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SHOP MANUAL

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CBR1000RR/RA/S1/S2

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CBR1000RR/RA/S1/S2H
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HOW TO USE THIS MANUAL

A Few Words About Safety
HOW TO USE THIS MANUAL

Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.

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Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also

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damage the vehicle or create an unsafe condition.

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This manual describes the proper methods and procedures for performing service, maintenance and repairs. Some procedures
require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service

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procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of
the vehicle.
If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend

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that you do not use replacement parts of inferior quality.
For Your Customer’s Safety

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Proper service and maintenance are essential to the customer’s safety and the reliability of the vehicle. Any error or oversight while
servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others.

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Improper service or repairs can create an unsafe

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condition that can cause your customer to be
seriously hurt or killed.

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Follow the procedures and precautions in this
manual and other service materials carefully.

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For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
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practices (e.g., Hot parts–wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt to perform the procedures described in this manual.
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Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
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Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
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Follow the procedures and precautions in this

manual carefully.
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Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
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using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
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required to perform the tasks safely and completely.

• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around
pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
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burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
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• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack,
make sure that it is always securely supported. Use jack stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
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• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
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• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
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Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

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HOW TO USE THIS MANUAL

How To Use This Manual
This manual describes the service procedures for the CBR1000RR/RA/S1/S2.
Sections 1 and 4 apply to the whole vehicle. Section 3 illustrates procedures for removal/installation of components that may be

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required to perform service described in the following sections.
Section 5 through 22 describe parts of the motorcycle, grouped according to location.

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Follow the Maintenance Schedule recommendations to ensure that the vehicle is in peak operating condition.

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Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in

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period.
Find the section you want on this page, then turn to the table of contents on the first page of the section.
Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent

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pages give detailed procedure.
Refer to the troubleshooting in each section according to the malfunction or symptom. In case of an engine trouble, refer to PGM-FI
section troubleshooting first.

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Your safety, and the safety of others, is very important. To help you make informed decisions we have provided safety

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messages and other information throughout this manual. Of course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.

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You must use your own good judgement.
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle

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• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:

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You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
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You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
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You CAN be HURT if you don’t follow instructions.

• Instructions – how to service this vehicle correctly and safely.
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As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environment.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
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Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
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INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda MOTORCYCLES, MOTOR SCOOTERS OR ATVS.
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© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
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Date of Issue: December, 2016

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HOW TO USE THIS MANUAL

SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.

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Replace the part(s) with new one(s) before assembly.

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Use the recommend engine oil, unless otherwise specified.

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Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).

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Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

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Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).

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Example:
• Molykote® BR-2 plus manufactured by Dow Corning U.S.A.
• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan

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Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent).
Example:

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• Molykote® G-n Paste manufactured by Dow Corning U.S.A.
• Pro Honda M-77 Assembly Paste (Moly) (U.S.A. only)
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• Rocol ASP manufactured by Rocol Limited, U.K.
• Rocol Paste manufactured by Sumico Lubricant, Japan
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Use silicone grease.

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Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
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Apply sealant.
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Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
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Use fork or suspension fluid.

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CONTENTS
GENERAL INFORMATION 1

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FRAME/BODY PANELS/EXHAUST SYSTEM 2

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MAINTENANCE 3

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PGM-FI SYSTEM 4
IGNITION SYSTEM 5

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ELECTRIC STARTER 6
FUEL SYSTEM

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ENGINE/ELECTRICAL

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COOLING SYSTEM 8

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LUBRICATION SYSTEM 9

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CYLINDER HEAD/VALVES 10

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CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE 11
ALTERNATOR 12
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CRANKCASE/TRANSMISSION/BALANCER 13
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CRANKSHAFT/PISTON/CYLINDER 14
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ENGINE REMOVAL/INSTALLATION 15
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FRONT WHEEL/SUSPENSION/STEERING 16
CHASSIS

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REAR WHEEL/SUSPENSION 17
HYDRAULIC BRAKE 18
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ANTI-LOCK BRAKE SYSTEM (ABS) (Except CBR1000RR) 19

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BATTERY/CHARGING SYSTEM 20
ELECTRICAL
FRAME

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LIGHTS/METERS/SWITCHES 21
IMMOBILIZER SYSTEM (HISS)
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22
WIRING DIAGRAM 23
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MEMO

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1. GENERAL INFORMATION

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SERVICE RULES ··········································1-2 SPECIAL TOOL LIST ································· 1-21

MODEL IDENTIFICATION ····························1-3 CABLE & HARNESS ROUTING················· 1-23

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SPECIFICATIONS ·········································1-5 EMISSION CONTROL SYSTEMS ·············· 1-52

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TORQUE VALUES ······································1-13 TECHNICAL FEATURES···························· 1-55

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LUBRICATION & SEAL POINTS················1-19
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GENERAL INFORMATION
SERVICE RULES
GENERAL INFORMATION

1. Use Honda genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design
specifications may cause damage to the motorcycle.

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2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English

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fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.

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5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in

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incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-23).

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9. Do not bend or twist control cables. Damaged control cables will not operates smoothly and may stick or bind.

ABBREVIATION

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Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term

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ABS Anti-lock Brake System
APS Accelerator Position Sensor

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CKP sensor Crankshaft Position sensor
CMP sensor Camshaft Position sensor

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DLC Data Link Connector
DTC Diagnostic Trouble Code
ECM Engine Control Module

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ECT sensor Engine Coolant Temperature sensor
EEPROM Electrically Erasable Programmable Read Only Memory
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ECV Exhaust Control Valve
ECV POT Exhaust Control Valve Potentiometer
EGCA Exhaust Gas Control Actuator
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EOP switch Engine Oil Pressure switch

EVAP Evaporative Emission
HESD Honda Electronic Steering Damper
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HISS Honda Ignition Security System

IAT sensor Intake Air Temperature sensor
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IMU Inertia Measurement Unit

MAP sensor Manifold Absolute Pressure sensor
MCS Motorcycle Communication System
MIL Malfunction Indicator Lamp
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PAIR Pulsed Secondary Air Injection

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PGM-FI Programmed Fuel Injection

SCS short connector Service Check Signal short connector
SCU Suspension Control Unit
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TBW Throttle By Wire

TP sensor Throttle Position sensor
VS sensor Vehicle Speed sensor
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DESTINATION CODES
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Throughout this manual, the following codes are used to identify individual types for each region.
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DESTINATION CODE REGION

IIBR Brazil
CH, IICH China
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ED, IIED European direct sales (Includes France, Turkey, South Africa and Ukraine)
FO, IIFO Taiwan
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GS, IIGS Gulf countries

II-IN Indonesia
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KO, IIKO Korea

RU, IIRU Russia
TH, IITH Thailand
U, IIU Australia, New Zealand

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GENERAL INFORMATION
MODEL IDENTIFICATION
CBR1000RR/RA CBR1000S1/S2

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SERIAL NUMBERS/LABELS

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The Vehicle Identification Number (VIN) [1] is stamped on the The engine serial number [1] is stamped on the front side of

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right side of the steering head as shown. the lower crankcase.
[1]

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[1]
The throttle body identification numbers [1] are stamped on The color label [1] (CH/ED/KO/RU/U only) is attached on the
the front lower surfaces of the throttle body. left air duct cover. When ordering color-coded parts, always
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specify the designated color code.

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