2001-2006 CBR600F4i Service Repair Manual (Highly Detailed FSM Preview)

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UGS: 157479

Mots clés: 2001 2002 2003 2004 2005 2006 CBR Series CBR600F4i Featured Honda Motorcycle Motorcycles

Variantes de produits

Description

This manual covers the Honda CBR600F4i, a distinguished sportbike produced from 2001 to 2006. Known for its high-revving, liquid-cooled, inline four-cylinder engine with Programmed Fuel Injection (PGM-FI), the F4i offers a potent blend of performance and advanced engineering. Its lightweight aluminum twin-spar frame, coupled with adjustable front forks and a rear shock absorber, provides exceptional handling and stability, making it a favorite in the supersport class. The F4i is celebrated for its sporty ergonomics, impressive braking performance, and Honda's renowned reliability and build quality, positioning it as a competitive and enjoyable machine for both spirited riding and daily use. This comprehensive workshop service and repair manual, presented in English and formatted as a printable document, provides detailed guidance for maintaining and repairing the Honda CBR600F4i. It encompasses all essential systems, including the engine, drivetrain, chassis, suspension, brakes, and electrical components. The manual details routine maintenance schedules, fluid specifications, repair and rebuild procedures, troubleshooting diagnostics, and essential technical data such as torque specifications and part diagrams. Its thorough coverage ensures that owners, mechanics, and technicians have the necessary information to keep the CBR600F4i in optimal condition, mirroring the depth of information found in official dealer manuals.

🏷️ Basic Information

Identification

Make:

Honda

Model:

CBR600F4i

Model Nickname:

Vehicle Type:

Sportbike / Motorcycle

Generation

Generation:

Second Generation (F4i variant)

Codes

Internal Model Code:

PC37 (often referred to, though specific variants may differ slightly)

👋 Introduction

Market Position

Market Segment:

High-performance sportbike, popular in the supersport class for its balance of power, handling, and technological advancement.

Competitive Analysis

Key Competitors:

Yamaha YZF-R6, Suzuki GSX-R600, Kawasaki ZX-6R.

Key Features

Headline Features:

Fuel injection, high-revving inline-four engine, advanced chassis and suspension, sporty ergonomics, excellent braking performance.

Value Proposition

Dealer Equivalence:

Contains the same information and level of detail as the official Honda dealer workshop manuals.

Benefit To Owner

Cost Savings:

Enables owners to perform their own maintenance and repairs, significantly reducing labor costs compared to dealership service.

📋 Manual Details

Coverage Areas

Production Model Years:

2001, 2002, 2003, 2004, 2005, 2006

Page Count

Total Pages:

Manual Type

Manual Type:

Official Full Workshop Service and Repair Manual (FSM - Factory Service Manual)

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine teardown and rebuild, cylinder head, valves, lubrication system, cooling system, fuel system (programmed fuel injection - PGM-FI), crankshaft, piston, cylinder.

Drivetrain:

Clutch, gearshift linkage, transmission, alternator, starter clutch, primary reduction gear.

Chassis And Suspension:

Frame, body panels, exhaust system, front wheel, front suspension (forks), steering, rear wheel, rear suspension (swingarm).

Brakes:

Hydraulic brake system (front and rear), brake pads, rotors.

Electrical:

Battery, charging system, ignition system, electric starter, lights, meters, switches, wiring diagram, stator, rectifier, coils.

Fuel System:

Programmed Fuel Injection (PGM-FI) system, fuel pump, injectors, throttle body.

Procedures Included

Maintenance:

Routine maintenance schedules, fluid changes (oil, coolant), filter replacements, chain adjustment, brake system checks, tire pressure, battery care.

Repair And Rebuild:

Complete engine rebuild, transmission overhaul, suspension fork rebuild, brake system repair, electrical component replacement, body panel repair and installation.

Troubleshooting:

Diagnostic procedures for common problems, error code interpretation (if applicable), electrical system diagnostics, engine performance issues.

Technical Specifications:

Detailed torque specifications for all fasteners, valve clearance specifications, engine component measurements, fluid capacities, electrical system data.

Part Diagrams:

Illustrations and diagrams of all major components and sub-assemblies, aiding in identification and reassembly.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and chassis teardown and rebuild, mirroring dealer-level service.

📊 Manual Specifications

File Format

File Type:

Compatibility:

All versions of Windows & Mac

Requirements:

Adobe PDF Reader

Print Quality

Printability:

All pages are printable

Binding Type

Binding:

Digital Download (Printable PDF)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, DOHC, 16-valve, inline four-cylinder

Displacement:

599 cc

Bore X Stroke:

67.0 mm x 42.5 mm

Compression Ratio:

12.0:1

Performance

Horsepower Estimated:

Approx. 110-115 hp (at crankshaft)

Torque Estimated:

Approx. 47-50 lb-ft (at crankshaft)

Fuel System

Fuel Delivery:

Programmed Fuel Injection (PGM-FI) with dual injectors per cylinder.

Fuel Type:

Unleaded premium gasoline (91 octane or higher recommended)

Lubrication System

Oil Type Recommendation:

API SG or SH, JASO MA certified 10W-40 motorcycle oil (specific viscosity may vary by temperature).

Cooling System

Coolant Type:

Honda Motorcycle Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitor).

🔧 Transmission

Standard

Transmission Type:

6-speed, constant mesh

Final Drive:

Sealed O-ring chain

Features

Clutch Type:

Wet, multi-plate, diaphragm spring

📐 Dimensions

Exterior

Overall Length:

Approx. 80.5 inches (2045 mm)

Overall Width:

Approx. 28.0 inches (710 mm)

Overall Height:

Approx. 45.3 inches (1150 mm)

Weights

Dry Weight:

Approx. 368 lbs (167 kg)

Wet Weight:

Approx. 403 lbs (183 kg)

Weight Distribution:

Designed for optimal balance and handling.

🛡️ Safety Features

Ratings

Safety Certifications:

Meets or exceeds relevant safety standards for motorcycles.

Active Features

Braking System:

Dual front 296mm discs with four-piston calipers, single rear 240mm disc with single-piston caliper. Highly effective hydraulic system.

Suspension:

Adjustable front forks and rear shock absorber contribute to stability and control.

Passive Features

Frame Construction:

Lightweight yet strong aluminum twin-spar frame.

Lighting:

Halogen headlight for enhanced visibility.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital speedometer, analog tachometer, odometer, trip meters, fuel gauge, coolant temperature gauge, clock, indicator lights.

Driver Assistance

Engine Management:

PGM-FI (Programmed Fuel Injection) with ECU control for optimal fuel delivery and ignition timing.

Connectivity

Diagnostics:

On-board diagnostics facilitated by dealer tools, covered in detail within the service manual.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,700 miles (6,000 km) or 12 months, whichever comes first (refer to manual for precise interval).

Valve Clearance Check:

Typically at 15,000 miles (24,000 km) or as indicated in the manual.

Coolant Change Interval:

Refer to manual, often every 2 years or specific mileage.

Fluid Specifications

Engine Oil Capacity:

Approx. 3.4 US qt (3.2 L) with filter change.

Coolant Capacity:

Approx. 2.0 US qt (1.9 L).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Chain and sprockets, brake pads, tires, clutch plates (under heavy use), regulator/rectifier (though less common on this generation than some others).

Potential Problems:

Fuel injectors can become clogged with age or poor fuel quality, potential for stator or rectifier failure over time, though generally reliable.

Technical Data

Spark Plug Type:

NGK CR9EH-9 or equivalent (refer to manual for exact spec).

Tire Pressure Front:

Typically 36 psi (2.5 bar) (refer to manual for exact spec).

Tire Pressure Rear:

Typically 42 psi (2.9 bar) (refer to manual for exact spec).

📚 Vehicle History

Brand Heritage

Manufacturer:

Honda Motor Co., Ltd.

Brand Reputation:

Renowned for engineering excellence, reliability, and innovation in motorcycle manufacturing.

Model Evolution

Predecessor:

CBR600F3, CBR600F4.

Key Advancement F4I:

Introduction of Programmed Fuel Injection (PGM-FI), stiffer chassis, revised styling, and improved aerodynamics over the F4 model.

Production

Production Period:

The F4i variant was produced from 2001 to 2006, before being superseded by the CBR600RR for the track-focused segment and a revised CBR600F model in some markets.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

Consistently praised by motorcycle journalists and riders for its balanced performance, handling characteristics, and value in the 600cc supersport class during its production run.