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CBR600RR 2005 HONDA Service Repair Manual

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🏷️ Basic Information Identification Make: Honda Model: CBR600RR Year: 2005 Codes Chassis Code: PC37 Engine Code: PC37E 👋 Introduction Market Position Market Segment: Supersport Motorcycle Target Audience: Performance-oriented riders, track...
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类型: Motorcycle
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斯库: 500393
CBR600RR 2005 HONDA Service Repair ManualCBR600RR 2005 HONDA Service Repair ManualCBR600RR 2005 HONDA Service Repair ManualCBR600RR 2005 HONDA Service Repair Manual
🏷️ Basic Information
Identification
Make:
Honda
Model:
CBR600RR
Year:
2005
Codes
Chassis Code:
PC37
Engine Code:
PC37E
👋 Introduction
Market Position
Market Segment:
Supersport Motorcycle
Target Audience:
Performance-oriented riders, track day enthusiasts, experienced motorcycle mechanics.
Competitive Analysis
Key Competitors:
Yamaha R6, Kawasaki ZX-6R, Suzuki GSX-R600.
Key Features
Vehicle Selling Points:
Lightweight chassis, high-revving engine, advanced suspension, sharp handling, racing heritage.
Manual Value Proposition
Cost Savings:
Enables owners to perform DIY maintenance and repairs, saving on labor costs.
Professional Standard:
Identical manual used by authorized Honda service technicians.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
PDF Download
Page Count
Page Count:
532
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine disassembly, assembly, inspection, tuning, lubrication, cooling.
Fuel System:
Fuel injection system, throttle body, injectors, fuel pump, pressure regulator, evaporative emission control system.
Lubrication System:
Oil pump, oil filter, oil passages, oil pressure testing.
Electrical System:
Ignition system, charging system, starting system, lighting system, wiring diagrams, sensors, ECUs.
Chassis Systems:
Frame, suspension (front and rear), steering, wheels, tires, brakes (front and rear), bodywork, seat.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, chain adjustment, brake fluid flush, coolant flush, spark plug replacement, air filter service.
Tune Up Procedures:
Idle speed adjustment, ignition timing checks, fuel system diagnostics, emissions control checks.
Diagnostic Procedures:
Troubleshooting guides for common malfunctions, symptom-based diagnostics, component testing.
Repair Procedures:
Step-by-step instructions for engine rebuilds, transmission overhaul, suspension component replacement, electrical system repairs.
Technical Depth
Depth Of Coverage:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers detailed disassembly, assembly, and diagnostic procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Printable:
Yes
Compatibility:
Windows/Mac
Requirements:
Adobe PDF Reader
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
90-degree V4, Four-stroke, DOHC, 16-valve
Displacement:
599 cc
Bore X Stroke:
65 mm x 45.2 mm
Compression Ratio:
12.0:1
Performance
Horsepower:
Approx. 117 hp @ 13,000 rpm (at crankshaft, specifications may vary by region)
Torque:
Approx. 6.5 kgf·m @ 11,000 rpm (at crankshaft, specifications may vary by region)
Fuel System
Fuel Delivery:
Programmed Fuel Injection (PGM-FI) with dual injectors per cylinder.
Fuel Type:
Unleaded gasoline, minimum 91 octane rating.
Lubrication System
Oil Type Recommendation:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Cooling System
Cooling Type:
Liquid-cooled
Coolant Type Recommendation:
Honda Genuine Motorcycle Coolant or equivalent 50/50 mixture of antifreeze and distilled water.
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh, multi-plate wet clutch.
Features
Final Drive:
Sealed chain drive (520).
Clutch Type:
Hydraulically operated, multi-plate wet clutch.
📐 Dimensions
Exterior
Overall Length:
2035 mm
Overall Width:
695 mm
Overall Height:
1115 mm
Wheelbase:
1395 mm
Weights
Dry Weight:
169 kg
Wet Weight:
193 kg (approx., with all fluids)
Fuel Tank Capacity:
18 Liters (including 3.4L reserve)
Seat Height:
825 mm
🛡️ Safety Features
Ratings
Safety Features Overview:
Focuses on rider control and handling. No electronic rider aids like ABS or traction control on this model.
Active Features
Braking System:
Dual hydraulic disc front brakes (310mm discs, 4-piston calipers), Single hydraulic disc rear brake (220mm disc, 2-piston caliper).
Suspension Damping Adjustment:
Adjustable front forks (preload, compression, rebound damping), adjustable rear shock absorber (preload, compression, rebound damping).
Passive Features
Lighting:
Dual Halogen headlights, LED tail light.
Tires Front:
120/70ZR17 M/C (58W)
Tires Rear:
180/55ZR17 M/C (73W)
💡 Technology Features
Infotainment
Infotainment Systems:
N/A (Performance-focused supersport, not equipped with infotainment features).
Driver Assistance
Rider Aids:
No electronic rider aids such as ABS or traction control. Pure mechanical feedback and rider skill are paramount.
Instrumentation
Instrument Cluster:
Analog tachometer, digital speedometer, LCD multi-function display (odometer, trip meters, fuel gauge, clock, engine temperature).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months.
Air Filter Inspection Interval:
Every 6,000 km (3,700 miles).
Spark Plug Replacement Interval:
Every 12,000 km (7,500 miles) or 12 months.
Coolant Replacement Interval:
Every 24,000 km (15,000 miles) or 24 months.
Brake Fluid Replacement Interval:
Every 24,000 km (15,000 miles) or 24 months.
Fluid Specifications
Engine Oil Capacity:
3.2 Liters (3.4 US qt) without filter change; 3.5 Liters (3.7 US qt) with filter change.
Brake Fluid Spec:
DOT 4
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals (dependent on riding style and maintenance).
Potential Electrical Gremlins:
While generally reliable, some owners have reported intermittent issues with the stator or rectifier under high mileage or specific conditions. The manual details testing procedures.
Engine Performance Quirks:
Some units may experience a slight flat spot in the powerband around 5,000-7,000 RPM, often addressable through ECU remapping or adjustments covered in advanced sections of the manual.
📚 Vehicle History
Brand Heritage
Honda Motorcycle Division:
Honda's renowned reputation for engineering excellence, reliability, and performance in the motorcycle industry.
Model Evolution
Cbr600Rr Genesis:
The CBR600RR line, introduced in 2003, was Honda's answer to the growing demand for 600cc supersport machines, directly competing with Yamaha's YZF-R6 and Suzuki's GSX-R600.
2005 Updates:
The 2005 model saw significant refinements, including updated internal engine components for improved power delivery, revised suspension settings for better feedback and control, and subtle aerodynamic tweaks.
Production
Manufacturing Location:
Primarily manufactured in Japan.
Production Years For Pc37 Chassis:
2003-2006
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
Consistently praised by motorcycle publications for its sharp handling, accessible powerband, and excellent build quality for its class.
Track Performance:
The CBR600RR platform has a strong racing pedigree, with numerous championships won in various supersport racing series worldwide.
Ratings
Reliability Reputation:
Honda is known for its robust engineering and reliability, and the CBR600RR generally upholds this reputation with proper maintenance.
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