Honda Cbr600rr Swingarm Dust Seal

Axle

Place the axle in V-blocks and measure the runout. Actual runout is 1/2 the total indicator reading.

Total Indicator RunoutHonda Cbr Sprocket Washer Nut

WASHER [rCM

AXLE NUT

Worn Sprocket Measur

AXLE

DRIVE CHAIN

ADJUSTING PLATE

SIDE COLLARS

Wheel bearing

Turn the inner race of each bearing with your finger. Bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub.

Replace the Hemove and discard the bearings if the races do not wheef bearings in turn smoothly and quietly, or if they fit luosely in the Pairs, hub.

Wheel rim runout

Check the rim runout by placing the wheel in a true-ing stand.

Spin the wheel slowly and read the runout using a dial indicator.

Actual runout is 1/2 the total indicator reading.

SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in)

Driven sprocket

Check the condition of the final driven sprocket teeth.

Replace the sprocket it worn or damaged.

• If the final driven sprocket requires replacement, inspect the drive chain and drive sprocket.

• Never install a new drive chain on a worn sprocket or a worn chain on new sprockets. Both chain and sprocket must be in good condition or the replacement chain or sprocket will wear rapidly.

Wheel balance

See page 13-11 for wheel balance.

DISASSEMBLY

Remove the bolts and brake disc. Remove the right dust seal.

BRAKE DISC

BOLTS

DUST SEAL

If you dmnaaem- Remove the driven flange assembly from the left bic the driven wheel hub. fiange. loosen the driven sprocket nuts before removing the driven flange from the wheel hub.

Remove the wheel rubber dampers. Remove the O-ring.

Driven flange bearing removal

Loosen the driven sprocket nuts.

Remove the driven flange from the wheel hub, then remove the driven sprocket nuts and sprocket.

Remove the dust seal.

07749 0010000

Drive the driven flange collar out from the driven flange bearing.

TOOLS:

Driver 07749-0010000

Attachment 24 x 26 mm 07746 0010700

Pilot, 20 mm 07746-0040500

07749 0010000

RUBBER DAMPERS

DRIVER

HEAD

DRIVER

HEAD

Drive the driven flange bearing out using the special tools.

DRIVER

TOOLS: Driver

Attachment, 37 x 40 mm Pilot, 25 mm

07749-0010000 07746-0010200 07746-0040600

Wheel bearing removal

Install the bearing remover head into the bearing. From the opposite side install the bearing remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing.

TOOLS:

Bearing remover head, 20 mm 07746-0050600 Bearing remover shaft 07746-0050100

DRIVER

07749 0010000

ASSEMBLY

RIGHT WHEEL BEARING (6204UU)

O-HING

DRIVEN FLANGE

DRIVEN FLANGE BEARING <27 X 52 X 23.8)

DRIVEN FLANGE COLLAR RIGHT DUST SEAL

LEFT DUST SEAL

DRIVEN SPROCKET RUBBER DAMPERS

DISTANCE COLLAR

LEFT WHEEL BEARI (6204UU)

BRAKE DISC

14-6

Never install The Wheel bearing installation old hearings. Once The bearings have been removed, the bearing must be replaced witn new ones

Drive in a new right bearing squarely.

TOOLS: Driver

Attachment, 42 x 47 mm Pilot, 20 mm

07749-0010000 07746-0010300 07746-0040500

Install the distance collar

Drive in the left side bearing using the same tools.

Press the driven flange collar in the new driven flange bearing until it is fully seated.

TOOLS:

Driver 07749-0010000

Attachment, 28 x 30 mm 07746-1870100

Pilot, 20 mm 07746-0040500

DRIVEN FLANGE COLLAR

DRIVEN FLANGE BEARING

Driven flange bearing installation

Drive the new driven flange hearing into the driven flange using the special tools.

TOOLS:

Driver 07749-0010000

Attachment 52 x 55 mm 07746-0010400

Pilot, 20 mm 07746-0040500

Install the wheel rubber dampers into the wheel hub. Apply oil to the new 0 ring and install it into the groove of the wheel hub.

DRIVER

ATTACHMENT/PILOT

DRIVER

DRIVER

Cbr 929rr Damper Rubber Wheel

RUBBER DAMPERS

O-RING

Install the driven flange assembly into the left wheel hub.

If the driven sprocket was removed, install the driven sprocket and tighten the nuts.

Apply grease to the dust seal lips, then install it into the driven flange.

Install the brake disc with the mark facing out. Install and tighten the new bolts to the specified torque.

INSTALLATION

Apply grease to the side collar inside and grooves. Install the side collars.

Install the rear brake caliper bracket onto the guide of the swingarm.

CALIPER BRACKET l am*

Cbr 250r Chain Spraket Instalation

DUS I SI Al

DRIVEN SPROCKET

NUTS

Lipped Brake Disc

BRAKE DISC

BOLTS

DUST SEAL ■ ROTATING DIRECTION MARK

Re careful not to Place The rear wheel into the swingarm. damage the brake Install the drive chain over the driven sprocket. pads, install the rear axle from the left side.

Install the washer and axle nut. Adjust the drive chain slack (page 3-19). Tighten the axle nut to the specified torque. TORQUE: 93 N-m (9.5 kgf-m, 69 lbf-ft)

SHOCK ABSORBER

REMOVAL

Remove the seat (page 2 2).

Support the motorcycle using a hoist or an equivalent.

Loosen the shock absorber reservoir band screw and remove the reservoir from the seat rail.

BAND SCREW

BAND SCREW

RFSERVOIR

Remove the shock absorber lower mounting bolt/nut.

AXLE

DRIVE CHAIN

ADJUSTING PLATE

WASHER

AXLE NIJT

LOWER MOUNTIN

Remove the shock absorber upper mounting bolt/nut and the shock absorber.

SHOCK ABSORBER

SHOCK ABSORBER

UPPER MOUNTING BOLT/NUT

INSPECTION

Check the damper unit, reservoir hose and reservoir for leakage or other damage.

Check the upper joint bushing for wear or damage. Replace the shock absorber assembly if necessary.

Remove the lower joint pivot collar.

Check the needle bearing, pivot collar and dust seals for wear or damage.

DAMPER

DAMPER

NEEDLE BEARING REPLACEMENT

Remove the pivot collar and dust seals.

Press the needle hearing out of the shock absorber lower mount using the special tools.

TOOLS:

Driver 04949-3710001 or

07946-MJ00100 Attachment, 22 x 24 mm 07746-0010800

Pilot, 17 mm 07746-0040400

DUST

DUST

PIVOT COLLAR

Press the needle bearing into the lower mount with the marked side facing out.

Press a new needle hearing into the lower mount SO the needle bearing surface is 7.8 - 8.2 mm (0.31 - 0.32 in) lower from the end of the lower mount using the same tools.

Apply grease to the new dust seal lips and install them into the lower mount. Install the pivot collar.

SHOCK ABSORBER DISPOSAL PROCEDURE

Center punch the reservoir tank end to mark the drilling point.

Wrap the damper unit inside a plastic bag. Support the reservoir tank in a vise as shown. Through the open end of the bag, insert a drill motor with a sharp 2-3 mm (5/64 - 1/8 in ) drill hit.

• Do not use a dull drill bit which could cause a buildup of excessive heat and pressure inside the damper, leading to explosion and severe personal injury.

• The shock absorber contains nitrogen gas and oil under high pressure. Do not drill any farther down the damper case than the measurement given above, or you may drill into the oil chamber; oil escaping under high pressure may cause serious personal injury.

• Always wear eye protection to avoid getting metal shaving In your eye when the gas pressure is released. The plastic bag is only intended to shield you from the escaping gas.

Hold the bag around the drill motor and briefly run the drill motor inside the bag; this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when your start.

Install Cbr 600 F4i Idle Screw

NOTICE

DUST

DUST

PIVOT COLLAR

INSTALLATION

Install the shock absorber into the frame with the reserve tank outlet facing to the left. Install the upper and lower mounting boll/nut. Tighten the upper mounting nut to the specified torque.

Tighten the lower mounting nut to the specified torque.

Install the reservoir into the reservoir hand. Tighten the band screw securely.

Install the removed parts in the reverse order of removal.

SUSPENSION LINKAGE

REMOVAL

Support the motorcycle using a hoist or equivalent.

Remove the following:

- Shock absorber lower mounting bolt/nut Shock link plate-to-swingarm bolt/nut

- Shock link plate-to-shock link bolt/nut

- Shock link plates

SHOCK ABSORBER

UPPER MOUNTING BOLT/NUT

Install Cbr 600 F4i Idle Screw

LOWER MOUNTING BOL"

BAND SCREW

RLSrnVOIR

BAND SCREW

RLSrnVOIR

LINK PLATE BOLT/NUT

LINK PLATES

If the shock link cannot he removed, support the motorcycle securcly with a hoist or equivalent and loosen the shock link brocket nuts to get the clearance between the shock link and brackets ipage 7-4).

Shock link-to-brackct bolt/nut Shock link

SHOCK LINK

SHOCK LINK

Or f

SHOCK LINK BOLT/NUT

INSPECTION

Chock that the suspension linkage components tor damage, replace any damaged components.

SHOCK LINK BEARING REPLACEMENT

Remove the pivot collar and dust seals.

Press the needle bearing out of the shock link using the special tools.

TOOLS: Driver

Attachment. 22 x 24 mm Pilot 17 mm

04949-3710001 or 07946-M J00100 07746-0010800 07746-0040400

DRIVER

ATTACHMENT/PILOT

fJress the noodle bearing into the shock link with the marked side facing out.

Press a new needle bearing into the shock link so the needle bearing surface is 5.2 - 5.7 mm (0.20 0.22 in) lower from the end of the shock link using the same tools.

PIVOT COLLAR

DUST

DUST

PIVOT COLLAR

Apply grease to the new dust seal lips and install them into the shock link. Install the pivot collar.

INSTALLATION

Install the shock link into the link brackets. Install the shock link socket bolt from the left side. Install the nut.

DRIVE CHAIN CASE

Install Cbr 600 F4i Idle Screw

Install the shock link plates with the arrow facing the left and front side.

Install the shock link plate bolt from the right side. Install the nut.

Tighten the link bracket nuts if they were loosened (page 7-17).

Tighten the suspension linkage nuts to the specified torque.

SWINGARM

REMOVAL

Remove the rear wheel (page 14-3) Remove the two screws and drive chain ease.

DRIVE CHAIN CASE

SHOCK LINK

SHOCK LINK BOLT/NUT

SHOCK LINK

Remove the bolts ond brake hose guides.

Remove the shock link plate-to-swingarm bolt/nut.

Remove the swingarm pivot nut and washer. Remove the swingarm pivot bolt.

Loosen the left pivot adjusting bolt lock nut using the special tool.

TOOL:

Lock nut wrench 07908-4690003

PIVOT NUT/WASHER

PIVOT NUT/WASHER

Bilder Decoupage Bad

BRAKE HOSE GUIDES

BOLTS

SHOCK LINK PLATE-TO-SWINGARM BOLTS/NUT

Loosen the right pivot adjusting bolt lock nut using the special tool

TOOL:

Lock nut wrench 07908-4690003

Loosen the left pivot adjusting bolt, then remove swingarrn.

DISASSEMBLY/INSPECTION

Remove the three SH bolts and drive chain slider. Check the drive chain slider for wear or damage.

Cr80 Swingarm Seals Inner Outer

Remove the pivot collar and dust seals from the left swingarm pivot.

Check the dust seals and collars for damage or fatigue.

Remove the pivot distance collar and dust seals from the swingarm right pivot.

Check the dust seals and collars for damage or fatigue.

Turn the inner race of the right pivot bearings with your finger.

The bearings should turn smoothly and quietly. Also chcck that the bearing outer race fits tightly in the swingarm pivot.

Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the swingarm pivot.

SNAP RING

PIVOT BEARING REPLACEMENT

Remove the snap ring.

SNAP RING

DUST

PIVOT DISTANCE

DUST

PIVOT DISTANCE

/ BEARING

Remove the right pivot radial ball bearing using the special tools.

TOOLS:

Bearing remover handle Bearing remover head Remover weight

07936-3710100 0793G-3710600 07741-0010201

Press the right pivot needle bearing out using the special tools and a hydraulic press.

TOOLS: Driver

Attachment, 34 mm or

Driver shaft Attachment, 34 mm

07949-3710001 07ZMD-MBW0100

07946-MJ00100 07ZMD-MBW0100

DRIVER SHAFT

DRIVER SHAFT

ATTACHMENT

Pack a new needle bearing with grease. Press the needle bearing into the right swingarm pivot until it seats using the special tools and a hydraulic press.

TOOLS: Driver

Attachment, 37 mm Pilot, 28 mm

07749-0010000

07ZMD-MBW0200

07746-0041100

DRIVER

DRIVER

ATTACHMENT

Press in the radial ball bearing using the special tools and a hydraulic press.

TOOLS: Driver

Attachment, 32 x 35 mm Pilot, 20 mm or

Driver

Attachment, 37 mm Pilot, 20 mm

07749-0010000 07746-0010100 07746-0040500

07749-0010000

07ZMD-MBW0200

07746-0040500

DRIVER

DRIVER

ATTACHMENT/PILOT

ATTACHMENT/PILOT

SNAP RING

Install the snap ring into the groove securely.

SNAP RING

Remove the left pivot needle bearing from the swingarm pivot using the special tools.

TOOLS:

Driver

Attachment, 37 mm or

Driver shaft Attachment, 37 mm or

Driver shaft

Needle bearing remover

07949-3710001 07ZMD-MBW0200

07946-MJ00100 07ZMD-MBW0200

07946-M J00100 07HMC-MR70100

Press a new left pivot needle bearing into the swingarm pivot so the needle bearing surface is 5.0 -6.0 mm (0.20 - 0.24 in) lower from the end of the swingarm pivot surface using the special tools and a hydraulic press.

TOOLS: Driver

Attachment, 37 x 40 mm Pilot, 28 mm or

Driver

Attachment, 37 mm Pilot, 28 mm

07749-0010000 07746-0010200 07746-0041100

07749-0010000

07ZMD-MBW0200

07746-0041100

Shock link plate bearing replacement

Remove the pivot collar and dust seals from the shock link plate pivot of the swingarm.

DRIVER

DRIVER

ATTACHMENT/PILOT

DUST SEALS

Draw the needle bearing out of the swingarm using the special tool.

TOOL:

Bearing remover set

07LMC-KV30100

NEEDLE BEARING REMOVER

NEEDLE BEARING REMOVER

Apply grease to the needle rollers of the new bearing. Install the needle bearing into the pivot until the depth from the swingarm outer surface is 5.5 - 6.0 mm (0.22 - 0.24 in), using the same tool.

Apply grease to the dust seal lips, then install the dust seals and pivot collar into the swingarm.

PIVOT COLLAR

ASSEMBLY

PIVOT COLLAR

RIGHT PIVOT BEARING (20 x 37 x 9) RIGHT PIVOT

I SNAP RING

LEFT PIVOT NEEDLE BEARING

DRIVE CHAIN SLIDER

PIVOT COLLAR

LEFT PIVOT NEEDLE BEARING

DRIVE CHAIN SLIDER

Pictures Honda Cbr 600 Chain Snap

PIVOI COLLAR

NEEULh BtARING

PIVOI COLLAR

NEEULh BtARING

Apply grease to the dust seal lips, then install the dust seals into the right swingarm pivot. Fill the grease up between the inner dust seal and needle bearing. The right pivot Install the pivot distance collar. distance collar has an identification yiuuve on the flange.

DUST SEALS

DUST SEALS

PIVOT DISTANCE COLLAR

Apply grease to the dust seal lips, then install the dust seals and pivot collar into the left swingarm pivot.

< DUST SEALS

DRIVE CHAIN SLIDER

Install the drive chain slider aligning the slit with the boss on the swingarm.

Install the drive chain slider bosses into the hole in the swingarm.

Install and tighten the new drive chain slider mounting bolts to the specified torque

When tightening U>e lock nut with the lock nut wrench, refer to torque wrench reading information on page 14-1 "SERVICE INFORMATION".

INSTALLATION

Re sure to tighten the swingarm pivot fasteners to the specified torque in the specified sequence. If you do not tighten the fasteners to the correct torque or in the proper sequence, loosen all pivot fasteners, then tighten them again to the specified torque in the correct sequence.

1. Install the left and right adjusting bolts sot they do not project out of the frame inner surface.

2. Obtain a spore pivot bolt (P/N 52101-MBW-000) or use a 20 mm (0.8 in) O.D. shaft. Ret the swingarm into the frame and the shock link plates and temporarily insert the pivot bolt from the left side to support the swingarm.

PIVOT BOLT

PIVOT BOLT

BOLTS

DRIVE CHAIN SLIDER

BOLTS

3.Tighten the right pivot adjusting bolt to the initial torque.

Loosen the right pivot adjusting bolt, and retighten it to the specified torque.

4. Install the right pivot lock nut. Hold the right pivot adjusting bolt, then tighten the lock nut to the specified torque using the special tool.

TOOL:

Lock nut wrench 07908-4690003

TORQUE:

Actual: 64 N-m (6.5 kgf-m, 47 lbf-ft) Indicated: 58 N-m (5.9 kgf-m, 43 lbf-ft)

LEFT ADJUSTING BOLT

PIVOT BOLT

LEFT ADJUSTING BOLT

5. Insert the other pivot holt from the right side, gradually pushing the left side pivot bolt out from the left side.

6. Tighten the left pivot adjusting bolt to the initial torque.

Loosen the left pivot adjusting holt and retighten it to the specified torque.

PIVOT BOLT

LOCK NUT

LOCK NUT

7. Install the left lock nut.

Hold the left pivot adjusting holt, then tighten the lock nut to the specified torque using the special tool.

TOOL:

Lock nut wrench 07908-4690003

TOROUE:

Actual: 64 N-m (6.5 kgf-m. 47 lbf-ft) Indicated: 58 N-m (5.9 kgf.m, 43 lbf-ft)

8. Push the pivot bolt until it is seated. Install the pivot nut with the washer and tighten the pivot nut to the specified torque.

Install Cbr 600 F4i Idle Screw

Install the shock link plate-to-swingarm bolt/nut, then tighten the nut to the specified torque.

Route the brake hose properly, then install the rear brake caIiper/bracket onto the boss of the swingarm.

Install the brake hose guide and tighten the bolts.

Install the drive chain case aligning the hole with boss of the swingarm.

Tighten the drive chain case screws securely. Install the rear wheel (page 14-8).

BRAKE HOSE GUIDES

BOLTS

FRONT:

2001 Cbr 600 F4i Engine Hose With Valve
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