I Notice
The adjuster may be damaged if it is positioned too far out, leaving minimal thread engagement. If the adjuster is threaded out near its limit and the correct free play cannot be obtained, turn the adjuster all the way in and back out one turn. Tighten the lock nut and make a major adjustment as described as follow. Major adjustments are performed at the clutch arm. Loosen the lock nut and turn the adjusting nut to adjust the free play. Hold the adjusting nut securely while tightening the lock...
Selfdiagnostic Procedures
The me function indicator lamp MIL will star blinking only with i ie side stand down and with the engine off engine stop switch turned to run or engine revs are below 5.000 rpm. In any other conditions, the MIL wili illuminate and stay on. Place the motorcycle on its side stand. Start the engine and let it idle. If the malfunction indicator lamp MIL does not light or blink, the system has no memory of problem data. If the malfunction indicator blinks, note how many times the MIL blinks, and...
Specifications Hpn
Throttle body identification Except Califor nia type Starter valve vacuum difference Base throttle valve for synchronization Intake air temperature sensor resistance at 20X 68T Engine coolant temperature sensor resistance at 20'C 68 F Fuel injector resistance at 20 C 68 F 2-6 mm 1 16-1 4 in 1 - 4 kft 2.3-2.6 k PAIR solenoid valve resistance at 20eC 68T Cam pulse yenerator peak voltage at 20'C 68F Ignition pulse generator peak voltage at 20C 68'F 188 cm3 6.4 US oz, 6.6 Imp oz minimum 10 seconds
Inspection
Check the following and replace if necci mended spark plug page 3-2 Insulator for damage Burning condition, coloration This motorcycle's spark plug is eauipped v ith on iridium renter electrode. Replace the spark plug if the e'ecjroties are contaminated. If the electrodes are contaminated with accumulated objects or dirt, replace the spark plug. Replace the plug if the center electrode is rounded as shown in the illustration. Always use specified spark plugs on this motorcycle SPECIFIED SPARK...
Service Information Ncm
Be sure to relieve the fuel pressure with the engine off. Bending or twisting the control cables will impair smooth operation and could causc the cables to stick or bind, resulting in loss of vehicle control. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. Do not apply commercially available carburetor cleaners to the inside uf the throttle bore, which is coated with molybdc num. Do not snap the...
Noise Emission Control System
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal, state and local law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use 2 the use of the vehicle after such device or element of design has...
Troubleshooting 1
Fuel contaminated deteriorated Pinched or clogged fuel hose Clogged fuel injector filter Sticking fuel injector needle Faulty fuel pump operating system Engine stall, hard to start, rough idling Fuel contaminated deteriorated Pinched or clogged fuel hose Starter valve synchronization misadjusted 23 N-m 2.3 kgf-m, 17 lbf-ft See page 1-14. 3 N-m 0.35 kgf-m, 2.5 lbf-ft 1 N-m 0.09 kgf-m, 0.7 lbf-ft 5 N-m 0.5 kgf-m, 3.6 lbf-ft 10 N-m 1.0 kgf-m. 7 lbf-ft 2 N-m 0.2 kgf-m, 1.4 lbf-ft 15 N-m 1.5 kyf-m,...
System Location
PURGE CONTROL SOLENOID VALVE California type only INJECTOR PRESSURE RFGUl IGNITION PULSE GENERATOR PURGE CONTROL SOLENOID VALVE California type only EVAP purge control solenoid valve California type only EVAP canister California type only
Removal Yhi
Release the bosses from the rear fender, then remove the battery tray cover. Unhook the retaining tab and remove the PGM Fl fuse case and fuse box. Remove the starter relay switch from the rear fender boss. Disconnect the following connectors - License light connector Tail brake light connectors Unhook the seat lock cable from the cable stay. LICENSE LIGHT CONNECTOR TURN SIGNAL CONNECTORS Remove the fuel cut-off relay and engine stop relay from the rear fender bosses. Release the rear...
Specifications
0.20 i 0.03 mm lt 0.008 0.001 in 0.28 j. 0.03 mm lt 0.011 - 0.001 in Pro Honda GN4 or HP4 4-stroke oil U.S.A. and Canada , or Honda 4-strokc oil Canada only , or equivalent motor oil API service classification SF or SG Viscosity SAE 10W-40
Fuel Line
Remove the air duct covers page 2-7 . Remove the fuel tank front mounting bolts. Lift the fuel tank Open and support the front end of the fuel tank using slowly, being suitahle support 250-mm as shown. corcfui not to ov amp raxT amp n amp d the ue hose. Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary. Install the fuel tank in the reverse order of removal.
Notice
Be careful nut Lu damage the radiator fins. Remove the lower cowl and inner half cowl page 2-4 . Disconnect the fan motor sub-harness P Black connector. Remove the radiator lower mounting bolt, nut and washer. Remove the radiator upper mounting bolt and UPPER MOUNTING BOLT WASHER washer. Remove the radiator grommet from the frame boss by moving it to the right, then move the radiator forward. Clean around the spark plug bases with compressed air b9fore removing the spark piuys, and be curc that...
Oil Level Inspection
Start the engine and let it idle for 2 - 3 minutes. Turn off the engine and support the motorcycle on a level surface. Check the oil level through the inspection window. If the level is below the lower line, remove the oil filler cap and fill the crankcasc with the recommended oil to the upper level line. Add the recommended engine oil until the oil level is to the upper level line. Othei viscosities RECOMMENDED ENGINE OIL shown in The chart may be used when the average tcmpcro tu re in your...
How To Use This Manual
This service manual describes the service procedures for the CBR600F41. Follow the Maintenance Schedule Section 3 recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency, California Air Resources Board and Transport Canada. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply...
Adjustment
The shims may stick to the inside of the valve lifter. Do not allow the shims to fall into the crankcase. Mark all valve lifters and shims to ensure correct reassembly in their original locations. The valve lifter can be easily removed with a valve lapping tool or magnet. The shims can be easily removed with tweezers or a magnet. Clean the valve shim contact area in the valve lifter with compressed air. Sixty-five different shin thicknesses are available from 1.200 mm to 2 800 mm in intervals...
Cooling System
Remove the lower r.owl and inner half cowl page 2-4 . Check the radiator air passages for clogs or damage. Straighten any bent fins, and remove insects, mud or other obstructions with compressed air or low water pressure. Replace the radiator if the air flow is restricted over more than 20 of the radiating surface. Inspect the radiator hoses for cracks or deterioration, and replacc if necessary. Check the tightness of all hose clamps and fasteners.
Installation Mhl
Coat a new O-ring with engine oil and install it into the oil cooler groove. Install the oil cooler aligning its guide groove with the lug on the c.rankcase. Apply oil lo the oil cooler bolt threads and seating cur face. install the lock Install the lock washer and oil cooler bolt. washer with its concave side o mark facing the Make sure the oil Tighten the oil cooler bolt to thft specified torque. slides inside the TORQUE 64 N m 6.5 kgf.m, 47 Ibf-ft Connect the oil cooler water hoses and...
Assembly
Install the outer Install the outer rotor into the oil pump body with its punch mark facing the oil pump cover. Install the inner rotor into the outer rotor with its drive pin groove facing the oil pump cover. Install the oil pump shaft through the inner rotor and oil pump body. rotor with its punch mark facing the oil pump cover. Install the drive pin into the hole in the pump shaft and align the pin with the groove in the inner rotor as shown. Install the oil pump cover and tighten the bolt...
Rear Suspension Inspection
Support the motorcycle securely and raise the rear wheel off the ground. Hold the swingarm and move the rear wheel sideways with force to see if the wheel bearings ore worn. Check for worn swingarm bearings by grahbing the rear swingarm and attempting to move the swingarm side to side. Replace the bearings if any looseness is noted. Check the action of the shock absorber by compressing it several times. Check the entire shock absorber assemhly for signs of leaks, damage or loose fasteners....
Oil Pressure Inspection
If the of pressure indicator light remains on a few scconds, check the indicator system before checking the oii pressure. Warm up The engine to normal operating temperature approximately 8CTC 176T . Stop the engine and remove the oil main gallery sealing bolt. Connect an oil pressure gauge and attachment to the Oil pressure gauge set 07506-3000000 equivalent commercially available in U.S.A. 07510-MJ10100 equivalent commercially available in U.S.A. Start the engine and increase engine speed to...
Throttle Operation
Check for smooth throttle grip full opening and automatic full closing in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged. Lubricate the throttle cables, if throttle operation is not smooth. Measure the free play at the throttle grip flange. FREE PLAY 2 - 6 mm 1 16 - 1 4 in Throttle grip tree play can he adjusted at either end of the throttle cable. Minor adjustments are made with the upper adjuster. Adjust the free play by...
Brake Fluid
Do not mix different types of fluid, as they are not compatible with cach other. Do not allow foreign material lo enter the system when filling the reservoir. Avoid spilling fluid on painted, plastic or rubber parts. Place a raq over these parts whenever the system is serviced. When the fluid level is low, check the brake pads for wear see next page . A low fluid level may be due to wear of the brake pads. It the brake pads are worn, the caliper piston is pushed out, and this accounts for a...
Headlight Aim
Adjust the head- Place the motorcycle on a level surface. specified by local Adjust the headlight beam vertically by turning the lows and rcgulo vcrtica beam adjuster. A clockwise rotation moves the beam up and counterclockwise rotation moves the beam down. Adjust the headlight beam horizontally by turning the horizontal beam adjuster A clockwise rotation moves the beam toward the right side of the rider.
Installation Qtd
Always replace Install the new exhaust pipe gaskets onto the exhaust the exhaust pipe ports of the cylinder head. Install the mounting rubbers and collar into the exhaust pipe mounting bracket. install the washer. Install the exhaust pipe, temporarily install the holt find nut exhaust pipe joint nuts, mounting washer and mount-properly. ing bolt nut. Tighten the exhaust pipe joint nuts to the specified torque. TORQUE 12 N-m 1.2 kgf-m. 9 Ibf.ft Tighten the exhaust pipe mounting bolt nut. Install...
Secondary Air Supply System
This model is equipped with a built-in secondary air supply system. The pulse secondary air supply sys tern is located on the cylinder head cover. The secondary air supply system introduces filtered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust purl whenever there is negative pressure pulse in the exhaust system. This charged secondary air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon...
Steering Head Bearings
Check that the control cables do not interfere with handlebar rotation. Support the motorcycle securely and raise the front wheel off the ground. Check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings Section 13 .
Side Stand
Support the motorcycle on a level surface. Check the side stand spring for fatigue or damage. Check the side stand assembly tor movement and lubricate the side stand pivot if necessary. Check the side stand ignition cut-off system - vSit astride the motorcycle and raise the side stand. Start the engine with the transmission in neutral, then shift the transmission into gear, with the clutch lever squeezed. - The engine should stop as the side stand is lowered. If there is a problem with the...
Removal
Unhook the pillion seat lock using the ignition key. Pull up the rear end of the pillion scot ond then remove the seat. Remove the rear cowl setting bolts and washers. Remove the two 5 mm screws and four trim clips. Car efully pull both sides of the rear cowl, then remove it from the seat rail.
Brake Light Switch
The front brake Adjust the brake light switch so the brake light comes light switch does on just prior to the brake actually being engaged. not require adjust- if the light fails to come on, adjust the switch so the light comes on at the proper time. Hold the switch body and turn the adjuster. Do not turn the switch body.
Front Suspension Adjustment
Spring pre-load can be adjusted by turning the adjuster. Increase the spring pre-load TURN COUNTERCLOCKWISE Decrease the spring pre-load PRE LOAD ADJUSTER ADJUSTABLE RANGE 6-21 mm 0.2 - 0.8 in from the top of the fork bolt PRE-LOAD ADJUSTER STANDARD POSITION 4th groove from the top of the fork bolt
Notice I
Never reuse the old drive chain, master link, master link plate and O-rings. Insen the master Assemble the new master link, O-rings and plate. link from the inside of the drive chain, and install the jiate with the identification mark facing out. Assemble and install the drive chain tool set. 07HMH-MR10103 or 07HMH-MR1010A U.S.A. only Make sure the master link pins are installed properly. Measure the master link pin length projected from the plate. STANDARD LENGTH DID 1.15 - 1.55 mm 0.045 -...
Removal 1
Remove the two trim clips from the bottom of the lower cowl. Remove the two trim clips and four screws from the inner half cowl. Remove the six lower cowl mounting screws. Release the lower cowl boss from the air intake duct cover grommet, then remove the lower cowl. Remove the two trim clips and inner half cowl
ni i
Set the lower cowl onto the frame and install the lower cowl boss into the air duct cover grommet. lns al the 4-mm Install the six screws. Correct location 3s Tighten the upper cowl to lower cowl screws to the TORQUE 2 N-m 0.1b kgf-m, 1.1 lbf-tt Install the inner half cowl-to-lower r.owl two trim clips and four screws. Tighten the screws to the specified torque. TORQUE 2 N-m 0.15 kgf-m, 1.1 lbf-ft Install the two trim clips into the bottom of the lower cowl.
Installation
Route the turn signal wire into the upper cowl, inner middle cowl and setting plate. Install and tighten the nut securely. Conncct the turn signal running light connectors. Install the front air duct covers into the upper cowl and tighten the screw securely. Install the resonator onto the air duct and secure it with a trim clip. Install the air duct into the air cleaner intake duct. Hook the resonator chamber stays to the chambers. Install the upper cowl onto the upper cowl stay while aligning...
Evaporative Emission Control System California Type Only 1
Check the hoses between the fuel tank, EVAP canister, EVAP purge control solenoid valve for deterioration, damage or loose connections. Cheek the EVAP canister for cracks or other damage. Refer to the Vacuum Hose Routing Diagram Label page 1 41 and Cable amp Harness Routing page 1-23 for hose connections.
Sprockets Inspection
Inspect the drive and driven sprocket teeth for wear or damage, replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition, or the new replacement chain will wear rapidly. NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT Check the attaching bolts and nuts on the drive and Drive sprocket bolt 54 N-m 5.5 kgf-m, 40 lbf-ft Driven sprocket nut 64 N-m 6.5 kgf-m, 47 lbf-ft When using the special too ,...
r
Liquid sealant Three Bond 1207B or equivalent Do not apply sealant to the thread head 3-4 mm 0.1 - 0.2 in . Connecting rod small end inner surface Camshaft lobes journals and thrust surface Valve stem valve guide sliding surface Water pump shaft spline and thrust washer sliding surface Clutch outer piimary driven year sliding surface M3 4, C5. C6 shifter gear shift fork grooves Starier reduction gear shaft outer surface Primary sub-gear friction spring sliding surface Molybdenum disulfide oil a...
Radiator Coolant
Check the coolant level in the reserve tank with the engine running at normal operating temperature. The level should be between the UPPER and LOWER level lines. It necessary, add the recommended coolant. RECOMMENDED ANTIFREEZE Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors. Remove the reserve tank filler cap and fill to the UPPER level line with a 1 1 mixture of distilled water and antifreeze. Reinstall the filler cap.
Air Cleaner
Support the front end of fuel tank page 3-4 . Disconnect the IAT Intake Air Temperature sensor connector. Remove the screws and air cleaner housing cover. Remove and discard the air cleaner element in accordance with the maintenance schedule page 3-3 . Also replace the air cleaner element any time it is excessively dirty or damage. Install the removed parts in the reverse order of removal.
Cable Harness Routing
RIGHT HANDLEBAR SWITCH 9P BLACK CONNECTOR COMBINATION METER 9P BLACK CONNECTOR LEFT HANDLEBAR SWITCH 9P BLACK CONNECTOR IGNITION SWITCH 4P NATURAL CONNECTOR COMBINATION METER 9P BLACK CONNECTOR LEFT HANDLEBAR SWITCH 9P BLACK CONNECTOR IGNITION SWITCH 4P NATURAL CONNECTOR RIGHT HANDLEBAR SWITCH 9P BLACK CONNECTOR FRONT SUB-HARNESS 12P GRAY CONNECTOR COMBINATION METER 9P BLACK CONNECTOR COMBINATION METER DP NATURAL CONNECTOR FRONT SUB-HARNESS 12P GRAY CONNECTOR COMBINATION METER 9P BLACK...
Exhaust Emission Control System Pulse Secondary Air Supply System
The exhaust emission control system is composed of a lean fuel injection setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcasc emis sion control system. The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the Pulse Secondary...
Engine Oil Filter Change
Stop the engine and remove the oil filler cap. Remove the drain bolt and drain the oil completely. Remove and discard the oil filter cartridge using the special tool. OIL FILTER WRENCH OIL FILTER CARTRIDGE OIL FILTER WRENCH OIL FILTER CARTRIDGE Check that the sealing washer nn the drain bolt is in good condition and replacc if ncccssory. Install and lighten Ihe drain bolt. TORQUE 29 N-m 3.0 kgf-m. 22 lbf-ft Apply clean engine oil to the new oil filter O-ring. Install the now oil filter and...
Valve Clearance
Inspect und adjust INSPECTION the valve clearance v hne the Remove the cylinder head cover page 8-4 bciow35'C 95'F . Remove the cam chain tensioner lifter sealing bolt and sealing washer. Turn the cam chain tensioner lifter shaft fully and secure it using the mechanic's tensioner stopper tool page 8-7 . Remove the timing hole cap and 0 ring. Turn the crankshaft clockwise and align the T mark on the ignition pulse generator rotor with the index mark on the right crankcase cover. The timing marks...
Installation 1
White installing Install the rear tender while aligning its lower groove the rear fender, with the scot roil brocc. route the wire harness properly pogc 1 23 . Install the rear fender mounting collars and bolts, and tighten the bolls securely. Route the rear sub-harness properly and install it into the rear fender wire guides. Install the fuel cut-off relay and turn signal relay onto the rear fender bosses. Connect the seat lock cahle to the r.ahle stay. Install the removed parts in the reverse...
Model Identification
1 The frame serial number is stamped on the right side of the steering head. 2 The engine serial number is stamped on the right side of the upper crankcase. 3 The Vehicle Identification Number VIN is located on left side of the main frame on the Safety Certification Labels. h IHHOTTLT BODY IDENTIFICATION NUMBER 4 The throttle body identification number is stomped on the intake side of the throttle body as shown. h IHHOTTLT BODY IDENTIFICATION NUMBER 4 The throttle body identification number is...
Installation Ycn
Install the left pillion footpeg bracket and tighten the bolts to the specified torque. TORQUE 26 N m 2.7 kgf-m, 20 Ibf.ft Install thc left pillion footpeg bracket and tighten the bolts to the specified torque. TORQUE 26 N-m 2.7 kgf-m, 20 Ibf.ft Install the muffler mounting bolt, washer and riut, and tighten the nut securely. Install the regulator rectifier page 16-8 . Route the rear brake reservoir hose properly, install and tighten the bolt nut to the specified torque. TORQUE 12 N m 1.2...
F4i Foot Peg Bracket Bolt
Loosen the rear shock absorber reservoir tank band and remove the reservoir tank from the seat rail. Remove the brake light switch wire band. Remove the bolt nut and rear brake reservoir tank from the seat rail. Remove the regulator rectifier page 16-8 . Remove the muffler mounting bolt nut. Remove the holts and right pillion footpeg bracket. Remove the bolts and left pillion footpeg bracket. Remove the seat rail mounting holts nuts, coolant reservoir tank mounting collar washcr and seat roil....
Cbr600 F4i Radiator Removal
Remove the lower cowl and inner half cowl page 2-4 . California type Disconnect the o2 sensor 4P Natural connector. only Remove the o2 sensor wire from the frame. Remove the muffler mounting bolt nut and washer, then remove the muffler. Remove the radiator lower mounting bolt nut, then move the radiator forward. - Exhaust pipe mounting bolt nut Remove the collar and mounting rubbers from the exhaust pipe bracket.
California Type
TURN SIGNAL LICENSE LIGHT CONNECTORS REGULATOR RECTIFIER 6P BLACK CONNECTOR REAR SUB-HARNESS 14H GRAY CONNECTOR BRAKE LIGHT SWITCH 2P BLACK CONNECTOR TURN SIGNAL LICENSE LIGHT CONNECTORS REGULATOR RECTIFIER 6P BLACK CONNECTOR REAR SUB-HARNESS 14H GRAY CONNECTOR BRAKE LIGHT SWITCH 2P BLACK CONNECTOR
Vacuum Hose Routing Diagram Label California Type Only
The Vacuum Hose Routing Diagram Label is on the air cleaner housing cover as shown. The fuel tank must be opened to read it. Refer to page 3-4 for fuel tank opening. EVAPORATIVE FAMILY- CAl IFORNIA VEHICLE