreign matter out cover the disconnected connector and fuel joint end with the plastic bags QUICK CONNECT FITTING INSTALLATION Always replace the retainer of the quick connect fitting when the fuel feed hose is disconnected If any damage or cut out on the rubber cap replace it with...

Page 167: ...ure the rubber cap is in place between the flange and retainer tab 5 Connect the fuel pump 2P Black connector and clamp the wire 6 Connect the battery negative cable to the bat tery 7 Turn the ignition switch ON and engine stop switch The fuel pump will run for about 2 seconds and fuel pressure will rise Repeat 2 or 3 times and check that there is no leakage in the fuel supply system Remove the su...

Page 168: ...nk breather hose fuel pump page 5 56 clogged fuel filter Assembly of the fuel pump page 5 56 Wrap a shop towel around the attachment to soak up any spilled fuel After inspection relieve the fuel pressure by discon necting the quick connect fitting page 5 51 Remove the fuel pressure gauge attachment joint and manifold from the fuel pump Connect the quick connect fitting page 5 52 TOOLS 1 Fuel press...

Page 169: ...fuel joint Turn the ignition switch ON for 10 seconds Measure the amount of fuel flow If the fuel flow is less than specified inspect the following pinched or clogged fuel hose fuel pump unit page 5 56 Remove the hose attachment from the fuel joint and connect the quick connect fitting page 5 52 FUEL CUT OFF RELAY CBF600S SA CBF600N NA FUEL CUT OFF RELAY JUMPER WIRE RELAY TERMINALS Black white Bro...

Page 170: ...f there is battery voltage a few seconds replace the fuel pump unit If there is no battery voltage inspect the following main fuse 30A sub fuse 20A FI Ignition sub fuse 10A Bank angle sensor engine stop switch page 20 32 fuel cut off relay page 5 58 engine stop relay page 5 96 bank angle sensor page 5 94 ECM page 5 97 REMOVAL Remove the fuel tank page 5 59 Remove the fuel pump unit mounting nuts 2...

Page 171: ...r damage replace them as an assembly if necessary Clean the fuel strainer screen with non flammable or high flash point solvent INSTALLATION Install the fuel pump chamber hooking its tab to the hole of fuel pump unit FUEL PUMP PACKING FUEL PUMP CHAMBER CHAMBER FUEL STRAINER SCREEN CHAMBER Hook Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomat...

Page 172: ... the fuel cut off relay con nector terminals Connect the 12 V battery to the following fuel cut off relay connector terminals There should be continuity only when the 12 V bat tery is connected If there is no continuity when the 12 V battery is connected replace the fuel cut off relay Be careful not to damage the pump wire FUEL PUMP PACKING TORQUE 12 N m 1 2 kgf m 9 lbf ft FUEL PUMP NUTS 1 6 4 2 7...

Page 173: ...een connec tor Disconnect the fuel tank drain hose and breather hose from the hose joint Remove the nut and fuel tank stopper cable Remove the nut and pivot bolt then remove the fuel tank CBF600S SA CBF600N NA 2P Blue or Green CONNECTOR BREATHER HOSE DRAIN HOSE HOSE JOINT NUT STOPPER CABLE FUEL TANK PIVOT BOLT NUT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Ke...

Page 174: ...ll and tighten the nut securely 2P Black CONNECTOR PIVOT BOLT FUEL FEED HOSE NUT BOLTS WASHERS COLLARS FUEL TANK NUT 2P Blue or Green CONNECTOR STOPPER CABLE BREATHER HOSE DRAIN HOSE 16 N m 1 6 kgf m 12 lbf ft WASHERS COLLARS Tighten the nut to fuel tank slot upper side securely as shown TORQUE 16 N m 1 6 kgf m 12 lbf ft FUEL TANK PIVOT BOLT NUT WASHERS COLLARS SLOT NUT STOPPER CABLE GROOVE Manual...

Page 175: ...e the support tool then install and tighten the fuel tank front mounting bolts page 3 6 AIR CLEANER HOUSING REMOVAL CBF600S SA only Remove the cowl page 2 9 Make the throttle cable freeplay at the handlebar side page 3 6 Loosen the throttle cable nuts fully Disconnect the throttle cables from the throttle pipe CBF600S SA only Release the throttle cables from the clamp Release the throttle cables f...

Page 176: ... the IDC solenoid valve vacuum hose from the ECM Disconnect the injector sub harness 10P Black and 10P White connectors and O2 sensor 4P Black connector Remove the screw and ECM stay Pull out the ECM from the air cleaner housing SCREW RESONATOR SCREWS DUCT RESONATOR STAY SCREW 10P White CONNECTOR 10P Black CONNECTOR 4P Black CONNECTOR STAY VACUUM HOSE ECM SCREW STAY Manuals by Motomatrix www motom...

Page 177: ...ose from the guide of air cleaner housing Disconnect the crankcase breather hose from the air cleaner housing Disconnect the 1 4 ignition coil connectors ECM 33P Black CONNECTOR 33P Light gray CONNECTOR 2P Red CONNECTOR GUIDE VACUUM HOSE BREATHER HOSE CONNECTORS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 178: ...Remove the screws and left air cleaner duct from the air cleaner housing Disconnect the vacuum hose from the diaphragm Remove the air cleaner element PAIR AIR SUCTION HOSE WIRES HOSES GUIDE GUIDES WIRE DUCT SCREWS DIAPHRAGM VACUUM HOSE ELEMENT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 179: ...ack connector Disconnect the 2 3 ignition coil connectors Disconnect the PAIR control solenoid valve 2P Black connector 3P Black CONNECTOR 6P Black CONNECTOR CONNECTORS 2P Black CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 180: ...e the throttle cables from the frame then pull out the air cleaner housing with the throttle body to the left side Be careful not to damage the harness and hoses BOLT COLLAR RADIATOR SIPHON HOSE INSULATOR BAND CYLINDER HEAD SIDE AIR CLEANER HOUSING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 181: ...k connector Disconnect the MAP sensor 3P Black connector Disconnect the vacuum hose from the MAP sensor Remove the screw and MAP sensor from the air cleaner housing 2P Gray CONNECTOR SCREWS IAT SENSOR O RING 2P Gray CONNECTOR 3P Black CONNECTOR VACUUM HOSE SCREW 3P Black CONNECTOR MAP SENSOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatri...

Page 182: ...ector from the stay Release the injector sub harness from the guides Disconnect the IACV 4P Black connector Remove the injector sub harness from the air cleaner housing FUEL FEED HOSE QUICK CONNECT FITTING 2P Gray CONNECTORS 2P Red CONNECTOR SUB HARNESS GUIDES 4P Black CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 183: ...ses from the one way valve Remove the hose clamp and crankcase breather drain hose Remove the left air cleaner duct packing Remove the right air cleaner duct packing IDCSOLENOID VALVE SCREW ONE WAY VALVE SCREW VACUUM CHAMBER VACUUM HOSES CLAMP DRAIN HOSE PACKING PACKING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 184: ...ssed air Loosen the screws then remove the air funnels and throttle body from the lower air cleaner housing Remove the rubber seals from the lower air cleaner housing SCREWS UPPER AIR CLEANER HOUSING MESH SCREEN GUIDE SCREWS AIR FUNNELS RUBBER SEALS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 185: ... securely THROTTLE BODY ASSEMBLY AIR CLEANER LOWER HOUSING MAP SENSOR AIR CLEANER UPPER HOUSING VACUUM CHAMBER IDC SOLENOID VALVE AIR FUNNELS RUBBER SEALS MESH SCREEN DRAIN HOSE SUB HARNESS O RING IAT SENSOR FUEL FEED HOSE PACKING PACKING 3 5 N m 0 4 kgf m 2 6 lbf ft RUBBER SEALS SCREWS AIR FUNNELS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info mo...

Page 186: ...ws to the specified torque Install a new right air cleaner duct packing into the groove on the housing Install a new left air cleaner duct packing into the groove on the housing MESH SCREEN GUIDE TORQUE 3 5 N m 0 4 kgf m 2 6 lbf ft SCREWS UPPER AIR CLEANER HOUSING PACKING PACKING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 187: ...hoses to the one way valve Route the vacuum hoses and connect them to the IDC solenoid valve and vacuum chamber Install the injector sub harness on the air cleaner housing Connect the IACV 4P Black connector CLAMP DRAIN HOSE Align VACUUM CHAMBER Refer to the wires properly page 1 24 IDCSOLENOID VALVE SCREW ONE WAY VALVE SCREW VACUUM CHAMBER VACUUM HOSES 4P Black CONNECTOR Manuals by Motomatrix www...

Page 188: ...ose and connect the quick con nect fitting to the fuel rail page 5 52 Install the MAP sensor and tighten the screw securely Connect the MAP sensor vacuum hose Connect the MAP sensor 3P Black connector 2P Red CONNECTOR SUB HARNESS GUIDES 2P Gray CONNECTORS FUEL FEED HOSE QUICK CONNECT FITTING VACUUM HOSE SCREW 3P Black CONNECTOR MAP SENSOR Manuals by Motomatrix www motomatrix co uk The Solution For...

Page 189: ...erly page 1 24 Route the throttle cables to the frame properly then install the air cleaner housing with the throttle body from the left side Be careful not to damage the harness and hoses Make sure each insulator is firmly installed to the intake port 3P Black CONNECTOR 2P Gray CONNECTOR 2P Gray CONNECTOR IAT SENSOR O RING SCREW AIR CLEANER HOUSING Manuals by Motomatrix www motomatrix co uk The S...

Page 190: ...r siphon hose Install mounting bolt with the collar then tighten the bolt securely Connect the PAIR control solenoid valve 2P Black connector 7 1 mm 0 28 0 04 INSULATOR BAND CYLINDER HEAD SIDE RADIATOR SIPHON HOSE BOLT COLLAR 2P Black CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 191: ... Connect the ECT sensor 3P Black connector Install the air cleaner element Connect the vacuum hose to the diaphragm CONNECTORS 6P Black CONNECTOR 3P Black CONNECTOR DIAPHRAGM VACUUM HOSE ELEMENT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 192: ...oute the wires and hoses to the guides of air cleaner housing Connect the PAIR air suction hose to the air cleaner housing Connect the 1 4 ignition coil connectors DUCT SCREWS WIRES HOSES GUIDE GUIDES WIRE PAIR AIR SUCTION HOSE CONNECTORS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 193: ... Connect the ECM 33P Black and Light gray connec tors to the ECM Install the ECM on the air cleaner housing Install the ECM stay with the screws then tighten the screws securely BREATHER HOSE 2P Red CONNECTOR GUIDE VACUUM HOSE ECM 33P Black CONNECTOR 33P Light gray CONNECTOR ECM SCREW STAY Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix ...

Page 194: ...urely Route the fuel feed hose to the guide of front reso nator Connect the quick connect fitting to the fuel tank page 5 52 Remove the support tool then install and tighten the fuel tank front mounting bolts page 3 6 CBF600S SA only Secure the throttle cables with the clamp Secure the throttle cables route them to the guide 10P White CONNECTOR 10P Black CONNECTOR 4P Black CONNECTOR STAY VACUUM HO...

Page 195: ... THROTTLE BODY REMOVAL Remove the throttle body from the air cleaner hous ing page 5 67 Loosen the lock nuts and disconnect the throttle cables from the throttle drum Loosen the insulator band screws and remove the insulators Mark each insulator to be sure of their insulator bands direction for reassembly THROTTLE CABLES NUTS THROTTLE CABLES LOCK NUTS INSULATORS Manuals by Motomatrix www motomatri...

Page 196: ...hite painted bolts nut and screws of the throttle body Loosening or tightening them can cause throttle valve and idle control failure Viewed from cylinder head side and throttle sensor side Viewed from air cleaner housing side and throttle drum side PAINTED WHITE PAINTED WHITE PAINTED WHITE 5 1 N m 0 5 kgf m 3 8 lbf ft PAINTED WHITE Manuals by Motomatrix www motomatrix co uk The Solution For Lost ...

Page 197: ...d from bottom 2 1 N m 0 2 kgf m 1 5 lbf ft Do not loosen or remove Do not loosen or remove Do not loosen or tighten Do not loosen or tighten PAINTED WHITE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 198: ...s shown Tighten the throttle body side insulator band screws so that the width between the band ends is 7 1 mm 0 28 0 04 in Connect the throttle cables and tighten the lock nuts Install the throttle body onto the air cleaner housing page 5 71 Align BOSSES INSULATORS 3 4 INSULATOR BAND 1 2 INSULATOR BAND 10 1 mm 0 39 0 04 in THROTTLE CABLES LOCK NUTS Manuals by Motomatrix www motomatrix co uk The S...

Page 199: ... REMOVAL Remove the throttle body page 5 81 Disconnect the MAP sensor vacuum hoses and IDC solenoid valve vacuum hose Remove the bolts and fuel rail Disconnect the IACV distribution hoses SOUNDING ROD VACUUM HOSES MAP SENSOR VACUUM HOSE IDC SOLENOID VALVE BOLTS FUEL RAIL HOSES Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 200: ...ACV joints and O rings Remove the injectors from the fuel rail Remove the seal ring and O ring from each injector SCREW JOINT PLATE O RINGS IACV JOINTS FUEL RAIL INJECTORS O RING SEAL RING INJECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 201: ...UEL RAIL FUEL RAIL JOINT SCREWS IACV MOTOR SETTING PLATE 5 1 N m 0 5 kgf m 3 8 lbf ft THROTTLE BODY 5 1 N m 0 5 kgf m 3 8 lbf ft FUEL RAIL O RING O RINGS INJECTOR O RINGS JOINT PLATE O RING 2 1 N m 0 2 kgf m 1 5 lbf ft IACV DISTRIBUTION HOSES INSULATORS SCREW 2 1 N m 0 2 kgf m 1 5 lbf ft IACV JOINT FUEL RAIL JOINT O RINGS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle ...

Page 202: ...rings and install them to the IACV joints Install the IACV joints to the throttle body Install the joint plate and tighten the torx screw to the specified torque O RING SEAL RING INJECTOR FUEL RAIL INJECTORS O RINGS IACV JOINTS TORQUE 2 1 N m 0 2 kgf m 1 5 lbf ft SCREW JOINT PLATE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 203: ...onnect the MAP sensor vacuum hoses and IDC solenoid valve air hoses Install the throttle body to the air cleaner housing page 5 71 HOSES TORQUE 5 1 N m 0 5 kgf m 3 8 lbf ft BOLTS FUEL RAIL VACUUM HOSES MAP SENSOR VACUUM HOSE IDC SOLENOID VALVE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 204: ...nd warm it up to coolant tempera ture 80 C 176 F then check the idle speed If the idle speed is out of the specification check the following throttle operation and throttle grip freeplay page 3 6 intake air leak or engine top end problem page 8 3 IACV operation page 5 90 IACV INSPECTION The IACV is installed on the throttle body and is operated by the step motor When the ignition switch is turned ...

Page 205: ...move the IACV motor and O ring INSTALLATION Turn the slide valve clockwise until lightly seated on IACV Apply oil to new O ring and install it to the IACV motor Install the IACV motor aligning its groove with the pin inside the motor housing SETTING PLATE SCREWS IACV MOTOR O RING GROOVE PIN IACV MOTOR O RING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ema...

Page 206: ...36 The MAP sensor output voltage above is mea sured under the standard atmosphere 1 atm 1 013 hPa The MAP sensor output voltage is affected by the distance above sea level because the output volt age is changed by atmosphere Check the sea level measurement and be sure that the measured voltage falls within the specified value SETTING PLATE Align TORQUE 2 1 N m 0 2 kgf m 1 5 lbf ft SETTING PLATE SC...

Page 207: ...SENSOR REMOVAL INSTALLATION Remove the left side cover page 2 5 Disconnect the IAT sensor 2P Gray connector Remove the screws and IAT sensor from the air cleaner housing Installation is in the reverse order of removal VACUUM HOSE 3P Black CONNECTOR MAP SENSOR SCREW 2P Gray CONNECTOR Always replace the O ring with a new one SCREWS IAT SENSOR O RING Manuals by Motomatrix www motomatrix co uk The Sol...

Page 208: ...ct the ECT sensor 3P Black connector Fill the cooling system with recommended coolant page 6 7 BANK ANGLE SENSOR REMOVAL INSTALLATION Remove the rear cowl page 2 5 Disconnect the 3P Green connector Remove the screws washers and bank angle sen sor Always replace a sealing washer with a new one TORQUE 23 N m 2 3 kgf m 17 lbf ft SEALING WASHER 3P Black CONNECTOR ECT SENSOR 3P Green CONNECTOR BANK ANG...

Page 209: ...ion switch ON and engine stop switch The bank angle sensor is normal if the engine stop relay clicks and power supply is closed Incline the bank angel sensor approximately 60 degrees to the left or right with keeping the ignition switch ON and engine stop switch The bank angle sensor is normal if the engine stop relay clicks and power supply is open If you repeat this test first turn the ignition ...

Page 210: ...V battery to the following engine stop relay connector terminals There should be continuity only when the 12 V bat tery is connected If there is no continuity when the 12 V battery is connected replace the engine stop relay ENGINE STOP RELAY CBF600S SA CBF600N NA ENGINE STOP RELAY CONNECTION A B CONNECTION C D BATTERY A C D B ENGINE STOP RELAY Manuals by Motomatrix www motomatrix co uk The Solutio...

Page 211: ...Input Voltage Inspection Before starting the inspection check for loose or poor contact on the ECM 33P connectors and recheck the MIL blinking Disconnect the ECM 33P Black connector Turn the ignition switch ON and engine stop switch Measure the voltage at the ECM 33P Black con nector terminal and ground Is there battery voltage YES GO TO STEP 2 NO GO TO STEP 3 SCREW ECM 33P Black CONNECTOR 33P Lig...

Page 212: ...the engine stop relay connector terminals with jumper wire Turn the ignition switch ON and engine stop switch Measure the voltage at the ECM 33P Black con nector terminal and ground Is there battery voltage YES Replace the ECM with a known good one and recheck refer to Key Registra tion Procedures page 21 6 NO Open circuit in power input line Black white or Red white between the battery and ECM TO...

Page 213: ... page 8 7 Start the engine and open the throttle slightly to be certain that the air sucked in through the air supply hose If the air is not drawn in check the air supply hoses for clogs and the PAIR solenoid valve PAIR CONTROL SOLENOID VALVE Removal Installation Lift and support the fuel tank page 3 5 Disconnect the right and left PAIR air suction hoses from the cylinder head cover AIR INTAKE POR...

Page 214: ...nected to the PAIR control solenoid valve ter minals Air should not flow A to B when the bat tery is disconnected Check the resistance between the terminals of the PAIR control solenoid valve If the resistance is out of specification replace the PAIR control solenoid valve 2P Black CONNECTOR STAY PAIR CONTROL SOLENOID VALVE B B A STANDARD 23 27 Ω 20 C 68 F PAIR SOLENOID VALVE Manuals by Motomatrix...

Page 215: ...2 sensor onto the exhaust pipe and tighten it securely Install the exhaust pipe page 2 12 INTAKE AIR DUCT INTAKE AIR DUCT VALVE DIAPHRAGM Inspection Remove the left intake air duct from the air cleaner housing page 5 64 Disconnect the vacuum hose from the diaphragm Connect a vacuum pump to the diaphragm and apply specified vacuum The vacuum should hold and the duct valve should remain open O2 SENS...

Page 216: ...ing page 5 61 Disconnect the IDC solenoid valve 2P Gray connec tor Disconnect the vacuum hoses and remove the screw and IDC solenoid valve Disconnect the vacuum hose and remove the screw and vacuum chamber Installation is in the reverse order of removal ROD INTAKE AIR DUCT DIAPHRAGM VALVE 2P Gray CONNECTOR IDCSOLENOID VALVE SCREW SCREW VACUUM CHAMBER HOSES Align the vacuum chamber boss with the ho...

Page 217: ...ve by disconnecting the vacuum hoses Installation is in the reverse order of removal Inspection Check the one way valve operation as follows Air should flow A to B Air should flow A to C Air should not flow B to A Air should not flow B to C If the operation is incorrect replace the one way valve CONNECTION Battery terminal Black white terminal Battery terminal Yellow black terminal A B STANDARD 28...

Page 218: ...MEMO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 219: ...RMATION 6 3 TROUBLESHOOTING 6 4 SYSTEM TESTING 6 5 COOLANT REPLACEMENT 6 6 THERMOSTAT 6 8 RADIATOR 6 11 RADIATOR RESERVE TANK 6 17 WATER PUMP 6 17 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 220: ...IATOR RESERVE TANK AIR BLEED HOSE OVERFLOW HOSE LOWER RADIATOR HOSE UPPER RADIATOR HOSE FILLER NECK TO THERMOSTAT HOSE FILLER NECK BYPASS HOSE CYLINDER BLOCK TO WATER PUMP HOSE ECT SENSOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 221: ... radiator cap ITEM SPECIFICATIONS Coolant capacity Radiator and engine 2 42 liter 2 56 US qt 2 13 lmp qt Reserve tank 0 35 liter 0 37 US qt 0 31 lmp qt Radiator cap relief pressure 108 137 kPa 1 1 1 4 kgf cm2 16 20 psi Thermostat Begin to open 80 84 C 176 183 F Fully open 95 C 203 F Valve lift 8 mm 0 3 in minimum Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion p...

Page 222: ...y fan motor relay Faulty water pump Engine temperature too low Faulty temperature gauge or ECT sensor Thermostat stuck open Faulty cooling fan motor relay Coolant leak Faulty water pump mechanical seal Deteriorated O rings Faulty radiator cap Damaged or deteriorated cylinder head gasket Loose hose connection or clamp Damaged or deteriorated hose Manuals by Motomatrix www motomatrix co uk The Solut...

Page 223: ... 10 1 018 1 017 1 017 1 016 1 015 1 014 1 013 1 011 1 009 1 007 1 005 15 1 028 1 027 1 026 1 025 1 024 1 022 1 020 1 018 1 016 1 014 1 012 20 1 036 1 035 1 034 1 033 1 031 1 029 1 027 1 025 1 023 1 021 1 019 25 1 045 1 044 1 043 1 042 1 040 1 038 1 036 1 034 1 031 1 028 1 025 30 1 053 1 052 1 051 1 047 1 046 1 045 1 043 1 041 1 038 1 035 1 032 35 1 063 1 062 1 060 1 058 1 056 1 054 1 052 1 049 1 0...

Page 224: ...OLANT REPLACEMENT PREPARATION The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usage Therefore for best performance change the coolant regularly as specified in the maintenance schedule Mix only distilled low mineral water with the antifreeze RADIATOR CAP RELIEF PRESSURE 108 137 kPa 1 1 1 4 kgf cm2 16 20 psi RADIATOR CAP T...

Page 225: ...th new sealing washers Tighten the drain bolts securely Remove the rear cowl page 2 5 Disconnect the siphon hose from the reserve tank and drain the reserve tank coolant Empty the coolant and rinse the inside of the reserve tank with water Connect the siphon hose to the reserve tank Fill the system with the recommended coolant through the filler opening up to filler neck Always let the engine and ...

Page 226: ...l tank and install the front mounting bolts page 3 5 THERMOSTAT REMOVAL Drain the coolant page 6 7 Lift and support the fuel tank page 3 5 Disconnect the 4 spark plug cap Remove the bolt and pull out the filler neck Loosen the hose band screw and disconnect the water hose from the filler neck Disconnect the ETC sensor 3P Black connector Loosen the hose band screw and disconnect the bypass hose fro...

Page 227: ...r with an electric heating element to operating temperature for 5 minutes Suspend the thermostat in heated water to check its operation Replace the thermostat if the valve stays open at room temperature or if it responds at temperatures other than those specified HOUSING COVER BOLTS HOUSING COVER SCREW THERMOSTAT THERMOSTAT HOUSING THERMOSTAT SEAL RING THERMOSTAT OPERATING TEMPERATURE BEGIN TO OPE...

Page 228: ...ring to the thermostat housing groove Install the thermostat housing to the cylinder head and tighten the bolts securely Connect the bypass hose to the thermostat housing and tighten the hose band screw securely Connect the ETC sensor 3P Black connector THERMOSTAT BOSS Align STAMP MARK TORQUE 12 N m 1 2 kgf m 9 lbf ft HOUSING COVER BOLTS Align O RING THERMOSTAT HOUSING 3P Black CONNECTOR BOLTS SCR...

Page 229: ...ts page 3 5 Fill the system with recommended coolant and bleed the air page 6 7 RADIATOR REMOVAL Drain the coolant page 6 7 Lift and support the fuel tank page 3 5 Release the hooks from the tabs on the radiator and remove the radiator grill Disconnect the fan motor 2P Black connector WATER HOSE SCREW FILLER NECK FILLER NECK BOLT 4 SPARK PLUG CAP CBF600N NA only RADIATOR GRILL HOOKS 2P Black CONNE...

Page 230: ...ose Loosen the hose band screw and disconnect the lower radiator hose Remove the lower mounting bolt washer and mounting rubber HORN WIRE GUIDES BAND SCREW UPPER RADIATOR HOSE LOWER RADIATOR HOSE BAND SCREW BOLT WASHER RUBBER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 231: ... fan motor assembly from the radiator Remove the nut and cooling fan Release the fan motor wire from the guide of fan motor shroud Remove the mounting bolts and fan motor from the fan motor shroud BOLTS WASHERS RUBBERS FAN MOTOR ASSEMBLY BOLTS WASHERS COOLING FUN NUT FAN MOTOR BOLTS GUIDE FANMOTOR WIRE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email inf...

Page 232: ...d Install the cooling fan onto the fan motor shaft by aligning the flat surfaces NUT COOLING FAN FAN MOTOR SHROUD 5 0 N m 0 5 kgf m 3 7 lbf ft FAN MOTOR RADIATOR 8 4 N m 0 9 kgf m 6 2 lbf ft TORQUE 5 0 N m 0 5 kgf m 3 7 lbf ft FAN MOTOR GUIDE FANMOTOR WIRE BOLTS COOLING FUN Align Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 233: ...damage the radiator fins Install the radiator assembly with the mounting rub bers washers and upper mounting bolts Tighten the bolts to the specified torque Install the lower mounting bolt with mounting rub ber and washer NUT TORQUE 8 4 N m 0 9 kgf m 6 2 lbf ft FAN MOTOR ASSEMBLY BOLTS WASHERS TORQUE 3 5 N m 0 4 kgf m 2 6 lbf ft BOLTS WASHERS RUBBERS BOLT WASHER RUBBER Manuals by Motomatrix www mo...

Page 234: ...he guide of fan motor shroud Connect the fan motor 2P Black connector Lower the fuel tank and install the front mounting bolts page 3 5 Fill the system with recommended coolant page 6 6 LOWER RADIATOR HOSE BAND SCREW BAND SCREW UPPER RADIATOR HOSE HORN WIRE GUIDES 2P Black CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 235: ... reserve tank Installation is in the reverse order of removal Fill the reserve tank with coolant page 6 7 WATER PUMP MECHANICAL SEAL INSPECTION Check for signs of coolant leakage A small amount of weeping from the bleed hole is normal RADIATOR GRILL HOOKS Refer to the wires properly page 1 24 SIPHON HOSE RESERVE TANK OVERFLOW HOSE BOLT BLEED HOLE WATER PUMP Manuals by Motomatrix www motomatrix co ...

Page 236: ...per radiator hose from the water pump cover Loosen the hose band screw and disconnect the bypass hose from the water pump cover Remove the bolt joint pipe and O ring Remove the mounting bolts Remove the assembly bolts LOWER RADIATOR HOSE BAND SCREWS UPPER RADIATOR HOSE BAND SCREWS BYPASS HOSE JOINT PIPE O RING BOLT BOLTS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle C...

Page 237: ...ump body Remove the water pump body from the crankcase Remove the O ring from the water pump body BOLTS Do not disassemble the water pump body O RING WATER PUMP BODY WATER PUMP BODY O RING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 238: ...ing the water pump impeller Align the mounting bolt holes in the water pump and crankcase and make sure the water pump is securely installed O RING O RING WATER PUMP BODY WATER PUMP COVER O RING JOINT PIPE 12 N m 1 2 kgf m 9 lbf ft ASSEMBLY BOLTS LOWER RADIATOR HOSE BYPASS HOSE CYLINDER BLOCK TO WATER PUMP HOSE WATER PUMP BODY O RING Align Manuals by Motomatrix www motomatrix co uk The Solution Fo...

Page 239: ...ely Install the water pump cover assembly bolts Tighten the assembly bolts to the specified torque Install a new O ring to the joint pipe O RING WATER PUMP BODY BOLTS TORQUE 12 N m 1 2 kgf m 9 lbf ft BAND SCREW O RING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 240: ...tall the crankcase rear cover page 7 17 Fill the system with recommended coolant and bleed the air page 6 7 Start the engine and check for coolant leaks BOLT JOINT PIPE BAND SCREW BYPASS HOSE OIL COOLER WATER HOSE LOWER RADIATOR HOSE BAND SCREWS 0 1 mm 0 0 04 in LOWER RADIATOR HOSE BAND SCREWS UPPER RADIATOR HOSE 0 1mm 0 0 04 in Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 241: ... 2 SERVICE INFORMATION 7 3 CRANKCASE REAR COVER REMOVAL 7 4 ENGINE REMOVAL 7 4 ENGINE INSTALLATION 7 10 CRANKCASE REAR COVER INSTALLATION 7 17 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 242: ...PONENT LOCATION 59 N m 6 0 kgf m 43 lbf ft 59 N m 6 0 kgf m 43 lbf ft 20 N m 2 0 kgf m 15 lbf ft 54 N m 5 5 kgf m 40 lbf ft 49 N m 5 0 kgf m 36 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 243: ...en the engine mounting fasteners to the specified torque in the specified sequence If you mistake the torque or sequence loosen all mounting fasteners then tighten them again to the speci fied torque in the correct sequence SERVICE DATA TORQUE VALUES ITEM SPECIFICATIONS Engine dry weight 57 3 kg 126 4 lbs Engine oil capacity After disassembly 3 5 liter 3 7 US qt 3 1 lmp qt Coolant capacity Radiato...

Page 244: ... chain guide plate ENGINE REMOVAL Remove the following exhaust pipe page 2 11 air cleaner housing page 5 61 crankcase rear cover page 7 4 Loosen the rear axle nut Turn the drive chain adjusting bolts make the drive chain slack fully page 3 19 Remove the drive sprocket bolt washer and drive sprocket REAR COVER B REAR COVER A GEARSHIFT ARM PINCH BOLT REAR COVER B WIRE CLIP GUIDE PLATE BOLTS DRIVE SP...

Page 245: ...the rubber cap then remove the terminal nut and disconnect the starter motor cable from the starter motor Remove the starter motor mounting bolt and dis connect the ground cable PAIR AIR SUCTION HOSES SPARK PLUG CAPS 3P Black CONNECTOR CLAMPS ALTERNATOR WIRE GROUND CABLE NUT STARTER MOTOR CABLE BOLT RUBBER CAP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys e...

Page 246: ...ead Disconnect the horn wire connectors then release the horn wire Remove the mounting bolt and horn Release the EOP switch wire from the guide of pivot bracket Release the EOP switch wire clip from the pivot bracket SCREW WATER HOSE SCREW AIR BLEED HOSE BOLT HORN CONNECTORS WIRE CLIP EOP SWITCH WIRE GUIDE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email...

Page 247: ...tor hose from the water pump cover Remove the radiator lower mounting bolt and washer Support the engine using a jack or other adjustable support Remove the left front engine mounting bolt and col lar BOLT GUIDE PLATE CLUTCH CABLE SCREW LOWER RADIATOR HOSE BOLT WASHER BOLT COLLAR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 248: ...ngine hanger bracket bolts washers nuts and release the horn wire Remove the front engine hanger bracket from the frame Disconnect the sidestand switch 2P Green connec tor BOLT COLLAR BOLTS WASHERS NUTS BOLTS WASHERS NUTS HORN WIRE HANGER BRACKET 2P Green CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 249: ...ear lower engine mounting bolt as shown Remove the rear upper engine mounting bolt nut and collar Carefully lower the adjustable support then remove the engine from the frame BOLTS NUTS PIVOT NUTS BOLTS NUTS COLLAR NUT BOLT BOLT NUT COLLAR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 250: ...left side and install the collar between the engine and rear engine hanger Install the upper engine mounting nut Install the collar onto the right side engine mount Install the rear lower engine mounting bolt from the left side Install the collar between the engine and rear engine hanger Install the lower engine mounting nut Install the collar onto the right side engine mount BOLT NUT COLLAR BOLT ...

Page 251: ...anger bracket to the frame Install the right front engine hanger bracket bolts horn stay and nuts Install the left front engine hanger bracket bolts washers and nuts TORQUE 69 N m 7 0 kgf m 51 lbf ft TORQUE 98 N m 10 0 kgf m 72 lbf ft BOLTS NUTS PIVOT NUTS 2P Green CONNECTOR BOLTS WASHERS NUTS HORN WIRE HANGER BRACKET BOLTS WASHERS NUTS Manuals by Motomatrix www motomatrix co uk The Solution For L...

Page 252: ...ight and left front engine hanger bracket nuts to the specified torque Tighten the lower engine mounting nut to the speci fied torque BOLT COLLAR BOLT COLLAR TORQUE 49 N m 5 0 kgf m 36 lbf ft NUTS TORQUE 59 N m 6 0 kgf m 44 lbf ft BOLTS NUTS NUT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 253: ... bolt and washer to the front engine hanger Tighten the mounting bolt securely Connect the lower radiator hose to the water pump and tighten the hose band screw securely TORQUE 59 N m 6 0 kgf m 44 lbf ft BOLT NUT COLLAR TORQUE 59 N m 6 0 kgf m 44 lbf ft BOLTS BOLT WASHER SCREW LOWER RADIATOR HOSE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info moto...

Page 254: ...P switch wire to the guide of pivot bracket Install the horn and tighten the bolt securely Connect the horn wire connectors to the horn Connect the air bleed hose to the hose joint on the cylinder head and tighten the hose band screw securely BOLT GUIDE PLATE CLUTCH CABLE Align WIRE CLIP EOP SWITCH WIRE GUIDE BOLT HORN CONNECTORS SCREW AIR BLEED HOSE Manuals by Motomatrix www motomatrix co uk The ...

Page 255: ...d cable Connect the starter motor cable then tighten the terminal nut to the specified torque Install the rubber cap securely Secure the alternator wire with the clamps Connect the alternator 3P Black connector SCREW WATER HOSE TORQUE 10 N m 1 0 kgf m 7 lbf ft GROUND CABLE NUT STARTER MOTOR CABLE BOLT RUBBER CAP CLAMPS ALTERNATOR WIRE 3P Black CONNECTOR Manuals by Motomatrix www motomatrix co uk T...

Page 256: ...and drive sprocket bolt Tighten the drive sprocket bolt to the specified torque Install the following crankcase rear cover page 7 17 air cleaner housing page 5 75 exhaust pipe page 2 12 PAIR AIR SUCTION HOSES SPARK PLUG CAPS TORQUE 54 N m 5 5 kgf m 40 lbf ft DRIVE SPROCKET BOLT WASHER 16T MARK Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomat...

Page 257: ...l the gearshift arm aligning its slit with the punch mark on the gearshift spindle Install and tighten the pinch bolt to the specified torque Install the rear cover B aligning its bosses with the grommets of rear cover A REAR COVER B GUIDE PLATE BOLTS WIRE CLIP HOLE TORQUE 20 N m 2 0 kgf m 15 lbf ft GEARSHIFT ARM PINCH BOLT Align REAR COVER B REAR COVER A Manuals by Motomatrix www motomatrix co uk...

Page 258: ...MEMO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 259: ...DER HEAD REMOVAL 8 12 CYLINDER HEAD DISASSEMBLY 8 14 CYLINDER HEAD INSPECTION 8 15 VALVE GUIDE REPLACEMENT 8 18 VALVE SEAT INSPECTION REFACING 8 19 CYLINDER HEAD ASSEMBLY 8 22 CYLINDER HEAD INSTALLATION 8 24 CAMSHAFT INSTALLATION 8 26 CYLINDER HEAD COVER ASSEMBLY 8 30 CYLINDER HEAD COVER INSTALLATION 8 31 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email ...

Page 260: ... 35 lbf ft 20 N m 2 0 kgf m 15 lbf ft 10 N m 1 0 kgf m 7 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft 20 N m 2 0 kgf m 15 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 261: ... 1571 3 965 0 1561 EX 3 965 3 980 0 1561 0 1567 3 955 0 1557 Valve guide I D 4 000 4 012 0 1575 0 1580 4 04 0 159 Stem to guide clearance IN 0 010 0 037 0 0004 0 0015 0 075 0 0030 EX 0 020 0 047 0 0008 0 0019 0 085 0 0033 Valve guide projection above cylinder head IN 17 1 17 4 0 67 0 69 EX 13 3 13 6 0 52 0 54 Valve seat width 0 90 1 10 0 035 0 043 1 5 0 06 Valve spring free length IN 40 19 1 582 3...

Page 262: ...008 mm 07MMH MV90100 Cutter holder 4 0 mm 07781 0010500 or equivalent commercially avail able Valve seat cutter 29 mm 45 IN 07780 0010300 or equivalent commercially avail able Valve seat cutter 24 mm 45 EX 07780 0010600 or equivalent commercially avail able Flat cutter 29 mm 32 IN 07780 0013400 or equivalent commercially avail able Flat cutter 24 mm 32 EX 07780 0012500 or equivalent commercially a...

Page 263: ... piston or piston rings page 12 15 Compression too high overheating or knocking Excessive carbon build up on piston crown or on combustion chamber Excessive smoke Cylinder head Worn valve stem or valve guide Damaged stem seal Worn cylinder piston or piston rings page 12 15 Excessive noise Cylinder head Incorrect valve adjustment Sticking valve or broken valve spring Damaged or worn camshaft Loose ...

Page 264: ...n be caused by Blown cylinder head gasket Improper valve adjustment Valve leakage Worn piston rings or cylinder High compression can be caused by Carbon deposits in combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL Remove the fuel tank page 5 59 Disconnect the spark plug caps Disconnect the PAIR air suction hoses from the cyl inder head cover 2P Black CONNECTOR TOOL Compression gaug...

Page 265: ...AD COVER DISASSEMBLY Remove the cylinder head cover packing Remove the bolts and PAIR check valve cover Remove the PAIR check valves from the cylinder head cover Check the PAIR check valve for wear or damage replace if necessary BOLTS WASHERS BREATHER HOSE PACKING BOLTS COVER PAIR CHECK VALVES Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomat...

Page 266: ...he timing marks IN and EX on the cam sprockets must be flush with the cylinder head sur face and facing outward as shown If the timing marks on the cam sprocket are facing inward turn the crankshaft clockwise one full turn 360 and realign the timing marks with the cylin der head surface so they are facing outward PORT PLATES TIMING HOLE CAP O RING INDEX MARK T MARK TIMING MARKS Manuals by Motomatr...

Page 267: ... bolts as follows Remove the cam sprocket bolts from the intake and exhaust camshafts Turn the crankshaft clockwise one full turn 360 remove the other cam sprocket bolts from the camshafts Remove the bolts and cam chain guide B Remove the cam sprockets from the camshafts BOLT SEALING WASHER CAM CHAIN TENSIONER LIFTER TOOL Tensioner stopper 070MG 0010100 STOPPER TOOL Be careful not to drop the cam ...

Page 268: ...allow the shims to fall into the crankcase Mark all valve lifters and shims to ensure correct reassembly in their original locations The valve lifter can be easily removed with a valve lapping tool or magnet The shims can be easily removed with a twee zers or magnet INSPECTION CAMSHAFT Check the cam and journal surfaces of the camshaft for scoring scratches or evidence of insufficient lubrication ...

Page 269: ... or damage CAMSHAFT OIL CLEARANCE Do not rotate the camshaft when using plastigauge Remove the cylinder head and valves page 8 12 Wipe any oil from the journals of the camshaft cyl inder head and camshaft holders Lay a strip of plastigauge lengthwise on top of each camshaft journal SERVICE LIMITS IN 34 36 mm 1 353 in EX 33 84 mm 1 332 in CAMSHAFT HOLDER A CAMSHAFT HOLDER B CAMSHAFT HOLDER C CAM CH...

Page 270: ...k Tighten all camshaft holder bolts in the numerical order cast on the camshaft holders Remove the camshaft holders and measure the width of each plastigauge The widest thickness determines the oil clearance When the service limits are exceeded replace the camshaft and recheck the oil clearance Replace the cylinder head and camshaft holders as a set if the clearance still exceeds the service limit...

Page 271: ... chain guide A Remove the bolt cam chain tensioner A and collar Remove the cam chain and timing sprocket from the crankshaft Loosen the 9 mm bolts in a crisscross pattern in two or three steps 9 mm BOLTS WASHERS 6 mm BOLTS GASKET DOWEL PINS CAM CHAIN TENSIONER A CAM CHAIN GUIDE A BOLT WASHER BOLT COLLAR CAM CHAIN TIMING SPROCKET Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 272: ...cylinder head Install the tappet hole protector into the valve lifter bore An equivalent tool can easily be made from a plastic 35 mm film container as shown CAM CHAIN TENSIONER B BOLT SEALING WASHER BLEEDING JOINT SEALING WASHER TOOL Tappet hole protector 07HMG MR70002 TAPPET HOLE PROTECTOR TOP VIEW 25 mm I D when compressed 31 mm 5 mm 5 mm 15 mm Manuals by Motomatrix www motomatrix co uk The Sol...

Page 273: ... INSPECTION CYLINDER HEAD Avoid damaging the gasket surface Remove carbon deposits from the combustion chambers Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge TOOLS Valve spring compressor 07757 0010000 Valve spring compressor attachment 07959 KM30101 VALVE SPRING COMPRESSOR ATTACHMENT VALVE STEM SEAL SPRING SEAT RETAI...

Page 274: ...alve springs Replace the springs if they are shorter than the ser vice limits CAM CHAIN TENSIONER CAM CHAIN GUIDE Inspect the cam chain tensioner A and cam chain guide A for excessive wear or damage replace them if necessary SERVICE LIMIT 26 04 mm 1 025 in SERVICE LIMIT 25 97 mm 1 022 in SERVICE LIMITS IN 39 4 mm 1 55 in EX 39 0 mm 1 54 in CAM CHAIN TENSIONER A CAM CHAIN GUIDE A Manuals by Motomat...

Page 275: ...stopper tool is released VALVE VALVE GUIDE Check that the valve moves smoothly in the guide Inspect each valve for bending burning or abnor mal stem wear Measure and record each valve stem O D Ream the guides to remove any carbon deposits before checking clearances Insert the reamer from the combustion chamber side of the cylinder head and always rotate the reamer clockwise CAM CHAIN TENSIONER B S...

Page 276: ...r head Drive in the guides to the specified depth from the top of the cylinder head Let the cylinder head cool to room temperature Use cutting oil on the reamer during this operation Ream the new valve guides after installation Insert the reamer from the combustion chamber side of the head and also always rotate the reamer clockwise Clean the cylinder head thoroughly to remove any metal particles ...

Page 277: ...pecification reface the valve seat page 8 20 Inspect the valve seat face for Uneven seat width Replace the valve and reface the valve seat Damaged face Replace the valve and reface the valve seat The valves cannot be ground If a valve face is burned or badly worn or if it contacts the seat unevenly replace the valve Contact area too high or too low Reface the valve seat HAND LAPPING TOOL STANDARD ...

Page 278: ... replaced Use a 45 degree cutter to remove any roughness or irregularities from the seat Use a 32 degree cutter to remove the top 1 4 of the existing valve seat material 32 60 45 60 32 OLD SEAT WIDTH OLD SEAT WIDTH CONTACT TOO HIGH CONTACT TOO LOW TOOLS Seat cutter 29 mm IN 07780 0010300 Seat cutter 24 mm EX 07780 0010600 Cutter holder 4 0 mm 07781 0010500 or equivalent commer cially available ROU...

Page 279: ...essure may deform or dam age the seat Change the angle of lapping tool frequently to prevent uneven seat wear Do not allow lapping compound to enter the guides After lapping wash all residual compound off the cylinder head and valve TOOLS Interior cutter 30 mm IN 07780 0014000 Interior cutter 24 mm EX 070PH Z0D0100 Cutter holder 4 0 mm 07781 0010500 or equivalent commer cially available 60 OLD SEA...

Page 280: ...lution Insert the valve into the valve guide while turning it slowly to avoid damage to the stem seal SPRING RETAINER COTTERS SHIM SPRING SEAT VALVE GUIDE INTAKE VALVE VALVE LIFTER STEM SEAL VALVE SPRING EXHAUST VALVE TOOL Tappet hole protector 07HMG MR70002 or refer to page 8 14 for alternative tool TAPPET HOLE PROTECTOR VALVE STEM SEAL SPRING SEAT RETAINER VALVE SPRING Manuals by Motomatrix www ...

Page 281: ...stems gently with plastic hammer and pin driver as shown to seat the cotters firmly Install and tighten the spark plugs Apply a locking agent to the bleeding joint threads Install the bleeding joint with a new sealing washer to the cylinder head Tighten the bleeding joint to the specified torque EXHAUSTVALVE SPRING INTAKE VALVE SPRING COMBUSTION CHAMBER SIDE TOOLS Valve spring compressor 07757 001...

Page 282: ...orque CYLINDER HEAD INSTALLATION Install the timing sprocket by aligning the wide teeth between the crankshaft and sprocket Install the cam chain Install the cam chain guide A and bolt TORQUE 20 N m 2 0 kgf m 15 lbf ft BOLT SEALING WASHER CAM CHAIN TENSIONER B TIMING SPROCKET Align CAM CHAIN BOLT CAM CHAIN GUIDE A Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Ke...

Page 283: ...ver page 9 25 Install the dowel pins and a new cylinder head gas ket as shown Install the cylinder head onto the cylinder block while aligning the cam chain tensioner A and B as shown COLLAR CAM CHAIN TENSIONER A BOLT TORQUE 12 N m 1 2 kgf m 9 lbf ft TORQUE 12 N m 1 2 kgf m 9 lbf ft CAM CHAIN TENSIONER A CAM CHAIN GUIDE A BOLT WASHER BOLT COLLAR GASKET DOWEL PINS CYLINDER HEAD CAM CHAIN TENSIONER ...

Page 284: ...t page 8 26 thermostat housing page 6 10 air cleaner housing page 5 75 exhaust system page 2 12 CAMSHAFT INSTALLATION Apply molybdenum oil solution to the outer surface of the each valve lifter Install the shims on the retainers and valve lifters into the valve lifter bores The each camshaft has identification mark FG Intake camshaft EX ER Exhaust camshaft TORQUE 47 N m 4 8 kgf m 35 lbf ft 9 mm BO...

Page 285: ...cing up and out as shown Clean and apply a locking agent to the cam sprocket bolt threads Install the cam sprocket bolts Turn the crankshaft clockwise and align the T mark on the CKP sensor rotor with the index mark on the right crankcase cover Apply molybdenum oil solution to the camshaft journal of the cylinder head EXHAUST CAM SPROCKET INTAKE CAM SPROCKET NO 1 CYLINDER CAM LOBES BOLTS INDEX MAR...

Page 286: ...as shown Coat new O rings with oil and install them into the grooves in the camshaft holders Apply molybdenum oil solution to the camshaft journals of the camshaft holders Note the correct locations with the identification marks as shown No mark right camshaft holder R mark center camshaft holder L mark left camshaft holder INTAKE CAMSHAFT EXHAUST CAMSHAFT IDENTIFICATION MARKS TIMING MARKS CYLINDE...

Page 287: ...he bolts Gradually tighten the camshaft holder bolts until the camshaft holders lightly contact the cylinder head surface Failure to tighten the camshaft holder in a criss cross pattern might cause a camshaft holder to break Tighten all camshaft holder bolts in the numerical order cast on the camshaft holders Install the cam chain guide B and tighten the bolts CAMSHAFT HOLDER SEALING WASHERS TORQU...

Page 288: ... chain tensioner lifter Install a new sealing washer and tighten the sealing bolt Recheck the valve timing CYLINDER HEAD COVER ASSEMBLY Install the PAIR check valve port plates into the cyl inder head cover TORQUE 20 N m 2 0 kgf m 15 lbf ft CAM SPROCKET BOLTS STOPPER TOOL BOLT SEALING WASHER CAM CHAIN TENSIONER LIFTER PORT PLATES Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mot...

Page 289: ...ue CYLINDER HEAD COVER INSTALLATION Install the cylinder head packing into the groove of the cylinder head cover Apply sealant to the cylinder head semi circular cut outs as shown PAIR CHECK VALVES TORQUE 12 N m 1 2 kgf m 9 lbf ft BOLTS COVER PACKING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 290: ...crankcase breather hose to the cylinder head cover Route the hoses wires properly page 1 24 Connect the PAIR air suction hoses to the cylinder head cover Connect the spark plug caps securely Install the fuel tank page 5 60 UP MARK TORQUE 10 N m 1 0 kgf m 7 lbf ft BOLTS WASHERS BREATHER HOSE PAIR AIR SUCTION HOSES SPARK PLUG CAPS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Moto...

Page 291: ... INFORMATION 9 3 TROUBLESHOOTING 9 4 RIGHT CRANKCASE COVER REMOVAL 9 5 CLUTCH 9 6 STARTER CLUTCH 9 17 GEARSHIFT LINKAGE 9 22 RIGHT CRANKCASE COVER INSTALLATION 9 25 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 292: ... 23 N m 2 3 kgf m 17 lbf ft 128 N m 13 1 kgf m 94 lbf ft 12 N m 1 2 kgf m 9 lbf ft 15 N m 1 5 kgf m 11 lbf ft 83 N m 8 5 kgf m 61 lbf ft 20 N m 2 0 kgf m 15 lbf ft 12 N m 1 2 kgf m 9 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 293: ... 35 025 35 145 1 3789 1 3837 35 155 1 3841 Mainshaft O D at clutch outer guide 24 980 24 990 0 9835 0 9839 24 960 0 9827 Mainshaft O D at oil pump drive sprocket guide 24 980 24 990 0 9835 0 9839 24 960 0 9827 Starter idle gear Gear I D 10 013 10 035 0 3942 0 3951 10 05 0 396 Shaft O D 9 991 10 000 0 3933 0 3937 9 98 0 393 Starter driven gear boss O D 45 657 45 673 1 7975 1 7981 45 642 1 7969 Clut...

Page 294: ...fork shaft page 11 8 Bent fork claw page 11 8 Damaged gearshift cam page 11 8 Loose stopper plate bolt Damaged stopper plate and pin Damaged gearshift spindle Transmission jumps out of gear Worn shift drum stopper arm Weak or broken shift drum stopper arm return spring Loose stopper plate bolt Bent shift fork shaft Damaged gearshift cam page 11 8 Damaged or bent shift forks page 11 8 Worn gear eng...

Page 295: ...of the right crankcase cover Remove the right crankcase cover while turning the clutch lifter lever counterclockwise to disengage the lifter lever spindle from the lifter piece Be careful not to drop the thrust wave washers into the crankcase when removing the right crankcase cover Remove the thrust washer and wave washer from the starter idle gear GUIDE PLATE LIFTER LEVER CLUTCH CABLE BOLT RIGHT ...

Page 296: ...kcase cover Check the lifter lever spindle for wear or damage Check the return spring for fatigue or damage Check the lifter lever oil seal and needle bearings for wear or damage Install the clutch lifter lever with the washer and spring in the reverse order of removal CLUTCH REMOVAL Remove the right crankcase cover page 9 5 Remove the starter idle gear and shaft DOWEL PINS RETURN SPRING WASHER LI...

Page 297: ...es clutch disc B judder spring spring seat Unstake the clutch center lock nut Hold the clutch center with the special tool and remove the clutch center lock nut Discard the lock nut PRESSURE PLATE BOLTS SPRINGS LIFTER PIECE CLUTCH DISCS PLATES LOCK NUT Unstake TOOL Clutch center holder 07724 0050002 or equivalent commer cially available CLUTCHCENTER HOLDER CLUTCH CENTER Manuals by Motomatrix www m...

Page 298: ... the thrust washer Remove the clutch outer guide and needle bearing Remove the clutch outer CLUTCH CENTER LOCK WASHER THRUST WASHER THRUST WASHER CLUTCH OUTER GUIDE NEEDLE BEARING CLUTCH OUTER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 299: ...rive sprocket guide INSPECTION Clutch lifter bearing Turn the inner race of the lifter bearing with your finger The bearing should turn smoothly and freely with out excessive play If necessary replace the bearing CHAIN GUIDE B BOLT CHAIN GUIDE A BOLT DRIVE CHAIN DRIVEN SPROCKET BOLT WASHER DRIVE SPROCKET DRIVE SPROCKET GUIDE LIFTER BEARING Manuals by Motomatrix www motomatrix co uk The Solution Fo...

Page 300: ...ce it if necessary Clutch lifter piece Check the clutch lifter piece for damage or abnormal wear Clutch disc Replace the clutch discs and plates as a set Replace the clutch discs if they show signs of scor ing or discoloration Measure the disc thickness of each disc SERVICE LIMIT 47 2 mm 1 86 in SERVICE LIMIT 2 6 mm 0 10 in Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycl...

Page 301: ...outer primary driven gear Check the slots of the clutch outer for damage or wear caused by the clutch discs Check the primary driven gear for abnormal wear or damage Measure the I D of the primary driven gear Replace the clutch outer assembly if necessary Clutch outer guide needle bearing Measure the O D and I D of the clutch outer guide Check the needle bearing turns smoothly and qui etly Replace...

Page 302: ...arter idle gear idle gear shaft Check the starter idle gear and shaft for wear or damage Measure the starter idle gear I D and shaft O D SERVICE LIMITS O D 34 940 mm 1 3756 in I D 25 031 mm 0 9855 in SERVICE LIMIT 35 155 mm 1 3841 in SERVICE LIMITS Oil pump drive sprocket guide position 24 960 mm 0 9827 in Clutch outer guide position 24 960 mm 0 9827 in SERVICE LIMITS Shaft O D 9 98 mm 0 393 in Ge...

Page 303: ... WASHER LIFTER BEARING CLUTCH OUTER LIFTER PLATE CLUTCH DISCS CLUTCH PLATES DRIVE SPROCKET GUIDE CLUTCH CENTER 12 N m 1 2 kgf m 9 lbf ft LIFTER PIECE SPRING CLUTCH OUTER GUIDE NEEDLE BEARING SPRING SEAT JUDDER SPRING THRUST WASHER LOCK WASHER CHAIN GUIDE A CHAIN GUIDE B 128 N m 13 1 kgf m 94 lbf ft LOCK NUT 15 N m 1 5 kgf m 11 lbf ft DRIVE SPROCKET GUIDE Install the oil pump driven sprocket with i...

Page 304: ...ll the clutch outer while aligning the tabs of the oil pump drive sprocket with holes of the clutch outer Apply molybdenum oil solution to the clutch outer guide sliding surface Install the clutch outer guide and needle bearing onto the mainshaft Install the thrust washer CHAIN GUIDE B BOLT CHAIN GUIDE A BOLT Align CLUTCH OUTER Align Install the clutch outer guide with its grooves facing out NEEDL...

Page 305: ...ified torque Be careful not to damage the mainshaft threads Stake the lock nut into the mainshaft groove with a punch Install the spring seat and judder spring onto the clutch center as shown CLUTCH CENTER LOCK WASHER THRUST WASHER OUT MARK TOOL Clutch center holder 07724 0050002 or equivalent commer cially available TORQUE 128 N m 13 1 kgf m 94 lbf ft CLUTCH CENTER CLUTCHCENTER HOLDER LOCK NUT St...

Page 306: ...ter bearing into the pressure plate Install the clutch lifter piece into the lifter bearing Install the pressure plate Install the clutch springs and spring bolts Tighten the bolts to the specified torque in a criss cross pattern in two to three steps CLUTCH DISC B CLUTCH DISC A CLUTCH DISCS CLUTCH PLATES SHALLOW SLOT LIFTER PIECE LIFTER BEARING TORQUE 12 N m 1 2 kgf m 9 lbf ft PRESSURE PLATE BOLT...

Page 307: ...e following starter idle gear starter idle gear shaft Insert the gear holder between the starter idle gear and driven gear as shown Remove the starter clutch mounting bolt and washer Remove the temporarily installed parts Remove the starter clutch outer assembly IDLE GEAR SHAFT STARTER REDUCTION GEAR TOOL Gear holder M2 5 07724 0010100 GEAR HOLDER BOLT WASHER IDLE GEAR SHAFT DRIVEN GEAR STARTER CL...

Page 308: ...othly but the gear should not turn coun terclockwise DISASSEMBLY Remove the starter driven gear by turning it clock wise Remove the needle bearing Remove the snap ring and one way clutch THRUST WASHER STARTER DRIVEN GEAR NEEDLE BEARING STARTER DRIVEN GEAR NEEDLE BEARING SNAP RING ONE WAY CLUTCH Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motoma...

Page 309: ... starter driven gear for abnormal wear or damage Measure the starter driven gear boss O D Check the starter reduction gear for wear or damage and replace it if necessary STARTER CLUTCH OUTER ONE WAY CLUTCH SERVICE LIMIT 45 642 mm 1 7969 in STARTER REDUCTION GEAR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 310: ...ng out Install the snap ring into the starter clutch outer groove securely SNAP RING STARTER CLUTCH OUTER ONE WAY CLUTCH 83 N m 8 5 kgf m 61 lbf ft NEEDLE BEARING STARTER DRIVEN GEAR STARTER CLUTCH OUTER ONE WAY CLUTCH PAINT MARK SNAP RING STARTER CLUTCH OUTER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 311: ...tch operation page 9 18 INSTALLATION Install the thrust washer into the crankshaft Install the starter clutch outer assembly into the crankshaft while aligning the tab of the crankshaft with the wide groove of the starter clutch assembly STARTER DRIVEN GEAR NEEDLE BEARING THRUST WASHER STARTER CLUTCH OUTER ASSEMBLY Align Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle C...

Page 312: ...num oil solution to the starter reduc tion gear sliding surface Install the starter reduction gear into the crankcase Install the clutch page 9 13 GEARSHIFT LINKAGE REMOVAL Remove the following right crankcase cover page 9 5 clutch page 9 6 Remove the pinch bolt and disconnect the gearshift arm from the gearshift spindle BOLT WASHER Be careful not to drop the gear holder into the crankcase TOOL Ge...

Page 313: ... shift drum center socket bolt gearshift cam dowel pin INSPECTION Check the gearshift spindle for wear damage or bending Check the return spring for fatigue or damage BOLT SETTING PLATE GEARSHIFT SPINDLE THRUST WASHER STOPPER ARM BOLT SPRING WASHER GEARSHIFT CAM SOCKET BOLT DOWEL PIN GEARSHIFT SPINDLE RETURN SPRING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded K...

Page 314: ...rum center socket bolt threads Tighten the socket bolt to the specified torque Install the thrust washer and gearshift spindle assembly into the crankcase while aligning the spring ends with the crankcase stopper pin TORQUE 12 N m 1 2 kgf m 9 lbf ft STOPPER ARM WASHER PIVOT BOLT RETURN SPRING Align the dowel pin on the shift drum with the wide groove on the gearshift cam WIDE GROOVE DOWEL PIN GEAR...

Page 315: ...ten the pinch bolt to the specified torque Install the following clutch page 9 13 right crankcase cover page 9 25 RIGHT CRANKCASE COVER INSTALLATION Apply sealant to the mating surfaces of the right crankcase cover and crankcase BOLT SETTING PLATE TORQUE 20 N m 2 0 kgf m 15 lbf ft GEARSHIFT ARM PINCH BOLT Align Cover side Crankcase side 10 15 mm 0 4 0 6 in 10 15 mm 0 4 0 6 in Manuals by Motomatrix...

Page 316: ...ter lever spin dle groove with the lifter piece flange Install the right crankcase cover bolts with the clamp Tighten the right crankcase cover bolts crisscross pattern in two to three steps Secure the EOP switch wire with the clamp DOWEL PINS WAVE WASHER THRUST WASHER LIFTER LEVER RIGHT CRANKCASE COVER BOLTS CLAMP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded K...

Page 317: ...late aligning its hole with the boss of right crankcase cover Tighten the bolt securely Add the recommended engine oil page 3 15 Adjust the clutch lever freeplay page 3 28 GUIDE PLATE LIFTER LEVER CLUTCH CABLE BOLT Align Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 318: ...MEMO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 319: ...ION 10 2 SERVICE INFORMATION 10 3 ALTERNATOR COVER REMOVAL 10 4 STATOR 10 5 FLYWHEEL 10 6 ALTERNATOR COVER INSTALLATION 10 7 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 320: ...RNATOR COMPONENT LOCATION 113 N m 11 5 kgf m 83 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 321: ...or servicing page 19 6 TORQUE VALUES TOOLS Stator mounting socket bolt 12 N m 1 2 kgf m 9 lbf ft Flywheel flange bolt 113 N m 11 5 kgf m 83 lbf ft Apply engine oil to the threads and seating surface Stator wire clamp flange bolt 12 N m 1 2 kgf m 9 lbf ft CT bolt Flywheel holder 07725 0040001 or equivalent commercially avail able Rotor puller 07733 0020001 Manuals by Motomatrix www motomatrix co uk...

Page 322: ...nator cover stator is magnetically attached to the flywheel be careful during removal Remove the bolts and alternator cover Engine oil will run out when the alternator cover is removed Set a clean oil pan under the engine and add the recommended oil to the specified level after installation 3P Black CONNECTOR CLAMPS ALTERNATOR WIRE ALTERNATOR WIRE GUIDE ALTERNATOR COVER BOLTS Manuals by Motomatrix...

Page 323: ...ve the alternator wire grommet from the alter nator cover Remove the socket bolts and stator INSTALLATION DOWEL PINS WIRE CLAMP SOCKET BOLTS GROMMET STATOR BOLT WIRE CLAMP ALTERNATOR COVER 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft STATOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 324: ...l using the special tool then remove the flywheel bolt Remove the washer Remove the flywheel using the special tool INSTALLATION Clean any oil off from the crankshaft taper area TORQUE 12 N m 1 2 kgf m 9 lbf ft TORQUE 12 N m 1 2 kgf m 9 lbf ft WIRE CLAMP SOCKET BOLTS GROMMET STATOR BOLT TOOL Flywheel holder 07725 0040001 or equivalent commer cially available FLYWHEEL HOLDER BOLT WASHER TOOL Rotor ...

Page 325: ...torque ALTERNATOR COVER INSTALLATION Apply sealant to the mating surfaces of the alterna tor cover and crankcase BOLT WASHER FLYWHEEL TOOL Flywheel holder 07725 0040001 or equivalent commer cially available TORQUE 113 N m 11 5 kgf m 83 lbf ft FLYWHEEL HOLDER Cover side Crankcase side 10 15 mm 0 4 0 6 in 10 15 mm 0 4 0 6 in Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle...

Page 326: ... in a crisscross pattern in two or three steps securely Refer to the wires properly page 1 24 Route the alternator wire and hook the alternator wire on the guide Secure the alternator wire with the clamps DOWEL PINS ALTERNATOR COVER BOLTS ALTERNATOR WIRE GUIDE CLAMPS ALTERNATOR WIRE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 327: ...tor Install the following crankcase rear cover A page 7 17 rear cowl page 2 5 left side cover page 2 5 seat page 2 4 BOLTS 3P Black CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 328: ...MEMO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 329: ...1 2 SERVICE INFORMATION 11 3 TROUBLESHOOTING 11 4 CRANKCASE SEPARATION 11 5 SHIFT FORK SHIFT DRUM TRANSMISSION 11 6 CRANKCASE ASSEMBLY 11 16 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 330: ...N m 1 2 kgf m 9 lbf ft 15 N m 1 5 kgf m 11 lbf ft 120 39 N m 4 0 kgf m 29 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft 24 N m 2 4 kgf m 18 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 331: ...1 0 9449 0 9457 26 04 1 025 C2 C3 C4 31 000 31 025 1 2205 1 2215 31 04 1 222 Gear busing O D M5 M6 27 959 27 980 1 1007 1 1016 27 94 1 100 C2 30 955 30 980 1 2187 1 2197 30 94 1 218 C3 C4 30 950 30 975 1 2185 1 2195 30 93 1 218 Gear to bushing clearance M5 M6 0 020 0 062 0 0008 0 0024 0 10 0 004 C2 0 020 0 070 0 0008 0 0028 0 10 0 004 C3 C4 0 025 0 075 0 0010 0 0030 0 11 0 004 Gear bushing I D M5 ...

Page 332: ... stopper arm page 9 23 Broken shift drum stopper arm spring page 9 23 Worn or bent shift forks Broken gearshift spindle return spring page 9 23 Excessive engine noise Worn or damaged transmission gear Worn or damaged transmission bearings Bearing remover set 20 mm 07936 3710600 Remover weight 07741 0010201 Bearing remover handle 07936 3710100 Driver 07949 3710001 Attachment 42 x 47 mm 07746 001030...

Page 333: ...e page 11 3 Remove the bolt oil level plate and oil level finder from the crankcase Remove the bolts and cover Remove the bolts and sealing washers OIL LEVEL PLATE BOLTS OIL LEVEL FINDER BOLTS COVER BOLTS SEALING WASHERS BOLTS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 334: ...case from the upper crank case Remove the dowel pins and oil orifices Clean any sealant off from the crankcase mating surface SHIFT FORK SHIFT DRUM TRANSMISSION REMOVAL DISASSEMBLY Separate the crankcase halves page 11 5 Remove the countershaft assembly 10 mm BOLT 8 mm BOLTS MAIN JOURNAL BOLTS 6 mm BOLTS SEALING WASHERS 6 mm BOLTS 6 mm BOLTS OIL ORIFICES DOWEL PINS COUNTERSHAFT Manuals by Motomatr...

Page 335: ...ent thoroughly Remove the shift drum bearing set bolts washers Remove the fork shaft and shift forks Remove the shift drum and shift drum bearing DOWEL PIN BEARING SET RING BOLTS WASHERS SHIFT FORK SHAFT SHIFT FORKS SHIFT DRUM BEARING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 336: ...mble the mainshaft Clean all disassembled parts in solvent thoroughly SHIFT DRUM SHIFT FORK INSPECTION Check the shift fork guide pin for abnormal wear or damage Measure the shift fork I D Measure the shift fork claw thickness SET PLATE BOLTS BEARING MAINSHAFT SERVICE LIMIT 12 03 mm 0 474 in SERVICE LIMIT 5 9 mm 0 23 in Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Co...

Page 337: ...ace fits tightly on the shift drum If necessary replace the bearing TRANSMISSION INSPECTION Check the gear shifter groove for abnormal wear or damage Check the gear dogs dog holes and teeth for abnor mal wear or lack of lubrication Measure the I D of each gear SERVICE LIMIT 11 95 mm 0 470 in SERVICE LIMITS M5 M6 28 04 mm 1 104 in C1 26 04 mm 1 025 in C2 C3 C4 31 04 mm 1 222 in Manuals by Motomatri...

Page 338: ...eplace the countershaft collar and bearing as an assembly if the race does not turn smoothly qui etly or fits loosely on the countershaft The countershaft bearing cannot be replaced If the countershaft bearing is faulty replace the countershaft as an assembly SERVICE LIMITS M5 M6 27 94 mm 1 100 in C2 30 94 mm 1 218 in C3 C4 30 93 mm 1 218 in SERVICE LIMITS M5 25 016 mm 0 9849 in C2 28 021 mm 1 103...

Page 339: ... following crankshaft page 12 5 piston page 12 14 Remove the mainshaft bearing using the special tools as shown Drive in a new bearing squarely with the marking side facing up Drive a new bearing into the crankcase using the special tools BEARING TOOLS Bearing remover set 20 mm 07936 3710600 Remover weight 07741 0010201 Remover handle 07936 3710100 BEARING REMOVER TOOLS Driver 07949 3710001 Attach...

Page 340: ...es and bushings Assemble the mainshaft and countershaft M2 GEAR 16T M6 GEAR 24T M4 3 GEAR 23 18T M5 GEAR 20T MAINSHAFT M1 GEAR 12T C1 GEAR 33T C6 GEAR 25T C5 GEAR 23T C3 GEAR 28T C2 GEAR 31T COUNTERSHAFT C4 GEAR 30T Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 341: ...l the thrust washer and snap ring with the chamfered rolled edge facing away from the thrust load Install the snap ring so that its end gap aligns with the groove of the splines Make sure that the snap ring is fully seated in the shaft groove after installing it Align CORRECT INCORRECT SNAP RING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motom...

Page 342: ...ing out Install the mainshaft bearing into the crankcase Apply a locking agent to the set plate bolt threads Install the mainshaft bearing set plate with its OUT SIDE mark facing out Tighten the set plate bolts to the specified torque MAINSHAFT BEARING TORQUE 12 N m 1 2 kgf m 9 lbf ft SET PLATE BOLTS OUT SIDE MARK Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Ke...

Page 343: ...grooves with the identification marks facing toward the right side of the engine and insert the fork shaft Apply a locking agent to the shift drum bearing set bolt threads Tighten the bolts washers to the specified torque SHIFT DRUM BEARING L C R SHIFT FORK SHAFT SHIFT FORKS TORQUE 12 N m 1 2 kgf m 9 lbf ft BOLTS WASHERS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle C...

Page 344: ...wel pin Also align the countershaft bearing stopper pin with the groove in the crankcase CRANKCASE ASSEMBLY Apply a light but thorough coating of liquid sealant to the crankcase mating surface Do not apply sealant to the crankcase 8 mm bolt main journal bolt area and the oil passage area as shown DOWEL PIN BEARING SET RING COUNTERSHAFT BEARING SET RING DOWEL PIN STOPPER PIN Manuals by Motomatrix w...

Page 345: ...urface Install the lower crankcase onto the upper crank case Install new crankcase 8 mm bolts main journal 8 mm bolts Loosely install all the crankcase bolts PLASTIC REGION TIGHTENING METHOD Make sure the upper and lower crankcase are seated securely Tighten the crankcase 8 mm bolts main journal bolts as follow Tighten the crankcase 8 mm bolts main journal bolts in numerical order in the illustrat...

Page 346: ...ith a new sealing washer Tighten the 8 mm bolt to the specified torque TORQUE 39 N m 4 0 kgf m 29 lbf ft TORQUE 12 N m 1 2 kgf m 9 lbf ft 10 mm BOLT 6 mm BOLTS SEALING WASHERS 6 mm BOLTS 6 mm BOLTS The sealing washer locations are indi cated on the upper crankcase using the mark TORQUE 12 N m 1 2 kgf m 9 lbf ft TORQUE 24 N m 2 4 kgf m 18 lbf ft 8 mm BOLTS SEALING WASHER 6 mm BOLTS SEALING WASHER 6...

Page 347: ... locking agent to the oil level plate bolt threads Install the oil level plate and tighten the bolt securely Install the removed parts in the reverse order of removal BOLTS COVER Align the oil level plate groove with the crankcase tab OIL LEVEL PLATE BOLTS Align OIL LEVEL FINDER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 348: ...MEMO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 349: ...ON 12 2 SERVICE INFORMATION 12 3 TROUBLESHOOTING 12 4 CRANKSHAFT 12 5 MAIN JOURNAL BEARING 12 8 CRANKPIN BEARING 12 11 PISTON CYLINDER 12 14 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 350: ...T PISTON CYLINDER 12 2 CRANKSHAFT PISTON CYLINDER COMPONENT LOCATION 26 N m 2 7 kgf m 19 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 351: ...0 002 Piston piston rings Piston O D at 6 0 2 from bottom 66 965 66 985 2 6364 2 6372 66 90 2 634 Piston pin bore I D 16 002 16 008 0 6300 0 6302 16 02 0 631 Piston pin O D 15 994 16 000 0 6297 0 6299 15 98 0 629 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 04 0 002 Piston ring end gap Top 0 10 0 20 0 004 0 008 0 4 0 02 Second 0 21 0 31 0 008 0 012 0 5 0 02 Oil side rail 0 2 0 7 0 01...

Page 352: ...lt up on piston head or combustion chamber Excessive smoke Worn cylinder piston or piston ring Improper installation of piston rings Scored or scratched piston or cylinder wall Abnormal noise Worn piston pin or piston pin hole Worn connecting rod small end Worn cylinder piston or piston rings Worn main journal bearings Worn crankpin bearings Engine vibration Excessive crankshaft runout Manuals by ...

Page 353: ...installed in their original locations or the correct bearing oil clearance may not be obtained resulting in engine damage Mark the bearing caps and bearings as you remove them to indicate the correct cylinder for reassembly Remove the connecting rod bearing cap nuts and bearing caps Tap the side of the cap lightly if the bearing cap is hard to remove Remove the crankshaft Remove the main journal b...

Page 354: ...g inserts they must be installed in their original locations or the correct bearing oil clearance may not be obtained resulting in engine damage Apply molybdenum oil solution to the thrust sur faces of the crankshaft as shown Position all the pistons at TDC Top Dead Center to prevent damaging the crankpin with the connecting rod Install the crankshaft onto the upper crankcase Set the connecting ro...

Page 355: ...inal position as noted during removal Apply engine oil to the connecting rod bearing cap nut threads and seating surfaces and install them Tighten the nuts in two or three steps alternately then tighten the nuts to the specified torque Assemble the upper and lower crankcase page 11 16 BEARING CAP Align BEARING CAP NUTS TORQUE 26 N m 2 7 kgf m 19 lbf ft BEARING CAP NUTS Manuals by Motomatrix www mo...

Page 356: ... wear or peeling Check the bearing tabs for damage OIL CLEARANCE INSPECTION Clean off any oil from the bearing inserts and main journals Install the crankshaft onto the upper crankcase Put a strip of plastigauge lengthwise on each main journal avoiding the oil hole Do not rotate the crankshaft during inspection Install the dowel pins in the upper crankcase Install the lower crankcase onto the uppe...

Page 357: ...dest point on each main journal to determine the oil clearance If the oil clearance exceeds the service limit select a replacement bearing BEARING SELECTION Letters A B or C on the left side of upper crankcase are the codes for the bearing support I D s from left to right Record the crankcase bearing support I D code let ters from the pad on the left side of the upper crank case as shown Numbers 1...

Page 358: ...pper crankcase Install the main journal bearing inserts onto the crankcase bearing supports aligning each tabs with each grooves BEARING SUPPORT I D CODE A B C 34 000 34 006 mm 1 3386 1 3388 in 34 006 34 012 mm 1 3388 1 3391 in 34 012 34 018 mm 1 3391 1 3393 in MAINJOURNAL O D CODE 1 30 999 31 005 mm 1 2204 1 2207 in Pink Yellow Green 2 30 993 30 999 mm 1 2202 1 2204 in Yellow Green Brown 3 30 987...

Page 359: ... oil from the bearing inserts and crank pins Carefully install the crankshaft onto the upper crank case Set the connecting rods onto the crankpins Put a strip of plastigauge lengthwise on each crankpin avoiding the oil hole Do not rotate the crankshaft during inspection Carefully install the connecting rod bearing caps by aligning the I D code Apply engine oil to the connecting rod bearing cap nut...

Page 360: ...I D Record the connecting rod I D code number 1 or 2 or measure the I D with the connecting rod bearing cap installed without bearing inserts Letters A or B on the crankweight are the codes for the crankpin O D s from left to right If you are replacing the crankshaft record the corre sponding crankpin O D code letter A or B If you are reusing the crankshaft measure the crankpin O D with the microm...

Page 361: ...aring cap and connecting rod Install the crankpin bearing inserts onto the bearing cap and connecting rod aligning each tab with each groove CONNECTING ROD I D CODE 1 2 33 500 33 508 mm 1 3189 1 3192 in 33 508 33 516 mm 1 3192 1 3195 in CRANK PIN O D CODE A 30 995 31 003 mm 1 2203 1 2206 in Yellow Green B 30 984 30 995 mm 1 2198 1 2203 in Green Brown BEARING THICKNESS Brown Thickest Green Yellow T...

Page 362: ...ing in engine damage Separate the crankcase halves page 11 5 Remove the nuts and connecting rod bearing caps Do not try to remove the connecting rod piston assembly from the bottom of the cylinder the assembly will be locked so that the oil ring expands in the gap between the cylinder liner and the upper crankcase Remove the piston connecting rod assembly from the top of the cylinder PISTON REMOVA...

Page 363: ... be able to move in their grooves without catching Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring to ring groove clearance Push the rings into the cylinder with the top of the piston to be sure they are squarely in the cylinder Insert the piston ring squarely into the top of the cyl inder and measure the ring end gap SERVICE LIMITS Top...

Page 364: ...ole CONNECTING ROD INSPECTION Measure the connecting rod small end I D Calculate the connecting rod to piston pin clear ance SERVICE LIMIT 16 02 mm 0 631 in SERVICE LIMIT 15 98 mm 0 629 in SERVICE LIMIT 0 04 mm 0 002 in SERVICE LIMIT 66 90 mm 2 634 in 6 mm 0 2 in SERVICE LIMIT 16 05 mm 0 632 in SERVICE LIMIT 0 07 mm 0 003 in Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcyc...

Page 365: ... axis Take the maximum reading to determine them The cylinder must be rebored and an oversize pis ton fitted if the service limits are exceeded The piston to cylinder clearance for the oversize pis ton must be 0 015 0 050 mm 0 0006 0 0020 in Inspect the top of the cylinder for warpage SERVICE LIMIT 67 10 mm 2 642 in SERVICE LIMIT 0 10 mm 0 004 in SERVICE LIMITS Taper 0 10 mm 0 004 in Out of round ...

Page 366: ...agger the side rail end gaps as shown After installation the rings should rotate freely in the ring groove PISTON INSTALLATION Apply molybdenum oil solution to the connecting rod small end inner surfaces and piston pin outer surfaces Assemble the piston and connecting rod with the journal bearing tab facing to the piston IN mark Install the piston pin and secure it using new piston pin clips Make ...

Page 367: ...ring sliding surfaces on the connecting rod bear ing caps Install the connecting rod bearing caps by aligning the I D code on the connecting rod and bearing cap Be sure each part is installed in its original position as noted during removal Apply engine oil to the connecting rod bearing cap nut threads and seating surfaces and install them Tighten the bolts in two or three steps alternately then t...

Page 368: ...MEMO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 369: ...MPONENT LOCATION 13 2 SERVICE INFORMATION 13 4 TROUBLESHOOTING 13 7 HANDLEBAR 13 8 FRONT WHEEL 13 15 FORK 13 21 STEERING STEM 13 33 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 370: ... 22 N m 2 2 kgf m 16 lbf ft 30 N m 3 1 kgf m 22 lbf ft 22 N m 2 2 kgf m 16 lbf ft 10 N m 1 0 kgf m 7 lbf ft 103 N m 10 5 kgf m 76 lbf ft 22 N m 2 2 kgf m 16 lbf ft 39 N m 4 0 kgf m 29 lbf ft 10 N m 1 0 kgf m 7 lbf ft 12 N m 1 2 kgf m 9 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 371: ...kgf m 22 lbf ft 22 N m 2 2 kgf m 16 lbf ft 10 N m 1 0 kgf m 7 lbf ft 103 N m 10 5 kgf m 76 lbf ft 22 N m 2 2 kgf m 16 lbf ft 39 N m 4 0 kgf m 29 lbf ft 10 N m 1 0 kgf m 7 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 372: ...ead bearing pre load 8 8 13 7 N 0 9 1 4 kgf 2 0 3 1 lbf Handlebar holder bolt 27 N m 2 8 kgf m 20 lbf ft Steering stem nut 103 N m 10 5 kgf m 76 lbf ft See page 13 38 Steering bearing adjustment nut lock nut See page 13 38 Steering bearing adjustment nut See page 13 38 Fork top bridge pinch bolt 22 N m 2 2 kgf m 16 lbf ft Fork bottom bridge pinch bolt 39 N m 4 0 kgf m 29 lbf ft Front axle bolt 59 ...

Page 373: ...0300 Attachment 52 X 55 mm 07746 0010400 Pilot 20 mm 07746 0040500 Slider weight 07947 KA50100 Oil seal driver attachment 07947 KF00100 Steering stem socket 07916 3710101 Steering stem driver 07946 MB00000 Ball race remover set 07946 KM90002 Driver attachment A 07946 KM90100 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 374: ... 07946 KM90200 Driver shaft assembly 07946 KM90301 Bearing remover A 07946 KM90401 Bearing remover B 07946 KM90500 Assembly base 07946 KM90600 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 375: ...ivot bearings Front wheel wobbling Bent rim Worn or damaged front wheel bearings Faulty tire Unbalanced front tire and wheel Front wheel turns hard Faulty front wheel bearing Bent front axle Front brake drag Soft suspension Insufficient fluid in fork Incorrect fork fluid weight Weak fork springs Insufficient tire pressure Hard suspension Bent fork tubes To much fluid in fork Incorrect fork fluid w...

Page 376: ...oth handlebar weights from the handlebar Loosen the lock nut and disconnect the clutch cable end from the clutch lever CBF600N NA only REAR VIEW MIRROR CBF600S SA only WIRE BANDS For inner weight replacement seepage 13 15 SCREW HANDLEBAR WEIGHT LOCK NUT CLUTCH SWITCH CABLE END Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 377: ...ew then remove the clutch switch Remove the screws Remove the left handlebar switch housing Remove the left handle grip and switch housing plate SCREW CLUTCH SWITCH CONNECTORS SCREWS HANDLEBAR SWITCH HOUSING HANDLE GRIP PLATE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 378: ...ing screws Disconnect the throttle cable ends from the throttle pipe and remove the right handlebar switch throttle housing Remove the right handlebar grip throttle pipe CLUTCH LEVER BRACKET BOLT Keep the brake master cylinder upright to prevent air from entering the hydraulic system MASTER CYLINDER BOLTS HOLDER CONNECTORS SCREWS SWITCH THROTTLE HOUSING CABLE ENDS THROTTLE PIPE Manuals by Motomatr...

Page 379: ...he inside of the grip and to the clean surfaces of the left handlebar and throttle grip Wait 3 5 minutes and install the grip Rotate the grip for even application of the adhesive Apply grease to the throttle pipe flange groove and sliding surfaces Connect the throttle cable ends to the throttle pipe flange Install the throttle pipe onto the handlebar HANDLEBAR HOLDER HANDLEBAR BOLTS TORQUE 27 N m ...

Page 380: ...handlebar and bracket Tighten the bolt to specified torque Apply Honda Bond A Honda hand grip cement or equivalent adhesive to the inside of the grip and to the clean surfaces of the left handlebar and throttle grip Wait 3 5 minutes and install the grip Rotate the grip for even application of the adhesive SWITCH THROTTLE HOUSING LOCATION PIN HOLE SCREWS SWITCH THROTTLE HOUSING TORQUE 12 N m 1 2 kg...

Page 381: ...ll the clutch switch with its hook to the groove on the clutch lever bracket Connect the clutch switch wire connectors to the switch Apply grease to the clutch cable end Connect the clutch cable end to the clutch lever and tighten the lock nut HANDLEBAR SWITCH HOUSING Align PLATE GROOVE SCREWS SCREW CLUTCH SWITCH CONNECTORS HOOK GROOVE LOCK NUT CLUTCH SWITCH CABLE END CONNECTORS Manuals by Motomat...

Page 382: ...nstall and tighten the screw securely CBF600S SA only Install the wire band Install the rear view mirrors Tighten the mounting nuts Align HANDLEBAR WEIGHT SCREW HANDLEBAR WEIGHT WIRE BANDS CBF600N NA only REAR VIEW MIRROR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 383: ...ly into the han dlebar Turn the handlebar weight and hook the retainer tab with the hole in the handlebar FRONT WHEEL REMOVAL Remove the brake pad page 15 15 Remove the mounting bolts and left brake caliper Loosen the right axle holder bolt and axle bolt Support the motorcycle securely using a safety stand or a hoist Remove the axle bolt Apply lubricant spray through the tab locking hole to the ru...

Page 384: ...and quietly Also check that the bearing outer race fits tightly in the hub Remove and discard the bearings if they do not turn smoothly quietly or if they fit loosely in the hub Replace the new bearings if necessary page 13 18 CBF600SA NA Be careful not to damage the speed sensor on the brake caliper AXLE HOLDER BOLT SIDE COLLARS LEFT SIDE RIGHT SIDE SERVICE LIMIT 0 2 mm 0 01 in AXLE Replace the b...

Page 385: ...paint dot on the side wall must be located next to the valve stem Remount the tire if necessary Mount the wheel tire and brake discs and pulser ring CBF600SA NA assembly in an inspection stand Spin the wheel allow it to stop and mark the lowest heaviest point of the wheel with a chalk Do this two or three times to verify the heaviest area If the wheel is balanced it will not stop consistently in t...

Page 386: ... to the wheel DISASSEMBLY Remove the bolts and pulser ring Remove the bolts and brake discs Remove the dust seals Install the bearing remover head into the bearing From the opposite side install the bearing remover shaft and drive the bearing out of the wheel hub Remove the distance collar and drive out the other bearing BALANCE WEIGHT CBF600SA NA only BOLTS PULSER RING BRAKE DISC DUST SEAL BOLTS ...

Page 387: ...ighten the new mounting bolts to the specified torque Apply grease to the dust seal lips then install them into the wheel hub LEFT DUST SEAL RIGHT BRAKE DISC DISTANCE COLLAR LEFT WHEEL BEARING 20 X 45 X 12 RIGHT WHEEL BEARING 20 X 45 X 12 RIGHT DUST SEAL 7 0 N m 0 7 kgf m 5 2 lbf ft LEFT BRAKE DISC 20 N m 2 0 kgf m 14 lbf ft PULSER RING CBF600SA NA TOOLS Driver 07749 0010000 Attachment 42 X 47 mm ...

Page 388: ...roove is flush with the outer surface of the left fork leg Hold the axle and tighten the axle bolt to the speci fied torque Tighten the right axle holder bolt to the specified torque CBF600SA NA only TORQUE 7 0 N m 0 7 kgf m 5 2 lbf ft BOLTS PULSER RING SIDE COLLARS LEFT SIDE RIGHT SIDE CBF600SA NA Be careful not to damage the speed sensor on the brake caliper AXLE HOLDER BOLT TORQUE 59 N m 6 0 kg...

Page 389: ...e holder bolt to the specified torque Check the front wheel speed sensor air gap page 16 24 FORK REMOVAL Remove the following front wheel page 13 15 front brake caliper CBF600SA NA page 15 30 CBF600S N page 15 34 front fender page 2 6 Loosen the fork top bridge pinch bolt If it is necessary to disassemble the fork loosen the fork cap at this moment TORQUE 30 N m 3 1 kgf m 22 lbf ft BOLTS BRAKE CAL...

Page 390: ...ube Remove the B clip and plate from the fork cap Remove the spring collar and spring seat from the fork tube BOTTOM BRIDGE PINCH BOLT FORK TUBE The fork spring is under pressure Use care when removing the fork cap FORK CAP FORK TUBE FORK CAP B CLIP PLATE SPRING COLLAR SPRING SEAT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 391: ...in a vice with soft jaws or a shop towel Remove the fork socket bolt and sealing washer FORK TUBE FORK SPRING FORK TUBE HOLDER BOLT FORK SLIDER If the fork piston turns together with the socket bolt temporarily install the fork spring spring seat spring collar and fork cap FORK SLIDER FORK SOCKET BOLT SEALING WASHER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded ...

Page 392: ...he fork tube sliding surface Remove the stopper ring Do not remove the fork piston ring unless it is necessary to replace with a new one FORK PISTON REBOUND SPRING FORK TUBE FORK PISTON RING Be careful not to scratch the fork tube or damage the dust seal FORK PROTECTOR DUST SEAL STOPPER RING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatri...

Page 393: ...iece from the fork slider Remove the oil seal back up ring and slider bushing from the fork tube Carefully remove the fork tube bushing by prying the slit with a screwdriver until the bushing can be pulled off by hand OIL LOCK PIECE FORK SLIDER SLIDER BUSHING BACK UP RING OIL SEAL Do not remove the fork tube bushing unless it necessary to replace it with a new one FORK TUBE BUSHING Manuals by Moto...

Page 394: ...y Place the fork tube in V block and measure the runout Actual runout is 1 2 the total indicator reading Check the fork piston ring for wear or damage Check the rebound spring for fatigue or damage Replace the component if necessary SERVICE LIMIT 321 9 mm 12 67 in FORK TUBE FORK SLIDER SERVICE LIMIT 0 20 mm 0 008 in DIAL GAUGE FORK TUBE FORK PISTON RING FORK PISTON REBOUND SPRING Manuals by Motoma...

Page 395: ...s from the bushing mating surface being careful not to peel off the coating Install the new fork tube bushing being careful no to damage the coating of the bushing if it has been removed BUSHING CHECK POINTS BACK UP RING COPPER SURFACES FORK CAP SPRING COLLAR FORK PISTON FORK TUBE FORK SPRING FORK TUBE BUSHING FORK PROTECTOR FORK SLIDER SLIDER BUSHING OIL SEAL BACK UP RING DUST SEAL STOPPER RING 2...

Page 396: ...rive the oil seal in using the special tools Install the stopper ring into the fork slider groove securely Install the oil seal with its marked side facing up SLIDER BUSHING BACK UP RING OIL SEAL OIL LOCK PIECE FORK SLIDER TOOLS Fork seal driver weight 07947 KA50100 Oil seal driver attachment 07947 KF00100 DRIVER WEIGHT ATTACHMENT OIL SEAL SLIDER BUSHING BACK UP RING STOPPER RING Manuals by Motoma...

Page 397: ...he fork piston and rebound spring to the fork tube Apply a locking agent to the fork socket bolt threads Install the socket bolt with a new sealing washer DUST SEAL FORK PROTECTOR PAWL GROOVE FORK PISTON REBOUND SPRING FORK TUBE FORK SOCKET BOLT SEALING WASHER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 398: ...rk tube while compressing the fork tube all the way after stroking the fork tube slowly more than 5 times If the fork piston turns together with the socket bolt temporarily install the fork spring spring seat spring collar and fork cap TORQUE 20 N m 2 0 kgf m 14 lbf ft FORK SLIDER FORK SOCKET BOLT SEALING WASHER HOLDER BOLT FORK SLIDER RECOMMENDED FORK FLUID Honda Ultra Cushion Oil 10W or equivale...

Page 399: ...ring seat and distance collar Install the plate the fork cap Install the B clip securely Apply fork fluid to the new O ring FORK TUBE FORK SPRING TIGHTLY WOUND COIL END SPRING COLLAR SPRING SEAT FORK CAP B CLIP PLATE O RING FORK CAP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 400: ...que if it was removed Tighten the top bridge pinch bolt to the specified torque Install the following front fender page 2 6 front brake caliper CBF600SA NA page 15 33 CBF600S N page 15 37 front wheel page 13 20 FORK CAP FORK TUBE TOP BRIDGE FORK CAP Align TORQUE 39 N m 4 0 kgf m 29 lbf ft BOTTOM BRIDGE PINCH BOLT FORK TUBE TORQUE 22 N m 2 2 kgf m 16 lbf ft TORQUE 22 N m 2 2 kgf m 16 lbf ft TOP BRI...

Page 401: ...nnect the ignition switch 2P Brown connector and immobilizer 4P connector CBF600S SA only Remove the clamp Release the wire clamp and remove the main wire harness and left handlebar switch wire CBF600S SA only RUBBER 2P Brown CONNECTOR 4P CONNECTOR CBF600S SA shown CLAMP LEFT HANDLEBAR SWITCH WIRE MAIN WIRE HARNESS WIRE CLAMP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcy...

Page 402: ...ve the headlight case bracket assembly from the bottom bridge page 20 9 Remove the bolt and brake hose clamp Remove the forks page 13 21 Straighten the tabs of the lock washer Remove the steering bearing adjustment nut lock nut and lock washer BOLT HOSE CLAMP CBF600S SA only CBF600N NA only STEM NUT PINCH BOLTS TOP BRIDGE CBF600N S only BOLT HOSE CLAMP LOCK NUT TAB LOCK WASHER Manuals by Motomatri...

Page 403: ...edure TOOL Steering stem socket 07916 3710101 STEERING STEM SOCKET ADJUSTMENT NUT CBF600SA NA only Be careful not to bend or damage the brake pipes MOUNTING BOLT BOLT STAY BRAKE PIPE JOINT INNER RACE DUST SEAL UPPER BEARING LOWER BEARING STEERING STEM TOOLS Ball race remover set 07946 KM90002 Driver attachment A 1 07946 KM90100 Driver attachment B 2 07946 KM90200 Driver shaft assembly 3 07946 KM90...

Page 404: ...to the steering head pipe as shown and remove the lower outer race using the same procedure as for the upper race DRIVER SHAFT NUT B NUT A DRIVER ATTACHMENT upper UPPEROUTER RACE BEARING REMOVER A DRIVER ATTACHMENT lower ASSEMBLY BASE Note the installation direction of the assembly base the large I D side facing the lower attachment Be careful not to bend or damage the brake pipes CBF600SA NA DRIV...

Page 405: ...ith a wrench and turn the nut A gradually until lower outer race is fully seated Note the installation direction of the assembly base the large I D side facing the lower attachment Be careful not to bend or damage the brake pipes CBF600SA NA DRIVER ATTACHMENT upper DRIVER SHAFT UPPEROUTER RACE DRIVER ATTACHMENT lower ASSEMBLY BASE NUT A Note the installation direction of the assembly base the smal...

Page 406: ...lower bearing inner race using a spe cial tool and a hydraulic press INSTALLATION DUST SEAL LOWER INNER RACE STEERING STEM NUT TOOL Steering stem driver 07946 MB00000 LOWER INNERRACE STEERING STEM DRIVER DUST SEAL UPPER OUTER RACE UPPER DUST SEAL LOWER INNER RACE LOCK NUT ADJUSTMENT NUT LOCK WASHER STEERING STEM LOWER BEARING BEARINGS BEARING RACE DUST SEAL UPPER INNER RACE UPPER BEARING LOWER OUT...

Page 407: ...o seat the bearings Make sure that the steering stem moves smoothly without play or binding Retighten the bearing adjusting nut to the specified torque Recheck that the steering stem moves smoothly without play or binding INNER RACE DUST SEAL UPPER BEARING LOWER BEARING STEERING STEM TOOL Steering stem socket 07916 3710101 TORQUE 25 N m 2 5 kgf m 18 lbf ft ADJUSTMENT NUT STEERING STEM SOCKET STEER...

Page 408: ...y Install the bolt and separate brake pipe joint Apply a locking agent to the hose clamp bolt Install the brake hose clamp and tighten the bolt to the specified torque Install the forks page 13 20 Install the headlight case bracket assembly to the bottom bridge page 20 9 ADJUSTMENT NUT LOCK WASHER LOCK NUT Do not over tighten the lock nut until the lock washer being flat LOCK NUT TAB LOCK WASHER C...

Page 409: ...hose clamp and tighten the bolt securely Install the main wire harness and left handlebar switch wire to the wire clamp securely CBF600N NA only HEADLIGHT CASE BRACKET GROMMETS HOLES Align TORQUE 103 N m 10 5 kgf m 76 lbf ft STEM NUT WASHER BOLT HOSE CLAMP CBF600S SA only LEFT HANDLEBAR SWITCH WIRE MAIN WIRE HARNESS WIRE CLAMP Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorc...

Page 410: ...ground Position the steering stem to the straight ahead position Hook a spring scale to the fork tube and measure the steering head bearing pre load The pre load should be within 8 8 13 7 N 0 9 1 4 kgf 2 0 3 1 lbf If the readings do not fall within the limits lower the front wheel to the ground and adjust the steering bearing adjusting nut CLAMP 4P CONNECTOR 2P Brown CONNECTOR CBF600S SA shown CBF...

Page 411: ...OMPONENT LOCATION 14 2 SERVICE INFORMATION 14 3 TROUBLESHOOTING 14 6 REAR WHEEL 14 7 SHOCK ABSORBER 14 14 SWINGARM 14 18 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 412: ... 72 lbf ft 42 N m 4 3 kgf m 31 lbf ft 42 N m 4 3 kgf m 31 lbf ft 37 N m 3 8 kgf m 27 lbf ft 21 N m 2 1 kgf m 15 lbf ft 12 N m 1 2 kgf m 9 lbf ft 98 N m 10 0 kgf m 72 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 413: ...psi Driver and passenger 290 kPa 2 90 kgf cm2 42 psi Axle runout 0 2 0 01 Wheel rim runout Radial 2 0 0 08 Axial 2 0 0 08 Wheel balance weight 60 g 2 1 oz max Drive chain Size link DID 525VM2 124LE REGINA 525ZRPB 124L Slack 20 30 1 0 1 2 50 2 0 Rear axle nut 98 N m 10 0 kgf m 72 lbf ft U nut Rear brake disc mounting bolt 42 N m 4 3 kgf m 31 lbf ft ALOC bolt replace with a new one Final driven spro...

Page 414: ...mm 07746 0010100 Attachment 42 X 47 mm 07746 0010300 Attachment 52 X 55 mm 07746 0010400 Attachment 22 X 24 mm 07746 0010800 Pilot 20 mm 07746 0040500 Pilot 17 mm 07746 0040400 Pilot 22 mm 07746 0041000 Driver 07949 3710001 Attachment 37 mm 07ZMD MBW0200 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 415: ...0100 Pilot 28 mm 07746 0041100 Remover weight 07741 0010201 Bearing remover shaft 20 mm 07936 3710600 Remover shaft handle 07936 3710100 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 416: ... pressure too high Rear wheel wobbling Bent rim Worn or damaged rear wheel bearings Faulty rear tire Unbalanced rear tire and wheel Insufficient rear tire pressure Faulty swingarm pivot bearings Rear wheel hard to turn Faulty rear wheel bearings Bent rear axle Rear brake drag Drive chain too tight Rear suspension noise Faulty rear shock absorber Loose rear suspension fasteners Worn rear suspension...

Page 417: ... washer then remove the rear wheel Remove the side collars INSPECTION Axle Place the axle in V blocks and measure the runout Actual runout is 1 2 the total indicator reading AXLE NUT WASHER LOCK NUT ADJUSTING NUT AXLE WASHER Do not operate the brake pedal after the rear wheel is removed CBF600SA NA Be careful not to damage the speed sensor on the brake caliper AXLE DRIVE CHAIN AXLE WASHER SIDE COL...

Page 418: ...on of the final driven sprocket teeth Replace the sprocket if worn or damaged If the final driven sprocket requires replacement inspect the drive chain and drive sprocket Never install a new drive chain on a worn sprocket or a worn chain on new sprockets Both chain and sprocket must be in good condition or the replacement chain or sprocket will wear rap idly Wheel balance Refer to the wheel balanc...

Page 419: ...driven flange from the wheel hub Remove the left dust seal Remove the driven flange assembly from the left wheel hub Remove the wheel damper rubbers Remove the O ring BRAKE DISC DUST SEAL BOLTS DRIVEN SPROCKET NUTS DUST SEAL DRIVEN FLANGE ASSEMBLY O RING DAMPER RUBBERS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 420: ...ive the bearing out of the wheel hub Remove the distance collar and drive out the other bearing DRIVEN SPROCKET NUTS DRIVEN FLANGE COLLAR DRIVEN FLANGE BEARING TOOLS Driver 07749 0010000 Attachment 42 X 47 mm 07746 0010300 Pilot 22 mm 07746 0041000 ATTACHMENT PILOT DRIVER BEARING TOOLS Bearing remover head 20 mm 07746 0050600 Bearing remover shaft 07GGD 0010100 or 07746 0050100 REMOVER SHAFT REMOV...

Page 421: ...ly seated RIGHT WHEEL BEARING 6204UU LEFT WHEEL BEARING 6204UU 42 N m 4 3 kgf m 31 lbf ft BRAKE DISC RIGHT DUST SEAL 108 N m 11 0 kgf m 80 lbf ft DAMPER RUBBERS DRIVEN SPROCKET O RING DISTANCE COLLAR DRIVENFLANGE BEARING 63 22 LEFT DUST SEAL DRIVEN FLANGE DRIVENFLANGE COLLAR PULSER RING 7 0 N m 0 7 kgf m 5 2 lbf ft TOOLS Driver 07749 0010000 Attachment 42 X 47 mm 07746 0010300 Pilot 20 mm 07746 00...

Page 422: ...he groove of the wheel hub Apply grease to the driven flange and rear wheel hub contact area Install the driven flange assembly into the left wheel hub TOOLS Driver 07749 0010000 Attachment 52 X 55 mm 07746 0010400 Pilot 20 mm 07746 0040500 ATTACHMENT PILOT DRIVER BEARING COLLAR DRIVEN SPROCKET NUTS Replace the damper rubbers as a set O RING DAMPER RUBBERS REAR WHEEL DRIVEN FLANGE Manuals by Motom...

Page 423: ...ied torque Install the pulser ring Install and tighten the new mounting bolts to the specified torque INSTALLATION Install the left and right side collars TORQUE 108 N m 11 0 kgf m 80 lbf ft DRIVEN SPROCKET NUTS DUST SEAL TORQUE 42 N m 4 3 kgf m 31 lbf ft BRAKE DISC DUST SEAL BOLTS CBF600SA NA only TORQUE 7 0 N m 0 7 kgf m 5 2 lbf ft PULSER RING BOLTS SIDE COLLARS LEFT SIDE RIGHT SIDE Manuals by M...

Page 424: ...washer nut and axle nut Adjust the drive chain slack page 3 19 Tighten the axle nut to the specified torque SHOCK ABSORBER REMOVAL Support the motorcycle using a safety stand or a hoist raise the rear wheel off the ground Remove the side cover page 2 5 Remove the rear wheel page 14 7 Remove the shock absorber lower mounting bolt nut GUIDE CALIPER BRACKET AXLE DRIVE CHAIN AXLE WASHER TORQUE 98 N m ...

Page 425: ...the damper unit for damage Check for the Damper rod for bend or damage Damper unit for deformation or oil leaks Upper mounting bushing for wear or damage Inspect all the other parts for wear or damage MAIN WIRE HARNESS CLIP 3 WAY HOSE HOSE CLAMP SHOCK ABSORBER UPPER MOUNTING BOLT NUT UPPER MOUNTING BUSHING DAMPER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Key...

Page 426: ...nflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start NEEDLE BEARING REPLACEMENT Remove the pivot collar and dust seals Press out the needle bearing out of the shock absorber lower mount using the special tools Point the valve away from you to prevent debris getting in your eyes 35 mm 1 4 in SHOCK ABSORBER DUST SEALS PIVOT COLLAR TOOLS Driver sh...

Page 427: ... mounting bolt nut Tighten the upper mounting nut to the specified torque Install the 3 way hose to the hose clamp Press the needle bearing into the lower mount with the marked side facing out TOOLS Driver 07749 0010000 Attachment 22 X 24 mm 07746 0010800 Pilot 17 mm 07746 0040400 5 0 5 5 mm 0 20 0 22 in ATTACHMENT PILOT DRIVER NEEDLE BEARING DUST SEALS PIVOT COLLAR TORQUE 42 N m 4 3 kgf m 31 lbf ...

Page 428: ...ng a safety stand or a hoist raise the rear wheel off the ground Remove the side cover page 2 5 Remove the rear wheel page 14 7 Remove the socket bolts and left footpeg holder Carefully slide back drive chain case Remove the bolts and drive chain case MAIN WIRE HARNESS CLIP TORQUE 42 N m 4 3 kgf m 31 lbf ft LOWER MOUNTING BOLT NUT LEFT FOOTPEG HOLDER SOCKET BOLTS DRIVE CHAIN CASE BOLTS Manuals by ...

Page 429: ... Remove the swingarm pivot nut and washer Slightly pull the pivot bracket outward Remove the swingarm pivot bolt and swingarm BRAKE HOSE CLAMPS SCREWS LOWER MOUNTING BOLT NUT PIVOT NUT WASHER UPPER NUT LOWER NUT PIVOT BRACKET PIVOT BOLT SWINGARM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 430: ...e swingarm right pivot Check the dust seals and collars for damage or fatigue Turn the inner race of right pivot bearings with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Remove and discard the bearings if the races do not turn smoothly and quietly or if they fit loosely in the pivot DRIVE CHAIN SLIDER SCREWS DUST SEALS P...

Page 431: ...special tools and a hydraulic press SNAP RING TOOLS Bearing remover shaft 20 mm 07936 3710600 Remover shaft handle 07936 3710100 Remover weight 07741 0010201 BEARING REMOVER SHAFT BALL BEARINGS TOOLS Driver 07949 3710001 Attachment 37 mm 07ZMD MBW0200 Pilot 28 mm 07746 0041100 DRIVER ATTACHMENT PILOT NEEDLE BEARING TOOLS Driver 07749 0010000 Attachment 37 mm 07ZMD MBW0200 Pilot 28 mm 07746 0041100...

Page 432: ...achment 37 mm 07ZMD MBW0200 Pilot 20 mm 07746 0040500 ATTACHMENT PILOT DRIVER BALL BEARINGS SNAP RING 5 9 N m 0 60 kgf m 4 3 lbf ft DRIVE CHAIN SLIDER DUST SEALS DUST SEAL SNAP RING DUST SEAL LEFT PIVOT NEEDLE BEARING RIGHT PIVOT BEARINGS 6002 SIDE COLLAR PIVOT COLLAR SIDE COLLAR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 433: ...left swingers pivot Install the drive chain slider aligning the slit with the boss on the swingarm Install the drive chain slider bosses into the holes in the swingarm Install and tighten the drive chain slider bolts to the specified torque DUST SEALS SIDE COLLARS DUST SEALS PIVOT COLLAR DRIVE CHAIN SLIDER SLIT BOSS BOSSES HOLES TORQUE 5 9 N m 0 60 kgf m 4 3 lbf ft DRIVE CHAIN SLIDER SCREWS Manual...

Page 434: ... swingarm pivot nut to the specified torque Move the swingarm up and down several times and make sure it moves smoothly Install the shock absorber lower mounting bolt nut then tighten the nut to the specified torque PIVOT BRACKET PIVOT BOLT SWINGARM TORQUE 69 N m 7 0 kgf m 51 lbf ft PIVOT NUT WASHER UPPER NUT LOWER NUT TORQUE 98 N m 10 0 kgf m 72 lbf ft PIVOT NUT TORQUE 42 N m 4 3 kgf m 31 lbf ft ...

Page 435: ...hain case bolts to the specified torque Route the brake hose properly then install the rear brake caliper bracket onto the guide of the swing arm BRAKE HOSE CLAMPS SCREWS DRIVE CHAIN CASE SLIT BOSS TORQUE 12 N m 1 2 kgf m 9 lbf ft DRIVE CHAIN CASE BOLTS GUIDE CALIPER BRACKET Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 436: ...ket bolts to the specified torque Install the rear wheel page 14 13 Remove the side cover page 2 5 TORQUE 37 N m 3 8 kgf m 27 lbf ft LEFT FOOTPEG HOLDER SOCKET BOLTS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 437: ...AIR BLEEDING CBF600S N 15 13 BRAKE PAD DISC 15 15 FRONT MASTER CYLINDER 15 19 REAR MASTER CYLINDER BRAKE PEDAL 15 24 FRONT BRAKE CALIPER CBF600SA NA 15 30 FRONT BRAKE CALIPER CBF600S N 15 34 REAR BRAKE CALIPER CBF600SA NA 15 38 REAR BRAKE CALIPER CBF600S N 15 41 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 438: ...lbf ft 2 5 N m 0 25 kgf m 1 8 lbf ft 1 5 N m 0 2 kgf m 1 1 lbf ft CBF600S N CBF600SA NA 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft 30 N m 3 1 kgf m 22 lbf ft 17 N m 1 7 kgf m 13 lbf ft 17 N m 1 7 kgf m 13 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 439: ...bf ft 12 N m 1 2 kgf m 9 lbf ft 22 N m 2 2 kgf m 16 lbf ft 34 N m 3 5 kgf m 17 lbf ft 17 N m 1 7 kgf m 13 lbf ft 17 N m 1 7 kgf m 13 lbf ft 22 N m 2 2 kgf m 16 lbf ft CBF600S N CBF600SA NA 10 N m 1 0 kgf m 7 lbf ft Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 440: ... Brake disc thickness 4 5 0 18 3 5 0 14 Brake disc runout 0 30 0 012 Master cylinder I D 12 700 12 743 0 5000 0 5017 12 755 0 5022 Master piston O D 12 657 12 684 0 4983 0 4994 12 645 0 4978 Caliper cylinder I D CBF600SA NA Upper 22 650 22 700 0 8917 0 8937 22 712 0 8942 Middle 22 650 22 700 0 8917 0 8937 22 712 0 8942 Lower 22 650 22 700 0 8917 0 8937 22 712 0 8942 Caliper cylinder I D CBF600S N ...

Page 441: ...n plug 2 5 N m 0 25 kgf m 1 8 lbf ft Front brake hose clamp bolt 12 N m 1 2 kgf m 9 lbf ft ALOC bolt replace with a new one Brake caliper bleeder 5 4 N m 0 6 kgf m 4 0 lbf ft Rear master cylinder reservoir mount ing bolt 10 N m 1 0 kgf m 7 lbf ft Rear master cylinder mounting bolt 12 N m 1 2 kgf m 9 lbf ft Rear master cylinder hose joint screw 1 5 N m 0 2 kgf m 1 1 lbf ft Apply a locking agent to ...

Page 442: ...cylinder piston Contaminated master cylinder Bent brake lever pedal Brake lever pedal hard Clogged restricted brake system Sticking worn caliper piston Caliper not sliding properly Clogged restricted fluid passage Worn caliper piston seal Sticking worn master cylinder piston Bent brake lever pedal Brake drags Contaminated brake pad disc Misaligned wheel Warped deformed brake disc Caliper not slidi...

Page 443: ...to the left until the reservoir is parallel to the ground before removing the reservoir cap Remove the screws and reservoir cap Remove the set plate and diaphragm Connect a bleed hose to the left caliper bleed valve Loosen the bleed valve and pump the brake lever until no more fluid flows out of the bleed valve Connect a bleed hose to the right caliper bleed valve Loosen the upper bleed valve and ...

Page 444: ...re fluid flows out of the bleed valve Connect a bleed hose to the rear caliper bleed valve Loosen the bleed valve and pump the brake pedal until no more fluid flows out of the bleed valve FRONT BRAKE FLUID FILLING AIR BLEEDING Close the bleed valves Fill the reservoir with DOT 4 brake fluid from a sealed container RESERVOIR CAP DIAPHRAGM PLATE DIAPHRAGM BOLT BLEED VALVE BLEED HOSE BLEED VALVE BLEE...

Page 445: ...ally available brake bleeder to the right caliper upper bleed valve Operate the brake bleeder and loosen the bleed valve Close the bleed valve to the specified torque Perform the bleeding procedure until the system is completely flushed bled Operate the brake lever If it is still spongy bleed the system again If a brake bleeder is not available use the following procedure Fill the reservoir with D...

Page 446: ... 1 Squeeze the brake lever open the bleed valve 1 4 of a turn and then close it 2 Release the brake lever slowly and wait several seconds after it reaches the end of its travel Do not release the lever until the bleed valve has been closed Repeat steps 1 and 2 until air bubbles do not appear in the bleed hose After bleeding the air completely tighten the bleed valve to the specified torque Fill th...

Page 447: ...ads seal the threads with teflon tape 1 Operate the brake bleeder and loosen the right front caliper center bleed valve Add fluid when the fluid level in the master cylinder is low to pre vent drawing air into the system 2 Repeat the above procedures until a sufficient amount of fluid flows out of the caliper center bleed valve It is not problem if the fluid flowing out from the center bleed valve...

Page 448: ...r bleed valve Bleed the hydraulic system page 15 12 Air Bleeding Connect a bleed hose to the right front caliper cen ter bleed valve 1 Pump the brake pedal several 5 10 times quickly then push the brake pedal all the way down loosen the right front caliper center bleed valve 1 4 of turn Wait several seconds and close the bleed valve Release the brake pedal slowly and wait several seconds after it ...

Page 449: ...CBF600S N BRAKE FLUID DRAINING Turn the handlebar to the left until the master cylin der reservoir is level before removing the reservoir cap Remove the screws and reservoir cap Remove the set plate and diaphragm Remove the right side cover page 2 5 Remove the reservoir mounting bolt Remove the reservoir cap set plate and diaphragm Connect a bleed hose to the caliper bleed valve Loosen the bleed v...

Page 450: ...e system again If a brake bleeder is not available use the following procedure Connect a bleed hose to the bleed valve Pressurize the system with the brake lever until lever resistance is felt 1 Squeeze the brake lever depress the brake pedal open the bleed valve 1 4 of a turn and then close the valve 2 Release the brake lever pedal slowly and wait several seconds after it reaches the end of its t...

Page 451: ...side cover page 2 5 BRAKE PAD DISC FRONT BRAKE PAD REPLACEMENT CBF600SA NA Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise Push the caliper pistons all the way in to allow installation of new brake pads by pushing the cali per body inward TORQUE 1 5 N m 0 20 kgf m 1 1 lbf ft UPPER LEVEL LINE CASTING LEDGE SET PLATE DIAPHRAGM RESERVOIR U...

Page 452: ...iper body Tighten the pad pin to the specified torque Operate the brake lever to seat the caliper pistons against the pads FRONT BRAKE PAD REPLACEMENT CBF600S N Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise Push the caliper pistons all the way in to allow installation of new brake pads by pushing the cali per body inward PAD PIN PLUG ...

Page 453: ...the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise Push the caliper piston all the way in to allow instal lation of new brake pads by pushing the caliper body inward PAD PIN PLUG Always replace the brake pads in pairs to assure even disc pressure PAD PIN BRAKE PADS PAD SPRING TORQUE 17 N m 1 7 kgf m 13 lbf ft TORQUE 2 5 N m 0 25 kgf m 1 8 lbf ft...

Page 454: ...n the pad pin end with the silicone grease Install the pad pin by pushing in the pads against the pad spring to align the pad pin holes in the pads and caliper body Install and tighten the new caliper sub slide pin to the specified torque Tighten the pad pin to the specified torque PAD PIN CALIPER SUB SLIDE PIN Always replace the brake pads in pairs to assure even disc pressure BRAKE PADS CALIPER ...

Page 455: ...irror page 13 8 Drain the front hydraulic system page 15 7 Disconnect the brake light switch wire connectors Remove the brake hose oil bolt sealing washers and brake hose eyelet Remove the bolts from the master cylinder holder and remove the master cylinder assembly SERVICE LIMITS FRONT 3 5 mm 0 14 in REAR 4 0 mm 0 16 in SERVICE LIMITS FRONT 0 30 mm 0 012 in REAR 0 30 mm 0 012 in Avoid spilling fl...

Page 456: ... switch Remove the boot Remove the snap ring from the master cylinder body using the special tool BRAKE LEVER PIVOT BOLT NUT SWITCH SCREW BOOT TOOL Snap ring pliers 07914 SA50001 PLIERS SNAP RING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 457: ...oring scratches or damage Measure the master cylinder I D Measure the master piston O D ASSEMBLY SPRING MASTER PISTON MASTER CYLINDER SERVICE LIMIT 12 755 mm 0 5022 in SERVICE LIMIT 12 645 mm 0 4978 in MASTER PISTON BRAKE LEVER PIVOTBOLT SPRING SNAP RING BOOT BRAKE LIGHT SWITCH SCREW NUT MASTER CYLINDER 1 0 N m 0 1 kgf m 0 7 lbf ft 1 2 N m 0 1 kgf m 0 9 lbf ft 5 9 N m 0 6 kgf m 4 4 lbf ft CUPS Man...

Page 458: ... groove in the master cylinder Apply silicone grease inside the boot Install the boot into the master cylinder and the pis ton groove Apply silicone grease to the brake lever contacting surface of the master piston Do not allow the piston cup lips to turn inside out MASTER PISTON MASTER CYLINDER SPRING TOOL Snap ring pliers 07914 SA50001 PLIERS SNAP RING BOOT Manuals by Motomatrix www motomatrix c...

Page 459: ...st then the lower bolt to the specified torque Connect the brake hose to the master cylinder with the oil bolt and new sealing washers Tighten the oil bolt while holding the hose eyelet against the stopper Install the rear view mirror page 13 11 TORQUE 1 2 N m 0 1 kgf m 0 9 lbf ft SWITCH SCREW TORQUE 1 0 N m 0 1 kgf m 0 7 lbf ft TORQUE 5 9 N m 0 6 kgf m 4 4 lbf ft BRAKE LEVER PIVOT BOLT NUT TORQUE...

Page 460: ...lt sealing washers and brake hose Remove the muffler mounting bolt nut washer and collar Loosen the rear master cylinder mounting bolts Remove the bolts and right footpeg holder BOLT RESERVOIR 2P Black CONNECTOR CLAMP Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced OIL BOLT BRAKE HOSE SEALING WASHERS BOLT WASHER COLLAR NUT FOOTPE...

Page 461: ...h Remove the snap ring washer and brake pedal DISASSEMBLY Remove the screw and reservoir hose joint and O ring from the master cylinder BOLTS COTTER PIN JOINT PIN MASTER CYLINDER RETURN SPRINGS REAR BRAKE LIGHT SWITCH BRAKE PEDAL SNAP RING WASHER SCREW RESERVOIR JOINT O RING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 462: ...mage Check the master cylinder and piston for scoring scratches or damage Measure the master cylinder I D Measure the master piston O D TOOL Snap ring pliers 07914 SA50001 SNAP RING PLIERS BOOT SNAP RING MASTER CYLINDER PRIMARY CUP PUSH ROD ASSEMBLY SPRING MASTER PISTON SERVICE LIMITS CBF600SA NA 15 925 mm 0 6270 in CBF600S N 14 055 mm 0 5533 in SERVICE LIMITS CBF600SA NA 15 815 mm 0 6226 in CBF60...

Page 463: ...N SPRING RESERVOIR CUP MASTER CYLINDER O RING PRIMARY CUP RESERVOIR JOINT RESERVOIR HOSE 1 5 N m 0 2 kgf m 1 1 lbf ft MASTER PISTON LOWERJOINT SNAP RING BOOT PRIMARY CUP SPRING MASTER CYLINDER CBF600SA NA CBF600S N MASTER PISTON PUSH ROD ASSEMBLY When installing the cups do not allow the lips to turn inside out MASTER CYLINDER PRIMARY CUP PUSH ROD ASSEMBLY SPRING MASTER PISTON Manuals by Motomatri...

Page 464: ...nstall it onto the reservoir joint Install the reservoir joint into the master cylinder Apply a locking agent to the reservoir joint screw threads Install and tighten the screw to the specified torque Be certain the snap ring is firmly seated in the groove TOOL Snap ring pliers 07914 SA50001 SNAP RING PLIERS BOOT SNAP RING TORQUE 17 N m 1 7 kgf m 13 lbf ft JOINT NUT 67 5 mm 2 66 in O RING RESERVOI...

Page 465: ... to the specified torque Install the muffler mounting collar bolt washer and nut Tighten the rear master cylinder mounting nut to the specified torque Tighten the rear master cylinder mounting bolts to the specified torque BRAKE PEDAL SNAP RING WASHER COTTER PIN JOINT PIN RETURN SPRING REAR BRAKE LIGHT SWITCH SWITCH SPRING BOLTS TORQUE 37 N m 3 8 kgf m 27 lbf ft TORQUE 22 N m 2 2 kgf m 16 lbf ft T...

Page 466: ...page 15 11 Install the right side cover page 2 5 FRONT BRAKE CALIPER CBF600SA NA REMOVAL Drain the front brake hydraulic system page 15 7 Remove the brake pads page 15 15 Remove the oil bolt sealing washers and brake hose eyelet joint TORQUE 34 N m 3 5 kgf m 25 lbf ft OIL BOLT BRAKE HOSE SEALING WASHERS CLAMP 2P BLACK CONNECTOR Avoid spilling fluid on painted plastic or rubber parts Place a rag ov...

Page 467: ...the pistons Position the caliper body with the pistons facing down and apply small squirts of air pressure to the fluid inlet to remove the pistons Be careful not to damage the piston sliding surface Push the dust seals and piston seals in and lift them out Clean the seal grooves caliper cylinders and pis tons with clean brake fluid BOLTS BRAKE CALIPER CALIPER BODY CALIPER BRACKET BOOT BOOT PAD SP...

Page 468: ...e each caliper piston O D ASSEMBLY SERVICE LIMIT 22 712 mm 0 8942 in CALIPER CYLINDER SERVICE LIMIT 22 560 mm 0 8882 in CALIPER PISTON 5 4 N m 0 60 kgf m 4 0 lbf ft DUST SEAL CALIPER PISTON PAD SPRING CALIPER PIN BOOT BRACKET PIN BOOT CALIPER BODY CALIPER BRACKET PAD RETAINER PISTON SEAL Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co...

Page 469: ...ork leg Install and tighten the new brake caliper mounting bolts to the specified torque Install the front wheel speed sensor page 16 24 Install the brake hose eyelet to the caliper body with two new sealing washers and oil bolt Push the brake hose eyelet to the stopper on the cal iper body then tighten the oil bolt to the specified torque Install the front brake pads page 15 15 Fill and bleed the...

Page 470: ...t from the caliper body Remove the pad retainer and caliper pin boot from the caliper bracket If the bracket pin boot is hard or deteriorated replace it with a new one Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced OIL BOLT SEALING WASHERS BOLTS BRAKE CALIPER CALIPER BODY CALIPER BRACKET PAD RETAINER BOOT CALIPER BRACKET Manuals...

Page 471: ...sh the dust seals and piston seals in and lift them out Clean the seal grooves with clean brake fluid INSPECTION Check the caliper cylinder for scoring or other dam age Measure the each caliper cylinder I D CALIPER BODY PAD SPRING BOOT Do not use high pressure air or bring the nozzle too close to the inlet Be careful not to damage the piston sliding surface PISTON SEAL DUST SEAL SERVICE LIMIT 25 4...

Page 472: ... seal grooves in the caliper Coat the caliper pistons with clean brake fluid and install them into the caliper cylinders with the open ing toward the pads SERVICE LIMIT 25 310 mm 0 9965 in 5 4 N m 0 60 kgf m 4 0 lbf ft DUST SEAL CALIPER PISTON PAD SPRING CALIPER PIN BOOT BRACKET PIN BOOT CALIPER BODY CALIPER BRACKET PAD RETAINER PISTON SEAL PISTON SEALS DUST SEALS CALIPER PISTONS Manuals by Motoma...

Page 473: ...liper and bracket pins and install the caliper bracket over the caliper body INSTALLATION Install the brake caliper onto the fork leg Install and tighten the new brake caliper mounting bolts to the specified torque CALIPER BODY PAD SPRING BOOT PAD RETAINER BOOT CALIPER BRACKET CALIPER BODY CALIPER BRACKET TORQUE 30 N m 3 1 kgf m 22 lbf ft BOLTS BRAKE CALIPER Manuals by Motomatrix www motomatrix co...

Page 474: ...s page 15 17 Remove the oil bolt sealing washers and brake hose eyelet joint Pivot the caliper up and remove it DISASSEMBLY Remove the pad retainer and caliper main slide pin boot from the caliper bracket If the caliper main slide pin boot is hard or deterio rated replace it with a new one TORQUE 34 N m 3 5 kgf m 25 lbf ft OIL BOLT SEALING WASHERS Avoid spilling fluid on painted plastic or rubber ...

Page 475: ...ton sliding surface Push the dust seal and piston seal in and lift them out Clean the seal grooves with clean brake fluid INSPECTION Check the caliper cylinder and piston for scoring or other damage Measure the each caliper cylinder I D Measure the each caliper piston O D CALIPER BODY BOOT PAD SPRING COLLAR Do not use high pressure air or bring the nozzle too close to the inlet PISTON SEAL DUST SE...

Page 476: ...g end toward the pad Install the pad spring into the caliper body Apply silicone grease to the inside of the caliper sub slide pin boot Install the caliper sub slide pin boot and collar into the caliper body PISTON SEAL CALIPER PISTON COLLAR PAD SPRING DUST SEAL 5 4 N m 0 6 kgf m 4 0 lbf ft BRACKET PIN BOOT CALIPER CYLINDER CALIPER PISTON DUST SEAL PISTON SEAL CALIPER BODY BOOT PAD SPRING COLLAR M...

Page 477: ...e 15 7 REAR BRAKE CALIPER CBF600S N REMOVAL Drain the rear brake hydraulic system page 15 7 Remove the rear brake pads page 15 17 Remove the oil bolt sealing washers and brake hose eyelet joint BOOT PAD RETAINER Be careful not to come the pad spring off from the caliper PAD SPRING CALIPER TORQUE 34 N m 3 5 kgf m 25 lbf ft OIL BOLT SEALING WASHERS Avoid spilling fluid on painted plastic or rubber p...

Page 478: ...e caliper body If the caliper sub slide pin boot is hard or deterio rated replace it with a new one Place a shop towel over the piston Position the caliper body with the pistons down and apply small squirts of air pressure to the fluid inlet to remove the piston BRAKE CALIPER BOOT PAD RETAINER COLLAR BOOT PAD SPRING Do not use high pressure air or bring the nozzle too close to the inlet Manuals by...

Page 479: ... the caliper piston for scratches scoring or other damage Measure the each caliper cylinder I D Measure the each caliper piston O D ASSEMBLY PISTON SEAL DUST SEAL SERVICE LIMIT 38 24 mm 1 506 in SERVICE LIMIT 38 09 mm 1 500 in PISTON SEAL CALIPER PISTON COLLAR PAD SPRING DUST SEAL 5 4 N m 0 6 kgf m 4 0 lbf ft BRACKET PIN BOOT CALIPER CYLINDER Manuals by Motomatrix www motomatrix co uk The Solution...

Page 480: ...ply silicone grease to the inside of the caliper sub slide pin boot Install the caliper sub slide pin boot and collar into the caliper body Install the pad retainer and caliper main slide pin boot into the caliper bracket INSTALLATION Install the caliper main slide pin into the boot on the caliper bracket CALIPER PISTON DUST SEAL PISTON SEAL COLLAR BOOT PAD SPRING BOOT PAD RETAINER Be careful not ...

Page 481: ...e stopper on the cal iper then tighten the oil bolt to the specified torque Install the brake pads page 15 17 Fill and bleed the rear brake hydraulic system page 15 7 TORQUE 34 N m 3 5 kgf m 25 lbf ft SEALING WASHERS OIL BOLT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 482: ...MEMO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 483: ... LOCATIONS 16 5 ABS SELF DIAGNOSIS INFORMATION 16 7 ABS PROBLEM CODE INDEX 16 10 ABS TROUBLESHOOTING 16 11 ABS INDICATOR CIRCUIT TROUBLESHOOTING 16 21 WHEEL SPEED SENSOR 16 24 ABS MODULATOR 16 27 PCV 16 29 DELAY VALVE 16 29 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 484: ...CHECK CONNECTOR FRONT WHEEL SPEED SENSOR 2P BLUE CONNECTOR ABS FUSE BOX ABS MAIN FUSE REAR WHEEL SPEED SENSOR 2P RED CONNECTOR FRONT PULSER RING FRONT WHEEL SPEED SENSOR FRONT BRAKE CALIPER REAR PULSER RING REAR WHEEL SPEED SENSOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 485: ...VSP 18 RR VSP 3 FR VSP 12 FR VSP WARN IND 7 Pump relay Solenoids Pump P R R Br R Bl W G Bl 9 MOTOR 8 16 IGN POWER 4 STOP LAMP SW Rear Front R R BI Main Fuse A 30 A Battery Ignition SW Rear Wheel Speed Sensor Front Pulser Ring TIRE SIZE Rear Pulser Ring 51 52 53 31 32 33 34 37 38 21 71 23 11 12 13 14 ABS Indicator Bl Br R Bl G R G 61 62 54 CPU 81 Bl R W Bu Y G O P Br BLACK RED WHITE BLUE YELLOW GRE...

Page 486: ...hat the ABS indicator is operating normally When the wheel speed sensor and or pulser ring is replaced check the clearance air gap between both components The ABS control unit ECU is mounted on the modulator the modulator with the built in ECU Do not disassemble the ABS modulator Replace the ABS modulator as an assembly when the it is faulty The ABS modulator may be damaged if dropped Also if a co...

Page 487: ...port the fuel tank page 3 5 NOTE 2 Remove the seat page 2 4 FRONT WHEEL SPEED SENSOR 2P Blue CONNECTOR NOTE 1 Sensor side Main harness side ABS SERVICE CHECK CONNECTOR NOTE 2 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 488: ...e the right side cover page 2 5 ABS MODULATOR 25P CONNECTOR NOTE 2 REAR WHEEL SPEED SENSOR 2P Red CONNECTOR NOTE3 Sensor side Main harness side Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 489: ... indicator goes off just after a road speed of 10 km h 6 mph indicating that the diagnosis is completed If a problem is detected the ABS indicator blinks or comes on and stays on to notify the rider of the problem The self diag nosis is also made while the motorcycle is running and the indicator blinks when a problem is detected When the indicator blinks the cause of the problem can be identified ...

Page 490: ...ODE READOUT The problem code is not erased by turning the ignition switch to OFF while the problem code is being output Note that turning the ignition switch to ON again does not indicate the prob lem code To show the problem code again repeat the problem code retrieval procedures from the beginning After diagnostic troubleshooting erase the prob lem code s and perform the pre start self diag nosi...

Page 491: ...h the ignition switch turned to OFF in the same manner as retrieval 2 Turn the ignition switch to ON while squeezing the brake lever The ABS indicator should come on 2 seconds and go off 3 Release the brake lever immediately after the ABS indicator is off The ABS indicator should come on 4 Squeeze the brake lever immediately after the ABS indicator is on The ABS indicator should go off 5 Release t...

Page 492: ...Front wheel speed sensor circuit malfunction Wheel speed sensor or related wires Stops ABS operation 16 11 12 Front wheel speed sensor malfunction Wheel speed sensor or related wires Electrical noise intermittent interruption Stops ABS operation 16 11 13 Rear wheel speed sensor circuit malfunction Wheel speed sensor or related wires Stops ABS operation 16 13 14 Rear wheel speed sensor Wheel speed ...

Page 493: ... self diagnosis before troubleshoot ing The ABS is normal if the indicator goes off If the problem code 41 is indicated check the front brake for drag 1 Speed Sensor Air Gap Inspection Measure the air gap between the wheel speed sensor and pulser ring page 16 24 Is the air gap correct YES GO TO STEP 2 NO Check each part for deformation and looseness and correct accordingly Recheck the air gap 2 Sp...

Page 494: ...y YES Faulty front wheel speed sensor NO GO TO STEP 5 5 Speed Sensor Line Open Circuit Inspection Short the Yellow black and Green orange 3 wire terminals of the 25P connector with a jumper wire Check for continuity between the terminals of the wire harness side sensor 2P Blue connec tor Is there continuity YES GO TO STEP 6 NO Open circuit in wire between the ABS modulator and speed sensor TOOL Te...

Page 495: ...ag 1 Speed Sensor Air Gap Inspection Measure the air gap between the speed sensor and pulser ring page 16 24 Is the air gap correct YES GO TO STEP 2 NO Check each part for deformation and looseness and correct accordingly Recheck the air gap 2 Speed Sensor Condition Inspection Inspect the area around the speed sensor Check that there is iron or other magnetic depos its between the pulser ring and ...

Page 496: ...ous step Is there continuity YES Faulty rear wheel speed sensor NO GO TO STEP 5 5 Speed Sensor Line Open Circuit Inspection Short the Pink white and Green red wire termi nals of the 25P connector with a jumper wire Check for continuity between the terminals of the wire harness side sensor 2P Red connector Is there continuity YES GO TO STEP 6 NO Open circuit in wire between the ABS modulator and sp...

Page 497: ...oduction Erase the problem code page 16 9 Perform the pre start self diagnosis page 16 7 Retrieve the problem code page 16 8 Does the indicator indicate the code 31 32 33 or 34 YES Faulty ABS modulator NO Normal problem code is not stored temporary failure PROBLEM CODE 51 52 or 53 Pump Motor 1 Fuse Inspection Remove the right side cover page 2 5 Check the ABS MOTOR fuse 30A in the ABS fuse box for...

Page 498: ... Is there battery voltage YES GO TO STEP 5 NO GO TO STEP 4 4 Motor Power Input Line Open Circuit Inspection at fuse box side Disconnect the sub fuse box connector Disconnect the ABS MOTOR MAIN fuses Measure the voltage between Red green wire terminal of the fuse box side connector and ground There should be battery voltage at all times Is there battery voltage YES Open circuit in Red green wire be...

Page 499: ... the fuse blown YES GO TO STEP 2 NO GO TO STEP 3 2 Relay Power Input Line Short Circuit Inspection Disconnect the ABS modulator 25P connector Check for continuity between the Black wire ter minal of the 25P connector and ground with ABS FAIL SAFE RELAY fuse removed Is there continuity YES Short circuit in Black wire between the fuse box and ABS modulator NO Temporary failure install a spare fuse a...

Page 500: ...ground There should be battery voltage at all times Is there battery voltage YES Open circuit in Red green wire between the fuse box and control unit NO Open circuit in Red green wire between the battery and fuse box 5 Failure Reproduction Connect the ABS modulator 25P connector Erase the problem code page 16 9 Perform the pre start self diagnosis page 16 7 Retrieve the problem code page 16 8 Does...

Page 501: ...3 Power Input Line Open Circuit Inspection Install the ABS main fuse Disconnect the ABS modulator 25P connector Measure the voltage between the Red brown wire terminal of 25P connector and ground There should be battery voltage with the ignition switch turned to ON Is there battery voltage YES GO TO STEP 4 NO Open circuit in Red brown or Red black wire between the ignition switch and control unit ...

Page 502: ...tems are normal recheck the prob lem code indication Erase the problem code page 16 9 Perform the pre start self diagnosis page 16 7 Retrieve the problem code page 16 8 Does the indicator indicate the code 71 YES Faulty ABS modulator NO Normal problem code is not stored temporary failure PROBLEM CODE 81 CPU ABS Control Unit 1 Failure Reproduction Erase the problem code page 16 9 Perform the pre st...

Page 503: ...YES Faulty ABS modulator NO GO TO STEP 3 3 Indicator Signal Line Short Circuit Inspection CBF600SA Remove the front center cowl page 2 10 Remove the dust cover CBF600NA Remove the headlight unit page 20 7 With the connector connected check for conti nuity between the Red black wire terminal of the harness side connector and ground Is there continuity YES Short circuit in Red black wire between the...

Page 504: ...fuse and recheck from the first step 3 Power Input Line Open Circuit Inspection Install the ABS MAIN fuse Disconnect the ABS modulator 25P connector Measure the voltage between the Red brown wire terminal of the 25P connector and body ground There should be battery voltage with the ignition switch turned to ON Is there battery voltage YES GO TO STEP 4 NO Open circuit in Red brown wire between the ...

Page 505: ...h turned to ON Does it go off YES GO TO STEP 6 NO Faulty combination meter 6 Indicator Signal Line Open Circuit Inspection Remove the jumper wire from the combination meter 16P connector CBF600SA 9P CBF600NA Short the Red black wire terminal of the 25P con nector and ground with a jumper wire Check the ABS indicator with the ignition switch turned to ON Does it go off YES GO TO STEP 7 NO Open circ...

Page 506: ...uivalent and raise the wheel off the ground Measure the clearance air gap between the sensor and pulser ring at several points by turning the wheel slowly It must be within specification The sensor air gap cannot be adjusted If it is not within specification check each installa tion part for deformation looseness and damage REPLACEMENT FRONT WHEEL SPEED SENSOR Lift and support the fuel tank page 3...

Page 507: ...d the mounting area of the caliper bracket thoroughly and be sure that no foreign material is allowed to enter the mounting hole Install a new speed sensor in the reverse order of removal After installation check the air gap page 16 24 SENSOR WIRE CLAMPS BOLTS CLAMPS SENSOR WIRE BOLT Route the sensor wire properly page 1 24 WHEEL SPEED SENSOR Manuals by Motomatrix www motomatrix co uk The Solution...

Page 508: ...re clip from the PCV stay Release the sensor wire from the clamp Release the sensor wire from the clamp Release the sensor wire clips from the caliper bracket Remove the wheel speed sensor mounting bolts and guide 2P Red CONNECTOR WIRE CLIP CLAMP CLAMP CLIPS GUIDE BOLTS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 509: ...e fluid from the front and rear hydrau lic systems page 15 7 Remove the rear fender page 2 7 Pull the lock lever up and disconnect the ABS modu lator 25P connector Loosen the brake pipe joint nuts and disconnect the brake pipes Remove the modulator side mounting bolt washer Route the sensor wire properly page 1 24 WHEEL SPEED SENSOR 25P CONNECTOR LOCK LEVER When loosening the joint nuts cover the ...

Page 510: ...nt nut threads Tighten the modulator lower mounting bolt and side mounting bolt washer securely Tighten the brake pipe joint nuts to the specified torque Install the rear fender page 2 7 Fill and bleed the hydraulic systems page 15 7 Be careful not to bend or damage the brake pipes during removal BOLTS STAY 14 N m 1 4 kgf m 10 lbf ft 14 N m 1 4 kgf m 10 lbf ft TORQUE 14 N m 1 4 kgf m 10 lbf ft JOI...

Page 511: ...e the right side cover page 2 5 Remove the brake pipe joint nuts Remove the mounting bolts and the delay valve Installation is in the reverse order of removal Apply brake fluid to the brake pipe joint nut threads TORQUE Brake pipe joint nut 14 N m 1 4 kgf m 10 lbf ft PCV mounting bolt 12 N m 1 2 kgf m 9 lbf ft JOINT NUTS BOLTS PCV Apply brake fluid to the brake pipe joint nut threads TORQUE Brake ...

Page 512: ...MEMO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 513: ...RVICE INFORMATION 17 3 TROUBLESHOOTING 17 4 BATTERY 17 5 CHARGING SYSTEM INSPECTION 17 7 ALTERNATOR CHARGING COIL 17 8 REGULATOR RECTIFIER 17 8 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 514: ...SYSTEM 17 2 BATTERY CHARGING SYSTEM SYSTEM DIAGRAM ALTERNATOR REGULATOR RECTIFIER MAIN FUSE 30A BATTERY Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 515: ...ry every two weeks to prevent sulfation from occurring When checking the charging system always follow the steps in the troubleshooting flow chart page 17 4 For battery charging do not exceed the charging current and time specified on the battery Use of excessive current or charging time may damage the battery Refer to procedure for alternator removal and disassembly page 10 4 BATTERY CHARGING Tur...

Page 516: ...r charging coil resistance within 0 1 1 0 Ω 20 C 68 F YES GO TO STEP 5 No Faulty charging coil 5 CHARGING VOLTAGE INSPECTION Measure and record the battery voltage using a digital multimeter page 17 7 Start the engine Measure the charging voltage page 17 7 Compare the measurement to result of the following calculation Is the measured charging voltage within the standard voltage YES Faulty battery ...

Page 517: ...over Remove the terminal screw then disconnect the positive cable from the battery positive terminal Record the seat height position Remove the bolts and front seat bracket Remove the bolts and rear seat bracket NEGATIVE TERMINAL POSITIVE TERMINAL SEAT BRACKET BOLTS Low position Middle position High position FRONT SEAT BRACKET REAR SEAT BRACKET BOLTS REAR SEAT BRACKET Manuals by Motomatrix www mot...

Page 518: ...ecified torque Install the rear seat bracket and bolts with proper seat bracket position as shown Tighten the bolt to the specified torque BOLT WASHER BATTERY STOPPER Connect the positive terminal first and then the negative cable TORQUE 27 N m 2 8 kgf m 20 lbf ft BOLT WASHER BATTERY STOPPER NEGATIVE TERMINAL POSITIVE TERMINAL FTZ10S type YTZ10S type BOLT WASHER WASHER BOLT TORQUE 22 N m 2 2 kgf m...

Page 519: ...ry termi nal With the ignition switch off check for current leak age When measuring current using a tester set it to a high range and then bring the range down to an appropriate level Current flow higher than the range selected may blow out the fuse in the tester While measuring current do not turn the ignition on A sudden surge of current may blow out the fuse in the tester TORQUE 22 N m 2 2 kgf ...

Page 520: ...emove the stator coil to make this test Remove the left rear cowl page 2 5 Disconnect the alternator 3P Black connector Check the resistance between all three Yellow termi nals Check for continuity between all three Yellow termi nals and ground There should be no continuity If readings are far beyond the standard or if any wire has continuity to ground replace the alternator stator page 10 5 REGUL...

Page 521: ...ator rectifier 2P Black and alternator 3P Black connector Remove the regulator rectifier unit mounting bolts and nuts Install the regulator rectifier unit in the reverse order of removal Item Terminal Specification Battery charging line Red and Green Battery voltage should register Charging coil line Yellow and Yellow 0 1 1 0 Ω at 20 C 68 F Ground line Green and ground Continuity should exist REGU...

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Page 523: ...SERVICE INFORMATION 18 3 TROUBLESHOOTING 18 4 IGNITION SYSTEM INSPECTION 18 5 CKP SENSOR 18 7 IGNITION COIL 18 7 IGNITION TIMING 18 7 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 524: ...UTRAL SWITCH IGNITION COILS SIDE STAND SWITCH TP SENSOR SPARK PLUGS ENGINE STOP SWITCH IGNITION SWITCH BATTERY CLUTCH SWITCH ECM FUSE BOX MAIN FUSE 30A Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 525: ...onnections before proceeding Make sure the battery is adequately charged Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug Refer to the following components informations ECM page 5 97 Sidestand switch page 20 36 Engine stop relay page 5 96 Engine stop switch page 20 32 Ignition switch page 20 30 Clutch switch page 20 34 SPEC...

Page 526: ...een the ignition coils and ECM 6 Short circuit in ignition primary coil 7 Faulty sidestand switch or neutral switch 8 An open circuit or loose connection in No 7 related cir cuit wires Sidestand switch line Green white wire Neutral switch line Light green or Green red wires 9 Faulty CKP sensor measure the peak voltage 10 Faulty ECM in case when above No 1 9 are normal Initial voltage is normal but...

Page 527: ...red Check cylinder compression and check that the spark plugs are installed correctly Disconnect all spark plug caps from the spark plugs page 3 8 Shift the transmission into neutral Connect a known good spark plugs to the spark plug cap and ground the spark plugs to the cylinder head as done in a spark test With the ignition coil primary wire connected con nect the peak voltage adaptor or peak vo...

Page 528: ...voltage measured at ECM 33P connec tors is abnormal measure the peak voltage at the CKP sensor connector Disconnect the CKP sensor 2P Red connector and connect the tester probes to the terminal Yellow and White yellow In the same manner as at the ECM connectors mea sure the peak voltage and compare it to the voltage measured at the ECM connectors If the peak voltage measured at the ECM is abnormal...

Page 529: ...crankcase cover page 9 25 IGNITION COIL REMOVAL INSTALLATION Lift up fuel tank page 3 5 Disconnect the spark plug caps from the spark plugs page 3 8 Disconnect the ignition coil primary wires from the ignition coil Remove the bolts and ignition coil Installation is in the reverse order of removal IGNITION TIMING Warm up the engine Stop the engine and remove the timing hole cap CKP SENSOR BOLTS GRO...

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Page 531: ...EM DIAGRAM 19 2 SERVICE INFORMATION 19 3 TROUBLESHOOTING 19 4 STARTER MOTOR 19 6 STARTER RELAY SWITCH 19 15 DIODE 19 17 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 532: ...OR NEUTRAL SWITCH SIDESTAND SWITCH FUSE BOX DIODE BATTERY STARTER RELAY SWITCH MAIN FUSE STARTER SWITCH IGNITION SWITCH CLUTCH SWITCH ENGINE STOP SWITCH Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 533: ... page 19 4 A weak battery may be unable to turn the starter motor quickly enough or supply adequate ignition current Refer to the procedure for starter clutch servicing page 9 17 Refer to the following components informations Ignition switch page 20 30 Engine stop switch page 20 32 Starter switch page 20 32 Neutral switch page 20 35 Sidestand switch page 20 36 Clutch switch page 20 34 SPECIFICATIO...

Page 534: ...ground wire lines as below for continuity 1 Green red terminal clutch switch diode neutral switch line with the transmission in neutral and clutch lever released 2 Green red terminal clutch switch sidestand switch line in any gear except neutral and with the clutch lever pulled in and the sidestand up Is there continuity YES GO TO STEP 6 NO Faulty neutral switch page 20 35 Faulty clutch diode page...

Page 535: ...s the clutch switch operation normal YES GO TO STEP 2 NO Faulty clutch switch 2 Sidestand Switch Inspection Check the sidestand switch operation page 20 36 Is the sidestand switch operation normal YES Open circuit in wire harness Loose or poor contact connector NO Faulty sidestand switch Starter motor turns engine slowly Low battery voltage Poorly connected battery terminal cables Poorly connected...

Page 536: ... and O ring Open the rubber cap then remove the terminal nut and starter motor cable from the starter motor Remove the starter motor mounting bolts and ground cable Pull the starter motor out of the crankcase Remove the O ring from the starter motor WATER HOSE JOINT BOLTS O RING STARTER MOTOR CABLE NUT GROUND CABLE BOLTS RUBBER CAP O RING Manuals by Motomatrix www motomatrix co uk The Solution For...

Page 537: ...otor case and seal ring Remove the armature from the rear cover Remove the brushes and springs from the brush holder CASE BOLTS FRONT COVER SEAL RING SEAL RING STARTER MOTOR CASE ARMATURE REAR COVER BRUSHES SPRINGS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 538: ...ontinuity Check for continuity between positive and negative brushes There should be no continuity Remove the screw washer and negative brushes Remove the terminal nut Continuity STARTER MOTOR CABLE TERMINAL POSITIVE BRUSHES REAR COVER Nocontinuity POSITIVE BRUSHES NEGATIVE BRUSHES NEGATIVE BRUSHES SCREW WASHER NUT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded K...

Page 539: ... turning the terminal bolt Disassemble the terminal bolt positive brushes and brush holder INSPECTION Measure each brush length O RING INSULATOR TERMINAL STOPPER WASHER REAR COVER BRUSH HOLDER PLATE TERMINAL BOLT BRUSH HOLDER POSITIVE BRUSHES TERMINAL BOLT SERVICE LIMIT 6 5 mm 0 26 in Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk...

Page 540: ...idual com mutator bar and armature shaft There should be no continuity Check the dust seal for deterioration wear or dam age Turn the inner race of the starter motor bearing with your finger The bearing should turn smoothly and quietly Also check that the outer race of the bearing fits tightly in the front cover Do not use emery or sand paper on the commutator COMMUTATOR ARMATURE Continuity Nocont...

Page 541: ...R CASE REAR COVER NUT WASHER TERMINAL STOPPER FRONT COVER ARMATURE POSITIVE BRUSHES NEGATIVE BRUSHES TERMINAL BOLT INSULATOR BRUSH HOLDER O RING SCREW WASHER SPRINGS SEAL RING SEAL RING CASE BOLTS O RING BRUSH HOLDER POSITIVE BRUSHES TERMINAL BOLT Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 542: ...pper insulator and washer Install and tighten the terminal nut securely Install the negative brushes and screw washer and tighten the screw securely BRUSH HOLDER PLATE TERMINAL BOLT O RING INSULATOR TERMINAL STOPPER WASHER REAR COVER NUT NEGATIVE BRUSHES SCREW WASHER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 543: ...ew seal ring to the starter motor case Install the starter motor case with its groove with the tab on the rear cover The coil may be damaged if the magnet pulls the armature against the case SPRINGS BRUSHES ARMATURE REAR COVER SEAL RING Align Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 544: ...oil seal lip with the armature shaft Align the index marks on the front cover starter motor case and rear cover Tighten the case bolts securely INSTALLATION Apply oil to a new O ring and install it to the starter motor groove FRONT COVER SEAL RING INDEXMARKS CASE BOLTS O RING Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 545: ...nd engine stop switch Press the starter switch button The coil is normal if the starter relay switch clicks If you don t hear the switch click inspect the relay switch using the procedure below GROUND LINE INSPECTION Disconnect the starter relay switch 4P connector Check for continuity between the Green red wire ground line and ground If there is continuity when the transmission is in neutral or w...

Page 546: ...wire terminal and nega tive wire to the Green red wire terminal Connect an ohmmeter to the starter relay switch large terminals There should be continuity between the large termi nals when the battery is connected and no continu ity when the battery is disconnected REMOVAL INSTALLATION Remove the right side cover page 2 5 Disconnect the starter relay switch 4P connector Remove the bolts and discon...

Page 547: ...order of removal INSPECTION Check for continuity between the diode terminals When there is continuity a small resistance value will register If there is continuity in one direction the diode is normal DIODE FUSE BOX DIODE C A B C A B Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 548: ...MEMO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 549: ...20 23 TACHOMETER 20 25 ENGINE COOLANT TEMPERATURE INDICATOR ECT SENSOR 20 27 ENGINE OIL PRESSURE INDICATOR EOP SWITCH 20 28 FUEL LEVEL SENSOR 20 29 IGNITION SWITCH 20 30 HANDLEBAR SWITCHES 20 32 BRAKE LIGHT SWITCH 20 34 CLUTCH SWITCH 20 34 NEUTRAL SWITCH 20 35 SIDESTAND SWITCH 20 36 HORN 20 37 TURN SIGNAL RELAY 20 38 HEADLIGHT RELAY CBF600S SA 20 39 FAN CONTROL RELAY 20 39 Manuals by Motomatrix ww...

Page 550: ...GHT SWITCH IGNITION SWITCH VS SENSOR SIDESTAND SWITCH NEUTRAL SWITCH HORN CLUTCH SWITCH LEFT HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH HEADLIGHT RELAY CBF600S SA TURN SIGNAL RELAY FUEL LEVEL SENSOR FAN CONTROL RELAY Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 551: ...quires proper battery voltage A continuity test can be made with the switches installed on the motorcycle The following color codes are used throughout this section SPECIFICATIONS Bu Blue G Green Lg Light Green R Red Bl Black Gr Gray O Orange W White Br Brown Lb Light Blue P Pink Y Yellow ITEM SPECIFICATIONS CBF600S CBF600SA CBF600N CBF600NA Bulbs Headlight Hi 12V 55 W 12V 60 55 W Lo 12V 55 W Posi...

Page 552: ...f ft Steering stem nut 103 N m 10 5 kgf m 76 lbf ft See page 13 38 Fork top bridge pinch bolt 23 N m 2 3 kgf m 17 lbf ft Handlebar holder bolt 26 N m 2 7 kgf m 20 lbf ft License light screw 1 7 N m 0 2 kgf m 1 3 lbf ft Peak voltage adaptor 07HGJ 0020100 with commercially available digital multimeter impedance 10 MΩ DCV minimum or Imrie diagnostic tester model 625 Test probe 07ZAJ RDJA110 Manuals b...

Page 553: ...ector CBF600S SA or combination meter 9P Natural connector With the ignition switch ON and measure the voltage at bottom of the combination meter 16P Black connector CBF600S SA or combination meter 9P Natural connector CBF600N NA Is there Battery Voltage NO Loose or poor contact of related terminals Open circuit in Black brown or Green black wires between the battery and speed sensor YES GO TO STE...

Page 554: ...e headlight bulb connector Install the dust cover tightly aligning its tab with the proper position REMOVE INSTALLATION CBF600S SA Remove the front center cowl page 2 10 Remove the upper two silver screws and lower two black screws and headlight unit Install the headlight unit in the reverse order of removal CONNECTOR DUST COVER Avoid touching halogen headlight bulb Finger prints can create hot sp...

Page 555: ...lb If you touch the bulb with your bare hands clean it with cloth moistened with denatured alcohol to pre vent early bulb failure HEADLIGHT UNIT SCREWS HEADLIGHT BULB SOCKET POSITION BULB CONNECTORS DUST COVER Avoid touching halogen headlight bulb Finger prints can create hot spots that cause a bulb to break HEADLIGHT BULB HEADLIGHT UNIT RETAINER Manuals by Motomatrix www motomatrix co uk The Solu...

Page 556: ...ight bulb sockets to the head light bulbs Connect the position light connector Install the headlight unit Install and tighten the screws securely HEADLIGHT BULB HEADLIGHT UNIT RETAINER DUST COVER HEADLIGHT BULB SOCKET POSITION BULB CONNECTORS HEADLIGHT UNIT SCREWS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 557: ... the headlight unit page 20 7 Adjust the headlight aim page 3 27 POSITION LIGHT BULB REPLACEMENT CBF600S SA Pull out the position light bulb socket Remove the bulb from the socket replace it with a new one Install the position light bulb socket in the reverse order of removal CONNECTORS Route the wires properly page 1 24 BOLTS SPECIAL NUTS HEADLIGHT CASE BULB SOCKET BULB Manuals by Motomatrix www ...

Page 558: ...0S SA Remove the front side cowl page 2 9 Turn the bulb socket counterclockwise then remove the bulb socket While pushing in turn the bulb counterclockwise to remove it and replace with a new one Install the bulb socket in the reverse order of removal BULB REPLACEMENT CBF600N NA Remove the screw and turn signal lens POSITION LIGHT SOCKET BULB SOCKET SCREW Manuals by Motomatrix www motomatrix co uk...

Page 559: ...tall the turn signal lens in the reverse order of removal REMOVAL INSTALLATION CBF600N NA Remove the headlight unit page 20 7 Disconnect the front winker 2P Blue and 2P Orange connectors Remove the mounting nut and turn signal unit Installation is in the reverse order of removal BULB PACKING SLIT CONNECTORS 2P Orange CONNECTOR 2P Blue CONNECTOR NUT TURN SIGNAL UNIT Manuals by Motomatrix www motoma...

Page 560: ...nd replace with a new one Install the tail brake light lens in the reverse order of removal LICENSE LIGHT BULB REPLACEMENT Remove the screws and license light case Remove the license light bulb and replace with a new one SCREWS LENS BULB SCREWS LICENCE LIGHT CASE BULB Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 561: ...isconnect the 16P Black connector Remove the combination meter mounting bolts Remove the combination meter Installation is the reverse order of removal DISASSEMBLY Remove the screws Remove the clear cover TORQUE 1 7 N m 0 2 kgf m 1 3 lbf ft SCREWS LICENCE LIGHT CASE 16P BLACK CONNECTOR BOLTS SCREWS CLEAR COVER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys e...

Page 562: ...ly from the rear cover ASSEMBLY Install the print board assembly into the rear cover Tighten the screws securely Install the clear cover then tighten the screws securely SCREWS PRINT BOARD SCREWS SCREWS CLEAR COVER Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 563: ...ors Disconnect the ignition switch 2P Brown connec tor Disconnect the immobilizer receiver 4P Natural connector Remove the handle bar page 13 8 Remove the cap nuts 9P Black CONNECTOR 9P NATURAL CONNECTOR 2P Brown CONNECTOR 4P Natural CONNECTOR CAP NUTS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 564: ...nd combination meter assembly DISASSEMBLY Remove the mounting bolts and the top bridge from the combination meter Remove the screws and lower cover WIRE BAND COMBINATION METER PINCH BOLTS STEM NUT TOP BRIDGE BOLTS LOWER COVER SCREWS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 565: ...he speedometer tachometer and indicator plate ASSEMBLY Install the speedometer tachometer and indicator plate to the combination meter case SCREWS FRONT COVER SCREWS SCREW CLAMP BULB SOCKETS SUB HARNESS SPEEDOMETER TACHOMETER INDICATOR PLATE SPEEDOMETER TACHOMETER INDICATOR PLATE Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 566: ...ation meter case then tighten the screws securely Install the lower cover to the combination meter case then tighten the screws securely INSTALLATION Install the top bridge to the combination meter Install and tighten the mounting bolts securely SCREWS SCREW CLAMP BULB SOCKETS SUB HARNESS SCREWS FRONT COVER LOWER COVER SCREWS TOP BRIDGE BOLTS Manuals by Motomatrix www motomatrix co uk The Solution...

Page 567: ...dlebar page 13 11 Route the wire properly page 1 24 Install the wire band Install and tighten the cap nuts securely Install the handle bar and tighten the holder bolt to the specified torque page 13 11 HEADLIGHT CASE BRACKET GROMMETS HOLES Align TORQUE 103 N m 10 5 kgf m 76 lbf ft TORQUE 23 N m 2 3 kgf m 17 lbf ft COMBINATION METER PINCH BOLTS STEM NUT WIRE BAND TORQUE 26 N m 2 7 kgf m 20 lbf ft C...

Page 568: ... Route the wires properly page 1 24 Connect the combination meter 9P Natural and 9P Black connectors Install the headlight unit page 20 7 2P Brown CONNECTOR 4P Natural CONNECTOR 9P Black CONNECTOR 9P Natural CONNECTOR Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 569: ...ure the voltage between the Red green wire terminal and body ground There should be battery voltage at all times If there is no voltage check for open circuit in Red green wire Ground line Measure the continuity between the Green black wire terminal and body ground There should be continuity If there is no continuity check for open circuit in Green black wire 16P Black CONNECTOR Black brown Viewed...

Page 570: ...atural Red green wire terminal and body ground There should be battery voltage at all times If there is no voltage check for open circuit in Red green wire Ground line Measure the continuity between the 9P Black Green black wire terminal and body ground There should be continuity If there is no continuity check for open circuit in Green black wire 9P Black CONNECTOR 9P Natural CONNECTOR Black brow...

Page 571: ...pulse voltage appears replace the speedome ter page 20 16 If pulse voltage does not appear check for open or short circuit in Pink Green wire If the Pink Green wire is OK check for the vehicle speed sensor page 20 24 CBF600N NA Check that the indicators function properly If they do not function perform the power and ground line inspection of the combination meter page 20 21 If they function shift ...

Page 572: ... side 3P connector There should be battery voltage If there is no voltage check for open circuit in related wires If the speedometer does not operate check the speedometer inspection page 20 21 Then check the VS sensor power line inspection If the speedometer and wire harness between the speedometer and VS sensor are normal replace the VS sensor page 20 24 REMOVAL INSTALLATION Remove the air clean...

Page 573: ...tage If the peak voltage is normal replace the combina tion meter circuit board page 20 13 If the measured value is below 10 5 V replace the ECM page 5 97 O RING SPEED SENSOR 16P Black CONNECTOR TOOLS Imrie diagnostic tester model 625 or Peak voltage adaptor 07HGJ 0020100 with commercially available digital multimedia impedance 10 MΩ DCV minimum CONNECTION Yellow Green and Green black PEAK VOLTAGE...

Page 574: ...ontinuity between the combination meter 9P connector and ECM 33P Light gray connector Yellow green terminals If there is no continuity check the wire harness for an open circuit If there is continuity replace the ECM page 5 97 TOOL Test probe 07ZAJ RDJA110 33P Light gray CONNECTOR Wire side female terminals 16P CONNECTOR Viewed from harness side Yellow green 9P Black CONNECTOR 9P Natural CONNECTOR...

Page 575: ...ombination meter ECT SENSOR INSPECTION Remove the ECT sensor page 5 94 Suspend the ECT sensor in a pan of coolant 1 1 mixture an electric heating element and measure the resistance through the sensor as the coolant heats up Soak the ECT sensor in coolant up to its threads with at least 40 mm 1 6 in from the bottom of the pan to the bottom of the sensor Keep the temperature constant for 3 minutes b...

Page 576: ...If the indicators do not come on replace the EOP switch If the engine oil pressure and warning indicators do not function check the following Remove the rubber cap and disconnect the EOP switch wire by removing the terminal bolt Ground the wire terminal to the engine using a jumper wire Start the engine and check the engine oil pressure and warning indicators If the indicators come on replace the ...

Page 577: ...ural connector to the main wire harness Move the float from bottom empty to top full positions to check the fuel meter needle indication Turn the ignition switch ON If the fuel meter needle does not indicate properly check for open or short circuit in wire harness If the wire harness is good replace the combination meter printed circuit board with new one page 20 13 Be careful not to damage or ben...

Page 578: ...Disconnect the ignition switch 2P Brown connec tor Check for continuity between the wire terminals of the ignition switch connector in each switch posi tion Continuity should exist between the color coded wires as follows IGNITION SWITCH 2P Brown CONNECTOR 2P Brown CONNECTOR IGNITION SWITCH Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix...

Page 579: ...ge 20 15 Remove the bolts and ignition switch Install the ignition switch in the reverse order of removal Tighten the ignition switch mounting bolt to the specified torque CBF600N NA 2P Brown CONNECTOR TORQUE 25 N m 2 5 kgf m 18 lbf ft BOLTS IGNITION SWITCH S SA Shown Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 580: ... handlebar switch connec tor Continuity should exist between the terminals as follows RIGHT HANDLEBAR SWITCH CBF600S SA RIGHT HANDLEBAR SWITCH 9P Brown AND 2P Natural CONNECTOR LEFT HANDLEBAR SWITCH 6P Blue AND 4P Black CONNECTOR CBF600N NA RIGHT HANDLEBAR SWITCH 9P Brown AND 2P Natural CONNECTOR LEFT HANDLEBAR SWITCH 6P Blue AND 6P Black CONNECTOR ENGINE STOP SWITCH STARTER SWITCH HAZARD SWITCH M...

Page 581: ... wire terminals of the handlebar switch connector Continuity should exist between the terminals as follows LEFT HANDLEBAR SWITCH PASSING SWITCH DIMMER SWITCH HORN SWITCH TURN SIGNAL SWITCH Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 582: ...nector and check for continuity between the ter minals There should be continuity with the brake pedal applied and there should be no continuity with the brake pedal is released CLUTCH SWITCH Disconnect the clutch switch connectors and check for continuity between the terminals There should be continuity with the clutch lever applied and there should be no continuity with the clutch lever is relea...

Page 583: ...the transmission is into gear REMOVAL INSTALLATION Disconnect the neutral switch connector from the switch Remove the neutral switch and sealing washer Install the neutral switch with a new sealing washer Tighten the neutral switch to the specified torque Installation is in the reverse order of removal NEUTRAL SWITCH CONNECTOR TORQUE 12 N m 1 2 kgf m 9 lbf ft NEUTRAL SWITCH SEALING WASHER Manuals ...

Page 584: ...Remove the left side cover page 2 5 Disconnect the sidestand switch 2P Green connec tor Release the sidestand switch wire from the clamp Remove the crankcase rear cover A Unhook the sidestand wire from the guide Release the sidestand wire clip from the crankcase rear cover B and left pivot bracket 2P Green CONNECTOR SIDESTAND 2P Green CONNECTOR CLAMP GUIDE REAR COVER A SIDESTAND WIRE WIRE CLIPS Ma...

Page 585: ... bolt Install the removed parts in the reverse order of removal HORN INSPECTION Disconnect the wire connectors from the horn Connect the 12V battery to the horn terminal directly and check the horn sound SIDESTAND SWITCH BOLT SIDESTAND SWITCH HOLDING PIN HOLE Route the sidestand wire properly page 1 24 BOLT HORN Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys...

Page 586: ...od condition YES GO TO STEP 2 NO Replace or repair the malfunction part s 2 Turn Signal Circuit Inspection Remove the rear cowl page 2 5 Disconnect the turn signal 4P connector and short the Gray and White green terminals of the wire harness side connector with a jumper wire Turn the ignition switch ON and check the turn signal light by turning the turn signal switch on Does the light come on YES ...

Page 587: ... relay con nector terminals Connect the 12 V battery to the following headlight relay connector terminals There should be continuity when the 12 V battery is connected If there is no continuity when the 12 V battery is connected replace the headlight relay FAN CONTROL RELAY Remove the rear cowl page 2 5 Remove the fan control relay from the rubber holder Disconnect the fan control relay 4P connect...

Page 588: ...s There should be continuity when the 12 V battery is connected If there is no continuity when the 12 V battery is connected replace the headlight relay CONNECTION A Red green B Black blue CONNECTION C Green blue D Black white C D HEADLIGHT RELAY BATTERY B A Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 589: ...EGISTRATION PROCEDURES 21 4 HISS DIAGNOSTIC INFORMATION 21 7 TROUBLESHOOTING 21 9 IMMOBILIZER INDICATOR S SA model 21 12 IMMOBILIZER INDICATOR N NA model 21 13 ECM 21 14 IMMOBILIZER RECEIVER 21 15 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 590: ... HISS COMPONENT LOCATION SYSTEM DIAGRAM CKP SENSOR BATTERY MAIN FUSE 30A FUSE 20A IMMOBILIZER RECEIVER ECM ENGINE STOP SWITCH FUSE 10A Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 591: ... rise Do not leave the key in the water for a prolonged time such as by washing the clothes The ECM as well as the transponder keys must be replaced if all transponder keys have been lost The system does not function with a duplicated key unless the code is registered into the transponder with the immobi lizer system HISS The ECM can store up to four key codes The four keys can be registered Do no...

Page 592: ...ation of the lost key or spare key is cancelled The spare key must be registered again 6 Turn the ignition switch to OFF and remove the key 7 Turn the ignition switch to ON with a new key or the spare key Never use the key registered in previous steps The indicator comes on for two seconds then it blinks four times repeatedly The new key or spare key is registered in the ECM If there is any proble...

Page 593: ...it blinks four times repeatedly The first key is registered in the ECM If there is any problem in the registration the system will enter the diagnostic mode and the indicator will remain for approx ten seconds then it will indicate the diagnostic code page 21 8 10 Turn the ignition switch to OFF and disconnect the red clip of the inspection adaptor from the battery positive ter minal 11 Turn the i...

Page 594: ...3 Replace the ECM with a new one page 5 97 4 Turn the ignition switch to ON with a first new key The immobilizer indicator comes on for two seconds then it blinks four times repeatedly The first key is registered in the ECM If there is any problem in the registration the system will enter the diagnostic mode and the indicator will remain for approx ten seconds then it will indicate the diagnostic ...

Page 595: ... system is in the normal mode and the diagnostic code does not appear HISS DIAGNOSTIC CODE When the system ECM enters the diagnostic mode from the normal mode TOOLS Inspection harness 07XMZ MBW0101 Test harness adaptor 070MZ MEC0101 2P Red CONNECTOR INSPECTION HARNESS ADAPTOR IMMOBILIZER INDICATOR S SA model N NA model BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE ECM data is abnormal Faulty ECM Repl...

Page 596: ...d The key is already regis tered properly Use a new key or cancelled key Code signals cannot send or receive Communication fails Follow the trouble shooting page 21 9 Registration is impossible The key is already regis tered on the other system Use a new key Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 597: ...Indicator Line Inspection At The ECM Connector Check the immobilizer indicator line White red wire at the ECM connector page 21 14 Is the voltage specified value YES GO TO STEP 6 NO GO TO STEP 5 5 Immobilizer Indicator Line Inspection At The Combination Meter Connector Check the immobilizer indicator line White red wire at the combination meter connector page 21 12 Is the voltage specified value Y...

Page 598: ...Inspection Perform the diagnostic code indication procedure page 21 7 and check that the immobilizer indica tor comes on then it starts blinking Is there indicator Blinks or Stay Lit BLINKS Read the diagnostic code page 21 7 STAY LIT GO TO STEP 4 4 Immobilizer Indicator Line Inspection At The ECM Connector Check the immobilizer indicator line White red wire at the ECM connector page 21 14 Is the v...

Page 599: ...Check the ground line Green orange at the immobilizer receiver connector page 21 16 Is there continuity YES GO TO STEP 3 NO Open circuit in the Green orange wire 3 Immobilizer Receiver Signal Line Inspection Check the signal lines Pink and Yellow blue between the immobilizer receiver and ECM connectors page 21 16 Are the wires normal YES Faulty the immobilizer receiver NO Open or short circuit in ...

Page 600: ...INSPECTION Measure the voltage between the White red wire terminal and ground There should be battery voltage when the ignition switch is turned to ON There should be no voltage for approx two sec onds after the ignition switch is turned to ON then the battery voltage should appear if the system is normal 16P Black CONNECTOR Viewed from harness side the 16P connector Green black Black blown Viewed...

Page 601: ...Measure the voltage between the White red wire terminal and ground There should be battery voltage when the ignition switch is turned to ON There should be no voltage for approx two sec onds after the ignition switch is turned to ON then the battery voltage should appear if the system is normal 9P BLACK CONNECTOR 9P NATURAL CONNECTOR Green black Black blown Viewed from harness side the 9P Black co...

Page 602: ...ld be battery voltage when the ignition switch is turned to ON GROUND LINE INSPECTION Check the continuity between the B4 Green wire terminal and ground Also check the continuity between the A23 and A24 Green white wire terminals and ground There should be continuity at all times TOOL Test probe 07ZAJ RDJA110 ECM 33P Black CONNECTOR 33P Light gray CONNECTOR 33P Light gray CONNECTOR B Wire side fem...

Page 603: ...tor CBF600N NA Remove the headlight unit page 20 6 Disconnect the immobilizer receiver 4P Natural connector POWER INPUT LINE INSPECTION Measure the voltage between the Yellow red wire terminal and ground There should be approx 5 V when the ignition switch is turned to ON 2P Red CONNECTOR Wire side male terminals Yellow White yellow B22 33P Light gray CONNECTOR B Wire side female terminals 33P Blac...

Page 604: ...be continuity Check for continuity between the Yellow blue wire terminal and ground There should be no continuity REPLACEMENT CBF600S SA Remove the front center cowl page 2 10 Disconnect the immobilizer receive 4P Natural connector Remove the combination meter page 20 15 Green orange 4P Natural CONNECTOR Wire side female terminals Pink 4P Natural CONNECTOR Wire side female terminals TOOL Test prob...

Page 605: ...the receiver wire properly page 1 24 IMMOBILIZER RECEIVER SCREWS S SA Shown Problem Replacement parts Transponder Key Immobilizer receiver ECM Ignition switch Accessory lock and key One key has been lost or addi tional spare key is required All key have been lost or ECM is faulty Immobilizer receiver is faulty Ignition switch is faulty Accessory lock is faulty Manuals by Motomatrix www motomatrix ...

Page 606: ...MEMO Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 607: ...22 1 22 22 WIRING DIAGRAMS CBF600S 22 3 CBF600SA 22 4 CBF600N 22 5 CBF600NA 22 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 608: ...RD COLOR CORD COLOR CORD COLOR CORD COLOR CORD COLOR CORD COLOR CORD COLOR PUSH Ho Lg BAT3 Bl Br IG BAT2 FREE PUSH ST IG BAT4 HL Y R Bl Bl R Bu W W Bl Bl LOCK BAT1 IG R R Bl ON OFF W R L Gr Lb O ABCDEF BATTERY 12V 10A 0030Z MER R600 UP DOWN IACV FUEL FI TURN R HISS OIL TURN L HIGH BEAM BATT ABS IGN Vcc OUT SP PULSE TEMP P GND TA PULSE NEUTRAL 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 ...

Page 609: ... PUSH BAT5 Hi Bl R Bu N HL Lo Hi Bu W Bu FREE CORD COLOR CORD COLOR CORD COLOR CORD COLOR CORD COLOR CORD COLOR CORD COLOR CORD COLOR PUSH Ho Lg BAT3 Bl Br IG BAT2 FREE PUSH ST IG BAT4 HL Y R Bl Bl R Bu W W Bl Bl LOCK BAT1 IG R R Bl ON OFF W R L Gr Lb O ABCDEF BATTERY 12V 10A GH I J WPC 0030Z MER R800 UP DOWN IACV FUEL FI TURN R HISS OIL TURN L HIGH BEAM BATT ABS IGN Vcc OUT SP PULSE TEMP P GND TA...

Page 610: ...WN IACV 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 7 23 24 25 26 27 28 29 30 31 32 33 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 7 23 24 25 26 27 28 29 30 31 32 33 O G Lb G O G Lb G 2P Lb 2P O O Lb Bu W Bl R Gr Bl Lg R G Bu G Bl Bl Br G Bu Lb G Bl G Bl O Bl Br W R Bl Br W Bu Bl Br Bu R Bl Br Lg R Bu Bl G Bl Bl Br Y G P G R G W R Lb Bu R Bu Bl W Bu Y R Gr Bl Lg R G Bu G Bl B...

Page 611: ...BAT4 HL Y R Bl Bl R Bu W W Bl Bl LOCK BAT1 IG R R Bl ON OFF W R L Gr Lb O ABCDEF BATTERY 12V 10A GH I J WPC 0030Z MER R900 UP DOWN IACV 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 7 23 24 25 26 27 28 29 30 31 32 33 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 7 23 24 25 26 27 28 29 30 31 32 33 O G Lb G O G Lb G 2P Lb 2P O O Lb Bu W Bl R Gr Bl Lg R G Bu G Bl R Bl Bl Br G Bu Lb ...

Page 612: ...HARD TO START 23 2 ENGINE LACKS POWER 23 3 POOR PERFORMANCE AT LOW AND IDLE SPEED 23 5 POOR PERFORMANCE AT HIGH SPEED 23 6 POOR HANDLING 23 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 613: ...e fuel pump unit normal YES GO TO STEP 4 NO Faulty fuel pump unit page 5 56 4 PGM FI System Inspection Check the PGM FI system Is the PGM FI system normal YES GO TO STEP 5 NO Faulty PGM FI system page 5 11 5 Cylinder compression Inspection Test the cylinder compression page 8 6 Is the compression as specified YES GO TO STEP 6 NO Improper valve clearance Valve stuck open Worn cylinder and piston ri...

Page 614: ...ngine Performance Inspection Accelerate lightly Did the Engine speed increase YES GO TO STEP 5 NO Dirty air cleaner Restricted fuel flow Clogged muffler 5 Spark Plug Inspection Remove and inspect spark plugs Are the spark plugs in good condition YES GO TO STEP 6 NO Plugs not serviced frequently enough Incorrect spark plug heat range Incorrect spark plug gap 6 Engine Oil Inspection Check the oil le...

Page 615: ... lubricated properly YES GO TO STEP 12 NO Faulty oil pump Faulty pressure relief valve Clogged oil strainer Clogged oil passage 12 Over Heating Inspection Check for engine over heating Is the engine over heating YES Coolant level too low Fan motor not working Thermostat stuck closed Excessive carbon build up in combustion chamber Use of poor quality fuel Wrong type of fuel Clutch slipping NO GO TO...

Page 616: ... Pump Inspection Inspect the fuel flow Is the fuel pump unit normal YES GO TO STEP 4 NO Faulty fuel pump unit page 5 56 4 PGM FI System Inspection Check the PGM FI system Is the PGM FI system normal YES GO TO STEP 5 NO Faulty PGM FI system page 5 11 5 IACV Inspection Check the IACV operation page 5 90 Does the IACV operates normally YES GO TO STEP 6 NO Faulty IACV 6 Intake Pipes Leaking Inspection...

Page 617: ...k the valve timing page 8 28 Is the valve timing correct YES GO TO STEP 5 NO Camshafts not installed properly 5 Valve Spring Inspection Check the valve springs Is the valve spring free length as specified YES Not weak NO Faulty valve springs POOR HANDLING Steering is heavy Steering stem adjusting nut too tight Damaged steering head bearings Insufficient tire pressure Either wheel is wobbling Exces...

Page 618: ...L 7 4 CRANKCASE SEPARATION 11 5 CRANKCASE TRANSMISSION SPECIFICATIONS 1 10 CRANKPIN BEARING 12 11 CRANKSHAFT 12 5 CRANKSHAFT PISTON CYLINDER SPECIFICATIONS 1 10 CYLINDER COMPRESSION TEST 8 6 CYLINDER HEAD ASSEMBLY 8 22 CYLINDER HEAD COVER ASSEMBLY 8 30 CYLINDER HEAD COVER DISASSEMBLY 8 7 CYLINDER HEAD COVER INSTALLATION 8 31 CYLINDER HEAD COVER REMOVAL 8 6 CYLINDER HEAD DISASSEMBLY 8 14 CYLINDER H...

Page 619: ...ATION 7 3 FRAME BODY PANELS EXHAUST SYSTEM 2 3 FRONT WHEEL SUSPENSION STEERING 13 4 FUEL SYSTEM PGM FI 5 3 HYDRAULIC BRAKE 15 4 IGNITION SYSTEM 18 3 IMMOBILIZER SYSTEM HISS 21 3 LIGHTS METERS SWITCHES 20 3 LUBRICATION SYSTEM 4 3 MAINTENANCE 3 2 REAR WHEEL SUSPENSION 14 3 SERVICE RULES 1 2 SHIFT FORK SHIFT DRUM TRANSMISSION 11 6 SHOCK ABSORBER 14 14 SIDE COVER 2 5 SIDESTAND 3 28 SIDESTAND SWITCH 20...

Page 620: ...INDEX 24 3 WIRING DIAGRAM CBF600S 22 3 CBF600SA 22 4 CBF600N 22 5 CBF600NA 22 6 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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