Honda CBR1000RR2007 (2007), CBR1000RR REPSOL EDITION (2007) Repsol Edition Set-up Instructions

2007 CBR1000RR REPSOL EDITION

SET-UP INSTRUCTIONS

Set-up and pre-delivery service must be performed by an authorized Honda motorcycle dealer.

MPD 11780 (0701) Issue d: February 2007

IMPORTANCE OF PROPER SET-UP AND PRE-DELIVERY SERVICE

FOR YOUR CUSTOMER'S SAFETY

Proper set-up and pre-delivery service are essential to rider safety and the reliability of the machine. Any error or oversight ma de by the t echnician as sembling and ser vicing a new machine can result in faulty operation, damage to the machine, or injury to the rider.

WARNING

Improper set-up or pre-delivery service can create an unsafe condition that can cause your customer to be seriously hurt or killed.

Follow the procedures and precautions in this manual and the Service Manual carefully.

FOR YOUR SAFETY

Some of the most important safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing set-up and pre-delivery service. Only you can decide whether or not you should perform a given task.

WARNING

Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed.

Follow the procedures and precautions in this manual carefully.

IMPORTANT SAFETY PRECAUTIONS

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment. When performing the set-up or pre-delivery service, be especially careful of the following:

• Read the instructions before you begin, a nd make sure you have the tools and skills requi red to

perform the tasks safely.

• To prevent the machine from falling on you, park it on a firm, level surface, using the proper

stand(s) to provide firm support.

Make sure the engine is off before you begin any servicing procedures. This will help eliminate several potential hazards:

• Carbon monoxide poisoning from engine exhaust—be sure there is adequate ventilation

whenever you run the engine.

• Burns from hot parts—let the engine and exhaust system cool before touching.

• Injury from moving parts—do not run the engine unless the instruction tells you to do so.

Even then, keep your hands, fingers, and clothing away.

To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. Use only a nonflammable solvent, not gasoline, to clean parts. Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.

2007 CBR1000RR REPSOL EDITION

How To Use This Manual

Follow the complete sequence of steps as shown. Do not short-cut any steps. The sequence has been established to ensure the unit is properly assembled.

The individual steps are composed of three components:

• Sub-heading—The large sub-headings are a brief description of the step. They are intended

to be used by the experienced technician, one who only needs a brief reminder of the set-up sequence.

• Descriptive text—The descriptive text explains in detail what is to be done during that step.

This explanation is intended as a guide for the technician needing additional information.

• Photographs/Line art—The photographs or line art support both the sub-headings and the

detailed text.

Indicates the set-up section Indicates the pre-delivery sect ion

Modifications and Accessories

Modifications that you may have made, or should make in the future, to any Honda product, shall be deemed by our company to have been performed at your sole risk and responsibility, and without our company's or the manufacturer's approval, or consent, implied or expressed. We further discla im a ny and all liability, obli gation, or responsibilit y for a ny defe cts of modif ie d pa rt s or of the modified product, and for any claims, demands, or causes of action for damage to property or for personal injuries resulting from the modification of said Honda product.

Tor q u e Tab l e

ITEM SIZE TORQUE

Passenger footpeg bol ts 8 mm 37 N·m (3.8 kgf·m, 27 lbf·ft) Clutch lever assembly bolts 6 mm 12 N·m (1.2 kgf·m, 9 lbf·ft) Rider footpeg bolts 8 mm 37 N·m (3.8 kgf·m, 27 lbf·ft) Windscreen screws 5 mm 0.45 N·m (0.05 kgf·m, 0.3 lbf·ft) Mirror bolts 6 mm 7 N·m (0.7 kgf·m, 5.2 lbf·ft) Seat pan screws 6 mm 9 N·m (0.9 kgf·m, 6.6 lbf·ft ) Front brake reservoir screw 4 mm 1.2 N·m (0.12 kgf·m, 0.9 lbf· ft) Rear brake reservoir sc rew s 4 mm 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft ) Clutch reservoir screw 4 mm 1.2 N·m (0.12 kgf·m, 0.9 lbf·ft) Rear axle nut -------- 113 N·m (11. 5 kgf·m, 83 lbf·ft)

1. Remove the crate cover and check for damage.

The CBR1000RR Repsol Edition is crated at the factory in either a covered or uncovered crate. Yo u m ay receive ei th er o n e.

Polypropylene covered crate:

Cut the strap, open the fastener, and remove the polypropylene cover.

POLYPROPYL ENE COVERED CRATE

POLYPROPYLENE COVER

STRAP

Carton covered crate:

Cut the str ap and remo ve the carton c o ver. Remove the cardboard top.

Uncovered crate:

When stacking, protect the motorcycle from falling objects and bad weather.

Check th e u n i t fo r da m age. If damage is found, follow the instruct ions on

the Delivery and Damage Claims Guidelines wall char t (Reorder N o . S 0477) before proceeding further.

CARTON COVER

CRATE LABEL

CARTON COVERED CRATE

STRAP

UNCOVERED CRATE

2. Remove the parts carton.

Cut the strap and remove the parts carton from the crate base.

Keep the You and Your Motorcycle - Riding Tips & Practice Guide booklet separate and hand deliver to the customer at the time of delivery.

PARTS CARTON

STRAP

2007 CBR1000RR REPSOL EDITION

3. Loose Parts Information.

Unpack the remaining loose parts and check them against this illustration and list.

2.1.

DESCRIPTION QTY PART NUMBER STEP

1. Windscreen 1 64250-MEL-D50ZA 11

2. Right mirror 1 88110-MEL-013 12 Left mirror 1 88120-MEL-013 12

3. Tool bag 1 89101-ME5-670

4. Riding Tips & Practice Guide 1 G0045* 2

5. Owner’s Manual 1 31MEL630** 13

6. Owner’s Manual bag 1 772 51-GR1-000 13

(Continued on next page.)

*If missing, order from Resolve Corp. **If missing, order from Helm Inc.

3. Loose Parts Information (cont.).

DESCRIPTION QTY PART NUMBER STEP

7. Attaching Parts:

Passenger footpeg bracket:

Socket bolt 8 x 22 mm 2 90157-ME9-000 5

Top triple clamp:

Top triple clamp cap 2 53174-GS9-610 7

Rider footpeg bracke ts:

Socket bolt 8 x 22 mm 2 90157-ME9-000 10

Windscreen:

Rubber washer 6 64205-166-610 11 Thrust washer 5 mm 6 90504-964-000 11 Truss screw 5 x 18 mm 6 90111-MEL-000 11 Cowl set nut 5 mm 6 90111-KW3-003 11

Mirrors:

Socket bolt 6 x 13 mm 4 90130-MEE-000 12

Battery:

Pan screw 6 x 14 mm 1 90118-MR1-000 16 Collar 1 90522-170-700 16

8. Repsol ed ition decal set* 1 ------------------ ---- 15 *Controlled Part

INCLUDED TOOL(S) Phillips screwdriver, handle, 5mm hex wrench, helmet wire set

Missing Parts or Shipping Damage

Identify missing parts by referring to the Loose Parts Information section. Order the parts using normal parts ordering procedures. Claims for missing loose parts or those damaged during transit should be submitted to American Honda, not the carrier. After completing repairs, submit a Transportation Claim via iN. For complete details, please refer to the Warranty Policy and Procedures Manual.

2007 CBR1000RR REPSOL EDITION

4. Remove the shipping bracket nuts and plate.

Remove the nuts and plate that attach the front shipping bracket to the upper shipping brace.

NUTS

UPPER SHIPPING BRACE

PLATE

5. Remove the rear shipping brackets.

PART S QTY

Socket bolt 8 x 22 mm 2

While supporting the rear shipping brackets, remove and discard the nuts, bolts, and rear shipping brackets on both sides of the motorcycle.

Install and torque the 8 x 22 mm socket bolts to secure the passenger footpeg brackets.

Torque: 37 N·m (3.8 kgf·m, 27 lbf·ft)

6. Lift off the crate frame.

Remov e th e bolts that att ac h th e c r ate frame. Using two people, carefully lift off the

crate frame. Use extr eme care not to d amage the

motorcycle while re m o vi n g th e c r ate frame.

NUT

8 x 22 mm SOCKET BOLT

REAR SHIPPING BRACKET

BOLT

7. Remove the front shipping bracket.

PART S QTY

Top triple clamp cap 2

Being careful not to damage the upper cowl, remove the bolts and front shipping bracket.

Install the top triple clamp caps.

CAPS

BOLTS

FRONT SHIPPING BRACKET

8. Relocate the ignition keys.

Remove the ignition keys and protective tube from the th r o ttl e c ab l es .

Remove the packaging from the keys and insert one of them into the ignition.

PROTECTIVE TU BE

IGNITION KEYS

9. Position and secure the clutch lever assembly.

Loosen the two bolts attaching the clutch lever assembly.

Align the split between the holder and the assembly with the punch mark on the handlebar.

Torque the bolts, starting with the top one.

Torque: 12 N·m (1.2 kgf·m, 9 lbf·ft)

CLUTCH LEVER ASSEMBLY

BOLTS

PUNCH MARK

+ 17 hidden pages

Honda CBR1000RR2007 (2007), CBR1000RR REPSOL EDITION (2007) Repsol Edition Set-up Instructions

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