1988 Honda Hurricane 600 Service Manual

The 1988 Honda Hurricane 600 is a sport motorcycle featuring a 598cc liquid-cooled inline-four engine, 16-valve DOHC configuration, 6-speed transmission, steel diamond frame, 41mm front forks, Pro-Link rear suspension, dual front disc brakes, single rear disc brake, and digital/analog instrumentation. This manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for proper servicing of the CBR600F model.

1. General Information 2. Maintenance Schedule 3. Engine Service 4. Chassis Specifications 5. Fuel System 6. Electrical System 7. Cooling System 8. Brake System 9. Suspension 10. Troubleshooting

General Information

Model identification: CBR600F. VIN location: steering head. Key components: frame, engine, suspension, brakes, electrical system.

Component	Description
Engine Type	598cc liquid-cooled inline-four
Valve System	16-valve DOHC
Bore x Stroke	63.0mm x 48.0mm
Compression Ratio	11.0:1
Fuel System	Four 34mm constant velocity carburetors
Ignition System	CDI electronic ignition
Transmission	6-speed constant mesh
Final Drive	#530 O-ring chain
Frame Type	Steel diamond frame
Curb Weight	463 lbs (210 kg)

Maintenance Schedule

Regular maintenance intervals for optimal performance and safety.

Every 600 miles (1,000 km): Check/adjust chain, check tire pressure, check brake pads.
Every 4,000 miles (6,400 km): Change engine oil and filter, check valve clearance.
Every 8,000 miles (12,800 km): Replace spark plugs, clean air filter, check carburetor synchronization.
Every 12,000 miles (19,200 km): Replace brake fluid, check wheel bearings, inspect suspension.
Every 16,000 miles (25,600 km): Replace coolant, check clutch operation.

WARNING! Always use Honda Genuine parts and recommended fluids. Wear appropriate safety gear during maintenance.

Engine Service

Engine removal, disassembly, inspection, and reassembly procedures.

Remove engine: Drain coolant and oil, disconnect electrical connectors, remove mounting bolts.
Cylinder head: Check valve clearance (IN: 0.15-0.19mm, EX: 0.17-0.21mm), inspect camshafts.
Cylinder and pistons: Measure cylinder bore, check piston ring end gap.
Crankshaft and connecting rods: Check bearing clearance, inspect crankshaft runout.
Clutch: Inspect plates and discs, check spring free length.

CAUTION! Torque all fasteners to specified values. Use new gaskets during reassembly.

Chassis Specifications

Front Suspension: 41mm telescopic fork, 5.1 inches (130mm) travel
Rear Suspension: Pro-Link single shock, 4.7 inches (120mm) travel
Front Tire: 110/80V17
Rear Tire: 140/70V17
Front Brake: Dual hydraulic disc, 276mm
Rear Brake: Single hydraulic disc, 220mm
Wheelbase: 55.7 inches (1415mm)
Seat Height: 30.7 inches (780mm)
Fuel Capacity: 4.8 gallons (18 liters)

Fuel System

Carburetor service and fuel delivery system maintenance.

Carburetors: Keihin CV34, main jet #112, slow jet #38, float height 14.5mm. Synchronization: Use vacuum gauges, adjust to equal vacuum at 1500 rpm.

Fuel pump: Check operation, flow rate 500ml/min minimum. Fuel filter: Replace every 12,000 miles. Throttle cables: Check free play (2-3mm), lubricate regularly.

Electrical System

Battery: 12V 10Ah. Charging system: Three-phase AC generator, output 350W at 5000 rpm.

Battery maintenance: Check specific gravity (1.260-1.280), clean terminals.
Ignition system: Check spark plug gap (0.8-0.9mm), ignition timing 10° BTDC at 1500 rpm.
Lighting: Headlight 60/55W, brake light 21/5W, turn signals 21W.
Fuses: Main 30A, headlight 15A, signal 10A, ignition 10A.

Tip: Use multimeter for electrical diagnostics. Check all ground connections.

Cooling System

Liquid cooling system with radiator and thermostat.

Coolant capacity: 2.2 liters (2.3 US qt). Use ethylene glycol antifreeze.
Radiator cap pressure: 1.1-1.4 kg/cm² (16-20 psi).
Thermostat: Opens at 80-84°C (176-183°F).
Water pump: Check for leaks, impeller damage.
Cooling fan: Activates at 103-108°C (217-226°F).

WARNING! Never open radiator cap when engine is hot. Allow engine to cool completely.

Brake System

Hydraulic disc brake maintenance and service.

Front brakes: Dual piston calipers, disc thickness 4.0mm (service limit 3.5mm). Pad thickness: 4.0mm (replace at 1.5mm).

Rear brake: Single piston caliper, disc thickness 5.0mm (service limit 4.5mm). Pad thickness: 4.0mm (replace at 1.5mm).

Brake fluid: DOT 4, replace every 2 years. Bleed system after service.

Suspension

Front fork and rear shock adjustment and service.

Front forks: Oil capacity 486ml per leg, oil weight 10W. Spring free length: 524.5mm (service limit 518mm).

Rear shock: Spring preload 5-position adjustable. Check for oil leaks, bushing wear.

Wheels: Runout limit 2.0mm axial, 2.0mm radial. Bearings: Check for smooth rotation, replace if rough.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel flow, spark plugs, compression test.
Poor idle	Carb sync, vacuum leak	Synchronize carburetors, check intake boots.
Overheating	Coolant, thermostat	Check coolant level, radiator, thermostat operation.
Brake fade	Fluid, pads, discs	Replace brake fluid, inspect pads and discs.
Electrical issues	Battery, charging	Test battery, regulator/rectifier output.

Torque Specifications: Cylinder head bolts 30 Nm, axle nuts 90 Nm, sprocket nuts 65 Nm.

Service: Contact authorized Honda dealer for technical support and genuine parts.