Home > Motorcycles & ATV's > Honda Motorcycle/ATV > Honda Sport Bike Manuals >   Honda CBR600RR Repair Manual 2003-2006
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Details   Details This repair and service manual covers Honda CBR600RR models from 2003 through 2006. Hundreds of photos and illustrations guide the reader through every job, with step-by-step instructions. Table of Contents QUICK REFERENCE DATA CHAPTER ONE: GENERAL INFORMATION Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage CHAPTER TWO: TROUBLESHOOTING Starting the engine | Engine will not start | Engine performance | Engine | Engine lubrication | Cylinder leakdown test | Clutch | Gearshift linkage | Transmission | Fuel system | Electrical testing | Lighting system | Charging system | Ignition system | Starting system | Front suspension and steering | Brake system CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP Fuel type | Tune-up | Air filter | Compression test | Spark plugs | Ignition timing inspection | Valve clearance | EFI starter valve synchronization | Idle speed adjustment | Fuel hose inspection | Control cable lubrication | Throttle cables | Clutch cable adjustment | Engine oil and filter | Cooling system | Emission control systems | Battery | Tires and wheels | Front fork oil change | Drive chain | Brake system | Headlight aim | Sidestand and ignition cutoff switch | Steering bearing inspection | Front suspension inspection | Rear suspension inspection | Fastener inspection | Wheel bearing inspection | Lights and horn inspection CHAPTER FOUR: ENGINE TOP END and EXHAUST SYSTEM Engine service | Exhaust system | Cylinder head cover | Camshafts | Camshaft chain tensioner | Camshaft chain, timing sprocket and chain guides | Cylinder head | Valve lifters and shims | Valves and valve components CHAPTER FIVE: ENGINE LOWER END Engine | Oil pan, oil strainer and pressure relief valve | Oil pump | Oil cooler | Crankcase | Piston and connecting rod assembly | Crankshaft | Break-in procedure CHAPTER SIX: CLUTCH, STARTER CLUTCH and EXTERNAL SHIFT MECHANISM Right crankcase cover | Clutch | Starter clutch and reduction gear assembly | External shift mechanism CHAPTER SEVEN: TRANSMISSION and INTERNAL GEARSHIFT MECHANISM Transmission and internal shift mechanism | Transmission inspection | Internal shift mechanism inspection CHAPTER EIGHT: FUEL INJECTION and EMISSION CONTROL SYSTEMS Fuel system precautions | Fuel pressure test | Fuel flow test | Fuel tank cover | Fuel tank | Fuel pump | Air filter housing | Secondary fuel injection | Throttle body (primary fuel injection) | Fuel injectors (primary fuel injection) | Fast idle hot wax unit (2003-2004 models) idle air control (IAC) and thermal valve (2005-2006 models) | Starter valves | Fuel cut relay | Map sensor | Intake air temperarure (IAT) sensor | Camshaft position (CMP) sensor | Throttle position (TP) sensor | Bank angle sensor | Engine stop relay | Engine control module (ECM) | Throttle cable replacement | Emission control system labels | Secondary air supply system | Evaporative emission control system | Oxygen sensor(s) (California models) | Malfunction indicator lamp (MIL) CHAPTER NINE: ELECTRICAL SYSTEM Electrical component replacement | Electrical connectors | Battery | Charging system | Alternator cover and stator coil | Flywheel | Ignition system | Starter | Starter relay | Clutch diode | Lighting system | Combination meter | Tachometer | Speedometer | vehicle speed (VS) sensor | Engine coolant temperature (ECT) sensor | Fuel level sensor | Relays | Horn | Switches | Fuses | Wiring diagrams CHAPTER TEN: COOLING SYSTEM Cooling system precautions | Cooling system inspection | Coolant reserve tank and bracket | Radiator | Cooling fan | Thermostat | Thermostat housing | Cylinder block coolant joint | Water pump CHAPTER ELEVEN: WHEELS, TIRES and DRIVE CHAIN Motorcycle stands | Front wheel | Rear wheel | Rear coupling and rear sprocket | Front and rear hubs | Wheel runout and balance | Tires | Drive chain CHAPTER TWELVE: FRONT SUSPENSION and STEERING Handlebar assemblies | Front fork | Steering head and stem | Steering bearing preload | Steering head bearing races CHAPTER THIRTEEN: REAR SUSPENSION Suspension linkage | Shock absorber | Swing arm CHAPTER FOURTEEN: BRAKE SYSTEM Brake service | Front brake pad replacement | Front brake caliper | Front master cylinder | Rear brake pads | Rear brake caliper | Rear master cylinder | Brake hose replacement | Brake disc | Rear brake pedal | Brake bleeding CHAPTER FIFTEEN: BODY PANELS Body panel fasteners | Riders seat | Pillon seat | Side covers and rear cowl | Lower cowl | Air duct covers | Side fairing panel | Mirrors | Windscreen | Front fairing and air ducts | Front fender | Upper rear fender (2003-2004 models) | Rear fender (2005-2006 models) | Rear frame rail | Battery tray (2003-2004 models) COLOR WIRING DIAGRAMS Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild. PRODUCT DETAILS: Publisher: Clymer Manuals — 2007 Author: Ed Scott Binding: Paperback — 7 x 10 inches Pages: 526 — Over 1500 b&w photos and illustrations ISBN: 9781599691084

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