Hello everybody .

I've been the proud owner of the above for more than a year , and the second MOT has come .
However , it didn't pass .

Now i'm looking for advice to fix it myself as i'm quite good mechanically , not afraid of a challenge and to cut cost if it's fairly simple .
I will lay out the failings .

001 Front ( control 1 ) Stop lamp does not illuminate immediately a brake applies [ 1.3.1a]
002 Front brake fluid dangerously low
003 Steering headbearing has excessive free play [2.2.2]
004 Front roller brake test indicates excessive fluctuation of brake effort [3.3.A1d]
005 Front roller brake test indicates a binding brake [3.3.A1a]
006 Headlamp aim beam image kick up to the offside [1.6]

And advisories
007 Drive chain slightly loose
008 Front suspension has a slightly reduced damping effect .

Any advice will be much appreciated .
Thanks in advance .
Marius .

 

Your bike is listed here as an F2.

Moved to the F2 section.

 

Hi and welcome to the forum, obviously you're a UK dweller as you want an MOT.

I think the biggest job there is the head bearing replacement.
Fault 001 and 002 are relatively easy fix's, best to just replace the switch which applies the brake light on the lever, assuming it is the front brake they refer to..?
brake fluid is easy as well.

Do you have a Haynes Manual? i found this very helpfull whilst working on my bike. There is also online manuals you can find for more detail.

 

Hi , thanks , yes i'm in the uk , sunny Hastings ...

I don't have a Haynes manual .

Are the points 3,4,5 all related to the headbearing do you think ?
Is this the part i will need please CBR600F 87-07 KOYO Steering Head Bearing Kit CBR 600 | eBay ?

 

No points 4 & 5 unfortunately are gonna be the expensive parts. Binding in laymans terms mean that when they moved the bike around the pads were catching the discs, both the brake discs and the pads will probably need replacing. Fortunately it's pretty easy to do yourself. And the replacement parts on eBay are pretty cheap. Also. I've just ordered some off of amazon at a pretty good rate.
First thing is to get a Haynes, somewhere like halfords will have one. It'll tell you exactly how to do it.

 

Already downloaded a couple of Haynes manuals ..
I would like to tackle the headbearing first as that looks the most difficult part , which bearing do i need , seals and what else , any links ?
Thanks a lot so far .

 

Honda CBR 600 1987-2010 Tapered Headrace Bearing Set | eBay
This looks the part .. do i need anything else ?

 

Ok , i went ahead and disassembled the forks and and everything , took the old bearings out , clean them well ans grease them and put everything back together nice and tight .
No more movement .
Moving on to the brakes , calipers .. any pointers ?.. i think i need to release the pressure in the brake system , something to make the calipers pull back enough so they don't stick anymore ....

 

Remove the calipers from the bike and make sure the hanger pins are clean and lubed. Also check the pot seals to make sure they haven't eroded and aren't binding. You can buy rebuild kits for about $30 USD a side.

 

the reduced dampening effort on the fork is probably telling you that you need a fork fluid change, or my just be a little low.

Brake switch could be refurbished depending on the corrosion or wear on the contacts - but a new one isn't terribly expensive either.