HONDA CBR1100XX Workshop Repair Manual 1997-1998

IMPORTANT SAFETY NOTICE mm:m:m:B Indicates a strong possibility of severe personal injury or death if instructions are not followed. CAUTION : Indicates a possibility of equipment damage if instructions are not followed. NOTE: Gives helpful information. Detailed descriptions of standard workshop procedures, safety princip les and service operations are not included. It is important to note that this manual contains some warnings and cautions against some spec ifi c service methods which cou ld cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable way s in which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways . Anyone using service procedures or too ls, whether or not recommended by Honda, must satisfy h imself thoroughly that neither personal safety nor veh icle safety will be jeopardi zed by the service methods or tools selected.

SYMBOLS The symbo ls used th rougho ut th is manu al show specific servi ce pro cedures. If s upp lementary inform ation is requi red perta in ing to these symbols, it wou ld be expl ained specifically in the text w ithout the use of the symbo ls. ~ S Repla ce t he pa rt ts) wi th new o ne(s) befor e assem bly . ~ Use reco m m ended engi ne oil, un less oth erw ise spe cif ied . ~ Use m o lybdenum oil so lut ion (m ixtu re of t he en g ine oil and mo ly bdenum g rease in a rat io of 1: 1). -~ Use m ulti -purpose grease (Lithium based m ulti -pu rpo se g rease NLGI # 2 or eq uivalent). ~ Use m o ly bden um d is ulf ide gr ease (co nt ai ning m o re t han 3% m olybdenum dis ulf id e, NL GI # 2 or eq uiv alent). Exam pl e: Mo lv kote'" BR-2 plu s manufact ured by Dow Co rn ing , U.S.A. M ulti-purp ose M-2 man ufact ured by M itsu bis hi Oil , Ja pan ~ Use molybde num dis ulf id e paste (co ntaining mor e t han 40% m o lybd en um d isulfid e, NLGI # 2 or eq uiva lent). Exam ple: Mol vkot e" G-n paste, ma nufact ured by Dow Co rning , U.S.A. Hond a Mo ly 60 (U.S.A. on ly ) Roco l AS P manuf act ure d by Roco l Limi ted, U.K. Rocol Paste manufa ctured by Sum ico Lubricant, J apan ~ Use sil ico ne grease. L1mI Apply a lock ing agent. Use a mi ddle st rengt h lock ing agent un less ot herwi se specif ied. J 1um Appl y sealant . I Use DOT 4 brake f luid. Use the recomm ende d br ake fl uid unless ot herwi se spe cifie d. ell Use Fo rk or Sus pe nsio n Fluid. ..

1. GENERAL INFORMATION .. GENERAL SAFETY 1-1 LUBRICATION & SEAL POINTS 1-20 SERVICE RULES 1-2 CABLE & HARNESS ROUTING 1-24 MODEL IDENTIFICATION 1-3 EMISSION CONTROL SYSTEMS 1-36 SPECIFICATIONS 1-4 EMISSION CONTROL INFORMATION LABELS 1-39 TORQUE VALUES 1-13 TOOLS 1-18 GENERAL SAFETY CARBON MONOXIDE If the engine mu st be runnin g to do so me wo rk, ma ke sure t he area is we ll ventilated. Ne ver run th e engine in an enclosed area. ~ '-------- - - - - - - - - - - - The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Run th e engine in an ope n area or w ith an exh aust evacuation syste m in an enclosed area. GASOLINE Work in a well vent ilated area. Keep cigarettes, flames or sparks away fro m th e work area or wh ere gasoline is sotred. ~'--- --------- Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS ~'---- -------- Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. USED ENGINE OIL ~L-- _ Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. BRAKE FLUID CAUTION: Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. 1-1

GENERAL INFORMATION COOLANT BATTERY HYDROGEN GAS & ELECTROLYTE Under some conditions, the ethylene glycol in engin e coolant is combustib le and its f lame is not visible. If the aBmmI'----- _ ethylene glycol do es ign ite , you will not see any flame, but yo u can be burned. • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. aBmmIL-- _ • The battery contains sulfuric acid (electrolyte). Contact • Avoid spilling engine coolant on the exhaust system or with skin or eyes may cause severe burns. Wear engine parts. They may be hot enough to cause the protective clothing and a face shield. coolant to ignite and burn without a visible flame. - If electrolyte gets on your skin, flush with water. • Coolant (ethylene glycol) can cause some skin irritation - If electrolyte gets in your ~yes, flush with wa ter for at and is poisonous if swallowed , KEEP OUT OF REACH OF least 15 minutes and call a physician immediately. CHILDREN. • Electrolyte is poisonous. • Do not remove the radiator cap when the engine is hot. - If swallowed , drink large quantities of water or milk The coolant is under pressure and could scaled you. and follow with milk of magnesia or vegetable oil and - • Keep hands and clothing away from the cooling fan, as it call a physician. KEEP OUT OF REACH OF CHILDREN. starts automatically. SERVICE RULES 1. Use genuine HONDA or HONDA-recom mended parts and lubricants or the ir equivalents. Parts that don't meet HONDA's design specifications may cause damage to the mot orcycle. 2. Use the special tools designed for th is prod uct to avo id dam age and incorrect asse mb ly. 3. Use only m etr ic tools when serv icing the motor cycle. Metr ic bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, a -rings, corter pins, and lock plates w hen reass emb lin g. 5. Whe n tighten ing bolts or nuts, begin with th e larger diameter or i nner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particu lar sequence is specified. _ 6.Clean parts in cleaning solvent upon disasse mbly. Lubricate any sliding surfac es befo re reassembly. 7. After reassembly, check all parts for prope r i nsta llat ion and operation. 8. Route all electrical w ires as show on pages 1-24 thr ough 1-35, Cable and Harness Routing . - - 1-2

- - - - - - - - - -- - - - - - - - - -- - - - - - - - - - - --- - - - - -- -- GENERAL INFORMATION MODEL IDENTIFICATION (1) The frame ser ial number is stamped on the right side of th e steering head. (2) The engine seria l number is stamped on the right side of the upper crankcase. VEHICLE IDENTIFICATION NUMBER (VIN) (3) The Veh icle Identification Number (VIN ) is located on right side of the frame near the steering head on the Safety Cert if ication Label. CARBURETOR IDENTIFICATION NUM BER (4) The carburetor ident ificat io n n umb ers are sta mped on the intake side of the carburetor body as sho wn. (5) The color label is attached as shown . When o rder ing color-coded parts, always specify the designated color code. 1-3

GENERAL INFORMATION SPECIFICATIONS - GENERAL SPECIFICATIONS ITEM DIM ENSIONS 2,160 mm (85.0 in) Overa ll width Ove rall lengt h 720 m m (28.3 in) Ove rall height 1,170 mm (46.1 in) Whee lbase 1,485 m m (58.5 in) Seat height 810 mm (31.9 in) Footpeg heig ht 372 mm (14.6 in ) Ground clearance 130 mm (5.1 in) Dry w eig ht 49 states/Canada type 223 kg (492 lbs ) Cal ifornia ty pe 225 kg (496 lbs ) Curb w eight 49 states/Canada ty pe 250 kg (551 Ibs) Califo rn ia type 252 kg (556 Ibs) Max imum w eight capa city 49 state s/Cal ifornia type 174 kg (384 Ibs) Canad a typ e 178 kq (393 lbs ) FRAM E Frame type Diamond Front suspension Telescopic fork Fro nt w hee l trave l 109 mm (4.3 in) Rear susp ension Swing arm Rear w hee l t rave l 120 mm (4.7 in) Rear d amper Nitrog en gas f illed d amper Front tire size 120/70 ZR17 (Radial) Rear tire size 180/55 ZR17 (Radial) Ti re br and Bridgestone Front: BT57F RADIAL G/ Rear: BT57R RADIAL G Dunlop Front: D205FJ/ Rear: D205G Mich el in Front: MACADAM 90X S/ Rear: MACADAM 90X S Fron t brak e Hydraulic double disc brake with 3 pots caliper Rear brake Hydraulic single disc brake with 3 pots caliper Caster angle 25° Trail length 99 mm (3.9 in) Fuel tank capac ity 22.0 Q (5.81 US gal , 4.841mp gal ) Fuel tank reserve capac ity 3.0 Q (0.79 US qal r 0.66 Imp ca l) ENGINE Bore and stro ke 79.0 X 58.0 mm (3.11 X 2.28 in) Displacement 1,137 ern" (69.4 cu-i n) Comp ression ratio 11.0 : 1 Va lve train Chain dr iv e and DOHC Intake valve 20° BTDC ope " mm f '" closes (0.04 in) 40° ABD C Exhaust valve opens lift 40° BBDC close s 10° ATDC Lubrication system Forced pressure and w et s ump Oil pu mp type Trochoid/ double rotor Cool ing system Liquid cooled Air filtration Paper fi lter Crankshaft type Unittype Engine dry weight 83.0 kg (183.0 lbs) Cylinde r arranqernent Four cyli nde r, inline 30° inc lind ed f ro m vert ical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - -_ ._ -- 1-4

GENERAL INFORMATION c - GENERAL ( ont'd) ITEM SPECIFICATIONS CV (Constant Veloc ity ) type, wi th f lat valve 42 mm (1.7 in ) CARBUR ETOR Carbureto r ty pe Thrott le bore DRIVE TRAIN Clutch system Clutch operation system Transmissio n Pri mary reduction Fina l reduction Gear ratio Gearshift pattern 1st 2nd 3rd 4th 5th 6th Mu lti-plate, we t Hydraulic operated typ e Constant mesh , 6-speed 1.571 (88/56) 2.647 (45/17) 2.769 (36/13) 2.000 (32/16) 1.579 (30/ 19) 1.333 (28/21) 1.167 (28/24) 1.042 (25/24) Left foot op erated ret urn syst em, 1-N-2-3-4-5-6 ELECTRICA L Ignitio n syst em Sta rt ing system Charging system Regulator/ rec tifie r l.iq htinq system Co mp uter-cont rolled dig ita l tr an si st or ized wi t h electric advanc e Electric st art er motor Tr iple phase out put alternator SCR sh o rte d/t riple phase, ful l wave rectifica t ion Batt ery 1-5 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --- - - -- _ .

GENERAL INFORMATION - LUBRICATION SYSTEM Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engin e oil capac ity At dra ininq 3.8 Q (4.0 US qt , 3.3 Im p qt) At di sasse m bly 4.6 Q(4.9 US qt , 4.0 Im p qt ) At oil f ilter cha nce 3.9 Q(4.1 US ut , 3.4 Im p qt) Reco mm ende d eng ine oi l HONDA GN4 4-stro ke oi l or eq uivalent motor oil API serv ice classifi cat ion SF or SG Visco sit y : SAE 10W-40 Oi l pressure at oil pressure switch 490 kPa (5.0 kgf/cm 2 r 7 1 psi ) at 5,400 rpm / (176 °F/80 °C) Oil pu m p roto r Feed pump Tip clearance 0.15 (O .006) max . 0.20 (0.008) Bod y clea rance 0.15 - 0.21 (0.006 -0. 008) 0.35 (0.014) Side clearance 0.04 - 0.09 (0.002 - 0.004 ) 0.12 (0.005) Coo ler Ti p clearance 0.15 (0.006) max. 0.20 (0.008) pu mp Body clearance 0.15 - 0.21 (0.006 - 0.008) 0.35 (0.014) Side cle arance 0.04 - 0.09 (0.002 - 0.004) 0.12 (O .005) FUEL SYSTEM ~ ITEM SPECIFICATIONS Car buretor identification nu mber 49 states/Canada type VPS2A Ca lifornia ty pe VPS1A Ma in jet No. 1, 4: # 140/No . 2, 3: # 142 Slow iet # 42 J et need le number 49 states/Cana da ty pe J5F Z California type J5FU Pilot screw initia l open ing 49 states/Ca nada ty pe 2-3/4 t urn s out Cal iforn ia typ e 2-1/2 tu rn s ou t Float level 13.7 mm (0.54 in ) Idle speed 1,100 ± 100 rpm Th rott le crio free play 2-6 mm (1/ 12 - 1/4 in ) 1-6

GENERAL INFORMATION Unit: m m (i n) - COOLING SYSTEM ITEM SPECIFICATIONS Coo la nt capac ity Rad iato r and enq ine 3.2 Q (0.85 US ual , 0.70 Im p qal) Reserve tank 1.1 Q (0.29 US qa l t 0.24 Imp qa l) Radiator cap reli ef pressur e 108 -1 37 kPa (1.1- 1.4 kef/ern", 16 -20 psi) Ther m ostat Beqin to open 176 - 183 of (80 -84 °C) Fullv open 203 of (95 °C) Valve lift 8 mm (0.3 in) m ini m um - CYLINDER HEAD/VALVES ITEM Cy l inder compr ess ion Cyl inder head w arpaue STANDARD 1,275 kPa (13.0 kqf /c rn" , 185 psi) at 350 rp m 0.16 + 0.03 (0.006 + 0.001) SERVICE LIMIT 0.10 (0.004) Valve, valve gu ide Valve cl earance IN EX 0.22 + 0.03 (0.009 + 0.001) Valve stem O.D. IN 4.975 - 4.990 (0.1959 - 0.1965) 4.965 (0.1955) EX 4.960 - 4.975 (0.1953 - 0.1959) 4.950 (0.1949) Va lve gu ide I.D. IN 5.000 - 5.012 (0.1969 - 0.1973) 5.040 (0.1984) EX 5.000 -5 .012 (0.1969 - 0.1973) 5.040 (0.1984) Ste m-to-g uid e clearance IN 0.010 0.037 (0.0004 0.0015) 0.025 0.052 (0.0010 0.0020) 16.3 16.5 (0.64 0.65) 16.3 16.5 (0.64 0.6 5) 0.90 - 1.10 (0.035 - 0.043) EX Valve gu ide project ion ab ove cv linder head IN EX Val ve seat widt h IN/EX 1.5 (0.06) Valve spr ing f ree len qt h Inner IN/EX 37. 4 (1.47) 40.6 (1.60) 25.978 - 25.993 (1.0228 - 1.0233) 35.4 (1.39) Outer IN/EX 38.6 (1.52) Va lve lifte r Va lve lifte r O.D. IN/EX 25.97 (1.022) Valv e lift er bore I.D. IN/EX 26.010 - 26.026 (1.0240 - 1.0246) 26.04 (1.025) Cams haft Cam lo be hei ght IN 38.54 - 38.78 (1.517 -1 .527) 38.24 (1.506) EX 38.30 -38 .54 (1.508 - 1.517) 38.00 (1.496) Runo ut Oil clearance 0.020 -0 .074 (0.0008 -0 .0029) 0.05 (0.002) 0.10 (0.004) 1-7

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HONDA CBR1100XX Workshop Repair Manual 1997-1998

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