Table Of Contents - Honda 1998 CB600Fw Shop Manual

Table of Contents

Important Safety Notice2
Type Code2
Contents3
Symbols4
General Information5
General Safety5
Carbon Monoxide5
Gasoline5
Service Rules6
Coolant6
Battery Hydrogen Gas & Electrolyte6
Model Identification7
Frame Serial Number7
Carburetor Identification Number7
Engine Serial Number7
Specifications8
Torque Values17
Cylinder Head Stud Bolt18
Connecting Tube Clamp18
Insulator Clamp18
Exhaust Pipe Joint Nut Tightening Sequence20
Tools21
Lubrication & Seal Points23
Cable & Harness Routing26
Emission Control Systems36
Source Of Emissions36
Crankcase Emission Control System36
Exhaust Emission Control System (Secondary Air Supply System)37
Noise Emission Control System38
Body Panel Locations39
Frame/Body Panels/Exhaust System Service Information40
Frame/Body Panels/Exhaust System Troubleshooting40
Frame/Body Panels/Exhaust System Torque Values40
Seat Removal41
Seat Installation41
Side Cover Removal41
Side Cover Installation41
Trim Clip Removal/Installation42
Rear Cowl Removal42
Rear Cowl Installation42
Fuel Tank Removal43
Fuel Tank Installation43
Front Fender Removal/Installation43
Rear Fender Removal44
Rear Fender Installation44
Muffler Removal/Installation44
Exhaust Pipe Removal/Installation45
Maintenance Service Information47
Maintenance Specifications47
Maintenance Schedule49
Fuel Line50
Throttle Operation50
Carburetor Choke51
Air Cleaner51
Spark Plug Removal51
Spark Plug Inspection52
Valve Clearance Inspection53
Reusing A Spark Plug53
Replacing A Spark Plug53
Valve Clearance Adjustment56
Engine Oil Level Inspection58
Engine Oil & Filter Change58
Recommended Engine Oil58
Carburetor Synchronization60
Engine Idle Speed61
Radiator Coolant62
Cooling System62
Secondary Air Supply System63
Drive Chain Slack Inspection63
Cleaning And Lubrication64
Sprockets Inspection65
Drive Chain Guide Plate Inspection67
Drive Chain Slider68
Brake Fluid68
Front Brake68
Rear Brake68
Brake Pad Wear69
Brake System Inspection69
Front Brake Pads69
Rear Brake Pads69
Brake Light Switch70
Headlight Aim70
Brake Pedal Height Adjustment70
Clutch System71
Side Stand71
Suspension72
Front Suspension Inspection72
Rear Suspension Inspection72
Nuts, Bolts, Fasteners73
Wheels/Tires73
Recommended Tire Pressure And Tire Size73
Steering Head Bearings74
Lubrication System Diagram75
Lubrication System Service Information76
Lubrication System Specifications76
Lubrication System Troubleshooting77
Lubrication System Torque Values77
Lubrication System Tools77
Engine Oil Level Too Low77
Oil Pressure Inspection78
Oil Strainer/Pressure Relief Valve79
Oil Pump Removal81
Oil Pump Disassembly81
Oil Pump Inspection81
Oil Pump Assembly82
Oil Pump Installation84
Oil Cooler Removal85
Oil Cooler Disassembly86
Oil Cooler Assembly86
Oil Cooler Installation88
Fuel System Service Information90
Fuel System Specifications91
Fuel System Torque Values91
Fuel System Tools91
Fuel System Troubleshooting92
Air Cleaner Housing Removal93
Air Cleaner Housing Installation94
Carburetor Removal97
Carburetor Separation98
Carburetor Disassembly100
Air Funnel100
Starting Enrichment Valve100
Diaphragm/Vacuum Piston101
Float And Jets102
Air Cut-Off Valve103
Carburetor Assembly104
Carburetor Combination109
Carburetor Installation113
Pilot Screw Adjustment114
Idle Drop Procedure114
Fuel Valve Inspection116
Fuel Valve Disassembly116
System Flow Pattern119
Cooling System Service Information120
Cooling System Specifications120
Cooling System Torque Values120
Cooling System Troubleshooting121
Cooling System Testing122
Coolant (Hydrometer Test)122
Coolant Specific Graavity122
Coolant Replacement123
Radiator Cap/System Pressure Inspection123
Thermostat Removal125
Thermostat Inspection126
Thermostat Installation127
Radiator Removal128
Cooling Fan Disassembly129
Cooling Fan Assembly130
Radiator Reserve Tank Removal/Installation133
Water Pump Mechanical Seal Inspection133
Engine Removal/Installation Service Information137
Engine Removal/Installation Service Data137
Engine Removal/Installation Torque Values137
Engine Removal138
Engine Installation142
Cylinder Head/Valves Service Information149
Cylinder Head/Valves Specifications150
Cylinder Head/Valves Torque Values150
Cylinder Head/Valves Troubleshooting151
Cylinder Head/Valves Tools151
Cylinder Compression Test152
Cylinder Head Cover Removal152
Camshaft Removal153
Camshaft Holder155
Camshaft Runout155
Cam Lobe Height155
Camshaft Oil Clearance155
Cylinder Head Removal156
Cam Chain Guide B156
Cylinder Head Disassembly158
Cylinder Head Inspection159
Cam Chain Tensioner/Cam Chain Guide160
Valve Spring160
Valve Lifter160
Valve Lifter Bore160
Valve/Valve Guide161
Valve Guide Replacement162
Valve Seat Inspection/Refacing163
Cylinder Head Assembly165
Cylinder Head Installation167
Camshaft Installation168
Cylinder Head Cover Installation171
Cam Chain Tensioner Lifter Removal173
Cam Chain Tensioner Lifter Installation173
Clutch/Gearshift Linkage Service Information176
Clutch/Gearshift Linkage Specifications176
Clutch/Gearshift Linkage Torque Values176
Clutch/Gearshift Linkage Tools176
Clutch/Gearshift Linkage Troubleshooting177
Hard To Shift177
Transmission Jumps Out Of Gear177
Gearshift Pedal Will Not Return177
Right Crankcase Cover Removal178
Clutch Lifter Inspection178
Clutch Removal179
Clutch Inspection180
Clutch Lifter Bearing180
Clutch Spring181
Clutch Disc181
Clutch Plate181
Clutch Center181
Clutch Outer182
Judder Spring/Spring Seat182
Clutch Outer Guide182
Mainshaft182
Clutch Outer Needle Bearing Replacement183
Clutch Lifter Rod183
Gearshift Linkage Removal186
Gearshift Linkage Inspection187
Gearshift Linkage Installation187
Right Crankcase Cover Installation189
Alternator/Starter Clutch190
Alternator/Starter Clutch Service Information191
Alternator/Starter Clutch Specifications191
Alternator/Starter Clutch Torque Values191
Alternator/Starter Clutch Troubleshooting191
Alternator Cover Removal192
Stator Removal193
Stator Installation193
Flywheel Removal194
Starter Clutch Inspection195
Starter Clutch Disassembly195
Starter Clutch Assembly196
Flywheel Installation198
Alternator Cover Installation199
Crankcase/Piston/Cylinder Service Information202
Crankcase/Piston/Cylinder Troubleshooting203
Crankcase/Piston/Cylinder Specifications203
Crankcase/Piston/Cylinder Torque Values203
Crankcase Separation204
Piston/Connecting Rod Removal205
Piston Removal205
Piston Disassembly206
Piston Inspection206
Cylinder Inspection207
Connecting Rod Inspection208
Crank Pin Bearing Inspection209
Crank Pin Bearing Selection209
Crank Pin Bearing Selection Table210
Piston Assembly211
Piston Installation211
Crankcase Combination212
Crankshaft/Transmission216
Crankshaft/Transmission Service Information217
Crankshaft/Transmission Specifications217
Crankshaft/Transmission Troubleshooting218
Crankshaft/Transmission Torque Values218
Crankshaft/Transmission Tools218
Excessive Noise218
Crankshaft Removal219
Crankshaft Inspection219
Crankshaft Runout219
Main Journal Bearing220
Main Journal Bearing Selection221
Main Journal Bearing Selection Table221
Starter Clutch Needle Bearing Replacement222
Transmission Removal/Disassembly223
Mainshaft Bearing Replacement226
Front Wheel/Suspension/Steering231
Front Wheel/Suspension/Steering Service Information232
Front Wheel/Suspension/Steering Specifications232
Front Wheel/Suspension/Steering Torque Values233
Front Wheel/Suspension/Steering Tools233
Front Wheel/Suspension/Steering Troubleshooting233
Handlebar Removal234
Handlebar Installation236
Handlebar Weight Replacement237
Front Wheel Removal240
Front Wheel Inspection242
Axle242
Wheel Bearing242
Wheel Rim Runout242
Front Wheel Disassembly243
Front Wheel Assembly244
Front Wheel Installation245
Fork Removal247
Fork Disassembly248
Fork Inspection250
Fork Tube/Slider/Piston251
Fork Tube Bushing251
Fork Assembly252
Recommended Fork Fluid254
Fork Fluid Capacity254
Fork Installation255
Steering Stem Removal256
Steering Stem Bearing Replacement258
Steering Head Bearing Preload263
Rear Wheel/Suspension Service Information265
Rear Wheel/Suspension Specifications265
Rear Wheel/Suspension Torque Values265
Rear Wheel/Suspension Troubleshooting266
Rear Wheel/Suspension Tools266
Rear Wheel Removal267
Rear Wheel Inspection268
Rear Wheel Disassembly269
Rear Wheel Assembly270
Driven Flange Bearing Removal270
Wheel Bearing Removal270
Wheel Bearing Installation271
Driven Flange Bearing Installation271
Rear Wheel Installation273
Shock Absorber Removal274
Shock Absorber Inspection275
Shock Absorber Disposal Procedure275
Shock Absorber Installation276
Swingarm Removal276
Swingarm Disassembly/Inspection278
Pivot Bearing Replacement279
Shock Link Pivot Bearing Replacement280
Swingarm Assembly281
Swingarm Installation282
Hydraulic Brake285
Hydraulic Brake Service Information287
Hydraulic Brake Specifications287
Hydraulic Brake Torque Values288
Hydraulic Brake Tools288
Hydraulic Brake Troubleshooting288
Brake Fluid Replacement/Air Bleeding289
Brake Fluid Draining289
Brake Fluid Filling289
Blade Bleeding290
Brake Pad/Disc291
Front Brake Pad Replacement291
Rear Brake Pad Replacement292
Brake Disc Inspection294
Front Master Cylinder Removal294
Front Master Cylinder Disassembly295
Front Master Cylinder Inspection296
Front Master Cylinder Assembly296
Rear Master Cylinder Removal298
Rear Master Cylinder Disassembly299
Rear Master Cylinder Inspection300
Rear Master Cylinder Assembly300
Rear Master Cylinder Installation302
Front Brake Caliper Removal303
Front Brake Caliper Disassembly303
Front Brake Caliper Inspection304
Front Brake Caliper Assembly304
Front Brake Caliper Installation305
Rear Brake Caliper Removal306
Rear Brake Caliper Disassembly306
Rear Brake Caliper Inspection307
Rear Brake Caliper Assembly307
Rear Brake Caliper Installation308
Brake Pedal Removal309
Brake Pedal Installation309
Battery/Charging System Diagram311
Battery/Charging System Service Information312
Battery/Charging System Specifications313
Battery/Charging System Troubleshooting314
Battery Undercharging314
Battery Overcharging315
Battery Removal/Installation316
Battery Voltage Inspection316
Battery Charging316
Charging System Inspection317
Regulated Voltage Inspection317
Current Leakage Inspection318
Alternator Inspection319
Regulator/Rectifier Inspection319
Regulator/Rectifier Removal/Installation320
Regulator/Rectifier System Diagram321
Ignition System Service Information322
Ignition System Specifications322
Ignition System Torque Values323
Ignition System Tools323
Ignition System Troubleshooting324
No Spark At All Plugs324
Ignition System Inspection325
Ignition Coil Primary Peak Voltage325
Ignition Pulse Generator Peak Voltage326
Ignition Coil Removal/Installation327
Ignition Pulse Generator Rotor Removal328
Ignition Pulse Generator Rotor Installation329
Throttle Sensor Operation Inspection331
Throttle Sensor System Inspection331
Ignition Control Module Removal/Installation332
Ignition Timing333
Electric Starter System Diagram335
Electric Starter Service Information336
Electric Starter Troubleshooting337
Starter Motor Does Not Turn337
Starter Motor Turns Engine Slowly338
Starter Motor Turns, But Engine Does Not Turn338
Starter Relay Switch "Clicks", But Engine Does Not Turn Over338
Starter Motor Removal339
Starter Motor Disassembly339
Starter Motor Inspection339
Starter Motor Assembly342
Starter Motor Installation344
Starter Relay Switch Operation Inspection345
Starter Relay Switch Ground Line Inspection345
Starter Relay Switch Voltage Inspection345
Starter Relay Switch Continuity Inspection346
Diode Removal346
Diode Inspection346
Lights/Meters/Switches System Location347
Lights/Meters/Switches Service Information348
Lights/Meters/Switches Specifications349
Lights/Meters/Switches Torque Values349
Headlight Bulb Replacement350
Headlight Case Removal/Installation351
Position Light Bulb Replacement351
Turn Signal Bulb Replacement351
Tail/Brake Light Bulb Replacement352
Combination Meter Removal352
Tachometer Inspection356
Coolant Temperature Gauge/Sensor Inspection357
Thermo Sensor Unit Inspection357
Coolant Fan Motor Switch Inspection358
Fan Motor Does Not Stop358
Fan Motor Does Not Start358
Oil Pressure Switch Inspection359
Ignition Switch Inspection360
Ignition Switch Removal/Installation360
Handlebar Switches361
Clutch Switch362
Neutral Switch362
Side Stand Switch Inspection363
Side Stand Switch Removal/Installation363
Horn364
Turn Signal Relay Inspection364
Troubleshooting367
Engine Does Not Start Or Is Hard To Start367
Engine Lacks Power368
Poor Performance At Low And Idle Speed369
Poor Performance At High Speed370
Poor Handling370
Index371