Honda CBR 600 F4 - Service Manual

This service manual provides in-depth maintenance procedures, troubleshooting tips, and detailed specifications for the Honda CBR 600 F4 (1999-2000 Model).

How to Use This Manual

This service manual provides detailed procedures for servicing the CBR600F4. Adhering to the Maintenance Schedule outlined in Section 3 is essential to maintain the vehicle's peak operating condition and ensure its emission levels comply with standards set by the U.S. Environmental Protection Agency, California Air Resources Board, and Transport Canada.

Performing the first scheduled maintenance is crucial as it compensates for initial wear that occurs during the break-in period.

Sections 1 and 3 apply to the entire motorcycle. Section 2 details procedures for the removal and installation of components necessary for services described in subsequent sections. Sections 4 through 19 are organised by the motorcycle's parts, grouped by location.

To find the section you need, refer to this page, then turn to the table of contents on the first page of the section.

Most sections include assembly or system illustrations, service information, and troubleshooting guides. Detailed procedures follow these illustrations.

If the source of a problem is unknown, consult Section 22: Troubleshooting.

Notice

All information, illustrations, directions, and specifications in this publication are based on the latest product information available at the time of approval for printing. Honda Motor Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. This manual is intended for individuals who have acquired basic knowledge of maintenance on Honda motorcycles, motor scooters, or ATVs.

Table of Contents

1. General Information
2. Frame/Body Panels/Exhaust System
3. Maintenance

Engine and Drive Train

4. Lubrication System
5. Fuel System
6. Cooling System
7. Engine Removal/Installation
8. Cylinder Head/Valve
9. Clutch/Gearshift Linkage
10. Alternator/Starter Clutch
11. Crankcase/Transmission
12. Crankshaft/Piston/Cylinder

Chassis

13. Front Wheel/Suspension/Steering
14. Rear Wheel/Suspension
15. Hydraulic Brake

Electrical

16. Battery/Charging System
17. Ignition System
18. Electric Starter
19. Lights/Meters/Switches
20. Wiring Diagrams

Miscellaneous

21. Technical Features
22. Troubleshooting
23. Index

1. General Information

Index

• General Safety
• Service Rules
• Model Identification
• Specifications
• Torque Values
• Tools
• Lubrication & Seal Points
• Cable & Harness Routing
• Emission Control Systems
• Emission Control Information Labels

General Safety

Carbon Monoxide

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.

WARNING: The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death.

Used Engine Oil

WARNING: Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil.

Gasoline

Work in a well-ventilated area. Keep cigarettes, flames, or sparks away from the work area or where gasoline is stored.

WARNING: Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.

Brake Dust

WARNING: Never use an air hose or dry brush to clean the brake assemblies. Use a vacuum cleaner or alternate method to minimize the hazard caused by airborne asbestos fibers.

Hot Components

WARNING: Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts.

Coolant

Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the ethylene glycol does ignite, you will not see any flame, but you can be burned.

WARNING

• Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flame.
• Coolant (ethylene glycol) can cause some skin irritation and is poisonous if swallowed. KEEP OUT OF REACH OF CHILDREN.
• Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you.
• Keep hands and clothing away from the cooling fan, as it starts automatically.

Caution Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage.

Battery Hydrogen Gas & Electrolyte

WARNING

• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
  • If electrolyte gets on your skin, flush with water.
  • If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
• Electrolyte is poisonous.
  • If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN.

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 shown on pages 1-18 through 1-28, Cable and Harness routing.

Model Identification

Vehicle Identification Number (VIN)

The Vehicle Identification Number (VIN) is located on the left side of the frame.

Frame Serial Number

The frame serial number is stamped on the right side of the steering head.

Engine Serial Number

The engine serial number is stamped on the rear side of the upper crankcase.

Carburetor Identification Number

The carburetor identification number is stamped on the intake side of the carburetor body.

Color Label

The color label is attached on the rear fender under the seat. When ordering color-coded parts, always specify the designated color code.

Specifications

Dimensions

Frame

Engine

Carburetor

Drive Train

Electrical

Lubrication System

Fuel System

Cooling System

Lubrication System

Fuel System

Cooling System

Cylinder Head/Valve

Clutch/Gearshift Linkage

Alternator/Starter Clutch

Crankcase/Transmission

Crankshaft/Piston/Cylinder

Front Wheel/Suspension/Steering

Rear Wheel/Suspension

Hydraulic Brake

Battery/Charging System

Ignition System

Electric Starter

Lights/Meters/Switches

Torque Values

Standard Torque Values

Notes:

1. Apply sealant to the threads.
2. Apply locking agent to the threads.
3. Stake.
4. Apply oil to the threads and seating surface.
5. U-nut.
6. ALOC bolt/screw: replace with a new one.
7. Apply grease to the threads.
8. Apply molybdenum oil solution to the threads and seating surface.

Engine Torque Values

Frame Torque Values

Tools

Lubrication & Seal Points

Engine

Frame

Cable & Harness Routing

Emission Control Systems

The U.S. Environmental Protection Agency, Transport Canada, and California Air Resources Board (CARB) require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect.

Source of Emissions

The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emissions is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons.

Crankcase Emission Control System

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.

Exhaust Emission Control System (Pulse Secondary Air Injection System)

The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.

This model has the pulse secondary air injection (PAIR) control valve and PAIR check valves. PAIR check valve prevents reverse air flow through the system. The PAIR control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system.

No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the components is recommended.

Evaporative Emission Control System (California type only)

This model complies with California Air Resources Board evaporative emission requirements.

Fuel vapor from the fuel tank and carburetors is routed into the evaporative emission (EVAP) canister where it is adsorbed and stored while the engine is stopped. When the engine is running and the EVAP purge control valve is open, fuel vapor in the EVAP canister is drawn into the engine through the carburetor. At the same time, the EVAP carburetor air vent (CAV) solenoid valve is open and air is drawn into the carburetor through the valve.

Noise Emission Control System

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1. Removal of or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

Emission Control Information Labels

An Emission Control Information Label is located on the rear fender under the seat as shown. It gives basic tune-up specifications.

Vehicle Emission Control Information Update Label

After making a high altitude carburetor adjustment, attach an update label on the rear fender under the seat as shown.

Instructions for obtaining the update label are given in Service Letter No. 132.

When readjusting the carburetors back to the low altitude specifications, be sure to remove this update label.

Vacuum Hose Routing Diagram Label (California type only)

The Vacuum Hose Routing Diagram Label is located on the air cleaner housing cover as shown. The fuel tank must be removed to read it.

2. Frame/Body Panels/Exhaust System

Index

• Service Information
• Troubleshooting
• Seat
• Seat Cowl
• Fuel Tank
• Side Fairing
• Front Inner Fairing
• Front Fairing
• Windshield
• Direct Air Intake Duct
• Exhaust System
• Rear Fender/Seat Rail

Service Information

General

WARNING

• Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.
• Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.

• Work in a well-ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.
• This section covers removal and installation of the body panels, fuel tank, and exhaust system.
• Always replace the exhaust pipe gasket when removing the exhaust pipe from the engine.
• Always inspect the exhaust system for leaks after installation.

Torque Values

• Exhaust pipe joint nut: 12 N·m (1.2 kgf·m, 9 lbf·ft)
• Muffler band bolt: 23 N·m (2.3 kgf·m, 17 lbf·ft)
• Seat cowl screw: 2 N·m (0.2 kgf·m, 1.4 lbf·ft)
• Front inner fairing screw: 2 N·m (0.2 kgf·m, 1.4 lbf·ft)
• Front fairing-to-side fairing bolt: 2 N·m (0.2 kgf·m, 1.4 lbf·ft)
• Passenger footpeg bracket bolt: 26 N·m (2.7 kgf·m, 20 lbf·ft)
• Seat rail mounting bolt: 49 N·m (5.0 kgf·m, 36 lbf·ft)

Troubleshooting

Excessive Exhaust Noise

• Broken exhaust system
• Exhaust gas leaks

Poor Performance

• Deformed exhaust system
• Exhaust gas leaks
• Clogged muffler

Seat

Removal

Unlock the seat with the ignition key. Pull the seat back and remove it.

Installation

Install the seat by inserting the prong into the retainer on the fuel tank and the hooks into the catches on the frame. Push the seat forward, then down to lock it.

Seat Cowl

Remove the seat. Remove the two socket bolts. Remove the two screws. Remove the two trim clips. Disconnect the taillight connectors. Pull the seat cowl back out of the frame while opening the front portion of it. Installation is in the reverse order of removal.

Note: Make sure that the mating surfaces of the cowl bottom are seated onto the rear fender properly before tightening the fasteners.

Torque: Screw: 2 N·m (0.2 kgf·m, 1.4 lbf·ft)

Fuel Tank

WARNING Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.

Remove the seat. Remove the duct cover socket bolts. Remove the air duct covers by releasing the cover tab from the instrument panel and the side fairing boss from the cover grommet. Remove the two 6 mm tank mounting bolts and washers. Remove the two collars from the mounting rubbers.

Raise the front portion of the fuel tank and support it with the eyelet wrench in the tool kit by setting it between the end of the shock absorber and the recess of the tank bottom properly as shown.

Turn the fuel valve OFF and disconnect the following:

• fuel tube
• drain tube
• breather tube (California: No. 1 tube)
• fuel level sensor connectors

Remove the eyelet wrench and rest the fuel tank on the frame. Remove the two 8 mm mounting bolts and seat retainer. Remove the fuel tank. Install the removed parts in the reverse order of removal.

Note:

• When tightening the tank mounting fasteners, loosely install all mounting bolts and tighten the 6 mm bolts first, then the 8 mm bolts securely.
• Be careful not to dislodge the rubber nuts in the fuel tank when tightening the duct cover bolts.

Torque: Duct cover bolt: 2 N·m (0.2 kgf·m, 1.4 lbf·ft)

Side Fairing

Remove the following:

• three trim clips
• two screws
• six socket bolts

Release the boss from the duct cover grommet and remove the side cowl. Remove the fuel tank drain and breather tubes. Installation is in the reverse order of removal.

Note: Be careful not to dislodge the rubber nuts in the side fairing when tightening the front side bolts.

Torque: Socket bolt (Three bolts on front side): 2 N·m (0.2 kgf·m, 1.4 lbf·ft)

Front Inner Fairing

Remove the following:

• four trim clips
• four screws
• inner fairing by releasing front fairing tabs from inner fairing slits

Installation is in the reverse order of removal.

Note: Make sure that the mating areas are aligned properly before tightening the fasteners.

Torque: Screw: 2 N·m (0.2 kgf·m, 1.4 lbf·ft)

Front Fairing

Remove the socket bolts and the rearview mirrors. Remove the trim clip from the instrument panel. Remove the six screws and two nuts. Remove the instrument panels. Release the air vent hose (California: No. 8) from the hose clip and disconnect it from the 3-way hose joint. Remove the front fairing off the rearview mirror bolt hole studs and rest it on the front fender. Disconnect the headlight and turn signal connectors. Installation is in the reverse order of removal.

Note:

• Install the front fairing air duct grill over the air intake ducts and the bosses into the fairing stay grommets and align the front fairing tabs with the inner fairing slits.
• When tightening the fairing socket bolts, be careful not to dislodge the rubber nuts in the side fairing.
• When installing the instrument panel, align the groove with the tab of the duct cover.

Torque: Fairing socket bolt: 2 N·m (0.2 kgf·m, 1.4 lbf·ft)

Windshield

Remove the rearview mirrors. Remove the following:

• two screws and nuts
• four screws with rubber and plastic washers

Note: Be careful not to scratch the shield surface.

Installation is in the reverse order of removal.

Direct Air Intake Duct

Remove the duct cover. Remove the instrument panel. Loosen the connecting tube band screw.

Right duct: Remove the outer air vent hose (California: No. 8) from the duct by releasing the hose clip. Left duct: Remove the wire harness from the duct.

Remove the air intake duct from the air duct grill of the front fairing and the front fairing stay.

Installation is in the reverse order of removal.

Exhaust System

WARNING Do not service the exhaust system while it is hot.

Caution Be careful not to damage the radiator fins.

Removal

Muffler: Loosen the muffler band bolts. Remove the mounting bolt, washer, and nut. Remove the muffler from the exhaust pipe. Remove the muffler gasket.

Exhaust Pipe: Remove the radiator from the frame without disconnecting the water hoses (as described in spark plug removal procedure). Remove the radiator air guide rubber from the cylinder head. Remove the exhaust pipe joint nuts. Remove the mounting bolt, washer and nut, and the exhaust pipe. Remove the exhaust pipe joint gaskets.

Installation

Exhaust Pipe: If the joint stud bolts are loose, tighten them. Be sure to verify the distance from top of stud to the cylinder head surface as shown. Install new joint gaskets into the exhaust ports. Set the exhaust pipe onto the engine by aligning the exhaust flanges with the cylinder head studs, then install the joint nuts and the mounting bolt, washer and nut. Tighten the joint nuts.

Torque: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Tighten the mounting bolt.

Muffler: Install a new muffler gasket and the muffler over the exhaust pipe. Install the mounting bolt/washer and nut, and tighten it. Tighten the muffler band bolts.

Torque: 23 N·m (2.3 kgf·m, 17 lbf·ft)

Install the air guide rubber into the cylinder head and the radiator onto the frame if the exhaust pipe is removed. Install the side fairing and front inner fairing.

Rear Fender/Seat Rail

Removal

Remove the seat cowl. Remove the battery.

Disconnect the following:

• turn signal and license light connectors (release the clamp)
• seat lock cable from seat catch on cross member

Remove the following:

• fuel cut-off relay
• turn signal relay
• fuel pump transfer relay
• air vent control solenoid valve relay (49 state/Canada only)
• fuse box by releasing the tab on reverse side of fender
• rear shock absorber reservoir by loosing band screw
• starter relay switch

Remove the fender mounting nuts, washers and bolts. Slide the rear fender rearward, then remove the mounting collars (between the seat rail and fender) and remove the fender from the seat rail.

Remove the fuel tank.

Remove the following:

• wire harness bands
• ignition control module (ICM)
• bolts and regulator/rectifier
• bolts, collars and fuel pump

Secure the reservoir so that it remains upright. Remove the nuts, bolts, washer and the passenger footpeg brackets. Remove the four mounting nuts, bolts and seat rail.

Installation

Torque:

• Seat rail mounting: 49 N·m (5.0 kgf·m, 36 lbf·ft)
• Footpeg bracket: 26 N·m (2.7 kgf·m, 20 lbf·ft)

Installation is in the reverse order of removal.

3. Maintenance

Index

• Service Information
• Maintenance Schedule
• Fuel Line
• Throttle Operation
• Carburetor Choke
• Air Cleaner
• Spark Plug
• Valve Clearance
• Engine Oil
• Engine Oil Filter
• Carburetor Synchronization
• Engine Idle Speed
• Radiator Coolant
• Cooling System
• Secondary Air Supply System
• Evaporative Emission Control System (California type only)
• Drive Chain
• Brake Fluid
• Brake Pads Wear
• Brake System
• Brake Light Switch
• Headlight Aim
• Clutch System
• Side Stand
• Suspension
• Nuts, Bolts, Fasteners
• Wheels/Tires
• Steering Head Bearings

Service Information

General

WARNING When 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. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

Specifications

Torque Values

• Spark plug: 12 N·m (1.2 kgf·m, 9 lbf·ft)
• Timing hole cap: 18 N·m (1.8 kgf·m, 13 lbf·ft) Apply grease to the threads
• Oil filter cartridge: 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply oil to the threads and seating surface
• Engine oil drain bolt: 29 N·m (3.0 kgf·m, 22 lbf·ft)
• Rear axle nut: 93 N·m (9.5 kgf·m, 69 lbf·ft) U-nut
• Rear brake reservoir mounting bolt: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Tool

• Oil filter wrench: 07HAA-PJ70100
• Drive chain tool set: 07HMH-MR10103 or 07HMH-MR1010B (U.S.A. only)

Maintenance Schedule

Perform the pre-ride inspection in the Owner’s Manual at each scheduled maintenance period. Inspect and Clean, Adjust, Lubricate or Replace if necessary.

I: Inspect | C: Clean | R: Replace | A: Adjust | L: Lubricate

The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools. Consult your Honda dealer.

NOTE:

1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently if the motorcycle is ridden in unusually wet or dusty areas.
3. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.
4. California type only.

• *Should be serviced by your dealer, unless the owner has proper tools and service data and is mechanically qualified.
• **In the interest of safety, we recommend these items be serviced only by your Honda dealer.

Fuel Line

Raise the fuel tank.

Check the fuel lines for deterioration, damage or leakage. Replace the fuel lines if necessary.

Throttle Operation

Check for any deterioration or damage to the throttle cables. Check that the throttle grip for smooth operation. Check that the throttle opens and automatically closes in all steering positions.

If the throttle grip does not return properly, lubricate the throttle cables and overhaul and lubricate the throttle grip housing. For cable lubrication: Disconnect the throttle cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil.

If the throttle grip still does not return properly, replace the throttle cables.

WARNING

Reusing a damaged or abnormally bent or kinked throttle cable can prevent proper throttle slide operation and may lead to a loss of throttle control while riding.

With the engine idling, turn the handlebar all the way to the right and left to ensure that the idle speed does not change. If idle speed increases, check the throttle grip free play and the throttle cable connection.

Measure the throttle grip free play at the throttle grip flange.

Throttle Grip Free Play: 2—6 mm (1/16—1/4 in)

Throttle grip free play can be adjusted at either end of the throttle cable. Minor adjustments are made with the upper adjuster.

Loosen the lock nut, turn the adjuster as required and tighten the lock nut.

Major adjustments are made with the lower adjuster.

Raise the fuel tank and support it. Loosen the lock nut, turn the adjusting nut as required and tighten the lock nut.

Recheck the throttle operation and install the fuel tank.

Carburetor Choke

This model's choke system uses a fuel enriching circuit controlled by a starting enrichment (SE) valve. The SE valve opens the enriching circuit via a cable when the choke lever on the left handlebar is turned this side.

Check for smooth choke lever operation and lubricate the choke if required.

Check the choke cable for frayed, kinked or other damage.

Air Cleaner

NOTE:

• The viscous paper element type air cleaner cannot be cleaned because the element contains a dust adhesive.
• If the motorcycle is used in wet or dusty areas, more frequent inspections are required.

Raise the fuel tank and support it.

Remove the ten cover screws and the air cleaner housing cover. Replace the element in accordance with the maintenance schedule or any time it is excessively dirty or damaged.

Install the air cleaner element and cover, and tighten the screws.

Install the fuel tank.

Spark Plug

WARNING

Wear insulated gloves to avoid burns while the engine is hot.

Remove the side fairings and the front inner fairing (page 2-4).

Disconnect the fan motor switch 2P (Black) connector. Disconnect the horn connectors. Remove the horn bolt and horn. Remove the radiator mounting bolts, washers and nut.

Cover the radiator with a shop towel to avoid damaging the radiator fins. Swing the radiator forward so that the lower mounting stay is not interfered with the radiator. Slide the radiator to the right to remove it off the boss of the frame. Move the radiator down without disconnecting the water hoses and secure it to the fork legs.

Disconnect the ignition coil 2P connectors and remove the direct ignition coils. Clean around the spark plug bases.

NOTE:

• This motorcycle adopted the direct type ignition coil that the spark plug cap and ignition coil are integrated.
• Clean around the spark plug bases with compressed air before removing the plugs, and be sure that no debris is allowed to enter the combustion chamber.

Remove the spark plugs.

Check the insulator for cracks or damage, and the electrodes for wear, fouling or discoloration. Replace the plug if necessary.

Recommended Spark Plug: CR9EH-9 (NGK) U27FER-9 (DENSO)

If the electrode is contaminated with carbon deposits, clean the spark plug electrodes using a wire type brush or spark plug cleaner.

Measure the gap between the center and side electrodes with a wire-type feeler gauge. If necessary, adjust the gap by bending the side electrode carefully.

SPARK PLUG GAP:
0.80 – 0.90 mm (0.031 – 0.035 in)

Install the spark plug.

California type: Check the insulator for cracks or damage, and the electrodes for wear, fouling or discoloration. Replace the plug if necessary.
If the electrode is contaminated with carbon deposits, clean the electrode using the spark plug cleaner.

CAUTION:

• This motorcycle's (California type) spark plug is equipped with platinum type electrodes. Do not use wire brush to clean the electrodes.
• The plug cleaner should be used with the air pressure of less than 6 kgf/cm² (85 psi) and for less than 20 seconds.

Replace the plug if the center electrode is rounded as shown.

Always use specified spark plugs on this motorcycle.

SPECIFIED SPARK PLUG: CR9EHVX-9 (NGK)

Measure the gap between the center and side electrodes with a wire-type feeler gauge.

CAUTION:
To prevent damaging the platinum coating of the center electrode, use a wire type feeler gauge to check the spark plug gap.

Make sure that the 1.0 mm (0.04 in) wire type feeler gauge cannot be inserted into the gap.
If the gauge can be inserted into the gap, replace the plug with a new one.

CAUTION:
Do not adjust the spark plug gap. If the gap is out of specification, replace with a new one.

CAUTION:
To prevent damage to the cylinder head, hand-tighten the spark plug before using a wrench to tighten to the specified torque.

With the plug washer attached, screw the spark plug in by hand to prevent cross-threading. Tighten the spark plug.

TORQUE: 12 N·m (1.2 kgf·m , 9 lbf·ft)

Install the removed parts in the reverse order of removal.

NOTE:
When installing the radiator, set the air guide rubber properly. Do not pinch the air guide rubber between the frame and radiator.

Valve Clearance

Inspection

NOTE:
Inspect and adjust the valve clearance while the engine is cold (below 35 °C, 95 °F).

Remove the cylinder head cover.
Remove the timing hole cap.

Rotate the crankshaft clockwise and align the "T" mark on the ignition pulse generator rotor with the index notch on the right crankcase cover.

The timing marks ("IN" for intake and "EX" for exhaust) on the cam sprockets must be flush with the cylinder head surface and facing outward as shown.

If the timing marks are facing inward, rotate the crankshaft clockwise 360° (1 full turn) and align the "T" mark with the index notch.

Turn the tensioner shaft clockwise with the stopper tool to retract the tensioner and hold it in the fully retracted position (page 8-4).

Measure the No. 1 and No. 3 cylinder intake valve clearance by inserting a feeler gauge between the valve lifter and cam lobe.

VALVE CLEARANCE:
IN: 0.20 ± 0.03 mm (0.008 ± 0.001 in)

Rotate the crankshaft clockwise 1/2 (180°) turn from previous position and align the punch mark with the index notch.
Measure the No. 2 and No. 4 cylinder exhaust valve clearance.

VALVE CLEARANCE:
EX: 0.28 ± 0.03 mm (0.011 ± 0.001 in)

Rotate the crankshaft clockwise 1/2 (180°) turn from previous position and align the "T" mark with the index notch.
Measure the No. 2 and No. 4 cylinder intake valve clearance.

VALVE CLEARANCE:
IN: 0.20 ± 0.03 mm (0.008 ± 0.001 in)

Rotate the crankshaft clockwise 1/2 (180°) turn from previous position and align the punch mark with the index notch.
Measure the No. 1 and No. 3 cylinder exhaust valve clearance.

VALVE CLEARANCE:
EX: 0.28 ± 0.03 mm (0.011 ± 0.001 in)

Adjustment

Remove the valve lifters and shims.
Clean the valve shim contact area in the valve lifter with compressed air.

Measure the shim thickness and record it.

NOTE:
Sixty-nine different thickness shims are available from the thinnest (1.200 mm thickness) shim to the thickest (2.900 mm thickness) in intervals of 0.025 mm.

Calculate the new shim thickness using the equation below.

$$A = (B - C) + D$$

• A: New shim thickness
• B: Recorded valve clearance
• C: Specified valve clearance
• D: Old shim thickness

NOTE:

• Make sure of the correct shim thickness by measuring the shim with the micrometer.
• Reface the valve seat if carbon deposits result in a calculated dimension of over 2.900 mm.

Install the newly selected shims on the valve retainers.
Install the valve lifters and camshafts.

Rotate the camshafts by rotating the crankshaft clockwise several times.
Recheck the valve clearances.

Install the cylinder head cover.

Coat a new O-ring with grease and install it onto the timing hole cap.
Apply grease to the timing hole cap threads.
Install and tighten the timing hole cap.

TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft)

Engine Oil

Start the engine and let it idle for a few minutes.
Stop the engine, support the motorcycle upright on a level surface.
Wait for a few minutes and check that the oil level is between the upper and lower level marks in the inspection window.

If the oil level is below or near the lower level mark, remove the oil filler cap and add the recommended engine oil up to the upper level mark.

RECOMMENDED ENGINE OIL:

• Honda GN4 4-stroke oil or equivalent motor oil
• API service classification: SF or SG
• Viscosity: SAE 10W-40

NOTE:
Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range.

Reinstall the filler cap.
For engine oil change, see next page.

Engine Oil Filter

NOTE:
Change the oil with the engine warm and the motorcycle on its side stand to assure complete and rapid draining.

WARNING:
Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves.

Warm up the engine.
Stop the engine and remove the side and inner fairings.
Remove oil filler cap and drain bolt, and drain the oil.
Remove the oil filter cartridge and let the remaining oil drain out. Discard the filter cartridge.

TOOL:
Oil filter wrench 07HAA-PJ70100

CAUTION:
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil.

Apply oil to the O-ring and threads of a new oil filter cartridge and install the filter cartridge.

TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

After draining the oil completely check that the sealing washer on the drain bolt is in good condition and replace it if necessary.
Install and tighten the drain bolt.

TORQUE: 29 N·m (3.0 kgf·m, 22 lbf·ft)

Fill the crankcase with the recommended oil.

OIL CAPACITY:

• 3.3 ℓ (3.5 US qt, 2.9 Imp qt) after draining/filter change
• 3.7 ℓ (3.9 US qt, 3.3 Imp qt) at disassembly

Reinstall the oil filler cap.
Check the engine oil level.
Make sure there are no oil leaks.
Install the side and inner fairings.

Carburetor Synchronization

NOTE:
Perform this maintenance with the engine at normal operating temperature and transmission in neutral. Place the motorcycle on a level surface.

Raise the fuel tank and support it.
Disconnect the vacuum tubes from the air cleaner housing.

Connect the vacuum gauges to the vacuum tubes.

Start the engine and adjust the idle speed with the throttle stop screw.

IDLE SPEED:

• 49 state/Canada type: 1,300 ± 100 rpm
• California type: 1,400 ± 100 rpm

Check the difference between each carburetor.

CARBURETOR VACUUM DIFFERENCE:
Within 30 mm Hg (1.2 in Hg)

NOTE:
The base carburetor is the No. 4 carburetor.

Synchronize to specification by turning the synchronization adjusting screws.
Rev the engine up several times.
Recheck the idle speed and synchronization.

Disconnect the vacuum gauges.
Connect the vacuum tubes to the joints of the air cleaner housing.
Install the fuel tank (page 2-3).

Engine Idle Speed

NOTE:

• Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications.
• The engine must be warm for accurate idle speed inspection and adjustment. Ten minutes of stop-and-go riding is sufficient.

Warm up the engine, shift the transmission into neutral and place the motorcycle on a level surface.
Check the idle speed and adjust by turning the throttle stop screw as required.

IDLE SPEED:

• 49 state/Canada type: 1,300 ± 100 rpm
• California type: 1,400 ± 100 rpm

Radiator Coolant

Check the coolant level of the reserve tank with the engine running at normal operating temperature.
The level should be between the "UPPER" and "LOWER" level lines with the motorcycle upright on a level surface.
If the level is low, remove the right side fairing (page 2-4) and the reserve tank cap, and fill the tank to the "UPPER" level line with a 50/50 mixture of distilled water and antifreeze (coolant preparation).

RECOMMENDED ANTIFREEZE:
Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors

CAUTION:
Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage.

Check to see if there are any coolant leaks when the coolant level decreases very rapidly.

If reserve tank becomes completely empty, there is a possibility of air getting into the cooling system. Be sure to remove all air from the cooling system.

Cooling System

Remove the side fairings.

Check for any coolant leakage from the water pump, water hoses and hose joints.
Check the water hoses for cracks or deterioration and replace if necessary.
Check that all hose clamps are tight.

Check the radiator air passage for clogging or damage.
Straighten bent fins with a small, flat blade screwdriver and remove insects, mud or other obstructions with compressed air or low pressure water.
Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.

Install the side fairings.

Secondary Air Supply System

Check the air supply hoses between the pulse secondary air injection (PAIR) control valve and PAIR check valves for damage or loose connections.
Check the air supply hoses for cracks or deterioration.

NOTE:
If the hoses show any signs of heat damage, inspect the PAIR check valves.

Check the vacuum tube between the No. 4 cylinder head vacuum joint and PAIR control valve for deterioration, damage or loose connections. Also check that the tube is not kinked or pinched.

For PAIR control valve inspection, see section 5.

This manual serves as a guide for proper servicing of my Honda CBR 600 F4 (2000). For detailed procedures, refer to the official Honda Service Manual.

Ride safe! 🏍️