by James Grooms
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Honda CBR600RR 2003 - 2006 Owners Service & Repair Manual Covers: Honda CBR600RR
● QUICK REFERENCE DATA
● GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications
Starting the engine / Engine will not start / Engine performance / Engine removal and installation / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Fuel system / Electrical testing / Lighting system / Charging system / Ignition system / Starting system / Front suspension and steering / Brake system / Specifications
● LUBRICATION, MAINTENANCE AND TUNE-UP
Air filter / Compression test / Spark plugs / Ignition timing / Valve clearance / EFI starter valve synchronization / Idle speed adjustment / Engine oil and filter / Sidestand and ignition cutoff switch / Speciofications
● ENGINE TOP END AND EXHAUST SYSTEM
Cylinder head / Camshafts / Camshaft chain tensioner / Camshaft chain, timing sprocket and chain guides / Valve lifters and shims / Valves and components / Speciofications
● ENGINE LOWER END
Removal installation / Oil pan, oil strainer and pressure relief valve / Oil pump / Oil cooler / Crankcase / Piston and connecting rod assembly / Crankshaft / Break-in procedure / Speciofications
● CLUTCH, STARTER CLUTCH AND EXTERNAL SHIFT MECHANISM
Right crankcase cover / Clutch / Starter clutch and reduction gear assembly / External shift mechanism / Speciofications
● TRANSMISSION AND INTERNAL GEARSHIFT MECHANISM
Transmission and internal shift mechanism / Transmission inspection / Internal shift mechanism inspection / Speciofications
● FUEL INJECTION AND EMISSION CONTROL SYSTEMS
Fuel pressure test / Fuel flow test / Fuel tank cover / Fuel tank / Fuel pump / Air filter housing / Secondary fuel injection / Throttle body primary fuel injection / Fuel injectors (primary fuel injection) / Fast idle hot wax unit / idle air control IAC and thermal valve / Starter valves / Fuel cut relay / Map sensor / Intake air temperature IAT sensor / Camshaft position CMP sensor / Throttle position TP sensor / Bank angle sensor / Engine stop relay / Engine control module ECM / Throttle cable / Emission control system labels / Secondary air supply system / Evaporative emission control system / Oxygen sensor / Malfunction indicator lamp MIL / Speciofications
● ELECTRICAL SYSTEM
Fuel system precautions / Fuel pressure test / Fuel flow test / Fuel tank cover / Fuel tank / Fuel pump / Air filter housing / Secondary fuel injection / Throttle body (primary fuel injection) / Fuel injectors (primary fuel injection) / Fast idle hot wax unit (2003-2004 models) / Idle air control (IAC) and thermal valve (2005-2006 models) / Starter valves / Fuel cut relay / Map sensor / Intake air temperature (IAT) sensor / Camshaft position (CMP) sensor / Throttle position (TP) sensor / Bank angle sensor / Engine stop relay / Engine control module (ECM) / Throttle cable replacement / Emission control system labels / Secondary air supply system / Evaporative emission control system / Oxygen sensor(s) (California models) / Malfunction indicator lamp (MIL) / Specifications
● COOLING SYSTEM
Coolant reserve tank and bracket / Radiator / Cooling fan / Thermostat / Thermostat housing / Cylinder block coolant joint / Water pump / Speciofications
● WHEELS, TYRES AND DRIVE CHAIN
Motorcycle stands / Front wheel / Rear wheel / Rear coupling and rear sprocket / Front and rear hubs / Wheel runout and balance / Tyres / Drive chain / Specifications
● FRONT SUSPENSION AND STEERING
Handlebar / Front fork / Steering head and stem / Steering bearing preload / Steering head bearing races / Speciofications
● REAR SUSPENSION
Suspension linkage / Shock absorber / Swing arm / Speciofications
● BRAKE SYSTEM
Brake pads / Front and rear brake caliper / Front and rear master cylinder / Brake hose / Brake disc / Rear brake pedal / Brake bleeding / Speciofications
● BODY PANELS
Body panel fasteners / Riders seat / Pillon seat / Side covers and rear cowl / Lower cowl / Air duct covers / Side fairing panel / Mirrors / Windscreen / Front fairing and air ducts / Front fender / Upper rear fender / Rear fender / Rear frame rail / Battery tray / Speciofications
● COLOUR WIRING DIAGRAMS
Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.
Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.
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