Honda CBR650 - Service manual > Fuel tank

REMOVAL/INSTALLATION

Disconnect the quick connect fitting from the fuel tank.

Release the wire clip [1] from the rear fender B.

Lower the fuel tank, being careful not to pinch the wire and hoses.

Remove the nut [2], washer [3], bolt [4] and fuel tank [5].

Installation is in the reverse order of removal.

NOTE:

• The mounting bolt is installed from the left side.

TORQUE:
Fuel tank mounting nut: 12 N*m (1.2 kgf*m, 9 lbf*ft)

Connect the quick connect fitting.

Fuel pump unit

INSPECTION

Turn the ignition switch ON with the engine stop switch "" and confirm that the fuel pump operates for 2 seconds.

If the fuel pump does not operate, inspect as follows: Turn the ignition switch OFF.

Lift the fuel tank and support it.

Disconnect the fuel pump 3P (Black) connector [1].

Turn the ignition switch ON with the engine stop switch "".

Measure the voltage between the terminals of the wire harness side fuel pump 3P (Black) connector [1].

CONNECTION: Black (+) - Green/red (-)

There should be battery voltage for 2 seconds.

If there is battery voltage, replace the fuel pump unit.

If there is no voltage, inspect the following:

• Green/red wire between the fuel pump and ground for open circuit
• Black wire between the fuel pump relay and fuel pump for open circuit
• Fuel pump relay and its circuits
• ECM

REMOVAL/INSTALLATION

Remove the fuel tank.

Clean around the fuel pump.

Loosen the six mounting nuts [1] in a crisscross pattern in several steps and remove them.

Be careful not to deform the float arm of the fuel level sensor.

Remove the fuel pump unit [2] and rubber seal [3].

Installation is in the reverse order of removal.

NOTE:

• Replace the rubber seal [1] with a new one.
• Clean the rubber seal seating areas of the fuel tank and fuel pump base plate, and be sure that no foreign materials are allowed.
• Place the rubber seal with the boss [2] facing toward the fuel pipe [3] and pull the three retaining pins [4] in the holes securely to seat it on the base plate.
• Tighten the six mounting nuts to the specified torque in the sequence as shown.

TORQUE:
Fuel pump mounting nut:
12 N*m (1.2 kgf*m, 9 lbf*ft)

DISASSEMBLY/INSPECTION

Remove the screws [1], Black wire terminals [2] and stoppers [3].

Disconnect the Pink wire connector [4] and Blue wire connector [5].

Remove the fuel pump unit assembly [1] and O-ring [2] from the fuel pump stay [3].

Remove the chamber [1].

Remove the fuel pump [1] and O-ring [2].

Visually inspect the fuel pump filter [3] for dirt, debris or any clogging.

Replace fuel pump unit as an assembly if necessary.

Remove the pressure regulator [1] and O-ring [2] from the fuel filter [3].

ASSEMBLY

Replace the fuel filter [1] with a new one if necessary.

Install a new O-ring [2] to the pressure regulator [3].

Install the pressure regulator.

Install a new O-ring [1] to the fuel pump [2].

Install the fuel pump.

• Align the Blue wire with the fuel filter groove.

Insert the fuel pump filter edge [1] between the fuel pump and pressure regulator.

Install the chamber [2].

Install a new O-ring [1] to the fuel pump stay [2].

Install the fuel pump unit assembly [3] by aligning the grooves with the fuel pump stay tabs.

Install the stoppers [1], Black wire terminals [2] and screws [3].

Tighten the screws securely.

Connect the Pink wire connector [4] and Blue wire connector [5].

Air cleaner housing

REMOVAL/INSTALLATION

Remove the following:

• Fuel tank
• Air cleaner lid

Release the following:

• EOP switch 1P (White) connector [1] from the slot
• Clutch cable [2] from the wire guide [3]

• Wire clip [1]

• Wire clip [1]
• Front wheel speed sensor 2P (Blue) connector [2] from the stay

Disconnect the MAP sensor 3P (Black) connector [3] and vacuum hose [4] from the air cleaner housing.

Loosen the six screws [1] fully and remove the intake ducts [2].

Slightly pull up the air cleaner housing.

Disconnect the crankcase breather hose [1] and air supply hose [2] from the air cleaner housing.

Release the PAIR control valve [3] from the stay [4], then remove the air cleaner housing from the throttle body.

Remove the O-rings [1] from the air cleaner housing.

Installation is in the reverse order of removal.

• Replace the O-rings with new ones.

See also: