Honda CBR 954RR Service Manual
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Honda CBR 954RR Service Manual

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SERVICE RULES

MODEL
I
SERVICE RULES
1 . Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's
design specifications may cause damage t o the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, O-rings, cotter
5 . When tightening bolts or nuts, begin w i t h the larger diameter or inner bolt first. Then tighten t o the specified torque
diagonally in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown o n pages 1-23 through 1-36, Cable and Harness Routing.

MODEL IDENTIFICATION

GENERAL INFORMATION
LUBRICATION & SEAL POINTS
1-1
1-1
CABLE & HARNESS ROUTING
1-3
EMISSION CONTROL SYSTEMS
1-12
EMISSION CONTROL INFORMATION
LABELS
1-17
pins, and lock plates when reassembling.
1-19
1-23
1-37
1-40

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Summary of Contents for Honda CBR 954RR

  • Page 1 TOOLS SERVICE RULES 1 . Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage t o the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.
  • Page 2 GENERAL INFORMATION (2) The engine serial number is stamped on the right side of the upper crankcase. of the steering head. VEHICLE IDENTIFICATION NUMBER (VIN) THROTTLE BODY ID~NTIFICATION NUMBER The Vehicle Identification Number (VIN) is located o n The throttle body identification number is stamped o n the intake side of the throttle body as shown.

  • Page 3: Specifications

    GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS ITEM 2,025 mm (79.7 in) Overall length DIMENSIONS 680 mm (26.8 in) Overail width 1,135 m m (44.7 in) Overal I height 1,395 mm (54.9 in) Wheelbase (32.3 in) Seat height 383 mm (15.1 in) Footpeg height (5.1 in) Ground clearance...
  • Page 4 GENERAL INFORMATION GENERAL (Cont’d) ITEM SPECIFICATIONS PGM-FI (Programmed Fuel Injection) Throttle bore 42 mm (1.7 in) TRAIN DRIVE Clutch system Multi-plate, w e t Clutch operation system Cable operating Transmission Constant mesh, 6-speeds Primary reduction 1.520 (73/48) Final reduction 2.687 (43/16) Gear ratio 1 st 2.692 (35/13)
  • Page 5 3.7 liter (3.9 US qt, 3.3 Imp qt) A t disassembly 4.0 liter (4.2 US 3.5 Imp Pro Honda GN4 or HP4 (without molybde- n u m additives) 4-stroke oil or equivalent motor oil API service classification: SG or higher...
  • Page 6 182°F) Fully open 95°C (203°F) Valve lift 8 rnm (0.3 in) minimum Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors Standard coolant concentration Unit: mm (in) CYLINDER HEADNALVES ITEM STANDARD...
  • Page 7 Unit: m m (in) ITEM STANDARD SERVICE LIMIT Clutch lever free play 20 (3/8 13/16) Clutch spring free length 48.8 (1.92) 47.4 (1.87) Clutch disc thickness 2.92 3.08 (0.115-0.121) 2.6 (0.10) Clutch plate warpage 0.30 (0.012) I.D. 25.000 25.021 (0.9843 0.9851) 25.03 (0.985) Clutch outer guide...
  • Page 8 GENERAL INFORMATION ITEM STANDARD SERVICE LIMIT Side clearance 0.05 - 0.20 (0.002 - 0.008) 0.30 (0.012) 0.03 (0.001) Main journal oil clearance 0.017 - 0.035 (0.0007 - 0.0014) 0.045 (0.0018) 31.000 - 31.025 (1.2205 - 1.2215) Gear I.D. M5, M 6 31.04 (1.222) 26.000 26.021 (1.0236...
  • Page 9 255.8 (10.07) 250.8 (9.87) Spring direction With the tapered end facing u p Fork pipe runout 0.20 (0.008) Recommended fork oil Pro Honda Suspension Fluid SS-8 Fluid level 73 (2.9) Fluid capacity 2.5 cm3 (17.3 0.08 US 18.1 0.09 Imp...
  • Page 10 GENERAL INFORMATION ITEM STANDARD SERVICE LIMIT Front Specified brake fluid Honda DOT 4 Brake Fluid Brake disc thickness 4.5 (0.18) 3.5 (0.14) Brake disc runout 0.30 (0.012) Master cylinder I.D. 17.460 - 17.503 (0.6874 - 0.6891) 17.515 (0.6896) Master piston O.D.
  • Page 11 GENERAL INFORMATION Starter motor brush length 10.0 10.5 (0.39 - 0.41) 3.5 (0.14) ITEM SPECIFICATIONS Bulbs 5 5 w 12V - 3 2 / 3 ~ p (23/8W) X 2 Front turn signal light Rear turn signal light License light Instrument light LED X Turn signal indicator...

  • Page 12: Torque Values

    GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE 4 (0.4, 2.9) 5 m m hex bolt and nut 5 (0.5, 3.6) 5 mm screw small flange) 34 (3.5, 25) 12 (1.2, 9) 6 mm flange bolt (8 m m head, 12 m m hex bolt and nut 54 (5.5, 40) large flange)
  • Page 13 GENERAL INFORMATION ENGINE (Cont’d) TORQUE REMARKS ITEM CYLINDER HEADNALVES: Cylinder head cover bolt PAIR reed valve cover flange bolt 12 (1.2, 9) NOTE 2 NOTE 2 Breather plate flange bolt 12 (1.2, 9) Camshaft holder flange bolt 12 (1.2, 9) NOTE 5 Cylinder head sealing bolt 27 (2.8, 20)
  • Page 14 GENERAL INFORMATION ENGINE (Cont'd) ITEM REMARKS Q'TY DIA. NOTE Ignition pulse generator rotor mounting bolt ELECTRIC STARTER: Starter motor terminal nut Neutral switch Insulator clamp (Throttle body side): insulator clamp (Cylinder head side): m m (0.5 0.04 in) m m (0.3 0.04 in) Exhaust 1-14...
  • Page 15 GENERAL INFORMATION FRAME TORQUE REMARKS ITEM FRAME BODY PANELWEXHAUST SYSTEM: 26 (2.7, 20) Upper cowl stay mounting bolt 7 (0.7, 5.1) Upper cowl stay mounting bolt 1.5 (0.15, 1.1) Upper cowl pan screw 1.5 (0.15, 1.1) Lower cowl pan screw 1.5 (0.15, 1.1) Rear cowl truss screw NOTE7...
  • Page 16 GENERAL INFORMATION FRAME (Cont'd) TORQUE THREAD REMARKS ITEM Q'TY DIA. (mm) NOTE 8 Gearshift pedal link pinch bolt FRONT WHEEL/SUSPENSION/STEERING: Handlebar pinch bolt 26 (2.7, 20) NOTE 8 Handlebar weight mountign screw (1.0, 7) 13-30 Steering stem nut See page Steering stem adjusting nut Steering stem lock nut Fork top bridge pinch bolt...
  • Page 17 GENERAL INFORMATION TOOLS NOTES: 1. Equivalent commercially available in U.S.A. 2. Alternative tool. 3. Newly designed tool. 4. Not available i n U.S.A. REF. SEC. DESCRIPTION TOOL NUMBER REMARKS ECM test harness, 26P Fuel pressure gauge NOTE 2: 07406-OO4000A 07406-0040003 (U.S.A.
  • Page 18 GENERAL INFORMATION DESCRIPTION REF. SEC. TOOL NUMBER REMARKS Race remover NOTE 4 Driver attachment NOTE 4 Compression gauge attachment 07RMJ-MY50100 Fork damper holder handle Installer attachment, A U.S.A. only Installer attachment, 07VMF-MAT0200 U.S.A. only Remover attachment, A 07VMF-MAT0300 U.S.A. only Remover attachment, 07VMF-MAT0400 U.S.A.
  • Page 19 GENERAL INFORMATION LUBRICATION & SEAL POINTS REMARKS MATERIAL LOCATION Liquid sealant Crankcase mating surface (Three Bond 1207B or pressure switch threads not apply sealant to the thread m m (0.1 0.2 in) 1-19...
  • Page 20 GENERAL INFORMATION ENGINE (Cont'd) REMARKS MATERIAL LOCATION Cylinder head semi-circular cut-out Sealant Molybdenum disulfide Main journal bearing surface oil (a mixture of 1/2 Piston pin sliding surface engine oil and 1/2 Connecting rod bearing surface Connecting rod small end inner surface m o I ybdenum d isulfide Crankshaft thrust surface grease...
  • Page 21 GENERAL INFORMATION REMARKS MATERIAL LOCATION Multi-purpose grease Timing hole cap threads Each oil seal lip Locking agent Upper crankcase sealing bolt threads Lower crankcase sealing bolt threads Cam chain guide mounting bolt threads Cam pulse generator rotor bolt threads Cylinder head sealing bolt threads Cylinder head cover breather joint threads Coating width: 6.5 1 m m...
  • Page 22 Rear brake caliper slide pin surface Rear brake caliper slide pin threads Locking agent Rear master cylinder hose joint screw threads Driven sprocket stud bolt threads Handlebar grip rubber inside Honda Bond Fork fluid Fork cap O-ring Fork oil seal lips 1-22...
  • Page 23 GENERAL INFORMATION CABLE & HARNESS ROUTING BANK ANGLE SENSOR RIGHT TURN ~ I G N A L HEAD LIGHT CONNECTOR (Hi) CON N ECTORS HEAD LIGHT CONNECTOR 1-23...
  • Page 24 GENERAL INFORMATION CLUTCH CABLE MAIN HORN WIRE 1-24...
  • Page 25 GENERAL INFORMATION FRONT 1-25...
  • Page 26 GENERAL INFORMATION ' I -26...
  • Page 27 GENERAL INFORMATION EXCEPT CALIFORNIA TYPE: STARTER MOTOR'GROUND CABLE 1-27...
  • Page 28 GENERAL INFORMATION CALIFORNIA TYPE: PAIR CONTROL SOLENOID VALVE 2P (NATURAL) CONNECTOR GROUND 1-28...
  • Page 29 GENERAL INFORMATION LOWER FAST UNIT 1-29...
  • Page 30 GENERAL INFORMATION THROTTLE STOP CONTROL CABLE FUEL TANK AIR VENT HOSE EGCV C O N T ~ O L CABLES 1-30...
  • Page 31 GENERAL INFORMATION PAIR SUCTION HOSE SIPHON HOSE FUEL TANK AIR VENT HOSE FUEL TANK OVERFLOW IGNITI O N PULSE GENERATOR WIRE RESERVOIR TANK OVERFLOW HOSE 1-31...
  • Page 32 GENERAL INFORMATION INJECTOR CONNECTORS 1-32...
  • Page 33 GENERAL INFORMATION IAT SENSOR H CONNECTOR KE VALVE SERVO MOTOR CONNECTOR MAP SENSOR SPEED SENSOR VACUUM HOSE CONNECTOR FUEL HOSE 1-33...
  • Page 34 GENERAL INFORMATION REAR BRAKE LIGHT SWITCH CON N ECTOR BATTERY NEGATIVE FUSE ECM 26P (LIGHT GRAY) CONNECTOR ECM 26P (BLACK) CON N ECTOR ALTERNATOR 3P (WHITE) CONNECTOR 1-34...
  • Page 35 GENERAL INFORMATION HEADLIGHT RELAY CONNECTOR BOOT: REAR TURN SIGNAL LIGHT CONNECTOR LICENSE LIGHT CONNECTOR CONNECTOR REAR BRAKE LIGHT SWITCH WlRE SENSOR WIRE (California type only) REAR BRAKE LIGHT SWITCH 1-35...
  • Page 36 GENERAL INFORMATION REAR BRAKE HOSE RESERVOIR HOSE REAR BRAKE SWITCH 1-36...

  • Page 37: Crankcase Emission Control System

    Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean injection settings as well as other systems, t o reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system t o prevent discharging crankcase emissions into the atmosphere.
  • Page 38 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) The exhaust emission control system is composed of a lean fuel injection setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emis- sion control system.
  • Page 39 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) This model complies with CARB evaporative emission requirements. Fuel vapor from the fuel tank is routed into the evaporative emission (EVAP) canister where it is absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission (EVAP) purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn into the engine through the throttle body.
  • Page 40 GENERAL INFORMATION EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION LABEL LABELS An Emission Control Information Label is located on the storage compartment as shown. The seat must be removed t o read it. It gives base tune-up specifications. N C O ~ T R O L I N FO R MATI EM I LABEL (Canada only) VACUUM HOSE ROUTING DIAGRAM...

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