2004-cbr1000rr parts list - O2 Racing Service / Yoshimura

Transcription

2004CBR1000KIT（E_list） 04.4.27 5:12 PM ページ1
2004-CBR1000RR PARTS LIST
CONTENTS
INSTRUCTIONS FOR USE OF PARTS LIST..................................................... 4- 2
ENGINE GROUP
FRAME GROUP
E- 1
ENGINE POWER UP KIT I ............................................................................................. 4- 3
F- 1
AIR BOX DUCT SET
E- 1-1
ENGINE POWER UP KIT II
4- 4
F- 2
BREATHER CASE SET ....................................................................................................... 4-14
E- 2
A.C. GENERATOR SET ..................................................................................................... 4- 5
F- 3
EXHAUST SET ............................................................................................................................. 4-15
E- 3
WIRE LOCKING KIT / AIR FUNNEL SET .................................................... 4- 7
F- 4
FRONT FORK ................................................................................................................................. 4-17
E- 4
WATER HOSE PLUG SET ............................................................................................. 4- 8
F- 5
SWINGARM .................................................................................................................................... 4-19
E- 5
AIR INJECTION PLUG SET ......................................................................................... 4- 9
F- 6
REAR CUSHION
E- 6
TRANSMISSION SET / DRIVE SPROCKET SET
4-10
F- 7
STEERING DAMPER ............................................................................................................ 4-22
E- 7
CAM CHAIN / TENSIONER .......................................................................................... 4-12
F- 8
RADIATOR ......................................................................................................................................... 4-23
F- 9
FRAME PARTS
F-10
WIRE HARNESS
F-11
REAR WHEEL ................................................................................................................................ 4-27
F-12
FRONT WHEEL
F-13
BRAKE
F-14
QUICK SHIFTER SET
...........................................................................................
..............................
INDEX
.............................................................................................................
........................................................................................................................
............................................................................................................................
........................................................................................................................
4-13
4-21
4-24
4-25
...........................................................................................................................
4-29
....................................................................................................................................................
4-30
..........................................................................................................
4-31
................................................................................................................................................................................ 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
M. …………… Middle
ASSY.………… Assembly
mm…………… Millimeter
C.……………… Center
R.……………… Right
COMP. ……… Complete
STD. ………… Standard
G ……………… Gram
T(22T)………… Tooth（22 Teeth）
L. ……………… Left
T.W. ………… Thermo Water
L(100L) ……… Link（100Links）
4-2
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
Block No.
E-1
ENGINE POWER UP KIT I
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06110-NL9-000
ENGINE POWER UP KIT I.............................................................................................. 1
1
• 2
14110-MEL-R10
CAMSHAFT COMP, IN................................................................................................... 1
1
• 3
14210-MEL-R10
CAMSHAFT COMP, EX.................................................................................................. 1
1
• 4
14751-MEL-R10
SPG, IN VALVE............................................................................................................... 8
8
• 5
22401-MEL-R10
SPRING, CLUTCH .......................................................................................................... 5
5
• 6
31910-NL3-620
PLUG, SPARK, R0045Q-10 ............................................................................................ 4
4
Remarks
4-3
Block No.
E-1-1
ENGINE POWER UP KIT II
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06120-NL9-000
ENGINE POWER UP KIT II............................................................................................. 1
1
• 2
12251-NL9-000
GASKET, CYLINDER HEAD 0.60 ................................................................................... 1
1
•
12252-NL9-000
1
•
12253-NL9-000
1
• 3
13101-NL9-000
PISTON ........................................................................................................................... 4
4
• 4
13112-NL9-000
CLIP, PISTON PIN 17MM............................................................................................... 8
8
• 5
13121-NL9-003
RING, PISTON TOP 75X0.8X2.3.................................................................................... 4
4
• 6
13131-NL9-003
RING, PISTON 2ND 75X0.8X2.4 ................................................................................... 4
4
• 7
13141-NL9-003
RING, PISTON OIL 75X1.5X1.95 ................................................................................... 4
4
• 8
14711-NL9-000
VALVE, INLET(29) .......................................................................................................... 8
8
• 9
14721-NL9-000
VALVE, EXHAUST(24) ................................................................................................... 8
8
4-4
Remarks
Block No.
E-2
A.C. GENERATOR SET
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06130-NL9-000
ACG SET......................................................................................................................... 1
1
• 2
11000-NL9-000
CRANKCASE SET .......................................................................................................... 1
1
• 3
11100-NL9-000
BLOCK COMP., CYLINDER............................................................................................ 1
1
• 4
11200-NL9-000
CRANK CASE, LOWER .................................................................................................. 1
1
• 5
11201-NL9-000
COLLAR, 6.2X13X10 ...................................................................................................... 1
1
6
11300-MEL-000
HOLDER COMP., MISSION............................................................................................ 1
1
• 7
11321-NL9-000
COVER, ACG .................................................................................................................. 1
1
8
11333-MEL-000
CLAMP, ACG CODE........................................................................................................ 1
1
9
12208-PR3-000
BOLT, SEALING, 20MM ................................................................................................. 1
1
• 10
31110-NL9-000
ROTER COMP................................................................................................................. 1
1
• 11
31120-NL9-000
STATOR COMP .............................................................................................................. 1
1
• 12
90003-NL9-000
BOLT, FLANGE, 10X35 .................................................................................................. 1
1
13
90004-MEL-000
BOLT, SPECIAL, 7X42.5.................................................................................................. 1
1
14
90006-GHB-660
BOLT, FLANGE, NSHF, 6X22.......................................................................................... 5
5
15
90006-GHB-670
BOLT, FLANGE, NSHF, 6X25.......................................................................................... 3
3
16
90008-MEL-000
BOLT, SOCKET, 10MM................................................................................................... 1
1
17
90010-MEL-000
BOLT, FLANGE, 8X12 ..................................................................................................... 1
1
18
90015-MEL-003
BOLT, FLANGE, 9X105 ................................................................................................... 6
6
19
90016-MEL-003
BOLT, FLANGE, 9X125 ................................................................................................... 4
4
20
90017-MAT-000
BOLT, FLANGE, 7X40 ..................................................................................................... 9
9
Remarks
4-5
Block No.
E-2
A.C. GENERATOR SET
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
21
90017-MEL-000
BOLT, FLANGE, 7X60 ..................................................................................................... 1
1
22
90018-MEL-000
BOLT, FLANGE, 7X80 ..................................................................................................... 1
1
23
90048-MEL-000
BOLT, SEALING, 22MM ................................................................................................. 1
1
24
90119-MB0-000
BOSS, OIL FILTER .......................................................................................................... 1
1
25
90133-MEL-000
BOLT, FLANGE, 8X30 ..................................................................................................... 6
6
26
90447-KE1-000
WASHER, SEALING, 7MM ............................................................................................. 1
1
27
90701-MV9-670
DOWEL PIN, 10X16 ........................................................................................................ 3
3
28
91001-MEL-003
BRG, BALL RADIAL, 28X62X16 ...................................................................................... 1
1
29
91002-MEL-003
BRG, BALL SPECIAL, 20X47X15.5 ................................................................................. 1
1
30
91003-MEL-003
BRG, SPECIAL, 20X52X15 .............................................................................................. 1
1
31
91004-MEL-003
BRG, BALL SPECIAL, 35X72X17 .................................................................................... 1
1
32
91201-MEL-013
OIL SEAL, 34.8X53X8 ..................................................................................................... 1
1
33
91202-MEL-003
OIL SEAL, 8X16X7 .......................................................................................................... 1
1
34
95701-06012-00
BOLT, FLANGE, 6X12 ..................................................................................................... 1
1
35
95701-06055-00
BOLT, FLANGE, 6X55 ..................................................................................................... 1
1
36
95701-08040-00
BOLT, FLANGE, 8X40 ..................................................................................................... 1
1
37
95701-08055-00
BOLT, FLANGE, 8X55 ..................................................................................................... 5
5
38
96600-06028-00
BOLT, SOCKET, 6X28 ..................................................................................................... 4
4
4-6
Remarks
Block No.
E-3
WIRE LOCKING KIT /
AIR FUNNEL SET
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06140-NL9-000
WIRE LOCKING KIT ....................................................................................................... 1
1
• 2
06160-NL9-000
AIR FUNNEL SET ........................................................................................................... 1
1
• 3
15611-NF4-900
CAP, OIL FILLER............................................................................................................. 1
1
• 4
17215-NL9-000
FUNNEL, AIR #1 ............................................................................................................. 1
1
• 5
17216-NL9-000
FUNNEL, AIR #2............................................................................................................. 1
1
• 6
17217-NL9-000
FUNNEL, AIR #3............................................................................................................. 1
1
• 7
17218-NL9-000
FUNNEL, AIR #4............................................................................................................. 1
1
• 8
17240-NL9-000
WASHER COMP, TONGUED ........................................................................................ 2
2
9
50252-GC4-830
BAND, SUB TANK ........................................................................................................... 1
1
90012-MEL-R10
BOLT, DRAIN PLUG 12MM .......................................................................................... 1
1
• 10
Remarks
4-7
Block No.
E-4
WATER HOSE PLUG SET
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06150-NL9-000
PLUG SET, WATER HOSE ............................................................................................ 1
1
2
19504-KY1-003
CLAMP , WATER HOSE D25 .......................................................................................... 2
2
• 3
19511-NL3-650
PLUG, FAST IDLE........................................................................................................... 2
2
• 4
19512-NL8-700
PLUG, HOSE 16MM....................................................................................................... 2
2
5
90454-ZV1-000
WASHER, THRUST ......................................................................................................... 1
1
4-8
Remarks
Block No.
E-5
AIR INJECTION PLUG SET
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
Remarks
SP AMA
• 1
06195-NL3-650
PLUG SET, EXHAUST A/I.............................................................................................. 1
1
2
17460-MEL-R10
TUBE, AIR SECTION UP ................................................................................................. 1
1
• 3
17470-MEL-R10
TUBE ASSY., A/S UPPER .............................................................................................. 1
1
4
19505-KS6-700
CLAMP, A WATER HOSE ............................................................................................... 3
3
5
96205-14012
PLUG, CONE TYPE 14X12 .............................................................................................. 3
3
No sale by HRC
4-9
Block No.
E-6
TRANSMISSION SET
DRIVE SPROCKET SET
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06210-NL9-000
TRNSMISSON SET ........................................................................................................ 1
1
• 2
06220-NL9-000
DRV SPRKT SET............................................................................................................. 1
1
• 3
23211-MEL-R10
SHAFT, MAIN................................................................................................................. 1
1
• 4
23220-MEL-R10
SHAFT COMP., CCOUNTER.......................................................................................... 1
1
• 5
23421-MEL-R10
GEAR, C-1....................................................................................................................... 1
1
• 6
23431-MEL-R10
GEAR, M-2...................................................................................................................... 1
1
• 7
23441-MEL-R10
GEAR, C-2....................................................................................................................... 1
1
8
23442-MS2-610
COLLOAR, 30x11.2......................................................................................................... 1
1
• 9
23451-MEL-R10
GEAR, M-3 M-4 .............................................................................................................. 1
1
• 10
23461-MEL-R10
GEAR, C-3....................................................................................................................... 1
1
• 11
23481-MEL-R10
GEAR, C-4....................................................................................................................... 1
1
12
23482-MR7-000
COLLAR, SPLINE, 28X13.5 ............................................................................................. 1
1
• 13
23491-MEL-R10
GEAR, M-5...................................................................................................................... 1
1
• 14
23501-MEL-R10
GEAR, C-5....................................................................................................................... 1
1
• 15
23511-MEL-R10
GEAR, M-6...................................................................................................................... 1
1
• 16
23521-MEL-R10
GEAR, C-6....................................................................................................................... 1
1
• 17
23801-NL6-700
SPROCKET, DRIVE,15(525) ........................................................................................... 1
1
•
23802-NL6-700
SPROCKET, DRIVE,16(525) ........................................................................................... 1
1
•
23803-NL6-700
SPROCKET, DRIVE,17(525) ........................................................................................... 1
1
• 18
37700-MEL-R10
SENSOR ASSY, SPEED ................................................................................................. 1
1
4-10
Remarks
Block No.
E-6
TRANSMISSION SET
DRIVE SPROCKET SET
2004 CBR1000RR
Ref.
No.
19
• 20
Part No.
Description
Reqd. No.
SP AMA
90004-492-010
SPL..BOLT, FLANGE, 10X22........................................................................................... 1
1
90402-NL6-000
WASHER, 10.2X37X3 .................................................................................................... 1
1
Remarks
4-11
Block No.
E-7
CAM CHAIN / TENSIONER
2004 CBR1000RR
Ref.
No.
1
Part No.
94101-06000
4-12
Description
Reqd. No.
SP AMA
WASHER, PLAIN, 6MM .................................................................................................. 2
2
Remarks
Block No.
F-1
AIR BOX DUCT SET
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06172-NL9-000
AIR BOX DUCT SET....................................................................................................... 1
1
• 2
17210-MEL-R11
ELEMENT, AIR/C ............................................................................................................ 2
2
• 3
17211-NL9-000
SPONGE, ELEMENT ...................................................................................................... 1
1
• 4
17251-NL9-000
DUCT, AIR BOX.............................................................................................................. 1
1
5
18315-GAG-750
RUBBER A, PROTR......................................................................................................... 2
2
• 6
19120-NL9-000
STAY R, RAD UPPER ..................................................................................................... 1
1
• 7
19170-NL9-000
STAY L, RAD UPPER ..................................................................................................... 1
1
8
90110-147-000
BOLT, FLANGE, 6MM..................................................................................................... 2
2
9
93891-05012-18
SCREW-WASH, 5X12...................................................................................................... 2
2
Remarks
4-13
Block No.
F-2
BREATHER CASE SET
2004 CBR1000RR
Ref.
No.
• 1
Part No.
Description
Reqd. No.
SP AMA
06552-NL9-000
BREATHER CASE SET ................................................................................................... 1
1
2
17724-102-700
CLIP................................................................................................................................. 3
3
3
18315-GAG-750
RUBBER A, PROTR......................................................................................................... 2
2
4
19052-KV0-000
COLLAR, RADIATOR MOUNTING.................................................................................. 2
2
5
19505-KS6-700
CLAMP A, WATER HOSE ............................................................................................... 3
3
• 6
31517-NL9-000
SPONGE, MT 5MM........................................................................................................ 1
1
• 7
55200-NL9-000
CASE COMP, BREATHER .............................................................................................. 1
1
• 8
55210-NL9-000
TUBE, BREATHER.......................................................................................................... 1
1
• 9
55220-NL9-000
TUBE, BREATHER RETURN .......................................................................................... 1
1
• 10
55231-NL9-000
STAY, BREATHER CASE ............................................................................................... 1
1
11
81351-124-830
RUBBER CARRIER MOUNT ........................................................................................... 2
2
12
90104-KR3-670
BOLT METER SET .......................................................................................................... 2
2
13
90525-030-000
WASHER B, HANDLE HOLDER...................................................................................... 2
2
14
94050-06000
NUT FLANGE 6MM......................................................................................................... 2
2
15
96001-06020-00
BOLT, FLANGE, SH, 6X20 .............................................................................................. 2
2
4-14
Remarks
Block No.
F-3
EXHAUST SET
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06183-NL9-000
EXHAUST SET ............................................................................................................... 1
1
• 2
18291-NL9-000
GASKET, EXH PIPE........................................................................................................ 4
4
• 3
18293-NL9-000
FLANGE, EXH................................................................................................................. 4
4
• 4
18295-NL9-000
COLLAR, EXH................................................................................................................. 4
4
• 5
18300-NL9-000
PIPE ASSY, EXH............................................................................................................. 1
1
• 6
18301-NL9-000
PIPE COMP, EXH(#1) ..................................................................................................... 1
1
• 7
18302-NL9-000
PIPE COMP, EXH(#2) ..................................................................................................... 1
1
• 8
18303-NL9-000
PIPE COMP, EXH(#3) ..................................................................................................... 1
1
• 9
18304-NL9-000
PIPE COMP, EXH(#4) ..................................................................................................... 1
1
• 10
18305-NL9-000
JOINT A, EXH PIPE ........................................................................................................ 1
1
• 11
18309-NL9-000
PIPE COMP,TAIL ............................................................................................................ 1
1
• 12
18320-NL9-000
STAY, EXH PIPE JOINT ................................................................................................. 1
1
• 13
18334-NL6-000
SPRING, EXH PIPE......................................................................................................... 15
15
• 14
18370-NL9-000
BAND, MUFFLER ........................................................................................................... 1
1
• 15
18375-NL9-000
STAY, MUFFLER ............................................................................................................ 1
1
• 16
18380-NL9-000
MUFFLER COMP............................................................................................................ 1
1
17
18421-MN5-000
RUBBER, MUFF MOUNT................................................................................................ 1
1
18
19051-KA3-830
RUBBER, RAD.MOUNT .................................................................................................. 1
1
19
19052-MAC-680
COLLAR, RAD MT........................................................................................................... 1
1
20
90201-GCC-C50
NUT, HEX., 7MM ............................................................................................................ 2
2
Remarks
4-15
Block No.
F-3
EXHAUST SET
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
21
90202-MBB-000
COLLAR, 8X18 ................................................................................................................ 2
2
22
93404-06025-00
BOLT-WASHER, 6X25..................................................................................................... 1
1
23
94050-06000
NUT, FLANGE, 6MM....................................................................................................... 1
1
24
94050-08000
NUT, FLANGE, 8MM....................................................................................................... 1
1
25
95701-06010-00
BOLT, FLANGE, 6X10 ..................................................................................................... 2
2
26
95701-08020-00
BOLT, FLANGE, 8X20 ..................................................................................................... 8
8
27
95701-08055-00
BOLT, FLANGE, 8X55 ..................................................................................................... 1
1
4-16
Remarks
Block No.
F-4
FRONT FORK
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
51400-MEL-R10
FORK ASSY, R FRONT .................................................................................................. 1
1
• 2
51401-MEL-R10
SPRING, FR FORK 0.95.................................................................................................. 2
2
•
51401-NL9-900
SPRING, FR FORK 0.90.................................................................................................. 2
2
•
51402-NL9-900
SPRING, FR FORK 1.00.................................................................................................. 2
2
• 3
51403-MEL-R10
COLLAR, SPRING........................................................................................................... 2
2
• 4
51404-MEL-R11
COLLAR B, SPRING ....................................................................................................... 2
2
• 5
51406-MEL-R11
STOPPER, SPRING SEAT .............................................................................................. 2
2
6
51410-MEL-003
TUBE, OUTER ................................................................................................................. 2
2
7
51412-MEL-003
RING, BACK UP............................................................................................................... 2
2
8
51414-MAZ-003
BUSH, GUIDE.................................................................................................................. 2
2
9
51415-MAZ-003
BUSH, SLIDER ................................................................................................................ 2
2
10
51423-MCJ-751
RING B, STOPPER .......................................................................................................... 2
2
11
51425-MEL-003
PIPE COMP., R. SLIDE.................................................................................................... 1
1
12
51430-MEL-003
DAMPER COMP., FR. ..................................................................................................... 2
2
13
51447-KA4-711
RING, OIL SEAL STOPPER ............................................................................................. 2
2
14
51450-MEL-003
BOLT, FR. FORK ............................................................................................................. 2
2
15
51451-MEL-003
NUT, LOCK...................................................................................................................... 2
2
16
51453-MCJ-751
PLATE B, ADJUSTING .................................................................................................... 2
2
17
51455-MW4-003
RING, STOPPER.............................................................................................................. 2
2
18
51456-MCJ-751
RING, STOPPER.............................................................................................................. 2
2
Remarks
4-17
Block No.
F-4
FRONT FORK
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
19
51490-MEJ-003
SEAL SET, FR. FORK ...................................................................................................... 2
2
20
51496-MCJ-751
LABEL ............................................................................................................................. 2
2
• 21
51500-MEL-R10
FORK ASSY,L FRONT.................................................................................................... 1
1
22
51525-MEL-003
PIPE COMP., L. SLIDE .................................................................................................... 1
1
23
52442-KA3-711
WASHER, SPECIAL, 10MM............................................................................................ 2
2
24
53702-MCJ-751
PLATE, SPRING ADJUSTER ........................................................................................... 2
2
25
90109-MR7-000
BOLT, FLANGE, 8X45 ..................................................................................................... 4
4
26
90126-MR7-003
BOLT, SOCKET, 10X35 ................................................................................................... 2
2
27
91254-MEJ-003
DUST SEAL ..................................................................................................................... 2
2
28
91255-MCJ-751
O-RING, 10.8X2.4............................................................................................................ 2
2
29
91256-MCJ-751
O-RING, 23.3X2.4............................................................................................................ 2
2
30
91257-MCJ-751
O-RING, 9.5X1.5.............................................................................................................. 2
2
31
91258-GF4-003
O-RING, 42.2X2.4............................................................................................................ 2
2
4-18
Remarks
Block No.
F-5
SWINGARM
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06405-NL9-000
DRIVE CHAIN ADJ SET ................................................................................................. 1
1
• 2
40542-NL9-000
ADJ, R DRIVE CHAIN..................................................................................................... 1
1
• 3
40543-NL9-000
ADJ, L DRIVE CHAIN ..................................................................................................... 1
1
• 4
40544-NL9-000
LID, L DRIVE CHAIN ADJ............................................................................................... 1
1
• 5
40545-NL9-000
SPACER, ADJ DRIVECHAIN L ....................................................................................... 1
1
6
41405-HA7-670
RING, STOPPER.............................................................................................................. 1
1
• 7
42301-NL9-000
AXLE, REAR WHEEL...................................................................................................... 1
1
• 8
42302-NL6-700
GUIDE, RR AXLE CNT ................................................................................................... 1
1
• 9
42304-NL9-000
COLLAR, RR AXLE R SIDE ............................................................................................ 1
1
• 10
42305-MEL-R10
COLLAR L, RR AXLE ...................................................................................................... 1
1
• 11
42306-MEL-R10
COLLAR R, RR AXLE...................................................................................................... 1
1
• 12
42307-MEL-R10
COLLAR, R JOINT .......................................................................................................... 1
1
• 13
42314-NL9-000
COLLAR, RR AXLE L SIDE............................................................................................. 1
1
• 14
52100-MEL-R10
SWINGARM ASSY......................................................................................................... 1
1
• 15
52157-NL3-650
PROTECTOR, SPRKT ..................................................................................................... 1
1
• 16
90106-NL9-000
BOLT, HEX, 8X55 ........................................................................................................... 2
2
• 17
90308-NL9-000
NUT, RR AXLE ............................................................................................................... 1
1
• 18
90536-NL9-000
WASH, RR AXLE ............................................................................................................ 1
1
Remarks
4-19
Block No.
F-5
SWINGARM
2004 CBR1000RR
Ref.
No.
19
Part No.
Description
Reqd. No.
SP AMA
93500-05020-0A
SCREW, PAN, 5X20 ........................................................................................................ 2
2
93500-05035-0A
SCREW, PAN, 5X35 ........................................................................................................ 2
2
93500-05050-0A
SCREW, PAN, 5X50 ........................................................................................................ 2
2
20
94050-05000
NUT, FLANGE, 5MM....................................................................................................... 2
2
21
96001-06012-00
BOLT, FLANGE, SH, 6X12 .............................................................................................. 2
2
4-20
Remarks
Block No.
F-6
REAR CUSHION
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
52400-MEL-R10
CUSHION ASSY, RR ...................................................................................................... 1
1
• 2
52401-MEL-R10
SPRING, RR CHSH 10.0 ................................................................................................. 1
1
•
52401-NL9-900
SPRING, RR CHSH 9.5 ................................................................................................... 1
1
•
52402-NL9-900
SPRING, RR CHSH 10.5 ................................................................................................. 1
1
•
52403-NL9-900
SPRING, RR CHSH 11.0 ................................................................................................. 1
1
•
52404-NL9-900
SPRING, RR CHSH 11.5 ................................................................................................. 1
1
• 3
52430-MEL-R10
STAY, RR CUSH ADJ..................................................................................................... 1
1
• 4
52460-MEL-R10
ARM ASSY, CUSHION .................................................................................................. 1
1
5
52463-KZ4-B00
COLLAR D, CUSHION....................................................................................................
1
1
6
52463-MEE-000
COLLAR, CUSHION ARM ..............................................................................................
1
1
7
52464-MEE-000
COLLAR, BEARING SIDE ...............................................................................................
2
2
8
52466-MEE-000
COLLAR A, CUSHION ARM...........................................................................................
1
1
9
52467-MEE-000
WASHER, THRUST ........................................................................................................
4
4
• 10
52470-MEL-R10
CONN ROD ASSY, CUSHION ....................................................................................... 1
1
11
52472-MEL-000
COLLAR, CONNECTING ROD PIVOT ............................................................................
1
1
12
91071-MY1-005
BEARING, NEEDLE, 17X24X17......................................................................................
6
6
13
91074-KZ4-B01
BEARING, NEEDLE, 19X26X15......................................................................................
1
1
14
91262-KV3-831
DUST SEAL, 17X24X5 (ARAI).........................................................................................
6
6
15
91351-MAC-671
DUST SEAL, 16X26X3 ....................................................................................................
2
2
Remarks
4-21
Block No.
F-7
STEERING DAMPER
2004 CBR1000RR
Ref.
No.
• 1
Part No.
53700-NL9-003
4-22
Description
Reqd. No.
SP AMA
DAMPER ASSY, STRG .................................................................................................. 1
1
Remarks
Block No.
F-8
RADIATOR
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
19010-MEL-R11
RADIATOR COMP .......................................................................................................... 1
1
• 2
19502-MEL-R10
HOSE, OIL/C ................................................................................................................... 1
1
• 3
19503-MEL-R10
HOSE RADIATOR L........................................................................................................ 1
1
Remarks
4-23
Block No.
F-9
FRAME PARTS
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06531-NL3-750
HOUSING SET, THROT ................................................................................................. 1
1
• 2
17910-NL9-000
CABLE COMP A, THROT ............................................................................................... 1
1
• 3
17920-NL9-000
CABLE COMP B, THROT ............................................................................................... 1
1
• 4
22900-NL6-000
HOSE, CLUTCH .............................................................................................................. 1
1
• 5
35200-MEL-R10
SW ASSY, WINKER ....................................................................................................... 1
1
• 6
37100-MEL-R10
METER ASSY, COMB .................................................................................................... 1
1
7
53141-MT7-000
PIPE, THROT GRIP.......................................................................................................... 1
1
8
53167-KV3-701
HOUSING, THROT UP .................................................................................................... 1
1
9
53168-KV3-701
HOUSING, THROT UND ................................................................................................. 1
1
10
93500-05020-0G
SCREW, PAN, 5X20 ........................................................................................................ 2
2
4-24
Remarks
Block No.
F10
WIRE HARNESS
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06321-NL9-000
HARNESS SET ............................................................................................................... 1
1
2
17556-MEL-300
FILM A, PROTECTOR ..................................................................................................... 1
1
3
18357-KA4-710
COLLAR, SILENCER ....................................................................................................... 2
2
• 4
32100-NL9-000
HARNESS, WIRE............................................................................................................ 1
1
• 5
35130-NL6-000
SW ASSY, ST KILL......................................................................................................... 1
1
• 6
35160-NKC-000
SENSOR ASSY, KILL ..................................................................................................... 1
1
• 7
35400-NL9-000
REGISTER COMP ........................................................................................................... 1
1
8
38500-GC7-612
RELAY ASSY, START ...................................................................................................... 1
1
• 9
38520-NL9-000
STAY, RELAY ................................................................................................................. 1
1
• 10
38770-NL9-000
UNIT ASSY., PGM-FI / IGN............................................................................................ 1
1
• 11
38771-NL9-000
CD-ROM, PGM-FI / IGN ................................................................................................. 1
1
• 12
38880-NL3-750
UNIT ASSY, SERIAL I/F ................................................................................................. 1
1
• 13
64502-NL9-000
STAY, ECU ..................................................................................................................... 1
1
• 14
64503-NL9-000
STAY, CATCH TANK...................................................................................................... 1
1
15
90620-SB2-003
BAND, WIRE HARN ........................................................................................................ 1
1
16
90649-SC2-003
BAND, HARNESS............................................................................................................ 1
1
• 17
91080-NL6-300
POP RIVET 3.2X9.2 ........................................................................................................ 2
2
• 18
91081-ND4-750
BLIND RIVET 3.2X8........................................................................................................ 2
2
19
91406-657-671
CLIP, WIRE HARNESS .................................................................................................... 1
1
20
93891-04022-07
SCREW-WASHER, 4X22 ................................................................................................. 2
2
Remarks
4-25
Block No.
F-10
WIRE HARNESS
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
21
94001-06000-0S
NUT, HEX, 6MM ............................................................................................................. 2
2
22
94050-04000
NUT, FLANGE,4MM........................................................................................................ 2
2
23
94101-03000
WASHER, PLAIN,3MM ................................................................................................... 2
2
24
94103-06000
WASHER, PLAIN ,6MM .................................................................................................. 2
2
25
94591-27000
CLIP, 2X70....................................................................................................................... 1
1
26
96001-06022-00
BOLT, FLANGE,SH,6X22 ................................................................................................ 2
2
4-26
Remarks
Block No.
F-11
REAR WHEEL
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
1
40540-MAS-005
CHAIN, DRIVE RKGB525R0Z1-120LJF ........................................................................... 1
1
2
40545-MAS-005
JOINT, DRIVE CHAIN...................................................................................................... 1
1
• 3
41238-NL6-700
SPRKT, FINAL DRIVE 38T.............................................................................................. 1
1
•
41239-NL6-700
1
•
41240-NL6-700
1
•
41241-NL6-700
1
•
41242-NL6-700
1
•
41243-NL6-700
1
• 4
42311-NL9-000
COLLAR, L DRIVEN FLANGE SIDE ............................................................................... 1
1
• 5
42312-NL6-000
COLLAR, R DRIVEN FLANGE SIDE............................................................................... 1
1
• 6
42603-NL6-000
WHEEL, REAR 6.00-17 ................................................................................................... 1
1
•
42606-NL6-000
WHEEL, REAR 6.00-16.5 ................................................................................................ 1
1
•
42608-NL6-000
WHEEL, REAR 6.25-16.5 ................................................................................................ 1
1
• 7
42609-NL6-000
FLANGE, FINAL DRIVEN ............................................................................................... 1
1
• 8
42621-NL6-000
RETAINER, RR WHEEL BRG.......................................................................................... 1
1
• 9
42624-NL6-000
COLLAR, RR WHEEL DISTANCE................................................................................... 1
1
• 10
42633-NL6-003
DAMPER, RR WHEEL..................................................................................................... 6
6
• 11
42720-NC8-000
WEIGHT, BALANCE (10G)............................................................................................. N
N
•
42721-NC8-000
N
12
42753-ML7-004
VALVE, RIM (DUNLOP)................................................................................................... 1
1
• 13
43121-NL6-000
DISK, RR. BRAKE ........................................................................................................... 1
1
Remarks
4-27
Block No.
F-11
REAR WHEEL
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 14
87000-NL6-000
TOOL, RETAINER A ....................................................................................................... 1
1
15
90003-MC7-000
BOLT, FLANGE, 6X20 ..................................................................................................... 4
4
• 16
90120-NL6-300
BOLT, DRIVEN FLANGE 8MM ...................................................................................... 6
6
17
90309-KF0-003
NUT, FLANGE, 8MM....................................................................................................... 6
6
• 18
90501-NL6-000
WASHER, RR WHEEL BRG............................................................................................ 1
1
19
90651-ML0-731
CIRCLIP, INTERNAL, 62.................................................................................................. 1
1
• 20
91051-NL6-000
BRG., BALL RADIAL 6205 2RS...................................................................................... 2
2
• 21
91052-NL6-003
BRG., ANGULAR 30X62X23.8....................................................................................... 1
1
4-28
Remarks
Block No.
F-12
FRONT WHEEL
2004 CBR1000RR
Ref.
No.
1
• 2
Part No.
Description
Reqd. No.
SP AMA
41231-KZ4-000
RETAINER, RR WHEEL BRG .......................................................................................... 1
1
42720-NC8-000
N
42721-NC8-000
N
3
42753-ML7-004
VALVE, RIM (DUNLOP)................................................................................................... 1
1
• 4
44301-NL6-000
AXLE, FR WHEEL ........................................................................................................... 1
1
• 5
44303-NL9-000
NUT, FR AXLE................................................................................................................ 1
1
• 6
44304-NL9-000
GUIDE A, FR AXLE......................................................................................................... 1
1
• 7
44305-NL9-000
GUIDE B, FR AXLE......................................................................................................... 1
1
• 8
44311-NL6-000
COLLAR, FR WHEEL SIDE ............................................................................................. 2
2
• 9
44601-NL6-000
WHEEL, FR,17X3.50....................................................................................................... 1
1
•
44602-NL6-000
WHEEL, FR,16.5X3.5...................................................................................................... 1
1
•
44603-NL6-000
WHEEL, FR,17X3.75....................................................................................................... 1
1
• 10
44620-NL6-010
COLLAR, FR WHEEL DISTANCE ................................................................................... 1
1
• 11
90305-NL6-000
NUT, M28X1.0................................................................................................................ 1
1
• 12
90503-NL6-000
WASHER, 45X22X3 ....................................................................................................... 1
1
• 13
90525-NL9-000
SHIM 0.2, FR FORK SIDE............................................................................................... 2
2
•
90526-NL9-000
SHIM 0.3, FR FORK SIDE............................................................................................... N
N
91051-KZ4-J21
BEARING, RADIAL, BALL 6905 2RS............................................................................... 2
2
14
Remarks
4-29
Block No.
F-13
BRAKE
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
43100-NL5-701
CALIPER ASSY, RR ........................................................................................................ 1
1
• 2
43105-NL5-700
PAD COMP, RR (X95) .................................................................................................... 2
2
•
43105-NL6-700
PAD COMP, RR (TT2450)............................................................................................... 2
2
3
43110-MEL-R11
BRACKET COMP, RR...................................................................................................... 1
1
• 4
43110-NL9-000
BRKT, RR CALIPER ........................................................................................................ 1
1
5
43112-MCF-006
RETAINER, RR. BRACKET .............................................................................................. 1
1
• 6
45105-NL9-000
PAD CPMP, FR (N614) ................................................................................................... 4
4
•
45105-NL9-900
PAD CPMP, FR (N608) ................................................................................................... 4
4
• 7
45250-NL5-800
DISK COMP, FR 320....................................................................................................... 2
2
• 8
45500-NL5-701
M/C ASSY, BR L18 ......................................................................................................... 1
1
• 9
45520-NL5-701
CUP ASSY, FR M/C ........................................................................................................ 1
1
• 10
53160-NL5-701
LEVER, FR. BRAKE L 18P............................................................................................... 1
1
11
90003-MC7-000
BOLT, FLANGE, 6X20 ..................................................................................................... 12
12
12
90104-GT8-600
SCREW, SPECIAL, 6X14 ................................................................................................. 1
1
13
95002-40850-08
CLAMP, TUBE (D8.5) ...................................................................................................... 2
2
14
95003-11015-60
TUBE, VINYL, 5X9X150................................................................................................... 1
1
4-30
Remarks
Block No.
F-14
QUICK SHIFTER SET
2004 CBR1000RR
Ref.
No.
Part No.
Description
Reqd. No.
SP AMA
• 1
06382-NL9-000
QUICK SHIFTER SET ..................................................................................................... 1
1
2
30401-GB6-000
CUSHION, CDI UNIT ....................................................................................................... 1
1
• 3
38200-NL9-000
SENSOR ASSY, Q/SHIFT............................................................................................... 1
1
• 4
38300-NL9-000
UNIT ASSY, Q/SHIFT..................................................................................................... 1
1
• 5
38410-NL9-000
CD-ROM, Q/SHIFTER ..................................................................................................... 1
1
• 6
38411-NL9-000
USB CABLE .................................................................................................................... 1
1
• 7
38520-NL9-000
STAY, RELAY ................................................................................................................. 1
1
• 8
91080-NL6-300
POP RIVET, 3.2X9.2 ....................................................................................................... 2
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
Damage Prevention 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.
You will also see other important messages that are preceded by the word
NOTICE.
This word means:
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:
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.
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.
Each message tells you what the hazard is, what can happen and what you
can do to avoid or reduce injury.
00. Introduction_r1
04.4.27 18:10
Page 3
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.
00. Introduction_r1
04.4.27 18:10
Page 4
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.
Item
Engine
2004 Standard
Type
–
Cylinder arrangement
28˚ inclined inline four
–
Bore and stroke
75.0 x 56.5 mm
–
3
Displacement
998.4 cm
Compression ratio
11.9 : 1
13.6 : 1
Head gasket thickness
t0.4
t0.6
Valve train
DOHC, chain driven
Valve timing
Intake
Exhaust
Electrical
2004 Racing Kit (Super Bike Kit)
Water cooled 4-stroke DOHC 16 valve
Spark plug
–
–
opens
18˚ BTDC
22˚ BTDC
close
46˚ ABDC
53˚ ABDC
opens
39˚ BBDC
47˚ BBDC
close
11˚ ATDC
23˚ ATDC
NGK: IMR9C-9HES, DENSO: VUH27ES
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
04.4.27 18:11
Page 2
Service Information
Torque Values
Standard Torque
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
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)
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
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
Connecting rod bolt
M8 x 0.75
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)
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
Remarks
Apply oil
Included SH bolt; apply oil
Apply oil
Apply oil
Apply oil
Included NSHF bolt; apply oil
Apply oil
Apply oil
Engine
Item
Main journal bolt
Crankcase bolt
Starter clutch outer bolt
Flywheel bolt
1-2
Standard
Racing kit
M10 x 1.25
M10 x 1.25
M10 x 1.25
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
04.4.27 18:11
Page 3
Service Information
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
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
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
–
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)
–
–
Remarks
Apply LOCKTITE
Apply LOCKTITE
Apply LOCKTITE
Apply LOCKTITE
CT bolt
Apply LOCKTITE
Apply oil
Apply oil
CT bolt
CT bolt
Left hand thread
Apply oil
271
271
271
271
271
Wire lock
Apply LOCKTITE 271
Apply oil
Apply oil
Apply LOCKTITE 271
Apply LOCKTITE 271
Apply oil
Apply oil
Apply Three bond 1207B
Band width: 7 ± 1 mm
Tightening width: 1 mm on each side
1-3
04.4.27 18:11
Page 4
Service Information
Frame
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
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
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
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)
Steering stem nut
M24 x 1.0
98 (10.0, 72)
Handlebar stopper bolt
Top bridge/bottom bridge pinch bolt
M8 x 1.25
M8 x 1.25
9.8 (1.0, 7)
22 (2.2, 16)
Item
1-4
Remarks
Apply molybdenum grease to the threads
Apply LOCKTITE 271
Apply LOCKTITE 271
Apply LOCKTITE 271
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
04.4.27 18:11
Page 5
Service Information
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
Apply
Apply
Apply
Apply
Apply
Apply
molybdenum
molybdenum
molybdenum
molybdenum
molybdenum
molybdenum
grease to the threads
1-5
04.4.27 18:11
Page 6
Service Information
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
Material
Elf XT3818 oil
Main journal bearing sliding surface
Connecting rod bearing
Crankshaft thrust surface
Molybdenum disulfide oil
(a mixture of 1/2 Elf XT3818 oil
and 1/2 of molybdenum
disulfide grease)
Timing hole cap threads
Each oil seal lips
Balancer rubber contact surface
Multi-purpose grease
Crankcase mating surface
Crankcase/cover mating surface
Oil pan mating surface
Three bond 1207B or an
equivalvent
1-6
Remarks
3.3 to 3.8 liter
Do not apply more than necessary
Do not apply more than necessary
04.4.27 18:11
Page 7
Service Information
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
Material
Multi-purpose grease
Front axle bolt threads
Rear axle bolt threads
UN-LOCK (manufactured by
NCH) or molybdenum grease
Fuel pump connector
Clutch lever-to-master piston contact area
Rear brake master piston-to-push rod contact area
Silicone grease
Throttle cable sliding surface
Gearshift pedal link/rear brake pedal rod end
Throttle pipe inner surface
CRC
Handle grip inner surface
Seat rubber
Seat back rubber
Honda Bond A
Fork inside
Fork oil seal lip
Fork fluid
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
Locking agent
Clutch master cylinder inside
Brake master cylinder/caliper inside
AP600 or
DOT 4 brake fluid
Clutch slave cylinder
CCI Metal rubber MR20
Remarks
or BELL-CLAW TAPE
1-7
04.4.27 18:11
Page 8
Service Information
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
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
Each race
or about
2.5 hours
I
I
I
I
R
R
I
I
I
I
I
I
I
I
I
I
I
I
I, L
I
I
Brake Fluid
I
Brake Pad Wear
Brake System
Clutch System
I
I
I
Clutch Fluid
I
Exhaust Pipe/Muffler
Suspension
Nuts, Bolts, Fasteners
Wheels And Tires
Steering Head Bearings
I
I
I
I
I
Remarks
R:
R:
R:
R:
R:
every
every
every
every
every
2,000
3,000
6,000
3,000
3,000
km
km
km
km
km
(1,200
(1,850
(3,700
(1,850
(1,850
mi)
mi)
mi)
mi)
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
04.4.27 18:11
Page 9
Service Information
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
Replacement Interval
Cause
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)
Every 3,000 km (1,850 mi)
–
Every 3,000 km (1,850 mi)
–
Every 6,000 km (3,700 mi)
Repalce with crankcase
Every 6,000 km (3,700 mi)
Replace with connecting rod
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)
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)
Sleeve wear or other damage
Tightening torque
Cracks
Valve seat warpage
Gear wear, Crankpin/main journal wear or damage
Wear or damage
Small end wear or damage
Wear or damage
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
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
04.4.27 18:11
Page 10
Service Information
Removal/Replacement Parts
Ignition switch
Rearview mirror
Pillion step
Pillion seat
Tail/brake light
License light
Replace the combination
meter with the racing kit
Turn signal light
Replace the standard
bank angle sensor with
the racing kit sensor.
Rear fender A
Headlight unit
Variable air intake
diaphragm/chamber
1-10
Horn
Cooling fan motor
Side stand switch
Rear brake light
switch
Chain case
04.4.27 18:11
Page 11
Service Information
Cable & Harness Routing
9
18
10
7
6
1
14
12
17
13
8
16
15
2
11
3
19
20
No.
1
2
3
4
5
6
Item
Combination meter
Bracket, bank angle sensor
Sensor assy., bank angle
CD-ROM, PGM-FI/IGN
Unit assy., serial I/F
Sub harness, IGN
No.
7
8
9
10
11
12
Item
Coil, cap & ignition
Harness, wire
Band, battery
Battery
Band, PGM-FI unit
Bracket, PGM-FI unit
No.
13
14
15
16
17
18
Item
Unit, PGM-FI
Cable, starter battery
Cable, starter motor
Battery ground cable
Switch assy., starter magnetic
Relay, fuel cut
No.
Item
19 Spacer, regulator/rectifier
20 Rectifier assembly., regulator
1-11
04.4.27 18:11
Service Information
Wiring Diagram
1-12
Page 12
02. Racing Kit6
04.4.27 18:20
Page 1
2. Racing Kit
Replacement Necessary Parts
Refer to CBR1000RR SHOP MANUAL (62MEL00) for replacement procedure.
Camshafts
Use following intake and exhaust camshafts.
• 14110-MEL-R10
CAMSHAFT COMP., IN
• 14210-MEL-R10
CAMSHAFT COMP., EX
Intake valve springs.
• 14751-MEL-R10
SPRING, IN VALVE
Clutch springs.
• 22401-MEL-R10
SPRING, CLUTCH
Spark plugs.
• 31910-NL3-620
PLUG, SPARK, R0045Q-10
Additional kit for Super Bike
Piston and piston rings.
• 13101-NL9-000
PISTON
• 13112-NL9-000
CLIP, PISTON PIN 17 mm
• 13121-NL9-000
RING, PISTON TOP 75 x 0.8 x 2.3
• 13131-NL9-000
RING, PISTON 2ND 75 x 0.8 x 2.4
• 13141-NL9-000
RING, PISTON TOIL 75 x 1.5 x 1.95
Intake and exhaust valves.
• 14711-NL9-000
VALVE, INLET (29)
• 14721-NL9-000
VALVE, EXHAUST (24)
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
Racing Kit
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
0.2 mm
(0.03 in)
Use 0.6 mm thickness gasket.
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.
Racing kit
Standard
Gear ratio (T= Teeth)
Gear ratio (T= Teeth)
1st
2.286 (14/32T)
2.538 (13/33T)
2nd
1.941 (17/33T)
1.941 (17/33T)
3rd
1.667 (18/30T)
1.578 (19/30T)
4th
1.500 (20/30T)
1.380 (21/29T)
5th
1.348 (23/31T)
1.250 (20/25T)
6th
1.227 (22/27T)
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
Racing Kit
ACG Set Installation
1. Remove the standard AC generator cover and flywheel.
Flywheel
Replace the ACG set and the upper and lower crankcase as a set.
2.
3.
4.
5.
Clean any oil off from the crankshaft taper.
Install and racing kit flywheel to the crankshaft.
Apply engine oil to the flywheel mounting bolt threads and seating surface.
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.
Stator
AC generator cover
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
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
Racing Kit
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
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
4. Further tighten the main journal bolts 60 degrees in numerical order.
5. Further tighten the main journal bolts 60 degrees in numerical order
2-7
02. Racing Kit6
04.4.27 18:20
Page 8
Racing Kit
Engine Hanger Tightening Sequence
POINT C
APPLY MOLYBDENUM
DISULFIDE GREASE
APPLY MOLYBDENUM
DISULFIDE GREASE
POINT B
POINT D
APPLY MOLYBDENUM
DISULFIDE GREASE
POINT A
APPLY MOLYBDENUM
DISULFIDE GREASE
APPLY MOLYBDENUM
DISULFIDE GREASE
POINT B
APPLY MOLYBDENUM
DISULFIDE GREASE
2-8
POINT A
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:
Scale reading:
54 N•m (5.5 kgf•m, 40 lbf•ft)
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.
17. Tighten the right side middle engine hanger bolt
(B) to the specified torque.
11. Tighten the rear upper engine hanger adjusting
bolt lock nut (C) to the specified torque.
Install the removed parts in the reverse order of
removal.
Tool:
Lock nut wrench, 5.8 X 46 mm
07VMA-MBB0100 or 07VMA-MBB0101
Torque:
Actual:
Scale reading:
C
54 N•m (5.5 kgf•m, 40 lbf•ft)
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.
D
A
B
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.
2-9
02. Racing Kit6
04.4.27 18:20
Page 10
Racing Kit
Wire Lock
Drill hole (3 - 4 mm)
Before riding the machine, secure the following bolts and nuts:
– Engine oil filler cap
– Engine oil drain plug
– Oil filter cartridge
1.
2.
3.
4.
Oil filler cap
Insert the proper length locking wire to the bolt.
Twist the wire using a commercially available wire twisting tool.
Insert the wire in the other side hole, and twist the wire.
Cut off any excess wire.
Wire twisting tool
No good
Good
Sub-tank band
Oil filter cartridge
Drain plug
• 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
Drill hole (3 - 4 mm)
02. Racing Kit6
04.4.27 18:20
Page 11
Racing Kit
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.
5.
6.
7.
Remove the gearshift pedal and pedal link.
Install the pedal rod sensor into the pedal link rod.
Connect the sensor connector to the quick shift unit connector.
Reinstall the gearshift pedal and pedal link.
Pedal link
Rubber suspension
Pedal rod sensor
Pedal link rod
Quick shift unit
45mm
Z
10mm
Z
3.3 - 3.5 mm
16mm
Gearshift pedal
2-11
02. Racing Kit6
04.4.27 18:20
Page 12
Racing Kit
Secondary Air Supply System Removal
Thermostat and Bypass Hose 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.
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.
Cone plug
(racing kit)
Clamp
(racing kit)
Clamp
(racing kit)
Remove
them
Remove
them
Rubber
(standard)
Washer
(racing kit)
Plugs
(racing kit)
Cone plug
(racing kit)
Clamp
(racing kit)
Remove
them
50 mm
Cone plug
(racing kit)
2-12
50 mm
Clamp
(racing kit)
Clamp
(racing kit)
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.
Link
(remove)
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.
Remove
Screw
(remove)
Plug
(racing kit)
Remove
Plug
(racing kit)
Wax unit
(remove)
Bracket
Throttle stop screw set
2-13
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04.4.27 18:20
Page 14
Racing Kit
Variable Air Intake Valve Removal/Air Duct Installation
Radiator Kit 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.
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.
Remove
Heat resisitance tape
Radiator
(Racing kit)
Oil cooler water hose
(Racing kit)
Right radiator bracket
(Racing kit)
Air duct
(racing kit)
2-14
Left radiator bracket
(Racing kit)
Lower radiator hose
(Racing kit)
02. Racing Kit6
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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
Under throttle
housing
Throttle cable B
Upper throttle
housing
Boss (grind off)
Starter/engine
stop switch
Throttle cable A
2-15
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Page 16
Racing Kit
Oil Catch Tank Installation
Air Funnel/Air Cleaner Element Replacement
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.
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)
Air funnel (#3)
Breather return tube
Air funnel (#2)
Air funnel (#1)
Breather tube
Tongued washer
Oil catch tank
2-16
Air cleaner elements
(racing kit)
02. Racing Kit6
04.4.27 18:21
Page 17
Racing Kit
Steering Stem Modifying
Steering Damper Replacement
1. Make the stopper pieces from aluminium block. The piece dimensions are
shown in the illustration below.
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.
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.
Bottom bridge
Stopper piece
Frame body
2-17
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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
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Page 19
Racing Kit
Rear Fender B Modification
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.
1. Cut and remove the indicated portion of the rear fender B.
Relay
Bracket
Cut area
Rear fender B
2-19
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04.4.27 18:21
Page 20
Racing Kit
Exhaust Pipe Inner Protector Modification
Exhaust Pipe/Muffle Replacement
Cut and remove the indicated portion of the exhaust pipe inner protector.
Remove the muffler and exhaust pipe (see Shop Manual).
Remove the exhaust pipe stud bolts using the 7 mm nuts in the racing kit.
Inner protector
Install a racing kit exhaust pipe and muffler as shown.
Muffler comp.
Muffler stay
Inner protector
Muffler band
2-20
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04.4.27 18:21
Page 21
Racing Kit
Drive Chain Guard Installation
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.
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.
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
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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
Driven
38T
39T
40T
41T
42T
43T
114L
114L
114L
114L
116L
116L
116L
116L
114L
114L
114L
116L
116L
116L
116L
116L
112L
15T
114L
114L
16T
118L
17T
114L
114L
114L
116L
116L
116L
116L
: Use 8 x 55 mm drive chain adjusting bolts
2-22
116L
116L
118L
118L
02. Racing Kit6
04.4.27 18:21
Page 23
Racing Kit
(1)
(2)
(1)
(3)
(4)
(2)
(1) PRE-LOAD ADJUST PLATE B
(2) STOPPER RING
(1) FORK SPRING (2) SPRING COLLAR
(3) SPRING SEAT STOPPER
(4) SPRING COLLAR B
(1)
(1)
(2)
Remove the following:
– Spring collar B
– Spring seat stopper
– Spring collar
– Fork spring
Three optional for springs are available.
(3)
(2)
(1) O-RING (2) FORK BOLT
(1) DAMPER ROD ADJUST CASE
(2) LOCK NUT (3) FORK BOLT
Fork Spring Replacement
Push the fork slider slowly down, and gently seat the
dust seal onto the axle holder.
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.
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.
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.
SPRING RATE LETTER
2-23
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04.4.27 18:21
Page 24
Racing Kit
(1)
(1)
(3)
(2)
(2)
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.
(1) TAPERED END
(2) FORK SPRING
(1) DAMPER ROD HOLDER
(2) SPRING COLLAR
(3) SPRING SEAT STOPPER
Install the fork spring into the fork slider with the
tapered end facing up.
Extend the fork damper fully and install the damper
rod holder onto the damper rod adjust case.
TOOL:
Damper rod holder
Showa special tool
070MB-MEL0200 or
070MB-MELC200 or
No.301
Install the spring collar and spring seat stopper.
2-24
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04.4.27 18:21
Page 25
Racing Kit
(1)
(1)
(2)
(3)
(2)
(1)
(3)
(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) 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
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Page 26
Racing Kit
(1)
(1)
(1)
(2)
(2)
(1) LOCK NUT
(1) O-RING (2) FORK BOLT
(1) PRE-LOAD ADJUST PLATE B
(2) STOPPER RING
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.
Install the fork bolt to the fork slider.
Install new O-ring to the damper rod adjust case.
Install the pre-load adjust plate B and stopper ring.
Remove the 14 mm spanner from the damper rod
adjust case.
2-26
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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
Suspension Setting
Three optional rear cushion springs are available.
Rebound Damping Adjuster
The rebound damping adjuster clockwise until it
stops (full hard position), then turn the adjuster
counterclockwise.
52403-NL9-901 108.0 N/mm (K=11.0)
Black
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.
52404-NL9-901 113.0 N/mm (K=11.5)
Green
Standard position: 6 turns in from full soft
52405-NL9-901 118.0 N/mm (K=12.0)
Sliver
Part number
Spring rate
52401-NL9-901
93.2 N/mm (K=9.5)
52402-NL9-901 103.0 N/mm (K=10.5)
Identification
color
Blue
White
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) COMPRESSION DAMPING ADJUSTER (Lo)
(2) COMPRESSION DAMPING ADJUSTER (Hi)
(1) REBOUND DAMPING ADJUSTER
Hi-speed Compression Damping Adjuster
The hi-speed compression damping adjuster counterclockwise until it stops (full soft position), then
turn the adjuster clockwise.
Rebound Damping Adjuster
The rebound damping adjuster clockwise until it
stops (full hard position), then turn the adjuster
counterclockwise.
Standard position: 3 ± 0.25 turns in from full soft
Standard position: 5 – 8 clicks out from full hard
(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.
2-28
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
02. Racing Kit6
04.4.27 18:21
Page 29
Racing Kit
Optional Front Wheel
Front axle
Axle guide B
Axle guide A
Ball bearing (6905 2RS)
Washer
Distance collar
Shim
Bearing retainer
Side collar
Front axle nut
Axle nut
Side collar
Shim
2-29
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04.4.27 18:21
Page 30
Racing Kit
(2)
(2)
(1)
(1)
(2)
(1)
(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
Remove the bolts and brake discs.
Unstake the bearing retainer.
Remove the bearing retainer using a special tool.
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 right and left side collars using two
screw drivers as shown.
2-30
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.
Tools:
Retainer wrench B
Retainer wrench body
07710–0010200
07710–0010401
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04.4.27 18:21
Page 31
Racing Kit
(1)
(1)
(1)
(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.
Remove the right side bearing using the special
tools.
Assembly
Tools:
Driver
Attachment, 42 x 47 mm
Pilot, 25 mm
Press the right wheel bearing more than necessary,
or the right bearing fall into the wheel hub.
Tools:
Driver
Pilot, 25 mm
07749–0010000
07746–0010300
07746–0040600
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.
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)
(1)
(2)
(2)
(2)
(1) RETAINER WRENCH B
(2) RETAINER WRENCH BODY
(1) DRIVER
Install the distance collar, then drive the right side
bearing into the hub using the same tools.
Tools:
Driver
Pilot, 25 mm
(1) BRAKE DISC
(2) BOLTS
(2)
(1)
(1)
07749–0010000
07746–0010300
07746–0040600
(2)
(1) BEARING RETAINER
(2) PUNCH
Apply molybdenum disulfide grease to the new
bearing retainer threads and install it into the hub.
Tighten the bearing retainer using the special tools.
Install the brake discs and tighten the bolts to the
specified torque.
Tools:
Retainer wrench B
Retainer wrench body
07710–0010200
07710–0010401
Secure the bearing retainer with a punch.
2-32
Install the wheel side collars.
02. Racing Kit6
04.4.27 18:21
Page 33
Racing Kit
Front axle installed view from forward
(6)
(2)
(7)
(1)
(2)
(1) AXLE NUT (2) AXLE SIDE NUT
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.
(1)
(4)
(5)
(3)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
FRONT AXLE NUT
AXLE SIDE NUT
AXLE GUIDE A
AXLE GUIDE B
SHIMS
AXLE WASHER
AXLE BOLT
2-33
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04.4.27 18:21
Page 34
Racing Kit
(3)
(1)
(2)
(1) AXLE GUIDE A
(2) AXLE GUIDE B
(3) SHIM (S)
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
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04.4.27 18:21
Page 35
Racing Kit
Optional Rear Wheel
Damper rubber
Driven flange
Brake disc
15 N•m (1.5 kgf•m, 11 lbf•ft)
Circlip
Driven sprocket
Driven flange right
side collar
Angular bearing
(30 x 62 x 23.8)
Distance collar
Driven flange left
side collar
34 N•m (3.5 kgf•m, 25 lbf•ft)
Bearing washer
Bearing retainer
2-35
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04.4.27 18:21
Page 36
Racing Kit
(1)
(2)
(2)
(1)
(1)
(1) NUTS
(2) DRIVEN SPROCKET
(2) RETAINER TOOL
(1) DRIVEN FLANGE
(1)
Wheel Bearing Replacement
(2)
(3)
Remove the wheel bearing retainer using the special
tool.
Wheel bearing retainer has left hand threads.
Tool:
Retainer tool
(1)
(2) BOLTS (3) BRAKE DISC
(1) DAMPER RUBBERS
Disassembly
Remove the final driven flange assembly from the
left wheel hub.
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.
2-36
Remove the damper rubbers.
87000-NL6-000
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Page 37
Racing Kit
(1)
(1)
(1)
(2)
(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.
Remove the right side bearing using the special
tools.
Assembly
Tools:
Driver
Attachment, 52 mm
Pilot, 25 mm
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
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.
Apply oil to the bearing outer surface.
Drive the new left wheel bearing into the hub until it
seat.
Tools:
Driver
Attachment, 52 mm
Pilot, 25 mm
07749–0010000
07946–3710200
07746–0040600
2-37
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Page 38
Racing Kit
(1)
(2)
(1)
(2)
(2)
(1)
(1) DRIVER
(2) RETAINER TOOL
Install the distance collar, then drive the right side
bearing into the hub using the same tools.
Apply a locking agent to the bearing retainer threads
and install it into the hub.
The bearing retainer has left hand threads.
Tools:
Driver
Attachment, 52 mm
Pilot, 25 mm
07749–0010000
07946–3710200
07746–0040600
(1)
Tighten the bearing retainer to the specified torque.
Tool:
Retainer tool
87000–NL6–000
(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
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Page 39
Racing Kit
(1)
(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
Install the driven flange left side collar.
(1)
07749–0010000
07746–0010500
07746–0040600
(1) CIRCLIP
Install the driven flange right side collar.
Install the circlip into the groove securely.
2-39
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Page 40
Racing Kit
Assembly
(1)
(5)
(9)
(2)
(12)
(1) DAMPER RUBBERS
(1)
(2)
(11)
(1)
(10)
(3)
(8)
(4)
(6)
(7)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
LEFT DRIVE CHAIN ADJUSTING PLATE
LEFT DRIVE CHAIN ADJUSTING BOLT
REAR AXLE NUT
DRIVEN FLANGE COLLAR
DRIVEN FLANGE
REAR WHEEL
BRAKE DISC
(8)
(9)
(10)
(11)
(12)
REAR BRAKE CALIPER BRACKET
RIGHT DRIVE CHAIN ADJUSTING BOLT
RIGHT DRIVE CHAIN ADJUSTING PLATE
WASHER
REAR AXLE
(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
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Page 41
Racing Kit
(2)
(1)
(3)
(1) BRAKE DISC (2) BOLTS
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.
2-41
02. Racing Kit6
04.4.27 18:21
Page 42
Memo
03. Machine Setting_03
04.4.27 19:21
Page 1
3. Machine Setting
This section covers the ECU setting procedure by PC communications.
Software Install
ECU Setting
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.
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
2.The attachment
• UNIT, ASSY SERIAL I/F: 38880-NL3-750
3. A window like below will appear and will prepare for setup process.
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Machine Setting
4. Then, a window like below will appear. To continue setup, click “Next.”
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.”
NOTE:
• Exit all other programs before starting installation.
7. Select program folder, the clock “Next.”
5. When you using the Windows XP, the using information window is appered.
Click “Next.”
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Machine Setting
8. Confirm the folder and name etc. to install the application in, then click
“Next.”
10. Now, installation is completed.
Click “Finish.”
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.
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Machine Setting
Operation
Functional Descriptions
When you start up the setting tool, a window like below will appear.
(9)
(1)
(4)
Before you begin
• About the pull-down menu
Data Edit Selector of No. 4 in the previous section is a pull-down menu.
(2)
(5)
(3)
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.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Name
File information display
Open file
Save File
Data Edit Selector
Data display area
Data Read
Data Write
Quit
COM Port
Function
Displays information on the setting file.
Reads in setting data saved before.
Saves setting data you have changed.
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.
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Machine Setting
Connection with the Vehicle
• Checking communication port (COM port)
1. Connect the “UNIT, ASSY SERIAL I/F: 38880-NL3-750” to the serial-port of
your PC.
When you click “ CommPort”, pulldown
menu of communication ports will appear.
You can select from COM1 to 16.
Current setting is shown.
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.
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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.”
Type a file name and click OK to save your file.
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.
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.)
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Machine Setting
Changing Setting
If the process of Save File is aborted, the window below will appear.
Click “OK” to continue.
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.
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Machine Setting
Practice to Change Setting
Changing Engine Speed Segmentation
You can arbitrarily change engine speed segmentation.
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.
3-8
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.
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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
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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.
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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.
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Machine Setting
2). How to change all data at once
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.”
3-12
4. Changing fuel distribution percentage between teh upper and lower injector
When you select “RU MAP”, a screen like below will appear.
You can change the fuel distribution percentage between the upper and lower
injector.
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Machine Setting
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.
Transferring Setting Data
Transmitting data (PC to ECU)
Use up/down arrow keys to make change.
You may change values in the range ± 15%.
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.
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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.
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.
Contents of the display will change
to the setting data in ECU and its file
name will be displayed here.
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Machine Setting
Troubleshooting
*1: CD-ROM drive
No.
1
2.
3.
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
The serial port
setting incorrect
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.
4.
Default file is not
displayed when
starting up first
A same problem
is occurs with
the English version.
Action to take
*refer to 1
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 CDROM drive or is not
recognizing one.
Consult instruction
manual of your PC to
confirm this.
Make the drive recognized and
try installation again
Please contact HRC service.
This tool runs on windows
95/98/Me/XP.
*refer to 2
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
*2: How to check serial port
Open the Control
Panel.
Select System and
click on it.
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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.
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Machine Setting
Quick Shift Setting
System requirements and communication attachment
USB Driver Install
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
• 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.
2.The attachment
• USB Cable: 38411-NL9-000 (or commercially available USB cable)
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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.”
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Machine Setting
Correction of the COM Number
4. When a window is change, installation is continued.
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.”
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Machine Setting
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. 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.
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Machine Setting
4. Double-click “setup” icon, start the set-up program.
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.”
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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.
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.
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3. Select “CBR1K01.DAT”, click “Open.”
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Machine Setting
4. Application main window is open.
Make sure the file name is correct.
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.
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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.
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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.
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.
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Machine Setting
<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”.
<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”.
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Machine Setting
Note:
See following page’s “10. Read and write data” for detail.
<Write to QS unit>
Push this button, editing data or saved data can be written to QS unit.
<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.
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Machine Setting
QS Unit Set-up; Changing the Unit of Cutout Time
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.
Click "Communication" and select "Set Up QS unit".
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Machine Setting
QS Unit Set-up; Other 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.
Do not change these radio buttons on this vehicle.
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.
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Machine Setting
Monitor Screen “How to Display”
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.
Click "Communication" and select "Monitor".
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Machine Setting
Monitor Screen “CAL (0 point adjustment of shift rod force sensor)”
<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.
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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.
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Machine Setting
Read and Write Data
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.
<Write to QS unit>
Push this button, the editing data or saved data can be written to QS unit.
<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.
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Machine Setting
Data reading
Click "OK" button, and finish reading.
Click "Read from QS unit" button.
Click "OK" button and start reading.
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"Progress bar" moves during reading.
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.
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Machine Setting
Data writing
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.
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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.
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1. First please start-up a program.
2. Right click "Help" button.
3. Please use table of contents in the menu.
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Machine Setting
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".
Double click the "regedit".
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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.
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Machine Setting
(1)
(1)
(2)
(1) “SEL” BUTTON
(2) “RESET” BUTTON
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).
(2)
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.
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Machine Setting
(4)
(5)
(1)
(2)
(1)
(3)
(5)
(2)
(3)
(4)
(1)
(2)
(1) SESSION NUMBER (2) LAP NUMBER
(3) COOLANT TEMPERATURE
(4) LAP TIME (MIN.) (5) LAP TIME (SEC.)
(1) SESSION NUMBER (2) LAP NUMBER
(3) MAX. COOLANT TEMPERATURE (4) LAP TIME
(5) CURRENT COOLANT TEMPERATURE
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.
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.
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.
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.
2-40
When
stored
When
stored
the “RESET” button is pressed, the next
data is displayed.
the “SEL” button is pressed, the previous
data is displayed.
The maximum coolant temperature during each lap
is displayed on upward of the section/lap number.
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Machine Setting
(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.
2-41
04.4.27 20:25
Page 42
Memo

2004-cbr1000rr parts list - O2 Racing Service / Yoshimura

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