Honda CBR650RA - Shop Manual

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SHOP MANUAL

CBR650RA, CB650RA

CBR650RA

M,

CB650RA

M

CBR650RA

N,

CB650RA

N

Table of Contents

A Few Words About Safety2
- Service Information2
- For Your Customer’s Safety2
- For Your Safety2
- Important Safety Precautions2
How To Use This Manual3
SYMBOLS4
1. GENERAL INFORMATION7
- SERVICE RULES8
  - ABBREVIATION8
  - DESTINATION CODE8
- MODEL IDENTIFICATION9
  - SERIAL NUMBERS/LABELS10
- SPECIFICATIONS11
- TORQUE VALUES17
  - STANDARD TORQUE VALUES17
  - ENGINE & FRAME TORQUE VALUES18
- LUBRICATION & SEAL POINTS23
  - ENGINE23
  - FRAME24
- SPECIAL TOOL LIST26
- CABLE & HARNESS ROUTING28
- EMISSION CONTROL SYSTEMS54
- TECHNICAL FEATURE57
  - OBD (On-Board Diagnostic) SYSTEM57
  - OBD2 (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models)59
2. FRAME/BODY PANELS/EXHAUST SYSTEM61
- SERVICE INFORMATION62
  - GENERAL62
- TROUBLESHOOTING62
- BODY PANEL LOCATIONS/REMOVAL CHART63
  - CBR650RA63
  - CB650RA64
- REARVIEW MIRROR65
  - REMOVAL/INSTALLATION65
- FRONT FENDER65
  - REMOVAL/INSTALLATION65
- WINDSCREEN (CBR650RA)66
  - REMOVAL/INSTALLATION66
- MIDDLE COWL (CBR650RA)67
  - REMOVAL/INSTALLATION67
  - DISASSEMBLY/ASSEMBLY67
- TANK COVER67
  - REMOVAL/INSTALLATION67
- INTAKE AIR DUCT (CBR650RA)68
  - REMOVAL/INSTALLATION68
- UPPER INNER PANEL (CBR650RA)68
  - REMOVAL/INSTALLATION68
- METER PANEL (CBR650RA)68
  - REMOVAL/INSTALLATION68
- FRONT COWL (CBR650RA)69
  - REMOVAL/INSTALLATION69
- FRONT LOWER COWL (CBR650RA)69
  - REMOVAL/INSTALLATION69
- FRONT COWL STAY (CBR650RA)69
  - REMOVAL/INSTALLATION69
- SHROUD (CB650RA)70
  - REMOVAL/INSTALLATION70
  - DISASSEMBLY/ASSEMBLY70
- UNDER COWL (CBR650RA)71
  - REMOVAL/INSTALLATION71
  - DISASSEMBLY/ASSEMBLY71
- MAIN SEAT71
  - REMOVAL/INSTALLATION71
- PILLION SEAT72
  - REMOVAL/INSTALLATION72
- SIDE COVER72
  - REMOVAL/INSTALLATION72
- REAR COWL72
  - REMOVAL/INSTALLATION72
- REAR FENDER STAY73
  - REMOVAL/INSTALLATION73
  - DISASSEMBLY/ASSEMBLY73
- REAR FENDER B74
  - REMOVAL/INSTALLATION74
- FRONT LICENSE PLATE STAY75
  - REMOVAL/INSTALLATION75
- DRIVE SPROCKET COVER75
  - REMOVAL/INSTALLATION75
- DRIVE CHAIN COVER/MUD GUARD76
  - REMOVAL/INSTALLATION76
  - DISASSEMBLY/ASSEMBLY76
- SIDESTAND76
  - REMOVAL/INSTALLATION76
- FOOTPEG BRACKET77
  - REMOVAL/INSTALLATION77
- EXHAUST PIPE/MUFFLER77
  - MUFFLER PROTECTOR REMOVAL/ INSTALLATION77
  - REMOVAL/INSTALLATION78
  - STUD BOLT REPLACEMENT78
3. MAINTENANCE79
- SERVICE INFORMATION80
  - GENERAL80
- MAINTENANCE SCHEDULE80
  - ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO, U, IIU models80
  - TH, IITH, IN, MA, IIMA, BR, IIBR models81
- FUEL LINE82
  - FUEL TANK LIFTING/LOWERING82
  - INSPECTION82
- THROTTLE OPERATION82
- AIR CLEANER83
- SPARK PLUG84
  - REMOVAL/INSTALLATION84
  - INSPECTION85
- VALVE CLEARANCE86
  - INSPECTION86
  - ADJUSTMENT87
- ENGINE OIL/OIL FILTER88
  - OIL LEVEL CHECK88
  - ENGINE OIL & FILTER CHANGE89
- ENGINE IDLE SPEED90
- EXHAUST SYSTEM (BR, IIBR models only)90
  - EXHAUST EMISSION MEASUREMENT AT IDLE90
- RADIATOR COOLANT91
- COOLING SYSTEM91
- SECONDARY AIR SUPPLY SYSTEM92
- EVAPORATIVE EMISSION CONTROL SYSTEM (Except MA, IIMA, IN, U, IIU models)92
- DRIVE CHAIN93
  - DRIVE CHAIN SLACK INSPECTION93
  - ADJUSTMENT93
  - CLEANING AND LUBRICATION94
  - SPROCKET INSPECTION94
  - REPLACEMENT94
- DRIVE CHAIN SLIDER95
- BRAKE FLUID96
  - FRONT BRAKE96
  - REAR BRAKE97
- BRAKE PADS WEAR98
  - FRONT BRAKE PADS98
  - REAR BRAKE PADS98
- BRAKE SYSTEM99
  - INSPECTION99
  - BRAKE LEVER ADJUSTMENT99
- BRAKE LIGHT SWITCH99
- HEADLIGHT AIM100
- CLUTCH SYSTEM101
- SIDESTAND101
- SUSPENSION102
  - FRONT SUSPENSION INSPECTION102
  - REAR SUSPENSION INSPECTION102
  - REAR SUSPENSION ADJUSTMENT102
- NUTS, BOLTS, FASTENERS102
- WHEELS/TIRES103
- STEERING HEAD BEARINGS103
4. PGM-FI SYSTEM105
- SERVICE INFORMATION106
  - GENERAL106
  - ECM-to-COMBINATION METER TWO-WAY SERIAL COMMUNICATION107
- SYSTEM LOCATION108
- SYSTEM DIAGRAM109
- PGM-FI TROUBLESHOOTING INFORMATION111
  - GENERAL TROUBLESHOOTING111
  - SYSTEM DESCRIPTION111
  - GST (General Scan Tool) INFORMATION112
  - MCS INFORMATION112
  - DTC READOUT113
  - ERASING DTC113
  - CIRCUIT INSPECTION114
- PGM-FI SYMPTOM TROUBLESHOOTING115
- DTC INDEX (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models)116
- DTC TROUBLESHOOTING (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models)118
  - PRIOR DIAGNOSIS118
  - COMMON TROUBLESHOOTING INFORMATION118
  - DTC P0031/DTC P0032119
  - DTC P00D1120
  - DTC P0105120
  - DTC P0106121
  - DTC P0107/DTC P0108121
  - DTC P0111122
  - DTC P0112/DTC P0113123
  - DTC P0115124
  - DTC P0117/DTC P0118124
  - DTC P011B126
  - DTC P0122/DTC P0123127
  - DTC P0125128
  - DTC P0131/DTC P0132129
  - DTC P0133/DTC P0134130
  - DTC P0201/DTC P0202/DTC P0203/ DTC P0204131
  - DTC P0300132
  - DTC P0315133
  - DTC P0351/DTC P0352134
  - DTC P0412136
  - DTC P0443137
  - DTC P0500139
  - DTC P0511140
  - DTC P0519141
  - DTC P0562141
  - DTC P0600142
  - DTC P062F143
  - DTC P064D144
  - DTC P0914144
  - DTC P1000/DTC P1001145
  - DTC P1100147
  - DTC P2158148
  - DTC P2195/DTC P2196149
  - DTC P2A00149
- DTC INDEX (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models)150
- DTC TROUBLESHOOTING (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models)152
  - P0107 (MAP SENSOR LOW VOLTAGE)152
  - P0108 (MAP SENSOR HIGH VOLTAGE)153
  - P1002 (MAP sensor performance problem)154
  - P0117 (ECT SENSOR LOW VOLTAGE)155
  - P0118 (ECT SENSOR HIGH VOLTAGE)155
  - P0122 (TP SENSOR LOW VOLTAGE)156
  - P0123 (TP SENSOR HIGH VOLTAGE)158
  - P0112 (IAT SENSOR LOW VOLTAGE)159
  - P0113 (IAT SENSOR HIGH VOLTAGE)159
  - P0201 (No. 1 FUEL INJECTOR)/ P0202 (No. 2 FUEL INJECTOR)/ P0203 (No. 3 FUEL INJECTOR)/ P0204 (No. 4 FUEL INJECTOR)160
  - P0131 (O2 SENSOR LOW VOLTAGE)162
  - P0132 (O2 SENSOR HIGH VOLTAGE)163
  - P0135 (O2 SENSOR HEATER)164
  - P0511 (IACV)165
  - P062F (EEPROM)166
  - P0914 (GEAR POSITION SWITCH)167
  - P1000 (BANK ANGLE SENSOR LOW VOLTAGE)168
  - P1001 (BANK ANGLE SENSOR HIGH VOLTAGE)169
  - P2158 (REAR WHEEL SPEED SENSOR SIGNAL)170
  - P1500 (FRONT WHEEL SPEED SENSOR SIGNAL)171
  - P0600 (SERIAL COMMUNICATION)173
  - P0443 (EVAP PURGE CONTROL SOLENOID VALVE)175
  - P0412 (PAIR CONTROL SOLENOID VALVE)176
  - P0351 (IGNITION COIL 1 PRIMARY CIRCUIT)/ P0352 (IGNITION COIL 2 PRIMARY CIRCUIT)178
- MIL CIRCUIT TROUBLESHOOTING180
- ECM180
  - REMOVAL/ INSTALLATION180
  - POWER/GROUND LINE INSPECTION181
- MAP SENSOR183
  - REMOVAL/INSTALLATION183
- ECT SENSOR183
  - REMOVAL/INSTALLATION183
- IAT SENSOR183
  - REMOVAL/INSTALLATION183
- A/F SENSOR (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models)184
  - REMOVAL/INSTALLATION184
- O2 SENSOR (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models)184
  - REMOVAL/INSTALLATION184
- GEAR POSITION SWITCH185
  - REMOVAL/INSTALLATION185
- BANK ANGLE SENSOR185
  - REMOVAL/INSTALLATION185
  - INSPECTION186
- CKP SENSOR (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models)186
  - REMOVAL/INSTALLATION186
  - CKP SENSOR LINE INSPECTION187
  - CRANK PULSE LEARNING188
- MAIN RELAY189
  - CIRCUIT INSPECTION (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models)189
  - CIRCUIT INSPECTION (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models)190
- MAIN RELAY DIODE191
  - INSPECTION191
5. IGNITION SYSTEM193
- SERVICE INFORMATION194
  - GENERAL194
- TROUBLESHOOTING195
  - ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models195
  - MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models196
- SYSTEM LOCATION197
- SYSTEM DIAGRAM197
- IGNITION SYSTEM INSPECTION199
- IGNITION TIMING202
- IGNITION COIL203
  - REMOVAL/INSTALLATION203
- CKP SENSOR (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models)203
  - REMOVAL/INSTALLATION203
6. ELECTRIC STARTER205
- SERVICE INFORMATION206
  - GENERAL206
- TROUBLESHOOTING207
- SYSTEM LOCATION208
- SYSTEM DIAGRAM208
- STARTER MOTOR209
- STARTER RELAY SWITCH211
- DIODE213
  - REMOVAL/INSTALLATION213
  - INSPECTION214
7. FUEL SYSTEM215
- SERVICE INFORMATION216
  - GENERAL216
- COMPONENT LOCATION217
- FUEL LINE INSPECTION218
- FUEL TANK221
  - REMOVAL/INSTALLATION221
- FUEL FILLER CAP222
  - REMOVAL/INSTALLATION222
- FUEL PUMP UNIT222
- AIR CLEANER HOUSING226
  - REMOVAL/INSTALLATION226
- THROTTLE BODY227
  - REMOVAL/INSTALLATION227
  - DISASSEMBLY/ASSEMBLY229
- INSULATOR230
  - REMOVAL/INSTALLATION230
- FUEL INJECTOR230
  - REMOVAL/INSTALLATION230
- IACV231
- FUEL PUMP RELAY233
  - CIRCUIT INSPECTION233
- SECONDARY AIR SUPPLY SYSTEM233
- EVAP PURGE CONTROL SOLENOID VALVE (Except MA, IIMA, IN, U, IIU models)236
  - REMOVAL/INSTALLATION236
  - INSPECTION236
- EVAP CANISTER (Except MA, IIMA, IN, U, IIU models)237
  - REMOVAL/INSTALLATION237
8. COOLING SYSTEM239
- SERVICE INFORMATION240
  - GENERAL240
- TROUBLESHOOTING240
- SYSTEM FLOW PATTERN241
- SYSTEM TESTING242
  - RADIATOR CAP/SYSTEM PRESSURE INSPECTION242
- COOLANT REPLACEMENT242
  - REPLACEMENT/AIR BLEEDING242
- THERMOSTAT244
  - REMOVAL/INSTALLATION244
  - INSPECTION245
- RADIATOR/COOLING FAN245
- RADIATOR RESERVE TANK247
  - REMOVAL/INSTALLATION247
- WATER PUMP248
  - MECHANICAL SEAL INSPECTION248
  - REMOVAL/INSTALLATION248
- WATER HOSE JOINT B249
  - REMOVAL/INSTALLATION249
- THERMOSTAT CASE ASSEMBLY250
  - REMOVAL/INSTALLATION250
9. LUBRICATION SYSTEM251
- SERVICE INFORMATION252
  - GENERAL252
- TROUBLESHOOTING252
- LUBRICATION SYSTEM DIAGRAM253
- OIL PRESSURE INSPECTION254
- OIL PUMP254
- PRESSURE RELIEF VALVE256
  - REMOVAL/INSTALLATION256
  - INSPECTION256
- OIL STRAINER256
  - REMOVAL256
  - INSTALLATION257
- OIL COOLER258
  - REMOVAL/INSTALLATION258
10. CYLINDER HEAD/VALVES259
- SERVICE INFORMATION260
  - GENERAL260
- TROUBLESHOOTING260
- COMPONENT LOCATION261
- CYLINDER COMPRESSION TEST262
- CYLINDER HEAD COVER262
  - REMOVAL/INSTALLATION262
- CAMSHAFT263
- CYLINDER HEAD269
- CAM CHAIN TENSIONER LIFTER278
  - REMOVAL/INSTALLATION278
  - INSPECTION278
11. CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH279
- SERVICE INFORMATION280
  - GENERAL280
- TROUBLESHOOTING280
- COMPONENT LOCATION281
- RIGHT CRANKCASE COVER282
  - REMOVAL/INSTALLATION282
  - DISASSEMBLY/ASSEMBLY283
- CLUTCH284
- STARTER CLUTCH292
- GEARSHIFT LINKAGE297
12. ALTERNATOR301
- SERVICE INFORMATION302
  - GENERAL302
- COMPONENT LOCATION302
- LEFT CRANKCASE COVER303
  - REMOVAL/INSTALLATION303
- STATOR304
  - REMOVAL/INSTALLATION304
- FLYWHEEL305
  - REMOVAL305
  - INSTALLATION305
13. CRANKCASE/TRANSMISSION307
- SERVICE INFORMATION308
  - GENERAL308
- TROUBLESHOOTING308
- COMPONENT LOCATION309
- CRANKCASE310
  - SEPARATION310
  - ASSEMBLY311
- TRANSMISSION313
14. CRANKSHAFT/PISTON/CYLINDER319
- SERVICE INFORMATION320
  - GENERAL320
- TROUBLESHOOTING320
- COMPONENT LOCATION321
- CRANKSHAFT322
- MAIN JOURNAL BEARING325
- CRANKPIN BEARING328
- PISTON/CYLINDER331
15. ENGINE REMOVAL/INSTALLATION335
- SERVICE INFORMATION336
  - GENERAL336
- COMPONENT LOCATION337
- ENGINE REMOVAL338
- ENGINE INSTALLATION341
16. FRONT WHEEL/SUSPENSION/STEERING343
- SERVICE INFORMATION344
  - GENERAL344
- TROUBLESHOOTING344
- COMPONENT LOCATION345
- HANDLEBAR347
- FRONT WHEEL357
- FORK363
- STEERING STEM380
17. REAR WHEEL/SUSPENSION387
- SERVICE INFORMATION388
  - GENERAL388
- TROUBLESHOOTING388
- COMPONENT LOCATION389
- REAR WHEEL390
- SHOCK ABSORBER394
- SWINGARM396
18. HYDRAULIC BRAKE401
- SERVICE INFORMATION402
  - GENERAL402
- TROUBLESHOOTING402
- COMPONENT LOCATION403
  - FRONT:403
  - REAR:404
- BRAKE FLUID REPLACEMENT/AIR BLEEDING405
  - BRAKE FLUID DRAINING405
  - BRAKE FLUID FILLING/AIR BLEEDING406
- BRAKE PAD/DISC408
  - BRAKE PAD REMOVAL/ INSTALLATION408
  - BRAKE DISC INSPECTION410
- FRONT MASTER CYLINDER410
- REAR MASTER CYLINDER412
- FRONT BRAKE CALIPER414
- REAR BRAKE CALIPER415
- BRAKE PEDAL416
  - REMOVAL/INSTALLATION416
19. ANTI-LOCK BRAKE SYSTEM (ABS)417
- SERVICE INFORMATION418
  - GENERAL418
- SYSTEM LOCATION419
- SYSTEM DIAGRAM420
- ABS TROUBLESHOOTING INFORMATION422
- DTC INDEX426
- ABS INDICATOR CIRCUIT TROUBLESHOOTING428
  - ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON)428
  - ABS INDICATOR STAYS ON (Indicator does not go off when the motorcycle is running)428
- ABS TROUBLESHOOTING430
- WHEEL SPEED SENSOR439
  - AIR GAP INSPECTION439
  - REMOVAL/INSTALLATION439
- ABS MODULATOR442
  - REMOVAL/INSTALLATION442
20. BATTERY/CHARGING SYSTEM443
- SERVICE INFORMATION444
  - GENERAL444
- TROUBLESHOOTING445
- SYSTEM LOCATION446
- SYSTEM DIAGRAM446
- BATTERY447
  - REMOVAL/INSTALLATION447
  - VOLTAGE INSPECTION447
- CHARGING SYSTEM INSPECTION448
  - CURRENT LEAKAGE TEST448
  - CHARGING VOLTAGE INSPECTION448
- ALTERNATOR CHARGING COIL449
  - INSPECTION449
- REGULATOR/RECTIFIER449
  - WIRE HARNESS INSPECTION449
  - REMOVAL/INSTALLATION449
21. LIGHTS/METERS/SWITCHES451
- SERVICE INFORMATION452
  - GENERAL452
- SYSTEM LOCATION452
- HEADLIGHT453
  - REMOVAL/INSTALLATION453
  - DISASSEMBLY/ASSEMBLY453
- TURN SIGNAL LIGHT454
  - FRONT TURN SIGNAL LIGHT REMOVAL/INSTALLATION454
  - REAR TURN SIGNAL LIGHT REMOVAL/INSTALLATION454
- BRAKE/TAIL LIGHT455
  - BRAKE/TAIL LIGHT UNIT REMOVAL/ INSTALLATION455
- LICENSE LIGHT455
  - REMOVAL/INSTALLATION455
- COMBINATION METER456
  - INITIAL OPERATION CHECK456
  - POWER/GROUND LINE INSPECTION456
  - SERIAL COMMUNICATION LINE INSPECTION457
  - REMOVAL/INSTALLATION458
  - DISASSEMBLY/ASSEMBLY460
  - DIGITAL CLOCK SETTING PROCEDURE460
- SPEEDOMETER460
  - SYSTEM INSPECTION460
- TACHOMETER461
  - SYSTEM INSPECTION461
- COOLANT TEMPERATURE GAUGE/ECT SENSOR461
  - SYSTEM INSPECTION461
  - ECT SENSOR INSPECTION461
- ENGINE OIL PRESSURE INDICATOR/ EOP SWITCH462
  - SYSTEM INSPECTION462
  - EOP SWITCH LINE INSPECTION462
  - EOP SWITCH REMOVAL/ INSTALLATION463
- FUEL GAUGE/FUEL LEVEL SENSOR463
  - FUEL GAUGE INSPECTION463
  - FUEL LEVEL SENSOR INSPECTION464
  - REMOVAL/INSTALLATION464
- IGNITION SWITCH464
  - INSPECTION464
  - REMOVAL/INSTALLATION465
- HANDLEBAR SWITCH466
  - LEFT HANDLEBAR SWITCH466
  - RIGHT HANDLEBAR SWITCH466
- BRAKE LIGHT SWITCH467
  - FRONT467
  - REAR467
- CLUTCH SWITCH468
- SIDESTAND SWITCH468
  - INSPECTION468
  - REMOVAL/INSTALLATION468
- HORN469
  - INSPECTION469
  - REMOVAL/INSTALLATION469
- HSTC (Honda Selectable Torque Control) SYSTEM470
  - SYSTEM INSPECTION470
  - TORQUE CONTROL SWITCH INSPECTION470
- TURN SIGNAL RELAY471
  - REMOVAL/INSTALLATION471
  - SYSTEM INSPECTION471
  - ESS SYSTEM INSPECTION472
- CONTROL RELAY474
  - RELAY REMOVAL/INSTALLATION474
  - RELAY INSPECTION474
- USB CHARGER UNIT (Except KO, IIKO, U, IIU, BR, IIBR)475
  - INSPECTION475
  - REMOVAL/INSTALLATION475
22. IMMOBILIZER SYSTEM (HISS)477
- SERVICE INFORMATION478
  - GENERAL478
- SYSTEM LOCATION478
- SYSTEM DIAGRAM479
- KEY REGISTRATION PROCEDURES (ED, IIED, IIIED, IVED, FO, IIFO, KO, IIKO models)480
- KEY REGISTRATION PROCEDURES (MA, IIMA, IN, TH, IITH, U, IIU, BR, IIBR models)483
- DIAGNOSTIC CODE INDICATION487
- TROUBLESHOOTING489
- IMMOBILIZER RECEIVER490
  - INSPECTION490
  - REMOVAL/INSTALLATION492
- REPLACEMENT PARTS FOR PROBLEM493
23. WIRING DIAGRAMS495

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