HRC 2006 CBR1000RR Manual

00. Introduction_P1 06.2.20 6:52 PM Page 1

Safety Messages
Your safety and the safety of others is very important. We have provided
important safety messages in this manual and on the HRC CBR1000RR.
Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you or
others. Each safety message is preceded by a safety alert symbol and
one of three words, DANGER, WARNING, or CAUTION.
These mean:
You WILL be KILLED or SERIOUSLY HURT
if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT
if you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.
Each message tells you what the hazard is, what can happen and what you
can do to avoid or reduce injury.
Damage Prevention Messages
You will also see other important messages that are preceded by the word
NOTICE.
This word means:
Your HRC CBR1000RR or other property can be
damaged if you don’t follow instructions.
The purpose of these messages is to help prevent damage to your HRC
CBR1000RR, other property, or the environment.
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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.
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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.
•Refer to section 2 for function of the handlebar switches.
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Hi Throttle Set/Engine Stop Switch
Installation 2-48
Oil Catch Tank Installation 2-49
Air Funnel/Air Cleaner Element
Replacement 2-50
Steering Stem Modifying 2-51
Steering Damper Replacement 2-51
Fuel Tank Replacement 2-52
ECM/Bank Angle Sensor Installation 2-53
Seat Rail Replacement/Battery Tray
Installation 2-54
Rear Fender B Modification 2-55
Exhaust Pipe Inner Protector Modification 2-56
Exhaust Pipe/Muffler Replacement 2-56
Drive Chain Guard Installation 2-57
Optional Drive/Driven Sprocket 2-58
Fork Spring Replacement 2-59
Rear Cushion Spring 2-63
Front Suspension Setting 2-63
Rear Suspension Setting 2-64
Optional Front Wheel 2-65
Optional Rear Wheel 2-73
Combination Meter Function 2-81
Left Handlebar Switch Function 2-83
Contents
1. Service Information
General Information 1-1
Service Data 1-1
Torque Values 1-2
Lubrication & Seal Points 1-6
Maintenance Schedule 1-9
Inspection/Replacement Parts 1-10
Removal/Replacement Parts 1-11
Cable & Harness Routing 1-12
Wiring Diagram 1-13
2. Racing Kit
Replacement Necessary Parts 2-1
Modifying the Cylinder Head Ports 2-2
Adjusting the Compression Ratio 2-3
Modifying Crankcase and Right Crankcase
Cover 2-4
Oil Pump Kit Installation 2-10
Oil Pan Set Installation 2-11
Cam Sprocket Kit Installation 2-12
Cylinder Head Bolt Tightening 2-14
ACG Set Installation 2-15
Transmission Set Installation 2-17
Optional Transmission Gears 2-18
Drive Sprocket Cover Damper Removal 2-20
Right Crankcase Cover Replacement 2-20
Clutch Spring/Clutch Disc Replacement 2-21
BTL (Back Torque Limiter) Kit 2-22
Main Journal Bearing 2-35
Crankpin Bearing 2-36
Main Journal Bolt Tightening 2-38
Crankshaft Thrust Play Adjustment 2-38
Balancer Backlash Adjustment 2-39
Engine Hanger Tightening Sequence 2-40
Wire Lock 2-42
Quick Shift Kit Installation 2-43
Secondary Air Supply System Removal 2-44
Thermostat and Bypass Hose Removal 2-44
Fast Idle Wax Unit Removal 2-45
Variable Air Intake Valve Removal/
Air Duct Installation 2-46
Radiator Kit Installation 2-47
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Memo
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1. Service Information
1-1
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 2006 Standard 2006 Racing Kit (Super Bike Kit)
Engine Type Water cooled 4-stroke DOHC 16 valve
Cylinder arrangement 28˚ inclined inline four
Bore and stroke 75.0 x 56.5 mm (2.95 x 2.22 in)
Displacement 998.4 cm3 (60.9 cu-in)
Compression ratio 12.1 : 1 14.5 : 1
Cylinder head gasket thickness t0.7 t0.6
Valve clearance IN 0.16 ± 0.03 mm (0.006 ± 0.001 in) 0.20 ± 0.02 mm (0.008 ± 0.001 in)
EX 0.30 ± 0.03 mm (0.012 ± 0.001 in) 0.30 ± 0.02 mm (0.012 ± 0.001 in)
Valve train DOHC, chain driven
Valve timing Intake opens 18˚ BTDC 22˚ BTDC
closes 46˚ ABDC 58˚ ABDC
Exhaust opens 39˚ BBDC 53˚ BBDC
closes 11˚ ATDC 22˚ ATDC
Valve lift Intake 9.1 mm 9.5 mm
Exhaust 8.4 mm 9.0 mm
Fuel deliverly system PGM-DSFI, ø44
Electrical Spark plug 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 com-
ponents.
Use unleaded premium gasoline (research octane number 100)
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Service Information
1-2
Item Thread/ Torque Remarks
pitch N•m (kgf•m, lbf•ft)
Main journal bolt M9 x 1.25 20 (2.0, 14) + 60˚ + 60˚ Apply oil after removing anti-rust additive; retightening limit: 10 times
Crankcase bolt M8 x 1.25 24 (2.5, 18) Apply oil
M7 x 1.0 18 (1.8, 13) Apply oil
Transmission bearing holder bolt M8 x 1.25 29 (3.0, 22) Apply oil
Oil drain bolt M12 x 1.5 29 (3.0, 22) Wire lock
Oil level finder stopper plate bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271
Timing hole cap M45 x 1.5 18 (1.8, 13) Apply grease
Cylinder head tightening bolt M9 x 1.25 20 (2.0, 14) + 53˚ + 53˚ Apply oil after removing anti-rust additive
Camshaft holder bolt M6 x 1.0 12 (1.2, 9) Apply oil
Cylinder head cover bolt M6 x 1.0 9.8 (1.0, 7) Apply oil
Breather plate bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271
PAIR reed valve cover bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271
Connecting rod bolt M8 x 0.75 20 (2.0, 14) + 45˚ + 45˚ New bolt: temporarily tighten 1 time
14 (1.4, 10) + 45˚ + 45˚ Checking oil clearance: Apply oil; retightening limit: 10 times
Starter clutch outer bolt M10 x 1.25 20 (2.0, 14) + 50˚ Apply oil; retightening limit: 5 times
Torque Values
Standard Torque
Item Thread/ Torque Remarks
pitch N•m (kgf•m, lbf•ft)
M5 bolt and nut M5 x 0.8 4.9 (0.5, 3.6) Apply oil
M6 bolt and nut M6 x 1.0 12 (1.2, 9) Included SH bolt; apply oil
M8 bolt and nut M8 x 1.25 22 (2.2, 16) Apply oil
M10 bolt and nut M10 x 1.25 34 (3.5, 25) Apply oil
M12 bolt and nut M12 x 1.25 54 (5.5, 40) Apply oil
M5 screw M5 x 0.8 4 (0.4, 2.9)
M6 screw M6 x 1.0 9 (0.9, 6.5)
M6 flange bolt and nut M6 x 1.0 12 (1.2, 9) Included NSHF bolt; apply oil
M8 flange bolt and nut M8 x 1.25 26 (2.7, 20) Apply oil
M10 flange bolt and nut M10 x 1.25 39 (4.0, 29) Apply oil
Engine
Use Honda Ultra S9 oil to the bolt and nut that are oil
application is specified. Actual torque down and
cross threads will ocuur if using the oil other than
specified.
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1-3
Service Information
Item Thread/ Torque Remarks
pitch N•m (kgf•m, lbf•ft)
Flywheel bolt Standard M10 x 1.25 103 (10.5, 76) Apply oil; • When using the new crankshaft or flywheel:
Temporarily tighten 2 times with 103 N•m (10.5 kgf•m,
76 lbf•ft).
•Temporarily tighten 1 time when flywheel reinstallation
We recommend that the racing kit flywheel bolt (90003-NL9-000) is
used whenever the standard flwheel is installed (page 2-14).
When using the racing kit flywheel bolt, follow the racing kit
tightening method and torque value (see below).
Racing kit M10 x 1.25 15 (1.5, 11) + 60˚ Apply oil; • Temporarily tighten 3 times with 135 N•m (13.8 kgf•m,
100 lbf•ft).
•After tightening flywheel bolt with 15 N•m (1.5 kgf•m,
11 lbf•ft) + 60˚ , check the tightening torque is more than
128 N•m (13.0 kgf•m, 94 lbf•ft).
Cam sprocket bolt Standard M7 x 1.0 20 (2.0, 14) Apply oil
Racing kit M7 x 1.0 22 (2.2, 16) Apply oil
Camshaft position sensor rotor bolt M6 x 1.0 12 (1.2, 9) Apply oil
Cam chain tensioner bolt M6 x 1.0 9.8 (1.0, 7) Apply LOCKTITE 271
Cam chain guide bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271
Oil pump assembly bolt M6 x 1.0 12 (1.2, 9) CT bolt
Oil pump driven sprocket bolt M6 x 1.0 15 (1.5, 11) Apply LOCKTITE 271
Oil filter cartridge M20 x 1.5 26 (2.7, 20) Apply oil
Throttle body insulator bolt M6 x 1.0 12 (1.2, 9) Apply oil
Thermostat cover bolt M6 x 1.0 12 (1.2, 9) CT bolt
Water pump cover bolt M6 x 1.0 12 (1.2, 9) CT bolt
Water pump impeller M6 x 1.0 12 (1.2, 9) Left hand thread
Clutch center lock nut M25 x 1.0 128 (13.0, 94) Apply oil
Clutch lifter plate bolt M6 x 1.0 12 (1.2, 9) Apply oil
Transmission bearing set plate bolt M6 x 1.0 14 (1.4, 10) Apply LOCKTITE 271
Lifter plate bolt M6 x 1.0 14 (1.4, 10) Apply oil
Drive sprocket bolt M10 x 1.25 54 (5.5, 40) Wire lock
Shift drum center bolt M8 x 1.25 23 (2.3, 17) Apply LOCKTITE 271
Shift drum stopper arm bolt M6 x 1.0 12 (1.2, 9) Apply oil
Shift return spring pin M8 x 1.25 23 (2.3, 17) Apply oil
Shift drum bearing set plate bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271
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Service Information
1-4
Item Thread/ Torque Remarks
pitch N•m (kgf•m, lbf•ft)
Fuel tank cap socket bolt M4 x 0.7 4.9 (0.5, 3.6)
Fuel hose banjo bolt (tank side) M12 x 1.25 26 (2.7, 20)
ECT sensor M12 x 1.5 23 (2.3, 17)
Swingarm pivot adjusting bolt M36 x 1.5 15 (1.5, 11) Apply molybdenum grease to the threads
Swingarm pivot adjusting bolt lock nut M36 x 1.5 59 (6.0, 43) Apply molybdenum grease to the threads
Swingarm pivot nut M22 x 1.5 118 (12.0, 87) Apply molybdenum grease to the threads
Clutch oil bleeder bolt M10 x 1.25 23 (2.3, 17)
Clutch bleeder screw M8 x 1.25 7.8 (0.8, 5.8)
Rear wheel bearing retainer M56 x 1.0 98 (10.0, 72) Apply LOCKTITE 271
Rear brake disc bolt M6 x 1.0 16 (1.6, 12) Apply LOCKTITE 271
Rear axle M18 x 1.5 98 (10.0, 72) Apply molybdenum grease to the threads
Final driven sprocket nut M8 x 1.25 34 (3.5, 25) Apply oil to the threads
Rear brake oil bleeder bolt M10 x 1.25 23 (2.3, 17)
Rear brake bleeder screw M8 x 1.25 7.8 (0.8, 5.8)
Rear brake caliper mounting bolt M7 x 1.0 17 (1.7, 12) Apply molybdenum grease to the threads
Front wheel axle M18 x 1.5 59 (6.0, 43) Apply molybdenum grease to the threads
Frame
Item Thread/ Torque Remarks
pitch N•m (kgf•m, lbf•ft)
Shift drum stopper plate bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271
Alternator stator mounting bolt M6 x 1.0 12 (1.2, 9) Apply oil
Starter motor terminal nut M6 x 1.0 12 (1.2, 9) Apply oil
Spark plug M10 x 1.0 14 (1.4, 11)
Main oil gallery sealing taper plug PT1/8 12 (1.2, 9) Apply Three bond 1207B
Neutral switch M10 x 1.25 12 (1.2, 9)
ECT sensor M12 x 1.5 23 (2.3, 17)
Insulator band M5 x 0.8 – Band width: 7 ± 1 mm
Water hose band – – Tightening width: 1 mm on each side
Air funnel bolt M5 x 0.8 6.8 (0.7, 5.1) Wire lock
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