Honda CBR1000RR (2004-2011) - Service Manual - Parts Catalogue - Wiring Diagram View larger

Honda CBR1000RR (2004-2011) - Service Manual - Parts Catalogue - Wiring Diagram

Honda CBR1000RR (2004-2011) - Service Manual - Parts Catalogue - Wiring Diagram.

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HONDA CBR1000RR (2004-2011) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING - OWNERS

- English Service Manual, Parts Catalogue and Wiring Diagram to motorcycles Honda CBR1000RR.


FILES INCLUDED:


- Honda CBR1000RR (2004) -  Service Manual.pdf - (586 pages)
- Honda CBR1000RR (2008) -  Service Manual.pdf - (554 pages)
- Honda CBR1000RR (2004) -  Parts Manual.pdf - (147 pages)
- Honda CBR1000RR (2004-2011) - Owners Manual.pdf - (1306 pages)


CONTENTS:


SERVICE MANUAL:


SERVICE INFORMATION.
CONTENTS.
SYMBOLS.

1.GENERAL INFORMATION.
- 1.1 Contents.
- 1.2 Service Rules.
- 1.3 Model Identification.
- 1.4 Labels.
- 1.5 General Specifications.
- 1.6 Electrical Specifications.
- 1.7 Lubrication, Fuel & Cooling System Specifications.
- 1.8 Cylinder Head & Valve Specifications.
- 1.9 Crankcase, Transmission & Balancer Specifications.
- 1.10 Wheel, Suspension & Steering Specifications.
- 1.11 Brake, Battery & Ignition Specifications.
- 1.12 Lights, Meters & Switches Specifications.
- 1.13 Torque Values.
- 1.14 Lubrication, Fuel & Cooling.
- 1.15 Cylinder Head, Clutch & Starter.
- 1.16 Crank, Wheels & Suspension.
- 1.17 Brakes, Starter & Lights.
- 1.18 Lubrication & Seal Points.
- 1.19 Frame.
- 1.20 Cable & Harness Routing.
- 1.21 IDC.
- 1.22 Throttle & Clutch.
- 1.23 Brakes.
- 1.24 ECM.
- 1.25 Injectors.
- 1.26 HESD.
- 1.27 Fuel Pump.
- 1.28 PAIR & Fan.
- 1.29 Starter & Battery.
- 1.30 Oil Cooler & Sidestand.
- 1.31 Radiator.
- 1.32 Sub Harness.
- 1.33 Tail & Signals.
- 1.34 EGCA.
- 1.35 EVAP (California).
- 1.36 EVAP Purge.
- 1.37 Emission Control Systems.
- 1.38 Exhaust ECS.
- 1.39 Evaporative ECS.

2.TECHNICAL FEATURES.
- 2.1 Contents.
- 2.2 Exhaust System.
- 2.3 EGBV.
- 2.4 ECV.
- 2.5 CMP Sensor.
- 2.6 Fan Motor Control System.
- 2.7 Clutch System.
- 2.8 Clutch Mechanism.
- 2.9 Clutch Assist.

3.FRAME, BODY PANELS & EXHAUST SYSTEM.
- 3.1 Contents.
- 3.2 Body Panel Locations.
- 3.3 Service Information.
- 3.4 Trim Clips.
- 3.5 Trim Clip 3.
- 3.6 Seat, Side Covers & Pillion Seat.
- 3.7 Tank Cover.
- 3.8 Rear Seat Cowl.
- 3.9 Upper Inner Cover & Lower Cowl.
- 3.10 Middle Cowl.
- 3.11 Mirrors.
- 3.12 Windscreen.
- 3.13 Upper Cowl.
- 3.14 Vacuum Chamber.
- 3.15 Lights.
- 3.16 Bank Angle Sensor.
- 3.17 Wire Harness.
- 3.18 Front Fender.
- 3.19 Rear Fender.
- 3.20 Rear Fender C.
- 3.21 License Light Stay.
- 3.22 Undertray.
- 3.23 Seat Rail.
- 3.24 Muffler.
- 3.25 EGCA Cable.
- 3.26 Disassembly.
- 3.27 Assembly.
- 3.28 Heat Guard.
- 3.29 Installation.
- 3.30 Main Step Bracket.
- 3.31 Exhaust Pipe.
- 3.32 Installation.
- 3.33 Headers.
- 3.34 Mountings.

4.MAINTENANCE.
- 4.1 Contents.
- 4.2 Service Information.
- 4.3 Tools.
- 4.4 Maintenance Schedule.
- 4.5 Fuel Line.
- 4.6 Inspection.
- 4.7 Fuel Tank.
- 4.8 Throttle Operation.
- 4.9 Air Cleaner.
- 4.10 Spark Plug.
- 4.11 Inspection.
- 4.12 Valve Clearance.
- 4.13 Timing.
- 4.14 Intake & Exhaust Valves.
- 4.15 Adjustment.
- 4.16 Shims.
- 4.17 Engine Oil.
- 4.18 Filter Change.
- 4.19 Sump.
- 4.20 Radiator Coolant.
- 4.21 Secondary Air Supply.
- 4.22 EVAP (California).
- 4.23 EGCA Cable.
- 4.24 Cable Inspection.
- 4.25 Adjustment.
- 4.26 Drive Chain.
- 4.27 Cleaning & Lubrication..
- 4.28 Sprockets.
- 4.29 Chain Replacement.
- 4.30 Chain Links.
- 4.31 Brake Fluid.
- 4.32 Brake Pads Wear.
- 4.33 Brake Light Switch.
- 4.34 Headlight & Clutch.
- 4.35 Sidestand & Suspension.
- 4.36 Front Suspension.
- 4.37 Rear Suspension.
- 4.38 Nuts, Bolts & Fasteners.
- 4.39 Wheels & Tires.
- 4.40 Steering Head Bearings.

5.LUBRICATION SYSTEM.
- 5.1 Contents.
- 5.2Lubrication System Diagram.
- 5.3 Service Information.
- 5.4 Troubleshooting.
- 5.5 Oil Pressure Inspection.
- 5.6 Oil Pump.
- 5.7 Disassembly.
- 5.8 Inspection.
- 5.9 Assembly.
- 5.10 Installation.
- 5.11 Sprockets.
- 5.12 Sump.
- 5.13 Oil Cooler.
- 5.14 Installation.

6.FUEL SYSTEM (PGM-FI)
- 6.1 Contents.
- 6.2 Component Location.
- 6.3 Service Information.
- 6.4 Specifications.
- 6.5 Tools.
- 6.6 Tools (Cont).
- 6.7 PGM-FI Symptom Troubleshooting.
- 6.8 PGM-FI System Location.

- 6.9 PGM-FI System Diagram.
- 6.10 Connector Location.
- 6.11 ECM Connectors.
- 6.12 PGM-FI Troubleshooting Information.
- 6.13 HDS Information.
- 6.14 Clearing DTC.
- 6.15 DTC Index.
- 6.16 DTC Index.
- 6.17DTC Troubleshooting.
- 6.18 MAPSensor Output. .
- 6.19 MAPSensor Input.
- 6.20 MAPSensor Inspection.
- 6.21 ECT Resistance.
- 6.22 ECT Sensor Output.
- 6.23 TP Sensor.
- 6.24 TP Sensor HV.
- 6.25 IAT Sensor LV.
- 6.26 IAT Sensor Inspection.
- 6.27 VS Sensor Input.
- 6.28Primary Injector.
- 6.29 Injector Inspection.
- 6.30 CMP Sensor.
- 6.31 CMP Sensor Input.
- 6.32 CKPSensor Inspection.
- 6.33 Knock Sensor Inspection.
- 6.34 Knock Sensor LV.
- 6.35 IACV Inspection.
- 6.36 ECV Pot LV.
- 6.37 ECV PotInspection.
- 6.38 ECV Pot HV.
- 6.39 EGCA Lock.
- 6.40 MIL Circuit Troubleshooting.
- 6.41 Fuel Line Inspection.
- 6.42 Fuel Rail.
- 6.43 Quick Connect Fitting.
- 6.44 Fuel Pressure Test.
- 6.45 Tools.
- 6.46 Fuel Flow Inspection.
- 6.47 Fuel Pump Unit
- 6.48 Removal.
- 6.49 Installation.
- 6.50 Fuel Pump Relay.
- 6.51 Fuel Tank.
- 6.52 Air Cleaner Housing.
- 6.53 Removal.
- 6.54 Installation.
- 6.55 Secondary Injector.
- 6.56 Removal.
- 6.57 Installation.
- 6.58 Throttle Body.
- 6.59 Removal.
- 6.60 Diagram.
- 6.61 Hose Routing.
- 6.62 Installation.
- 6.63 Primary Injector.
- 6.64 Removal.
- 6.65 Installation.
- 6.66 Engine Idle Speed.
- 6.67 Removal/Installation.
- 6.68 Knock Sensor.
- 6.69 MAP Sensor.
- 6.70 IAT &ECT Sensor.
- 6.71 CMPSensor.
- 6.72 Bank Angle Sensor.
- 6.73 Engine Stop Relay.
- 6.74 ECM.
- 6.75 Power Line Inspection.
- 6.76 Engine Stop Relay Inspection.
- 6.77 Secondary Air Supply System.
- 6.78 PAIR Control Solenoid.
- 6.79 EGCA.
- 6.80 Inspection.
- 6.81 Intake Air Duct Control.
- 6.82 One-Way Valve.
- 6.83 EVAP (California).
- 6.84 Removal.
- 6.85 Installation.

7.COOLING SYSTEM.
- 7.1 Contents.
- 7.2 System Flow Pattern.
- 7.3 Service Information.
- 7.4 Troubleshooting.
- 7.5 System Testing.
- 7.6 Coolant Replacement.
- 7.7 Replacement/Air Bleeding.
- 7.8 Thermostat.
- 7.9 Inspection.
- 7.10 Installation.
- 7.11 Radiator/Cooling Fan.
- 7.12 Removal.
- 7.13 Disassembly.
- 7.14 Cooling Fan.
- 7.15 Fan Motor.
- 7.16 Assembly.
- 7.17 Fittings.
- 7.18 Alignment.
- 7.19 Installation.
- 7.20 Connections.
- 7.21 Water Pump.
- 7.22 Installation.
- 7.23 Connections.
- 7.24 Radiator Reserve Tank.

8.ENGINE REMOVAL & INSTALLATION.
- 8.1 Contents.
- 8.2 Component Location.
- 8.3 Service Information.
- 8.4 Engine Removal.
- 8.5 Sensors.
- 8.6 Mountings.
- 8.7 Tools.
- 8.8 Engine Installation.
- 8.9 Frame.
- 8.10 Mountings.
- 8.11 Brackets.
- 8.12 Fittings.
- 8.13 Sensors
- 8.14 Switches.

9.CYLINDER HEAD & VALVES.
- 9.1 Contents.
- 9.2 Component Location.
- 9.3 Service Information.
- 9.4 Tools.
- 9.5 Tools.
- 9.6 Troubleshooting.
- 9.7 Cylinder Compression Test.
- 9.8 Cylinder Head Cover Disassembly.
- 9.9 Camshaft Removal.
- 9.10 Cam Sprocket.
- 9.11 Cam Chain.
- 9.12 Inspection.
- 9.13 Camshaft Oil Clearance.
- 9.14 Cylinder Head Removal.
- 9.15 Cylinder Head Disassembly.
- 9.16 Tools.
- 9.17 Cylinder Head Inspection.
- 9.18 Valve Springs.
- 9.19 Valve Guide.
- 9.20 Valve Guide Replacement.
- 9.21 Valve Seat Inspection.
- 9.22 Valve Seat Refacing.
- 9.23 Tools.
- 9.24 Cylinder Head Assembly.
- 9.25 Tools.
- 9.26 Cylinder Head Installation.
- 9.27 Cam Chain Tensioner.
- 9.28 Cylinder Layout.
- 9.29 Tightening Sequence.
- 9.30 Camshaft Installation.
- 9.31 Alignment.
- 9.32 Identification.
- 9.33 Cam Sprockets.
- 9.34 Cylinder Head Cover Assembly.
- 9.35 Cylinder Head Cover Installation.
- 9.36 Fixings.
- 9.37 Cam Chain Tensioner Lifter.
- 9.38 Tensioner Stopper.

10. CLUTCH, STARTER & GEARSHIFT.
- 10.1 Contents.
- 10.2 Component Location.
- 10.3 Service Information.
- 10.4 Troubleshooting.
- 10.5 Right Crankcase Cover Removal.
- 10.6 Clutch Lifter Lever.
- 10.7 Clutch.
- 10.8 Clutch Center Lock Nut.
- 10.9 Pressure Plate.
- 10.10 Clutch Outer.
- 10.11 Inspection.
- 10.12 Clutch Spring.
- 10.13 Clutch Disc.
- 10.14 Primary Driven Gear.
- 10.15 Mainshaft.
- 10.16 Needle Bearing Selection.
- 10.17 Installation.
- 10.18 Reduction Gear.
- 10.19 Clutch Plates.
- 10.20 Clutch Assembly.
- 10.21 Clutch Holder.
- 10.22 Lifter Plate.
- 10.23 Starter Clutch.
- 10.24 Inspection.
- 10.25 Assembly.
- 10.26 Installation.
- 10.27 Gearshift Linkage.
- 10.28 Inspection.
- 10.29 Installation.
- 10.30 Right Crankcase Cover.
- 10.31 Gaskets.
- 10.32 Clutch Cable.

11.ALTERNATOR.
- 11.1 Contents.
- 11.2Component Location.
- 11.3 Service Information.
- 11.4 Alternator Cover Removal.
- 11.5 Stator.
- 11.6 Flywheel.
- 11.7 Alternator Cover Installation.
- 11.8 Sensors.

12. CRANKCASE, TRANSMISSION & BALANCER.
- 12.1 Contents.
- 12.2 Component Location.
- 12.3 Service Information.
- 12.4 Troubleshooting.
- 12.5 Crankcase Separation.
- 12.6 Shift Fork, Drum & Transmission.
- 12.7 Removal.
- 12.8 Shift Fork & Drum Inspection.
- 12.9 Transmission Inspection.
- 12.10 Mainshaft Bearing.
- 12.11 Mainshaft Bearing Replacement.
- 12.12 Transmission Assembly.
- 12.13 Gear & Shafts.
- 12.14 Installation.
- 12.15 Fork Shaft.
- 12.16 Balancer.
- 12.17 Inspection.
- 12.18 Balancer Bearing Selection.
- 12.19 Disassembly.
- 12.20 Installation.
- 12.21 Balancer Gear Backlash Adjuster.
- 12.22 Crankcase Assembly.
- 12.23 Tightening Mehod.
- 12.24 Hoses & Seals.

13. CRANKSHAFT, PISTON & CYLINDER.
- 13.1 Contents.
- 13.2 Component Location.
- 13.3 Service Information.
- 13.4 Troubleshooting.
- 13.5 Crankshaft.
- 13.6 Inspection.
- 13.7 Installation.
- 13.8 Connecting Rods.
- 13.9 Main Journal Bearing.
- 13.10 Bearing Selection.
- 13.11 Bearing Installation.
- 13.12 Crankpin Bearing.
- 13.13 Bearing Selection.
- 13.14 Piston & Cylinder.
- 13.15 Removal.
- 13.16 Piston Inspection.
- 13.17 Connecting Rod Inspection.
- 13.18 Cylinder Inspection.
- 13.19 Piston Assembly.
- 13.20 Piston Installation.
- 13.21 Tightening Method.

14. FRONT WHEEL, SUSPENSION & STEERING.
- 14.1 Contents.
- 14.2 Component Location.
- 14.3 Service Information.
- 14.4 Tools.
- 14.5 Tools (Cont).
- 14.6 Troubleshooting.
- 14.7 HESD Troubleshooting.
- 14.8 DTC Troubleshooting.
- 14.9 Handlebars.
- 14.10 Throttle.
- 14.11 Top Yoke.
- 14.12 Installation.
- 14.13 Steering Damper.
- 14.14 Grips.
- 14.15 HandlebarWeights.
- 14.16 Front Wheel.
- 14.17 Inspection.
- 14.18 Wheel Balance.
- 14.19 Disassembly.
- 14.20 Installation.
- 14.21 Tightening.
- 4.22 Fork.
- 4.23 Removal.
- 4.24 Stopper Plate.
- 4.25 Fork Damper.
- 4.26 Inspection.
- 4.27 Assembly.
- 4.28 Oil Seals.
- 4.29 Slider.
- 4.30 Bleeding.
- 4.31 Compression.
- 4.32 Installation.
- 14.33 HESD.
- 14.34 Steering Stem.
- 14.35 Bearing Replacement.
- 14.36 Driver Shaft.
- 14.37 Assembly Base.
- 14.38 Tools.
- 14.39 Upper Bearings.
- 14.40 Lower Inner Race Replacement.
- 14.41 Bearings.
- 14.42 Steering Head Bearing Pre-Load.

15. REAR WHEEL & SUSPENSION.
- 15.1 Contents.
- 15.2 Component Location.
- 15.3 Service Information.
- 15.4 Tools.
- 15.5 Troubleshooting.
- 15.6 Rear Wheel.
- 15.7 Disassembly.
- 15.8 Inspection.
- 15.9 Driven Flange Bearing Replacement.
- 15.10 Wheel Bearing Replacement.
- 15.11 Assembly.
- 15.12 Installation.
- 15.13 Suspension Linkage.
- 15.14 Shock Absorber.
- 15.15 Inspection.
- 15.16 Lower Bearing.
- 15.17 Shock Absorber Disposal.
- 15.18 Swingarm.
- 15.19 Disassembly.
- 15.20 Inspection.
- 15.21 Bearings.
- 15.22 Shock Arm.
- 15.23 Assembly.
- 15.24 Installation.
- 15.25 Hose Routing.

16. HYDRAULIC BRAKE.
- 16.1 Contents.
- 16.2 Component Location.
- 16.3 Rear.
- 16.4 Service Information.
- 16.5 Troubleshooting.
- 16.6 Brake Fluid Replacement.
- 16.7 Air Bleeding.
- 16.8 Brake Pad & Disc.
- 16.9 Front Brake Pad Replacement.
- 16.10 Rear Brake Pad Replacement.
- 16.11 Brake Disc Inspection.
- 16.12 Front Master Cylinder.
- 16.13 Disassembly.
- 16.14 Inspection.
- 16.15 Assembly.
- 16.16 Brake Light Switch.
- 16.17 Installation.
- 16.18 Rear Master Cylinder.
- 16.19 Removal.
- 16.20 Disassembly.
- 16.21 Inspection.
- 16.22 Assembly.
- 16.23 Snap Ring.
- 16.24 Installation.
- 16.25 Master Cylinder.
- 16.26 EGCA Cable.
- 16.27 Front Brake Calipers.
- 16.28 Inspection.
- 16.29 Assembly.
- 16.30 Rear Brake Caliper.
- 16.31 Inspection.
- 16.32 Assembly.
- 16.33 Installation.

17.BATTERY & CHARGING SYSTEM.
- 17.1 Contents.
- 17.2 System Diagram.
- 17.3 Service Information.
- 17.4 Tools.
- 17.5 Troubleshooting.
- 17.6 Battery.
- 17.7 Charging System Inspection.
- 17.8 Alternator Charging Coil.
- 17.9 Regulator & Rectifier.

18.IGNITION SYSTEM.
- 18.1 Contents.
- 18.2 System Diagram.
- 18.3 System Information.
- 18.4 Troubleshooting.
- 18.5 Ignition System Inspection.
- 18.6 CKP Sensor.
- 18.7 Ignition Timing.
- 18.8 Timing Cover.

19.ELECTRIC STARTER.
- 19.1 Contents.
- 19.2 System Diagram.
- 19.3 System Information.
- 19.4 Troubleshooting.
- 19.5 Inspection.
- 19.6 Starter Motor.
- 19.7 Disassembly.
- 19.8 Inspection.
- 19.9 Brushes.
- 19.10 Bearings.
- 19.11 Assembly.
- 19.12 Components.
- 19.13 Seal Rings.
- 19.14 Starter Relay Switch.
- 19.15 Operation Inspection.
- 19.16 Diode.

20. LIGHTS, METERS & SWITCHES.
- 20.1 Contents.
- 20.2 System Location.
- 20.3 Service Information.
- 20.4 Tools.
- 20.5 Troubleshooting.
- 20.6 Headlight.
- 20.7 Brake & Tail Light.
- 20.8 Licence Light.
- 20.9 Combination Meter.
- 20.10 Removal & Installation.
- 20.11 Speedomoter.
- 20.12 Tachometer.
- 20.13 ECT Sensor.
- 20.14 EOP Switch.
- 20.15 Fuel Reserve Sensor.
- 20.16 Ignition Switch.
- 20.17 Handlebar Switches.
- 20.18 Brake Light Switch.
- 20.19 Clutch Switch.
- 20.20 Neutral Switch.
- 20.21 Sidestand Switch.
- 20.22 Horn & Turn Signal Relay.
- 20.23 Headlight Relay.

21.WIRING DIAGRAMS.
- 21.1 Contents.
- 21.2 United Kingdom & Europe.
- 21.3 United States.

22.TROUBLESHOOTING.
- 22.1 Contents.
- 22.2 Engine Does Not Start Or Is Hard To Start.
- 22.3 Engine Lacks Power.
- 22.4 Ignition Timing.
- 22.5 Poor Performance At Low And Idle Speed.
- 22.6 Poor Performance At High Speed.

23.INDEX
- 23.1 Index
- 23.2 Index

BACK COVER



PARTS MANUAL:


ENGINE SECTION

- Cylinder head cover
- Cylinder head
- Camshaft valve
- Cam chain tensioner
- Right crankcase cover
- Clutch
- Starting clutch
- Left crankcase cover
- Alternator
- Water pump
- Starting motor
- Oil pan oil pump
- Crankcase

- Crankshaft piston
- Transmission
- Gearshift drum
- Thermostat
- Throttle body (assy)
- Throttle body (injection)

FRAME SECTION

- Headlight
- Speedometer
- Switch cable
- Fr brake master cylinder
- Clutch master cylinder
- Handlebar top bridge
- Steering damper
- Steering stem
- Front fender
- Front fork
- Front brake caliper
- Front wheel
- Rear brake master cylinder
- Rear brake caliper
- Rear wheel
- Top shelter
- Fuel tank fuel pump
- Seat
- Seat cowl
- Air cleaner
- Air intake duct solenoid valve
- Air injection control valve
- Canister(ac)
- Muffler
- Pedal
- Step
- Stand
- Swingarm
- Rr shock absorber  
- Rear fender  
- Fr/rr turn signal  
- Taillight
- Battery  
- Servo motor
- Wire harness  
- Frame  
- Tools  
- Radiator
- Upper cowl
- Middle cowl  
- Lower cowl  
- Caution label
- Stripe mark (1)  
- Stripe mark (2)  



OWNERS MANUAL:


WELCOME
A FEW WORDS ABOUT SAFETY
CONTENTS

MOTORCYCLE SAFETY
- Safety Guidelines
- Image Labels
- Safety Precautions
- Riding Precautions
- Accessories & Modifications
- Loading

OPERATION GUIDE
- Parts Location
- Instruments
- Indicators
- Switches
- Starting the Engine
- Shifting Gears
- Refuelling
- Storage Compartment

MAINTENANCE
- Importance of Maintenance
- Maintenance Schedule
- Maintenance Fundamentals
- Tool kit
- Removing & Installing Body Components
- Engine Oil
- Coolant
- Brakes
- Side Stand
- Drive Chain
- Clutch
- Throttle
- Other Adjustments

TROUBLESHOOTING
- Engine Will Not Start (HISS indicator stays on)
- Overheating (High coolant temperature indicator is on)
- Warning Indicators On or Flashing
- Tyre Puncture
- Electrical Trouble

INFORMATION
- Keys
- Instruments, Controls, & Other Features
- Fuels Containing Alcohol
- Catalytic Converter
- Caring for Your Motorcycle
- Storing Your Motorcycle
- Transporting Your Motorcycle
- You & the Environment
- Serial Numbers

SPECIFICATIONS
INDEX