![Honda CBR600F4I (2001-2003) [314/492] Crankcase transmission](/img/pdf.png)
Honda CBR600F4I (2001-2003) [314/492] Crankcase transmission
![Honda CBR600F4I (2001-2003) [314/492] Crankcase transmission](/views2/1121104/page314/bg13a.png)
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 Install the lower crankcase onto the upper crankcase Clean the new crankcase 8 mm bolts thoroughly with solvent and blow them dry Apply oil to the 8 mm bolt threads and seating sur face and install them Install the 10 mm bolt six 7 mm bolts and two 6 mm bolts Make sure the upper and lower crankcases are sealed securely From the inside to outside tighten the lower crankcase 8 mm bolts main journal bolts in a criss cross pattern in two or three steps TORQUE 25 N m 2 6 kgf m 19 lbf ft Tighten the 10 mm bolt to the specified torque and then tighten 7 mm bolts and 6 mm bolts TORQUE 10 mm bolt 39 N m 4 0 kgf m 29 lbf ft 7 mm bolt 18 N m 1 8 kgf m 13 lbf ft I he sealing wash er locations are indicated on the upper crankcase using the A mark Install the upper crankcase five 8 mm bolts and seven 6 mm bolts with new sealing washers Tighten the 8 mm bolts in a crisscross pattern in two or three steps TORQUE 25 N m 2 5 kgf m 18 lbf ft Tighten the 6 mm bolts in a crisscross pattern in two or three steps securely 11 13