Honda CBR600F4I (2001-2003) [305/492] Crankcase transmission

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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CRANKCASE TRANSMISSION Place the engine with the upper side down Loosen the two 6 mm bolts six 7 mni bolls Leri 8 mrn bolls and 10 mm bolt in a crisscross pattern in two or three steps Remove the bolts and sealing washers Separate the crankcase lower crankcase from the upper Remove the three dowel pins and two oil orifices If necessary remove the swingarm pivot collar from the lower crankcase Clean any sealant off from the crankcase mating sur face DOWFL PINS SHIFT FORK SHIFT DRUM REMOVAL Separate the crankcase halves page 11 3 Remove the shift drum bearing set plate bolt washer Remove the shift fork shaft and shift forks Remove the shift drum 11 4