Honda CBR600F4I (2001-2003) [240/492] Engine removal installation

Содержание

• Contents 2
• How to use this manual 2
• Symbols 3
• General info 4
• General information 4
• Model identification 4
• Service rules 4
• General information 5
• General information 6
• P general 6
• Specifications 6
• General cont dl 7
• General information 7
• Fuel system programmed fuel injection 8
• General information 8
• Lubrication system 8
• Cooling system 9
• Cylinder 9
• General information 9
• Clutch gearshift linkage 10
• General information 10
• Crankshaft piston cyunder 11
• General information 11
• Front wheel suspension steering 12
• General information 12
• Rear wheel suspension 12
• Battery charging system 13
• General information 13
• Hydraulic brake 13
• Ignition system 13
• Electric starter 14
• General information 14
• Lights meters switches 14
• General information 15
• Torque values 15
• General information 16
• General information 17
• Xo o ox 18
• General information 19
• General information 20
• General information 21
• Engine 22
• General information 22
• Lubrication seal points 22
• Engine cont d 23
• General information 23
• Engine cont d 24
• General information 24
• General information 25
• Cable harness routing 26
• General information 26
• General information 27
• General information 29
• General information 31
• General information 32
• General information 33
• General information 34
• General information 35
• General information 36
• General information 37
• General information 39
• General information 40
• Crankcase emission control system 41
• Emission control systems 41
• General information 41
• Source of emissions 41
• Exhaust emission control system pulse secondary air supply system 42
• General information 42
• Evaporative emission control system california type only 43
• General information 43
• Noise emission control system 43
• Emission control information labels u s a only 44
• General information 44
• Vacuum hose routing diagram label california type only 44
• Frame body 45
• Body panel locations 2 0 upper cowl 2 7 46
• Frame body panels exhaust system 46
• General 46
• Lower cowl 2 4 46
• Pillion seat rear cowl 2 2 muffler exhaust pipe 2 19 46
• Seat 2 2 seat rail 2 16 46
• Service information 46
• Service information 2 1 front fender 2 12 46
• Torque values 46
• Troubleshooting 46
• Troubleshooting 2 1 rear fender 2 13 46
• Frame body panels exhaust system 47
• Installation 47
• Pillion seat rear cowl 47
• Removal 47
• Frame body panels exhaust system 49
• Lower cowl 49
• Removal 49
• Frame body panels exhaust system 50
• Installation 50
• Frame body panels exhaust system 51
• Frame body panels exhaust system 52
• Removal 52
• Upper cowl 52
• Frame body panels exhaust system 53
• Frame body panels exhaust system 54
• Installation 54
• Frame body panels exhaust system 55
• Frame body panels exhaust system 56
• Frame body panels exhaust system 57
• Front fender 57
• Installation 57
• Removal 57
• Frame body panels exhaust system 58
• Rear fender 58
• Removal 58
• Frame body panels exhaust system 59
• Installation 59
• Frame body panels exhaust system 60
• Frame body panels exhaust system 61
• Removal 61
• Seat rail 61
• Frame body panels exhaust system 62
• Installation 62
• Frame body panels exhaust system 63
• Frame body panels exhaust system 64
• Muffler exhaust pipe 64
• Removal 64
• Frame body panels exhaust system 65
• Installation 65
• Frame body panels exhaust system 66
• Frame body panels exhaust system 67
• Frame body panels exhaust system 68
• Maintanance 70
• Maintenance 70
• Service information 70
• Maintenance 71
• Specifications 71
• Torque values 71
• Maintenance 72
• Maintenance schedule 72
• Fuel line 73
• Maintenance 73
• Throttle operation 73
• Air cleaner 74
• Maintenance 74
• Maintenance 75
• Notice 75
• Removal 75
• Spark plug 75
• Inspection 76
• Maintenance 76
• Maintenance 77
• Inspection 78
• Maintenance 78
• Valve clearance 78
• Maintenance 79
• Maintenance 80
• Adjustment 81
• Maintenance 81
• Maintenance 82
• Engine oil oil filter 83
• Maintenance 83
• Oil level inspection 83
• Engine oil filter change 84
• Maintenance 84
• Maintenance 85
• Cooling system 86
• Engine idle speed 86
• Maintenance 86
• Radiator coolant 86
• Maintenance 87
• Secondary air supply system 87
• Adjustment 88
• Drive chain 88
• Drive chain slack inspection 88
• Evaporative emission control system california type only 88
• Maintenance 88
• Noticej 88
• Cleaning and lubrication 89
• Maintenance 89
• Sprockets inspection 89
• Maintenance 90
• Replacement 90
• Maintenance 91
• Notice 91
• Brake fluid 92
• Front brake 92
• Maintenance 92
• Notice i 92
• Rear brake 92
• Brake lever adjustment 93
• Brake pad wear 93
• Brake system 93
• Front brake pads 93
• Inspection 93
• Maintenance 93
• Rear brake pads 93
• Brake light switch 94
• Brake pedal height adjustment 94
• Headlight aim 94
• Maintenance 94
• Clutch system 95
• Maintenance 95
• Notice 95
• Side stand 95
• Front suspension adjustment 96
• Front suspension inspection 96
• Maintenance 96
• Suspension 96
• Maintenance 97
• Notice 97
• Rear suspension inspection 97
• Maintenance 98
• Rear suspension adjustment 98
• _notice i 98
• Maintenance 99
• Nuts bolts fasteners 99
• Wheels tires 99
• Maintenance 100
• Steering head bearings 100
• A caution 102
• Lubrication system 102
• Service information 102
• Lubrication system 103
• Troubleshooting 103
• Lubrication system 104
• Oil pressure inspection 104
• Oil strainer pressure relief valve 104
• Removal 104
• Inspection 105
• Lubrication system 105
• Lubrication system 106
• Oil pump 106
• Removal 106
• Disassembly 107
• Inspection 107
• Lubrication system 107
• Assembly 108
• Lubrication system 108
• Installation 109
• Lubrication system 109
• Oil cooler 109
• Removal 109
• Inspection 110
• Lubrication system 110
• Lubrication system 111
• Fuel system 113
• E codes 114
• Fuel system programmed fuel injection 114
• Service information 114
• Fuel system programmed fuel injection 115
• Specifications 115
• Fuel system programmed fuel injection 116
• Torque values 116
• Troubleshooting 116
• Fuel system programmed fuel injection 117
• System location 117
• Fuel system programmed fuel injection 118
• Fuel system programmed fuel injection 119
• Pgm fi programmed fuel injection system 119
• Self diagnostic procedures 119
• Fuel system programmed fuel injection 120
• Self diagnosis reset procedure 120
• Fuel system programmed fuel injection 121
• Peak voltage inspection proce dure 121
• Test harness connection 121
• Fuel system programmed fuel injection 122
• Test harness terminal layout 122
• Fuel system programmed fuel injection 123
• Pgm fi self diagnosis malfunction indicator lamp mil failure codes 123
• Fuel system programmed fuel injection 124
• Fuel system programmed fuel injection 127
• Pgm fi mil 2 blinks map sensor 127
• Fuel system programmed fuel injection 129
• Pgm fi mil 7 blinks ect sensor 129
• Fuel system programmed fuel injection 130
• Fuel system programmed fuel injection 131
• Pgm fi mil 8 blinks tp sensor 131
• Fuel system programmed fuel injection 132
• ______ i_________ 132
• Fuel system programmed fuel injection 133
• Fuel system programmed fuel injection 134
• Fuel system programmed fuel injection 136
• Fuel system programmed fuel injection 137
• Pgm fi mil 11 blinks vehicle speed sensor 137
• Fuel system programmed fuel injection 138
• Fuel system programmed fuel injection 139
• Pgm fi mil 12 blinks no injector 139
• Fuel system programmed fuel injection 140
• Fuel system programmed fuel injection 141
• Fuel system programmed fuel injection 142
• Pgm fi mil 13 blinks no injector 142
• Fuel system programmed fuel injection 143
• Fuel system programmed fuel injection 144
• Fuel system programmed fuel injection 145
• I _______ 145
• Pgm fi mil 14 blinks no injector 145
• Fuel system programmed fuel injection 146
• _____ i______ 146
• Fuel system programmed fuel injection 147
• Fuel system programmed fuel injection 148
• Pgm fi mil 15 blinks no injector 148
• Fuel system programmed fuel injection 149
• Fuel system programmed fuel injection 150
• Fuel system programmed fuel injection 153
• Pgm fi mil 19 blinks ignition pulse generator 153
• Fuel system programmed fuel injection 154
• Fuel system programmed fuel injection 155
• Pgm fi mil 21 blinks 155
• Sensor california type only 155
• Fuel system programmed fuel injection 156
• _ ______ i_______ 156
• Fuel system programmed fuel injection 159
• Fuel system programmed fuel injection 160
• Fuel system programmed fuel injection 162
• Fuel line inspection 163
• Fuel pressure inspection 163
• Fuel system programmed fuel injection 163
• Notice 163
• Fuel system programmed fuel injection 164
• Fuel flow inspection 165
• Fuel system programmed fuel injection 165
• Fuel pump 166
• Fuel system programmed fuel injection 166
• Inspection 166
• Notice 166
• Removal 166
• Fuel cut relay 167
• Fuel filter replacement 167
• Fuel system programmed fuel injection 167
• Inspection 167
• Installation 167
• Fuel system programmed fuel injection 168
• Fuel tank 168
• Removal 168
• Fuel system programmed fuel injection 169
• I notice i 169
• Notice 169
• Fuel system programmed fuel injection 170
• Installation 170
• Fuel system programmed fuel injection 171
• Notice 171
• Notice i 171
• Fuel system programmed fuel injection 172
• Air cleaner housing 173
• Fuel system programmed fuel injection 173
• Removal 173
• Fuel system programmed fuel injection 174
• Installation 174
• Fuel system programmed fuel injection 175
• Removal 175
• Throttle body 175
• Fuel system programmed fuel injection 176
• Notice 176
• Fuel system programmed fuel injection 177
• Notice 177
• Fuel system programmed fuel injection 178
• Fuel system programmed fuel injection 179
• Installation 179
• Throttle body vacuum hose routing 179
• Fuel system programmed fuel injection 180
• Notice 180
• Fuel system programmed fuel injection 181
• Fuel system programmed fuel injection 182
• Injector 182
• Inspection 182
• Installation 182
• Removal 182
• Fuel system programmed fuel injection 183
• Notice 183
• Pressure regulator 183
• Removal installation 183
• Disassembly 184
• Fast idle wax unit 184
• Fuel system programmed fuel injection 184
• Assembly 185
• Fuel system programmed fuel injection 185
• Inspection 185
• Disassembly 186
• Fuel system programmed fuel injection 186
• Starter valve 186
• Fuel system programmed fuel injection 187
• Fuel system programmed fuel injection 188
• Fuel system programmed fuel injection 189
• Fuel system programmed fuel injection 190
• Starter valve synchronization 190
• Fuel system programmed fuel injection 191
• Fuel system programmed fuel injection 192
• Map sensor 192
• Map sensor removal installa 192
• Output voltage inspection 192
• Ect sensor 193
• Fuel system programmed fuel injection 193
• Iat sensor 193
• Removal installation 193
• Cam pulse generator 194
• Fuel system programmed fuel injection 194
• Removal installation 194
• Fuel system programmed fuel injection 195
• Inspection 195
• Tp sensor 195
• Bank angle sensor 196
• Fuel system programmed fuel injection 196
• Inspection 196
• Fuel system programmed fuel injection 197
• Removal installation 197
• Ecm engine control module 198
• Engine stop relay 198
• Fuel system programmed fuel injection 198
• Inspection 198
• Power ground line inspection 198
• Removal installat1on 198
• Fuel system programmed fuel injection 199
• Inspection 199
• Pair solenoid valve 199
• Removal installation 199
• Evap purge control valve cali fornia type only 200
• Fuel system programmed fuel injection 200
• Inspection 200
• Removal 200
• Fuel system programmed fuel injection 201
• Notice 201
• O2 sensor california type only 201
• Removal 201
• Fuel system programmed fuel injection 202
• Cooling system 203
• A caution 204
• A warning__________ _ _________ kl 204
• Cooling system 204
• Service information 204
• Cooling system 205
• Specifications 205
• Torque values 205
• Troubleshooting 205
• Coolant hydrometer test 206
• Cooling system 206
• System testing 206
• Coolant replacement 207
• Cooling system 207
• Notice 207
• Preparation 207
• Radiator cap system pressure inspection 207
• Replacement air bleeding 207
• Cooling system 208
• Cooling system 209
• Inspection 209
• Thermostat 209
• Thermostat removal 209
• Cooling system 210
• Thermostat housing installation 210
• Thermostat housing removal 210
• Thermostat installation 210
• Cooling system 211
• Radiator 211
• Removal 211
• Cooling system 212
• Disassembly 212
• Assembly 213
• Cooling system 213
• Cooling system 214
• Installation 214
• Cooling system 215
• Cooling system 216
• Mechanical seal inspection 216
• Removal 216
• Water pump 216
• Cooling system 217
• Cooling system 218
• Radiator reserve tank 218
• Removal 218
• Cooling system 219
• Installation 219
• Cooling system 220
• Engine removal installation 221
• Engine removal installation 222
• Engine removal installation 223
• General 223
• Notice 223
• Service data 223
• Service information 223
• Torque values 223
• Engine removal installation 224
• Shock link lower bracket removal 224
• Engine removal installation 225
• Engine removal 226
• Engine removal installation 226
• Engine removal installation 227
• Engine removal installation 228
• Engine removal installation 229
• Engine removal installation 230
• Engine installation 231
• Engine removal installation 231
• Notice 231
• Engine rem0val 1nstallati0n 232
• Engine removal installation 233
• Engine removal installation 234
• Engine removal installation 235
• Engine removal installation 236
• Engine removal installation 237
• Shock link lower bracket installation 237
• Engine removal installation 238
• Engine removal installation 239
• Engine removal installation 240
• Cylinder head valves 241
• Cylinder head valves 242
• Service information 242
• Cylinder head valves 243
• Specifications 243
• Torque values 243
• Cylinder head valves 244
• Troubleshooting 244
• Cylinder compression test 245
• Cylinder head cover removal 245
• Cylinder head valves 245
• Cylinder head cover disassembly 246
• Cylinder head valves 246
• Camshaft removal 247
• Cylinder head valves 247
• Cylinder head valves 248
• Cylinder head valves 249
• Notice 249
• Cylinder head valves 250
• Inspection 250
• Cylinder head valves 251
• Cylinder head removal 252
• Cylinder head valves 252
• Cylinder head disassembly 253
• Cylinder head valves 253
• Cylinder head 254
• Cylinder head inspection 254
• Cylinder head valves 254
• Notice 254
• Cam chain tensioner cam chain guide 255
• Cylinder head valves 255
• Exhaust 35 7 mm 1 00 in 255
• Inner 35 7 mm 1 00 in 255
• Inspect each valve lifter for scratches or abnormal weai 255
• Intake outer 41 6 mm 1 28 in 255
• Service limit 25 7 mm 1 22 in 255
• Service limit 26 4 mm 1 25 in 255
• Service limits 255
• Valve lifter 255
• Valve lifter bore 255
• Valve spring 255
• Cylinder head valves 256
• Valve valve guide 256
• Cylinder head valves 257
• Notice 257
• Valve guide replacement 257
• Valve seat inspection refacing 257
• Cylinder head valves 258
• Valve seat refacing 258
• Cylinder head valves 259
• Cylinder head assembly 260
• Cylinder head valves 260
• Notice i 260
• Cylinder head valves 261
• Notice 261
• Cylinder head installation 262
• Cylinder head valves 262
• Cylinder head valves 263
• Camshaft installation 264
• Cylinder head valves 264
• Cylinder head valves 265
• Cylinder head valves 266
• Cylinder head valves 267
• Cylinder head cover assembly 268
• Cylinder head valves 268
• Cylinder head cover installation 269
• Cylinder head valves 269
• Cam chain tensioner lifter 270
• Cylinder head valves 270
• Removal 270
• Cylinder head valves 271
• Installation 271
• Cylinder head valves 272
• Clutch gearshift linkage 273
• Clutch 9 4 274
• Clutch gearshift linkage 274
• Gearshift linkage 9 12 274
• General 274
• Right crankcase cover installation 9 15 274
• Right crankcase cover removal 274
• Service information 274
• Service information 9 1 274
• Specifications 274
• Torque values 274
• Troubleshooting 9 2 274
• Clutch gearshift linkage 275
• Troubleshooting 275
• Clutch gearshift linkage 276
• Right crankcase cover removal 276
• Clutch 277
• Clutch gearshift linkage 277
• Clutch lifter lever 277
• Removal 277
• Clutch gearshift linkage 278
• Clutch gearshift linkage 279
• Inspection 279
• Clutch gearshift linkage 280
• Clutch gearshift linkage 281
• Clutch outer needle bearing replacement 281
• Clutch gearshift linkage 282
• Installation 282
• Clutch gearshift linkage 283
• Clutch gearshift linkage 284
• Clutch gearshift linkage 285
• Gearshift linkage 285
• Gearshift linkage removal 285
• Clutch gearshift linkage 286
• Gearshift linkage inspection 286
• Gearshift linkage installation 286
• Clutch gearshift linkage 287
• F o z is s 288
• Clutch gearshift linkage 289
• Alternator starter clutch 291
• Alternator cover removal 10 2 flywheel installation 10 7 292
• Alternator starter clutch 292
• General 292
• Service information 292
• Service information 10 1 flywheel removal 10 3 292
• Specifications 292
• Stator 10 2 alternator cover installation 10 8 292
• Torque values 292
• Troubleshooting 292
• Troubleshooting 10 1 starter clutch 10 5 292
• Alternator cover removal 293
• Alternator starter clutch 293
• Removal 293
• Stator 293
• Alternator starter clutch 294
• Flywheel removal 294
• Alternator starter clutch 295
• Alternator starter clutch 296
• Disassembly 296
• Inspection 296
• Starter clutch 296
• Alternator starter clutch 297
• Assembly 297
• Alternator starter clutch 298
• Flywheel installation 298
• Alternator cover installation 299
• Alternator starter clutch 299
• Alternator starter clutch 300
• Crankcase tranny 301
• Crankcase transmission 301
• Crankcase separation 11 3 crankcase assembly 11 12 302
• General 302
• Service information 302
• Service information 11 1 shift fork shift drum 11 4 302
• Specifications 302
• Tcrankcase transmissi0n 302
• Troubleshooting 112 transmission 11 6 302
• Crankcase transmission 303
• Torque values 303
• Troubleshooting 303
• Crankcase separation 304
• Crankcase transmission 304
• Crankcase transmission 305
• Removal 305
• Shift fork shift drum 305
• Crankcase transmission 306
• Installation 306
• Shift drum shift fork inspection 306
• Crankcase transmission 307
• Removal disassembly 307
• Transmission 307
• Crankcase transmission 308
• Crankcase transm1ssi0n 309
• Crankcase transmission 311
• Crankcase transmission 312
• Installation 312
• Crankcase assembly 313
• Crankcase transmission 313
• Crankcase transmission 314
• Crankcase transmission 315
• Crankshaft piston cylinder 317
• Crankshaft 12 3 piston cylinder 12 11 318
• Crankshaft piston cylinder 318
• General 318
• Service information 318
• Service information 12 1 main journal bearing 12 6 318
• Specifications 318
• Troubleshooting 12 2 crankpin bearing 12 8 318
• Crankshaft p1st0n cylinder 319
• Torque values 319
• Troubleshooting 319
• Crankshaft 320
• Crankshaft piston cylinder 320
• Inspection 320
• Primary drive sub gear removal 320
• Removal 320
• Side clearance inspection 320
• Crankshaft piston cylinder 321
• Primary drive sub gear installa tion 321
• Starter clutch needle bearing replacement 321
• Crankshaft piston cylinder 322
• Installation 322
• Bearing inspection 323
• Crankshaft piston cylinder 323
• Main journal bearing 323
• Notice 323
• Oil clearance inspection 323
• Bearing selection 324
• Crankshaft piston cylinder 324
• Bearing inspection 325
• Bearing installation 325
• Crankpin bearing 325
• Crankshaft piston cylinder 325
• Notice 325
• Bearing selection 326
• Crankshaft piston cylinder 326
• Oil clearance inspection 326
• Bearing installation 327
• Crankshaft piston cylinder 327
• Notice 327
• Crankshaft piston cylinder 328
• Piston connecting rod removal 328
• Piston cylinder 328
• Piston disassembly 328
• Piston removal 328
• Crankshaft piston cylinder 329
• Piston inspection 329
• Connecting rod inspection 330
• Crankshaft piston cylinder 330
• Cylinder inspection 330
• Crankshaft piston cylinder 331
• Piston assembly 331
• Crankshaft piston cylinder 332
• Notice 332
• Piston installation 332
• Crankshaft piston cylinder 333
• Front wheel suspension steering 335
• Front wheel suspension steering 336
• General 336
• Handlebars 13 3 steering stem 13 24 336
• Service information 336
• Service information 13 1 front wheel 13 9 336
• Specifications 336
• Troubleshooting 13 2 fork 13 14 336
• Front wheel suspension steering 337
• Torque values 337
• Troubleshooting 337
• Front wheel suspension steering 338
• Handlebar removal 338
• Handlebars 338
• Front wheel suspension steering 339
• Switch housing 339
• Front wheel suspension steering 340
• Installation 340
• M 38s 7 340
• Front wheel suspension steering 341
• Front wheel suspension steering 342
• Front wheel suspension steering 343
• Front wheel 344
• Front wheel suspension steering 344
• Removal 344
• Front wheel suspension steering 345
• Inspection 345
• Notice 345
• Disassembly 346
• Front wheel suspension steering 346
• Assembly 347
• Front wheel suspension steering 347
• Front wheel suspension steering 348
• Installation 348
• Front wheel suspension steering 349
• Removal 349
• Disassembly 350
• Front wheel suspension steering 350
• Front wheel suspension steering 351
• Illllllilllu lllinuhh 351
• Iukrthinmiih 351
• Front wheel suspension steering 352
• Front wheel suspension steering 353
• Inspection 353
• Assembly 354
• Front wheel suspension steering 354
• Front wheel suspension steering 355
• Front wheel suspension steering 356
• Front wheel suspension steering 357
• Front wheel suspension steering 358
• Installation 358
• Front wheel suspension steering 359
• Removal 359
• Steering stem 359
• Front wheel suspension steering 360
• Bearing replacement 361
• Front wheel suspension steering 361
• Front wheel suspension steering 362
• Front wheel suspension steering 363
• Front wheel suspension steering 364
• Front wheel suspension steering 365
• Front wheel suspension steering 366
• Installation 366
• Front wheel suspension steering 367
• Front wheel suspension steering 368
• Front wheel suspension steering 369
• Steering head bearing pre load 369
• Rear wheel suspension 371
• Rear wheel suspension 372
• Service information 372
• Rear wheel suspension 373
• Torque values 373
• Troubleshooting 373
• Inspection 374
• Rear wheel 374
• Rear wheel suspension 374
• Removal 374
• Disassembly 375
• Rear wheel suspension 375
• Rear wheel suspension 376
• Assembly 377
• Rear wheel suspension 377
• Rear wheel suspension 378
• Installation 379
• Rear wheel suspension 379
• Rear wheel suspension 380
• Removal 380
• Shock absorber 380
• Inspection 381
• Needle bearing replacement 381
• Rear wheel suspension 381
• Notice 382
• Rear wheel suspension 382
• Shock absorber disposal procedure 382
• Installation 383
• Rear wheel suspension 383
• Removal 383
• Suspension linkage 383
• Inspection 384
• Rear wheel suspension 384
• Shock link bearing replacement 384
• Installation 385
• Rear wheel suspension 385
• Removal 385
• Swingarm 385
• Rear wheel suspension 386
• Disassembly inspection 387
• Rear wheel suspension 387
• Rear wheel suspension 388
• Rear wheel suspension 389
• Rear wheel suspension 390
• Rear wheel suspension 391
• N x a x7 392
• Installation 393
• Rear wheel suspension 393
• Rear wheel suspension 394
• Rear wheel suspension 395
• Rear wheel suspension 396
• Hydraulic brake 397
• Hydraulic brake 398
• A caution 399
• General 399
• Hydraulic brake 399
• Service information 399
• Specifications 399
• Hydraulic brake 400
• Torque values 400
• Troubleshooting 400
• Brake fluid draining 401
• Brake fluid replacement air bleeding 401
• Hydraulic brake 401
• Notice 401
• Brake fluid filling 402
• Hydraulic brake 402
• Notice 402
• Brake bleeding 403
• Hydraulic brake 403
• Brake pad disc 404
• Front brake pad replacement 404
• Hydraulic brake 404
• Hydraulic brake 405
• Rear brake pad replacement 405
• Hydraulic brake 406
• Brake disc inspection 407
• Front master cylinder 407
• Hydraulic brake 407
• Removal 407
• Disassembly 408
• Hydraulic brake 408
• Hydraulic brake 409
• Inspection 409
• Hydraulic brake 410
• Hydraulic brake 411
• Hydraulic brake 412
• Rear master cylinder 412
• Removal 412
• Disassembly 413
• Hydraulic brake 413
• Assembly 414
• Hydraulic brake 414
• Inspection 414
• Hydraulic brake 415
• Front brake caliper 416
• Hydraulic brake 416
• Installation 416
• Removal 416
• Disassembly 417
• Hydraulic brake 417
• Assembly 418
• Hydraulic brake 418
• Inspection 418
• Hydraulic brake 419
• Installation 419
• Disassembly 420
• Hydraulic brake 420
• Rear brake caliper 420
• Removal 420
• Hydraulic brake 421
• Inspection 421
• Hydraulic brake 422
• Brake pedal 423
• Hydraulic brake 423
• Installation 423
• Removal 423
• Hydraulic brake 424
• Installation 424
• Hydraulic brake 425
• Battery charging system 427
• A warning 428
• Battery charging system 428
• Service information 428
• Battery charging system 429
• Specifications 429
• Battery charging system 430
• Troubleshooting 430
• Battery charging system 431
• Battery 432
• Battery charging system 432
• Battery testing 432
• Removal installation 432
• Voltage inspection 432
• Battery charging 433
• Battery charging system 433
• Battery charging system 434
• Charging system inspection 434
• Current leakage inspection 434
• Alternator charging coil 435
• Battery charging system 435
• Charging voltage inspection 435
• Inspection 435
• Battery charging system 436
• Regulator rectifier 436
• Removal installation 436
• System inspection 436
• Ignition system 437
• System diagram 437
• General 438
• Ignition system 438
• Service information 438
• Service information 17 1 ignition pulse generator 17 6 438
• Specifications 438
• System diagram 17 0 ignition system inspection 17 4 438
• Troubleshooting 17 3 ignition timing 17 8 438
• Ignition system 439
• Torque values 439
• Ignition system 440
• Troubleshooting 440
• Ignition coil primary peak volt age 441
• Ignition system 441
• Ignition system inspection 441
• Ignition pulse generator peak 442
• Ignition system 442
• Voltage 442
• Ignition pulse generator 443
• Ignition system 443
• Removal 443
• Ignition system 444
• Installation 444
• Ignition system 445
• Ignition timing 445
• Ignition system 446
• Electric starter 447
• Electric starter 448
• General 448
• Service information 448
• Service information 18 1 starter relay switch 18 10 448
• Specification 448
• System diagram 18 0 starter motor 18 4 448
• Torque value 448
• Troubleshooting 18 2 diode 18 11 448
• Electric starter 449
• Troubleshooting 449
• _____________l 449
• Electric starter 450
• Disassembly 451
• Electric starter 451
• Removal 451
• Starter motor 451
• Electric starter 452
• Inspection 452
• Electric starter 453
• Assembly 454
• Electric starter 454
• Electric starter 455
• Notice 455
• Electric starter 456
• Installation 456
• Electric starter 457
• Ground line inspection 457
• Operation inspection 457
• Starter relay switch 457
• Starter relay voltage inspection 457
• Continuity inspection 458
• Electric starter 458
• Inspection 458
• Installation 458
• Removal 458
• Lights meters switches 459
• System location 459
• Wiring diagram 460
• Z mbw a100 0030z mbw l100 460
• Lights meters switches 461
• Service information 461
• Lights meters switches 462
• Specifications 462
• Torque values 462
• Lights meters switches 463
• Speed sensor speedometer 463
• Troubleshooting 463
• ________j_____________________ 463
• Bulb replacement 464
• Headlight 464
• Lights meters switches 464
• Lights meters switches 465
• Removal installation 465
• Bulb replacement 466
• Lights meters switches 466
• Removal installation 466
• Turn signal 466
• Bulb replacement 467
• License light 467
• Lights meters switches 467
• Removal installation 467
• Tail brake light 467
• Combination meter 468
• Disassembly 468
• Lights meters switches 468
• Removal 468
• Assembly 469
• Lights meters switches 469
• Installation 470
• Lights meters switches 470
• Lights meters switches 471
• Power ground line inspection 471
• Speedometer vehicle speed sensor 471
• System inspection 471
• Lights meters switches 472
• Removal installation 472
• Speed sensor inspection 472
• Lights meters switches 473
• System inspection 473
• Tachometer 473
• Coolant temperature gauge sensor 474
• Lights meters switches 474
• Thermo sensor unit inspection 474
• Cooling fan motor switch 475
• Inspection 475
• Lights meters switches 475
• Inspection 476
• Lights meters switches 476
• Oil pressure switch 476
• Removal installation 476
• Fuel reserve sensor 477
• Inspection 477
• Lights meters switches 477
• Removal installation 477
• Ignition switch 478
• Inspection 478
• Lights meters switches 478
• Removal installation 478
• Handlebar switches 479
• Lights meters switches 479
• Brake light switch 480
• Clutch switch 480
• Lights meters switches 480
• Neutral switch 480
• Inspection 481
• Installation 481
• Lights meters switches 481
• Removal 481
• Side stand switch 481
• L1ghts meters switches 482
• Inspection 483
• Lights meters switches 483
• Turn signal relay 483
• Fuel reserve trip indicator 485
• System diagram 485
• Techincal feature 485
• Technical feature 485
• Function 486
• Technical feature 486
• Engine does not start or is hard to start 487
• Engine does not start or is poor performance at high 487
• Engine lacks power 22 2 poor handling 487
• Hard to start 22 1 speed 487
• Poor performance at low and idle speed 22 3 487
• Trouble shooting 487
• Troubleshooting 487
• Engine lacks power 488
• Troubleshooting 488
• Poor performance at low and idle speed 489
• Troubleshooting 489
• Poor handling 490
• Poor performance at high speed 490
• Troubleshooting 490

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ENGINE REMOVAL INSTALLATION Route the side stand wire properly connect the side stand switch 2P Green connector Install the following Throttle body page 5 66 Muffler exhaust pipe page 2 20 Install the removed parts in the reverse order of removal 2P GREEN CONNECTOR