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Description   This repair manual covers Honda CBR600-F4 models including, CBR600F4 (US) 1999-2000, CBR600F4i (US) 2001-2006, CBR600F (UK) 1999-2000, and CBR600F Sport (UK) 2001-2006. Table of Contents QUICK REFERENCE DATA CHAPTER ONE: GENERAL INFORMATION Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Basic tools | Precision measuring tools | Electrical system fundamentals | Special tools | Basic service methods | Storage CHAPTER TWO: TROUBLESHOOTING Operating requirements | Starting the engine (carbureted models) | Starting the engine (fuel injected models) | Starting difficulties | Engine performance | Engine noises | Engine lubrication | Cylinder leakdown test | Clutch | Gearshift linkage | Transmission | Fuel system (carbureted models) | Fuel system (fuel injection models) | Electrical troubleshooting | Troubleshooting test equipment | Basic test procedures | Lighting system | Charging system | Ignition system | Starting system | Front suspension and steering | Brake system CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP Fuel type | Tune-up procedures | Air filter | Engine compression test | Spark plugs | Ignition timing inspection | Valve clearance | Carburetor synchronization (1999-2000 models) | Fuel injection starter valve synchronization (2001-on models) | Idle speed adjustment (all models) | Fuel hose inspection | Control cable lubrication (non-nylon lined cables only) | Throttle cable (all models) | Starting enrichment (choke) cable | Clutch cable adjustment | Engine oil and filter | Cooling system | Emission control systems | Battery | Tires and wheels | Front fork oil change | Drive chain | Brake system | Headlight aim inspection | Sidestand and ignition cut-off switch inspection | Steering bearing inspection | Front suspension inspection | Rear suspension inspection | Fastener inspection | Wheel bearing inspection | Lights and horn inspection CHAPTER FOUR: ENGINE TOP-END and EXHAUST Engine service notes | Engine principles | Exhaust system | Cylinder head cover | Camshafts | Camshaft chain tensioner | Camshaft chain, timing sprocket and chain guides | Cylinder head | Valve lifters and shims | Valves and valve components CHAPTER FIVE: ENGINE LOWER-END Servicing engine in frame | Engine service notes | Engine | Oil pan, oil strainer and pressure relief valve | Oil pump | Oil cooler | Starter clutch | Crankcase | Piston and connecting rod assembly | Crankshaft | Break-in procedure CHAPTER SIX: CLUTCH and EXTERNAL SHIFT MECHANISM Right crankcase cover | Clutch | External shift mechanism CHAPTER SEVEN: TRANSMISSION and INTERNAL GEARSHIFT MECHANISM Transmission | Transmission inspection | Internal shift mechanism CHAPTER EIGHT: FUEL, CARBURETORS and EMISSION CONTROL SYSTEMS Fuel tank | Air filter housing | Carburetor operation | Carburetor service | Carburetor assembly | Carburetor overhaul | Carburetor separation | Carburetor adjustments | Throttle cable replacement | Starter (choke) cable replacement | Fuel pump assembly | Fuel filter replacement | Emission control system labels | Crankcase breather system | Evaporative emission control system (California models only) | PAIR system | Direct air induction (carbureted models) CHAPTER NINE: FUEL and ELECTRONIC FUEL INJECTION SYSTEMS Fuel injection system precautions \ Hose and wiring harness identification | Depressurizing the fuel system | Fuel tank | Air filter housing | Throttle body | Fuel injectors | Starter valves | Fast idle wax unit | Pressure regulator | Fuel pressure check | Fuel flow test | Fuel pump assembly | Fuel filter replacement | Fuel cut relay | Manifold absolute pressure (MAP) sensor | Intake air temperature (IAT) sensor | Engine coolant temperature (ECT) sensor | Camshaft pulse generator | Throttle position (TP) sensor | Bank angle sensor | Oxygen sensor (California models) | Emission control system | Engine stop relay | Engine control module (ECM) | Malfunction indicator light (MIL) | Throttle cable replacement CHAPTER TEN: ELECTRICAL SYSTEM Electrical component replacement | Electrical connectors | Battery | Charging system | Stator coil and left crankcase cover | Flywheel, starter clutch and starter reduction gear | Ignition system | Starter | Starter relay switch | Clutch diode | Lighting system | Combination meter | Tachometer test | Speedometer/speed sensor | Coolant temperature gauge | Thermosensor/ECT sensor (all models) | Low fuel indicator/fuel reserve sensor (1999-2000 models) | Fuel reserve sensor (2001-on models) | Turn signal relay | Horn | Switches | Fuses | Wiring diagrams CHAPTER ELEVEN: COOLING SYSTEM Cooling system inspection | Hoses and hose clamps | Coolant reserve tank | Radiator | Cooling fan | Thermostat | Thermostat housing | Water pump | Water pump outlet hose CHAPTER TWELVE: WHEELS, TIRES and DRIVE CHAIN Motorcycle stands | Front wheel | Rear wheel | Rear coupling and rear sprocket | Front and rear hubs | Wheel runout and balance | Tire changing | Tire repairs | Drive chain CHAPTER THIRTEEN: FRONT SUSPENSION and STEERING Handlebar assemblies | Front fork | Steering head and stem | Steering bearing preload | Steering head bearing races CHAPTER FOURTEEN: REAR SUSPENSION Shock linkage | Shock absorber | Swing arm CHAPTER FIFTEEN: BRAKES Brake fluid selection | Preventing brake fluid damage | Brake service | Front brake pads | Front brake caliper | Front master cylinder | Rear brake pads | Rear brake caliper | Rear master cylinder | Brake hose replacement | Brake disc | Rear brake pedal | Brake bleeding | Bleeding the system | Brake fluid draining | Flushing the brake system CHAPTER SIXTEEN: BODY PANELS Plastic trim clips | Seat (1999-2000 U.S. and Canada, 1999-on U.K. models) | Rider's seat (2001-on U.S. and Canada models) | Pillon seat (2001-on U.S. and Canada models) | Rear cowl (1999-2000 U.S. and Canada, 1999-on U.K. models) | Rear cowl (2001-on U.S. and Canada models) | Side fairing (all models) | Front inner fairing (all models) | Mirrors (all models) | Windshield (1999-2000 models) | Windshield (2001-on models) | Front fairing and air ducts (1999-2000 models) | Front fairing and air ducts (2001-on models) | Front fender | Rear fender and seat rail (1999-2000 models) | Rear fender and seat rail (2001-on models) COLOR WIRING DIAGRAMS Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild. PRODUCT DETAILS: Publisher: Clymer Manuals 2003, 2006 Author: Ed Scott Binding: Paperback 7 x 10 inches Pages: 558 Hundreds of b&w photos and illustrations ISBN: 9781599690827

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