Honda CBR650 - Service manual > Service information

GENERAL

• This section covers service of the clutch, gearshift linkage and starter clutch. All service can be done with the engine installed in the frame.
• Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motorcycle creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.
• For starter motor service.

Troubleshooting

Clutch lever is too hard to pull in

• Damaged, kinked or dirty clutch cable
• Improperly routed clutch cable
• Damaged clutch lifter mechanism
• Faulty clutch lifter bearing
• Clutch lifter piece installed improperly

Clutch slips when accelerating

• Clutch lifter sticking
• Worn clutch discs
• Weak clutch springs
• No clutch lever freeplay
• Engine oil mixed with molybdenum or graphite additive

Clutch will not disengage or motorcycle creeps with clutch disengaged

• Excessive clutch lever freeplay
• Clutch plate warped
• Engine oil level too high, improper engine oil viscosity or additive used
• Loose clutch center lock nut
• Damaged clutch lifter mechanism
• Clutch lifter piece installed improperly
• Worn clutch outer slot and clutch center grooves
• Improper clutch operation

Hard to shift

• Incorrect clutch cable adjustment
• Improper clutch operation
• Improper engine oil viscosity
• Damaged or bent shift forks
• Bent shift fork shaft
• Bent shift fork claw
• Loose shift drum center bolt
• Damaged shift drum center
• Damaged shift drum guide grooves
• Damaged or bent gearshift spindle

Transmission jumps out of gear

• Worn shift drum stopper arm
• Weak or broken shift drum stopper arm return spring
• Loose shift drum center bolt
• Damaged shift drum center
• Bent shift fork shaft
• Damaged or bent shift forks
• Worn gear engagement dogs or slots

Gearshift pedal will not return

• Weak or broken gearshift spindle return spring
• Damaged or bent gearshift spindle

Starter motor turns, but engine does not turn

• Faulty starter clutch
• Damaged starter reduction gear/shaft
• Damaged or faulty starter motor pinion gear
• Damaged starter driven gear

Component location

Right crankcase cover

REMOVAL/INSTALLATION

Remove the under cowl (CBR650F/FA only).

Drain the engine oil.

Disconnect the CKP sensor 2P (Black) connector [1].

Remove the bolt [1] and clutch cable holder [2], then disconnect the clutch cable [3] from the clutch lifter arm [4].

Remove the following:

• Right crankcase cover bolts [1]
• Under cowl stay (CBR650F/FA only) [2]
• Right crankcase cover [3]

Remove the dowel pins [1].

Be careful not to damage the mating surfaces.

Clean any sealant off from the right crankcase cover mating surfaces.

Installation is in the reverse order of removal.

TORQUE:
Right crankcase cover bolt:
12 N*m (1.2 kgf*m, 9 lbf*ft)

NOTE:

• Apply sealant (TB1207B manufactured by ThreeBond or an equivalent) to the mating areas of crankcase cover and crankcase as shown.
• Align the clutch cable holder hole with the right crankcase cover boss.

Adjust the clutch lever freeplay.

Fill the engine with the recommended engine oil and check that there are no oil leaks.

DISASSEMBLY/ASSEMBLY

Remove the clutch lifter arm [1] and return spring [2] from the right crankcase cover.

Check the clutch lifter arm and return spring for scratch, damage, abnormal wear and deformation.

Replace if necessary.

Remove the oil seal [1] from the right crankcase cover.

Check the needle bearings [2] for wear or damage, replace them if necessary.

Assembly is in the reverse order of disassembly.

NOTE:

• Apply grease to a new oil seal lips.
• Align the return spring hook with right crankcase cover.

See also: