00. introduction p1 - yoshimura, hrc, valtermoto, arro - 2006 cbr1000rr … · radiator kit...

00. Introduction_P1 06.2.20 6:52 PM

Safety Messages

Your safety and the safety of others is very important. We have providedimportant safety messages in this manual and on the HRC CBR1000RR.Please read these messages carefully.

A safety message alerts you to potential hazards that could hurt you orothers. Each safety message is preceded by a safety alert symbol andone of three words, DANGER, WARNING, or CAUTION.

These mean:

You WILL be KILLED or SERIOUSLY HURTif you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURTif you don’t follow instructions.

You CAN be HURT if you don’t followinstructions.

Each message tells you what the hazard is, what can happen and what youcan do to avoid or reduce injury.

Damage Prevention Messages

You will also see other important messages that are preceded by the wordNOTICE.

This word means:

Your HRC CBR1000RR or other property can bedamaged if you don’t follow instructions.

The purpose of these messages is to help prevent damage to your HRCCBR1000RR, other property, or the environment.


HRC CBR1000RR Racing KitSet-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.


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 CBR1000RR, and as is stated in the CBR1000RR 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 issuedby the local governmental authority having jurisdiction.

• This kit is not suitable for use with any other parts.• Refer to section 2 for function of the handlebar switches.


Hi Throttle Set/Engine Stop Switch Installation 2-48Oil Catch Tank Installation 2-49Air Funnel/Air Cleaner Element Replacement 2-50Steering Stem Modifying 2-51Steering Damper Replacement 2-51Fuel Tank Replacement 2-52ECM/Bank Angle Sensor Installation 2-53Seat Rail Replacement/Battery Tray Installation 2-54Rear Fender B Modification 2-55Exhaust Pipe Inner Protector Modification 2-56Exhaust Pipe/Muffler Replacement 2-56Drive Chain Guard Installation 2-57Optional Drive/Driven Sprocket 2-58Fork Spring Replacement 2-59Rear Cushion Spring 2-63Front Suspension Setting 2-63Rear Suspension Setting 2-64Optional Front Wheel 2-65Optional Rear Wheel 2-73Combination Meter Function 2-81Left Handlebar Switch Function 2-83

Contents

1. Service Information

General Information 1-1Service Data 1-1Torque Values 1-2Lubrication & Seal Points 1-6Maintenance Schedule 1-9Inspection/Replacement Parts 1-10Removal/Replacement Parts 1-11Cable & Harness Routing 1-12Wiring Diagram 1-13

2. Racing Kit

Replacement Necessary Parts 2-1Modifying the Cylinder Head Ports 2-2Adjusting the Compression Ratio 2-3Modifying Crankcase and Right CrankcaseCover 2-4Oil Pump Kit Installation 2-10Oil Pan Set Installation 2-11Cam Sprocket Kit Installation 2-12Cylinder Head Bolt Tightening 2-14ACG Set Installation 2-15Transmission Set Installation 2-17Optional Transmission Gears 2-18Drive Sprocket Cover Damper Removal 2-20Right Crankcase Cover Replacement 2-20Clutch Spring/Clutch Disc Replacement 2-21BTL (Back Torque Limiter) Kit 2-22Main Journal Bearing 2-35Crankpin Bearing 2-36Main Journal Bolt Tightening 2-38Crankshaft Thrust Play Adjustment 2-38Balancer Backlash Adjustment 2-39Engine Hanger Tightening Sequence 2-40Wire Lock 2-42Quick Shift Kit Installation 2-43Secondary Air Supply System Removal 2-44Thermostat and Bypass Hose Removal 2-44Fast Idle Wax Unit Removal 2-45Variable Air Intake Valve Removal/Air Duct Installation 2-46Radiator Kit Installation 2-47


Memo


1. Service Information

1-1

General Information

• This Set-up Manual contains information for CBR1000RR Racing Kit.• Refer to Shop Manual for service procedures and data not included in this manual.

Service Data

Different items between standard CBR1000RR and Racing kit installed CBR1000RR.

Item 2006 Standard 2006 Racing Kit (Super Bike Kit)

Engine Type Water cooled 4-stroke DOHC 16 valve

Cylinder arrangement 28˚ inclined inline four

Bore and stroke 75.0 x 56.5 mm (2.95 x 2.22 in)

Displacement 998.4 cm3 (60.9 cu-in)

Compression ratio 12.1 : 1 14.5 : 1

Cylinder head gasket thickness t0.7 t0.6

Valve clearance IN 0.16 ± 0.03 mm (0.006 ± 0.001 in) 0.20 ± 0.02 mm (0.008 ± 0.001 in)

EX 0.30 ± 0.03 mm (0.012 ± 0.001 in) 0.30 ± 0.02 mm (0.012 ± 0.001 in)

Valve train DOHC, chain driven

Valve timing Intake opens 18˚ BTDC 22˚ BTDC

closes 46˚ ABDC 58˚ ABDC

Exhaust opens 39˚ BBDC 53˚ BBDC

closes 11˚ ATDC 22˚ ATDC

Valve lift Intake 9.1 mm 9.5 mm

Exhaust 8.4 mm 9.0 mm

Fuel deliverly system PGM-DSFI, ø44

Electrical Spark plug NGK: IMR9C-9HES, DENSO: VUH27ES NGK: R0045Q-10

• Honda’s testing has shown that the optimum overall performance of the Honda CBR1000RR engine power up kit can be obtained by using appropriate exhaustsystem.

• 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 com-ponents.

Use unleaded premium gasoline (research octane number 100)

01. Service Information_P1 06.2.20 6:52 PM Page 1

Service Information

1-2

ItemThread/ Torque

Remarkspitch N•m (kgf•m, lbf•ft)

Main journal bolt M9 x 1.25 20 (2.0, 14) + 60˚ + 60˚ Apply oil after removing anti-rust additive; retightening limit: 10 timesCrankcase bolt M8 x 1.25 24 (2.5, 18) Apply oil

M7 x 1.0 18 (1.8, 13) Apply oilTransmission bearing holder bolt M8 x 1.25 29 (3.0, 22) Apply oilOil drain bolt M12 x 1.5 29 (3.0, 22) Wire lockOil level finder stopper plate bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271Timing hole cap M45 x 1.5 18 (1.8, 13) Apply greaseCylinder head tightening bolt M9 x 1.25 20 (2.0, 14) + 53˚ + 53˚ Apply oil after removing anti-rust additiveCamshaft holder bolt M6 x 1.0 12 (1.2, 9) Apply oilCylinder head cover bolt M6 x 1.0 9.8 (1.0, 7) Apply oilBreather plate bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271PAIR reed valve cover bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271Connecting rod bolt

M8 x 0.7520 (2.0, 14) + 45˚ + 45˚ New bolt: temporarily tighten 1 time14 (1.4, 10) + 45˚ + 45˚ Checking oil clearance: Apply oil; retightening limit: 10 times

Starter clutch outer bolt M10 x 1.25 20 (2.0, 14) + 50˚ Apply oil; retightening limit: 5 times

Torque Values

Standard Torque

ItemThread/ Torque


M5 bolt and nut M5 x 0.8 4.9 (0.5, 3.6) Apply oilM6 bolt and nut M6 x 1.0 12 (1.2, 9) Included SH bolt; apply oilM8 bolt and nut M8 x 1.25 22 (2.2, 16) Apply oilM10 bolt and nut M10 x 1.25 34 (3.5, 25) Apply oilM12 bolt and nut M12 x 1.25 54 (5.5, 40) Apply oilM5 screw M5 x 0.8 4 (0.4, 2.9)M6 screw M6 x 1.0 9 (0.9, 6.5)M6 flange bolt and nut M6 x 1.0 12 (1.2, 9) Included NSHF bolt; apply oilM8 flange bolt and nut M8 x 1.25 26 (2.7, 20) Apply oilM10 flange bolt and nut M10 x 1.25 39 (4.0, 29) Apply oil

Engine

Use Honda Ultra S9 oil to the bolt and nut that are oilapplication is specified. Actual torque down andcross threads will ocuur if using the oil other thanspecified.


1-3

Service Information

ItemThread/ Torque


Flywheel bolt Standard M10 x 1.25 103 (10.5, 76) Apply oil; • When using the new crankshaft or flywheel:Temporarily tighten 2 times with 103 N•m (10.5 kgf•m, 76 lbf•ft).

• Temporarily tighten 1 time when flywheel reinstallationWe recommend that the racing kit flywheel bolt (90003-NL9-000) isused whenever the standard flwheel is installed (page 2-14).When using the racing kit flywheel bolt, follow the racing kittightening method and torque value (see below).

Racing kit M10 x 1.25 15 (1.5, 11) + 60˚ Apply oil; • Temporarily tighten 3 times with 135 N•m (13.8 kgf•m,100 lbf•ft).

• After tightening flywheel bolt with 15 N•m (1.5 kgf•m, 11 lbf•ft) + 60˚ , check the tightening torque is more than128 N•m (13.0 kgf•m, 94 lbf•ft).

Cam sprocket bolt Standard M7 x 1.0 20 (2.0, 14) Apply oilRacing kit M7 x 1.0 22 (2.2, 16) Apply oil

Camshaft position sensor rotor bolt M6 x 1.0 12 (1.2, 9) Apply oilCam chain tensioner bolt M6 x 1.0 9.8 (1.0, 7) Apply LOCKTITE 271Cam chain guide bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271Oil pump assembly bolt M6 x 1.0 12 (1.2, 9) CT boltOil pump driven sprocket bolt M6 x 1.0 15 (1.5, 11) Apply LOCKTITE 271Oil filter cartridge M20 x 1.5 26 (2.7, 20) Apply oilThrottle body insulator bolt M6 x 1.0 12 (1.2, 9) Apply oilThermostat cover bolt M6 x 1.0 12 (1.2, 9) CT boltWater pump cover bolt M6 x 1.0 12 (1.2, 9) CT boltWater pump impeller M6 x 1.0 12 (1.2, 9) Left hand threadClutch center lock nut M25 x 1.0 128 (13.0, 94) Apply oilClutch lifter plate bolt M6 x 1.0 12 (1.2, 9) Apply oilTransmission bearing set plate bolt M6 x 1.0 14 (1.4, 10) Apply LOCKTITE 271Lifter plate bolt M6 x 1.0 14 (1.4, 10) Apply oilDrive sprocket bolt M10 x 1.25 54 (5.5, 40) Wire lockShift drum center bolt M8 x 1.25 23 (2.3, 17) Apply LOCKTITE 271Shift drum stopper arm bolt M6 x 1.0 12 (1.2, 9) Apply oilShift return spring pin M8 x 1.25 23 (2.3, 17) Apply oilShift drum bearing set plate bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271


Service Information

1-4

ItemThread/ Torque


Fuel tank cap socket bolt M4 x 0.7 4.9 (0.5, 3.6)Fuel hose banjo bolt (tank side) M12 x 1.25 26 (2.7, 20)ECT sensor M12 x 1.5 23 (2.3, 17)Swingarm pivot adjusting bolt M36 x 1.5 15 (1.5, 11) Apply molybdenum grease to the threadsSwingarm pivot adjusting bolt lock nut M36 x 1.5 59 (6.0, 43) Apply molybdenum grease to the threadsSwingarm pivot nut M22 x 1.5 118 (12.0, 87) Apply molybdenum grease to the threadsClutch oil bleeder bolt M10 x 1.25 23 (2.3, 17)Clutch bleeder screw M8 x 1.25 7.8 (0.8, 5.8)Rear wheel bearing retainer M56 x 1.0 98 (10.0, 72) Apply LOCKTITE 271Rear brake disc bolt M6 x 1.0 16 (1.6, 12) Apply LOCKTITE 271Rear axle M18 x 1.5 98 (10.0, 72) Apply molybdenum grease to the threadsFinal driven sprocket nut M8 x 1.25 34 (3.5, 25) Apply oil to the threadsRear brake oil bleeder bolt M10 x 1.25 23 (2.3, 17)Rear brake bleeder screw M8 x 1.25 7.8 (0.8, 5.8)Rear brake caliper mounting bolt M7 x 1.0 17 (1.7, 12) Apply molybdenum grease to the threadsFront wheel axle M18 x 1.5 59 (6.0, 43) Apply molybdenum grease to the threads

Frame

ItemThread/ Torque


Shift drum stopper plate bolt M6 x 1.0 12 (1.2, 9) Apply LOCKTITE 271Alternator stator mounting bolt M6 x 1.0 12 (1.2, 9) Apply oilStarter motor terminal nut M6 x 1.0 12 (1.2, 9) Apply oilSpark plug M10 x 1.0 14 (1.4, 11)Main oil gallery sealing taper plug PT1/8 12 (1.2, 9) Apply Three bond 1207BNeutral switch M10 x 1.25 12 (1.2, 9)ECT sensor M12 x 1.5 23 (2.3, 17)Insulator band M5 x 0.8 – Band width: 7 ± 1 mmWater hose band – – Tightening width: 1 mm on each sideAir funnel bolt M5 x 0.8 6.8 (0.7, 5.1) Wire lock


1-5

Service Information

ItemThread/ Torque


Front wheel bearing retainer M46 x 1.25 39 (4.0, 29) Apply molybdenum grease to the threads, stakeFront axle side nut M28 x 1.0 78 (8.0, 58) Apply molybdenum grease to the threadsFront brake caliper mounting bolt M10 x 1.25 39 (4.0, 29) Apply molybdenum grease to the threadsFront brake caliper oil bolt M10 x 1.25 34 (3.5, 25)Front axle holder bolt M8 x 1.25 22 (2.2, 16) Apply molybdenum grease to the threadsRear shock absorber upper bolt M10 x 1.25 34 (3.5, 25) Apply molybdenum grease to the threadsShock arm/shock link bolt/nut M10 x 1.25 34 (3.5, 25) Apply molybdenum grease to the threadsSteering stem top threads M26 x 1.0 9.8 (1.0, 7) Adjusting range: 0.6 to 1.5 kgf•mSteering stem nut M24 x 1.0 78 (8.0, 58) Apply molybdenum grease to the threadsHandlebar stopper bolt M8 x 1.25 9.8 (1.0, 7) Apply LOCKTITE 271Top bridge/bottom bridge pinch bolt M8 x 1.25 22 (2.2, 16) Apply molybdenum grease to the threadsFront engine hanger bolt M12 x 1.25 59 (6.0, 43) Apply molybdenum grease to the threadsMiddle engine hanger bolt M12 x 1.25 59 (6.0, 43) Apply molybdenum grease to the threadsRear upper engine hanger nut M12 x 1.25 59 (6.0, 43) Apply molybdenum grease to the threadsRear lower engine hanger nut M12 x 1.25 59 (6.0, 43) Apply molybdenum grease to the threadsEngine hanger adjusting bolt M20 x 1.5 15 (1.5, 11) Apply molybdenum grease to the threadsEngine hanger adjusting bolt lock nut M20 x 1.5 59 (6.0, 43) Apply molybdenum grease to the threads


Service Information

1-6

Lubrication & Seal Point

Engine

Item Material Remarks

Piston pin surface Elf XT3821 oilConnecting rod small end inner surfaceClutch lifter piece sliding surfaceCamshaft sliding surface and thrust surfaceIN/EX valve stem sliding surfaceValve lifter sliding surfaceClutch outer guide sliding surfaceOil pump sprocket collar sliding surfaceM3/4, C5, C6 gear shift fork grooveStarter reduction shaft pivot sliding surfaceStarter idle gear shaft sliding surfaceClutch lifter rod surfacePiston ring groovesPiston ring surfaceOil strainer packing surfaceClutch disc surfaceStarter one-way clutch surfaceEach gear teethEach ball bearing and needle bearingEach O-ringOther rotating and sliding surfaceEngine inside When using the racing kit oil pan:

Elf XT3821 oil: between 3.0 to 4.0 liter

Standard pan: Racing kit oil pan:

14 mm

3.0L


1-7

Service Information


Main journal bearing sliding surface Molybdenum disulfide oil Do not apply more than necessaryConnecting rod bearing (a mixture of 1/2 Elf XT3821 Do not apply more than necessaryCrankshaft thrust surface oil and 1/2 of molybdenum

disulfide grease)

Timing hole cap threads Multi-purpose greaseEach oil seal lipsBalancer damper rubber contact surface

Crankcase mating surface Three bond 1207BCrankcase/cover mating surfaceOil pan mating surface

Oil level finder stopper bolt threads Locking agent


Service Information

1-8


Brake pedal pivot bushing Multi-purpose greaseGearshift pedal pivot bearingRear wheel damper rubber-to-driven flange contact areaSwingarm pivot dust seal lips/needle bearingShock arm dust seal lips/needle bearingShock link dust seal lips/needle bearingRear shock absorber pivot needle bearingSteering stem bearing

Front axle bolt threads and seating surface Molybdenum grease UN-LOCK (manufactured by NCH) for shaft portionRear axle bolt threads and seating surface

Fuel pump connector Silicone greaseClutch lever-to-master piston contact areaRear brake master piston-to-push rod contact area

Throttle cable sliding surface CRCGearshift pedal link/rear brake pedal rod endThrottle pipe inner surface

Handle grip inner surface Honda Bond ASeat rubberSeat back rubber or BELL-CLAW TAPE

Fork inside Fork fluidFork oil seal lip

Fuel tank rear mounting bolt threads Locking agentGearshift pedal link bolt threadsHandlebar weight mounting screw threadsDrive chain slider pan screw threadsDrive sprocket protector bolt threads

Clutch master cylinder inside AP600 orBrake master cylinder/caliper inside DOT 4 brake fluid

Clutch slave cylinder CCI Metal rubber MR20

Frame


1-9

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 raceor about Remarks

Item 2.5 hoursFuel Line IThrottle Operation ISpark Plug IValve Clearance IEngine Oil REngine Oil Filter RIntake Valves I R: every 6,000 km (3,700 mi)Exhaust Valves I R: every 6,000 km (3,700 mi)Valve Lifter I R: every 6,000 km (3,700 mi)Valve Springs I R: every 6,000 km (3,700 mi)Pistons/Piston rings I R: every 3,000 km (1,850 mi)Crankpin Bearings IMain journal bearings ICylinder Head ICamshaft ICylinder Sleeve IRadiator Coolant I

Flywheel bolt I Every 1,500 km (930 mi);Check tightening torque: more than 128 N•m (13.0 kgfm, 94 lbf•ft)

Cooling System IDrive Chain I, LDrive Chain Slider IDrive/Driven Sprocket IBrake Fluid I R: every 3 races, replace after riding in rainBrake Pad Wear IBrake System IClutch System I R: every race (clutch discs and plates)Clutch Fluid I R: every 3 races, replace after riding in rainExhaust Pipe/Muffler ISuspension INuts, Bolts, Fasteners IWheels And Tires I R: every 2 years (magnesium wheel)Steering Head Bearings IRegulator/rectifier Stay (Spacer) ICam pulse generator connector I

Check for other parts not listed above for wear or damage. Replace any faulty parts as necessary.


Service Information

1-10

Inspection/Replacement Parts

Parts Requiring Periodic Inspection/Replacement

Item Inspection Interval Replacement Interval Cause

EngineCrankcase/transmission holder Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Sleeve wear or other damageCrankcase 7 mm bolt Every 1,500 km (930 mi) – Tightening torqueCylinder head Every 1,500 km (930 mi) Every 3,000 km (1,850 mi) CracksCylinder head (Valve seat) Every 1,500 km (930 mi) – Valve seat warpageCrankshaft Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Gear wear, crankpin/main journal wear or damageCrankshaft bearing Every 1,500 km (930 mi) Replace with crankcase Wear or damageConnecting rod Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Small end wear or damageConnecting rod bearing Every 1,500 km (930 mi) Replace with connecting rod Wear or damagePiston Every 1,500 km (930 mi) Every 3,000 km (1,850 mi) Skirt and piston land wear or damagePiston ring Every 1,500 km (930 mi) Every 3,000 km (1,850 mi) Wear or damagePiston pin Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Wear or damageBalancer weight Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Bearing contact face wearBalancer shaft Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Bearing contact face wearBalancer bearing Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Needle bearing Valve spring Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Wear or deformationIN/EX valve Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Valve seat warpageCam chain Every 500 km (310 mi) Every 1,000 km (620 mi) StickCam sprocket Every 500 km (310 mi) Every 3,000 km (1,850 mi) DamageCam chain tensioner/guideA, B/lifter Every 500 km (310 mi) Every 3,000 km (1,850 mi) DamageOil pump chain Every 1,500 km (930 mi) Every 3,000 km (1,850 mi) StickOil pump drive/driven sprocket Every 1,500 km (930 mi) Every 3,000 km (1,850 mi) DamageWater pump Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) CrackClutch outer Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Gear wear, wear by the discTransmission gear/shaft/collar Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Wear or damageOil cooler Every 1,500 km (930 mi) Every 3,000 km (1,850 mi) DamageStarter bearing Every 1,500 km (930 mi) Every 3,000 km (1,850 mi) DamageSpark plug Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) Wear at side face of the center electrodesIgnition pulse generator Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) DamageCam pulse generator Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) DamageFlywheel bolt Every 1,500 km (930 mi) Every 6,000 km (3,700 mi) or tighten it 5 times to the specified sequence;

15 N•m (1.5 kgfm, 11 lbf•ft) +60˚AC generator cover bolt Every 1,500 km (930 mi) – Tightening torque

Check for other parts not listed above for wear or damage. Replace any faulty parts as necessary.


1-11

Service Information

Removal/Replacement Parts

Replace the combinationmeter with the racing kit

Rearview mirror Ignition switch Tail/brake light License light

Turn signal light

Rear brake lightswitch

Side stand switchCooling fan motorHorn

Headlight unit

Replace the standardbank angle sensor withthe racing kit sensor.

Pillion step Pillion seat

Rear fender A

Variable air intakediaphragm/chamber

Chain case

Rear fender C


Service Information

1-12

Cable & Harness Routing

No. Item No. Item No. Item No. Item

1 Combination meter 7 Coil, cap & ignition 13 Unit, PGM-FI 19 Spacer, regulator/rectifier2 Bracket, bank angle sensor 8 Harness, wire 14 Cable, starter battery 20 Rectifier assembly., regulator3 Sensor assy., bank angle 9 Band, battery 15 Cable, starter motor4 CD-ROM, PGM-FI/IGN 10 Battery 16 Battery ground cable5 Unit assy., serial I/F 11 Band, PGM-FI unit 17 Switch assy., starter magnetic6 Sub harness, IGN 12 Bracket, PGM-FI unit 18 Relay, fuel cut

3

1

2

11

13

12

7

6

8 16 15

14

10

17

9

1920

18


1-13

Service Information

Wiring Diagram


Memo


2. Racing Kit

2-1

Replacement Necessary Parts

Refer to CBR1000RR SHOP MANUAL (62MEL00) and addendum (62MEL00Z,62MEL00Y) for replacement procedure.

Clutch spring:Replace the clutch springs with the racing kit springs.• 22401-MEL-R30 SPRING, CLUTCH

Spark plugs:• 31910-NL3-620 PLUG, SPARK, R0045Q-10

No. Part Number Item Q’ty

06120-NL9-C00 Engine Power-up Kit IV, SBK

1 13101-NL9-C00 Piston 4

2 13121-NL9-003 Ring, piston top, 75 x 0.8 x 2.3 4

3 13131-NL9-003 Ring, piston 2nd, 75 x 0.8 x 2.4 4

4 13141-NL9-003 Ring, piston oil, 75 x 1.5 x 1.95 4

5 13112-NL9-000 Clip, piston pin 17 mm 8

6 14711-NL9-C00 Valve, inlet (29) 8

7 14721-NL9-000 Valve, exhaust (24) 8

06110-NL9-C00 Engine Power-up Kit V, SBK

1 14110-NL9-C00 Camshaft comp., IN 1

2 14210-NL9-C00 Camshaft comp., EX 1

3 14312-NL9-C00 Sprocket, timing 1

4 14321-NL9-C00 Sprocket, cam 2

5 14401-NL9-C01 Chain, cam 1

6 14520-NL9-C00 Lifter assembly, tensioner 1

7 14751-NL9-C00 Spring IN, valve (color: orange) 8

8 14761-NL9-C00 Spring EX, valve (color: yellow) 8

9 90082-NL9-710 Bolt, flange knock, 7 x 10.5 4

10 90488-425-000 Washer, sealing 6 mm 2

02. Racing Kit_P1 06.2.20 6:54 PM Page 1

Racing Kit

2-2

Exhaust port Intake port

Modifying the Cylinder Head Ports

Reworking on valve ports• On CBR1000RR, 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 rough-

nesses on port surfaces.

Intake port• Grind the insulator bore as indicated in the illustration below, then grind the intake port so that no height difference between the insulator and 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.• Grind the exhaust collar as indicated in the illustration below, then grind the exhaust port so that no height difference between the collar and exhaust port.• Lightly polish the other surfaces using a emery cloth.

Exhaust collar

Insulator


2-3

Racing Kit

Adjusting the Compression Ratio

Cylinder head gasket selection:

1. Remove carbon deposits from the piston heads and install them into theeach cylinder bore.

2. With the aid of the dial gauge, bring the piston at TDC (Top Dead Center).3. Measure the clearance between the top of cylinder and piston head at two

points (intake and exhaust). Calculate average distance.Measure the clearance at each cylinder, and select cylinder head gasketthickness from minimum measurement.

Expected compression ratio: 14.5 : 1

Clearance Gasket (t= thickness) Identification color

0 – 0.05 mm 0.70 t Yellow

0.05 – 0.10 mm 0.65 t Orange

0.10 – 0.15 mm 0.60 t –

more than 0.15 mm 0.55 t Purple


Racing Kit

2-4

Modifying Crankcase and Right Crankcase Cover

Prepare the following reference seats for modifying the crankcases.

Seat A Seat B Seat C

Seat D Seat E Seat F


2-5

Racing Kit

Lower Crankcase (Upper Crankcase Side)

Make the four holes to the lower crankcase using reference seat A.Chamfer the indicated area to R5 with rubber grindstone.


Racing Kit

2-6

Lower Crankcase (Oil Pan Side)

Make the three holes to the lower crankcase using reference seat B.


2-7

Racing Kit

Upper Crankcase

Enlarge the four upper crankcase holes using reference seat C and D.Enlarge the two oil return holes as shown. Remove the oil return hole edge burrs with hand grinding tool.


Racing Kit

2-8

Upper Crankcase

• Make the seven 10 mm holes to the upper crankcase using reference seat C and D.• Make the three holes (A) to the upper crankcase using reference seat E.• Make the two holes (B) to the upper crankcase using reference seat F.• When modifying with the construction cutter is difficult, use hand grinding tool.


2-9

Racing Kit

Right Crankcase Cover (when using the standard right crankcase cover)

• Grind off the indicated portion of the right crankcase cover rib as shown.• Must be grind off the right crankcase cover rib when using the BTL (Back Torque Limiter) clutch kit.

10


Racing Kit

2-10

Oil Pump Kit Installation

1. Remove the oil pan and replace the oil pressure relief valve with racing kit.2. Remove the standard oil pump drive/driven sprocket and drive chain.

3. Remove the mainshaft bearing set plate from the transmission bearing hold-er, and replace it with racing kit. When installing the set plate, apply lockingagent to the set plate bolt threads.

4. Remove a transmission bearing holder bolt (see below), and replace it withracing kit bolt.

5. Install the oil pump drive sprocket, driven sprocket (racing kit) and drivechain (racing kit).

Pressure relief valve(racing kit)

Bearing set plate(racing kit)

Holder bolt(racing kit)

Driven sprocket(racing kit)

Drive chain(racing kit)

Bearing set plate(racing kit)

Holder bolt(racing kit)


2-11

Racing Kit

Oil Pan Set Installation

Clean any oil off the mating surface of the oil level finder and racing kit oil pan.Avoid damaging the oil seal, carefully install the oil level finder into the racingkit oil pan by pushing it by hand.Apply locking agent to the oil level finder stopper plate bolt threads.Install the stopper plate and tighten the bolt securely.

Remove the standard oil pan and oil strainer.Install the oil strainer gasket to the racing kit strainer, then install the racing kitoil strainer to the oil pump.Apply sealant to the mating surface of the oil pan.Install the racing kit oil pan and tighten the bolts in a crisscross pattern in 2 or3 steps.Install the racing kit oil drain bolt with a new sealing washer.

Secure the oil drain bolt with a locking wire.

Oil level finder(racing kit)

Stopper plate(racing kit)

Bolt(racing kit)

Apply lockingagent

Oil strainer(racing kit)

Drain bolt(racing kit)

New sealing washer(racing kit)

Oil pan(racing kit)

Flange bolts(racing kit)


Racing Kit

2-12

Cam Sprocket Kit Installation

Replace the racing kit cam sprockets, timing sprocket and cam chain as a set.

Standard bolt holes

Long bolt holes(for valve timing adjustment)

If you cannot be measure the valve timing:Use standard bolt holes on the racing kit cam sprockets.Place the No.1/4 pistons at TDC (Top Dead Center).Install the cam sprocket with the No.4 camshaft cam lobes facing up as shown.

No.4 cam lobes

Valve timing (when using the standard bolt holes)

Intake Opens 22˚ BTDC

Close 58˚ ABDC

Exhaust Opens 53˚ BBDC

Close 22˚ ATDC

Racing kit sprockets has two kind of bolt holes.

Long bolt holes are used when you adjust the valve timing.

Cam chain(racing kit)Cam sprocket

(racing kit)

Knock bolt(racing kit)

Timing sprocket(racing kit)


2-13

Racing Kit

Apply Honda Ultra S9 oil to the racing kit cam sprocket bolt threads and seat-ing surface, the tighten them to the specified torque.

Torque: 22 N•m (2.2 kgf•m, 14 lbf•ft)

Turn the crankshaft clockwise turn, align the “T” mark on the ignition pulsegenerator rotor with the index mark on the ignition pulse generator rotor cover(the No.1/4 piston at TDC).

Install the camshafts onto the cylinder head.Make sure that the timing marks on the cam sprockets are facing outward andflush with the cylinder head upper surface as shown.

Index mark

“T” mark

Timing marks

If you can be able to measure the valve timing:Install the racing kit cam sprockets to the camshafts using the long bolt holes.Install the cam sprockets with No.3 cam lobes facing up and outward as shown.Apply Honda Ultra S9 oil to the racing kit cam sprocket bolt threads and seat-ing surface, temporarily tighten them.

• When tightening the sprocket bolts temporarily, push the intake cam sprock-et to retard direction fully, and the exhaust cam sprocket to advance directionfully as shown.

No.3 cam lobes

Place the No.2/3 pistons at TDC (Top Dead Center) and the ignition pulse gen-erator index line facing up as shown, and mark the No.2/3 piston top positiononto the ignition pulse generator rotor.Install the camshafts onto the cylinder head.Make sure that the timing marks on the cam sprockets are facing outward andflush with the cylinder head upper surface as shown.

Index mark

New marking

Timing marks

Index line


Racing Kit

2-14

Cylinder Head Bolt Tightening

If the cylinder head head gasket, tightening bolt and/or cylinder block arereplaced with new one, tighten the cylinder head bolts as follows;

Break-in procedure:1. Clean the bolts and threaded hole of the cylinder block.2. Apply Honda Ultra S9 oil to the cylinder head bolts threads and seating sur-

face.3. Tighten the cylinder head bolts to the specified torque in numerical order as

noted in the illustration.4. Retighten the cylinder head bolts to the specified torque in numerical order

as noted in the illustration.


5. Further tighten the cylinder head bolts 53 degrees in numerical order.6. Further tighten the cylinder head bolts 53 degrees in numerical order again.7. Loosen and remove the cylinder head bolts.

Final tightening procedure:1. Clean the bolts and threaded hole of the cylinder block.2. Apply Honda Ultra S9 oil to the cylinder head bolts threads and seating sur-

face.3. Tighten the cylinder head bolts to the specified torque in numerical order as

noted in the illustration.4. Retighten the cylinder head bolts to the specified torque in numerical order

as noted in the illustration.


5. Further tighten the cylinder head bolts 53 degrees in numerical order.6. Further tighten the cylinder head bolts 53 degrees in numerical order

IN

EX

Measure the valve timing.

Recommended valve timing:

Intake Opens 22˚ BTDC

Close 58˚ ABDC

Exhaust Opens 53˚ BBDC

Close 22˚ ATDC

Do not set the overlap beyond the recommended values, so the valve may betouch to the piston head. Be careful not to the touch the valve to the pistonhead when adjusting the valve timing.

Tighten the cam sprocket bolts to the specified torque.


Measure the piston and valve clearance and make sure the clearance is overthe minimum values.

Piston and valve clearance (minimum):IN: 1.2 mmEX: 1.4 mm

The measured values are below the minimum values, adjust the valve timingso that the clearance is over the minimum values.

Example:If the intake valve and piston clearance is 1.1 mm, adjust the valve timing asnoted below, and recheck the valve and piston clearance.

Intake Opens 22˚ BTDC to 21˚ BTDC

Close 58˚ ABDC to 59˚ ABDC

Exhaust Opens 53˚ BTDC to 54˚ BTDC

Close 22˚ ABDC to 21˚ ABDC


2-15

Racing Kit

ACG Set Installation

1. Remove the standard AC generator cover and flywheel.2. Clean any oil off from the crankshaft taper and flywheel 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.


Loosen the bolt and retighten the bolt to the specified torque again.Follow above procedure once more (temporarily tighten the bolt threetimes).Tighten the bolt to the following torque, then further tighten the bolt 60˚.

Torque: 15 N•m (1.5 kgf•m, 11 lbf•ft) + 60˚

After tighten the bolt, make sure the tightening torque is more than 128 N•m(13.0 kgf•m, 94 lbf•ft).

6. Install the racing kit stator onto the racing kit alternator cover, then tightenthe stator bolts and the wire clamp bolt to the specified torque.


7. Install the new gasket and AC generator cover onto the crankcase, tightenthe bolts securely.

8. Install the left crankcase cover guard with two collars, and tighten the boltssecurely.

• We recommended that the racing kit flywheel bolt is used whenever the stan-dard flywheel is installed.

• When using the racing kit flywheel bolt, follow the racing kit tighteningmethod and torque value.

• Replace the flywheel bolt with a new one every 6,000 km (3,700 mi).• When using the standard flywheel and bolt;

– flywheel reinstallation, temporarily tighten the bolt 1 time.– flywheel and/or crankshaft are replaced, temporarily tighten the bolt two

times.• Do not interchange the standard bolt and the racing kit bolt (see illustration).

Flywheel(racing kit)

Stator(racing kit)

AC generator cover(racing kit)


Gasket(racing kit)

Flange bolt(racing kit)

17

24

14

20.5

Flywheel bolt

Standard bolt(90003-MN4-000)

Racing kit bolt(90003-NL9-000)

Collars(racing kit)

Cover guard(racing kit)


(1) ROTOR HOLDER

Install the flywheel onto the crankshaft.Apply oil to the flywheel bolt threads and seatingsurface.Install the washer and flywheel bolt.

Hold the flywheel with rotor holder by inserting theholder bosses into the flywheel holes and seat theholder into the flywheel.

Tool:Rotor holder 89030–NL9–711

Refer to page 2-15 for detail of the tightening proce-dure.

(1) ROTOR HOLDER

Flywheel Holding

Hold the flywheel with rotor holder by inserting theholder bosses into the flywheel holes and seat theholder into the flywheel.Loosen and remove the flywheel bolt.

Tool:Rotor holder 89030–NL9–711

2-16

Racing Kit

(1) (1)


2-17

Racing Kit

Standard Racing kit

Gear ratio Gear ratio (T= Teeth)

(T= Teeth) R1 P1 P2 P3

1st 2.538 (13/33T) 2.286 (14/32T) – 2.400 (15/36T) 2.214 (14/31T)

2nd 1.941 (17/33T) 1.941 (17/33T) – 2.000 (15/30T) 1.882 (17/32T)

3rd 1.578 (19/30T) 1.667 (18/30T) – 1.772(18/31T) 1.632 (19/31T)

4th 1.380 (21/29T) 1.500 (20/30T) – 1.526 (19/29T) 1.450 (20/29T)

5th 1.250 (20/25T) 1.348 (23/31T) 1.400 (20/28T) 1.368 (19/26T) 1.318 (22/29T)

6th 1.160 (25/29T) 1.227 (22/27T) 1.273 (22/28T) 1.205 (24/30T) 1.200 (25/30T)

Transmission Set Installation

1. Remove and disassemble the transmission.2. Assemble the transmission using the racing kit mainshaft, countershaft,

gears and collar (30 x 11.2 mm ).

• Use standard vehicle collars and washers (except the collar, 30 x 11.2 mmand collar, 28 x 11.2 mm).

• Do not assemble the standard gear with the racing kit gear.• 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.

Check the gear dog edges for wear.

Service limit: 1.0 mm (0.04 in)

The gear jumps occur, if the gear dogedges are wear.Replace the gear with new ones whenthe wear to the service limit.


Racing Kit

2-18

Optional Transmission Gears

The following optional transmission gears are available for use in the transmission. Care should be taken substituting optional gears for the standard gears. The optional gear has marking groove on the outer surface of gear for identification.

Mainshaft CountershaftGear Plan Ratio Plan Teeth Part Number Identify Groove Plan Teeth Part Number Identify Groove

P-2 2.400P-2, BTL 15T 23212-NL9-710

– 1 P-2 36T 23422-NL9-710 – 1P-2 15T 23212-NL9-910

1st R1 2.286BTL 14T 23211-NL9-710

– 2 R1 32T 23421-MEL-R10 – 2R1 14T 23211-MEL-R10

P-3 2.214P-3, BTL 14T 23213-NL9-710

– 3 P-3 31T 23423-NL9-710 – 3P-3 14T 23213-NL9-910

P-2 2.000 P-2 15T 23432-NL9-710 – No P-2 30T 23442–NL9-710 – No2nd R1 1.941 R1 17T 23431-MEL-R10 – 1 R1 33T 23441-MEL-R10 – 1

P-3 1.882 R1 17T 23431-MEL-R10 – 1 P-3 32T 23443-NL9-710 – 2P-2 1.772 R1 18T No P-2 31T 23462-NL9-710 3 No

3rd R1 1.667 R1 18T No R1 30T 23461-MEL-R10 3 1 (edge)P-3 1.632 P-3 19T 2 P-3 31T 23463-NL9-710 3 2P-2 1.526 P-2 19T 1 P-2 29T 23482-NL9-710 – 1

4th R1 1.500 R1 20T 2 R1 30T 23481-MEL-R10 – 2P-3 1.450 R1 20T 2 P-2 29T 23482-NL9-710 – 1P-1 1.400 P-1 20T 23491-NL9-C00 M5 No P-1 28T 23501-NL9-C00 C5 No

5thP-2 1.368 P-2 19T 23492-NL9-710 M5 1 P-2 26T 23502-NL9-710 C5 1R1 1.348 R1 23T 23491-MEL-R10 M5 2 R1 31T 23501-MEL-R10 C5 2P-3 1.318 P-3 22T 23493-NL9-710 M5 3 P-3 29T 23503-NL9-710 C5 3P-1 1.273 P-1 22T 23511-NL9-C00 M6 No P-1 28T 23521-NL9-C00 C6 No

6thP-2 1.250 P-2 24T 23512-NL9-710 M6 1 P-2 30T 23522-NL9-710 C6 1R1 1.227 R1 22T 23511-MEL-R10 M6 2 R1 27T 23521-MEL-R10 C6 2P-3 1.200 P-3 25T 23513-NL9-710 M6 3 P-2 30T 23522-NL9-710 C6 1

M3/4 Gear matrix

M3-4 Plan3rd Plan

P-2 R1 P-3P-2 P-2 P-2 P-3

4th Plan R1 R1 R1 P-4P-3 R1 R1 P-4

M3-4Plan Part Number Identify Groove CombiP-2 23452-NL9-710 – 0/1 R1/P-2R1 23451-MEL-R10 – 0/2 R1/R1P-3 23453-NL9-710 – 2/1 P-3/P-2P-4 23454-NL9-710 – 2/2 P-3/R1

M3-4 PlanM3 Plan

R1 (18T) P-3 (19T)

M4 PlanP-2 (19T) P-2 P-3R1 (20T) R1 P-4


2-19

Racing Kit

Speed list (13,000 rpm) Primary reduction: 48/77, Tire radius: 0.315 m

GearNo. of teeth

Gear ratioDrive

M C Driven

1st P-2 15 36 2.400

R1 14 32 2.286

P-3 14 31 2.214

2nd P-2 15 30 2.000

R1 17 33 1.941

P-3 17 32 1.882

3rd P-2 18 31 1.722

R1 18 30 1.667

P-3 19 31 1.632

4th P-2 19 29 1.526

R1 20 30 1.500

P-3 20 29 1.450

5th P-1 20 28 1.400

P-2 19 26 1.368

R1 23 31 1.348

P-3 22 29 1.318

6th P-1 22 28 1.273

P-2 24 30 1.250

R1 22 27 1.227

P-3 25 30 1.200

17 17 17 16 17 16 17 16 17 15 16 15 16 15 16 15 15 15

38 39 40 38 41 39 42 40 43 38 41 39 42 40 43 41 42 43

179 174 170 168 166 164 162 160 158 158 156 154 152 150 149 146 143 139

188 183 178 177 174 172 170 168 166 166 164 161 160 157 156 154 150 146

194 189 184 182 180 178 175 173 171 171 169 167 165 162 161 159 155 151

215 209 204 202 199 197 194 192 190 189 187 185 183 180 179 176 171 167

221 216 210 208 205 203 200 198 195 195 193 190 188 185 184 181 177 172

228 222 217 215 211 209 206 204 202 201 199 196 194 191 190 187 182 178

249 243 237 235 231 229 226 223 220 220 218 214 212 209 207 204 199 194

258 251 245 243 239 236 233 230 228 227 225 222 219 216 214 211 206 201

263 257 250 248 244 241 238 235 233 232 230 226 224 221 219 215 210 205

282 274 267 265 261 258 255 252 249 248 246 242 240 236 234 230 225 219

287 279 272 270 266 263 259 256 253 253 250 246 244 240 238 234 229 223

296 289 282 279 275 272 268 265 262 261 259 255 252 248 246 242 237 231

307 299 292 289 285 282 278 274 271 271 268 264 261 257 255 251 245 239

314 306 298 296 291 288 284 281 278 277 274 270 267 263 261 257 251 245

319 311 303 300 296 292 289 285 282 281 278 274 272 267 265 261 255 249

326 318 310 307 302 299 295 292 288 288 284 280 278 273 271 267 260 254

338 329 321 318 313 310 306 302 298 298 295 290 288 283 281 276 270 263

344 335 327 324 319 315 311 307 304 303 300 296 293 288 286 281 274 268

350 341 333 330 325 321 317 313 310 309 306 301 298 294 291 286 280 273

358 349 340 337 332 329 324 320 317 316 312 308 305 300 298 293 286 279

Since the values in the speed list differ somewhat depending on the tire manufacturer and size, selection should be made based on the gear ratio.


Racing Kit

2-20

Right Crankcase Cover Replacement

Replace the following racing kit right crankcase cover as shown.

Drive Sprocket Cover Damper Removal

To avoid interference with a drive sprocket bolt locking washer and damperrubber, remove the damper rubber from the drive sprocket cover.

Right crankcase cover(racing kit)

Flange bolts, 6 x 22 mm(racing kit)

Collars(racing kit)

Cover guard(racing kit)

Filler cap(racing kit)


Drive sprocket cover

Damper rubber(remove)

O-ring(racing kit)


2-21

Racing Kit

Clutch Spring/Clutch Disc Replacement

Replace the clutch springs and clutch discs with racing kit.

Install the clutch disc with their half cut-out side facing the pressure plate or clutch center.

Clutch discs(racing kit)

Clutch spring(racing kit)


Racing Kit

2-22

BTL (Back Torque Limiter) Kit

Lifter plate

Lifter piece(‘06 MEL standard)

Lock nut(‘06 MEL standard)

Lock washer(‘06 MEL standard)90432-MM8-003

Center guide

Clutch disc(no paint)

Clutch shim

Clutch springPressure plate

Stroke shim

Clutch VC spring

Lifter rod

Clutch plate

Clutch center B

Lifter cam plate

Clutch center

Thrust washer(‘06 MEL standard)

Clutch outer(‘06 MEL standard)

Needle bearing(‘06 MEL standard)

Outer guide(‘06 MEL standard)

Judder spring

Spring seat

Clutch disc(large I.D.)

Clutch disc(yellow/blue paint)

Lifter bearing(‘06 MEL standard)


2-23

Racing Kit

(1) THRUST WASHER

Install the thrust washer with its grooved side facingin.

Install the clutch center onto the mainshaft.Install the clutch lifter cam plate aligning its pinswith the hole in the clutch center.

(1) CLUTCH OUTER (2) MAINSHAFT

Installation

• When installing the BTL kit, must be modify theright crankcase cover (page 2-9).

• The BTL kit is used with the special mainshaft.

Apply molybdenum disulfide oil to the clutch outerneedle bearing.Install the needle bearing to the clutch outer guide.

Install the clutch outer while aligning the primarydriven gear with the primary drive gear.Align the holes in the clutch outer with the pins onthe oil pump drive sprocket by turning the oil pumpdriven sprocket while pushing in the clutch outer.

(1) CLUTCH CENTER(2) LIFTER CAM PLATE

(1)

(2) (1)

(1)

(2)

(1) LIFTER CAM PLATE (2) ANGLE(3) IDENTIFICATION MARK

Following optional clutch lifter cam plates are avail-able.

• When the clutch lifter cam plate is replaced withoptional narrow cam angle type, the clutchengage time from the back torque limiter is acti-vated is longer than the larger angle one.

• The clutch lifter cam plate has identification markon the side face as shown.

Part number Cam angle Identification mark

22122-NL9-710 STD; 50˚ No mark

22123-NL9-710 OP; 45˚ 45

22124-NL9-710 OP; 40˚ 40

(1)

(2)

(3)


2-24

Racing Kit

(1) JUDDER SPRING SEAT(2) JUDDER SPRING

Install the judder spring seat and judder spring ontothe clutch center.

Note the installation direction of the judder spring.

(1) JUDDER SPRING SEAT(2) JUDDER SPRING

(1) CLUTCH PLATE 1.9 (1 IDENTIFIED GROOVE)(2) CLUTCH PLATE 2.0 (NO GROOVE)(3) CLUTCH PLATE 2.1 (2 IDENTIFIED GROOVE)

Measure the clearance between the pressure plateand clutch center B and adjust by combination of thethree different thickness clutch disc (page 2-32).

22321-NL9-710:Clutch plate 1.9 mm

22321-MT3-000:Clutch plate 2.0 mm

22322-NL9-710:Clutch plate 2.1 mm

Three different clutch discs are available.The clutch disc has a identification color paint.

22201-NL9-C30:No paint (thickness: 3.8 mm) 1

22201-MEN-670:Yellow/Blue painted (thickness: 3.0 mm) 7

22201-NL9-C00:No paint (thickness: 3.0 mm) 1

Install the clutch disc with their half cut-out side fac-ing the pressure plate or clutch center.

(1)(2)

(1)(2)

(2) (1)

(1) (3)


2-25

Racing Kit

(1) CLUTCH CENTER GUIDE (2) CLUTCH SHIMS(3) CLUTCH SPRING (4) STROKE SHIM(5) CLUTCH VC SPRING

(1) CLUTCH CENTER B

Check that the the clutch center B is installed secure-ly onto the clutch lifter cam plate by pushing theclutch center B.

Install the clutch pressure plate onto the clutch cen-ter B.

(1) PRESSURE PLATE

(1)

(1)

(1)

(2)

(3)

(4)(5)

Assemble the clutch center guide, shim(s), clutchstroke shim and clutch VC spring as shown.

(1) CLUTCH CENTER B(2) CLUTCH DISCS/PLATES

Install the clutch center B while aligning its bosseswith the grooves in the clutch lifter cam plate.While holding the clutch center B, install the clutchdiscs and plates alternately.

Install the 3.8 mm thickness clutch disc (22201-NL9-C30) first, and the 3.0 mm thickness clutch disc(22201-NL9-C00) to the outer end.

(1)

(2)


Install the clutch center guide assembly onto themainshaft.Install the lock washer.

(1) GEAR HOLDER

Apply oil (Honda Ultra S9) to the new clutch centerlock nut threads and seating surfaces.Screw the center lock nut by hand fully.

Hold the primary drive and driven gear with a gearholder.

Tool:Gear holder 07724–0010100

Tighten the clutch center lock nut to the specifiedtorque.


2-26

Racing Kit

(1) CENTER GUIDE(2) LOCK WASHER

(1)

(2) (1)

(1) CLUTCH VC SPRING(2) IDENTIFICATION PAINT MARKS

Following optional clutch VC spring is available.

• The optional clutch VC spring has less spring loadthan the standard VC spring. When the optionalVC spring is installed, the back torque limiter willoperated faster than the standard.

• The optional clutch VC spring has identificationpaint marks on the spring face as shown.

Part number Spring load Identification mark

22172-NL9-710 STD; 7 kgf Orange paint

22173-NL9-710 OP; 4 kgf Green paint

(1)

(2)


2-27

Racing Kit

(1) LIFTER PLATE (2) BEARING

Inspection

Clutch lifter plate/bearingTurn the inner race of the lifter bearing with your fin-ger.The bearing should turn smoothly and quietly.Also check that the outer race of the bearing fitstightly in the lifter plate.Replace the bearing if the inner race does not turnsmoothly, quietly, or if the outer race fits loosely inthe lifter plate.

(1) (2)

(1) LIFTER PLATE(2) BOLTS

Install the clutch lifter rod into the mainshaft.Apply molybdenum disulfide oil to the clutch lifterpiece, then install it into the mainshaft.

Install the clutch lifter plate with the lifter bearingand install and tighten the bolts to the specifiedtorque.


Install the right crankcase cover.

(2)

(1)

(1) LIFTER ROD(2) LIFTER PIECE

(1)

(2)

(1)

(1) STAKE

Stake the clutch center lock nut into the mainshaftbeing careful not to damage the mainshaft.


(1) CLUTCH OUTER

Clutch outerCheck the slots in the clutch outer for nicks, inden-tations or abnormal wear made by the clutch discs.

Check the needle bearing for wear or damage.

(1) CLUTCH DISC

Clutch discCheck the clutch discs for signs or spring or discol-oration.

Replace the clutch discs and plates as a set.Always adjust the back torque limiter whenever theclutch discs and plates are replaced (page 2-31).

2-28

Racing Kit

(1) CLUTCH PLATE

Clutch plateCheck the plates for discoloration.Check the plate warpage on a surface plate using afeeler gauge.

Replace the clutch discs and plates as a set.Always adjust the back torque limiter whenever theclutch discs and plates are replaced (page 2-31).

(1)

(1)

(1)


2-29

Racing Kit

(1) LIFTER ROD

Clutch center/clutch lifter cam plate

Check the clutch lifter cam plate grooves slidingarea of clutch center B bosses for wear or damage.

Clutch lifter rodCheck the clutch lifter rod for bending or damage.

See CBR Service Manual for clutch outer guide andmainshaft inspection.

(1) CLUTCH CENTER(2) LIFTER CAM PLATE

(1) (2)

(1)

(1) CLUTCH CENTER B(2) CENTER GUIDE

Clutch center BCheck the clutch center B for nicks, indentations orabnormal wear made by the clutch plates.Check the clutch center B bosses sliding area ofclutch lifter cam plate grooves for wear or damage.

Clutch center guideCheck the clutch center guide for wear or damage.

(1)

(2)

(1) PRESSURE PLATE

Pressure plateCheck the clutch pressure plate for nicks, indenta-tions or abnormal wear made by the clutch disc.

(1)


2-30

Racing Kit

Pressure plate does not lift

Clutch center does not move

Clearance between the pressureplate and clutch center (B) is toolarge

Clearance between the clutch cen-ter and clutch center guide (A) istoo small

Adjust clearance between the pres-sure plate and clutch center (B) to thespecified value (page 2-32)

Adjust clearance between the clutchcenter and clutch center guide (A) tothe specified value (page 2-31)

Sticking clutch center and clutchcenter guide or damaged slidingsurface

Replace the clutch center and clutchcenter guide

Pressure plate lift too large Clearance between the pressureplate and clutch center (B) is toosmall

Clearance between the clutch cen-ter and clutch center guide (A) istoo large

Adjust clearance between the pres-sure plate and clutch center (B) to thespecified value (page 2-32)

Adjust clearance between the clutchcenter and clutch center guide (A) tothe specified value (page 2-31)

Back Torque Limiter

Troubleshooting

• Back torque limiter effect is poor or does not effect

• Back torque limiter excessively effect(less engine brake)

B

A

Weak clutch VC spring Replace clutch VC spring.

Clutch disc wear Replace clutch discs and plates, andadjust BTL (page 2-31).


2-31

Racing Kit

(1) CLUTCH VC SPRING

2. Measure the clutch VC spring thickness (B).3. Note the stroke shim thickness (C).

• The stroke shim has a thickness identification let-ter on its side surface.Example: mark 18 = 1.8 mm thickness

4. Calculate the clutch center stroke (D) using theequation below.

D = A – (B + C)

Example:Measured height (A) = 3.6 mmVC spring thickness (B) = 0.6 mmStroke shim thickness (C) = 2.0 mm

1.0 mm = 3.6 mm – (0.6 mm + 2.0 mm)

Clutch center stroke (D) = 1.0 mm

Specified stroke: 0.95 – 1.1 mm

(1) STROKE SHIM

Adjust the stroke by selecting the stroke shim thick-ness.

Six different thickness clutch stroke shims are avail-able.

Stroke shim thickness:Mark 18: 1.8 mm thicknessMark 19: 1.9 mm thicknessMark 20: 2.0 mm thicknessMark 21: 2.1 mm thicknessMark 22: 2.2 mm thicknessMark 23: 2.3 mm thickness

Select the stroke shim so that the stroke is fallbetween the specified range.

(1) CLUTCH CENTER B(2) CLUTCH CENTER GUIDE

Adjustment

• Clutch Center Stroke Adjustment

Calculate the clutch center stroke as follow:1. Install the clutch center guide into the clutch cen-

ter B.Support the center guide so that its flange con-tacts to the clutch center B.Measure the clutch center guide height extendedfrom the clutch center B surface (A) as shown.

(2)

(1)

(1)

(1)


2-32

Racing Kit

(1) CLUTCH PLATE 1.9 (1 IDENTIFIED GROOVE)(2) CLUTCH PLATE 2.0 (NO GROOVE)(3) CLUTCH PLATE 2.1 (2 IDENTIFIED GROOVE)

Adjust the clearance by selecting the clutch platethickness.

Three different thickness clutch plates are available.

Clutch plate thickness:1.9 mm2.0 mm2.1 mm

The clutch plate 1.9 has one identification grooveand clutch plate 2.1 has two identification groove(2.0 mm has no groove).

Select and combine the clutch plates so that theclearance is fall between the specified range.

Clearance is too small:– Easy to slip clutchClearance is too large:– Does not effect the back torque limiter

If the clutch discs are worn, the clearance is toosmall and can cause clutch slipping.

2. Measure the depth from the clutch pressure plateouter surface to clutch center B (B) by installingthe depth gauge into the plate holes as shown.

3. Calculate the clearance (C) using the equationbelow.

C = B – A

Example:Pressure plate thickness (A) = 6.00Measured depth (B) = 6.6Clearance (C) = 0.6

0.6 mm = 6.6 mm – 6.00 mm

Specified clearance: 0.5 – 0.6 mm

(1) PRESSURE PLATE THICKNESS LETTER

• Pressure plate-to-clutch center B clearanceadjustment

• For the racing use, the clutch discs and platesmust be finished the break-in.

• While the break-in, do not use racing start.• Always adjust the clearance before you start the

race.

Measure the clutch pressure plate-to-clutch center Bclearance as follow:1. Note the clutch pressure plate thickness lettered

on the plate (A).

(1)

(2) (1)

(1) (3)


2-33

Racing Kit

2. Tighten the clutch center lock nut to the specifiedtorque (page 9-11), and measure the heightbetween the clutch pressure plate-to-clutch centerguide (B).

3. Calculate the clutch spring initial stroke (C) usingthe equation below.

C = A – B

Specified stroke: 2.1 – 2.3 mm

4. Tighten the clutch center lock nut (page 2-26).

(1) CLUTCH SHIMS

Adjust the stroke by selecting the clutch shim thick-ness.

Seven different thickness clutch shims are available.The clutch shim has a thickness identification letteron its surface.

Clutch shim thickness:Mark 09: 0.9 mm thicknessMark 10: 1.0 mm thicknessMark 11: 1.1 mm thicknessMark 12: 1.2 mm thicknessMark 13: 1.3 mm thicknessMark 14: 1.4 mm thicknessMark 15: 1.5 mm thickness

Select the clutch shims so that the stroke is fallbetween the specified range.Must be use two clutch shims.

If the initial tension is less than the specified range:– Clutch slips easilyIf the initial tension is more than the specified range:– Clutch spring weak easily

• Clutch Spring Initial Tension Adjustment

Measure the clutch spring initial stroke as follow:1. Install and hand tighten the clutch center lock nut,

and measure the height between the clutch pres-sure plate-to-clutch center guide (A).

(1)


2-34

Racing Kit

(1) LIFTER CAM PLATE (2) ANGLE(3) IDENTIFICATION MARK

(1)

(2)

(3)

(1)

(2)

(1) CLUTCH VC SPRING(2) IDENTIFICATION PAINT MARKS

Following optional clutch VC spring and clutch liftercam plates are available.

Select the optional clutch lifter cam and clutch VCspring for rider’s preference.


2-35

Racing Kit

(1) CRANKCASE I.D. CODE LETTER

Main Journal Bearing

Main journal bearing selection

Record the crankcase I.D. letters from the pad on theleft side of the upper crankcase as shown.Record the corresponding main journal O.D. codenumbers from the crank weight.Cross reference the case and journal codes to deter-mine the reference bearing color code.

(1) MAIN JOURNAL BEARING(2) COLOR

The main journal bearings are identified by thecolor.

Main journal bearing selection table:

(1) MAIN JOURNAL BEARING

Clean off any oil from the selected main journalbearings and main journals.Install the main journal bearings.Assemble the crankcase halves and tighten the mainjournal bolts to the specified torque (page 2-38).

Measure the main journal bearing I.D.s using a dialgauge in an Y axis at two points.Take the minimum reading to determine the bearingI.D.s.

(1) MAIN JOURNAL O.D. CODE LETTER

Crankcase I.D. Code

A B C

Main journal 1 Red Pink Yellow

O.D. Code 2 Pink Yellow Green

3 Yellow Green Brown

BEARING THICKNESS:B (Brown): ThickC (Green):D (Yellow):E (Pink):F (Red):G (White):H (Purple): Thin

• The main journal bearing thickness is differabout 0.003 mm by 1 rank (0.006 mm by oil clear-ance)

• Do not combine the difference color code bear-ings.

(1)

(1)

(1)

(2) (1)


2-36

Racing Kit

(1) MAIN JOURNAL

Measure the crankshaft main journal O.D.s using amicrometer in an X, Y and Z axis.Take the maximum reading to determine the mainjournal O.D.s.

From the measured bearing I.D.s and main journalO.D.s, calculate the clearance.

Specified oil clearance: 0.029 – 0.039 mm (0.0012 – 0.0015 in)

If the clearance does not fall in the specified oilclearance, select the bearing inserts so that the oilclearance fall in the specified oil clearance.

(1) CONNECTING ROD I.D. CODE LETTER

(1) CRANKPIN O.D. CODE LETTER

Crankpin Bearing

Crankpin bearing selection

Record the connecting rod big end I.D. letters fromthe connecting rod as shown.Record the corresponding crankpin O.D. code num-bers from the crank weight.Cross reference the connecting rod big end I.D. codeand crankpin codes to determine the reference bear-ing color code.

(1) CRANKPIN BEARING(2) COLOR

The crankpin bearings are identified by the color.

Crankpin bearing selection table:

BEARING THICKNESS:A (Pink/Blue): ThickB (Pink/Black):C (Pink/Brown):D (Pink/Green):E (Pink/Yellow):F (Pink/Pink):G (Pink/Purple): Thin

• The crankpin bearing thickness is differ about0.003 mm by 1 rank (0.006 mm by oil clearance)

• Do not combine the difference color code bear-ings.

Connecting rodbig end I.D. Code

1 2 3

A Pink/ Pink/ Pink/Yellow Green Brown

Crankpin B Pink/ Pink/ Pink/O.D. Code Green Brown Black

C Pink/ Pink/ Pink/Brown Black Blue

(1)

(1)

(1)

(2)

(1)


2-37

Racing Kit

(1) CRANKPIN BEARING

Clean off any oil from the selected crankpin bearingsand crankpins.Carefully install the bearing caps, aligning the dowelpins with the holes in the connection rods.

(1) CRANKPIN BEARING

Apply oil (Honda Ultra S9) to the connecting rod boltthreads and seating surfaces and install the bolts.

Tighten the connecting rod bolts in 2 or 3 steps alter-nately to the specified torque.

Tighten the bearing tab side bolt first, then the otherbolt.


Further tighten the connecting rod bolts 45 degreealternately, then further tighten 45 degree again(total 90 degree).

Measure the crankpin bearing I.D.s using a dialgauge in an Y axis at two points.Take the minimum reading to determine the bearingI.D.s.

(1) CRANKPIN

Measure the crankpin O.D.s using a micrometer inan X, Y and Z axis.Take the maximum reading to determine thecrankpin O.D.s.From the measured bearing I.D.s and main journalO.D.s, calculate the clearance.

Specified oil clearance: 0.042 – 0.052 mm (0.0018 – 0.0022 in)

If the clearance does not fall in the specified oilclearance, select the bearing inserts so that the oilclearance fall in the specified oil clearance.

If the oil clearance cannot be measured, select bear-ing from the crankpin bearing selection table.

(1)

(1)(1)


Racing Kit

2-38

Main Journal Bolt Tightening

If the main journal bolts are replaced with new ones, tighten the main journalbolts as follows;

Break-in procedure:1. Clean the bolts and threaded hole of the cylinder block.2. Apply Honda Ultra S9 oil to the main journal bolts threads and seating sur-

face.3. Tighten the main journal bolts to the specified torque in numerical order as

noted in the illustration.


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:1. Clean the bolts and threaded hole of the cylinder block.2. Apply Honda Ultra S9 oil to the main journal bolts threads and seating sur-

face.3. Tighten the main journal bolts to the specified torque in numerical order as

noted in the illustration.


4. Further tighten the main journal bolts 60 degrees in numerical order.5. Further tighten the main journal bolts 60 degrees in numerical order

Crankshaft Thrust Play Adjustment

The crankshaft thrust play adjustment can be performed with the racing kitcrankcase.

1. Select the main journal bearings (page 2-35).Set the selected main journal bearings onto the upper crankcase.

2. Install the two suitable selected thrust shims to the both side of the uppercrankcase #3 journal (example: B and B shim).

3. Set the crankshaft onto the upper crankcase.

Thrust shims(racing kit)


4. Set the pick-up gauge to the either end of the crankshaft.Move the crankshaft to thrust direction and measure the free play.

5. Replace the thrust shim so that the crankshaft thrust play is within the stan-dard value.

Standard: 0.20 – 0.30 mm (0.008 – 0.012 in)

Do not select the two A shims (maximum thickness shim) or C shims (mini-mum thickness shim).

2-39

Racing Kit

Balancer Backlash Adjustment

Adjust the balancer backlash while the engine is cold (below 35˚C/95˚F) andengine off.

Loosen the balancer shaft holder pinch bolt.

Turn the balancer shaft counterclockwise turn until the resistance is felt, thenreturn 2 graduations.

Do not turn the balancer shaft more than necessary so the balancer gear, bear-ing and shaft are damaged.

Tighten the balancer shaft holder pinch bolt to the specified torque.


(1)

Until resistance is felt Return 2 graduations


Racing Kit

2-40

Engine Hanger Tightening Sequence

POINT B

POINT C

POINT D

POINT A

POINT B

APPLY MOLYBDENUMDISULFIDE GREASE






POINT A


2-41

Racing Kit

When using the lock nut wrench for the adjustingbolt lock nut, use a deflecting beam type torquewrench 20 inches long. The lock nut wrenchincreases the torque wrench’s leverage, so thetorque wrench reading will be less than the torqueactually applied to the lock nut. The specificationgiven is the actual torque applied to the lock nut, notthe reading on the torque wrench. Do not over-tighten the lock nut.

Apply molybdenum disulfide grease to the allmounting bolt threads and seating surface of thenuts.

Install and tighten the engine hanger bolts as follow:1. Install the point C and point D engine hanger

adjusting bolt fully from the inside of the frame.2. Install the engine into the frame.3. Install the rear upper engine hanger distance col-

lars and bolt (C).4. Install the rear lower engine hanger bolt (D).5. Install the point A, B engine hanger distance col-

lars 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.


8. Tighten the rear lower engine hanger adjustingbolt lock nut (D) to the specified torque.

Tool:Lock nut wrench, 5.8 x 46 mm

07VMA-MBB0100 or 07VMA-MBB0101

Torque:Actual: 59 N•m (6.0 kgf•m, 43 lbf•ft)Scale reading: 54 N•m (5.5 kgf•m, 40 lbf•ft)

A

B

C

D

9. Tighten the rear upper hanger adjusting boltwhile turning the hanger bolt until it seats.

10. Tighten the rear upper engine hanger adjustingbolt (C) to the specified torque.


11. Tighten the rear upper engine hanger adjustingbolt lock nut (C) to the specified torque.

Tool:Lock nut wrench, 5.8 x 46 mm

07VMA-MBB0100 or 07VMA-MBB0101

Torque:Actual: 59 N•m (6.0 kgf•m, 43 lbf•ft)Scale reading: 54 N•m (5.5 kgf•m, 40 lbf•ft)

12. Install the rear lower engine hanger nut (D), thentighten the nut to the specified torque whileholding the hanger bolt.


13. Install the rear upper engine hanger nut (C), thentighten the nut to the specified torque whileholding the hanger bolt.


14. Tighten the left side front engine hanger bolt (A)to the specified torque.


15. Tighten the left side middle engine hanger bolt(B) to the specified torque.


16. Tighten the right side front engine hanger bolt(A) to the specified torque.


17. Tighten the right side middle engine hanger bolt(B) to the specified torque.


Install the removed parts in the reverse order ofremoval.


Racing Kit

2-42

Before riding the machine, secure the following bolts and nuts:– Engine oil filler cap– Engine oil drain plug– Oil filter cartridge/main oil garalley taper plug

1. Insert the proper length locking wire to the bolt.2. 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.

Wire twisting tool

No good Good

Wire Lock

• 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)

Drill hole (3 - 4 mm)

Drain plugSub-tank band Oil filter cartridge

Oil filler cap

Taper plug


2-43

Racing Kit

Quick Shift Kit Installation

1. Install the quick shift unit rubber suspension bracket onto the frame, andtighten two mounting bolts securely.

2. Install the rubber suspension onto the quick shift unit, then install the unit tothe bracket, then connect the connector to the wire harness.

3. Remove the gearshift pedal and pedal link.4. Install the pedal rod sensor into the pedal link rod.5. Connect the sensor connector to the quick shift unit connector.7. Reinstall the gearshift pedal and pedal link.

Pedal link

Pedal link rod

Pedal rod sensor(racing kit)

Gearshift pedal

Quick shift unit(racing kit)

Rubber suspension(racing kit)

Bracket(racing kit)

Bolts(racing kit)


Racing Kit

2-44

Cone plug(racing kit)

Clamp(racing kit)

Clamp(racing kit)


Clamp(racing kit)


Removethem

Removethem

Rubber(standard)

Washer(racing kit)

Clamp(racing kit)

Plugs(racing kit)

Clamp(racing kit)

50 mm

50 mm

Removethem

Secondary Air Supply System Removal

1. Disconnect the secondary air supply hoses from the cylinder head reed valvecovers and air cleaner housing.

2. Cut the removed hoses 40 mm from the each end of the cylinder head reedvalve cover side and air cleaner housing side.

3. Install the cutted hoses to the cylinder head reed valve covers and air clean-er housing, then secure them with removed clips (air cleaner housing sidehose: also provided in the racing kit).

4. Plug the hoses with cone plugs in the racing kit, and secure them withclamps also in the racing kit.

Thermostat and Bypass Hose Removal

1. Drain the coolant.2. 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

clamps in the racing kit.


2-45

Racing Kit

6. Remove the fast idle wax unit water hoses from the thermostat housing andwater 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 securethem with clamps.

8. Install the hose plugs in the racing kit to the hose ends, and secure them withthe clamps that are attached on the fast idle wax unit.

Link(remove) Screw

(remove)

Wax unit(remove)

Throttle stop screw set

Bracket

Plug(racing kit)

Plug(racing kit)

Remove

Remove

Fast Idle Wax Unit Removal

1. Remove the throttle body.2. 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.

50 mm50 mm


Racing Kit

2-46

Variable Air Intake Valve Removal/Air Duct Installation

1. Remove the variable air control solenoid valve and vacuum chamber.2. 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.

Air duct(racing kit)

Remove

Left radiator bracket(Racing kit)

Right radiator bracket(Racing kit)

5. Install the steel ball into the vacuum hose that is connected to the intake airduct control valve. Bent the vacuum hose as shown and secure it with tie-lap.

Steel ball 5: 96211-05000

Note:Do not cut the vacuum tube.

Steel ball

Vacuum hose

Tie-lap


2-47

Racing Kit

Left radiator hose(Racing kit)

Right radiator hose(Racing kit)

Radiator(Racing kit)

Radiator Kit Installation

1. Remove the standard radiator and radiator reserve tank.2. Install the racing kit radiator with the racing kit right and left radiator hose,

oil cooler hoses and oil cooler pipe. The right radiator hose can use thestandard part.

3. Tighten the hose clamps securely.

Note:Avoid damaging the oil cooler water hose from the exhaust pipe heat, installthe heat resistance tape to the oil cooler water hose as shown.

Heat resistance tape

Oil cooler hose A(Racing kit)

Oil cooler pipe(Racing kit)

Oil cooler hose B(Racing kit)

Hose clamp A(Racing kit)


Racing Kit

2-48

Boss (grind off)

Throttle pipe

Under throttlehousing(racing kit)

Upper throttlehousing(racing kit)

Starter/engine stop switch(racing kit)

Throttle cable B(racing kit)

Throttle cable A(racing kit)

Hi Throttle Set/Engine Stop Switch Installation

1. Remove the standard throttle housing and right grip comp. from the righthandlebar.

2. 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 starter/engine stop switch to the right handlebar.

Tighten the forward screw first, then the rear screw.

Note:• Do not overtighten the throttle housing screw, so the starter switch hard to

return.• If the starter switch is moved around the handlebar, tape around the han-

dlebar.

7. Connect the starter/engine stop switch 9P connector to the wire harness.


2-49

Racing Kit

Oil catch tank(racing kit)

Breather tube(racing kit)

Breather return tube(racing kit)

Oil Catch Tank Installation

1. Disconnect the crankcase breather tube from the air cleaner housing andcylinder head cover, then remove the breather tube.

2. 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.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 hous-

ing and secure them with clips.

Clamp(racing kit)

Stay(racing kit)Clip

(racing kit)


Racing Kit

2-50

Air Funnel/Air Cleaner Element Replacement

1. Remove the original air cleaner element and air funnels.2. Install the racing kit air funnels into proper location according to each iden-

tification mark on the funnel.3. Install and tighten the screws securely.4. Wire lock the screws using the screw groove.5. Install racing kit air cleaner element.

Air cleaner elements(racing kit)

Air funnel (#4)(racing kit)




Secure the air funnel screw with wire prevent falling the screw into the cylin-der1. Put the wire around the screw groove.2. Twist the wire and tighten the screw.3. Put the wire around the other screw groove.4. Twist the wire and tighten the screw.

• Route the twisted wire under the air funnel as shown.

Standard (06160-NL9-710) Optional (06160-NL9-C30)

Item Height Item Height

Funnel #1 45 mm Funnel #1 55 mm




The optional air funnel set is available.


2-51

Racing Kit

Steering Stem Modifying

1. Make the steering stopper pieces from aluminium block. The piece dimen-sions are shown in the illustration below.

Stopper piece

2. Weld the stopper pieces onto the bottom bridge as shown.3. Make sure the steer angle is minimum of 15˚ on both side.

Frame body

Bottom bridge

Steering Damper Replacement

1. Remove the standard steering damper cover and steering damper.2. Install the racing kit steering damper without installing the covers.

When the racing kit steering damper is installed (2P Black connector is discon-nected), the waring LED on the combination meter is illuminated but there areno problem in the system.

• When using the standard HESD, the unit can be set by using the PC.• On racing kit mechanical steering damper, the damping force is adjusted by

the screwdriver.


Racing Kit

2-52

Fuel Tank Replacement

1. Remove the original fuel tank, and remove the fuel pump from the fuel tank.2. Remove the packing base from the fuel pump.3. Cut the baffle sponge (racing kit) with 210 x 100 x 20 mm size.4. Wrap the fuel pump with the baffle sponge, so that the mating face of the

sponge is aligned with the fuel inlet on the packing base.5. Install the new packing base (racing kit) onto the fuel pump.6. Recheck the mating face of the baffle sponge is aligned with the fuel inlet on

the packing base.7. Check that the baffle sponge is installed into the end of the packing base

properly.8. Make sure the baffle sponge does not pinch between the packing base and

fuel pump tightening surface, then install the fuel pump into the fuel tank.9. Install and tighten the pan screws (racing kit) in the sequence listed below.

10. Install the fuel tank onto the vehicle.11. Install the fuel hose banjo bolt with new sealing washers, and tighten the

banjo bolt to the specified torque.


12. Route the fuel tank breather hose properly and connect it to the fuel tank.

NOTE:When the fuel pump is removed, always replace the packing base with a newone.

Packing base(racing kit)

Baffle sponge(racing kit)

Fuel pump

Breather hose


2-53

Racing Kit

ECM/Bank Angle Sensor Installation

1. Make a two ø3.5 mm drill holes into the upper face of the upper cowl stay asshown.

2. 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 nutsas shown.

4. Install the bank angle relay and overflow catch tank stay onto the upper cowlstay and secure it bolts and nuts.

5. Install the catch tanks and secure them with tie-laps.

Upper cowl stay

ECM stay(racing kit)

Bank angle sensor(racing kit)

Catch tank(racing kit) Stay

(racing kit)

Catch tank(racing kit)


Racing Kit

2-54

Seat Rail Replacement/Battery Tray Installation

1. Remove the original rear fender B and seat rail.2. Install the racing kit seat rail onto the frame, and tighten the mounting bolts

to the specified torque.


3. Install and tighten the fuel tank pivot bolt to the specified torque.

Torque: 9.8 N•m (1.0 kgf•m, 7 lbf•ft)

4. Install the muffler and tighten the mounting bolts.5. Install the rubber cushion/battery tray (racing kit) and rear shock absorber

adjuster plate (racing kit) onto the seat rail and secure them with mountingbolts.

6. Install the starter relay (racing kit) to the battery tray.7. Route the wire harness, battery cable (racing kit) and ground cable (racing

kit), then connect them to the battery and starter relay.

Starter relay/cable(racing kit)

Battery/rubber cushion(racing kit)

Battery tray(racing kit)

Seat rail(racing kit)

Ground cable(racing kit)

Adjuster plate(racing kit)


2-55

Racing Kit

Rear Fender B Modification

1. Cut and remove the indicated portion of the rear fender B.

Cut area

Rear fender B

2. Drill ø3.3 - 3.5 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(racing kit) Bracket

(racing kit)


Racing Kit

2-56

Exhaust Pipe Inner Protector Modification

Use 18325-MEL-013 inner protector for the racing kit exhaust system.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 the racing kit exhaust pipe and muffler as shown.

When using the ‘06 model seat rail, use exhaust pipe mounting rubber and col-lar included in the racing kit.When using the ‘04 – ‘05 seat rail, use standard mounting rubber.

Muffler comp.(racing kit)

Modified innerprotector

Muffler stay(racing kit)

Muffler band(racing kit)

Cut


2-57

Racing Kit

Drive Chain Guard Installation

Inside of the swingarm is filled with urethane foam. Do not weld the drivechain guard because of the urethane form is burned.

1. Remove the swingarm. Drill ø9.05 - 9.25 mm holes for the pop nut as shown.

ø9.05 - 9.25 mm

Applyadhesive

Pop nut, 6 mm(manufactured by POP RIVET FASTENER LTD.; SPH650R or equivalent)

Stake

Washers(racing kit)

Drive chain guard(racing kit)

Bolts(racing kit)

2. Apply adhesive to the drill holes and pop nut seat, and install the pop nutsinto the holes. Stake the pop nut using a commercially available tool.

3. After the adhesive hardened, install the washer and drive chain guard andtighten the bolt/washers securely.


Racing Kit

2-58

DrivenDrive

38T 39T 40T 41T 42T 43T

112L

15T 114L 114L 114L 114L 114L

116L 116L 116L 116L

114L 114L 114L 114L

16T 116L 116L 116L 116L 116L

118L

114L 114L 114L

17T 116L 116L 116L 116L 116L 116L

118L 118L

: Use 8 x 55 mm drive chain adjusting bolts

Optional Drive/Driven Sprocket

The optional drive sprockets are available.When using the optional drive/driven sprocket, replace the rear wheel with theoptional one.

Drive sprockets:15T (23801-NL6-700)16T (23802-NL6-700)17T (23803-NL6-700)

Driven sprockets:38T (41238-NL6-700)39T (41239-NL6-700)40T (41240-NL6-700)41T (41241-NL6-700)42T (41242-NL6-700)43T (41243-NL6-700)

Drive chain:RKGB525ROZ1-120J

When using the racing kit swingarm, select rear axle adjusting screws (50/35/20mm) according to the rear axle position.

DrivenDrive

38T 39T 40T 41T 42T 43T

114L 114L 114L 114L 114L

15T 116L 116L 116L 116L 116L 116L

118L 118L

114L 114L 114L 114L

16T 116L 116L 116L 116L 116L 116L

118L 118L 118L

114L 114L 114L

17T 116L 116L 116L 116L 116L 116L

118L 118L 118L 118L

: Use 8 x 55 mm drive chain adjusting bolts included in the racingkit

When using the 2006 racing kit swingarm:


2-59

Racing Kit

(1) FORK SPRING (2) SPRING COLLAR(3) SPRING SEAT STOPPER(4) SPRING COLLAR B

Remove the following:– Spring collar B– Spring seat stopper– Spring collar– Fork spring

The following optional fork springs are available.The setting has been changed from ‘04-’05 models.

(1) DAMPER ROD ADJUST CASE(2) LOCK NUT (3) FORK BOLT

(1) PRE-LOAD ADJUST PLATE B(2) STOPPER RING

(1) O-RING (2) FORK BOLT

Fork Spring Replacement

Make sure that the pre-load adjuster softest positionby turning the adjuster counterclockwise.Remove the stopper ring and pre-load adjust plateB.

Remove the O-ring from the damper rod adjustcase.Remove the fork bolt from the fork slider.

Push the fork slider slowly down, and gently seat thedust seal onto the axle holder.

Insert a 14 mm spanner between the spring collar Band spring seat stopper, and hold the damper rodadjust case, then loosen the lock nut.Remove the lock nut and fork bolt.

(1)(2)

(1)

(2)

(1)

(3)

(2)

Part number Spring rate Oil level

51401-NL9-901 8.8 N/mm (K=0.90) 83 mm

51401-MEL-R11 9.3 N/mm (K=0.95) 86 mm

51402-NL9-901 9.8 N/mm (K=1.00) 87 mm

51401-NL9-711 10.5 N/mm (K=1.05) 86 mm

51402-NL9-711 10.8 N/mm (K=1.10) 92 mm

Optional springs are identified by the spring rate let-ter on the spring end as shown.

(4)

SPRING RATE LETTER

(2)

(3)

(1)


2-60

Racing Kit

(1) TAPERED END(2) FORK SPRING

Install the fork spring into the fork slider with thetapered end facing up.

(1) DAMPER ROD HOLDER(2) SPRING COLLAR(3) SPRING SEAT STOPPER

Extend the fork damper fully and install the damperrod holder onto the damper rod adjust case.

TOOL:Damper rod holder 070MB-MEL0200 or

070MB-MELC200 orShowa special tool No.301

Install the spring collar and spring seat stopper.

(1) OIL LEVEL

Slowly down the slider, and gently seat the dust sealonto the axle holder and leave it for 5 minutes.

After the oil level stabilizes, measure the oil levelfrom top of the fork slider.Be sure the oil level is the same in the both forks.

(1)

(2)

(1)

(3)

(2)

(1)


2-61

Racing Kit

(1) SPRING COLLAR B(2) FORK BOLT(3) ALIGN

Install the spring collar B with its flange side facingdown.

Install the fork bolt to the damper rod adjust casewhile aligning the grooves of the adjust plate withthe damper rod adjust case.

(1) FORK BOLT (2) O-RINGS

(1) PRE-LOAD ADJUSTING PLATE

(1) HANDLE (2) DAMPER ROD HOLDER(3) SPANNER (4) SPRING COLLAR

Attach the handle to the damper rod holder, thenlower the spring collar while pulling up the damperrod holder.Attach the 14 mm spanner to the damper rod adjustcase as shown.

Apply fork fluid to new O-rings and install them tothe fork bolt.

Turn the pre-load adjust plate clockwise until it seatslightly.

(1)

(2)

(3)

(4)

(2)

(1)

(1)

(2)

(3)(1)


2-62

Racing Kit

(1) O-RING (2) FORK BOLT

Install the pre-load adjust plate B and stopper ring.

(1) LOCK NUT

Install the lock nut to the damper rod adjust case.Tighten the lock nut to the specified torque, whileholding the damper rod adjust case.


Remove the 14 mm spanner from the damper rodadjust case.

(1) PRE-LOAD ADJUST PLATE B(2) STOPPER RING

(1)(1)

(2)

(1)(2)

Install the fork bolt to the fork slider.Install new O-ring to the damper rod adjust case.


2-63

Racing Kit

(1) REBOUND ADJUSTER(2) COMPRESSION ADJUSTER

Rebound Damping AdjusterThe rebound damping adjuster clockwise until itstops (full hard position), then turn the adjustercounterclockwise.

Standard position: 2 turns out from full hard

Compression Damping AdjusterThe compression damping adjuster clockwise untilit stops (full hard position), then turn the adjustercounterclockwise.

Standard position: 2 turns out from full hard

(1) PRE-LOAD ADJUSTER

Front Suspension Setting

Front Suspension SettingPre-load AdjusterSpring pre-load can be adjusted by turning the pre-load adjuster.Turn the adjuster clockwise, the spring pre-loadincrease.Turn the adjuster counterclockwise, the spring pre-load decrease.

Standard position: 6 turns in from full soft

(1) SPRING(2) STANDARD LENGTH (L=318 mm)

Rear Cushion Spring

Three optional rear cushion springs are available.

The optional rear shock absorber springs are identi-fied by color.

Part number Spring rate Identificationcolor

52401-NL9-901 93.2 N/mm (K=9.5) Blue

52401-MEL-R11 98.1 N/mm (K=10.0) Red

52402-NL9-901 103.0 N/mm (K=10.5) White

52403-NL9-901 108.0 N/mm (K=11.0) Black

52404-NL9-901 113.0 N/mm (K=11.5) Green

52405-NL9-901 118.0 N/mm (K=12.0) Sliver

(1)

(1)

(2)

(1)

(2)


2-64

Racing Kit

(1) COMPRESSION DAMPING ADJUSTER (Lo)(2) COMPRESSION DAMPING ADJUSTER (Hi)

Hi-speed Compression Damping AdjusterThe hi-speed compression damping adjuster coun-terclockwise until it stops (full soft position), thenturn the adjuster clockwise.

Standard position: 1 ± 0.25 turns in from full soft

Low-speed Compression Damping AdjusterThe low-speed compression damping adjusterclockwise until it stops (full hard position), then turnthe adjuster counterclockwise.

Standard position: 9 clicks out from full hard

(1) REBOUND DAMPING ADJUSTER

Rebound Damping AdjusterThe rebound damping adjuster clockwise until itstops (full hard position), then turn the adjustercounterclockwise.

Standard position: 9 clicks out from full hard

Suspension LinkageWhen using the racing kit suspension linkage, spe-cific curve is changed as shown below.

(1) PRE-LOAD ADJUSTING KNOB

Rear Suspension Setting

Pre-load AdjusterSpring pre-load can be adjusted by turning the pre-load adjuster knob on the seat rail.Turn the adjuster clockwise, the spring pre-loadincrease.Turn the adjuster counterclockwise, the spring pre-load decrease.

Standard position: 16 clicks in from full soft

When installing the racing kit rear shock absorber,route the pre-load adjuster hose properly referringto the illustration above.

(1)

(1)

(2)

(1)

Stroke

Ratio

‘04-’05 MEL STD

‘06 MEL STD

P2

P4


2-65

Racing Kit

Optional Front Wheel

Refer to following chart for combination of the optional front wheel, fork and brake disc.

• When using the NL6 or NL9 wheel with the standard fork, replace the brake disc with Brembo.• The caliper collar is used when you use the standard brake caliper with the Brembo disc.• Since the NL9 brake disc is thicker than the MEL standard disc, use NL9 discs at the circuit from which higher brake performance is needed.

Fork STD STD STD STD Showa SP Showa SP

Brake disc STD STD Brembo Brembo Brembo Brembo(ø310) (ø320)

Wheel STD STD NL6 NL9 NL6 NL9

Axle kit NL9 NL9 NL9 NL9 NL9 NL9

No. Part Number Item Q’ty

Wheel side collar1 44311-NL6-000 Collar, front wheel side 2 O2 44311-NL9-710 Collar, front wheel side 2 O3 44311-NL9-810 Collar, front wheel side 2 O4 44311-NL9-720 Collar, front wheel side 2 O5 44311-NL9-910 Collar, front wheel side 2 O O

Disc plate6 45250-NL5-800 Disc comp., front 320 2 O O7 45250-NL9-910 Disc comp., front 320 x T6 2 O O8 45250-NL9-720 Disc comp., front 320 x T6 2 O O

945120-NL3-901 Disc comp., R. front 1

O45220-NL3-901 Disc comp., L. front 1

1045120-MEL-R11 Disc comp., R. front 1

O45220-MEL-R11 Disc comp., L. front 1

1145120-NL9-801 Disc comp., R. front 1

O45220-NL9-801 Disc comp., L. front 1

1245120-MEL-R31 Disc comp., R. front 1

O45220-MEL-R31 Disc comp., L. front 1

1345120-NL9-C30 Disc comp., R. front 1

O45220-NL9-C30 Disc comp., L. front 1

14 45250-NL9-C40 Disc assy., front 305 x T6 2 ODisc spacer

15 45130-NL9-000 Spacer, front wheel disc 1.5 2 O O16 45132-NL9-720 Spacer, front wheel disc 2.3 2 O O

Caliper collar17 51497-NL9-720 Spacer, front fork 4 O O18 90131-NL9-720 Bolt, flange 10 x 65 4 O O


2-66

Racing Kit

137.6

153

1082.3

2.3100

153

137.6

Front Axle Assembly (View from front)

Fork: MEL forkWheel: NL9, NL6 or MEL WheelAxle: NL9 kit

CBR1000RR Kit (NL9) Wheel

VTR1000SP-1/2 Kit (NL6) Wheel

Wheel parts for MEL Fork(1) Front wheel side collar

NL9 wheel: 44311-NL9-810NL6 wheel: 44311-NL9-720

(2) Disc plateNL9 wheel: 45250-NL5-800

45250-NL9-910NL6 wheel: 44250-NL9-720

(3) Disc spacer 45132-NL9-720

Axle parts for MEL Fork(1) Front wheel axle 44301-NL9-720(2) Front axle nut 44303-NL9-720(3) Front axle guide 44304-NL9-720(4) Front axle guide washer 44306-NL9-720(5) Nut, M30 x 1.0 90305-NL6-720(6) Front axle washer 90535-NL6-720(7) Fork R. side shim, 0.2 90525-NL9-720(8) Fork R. side shim, 0.3 90526-NL9-720

• When using the NL6 or NL9 wheel with standardfork, use Brembo caliper.

• When installing the Brembo caliper, install thefork spacer (51497-NL9-720) onto the calipermount, and use tightening bolt 10 x 65 mm bolt(90131-NL9-720).

• When using the Brembo ø320 brake disc with 16.5inch wheel, brake caliper removal is needed forthe front wheel removal.

(1) (4) (3) (2) (5)

(7)(6)

(1)

(3)

(2)


2-67

Racing Kit

136

158

1081.5

1.5

158

100

136

Axle parts for Showa Special Fork(1) Front wheel axle 44301-NL6-000(2) Front axle nut 44303-NL9-000(3) Front axle guide A 44304-NL9-000(4) Front axle guide B 44305-NL9-000(5) Nut, M28 x 1.0 90305-NL6-000(6) Washer, 45 x 22 x 3 90503-NL6-000(7) Fork side shim, 0.2 90525-NL9-000(8) Fork side shim, 0.3 90526-NL9-000

Wheel parts for Showa Special Fork(1) Front wheel side collar

NL9 wheel: 44311-NL9-710NL6 wheel: 44311-NL6-000

(2) Disc plateNL9 wheel: 45250-NL5-900

45250-NL9-910NL6 wheel: 44250-NL9-720

(3) Disc spacer 45132-NL9-000

Front Axle Assembly (View from front)

Fork: Showa Special ForkWheel: NL9 or NL6 WheelAxle: NL9 kit

CBR1000RR Kit (NL9) Wheel

VTR1000SP-1/2 Kit (NL6) Wheel

(1)(4) (3) (2) (5)

(7) (8)(6)

(1)

(3)

(2)


2-68

Racing Kit

(1) RETAINER WRENCH B(2) RETAINER WRENCH BODY

NL6 Wheel:Unstake the bearing retainer.Remove the bearing retainer using a special tool.

Tools:Retainer wrench B 07710–0010200Retainer wrench body 07710–0010401

(1) BOLTS(2) BRAKE DISC

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 inthe hub.

Remove the discard the bearings if the races do notturn smoothly, quietly, or if they fit loosely in thehub.

Replace the bearings in pairs.

(1) (2)(1) (2)

(1) RIGHT SIDE COLLAR(2) LEFT SIDE COLLAR

Disassembly/Wheel Bearing Replacement

A contaminated brake disc or pad reduces stop-ping power, and can cause a serious injury ordeath.

Discard contaminated pads and clean a contami-nated disc with a high quality brake degreasingagent.

Remove the right and left side collars using twoscrew drivers as shown.

(1) (2)


2-69

Racing Kit

(1) DRIVER(2) ATTACHMENT/PILOT

Remove the right side bearing using the specialtools.

Tools:Driver 07749–0010000Attachment, 42 x 47 mm 07746–0010300Pilot, 25 mm 07746–0040600

Never install old bearings; once the bearing havebeen removed, they must be replaced with newones.Replace the wheel bearings in pairs.


Press the right wheel bearing and distance collarusing a special tools and a hydraulic press until theleft wheel bearing is removed.

Press the right wheel bearing more than necessary,or the right bearing fall into the wheel hub.


(1)

(2)

(1)

(2)

(1) LOCK NUT WRENCH

NL9 Wheel:Unstake the bearing retainer.Remove the bearing retainer using a special tool.

Tool:Lock nut wrench, 5.5 x 32/37 07716–0020203

(1)


2-70

Racing Kit


Assembly

Apply oil to the bearing outer surface.Drive the new left wheel bearing into the hub until itseat using a special tools and a hydraulic press.


Press the bearing with 3 tons pressure.Hydraulic press pressure:

29.4 kN (3,000 kgf)Gauge reading pressure:

29.4 ÷ (press piston area) kN/mm2

(1)

(2)


Install the distance collar, then drive the right sidebearing into the hub using the same tools.


(1) RETAINER WRENCH B(2) RETAINER WRENCH BODY

(1) (2)

NL6 Wheel:Apply molybdenum disulfide grease to the newbearing retainer threads and install it into the hub.Tighten the bearing retainer using the special tools.

Tools:Retainer wrench B 07710–0010200Retainer wrench body 07710–0010401


(1)

(2)


2-71

Racing Kit

(2)

(1)

(1) RETAINER WRENCH

NL9 Wheel:Apply molybdenum disulfide grease to the newbearing retainer threads and install it into the hub.Tighten the bearing retainer using the special tools.

Tool:Lock nut wrench, 5.5 x 32/37 07716–0020203


(1) BEARING RETAINER(2) PUNCH

Secure the bearing retainer with a punch.

(1) BRAKE DISC(2) BOLTS

Install the brake discs and tighten the bolts to thespecified torque.


Install the wheel side collars.

(1) RIGHT SIDE COLLAR(2) LEFT SIDE COLLAR

(1)

(2) (1)

(1) (2)


2-72

Racing Kit

(1) AXLE (2) AXLE NUT (3) AXLE GUIDE(4) AXLE GUIDE WASHER (5) SIDE NUT(6) AXLE WASHER (7) SHIM (S)

Standard Fork:If the wheel, fork leg, and/or distance collar has beenreplaced, adjust the axle distance as follow:1. Apply molybdenum disulfide grease to the axle

nut and axle side nut threads. Install the front axlenut into the left fork axle from the inside, installand tighten the axle side nut to the specifiedtorque.


2. Install the front axle guide into the right fork axle.3. Temporarily install the front wheel between the

fork legs and then install the front axle and axlewasher but do not tighten.

4. With the front brake applied, pump the fork upand down several times to parallel the fork.

5. Measure the clearance between the right wheelside collar and axle guide A.

6. Adjust the clearance by inserting shim(s) betweenthe right fork axle holder and axle guide.

7. Tighten the axle holder bolts to the specifiedtorque.


(1) AXLE (2) AXLE NUT (3) AXLE GUIDE A(4) AXLE GUIDE B (5) SIDE NUT(6) AXLE WASHER (7) SHIM (S)

Showa Special Fork:If the wheel, fork leg, and/or distance collar has beenreplaced, adjust the axle distance as follow:1. Apply molybdenum disulfide grease to the axle

nut and axle side nut threads. Install the front axlenut into the left fork axle from the inside, installand tighten the axle side nut to the specifiedtorque.


2. Install the front axle guide A and B into the rightfork axle.

3. Temporarily install the front wheel between thefork legs and then install the front axle and axlewasher but do not tighten.

4. With the front brake applied, pump the fork upand down several times to parallel the fork.

5. Measure the clearance between the right wheelside collar and axle guide A.

6. Adjust the clearance by inserting shim(s) betweenthe right fork axle holder and axle guide A.

7. Tighten the axle holder bolts to the specifiedtorque.


(1) (4) (3) (2) (5)

(7)(6)

(1)(4) (3) (2) (5)

(7) (8)(6)


2-73

Racing Kit

(1) NUTS(2) DRIVEN SPROCKET

(1) RIGHT SIDE COLLAR(2) BOLTS (3) BRAKE DISC

(2)(1)(2)(1)

Optional Rear Wheel

The optional rear wheel (for NL6) is used with thedrive chain adjuster set, brake caliper and caliperbracket included in the racing kit.

Disassembly

If you will replace the driven sprocket, loosen thedriven sprocket nuts.

Remove the bolts and brake disc.

(1) DRIVEN FLANGE

Remove the final driven flange assembly from theleft wheel hub.

Remove the damper rubbers.

(1)

(1)

(1) DAMPER RUBBERS


2-74

Racing Kit

(1) BEARING RETAINER(2) RETAINER TOOL

Wheel Bearing Replacement

Remove the wheel bearing retainer using the specialtool.Wheel bearing retainer has left hand threads.

Tool:Retainer tool 87000-NL6-000

(2)

(1)


Remove the right side bearing using the specialtools.

Tools:Driver 07749–3710001Attachment, 52 mm 07946–3710200Pilot, 25 mm 07746–0040600

Never install old bearings; once the bearing havebeen removed, they must be replaced with newones.Replace the wheel bearings in pairs.


Press the right wheel bearing and distance collarusing a special tools and a hydraulic press until theleft wheel bearing is removed.

Press the right wheel bearing more than necessary,or the right bearing fall into the wheel hub.


(1)

(2)

(1)

(2)(2)


2-75

Racing Kit


Assembly

NOTE:When using the brake disc off-set type wheel, notethat the left and right bearing size (page 2-80).

Apply oil to the bearing outer surface.Drive the new left wheel bearing into the hub until itseat.


Press the bearing with 3 tons pressure.Hydraulic press pressure:

29.4 kN (3,000 kgf)Gauge reading pressure:

29.4 ÷ (press piston area) kN/mm2

(1)


Install the distance collar, then drive the right sidebearing into the hub using the same tools.


(2)

(1)

(2)

(1) BEARING RETAINER(2) RETAINER TOOL

Apply a locking agent to the bearing retainer threadsand install it into the hub.The bearing retainer has left hand threads.

Tighten the bearing retainer to the specified torque.

Tool:Retainer tool 87000–NL6–000


(2)

(1)(2)


2-76

Racing Kit

(1) LEFT SIDE COLLAR

Driven flange bearing replacement

Remove the driven flange left side collar using twoscrewdrivers as shown.

Remove the circlip from the drive flange.

Drive out the driven flange bearing and right sidecollar as an assembly from the driven flange.

(1)

(1)

(1) CIRCLIP

(1) RIGHT SIDE COLLAR

Install the driven flange right side collar.

Install the circlip into the groove securely.


Drive the new driven flange bearing into the drivenflange until it seat using the special tools.Never install old bearings; once the bearing havebeen removed, they must be replaced with newones.


(1)

(1)

(2)

(1)

(1) CIRCLIP


2-77

Racing Kit

(1) LEFT SIDE COLLAR

Install the driven flange left side collar.

(1) (1)

(1) DAMPER RUBBERS

(1) DRIVEN SPROCKET(2) NUTS

Install the damper rubbers into the left wheel hub.Install the final driven flange assembly onto the leftwheel hub.If the driven sprocket is removed, apply oil (ElfXT3818) to the driven flange nut threads and seatingsurfaces.Tighten the driven sprocket nuts to the specifiedtorque.


(1) BRAKE DISC (2) BOLTS

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 thespecified torque.


Install the right side collar.

(1)(2)

(1)(2)


2-78

Racing Kit

Installation

Install the rear wheel as follows:1. Install the rear wheel into the swingarm and tem-

porarily install the each parts.2. Adjust the drive chain free play by turning the

drive chain adjusting bolts (1).Make sure the axle is installed smoothly.

3. Temporarily tighten the rear axle.4. Secure the drive chain adjusting bolts by tighten-

ing the lock nuts (2).5. Hand tighten the stopper screws (12) until the

screw just touch the left rear axle side collar (10)and right rear axle side collar (6).

Note that the axle side collars are tilt when tighten-ing the the stopper screws.

6. Secure the stopper screws by tightening the locknuts (11).

7. Loosen the rear axle and check that there are nofree play on adjusting plate (8, 16).

8. Make sure the axle is installed smoothly withoutstress.

9. Tighten the rear axle to the specified torque.

• Do not pull the rear wheel applying the externalforce by installing the T wrench between the drivechain and driven sprocket while tightening therear axle.The alignment of a rear wheel may not comingout and the axle’s actual torque is lowered by thefriction of the axle.

• Make sure the rear axle threads are seated to theaxle nut threads before tightening the axle usingthe impact wrench.

Rear Axle Illustration (view from rearward)

(1) DRIVE CHAIN ADJUSTING BOLT(2) DRIVE CHAIN ADJUSTING BOLT LOCK NUT(3) DRIVEN FLANGE LEFT SIDE COLLAR(4) DRIVEN FLANGE(5) DRIVEN FLANGE RIGHT SIDE COLLAR(6) REAR AXLE RIGHT SIDE COLLAR(7) REAR AXLE(8) LEFT DRIVE CHAIN ADJUSTING PLATE(9) REAR AXLE NUT

(10) REAR AXLE LEFT SIDE COLLAR(11) STOPPER SCREW LOCK NUT(12) STOPPER SCREW(13) REAR WHEEL(14) REAR BRAKE CALIPER BRACKET(15) BRAKE DISC(16) RIGHT DRIVE CHAIN ADJUSTING PLATE(17) WASHER

(1)

(2)

(8)(9)

(10)

(11)

(12)(13)

(14) (15)

(12)

(11)

(16)

(17)

(7)

(1)

(2)(6)

(3) (4)

(5)


2-79

Racing Kit

Brake Disc Off-set Type Rear Wheel

When using the brake disc off-set type rear wheel, the grind-off the brake caliper bracket guide bosses from the racing kit swingarm (55100-MEL-R30).

Caliper bracketguide bosses(Grind off)


2-80

Racing Kit

(1) DRIVE CHAIN ADJUSTING BOLT(2) DRIVE CHAIN ADJUSTING BOLT LOCK NUT(3) DRIVEN FLANGE LEFT SIDE COLLAR(4) DRIVEN FLANGE(5) DRIVEN FLANGE RIGHT SIDE COLLAR(6) BRAKE DISC SPACER(7) BRAKE DISC(8) REAR AXLE RIGHT SIDE COLLAR(9) REAR AXLE

(10) LEFT DRIVE CHAIN ADJUSTING PLATE(11) REAR AXLE NUT(12) REAR AXLE LEFT SIDE COLLAR(13) STOPPER SCREW LOCK NUT(14) STOPPER SCREW(15) REAR WHEEL(16) REAR BRAKE CALIPER BRACKET(17) RIGHT DRIVE CHAIN ADJUSTING PLATE(18) WASHER

(1)

(2)

(10)(11)

(12)

(13)

(14)(15)

(16)

(14)

(13)

(17)

(18)

(9)

(1)

(2)(6)

(3) (4)

(5)

(7)

(8)

Brake Disc Off-set Type Rear Axle Illustration (view from rearward)

(1) (2)

(1) ROUND EDGE COLLAR(2) FLAT EDGE COLLAR

Left Driven flange side collar selection

Two types of the left driven flange side collars areavailable.Use the color appropriately according to the usagecondition.


2-81

Racing Kit

(1) “SEL” BUTTON(2) “RESET” BUTTON

3. Press “RESET” button and select a illuminatingor flashing pattern.

• Illuminating pattern and brightness (3 pat-terns)

• Flashing pattern and brightness (6 pattern)

4. After the shift-up indicator setting is finished,press “SEL” button. The combination meter isreturned to normal indication mode (thetachometer needle returns to 0).

When the tachometer or speedometer input signalis detected, or not access for more than 30 secondsduring setting, the setting value is cancelled andreturn to normal indication mode.

How to set the shift-up indicator1. Turn the engine stop switch to RUN while press-

ing the “SEL” button until the combination meterinitial action have finished. The needle indicatesthe current setting revolution.

2. Align the needle with required revolution bypressing the “RESET” button. Whenever the but-ton is pressed 1 time, the needle increases by thescale of 250 min-1 (rpm), and when the button ispressed for more than one second, the needleincreases by the scale of 1,000 min-1 (rpm).When the maximum setting value (15,500 min-1

(rpm)) is exceeded, the needle returns to 4,000min-1 (rpm).After determine the illuminating rev., press the“SEL” button.


Combination Meter Function

The racing kit combination meter has followingfunctions:• Shift-up indication• Lap time indication• Coolant temperature indication

Shift-up IndicatorWhen the engine rev. exceeds the setting value, theshift-up indicator illuminates or flashes.The shift-up indicator can be set in range between4,000 – 15,500 min-1 (rpm).

(1) (2)(1) (2)


(1) SESSION NUMBER (2) 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 combi-nation 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 1to latest lap by pushing the ‘RESET” button.

When the “RESET” button is pressed, the nextstored data is displayed.When the “SEL” button is pressed, the previousstored data is displayed.

The maximum coolant temperature during each lapis displayed on upward of the section/lap number.


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 morethan 2 seconds.

(1) SESSION NUMBER (2) LAP NUMBER(3) COOLANT TEMPERATURE(4) LAP TIME (MIN.) (5) LAP TIME (SEC.)

Lap Time IndicatorGO mode:When the engine stop switch to RUN, the combina-tion meter is in “STOP” mode.The combination meter is received the LAP markersignal (passing switch is pressed) or engine rev. isover 5,000 min-1 (rpm), the lap time indicator systementers the “GO” mode.Under the “GO” mode, the combination meterrecords the session number, lap number, each laptime and maximum coolant temperature in each lap.

During vehicle running, the combination meter dis-plays the current session number, lap number, laptime 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 old-est data is overwrite to current lap data.If you wish to read out each lap data, make sure thecombination meter is in “STOP” mode.

2-82

Racing Kit

(1) (2)(3)(1) (2)

(5) (3)(1) (2)

(4)

(4)

(5)


2-83

Racing Kit

(1) PASSING SWITCH (STOP WATCH SWITCH)(2) HORN SWITCH (QUICK SHIFTER SWITCH)

Left Handlebar Switch Function

On this machine, the each switch of the left handle-bar switch is function as follows:

Passing switch: Stop watch function (lap time)Horn switch: Quick sifter functionTurn signal switch: Pit lane speed limit function

Stop Watch:When the switch is pushed, the stop watch is start-ed.See page 2-80 for lap time indicator function.

Quick Sifter:While pushing the switch, both the ignition and fuelinjection cut-off system is activated.

Pit Lane Speed Limit:While pushing the turn signal switch to the right orleft, the engine speed limiter is activated.The engine speed limiter is deactivated, when youturn the turn signal switch off.See Setting Manual in the CD-ROM for pit lanespeed limit function.

(1)

(2)


Memo


3-1

2006-CBR1000RR PARTS LIST

E- 1

E- 1-1

E- 1-2

E- 2

E- 3

E- 3-1

E- 4

E- 5

E- 6

E- 7

E- 8

E- 8-1

E- 9

E-10

E-11

CYLINDER HEAD GASKET /

ENGINE POWER UP KIT V (For SBK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 3

ENGINE POWER UP KIT IV (For SBK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 4

CYLINDER HEAD GASKET /

ENGINE POWER UP KIT V (For JSB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 5

OIL PUMP SET / OIL PAN SET (For SBK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 7

BTL CLUTCH SET (For SBK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 8

CRANKCASE SET /

CRANK SHAFT WASHER SET (For SBK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

A.C. GENERATOR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

R. CRANKCASE SET SET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

BEARING SET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

TRANSMISSION SET (R/B). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

TRANSMISSION (OPTIONAL PARTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

AIR FUNNEL SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

AIR INJECTION PLUG SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

WATER HOSE PLUG SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

THROTTLE / CLATCH HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

FRONT FORK / STEERING DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

FRONT WHEEL / AXLE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

REAR WHEEL (REAR BRAKE DISK OFF-SET MODEL) . . . . . . . . . . 3-32

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

QUICK FILLER SET (ENDURANCE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

AIR BOX DUCT SET / AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

BREATHER CASE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

EXHAUST SET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

SWINGARM / DRAIVE CHAIN ADJUST SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

REAR CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

BATTERY / CABLE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

WIRE HARNESS SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

LIGHT SET (ENDURANCE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

QUICK SHIFTER SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

SEAT RAIL SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

F- 1

F- 2

F- 3

F- 4

F- 5

F- 6

F- 6-1

F- 7

F- 8

F- 9

F-10

F-11

F-12

F-13

F-14

F-15

F-16

F-17

F-18

F-19

INSTRUCTIONS FOR USE OF PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 2

ENGINE GROUP FRAME GROUP

INDEX ............................................................................................................................................. 3-52

CONTENTS

2006CBR1000KIT（E_list) 06.2.20 6:58 PM ページ1

3-2

This parts list is to be used when ordering replacement parts; it containsall parts for model 2006-CBR1000RR.

. How to order parts

●Information required

Replacement parts orders must contain both the part number and thestamped number(s) as described belew. This is because any changes andmodifications of parts are registered at Honda with the pertinent parts andstamped numbers.• If quantities are shown in ( ), the parts are optional.• If“N”is indicated in the quantity column, the parts quantity is to bedetermined as required.

. How to read this parts list

●Make-up of the part number

(Example) General parts

○○○○○―○○○―○○○○○

(Example) Bolts, nuts and other standard parts

○○○○○―○○○○○―○○

●AbbreviationsThe following abbreviations are used in this parts list.A.C.…………… Alternating currentASSY.………… AssemblyC.……………… CenterCOMP. ……… CompleteG……………… GramL.……………… LeftL(100L) ……… Link (100Links)M. ……………Middlemm……………Millimeter

R.……………… RightSTD. ………… StandardT(22T)………… Tooth（22 Teeth）T.W. ………… Thermo WaterR/B …………… Racer base vehicle

(for Japan only)JSB…………… Japan superbikeSBK…………… FIM SuperbikeOP …………… Optional parts

INSTRUCTIONS FOR USE OF PARTS LIST

Function and component No.

Modelcode No.

Modification designationSubcontractor designation

Color code

Function and component No.

DimensionISO

Chemical surface treatment

• The parts which have a dot “•”on the left side of the “Ref. No.”areexclusive for HRC products. To purchase these parts, consult yourHonda dealer.

• The parts which have no dot are Honda products and can be purchasedfrom your nearest Honda motorcycle dealer, or from HRC-JAPAN/EUROPE if you can’t obtain the parts locally.

• The parts which doesn’t have“Ref. No.”in the illustration are Hondaproducts.

MEMO

IMPORTANT INFORMATION


3-3

1

2

3

4

5

6

7

8

9

10

11

12

13

14

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

00X32-NL9-C00

06110-NL9-C00

12251-NL9-000

12252-NL9-000

12253-NL9-000

12256-NL9-710

14110-NL9-C00

14210-NL9-C00

14312-NL9-C00

14321-NL9-C00

14401-NL9-C01

14520-NL9-C00

14751-NL9-C00

14761-NL9-C00

31910-NL3-620

90082-NL9-710

90488-425-000

SET UP MANUAL PARTS LIST .....................................................................................

ENGINE POWER UP KIT V, SBK ...................................................................................

GASKET, CYLINDER HEAD 0.60 ...................................................................................




CAMSHAFT COMP, IN...................................................................................................

CAMSHAFT COMP, EX..................................................................................................

SPROCKET, TIMING ......................................................................................................

SPROCKET, CAM ...........................................................................................................

CHAIN CAM....................................................................................................................

LIFTER ASSY, TENSIONER ...........................................................................................

SPG, IN VALVE...............................................................................................................

SPG, EX VALVE..............................................................................................................

PLUG, SPARK, R0045Q-10 ............................................................................................

BOLT, FLANGE KNOCK, 7X10.5 ...................................................................................

WASHER .........................................................................................................................

No paint

Orange paint

Yellow paint

Purple paint

IN 9C0

EX 9C0

9C0

9C0

Orange paint

Yellow paint

E-1

Ref.No.

Part No. Description Remarks

CYLINDER HEAD GASKET / ENGINE POWER UP KIT V

(For SBK)

2006 CBR1000RR

Block No.

Reqd.No.

1

-

1

1

1

1

-

-

-

-

-

-

-

-

4

4

2

1

1

1

1

1

1

1

1

1

2

1

1

8

8

4

4

2

SBKJSB


3-4

1

2

3

4

5

6

7

8

•

•

•

•

•

•

•

•

06120-NL9-C00

13101-NL9-C00

13112-NL9-000

13121-NL9-003

13131-NL9-003

13141-NL9-003

14711-NL9-C00

14721-NL9-000

ENGINE POWER UP KIT IV, SBK .................................................................................

PISTON ..........................................................................................................................

CLIP, PISTON PIN 17MM..............................................................................................

RING, PISTON TOP 75X0.8X2.3...................................................................................

RING, PISTON 2ND 75X0.8X2.4 ..................................................................................

RING, PISTON OIL 75X1.5X1.95 ..................................................................................

VALVE, INLET(29) .........................................................................................................

VALVE, EXHAUST(24) ..................................................................................................

9C0

E-1-1

Ref.No.


ENGINE POWER UP KIT IV(For SBK)

2006 CBR1000RR

Block No.

Reqd.No.

-

-

-

-

-

-

-

-

1

4

8

4

4

4

8

8

SBKJSB


3-5

1

2

3

4

5

6

7

8

9

10

11

12

•

•

•

•

•

•

•

•

•

•

•

•

•

•

06110-NL9-C30

06180-NL9-710

12251-NL9-000

12252-NL9-000

12253-NL9-000

12256-NL9-710

14110-MEL-R10

14110-NL9-C30

14210-MEL-R10

14210-NL9-C30

14321-NL9-C30

14321-NL9-710

14405-MEE-000

31910-NL3-620

90082-NL9-710

90488-425-000

ENGINE POWER UP KIT V, JSB....................................................................................

CAM SPROCKET SET, JSB ...........................................................................................





CAMSHAFT COMP, IN...................................................................................................

CAMSHAFT COMP, IN...................................................................................................

CAMSHAFT COMP, EX..................................................................................................

CAMSHAFT COMP, EX..................................................................................................

SPROCKET, CAM ...........................................................................................................

SPROCKET, CAM ...........................................................................................................

ROTOR, CAM PULSE......................................................................................................

PLUG, SPARK, R0045Q-10 ............................................................................................

BOLT, FLANGE KNOCK, 7X10.5 ...................................................................................

WASHER .........................................................................................................................

R/B

No paint

Orange paint

Yellow paint

Purple paint

R/B

IN 9C3

R/B

EX 9C3

9C3

R/B

R/B

E-1-2

Ref.No.


CYLINDER HEAD GASKET / ENGINE POWER UP KIT V

(For JSB)

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

(1)

1

(1)

1

2

2

(1)

4

4

2

-

-

1

1

1

1

-

-

-

-

-

-

-

4

4

2

SBKJSB


3-6

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

•

•

•

•

•

•

•

•

•

•

•

•

06190-NL9-C00

06260-NL9-C00

11211-NL9-C00

15134-NL9-710

15150-NL9-C00

15220-NL9-710

15661-MAS-003

15662-NL9-C00

19225-MCS-003

23219-NL9-C00

90006-GHB-680

90012-MEL-R10

90052-NL9-710

90081-NX4-000

94109-12000

96001-06012-00

OIL PUMP SET, SBK .....................................................................................................

OIL PAN SET, SBK ........................................................................................................

OIL PAN .........................................................................................................................

SPROCKET, OIL PUMP DRIVEN...................................................................................

STRAINER COMP., OIL.................................................................................................

VALVE ASSY, RELIEF ...................................................................................................

FINDER, OIL LEVEL .......................................................................................................

STOPPER, LEVEL FINDER ............................................................................................

CHAIN, PUMP ................................................................................................................

PLATE, BRG SET...........................................................................................................

BOLT, FLANGE, NSHF, 6X28.........................................................................................

BOLT, DRAIN 12MM.....................................................................................................

BOLT, FLANGE, SPL, 8X30 ..........................................................................................

BOLT, DRAIN 12MM.....................................................................................................

WASHER, PLUG, DRAIN 12MM...................................................................................

BOLT, FLANGE, SH, 6X12 .............................................................................................

R/B, For STD OIL PAN

E-2

Ref.No.


OIL PUMP SET / OIL PAN SET(For SBK)

2006 CBR1000RR

Block No.

Reqd.No.

-

-

-

-

-

-

-

-

-

-

-

1

-

-

-

-

1

1

1

1

1

1

1

1

1

1

12

(1)

1

1

1

1

SBKJSB


3-7

1

2

•

•

22201-NL9-C30

22401-MEL-R30

DISK, CLUTCH FRICTION .............................................................................................

SPRING, CLUTCH .........................................................................................................

Thickness : t3.8

R/B, Green paint

E-3

Ref.No.


CLUTCH

2005 CBR1000RR

Block No.

Reqd.No.

2

5

2

5

SBKJSB


3-8

1

2

3

4

5

6

7

8

9

10

11

12

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

06230-NL9-C00

22121-NL9-C00

22122-NL9-710

22123-NL9-710

22124-NL9-710

22131-NL9-710

22132-NL9-710

22134-NL6-000

22135-NL6-000

22136-NL6-000

22137-NL6-000

22138-NL6-000

22139-NL6-000

22172-NL9-710

22173-NL9-710

22201-MEN-670

22201-NL9-C00

22201-NL9-C30

22321-MT3-000

22321-NL9-710

22322-NL9-710

BTL CLUTCH SET, SBK ................................................................................................

CENTER, CLUTCH.........................................................................................................

PLATE 50, CLUTCH LIFTER CAM VC...........................................................................



CENTER B, CLUTCH .....................................................................................................

GUIDE, CLUTCH CENTER VC.......................................................................................

SHIM, STROKE 1.8........................................................................................................

SHIM, STROKE 1.9........................................................................................................

SHIM, STROKE 2.0........................................................................................................

SHIM, STROKE 2.1........................................................................................................

SHIM, STROKE 2.2........................................................................................................

SHIM, STROKE 2.3........................................................................................................

SPRING, CLUTCH VC 7K ..............................................................................................

SPRING, CLUTCH VC 4K ..............................................................................................

DISK, CLUTCH FRICTION ..............................................................................................



PLATE, CLUTCH.............................................................................................................

PLATE, CLUTCH 1.9......................................................................................................

PLATE, CLUTCH 2.1......................................................................................................

45, OP

40, OP

Orange paint

Green paint, OP

Thickness : t3.0

Thickness : t3.8

Groove : 1

Groove : 2

E-3-1

Ref.No.


BLT CLUTCH SET(For SBK)

2006 CBR1000RR

Block No.

Reqd.No.

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

1

1

1

(1)

(1)

1

1

1

1

1

1

1

1

1

(1)

7

1

1

7

2

4

SBKJSB


3-9

13

14

15

16

17

18

19

20

•

•

•

•

•

•

•

•

•

•

22325-MEL-000

22326-MEL-000

22351-NL9-710

22353-NL9-710

22441-NL9-710

22850-MBB-D40

90567-NL6-000

90568-NL6-000

90569-NL6-000

90570-NL6-000

90571-NL6-000

90572-NL6-000

90573-NL6-000

95701-06016-00

SPRING, CLUTCH PLATE...............................................................................................

SPRING SEAT, JUDDER ................................................................................................

PLATE, CLUTCH PRESSURE........................................................................................

PLATE, CLUTCH LIFTER ...............................................................................................

SPRING, CLUTCH .........................................................................................................

ROD COMP, CLUTCH LIFTER .......................................................................................

SHIM, CLCH 0.9.............................................................................................................

SHIM, CLCH 1.0.............................................................................................................

SHIM, CLCH 1.1.............................................................................................................

SHIM, CLCH 1.2.............................................................................................................

SHIM, CLCH 1.3.............................................................................................................

SHIM, CLCH 1.4.............................................................................................................

SHIM, CLCH 1.5.............................................................................................................

BOLT FLANGE, 6X16 .....................................................................................................

E-3-1

Ref.No.


BLT CLUTCH SET(For SBK)

2006 CBR1000RR

Block No.

Reqd.No.

-

-

-

-

-

-

-

-

-

-

-

-

-

-

1

1

1

1

1

1

2

2

2

2

2

2

2

6

SBKJSB


3-10

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

•

•

•

•

•

•

•

06240-NL9-C00

06250-NL9-C00

11000-NL9-C00

12208-PR3-000

13331-NL9-C00

13332-NL9-C00

13333-NL9-C00

90001-MFA-D00

90003-NL5-000

90004-MFA-D00

90005-MZA-000

90010-MEL-000

90015-MEL-003

90016-MEL-003

90017-MFA-D00

90018-MFA-D00

90019-MB0-000

90019-MFA-D00

90048-MEL-D00

90133-MEL-000

CRANKCASE SBK SET ..................................................................................................

WASHER, CRANK SHAFT SET, SBK ............................................................................

CRANKCASE SET ..........................................................................................................

BOLT, SEALING, 20MM .................................................................................................

WASHER A, CRANK SHFAT..........................................................................................

WASHER B, CRANK SHFAT..........................................................................................

WASHER C, CRANK SHFAT..........................................................................................

BOLT, FLANGE, 8X55 .....................................................................................................

PLUG, TAPER .................................................................................................................

BOLT, SPECIAL, 7X42.5..................................................................................................

BOLT, SOCKET, 10MM...................................................................................................

BOLT, SOCKET, 8X12 .....................................................................................................

BOLT, FLANGE, 9X105 ...................................................................................................

BOLT, FLANGE, 9X125 ...................................................................................................

BOLT, FLANGE, 7X60 .....................................................................................................

BOLT, FLANGE, 7X80 .....................................................................................................

BOSS, OIL FILTER ..........................................................................................................

BOLT, FLANGE, 7X40 .....................................................................................................

BOLT, SEALING, 22MM .................................................................................................

BOLT, FLANGE, 8X30 .....................................................................................................

E-4

Ref.No.


CRANKCASE SET /CRANK SHAFT WASHER SET

(For SBK)

2006 CBR1000RR

Block No.

Reqd.No.

-

-

-

-

-

-

-

-

1

-

-

-

-

-

-

-

-

-

-

-

1

1

1

1

2

2

2

5

1

1

1

1

6

4

1

1

1

9

1

6

SBKJSB


3-11

21

22

23

24

25

26

27

28

29

90447-KE1-000

90701-MV9-670

91001-MEL-003

91002-MEL-003

91003-MEL-003

91004-MEL-003

91201-MEL-013

91202-MEL-003

95701-08040-00

WASHER, SEALING, 7MM .............................................................................................

DOWEL PIN, 10X16 ........................................................................................................

BRG, BALL RADIAL, 28X62X16 ......................................................................................

BRG, BALL SPECIAL, 20X47X15.5 .................................................................................

BRG, SPECIAL, 20X52X15 ..............................................................................................

BRG, BALL SPECIAL, 35X72X17 ....................................................................................

OIL SEAL, 34.8X53X8 .....................................................................................................

OIL SEAL, 8X16X7 ..........................................................................................................

BOLT, FLANGE, 8X40 .....................................................................................................

E-4

Ref.No.


CRANKCASE SET /CRANK SHAFT WASHER SET

(For SBK)

2006 CBR1000RR

Block No.

Reqd.No.

-

-

-

-

-

-

-

-

-

1

3

1

1

1

1

1

1

1

SBKJSB


3-12

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

•

•

•

•

•

•

•

•

•

•

06130-NL9-C00

11321-NL9-C00

11325-NL9-C00

11329-NL9-C00

11333-MEL-000

11392-NL9-710

31110-NL9-000

31110-NL9-C01

31120-NL9-C00

89030-NL9-711

90003-NL9-000

90006-GHB-640

90006-GHB-660

90006-GHB-670

90405-MCA-780

95701-06012-00

96600-06028-00

ACG SET........................................................................................................................

COVER, ACG .................................................................................................................

GUARD, ACG COVER ...................................................................................................

COLLAR, GUARD ..........................................................................................................

CLAMP, ACG CODE.......................................................................................................

GASKET, ACG COVER..................................................................................................

ROTER COMP 36K ........................................................................................................

ROTER COMP 46K ........................................................................................................

STATOR COMP .............................................................................................................

HOLDER COMP., ROTER ..............................................................................................

BOLT, FLANGE, 10X35 .................................................................................................




WASHER, 10.5X27.........................................................................................................

BOLT, FLANGE, 6X12 ....................................................................................................

BOLT, SOCKET, 6X28 ....................................................................................................

STD

OP

OP

STD

E-5

Ref.No.


A.C. GENERATOR SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

2

1

1

(1)

1

1

(1)

1

2

5

3

1

1

4

1

1

1

2

1

1

(1)

1

1

(1)

1

2

5

3

1

1

4

SBKJSB


3-13

1

2

3

4

5

6

7

8

9

10

11

•

•

•

•

•

•

06270-NL9-C00

11331-NL9-C00

11335-NL9-C00

11329-NL9-C00

15611-NF4-900

15611-NL9-C00

50252-GC4-830

90006-GHB-640

90006-GHB-660

90006-GHB-680

91307-425-030

R. COVER SET, SBK, JSB .............................................................................................

COVER, R.......................................................................................................................

GUARD, R. COVER........................................................................................................

COLLAR, GUARD ..........................................................................................................

CAP, OIL FILLER............................................................................................................

CAP, OIL FILLER............................................................................................................

BAND, SUB TANK ..........................................................................................................




O-RING, 21.5X3.2...........................................................................................................

R/B, For STD COVER

E-6

Ref.No.


R. CRANKCASE COVER SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

2

(1)

1

1

2

2

12

1

1

1

1

2

(1)

1

1

2

2

12

1

SBKJSB


3-14

1

2

•

•

•

•

•

•

•

•

•

•

•

•

•

•

13214-NL9-711

13215-NL9-711

13216-NL9-711

13217-NL9-711

13218-NL9-711

13219-NL9-711

13220-NL9-711

13314-NL9-711

13315-NL9-711

13316-NL9-711

13317-NL9-711

13318-NL9-711

13319-NL9-711

13320-NL9-711

BRG, CONN-ROD, A ......................................................................................................

BRG, CONN-ROD, B.......................................................................................................

BRG, CONN-ROD, C.......................................................................................................

BRG, CONN-ROD, D ......................................................................................................

BRG, CONN-ROD, E.......................................................................................................

BRG, CONN-ROD, F .......................................................................................................

BRG, CONN-ROD, G ......................................................................................................

BRG, CRANK SHAFT, B .................................................................................................

BRG, CRANK SHAFT, C .................................................................................................

BRG, CRANK SHAFT, D.................................................................................................

BRG, CRANK SHAFT, E .................................................................................................

BRG, CRANK SHAFT, F .................................................................................................

BRG, CRANK SHAFT, G.................................................................................................

BRG, CRANK SHAFT, H.................................................................................................

PINK-BLUE

PINK-BLACK

PINK-BROWN

PINK-GREEN

PINK-YELLOW

PINK-PINK

PINK-PURPLE

BROWN

GREEN

YELLOW

PINK

RED

WHITE

PURPLE

E-7

Ref.No.


BEARING SET

2006 CBR1000RR

Block No.

Reqd.No.

8

8

8

8

8

8

8

10

10

10

10

10

10

10

8

8

8

8

8

8

8

10

10

10

10

10

10

10

SBKJSB


3-15

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

06210-NL9-C00

06220-NL9-000

23211-MEL-R10

23220-MEL-R10

23421-MEL-R10

23431-MEL-R10

23441-MEL-R10

23442-MS2-610

23451-MEL-R10

23461-MEL-R10

23481-MEL-R10

23491-MEL-R10

23501-MEL-R10

23511-MEL-R10

23521-MEL-R10

23801-MCJ-750

23801-NL6-700

23802-NL6-700

23803-NL6-700

37700-MEL-R10

TRNSMISSON SET .......................................................................................................

DRIVE SPROCKET SET (525)........................................................................................

SHAFT, MAIN (14T) ......................................................................................................

SHAFT COMP, COUNTER ............................................................................................

GEAR, C-1 (32T) ............................................................................................................

GEAR, M-2 (17T) ...........................................................................................................

GEAR, C-2 (33T) ............................................................................................................

COLLOAR, 30x11.2........................................................................................................

GEAR, M-3 M-4 (18T/20T) ............................................................................................

GEAR, C-3 (30T) ............................................................................................................

GEAR, C-4 (30T) ............................................................................................................

GEAR, M-5 (23T) ...........................................................................................................

GEAR, C-5 (31T) ............................................................................................................

GEAR, M-6 (22T) ...........................................................................................................

GEAR, C-6 (27T) ............................................................................................................

SPROCKET, DRIVE, 16T(530) .......................................................................................

SPROCKET, DRIVE, 15T(525) .......................................................................................

SPROCKET, DRIVE, 16T(525) .......................................................................................

SPROCKET, DRIVE, 17T(525) .......................................................................................

SENSOR ASSY, SPEED ................................................................................................

R/B, Groove : 2

R/B

R/B, Groove : 2

R/B, Groove : 1

R/B, Groove : 1

R/B

R/B, Groove : 0/2

R/B, Groove : End-1

R/B, Groove : 2

R/B, Groove : 2

R/B, Groove : 2

R/B, Groove : 2

R/B, Groove : 2

R/B

R/B

E-8

Ref.No.


TRANSMISSION SET (R/B)

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

-

1

-

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

SBKJSB


3-16

19

20•

90004-492-010

90402-NL6-000

SPL. BOLT, FLANGE, 10X22..........................................................................................

WASHER, 10.2X37X3 ...................................................................................................

E-8

Ref.No.


TRANSMISSION SET (R/B)

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

SBKJSB


3-17

1

2

3

4

5

6

7

8

9

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

23211-NL9-710

23212-NL9-710

23212-NL9-910

23213-NL9-710

23213-NL9-910

23422-NL9-710

23423-NL9-710

23432-NL9-710

23442-NL9-710

23443-NL9-710

23452-NL9-710

23453-NL9-710

23454-NL9-710

23462-NL9-710

23463-NL9-710

23482-NL9-710

23491-NL9-C00

23492-NL9-710

23493-NL9-710

23501-NL9-C00

23502-NL9-710

23503-NL9-710

SHAFT, MAIN, BTL (14T)..............................................................................................

SHAFT, MAIN P-2, BTL (15T) .......................................................................................

SHAFT, MAIN P-2 (15T)................................................................................................

SHAFT, MAIN P-3, BTL (14T) .......................................................................................

SHAFT, MAIN P-3 (14T)................................................................................................

GEAR, C-1 P-2 (36T)......................................................................................................

GEAR, C-1 P-3 (31T)......................................................................................................

GEAR, M-2 P-2 (15T).....................................................................................................

GEAR, C-2 P-2 (30T)......................................................................................................

GEAR, C-2 P-3 (32T)......................................................................................................

GEAR, M-3 M-4 P-2 (18T/19T) ......................................................................................

GEAR, M-3 M-4 P-3 (19T/19T) ......................................................................................

GEAR, M-3 M-4 P-4 (19T/20T) ......................................................................................

GEAR, C-3 P-2 (31T)......................................................................................................

GEAR, C-3 P-3 (31T)......................................................................................................

GEAR, C-4 P-2 (29T)......................................................................................................

GEAR, M-5 P-1 (20T).....................................................................................................

GEAR, M-5 P-2 (19T).....................................................................................................

GEAR, M-5 P-3 (22T).....................................................................................................

GEAR, C-5 P-1 (28T)......................................................................................................

GEAR, C-5 P-2 (26T)......................................................................................................

GEAR, C-5 P-3 (29T)......................................................................................................

Groove : 2

Groove : 1

Groove : 1

Groove : 3

Groove : 3

Groove : 1

Groove : 3

Groove : 0

Groove : 0

Groove : 2

Groove : 0/1

Groove : 2/1

Groove : 2/2

Groove : 0

Groove : 2

Groove : 1

Groove : 0

Groove : 1

Groove : 3

Groove : 0

Groove : 1

Groove : 3

E-8-1

Ref.No.


TRANSMISSION SET (OPTIONAL PARTS)

2006 CBR1000RR

Block No.

Reqd.No.

-

-

1

-

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

-

1

-

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

SBKJSB


3-18

10

11

•

•

•

•

•

23511-NL9-C00

23512-NL9-710

23513-NL9-710

23521-NL9-C00

23522-NL9-710

GEAR, M-6 P-1 (22T).....................................................................................................

GEAR, M-6 P-2 (24T).....................................................................................................

GEAR, M-6 P-3 (25T).....................................................................................................

GEAR, C-6 P-1 (28T)......................................................................................................

GEAR, C-6 P-2 (30T)......................................................................................................

Groove : 0

Groove : 1

Groove : 3

Groove : 0

Groove : 1

E-8-1

Ref.No.


TRANSMISSION SET (OPTIONAL PARTS)

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

1

1

1

1

SBKJSB


3-19

1

2

3

4

5

6

7

8

9

10

11

•

•

•

•

•

•

•

•

•

•

•

06160-NL9-710

06160-NL9-C30

16514-NL9-710

17215-NL9-710

17215-NL9-C30

17216-NL9-710

17216-NL9-C30

17217-NL9-710

17217-NL9-C30

17218-NL9-710

17218-NL9-C30

AIR FUNNEL SET ..........................................................................................................

AIR FUNNEL SET ..........................................................................................................

BOLT, 5MM ...................................................................................................................

FUNNEL, AIR#1 (45) .....................................................................................................

FUNNEL, AIR#1 (55) .....................................................................................................

FUNNEL, AIR#2 (25) .....................................................................................................

FUNNEL, AIR#2 (35) .....................................................................................................

FUNNEL, AIR#3 (25) .....................................................................................................

FUNNEL, AIR#3 (35) .....................................................................................................

FUNNEL, AIR#4 (45) .....................................................................................................

FUNNEL, AIR#4 (55) .....................................................................................................

OP

1B / 1-45

OP, 1-55

2B / 2-25

OP, 2-35

3B / 3-25

OP, 3-35

4B / 4-45

OP, 4-55

E-9

Ref.No.


AIR FUNNEL SET

2006 CBR1000RR

Block No.

Reqd.No.

1

(1)

6

1

(1)

1

(1)

1

(1)

1

(1)

1

(1)

6

1

(1)

1

(1)

1

(1)

1

(1)

SBKJSB


3-20

1

2

3

4

5

6

•

•

•

06195-NL3-650

17460-MEL-R10

17470-MEL-R10

17724-102-700

19505-KS6-700

96205-14012

PLUG SET, EXHAUST A/I ..............................................................................................

TUBE, AIR SECTION UP ................................................................................................

TUBE ASSY., A/S UPPER ..............................................................................................

CLIP.................................................................................................................................

CLAMP, A WATER HOSE ...............................................................................................

PLUG, CONE TYPE 14X12 ..............................................................................................

STD

E-10

Ref.No.


AIR INJECTION PLUG SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

2

3

3

1

1

1

2

3

3

SBKJSB


3-21

1

2

3

4

5

•

•

•

06150-NL9-900

19504-KY1-003

19511-NL3-650

19512-NL8-700

90454-ZV1-000

PLUG SET, WATER HOSE ...........................................................................................

CLAMP, WATER HOSE D25 ..........................................................................................

PLUG, FAST IDLE..........................................................................................................

PLUG, HOSE 16MM......................................................................................................

WASHER, THRUST ........................................................................................................

E-11

Ref.No.


WATER HOSE PLUG SET

2006 CBR1000RR

Block No.

Reqd.No.

1

2

2

2

1

1

2

2

2

1

SBKJSB


3-22

1

2

3

4

5

6

7

8

9

•

•

•

•

•

06531-NL3-750

17910-NL9-000

17920-NL9-000

22900-NL6-000

53141-MT7-000

53167-KV3-701

53168-KV3-701

64501-NL9-910

93500-05020-0G

HOUSING SET, THROT .................................................................................................

CABLE COMP A, THROT ...............................................................................................

CABLE COMP B, THROT ...............................................................................................

HOSE, CLUTCH ..............................................................................................................

PIPE, THROT GRIP..........................................................................................................

HOUSING, THROT UP ....................................................................................................

HOUSING, THROT UND .................................................................................................

STAY, UPPER COWL .....................................................................................................

SCREW, PAN, 5X20 ........................................................................................................

F-1

Ref.No.


THROTTLE / CLUTCH HOSE

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

2

SBKJSB


3-23

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

•

•

•

•

•

•

•

•

•

•

•

•

51400-MEL-R31

51401-MEL-R11

51401-NL9-711

51401-NL9-901

51402-NL9-711

51402-NL9-901

51403-MEL-R31

51404-MEL-R11

51406-MEL-R11

51410-MEL-R11

51412-MEL-003

51414-MAZ-003

51415-MAZ-003

51423-MCJ-751

51425-MEL-D21

51430-MEL-D21

51447-KA4-711

51450-MEL-R11

51451-MCJ-751

51453-MEL-R11

FORK ASSY, R. FRONT .................................................................................................

SPRING, FR. FORK 0.95.................................................................................................

SPRING, FR. FORK 1.05.................................................................................................

SPRING, FR. FORK 0.90.................................................................................................

SPRING, FR. FORK 1.10.................................................................................................

SPRING, FR. FORK 1.00.................................................................................................

COLLAR, SPRING...........................................................................................................

COLLAR B, SPRING .......................................................................................................

SLIDER............................................................................................................................

TUBE, OUTER ................................................................................................................

RING, BACK UP...............................................................................................................

BUSH, GUIDE..................................................................................................................

BUSH, SLIDER ................................................................................................................

RING B, STOPPER ..........................................................................................................

PIPE COMP., R. SLIDE....................................................................................................

DAMPER COMP., FR. .....................................................................................................

RING, OIL SEAL STOPPER .............................................................................................

BOLT, FR. FORK .............................................................................................................

NUT, LOCK......................................................................................................................

PLATE B, ADJUSTING...................................................................................................

R/B

`04-`05 R/B, OP

`06 R/B

OP

OP

OP

R/B

R/B

R/B

No sale. 51410-MEL-003 (COLOR: NATURAL)

No sale. 51450-MEL-003 (COLOR: GOLD)

No sale. 51453-MCJ-751 (COLOR: BLACK)

F-2

Ref.No.


FRONT FORK / STEERING DAMPER

2006 CBR1000RR

Block No.

Reqd.No.

1

(2)

2

(2)

(2)

(2)

2

2

2

2

2

2

2

2

1

2

2

2

2

2

1

(2)

2

(2)

(2)

(2)

2

2

2

2

2

2

2

2

1

2

2

2

2

2

SBKJSB


3-24

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

•

•

51455-MW4-003

51456-MCJ-751

51490-MEJ-003

51496-MCJ-751

51500-MEL-R31

51525-MEL-D21

52442-KA3-711

53700-NL9-003

53702-MCJ-751

90109-MR7-000

90126-MR7-003

91254-MEJ-003

91255-MCJ-751

91256-MCJ-751

91257-MCJ-751

91258-GF4-003

RING, STOPPER..............................................................................................................

RING, STOPPER..............................................................................................................

SEAL SET, FR. FORK ......................................................................................................

LABEL .............................................................................................................................

FORK ASSY, L. FRONT..................................................................................................

PIPE COMP., L. SLIDE ....................................................................................................

WASHER, SPECIAL, 10MM............................................................................................

DAMPER ASSY, STRG ..................................................................................................

PLATE, SPRING ADJUSTER ...........................................................................................

BOLT, FLANGE, 8X45 .....................................................................................................

BOLT, SOCKET, 10X35 ...................................................................................................

DUST SEAL .....................................................................................................................

O-RING, 10.8X2.4............................................................................................................

O-RING, 23.3X2.4............................................................................................................

O-RING, 9.5X1.5..............................................................................................................

O-RING, 42.2X2.4............................................................................................................

R/B

F-2

Ref.No.


FRONT FORK / STEERING DAMPER

2006 CBR1000RR

Block No.

Reqd.No.

2

2

2

2

1

1

2

1

2

4

2

2

2

2

2

2

2

2

2

2

1

1

2

1

2

4

2

2

2

2

2

2

SBKJSB


3-25

1

2

3

4

5

6

7

8

9

10

11

12

13

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

45105-NL3-921

45105-NL9-801

45106-NL3-921

45105-NL9-000

45105-NL9-900

45105-NL9-C00

45120-NL3-901

45120-NL9-801

45120-NL9-C30

45130-NL9-000

45132-NL9-720

45220-NL3-901

45220-NL9-801

45220-NL9-C30

45250-NL5-800

45250-NL9-720

45250-NL9-910

45250-NL9-C40

45500-NL5-701

45520-NL5-701

51497-NL9-720

PAD COMP, FR. (H21A) ................................................................................................

PAD COMP, FR. (N615).................................................................................................

PAD COMP, FR. (N608).................................................................................................

PAD COMP, FR. (N614).................................................................................................

PAD COMP, FR. (N608).................................................................................................

PAD COMP, FR. (N615).................................................................................................

DISK COMP, R. FR. BRAKE ..........................................................................................



SPACER, FR. WHEEL DISK 1.5.....................................................................................

SPACER, FR. WHEEL DISK 2.3.....................................................................................

DISK COMP, L. FR. BRAKE...........................................................................................



DISK COMP, FR. 320.....................................................................................................

DISK ASSY, FR. 320XT6 ...............................................................................................

DISK ASSY, FR. 320XT6 ...............................................................................................

DISK ASSY, FR. 305XT6 ...............................................................................................

M/C ASSY, BR L18 ........................................................................................................

CUP ASSY, FR. M/C ......................................................................................................

SPACER, FR. FORK .......................................................................................................

For STD CALIPER

For STD CALIPER

For STD CALIPER

For BREMBO CALIPER

For BREMBO CALIPER

For BREMBO CALIPER

For STD WHEEL Ø310 t5.0 OFFSET 12.3






BREMBO Ø320 t5.5 OFFSET 12.5

For NL6 WHEEL BREMBO Ø320 t6.0 OFFSET 16.5



BREMBO

For STD FORK, BREMBO Ø320 DISK

F-3

Ref.No.


FRONT BRAKE

2006 CBR1000RR

Block No.

Reqd.No.

4

4

4

4

4

4

1

1

1

2

2

1

1

1

2

2

2

2

1

1

4

4

4

4

4

4

4

1

1

1

2

2

1

1

1

2

2

2

2

1

1

4

SBKJSB


3-26

14

15

16

17

18

19

•

•

53160-NL5-701

90003-MC7-000

90104-GT8-600

90131-NL9-720

95002-40850-08

95003-11015-60

LEVER, FR. BRAKE L 18P..............................................................................................

BOLT, FLANGE, 6X20 ....................................................................................................

SCREW, SPECIAL, 6X14 ................................................................................................

BOLT, FLANGE, 10X65 .................................................................................................

CLAMP, TUBE (D8.5) .....................................................................................................

TUBE, VINYL, 5X9X150..................................................................................................

BREMBO

Made of titanium, For STD FORK, BREMBO Ø320 DISK

F-3

Ref.No.


FRONT BRAKE

2006 CBR1000RR

Block No.

Reqd.No.

1

12

1

4

2

1

1

12

1

4

2

1

SBKJSB


3-27

1

2

3

4

5

6

7

8

9

•

•

•

•

•

•

•

•

•

•

•

43100-NL5-701

43105-NL5-700

43105-NL9-C00

43105-NL9-C30

43105-NL9-C40

43106-NL9-C30

43106-NL9-C40

43110-MEL-R31

43110-NL9-000

43110-NL9-C40

43112-MEL-D21

90101-NL6-000

CALIPER ASSY, RR. ......................................................................................................

PAD COMP, RR. (X95) ..................................................................................................

PAD COMP, RR. (TT2450).............................................................................................

PAD COMP, A RR. (TT2450) .........................................................................................

PAD COMP, A RR. (X95A) ............................................................................................

PAD COMP, B RR. (TT2450) .........................................................................................

PAD COMP, B RR. (X95A) ............................................................................................

BRACKET COMP, RR. ...................................................................................................

BRKT, RR CALIPER .......................................................................................................

BRKT, RR CALIPER .......................................................................................................

RETAINER ......................................................................................................................

BOLT, FLANGE, 7X21 ...................................................................................................

For NL5 CALIPER

For NL5 CALIPER

For ’06 STD CALIPER




R/B

For NL5 CALIPER, NL9 WHEEL

REAR BRAKE DISK OFF-SET MODEL (For NL5 CALIPER, NL9 WHEEL)

R/B

F-4

Ref.No.


REAR BRAKE

2006 CBR1000RR

Block No.

Reqd.No.

1

2

2

1

1

1

1

1

1

1

1

2

1

2

2

1

1

1

1

1

1

1

1

2

SBKJSB


3-28

1

2

3

4

5

6

7

8

9

10

11

12

13

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

06443-NL9-000

06443-NL9-720

42753-ML7-004

44301-NL6-000

44301-NL9-720

44303-NL9-000

44303-NL9-720

44304-NL9-000

44304-NL9-720

44305-NL9-000

44306-NL9-720

44311-NL6-000

44311-NL9-710

44311-NL9-720

44311-NL9-810

44311-NL9-910

44601-NL6-000

44602-NL6-000

44603-NL6-000

44601-NL9-710

FR. AXLE SET................................................................................................................

FR. AXLE SET................................................................................................................

VALBE, RIM (DUN).........................................................................................................

AXLE, FR. WHEEL .........................................................................................................

AXLE, FR. WHEEL .........................................................................................................

NUT, FR. AXLE..............................................................................................................

NUT, FR. AXLE..............................................................................................................

GUIDE A, FR. AXLE.......................................................................................................

GUIDE, FR. AXLE ..........................................................................................................

GUIDE B, FR. AXLE.......................................................................................................

GUIDE WASH, FR. AXLE ..............................................................................................

COLLAR, FR. WHEEL SIDE ...........................................................................................





WHEEL, FR. 3.5-17 ........................................................................................................

WHEEL, FR. 3.5-16.5 .....................................................................................................

WHEEL, FR. 3.75-17 ......................................................................................................

WHEEL, FR. 3.5-16.5 .....................................................................................................

For SHOWA SPL FORK

For STD FORK

For SHOWA SPL FORK

For STD FORK

For SHOWA SPL FORK

For STD FORK

For SHOWA SPL FORK

For STD FORK

For SHOWA SPL FORK

For STD FORK

For SHOWA SPL FORK, NL6 WHEEL, AXLE KIT

For SHOWA SPL FORK, NL9 WHEEL, AXLE KIT

For STD FORK, NL6 WHEEL, AXLE KIT

For STD FORK, NL9 WHEEL, AXLE KIT

For STD FORK, STD WHEEL, AXLE KIT

CASTING WHEEL, OP

CASTING WHEEL, OP

CASTING WHEEL, OP

FORGING WHEEL, STD

F-5

Ref.No.


FRONT WHEEL /AXLE SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

1

1

2

1

1

2

2

2

2

2

(1)

(1)

(1)

1

1

1

1

1

1

1

1

1

2

1

1

2

2

2

2

2

(1)

(1)

(1)

1

SBKJSB


3-29

14

15

16

17

18

19

20

21

22

23

24

25

•

•

•

•

•

•

•

•

•

•

•

•

•

44620-NL6-010

44620-NL9-710

44622-NL0-810

44650-NL9-710

90305-NL6-000

90305-NL9-720

90503-NL6-000

90525-NL9-000

90525-NL9-720

90526-NL9-000

90526-NL9-720

90535-NL9-720

91057-NL9-710

COLLAR, FR. WHEEL DIST ...........................................................................................

COLLAR, FR. WHEEL DIST ...........................................................................................

RETAINER, FR. WHEEL.................................................................................................

WHEEL ASSY, FR. 3.5-16.5 ..........................................................................................

NUT, M28X1.0...............................................................................................................

NUT, M30X1.0...............................................................................................................

WASHER, 45X22X3 ......................................................................................................

SHIM 0.2, FR. FORK SIDE.............................................................................................

SHIM 0.2, FR. FORK R SIDE .........................................................................................

SHIM 0.3, FR. FORK SIDE.............................................................................................

SHIM 0.3, FR. FORK R SIDE .........................................................................................

WASH, FR. AXLE ..........................................................................................................

BEARING, RADIAL, BALL ............................................................................................

For NL6 WHEEL, OP

For NL9 WHEEL

For SHOWA SPL FORK

For STD FORK

For SHOWA SPL FORK

For SHOWA SPL FORK

For STD FORK

For SHOWA SPL FORK

For STD FORK

For STD FORK

F-5

Ref.No.


FRONT WHEEL /AXLE SET

2006 CBR1000RR

Block No.

Reqd.No.

(1)

1

1

1

1

1

1

N

N

N

N

1

2

(1)

1

1

1

1

1

1

N

N

N

N

1

2

SBKJSB


3-30

1

2

3

4

5

6

7

8

9

10

11

12

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

40540-MAS-005

40545-MAS-005

41201-MEL-J20

41201-MCJ-J00

41201-MCJ-000

41201-MCJ-670

41238-NL6-700

41239-NL6-700

41240-NL6-700

41241-NL6-700

41242-NL6-700

41243-NL6-700

42311-NL9-000

42311-NL9-C40

42312-NL6-000

42601-NL9-710

42609-NL6-000

42621-NL6-000

42624-NL6-000

42633-NL6-003

42650-NL9-710

CHAIN, DRIVE RKGB525R0Z1-120LJF ..........................................................................

JOINT, DRIVE CHAIN.....................................................................................................

SPRKT, FINAL DRIVE 40T ..............................................................................................




SPRKT, FINAL DRIVE 38T.............................................................................................






COLLAR, L. DRIVEN FLANGE SIDE .............................................................................


COLLAR, R. DRIVEN FLANGE SIDE.............................................................................

WHEEL, REAR 6.25-16.5 ...............................................................................................

FLANGE, FINAL DRIVEN ..............................................................................................

RETAINER, RR. WHEEL BRG........................................................................................

COLLAR, RR. WHEEL DISTANCE.................................................................................

DAMPER, RR. WHEEL...................................................................................................

WHEEL ASSY, RR. 6.25-16.5 ........................................................................................

For STD WHEEL, 530 CHAIN, R/B

For STD WHEEL, 530 CHAIN



For NL6/9 WHEEL, 525 CHAIN






Chamfering (large)

Chamfering (small)

FORGING WHEEL

F-6

Ref.No.


REAR WHEEL

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

6

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

6

1

SBKJSB


3-31

13

14

15

16

17

18

19

20

21

22

•

•

•

•

•

•

•

42753-ML7-004

43121-NL6-000

87000-NL6-000

90003-MC7-000

90120-NL6-300

90309-KF0-003

90501-NL6-000

90651-ML0-731

91051-NL6-000

91052-NL6-003

VALBE, RIM (DUN).........................................................................................................

DISK, RR. BRAKE ..........................................................................................................

TOOL, RETAINER A ......................................................................................................

BOLT, FLANGE, 6X20 ....................................................................................................

BOLT, DRIVEN FLANGE 8MM .....................................................................................

NUT, FLANGE, 8MM......................................................................................................

WASHER, RR. WHEEL BRG..........................................................................................

CIRCLIP, INTERNAL, 62 ................................................................................................

BRG., BALL RADIAL 6205 2RS.....................................................................................

BRG., ANGULAR 30X62X23.8......................................................................................

F-6

Ref.No.


REAR WHEEL

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

4

6

6

1

1

2

1

1

1

1

4

6

6

1

1

2

1

SBKJSB


3-32

1

2

3

4

5

6

7

8

9

10

11

12

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

40540-MAS-005

40545-MAS-005

41201-MEL-J20

41201-MCJ-J00

41201-MCJ-000

41201-MCJ-670

41238-NL6-700

41239-NL6-700

41240-NL6-700

41241-NL6-700

41242-NL6-700

41243-NL6-700

42311-NL9-000

42311-NL9-C40

42312-NL6-000

42601-NL9-710

42609-NL6-000

42611-NL9-C40

42621-NL6-000

42624-NL9-C40

42631-NL9-C40

CHAIN, DRIVE RKGB525R0Z1-120LJF ..........................................................................

JOINT, DRIVE CHAIN.....................................................................................................













COLLAR, R. DRIVEN FLANGE SIDE.............................................................................

WHEEL, REAR 6.25-16.5 ...............................................................................................

FLANGE, FINAL DRIVEN ..............................................................................................

SPACER, RR. BRAKE DISK ...........................................................................................

RETAINER, RR. WHEEL BRG........................................................................................

COLLAR, RR. WHEEL DISTANCE.................................................................................

COLLAR, RR. WHEEL R. SIDE ......................................................................................

For STD WHEEL, 530 CHAIN, R/B










Chamfering (large)

Chamfering (small)

FORGING WHEEL

REAR BRAKE DISK OFF-SET MODEL



F-6-1

Ref.No.


REAR WHEEL(REAR BRAKE DISK OFF-SET MODEL)

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

SBKJSB


3-33

13

14

15

16

17

18

19

20

21

22

23

24

25

•

•

•

•

•

•

•

•

•

•

•

42633-NL6-003

42650-NL9-C40

42753-ML7-004

43121-NL6-700

87000-NL6-000

90119-NL9-C40

90120-NL6-300

90309-KF0-003

90501-NL6-000

90651-ML0-731

91051-NL6-000

91052-NL6-003

91053-NL6-701

DAMPER, RR. WHEEL...................................................................................................

WHEEL ASSY, RR. 6.25-16.5 ........................................................................................

VALBE, RIM (DUN).........................................................................................................

DISK, RR. BRAKE ..........................................................................................................

TOOL, RETAINER A ......................................................................................................

BOLT, RR DISK (Ti) .......................................................................................................

BOLT, DRIVEN FLANGE 8MM .....................................................................................

NUT, FLANGE, 8MM......................................................................................................

WASHER, RR. WHEEL BRG..........................................................................................

CIRCLIP, INTERNAL, 62 ................................................................................................

BRG., BALL RADIAL 6205 2RS.....................................................................................

BRG., ANGULAR 30X62X23.8......................................................................................

BRG., BALL RADIAL 52X27X15 ...................................................................................



REAR BRAKE DISK OFF-SET MODEL, Made of titanium


F-6-1

Ref.No.


REAR WHEEL(REAR BRAKE DISK OFF-SET MODEL)

2006 CBR1000RR

Block No.

Reqd.No.

6

1

1

1

1

4

6

6

1

1

1

1

1

6

1

1

1

1

4

6

6

1

1

1

1

1

SBKJSB


3-34

1

2

3

4

5

6

7

8

9

•

•

•

•

•

•

•

06175-NL9-910

17510-NL9-910

17515-NX5-770

17521-NX4-680

17522-NF5-690

17574-NL9-910

31517-NL9-000

90105-MM4-000

96600-08025-00

TANK SET FUEL............................................................................................................

TANK COMP, FUEL.......................................................................................................

PKG, FUEL TANK ..........................................................................................................

CAP, FUEL TANK ..........................................................................................................

SPONGE, BUFFLE.........................................................................................................

PACKING, BASE............................................................................................................

SPONGE, MT 5MM.......................................................................................................

SCREW, PAN 6X10 ........................................................................................................

BOLT, SOCKET 8X25 ..................................................................................................... In the left side, use the STD

F-7

Ref.No.


FUEL TANK

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

4

1

1

6

1

1

1

1

1

4

1

1

6

1

SBKJSB


3-35

1

2

3

4

5

6

7

8

9

•

•

•

•

•

•

•

•

06176-NL5-700

17504-NH3-303

17515-NX5-770

17521-NX4-680

17560-NL5-700

17565-NL5-700

90101-NL5-000

91353-NL5-701

93600-04010-0A

FILLER, QUICK SET........................................................................................................

FILLER, QUICK ...............................................................................................................

PACKING, FUEL CAP .....................................................................................................

CAP, FUEL TANK ...........................................................................................................

BASE, FUEL TANK CAP.................................................................................................

CAP, FUEL TANK BLIND ...............................................................................................

SCREW, TRUSS, 4X8.....................................................................................................

O-RING, 82X2.8..............................................................................................................

SCREW, FLAT, 4X10 .......................................................................................................

F-8

Ref.No.


QUICK FILLER SET(ENDURANCE)

2006 CBR1000RR

Block No.

Reqd.No.

1

2

1

1

1

1

18

2

18

1

2

1

1

1

1

18

2

18

SBKJSB


3-36

1

2

3

4

5

6

7

8

9

•

•

•

•

•

•

06172-NL9-710

17210-MEL-R11

17211-NL9-000

17251-NL9-710

18315-GAG-750

19120-NL9-000

19170-NL9-000

90110-147-000

93891-05012-18

AIR BOX DUCT SET......................................................................................................

ELEMENT, AIR/C ...........................................................................................................

SPONGE, ELEMENT .....................................................................................................

DUCT, AIR BOX.............................................................................................................

RUBBER A, PROTR........................................................................................................

STAY R, RAD UPPER ....................................................................................................

STAY L, RAD UPPER ....................................................................................................

BOLT, FLANGE, 6MM....................................................................................................

SCREW-WASH, 5X12.....................................................................................................

R/B

CFRP

F-9

Ref.No.


AIR BOX DUCT SET /AIR CLEANER ELEMENT

2006 CBR1000RR

Block No.

Reqd.No.

1

2

1

1

2

1

1

2

2

1

2

1

1

2

1

1

2

2

SBKJSB


3-37

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

•

•

•

•

•

•

06552-NL9-000

17724-102-700

18315-GAG-750

19052-KV0-000

19505-KS6-700

31517-NL9-000

55200-NL9-000

55210-NL9-000

55220-NL9-000

55231-NL9-000

81351-124-830

90104-KR3-670

90525-030-000

94050-06000

96001-06020-00

BREATHER CASE SET ..................................................................................................

CLIP................................................................................................................................

RUBBER A, PROTR........................................................................................................

COLLAR, RADIATOR MOUNTING.................................................................................

CLAMP A, WATER HOSE ..............................................................................................

SPONGE, MT 5MM.......................................................................................................

CASE COMP, BREATHER .............................................................................................

TUBE, BREATHER.........................................................................................................

TUBE, BREATHER RETURN .........................................................................................

STAY, BREATHER CASE ..............................................................................................

RUBBER CARRIER MOUNT ..........................................................................................

BOLT METER SET ....................................................................................................

WASHER B, HANDLE HOLDER.....................................................................................

NUT, FLANGE 6MM.......................................................................................................

BOLT, FLANGE, SH, 6X20 .............................................................................................

F-10

Ref.No.


BREATHER CASE SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

2

2

3

1

1

1

1

1

2

2

2

2

2

1

1

2

2

3

1

1

1

1

1

2

2

2

2

2

SBKJSB


3-38

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

06183-NL9-C00

06183-NL9-C30

18291-NL9-000

18293-MCA-A20

18293-NL9-910

18295-NL9-910

18300-NL9-C00

18301-NL9-C00

18302-NL9-C00

18303-NL9-C00

18304-NL9-C00

18305-NL9-910

18306-NL9-910

18307-NL9-910

18309-NL9-C00

18311-NL9-910

18320-NL9-000

18325-MEL-013

18336-NL9-000

18339-NL9-910

EXHAUST SET Ti (SBK) ...............................................................................................

EXHAUST SET Ti (JSB)................................................................................................

GASKET, EXH PIPE .......................................................................................................

RUBBER, PKG. PROTR ..................................................................................................

FLANGE, EXH................................................................................................................

COLLAR, EXH................................................................................................................

PIPE ASSY, EXH............................................................................................................

PIPE COMP, EXH(#1) ....................................................................................................

PIPE COMP, EXH(#2) ....................................................................................................

PIPE COMP, EXH(#3) ....................................................................................................

PIPE COMP, EXH(#4) ....................................................................................................

JOINT COMP, (#1-#2) ...................................................................................................

JOINT COMP, (#3-#4) ...................................................................................................

JOINT COMP, RR. .........................................................................................................

PIPE COMP, TAIL ..........................................................................................................

NUT, TAIL PIPE .............................................................................................................

STAY, EXH PIPE JOINT ................................................................................................

PROTECTOR, EXH PIPE INNER.....................................................................................

SPRING, EXH PIPE........................................................................................................

GREASE, ANTI SEIZING...............................................................................................

Not included with EXHAUST SET Ti (SBK)

Made of titanium

Made of titanium

Made of titanium

Made of titanium

Made of titanium

Made of titanium

Made of titanium

Made of titanium

Made of titanium


F-11

Ref.No.


EXHAUST SET

2006 CBR1000RR

Block No.

Reqd.No.

-

1

4

2

4

4

1

1

1

1

1

1

1

1

1

1

1

1

17

1

1

-

4

2

4

4

1

1

1

1

1

1

1

1

1

1

1

1

17

1

SBKJSB


3-39

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

•

•

•

•

•

•

•

18345-MBT-610

18370-NL9-710

18370-NL9-910

18375-NL9-000

18380-NL9-710

18380-NL9-910

18421-MN5-000

18421-NL9-C00

18424-MN5-000

19051-KA3-830

19052-MAC-680

84706-415-000

90118-MBV-000

90201-GCC-C50

90202-MBB-000

90572-MEL-000

93404-06025-00

94050-06000

94050-08000

RUBBER, PROTECTOR MOUNT ...................................................................................

BAND, MUFFLER(SBK).................................................................................................

BAND, MUFFLER(JSB) .................................................................................................

STAY, MUFFLER ...........................................................................................................

MUFFLER COMP(SBK) .................................................................................................

MUFFLER COMP(JSB)..................................................................................................

RUBBER, MUFF MOUNT...............................................................................................

RUBBER, EXH MT.........................................................................................................

COLLAR, CHAMBER MOUNT ......................................................................................

RUBBER, RAD. MOUNT ................................................................................................

COLLAR, RAD MT..........................................................................................................

COLLAR, NO PLATE BRACKET .....................................................................................

SCREW, PAN, 6X14 .......................................................................................................

NUT, HEX., 7MM ...........................................................................................................

COLLAR, 8X18 ...............................................................................................................

RUBBER, PROTECTOR..................................................................................................

BOLT-WASHER, 6X25....................................................................................................

NUT, FLANGE, 6MM......................................................................................................

NUT, FLANGE, 8MM......................................................................................................


For ’06 STD SEAT RAIL, R/B





F-11

Ref.No.


EXHAUST SET

2006 CBR1000RR

Block No.

Reqd.No.

1

-

1

1

-

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

-

1

1

-

1

1

1

1

1

1

1

2

2

1

1

1

1

SBKJSB


3-40

37

38

39

40

41

94103-08700

95701-06010-00

95701-08020-00

95701-08055-00

96400-08045-07

WASHER, PLAIN 8MM ..................................................................................................

BOLT, FLANGE, 6X10 ....................................................................................................

BOLT, FLANGE, 8X20 ....................................................................................................

BOLT, FLANGE, 8X55 ....................................................................................................

BOLT, FLANGE, 8X45 ....................................................................................................



F-11

Ref.No.


EXHAUST SET

2006 CBR1000RR

Block No.

Reqd.No.

1

2

8

1

1

1

2

8

1

1

SBKJSB


3-41

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

06405-NL9-000

06405-NL9-C40

40542-NL9-000

40543-NL9-000

40544-NL9-000

40545-NL9-000

41405-HA7-670

42301-NL9-000

42302-NL6-700

42304-NL9-000

42304-NL9-C40

42305-MEL-R10

42306-MEL-R10

42307-MEL-R10

42314-NL9-000

52100-MEL-R30

52102-MEL-000

52143-MEL-000

52144-MEL-000

52157-NL3-650

DRIVE CHAIN ADJ SET .................................................................................................

DRIVE CHAIN ADJ SET .................................................................................................

ADJ, R. DRIVE CHAIN....................................................................................................

ADJ, L. DRIVE CHAIN ....................................................................................................

LID, L. DRIVE CHAIN ADJ..............................................................................................

SPACER, ADJ DRIVECHAIN L .......................................................................................

RING, STOPPER..............................................................................................................

AXLE, REAR WHEEL......................................................................................................

GUIDE, RR. AXLE CNT ..................................................................................................

COLLAR, RR. AXLE R SIDE ...........................................................................................

COLLAR, RR. AXLE R SIDE ...........................................................................................

COLLAR L, RR. AXLE .....................................................................................................

COLLAR R, RR. AXLE.....................................................................................................

COLLAR, R. JOINT .........................................................................................................

COLLAR, RR. AXLE L SIDE............................................................................................

SWINGARM ASSY.........................................................................................................

COLLAR, RR. SWINGARM PIVOT DISTANCE...............................................................

COLLAR, L. PIVOT DISTANCE.......................................................................................

COLLAR, R. PIVOT DISTANCE ......................................................................................

PROTECTOR, SPRKT .....................................................................................................



R/B

R/B

R/B

R/B

F-12

Ref.No.


SWINGARM /DRAIVE CHAIN ADJUST SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

SBKJSB


3-42

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

•

•

•

52170-MEL-000

81312-GJ5-000

90105-MY9-000

90106-NL9-000

90130-MCJ-750

90308-NL9-000

90309-357-000

90536-NL9-000

91053-MCJ-003

91053-MCJ-751

91071-MCJ-003

91252-MCF-003

91253-MCF-003

93500-05020-0A

93500-05035-0A

93500-05050-0A

94050-05000

94101-06700

94520-45000

96001-06012-00

96001-06016-07

SLIDER, CHAIN ..............................................................................................................

COLLAR .........................................................................................................................

BOLT, FLANGE, 6X18 ....................................................................................................

BOLT, HEX, 8X55 ...........................................................................................................

BOLT, CHAIN SLIDER....................................................................................................

NUT, RR. AXLE ..............................................................................................................

NUT, HEX., 8MM ............................................................................................................

WASH, RR. AXLE ...........................................................................................................

BEARING, RADIAL BALL, 6905 .....................................................................................

BEARING, NEEDLE, 32X42X20......................................................................................


DUST SEAL, 32X45X5....................................................................................................

DUST SEAL, 32X42X5....................................................................................................

SCREW, PAN, 5X20 ........................................................................................................

SCREW, PAN, 5X35 ........................................................................................................

SCREW, PAN, 5X50 ........................................................................................................

NUT, FLANGE, 5MM.......................................................................................................

WASHER, PLAIN 6MM ..................................................................................................

CIRCLIP, INTERNAL, 45MM ..........................................................................................

BOLT, FLANGE, SH, 6X12 ..............................................................................................

BOLT, FLANGE, SH, 6X16 .............................................................................................

F-12

Ref.No.


SWINGARM /DRAIVE CHAIN ADJUST SET

2006 CBR1000RR

Block No.

Reqd.No.

1

2

2

2

1

1

2

1

1

1

1

1

1

2

2

2

2

2

1

2

2

1

2

2

2

1

1

2

1

1

1

1

1

1

2

2

2

2

2

1

2

2

SBKJSB


3-43

1

2

3

4

5

6

7

8

9

10

11

12

•

•

•

•

•

•

•

•

•

•

•

•

•

•

52400-MEL-R31

52401-MEL-R11

52401-NL9-901

52402-NL9-901

52403-NL9-901

52404-NL9-901

52405-NL9-901

52430-MEL-R10

52460-MEL-R10

52460-NL9-C00

52460-NL9-C10

52463-KZ4-B00

52463-MEE-000

52464-MEE-000

52466-MEE-000

52467-MEE-000

52470-MEL-R10

52470-NL9-C00

52470-NL9-C10

52472-MEL-000

58487-KA4-831

CUSHION ASSY, RR. .....................................................................................................

SPRING, RR. CUSH 10.0................................................................................................

SPRING, RR. CUSH 9.5..................................................................................................

SPRING, RR. CUSH 10.5................................................................................................

SPRING, RR. CUSH 11.0................................................................................................

SPRING, RR. CUSH 11.5................................................................................................

SPRING, RR. CUSH 12.0................................................................................................

STAY, RR. CUSH ADJ....................................................................................................

ARM ASSY, CUSHION ..................................................................................................

ARM ASSY, CUSHION (P2)...........................................................................................

ARM ASSY, CUSHION (P4)...........................................................................................

COLLAR D, CUSHION....................................................................................................

COLLAR, CUSHION ARM ..............................................................................................

COLLAR, BEARING SIDE...............................................................................................

COLLAR A, CUSHION ARM...........................................................................................

WASHER, THRUST ........................................................................................................

CONN ROD ASSY, CUSHION .......................................................................................

CONN ROD ASSY, CUSHION (P2)................................................................................

CONN ROD ASSY, CUSHION (P4)................................................................................

COLLAR, CONNECTING ROD PIVOT ............................................................................

RING, STOPPER.............................................................................................................

R/B

R/B

OP

OP

OP

OP

OP

R/B

R/B

R/B

F-13

Ref.No.


REAR CUSHION

2006 CBR1000RR

Block No.

Reqd.No.

1

1

(1)

(1)

(1)

(1)

(1)

1

1

1

1

1

1

2

1

4

1

1

1

1

1

1

1

(1)

(1)

(1)

(1)

(1)

1

1

1

1

1

1

2

1

4

1

1

1

1

1

SBKJSB


3-44

13

14

15

16

17

18

19

20

21

22

23

•

•

•

•

•

90114-NL9-C00

90115-NL9-C00

90116-NL9-C00

90117-NL9-C00

90118-NL9-C00

91071-MY1-005

91074-KZ4-B01

91074-MBR-722

91262-KV3-831

91351-KZ3-731

91351-MAC-671

BOLT, FLANGE 10X75 ..................................................................................................

BOLT, FLANGE 10X112 ................................................................................................

BOLT, FLANGE 10X56 ..................................................................................................

BOLT, FLANGE 10X135 ................................................................................................

BOLT, FLANGE 10X78 ..................................................................................................



BEARING, SPHERICAL, 10 ............................................................................................

DUST SEAL, 17X24X5 (ARAI).........................................................................................

DUST SEAL, RR. CUSHION PIVOT ................................................................................

DUST SEAL, 16X26X3....................................................................................................

Made of titanium

Made of titanium

Made of titanium

Made of titanium

Made of titanium

F-13

Ref.No.


REAR CUSHION

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

6

1

1

6

1

3

1

1

1

1

1

6

1

1

6

1

3

SBKJSB


3-45

1

2

3

4

5

6

7

•

•

•

•

06324-NL9-C00

31500-GEE-007

32401-NL9-720

32410-NL9-720

32601-NL9-C00

35850-MT4-000

35856-KBH-000

BATTERY & CABLE SET...............................................................................................

BATTERY YTZ7S ............................................................................................................

CABLE, BATT-ST MAG.................................................................................................

CABLE, STARTER MOTOR...........................................................................................

CABLE, BAT EARTH......................................................................................................

SW ASSY, START MAG .................................................................................................

RUBBER, SHOCK...........................................................................................................

F-14

Ref.No.


BATTERY / CABLE SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

SBKJSB


3-46

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

06321-NL9-C00

17556-MEL-300

18357-KA4-710

31517-NL9-910

32100-MEL-R30

32100-NL9-C00

35130-NL6-000

35160-MBW-Y02

35200-MEL-R10

35400-NL9-000

37100-MEL-R10

38500-GC7-612

38520-NL9-000

38770-MEL-R31

38770-NL9-C00

38770-NL9-C30

38770-NL9-C40

38771-NL9-C00

38880-NL3-750

38880-NL9-C00

HARNESS SET ..............................................................................................................

FILM A, PROTECTOR ....................................................................................................

COLLAR, SILENCER ......................................................................................................

SPONGE, MT 3MM.......................................................................................................

HARNESS, WIRE...........................................................................................................

HARNESS, WIRE...........................................................................................................

SW ASSY, ST ENGINE STOP.......................................................................................

SENSOR ASSY, BANK ANGLE ....................................................................................

SW ASSY, WINKER ......................................................................................................

REGISTER COMP ..........................................................................................................

METER ASSY, COMB ...................................................................................................

RELAY ASSY, START .....................................................................................................

STAY, RELAY ................................................................................................................

UNIT ASSY PGM-FI/IGN...............................................................................................

UNIT ASSY PGM-FI/IGN(SBK) .....................................................................................

UNIT ASSY PGM-FI/IGN(JSB) .....................................................................................

UNIT ASSY PGM-FI/IGN(JSB ENDU) ..........................................................................

CD-ROM, PGM-FI/IGN ..................................................................................................

UNIT ASSY, SERIALI/F .................................................................................................

UNIT ASSY, SERIALI/F .................................................................................................

R/B

R/B

R/B

R/B

R/B

RC232C TYPE

USB TYPE

F-15

Ref.No.


WIRE HARNESS SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

2

1

1

1

1

1

1

1

1

1

1

1

-

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

-

-

1

1

1

SBKJSB


3-47

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

•

•

•

•

64502-NL9-C00

64503-NL9-000

90620-SB2-003

90649-SC2-003

91080-NL6-300

91081-ND4-750

91406-657-671

93891-04022-07

94001-06000-0S

94050-04000

94101-03000

94103-06000

94591-27000

95012-11001

96001-06022-00

STAY, ECU ....................................................................................................................

STAY, CATCH TANK.....................................................................................................

BAND, WIRE HARN .......................................................................................................

BAND, HARNESS...........................................................................................................

POP RIVET 3.2X9.2 .......................................................................................................

BLIND RIVET 3.2X8.......................................................................................................

CLIP, WIRE HARNESS ...................................................................................................

SCREW-WASHER, 4X22 ................................................................................................

NUT, HEX, 6MM ............................................................................................................

NUT, FLANGE, 4MM......................................................................................................

WASHER, PLAIN, 3MM .................................................................................................

WASHER, PLAIN , 6MM ................................................................................................

CLIP, 2X70......................................................................................................................

BAND A, BATTRY...........................................................................................................

BOLT, FLANGE, SH, 6X22 .............................................................................................

For `06 ECU

SAME `04, `05 STD

F-15

Ref.No.


WIRE HARNESS SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

2

2

1

2

2

2

2

2

1

1

2

1

1

1

1

2

2

1

2

2

2

2

2

1

1

2

SBKJSB


3-48

1

2

3

4

5

6

7

8

9

10

11

•

•

•

•

•

•

06322-NL9-700

32200-NL9-700

32430-NL6-700

33100-MR7-003

33150-MR7-003

33700-NL6-700

34901-MC7-602

38500-GC7-612

38520-NL9-000

91081-ND4-750

94101-03000

LIGHT HARNESS SET....................................................................................................

SUB HARNESS, LIGHT..................................................................................................

SUB HARNESS, TAIL LIGHT .........................................................................................

HEAD LIGHT ASSY., R ....................................................................................................

HEAD LIGHT ASSY., L ....................................................................................................

TAIL LIGHT ASSY (LED) ................................................................................................

BULB, HEADLIGHT (H4) .................................................................................................

RELAY ASSY., START .....................................................................................................

STAY, RELAY .................................................................................................................

BLIND RIVET 3.2X8........................................................................................................

WASHER, PLAIN, 3MM ..................................................................................................

OP

F-16

Ref.No.


LIGHT SET(ENDURANCE)

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

(1)

2

2

1

1

2

2

1

1

1

1

(1)

2

2

1

1

2

2

SBKJSB


3-49

1

2

3

4

5

6

7

8

•

•

•

•

•

•

06382-NL9-C00

30401-GB6-000

38200-NL9-000

38300-NL9-000

38410-NL9-000

38411-NL9-000

38510-NL9-C00

96001-06010-00

QUICK SHIFTER SET ....................................................................................................

CUSHION, CDI UNIT ......................................................................................................

SENSOR ASSY, Q/SHIFT..............................................................................................

UNIT ASSY, Q/SHIFT....................................................................................................

CD-ROM, Q/SHIFTER ....................................................................................................

USB CABLE ...................................................................................................................

STAY, P/S UNIT ............................................................................................................

BOLT, FLANGE, SH 6X10 ..............................................................................................

F-17

Ref.No.


QUICK SHIFTER SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

2

SBKJSB


3-50

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

•

•

•

•

•

06502-NL9-910

18422-KR3-870

18423-KR3-600

19014-KEA-003

31510-NL9-910

31517-NL9-910

50240-NL9-910

52430-NL9-910

94101-10000

96001-06012-00

96300-06012-00

96300-08025-00

96300-10025-00

96300-10028-00

95012-12001

SEAT TAIL SET .............................................................................................................

RUBBER A, MUFF MOUNT ...........................................................................................

COLLAR, MUFF MOUNT ...............................................................................................

SET, NUT........................................................................................................................

TRAY COMP, BATTERY................................................................................................

SPONGE, MT 3MM.......................................................................................................

SEAT RAIL COMP .........................................................................................................

PLATE, RR. CHSH ADJ .................................................................................................

WASHER, PLAIN, 10MM ...............................................................................................

BOLT, FLANGE, SH, 6X12 .............................................................................................

BOLT, FLANGE, DR, 6X12 .............................................................................................

BOLT, FLANGE, DR, 8X25 .............................................................................................

BOLT, FLANGE, DR, 10X25 ...........................................................................................

BOLT, FLANGE, DR, 10X28 ...........................................................................................

BAND B1, BATTERY ......................................................................................................

F-18

Ref.No.


SEAT RAIL SET

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

1

1

1

1

1

1

2

5

1

2

2

1

1

1

1

1

1

1

1

1

1

2

5

1

2

2

1

SBKJSB


3-51

1

2

3

4

5

6

7

8

•

•

•

•

•

•

•

•

19100-MEL-R31

19502-MEL-R30

19503-MEL-R30

19505-KS6-700

19505-MEL-R30

19507-MEL-R30

19510-NL9-C00

19516-GAG-003

RADIATOR COMP .........................................................................................................

HOSE, OIL/C A...............................................................................................................

HOSE, RADIATOR L......................................................................................................

CLAMP A, WATER HOSE .............................................................................................

HOSE, OIL/C B...............................................................................................................

PIPE, OIL/C.....................................................................................................................

HOSE R, RADIATOR .....................................................................................................

CLAMP, HOSE 30-37.....................................................................................................

R/B

R/B

R/B

R/B

R/B

R/B

OP, Integrated rubber hose (between Thermostat and Filler-neck)

R/B

F-19

Ref.No.


RADIATOR

2006 CBR1000RR

Block No.

Reqd.No.

1

1

1

4

1

1

(1)

2

1

1

1

4

1

1

(1)

2

SBKJSB


3-52

2006-CBR1000RR PART NO. INDEX

Block Block Block Block

E- 1-0

E- 1E- 1-2E- 1-1E- 5E-11E- 9E- 9F- 9F- 7F- 8E- 1-2F-11F-11E- 2E-10E- 8E- 8E- 3-1E- 4E- 4E- 2E- 6F-15F-16F-14F-17F-12F-12

F- 5F- 5F-18F- 1F-10

E- 4E- 2E- 5E- 5E- 5E- 6E- 6E- 5E- 6E- 5

E- 4E- 1E- 1-2E- 1E- 1-2E- 1E- 1-2E- 1E- 1-2

06443-NL9-00006443-NL9-72006502-NL9-91006531-NL3-75006552-NL9-000

11000-NL9-C0011211-NL9-C0011321-NL9-C0011325-NL9-C0011329-NL9-C00

11331-NL9-C0011333-MEL-00011335-NL9-C0011392-NL9-710

12208-PR3-00012251-NL9-000

12252-NL9-000

12253-NL9-000

12256-NL9-710

E- 1-1E- 1-1E- 1-1E- 1-1E- 1-1E- 7E- 7E- 7E- 7E- 7E- 7E- 7E- 7E- 7E- 7E- 7E- 7E- 7E- 7E- 4E- 4E- 4

E- 1-2E- 1E- 1-2E- 1-2E- 1E- 1-2

13101-NL9-C0013112-NL9-00013121-NL9-00313131-NL9-00313141-NL9-00313214-NL9-71113215-NL9-71113216-NL9-71113217-NL9-71113218-NL9-71113219-NL9-71113220-NL9-71113314-NL9-71113315-NL9-71113316-NL9-71113317-NL9-71113318-NL9-71113319-NL9-71113320-NL9-71113331-NL9-C0013332-NL9-C0013333-NL9-C00

14110-MEL-R1014110-NL9-C0014110-NL9-C3014210-MEL-R1014210-NL9-C0014210-NL9-C30

E- 1E- 1-2E- 1E- 1-2E- 1E- 1-2E- 1E- 1-1E- 1-1E- 1E- 1

E- 2E- 2E- 2E- 6E- 6E- 2E- 2

E- 9

F- 9F- 9E- 9E- 9

14312-NL9-C0014321-NL9-71014321-NL9-C0014321-NL9-C3014401-NL9-C0114405-MEE-00014520-NL9-C0014711-NL9-C0014721-NL9-00014751-NL9-C0014761-NL9-C00

15134-NL9-71015150-NL9-C0015220-NL9-71015611-NF4-90015611-NL9-C0015661-MAS-00315662-NL9-C00

16514-NL9-710

17210-MEL-R1117211-NL9-00017215-NL9-71017215-NL9-C30

Part No. Part No. Part No. Part No.

00X32-NL9-C00

06110-NL9-C0006110-NL9-C3006120-NL9-C0006130-NL9-C0006150-NL9-90006160-NL9-71006160-NL9-C3006172-NL9-71006175-NL9-91006176-NL5-70006180-NL9-71006183-NL9-C0006183-NL9-C3006190-NL9-C0006195-NL3-65006210-NL9-C0006220-NL9-00006230-NL9-C0006240-NL9-C0006250-NL9-C0006260-NL9-C0006270-NL9-C0006321-NL9-C0006322-NL9-70006324-NL9-C0006382-NL9-C0006405-NL9-00006405-NL9-C40


3-53



E- 9E- 9E- 9E- 9E- 9E- 9F- 9E-10E-10F- 8F- 7F- 7F- 8F- 7F- 8F- 7F-15F- 8F- 8F- 7E-10F-10F- 1F- 1

F-11F-11F-11F-11F-11

F-11F-11F-11F-11F-11F-11F-11F-11F-11F- 9F-10F-11F-11F-11F-11F-11F-15F-11F-11F-11F-11F-11F-11F-11F-18F-18F-11

F-18F-11

18301-NL9-C0018302-NL9-C0018303-NL9-C0018304-NL9-C0018305-NL9-91018306-NL9-91018307-NL9-91018309-NL9-C0018311-NL9-91018315-GAG-750

18320-NL9-00018325-MEL-01318336-NL9-00018339-NL9-91018345-MBT-61018357-KA4-71018370-NL9-71018370-NL9-91018375-NL9-00018380-NL9-71018380-NL9-91018421-MN5-00018421-NL9-C00 18422-KR3-87018423-KR3-60018424-MN5-000

19014-KEA-00319051-KA3-830

F-10F-11F-19F- 9F- 9E- 2F-19F-19E-11E-10F-10F-19F-19F-19F-19E-11E-11F-19

E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1

19052-KV0-00019052-MAC-68019100-MEL-R3119120-NL9-00019170-NL9-00019225-MCS-00319502-MEL-R3019503-MEL-R3019504-KY1-00319505-KS6-700

19505-MEL-R3019507-MEL-R3019510-NL9-C0019511-NL3-65019512-NL8-70019516-GAG-003

22121-NL9-C0022122-NL9-71022123-NL9-71022124-NL9-71022131-NL9-71022132-NL9-71022134-NL6-00022135-NL6-00022136-NL6-00022137-NL6-00022138-NL6-000

E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1E- 3E- 3-1E- 3-1F- 1

E- 8E- 8-1E- 8-1E- 8-1E- 8-1E- 8-1E- 2E- 8E- 8E- 8-1E- 8-1

22139-NL6-00022172-NL9-71022173-NL9-71022201-MEN-67022201-NL9-C00 22201-NL9-C30

22321-MT3-00022321-NL9-71022322-NL9-71022325-MEL-00022326-MEL-00022351-NL9-71022353-NL9-71022401-MEL-R3022441-NL9-71022850-MBB-D4022900-NL6-000

23211-MEL-R1023211-NL9-71023212-NL9-71023212-NL9-91023213-NL9-71023213-NL9-91023219-NL9-C0023220-MEL-R1023421-MEL-R1023422-NL9-71023423-NL9-710


17216-NL9-71017216-NL9-C3017217-NL9-71017217-NL9-C3017218-NL9-710 17218-NL9-C30 17251-NL9-71017460-MEL-R1017470-MEL-R1017504-NH3-30317510-NL9-91017515-NX5-770

17521-NX4-680

17522-NF5-69017556-MEL-30017560-NL5-70017565-NL5-70017574-NL9-91017724-102-700

17910-NL9-00017920-NL9-000

18291-NL9-00018293-MCA-A2018293-NL9-91018295-NL9-91018300-NL9-C00


3-54



E- 8E- 8-1E- 8E- 8E- 8-1E- 8-1E- 8E- 8-1E- 8-1E- 8-1E- 8E- 8-1E- 8-1E- 8E- 8-1E- 8E- 8-1E- 8-1E- 8-1E- 8E- 8-1E- 8-1E- 8-1E- 8E- 8-1E- 8-1E- 8-1E- 8E- 8-1E- 8-1E- 8E- 8

E- 8E- 8

F-17

E- 5E- 5E- 5F-14F-18F- 7F-10F-15F-18E- 1E- 1-2

F-15F-15F-16F-14F-14F-16F-14

23802-NL6-70023803-NL6-700

30401-GB6-000

31110-NL9-00031110-NL9-C0131120-NL9-C0031500-GEE-00731510-NL9-91031517-NL9-000

31517-NL9-910

31910-NL3-620

32100-MEL-R3032100-NL9-C0032200-NL9-70032401-NL9-72032410-NL9-72032430-NL6-70032601-NL9-C00

F-16F-16F-16

F-16

F-15F-15F-15F-15F-14F-14

F-15E- 8

F-17F-17F-17F-17F-15F-16F-17

33100-MR7-00333150-MR7-00333700-NL6-700

34901-MC7-602

35130-NL6-00035160-MBW-Y0235200-MEL-R1035400-NL9-00035850-MT4-00035856-KBH-000

37100-MEL-R1037700-MEL-R10

38200-NL9-00038300-NL9-00038410-NL9-00038411-NL9-00038500-GC7-612

38510-NL9-C00

F-15F-16F-15F-15F-15F-15F-15F-15F-15

F- 6F- 6-1F-12F-12F-12F- 6F- 6-1F-12

F- 6F- 6-1F- 6F- 6-1F- 6F- 6-1F- 6F- 6-1F- 6

38520-NL9-00038520-NL9-00038770-MEL-R3138770-NL9-C0038770-NL9-C3038770-NL9-C4038771-NL9-C0038880-NL3-75038880-NL9-C00

40540-MAS-005

40542-NL9-00040543-NL9-00040544-NL9-00040545-MAS-005

40545-NL9-000

41201-MCJ-000

41201-MCJ-670

41201-MCJ-J00

41201-MEL-J20

41238-NL6-700


23431-MEL-R1023432-NL9-71023441-MEL-R1023442-MS2-61023442-NL9-71023443-NL9-71023451-MEL-R1023452-NL9-71023453-NL9-71023454-NL9-71023461-MEL-R1023462-NL9-71023463-NL9-71023481-MEL-R1023482-NL9-71023491-MEL-R1023491-NL9-C0023492-NL9-71023493-NL9-71023501-MEL-R1023501-NL9-C0023502-NL9-71023503-NL9-71023511-MEL-R1023511-NL9-C0023512-NL9-71023513-NL9-71023521-MEL-R1023521-NL9-C0023522-NL9-71023801-MCJ-75023801-NL6-700


3-55



F- 6-1F- 6F- 6-1F- 6F- 6-1F- 6F- 6-1F- 6F- 6-1F- 6F- 6-1F-12

F-12F-12F-12F-12F-12F-12F-12F- 6F- 6-1F- 6F- 6-1F- 6F- 6-1F-12F- 6F- 6-1F- 6

F- 6-1F- 6-1F- 6F- 6-1F- 6F- 6-1F- 6-1F- 6F- 6-1F- 6F- 6-1F- 5F- 6F- 6-1

F- 4F- 4F- 4F- 4F- 4F- 4F- 4F- 4F- 4F- 4F- 4F- 6F- 6-1

42611-NL9-C4042621-NL6-000

42624-NL6-00042624-NL9-C4042631-NL9-C4042633-NL6-003

42650-NL9-71042650-NL9-C4042753-ML7-004

43100-NL5-70143105-NL5-70043105-NL9-C00 43105-NL9-C3043105-NL9-C4043106-NL9-C3043106-NL9-C4043110-MEL-R3143110-NL9-00043110-NL9-C4043112-MEL-D2143121-NL6-00043121-NL6-700

F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5F- 5

F- 3F- 3F- 3F- 3F- 3F- 3F- 3

44301-NL6-00044301-NL9-72044303-NL9-00044303-NL9-72044304-NL9-00044304-NL9-72044305-NL9-00044306-NL9-72044311-NL6-00044311-NL9-71044311-NL9-72044311-NL9-81044311-NL9-91044601-NL6-00044601-NL9-71044602-NL6-00044603-NL6-00044620-NL6-01044620-NL9-71044622-NL0-81044650-NL9-710

45105-NL3-92145105-NL9-00045105-NL9-80145105-NL9-90045105-NL9-C0045106-NL3-92145120-NL3-901

F- 3F- 3F- 3F- 3F- 3F- 3F- 3F- 3F- 3F- 3F- 3F- 3F- 3

F-18E- 6

F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 2

45120-NL9-80145120-NL9-C3045130-NL9-00045132-NL9-72045220-NL3-90145220-NL9-80145220-NL9-C3045250-NL5-80045250-NL9-72045250-NL9-91045250-NL9-C4045500-NL5-70145520-NL5-701

50240-NL9-91050252-GC4-830

51400-MEL-R3151401-MEL-R1151401-NL9-71151401-NL9-90151402-NL9-71151402-NL9-90151403-MEL-R3151404-MEL-R1151406-MEL-R1151410-MEL-R1151412-MEL-003


41239-NL6-700

41240-NL6-700

41241-NL6-700

41242-NL6-700

41243-NL6-700

41405-HA7-670

42301-NL9-00042302-NL6-70042304-NL9-00042304-NL9-C4042305-MEL-R1042306-MEL-R1042307-MEL-R1042311-NL9-000

42311-NL9-C40

42312-NL6-000

42314-NL9-00042601-NL9-710

42609-NL6-000


3-56



F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 2F- 3F- 2F- 2

F-12F-12F-12F-12F-12F-12F-13F-13F-13F-13F-13F-13F-13

F-13F-18F- 2F-13F-13F-13F-13F-13F-13F-13F-13F-13F-13F-13F-13

F- 1F- 3F- 1F- 1F- 2F- 2

F-10F-10F-10F-10

52430-MEL-R1052430-NL9-91052442-KA3-71152460-MEL-R1052460-NL9-C0052460-NL9-C1052463-KZ4-B0052463-MEE-00052464-MEE-00052466-MEE-00052467-MEE-00052470-MEL-R1052470-NL9-C0052470-NL9-C1052472-MEL-000

53141-MT7-00053160-NL5-70153167-KV3-70153168-KV3-70153700-NL9-00353702-MCJ-751

55200-NL9-00055210-NL9-00055220-NL9-00055231-NL9-000

F-13

F- 1F-15F-15

F-12F-10

F-11

F- 6F- 6-1

E- 5

E- 4F- 3

58487-KA4-831

64501-NL9-91064502-NL9-C0064503-NL9-000

81312-GJ5-00081351-124-830

84706-415-000

87000-NL6-000

89030-NL9-711

90001-MFA-D0090003-MC7-000

F- 6E- 4E- 5E- 8E- 4E- 4E- 5E- 6E- 5E- 6E- 5E- 2E- 6E- 4E- 2E- 4E- 4E- 4E- 4E- 4E- 4E- 4E- 2E- 2E- 1E- 1-2F- 8F- 4F- 3F-10F- 7F-12

90003-NL5-00090003-NL9-00090004-492-01090004-MFA-D0090005-MZA-00090006-GHB-640

90006-GHB-660

90006-GHB-67090006-GHB-680

90010-MEL-00090012-MEL-R10 90015-MEL-00390016-MEL-00390017-MFA-D0090018-MFA-D0090019-MB0-00090019-MFA-D0090048-MEL-D0090052-NL9-71090081-NX4-00090082-NL9-710

90101-NL5-00090101-NL6-00090104-GT8-60090104-KR3-67090105-MM4-00090105-MY9-000


51414-MAZ-00351415-MAZ-00351423-MCJ-75151425-MEL-D2151430-MEL-D2151447-KA4-71151450-MEL-R1151451-MCJ-75151453-MEL-R1151455-MW4-00351456-MCJ-75151490-MEJ-00351496-MCJ-75151497-NL9-72051500-MEL-R3151525-MEL-D21

52100-MEL-R3052102-MEL-00052143-MEL-00052144-MEL-00052157-NL3-65052170-MEL-00052400-MEL-R3152401-MEL-R1152401-NL9-90152402-NL9-90152403-NL9-90152404-NL9-90152405-NL9-901


3-57



F-12F- 2F- 9F-13F-13F-13F-13F-11F-13F- 6-1F- 6F- 6-1F- 2F-12F- 3E- 4F-11F-11F- 5F- 5F-12F-12F- 6F- 6-1E- 8E- 5E- 4E-11E- 1E- 1-2F- 6F- 6-1

F- 5F-10F- 5F- 5F- 5F- 5F- 5F-12E- 3-1E- 3-1E- 3-1E- 3-1E- 3-1F-11E- 3-1E- 3-1F-15F-15F- 6F- 6-1E- 4

E- 4E- 4E- 4E- 4F- 6F- 6-1F- 6F- 6-1

90503-NL6-00090525-030-00090525-NL9-00090525-NL9-720 90526-NL9-00090526-NL9-72090535-NL9-72090536-NL9-00090567-NL6-00090568-NL6-00090569-NL6-00090570-NL6-00090571-NL6-00090572-MEL-00090572-NL6-00090573-NL6-00090620-SB2-00390649-SC2-00390651-ML0-731

90701-MV9-670

91001-MEL-00391002-MEL-00391003-MEL-00391004-MEL-00391051-NL6-000

91052-NL6-003

F-12F-12F- 6-1F- 5F-12F-13F-13F-13F-15F-15F-16E- 4E- 4F-12F-12F- 2F- 2F- 2F- 2F- 2F-13E- 6F-13F-13F- 8F-15

F-11F-12F- 1

91053-MCJ-00391053-MCJ-75191053-NL6-70191057-NL9-71091071-MCJ-00391071-MY1-00591074-KZ4-B0191074-MBR-72291080-NL6-30091081-ND4-750

91201-MEL-01391202-MEL-00391252-MCF-00391253-MCF-00391254-MEJ-00391255-MCJ-75191256-MCJ-75191257-MCJ-75191258-GF4-00391262-KV3-83191307-425-03091351-KZ3-73191351-MAC-67191353-NL5-70191406-657-671

93404-06025-0093500-05020-0A93500-05020-0G

F-12F-12F- 8F-15F- 9

F-15F-15F-12F-10F-11F-11F-15F-16F-12F-18F-15F-11E- 2F-12F-15

F- 3F- 3F-15F-18F-11E- 5

93500-05035-0A93500-05050-0A93600-04010-0A93891-04022-0793891-05012-18

94001-06000-0S94050-0400094050-0500094050-06000

94050-0800094101-03000

94101-0670094101-1000094103-0600094103-0870094109-1200094520-4500094591-27000

95002-40850-0895003-11015-6095012-1100195012-1200195701-06010-0095701-06012-00


90106-NL9-00090109-MR7-00090110-147-00090114-NL9-C0090115-NL9-C0090116-NL9-C0090117-NL9-C0090118-MBV-00090118-NL9-C0090119-NL9-C4090120-NL6-300

90126-MR7-00390130-MCJ-75090131-NL9-72090133-MEL-00090201-GCC-C5090202-MBB-00090305-NL6-00090305-NL9-72090308-NL9-00090309-357-00090309-KF0-003

90402-NL6-00090405-MCA-78090447-KE1-00090454-ZV1-00090488-425-000

90501-NL6-000


3-58



E- 3-1F-11E- 4F-11

F-17E- 2F-12F-18F-12F-10F-15E-10F-18F-18F-18F-18F-11E- 5F- 7


95701-06016-0095701-08020-0095701-08040-0095701-08055-00

96001-06010-0096001-06012-00

96001-06016-0796001-06020-0096001-06022-0096205-14012 96300-06012-0096300-08025-0096300-10025-0096300-10028-0096400-08045-0796600-06028-0096600-08025-00


00. introduction p1 - yoshimura, hrc, valtermoto, arro - 2006 cbr1000rr … · radiator kit...

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