Table Of Contents - Honda CB900F Hornet Service Manual

Table of Contents

A Few Words About Safety2
Service Information2
For Your Safety2
Important Safety Precautions2
How To Use This Manual3
Contents3
Symbols4
General Information5
Service Rules5
Model Identification6
Frame Serial Number6
Throttle Body Identification Number6
Vehicle Identification Number6
Specifications7
Lubrication System9
Fuel System9
Cooling System10
Cylinder Head/Valves10
Clutch/Gearshaft Linkage11
Alternator/Starter Clutch11
Crankcase/Piston/Cylinder11
Crankshaft/Transmission12
Front Wheel/Suspension/Steering13
Rear Wheel/Suspension13
Hydraulic Brake14
Battery/Charging System14
Ignition System14
Electric Starter15
Lights/Meters/Switches15
Torque Values16
Engine16
Insulator Clamp (Throttle Body Side)18
Insulator Clamp (Cylinder Head Side)18
Exhaust Pipe Stud Bolt18
Frame19
Tools21
Lubrication And Seal Points22
Cable And Harness Routing26
California Type Only37
Emission Control System39
Source Of Emissions39
Crankcase Emission Control System39
Exhaust Emission Control System ( Secondary Air Supply System)40
Evaporative Emission Control Systrem (California Type Only)41
Noise Emission Control System41
Emission Control Information Labels (Usa Only)42
Vacuum Hose Routing Diagarm Label (California Type Only)42
Body Panel Locations43
Frame/Body Panels/Exhaust System Contents44
Troubleshooting44
General44
Seat Removal And Installation45
Side Cover Removal45
Air Cleaner Housing Side Cover Removal And Installation45
Rear Cowl Removal And Installation46
Front Fender Removal And Installation46
Rear Fender Removal And Installation47
Muffler Removal48
Muffler Disassembly And Assembly48
Muffler Installation49
Exhaust Pipe Removal49
Exhaust Pipe Installation50
Maintenance Contents51
Maintenance Schedule53
Fuel Line54
Throttle Operation54
Choke Operation55
Air Cleaner55
Crankcase Breather56
Spark Plug Removal56
Spark Plug Inspection56
Valve Clearance Inspection57
Reusing A Spark Plug57
Replacing A Spark Plug57
Valve Clearance Adjustment60
Oil Level Inspection62
Engine Oil And Filter Change62
Recommended Engine Oil62
Engine Idle Speed63
Radiator Coolant63
Recommended Antifreeze64
Secondary Air Supply System65
Evaporative Emission Control System (California Type Only)65
Drive Chain Slack Inspection66
Drive Chain Adjustment66
Drive Chain Cleaning And Lubrication67
Sprocket Inspection67
Sprocket Replacement68
Brake Fluid70
Drive Chain Guide Plate Inspection70
Front Brake70
Rear Brake70
Brake Pad Wear71
Brake System Inspection71
Front Brake Pads71
Rear Brake Pads71
Brake Light Switch72
Headlight Aim72
Brake Pedal Height Adjustment72
Clutch System73
Side Stand74
Front Suspension Inspection74
Rear Suspension Inspection74
Nuts, Bolts, Fasteners75
Wheels/Tires75
Rear Suspension Adjustment75
Spring Pre-Load Adjuster75
Steering Head Bearings76
Lubrication System Diagram77
Lubrication System Contents78
Oil Pressure Inspection80
Oil Strainer/Pressure Relief Valve80
Oil Pump Removal82
Oil Pump Disassembly83
Oil Pump Inspection83
Oil Pump Assembly84
Oil Pump Installation85
Oil Cooler Removal85
Oil Cooler Inspection86
Oil Cooler Installation86
Fuel System (Programmed Fuel Injection)88
Fuel System Contents89
System Location92
System Diagram93
Pgm-Fi (Programmed Fuel Injection) System94
Self-Diagnostic Procedures94
To Read The Stored Problem Data94
Self-Diagnostic Reset Procedures95
Peak Voltage Inspection Procedure96
Test Harness Connection96
Test Harness Terminal Layout97
Pgm-Fi Self-Diagnosis Malfunction Indicator Lamp (Mil) Failure Codes98
Pgm-Fi Mil 1 Blink (Map Sensor)100
Pgm-Fi Mil 2 Blinks (Map Sensor)102
Pgm-Fi Mil 7 Blinks (Ect Sensor)104
Pgm-Fi Mil 8 Blinks (Tp Sensor)106
Pgm-Fi Mil 9 Blink (Iat Sensor)110
Pgm-Fi Mil 11 Blinks (Vehicle Speed Sensor)112
Pgm-Fi Mil 12 Blink (No. 1 Injector)114
Pgm-Fi Mil 13 Blink (No.2 Injector)117
Pgm-Fi Mil 14 Blinks (No.3 Injector)120
Pgm-Fi Mil 15 Blinks (No.4 Injector)123
Pgm-Fi Mil 18 Blinks (Cam Pulse Generator)126
Pgm-Fi Mil 19 Blinks (Ignition Pulse Generator)128
Pgm-Fi Mil 20 Blinks (E2-Prom)130
Fuel Line Inspection132
Fuel Pressure Inspection132
Fuel Flow Inspection134
Fuel Pump Inspection135
Fuel Pump Removal135
Fuel Filter Replacement136
Fuel Filter Installation136
Fuel Cut Relay Inspection136
Fuel Tank Removal137
Air Cleaner Housing Removal141
Air Cleaner Housing Disassembly142
Air Cleaner Housing Assembly143
Air Cleaner Housing Installation144
Throttle Body Removal146
Throttle Body Disassembly146
Top View147
Rear View147
Throttle Body Vacuum Tube Routing148
Right Side View148
Throttle Body Assembly149
Injector Inspection150
Injector Removal150
Injector Installation151
Pressure Regulator Removal/Installation151
Starter Valve Cable/Throttle Stop Control Knob Removal152
Starter Valve Cable/Throttle Stop Control Knob Installation152
Starter Valve153
Starter Valve Arm153
Link Arm153
Starter Valve Assembly154
Starter Valve Synchronization156
Map Sensor158
Output Voltage Inspection158
Map Sensor Removal/Installation158
Iat Sensor Removal/Installation159
Ect Sensor Removal/Installation159
Cam Pulse Generator Removal/Installation160
Tp Sensor Inspection161
Input Voltage Inspection161
Output Voltage Inspection With Throttle Fully Open161
Output Voltage Inspection With Throttle Fully Closed161
Bank Angle Sensor Inspection162
Calculate Result Comparison162
Bank Angle Sensor Removal/Installation163
Engine Stop Relay Inspection163
Ecm (Engine Control Module) Removal/Installation164
Power/Ground Line Inspection164
Power Input Line164
Pair Solenoid Valve Removal/Installation165
Pair Solenoid Valve Inspection165
Evaporative Emission Control System (California Type Only)Evaporative Emission (Evap) Canister Removal/Installation166
Evap Purge Control Solenoid Valve Removal/Installation166
Evap Purge Control Solenoid Valve Inspection166
System Flow Pattern167
Cooling System Contents168
Coolant (Hydrometer Test)170
Coolant Gravity Chart170
Coolant Replacement Preparation171
Radiator Cap/System Pressure Inspection171
Replacement/Air Bleeding171
Thermostat Removal173
Thermostat Inspection173
Thermostat Installation174
Radiator Removal174
Radiator Disassembly175
Radiator Assembly177
Water Pump179
Radiator Installation179
Mechanical Seal Inspection179
Water Pump Removal180
Water Pump Installation181
Rediator Reserve Tank Removal182
Radiator Reserve Tank Installation182
Engine Removal/Installation Contents184
Drive Sprocket Removal186
Engine Removal187
Engine Installation189
Drive Sprocket Installation191
Cylinder Head/Valves Contents194
Cylinder Compression Test197
Cylinder Head Cover Removal197
Cylinder Head Cover Disassembly/Assembly198
Camshaft Removal199
Camshaft Inspection202
Camshaft Holder Inspection202
Cam Chain Guide B203
Camshaft Oil Clearance203
Cylinder Head Removal204
Cylinder Head Disassembly205
Cylinder Head Inspection206
Valve Lifter Bore207
Valve Filter207
Valve Spring207
Cam Chain Tensioner/Cam Chain Guide207
Valve/Valve Guide208
Valve Guide Replacement209
Valve Seat Inspection/Refacing210
Valve Seat Refacing211
Cylinder Head Assembly213
Cylinder Head Installation214
Camshaft Installation216
Cylinder Head Cover Installation221
Cam Chain Tensioner Lifter Removal222
Cam Chain Tensioner Lifter Installation223
Clutch/Gearshift Linkage Contents225
Right Crankcase Cover Removal227
Clutch Removal228
Clutch Lifter Lever228
Clutch Inspection230
Clutch Lifter Bearing230
Clutch Center231
Clutch Lifter Piece231
Clutch Disc231
Clutch Plate231
Clutch Outer Needle Bearing Replacement232
Clutch Outer/Clutch Outer Guide232
Clutch Outer Needle Bearing Installation233
Gearshaft Linkage Removal236
Shift Fork/Shift Drum Removal237
Gearshaft Linkage Inspection237
Shift Drum/Shift Fork Inspection238
Shift Drum/Shift Fork Installation239
Gearshaft Linkage Installation239
Right Crankcase Cover Installation240
Alternator/Starter Clutch Contents243
Alternator Cover Removal244
Stator Removal244
Stator Installation245
Flywheel Removal245
Starter Clutch Inspection247
Starter Clutch Disassembly247
Starter Clutch Assembly248
Flywheel Installation249
Alternator Cover Installation250
Crankcase/Piston/Cylinder Contents253
Crankcase Separation255
Piston/Connecting Rod Removal256
Piston Removal256
Piston Disassembly256
Piston Inspection257
Cylinder Inspection258
Connecting Rod Inspection259
Side Clearance Inspection259
Crankpin Bearing Inspection259
Crankpin Bearing Selection260
Bearing Installation261
Crankpin Bearing Selection Table261
Piston Assembly262
Piston Installation262
Crankcase Combination264
Crankshaft Removal270
Primary Drive Sub-Gear Removal271
Primary Drive Sub-Gear Installation271
Starter Clutch Needle Bearing Replacement272
Starter Clutch Needle Bearing Installation272
Main Journal Bearing273
Starter Clutch Needle Bearing Inspection273
Bearing Inspection273
Oil Clearance Inspection273
Bearing Selection274
Main Journal Bearing Selection Table275
Bearing Thickness275
Transmission Removal/Disassembly276
Mainshaft Bearing Replacement278
Transmission Assembly279
Transmission Installation281
Front Wheel/Suspension/Steering Contents283
Handlebar Removal285
Handlebar Installation287
Inner Weight Replacement288
Front Wheel Removal292
Front Wheel Inspection293
Front Wheel Disassembly293
Axle293
Wheel Bearing293
Front Wheel Assembly294
Wheel Balance295
Front Wheel Installation296
Fork Removal297
Fork Disassembly298
Fork Inspection301
Fork Tube/Slider/Damper301
Fork Assembly302
Fork Tube Bushing302
Fork Installation306
Steering Stem Removal307
Bearing Race Replacement309
Steering Stem Assembly310
Steering Head Bearing Pre-Load314
Rear Wheel/Suspension Contents316
Rear Wheel Removal318
Rear Wheel Inspection319
Wheel Rim Runout319
Driven Sprocket319
Rear Wheel Disassembly320
Driven Flange Bearing Removal320
Rear Wheel Assembly321
Wheel Bearing Removal321
Wheel Bearing Installation321
Driven Flange Bearing Installation322
Wheel Balance Installation324
Shock Absorber Removal325
Shock Absorber Inspection326
Needle Bearing Replacement326
Shock Absorber Disposal Procedure328
Swingarm Removal329
Swingarm Disassembly/Inspection329
Pivot Bearing Replacement331
Swingarm Assembly332
Swingarm Installation334
Hydraulic Brake Contents337
Brake Fluid Replacement/ Air Bleeding340
Brake Fluid Draining340
Brake Fluid Feeling/Bleeding341
Brake Pad/Disc343
Front Brake Pad Replacement343
Rear Brake Pad Replacement344
Front Master Cylinder Removal346
Brake Disc Inspection346
Front Master Cylinder Disassembly347
Front Master Cylinder Inspection348
Front Master Cylinder Assembly349
Rear Master Cylinder Removal351
Rear Master Cylinder Disassembly352
Rear Master Cylinder Inspection353
Rear Master Cylinder Assembly353
Front Brake Caliper Removal355
Rear Master Cylinder Installation355
Front Brake Caliper Inspection357
Front Brake Caliper Assembly357
Front Brake Caliper Installation358
Rear Brake Caliper Removal359
Rear Brake Caliper Disassembly359
Rear Brake Caliper Inspection360
Rear Brake Caliper Assembly361
Brake Pedal Removal362
Rear Brake Caliper Installation362
Brake Pedal Installation363
Battery/Charging System Diagram365
Battery/Charging System Contents366
Battery Removal/Installation370
Voltage Inspection370
Battery Testing371
Battery Charging372
Charging System Inspection373
Current Leakage Inspection373
Charging Voltage Inspection373
Alternator Charging Coil Inspection374
Regulator/Rectifier374
System Inspection374
Regulator/Rectifier Removal/Installation375
Ignition System System Diagram377
Ignition System Contents378
Ignition System Inspection381
Ignition Coil Primary Peak Voltage381
Ignition Pulse Generator Peak Voltage382
Ignition Coil Removal/Installation384
Ignition Pulse Generator Removal384
Ignition Pulse Generator Installation385
Ignition Timing387
Electrical Starter System Diagram389
Electrical Starter Contents390
Starter Motor Removal393
Starter Motor Disassembly393
Starter Motor Inspection394
Starter Motor Assembly396
Starter Motor Installation398
Starter Relay Switch399
Operation Inspection399
Groud Line Inspection399
Starter Relay Voltage Inspection399
Diode Removal400
Diode Inspection400
Diode Installation400
Starter Relay Switch Removal/Installation400
Lights/Meters/Switches System Location401
Lights/Meters/Switches Contents402
Headlight405
Bulb Replacement405
Bulb Removal406
Bulb Installation406
Turn Signal Bulb Replacement407
Turn Signal Removal/Installation408
Tail/Brake Light Bulb Replacement408
License Light Bulb Replacement409
Combination Meter Removal409
Combination Meter Disassembly410
Combination Meter Assembly411
Combination Meter Installation411
Tachometer System Inspection412
Speedometer/Speed Sensor System Inspection413
Speed Sensor Removal/Installation414
Coolant Temperature Gauge/Sensor Inspection415
Ect Sensor Unit Inspection416
Oil Pressure Switch Inspection417
Oil Pressure Switch Removal/Installation418
Fan Motor Control Relay Inspection419
Fuel Reserve Sensor Inspection419
Ignition Switch Inspection420
Ignition Switch Removal/Installation420
Handlebar Switches421
Clutch Switch422
Neutral Switch422
Side Stand Switch Inspection423
Side Stand Switch Istallation423
Turn Signal Relay Inspection424
Horn424
Wiring Diagrams425
Troubleshooting Contents426
Engine Does Not Start Or Is Hard To Start426
Engine Lacks Power427
Poor Performance At Low And Idle Speed428
Poor Performance At High Speed429
Poor Handling429
Index430