HRC CBR600RR Manual

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 CBR600RR.
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 CBR600RR 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
CBR600RR, other property, or the environment.

HRC CBR600RR 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.

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 CBR600RR, and as is stated in the CBR600RR 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.

Steering Damper Replacement 2-27
Rear Fender B Modification 2-28
Exhaust Pipe/Muffler Replacement 2-29
Drive Chain Guard Installation 2-30
Optional Drive/Driven Sprocket 2-31
Brake Pad Selection 2-31
Front Brake Hose Replacement 2-32
Fork Spring Replacement 2-33
Rear Shock Absorber Spring 2-37
Front Suspension Setting 2-37
Rear Suspension Setting 2-38
Left Handlebar Switch Function 2-39
Shift-up Indicator 2-40
Contents
1. Service Information
General Information 1-1
Service Data 1-1
About the Racing Kit 1-2
Torque Values 1-3
Lubrication & Seal Points 1-8
Maintenance Schedule 1-11
Inspection/Replacement Parts 1-12
Removal/Replacement Parts 1-13
Cable & Harness Routing 1-14
Wiring Diagram 1-15
2. Racing Kit
Replacement Necessary Parts 2-1
Modifying the Cylinder Head Ports 2-2
Adjusting the Compression Ratio 2-3
Valve Spring Replacement 2-4
Camshaft and Cam Pulse Generator
Rotor Replacement 2-4
ACG Set Installation 2-6
Transmission Set Installation 2-8
Connecting Rod Bolt Tightening 2-9
Main Journal Bolt Tightening 2-9
Engine Hanger Tightening Sequence 2-10
Wire Lock 2-12
Quick Shifter Installation 2-13
Secondary Air Supply System Removal 2-14
Thermostat and Bypass Hose Removal 2-15
Radiator Kit Installation 2-16
Fuel Feed Hose Removal/Installation 2-18
Fuel Tank Breather Hose Installation 2-19
Hi Throttle Set Installation 2-20
Breather Case Installation 2-21
Resister Installation 2-22
Turn Signal Switch Modification 2-22
Starter/Battery Cable Modification 2-23
Air Funnel/Air Cleaner Element
Replacement (2007 Model Kit) 2-24
Air Funnel/Air Cleaner Element
Replacement (2008 Model Kit) 2-25
Steering Stem Modification 2-26
Steering Stem Nut/Washer Replacement 2-26

Memo

1. Service Information
1-1
General Information
•This Set-up Manual contains information for the CBR600RR Racing Kit.
•Refer to the Shop Manual for service procedures and data not included in this manual.
Service Data
Comparison between standard CBR600RR and Racing kit installed CBR600RR.
Item 2010 Standard 2010 Racing Kit (Super Bike Kit)
Engine Type Water cooled 4-stroke DOHC 16 valve
Cylinder arrangement Inline four
Bore and stroke 67.0 x 42.5 mm (2.64 x 1.67 in)
Displacement 599 cm3 (36.5 cu-in)
Compression ratio 12.2 : 1 12.6 : 1
Cylinder head gasket thickness t0.6 t0.65
Valve clearance IN 0.20 ± 0.03 mm (0.008 ± 0.001 in)
EX 0.28 ± 0.03 mm (0.011 ± 0.001 in)
Valve train DOHC, chain driven
Valve timing Intake opens 21˚ BTDC 23˚ BTDC
closes 44˚ ABDC 52˚ ABDC
Exhaust opens 40˚ BBDC 45˚ BBDC
closes 5˚ ATDC 10˚ ATDC
Valve lift Intake 8.3 mm
Exhaust 7.2 mm
Fuel deliverly system PGM-DSFI, ø40
Electrical Spark plug NGK: IMR9C-9HES, DENSO: VUH27D NGK: R0109B-10
•Honda’s testing has shown that the optimum overall performance of the Honda CBR600RR engine power up kit can be obtained by using an 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)

Service Information
1-2
About the Racing Kit
Engine Starting
If you turn the engine stop switch ON while the engine is running, the ECU cannot detect the atmospheric pressure correctly.
So, turn the engine stop switch ON and wait more than 0.2 seconds before starting the engine with the starter motor and/or pushing.
Do not do the following operations:
–Turn the engine stop switch ON while the starter switch is ON.
–Turn the engine stop switch ON while pushing the vehicle.
–Turn the engine stop switch from OFF to ON while running the vehicle.
If you do any of the "once stop the crankshaft rev and" does not make sense and turn the engine stop switch from OFF to ON, then start the engine with the spec-
ified procedure.
Engine Idle Speed
•The CBR600RR’s idle speed is automatically adjusted by the IACV (Idle Air Control Valve). So idle speed cannot be adjusted manually like the 2006 CBR600RR.
For racing use, engine idle speed can be adjusted using the optional PGM-FI Setting Tool.
Adjustable range is between the 1,400 – 3,000 min-1 (rpm) by 200 min-1 (rpm) increments.
The adjusted idle speed differs from real engine idle speed because of the engine oil, exhaust system and/or other vehicle conditions.
•For adjustment, use the HRC PGM-FI Setting Tool CD-ROM and Serial Interface Unit. For adjustment procedure, refer to PGM-FI Setting Manual included in the
CD-ROM.
Steering Damper
When using the racing kit wire harness, the standard steering damper is not operated (the damper damping is locked in the softest position).
We recommended using the steering damper included in the racing kit or using a commercially available manual steering damper.

1-3
Service Information
Item Thread/ Torque Remarks
pitch N•m (kgf•m, lbf•ft)
Main journal bolt M8 x 1.25 15 (1.5, 11) + 120˚ Apply oil to the threads and seating surface
Crankcase bolt M10 x 1.25 39 (4.0, 29) Apply oil to the threads and seating surface
M8 x 1.25 24 (2.4, 17)
M6 x 1.0 12 (1.2, 9) Apply oil to the threads and seating surface
Lower crankcase sealing bolt M20 x 1.0 30 (3.1, 22) Apply locking agent
Oil drain bolt M12 x 1.5 30 (3.1, 22) Wire lock
Timing hole cap M45 x 1.5 18 (1.8, 13) Apply grease
ACG wire clamp flange bolt M6 x 1.0 12 (1.2, 9) CT bolt (standard), SH bolt 6 x 16 (racing kit)
Cylinder head bolt M9 x 1.25 47 (4.8, 35) Apply oil to the threads and seating surface after removing anti-rust additive
M6 x 1.0 12 (1.2, 9)
Apply oil to the threads and seating surface after removing anti-rust additive
M14 x 1.0 18 (1.8, 13) Apply locking agent
Camshaft holder bolt M6 x 1.0 12 (1.2, 9) Apply oil to the threads and seating surface
Cylinder head cover bolt M6 x 1.0 10 (1.0, 7) Apply oil to the threads and seating surface
Breather plate bolt M6 x 1.0 12 (1.2, 9) Apply locking agent
PAIR reed valve cover bolt M6 x 1.0 12 (1.2, 9) CT bolt, apply locking agent
Connecting rod bolt M7 x 0.75 20 (2.0, 14) + 90˚ New bolt, apply oil to the threads and seating surface
14 (1.4, 10) + 90˚ Only when checking oil clearance (see above for final torque)
Torque Values
Standard Torque
Item Thread/ Torque
pitch N•m (kgf•m, lbf•ft)
M5 bolt and nut M5 x 0.8 4.9 (0.5, 3.6)
M6 hex/SH bolt and nut M6 x 1.0 12 (1.2, 9)
M8 bolt and nut M8 x 1.25 22 (2.2, 16)
M10 bolt and nut M10 x 1.25 34 (3.5, 25)
M12 bolt and nut M12 x 1.25 54 (5.5, 40)
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 (NSHF) M6 x 1.0 12 (1.2, 9)
M8 flange bolt and nut M8 x 1.25 26 (2.7, 20)
M10 flange bolt and nut M10 x 1.25 39 (4.0, 29)
Engine
•Use Honda 4-stroke oil on the specified bolts and nuts. Inaccurate
torque or cross threading may occur if the specified oil is not used.
•Check the crankcase cover bolt seating surfaces before tightening the
cover bolts. If the crankcase cover painting peels off, remove paint
from the bolt seating surfaces, then tighten the bolts.

Service Information
1-4
Item Thread/ Torque Remarks
pitch N•m (kgf•m, lbf•ft)
Starter clutch outer special bolt M10 x 1.25 83 (8.5, 61) Apply oil to the threads and seating surface
Flywheel bolt M10 x 1.25 103 (10.5, 76) Apply oil to the threads and seating surface
Cam sprocket knock bolt M7 x 1.0 20 (2.0, 14) Apply locking agent
Cam pulse generator rotor knock bolt M6 x 1.0 12 (1.2, 9) Apply locking agent
Cam chain tensioner A bolt M6 x 1.0 12 (1.2, 9) Apply locking agent
Cam chain tensioner B bolt M10 x 1.25 20 (2.0, 14) Apply locking agent
Cam chain guide bolt/washer M6 x 1.0 12 (1.2, 9)
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 locking agent
Oil filter cartridge M20 x 1.5 26 (2.7, 20) Apply oil to the threads and seating surface
Spark plug M10 x 1.0 16 (1.6, 12)
Oil filter boss M20 x 1.5 – See page 1-5, apply locking agent to the threads of the crankcase side
Oil cooler bolt M20 x 1.5 59 (6.0, 43) Apply oil to the threads and seating surface, wire lock
ECT (Tw) sensor M12 x 1.5 23 (2.3, 17)
Primary fuel rail mounting bolt M5 x 1.0 5.1 (0.5, 3.6)
Secondary fuel rail mounting bolt M5 x 1.0 5.3 (0.5, 3.6)
IACV set plate screw M4 x 0.7 2.1 (0.2, 1.4)
Water pump assembly bolt M6 x 1.0 12 (1.2, 9) CT bolt
Thermostat housing 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
Drive sprocket bolt M10 x 1.25 54 (5.5, 40) Wire lock
Throttle body insulator bolt M6 x 1.0 12 (1.2, 9)
Insulator band M5 x 0.8 – See page 1-5
Clutch center lock nut M22 x 1.0 128 (13.1, 95) Apply oil to the threads and seating surface
Clutch spring bolt M6 x 1.0 12 (1.2, 9)
Shift drum center bolt M8 x 1.25 23 (2.3, 17) Apply locking agent
Shift drum stopper arm bolt M6 x 1.0 12 (1.2, 9) Apply locking agent
Shift spindle stopper pin M8 x 1.25 22 (2.2, 16)
Stator mounting socket bolt M6 x 1.0 12 (1.2, 9)
Mainshaft bearing set plate bolt M6 x 1.0 12 (1.2, 9) Apply locking agent
Shift drum bearing set plate bolt M6 x 1.0 12 (1.2, 9) Apply locking agent
Water pump impeller special bolt M6 x 1.0 13 (1.3, 9)
Oil jet pipe mounting bolt M6 x 1.0 12 (1.2, 9) Apply locking agent

1-5
Service Information
Item Thread/ Torque Remarks
pitch N•m (kgf•m, lbf•ft)
Starter motor terminal nut M6 x 1.0 10 (1.0, 7)
Oil pressure switch PT1/8 12 (1.2, 9) Apply sealant to the thread
Oil pressure switch terminal screw M4x 0.7 2 (0.2, 1.4)
Neutral switch M10 x 1.25 12 (1.2, 9)
Exhaust pipe stud bolt M8 x 1.25 – See illustration below
Insulator band Exhaust pipe stud Oil filter boss
12 ± 1 mm
45.5 ± 10.5 mm 16.5 ± 0.5 mm

Service Information
1-6
Item Thread/ Torque Remarks
pitch N•m (kgf•m, lbf•ft)
Seat rail mounting bolt M10 x 1.25 54 (5.5, 40) 10 x 45
Seat rail mounting bolt M10 x 1.25 54 (5.5, 40) 10 x 32
Fuel pump mounting nut M6 x 1.0 12 (1.2, 9)
Bank angle sensor mounting screw M4 x 0.7 1.5 (0.2, 1.4)
Fuel tank mounting bolt M8 x 1.25 30 (3.1, 22)
IAT sensor mounting screw M5 1.1 (0.1, 0.7) 5 x 16 tapping screw
MAP sensor mounting screw M5 1.1 (0.1, 0.7) 5 x 16 tapping screw
ECM set plate screw M5 0.7 (0.07, 0.6) 5 x 20 tapping screw
Front brake disc bolt M6 x 1.0 20 (2.0, 1.4) ALOCK bolt; replace with a new one
Front axle bolt M14 x 1.5 59 (6.0, 43)
Front axle holder bolt M8 x 1.25 22 (2.2, 16)
Fork socket bolt M10 x 1.25 34 (3.5, 25)
Fork bolt M44 x 1.5 34 (3.5, 25)
Handlebar pinch bolt M6 x 1.0 10 (1.0, 7)
Top bridge pinch bolt M8 x 1.25 22 (2.2, 16)
Bottom bridge pinch bolt M8 x 1.25 27 (2.8, 20)
Steering stem adjusting nut M26 x 1.0 25 (2.5, 18)
Steering stem adjusting nut lock nut M26 x 1.0 –
Steering stem nut M24 x 1.0 103 (10.5, 76)
Steering damper mounting bolt M6 x 1.0 10 (1.0, 7)
Second arm nut M6 x 1.0 12 (1.2, 9)
Rear brake disc bolt M8 x 1.25 42 (4.3, 31) ALOCK bolt; replace with a new one
Final driven sprocket nut M10 x 1.25 64 (6.5, 47)
Rear axle nut M22 x 1.5 113 (11.5, 83)
Rear shock absorber mounting nut M10 x 1.25 44 (4.5, 33) U-nut
Shock arm nut (swingarm side) M10 x 1.25 44 (4.5, 33) U-nut
Drive chain case bolt M6 x 1.0 12 (1.2, 9)
Drive chain slider bolt M6 x 1.0 9.0 (0.9, 6.5) ALOCK bolt; replace with a new one
Swingarm pivot adjust bolt M30 x 1.0 12 (1.2, 9) Apply oil to the threads
Swingarm pivot lock nut M30 x 1.0 64 (6.5, 47)
Swingarm pivot nut M18 x 1.5 93 (9.5, 69)
Shock arm nut M10 x 1.25 44 (4.5, 33) U-nut
Frame

1-7
Service Information
Item Thread/ Torque Remarks
pitch N•m (kgf•m, lbf•ft)
Front master cylinder reservoir stopper M4 x 0.7 1.2 (0.1, 0.7)
plate bolt
Brake lever pivot bolt M6 x 1.0 1.0 (0.1, 0.7)
Brake lever pivot nut M6 x 1.0 6.0 (0.6, 4.3)
Brake master cylinder holder bolt M6 x 1.0 12 (1.2, 9)
Front brake caliper assembly bolt M8 x 1.25 22 (2.2, 16) Apply locking agent
Front brake caliper mounting bolt M10 x 1.25 45 (4.6, 33) ALOCK bolt; replace with a new one
Front brake reservoir stay bolt M6 x 1.0 12 (1.2, 9)
Rear master cylinder push rod lock nut M8 x 1.25 18 (1.8, 13)
Rear brake reservoir cap screw M4 x 0.7 1.5 (0.2, 1.4)
Rear master cylinder mounting bolt M6 x 1.0 10 (1.0, 7)
Rear master cylinder reservoir tank M6 x 1.0 12 (1.2, 9)
mounting bolt
Rear brake hose screw M4 x 0.7 1.5 (0.2, 1.4)
Front brake caliper pad pin M10 x 1.25 15 (1.5, 11)
Rear brake caliper pad pin M10 x 1.25 15 (1.5, 11)
Brake hose oil bolt M10 x 1.25 34 (3.5, 25)
Front brake hose clamp bolt M6 x 1.0 9.0 (0.9, 6.5)
Front brake hose clamp nut M6 x 1.0 10 (1.0, 7)
Brake hose oil bolt M6 x 1.0 10 (1.0, 7)

Service Information
1-8
Lubrication & Seal Points
Engine
Material Item Remarks
Honda 4-stroke motorcycle oil Piston/piston ring sliding surface
or an equivalent Clutch disc whole surface
API service classification: SG or Starter one-way clutch sliding surface
higher (except oils labelled as Crankpin bearing cap bolt threads and seating surface
energy conserving on the Flywheel bolt threads and seating surface
circular API service label) Clutch center lock nut threads and seating surface
JASO T903 STANDARD: MA Oil filter cartridge threads and O-ring
Viscosity: SAE 10W-30 Oil cooler bolt threads, sealing washer seating surface
Camshaft holder bolt threads and seating surface
Starter clutch mounting bolt threads and seating surface
Each gear teeth
Each O-ring
Each ball bearing and needle bearing
Other rotating and sliding surface
Engine inside
Molybdenum disulfide oil Main journal bearing sliding surface
(a mixture of engine oil Piston pin sliding surface
and molybdenum Crankpin bearing sliding surface
disulfide grease) Connecting rod small end I.D.
Crankshaft thrust surface
Camshaft lobe and journal surface
Valve stem (valve guide sliding surface
Valve lifter sliding surface
Oil pump drive sprocket guide sliding surface
Water pump shaft/thrust washer sliding surface
Clutch outer sliding surface
Clutch outer guide sliding surface
M3/4, C5, C6 shifter gear (shift fork grooves)
Starter reduction gear sliding surface
Starter idle gear shaft sliding surface
Cylinder head bolt threads and surface

1-9
Service Information
Material Item Remarks
Multi-purpose grease Timing hole cap threads
Each oil seal lip
Three bond 1207B Crankcase mating surface
Oil pan mating surface
Crankcase/cover mating surface
Oil pressure switch threads
ACG cover wire grommet
Right crankcase cover wire grommet
Cylinder head semi-circular portion
Locking agent Cam pulse generator rotor bolt threads
Oil pump driven sprocket bolt threads Coating width: 6.5 ± 1 mm
Shift drum bearing set plate bolt threads Coating width: 6.5 ± 1 mm
Mainshaft bearing set plate bolt threads Coating width: 6.5 ± 1 mm
Cam sprocket bolt threads Coating width: 6.5 ± 1 mm
Shift drum center bolt threads Coating width: 6.5 ± 1 mm
Cam chain tensioner A pivot bolt threads Coating width: 6.5 ± 1 mm
Cam chain tensioner B pivot bolt threads Coating width: 6.5 ± 1 mm
Shift drum stopper arm pivot bolt threads Coating width: 6.5 ± 1 mm
Oil jet pipe mounting bolt threads Coating width: 6.5 ± 1 mm
Oil level plate bolt threads Coating width: 6.5 ± 1 mm
Oil pipe A/B mounting bolt threads Coating width: 6.5 ± 1 mm
AICV reed valve cover threads
Oil filter boss threads (crankcase side) Coating width: 6.5 ± 1 mm

Service Information
1-10
Frame
Material Item Remarks
Multi-purpose grease Front/rear wheel dust seal lip
Axle surface
Swingarm pivot bolt surface
Urea based multi-purpose Steering stem upper/lower bearings 3 – 5 g
grease for extreme pressure Steering stem dust seal 3 – 5 g
(example: EXCELITE EP2 Steering stem adjusting nut threads 0.1 – 0.3 g
manufactured by KYODO
YUSHI, Japan) or equivalent
Multi-purpose grease Swingarm pivot bolt bearing
(Shell Alvania EP2 or Swingarm pivot dust seal lips
equivalent) Shock link needle bearing
Shock link dust seal lips
Rear shock absorber needle bearing
Rear shock absorber dust seal lips
Engine oil Swingarm pivot adjusting bolt threads
Each O-ring
Silicone grease Front/rear brake push rod/master piston contact area
Brake lever pivot bolt sliding surface
Rear brake caliper pin sliding surface
Rear brake caliper pad pin, O-ring
DOT 4 Brake fluid Brake master piston, piston cups
Brake master cylinder/caliper cylinder I.D.
Fork fluid Fork inside
Fork oil seal lip
Locking agent Front caliper assembly torx bolt threads

1-11
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.
Check for other parts not listed above for wear or damage. Replace any faulty parts as necessary.
Frequency Each race
or about Remarks
Item 2.5 hours
Fuel Line I See page 2-16
Throttle Operation I
Spark Plug I
Valve Clearance I
Engine Oil R
Engine Oil Filter R
Intake Valves I I: Any unusual sound, inspect immediately, R: every 3,000 km (1,850 mi)
Exhaust Valves I I: Any unusual sound, inspect immediately, R: every 3,000 km (1,850 mi)
Valve Lifter I I: Chipping where contacting cam lobe, R: SS: every 1,500 km (930 mi), ST: every 3,000 km (1,850 mi)
Valve Springs I I: Any unusual sound, inspect immediately, R: every 3,000 km (1,850 mi)
Pistons I I: Any unusual sound, inspect immediately, R: SS: every 2,000 km (1,250 mi), ST: every 3,000 km (1,850 mi)
Piston Rings I I: Any unusual sound, inspect immediately, R: SS: every 2,000 km (1,250 mi), ST: every 3,000 km (1,850 mi)
Crankshaft I I: Any unusual sound, inspect immediately, R: SS: every 2,000 km (1,250 mi), ST: every 3,000 km (1,850 mi)
Crankpin Bearings I I: Any unusual sound, inspect immediately, R: SS: every 2,000 km (1,250 mi), ST: every 3,000 km (1,850 mi)
Main Journal Bearings I I: Any unusual sound, inspect immediately, R: SS: every 2,000 km (1,250 mi), ST: every 3,000 km (1,850 mi)
Cylinder Head I I: Any unusual sound, inspect immediately, R: every 3,000 km (1,850 mi)
Camshaft I I: Any unusual sound, inspect immediately, R: every 3,000 km (1,850 mi)
Cylinder Sleeve I I: Any unusual sound, inspect immediately
Radiator Coolant I
Cooling System I
Drive Chain I, L
Drive Chain Slider I
Drive/Driven Sprocket I
Brake Fluid I R: every 3 races, replace after riding in rain
Brake Pad Wear I
Brake System I
Clutch System I R: every race (clutch discs and plates)
Exhaust Pipe/Muffler I
Suspension I
Nuts, Bolts, Fasteners I
Wheels And Tires I R: every 2 years
Steering Head Bearings I

Service Information
1-12
Inspection/Replacement Parts
Parts Requiring Periodic Inspection/Replacement
Check for other parts not listed above for wear or damage. Replace any faulty parts as necessary.
Inspection Interval Replacement Interval
Item Cause
SS ST SS ST
Engine
IN/EX valve Every 1,500 km Every 1,500 km Every 3,000 km Every 3,000 km Valve face warpage
(930 mi) (930 mi) (1,850 mi) (1,850 mi)
Valve spring Every 1,500 km Every 1,500 km Every 3,000 km Every 3,000 km Wear or deformation
(930 mi) (930 mi) (1,850 mi) (1,850 mi)
Valve lifter Every 1,500 km Every 3,000 km
–– Cipping where contacting cam lobe
(930 mi) (1,850 mi)
Piston Every 1,000 km Every 1,500 km Every 2,000 km Every 3,000 km Skirt and piston land wear or damage
(620 mi) (930 mi) (1,250 mi) (1,850 mi)
Piston pin Every 1,000 km Every 1,500 km Every 2,000 km Every 3,000 km Wear or damage
(620 mi) (930 mi) (1,250 mi) (1,850 mi)
Piston ring Every 1,000 km Every 1,500 km Every 2,000 km Every 3,000 km Wear or damage
(620 mi)z (930 mi) (1,250 mi) (1,850 mi)
Connecting rod Every 1,000 km Every 1,500 km Every 2,000 km Every 3,000 km Small end for wear or damage
(620 mi) (930 mi) (1,250 mi) (1,850 mi)
Connecting rod bolt Every 1,000 km Every 1,500 km Every 2,000 km Every 3,000 km Wear or damage
(620 mi) (930 mi) (1,250 mi) (1,850 mi) Do not reuse
Camshaft Every 1,500 km Every 1,500 km Every 3,000 km Every 3,000 km Wear or damage
(930 mi) (930 mi) (1,850 mi) (1,850 mi)
Cam chain Every 1,500 km Every 1,500 km Every 3,000 km Every 3,000 km Link plate damage and chain slack
(930 mi) (930 mi) (1,850 mi) (1,850 mi)
Cam sprocket Every 3,000 km Every 1,500 km
–– Damage
(1,850 mi) (930 mi)
Ignition pulse generator
––
Every 3,000 km Every 3,000 km Damage
(1,850 mi) (1,850 mi)
Crankpin bearing
––
Every 3,000 km Every 3,000 km Wear or damage (every overhaul)
(1,850 mi) (1,850 mi)
Main journal bearing
––
Every 3,000 km Every 3,000 km Wear or damage (every overhaul)
(1,850 mi) (1,850 mi)
Crankshaft
––
Every 3,000 km Every 3,000 km Wear or damage
(1,850 mi) (1,850 mi) Primary drive gear wear or damage
Crankcase Every overhaul Every overhaul Every 3,000 km Every 3,000 km Sleeve wear or other damage
(1,850 mi) (1,850 mi)
Crankcase main journal bolt
–– Every 4th torque Every 4th torque Tightening torque
Cylinder head Every overhaul Every overhaul Every 3,000 km Every 3,000 km Cracks
(1,850 mi) (1,850 mi)

1-13
Service Information
Removal/Replacement Parts
Replace the combi-
nation meter with
the racing kit Rearview mirror Ignition switch
Turn signal light
Rear brake light
switch
Side stand switchCooling fan motorHorn
Headlight unit
Replace the standard
bank angle sensor with
the racing kit sensor.
Pillion step
Pillion seat
Rear fender
AICV
Replace the ECM
with the racing kit
Exhaust valve servo
motor
Tail/brake/License
light
Knock sensor

Service Information
1-14
Cable & Harness Routing
No. Item No. Item No. Item No. Item
*1 Combination meter *7 Harness, wire 13 Data link connector 19 Battery
2Sub-harness, combination meter 8 Switch assy., starter magnetic *14 Unit assy., serial I/F 20 Rectifier assembly, regulator
*3 Sensor assy., bank angle 9 Cable, starter battery *15 CD-ROM, PGM-FI/IGN *21 Resistor
4Sub harness, IGN 10 Fuel cut-off relay 16 Cable, starter motor
5Coil, cap & ignition 11 Engine stop relay 17 Battery ground cable
*6 Unit, PGM-FI/IGN 12 Shift up indicator relay 18 Band, battery
*1
2
*7
*6
9
16
*15
*14
10
17
8
19
20
18
*3 4
5
11
12
*21
13
*: HRC racing kit

1-15
Service Information
Wiring Diagram