User manual | Honda CBR1000RR 2004 Motorcycle Parts list

2004CBR1000KIT（E_list） 04.4.27 5:12 PM ページ1

2004-CBR1000RR PARTS LIST

INSTRUCTIONS FOR USE OF PARTS LIST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4- 2

ENGINE GROUP

E- 1

E- 1-1

E- 2

E- 3

E- 4

E- 5

E- 6

E- 7

ENGINE POWER UP KIT I

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4- 3

ENGINE POWER UP KIT II

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4- 4

A.C. GENERATOR SET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4- 5

WIRE LOCKING KIT / AIR FUNNEL SET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4- 7

WATER HOSE PLUG SET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4- 8

AIR INJECTION PLUG SET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4- 9

TRANSMISSION SET / DRIVE SPROCKET SET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10

CAM CHAIN / TENSIONER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12

CONTENTS

F- 6

F- 7

F- 8

F- 9

F-10

F-11

F-12

F-13

F-14

F- 1

F- 2

F- 3

F- 4

F- 5

FRAME GROUP

AIR BOX DUCT SET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13

BREATHER CASE SET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14

EXHAUST SET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15

FRONT FORK

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-17

SWINGARM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-19

REAR CUSHION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21

STEERING DAMPER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-22

RADIATOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-23

FRAME PARTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-24

WIRE HARNESS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-25

REAR WHEEL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-27

FRONT WHEEL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-29

BRAKE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-30

QUICK SHIFTER SET

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-31

INDEX

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-32

4-1


INSTRUCTIONS FOR USE OF PARTS LIST

This parts list is to be used when ordering replacement parts; it contains all parts for model 2004-CBR1000RR.

Ⅰ. How to order parts

●Information required

Replacement parts orders must contain both the part number and the stamped number(s) as described belew. This is because any changes and modifications of parts are registered at Honda with the pertinent parts and stamped numbers.

• If quantities are shown in ( ), the parts are optional.

• If “N”is indicated in the quantity column, the parts quantity is to be determined as required.

Ⅱ. How to read this parts list

●Make-up of the part number

(Example) General parts

○○○○○―○○○―○○○○○

Function and component No.

Model code No.

Color code

Subcontractor designation

Modification designation

(Example) Bolts, nuts and other standard parts

○○○○○―○○○○○―○○

Function and component No.

Dimension Chemical surface treatment

ISO

●Abbreviations

The following abbreviations are used 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

IMPORTANT INFORMATION

• The parts which have a dot “•”on the left side of the “Ref. No.”are exclusive for HRC products. To purchase these parts, consult your

Honda dealer.

• The parts which have no dot are Honda products and can be purchased from your nearest Honda motorcycle dealer, or from HRC-JAPAN/

EUROPE if you can,t obtain the parts locally.

MEMO

4-2


Block No.

E-1

ENGINE POWER UP KIT I

2004 CBR1000RR

Ref.

No.

3

4

1

2

• 5

•

•

•

•

Part No.

06110-NL9-000

14110-MEL-R10

14210-MEL-R10

14751-MEL-R10

22401-MEL-R10

• 6 31910-NL3-620

Description

ENGINE POWER UP KIT I ..............................................................................................

CAMSHAFT COMP, IN...................................................................................................

CAMSHAFT COMP, EX..................................................................................................

SPG, IN VALVE...............................................................................................................

SPRING, CLUTCH ..........................................................................................................

1

8

1

1

5

Reqd. No.

SP AMA

1

8

1

1

5

PLUG, SPARK, R0045Q-10 ............................................................................................

4 4

Remarks

4-3


Block No.

E-1-1

ENGINE POWER UP KIT II

2004 CBR1000RR

Ref.

No.

•

•

1

2

•

•

•

•

3

4

• 5

Part No.

06120-NL9-000

12251-NL9-000

12252-NL9-000

12253-NL9-000

13101-NL9-000

13112-NL9-000

13121-NL9-003

•

•

•

•

8

9

6

7

13131-NL9-003

13141-NL9-003

14711-NL9-000

14721-NL9-000

Description

ENGINE POWER UP KIT II .............................................................................................

GASKET, CYLINDER HEAD 0.60 ...................................................................................



PISTON ...........................................................................................................................

CLIP, PISTON PIN 17MM...............................................................................................

RING, PISTON TOP 75X0.8X2.3....................................................................................

4

8

4

1

1

1

1

Reqd. No.

SP AMA

4

8

4

1

1

1

1

RING, PISTON 2ND 75X0.8X2.4 ...................................................................................

RING, PISTON OIL 75X1.5X1.95 ...................................................................................

VALVE, INLET(29) ..........................................................................................................

VALVE, EXHAUST(24) ...................................................................................................

8

8

4

4

8

8

4

4

4-4

Remarks


Block No.

E-2

A.C. GENERATOR SET

2004 CBR1000RR

Ref.

No.

3

4

1

2

• 5

•

•

•

•

Part No.

06130-NL9-000

11000-NL9-000

11100-NL9-000

11200-NL9-000

11201-NL9-000

•

6

7

8

9

• 10

11300-MEL-000

11321-NL9-000

11333-MEL-000

12208-PR3-000

31110-NL9-000

• 11

• 12

13

14

15

31120-NL9-000

90003-NL9-000

90004-MEL-000

90006-GHB-660

90006-GHB-670

16

17

18

19

20

90008-MEL-000

90010-MEL-000

90015-MEL-003

90016-MEL-003

90017-MAT-000

Description

ACG SET .........................................................................................................................

CRANKCASE SET ..........................................................................................................

BLOCK COMP., CYLINDER ............................................................................................

CRANK CASE, LOWER ..................................................................................................

COLLAR, 6.2X13X10 ......................................................................................................

1

1

1

1

1

Reqd. No.

SP AMA

1

1

1

1

1

HOLDER COMP., MISSION ............................................................................................

COVER, ACG ..................................................................................................................

CLAMP, ACG CODE........................................................................................................

BOLT, SEALING, 20MM .................................................................................................

ROTER COMP.................................................................................................................

1

1

1

1

1

1

1

1

1

1

STATOR COMP ..............................................................................................................

BOLT, FLANGE, 10X35 ..................................................................................................

BOLT, SPECIAL, 7X42.5..................................................................................................

BOLT, FLANGE, NSHF, 6X22 ..........................................................................................

BOLT, FLANGE, NSHF, 6X25 ..........................................................................................

1

5

3

1

1

1

5

3

1

1

BOLT, SOCKET, 10MM...................................................................................................

BOLT, FLANGE, 8X12 .....................................................................................................

BOLT, FLANGE, 9X105 ...................................................................................................

BOLT, FLANGE, 9X125 ...................................................................................................

BOLT, FLANGE, 7X40 .....................................................................................................

6

4

1

1

9

6

4

1

1

9

Remarks

4-5


Block No.

E-2

A.C. GENERATOR SET

2004 CBR1000RR

Ref.

No.

Part No.

21

22

23

24

25

90017-MEL-000

90018-MEL-000

90048-MEL-000

90119-MB0-000

90133-MEL-000

26

27

28

29

30

90447-KE1-000

90701-MV9-670

91001-MEL-003

91002-MEL-003

91003-MEL-003

31

32

33

34

35

91004-MEL-003

91201-MEL-013

91202-MEL-003

95701-06012-00

95701-06055-00

36

37

38

95701-08040-00

95701-08055-00

96600-06028-00

Description

BOLT, FLANGE, 7X60 .....................................................................................................

BOLT, FLANGE, 7X80 .....................................................................................................

BOLT, SEALING, 22MM .................................................................................................

BOSS, OIL FILTER ..........................................................................................................

BOLT, FLANGE, 8X30 .....................................................................................................

1

1

1

1

6

Reqd. No.

SP AMA

1

1

1

1

6

WASHER, SEALING, 7MM .............................................................................................

DOWEL PIN, 10X16 ........................................................................................................

BRG, BALL RADIAL, 28X62X16 ......................................................................................

BRG, BALL SPECIAL, 20X47X15.5 .................................................................................

BRG, SPECIAL, 20X52X15 ..............................................................................................

1

3

1

1

1

1

3

1

1

1

BRG, BALL SPECIAL, 35X72X17 ....................................................................................

OIL SEAL, 34.8X53X8 .....................................................................................................

OIL SEAL, 8X16X7 ..........................................................................................................

BOLT, FLANGE, 6X12 .....................................................................................................

BOLT, FLANGE, 6X55 .....................................................................................................

1

1

1

1

1

1

1

1

1

1

BOLT, FLANGE, 8X40 .....................................................................................................

BOLT, FLANGE, 8X55 .....................................................................................................

BOLT, SOCKET, 6X28 .....................................................................................................

1

5

4

1

5

4

4-6

Remarks


Block No.

E-3

WIRE LOCKING KIT /

AIR FUNNEL SET

2004 CBR1000RR

Ref.

No.

3

4

1

2

• 5

•

•

•

•

Part No.

06140-NL9-000

06160-NL9-000

15611-NF4-900

17215-NL9-000

17216-NL9-000

• 6

•

•

7

8

9

• 10

17217-NL9-000

17218-NL9-000

17240-NL9-000

50252-GC4-830

90012-MEL-R10

Description

WIRE LOCKING KIT .......................................................................................................

AIR FUNNEL SET ...........................................................................................................

CAP, OIL FILLER .............................................................................................................

FUNNEL, AIR #1 .............................................................................................................

FUNNEL, AIR #2 .............................................................................................................

1

1

1

1

1

Reqd. No.

SP AMA

1

1

1

1

1

FUNNEL, AIR #3 .............................................................................................................

FUNNEL, AIR #4 .............................................................................................................

WASHER COMP, TONGUED ........................................................................................

BAND, SUB TANK ...........................................................................................................

BOLT, DRAIN PLUG 12MM ..........................................................................................

1

1

2

1

1

1

1

2

1

1

Remarks

4-7


Block No.

E-4

WATER HOSE PLUG SET

2004 CBR1000RR

Ref.

No.

• 1

2

• 3

• 4

5

Part No.

06150-NL9-000

19504-KY1-003

19511-NL3-650

19512-NL8-700

90454-ZV1-000

Description

PLUG SET, WATER HOSE ............................................................................................

CLAMP , WATER HOSE D25 ..........................................................................................

PLUG, FAST IDLE...........................................................................................................

PLUG, HOSE 16MM .......................................................................................................

WASHER, THRUST .........................................................................................................

2

2

1

2

1

Reqd. No.

SP AMA

2

2

1

2

1

Remarks

4-8


Block No.

E-5

AIR INJECTION PLUG SET

2004 CBR1000RR

Ref.

No.

• 1

2

• 3

4

5

Part No.

06195-NL3-650

17460-MEL-R10

17470-MEL-R10

19505-KS6-700

96205-14012

Description

Reqd. No.

SP AMA

PLUG SET, EXHAUST A/I ..............................................................................................

TUBE, AIR SECTION UP .................................................................................................

TUBE ASSY., A/S UPPER ..............................................................................................

CLAMP, A WATER HOSE ...............................................................................................

PLUG, CONE TYPE 14X12 ..............................................................................................

1

1

1

3

3

1

1

1

3

3

No sale by HRC

Remarks

4-9


Block No.

E-6

TRANSMISSION SET

DRIVE SPROCKET SET

2004 CBR1000RR

Ref.

No.

•

•

1

2

• 3

• 4

• 5

Part No.

06210-NL9-000

06220-NL9-000

23211-MEL-R10

23220-MEL-R10

23421-MEL-R10

• 6

• 7

8

• 9

• 10

23431-MEL-R10

23441-MEL-R10

23442-MS2-610

23451-MEL-R10

23461-MEL-R10

• 11

12

• 13

• 14

• 15

23481-MEL-R10

23482-MR7-000

23491-MEL-R10

23501-MEL-R10

23511-MEL-R10

• 16

• 17

•

•

• 18

23521-MEL-R10

23801-NL6-700

23802-NL6-700

23803-NL6-700

37700-MEL-R10

4-10

Description

TRNSMISSON SET ........................................................................................................

DRV SPRKT SET.............................................................................................................

SHAFT, MAIN .................................................................................................................

SHAFT COMP., CCOUNTER ..........................................................................................

GEAR, C-1 .......................................................................................................................

1

1

1

1

1

Reqd. No.

SP AMA

1

1

1

1

1

GEAR, M-2 ......................................................................................................................

GEAR, C-2 .......................................................................................................................

COLLOAR, 30x11.2.........................................................................................................

GEAR, M-3 M-4 ..............................................................................................................

GEAR, C-3 .......................................................................................................................

1

1

1

1

1

1

1

1

1

1

GEAR, C-4 .......................................................................................................................

COLLAR, SPLINE, 28X13.5 .............................................................................................

GEAR, M-5 ......................................................................................................................

GEAR, C-5 .......................................................................................................................

GEAR, M-6 ......................................................................................................................

1

1

1

1

1

1

1

1

1

1

GEAR, C-6 .......................................................................................................................

SPROCKET, DRIVE,15(525) ...........................................................................................

SPROCKET, DRIVE,16(525) ...........................................................................................

SPROCKET, DRIVE,17(525) ...........................................................................................

SENSOR ASSY, SPEED .................................................................................................

1

1

1

1

1

1

1

1

1

1

Remarks


Block No.

E-6

TRANSMISSION SET

DRIVE SPROCKET SET

2004 CBR1000RR

Ref.

No.

Part No.

19

• 20

90004-492-010

90402-NL6-000

Description

Reqd. No.

SP AMA

SPL..BOLT, FLANGE, 10X22 ...........................................................................................

WASHER, 10.2X37X3 ....................................................................................................

1

1

1

1

Remarks

4-11


Block No.

E-7

CAM CHAIN / TENSIONER

2004 CBR1000RR

Ref.

No.

1

Part No.

94101-06000

Description

Reqd. No.

SP AMA

WASHER, PLAIN, 6MM ..................................................................................................

2 2

Remarks

4-12


Block No.

F-1

AIR BOX DUCT SET

2004 CBR1000RR

Ref.

No.

• 1

•

•

• 2

3

4

5

Part No.

06172-NL9-000

17210-MEL-R11

17211-NL9-000

17251-NL9-000

18315-GAG-750

• 6

• 7

8

9

19120-NL9-000

19170-NL9-000

90110-147-000

93891-05012-18

Description

AIR BOX DUCT SET .......................................................................................................

ELEMENT, AIR/C ............................................................................................................

SPONGE, ELEMENT ......................................................................................................

DUCT, AIR BOX..............................................................................................................

RUBBER A, PROTR .........................................................................................................

1

1

1

2

2

Reqd. No.

SP AMA

1

1

1

2

2

STAY R, RAD UPPER .....................................................................................................

STAY L, RAD UPPER .....................................................................................................

BOLT, FLANGE, 6MM.....................................................................................................

SCREW-WASH, 5X12......................................................................................................

1

1

2

2

1

1

2

2

Remarks

4-13


Block No.

F-2

BREATHER CASE SET

2004 CBR1000RR

Ref.

No.

• 1

2

3

4

5

Part No.

06552-NL9-000

17724-102-700

18315-GAG-750

19052-KV0-000

19505-KS6-700

• 6

•

•

7

8

• 9

• 10

31517-NL9-000

55200-NL9-000

55210-NL9-000

55220-NL9-000

55231-NL9-000

11

12

13

14

15

81351-124-830

90104-KR3-670

90525-030-000

94050-06000

96001-06020-00

Description

BREATHER CASE SET ...................................................................................................

CLIP .................................................................................................................................

RUBBER A, PROTR .........................................................................................................

COLLAR, RADIATOR MOUNTING ..................................................................................

CLAMP A, WATER HOSE ...............................................................................................

2

2

1

3

3

Reqd. No.

SP AMA

2

2

1

3

3

SPONGE, MT 5MM ........................................................................................................

CASE COMP, BREATHER ..............................................................................................

TUBE, BREATHER ..........................................................................................................

TUBE, BREATHER RETURN ..........................................................................................

STAY, BREATHER CASE ...............................................................................................

1

1

1

1

1

1

1

1

1

1

RUBBER CARRIER MOUNT ...........................................................................................

BOLT METER SET ..........................................................................................................

WASHER B, HANDLE HOLDER......................................................................................

NUT FLANGE 6MM.........................................................................................................

BOLT, FLANGE, SH, 6X20 ..............................................................................................

2

2

2

2

2

2

2

2

2

2

4-14

Remarks


Block No.

F-3

EXHAUST SET

2004 CBR1000RR

Ref.

No.

3

4

1

2

• 5

•

•

•

•

Part No.

06183-NL9-000

18291-NL9-000

18293-NL9-000

18295-NL9-000

18300-NL9-000

• 6

•

•

7

8

• 9

• 10

18301-NL9-000

18302-NL9-000

18303-NL9-000

18304-NL9-000

18305-NL9-000

• 11

• 12

• 13

• 14

• 15

18309-NL9-000

18320-NL9-000

18334-NL6-000

18370-NL9-000

18375-NL9-000

• 16

17

18

19

20

18380-NL9-000

18421-MN5-000

19051-KA3-830

19052-MAC-680

90201-GCC-C50

Description

EXHAUST SET ...............................................................................................................

GASKET, EXH PIPE ........................................................................................................

FLANGE, EXH.................................................................................................................

COLLAR, EXH .................................................................................................................

PIPE ASSY, EXH.............................................................................................................

4

4

1

4

1

Reqd. No.

SP AMA

4

4

1

4

1

PIPE COMP, EXH(#1) .....................................................................................................

PIPE COMP, EXH(#2) .....................................................................................................

PIPE COMP, EXH(#3) .....................................................................................................

PIPE COMP, EXH(#4) .....................................................................................................

JOINT A, EXH PIPE ........................................................................................................

1

1

1

1

1

1

1

1

1

1

PIPE COMP,TAIL ............................................................................................................

STAY, EXH PIPE JOINT .................................................................................................

SPRING, EXH PIPE .........................................................................................................

15

BAND, MUFFLER ...........................................................................................................

STAY, MUFFLER ............................................................................................................

1

1

1

1

1

1

15

1

1

MUFFLER COMP ............................................................................................................

RUBBER, MUFF MOUNT................................................................................................

RUBBER, RAD.MOUNT ..................................................................................................

COLLAR, RAD MT...........................................................................................................

NUT, HEX., 7MM ............................................................................................................

1

1

1

1

2

1

1

1

1

2

Remarks

4-15


Block No.

F-3

EXHAUST SET

2004 CBR1000RR

Ref.

No.

Part No.

21

22

23

24

25

90202-MBB-000

93404-06025-00

94050-06000

94050-08000

95701-06010-00

26

27

95701-08020-00

95701-08055-00

Description

COLLAR, 8X18 ................................................................................................................

BOLT-WASHER, 6X25.....................................................................................................

NUT, FLANGE, 6MM.......................................................................................................

NUT, FLANGE, 8MM.......................................................................................................

BOLT, FLANGE, 6X10 .....................................................................................................

1

1

2

1

2

Reqd. No.

SP AMA

1

1

2

1

2

BOLT, FLANGE, 8X20 .....................................................................................................

BOLT, FLANGE, 8X55 .....................................................................................................

8

1

8

1

Remarks

4-16


Block No.

F-4

FRONT FORK

2004 CBR1000RR

Ref.

No.

• 1

• 2

•

•

• 3

• 4

• 5

Part No.

51400-MEL-R10

51401-MEL-R10

51401-NL9-900

51402-NL9-900

51403-MEL-R10

51404-MEL-R11

51406-MEL-R11

8

9

6

7

10

51410-MEL-003

51412-MEL-003

51414-MAZ-003

51415-MAZ-003

51423-MCJ-751

11

12

13

14

15

51425-MEL-003

51430-MEL-003

51447-KA4-711

51450-MEL-003

51451-MEL-003

16

17

18

51453-MCJ-751

51455-MW4-003

51456-MCJ-751

Description

FORK ASSY, R FRONT ..................................................................................................

SPRING, FR FORK 0.95..................................................................................................

SPRING, FR FORK 0.90..................................................................................................

SPRING, FR FORK 1.00..................................................................................................

COLLAR, SPRING...........................................................................................................

COLLAR B, SPRING .......................................................................................................

STOPPER, SPRING SEAT ..............................................................................................

2

2

2

2

2

1

2

Reqd. No.

SP AMA

2

2

2

2

2

1

2

TUBE, OUTER .................................................................................................................

RING, BACK UP...............................................................................................................

BUSH, GUIDE..................................................................................................................

BUSH, SLIDER ................................................................................................................

RING B, STOPPER ..........................................................................................................

2

2

2

2

2

2

2

2

2

2

PIPE COMP., R. SLIDE....................................................................................................

DAMPER COMP., FR. .....................................................................................................

RING, OIL SEAL STOPPER .............................................................................................

BOLT, FR. FORK .............................................................................................................

NUT, LOCK ......................................................................................................................

1

2

2

2

2

1

2

2

2

2

PLATE B, ADJUSTING ....................................................................................................

RING, STOPPER ..............................................................................................................

RING, STOPPER ..............................................................................................................

2

2

2

2

2

2

Remarks

4-17


Block No.

F-4

FRONT FORK

2004 CBR1000RR

Ref.

No.

Part No.

19

20

51490-MEJ-003

51496-MCJ-751

• 21

22

23

24

25

51500-MEL-R10

51525-MEL-003

52442-KA3-711

53702-MCJ-751

90109-MR7-000

26

27

28

29

30

90126-MR7-003

91254-MEJ-003

91255-MCJ-751

91256-MCJ-751

91257-MCJ-751

31 91258-GF4-003

Description

Reqd. No.

SP AMA

SEAL SET, FR. FORK ......................................................................................................

LABEL .............................................................................................................................

2

2

2

2

FORK ASSY,L FRONT ....................................................................................................

PIPE COMP., L. SLIDE ....................................................................................................

WASHER, SPECIAL, 10MM ............................................................................................

PLATE, SPRING ADJUSTER ...........................................................................................

BOLT, FLANGE, 8X45 .....................................................................................................

2

2

1

1

4

2

2

1

1

4

BOLT, SOCKET, 10X35 ...................................................................................................

DUST SEAL .....................................................................................................................

O-RING, 10.8X2.4 ............................................................................................................

O-RING, 23.3X2.4 ............................................................................................................

O-RING, 9.5X1.5 ..............................................................................................................

2

2

2

2

2

2

2

2

2

2

O-RING, 42.2X2.4 ............................................................................................................

2 2

4-18

Remarks


Block No.

F-5

SWINGARM

2004 CBR1000RR

Ref.

No.

3

4

1

2

• 5

•

•

•

•

Part No.

06405-NL9-000

40542-NL9-000

40543-NL9-000

40544-NL9-000

40545-NL9-000

•

•

• 9

• 10

6

7

8

41405-HA7-670

42301-NL9-000

42302-NL6-700

42304-NL9-000

42305-MEL-R10

• 11

• 12

• 13

• 14

• 15

42306-MEL-R10

42307-MEL-R10

42314-NL9-000

52100-MEL-R10

52157-NL3-650

• 16

• 17

• 18

90106-NL9-000

90308-NL9-000

90536-NL9-000

Description

DRIVE CHAIN ADJ SET .................................................................................................

ADJ, R DRIVE CHAIN .....................................................................................................

ADJ, L DRIVE CHAIN .....................................................................................................

LID, L DRIVE CHAIN ADJ...............................................................................................

SPACER, ADJ DRIVECHAIN L .......................................................................................

1

1

1

1

1

Reqd. No.

SP AMA

1

1

1

1

1

RING, STOPPER ..............................................................................................................

AXLE, REAR WHEEL ......................................................................................................

GUIDE, RR AXLE CNT ...................................................................................................

COLLAR, RR AXLE R SIDE ............................................................................................

COLLAR L, RR AXLE ......................................................................................................

1

1

1

1

1

1

1

1

1

1

COLLAR R, RR AXLE......................................................................................................

COLLAR, R JOINT ..........................................................................................................

COLLAR, RR AXLE L SIDE .............................................................................................

SWINGARM ASSY.........................................................................................................

PROTECTOR, SPRKT .....................................................................................................

1

1

1

1

1

1

1

1

1

1

BOLT, HEX, 8X55 ...........................................................................................................

NUT, RR AXLE ...............................................................................................................

WASH, RR AXLE ............................................................................................................

2

1

1

2

1

1

Remarks

4-19


Block No.

F-5

SWINGARM

2004 CBR1000RR

Ref.

No.

Part No.

19

20

93500-05020-0A

93500-05035-0A

93500-05050-0A

94050-05000

21 96001-06012-00

Description

SCREW, PAN, 5X20 ........................................................................................................

SCREW, PAN, 5X35 ........................................................................................................

SCREW, PAN, 5X50 ........................................................................................................

NUT, FLANGE, 5MM.......................................................................................................

2

2

2

2

Reqd. No.

SP AMA

2

2

2

2

BOLT, FLANGE, SH, 6X12 ..............................................................................................

2 2

Remarks

4-20


Block No.

F-6

REAR CUSHION

2004 CBR1000RR

Ref.

No.

•

•

•

•

• 1

• 2

• 3

• 4

5

Part No.

52400-MEL-R10

52401-MEL-R10

52401-NL9-900

52402-NL9-900

52403-NL9-900

52404-NL9-900

52430-MEL-R10

52460-MEL-R10

52463-KZ4-B00

8

9

6

7

• 10

52463-MEE-000

52464-MEE-000

52466-MEE-000

52467-MEE-000

52470-MEL-R10

11

12

13

14

15

52472-MEL-000

91071-MY1-005

91074-KZ4-B01

91262-KV3-831

91351-MAC-671

Description

CUSHION ASSY, RR ......................................................................................................

SPRING, RR CHSH 10.0 .................................................................................................

SPRING, RR CHSH 9.5 ...................................................................................................

SPRING, RR CHSH 10.5 .................................................................................................

SPRING, RR CHSH 11.0 .................................................................................................

SPRING, RR CHSH 11.5 .................................................................................................

STAY, RR CUSH ADJ.....................................................................................................

ARM ASSY, CUSHION ..................................................................................................

COLLAR D, CUSHION....................................................................................................

1

1

1

1

1

1

1

1

1

Reqd. No.

SP AMA

1

1

1

1

1

1

1

1

1

COLLAR, CUSHION ARM ..............................................................................................

COLLAR, BEARING SIDE ...............................................................................................

COLLAR A, CUSHION ARM...........................................................................................

WASHER, THRUST ........................................................................................................

CONN ROD ASSY, CUSHION .......................................................................................

1

4

1

2

1

1

4

1

2

1

COLLAR, CONNECTING ROD PIVOT ............................................................................

BEARING, NEEDLE, 17X24X17......................................................................................

BEARING, NEEDLE, 19X26X15......................................................................................

DUST SEAL, 17X24X5 (ARAI).........................................................................................

DUST SEAL, 16X26X3 ....................................................................................................

1

6

1

6

2

1

6

1

6

2

Remarks

4-21


Block No.

F-7

STEERING DAMPER

2004 CBR1000RR

Ref.

No.

• 1

Part No.

53700-NL9-003

Description

Reqd. No.

SP AMA

DAMPER ASSY, STRG ..................................................................................................

1 1

Remarks

4-22


Block No.

F-8

RADIATOR

2004 CBR1000RR

Ref.

No.

•

•

1

2

• 3

Part No.

19010-MEL-R11

19502-MEL-R10

19503-MEL-R10

Description

Reqd. No.

SP AMA

RADIATOR COMP ..........................................................................................................

HOSE, OIL/C ...................................................................................................................

HOSE RADIATOR L ........................................................................................................

1

1

1

1

1

1

Remarks

4-23


Block No.

F-9

FRAME PARTS

2004 CBR1000RR

Ref.

No.

3

4

1

2

• 5

•

•

•

•

Part No.

06531-NL3-750

17910-NL9-000

17920-NL9-000

22900-NL6-000

35200-MEL-R10

• 6

7

8

9

10

37100-MEL-R10

53141-MT7-000

53167-KV3-701

53168-KV3-701

93500-05020-0G

Description

HOUSING SET, THROT .................................................................................................

CABLE COMP A, THROT ...............................................................................................

CABLE COMP B, THROT ...............................................................................................

HOSE, CLUTCH ..............................................................................................................

SW ASSY, WINKER .......................................................................................................

1

1

1

1

1

Reqd. No.

SP AMA

1

1

1

1

1

METER ASSY, COMB ....................................................................................................

PIPE, THROT GRIP ..........................................................................................................

HOUSING, THROT UP ....................................................................................................

HOUSING, THROT UND .................................................................................................

SCREW, PAN, 5X20 ........................................................................................................

1

1

1

1

2

1

1

1

1

2

4-24

Remarks


Block No.

F10

WIRE HARNESS

2004 CBR1000RR

Ref.

No.

• 1

2

•

• 5

3

4

Part No.

06321-NL9-000

17556-MEL-300

18357-KA4-710

32100-NL9-000

35130-NL6-000

• 6

• 7

8

• 9

• 10

35160-NKC-000

35400-NL9-000

38500-GC7-612

38520-NL9-000

38770-NL9-000

• 11

• 12

• 13

• 14

15

38771-NL9-000

38880-NL3-750

64502-NL9-000

64503-NL9-000

90620-SB2-003

16

• 17

• 18

19

20

90649-SC2-003

91080-NL6-300

91081-ND4-750

91406-657-671

93891-04022-07

Description

HARNESS SET ...............................................................................................................

FILM A, PROTECTOR .....................................................................................................

COLLAR, SILENCER .......................................................................................................

HARNESS, WIRE ............................................................................................................

SW ASSY, ST KILL.........................................................................................................

2

1

1

1

1

Reqd. No.

SP AMA

2

1

1

1

1

SENSOR ASSY, KILL .....................................................................................................

REGISTER COMP ...........................................................................................................

RELAY ASSY, START ......................................................................................................

STAY, RELAY .................................................................................................................

UNIT ASSY., PGM-FI / IGN............................................................................................

1

1

1

1

1

1

1

1

1

1

CD-ROM, PGM-FI / IGN .................................................................................................

UNIT ASSY, SERIAL I/F .................................................................................................

STAY, ECU .....................................................................................................................

STAY, CATCH TANK......................................................................................................

BAND, WIRE HARN ........................................................................................................

1

1

1

1

1

1

1

1

1

1

BAND, HARNESS ............................................................................................................

POP RIVET 3.2X9.2 ........................................................................................................

BLIND RIVET 3.2X8 ........................................................................................................

CLIP, WIRE HARNESS ....................................................................................................

SCREW-WASHER, 4X22 .................................................................................................

2

1

1

2

2

2

1

1

2

2

Remarks

4-25


Block No.

F-10

WIRE HARNESS

2004 CBR1000RR

Ref.

No.

Part No.

21

22

23

24

25

94001-06000-0S

94050-04000

94101-03000

94103-06000

94591-27000

26 96001-06022-00

Description

NUT, HEX, 6MM .............................................................................................................

NUT, FLANGE,4MM........................................................................................................

WASHER, PLAIN,3MM ...................................................................................................

WASHER, PLAIN ,6MM ..................................................................................................

CLIP, 2X70.......................................................................................................................

2

2

2

2

1

Reqd. No.

SP AMA

2

2

2

2

1

BOLT, FLANGE,SH,6X22 ................................................................................................

2 2

Remarks

4-26


Block No.

F-11

REAR WHEEL

2004 CBR1000RR

Ref.

No.

•

•

•

•

1

2

• 3

•

•

•

4

5

Part No.

40540-MAS-005

40545-MAS-005

41238-NL6-700

41239-NL6-700

41240-NL6-700

41241-NL6-700

41242-NL6-700

41243-NL6-700

42311-NL9-000

42312-NL6-000

• 6

•

•

• 7

•

•

8

9

• 10

42603-NL6-000

42606-NL6-000

42608-NL6-000

42609-NL6-000

42621-NL6-000

42624-NL6-000

42633-NL6-003

• 11

•

12

• 13

42720-NC8-000

42721-NC8-000

42753-ML7-004

43121-NL6-000

Description

CHAIN, DRIVE RKGB525R0Z1-120LJF ...........................................................................

JOINT, DRIVE CHAIN ......................................................................................................

SPRKT, FINAL DRIVE 38T..............................................................................................






COLLAR, L DRIVEN FLANGE SIDE ...............................................................................

COLLAR, R DRIVEN FLANGE SIDE ...............................................................................

1

1

1

1

1

1

1

1

1

1

Reqd. No.

SP AMA

1

1

1

1

1

1

1

1

1

1

WHEEL, REAR 6.00-17 ...................................................................................................

WHEEL, REAR 6.00-16.5 ................................................................................................

WHEEL, REAR 6.25-16.5 ................................................................................................

FLANGE, FINAL DRIVEN ...............................................................................................

RETAINER, RR WHEEL BRG..........................................................................................

COLLAR, RR WHEEL DISTANCE...................................................................................

DAMPER, RR WHEEL.....................................................................................................

1

1

1

1

1

1

6

1

1

1

1

1

1

6

WEIGHT, BALANCE (10G) .............................................................................................

WEIGHT, BALANCE (20G) .............................................................................................

VALVE, RIM (DUNLOP) ...................................................................................................

DISK, RR. BRAKE ...........................................................................................................

1

1

N

N

1

1

N

N

Remarks

4-27


Block No.

F-11

REAR WHEEL

2004 CBR1000RR

Ref.

No.

Part No.

• 14

15

87000-NL6-000

90003-MC7-000

• 16

17

• 18

19

• 20

90120-NL6-300

90309-KF0-003

90501-NL6-000

90651-ML0-731

91051-NL6-000

• 21 91052-NL6-003

Description

Reqd. No.

SP AMA

TOOL, RETAINER A .......................................................................................................

BOLT, FLANGE, 6X20 .....................................................................................................

1

4

1

4

BOLT, DRIVEN FLANGE 8MM ......................................................................................

NUT, FLANGE, 8MM.......................................................................................................

WASHER, RR WHEEL BRG............................................................................................

CIRCLIP, INTERNAL, 62 ..................................................................................................

BRG., BALL RADIAL 6205 2RS......................................................................................

1

1

6

6

2

1

1

6

6

2

BRG., ANGULAR 30X62X23.8.......................................................................................

1 1

Remarks

4-28


Block No.

F-12

FRONT WHEEL

2004 CBR1000RR

Ref.

No.

•

1

2

•

• 5

3

4

Part No.

41231-KZ4-000

42720-NC8-000

42721-NC8-000

42753-ML7-004

44301-NL6-000

44303-NL9-000

•

•

6

7

•

•

8

9

•

•

• 10

44304-NL9-000

44305-NL9-000

44311-NL6-000

44601-NL6-000

44602-NL6-000

44603-NL6-000

44620-NL6-010

• 11

• 12

• 13

•

14

90305-NL6-000

90503-NL6-000

90525-NL9-000

90526-NL9-000

91051-KZ4-J21

Description

Reqd. No.

SP AMA

RETAINER, RR WHEEL BRG ..........................................................................................

WEIGHT, BALANCE (10G) .............................................................................................

WEIGHT, BALANCE (20G) .............................................................................................

VALVE, RIM (DUNLOP) ...................................................................................................

AXLE, FR WHEEL ...........................................................................................................

NUT, FR AXLE ................................................................................................................

N

1

1

N

1

1

N

1

1

N

1

1

GUIDE A, FR AXLE.........................................................................................................

GUIDE B, FR AXLE .........................................................................................................

COLLAR, FR WHEEL SIDE .............................................................................................

WHEEL, FR,17X3.50 .......................................................................................................

WHEEL, FR,16.5X3.5 ......................................................................................................

WHEEL, FR,17X3.75 .......................................................................................................

COLLAR, FR WHEEL DISTANCE ...................................................................................

1

1

1

2

1

1

1

1

1

1

2

1

1

1

NUT, M28X1.0................................................................................................................

WASHER, 45X22X3 .......................................................................................................

SHIM 0.2, FR FORK SIDE ...............................................................................................

SHIM 0.3, FR FORK SIDE ...............................................................................................

BEARING, RADIAL, BALL 6905 2RS...............................................................................

2

N

1

1

2

2

N

1

1

2

Remarks

4-29


Block No.

F-13

BRAKE

2004 CBR1000RR

Ref.

No.

Part No.

•

•

•

1

2

•

3

4

5

43100-NL5-701

43105-NL5-700

43105-NL6-700

43110-MEL-R11

43110-NL9-000

43112-MCF-006

•

•

6

•

•

7

8

• 9

• 10

45105-NL9-000

45105-NL9-900

45250-NL5-800

45500-NL5-701

45520-NL5-701

53160-NL5-701

11

12

13

14

90003-MC7-000

90104-GT8-600

95002-40850-08

95003-11015-60

Description

CALIPER ASSY, RR ........................................................................................................

PAD COMP, RR (X95) ....................................................................................................

PAD COMP, RR (TT2450)...............................................................................................

BRACKET COMP, RR ......................................................................................................

BRKT, RR CALIPER ........................................................................................................

RETAINER, RR. BRACKET ..............................................................................................

2

1

1

2

1

1

Reqd. No.

SP AMA

2

1

1

2

1

1

PAD CPMP, FR (N614) ...................................................................................................

PAD CPMP, FR (N608) ...................................................................................................

DISK COMP, FR 320 .......................................................................................................

M/C ASSY, BR L18 .........................................................................................................

CUP ASSY, FR M/C ........................................................................................................

LEVER, FR. BRAKE L 18P...............................................................................................

2

1

4

4

1

1

2

1

4

4

1

1

BOLT, FLANGE, 6X20 .....................................................................................................

12

SCREW, SPECIAL, 6X14 .................................................................................................

CLAMP, TUBE (D8.5) ......................................................................................................

TUBE, VINYL, 5X9X150 ...................................................................................................

1

2

1

12

1

2

1

4-30

Remarks


Block No.

F-14

QUICK SHIFTER SET

2004 CBR1000RR

Ref.

No.

• 1

2

•

•

3

4

• 5

Part No.

06382-NL9-000

30401-GB6-000

38200-NL9-000

38300-NL9-000

38410-NL9-000

• 6

• 7

• 8

38411-NL9-000

38520-NL9-000

91080-NL6-300

Description

QUICK SHIFTER SET .....................................................................................................

CUSHION, CDI UNIT .......................................................................................................

SENSOR ASSY, Q/SHIFT...............................................................................................

UNIT ASSY, Q/SHIFT .....................................................................................................

CD-ROM, Q/SHIFTER .....................................................................................................

1

1

1

1

1

Reqd. No.

SP AMA

1

1

1

1

1

USB CABLE ....................................................................................................................

STAY, RELAY .................................................................................................................

POP RIVET, 3.2X9.2 .......................................................................................................

1

1

2

1

1

2

Remarks

4-31


Honda Racing Corporation

Head Office/3-15-1 Senzui, Asaka-shi, Saitama-pref., 351-0024 Japan

TEL. 048-461-9511 TELFAX. 048-469-0068

European Office/Wijngaardveld 1, B 9300. Aalst. Belgium.

TEL. 053-78-6131 TELFAX. 053-77-5767

00. Introduction_r1 04.4.27 18:10 Page 2

Safety Messages

Your safety and the safety of others is very important. We have provided important safety messages in this manual and on the HRC CBR1000RR.

Please read these messages carefully.

A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol and one of three words, DANGER, WARNING, or CAUTION.

These mean:

You WILL be 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.

Damage Prevention Messages

You will also see other important messages that are preceded by the word

NOTICE.

This word means:

Your HRC CBR1000RR or other property can be damaged if you don’t follow instructions.

The purpose of these messages is to help prevent damage to your HRC

CBR1000RR, other property, or the environment.

Each message tells you what the hazard is, what can happen and what you can do to avoid or reduce injury.


HRC CBR1000RR Racing Kit

Set-up Manual/Parts List

All information in this publication is 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 any obligation.

No part of this publication may be reproduced without written permission.


Important Information

• This kit is sold as is without warranty, and the entire risk as to quality and performance is with the buyer.

• This kit is designed and manufactured to enhance the performance of the CBR1000RR, and as is stated in the CBR1000RR 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 sanctioning body or by permit issued by the local governmental authority having jurisdiction.

• This kit is not suitable for use with any other parts.

01. Service Information_r3 04.4.27 18:11 Page 1

1. Service Information

General Information

• This Set-up Manual contains information for CBR1000RR Racing Kit.

• Refer to Shop Manual for service procedures and data not included in this manual.

Service Data

Different items between standard CBR1000RR and Racing kit installed CBR1000RR.

Engine

Electrical

Item

Type

Cylinder arrangement

Bore and stroke

Displacement

Compression ratio

Head gasket thickness

Valve train

Valve timing Intake

Spark plug

Exhaust

2004 Standard

Water cooled 4-stroke DOHC 16 valve

28˚ inclined inline four

75.0 x 56.5 mm

998.4 cm

3

11.9 : 1 t0.4

DOHC, chain driven opens 18˚ BTDC close 46˚ ABDC opens 39˚ BBDC close 11˚ ATDC

NGK: IMR9C-9HES, DENSO: VUH27ES

13.6 : 1 t0.6

2004 Racing Kit (Super Bike Kit)

–

–

–

–

–

22˚ BTDC

53˚ ABDC

47˚ BBDC

23˚ ATDC

NGK: R0045Q-10

• Honda’s testing has shown that the optimum overall performance of the Honda CBR1000RR engine power up kit can be obtained by using appropriate exhaust system.

• No testing was done to verify serviceability or overall quality. Honda makes no claim and assumes to responsibility as to the reliability or quality of these components.

Use unleaded premium gasoline (reserch octane number 100)

1-1


Service Information

Torque Values

Standard Torque

Item

M5 bolt and nut

M6 bolt and nut

M8 bolt and nut

M10 bolt and nut

M12 bolt and nut

M5 screw

M6 screw

M6 flange bolt and nut



Engine

Item

Main journal bolt

Crankcase bolt

Transmission holder bolt

Oil drain bolt

Timing hole cap

Alternator wire clamp bolt

Cylinder head tightening bolt

Camshaft holder bolt

Cylinder head cover bolt

Breather plate bolt

PAIR reed valve cover bolt

Connecting rod bolt

Starter clutch outer bolt

Flywheel bolt Standard

Racing kit

1-2

Thread/ pitch

M5 x 0.8

M6 x 1.0

M8 x 1.25

M10 x 1.25

M12 x 1.25

M5 x 0.8

M6 x 1.0

M6 x 1.0

M8 x 1.25

M10 x 1.25

Thread/ pitch

M9 x 1.25

M8 x 1.25

M7 x 1.0

M8 x 1.25

M12 x 1.5

M45 x 1.5

M6 x 1.0

M9 x 1.25

M6 x 1.0

M6 x 1.0

M6 x 1.0

M6 x 1.0

M8 x 0.75

M10 x 1.25

M10 x 1.25

M10 x 1.25

Torque

N•m (kgf•m, lbf•ft)

4.9 (0.5, 3.6)

12 (1.2, 9)

22 (2.2, 16)

34 (3.5, 25)

54 (5.5, 40)

4 (0.4, 2.9)

9 (0.9, 6.5)

12 (1.2, 9)

26 (2.7, 20)

39 (4.0, 29)

Apply oil

Included SH bolt; apply oil

Apply oil

Apply oil

Apply oil

Remarks

Included NSHF bolt; apply oil

Apply oil

Apply oil

Torque


20 (2.0, 14) + 60˚ + 60˚

24 (2.5, 18)

18 (1.8, 13)

29 (3.0, 22)

29 (3.0, 22)

18 (1.8, 13)

12 (1.2, 9)

20 (2.0, 14) + 53˚ + 53˚

12 (1.2, 9)

9.8 (1.0, 7)

12 (1.2, 9)

12 (1.2, 9)

20 (2.0, 14) + 45˚ + 45˚

14 (1.4, 10) + 45˚ + 45˚

83 (8.5, 61)

103 (10.5, 76)

118 (12.0, 87)

Remarks

Apply oil after removing anti-rust additive

Apply oil

Apply oil

Apply oil

Wire lock

CT bolt

Apply oil after removing anti-rust additive

Apply oil

Apply oil

Apply LOCKTITE 271

Apply LOCKTITE 271

New bolt: temporarily tighten 1 time

Apply oil; retightening limit: 10 times

Apply oil

Apply oil

Apply oil


Item

Cam sprocket bolt

Cam position sensor rotor bolt

Cam chain tensioner bolt

Cam chain guide

Oil pump assembly bolt

Oil pump driven sprocket bolt

Oil filter cartridge

Throttle body insulator bolt

Thermostat cover bolt

Water pump cover bolt

Water pump impeller

Clutch center lock nut

Clutch spring bolt

Transmission bearing set plate bolt

Drive sprocket bolt

Shift drum center bolt

Shift drum stopper arm bolt

Shift return spring pin

Shift drum bearing set plate bolt

Shift drum stopper plate bolt

Alternator stator mounting bolt

Starter motor terminal nut

Spark plug

Oil pressure switch

Oil pressure switch terminal screw

Neutral switch

ECT sensor

Insulator band

Water hose band

M6 x 1.0

M10 x 1.25

M8 x 1.25

M6 x 1.0

M8 x 1.25

M6 x 1.0

M6 x 1.0

M6 x 1.0

M6 x 1.0

M10 x 1.0

PT1/8

M4 x 0.7

M10 x 1.25

M12 x 1.5

M5 x 0.8

–

Thread/ pitch

M7 x 1.0

M6 x 1.0

M6 x 1.0

M6 x 1.0

M6 x 1.0

M6 x 1.0

M20 x 1.5

M6 x 1.0

M6 x 1.0

M6 x 1.0

M6 x 1.0

M25 x 1.0

M6 x 1.0

Torque


20 (2.0, 14)

12 (1.2, 9)

9.8 (1.0, 7)

12 (1.2, 9)

12 (1.2, 9)

15 (1.5, 11)

26 (2.7, 20)

12 (1.2, 9)

12 (1.2, 9)

12 (1.2, 9)

12 (1.2, 9)

128 (13.0, 94)

12 (1.2, 9)

12 (1.2, 9)

54 (5.5, 40)

23 (2.3, 17)

12 (1.2, 9)

23 (2.3, 17)

12 (1.2, 9)

12 (1.2, 9)

12 (1.2, 9)

12 (1.2, 9)

14 (1.4, 11)

12 (1.2, 9)

2.0 (0.2, 1.4)

12 (1.2, 9)

23 (2.3, 17)

–

–

Apply LOCKTITE 271

Apply LOCKTITE 271

Apply LOCKTITE 271

Apply LOCKTITE 271

CT bolt

Apply LOCKTITE 271

Apply oil

Apply oil

CT bolt

CT bolt

Left hand thread

Apply oil

Wire lock

Apply LOCKTITE 271

Apply oil

Apply oil

Apply LOCKTITE 271

Apply LOCKTITE 271

Apply oil

Apply oil

Apply Three bond 1207B

Remarks

Band width: 7 ± 1 mm

Tightening width: 1 mm on each side


1-3



Frame

Item

Fuel tank cap socket bolt

Fuel hose banjo bolt (tank side)

ECT sensor

Swingarm pivot adjusting bolt

Swingarm pivot adjusting bolt lock nut

Swingarm pivot nut

Clutch oil bleeder bolt

Clutch bleeder screw

Rear wheel bearing retainer

Rear wheel driven flange retainer

Rear wheel air valve

Rear brake disc bolt

Rear axle

Final driven sprocket nut

Rear brake oil bleeder bolt

Rear brake bleeder screw

Rear brake caliper mounting bolt

Front wheel air valve

Front wheel axle

Front wheel bearing retainer

Front axle collar nut

Front brake caliper mounting bolt

Front brake caliper oil bolt

Front axle holder bolt

Rear shock absorber upper bolt

Shock arm/shock link bolt/nut

Steering stem top threads

Steering stem nut

Handlebar stopper bolt

Top bridge/bottom bridge pinch bolt

M10 x 1.25

M8 x 1.25

M7 x 1.0

–

M18 x 1.5

M45 x 1.5

M28 x 1.0

M10 x 1.25

M10 x 1.25

M8 x 1.25

M10 x 1.25

M10 x 1.25

M26 x 1.0

Thread/ pitch

M4 x 0.7

M12 x 1.25

M12 x 1.5

M36 x 1.5

M36 x 1.5

M22 x 1.5

M10 x 1.25

M8 x 1.25

M56 x 1.0

M70 x 1.0

–

M6 x 1.0

M18 x 1.5

M8 x 1.25

M24 x 1.0

M8 x 1.25

M8 x 1.25

Torque


4.9 (0.5, 3.6)

26 (2.7, 20)

23 (2.3, 17)

15 (1.5, 11)

59 (6.0, 43)

118 (12.0, 87)

23 (2.3, 17)

7.8 (0.8, 5.8)

98 (10.0, 72)

98 (10.0, 72)

3.9 (0.4, 2.9)

16 (1.6, 12)

98 (10.0, 72)

34 (3.5, 25)

23 (2.3, 17)

7.8 (0.8, 5.8)

17 (1.7, 12)

3.9 (0.4, 2.9)

59 (6.0, 43)

44 (4.5, 33)

78 (8.0, 58)

39 (4.0, 29)

23 (2.3, 17)

22 (2.2, 16)

34 (3.5, 25)

34 (3.5, 25)

9.8 (1.0, 7)

98 (10.0, 72)

9.8 (1.0, 7)

22 (2.2, 16)

Apply molybdenum grease to the threads



Apply LOCKTITE 271

Apply LOCKTITE 271

Apply LOCKTITE 271

Remarks


Apply oil to the threads



Apply molybdenum grease to the threads, stake





Adjusting range: 0.6 to 1.5 kgf•m


Adjusting range: 8.0 to 13.0 kgf•m

Apply LOCKTITE 271


1-4


Item

Front engine hanger bolt

Middle engine hanger bolt

Rear upper engine hanger nut

Rear lower engine hanger nut

Engine hanger adjusting bolt

Engine hanger adjusting bolt lock nut

Thread/ pitch

M12 x 1.25

M12 x 1.25

M12 x 1.25

M12 x 1.25

M20 x 1.5

M20 x 1.5

Torque


59 (6.0, 43)

59 (6.0, 43)

59 (6.0, 43)

59 (6.0, 43)

15 (1.5, 11)

59 (6.0, 43)

Remarks








1-5



Lubrication & Seal Point

Engine

Item

Piston pin surface

Connecting rod small end inner surface

Clutch lifter piece silding surface

Camshaft sliding surface and thrust surface

IN/EX valve stem sliding surface

Valve lifter surface

Clutch outer gude sliding surface

Oil pump sprocket collar sliding surface

M3/4, C5, C6 gear shift fork groove

Starter reduction shaft pivot surface

Starter idle gear shaft surface

Clutch lifter rod surface

Piston ring grooves

Piston ring surface

Oil strainer packing surface

Clutch disc surface

Starter one-way clutch surface

Each gear teeth

Each ball bearing and needle bearing

Each O-ring

Other rotating and sliding surface

Engine

Main journal bearing sliding surface

Connecting rod bearing

Crankshaft thrust surface

Timing hole cap threads

Each oil seal lips

Balancer rubber contact surface

Crankcase mating surface

Crankcase/cover mating surface

Oil pan mating surface

1-6

Material

Elf XT3818 oil

Remarks

3.3 to 3.8 liter

Molybdenum disulfide oil Do not apply more than necessary

(a mixture of 1/2 Elf XT3818 oil Do not apply more than necessary and 1/2 of molybdenum disulfide grease)

Multi-purpose grease

Three bond 1207B or an equivalvent


Frame

Item

Fuel pump O-ring

Fuel filter case body O-ring

Fuel quick joint O-ring

Brake pedal pivot bushing

Gearshift pedal pivot bearing

Rear wheel damper rubber-to-driven flange contact area

Front fender stay O-ring and bushing

Swingarm pivot dust seal lips/needle bearing

Shock arm dust seal lips/needle bearing

Shock link dust seal lips/needle bearing

Rear shock aborber pivot needle bearing

Steering stem bearing

Front axle bolt threads

Rear axle bolt threads

Fuel pump connector

Clutch lever-to-master piston contact area

Rear brake master piston-to-push rod contact area

Throttle cable sliding surface

Gearshift pedal link/rear brake pedal rod end

Throttle pipe inner surface

Handle grip inner surface

Seat rubber

Seat back rubber

Fork inside

Fork oil seal lip

Rear fuel tank mounting bolt threads

Gearshift pedal link bolt threads

Handlebar weight mounting screw threads

Drive chain slider pan screw threads

Drive sprocket protector bolt threads

Clutch master cylinder inside

Brake master cylinder/caliper inside

Clutch slave cylinder

Material

Multi-purpose grease

UN-LOCK (manufactured by

NCH) or molybdenum grease

Silicone grease

CRC

Honda Bond A

Fork fluid

Locking agent

AP600 or

DOT 4 brake fluid

CCI Metal rubber MR20 or BELL-CLAW TAPE

Remarks


1-7



Item

Fuel Line

Throttle Operation

Spark Plug

Valve Clearance

Engine Oil

Engine Oil Filter

Intake Valves

Exhaust Valves

Valve Lifter

Valve Springs

Pistons/Piston rings

Crankpin Bearings

Main journal bearings

Cylinder Head

Camshaft

Cylinder Sleeve

Radiator Coolant

Cooling System

Drive Chain

Drive Chain Slider

Drive/Driven Sprocket

Brake Fluid

Brake Pad Wear

Brake System

Clutch System

Clutch Fluid

Exhaust Pipe/Muffler

Suspension

Nuts, Bolts, Fasteners

Wheels And Tires

Steering Head Bearings

Maintenance Schedule

Perform pre-ride Inspection at each scheduled maintenance period.

I: Inspect and clean, Adjust, Lubricate or Replacement if necessary. C: Clean, R: Replace, L: Lubricate.

Frequency Each race or about

2.5 hours

I

I

R

R

I

I

I

I

I

I

I

I

I

I

I, L

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Remarks

R: every 2,000 km (1,200 mi)

R: every 3,000 km (1,850 mi)

R: every 6,000 km (3,700 mi)

R: every 3,000 km (1,850 mi)

R: every 3,000 km (1,850 mi)

R: every 3 races

Replace after riding in rain

R: every race (clutch discs and plates)

R: every 3 races

Replace after riding in rain

Check for other parts not listed above for wear or damage. Replace any faulty parts as necessary.

1-8



Inspection/Replacement Parts

Parts Requiring Periodic Inspection/Replacement

Item

Engine

Crankcase/Transmission holder

Crankcase/Transmission holder bolt

Cylinder head

Cylinder head (Valve seat)

Crankshaft

Crankshaft bearing

Connecting rod

Connecting rod bearing

Piston

Piston ring

Piston pin

Balancer weight

Balancer shaft

Balancer bearing

Valve spring

IN/EX valve

Cam chain

Cam sprocket

Cam chain tensioner

Oil pump chain

Oil pump drive sprocket

Water pump

Clutch outer

Transmission gear/shaft/collar

Spark plug

Ignition pulse generator

Cam pulse generator

Inspection Interval

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 500 km (310 mi)



Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Every 1,500 km (930 mi)

Replacement Interval Cause

Every 3,000 km (1,850 mi)

–

Every 3,000 km (1,850 mi)

–

Sleeve wear or other damage

Tightening torque

Cracks

Valve seat warpage

Every 6,000 km (3,700 mi)

Repalce with crankcase

Gear wear, Crankpin/main journal wear or damage

Wear or damage

Every 6,000 km (3,700 mi) Small end wear or damage

Replace with connecting rod Wear or damage

Every 6,000 km (3,700 mi)

Every 3,000 km (1,850 mi)

Every 6,000 km (3,700 mi)

Every 3,000 km (1,850 mi)

Every 3,000 km (1,850 mi)

Every 3,000 km (1,850 mi)

Every 6,000 km (3,700 mi)

Every 6,000 km (3,700 mi)

Skirt and piston land wear or damage

Wear or damage

Wear or damage

Bearing contact face wear

Bearing contact face wear

Needle bearing

Wear or deformation

Seat warpage

Every 1,000 km (620 mi)

Every 1,000 km (620 mi)

Every 1,000 km (620 mi)

Every 3,000 km (1,850 mi)

Every 3,000 km (1,850 mi)

Every 3,000 km (1,850 mi)

Every 3,000 km (1,850 mi)

Every 3,000 km (1,850 mi)

Every 6,000 km (3,700 mi)

Every 6,000 km (3,700 mi)

Every 6,000 km (3,700 mi)

Stick

Damage

Damage

Stick

Damage

Crack

Gear wear, wear by the disc

Wear or damage

Wear at side face of the center electrodes

Damage

Damage

Check for other parts not listed above for wear or damage. Replace any faulty parts as necessary.

1-9



Removal/Replacement Parts

Rearview mirror Ignition switch Pillion step Pillion seat Tail/brake light

License light

Replace the combination meter with the racing kit

Replace the standard bank angle sensor with the racing kit sensor.

Headlight unit

Turn signal light

Rear fender A

Variable air intake diaphragm/chamber

Horn Cooling fan motor Side stand switch Rear brake light switch

Chain case

1-10


Cable & Harness Routing

2

3

1

12

13

6

7

8

16

15

10

9

18

14

17

11


No.

Item

1 Combination meter

2 Bracket, bank angle sensor

3 Sensor assy., bank angle

4 CD-ROM, PGM-FI/IGN

5 Unit assy., serial I/F

6 Sub harness, IGN

No.

Item

7 Coil, cap & ignition

8 Harness, wire

9 Band, battery

10 Battery

11 Band, PGM-FI unit

12 Bracket, PGM-FI unit

19

20

No.

Item

13 Unit, PGM-FI

14 Cable, starter battery

15 Cable, starter motor

16 Battery ground cable

17 Switch assy., starter magnetic

18 Relay, fuel cut

No.

Item

19 Spacer, regulator/rectifier

20 Rectifier assembly., regulator

1-11



Wiring Diagram

1-12

02. Racing Kit6 04.4.27 18:20 Page 1

Replacement Necessary Parts

Refer to CBR1000RR SHOP MANUAL (62MEL00) for replacement procedure.

Camshafts

Use following intake and exhaust camshafts.

• 14110-MEL-R10

• 14210-MEL-R10

CAMSHAFT COMP., IN

CAMSHAFT COMP., EX

Intake valve springs.

• 14751-MEL-R10

Clutch springs.

• 22401-MEL-R10

Spark plugs.

• 31910-NL3-620

SPRING, IN VALVE

SPRING, CLUTCH

PLUG, SPARK, R0045Q-10

Additional kit for Super Bike

Piston and piston rings.

• 13101-NL9-000

• 13112-NL9-000

• 13121-NL9-000

• 13131-NL9-000

• 13141-NL9-000

PISTON

CLIP, PISTON PIN 17 mm

RING, PISTON TOP 75 x 0.8 x 2.3

RING, PISTON 2ND 75 x 0.8 x 2.4

RING, PISTON TOIL 75 x 1.5 x 1.95

Intake and exhaust valves.

• 14711-NL9-000

• 14721-NL9-000

VALVE, INLET (29)

VALVE, EXHAUST (24)

2. Racing Kit

2-1

02. Racing Kit6 04.4.27 18:20 Page 2

Racing Kit

Modifying the Cylinder Head Ports

Reworking on valve ports

• On CBR1000RR, not much effect will be obtained by reworking on the valve ports as the machine is intended for competition use.

• However, you may improve breathing and encourage easier of spent gases by removing height difference between the valve seat and ports, and burrs or roughnesses on port surfaces.

Intake port

• Grind the intake port as indicated in the illustration below.

• Lightly polish the other surfaces using a emery cloth.

Exhaust port

• Grind the upper part of the exhaust port as indicated in the illustration below.

• Lightly polish the other surfaces using a emery cloth.

Intake port

Exhaust port

2-2

02. Racing Kit6 04.4.27 18:20 Page 3

Adjusting the Compression Ratio

Adjust the compression ratio by grinding the mating surface of the cylinder head.

1. Remove the cylinder head and piston and remove carbon deposits from the piston heads and combustion chambers.

2. Reinstall the piston.

3. With the aid of the dial gauge, bring the piston at TDC (Top Dead Center).

4. Grind the cylinder head mating surface 0.2 mm (0.008 in) by machining roughness 8S. Finish the surface using a oil stone.

Expected compression ratio: 13.6 : 1

Use 0.6 mm thickness gasket.

0.2 mm

(0.03 in)

Racing Kit

2-3

02. Racing Kit6 04.4.27 18:20 Page 4

Racing Kit

Transmission Set Installation

1. Remove and disassemble the transmission.

2. Assemble the transmission using the racing kit mainshaft, countershaft, gears, collar (30 x 11.2 mm ) and collar (28 x 13.5 mm).

• Use standard vehicle collars and washers (except the collar, 30 x 11.2 mm and collar, 28 x 11.2 mm).

• Do not assemble the standard gear with the racing kit gear because the racing kit gear dogs has reverse taper.

• When disassembling, always replace the circlips with new ones.

• Always install the thrust washer and snap ring with the chamfered (rolled) edge facing away from the thrust load as shown.

1st

2nd

3rd

4th

5th

6th

Racing kit

Gear ratio (T= Teeth)

2.286 (14/32T)

1.941 (17/33T)

1.667 (18/30T)

1.500 (20/30T)

1.348 (23/31T)

1.227 (22/27T)

Standard

Gear ratio (T= Teeth)

2.538 (13/33T)

1.941 (17/33T)

1.578 (19/30T)

1.380 (21/29T)

1.250 (20/25T)

1.160 (25/29T)

Check the gear dog edges for wear.

Service limit: 1.0 mm (0.04 in)

The gear jumps occur, if the gear dog edges are wear.

Replace the gear with new ones when the wear to the service limit.

2-4

02. Racing Kit6 04.4.27 18:20 Page 5

ACG Set Installation

1. Remove the standard AC generator cover and flywheel.

Replace the ACG set and the upper and lower crankcase as a set.

2. Clean any oil off from the crankshaft taper.

3. Install and racing kit flywheel to the crankshaft.

4. Apply engine oil to the flywheel mounting bolt threads and seating surface.

5. Install the bolt with washer, tighten the bolt to the specified torque.

Torque: 118 N•m (12.0 kgf•m, 87 lbf•ft)

If the flywheel bolt is reused, loosen the bolt and retighten the bolt to the specified torque again.

If the new bolt is used, do this procedure once more.

6. Install the racing kit stator onto the racing kit alternator cover, then tighten the bolts to the specified torque.


7. Install the wire clamp and tighten the bolt to the specified torque.


8. Apply sealant to the mating surface of the crankcase and alternator cover.

9. Install the AC generator cover onto the crankcase, tighten the bolts securely.

Flywheel

Stator

AC generator cover

Racing Kit

2-5

02. Racing Kit6 04.4.27 18:20 Page 6

Racing Kit

Cylinder Head Bolt Tightening

If the cylinder head head gasket, tightening bolt and/or cylinder block are replaced with new one, tighten the cylinder head bolts as follows;

Break-in procedure:

1. Clean the bolts and threaded hole of the cylinder block.

2. Apply Ultra-M oil to the cylinder head bolts threads and seating surface.

3. Tighten the cylinder head bolts to the specified torque in numerical order as noted in the illustration below.


4. Further tighten the cylinder head bolts 53 degrees in numerical order.

5. Further tighten the cylinder head bolts 53 degrees in numerical order again.

6. Loosen and remove the cylinder head bolts.

Final tightening procedure:


2. Apply Ultra-M oil to the cylinder head bolts threads and seating surface.

3. Tighten the cylinder head bolts to the specified torque in numerical order as noted in the illustration below.


4. Further tighten the cylinder head bolts 53 degrees in numerical order.

5. Further tighten the cylinder head bolts 53 degrees in numerical order

2-6

02. Racing Kit6 04.4.27 18:20 Page 7

Main Journal Bolt Tightening

If the main journal bolts are replaced with new ones, tighten the main journal bolts as follows;

Break-in procedure:


2. Apply Ultra-M oil to the main journal bolts threads and seating surface.

3. Tighten the main journal bolts to the specified torque in numerical order as noted in the illustration below.


4. Further tighten the main journal bolts 60 degrees in numerical order.

5. Further tighten the main journal bolts 60 degrees in numerical order again.

6. Loosen and remove the main journal bolts.

Final tightening procedure:


2. Apply Ultra-M oil to the main journal bolts threads and seating surface.

3. Tighten the main journal bolts to the specified torque in numerical order as noted in the illustration below.


4. Further tighten the main journal bolts 60 degrees in numerical order.

5. Further tighten the main journal bolts 60 degrees in numerical order

Racing Kit

2-7

02. Racing Kit6 04.4.27 18:20 Page 8

Racing Kit

Engine Hanger Tightening Sequence

POINT C

POINT B

POINT D

APPLY MOLYBDENUM

DISULFIDE GREASE

APPLY MOLYBDENUM

DISULFIDE GREASE

POINT A

APPLY MOLYBDENUM

DISULFIDE GREASE

APPLY MOLYBDENUM

DISULFIDE GREASE

2-8

POINT A

APPLY MOLYBDENUM

DISULFIDE GREASE

APPLY MOLYBDENUM

DISULFIDE GREASE

POINT B

02. Racing Kit6 04.4.27 18:20 Page 9

Racing Kit

When using the lock nut wrench for the adjusting bolt lock nut, use a deflecting beam type torque wrench 20 inches long. The lock nut wrench increases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The specification given is the actual torque applied to the lock nut, not the reading on the torque wrench. Do not overtighten the lock nut.

Apply molybdenum disulfide grease to the all mounting bolt threads and seating surface of the nuts.

Install and tighten the engine hanger bolts as follow:

1. Install the point C and point D engine hanger adjusting bolt fully from the inside of the frame.

2. Install the engine into the frame.

3. Install the rear upper engine hanger distance collars and bolt (C).

4. Install the rear lower engine hanger bolt (D).

5. Install the point A, B engine hanger distance collars and bolts.

6. Tighten the rear lower hanger adjusting bolt while turning the hanger bolt until it seats.

7. Tighten the rear lower engine hanger adjusting bolt (D) to the specified torque.


8. Tighten the rear lower engine hanger adjusting bolt lock nut (D) to the specified torque.

Tool:

Lock nut wrench, 5.8 X 46 mm

07VMA-MBB0100 or 07VMA-MBB0101

Torque:

Actual: 54 N•m (5.5 kgf•m, 40 lbf•ft)

Scale reading: 49 N•m (5.0 kgf•m, 39 lbf•ft)

9. Tighten the rear upper hanger adjusting bolt while turning the hanger bolt until it seats.

10. Tighten the rear upper engine hanger adjusting bolt (C) to the specified torque.


11. Tighten the rear upper engine hanger adjusting bolt lock nut (C) to the specified torque.

Tool:

Lock nut wrench, 5.8 X 46 mm

07VMA-MBB0100 or 07VMA-MBB0101

Torque:

Actual: 54 N•m (5.5 kgf•m, 40 lbf•ft)

Scale reading: 49 N•m (5.0 kgf•m, 39 lbf•ft)

12. Install the rear lower engine hanger nut (D), then tighten the nut to the specified torque while holding the hanger bolt.


13. Install the rear upper engine hanger nut (C), then tighten the nut to the specified torque while holding the hanger bolt.


14. Tighten the left side front engine hanger bolt (A) to the specified torque.


15. Tighten the left side middle engine hanger bolt

(B) to the specified torque.


16. Tighten the right side front engine hanger bolt

(A) to the specified torque.


17. Tighten the right side middle engine hanger bolt

(B) to the specified torque.


Install the removed parts in the reverse order of removal.

A

B

D

C

2-9

02. Racing Kit6 04.4.27 18:20 Page 10

Racing Kit

Wire Lock

Before riding the machine, secure the following bolts and nuts:

– Engine oil filler cap

– Engine oil drain plug

– Oil filter cartridge

1. Insert the proper length locking wire to the bolt.

2. Twist the wire using 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

Drill hole (3 - 4 mm)

Oil filler cap

No good Good

• Use new 0.8 mm (0.03 in) stainless wire.

• Secure the bolt as shown so that it cannot come loose.

• Twisting the wire too tightly will break a locking wire.

2-10

Sub-tank band

Oil filter cartridge

Drain plug

Drill hole (3 - 4 mm)

02. Racing Kit6 04.4.27 18:20 Page 11

Quick Shift Kit Installation

1. Drill ø3.3 - 3.5 mm holes as shown.

2. Install the quick shift unit rubber suspension bracket onto the frame, and secure it with pop rivet.

3. Install the rubber suspension onto the quick shift unit, then install the unit to the bracket, then connect the connector to the wire harness.

4. Remove the gearshift pedal and pedal link.

5. Install the pedal rod sensor into the pedal link rod.

6. Connect the sensor connector to the quick shift unit connector.

7. Reinstall the gearshift pedal and pedal link.

Racing Kit

Pedal link

Rubber suspension

Pedal rod sensor

Pedal link rod

Quick shift unit

4 5 mm

Z

Gearshift pedal

10mm

Z

2-11

02. Racing Kit6 04.4.27 18:20 Page 12

Racing Kit

Secondary Air Supply System Removal

1. Disconnect the secondary air supply hoses from the cylinder head reed valve covers and air cleaner housing.

2. Cut the removed hoses 40 mm from the each end of the cylinder head reed valve cover side and air cleaner housing side.

3. Install the cutted hoses to the cylinder head reed valve covers and air cleaner housing, then secure them with removed clips.

4. Plug the hoses with plugs in the racing kit, and secure them with clips also in the racing kit.

Cone plug

(racing kit)

Thermostat and Bypass Hose Removal

1. Drain the coolant.

2. Remove the thermostat housing cover, then remove the thermostat.

3. Remove the rubber from the thermostat, then install it on the thrust washer in the racing kit.

4. Install the thrust washer into the thermostat housing, install the thermostat housing cover in the reverse order of removal.

5. Remove the bypass hose.

6. Cut the bypass hose as shown in the illustration below.

7. Install the cutted bypass hose onto the water pump cover and thermostat housing, and secure them with removed hose bands.

8. Install the plugs in the racing kit to the hose ends, and clamp them with the hose bands in the racing kit.

Clamp

(racing kit)

Clamp

(racing kit)

Remove them

Rubber

(standard)

Remove them

Washer

(racing kit)

Cone plug

(racing kit)

Clamp

(racing kit)

Plugs

(racing kit)

Remove them

50 mm

50 mm

Clamp

(racing kit)

Cone plug

(racing kit)

Clamp

(racing kit)

2-12

02. Racing Kit6 04.4.27 18:20 Page 13

Racing Kit

Fast Idle Wax Unit Removal

1. Remove the throttle body.

2. Remove the fast idle wax unit from the throttle body.

3. Remove the screw and then remove the fast idle wax unit link from the link arm shaft.

4. Cut the wax unit bracket, then remove the wax unit.

5. Reinstall the removed bracket onto the throttle body.

6. Remove the fast idle wax unit water hoses from the thermostat housing and water joint, and cut the hose end about 50 mm as shown in the illustration.

7. Install the cutted hoses to the thermostat housing and water joint and secure them with hose bands.

8. Install the hose plugs in the racing kit to the hose ends, and secure them with the hose bands that are attached on the fast idle wax unit.

Link

(remove)

Remove

Screw

(remove)

Plug

(racing kit)

Remove

Plug

(racing kit)

Wax unit

(remove)

Bracket

Throttle stop screw set

2-13

02. Racing Kit6 04.4.27 18:20 Page 14

Racing Kit

Variable Air Intake Valve Removal/Air Duct Installation

1. Remove the variable air control solenoid valve and vacuum chamber.

2. Remove the variable air intake duct and diaphragm assembly from the air cleaner housing.

3. Replace the radiator bracket with racing kit.

4. Install the racing kit air duct onto the air cleaner housing and tighten the screws.

Remove

Radiator Kit Installation

1. Remove the standard radiator and radiator reserve tank.

2. Install the racing kit radiator with the racing kit left radiator hose and oil cooler hose.

Note:

Avoid damaging the oil cooler water hose from the exhaust pipe heat, install the heat resistance tape to the oil coolar water hose as shown.

Radiator

(Racing kit)

Heat resisitance tape

Oil cooler water hose

(Racing kit)

Right radiator bracket

(Racing kit)

Lower radiator hose

(Racing kit)

Left radiator bracket

(Racing kit)

Air duct

(racing kit)

2-14

02. Racing Kit6 04.4.27 18:21 Page 15

Racing Kit

Hi Throttle Set/Engine Stop Switch Installation

1. Remove the standard throttle housing 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 the racing kit throttle cable A and B to the under throttle housing.

5. Connect the throttle cable ends to the throttle pipe, then tighten the throttle housing screws.

6. Install the racing kit engine stop switch to the right handlebar. Tighten the forward screw first, then the rear screw.

7. Connect the starter/engine stop switch 9P connector to the wire harness.

Throttle pipe

Throttle cable B

Under throttle housing

Upper throttle housing

Boss (grind off)

Starter/engine stop switch

Throttle cable A

2-15

02. Racing Kit6 04.4.27 18:21 Page 16

Racing Kit

Oil Catch Tank Installation

1. Disconnect the crankcase breather tube from the air cleaner housing and cylinder head cover, then remove the breather tube.

2. Install the breather tubes in the racing kit to the oil catch tank.

3. Attach the suitable piece of rubbers between the tabs of the oil catch tank and frame as shown.

4. Install the oil catch tank assembly into the frame (the place previously installed the EVAP PAIR control valve), tighten the bolts and nuts securely.

5. Connect the breather tube to the cylinder head cover and air cleaner housing and secure them with clips.

Air Funnel/Air Cleaner Element Replacement

1. Remove the original air cleaner element and air funnels.

2. Install the racing kit air funnels into proper location according to its identification mark on the funnel.

3. Install the retainers and screws, then tighten the screws securely.

4. Bent the tabs of the retainer against the air funnel mounting screws.

5. Install racing kit air cleaner element.

Air funnel (#4)

Breather return tube

Air funnel (#3)

Air funnel (#2)

Air funnel (#1)

Breather tube

Tongued washer

Air cleaner elements

(racing kit)

Oil catch tank

2-16

02. Racing Kit6 04.4.27 18:21 Page 17

Steering Stem Modifying

1. Make the stopper pieces from aluminium block. The piece dimensions are shown in the illustration below.

Racing Kit

Steering Damper Replacement

1. Remove the standard steering damper cover and steering damper.

2. Install the racing kit steering damper without installing the covers.

2. Weld the stopper pieces onto the bottom bridge as shown.

3. Make sure the steer angle is 16˚ on both side.

Stopper piece

Bottom bridge

Frame body

When the racing kit steering damper is installed (2P Black connector is disconnected), the waring LED on the combination meter is illuminated but no problem in the system.

2-17

02. Racing Kit6 04.4.27 18:21 Page 18

Racing Kit

ECM/Bank Angle Sensor Installation

1. Make a two ø3.5 mm drill holes into the upper face of the upper cowl stay as shown.

2. Install the ECM stay onto the upper cowl stay and secure it with pop rivets.

3. Install the racing kit bank angle sensor using screw/washers and flange nuts as shown.

4. Install the bank angle relay and overflow catch tank stay onto the upper cowl stay and secure it bolts and nuts.

5. Install the catch tanks and secure them with tie-laps.

Upper cowl stay

Catch tank

Stay

Catch tank

Upper cowl stay

Bank angle sensor

2-18

02. Racing Kit6 04.4.27 18:21 Page 19

Rear Fender B Modification

1. Cut and remove the indicated portion of the rear fender B.

Racing Kit

2. Drill ø3.3 - 3.5 mm holes into the rear fender rib as shown.

3. Install the relay stay on the rear fender B and secure it with pop rivets.

4. Install the relay/rubber suspension onto the relay stay.

Relay

Bracket

Cut area

Rear fender B

2-19

02. Racing Kit6 04.4.27 18:21 Page 20

Racing Kit

Exhaust Pipe Inner Protector Modification

Cut and remove the indicated portion of the exhaust pipe inner protector.

Inner protector

Exhaust Pipe/Muffle Replacement

Remove the muffler and exhaust pipe (see Shop Manual).

Remove the exhaust pipe stud bolts using the 7 mm nuts in the racing kit.

Install a racing kit exhaust pipe and muffler as shown.

Muffler comp.

Muffler stay

Inner protector

Muffler band

2-20

02. Racing Kit6 04.4.27 18:21 Page 21

Racing Kit

Drive Chain Guard Installation

Inside of the swingarm is filled with urethane foam. Do not weld the drive chain guard because of the urethane form is burned.

1. Remove the swingarm. Drill ø9.05 - 9.25 mm holes for the pop nut as shown.

2. Apply adhesive to the drill holes and pop nut seat, and install the pop nuts into the holes. Stake the pop nut using a commercially available tool.

Apply adhesive

Stake

Pop nut, 6 mm

(manufactured by POP RIVET FASTENER LTD.; SPH650R or equivalent)

3. After the adhesive hardened, install the washer and drive chain guard and tighten the bolt/washers securely.

ø9.05 - 9.25 mm

Washers

Drive chain guard

Bolts

2-21

02. Racing Kit6 04.4.27 18:21 Page 22

Racing Kit

Optional Drive/Driven Sprocket

The optional drive sprockets are available.

When using the optional drive/driven sprocket, replace the rear wheel with the optional one.

Drive sprockets:

15T (23801-NL6-700)

16T (23802-NL6-700)

17T (23803-NL6-700)

Driven sprockets:

38T (41238-NL6-700)

39T (41239-NL6-700)

40T (41240-NL6-700)

41T (41241-NL6-700)

42T (41242-NL6-700)

43T (41243-NL6-700)

Drive chain:

RKGB525ROZ1-120J

Drive

15T

16T

17T

38T

112L

114L

114L

114L

116L

39T

114L

114L

116L

114L

116L

Driven

40T

114L

116L

114L

116L

114L

116L 116L

41T

114L

116L

114L

116L

42T

114L

116L

116L

116L

118L

43T

116L

116L

118L

116L

118L

: Use 8 x 55 mm drive chain adjusting bolts

2-22

02. Racing Kit6 04.4.27 18:21 Page 23

Racing Kit

(2)

(1)

(1)

(3)

(4)

(2)

(1) PRE-LOAD ADJUST PLATE B

(2) STOPPER RING

(1)

(2)

(2)

(3)

(1)

(1) O-RING (2) FORK BOLT (1) DAMPER ROD ADJUST CASE

(2) LOCK NUT (3) FORK BOLT

Fork Spring Replacement

Make sure that the pre-load adjuster softest position by turning the adjuster counterclockwise.

Remove the stopper ring and pre-load adjust plate

B.

Remove the O-ring from the damper rod adjust case.

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 14 mm spanner between the spring collar B and spring seat stopper, and hold the damper rod adjust case, then loosen the lock nut.

Remove the lock nut and fork bolt.

(1) FORK SPRING (2) SPRING COLLAR

(3) SPRING SEAT STOPPER

(4) SPRING COLLAR B

Remove the following:

– Spring collar B

– Spring seat stopper

– Spring collar

– Fork spring

Three optional for springs are available.

Part number Spring rate Oil level

51401-NL9-900 8.8 N/mm (K=0.90) 113 mm

51401-MEL-R10 9.3 N/mm (K=0.95) 110 mm

51402-NL9-900 9.8 N/mm (K=1.00) 109 mm

Optional springs are identified by the spring rate letter on the spring end as shown.

SPRING RATE LETTER

2-23

02. Racing Kit6 04.4.27 18:21 Page 24

Racing Kit

(1)

(1)

(3)

(2)

(1) TAPERED END

(2) FORK SPRING

Slowly down the slider, and gently seat the dust seal onto the axle holder and leave it for 5 minutes.

After the oil level stabilizes, measure the oil level from top of the fork slider.

Be sure the oil level is the same in the both forks.

Install the fork spring into the fork slider with the tapered end facing up.

(2)

(1) DAMPER ROD HOLDER

(2) SPRING COLLAR

(3) SPRING SEAT STOPPER

Extend the fork damper fully and install the damper rod holder onto the damper rod adjust case.

TOOL:

Damper rod holder 070MB-MEL0200 or

070MB-MELC200 or

No.301

Showa special tool

Install the spring collar and spring seat stopper.

2-24

02. Racing Kit6 04.4.27 18:21 Page 25

Racing Kit

(1)

(3)

(2)

(2)

(4)

(1) HANDLE (2) DAMPER ROD HOLDER

(3) SPANNER (4) SPRING COLLAR

Attach the handle to the damper rod holder, then lower the spring collar while pulling up the damper rod holder.

Attach the 14 mm spanner to the damper rod adjust case as shown.

(1) FORK BOLT (2) O-RINGS

(1)

(1)

(2)

(3)

(1)

(1) SPRING COLLAR B

(2) FORK BOLT

(3) ALIGN

Install the spring collar B with its flange side facing down.

Install the fork bolt to the damper rod adjust case while aligning the grooves of the adjust plate with the damper rod adjust case.

(1) PRE-LOAD ADJUSTING PLATE

Apply fork fluid to new O-rings and install them to the fork bolt.

Turn the pre-load adjust plate clockwise until it seats lightly.

2-25

02. Racing Kit6 04.4.27 18:21 Page 26

Racing Kit

(1)

(2)

(1)

(1)

(2)

(1) LOCK NUT (1) O-RING (2) FORK BOLT

Install the lock nut to the damper rod adjust case.

Tighten the lock nut to the specified torque, while holding the damper rod adjust case.


Remove the 14 mm spanner from the damper rod adjust case.

Install the fork bolt to the fork slider.

Install new O-ring to the damper rod adjust case.

(1) PRE-LOAD ADJUST PLATE B

(2) STOPPER RING

Install the pre-load adjust plate B and stopper ring.

2-26

02. Racing Kit6 04.4.27 18:21 Page 27

Racing Kit

(1)

(1)

(1)

(2)

(1) SPRING (1) PRE-LOAD ADJUSTER (1) REBOUND ADJUSTER

(2) COMPRESSION ADJUSTER

Rear Cushion Spring

Three optional rear cushion springs are available.

Part number Spring rate

52401-NL9-901 93.2 N/mm (K=9.5)

52402-NL9-901 103.0 N/mm (K=10.5)

52403-NL9-901 108.0 N/mm (K=11.0)

52404-NL9-901 113.0 N/mm (K=11.5)

52405-NL9-901 118.0 N/mm (K=12.0)

Identification color

Blue

White

Black

Green

Sliver

Suspension Setting

Front Suspension Setting

Pre-load Adjuster

Spring pre-load can be adjusted by turning the preload adjuster.

Turn the adjuster clockwise, the spring pre-load increase.

Turn the adjuster counterclockwise, the spring preload decrease.

Standard position: 6 turns in from full soft

Rebound Damping Adjuster

The rebound damping adjuster clockwise until it stops (full hard position), then turn the adjuster counterclockwise.

Standard position: 2 turns out from full hard

Compression Damping Adjuster

The compression damping adjuster clockwise until it stops (full hard position), then turn the adjuster counterclockwise.

Standard position: 2 turns out from full hard

The optional rear shock absorber springs are identified by color.

2-27

02. Racing Kit6 04.4.27 18:21 Page 28

Racing Kit

(1)

(2)

(1)

(1)

(1) REBOUND DAMPING ADJUSTER (1) COMPRESSION DAMPING ADJUSTER (Lo)

(2) COMPRESSION DAMPING ADJUSTER (Hi)

(1) PRE-LOAD ADJUSTING KNOB

Rear Suspension Setting

Pre-load Adjuster

Spring pre-load can be adjusted by turning the preload adjuster knob on the seat rail.

Turn the adjuster clockwise, the spring pre-load increase.

Turn the adjuster counterclockwise, the spring preload decrease.

Standard position: 16 clicks in from full soft

When installing the rear shock absorber, route the pre-load adjuster hose properly referring to the illustration above.

Hi-speed Compression Damping Adjuster

The hi-speed compression damping adjuster counterclockwise until it stops (full soft position), then turn the adjuster clockwise.

Standard position: 3 ± 0.25 turns in from full soft

Low-speed Compression Damping Adjuster

The low-speed compression damping adjuster clockwise until it stops (full hard position), then turn the adjuster counterclockwise.

Standard position: 6 clicks out from full hard

Rebound Damping Adjuster

The rebound damping adjuster clockwise until it stops (full hard position), then turn the adjuster counterclockwise.

Standard position: 5 – 8 clicks out from full hard

2-28

02. Racing Kit6 04.4.27 18:21 Page 29

Optional Front Wheel

Front axle

Axle guide B

Axle guide A

Ball bearing (6905 2RS)

Washer

Shim

Distance collar

Bearing retainer

Racing Kit

Side collar

Front axle nut

Axle nut


Side collar

Shim

2-29

02. Racing Kit6 04.4.27 18:21 Page 30

Racing Kit

(1)

(2)

(1)

(2)

(1)

(2)

(1) RIGHT SIDE COLLAR

(2) LEFT SIDE COLLAR

(1) BOLTS

(2) BRAKE DISC

(1) RETAINER WRENCH B

(2) RETAINER WRENCH BODY

Disassembly/Wheel Bearing Replacement

A contaminated brake disc or pad reduces stopping power, and can cause a serious injury or death.

Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.

Remove the bolts and brake discs.

Turn the inner race of each bearing with your finger.

The bearings should turn smoothly and quietly.

Also check that the bearing outer races fit tightly in the hub.

Remove the discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub.

Replace the bearings in pairs.

Unstake the bearing retainer.

Remove the bearing retainer using a special tool.

Tools:

Retainer wrench B

Retainer wrench body

07710–0010200

07710–0010401

Remove the right and left side collars using two screw drivers as shown.

2-30

02. Racing Kit6 04.4.27 18:21 Page 31

(1)

(1)

(1)

Racing Kit

(2)

(2)

(2)

(1) DRIVER

(2) ATTACHMENT/PILOT

(1) DRIVER


(1) DRIVER


Press the right wheel bearing and distance collar using a special tools and a hydraulic press until the left wheel bearing is removed.

Press the right wheel bearing more than necessary, or the right bearing fall into the wheel hub.

Tools:

Driver

Attachment, 42 x 47 mm

Pilot, 25 mm

07749–0010000

07746–0010300

07746–0040600

Remove the right side bearing using the special tools.

Tools:

Driver


Pilot, 25 mm

07749–0010000

07746–0010300

07746–0040600

Never install oil bearings; once the bearing have been removed, they must be replaced with new ones.

Replace the wheel bearings in pairs.

Assembly

Apply oil to the bearing outer surface.

Drive the new left wheel bearing into the hub until it seat.

Tools:

Driver


Pilot, 25 mm

07749–0010000

07746–0010300

07746–0040600

2-31

02. Racing Kit6 04.4.27 18:21 Page 32

Racing Kit

(1)

(1)

(2)

(2)

(1)

(2)

(1) DRIVER


Install the distance collar, then drive the right side bearing into the hub using the same tools.

Tools:

Driver


Pilot, 25 mm

07749–0010000

07746–0010300

07746–0040600

(1) RETAINER WRENCH B

(2) RETAINER WRENCH BODY

(1)

(1) BRAKE DISC

(2) BOLTS

(1)

(2)

(1) BEARING RETAINER

(2) PUNCH

(2)



Apply molybdenum disulfide grease to the new bearing retainer threads and install it into the hub.

Tighten the bearing retainer using the special tools.

Tools:

Retainer wrench B

Retainer wrench body

07710–0010200

07710–0010401


Secure the bearing retainer with a punch.

Install the brake discs and tighten the bolts to the specified torque.


Install the wheel side collars.

2-32

02. Racing Kit6 04.4.27 18:21 Page 33

Front axle installed view from forward

(7)

(6)

(4) (5)

(3)

Racing Kit

(1)

(1) FRONT AXLE NUT

(2) AXLE SIDE NUT

(3) AXLE GUIDE A

(4) AXLE GUIDE B

(5) SHIMS

(6) AXLE WASHER

(7) AXLE BOLT

(2)

(1)

(1) AXLE NUT (2) AXLE SIDE NUT

(2)

If the wheel, fork leg, and/or distance collar has been replaced, adjust the axle distance as follow:

1. Apply molybdenum disulfide grease to the axle nut and axle side nut threads. Install the front axle nut into the left fork axle from the inside, install and tighten the axle side nut to the specified torque.


2-33

02. Racing Kit6 04.4.27 18:21 Page 34

Racing Kit

(3)

(1)

(1) AXLE GUIDE A

(2) AXLE GUIDE B

(3) SHIM (S)

(2)

2. Install the front axle guide A and B into the right fork axle.

3. Temporarily install the front wheel between the fork legs and then install the front axle and axle washer but do not tighten.

4. With the front brake applied, pump the fork up and down several times to parallel the fork.

5. Measure the clearance between the right wheel distance collar and axle guide B.

6. Adjust the clearance by inserting shim(s) between the right fork axle holder and axle guide B.

2-34

02. Racing Kit6 04.4.27 18:21 Page 35

Optional Rear Wheel

15 N•m (1.5 kgf•m, 11 lbf•ft)

Brake disc


Racing Kit

Damper rubber

Driven flange

Circlip

Driven sprocket

Driven flange right side collar

Angular bearing

(30 x 62 x 23.8)

Distance collar

Driven flange left side collar

Bearing washer

34 N•m (3.5 kgf•m, 25 lbf•ft)


Bearing retainer

2-35

02. Racing Kit6 04.4.27 18:21 Page 36

Racing Kit

(1)

(2)

(1)

(2)

(1) NUTS

(2) DRIVEN SPROCKET

(3) (2)

(1) DRIVEN FLANGE

(1)


(2) BOLTS (3) BRAKE DISC

(1)

(1) DAMPER RUBBERS

Disassembly

If you will replace the driven sprocket, loosen the driven sprocket nuts.

Remove the rear wheel right side collar.

Remove the bolts and brake disc.

Remove the final driven flange assembly from the left wheel hub.

Remove the damper rubbers.

2-36

(1)


(2) RETAINER TOOL

Wheel Bearing Replacement

Remove the wheel bearing retainer using the special tool.

Wheel bearing retainer has left hand threads.

Tool:

Retainer tool 87000-NL6-000

02. Racing Kit6 04.4.27 18:21 Page 37

(1)

(1)

(1)

Racing Kit

(2)

(2)

(1) DRIVER


(1) DRIVER


(1) DRIVER


Press the right wheel bearing and distance collar using a special tools and a hydraulic press until the left wheel bearing is removed.

Press the right wheel bearing more than necessary, or the right bearing fall into the wheel hub.

Tools:

Driver

Attachment, 52 mm

Pilot, 25 mm

07749–0010000

07946–3710200

07746–0040600

Remove the right side bearing using the special tools.

Tools:

Driver


Pilot, 25 mm

07749–3710001

07946–3710200

07746–0040600

Never install oil bearings; once the bearing have been removed, they must be replaced with new ones.

Replace the wheel bearings in pairs.

Assembly

Apply oil to the bearing outer surface.

Drive the new left wheel bearing into the hub until it seat.

Tools:

Driver


Pilot, 25 mm

07749–0010000

07946–3710200

07746–0040600

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02. Racing Kit6 04.4.27 18:21 Page 38

Racing Kit

(1)

(1)

(2)

(1) DRIVER


(2)

(2) (1)


(2) RETAINER TOOL

Install the distance collar, then drive the right side bearing into the hub using the same tools.

Tools:

Driver


Pilot, 25 mm

07749–0010000

07946–3710200

07746–0040600

Apply a locking agent to the bearing retainer threads and install it into the hub.

The bearing retainer has left hand threads.

Tighten the bearing retainer to the specified torque.

Tool:

Retainer tool 87000–NL6–000



(1)

(1) CIRCLIP

Driven flange bearing replacement

Remove the driven flange left side collar using two screwdrivers as shown.

Remove the circlip from the drive flange.

Drive out the driven flange bearing and right side collar as an assembly from the driven flange.

2-38

02. Racing Kit6 04.4.27 18:21 Page 39

(1)

(1)

(2)

(1) DRIVER


Drive the new driven flange bearing into the driven flange until it seat using the special tools.

Tools:

Driver


Pilot, 25 mm

07749–0010000

07746–0010500

07746–0040600


(1)


Install the driven flange left side collar.

(1) CIRCLIP

Install the driven flange right side collar.

Install the circlip into the groove securely.

Racing Kit

(1)

2-39

02. Racing Kit6 04.4.27 18:21 Page 40

Racing Kit

Assembly

(5)

(1)

(2)

(1)

(3)

(4)

(6)

(1) LEFT DRIVE CHAIN ADJUSTING PLATE

(2) LEFT DRIVE CHAIN ADJUSTING BOLT

(3) REAR AXLE NUT

(4) DRIVEN FLANGE COLLAR

(5) DRIVEN FLANGE

(6) REAR WHEEL

(7) BRAKE DISC

(8) REAR BRAKE CALIPER BRACKET

(9) RIGHT DRIVE CHAIN ADJUSTING BOLT

(10) RIGHT DRIVE CHAIN ADJUSTING PLATE

(11) WASHER

(12) REAR AXLE

(7)

(9)

(12)

(1) DAMPER RUBBERS

(1)

(10)

(11)

(8)

(2)

(1) DRIVEN SPROCKET

(2) NUTS

Install the damper rubbers into the left wheel hub.

Install the final driven flange assembly onto the left wheel hub.

If the driven sprocket is removed, apply oil (Honda

Ultra GP) to the driven flange nut threads and seating surfaces.

Tighten the driven sprocket nuts to the specified torque.


2-40

02. Racing Kit6 04.4.27 18:21 Page 41

(1) (2)

(1) BRAKE DISC (2) BOLTS


(3)

Install the brake disc onto the right wheel hub.

Note the direction of the brake disc.

Apply a locking agent to the brake disc bolt threads.

Install the brake disc and tighten the bolts to the specified torque.


Install the right side collar.

Racing Kit

2-41

02. Racing Kit6 04.4.27 18:21 Page 42

Memo

03. Machine Setting_03 04.4.27 19:21 Page 1

This section covers the ECU setting procedure by PC communications.

ECU Setting

System requirements and communication attachment

1.System requirements

• IBM AT compatible PC

• OS: Windows 95/98/Me/XP

• CPU: Pentium 200MHz or higher (recommended)

• Main memory: 32MB or more (recommended)

• Display: 1024 x 768 or higher resolution (recommended)

• CD-ROM: CD-ROM drive is required (The product is provided with a CD-R)

• Serial port: Serial port is required (for communicate with ECU)

If the serial port is not equipped, use USB-RS232C adaptor

3. Machine Setting

Software Install

1. Set software CD-ROM in the CD-ROM drive and click on the CD-ROM icon.

2. When a window like below is displayed, double-click “SETUP.EXE” to install the application.

3. A window like below will appear and will prepare for setup process.

2.The attachment

• UNIT, ASSY SERIAL I/F: 38880-NL3-750

3-1


Machine Setting

4. Then, a window like below will appear. To continue setup, click “Next.”

NOTE:

• Exit all other programs before starting installation.

6. Setup will ask you to specify a directory to install the application in here. If you need not change the default directory, click “Next.”

5. When you using the Windows XP, the using information window is appered.

Click “Next.”

7. Select program folder, the clock “Next.”

3-2


8. Confirm the folder and name etc. to install the application in, then click

“Next.”

10. Now, installation is completed.

Click “Finish.”

Machine Setting

9. A window like below will appear and installation is continued.

When installation is completed, a shortcut folder like below will appear.

Use this folder putting on the desktop etc.

3-3


Machine Setting

Operation

Functional Descriptions

When you start up the setting tool, a window like below will appear.

(9)

(1)

(2)

(4)

(5)

(3)

Before you begin

• About the pull-down menu

Data Edit Selector of No. 4 in the previous section is a pull-down menu.

Click “ ” as shown in the figure above and a menu will appear below.

Items to edit are changed here.

Reverse video indicates the item to be selected.

• When you started up the application for the first time

Nothing will be displayed like below.

(6) (7) (8)

(Note: The figure above is partly different from actual screen for explanation purpose.)

No.

Name Function

(1) File information display Displays information on the setting file.

(2) Open file

(3) Save File

Reads in setting data saved before.

Saves setting data you have changed.

(4) Data Edit Selector

(5) Data display area

(6) Data Read

(7) Data Write

(8) Quit

(9) COM Port

Selects an item to change.

Displays setting data.

Transfers setting data from ECU.

Transfers setting data to ECU.

Exits the program without saving data.

Selects communication port

(default is COM 1).

Read in default file with “Open File.”

Note:

Be careful not to delete all files in the data directory. If you do, this program cannot be used any more.

To use this program again, you are needed to reinstall it.

When you start up the program next time, it will automatically open the last file you used.

In case default file is not displayed with "Open file ", refer to troubleshooting

No.4.

3-4


• Checking communication port (COM port)

When you click “ CommPort”, pulldown menu of communication ports will appear.

You can select from COM1 to 16.

Current setting is shown.

Machine Setting

Connection with the Vehicle

1. Connect the “UNIT, ASSY SERIAL I/F: 38880-NL3-750” to the serial-port of your PC.

2. Connect orange connector to the communication connector (quadrupole blue connector) in front of the battery.

Checking system property

Open system property of your PC to check the setting of communication port.

Port setting should accord with that of the setting tool.

If the communication port (COM1) is marked with “X”, communication is impossible.

Note:

• Do not drive your vehicle with the setting cord attached.

Use the setting cord only when you change setting.

3-5


Machine Setting

File Operation

Opening a File

When you click “Open File”, a list of files which can be read in will appear.

Select a file you wish to use and click OK. Then, the data will be read in.

Save a File

When you click “Save File”, a list of files already saved will appear and request you to input file name.

Select a file and click “OK.”

Note:

• Displayed file “04cbr1k.e2p” is a default data.

If the process of “Open File” is aborted, the following window will appear.

Click “OK” to continue.

Type a file name and click OK to save your file.

Note:

• Number of characters you may use for a file name is limited to eight or less.

What should be noted when typing in a file name

Note:

• Be sure to put the cursor before “.e2p” when you type in a file name. If you omit the extension (.e2p), you cannot open it. (It will not be listed.)

3-6


Machine Setting

If the process of Save File is aborted, the window below will appear.

Click “OK” to continue.

Changing Setting

Changing TH Segmentation

TH position can arbitrarily be changed.

If you use more than 8 characters for a file name, the window below will appear.

To continue “Save File”, click “OK” and type in again a file name with eight or less characters.

If you click TH segmentation, 60% for example, a scale as shown above will appear.

You can change 8 points excluding both ends (0% and 100).

Use mouse or up/down arrow keys to make change click “Enter key” to enter your change.

The change cancel is done by clicking "Cancel key".

The range in which you can make change is only within the zone of the scale.

3-7


Machine Setting

Changing Engine Speed Segmentation

You can arbitrarily change engine speed segmentation.

Practice to Change Setting

You can change air-fuel ratio either on map screen or on graph screen.

1. Changing air-fuel ratio (on map screen)

Engine speed segmentation can be changed like TH segmentation.

For example, if you click on 8,000 min -1 (rpm), a scale like above will appear.

You can change 14 points excluding both ends (0 min -1 (rpm) and 18,000 min -1

(rpm)).

Choose a point to change with mouse or left/right arrow keys and press "Enter key" after you put in a new value.

The range in which you can make change is only within the zone of the scale.

Change of segmentation made here will also take effect in changing ignition timing.

You cannot make setting of segmentation for air-fuel ratio map and ignition timing map separately.

Note:

• TH and engine speed segmentations can only be changed on “Fi Map” screen.

When you select “FI Map (number of percent), a screen like below will appear.

In order to change data, click on the point where desired TH position and the engine speed meets. Then, a scale as shown below will appear.

3-8


Machine Setting

How to change air-fuel ratio How to change data of all area

Make change using mouse or up/down keys.

Click “Enter Key” to make the change take effect.

Click “Cancel Key” to abort the process.

You may change values in the range from –30% to +30%.

0% is the standard setting.

When you click “All area Data change”, the screen will be like above.

This screen enables you to off set all data. Click “Enter Key” to have change take effect.

Only, be aware that this operation makes all data be the same value.

After change

3-9


Machine Setting

2. Changing air-fuel ratio (graph display)

Graph mode displays a horizontal axis of map display graphically.

When you select “Fi Map (graph mode)”, a screen like below will appear.

To change data, select TH position you wish to adjust.

Present status of setting will be graphically displayed along with engine speed by TH positions.

Here, click correction value display of the engine speed you wish to adjust.

3-10


Machine Setting

Adjustable areas will be selected with their color changed color. Use up/down arrow keys to make change.

Change made here will also take effect in the map display.

3. Changing ignition timing

When you select “IG offset”, a screen like below will appear.

1). How to change at each point

When you select “Fi Map (3D graph)”, a screen like below will appear.

Ignition timing can be changed based on engine speed.

TH position based changing is impossible.

To make change, click correction value display of the engine speed you wish to adjust. Then, adjustable areas will be selected with their color changed.

Use up/down arrow keys to make change.

You may change values in the range from 0 to –20 degrees.

You can change the graph color and graph size referring to the instruction on both sides of graph as shown.

3-11


Machine Setting

2). How to change all data at once 4. Changing fuel distribution percentage between teh upper and lower injector

When you select “RU MAP”, a screen like below will appear.

When you click “All area Data change”, a screen like above will appear enabling you to offset all values. The change takes effect when you click “Enter

Key.”


You can change the fuel distribution percentage between the upper and lower injector.

3-12


Same with “IGN OFFSET”, fuel distribution parcentage can be changed based on engine speed.

TH position based changing is impossible.

To make change, click correction value display of the engine speed you wish to adjust. Then, adjustable areas will be selected with their color changed.

Use up/down arrow keys to make change.

You may change values in the range ± 15%.

Transferring Setting Data

Transmitting data (PC to ECU)

Machine Setting

When you click “Data Write”, the following window will appear.

When you click “All area Data change”, a screen like above will appear enabling you to offset all values. The change takes effect when you click “Enter

Key.”


Turn off the main switch.

When you click “OK”, the following window will appear.

3-13


Machine Setting

Turn ON the main switch again and click “OK” or press Enter key within two seconds.

If communication is correctly completed, the following window will appear.

Receiving data (ECU to PC)

If communication could not be performed correctly, the following window will appear.

Check connection and communication settings and retry communication clicking “Data Write” again.

By clicking “Data Read”, you can retrieve setting data from ECU.

Take the same procedure as Data Write and the screen will be like below.

Contents of the display will change to the setting data in ECU and its file name will be displayed here.

File name becomes “ECU Read data” when the data retrieval is completed.

Note 1:

In this state, “Data Write” cannot be performed.

Note 2:

If you save or chage the date once, you will be able to transmit into ECU.

3-14


Troubleshooting

No.

1

2.

3.

4.

State

Unable to install

Unable run the tool

Unable to communicate with

ECU

Cause

Don’t know how to operate

CD-ROM drive is not recognize

Defect of CD-ROM

(deep scratch, etc.)

Unsupported OS This tool runs on windows

The serial port setting incorrect

Action to take

*refer to 1

Make the drive recognized and try installation again

Please contact HRC service.

95/98/Me/XP.

*refer to 2

Power supply of

ECU is turned off.

Communication cable connection is defective

Timing of transmission is not proper

Data read out from ECU cannot be transmitted.

Check power supply

Communication cable connection is defective.

Check connection (Refer to the page on connection with the vehicle)

Press return key within two seconds after turning OFF and

ON the main switch to transmit data (Refer to the page on data transmission)

The retrieved data cannot be retransmitted as it is.

In order to transmit retrieved data, you should save it once.

(Refer to the page on data reception)

*see 3 Default file is not displayed when starting up first

A same problem is occurs with the English version.

*1: CD-ROM drive

*2: How to check serial port

Machine Setting

If you click on the My

Computer icon, a window like left will appear.

Click CD-ROM drive in the window and installation will start.

If there is not CD-ROM icon displayed in the window, your PC might not be equipped with CD-

ROM drive or is not recognizing one.

Consult instruction manual of your PC to confirm this.

Open the Control

Panel.

Select System and click on it.

3-15


Machine Setting

System Properties window will open.

*3: In case you open "Open File" when starting up for the first time.

Normally 04cbr1k.e2p is displayed as default, however it’s not displayed in this picture.

Countermeasure : Open the directory including the tool, and change the file name.

It exists as a file, but does not displayed on the tool.

Select "Cbr1000_a.e2p" and change the file name.

e.g.) Change the file name as "04Cbr1k.e2p" to "04Cbr1k_1.e2p"

The file name is not specified if the name includes 8 letters or less.

Now you can open the file.

3-16


Machine Setting

Quick Shift Setting

System requirements and communication attachment

1.System requirements

• IBM AT compatible PC

• OS: Windows Me/2000 Professional edition

Windows XP Home Edition/Professional edition

• CPU: Pentium 200MHz or higher (recommended)

When using the Window XP: Pentium III 800MHz or higher

• Memory: 8MB for this application

• Display: 800 X 600 or higher resolution (recommended)

• CD-ROM: CD-ROM drive is required (The product is provided with a CD-R)

• USB port: USB 1.1 or higher

• Mouse or other pointing device

2.The attachment

• USB Cable: 38411-NL9-000 (or commercially available USB cable)

USB Driver Install

• The USB driver installation is needed only when you install this program.

1. Set software CD-ROM in the CD-ROM drive.

2. Connect the Quick Shift unit and PC with USB cable.

3-17


Machine Setting

3. Turn the Quick Shift unit ignition power ON (Vehicle ignition ON).

4. “Found New Hardware Wizard” is displayed.

5. To continue setup, click “Next.”

2. When a window like below is displayed, device search is begin.

3. A window like below will appear in device searching process. To continue setup, click “Continue Anyway.”

3-18


4. When a window is change, installation is continued.

Machine Setting

Correction of the COM Number

After installing the USB driver, check the COM (Communication Port) number for the USB serial port.

1. Right click “My computer” and select “Properties”.

2. Click “Hardware” tab in “Properties”, the click “Device Manager”.

5. When installation is completed, a window like below will appear, click

“Finish.”

3-19


Machine Setting

3. Click and open “PORT COM & LPT.”

Note the USB Serial Port COM No.

This COM No. is used in “Starting Quick Shift Setting Tool”.

Note:

The window shown above, COM No.4 is selected.

Quick Shift Setting Tool Installation

Using this set-up program, install “Quick Shift Setting Tool Program”, “Visual

Basic 6.0 run time routine (DLL) API component” and “Online Help File.”

Note:

Must be use set-up program to install Quick Shift Setting Tool, so that the each file does not install its proper location.

1. Set software CD-ROM in the CD-ROM drive.

2. When a window like below is displayed.

If the window does not displayed, double-click “CD-ROM” icon in “My

Computer”.

3. Open “English” holder.

3-20


4. Double-click “setup” icon, start the set-up program.

Machine Setting

6. Click Set-up icon.

If there is no problem, using directory as indicated in the set-up program.

7 Click “Continue.”

8. After this figure, follow the procedure as displayed.

5. Click “OK.”

3-21


Machine Setting

Starting Quick Shift Setting Tool

1. Click “Start” button on the task bar, point the following:

“Program”

“QS Setting Tool 3”

“QS Setting Tool 3”

The Quick Shift Setting Tool is start up.

3. Select “CBR1K01.DAT”, click “Open.”

Note:

For easy to start up this program, place the “QS Setting Tool 3” short cut icon on the desktop.

2. When you start this program first time, this window is displayed, so click “OK.”

The last used data file is displayed when you start this program again.

3-22


4. Application main window is open.

Make sure the file name is correct.

Machine Setting

5. Click “Communication” and open “Select COM No.”

6. Check the COM No. radio button as noted during application install, then click “OK.”

Note:

The application does not communicate, if you select wrong COM No.

3-23


Machine Setting

Main Menu

<Mode>

This is indicated that model name of this data file.

This model (CBR1000RR Racing Kit) is displayed CBR and that used with vehicle speed sensor.

Note:

Other mode named “VFW” or “VRW” are used with front and rear wheel speed sensor.

Be careful not to select the other mode when you setting your CBR.

Refer to next section “Quick Shift Unit Set-up” for detail.

<File Name>

When you open the data files saved in your PC, drive name, folder name and file name is displayed.

You can check file name before editing.

3-24


Type your machine’s gear ratio, gear teeth or other data into each input window.

Wrong data input will cause: quick shift does not function at higher gear or other fault.

Machine Setting

<Quick shifter operation prohibition condition>

This is a revolution value so that the quick shifter does not operate less than this revolution.

In case the CBR, this value is transmission revolution.

The quick shifter does not operate below 50 km/h shown in this value.

(This function prohibit that the quick shifter operate when the vehicle warmup or low speed running)

When you set the value 0, the quick shifter is operated with the 1st-to-2nd pedal rod force and cutout number of crank revolutions even if the vehicle speed sensor is failing.

When there are not a problem on practical use and a problem of a sensor, it is not necessary to change this value.

<Shift-up engine revolution>

This value is shift-up engine revolution for the rider’s preference.

The ECM is calculated the cutout number of crank revolution by this value, so that this values not differ from actual shift-up engine revolution.

In case that the unit of the cutout number of crank revolutions is selected

“milli-second”, the shift-up engine revolution is not related.

Refer to following pages.

3-25


Machine Setting

<Cutout number of crank revolution>

Cutout number of crank revolution can be set by the crankcase revolution or unit of “milli-second”.

When the crank revolution is selected, the cutout number of crank revolution is fixed by this input value.

The unit can be changed by the rider’s preference.

See next page for “QS Unit Set-up; changing the unit of cutout time”.

3-26

<Pedal rod force condition>

The pedal rod force can be set through 1st to 6th gear.

The quick shifter does not operate when the pedal rod forces are not exceed these setting force values.

When the gearshift pedal is not returned, do not do the next operation.

Release the gearshift pedal and release pedal rod force.

When the displayed value is differ from input value: the input value is changed by relation of the smallest unit.

Input value 348 means 34.8 kg of pedal rod force.

Note:

When the value of "6th to 7th" set to maximum values of "600", the false operation can prevent even if the rider shift ups from 6th gear incorrectly.

But when the rider shift ups exceed the input value, or the input value is incorrect, sometimes does not operate the “5th to 6th” quick shift.

So, we recommended that the "6th to 7th" value is set the same value of the

“5th to 6th”.


Machine Setting

Note:

See following page’s “10. Read and write data” for detail.

<Read from QS unit>

Push this button, data written in QS unit is read and indicated it to a screen.

Next, select save menu in file menu, the data can be saved in PC.

This is useful for copying the data from other machine.

<Write to QS unit>

Push this button, editing data or saved data can be written to QS unit.

3-27


Machine Setting

QS Unit Set-up; Changing the Unit of Cutout Time

Click "Communication" and select "Set Up QS unit".

3-28

Check radio button “Time (em)”, then click “Write to QS Unit”.

Follow the indication of a display.

Note:

It is necessary for communication cable is connected and the vehicle ignition power is turned ON before write data to QS unit.


QS Unit Set-up; Other Setting

Do not change these radio buttons on this vehicle.

Machine Setting

Normally use “Pushing”.

When the shift pattern is changed to street pattern, select “Pulling” radio button, so that it is not necessary to replace the sensor (when using the

CBR1000RR racing kit sensor).

This button can be set “0 point adjustment” for the shift rod force sensor.

Because of the value is indicated, we recommend this adjustment at the monitor screen.

Note:

When the data is changed, click “Write to QS Unit” button to write to data to a QS unit.

Note:

It is necessary for communication cable is connected and the vehicle ignition power is turned ON before write data to QS unit.

3-29


Machine Setting

Monitor Screen “How to Display”

Click "Communication" and select "Monitor".

3-30

This engine rpm is "Shift-up engine revolution" written in at QS unit, and not real engine rpm.

Note:

It is necessary for communication cable is connected and the vehicle ignition power is turned ON before monitor the QS unit data.


Monitor Screen “CAL (0 point adjustment of shift rod force sensor)”

Machine Setting

<Shift position>

Can be check the shift position (shifting rage) change in proportion to rear wheel revolution.

Be sure the rear wheel off the ground and secure the vehicle in safety stand other safety equipment.

<CAL>

If the pedal rod force value is out of range, do 0 point adjustment by pushing “CAL” button.

Must be follow this procedure, if the pedal rod force sensor is assembled or the vehicle is turn over.

After adjustment, the values slightly deviate from "0", but there is not a problem.

<Countershaft revolution>

When the rear wheel turning, this countershaft revolution value is changed in proportion to rear wheel revolution.

If no output or the rpm in proportion to rear wheel revolution, it indicated that:

– broken vehicle speed sensor

– disconnected vehicle speed sensor connector

– incorrect air gap between the vehicle speed sensor and M6 gear

<Pedal Rod Force>

This is the pedal rod force value.

Can be check the pedal rod force change by pushing the pedal.

Note:

If this value was excessively deviating from "0" before pushing the pedal, do

0 point adjustment by pushing “CAL” button.

See next page for detail.

3-31


Machine Setting

Monitor Screen “CAL (0 point adjustment of shift rod force sensor)”

Note:

Make sure that the shift rod force does not applied.

Slightly move the gearshift pedal up and down and make sure the the value is stabilized, push the “CAL” button.

Click the “CAL” button.

This screen is appeared, then click "OK" button.

The adjustment is finished when the pedal rod force value is “0” or an approximate value.

3-32


Read and Write Data

Machine Setting

These operation can read data written in at "QS unit" or can write data from the PC to QS unit.

Note:

It is necessary for communication cable is connected and the vehicle ignition power is turned ON before reading or writing data.

<Read from QS unit>

Push this button, data written in QS unit is read and indicated it to a screen.

Next, select save menu in file menu, the data can be saved in PC.

This is useful for copying the data from other machine.

<Write to QS unit>

Push this button, the editing data or saved data can be written to QS unit.

3-33


Machine Setting

Data reading

Click "OK" button, and finish reading.

Click "Read from QS unit" button.

"Progress bar" moves during reading.

Click "OK" button and start reading.

3-34

Note:

When this screen was indicated before reading, check that the communication cable connection and vehicle power supply is turned ON.

If the connection is correct, one the ignition power is turned OFF and ON again.


Data writing

Machine Setting

Click "OK" button, and finish writing.

Click "Write to QS unit" button.

"Progress bar" moves during writing.

Click "OK" button and start writing.

Note:

When this screen was indicated before writing, check that the communication cable connection and vehicle power supply is turned ON.

If the connection is correct, one the ignition power is turned OFF and

ON again.

3-35


Machine Setting

Indication of Help File

Please refer to “Help file”, if the procedure is not appeared in this instruction, or if the thing that it is not understood for using.

1. First please start-up a program.

2. Right click "Help" button.

3. Please use table of contents in the menu.

3-36


When a Screen of QS Unit Setting Tool Did Not Open

While using this tool, and a screen does not open by some cause, and a screen does not open even if the software reinstalled, please operate the following.

Most of cause, because the file or folder saved current has been erased.

Open folder “My computer”.

Open the "Local disk" (C:).

Open this folder.

Open this folder.

Open the folder "WINDOWS".

Machine Setting

Double click the "regedit".

3-37


Machine Setting

Delete this folder (with all files in this folder).

Next, try to start up "QS setting tool".

Make sure that the "Shift ControlUnit" was erased.

Function is correct, when the reading progress is appeared or the main menu is indicated.

If the start up is still incorrect, other problem is thought about.

3-38


Machine Setting

(1) (2)

(1) “SEL” BUTTON

(2) “RESET” BUTTON

(1)



(2)

Combination Meter Function

The racing kit combination meter has following functions:

• Shift-up indication

• Lap time indication

• Coolant temperature indication

Shift-up Indicator

When the engine rev. exceeds the setting value, the shift-up indicator illuminates or flashes.

The shift-up indicator can be set in range between

4,000 – 15,500 min

-1

(rpm).

How to set the shift-up indicator

1. Turn the engine stop switch to RUN while pressing the “SEL” button until the combination meter initial action have finished. The needle indicates the current setting revolution.

2. Align the needle with requied revolution by pressing the “RESET” button. Whenever the button is pressed 1 time, the needle increases by the scale of 250 min

-1

(rpm), and when the button is pressed for more than one second, the needle increases by the scale of 1,000 min

-1

(rpm).

When the maximum setting value (15,500 min

-1

(rpm)) is exceeded, the needle returns to 4,000 min

-1

(rpm).

After determine the illuminating rev., press the

“SEL” button.

3. Press “RESET” button and select a illuminating or flashing pattern.

• Illuminating pattern and brightness (3 patterns)

• Flashing pattern and brightness (6 pattern)

4. After the shift-up indicator setting is finished, press “SEL” button. The combination meter is returned to nomal indication mode (the tachometer needle returns to 0).

When the tachometer or speedometer input signal is detected, or not access for more than 30 seconds during setting, the setting value is cancelled and return to normal indication mode.

2-39


Machine Setting

(4)

(5)

(1)

(2)

(3)

(5)

(1)

(2)

(3)

(4)

(1)

(2)

(1) SESSION NUMBER (2) LAP NUMBER

(3) COOLANT TEMPERATURE

(4) LAP TIME (MIN.) (5) LAP TIME (SEC.)

Lap Time Indicator

GO mode:

When the engine stop switch to RUN, the combination meter is in “STOP” mode.

The combination meter is received the LAP marker signal (passing switch is pressed) or engine rev. is over 5,000 min

-1

(rpm), the lap time indicator system enters the “GO” mode.

Under the “GO” mode, the combination meter records the session number, lap number, each lap time and maximum coolant temperature in each lap.

During vehicle running, the combination meter displays the current session number, lap number, lap time and coolant temperature in each lap.

The lap data can be stored up to 99 laps.

When the stored data is exceed the 99 laps, the oldest data is overwrite to current lap data.

If you wish to read out each lap data, make sure the combination meter is in “STOP” mode.

(1) SESSION NUMBER (2) LAP NUMBER

(3) MAX. COOLANT TEMPERATURE (4) LAP TIME

(5) CURRENT COOLANT TEMPERATURE

STOP mode:

When the engine stop switch to RUN or the “SEL” button is pressed under the “GO” mode, the combination meter enters in “STOP” mode.

The stored lap data can be read out in this mode.

Stored lap data is displayed one by one from lap 1 to latest lap by pushing the ‘RESET” button.

When the “RESET” button is pressed, the next stored data is displayed.

When the “SEL” button is pressed, the previous stored data is displayed.

The maximum coolant temperature during each lap is displayed on upward of the section/lap number.



If the “RESET” or “SEL” button is pressed and hold, the lap time data will be advanced or returned.

When you wish to reset the lap data, press both the

“SEL” and “RESET” button simultaneously more than 2 seconds.

2-40


(1)

(2)

(1) PASSING SWITCH (STOP WATCH SWITCH)

(2) HORN SWITCH (POWER SHIFTER SWITCH)

Left Handlebar Switch Function

On this machine, the each switch of the left handlebar switch is fuction as follows:

Passing switch: Stop watch function (lap time)

Horn switch: Power sifter function

Stop Watch:

When the switch is pushed, the stop watch is started.

See page 2-39 for lap time indicator function.

Power Sifter:

While pushing the switch, both the ignition and fuel injection cut-off system is activated.

See page 2-17 for power shift setting.

Machine Setting

2-41


Memo

User manual | Honda CBR1000RR 2004 Motorcycle Parts list 131 Pages

User manual | Honda CBR1000RR 2004 Motorcycle Parts list

2004-CBR1000RR PARTS LIST

INSTRUCTIONS FOR USE OF PARTS LIST

ENGINE GROUP

FRAME GROUP

INDEX

INSTRUCTIONS FOR USE OF PARTS LIST

Ⅰ. How to order parts

Ⅱ. How to read this parts list

IMPORTANT INFORMATION

ENGINE POWER UP KIT I

ENGINE POWER UP KIT II

A.C. GENERATOR SET

A.C. GENERATOR SET

WIRE LOCKING KIT /

AIR FUNNEL SET

WATER HOSE PLUG SET

AIR INJECTION PLUG SET

TRANSMISSION SET

DRIVE SPROCKET SET

TRANSMISSION SET

DRIVE SPROCKET SET

CAM CHAIN / TENSIONER

AIR BOX DUCT SET

BREATHER CASE SET

EXHAUST SET

EXHAUST SET

FRONT FORK

FRONT FORK

SWINGARM

SWINGARM

REAR CUSHION

STEERING DAMPER

RADIATOR

FRAME PARTS

WIRE HARNESS

WIRE HARNESS

REAR WHEEL

REAR WHEEL

FRONT WHEEL

BRAKE

QUICK SHIFTER SET

Honda Racing Corporation

No good Good

Key Features

Frequently Answers and Questions

What is the difference between the ENGINE POWER UP KIT I and ENGINE POWER UP KIT II?

What is the purpose of the AIR BOX DUCT SET?

What is the function of the EXHAUST SET?

What is the difference between the 51401-MEL-R10 and 51401-NL9-900 springs?

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