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1998 CB600Fw
Honda 1998 CB600Fw Manuals
Manuals and User Guides for Honda 1998 CB600Fw. We have
1
Honda 1998 CB600Fw manual available for free PDF download: Shop Manual
Honda 1998 CB600Fw Shop Manual (373 pages)
Brand:
Honda
| Category:
Motorcycle
| Size: 89.74 MB
Table of Contents
Important Safety Notice
2
Type Code
2
Contents
3
Symbols
4
General Information
5
General Safety
5
Carbon Monoxide
5
Gasoline
5
Service Rules
6
Coolant
6
Battery Hydrogen Gas & Electrolyte
6
Model Identification
7
Frame Serial Number
7
Carburetor Identification Number
7
Engine Serial Number
7
Specifications
8
Torque Values
17
Cylinder Head Stud Bolt
18
Connecting Tube Clamp
18
Insulator Clamp
18
Exhaust Pipe Joint Nut Tightening Sequence
20
Tools
21
Lubrication & Seal Points
23
Cable & Harness Routing
26
Emission Control Systems
36
Source of Emissions
36
Crankcase Emission Control System
36
Exhaust Emission Control System (Secondary Air Supply System)
37
Noise Emission Control System
38
Body Panel Locations
39
Frame/Body Panels/Exhaust System Service Information
40
Frame/Body Panels/Exhaust System Troubleshooting
40
Frame/Body Panels/Exhaust System Torque Values
40
Seat Removal
41
Seat Installation
41
Side Cover Removal
41
Side Cover Installation
41
Trim Clip Removal/Installation
42
Rear Cowl Removal
42
Rear Cowl Installation
42
Fuel Tank Removal
43
Fuel Tank Installation
43
Front Fender Removal/Installation
43
Rear Fender Removal
44
Rear Fender Installation
44
Muffler Removal/Installation
44
Exhaust Pipe Removal/Installation
45
Maintenance Service Information
47
Maintenance Specifications
47
Maintenance Schedule
49
Fuel Line
50
Throttle Operation
50
Carburetor Choke
51
Air Cleaner
51
Spark Plug Removal
51
Spark Plug Inspection
52
Valve Clearance Inspection
53
Reusing a Spark Plug
53
Replacing a Spark Plug
53
Valve Clearance Adjustment
56
Engine Oil Level Inspection
58
Engine Oil & Filter Change
58
Recommended Engine Oil
58
Carburetor Synchronization
60
Engine Idle Speed
61
Radiator Coolant
62
Cooling System
62
Secondary Air Supply System
63
Drive Chain Slack Inspection
63
Cleaning and Lubrication
64
Sprockets Inspection
65
Drive Chain Guide Plate Inspection
67
Drive Chain Slider
68
Brake Fluid
68
Front Brake
68
Rear Brake
68
Brake Pad Wear
69
Brake System Inspection
69
Front Brake Pads
69
Rear Brake Pads
69
Brake Light Switch
70
Headlight Aim
70
Brake Pedal Height Adjustment
70
Clutch System
71
Side Stand
71
Suspension
72
Front Suspension Inspection
72
Rear Suspension Inspection
72
Nuts, Bolts, Fasteners
73
Wheels/Tires
73
Recommended Tire Pressure and Tire Size
73
Steering Head Bearings
74
Lubrication System Diagram
75
Lubrication System Service Information
76
Lubrication System Specifications
76
Lubrication System Troubleshooting
77
Lubrication System Torque Values
77
Lubrication System Tools
77
Engine Oil Level too Low
77
Oil Pressure Inspection
78
Oil Strainer/Pressure Relief Valve
79
Oil Pump Removal
81
Oil Pump Disassembly
81
Oil Pump Inspection
81
Oil Pump Assembly
82
Oil Pump Installation
84
Oil Cooler Removal
85
Oil Cooler Disassembly
86
Oil Cooler Assembly
86
Oil Cooler Installation
88
Fuel System Service Information
90
Fuel System Specifications
91
Fuel System Torque Values
91
Fuel System Tools
91
Fuel System Troubleshooting
92
Air Cleaner Housing Removal
93
Air Cleaner Housing Installation
94
Carburetor Removal
97
Carburetor Separation
98
Carburetor Disassembly
100
Air Funnel
100
Starting Enrichment Valve
100
Diaphragm/Vacuum Piston
101
Float and Jets
102
Air Cut-Off Valve
103
Carburetor Assembly
104
Carburetor Combination
109
Carburetor Installation
113
Pilot Screw Adjustment
114
Idle Drop Procedure
114
Fuel Valve Inspection
116
Fuel Valve Disassembly
116
System Flow Pattern
119
Cooling System Service Information
120
Cooling System Specifications
120
Cooling System Torque Values
120
Cooling System Troubleshooting
121
Cooling System Testing
122
Coolant (Hydrometer Test)
122
Coolant Specific Graavity
122
Coolant Replacement
123
Radiator Cap/System Pressure Inspection
123
Thermostat Removal
125
Thermostat Inspection
126
Thermostat Installation
127
Radiator Removal
128
Cooling Fan Disassembly
129
Cooling Fan Assembly
130
Radiator Reserve Tank Removal/Installation
133
Water Pump Mechanical Seal Inspection
133
Engine Removal/Installation Service Information
137
Engine Removal/Installation Service Data
137
Engine Removal/Installation Torque Values
137
Engine Removal
138
Engine Installation
142
Cylinder Head/Valves Service Information
149
Cylinder Head/Valves Specifications
150
Cylinder Head/Valves Torque Values
150
Cylinder Head/Valves Troubleshooting
151
Cylinder Head/Valves Tools
151
Cylinder Compression Test
152
Cylinder Head Cover Removal
152
Camshaft Removal
153
Camshaft Holder
155
Camshaft Runout
155
Cam Lobe Height
155
Camshaft Oil Clearance
155
Cylinder Head Removal
156
Cam Chain Guide B
156
Cylinder Head Disassembly
158
Cylinder Head Inspection
159
Cam Chain Tensioner/Cam Chain Guide
160
Valve Spring
160
Valve Lifter
160
Valve Lifter Bore
160
Valve/Valve Guide
161
Valve Guide Replacement
162
Valve Seat Inspection/Refacing
163
Cylinder Head Assembly
165
Cylinder Head Installation
167
Camshaft Installation
168
Cylinder Head Cover Installation
171
Cam Chain Tensioner Lifter Removal
173
Cam Chain Tensioner Lifter Installation
173
Clutch/Gearshift Linkage Service Information
176
Clutch/Gearshift Linkage Specifications
176
Clutch/Gearshift Linkage Torque Values
176
Clutch/Gearshift Linkage Tools
176
Clutch/Gearshift Linkage Troubleshooting
177
Hard to Shift
177
Transmission Jumps out of Gear
177
Gearshift Pedal will Not Return
177
Right Crankcase Cover Removal
178
Clutch Lifter Inspection
178
Clutch Removal
179
Clutch Inspection
180
Clutch Lifter Bearing
180
Clutch Spring
181
Clutch Disc
181
Clutch Plate
181
Clutch Center
181
Clutch Outer
182
Judder Spring/Spring Seat
182
Clutch Outer Guide
182
Mainshaft
182
Clutch Outer Needle Bearing Replacement
183
Clutch Lifter Rod
183
Gearshift Linkage Removal
186
Gearshift Linkage Inspection
187
Gearshift Linkage Installation
187
Right Crankcase Cover Installation
189
Alternator/Starter Clutch
190
Alternator/Starter Clutch Service Information
191
Alternator/Starter Clutch Specifications
191
Alternator/Starter Clutch Torque Values
191
Alternator/Starter Clutch Troubleshooting
191
Alternator Cover Removal
192
Stator Removal
193
Stator Installation
193
Flywheel Removal
194
Starter Clutch Inspection
195
Starter Clutch Disassembly
195
Starter Clutch Assembly
196
Flywheel Installation
198
Alternator Cover Installation
199
Crankcase/Piston/Cylinder Service Information
202
Crankcase/Piston/Cylinder Troubleshooting
203
Crankcase/Piston/Cylinder Specifications
203
Crankcase/Piston/Cylinder Torque Values
203
Crankcase Separation
204
Piston/Connecting Rod Removal
205
Piston Removal
205
Piston Disassembly
206
Piston Inspection
206
Cylinder Inspection
207
Connecting Rod Inspection
208
Crank Pin Bearing Inspection
209
Crank Pin Bearing Selection
209
Crank Pin Bearing Selection Table
210
Piston Assembly
211
Piston Installation
211
Crankcase Combination
212
Crankshaft/Transmission
216
Crankshaft/Transmission Service Information
217
Crankshaft/Transmission Specifications
217
Crankshaft/Transmission Troubleshooting
218
Crankshaft/Transmission Torque Values
218
Crankshaft/Transmission Tools
218
Excessive Noise
218
Crankshaft Removal
219
Crankshaft Inspection
219
Crankshaft Runout
219
Main Journal Bearing
220
Main Journal Bearing Selection
221
Main Journal Bearing Selection Table
221
Starter Clutch Needle Bearing Replacement
222
Transmission Removal/Disassembly
223
Mainshaft Bearing Replacement
226
Front Wheel/Suspension/Steering
231
Front Wheel/Suspension/Steering Service Information
232
Front Wheel/Suspension/Steering Specifications
232
Front Wheel/Suspension/Steering Torque Values
233
Front Wheel/Suspension/Steering Tools
233
Front Wheel/Suspension/Steering Troubleshooting
233
Handlebar Removal
234
Handlebar Installation
236
Handlebar Weight Replacement
237
Front Wheel Removal
240
Front Wheel Inspection
242
Axle
242
Wheel Bearing
242
Wheel Rim Runout
242
Front Wheel Disassembly
243
Front Wheel Assembly
244
Front Wheel Installation
245
Fork Removal
247
Fork Disassembly
248
Fork Inspection
250
Fork Tube/Slider/Piston
251
Fork Tube Bushing
251
Fork Assembly
252
Recommended Fork Fluid
254
Fork Fluid Capacity
254
Fork Installation
255
Steering Stem Removal
256
Steering Stem Bearing Replacement
258
Steering Head Bearing Preload
263
Rear Wheel/Suspension Service Information
265
Rear Wheel/Suspension Specifications
265
Rear Wheel/Suspension Torque Values
265
Rear Wheel/Suspension Troubleshooting
266
Rear Wheel/Suspension Tools
266
Rear Wheel Removal
267
Rear Wheel Inspection
268
Rear Wheel Disassembly
269
Rear Wheel Assembly
270
Driven Flange Bearing Removal
270
Wheel Bearing Removal
270
Wheel Bearing Installation
271
Driven Flange Bearing Installation
271
Rear Wheel Installation
273
Shock Absorber Removal
274
Shock Absorber Inspection
275
Shock Absorber Disposal Procedure
275
Shock Absorber Installation
276
Swingarm Removal
276
Swingarm Disassembly/Inspection
278
Pivot Bearing Replacement
279
Shock Link Pivot Bearing Replacement
280
Swingarm Assembly
281
Swingarm Installation
282
Hydraulic Brake
285
Hydraulic Brake Service Information
287
Hydraulic Brake Specifications
287
Hydraulic Brake Torque Values
288
Hydraulic Brake Tools
288
Hydraulic Brake Troubleshooting
288
Brake Fluid Replacement/Air Bleeding
289
Brake Fluid Draining
289
Brake Fluid Filling
289
Blade Bleeding
290
Brake Pad/Disc
291
Front Brake Pad Replacement
291
Rear Brake Pad Replacement
292
Brake Disc Inspection
294
Front Master Cylinder Removal
294
Front Master Cylinder Disassembly
295
Front Master Cylinder Inspection
296
Front Master Cylinder Assembly
296
Rear Master Cylinder Removal
298
Rear Master Cylinder Disassembly
299
Rear Master Cylinder Inspection
300
Rear Master Cylinder Assembly
300
Rear Master Cylinder Installation
302
Front Brake Caliper Removal
303
Front Brake Caliper Disassembly
303
Front Brake Caliper Inspection
304
Front Brake Caliper Assembly
304
Front Brake Caliper Installation
305
Rear Brake Caliper Removal
306
Rear Brake Caliper Disassembly
306
Rear Brake Caliper Inspection
307
Rear Brake Caliper Assembly
307
Rear Brake Caliper Installation
308
Brake Pedal Removal
309
Brake Pedal Installation
309
Battery/Charging System Diagram
311
Battery/Charging System Service Information
312
Battery/Charging System Specifications
313
Battery/Charging System Troubleshooting
314
Battery Undercharging
314
Battery Overcharging
315
Battery Removal/Installation
316
Battery Voltage Inspection
316
Battery Charging
316
Charging System Inspection
317
Regulated Voltage Inspection
317
Current Leakage Inspection
318
Alternator Inspection
319
Regulator/Rectifier Inspection
319
Regulator/Rectifier Removal/Installation
320
Regulator/Rectifier System Diagram
321
Ignition System Service Information
322
Ignition System Specifications
322
Ignition System Torque Values
323
Ignition System Tools
323
Ignition System Troubleshooting
324
No Spark at All Plugs
324
Ignition System Inspection
325
Ignition Coil Primary Peak Voltage
325
Ignition Pulse Generator Peak Voltage
326
Ignition Coil Removal/Installation
327
Ignition Pulse Generator Rotor Removal
328
Ignition Pulse Generator Rotor Installation
329
Throttle Sensor Operation Inspection
331
Throttle Sensor System Inspection
331
Ignition Control Module Removal/Installation
332
Ignition Timing
333
Electric Starter System Diagram
335
Electric Starter Service Information
336
Electric Starter Troubleshooting
337
Starter Motor Does Not Turn
337
Starter Motor Turns Engine Slowly
338
Starter Motor Turns, but Engine Does Not Turn
338
Starter Relay Switch "Clicks", but Engine Does Not Turn over
338
Starter Motor Removal
339
Starter Motor Disassembly
339
Starter Motor Inspection
339
Starter Motor Assembly
342
Starter Motor Installation
344
Starter Relay Switch Operation Inspection
345
Starter Relay Switch Ground Line Inspection
345
Starter Relay Switch Voltage Inspection
345
Starter Relay Switch Continuity Inspection
346
Diode Removal
346
Diode Inspection
346
Lights/Meters/Switches System Location
347
Lights/Meters/Switches Service Information
348
Lights/Meters/Switches Specifications
349
Lights/Meters/Switches Torque Values
349
Headlight Bulb Replacement
350
Headlight Case Removal/Installation
351
Position Light Bulb Replacement
351
Turn Signal Bulb Replacement
351
Tail/Brake Light Bulb Replacement
352
Combination Meter Removal
352
Tachometer Inspection
356
Coolant Temperature Gauge/Sensor Inspection
357
Thermo Sensor Unit Inspection
357
Coolant Fan Motor Switch Inspection
358
Fan Motor Does Not Stop
358
Fan Motor Does Not Start
358
Oil Pressure Switch Inspection
359
Ignition Switch Inspection
360
Ignition Switch Removal/Installation
360
Handlebar Switches
361
Clutch Switch
362
Neutral Switch
362
Side Stand Switch Inspection
363
Side Stand Switch Removal/Installation
363
Horn
364
Turn Signal Relay Inspection
364
Troubleshooting
367
Engine Does Not Start or Is Hard to Start
367
Engine Lacks Power
368
Poor Performance at Low and Idle Speed
369
Poor Performance at High Speed
370
Poor Handling
370
Index
371
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