cbr600-f4.pdf

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HOW TO USE THIS MANUAL
This service manual describes the service procedures
for tho C8R600F4.
Follow the Maintenance Schedule (Section 3) recom-
mendations 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
anrl
Tr;rn.srort
C:rnada.
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/
,...,~1'11iation
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 have an assembly or system
illustration, service information and troubleshooting
for the section.
The subsequent pages give detailed procedures.
If you don't know the source of the trouble, go to
::>t:lLlion 22 Troubleshooting.
(/)
CONTENTS
GENERAL INFORMATION
FRAME/BODY PANELS/EXHAUST
SYSTEM
MAINTENANCE
LUBRICATION SYSTEM
FUEL SYSTEM
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2
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0
0
2
COOLING SYSTEM
ENGINE REMOVAL/INSTALLATION
CYLINDER HEAD /VALVE
CLUTCH/GEARSHIFT LINKAGE
ALTERNATOR/STARTER CLUTCH
CRANKCASE/TRANSMISSION
CRANKSHAFT /PISTON/CYLINDER
FRONT WHEEL/SUSPENSION/STEERING
REAR WHEEL/SUSPENSION
HYDRAULIC BRAKE
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1-
a
2
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2
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(/)
ALL INFORMATION, ILLUSTRATIONS, DIREC·
TIONS 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
WRITIEN PERMISSION. THIS MANUAL IS
WRITIEN FOR PERSONS WHO HAVE ACQUIRED
BASIC KNOWLEDGE OF MAINTENANCE ON
HONDA MOTORCYCLES, MOTOR SCOOTERS
OR ATVS.
(.)
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BATTERY /CHARGING SYSTEM
....I
(.)
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(.)
1-
C2
IGNITION SYSTEM
ELECTRIC STARTER
LIGHTS/METERS/SWITCHES
WIRING DIAGRAMS
TECHNICAL FEATURE
TROUBLESHOOTING
INDEX
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Date of Issue: January,
1999
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required
pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.
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I
Replace the part(s) with new one(s) before assembly.
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~
~
Use recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of
1: 1).
Use multi-purpose grease (Lithium based multi-purpose grease NLGI
#
2 or equivalent).
,,.,
.
Use molybdenum disulfide grease (containing more than 3
%
molybdenum
equivalent).
Example: Molykote® BR-2 plus manufactured by Dow Corning, U.S. A.
Multi-pL1rpose M-2 manufactured by Mitsubishi Oil, Japan
.
•i
~
Use molybdenum disulfide paste (containing more than 40
%
molybdenum disulfide, NLGI
equivalent).
Example: Molykote® G-n paste, manufactured by Dow Corning, U.S.
A.
Honda Moly 60 (U.S.
A.
only)
Raco! ASP manufactured by Roca! Limited, U. K.
Rocol Paste manufactured by Sumico Lubricant, Japan
#
2 or
~
Use silicone
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Apply~
locking agent. Use a middle strength locking agent unless otherwise specified .
Apply sealant.
...
I
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified .
Use Fork or Suspension Fluid.
1.
GENERAL INFORMATION
GENERAL SAFETY
SERVICE RULES
MODEL IDENTIFICATION
SPECIFICATIONS
TORQUE VALUES
TOOLS
1-1
1-2
1-3
1-4
1-11
1-14
LUBRICATION
&
SEAL POINTS
CABLE
&
HARNESS ROUTING
EMISSION CONTROL SYSTEMS
EMISSION CONTROL INFORMATION
LABELS
1-16
1-18
1-29
1-32
GENERAL SAFETY
CARBON MONOXIDE
If the engine must be running to do some work, make
USED ENGINE OIL
sure the area is well ventilated. Never run the engine in an
enclosed area.
tMM@Hri
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 possible after handling used oil. KEEP
OUT OF REACH OF CHILDREN.
Run the engine in an open area or with an exhaust
evacuation system in an enclosed area.
GASOLINE
Work in a well ventilated area. Keep cigarettes, flames or
sparks away from the work area or where gasoline is
stored.
BRAKE DUST
Never use an air hose or dry brush to clean the brake
assemblies. Use a vacuum cleaner or alternate method to
minimize the hazard caused by air borne asbestos fibers.
tM/.hU!ml
Inhaled asbestos
fiber:;
have
been
found
to
cau:;e
tM/.hWOH
Gasoline is extremely flammable and is explosive under
certain conditions. KEEP OUT OF REACH OF CHILDREN.
respiratory disease and cancer.
BRAKE FLUID
CAUTION:
HOT COMPONENTS
tMf.MMH
Engine and exhaust system pans become very hot and
remain hot for some time after the engine is run. Wear
insulated gloves or wait until the engine and exhaust
system have cooled before handling these parts.
Spilling fluid on painted, plastic or rubber parts will
damage them. Place a clean shop towel over these parts
whenever the system is serviced. KEEP OUT OF REACH OF
CHILDREN.
1-1

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