Shim Selection

Remove the valve lifter and shims page 8-2). Do not allow shims to fall into the crankcase The shim(s) may occasionally stick to the valve lifter Mark the positions of all valve lifters and shims to ensure correct reassembly. It is easy to remove the valve lifter with a valve lapping tool or magnet. Remove the shims with tweezers or a magnet. Clean the valve lifter with compressed air. Measure the shim thickness with a micrometer and record it, Sixty-five different shims are available in...

Ignition Switch Removal Installation

Disconnect the 3P mini connector behind the combination meter. Release the ignition switch wire from the clamps. Remove the bolts and ignition switch. Tor* bit (T40) 07703-0010100 or Apply a locking agent to the bolt threads and install the Ignition switch in the reverse order of removal. Torque 25 N m (2,5 kg-m, 18 ft-lb)

Fork Assembly 9193

After assembling the fork legs, install each fork leg onto the steering stem first, then torque the fork tube cap and the top bridge pinch bott. Install the back up ring with the chamfered surface side facing down, Coat a new oil seal with the recommended fork oil and install with seal mark facing up._____ Replace with a new one if it was removed from the fork tube Install the oil seal with the marked side facing out. Wrap the fork tube top end with vinyl tape to prevent the oil seal lip from...

Side Cover Removal Installation

Unlock the quick release fasteners by aligning the long slot with the punch mark. Remove the side cover by releasing the bosses or the cover from the grommets. Be careful not to break the pins, tabs and slots in the side caver and tail cowl when removing the side cover. Install the side cover signing its bosses with the grommets and engage the tabs with the slots, and pins with the holes securely as shown. Lock the clip by aligning the A mark with the punch mark. Do the same on the other side.

Crankcase Separation

Refer to page 10-1 for the parts that is necessary to be removed for crankcase separation Lower crankcase bolt(8 mm) sealing washer From the outside to inside, loosen the bolts in a crisscross pattern in several steps. Clean the liquid sealant residue off the crankcase mating surfaces Piston Connecting Rod Removal Installation When disassembling, mark and store the disassembled parts lo ensure that they are reinstalled in their original locations. Determine the replacement bearing color code...

Maintenance Schedule

Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintnance period. f Inspcct and Clean, Adjust, Lubricate, or Replace if necessary. R Replace, C Clean, L Lubricate, A Adjust The following items require some mechanical knowledge. Certain items (particularly those marked * and * * ) may require more technical information and special tools. Consult your authorized Honda dealer. * Should be serviced by an authorized Honda dealer, unless the owner has the proper tools and...

Important Safety Notice

KlUXfliUliS Indicates a strong possibility of severe personal injury or death if instructions are not followed. CAUTION Indicates a possibility ol equipment damage if instructions are not followed. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included, It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a...

Poor Performance at Low and Idle Speeds

Check ignition timing and valve-Incorrect - 2. Check carburetor pilot screw -----Incorrect - 3. Check if air is leaking past intake -Leaking--- 4. Perform a spark test ------Weak or Intermittent Excessive carbon build-up on the piston Worn piston and cylinder Fuel-air mixture too lean Use of improper quality fuel Excessive carbon build-up on the piston head or combustion chamber Ignition timing too advanced (Faulty ignition control module or ignition pulse generator) (Faulty ignition control...

Crankcase Assembly

(7 '91 24(2.4, 17) 1 After '91 26(2.6, 19) (7 '91 24(2.4, 17) 1 After '91 26(2.6, 19) Refer to page 10-1 for the parts that is necessary to be installed after crankcase assembly Refer to page 10-8 for crankcase bolt location. - Do not apply sealant around the oil passage area and main bearing journal area. Refer to the illustration on page 10-8 for applying are. Install the oil orifice with the smaller diameter side facing the lower crankcase. Lower crankcase bo(t(8 mir J scaling washer From...

Jet Needle Holder Removal Installation

Screw a proper 4 mm thread screw In the jet needle holder as shown and pull out the jet needle holder with a pliers. NOTE 3e careful not damage the diaphragm. Do not remove the jet needle holder by pushing in the jet needle. Install the jet needle holder in the reverse order of removal. NOTE Push the jet needle holder in until the 0-ring on the holder seats completely in the groove in the vacuum piston.

Fork Removal Installation

Do not depress The brake lever when the calipers are removed, or it will be difficult to refit the disc between the brake pads. If you plan to disassemble the forks legs, loosen the top bridge bolts first then the fork cap bolts but do not remove thern at this time. Suspend the right and left handlebars properly so that the cables and wires are not bent tightly. Be careful not to damage the brake pipe Be sure to hold the fork leg while loosening the bolts Install the fork leg assembly aligning...

Countershaft Disassembly Assembly

Apply molybdenum oil to the shifter gear grooves. Apply oil to all sliding surfaces of the mainshaft, countershaft and bushings. Install the thrust washer that contacts with the rotating gear with the chamfered side facing the rotating gear Install the snap ring with the chamfered side facing the thrust load side Install the spline bushing aligning the oil holes in the bushing and the countershaft. Transmission removal installation (page 11 -6) Needle bearing case Needle bearing Thrust washer...

Mainshaft Disassembly Assembly

Apply molybdenum oil to the shifter gear grooves. Apply oil to all sliding surfaces of the malnshaft, countershaft and bushings. Install the thrust washer that contacts with the rotating gear with the chamfered side facing the rotating gear. Install the snap ring with the chamfered side facing the thrust load side. Install the spline bushing, aligning the oil holes in the bushing and the mainshaft. Transmission removal instal ation(page 11-6 Transmission removal instal ation(page 11-6 Assembly...

Fork Disassembly 9193

The fork tube cap is under spring pressure. Use care when removing it and wear eye and face protection. Temporarily Install the fork spring, spring seat, spacer and fork tube cap to loosen the socket bolt. Fork rernoval lnstallationlpage 12-8) Fork rernoval lnstallationlpage 12-8) Before removing the fork cap, turn the preload adjuster counterclockwise fully to lessen spring pressure. After removing the spring, pour out any remaining fork oil When removing, be careful not damage the fork tube...

Ignition System Inspection

Follow the steps in the troubleshooting flow chart for servicing. _ Remove the right side cover (page 2-2). Disconnect the ignition control module connector and co Battery voltage should register with the ignition switch ON and the engine stop switch at RUN. No. 1-4 Black,'White and Yellow Buie No continuity in any gear except neutral Cotinulty with the side stand retracted No continuity with the side stand down

Shock Absorber Disassembly Assembly 91

Disassembly Shock Absorber

The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Before disposal of shock absorber, release the nitrogen. (Step section 19 of the Common Service Manual Drilling point page 1-11) Shock absorber removal installation (page 13-4) Shock absorber removal installation (page 13-4) Assembly is in the reverse order of disassembly. Refer to page 1 3-7 for replacement. Refer to page 13-7 for removal and installation Install the spring guide...

Steering Stem Removal Installation

Replace each bearing and bearing race as a set. Do not reuse the lock washer. Fork removal installation (page 12-8) Ignition switch removal installation (page 18-8) Fork removal installation (page 12-8) Ignition switch removal installation (page 18-8) Installation is in the reverse order of removal Before removing, bend straight the tabs of the lock washer. Refer to page 12-19 for installation. Hold the steering stem while removing the adjustment nut. Searing Adjustment Nut Removal...

Requisite Service

Side fairing removal (page 2-3) * Exhaust system removal installation (page 2-10) Installation is in the reverse order of removal. Ignition pulse generator connector (2P mini) 3P mini connector (oil pressure switch wire neutral swich wire thermo sensor wire) Refer to page 7-4 for removal and installation. Install the link with the punch marks on the link and gearshift spindle. Disconnect the water hoses at the engine side. Install the long one to the left hanger arm and the short one to the...

Fork Assembly After

After assembling the fork legs, install them into the steenng stem first, then torque the fork cap and the top bridge pinch bolt. Install the hack up ring with the chambered surface side facing down. Coat a new oil seal with the recommended fork oil and install with seal mark facing up. - Install them on the fork tube. Drive the oil seal using special tools. Use the fork seal driver 07947 KA50100 and attach ment 07947-KF00100 for oil seal installation. Apply a locking agent to the threads. If...

Coolant Temperature Gauge Inspection

Disconnect the wire from the engine coolanttemperature ECT sensor and short it to body ground. Turn the ignition switch ON momentarily The coolant temperature gauge needle should move all the way to H7 Do not leave the thermo sensor wire grounded for longerthan a few seconds or the temperature gauge will be damaged. Replace the temperature gauge with a new oneif necessary.

Rear Wheel Removal Installation

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Do not suspend the brake caliper from the brake hose. Do not twist the brake hose. Put the motorcycle on its center stand. Do not depress the brake pedal when the caliper is removed, or it will be difficult to refit the disc between the brake pads. Adjust the drive chain slack after installing the wheel. Installation is in the reverse...

Korn s Bookshop

Thank you for purchasing an e-book through Korn's Bookshop. If you have any problems or questions you can get in touch with me via email on books kornel.com. I hope you are satisfied with your purchase and enjoy your book, happy reading Check out my other great books by visiting Korn's Bookshop on eBay. You may not copy, reproduce or redistribute this e-book in any form for commercial purposes. You are hereby granted a licence to read, store and print this book for personal use only. If you...

Side Fairing Removal Installation Front Cowl Removal Installation

Gasoline is extremely flammmable and explosive under certain conditions Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. Work in a well ventilated area. Smoking or allowing flames or sparks in the working area or where gasoline is stored can cause a fire or explosion. This section covers removal and installation of the frame body panels, fuel tank and exhaust system Frame body panel installation is in the reverse order of removal,...

Ignition Timing

Motorcycle Timing Marks

Stop the engine and connect a timing light to the spark plug wire. Read the manufacturer's instructions for the timing ' light before operating _____ -Ignition pulse generator rotor cover cap. The timing is correct if the F mark notch mark aligns with the index mark on the ignition pulse generator rotor cover. Increase the engine speed by rotating the throttle stop screw and make sure the F mark begins to move counter clockwise at approximately 1.600 rpm. The timing is correct if the F...

Cbr600fw Clutch Plate Order

Damaged, kinked or dirty clutch cable Oamaged clutch lifter mechanism Faulty clutch lifter bearing Clutch lifter rod installed inproperly Clutch Will Not Disengage Or Vehicle Creeps With Clutch Disengaged Too much clutch lever free play Oil level too high, improper oil viscosity or oil additive used - Damaged cluch lifter mechanism - Clutch lifter rod Installed improperly Damaged shift drum cam grooves Worn gear engagement dogs or slots Right Crankcase Cover Removal Installation Side fairing...

Side Stand Switch

Disconnect the side stand switch 3P mini connector Check for continuity between each terminals as below There should be continuity between the o o positions on the chart below. Disconnect the side stand switch 3 P mini connector Green and remove the bolt and side stand switch. Install the side stand switch aligning the pin on the switch Secure the side stand switch with the bolt. Torque 10 N m 1 .Okg-m, 7 ft-lb Install the removed parts in the reverse order of removal. Engine Does Not Start or...

Regulator Rectifier

Ironhead Changing Battery Ground

Remove the right side cover page 2-2 Disconnect the regulator rectifier connector and measure the following between rectifier connector terminals of the wire harness side. Disconnect the regulator rectifier connector and remove the bolts and regulator rectifier. Inspect the regulator rectifier unit by measuring the resistance between the terminals, You'll get false readings if you touch the probes with your finger. Use the specified multimeter. Using other equipment may not allow you to obtain...

Crankshaft Removal Installation

While disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original lacations. Determine the replacement bearing color code according to the main journal bearing selection table page 11-4 . ' At installation, apply molybdenum oil to the main journal bearing surface. Crankcase separation page 10-2 Crankcase assembly page 10-6 Crankcase separation page 10-2 Crankcase assembly page 10-6 Refer to page 1 1-5 for installation. Before installing the...

Engine Does Not Start or is Hard to Start

1 Check fuel flow to carburetor -Reaching Carburetor 3. Remove and inspect spark plug Spark jump 4. Test cylinder compression Compression normal 5. Start by following normal procedure Engine does not fire No fuel in tank Sticking float valve Clogged float valve Clogged fuel tank vent tube Fuel-air mixture too rich Carburetor flooded Carburetor choke excessively closed Cylinder flooded Air cleaner dirty Faulty EVAP purge control valve California type only Valve clearance too small Valve stuck...

Crankshaft Bearing Replacement

Universal Alphabetical Codes

Record the crankcase I D. code letters stamped on the left side of the upper crankcase. Letters A. 6 or C on the upper crankcase are the codes for the main journal I.D.s from the left side. Record the corresponding main journal O.D. code numbers Numbers 1 or 2 on the crank weight are the codes for the main journal O D.s from the left. Cross reference the case and journal codes to determine the replacement bearing color code 36.008 36.01 6 mir 1.41761.4180 in 32.992-33.000 ran 1 .2989-1.2992 in...

Headlight Bulb Replacement

Motobike Honda Cbr600 Bulbs

- Halogen headlight bulb becomes very hot while the headlight is ON. and remains hot for a while after it is turned OFF. Be sure to let it cool down before servicing. Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to break. If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. Be sure to install the dust cover after replacing the...

Poor Performance at High Speeds

1 Check ignition timing and valve clearance 2. Disconnect fuel tube at carburetor Fuel flows freely 3. Remove the carburetor and check for clogged jet s Improper valve clearance Faulty ignition control module Faulty ignition pulse generator Lack of fuel in tank Clogged fuel line Clogged fuel tank vent tube Clogged fuel valve Clogged fuel strainer Bearing adjustment nut too tight Damaged steering head bearing Bent steering stem Excessive wheel bearing play Bent rim Improperly Installed wheel hub...

Ignition Coil Inspection

Honda Cbr 600 Coils

Remove the following -maintenance lid page 2-3 -air cleaner casetpage 6-3 Measure each primary coil resistance at terminals Standard 2.5-3.1 Q 20'C 68 F Disconnect the spark plug caps from the plugs and measure the secondary coil resistance between the spark plug caps. If the resistance is out of range, remove the spark plug cap. from the spark plug wire and measure the resistance as shown. Maintenance lid removal installation page 2-3 Air cteaner housing removal installation page 6-3...

Front Brake Caliper Removal Installation

Do not get grease on the brake disc or stopping power will be reduced. Discard contaminated pads and clean a contaminated disc with a high quality brake decreasing agent, Check the brake system by applying the brake after pad replacement.___ - Operate the brake lever to seat the caliper pistons against the pads after the pad replacement. . Brake pad replacement can be done without disconnecting the hydraulic system. . Always replace the brake pads in pairs to assure even disc pressure. . if...

Camshaft Installation

Remove the ignition pulse generator rotor cover cap. Align, the T mark notch mark with the index mark on the ignition pulse generator rotor cover by turning the crankShaft clockwise. Apply molybdenum disulfide oil a 50 50 mixture of engine oil and molybdenum disulfide grease to the cam shaft journals of the cylider head and camshaft holders. Install each camshaft to the correct side Each camshaft has an identification mark IN is for the intake side and EX is for the exhaust side Install the...

Troubleshooting

Air bubbles In the hydraulic system Worn master cylinder piston seal Worn brake pad disc . Contaminated caliper Caliper not sliding properly - Low fluid level Sticking worn caliper piston Sticking worn master cylinder piston Contaminated master cylinder Contaminated brake pad disc Clogged restricted brake hose jointfs Contaminated brake pad disc - Clogged restricted brake system Sticking worn caliper piston Caliper not sliding properly Clogged restricted fluid passage Sticking worn master...

Trobel Shoting Cbr600

Faulty steering head bearings Damaged steering head bearings Steering head bearing adjustment nut too tight Steers To One Side Or Does Not Track Straight Unevenly adjusted right and left shock absorbers Bent axle wheel installed incorrectly Faulty steering head bearings Worn swingarm pivot bearing Right Handlebar Removal Installation Contaminants in the system may cause a reduction or loss of braking ability. - Spilled brake fluid will damage painted, plastic or rubber parts. Air cleaner...