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2003-2006 Honda CBR600RR service manual Preview image 1
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2003-2006 Honda CBR600RR service manual

Models covered in this manual:

2003 Honda CBR600RR

  • Initial release model

2004 Honda CBR600RR

  • Continued production with minor updates

2005 Honda CBR600RR

  • Introduction of radial front brakes
  • New suspension settings

2006 Honda CBR600RR

  • Major redesign with new bodywork
  • Upgraded suspension and brakes
  • New exhaust system

Serial numbers:

  • 2003 Honda CBR600RR: Serial number range from JH2PC3703M000001 to JH2PC3703M100000
  • 2004 Honda CBR600RR: Serial number range from JH2PC3704M100001 to JH2PC3704M200000
  • 2005 Honda CBR600RR: Serial number range from JH2PC3705M200001 to JH2PC3705M300000
  • 2006 Honda CBR600RR: Serial number range from JH2PC3706M300001 to JH2PC3706M400000
  • Production/model years: 2003, 2004, 2005, 2006

File specifications

File size: 56.68 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 1.16 Minutes
$18.99 Instant Download

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Product Information

Table of Contents

General Information

  • Service Rules
  • Model Identification
  • General Specifications
  • Lubrication System Specifications
  • Fuel System (Programmed Fuel Injection) Specifications
  • Cooling System Specifications
  • Cylinder Head/Valves Specifications
  • Clutch/Starter Clutch/Gearshift Linkage Specifications
  • Crankcase/Transmission Specifications
  • Crankshaft/Piston/Cylinder Specifications
  • Front Wheel/Suspension/Steering Specifications
  • Rear Wheel/Suspension Specifications
  • Hydraulic Brake Specifications
  • Battery/Charging System Specifications
  • Ignition System Specifications
  • Electric Starter Specifications
  • Lights/Meters/Switches Specifications
  • Standard Torque Values
  • Engine & Frame Torque Values
  • Lubrication & Seal Points
  • Cable & Harness Routing
  • Emission Control Systems
  • Emission Control Information Labels (U.S.A. only)

Technical Features

  • New Model Features
  • Technical Innovations

Frame/Body Panels/Exhaust System

  • Frame Components
  • Body Panels
  • Exhaust System


  • Maintenance Schedule
  • Lubrication Points
  • Maintenance Procedures

Lubrication System

  • System Components
  • Oil Change Procedures
  • Troubleshooting

Fuel System

  • Fuel Tank
  • Fuel Pump
  • Fuel Injection System
  • Troubleshooting

Cooling System

  • Radiator
  • Water Pump
  • Coolant Replacement
  • Troubleshooting

Engine Removal/Installation

  • Engine Removal Procedures
  • Engine Installation Procedures

Cylinder Head/Valves

  • Cylinder Head Removal
  • Valve Adjustment
  • Cylinder Head Installation

Clutch/Starter Clutch

  • Clutch Removal
  • Clutch Inspection
  • Clutch Installation


  • Alternator Removal
  • Alternator Inspection
  • Alternator Installation


  • Crankcase Disassembly
  • Transmission Inspection
  • Crankcase Assembly


  • Crankshaft Removal
  • Piston Removal
  • Cylinder Inspection
  • Reassembly Procedures

Front Wheel/Suspension/Steering

  • Front Wheel Removal
  • Suspension Inspection
  • Steering Adjustment

Rear Wheel/Suspension

  • Rear Wheel Removal
  • Suspension Inspection
  • Rear Suspension Adjustment

Hydraulic Brake

  • Brake System Overview
  • Brake Pad Replacement
  • Brake Bleeding Procedures

Battery/Charging System

  • Battery Maintenance
  • Charging System Inspection

Ignition System

  • Ignition Coil Inspection
  • Spark Plug Replacement
  • Ignition Timing Adjustment

Electric Starter

  • Starter Motor Removal
  • Starter Motor Inspection
  • Starter Motor Installation


  • Headlight Replacement
  • Meter Function Check
  • Switch Operation

Wiring Diagrams

  • Complete Wiring Diagrams


  • General Troubleshooting
  • Engine Troubleshooting
  • Electrical Troubleshooting


  • Alphabetical Listing of Topics
  • Page References

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