Refmo Fault Finding

Brake lever or pedal pulsates in operation Disc warped or irregularly worn. The disc must be renewed. Wheel axle bent. The axle may be straightened provided no structural damage has occurred. Brake squeal. Squealing can be caused by dust on the pads, usually in combination with glazed pads, or other contamination from oil, grease, brake fluid or corrosion. Persistent squealing which cannot be traced to any of the normal causes can often be cured by applying a thin layer of high temperature...

Engine clutch and transmission

20.9 Adjust balancer shaft backlash using that the index mark on the weight aligns with the adjacent line on the crankcase surface. 8 Apply a smear of oil to the balancer shaft O-ring and insert the shaft. Secure the shaft in position by refitting the shaft retaining bolt to the underside of the crankcase and tightening it securely. Apply a small amount of gasket sealant to the threads of the balancer shaft retaining clamp bolt and refit it to the engine unit, tightening it securely. Install...

Info

7 Installation is a reverse of the removal procedure. Refit the master cylinder to the brake pedaf and secure the pushrod pin in position with a new split pin. Secure the footrest bracket to the machine and refit the master cylinder and reservoir mounting bolts, tightening all bolts to the specified torque setting. 8 Refit the brake hose to the master cylinder, positioning a new sealing washer on each side of its union. Ensure that the neck of the hose union(s) abuts the tab on the master...

B B

' liit-Hi i B Si K I '.' i B Hi is -.H -'-*- > .> i '< < 'ii , . 4ii' -H js 14.9c Insert the pushrod and check the operation of the lifting arm permissible amount of warpage, or shows signs of blueing, all plain plates must be renewed as a set. 3 Inspect the clutch assembly for burrs and indentations on the edges of the protruding tangs of the friction plates and or slots in the edge of the clutch outer drum with which they engage. Similarly wear can occur between the inner tongues of...

Isbn 1 85960 228

Sparkford, Nr Yeovil, Somerset BA22 7JJ, England Haynes North America, Inc 861 Lawrence Drive, Newbury Park, California 91320, USA Tour Aurore - La D fense 2, 18 Place des Reflets, 92975 PARIS LA DEFENSE Cedex, France British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library

Ring Spanner On Secondary Master Cylinder Linkage Bolt

If it's not possible to produce a firm feel to the brake lever or pedal the fluid my be aerated. Let the fluid in the system stabilise for a few hours and then repeat the procedure when the tiny bubbles in the system have settled out 12.4 Tighten disc mounting bolts to the specified torque setting 12.4 Tighten disc mounting bolts to the specified torque setting 13.3 Connect brake clutch bleeding kit as 13.3 Connect brake clutch bleeding kit as Brake bleeding (1000 P models onward) Note Honda...

REF42 Fault Finding Equipment

Measuring open-circuit battery voltage Float-type hydrometer for measuring battery specific gravity Measuring open-circuit battery voltage Float-type hydrometer for measuring battery specific gravity Before any electrical fault is investigated the battery should be checked. You'll need a dc voltmeter or multimeter to check battery voltage. Check that the leads are inserted in the correct terminals on the meter, red lead to positive (+ve), black lead to negative (-ve). Incorrect connections can...

Epz

3.7 Check the left caliper mounting bracket to disc clearance as described in 4,2 Rear wheel -1000 models (600 similar) 4,2 Rear wheel -1000 models (600 similar) 6 Noise damper - 1000 H and J models 12 Dust seal - 1000 H and J models gauge cannot be easily inserted on both sides of the disc, slacken the axle pinch bolts on the left slider (lower leg) and push or pull the left fork slider (lower leg) inwards or outwards until the feeler gauge is a light sliding fit. Retighten the left axle pinch...

B

ABS (Anti-lock braking system) A system, usually electronically controlled, that senses incipient wheel lockup during braking and relieves hydraulic pressure at wheel which is about to skid. Aftermarket Components suitable for the motorcycle, but not produced by the motorcycle manufacturer. Allen key A hexagonal wrench which fits into a recessed hexagonal hole. Alternating current (ac) Current produced by an alternator. Requires converting to direct current by a rectifier for charging purposes....

Fault Finding REF39

15 Poor handling or roadholding (continued) Damping components worn or corroded. Advanced normal wear of the fork internals is unlikely to occur until a very high mileage has been covered. Continual use of the machine with damaged oil seals which allows the ingress of water, or neglect, will lead to rapid corrosion and wear. Dismantle the forks for inspection and overhaul. Weak fork springs. Progressive fatigue of the fork springs, resulting in a reduced spring free length, will occur after...

Engine clutch and transmission 251

28.13 and tighten bearing cap bolts to the specified torque setting activity even if new parts have not been fitted. Should the engine persist in not starting, check that the plugs have not become fouled by the oil used during reassembly. Failing this go through the troubleshooting section and work out what the fault is methodically. 2 When the engine does start, keep it running as slowly as possible to allow the oil to circulate. The oil pressure warning light should go out almost immediately...

H28907

1,1 Ignition system circuit diagrams 9 Side stand warning light 10 Neutral warning Bu Blue G Green Lg Light green R Red W White Y Yellow These models are fitted with a magnetically-triggered electronic ignition system, which due to its lack of mechanical parts is totally maintenance-free. The system comprises a rotor, pulser coii(s), spark unit and two ignition HT coils. The raised trigger on the rotor, which is fitted to the left end of the crankshaft, magnetically operates the pulser coil(s)...

Tools and Workshop Tips refi3

Dial gauge or DTI (Dial Test Indicator) A dial gauge can be used to accurately measure small amounts of movement. Typical uses are measuring shaft runout or shaft endfloat (sideplay) and setting piston position for ignition timing on two-strokes. A dial gauge set usually comes with a range of different probes and adapters and mounting equipment. The gauge needle must point to zero when at rest. Rotate the ring around its periphery to zero the gauge. Check that the gauge is capable of reading...

REF10 Tools and Workshop Tips

Locking compounds are used in locations where the fastener is prone to loosening due to vibration or on important safety-related items which might cause loss of control of the motorcycle if they fail. It is also used where important fasteners cannot be secured by other means such as lockwashers or split pins. Before applying locking compound, make sure that the threads (internal and external) are clean and dry with all old compound removed. Select a compound to suit the component being secured...

Hayn Es

Before renewing the camshafts or the cylinder head and bearing caps because of damage, check with local machine shops specialising in motorcycle engineering work. in the case of the camshafts, it may be possible for the cam lobes to be welded, reground and hardened at a cost far lower than that of a new camshaft. If the bearing surfaces in the cylinder head are damaged, it may be possible for them to be bored out to accept bearing inserts. Due to the cost of a new cylinder head and bearing...

Engine clutch and transmission 249

2 The crankshaft should be thoroughly cleaned using a high flash-point solvent. Be very careful to check that all oilways are completely free from dirt and other foreign matter. 3 Examine the crankshaft closely. Any obvious signs of damage such as marked bearings, damaged threads or sprockets will mean that it must be renewed. There are however many engineering firms, who advertise regularly in the motorcycle press, who can undertake major crankshaft repairs. In view of the expense of a new...

Encore clutch and transmission

22.9a Install all main bearing bolts and washers and tighten them as described in crankcase half is correctly seated and that ail shafts are free to rotate. 9 Install all the lower crankcase bolts and washers, using the cardboard template to ensure each bolt is fitted in its correct position. Do not omit the seating washers from the twelve 8 mm main bearing bolts and the single 6 mm bolt (number 21 in the tightening sequence) (see illustration). Tighten all the lower crankcase bolts in 2 or 3...

V

1 The side stand and neutral switches are linked to the ignition system to provide a safety feature which prevents the machine being ridden with the side stand down (see illustration). If at any time the transmission is put into gear whilst the side stand is down, the power from the spark unit will be 6.1 Side stand switch location - 600 K and automatically transmitted to earth (ground). This effectively breaks the ignition system and kills the engine. 2 A cfutch switch and diode are also...

Syy

Alternator - testing 5 Battery - inspection and maintenance 3 Bulbs - Charging system - checking the output 4 Coolant temperature gauge circuit - testing 14 Cooling fan circuit - testing 3 Electrical system - general information and preliminary checks 2 Fuel gauge circuit - testing (1000 models) 15 Fuel pump and relay - testing 1000 H, J and all 600 models) 16 General Horn - location and Oil pressure warning lamp circuit - testing 11 Regulator rectifier unit - Starter circuit - Starter motor -...

Xgm

5.15 Connect clutch cable and adjust correctly - 600 models 5.16 Engage engine sprocket with drive chain and refit sprocket retaining bolt and on the countershaft (output shaft) (see illustration). Fit the sprocket retaining bolt and washer and tighten it to the specified torque setting whilst locking the transmission as described in paragraph 8 to prevent the sprocket rotating. Check the drive chain tension as described in Chapter 1 and adjust if necessary. 17 Fit the two sprocket cover...

Cable Drilling Shock Absorber

Upper Spring Seat Motorcycle

Thick washer Guide for lower outer race steering head an can * ' gnd position with a f ensure that it is evenly around each ace to pr0ve driven out the end of the drift advantageous to curve> t ively( the slightly to improve acces _hammer races can be tse can often be type bearing extractor. races can be pressed into tne n a large oniy on the outer edge t Qn th 4 The lower 'nne eauire levering off the unless accent fr stheonly some cases. it is badly out satisfactory course ot e repa,r...

Tools and Workshop Tips refi7

installation of bearings can be eased by placing them in a freezer the night before installation. The steel bearing will contract slightly, allowing easy insertion in its housing. This is often useful when installing steering head outer races in the frame. Plain shell bearings, ball bearings, needle roller bearings and tapered roller bearings will all be found on motorcycles (see illustrations 5-14 and 5.15), The ball and roller types are usually caged between an inner and outer race, but...

Cbr 600 F1 Torque Link Bolt

Scoring may be due to contaminated fluid, and if this is suspected, it is probably worth checking the caliper seals and pistons as well. If measuring equipment is available, compare the dimensions of the master cylinder bore and piston with those given in the Specifications Section of this Chapter and renew any component that is worn beyond the specified service limit. It is advisable to renew the piston assembly as a matter of course as the replacement cost is relatively small and does warrant...

Piston Ring Arrangement

Piston Ring Off Thrust Side

Badly worn cylinder bores produce excessive smoking from the exhaUsts, initially iri the form of a blue, haze tending to deveipp into a white haze as the wear becomes more pronounced, The other indication is piston slap, a form of metallic rattle which occurs when there is little load oh th engin . If the top qf th bore i examined carefullyJf will be found thai there Is a ridge on the thrust side the depth of which will vary according to the raie of wear which has taken pi ce* 11,10 Carefully...

Fuel and lubrication systems

4.3 Fuel tank and fuel tap -1000 models 4.3 Fuel tank and fuel tap -1000 models and the rear pivot bolt from the fuel tank and disconnect the fuel pipe from the tap. Disconnect the prop stay and lift the tank away from the machine (see illustration). 4 On 1000 K models onward, remove the tank's two front mounting bolts and disconnect the fuel level sender block connector (see illustrations). Lift the tank up and remove the R-clip and washer which secures the prop stay to its bracket and...

E

Earth return The return path of an electrical circuit, utilising the motorcycle's frame. ECU (Electronic Control Unit) A computer which controls (for instance) an ignition system, EGO Exhaust Gas Oxygen sensor. Sometimes Electrolyte The fluid in a lead-acid battery. computer controlled system which manages the fue injection and the ignition systems in an Endfloat The amount of lengthways movement between two parts. As applied to a crankshaft, the distance that the crankshaft can move side-...

T

, y -, , III - ' H- I ' ' . 4 h- Iii - I H Hi 4.21 d Ensure the spring is fitted as described in text 4.21 d Ensure the spring is fitted as described in text 4.23b On the left fork leg fit the first circlip to the damper rod, followed by the spring 4.23b On the left fork leg fit the first circlip to the damper rod, followed by the spring tip the damper rod and rebound spring out of the tube. On the right fork leg simply remove the circlip from the damper rod to permit its removal. 20 To...

N

Needle roller bearing Inner race of caged needle rollers and hardened outer race. Examples of uncaged needle rollers can be found on some engines. Commonly used in rear suspension applications and in two-stroke engines. NOx Oxides of Nitrogen. A common toxic pollutant emitted by petrol engines at higher temperatures. Octane The measure of a fuel's resistance to knock. OE (Original Equipment) Relates to components fitted to a motorcycle as standard or replacement parts supplied by the motorcycle...

Honda Cbr600 F1 Main Jet Size

M m 9 Weak spark at plug or erratic firing Battery voltage low. In certain conditions low battery charge, especially when coupled with a badly sulphated battery, may result in misfiring. If the battery is in good general condition it should be recharged an old battery suffering from sulphated plates should be renewed. Spark plugs fouled, faulty or incorrectly adjusted. See Section 2 or refer to Chapter 1. Spark plug cap or high tension lead shorting. Check the condition of both these items...

REF20 Tools and Workshop Tips

Harley Hand Controls Wiring Diagram

8.8 Assemble the chain riveting tool over one pin at a time and tighten it fully 8.8 Assemble the chain riveting tool over one pin at a time and tighten it fully The second and third digits of the chain size relate to the width of the rollers, again in imperial units, eg the 525 shown has 5 16 inch 7.94 mm rollers see illustration 8.11 . 8.9 Pin end correctly riveted A , pin end unriveted B 8.9 Pin end correctly riveted A , pin end unriveted B the rivet ends and two pieces of the wood between a...

Ref38 Fault Finding

14 Oil pressure warning light comes on Engine oil defective. Oil pump shaft or locating pin sheared off from ingesting debris or seizing from lack of lubrication low oil level . Engine oil strainer clogged. Change oil and filter and clean strainer gauze, Engine oil level too low. Inspect for leak or other problem causing low oil level and add recommended lubricant. Engine oil viscosity too low. Very old, thin oil, or an improper weight of oil used in engine. Change to correct lubricant....

REF14 Tools and Workshop Tips

Checking individual components for warpage, such as clutch plain meta plates, requires a perfectly flat piate or piece or plate Torque describes the twisting force about a shaft. The amount of torque applied is determined by the distance from the centre of the shaft to the end of the lever and the amount of force being applied to the end of the lever distance multiplied by force equals torque. The manufacturer applies a measured torque to a bolt or nut to ensure that it will not slacken in use...

MOT Test Checks ref

In the UK, all vehicles more than three years old are subject to an annual test to ensure that they meet minimum safety requirements. A current test certificate must be issued before a machine can be used on public roads, and is required before a road fund licence can be issued. Riding without a current test certificate will also invalidate your insurance. For most owners, the MOT test is an annual cause for anxiety, and this is largely due to owners not being sure what needs to be checked...

Engine clutch and transmission 229

15.1a On 600 models slide the large spacer onto the mainshaft followed by the clutch drum centre collar measuring equipment is available, the piston and slave cylinder bore diameters can be compared with the limits given in the Specifications. 15 The pushrod oil seal set in the end of the piston and the fluid seal set in the piston .--groove must be renewed as a matter of course. Make careful note of which way round both seals are fitted before prying them out of position. Instalf the new seals...

Engine clutch and transmission 2M7

Ball Clutch Engine Start

26.1 Starter clutch and alternator drive -1000 models 4 Belleville washer -2 off where fitted 18 Alternator shaft and housing 32 Alternator cover and stator windings bushing onto the shaft ensuring that its holes align with the shaft oilways. Fit the 3rd gear pinion over its bushing so that its recessed surface faces the 6th gear pinion. Slide the special splined thrust washer along the shaft followed by the spiined lock washer ensuring the lock washer tabs are facing the left end of the shaft....

Cbr600f1 Rear Wheel Removal

12.3 Drawbolt tool for installing bearings or bushes in rear suspension components Long bolt or threaded rod 3 Component's housing 5 Large washers Bearing or bush 4 Nut ma sTowect the turn signal wiring and remove the left rear footpeg bracket icTstodtoiriteWtenliounting bote Manoeuvre i. away from the mach.ne ma sTowect the turn signal wiring ari mge nent can be made up as described rod fV'o e n'ut to one end ot the rod and Limes,s against the head then pass he S - -se installation, and remove...

Spark Plugs Condition Chart

Electrode gap check - use a wire type gauge for best results, Electrode gap adjustment - bend the side electrode using the correct tool. Normal condition - A brown, tan or grey firing end indicates that the engine is in good condition and that the plug type is correct. Carbon fouling - Dry, black sooty deposits leading to misfire and weak spark. Caused by an over-rich fuel air mixture, faulty choke operation or blocked air filter. Ash deposits - Light brown deposits encrusted on the electrodes...

Cbr600f1 Antifreeze

If a hose proves stubborn, release it by rotating it on its union before working it off. if all else fails, cut the hose with a sharp knife then slit it at each union so that it can be peeled off in two pieces. Whilst this is expensive it is preferable to buying a new radiator. 4 Serious leakage will be self-evident, though slight leakage can be difficult to spot. It is likely that the leak will only be apparent when the machine is running and the system is under pressure, and even then the...

Haynes

Freeplay in the fork due to worn fork bushes can be misinterpreted for steering head bearing play - do not confuse the two 2 Ensure that the front forks work smoothly and progressively by pumping them up and down whilst the front brake is held on. Any faults revealed by this check should be investigated immediately refer to Chapter 6, particularly if the oil seals are leaking. 3 Check that all the rear suspension pivot bolts are secure and that the pivots operate smoothly. With the machine...

Ref3o Storage

Preventative, oil or a stabiliser added to the fuel, drain and flush the tank and dispose of the fuel sensibly. If no action was taken with the fuel tank prior to storage, it is advised that the old fuel is disposed of since it will go off over a period of time. Refill the fuel tank with fresh fuel. Oil all pivot points and cables. Check the tyre pressures. They will definitely need inflating if pressures were reduced for storage. Lubricate the final drive chain where applicable . Remove any...

Routine maintenance and Servicing

Air cleaner element - cleaning 3 Air cleaner element - renewal 26 Brake and clutch fluid - Brake pads - wear check 7 Brake system - Carburettors - Clutch - check 1000 Clutch - check 600 models 8 Control cables and pivot points - lubrication 9 Coolant - renewal Cooling system - Crankcase breather - draining 1000 models 4 Drive chain - adjustment and lubrication 1 Drive chain slider - wear Engine idle speed - check 5 Engine transmission oil and filter - change 10 Evaporative emission control...

Fault Finding REF33

Check fuse for ignition circuit. See wiring diagram. Battery voltage low. The current draw required by a starter motor is sufficiently high that an under-charged battery may not have enough spare capacity to provide power for the ignition circuit during starting. Starter motor inefficient. A starter motor with worn brushes and a worn or dirty commutator will draw excessive amounts of current causing power starvation in the ignition system. See the preceding paragraph. Starter motor...