Honda CBF600S/SA/N/NA Service Repair Manual

TYPE CODE • Throughout this manual, the following abbreviations are used to identify individual model. CODE AREA TYPE E U.K, Ireland F France, Belgium ED EUROPEAN DIRECT SALES (Spain, Holland, Austria, Portugal, Belgium, Denmark, Greece, Italy, Macedonia, Romania, Burgaria, Ukuraine, Israel, Finland, Germany, Sweden, Island, Russia, Poland, Slovenia, Croatia, Latvia, Norway, Swiss, Luxemburug, Hungary, Czech, Slovakia) III ED Germany

A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. For Your Customer’s Safety Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: • Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. • Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. • Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. • Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: • Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. • Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. • Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. • Use only a nonflammable solvent, not gasoline, to clean parts. • Never drain or store gasoline in an open container. • Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts. Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully.

HOW TO USE THIS MANUAL This service manual describes the service procedures for the CBF600S/SA/N/NA. Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1, 2 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Section 4 through 21 describe parts of the motorcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. If you don't know the source of the trouble, go to section 23 Troubleshooting. Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: • Safety Labels – on the vehicle • Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAU- TION. These signal words mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions. • Instructions – how to service this vehicle correctly and safely. As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAIL- ABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITH- OUT INCURRING ANY OBLIGATION WHATSO- EVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PER- MISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS OR ATVS. Honda Motor Co., Ltd. SERVICE PUBLICATION OFFICE CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE ENGINE AND DRIVE TRAIN LUBRICATION SYSTEM FUEL SYSTEM (PGM-FI) COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CLUTCH/STARTER CLUTCH/ GEARSHIFT LINKAGE ALTERNATOR FRONT WHEEL/SUSPENSION/ STEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE ANTI-LOCK BRAKE SYSTEM (ABS; CBF600SA/NA) BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METER/SWITCHES CHASSIS ELECTRICAL 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 IMMOBILIZER SYSTEM (HISS) CRANKSHAFT/PISTON/CYLINDER CRANKCASE/TRANSMISSION WIRING DIAGRAMS TROUBLESHOOTING 23 Date of Issue: November, 2007 ©honda Motor Co., Ltd. INDEX 24

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1: 1). Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote ® BR-2 plus manufactured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: Molykote ® G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Use Fork or Suspension Fluid.

1-1 1 1. GENERAL INFORMATION SERVICE RULES ········································· 1-2 MODEL IDENTIFICATION··························· 1-3 GENERAL SPECIFICATIONS······················ 1-6 LUBRICATION SYSTEM SPECIFICATIONS········································ 1-8 FUEL SYSTEM (PGM-FI) SPECIFICATIONS········································ 1-8 COOLING SYSTEM SPECIFICATIONS ······ 1-8 CYLINDER HEAD/VALVES SPECIFICATIONS········································ 1-9 CLUTCH/STARTER CLUTCH/ GEARSHIFT LINKAGE SPECIFICATIONS·· 1-9 CRANKCASE/TRANSMISSION SPECIFICATIONS······································ 1-10 CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS······································ 1-10 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ····································· 1-11 REAR WHEEL/SUSPENSION SPECIFICATIONS ····································· 1-11 HYDRAULIC BRAKE SPECIFICATIONS··· 1-12 BATTERY/CHARGING SYSTEM SPECIFICATIONS ····································· 1-12 IGNITION SYSTEM SPECIFICATIONS ···· 1-12 ELECTRIC STARTER SPECIFICATIONS ·· 1-13 LIGHTS/METERS/SWITCHES SPECIFICATIONS ····································· 1-13 STANDARD TORQUE VALUES··············· 1-14 ENGINE & FRAME TORQUE VALUES ···· 1-14 LUBRICATION & SEAL POINTS ·············· 1-21 CABLE & HARNESS ROUTING ··············· 1-24 EMISSION CONTROL SYSTEMS ············ 1-48

GENERAL INFORMATION 1-2 GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as show in the Cable and Harness Routing (page 1-24). ABBREVIATION Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbrev. term Full term ABS Anti-lock Brake System CKP sensor Crankshaft Position sensor DLC Data Link Connector DTC Diagnostic Trouble Code ECM Engine Control Module ECT sensor Engine Coolant Temperature sensor EEPROM Electrically Erasable Programmable Read Only Memory EOP switch Engine Oil Pressure switch HDS Honda Diagnostic System HISS Honda Ignition Security System IACV Idle Air Control Valve IAT sensor Intake Air Temperature sensor IDC solenoid valve Intake Duct Control solenoid valve MAP sensor Manifold Absolute Pressure sensor MIL Malfunction Indicator Lamp PAIR Pulsed Secondary Air Injection PCV Proportional Control Valve PGM-FI Programmed Fuel Injection SCS connector Service Check Short connector TP sensor Throttle Position sensor VS sensor Vehicle Speed sensor

GENERAL INFORMATION 1-3 MODEL IDENTIFICATION CBF600SA shown: CBF600N shown:

GENERAL INFORMATION 1-4 SERIAL NUMBERS The Vehicle Identification Number (V.I.N) is stamped on the right side of the steering head. The registered number plate is located on left side of the frame tube. The engine serial number is stamped on the right side of the upper crankcase. The throttle body identification number is stamped on the throttle body as shown. VEHICLE IDENTIFICATION NUMBER REGISTERED NUMBER PLATE ENGINE SERIAL NUMBER THROTTLE BODY IDENTIFICATION NUMBER

GENERAL INFORMATION 1-5 LABEL The color label is attached to the frame under the seat. When ordering color-coded parts, always specify the designated color code. COLOR LABEL

GENERAL INFORMATION 1-6 GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,160 mm (85 in) Overall width 765 mm (30 in) Overall height CBF600S/SA Wind screen STD 1,240 mm (49 in) Wind screen HIGH 1,285 mm (51 in) CBF600N/NA 1,110 mm (44 in) Wheelbase 1,490 mm (59 in) Seat height 785 ± 15mm (31 ± 0.6in) Footpeg height 325 mm (12.8 in) Ground clearance 136 mm (5.4 in) Curb weight CBF600S 217 kg (478 lbs) CBF600SA 222 kg (489 lbs) CBF600N 213 kg (470 lbs) CBF600NA 218 kg (481 lbs) Maximum weight capacity 195 kg (430 lbs) FRAME Frame type Diamond Front suspension Telescopic fork Front axle travel 108 mm (4.3 in) Rear suspension Swingarm Rear axle travel 120 mm (4.7 in) Front tire size 120/70 ZR 17M/C (58W) Rear tire size 160/60 ZR 17M/C (69W) Front tire brand BT-57F RADIAL U (Bridgestone) PILOT ROAD B (Michelin) Rear tire brand BT-57R RADIAL E (Bridgestone) PILOT ROAD A (Michelin) Front brake Hydraulic double disc Rear brake Hydraulic single disc Caster angle 26° 00’ Trail length 110 mm (4.3 in) Fuel tank capacity 20 liter (5.28 US gal, 4.40 lmp gal) Fuel reserve capacity 4.0 liter (1.06 US gal, 0.88 lmp gal) ENGINE Cylinder arrangement 4 cylinders in-line, inclined 30° from vertical Bore and stroke 67.0 X 42.5 mm (2.64 X 1.67 in) Displacement 599 cm 3 (36.5 cu-in) Compression ratio 11.6: 1 Valve train Chain driven, DOHC Intake valve opens at 1 mm (0.04 in) lift 15° BTDC closes at 1 mm (0.04 in) lift 15° ABDC Exhaust valve opens at 1 mm (0.04 in) lift 30° BBDC closes at 1 mm (0.04 in) lift 0° ATDC Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Liquid cooled Air filtration Paper element Engine dry weight 57.3 kg (126.4 lbs) Firing order 1 - 2 - 4 - 3 FUEL DELIVERY SYSTEM Type PGM-FI (Programmed Fuel Injection) Throttle bore 32 mm (1.3 in)

Honda CBF600S/SA/N/NA Service Repair Manual

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