Side Fairing
Remove the following three trim clips two screws -six socket bolts. Release the boss from the duct cover grommet and remove the side cowl. Left side fairing Remove the fuel tank drain and breather tubes. only Installation is in the leverse order of removal. NOTE Be careful not to dislodge the rubber nuts in the Short side fairing when tightening the front side bolts. TORQUE Socket bolt Three bolts on front side
Maintenance Schedule
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period. I Inspect and Clean, Adjust, Lubricate or Replace if necessary. C Clean R Replace A Adjust L Lubricate The following items require some mechanical knowledge. Certain items particularly those marked and may require more technical information and tools. Consult your Honda dealer. Should be serviced by your dealer, unless the owner has proper tools and service data and is mechanically qualified. In the...
Service Information Ege
When the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. Used engine nil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily...
Cooling Fan Assembly
Install the fan motor onto the shroud as shown. Install and tighten the nuts. Install the fan motor connector onto the shroud and secure the wire with the clamp. Install the fan motor onto the shroud as shown. Install and tighten the nuts. Install the fan motor connector onto the shroud and secure the wire with the clamp. Install the cooling fan onto the motor shaft by aligning the flat surfaces. Install and tighten the nut. Install the cooling fan onto the motor shaft by aligning the flat...
Radiator Coolant
Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the UPPER and LOWER level lines with the motorcycle upright on a level surface. If the level is low, remove the right side fairing page 2-4 and the reserve tank cap, and fill the tank to the UPPER level line with a 50 50 mixture of distilled water and antitreeze coolant preparation page 6-4 . Pro Honda HP Coolant or an equivalent high quality ethylene glycol...
Troubleshooting Nch
Faulty temperature gauge or thermosensor Passenges blocked in radiator, hoses or water jacket Faulty temperature gauge or thermosensor Faulty water pump mechanical seal Damaged or deteriorated cylinder head gasket Loose hose connection or clamp Damaged or deteriorated hoses The engine must be cool before removing the radiator cap or severe scalding may result. Remove the right air intake duct page 2-6 . Remove the radiator cap. The engine must be cool before removing the radiator cap or severe...
Radiator Removal Installation
Drain the coolant from the system by removing the drain bolt on the water pump page 6-5 . Disconnect the fan motor 2P Black connector. Disconnect the horn connectors. Remove the horn bolt and horn. Disconnect the water hoses and tubes from the i adiatoi. Remove the radiator mounting bolts, washers and nut. Remove the radiator from the mounting boss of the frame. Remove the air guide rubber from the engine. Installation is in the reverse order of removal. Set the air guide rubber properly, being...
Oil Strainer
Remove the oil strainer and seal rubber from the oil pump. Clean the oil strainer screen thoroughly. Coat a new seal rubber with oil and install it onto the strainer. Install the oil strainer by aligning its tab with the groove in the crankcase. Remove the oil pressure relief valve from the crank-case. Remove the O-ring from the relief valve body. Remove the oil pressure relief valve from the crank-case. Remove the O-ring from the relief valve body. Remove the spring seat, spring and piston...
Idle Drop Procedure
Make sure the carburetor synchronization is within specification before pilot screw adjustment, The pilot screws are factory pre-set and no adjustment is necessary unless the pilot screws are replaced. Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change. 1. Raise the fuel tank and support it page 2-3 . Turn each pilot screw clockwise until it seats lightly. then back it out to the specification given. This is an initial setting prior to the...
Carburetor Assembly
AIR CUT-OFF VALVE PILOT SCREW FLOAT FLOAT PIN Install the pilot screw and return them to their original position as noted during removal. FLOAT CHAMBER Perform the pilot screw adjustment if new pilot screw is installed. Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat Install the needle jet holder, main jet and slow jet. Handle the jets with care. They can easily be tmrpr nr scratched. Hang the float valve onto the float arm lip. Install the float...
Carburetor Combination
Always replace the O-rings with new ones and coat them with oil. Apply grease to the synchronization adjusting screw tips. Install the following onto the carburetor air vent hose joint with new O-rings fuel tube joint with new O-rings joint collar choke cable holder, aligning groove with stopper thrust spring place over the synchronization nut Assemble the No. 3 and No. 4 carburetors. Always replace the O-rings with new ones and coat them with oil. Apply grease to the synchronization adjusting...
Removalinstallation
California type Remove the evaporative emission EVAP purge only control valve from the air cleaner housing. Remove the wire harness clip from the air cleaner housing. Be careful not to Disconnect the four vacuum tubes and secondary break the plastic air supply hose California No. 15 . plugs. Disconnect the crankcase breather hose from the Loosen the two connecting tube band screws of the air intake ducts. Disconnect the crankcase breather hose from the Loosen the two connecting tube band screws...
Float Chamber
Remove the three screws and the float chamber. Remove the float pin, float and float valve. Check the float for damage or fuel in the float. Check the float valve and valve seat for scoring, scratches, clogging or damage. Check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination. Check the operation of the float valve. Remove the main jet, needle jet holder and slow jet. Handle the jets with care. They can easily be scored or scratched. Turn the pilot...
Front Fairing
Bo oaroful not to scratch the front fairing and fender. Remove the socket bolts and the rearview mirrors. Remove the liim clip fioin the instrument panel. Remove the six screws and two nuts. Remove the instrument panels. Release the air vent hose California No. 8 from the hose clip and disconnect it from the 3-way hose joint. Remove the two trim clips and six socket bolts. Remove the front fairing off the rearview mirror bolt hole studs and rest it on the front fender. Disconnect the headlight...
Front Inner Fairing
Remove the following four trim clips four scrcws -inner fairing by releasing front fairing tabs from inner fairing slits. Installation is in the reverse order of removal. NOTE Make sure that the mating areas are aligned properly before tightening the fasteners. TORQUE Screw 2 N-m 0.2 kgf-m , 1.4 lbf-ft
Inspection
If any portion of the oil pump is worn beyond the service limit, replace the oil pump as an assembly. Temporarily assemble the oil pump. Measure the rotor tip clearance. Measure the pump body clearance. SERVICE LIMIT. 0.35 mm 0.014 in Measure the pump side clearance. SERVICE LIMIT 0.10 mm 0.004 in
Cbr600 Trable Shooting
No fuel to carburetor -Clogged fuel filter Clogged fuel tank breather tube Too much fuel getting to the engine Contaminated deteriorated fuel Improper throttle operation Fuel pump system malfunction No spark at plug faulty ignition system section 17 Engine stalls, hard to start, rough idling Contaminated deteriorated fuel Restricted fuel tank breather tube Starting enrichment valve open Fuel pump system malfunction Faulty EVAP CAV and or EVAP purge control system California type Faulty...
Carburetor Removal
Remove the air cleaner housing page 5-14 . California type Disconnect the No. 11 tube. only California type Disconnect the No. 5 tubes. only Remove the choke cable from the cable holder and disconnect it from the starting enrichment SE valve arm. Romovo tho throttle otop ocrcw from the holder. Loosen the four carburetor insulator band screws at the engine side, using a long screwdriver through the hole in both sides of the frame. Loosen the four carburetor insulator band screws at the engine...
Brake Pad Wear
Replace the brake pads if the wear limit groove of Check the brake pad for wear by looking from the rear side of the caliper. Replace the brake pads if either pad is worn to the bottom of the wear limit groove. Refer to page 15-5 for brake pad replacement.
Carburetor Choke
This model's choke system uses a fuel enriching circuit controlled by a starting enrichment SE valve. The SE valve opens the enriching circuit via a cable when the choke lever on the left handlebar is turned this side. Check for smooth choke lever operation and lubricate the choke if required. Check the choke cable for frayed, kinked or other damage. I he viscous paper element type air cleaner cannot be cleaned because the element contains a dust adhesive. If the motorcycle is used in wet or...
Model Identification
The Vehicle Identification Number VIN is located on the left side of the frame. The frame serial number is stamped on the right side of the steering head. The carburetor identification number is stamped on the intake side of the carburetor body. The carburetor identification number is stamped on the intake side of the carburetor body. The engine serial number is stamped on the rear side of the upper crankcase. The color label is attached on the rear fender under the seat. When ordering...
Fuel System
DIRECT AIR INDUCTION D.A.I. SYSTEM AIR FLOW PATTERN 49 state Canada type DIRECT AIR INDUCTION D.A.I. SYSTEM AIR FLOW PATTERN 49 state Canada type
Emission Control Systems
The U.S. Environmental Protection Agency, Transport Canada and California Air Resources Board iCARB require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km 3,730 miles after the time of sale to the ultimate purchaser, when operated...
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...
Carburetor Synchronization
Perform this maintenance with the engine at nor mal operating temperature and transmission in neutral. Place the motorcycle on a level surface. Raise the fuel tank and support it page 2-3 . Disconnect the vacuum tubes from the air cleaner housing. Connect the vacuum gauges to the vacuum tubes. Connect the vacuum gauges to the vacuum tubes. Start the engine and adjust the idle speed with the throttle stop screw. IDLE SPEED 49 state Canada type 1,300 100 rpm California type 1,400 100 rpm Check...
Lubrication Seal Points
Oil pan mating surface Cylinder head semi-circuler area Right crankcase cover mating surface Crankcase mating surfaces right side Crankcase mating surfaces left side Crankcase mating surface Oil pressure switch threads Thermosensor threads See page 9-14 See page 10-2 See page 11-11 See page 4-4 Do not apply to the sensor head. See page 6-13 Water pump shaft spindle and thrust washer sliding surface Cylinder head 9 mm bolt threads and seating surface Starter reduction gear shaft outer surface M3...
Honda Rotor Puller 07933-3950000
Valve seat cutter, 24.5 mm EX 45 Valve seat cutter, 27.5 mm IN 45 Fork seal driver attachment, 43 mm I.D.
General Safety
If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as...