2005-2006 CBR600RR Repair Manual

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🏷️ Basic Information Identification Make: Honda Model: CBR600RR Year: 2005 Model Variant: CBR600RR (PC37/PC40) Manual Product Name: 2005-2006 Honda CBR600RR Repair Manual 👋 Introduction Market Position Motorcycle Segment: Supersport, middleweight...

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Type: Motorcycle

Vendor:

Sku: 426682

Tags: 2005 2006 CBR Series CBR600RR Honda Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Honda

Model:

CBR600RR

Year:

Model Variant:

CBR600RR (PC37/PC40)

Manual Product Name:

2005-2006 Honda CBR600RR Repair Manual

👋 Introduction

Market Position

Motorcycle Segment:

Supersport, middleweight sportbike

Target Audience:

Performance-oriented riders, track day enthusiasts, experienced DIY mechanics

Competitive Analysis

Key Competitors:

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

Key Features

Vehicle Design Philosophy:

Mass-centralization, aerodynamic efficiency, razor-sharp handling

Manual Value Proposition:

Empowers owners and technicians with factory-level knowledge for maintenance and repair, reducing reliance on expensive dealer services.

📋 Manual Details

Coverage Areas

Engine:

Complete engine overhaul, tuning, and diagnostics

Transmission:

Clutch, gearbox, shift mechanism repair and adjustment

Chassis:

Frame, suspension, steering, wheels, and tires

Electrical System:

Ignition, charging, lighting, starting, ECU, sensors, wiring diagrams

Fuel System:

Fuel injection, injectors, fuel pump, pressure regulator

Brakes:

Hydraulic system, calipers, master cylinders, discs, pads, ABS (if equipped)

Cooling System:

Radiator, fan, thermostat, coolant flow

Exhaust System:

Muffler, catalytic converter, pipework

Bodywork And Fairings:

Disassembly, reassembly, and repair of all body panels

Troubleshooting:

Diagnostic procedures for common and uncommon issues

Maintenance:

Scheduled maintenance, inspections, adjustments

Torque Specifications:

All critical fastener torque values

Wiring Diagrams:

Comprehensive electrical system schematics

Page Count

Total Pages:

Estimated 400-500 pages (typical for a comprehensive repair manual)

Manual Type

Type:

Factory-authorized Repair Manual / Service Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (CBR600RR, 599cc inline-four), transmission, clutch, fuel injection (PGM-FI)

Chassis And Suspension:

Front telescopic fork (H.M.A.S. type), rear Pro-Link single shock absorber, steering system

Brakes And Wheels:

Front dual hydraulic discs (310mm), rear single hydraulic disc (220mm), wheel specifications, tire pressures

Electrical And Ignition:

Ignition system (DC-CDI), charging system (alternator, regulator/rectifier), lighting, instrumentation, ECU, wiring harness

Fuel And Emission Control:

Fuel pump, injectors, throttle body assembly, exhaust gas recirculation (EGR), evaporative emission control (EVAP)

Cooling And Lubrication:

Radiator, fan, water pump, oil pump, lubrication circuit

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning/replacement

Engine Rebuild:

Top-end overhaul (cylinder head, valves), bottom-end overhaul (crankshaft, pistons, connecting rods)

Fuel System Service:

Fuel injector cleaning, fuel pump replacement, fuel pressure testing

Brake System Maintenance:

Brake fluid flush and bleed, pad and disc replacement, master cylinder service

Suspension Adjustment And Repair:

Fork oil change, shock absorber service, linkage lubrication

Electrical Troubleshooting:

Diagnostic steps for common electrical faults, wiring harness repair

Bodywork Disassembly And Reassembly:

Fairing removal and installation, seat removal, tank removal

Diagnostic Fault Codes:

Interpretation and clearing of H.I.S.S. (Honda Ignition Security System) and ECU fault codes

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine and chassis rebuilds)

Diagnostic Capability:

Advanced, including troubleshooting charts and component testing procedures

Rebuild Instructions:

Detailed step-by-step instructions with exploded diagrams for major component overhauls

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Fully searchable text content

Printable:

Printable pages for workshop use

Print Quality

Image Resolution:

High-resolution images and diagrams suitable for detailed viewing

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, DOHC, 16-valve

Displacement:

599 cc

Bore X Stroke:

67 mm x 42.5 mm

Compression Ratio:

12.0:1

Fuel Delivery:

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

Ignition System:

Digital DC-CDI with electronic advance

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 117 hp @ 13,000 rpm (crank)

Torque:

Approx. 6.4 kgf·m (63 Nm) @ 11,000 rpm (crank)

Fuel System

Fuel Tank Capacity:

18 liters (4.7 US gal)

Recommended Fuel:

Unleaded gasoline, 91 octane or higher

🔧 Transmission

Standard

Transmission Type:

6-speed sequential manual

Clutch Type:

Wet, multi-plate

Features

Gear Ratios:

Refer to manual for specific gear ratios (e.g., 1st: 2.750, 2nd: 2.000, 3rd: 1.667, 4th: 1.375, 5th: 1.214, 6th: 1.071)

Final Drive:

O-ring sealed chain, 525 size

📐 Dimensions

Exterior

Length:

2,005 mm

Width:

685 mm

Height:

1,115 mm

Wheelbase:

1,395 mm

Ground Clearance:

130 mm

Seat Height:

820 mm

Weights

Dry Weight:

163 kg (approx.)

Curb Weight:

186 kg (approx., with all fluids)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle, not subjected to automotive crash testing standards)

Active Features

Braking System:

Linked Fuel Injection (LFI) and unified braking system (UBS) were not features of this model. Independent front and rear braking.

Hiss System:

Honda Ignition Security System (HISS) for anti-theft

Passive Features

Lighting:

Multi-reflector halogen headlights, LED taillight

💡 Technology Features

Infotainment

Instrumentation:

Digital LCD multi-function display: speedometer, tachometer, odometer, trip meters, clock, fuel gauge, engine temperature, H.I.S.S. indicator, neutral indicator.

Driver Assistance

ABS Availability:

ABS was an optional feature for certain model years/regions, typically designated by 'ABS' in the model name.

Connectivity

ECU Diagnostics:

Honda's PGM-FI system can be diagnosed using a Honda diagnostic tool or compatible aftermarket scan tool, providing access to real-time data and fault codes.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km or 12 months, whichever comes first

Oil Filter Replacement:

Every 12,000 km or 24 months

Air Filter Cleaning:

Every 6,000 km, replacement as needed

Chain Maintenance:

Lubricate every 1,000 km or after riding in wet conditions; adjust tension every 12,000 km or as needed

Spark Plug Replacement:

Every 24,000 km

Coolant Replacement:

Every 24,000 km or 24 months

Fluid Specifications

Engine Oil:

SAE 10W-40 API SG or higher, JASO MA certified

Engine Oil Capacity:

3.0 liters (without filter), 3.2 liters (with filter)

Coolant:

Honda Motorcycle Coolant or equivalent (50/50 mix of ethylene glycol and distilled water)

Brake Fluid:

DOT 4, Honda DOT4 Brake Fluid recommended

Fork Oil:

SHOWA SS-02 (SAE 5W equivalent) or equivalent

Fork Oil Capacity:

466 mL (16.1 US oz)

Known Issues

Common Wear Items:

Chain and sprockets, brake pads, tires, clutch plates (depending on usage)

Potential Electrical Faults:

Regulator/rectifier failure (overheating), intermittent headlight issues (less common)

Engine Specific Concerns:

Some early models might exhibit slightly more wear on valve seats if not maintained diligently. Clutch slave cylinder seal leaks can occur.

📚 Vehicle History

Brand Heritage

Honda Motorsports:

Honda has a long and successful history in motorcycle racing, including MotoGP and World Superbike championships, influencing the design and technology of models like the CBR600RR.

Model Evolution

Cbr600Rr Lineage:

The CBR600RR evolved from the CBR600F and CBR600RR-based CBR600F4i, focusing on track performance and agility. The 2003-2006 generation (PC37/PC40) introduced significant chassis and engine improvements.

Generation Differences 05 06:

The 2005 model received minor styling updates, including different graphics and colors. Mechanically, it remained largely similar to the 2003-2004 model. The 2006 model continued this lineage.

Production

Manufacturing Origin:

Japan

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

Consistently praised by motorcycle publications for its handling, engine performance, and track capability during its production years.

Ratings

Performance Benchmark:

Considered a benchmark for 600cc supersport performance and handling for its generation.