2007-2008 Honda CBR600RR service manual

Product Information

Table of Contents

GENERAL INFORMATION

1. Service Rules
   • 1-2
2. Model Identification
   • 1-3
3. General Specifications
   • 1-4
4. Lubrication System Specifications
   • 1-5
5. Fuel System (PGM-FI) Specifications
   • 1-6
6. Cooling System Specifications
   • 1-7
7. Cylinder Head/Valves Specifications
   • 1-8
8. Clutch/Starter Clutch/Gearshift Linkage Specifications
   • 1-8
9. Crankcase/Transmission Specifications
   • 1-8
10. Crankshaft/Piston/Cylinder Specifications
    • 1-9
11. Front Wheel/Suspension/Steering Specifications
    • 1-10
12. Rear Wheel/Suspension Specifications
    • 1-10
13. Hydraulic Brake Specifications
    • 1-11
14. Battery/Charging System Specifications
    • 1-11
15. Ignition System Specifications
    • 1-11
16. Electric Starter Specifications
    • 1-11
17. Lights/Meters/Switches Specifications
    • 1-12
18. Standard Torque Values
    • 1-12
19. Engine & Frame Torque Values
    • 1-13
20. Lubrication & Seal Points
    • 1-19
21. Cable & Harness Routing
    • 1-21
22. Emission Control Systems
    • 1-36

TECHNICAL FEATURES

1. Engine Features
   • Design and Performance
   • 2-1
2. Chassis Features
   • Frame and Suspension
   • 2-5
3. Electrical Features
   • Advanced Electronics
   • 2-10

FRAME/BODY PANELS/EXHAUST SYSTEM

1. Frame
   • Inspection and Repair
   • 3-1
2. Body Panels
   • Removal and Installation
   • 3-5
3. Exhaust System
   • Inspection and Replacement
   • 3-10

MAINTENANCE

1. Maintenance Schedule
   • Regular Maintenance Intervals
   • 4-1
2. Pre-ride Inspection
   • Checklist Before Riding
   • 4-3
3. Lubrication Points
   • Lubrication Requirements
   • 4-5

LUBRICATION SYSTEM

1. Engine Oil
   • Types and Specifications
   • 5-1
2. Oil Filter
   • Replacement Procedure
   • 5-3
3. Lubrication Circuit
   • Diagram and Function
   • 5-5

FUEL SYSTEM (PGM-FI)

1. Fuel Tank
   • Removal and Installation
   • 6-1
2. Fuel Pump
   • Inspection and Testing
   • 6-3
3. Fuel Injectors
   • Cleaning and Replacement
   • 6-5
4. Throttle Body
   • Synchronization and Adjustment
   • 6-7

COOLING SYSTEM

1. Radiator
   • Inspection and Replacement
   • 7-1
2. Coolant
   • Types and Replacement Procedure
   • 7-3
3. Water Pump
   • Inspection and Testing
   • 7-5
4. Cooling Fan
   • Operation and Maintenance
   • 7-7

ENGINE REMOVAL/INSTALLATION

1. Engine Removal
   • Step-by-step Procedure
   • 8-1
2. Engine Installation
   • Step-by-step Procedure
   • 8-10

CYLINDER HEAD/VALVES

1. Cylinder Head Removal
   • Procedure and Precautions
   • 9-1
2. Valve Inspection
   • Valve Clearance and Adjustment
   • 9-5
3. Cylinder Head Installation
   • Procedure and Precautions
   • 9-10

CLUTCH/STARTER CLUTCH

1. Clutch Removal
   • Step-by-step Procedure
   • 10-1
2. Clutch Inspection
   • Wear and Damage Check
   • 10-5
3. Clutch Installation
   • Step-by-step Procedure
   • 10-10
4. Starter Clutch
   • Inspection and Maintenance
   • 10-15

ALTERNATOR

1. Alternator Removal
   • Step-by-step Procedure
   • 11-1
2. Alternator Inspection
   • Testing and Maintenance
   • 11-5
3. Alternator Installation
   • Step-by-step Procedure
   • 11-10

CRANKCASE/TRANSMISSION

1. Crankcase Disassembly
   • Procedure and Precautions
   • 12-1
2. Transmission Inspection
   • Gear and Shaft Check
   • 12-5
3. Crankcase Assembly
   • Procedure and Precautions
   • 12-10

CRANKSHAFT/PISTON/CYLINDER

1. Crankshaft Removal
   • Step-by-step Procedure
   • 13-1
2. Piston Inspection
   • Wear and Damage Check
   • 13-5
3. Cylinder Inspection
   • Wear and Damage Check
   • 13-10
4. Crankshaft Installation
   • Step-by-step Procedure
   • 13-15

FRONT WHEEL/SUSPENSION/STEERING

1. Front Wheel Removal
   • Procedure and Precautions
   • 14-1
2. Front Suspension Inspection
   • Fork and Shock Absorber
   • 14-5
3. Steering Inspection
   • Handlebar and Stem
   • 14-10

REAR WHEEL/SUSPENSION

1. Rear Wheel Removal
   • Procedure and Precautions
   • 15-1
2. Rear Suspension Inspection
   • Swingarm and Shock Absorber
   • 15-5

HYDRAULIC BRAKE

1. Brake System Overview
   • Components and Operation
   • 16-1
2. Front Brake Inspection
   • Pad and Disc Check
   • 16-5
3. Rear Brake Inspection
   • Pad and Disc Check
   • 16-10
4. Brake Fluid Replacement
   • Procedure and Precautions
   • 16-15

BATTERY/CHARGING SYSTEM

1. Battery Maintenance
   • Inspection and Charging
   • 17-1
2. Charging System Inspection
   • Alternator and Regulator
   • 17-5

IGNITION SYSTEM

1. Ignition Coil
   • Testing and Replacement
   • 18-1
2. Spark Plug
   • Inspection and Replacement
   • 18-5
3. Ignition Timing
   • Adjustment Procedure
   • 18-10

ELECTRIC STARTER

1. Starter Motor
   • Removal and Inspection
   • 19-1
2. Starter Relay
   • Testing and Replacement
   • 19-5

LIGHTS/METERS/SWITCHES

1. Headlight
   • Bulb Replacement
   • 20-1
2. Tail/Brake Light
   • Bulb Replacement
   • 20-5
3. Turn Signals
   • Bulb Replacement
   • 20-10
4. Meter Panel
   • Inspection and Replacement
   • 20-15
5. Switches
   • Testing and Replacement
   • 20-20

WIRING DIAGRAM

1. Complete Wiring Diagrams
   • Overview and Details
   • 21-1

TROUBLESHOOTING

1. Engine Troubleshooting
   • Common Issues and Solutions
   • 22-1
2. Electrical Troubleshooting
   • Common Issues and Solutions
   • 22-10
3. Chassis Troubleshooting
   • Common Issues and Solutions
   • 22-20

INDEX

1. Index
   • Alphabetical Index of Topics
   • 23-1

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