honda cbf1000 GENERAL INFORMATION

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Page 1

1. GENERAL INFORMATION

SERVICE RULES ········································· 1-2

MODEL IDENTIFICATION··························· 1-3

GENERAL SPECIFICATIONS······················ 1-5

LUBRICATION SYSTEM SPECIFICATIONS········································ 1-7

FUEL SYSTEM (PGM-FI) SPECIFICATIONS········································ 1-7

COOLING SYSTEM SPECIFICATIONS ······ 1-7

CYLINDER HEAD/VALVES SPECIFICATIONS········································ 1-8

CLUTCH/STARTER CLUTCH SPECIFICATIONS········································ 1-8

TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS········································ 1-9

CRANKCASE/CRANKSHAFT/BALANCER/ PISTON/CYLINDER SPECIFICATIONS ······ 1-9

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ····································· 1-10

REAR WHEEL/SUSPENSION SPECIFICATIONS ····································· 1-10

HYDRAULIC BRAKE SPECIFICATIONS··· 1-11

BATTERY/CHARGING SYSTEM SPECIFICATIONS ····································· 1-11

IGNITION SYSTEM SPECIFICATIONS ···· 1-11

ELECTRIC STARTER SPECIFICATIONS ·· 1-11

LIGHTS/METERS/SWITCHES SPECIFICATIONS ····································· 1-12

STANDARD TORQUE VALUES ··············· 1-13

ENGINE & FRAME TORQUE VALUES ···· 1-13

LUBRICATION & SEAL POINTS ·············· 1-20

CABLE & HARNESS ROUTING ··············· 1-23

EMISSION CONTROL SYSTEMS ············ 1-42

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Page 2

GENERAL INFORMATION

SERVICE RULES

1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle.

2. Use the special tools designed for this product to avoid damage and incorrect assembly.

3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners.

4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.

5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified.

6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.

7. After reassembly, check all parts for proper installation and operation.

8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-23).

ABBREVIATION

Throughout this manual, the following abbreviations are used to identify the respective parts or systems.

Abbrev. term Full term

PGM-FI Programmed Fuel Injection MAP sensor Manifold Absolute Pressure sensor TP sensor Throttle Position sensor ECT sensor Engine Coolant Temperature sensor IAT sensor Intake Air Temperature sensor CKP sensor Crankshaft Position sensor VS sensor Vehicle Speed sensor IACV Idle Air Control Valve ECM Engine Control Module EEPROM Electrically Erasable Programmable Read Only Memory DLC Data Link Connector SCS connector Service Check Short connector HDS Honda Diagnostic System DTC Diagnostic Trouble Code MIL Malfunction Indicator Lamp FP Fuel Pump PAIR Pulsed Secondary Air Injection ABS Anti-lock Brake System HISS Honda Ignition Security System

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Page 3

MODEL IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

CBF1000A Shown:

GENERAL INFORMATION

SERIAL NUMBERS

The Vehicle Identification Number (V.I.N) is stamped on the right side of the steering head.

The engine serial number is stamped on the lower side of the lower crankcase.

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Page 4

GENERAL INFORMATION

THROTTLE BODY IDENTIFICATION NUMBER

MODEL IDENTIFICATION LABEL

COLOR LABEL

The throttle body identification number is stamped on the intake side of the throttle body as shown.

LABELS

The Model Identification Label is located on left side of the frame tube.

The color label is attached as shown. When ordering color-coded parts, always specify the designated color code.

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Page 5

GENERAL INFORMATION

GENERAL SPECIFICATIONS

ITEM SPECIFICATIONS

DIMENSIONS Overall length 2,156 mm (84.9 in)

Overall width 782 mm (30.8 in) Overall height 1,238 mm (48.7 in) Wheelbase 1,483 mm (58.4 in) Seat height 800 mm (31.5 in) Ground clearance 130 mm (5.1 in) Curb weight CBF1000: 244 kg (538 lbs)

CBF1000A: 251 kg (553 lbs)

Maximum weight capacity 195 kg (430 lbs)

FRAME Frame type Diamond type

Front suspension Telescopic fork Front axle travel 108 mm (4.3 in) Rear suspension Swingarm Rear axle travel 120 mm (4.7 in) Front tire size 120/70ZR17M/C (58W) Rear tire size 160/60ZR17M/C (69W) Front tire brand Bridgestone BT57F RADIAL U

Michelin Pilot ROAD B

Rear tire brand Bridgestone BT57R RADIAL E

Michelin Pilot ROAD A Front brake Hydraulic double disc Rear brake Hydraulic single disc Caster angle 26° 00’ Trail length 111 mm (4.4 in) Fuel tank capacity 19.3 liter (5.1 US gal, 4.2 lmp gal)

ENGINE Cylinder arrangement 4 cylinders in-line, inclined 28° from vertical

Bore and stroke 75.0 x 56.5 mm (2.95 x 2.22 in) Displacement 998.4 cm Compression ratio 11.0 : 1 Valve train Chain driven, DOHC Intake

valve Exhaust

valve Lubrication system Forced pressure and wet sump

Oil pump type Trochoid Cooling system Liquid cooled Air filtration Paper element Engine dry weight 66.5 kg (146.6 lbs) Firing order 1 - 2 - 4 - 3

FUEL DELIVERY SYSTEM

DRIVE TRAIN Clutch system Multi-plate, wet

Type PGM-FI (Programmed Fuel Injection) Throttle bore 36 mm (1.4 in)

Clutch operation system Hydraulic operating Transmission Constant mesh, 6-speeds Primary reduction 1.604 (77/48) Final reduction 2.687 (43/16) Gear ratio 1st 2.714 (38/14)

Gearshift pattern 1 - N - 2 - 3 - 4 - 5 - 6

opens: at 1 mm (0.04 in) lift 15° BTDC closes: at 1 mm (0.04 in) lift 15° ABDC opens: at 1 mm (0.04 in) lift 25° BBDC closes: at 1 mm (0.04 in) lift 5° ATDC

2nd 1.941 (33/17)

3rd 1.578 (30/19)

4th 1.363 (30/22)

5th 1.217 (28/23)

6th 1.115 (29/26)

(60.92 cu-in)

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Page 6

GENERAL INFORMATION

ITEM SPECIFICATIONS

ELECTRICAL Ignition system Computer-controlled digital transistorized

with electric advance Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier FET shorted/triple phase, full wave rectifica-

Lighting system Battery

tion

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Page 7

GENERAL INFORMATION

LUBRICATION SYSTEM SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Engine oil capacity After draining 2.7 liter (2.9 US qt, 2.4 lmp qt) –

After oil filter change 3.5 liter (3.7 US qt, 3.1 lmp qt) – After disassembly 3.6 liter (3.8 US qt, 3.2 lmp qt) –

Engine oil Suggested oil: –

Honda "4-stroke motorcycle oil" or an equivalent

Oil recommendation:

API classification: SG or higher (except oils labeled as energy conserving on the circular API service label) Viscosity: SAE 10W-30 JASO T 903 standard: MA

Oil pressure at EOP (engine oil pressure) switch 510 kPa (5.2 kgf/cm

6,000 min

Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)

Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014) Side clearance 0.04 – 0.09 (0.002 – 0.004) 0.17 (0.007)

-1

(rpm)/(80°C/176°F)

, 74 psi) at

FUEL SYSTEM (PGM-FI) SPECIFICATIONS

–

ITEM SPECIFICATIONS

Throttle body identification number GQ3BA Idle speed 1,200 ± 10 0 min Throttle grip free play 2 – 6 mm (1/12 – 1/4 in) IAT sensor resistance (at 20°C/68°F) 1 – 4 kΩ ECT sensor resistance (at 20°C/68°F) 2.3 – 2.6 kΩ Fuel injector resistance (at 20°C /68°F) 11.1 – 12.3 Ω PAIR control solenoid valve resistance (at 20°C/68°F) 23 – 27 Ω CKP sensor peak voltage (at 20°C/68°F) 0.7 V minimum Manifold absolute pressure at idle 29 – 32 kPa (0.30 – 0.33 kgf/cm Fuel pressure at idle 343 kPa (3.5 kgf/cm Fuel pump flow (at 12 V) 189 cm

(6.4 US oz, 6.7 lmp oz) minimum/10 seconds

-1

(rpm)

, 4.3 – 4.7 psi)

, 50 psi)

COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS

Coolant capacity Radiator and engine 2.71 liter (2.86 US qt, 2.38 lmp qt)

Reserve tank 0.30 liter (0.32 US qt, 0.26 lmp qt) Radiator cap relief pressure 108 – 137 kPa (1.1 – 1.4 kgf/cm Thermostat Begin to open 80 – 84 °C (176 – 183 °F)

Fully open 90 °C (194 °F)

Valve lift 8 mm (0.3 in) minimum Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion

protection inhibitors

Standard coolant concentration 1:1 mixture with distilled water

, 16 – 20 psi)

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GENERAL INFORMATION

CYLINDER HEAD/VALVES SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Cylinder compression 1,098 kPa (11.2 kgf/cm2, 159 psi)

Valve clearance IN 0.16 ± 0.03 (0.006 ± 0.001) –

EX 0.32 ± 0.03 (0.013 ± 0.001) –

Camshaft Cam lobe height IN 34.62 – 34.70 (1.363 – 1.366) 34.60 (1.362)

EX 34.58 – 34.66 (1.361 – 1.365) 34.56 (1.361) Runout – 0.05 (0.002) Oil clearance 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)

Valve lifter Valve lifter O.D. 25.978 – 25.993 (1.0228 – 1.0233) 25.97 (1.022)

Valve lifter bore I.D. 26.010 – 26.026 (1.0240 – 1.0246) 26.04 (1.025)

Valve, valve guide

Valve spring free length 39.55 (1.557) 38.76 (1.526) Cylinder head warpage – 0.10 (0.004)

Valve stem O.D. IN 4.475 – 4.490 (0.1762 – 0.1768) 4.465 (0.1758)

EX 4.465 – 4.480 (0.1758 – 0.1764) 4.455 (0.1754) Valve guide I.D. 4.500 – 4.512 (0.1772 – 0.1776) 4.540 (0.1787) Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.075 (0.0030)

EX 0.020 – 0.047 (0.0008 – 0.0019) 0.085 (0.0033) Valve guide projection above cylin-

der head Valve seat width 0.90 – 1.10 (0.035 – 0.043) 1.5 (0.06)

at 350 min

16.0 – 16.3 (0.63 – 0.64) –

-1

(rpm)

–

CLUTCH/STARTER CLUTCH SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Specified clutch fluid DOT 4 brake fluid – Clutch master cylinder Master cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022)

Master piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.645 (0.4978)

Clutch Spring free length 58.2 (2.29) 55.7 (2.19)

Disc A thickness 3.72 – 3.88 (0.146 – 0.153) 3.4 (0.13) Disc B thickness 3.22 – 3.38 (0.127 – 0.133) 2.9 (0.11)

Plate warpage – 0.30 (0.012) Clutch outer guide A (Without ID mark)

Clutch outer guide B (With ID mark)

Primary driven gear I.D. A 41.008 – 41.016 (1.6145 – 1.6148) 41.026 (1.6152)

Oil pump drive sprocket guide

Oil pump drive sprocket I.D. 35.025 – 35.145 (1.3789 – 1.3837) 35.155 (1.3841) Mainshaft O.D. at clutch outer guide 27.980 – 27.990 (1.1016 – 1.1020) 27.96 (1.101) Mainshaft O.D. at oil pump drive sprocket guide 27.980 – 27.990 (1.1016 – 1.1020) 27.96 (1.101) Starter idle gear Gear I.D. 10.013 – 10.035 (0.3942 – 0.3951) 10.05 (0.396)

Starter driven gear boss O.D. 45.657 – 45.673 (1.7975 – 1.7981) 45.642 (1.7969)

I.D. 27.993 – 28.003 (1.1021 – 1.1025) 28.012 (1.1028)

O.D. 35.004 – 35.012 (1.3781 – 1.3784) 34.994 (1.3777)

I.D. 27.993 – 28.003 (1.1021 – 1.1025) 28.012 (1.1028)

O.D. 34.996 – 35.004 (1.3778 – 1.3781) 34.986 (1.3774)

B 41.000 – 41.008 (1.6142 – 1.6145) 41.018 (1.6149)

I.D. 28.000 – 28.021 (1.1024 – 1.1032) 28.030 (1.1035)

O.D. 34.975 – 34.991 (1.3770 – 1.3776) 34.965 (1.3766)

Shaft O.D. 9.991 – 10.000 (0.3933 – 0.3937) 9.98 (0.393)

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GENERAL INFORMATION

TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Shift fork I.D. 12.000 – 12.018 (0.4724 – 0.4731) 12.03 (0.474)

Claw thickness 5.93 – 6.00 (0.233 – 0.236) 5.9 (0.23) Shift fork shaft O.D. 11.957 – 11.968 (0.4707 – 0.4712) 11.95 (0.470) Transmission Gear I.D. M5, M6 31.000 – 31.025 (1.2205 – 1.2215) 31.04 (1.222)

C1 28.000 – 28.021 (1.1024 – 1.1032) 28.04 (1.104) C2, C3, C4 33.000 – 33.025 (1.2992 – 1.3002) 33.04 (1.301)

Gear busing O.D. M5, M6 30.955 – 30.980 (1.2187 – 1.2197) 30.935 (1.2179)

C2 32.955 – 32.980 (1.2974 – 1.2984) 32.935 (1.2967) C3, C4 32.950 – 32.975 (1.2972 – 1.2982) 32.930 (1.2964)

Gear-to-bushing

clearance

Gear bushing I.D. M5 27.985 – 28.006 (1.1018 – 1.1026) 28.016 (1.1030)

Mainshaft O.D. at M5 27.967 – 27.980 (1.1011 – 1.1016) 27.957 (1.1007)

Countershaft O.D. at C2 29.967 – 29.980 (1.1798 – 1.1803) 29.960 (1.1795)

Bushing to shaft

clearance

M5, M6 0.020 – 0.070 (0.0008 – 0.0028) 0.10 (0.004) C2 0.020 – 0.070 (0.0008 – 0.0028) 0.10 (0.004) C3, C4 0.025 – 0.075 (0.0010 – 0.0030) 0.11 (0.004)

C2 29.985 – 30.006 (1.1018 – 1.1026) 30.021 (1.1819)

M5 0.005 – 0.039 (0.0002 – 0.0015) 0.06 (0.002) C2 0.005 – 0.039 (0.0002 – 0.0015) 0.06 (0.002)

CRANKCASE/CRANKSHAFT/BALANCER/PISTON/CYLINDER SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Crankshaft Connecting rod side clearance 0.05 – 0.20 (0.002 – 0.008) 0.25 (0.098)

Crankpin bearing oil clearance 0.030 – 0.052 (0.0012 – 0.0020) 0.06 (0.002) Main journal bearing oil clearance 0.019 – 0.037 (0.0007 – 0.0015) 0.05 (0.002) Runout – 0.05 (0.002)

Piston, piston rings

Cylinder I.D. 75.000 – 75.015 (2.9528 – 2.9533) 75.15 (2.959)

Cylinder-to-piston clearance 0.020 – 0.055 (0.0008 – 0.0022) 0.10 (0.004) Connecting rod small end I.D. 17.030 – 17.042 (0.6705 – 0.6709) 17.048 (0.6712) Connecting rod-to-piston pin clearance 0.030 – 0.046 (0.0012 – 0.0018) 0.07 (0.003)

Piston O.D. at 9.0 (0.35) from bottom

Piston pin bore I.D. 17.002 – 17.008 (0.6694 – 0.6696) 17.030 (0.6705) Piston pin O.D. 16.994 – 17.000 (0.6690 – 0.6693) 16.980 (0.6685) Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.04 (0.002) Piston ring end

gap

Piston ring-to-ring groove clearance

Out of round – 0.10 (0.004) Taper – 0.10 (0.004) Warpage – 0.10 (0.004)

Top 0.22 – 0.32 (0.009 – 0.013) 0.52 (0.020) Second 0.48 – 0.63 (0.019 – 0.025) 0.82 (0.032) Oil (side rail) Top 0.050 – 0.085 (0.0020 – 0.0033) 0.125 (0.0049) Second 0.015 – 0.050 (0.0006 – 0.0020) 0.075 (0.0030)

74.960 – 74.980 (2.9512 – 2.9520) 74.895 (2.9486)

0.2 – 0.7 (0.01 – 0.03) 1.0 (0.04)

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Page 10

GENERAL INFORMATION

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Minimum tire tread depth – 1.5 (0.06) Cold tire pres-

sure Axle runout – 0.2 (0.008) Wheel rim

runout Wheel balance weight – 60 g (2.1oz)

Fork Spring free length 358.8 (14.13) 352 (13.9)

Steering head bearing pre-load 9.8 – 13.7 N (1.0 – 1.4 kgf, 2.2 – 3.1 lbf) –

Driver only 250 kPa (2.50 kgf/cm Driver and passenger 250 kPa (2.50 kgf/cm

Radial – 2.0 (0.08) Axial – 2.0 (0.08)

Fork pipe runout – 0.20 (0.008) Recommended fork fluid Honda ULTRA CUSHION OIL 10W or

equivalent Fluid level 129 (5.1) – Fluid capacity 437 ± 2.5 cm

0.09 lmp oz)

(14.8 ± 0.08 US oz, 15.4 ±

, 36 psi) –

max.

REAR WHEEL/SUSPENSION SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Minimum tire tread depth – 2.0 (0.08) Cold tire pressure

Axle runout – 0.2 (0.01) Wheel rim runout

Wheel balance weight – 60 g

Drive chain Size/link DID DID50VA8/120 links –

Shock absorber spring pre-load adjuster standard position

Driver only 290 kPa (2.90 kgf/cm2, 42 psi) – Driver and passenger 290 kPa (2.90 kgf/cm

Radial – 2.0 (0.08) Axial – 2.0 (0.08)

RK RK50HFOZ5/120 links –

Slack 20 – 30 (4/5 – 1-1/5) –

Position 3 –

, 42 psi) –

(2.1 oz) max.

–

1-10

Page 11

GENERAL INFORMATION

HYDRAULIC BRAKE SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT

Front Specified brake fluid DOT 4 –

Brake disc thickness 4.5 (0.18) 3.5 (0.14) Brake disc runout – 0.30 (0.012) Master cylinder I.D. 12.700 – 12.743 (0.5000 – 0.5017) 12.755 (0.5022) Master piston O.D. 12.657 – 12.684 (0.4983 – 0.4994) 12.650 (0.4980) Caliper cylinder I.D. CBF1000A: 22.650 – 22.700 (0.8917 – 0.8937) 22.710 (0.8941)

CBF1000: 25.400 – 25.450 (1.0000 – 1.0020) 25.460 (1.0024)

Caliper piston O.D. CBF1000A: 22.585 – 22.618 (0.8892 – 0.8905) 22.560 (0.8882)

CBF1000: 25.318 – 25.368 (0.9968 – 0.9987) 25.310 (0.9965)

Rear Specified brake fluid DOT 4 –

Brake disk thickness

Brake disc runout – 0.30 (0.012) Master cylinder I.D. CBF1000A: 17.460 17.503 (0.6874 0.6891) 17.515 (0.6896)

Master piston O.D. CBF1000A: 17.417 – 17.444 (0.6857 – 0.6868) 17.405 (0.6852)

Caliper cylinder I.D. CBF1000A: 25.400 – 25.450 (1.0000 – 1.0020) 25.460 (1.0024)

Caliper piston O.D. CBF1000A: 25.318 – 25.368 (0.9968 – 0.9987) 25.310 (0.9965)

CBF1000A: 6.0 (0.24) 5.0 (0.20) CBF1000: 5.0 (0.20) 4.0 (0.16)

CBF1000: 14.000 – 14.043 (0.5512 – 0.5529) 14.055 (0.5533)

CBF1000: 13.957 – 13.984 (0.5495 – 0.5506) 13.945 (0.5490)

CBF1000: 38.180 – 38.230 (1.5031 – 1.5051) 38.24 (1.506)

CBF1000: 38.098 – 38.148 (1.4999 – 1.5019) 38.09 (1.500)

Unit: mm (in)

BATTERY/CHARGING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS

Battery Capacity 12 V – 8.6 Ah

Current leakage 0.5 mA max. Vol tage

(20°C/68°F)

Charging current Normal 0.9 A/5 – 10 h

Alternator Capacity 0.344 kW/5,000 min

Charging coil resistance (20°C/68°F) 0.1 – 1.0 Ω

Fully charged 13.0 – 13.2 V Needs

charging

Quick 4.5 A/1 h

Below 12.4 V

-1

(rpm)

IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS

Spark plug NGK CR8EH-9

DENSO U24FER9 Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in) Ignition coil peak voltage 100 V minimum CKP sensor peak voltage 0.7 V minimum Ignition timing ("F"mark) 5° BTDC at idle

ELECTRIC STARTER SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT

Starter motor brush length 12.0 – 13.0 (0.47 – 0.51) 6.5 (0.26)

Unit: mm (in)

1-11

Page 12

GENERAL INFORMATION

LIGHTS/METERS/SWITCHES SPECIFICATIONS

ITEM SPECIFICATIONS

Bulbs Headlight Hi 12 V – 55 W

Lo 12 V – 55 W Position light 12 V – 5 W x 2 Brake/tail light 12 V – 21/5 W Turn signal light 12 V – 21 W x 4 Instrument light LED Turn signal indicator LED High beam indicator LED Oil pressure indicator LED Neutral indicator LED Temp. indicator LED Malfunction indicator lamp (MIL) LED Immobilizer indicator LED ABS indicator (CBF1000A) LED

Fuse Main fuse 30 A

PGM-FI/IGN fuse 20 A Sub fuse 10 A x 3, 20 A x 2 ABS main fuse (CBF1000A) 10 A ABS fail-safe relay fuse (CBF1000A) 30 A ABS motor fuse (CBF1000A) 30 A

Tachometer peak voltage 10.5 V minimum ECT sensor resistance 80 °C (176 °F) 2.1 – 2.6 kΩ

120 °C (248 °F) 0.65 – 0.73 kΩ

1-12

Page 13

STANDARD TORQUE VALUES

GENERAL INFORMATION

FASTENER TYPE

5 mm hex bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9) 6 mm hex bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5) 8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head, small flange) 10 (1.0, 7) 10 mm hex bolt and nut 34 (3.5, 25) 6 mm flange bolt (8 mm head, large flange) 12 (1.2, 9) 12 mm hex bolt and nut 54 (5.5, 40) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9)

TORQUE

N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)

8 mm flange bolt and nut 26 (2.7, 20) 10 mm flange bolt and nut 39 (4.0, 29)

FASTENER TYPE

TORQUE

ENGINE & FRAME TORQUE VALUES

• Torque specifications listed below are for important fasteners.

• Others should be tightened to standard torque values listed above.

ENGINE

MAINTENANCE

ITEM Q'TY

Spark plug 4 10 16 (1.6, 12) Timing hole cap 1 45 18 (1.8, 13) Apply grease to the threads. Engine oil filter cartridge 1 20 26 (2.7, 19) Apply oil to the threads and

Oil filter boss 1 20 See page 4-16 Apply locking agent. Engine oil drain bolt 1 12 30 (3.1, 22)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

O-ring.

LUBRICATION SYSTEM

ITEM Q'TY

Oil pump assembly bolt 3 6 8 (0.8, 5.9) CT bolt

FUEL SYSTEM (PGM-FI)

ITEM Q'TY

ECT/thermo sensor 1 12 23 (2.3, 17) Insulator band screw (Throttle

body side) Insulator band screw (Cylinder

head side) Fuel rail mounting bolt 4 6 5.1 (0.5, 3.8)

COOLING SYSTEM

ITEM Q'TY

Coolant drain bolt 1 6 12 (1.2, 9) CT bolt Water pump assembly bolt 2 6 12 (1.2, 9) CT bolt

ENGINE REMOVAL/INSTALLATION

ITEM Q'TY

Drive sprocket bolt 1 10 54 (5.5, 40)

4 5 See page 6-72

4 5 See page 6-67

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

1-13

Page 14

GENERAL INFORMATION

CYLINDER HEAD/VALVES

ITEM Q'TY

Cylinder head mounting bolt 10 9 51 (5.2, 38) Apply molybdenum oil solu-

Camshaft holder flange bolt 20 6 12 (1.2, 9) Cylinder head sealing bolt 2 18 28 (2.9, 21) Apply locking agent. Cylinder head cover bolt 4 6 10 (1.0, 7) PAIR reed valve cover bolt 4 6 12 (1.2, 9) Apply locking agent. Cam sprocket bolt 4 7 20 (2.0, 15) Apply locking agent. Cam chain tensioner pivot bolt 1 6 10 (1.0, 7) Apply locking agent. Cam chain guide torx bolt 1 6 12 (1.2, 9) Apply locking agent. Exhaust pipe stud bolt 8 8 See page 3-13

CLUTCH/STARTER CLUTCH

ITEM Q'TY

Clutch center lock nut 1 25 128 (13.1, 94) Apply oil to the threads and

Clutch spring bolt 5 6 12 (1.2, 9) Oil pump driven sprocket bolt 1 6 15 (1.5, 11) Apply locking agent. Right crankcase cover rubber damper set plate bolt Starter clutch outer mounting bolt 1 10 83 (8.5, 61) Apply oil to the threads and

1 6 12 (1.2, 9) Apply locking agent.

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

tion to the threads and seating surface.

REMARKS

seating surface. Stake.

CT bolt

seating surface.

ALTERNATOR

ITEM Q'TY

Stator wire clamp flange bolt 1 6 12 (1.2, 9) CT bolt Flywheel flange bolt 1 10 103 (10.5, 76) Apply oil to the threads and

Stator mounting socket bolt 4 6 12 (1.2, 9)

TRANSMISSION/GEARSHIFT LINKAGE

ITEM Q'TY

Transmission holder flange bolt 6 8 29 (3.0, 21) Countershaft bearing set plate

bolt Mainshaft bearing set plate bolt 3 6 12 (1.2, 9) Apply locking agent. Shift drum center socket bolt 1 8 23 (2.3, 17) Apply locking agent. Shift drum stopper arm pivot bolt 1 6 12 (1.2, 9) Gearshift spindle return spring

pin Shift drum bearing setting bolt 2 6 12 (1.2, 9) Apply locking agent. Gearshift cam bolt 1 6 12 (1.2, 9) Apply locking agent.

1 6 12 (1.2, 9) Apply locking agent.

1 8 23 (2.3, 17)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

seating surface.

REMARKS

1-14

Page 15

GENERAL INFORMATION

CRANKCASE/CRANKSHAFT/BALANCER/PISTON

ITEM Q'TY

Crankcase 7 mm bolt 12 7 18 (1.8, 13)

8 mm bolt 6 8 24 (2.4, 18) 9 mm bolt (main

journal bolt) Lower crankcase sealing bolt 1 22 59 (6.0, 44) Apply locking agent. Lower crankcase socket bolt 1 10 12 (1.2, 9) Apply locking agent. Lower crankcase sealing bolt 1 20 30 (3.1, 22) Apply locking agent. Lower crankcase socket bolt 1 8 23 (2.3, 17) Apply locking agent. Connecting rod bolt (new bolt) 8 8 See page 13-23 Apply oil to the threads and

Connecting rod bolt (retightening) 8 8 See page 13-13 Apply oil to the threads and

ELECTRIC STARTER

ITEM Q'TY

Starter motor terminal nut 1 6 12 (1.2, 9)

LIGHTS/METERS/SWITCHES

ITEM Q'TY

EOP switch 1 PT 1/8 12 (1.2, 9) Apply sealant to the threads. EOP switch wire terminal bolt 1 4 2 (0.2, 1.5) Neutral switch 1 10 12 (1.2, 9)

10 9 See page 13-23

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

seating surface.

REMARKS

1-15

Page 16

GENERAL INFORMATION

0 – 1 mm (0 – 0.04 in)

FRAME

FRAME/BODY PANELS/EXHAUST SYSTEM

ITEM Q'TY

Exhaust pipe joint nut 8 7 20 (2.0, 15) Side stand pivot bolt 1 10 15 (1.5, 11) Side stand pivot nut 1 10 39 (4.0, 29) Grab rail mounting bolt 4 8 27 (2.8, 20) Front fender mounting bolt (front) 2 6 12 (1.2, 9) Front fender mounting bolt (rear) 2 6 12 (1.2, 9) Rearview mirror mounting bolt 4 6 14 (1.4, 10)

MAINTENANCE

ITEM Q'TY

Drive chain adjuster lock nut 2 8 21 (2.1, 15)

FUEL SYSTEM (PGM-FI)

ITEM Q'TY

Fuel tank rear mounting nut 1 6 12 (1.2, 9) Fuel filler cap mounting bolt 3 4 1.8 (0.2, 1.3) Fuel feed hose banjo bolt 1 12 22 (2.2, 16) Fuel pump mounting nut 6 6 12 (1.2, 9) See page 6-56 O

2 sensor 1 18 44 (4.5, 32)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

COOLING SYSTEM

ITEM Q'TY

Cooling fan nut 1 5 2.7 (0.3, 2.0) Fan motor nut 3 5 5.1 (0.5, 3.8) Apply locking agent. Fan motor bracket mounting bolt 3 6 8.4 (0.9, 6.2)

Radiator hose band:

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

1-16

Page 17

GENERAL INFORMATION

ENGINE REMOVAL/INSTALLATION

ITEM Q'TY

Front engine hanger bolt 2 12 60 (6.1, 44) Rear engine hanger nut (upper) 1 12 60 (6.1, 44) Rear engine hanger nut (lower) 1 12 60 (6.1, 44) Swingarm pivot bracket nut 2 12 69 (7.0, 51) Gearshift arm pinch bolt 1 6 10 (1.0, 7)

CLUTCH/STARTER CLUTCH

ITEM Q'TY

Clutch lever pivot bolt 1 6 1 (0.1, 0.7) Apply silicone grease to the

Clutch lever pivot nut 1 6 5.9 (0.6, 4.4) Clutch master cylinder holder bolt 2 6 12 (1.2, 9) Clutch master cylinder reservoir cap screw Clutch switch mounting screw 1 4 1.2 (0.1, 0.9) Clutch hose oil bolt 2 10 34 (3.5, 25)

FRONT WHEEL/SUSPENSION/STEERING

ITEM Q'TY

Steering stem adjusting lock nut 1 26 See page 14-34 Steering stem adjusting nut 1 26 25 (2.5, 18) Apply oil to the threads. Steering stem nut 1 24 103 (10.5, 76) Bottom bridge pinch bolt 2 10 39 (4.0, 29) Top bridge pinch bolt 2 8 22 (2.2, 16) Fork cap 2 37 22 (2.2, 16) Fork cap lock nut 210 19.6 (2.0, 14)

Fork center bolt 2 8 20 (2.0, 15) Apply locking agent. Front axle pinch bolt 2 8 22 (2.2, 16) Front axle bolt 1 14 59 (6.0, 44) Front brake disc bolt 12 6 20 (2.0, 15) ALOC bolt Front pulser ring mounting bolt (CBF1000A)

2 4 1.5 (0.2, 1.1)

3 5 7 (0.7, 5.2) ALOC bolt

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

sliding surface.

REMARKS

REAR WHEEL/SUSPENSION

ITEM Q'TY

Drive chain case mounting bolt 2 6 12 (1.2, 9) Rear axle nut 1 18 98 (10.0, 72) U-nut Rear brake disc bolt 4 8 42 (4.3, 31) ALOC bolt Driven sprocket nut 5 12 108 (11.0, 80) Shock absorber mounting nut 2 10 42 (4.3, 31) U-nut Shock arm nut 2 10 42 (4.3, 31) U-nut Shock link-to-frame nut 1 10 42 (4.3, 31) U-nut Swingarm pivot nut 1 18 98 (10.0, 72) U-nut Drive chain slider screw 2 5 6 (0.6, 4.4) Rear pulse ring mounting bolt (CBF1000A) Gearshift pedal pivot bolt 1 8 27 (2.8, 20)

4 5 7 (0.7, 5.2) ALOC bolt

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

1-17

Page 18

GENERAL INFORMATION

HYDRAULIC BRAKE

ITEM Q'TY

Brake hose oil bolt

CBF1000A: 6 10 34 (3.5, 25)

CBF1000: 5 10 34 (3.5, 25) Front brake caliper mounting bolt 4 8 30 (3.1, 22) ALOC bolt Caliper bleed valve

CBF1000A: 5 8 5.4 (0.6, 4.0)

CBF1000: 3 8 5.4 (0.6, 4.0) Brake pad pin 3 10 17 (1.7, 13) Pad pin plug (CBF1000) 2 10 2.5 (0.3, 1.8) Front brake caliper slide pin

CBF1000A: 2 10 22 (2.2, 16) Apply locking agent.

CBF1000: 2 8 22 (2.2, 16) Apply locking agent. Front brake caliper bracket pin

CBF1000A: 2 10 12 (1.2, 9)

CBF1000: 2 8 12 (1.2, 9) Rear brake caliper slide pin 1 12 27 (2.8, 20) Rear brake caliper bracket pin (CBF1000A) Rear brake caliper bolt (CBF1000) 1 8 22 (2.2, 16) Front master cylinder holder bolt 2 6 12 (1.2, 9) Front master cylinder reservoir cap screw Brake lever pivot bolt 1 6 1 (0.1, 0.7) Apply silicone grease to the

Brake lever pivot nut 1 6 5.9 (0.6, 4.4) Front brake light switch screw 1 4 1.2 (0.1, 0.9) Rear master cylinder mounting

bolt Rear master cylinder reservoir

hose joint screw Rear master cylinder push rod

lock nut Rear master cylinder reservoir

mounting bolt Front brake hose clamp bolt

CB F10 0 0A: 4 6 10 (1.0, 7)

CBF1000: 1 6 10 (1.0, 7) Front brake hose stay mounting

bolt (CBF1000A) Rear brake hose guide screw 2 5 4.2 (0.4, 3.1)

1 8 12 (1.2, 9) Apply locking agent.

2 4 1. 5 ( 0 . 2, 1. 1)

2 6 12 (1.2, 9)

1 4 1.5 (0.2, 1.1) Apply locking agent.

1 8 17 (1.7, 13)

1 6 10 (1.0, 7)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

sliding surface.

ABS (Anti-lock Brake System)

ITEM Q'TY

ABS modulator lower mounting bolt

ABS modulator left mounting bolt 1 6 10 (1.0, 7) Rear brake pipe stay bolt 1 6 12 (1.2, 9) Front brake hose joint bolt 2 6 10 (1.0, 7) Front wheel speed sensor mounting bolt Rear wheel speed sensor mounting bolt Speed sensor wire clamp bolt 2 6 10 (1.0, 7) ALOC bolt Brake pipe joint nut 12 10 17 (1.7, 13) Apply brake fluid to the

Proportional control valve mounting bolt

2 6 12 (1.2, 9) ALOC bolt

2 6 10 (1.0, 7)

2 6 12 (1.2, 9)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

threads.

1-18

Page 19

GENERAL INFORMATION

LIGHTS/METERS/SWITCHES

ITEM Q'TY

Ignition switch mounting bolt 2 8 25 (2.5, 18) One-way bolt License light mounting nut 2 5 1.8 (0.2, 1.3) Horn mounting bolt 1 8 32 (3.3, 24)

OTHERS

ITEM Q'TY

Footpeg holder mounting bolt 4 8 27 (2.8, 20) Footpeg lower plate bolt 4 5 5 (0.5, 3.7) Footpeg holder guard mounting

nut Gearshift pedal link pivot bolt 1 8 27 (2.8, 20) License light mounting nut 2 5 1.8 (0.2, 1.3) Front center cowl stay mounting

nut Side cowl stay mounting bolt 4 8 32 (3.3, 24)

4 6 12 (1.2, 9)

2 8 27 (2.8, 20)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

THREAD TORQUE

DIA. (mm) N·m (kgf·m, lbf·ft)

REMARKS

1-19

Page 20

GENERAL INFORMATION

LUBRICATION & SEAL POINTS

ENGINE

MATERIAL LOCATION REMARKS

Liquid sealant (Three Bond 1207B or equivalent)

Liquid sealant (Three Bond 5211C or equivalent)

Molybdenum disulfide oil (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease)

Engine oil Clutch joint piece sliding surface

Multi-purpose grease Timing hole cap threads

Crankcase mating surface See page 13-23 Oil pan mating surface See page 5-7 Right crankcase cover mating surface See page 10-33 Alternator cover mating surface See page 11-5 Oil pressure switch threads See page 21-19 Cylinder head semi-circular cut-out See page 9-31

Main journal bearing surface Piston pin sliding surface Connecting rod bearing surface Connecting rod small end inner surface Crankshaft thrust surface Camshaft lobes, journals and thrust surface Do not apply mating sur-

Valve stem (valve guide sliding surface) Valve lifter outer sliding surface Clutch outer/primary driven gear sliding surface Clutch outer guide sliding surface Oil pump drive sprocket and collar sliding surface M3/4, C5, C6 shifter gear (shift fork grooves) Starter reduction gear shaft sliding surface Starter idle gear shaft sliding surface Water pump shaft thrust washer sliding surface Cylinder head mounting bolt threads and seating surface

Clutch lifter rod outer surface Piston and piston ring sliding surface Oil strainer packing whole surface Clutch disc whole surface Starter one-way clutch sliding surface Flywheel bolt threads and seating surface Clutch center lock nut threads and seating surface Oil filter cartridge threads and O-ring surface Camshaft holder bolt threads and seating surface Starter clutch mounting bolt threads and seating surface Connecting rod bolt threads and seating surface Each gear teeth and rotating surface Each bearing rolling surface Each O-ring whole surface Other rotating area and sliding surface

Balancer damper rubber fitting area Each oil seal lips

face of the camshaft holder

1-20

Page 21

GENERAL INFORMATION

MATERIAL LOCATION REMARKS

Locking agent Gearshift spindle cover bolt threads See page 12-10

Lower crankcase 22 mm sealing bolt threads Lower crankcase 20 mm sealing bolt threads Lower crankcase 10 mm sealing bolt threads Lower crankcase 8 mm sealing bolt threads Cam chain guide A pivot bolt threads Cylinder head sealing bolt threads Cylinder head cover breather joint threads Oil pump driven sprocket bolt threads Coating width: 6.5 ± 1 mm Shift drum bearing setting bolt threads Coating width: 6.5 ± 1 mm Oil filter boss threads (stud side) Coating width: 6.5 ± 1 mm Right crankcase cover damper rubber plate bolt

threads Mainshaft/countershaft bearing set plate bolt

threads Cam sprocket bolt threads Coating width: 6.5 ± 1 mm Shift drum center bolt threads Coating width: 6.5 ± 1 mm Cam chain tensioner pivot bolt threads Coating width: 6.5 ± 1 mm Gearshift cam bolt threads Coating width: 6.5 ± 1 mm

Coating width: 6.5 ± 1 mm

1-21

Page 22

GENERAL INFORMATION

FRAME

MATERIAL LOCATION REMARKS

Multi-purpose grease Side stand pivot sliding area

Center stand pivot sliding area Throttle cable end Driver footpeg sliding area Passenger footpeg sliding area Gearshift pedal pivot sliding area Rear brake pedal pivot sliding area Rear wheel hub O-ring and sleeve (driven flange

contact area) Front wheel dust seal lips

Rear wheel dust seal lips Lithium based multi-purpose grease with extreme pressure (Shell Alvania EP2 or equivalent)

Urea based multi-purpose grease with extreme pressure agent (example: EXCELITE EP2 manufactured by KYODO YUSHI, Japan), Shell Stamina EP2 or equivalent Molybdenum paste Shock absorber spring adjuster cam sliding area

Engine oil Steering head bearing adjusting nut threads Cable lubricant Throttle cable A, B casing inside Honda bond A, Honda hand grip cement, Cemedine #540

or equivalent Silicone grease Brake caliper main and sub slide pin sliding surfaces Apply 0.4 g each

DOT 4 brake fluid Master cylinder inner surface

Fork fluid Fork cap O-ring

Locking agent Rear master cylinder reservoir hose joint screw

Swingarm pivot bearings

Swingarm pivot dust seal lips

Shock arm and shock link needle bearings

Shock arm and shock link dust seal lips

Shock absorber pivot dust seal lips

Shock absorber pivot needle bearing

Upper and lower steering head bearing Apply 3 – 5 g each

Steering head dust seal lips

Handlebar grip rubber inside

Brake caliper pin boot inside

Front brake lever pivot

Front brake lever-to-master piston contact area Apply 0.1 g min.

Rear master cylinder push rod-to-master piston con-

tact area

Rear master cylinder push rod boot inside

Brake caliper dust seal

Clutch lever pivot and master piston contact area

Clutch lever joint piece-to-push rod contact area

Brake master pistons and cups

Brake caliper pistons and piston seals

Fork dust seal and oil seal lips

threads

Fork socket bolt threads

Front brake caliper main and sub slide pin bolt

threads

Rear brake caliper sub slide pin bolt threads

Apply 0.1 g min.

1-22

Page 23

CABLE & HARNESS ROUTING

FRONT WHEEL SPEED SENSOR

FRONT WHEEL SPEED SENSOR WIRE

FRONT BRAKE HOSES

HOSE CLAMP

FRONT BRAKE HOSE

CBF1000A:

SPEED SENSOR WIRE

BRAKE HOSE

STOPPER

HOSE GUIDE

FRONT BRAKE HOSE

CBF1000:

GENERAL INFORMATION

1-23

Page 24

GENERAL INFORMATION

LEFT HANDLEBAR SWITCH WIRE

CLUTCH HOSE

THROTTLE CABLES

BRAKE HOSE

RIGHT HANDLEBAR SWITCH WIRE

CLUTCH SWITCH WIRE

CLUTCH HOSE EYELET

Front

LEFT TURN SIGNAL LIGHT WIRE

CLUTCH SWITCH WIRE

CLUTCH HOSE

IMMOBILIZER RECEIVER WIRE

LEFT HANDLEBAR SWITCH WIRE

IMMOBILIZER RECEIVER 4P CONNECTOR

1-24

Page 25

GENERAL INFORMATION

BANK ANGLE SENSOR 3P CONNECTOR

FRONT BRAKE HOSE

HEADLIGHT WIRE

IGNITION SWITCH WIRE

HANDLEBAR SWITCH WIRE

RIGHT HANDLEBAR SWITCH 2P (Natural), 9P (Brown) CONNECTORS/ IGNITION SWITCH 4P CONNECTOR

LEFT HANDLEBAR SWITCH 6P (Blue), 4P (Black) CONNECTORS

Front

CLAMP

HEADLIGHT WIRE

MAIN WIRE HARNESS

LEFT TURN SIGNAL LIGHT WIRE

IMMOBILIZER RECEIVER WIRE

20°

RIGHT TURN SIGNAL/ BANK ANGLE SENSOR WIRE

1-25

Page 26

GENERAL INFORMATION

BANK ANGLE SENSOR 3P (Green) CONNECTOR

THROTTLE CABLES

IGNITION SWITCH WIRE

RIGHT HANDLEBAR SWITCH WIRE

FRONT BRAKE HOSE

MAIN WIRE HARNESS

RIGHT HANDLEBAR SWITCH WIRE

IGNITION SWITCH WIRE

1-26

Page 27

GENERAL INFORMATION

Right

CRANKCASE BREATHER HOSE

ECT SENSOR 3P (Gray) CONNECTOR

PAIR AIR HOSE CKP SENSOR 2P (Red)

CONNECTOR

Left

FRONT WHEEL SPEED SENSOR WIRE (CBF1000A only)

Front

FRONT WHEEL SPEED SENSOR 2P (Blue) CONNECTOR (CBF1000A only)

HORN WIRE

CKP SENSOR WIRE

HORN WIRE

CKP SENSOR 2P (Red) CONNECTOR

1-27

Page 28

GENERAL INFORMATION

FUEL TANK BREATHER HOSEFUEL TANK DRAIN HOSE

FUEL FEED HOSEFUEL PUMP 3P (Black) CONNECTOR

DRAIN HOSE

BREATHER HOSE

INJECTOR SUB-HARNESS 10P (Black) CONNECTOR

IACV WIRE

MAIN WIRE HARNESS

INTAKE DUCT DIAPHRAGM VACUUM HOSE

#4 INJECTOR 2P (Gray) CONNECTOR

ENGINE SUB-HARNESS 8P CONNECTOR

IACV 4P CONNECTOR

1-28

Page 29

GENERAL INFORMATION

FRONT BRAKE PIPE (CBF1000A only)

CRANKCASE BREATHER HOSE

THERMOSTAT CASE SIPHON HOSE

FUEL TANK DRAIN HOSE

FUEL TANK BREATHER HOSE

Front

FUSE BOX WIRE (CBF1000A only)

To main wire harness

INJECTOR SUB-HARNESS 10P (Black) CONNECTOR

ABS/FI FUSE BOX (CBF1000A only)

BATTERY NEGATIVE (–) CABLE

BATTERY POSITIVE (+) CABLE

BATTERY LINE 1P CONNECTOR

STARTER RELAY SWITCH

CBF1000:

1-29

Page 30

GENERAL INFORMATION

O2 SENSOR WIRE

Hook

EOP SWITCH

O2 SENSOR

NEUTRAL SWITCH

REAR BRAKE LIGHT SWITCH WIRE

EOP SWITCH WIRE

CLAMP

20°

Bend the clamp upward

1-30

Page 31

GENERAL INFORMATION

FUEL FEED HOSE

PAIR AIR HOSE (To air cleaner housing)

CLUTCH HOSE

FRONT BRAKE PIPES (CBF1000A only)

IGNITION COIL #2/3 WIRE

SPARK PLUG #1WIRE

PAIR AIR HOSE

TP SENSOR WIRE

INTAKE DUCT CONTROL VALVE WIRE

INTAKE AIR DUCT VACUUM HOSE

FAN MOTOR 2P (Black) CONNECTOR

1-31

Page 32

GENERAL INFORMATION

CLUTCH HOSE

Left

SIDE STAND SWITCH WIRE

GROUND CABLE

STARTER MOTOR CABLE

ALTERNATOR WIRE

FUEL TANK DRAIN HOSE FUEL TANK BREATHER HOSE RADIATOR RESERVE TANK OVERFLOW HOSE

SIDE STAND SWITCH

GROUND CABLE

STARTER MOTOR CABLE

1-32

Page 33

GENERAL INFORMATION

INTAKE DUCT DIAPHRAGM VACUUM HOSE

SIDE STAND SWITCH 2P (Green) CONNECTOR

IAT SENSOR 2P (Gray) CONNECTOR

REGULATOR/ RECTIFIER

TP SENSOR WIRE

CLUTCH HOSE

ALTERNATOR WIRE

SIDE STAND SWITCH WIRE

ALTERNATOR WIRE

RIGHT REAR TURN SIGNAL LIGHT WIRE

LICENSE LIGHT WIRE

TAIL/BRAKE LIGHT WIRE

LEFT REAR TURN SIGNAL LIGHT WIRE

CLAMP

1-33

Page 34

GENERAL INFORMATION

LOWER RADIATOR HOSE

Left

Bottom

Right

Front Rear

Front

Rear

OIL COOLER WATER HOSE

RADIATOR RESERVE TANK OVERFLOW HOSE

FUEL TANK BREATHER HOSE

FUEL TANK DRAIN HOSE

1-34

Page 35

GENERAL INFORMATION

CLUTCH HOSE

IGNITION COIL #2/#3

To cooling fan motor

MAIN WIRE HARNESS

IGNITION COIL #1/#4

To air cleaner housing

CRANKCASE BREATHER HOSE

PAIR CONTROL VALVE

SPARK PLUG WIRES

PAIR AIR HOSE

1-35

Page 36

GENERAL INFORMATION

INJECTOR SUB-HARNESS

INTAKE AIR DUCT CONTROL VALVE 2P CONNECTOR

INTAKE AIR DUCT VACUUM HOSE

MAP SENSOR VACUUM HOSES

TP SENSOR WIRE

ONE-WAY VALVE

VACUUM CHAMBER

MAP SENSOR WIRE

To diaphragm

1-36

Page 37

GENERAL INFORMATION

STARTER MOTOR CABLE

VS SENSOR 3P CONNECTOR

STARTER MOTOR CABLE

GROUND CABLE

Front

ENGINE SUB-HARNESS

1-37

Page 38

GENERAL INFORMATION

PROPORTIONAL CONTROL VALVE

REGULATOR/ RECTIFIER

CONNECTOR BOOT:

– DLC – ABS CHECK CONNECTOR

FUSE BOX

ABS MODULATOR

From front master cylinder

To front brake calipers

To rear brake caliper

ABS MODULATOR 25P CONNECTOR

From rear master cylinder

CBF1000A:

To right front brake caliper

REGULATOR/ RECTIFIER

FUSE BOX

DLC

O2 SENSOR WIREMAIN WIRE HARNESS

CONNECTOR BOOT:

– ALTERNATOR 3P CONNECTOR – REGULATOR/RECTIFIER 2P CONNECTOR

CBF1000:

1-38

Page 39

GENERAL INFORMATION

STARTER RELAY SWITCH 4P CONNECTOR

MAIN WIRE HARNESS

FUSE BOX WIRE

REAR BRAKE LIGHT SWITCH WIRE

O2 SENSOR WIRE

To fuse box

REAR WHEEL SPEED SENSOR WIRE

ABS/FI FUSE BOX 3P CONNECTOR

O2 SENSOR WIRE

CBF1000A:

WIRE BAND (Bundle with the frame):

– Main wire harness – O

2 sensor wire

WIRE BAND (Bundle with the frame):

– Rear brake light switch wire – O

2 sensor wire

– Starter relay switch wire

STARTER RELAY SWITCH 4P CONNECTOR

CBF1000A:

O2 SENSOR WIRE

BATTERY LINE 1P CONNECTOR

REAR BRAKE LIGHT SWITCH 2P CONNECTOR

1-39

Page 40

GENERAL INFORMATION

ECM

CONNECTOR BOOT: – O

2 SENSOR 4P (Natural) CONNECTOR

TURN SIGNAL LIGHT RELAY

RELAY BOX

TAIL/BRAKE LIGHT WIRE LICENSE LIGHT WIRE

REAR WHEEL SPEED SENSOR WIRE

O2 SENSOR WIRE

CBF1000A:

– REAR WHEEL SPEED SENSOR

2P (Green) CONNECTOR

OPTION CONNECTOR

ECM

CONNECTOR BOOT: – O

2 SENSOR 4P (Natural) CONNECTOR

– OPTION CONNECTOR

TURN SIGNAL LIGHT RELAY

RELAY BOX

TAIL/BRAKE LIGHT WIRE LICENSE LIGHT WIRE

O2 SENSOR WIRE

CBF1000:

WIRE BAND (Bundle with the frame)

1-40

Page 41

GENERAL INFORMATION

HOSE GUIDES

REAR WHEEL SPEED SENSOR

SPEED SENSOR WIRE

REAR BRAKE HOSE

CLAMP

SPEED SENSOR WIRE

REAR BRAKE HOSE

CBF1000A:

REAR BRAKE HOSE

HOSE GUIDES

CBF1000:

1-41

Page 42

GENERAL INFORMATION

AIR CLEANER HOUSING

THROTTLE BODY

FRESH AIR

BLOW-BY GAS

EMISSION CONTROL SYSTEMS

SOURCE OF EMISSIONS

The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of carbon monoxide, oxides of nitrogen and hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

Honda Motor Co., Ltd. utilizes various systems (page 1-43) to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.

Blow-by gas is returned to the combustion chamber through the air cleaner and throttle body.

1-42

Page 43

GENERAL INFORMATION

AIR CLEANER HOUSING

THROTTLE BODY

PAIR CONTROL SOLENOID VALVE

PAIR CHECK VALVE

EXHAUST PORT

FRESH AIR

EXHAUST GAS

EXHAUST EMISSION CONTROL SYSTEM

The exhaust emission control system is composed of a pulse secondary air supply system, a three-way catalytic converter and PGM-FI system.

No adjustment should be made for the exhaust emission control system. The exhaust emission control system is separate from the crankcase emission control system.

SECONDARY AIR SUPPLY SYSTEM

The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the PAIR (Pulse Secondary Air Injection) control valve.

This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.

The reed valve prevents reverse air flow through the system. The PAIR control valve is operated by the solenoid valve. The solenoid valve is controlled by the PGM-FI unit, and the fresh air passage is opened/closed according the running condition.

No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended.

THREE-WAY CATALYTIC CONVERTER

This motorcycle is equipped with a three-way catalytic converter.

The three-way catalytic converter is in the exhaust system. Through chemical reactions, they convert HC, CO and NOx in the engine's exhaust to carbon dioxide (CO

No adjustment to these systems should be made although periodic inspection of the components is recommended.

2), nitrogen (N2) and water vapor.

1-43

Page 44

GENERAL INFORMATION

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law may prohibit the following acts or the causing there of: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:

1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.

2. Removal of, or puncturing of any part of the intake system.

3. Lack of proper maintenance.

4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those specified by the manufacturer.

1-44

Page 45

2. TECHNICAL FEATURES

IACV (Idle Air Control Valve)····················· 2-2 CAMSHAFT POSITION DETECTION WITH

MAP SENSOR············································· 2-4

2-1

Page 46

TECHNICAL FEATURES

IACV

DISTRIBUTION HOSES

Idle air flow

TECHNICAL FEATURES

IACV (Idle Air Control Valve)

SUMMARY

This motorcycle adopts an Idle Air Control system for the inline-four engine, this system is composed the IACV and distribution hoses onto the throttle body. The IACV consists of a step motor and a slide valve, and controls the amount of air bypassed around the closed throttle body. With the ignition switch on, the amount of inlet air is determined from information detected by the ECT sensor. During engine start-up or while maintaining idle (throttle valve closed), the amount of inlet air is corrected by various sensors' information.

This system eliminates the need for manual idle speed adjustment and the air screw adjustment for the throttle body synchronization.

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Page 47

TECHNICAL FEATURES

VALVE

STEP MOTOR

VALVE

STEP MOTOR

OPERATION

The ECM controls the IACV when engine idling, so the ECM stops to control the IACV operation at closed position in case that the ECM detects the following condition:

• Throttle valve open

• Neutral switch OFF (in gear) and clutch switch OFF (release clutch lever)

When engine idling, from ignition switch ON to warming up, the ECM control the IACV step motor as following operations:

With the ignition switch ON

When the ignition switch ON, the IACV activates initial function, idle – open – idle position. There will be a step motor operating sound.

Start the engine – warming up

This optimizes the bypass opening with the throttle valve closed, and the corrected amount of inlet air passes through allowing proper engine start up.

After the engine has started, the ECM controls the IACV slide valve position and adjust the amount of inlet air in response to the engine coolant temperature.

After warming up – idling

When the ECM denotes the engine warming-up by the engine coolant temperature, it operates the step motor to move the slide valve to the closed position. This results in a reduced amount of bypassed air compared to the amount during engine warm-up, which allows proper engine idle to be maintained.

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Page 48

TECHNICAL FEATURES

CAMSHAFT POSITION DETECTION WITH MAP SENSOR

SUMMARY

For PGM-FI, it is necessary to detect the stroke position not only of the crankshaft (TDC position) but also of the camshaft (TDC position in compression stroke). Existing PGM-FI for inline-4 engine, the system uses the CKP sensor and CMP sensor for the injection timing control. This motorcycle adopts the PGM-FI system that has the new detection system of the camshaft position. This PGM-FI system allows for the camshaft position detection with the MAP sensor and CKP sensor, and eliminates CMP sensor.

The detection system consists of the crankshaft rotor and CKP sensor for the crankshaft position (TDC position) detection, and MAP sensor connected to No.1, 2, 3 throttle manifold via vacuum hoses for the camshaft position (TDC position in compression stroke) detection.

DETECTION SYSTEM

The ECM always monitors the manifold pressure by the MAP sensor signal and figures it. In response to the camshaft position (TDC position in compression stroke), the MAP figure changes its wave profile. The ECM recognizes these wave profile repetition and combined with the CKP sensor, then detects the camshaft position.

2-4

Page 49

3. FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION ··························· 3-2

TROUBLESHOOTING ································· 3-2

SEAT···························································· 3-3

SEAT BRACKET ·········································· 3-3

RIGHT/LEFT SIDE COVER·························· 3-4

WINDSCREEN············································· 3-4

METER PANEL ············································ 3-5

RIGHT/LEFT FRONT COWLS····················· 3-6

REARVIEW MIRROR··································· 3-6

FRONT CENTER COWL······························ 3-7

REAR COWL ··············································· 3-8

FRONT FENDER ········································· 3-9

REAR FENDER ·········································· 3-10

MUFFLER ·················································· 3-12

EXHAUST PIPE········································· 3-13

MAIN STAND (CBF1000A)······················· 3-15

SIDE STAND ············································· 3-16

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Page 50

FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION

GENERAL

• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.

• This section covers removal and installation of the body panels and exhaust system.

• Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.

• Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine.

• When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust clamps first, then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.

• Always inspect the exhaust system for leaks after installation.

TORQUE VALUES

Exhaust pipe joint nut 20 N·m (2.0 kgf·m, 15 lbf·ft) Side stand pivot bolt 15 N·m (1.5 kgf·m, 11 lbf·ft) Side stand pivot nut 39 N·m (4.0 kgf·m, 29 lbf·ft) Grab rail mounting bolt 27 N·m (2.8 kgf·m, 20 lbf·ft) Front fender mounting bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Rearview mirror mounting bolt 14 N·m (1.4 kgf·m, 10 lbf·ft)

TROUBLESHOOTING

Excessive exhaust noise

• Broken exhaust system

• Exhaust gas leak

Poor performance

• Deformed exhaust system

• Exhaust gas leak

• Clogged muffler

3-2

Page 51

SEAT

REAR SEAT

HOOKS

HOOK

KEY

SOCKET BOLTS/ COLLARS

PRONG

FRONT SEAT

SEAT BRACKET BOLTS

FRAME/BODY PANELS/EXHAUST SYSTEM

REMOVAL/INSTALLATION

Unhook the pillion seat with the ignition key. Remove the rear seat.

Remove the socket bolts and collars. Remove the front seat backward while releasing the seat prong from the seat bracket.

Install the front seat while hooking the prong under the seat bracket cross pipe. Install the collars and tighten the socket bolts.

Install the rear seat and push the seat forward, then down to lock it.

After installation, make sure that the seats are installed properly by moving them.

SEAT BRACKET

REMOVAL/INSTALLATION

Remove the side socket bolts, rear socket bolts and seat bracket.

If you wish the seat position upward or downward, you can choose low or high position. There are three bolt holes each mounting point. Middle bolt hole is standard position.

Install the seat bracket. Install and tighten the side socket bolts (flange) and rear socket bolts securely.

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Page 52

FRAME/BODY PANELS/EXHAUST SYSTEM

GROMMET

SIDE COVER BOLT

COVER

WINDSCREEN

SPACERS

FRONT CENTER COWL

SCREWS

WINDSCREEN

SPACER

Front

High position

Low position

RIGHT/LEFT SIDE COVER

REMOVAL/INSTALLATION

Remove the side cover bolt.

Release the boss from the fuel tank grommet, then remove the side cover.

Install the side cover aligning the its boss with the grommets in the fuel tank.

WINDSCREEN

REMOVAL/INSTALLATION

Be careful not to

damage the

bosses.

Remove the windscreen covers by pulling its bosses.

Remove the four screws and the windscreen.

Installation is in the reverse order of removal.

• Install the spacer onto the windscreen as shown.

• It is possible to select the windscreen high or low position.

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Page 53

METER PANEL

TRIM CLIP INNER PANEL

TAB

SCREWS

BOSS

METER PANEL

GROMMET

REMOVAL/INSTALLATION

Remove the trim clip.

Unhook the tab of the inner panel from the front center cowl, then remove the inner panel.

Remove the other side inner panel.

Remove the windscreen (page 3-4).

Remove the two screws. Pull the boss of the meter panel from the combination meter grommet, then remove the meter panel.

Install the meter panel and inner panels in the reverse order of removal.

FRAME/BODY PANELS/EXHAUST SYSTEM

3-5

Page 54

FRAME/BODY PANELS/EXHAUST SYSTEM

BOLT

BOSS

RIGHT FRONT COWL

TRIM CLIP

TABS

BOLT

COLLAR

CONNECTOR

SOCKET BOLTS

REARVIEW MIRROR

RIGHT/LEFT FRONT COWLS

REMOVAL/INSTALLATION

Remove the following:

– Trim clip – Bolt and collar – Mounting bolts

Unhook the boss and tabs from the front center cowl, then disconnect the turn signal light wire connector.

Installation is in the reverse order of removal.

The illustration shows the right front cowl removal/ installation. Remove and install the left front cowl in the same manner.

REARVIEW MIRROR

REMOVAL/INSTALLATION

Remove the socket bolts and rearview mirror.

Installation is in the reverse order of removal.

TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft)

3-6

Page 55

FRONT CENTER COWL

BOSSES

HEADLIGHT CONNECTOR

BOSSES

METER GUARD RUBBER

REMOVAL/INSTALLATION

Remove the following:

– Rearview mirror (page 3-6) – Meter panel (page 3-5) – Right and left front cowls (page 3-6)

Release the rearview mirror mounting bosses from the front center cowl. Remove the front center cowl by pulling its bosses from the grommet, then disconnect the headlight connector. Remove the meter guard rubber from the front center cowl stay.

Be careful not to

jam the guard

rubber between the

front center cowl

and stay.

Installation is in the reverse order of removal.

FRAME/BODY PANELS/EXHAUST SYSTEM

3-7

Page 56

FRAME/BODY PANELS/EXHAUST SYSTEM

BOLT CAPS/ SOCKET BOLTS

REAR CENTER COWL

BOLTS

GRAB RAIL

BOLT

RIGHT REAR COWL

LEFT REAR COWL

HOOK BOLT

COLLAR

TRIM CLIP

Align

REAR COWL

REMOVAL

Remove the seat (page 3-3).

Remove the bolt caps. Remove the socket bolts and grab rails. Remove the bolts and rear center cowl.

Remove the trim clip. Remove the bolt, hook bolt and collar. Carefully release the tab of the rear cowl, then remove. Remove the other side rear cowl in the same manner.

3-8

Page 57

Align the tab on the

BOLT CAPS/ SOCKET BOLTS

REAR CENTER COWL

BOLTS

GRAB RAIL

TAB

FRONT FENDER

MOUNTING BOLTS

CLAMP

grab rail with the

hole on the rear

center cowl.

FRAME/BODY PANELS/EXHAUST SYSTEM

INSTALLATION

Installation is in the reverse order of removal.

Install the grab rail and mounting socket bolts. Tighten the socket bolts to the specified torque.

TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)

Install the bolt caps securely.

FRONT FENDER

REMOVAL/INSTALLATION

Remove the front mounting bolts and rear mounting bolts (brake hose clamp bolts).

Remove the front fender forward.

Installation is in the reverse order of removal.

Tighten the front fender mounting bolts to the specified torque.

TORQUE:

Front fender mounting bolt (front/rear):

12 N·m (1.2 kgf·m, 9 lbf·ft)

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Page 58

FRAME/BODY PANELS/EXHAUST SYSTEM

LICENSE LIGHT CONNECTOR

9P CONNECTORCLAMP

SIDE BOLTS

SCREWS

FUSE BOX

HOOKS

UPPER BOLTS

REAR FENDER ASSEMBLY

REAR FENDER

REMOVAL/INSTALLATION

Remove the rear cowl (page 3-8).

Release the wires from the harness clamp.

Disconnect the tail/brake light 9P (Black) and license light 2P (White) connectors.

Remove the screws, upper bolts and side bolts. Remove the fuse box from the rear fender. Release the hooks from the frame, then remove the rear fender assembly.

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Page 59

FRAME/BODY PANELS/EXHAUST SYSTEM

BOLTS

SCREWS

BOLTS

REAR FENDER STAY

REAR FENDER

MUDGUARD

Remove the screws and bolts.

Remove the tail/brake light unit from the rear fender assembly.

Remove the bolts and rear fender stay. Remove the mudguard from the rear fender.

Assemble the rear fender and install it in the reverse order.

3-11

Page 60

FRAME/BODY PANELS/EXHAUST SYSTEM

MUFFLER BANDS

MOUNTING BOLT

NUT

COLLAR

WASHER

NUT

MUFFLER

GASKET

BAND BOLT

BOLT

COLLAR

MUFFLER

REMOVAL/INSTALLATION

Loosen the muffler band bolt.

Hold the muffler mounting bolt and loosen the nut, then remove the mounting bolt, collar, washer, nut and the muffler.

Always replace the

gasket with a new

Remove the muffler gasket and replace it with new one.

one.

Install the muffler in the reverse order of removal.

Tighten the muffler band bolts securely. Hold the muffler mounting bolts and tighten the nuts securely.

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Page 61

EXHAUST PIPE

4P CONNECTOR

JOINT NUTS

NUT/MOUNTING BOLT/WASHER

EXHAUST PIPE

39 – 40 mm (1.5 – 1.6 in)

EXHAUST PIPE STUD BOLT

REMOVAL

Remove the following:

– Right rear cowl (page 3-8) – Mufflers (page 3-12)

Disconnect the O

Remove the exhaust pipe joint nuts.

FRAME/BODY PANELS/EXHAUST SYSTEM

2 sensor 4P (Natural) connector.

Carefully release

2 sensor wire

the O

from the frame.

Remove the nut, mounting bolt and washer.

Remove the exhaust pipe with the O

2 sensor wire.

INSTALLATION

Check that the exhaust pipe stud bolt protrusion from the exhaust port is specified length as shown.

SPECIFIED LENGTH: 39 – 40 mm (1.5 – 1.6 in)

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Page 62

FRAME/BODY PANELS/EXHAUST SYSTEM

GASKETS

EXHAUST PIPE

BOLT/ WASHER

NUT

JOINT NUTS

4P CONNECTOR

Always replace the

gaskets with new

ones.

Refer to "CABLE &

HARNESS

ROUTING" (page 1-

23)

Install the new gaskets to the exhaust ports.

Route the O2 sensor wire properly and install the exhaust pipe.

Temporarily install the exhaust pipe joint nuts, exhaust pipe mounting bolt, washer and nut.

First tighten the exhaust pipe joint nuts to the specified torque.

TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

Hold the exhaust pipe mounting bolt and tighten the nut securely.

3-14

Connect the O put the connector boot behind the ECM.

Install the following:

– Right rear cowl (page 3-9) – Mufflers (page 3-12)

2 sensor 4P (Natural) connector and

Page 63

MAIN STAND (CBF1000A)

BOLT

OUTER AND INNER SPRINGS

PIVOT SHAFT

MAIN STAND

PIVOT SHAFT

MAIN STAND

BOLT

OUTER AND INNER SPRINGS

REMOVAL

Support the motorcycle securely using the side stand.

Remove the right and left mufflers (page 3-12).

Unhook the main stand springs (outer and inner).

Remove the pivot shaft mounting bolt.

Pull the pivot shaft out and remove the main stand.

FRAME/BODY PANELS/EXHAUST SYSTEM

INSTALLATION

Apply multi-purpose grease to the pivot shaft sliding surfaces.

Install the main stand and pivot shaft.

Install and tighten the pivot shaft mounting bolt.

Hook the main stand springs (outer and inner).

Install the right and left mufflers (page 3-12).

After installation, check the main stand operation.

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Page 64

FRAME/BODY PANELS/EXHAUST SYSTEM

RETURN SPRING

PIVOT BOLT/NUT

SIDE STAND

REMOVAL/INSTALLATION

Support the motorcycle using the main stand (CBF1000A) or other support tool. Remove the side stand switch (page 21-25).

Retract the side stand. Unhook the side stand spring. Hold the pivot bolt and loosen the pivot nut. Remove the pivot nut, pivot bolt and side stand.

Installation is in the reverse order of removal.

TORQUE:

Side stand pivot bolt:

15 N·m (1.5 kgf·m, 11 lbf·ft)

Side stand pivot nut:

39 N·m (4.0 kgf·m, 29 lbf·ft)

3-16

Page 65

4. MAINTENANCE

SERVICE INFORMATION ··························· 4-2

MAINTENANCE SCHEDULE ······················ 4-4

FUEL LINE ··················································· 4-5

THROTTLE OPERATION····························· 4-6

AIR CLEANER·············································· 4-7

CRANKCASE BREATHER ··························· 4-7

SPARK PLUG ·············································· 4-8

VALVE CLEARANCE································· 4-11

ENGINE OIL/OIL FILTER ·························· 4-16

RADIATOR COOLANT ······························ 4-19

COOLING SYSTEM··································· 4-19

DRIVE CHAIN SLIDER ······························ 4-25

BRAKE FLUID ··········································· 4-25

BRAKE PAD WEAR··································· 4-26

BRAKE SYSTEM······································· 4-27

BRAKE LIGHT SWITCH ···························· 4-28

HEADLIGHT AIM ······································ 4-28

CLUTCH SYSTEM ···································· 4-28

CLUTCH FLUID ········································· 4-29

SIDE STAND ············································· 4-30

SUSPENSION ··········································· 4-30

NUTS, BOLTS, FASTENERS···················· 4-31

SECONDARY AIR SUPPLY SYSTEM······· 4-20

DRIVE CHAIN ············································ 4-21

WHEELS/TIRES ········································ 4-32

STEERING HEAD BEARINGS ·················· 4-32

4-1

Page 66

MAINTENANCE

SERVICE INFORMATION

GENERAL

• Place the motorcycle on a level ground before starting any work.

• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in and enclosed area.

SPECIFICATIONS

ITEM SPECIFICATIONS

Throttle grip free play 2 – 6 mm (1/12 – 1/4 in) Spark plug NGK CR8EH-9

DENSO U24FER9 Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in) Valve clearance

Engine oil capacity

Engine oil Suggested oil:

Engine idle speed 1,200 ± 100 mi n Drive chain slack 20 – 30 mm (4/5 – 1-1/5 in) Recommended brake fluid DOT 4 Recommended clutch fluid DOT 4 Tire size Front 120/70ZR17M/C (58W)

Tire brand Bridgestone Front BT57F RADIAL U

Tire air pressure

Minimum tire tread depth Front 1.5 mm (0.06 in)

IN 0.16 ± 0.03 mm (0.006 ± 0.001 in)

EX 0.32 ± 0.03 mm (0.013 ± 0.001 in)

After draining 2.7 liter (2.9 US qt, 2.4 Imp qt)

After oil filter change 3.5 liter (3.7 US qt, 3.1 lmp qt)

Honda "4-stroke motorcycle oil" or an equivalent

Oil recommendation:

API classification: SG or higher (except oils labeled as energy conserving on the circular API service label) Viscosity: SAE 10W-30 JASO T 903 standard: MA

Rear 160/60ZR17 M/C (69W)

Rear BT57R RADIAL E

Michelin Front Pilot ROAD B

Rear Pilot ROAD A

Driver only Front 250 kPa (2.50 kgf/cm

Rear 290 kPa (2.90 kgf/cm Driver and passenger

Front 250 kPa (2.50 kgf/cm

Rear 290 kPa (2.90 kgf/cm

Rear 2.0 mm (0.08 in)

-1

(rpm)

, 36 psi)

, 42 psi)

, 36 psi)

, 42 psi)

TORQUE VALUES

Spark plug 16 N·m (1.6 kgf·m, 12 lbf·ft) Timing hole cap 18 N·m (1.8 kgf·m, 13 lbf·ft) Apply grease to the threads.

Engine oil filter cartridge 26 N·m (2.7 kgf·m, 19 lbf·ft) Apply engine oil to the threads and O-

Engine oil drain bolt 30 N·m (3.1 kgf·m, 22 lbf·ft)

Drive chain adjuster lock nut 21 N·m (2.1 kgf·m, 15 lbf·ft) Rear axle nut 108 N·m (11.0 kgf·m, 80 lbf·ft) U-nut Air cleaner duct mounting screw 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft) Rear master cylinder push rod lock nut 17 N·m (1.7 kgf·m, 13 lbf·ft)

Oil filter boss See page 4-18 Apply a locking agent to the threads.

ring.

4-2

Page 67

TOOLS

MAINTENANCE

Oil filter wrench 07HAA-PJ70101

Drive chain tool set 07HMH-MR10103

Cam chain tensioner holder 07ZMG-MCAA400

4-3

Page 68

MAINTENANCE

MAINTENANCE SCHEDULE

Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period.

I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.

The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools. Consult an authorized Honda dealer.

FREQUENCY WHICHEVER

ITEMS Months 6 12 18 24 30 36

* FUEL LINE III4-5 * THROTTLE OPERATION I I I 4-6

AIR CLEANER NOTE 2 I I 4-7

CRANKCASE BREATHER NOTE 3 CCCCCC 4-7 * SPARK PLUG IRI4-8 * VALVE CLEARANCE I4-11

ENGINE OIL R R R R 4-16

ENGINE OIL FILTER R R R R 4-16

RADIATOR COOLANT NOTE 4 I I R 4-19 * COOLING SYSTEM I I I 4-19 * SECONDARY AIR SUPPLY SYSTEM I I I 4-20

DRIVE CHAIN EVERY 1,000 km (600 mi) I, L 4-21

DRIVE CHAIN SLIDER I I I 4-25

BRAKE FLUID NOTE 4 I I R I I R 4-25

BRAKE PAD WEAR IIIIII 4-26

BRAKE SYSTEM IIII4-27 * BRAKE LIGHT SWITCH I I I 4-28 * HEADLIGHT AIM I I I 4-28

CLUTCH SYSTEM IIIIIII 4-28

CLUTCH FLUID NOTE 4 I I R I I R 4-29

SIDE STAND I I I 4-30 *SUSPENSION I I I 4-30 *NUTS, BOLTS, FASTENERS IIII4-31

** WHEELS/TIRES I I I 4-32 **STEERING HEAD BEARINGS IIII4-32

COMES FIRST

ODOMETER READING (NOTE 1)

x 1,000 km 1 6 12 18 24 30 36

x 1,000 mi 0.6 4 8 12 16 20 24

REFER TO PAGE

* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is

mechanically qualified

** In the interest of safety, we recommended these items be serviced only by an authorized Honda dealer

Honda recommends that an authorized Honda dealer should road test your motorcycle after each periodic maintenance is carried out.

NOTES:

1. At higher odometer reading, repeat at the frequency interval established here.

2. Service more frequently when riding in unusually wet or dusty areas.

3. Service more frequently when riding in rain or at full throttle.

4. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.

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Page 69

FUEL LINE

BOLTS/COLLARS

NUT/PIVOT BOLT

HANDLE

PIN SPANNER

FUEL FEED HOSE

MAINTENANCE

Remove the following:

– Seat (page 3-3) – Side covers (page 3-4) – Right and left front cowl (page 3-6) – Inner panel (page 3-5)

Remove the fuel tank front mounting bolts and collars.

Hold the fuel tank rear pivot bolt and loosen the nut.

Lift the fuel tank and support it using the equipped tools (pin spanner and handle) as shown.

• Support the fuel tank mounting bolt hole with the pin spanner and hook the handle on the stay of the frame.

Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary (page 6-

51).

Check the fuel rails and injectors for damage or leakage. Replace them if necessary (page 6-73). Check the fuel pump mounting area for leakage. Replace the fuel pump packing if necessary (page 6-

55).

4-5

Page 70

MAINTENANCE

HOSE JOINTS

BOLTS/COLLARS

NUT/PIVOT BOLT

2 – 6 mm (1/12 – 1/4 in)

ADJUSTER

LOCK NUT

Remove a support tools, then lower the fuel tank.

• Route the hoses, wires and harness properly

• Be careful not to damage the harness and hoses.

• After installing the fuel tank, make sure the drain,

• Check the hose joints for loose or disconnection.

Install the fuel tank front mounting bolts and collars. Tighten the fuel tank mounting bolts and rear pivot nut securely.

Install the removed parts in the reverse order of removal.

(page 1-23).

breather and fuel hoses are not kinked or bound.

THROTTLE OPERATION

Check for smooth throttle grip full opening and automatic full closing in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged (page 6-69). Lubricate the throttle cables, if throttle operation is not smooth.

Measure the free play at the throttle grip flange.

FREE PLAY: 2 – 6 mm (1/12 – 1/4 in)

Throttle grip free play can be adjusted at either end of the throttle cable.

Minor adjustment is made with the throttle grip side adjuster. Adjust the free play by loosening the lock nut and turning the adjuster.

4-6

Page 71

Major adjustment is made with the throttle body

ADJUSTER LOCK NUT

AIR CLEANER DUCT SCREWS

ELEMENT

DRAIN TUBE CLAMP

side adjuster.

Remove the air cleaner housing (page 6-60).

Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securely. Install the air cleaner housing and recheck the throttle operation (page 6-67). Replace any damaged parts, if necessary.

AIR CLEANER

Remove the left side cover (page 3-4).

Remove the screws and air cleaner duct.

MAINTENANCE

Remove and inspect the air cleaner elements in accordance with the maintenance schedule (page 4-

4).

Clean the air cleaner element with the compressed air from outside of the element.

Install the air cleaner element with its opening

facing out.

Install the removed parts in the reverse order of removal.

TORQUE:

Air cleaner duct mounting screw:

CRANKCASE BREATHER

• Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or overturned. Service if the deposit level can be seen in the drain tube.

Remove the left side cover (page 3-4).

Remove the crankcase breather drain tube and drain the deposits into a suitable container, then reinstall the drain tube with the tube clamp.

1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)

4-7

Page 72

MAINTENANCE

BOLTS/NUTS

IGNITION COIL

CONNECTORS

BOLTS

IGNITION COIL

SPARK PLUG CAPS

BOLT

BREATHER HOSE

SPARK PLUG

REMOVAL

Lift and support the fuel tank (page 4-5).

Remove the ignition coil mounting bolts and nuts to disconnect the #2 and #3 spark plug caps.

Disconnect the #1/#4 ignition coil connectors.

Remove the mounting bolts to disconnect the #1 and #4 spark plug caps.

Disconnect the #1 and #2 spark plug caps.

If the #3 spark plug cap is hard to be disconnected, disconnect the crankcase breather hose and remove the thermostat case mounting bolt.

4-8

Page 73

Disconnect the #3 and #4 spark plug caps.

SPARK PLUG CAPS

SPARK PLUG WRENCH

CENTER ELECTRODE

INSULATOR

SIDE ELECTRODE

0.8 – 0.9 mm (0.031 – 0.035 in)

Remove the spark plugs using a equipped spark plug wrench or an equivalent tool.

MAINTENANCE

INSPECTION

Check the insulator for cracks or damage, and the electrodes for wear, fouling or discoloration.

Replace the spark plugs if necessary.

SPECIFIED SPARK PLUG:

NGK: CR8EH-9 DENSO: U24FER9

Clean the spark plug electrodes with a wire brush or special plug cleaner.

Check the gap between the center and side electrodes with a wire type feeler gauge.

SPARK PLUG GAP:

0.80 – 0.90 mm (0.031 – 0.035 in)

If necessary, adjust the gap by bending the side electrode carefully.

4-9

Page 74

MAINTENANCE

SPARK PLUG WRENCH

SPARK PLUG CAPS

BOLT

BREATHER HOSE

SPARK PLUG CAPS

INSTALLATION

For new spark plug;

install and hand-

tighten the spark

plug, then tighten it

about 1/2 turns

after the sealing

washer contacts

the seat of the plug

Thread each spark plug in by hand to prevent crossthreading, and tighten them using a spark plug wrench.

TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft)

hole.

Refer to "Cable & Harness Routing"

(page 1-23).

Route the spark plug wires properly and connect the #3 and #4 spark plug caps.

If the thermostat case is removed, install it onto the frame and tighten the mounting bolt.

Connect the crankcase breather hose.

Refer to "Cable & Harness Routing"

(page 1-23).

4-10

Route the spark plug wires properly and connect the #1 and #2 spark plug caps.

Page 75

Install the #1/#4 ignition coil with the spacers, and

CONNECTORS

BOLTS/SPACERS

IGNITION COIL

Y/Bu

Bl/W

BOLTS/NUTS

IGNITION COIL

SPACER

BOLT/SEALING WASHER

CAM CHAIN TENSIONER HOLDER

tighten the mounting bolts.

Connect the ignition coil connectors.

Install the #2/#3 ignition coil with the spacers.

Install the mounting bolts, spacers and nuts, then tighten the nuts securely.

Install the removed parts in the reverse order.

MAINTENANCE

VALVE CLEARANCE

INSPECTION

• Check the engine idle speed (page 6-76) after the

Inspect and adjust

the valve clearance

while the engine is

cold (below 35

Remove the cylinder head cover (page 9-6).

Remove the cam chain tensioner lifter sealing bolt and sealing washer.

F).

Turn the tensioner lifter shaft fully in (clockwise) and secure it using the special tool to prevent damaging the cam chain.

TOOL: Cam chain tensioner holder 07ZMG-MCAA400

valve clearance inspection.

4-11

Page 76

MAINTENANCE

TIMING HOLE CAP/O-RING

INDEX NOTCH

"T" MARK

TIMING MARKS

No.3 CAM LOBES (IN)

No.1 CAM LOBES (IN)

Remove the timing hole cap and O-ring.

Turn the crankshaft clockwise, align the "T" mark on the starter clutch outer with the index notch on the right crankcase cover.

Record the

clearance for each valve for reference in shim selection if

adjustment is

required.

The timing marks ("IN" and "EX") on the cam sprockets must be flush with the cylinder head surface and facing outward as shown.

If the timing marks on the cam sprockets are facing inward, turn the crankshaft clockwise one full turn (360°) and realign the timing marks with the cylinder head surface so they are facing outward.

Insert the feeler gauge between the valve lifter and cam lobe.

Check the valve clearance for the No.1 and No.3 cylinder intake valves using a feeler gauge.

VALVE CLEARANCE: IN: 0.16 ± 0.03 mm (0.006 ± 0.001 in)

4-12

Page 77

Turn the crankshaft clockwise 1/2 turn (180°), align

INDEX LINE

No.4 CAM LOBES (EX)

No.2 CAM LOBES (EX)

INDEX NOTCH

"T" MARK

No.2 CAM LOBES (IN)

No.4 CAM LOBES (IN)

the index line on the starter clutch outer so that it is facing up as shown.

MAINTENANCE

Record the

clearance for each valve for reference in shim selection if

adjustment is

required.

Check the valve clearance for the No.2 and No.4 cylinder exhaust valves using a feeler gauge.

VALVE CLEARANCE: EX: 0.32 ± 0.03 mm (0.013 ± 0.001 in)

Turn the crankshaft clockwise 1/2 turn (180°), align the "T" mark on the starter clutch outer with the index notch on the right crankcase cover.

Record the

clearance for each valve for reference in shim selection if

adjustment is

Check the valve clearance for the No.2 and No.4 cylinder intake valves using feeler gauge.

VALVE CLEARANCE: IN: 0.16 ± 0.03 mm (0.006 ± 0.001 in)

required.

4-13

Page 78

MAINTENANCE

INDEX LINE

No.1 CAM LOBES (EX)

No.3 CAM LOBES (EX)

SHIM

VALVE LIFTER

Turn the crankshaft clockwise 1/2 turn (180°), align the index line on the starter clutch outer so that it is facing up as shown.

Record the

clearance for each valve for reference in shim selection if

adjustment is

required.

It is not necessary

to remove the cam

sprocket from the

camshaft except

when replacing the

camshaft and/or

cam sprocket.

Check the valve clearance for the No.1 and No.3 cylinder exhaust valves using a feeler gauge.

VALVE CLEARANCE: EX: 0.32 ± 0.03 mm (0.013 ± 0.001 in)

ADJUSTMENT

Remove the camshafts (page 9-8).

Remove the valve lifters and shims.

• Shim may stick to the inside of the valve lifter. Do not allow the shims to fall into the crankcase.

• Mark all valve lifters and shims to ensure correct reassembly in their original locations.

• The valve lifter can be easily removed with a valve lapping tool or magnet.

• The shims can be easily removed with a tweezers or magnet.

4-14

Clean the valve shim contact area in the valve lifter with compressed air.

Page 79

Measure the shim thickness and record it.

SHIM

1.875 mm

1.85 mm

1.8 0 m m

1.825 mm

SHIM

VALVE LIFTER

O-RING

TIMING HOLE CAP

MAINTENANCE

Sixty-nine different

thickness shims are

available from the

thinnest 1.200 mm

thickness shim to

the thickest 2.900 mm thickness shim in intervals of 0.025

mm.

Install the shims

and valve lifters in

their original

locations

Calculate the new shim thickness using the equation below. A = (B – C) + D A: New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness

• Make sure of the correct shim thickness by measuring the shim by micrometer.

• Reface the valve seat if carbon deposit result in a calculated dimension of over 2.900 mm.

Install the newly selected shim on the valve spring retainer. Apply molybdenum disulfide oil to the valve lifters. Install the valve lifters into the valve lifter holes.

Install the camshafts (page 9-25).

Rotate the camshafts by rotating the crankshaft clockwise several times. Recheck the valve clearance.

Check that the O-

ring is in good

condition, replace if

necessary.

Apply oil to the timing hole cap O-ring. Apply grease the timing hole cap threads. Tighten the timing hole cap to the specified torque.

TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft)

Install the removed parts in the reverse order of removal.

4-15

Page 80

MAINTENANCE

INSPECTION WINDOW

UPPER LEVEL LINE

LOWER LEVEL LINE

OIL FILLER CAP

ENGINE OIL/OIL FILTER

OIL LEVEL INSPECTION

Start the engine and let it idle for 3 – 5 minutes. Stop the engine and wait 2 – 3 minutes. Hold the motorcycle in an upright position.

Check the oil level through the inspection window.

If the level is below the lower level line, fill the crankcase with the recommended oil up to the upper level line as following procedures.

Remove the oil filler cap.

Other viscosities

shown in the chart

may be used when

the average

temperature in your

riding area is within

the indicated range.

Fill the recommended engine oil up to the upper level line.

SUGGESTED OIL:

Honda "4-stroke motorcycle oil" or an equivalent

OIL RECOMMENDATION:

API classification: SG or higher (except oils labeled energy conserving on the circular API service label) Viscosity: SAE 10W-30 JASO T 903 standard: MA

Reinstall the oil filler cap.

ENGINE OIL & FILTER CHANGE

Hold the motorcycle in an upright position.

Remove the oil filler cap.

4-16

Page 81

Remove the oil drain bolt and sealing washer, then

OIL DRAIN BOLT/SEALING WASHER

BOLTS

COVER

OIL FILTER WRENCH

OIL FILTER CARTRIDGE

SEALING WASHER

OIL DRAIN BOLT

drain the engine oil completely.

Remove the bolts and oil filter cover.

MAINTENANCE

Remove and discard the oil filter cartridge using the special tool.

TOOL: Oil filter wrench 07HAA-PJ70101

Replace the sealing washer with new one. Install and tighten the oil drain bolt.

TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)

4-17

Page 82

MAINTENANCE

14.4 – 15.4 mm (0.57 – 0.61 in)

OIL FILTER BOSS

OIL FILTER CARTRIDGE

O-RING

OIL FILTER WRENCH

OIL FILTER CARTRIDGE

BOLTS

COVER

Check that the oil filter boss protrusion from the crankcase is specified length as shown.

SPECIFIED LENGTH: 14.4 – 15.4 mm (0.57 – 0.61 in)

Apply clean engine oil to new oil filter cartridge threads and O-ring.

Install the oil filter and tighten it to the specified torque.

TOOL: Oil filter wrench 07HAA-PJ70101

TORQUE: 26 N·m (2.7 kgf·m, 19 lbf·ft)

Install the oil filter cover and tighten the bolts securely.

4-18

Page 83

Fill the crankcase with recommended engine oil

OIL FILLER CAP

O-RING

UPPER LEVEL LINE

LOWER LEVEL LINE

FILLER CAP

(page 4-16).

OIL CAPACITY:

2.7 liter (2.9 US qt, 2.4 Imp qt) after draining

3.5 liter (3.7 US qt, 3.1 Imp qt) after oil filter change

Check that the O-ring on the oil filler cap is in good condition, and replace it if necessary. Install the oil filler cap.

Recheck the oil level (page 4-16).

Make sure there are no oil leaks.

RADIATOR COOLANT

Check the coolant level of the reserve tank with the engine running at normal operating temperature.

The level should be between the "UPPER" and "LOWER" level lines.

If necessary, add recommended coolant.

MAINTENANCE

COOLING SYSTEM

Remove the following:

– Seat (page 3-3) – Left side cover (page 3-4)

Remove the reserve tank filler cap and fill to the "UPPER" level line with 1:1 mixture of distilled water and antifreeze.

RECOMMENDED ANTIFREEZE:

High quality ethylene glycol antifreeze containing corrosion protection inhibitors.

Reinstall the filler cap.

Install the following:

– Left side cover (page 3-4) – Seat (page 3-3)

Check the radiator air passages for clogging or damage.

Straighten bent fins, and remove insects, mud or other obstructions with compressed air or low water pressure.

Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.

4-19

Page 84

MAINTENANCE

RADIATOR HOSE

WATER HOSES

CYLINDER HEAD COVER

PAIR CHECK VALVE

EXHAUST PORT

PAIR CONTROL SOLENOID VALVE

Inspect the radiator hoses for cracks or deterioration, and replace them if necessary. Check the tightness of all hose clamps and fasteners.

SECONDARY AIR SUPPLY SYSTEM

• This model is equipped built-in secondary air supply system. The pulse secondary air supply system is located on the cylinder head cover.

• The secondary air supply system introduces filtered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system. This charged secondary air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water.

If the hoses show

any signs of heat

damage, inspect

the reed valves in

the PAIR check

valves for damage.

4-20

Lift and support the fuel tank (page 4-5).

Check the PAIR (pulse secondary air injection) hoses between the PAIR control solenoid valve and cylinder head cover for deterioration, damage or loose connections. Make sure that the hoses are not cracked.

Check the air suction hose between the air cleaner housing and PAIR control solenoid valve for deterioration, damage or loose connections. Make sure that the hoses are not kinked, pinched or cracked.

Page 85

DRIVE CHAIN

20 – 30 mm (4/5 – 1-1/5 in)

AXLE NUT

ADJUSTING NUT

LOCK NUT

INDICATOR LABEL

RED ZONE

ARROW MARK

Clean

Wipe and Dry

SOFT BRUSH

NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT

Never inspect and

adjust the drive

chain while the

engine is running.

DRIVE CHAIN SLACK INSPECTION

Turn the ignition switch OFF, place the motorcycle on its side stand and shift the transmission into neutral.

Check the slack in the drive chain lower run midway between the sprockets.

CHAIN SLACK: 20 – 30 mm (4/5 – 1-1/5 in)

Excessive chain slack, 50 mm (2.0 in) or more, may damage the frame.

Lubricate the drive chain with #80 – 90 gear oil or chain lubricant designed specifically for use with Oring chains. Wipe off the excess oil or chain lubricant.

ADJUSTMENT

Loosen the rear axle nut and both drive chain adjuster lock nuts. Turn both adjusting nuts an equal number of turns until the correct drive chain slack is obtained. A scale is included on the adjusters. Be sure the reading on the scale is same for both sides.

Tighten the rear axle nut to the specified torque.

TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)

MAINTENANCE

Tighten each adjuster lock nut while holding the adjusting nut.

TORQUE: 21 N·m (2.1 kgf·m, 15 lbf·ft)

Recheck the drive chain slack and free wheel rotation. Check the index mark (arrow) on the left chain adjuster. If the index mark (arrow) reaches the red zone of the wear indicator label, replace the drive chain with a new one.

CLEANING AND LUBRICATION

Clean the chain with non-flammable or high flash point solvent and wipe it dry. Be sure the chain has dried completely before lubricating. Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. Inspect and replace sprocket as necessary.

4-21

Page 86

MAINTENANCE

#80 – 90 GEAR OIL OR DRIVE CHAIN LUBRICANT

Lubricate

DAMAGE

WEAR

NORMAL

BOLT

DRIVE SPROCKET

Lubricate the drive chain with #80 – 90 gear oil or drive chain lubricant designed specifically for use with O-ring chains. Wipe off the excess oil or chain lubricant.

SPROCKET INSPECTION

Remove the left crankcase rear cover (page 12-7).

Inspect the drive and driven sprocket teeth for wear or damage, replace if necessary.

Never use a new drive chain on worn or damaged sprockets.

Both chain and sprockets must be in good condition, or the new replacement chain will wear rapidly.

Check the attaching bolts and nuts on the drive and driven sprockets. If any are loose, torque them.

TORQUE:

Drive sprocket bolt:

54 N·m (5.5 kgf·m, 40 lbf·ft)

Final driven sprocket nut:

108 N·m (11.0 kgf·m, 80 lbf·ft)

4-22

Page 87

When using the

DRIVE CHAIN TOOL SET:

MASTER LINK

DRIVE CHAIN TOOL SET

120 LINKS

1 LINK

special tool, follow

the manufacturer's

instruction.

MAINTENANCE

REPLACEMENT

This motorcycle uses a drive chain with a staked master link.

Loosen the drive chain (page 4-21).

Assemble the special tool as shown.

TOOL: Drive chain tool set 07HMH-MR10103

Include the master

link when you

count the drive

chain links.

Locate the crimped pin ends of the master link from the outside of the chain, and remove the link with the drive chain tool set.

TOOL: Drive chain tool set 07HMH-MR10103

Remove the drive chain.

Remove the excess drive chain links from the new drive chain using the drive chain tool set.

STANDARD LINKS: 120 LINKS

REPLACEMENT CHAIN

DID: DID50VA8-120LE RK: RK50HFOZ5-120LE

4-23

Page 88

MAINTENANCE

O-RINGS

PLATE

MASTER LINK

DRIVE CHAIN TOOL SET

MASTER LINK PINS

SLIDE CALIPER

• Never reuse the old drive chain, master link,

Insert the master

link from the inside

of the drive chain,

and install the plate

with the identification mark facing the outside.

Assemble the new master link, O-rings and plate.

Assemble and set the drive chain tool set.

TOOL: Drive chain tool set 07HMH-MR10103

master link plate and O-rings.

Make sure that the master link pins are installed properly. Measure the master link pin length projected from the plate.

STANDARD LENGTH:

Stake the master link pins.

Make sure that the pins are staked properly by measuring the diameter of the staked area using a slide caliper.

DIAMETER OF THE STAKED AREA:

DID: 1.15 – 1.55 mm (0.045 – 0.061 in) RK: 1.2 – 1.4 mm (0.05 – 0.06 in)

DID: 5.50 – 5.80 mm (0.217– 0.228 in) RK: 5.30 – 5.70 mm (0.209 – 0.224 in)

4-24

Page 89

MAINTENANCE

NO GOOD

GOOD

CRACKED

DRIVE CHAIN SLIDER

WEAR INDICATORS

"LOWER" LEVEL MARK

SIGHT GLASS

A drive chain with a

clip-type master link

must not be used.

After staking, check the staked area of the master link for cracks. If there is any cracking, replace the master link, Orings and plate.

DRIVE CHAIN SLIDER

Remove the left crankcase rear cover (page 12-7).

Inspect the drive chain slider for excessive wear or damage.

If it is worn to the wear indicator, replace the drive chain slider (page 15-15).

BRAKE FLUID

Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced.

• Do not mix different types of fluid, as they are not compatible with each other.

• Do not allow foreign material to enter the system when filling the reservoir.

When the fluid level is low, check the brake pads for wear (page 4-26). A low fluid level may be due to wear of the brake pads. If the brake pads are worn, the caliper piston is pushed out, and this accounts for a low reservoir level. If the brake pads are not worn and the fluid level is low, check entire system for leaks (page 4-27).

FRONT BRAKE

Turn the handlebar to the left so the reservoir is level and check the front brake reservoir fluid level through the sight glass.

4-25

Page 90

MAINTENANCE

CASTING LEDGE

"LOWER"

"UPPER"

RESERVOIR CAP

BOLT

WEAR LIMIT GROOVES

WEAR LIMIT GROOVE

If the fluid level is near the "LOWER" level mark, remove the reservoir cap, set plate and diaphragm, and fill the reservoir with DOT 4 brake fluid from a sealed container to the casting ledge.

Install the diaphragm, set plate and reservoir cap, and tighten the cap screws.

TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

REAR BRAKE

Support the motorcycle upright on a level surface.

Check the fluid level in the rear brake reservoir. If the level is near the "LOWER" level line, remove the mounting bolt and the reservoir cap, and fill the reservoir with DOT 4 brake fluid from a sealed container to the "UPPER" level line. Install the reservoir cap with the diaphragm and set plate.

Install the reservoir onto the frame and tighten the mounting bolt.

TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

BRAKE PAD WEAR

FRONT BRAKE PADS

Check the brake pads for wear. Replace the brake pads if either pad is worn to the wear limit groove.

For front brake pad replacement:

– CBF1000A (page 16-15) – CBF1000 (page 16-16)

REAR BRAKE PADS

Check the brake pads for wear. Replace the brake pads if either pad is worn to the wear limit groove.

For rear brake pad replacement:

– CBF1000A (page 16-17) – CBF1000 (page 16-18)

4-26

Page 91

BRAKE SYSTEM

BRAKE HOSE

ADJUSTER

ARROW

INDEX MARK

LOCK NUT

BRAKE PEDAL

ADJUSTING BOLT

BRAKE PEDAL

LOWER POSITION: HIGHER POSITION:

THREAD

1 mm (0.04 in)

INSPECTION

Firmly apply the brake lever or pedal, and check that no air has entered the system.

If the lever or pedal feels soft or spongy when operated, bleed the air from the system.

Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required.

Refer the procedure for brake bleeding:

– CBF1000A (page 16-7) – CBF1000 (page 16-13)

BRAKE LEVER ADJUSTMENT

Align the index

mark on the

adjuster with the

arrow on the brake

The distance between the top of the brake lever and the grip can be adjusted by turning the adjuster.

lever.

MAINTENANCE

BRAKE PEDAL HEIGHT ADJUSTMENT

Loosen the lock nut and turn the master cylinder push rod to obtain the desired pedal height.

After adjustment, hold the adjusting bolt and tighten the lock nut.

TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft)

If the brake pedal is adjusted to the lower position, make sure that the clearance between the lower end of the push rod and the brake pedal does not fall below 1 mm (0.04 in).

If the brake pedal is adjusted to the higher position, make sure that the lower end of the push rod thread is visible inside the joint.

4-27

Page 92

MAINTENANCE

BRAKE LIGHT SWITCH

ADJUSTER

VERTICAL BEAM ADJUSTING KNOB

HORIZONTAL BEAM ADJUSTING SCREW

ADJUSTER

ARROW MARK

BRAKE LIGHT SWITCH

• The front brake light switch can not be adjusted.

Adjust the brake light switch so that the brake light comes on just prior to the brake actually being engaged.

If the light fails to come on, adjust the switch so that the light comes on at the proper time.

Hold the switch body and turn the adjuster. Do not turn the switch body.

HEADLIGHT AIM

Place the motorcycle on a level surface. Remove the front right/left side cowls (page 3-6).

Adjust the headlight

aim as specified by

local laws and

regulations.

Left Headlight:

Right Headlight:

Adjust the headlight aim vertically by turning the vertical beam adjusting knob. A clockwise rotation moves the beam up and counterclockwise rotation moves the beam down.

Adjust the headlight aim horizontally by turning the horizontal beam adjusting screw.

A clockwise rotation moves the beam toward the right and counterclockwise rotation moves the beam toward the left side of the rider.

A clockwise rotation moves the beam toward the left and counterclockwise rotation moves the beam toward the right side of the rider.

CLUTCH SYSTEM

CLUTCH LEVER ADJUSTMENT

Align the index

mark on the

adjuster with the

arrow on the brake

The distance between the tip of the clutch lever and the grip can be adjusted by turning the adjuster.

lever.

4-28

Page 93

CLUTCH FLUID

"LOWER" LEVEL MARK

SIGHT GLASS

CASTING LEDGE

CLUTCH HOSE

Spilled fluid can damage painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced.

• Do not mix different types of fluid, as they are not compatible with each other.

• Do not allow foreign material to enter the system when filling the reservoir.

• When the fluid level is low, check entire system for leaks.

Turn the handlebar to the right so that the reservoir is level and check the clutch fluid level.

MAINTENANCE

If the fluid level is near the "LOWER" level mark, remove the reservoir cap, set plate and diaphragm, and fill the reservoir with DOT 4 brake fluid from a sealed container to the casting ledge.

Install the diaphragm, set plate and reservoir cap, and tighten the cap screws.

TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

Firmly apply the clutch lever, and check that no air has entered the system. If the lever feels soft or spongy when operated, bleed the air from the system.

Inspect the clutch hose and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required.

Refer the procedure for clutch fluid bleeding (page 10-6).

4-29

Page 94

MAINTENANCE

SIDE STAND

SIDE STAND SWITCH

SIDE STAND

Support the motorcycle on a level surface using the center stand (CBF1000A) or maintenance stand.

Check the side stand spring for damage or loss of tension. Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary.

Check the side stand ignition cut-off system:

1. Sit astride the motorcycle and raise the side

2. Start the engine with the transmission in neutral,

3. Move the side stand full down.

4. The engine should stop as the side stand is low-

If there is a problem with the system, check the side stand switch (page 21-24).

stand.

then shift the transmission into gear, with the clutch lever squeezed.

ered.

SUSPENSION

Loose, worn or

damaged

suspension parts

impair motorcycles

stability and

control.

FRONT SUSPENSION INSPECTION

Check the action of the forks by operating the front brakes and compressing the front suspension several times. Check the entire assembly for signs of leaks, damage or loose fasteners.

Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to the fork service (page 14-19).

Check for worn steering stem bearings by grabbing the front fork leg and attempting to move the front fork side to side.

Replace the steering head bearings if any looseness is noted.

4-30

Page 95

REAR SUSPENSION INSPECTION

Support the motorcycle securely and raise the rear wheel off the ground.

Hold the swingarm and move the rear wheel side ways with force to see if the axle bearings are worn.

Check for worn swingarm bearings by grabbing the rear ends of the swingarm and attempting to move the swingarm side to side.

Replace the bearings if any are looseness is noted.

MAINTENANCE

Check the action of the shock absorber by compressing it several times. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts.

Refer to the shock absorber service (page 15-13).

NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-13). Check that all safety clips, hose clamps and cable stays are in place and properly secured.

4-31

Page 96

MAINTENANCE

WHEELS/TIRES

Check the tires for cuts, embedded nails, or other damage.

Check the wheel for trueness:

– Front wheel (page 14-13) – Rear wheel (page 15-6)

Tire pressure should be checked when the tires are COLD.

RECOMMENDED TIRE PRESSURE AND TIRE SIZE:

Tire pressure kPa (kgf/cm

Tire size

Tire bland

FRONT REAR

, psi)

Bridgestone

Michelin Pilot ROAD B Pilot ROAD A

250 (2.50, 36) 290 (2.90, 42)

120/70ZR17

M/C (58W)

BT57F

RADIAL U

160/60ZR17

M/C (73W)

BT57R

RADIAL E

Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the following limits.

MINIMUM TREAD DEPTH:

FRONT: 1.5 mm (0.06 in) REAR: 2.0 mm (0.08 in)

STEERING HEAD BEARINGS

Check that the control cables do not interfere with handlebar rotation.

Support the motorcycle securely and raise the front wheel off the ground. Check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (page 14-30).

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Page 97

5. LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM ·········· 5-2

SERVICE INFORMATION ··························· 5-3

TROUBLESHOOTING ································· 5-4

OIL PRESSURE INSPECTION····················· 5-5

OIL STRAINER/ PRESSURE RELIEF VALVE ························ 5-6

OIL PUMP ··················································· 5-8

OIL COOLER ············································· 5-12

5-1

Page 98

LUBRICATION SYSTEM

CAMSHAFTS

PISTON/ CONNECTING ROD

CRANKSHAFT

OIL FILTER CARTRIDGE

OIL STRAINER

OIL COOLER

OIL PRESSURE RELIEF VALVE

OIL PUMP

COUNTERSHAFT

MAINSHAFT

BALANCER

EOP SWITCH

LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM

5-2

Page 99

LUBRICATION SYSTEM

SERVICE INFORMATION

GENERAL

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil.

• The oil pump can be serviced with the engine installed in the frame.

• The service procedures in this section must be performed with the engine oil drained.

• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.

• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.

• After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct.

SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT

Engine oil capacity After draining 2.7 liter (2.9 US qt, 2.4 lmp qt) –

After oil filter change 3.5 liter (3.7 US qt, 3.1 lmp qt) – After disassembly 3.6 liter (3.8 US qt, 3.2 lmp qt) –

Engine oil Suggested oil: –

Honda "4-stroke motorcycle oil" or an equivalent

Oil recommendation:

API classification: SG or higher (except oils labeled as energy conserving on the circular API service label) Viscosity: SAE 10W-30 JASO T 903 standard: MA

Oil pressure at EOP (engine oil pressure) switch 510 kPa (5.2 kgf/cm

6,000 min

Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)

Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014) Side clearance 0.04 – 0.09 (0.002 – 0.004) 0.17 (0.007)

-1

(rpm)/(80°C/176°F)

, 74 psi) at

–

TORQUE VALUES

Oil pump assembly bolt 8 N·m (0.8 kgf·m, 5.9 lbf·ft) CT bolt Oil pump driven sprocket bolt 15 N·m (1.5 kgf·m, 11 lbf·ft) Apply a locking agent to the threads.

5-3

Page 100

LUBRICATION SYSTEM

TOOLS

Oil pressure gauge set 07506-3000001

or equivalent commercially available.

Oil pressure gauge attachment 07406-0030000

or equivalent commercially available.

TROUBLESHOOTING

Oil level too low

• Oil consumption

• External oil leak

• Worn piston rings

• Improperly installed piston rings

• Worn cylinders

• Worn valve stem seals

• Worn valve guide

Low oil pressure

• Oil level low

• Clogged oil strainer

• Internal oil leak

• Incorrect oil being used

No oil pressure

• Oil level too low

• Oil pressure relief valve stuck open

• Broken oil pump drive chain

• Broken oil pump drive or driven sprocket

• Damaged oil pump

• Internal oil leak

High oil pressure

• Oil pressure relief valve stuck closed

• Clogged oil filter, oil cooler gallery or metering orifice

• Incorrect oil being used

Oil contamination

• Oil or filter not changed often enough

• Worn piston rings

Oil emulsification

• Blown cylinder head gasket

• Leaky coolant passage

• Entry of water

5-4