2004 Cbr600rr Service Manual Pdf
Justina Ky
Attached is a free bike service manual for a Honda CBR600RR '03 Service Manual. Some of these service manuals are PDFs, some are compressed files so you may need third party software to open the manual.
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The Cyclepedia Honda CBR600RR online service manual features detailed full-color photographs and wiring diagrams, complete specifications with step-by-step procedures performed and written by a seasoned Honda dealer trained technician.
The 2007 and newer CBR600RR sport bikes are fantastic machines that have won many races and magazine shootouts. Keep yours running in excellent condition with the easy to use Cyclepedia Online Honda 2007- 2012 CBR600RR Service Manual. This instantly available manual covers everything from crankshaft inspection, to fork rebuild, and everything in between. If you ever have any questions on how to use the manual, or performing the procedures on your Honda CBR600RR, Cyclepedia.com provides expert tech support to assist you.
Air Filter Servicing, Spark Plugs, Engine Idle Speed, Throttle Free Play, Clutch Cable Adjustment, Chain Adjustment, Engine Oil, Tires, Brake Bleeding, Compression Check, Valve Clearance Inspection, Valve Clearance Adjustment
Cylinder Head Cover Removal, Camshaft Removal, Camshaft Installation, Cylinder Head Cover Installation, Stator Coil and Flywheel, Clutch, Right Side Engine Components, Oil Cooler, Engine Removal, Oil Pan, Cylinder Head, Crankcase Splitting, Crankshaft and Connecting Rods, Pistons and Cylinders, Transmission, Crankcase Assembly, Engine Installation
Having an issue and looking to see if anyone has had this problem before. If I am out riding for 30 minutes or longer and the bike is warm (over 200 degrees) I get some hesitation or surging when I whack the throttle all the way open. It doesn't happen at 80% throttle, only wide open.
On Friday I rode from downtown Columbus, OH up riverside (stop and go) for 30 minutes and ate lunch. On the way up I was running my high beams and the last couple of miles of the trip it would fall on its face at full throttle, then surge forward, then fall on its face again. On the way back to work, using the same route with my highbeam off it didn't do it at all. It has done this with a nearly empty tank and a full tank. There appears to be some scaling in the tank, but this only occurs when the bike is hot and I get no warning lights (FI etc) when it happens.
I checked the battery at autozone and it registered 12.5V under load and it registered the CCA as 1800. That indicated to me that perhaps there was a problem with a cell. I replaced the original battery this weekend with a new Yuasa and it still happened. This time is was at less than full throttle and once I pulled off to check it the idle was swinging between 1000 and 2000. I shut it off for less than 10 minutes and it didn't happen again during the next hour of riding.
I put Techron in the tank and ran the crap out of it as I have been commuting with the bike. It as never exceeded 228 degrees while riding and this only happens when it is over 200 degrees. In cooler weather or at night this never happens. The intermittent nature of this seems to indicate to me that some sensor is having an issue. I hope its not TPS. Could it be the MAP sensor?
Ya, I was going to say spark or fuel. When you get really frustrated after the fuel additives don't work, pull the plugs and see if they are black or white, see if you are getting too much fuel or not enough.
When I'm doing a lot of stop and go riding I don't use my high beams. There is a reason, but I'm not intelligent enough to expain. If you want a good solid explanation of why not to use your high beams talk to one of the mechanics at HNW.
I have never had a problem riding with my highbeams. I always have the highs on so I can be seen by cages. Dustin, you will have to enlighten me sometime. But back on topic could be battery or stator going out. Just my $.02
Hope its not the stator so will probably replace the battery this weekend. Anybody have suggestions on the best place to get a battery around the east side of Columbus? I think Batteries plus has them in stock and one store is close. Any other ideas?
Took the battery to autozone today and it tested bad. Actually tested at 12.5 volts but cold cranking amps were listed as like 1700+. Since the battery is 5 years old I just went ahead and replaced it.
5 years old... eek... actually, 12.5 is low for a 12 volt 6 cell battery. It should have around 14.5-14.8 new. My memory says something like 2.45 volt per cell. That would be 14.7 volt total. Charging system output is usually 14.5 volt.
Yep. Actually the bike has never cut out and idled smooth when warm etc. Only issue was WOT and, it seems, high beams while hot. Bike actually has run well except for this issue, and i am surprised considering that state of the battery. Here's to hoping that the battery was it.
The service manual I downloaded says anything below 12.4 is no beuno so I went ahead and bought the battery today. I will update this thread if this issue comes back. I mean, it's a honda right? Shouldn't have any issues with only 5000 miles on it. Especially since the 2 previous POs didn't butcher the thing.
Ok looks like the battery didn't fix it. Put 70 miles on today and only happened once on Taylor Rd on the east side of town. 45 mph speed limit and running a constant speed. Hit the throttle a little bit and it stuttered again. Pulled into the Kroger on Taylor and Main and sat for a few minutes. Fired it back up and it didn't happen again.
Will look at the plugs soon and will be dumping some fuel system clearner through it and then running the crap out of it. Have been taking Broad Street to downtown as my way to work. Maybe it needs to be run harder??
Make sure the plugs are the correct type/heat range. Looks like maybe fuel problem now, dirty carb or injectors. Be sure to re-check the voltage in the battery, and make sure it's not running down, from some other electrical problem. Is your can stock? Or swapped out?
Bike has 5500 miles on it and runs great except for when it is hot and I am running in stop and go traffic. Then only sometimes does it do this. I think it needs have the crap run out of it as I have been commuting with it for a couple weeks now and going slow. Not enough time above 12k rpm. The plugs should be original but I will definitely check them.
The can is a Leo Vince slip on. This bike appears to have a competition werkes fender eliminator, and some aftermarket turn signals. Is the stock tailight on a 2004 clear with red lights? That may be aftermarket, along with the slip on but otherwise the bike appears to be very stock.
Yes it has to be fuel or spark. However, when it happens sporadically I tend to lean towards a sensor that would cause issues like the TPS. Just took the bike back out and no issues at all. This happens when the bike is hot and running at lower speeds
I am just kinda thinking out loud on this as it happens infrequently. The idle weirdness that occurred once I had the issue today is something I haven't experienced before and makes me think that some sensor involved in the idle and throttle position is related to this somehow.
Agreed, intermittent is probably an electronic sensor. Maybe one or more is a potentiometer type position sensor or switch, or something, and cleaning it would work. Throttle position sensor. Ignition cutout devices (kickstand). I've downloaded your service manual, but haven't looked at it yet. I wonder how many copies of the cbr600rr manual I got now...
The 4th generation was a major overhaul in 2013, though a lot of the engine (and thus the maintenance) stayed the same. Sales dwindled over the years because the market cooled somewhat and more riders opted for naked bikes with handlebars. Times change.
Motorcycle and car nut. Chief editor at motofomo.com. Always reading about motorcycles and cars, looking at deals, and poring over manuals and forums, even for things I don't own. Sharing what I learn here.
Maintenance Schedules is an obsessively curated catalogue of maintenance schedules, recommended parts for everyday service (including oil, filters, spark plugs, and lubricants), and tips for service (adjusting chain, tire pressures, valve clearances, and so on) for motorcycles, cars, and trucks. Read more in the about section.
All the data here is entered manually. It's a labor of love. Many tables are manually copied from old PDFs or print manuals. We work hard to avoid errors, but if you've found a mistake, please tell us or leave a comment below.
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