Honda CBR 600 F4i - Dual Ratio Sprockets

Kit P/N
KIT-DRS-01HO-01
DRS
Installation Instructions
Honda CBR 600 F4i
www.dualratiosprockets.com
Please make sure before you begin you look over these instructions to see what is involved in installing your DRS. Although it is a simple process, if
you are not mechanically inclined or do not have the proper tools to remove your wheel you may want to consider having a professional bike shop
install your DRS for you.
There is also a video on our website www.dualratiosprockets.com which shows the installation process.
Inspect the DRS for signs of damage before installation. Please contact us immediately if there are any signs of a problem and do not install the kit.
Wear appropriate safety gear and NEVER install or make adjustment to the DRS with the motorcycle running.
1.
2.
Support the motorcycle securely so that the rear wheel can
be safely removed. Remove the axle nut ,washer and then
remove the axle. You can also remove your chain guard to
ease installation at this point.
Push the wheel forward and take the chain off the
sprocket. Remove the brake caliper and hang it to the side.
Then remove the wheel.
3.
The next step involves removing the stock “ Cush Drive ”
assembly from the wheel as pictured. You will not need the
stock Cush Drive or it ’ s inner and outer spacer.
4.
Pull out the Cush Drive rubber dampers from the wheel.
Trim off the 4 rubber nipples on the bottom of each
damper. Reinstall the dampers back into the wheel.
NOTE:
This mod will not affect the functionality of the stock Cush
Drive if it is ever reinstalled back on the bike.
5.
6.
Replace the stock Cush Drive with the DRS in the wheel.
Next remove the stock chain adjuster from the left side of
the swingarm. Then using snap ring pliers remove the snap
ring and threaded stud from the chrome bracket.
7.
8.
Test fit the stud into the swingarm bracket. Light grinding
may be required on the raised boss of the stud. Ensure
that it fits nicely into the recess in the swingarm bracket.
Install adjuster stud into the swingarm bracket using the
sock snap ring as shown.
9.
Begin installing the wheel back on the bike. Install your
chain onto the DRS sprocket. Reinstall your brake caliper
in reverse order of removal.
NOTE:
If you ordered a sprocket with your DRS that is much bigger or much smaller than what was already on your bike,
you may need to shorten or lengthen your chain at this
point.
10.
Next, install the bracket on the swingarm by threading in
the adjuster stud.
11.
Install the axle washer and nut. DO NOT FULLY TIGHTEN
THE AXLE NUT AT THIS POINT.
13.
12.
For the next step align the marks on the swingarm bracket
and the outer cover of the DRS by turning the wheel or the
sprocket. The bike should be in neutral.
14.
Remove All 4 lockout pins from their sprocket locations
using the hex key provided.
NOTE:
When the pins are installed in the sprocket the DRS is in
“ S ” ( S treet ) Mode.
Next begin installing one of the lockout pins into the swingarm bracket. Use a rocking motion on the sprocket with
your other hand while screwing in the pin. This will let the
pin locate easier. DO NOT FORCE THE PIN IN OR DAMAGE TO THE DRS MAY ACCUR.
15.
The pin should screw in without much resistance until it
bottoms. If it does not, recheck the alignment marks in step
13.
Once the first pin is in, install the remaining 3 pins. They
will be aligned automatically by the fist pin you put in.
Tighten all 4 pins
16.
Adjust your chain and align your wheel to specification.
Using the alignment marks on the swingarm bracket. The
marks match the stock adjuster and the adjustment procedure is the same as with the stock piece.
NOTE: 1
Always adjust your chain with the pins located in the swingarm bracket. This will ensure the pins always align after
the axle has been moved.
NOTE:2
When the pins are in the swingarm bracket, the DRS is in
“ R ” ( R eduction ) Mode.
Lastly torque the axle to 75lbs and recheck your chain
slack and wheel alignment. Recheck all bolts, axle, lockout
pins and chain adjusters for tightness. Reinstall your chain
guard if you removed it for installation.
Lube your chain and the installation is complete.
The DRS is ready to use.
DRS Sprocket Table
Mode
“S” “R”
40T = 58T
43T = 62T
46T = 66T
49T = 70T
Example:
If you ordered your DRS with a 46 tooth sprocket, when the
DRS is in R Mode the bike will feel like it has a 66 tooth
sprocket installed. If the DRS is in “ S ” Mode the bike will
feel like a 46 tooth sprocket you ordered.
Visit us at www.dualratiosprockets.com for affordable
replacement sprockets
Switching to “ S ” Mode
After installation above, the 4 lockout pins are in the swingarm bracket. This means your DRS is in “ R ” Reduction Mode. This mode will make the
bike feel like it has a large sprocket installed. ( see table ) Switching from “ R ” Mode to “ S ” Mode is easy and only takes about 2 minutes.
For S mode, remove All 4 pins from the swingarm bracket. Then make sure you can see a lineup mark on the DRS behind the sprocket.
( s ee arrow on picture below ) .
Next, start with one pin, thread it in only one thread or so into the nearest pin slot to the alignment mark. Line up the pin with the lineup mark by turning
the sprocket or the wheel.
When lined up, thread in the pin while rocking the sprocket lightly with your other hand, this will make the alignment easier. Once the first pin is in, the
other 3 will be automatically aligned. Install them around the perimeter of the sprocket and tighten all 4 pins.
THE PINS SHOULD GO IN WITH LITTLE OR NO RESISTANCE. IF THEY DO NOT, RECHECK YOU ALINGMENT MARKS AND TRY AGAIN.
DO NOT FORCE PINS IN, OR DAMAGE TO THE DRS MAY RESULT!
“R” Mode lineup marks.
(Line up marks on cover and bracket)
“S” Mode lineup mark. ( Line up pin with mark)
For “ S ” Mode line up the mark with the first pin by turning the sprocket in neutral or rolling the bike in gear. After
the first pin is in the other 3 are automatically lined up and
can be installed. Tighten all 4 pins.
SERVICING THE DRS
Your DRS does not need any special servicing procedures. It comes ready to use and is filled with the proper lubricant. However if for some reason the
lubricant is removed or leaks out, a grease nipple is provided as well as air escape plugs to make it easy to refill externally.
Use only a NLGI #1 EP Low Temp Grease with Extreme Pressure and Moly additives.
Such as ConocoPhillips or 76Lubricants ( Moly Low Temp #1 EP # MC302381 )
NEVER ride if the DRS is leaking or damaged. We offer DRS repair and rebuild services and quick turn around times for our customers.
Please visit us on the web for more information on these services or any other questions at www.dualratiosprockets.com
To add grease the DRS roll the wheel so that one of the small air release plugs is facing up and the grease nipple is at the bottom. From empty the DRS requires
approximately18-20 full pumps of the grease gun to fill.
Some air inside the unit is desirable to allow movement of the grease during operation.
However if you are not sure how much grease is in the unit, it is best fill it until you see
a sign of grease coming out of the air release plug hole.
Use a 1/8 hex to remove one of the air release plugs.
DANGER!
For your safety and to avoid damage to you, your bike or others NEVER switch between modes while the bike is running. Always shut off the bike and
ALWAYS double check the pins are installed correctly and are tight before riding.
NEVER ride without all 4 pins installed!
ALWAYS install All 4 pins in either the “ R ” or “ S ” position. NEVER in both.
Avoid using the DRS in “ R ” Mode at high speeds for extended periods of time like high speed highway riding ect. Use the “ S ” mode for this type
of riding instead.
Please read all the information including the disclaimer before using the DRS.
For more info visit us at www.dualratiosprockets.com
Thank you and have fun.