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
1999 HONDA CB 600F SHOP MANUAL – PDF DOWNLOAD:
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1999 Honda CB 600F Shop Manual – PDF DOWNLOAD1999 Honda CB 600F Shop Manual – PDF DOWNLOAD
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