Honda CBR600F4I 2001 - Piston Assembly

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Contents2
Symbols3
General Information4
Service Rules4
Model Identification4
Frame Serial Number5
Vehicle Identification Number (VIN)5
Color Label5
Engine Serial Number5
Specifications6
Torque Values15
Insulator Clamp (Throttle Body Side)17
Insulator Clamp (Cylinder Head Side)17
Exhaust Pipe Stud Bolt17
Tools20
Lubrication & Seal Points22
Cable & Harness Routing26
Emission Control Systems41
Crankcase Emission Control System41
Exhaust Emission Control System (Pulse Secondary Air Supply System)42
Evaporative Emission Control System43
Noise Emission Control System43
Emission Control Information Labels (U.S.A. Only)44
Vacuum Hose Routing Diagram Label (California Type Only)44
Body Panel Locations45
Frame/Body Panels/Exhaust System Service Information46
Frame/Body Panels/Exhaust System Troubleshooting46
Seat Removal47
Seat Installation47
Pillion Seat/Rear Cowl Removal47
Pillion Seat/Rear Cowl Installation48
Lower Cowl Removal49
Lower Cowl Installation50
Upper Cowl Removal52
Upper Cowl Installation54
Front Fender Removal57
Front Fender Installation57
Rear Fender Removal58
Rear Fender Installation59
Seat Rail Removal61
Seat Rail Installation62
Muffler/Exhaust Pipe Removal64
Muffler/Exhaust Pipe Installation65
Maintenance Service Information70
Maintenance Specifications71
Maintenance Schedule72
Fuel Line73
Throttle Operation73
Air Cleaner74
Spark Plug Removal75
Spark Plug Inspection76
Valve Clearance Inspection78
Valve Clearance Adjustment81
Engine Oil/Oil Filter83
Engine Oil Level Inspection83
Engine Oil & Filter Change84
Engine Idle Speed86
Radiator Coolant86
Cooling System86
Secondary Air Supply System87
Evaporative Emission Control System (California Type Only)88
Drive Chain Slack Inspection88
Drive Chain Slack Adjustment88
Drive Chain Cleaning and Lubrication89
Drive Chain Sprockets Inspection89
Drive Chain Replacement90
Front Brake Fluid92
Rear Brake Fluid92
Front Brake Pads Wear93
Rear Brake Pads Wear93
Brake System Inspection93
Brake Lever Adjustment93
Brake Light Switch94
Headlight Aim94
Brake Pedal Height Adjustment94
Clutch System95
Side Stand95
Front Suspension Inspection96
Front Suspension Adjustment96
Rear Suspension Inspection97
Compression and Rebound Damping Adjusters97
Compression Adjuster Standard Position97
Rear Suspension Adjustment98
Nuts, Bolts, Fasteners99
Wheels/Tires99
Recommended Tire Pressure and Tire Size99
Minimum Tread Depth99
Steering Head Bearings100
Lubrication System Diagram101
Lubrication System Service Information102
Lubrication System Specifications102
Lubrication System Troubleshooting103
Oil Pressure Inspection104
Oil Strainer/Pressure Relief Valve Removal104
Oil Strainer/Pressure Relief Valve Inspection105
Oil Pump Removal106
Oil Pump Disassembly107
Oil Pump Inspection107
Oil Pump Assembly108
Oil Pump Installation109
Oil Cooler Removal109
Oil Cooler Inspection110
Oil Cooler Installation110
Fuel System (Programmed Fuel Injection)113
Fuel System (Programmed Fuel Injection) Service Information114
Fuel System (Programmed Fuel Injection) Specifications115
Fuel System (Programmed Fuel Injection) Troubleshooting116
System Location117
System Diagram118
PGM-FI (Programmed Fuel Injection) System119
Self-Diagnostic Procedures119
Self-Diagnosis Reset Procedure120
Peak Voltage Inspection Procedure121
Test Harness Connection121
Test Harness Terminal Layout122
PGM-FI Self-Diagnosis Malfunction Indicator Lamp (MIL) Failure Codes123
PGM-FI MIL 1 Blink (Map Sensor)125
PGM-FI MIL 2 Blinks (Map Sensor)127
PGM-FI MIL 7 Blinks (ECT Sensor)129
PGM-FI MIL 8 Blinks (TP Sensor)131
PGM-FI MIL 9 Blinks (IAT Sensor)135
PGM-FI MIL 11 Blinks (Vehicle Speed Sensor)137
PGM-FI MIL 12 Blinks (No.1 Injector)139
PGM-FI MIL 13 Blinks (No.2 Injector)142
PGM-FI MIL 14 Blinks (No. 3 Injector)145
PGM-FI MIL 15 Blinks (No. 4 Injector)148
PGM-FI MIL 18 Blinks (Cam Pulse Generator)151
PGM-FI MIL 19 Blinks (Ignition Pulse Generator)153
PGM-FI MIL 21 Blinks (O2 Sensor/California Type Only)155
PGM-FI MIL 23 Blinks (O2 Sensor Heater/California Type Only)157
PGM-FI MIL 33 Blinks (E2-Prom)161
Fuel Line Inspection163
Fuel Pressure Inspection163
Fuel Flow Inspection165
Fuel Pump Inspection166
Fuel Pump Removal166
Fuel Filter Replacement167
Fuel Pump Installation167
Fuel Cut Relay Inspection167
Fuel Tank Removal168
Fuel Tank Installation170
Air Cleaner Housing Removal173
Air Cleaner Housing Installation174
Throttle Body Removal175
Throttle Body Top View177
Throttle Body Rear View177
Throttle Drum View178
Throttle Link View178
Right Side View178
Starter Valve Link View178
Throttle Body Vacuum Hose Routing179
Injector Inspection182
Injector Removal182
Injector Installation182
Pressure Regulator Removal/Installation183
Fast Idle Wax Unit Disassembly184
Fast Idle Wax Unit Inspection185
Fast Idle Wax Unit Assembly185
Starter Valve Disassembly186
Starter Valve Assembly188
Starter Valve Synchronization190
Output Voltage Inspection192
Map Sensor Removal/Installation192
IAT Sensor Removal/Installation193
ECT Sensor Removal/Installation193
Cam Pulse Generator Removal/Installation194
TP Sensor Inspection195
Back Angle Sensor Inspection196
Continuity Inspection196
Back Angle Sensor Removal/Installation197
Engine Stop Relay Inspection198
ECM (Engine Control Module) Removal/Installation198
Power/Ground Line Inspection198
Pair Solenoid Valve Removal/Installation199
Pair Solenoid Valve Inspection199
EVAP Purge Control Valve (California Type Only) Removal200
EVAP Purge Control Valve (California Type Only) Inspection200
O2 Sensor Removal201
System Flow Pattern203
Cooling System Service Information204
Cooling System Specifications205
Cooling System Troubleshooting205
Cooling System Testing206
Coolant (Hydrometer Test)206
Coolant Gravity Chart206
Coolant Replacement207
Radiator Cap/System Pressure Inspection207
Radiator Cap Relief Pressure207
Replacement/Air Bleeding207
Thermostat Removal209
Thermostat Inspection209
Thermostat Housing Removal210
Thermostat Housing Installation210
Thermostat Installation210
Radiator Removal211
Radiator Disassembly212
Radiator Assembly213
Radiator Installation214
Mechanical Seal Inspection216
Water Pump Removal216
Water Pump Installation217
Radiator Reserve Tank Removal218
Radiator Reserve Tank Installation219
Engine Removal/Installation222
Engine Removal/Installation Service Information223
Shock Link Lower Bracket Removal224
Engine Removal226
Engine Installation231
Shock Link Lower Bracket Installation237
Cylinder Head/Valves Service Information242
Cylinder Head/Valves Specifications243
Cylinder Head/Valves Troubleshooting244
Cylinder Compression Test245
Cylinder Head Cover Removal245
Cylinder Head Cover Disassembly246
Camshaft Removal247
Camshaft Inspection250
Camshaft Holder250
Cam Chain Guide B251
Camshaft Oil Clearance251
Cylinder Head Removal252
Cylinder Head Disassembly253
Cylinder Head Inspection254
Valve Lifter Bore255
Valve Lifter255
Valve Spring255
Cam Chain Tensioner/Cam Chain Guide255
Valve/Valve Guide256
Valve Guide Replacement257
Valve Seat Inspection/Refacing257
Valve Seat Refacing258
Cylinder Head Assembly260
Cylinder Head Installation262
Camshaft Installation264
Cylinder Head Cover Assembly268
Cylinder Head Cover Installation269
Cam Chain Tensioner Lifter Removal270
Cam Chain Tensioner Lifter Installation271
Clutch/Gearshift Linkage Service Information274
Clutch/Gearshift Linkage Specifications274
Clutch/Gearshift Linkage Troubleshooting275
Right Crankcase Cover Removal276
Clutch Lifter Lever277
Clutch Removal277
Clutch Inspection279
Clutch Lifter Bearing279
Clutch Center280
Clutch Lifter Piece280
Clutch Disc280
Clutch Plate280
Clutch Outer Needle Bearing Replacement281
Clutch Outer/Clutch Outer Guide281
Mainshaft281
Clutch Installation282
Gearshift Linkage Removal285
Gearshift Linkage Inspection286
Gearshift Linkage Installation286
Right Crankcase Cover Installation288
Alternator/Starter Clutch Service Information292
Alternator/Starter Clutch Specifications292
Alternator/Starter Clutch Troubleshooting292
Alternator Cover Removal293
Stator Removal293
Flywheel Removal294
Alternator Cover Installation294
Starter Clutch Inspection296
Starter Clutch Disassembly296
Starter Clutch Assembly297
Flywheel Installation298
Crankcase/Transmission Service Information302
Crankcase/Transmission Specifications302
Crankcase/Transmission Troubleshooting303
Crankcase Separation304
Shift Fork/Shift Drum Removal305
Shift Drum/Shift Fork Inspection306
Shift Drum/Shift Form Installation306
Transmission Removal/Disassembly307
Mainshaft Bearing Replacement309
Mainshaft Bearing Assembly310
Mainshaft Bearing Installation312
Crankcase Assembly313
Crankshaft/Piston/Cylinder Service Information318
Crankshaft/Piston/Cylinder Specifications318
Crankshaft/Piston/Cylinder Troubleshooting319
Crankshaft Side Clearance Inspection320
Crankshaft Removal320
Crankshaft Inspection320
Crankshaft Primary Drive Sub-Gear Removal320
Primary Drive Sub-Gear Installation321
Starter Clutch Needle Bearing Replacement321
Starter Clutch Needle Bearing Installation322
Main Journal Bearing Inspection323
Oil Clearance Inspection323
Main Journal Bearing Selection324
Main Journal Bearing Installation325
Crankpin Bearing Inspection325
Crankpin Bearing Selection326
Crankpin Bearing Installation327
Piston/Cylinder328
Piston/Connecting Rod Removal328
Piston Removal328
Piston Disassembly328
Piston Inspection329
Connecting Rod Inspection330
Cylinder Inspection330
Piston Assembly331
Piston Installation332
Front Wheel/Suspension/Steering Service Information336
Front Wheel/Suspension/Steering Specifications336
Front Wheel/Suspension/Steering Troubleshooting337
Handlebar Removal338
Handlebar Installation340
Handlebar Weight Replacement341
Front Wheel Removal344
Front Wheel Inspection345
Axle345
Wheel Bearing345
Wheel Rim Runout345
Front Wheel Disassembly346
Front Wheel Assembly347
Front Wheel Installation348
Fork Removal349
Fork Disassembly350
Fork Inspection353
Fork Spring353
Fork Tube/Slider/Damper353
Fork Assembly354
Fork Tube Bushing354
Fork Installation358
Steering Stem Removal359
Bearing Replacement361
Steering Stem Installation366
Steering Head Bearing Pre-Load369
Rear Wheel/Suspension Service Information372
Rear Wheel/Suspension Specifications372
Rear Wheel/Suspension Troubleshooting373
Rear Wheel Removal374
Rear Wheel Inspection374
Rear Wheel Disassembly375
Driven Sprocket375
Driven Flange Bearing Removal376
Rear Wheel Assembly377
Wheel Bearing Removal377
Wheel Bearing Installation378
Driven Flange Bearing Installation378
Rear Wheel Installation379
Shock Absorber Removal380
Shock Absorber Inspection381
Needle Bearing Replacement381
Shock Absorber Disposal Procedure382
Shock Absorber Installation383
Suspension Linkage Removal383
Shock Line Bearing Replacement384
Shock Line Bearing Installation385
Swingarm Removal385
Swingarm Disassembly/Inspection387
Pivot Bearing Replacement388
Shock Link Plate Bearing Replacement390
Swingarm Assembly392
Swingarm Installation393
Hydraulic Brake Front397
Hydraulic Brake Rear398
Hydraulic Brake Service Information399
Hydraulic Brake Specifications399
Hydraulic Brake Troubleshooting400
Brake Fluid Replacement/Air Bleeding401
Brake Fluid Draining401
Brake Fluid Filling402
Brake Bleeding403
Front Brake Pad Replacement404
Rear Brake Pad Replacement405
Brake Disc Inspection407
Front Master Cylinder Removal407
Front Master Cylinder Disassembly408
Front Master Cylinder Inspection409
Front Master Cylinder Assembly410
Rear Master Cylinder Removal412
Rear Master Cylinder Disassembly413
Rear Master Cylinder Inspection414
Rear Master Cylinder Assembly414
Rear Master Cylinder Installation416
Front Brake Caliper Removal416
Front Brake Caliper Disassembly417
Front Brake Caliper Inspection418
Front Brake Caliper Assembly418
Front Brake Caliper Installation419
Rear Brake Caliper Removal420
Rear Brake Caliper Disassembly420
Rear Brake Caliper Inspection421
Rear Brake Caliper Assembly422
Rear Brake Caliper Installation423
Brake Pedal Removal423
Brake Pedal Installation424
Battery/Charging System Diagram427
Battery/Charging System Service Information428
Battery/Charging System Specifications429
Battery/Charging System Troubleshooting430
Battery Removal/Installation432
Battery Voltage Inspection432
Battery Testing432
Battery Charging433
Charging System Inspection434
Current Leakage Inspection434
Charging Voltage Inspection435
Alternator Charging Coil Inspection435
Regulator/Rectifier System Inspection436
Regulator/Rectifier Removal/Installation436
Ignition System Diagram437
Ignition System Service Diagram438
Ignition System Specifications438
Ignition System Troubleshooting440
Ignition System Inspection441
Ignition Coil Primary Peak Voltage441
Ignition Pulse Generator Peak Voltage442
Ignition Pulse Generator Removal443
Ignition Pulse Generator Installation444
Ignition Timing445
Electric Starter System Diagram447
Electric Starter Service Information448
Electric Starter Specification448
Electric Starter Troubleshooting449
Starter Motor Removal451
Starter Motor Disassembly451
Starter Motor Inspection452
Starter Motor Assembly454
Starter Motor Installation456
Starter Relay Switch Operation Inspection457
Starter Relay Switch Ground Line Inspection457
Starter Relay Voltage Inspection457
Starter Relay Switch Continuity Inspection458
Diode Removal458
Diode Inspection458
Diode Installation458
Lights/Meters/Switches System Location459
Wiring Diagram460
Lights/Meters/Switches Service Information461
Lights/Meters/Switches Specifications462
Lights/Meters/Switches Troubleshooting463
Headlight Bulb Replacement464
Headlight Removal/Installation465
Turn Signal Bulb Replacement466
Turn Signal Removal/Installation466
Tail/Brake Light Bulb Replacement467
Tail/Brake Light Removal/Installation467
License Light Bulb Replacement467
Combination Meter Removal468
Combination Meter Disassembly468
Combination Meter Assembly469
Combination Meter Installation470
Speedometer/Vehicle Speed Sensor System Inspection471
Speed Sensor Inspection472
Speed Sensor Removal/Installation472
Tachometer System Inspection473
Coolant Temperature Gauge/Sensor474
Thermo Sensor Unit Inspection474
Cooling Fan Motor Switch Inspection475
Cooling Fan Motor Switch Removal/Installation476
Oil Pressure Switch Inspection476
Oil Pressure Switch Removal/Installation477
Fuel Reserve Sensor Inspection477
Ignition Switch Inspection478
Ignition Switch Removal/Installation478
Handlebar Switches479
Brake Light Switch Front480
Brake Light Switch Rear480
Clutch Switch480
Neutral Switch480
Side Stand Switch Inspection481
Side Stand Switch Removal481
Side Stand Switch Installation481
Horn482
Turn Signal Relay Inspection483
Technical Feature485
Fuel Reserve Trip Indicator485
Function486
Troubleshooting487
Engine Does Not Start or Is Hard to Start487
Engine Lacks Power488
Poor Performance at Low and Idle Speed489
Poor Performance at High Speed490
Poor Handling490
Index491

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