Honda CBR600RR Repair Manual 2003-2006

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Item # M220  ISBN: 9781599691084




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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.

Honda CBR600RR Repair Manual 2003-2006