Inspection
Wear insulated gloves and adequate eye protection. Keep flammable materials away from the electric heat ing element. Visually inspect the thermostat for damage. Heat the water with an electric heating element to operating temperature for 5 minutes. Suspend the thermostat in heated water to check its operation. Do not let the thermostat or thermometer touch the pan, or you will get false readings. Replace the thermostat if the valve stays open at room temperature, or if it responds at...
Troubleshooting Apu
Air vent tube clogged or restricted EVAP CAV solenoid valve faulty California type only, page 5-281. Air vent tube clogged or restricted EVAP CAV solenoid valve faulty California type only, page 5-28 . Engine stalls, rough idling at warm engine Air vent solenoid valve faulty see next page Incorrect air vent tube connections Engine stalls, rough idling in a strong wind Outer air vent tube out of connection Sub-air cleaner clogged or restricted Air vent tube clogged or restricted Sub-air cleaner...
Side Stand
Support the motorcycle on a level surface. Check the side stand spring for damage or loss of tension. Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary. Make sure that the side stand is not bent. Check the side stand ignition cut-off system - Sit astride the motorcycle and raise the side stand. - Start the engine with the transmission in neutral, then shift the transmission into gear, with the clutch lever squeezed. - Move the side stand fully...
Mechanical Seal Inspection
Inspect the telltale hole for signs of coolant leakage. If there is leakage, the mechanical seal is defective and the water pump assembly must be replaced.
Radiator Capsystem Pressure Inspection
The engine must be cool before removing the radiator cap, or severe scalding may result. Remove the upper fairing page 2-4 . Remove the radiator cap. Before installing the cap in the tester, wet the sealing surfaces. Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low. It must hold specified pressure for at least 6 seconds. 108 -137 kPa 1.1 - 1.4 kg cm , 15.6 - 19.9 psi Pressure the radiator, engine and hoses, and...
Brake Pad Wear
Replace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to page 14-6 for brake pad replacement.
Coolant Replacement
Radiator coolant is toxic. Keep it away from eyes, mouth skin and clothes. - If any coolant gets in your eyes, rinse them with water and consult a doctor immediately. - If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately. - If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. 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...
AIR VENT SOLENOID VALVE RELAY 49 state Canada type
AIR VENT SOLENOID VALVE RELAY VOLTAGE Remove the upper fairing page 2-4 . Check for loose or poor connection of the connector. Turn the ignition switch ON and measure the voltage between the connector terminals at the air vent solenoid valve relay connector. Connection Orange Black - ground - Standard Battery voltage Connection Black 1 - ground - Standard Battery voltage Connection Black 2 - ground - Standard Battery voltage
Troubleshooting 1
IT When checking the direct air intake system, follow the steps in the procedure on page 5-26. -Fuel tank breather tube restricted, 49 state Canada type - Evaporative emission tube No.1 restricted California type Too much fuel getting to the engine -Air cleaner clogged Fuel contaminated deteriorated Improper starting enrichment valve operation Starting enrichment valve circuit clogged Improper throttle operation No spark at plug ignition system faulty Emission control system faulty California...
EVAP CAV SOLENOID VALVE California type OPERATION CHECK
Disconnect the No.4, 8 tubes from the EVAP CAV solenoid valve. Connect the pressure pump to the No.4 tube fitting goes to EVAP canister. Pressure pump ST - AH - 255 - MC U.S.A. only Damage to the air vent solenoid valve may result from use of high pressure air source. Use a hand operated air pump only IGNITION SWITCH OFF 1 gt N0 4 TUBE fitting IGNITION SWITCH OFF 1 gt N0 4 TUBE fitting With the ignition switch OFF, pump air through the No.4 tube fitting goes to air vent solenoid valve. Connect...
Evaporative Emission Evap Purge Control Valve
Remove the EVAP purge control valve from the frame stay. Disconnect the No.11, No.5 and No.4 tube from their connections. Installation is in the reverse order of removal. The EVAP purge control valve should be inspected if hot restart is difficult. Remove the EVAP purge control valve see above . Connect a vacuum pump to the No.5 tube fitting output port that goes to the carburetors. Apply the specified vacuum to the EVAP purge control valve. Vacuum Pressure pump A937X - 041- XXXXX or Vacuum...
Air Cleaner Housingdirect Air Intake Dai Duct
Remove the air cleaner housing cover and air cleaner page 3-5 . Disconnect the cylinder head cover breather tube and remove the air cleaner base. Disconnect the sub-air cleaner tube and air vent tube from the direct air intake D.A.I. duct. Remove the trim clips. Remove the radiator mounting bolts and D.A.I, duct mounting screws. Disconnect the fan motor connector. Remove the upper fairing page 2-4 . Release the grommet on the left side radiator top from the boss. Release the hook on the filler...
Pulse Secondary Air Injection Pair Control Valve
Remove the exhaust pipe page 2-10 . Disconnect the PAIR control valve control tube and No.15 hose from the PAIR control valve. Disconnect the air injection hoses from the PAIR control valve. Remove the three bolts and PAIR control valve. Remove the four nuts and air injection pipes. Remove the air injection pipe gasket. Installation is in the reverse order of removal. Start the engine and warm it to operating temperature. Stop the engine and remove the air cleaner page 3-5 . Check the No.15...
Idle Drop Procedure
Make sure the carburetor synchronization is within specification before pilot screw adjustment. The pilot screws are factory pre-set and no adjustment is necessary unless the pilot screws are replaced. Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change. U.S.A. only Pilot screw wrench Adjustable guide 07MMA - MT3010A with 07PMA - MZ2011A 1. Turn each pilot screw clockwise until it seats lightly, then back it out to the specification given. This...
Carburetor Assembly
Install the new O-rings, air jet and air cut-off valve assembly 1 O-RINGS to the carburetor body. -- Install the screw and connect the vacuum tube. Install the pilot screws and return them to their original position as noted during removal. Perform pilot screw adjustment if new pilot screws are installed. Install the needle jet holder, main jet and slow jet. Hang the float valve onto the float arm lip. Install the float valve with float in the carburetor body, then install the float pin through...
Direct Air Intake Dai System
TO LOWER SECTION OF THE VACUUM PISTON BELOW 12 mph 20 km h AIR VENT OUTER VENT ABOVE 12 mph lt 20 km h AIR VENT INNER VENT
Carburetor Disassembly
vacuum chambers, float chambers and pilot screws can be serviced without separating the carburetors. Keep each carburetor's parts separate from the other's so you can install the parts in their original positions. Bend up the lock plate tabs and remove the screws. Remove the air chamber and air funnel assembly. Remove the O-rings. Disconnect the sub-air cleaner tube and air vent tubes from the carburetor. Disconnect the No.5 tube joint California type only from the vacuum tubes. Remove the...
Carburetor Installation
Note the cables and tubes properly page 1-20 . Connect the throttle cable ends to the throttle drum and install the throttle cables into the cable holder. Install the carburetor assembly onto the cylinder head. Tighten each insulator band screw alternately. Install the right engine hanger plate and collar. Install and tighten the hanger plate bolts. Torque 10 mm bolt 45 N m 4.5 kg-m, 33 Ib-ft Connect the carburetor heater tube to the thermostat valve. Connect the carburetor heater tube to the...
Installation
Apply oil to the new O-ring and install the pressure relief valve groove, and install the relief valve to the crankcase. Coat a new packing with the engine oil and install into the crankcase. Install the oil strainer by aligning the crankcase slot and strainer tab. Install the bolts. Tighten the bolts in a gradual, crisscross pattern. Install the exhaust pipe page 2-10 . Fill the engine with oil page 3-12 . Check that there are no oil leaks and that oil pressure is correct.
Oil Pressure Check
Remove the side fairing page 2-3 . NOTE If the engine is cold, the pressure reading will be abnormally high. Warm up the engine to normal operating temperature before starting this test. Remove the switch cover and disconnect the oil pressure switch wire by removing the screw. Remove the oil pressure switch and connect an oil pressure gauge attachment and gauge to the pressure switch hole. Oil pressure gauge attachment 07510 - 4220100 Oil pressure gauge 07506 - 3000000 or equivalent...
Info Yff
Check the valve clearance for the No.1 and No.3 cylinder intake valves using a feeler gauge. Insert the feeler gauge between the valve lifter and the cam lobe. Valve clearance IN 0.16 0.03 mm 0.006 0.001 in Record the clearance for each valve in case shim selection is required for adjustment. Turn the crankshaft clockwise 1 2 turn 180 and make sure the index line on the ignition pulse generator rotor is facing straight up as shown not aligned with the index mark . Check the valve clearance for...
Cbr 600 95 Battery Manual
5 FAN MOTOR SWITCH FAN MOTOR WIRE 5 FAN MOTOR SWITCH FAN MOTOR WIRE 6 PULSE SECONDARY AIR INJECTION PAIR CONTROL VALVE AIR INTAKE HOSE CALIFORNIA TYPE ONLY PULSE SECONDARY AIR INJECTION PAIR CONTROL VALVE TUBE CALIFORNIA TYPE ONLY 6 PULSE SECONDARY AIR INJECTION PAIR CONTROL VALVE AIR INTAKE HOSE CALIFORNIA TYPE ONLY PULSE SECONDARY AIR INJECTION PAIR CONTROL VALVE TUBE CALIFORNIA TYPE ONLY lt 3 gt IGNITION PULSE I GENERATOR 2P RED 2 SIDE STAND SWITCH 3P GREEN CONNECTOR 4 REAR BRAKE LIGHT...