Honda 1980 CB900F Manuals

Manuals and User Guides for Honda 1980 CB900F. We have 1 Honda 1980 CB900F manual available for free PDF download: Shop Manual

Honda 1980 CB900F Shop Manual

Honda 1980 CB900F Shop Manual (394 pages)

Brand: Honda | Category: Motorcycle | Size: 64.08 MB

Table of Contents

How to Use this Manual
2
General Information
4
General Safety
4
Service Rules
4
Specifications
5
Torque Values
7
Special Tools
10
Common Tools
11
Cable & Harness Routing
12
Maintenance Schedule
14
Exhaust Emission Control System
15
Crankcase Emission Control System
15
Emission Control Information Label
15
Engine Lubrication Diagram
17
Lubrication - Service Information
18
Lubrication: Specifications
18
Lubrication: Tools
19
Lubrication: Torque Values
19
Lubrication: Troubleshooting
19
Engine Lubrication
20
Engine Oil Level
20
Engine Oil & Filter Change
20
Oil Strainer Cleaning
21
Oil Pressure Check
21
Oil Cooler Inspection
22
Oil Pump Removal
22
Oil Pump Disassembly
23
Oil Pump Inspection
24
Oil Pump Assembly
25
Oil Pump Installation
26
Subtransmission Oil Check
26
Subtransmission Oil Change
26
Subtransmission Oil Pump Removal
27
Subtransmission Oil Pump Installation
28
Chassis Lubrication
29
Final Drive Gear Oil Check and Change
29
Drive Shaft Coupling
29
Control Cable Lubrication
29
Lubrication Points Diagram
30
Inspection and Adjustment - Service Information
32
Inspection and Adjustment - Tools Needed
32
Inspection and Adjustment - Specifications
32
Engine Inspection and Adjustment
34
Fuel Lines
34
Throttle Operation
34
Carburetor Choke
35
Air Cleaner
35
Crankcase Breather
36
Spark Plugs
36
Valve Clearance
37
Valve Clearance Adjustment
38
Valve Shim Selection Chart
40
Cam Chain Tensioner
41
Carburetor Synchronization
41
Carburetor Synchronization Adjustment
42
Carburetor Idle Speed
42
Ignition Timing
43
Spark Advancer
44
Cylinder Compression
44
Battery
45
Brake Fluid
45
Brake Pad Wear
46
Brake System
46
Rear Brake Pedal Height
46
Brake Light Switch
47
Headlight Aim
47
Clutch Inspection and Adjustment
48
Side Stand
49
Suspension Inspection
50
Nuts, Bolts, Fasteners Check
51
Wheels Check
51
Recommended Tire Pressure and Tire Size
51
Steering Head Bearings
52
Fuel System Exploded View
53
Fuel System Service Information
54
Fuel System - Tools Needed
54
Fuel System Specifications
54
Fuel System Troubleshooting
55
Carburetor Removal
56
Vacuum Cylinder Disassembly
56
Pilot Screw Removal
57
Pilot Screw Installation
58
Float and Jets
58
Air-Cutoff Valve Disassembly
59
Accelerator Pump Disassembly
60
Component Assembly
60
Float Level
61
Carburetor Separation
61
Linkage Disassembly
64
Linkage Assembly
65
Carburetor Assembly
65
Fast Idle Adjustment
69
Accelerator Pump Adjustment
69
Carburetor Installation
69
Pilot Screw Adjustment
70
Idle Drop Procedure
70
Limiter Cap Installation
71
Fuel Tank Checks
72
Air Cleaner Checks
72
Crankcase Ventilation System
72
Engine Removal/Installation - Diagram
73
Engine Removal/Installation - Service Information
74
Engine Removal/Installation - Specifications
74
Engine Removal/Installation - Torque Values
74
Engine Removal
75
Engine Installation
79
Exhaust Pipe Installation
79
Cylinder Head/Valve Exploded View
81
Cylinder Head/Valve Service Information
82
Cylinder Head/Valve - Tools Needed
82
Cylinder Head/Valve Torque Values
82
Cylinder Head/Valve Specifications
82
Cylinder Head/Valve Troubleshooting
83
Camshaft Removal
84
Cam Bearing Surface Inspection
87
Camshaft Runout
87
Cam Inspection
88
Cam Chain Length Measurement
88
Cam Chain Guide Inspection
88
Camshaft Oil Clearance
88
Cylinder Head Removal
90
Cylinder Head Disassembly
92
Valve Spring Free Length Inspection
94
Valve Stem-To-Guide Clearance
94
Cam Chain Guide and Cam Chain Tensioner Inspection
95
Valve Guide Replacement
96
Valve Seat Inspection/Refacing
97
Cylinder Head Assembly
98
Cylinder Head Installation
99
Camshaft Installation
101
Cylinder/Piston View
105
Cylinder/Piston Service Information
106
Cylinder/Piston - Tools Needed
106
Cylinder/Piston Specifications
106
Cylinder/Piston Troubleshooting
106
Cylinder Removal
107
Cam Chain Tensioner Inspection
108
Piston Removal
108
Piston/Piston Ring Inspection
109
Piston Ring Installation
111
Piston Installation
112
Cylinder Installation
112
Clutch Exploded View
115
Clutch Service Information
116
Clutch - Tools Needed
116
Clutch - Torque Values
116
Clutch Specifications
116
Clutch Troubleshooting
117
Clutch Cover Removal
118
Clutch Lifter Removal
118
Clutch Removal
118
Clutch Spring Inspection
119
Clutch Disc Inspection
120
Plate Inspection
120
Primary Drive Gear Removal
120
Clutch Installation
121
Clutch Cover Installation
123
Starter Clutch Disassembly
125
Starter Drive Gear Inspection
126
Starter Clutch Assembly
127
Gearshift Linkage Exploded View
129
Gearshift Linkage Service Information
130
Gearshift Linkage Troubleshooting
130
Gearshift Linkage Removal
131
Neutral Switch Inspection
132
Gearshift Linkage Installation
133
Subtransmission Exploded View
135
Subtransmission Service Information
136
Subtransmission - Tools Needed
136
Subtransmission Specifications
137
Subtransmission - Torque Values
137
Subtransmission Troubleshooting
137
Subtransmission Disassembly
138
Subtransmission Inspection
139
Subtransmission Assembly
141
Subtransmission Case Removal
144
Retainer B Oil Seal Relacement
144
Drive Gear Removal
144
Retainer B and Driven Gear Assembly Removal
145
Retainter B Oil Seal and O-Ring Replacement
146
Retainer B and Driven Gear Installation
147
Driven Gear Preload Inspection
148
Drive Gear Installation
149
Subtransmission Case Installation
150
Crankcase Exploded View
151
Crankcase Service Information
152
Crankcase Torque Values
152
Crankcase Disassembly
153
Crankcase Assembly
154
Transmission Exploded View
157
Transmission Service Information
158
Transmission - Tools Needed
158
Transmission Specifications
158
Transmission Troubleshooting
159
Transmission Disassembly
160
Transmission Inspection
161
Shift Fork and Shift Drum Removal
162
Gear Shift Drum and Shift Fork Inspection
162
Shift Drum and Shift Fork Installation
164
Transmission Assembly
165
Crankshaft/Primary Shaft Exploded View
169
Crankshaft/Primary Shaft Service Information
170
Crankshaft/Primary Shaft - Tools Needed
170
Crankshaft/Primary Shaft Torque Values
170
Crankshaft/Primary Shaft Specifications
171
Crankshaft/Primary Shaft Troubleshooting
171
Primary Shaft Removal
172
Primary Shaft Disassembly
172
Primary Shaft Inspection
172
Primary Chain Tensioner Disassembly
173
Crankshaft Inspection
174
Cam Chain Length Check
175
Primary Chain Length Measurement
175
Bearing Inspection
175
Connecting Rods
175
Main Bearings
176
Bearing Selection
177
Connecting Rod Bearing Inserts
177
Connecting Rod Installation
179
Primary Shaft Assembly
181
Primary Chain Tensioner Assembly
182
Front Wheel/Suspension Exploded View
183
Front Wheel/Suspension Service Information
184
Front Wheel/Suspension - Tools Needed
184
Front Wheel/Suspension Torque Values
184
Front Wheel/Suspension Specifications
185
Front Wheel/Suspension Troubleshooting
185
Headlight Case Removal
186
Headlight Disassembly/Assembly
186
Headlight Case Installation
186
Instruments
187
Indicator Light Bulb Replacement
187
Indicator Light Bulb Removal
188
Meter Bulb Replacement
188
Instruments Assembly and Installation
188
Handlebar Removal
189
Handlebar Installation
190
Fuse Holder Replacement
192
Ignition Switch Replacement
192
Front Wheel Removal
193
Front Wheel Disassembly
193
Wheel Bearings
194
Wheel Inspection
194
Axle Inspection
195
Axle Installation
197
Front Fork Removal
198
Front Fork Disassembly
199
Fork Tube Separation
200
Fork Inspection
201
Front Fork Assembly/Installation
202
Front Fork Installation
204
Steering Stem Removal
206
Steering Stem Installation
209
Rear Wheel/Suspension Exploded View
211
Rear Wheel/Suspension Service Information
212
Rear Wheel/Suspension - Tools Needed
212
Rear Wheel/Suspension Specifications
212
Rear Wheel/Suspension Troubleshooting
212
Rear Wheel Removal
213
Rear Wheel Disassembly
214
Rear Axle Inspection
215
Rear Wheel Bearing Play Inspection
215
Rear Wheel Rim Runout Inspection
215
Damper Rubber Inspection
216
Rear Wheel Assembly
216
Rear Wheel Installation
218
Rear Shock Absorber Removal
219
Rear Shock Absorber Disassembly
220
Rear Shock Absorber Assembly
221
Rear Shock Absorber Installation
222
Swing Arm Removal
223
Swing Arm Disassembly
224
Pivot Bearing Replacement
225
Swing Arm Assembly
225
Swing Arm Installation
226
Final Drive Exploded View
229
Final Drive Service Information
230
Final Drive - Tools Needed
230
Final Drive Specifications
230
Final Drive Torque Values
231
Final Drive Troubleshooting
231
Final Gear Case Removal
232
Backlash Inspection
232
Oil Seal Removal/Installation
233
Ring Gear Bearing Retainer
233
Gear Case
234
Pinion Gear Retainer
238
Preload Adjustment
240
Final Gear Case Installation
244
Hydraulic Brake Exploded View
245
Hydraulic Brake Service Information
246
Hydraulic Brake - Tools Needed
246
Hydraulic Brake Specifications
246
Hydraulic Brake Troubleshooting
247
Brake Fluid Replacement/Air Bleeding
248
Brake Fluid Draining
248
Brake Fluid Filling
248
Air Bleeding
249
Brake Pad/Disc
250
Front Pad Replacement
250
Rear Brake Pad Replacement
251
Disc Thickness
252
Front Master Cylinder Disassembly
253
Brake Disc Warpage
253
Front Master Cylinder I.D. Inspection
254
Front Master Piston O.D. Inspection
254
Front Master Cylinder Assembly
255
Front Brake Caliper Disassembly
256
Front Caliper Piston O.D. Inspection
257
Front Caliper Assembly
258
Rear Master Cylinder Removal
259
Front Caliper Bracket Disassembly
259
Front Caliper Bracket Assembly
259
Rear Master Cylinder Disassembly
260
Rear Master Cylinder Inspection
261
Rear Master Piston O.D. Inspection
261
Rear Master Cylinder Assembly
261
Rear Brake Caliper Removal
262
Rear Brake Caliper Disassembly
262
Rear Brake Caliper Piston O.D. Inspection
262
Rear Brake Caliper Cylinder I.D. Inspection
263
Rear Brake Caliper Assembly
263
Rear Caliper Bracket Disassembly
264
Rear Caliper Bracket Assembly
264
Brake Pedal Shaft Removal/Installation
265
Battery/Charging System Diagrams
267
Battery/Charging System Service Information
268
Battery/Charging System - Tool Needed
268
Battery/Charging System Specifications
268
Battery/Charging System Troubleshooting
269
Battery Removal
270
Testing Specific Gravity
270
Battery Charging
271
Charging System
271
A.C. Generator Removal/Installation
272
A.C. Generator Inspection
273
A.C. Generator Installation
274
Stator/Rotor Inspection
274
Stator Continuity Test
275
Rotor Continuity Test
275
Voltage Regulator/Rectifier
275
Voltage Regulator Test
275
Rectifier Test
276
Ignition System Diagram
277
Ignition System Service Information
278
Ignition System Specifications
278
Ignition System Troubleshooting
279
Ignition Coil Removal
280
Ignition Coil Performance Test
280
Transistorized Ignition System Inspection
280
Pulser Generator
281
Spark Unit
281
Pulser Replacement
282
Spark Advancer Service
282
Advancer Visual Inspection
283
Advancer Replacement
283
Electrical Starter Service Information
284
Electrical Starter Specifications
284
Electrical Starter Troubleshooting
284
Starter Motor Removal
285
Brush Inspection
286
Commutator Inspection
286
Field Coil Inspection
287
Field Coil Assembly/Installation
287
Starter Relay Switch Inspection
288
Switches Service Information
290
Oil Pressure Warning Switch
291
Brake Switches
291
Neutral Switch
291
Handlebar Switches
292
Headlight Hi-Low Switch
292
Turn Signal Switch
292
Horn Button
292
Starter Button
293
Engine Stop Switch
293
Ignition Switch
294
Clutch Switch Removal
294
Rear Suspension Warning System Troubleshooting
295
Technical Features
298
Oil Cooler, Oil Pump
299
Dual Range Subtransmission
300
Shaft Drive
302
Troubleshooting
304
Engine Does Not Start or Is Hard to Start
304
Engine Lacks Power
305
Poor Performance at Low and Idle Speeds
306
Poor Performance at Hight Speed
306
Poor Handling
306
Wiring Diagram
308
'81 CB900C Addendum
309
'81 Addendum: Specifications
310
'81 Addendum: Torque Values
310
'81 Addendum: Cable & Harness Routing
311
'81 Addendum: Maintenance Schedule
313
'81 Addendum: Inspection and Adjustment
314
'81 Addendum: Cam Chain Tension
314
'81 Addendum: Brake System
315
'81 Addendum: Rear Brake Pedal Height
315
'81 Addendum: Fuel System Service Information
316
'81 Addendum: Troubleshooting
316
'81 Addendum: Carburetor Disassembly and Assembly
316
Fuel Line Diaphragm Removal
317
Fuel Line Diaphragm Inspection
317
Fuel Line Diaphragm Installation
317
Carburetor Tube Routing
317
Pilot Screw Adjustment - Idle Drop Procedure
318
'81 Addendum: Front Wheel/Suspension Specifications
319
'81 Addendum: Front Wheel Removal
320
'81 Addendum: Front Wheel Installation
320
'81 Addendum: Battery/Charging System
322
'81 Addendum: Battery Removal
322
'81 Addendum: Voltage Regulator/Rectifier Inspection
322
'81 Addendum: Battery/Charging System Wiring Diagram
323
'81 Addendum: Switches
324
'81 Addendum: Ignition Switch Disassembly
324
'81 Addendum: Wiring Diagram
325
'81 CB900F Addendum
326
'81 CB900F Addendum: Model Identification
327
'81 CB900F Addendum: Specifications
328
'81 CB900F Addendum: Torque Values
330
'81 CB900F Addendum: Tools Needed
332
'81 CB900F Addendum: Cable & Harness Routing
334
'81 CB900F Addendum: Maintenance Schedule
336
'81 CB900F Addendum: Engine Lubrication Diagram
337
'81 CB900F Addendum: Oil Pump Removal
338
'81 CB900F Addendum: Oil Pump Installation
338
'81 CB900F Addendum: Lubrication Points
339
'81 CB900F Addendum: Inspection and Adjustment
340
'81 CB900F Addendum: Valve Clearance
340
'81 CB900F Addendum: Valve Clearance Adjustment
341
'81 CB900F Addendum: Cam Chain Tension
343
'81 CB900F Addendum: Drive Chain
343
'81 CB900F Addendum: Brake Pad Wear
345
'81 CB900F Addendum: Engine Removal/Installation - Specifications
346
'81 CB900F Addendum: Engine Removal/Installation - Torque Values
346
'81 CB900F Addendum: Engine Removal
347
'81 CB900F Addendum: Engine Installation
351
'81 CB900F Addendum: Crankcase Assembly
353
'81 CB900F Addendum: Front Wheel/Suspension Instruments
353
'81 CB900F Addendum: Indicator Light Bulb Replacement
353
'81 CB900F Addendum: Meter Bulb Replacement
354
'81 CB900F Addendum: Fuse Holder Replacement
354
'81 CB900F Addendum: Front Wheel Removal
355
'81 CB900F Addendum: Front Wheel Installation
355
'81 CB900F Addendum: Front Fork Specifications
356
'81 CB900F Addendum: Front Fork Removal
356
'81 CB900F Addendum: Front Fork Installation
357
'81 CB900F Addendum: Front Fork Separation
359
'81 CB900F Addendum: Front Fork Inspection
360
'81 CB900F Addendum: Front Fork Assembly
361
'81 CB900F Addendum: Rear Wheel/Suspension Service Information
363
'81 CB900F Addendum: Rear Wheel/Suspension Specifications
363
'81 CB900F Addendum: Rear Wheel/Suspension Troubleshooting
363
'81 CB900F Addendum: Rear Wheel Removal
364
'81 CB900F Addendum: Rear Wheel Disassembly
364
'81 CB900F Addendum: Rear Axle Inspection
365
'81 CB900F Addendum: Rear Wheel Bearing Inspection
366
'81 CB900F Addendum: Rear Wheel Rim Runout Inspection
366
'81 CB900F Addendum: Final Driven Sprocket Inspection
366
'81 CB900F Addendum: Damper Rubbers
367
'81 CB900F Addendum: Rear Wheel Assembly
367
'81 CB900F Addendum: Rear Wheel Installatoini
369
'81 CB900F Addendum: Shock Absorber Removal
369
'81 CB900F Addendum: Shock Absorber Disassembly
369
'81 CB900F Addendum: Shock Absorber Inspection
370
'81 CB900F Addendum: Shock Absorber Assembly
370
'81 CB900F Addendum: Shock Absorber Installation
371
'81 CB900F Addendum: Recommended Damping Adjuster Positions
372
'81 CB900F Addendum: Swingarm Removal
372
'81 CB900F Addendum: Swingarm Disassembly
372
'81 CB900F Addendum: Swingarm Inspection
373
'81 CB900F Addendum: Swingarm Assembly
373
'81 CB900F Addendum: Swingarm Installation
373
'81 CB900F Addendum: Hydraulic Brake
374
'81 CB900F Addendum: Front Pad Replacement
374
'81 CB900F Addendum: Rear Pad Replacement
376
'81 CB900F Addendum: Brake Caliper
376
'81 CB900F Addendum: Front Brake Caliper Removal
376
'81 CB900F Addendum: Rear Brake Caliper Removal
376
'81 CB900F Addendum: Caliper Disassembly
377
'81 CB900F Addendum: Caliper Piston O.D. Inspection
378
'81 CB900F Addendum: Caliper Cylinder I.D. Inspection
378
'81 CB900F Addendum: Caliper Assembly
378
'81 CB900F Addendum: Wiring Diagram
379
'81 CB900F Addendum: Rear Master Cylinder Removal
380
'81 CB900F Addendum: Rear Master Cylinder Installation
380
Brake Pedal Shaft Removal
381
Brake Pedal Shaft Installation
381
CB900C, CB900F Wiring Diagram
383
'82 CB900C/F Addendum
384
'82 CB900C/F Addendum: Specifications
385
'82 CB900C/F Addendum: Maintenance Schedule (CB900C)
386
'82 CB900C/F Addendum: Maintenance Schedule (CB900F)
387
'82 CB900C/F Addendum: Oil Recommendation
388
'82 CB900C/F Addendum: Fuel Strainer
388
'82 CB900C/F Addendum: Spark Plugs
389
'82 CB900C/F Addendum: Fuel System
389
'82 CB900C/F Addendum: Float and Jets
389
'82 CB900C/F Addendum: High Altitude Adjustment (USA Only)
390
'82 CB900C/F Addendum: Hydraulic Brakes Service Information/Specifications
391
'82 CB900C/F Addendum: Brake Pad Wear - CB900C
392
'82 CB900C/F Addendum: Valve Clearance
393

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