Honda Fireblade 929 - Cylinder Head Cover Disassembly

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Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.

email: info@motomatrix.co.uk

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General Information1
Service Rules1
Model Identification1
Specifications3
Torque Values12
Tools17
Lubrication and Seal Points19
Cable and Harness Routing23
Emission Control Systems40
Body Panel Locations44
Frame/Body Panels/Exhaust System45
Seat Removal46
Seat Installation46
Pillion Seat/Rear Cowl Removal46
Pillion Seat/Rear Cowl Installation48
Middle/Lower Cowl Removal49
Middle/Lower Cowl Installation51
Upper Cowl Removal53
Upper Cowl Installation55
Front Fender Removal and Installation58
Rear Fender Removal and Installation58
Seat Rail Removal and Installation61
Muffler/Exhaust Pipe Removal and Installation63
Maintenance70
Maintenance Specifications71
Maintenance Schedule72
Fuel Line Maintenance73
Throttle Operation74
Air Cleaner74
Spark Plug Removal75
Spark Plug Inspection77
Valve Clearance Inspection79
Valve Adjustment82
Engine Oil/Oil Filter84
Oil Level Inspection84
Engine Oil and Filter Change85
Engine Idle Speed87
Radiator Coolant87
Recommended Antifreeze87
Secondary Air Supply System88
Evaporative Emission Control System89
Drive Chain Slack Inspection89
Drive Chain Adjustment89
Drive Chain Cleaning and Lubrication90
Sprocket Inspection90
Drive Chain Replacement91
Brake Fluid94
Brake Pad Wear94
Brake System Inspection95
Brake Light Switch95
Brake Lever Adjustment95
Brake Pedal Height Adjustment95
Headlight Aim96
Clutch System96
Side Stand97
Front Suspension Inspection97
Front Suspension Adjustment98
Spring Pre-Load Adjuster98
Compression and Rebound Damping Adjusters98
Compression Adjuster Standard Position98
Rear Suspension Adjustment99
Rebound Adjuster Standard Position99
Wheels/Tires101
Steering Head Bearings101
Recommended Tire Pressure and Tire Size101
Lubrication System102
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 Removal110
Oil Cooler Inspection110
Oil Cooler Installation111
Fuel System Diagram113
Fuel System (Programmed Fuel Injection)114
Fuel System Specifications115
Fuel System Troubleshooting116
Fuel System Location117
Fuel System Diagram (Electrical)119
PGM-FI (Programmed Fuel Injection) System Self-Diagnostics121
Peak Voltage Inspection Procedure123
Test Harness Connection123
Test Harness Terminal Layout124
PGM-FI Self-Diagnosis Malfunction Indicator Lamp Failure Codes125
PGM-FI MIL 1 Blink (Map Sensor)127
PGM-FI MIL 2 Blinks (Map Sensor)129
PGM-FI MIL 7 Blinks (ECT Sensor)131
PGM-FI MIL 8 Blinks (TP Sensor)133
PGM-FI MIL 9 Blinks (IAT Sensor)137
PGM-FI MIL 11 Blinks (Vehicle Speed Sensor)139
PGM-FI MIL 12 Blinks (No. 1 Injector)141
PGM-FI MIL 13 Blinks (No. 2 Injector)144
PGM-FI MIL 14 Blinks (No. 3 Injector)147
PGM-FI MIL 15 Blinks (No. 4 Injector)150
PGM-FI MIL 18 Blinks (Cam Pulse Generator)153
PGM-FI MIL 19 Blinks (Ignition Pulse Generator)155
PGM-FI MIL 21 Blinks (O2 Sensor/California Type Only)157
PGM-FI MIL 23 Blinks (O2 Sensor Heater/California Type Only)159
PGM-FI MIL 33 Blinks (E2-Prom)163
PGM-FI MIL 33 Blinks (Egcv/Air Intake Potentiometer Voltage)165
PGM-FI MIL 35 Blinks (EGCV and Air Intake Valve Servo Motor)167
Fuel Line Inspection169
Fuel Pressure Inspection169
Fuel Flow Inspection171
Fuel Pump Inspection172
Fuel Pump Removal172
Fuel Cut Relay Inspection173
Fuel Filter Replacement173
Fuel Pump Installation173
Fuel Tank Removal174
Fuel Tank Installation176
Air Cleaner Housing Removal179
Air Cleaner Housing Installation180
Throttle Body Removal181
Throttle Body Vacuum Tube Routing184
Throttle Body Installation184
Injector Inspection186
Injector Removal186
Injector Installation187
Pressure Regulator Removal and Installation188
Fast Idle Wax Unit Disassembly188
Fast Idle Wax Unit Inspection189
Fast Idle Wax Unit Assembly190
Starter Valve Disassembly191
Starter Valve Synchronization194
Map Sensor Output Voltage Inspection196
IAT Sensor Removal and Installation197
Map Sensor Removal and Installation197
ECT Sensor Removal and Installation198
Cam Pulse Generator Removal and Installation198
TP Sensor Inspection199
Bank Angle Sensor Inspection201
Bank Angle Sensor Removal and Installation201
Engine Stop Relay Inspection202
ECM (Engine Control Module) System Inspection202
Power/Ground Line Inspection203
Pair Solenoid Valve Removal, Installation and Inspection204
EVAP Purge Control Valve Removal205
O2 Sensor Removal205
EGCV and Air Intake Valve Inspection207
Cable Adjustment208
EGCV and Air Intake Valve Servo Motor Removal210
Intake Valve Control Cable Adjustment210
EGCV and Air Intake Valve Servo Motor Inspection211
EGCV and Air Intake Valve Servo Motor Installation211
EGCV Operating Inspection214
EGCV Removal214
EGCV Disassembly215
EGCV Shaft Bushing Replacement216
EGCV Assembly217
EGCV Installation220
Variable Air Intake Valve Disassembly222
Variable Air Intake Valve Assembly223
Cooling System225
Cooling System Specifications226
Cooling System Troubleshooting226
Cooling System Testing227
Coolant Hydrometer Test227
Coolant Gravity Chart227
Coolant Replacement228
Radiator Cap/System Pressure Inspection228
Thermostat Removal230
Thermostat Inspection230
Thermostat Housing Removal231
Thermostat Housing Installation231
Thermostat Installation231
Radiator Removal232
Radiator Disassembly233
Radiator Assembly234
Radiator Installation236
Water Pump - Mechanical Seal Inspection237
Water Pump Removal237
Water Pump Istallation239
Radiator Reserve Tank Removal240
Radiator Reserve Tank Installation241
Engine Removal/Installation243
Lower Bracket Removal244
Engine Removal Procedure245
Engine Installation Procedure248
Lower Bracket Installation253
Cylinder Head/Valves256
Cylinder Head/Valves Specifications257
Cylinder Head/Valves Troubleshooting258
Cylinder Compression Test259
Cylinder Head Cover Removal260
Cylinder Head Cover Disassembly261
Camshaft Removal262
Camshaft Holder Inspection265
Cylinder Head Removal267
Cylinder Head Disassembly268
Cylinder Head Inspection269
Valve Guide Replacement272
Valve Seat Inspection/Refacing273
Cylinder Head Installation276
Camshaft Installation278
Cylinder Head Cover Assembly283
Cylinder Head Cover Installation284
Cam Chain Tensioner Lifter Removal286
Cam Chain Tensioner Lifter Installation287
Clutch/Gearshift Linkage Specifications289
Clutch/Gearshift Linkage Troubleshooting290
Right Crankcase Cover Removal291
Clutch Lifter Lever292
Clutch Removal292
Clutch Inspection294
Clutch Outer Needle Bearing Replacement296
Clutch Installation297
Gearshift Linkage Removal300
Gearshift Linkage Inspection301
Shift Drum/Shift Fork Removal301
Shift Drum/Shift Fork Inspection302
Shift Drum/Shift Fork Installation303
Gearshift Linkage Installation304
Right Crankcase Cover Installation305
Alternator/Starter Clutch308
Alternator Cover Removal309
Stator Removal309
Flywheel Removal310
Stator Installation310
Starter Clutch Inspection312
Starter Clutch Disassembly312
Starter Clutch Assembly313
Flywheel Installation314
Alternator Cover Installation315
Crankcase/Piston/Cylinder Specifications317
Crankcase/Piston/Cylinder Troubleshooting318
Crankcase Separation319
Piston/Connecting Rod Removal320
Piston Removal320
Piston Disassembly320
Piston Inspection321
Cylinder Inspection322
Connecting Rod Inspection323
Crankpin Bearing Inspection323
Crankpin Bearing Selection324
Piston Assembly326
Piston Installation326
Crankcase Combination328
Crankshaft/Transmission Specifications331
Crankshaft/Transmission Troubleshooting332
Crankshaft Removal333
Primary Drive Sub-Gear Removal333
Primary Drive Sub-Gear Installation334
Starter Clutch Needle Bearing Replacement335
Crankshaft Runout336
Main Journal Bearing Check336
Main Journal Bearing Selection337
Main Journal Bearing Installation338
Transmission Removal and Disassembly339
Transmission Assembly341
Transmission Installation343
Front Wheel/Suspension/Steering Specifications344
Front Wheel/Suspension/Steering Troubleshooting345
Handlebars Removal346
Handlebars Installation348
Handlebar Weight Replacement349
Front Wheel Removal352
Front Wheel Inspection353
Front Wheel Disassembly355
Front Wheel Assembly355
Front Wheel Installation356
Fork Removal358
Fork Disassembly358
Fork Tube/Slider/Damper Check361
Fork Tube Bushing Check361
Fork Assembly362
Fork Installation366
Steering Stem Removal367
Bearing Replacement368
Steering Stem Installation373
Steering Head Bearing Pre-Load375
Rear Wheel/Suspension Specifications376
Rear Wheel/Suspension Troubleshooting377
Rear Wheel Removal378
Rear Wheel Inspection378
Rear Wheel Disassembly379
Rear Wheel Assembly381
Rear Wheel Installation383
Suspension Linkage Removal384
Shock Arm Bearing Replacement385
Shock Absorber Removal386
Suspension Linkage Installation386
Shock Absorber Inspection387
Needle Bearing Replacement387
Shock Absorber Disposal Procedure388
Shock Absorber Installation388
Swingarm Removal389
Swingarm Disassembly and Inspection391
Pivot Bearing Replacement394
Swingarm Assembly397
Swingarm Installation399
Hydraulic Brake402
Hydraulic Brake Specifications403
Hydraulic Brake Troubleshooting404
Brake Fluid Replacement/Air Bleeding405
Brake Fluid Draining405
Brake Fluid Filling406
Brake Bleeding407
Brape Pad/Disc408
Front Brake Pad Replacement408
Rear Brake Pad Replacement409
Front Master Cylinder Removal411
Brake Disc Inspection411
Front Master Cylinder Disassembly412
Front Master Cylinder Inspection413
Front Master Cylinder Assembly414
Rear Master Cylinder Removal417
Rear Master Cylinder Disassembly417
Rear Master Cylinder Inspection418
Rear Master Cylinder Assembly419
Rear Master Cylinder Installation420
Front Brake Caliper Removal421
Front Brake Caliper Disassembly421
Front Brake Caliper Inspection422
Front Brake Caliper Assembly423
Front Brake Caliper Installation424
Rear Brake Caliper Removal425
Rear Brake Caliper Disassembly425
Rear Brake Caliper Inspection426
Rear Brake Caliper Assembly426
Rear Brake Caliper Installation427
Brake Pedal Removal428
Brake Pedal Installation428
Battery/Charging System431
Battery/Charging System Specifications432
Battery/Charging System Troubleshooting433
Battery Removal and Installation435
Voltage Inspection435
Battery Charging435
Charging System Inspection437
Current Leakage Inspection437
Charging Voltage Inspection437
Alternator Charging Coil Inspection438
Regulator/Rectifier System Inspection438
Regulator/Rectifier Removal and Installation439
Ignition System Specifications440
Ignition System Troubleshooting442
Ignition System Inspection443
Ignition Coil Primary Peak Voltage443
Ignition Pulse Generator Peak Voltage444
Ignition Pulse Generator Removal445
Ignition Pulse Generator Installation446
Ignition Timing447
Electric Starter Specifications449
Electric Starter Troubleshooting450
Starter Motor Removal452
Starter Motor Disassembly452
Starter Motor Inspection453
Starter Motor Assembly455
Starter Motor Installation457
Starter Relay Switch Operation Inspection458
Ground Line Inspection458
Diode Removal, Inspection and Installation459
Continuity Inspection459
Lights/Meters/Switches Service Information460
Lights/Meters/Switches Specifications461
Lights/Meters/Switches Troubleshooting462
Headlight Bulb Replacement463
Headlight Removal and Installation464
Turn Signal Bulb Replacement465
Turn Signal Bulb Removal/Installation465
Tail/Brake Light Bulb Replacement466
Tail/Brake Light Removal/Installation466
License Light Bulb Replacement466
Combination Meter Removal and Disassembly467
Combination Meter Assembly468
Speedometer/Vehicle Speed Sensor Voltage Inspection469
Speedometer/Speed Sensor Output Signal Inspection469
Speedometer/Vehicle Speed Sensor Removal/Installation470
Tachometer Inspection471
Coolant Temperature Gauge/Sensor Inspection472
Thermo Sensor Unit Inspection472
Cooling Fan Motor Switch Inspection473
Oil Pressure Switch Inspection474
Cooling Fan Motor Switch Removal/Installation474
Oil Pressure Switch Removal/Installation475
Fuel Reserve Sensor Inspection476
Ignition Switch Inspection476
Handlebar Switches477
Ignition Switch Removal/Installation477
Clutch Switch479
Neutral Switch479
Side Stand Switch479
Horn481
Turn Signal Relay Inspection481
Technical Features482
H-VIX482
EGCV Control482
Intake Valve Control482
Troubleshooting485
Engine Does Not Start or Is Hard to Start485
Engine Lacks Power486
Poor Performance at Low and Idle Speed487
Poor Performance at High Speed488
Poor Handling488

Honda Fireblade 929 - Cylinder Head Cover Disassembly

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