Honda CBR 954RR Service Manual 02 frame
FRAME/BODY PANELS/EXHAUST SYSTEM
BODY
PANEL
LOCATIONS
2-0
D
U
C
T
COVER
COWL
2,
FRAME/BODY
BODY PANEL LOCATIONS
SERVICE INFORMATION
P
2-0
2- 1
EL EXHAUST
SYST
LOWER COWL
INNER MIDDLE COWL
-
7
2
-
7
2
TROUBLESHOOTING
SEAT
PILLION SEAT/REAR
DUCT COVER
UPPER COWL
SERVICE
INFORMATION
COWL 2-2 REAR FENDER 2-9
2
-
1
-
2 FRONT FENDER
2
2-4
2-5
WINDSCREEN
SEAT RAIL 2-1 1
MUFFLER/EXHAUST PIPE 2-1
3
GENERAL
This section covers removal and installation of the
Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine.
When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust clamps
first, then tighten the mounting fasteners.
erly.
Always inspect the exhaust system for leaks after installation.
If
body
panels and exhaust system.
you tighten the mounting fasteners first, the exhaust pipe may not seat prop
TORQUE VALUES
Upper cowl pan screw
Lower cowl pan screw
Rear cowl truss screw
Pillion seat mounting nut
Pillion seat hinge special screw
Duct cover mounting screw
Windscreen mounting screw
8
Seat rail mounting bolt,
Seat rail mounting nut, 10
Pillion step mounting socket bolt
Exhaust pipe joint nut
EGCV cover mounting bolt
EGCV pulley cover mounting bolt
mm
mm
1.5 N*m
1.5 N*m (0.15 kgf-m, 1.1 Ibf-ft)
1.5 N-m (0.15 kgf-m,
11 N-m (1.1 kgfom,
12 N-m (1.2 kgf-m, 9 Ibf-ft)
1.5 N*m
0.3
39 N*m
39 N-m
39 N*m
12 N-m
12 N-m
12 N-m
(0.15 kgf*m, 1.1
(0.15
kgf-m, 1.1 Ibf-ft)
N*m
(0.03
kgfom, 0.22 Ibf-ft)
(4.0
kgf-m, 29 Ibfoft)
(4.0
kgfom, 29
(4.0
kgfom, 29 Ibf*ft)
1.2 kgf
1.2 kgfm, 9 lbf*ft)
1.2 kgf-m, 9
-
m, 9
1.1
8
Ibf-ft)
Ibf-ft)
IbfW
Ibf-ft)
Ibf*ft)
U-nut
Ibf-ft)
-
TROUBLESHOOTING
Excessive
Broken exhaust system
Exhaust gas leak
Poor
-
Deformed exhaust system
Exhaust gas leak
Clogged muffler
exhaust
performance
noise
2-1
FRAME/BODY PANELS/EXHAUST SYSTEM
SEAT
REMOVAL
Remove the two seat mounting bolts behind the seat.
Slide the seat back and then
Remove the mounting collars.
I
NSTALLATI 0 N
Install the collars into the seat bottom plate as shown.
Align the seat hook
install the seat.
Install and tighten the bolts securely.
with
off.
the fuel tank rear bracket and
BOLTS
COLLARS
\
PILLION
SEAT/REAR
COWL
REMOVAL
Remove the seat (see above).
Open the pillion seat using the ignition key.
Remove the pillion seat mounting nuts, then remove
the seat belt and pillion seat.
Disconnect the seat lock cable from the key cylinder.
PILLION SEAT kIGNI,TIY
NUTS
KEY
2-2
I
SEAT
LOCK
CABLE
FRAME/BODY PANELS/EXHAUST SYSTEM
Remove the two
Remove the screws, special screws, setting bolts,
lars and spacers.
Push down the pillion seat mounting bracket and
carefully spread the bottom of both sides of the rear
cowl, then remove
Disconnect the tail light connector.
trim
clips.
it
from the seat rail.
COI-
SETTING BOLT SCREWS
BRA'CKET
SPECIAL-SCREWS
IN
PILLION
STALLATION
1.5
N-m
(0.15
kgfom,
1.1
IbfW
2-3
FRAME BODY PANELS/EXHAUST SYSTEM
Connect the tail light connector.
Install the rear cowl over the seat rail being careful not
to damage the wire harness.
Install the spacers, setting collars and setting
Install the special screws and truss screws.
Install the trim clips.
Tighten the setting bolts and special screws securely.
Tighten the screws to the specified torque.
TORQUE:
Rear cowl
1.5
truss
screw:
N*m (0.15 kgf-m, 1.1 Ibf-ft)
bolts.
SETTING BOLT SCREWS
I
COLLAR
DUCT
Connect the seat lock cable to the key cylinder.
Install the pillion seat and nuts to the pillion seat
bracket.
Tighten the nuts to the specified torque.
TORQUE: 11 N-m (1.1 kgf-m, 8 Ibf-ft)
Push the pillion seat down to lock
it.
COVER
REMOVAL/INSTALLATION
SPECIAL SCREWS
V
SEAT LOCK CABLE
BRACKET
NUTS
2-4
Remove the screws.
Release the tab of the duct cover from the fuel tank,
then remove the duct cover.
Installation is in the reverse order of removal.
TORQUE: 1.5 N-m (0.15 kgfem, 1.1 Ibf*ft)
SCREWS
FRAME/BODY PANELS/EXHAUST SYSTEM
UPPER
COWL
BOLTS
REMOVAL
Remove the duct cover (page
Remove the socket bolts and rearview mirrors.
Disconnect the turn signal light connectors.
Remove the nuts, set plates and turn signal lights
from the inner middle cowl.
2-41.
h
Remove the trim clips.
Remove the windscreen
Remove the upper cowl
Remove the upper cowl mounting screws.
Pull the upper cowl forward.
Disconnect the headlight connectors, then remove the
upper cowl.
-to-
upper cowl bracket screws.
-to-
lower cowl screws.
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