honda cbr600rr 2009 owners User Manual

							RIGHT FRONT
(5) axle pinch bolts
(6) front axle bolt(6)
(5)
192
If You Have a Flat Tire
Taking Care of the Unexpected
Loosen the right and left axle pinch
bolts ( ) and remove the f ront axle bolt
().
Avoid getting grease, oil, or dirt on
the disc or pad surfaces. Any
contamination can cause poor brake
performance or rapid pad wear after
reassembly. To avoid damage to the brake hose
during removal, support the caliper
assembly so that it doesn’t hang f rom
the hose. Do not twist the brake hose.
Remove the caliper fixing bolts ( ) and
remove the right and left brake calipers
( ) f rom the f ork legs. Remove the wheel speed sensor ( ) by
removing the bolts ( ). Support the motorcycle securely and
raise the f ront wheel of f the ground
using a saf ety stand or a hoist.
2.
4. 5.
5
6
3. 1
4 2
3
(CBR600RR ABS only)
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							LEFT FRONT(5) (7)
(5) axle pinch bolts
(7) front axle shaft
193
If You Have a Flat Tire
Taking Care of the Unexpected
Remove the front axle shaft ( ), wheel
and side collars. Avoid pressing the brake lever when
the wheel is off the motorcycle. This
will f orce the caliper pistons out of
the cylinders. The result will be loss
of brake f luid. If this occurs, the
brake system will require service. See
your Honda dealer for this service.
6. 7
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							16 lbf·ft (22 N·m , 2.2 kgf·m)
44 lbf·ft (59 N·m , 6.0 kgf·m)
33 lbf·ft (45 N·m , 4.6 kgf·m)
LEFT FRONT(1) end of axle shaft
(2) surface of fork leg (3) front fork
spacers (2)
(1)
(3)
194
If You Have a Flat Tire
Taking Care of the Unexpected
Tighten the axle pinch bolts on the left
fork leg to the specified torque:
Tighten the front axle bolt to the
specified torque:
Make sure that the front fork spacers
( ) are installed into the caliper bracket
properly.
Install the right and left brake calipers
onto the f ork legs.
To avoid damaging the brake pads,
carefully fit the brake disc ( ) between
the pads.
Install the caliper fixing bolts and
tighten to the specified torque:
Install the side collars and position the
wheel between the fork legs. Insert the
f ront axle shaf t f rom the lef t side,
through the left fork leg and wheel hub.
Installation
Align the end of axle shaft ( ) with the
surf ace of f ork leg ( ). 4.
2. 3.
5.
6.
7.
1.
1
2 3
4
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							(5)(5)
(4)
(4) brake disc (5) brake caliper body
195
If You Have a Flat Tire
Taking Care of the Unexpected
Visually check that the clearances
between each surface of the brake disc
and the brake caliper body (not the
brake pads) are symmetrical.
If the clearances are not symmetrical,
loosen the left axle pinch bolts and pull
the lef t f ork outward or push inward to
adjust the clearance. Then follow the
next step. If the clearances between each surface
of the brake disc and the brake caliper
body ( ) (not the brake pads) are
symmetrical, follow next step. Operate the f ront brake and pump the
f ork several times. Check f or f ree
wheel rotation after the brake is
released. Recheck the wheel if the brake
drags or the wheel does not rotate freely.
(cont’d)
9. 8.
5
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							16 lbf·ft (22 N·m , 2.2 kgf·m)
196
If You Have a Flat Tire
Taking Care of the Unexpected
If a torque wrench was not used f or
installation, see your Honda dealer as soon
as possible to verif y proper assembly.
Improper assembly may lead to loss of
braking capability.
Tighten the axle pinch bolts on the right
fork leg to the specified torque:
Install the wheel speed sensor and
tighten the bolts, then check the
clearance between the wheel speed
sensor and the pulser ring.
10.
11.
(CBR600RR ABS only)
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							RIGHT REAR(1) (2)
(1) rear axle nut
(2) drive chain lock nut
(3) drive chain adjusting bolt
(7) right chain adjustment plate (7)
(3)
197
Emergency Rear Wheel
Removal/Installation
If You Have a Flat Tire
Taking Care of the Unexpected
Saf ety Precautions
Refer to on page .
We recommend wheel removal be done
only by your Honda dealer or another
qualified mechanic. Do not attempt to
remove the wheel on your own. Wheel
removal requires mechanical skill and
prof essional tools.
When removing and installing the wheel,
be careful not to damage the wheel speed
sensor and pulser ring. Removal
Park your motorcycle on a f irm, level
surface. (cont’d)
1.
76
(CBR600RR ABS only)
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							LEFT REAR
(2) drive chain lock nut
(3) drive chain adjusting bolt
(4) drive chain
(5) rear axle shaft
(6) left chain adjustment plate(6)
(4)
(2)
(3) (5)
198
If You Have a Flat Tire
Taking Care of the Unexpected
Support the motorcycle securely, raise
the rear wheel off the ground.
Loosen the rear axle nut ( ).
Loosen the drive chain lock nuts ( )
and turn the drive chain adjusting bolts
( ) so the rear wheel can be moved all
the way f orward f or maximum drive
chain slack.
Remove the rear axle nut and washer.
Remove the drive chain ( ) f rom the
rear wheel sprocket by pushing the rear
wheel forward.
2.
3.
4.
5.
6.
1
2
3
4
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							199
If You Have a Flat Tire
Taking Care of the Unexpected
Remove the rear axle shaft ( ), rear
wheel, left chain adjustment plate ( ),
right chain adjustment plate ( ), rear
brake bracket and side collars from the
swingarm.To avoid damage to the brake hose
during removal, support the caliper
assembly so that it doesn’t hang f rom
the hose. Do not twist the brake hose.
Avoid depressing the brake pedal
when the wheel is off the motorcycle.
This will force the caliper piston out
of the cylinder. The result will be a
loss of brake f luid. If this occurs, the
brake system will require service.
See your Honda dealer for this
service. Installation
Install the side collars and position the
wheel and rear brake bracket.While installing the wheel, carefully
fit the brake disc between the brake
pads to avoid damaging the pads.
Avoid getting grease, oil, or dirt on
the disc or pad surfaces. Any
contamination can cause poor brake
performance or rapid pad wear after
reassembly.
(cont’d)
1.
7. 5
6
7
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							83 lbf·ft (113 N·m , 11.5 kgf·m)
(1) lug
(2) slot(3) swingarm(1)
(2)
(3)
RIGHT REAR
200
If You Have a Flat Tire
Taking Care of the Unexpected
Make sure that the lug ( ) on the rear
brake bracket is positioned in the slot
( ) on the swingarm ( ). Insert the rear axle shaft from the left
side, through the lef t swingarm, wheel
hub and rear brake bracket.
Install the rear axle nut and tighten the
drive chain adjusting bolts.
Ref er to drive chain adjustment
(page ).
Tighten the rear axle nut to the
specified torque: Install the drive chain by pushing the
rear wheel forward.
Failure to provide adequate disc-to-rear
brake bracket clearance may damage
the brake discs and impair braking
efficiency.
2.
13.
4.
5.
6. 156
3
2
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							201
If You Have a Flat Tire
Taking Care of the Unexpected
After installing the wheel, apply the
brake pedal several times, then recheck
the disc for caliper holder to disc
clearance. Do not operate the
motorcycle without adequate clearance.If a torque wrench was not used f or
installation, see your Honda dealer as soon
as possible to verif y proper assembly.
Improper assembly may lead to loss of
braking capability.
7.
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