Honda CBR650 - Service manual > Service information

GENERAL

• Bending or twisting the control cable will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control.
• 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.
• Before disconnecting the fuel feed hose, relieve fuel pressure from the system.
• Do not snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle operation.
• Seal the intake port with a piece of tape or a clean cloth to keep dirt and debris from entering the engine after the throttle body has been removed.
• Do not damage the throttle body. It may cause incorrect throttle valve operation.
• Prevent dirt and debris from entering the throttle bore and air passages after the throttle body has been removed. Clean them using a compressed air if necessary.
• Do not loosen or tighten the white painted nut and screw of the throttle body. Loosening or tightening them can cause throttle valve and idle control failure.
• Do not apply commercially available carburetor cleaners to the inside of the throttle bore.
• The parts of the throttle body not shown in this manual should not be disassembled.
• For fuel level sensor inspection.
• The following color codes are used throughout this section.

Bl = Black
Br = Brown
Bu = Blue
G = Green
Gr = Gray
Lb = Light Blue
Lg = Light Green
O = Orange
P = Pink
R = Red
V = Violet
W = White
Y = Yellow

Component location

TH model shown:

Fuel line inspection

FUEL PRESSURE RELIEVING

NOTE:

• Before disconnecting fuel feed hose, relieve pressure from the system as follows.

1. Turn the ignition switch OFF.

2. Lift the fuel tank and support it.

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

4. Start the engine, and let it idle until the engine stalls.

5. Turn the ignition switch OFF.

QUICK CONNECT FITTING REMOVAL

NOTE:

• Clean around the quick connect fitting before disconnecting the fuel feed hose, and be sure that no dirt is allowed to enter into the fuel system.
• Do not bend or twist the fuel feed hose.

1. Relieve the fuel pressure.

2. Disconnect the negative (-) cable from the battery.

3. Lift the fuel tank and support it.

4. Unlock the slide retainer [1] of the quick connect fitting [2] by completely pulling it up.

5. Release the quick connect fitting from the joint pipe [3] while holding the connector housing.

• Prevent the remaining fuel in the fuel feed hose from flowing out, using a shop towel.
• Be careful not to damage the slide retainer and hose.
• Do not use tools.

6. To prevent damage and keep foreign matter out, cover the disconnected connector and pipe end with the plastic bags [1].

QUICK CONNECT FITTING INSTALLATION

NOTE:

• Do not bent or twist the fuel feed hose.

1. Be sure that the slide retainer [1] is completely pulled up before connecting the quick connect fitting.

Connect the quick connect fitting [2] to the joint pipe [3] until you hear the "CLICK" while holding the connector housing.

If it is hard to connect, put a small amount of engine oil on the pipe end.

Lock the slide retainer by pushing it until you hear the "CLICK".

2. Make sure the connection is secure and that the slide retainer is firmly locked into place; check visually and by pulling the connector.

3. Connect the battery negative (-) cable.

4. Normalize the fuel pressure.

FUEL PRESSURE NORMALIZATION

1. Be sure the fuel pump 3P (Black) connector [1] is connected.

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

NOTE:

• Do not start the engine.

The fuel pump will run for about 2 seconds, and fuel pressure will rise.

Turn the ignition switch OFF.

3. Repeat step 2 two or three times, and check that there is no leakage.

4. Install the fuel tank properly.

FUEL PRESSURE TEST

NOTE:

• Check the fuel tank breather hose on the frame for pinch or clogs when the fuel tank is lifted.

Disconnect the fuel injector side quick connect fitting.

Attach the special tools between the fuel feed hose and fuel pipe of the fuel pump.

TOOLS:
[1] Fuel pressure gauge 07406-0040004
[2] Pressure gauge manifold 07ZAJ-S5A0111
[3] Hose attachment, 9 mm/9 mm 07ZAJ-S5A0120
[4] Hose attachment, 8 mm/9 mm 07ZAJ-S7C0100
[5] Attachment joint, 8 mm/9 mm 07ZAJ-S7C0200

Temporarily connect the fuel pump 3P (Black) connector, fuel tank breather hose and battery negative (-) cable.

Start the engine and let it idle.

Read the fuel pressure.

STANDARD: 343 kPa (3.5 kgf/cm2, 50 psi)

If the fuel pressure is higher than specified pressure, replace the fuel pump unit.

If the fuel pressure is lower than specified pressure, inspect the following:

• Fuel line for leakage
• Fuel tank breather hose (tank side) for pinch or clogs
• Fuel filter for clogs
• Fuel pump

After inspection, relieve the fuel pressure.

Disconnect the negative (-) cable from the battery.

Remove the special tools.

Connect the quick connect fitting.

FUEL FLOW INSPECTION

NOTE:

• Check the fuel tank breather hose on the frame for pinch or clogs when the fuel tank is lifted.

Disconnect the fuel injector side quick connect fitting.

Wipe off spilled out gasoline.

Place the end of the fuel feed hose [1] into an approved gasoline container.

Temporarily connect the fuel pump 3P (Black) connector and battery negative (-) cable.

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

The fuel pump operates for 2 seconds. Repeat 5 times to meet the total measuring time.

NOTE:

• Return fuel to the fuel tank when the first fuel is flowed.

Measure the amount of fuel flow.

Amount of fuel flow:
125 cm3 (4.23 US oz, 4.40 Imp oz) minimum/ 10 seconds at 12 V

If fuel flow is less than specified volume, inspect the following:

• Fuel feed hose for clogs
• Fuel tank breather hose (tank side) for pinch or clogs
• Fuel filter for clogs
• Fuel pump

Connect the quick connect fitting.

See also: