2008 Honda CBR1000RR Service Manual – PDF DOWNLOAD
DESCRIPTION:
2008 Honda CBR1000RR Service Manual – PDF DOWNLOAD
A Few Words About Safety
Service Information
- The service and repair information contained in this manual is intended for use by qualllied. professional techniciens. Attempting service or repairs without the proper training. tools. and equipment could cause injury to you or others. it could also damage the vehicle or create an unsaie condition.
- This manual describes the proper methods and procedures for performing service. maintenance, and repaire. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part.
- service procedure or a tool that is not recommended by Honda. must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part. use genuine Honda parts with the correct part number or en equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing ane“ using safety equipment. When performing any service task. be especially careful of the following:
° Read all of the instructions before you begin, and make sure you have the tools. the replacement or repair parts. and the skills required to perform the tasks saier and completely.
° Protect your eyes by using proper safety glasses. goggies or face shieids any time you hammer. drill, grind, pry or work around pressurized air or liquide. and springs or other stored—energy components. if there is any doubt. put on eye protection.
° Use other protective wear when necessary. for example gioves or safety shoes. Handling hot or sharp parts can cause severe burns or cute. Before you grab something that looks like it can hurt you. stop and put on gloves.
° Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack. make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures. unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: *
° Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
° Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
° injury from moving parts. if the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion. be careful when working around gasoline or batteries.
° Use only & nonflammabie solvent. not gasoline. fo clean parts.
° Never drain or store gasoline in en open container.
° Keep all cigarettes, sparks and fiames away from the battery and all fuel-related parts. —
TABLE OF CONTENTS:
2008 Honda CBR1000RR Service Manual – PDF DOWNLOAD
2008 CBR1000RR Service Manual. ...................................... 1 Service Information. ............................................ 2 Contents. ....................................................... 3 Symbols. ........................................................ 4 1. General Information. ......................................... 5 1.1 Contents. ............................................... 5 1.2 Service Rules. ......................................... 6 1.3 Model Identification. ................................... 7 1.4 Labels. ............................................. 8 1.5 General Specifications. ................................. 9 1.6 Electrical Specifications. .......................... 10 1.7 Lubrication, Fuel & Cooling System Specifications. .... 11 1.8 Cylinder Head & Valve Specifications. ................... 12 1.9 Crankcase, Transmission & Balancer Specifications. ..... 13 1.10 Wheel, Suspension & Steering Specifications. ........... 14 1.11 Brake, Battery & Ignition Specifications. .............. 15 1.12 Lights, Meters & Switches Specifications. .............. 16 1.13 Torque Values. ........................................ 17 1.14 Lubrication, Fuel & Cooling. ....................... 18 1.15 Cylinder Head, Clutch & Starter. ................... 19 1.16 Crank, Wheels & Suspension. ........................ 20 1.17 Brakes, Starter & Lights. .......................... 21 1.18 Lubrication & Seal Points. ............................. 22 1.19 Frame. ............................................. 23 1.20 Cable & Harness Routing. ............................... 24 1.21 IDC. ............................................... 25 1.22 Throttle & Clutch. ................................. 26 1.23 Brakes. ............................................ 27 1.24 ECM. ............................................... 28 1.25 Injectors. ......................................... 29 1.26 HESD. .............................................. 30 1.27 Fuel Pump. ......................................... 31 1.28 PAIR & Fan. ........................................ 32 1.29 Starter & Battery. ................................. 33 1.30 Oil Cooler & Sidestand. ............................ 34 1.31 Radiator. .......................................... 35 1.32 Sub Harness. ....................................... 36 1.33 Tail & Signals. .................................... 37 1.34 EGCA. .............................................. 38 1.35 EVAP (California). ................................. 39 1.36 EVAP Purge. ........................................ 40 1.37 Emission Control Systems. .............................. 41 1.38 Exhaust ECS . ...................................... 42 1.39 Evaporative ECS .................................... 43 2. Technical Features. .......................................... 44 2.1 Contents. ............................................... 44 2.2 Exhaust System. ......................................... 45 2.3 EGBV. ............................................... 46 2.4 ECV. ................................................ 47 2.5 CMP Sensor. ............................................. 48 2.6 Fan Motor Control System. ............................... 49 2.7 Clutch System. .......................................... 50 2.8 Clutch Mechanism. ................................... 51 2.9 Clutch Assist. ...................................... 52 3. Frame, Body Panels & Exhaust System. ........................ 53 3.1 Contents. ............................................... 53 3.2 Body Panel Locations. ................................... 54 3.3 Service Information. .................................... 55 3.4 Trim Clips. ............................................. 56 3.5 Trim Clip 3. ........................................ 57 3.6 Seat, Side Covers & Pillion Seat. ....................... 58 3.7 Tank Cover. ............................................. 59 3.8 Rear Seat Cowl. ......................................... 60 3.9 Upper Inner Cover & Lower Cowl . ........................ 61 3.10 Middle Cowl. ........................................... 62 3.11 Mirrors. ............................................... 63 3.12 Windscreen. ........................................ 64 3.13 Upper Cowl. ............................................ 65 3.14 Vacuum Chamber. .................................... 66 3.15 Lights. ............................................ 67 3.16 Bank Angle Sensor. ................................. 68 3.17 Wire Harness. ...................................... 69 3.18 Front Fender. .......................................... 70 3.19 Rear Fender. ........................................... 71 3.20 Rear Fender C . .................................... 72 3.21 License Light Stay. .................................... 73 3.22 Undertray. ......................................... 74 3.23 Seat Rail. ............................................. 75 3.24 Muffler. ............................................... 76 3.25 EGCA Cable. ........................................ 77 3.26 Disassembly. ....................................... 78 3.27 Assembly. .......................................... 79 3.28 Heat Guard. ........................................ 80 3.29 Installation. ...................................... 81 3.30 Main Step Bracket. ................................. 82 3.31 Exhaust Pipe. .......................................... 83 3.32 Installation. ...................................... 84 3.33 Headers. ........................................... 85 3.34 Mountings. ......................................... 86 4. Maintenance. ................................................. 87 4.1 Contents................................................ 87 4.2 Service Information. .................................... 88 4.3 Tools. .................................................. 89 4.4 Maintenance Schedule. ................................... 90 4.5 Fuel Line. .............................................. 91 4.6 Inspection. ......................................... 92 4.7 Fuel Tank. .......................................... 93 4.8 Throttle Operation. ..................................... 94 4.9 Air Cleaner. ............................................ 95 4.10 Spark Plug. ............................................ 96 4.11 Inspection. ........................................ 97 4.12 Valve Clearance. ....................................... 98 4.13 Timing. ............................................ 99 4.14 Intake & Exhaust Valves. ...........................100 4.15 Adjustment. ........................................101 4.16 Shims. .............................................102 4.17 Engine Oil. ............................................103 4.18 Filter Change. .....................................104 4.19 Sump. ..............................................105 4.20 Radiator Coolant. ......................................106 4.21 Secondary Air Supply. ..................................107 4.22 EVAP (California). .....................................108 4.23 EGCA Cable. ............................................109 4.24 Cable Inspection. ..................................110 4.25 Adjustment. ........................................111 4.26 Drive Chain. ...........................................112 4.27 Cleaning & Lubrication. . ..........................113 4.28 Sprockets. .........................................114 4.29 Chain Replacement. .................................115 4.30 Chain Links. .......................................116 4.31 Brake Fluid. ...........................................117 4.32 Brake Pads Wear. .......................................118 4.33 Brake Light Switch. ....................................119 4.34 Headlight & Clutch. ....................................120 4.35 Sidestand & Suspension. ................................121 4.36 Front Suspension. ..................................122 4.37 Rear Suspension. ...................................123 4.38 Nuts, Bolts & Fasteners. ...............................124 4.39 Wheels & Tires. ........................................125 4.40 Steering Head Bearings. ................................126 5. Lubrication System. ..........................................127 5.1 Contents. ...............................................127 5.2 Lubrication System Diagram. .............................128 5.3 Service Information. ....................................129 5.4 Troubleshooting. ........................................130 5.5 Oil Pressure Inspection. ................................131 5.6 Oil Pump. ...........................................132 5.7 Disassembly. ........................................133 5.8 Inspection. .........................................134 5.9 Assembly. ...........................................135 5.10 Installation. ......................................136 5.11 Sprockets. .........................................137 5.12 Sump. ..............................................138 5.13 Oil Cooler. ............................................139 5.14 Installation. ......................................140 6. Fuel System (PGM-FI) .........................................141 6.1 Contents. ...............................................141 6.2 Component Location. .....................................142 6.3 Service Information. ....................................143 6.4 Specifications. .....................................144 6.5 Tools. ..............................................145 6.6 Tools (Cont) . ......................................146 6.7 PGM-FI Symptom Troubleshooting. .........................147 6.8 PGM-FI System Location. .................................148 6.9 PGM-FI System Diagram. ..................................149 6.10 Connector Location. ....................................150 6.11 ECM Connectors. ........................................151 6.12 PGM-FI Troubleshooting Information. ....................152 6.13 HDS Information. ...................................153 6.14 Clearing DTC. ......................................154 6.15 DTC Index. .............................................155 6.16 DTC Index. .........................................156 6.17 DTC Troubleshooting. ...................................157 6.18 MAP Sensor Output. . ...............................158 6.19 MAP Sensor Input. ..................................159 6.20 MAP Sensor Inspection. .............................160 6.21 ECT Resistance . ...................................161 6.22 ECT Sensor Output. .................................162 6.23 TP Sensor. .........................................163 6.24 TP Sensor HV. ......................................164 6.25 IAT Sensor LV. .....................................165 6.26 IAT Sensor Inspection. .............................166 6.27 VS Sensor Input. ...................................167 6.28 Primary Injector. ..................................168 6.29 Injector Inspection. ...............................169 6.30 CMP Sensor. ........................................170 6.31 CMP Sensor Input. ..................................171 6.32 CKP Sensor Inspection. .............................172 6.33 Knock Sensor Inspection. ...........................173 6.34 Knock Sensor LV. ...................................174 6.35 IACV Inspection. ...................................175 6.36 ECV Pot LV. ........................................176 6.37 ECV Pot Inspection. ................................177 6.38 ECV Pot HV. ........................................178 6.39 EGCA Lock. .........................................179 6.40 MIL Circuit Troubleshooting. ...........................180 6.41 Fuel Line Inspection. ..................................181 6.42 Fuel Rail. .........................................182 6.43 Quick Connect Fitting. .............................183 6.44 Fuel Pressure Test. ................................184 6.45 Tools. .............................................185 6.46 Fuel Flow Inspection. ..............................186 6.47 Fuel Pump Unit .........................................187 6.48 Removal. ...........................................188 6.49 Installation. ......................................189 6.50 Fuel Pump Relay. .......................................190 6.51 Fuel Tank. .............................................191 6.52 Air Cleaner Housing. ...................................192 6.53 Removal. ...........................................193 6.54 Installation. ......................................194 6.55 Secondary Injector. ....................................195 6.56 Removal. ...........................................196 6.57 Installation. ......................................197 6.58 Throttle Body. .........................................198 6.59 Removal. ...........................................199 6.60 Diagram. ...........................................200 6.61 Hose Routing. ......................................201 6.62 Installation. ......................................202 6.63 Primary Injector. ......................................203 6.64 Removal. ...........................................204 6.65 Installation. ......................................205 6.66 Engine Idle Speed. .....................................206 6.67 Removal/Installation. ..............................207 6.68 Knock Sensor. ..........................................208 6.69 MAP Sensor. ............................................209 6.70 IAT & ECT Sensor. ......................................210 6.71 CMP Sensor. ............................................211 6.72 Bank Angle Sensor. .................................212 6.73 Engine Stop Relay. .....................................213 6.74 ECM. ...................................................214 6.75 Power Line Inspection. .............................215 6.76 Engine Stop Relay Inspection. ......................216 6.77 Secondary Air Supply System. ...........................217 6.78 PAIR Control Solenoid. .............................218 6.79 EGCA. ..................................................219 6.80 Inspection. ........................................220 6.81 Intake Air Duct Control. ...............................221 6.82 One-Way Valve. .....................................222 6.83 EVAP (California). .....................................223 6.84 Removal. ...........................................224 6.85 Installation. ......................................225 7. Cooling System. ..............................................226 7.1 Contents. ...............................................226 7.2 System Flow Pattern. ....................................227 7.3 Service Information. ....................................228 7.4 Troubleshooting. ........................................229 7.5 System Testing. .........................................230 7.6 Coolant Replacement. ....................................231 7.7 Replacement/Air Bleeding. ...........................232 7.8 Thermostat. .............................................233 7.9 Inspection. .........................................234 7.10 Installation. ......................................235 7.11 Radiator/Cooling Fan. ..................................236 7.12 Removal. ...........................................237 7.13 Disassembly. .......................................238 7.14 Cooling Fan. .......................................239 7.15 Fan Motor. .........................................240 7.16 Assembly. ..........................................241 7.17 Fittings. ..........................................242 7.18 Alignment. .........................................243 7.19 Installation. ......................................244 7.20 Connections. .......................................245 7.21 Water Pump. ............................................246 7.22 Installation. ......................................247 7.23 Connections. .......................................248 7.24 Radiator Reserve Tank. .................................249 8. Engine Removal & Installation.................................250 8.1 Contents. ...............................................250 8.2 Component Location. .....................................251 8.3 Service Information. ....................................252 8.4 Engine Removal. .........................................253 8.5 Sensors. ............................................254 8.6 Mountings. ..........................................255 8.7 Tools. ..............................................256 8.8 Engine Installation. ....................................257 8.9 Frame. ..............................................258 8.10 Mountings. .........................................259 8.11 Brackets. ..........................................260 8.12 Fittings. ..........................................261 8.13 Sensors ............................................262 8.14 Switches. ..........................................263 9. Cylinder Head & Valves. ......................................264 9.1 Contents. ...............................................264 9.2 Component Location. .....................................265 9.3 Service Information. ....................................266 9.4 Tools. ..............................................267 9.5 Tools. ..............................................268 9.6 Troubleshooting. ........................................269 9.7 Cylinder Compression Test. ..............................270 9.8 Cylinder Head Cover Disassembly. ........................271 9.9 Camshaft Removal. .......................................272 9.10 Cam Sprocket. ......................................273 9.11 Cam Chain. .........................................274 9.12 Inspection. ........................................275 9.13 Camshaft Oil Clearance. ............................276 9.14 Cylinder Head Removal. .................................277 9.15 Cylinder Head Disassembly. .............................278 9.16 Tools. .............................................279 9.17 Cylinder Head Inspection. ..............................280 9.18 Valve Springs. .....................................281 9.19 Valve Guide. .......................................282 9.20 Valve Guide Replacement. ...............................283 9.21 Valve Seat Inspection. .................................284 9.22 Valve Seat Refacing. ...............................285 9.23 Tools. .............................................286 9.24 Cylinder Head Assembly. ................................287 9.25 Tools. .............................................288 9.26 Cylinder Head Installation. ............................289 9.27 Cam Chain Tensioner. ...............................290 9.28 Cylinder Layout. ...................................291 9.29 Tightening Sequence. ...............................292 9.30 Camshaft Installation. .................................293 9.31 Alignment. .........................................294 9.32 Identification. ....................................295 9.33 Cam Sprockets. .....................................296 9.34 Cylinder Head Cover Assembly. ..........................297 9.35 Cylinder Head Cover Installation. ......................298 9.36 Fixings. ...........................................299 9.37 Cam Chain Tensioner Lifter. ............................300 9.38 Tensioner Stopper. .................................301 10. Clutch, Starter & Gearshift. ................................302 10.1 Contents. ..............................................302 10.2 Component Location. ....................................303 10.3 Service Information. ...................................304 10.4 Troubleshooting. .......................................305 10.5 Right Crankcase Cover Removal. .........................306 10.6 Clutch Lifter Lever. ...............................307 10.7 Clutch. ................................................308 10.8 Clutch Center Lock Nut. ............................309 10.9 Pressure Plate. ....................................310 10.10 Clutch Outer. .....................................311 10.11 Inspection. .......................................312 10.12 Clutch Spring. ....................................313 10.13 Clutch Disc. ......................................314 10.14 Primary Driven Gear. ..............................315 10.15 Mainshaft. ........................................316 10.16 Needle Bearing Selection. .........................317 10.17 Installation. .....................................318 10.18 Reduction Gear. ...................................319 10.19 Clutch Plates. ....................................320 10.20 Clutch Assembly. ..................................321 10.21 Clutch Holder. ....................................322 10.22 Lifter Plate. .....................................323 10.23 Starter Clutch. .......................................324 10.24 Inspection. .......................................325 10.25 Assembly. .........................................326 10.26 Installation. .....................................327 10.27 Gearshift Linkage. ....................................328 10.28 Inspection. .......................................329 10.29 Installation. .....................................330 10.30 Right Crankcase Cover. ................................331 10.31 Gaskets. ..........................................332 10.32 Clutch Cable. .....................................333 11. Alternator. .................................................334 11.1 Contents. ..............................................334 11.2 Component Location. ....................................335 11.3 Service Information. ...................................336 11.4 Alternator Cover Removal. ..............................337 11.5 Stator. ................................................338 11.6 Flywheel. ..............................................339 11.7 Alternator Cover Installation. .........................340 11.8 Sensors. ...........................................341 12. Crankcase, Transmission & Balancer. .........................342 12.1 Contents. ..............................................342 12.2 Component Location. ....................................343 12.3 Service Information. ...................................344 12.4 Troubleshooting. .......................................345 12.5 Crankcase Separation. ..................................346 12.6 Shift Fork, Drum & Transmission. .......................347 12.7 Removal. ...........................................348 12.8 Shift Fork & Drum Inspection. ......................349 12.9 Transmission Inspection. ...........................350 12.10 Mainshaft Bearing. ................................351 12.11 Mainshaft Bearing Replacement. ....................352 12.12 Transmission Assembly. ............................353 12.13 Gear & Shafts. ....................................354 12.14 Installation. .....................................355 12.15 Fork Shaft. .......................................356 12.16 Balancer. .............................................357 12.17 Inspection. .......................................358 12.18 Balancer Bearing Selection. .......................359 12.19 Disassembly. ......................................360 12.20 Installation. .....................................361 12.21 Balancer Gear Backlash Adjuster. ..................362 12.22 Crankcase Assembly. ...................................363 12.23 Tightening Mehod. .................................364 12.24 Hoses & Seals. ....................................365 13. Crankshaft, Piston & Cylinder. ..............................366 13.1 Contents. ..............................................366 13.2 Component Location. ....................................367 13.3 Service Information. ...................................368 13.4 Troubleshooting. .......................................369 13.5 Crankshaft. ............................................370 13.6 Inspection. ........................................371 13.7 Installation. ......................................372 13.8 Connecting Rods. ...................................373 13.9 Main Journal Bearing. ..................................374 13.10 Bearing Selection. ................................375 13.11 Bearing Installation. .............................376 13.12 Crankpin Bearing. .....................................377 13.13 Bearing Selection. ................................378 13.14 Piston & Cylinder. ....................................379 13.15 Removal. ..........................................380 13.16 Piston Inspection. ................................381 13.17 Connecting Rod Inspection. ........................382 13.18 Cylinder Inspection. ..............................383 13.19 Piston Assembly. ..................................384 13.20 Piston Installation. ..............................385 13.21 Tightening Method. ................................386 14. Front Wheel, Suspension & Steering. .........................387 14.1 Contents. ..............................................387 14.2 Component Location. ....................................388 14.3 Service Information. ...................................389 14.4 Tools. .............................................390 14.5 Tools (Cont). ......................................391 14.6 Troubleshooting. .......................................392 14.7 HESD Troubleshooting. ..................................393 14.8 DTC Troubleshooting. ...............................394 14.9 Handlebars. ............................................395 14.10 Throttle. .........................................396 14.11 Top Yoke. .........................................397 14.12 Installation. .....................................398 14.13 Steering Damper. ..................................399 14.14 Grips. ............................................400 14.15 Handlebar Weights..................................401 14.16 Front Wheel. ..........................................402 14.17 Inspection. .......................................403 14.18 Wheel Balance. ....................................404 14.19 Disassembly. ......................................405 14.20 Installation. .....................................406 14.21 Tightening. .......................................407 4.22 Fork. ..................................................408 4.23 Removal. ...........................................409 4.24 Stopper Plate. .....................................410 4.25 Fork Damper. .......................................411 4.26 Inspection. ........................................412 4.27 Assembly. ..........................................413 4.28 Oil Seals. .........................................414 4.29 Slider. ............................................415 4.30 Bleeding. ..........................................416 4.31 Compression. .......................................417 4.32 Installation. ......................................418 14.33 HESD. .................................................419 14.34 Steering Stem. ........................................420 14.35 Bearing Replacement. ..............................421 14.36 Driver Shaft. .....................................422 14.37 Assembly Base. ....................................423 14.38 Tools. ............................................424 14.39 Upper Bearings. ...................................425 14.40 Lower Inner Race Replacement. .....................426 14.41 Bearings. .........................................427 14.42 Steering Head Bearing Pre-Load. ...................428 15. Rear Wheel & Suspension. ....................................429 15.1 Contents. ..............................................429 15.2 Component Location. ....................................430 15.3 Service Information. ...................................431 15.4 Tools. .............................................432 15.5 Troubleshooting. .......................................433 15.6 Rear Wheel. ............................................434 15.7 Disassembly. .......................................435 15.8 Inspection. ........................................436 15.9 Driven Flange Bearing Replacement. .................437 15.10 Wheel Bearing Replacement. ........................438 15.11 Assembly. .........................................439 15.12 Installation. .....................................440 15.13 Suspension Linkage. ...................................441 15.14 Shock Absorber. .......................................442 15.15 Inspection. .......................................443 15.16 Lower Bearing. ....................................444 15.17 Shock Absorber Disposal. ..........................445 15.18 Swingarm. .............................................446 15.19 Disassembly. ......................................447 15.20 Inspection. .......................................448 15.21 Bearings. .........................................449 15.22 Shock Arm. ........................................450 15.23 Assembly. .........................................451 15.24 Installation. .....................................452 15.25 Hose Routing. .....................................453 16. Hydraulic Brake. ............................................454 16.1 Contents. ..............................................454 16.2 Component Location. ....................................455 16.3 Rear. ..............................................456 16.4 Service Information. ...................................457 16.5 Troubleshooting. .......................................458 16.6 Brake Fluid Replacement. ...............................459 16.7 Air Bleeding. ......................................460 16.8 Brake Pad & Disc. ......................................461 16.9 Front Brake Pad Replacement. .......................462 16.10 Rear Brake Pad Replacement. .......................463 16.11 Brake Disc Inspection. ............................464 16.12 Front Master Cylinder. ................................465 16.13 Disassembly. ......................................466 16.14 Inspection. .......................................467 16.15 Assembly. .........................................468 16.16 Brake Light Switch. ...............................469 16.17 Installation. .....................................470 16.18 Rear Master Cylinder. .................................471 16.19 Removal. ..........................................472 16.20 Disassembly. ......................................473 16.21 Inspection. .......................................474 16.22 Assembly. .........................................475 16.23 Snap Ring. ........................................476 16.24 Installation. .....................................477 16.25 Master Cylinder. ..................................478 16.26 EGCA Cable. .......................................479 16.27 Front Brake Calipers. .................................480 16.28 Inspection. .......................................481 16.29 Assembly. .........................................482 16.30 Rear Brake Caliper. ...................................483 16.31 Inspection. .......................................484 16.32 Assembly. .........................................485 16.33 Installation. .....................................486 17. Battery & Charging System. ..................................487 17.1 Contents. ..............................................487 17.2 System Diagram. ........................................488 17.3 Service Information. ...................................489 17.4 Tools. .............................................490 17.5 Troubleshooting. .......................................491 17.6 Battery. ...............................................492 17.7 Charging System Inspection. ............................493 17.8 Alternator Charging Coil. ..............................494 17.9 Regulator & Rectifier. .................................495 18. Ignition System. ............................................496 18.1 Contents. ..............................................496 18.2 System Diagram. ........................................497 18.3 System Information. ....................................498 18.4 Troubleshooting. .......................................499 18.5 Ignition System Inspection. ............................500 18.6 CKP Sensor. ........................................501 18.7 Ignition Timing. .......................................502 18.8 Timing Cover. ......................................503 19. Electric Starter.............................................504 19.1 Contents. ..............................................504 19.2 System Diagram. ........................................505 19.3 System Information. ....................................506 19.4 Troubleshooting. .......................................507 19.5 Inspection. ........................................508 19.6 Starter Motor. .........................................509 19.7 Disassembly. .......................................510 19.8 Inspection. ........................................511 19.9 Brushes. ..........................................512 19.10 Bearings. .........................................513 19.11 Assembly. .........................................514 19.12 Components. .......................................515 19.13 Seal Rings. .......................................516 19.14 Starter Relay Switch. .................................517 19.15 Operation Inspection. .............................518 19.16 Diode. ................................................519 20. Lights, Meters & Switches. ..................................520 20.1 Contents. ..............................................520 20.2 System Location. .......................................521 20.3 Service Information. ...................................522 20.4 Tools. .............................................523 20.5 Troubleshooting. .......................................524 20.6 Headlight. .............................................525 20.7 Brake & Tail Light. ....................................526 20.8 Licence Light. .........................................527 20.9 Combination Meter. .....................................528 20.10 Removal & Installation. ...........................529 20.11 Speedomoter. ..........................................530 20.12 Tachometer. ...........................................531 20.13 ECT Sensor. ...........................................532 20.14 EOP Switch. ...........................................533 20.15 Fuel Reserve Sensor. ..................................534 20.16 Ignition Switch. ......................................535 20.17 Handlebar Switches. ...................................536 20.18 Brake Light Switch. ...................................537 20.19 Clutch Switch. ........................................538 20.20 Neutral Switch. .......................................539 20.21 Sidestand Switch. .....................................540 20.22 Horn & Turn Signal Relay. .............................541 20.23 Headlight Relay. ......................................542 21. Wiring Diagrams. ............................................543 21.1 Contents. ..............................................543 21.2 United Kingdom & Europe. ...............................544 21.3 United States. .........................................545 22. Troubleshooting. ............................................546 22.1 Contents. ..............................................546 22.2 Engine Does Not Start Or Is Hard To Start. .............547 22.3 Engine Lacks Power. ....................................548 22.4 Ignition Timing. ...................................549 22.5 Poor Performance At Low And Idle Speed. ................550 22.6 Poor Performance At High Speed. ........................551 23. Index .......................................................552 23.1 Index ..................................................552 23.2 Index ..................................................553 Back Cover ......................................................554
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