Lubrication Seal Points

ENGINE

LOCATION

MATERIAL

REMARKS

Oil pan mating surface Cylinder head semi-circuler area Right crankcase cover mating surface Crankcase mating surfaces (right side) Crankcase mating surfaces (left side) Crankcase mating surface Oil pressure switch threads Thermosensor threads

Sealant

See page 9-14 See page 10-2 See page 11-11 See page 4-4

Do not apply to the sensor head. See page 6-13

Water pump shaft spindle and thrust washer sliding surface

Cylinder head 9 mm bolt threads and seating surface

Valve stem sliding surface

Valve lifter outer surface

Camshaft journals and cam lobes

Clutch outer guide sliding surfaces

Starter reduction gear shaft outer surface

M3/4, C5, C6 gear shift fork grooves

Connecting rod small end inner surface

Piston pin outer surface

Crankpin bearing sliding surface

Crankshaft main journal bearing sliding surface

Primary drive sub-gear sliding surfaces

Crankshaft thrust surfaces

Molybdenum oil solution (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide grease)

See page 12-5

Engine oil filter cartridge threads and seating surface Oil cooler bolt (filter boss) threads and seating surface Cylinder head bolt threads and seating surface Camshaft holder bolt threads and seating surface Clutch disc lining surfaces

Clutch center Inr.k nut threads and seating surface Starter sprag clutch contacting surfaces Flywheel bolt threads and seating surface Piston outer surface Pislun ring whole surfaces

Connecting rod bearing cap nut threads and seating surface

Crankcase bolt (main journal 8 mm) threads

Each gear teeth and rotating surface

Each bearing rotating area

Each O-ring and packing whole surface

Other rotating and sliding area_

Engine oil

Timing hole cap threads

Carburetor synchronization adjusting screw tip

Each oil seal lips_

Multi-purpose grease

Oil pump driven sprocket bolt threads

Cam sprocket bolt threads

Gearshift cam bolt threads

Gearshift spindle oil seal plate bolt threads

Starter clutch bolt threads

Mainshaft bearing set plate bolt threads

Gearshift drum bearing and fork shaft set bolt threads

Cam chain tensioner pivot bolt threads

Oil main gallery 20 mm sealing bolt threads_

Locking agent

FRAME

LOCATION

MATERIAL

REMARKS

Seat catch hook sliding area Front wheel dust seal lips Steering head bearings Steering head bearing dust seal lips Final driven flange-to-rear wheel hub mating surface and O-ring

Rear wheel dust seal lips

Rear wheel side collar inner surfaces

Shock absorber needle bearings

Shock absorber dust seal lips

Shock link and shock arm (swingarm) needle bearings

Shock link and shock arm (swingarm) dust seal lips

Swingarm pivot bearings

Swingarm pivot dust seal lips

Throttle grip pipe flange

Clutch lever pivot

Rear brake pedal pivot

Gearshift pedal link tie-rod ball joints

Gearshift pedal pivot

Driver footpeg sliding area

Passenger footpeg sliding area

Side stand pivot _

Multi-purpose grease

Throttle cable outer inside Clutch cable outer inside Choke cable outer inside

Cable lubricant

Handlebar grip rubber inside

Honda bond A or equivalent

Steering bearing adjustment nut threads

Engine oil

Front brake lever-to-master piston contacting area Front brake lever pivot

Rear brake master piston-to-push rod contacting area and push rod boot groove

Rear brake caliper boot inside (collar outer surface) Hear brake caliper pin bolt boot inside_

Silicon grease

Brake master piston and cups Brake caliper piston and piston seals

DOT 4 brake fluid

Fork dust seal and oil seal lips

Fork fluid

Rear brake reservoir hose joint screw threads Front brake caliper assembly bolt threads Rear brake caliper pin bolt threads _

Locking agent

CABLE & HARNESS ROUTING

TURN SIGNAL CONNECTORS

TURN SIGNAL CONNECTORS

Shimano Caliper Seals
SWITCH WIRE
600e 3tb Wires Fittings

CLUTCH CABLE

CLU ICH SWI ICH CONNECTORS

FRONT BRAKE LIGHT SWITCH CONNECTORS

LEFT HANDLEBAR SWITCH WIRE

HORN WIRE

WATER HOSE

CLUTCH CABLE

CLU ICH SWI ICH CONNECTORS

HORN WIRE

LEFT HANDLEBAR SWITCH WIRE

WATER HOSE

Honda Cbr 600 Reserve

FRONT BRAKE LIGHT SWITCH CONNECTORS

RIGHT HANDLEBAR SWITCH WIRE

THROTTLE CABLES

Cl 1JTCH CARI F

OUTER AIR VENT HOSE (California type: No. 8)

DRAIN TUBE

SUB-AIR CLEANER DRAIN TUBE

RESERVE TANK BREATHER TUBE

SIPHON TUBE

RIGHT HANDLEBAR SWITCH WIRE

THROTTLE CABLES

Cl 1JTCH CARI F

OUTER AIR VENT HOSE (California type: No. 8)

DRAIN TUBE

SUB-AIR CLEANER DRAIN TUBE

RESERVE TANK BREATHER TUBE

SIPHON TUBE

IGNITION SWITCH

COMBINATION METER CONNECTOR

AIR VENT CONTROL SOLENOID VALVE

EVAP CAV SOLENOID VALVE (California type only) /

GNITION COIL 6P (Black) CONNECTOR

AIR VENT CONTROL SOLENOID VALVE

IGNITION SWITCH

COMBINATION METER CONNECTOR

BRAKE HOSE

Moto Solenoid Valve

EVAP CAV SOLENOID VALVE (California type only) /

GNITION COIL 6P (Black) CONNECTOR

AIR VENT CONTROL SOLENOID VALVE 2P (Black) CONNECTOR

FAN MOTOR SWITCH

FAN MOTOR SWITCH 2P CONNECTOR

CONNECTORS Ignition switch 4P (White) Left handlebar switch 13P (Black) Right handlebar switch 4P and 3P (Red) Headlight and turn signal 9P (White)

BRAKE HOSE

AIR VENT CONTROL SOLENOID VALVE 2P (Black) CONNECTOR

FAN MOTOR SWITCH

EVAP CAV SOLENOID VALVE 2P (Black) CONNECTOR (California type only)

FAN MOTOR SWITCH 2P CONNECTOR

Yamaga Neutral Switch

NEUTRAL SWITCH

FUEL TANK BREATHER TUBE (49 state/Canada type)

CONNECTORS: Alternator 3P (White) Side stand switch 2P (Green) Ignition pulse generator 2P (Red) Sub-harness 9P (White)

— Oil pressure switch

— Neutral switch —Thermosensor —Throttle sensor

NEUTRAL SWITCH

EDGE

FUEL TANK BREATHER TUBE (49 state/Canada type)

SIDE STAND SWITCH FUEL TANK DRAIN TUBE

FUELTANK BREATHER TUBE (49 state/Canada type)

EDGE

Fazer 600 Fuel Tank Drain Hose
FUELTANK DRAIN TUBE

49 state/Canada type shown;

FLOAT CHAMBER INNER AIR VENT HOSE

CRANKCASE BREATHER HOSE

IGNITION COILS

GROUND POINT

AIR VENT CONTROL SOLENOID VALVE

SUB-AIR CLEANER

FLOAT CHAMBER INNER AIR VENT HOSE

AIR VENT CONTROL SOLENOID VALVE

SUB-AIR CLEANER

CRANKCASE BREATHER HOSE

IGNITION COILS

GROUND POINT

Crankcase Breather Tube Honda Cbr 600

FLOAT CHAMBER OUTER AIR VC NT HOSE

CHOKE CABLE

VACUUM CHAMBER AIR VENT HOSE

THROTTLE CABLES

PAIR CONTROL VALVE VACUUM TUBE

THROTTLE SENSOR

CARBURETOR HEATER WATER TUBES

FUEL TUBE

FLOAT CHAMBER OUTER AIR VC NT HOSE

CHOKE CABLE

VACUUM CHAMBER AIR VENT HOSE

THROTTLE CABLES

PAIR CONTROL VALVE VACUUM TUBE

THROTTLE SENSOR

CARBURETOR HEATER WATER TUBES

FUEL TUBE

AIR SUPPLY HOSES (California: No. 16)

AIR SUPPLY HOSE (California: No. 15)

THERMOSTAT

THERMOSENSOR

STARTER MOTOR CABLE

VACUUM TUBE (California: No. 10)

AIR SUPPLY HOSES (California: No. 16)

VACUUM TUBE (California: No. 10)

AIR SUPPLY HOSE (California: No. 15)

THERMOSTAT

THERMOSENSOR

STARTER MOTOR CABLE

Oil Pressure Suzuki Bandit

PULSE SECONDARY AIR INJECTION (PAIR) CONTROL VALVE

OIL PRESSURE SWITCH

IGNITION PULSE GENERATOR 2P(Red) CONNECTOR

THROTTLE SENSOR WIRE

SPEED SENSOR 3P (Black) CONNECTOR

PULSE SECONDARY AIR INJECTION (PAIR) CONTROL VALVE

OIL PRESSURE SWITCH

IGNITION PULSE GENERATOR 2P(Red) CONNECTOR

THROTTLE SENSOR WIRE

SPEED SENSOR 3P (Black) CONNECTOR

Ignition Pulse Generator Honda

SEAT LOCK CABLE

BRAKE/TAIL LIGHT CONNECTORS

REAR BRAKE LIGHT SWITCH WIRE

AIR VENT CONTROL SOLENOID VALVE RELAY (49 state/Canada type only)

FUEL PUMP

TRANSFER

RELAY

CLAMP

SEAT LOCK CABLE

BRAKE/TAIL LIGHT CONNECTORS

REAR BRAKE LIGHT SWITCH WIRE

AIR VENT CONTROL SOLENOID VALVE RELAY (49 state/Canada type only)

FUEL PUMP

TRANSFER

RELAY

CLAMP

TURN SIGNAL RELAY

Cbr600 F4i Fuel Pump Transfer Relay

GROUND CABLE

REAR BRAKE LIGHT SWITCH

LICENSE LIGHT WIRE

GROUND CABLE

TURN SIGNAL RELAY

REAR BRAKE LIGHT SWITCH

LICENSE LIGHT WIRE

California type only:

AIR VENT CONTROL SOLENOID VALVE

No. 4 HOSE

VACUUM CHAMBER AIR VENT HOSE (From air cleaner housing)

No. 7 HOSE (From air cleaner housing)

EVAPORATIVE EMISSION (EVAP) PURGE CONTROL VALVE

No. 4 HOSE (From EVAP canister)

AIR VENT CONTROL SOLENOID VALVE

No. 4 HOSE

VACUUM CHAMBER AIR VENT HOSE (From air cleaner housing)

EVAPORATlVfc EMISSION CARBURETOR AIR VENT (EVAP CAV) SOLENOID VALVE

Vent Hose Carburetor

EVAPORATIVE EMISSION (EVAP) PURGE CONTROL VALVE

No. 4 HOSE (From EVAP canister)

CRANKCASE BREATHER HOSE

(Tn air cleaner housing)

No. 15 HOSE

No. 5 HOSE

EVAPORATlVfc EMISSION CARBURETOR AIR VENT (EVAP CAV) SOLENOID VALVE

CRANKCASE BREATHER HOSE

(Tn air cleaner housing)

No. 15 HOSE

No. 5 HOSE

Cbr 600 Carb Vacum
No. 5 HOSES

California type only;

EVAPPURGE CONTROL VALVE

No. 4 HOSE

No. 1 TUBE

U-UtL S ANK BKfcA I HtK 1 UBfc)

EVAPPURGE CONTROL VALVE

No. 4 HOSE

Cbr600 Throttle Cable Route

No. 1 TUBE

U-UtL S ANK BKfcA I HtK 1 UBfc)

No. 2 HOSE

WATER HOSES

WATER HOSES

Gsf600 Hose Diagram

No. 2 HOSE FUEL TANK DRAIN TUBE

EVAPORATIVE EMISSION (EVAP) CANISTER

No. 4 HOSE

No. 4 HOSE

Evap Sys Honda 1996
FUEL TANK
Honda Cbr 600 Fuel Tank Floats
0 0

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