Table Of Contents - Honda CBR900RR Shop Manual

Table of Contents

How To Use This Manual1
Contents1
Important Safety Notice2
Type Code2
Shop Manual News3
Previous Information For Cbr900Rr3
Wiring Diagram3
Cooling System Flow Pattern4
Water Pump Removal5
Water Pump Installation5
Cylinder Head Removal6
General Information Contents7
General Safety7
Service Rules8
Model Identification9
Frame And Engine Serial Numbers9
Carburetor Identification Numbers9
Color Label9
Specifications10
Torque Values19
Insulator Band Screw Tightening19
Tools22
Lubrication And Seal Points24
Engine24
Frame26
Cable And Harness Routing27
Secondary Air Supply System Routing (Sw, Ar Type)37
Frame/Body Panels/Exhaust System38
Body Panel Locations38
Frame/Body Panels/Exhaust System Contents39
Frame/Body Panels/Exhaust System Service Information39
Frame/Body Panels/Exhaust System Troubleshooting39
Seat/Fuel Tank Removal40
Seat/Fuel Tank Installation41
Pillion Seat/Side Cover Removal41
Pillion Seat/Side Cover Installation43
Middle/Lower Cowl Removal44
Upper Cowl45
Middle/Lower Cowl Installation45
Rearview Mirror Removal45
Upper Cowl Removal46
Windscreen Replacement48
Windscreen Installation48
Upper Cowl Installation49
Rearview Mirror Installation50
Front Fender Removal51
Front Fender Installation51
Rear Fender Removal52
Rear Fender Installation53
Seat Rail Removal53
Seat Rail Installation54
Muffler/Exhaust Pipe Removal54
Muffler/Exhaust Pipe Installation55
Maintenance Contents57
Maintenance Service Information57
Maintenance Specifications57
Maintenance Torque Values58
Maintenance Schedule59
Fuel Line60
Throttle Operation60
Carburetor Choke61
Air Cleaner61
Spark Plug61
Spark Plug Inspection62
Reusing A Spark Plug62
Replacing A Spark Plug62
Valve Clearance Inspection63
Valve Clearance Adjustment66
Engine Oil/Oil Filter67
Oil Level Inspection67
Engine Oil And Filter Change68
Carburetor Synchronization69
Engine Idle Speed71
Radiator Coolant71
Cooling System72
Secondary Air Supply System (Sw, Ar Type)72
Drive Chain73
Drive Chain Slack Inspection73
Drive Chain Adjustment73
Drive Chain Cleaning And Lubrication74
Sprocket Inspection74
Drive Chain Replacement75
Drive Chain Slider77
Brake Fluid77
Front Brake77
Rear Brake77
Brake Pad Wear78
Brake System Inspection78
Front Brake Pads78
Rear Brake Pads78
Brake Light Switch79
Headlight Aim79
Brake Lever Adjustment79
Brake Pedal Height Adjustment79
Clutch System80
Side Stand81
Suspension81
Front Suspension Inspection81
Front Suspension Adjustment81
Rear Suspension Inspection82
Compression And Rebound Damping Adjusters82
Nuts, Bolts, Fasteners83
Rear Suspension Adjustment83
Spring Pre-Load Adjuster83
Wheels/Tires84
Steering Head Bearings84
Recommended Tire Pressure And Tire Size84
Lubrication System Diagram85
Lubrication System Contents86
Lubrication System Service Information86
Lubrication System Specifications86
Lubrication System Torque Values86
Lubrication System Troubleshooting87
Oil Pressure Inspection88
Oil Strainer/Pressure Relief Valve Removal89
Oil Strainer/Pressure Relief Valve Inspection89
Oil Strainer/Pressure Relief Valve Installation90
Oil Pump Removal91
Oil Pump Disassembly91
Oil Pump Inspection92
Oil Pump Assembly93
Oil Pump Installation94
Oil Cooler Removal95
Oil Cooler Inspection96
Oil Cooler Installation96
Fuel System98
Fuel System Contents99
Fuel System Service Information99
Fuel System Specifications100
Fuel System Torque Values100
Fuel System Tools100
Fuel System Troubleshooting101
Air Cleaner Housing Removal102
Air Cleaner Housing Installation102
Carburetor Removal103
Carburetor Separation104
Carburetor Disassembly105
Air Funnel105
Starting Enrichment Valve106
Diaphragm/Vacuum Piston106
Float And Jets107
Carburetor Assembly109
Float Level Inspection110
Carburetor Combination113
Carburetor Installation117
Pilot Screw Adjustment118
Idle Drop Procedure118
System Inspection119
Fuel Valve120
Fuel Auto Valve Inspection120
Diaphragm Replacement120
Fuel Strainer Cleaning121
Cooling System Contents123
Cooling System Service Information123
Cooling System Specifications123
Cooling System Torque Values123
Cooling System Troubleshooting124
System Testing125
Coolant (Hydrometer Test)125
Radiator Cap/System Pressure Inspection125
Coolant Replacement126
Preparation126
Replacement/Air Bleeding126
Thermostat Removal127
Thermostat Inspection128
Thermostat Installation128
Radiator Removal129
Radiator Disassembly129
Radiator Assembly130
Water Pump132
Radiator Installation132
Mechanical Seal Inspection132
Mechanical Seal Removal133
Mechanical Seal Installation133
Radiator Reserve Tank Removal134
Radiator Reserve Tank Installation135
Engine Removal/Installation136
Engine Removal/Installation Contents137
Engine Removal/Installation Service Information137
Engine Specifications137
Engine Torque Values137
Engine Removal138
Engine Installation142
Cylinder Head/Valves147
Cylinder Head/Valves Contents148
Cylinder Head/Valves Service Information148
Cylinder Head/Valves Specifications148
Cylinder Head/Valves Torque Values149
Cylinder Head/Valves Tools149
Cylinder Head/Valves Troubleshooting150
Cylinder Compression Test151
Cylinder Head Cover Removal151
Camshaft Removal152
Camshaft Holder Inspection154
Camshaft Runout Inspection154
Cam Lobe Height Inspection155
Camshaft Oil Clearance155
Cam Chain Guide B156
Cylinder Head Disassembly157
Cylinder Head Inspection158
Cam Chain Tensioner/Cam Chain Guide159
Valve Spring159
Valve Lifter159
Valve Lifter Bore160
Valve/Valve Guide160
Valve Guide Replacement161
Valve Seat Inspection/Refacing162
Cylinder Head Assembly164
Cylinder Head Installation166
Camshaft Installation167
Cylinder Head Cover Installation171
Cam Chain Tensioner Lifter Removal172
Cam Chain Tensioner Lifter Installation173
Clutch/Gearshift Linkage175
Clutch/Gearshift Linkage Contents176
Clutch/Gearshift Linkage Service Information176
Clutch/Gearshift Linkage Specifications176
Clutch/Gearshift Linkage Torque Values176
Clutch/Gearshift Linkage Troubleshooting177
Right Crankcase Cover Removal178
Clutch Lifter Inspection178
Clutch Removal179
Clutch Lifter Bearing Inspection181
Clutch Spring Inspection181
Clutch Center Inspection181
Clutch Disc Inspection181
Clutch Plate Inspection182
Clutch Outer/Clutch Outer Guide Inspection182
Mainshaft Inspection182
Judder Spring/Spring Seat Inspection182
Clutch Outer Needle Bearing Replacement183
Clutch Installation183
Gearshift Linkage Removal186
Gearshift Linkage Inspection187
Shiift Drum/Shift Fork Removal187
Shiift Drum/Shift Fork Inspection188
Shiift Drum/Shift Fork Installation189
Gearshift Linkage Installation190
Right Crankcase Cover Installation191
Alternator/Starter Clutch193
Alternator/Starter Clutch Contents194
Alternator/Starter Clutch Service Information194
Alternator/Starter Clutch Troubleshooting194
Alternator/Starter Clutch Specifications194
Alternator Cover Removal195
Stator Removal196
Stator Installation196
Flywheel Removal197
Starter Clutch Disassembly198
Starter Clutch Inspection198
Starter Clutch Assembly199
Flywheel Installation200
Alternator Cover Installation201
Crankcase/Piston/Cylinder203
Crankcase/Piston/Cylinder Contents204
Crankcase/Piston/Cylinder Service Information204
Crankcase/Piston/Cylinder Specifications204
Crankcase/Piston/Cylinder Troubleshooting205
Crankcase/Piston/Cylinder Torque Values205
Crankcase Separation206
Piston/Connecting Rod Removal207
Piston Removal207
Piston Disassembly207
Piston Inspection208
Cylinder Inspection209
Connecting Rod Inspection210
Crankpin Bearing Inspection210
Crankpin Bearing Selection211
Connecting Rod Selection212
Crankpin Bearing Selection Table212
Piston Assembly213
Piston Installation213
Crankcase Combination215
Crankshaft/Transmission217
Crankshaft/Transmission Contents218
Crankshaft/Transmission Service Information218
Crankshaft/Transmission Specifications218
Crankshaft/Transmission Troubleshooting219
Crankshaft/Transmission Torque Values219
Crankshaft Removal220
Primary Drive Sub-Gear Removal221
Primary Drive Sub-Gear Installation221
Starter Clutch Needle Bearing Replacement222
Crankshaft Runout Inspection223
Main Journal Bearing Inspection223
Main Journal Bearing Selection224
Main Journal Bearing Selection Table225
Main Journal Bearing Installation225
Transmission Removal/Disassembly226
Bearing Replacement228
Transmission Assembly229
Transmission Installation230
Front Wheel/Suspension/Steering231
Front Wheel/Suspension/Steering Contents232
Front Wheel/Suspension/Steering Service Information232
Front Wheel/Suspension/Steering Specifications232
Front Wheel/Suspension/Steering Torque Values232
Front Wheel/Suspension/Steering Troubleshooting233
Front Wheel/Suspension/Steering Tools233
Handlebars Removal234
Handlebars Installation236
Handlebar Weight Replacement236
Front Wheel Removal239
Front Wheel Inspection240
Wheel Bearing241
Wheel Rim Runout241
Wheel Balance241
Front Wheel Disassembly242
Front Wheel Assembly242
Front Wheel Installation243
Fork Removal245
Fork Disassembly246
Fork Spring Inspection248
Fork Tube/Slider/Piston Inspection249
Fork Tube Bushing Inspection249
Compression Adjuster Inspection249
Fork Assembly250
Fork Installation253
Steering Stem Removal254
Steering Stem Installation259
Steering Head Bearing Pre-Load261
Rear Wheel/Suspension262
Rear Wheel/Suspension Contents263
Rear Wheel/Suspension Service Information263
Rear Wheel/Suspension Specifications263
Rear Wheel/Suspension Torque Values263
Rear Wheel/Suspension Troubleshooting264
Rear Wheel/Suspension Tools264
Rear Wheel Removal265
Rear Wheel Inspection265
Rear Wheel Disassembly266
Driven Sprocket266
Driven Flange Bearing Removal267
Rear Wheel Assembly268
Wheel Bearing Removal268
Wheel Bearing Installation268
Driven Flange Bearing Installation269
Rear Wheel Installation270
Shock Absorber Removal271
Shock Absorber Disassembly271
Shock Absorber Inspection272
Shock Absorber Disposal Procedure273
Lower Joint Needle Bearing Replacement273
Shock Absorber Assembly274
Shock Absorber Installation275
Suspension Linkage Removal/Disassembly276
Suspension Linkage Inspection276
Suspension Linkage Installation277
Shock Link Needle Bearing Replacement277
Swingarm Removal278
Swingarm Disassembly/Inspection280
Pivot Bearing Replacement281
Swingarm Assembly283
Shock Link Pivot Bearing Replacement283
Swingarm Installation284
Hydraulic Brake287
Hydraulic Brake Contents288
Hydraulic Brake Service Information288
Hydraulic Brake Specifications288
Hydraulic Brake Troubleshooting289
Hydraulic Brake Torque Values289
Brake Fluid Replacement/Air Bleeding290
Brake Fluid Draining290
Brake Fluid Filling290
Brake Bleeding291
Brake Pad/Disc292
Front Brake Pad Replacement292
Rear Brake Pad Replacement293
Front Master Cylinder Removal295
Brake Disc Inspection295
Front Master Cylinder Disassembly296
Front Master Cylinder Inspection297
Front Master Cylinder Assembly297
Rear Master Cylinder Removal299
Rear Master Cylinder Disassembly300
Rear Master Cylinder Inspection300
Rear Master Cylinder Assembly301
Rear Master Cylinder Installation302
Front Brake Caliper Removal303
Front Brake Caliper Disassembly303
Front Brake Caliper Inspection304
Front Brake Caliper Assembly305
Rear Brake Caliper Removal306
Front Brake Caliper Installation306
Rear Brake Caliper Disassembly307
Rear Brake Caliper Inspection308
Rear Brake Caliper Assembly308
Rear Brake Caliper Installation309
Brake Pedal Removal310
Brake Pedal Installation311
Battery/Charging System Diagram314
Battery/Charging System Contents315
Battery/Charging System Service Information315
Battery/Charging System Specifications316
Battery/Charging System Troubleshooting317
Battery Removal319
Battery Installation319
Battery Voltage Inspection319
Battery Charging319
Charging System Inspection320
Regulated Voltage Inspection320
Current Leakage Inspection321
Alternator Charging Coil Inspection322
Regulator/Rectifier System Inspection322
Regulator/Rectifier Removal/Installation323
Ignition System Diagram324
Ignition System Contents325
Ignition System Service Information325
Ignition System Specifications325
Ignition System Torque Values326
Ignition System Tools326
Ignition System Troubleshooting327
Ignition System Inspection328
Ignition Coil Primary Peak Voltage328
Ignition Pulse Generator Peak Voltage329
Ignition Coil Removal/Installation330
Ignition Pulse Generator Removal331
Ignition Pulse Generator Installation332
Throttle Sensor Inspection334
Input Voltage Inspection334
Output Voltage Inspection334
Electric Starter System Diagram337
Electric Starter Contents338
Electric Starter Service Information338
Electric Starter Specification338
Electric Starter Troubleshooting339
Starter Motor Removal341
Starter Motor Disassembly341
Starter Motor Inspection342
Starter Motor Assembly344
Starter Motor Installation346
Starter Relay Switch347
Operation Inspection347
Ground Line Inspection347
Voltage Inspection347
Diode Removal348
Diode Inspection348
Diode Installation348
Lights/Meters/Switches349
Lights/Meters/Switches Contents350
Lights/Meters/Switches Service Information350
Lights/Meters/Switches Specifications351
Lights/Meters/Switches Torque Values351
Lights/Meters/Switches Troubleshooting352
Headlight Bulb Replacement353
Position Light Bulb Replacement354
Headlight Bulb Removal/Installation354
Position Light Removal/Installation354
Turn Signal Bulb Replacement355
Turn Signal Removal/Installation355
Tail/Brake Light Bulb Replacement356
Combination Meter Removal356
Combination Meter Bulb Replacement357
Combination Meter Disassembly357
Combination Meter Assembly358
Speedometer/Speed Sensor359
Combination Meter Installation359
Sensor Inspection359
Output Signal Inspection359
Wire Harness Inspection360
Speedometer/Speed Sensor Removal/Installation360
Tachometer Inspection361
Coolant Temperature Gauge/Sensor Inspection361
Thermo Sensor Unit Inspection362
Cooling Fan Motor Switch Inspection363
Oil Pressure Switch Inspection364
Cooling Fan Motor Switch Removal/Installation364
Ignition Switch Inspection365
Ignition Switch Removal/Installation365
Handlebar Switches366
Clutch Switch367
Neutral Switch367
Side Stand Switch Inspection368
Side Stand Switch Removal368
Side Stand Switch Installation368
Horn369
Turn Signal Relay Inspection369
Wiring Diagrams370
Troubleshooting Contents372
Engine Does Not Start Or Is Hard To Start372
Engine Lacks Power373
Poor Performance At Low And Idle Speed374
Poor Performance At High Speed375
Poor Handling375
Index376
Cbr900Rr Addendum Contents378
Headlight/Position Light429
Coolant Temperature Gauge/Thermo Sensor Inspection435