Shock Absorber Disassembly Assembly 91

The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Before disposal of shock absorber, release the nitrogen. (Step section 19 of the Common Service Manual Drilling point page 1-11) Shock absorber removal installation (page 13-4) Shock absorber removal installation (page 13-4) Assembly is in the reverse order of disassembly. Refer to page 1 3-7 for replacement. Refer to page 13-7 for removal and installation Install the spring guide...

Ignition System Inspection

Follow the steps in the troubleshooting flow chart for servicing. _ Remove the right side cover (page 2-2). Disconnect the ignition control module connector and co Battery voltage should register with the ignition switch ON and the engine stop switch at RUN. No. 1-4 Black,'White and Yellow Buie No continuity in any gear except neutral Cotinuity with the side stand retracted No continuity with the side stand down

Crankshaft Bearing Replacement

Crankshaft Max Bearing Code

Record the crankcase I D. code letters stamped on the left side of the upper crankcase. Letters (A, 6 or C (on the upper crankcase are the codes for the main journal I.D.s from the left side. Record the corresponding main journal O.D. code numbers Numbers (1 or 2)on the crank weight are the codes for the main journal O D.s from the left. Cross reference the case and journal codes to determine the replacement bearing color code 36.008 36.01 6 mil 1.41761.4180 in) 32.992-33.000 ran (1...

Front Brake Caliper Removal Installation

Do not get grease on the brake disc or stopping power will be reduced. Discard contaminated pads and clean a contaminated disc with a high quality brake decreasing agent, Check the brake system by applying the brake after pad replacement.___ - Operate the brake lever to seat the caliper pistons against the pads after the pad replacement. . Brake pad replacement can be done without disconnecting the hydraulic system. . Always replace the brake pads in pairs to assure even disc pressure. . if...

High Altitude Adjustment USA Only

07kma Mn90100

When the vehicle is to be operated continuously above 2,000 m 6,500 feet , the carburetor must be readjusted as follows to improve driveability and decrease exhaust emissions. Warm up the engine to operating temperature. Stop and go riding for 10 minutes is sufficient. Turn each pilot screw to the Highi Attitude Setting specified below. 1 PILOT SCREW 2 PILOT SCREW 1 PILOT SCREW 2 PILOT SCREW Pilot screw wrench 07KMA-MN90100 or Adjust the idle speed to 1,200 100 rpm California 1,400 100 rpm with...

Why Do Shift Forks Have Center Left And Right

07jmb Mn50300

Damaged, kinked or dirty clutch cable Oamaged clutch lifter mechanism Faulty clutch lifter bearing Clutch lifter rod installed inproperly Clutch Will Not Disengage Or Vehicle Creeps With Clutch Disengaged Too much clutch lever free play Oil level too high, improper oil viscosity or oil additive used - Damaged cluch lifter mechanism - Clutch lifter rod Installed improperly Damaged shift drum cam grooves Worn gear engagement dogs or slots Right Crankcase Cover Removal Installation Side fairing...

Clutch Installation

Right crankcase cover installation page 9-2 Needle bearing Clutch outer Clutch outer guide Thrust washer Clutch pressure plate Clutch center lock nut Clutch spring Radial ball bearing 16001 Stopper ring Clutch lifter rod Clutch lifter plate Clutch lifter plate bolt Refer to page 9-6 for replacement. Refer to page 9-14 for installation. Align the punch marks on the clutch center and clutch pressure plate - Install the cone washer with the OUT SIDE mark facing out. Refer to page 9-14 for...

Camshaft Installation

Honda Cbr 600 1991

Remove the ignition pulse generator rotor cover cap. Align, the T mark notch mark with the index mark on the ignition pulse generator rotor cover by turning the crankShaft clockwise. Apply molybdenum disulfide oil a 50 50 mixture of engine oil and molybdenum disulfide grease to the cam shaft journals of the cylider head and camshaft holders. Install each camshaft to the correct side Each camshaft has an identification mark IN is for the intake side and EX is for the exhaust side Install the...

Requisite Service

Cbr 1100 Front Cowl

Side fairing removal instalation page 2-3 Side fairing removal instalation page 2-3 Front turn signal connector 3P mini Align the basses on the headlight case with the grommets. Front turn signal connector 3P mini Instal the right seat rubber with the mark MT4-R facing in. Install the left seat rubber with the mark MT4-L facing in. Install the right plate with the marked side in and each arrow Install the left plate with the marked side out and each arrow Front cowl removal installation page...

Pilot Screw Adjustment

07kma Mn90100

If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Make sure the carburetor synchronization is within specification before pilot screw adjustment see page 1-6 . The pilot screws are factory pre-setand no adjustment is necessary unless the pilot screws are replaced. Use a tachometer with graduations of 50 rpm...

Service Information

Gasoline is extremely flammable and is explosive under certain conditions, KEEP OUT OF REACH OF Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control. ________ Work in a well ventilated area. Smoking or allowing flames in the work or where gasoline is stored can cause a fire or explosion. Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms might...

Side Cover Removal Installation

Unlock the quick release fasteners by aligning the long slot with the punch mark. Remove the side cover by releasing the bosses or the cover from the grommets. Be careful not to break the pins, tabs and slots in the side cower ant tail cowl when removing the side cover. Install the side cover signing its bosses with the grommets and engage the tabs with the slots, and pins with the holes securely as shown. Lock the clip by aligning the A mark with the punch mark. Do the same on the other side.

Jet Needle Holder Removal Installation

Screw a proper 4 mm thread screw in the jet needle holder as shown and pull out the jet needle holder with a pliers. NOTE 3e careful not damage the diaphragm. Do not remove the jet needle holder by pushing in the jet needle. Install the jet needle holder In the reverse order of removal. NOTE Push the jet needle holder in until the 0-ring on the holder seats completely In the groove in the vacuum piston.

Shim Selection

Remove the valve lifter and shims page 8-2 . Do not allow shims to fall into the crankcase The shim s may occasionally stick to the valve lifter Mark the positions of all valve lifters and shims to ensure correct reassembly. It Is easy to remove the valve lifter with a valve lapping too or magnet. Remove the shims with tweezers or a magnet. Clean the valve lifter with compressed air. Measure the shim thickness with a micrometer and record it, Sixty-five different shims are available in...

Coolant Draining

Wait until the engine is cool before servicing the cooling system. Removing the radiator cap while the engine is hot and the coolant is under pressure may serious scalding. For coolant replacement, refer to section 5 of the Common Service Manual Remove the left side fairing page 2-3 . Remove the water pump drain bolt and sealing washer. Remove the radiator cap and drain the coolant. Place a suitable tray under the siphon tube joint of the reserve tank and disconnect the siphon tube from the...

Service Access Guide

Honda Cbr Petrol Reserve

The following shows the locations of the parts that must be removed for the maintenance items listed beiow. Refer to the Common Service Manual for items not included in this manual. Refer to section 2 Frame Body Panels Exhaust System for the parts that must be removed for service For exampleiAIR CLEANER Contamination, clogging, replacement Parts Fuel tank-------The parts must be removed for service- Reserve Tank Cap Coolant fiHingl Riylit side cover Level check, fluid replacement Right side...

Carburetor Synchronization

Honda Cbr 600 Del 2000

Refer to section 2 of the Common Service Manual for carburetor synchronization procedure Synchronize the carburetors with the engine at normal operating temperature and the transmission in neutral. - No. 2 carburetor is the base carburetor. Disconnect the fuel valve vacuum tube from the No. 1 Remove the rubber cap from the No. 2 carburetor vacuum Remove the rubber cap by pinching the end of the cap. Do not pinch the cap body or it will be damaged. Remove the vacuum plugs from the No.3 and No.4...

Inspection

Cbr 250 Timing Marks

Adjust the valve clearance while the engine is cold below 35 C 95 F . Remove the air cleaner housing base page 6-3 . Remove the radiator mounting bolts and release the grommet on the radiator top from the boss on the frame. Move the radiator forward and secure it to the fork tubes with pieces of string as shown. Remove the ignition pulse generator rotor cover cap. Remove the cylinder head cover page 8-2 . Align the T mark notch mark with the index mark on the ignition pulse generator rotor...

Korn s Bookshop

Bottom View Cbr 600 Frame Diagram

Thank you for purchasing an e-book through Korn's Bookshop. If you have any problems or questions you can get in touch with me via email on books kornel.com. I hope you are satisfied with your purchase and enjoy your book, happy reading Check out my other great books by visiting Korn's Bookshop on eBay. You may not copy, reproduce or redistribute this e-book in any form for commercial purposes. You are hereby granted a licence to read, store and print this book for personal use only. If you...