2000-2001 Honda CBR929RR Service & Repair Manual

SERVICERULES 1-1LUBRICATION&SEALPOINTS 1-19 MODELIDENTIFICATION 1-1 CABLE&HARNESSROUTING 1-23 SPECIFICATIONS  1-3  EMISSIONCONTROLSYSTEMS  1-40 TORQUEVALUES  1-12  EMISSIONCONTROLINFORMATION LABELS (U .S .A .ONLY)  1-43 TOOLS  1-17 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showonpages1-23through1-39,CableandHarnessRouting . MODELIDENTIFICATION 4 4 0 0 0 N ___1 ~0 I .  + OOD 0 0 000 O • o 7 • O 1 G O O C: /  _ QO_ 1 I. 1 . GENERAL I FORMATION

GENERAL INFORMATION FHAIVML5EiiIALJillr„IHE- (1) Theframeserialnumberisstampedonthe rightsideofthesteeringhead . I VEHICLEIDENTIFICATIONNUMBER(VIN) (3)TheVehicleIdentificationNumber(VIN)is locatedonleftsideofthemainframeonthe SafetyCertificationLabal . COLORLABEL i (5)Thecolorlabelisattachedasshown .When orderingcolor-codedparts,alwaysspecifythe designatedcolorcode . ENGINESERIALNUMBER (2)Theengineserialnumberisstampedontheright sideoftheuppercrankcase . THROTTLEBODYIDENTIFICATIONNUMBER (4)Thethrottlebodyidentificationnumberis stampedontheintakesideofthethrottlebodyas shown . 0 0 0

SPECIFICATIONS GENERAL DIMENSIONS FRAME ENGINE ITEM Overalllength Overallwidth Overallheight Wheelbase Seatheight Footpegheight Groundclearance Dryweight 49states,Canadatype Californiatype Curbweight 49states,Canadatype Californiatype Maximumweightcapacity 49states,Canadatype Californiatype Frametype Frontsuspension Frontwheeltravel Rearsuspension Rearwheeltravel Reardamper Fronttiresize Reartiresize Tirebrand Bridgestone Michelin Frontbrake Rearbrake Casterangle Traillength Fueltankcapacity Boreandstroke Displacement Compressionratio Valvetrain Intakevalve opens  at1mm closes- (0 .04in)lift Exhaustvalveopens - closes Lubricationsystem Oilpump type Coolingsystem Airfiltration Crankshafttype Enginedryweight Cylinderarrangement FiringOrder 2,065mm(81 .3in) 680mm(26 .8in) 1,125mm(44 .3in) 1,395mm(54 .9in) 820mm(32 .3in) 384mm(15 .1in) 130mm(5 .1in) 172kg(379Ibs) 174kg(384Ibs) 197kg(434Ibs) 199kg(439Ibs) 160kg(353Ibs) 164kg(362Ibs) Diamond Invertedtelescopicfork 110mm(4 .3in) Swingarm 135mm(5 .3in) Nitrogengasfilleddamper 120/70ZR17(58W)/Radial 190/50ZR17(73W)/Radial GENERAL INFORMATION SPECIFICATIONS Front :BT01OF/Rear :BT010R Front :PilotSPORTE/Rear :PilotSPORTE Hydraulicdoublediscbrakewith4potcaliper Hydraulicsinglediscbrakewith1potcaliper 23°45' 97mm(3 .8in) 18 .02(4 .76USgal,3 .96Impgal) 74 .0 X 54 .0mm(2 .91 X 2 .13in) 929cm 3 (56 .7cu-in) 11 .3 :1 ChaindriveandDOHC 25°BTDC 35°ABDC 40°BBDC 20°ATDC Forcedpressureandwetsump Trochoid Liquidcooled Paperfilter Unittype 62 .1kg(136 .91bs) Fourcylinder,inline30°inclinedfromvertical 1-2-4-3

GENERALINFORMATION - GENERAL(Cont'd) ITEM CARBURETION  Type Throttl e bore DRIVETRAIN  Clutchsystem Clutchoperationsystem Transmission Primaryreduction Finalreduction Gearratio  1st 2nd 3rd 4th 5th 6th Gearshiftpattern ELECTRICAL  Ignitionsystem Startingsystem Chargingsystem Regulator/rectifier Lightingsystem SPECIFICATIONS PGM-FI(ProgrammedFuelInjection)  40mm (1 .6in)  Multi-plate,wet Cableoperatedtype Constantmesh,6-speed 1 .521(73/48) 2 .687(43/16) 2 .692(35/13) 1 .933(29/15) 1 .600(32/20) 1 .400(28/20) 1 .286(27/21) 1 .190(25/21) Left footoperatedreturnsystem,1-N -2-3-4-5-6 Computer-controlleddigitaltransistorizedwithelectronic advance Electricstartermotor Triplephaseoutputalternator SCRshorted/triplephase,fullwaverectification Battery

LUBRICATION SYSTEM ITEM STANDARD Engineoilcapacity  Atdraining_ 3 .5Q - (3 .7USqt , 3 .1Impqt) At disassembly 4 .0Q (4 .2 USqt, 3 .5 Impqt) Atoilfilterchange  3 .72(3 .9US - qt,3 .3 Impqt) Recommendedengineoil  ProHondaGN4orHP44-strokeoil (U .S .A&Canada)orHonda4-stroke oil(Canadaonly),orequivalentmotoroil APIserviceclassificationSForSG  Viscosity :SAE1OW--40 Oilpressureatoilpressureswitch  490kPa(5 .0kgf/cm 2 , 71psi)  at 5,400rpm(80°C/176°F) Oilpumprotor  Tipclearance0 .15(0 .006) max . Bodyclearance  0 .15 --0 .22(0 .006-0 .009) Sideclearance0 .02-0 .07 (0 .001 -0 .003) FUELSYSTEM(ProgrammedFuelInjection) - ITEM  SPECIFICATIONS GENERALINFORMATION SERVICELIMIT Unit :mm(in) 0 .20 (0 .008) 0 .35(0 .014) _ 0 .10(0 .004) Throttlebodyidentification  49states, Canadatype_ number j Californiatype _ Starter valve vacuumdifference Basethrottlevalveforsynchronization Idlespeed Throttle gripfree play- _ _ _Intake air temperaturesensorresistance(at20°C/68°F)_ __Engine coolant_ temperaturesensorresistance(at20°C/68°F) Fuel injector resistance(at20°C/68°F)  _PAIRsolenoid valveresistance(at20°C/68°F) _ Purgecontrolsolenoidvalveresistance(at20°C/68°F)  30 - 34k2 Campulsegenerator_ peakvoltage(at20°C/68°F) 0 .7Vminimum Ignitionp ulse generatorpeakvoltage(at20°C/68°F)  0 .7Vminimum Manifold absolute pressure ureatidle 150-250mm Hg _ _Fuel pressureatidle 343kPa(3 .5kgf/cm 2 ,50psi)_ Fuelpumpflow(at12V)  188cm 3 (6 .4US oz, 6 .6 Imp oz) minimum/10seconds GQ60C GQ60B 20mmHg No .1 1,200±100rpm 2-6mm (1/16-1/4 in) 1-4k2 - 2 .3-2 .6 kd2 11 .1-12 .3 2 20-24k2

GENERALINFORMATION COOLINGSYSTEM ITEM Coolantcapacity Radiatorcap_reliefpressure R adiator andengine Reserve tank Thermostat  Begin to open Fully open V alve lift Recommendedantifreeze Standardcoolantconcentration - CYLINDERHEAD/VALVES ITEM Cylindercompression Cylinderhead warpage Valve,  Valveclearance valveguide ValvestemO .D .  IN0 .16±0 .03(0 .006 T 0 .001)  __ EX0 .27 ±0 .03(0 .011 ~:0 .001) IN4 .475-4 .490(0 .1762-0 .1768) EX4 .465-4 .480(0 .1758 - 0.1764) IN4 .500--4 .512(0 .1772-0 .1776)4 .540(0 .1787) EX 4 .500 - 4 .512 (0 .1772 -0 .1776)4.540(0,1787) --- I I N0 .010-0 .037 (0 .0004 -- 0.0015) --------- 1 EX  0 .020 - 0 .047(0 .0008--0 .0019) Valveguideprojection  i IN  14 .3-14 .6(0 .56--0 .57) above cylinder head  EX12 .4-12 .7(0 .49-0 .50) Valve seatwidth  IN/EX0 .90 - 1 .10(0 .035 - 0 .043) Valvespring  Inner  _IN/EX34 .8 0 (1 .370) freelength  Outer IN/EX37 .97(1 .495) 1 37 .2(1 .46) Valvelifter  Valve lifter O .D .IN/EX25 .978- _ 25 .993(1 .0228--1 .0233)L 25 .97 (1 .022) Valvelifterbore I .D ._  IN/EX26 .010-26 .026(1 .0240-1 .0246)  26 .04(1 .025)  Camshaft  [ Camlobeheight  IN36 .48-36 .72(1 .43 _ 6-1 .446)36 .45(1 .435) i EX36 .08-36 .32(1 .420-1 .430)36 .50(1 .437)  _ L Runout 0 .05 (0 .002) Oilclearance  0 .020 - 0 .062 (0 .0008-0 .0024) 0 .10(0 .004) ValveguideI .D . Stem-to-guideclearance SPECIFICATIONS 3 .2Q(3 .4USgt,2 .8Impgt) 0 .42 (0 .4US qt,0 .4 Imp qt) 108--137kPa(1 .1-1 .4kgf/cmz ,16--20psi) _ _  --- 80 .5 --83 .5°C(177-182 °F) 95°C(203 °F) -8mm(0 .3in) mi n imum Highqualityethyleneglycolantifreezecontainingcorrosion  protectioninhibitors  - 50%mixturewithsoftwater STANDARD 1,226kPa(12 .5kgf/cmz , 178psi) at350 rpm T- 0 .10(0 .004) 4 .465(0 .1758) 4 .455 SERVICELIMIT 1 .5(0 .06) 34 .1 1 Unit :mm(in) (0 .1754) 34)

CLUTCH/GEARSHIFTLINKAGE ITEM Clutch leverfreeplay Clutchspringfreelength Clutchdiscthickness Clutchplatewarpage Clutchouterguide Mainshaft O .D . atclutchouterguide Shiftfork,  Fork forkshaft  I ForkshaftO .D . CRANKCASE/PISTON/CYLINDER ITEM  Green color Purplecolor I .D . O .D . -ALTERNATOR/STARTERCLUTCH ITEM I . D . Claw thickness STANDARD  10-20(3/8--13/16) _4 _ 8 .8 (1 .92) 2 .92-3 .08(0 .115-0 .121) 2 .92-3 .08(0 .115--0 .121) STANDARD GENERAL INFORMATION SERVICELIMIT 47 .40 .87) 2 .6 (0 .10)  2 .6(0 .1 - 0) 0.30 (0 .012) Unit :mm(in) 25.000-25 .021(0 .9843-0 .9851)25 .03(0 .985) 34 .975--34 .991(1 .377 _0-1 .3776) 34 .97(1 .377)  24 .98 _ 0 - 24 .993(0 .9835--0 .9840)_24 .96(0 .983) 12 .000-12 .018 (0 .4724-0 .4731)12.03 (0 .474) 5 .93--6 .00(0 .233-0 .236)5 .9 (0 .23) 11 .957-11 .968(0 .4707-0 .4712)  11 .95(0 .470) Unit :mm(in) STANDARD  SERVICELIMIT StarterdrivengearbossO .D . I 51 .699-51 .718(2 .0354-2 .0361)  11 . 84(2 .0348) Unit :mm(in) SERVICELIMIT Cylinder  I .D . Outof round Taper - Warpage Piston,  Piston markdirection"IN" markfacing towardtheintakeside pistonrings  PistonO .D .  73 .965 - 73 .985(2 .9120 - 2 .91 PistonO .D .measurementpoint-i_13 mm(0 .5in)frombottomofskirt PistonpinboreI .D .  _ 17 .002-17 .008(0 .6694--0 .6696) r pistonpin O .D . _  16 .994- _ 17 .000 (0 .66 _ 9 1 -0 .6693)_ Piston-to-pistonpinclearance 0 .002-0 .014(0 .0001-0 .0006) Pistonring-to-ring  I Top ---- 0 .030--0 .065(0 .0012-0 .0026) grooveclearanceI Second0 .015-0 .045(0 .0006-0 .0018) Pistonringendgap  Top0 .28-0 .38(0 .011 -0 .015) Second0 .40-0 .55 (0 .016-0 .022) Oil(siderail)0 .2-0 .7(0 .01--0 .03) Cylinder-to-pistonclearance  __0 .020-0 .055(0 .0008--0 .0022) C onnecting rodsmallendI .D . 17 .016-17 .034(0 .6699--0 .6706)17 2 04(0.671) Connecting rod-to-pistonpinclearance i 0 .016-0 .040(0 .0006-0 .0016) Crankpinoilclearance -I 0 .030-0 .052(0 .0012-0 .0020) 74 .005 --74 .020(2 .9136--2 .9142) 28) ____ 74 .15 (2 .919) __0 .10(0 .004) I 0 .10(0 .004) _ 0 .05(0 .002) 73 90(2909) 17 .03(0 .670) 16 .98(0 .669) 0 .08 (0 .003) 0 .06(0 .002) 0 .5(0 .02) 0 .7(0 .03) 0 .9 (0 .04) 0 .062(0 .0024)

GENERAL INFORMATION - CRANKSHAFT/TRANSMISSION STANDARD 0 .05 -0 .20(0 .002 - 0 .008) ITEM Crankshaft  Side clearance Runout Mainjournaloil  clearance GearI .D . Transmission BushingO .D . BushingI .D . Gear-to-bushing clearance MainshaftO .D . Countershaft O .D . Bushing-to-shaft clearance No .1and No .50.017 - 0 .035(0 .0007- 0 .0014)0 .045(0 .0018) __No .2toNo .40 .027-0 .045(0 .0011 --0 .0018)0 .055(0 .0022) M5,M631 .000 - 31 .025(1 .2205-1 .2215)! 31 .04 (1 .222) C126 .000-26 .021(1 .0236 - 1 .0244)26 .04(1 .025) C2,3,433 .000 - 33 .025(1 .2992-1 .3002)33 .0 4 (1 .301) M5,M6 _30 .950-30 .975(1 .2185-1 .2195)30 .93(1 .218) C332 .950 - 32 .975(l .2972 - 1 .2982) 1 32 .93(1 .296) 32 .950-32 .975(1 .2972 -- 1 .2982)  32 .93 (1 .296) 27 .985-28 .006(1 .1018-1 .1026)28 .02(1 .103) 29 .985-30 .006(1 .1805-1 .1813)  30 .02(1 .182) 0 .025-0 .0 _ 75(0 .0010-0 .0030) : 0 .11 (0 .004) 0 .025 _-0 .0 _ 75(0 .0010-0 .0030)1 0 .11(0 .004) 27 .967 - 27 .980(1 .1011 -1 .1016)  27 .957 _(1 .1007) ClutchouterguideI 24 .980 - 24 .993(0 .9835 - 0 .9840)24 .96(0 .983) C229 .967-29 .980(1 .1798-1 .1803)29 .96(1 .180) M5_ 0 .005-0 .039(0 .0002-0 .0015)0 .08( 0 .003)_ C20 .005-0 .039(0 .0002-0 .0015)0 .08(0 .003) C4 MS C2 M5,M6 C3 M5 SERVICELIMIT  0 .30(0 .012) 0 .30(0 .012) Unit :mm(in)

- FRONTWHEEL/SUSPENSION/STEERING ITEM Axle runout Wheelrimrunout  R adial Axial Fork  Spring free lepgth___ Spring_ direction __ Tube runout Reco m mended forkfluid Fluidlevel Fluidcapacity - REARWHEEL/SUSPENSION ITEM Axle runout Wheelrimrunout STANDARD Min i mum tiretreaddepth Coldtirepressure  Upto90kg(200Ib)load  Uptomaximumweight capacity 1 250 kPa (2 .50kgf/cmz 36psi) 250kPa(2 .50kgf/cm- 36psi) STANDARD Minimumtirethreaddepth Coldtirepressure  Upto 90kg(200lb)load290kPa(2 .90k gf/cmz , 42psi) Uptomaximumweightcapacity 290kPa(2 .90kgf/cmz,42psi) Radial Axial Drivechain Size/link DID D .I .D .50VA8C1  R_KRKGB50HFO _ Z5 Slack 40-50(1 .6-2 .0) Shockabsorber  Spring adjusterstandardposition 4thgroove Tensionadjusterinitialsettin  2turnsfromfullhard Compressionadjusterinitialsetting 1turnfromfullhard GENERALINFORMATION I 2 .0(0 .08) 0 .20(0 .008) Unit :mm(in) SERVICELIMIT  1 .5( 0 .06)  0 .20(0 .008) 2 .0 (0 .08) 2 .0(0 .08) 230 .5(9 .07) 2 25 .9 - ( 8 .8 ' 9 . ) - Withthetaperedendfacing up 0 .20(0 .008) ProHondaSuspensionFluidSS-8 90(3 .5) 488  2.5cm'(16 .5±0 .08USoz, 172+009Impoz) Pre-loadadjusterinitialsetting 1 18mm(0 .7in)fromtopofforkbolt Tension adjust er initial setting1turnfromfullhard Compressionadjusterinitialsetting _ 1-1/2 turns fromfullhard Steeringheadbearing pre-load 10 - 15 N (1 .0-1 .5 kgf) Unit :mm(in) SERVICELIMIT 2 .0(0 .08) 2 .0 (0.08) 50(2 .0) _

GENERALINFORMATION HYDRAULICBRAKE ITEM IGNITIONSYSTEM ITEM Front  Specifiedbrakefluid Brake discth ickness  Brakediscrunout _Mastercylinder I .D . _MasterpistonO .D . CalipercylinderI .D .  Upper _ Lower CaliperpistonO .D .  Upper Lower Rear  Specified brakefluid Brakepedal _ height Brake discthickness Brake disc runout MastercylinderI .D . MasterpistonO .D . CalipercylinderI .D ._ Caliper pistonO .D . BATTERY/CHARGINGSYSTEM ITEM Battery  Capacity Current leakage Voltage(20°C/68°F)  Fullycharged Needscharging_ Chargingcurrent  Normal Quick Alternator  Capacity Chargingcoilresistance(20°C/68°F) Sparkplug   Standard Optional Sparkplug gap Ignition coilpeakvoltage __ Ignitionpulsegeneratorpeakvoltage Ignitiontiming("F"mark) STANDARD  HondaDOT4BrakeFluid 4 .5 (0 .18) _'19 .050 - 19 .093(0 .7500 - 0.7517) _  r 19 .018-19 .034(0 .7487-0 .7494) _ 33.960--34 .010(1 .3370 - 1 .3390) 30 .250 - 30 .280 (1 .1909-1 .1921) _  33 .802-33 .835(1 .3308-1 .3321)  _ 30 .082 -- 30 .115(1 .1843-1 .1856) DOT4 75(30) 5 .0(0 .20) 4 .0(0 .16)  _ 0.30 (0 .012 ) 15 .870-15 .913(0 .6248-0 .6265)15 .925(0 .6270) 15 .827-15 .854(0 .6231-0 .6242)15 .815(0 .6226) 38 .180-38 .230(1 .5031 --1 .5051)38 .24(1 .506)  _ 38 .098 - 38 .148(1 .4999-1 .5019)  38 .090(1 .4996) SPECIFICATIONS 12V-8 .6Ah _ 0 .2 mA max . 13 .0 - 13 .2V Below12 .3V 0 .9 A/5 -10 h - 4 .0A/0 .5h 0 .421kW/5,000rpm 0 .1--1 .02 SPECIFICATIONS IUH27D(DENSO) IUH24D(DENSO)  3 .5(0 .14) 0 .30(0 .012) 0 .80 - 0 .90mm(0 .031-0 .035in) 100V minimum 0 .7Vminimum 15°BTDCatidle Unit:mm(in) SERVICELIMIT  19 .105(0 .7522) 19 .006 (0 .7483) 34 .02(1 .339) 30 .29 (1 .193) 33 .794(1 .3305) 30 .074(1 .1840)

2000-2001 Honda CBR929RR Service & Repair Manual

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