HRC CBR600RR Set-Up Manual/Parts List Download Page 20 | Manualshive

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Service Information

Wiring Diagram

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Summary of Contents for CBR600RR

Page 1: ...KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instructions Each message tells you w...

Page 2: ...s based on the latest product information available at the time of approval for printing Honda Racing Corporation reserves the right to make changes at any time without notice and without incurring an...

Page 3: ...CBR600RR and as is stated in the CBR600RR owner s manual should be used only in an organized racing or competitive event upon a closed course which is conducted under the auspices of a recognized san...

Page 4: ...1 Modifying the Cylinder Head Ports 2 2 Adjusting the Compression Ratio 2 3 Valve Spring Replacement 2 4 Camshaft and Cam Pulse Generator Rotor Replacement 2 4 ACG Set Installation 2 6 Transmission Se...

Page 5: ...Memo...

Page 6: ...6 t0 65 Valve clearance IN 0 20 0 03 mm 0 008 0 001 in EX 0 28 0 03 mm 0 011 0 001 in Valve train DOHC chain driven Valve timing Intake opens 21 BTDC 23 BTDC closes 44 ABDC 52 ABDC Exhaust opens 40 B...

Page 7: ...Engine Idle Speed The CBR600RR s idle speed is automatically adjusted by the IACV Idle Air Control Valve So idle speed cannot be adjusted manually like the 2006 CBR600RR For racing use engine idle spe...

Page 8: ...1 0 10 1 0 7 Apply oil to the threads and seating surface Breather plate bolt M6 x 1 0 12 1 2 9 Apply locking agent PAIR reed valve cover bolt M6 x 1 0 12 1 2 9 CT bolt apply locking agent Connecting...

Page 9: ...pply oil to the threads and seating surface wire lock ECT Tw sensor M12 x 1 5 23 2 3 17 Primary fuel rail mounting bolt M5 x 1 0 5 1 0 5 3 6 Secondary fuel rail mounting bolt M5 x 1 0 5 3 0 5 3 6 IACV...

Page 10: ...x 1 0 10 1 0 7 Oil pressure switch PT1 8 12 1 2 9 Apply sealant to the thread Oil pressure switch terminal screw M4x 0 7 2 0 2 1 4 Neutral switch M10 x 1 25 12 1 2 9 Exhaust pipe stud bolt M8 x 1 25 S...

Page 11: ...bar pinch bolt M6 x 1 0 10 1 0 7 Top bridge pinch bolt M8 x 1 25 22 2 2 16 Bottom bridge pinch bolt M8 x 1 25 27 2 8 20 Steering stem adjusting nut M26 x 1 0 25 2 5 18 Steering stem adjusting nut lock...

Page 12: ...olt replace with a new one Front brake reservoir stay bolt M6 x 1 0 12 1 2 9 Rear master cylinder push rod lock nut M8 x 1 25 18 1 8 13 Rear brake reservoir cap screw M4 x 0 7 1 5 0 2 1 4 Rear master...

Page 13: ...eads and seating surface Starter clutch mounting bolt threads and seating surface Each gear teeth Each O ring Each ball bearing and needle bearing Other rotating and sliding surface Engine inside Moly...

Page 14: ...plate bolt threads Coating width 6 5 1 mm Mainshaft bearing set plate bolt threads Coating width 6 5 1 mm Cam sprocket bolt threads Coating width 6 5 1 mm Shift drum center bolt threads Coating width...

Page 15: ...t bearing Shell Alvania EP2 or Swingarm pivot dust seal lips equivalent Shock link needle bearing Shock link dust seal lips Rear shock absorber needle bearing Rear shock absorber dust seal lips Engine...

Page 16: ...2 000 km 1 250 mi ST every 3 000 km 1 850 mi Piston Rings I I Any unusual sound inspect immediately R SS every 2 000 km 1 250 mi ST every 3 000 km 1 850 mi Crankshaft I I Any unusual sound inspect im...

Page 17: ...m Every 2 000 km Every 3 000 km Small end for wear or damage 620 mi 930 mi 1 250 mi 1 850 mi Connecting rod bolt Every 1 000 km Every 1 500 km Every 2 000 km Every 3 000 km Wear or damage 620 mi 930 m...

Page 18: ...nition switch Turn signal light Rear brake light switch Side stand switch Cooling fan motor Horn Headlight unit Replace the standard bank angle sensor with the racing kit sensor Pillion step Pillion s...

Page 19: ...gnetic 14 Unit assy serial I F 20 Rectifier assembly regulator 3 Sensor assy bank angle 9 Cable starter battery 15 CD ROM PGM FI IGN 21 Resistor 4 Sub harness IGN 10 Fuel cut off relay 16 Cable starte...

Page 20: ...1 15 Service Information Wiring Diagram...

Page 21: ...Memo...

Page 22: ...ce the insulator comp with ED type insulator No Part Number Item Q ty 06130 N1A D00 Engine Power up Kit 1 12251 NL3 751 Gasket cylinder head 0 65 1 2 14110 NL3 750 Camshaft comp IN 1 3 14210 N1A D00 C...

Page 23: ...y polish the other surfaces using an emery cloth Exhaust port Grind the exhaust port so that there is no height difference between the collar and exhaust port Lightly polish the other surfaces using a...

Page 24: ...valve and the piston head using a solder When the clearance is hin 1 2 mm Use a racing kit gasket t 0 65 mm because there is a possibility that the piston may contact with the valve When the clearanc...

Page 25: ...nerator rotor with the index mark on the right crankcase cover Make sure the No 1 piston is TDC Top Dead Center on the compression stroke 6 Make sure that the timing marks on the cam sprockets are fac...

Page 26: ...order let tered on the camshaft holder Torque 12 N m 1 2 kgf m 9 lbf ft Cam Pulse Rotor Adjustment 1 With the No 1 piston TDC check that the cam pulse rotor index line aligns with the cylinder head u...

Page 27: ...l the bolt with washer tighten the bolt to the specified torque Torque 103 N m 10 5 kgf m 76 lbf ft 7 Install the racing kit stator onto the racing kit alternator cover then tighten the stator bolts a...

Page 28: ...serting the holder bosses into the flywheel holes and seat ing the holder into the flywheel Tool Rotor holder 89030 NL9 711 Refer to previous page for tightening procedure 1 ROTOR HOLDER Flywheel Hold...

Page 29: ...e the transmission 2 Assemble the transmission using the racing kit mainshaft and C1 gear When disassembling always replace the circlips with new ones Always install the thrust washer and snap ring wi...

Page 30: ...e main journal bolts 45 degrees in numerical order again total 90 degrees Main Journal Bolt Tightening Replace the main journal bolts with new ones after every fourth tightening Tighten the main journ...

Page 31: ...quence POINT C POINT D POINT A APPLY MOLYBDENUM DISULFIDE GREASE APPLY MOLYBDENUM DISULFIDE GREASE APPLY MOLYBDENUM DISULFIDE GREASE APPLY MOLYBDENUM DISULFIDE GREASE APPLY MOLYBDENUM DISULFIDE GREASE...

Page 32: ...justing bolt while turning the hanger bolt until it seats 7 Tighten the rear lower engine hanger adjusting bolt D to the specified torque Torque 10 N m 1 0 kgf m 7 lbf ft A C D 8 Tighten the rear lowe...

Page 33: ...g a commercially available wire twisting tool 3 Insert the wire in the other side hole and twist the wire 4 Cut off any excess wire Wire twisting tool No good Good Wire Lock Use new 0 8 mm 0 03 in sta...

Page 34: ...old the pedal rod sensor securely When tightening the lock nut A hold the sensor flat portion 1 When tightening the lock nut B hold the sensor flat portion 2 Tighten the lock nuts to 18 N m 1 8 kgf m...

Page 35: ...3 Install the hoses to the cylinder head reed valve covers and air cleaner housing then secure them with removed clips 4 Plug the hoses with cone plugs from the racing kit and secure them with clamps...

Page 36: ...removal 5 Remove the bypass hose 6 Cut 50mm from both ends of the removed hoses 7 Install the cut hoses to the water pump and thermostat housing then secure them with clips in the racing kit 8 Install...

Page 37: ...ight and left radiator hoses oil cooler hoses and oil cooler pipe using the standard hose clamps When installing the racing kit install the radiator filler neck in the reverse direction as shown in th...

Page 38: ...iator overflow hose properly referring to the illustration below then connect to the catch tank 8 Fill the radiator with coolant and bleed air Warm up the engine and check for coolant leaks Catch tank...

Page 39: ...emoved cover the joint portion to avoid entering the dust and dirt into the fuel line Installation 1 Install the new retainer into the fuel feed hose joint as shown 2 Check the rubber cap condition re...

Page 40: ...illustration 1 Install the fuel breather catch tank to the air duct 2 Install the one way valve as shown in the illustration 3 Route the fuel tank breather hose referring to the illustration below an...

Page 41: ...sing and right grip comp from the right handlebar 2 Install the racing kit throttle pipe onto the right handlebar 3 Grind off the boss in the upper throttle housing as shown 4 Install racing kit throt...

Page 42: ...kit 4 Install the breather hose C to the racing kit breather case using the clip in the racing kit 5 Install the breather case assembly into the frame same location as the previously installed EVAP PA...

Page 43: ...led the ignition cut off system is activated incorrect ly Turn Signal Switch Modification Remove the turn signal switch from the handlebar Cut and remove the clutch switch wire from the turn signal sw...

Page 44: ...2 23 Racing Kit Starter Battery Cable Modification Remove the unnecessary parts from the starter battery cable and seal with tape securely Remove and discard...

Page 45: ...funnels into their proper location according to each identification mark on the funnel 3 Install the tongued washer and screws then tighten the screws securely 4 Bend the tabs of the tongued washer an...

Page 46: ...ach identification mark on the funnel 5 Install the lock washers tongued washers and screws then tighten the screws securely 6 Bend the tabs of the lock washer and lock the screws 7 Install the racing...

Page 47: ...des Frame body Bottom bridge Make sure the tip of the stopper piece does not project from the stopper ends as shown 5 4 12 15 24 3 32 2 9 8 4 7 C 2 OK NG Steering Stem Nut Washer Replacement The stem...

Page 48: ...steering damper but don t reinstall the link cover On the racing kit mechanical steering damper the damping force is adjusted by with a screwdriver We recommend drilling a hole in the top shelter to a...

Page 49: ...h the rear fender B Rear Fender B Modification FX SS 1 Cut and remove the indicated portion of the rear fender B Rear fender B Cut area Cut area Cut area Exhaust pipe Heat protect sheet 2 Install the...

Page 50: ...er use standard mounting bolts collar and grommets except the muffler stay bolts Right exhaust pipe racing kit Muffler stay racing kit Muffler stay racing kit Stay bolt racing kit Springs racing kit L...

Page 51: ...ut as shown Apply adhesive Pop nut 6 mm manufactured by POP RIVET FASTENER LTD SPH650R or equivalent Stake Washers racing kit Drive chain guard racing kit Bolt washers racing kit 2 Apply adhesive to t...

Page 52: ...ve driven sprockets are available Drive sprockets 14T 23801 NL3 620 15T 23802 NL3 620 16T 23803 NL3 620 Driven sprockets 41T 41201 NL3 651 42T 41202 NL3 651 43T 41203 NL3 651 44T 41204 NL3 651 45T 412...

Page 53: ...Racing Kit 2 32 Front Brake Hose Replacement Replace the front brake hose with the racing kit hose Brake hose joint racing kit Brake hose stay racing kit...

Page 54: ...osition by turning the adjuster counterclockwise Remove the fork bolt from the fork slider Push the fork slider slowly down and gently seat the dust seal onto the axle holder Insert a 17 mm spanner be...

Page 55: ...l the damper rod up and hold it between the spring coil as shown 1 OIL LEVEL Slowly lower the slider and gently seat the dust seal onto the axle holder and leave it for 5 minutes After the oil level s...

Page 56: ...all the 17 mm spanner to the flat surface Remove the fork bolt assembly again Remove the spring collar holder 1 PRE LOAD ADJUST PLATE 2 O RING Apply fork fluid to a new O ring and install it to the fo...

Page 57: ...r installing the fork legs to the steering stem 1 PRE LOAD ADJUSTER 1 SPRING COLLAR B 2 FORK BOLT Install the spring collar B and then install the fork bolt While holding the damper rod tighten the pr...

Page 58: ...the pre load adjuster Turn the adjuster clockwise to increase the spring pre load Turn the adjuster counterclockwise to decrease the spring pre load Standard position 5 mm from full soft Fork Height F...

Page 59: ...n the adjuster counterclockwise to decrease the spring pre load Standard position 10 turns from full soft 5 mm The spring pre load is already 5 mm when installing the spring to the shock absorber The...

Page 60: ...indicator on the combination meter lights See the Setting Manual in the CD ROM for pit lane speed limit function 1 INDICATOR LAMP The engine speed limiter is deactivated when you turn the hazard switc...

Page 61: ...SHIFT UP INDICATOR Shift up Indicator When the engine revs reach the specified rpm the turn signal indicator on the combination meter lights See Setting Manual in the CD ROM for shift up indi cator s...

Page 62: ...ing damper 3 9 Front fork 3 10 Air funnel set Breather case set 3 12 Air injection plug set 3 14 Exhaust set 3 15 Chain 3 16 Rear cushion 3 17 Wire harness 2008 TYPE 3 18 Wire harness 2007 TYPE 3 19 Q...

Page 63: ...d in this parts list A C Alternating current ASSY Assembly C Center COMP Complete G Gram L Left L 100L Link 100Links M Middle mm Millimeter R Right STD Standard T 22T Tooth 22 Teeth T W Thermo Water R...

Page 64: ...ET CYLINDER HEAD 0 6 GASKET CYLINDER HEAD 0 65 CAM SHAFT COMP IN 23 52 CAM SHAFT COMP EX 10 45 ROTOR CAM PULSE SPG IN VALVE OUTER SPG IN VALVE INNER SPARK PLUG NGK R0409B 10 STD t0 6 t0 65 23 52 7500...

Page 65: ...0 31120 NL3 750 96001 06016 00 96001 06028 00 COVER ACG CLAMP ACG COOD A C GEN ASSY ROTOR COMP STATOR COMP BOLT FLANGE SH 6 X 16 BOLT FLANGE SH 6 X 28 N1AA E 2 Ref No Part No Description Remarks A C g...

Page 66: ...X4 000 90402 MFJ D01 94109 12000 BAND SUB TANK BOLT OIL COOLER BOLT DRAIN 12mm WASHER SEALING 34 5mm WASHER DRAIN PLUG 12mm hole for wire lock STD STD E 3 Ref No Part No Description Remarks Oil pan 20...

Page 67: ...211 N1A D00 23421 N1A D00 90004 492 010 TRANSMISSION SET SHAFT MAIN GEAR C 1 BOLT SPECIAL 10mm 18T 39T hole for wire lock E 4 Ref No Part No Description Remarks Transmission set 2010 CBR600RR Block No...

Page 68: ...D00 19505 KS6 700 19512 NL3 620 90454 ZV1 000 WATER HOSE PLUG SET CLAMP A WATER HOSE PLUG HOSE B WASHER THRUST E 5 Ref No Part No Description Remarks Water hose plug set 2010 CBR600RR Block No 2 3 2...

Page 69: ...N608 DISK COMP R FR BRK t5mm HOSE COMP FR BRAKE STAY COMP FR BRAKE DISK COMP L FR BRK t5mm PIPE THROTTLE GRIP HOUSING UP THROTTLE HOUSING UND THROTTLE SCREW PAN 5 X 20 BOLT FLANGE SH 6 X 12 BOLT FLAN...

Page 70: ...3 9 1 53700 MFJ R01 DAMPER ASSY STRG F 2 Ref No Part No Description Remarks Steering damper 2010 CBR600RR Block No 1 1 Reqd No...

Page 71: ...ASSY R FRONT SPRING FR FORK 0 95 SPRING FR FORK 0 90 SPRING FR FORK 1 00 SPRING FR FORK 1 05 COLLAR SPRING COLLAR B SPRING STOPPER SPRING SEAT TUBE OUTER RING BACK UP BUSH GUIDE BUSH SLIDER PIPE ASSY...

Page 72: ...254 MEE D01 91258 GF4 003 WASHER SPECIAL 10mm BOLT FLANGE DR 8 X 45 BOLT SOCKET 10 X 35 DUST SEAL O RING 42 2 X 2 4 F 3 Ref No Part No Description Remarks 2 4 2 2 2 Front fork 2010 CBR600RR Block No 1...

Page 73: ...ASSY PGM FI IGN use with set 38770 N1A D10 UNIT ASSY PGM FI IGN use with set hole for wire lock 15611 MEE R00 N1A D10 1 L11 38770 N1A D10 UNIT ASSY PGM FI IGN use with set N1A D10 2 L17 38770 N1A D10...

Page 74: ...EATHER CLAMP A WATER HOSE CASE COMP BREATHER BOLT SH DR 8 X16 O RING 18 X 3 F 4 Ref No Part No Description Remarks 1 1 1 1 1 1 1 1 1 1 1 1 Air fannel set Breather case set 2010 CBR600RR Block No R CRA...

Page 75: ...700 96205 14012 96205 15012 PLUG SET EXHAUST A I CLAMP A WATER HOSE PLUG CONE TYPE 14 X 12 PLUG CONE TYPE 15 X 12 14 15 F 5 Ref No Part No Description Remarks Air injection plug set 2010 CBR600RR Blo...

Page 76: ...AIR CLEANER PIPE COMP R EXHAUST PIPE COMP L EXHAUST JOINT RR EXH PIPE TAIL PIPE EXH FLANGE EXH COLLAR EXH SILENCER COMP FIM SPRING EXH PIPE BAND A MUFFLER BAND B MUFFLER RUBBER EXH PIPE MOUNT COLLAR...

Page 77: ...20 SPROCKET DRIVE 15T 520 SPROCKET DRIVE 16T 520 CHAIN DRIVE GB520 HRVZ2 120LJ F JOINT DRIVE CHAIN SPROCKET FINAL DRIVEN 41T 520 SPROCKET FINAL DRIVEN 42T 520 SPROCKET FINAL DRIVEN 43T 520 SPROCKET FI...

Page 78: ...G RR CUSHION 10 5 SPRING RR CUSHION 10 0 SPRING RR CUSHION 10 3 SPRING RR CUSHION 10 8 SPRING RR CUSHION 11 0 SPRING RR CUSHION 11 3 STAY PRELOAD ADJ BOLT SOCKET 8 X 22 BOLT FLANGE SH 6 X 22 Yellow pa...

Page 79: ...IC SET ST HARNESS WIRE WIRE HARN FR SUB SENSOR ASSY BANK ANGLE RESISTER COMP METER ASSY COMBINATION UNIT ASSY PGM FI IGN UNIT ASSY PGM FI IGN UNIT ASSY PGM FI IGN CD ROM PGM FI IGN UNIT ASSY SERIAL I...

Page 80: ...ECTRIC SET ST HARNESS WIRE WIRE HARN FR SUB SENSOR ASSY BANK ANGLE RESISTER COMP METER ASSY COMBINATION UNIT ASSY PGM FI IGN UNIT ASSY PGM FI IGN CD ROM PGM FI IGN UNIT ASSY SERIAL I F USB TYPE 06170...

Page 81: ...38411 NL9 000 38520 NL9 000 91080 NL6 300 QUICK SHIFTER SET CUSHION CDI UNIT SENSOR ASSY Q SHIFT UNIT ASSY Q SHIFT CD ROM Q SHIFTER USB CABLE STAY RELAY POP RIVET 3 2X9 2 F 10 Ref No Part No Descripti...

Page 82: ...4081 10 RADIATOR SET RADIATOR COMP STAY RADIATOR LOWER HOSE RADIATOR R HOSE RADIATOR L HOSE OIL C TANK CATCH 250 TY LAP 3 6 X 281 VINYL TUBE 6 X 9 X 800 Order 95003 14001 10M 6 x 9 x 1000 F 11 Ref No...

Page 83: ...17910 N1A D00 17920 N1A D00 18151 N1A D00 18152 N1A D00 18157 N1A D00 18158 N1A D00 18231 N1A D00 18232 NL3 900 18310 N1A D00 18334 NL3 750 18371 N1A D00 18372 N1A D00 18422 MFJ D00 18423 MFJ D00 184...

Page 84: ...51412 MB4 003 51414 KCR 003 51415 KCR 003 51420 MFJ R01 51430 MFJ R11 51447 KA4 711 51450 MFJ R01 51455 MEE D01 51490 MEE D01 51500 MFJ R11 51520 MFJ R01 52157 NL3 650 52400 MFJ R11 52401 MFJ R01 524...

Page 85: ...6 E 2 F 1 F 8 E 2 F 5 F 5 Part No Part No Part No Part No 91080 NL6 300 91254 MEE D01 91258 GF4 003 91307 KF0 003 93401 06028 00 93404 06010 08 93500 05020 0G 94109 12000 95003 14081 10 96001 06012 0...

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