Honda CBR600F2 (1991-1994) [124/196] Front wheel suspension steering

Содержание

• Brake system p.2
• Fuel system p.2
• Cooling system p.2
• C c ш p.2
• Charging system alternator p.2
• Cylinder head p.2
• Clutch gearshift linkage p.2
• Lubrication system p.2
• Engine removal installation p.2
• Electric starter starter clutch p.2
• Crankcase cylinder piston p.2
• Ignition system p.2
• Front wheel suspension steering p.2
• Crankshaft transmission p.2
• Lights meters switches p.2
• Frame body panels exhaust system p.2
• Wiring diagram p.2
• Maintenance p.2
• General information p.2
• Troubleshooting p.2
• Sbsbbsbbsesbm p.2
• Rear wheel suspension p.2
• Introduction contents p.2
• Important safety notice p.3
• Symbols p.4
• How to use this manual p.5
• Finding the information you need p.5
• Understanding the instructions p.5
• Service information p.6
• Troubleshooting p.6
• Frame body panels exhaust system p.6
• Seat removal lnstallation p.7
• Side cover removal lnstallation p.7
• Frame body panels exhaust system p.7
• Side fairing removal installation p.8
• Requisite service p.8
• Frame body panels exhaust system p.8
• Requisite service p.10
• Frame body panels exhaust system p.10
• Requisite service p.11
• Front cowl disassembly assembly p.11
• Frame body panels exhaust system p.11
• Frame body panels exhaust system p.12
• Tail cowl removal lnstallation p.12
• Rear fender b removal lnstallation p.12
• Requisite service p.14
• Frame body panels exhaust system p.14
• Requisite service p.15
• Frame body panels exhaust system p.15
• Exhaust system removal fnstallation p.15
• Requisite service p.16
• Fuel tank removal lnstallation p.16
• Frame body panels exhaust system p.16
• Service information p.17
• Maintenance p.17
• Service access guide p.18
• Maintenance p.18
• Maintenance p.19
• Maintenance p.20
• Maintenance schedule p.20
• Spark plug p.21
• Valve clearance p.21
• Maintenance p.21
• Inspection p.21
• Air cleaner p.21
• Maintenance p.22
• Maintenance p.23
• Shim selection p.24
• Maintenance p.24
• Maintenance p.25
• Carburetor synchronization p.25
• Side stand p.26
• Maintenance p.26
• Oil pan removal lnstallation 4 3 oil cooler disassembly assembly 4 7 p.27
• Lubrication system diagram 4 2 oil cooler removal lnstallation 4 6 p.27
• Service information 4 1 oil pump removal lnstallation 4 4 p.27
• Lubrication system p.27
• Troubleshooting 4 1 oil pump disassembly assembly 4 5 p.27
• Troubleshooting p.27
• Service information p.27
• Requisite service p.29
• Oil pan removal lnstallation p.29
• Lubrication system p.29
• Requisite service p.30
• Oil pump removal lnstallation p.30
• Lubrication system p.30
• Requisite service p.31
• Oil cooler removal lnstallation p.32
• Requisite service p.32
• Lubrication system p.32
• Lubrication system p.33
• Requisite service p.33
• Oil cooler disassembly assembly p.33
• Water pump disassembly assembly 5 7 p.34
• Troubleshooting 5 1 p.34
• Troubleshooting p.34
• Thermostat removal installation 5 4 p.34
• System flow pattern 5 2 p.34
• Service information 5 1 p.34
• Service information p.34
• Reserve tank removal lnstallation 5 8 p.34
• Radiator removal lnstallation 5 5 p.34
• Radiator disassembly assembly 5 6 p.34
• Cooling system p.34
• Coolant draining 5 3 p.34
• Cooling system p.36
• Coolant draining p.36
• Requisite service p.37
• Thermostat removal lnstallation p.37
• Cooling system p.37
• Requisite service p.38
• Radiator removal installation p.38
• Cooling system p.38
• Requisite service p.39
• Radiator disassembly assembly p.39
• Cooling system p.39
• Water pump disassembly assembly p.40
• Requisite service p.40
• Cooling system p.40
• Reserve tank removal lnstallation p.41
• Requisite service p.41
• Cooling system p.41
• Fuel system p.42
• Service information p.42
• Toroubleshooting p.43
• Fuel system p.43
• Requisite service p.44
• Air cleaner housing removal lnstallation p.44
• Fuel system p.44
• Requisite service p.46
• Fuel system p.46
• Fuel system p.48
• Requisite service p.48
• Requisite service p.50
• Jet needle holder removal lnstailation p.50
• Fuel system p.50
• Requisite service p.52
• Fuel system p.52
• Fuel system p.53
• California type only p.53
• Requisite service p.53
• Pulse secondary air injection pair control valve removal lnstallation p.53
• Requisite service p.54
• Fuel system p.54
• Evaporative emission evap canister removal lnstallation california type only p.54
• Pilot screw adjustment p.55
• Idle drop procedure p.55
• Fuel system p.55
• High altitude adjustment u s a only p.56
• Service information 7 1 engine removal lnstallation 7 2 p.57
• Service information p.57
• Engine removal lnstallation p.57
• Requisite service p.59
• Engine removal lnstallation p.59
• Drive sprocket removal lnstallation p.60
• Engine removal lnstallation p.60
• Engine hanger adjusting bolt lock nut installation p.60
• Cylinder head p.61
• Troubleshooting 8 1 cylinder head disassembly assembly 8 8 p.61
• Troubleshooting p.61
• Service information 8 1 cylinder head removal lnstallation 8 7 p.61
• Service information p.61
• Camshaft removal lnstallation 8 2 p.61
• Requisite service p.63
• Cylinder head p.63
• Cylinder head p.64
• Camshaft installation p.64
• Cylinder head p.65
• Cylinder head p.66
• Cylinder head removal installation p.67
• Cylinder head p.67
• Requisite service p.67
• Requisite service p.68
• Cylinder head disassembly assembly p.68
• Cylinder head p.68
• Cylinder head p.69
• Valve cotters removal lnstallation p.69
• Troubleshooting 9 1 shift drum shift forks removal p.70
• Troubleshooting p.70
• Service information 9 1 gearshift linkage removal lnstallation 9 8 p.70
• Service information p.70
• Right crankcase cover removal installation 9 10 p.70
• Installation 9 2 clutch installation 9 12 p.70
• Clutch removal 9 4 p.70
• Clutch gearshift linkage p.70
• Requisite service p.72
• Ciutch gearshift linkage p.72
• Requisite service p.74
• Clutch gearshift linkage p.74
• Clutch outer removal p.75
• Clutch gearshift linkage p.75
• Clutch center lock nut removal p.75
• Clutch outer needle bearing replacement p.76
• Clutch gearshift linkage p.76
• Requisite service p.78
• Clutch gearshift linkage p.78
• Shift drum shift forks removal lnstallation p.79
• Requisite service p.79
• Clutch gearshift linkage p.79
• Shift fork installation p.80
• Clutch gearshift linkage p.80
• Clutch installation p.81
• Clutch gearshift linkage p.82
• Requisite service p.82
• Clutch outer installation p.83
• Clutch gearshift linkage p.83
• Clutch center lock nut installation p.83
• Clutch lifter rod installation p.84
• Clutch gearshift linkage p.84
• Troubleshooting 10 1 installation 10 4 p.85
• Troubleshooting p.85
• Service information 10 1 piston connecting rod removal p.85
• Service information p.85
• Crankcase separation 10 2 crankcase assembly 10 6 p.85
• Crankcase cylinder piston p.85
• Crankcase cy lindar piston p.87
• Requisite service p.89
• Crankcase cylinder piston p.89
• Crankcase cylinder piston p.91
• Liquid sealant application p.92
• Crankcase cylinder piston p.92
• Crankcase bolt location p.92
• Service information p.93
• Troubleshooting 11 1 mainshaft disassembly assembly 11 8 p.93
• Troubleshooting p.93
• Service information 11 1 transmission removal lnstallation 11 6 p.93
• Crankshafttransmission p.93
• Crankshaft removal lnstallation 11 2 countershaft disassembly assembly 11 10 p.93
• Crankshaft bearing replacement 11 4 p.93
• Requisite service p.95
• Crankshaft transmission p.95
• Main journal bearing selection p.96
• Crankshaft transmission p.96
• Crankshaft bearing replacement p.96
• Connecting rod bearing selection p.96
• Starter clutch needle bearing replacement p.97
• L aaö b p.97
• Connecting rod selection p.97
• C rankshaft t ransm i ssion p.97
• Requisite service p.99
• Crankshaft t ransmission p.99
• Requisite service p.101
• Crankshaft transmission p.101
• Requisite service p.103
• Crankshaft transmission p.103
• Mainshaft bearing replacement p.104
• Crankshaft transmission p.104
• Fork assembly 91 93 12 14 p.105
• Fork disassembly after 93 12 12 p.105
• Fork disassembly 91 93 12 10 p.105
• Fork assembly after 93 12 16 p.105
• Troubleshooting 12 1 p.105
• Troubleshooting p.105
• Steering stem removal lnstallation 12 18 p.105
• Service information 12 1 p.105
• Service information p.105
• Right handlebar removal installation 12 2 p.105
• Left handlebar removal lnstallation 12 3 p.105
• Front wheel suspension steering p.105
• Front wheel removal lnstallation 12 4 p.105
• Front wheel disassembly assembly 12 6 p.105
• Fork removal lnstallation 12 8 p.105
• Requisite service p.106
• Right handlebar removal installation p.106
• Front wheei suspension steering p.106
• Left handlebar removal lnstallation p.107
• Front wheel suspension steering p.107
• Requisite service p.109
• Front wheel suspension steering p.109
• Requisite service p.111
• Front wheel suspension steering p.111
• Requisite service p.113
• Front wheel suspension steering p.113
• Requisite service p.115
• Front whee suspensian steering p.115
• Requisite service p.117
• Front wheel suspension steering p.117
• Requisite service p.119
• Front wheel suspension steering p.119
• Requisite service p.121
• Front wheel suspension steering p.121
• Requisite service p.122
• Front wheel suspension steering p.122
• Steering stem removal lnstallation p.122
• Front wheel suspension steering p.123
• Bearing adjustment nut removal installation p.123
• Front wheel suspension steering p.124
• Troubleshooting p.125
• Swingarm removal lnstabation 13 12 p.125
• Shock absorber removal 13 5 p.125
• Shock absorber removal 13 4 p.125
• Service information 13 1 shock absorber disassembly 13 6 p.125
• Service information p.125
• Rear wheel suspension p.125
• Rear wheel removal installation 13 2 suspension linkage removal 13 8 p.125
• Rear wheel disassembly assembly 1 3 3 suspension linkage disassembly 13 9 p.125
• Installation after 93 swingarm disassembly assembly 13 14 p.125
• Installation 91 93 p.125
• Assembly p.125
• Troubleshooting 13 1 assembly 91 93 p.125
• Rear wheel suspension p.126
• Rear wheel removal lnstallation p.126
• Requisite service p.127
• Rear wheel suspension p.127
• Rear wheel disassembly assembly p.127
• Shock absorber removal lnstallation 91 93 p.128
• Requisite service p.128
• Rear wheel suspension p.128
• Shock absorber removal lnstallation after 93 p.129
• Requisite service p.129
• Rear wheelsuspension p.129
• Shock absorber disassembly assembly 91 93 p.130
• Requisite service p.130
• Rear wheel suspension p.130
• Lower joint needle bearing replacement p.131
• Stopper ring removal fnstallation p.131
• Rear wheel suspension p.131
• Suspension linkage removal lnstallation p.132
• Requisite service p.132
• Rear wheel suspension p.132
• Suspension linkage disassembly assembly p.133
• Requisite service p.133
• Rear wheelsuspension p.133
• Suspension linkage pivot needle bearing replacement p.134
• Rear wheel suspension p.134
• Requisite service p.137
• Rear wheelsuspension p.137
• Requisite service p.139
• Rear wheel suspension p.139
• Swingarm pivot bearing replacement p.140
• Rear wheel suspension p.140
• Troubleshooting 14 1 p.141
• Troubleshooting p.141
• Service information 14 1 p.141
• Service information p.141
• Rear master cylinder removal lnstallation 14 8 p.141
• Rear master cylinder disassembly assembly 14 10 p.141
• Rear brake pad replacement 14 2 p.141
• Rear brake caliper removal lnstallation 14 11 p.141
• Rear brake caliper disassembly assembly 14 12 p.141
• Front master cylinder removal lnstallation 14 3 p.141
• Front master cylinder disassembly assembly 14 4 p.141
• Front brake caliper removal installation 14 5 p.141
• Front brake caliper disassembly assembly 14 6 p.141
• Brake system p.141
• Brake system p.142
• Brake system p.143
• Front master cylinder removal lnstallation p.143
• Front master cylinder disassembly assembly p.144
• Brake system p.144
• Front brake caliper removal lnstallation p.145
• Brake system p.145
• _____________________________________________________ ____________ p.147
• Requisite service p.149
• Brake system p.149
• Requisite service p.150
• Rear iwaste cylinde disassembly assembly p.150
• Brake system p.150
• Requisite service p.151
• Rear brake caliper removal lnstallation p.151
• Brake system p.151
• Requisite service p.152
• Rear brake caliper disassembly assembly p.152
• Troubleshooting 15 3 flywheel removal lnstallation 15 9 p.153
• System location 15 2 regulator rectifier 15 7 p.153
• Service information 15 1 charging system inspection 15 6 p.153
• Service information p.153
• Circuit diagram 15 2 alternator removal lnstallation 15 8 p.153
• Charging system alternator p.153
• Battery removal lnstallation 15 4 charging coil inspection 15 11 p.153
• Troubleshooting p.155
• Charging system alternator p.155
• Requisite service p.157
• Charging system alternator p.157
• Leak test p.158
• Charging voltage inspection p.158
• Charging systemalternatnr p.158
• Charging system inspection p.158
• Charging system alternator p.159
• Wire harness inspection p.159
• Unit inspection p.159
• Regulator rectifier p.159
• Requisite service p.160
• Charging system alternator p.160
• Alternator removal lnstallation p.160
• Requisite service p.161
• Flywheel removal lnstallation p.161
• Charging system alternator p.161
• Starter clutch bolt removal lnstallation p.162
• Flywheel bolt removal lnstallation p.162
• Charging sy stem alternator p.162
• Charging system alternator p.163
• Charging coil inspection p.163
• Ignition system p.164
• Circuit diagram 16 2 ignition pulse generator 16 9 p.164
• Troubleshooting 16 3 ignition timing 16 9 p.164
• System location 16 2 ignition coil removal lnstallation 16 8 p.164
• Service information 16 1 ignition coil inspection 16 7 p.164
• Service information p.164
• Ignition system inspection 16 6 ignition pulse generator rotor cover removal installation 16 10 p.164
• System location p.165
• Ignition system p.165
• Circuit diagram p.165
• Troubleshooting p.166
• No spark at all plugs faulty input system p.166
• Ignition system p.166
• No spark at one plug trouble in secondary coil side p.167
• No spark at either ignition group p.167
• Ignition system p.167
• Ignition system p.168
• Circuit inspection p.169
• Ignition system inspection p.169
• Ignition system p.169
• Ignition system p.170
• Ignition coil inspection p.170
• Requisite service p.171
• Ignition system p.171
• Ignition coil removal lnstallation p.171
• Inspection p.172
• Ignition timing p.172
• Ignition system p.172
• Ignition pulse generator p.172
• Requisite service p.173
• Ignition system p.173
• Ignition pulse generator rotor cover removal lnstallation p.173
• Electric starter p.174
• Circuit diagram 17 2 starter motor disassembly assembly 17 6 p.174
• System location 17 2 starter motor removal lnstallation 17 5 p.174
• Service information 17 1 t roubles hooti ng 17 3 p.174
• Service information p.174
• System location p.175
• Electric starter p.175
• Circuit diagram p.175
• Troubleshooting p.176
• Electric starter p.176
• Electric starter p.177
• Starter motor removal installation p.178
• Requisite service p.178
• Electric starter p.178
• Requisite service p.180
• Electric starter p.180
• Combination meter removal installation 18 5 side stand switch 18 9 p.181
• Combination meter bulb replacement 18 4 ignition switch removal lnstallation 18 8 p.181
• System location 18 2 tachometer inspection 18 8 p.181
• Service information 18 1 combination meter disassembly assembly 18 6 p.181
• Service information p.181
• Lights meters switches p.181
• Headlight bulb replacement 18 3 coolant temperature gauge inspection 18 8 p.181
• System location p.182
• Lig hts m eters sw itc h es p.182
• Lights meters switches p.183
• Headlight bulb replacement p.183
• Lights meters switches p.184
• Combination meter bulb replacement p.184
• Lights meters switches p.185
• Combination meter removal lnstallation p.185
• Requisite service p.187
• Lights meters switches p.187
• Coolant temperature gauge p.188
• Tachometer inspection p.188
• Inspection p.188
• Ignition switch removal installation p.188
• Removal lnstallation p.189
• Side stand switch p.189
• Li g hts m ete rs s w i te h es p.189
• Inspection p.189
• Wiring diagram p.190
• Engine does not start or is hard to start p.191
• Troubleshooting p.191
• Poor performance at low and idle speeds 20 3 p.191
• Engine lacks power 20 2 poor handling 20 4 p.191
• Engine does not start or is hard to start 20 1 poor performance at high speeds 20 4 p.191
• Troubleshooting p.192
• Engine lacks power p.192
• Poor performance at low and idle speeds p.193
• Troubleshooting p.193
• Troubleshooting p.194
• Poor performance at high speeds p.194
• Poor handling _ p.194