CBR1000RR PARTS LIST CONTENTS INSTRUCTIONS FOR USE OF PARTS LIST INDEX

Transcription

1 004-CBR000RR PARTS LIST CONTENTS INSTRUCTIONS FOR USE OF PARTS LIST ENGINE GROUP E- ENGINE POWER UP KIT I E- - ENGINE POWER UP KIT II E- A.C. GENERATOR SET E- 3 WIRE LOCKING KIT / AIR FUNNEL SET E- 4 WATER HOSE PLUG SET E- 5 AIR INJECTION PLUG SET E- 6 TRANSMISSION SET / DRIVE SPROCKET SET E- 7 CAM CHAIN / TENSIONER FRAME GROUP F- AIR BOX DUCT SET F- BREATHER CASE SET F- 3 EXHAUST SET F- 4 FRONT FORK F- 5 SWINGARM F- 6 REAR CUSHION F- 7 STEERING DAMPER F- 8 RADIATOR F- 9 FRAME PARTS F-0 WIRE HARNESS F- REAR WHEEL F- FRONT WHEEL F-3 BRAKE F-4 QUICK SHIFTER SET INDEX

2 INSTRUCTIONS FOR USE OF PARTS LIST This parts list is to be used when ordering replacement parts; it contains all parts for model 004-CBR000RR.. How to order parts Information required Replacement parts orders must contain both the part number and the stamped number(s) as described belew. This is because any changes and modifications of parts are registered at Honda with the pertinent parts and stamped numbers. If quantities are shown in ( ), the parts are optional. If N is indicated in the quantity column, the parts quantity is to be determined as required.. How to read this parts list Make-up of the part number (Example) General parts Function and component No. Model code No. Color code Subcontractor designation Modification designation IMPORTANT INFORMATION The parts which have a dot on the left side of the Ref. No. are exclusive for HRC products. To purchase these parts, consult your Honda dealer. The parts which have no dot are Honda products and can be purchased from your nearest Honda motorcycle dealer, or from HRC-JAPAN/ EUROPE if you can,t obtain the parts locally. MEMO (Example) Bolts, nuts and other standard parts Function and component No. Dimension Abbreviations The following abbreviations are used in this parts list. A.C. Alternating current ASSY. Assembly C. Center COMP. Complete G Gram L. Left L(00L) Link 00Links Chemical surface treatment ISO M. Middle mm Millimeter R. Right STD. Standard T(T) Tooth Teeth T.W. Thermo Water 4-

3 Block No. E- ENGINE POWER UP KIT I 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL MEL-R0 40-MEL-R0 475-MEL-R0 40-MEL-R0 ENGINE POWER UP KIT I... CAMSHAFT COMP, IN... CAMSHAFT COMP, EX... SPG, IN VALVE... SPRING, CLUTCH NL3-60 PLUG, SPARK, R0045Q

4 Block No. E-- ENGINE POWER UP KIT II 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL NL NL NL NL NL NL9-003 ENGINE POWER UP KIT II... GASKET, CYLINDER HEAD GASKET, CYLINDER HEAD GASKET, CYLINDER HEAD PISTON... CLIP, PISTON PIN 7MM... RING, PISTON TOP 75X0.8X NL NL NL NL9-000 RING, PISTON ND 75X0.8X.4... RING, PISTON OIL 75X.5X VALVE, INLET(9)... VALVE, EXHAUST(4)

5 Block No. E- A.C. GENERATOR SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL NL NL NL NL9-000 ACG SET... CRANKCASE SET... BLOCK COMP., CYLINDER... CRANK CASE, LOWER... COLLAR, 6.X3X MEL NL MEL PR NL9-000 HOLDER COMP., MISSION... COVER, ACG... CLAMP, ACG CODE... BOLT, SEALING, 0MM... ROTER COMP NL NL MEL GHB GHB-670 STATOR COMP... BOLT, FLANGE, 0X35... BOLT, SPECIAL, 7X BOLT, FLANGE, NSHF, 6X... BOLT, FLANGE, NSHF, 6X MEL MEL MEL MEL MAT-000 BOLT, SOCKET, 0MM... BOLT, FLANGE, 8X... BOLT, FLANGE, 9X05... BOLT, FLANGE, 9X5... BOLT, FLANGE, 7X

6 Block No. E- A.C. GENERATOR SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks MEL MEL MEL MB MEL-000 BOLT, FLANGE, 7X60... BOLT, FLANGE, 7X80... BOLT, SEALING, MM... BOSS, OIL FILTER... BOLT, FLANGE, 8X KE MV MEL MEL MEL-003 WASHER, SEALING, 7MM... DOWEL PIN, 0X6... BRG, BALL RADIAL, 8X6X6... BRG, BALL SPECIAL, 0X47X BRG, SPECIAL, 0X5X MEL MEL MEL BRG, BALL SPECIAL, 35X7X7... OIL SEAL, 34.8X53X8... OIL SEAL, 8X6X7... BOLT, FLANGE, 6X... BOLT, FLANGE, 6X BOLT, FLANGE, 8X40... BOLT, FLANGE, 8X55... BOLT, SOCKET, 6X

7 Block No. E-3 WIRE LOCKING KIT / AIR FUNNEL SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL NL NF NL NL9-000 WIRE LOCKING KIT... AIR FUNNEL SET... CAP, OIL FILLER... FUNNEL, AIR #... FUNNEL, AIR # NL NL NL GC MEL-R0 FUNNEL, AIR #3... FUNNEL, AIR #4... WASHER COMP, TONGUED... BAND, SUB TANK... BOLT, DRAIN PLUG MM

8 Block No. E-4 WATER HOSE PLUG SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL KY NL NL ZV-000 PLUG SET, WATER HOSE... CLAMP, WATER HOSE D5... PLUG, FAST IDLE... PLUG, HOSE 6MM... WASHER, THRUST

9 Block No. E-5 AIR INJECTION PLUG SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL MEL-R MEL-R KS PLUG SET, EXHAUST A/I... TUBE, AIR SECTION UP... TUBE ASSY., A/S UPPER... CLAMP, A WATER HOSE... PLUG, CONE TYPE 4X No sale by HRC 4-9

10 Block No. E-6 TRANSMISSION SET DRIVE SPROCKET SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL NL MEL-R0 30-MEL-R0 34-MEL-R0 TRNSMISSON SET... DRV SPRKT SET... SHAFT, MAIN... SHAFT COMP., CCOUNTER... GEAR, C MEL-R0 344-MEL-R0 344-MS MEL-R0 346-MEL-R0 GEAR, M-... GEAR, C-... COLLOAR, 30x... GEAR, M-3 M-4... GEAR, C MEL-R0 348-MR MEL-R0 350-MEL-R0 35-MEL-R0 GEAR, C-4... COLLAR, SPLINE, 8X GEAR, M-5... GEAR, C-5... GEAR, M MEL-R0 380-NL NL NL MEL-R0 GEAR, C-6... SPROCKET, DRIVE,5(55)... SPROCKET, DRIVE,6(55)... SPROCKET, DRIVE,7(55)... SENSOR ASSY, SPEED

11 Block No. E-6 TRANSMISSION SET DRIVE SPROCKET SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL6-000 SPL..BOLT, FLANGE, 0X... WASHER, 0.X37X

12 Block No. E-7 CAM CHAIN / TENSIONER 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks WASHER, PLAIN, 6MM... 4-

13 Block No. F- AIR BOX DUCT SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL MEL-R 7-NL NL GAG-750 AIR BOX DUCT SET... ELEMENT, AIR/C... SPONGE, ELEMENT... DUCT, AIR BOX... RUBBER A, PROTR NL NL STAY R, RAD UPPER... STAY L, RAD UPPER... BOLT, FLANGE, 6MM... SCREW-WASH, 5X

14 Block No. F- BREATHER CASE SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL GAG KV KS6-700 BREATHER CASE SET... CLIP... RUBBER A, PROTR... COLLAR, RADIATOR MOUNTING... CLAMP A, WATER HOSE NL NL NL NL NL9-000 SPONGE, MT 5MM... CASE COMP, BREATHER... TUBE, BREATHER... TUBE, BREATHER RETURN... STAY, BREATHER CASE KR RUBBER CARRIER MOUNT... BOLT METER SET... WASHER B, HANDLE HOLDER... NUT FLANGE 6MM... BOLT, FLANGE, SH, 6X

15 Block No. F-3 EXHAUST SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL NL NL NL NL9-000 EXHAUST SET... GASKET, EXH PIPE... FLANGE, EXH... COLLAR, EXH... PIPE ASSY, EXH NL NL NL NL NL9-000 PIPE COMP, EXH(#)... PIPE COMP, EXH(#)... PIPE COMP, EXH(#3)... PIPE COMP, EXH(#4)... JOINT A, EXH PIPE NL NL NL NL NL9-000 PIPE COMP,TAIL... STAY, EXH PIPE JOINT... SPRING, EXH PIPE... BAND, MUFFLER... STAY, MUFFLER NL MN KA MAC GCC-C50 MUFFLER COMP... RUBBER, MUFF MOUNT... RUBBER, RAD.MOUNT... COLLAR, RAD MT... NUT, HEX., 7MM

16 Block No. F-3 EXHAUST SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks MBB COLLAR, 8X8... BOLT-WASHER, 6X5... NUT, FLANGE, 6MM... NUT, FLANGE, 8MM... BOLT, FLANGE, 6X BOLT, FLANGE, 8X0... BOLT, FLANGE, 8X

17 Block No. F-4 FRONT FORK 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks MEL-R0 540-MEL-R0 540-NL NL MEL-R MEL-R 5406-MEL-R FORK ASSY, R FRONT... SPRING, FR FORK SPRING, FR FORK SPRING, FR FORK COLLAR, SPRING... COLLAR B, SPRING... STOPPER, SPRING SEAT MEL MEL MAZ MAZ MCJ-75 TUBE, OUTER... RING, BACK UP... BUSH, GUIDE... BUSH, SLIDER... RING B, STOPPER MEL MEL KA MEL MEL-003 PIPE COMP., R. SLIDE... DAMPER COMP., FR.... RING, OIL SEAL STOPPER... BOLT, FR. FORK... NUT, LOCK MCJ MW MCJ-75 PLATE B, ADJUSTING... RING, STOPPER... RING, STOPPER

18 Block No. F-4 FRONT FORK 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks MEJ MCJ-75 SEAL SET, FR. FORK... LABEL MEL-R0 555-MEL KA MCJ MR7-000 FORK ASSY,L FRONT... PIPE COMP., L. SLIDE... WASHER, SPECIAL, 0MM... PLATE, SPRING ADJUSTER... BOLT, FLANGE, 8X MR MEJ MCJ MCJ MCJ-75 BOLT, SOCKET, 0X35... DUST SEAL... O-RING, 0.8X.4... O-RING, 3.3X.4... O-RING, 9.5X GF4-003 O-RING, 4.X

19 Block No. F-5 SWINGARM 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL NL NL NL NL9-000 DRIVE CHAIN ADJ SET... ADJ, R DRIVE CHAIN... ADJ, L DRIVE CHAIN... LID, L DRIVE CHAIN ADJ... SPACER, ADJ DRIVECHAIN L HA NL NL NL MEL-R0 RING, STOPPER... AXLE, REAR WHEEL... GUIDE, RR AXLE CNT... COLLAR, RR AXLE R SIDE... COLLAR L, RR AXLE MEL-R MEL-R0 434-NL MEL-R0 557-NL3-650 COLLAR R, RR AXLE... COLLAR, R JOINT... COLLAR, RR AXLE L SIDE... SWINGARM ASSY... PROTECTOR, SPRKT NL NL NL9-000 BOLT, HEX, 8X55... NUT, RR AXLE... WASH, RR AXLE

20 Block No. F-5 SWINGARM 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks A A A SCREW, PAN, 5X0... SCREW, PAN, 5X35... SCREW, PAN, 5X50... NUT, FLANGE, 5MM BOLT, FLANGE, SH, 6X

21 Block No. F-6 REAR CUSHION 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks MEL-R0 540-MEL-R0 540-NL NL NL NL MEL-R MEL-R KZ4-B00 CUSHION ASSY, RR... SPRING, RR CHSH SPRING, RR CHSH SPRING, RR CHSH SPRING, RR CHSH.0... SPRING, RR CHSH.5... STAY, RR CUSH ADJ... ARM ASSY, CUSHION... COLLAR D, CUSHION MEE MEE MEE MEE MEL-R0 COLLAR, CUSHION ARM... COLLAR, BEARING SIDE... COLLAR A, CUSHION ARM... WASHER, THRUST... CONN ROD ASSY, CUSHION MEL MY KZ4-B0 96-KV MAC-67 COLLAR, CONNECTING ROD PIVOT... BEARING, NEEDLE, 7X4X7... BEARING, NEEDLE, 9X6X5... DUST SEAL, 7X4X5 (ARAI)... DUST SEAL, 6X6X

22 Block No. F-7 STEERING DAMPER 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL9-003 DAMPER ASSY, STRG... 4-

23 Block No. F-8 RADIATOR 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks MEL-R 950-MEL-R MEL-R0 RADIATOR COMP... HOSE, OIL/C... HOSE RADIATOR L

24 Block No. F-9 FRAME PARTS 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL NL NL NL MEL-R0 HOUSING SET, THROT... CABLE COMP A, THROT... CABLE COMP B, THROT... HOSE, CLUTCH... SW ASSY, WINKER MEL-R0 534-MT KV KV G METER ASSY, COMB... PIPE, THROT GRIP... HOUSING, THROT UP... HOUSING, THROT UND... SCREW, PAN, 5X

25 Block No. F0 WIRE HARNESS 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL MEL KA NL NL6-000 HARNESS SET... FILM A, PROTECTOR... COLLAR, SILENCER... HARNESS, WIRE... SW ASSY, ST KILL NKC NL GC NL NL9-000 SENSOR ASSY, KILL... REGISTER COMP... RELAY ASSY, START... STAY, RELAY... UNIT ASSY., PGM-FI / IGN NL NL NL NL SB-003 CD-ROM, PGM-FI / IGN... UNIT ASSY, SERIAL I/F... STAY, ECU... STAY, CATCH TANK... BAND, WIRE HARN SC NL ND BAND, HARNESS... POP RIVET 3.X9.... BLIND RIVET 3.X8... CLIP, WIRE HARNESS... SCREW-WASHER, 4X

26 Block No. F-0 WIRE HARNESS 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks S NUT, HEX, 6MM... NUT, FLANGE,4MM... WASHER, PLAIN,3MM... WASHER, PLAIN,6MM... CLIP, X BOLT, FLANGE,SH,6X

27 Block No. F- REAR WHEEL 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks MAS MAS NL NL NL NL NL NL NL NL6-000 CHAIN, DRIVE RKGB55R0Z-0LJF... JOINT, DRIVE CHAIN... SPRKT, FINAL DRIVE 38T... SPRKT, FINAL DRIVE 39T... SPRKT, FINAL DRIVE 40T... SPRKT, FINAL DRIVE 4T... SPRKT, FINAL DRIVE 4T... SPRKT, FINAL DRIVE 43T... COLLAR, L DRIVEN FLANGE SIDE... COLLAR, R DRIVEN FLANGE SIDE NL NL NL NL NL NL NL6-003 WHEEL, REAR WHEEL, REAR WHEEL, REAR FLANGE, FINAL DRIVEN... RETAINER, RR WHEEL BRG... COLLAR, RR WHEEL DISTANCE... DAMPER, RR WHEEL NC NC ML NL6-000 WEIGHT, BALANCE (0G)... WEIGHT, BALANCE (0G)... VALVE, RIM (DUNLOP)... DISK, RR. BRAKE... N N N N 4-7

28 Block No. F- REAR WHEEL 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL MC7-000 TOOL, RETAINER A... BOLT, FLANGE, 6X NL KF NL ML NL6-000 BOLT, DRIVEN FLANGE 8MM... NUT, FLANGE, 8MM... WASHER, RR WHEEL BRG... CIRCLIP, INTERNAL, 6... BRG., BALL RADIAL 605 RS NL6-003 BRG., ANGULAR 30X6X

29 Block No. F- FRONT WHEEL 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks KZ NC NC ML NL NL9-000 RETAINER, RR WHEEL BRG... WEIGHT, BALANCE (0G)... WEIGHT, BALANCE (0G)... VALVE, RIM (DUNLOP)... AXLE, FR WHEEL... NUT, FR AXLE... N N N N NL NL NL NL NL NL NL6-00 GUIDE A, FR AXLE... GUIDE B, FR AXLE... COLLAR, FR WHEEL SIDE... WHEEL, FR,7X WHEEL, FR,6.5X WHEEL, FR,7X COLLAR, FR WHEEL DISTANCE NL NL NL NL KZ4-J NUT, M8X.0... WASHER, 45XX3... SHIM 0., FR FORK SIDE... SHIM 0.3, FR FORK SIDE... BEARING, RADIAL, BALL 6905 RS... N N 4-9

30 Block No. F-3 BRAKE 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL NL NL MEL-R 430-NL MCF-006 CALIPER ASSY, RR... PAD COMP, RR (X95)... PAD COMP, RR (TT450)... BRACKET COMP, RR... BRKT, RR CALIPER... RETAINER, RR. BRACKET NL NL NL NL NL NL5-70 PAD CPMP, FR (N64)... PAD CPMP, FR (N608)... DISK COMP, FR M/C ASSY, BR L8... CUP ASSY, FR M/C... LEVER, FR. BRAKE L 8P MC GT BOLT, FLANGE, 6X0... SCREW, SPECIAL, 6X4... CLAMP, TUBE (D8.5)... TUBE, VINYL, 5X9X

31 Block No. F-4 QUICK SHIFTER SET 004 CBR000RR Ref. No. Reqd. No. Part No. Description SP AMA Remarks NL GB NL NL NL9-000 QUICK SHIFTER SET... CUSHION, CDI UNIT... SENSOR ASSY, Q/SHIFT... UNIT ASSY, Q/SHIFT... CD-ROM, Q/SHIFTER NL NL NL6-300 USB CABLE... STAY, RELAY... POP RIVET, 3.X

32 Honda Racing Corporation Head Office/3-5- Senzui, Asaka-shi, Saitama-pref., Japan TEL TELFAX European Office/Wijngaardveld, B Aalst. Belgium. TEL TELFAX

33 00. Introduction_r :0 Page Safety Messages Your safety and the safety of others is very important. We have provided important safety messages in this manual and on the HRC CBR000RR. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol and one of three words, DANGER, WARNING, or CAUTION. Damage Prevention Messages You will also see other important messages that are preceded by the word NOTICE. This word means: Your HRC CBR000RR or other property can be damaged if you don t follow instructions. These mean: You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions. You CAN be HURT if you don t follow instructions. The purpose of these messages is to help prevent damage to your HRC CBR000RR, other property, or the environment. Each message tells you what the hazard is, what can happen and what you can do to avoid or reduce injury.

34 00. Introduction_r :0 Page 3 HRC CBR000RR Racing Kit Set-up Manual/Parts List All information in this publication is based on the latest product information available at the time of approval for printing. HONDA RACING CORPORATION reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission.

35 00. Introduction_r :0 Page 4 Important Information This kit is sold as is without warranty, and the entire risk as to quality and performance is with the buyer. This kit is designed and manufactured to enhance the performance of the CBR000RR, and as is stated in the CBR000RR owner s manual, should be used only in an organized racing or competitive event upon a closed course which is conducted under the auspices of a recognized sanctioning body or by permit issued by the local governmental authority having jurisdiction. This kit is not suitable for use with any other parts.

36 0. Service Information_r : Page. Service Information General Information This Set-up Manual contains information for CBR000RR Racing Kit. Refer to Shop Manual for service procedures and data not included in this manual. Service Data Different items between standard CBR000RR and Racing kit installed CBR000RR. Item 004 Standard 004 Racing Kit (Super Bike Kit) Engine Type Water cooled 4-stroke DOHC 6 valve Cylinder arrangement 8 inclined inline four Bore and stroke 75.0 x 56.5 mm Displacement cm 3 Compression ratio.9 : 3.6 : Head gasket thickness t0.4 t0.6 Valve train DOHC, chain driven Valve timing Intake opens 8 BTDC BTDC close 46 ABDC 53 ABDC Exhaust opens 39 BBDC 47 BBDC close ATDC 3 ATDC Electrical Spark plug NGK: IMR9C-9HES, DENSO: VUH7ES NGK: R0045Q-0 Honda s testing has shown that the optimum overall performance of the Honda CBR000RR engine power up kit can be obtained by using appropriate exhaust system. No testing was done to verify serviceability or overall quality. Honda makes no claim and assumes to responsibility as to the reliability or quality of these components. Use unleaded premium gasoline (reserch octane number 00) -

37 0. Service Information_r : Page Service Information Torque Values Standard Torque Item Thread/ Torque pitch N m (kgf m, lbf ft) Remarks M5 bolt and nut M5 x (0.5, 3.6) Apply oil M6 bolt and nut M6 x.0 (., 9) Included SH bolt; apply oil M8 bolt and nut M8 x.5 (., 6) Apply oil M0 bolt and nut M0 x.5 34 (3.5, 5) Apply oil M bolt and nut M x.5 54 (5.5, 40) Apply oil M5 screw M5 x (0.4,.9) M6 screw M6 x.0 9 (0.9, 6.5) M6 flange bolt and nut M6 x.0 (., 9) Included NSHF bolt; apply oil M8 flange bolt and nut M8 x.5 6 (.7, 0) Apply oil M0 flange bolt and nut M0 x.5 39 (4.0, 9) Apply oil Engine Item Thread/ Torque pitch N m (kgf m, lbf ft) Remarks Main journal bolt M9 x.5 0 (.0, 4) Apply oil after removing anti-rust additive Crankcase bolt M8 x.5 4 (.5, 8) Apply oil M7 x.0 8 (.8, 3) Apply oil Transmission holder bolt M8 x.5 9 (3.0, ) Apply oil Oil drain bolt M x.5 9 (3.0, ) Wire lock Timing hole cap M45 x.5 8 (.8, 3) Alternator wire clamp bolt M6 x.0 (., 9) CT bolt Cylinder head tightening bolt M9 x.5 0 (.0, 4) Apply oil after removing anti-rust additive Camshaft holder bolt M6 x.0 (., 9) Apply oil Cylinder head cover bolt M6 x (.0, 7) Apply oil Breather plate bolt M6 x.0 (., 9) Apply LOCKTITE 7 PAIR reed valve cover bolt M6 x.0 (., 9) Apply LOCKTITE 7 Connecting rod bolt M8 x (.0, 4) New bolt: temporarily tighten time 4 (.4, 0) Apply oil; retightening limit: 0 times Starter clutch outer bolt M0 x.5 83 (8.5, 6) Apply oil Flywheel bolt Standard M0 x.5 03 (0.5, 76) Apply oil Racing kit M0 x.5 8 (.0, 87) Apply oil -

38 0. Service Information_r : Page 3 Service Information Item Thread/ Torque pitch N m (kgf m, lbf ft) Remarks Cam sprocket bolt M7 x.0 0 (.0, 4) Apply LOCKTITE 7 Cam position sensor rotor bolt M6 x.0 (., 9) Apply LOCKTITE 7 Cam chain tensioner bolt M6 x (.0, 7) Apply LOCKTITE 7 Cam chain guide M6 x.0 (., 9) Apply LOCKTITE 7 Oil pump assembly bolt M6 x.0 (., 9) CT bolt Oil pump driven sprocket bolt M6 x.0 5 (.5, ) Apply LOCKTITE 7 Oil filter cartridge M0 x.5 6 (.7, 0) Apply oil Throttle body insulator bolt M6 x.0 (., 9) Apply oil Thermostat cover bolt M6 x.0 (., 9) CT bolt Water pump cover bolt M6 x.0 (., 9) CT bolt Water pump impeller M6 x.0 (., 9) Left hand thread Clutch center lock nut M5 x.0 8 (3.0, 94) Apply oil Clutch spring bolt M6 x.0 (., 9) Transmission bearing set plate bolt M6 x.0 (., 9) Drive sprocket bolt M0 x.5 54 (5.5, 40) Wire lock Shift drum center bolt M8 x.5 3 (.3, 7) Apply LOCKTITE 7 Shift drum stopper arm bolt M6 x.0 (., 9) Apply oil Shift return spring pin M8 x.5 3 (.3, 7) Apply oil Shift drum bearing set plate bolt M6 x.0 (., 9) Apply LOCKTITE 7 Shift drum stopper plate bolt M6 x.0 (., 9) Apply LOCKTITE 7 Alternator stator mounting bolt M6 x.0 (., 9) Apply oil Starter motor terminal nut M6 x.0 (., 9) Apply oil Spark plug M0 x.0 4 (.4, ) Oil pressure switch PT/8 (., 9) Apply Three bond 07B Oil pressure switch terminal screw M4 x (0.,.4) Neutral switch M0 x.5 (., 9) ECT sensor M x.5 3 (.3, 7) Insulator band M5 x 0.8 Band width: 7 ± mm Water hose band Tightening width: mm on each side -3

39 0. Service Information_r : Page 4 Service Information Frame Item Thread/ Torque pitch N m (kgf m, lbf ft) Remarks Fuel tank cap socket bolt M4 x (0.5, 3.6) Fuel hose banjo bolt (tank side) M x.5 6 (.7, 0) ECT sensor M x.5 3 (.3, 7) Swingarm pivot adjusting bolt M36 x.5 5 (.5, ) Apply molybdenum grease to the threads Swingarm pivot adjusting bolt lock nut M36 x.5 59 (6.0, 43) Apply molybdenum grease to the threads Swingarm pivot nut M x.5 8 (.0, 87) Apply molybdenum grease to the threads Clutch oil bleeder bolt M0 x.5 3 (.3, 7) Clutch bleeder screw M8 x (0.8, 5.8) Rear wheel bearing retainer M56 x.0 98 (0.0, 7) Apply LOCKTITE 7 Rear wheel driven flange retainer M70 x.0 98 (0.0, 7) Apply LOCKTITE 7 Rear wheel air valve 3.9 (0.4,.9) Rear brake disc bolt M6 x.0 6 (.6, ) Apply LOCKTITE 7 Rear axle M8 x.5 98 (0.0, 7) Apply molybdenum grease to the threads Final driven sprocket nut M8 x.5 34 (3.5, 5) Apply oil to the threads Rear brake oil bleeder bolt M0 x.5 3 (.3, 7) Rear brake bleeder screw M8 x (0.8, 5.8) Rear brake caliper mounting bolt M7 x.0 7 (.7, ) Apply molybdenum grease to the threads Front wheel air valve 3.9 (0.4,.9) Front wheel axle M8 x.5 59 (6.0, 43) Apply molybdenum grease to the threads Front wheel bearing retainer M45 x.5 44 (4.5, 33) Apply molybdenum grease to the threads, stake Front axle collar nut M8 x.0 78 (8.0, 58) Front brake caliper mounting bolt M0 x.5 39 (4.0, 9) Apply molybdenum grease to the threads Front brake caliper oil bolt M0 x.5 3 (.3, 7) Front axle holder bolt M8 x.5 (., 6) Apply molybdenum grease to the threads Rear shock absorber upper bolt M0 x.5 34 (3.5, 5) Apply molybdenum grease to the threads Shock arm/shock link bolt/nut M0 x.5 34 (3.5, 5) Apply molybdenum grease to the threads Steering stem top threads M6 x (.0, 7) Adjusting range: 0.6 to.5 kgf m Steering stem nut M4 x.0 98 (0.0, 7) Apply molybdenum grease to the threads Adjusting range: 8.0 to 3.0 kgf m Handlebar stopper bolt M8 x (.0, 7) Apply LOCKTITE 7 Top bridge/bottom bridge pinch bolt M8 x.5 (., 6) Apply molybdenum grease to the threads -4

40 0. Service Information_r : Page 5 Service Information Item Thread/ Torque pitch N m (kgf m, lbf ft) Remarks Front engine hanger bolt M x.5 59 (6.0, 43) Apply molybdenum grease to the threads Middle engine hanger bolt M x.5 59 (6.0, 43) Apply molybdenum grease to the threads Rear upper engine hanger nut M x.5 59 (6.0, 43) Apply molybdenum grease to the threads Rear lower engine hanger nut M x.5 59 (6.0, 43) Apply molybdenum grease to the threads Engine hanger adjusting bolt M0 x.5 5 (.5, ) Apply molybdenum grease to the threads Engine hanger adjusting bolt lock nut M0 x.5 59 (6.0, 43) Apply molybdenum grease to the threads -5

41 0. Service Information_r : Page 6 Service Information Lubrication & Seal Point Engine Item Material Remarks Piston pin surface Elf XT388 oil Connecting rod small end inner surface Clutch lifter piece silding surface Camshaft sliding surface and thrust surface IN/EX valve stem sliding surface Valve lifter surface Clutch outer gude sliding surface Oil pump sprocket collar sliding surface M3/4, C5, C6 gear shift fork groove Starter reduction shaft pivot surface Starter idle gear shaft surface Clutch lifter rod surface Piston ring grooves Piston ring surface Oil strainer packing surface Clutch disc surface Starter one-way clutch surface Each gear teeth Each ball bearing and needle bearing Each O-ring Other rotating and sliding surface Engine 3.3 to 3.8 liter Main journal bearing sliding surface Molybdenum disulfide oil Do not apply more than necessary Connecting rod bearing (a mixture of / Elf XT388 oil Do not apply more than necessary Crankshaft thrust surface and / of molybdenum disulfide grease) Timing hole cap threads Multi-purpose grease Each oil seal lips Balancer rubber contact surface Crankcase mating surface Three bond 07B or an Crankcase/cover mating surface equivalvent Oil pan mating surface -6

42 0. Service Information_r : Page 7 Service Information Frame Item Material Remarks Fuel pump O-ring Multi-purpose grease Fuel filter case body O-ring Fuel quick joint O-ring Brake pedal pivot bushing Gearshift pedal pivot bearing Rear wheel damper rubber-to-driven flange contact area Front fender stay O-ring and bushing Swingarm pivot dust seal lips/needle bearing Shock arm dust seal lips/needle bearing Shock link dust seal lips/needle bearing Rear shock aborber pivot needle bearing Steering stem bearing Front axle bolt threads UN-LOCK (manufactured by Rear axle bolt threads NCH) or molybdenum grease Fuel pump connector Silicone grease Clutch lever-to-master piston contact area Rear brake master piston-to-push rod contact area Throttle cable sliding surface CRC Gearshift pedal link/rear brake pedal rod end Throttle pipe inner surface Handle grip inner surface Honda Bond A Seat rubber Seat back rubber or BELL-CLAW TAPE Fork inside Fork fluid Fork oil seal lip Rear fuel tank mounting bolt threads Locking agent Gearshift pedal link bolt threads Handlebar weight mounting screw threads Drive chain slider pan screw threads Drive sprocket protector bolt threads Clutch master cylinder inside AP600 or Brake master cylinder/caliper inside DOT 4 brake fluid Clutch slave cylinder CCI Metal rubber MR0-7

43 0. Service Information_r : Page 8 Service Information Maintenance Schedule Perform pre-ride Inspection at each scheduled maintenance period. I: Inspect and clean, Adjust, Lubricate or Replacement if necessary. C: Clean, R: Replace, L: Lubricate. Frequency Each race or about Remarks Item.5 hours Fuel Line I Throttle Operation I Spark Plug I Valve Clearance I Engine Oil R Engine Oil Filter R Intake Valves I R: every,000 km (,00 mi) Exhaust Valves I R: every 3,000 km (,850 mi) Valve Lifter I R: every 6,000 km (3,700 mi) Valve Springs I R: every 3,000 km (,850 mi) Pistons/Piston rings I R: every 3,000 km (,850 mi) Crankpin Bearings I Main journal bearings I Cylinder Head I Camshaft I Cylinder Sleeve I Radiator Coolant I Cooling System I Drive Chain I, L Drive Chain Slider I Drive/Driven Sprocket I Brake Fluid I R: every 3 races Replace after riding in rain Brake Pad Wear I Brake System I Clutch System I R: every race (clutch discs and plates) Clutch Fluid I R: every 3 races Replace after riding in rain Exhaust Pipe/Muffler I Suspension I Nuts, Bolts, Fasteners I Wheels And Tires I Steering Head Bearings I Check for other parts not listed above for wear or damage. Replace any faulty parts as necessary. -8

44 0. Service Information_r : Page 9 Service Information Inspection/Replacement Parts Parts Requiring Periodic Inspection/Replacement Item Inspection Interval Replacement Interval Cause Engine Crankcase/Transmission holder Every,500 km (930 mi) Every 3,000 km (,850 mi) Sleeve wear or other damage Crankcase/Transmission holder bolt Every,500 km (930 mi) Tightening torque Cylinder head Every,500 km (930 mi) Every 3,000 km (,850 mi) Cracks Cylinder head (Valve seat) Every,500 km (930 mi) Valve seat warpage Crankshaft Every,500 km (930 mi) Every 6,000 km (3,700 mi) Gear wear, Crankpin/main journal wear or damage Crankshaft bearing Every,500 km (930 mi) Repalce with crankcase Wear or damage Connecting rod Every,500 km (930 mi) Every 6,000 km (3,700 mi) Small end wear or damage Connecting rod bearing Every,500 km (930 mi) Replace with connecting rod Wear or damage Piston Every,500 km (930 mi) Every 6,000 km (3,700 mi) Skirt and piston land wear or damage Piston ring Every,500 km (930 mi) Every 3,000 km (,850 mi) Wear or damage Piston pin Every,500 km (930 mi) Every 6,000 km (3,700 mi) Wear or damage Balancer weight Every,500 km (930 mi) Every 3,000 km (,850 mi) Bearing contact face wear Balancer shaft Every,500 km (930 mi) Every 3,000 km (,850 mi) Bearing contact face wear Balancer bearing Every,500 km (930 mi) Every 3,000 km (,850 mi) Needle bearing Valve spring Every,500 km (930 mi) Every 6,000 km (3,700 mi) Wear or deformation IN/EX valve Every,500 km (930 mi) Every 6,000 km (3,700 mi) Seat warpage Cam chain Every 500 km (30 mi) Every,000 km (60 mi) Stick Cam sprocket Every 500 km (30 mi) Every,000 km (60 mi) Damage Cam chain tensioner Every 500 km (30 mi) Every,000 km (60 mi) Damage Oil pump chain Every,500 km (930 mi) Every 3,000 km (,850 mi) Stick Oil pump drive sprocket Every,500 km (930 mi) Every 3,000 km (,850 mi) Damage Water pump Every,500 km (930 mi) Every 3,000 km (,850 mi) Crack Clutch outer Every,500 km (930 mi) Every 3,000 km (,850 mi) Gear wear, wear by the disc Transmission gear/shaft/collar Every,500 km (930 mi) Every 3,000 km (,850 mi) Wear or damage Spark plug Every,500 km (930 mi) Every 6,000 km (3,700 mi) Wear at side face of the center electrodes Ignition pulse generator Every,500 km (930 mi) Every 6,000 km (3,700 mi) Damage Cam pulse generator Every,500 km (930 mi) Every 6,000 km (3,700 mi) Damage Check for other parts not listed above for wear or damage. Replace any faulty parts as necessary. -9

45 0. Service Information_r : Page 0 Service Information Removal/Replacement Parts Rearview mirror Ignition switch Pillion step Pillion seat Tail/brake light License light Replace the combination meter with the racing kit Turn signal light Replace the standard bank angle sensor with the racing kit sensor. Headlight unit Rear fender A Variable air intake diaphragm/chamber Horn Cooling fan motor Side stand switch Rear brake light switch Chain case -0

46 0. Service Information_r : Page Service Information Cable & Harness Routing No. Item No. Item No. Item No. Item Combination meter 7 Coil, cap & ignition 3 Unit, PGM-FI 9 Spacer, regulator/rectifier Bracket, bank angle sensor 8 Harness, wire 4 Cable, starter battery 0 Rectifier assembly., regulator 3 Sensor assy., bank angle 9 Band, battery 5 Cable, starter motor 4 CD-ROM, PGM-FI/IGN 0 Battery 6 Battery ground cable 5 Unit assy., serial I/F Band, PGM-FI unit 7 Switch assy., starter magnetic 6 Sub harness, IGN Bracket, PGM-FI unit 8 Relay, fuel cut -

47 0. Service Information_r : Page Service Information Wiring Diagram -

48 0. Racing Kit :0 Page. Racing Kit Replacement Necessary Parts Refer to CBR000RR SHOP MANUAL (6MEL00) for replacement procedure. Camshafts Use following intake and exhaust camshafts. 40-MEL-R0 CAMSHAFT COMP., IN 40-MEL-R0 CAMSHAFT COMP., EX Intake valve springs. 475-MEL-R0 SPRING, IN VALVE Clutch springs. 40-MEL-R0 SPRING, CLUTCH Spark plugs. 390-NL3-60 PLUG, SPARK, R0045Q-0 Additional kit for Super Bike Piston and piston rings. 30-NL9-000 PISTON 3-NL9-000 CLIP, PISTON PIN 7 mm 3-NL9-000 RING, PISTON TOP 75 x 0.8 x.3 33-NL9-000 RING, PISTON ND 75 x 0.8 x.4 34-NL9-000 RING, PISTON TOIL 75 x.5 x.95 Intake and exhaust valves. 47-NL9-000 VALVE, INLET (9) 47-NL9-000 VALVE, EXHAUST (4) -

49 0. Racing Kit :0 Page Racing Kit Modifying the Cylinder Head Ports Reworking on valve ports On CBR000RR, not much effect will be obtained by reworking on the valve ports as the machine is intended for competition use. However, you may improve breathing and encourage easier of spent gases by removing height difference between the valve seat and ports, and burrs or roughnesses on port surfaces. Intake port Grind the intake port as indicated in the illustration below. Lightly polish the other surfaces using a emery cloth. Exhaust port Grind the upper part of the exhaust port as indicated in the illustration below. Lightly polish the other surfaces using a emery cloth. Intake port Exhaust port -

50 0. Racing Kit :0 Page 3 Racing Kit Adjusting the Compression Ratio Adjust the compression ratio by grinding the mating surface of the cylinder head.. Remove the cylinder head and piston and remove carbon deposits from the piston heads and combustion chambers.. Reinstall the piston. 3. With the aid of the dial gauge, bring the piston at TDC (Top Dead Center). 4. Grind the cylinder head mating surface 0. mm (0.008 in) by machining roughness 8S. Finish the surface using a oil stone. Expected compression ratio: 3.6 : 0. mm (0.03 in) Use 0.6 mm thickness gasket. -3

51 0. Racing Kit :0 Page 4 Racing Kit Transmission Set Installation. Remove and disassemble the transmission.. Assemble the transmission using the racing kit mainshaft, countershaft, gears, collar (30 x. mm ) and collar (8 x 3.5 mm). Use standard vehicle collars and washers (except the collar, 30 x. mm and collar, 8 x. mm). Do not assemble the standard gear with the racing kit gear because the racing kit gear dogs has reverse taper. When disassembling, always replace the circlips with new ones. Always install the thrust washer and snap ring with the chamfered (rolled) edge facing away from the thrust load as shown. Racing kit Standard Gear ratio (T= Teeth) Gear ratio (T= Teeth) st.86 (4/3T).538 (3/33T) nd.94 (7/33T).94 (7/33T) 3rd.667 (8/30T).578 (9/30T) 4th.500 (0/30T).380 (/9T) 5th.348 (3/3T).50 (0/5T) 6th.7 (/7T).60 (5/9T) Check the gear dog edges for wear. Service limit:.0 mm (0.04 in) The gear jumps occur, if the gear dog edges are wear. Replace the gear with new ones when the wear to the service limit. -4

52 0. Racing Kit :0 Page 5 Racing Kit ACG Set Installation. Remove the standard AC generator cover and flywheel. Replace the ACG set and the upper and lower crankcase as a set. Flywheel. Clean any oil off from the crankshaft taper. 3. Install and racing kit flywheel to the crankshaft. 4. Apply engine oil to the flywheel mounting bolt threads and seating surface. 5. Install the bolt with washer, tighten the bolt to the specified torque. Torque: 8 N m (.0 kgf m, 87 lbf ft) If the flywheel bolt is reused, loosen the bolt and retighten the bolt to the specified torque again. If the new bolt is used, do this procedure once more. 6. Install the racing kit stator onto the racing kit alternator cover, then tighten the bolts to the specified torque. Torque: N m (. kgf m, 9 lbf ft) 7. Install the wire clamp and tighten the bolt to the specified torque. Torque: N m (. kgf m, 9 lbf ft) 8. Apply sealant to the mating surface of the crankcase and alternator cover. 9. Install the AC generator cover onto the crankcase, tighten the bolts securely. Stator AC generator cover -5

53 0. Racing Kit :0 Page 6 Racing Kit Cylinder Head Bolt Tightening If the cylinder head head gasket, tightening bolt and/or cylinder block are replaced with new one, tighten the cylinder head bolts as follows; Break-in procedure:. Clean the bolts and threaded hole of the cylinder block.. Apply Ultra-M oil to the cylinder head bolts threads and seating surface. 3. Tighten the cylinder head bolts to the specified torque in numerical order as noted in the illustration below. Torque: 0 N m (.0 kgf m, 4 lbf ft) 4. Further tighten the cylinder head bolts 53 degrees in numerical order. 5. Further tighten the cylinder head bolts 53 degrees in numerical order again. 6. Loosen and remove the cylinder head bolts. Final tightening procedure:. Clean the bolts and threaded hole of the cylinder block.. Apply Ultra-M oil to the cylinder head bolts threads and seating surface. 3. Tighten the cylinder head bolts to the specified torque in numerical order as noted in the illustration below. Torque: 0 N m (.0 kgf m, 4 lbf ft) 4. Further tighten the cylinder head bolts 53 degrees in numerical order. 5. Further tighten the cylinder head bolts 53 degrees in numerical order -6

54 0. Racing Kit :0 Page 7 Racing Kit Main Journal Bolt Tightening If the main journal bolts are replaced with new ones, tighten the main journal bolts as follows; Break-in procedure:. Clean the bolts and threaded hole of the cylinder block.. Apply Ultra-M oil to the main journal bolts threads and seating surface. 3. Tighten the main journal bolts to the specified torque in numerical order as noted in the illustration below. Torque: 0 N m (.0 kgf m, 4 lbf ft) 4. Further tighten the main journal bolts 60 degrees in numerical order. 5. Further tighten the main journal bolts 60 degrees in numerical order again. 6. Loosen and remove the main journal bolts. Final tightening procedure:. Clean the bolts and threaded hole of the cylinder block.. Apply Ultra-M oil to the main journal bolts threads and seating surface. 3. Tighten the main journal bolts to the specified torque in numerical order as noted in the illustration below. Torque: 0 N m (.0 kgf m, 4 lbf ft) 4. Further tighten the main journal bolts 60 degrees in numerical order. 5. Further tighten the main journal bolts 60 degrees in numerical order -7

55 0. Racing Kit :0 Page 8 Racing Kit Engine Hanger Tightening Sequence POINT B POINT C APPLY MOLYBDENUM DISULFIDE GREASE APPLY MOLYBDENUM DISULFIDE GREASE POINT D APPLY MOLYBDENUM DISULFIDE GREASE POINT A APPLY MOLYBDENUM DISULFIDE GREASE APPLY MOLYBDENUM DISULFIDE GREASE POINT B APPLY MOLYBDENUM DISULFIDE GREASE POINT A -8

56 0. Racing Kit :0 Page 9 Racing Kit When using the lock nut wrench for the adjusting bolt lock nut, use a deflecting beam type torque wrench 0 inches long. The lock nut wrench increases the torque wrench s leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The specification given is the actual torque applied to the lock nut, not the reading on the torque wrench. Do not overtighten the lock nut. Apply molybdenum disulfide grease to the all mounting bolt threads and seating surface of the nuts. Install and tighten the engine hanger bolts as follow:. Install the point C and point D engine hanger adjusting bolt fully from the inside of the frame.. Install the engine into the frame. 3. Install the rear upper engine hanger distance collars and bolt (C). 4. Install the rear lower engine hanger bolt (D). 5. Install the point A, B engine hanger distance collars and bolts. 6. Tighten the rear lower hanger adjusting bolt while turning the hanger bolt until it seats. 7. Tighten the rear lower engine hanger adjusting bolt (D) to the specified torque. Torque: 5 N m (.5 kgf m, lbf ft) 8. Tighten the rear lower engine hanger adjusting bolt lock nut (D) to the specified torque. Tool: Lock nut wrench, 5.8 X 46 mm 07VMA-MBB000 or 07VMA-MBB00 9. Tighten the rear upper hanger adjusting bolt while turning the hanger bolt until it seats. 0. Tighten the rear upper engine hanger adjusting bolt (C) to the specified torque. Torque: 5 N m (.5 kgf m, lbf ft). Tighten the rear upper engine hanger adjusting bolt lock nut (C) to the specified torque. Tool: Lock nut wrench, 5.8 X 46 mm 07VMA-MBB000 or 07VMA-MBB00 Torque: Actual: Scale reading: 54 N m (5.5 kgf m, 40 lbf ft) 49 N m (5.0 kgf m, 39 lbf ft). Install the rear lower engine hanger nut (D), then tighten the nut to the specified torque while holding the hanger bolt. Torque: 59 N m (6.0 kgf m, 43 lbf ft) 3. Install the rear upper engine hanger nut (C), then tighten the nut to the specified torque while holding the hanger bolt. Torque: 59 N m (6.0 kgf m, 43 lbf ft) 4. Tighten the left side front engine hanger bolt (A) to the specified torque. Torque: 59 N m (6.0 kgf m, 43 lbf ft) 5. Tighten the left side middle engine hanger bolt (B) to the specified torque. Torque: 59 N m (6.0 kgf m, 43 lbf ft) 7. Tighten the right side middle engine hanger bolt (B) to the specified torque. Torque: 59 N m (6.0 kgf m, 43 lbf ft) Install the removed parts in the reverse order of removal. A B D C Torque: Actual: Scale reading: 54 N m (5.5 kgf m, 40 lbf ft) 49 N m (5.0 kgf m, 39 lbf ft) 6. Tighten the right side front engine hanger bolt (A) to the specified torque. Torque: 59 N m (6.0 kgf m, 43 lbf ft) -9

57 0. Racing Kit :0 Page 0 Racing Kit Wire Lock Drill hole (3-4 mm) Before riding the machine, secure the following bolts and nuts: Engine oil filler cap Engine oil drain plug Oil filter cartridge. Insert the proper length locking wire to the bolt.. Twist the wire using a commercially available wire twisting tool. 3. Insert the wire in the other side hole, and twist the wire. 4. Cut off any excess wire. Oil filler cap Wire twisting tool No good Good Sub-tank band Oil filter cartridge Drain plug Use new 0.8 mm (0.03 in) stainless wire. Secure the bolt as shown so that it cannot come loose. Twisting the wire too tightly will break a locking wire. Drill hole (3-4 mm) -0

58 0. Racing Kit :0 Page Racing Kit Quick Shift Kit Installation. Drill ø mm holes as shown.. Install the quick shift unit rubber suspension bracket onto the frame, and secure it with pop rivet. 3. Install the rubber suspension onto the quick shift unit, then install the unit to the bracket, then connect the connector to the wire harness. 4. Remove the gearshift pedal and pedal link. 5. Install the pedal rod sensor into the pedal link rod. 6. Connect the sensor connector to the quick shift unit connector. 7. Reinstall the gearshift pedal and pedal link. Rubber suspension Pedal link Pedal rod sensor Quick shift unit Pedal link rod 45mm Z Gearshift pedal 6mm 0mm Z mm -

59 0. Racing Kit :0 Page Racing Kit Secondary Air Supply System Removal. Disconnect the secondary air supply hoses from the cylinder head reed valve covers and air cleaner housing.. Cut the removed hoses 40 mm from the each end of the cylinder head reed valve cover side and air cleaner housing side. 3. Install the cutted hoses to the cylinder head reed valve covers and air cleaner housing, then secure them with removed clips. 4. Plug the hoses with plugs in the racing kit, and secure them with clips also in the racing kit. Cone plug (racing kit) Thermostat and Bypass Hose Removal. Drain the coolant.. Remove the thermostat housing cover, then remove the thermostat. 3. Remove the rubber from the thermostat, then install it on the thrust washer in the racing kit. 4. Install the thrust washer into the thermostat housing, install the thermostat housing cover in the reverse order of removal. 5. Remove the bypass hose. 6. Cut the bypass hose as shown in the illustration below. 7. Install the cutted bypass hose onto the water pump cover and thermostat housing, and secure them with removed hose bands. 8. Install the plugs in the racing kit to the hose ends, and clamp them with the hose bands in the racing kit. Clamp (racing kit) Remove them Clamp (racing kit) Rubber (standard) Remove them Washer (racing kit) Cone plug (racing kit) Clamp (racing kit) Plugs (racing kit) Remove them 50 mm Cone plug (racing kit) Clamp (racing kit) 50 mm Clamp (racing kit) -

60 0. Racing Kit :0 Page 3 Racing Kit Fast Idle Wax Unit Removal. Remove the throttle body.. Remove the fast idle wax unit from the throttle body. 3. Remove the screw and then remove the fast idle wax unit link from the link arm shaft. 4. Cut the wax unit bracket, then remove the wax unit. 5. Reinstall the removed bracket onto the throttle body. 6. Remove the fast idle wax unit water hoses from the thermostat housing and water joint, and cut the hose end about 50 mm as shown in the illustration. 7. Install the cutted hoses to the thermostat housing and water joint and secure them with hose bands. 8. Install the hose plugs in the racing kit to the hose ends, and secure them with the hose bands that are attached on the fast idle wax unit. Link (remove) Screw (remove) Remove Plug (racing kit) Remove Plug (racing kit) Wax unit (remove) Bracket Throttle stop screw set -3

61 0. Racing Kit :0 Page 4 Racing Kit Variable Air Intake Valve Removal/Air Duct Installation. Remove the variable air control solenoid valve and vacuum chamber.. Remove the variable air intake duct and diaphragm assembly from the air cleaner housing. 3. Replace the radiator bracket with racing kit. 4. Install the racing kit air duct onto the air cleaner housing and tighten the screws. Remove Radiator Kit Installation. Remove the standard radiator and radiator reserve tank.. Install the racing kit radiator with the racing kit left radiator hose and oil cooler hose. Note: Avoid damaging the oil cooler water hose from the exhaust pipe heat, install the heat resistance tape to the oil coolar water hose as shown. Heat resisitance tape Radiator (Racing kit) Oil cooler water hose (Racing kit) Right radiator bracket (Racing kit) -4 Air duct (racing kit) Left radiator bracket (Racing kit) Lower radiator hose (Racing kit)

62 0. Racing Kit : Page 5 Racing Kit Hi Throttle Set/Engine Stop Switch Installation. Remove the standard throttle housing and right grip comp. from the right handlebar.. Install the racing kit throttle pipe onto the right handlebar. 3. Grind off the boss in the upper throttle housing as shown. 4. Install the racing kit throttle cable A and B to the under throttle housing. 5. Connect the throttle cable ends to the throttle pipe, then tighten the throttle housing screws. 6. Install the racing kit engine stop switch to the right handlebar. Tighten the forward screw first, then the rear screw. 7. Connect the starter/engine stop switch 9P connector to the wire harness. Throttle pipe Under throttle housing Boss (grind off) Throttle cable B Upper throttle housing Throttle cable A Starter/engine stop switch -5

63 0. Racing Kit : Page 6 Racing Kit Oil Catch Tank Installation. Disconnect the crankcase breather tube from the air cleaner housing and cylinder head cover, then remove the breather tube.. Install the breather tubes in the racing kit to the oil catch tank. 3. Attach the suitable piece of rubbers between the tabs of the oil catch tank and frame as shown. 4. Install the oil catch tank assembly into the frame (the place previously installed the EVAP PAIR control valve), tighten the bolts and nuts securely. 5. Connect the breather tube to the cylinder head cover and air cleaner housing and secure them with clips. Air Funnel/Air Cleaner Element Replacement. Remove the original air cleaner element and air funnels.. Install the racing kit air funnels into proper location according to its identification mark on the funnel. 3. Install the retainers and screws, then tighten the screws securely. 4. Bent the tabs of the retainer against the air funnel mounting screws. 5. Install racing kit air cleaner element. Breather return tube Air funnel (#4) Air funnel (#3) Air funnel (#) Air funnel (#) Breather tube Tongued washer Air cleaner elements (racing kit) Oil catch tank -6

64 0. Racing Kit : Page 7 Racing Kit Steering Stem Modifying. Make the stopper pieces from aluminium block. The piece dimensions are shown in the illustration below. Steering Damper Replacement. Remove the standard steering damper cover and steering damper.. Install the racing kit steering damper without installing the covers.. Weld the stopper pieces onto the bottom bridge as shown. 3. Make sure the steer angle is 6 on both side. Bottom bridge When the racing kit steering damper is installed (P Black connector is disconnected), the waring LED on the combination meter is illuminated but no problem in the system. Stopper piece Frame body -7

65 0. Racing Kit : Page 8 Racing Kit ECM/Bank Angle Sensor Installation. Make a two ø3.5 mm drill holes into the upper face of the upper cowl stay as shown.. Install the ECM stay onto the upper cowl stay and secure it with pop rivets. 3. Install the racing kit bank angle sensor using screw/washers and flange nuts as shown. 4. Install the bank angle relay and overflow catch tank stay onto the upper cowl stay and secure it bolts and nuts. 5. Install the catch tanks and secure them with tie-laps. Upper cowl stay Catch tank Stay Upper cowl stay Catch tank Bank angle sensor -8

66 0. Racing Kit : Page 9 Racing Kit Rear Fender B Modification. Cut and remove the indicated portion of the rear fender B.. Drill ø mm holes into the rear fender rib as shown. 3. Install the relay stay on the rear fender B and secure it with pop rivets. 4. Install the relay/rubber suspension onto the relay stay. Relay Bracket Cut area Rear fender B -9

67 0. Racing Kit : Page 0 Racing Kit Exhaust Pipe Inner Protector Modification Cut and remove the indicated portion of the exhaust pipe inner protector. Inner protector Exhaust Pipe/Muffle Replacement Remove the muffler and exhaust pipe (see Shop Manual). Remove the exhaust pipe stud bolts using the 7 mm nuts in the racing kit. Install a racing kit exhaust pipe and muffler as shown. Muffler comp. Muffler stay Inner protector Muffler band -0

68 0. Racing Kit : Page Racing Kit Drive Chain Guard Installation Inside of the swingarm is filled with urethane foam. Do not weld the drive chain guard because of the urethane form is burned.. Apply adhesive to the drill holes and pop nut seat, and install the pop nuts into the holes. Stake the pop nut using a commercially available tool.. Remove the swingarm. Drill ø mm holes for the pop nut as shown. Apply adhesive Stake Pop nut, 6 mm (manufactured by POP RIVET FASTENER LTD.; SPH650R or equivalent) 3. After the adhesive hardened, install the washer and drive chain guard and tighten the bolt/washers securely. ø mm Washers Drive chain guard Bolts -

69 0. Racing Kit : Page Racing Kit Optional Drive/Driven Sprocket The optional drive sprockets are available. When using the optional drive/driven sprocket, replace the rear wheel with the optional one. Drive sprockets: 5T (380-NL6-700) 6T (380-NL6-700) 7T (3803-NL6-700) Driven sprockets: 38T (438-NL6-700) 39T (439-NL6-700) 40T (440-NL6-700) 4T (44-NL6-700) 4T (44-NL6-700) 43T (443-NL6-700) Drive chain: RKGB55ROZ-0J Driven Drive 38T 39T 40T 4T 4T 43T L 5T 4L 4L 4L 4L 4L 6L 6L 6L 6L 4L 4L 4L 4L 6T 6L 6L 6L 6L 6L 8L 4L 4L 4L 7T 6L 6L 6L 6L 6L 6L 8L 8L : Use 8 x 55 mm drive chain adjusting bolts -

70 0. Racing Kit : Page 3 Racing Kit () () () (3) (4) () () PRE-LOAD ADJUST PLATE B () STOPPER RING () FORK SPRING () SPRING COLLAR (3) SPRING SEAT STOPPER (4) SPRING COLLAR B () O-RING () FORK BOLT () () () (3) () () DAMPER ROD ADJUST CASE () LOCK NUT (3) FORK BOLT Remove the following: Spring collar B Spring seat stopper Spring collar Fork spring Three optional for springs are available. Part number Spring rate Oil level 540-NL N/mm (K=0.90) 3 mm 540-MEL-R0 9.3 N/mm (K=0.95) 0 mm 540-NL N/mm (K=.00) 09 mm Optional springs are identified by the spring rate letter on the spring end as shown. Fork Spring Replacement Make sure that the pre-load adjuster softest position by turning the adjuster counterclockwise. Remove the stopper ring and pre-load adjust plate B. Remove the O-ring from the damper rod adjust case. Remove the fork bolt from the fork slider. Push the fork slider slowly down, and gently seat the dust seal onto the axle holder. Insert a 4 mm spanner between the spring collar B and spring seat stopper, and hold the damper rod adjust case, then loosen the lock nut. Remove the lock nut and fork bolt. SPRING RATE LETTER -3

71 0. Racing Kit : Page 4 Racing Kit () () (3) () () Slowly down the slider, and gently seat the dust seal onto the axle holder and leave it for 5 minutes. () TAPERED END () FORK SPRING Install the fork spring into the fork slider with the tapered end facing up. () DAMPER ROD HOLDER () SPRING COLLAR (3) SPRING SEAT STOPPER Extend the fork damper fully and install the damper rod holder onto the damper rod adjust case. After the oil level stabilizes, measure the oil level from top of the fork slider. Be sure the oil level is the same in the both forks. TOOL: Damper rod holder Showa special tool 070MB-MEL000 or 070MB-MELC00 or No.30 Install the spring collar and spring seat stopper. -4

72 0. Racing Kit : Page 5 Racing Kit () () () (3) () (3) () () () HANDLE () DAMPER ROD HOLDER (3) SPANNER (4) SPRING COLLAR Attach the handle to the damper rod holder, then lower the spring collar while pulling up the damper rod holder. Attach the 4 mm spanner to the damper rod adjust case as shown. (4) () FORK BOLT () O-RINGS () () SPRING COLLAR B () FORK BOLT (3) ALIGN Install the spring collar B with its flange side facing down. Install the fork bolt to the damper rod adjust case while aligning the grooves of the adjust plate with the damper rod adjust case. () PRE-LOAD ADJUSTING PLATE Apply fork fluid to new O-rings and install them to the fork bolt. Turn the pre-load adjust plate clockwise until it seats lightly. -5

73 0. Racing Kit : Page 6 Racing Kit () () () () () () LOCK NUT () O-RING () FORK BOLT () PRE-LOAD ADJUST PLATE B () STOPPER RING Install the lock nut to the damper rod adjust case. Tighten the lock nut to the specified torque, while holding the damper rod adjust case. Torque: 5 N m (.5 kgf m, 9 lbf ft) Remove the 4 mm spanner from the damper rod adjust case. Install the fork bolt to the fork slider. Install new O-ring to the damper rod adjust case. Install the pre-load adjust plate B and stopper ring. -6

74 0. Racing Kit : Page 7 Racing Kit () () () () () SPRING () PRE-LOAD ADJUSTER () REBOUND ADJUSTER () COMPRESSION ADJUSTER Rear Cushion Spring Three optional rear cushion springs are available. Part number Spring rate Identification color 540-NL N/mm (K=9.5) Blue 540-NL N/mm (K=0.5) 5403-NL N/mm (K=.0) 5404-NL N/mm (K=.5) 5405-NL N/mm (K=.0) White Black Green Sliver Suspension Setting Front Suspension Setting Pre-load Adjuster Spring pre-load can be adjusted by turning the preload adjuster. Turn the adjuster clockwise, the spring pre-load increase. Turn the adjuster counterclockwise, the spring preload decrease. Standard position: 6 turns in from full soft Rebound Damping Adjuster The rebound damping adjuster clockwise until it stops (full hard position), then turn the adjuster counterclockwise. Standard position: turns out from full hard Compression Damping Adjuster The compression damping adjuster clockwise until it stops (full hard position), then turn the adjuster counterclockwise. Standard position: turns out from full hard The optional rear shock absorber springs are identified by color. -7

75 0. Racing Kit : Page 8 Racing Kit () () () () () COMPRESSION DAMPING ADJUSTER (Lo) () COMPRESSION DAMPING ADJUSTER (Hi) () REBOUND DAMPING ADJUSTER () PRE-LOAD ADJUSTING KNOB Rear Suspension Setting Pre-load Adjuster Spring pre-load can be adjusted by turning the preload adjuster knob on the seat rail. Turn the adjuster clockwise, the spring pre-load increase. Turn the adjuster counterclockwise, the spring preload decrease. Standard position: 6 clicks in from full soft When installing the rear shock absorber, route the pre-load adjuster hose properly referring to the illustration above. Hi-speed Compression Damping Adjuster The hi-speed compression damping adjuster counterclockwise until it stops (full soft position), then turn the adjuster clockwise. Standard position: 3 ± 0.5 turns in from full soft Low-speed Compression Damping Adjuster The low-speed compression damping adjuster clockwise until it stops (full hard position), then turn the adjuster counterclockwise. Standard position: 6 clicks out from full hard Rebound Damping Adjuster The rebound damping adjuster clockwise until it stops (full hard position), then turn the adjuster counterclockwise. Standard position: 5 8 clicks out from full hard -8

76 0. Racing Kit : Page 9 Racing Kit Optional Front Wheel Front axle Axle guide B Axle guide A Ball bearing (6905 RS) Washer Distance collar Shim Bearing retainer Side collar Front axle nut Axle nut Ball bearing (6905 RS) Side collar Shim -9

77 0. Racing Kit : Page 30 Racing Kit () () () () () () () RIGHT SIDE COLLAR () LEFT SIDE COLLAR () BOLTS () BRAKE DISC () RETAINER WRENCH B () RETAINER WRENCH BODY Disassembly/Wheel Bearing Replacement A contaminated brake disc or pad reduces stopping power, and can cause a serious injury or death. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Remove the bolts and brake discs. Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer races fit tightly in the hub. Remove the discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub. Replace the bearings in pairs. Unstake the bearing retainer. Remove the bearing retainer using a special tool. Tools: Retainer wrench B Retainer wrench body Remove the right and left side collars using two screw drivers as shown. -30

78 0. Racing Kit : Page 3 Racing Kit () () () () DRIVER () ATTACHMENT/PILOT () () DRIVER () ATTACHMENT/PILOT () () DRIVER () ATTACHMENT/PILOT () Press the right wheel bearing and distance collar using a special tools and a hydraulic press until the left wheel bearing is removed. Press the right wheel bearing more than necessary, or the right bearing fall into the wheel hub. Tools: Driver Attachment, 4 x 47 mm Pilot, 5 mm Remove the right side bearing using the special tools. Tools: Driver Attachment, 4 x 47 mm Pilot, 5 mm Never install oil bearings; once the bearing have been removed, they must be replaced with new ones. Replace the wheel bearings in pairs. Assembly Apply oil to the bearing outer surface. Drive the new left wheel bearing into the hub until it seat. Tools: Driver Attachment, 4 x 47 mm Pilot, 5 mm

79 0. Racing Kit : Page 3 Racing Kit () () () () () () () DRIVER () ATTACHMENT/PILOT () RETAINER WRENCH B () RETAINER WRENCH BODY () BRAKE DISC () BOLTS Install the distance collar, then drive the right side bearing into the hub using the same tools. Tools: Driver Attachment, 4 x 47 mm Pilot, 5 mm () () () () () BEARING RETAINER () PUNCH () RIGHT SIDE COLLAR () LEFT SIDE COLLAR Apply molybdenum disulfide grease to the new bearing retainer threads and install it into the hub. Tighten the bearing retainer using the special tools. Tools: Retainer wrench B Retainer wrench body Install the brake discs and tighten the bolts to the specified torque. Torque: 5 N m (.5 kgf m, lbf ft) Install the wheel side collars. Torque: 39 N m (4.0 kgf m, 9 lbf ft) -3 Secure the bearing retainer with a punch.

80 0. Racing Kit : Page 33 Racing Kit Front axle installed view from forward (7) (6) () () () () AXLE NUT () AXLE SIDE NUT If the wheel, fork leg, and/or distance collar has been replaced, adjust the axle distance as follow:. Apply molybdenum disulfide grease to the axle nut and axle side nut threads. Install the front axle nut into the left fork axle from the inside, install and tighten the axle side nut to the specified torque. Torque: 83 N m (8.5 kgf m, 6 lbf ft) (4) (5) (3) () () FRONT AXLE NUT () AXLE SIDE NUT (3) AXLE GUIDE A (4) AXLE GUIDE B (5) SHIMS (6) AXLE WASHER (7) AXLE BOLT -33

81 0. Racing Kit : Page 34 Racing Kit (3) () () () AXLE GUIDE A () AXLE GUIDE B (3) SHIM (S). Install the front axle guide A and B into the right fork axle. 3. Temporarily install the front wheel between the fork legs and then install the front axle and axle washer but do not tighten. 4. With the front brake applied, pump the fork up and down several times to parallel the fork. 5. Measure the clearance between the right wheel distance collar and axle guide B. 6. Adjust the clearance by inserting shim(s) between the right fork axle holder and axle guide B. -34

82 0. Racing Kit : Page 35 Racing Kit Optional Rear Wheel Brake disc Damper rubber Driven flange 5 N m (.5 kgf m, lbf ft) Circlip Driven sprocket Driven flange right side collar Angular bearing (30 x 6 x 3.8) Distance collar Driven flange left side collar 34 N m (3.5 kgf m, 5 lbf ft) Bearing washer Ball bearing (605 RS) Ball bearing (605 RS) Bearing retainer -35

83 0. Racing Kit : Page 36 Racing Kit () () () () () () NUTS () DRIVEN SPROCKET () DRIVEN FLANGE () BEARING RETAINER () RETAINER TOOL (3) () () Wheel Bearing Replacement Remove the wheel bearing retainer using the special tool. Wheel bearing retainer has left hand threads. Tool: Retainer tool NL6-000 () () RIGHT SIDE COLLAR () BOLTS (3) BRAKE DISC () DAMPER RUBBERS Disassembly If you will replace the driven sprocket, loosen the driven sprocket nuts. Remove the final driven flange assembly from the left wheel hub. Remove the damper rubbers. Remove the rear wheel right side collar. Remove the bolts and brake disc. -36

84 0. Racing Kit : Page 37 Racing Kit () () () () () () () DRIVER () ATTACHMENT/PILOT () DRIVER () ATTACHMENT/PILOT () DRIVER () ATTACHMENT/PILOT Press the right wheel bearing and distance collar using a special tools and a hydraulic press until the left wheel bearing is removed. Press the right wheel bearing more than necessary, or the right bearing fall into the wheel hub. Tools: Driver Attachment, 5 mm Pilot, 5 mm Remove the right side bearing using the special tools. Tools: Driver Attachment, 5 mm Pilot, 5 mm Never install oil bearings; once the bearing have been removed, they must be replaced with new ones. Replace the wheel bearings in pairs. Assembly Apply oil to the bearing outer surface. Drive the new left wheel bearing into the hub until it seat. Tools: Driver Attachment, 5 mm Pilot, 5 mm

85 0. Racing Kit : Page 38 Racing Kit () () () () () () () DRIVER () ATTACHMENT/PILOT () BEARING RETAINER () RETAINER TOOL () LEFT SIDE COLLAR Install the distance collar, then drive the right side bearing into the hub using the same tools. Tools: Driver Attachment, 5 mm Pilot, 5 mm Apply a locking agent to the bearing retainer threads and install it into the hub. The bearing retainer has left hand threads. Tighten the bearing retainer to the specified torque. Tool: Retainer tool Torque: 98 N m (0.0 kgf m, 7 lbf ft) NL6 000 () () CIRCLIP Driven flange bearing replacement Remove the driven flange left side collar using two screwdrivers as shown. Remove the circlip from the drive flange. Drive out the driven flange bearing and right side collar as an assembly from the driven flange. -38

86 0. Racing Kit : Page 39 Racing Kit () () () () () DRIVER () ATTACHMENT/PILOT () RIGHT SIDE COLLAR () LEFT SIDE COLLAR Drive the new driven flange bearing into the driven flange until it seat using the special tools. Tools: Driver Attachment, 6 x 68 mm Pilot, 5 mm () Install the driven flange left side collar. () CIRCLIP Install the driven flange right side collar. Install the circlip into the groove securely. -39

87 0. Racing Kit : Page 40 Racing Kit Assembly () (5) () (9) () () DAMPER RUBBERS () () () (0) () (3) (8) (4) (6) () LEFT DRIVE CHAIN ADJUSTING PLATE () LEFT DRIVE CHAIN ADJUSTING BOLT (3) REAR AXLE NUT (4) DRIVEN FLANGE COLLAR (5) DRIVEN FLANGE (6) REAR WHEEL (7) BRAKE DISC (7) (8) REAR BRAKE CALIPER BRACKET (9) RIGHT DRIVE CHAIN ADJUSTING BOLT (0) RIGHT DRIVE CHAIN ADJUSTING PLATE () WASHER () REAR AXLE () DRIVEN SPROCKET () NUTS Install the damper rubbers into the left wheel hub. Install the final driven flange assembly onto the left wheel hub. If the driven sprocket is removed, apply oil (Honda Ultra GP) to the driven flange nut threads and seating surfaces. Tighten the driven sprocket nuts to the specified torque. Torque: 34 N m (3.5 kgf m, 5 lbf ft) -40

88 0. Racing Kit : Page 4 Racing Kit () () (3) () BRAKE DISC () BOLTS (3) RIGHT SIDE COLLAR Install the brake disc onto the right wheel hub. Note the direction of the brake disc. Apply a locking agent to the brake disc bolt threads. Install the brake disc and tighten the bolts to the specified torque. Torque: 5 N m (.5 kgf m, lbf ft) Install the right side collar. -4

89 0. Racing Kit : Page 4 Memo

90 03. Machine Setting_ : Page 3. Machine Setting This section covers the ECU setting procedure by PC communications. ECU Setting System requirements and communication attachment Software Install. Set software CD-ROM in the CD-ROM drive and click on the CD-ROM icon.. When a window like below is displayed, double-click SETUP.EXE to install the application..system requirements IBM AT compatible PC OS: Windows 95/98/Me/XP CPU: Pentium 00MHz or higher (recommended) Main memory: 3MB or more (recommended) Display: 04 x 768 or higher resolution (recommended) CD-ROM: CD-ROM drive is required (The product is provided with a CD-R) Serial port: Serial port is required (for communicate with ECU) If the serial port is not equipped, use USB-RS3C adaptor.the attachment UNIT, ASSY SERIAL I/F: NL A window like below will appear and will prepare for setup process. 3-

91 03. Machine Setting_ : Page Machine Setting 4. Then, a window like below will appear. To continue setup, click Next. NOTE: Exit all other programs before starting installation. 6. Setup will ask you to specify a directory to install the application in here. If you need not change the default directory, click Next. 7. Select program folder, the clock Next. 5. When you using the Windows XP, the using information window is appered. Click Next. 3-

92 03. Machine Setting_ : Page 3 Machine Setting 8. Confirm the folder and name etc. to install the application in, then click Next. 0. Now, installation is completed. Click Finish. 9. A window like below will appear and installation is continued. When installation is completed, a shortcut folder like below will appear. Use this folder putting on the desktop etc. 3-3

93 03. Machine Setting_ : Page 4 Machine Setting Operation Functional Descriptions When you start up the setting tool, a window like below will appear. Before you begin About the pull-down menu Data Edit Selector of No. 4 in the previous section is a pull-down menu. (9) () () (4) (5) (3) Click as shown in the figure above and a menu will appear below. Items to edit are changed here. Reverse video indicates the item to be selected. When you started up the application for the first time Nothing will be displayed like below. (Note: The figure above is partly different from actual screen for explanation purpose.) No. Name Function () File information display Displays information on the setting file. () Open file Reads in setting data saved before. (3) Save File Saves setting data you have changed. (4) Data Edit Selector Selects an item to change. (5) Data display area Displays setting data. (6) Data Read Transfers setting data from ECU. (7) Data Write Transfers setting data to ECU. (8) Quit Exits the program without saving data. (9) COM Port Selects communication port (default is COM ). 3-4 (6) (7) (8) Read in default file with Open File. Note: Be careful not to delete all files in the data directory. If you do, this program cannot be used any more. To use this program again, you are needed to reinstall it. When you start up the program next time, it will automatically open the last file you used. In case default file is not displayed with "Open file ", refer to troubleshooting No.4.

94 03. Machine Setting_ : Page 5 Machine Setting Checking communication port (COM port) Connection with the Vehicle. Connect the UNIT, ASSY SERIAL I/F: NL3-750 to the serial-port of your PC. When you click CommPort, pulldown menu of communication ports will appear. You can select from COM to 6. Current setting is shown.. Connect orange connector to the communication connector (quadrupole blue connector) in front of the battery. Checking system property Open system property of your PC to check the setting of communication port. Port setting should accord with that of the setting tool. If the communication port (COM) is marked with X, communication is impossible. Note: Do not drive your vehicle with the setting cord attached. Use the setting cord only when you change setting. 3-5

95 03. Machine Setting_ : Page 6 Machine Setting File Operation Opening a File When you click Open File, a list of files which can be read in will appear. Select a file you wish to use and click OK. Then, the data will be read in. Save a File When you click Save File, a list of files already saved will appear and request you to input file name. Select a file and click OK. Note: Displayed file 04cbrk.ep is a default data. If the process of Open File is aborted, the following window will appear. Click OK to continue. Type a file name and click OK to save your file. Note: Number of characters you may use for a file name is limited to eight or less. What should be noted when typing in a file name Note: Be sure to put the cursor before.ep when you type in a file name. If you omit the extension (.ep), you cannot open it. (It will not be listed.) 3-6

96 03. Machine Setting_ : Page 7 Machine Setting If the process of Save File is aborted, the window below will appear. Click OK to continue. Changing Setting Changing TH Segmentation TH position can arbitrarily be changed. If you use more than 8 characters for a file name, the window below will appear. To continue Save File, click OK and type in again a file name with eight or less characters. If you click TH segmentation, 60% for example, a scale as shown above will appear. You can change 8 points excluding both ends (0% and 00). Use mouse or up/down arrow keys to make change click Enter key to enter your change. The change cancel is done by clicking "Cancel key". The range in which you can make change is only within the zone of the scale. 3-7

97 03. Machine Setting_ : Page 8 Machine Setting Changing Engine Speed Segmentation You can arbitrarily change engine speed segmentation. Practice to Change Setting You can change air-fuel ratio either on map screen or on graph screen.. Changing air-fuel ratio (on map screen) Engine speed segmentation can be changed like TH segmentation. For example, if you click on 8,000 min - (rpm), a scale like above will appear. You can change 4 points excluding both ends (0 min - (rpm) and 8,000 min - (rpm)). Choose a point to change with mouse or left/right arrow keys and press "Enter key" after you put in a new value. The range in which you can make change is only within the zone of the scale. Change of segmentation made here will also take effect in changing ignition timing. You cannot make setting of segmentation for air-fuel ratio map and ignition timing map separately. When you select FI Map (number of percent), a screen like below will appear. In order to change data, click on the point where desired TH position and the engine speed meets. Then, a scale as shown below will appear. Note: TH and engine speed segmentations can only be changed on Fi Map screen. 3-8

98 03. Machine Setting_ : Page 9 Machine Setting How to change air-fuel ratio How to change data of all area Make change using mouse or up/down keys. Click Enter Key to make the change take effect. Click Cancel Key to abort the process. You may change values in the range from 30% to +30%. 0% is the standard setting. When you click All area Data change, the screen will be like above. This screen enables you to off set all data. Click Enter Key to have change take effect. Only, be aware that this operation makes all data be the same value. After change 3-9

99 03. Machine Setting_ : Page 0 Machine Setting. Changing air-fuel ratio (graph display) Graph mode displays a horizontal axis of map display graphically. When you select Fi Map (graph mode), a screen like below will appear. To change data, select TH position you wish to adjust. Present status of setting will be graphically displayed along with engine speed by TH positions. Here, click correction value display of the engine speed you wish to adjust. 3-0

100 03. Machine Setting_ : Page Machine Setting Adjustable areas will be selected with their color changed color. Use up/down arrow keys to make change. Change made here will also take effect in the map display. 3. Changing ignition timing When you select IG offset, a screen like below will appear. ). How to change at each point When you select Fi Map (3D graph), a screen like below will appear. Ignition timing can be changed based on engine speed. TH position based changing is impossible. To make change, click correction value display of the engine speed you wish to adjust. Then, adjustable areas will be selected with their color changed. Use up/down arrow keys to make change. You may change values in the range from 0 to 0 degrees. You can change the graph color and graph size referring to the instruction on both sides of graph as shown. 3-

101 03. Machine Setting_ : Page Machine Setting ). How to change all data at once 4. Changing fuel distribution percentage between teh upper and lower injector When you select RU MAP, a screen like below will appear. When you click All area Data change, a screen like above will appear enabling you to offset all values. The change takes effect when you click Enter Key. Only, be aware that this operation makes all data be the same value. You can change the fuel distribution percentage between the upper and lower injector. 3-

102 03. Machine Setting_ : Page 3 Machine Setting Same with IGN OFFSET, fuel distribution parcentage can be changed based on engine speed. TH position based changing is impossible. To make change, click correction value display of the engine speed you wish to adjust. Then, adjustable areas will be selected with their color changed. Transferring Setting Data Transmitting data (PC to ECU) Use up/down arrow keys to make change. You may change values in the range ± 5%. When you click Data Write, the following window will appear. When you click All area Data change, a screen like above will appear enabling you to offset all values. The change takes effect when you click Enter Key. Only, be aware that this operation makes all data be the same value. Turn off the main switch. When you click OK, the following window will appear. 3-3

103 03. Machine Setting_ : Page 4 Machine Setting Turn ON the main switch again and click OK or press Enter key within two seconds. If communication is correctly completed, the following window will appear. Receiving data (ECU to PC) If communication could not be performed correctly, the following window will appear. Check connection and communication settings and retry communication clicking Data Write again. By clicking Data Read, you can retrieve setting data from ECU. Take the same procedure as Data Write and the screen will be like below. File name becomes ECU Read data when the data retrieval is completed. Note : In this state, Data Write cannot be performed. Note : If you save or chage the date once, you will be able to transmit into ECU. Contents of the display will change to the setting data in ECU and its file name will be displayed here. 3-4

104 03. Machine Setting_ : Page 5 Machine Setting Troubleshooting No. State Cause Action to take Unable to install Don t know how to operate *refer to CD-ROM drive is Make the drive recognized and not recognize try installation again Defect of CD-ROM Please contact HRC service. (deep scratch, etc.). Unable run the tool Unsupported OS This tool runs on windows 95/98/Me/XP. 3. Unable to communicate The serial port *refer to with setting incorrect ECU Power supply of Check power supply ECU is turned off. Communication Communication cable connection is defective. cable connection is defective Check connection (Refer to Timing of transmission is not the vehicle) the page on connection with proper Press return key within two seconds after turning OFF and ON the main switch to transmit data (Refer to the page on data transmission) Data read out from ECU cannot be transmitted. reception) 4. Default file is not A same problem *see 3 displayed when starting up first is occurs with the English version. The retrieved data cannot be retransmitted as it is. In order to transmit retrieved data, you should save it once. (Refer to the page on data *: CD-ROM drive *: How to check serial port If you click on the My Computer icon, a window like left will appear. Click CD-ROM drive in the window and installation will start. If there is not CD-ROM icon displayed in the window, your PC might not be equipped with CD- ROM drive or is not recognizing one. Consult instruction manual of your PC to confirm this. Open the Control Panel. Select System and click on it. 3-5

105 03. Machine Setting_ : Page 6 Machine Setting System Properties window will open. *3: In case you open "Open File" when starting up for the first time. Normally 04cbrk.ep is displayed as default, however it s not displayed in this picture. Countermeasure : Open the directory including the tool, and change the file name. It exists as a file, but does not displayed on the tool. Select "Cbr000_a.ep" and change the file name. e.g.) Change the file name as "04Cbrk.ep" to "04Cbrk_.ep" The file name is not specified if the name includes 8 letters or less. Now you can open the file. 3-6

106 03. Machine Setting_ : Page 7 Machine Setting Quick Shift Setting System requirements and communication attachment.system requirements IBM AT compatible PC OS: Windows Me/000 Professional edition Windows XP Home Edition/Professional edition CPU: Pentium 00MHz or higher (recommended) When using the Window XP: Pentium III 800MHz or higher Memory: 8MB for this application Display: 800 X 600 or higher resolution (recommended) CD-ROM: CD-ROM drive is required (The product is provided with a CD-R) USB port: USB. or higher Mouse or other pointing device USB Driver Install The USB driver installation is needed only when you install this program.. Set software CD-ROM in the CD-ROM drive.. Connect the Quick Shift unit and PC with USB cable..the attachment USB Cable: 384-NL9-000 (or commercially available USB cable) 3-7

107 03. Machine Setting_ : Page 8 Machine Setting 3. Turn the Quick Shift unit ignition power ON (Vehicle ignition ON). 4. Found New Hardware Wizard is displayed. 5. To continue setup, click Next.. When a window like below is displayed, device search is begin. 3. A window like below will appear in device searching process. To continue setup, click Continue Anyway. 3-8

108 03. Machine Setting_ : Page 9 Machine Setting Correction of the COM Number 4. When a window is change, installation is continued. After installing the USB driver, check the COM (Communication Port) number for the USB serial port.. Right click My computer and select Properties.. Click Hardware tab in Properties, the click Device Manager. 5. When installation is completed, a window like below will appear, click Finish. 3-9

109 03. Machine Setting_ : Page 0 Machine Setting Quick Shift Setting Tool Installation Using this set-up program, install Quick Shift Setting Tool Program, Visual Basic 6.0 run time routine (DLL) API component and Online Help File. Note: Must be use set-up program to install Quick Shift Setting Tool, so that the each file does not install its proper location.. Set software CD-ROM in the CD-ROM drive.. When a window like below is displayed. If the window does not displayed, double-click CD-ROM icon in My Computer. 3. Open English holder. 3. Click and open PORT COM & LPT. Note the USB Serial Port COM No. This COM No. is used in Starting Quick Shift Setting Tool. Note: The window shown above, COM No.4 is selected. 3-0

110 03. Machine Setting_ : Page Machine Setting 4. Double-click setup icon, start the set-up program. 6. Click Set-up icon. If there is no problem, using directory as indicated in the set-up program. 7 Click Continue. 8. After this figure, follow the procedure as displayed. 5. Click OK. 3-

111 03. Machine Setting_ : Page Machine Setting Starting Quick Shift Setting Tool. Click Start button on the task bar, point the following: Program QS Setting Tool 3 QS Setting Tool 3 3. Select CBRK0.DAT, click Open. The Quick Shift Setting Tool is start up. Note: For easy to start up this program, place the QS Setting Tool 3 short cut icon on the desktop.. When you start this program first time, this window is displayed, so click OK. The last used data file is displayed when you start this program again. 3-

112 03. Machine Setting_ : Page 3 Machine Setting 4. Application main window is open. Make sure the file name is correct. 5. Click Communication and open Select COM No. 6. Check the COM No. radio button as noted during application install, then click OK. Note: The application does not communicate, if you select wrong COM No. 3-3

113 03. Machine Setting_ : Page 4 Machine Setting Main Menu <Mode> This is indicated that model name of this data file. This model (CBR000RR Racing Kit) is displayed CBR and that used with vehicle speed sensor. Note: Other mode named VFW or VRW are used with front and rear wheel speed sensor. Be careful not to select the other mode when you setting your CBR. Refer to next section Quick Shift Unit Set-up for detail. <File Name> When you open the data files saved in your PC, drive name, folder name and file name is displayed. You can check file name before editing. 3-4

114 03. Machine Setting_ : Page 5 Machine Setting <Quick shifter operation prohibition condition> This is a revolution value so that the quick shifter does not operate less than this revolution. In case the CBR, this value is transmission revolution. The quick shifter does not operate below 50 km/h shown in this value. (This function prohibit that the quick shifter operate when the vehicle warmup or low speed running) When you set the value 0, the quick shifter is operated with the st-to-nd pedal rod force and cutout number of crank revolutions even if the vehicle speed sensor is failing. When there are not a problem on practical use and a problem of a sensor, it is not necessary to change this value. <Shift-up engine revolution> This value is shift-up engine revolution for the rider s preference. The ECM is calculated the cutout number of crank revolution by this value, so that this values not differ from actual shift-up engine revolution. In case that the unit of the cutout number of crank revolutions is selected milli-second, the shift-up engine revolution is not related. Refer to following pages. Type your machine s gear ratio, gear teeth or other data into each input window. Wrong data input will cause: quick shift does not function at higher gear or other fault. 3-5

115 03. Machine Setting_ : Page 6 Machine Setting <Pedal rod force condition> The pedal rod force can be set through st to 6th gear. The quick shifter does not operate when the pedal rod forces are not exceed these setting force values. When the gearshift pedal is not returned, do not do the next operation. Release the gearshift pedal and release pedal rod force. When the displayed value is differ from input value: the input value is changed by relation of the smallest unit. Input value 348 means 34.8 kg of pedal rod force. Note: When the value of "6th to 7th" set to maximum values of "600", the false operation can prevent even if the rider shift ups from 6th gear incorrectly. But when the rider shift ups exceed the input value, or the input value is incorrect, sometimes does not operate the 5th to 6th quick shift. So, we recommended that the "6th to 7th" value is set the same value of the 5th to 6th. <Cutout number of crank revolution> Cutout number of crank revolution can be set by the crankcase revolution or unit of milli-second. When the crank revolution is selected, the cutout number of crank revolution is fixed by this input value. The unit can be changed by the rider s preference. See next page for QS Unit Set-up; changing the unit of cutout time. 3-6

116 03. Machine Setting_ : Page 7 Machine Setting Note: See following page s 0. Read and write data for detail. <Write to QS unit> Push this button, editing data or saved data can be written to QS unit. <Read from QS unit> Push this button, data written in QS unit is read and indicated it to a screen. Next, select save menu in file menu, the data can be saved in PC. This is useful for copying the data from other machine. 3-7

117 03. Machine Setting_ : Page 8 Machine Setting QS Unit Set-up; Changing the Unit of Cutout Time Check radio button Time (em), then click Write to QS Unit. Follow the indication of a display. Note: It is necessary for communication cable is connected and the vehicle ignition power is turned ON before write data to QS unit. Click "Communication" and select "Set Up QS unit". 3-8

118 03. Machine Setting_ : Page 9 Machine Setting QS Unit Set-up; Other Setting Normally use Pushing. When the shift pattern is changed to street pattern, select Pulling radio button, so that it is not necessary to replace the sensor (when using the CBR000RR racing kit sensor). This button can be set 0 point adjustment for the shift rod force sensor. Because of the value is indicated, we recommend this adjustment at the monitor screen. Do not change these radio buttons on this vehicle. Note: When the data is changed, click Write to QS Unit button to write to data to a QS unit. Note: It is necessary for communication cable is connected and the vehicle ignition power is turned ON before write data to QS unit. 3-9

119 03. Machine Setting_ : Page 30 Machine Setting Monitor Screen How to Display This engine rpm is "Shift-up engine revolution" written in at QS unit, and not real engine rpm. Note: It is necessary for communication cable is connected and the vehicle ignition power is turned ON before monitor the QS unit data. Click "Communication" and select "Monitor". 3-30

120 03. Machine Setting_ : Page 3 Machine Setting Monitor Screen CAL (0 point adjustment of shift rod force sensor) <Shift position> Can be check the shift position (shifting rage) change in proportion to rear wheel revolution. Be sure the rear wheel off the ground and secure the vehicle in safety stand other safety equipment. <CAL> If the pedal rod force value is out of range, do 0 point adjustment by pushing CAL button. Must be follow this procedure, if the pedal rod force sensor is assembled or the vehicle is turn over. After adjustment, the values slightly deviate from "0", but there is not a problem. <Countershaft revolution> When the rear wheel turning, this countershaft revolution value is changed in proportion to rear wheel revolution. If no output or the rpm in proportion to rear wheel revolution, it indicated that: broken vehicle speed sensor disconnected vehicle speed sensor connector incorrect air gap between the vehicle speed sensor and M6 gear <Pedal Rod Force> This is the pedal rod force value. Can be check the pedal rod force change by pushing the pedal. Note: If this value was excessively deviating from "0" before pushing the pedal, do 0 point adjustment by pushing CAL button. See next page for detail. 3-3

121 03. Machine Setting_ : Page 3 Machine Setting Monitor Screen CAL (0 point adjustment of shift rod force sensor) Note: Make sure that the shift rod force does not applied. Slightly move the gearshift pedal up and down and make sure the the value is stabilized, push the CAL button. Click the CAL button. This screen is appeared, then click "OK" button. The adjustment is finished when the pedal rod force value is 0 or an approximate value. 3-3

122 03. Machine Setting_ : Page 33 Machine Setting Read and Write Data These operation can read data written in at "QS unit" or can write data from the PC to QS unit. Note: It is necessary for communication cable is connected and the vehicle ignition power is turned ON before reading or writing data. <Write to QS unit> Push this button, the editing data or saved data can be written to QS unit. <Read from QS unit> Push this button, data written in QS unit is read and indicated it to a screen. Next, select save menu in file menu, the data can be saved in PC. This is useful for copying the data from other machine. 3-33

123 03. Machine Setting_ : Page 34 Machine Setting Data reading Click "OK" button, and finish reading. Click "Read from QS unit" button. "Progress bar" moves during reading. Click "OK" button and start reading. Note: When this screen was indicated before reading, check that the communication cable connection and vehicle power supply is turned ON. If the connection is correct, one the ignition power is turned OFF and ON again. 3-34

124 03. Machine Setting_ : Page 35 Machine Setting Data writing Click "OK" button, and finish writing. Click "Write to QS unit" button. "Progress bar" moves during writing. Click "OK" button and start writing. Note: When this screen was indicated before writing, check that the communication cable connection and vehicle power supply is turned ON. If the connection is correct, one the ignition power is turned OFF and ON again. 3-35

125 03. Machine Setting_ :3 Page 36 Machine Setting Indication of Help File Please refer to Help file, if the procedure is not appeared in this instruction, or if the thing that it is not understood for using.. First please start-up a program.. Right click "Help" button. 3. Please use table of contents in the menu. 3-36

126 03. Machine Setting_ :5 Page 37 Machine Setting When a Screen of QS Unit Setting Tool Did Not Open While using this tool, and a screen does not open by some cause, and a screen does not open even if the software reinstalled, please operate the following. Most of cause, because the file or folder saved current has been erased. Open folder My computer. Open the "Local disk" (C:). Open this folder. Open this folder. Open the folder "WINDOWS". Double click the "regedit". 3-37

127 03. Machine Setting_ :5 Page 38 Machine Setting Delete this folder (with all files in this folder). Next, try to start up "QS setting tool". Make sure that the "Shift ControlUnit" was erased. Function is correct, when the reading progress is appeared or the main menu is indicated. If the start up is still incorrect, other problem is thought about. 3-38

128 03. Machine Setting_ :5 Page 39 Machine Setting () () () SEL BUTTON () RESET BUTTON () () () SEL BUTTON () RESET BUTTON Combination Meter Function The racing kit combination meter has following functions: Shift-up indication Lap time indication Coolant temperature indication Shift-up Indicator When the engine rev. exceeds the setting value, the shift-up indicator illuminates or flashes. The shift-up indicator can be set in range between 4,000 5,500 min - (rpm). How to set the shift-up indicator. Turn the engine stop switch to RUN while pressing the SEL button until the combination meter initial action have finished. The needle indicates the current setting revolution.. Align the needle with requied revolution by pressing the RESET button. Whenever the button is pressed time, the needle increases by the scale of 50 min - (rpm), and when the button is pressed for more than one second, the needle increases by the scale of,000 min - (rpm). When the maximum setting value (5,500 min - (rpm)) is exceeded, the needle returns to 4,000 min - (rpm). After determine the illuminating rev., press the SEL button. 3. Press RESET button and select a illuminating or flashing pattern. Illuminating pattern and brightness (3 patterns) Flashing pattern and brightness (6 pattern) 4. After the shift-up indicator setting is finished, press SEL button. The combination meter is returned to nomal indication mode (the tachometer needle returns to 0). When the tachometer or speedometer input signal is detected, or not access for more than 30 seconds during setting, the setting value is cancelled and return to normal indication mode. -39

129 03. Machine Setting_ :5 Page 40 Machine Setting (4) (5) () () (3) () () (5) (3) (4) () () () SESSION NUMBER () LAP NUMBER (3) COOLANT TEMPERATURE (4) LAP TIME (MIN.) (5) LAP TIME (SEC.) Lap Time Indicator GO mode: When the engine stop switch to RUN, the combination meter is in STOP mode. The combination meter is received the LAP marker signal (passing switch is pressed) or engine rev. is over 5,000 min - (rpm), the lap time indicator system enters the GO mode. Under the GO mode, the combination meter records the session number, lap number, each lap time and maximum coolant temperature in each lap. During vehicle running, the combination meter displays the current session number, lap number, lap time and coolant temperature in each lap. The lap data can be stored up to 99 laps. When the stored data is exceed the 99 laps, the oldest data is overwrite to current lap data. If you wish to read out each lap data, make sure the combination meter is in STOP mode. () SESSION NUMBER () LAP NUMBER (3) MAX. COOLANT TEMPERATURE (4) LAP TIME (5) CURRENT COOLANT TEMPERATURE STOP mode: When the engine stop switch to RUN or the SEL button is pressed under the GO mode, the combination meter enters in STOP mode. The stored lap data can be read out in this mode. Stored lap data is displayed one by one from lap to latest lap by pushing the RESET button. When the RESET button is pressed, the next stored data is displayed. When the SEL button is pressed, the previous stored data is displayed. The maximum coolant temperature during each lap is displayed on upward of the section/lap number. () SEL BUTTON () RESET BUTTON If the RESET or SEL button is pressed and hold, the lap time data will be advanced or returned. When you wish to reset the lap data, press both the SEL and RESET button simultaneously more than seconds. -40

130 03. Machine Setting_ :5 Page 4 Machine Setting () () PASSING SWITCH (STOP WATCH SWITCH) () HORN SWITCH (POWER SHIFTER SWITCH) () Left Handlebar Switch Function On this machine, the each switch of the left handlebar switch is fuction as follows: Passing switch: Stop watch function (lap time) Horn switch: Power sifter function Stop Watch: When the switch is pushed, the stop watch is started. See page -39 for lap time indicator function. Power Sifter: While pushing the switch, both the ignition and fuel injection cut-off system is activated. See page -7 for power shift setting. -4