@HONDA SHOP MANUAL CBF600S/SA/N/NA CBF600N/NA/S/SATYPE CODE “+ Throughout this manuel, the following abbreviations are used to identify individual model. CODE AREA TYPE EUROPEAN DIRECT SALES ED (ltaly, Germany, Portugal, Norway, Finland, Sweden, Denmark, Austria, Belgium, Greece, Spain, Luxembourg, Netherlands, Switzerland, Russia, Eastern Europe) 3ED Germany E UL, Ireland F France, BelgiumA Few Words About Safety Service Information ‘The service and repair information contained in this manual is intended for use by qualified, professional technicians, Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition, ‘This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle, IT you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part, We strongly recommend that you do not use replacement parts of inferior quality. pouvour Safety. Follow the procedures and precautions in this feel confident about your knowledge of alo. servicing practice, we CNN) in this manual. precautions can cause you to be seriously hurt ‘Some of the most important general service safety precautions are given | nae below. However, we cannot warn you of every conceivable hazard that can | arise in performing service and repair procedures. Only you can decide | whether or not you should perform a given task. ; Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and Using safety equipment. When performing any service task, be especially careful of the following: Follow the procedures and precautions in this manual carefully. ‘+ Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. + Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, dil, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. + Use other protective wear when necessary, for example gloves or safely shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. * Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack. make sure that itis always securely supported. Use jack stands, Make sure the engine is off before you begin any servicing procedures, unless the This will help eliminate several potential hazards: struction tells you to do otherwise. * Carbon monoxide poisoning from eng exhaust. Be sure there is adequate ventilation whenever you run the engine, + Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. * Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibilty of a fire or explosion, be careful wh working around gasoline or batteries. * Use only a nonflammable solvent, not gasoline, to clean parts. * Never drain or store gasoline in an open container, * Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts,HOW TO USE THIS MANUAL This service maual describes the sence procedures forthe CBFEOON NASISA. Follow the Naintonance Schedule (Secon 3) recommendations to ‘ensure thal he vehicle is in peak operating condo, Performing the frst scheduled maintonance le very important. It Ccompensats fx the inl wear tht cocute diag the beak poi. Sections 1 and 3 apply tothe whole motoreyete, Section 2 Mustrstos procedures for renavarsatation of components tht may be required {o porn sorvce described nthe folowing s0ctns Seolon 4 trough 20 descrbe paris of the mtorysle, growed _220orng to leet. Fd the section you want on this pag, than turn othe table of contens ‘onthe fist page ofthe section, ost sections start win an assembly or system Wustraton, service Information and rouleshooting for tho eaoton, The sudsequont pages ‘ve dotaed procedure 1 you dont inow the source of the rouble, go to seston 22 ‘rotbleshosting ‘Your sale and he stey of oer, s very important. To ep you make itornad decisens we have provided salety messages and ter information thoughout this manual OF course, iis not Bacto! or posse to warn you about al the hazarés associated ath servicing this vehicle ‘ou must us your own good juégemant. ‘ou ‘wil find important safely information In @ verety of forme sneuaing * Saal Labels on the vehicle 1 Salty Messages — preceded by a solely alert symbol d\. ard fone of tres signal worde, DANGER, WARNING, or CAUTION. ‘Toco cignal words moar: You WILL be KILLED or SERIOUSLY HURT I you dontotow msructons ‘You CA bo KILLED or SERIOUSLY HURT you dont folow instructions. ‘You CAN be HURT if you dont folow ‘natuetons, Pe + Inaction —how fo sence this vehicle corecty and safely. CONTENTS GENERAL INFORMATION Be FRAME/BODY PANELSIEXHAUST SYSTEM MAINTENANCE EEE ENGINE AND DRIVE TRAIN LUBRICATION SYSTEM EZ FUEL SYSTEM EG | CYLINDERHEADVALVES EZ [ ALTERNATORISTARTER CLUTCH ED CRANKCASE/TRANSMISSION Ea CRANKSHAFTIPISTONCYLINDER EE CHASSIS FRONT WHEEL/SUSPENSION/ STEERING REAR WHEEL/SUSPENSION El HYDRAULIC BRAKE 7 Ea ANTI-LOCK BRAKE SYSTEM (ABS) EG BATTERY/CHARGING SYSTEM mo IGNITION SYSTEM Ey ‘hs you tad hi manu, you wil ind formation st is prosaded by 2 NOME) symbol The purpose ofthis messege is to help provent ‘damage to your veil, eter propery, othe envionment. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LAT- EST 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 WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MAN- UAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTE- NANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co.,Ltd. SERVICE PUBLICATION OFFICE Date of Issuer December, 2005 (Honda Motor Co., Lt. ELECTRICAL ELECTRIC STARTER Ea LIGHTS/METERS/SWITCHES EI WIRING DIAGRAMS EEE TROUBLESHOOTING 2 INDEX EaSYMBOLS ‘The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained spocifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. g ep part(s) 2(6) iy. 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 molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote® BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan —Szzaa_—_ | Use mult-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent) Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example; Molykote® G-n Paste manufactured by Dow Corning U.S.A. AX Honda Moly 60 (U.S.A. only) FRocol ASP manufactured by Rocol Limted, UK. FRocol Paste manufactured by Sumico Lubricant, Japan Aa Use silicone grease. ‘Apply a locking agent. Use a middle strength locking agent unless otherwise specified Apply sealant. A Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specifi. on Use Fork or Suspension Fluid.1. GENERAL INFORMATION SERVICE RULES MODEL IDENTIFICATION GENERAL SPECIFICATIONS LUBRICATION SYSTEM SPECIFICATIONS: FUEL SYSTEM- COOLING SYSTEM SPECIFICATIONS CYLINDER HEAD/VALVES SPECIFICATIONS- CLUTCH/GEARSHIFT LINKAGE ‘SPECIFICATIONS- ALTERNATOR/STARTER CLUTCH ‘SPECIFICATIONS- CRANKCASE/TRANSMISSION SPECIFICATIONS: CRANKSHAFT/PISTON/CYLINDER ‘SPECIFICATIONS: FRONT WHEEL/SUSPENSION/STEERING ‘SPECIFICATIONS REAR WHEEL/SUSPENSION ‘SPECIFICATIONS-~ HYDRAULIC BRAKE SPECIFICATIONS BATTERY/CHARGING SYSTEM ‘SPECIFICATIONS-~ IGNITION SYSTEM SPECIFICATIONS ELECTRIC STARTER SPECIFICATIONS ~ LIGHTS/METERS/SWITCHES. SPECIFICATIONS-- STANDARD TORQUE VALUES. ENGINE & FRAME TORQUE VALUES LUBRICATION & SEAL POINTS -- CABLE & HARNESS ROUTING EMISSION CONTROL SYSTEMSGENERAL INFORMATION SERVICE RULES 1 ge on 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. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling, When tightening bolts or nuts, begin with the larger diameter or inner boit first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operetion. Route all electrical wires as show in the Cable and Harness Routing (page 1-24).GENERAL INFORMATION MODEL IDENTIFICATION CBF600S shown: ‘CBF600N shown:GENERAL INFORMATION ‘The vehicle Identification Number (V.1.N) is stamped on the right side of the steering head. The engine serial number is stamped on the lower right side of the crankcase. ‘The carburetor identification numbor is stamped on the intake side of the carburetor body as shown. ‘The color label is attached as shown. When ordering color-coded parts, always specify the designated color code.GENERAL SPECIFICATIONS GENERAL INFORMATION TEM ‘SPECIFICATIONS ] DIMENSIONS] Overall length 2,170 mm (85 in) Overall width 765 mm (30.1 in) Overall height CBFE00S/SA Wind screen STD | 1,230. mm (48.4 in) Wind screen HIGH | 1,275 mm (50.2 in) (CBFBOONINA, 41.110 mm (43.7 in) ‘Wheelbase 1,480 mo (58.3 in) Seat height 785 + 15mm (31.0 + 0.6in) Footpeg height 296 mm (11.7 in) Ground clearance 127 mm (6.0 in) Dry weight ‘cBF600s 197 kg (434 Ibs) ‘CBFEO0SA 202 kg (445 Ibs) ‘CBF6OON 191 kg (421 Ibs} ‘CBF600NA 198 kg (430 Ibs) Curb weight CBFBD0S 219 kg (483 Ibs) CBF600SA 224 kg (494 Ibs) CBF600N 215 kg (474 Ibe) CBFEDONA 220 kg (485 Ibs) Maximum weight capacity 7 180 kg (397 Ibs) FRAME Frame type Diamond Front suspension Telescopic fork Front axle travel 108 mm (4.3 in) Rear suspension ‘Swingarm Rear axle travel 125 mm (4.9 in) Front tire size 12070 2R 17M/C (58W) Rear tire size 160/60 ZR 17 M/C (69) Front tie brand BT-S7F RADIAL U (Bridgo- stone) PILOT ROAD B (Michelin) Rear tire brand BT-57 RADIAL E (Bridgestone) PILOT ROAD (Michelin) Fromt brake Hydraulic double disc Roar brake Hydraulic single disc Caster angle 25° 00" Trail length 110 mm (4. Fuol tank capacity 19.0 liter (6.01 US gal, 4.18 Imp gal) Fuel reserve capacity 3.5 liter (0.82 US gal, 0.77 Imp gal) ENGINE Cylinder arrangement 4 oylinders indine, inclined 30° from vertical Bore and stroke 65.0 X 45.2 mm (2.56 X 1.78 in) Displacement 599 cm? (38.5 cu-in} Compression ratio 16:1 Valve train Chain driven, DOHC Intake valve opens at 1 mm (0.04 in) 5° BTDC lift closes at 1 mm (0.04 in) 25° ABDC lit Exhaust valve opens at 1 mm (0.04 in) 30° BBDC fit closes at 1 mm (0.04 in} o* ATOC lit Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Liquid cooled Ai filtration Paper element Engine dry weight 63.2 kg (139.3 Ibs) Firing order 7 1-2-4-3 CARBURETOR | Type 7 Constant volocity Throttle bore 7 34 mm (1.3 in) ‘ LL 1-5GENERAL INFORMATION TEM ‘SPECIFICATIONS DRIVE TRAIN | Clutch system Mulir-plate, wet Clutch operation system Cable operating Transmission Constant mesh, 6-speeds Primary reduc- 1.863 (82/44) tion Final reduction 2.866 (43/15) Gear ratio Ast 2.928 (41/14) 2nd 2.062 (33/16) 3rd 1.647 (28/17) ath 1,368 (26/19) sth 1.200 (24/20) 6th 1.086 (25/23) Gearshift pat- Left foot operated return sys- tern tem, 1-N-2-3-4-5-6 ELECTRICAL Ignition sys" Full ransistorized ignition tem Starting sys- Electric starter motor tem Charging sys- Triple phase output alternator tem Regulator/rec- SCR shorteditriple phase, full tifier wave rectification Lighting sys- ~ Battery ei temGENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mam (in) ‘SERVICE TEM STANDARD ae Engine oll capacity After dai BB iter B.7 US at SA Imp gl = After dra ‘3B liter (4.0 US qt, 331mp at) = chang _____— after cisassembly | 42 iter (a4 US qt, 3:7 Imp atl js Recommended engine oil Honda 4-stroke oil or equivalent motor 0 = API service classification SE, SF or SG Viscosity: SAE 10W.30 Oil pressure at engine oil pressure switch “490 kPa (6.0 koflom’, 71 psi) at = 6,000 min’ (gpm)/t802C/1 76°F) [Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance ‘0.15 - 0.22 (0,006 = 0.008) (0.35 (0.014) Side clearance (0.02 0.07 (0.001 = 0.008) 0.10 (0.004) | hom pump drive sprocket - 34.050 - 34.075 (1.3405 - 1.3415) | | oirpump drive sprocket 0. 35075 = 35.075 (1.3789 1.3809) FUEL SYSTEM TEM SPECIFICATIONS ~ Carburetor identification number VP4AR - Main jot No.1/4; #102, No.2/3; #105 ‘Slow jet #0 Jet need 8970 Pilot screw [initial opening 2174 turns out Float level 73.7 mm (0.58 in} Idle speed 7,300 £100 min™ (rpm) Throttle grip Wee play 2=6 mm (i6= 1/4 in} Carburetor vacuum difference —__ Within 30 mm Hg (1.2 in Ha) Base carburetor for synchronization No.3 carburetor COOLING SYSTEM SPECIFICATIONS TEM ‘SPECIFICATIONS Coolant capacity Radiator and engine Reserve tank_ 2.05 Titer (2.17 US qt, 1.80 Imp at) 0.30 Titer (0.32 US gt, 0.26 imp at) Radiator cap relief pressure 108 kPa (1.1 kaf/em?, 16 psi) Thermostat Begin to open ‘80 84°C (176 - 183) Fully open. ‘95°C (203 F) Valve lift, Racommonded antifreeze mm (033 in) minimum High quality ethylene glycol antifreeze containing corrosion protection inhibitors Stendard coolant concentration 7: mixture with soft water 1-7GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) TEM ‘STANDARD ‘SERVICE LIMIT Cylinder compression 7.204 KPa (13.2 kai/em’, T88psi) = £8 350 min* (rpm) Valve clearance W 0.16 + 0.03 (0.006 £0.001) = EX (0.22 £ 0.03 (0.009 + 0.001) = a Camshaft Cam Tobe height iu 34,540 - 34,780 11.3598 - 1.3692). 341520 (1.3580) _| EX '33,800 ~ 34.040 (1.3307 - 1.3401) 33.780 (1.3299) Journal 0.0. 23,959 = 23.980 (0.9433 - 0.9411) 24,955 (0.9825), Runout = (0.05 (0.002) Oil clearance {0,020 - 0.062 (0.0008 - 0.0024) 0.10 (0.008) Valve iter Valve lifter 0D. : 25.878 - 26.988 (1.0228 - 1.0233) 25.97 (1.022) | Valve lifter bore 1D. 26.010 ~ 26.026 {1.0240 — 1.0246) 26.04 (1.025) Valve, Valve stem 0.0. WN 3.975 ~ 8.990 (0.1565 - 0.1571) 3.965 (0.1561) valve guide EX 3.965 ~ 3.980 (0.1561 - 0.1567) 3.956 (0.1557) Valve guide 1D. INIEX| 4,000 = 4.012 (0.1575 — 0.1580) 4.04 (0.159) Stermto-guide clearance |_IN 0.010 — 0.037 (0.0004 — 0.0075) (0.075 (0.0030) ex (0.020 0:047 (0.0008 - 0.0019) 0.085 (0.0033) Valve guide projection |_IN 73.10 13.30 (0.516 - 0.524) = above cylinder head EX 11.30= 11.50 (0.445 0.453) = Valve seat width IWEX | 0.90 - 1.10 (0.035 - 0.043) 7.5 (0.06) Valve spring free Tongth INVEX | ~37.49 (1.474) 36.68 (1.44), [Cylinder head warpage 0.10 (0.004) CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS Unit: mm TEM ‘STANDARD ‘SERVICE LIMIT Clutch Tever free play = 70-70 (38- 13/16) = [Clutch Spring free length 48.9 (1.93) a5 (087) Disc thickness 2.92 - 3.08 (0.115 - 0.127) 26 (0.10) Plate werpage = 0.30 (0.012) ‘Clutch outer guide 1D. 21,984 — 79,007 10.8659 — 0.8664) 22.017 (0.8668) OD. 4,975 — 34.981 (1.3770 - 1.3770) 34.965 (1.3766) ‘Wainshaft O.D. at clutch outer guide 21.980 — 21.993 (0.8654 - 0.8659) 21.95 (0.864) ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Unit: mm (in) TEM ‘STANDARD SERVICE LIMIT ‘Starter driven gear boss 0.0. ‘1.500 ~ 51.718 (2.0354 ~ 2.0961) 51.684 (2.0348)GENERAL INFORMATION CRANKCASE/TRANSMISSION SPECIFICATIONS Unit: mm (in) TEM ‘STANDARD SERVICE LIMIT Shift fork, 10. 12.000 12.021 (0.4724 — 0.4733) "12.03 (0.474) fork shaft Claw thickness 5.93 - 6:00 (0.233 - 0.236) 5.9 (0.23) ‘Shift fork shaft 0.D. "11.957 — 11.968 (0.4707 - 0.4712) 11.95 (0.470) Transmission | Gear LD. M5ME 28.000 = 28.021 (1.1024 = 1.1032) 28.04 (1.104), €2,C3, C4 | 31.000 31.026 (1.2205 — 1.2215) ‘31.04 (1.222) Gear busing OD. |_MS5, M6 27.959 = 27.980 (1.1007 - 1.1016) 27.94 (1.100) (€2,C3, C4 | 30.950 - 30.975 (1.2189 — 1.2197) 30.94 (1.218) Gearcto-bushing _[_M5, M6 0.020 — 0.062 (0.0008 - 0.0024) 10.10 (0.004) clearance 2,03, C4 | 0.025 = 0.075 (0.0010 0.0030) 0.17 (0.004) Gear bushing [D. |W 24,985 — 26,006 (0.9837 - 0.9845) 25.016 (0.9849) cz 27.985 ~ 28.006 (1.1018 1.1026) 28.021 (1.1032) Mainshaft 0.0. at MB 24.987 ~ 24.980 (0.9830 — 0.9835) 24.96 (0.983) Countershaft 0.0. [at C2 27.967 = 27.980 (1.1011 = 1.1016) 27.96 (1.101) Bushing to shaft [MS {0.005 — 0.039 (0.0002 — 0.0018) (0.06 (0.002) clearance CZ ‘0.005 = 0.039 (0.0002 - 0.0018) 0.08 (0.002) CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS Unit: mm {in} TEM "STANDARD. ‘SERVICE LIMIT Crankshaft [Connecting rod side clearance {0.40 -0.25 (0.004 - 0.010) 0.30 (0.012) rankpin bearing oil clearance (0.028 = 0.052 (0.0011 - 0.0020) ‘0.06 (0.002) Main journal bearing oil clearance | 0.020 - 0.045 (0.0008 - 0.0018) ‘0.05 (0.002) Runout = ‘0.05 (0.002) Piston, piston | Piston O.D. at 11 (0.4) from bottom | 64370 64.990 (2.5679 - 2.56671 (64.90 (2.555) rings: Piston pin bore ID. 17.002 = 17.008 (0.6694 - 0.6696) 17.02 (0.670) Piston pin 0.D. 716.994 - 17.000 (0.6691 — 0.6693) 716.98 (0.669) Piston -to piston pin clearance (0.002 = 0.014 (0.0007 - 0.0008) (0.04 (0.002) Piston ring end Top. 0.10 =0.20 (0.004 - 0.008) 0.4 (0.02), gap Second ‘0.18- 0.30 (0.007 - 0.012) 05 (0.02) Oi! 0.20 =0.70 (0.008 - 0.028) 7.0 (0.04) (side rail) Piston ring-to-ring |Top ‘0.025 = 0.060 (0.0010 = 0.0024) 0.08 (0.003) groove clearance | Second (0.015 ~ 0.050 (0.0006 - 0.0020) 0.08 (0.003) Cylinder 10. {65,000 = 65.015 (2.5591 - 2.5596) 65.10 (2.563) Out of round = (0.10 (0.004) Taper = 10:10 (0.004) Warpage = 0.10 (0.004) Cylinder-to-piston clearance, 0,010 = 0.046 (0.0004 - 0.0078) 0.10 (0.004) Connecting rod small end .D- "7.016 = 17.034 (0.6699 - 0.6706) 77.04 (0.6711 Connecting rod-to-piston pin clearance 0.076 - 0.040 (0.0006 - 0.0076) 0.08 10.002)GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS 7 Unit: mm (in) TEM. ‘STANDARD [_ SERVICE LIMIT ‘Minimum tie tread depth = 7510.08) Cold tire pres- |_Driver only 250 KPa (2.50 kgt/om®, 36 pail = sure Driver and passenger 250 kPa (2.50 kafiem?, 36 psi) = ‘Axle runout = OZ.) Wheel rim Radial = 2.0 (0.08) runout ‘Axial = 2.0 (0.08) ‘Wheel balance weight = 80 g (2.102) max. Fork Spring free iength 358.8 (13.38) 333 (7317) Tube runout = (0.20 (0.008) ‘Recommended fork fluid Fonda Ultra Cushion O11 TOW = or equivalent Fluid level 160 (6.3) Fluid capacity 440+ 2.5 om 14.9 £ 0.08 US 02, T55E \ 0.09 Imp oz) Steering head bearing preload 70-14 N(1.0- 14 kof) = REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm {in} TEM ‘STANDARD SERVICE LIMIT [CMtinimum tire tread depth T 7 0 (0.08) Cold tire pres- [Driver only Zo0 KPa BO Kaen, 41 psi) = sure Driver and passenger 290 KPa (2.90 kaflem’, 41 = ‘Axle runout = 0210.07) Wheel rim Radial = 2.0 (0.08) runout ‘Axial = 2.0 (0.08) | Wheel balance weight 5 9 (2.4 02) max Drive chain | Sizallink DID__|_S26vM2-T10LE = RK 525RO-T10LE = Slack 30-40 (1.2- 16) B12) ‘Shock absorber pre-load adjuster standard position | 3nd groove = 1-10GENERAL INFORMATION HYDRAULIC BRAKE SPECIFICATIONS Unit: mam lin) Tem ‘STANDARD SERVICE LIMIT Front Specified brake fluid Dora = Brake disc thickness 45 (0.18) 3510.14) Brake disc runout = 0.30 (0.072) Master cylinder 1.D. 72.700 - 12,743 10.5000 - 0.5017) [12:76 (0.6027) Caliper eylinder LD. Upper_| 25.40 (7.000) = Lower |~ 25.40 (7.000) Sooo Roar Specified broke fluid DoT 4 = Brake pedel height 67.5 (2.68) = Brake disk thickness 5.0 (0.20) 4070.16) Brake disc runout. 0.30 (0.072) 14.000 ~ 14,043 (0.5512 - 0.5529) Master cylinder LD. Caliper cylinder |.D. 14.085 (0.5533) 38.18 (7.503) 7 BATTERY/CHARGING SYSTEM SPECIFICATIONS TEM ‘SPECIFICATIONS Batiery Capacity a 12V-6 Ah a Current leakage 7.2 mA max. “Voltage Fully charged | 73.0 -13.2V (20°C/68°F) Neods Below 12.3V charging Charging current |_ Normal O9A5-10h Quick 4.0 ALOR Alternator Capacity (0:34 KWI5,000 min” (rpm Charging coil resistance (20°CI6S°F) 01-102 IGNITION SYSTEM SPECIFICATIONS : TEM 7 ~ SPECIFICATIONS ‘Spark plug NGK ic CROEH-9 7 DENSO- U27FERS Spark plug gap 0.80 0.30 mm (0.031 - 0.036 Ta) \n coll peak vortage: 100 V minimum in pulse generator peak voltage 0.7 Viminimum timing (F’mark) _P BTDC at idle | Idle speed 7,300 = 100 min" (romp i} ELECTRIC STARTER SPECIFICATIONS Unit: mm {in} Tem ‘STANDARD ‘SERVICE LIMIT Starter motor brush Tength 720 - 13.0 (0.47 - 0.61) 4.5 (0.18)GENERAL INFORMATION LIGHTS/METERS/SWITCHES SPECIFICATIONS Trea SPECIFICATIONS TBFSOOS[—CEFEDOSA | _CBF600N | — CBF6O0NA Bulbs | Headlight Hi T2v= 55 W. T2V = 60155 W Lo 12V= 55 W Position light T2v-5WX2 iav=5W Brakeltall ight iaV- 215 W TTurn signal light [Front Tav=21WX2 Fear iav=21WX2 Instrument light TED T2V-T7WX2 ‘Turn signal indicator LED 12V-17WX2 High beam indicator LED ‘Neutral indicator LED Engine oll pressure indicator LED Low fuel indicator LED ‘ABS indicator = a = I TED Fuse Main fuse 30K Sub fuse WAT | 30AX2, TAKE BOAX2 qoaxs | 20AX1, WAX7 WAX6 Tachometer peak voltage 7S V minimum Fan ON ‘98 - 102 °C (208- 216 °F) motor ‘OFF 93 = 97 °C (199 = 207 °F) switch 1-12GENERAL INFORMATION —_—_—_—— SSS STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE Nem (kgm, Ibe) Num (kgm, Hof) Sra hex bolt and nut 49(05,38) | Smmscrew 39 (0.4, 29) 6 mm hex bolt and nut 9.8 (1.0,7) 6 mm screw 8.8 (09,65) 8mm hex bolt ond nut 22(2.2,16) | 6mm lange bolt 9.8(1,7) 40 mm hex bolt and nut 34(35,25) | (6 mmhead, small flange) 12 mmbex bolt and nut 54 (65,40) | 6mm ange bolt 1212.9) (8 mm head, large flange) 6 mm flange bolt 12(12,9) (10 mm head) and nut 8 mm flange bolt and nut 26(2.7, 20) 10 mm flange bott and nut 39(40, 28) ENGINE & FRAME TORQUE VALUES + Torque specifications listed below ere for important fasteners. + Others should be tightened to standard torque values listed above. Note: 1. Apply sealant tothe threads. 2, Apply a locking agent to the threads. 3. Stake 4. Apply oil to the threads and flange surface. 5. Usnut 8. ALOC bokvscrew: replace with @ new one. 7. Apply grease to the threads. 8. Apply molybdenum disulfide oil tothe threads end sesting surface 3. CT bolt ENGINE MAINTENANCE ; THREAD TORGUE nes TY | pia (mm) | Nem igtm, tte) | REMARKS Spark plug a 10 781.8, 13) Timing hole cap 1 45 18 (18, 13) NOTE? Engine oil ftor ca 1 20 26 (27,20) NOTES Enaine oil drain bolt : 1 | 2 29 (3.0, 22) LUBRICATION ; THREAD TORQUE eM TY | pia. (mm)_| Nem tkgtem, tees) | REMARKS Oil filter boss 7 20 78 (1.8, 13) NOTEZ Oil pump driven sprocket bolt 1 6 15(15,11) NOTE2 Oil pump assembly bolt 1 6 7.8(080,58) | NOTES Oil cooler sealing bolt 1 18 49 (6.0, 36) NOTE 2 FUEL SYSTEM | THREAD TORQUE rem OTY | pia tmm) | nim tkgtm wer) | REMARKS insulator band serew 3 5 7 page 116 Carburetor drain screw 4 4 1.5 (0.15,1.1) Sterting enrichment (SE) valve arm screw 2 4 118 (0.18,1.3) Starting enrichment (SE) valve nut 4 10 1.8 (0.18, 1:3) Vacuum chamber cover screw 12 4 2.1 (0.21, 1.5) Air funnel holder serew 16 4 24 (0.21, 1.5) Float chamber screw 12 5 3.4(0.35,2.5) Throttl cable holder serow 2 5 3.40.35, 25) Throttle position (TP) sensor bracket screw 1 5 3.4 035,25) Carburetor connecting nut, § mm 2 5 5.1 (052,38) Carburetor connecting nut, 6 mm 2 | 6 40(1.0,7) 1-1 3GENERAL INFORMATION COOLING SYSTEM pe = THREAD TORQUE eM OTY | piA.tmm) | Nem kgf, ttt) | REMARKS Water purip cover Balt z 3 73 (13,3) NOTES ECT sensor 4 12 232317) Water hose joint 12 mm 1 12 29 (3.0, 22) Weter hose joint 10 mm 1 10 25 (25,18) ENGINE MOUNTING f THREAD TORGUE MES TY | DIA. tovm)_| Nem (egtm, oesey | REMARKS Drive sprocket special bal 7 70 54 (5.5, 40) CYLINDER HEAD/VALVES ; THREAD TORQUE ee OTY | iA.tmm) | Nem ikgfm,tbfsty | REMARKS Cylinder head sealing bole 7 18 32 (33,24) NOTED Cylinder head bolt 10 9 47 (48, 35) NOTE 4 No.1 intake vacuum port plug 1 5 3103,22) Cylinder head cover bolt 6 6 98 (10,7) Camshaft holder flange bolt 20 6 1211.2, 9) NoTe4 Breather plate fiange bolt 5 6 13(13,9) NOTE 2 Cam sprocket bolt 4 7 20 (20,14) NOTE? Cam chain tensioner cap nut 1 6 12(1.2,9) Cam chain lifter sealing bott 1 6 98 (1.0,7) Reed valve cover bolt 4 6 13113.9) NOTES CLUTCH/GEARSHIFT LINKAGE : THREAD TORQUE Mb OT | DIA. imm)_| Neem (gt, tbtst)_|_PEMARKS Clatoh center Took nut 7 20 708 (17.0,80) | NOTES,# Clutch epring bolt 4 6 12(1.2,9) Shift drum center socket bott 1 8 23.(23,17) NoTe2 Shift drum stopper arm pivot bolt 1 6 12(1.2,9) Gearshift return spring pin 1 8 23(23,17) ALTERNATOR/STARTER CLUTCH ; THREAD TORQUE 7 a QTY | DIA. mm) _|_ Nem (kgm, tbe) _| REMARKS Flywheel flange bok 7 10 103 (10,76) | NOTE® Stator mounting socket bolt 4 6 12(1.2,8) Alternator wire clamp socket bolt 1 6 9.8(10,7) [_ Starter clutch outer torx bolt 6 8 16116, 12) NoTE2 ‘CRANKCASE/TRANSMISSION : THREAD TORQUE oN TY | pia.imm) | nem ktm, thst) | REMARKS Main journal bole 70 3 24 (24, 17) NOTES Crank case bolt, 10 mm 1 10 39 (40,28), Grankcase bolt, 8 mm 1 a 24124, 17) Lower erankcase sealing bolt, 20 mm 1 20 29 (80, 22) NoTE2 Lower crankcase sealing bolt, 14 mm 1 4 24 (25,18) NOTE? 1-14‘CRANKSHAFT/PISTON/CYLINDER GENERAL INFORMATION —— SSSSSSSSSSSSsS ; THREAD TORQUE bed) OT | piatmm)_| nem (kam, bese) _|_ REMARKS Connecting rod bearing cap nut 3 7 25 (26, 19) 1 a IGNITION SYSTEM : THREAD TOROUE we TY | pia. (mm) _|_Nem tag, toes) | REMARKS Ignition pulée generator rotor special bolt i 70 396.0, 43} ELECTRIC STARTER THREAD TORQUE ire OT | iA. tm) | Nemikgtm, eet) | REMARKS Starter motor terminal nuk ra ne 98 (10,71 LIGHTS/METERS/SWITCHES : TORQUE et S DIA. (mm)_| Nem (kgm, tee) | REMARKS Engine oll pressure ewich 7 Pre T2U12, 9) NOTET Engine oil pressure switch terminal screw 1 4 2.0 (020, 1.4) Neutral switch 1 10 12(1.2,9) License light serew 2 5 18 (0.18, 1.3) 1-15GENERAL INFORMATION Insulator clamp (carburetor side): Insulator clamp (Cylinder head side}: Exhaust pipe stud bolt: 1-16 10+1mm (0.4 4.0.04 in) 4¢1mm (0.20.04 in) oa a ce 21.8 +0.5 mm (0.85 + 0.04 in}GENERAL INFORMATION FRAME FRAME BODY PANELS/EXHAUST SYSTEM : THREAD TORQUE : re QTY | pia. tmm) | Nem (kgtm, ibe) | REMARKS Footpeg holder bork 7 2 26 (2.7, 20) Exhaust pipe joint nut 6 7 20 (2.0, 14) Exhaust pipe mounting nut 1 8 22.(2.2, 16) Mutfer mounting bolt 1 8 22 (22,16) Muffler band bolt 1 8 22 (22,16) Grab rail mounting socket bott 4 8 26 (2.7, 20) Front fender mounting bolt 2 6 12(12,9) Back mirror mounting aut 2 10 3435, 25) Rear turn signal unit mounting nut 2 10 4.9 (050,36) Taillight mounting nut 2 6 6.9 (0.70,5.1) FUEL SYSTEM : ; THREAD TOROUE f Wren TY | pia.tmm)_| nem (kgm, totst) | REMARKS Fuolvaive nut 7 2 34 (35, 25) |_ Fuel tank stay nut 2 6 12(1.2,9) COOUING SYSTEM THREAD TORQUE ee TY | DiA.(mm)_| Nim kgm, test) | REMARKS Fan motor awiteh 7 16 78(1.8, 13) NOTET Cooling fan nut 1 5 2.710.28,20) | NOTE2 Fan motor mounting nut 3 5 49 (05,36) Fan motor bracket mounting bolt Fa 6 | _831085,6.1) ENGINE MOUNTING ; THREAD TORQUE TEM {@TV | pia.tmm) |e (kgm, bese) | REMARKS Front engine hangor nut 2 70 54 (55, 40) Roar engine hanger nut (upper) 1 10 54 (6.5, 40) Rear engine hanger nut (lower) 1 10 54 (55,40) CLUTCH/GEARSHIFT LINKAGE THREAD TORGUE ire TY | puctmm) | Nim (kgf, tse) | REMARKS Gearshift podal link bolt (gearshift pedal side) 7 3 26 (2.7, 20) Gearshift pedal link bol (gearshift spindle side) 1 6 20 (2.0, 14) 1-17GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING THREAD TORQUE ied - OTY | pia. (mm) | Nem (kgf-m, tote) | REMARKS Handlebar holder bolt 7 3 26 (2.7, 20) Steering stem nut 14 4 103 (108,76, | Seepage | 1338 Steering bearing adjustment nut lock nut, 1 26 = See page | 13.36 Steering bearing adjustment nut }4 26 a See page | 13:36 Fork top bridge pinch bolt } 2 8 23 (23,17) Fork bottom bridge pinch bott | 2 10 39 (40, 29) Front axle bolt } 4 14 59 (6.0, 43) Front axle holder bolt Lo 8 22(22, 16) Front brake dise mounting bott | 2 6 20 (20, 14) NoTE6 Fork cap | 2 7 23 (2.3, 17) Fork socket bolt } 2 8 20(20,14) Note2 Front pulser ring bolt (CBF600SA/NA} 3 5 7810858) | NOTES REAR WHEEL/SUSPENSION ; THREAD TORQUE da CTY | pIA.tmm)_|_ Nim (kgfm, tote) | REMARKS ear axle nut 7 16 9319.5, 69) NOTES Rear brake disc mounting bolt 4 a 42 (43,31) NOTES Final driven sprocket nut 5 12 108(11.0,80) | NOTES Swingerm pivot nut 1 14 78 (8.0, 58), NOTES ive chain case bolt 2 6 12(1.2,9) chain slider tapping screw 2 6 5.9 (0.60, 43) Drive chain adjuster lock nut 2 8 24 (21,15), Rear shock absorber upper mounting nut 1 10 42(43,31) NOTES Rear shock absorber lower mounting nut 1 10 22 (43,31) NOTES Rear pulser ring bolt (CBF600S AINA) 4 5 78 (08, 5.8) NOTES HYDRAULIC BRAKE ; THREAD TORQUE ee CTY | pia.tmm) | nm (kgm tort) | REMARKS Front brake master cylinder holder bolt z 3 72 (1.2, 9), Front brake master cylinder reservoir cap screw 2 4 1.50.15, 1.1) Brake lover pivot bolt 1 6 1.0 (0.10, 07) Brake lever pivot nut 1 6 5.90.60, 43) Front brake light switch screw 1 4 1.2 (0.12, 0) Front brake caliper mounting bolt 4 8 30 (3.1, 22) NOTES Front brake caliper pin bolt A 1 12 23(23,17) NOTE? Front brake caliper pin bolt, 1 8 13(13,9) NOTE2 Pad pin 3 10 18 (1.8, 13) Pad pin plug 3 10 25 (0.25, 18) Front brake hose clamp bolt 2 6 98 (1.07) NOTES Brake calipor bloader 3 8 5.9 (0.60, 43) Fear master cylinder mounting bolt 2 6 12(1.2,9) Rear master cylinder hose joint scrow 1 4 151018,1.1) | NoTE2 Rear master cylinder push rod nut 1 8 1811.8, 13) Rear brake caliper main slide pin 1 12 27 (28,20) Rear brake caliper sub slide pin 1 8 23(23,17) NoTE6 Rear brake hose clamp bolt 1 6 28 (090,65) | NOTES Brake hose oil bolt 5 10 34 (35,25), 1-18‘ABS SYSTEM (CBF600SA/NA) GENERAL INFORMATION ——— —— sy] THREAD TORQUE Ge) QTY | pia. tmm)_|_Nem thf, these) | REMARKS Front whedl pulser ring mounting bolt 3 “5 78108,58) —| NOTES Rear wheel pulser ring mounting bolt 4 5 7810858) | NOTES Modulator body mounting bolt (under) 2 6 12002,9) NOTE 2 Modulator body mounting bolt (sida) 1 6 1212.9) Rear brake pipe stay 1 6 1212.9) NoTE2 Front brake hose joint 4 6 9.8(1.,7) Front wheel speed sensor mounting bolt 2 6 98(1.0,7) Rear wheel speed sensor mounting bolt 2 6 981.0, 7) Sensor wire clamper mounting bolt a 6 9.8(1.0,7) NoTe2 | Brake pipe joint nut 3 wo | 1) LUGHTS/METERS/SWITCHES ; THREAD TORQUE ed QTY | pia(mm) |_nim (kgtm, ies) | REMARKS Ignition saitah mounting bole z 3 25 (25, 18) Steering stem nut 1 24 103 (10.8, 78) Fork top bridge pinch bott 2 8 23(23,17) OTHERS THREAD TORQUE ITEM ibn QTY | DIA. (mm)_| Nim (kgm, bese) | REMARKS Side stand pivot bot 7 rd Side stand pivot lock nut 1 33(40,29) | 1-19GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE 10- 18mm. (04-06 in) 10- 15mm (0.4- 0.6 in) il pen mating surface LOCATION MATERIAL REMARKS, ‘Grankcese mating surface Liquid sealant (Three Bond 12078 or equivalent)GENERAL INFORMATION LOCATION MATERIAL REMARKS Engine oll pressure switch threads Do not apply to the thread head “= 3-4mm (0.1-0.2in) Ignition pulse generator cover grommet Alternator cover grommet Tiquid sealant (Three Bond 12078 or equivalent) Crankcase mating surface Crankcase mating surface ECT sensor threads Lower crankcase sealing bolt threads Cylinder head sealing bolt threads Cylinder head semi-circular cut-out >| 5-10 mm (0.2- 0.4 in) 5- 10mm (0.2-0.4 in) SEALANT Cylinder head bolt threads and seating surface Camshaft lobes/journals Valve lifter outer sliding surface Valve stem (valve guide sliding surface) Connecting rod small end bore Main journal bearing surface Connecting rod bearing surface M3/4, C5, C8 shifter gear (shift fork grooves) Crankshaft thrust surface Clutch outer sliding surface Starter idle gear shaft sliding surface Molybdenum disulfide of (amixture of engine ol ‘end 1/2 molybdenum disulfide grease Clean anti-rust olf and apply to the threads and seating surfaceGENERAL INFORMATION LOCATION. MATERIAL REMARKS ‘Clutch center tock nut threads Main journal 8 mm bolt threads and seating surface Connecting rod boltinut threads Camshaft holder bolt threads and seating surface Flywheel bolt threads il filter cartridge threads and mating surface Starter clutch sliding surface Piston surface Piston pin bore Piston ring grooves Piston pin surface Piston ring surface Cam chain tensioner collar sliding surface Cam chain tensioner and slipper surface Clutch friction disc lining surface il seal lip (without dust lip) Each gear teeth and rotating surface Each bearing Each O-ring Other rotating area and sliding surface Engine oil [Timing hole cap threads Each oil seal lips (without dust lip) Cylinder head cover breather plete bolt threads Cam sprocket bolt threads il pump driven sprocket bolt threads Shift drum bearing set plate bolt threads Starter clutch outer torx bolt threads Shift drum center bolt threads Mainshaft bearing set piate bolt threads Gearshift spindle oil seal set plate bolt threads Oil filter boss threads Oil cooler sealing bolt threads Multi-purpose grease Locking agent Coating width: 651mm Coating width: 6.5 1mm Coating width: 6.51 mm Coating width: 6.51 mm Coating width: 65+ 1mm. Coating width: 6.5 + 1mm Coating width: 6.5 1 mm. Coating width: 6.541 mm 1-22GENERAL INFORMATION He FRAME TOCATION MATERIAL REMARKS Siearing head Bearing sliding surface Urea Based multi-purpose Steering head dust seal lips grease with extreme pros- sure (example: EXCELITE EP2 manufactured by KYODO YUSHI, Japan), Sholl Stam- ina EP or equivalent ‘Seat catch hook sliding area Multi-purpose grease ‘Swingarm pivot needle bearing Rear wheel sleeve sliding surface Rear wheel hub O- Side stand pivot sliding surface Clutch lever pivot sliding surface ‘Throttle pipe sliding area and cable end Footpeg pivot sliding area Gearshift pedal link sliding area Swingarm dust seal lips Rear brake pedal sliding surface Each oil seal lips Each dust seal lips Steering bearing adjustment nut threads Engine off Drive chain #80 -90 gear oll or drive chain lubricant for use with O-ring chains Brake master piston and cups DOT 4 brake Wid Brake caliper piston and piston seals Front brake lever pivot and piston tips ‘Silicone Grease Rear master cylinder boot inside and push rod tips Brake caliper slide pin surface Brake caliper dust seals. Brake lever adjuster stoppor bolt threads Fork socket bolt threads Rear brake caliper bracket retainer joint with bracket Front brake caliper pin bolt A threads Front brake caliper pin bolt threads Fan motor switch threads and O-ring Sealant Handlebar grip rubber inside Honda bond A or equivalent Fork oil seal ips Honda Ultra Cushion OW TOW or equivalentGENERAL INFORMATION CABLE & HARNESS ROUTING cBF600s: RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLES CLUTCH CABLE LEFT HANDLEBAR, RIGHT TURN SIGNAL WIRE METER CONNECTER BRAKE HOSE LEFT TURN ‘SIGNAL HEAD LIGHT HARNESS WIRE a (CBFE00SA: HANDLEBAR, ‘SWITCH WIRE CLUTCH CABLE LEFT HANDLEBAR, SWITCH RIGHTTURN WIRE SIGNAL WIRE METER CONNECTER BRAKE HOSE LEFT TURN SIGNAL) HEAD LIGHT WIRE SPEED SENSOR wri BRAKE HOSE HARNESS WIREGENERAL INFORMATION CBF6OON: COMBINATION METER 6P (NATURAL) LEFT HANDLEBAR CONNECTOR ‘SWITCH 6P (BLUE) CONNECTOR COMBINATION METER 9P (BLACK) CONNECTOR, LEFT HANDLEBAR ‘SWITCH 6P (BLACK) RIGHT HANDLEBAR CONNECTOR ‘SWITCH9P (BROWN) CONNECTOR IGNITION SWITCH 4P (NATURAL) CONNECTOR FRONT TURN SIGNAL CONNECTORS: POSITIONLIGHT | af oan HEADLIGHT 2P ati CONNCTOR CBFE0ON: RIGHT HANDLEBAR 7 Leal CLUTCH CABLE LEFTHANDLEBAR SWITCH WIRE THROTTLE CABLES: IGNITION SWITCH WIRE RIGHT TURN LEFT TURN p = SIGNAL SIGNAL WIRE FRONT BRAKE HOSE 1-25GENERAL INFORMATION CBFEOONA: COMBINATION METER 6P (NATURAL) CONNECTOR LEFT HANDLEBAR ‘SWITCH 6P (BLUE) CONNECTOR COMBINATION METERSP (BLACK) CONNECTOR LEFT HANDLEBAR ‘SWITCH 6P (BLACK) CONNECTOR RIGHT HANDLEBAR ‘SWITCH 9P (BROWN) CONNECTOR IGNITION SWITCH 4P (NATURAL) ‘CONNECTOR FRONT TURN SIGNAL CONNECTORS POSITIONLIGHT CONNECTORS HEADLIGHT 2P CONNECTOR CBFSOONA: RIGHT HANDLEBAR CLUTCH CABLE SWITCH WIRE tt LEFT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE RIGHT TURN SIGNAL WIRE LEFT TURN. SIGNAL FRONT BRAKE HOSE 1-26GENERAL INFORMATION CBF600S: RIGHT HANDLE BAR SWITCH WIRE THROTTLE CABLES LEFTHANDLE BAR, SWITCH WIRE MAIN WIRE |] FRONT BRAKE HOSES 1-27GENERAL INFORMATION ‘CBFS00SA: RIGHT HANDLE BaR SWITCH WIRE (ROTTLE CABLES a LEFT HANDLE BAR SWITCH WIRE MAIN WIRE HARNESS CLUTCH CABLE BRAKE HOSE )))) tron anaxe j/ HOSESGENERAL INFORMATION CBF6OON: RIGHT HANDLE BAR SWITCH WIRE 1-29GENERAL INFORMATION ‘CBF600NA: RIGHT HANDLE BAR SWITCH WIRE THROTTLE CABLES LEFT HANDLE BAR SWITCH WIRE MAIN WIRE HARNESS CLUTCH CABLE 1-30RIGHT HANDLE. BAR SWITCH WIRE GENERAL INFORMATIONGENERAL INFORMATION CBFEO0SA: 1-32GENERAL INFORMATIONGENERAL INFORMATION ‘CBF6OONA: RIGHT HANDLE BAR SWITCH WIRE LEFT HANDLE BAR, ‘SWITCH WIRE THROTTLE CABLES FUEL TANK BREATHER HOSE FUEL TANK Kat KZN FRONT E HOSES/PIPE FRONT WHEEL ‘SPEED SENSOR ‘WIRE xq SM ee LS aes. 3 [SA ok yi <<" XK IGNITION PULSE GENERATOR WIRE CLUTCH CABLEGENERAL INFORMATION CBF600SA/NA: BRAKE PIPE BRAKE HOSE eS © a (3 v, BRAKE HOSE ‘SPEED SENSOR WIRE /./ > Front wheel a S \S ath D LEER 6) af |GENERAL INFORMATION (CBF600S/N: FUEL RESERVE GROUND TERMINAL CLUTCH CABLE SENSOR WIRE MAIN WIRE HARNESS FAN MOTOR SWITCH WIRE AIR AIR FUELVALVE _ TP{THROTTLE NEUTRAL SIDE STAND SUCTION HOSE VACUUM HOSE POSITION) SWITCH WIRE SWITCH WIRE SENSOR WIRE 1-36GENERAL INFORMATION CBF600SA/NA: FUEL RESERVE (GROUND TERMINAL CLUTCH CABLE — SENSOR WIRE BRAKE PIPE MAIN WIRE HARNESS FRONT WHEEL, pe SPEED SENSOR ‘SWITCH WIRE PAIR AIR FUELVALVE TP(THROTTLE NEUTRAL SIDE STAND SUCTION HOSE — VACUUMHOSE POSITION) SWITCH WIRE SWITCH WIRE SENSOR WIREGENERAL INFORMATION Wee ‘CBF600S/N: FUEL TANK SUB AIR BREATHER HOSE CLEANER HOSE FUEL TANK DRAIN HOSE PAIR AIR SUCTION PAIR AIR SUCTION (NO.15) HOSE (NO.16) HOSE BATTERY POSITIVE (+) CABLE | HORN WIRE \ CRANKCASE BREATHER HOSE ENGINE OIL PRESSURE SWITCH WIRE REAR BRAKE LIGHT SWITCH WIRE, STARTER MOTOR CABLE -38GENERAL INFORMATION CBFEOOSA/NA: FUEL TANK SUB AIR BREATHER HOSE CLEANER HOSE FUEL TANK DRAIN PAIR AIR SUCTION PAIR AIR SUCTION HOSE (NO.15) HOSE (NO.16) HOSE BATTERY POSITIVE (+) CABLE BATTERY NEGATIVE (-) CABLE CRANKCASE BREATHER HOSE ENGINE OIL PRESSURE SWITCH WIRE EB IGNITION PULSE REAR BRAKE LIGHT GENERATOR WIRE SWITCH WIRE ECT SENSOR WIRE STARTER MOTOR CABLEGENERAL INFORMATION PAIR AIR SUCTION (NO.16) HOSES NO.2 SPARK PLUG WIRE NO.3 SPARK PLUG WIRE NO.1 SPARK PLUG WIRE NO4 SPARK PLUG WIRE CRANKCASE BREATHER HOSE PAIR CONTROL VALVE VACUUM (NO.10) HOSE PAIR AIR SUCTION (INO.15) HOSE tenmion con PAREONTROL PRIMARY WIRES. 1-40GENERAL INFORMATION CLUTCH CABLE d\ Te rurotme postion) “ y SENSOR WIRE = PAIR CONTROL VALVE VACUUM (NO.10) HOSE FUEL HOSE PAIR AIR SUCTION (NO.15) HOSE CRANKCASE BREATHER HOSE FUEL VALVE VACUUM HOSE CARBURETOR AIR VENT HOSE ENGINE OIL PRESSURE SWITCH WIRE ECT SENSOR ‘WIRE IGNITION PULSE GENERATOR WIRE NEUTRAL SWITCH WIRE STARTER MOTOR CABLE GROUND CABLE VEHICLE SPEED SENSOR WIRE 1-41GENERAL INFORMATION CBFEO0S/N: \ PAIR AIR SUCTION (INO.15) HOSE SIPHON HOSE CRANKCASE Fi : BREATHER HOSE PAIR AIR SUCTION (NO.16) HOSES (CBF600SA/NA: BRAKE PIPE PAIR AIR SUCTION (INO.15) HOSE [0.4 SPARK PLUG WIRE NO.1 SPARK PLUG WIRE NO.2 SPARK PLUG WIRE { 'NO.3 SPARK PLUG WIRE AIR VENT HOSE a - CHOKE CABLE SIPHON HOSE CRANKCASE \ BREATHER HOSE PAIR AIR SUCTION (NO.16) HOSES 1-42GENERAL INFORMATION CBF600S/N: FUSE BOX LICENSE LIGHT CONNECTORS _ —_ ~-REGULATOR/RECTIFIER 5P CONNECTOR MAINWIREHaRNEss 2 CBFG00SA/NA: FUSE BOX LICENSE LIGHT 4 oe 7 a ‘ MAIN WIRE HARNESS EP anacives 5P CONNECTOR 1-43GENERAL INFORMATION (CBF600SA/NA: FUSE BOX ABS MODURATOR SERVICE CHECK \\ FRONT WHEELSPEED ee ‘SENSOR WIRE REAR TURN SIGNAL LIGHT CONNECTORS/ TAILIBRAKE LIGHT SP (NATURAL) CONNECTOR, LICENSE LIGHT CONNECTORS 1-44GENERAL INFORMATION (CBF600S/N: REAR BRAKE HOSE REAR MASTER CYLINDER — RESERVOIR HOSE CBFEOOSA/NA: REAR MASTER CYLINDER RESERVOIR HOSE REAR WHEELSPEED ‘SENSOR WIRE 1-45GENERAL INFORMATION EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but itis toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor. AIR CLEANER HOUSING CARBURETOR FRESH AIR BLOW-BY GAS. So Gem 1-46GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM ‘The exhaust emission control system is composed of a pulse secondary air supply system and lean carburetor settings. ‘And no adjustment should be made except idle speed adjustment with the throttle stop screw. The exhaust emission ‘control system is separate from the crankcase emission control system. PULSE SECONDARY AIR SUPPLY SYSTEM The pulse 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 PAIR (Pulse Secondary Air Injection) control valve. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon diode and water vapor. ‘The reed valve prevents reverse air flow through the system. The PAIR control valve reacts to high inteke manifold vacuum and will cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system. No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended. PAIR CONTROL VALVE AIR CLEANER HOUSING PAIR REED VALVE CARBURETOR EXHAUST PORT < rrestan Gea v.51 0s OXIDATION CATALYSTIC CONVERTER This motorcycle is also equipped with oxidation catalytic converter. The oxidation catalytic converter is in the exhaust system, Through chemical reactions, they convert HC and CO in the engine's exhaust to carbon dioxide (CO2] and water vapor. 1-47GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: The local law prohibits the following acts or the causing there of: (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 tots 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 been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases. 2. Removal of, or puncturing of any part of the intake system. 3. Lack of proper maintenance. 4, Replacing any moving parts of the vel fied by the manufacturer. le, or parts of the exhaust or intake system, with parts other then those speci- 1-482. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS SERVICE INFORMATION -~ TROUBLESHOOTING - SEAT- SEAT BRACKET SIDE COVER REAR COW! FUEL TANK FRONT FENDER REAR FENDER REAR VIEW MIRROR (CBF600S/SA) ~ FRONT LEFT/RIGHT COWL (CBF600S/SA)-- WINDSCREEN (CBF600S/SA) -- METER PANEL (CBF600S/SA).-- FRONT CENTER COWL (CBF600S/SA) MUFFLER - EXHAUST PIP! MAIN STAND (CBF600SA/NA)FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS CBF600S/SA: FRONT LEFT/ WIND SCREEN RIGHT COWL FRONT CENTER, cowl FUEL TANK REAR COWL CBFBOONINA: SIDE COVER, 2-2FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL + 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, ‘This section covers removal and installation of the body panels and exhaust system. * Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. ‘+ Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. + When installing the exhaust system, loosely install all of the oxhaust pipe fasteners. Always tighten the exhaust clamps first, then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly. * Always inspect the exhaust system for leaks after installation. TORQUE VALUES Exhaust pipe joint nut 20 Nem (2.0 kgf-m, 14 Ibf-ft) Muffler mounting bolt 22 Nem (2.2 kgf-m, 16 Ibf-ft), Exhaust pipe mounting nut 22 Nem (2.2 kgf-m, 16 Ibf-ft). Muffler band bolt 22 N-m (2.2 kgf'm, 16 Ibf-ft) Grab rail mounting socket bolt 26 N-m (2.7 kgfm, 20 IbFft) Front fender mounting bolt 12. N-m (1.2 kgf-m, 9 Ibf-ft) Rear view mirror mounting nut 34 Nom (3.5 kgf-m, 25 IbFft) Rear turn signal unit mounting nut 4.9 Nom (0.50 kgf-m, 3.6 Ibf-ft) Taillight mounting nut 69 Nem (0.70 kgm, 5.1 Ibft) Fuel valve nut. 34 Nem (3.5 kgf-m, 25 Ibf-ft) Fuel tank stay nut 12. Nem (1.2 kgfim, 9 Ibf-ft) Front brake hose clamp bolt 9.8.N-m (1.0 kgf-m, 7 Ibfft) Front center cowl stay mounting bolt 26 Nim (2.7 kgfm, 20 Ibt ft) TROUBLESHOOTING Excessive exhaust noise * Broken exhaust system + Exhaust gas leak Poor performance + Deformed exhaust system + Exhaust gas leak + Clogged mufflerFRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL/INSTALLATION Unhook the pillion seat with the ignition key. Remove the pillfon seat. Remove the socket bolts. Remove the main seat backward while releasing the seat hooks from the frame hooks Install the main seat, inserting the hooks into the framo hooks. Install the socket bolts. Install the pillion seat and push the seat forward, then down to lock it ‘After installation, make sure that the seat is installed properly by moving the seat. SEAT BRACKET 2-4 REMOVAL/INSTALLATION Remove the four socket bolts. Remove the seat bracket. If you wish the seat position upward or downward, you can choose low or high position, ‘There are three bolt holes each mounting point. Middle bolt hole is standard position, Install the seat bracket. Install the four socket bolts. After installation, make sure that the seat bracket is installed properly by moving the bracket. PILLION SEAT HOOKS ‘SEAT BRACKETFRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER REMOVAL/INSTALATION Remove the seat (page 2-4) Release the rear tabs from the swingarm pivot bracket and fuel tank grommets, then remove the side cover. Install the side cover aligning the its tabs with the grommets in the swingarm pivot bracket and fuel tank, REAR COWL REMOVAL Remove the seat (page 2-4). Remove the bolt caps. Remove the socket bolts and grab rail Remove the socket bolts and rear center cowl. Remove the socket bolts. Remove the trim clips. Carefully release the tabs of the rear lefvright cow!, then remove the rear cowl. ‘SOCKET BOLTS REAR CENTER COWL Vy wa — BOLT CAPS GROMMETS Gas RAIL, 2-5FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Installation is in the reverse order of removal. ‘SOCKET BOLTS Install the grab rail and mounting bolts. Tighten the mounting socket bolts to the specified : torque. re — TORQUE: 26 N-m (2.7 kgf-m, 20 Ibf-ft) fom ra BOLT CAPS Install the bolt caps securely. GRAB RAIL FUEL TANK REMOVAL Remove the following: [FUEL RESERVE ~ Seat (page 2-4) SENSOR CONNECTORS TANK cBF=005/64 ony ~ Front leftright cow! (page 2-6) vacuum é 7 - 7 HOSE Remove the fuel tank stay bolt and nut Disconnect the fuel valve vacuum hose from the ‘5 joint. tgs Disconnect the fuel hose from the fuel valve 1) Disconnect the fuel tank drain hose and fuel tank Vy breather hose. BOLTNUT Disconnect the two fuel reserve sensor connectors. Swing the rear ond of the fuel tank and release the | FUEL HOSE fuel tank from the mounting rubbers, then remove BREATHER HOSE “DRAIN HOSE the fuel tank upward, INSTALLATION Installation is in the reverse order of removal. BOLT/NUT, Tighten the fuel tank stay nut to the specified torque. ‘TORQUE: 12 N-m (1.2 kgf-m, 9 IbF-ft) After installation, make sure there are no fuel leaks. 2-6FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALATION Remove the front brake hose clamp bolts, Remove the front wheel (page 13-14), Remove the mounting bolts and front fender. ag} CLAMP BOLTS 2 Installation is in the reverse order of removal. Install the front fender mounting bolts and new front brake hose clamp bolts. Tighten the front fender mounting bolts to the spec- ified torque. TORQUE: 12 Nim (1.2 kgf-m, 9 IbF-ft) Tighten the front brake hose clamp bolts to the specified torque. FRONT FENDER TORQUE: 9.8 N-m (1.0 kgf-m, 7 Ibfft) MOUNTING BOLTS REAR FENDER Whi instaling the reer fender, route the wire harness property (age 1- 24). REMOVAL/INSTALLATION Remove the following: - Rear cowl (page 2-5) = Turn signal relay (page 20-34) Remove the fuse box. Disconnect the license light connectors and rear turn signal connectors. REAR FENDER, TURN SIGNAL RELAY / conneCTORS GROOYES \ yi MupGuUARD CONNECTOR Remove the bolts and screws. Release the grooves of the rear fender from the frame braces and release the stays from the grooves, then remove the rear fender assembly, Remove the bolts and separate the mudguard form the rear fender, Installation is in the reverse order or removal, ‘SCREWS stays FUSE BOXFRAME/BODY PANELS/EXHAUST SYSTEM REAR VIEW MIRROR (CBF600S/SA) REMOVAL/INSTALLATION Remove the two socket bolts. Remove the rear view mirror. Installation is in the reverse order or removal. REAR VIEW MIRROR FRONT LEFT/RIGHT COWL (CBF600S/SA) REMOVAL/INSTALLATION Remove the two socket bolts, screws and trim clip. [eos ‘SOCKET Release the bosses from the grommets on the ¥ BOLTS upper cowl. 4 ; Disconnect the turn signal connector. b Installation is in the reverse order or removal. bosses) »p ——r! GrommMerEs cu WINDSCREEN (CBF600S/SA) REMOVAL Remove the windscreen covers. Remove the screws and windscreen. L & WINDSCREEN 2-8FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Install the screws and windscreen. Install the windscreen covers. If you wish the windscreen position upward, you ‘can choose high position, WINDSCREEN METER PANEL (CBF600S/SA) REMOVAL/INSTALLATION Remove the following: = Windscreen (page 2-8) Front leftright cowl (page 2-8) Remove the two tapping screws and screws. ‘TAPPING SCREWS. METER PANEL Remove the meter panel. Installation is in the reverse order or removal. FRONT CENTER COWL (CBF600S/SA) REMOVAL/INSTALLATION Romove the following: = Windscreen (page 2-8) = Front letright cow! (page 2-8) Meter panel page 2-9) = Rear view mirror (page 2-8) Release the grooves of the front center cowl from the Rear view mirror stay mounting boss. Pull the front center cow! and remove it from the grommets. Disconnect the head light connector. Installation is in the reverse order or removal. MOUNTING BOSS CONNECTORFRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER Alvrays replace the gasket with a new REMOVAL/INSTALLATION Loosen the Muffler band bolt. Remove the muffler mounting bolt, washer and col- lar, Remove the muffler and gasket. Installation is in the reverse order of removal. Tighten the muffler mounting bolt to the specified torque. TORQUE: 22 Nem (2.2 kgfm, 16 IbF-ft) Tighten the muffler band bolt to the specified torque. TORQUE: 22 N-m (2.2 kgf-m, 16 Ibf-tt) EXHAUST PIPE 2-10 REMOVAL Remove the exhaust pipe joint nuts. JOINT NUTSFRAME/BODY PANELS/EXHAUST SYSTEM Remove the exhaust collar and bolt, Remove the exhaust pipe and gaskets, ye mounting nut, washer, INSTALLATION Always replace the Install the exhaust pipe and new gaskets to the cyl- ‘gastets with new inder head. ones Temporarily install the exhaust pipe joint nuts, exhaust pipe mounting bolt, collar, washer and nut, BOLTICOLLAR/ WASHER/NUT GASKETS, sont NUTS EXHAUST PIPE GASKETS JOINT NUTS EXHAUST PIPEFRAME/BODY PANELS/EXHAUST SYSTEM Tighten the exhaust First tighten the exhaust pipe joint nuts to the speci- pipe jont nuts in fied torque. ‘numerical order shown inthe lug. TORQUE: 20 N-m (2.0 kgf-m, 14 Ibf-t) tration. Tighten the exhaust pipe mounting nut to the speci fied torque. ‘TORQUE: 22 N-m (2.2 kgf-m, 16 IbF-ft) MAIN STAND (CBF600SA/NA) REMOVAL Support the motorcycle securely using the side stand. Remove the bolt. Pull the pivot pipe out. Unhook the return spring. Remove the main stand. 2-12 JOINT NUTS Dt icouaviaSRERUTFRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Install the main stand. Install the pivot pipe. Hook the return springs. Install and tighten the bolt. After installation, check the main stand operation. Do ST Se eT ee ee eee 2-13MEMO3. MAINTENANCE SERVICE INFORMATION MAINTENANCE SCHEDULE - FUEL LINE THROTTLE OPERATION. CARBURETOR CHOKE AIR CLEANER- CRANKCASE BREATHER ~~ ‘SPARK PLUG « VALVE CLEARANCE: ENGINE OIL/OIL FILTER -~~ 3-14 CARBURETOR SYNCHRONIZATION 3-17 ENGINE IDLE SPEED-~. 3-18 RADIATOR COOLANT: 3-19 COOLING SYSTEI 3-19 SECONDARY AIR SUPPLY SYSTEM DRIVE CHAIN.. DRIVE CHAIN SLIDER - BRAKE FLUID. BRAKE PAD WEAR.- BRAKE SYSTEM --- BRAKE LIGHT SWITCH 3-28 HEADLIGHT AIM -- CLUTCH SYSTEM- SIDE STAND -» SUSPENSION --- 3-31 NUTS, BOLTS, FASTENERS- WHEELS/TIRES --- 3-31 STEERING HEAD BEARINGS 3-31MAINTENANCE SERVICE INFORMATION GENERAL Place the motorcycle on level ground before starting any work. * Gasoline is extremely flammable and is explosive under certain conditions. + Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gesoline is stored can cause a fire or explosion. ‘+ The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in and enclosed area. SPECIFICATIONS TEM. ‘SPECIFICATIONS ‘Throttle grip free pia 2-6 mm (1/16 - 1/4 in) im ‘Spark plug NGK CROEH-S DENSO, U27FERS ‘Spark plug gap 0.80 0.90 mm (0.031 - 0.035 in} Valve clearance 1 0.16 + 0.03 mm {0.006 # 0.007 in) Ex, 0.22 + 0.03 mm (0.009 * 0.001 in) Engine oil capacity | After draining 3.5 liter (3.7 US qt. 3.1 Imp atl ‘After oll filter change 3.8 liter (4.0 US qt, 3.3 Imp at) Recommended engine oi Honda 4-stroke oil or equivalent motor oi! API sorvice classification SE, SF or SG Viscosity: SAE 10W-30 Engine idle speed 7,300 #100 min" (rpm) Drive chain slack ‘30= 40 mm (1.2 1.6 in) Recommended brake fluid DOT4 Clutch lever free play 70-20 mm (3/8 - 13716 in) Tire size "120770 ZR T7MIC T5BW) ie 5 160/60 ZR T7MIC (631) Tire brand ~ | Bridgestone BrS7F , BrS7 Michelin’ PILOT ROAD B = K PILOT ROAD Tire air pressure | Driver only 250 kPe (2.50 kgi/am’, 36 pail [290 kPa (2.90 kaf/cm®, 42 psi) Driver and 250 kPa (2.50 kgf/cm’, 36 psi) Passenger 290 kPa (2.90 kgf/cm’, 42 psi) Minimum tire tread depth 4.5 mm (0.06 zi 2.0 mm (0.08 TORQUE VALUES Spark plug 18 Nem (1.8 kgf, 13 Ibf-t) Timing hole cap 18 Nem (1.8 kgf-m, 13 Ibfft) Apply grease to the threads 28 Nem (3.0 kgf, 22 IbF-ft) 26 N-m (2.7 kgf'm, 20 Ibf-ft) Apply oil to the threads and flange surface *Cylinder head cover bolt Camshaft holder flange bolt 9.8.Nem (10 kgfm, 7 IbF-«t) 12 Nem (1.2 kgf-m, 9 Ibf-ft) Apply oil to the threads and flange surface Rear axle nut 93 Nem (9.5 kgfim, 69 Ibfft) —-U-nut Drive chain adjuster lock nut Drive sprocket special bolt Final driven sprocket nut, 21 Nem (2.1 kgm, 15 Ibfft) 54 Nem (5.5 kgfim, 40 lof) 108 Nem (TO kgfm, 80 Ibft). —U-nutMAINTENANCE TOOLS il filter wrench Drive chain tool set ‘Tensioner stopper O7HAA-PI70107 O7HMH-MR10103 070MG-0010100 3-3MAINTENANCE MAINTENANCE SCHEDULE Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period. {i Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require ‘more technical information and tools. Consult their authorized Honda dealer. FREQUENCY] WHICHEVER = REFER TO COMES FIRST ODOMETER READING (NOTE 1) PAGE LL PRtpooKm| T_T 6 | v2 [18 | 24 | 30 P36 1,000 mi[ 0.6] 4 | 8 | 12] 16] 20] 24 ITEMS ‘Months 6 [12] 18 | 24 | 30 | 36 [FUEL LINE T T L335 % [THROTTLE OPERATION T T cp 3s [CHOKE OPERATION T T Ty] 36 ‘AIR CLEANER NOTED T T|_ 36 CRANK CASE BREATHER NOTES, c[e[cyeye[cl[ 37 [SPARK PLUG T R | 37 = [VALVE CLEARANCE T 39 ENGINE OIL. 7 R R R R314 ENGINE OIL FILTER R R R Roa CARBURETOR SYNCHRONIZATION T 1 1) 347 ENGINE IDLE SPEED Ct RADIATOR COOLANT NOTEd T ml R319 COOLING SYSTEM T T L319 ‘SECONDARY AIR SUPPLY SYSTEM T T TP 320 DRIVE CHAIN VERY 1000 km (600 mi} LL. 3:20 | DRIVE CHAIN SLIDER T T Tp 324 BRAKE FLUID NOTEa COOPR PPaeypr } 325 BRAKE PAD WEAR CO BRAKE SYSTEM. 1 1 T T3826 = [BRAKE LIGHT SWITCH T T i | 3a [HEADLIGHT AIM T 1 T [38 CLUTCH SYSTEM CPE eye 8 [SIDE STAND T 1 (| p29 = [SUSPENSION T T T|~ 3:30 = _|NUTS, BOLTS, FASTENERS T T T | 331 5* |WHEELS/TIRES T T r]—33t a ING HEAD BEARINGS T T T T3331 Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified ** In the interest of safety, we recommended these items be serviced only by an authorized Honda dealer NoTES: 1, Athigher odometer reading, re 2. Service more frequently when ri 3. Service more frequently when ri the frequency interval established here. in unusually wet or dusty areas. gin rain or at full throttle. 4. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.MAINTENANCE FUEL LINE Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary. Also check the fuel line fittings for leakage. Check the fuel valve vacuum hose for damage or pinched hose, 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. Lubricato 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 free play can be adjusted at either end of the throttle cable. Minor adjustment are made with the upper adjuster. ‘Adjust the free play by loosening the lock nut and turning the adjuster. Major adjustments are made with the lower adjuster. ‘Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securely. Recheck the throttle operation. Replace any damaged parts, if necessary.MAINTENANCE CARBURETOR CHOKE Check for smooth operation of the choke knob. Lubricate the choke cable if the operation is not ji ‘smooth, AIR CLEANER Remove the left side cover (page 2-5). Disconnect the TP (Throttle position) sensor 3P con- nector. Remove the screws and air cleaner housing cover. Remove and inspect the air cleaner element in accordance with the maintenance schadule (page 3- 4). 2 Clean the ae cleaner element with the compressed fay air from carburetor side. Install the removed parts in the reverse order of removal,MAINTENANCE CRANKCASE BREATHER Remove the left side cover. Disconnect and clean the drain tube. Connect the drain tube, DRAIN TUBE SPARK PLUG REMOVAL CBFE0OS/SA only. Remove the front lefuright cowl (page 2-8). Disconnect the fan motor switch connector. Disconnect the radiator sub-harness 3P (Black) con- nector. Remove the radiator mounting bolts, then release the grommet of the radiator from the tab on the frame (page 6-10). RADIATORMAINTENANCE Clean around the Disconnect the spark plugs caps from the spark ' spark plug bases plugs. with compressed air before remov- ing, and be sure that no debris is allowed to enter the combustion chamber, Remove the spark plug using a equipped spark plug By wrench or an equivalent tool. Inspect or replace as described in the maintenance schedule (page 3-4), INSPECTION Check the following and replace if necessary (rec- ommended spark plug: page 3-2) CENTER ELECTRODE * Insulator for damage * Electrodes for wear * Burning condition, coloration If the electrodes is contaminated with accumulated, objects or dirt, replace the spark plug. INSULATOR SIDE ELECTRODE Clean the spark plug electrodes with a wire brush or special plug cleaner. 2 0.80-0.90mm A Check the gap between the conter and side elec- trodes with a wire-type feeler gauge. {0.031 - 0.035 in} 4 If necessary, adjust the gap by bending the side electrodes carefully. ‘SPARK PLUG GAP: 0.80 - 0.90 mm (0.031 - 0.035 in)INSTALLATION Install the spark plugs in the cylinder head and hand tighten, then torque to the specification. TORQUE: 18 N-m (1.8 kgf'm, 13 Ibf-ft) Instal the spark plug caps. Install the radiator. The installation is reverse order of removal. VALVE CLEARANCE Inspect and adjust the valve clearance While the engine is ‘cold (below 35°C/ 95°F) Failure to release the cam chain tensioner will result Jn inaccurate valve clearance reading. INSPECTION Remove the cylinder head cover (page 8-6). Remove the cam chain tensioner lifter sealing bolt and sealing washer. Turn the cam chain tensioner lifter shaft fully and secure it using the special tool, Too! Tensioner stopper 070MG-0010100 This tool can easily be made from a thin (1 mm thickness) piece of ste! (page 8-7). Remove the timing hole cap and O-ring, MAINTENANCE BOLT CAM CHAIN TENSIONER LIFTER 3-9MAINTENANCE "Record the clear: ‘ance for each valve for reference in shim selection it agjustment is required. 3-10 Turn the crankshaft clockwise, align the *T* mark on the ignition pulse generator rotor with the index mark on the ignition pulse generator rotor cover. The timing marks (IN" and "EX") on the cam sprockets must be flush with the cylinder head sur- face and facing outward as shown. If the timing marks on the cam sprocket facing inward, turn the crankshaft clockwise one full turn (360°) and realign the timing marks with the oylin- der head surface so they are facing outward. Ingort the fosler gauge between the valve lifter and the cam lobe. Check the valve clearance for the No.1 and No.3 cyl- inder intake valves using a feeler gauge. VALVE CLEARANCE: IN: 0.16 + 0.03 mm (0.006 + 0.001 in) “T* MARK INDEX MARKMAINTENANCE Record the clear- ‘ance for each valve for reference in shim selection if adjustment is required, Record the clear ‘ance for each valve for raference in shim selection ‘adjustment is required, Turn the crankshaft clockwise 1/2 turn (180°), align the index fine on the ignition pulse generator rotor so that its facing up as shown. Check the valve clearance for the No.2 and No.4 cyl- inder exhaust valves using a feeler gauge. VALVE CLEARANCE: EX: 0.224 0.03 mm (0.009 + 0.001 in} Turn the crankshaft clockwise 1/2 turn (180°), align the ‘T* mark on the ignition pulse generator rotor with the index merk on the ignition pulse generator rotor cover. Check the valve clearance for the No.2 and No.4 eyl- inder intake valves using feeler gauge. VALVE CLEARANCE: IN: 0.16 + 0.03 mm (0.006 + 0.001 in} INDEX LINE % NO.4 EXHAUST VALVES NO.2 EXHAUST VALVES “T MARK INDEX MARK 3-11MAINTENANCE Record the clear- ance for each'valvea for reference in ‘shim selection it ‘adjustment is required. Turn the crankshaft clockwise 1/2 turn (180°), align the indox line on the ignition pulse generator rotor so that itis facing up #8 shown, Check the valve clearance for the No.1 and No.3 cyl- inder exhaust valves using a feeler gauge. VALVE CLEARANCE: EX: 0.22 + 0.03 mm (0.009 + 0.001 in) ADJUSTMENT Remove the camshafts (page 8-7). Remove the valve lifters and shim: ‘Shim 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 shi zers or magnet. Clean the valve shim contact area in the valve lifter, with compressed air. INDEX LINE NO.3 EXHAUST VALVES NO.1 EXHAUST VALVES . POE UIFTER VALVE LIFTERSixtytve different thickness shims are ‘available trom the thinnest 1.200 mm thickness shim t0 the thickest 2.800 ‘mm thickness shim in tervals of 0.025 Install the shims and valve lifters in their original loca- tons MAINTENANCE Measure the shim thickness and record it. SHIM Calculate the new shim thickness using the equa- tion below. A=(B-C)+D ‘A: New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness ‘+ Make sure of the correct shim thickness by mea- suring the shim by micromete ‘* Reface the valve seat if carbon deposit result ina calculated dimension of over 2.800 mm. Install the newly selected shim on the valve retainer. Apply molybdenum disulfide oil to the valve lifters. Install the valve lifters into the valve lifter holes. Install the camshaft (page 8-27). Rotate the camshafts by rotating the crankshaft clockwise several times. Recheck the valve clearance. Farr t Remove the cam chain tensioner stopper tool. Install the new sealing washer and cam chain te! ner lifter sealing bolt Tighten the bolt securely. Install the removed parts in the reverse order of removal, SEALING WASHER, 3-13MAINTENANCE ‘Check that the O- ‘ing isin good com dition, replace if, ocessary. ENGINE OIL/OIL FILTER Other viscosities ‘shown in the chart ‘may be used when the average tom- perature in your riding area is within the indicated range. Apply grease to the timing hole cap threads. Install and tighten the timing hole cap to the speci- fied torque. TORQUE: 18 Nem (1.8 kgf-m, 13 Ibf-ft) OIL LEVEL INSPECTION Start the engine and let it idle for 3- 5 minutes. Stop the engine and wait 2-3 minutes Hold the motorcycle in an upright position, Remove the oil level dipstick and wipe the oil from the dipstick with a clean cloth. OIL LEVEL DIPSTICK mY Insert the dipstick into the stick hole without screw: 1 dipstick into the stick hole without s SES Remove the dipstick and check for oil level. If the level is below the lower line, fill the crankcase with recommended oil up to the upper level lino. UPPER LEVEL LINE Fill the recommended engine oil up to the upper level line. RECOMMENDED ENGINE OIL: Honda 4-stroke oil or equivalent motor oil API service classification SE, SF or SG Viscosity: SAE 10W-30 Reinstall the oll level dipstick.MAINTENANCE ENGINE OIL & FILTER CHANGE Warm up the engine. Change the oil with Stop the engine and remove the oil level dipstick. the engine warm ‘and the motorcycle ‘on level ground to ‘assure complete draining Remove the drain bolt and sealing washer, then drain the oil completely. COIL DRAIN BOLT/SEALING WASHER Remove and discard the ol iter cartridge using the AN rac ua special tool Toot: Oil filter wrench o7HAAPI70101 Check that the sealing washer on the drain bolt is in ‘good condition, and replace if necessary. Install and tighten the drain bolt. TORQUE: 29 Nem (3.0 kgf-m, 22 IbF-t) OIL DRAIN BOLT/SEALING WASHER 3-15MAINTENANCE Apply clean engine oil to the new oil filter O-ring, OIL FILTER CARTRIDGE Install the new oil filter and tighten it to the specified rae ww torque. ‘OIL FILTER WRENCH TOOL: Oil filter wrench O7HAA-PJ70101 TORQUE: 26 Nem (2.7 kgf-m, 20 IbF-t) Fill the crankcase with recommended engine oi lL CAPACITY: 3.5 liter (3.7 US qt, 3.1 Imp qt) after draining 3.8 liter (4.0 US qt, 3.3 Imp at) after draining/filter change Install the oil level dips Start the engine and let it idle for 3-5 minutes. Stop the engine and wait 2-3 minutes. Hold the motorcycle in an upright position. Recheck the oil level. Make sure there are no oil leaks. 3-16MAINTENANCE CARBURETOR SYNCHRONIZATION * Synchronize the cerburetors with the engine at the normal operating temperature and with the ‘transmission in noutral. ‘© Use a tachometer with graduations of 50 min* (rpm) or smaller that will accurately indicate 50 min” (rpm) change. Pleze he mouyoyde on aleve aceon suppO% NOAINTARE NDA me JOINT INTAKE JOINT f Romove the fuel tank (page 2-6) FAN Remove the plug and washer from the No.1 intake port. Remove the rubber cap from the No.4 intake port. Screw the adaptor into the No.1 intake port. ) No.4 | INTAKE JOINT No.3 PLUG VACUUMHOSE _ INTAKE JOINT Disconnect the vacuum hoses from the No.2 and No.3 intake ports. Connect the 3-way joint to the No.2 intake joint. Connect the fuel hose, Connect the fuel valve vacuum hose to the 3-way joint. FUEL VALVE — VACUUM SS Noges S.WAY JOINT Connect the vacuum gauge hose to the adaptor and intake joints. 3-17MAINTENANCE The No.3 carburetor Check the each carburetor intake vacuum pressure cannot bo adjusted, itis the base carbu: ENGINE IDLE SPEED rotor. Start the engine and adjust the idle speed by turn- ing the throttle stop screw. IDLE SPEED: 1,300 + 100 min* (rpm) ie within 30 mm (1.2 in) Hg of the base carburetor. ‘Synchronize to specification by turning the adjust- ing screw with the phillips screwdriver. Recheck the idle speed and each cylinder intake vac- uum pressure so itis within 30 mm (1.2 in) Hg of the base carburetor reading after snapping the throttle grip 3-4 times. Remove the vacuum gauge hoses. Connect the fuel valve vacuum hose and PAIR con- trol valve hose. Install the rubber cap to the No.4 intake port. Install the vacuum plug into the No.1 intake port, and tighten it securely. Install the fuel tank (page 2-6). + Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications. © The engine must be warm for accurate adjust- ‘ment. Ten minutes of stop-and-go riding is suffi- cient. Warm up the engine, shift the transmission into Neutral and place the vehicle on a level surface, Check the idle speed and adjust by turning the throt- tle stop screw as required, IDLE SPEED: 1,300 + 100 min* (rpm)MAINTENANCE RADIATOR COOLANT COOLING Check the coolant level of the reserve tank with the engine running at normal operating temperature. ‘The level should be between the "UPPER" and *LOWER" level lines. Ht necessary, add recommended coolant. RECOMMENDED ANTIFREEZE: High quality ethylene glycol antifreeze containing corrosion protection inhibitors. Remove the seat (page 2-4). Remove the reserve tank filler cap and fill to the *UPPER" level line with 50/50 mixture of distilled water and antifreeze. Reinstall the filler cap. SYSTEM Check the radiator air passages for clogging or dam- age. Straighten bend 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 deteriora tion, and replace if necessary. Check the tightness of all hose clamps and faster ors. 3 1 9MAINTENANCE SECONDARY AIR SUPPLY SYSTEM * This model is equipped built-in secondary air supply system. The pulse secondary air supply system is located on the cylinder head cover. * The secondary air supply system introduces fil- tered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system. This charged secondary air pro- motes burning of the unburned exhaust gases and changes a considerable amount of hydrocar- bons and carbon monoxide into relatively harm- less carbon dioxide and water. Remove the fuel tank (page 2-6). Ifthe hoses show Check the PAIR (pulse secondary air injection) hoses ‘any signs of heat between the PAIR control valve and cylinder head | damage, inspect cover for deterioration, damage ot loose connec- fi. the PAIR check tions. Make sure that the hoses are not cracked. valve in the PAIR reed valve cover for damage. Check the air suction hose between the air cleaner housing and PAIR control vaive for deterioration, damage or loose connections. Make sure that the hoses are not kinked, pinched or cracked. DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION ‘Never inspect and Turn the ignition switch OFF, place the motorcycle ‘adjust the drive on its side stand and shift the transmission into neu- chain while the tral. engine's 1u™NS- Check the slack in the drive chain lower run midway between the sprockets. (CHAIN SLACK: 30-40 mm (1.2 1.6 in) NOTICE Excessive chain slack, 50 mm (2.0 in) or more, may damage the frame. Lubricate the drive chain with #80 - 90 gear oil or chain lubricant designed specifically for use with O- ‘30-40 mm (1.2~1.6 in) ring chains. Wipe off the excess oil or chain lubri- cant. 3-20MAINTENANCE ADJUSTMENT Loosen the rear axle nut and adjuster lock nuts. Turn both adjusting nuts until the correct drive chain slack is obtained. Make sure the index marks on the both axle wash- ars are aligned with the index marks of the swing- Tighten the both drive chain adjuster lock nuts to the specified torque. TORQUE: 21 Nem (2.1 kgfm, 15 Ibfft) ighten the rear axle nut to the specified torque. TORQUE: 93 Nm (9.5 kgf-m, 69 Ibfft) Recheck the drive chain slack and free wheel rota- tion. Lubricate the drive chain with #80 drive chain lubricant designed speci with O-ring chains. Wipe off the excess oil or chain lubricant. Check the drive chain wear indicator label attached on the swingarm. If the rear axle bolt reaches red zone of the indicator label, replace the drive chain with a new one (page 3:22) CLEANING AND LUBRICATION Clean the chain with non-flammable or point solvent and wipe it dry. NON-FLAMMABLE OR HIGH Be sure the chain has dried completely before lubri- | FLASH POINT SOLVENTS. cating. ~ Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Installing a new chain on badly worn sprockets wi ‘cause the new chain to wear quickly. Inspect and replace sprocket as necessary. Lubricate the drive chain with #80 - 90 gear oil or Grive chain lubricant designed specifically for use e with O-ring chains. Wipe off the excess oil or chain LUBRICATE lubricant. #80 - 90 GEAR OIL OR DRIVE CHAIN LUBRICANT 21MAINTENANCE When using the special too, follow the manufacturer's instruction. 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 condi- tion, or the new replacement chain will wear rap- idly. DAMAGE driven sprockets. I any are loose, torque them. 54 N-m (5.5 kgf-m, 40 IbF-ft) 108 Nem (11.0 kgf-m, 80 Ibftt) REPLACEMENT This motorcycle uses a drive chain with a staked master link. Loosen the drive chain (page 3-21). Assemble the special tool as shown. TOOL: Drive chain tool set O7HMH-MR10103 DRIVE CHAIN TOOL SETMAINTENANCE Locate the crimped pin ends of the master link from the outside of the chain, and remove the link wit the drive chain tool set. TOOL: Drive chain tool set O7HMH-MR 10103 Remove the drive chain. Include the master Remove the excess drive chain links from the new link when you drive chain with the drive chain tool set, count the chive chain inks STANDARD LINKS: 116 LINKS REPLACEMENT CHAIN DID: 525vM2 RK: 525R0_ ver rouse the od Insert the new master link with new O-rings from ve chain, master the inside of the drive chain, and install the new link, master ink plate and O-rings with the identification mark facing plate and O-rings, the outside. Assemble and set the drive chain tool set. TOOL: Drive chain tool set O7HMH-MR10103 MASTER LINK DRIVE CHAIN TOOL SET MASTER LINK DRIVE CHAIN TOOL SET 3-23MAINTENANCE Make sure that the master properly. Measure the master link pin length projected from the plate. ‘STANDARD LENGTH: DID: 1.15 ~ 1.55 mm (0.045 - RK: 1.2 ~ 1.4 mm (0.05 - 04 Stake the master link pins. pins are installed .061 in) MASTER LINK PINS Make sure that the pins are staked properly by mea- suring the diameter of the staked area using a slide caliper. DIAMETER OF THE STAKED AREA: DID: 5.50 5.80 mm (0.217 - 0.228 RK: 5.50 5.80 mm (0.217 - 0.228 in) SLIDE CALIPER ‘A drive chain witha After staking, check the staked area of the master Cilip-type master ink link for cracks. ‘must not be used. If there is any cracking, replace the master link, O- rings and plate. No GOOD ep). V CRACKED DRIVE CHAIN SLIDER Inspect the drive chain slider for excessive wear or damage. If it is worn to the wear limit line, replace the drive chain slider. 3-24MAINTENANCE BRAKE FLUID NOTICE * Do not mix different types of fluid, as they are not compatible with each other. * Do not allow foreign material to enter the system when filling the reservoir. * Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. When the fluid level is low, check the brake pads for wear (page 3-26). A low fluid level may be due to wear of the brake pads. If the brake pads are worn, the caliper piston is pushed out, and this accounts for a low reservoir level. If the brake pads are not worn and the fluid level is low, check entire system for leaks (page 3-26), FRONT BRAKE Turn the handlebar to the left so that the reservoir is level and check the front brake fluid reservoir level. If the level is near the lower level line, check the brake pad wear (page 3-26). REAR BRAKE Remove the side cover (page 2-5). Place the motorcycle on a level surface, and support, it upright position. Check the rear brake fluid reservoir level. If the level is near the lower level line, check the brake pad wear (page 3-26). LOWER LEVEL LINE 3-25MAINTENANCE BRAKE PAD WEAR FRONT BRAKE PADS Check the brake pad for wear. Replace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to brake pad replacement (page 15-10). REAR BRAKE PADS ‘Check the brake pad for wear. Replace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to brake pad replacement (page 15-11). BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal, and check that no air has entered the system. If the lever or pedal feols soft or spongy when oper- ated, bleed the air from the system. Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. Refer the procedure for brake bleeding (page 15-8).‘Align the arrow on the brake lever with the index mark on BRAKE LIGHT SWITCH The front brake light switch does ot require acjust- ‘ment. MAINTENANCE BRAKE LEVER ADJUSTMENT The distance between the top of the brake lever and the grip can be adjusted by turning the adjuster. comes on just prior to the brake actually being ADJUSTER engaged. If the light fails to come on, adjust the switch so that the light comes on at the proper time. Hold the switch body and turn the adjuster. Do not turn the switch body, Adjust the brake light switch so that the brake light ye a 3-27MAINTENANCE HEADLIGHT AIM CBF600S/SA: Place the motorcycle on a level surface. ‘Adjust the headlight Adjust the headlight beam horizontally by turning [VERTICALLY ADJUSTING SCREW. | ‘beam as spectied the horizontal beam adjusting screw. by lecal laws and A clockwise rotation moves the beam toward the reguistions. right side of the rider, Adjust the headlight beam vertically by turning the vertical beam adjuster. A clockwise rotation moves the beam up. CBF600N/NA: Place the motorcycle on a level surface. ‘Aduust the headiight Adjust the headlight beam horizontally by turning ‘boem as specified the horizontal beam adjusting screw. by local laws and A clockwise rotation moves the beam toward the ‘regulations. right side of the rider. ‘Adjust the headlight beam vertically by turning the head light case assombly. Loose the headlight case mounting bolts and adjust the vertical beam by moving the headlight case assembly. HORIZONTALY ADJUSTING SCREW | CLUTCH SYSTEM Measure the clutch lever free play at the end of the clutch lever. FREE PLAY: 10-20 mm (3/8 - 13/16 in) 3-28MAINTENANCE Minor adjustments are made using the upper adjuster at the clutch lever. LOCK NUT ADJUSTER, Loosen the lock nut and turn the adjuster. NOTICE The adjuster may be damaged if itis 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 @ major adjustment as described as follow. Major adjustments are performed at the clutch arm. Loosen the lock nut end turn the adjusting nut to adjust free play. Hold the adjusting nut securely w! lock nut. If proper free play cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch {page 9-7). tightening the SIDE STAND Support the motorcycle on a level surface. Check the side stand spring for damage or loss of tension. Check the side stand assembly for freedom of movement and lubricate the side stand pivot if nec- essary. SIDE STAND Check the side stand ignition cut-off system: = Sit 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. = Move the side stand full down. = The engine should stop as the side stand is low- ered. If there is a problem with the system, check the side stand switch, Pesos stand SWITCH 3 3-29MAINTENANCE SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brakes and compressing the front suspension sev- eral times. Check the entire assembly for signs of leaks, dam- age or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to the fork service (page 13-21). REAR SUSPENSION INSPECTION Support the motoreycle using a hoist or equivalent 7 and raise the rear wheel off the ground. Hold the swingarm and move the rear wheel side- ways with force to see if the wheel bearings ere __ Check for worn swingarm bearings by grabbing the rear swingarm and attempting to move the swing- arm side to side. Replace the bearings if any are looseness is noted. Check the action of the shock absorber by com- pressing it several times. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to the shock absorber service (page 14-13).MAINTENANCE NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened posse to their correct torque values (page 1-13) REAR AXLE NUT Check that all safety clips, hose clamps and cable } Bi stays ere in place and properly secured. WHEELS/TIRES Tire pressure should be checked when the tires are coLb, : RECOMMENDED TIRE PRESSURE AND TIRE SIZE: FRONT REAR} Tire pressure KPa 1 erent 250 (2.50, 36) |290 (2.90, 42) ‘zoo ZR | 160060 ZR Tire size T7MWiC TMC (eaw) (6a) iTire —[Bridgastone_|BF57F BT57 [bland [Michelin [PILOT ROAD B [PILOT ROAD Check the tires for cuts, embedded nails, or other damage. Check the front wheel (page 13-14) and rear whee! (page 14-6) for trueness: Measure the tread depth at the center of the tres. Replace the tires when the tread depth reaches the following limits. MINIMUM TREAD DEPTH: FRONT: 1.5 mm (0.06 in) REAR: 2.0 mm (0.08 in) STEERING HEAD BEARINGS Check that the control cables do not interfere with handlebar rotation. ‘Support the motorcycle using a safety stand or hoist 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 ver- tical movement, inspect the steering head bearings (page 13-32).MEMO4. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM --- OIL STRAINER/ PRESSURE RELIEF VALVE SERVICE INFORMATION - OIL PUMP.--- TROUBLE SHOOTING - OIL COOLER-+ OIL PRESSURE INSPECTION... miLUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM EXHAUST CAM SHAFT INTAKE CAM SHAFT Pit Ere PISTON II II ENGEINE OIL OIL COOLER MAINSHATT. PRESSURE SWITCH == —>_ OIL FILTER CARTRIDGE RELIEF VALVE i Tm | “7 | COUNTERSHAFT Sal! il OIL PUMP OIL STRAINERLUBRICATION SYSTEM —_—_—— SERVICE INFORMATION GENERAL ACAUTION 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, itis still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. © The oil pump can be serviced with the engine installed in the frame. ‘© The service procedures in this section must be performed with the engine oil drained. = When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. * If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an essembly. + After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct. SPECIFICATIONS Unit: mm (in) TEM ‘STANDARD. ‘SERVICE LIMIT Engine oll capacity ‘After draining 3.5 Iter (3.7 US qt, 3.1 Imp at) = [After draining/fiter 3.8 liter (4.0 US qt, 3.3 Imp ql) = change ‘Afr disassembly 2 liter (6.4 US qt 3.7 Imp at) = Recommended engine of Honda d-stroke oll or equivalent motor ofl = API service classification SE, SF or SG Viscosity: SAE 10W-30 Oil pressure at engine oll pressure switch “490 KPa (5.0 kgticm?, 71 psi) at = 6,000 min’ (rpm\/I80°C/176°F)__ [Olt pump rotor Tip dearance 0.15 (0.006) 0.20 (0.008) Body clearance (0.15 - 0.22 (0.006 - 0.009), 0.35 (0.014) Side clearance 0.02 0.07 (0.001 = 0.003) (0.10 (0.004) Oil pump drive sprocket collar 0.D. "34,050 - 34.075 (13405 - 13415) 34.08 (1340) [Dit pump drive sprocket ID. [36,025 ~ 36.075 (1.3789 — 1.3809) 35.10 (1.382), TORQUE VALUES Engine oil drain bolt 29 Nem (3.0 kgf-m, 22 Ibf-A) Engine oil filter cartridge 26 Nem (227 kgf-m, 20 Ibf-t) ‘Apply oil to the threads and flange surface Oil filter boss 18 Nem (1.8 kgtm, 13 Ib) ‘Apply locking agent to the threads Oil pump driven sprocket bolt 45 Nem (1.5 kgm, 11 IbFft) Apply locking agent to the threads Oil pump assembly bolt 78Nm (0.80 kgtm, 5.8 IbFft) CT bolt Gil cooler sealing bolt 49 Nem (5.0 kgf-m, 36 IbF ft) Apply locking agent to the threads Engine oll prossure switch 12.Nem (1.2 kgm, 9 IDFA) Apply sealant to the threads Engine oll pressure switch 2.0 N-m (0.20 kgf, 14 Ibff) terminal screwLUBRICATION SYSTEM TOOLS Oil pressure gauge Oil pressure gauge attachment it fiter wrench 07508-3000001 o7st0-4220100 O7HAA-PJTOIo! eo _—< eo LP coe TROUBLE SHOOTING Oil level too low * Oil consumption * External oil leak * Wom piston rings * Improperly installed piston rings Worn cylinders Worn stem seals + Worn valve guide Low oil pressure © Oil level low * Clogged oil strainer * Internal oil leak © Incorrect oil being used No oil pressure * Oil level too low Oil pressure relief valve stuck open Broken oil pump drive chain Broken oil pump drive or driven sprocket Damaged oil pump Internal oil leak jh oil pressure * Oil pressure relief valve stuck closed + Clogged oil filter, gallery or metering orifice * Incorrect oil being used -ontamination Oil or filter not changed often enough * Worn piston rings Oil emul: ication * Blown cylinder head gasket * Leaky coolant passage * Entry of waterLUBRICATION SYSTEM OIL PRESSURE INSPECTION lf the oil pressure Check the oil level (page 3-14). CABLE GUIDE. remai dearer Ho" Remove the bolts and clutch cable gui the indicator syo- tem before check- ing th oi pressure. Remove the rubber cap. (a Remove the oil pressure terminal switch screw and | RUBBER CAP SCREW terminal eyelet. Remove the engine oil pressure switch. ~ 2 CENGINE OIL SAO i PRESSURE ERMINAL EYELET SWITCH Connect an oil pressure gauge and attachment to the engine oil pressure switch hole, ATTACHMENT Toots: Oil pressure gauge 07506-3000001 Oil pressure gauge 07510-4220100 attachment Warm up the engine to normal operating tempera- ture (approximately 80°C/176°F) and increase the min" (rpm) to 6,000 min? (rpm) and read the oil pressure. OIL PRESSURE: 490 kPa (5.0 kgf/em?, 71 psi) at 6,000 min" (tpm)/ IL PRESSURE GAUGE (80°C/176"F) Stop the engine and remove the tools. Apply @ sealant to the engine oil pressure switch | Do not apply to the ‘threads as shown. PS thread head Install and tighten the engine oil pressure switch to 3-4 mm (0.1 -0.2 in) the specified torque. TORQUE: 12 Nem (1.2 kaf-m, 9 Ibf-ft) ses ENGINE OIL PRESSURE SWITCH 4-5LUBRICATION SYSTEM Connect the engine oil pressure switch wire and ‘screw to the specified torque. TORQUE: 2.0 Nem (0.20 kgf-m, 1.4 Ibf-ft) Instal the rubber cap securely. RUBBER CAP Se [- 2S ENGINE OIL oT) PRESSURE TERMINALEYELET — witcH Instal the clutch cable guide and tighten the bolts securely. Start the engine, Check that the oil pressure indicator goes out after ‘one or two seconds. If the oil pressure indicator stays on, stop the engine immediately and deter- mine the cause. OIL STRAINER/ PRESSURE RELIEF VALVE F 6 REMOVAL Drain the engine oil (page 3-15). Remove the exhaust pipe (page 2-10), Remove the bolts and oil pan, Remove the pressure relief valve and O-ring Remove the oil strainer and packing. Check the oil strainer for damage or clogging, Clean the oil strainer screen,LUBRICATION SYSTEM INSPECTION Check the operation of the pressure relief valve by pushing on the piston, Disassemble the relief valve by removing the snap ring. a L, we INSTALATION Apply oil to the new O- valve groove. Install the relief valve into the crankcase. ng and install it to the relief Apply oil to the new packing and install it onto he — A oil strainer. > 7B PACKING Install the oil strainer into the crankcase while align- ing its boss with the groove of the crankcase.LUBRICATION SYSTEM Do not apply seal- Apply Three Bond 1207B or an equivalent to the {ant more than nec- mating surface. OIL PUMP essary. Clean the oil pan mating surface thoroughly. Carefully install the oil pan onto the lower crank: case. Install and tighten the bolts in a crisscross pattert 2-3 steps. Install the exhaust pipe (page 2-10). Fill the crankcase with recommended oil (page 3- 14). After installation, check that there are no oil leaks. REMOVAL Remove the oil strainer and pressure relief valve "DEVE SPROCKET {page 4-6). Remove the clutch assembly (page 9-7). Remove the bolt/washer, then remove the oil pump drive/driven sprocket and drive chain as an assem- p bly.LUBRICATION SYSTEM Remove the drive sprocket collar from the mainshaft. DRIVE SPROCKET COLLAR Remove the bolts and oil pump assembly. DISASSEMBLY Remove the oil pump assembly bolt. ‘ASSEMBLY BOLT Remove the oil pump cover and dowel pin. DOWEL PIN IL PUMP COVER,LUBRICATION SYSTEM Remove the thrust washer, drive pin, oil pump shaft, outer rotor and inner rotor from the oil pump OUTER ROTOR INNER ROTOR body. DRIVE PIN OIL PUMP SHAFT WASHER INSPECTION it any portion of the Temporarily install the oil pump shaft. TIP CLEARANCE: ‘ol pump is wom Install the outer and inner rotors into the oil pump beyond the service body. limit, replace the Ol jeasure the rotor tip clearance. ‘pump as an assem bly, SERVICE LIMIT: 0.20 mm (0.008 in) Measure the pump body clearance. SERVICE LIMIT: 0.35 mm (0.014 in) BODY CLEARANCE: Measure the side clearance using a straight edge and feeler gauge. ‘SERVICE LIMIT: 0.10 mm (0.004 in) SIDE CLEARANCE: 4-10LUBRICATION SYSTEM Measure the oll pump drive sprocket collar 0.0. ‘SERVICE LIMIT: 34.03 mm (1.340 in) Measure the oil pump drive sprocket I.D. SERVICE LIMIT: 35.10 mm (1.362 in) we DRIVE SPROCKET DRIVEN SPROCKET COLLAR ASSEMBLY INNER ROTOR OIL PUMP BODY DRIVE PIN OIL PUMP SHAFT DOWEL PIN OUTER ROTOR —_— INNER ROTOR DRIVE Pit WASHER OILPUMP COVER 78 N-m (0.80 kgf-m, 6.8 IDFA) Install the outer rotor into the oll pump body. Install the inner rotor into the outer rotor with its INNER ROTOR ute ROTOR drive pin groove facing the oil pump cover. OL PUMP BODY DRIVE PIN GROOVE 4-11LUBRICATION SYSTEM 4-12 Install the oil pump shaft through the inner rotor and oil pump body. OUTER ROTOR INNER ROTOR 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 thrust washer. DRIVE PIN OIL PUMP SHAFT Install the dowel pi Install the oil pump cover. DOWEL PIN o OIL PUMP COVER Install and tighten the assembly bolt to the specified torque. ‘ASSEMBLY BOLT TORQUE: 7.8 N-m (0.80 kgf-m, 5.8 Ibf-ft) Check the oil pump operation by turning the pump shaft. Ifnecessary, reassemble the oil pump. INSTALLATION Install the oil pump onto the crankcase while align- ing the pump shaft lug with the water pump shaft groove by turning the oil pump shaft.Align the fat sur faces of the driven ‘sprocket withthe cil pump dive shaft end. LUBRICATION SYSTEM Install and tighten the bolts securely. Apply oil to the oil pump drive sprocket collar. Install the drive sprocket collar onto the mainshaft, Apply oll to the drive sprocket and drive chain. ———— ea Install the drive/driven sprocket and drive chain as x S ] i fan assembly with the "OUT" mark on the driven Vex 1 7 sprocket facing out. | to the specified torque. TORQUE: 15 Nom (1.5 kgfm, 11 Ibf-ft) Install the clutch assembly (page 9-12) After installation, fill the crankcase with recom- ‘mended oil and check that there is no cil leaks. Check the oil pressure (page 4-5). | BOLTWASHERLUBRICATION SYSTEM OIL COOLER REMOVAL Remove the exhaust pipe (page 2-10). y Drain the engine oil and remove the oil filter car WATER HOSE tridge (page 3-15) F i Drain the coolant from the system (page 6-6). Loosen the hose band screw and disconnect the oil cooler water hose from the cooler. Remove the bolts and oil cooler assembly. Remove the joint collars/O-rings from the crank case. Remove the O-ring from the oil cooler. OIL COOLERLUBRICATION SYSTEM i el A) DISASSEMBLY Remove the oil cooler cover bolts and sealing washer. OIL COOLER COVER/O-RING Remove the oil cooler cover and O-ring, Remove the bolts and oil cooler. BOLTS 198 from the oil cooler base. O-RINGS 4-15LUBRICATION SYSTEM ASSEMBLY OIL COOLER BASE OIL COOLER PB Boas OIL COOLER COVER g 7a O-RING Apply clean engine oll to the new O-rings and install, them into the oil cooler base. cece lee Install the oil cooler. Install the bolts, then tighten the bolts securely, OIL COOLER, or BOLTSLUBRICATION SYSTEM y oll to the nd inetal i Apply fl to the naw O-ing and instal eto the oll SSE OIL COOLER COVER Assemble the oil cooler cover and base, then install the bolts and new sealing washer. OIL COOLER COVER/O-RING BOLT Tighten the bolts securely. L BOLTISEALING WasHeR SOP a | INSTALLATION Apply oil to the new O-ring and install it into the groove of the oll cooler base. A Ss 2 te OIL COOLER Apply clean engine oil to the new O-rings, and install them onto the joint collars. COLLAFVO-RINGS Install the Joint collars to the crankcase with its large 5 0.0. side facing the crankcase. /y iLUBRICATION SYSTEM Install the oil cooler assembly onto the crankcase. Install the bolt, then tighten the oil cooler assembly mounting bolts. Connect the water hose to the oil cooler and tighten the band screw securely. Install the exhaust pipe (page 2-10). Install the oil filter cartridge and fill the crankcase with recommended oil (page 3-15). Fill the cooling system and bleed air (page 6-6). BAND SCREW 4-185. FUEL SYSTEM COMPONENT LOCATION-- CARBURETOR ASSEMBLY- SERVICE INFORMATION CARBURETOR COMBINATION TROUBLESHOOTING -- CARBURETOR INSTALLATION AIR CLEANER HOUSING PILOT SCREW ADJUSTMENT- CARBURETOR REMOVAL- SECONDARY AIR SUPPLY SYSTEM - CARBURETOR SEPARATION ~ FUEL VALVE CARBURETOR DISASSEMBLY:COMPONENT LOCATION FUEL SYSTEM 5-2SERVICE INFORMATION GENERAL FUEL SYSTEM Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, result- ing in loss of vehicle control. ‘© Work in @ well ventilated area, Smoking or allowing flames or sparks in the work area or where gasoline is stored can ‘cause a fire or explosion, ‘= Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the carburetor has been removed, * Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms might be damaged. * Before disassembling carburetor, place the suitable container under the carburetor drain hose. Loosen the bolt and drain the carburetor. ‘© The vacuum chamber and float chamber can be serviced with the carburetors assembled. When disassembling fuel system parts, note the location of the O-rings. Replace them with new ones on reassembly. © If the vehicle is to be stored for more than one month, drain the float bowls may cause clogged lets resulting in hard starting or poor driveabi ity. ‘© Refer to procedures for fuel reserve sensor inspection (page 20-27). ‘Refer to procedures for fuel tank removal and installation (page 2-6). SPECIFICATIONS [ TEM SPECIFICATIONS (Carburetor identification number VP4AK ("Main jet No.174; #102, No.2/3; #105 Slow jet #40 Jet needle 5970 Pilot screw [initial opening 2-478 turns out Float level 78.7 mm (0.54 in} Tale speed 7,300 * 100 min" (rpm) a Throttle grip free play Carburetor vacuum difference 2—6 mm (16 - 1/4 in) Withi 30. mm Hg (1.2 in Hg) Base carburetor for synchronization No.3 carburetor TORQUE VALUES Insulator band screw Carburetor drain screw Starting enrichment (SE) valve arm screw Starting enrichment (SE) valve nut Vacuum chamber cover screw Air funnel holder screw Float chamber screw ‘Throttle cable holder screw Throttle position (TP) sensor bracket screw Carburetor connecting nut, § mm Carburetor connecting nut, 6 mm Fuol valve nut TOOLS Carburetor float level gauge 07401-0010000 Pilot screw wrench 07908-4730002 See page 5-26 1.5 Nem (0.16 kgf-m, 1.1 IDF) 18 Nem (0.18 kgm, 1.3 IDF) 1.8 Nem (0.18 kgfim, 1.3 Ibff) 2.1. Nem (0.21 kaf-m, 1.5 IDFA) 2.1. Nem (0.21 kgf'm, 1.5 IDFA 3.4 N-m (0.35 kaf-m, 2.6 Ibfft) 3.4 N-m (0.35 kgf'm, 2.6 Ibfft) 2.4 Nem (0.35 kgf-m, 2.5 loft) 5.1 Nem (0.52 kgf'm, 3.8 IbFft) 8.8 Nem (1.0 kgf'm, 7 Ibfft) 34 Nem (3.5 kgh'm, 25 IDF) 5-3