Honda CBR600F4I (2001-2003) [302/492] Tcrankcase transmissi0n

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1TCRANKCASE TRANSMISSI0N SERVICE INFORMATION 11 1 SHIFT FORK SHIFT DRUM 11 4 TROUBLESHOOTING 112 TRANSMISSION 11 6 CRANKCASE SEPARATION 11 3 CRANKCASE ASSEMBLY 11 12 SERVICE INFORMATION GENERAL The crankcase must be separated to service the following Transmission Crankshaft Section 12 Piston connecting rod Section 12 The following components must be removed before separating the crankcase Alternator flywheel Section 10 Clutch gcarshift linkage Section 9 Cylinder head Section 8 Engine Section 7 Oil pan oil pump and oil cooler Section 4 Starter motor Section 18 Water pump Section 6 Be careful not to damage the crankcase mating surfaces when servicing Prior to assembling the crankcase halves apply sealant to their mating surfaces Wipe off any excess sealant thoroughly SPECIFICATIONS Unit mm in ITEM Shift fork fork shaft STANDARD I D 12 000 12 021 0 4724 0 4733 Claw thickness 5 93 6 00 0 233 0 236 Shift fork shaft O D SERVICE LIMIT 12 03 0 474 5 9 0 23 11 957 11 968 0 4707 0 4712 11 95 0 470 M5 M6 28 000 28 021 1 1024 1 1032 28 04 1 104 C2 C3 C4 31 000 31 025 1 2205 1 2215 31 04 1 222 MS M6 27 959 27 980 1 1007 1 1016 27 94 1 100 C2 30 955 30 980 1 2187 1 2197 30 94 1 218 03 C4 30 950 30 975 1 2185 1 2195 30 93 1 218 M5 M6 0 020 0 062 0 0008 0 0024 0 10 0 004 C2 0 020 0 070 0 0008 0 0028 0 10 0 004 C3 C4 0 025 0 075 0 0010 0 0030 0 11 0 004 M5 24 985 25 006 0 9837 0 9845 25 016 0 9849 C2 27 985 28 006 1 1018 1 1026 28 021 1 1032 Mainshaft O D at M5 24 967 24 980 0 9830 0 9835 24 96 0 983 Countershaft O D at C2 27 967 27 980 1 1011 1 1016 27 96 1 101 Bushing to shaft clearance M5 0 005 0 039 0 0002 0 0015 0 06 0 002 C2____________ 0 005 0 039 0 0002 0 0015 0 06 0 002 Transmission Gear I D Gear bushing O D Gear to bushing clearance Gear bushing I D

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