Honda 2004 CB600F 599 Owner'S Manual Download Page 219 | Manualshive

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$60.00

$48.00

$16.00

61MBZ00

61CM001

31MBZ600

2004 CB600F Service Manual

Common Service Manual

2004 CB600F Owner’s Manual

Publication Item No.

Description

Price Each

Pr ices ar e subject to change without notice and without incur r ing obligation.

210

Authorized Manuals

Consumer Information

The Service Manual (Publication Item No.

) used by your authorized Honda

dealer is available from Helm, Inc. (USA only, Canada: See your Honda dealer to order
authorized manuals.)

Also available, but not necessary, to service your model is the Honda Common Service
Manual (Publication No. 61CM001 ), which explains theory of operation and basic service
information for various systems common to all Honda motorcycles, motor scooters and
ATVs.

These Honda manuals are written for the professional technician, but most mechanically-
capable owners should find them easy to use if they have the proper tools and observe proper
safety standards. Special Honda tools are necessary for some procedures.

61MBZ00

03/04/26 14:01:59 31MBZ600_219

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Summary of Contents for 2004 CB600F 599

Page 1: ...tion available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation This manual should be considered a permanent part o...

Page 2: ...2004 Honda CB600F 599 OWNER S MANUAL 03 04 26 13 33 28 31MBZ600_002...

Page 3: ...ut it s just as important to observe the break in guidelines and perform all pre ride and other periodic checks detailed in this manual We also recommend that you read this owner s manual before you r...

Page 4: ...nows your motorcycle best and is dedicated to your complete satisfaction Please report any change of address or ownership to your Honda dealer so we will be able to contact you concerning important pr...

Page 5: ...nd other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others Of course it is not practical or possible to warn you about all hazards...

Page 6: ...t follow instructions A Few Words About Safety Safety Messages Safety Headings Safety Section Instructions such as Important Safety Reminders or Important Safety Precautions such as Motorcycle Safety...

Page 7: ...make sure you and your motorcycle are ready to ride and important information about loading Important safety information you should know plus a look at the safety related labels on your motorcycle The...

Page 8: ...nance schedule and instructions for specific maintenance and adjustment items How to store and transport your motorcycle and how to be an environmentally responsible rider What to do if you have a fla...

Page 9: ...03 04 26 13 34 20 31MBZ600_009...

Page 10: ...recommendations to help you ride your motorcycle safely Please take a few moments to read these pages This section also includes information about the location of safety labels on your motorcycle Imp...

Page 11: ...o to protect yourself when you ride You ll find many helpful recommendations throughout this manual The following are a few that we consider most important It s a proven fact helmets significantly red...

Page 12: ...e clothing position yourself so other drivers can see you signal before turning or changing lanes and use your horn when it will help others notice you Even if you have ridden other motorcycles take t...

Page 13: ...hol and riding don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets worse with every additional drink So don t drink and ride and don t let yo...

Page 14: ...he following information We strongly recommend that you use only genuine Honda accessories that have been specifically designed and tested for your motorcycle Because Honda cannot test all other acces...

Page 15: ...l any fairing or windshield unless it was designed and tested by Honda for your motorcycle Some fairings or windshields even smaller ones can cause unstable handling of your motorcycle This is especia...

Page 16: ...arn you of potential hazards that could cause serious injury or they provide important safety information Read these labels carefully and don t remove them If a label comes off or becomes hard to read...

Page 17: ...For USA For Canada 8 Safety Labels Motorcycle Safety 03 04 26 13 35 25 31MBZ600_017...

Page 18: ...e are described in this section Instructions for other components are presented in other sections of this manual where they will be most useful Component Locations 10 Gauges Indicators 13 Controls Fea...

Page 19: ...dlight dimmer switch start button ignition switch indicators tachometer horn button speedometer rearview mirror front brake fluid reservoir front brake lever engine stop switch throttle grip 10 Compon...

Page 20: ...pedal coolant reserve tank footpeg battery rear brake fluid reservoir storage compartment for U shaped lock tool kit compartment oil filler cap dipstick 11 Component Locations Instruments Controls 03...

Page 21: ...et holder side stand footpeg air cleaner seat lock owner s manual storage rear suspension spring pre load adjuster choke lever shift lever fuse box 12 Component Locations Instruments Controls 03 04 26...

Page 22: ...r to the gauges indicators and displays frequently Their functions are described on the following pages 1 speedometer 2 neutral indicator 3 high beam indicator 4 low oil pressure indicator 5 fuel rese...

Page 23: ...comes on when you turn the ignition switch ON so you can check that it is working The indicator remains on until after the engine is started The low oil pressure indicator is identified in the table o...

Page 24: ...l Lights when the headlight is on high beam high beam indicator blue Lights when engine oil pressure is low enough to cause engine damage If the indicator lights pull safely to the side of the road Se...

Page 25: ...ge the engine Do not let the tachometer needle enter the red zone coolant temperature gauge Shows engine coolant temperature When the needle moves above the C cold mark the engine is warm enough to st...

Page 26: ...page Shows hour and minute page odometer tripmeter clock display tripmeter 1 2 RIGHT switch LEFT switch Resets the tripmeter or selects the operation mode tripmeter odometer page or digital clock pag...

Page 27: ...dometer shows the total miles ridden Tripmeter 1 and tripmeter 2 show number of miles ridden since you last reset the meter To select the odometer tripmeter 1 or tripmeter 2 push the LEFT switch To re...

Page 28: ...ts Controls Turn the ignition switch ON Shows hour and minute To adjust the time proceed as follows cont d Press and hold both the RIGHT switch and LEFT switch for more than 2 seconds The clock will b...

Page 29: ...press the reset RIGHT switch until the desired minute is displayed The minute display will return to 00 when 60 is reached without affecting the hour display To set the hour press the LEFT switch unt...

Page 30: ...truments Controls To end the adjustment turn the ignition switch OFF The display will stop flashing automatically and the adjustment will be cancelled if the button is not pressed for about 30 seconds...

Page 31: ...ols Features RES for extra fuel to get to a gas station for refueling OFF for parking storing or transportation ON normal position for riding The three way fuel valve is used to control the flow of fu...

Page 32: ...nstruments Controls The ignition switch is used for starting and stopping the engine page and to lock the steering for theft prevention page Insert the key and turn it to the right for the ON position...

Page 33: ...The starter motor will not operate if the engine stop switch is in the OFF position when the start button is pushed The start button is used for starting the engine Pushing the button in starts the en...

Page 34: ...will remain on resulting in battery discharge The turn signal switch is used to signal a turn or a lane change To operate move the switch all the way in the proper direction and release it The approp...

Page 35: ...ts To operate push the horn button The LEFT switch is used to reset the tripmeter To reset the tripmeter push and hold the switch with display in the tripmeter mode The LEFT switch is also used to set...

Page 36: ...adjustments to make for your comfort convenience or safety This section also includes important information about loading For information about adjusting the suspension on your Honda see page Are You...

Page 37: ...For your safety we strongly recommend that you always wear an approved motorcycle helmet eye protection boots gloves long pants and a long sleeved shirt or jacket whenever you ride Although complete...

Page 38: ...ead comfortably and securely A bright colored helmet and reflective strips can make you more noticeable in traffic An open face helmet offers some protection but a full face helmet offers more Regardl...

Page 39: ...works and handles Practice riding the motorcycle in a safe area to build your skills Do not ride in traffic until you get accustomed to the motorcycle s controls and feel comfortable with its size and...

Page 40: ...ortant to inspect your motorcycle and make sure any problem you find is corrected A pre ride inspection is a must not only for safety but because having a breakdown or even a flat tire can be a major...

Page 41: ...ars unusual such as a leak or loose cable Make sure the headlight brake light taillight and turn signals are working properly If you are carrying a passenger or cargo also check the following Make sur...

Page 42: ...e at least once a month no matter how often you ride Remember be sure to take care of any problem you find or have your Honda dealer correct it before you ride Check these items after you get on the m...

Page 43: ...ep your motorcycle well maintained with good tires and brakes you can safely carry loads within the given limits and guidelines However exceeding the weight limit or carrying an unbalanced load can se...

Page 44: ...cargo check with your Honda dealer for advice and be sure to read the information regarding accessories on page Following are the load limits for your motorcycle includes the weight of the rider passe...

Page 45: ...e If you change your normal load you may need to adjust the rear suspension page To prevent loose items from creating a hazard make sure that all cargo is tied down securely before you ride Place carg...

Page 46: ...re Riding Your motorcycle is equipped with retractable luggage tie down hooks on the underside of the seat To use the hooks remove the seat and pull the hooks outward Install the hooks in the clips an...

Page 47: ...38 Before Riding 03 04 26 13 39 26 31MBZ600_047...

Page 48: ...our new engine and enjoy optimum performance and service life refer to Break in Guidelines page Safe Riding Precautions 40 Starting Stopping the Engine 41 Preparation 41 Starting Procedure 42 Flooded...

Page 49: ...ge Even if you have ridden other motorcycles take time to become familiar with how this motorcycle works and handles Practice in a safe area until you build your skills and get accustomed to the motor...

Page 50: ...starter Your motorcycle is equipped with a side stand ignition cut off system If the side stand is down the engine cannot be started unless the transmission is in neutral If the side stand is up the e...

Page 51: ...Riding High Air Temperature The low oil pressure indicator should go off a few seconds after the engine starts If the indicator stays on stop the engine immediately and check the engine oil level To r...

Page 52: ...gine with the choke on This will lean the mixture resulting in hard starting About a half minute after the engine starts push the choke lever forward all the way to fully OFF If idling is unstable ope...

Page 53: ...to start after repeated attempts it may be flooded with excess fuel To clear a flooded engine Leave the engine stop switch set to RUN Push the choke lever forward all the way to fully OFF Open the thr...

Page 54: ...uld normally remain in the RUN position even when the engine is OFF If your motorcycle is stopped with the engine stop switch OFF and the ignition switch ON the headlight and taillight will remain on...

Page 55: ...e clutch lever It is at this point the transmission of power to the rear wheel resumes Upshift to a higher gear or reduce throttle before engine rpm speed gets too high Learn the relationship between...

Page 56: ...the highest gear that lets the engine run and accelerate smoothly This will give you good fuel economy and effective emissions control When changing gears under normal conditions use these recommende...

Page 57: ...d The increase in engine compression from downshifting will help slow your motorcycle To prevent stalling the engine pull the clutch lever in before coming to a complete stop For support put your left...

Page 58: ...akelight giving a false indication to other drivers It may also overheat the brakes reducing effectiveness Your ability to brake in a turn and to brake hard in an emergency situation are important rid...

Page 59: ...member that lowering the side stand with the transmission in gear will stop the engine even if the clutch lever is pulled in That is a function of the side stand ignition cut off system Check that the...

Page 60: ...ion Riding To unlock the steering lock insert and push down on the key and turn it to the right to the OFF position Use the steering lock which locks the handlebar in place Turn the handlebar all the...

Page 61: ...2 helmet holder wire 3 D ring 4 helmet holder 52 Parking Basic Operation Riding Use the helmet holder wire stored in the tool kit to secure your helmet with your motorcycle Hook the loops of the wire...

Page 62: ...ment due to their size or design Park your motorcycle in a locked garage whenever possible If a garage isn t available park in a concealed area or in a well lit area with enough pedestrian traffic to...

Page 63: ...peration Riding Keep your owner s manual current registration and insurance information with your motorcycle This will make it easier for the authorities to find you if your motorcycle is stolen and r...

Page 64: ...ension page for the extra load Be aware that carrying a passenger or heavy cargo can affect acceleration braking and handling Before riding with a passenger make sure your passenger is wearing the pro...

Page 65: ...56 Basic Operation Riding 03 04 26 13 41 43 31MBZ600_065...

Page 66: ...t once a month and step by step instructions for specific maintenance tasks You ll also find important safety precautions information on fuels and oils and tips for keeping your Honda looking great Fo...

Page 67: ...Kit 76 Owner s Manual Storage 77 Seat Removal 78 Side Cover Removal 79 Fluids Filters Fuel 80 Engine Oil Filter 83 Coolant 93 Air Cleaner 97 Throttle 99 Clutch System 101 Engine Idle Speed 105 Spark P...

Page 68: ...ce The periodic checks provide additional confidence in your motorcycle s performance more often if you ride frequently or long distances or anytime you clean your motorcycle unless you have the prope...

Page 69: ...l to your safety It s also a good way to protect your investment get maximum performance avoid breakdowns and have more fun A properly maintained motorcycle will also help to reduce air pollution Reme...

Page 70: ...ese tasks with the tools provided with your motorcycle Other tasks that are more difficult and require special tools are best performed by professionals Wheel removal should normally be handled only b...

Page 71: ...tial hazards Be sure there is adequate ventilation whenever you operate the engine Let the engine and exhaust system cool before touching Do not run the engine unless instructed to do so To help preve...

Page 72: ...pped to maintain and repair it To ensure the best quality and reliability use only new genuine Honda parts or their equivalents for repair and replacement If you have the tools and skills required for...

Page 73: ...a month even if you haven t ridden your motorcycle or as often as once a week if you ride frequently or for long distances It s a good idea to perform this maintenance any time you clean your motorcyc...

Page 74: ...auge and add air if needed page Examine the tread for wear page Look closely for nails embedded objects cuts and other types of damage page Roll your motorcycle so you can inspect the entire surface C...

Page 75: ...ems involve more extensive procedures and may require special training tools and equipment We recommend that you have your Honda dealer perform these tasks unless you have advanced mechanical skills a...

Page 76: ...t your Honda dealer knows your motorcycle best and is fully equipped to maintain and repair it If you decide to do your own maintenance use only genuine Honda parts or their equivalents for repair or...

Page 77: ...motorcycle is ridden in unusually wet or dusty areas Maintenance Procedures I inspect and clean adjust lubricate or replace if necessary C clean A adjust L lubricate R replace Replace every 2 years o...

Page 78: ...I R I R R I I I I I 20 32 0 I I 24 38 4 I I I I R R R I I R I I I Refer to page 97 107 83 88 105 93 12 19 2 I I I I 0 6 1 0 I R R I ODOMETER READING Note 1 ITEM FREQUENCY EMISSION RELATED ITEMS 69 Se...

Page 79: ...I I 24 38 4 R I I I I I I I I I I NOTE 3 Refer to page 128 115 118 114 101 127 ODOMETER READING Note 1 ITEM FREQUENCY I L EVERY 500 mi 800 km NON EMISSION RELATED ITEMS 70 Maintenance Schedule Servic...

Page 80: ...fy the maintenance was performed If the motorcycle is sold these receipts should be transferred with the motorcycle to the new owner Make sure whoever performs the maintenance completes this record Al...

Page 81: ...Miles km Odometer Date Notes Performed By 24 000 38 400 28 000 44 800 32 000 51 200 36 000 57 600 40 000 64 000 44 000 70 400 48 000 76 800 52 000 83 200 56 000 89 600 60 000 96 000 64 000 102 400 68...

Page 82: ...fuel fill cap front brake fluid reservoir front brake lever throttle grip 73 Component Locations Servicing Your Honda 03 04 26 13 44 07 31MBZ600_082...

Page 83: ...ake fluid reservoir rear brake caliper front brake caliper coolant reserve tank battery tool kit compartment oil filler cap dipstick 74 Component Locations Servicing Your Honda 03 04 26 13 44 12 31MBZ...

Page 84: ...ive chain fuse box side stand front brake caliper rear spring pre load adjuster choke lever spark plugs owner s manual storage 75 Component Locations Servicing Your Honda 03 04 26 13 44 17 31MBZ600_08...

Page 85: ...ustments and parts replacement can be performed with the tools contained in the kit 10 12 mm open end wrench 14 17 mm open end wrench no 3 Phillips screwdriver screwdriver handle spark plug wrench 24...

Page 86: ...Your motorcycle provides storage for the owner s manual so you ll have it with you for easy reference Store your owner s manual and other documents in the plastic storage bag in the storage compartmen...

Page 87: ...ion key into the seat lock Turn it clockwise and pull up on the rear of the seat Push forward and then down on the rear of the seat Be sure to securely lock the seat after reinstalling it Insert the f...

Page 88: ...ers can be removed in the same manner Remove the bolt Installation can be done in the reverse order of removal Remove tab A from the grommet Remove tab B from the rear cowl Remove the side cover The r...

Page 89: ...or concern If pinging or spark knock occurs at a steady engine speed under normal load change brands of gasoline If pinging or spark knock persists consult your Honda dealer We recommend that you use...

Page 90: ...Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank Refer to on page Insert the ignition key in the fuel fill cap and turn it clockwi...

Page 91: ...only outdoors Wipe up spills immediately 82 Fuel Servicing Your Honda Open the cap Add fuel until the level reaches the bottom of the filler neck Avoid overfilling the tank There should be no fuel in...

Page 92: ...ing the proper oil page and filter and regularly checking adding and changing oil will help extend your engine s life Even the best oil wears out Changing oil helps get rid of dirt and deposits in the...

Page 93: ...r except oils labeled as energy conserving on the circular API service label API classification JASO T 903 standard viscosity weight suggested oil 84 Oil Recommendation Engine Oil Filter Servicing You...

Page 94: ...e recommended oil Other viscosities shown in the following chart may be used when the average temperature in your riding area is within the indicated range Do not use non detergent vegetable or castor...

Page 95: ...Filter Servicing Your Honda JASO T 903 standard The JASO T 903 standard is an index to choose engine oils for 4 stroke motorcycle engines There are two classes MA and MB Oil conforming to the standard...

Page 96: ...ut don t screw it in Hold the motorcycle in an upright position Remove the oil filler cap dipstick and wipe it clean Stop the engine and wait 2 3 minutes Start the engine and let it idle for 3 5 minut...

Page 97: ...rements Use a new genuine Honda oil filter or a filter of equal quality specified for your model Remove the dipstick and check the oil level If the oil is at or near the upper level mark you do not ha...

Page 98: ...e drained fluid page If you do not have the skills or the tools see your Honda dealer Park the motorcycle on its side stand on a firm level surface If the engine is cold start it and let it idle for 3...

Page 99: ...drained fluids is harmful to the environment Remove the oil filter with a filter wrench and let the remaining oil drain out Discard the oil filter in an approved manner page Pour the drained oil into...

Page 100: ...tighten it by hand Check the condition of the sealing washer on the drain bolt Replace the washer every other time the oil is changed Install the drain bolt and tighten it to the specified torque Fil...

Page 101: ...everal minutes Hold the motorcycle upright and check that the oil level is at the upper level mark on the dipstick page Check that there are no oil leaks If a torque wrench is not used for installatio...

Page 102: ...pecifically recommended for use in aluminum engines Check the antifreeze container label Maintaining the coolant will allow the cooling system to work properly and prevent freezing overheating and cor...

Page 103: ...utions Increasing the concentration of antifreeze is not recommended because it decreases cooling system performance Higher concentrations of antifreeze up to 60 should only be used to provide additio...

Page 104: ...and see your Honda dealer for repair Coolant should be replaced by your Honda dealer unless you have the proper tools and service data and are mechanically qualified Refer to the official Honda Servic...

Page 105: ...calding you Always let the engine and radiator cool down before removing the radiator cap 96 Coolant Servicing Your Honda You the Environment Improper disposal of drained fluids is harmful to the envi...

Page 106: ...ide in unusually wet or dusty areas Your Honda dealer can help you determine the correct service interval for your riding conditions Your motorcycle s air cleaner has very specific performance require...

Page 107: ...emove the attaching screws 1 and air cleaner housing cover 2 Remove the left side cover page Pull out the air cleaner 3 and clean the air cleaner using compressed air from the outside or replace it if...

Page 108: ...fer to on page Inspection Check freeplay at the throttle grip flange Freeplay If necessary adjust to the specified range Adjustment Loosen the lock nut Turn the adjuster After adjustment check for smo...

Page 109: ...o on page Check that the throttle assembly is positioned properly and the securing bolts are tight Check for smooth rotation of the throttle from fully open to fully closed in all steering positions I...

Page 110: ...cautions Refer to on page Your motorcycle s manually activated wet multiplate clutch is part of the primary drive system Proper freeplay adjustment allows a smooth gradual engagement when shifting gea...

Page 111: ...Your Honda Inspection Check freeplay If necessary adjust to the specified range Upper Adjustment Attempt adjustment with the upper clutch cable adjuster first Loosen the upper lock nut Turn the upper...

Page 112: ...rect freeplay cannot be obtained attempt adjustment with the lower clutch cable adjuster Loosen the upper lock nut and turn the upper clutch cable adjuster all the way in to provide maximum freeplay T...

Page 113: ...y If you cannot get proper adjustment or the clutch does not work properly the cable or clutch friction discs may be worn See your Honda dealer or refer to the official Honda Service Manual page Lubri...

Page 114: ...d adjustment is not a cure all for other problems in your engine s fuel delivery system Adjusting the idle will not compensate for a fault elsewhere The engine must be at normal operating temperature...

Page 115: ...eed Servicing Your Honda Adjust idle speed with the throttle stop screw Idle speed in neutral Shift into neutral Start the engine Place your motorcycle on its side stand on a firm level surface 3 4 1...

Page 116: ...plug 107 Spark Plug Recommendation Spark Plugs Servicing Your Honda Using spark plugs with an improper heat range can cause engine damage Use only the recommended type of spark plugs in the recommende...

Page 117: ...lts and collars Move the radiator out of the way and remove the grommet from the radiator stay Pull the radiator toward the front Clean any dirt from around the spark plug base Disconnect the spark pl...

Page 118: ...ing If the corrosion or deposits are heavy replace the plug Clean a carbon or wet fouled plug with a plug cleaner if available or a wire brush Check the spark plug gap of each new plug using a wire ty...

Page 119: ...ug is too tight the threads may be damaged Tighten each spark plug 1 8 1 4 turn after it seats if the old plug is good 1 2 turn after it seats if installing a new plug Reinstall the spark plug caps Ta...

Page 120: ...er systems hydraulically control the natural compression and rebound of the suspension springs so that traction and comfort are maintained as the wheels ride over road surfaces Consider adjusting your...

Page 121: ...ditions by changing the spring pre load The rear shock absorber includes a damper unit that contains high pressure nitrogen gas Do not attempt to disassemble service or dispose of the damper see your...

Page 122: ...use the pin spanner and extension bar to adjust the rear shock spring pre load Always adjust the shock absorber position in sequence 1 2 3 4 5 6 7 or 7 6 5 4 3 2 1 Attempting to adjust directly from...

Page 123: ...l to drop Frequently inspect the system to ensure there are no fluid leaks Periodically inspect the brake fluid level and the brake pads for wear If the brake lever or brake pedal freeplay does not fe...

Page 124: ...id from a sealed container Be sure to read the label before opening the sealed container An opened container may be contaminated or may have absorbed moisture from the air Apply the brake release it t...

Page 125: ...tion indicates a low fluid level have your Honda dealer add the recommended brake fluid Wipe up spills immediately Avoid contact with skin or eyes In case of contact wash thoroughly and call a doctor...

Page 126: ...WER level marks If the level is at or below the LOWER level mark check the brake pads for wear page Remove the side cover page Worn pads should be replaced If the pads are not worn beyond the recommen...

Page 127: ...d road conditions Generally the pads will wear faster on wet and dirty roads Inspect the pads at each regular maintenance interval page Front Brake Always inspect both pads in both the right and left...

Page 128: ...cutouts 119 Brakes Servicing Your Honda Rear Brake Check the cutouts in each pad If either pad is worn to the cutout replace both pads as a set See your Honda dealer for this service 2 03 04 26 13 50...

Page 129: ...nly adversely affect handling and are more likely to fail from being overheated Overinflated tires make your motorcycle ride more harshly are more prone to damage from road hazards and wear unevenly R...

Page 130: ...have some degree of self sealing ability if they are punctured However because leakage is often very slow you should look closely for punctures whenever a tire is not fully inflated Always check air...

Page 131: ...ire or the tread Replace any tire that has a bump or bulge Cuts slits or cracks in the tires Replace the tire if you can see fabric or cord Nails or other foreign objects embedded in the side of the t...

Page 132: ...s repaired either temporarily or permanently will have lower speed and performance limits than a new or undamaged tire If the wear indicators are visible replace the tire immediately as it is no longe...

Page 133: ...safely carry as much weight If you choose to have a tire repaired be sure the repair work is performed by a professional and that the wheel is balanced before you ride Refer to on page The tires that...

Page 134: ...riously hurt or killed Always use the size and type of tires recommended in this owner s manual front rear 125 Tires Servicing Your Honda The recommended tires for your motorcycle are You should repla...

Page 135: ...ess tires and during hard acceleration or braking a tube type tire could slip on the rim and cause the tire to rapidly deflate Do not install a tube inside a tubeless tire on this motorcycle Excessive...

Page 136: ...utral Raise the side stand Start the engine Pull the clutch lever in Shift the transmission into gear Lower the side stand all the way The engine should stop as you lower the side stand If the engine...

Page 137: ...reas more frequent maintenance will be necessary The service life of the chain depends on proper lubrication and adjustment Poor maintenance can cause premature wear or damage to the drive chain or sp...

Page 138: ...w the following vertical movement by hand Check drive chain slack at several points along the chain The slack should remain constant If it isn t some links may be kinked and binding Lubricating the ch...

Page 139: ...and rear sprocket teeth for excessive wear or damage If necessary have your Honda dealer replace a worn sprocket Replace the drive chain page if it has damaged rollers loose pins or kinks that cannot...

Page 140: ...sted if necessary every 500 miles 800 km When operated at sustained high speeds or under conditions of frequent rapid acceleration the chain may require more frequent adjustments Refer to on page Chec...

Page 141: ...n equal number of turns until the correct drive chain slack is obtained Turn the adjusting bolts counterclockwise to tighten the chain or clockwise to provide more slack Adjust the chain slack at a po...

Page 142: ...urn the right or left adjusting bolt until the marks are aligned and recheck chain slack Torque the rear axle nut to If a torque wrench is not used for this installation see your Honda dealer as soon...

Page 143: ...by your Honda dealer The O rings can be damaged by steam cleaning high pressure washers and certain solvents Clean the side surfaces of the chain with a dry cloth Use a high flashpoint solvent such a...

Page 144: ...ou remove the battery or at least disconnect the battery cables negative cable first Electrical accessories use current from the battery even when the ignition is OFF Limited operation also allows the...

Page 145: ...to on page If you plan to store your motorcycle we recommend you remove the battery and store it where it can be charged at least every 30 days to maintain its service life If you do not remove the b...

Page 146: ...ight side cover page The battery is in the battery box behind the right side cover Unhook the strap and remove the positive cable from the hook securing it Pull the battery out of the battery box Disc...

Page 147: ...an easy to reach location off the floor in an area protected from freezing temperatures and direct sunlight Clean the battery box after removing the battery for storage Dry the battery box and if pain...

Page 148: ...intentionally leave the charger connected longer than the time period recommended in the charger s instructions Avoid using an automotive type battery charger An automotive charger can overheat a mot...

Page 149: ...a mild spray and rinse cleaner degreaser and water Avoid products that contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your motorcycle If your motorcycl...

Page 150: ...your motorcycle We recommend the use of a garden hose to wash your motorcycle High pressure washers like those at coin operated car washes can damage certain parts of your motorcycle After cleaning in...

Page 151: ...a sponge or a soft towel As you wash check for heavy grime If necessary use a mild cleaner degreaser to remove the grime Clean the headlight and other plastic parts using a cloth or sponge dampened wi...

Page 152: ...r on the surface to air dry can cause dulling and water spots As you dry inspect for chips and scratches As a precaution ride your motorcycle at a slow speed and apply the brakes several times This wi...

Page 153: ...a mild detergent to clean the matte paint Dry with a soft clean cloth Do not use polishing compounds or wax containing polishing compounds These can damage or discolor the paint Suggestions for using...

Page 154: ...polish and wipe with a non abrasive cloth Use a spray cleaner degreaser If necessary rub with a sponge Rinse and dry Apply a spray cleaner polish and wipe with a non abrasive cloth Apply a high quali...

Page 155: ...irt mud or road salt Clean the wheels after riding through any of these substances Use a wet sponge and mild detergent Avoid stiff brushes steel wool or cleaners containing abrasives or chemical compo...

Page 156: ...tomobiles Apply the polish or wax according to the instructions on the container If a surface on your motorcycle is chipped or scratched your Honda dealer has touch up paint to match your motorcycle s...

Page 157: ...148 Servicing Your Honda 03 04 26 13 54 09 31MBZ600_157...

Page 158: ...helpful tips on how to store and transport your Honda and how to be an environmentally responsible motorcycle owner Storing Your Honda 150 Transporting Your Motorcycle 154 You the Environment 157 03 0...

Page 159: ...This procedure requires a means for draining and disposing of drained fuel page Change the engine oil and filter page Make sure the cooling system is filled with a 50 50 antifreeze solution page Fill...

Page 160: ...ny convenient plastic body part so that they are positioned away from the spark plugs Remove the spark plugs from the engine and store them in a safe place Do not connect the spark plugs to the spark...

Page 161: ...cycle Wax all painted surfaces Apply rust inhibiting oil to the chrome pieces Lubricate the drive chain page Inflate the tires to their recommended pressures page Store your motorcycle in an unheated...

Page 162: ...months change the engine oil page If your motorcycle has been stored for more than two months ask your Honda dealer to drain and replace the fuel Charge the battery page as required Install the batter...

Page 163: ...rea For information about 24 hour emergency assistance see page USA only Do not tow your motorcycle as towing can seriously damage the transmission When contacting a towing or transporting service be...

Page 164: ...he following guidelines for proper disposal It s illegal and thoughtless to put used engine oil in the trash down a drain or on the ground Used oil gasoline coolant and cleaning solvents contain poiso...

Page 165: ...156 Tips 03 04 26 13 55 03 31MBZ600_165...

Page 166: ...lem cannot be safely solved this section also gives instructions on the proper way to have your motorcycle transported For information about transporting your motorcycle see page General Guidelines 15...

Page 167: ...do If the problem is relatively minor and you have the tools supplies and skills to make a temporary repair be sure to have permanent repairs made as soon as possible Do not continue riding if you are...

Page 168: ...the problem may be a simple operational oversight If you have a problem starting the engine or experience poor engine performance the following information may help you If you can t correct the probl...

Page 169: ...into neutral Raise the side stand Put the transmission in neutral pull the clutch lever in or raise the side stand Replace with a new fuse of the same rating page Tighten the battery lead Charge the b...

Page 170: ...If the engine still won t start see your Honda dealer Tighten the battery terminal bolts loose battery cables weak battery Charge the battery page If charging doesn t help see your Honda dealer 44 139...

Page 171: ...See your Honda dealer blubbers rich fuel mixture runs erratically misfires See your Honda dealer Check the coolant temperature gauge Refer to page Check the low oil pressure indicator Refer to page 1...

Page 172: ...backfires See your Honda dealer If applicable switch to the recommended octane gasoline page or change your brand of gasoline If the problem persists see your Honda dealer See your Honda dealer See yo...

Page 173: ...Transported If a tire has a major puncture or a cut in the tread or sidewall or the bead has come loose from the rim there is probably not much you can do except have your motorcycle transported to a...

Page 174: ...epair you should ride slowly not over 30 mph 50 km h and carefully preferably without a passenger or cargo until the tire is replaced or permanently repaired Stop frequently and check the air pressure...

Page 175: ...n the tire tread do not remove it at this time The idea here is to do something to temporarily stop the leak If you have a tubeless tire repair kit you can pull out the nail and try inserting an exter...

Page 176: ...Unexpected Safety Precautions Refer to on page Removal Park your motorcycle on a firm level surface We recommend wheel removal be done only by your Honda dealer or another qualified mechanic Do not a...

Page 177: ...he axle bolt Remove the fixing bolts and remove the right and left caliper assemblies from the fork legs To avoid damage to the brake hose during removal support the caliper assembly so that it doesn...

Page 178: ...is off the motorcycle This will force the caliper pistons out of the cylinders The result will be loss of brake fluid If this occurs the brake system will require service See your Honda dealer for th...

Page 179: ...he brake discs and impair braking efficiency Operate the front brake and pump the fork several times Temporarily tighten the axle pinch bolts on the left fork leg until lightly seated Install the cali...

Page 180: ...n recheck both discs for caliper body to disc clearance Do not operate the motorcycle without adequate clearance If a torque wrench was not used for installation see your Honda dealer as soon as possi...

Page 181: ...dealer or another qualified mechanic Do not attempt to remove the wheel on your own Wheel removal requires mechanical skill and professional tools Loosen the rear axle nut Park your motorcycle on a fi...

Page 182: ...otorcycle This will force the caliper pistons out of the cylinders The result will be a loss of brake fluid If this occurs the brake system will require service See your Honda dealer for this service...

Page 183: ...over the rear sprocket While installing the wheel carefully fit the brake disc between the brake pads to avoid damaging the pads Tighten the axle nut to the specified torque Failure to provide adequat...

Page 184: ...recheck both discs for caliper holder to disc clearance Do not operate the motorcycle without adequate clearance If a torque wrench was not used for installation see your Honda dealer as soon as poss...

Page 185: ...her may cause the needle to rise higher than normal So will temporary stress such as climbing a hill If you re stuck in stop and go traffic the needle may climb some but the radiator fan is designed t...

Page 186: ...radiator system If the reserve tank is low or empty don t ride without adding coolant page After adding coolant turn the engine on and check the temperature gauge If the needle doesn t drop do not ri...

Page 187: ...stem If the indicator comes on while you re riding don t ignore it Pull safely to the side of the road If possible pull the clutch lever in and coast to a stop Stop the engine as soon as it s safe to...

Page 188: ...it fuse box cover which fuse or fuses control that component Check those fuses first but check all the fuses before looking elsewhere for another possible cause of the problem Replace any blown fuses...

Page 189: ...expected To access the main fuse remove the right side cover page Open the fuse box cover to access the fuse box Reconnect the wire connector The spare main fuse is located near the starter magnetic s...

Page 190: ...ck or replace the circuit fuse pull the old fuse out of its retaining clips with a fuse remover Look for a burned wire inside the fuse If the fuse is blown replace it with a spare fuse of the same rat...

Page 191: ...arily If you replace a blown fuse with a spare fuse that has a lower rating replace the fuse with the correct rating as soon as you can Also remember to replace any spare fuses that were installed If...

Page 192: ...ing safely carefully inspect your motorcycle for damage and determine if it is safe to ride Check the tightness of critical nuts and bolts securing such parts as the handlebar control levers brakes an...

Page 193: ...licate in your wallet If you lose your key and aren t carrying a duplicate either get your spare or have one made If you don t know your key number call the dealer you purchased your Honda from They m...

Page 194: ...use an automobile battery The greater amperage of an automobile battery when the car engine is running can damage your motorcycle s electrical system Bump starting is also not recommended If you can...

Page 195: ...186 Taking Care of the Unexpected 03 04 26 13 58 55 31MBZ600_195...

Page 196: ...ta plus information on government requirements and how to break in your motorcycle Vehicle Identification 188 Specifications 191 Break in Guidelines 198 High Altitude Carburetor Adjustment 199 Emissio...

Page 197: ...when you register your motorcycle They may also be required when ordering replacement parts You may record these numbers in the Quick Reference section at the rear of this manual The VIN vehicle ident...

Page 198: ...ne number 2 3 RIGHT SIDE 189 Vehicle Identification Technical Information The frame number is stamped on the right side of the steering head The engine number is stamped on the top of the crankcase 2...

Page 199: ...mation The color code is helpful when ordering replacement parts You may record the color and code in the Quick Reference section at the rear of this manual The color label is attached to the frame un...

Page 200: ...55 9 in 1 420 mm 5 5 in 140 mm 403 lbs 183 kg 406 lbs 184 kg overall length overall width overall height wheelbase ground clearance dry weight California only Dimensions Weight 191 Specifications Tech...

Page 201: ...0 or 90 gear oil 2 4 US qt 2 3 4 49 US gal 17 0 0 69 US gal 2 6 after disassembly after draining including reserve after draining oil filter change engine oil capacity engine oil recommendation coolin...

Page 202: ...GK U27FER9 DENSO 0 03 0 04 in 0 8 0 9 mm 1 400 100 rpm USA Canada or operator and one passenger passenger capacity maximum weight capacity spark plug standard compression ratio bore stroke displacemen...

Page 203: ...hain 42 teeth 15 teeth drive engine sprocket driven rear wheel sprocket or primary reduction gear ratio 1st 2nd 3rd 4th 5th 6th final reduction standard sprocket sizes final drive Power Transmission 1...

Page 204: ...0 kgf cm 42 psi 290 kPa 2 90 kgf cm 12V 6 Ah 0 343 kW 5 000 rpm caster trail tire size front tire size rear tire pressure front cold tire pressure rear cold generator battery Chassis Suspension Electr...

Page 205: ...5W 30A 10A 20A 2 bulbs front rear 2 bulbs 2 bulbs 2 bulbs headlight turn signal lights brake tail light instrument lights turn signal indicator license light main other fuses Lights Fuses 196 Specific...

Page 206: ...N m 3 1 kgf m 16 lbf ft 22 N m 2 2 kgf m 65 lbf ft 88 N m 9 0 kgf m oil drain bolt oil filter front wheel axle bolt front wheel caliper fixing bolts front wheel axle pinch bolts rear wheel axle nut T...

Page 207: ...on Help assure your motorcycle s future reliability and performance by paying extra attention to how you ride during the first 300 miles 500 km During this period avoid full throttle starts and rapid...

Page 208: ...ease fuel consumption To compensate you can have the carburetors adjusted for high altitude riding See your Honda dealer However the carburetors must be returned to standard factory specifications bef...

Page 209: ...cal Information Compliance with the terms of the Distributor s Warranties for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect USA only T...

Page 210: ...3 comply with applicable noise emission standards for one year or 3 730 miles 6 000 km after the time of sale to the ultimate purchaser when operated and maintained according to the instructions provi...

Page 211: ...or is directed into the charcoal canister and air cleaner where it is absorbed and stored while the engine is stopped When the engine is running and the purge control diaphragm valve is open fuel vapo...

Page 212: ...ough idle Misfiring or backfiring during acceleration After burning backfiring Poor performance driveability and poor fuel economy The oxidation catalytic converter is in the exhaust system Through ch...

Page 213: ...TE TAMPERING ARE THE FOLLOWING ACTS TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED U S federal law prohibits or Canadian provincial laws may prohibit the following acts or the causing thereof T...

Page 214: ...iring backfiring stalling or otherwise not running properly This motorcycle is equipped with an oxidation catalytic converter The catalytic converter contains precious metals that serve as catalysts p...

Page 215: ...ded and meets the minimum octane rating requirement Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The follo...

Page 216: ...pill fuel when filling the fuel tank Wipe up any spills immediately If you notice any undesirable operating symptoms try another service station or switch to another brand of gasoline METHANOL methyl...

Page 217: ...208 Technical Information 03 04 26 14 01 44 31MBZ600_217...

Page 218: ...on your warranty and how to get an official Honda service manual Authorized Manuals 210 Warranty Coverage 213 Warranty Service 214 Contacting Honda 215 Your Honda Dealer 216 The Honda Rider s Club US...

Page 219: ...nada See your Honda dealer to order authorized manuals Also available but not necessary to service your model is the Honda Common Service Manual Publication No 61CM001 which explains theory of operati...

Page 220: ...nd Total 4 00 211 Order On Line www helminc com Order Toll Free 1 888 CYCLE93 OR Consumer Information NOTE For Credit Card Orders Only 1 888 292 5393 Monday Friday 8 00 AM 6 00 PM EST By completing th...

Page 221: ...ney order enclosed payable to Helm Inc U S funds only Do not send cash MasterCard VISA Discover Account Number Date These Publications cannot be returned for credit without receiving advance authoriza...

Page 222: ...mportant to realize that your warranty applies to defects in material or workmanship of your Honda Your warranty coverage does not apply to normal wear or deterioration associated with using the motor...

Page 223: ...results of the inspection If the problem is covered under warranty your dealer will perform the warranty repairs for you If you have questions about warranty coverage or the nature of the repair it i...

Page 224: ...ied with your vehicle Please include the following information in your letter name address and telephone number product model year and frame VIN serial number date of purchase dealer name and address...

Page 225: ...only The same quality that went into your Honda can be found in Genuine Honda replacement parts You ll also find comparable quality in the accessories and products available from the parts department...

Page 226: ...r or service facility if roadside assistance can t get you going again Reimbursement to 75 for motorcycle and scooter rider training from the Motorcycle Safety Foundation Free ATV rider training is av...

Page 227: ...fety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other information about motor ve...

Page 228: ...219 Consumer Information 03 04 26 14 03 16 31MBZ600_228...

Page 229: ...ons 10 Gauges Indicators 13 Controls Features Choke lever 22 Ignition Switch 23 Start Button 24 Engine Stop Switch 24 Headlight Dimmer Switch 25 Turn Signal Switch 25 Horn Button 26 LEFT Switch 26 RIG...

Page 230: ...rting Procedure 42 Flooded Engine 44 How to Stop the Engine 45 Shifting Gears 46 Braking 48 Parking 50 Riding with a Passenger or Cargo 55 The Importance of Maintenance 60 Maintenance Safety 61 Import...

Page 231: ...80 Engine Oil Filter 83 Coolant 93 Air Cleaner 97 Engine Throttle 99 Clutch System 101 Engine Idle Speed 105 Spark Plugs 107 Suspension 111 Brakes 114 Tires 120 Side Stand 127 Drive Chain 128 Battery...

Page 232: ...or Lights 178 If a Fuse Blows 179 If You Crash 183 If You Lose Your Key 184 If Your Battery is Low or Dead 185 Vehicle Identification 188 Specifications 191 Break in Guidelines 198 High Altitude Carbu...

Page 233: ...118 braking 48 break in guidelines 198 capacity fuel 81 care appearance 140 chain drive 128 cleaner air 96 cleaning appearance care 140 cleaning matte color painted surface 144 clutch system 101 color...

Page 234: ...ion control systems 200 engine flooded 44 idle speed 105 low oil pressure 178 number 188 oil 83 overheats 176 pinging 80 starting 41 stop switch 24 stopping 45 won t start 159 environment 155 flat tir...

Page 235: ...altitude carburetor adjustment 199 high beam indicator 15 Honda contacting 215 Rider s Club 217 dealer 216 Honda service manual 210 horn button 26 identification vehicle 188 idle speed engine 105 igni...

Page 236: ...guidelines 35 location components indicators controls 10 maintenance 73 lock steering 51 maintenance importance 60 periodic 64 record 71 safety 61 schedule 66 manual service 210 matte color painted su...

Page 237: ...ne 80 plugs spark 107 pre load rear suspension 113 pre ride inspection 31 problems unexpected 157 protective apparel 28 removal seat 78 side cover 79 reporting safety defects 218 rider training 2 30 R...

Page 238: ...umbers 188 service customer 215 manuals 210 warranty 214 shifting gears 46 side stand 127 side stand ignition cutoff system 37 spark knock 80 spark plugs 107 specifications 191 speedometer 13 stand si...

Page 239: ...mmer 25 ignition 26 left 26 right 26 turn signal 25 tachometer 13 16 temperature gauge coolant 16 theft prevention tips 53 throttle 99 tires air pressure 120 flat 164 replacing 124 tool kit 76 trainin...

Page 240: ...Index W V vehicle identification no VIN 188 warranty coverage 213 extended 213 service 214 washing your motorcycle 140 weight limit 35 wheels front removal 167 rear removal 172 03 04 26 14 04 27 31MB...

Page 241: ...232 Memo 03 04 26 14 04 29 31MBZ600_241...

Page 242: ...233 Memo 03 04 26 14 04 32 31MBZ600_242...

Page 243: ...234 Memo 03 04 26 14 04 34 31MBZ600_243...

Page 244: ...engine of your Honda can be the most expensive component to repair Proper maintenance especially the use of the recommended fluids and filters prevents premature wear and damage Frequent causes of cos...

Page 245: ...Reference Quick Reference VIN Frame No Engine No Frame No Ignition Key No Color Label Owner s Name Address City State Phone Dealer s Name Address City State Phone Service Mgr 03 04 26 14 04 45 31MBZ60...

Page 246: ...es fluids lights freeplay drive chain fuses nuts bolts unleaded gasoline pump octane number 86 or higher Maximum Weight Capacity rider passenger all cargo and accessories ethylene glycol antifreeze si...

Page 247: ...R9EH 9 NGK U27FER9 DENSO 30A 10A 20A BRIDGESTONE BT 56F RADIAL N MICHELIN Pilot ROAD S BRIDGESTONE BT 56R RADIAL G MICHELIN Pilot ROAD S Quick Reference Quick Reference Tires Tire Pressure cold Spark...

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