How to Remove the Engine From a CBR 1000by Chris Gilliland
The majority of the work needed by a Honda CBR 1000's engine can be performed with it still mounted on the motorcycle. Major repairs will require the engine to be removed as a whole, a process that uses basic hand tools almost exclusively. Take note that newer CBR models made after 2004 require a specialized tool to unscrew the engine's mounting bolts. The task is straightforward, but does require a certain familiarity with your CBR's basic anatomy. Do not attempt to complete this task unless you are confident that you can complete it properly.
Secure your CBR 1000 in an upright position with a motorcycle stand. Remove the passenger seat from the motorcycle, using the ignition key. Unscrew the bolts under the rear of the rider's seat with a 5 mm Allen key, then remove the seat from the motorcycle to allow access to the battery. Unscrew the bolts attaching the battery cables to the battery's terminals with a Phillips screwdriver; starting with the black negative cable followed by the red positive cable. Lift the battery out of the frame's seat rails.
Unscrew the bolts attaching the side and lower fairing panels to the motorcycle's frame, using 4 and 5 mm Allen wrenches. Slide the lower fairings out from under the motorcycle, then pull the side fairings away from the frame. Reach behind the side fairings and unplug the front turn signals from the motorcycle's wiring harness.
Remove the gas tank cover's trim panels and mounting bolts, using a 5 mm Allen wrench. Unscrew the bolts lining the rim of the gas cap, using a 4 mm Allen wrench. Unlock the cap with the ignition key, then pull the cap off of the tank. Lift the tank cover off of the gas tank. This step only applies to 2004 and newer CBR 1000 models.
Remove the mounting bolts on the front and rear of the tank with a 5 mm Allen wrench. Lift the tank off of the frame and unplug the fuel pump's electrical connector and the fuel lines from the bottom of the tank.
Remove the air box from the top of the motor, using a Phillips screwdriver. Unscrew the air box's lid, then lift the lid and the air filters out of the air box. Loosen the hose clamps securing the air box to the motorcycle's throttle bodies or carburetors with a Phillips screwdriver, then pull the air box off of the motor.
Remove the carburetors or throttle bodies from the motor. Slip the throttle cables out of the throttle bodies or carburetors' throttle valve. Unplug the fuel injectors' and throttle position sensor's wiring connectors from the top of the throttle bodies. Loosen the clamps attaching the throttle bodies or carburetors to the motor, using a Phillips screwdriver. Pull the carburetors or throttle bodies off of the motor.
Unscrew the bolts from the front sprocket cover on the left side of the motor with a socket wrench fitted with a 8 mm socket. Pull the cover away from the motor to access the sprocket. Unscrew the bolt securing the front sprocket to the motor, using a 17 mm socket. Pull the sprocket out of the motor.
Pull the radiator hoses off of the motor. Unplug any electrical connectors attached to the motor. Remove the shift lever's arm from the left side of the motorcycle, using a 10 mm socket. Unscrew the shift lever's pivot bolt with a 6 mm Allen wrench. Pull the shift and and its arm off of the motor.
Place a jack under the motor for support. Unscrew the motor mount bolts from the motorcycle's frame with a 20 mm socket. 2004 and newer models will need a special 20 mm lock nut wrench to unscrew the motor mount bolts. Lower the motor away from the frame and pull it away from the motorcycle.
- Detailed engine removal instructions and a list of specialized tools are provided in a Honda service manual. These manuals may be obtained from your local Honda dealership