2004-2006 Honda CBR1000RR Fireblade Service & Repair Manual

HOW TO USE THIS MANUAL This service manual describes the servic e procedures lor the CBR 1000 RR-4. Follow the Maintenance SChedule (Section 4) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency, California Air Resources Board and Transport Canada . Perlorming the first scheduled maintenance is very important. 1\ compensates for the initial wear that occurs during the break-in period. Sections 1 and 4 apply to the whole motorcycle. Section 3 illustrates procedures tor removal/installation of components thai may be required 10perform service described in the following sections. Section 5 through 20 descri be pari s of the motorcycle , grouped acco rding to location. Find the section you want on this page, then turn to the table of contents on the first page of the sectio n. Most sectio ns start with an assembly or system illustra tion , service information and troubleshooting lor the section. The subsequent pages give detailed procedure. If you are not familiar with this motorcycle , read Technical Featu res in Section 2. If you don't knOW" the source 'of the trouble, go to section 22 TroubleShooting . Your safety, and the safety of others, is very important. To help you make informed decisions we have provide d safety messages and other informalion throughout this manual. Of course, it is not practical or possible to warn you about all the hazards associated with ser vicing this vehicle. You must use your own good judgement. You will find important safety information in a variety of forms including: . • Safety Labels - on the vehicle • Safety Messages - preceded by a safety alert symbol & and one of three signal words, DANGER, WARN ING , or CAUTION. These signal words mean : ~ You WILL be KILLED or SERIOUSLY ~ HURT if you don't fellow instructions. ~ You CAN be KILLED or SERIOUSLY HURT ~ if you don't f ollOW" instructions. ~ You CAN be HURT if you don 't follow ~ instructions. • Instructions - how to service this vehicle correctly and safely. As you read this manual, you will find information mat is preceded by a CNOnC(] symbol . The purpose of this message is to help prevent damage to your vehicle, other property, Of the environment. Date of Issue: March, 2004 CONTENTS GENERAL INFORMATION TECHNICAL FEATURES FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM z « COOLING SYSTEM II: I- w ENGINE REMOVAUINSTALLATION > 0: CYLINDER HEADNALVES c c z CLUTCH/STARTER CLUTCH « w z ALTERNATOR a z w TRANSMISSION/GEARSHIFT LINKAGE CRANKCASE/CRANKSHAFT/BALANCER/ PISTON/CYLINDER FRONT WHEEUSUSPENSION/ (J) STEERING Cii (J) REAR WHEEUSUSPENSION « J: o HYDRAULIC BRAKE BATTERY/CHARGING SYSTEM ..J IGNITION SYSTEM « o 0: ELECTRIC STARTER I- U W ..J LIGHTS/METERS/SWITCHES w WIRING DIAGRAM TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. ~ Replace the part(s) with new one(s) before assembly. S -, Use recomme nded engine oil, unless otherwise specified. ~ Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1). _-$iiiffi Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). ~ Example: Molykote® BR-2 plus manufactured by Dow Corning U.S.A. MUlti-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Exampl e: Molykote® G-n Paste manufactu red by Dow Corning U.S.A. ~ Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan ~ Use silicone grease. 0 Apply a locking agent. Use a middle strength locking agent unless otherwise specified. MJ ",,'Uill Apply sealant. I Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. .. Use Fork or Suspension Fluid.

1. GENERAL INFORMATION • SERVICE RULES 1-2 MODEL IDENTIFiCATION..···························· 1-2 GENERAL SPECiFiCATIONS..·..·..··..··..· ........ 1-4 LUBRICATION SYSTEM SPECiFiCATIONS··..····..··..·..··..··..··..· ....··..····· 1-6 FUEL SYSTEM (Programmed Fuel Injection) SPECiFiCATIONS · · 1-6 COOLING SYSTEM SPECIFICATIONS ......... 1-6 CYLINDER HEADIVALVES SPECiFiCATIONS .... ·· ...... ·..··..·····..··..···..··· ....· 1-7 CLUTCH/STARTER CLUTCH SPECiFiCATIONS ..........··..··....···· ........· ....· ....· 1-7 TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS 1-8 CRANKCASE/CRANKSHAFT/BALANCER/ PISTON/CYLINDER SPECIFICATIONS 1-8 FRONT WHEEl/SUSPENSION/STEERING SPECiFiCATIONS ·..·..··..· ...... · ....·..· ........ ·..······ 1-9 REAR WHEEL:/SUSPENSION SPECIFICATIONS · · · ·..1-9 HYDRAULIC BRAKE SPECIFICATIONS..··..···..·..··..··..·· ...... ·..·....·..·1-10 BATTERY/CHARGING SYSTEM SPECIFICATIONS..··..· ....·· .... ···..·..·..··..···..··..·1-10 IGNITION SYSTEM SPECIFICATIONS ........ 1-10 ELECTRIC STARTER SPECIFICATIONS ·.... ·1-10 LIGHTS/METERS/SWITCHES SPECIFICATIONS··..·..·· ...... ··· ........···..·..·· ...... 1-11 STANDARD TORQUE VALUES ...... ··..··..· .... 1-12 ENGINE & FRAME TORQUE VALUES ....··..1-12 LUBRICATION & SEAL POINTS ...... ·........ ·..1-20 . CABLE & HARNESS ROUTING ·..1-24 EMISSION CONTROL SYSTEMS ..··.... ····..··1-36 EMISSION CONTROL INFORMATION LABEL (U.S.A. ONLY)·...... ···· ....··..··..··· ........ ·1-39 1-1

GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-reco mmended parts and lubricants or their equivalents. Parts that don 't meet Honda's design specificat ions may cause damage to the moto rcycle. 2. Use th e special too ls des igned for this product to avoid damage and inco rrect assembly. 3. Use on ly metric tools when servicing the motorcycle . Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, Ovrinqs, cotter pins, and lock plat es when reassembling. 5. Wh en t ighte ning bolts or nuts, begin with the large r diameter or inner bolt first. Then tighten to the spec ified torque diag onall y in in crem ental steps unless a parti cular sequence is specified. 6. Clean part s in cleani ng solve nt upon disassembly. Lubricate any slidi ng surfaces before reassembly . 7. Aft er reassem bly, check all parts for proper in sta llation and operation. S. Route all electrical w ires as shown in the Cab le an d Harness Rout ing (page 1-24). MODEL IDENTIFICATION 1-2

The frame serial nu mber is stamped on the right side of the stee ring head. The engine serial number is stamped on the rear side of the lower crankcase. The th rottle body ide ntificat ion num ber is stamped on the intake side of the throttl e body as shown . The co lor label is attached on the rear fender B as show n. When order ing color-coded parts, always specify the designated color code. GENERAL INFORMATION " THROTTLE BODY IDENT IFICATION NUMBER 1-3

GENERAL INFORMATION The Vehicle Ident ificat ion Number (VIN) is located on the l eft side of the main frame on the Safety Certification Labels. GENERAL SPECIFICATIONS VEHICLE IDENTIFICATiON NUMBER (VIN) ITEM SPECIFICATIONS DIMENSIONS Overall length 2,035 mm (80.1 in ) Overa ll width 720 mm (28.3 in ) Overa ll height 1,120 mm (44.1 in) Wheelbase 10405 mm (55.3 in ) Seat heig ht 820 mm (32.3 in) Ground clea rance 130 mm (5.1 in) Dry weig ht A, CM type : 180 kg (397 Ibs) AC type: 181 kg (399 Ibs) Curb weight A, CM type: 210 kg (463 lbs) AC ty pe: 211 kg (465 Ibs) M ax imum weight A. AC t ype : 166 kg (366 Ibs) capac ity CM type : 170 kg (375 Ibs) FRAME Frame type Diamo nd Fro nt suspens ion Telescopi c fork Front axle tra vel 110 mm (4.3 in) Rear suspension Swinga rm Rear axle tra ve l 135 mm (5.3 in) Front tire size 120170 ZR17 M /C (58W) Rear tire size 190 /50 ZR17 M /C (73W) Front tire brand Bridgestone: BT014F RADIAL G Pirell i: DiAB LO CORSA H Rear tire brand Bridgestone: BT014R RADIAL G Pirelli: DIABLO CORSA H Front brake Hydraulic double disc Rear brake Hydraulic single disc Caster angle 23 04 5' Trail length 102 m m (4.0 in ) Fuel tank capacity 18.0 liter (4.76 US gal, 3.96 Imp gal ) 1-4

GENERAL INFORMATION ITEM SPECIFICATIONS ENGINE Cylinder arra ngement 4 cylinders in-line, inclined 28° from vertical Bore and stroke 75.0 x 56.5 mm 12.95 x 2.22 in ) Displacem ent 998.4 em' (60.92 cu -ln] Compression ratio 11 .9: 1 Valve train Chain driven, DOHC Intake opens: at 1 m m 10.04 in ) lift 18' BTDC va lve closes: at 1 m m 10.04 in) lift 46' ABDC Exh aust opens: at 1 m m (0.04 in) lift 39' BBDC valve closes: at 1 mm (0.04 in) lift 11 ' ATDC Lubrication system Fo rced pressu re and w et sump Oil pump type Trochoid Cooling system Liquid cooled Air filtration Paper eleme nt Engi ne dry weigh t 65.8 kg (145.1 Ibs) Firing order 1 -2 -4 -3 FUEL DELIVERY Type PGM-FI (Programmed Fuel Inj ection ) SYSTEM Th rottle bore 44.0 mm (1.73 in) DRIVE TRAIN Clutch system Multi -plate, wet Clutch operation system Hydr aulic ope rati ng Transmission Constant mes h, 6-speeds Primary reduc tion 1.604 (77/48T) Final reduction 2.562 (16/41T) Gear ratio 1st 2.538 (33/13T) 2nd 1.941 133/17T) 3rd 1.578 130/19T) 4th 1.380 (29/21T) 5th 1.250 (25/20T) 6t h 1.160 (29/25T) Gearshift pattern 1- N-2 -3 -4 -5-6 ELECTRICAL Ign ition syste m Co mp ute r-co nt rolle d digital transistorized w ith electric adva nce Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted/triple phase, full wave rectifica- tion Lighting system Battery 1-5

GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) ITEM STAN DARD SERVICE LIMIT Eng i ne oil capacity After draining 3.0 liter (3.2 US qt. 2.6 Imp qt) - After oil filter change 3.1 liter (3.3 US qt, 2.7 Imp qt ) After disassembly 3.8 liter (4.0 US qt, 3.3 Imp qt ) Recommended engine oil Pro Honda GN4 or HP4 (w ithout molyb- - denum additives) 4·stroke oil (U.S.A. and Canada), or Honda 4-stroke oil (Canada only), or an equivalent motor oil API service classificat ion: SG or Highe r except oils labeled as energy conserv- ing on the circular API service label JASO T 903 sta nda rd : MA Viscosity: SAE 10W-40 Oil pressure at EOP (engine oil pre ssure ) swit ch 490 kPa 15.0 kgfle m ' , 7 1 p si) at 6,000 rpm /(80°C/176°F) Oil pump Tip cl earance 0. 15 (0.006 ) 0.20 (0.008) Body clearance 0.15 - 0.21 (0.006 - 0.008 ) 0.3510.014) Side clearance 0.04 0.0910.002 0.004) 0.17 (0.007) FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS ITEM SPECIFICATIONS Thr ottle body identifica- I A, CM typ e GQAOC tion number I AC type GQAOB Starter valve vacuum difference 20mm Hg Base throttle valve for synchronization No .1 Idle speed 1,200 ± 100 rpm Throttle grip free play . 2-4 mm (1/16 - 3/16 in) Intake air temperature sensor resistance (at 20°C/68°F) 1 4 kQ Engine coolant t empe rature sensor resistance 2.3 2.6 kQ (at 20°C/68°F) Fuel injection resistance I Primary injector 10.5 14.5 Q (at 20°C 168' F) I Secondary injector 10.5 - 14.5 Q PAIR control solenoid valve resistance (at 20°C/68°F) 20 24 Q CMP (Camshaft position) sensor peak voltage (at 20°CI 0.7 V minimum 68' F) CKP (Crankshaft position ) sensor peak voltage (at 20°CI 0.7 V min imum 68'F ) Manifold absolute pressure at idle 150 250 mm Hg Fuel pressure at idle 343 kPa (3.5 kgf/em ' , 50 psi ) Fuel pump flow (at 12V ) 189 em (6.4 US oz, 6.7 Imp oz) mi nimum /10 seconds COOLING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 3.15 liter (3.33 US qt. 2.77 Imp qt) I Reserve tank 0.4 liter 10.42 US qt , 0.35 Imp qt) Radiator cap relief pressure 108- 137 kPa 11.1 - 1.4 kgf/em ' , 16 - 20 psi) The rmost at Begin to open 80 84 °C (176 183 OF) Full y op en 90 °C 1194 'F) Valve lift 8 mm (0.3 in) minimum Recommended antifreeze High qual ity ethy lene glyco l ant ifreeze conta ining corrosion protection inhibitors Standard coolant concentration 1:1 mixture with distilled water 1-6

CYLINDER HEAD/VALVES SPECIFICATIONS GENERAL INFORMATION Unit· mm (in) ITEM STANDARD SERVICE LIM IT Cylinder compression 1,098 kPa (11.2 kgflc m', 159 psi ) at 350 - rpm Valve clearance IN 0.1 6 + 0.03 (0.006 ± 0.001) - EX 0.30 ± 0 .03(0 .012 + 0.001) - Cam sh aft Cam lo be he ig ht IN 37.02 - 37.10 (1.457 1.461 ) 37 .00 (1.457) EX 36 .66 - 36 .74 (1.443 - 1.446 ) 36.64 (1.443) Runout 0.05 (0.002) Oil clearance 0.020 0.062 (0.0008 0 .0024) 0.10 (0.004) Valve lifter Valve lifter 0.0. 25.978 - 25.993 (1.0228 - 1. 0233 ) 25.97 (1.022) Valve lifter bore 1. 0. 26 .010 26.026 (1.0240 1.0246) 26.04 (1.025) Valve , Valve stem 0 .0 . IN 3.975 3.990 (0.1565 0 .1571 ) 3.965 (0.1561) valve guide EX 3.965 - 3.980 (0.1561 - 0.1567) 3.955 (0.1557) Valve guide 1. 0. iN/E X 4.000 4.01.2(0.1575 0.1580) 4.04 (0.159) Ste m-ta -guide clearance IN 0.010 - 0.037 (0.0004 0.00 15) 0. 075 (0.0 030 ) EX 0.020 - 0.047 (0.0008 - 0 .0019 ) 0.085 (0.0033) Valve guide projection IN 16.I 16.4 (0.63 0.65) - above cylinder head EX 15.5 - 15.8(0 .61 0.62 ) Valve seat width IN 0.90 - 1.10 (0.035 - 0.043) 1.5 (0.06) EX 0.90 1.10 (0 .03 5 0.043) 1.5 (0.06) Valve spring IN 39 .5 (1.56) 38 .7 (1.52) fre e leng th EX 39 .5 (1.56) 38.7 (1.52) Cylinder head warpage - 0.10 (0.004) CLUTCH/STARTER CLUTCH SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Spe cified clutch fluid DOT 4 brak e flu id - Clutch master cylinder Ma ster cylinder 1.0. 12,7 00 - 12.743 (0.5000 0.5017) 12.755 (0.5022) Mast er piston 0 .0 . 12.657 - 12.684 (0.4983 - 0.4994 ) 12.645 (0.4978) Clutch Spring free length 56.8 (2.24) 55 .7 (2.19 ) Disc A thickn ess 3.72 3.88 (0.146 0.153) 3.4 (0.13) Disc 8 th ickness 3.22 3.38 (0.127 0.133) 2.9 (0.11) Plate warpage - 0.30 (0.012) Clutch oute r guide A 1. 0. 27.993 28.003( 1.1021 1.1025) 28.012 (1.1028) (Wit ho ut 10 mark) 0.0. 35.004 - 35.012 (1.3781 1.3784 ) 34.99 4( 1.3777) Clutch outer guide 8 1. 0. 27.993 - 28. 003 (1.102 1 - 1.1025 ) 28. 012 (1.1028 ) (With iD ma rk) 0 .0 . 34.996 - 35.004 (1.3778 - 1.3781) 34.986( 1.3774) Prim ary d rive n gea r 1. 0. A 41 .008 41.0 16(1.6145 -1.6 148 ) 4 1.026 (1.6152) B 41.000 - 41.008 (1.6142 - 1.6145) 41.018 (1.6149) Oil pump drive spro cket 1. 0. . 28 .000 28.021 (1.1024 - 1.10321 28 .030 (1.103 5) guide 0 .0 . 34.975 34 .99 1 (1.377 0 1.3776) 34 .965 (1.376 6) Oil pump dri ve sprock et I.D. 35.025 - 35.145 (1.3789 1.38 37 ) 35.155 (1.384 11 Main shaft 0 .0. at clutch oute r guide 27.980 - 27.990 (1.1016 - 1.10201 27.96 (1.1011 Mainshaft 0. 0 . at oil pump drive sprocket guide 27.980 27.990 (1.1016 - 1.10201 27.96 (1.101) Starter idle gear I Ge ar 1. 0. 10.013 -1 0.035 (0.3942 - 0.39511 10.05 (0.396) I S ha ft 0.0. 9.991 - 10.000 (0.3933 0.3937) 9.98 (0.393) Starter driven gear boss 0. 0 . 45.657 - 45.673 (1.7975 1.798 1) 45.642 (1.7969) 1-7

2004-2006 Honda CBR1000RR Fireblade Service & Repair Manual

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