1999 Honda CB 600F Shop Manual – PDF DOWNLOAD
DESCRIPTION:
1999 Honda CB 600F Shop Manual – PDF DOWNLOAD
HOW TO USE THIS MANUAL :
This service manual describes the service procedures for the CB600F. Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition. 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 to the whole motorcycle. Section 2 illustrates procedures for removal! installation of components that may be required to perform service described in the following sections. Sections 4 through 19 describe parts of the motorcycle, grouped according to location.
- Find the section you want on this page. then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting‘ for the section. The subsequent pages give detailed procedure. If you don’t know the source of the trouble, go to section 21 Troubleshooting.
TABLE OF CONTENTS:
1999 Honda CB 600F Shop Manual – PDF DOWNLOAD
Safety........................................... 2 Contents......................................... 3 Symbols.......................................... 4 1: General Information........................... 5 Service Rules................................ 6 Model identification......................... 7 Specification................................ 8 Torque values................................ 17 Tools........................................ 21 Lubrification & seal points.................. 23 Cable & harness routing...................... 26 Emission control system...................... 36 2: Frame/Body panels/Exhaust system.............. 40 Body panel locations......................... 39 Service information.......................... 40 Troubleshooting.............................. 40 Seat......................................... 41 Side cover................................... 41 Rear cowl.................................... 42 Fuel tank.................................... 43 Front fender................................. 43 Rear fender.................................. 44 Muffler / exhaust pipe....................... 44 3: Maintenance................................... 47 Service information.......................... 47 Maintenance schedule......................... 49 Fuel line.................................... 50 Throttle operation........................... 50 Carburetor choke............................. 51 Air cleaner.................................. 51 Spark plug................................... 51 Valve clearence.............................. 53 Engine oil/oil filter........................ 58 Carburetor syncronization.................... 60 Engine idle speed............................ 61 Radiator coolant............................. 62 Cooling system............................... 62 Secondary air supply system.................. 63 Drive chain.................................. 63 Drive chain slider........................... 68 Brake fluid.................................. 68 Brake pad wear............................... 69 Brake system................................. 69 Brake light switch........................... 70 Headlight aim................................ 70 Clutch system................................ 71 Side stand................................... 71 Suspension................................... 72 Nuts, bolts, fasteners....................... 73 Wheel/tires.................................. 73 Steering head bearings....................... 74 4: Lubrification system.......................... 76 Lubrification sysetm diagram................. 75 Service information.......................... 76 Troubleshooting.............................. 77 Oil pressure inspection...................... 78 Oil strainer/pressure relief valve........... 79 Oil pump..................................... 81 Oil cooler................................... 85 5: Fuel system................................... 90 Service information.......................... 90 Troubleshooting.............................. 92 Air cleaner housing.......................... 93 Carburetor removal........................... 97 Carburetor separation........................ 98 Carburetor disassembly.......................100 Carburetor assembly..........................104 Carburetor combination.......................109 Carburetor installation......................113 Pilot screw adjustment.......................114 Fuel valve...................................116 6: Cooling system................................120 System flow pattern..........................119 Service information..........................120 Troubleshooting..............................121 System testing...............................122 Coolant replacement..........................123 Thermostat...................................125 Radiator.....................................128 Radiator reserve tank........................133 Water pump...................................133 7: Engine removal/installation...................137 Service information..........................137 Engine removal...............................138 Engine installation..........................142 8: Cylinder head/valves..........................149 Service information..........................149 Troubleshooting..............................151 Cylinder compression test....................152 Cylinder head cover removal..................152 Camshaft removal.............................153 Cylinder head removal........................156 Cylinder head disassembly....................158 Cylinder head inspection.....................159 Valve guide replacement......................162 Valve seat inspection/refacing...............163 Cylinder head assembly.......................165 Cylinder head installation...................167 Camshaft installation........................168 Cylinder head cover installation.............171 Cam chain tensioner lifter...................173 9: Clutch/gearshift linkage......................176 Service information..........................176 Troubleshooting..............................177 Right cranckcase cover removal...............178 Clutch.......................................179 Gearshift linkage............................186 Right cranckcase cover installation..........189 10: Alternator/starter clutch....................191 Service information..........................191 Troubleshooting..............................191 Alternator cover removal.....................192 Stator.......................................193 Flywheel removal.............................194 Starter clutch...............................195 Flywheel installation........................198 Alternator cover installation................199 11: Crankcase/piston/cylinder....................202 Service information..........................202 Troubleshooting..............................203 Cranckcase separation........................204 Piston/connecting rod........................205 Cranckcase combination.......................212 12: Crankshaft/trasmission.......................217 Service information..........................217 Troubleshooting..............................218 Cranckshaft..................................219 Trasmission..................................223 13: Front wheel/suspension/steering..............232 Service information..........................232 Troubleshooting..............................233 Handlebar....................................234 Front wheel..................................240 Fork.........................................247 Steering stem................................256 14: Rear wheel/suspension........................265 Service information..........................265 Troubleshooting..............................266 Rear wheel...................................267 Shock absorber...............................274 Swingarm.....................................276 15: Hydrulic brake...............................286 Service information..........................286 Troubleshooting..............................288 Brake fluid replacement/air bleeding.........289 Brake pad/disc...............................291 Front master cylinder........................294 Rear master cylinder.........................298 Front brake caliper..........................303 Rear break caliper...........................306 Brake pedal..................................309 16: Battery/charging system......................312 System diagram...............................311 Service information..........................312 Troubleshooting..............................314 Battery......................................316 Chrging system inspection....................317 Alternator inspection........................319 Regulator/rectifier..........................319 17: Ignition system..............................322 System diagram...............................321 Service information..........................322 Troubleshooting..............................324 Ignition system inspection...................325 Ignition coil................................327 Ignition pulse generator rotor...............328 Throttle sensor..............................331 Ignition control module......................332 Ignition timing..............................333 18: Electric starter.............................336 System diagram...............................335 Service information..........................336 Troubleshooting..............................337 Starter motor................................339 Starter relay switch.........................345 Diode........................................346 19: Light/meters/switches........................348 System location..............................347 Service information..........................348 Headlight....................................350 Position light...............................351 Turn signal..................................351 Tail/brake light.............................352 Combination meter............................352 Tachometer...................................356 Coolant temperature gauge/sensor.............357 Coolant fan motor switch.....................358 Oil pressure switch..........................359 Ignition switch..............................360 Handlebar switches...........................361 Brake light switch...........................362 Clutch switch................................362 Neutral switch...............................362 Side stand switch............................363 Horn.........................................364 Turn signal relay............................364 20: Wiring diagrams..............................365 Diagram 1# : U type..........................365 Diagram 2# : Except U type...................366 21: Troubleshooting..............................367 Engine does not start or is hard to start....367 Engine lacks power...........................368 Poor performance at low idle speed...........369 Poor performance at high speed...............370 Poor handling................................370 Index............................................371
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