Honda CBR-600 F4 / F4i – Installation Instructions

1. Remove the lower fairing. Remove the lower radiator mounting bolts, loosen the upper bolts and pivot the
radiator forward to provide access to the exhaust nuts (flange nuts).
2. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting
bolt and nut for the end can to the passenger footpeg for reuse as well.
3. Inspect the exhaust gaskets. Replace if necessary.
4. Assemble the head pipes 1 (blue), 2 (red), 3 (yellow), and 4 (green) by matching the joints of the same color to
the pair of front Y-pipes. Do not install the exhaust springs at this time.
5. Place the billet aluminum exhaust port centering flange Z on each TiForce headpipe so that the flat sections are
between the studs on the cylinder head– see figure 3 for details.
6. Attach the assembled head pipe sections to the exhaust ports, but do not tighten the flange nuts fully, allowing
for some adjustment in the remaining steps. Reuse the flange nuts saved from step 2 above. Make sure the
ends of the headpipes fit flush and snug in the ports and centering flanges Z before tightening.
7. Install the S-Bend to the front section of the headpipes and two Y-pipes.
8. Go back and retighten the head pipe flange nuts per factory specifications – make sure the headpipes and the
exhaust port centering flanges Z are centered in each port -see figure 3.
9. Slide the TiForce end can into place. Loosely attach the two rubber bands, stainless steel bands K, and stay /
hanger G to the end can using the supplied 6mm hardware H. See figure 1 for details.
10. Place the bands approximately 190-200mmfrom the edge of the end can. See figure 2 for details.
11. Using the stock provided mounting point on the passenger footpeg, and using the stock mounting bolt, mount
the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G.
12. Attach the supplied springs to all the joints, starting from the headpipes and working back to the end can.
13. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance.

14. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can
(refer to step 11 / figure 2), then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure
that the rubber pads fully cover the band(s). USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE
AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN.
15. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire exhaust system to remove
any residual oils, anti seize, fingerprints and dirt prior to starting the motor. FAILURE TO CLEAN THE
TUBING AND CAN MAY RESULT IN PERMANENT STAINING OF THE SYSTEM WHEN HEATED.
16. Go back and reinstall the radiator per factory specifications. Verify fluid levels as needed.
17. Check that all hardware is properly tightened, then start the motor and check for exhaust leaks.
18. Reinstall the fairing and tighten any fasteners per factory specification.

Download Honda CBR-600 F4 / F4i – Installation Instructions


November 26, 2009 | Posted in Automotive Manual, Honda Manual

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