2000–2002 Honda CBR900RR / 929 / CBR900 / FireBlade Service Manual (P/N 61MCJ01)

• Covers the 2000 Honda CBR900RR / CBR929RR FireBlade with the 929 cc, liquid-cooled PGM-FI inline-four. The 2002 CBR954RR and its 954 cc engine require a different factory service publication.
• The 1,026-page PDF set contains a 516-page image-based factory service manual, a 489-page OCR companion copy of the core service material, and a separate 21-page Honda setup booklet. The 516-page scan is the more complete service file; the OCR edition uses different pagination and omits HISS, the full wiring diagrams, and the index.
• PGM-FI coverage includes MIL self-diagnosis and failure-code charts, fuel-line pressure and delivery testing, fuel pump and fuel-cut relay checks, injector and sensor diagnosis, ECM and actuator testing, starter-valve synchronization, and Exhaust Gas Control Valve, H-VIX, and variable-air-intake controls.
• Engine repair coverage runs from removal and installation and compression testing through cylinder-head teardown, valve-guide replacement and seat refacing, cam timing, clutch and gearshift linkage, alternator/starter clutch, crankcase and piston work, crankshaft bearings, and transmission teardown and reassembly.
• Chassis procedures address inverted-fork disassembly, seal and bushing inspection, steering-stem bearings, front and rear wheel service, suspension linkage, nitrogen-charged shock removal, swingarm and drive-chain work, brake bleeding, and master-cylinder and caliper repair.
• Electrical diagnosis covers battery and charging output, ignition peak-voltage testing, starter circuits, lamps, combination meter and switches, HISS key registration and fault tracing for applicable types, full-page wiring diagrams, and symptom-based troubleshooting.
• The dealer-oriented 21-page setup booklet adds shipping-crate removal, supplied-parts installation, windshield, mirror, seat, and battery setup, final fastener and fluid checks, and Honda’s pre-delivery test-ride checklist.

929 cc Factory Repair Scope

This is the factory shop publication for the 929 cc generation, not a maintenance-only owner’s guide. Each system section combines service information, troubleshooting, specifications, special-tool references, component illustrations, and the related removal, inspection, repair, assembly, and adjustment procedures. The General Information material supplies model identification, torque tables, lubrication and seal points, emissions-system descriptions, and detailed cable, hose, and wiring-harness routing. A separate maintenance chapter covers the scheduled inspections and adjustments. Page and section cross-references, together with the alphabetical index in the 516-page scan, help locate connected procedures.

The engine-removal chapter also states which jobs can be handled with the powerplant still in the frame. Alternator, camshaft, clutch, gearshift linkage, oil cooler and pump, shift drum and forks, and water-pump service are treated as in-frame work. Crankshaft and transmission repair, cylinder-head and valve work, and piston and cylinder service are assigned to engine-out procedures. That distinction shows the actual disassembly depth and support equipment required before a repair is started.

PGM-FI, HISS, and Wiring Reference

The PGM-FI section goes beyond parts replacement. It provides the system diagram and component locations, MIL code interpretation, self-diagnostic checks, and fuel-supply testing. Fault isolation covers the MAP, IAT, ECT, and throttle-position sensors; cam pulse and bank-angle inputs; injectors, relays, ECM, and PAIR system; California evaporative-emissions and oxygen-sensor circuits; and the shared servo for the exhaust and intake control valves.

Honda Ignition Security System (HISS) coverage includes key registration, diagnostic-code indication, troubleshooting flowcharts, and checks of the indicator, ECM, and receiver. Honda marks that chapter as not applicable to BR and MX types. Useful illustrations include the PGM-FI system diagram and component-location views, cable and harness routing drawings, the cooling-system flow pattern, charging and ignition circuit diagrams, HISS troubleshooting charts, and full-page wiring diagrams for ED/E/F, U, and BR/MX market types.

Tool listings identify factory equipment such as ECU test harness 07YMZ-0010100, peak-voltage adaptor 07HGJ-0020100, HISS inspection adaptor 07XMZ-MBW0100, and drive-chain tool set 07HMH-MR10103. The related chapters carry component-specific torque tables, fluid specifications and capacities, clearance data, wear limits, and electrical test specifications.

Manual-Specific Repair Cautions

The PGM-FI chapter warns that ordinary carburetor cleaner can damage the molybdenum-coated throttle bores, and that disturbing the white-painted throttle-body screws can upset the factory throttle and starter-valve synchronization. During engine removal, Honda calls for separate support of the motorcycle and engine and specifically warns against using the oil filter as a jacking point.

Work on the pressurized fuel system, hot cooling system, hydraulic brakes, high-current electrical circuits, and nitrogen-charged rear shock should be carried out with the motorcycle securely supported and with the section-specific warnings followed before repair begins.