![Honda CBR600F2 (1991-1994) [93/196] Service information](/img/pdf.png)
Honda CBR600F2 (1991-1994) [93/196] Service information
![Honda CBR600F2 (1991-1994) [93/196] Service information](/views2/1121105/page93/bg5d.png)
Содержание
- Brake system 2
- C c ш 2
- Charging system alternator 2
- Clutch gearshift linkage 2
- Cooling system 2
- Crankcase cylinder piston 2
- Crankshaft transmission 2
- Cylinder head 2
- Electric starter starter clutch 2
- Engine removal installation 2
- Frame body panels exhaust system 2
- Front wheel suspension steering 2
- Fuel system 2
- General information 2
- Ignition system 2
- Introduction contents 2
- Lights meters switches 2
- Lubrication system 2
- Maintenance 2
- Rear wheel suspension 2
- Sbsbbsbbsesbm 2
- Troubleshooting 2
- Wiring diagram 2
- Important safety notice 3
- Symbols 4
- Finding the information you need 5
- How to use this manual 5
- Understanding the instructions 5
- Frame body panels exhaust system 6
- Service information 6
- Troubleshooting 6
- Frame body panels exhaust system 7
- Seat removal lnstallation 7
- Side cover removal lnstallation 7
- Frame body panels exhaust system 8
- Requisite service 8
- Side fairing removal installation 8
- Frame body panels exhaust system 10
- Requisite service 10
- Frame body panels exhaust system 11
- Front cowl disassembly assembly 11
- Requisite service 11
- Frame body panels exhaust system 12
- Rear fender b removal lnstallation 12
- Tail cowl removal lnstallation 12
- Frame body panels exhaust system 14
- Requisite service 14
- Exhaust system removal fnstallation 15
- Frame body panels exhaust system 15
- Requisite service 15
- Frame body panels exhaust system 16
- Fuel tank removal lnstallation 16
- Requisite service 16
- Maintenance 17
- Service information 17
- Maintenance 18
- Service access guide 18
- Maintenance 19
- Maintenance 20
- Maintenance schedule 20
- Air cleaner 21
- Inspection 21
- Maintenance 21
- Spark plug 21
- Valve clearance 21
- Maintenance 22
- Maintenance 23
- Maintenance 24
- Shim selection 24
- Carburetor synchronization 25
- Maintenance 25
- Maintenance 26
- Side stand 26
- Lubrication system 27
- Lubrication system diagram 4 2 oil cooler removal lnstallation 4 6 27
- Oil pan removal lnstallation 4 3 oil cooler disassembly assembly 4 7 27
- Service information 27
- Service information 4 1 oil pump removal lnstallation 4 4 27
- Troubleshooting 27
- Troubleshooting 4 1 oil pump disassembly assembly 4 5 27
- Lubrication system 29
- Oil pan removal lnstallation 29
- Requisite service 29
- Lubrication system 30
- Oil pump removal lnstallation 30
- Requisite service 30
- Requisite service 31
- Lubrication system 32
- Oil cooler removal lnstallation 32
- Requisite service 32
- Lubrication system 33
- Oil cooler disassembly assembly 33
- Requisite service 33
- Coolant draining 5 3 34
- Cooling system 34
- Radiator disassembly assembly 5 6 34
- Radiator removal lnstallation 5 5 34
- Reserve tank removal lnstallation 5 8 34
- Service information 34
- Service information 5 1 34
- System flow pattern 5 2 34
- Thermostat removal installation 5 4 34
- Troubleshooting 34
- Troubleshooting 5 1 34
- Water pump disassembly assembly 5 7 34
- Coolant draining 36
- Cooling system 36
- Cooling system 37
- Requisite service 37
- Thermostat removal lnstallation 37
- Cooling system 38
- Radiator removal installation 38
- Requisite service 38
- Cooling system 39
- Radiator disassembly assembly 39
- Requisite service 39
- Cooling system 40
- Requisite service 40
- Water pump disassembly assembly 40
- Cooling system 41
- Requisite service 41
- Reserve tank removal lnstallation 41
- Fuel system 42
- Service information 42
- Fuel system 43
- Toroubleshooting 43
- Air cleaner housing removal lnstallation 44
- Fuel system 44
- Requisite service 44
- Fuel system 46
- Requisite service 46
- Fuel system 48
- Requisite service 48
- Fuel system 50
- Jet needle holder removal lnstailation 50
- Requisite service 50
- Fuel system 52
- Requisite service 52
- California type only 53
- Fuel system 53
- Pulse secondary air injection pair control valve removal lnstallation 53
- Requisite service 53
- Evaporative emission evap canister removal lnstallation california type only 54
- Fuel system 54
- Requisite service 54
- Fuel system 55
- Idle drop procedure 55
- Pilot screw adjustment 55
- High altitude adjustment u s a only 56
- Engine removal lnstallation 57
- Service information 57
- Service information 7 1 engine removal lnstallation 7 2 57
- Engine removal lnstallation 59
- Requisite service 59
- Drive sprocket removal lnstallation 60
- Engine hanger adjusting bolt lock nut installation 60
- Engine removal lnstallation 60
- Camshaft removal lnstallation 8 2 61
- Cylinder head 61
- Service information 61
- Service information 8 1 cylinder head removal lnstallation 8 7 61
- Troubleshooting 61
- Troubleshooting 8 1 cylinder head disassembly assembly 8 8 61
- Cylinder head 63
- Requisite service 63
- Camshaft installation 64
- Cylinder head 64
- Cylinder head 65
- Cylinder head 66
- Cylinder head 67
- Cylinder head removal installation 67
- Requisite service 67
- Cylinder head 68
- Cylinder head disassembly assembly 68
- Requisite service 68
- Cylinder head 69
- Valve cotters removal lnstallation 69
- Clutch gearshift linkage 70
- Clutch removal 9 4 70
- Installation 9 2 clutch installation 9 12 70
- Right crankcase cover removal installation 9 10 70
- Service information 70
- Service information 9 1 gearshift linkage removal lnstallation 9 8 70
- Troubleshooting 70
- Troubleshooting 9 1 shift drum shift forks removal 70
- Ciutch gearshift linkage 72
- Requisite service 72
- Clutch gearshift linkage 74
- Requisite service 74
- Clutch center lock nut removal 75
- Clutch gearshift linkage 75
- Clutch outer removal 75
- Clutch gearshift linkage 76
- Clutch outer needle bearing replacement 76
- Clutch gearshift linkage 78
- Requisite service 78
- Clutch gearshift linkage 79
- Requisite service 79
- Shift drum shift forks removal lnstallation 79
- Clutch gearshift linkage 80
- Shift fork installation 80
- Clutch installation 81
- Clutch gearshift linkage 82
- Requisite service 82
- Clutch center lock nut installation 83
- Clutch gearshift linkage 83
- Clutch outer installation 83
- Clutch gearshift linkage 84
- Clutch lifter rod installation 84
- Crankcase cylinder piston 85
- Crankcase separation 10 2 crankcase assembly 10 6 85
- Service information 85
- Service information 10 1 piston connecting rod removal 85
- Troubleshooting 85
- Troubleshooting 10 1 installation 10 4 85
- Crankcase cy lindar piston 87
- Crankcase cylinder piston 89
- Requisite service 89
- Crankcase cylinder piston 91
- Crankcase bolt location 92
- Crankcase cylinder piston 92
- Liquid sealant application 92
- Crankshaft bearing replacement 11 4 93
- Crankshaft removal lnstallation 11 2 countershaft disassembly assembly 11 10 93
- Crankshafttransmission 93
- Service information 93
- Service information 11 1 transmission removal lnstallation 11 6 93
- Troubleshooting 93
- Troubleshooting 11 1 mainshaft disassembly assembly 11 8 93
- Crankshaft transmission 95
- Requisite service 95
- Connecting rod bearing selection 96
- Crankshaft bearing replacement 96
- Crankshaft transmission 96
- Main journal bearing selection 96
- C rankshaft t ransm i ssion 97
- Connecting rod selection 97
- L aaö b 97
- Starter clutch needle bearing replacement 97
- Crankshaft t ransmission 99
- Requisite service 99
- Crankshaft transmission 101
- Requisite service 101
- Crankshaft transmission 103
- Requisite service 103
- Crankshaft transmission 104
- Mainshaft bearing replacement 104
- Fork assembly 91 93 12 14 105
- Fork assembly after 93 12 16 105
- Fork disassembly 91 93 12 10 105
- Fork disassembly after 93 12 12 105
- Fork removal lnstallation 12 8 105
- Front wheel disassembly assembly 12 6 105
- Front wheel removal lnstallation 12 4 105
- Front wheel suspension steering 105
- Left handlebar removal lnstallation 12 3 105
- Right handlebar removal installation 12 2 105
- Service information 105
- Service information 12 1 105
- Steering stem removal lnstallation 12 18 105
- Troubleshooting 105
- Troubleshooting 12 1 105
- Front wheei suspension steering 106
- Requisite service 106
- Right handlebar removal installation 106
- Front wheel suspension steering 107
- Left handlebar removal lnstallation 107
- Front wheel suspension steering 109
- Requisite service 109
- Front wheel suspension steering 111
- Requisite service 111
- Front wheel suspension steering 113
- Requisite service 113
- Front whee suspensian steering 115
- Requisite service 115
- Front wheel suspension steering 117
- Requisite service 117
- Front wheel suspension steering 119
- Requisite service 119
- Front wheel suspension steering 121
- Requisite service 121
- Front wheel suspension steering 122
- Requisite service 122
- Steering stem removal lnstallation 122
- Bearing adjustment nut removal installation 123
- Front wheel suspension steering 123
- Front wheel suspension steering 124
- Assembly 125
- Installation 91 93 125
- Installation after 93 swingarm disassembly assembly 13 14 125
- Rear wheel disassembly assembly 1 3 3 suspension linkage disassembly 13 9 125
- Rear wheel removal installation 13 2 suspension linkage removal 13 8 125
- Rear wheel suspension 125
- Service information 125
- Service information 13 1 shock absorber disassembly 13 6 125
- Shock absorber removal 13 4 125
- Shock absorber removal 13 5 125
- Swingarm removal lnstabation 13 12 125
- Troubleshooting 125
- Troubleshooting 13 1 assembly 91 93 125
- Rear wheel removal lnstallation 126
- Rear wheel suspension 126
- Rear wheel disassembly assembly 127
- Rear wheel suspension 127
- Requisite service 127
- Rear wheel suspension 128
- Requisite service 128
- Shock absorber removal lnstallation 91 93 128
- Rear wheelsuspension 129
- Requisite service 129
- Shock absorber removal lnstallation after 93 129
- Rear wheel suspension 130
- Requisite service 130
- Shock absorber disassembly assembly 91 93 130
- Lower joint needle bearing replacement 131
- Rear wheel suspension 131
- Stopper ring removal fnstallation 131
- Rear wheel suspension 132
- Requisite service 132
- Suspension linkage removal lnstallation 132
- Rear wheelsuspension 133
- Requisite service 133
- Suspension linkage disassembly assembly 133
- Rear wheel suspension 134
- Suspension linkage pivot needle bearing replacement 134
- Rear wheelsuspension 137
- Requisite service 137
- Rear wheel suspension 139
- Requisite service 139
- Rear wheel suspension 140
- Swingarm pivot bearing replacement 140
- Brake system 141
- Front brake caliper disassembly assembly 14 6 141
- Front brake caliper removal installation 14 5 141
- Front master cylinder disassembly assembly 14 4 141
- Front master cylinder removal lnstallation 14 3 141
- Rear brake caliper disassembly assembly 14 12 141
- Rear brake caliper removal lnstallation 14 11 141
- Rear brake pad replacement 14 2 141
- Rear master cylinder disassembly assembly 14 10 141
- Rear master cylinder removal lnstallation 14 8 141
- Service information 141
- Service information 14 1 141
- Troubleshooting 141
- Troubleshooting 14 1 141
- Brake system 142
- Brake system 143
- Front master cylinder removal lnstallation 143
- Brake system 144
- Front master cylinder disassembly assembly 144
- Brake system 145
- Front brake caliper removal lnstallation 145
- _____________________________________________________ ____________ 147
- Brake system 149
- Requisite service 149
- Brake system 150
- Rear iwaste cylinde disassembly assembly 150
- Requisite service 150
- Brake system 151
- Rear brake caliper removal lnstallation 151
- Requisite service 151
- Rear brake caliper disassembly assembly 152
- Requisite service 152
- Battery removal lnstallation 15 4 charging coil inspection 15 11 153
- Charging system alternator 153
- Circuit diagram 15 2 alternator removal lnstallation 15 8 153
- Service information 153
- Service information 15 1 charging system inspection 15 6 153
- System location 15 2 regulator rectifier 15 7 153
- Troubleshooting 15 3 flywheel removal lnstallation 15 9 153
- Charging system alternator 155
- Troubleshooting 155
- Charging system alternator 157
- Requisite service 157
- Charging system inspection 158
- Charging systemalternatnr 158
- Charging voltage inspection 158
- Leak test 158
- Charging system alternator 159
- Regulator rectifier 159
- Unit inspection 159
- Wire harness inspection 159
- Alternator removal lnstallation 160
- Charging system alternator 160
- Requisite service 160
- Charging system alternator 161
- Flywheel removal lnstallation 161
- Requisite service 161
- Charging sy stem alternator 162
- Flywheel bolt removal lnstallation 162
- Starter clutch bolt removal lnstallation 162
- Charging coil inspection 163
- Charging system alternator 163
- Circuit diagram 16 2 ignition pulse generator 16 9 164
- Ignition system 164
- Ignition system inspection 16 6 ignition pulse generator rotor cover removal installation 16 10 164
- Service information 164
- Service information 16 1 ignition coil inspection 16 7 164
- System location 16 2 ignition coil removal lnstallation 16 8 164
- Troubleshooting 16 3 ignition timing 16 9 164
- Circuit diagram 165
- Ignition system 165
- System location 165
- Ignition system 166
- No spark at all plugs faulty input system 166
- Troubleshooting 166
- Ignition system 167
- No spark at either ignition group 167
- No spark at one plug trouble in secondary coil side 167
- Ignition system 168
- Circuit inspection 169
- Ignition system 169
- Ignition system inspection 169
- Ignition coil inspection 170
- Ignition system 170
- Ignition coil removal lnstallation 171
- Ignition system 171
- Requisite service 171
- Ignition pulse generator 172
- Ignition system 172
- Ignition timing 172
- Inspection 172
- Ignition pulse generator rotor cover removal lnstallation 173
- Ignition system 173
- Requisite service 173
- Circuit diagram 17 2 starter motor disassembly assembly 17 6 174
- Electric starter 174
- Service information 174
- Service information 17 1 t roubles hooti ng 17 3 174
- System location 17 2 starter motor removal lnstallation 17 5 174
- Circuit diagram 175
- Electric starter 175
- System location 175
- Electric starter 176
- Troubleshooting 176
- Electric starter 177
- Electric starter 178
- Requisite service 178
- Starter motor removal installation 178
- Electric starter 180
- Requisite service 180
- Combination meter bulb replacement 18 4 ignition switch removal lnstallation 18 8 181
- Combination meter removal installation 18 5 side stand switch 18 9 181
- Headlight bulb replacement 18 3 coolant temperature gauge inspection 18 8 181
- Lights meters switches 181
- Service information 181
- Service information 18 1 combination meter disassembly assembly 18 6 181
- System location 18 2 tachometer inspection 18 8 181
- Lig hts m eters sw itc h es 182
- System location 182
- Headlight bulb replacement 183
- Lights meters switches 183
- Combination meter bulb replacement 184
- Lights meters switches 184
- Combination meter removal lnstallation 185
- Lights meters switches 185
- Lights meters switches 187
- Requisite service 187
- Coolant temperature gauge 188
- Ignition switch removal installation 188
- Inspection 188
- Tachometer inspection 188
- Inspection 189
- Li g hts m ete rs s w i te h es 189
- Removal lnstallation 189
- Side stand switch 189
- Wiring diagram 190
- Engine does not start or is hard to start 191
- Engine does not start or is hard to start 20 1 poor performance at high speeds 20 4 191
- Engine lacks power 20 2 poor handling 20 4 191
- Poor performance at low and idle speeds 20 3 191
- Troubleshooting 191
- Engine lacks power 192
- Troubleshooting 192
- Poor performance at low and idle speeds 193
- Troubleshooting 193
- Poor handling _ 194
- Poor performance at high speeds 194
- Troubleshooting 194
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11 CrankshaftTransmission Service Information 11 1 Transmission Removal lnstallation 11 6 Troubleshooting 11 1 Mainshaft Disassembly Assembly 11 8 Crankshaft Removal lnstallation 11 2 Countershaft Disassembly Assembly Crankshaft Bearing Replacement 11 4 11 10 Service Information The crankcase must be separated to repair the transmission or crankshaft During crankshaft removal and installation do not damage the crankshaft main journal bearings All bearing inserts are select fitted and are identified by color code Select replacement bearings from the code tables After installing new bearings recheck them with piastigauge to verify clearance Apply molybdenum disulfide oil to the main journals and crankpins during assembly Troubleshooting Crankshaft Noisy Worn crankshaft main journal bearings Worn connecting rod bearings Bent connecting rod Hard To Shift Improper clutch adjustment Incorrect engine oil viscosity Improper clutch operation Bent shift forks Bent shift fork shaft Bent shift fork claw Damaged shift drum cam grooves Bent shift spindle Transmission Jumps Out Of Slots Worn gear engagement dogs or slots Bent shift fork shaft Damaged shift drum stopper arm Damaged or bent shift fork Broken shift linkage return spring Damaged shift drum cam grooves 11 1
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