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HRC CBR600RR - User Manual

HRC CBR600RR
85 pages
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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 CBR600RR.
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.
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.
Each message tells you what the hazard is, what can happen and what you
can do to avoid or reduce injury.
Damage Prevention Messages
You will also see other important messages that are preceded by the word
NOTICE.
This word means:
Your HRC CBR600RR or other property can be
damaged if you don’t follow instructions.
The purpose of these messages is to help prevent damage to your HRC
CBR600RR, other property, or the environment.

Table of Contents

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Summary

Safety and Damage Prevention Messages

Safety Message Definitions

Explains the meaning of DANGER, WARNING, and CAUTION safety alerts.

Damage Prevention Notice

Defines the NOTICE warning for preventing damage to the vehicle or property.

Service Information and Procedures

General Information and Kit Overview

Introduces the manual and the CBR600RR Racing Kit, covering general data.

Service Data Comparison

Compares standard CBR600RR specifications with the Racing Kit installed specs.

Torque Values

Lists torque specifications for various bolts and nuts used in engine and frame.

Lubrication and Seal Points

Details specific points requiring lubrication or sealants for engine components.

Maintenance Schedule

Outlines periodic inspection and replacement intervals for various parts.

Inspection and Replacement Parts

Lists parts requiring periodic inspection and their replacement intervals.

Removal;Replacement Parts Identification

Illustrates parts that need to be removed or replaced for the racing kit.

Cable and Harness Routing

Shows the proper routing of cables and wiring harnesses for the racing kit.

Wiring Diagram

Provides a detailed electrical wiring diagram for the racing kit components.

Racing Kit Installation Procedures

Replacement Parts for Racing Kit

Lists the specific parts included in the Racing Kit for replacement.

Cylinder Head and Compression Adjustment

Instructions for modifying cylinder head ports and adjusting compression ratio.

Engine Component Installation

Guides for valve spring, camshaft, and ACG set installation.

Transmission and Drive Train Installation

Instructions for transmission assembly, connecting rod, and main journal bolt tightening.

Connecting Rod Bolt Tightening

Procedure for tightening connecting rod bolts using the plastic region method.

Main Journal Bolt Tightening

Procedure for tightening main journal bolts using the plastic region method.

Engine Hanger Tightening Sequence

Details the sequence and points for tightening engine hanger bolts.

Wire Lock Procedures

Explains how to secure critical bolts and nuts using locking wire.

Quick Shift Kit Installation

Steps for installing the quick shift kit and its related components.

Secondary Air Supply System Removal

Procedure for removing the secondary air supply system hoses.

Thermostat and Bypass Hose Removal

Instructions for removing the thermostat and bypass hoses.

Radiator Kit Installation

Steps for installing the racing kit radiator and associated hoses.

Fuel Feed Hose Removal;Installation

Procedure for removing and installing the fuel feed hose and retainer.

Fuel Tank Breather Hose Installation

Guide for installing the fuel tank breather hose and catch tank.

Hi Throttle Set Installation

Steps for installing the hi-throttle set on the right handlebar.

Breather Case Installation

Instructions for installing the breather case assembly and related hoses.

Resister Installation

Procedure for installing the racing kit resister in the wire harness.

Turn Signal Switch Modification

Details on modifying the turn signal switch for racing kit functionality.

Starter;Battery Cable Modification

Instructions for modifying the starter/battery cables.

Air Funnel;Air Cleaner Element Replacement (2007 Model Kit)

Guide for replacing air funnels and air cleaner elements for 2007 model.

Air Funnel Replacement (2008 Model Kit)

Steps for replacing air funnels and air cleaner elements for 2008 model.

Steering Stem Modification

Instructions for modifying the steering stem stopper pieces.

Steering Stem Nut;Washer Replacement

Procedure for replacing the steering stem nut and washer for smoother steering.

Steering Damper Replacement

Steps for replacing the standard steering damper with the racing kit damper.

Rear Fender B Modification

Instructions for modifying the rear fender B for clearance and heat protection.

Exhaust Pipe;Muffler Replacement

Guide for replacing the standard exhaust pipes and muffler with the racing kit.

Drive Chain Guard Installation

Steps for installing the drive chain guard onto the swingarm.

Sprocket and Brake Pad Selection

Information on optional sprockets and available brake pads for racing.

Front Brake Hose Replacement

Procedure for replacing the front brake hose with the racing kit hose.

Fork Spring Replacement

Instructions for replacing the front fork springs and setting pre-load.

Rear Shock Absorber Spring

Details on the optional rear shock absorber springs and their identification.

Front Suspension Setting

Guide to adjusting front suspension settings like pre-load and damping.

Vehicle Height Adjustment

Procedure for adjusting the vehicle height by modifying the rear shock absorber length.

Rear Suspension Setting

Instructions for adjusting rear suspension pre-load and damping.

Left Handlebar Switch Function

Explains the function of the left handlebar switches, including pit lane speed limit.

Shift-up Indicator

Describes the function and activation of the shift-up indicator.

2010 CBR600 RR Parts List and Index

Parts List Usage Instructions

Guidance on how to order parts, read the list, and understand abbreviations.

Engine Group Parts Listing

Lists all part numbers and quantities for the engine group.

Frame Group Parts Listing

Lists all part numbers and quantities for the frame group.

Part Number Identification Index

An index to locate parts by their part number and corresponding block.

HRC CBR600RR Specifications

General IconGeneral
Compression Ratio12.2:1
IgnitionComputer-controlled digital transistorized with electronic advance
Front Tire120/70ZR-17
Rear Tire180/55ZR-17
Bore x Stroke67.0 mm x 42.5 mm
Transmission6-speed
Final DriveChain
Front Suspension41mm inverted HMAS cartridge fork with spring preload, rebound and compression damping adjustability
Rear SuspensionUnit Pro-Link with gas-charged HMAS shock, spring preload, rebound and compression damping adjustability
Front BrakeDual radial-mounted four-piston calipers with 310mm discs
Rear BrakeSingle-piston caliper with 220mm disc
Seat Height32.3 inches
Fuel Capacity4.8 gallons
Max Power118 hp @ 13, 500 rpm
Trail3.8 inches

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