2001–2003 Honda CBR600F4i OEM Service Manual (P/N 61MBW52)

• Model and variant coverage: Covers 2001-2003 Honda CBR600F4i motorcycles, with separate specifications for 49-state/Canada and California types; their throttle-body identification numbers are GQ90C and GQ90B, respectively.
• PGM-FI diagnosis and fuel-system repair: Provides MIL self-diagnosis, fuel pressure and flow testing, fuel pump and relay checks, injector and pressure-regulator service, starter-valve synchronization, and ECM/sensor fault isolation.
• Internal engine and drivetrain work: Documents engine removal and installation, cylinder-head and valve service, camshaft timing, valve-guide replacement and seat refacing, clutch and shift-linkage repair, crankcase separation, transmission service, and crankshaft/piston inspection.
• Chassis and brake procedures: Details front and rear wheel service, fork disassembly and setup, steering-stem bearings, shock and linkage work, swingarm removal, brake-fluid replacement and bleeding, and master-cylinder and caliper overhaul.
• Electrical troubleshooting and diagrams: Combines test sequences for the battery and charging system, direct ignition, electric starter, lights, meters, and switches with harness routing, PGM-FI diagnostic charts, and the full motorcycle wiring diagram.
• 490-page factory reference: The PDF supplies component-specific torque tables, fluid data, wear and service limits, clearances, electrical test specifications, lubrication points, special-tool references, and 23 numbered technical sections.

Coverage and Shop Use

This 490-page PDF reproduces the Honda factory service manual for the 2001-2003 CBR600F4i. The specifications distinguish the 49-state/Canada setup from the California type; California-only material covers the evaporative-emissions system, purge-control solenoid valve, oxygen sensor, and catalyst-related service information. The depth of the electrical tests, special-tool calls, and internal engine procedures makes the manual suited to experienced motorcycle technicians and advanced owners working in a properly equipped shop.

PGM-FI, Engine, and Drivetrain

The fuel chapter goes well beyond routine maintenance. Its PGM-FI material maps system locations and operating circuits, explains service-check-connector and MIL blink-code diagnosis, and traces faults through the MAP, IAT, ECT, TP, bank-angle, and cam-pulse inputs. Separate procedures cover the throttle body, fast-idle wax unit, fuel tank, pump, cut-off relay, injectors, pressure regulator, PAIR system, ECM, and California emissions hardware.

Major mechanical repair is covered at component level. The manual walks through engine removal and installation, cylinder-compression testing, cylinder-head disassembly and inspection, camshaft removal and timing installation, valve-guide replacement, valve-seat inspection and refacing, and final reassembly. Lower-end coverage includes crankcase separation, shift forks and drum, the six-speed transmission, crankshaft and connecting-rod bearings, pistons, rings, and cylinders. Clutch, gearshift linkage, alternator, flywheel, starter clutch, lubrication, oil-pump, cooling-system, radiator, thermostat, and water-pump work are handled in their own sections.

Chassis, Brakes, and Electrical Systems

Chassis chapters support wheel-bearing and axle inspection, fork removal and internal service, steering-stem and race replacement, rear-shock and linkage service, and swingarm pivot work. The hydraulic-brake section addresses fluid replacement and air bleeding, pad and disc inspection, front and rear master cylinders, both calipers, and brake-pedal setup. Adjustment data is provided for the fork, rear shock, steering head, drive chain, controls, and related chassis assemblies.

Electrical repair coverage combines system diagrams with test sequences for the battery, charging coil, regulator/rectifier, direct ignition coils, ignition-pulse generator, starter motor, starter relay, diode, combination meter, vehicle-speed sensor, fuel-reserve sensor, lights, and switches. Particularly useful visual references include the PGM-FI System Diagram, MIL Failure-Code Charts, Cooling System Flow Pattern, Battery/Charging System Diagram, Cable & Harness Routing views, and the complete Wiring Diagram.

Special Tools and Repair Cautions

The factory tool table identifies the oil-filter wrench 07HAA-PJ70100, ECM test harness 07YMZ-0010100, and peak-voltage adapter 07HGJ-0020100, along with pullers, bearing tools, valve-seat cutters, and steering and fork drivers.

Two CBR600F4i-specific repair traps deserve attention. The throttle bodies are factory preset; loosening the white-painted screws can upset throttle and idle-valve synchronization, while carburetor cleaner can damage the molybdenum-coated bores. The crankshaft chapter treats the main-journal and crankpin bearing inserts as color-coded select-fit parts, warning that incorrect oil clearance can cause major engine damage.

Fuel pressure, brake fluid, hot coolant, high-pressure shock nitrogen, and battery electrolyte all receive component-specific safety warnings. Proper support equipment, protective gear, and the manual's safety precautions should be used throughout service and repair work.