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Everything posted by BartmanEH

  1. BartmanEH

    Hydraulic Brake Circuit (labelled)

    From the album: Brakes

  2. BartmanEH


  3. Version v3


    As originally made available by HispanicSlammer, this manual first came out for the 2002 model (first 6th generation model year). Not much has changed with respect to servicing the 6th gen VTEC since it was introduced in 2002. By-and-large, this manual applies to all 6th generation VFRs for years 2002 to 2011. There are only minor differences in some later years, most notably starting in 2006, with changes to VTEC engagement RPM and the wiring harness. All the hard work for this scanned version was done by an unknown source. The actual manual part is not searchable since it is a compilation of page scans only. I was tired of scrolling around the huge document trying to find what I needed. So I spent a few hours generating bookmarks. This version has bookmarks for all the subsections for each major section in the manual. The first page for each major section lists all the subsections and these each now have a bookmark for quick and easy document navigation. If you enable bookmark searching in your PDF reader - and most PDF readers support this - you can then search for major terms and subsections and get search results in the bookmarks. Remember, this Factory Service Manual is far from perfect. Firstly, it presumes you have a reasonable level of mechanic/shop experience. Secondly, it contains many errors. Not just typos, but erroneous information. Some of it was fixed in errata releases in subsequent years but not all of it (trust me, I've checked). I strongly advise that you search for relevant topics, review them and post any questions you may have in this most excellent of forums, VFRD, prior to performing your own major servicing of your VFR. There are amazingly helpful members here and a lot of great How-To posts. Enjoy and be safe! P.S. new version v3 has fully searchable text thanks to Adobe Acrobat's amazing "recognize text" OCR feature which has the added bonus of deskewing the page images as well as generating fully searchable text!
  4. In the fall of 2010 I replaced the fluids in my 06. It was a pretty straight forward task, albeit time consuming. The oil&filter change was easiest. Next easiest was the clutch fluid change - only one straight forward bleeder there to deal with. The coolant change took a little more work. I went all out and removed the drain plugs, replaced their copper crush washers, drained the cross tube under the engine by taking it apart, etc. When I was burping the system after refilling it, I forgot to take the bike off the center stand and put it on the side stand. Purging the system of air is really a lot easier when on the side stand and not the center stand. Lesson learned. Now replacing the brake fluid in my ABS model, that was really something. There are no less than 7 bleeders! It took 3 people to do it. The first person operated the level/pedal and refilled the reservoirs as required, the second person opened/closed each bleeder in succession and the third person was required for the one bleeder that required manually pumping the second master cylinder on the left front brake. I will definitely be looking into SpeedBleeders or Stahlbus Bleeders for the next time to simplify the process. In the meantime, I thought I'd document the procedure I came up with for doing the brake fluid change. The Service Manual has a few errors in it e.g. tells you to remove and tilt up the fr. left caliper but never tells you to reinstall it and it tells you refill and reinstall the lever reservoir cover but then goes on to bleed a few more bleeders that use fluid from that reservoir. There's been a lot of posts about what the correct order is and people having problems with spongy brakes which turned out to be because they forgot a bleeder or did it in the wrong order. The following system worked very well for the two 6th gen ABS models I did last fall. It's not a tutorial per se; there's no pictures and no details (for that, you can look up the excellent HS pictorial-based tutorial or the new Jay-D tutorial) and I didn't include obvious steps like removing the seat etc. Note: although recommended in the FSM and elsewhere, I don't remove the front left caliper for fluid replacement—only when I need to bleed air which is normally not required for fluid replacement. I just manually actuate the SMC with the caliper in place. Works well and you don't risk wearing out the mounting bolts or squeezing the pads together making reassembly difficult. I made an overall hydraulic system picture by combining elements of several pictures from the Factory Service Manual: This took a lot of image manipulation to create but it was worth it. This overall view of the braking hydraulic circuit helps to visualize how the system works. For example, it clearly shows that the Second Master Cylinder (SMC) is refilled from the rear reservoir with the pedal. These are the steps you need to take: - Turn handlebar all the way to the left to level Lever Reservoir - Open Lever and Pedal Reservoirs - Remove old fluid from Lever and Pedal Reservoirs - Fill Lever and Pedal Reservoirs with new fluid - Remove the rear wheel - Remove Rear Brake Caliper and install on top rear of Rear Brake Disc at 10 o'clock position - Maintain fluid level in both Reservoirs at all times Operate the Lever during bleeding of the initial two bleeders in the following order: Lever Brake Line: Master Cylinder to Front Brake Caliper[1] Left Front Brake Caliper outer (upper) bleeder (use Lever) [2] Right Front Brake Caliper bleeder (use Lever) Servo Brake Line: Second Master Cylinder to Servo Proportional Control Valve NOTE: this bleeder (even if it's a SpeedBleeder) must be closed after each manual activation of the SMC; [3a] open Servo Proportional Control Valve bleeder (left/battery side) [3b] manually actuate Second Master Cylinder at Left Front Caliper [3c] close bleeder (if you don't close the bleeder or SpeedBleeder on SPCV, the rear pedal will not force the SMC back out very effectively) [3d] use Pedal to recharge Second Master Cylinder (SMC) repeat [3a]-[3d] several times Servo Brake Line: Rear Proportional Control Valve to Rear Brake Caliper [4] Rear Brake Caliper Center bleeder (use Pedal) Operate the Pedal during bleeding of the remaining three bleeders in the following order: Pedal Brake Line: Rear Master Cylinder to Rear Proportional Control Valve [5] Rear Proportional Control Valve (right side) bleeder (use Pedal) Pedal Brake Line: Rear Proportional Control Valve to Rear Brake Caliper [6] Rear Brake Caliper Outer bleeder (use Pedal) Pedal Brake Line: Rear Master Cylinder to Left Front Brake Caliper [7] Left Front Caliper Center bleeder (use Pedal) - Reinstall Left Front Brake Caliper (if removed) - Reinstall Rear Brake Caliper using new mounting bolts: 2 X 90131-GAA-000, BOLT, FLANGE (8X25) (torque 23ft-lbs) - Refill Lever and Pedal Reservoirs as required to Upper Level Marks - Close Lever and Pedal Reservoirs - Reinstall rear wheel (torque 80ft-lbs)
  5. BartmanEH

    Gsxr Mirrors On 6th Gen

    Something in the order of $80/pair maybe? I'm Canadian and need to add 40% to that :-(
  6. BartmanEH

    6th gen ABS Brake Fluid Change Guide

    I edited the post above and updated it based on this year's fluid change experience.
  7. BartmanEH

    Hydraulic Brake Circuit

    From the album: Brakes

  8. BartmanEH

    Starter Valve sync 18 AUG 2014

  9. BartmanEH


  10. BartmanEH


  11. BartmanEH

    Air Box

  12. BartmanEH

    Air box top insulated

    From the album: Air Box

  13. BartmanEH

    Air box top insulated

    From the album: Air Box

  14. BartmanEH


    From the album: Air Box

  15. BartmanEH


    From the album: Air Box

  16. From the album: Air Box

    self-stick 5" x 15' vinyl foam aluminum backed self-stick insulation
  17. BartmanEH


  18. BartmanEH

    Power Bronze hugger crack 4

    From the album: Hugger

  19. BartmanEH

    Power Bronze hugger crack 3

    From the album: Hugger

  20. BartmanEH

    Power Bronze hugger crack 2

    From the album: Hugger

  21. BartmanEH

    Power Bronze hugger crack 1

    From the album: Hugger


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