Honda CB-600F Workshop Service Manual – PDF DOWNLOAD

Description

Honda CB-600F Workshop Service Manual – PDF DOWNLOAD

DESCRIPTION:

Honda CB-600F Workshop Service Manual – PDF DOWNLOAD

1. GENERAL INFORMATION

GENERAL SAFETY CARBON MONOXIDE 1-1 1-2 1-3 1-4 1-13 If the engine must be running to do some work, make sure t he area is well ventilated. Never run the engine in an enclosed area

WARNING:

The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

COOLANT

Under some condition, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the ethylene glycol does ignite, you will not see any flame, but you can be burned.

WARNING:

• Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flame.

• Coolant (ethylene glycol) can cause some skin irritation and is poisonous if swallowed. KEEP OUT OF REACH OF CHILDREN.

• Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. • Keep hands and clothing away from the cooling fan, as it starts automatically

BATTERY HYDROGEN GAS & ELECTROLYTE

WARNING

The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. – If electrolyte gets on your skin, flush with water. – If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. • Electrolyte is poisonous. – If swallowed, drink TAKE quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN

SERVICE RULES

1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don’t meet HONDA’s design specifications may cause damage to the motorcycle
2. Use the special tools designed for this product to avoid damage and incorrect assembly.

3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners.

4. Install new gaskets, other, cotter pins, and lock plates when reassembling.

5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten. to t he specified torque diagonally in incremental steps unless a particular sequence is specified.

6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.

7. After reassembly, check all parts for p roper installation and operation. 8. Route all electrical wires as show on pages 1 s22 trough 1-31, Cable and Harness Routing.

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 t he break-in period. Sections 1 and 3 apply to the whole motorcycle.
• Section 2 illustrates procedu res for removal/ installation of components that may be required to perform service described in the following sections. Sections 4 through 19 describe parts of t he 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 detaile procedure. If you don’t know the source of the trouble, go to section 21 Troubleshooting.
• ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING.
• HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS ORATVS.

TABLE OF CONTENTS:

Honda CB-600F Workshop Service 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

Need help? Contact: [email protected]

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]