Honda Hornet 2023 Shop Manual
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Honda Hornet 2023 Shop Manual

Honda Hornet 2023 Shop Manual

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Summary of Contents for Honda Hornet 2023

  • Page 1 CB750 Hornet Shop Manual SHOP MANUAL CB750A CB750A...

  • Page 2: How To Use This Manual

    Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.
  • Page 3 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 4 Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). Example: • Molykote® G-n Paste manufactured by Dow Corning U.S.A. • Pro Honda M-77 Assembly Paste (Moly) (U.S.A. only) • Rocol ASP manufactured by Rocol Limited, U.K. • Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease.

  • Page 5: Table Of Contents

    dummyhead dummyhead CB750 Hornet Shop Manual CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE PGM-FI SYSTEM IGNITION SYSTEM ELECTRIC STARTER FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM CYLINDER HEAD/VALVE/CAMSHAFT ALTERNATOR/STARTER CLUTCH CLUTCH/GEARSHIFT LINKAGE CRANKCASE/TRANSMISSION/BALANCER CRANKSHAFT/PISTON/CYLINDER ENGINE REMOVAL/INSTALLATION FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE ANTI-LOCK BRAKE SYSTEM (ABS) BATTERY/CHARGING SYSTEM LIGHTS/METERS/SWITCHES...
  • Page 6 dummyhead dummyhead CB750 Hornet Shop Manual MEMO...

  • Page 7: General Information

    dummytext CB750 Hornet Shop Manual 1. GENERAL INFORMATION SERVICE RULES··································· 1-2 LUBRICATION & SEAL POINTS ············ 1-17 MODEL IDENTIFICATION ······················· 1-3 SPECIAL TOOL LIST ··························· 1-19 SPECIFICATIONS·································· 1-5 CABLE & HARNESS ROUTING ············· 1-21 TORQUE VALUES ······························· 1-11 EMISSION CONTROL SYSTEMS ··········· 1-46...

  • Page 8: Service Rules

    SERVICE RULES GENERAL INFORMATION 1. Use Honda genuine or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.

  • Page 9: Model Identification

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION MODEL IDENTIFICATION SERIAL NUMBERS/LABELS The Vehicle Identification Number (V.I.N) [1] is stamped on The engine serial number [1] is stamped on the left side of the right side of the steering head. the crankcase.
  • Page 10 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION TYPES Destination code OBD2 35 kW conversion 35 kW full power HSTC HSVCS ED, III ED ll ED, IV ED – KO, ll KO – – GS, ll GS – – – –...

  • Page 11: General Specifications

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,090 mm (82.3 in) Overall width 780 mm (30.7 in) Overall height 1,085 mm (42.7 in) Wheelbase 1,420 mm (55.9 in) Seat height 795 mm (31.3 in) Footpeg height 320 mm (12.6 in) Ground clearance...

  • Page 12: Pgm-Fi System Specifications

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION ITEM SPECIFICATIONS DRIVE TRAIN Clutch system Multi-plate, wet Clutch operation system Cable operating Transmission Constant mesh, 6-speeds Primary reduction 1.777 (80/45) Final reduction 2.812 (45/16) Gear ratio 3.000 (39/13) 2.187 (35/16) 1.650 (33/20) 1.320 (33/25) 1.096 (34/31) 0.939 (31/33)

  • Page 13: Cooling System Specifications

    3.5 liters (3.7 US qt, 3.1 Imp qt) – After disassembly 3.8 liters (4.0 US qt, 3.3 Imp qt) – Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent motor oil. API service classification: SJ or higher – JASO T903 standard: MA Viscosity: SAE 10W-30 Oil pressure (at oil filter cartridge) 500 kPa (5.1 kgf/cm...

  • Page 14: Clutch/Gearshift Linkage Specifications

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION ALTERNATOR/STARTER CLUTCH SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter driven gear boss I.D. 42.000 – 42.025 (1.6535 – 1.6545) – O.D. 57.749 – 57.768 (2.2736 – 2.2743) – CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS Unit: mm (in) ITEM STANDARD...

  • Page 15: Front Wheel/Suspension/Steering Specifications

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cold tire Driver only 250 kPa (2.50 kgf/cm , 36 psi) – pressure Driver and passenger 250 kPa (2.50 kgf/cm , 36 psi) –...

  • Page 16: Lights/Meters/Switches Specifications

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Type YTZ10S Capacity 12 V-8.6 Ah (10 HR) / 12 V-9.1 Ah (20 HR) Voltage Fully charged 13.0 – 13.2 V (at 20°C/68°F) Needs charging Below 12.4 V Charging Normal 0.9 A/5 –...

  • Page 17: Standard Torque Values

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt (Include SH flange bolt) 10 (1.0, 7) 6 mm screw 9.0 (0.9, 6.6)
  • Page 18 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION PGM-FI SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) ECT sensor 10 (1.0, 7) A/F sensor 24.5 (2.5, 18) IAT sensor mounting screw 1.1 (0.1, 0.8) MAP sensor mounting screw 4.9 (0.5, 3.6) GP sensor mounting bolt 12 (1.2, 9)
  • Page 19 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION ALTERNATOR/STARTER CLUTCH THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Stator bolt 12 (1.2, 9) Apply locking agent to the threads. Coating width: 6.5 ± 1.0 mm (0.26 ± 0.04 in) except 2.0 ± 1.0 mm (0.08 ±...
  • Page 20 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION CRANKCASE/TRANSMISSION/BALANCER THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Main journal bolt 20 (2.0, 15) + 65° Apply molybdenum oil solution to the threads. Crankcase 8 x 55 bolt 24 (2.4, 18) Crankcase 10 x 70 bolt 39 (4.0, 29) Balancer journal 8 x 45 bolts...
  • Page 21 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Steering stem nut 103 (10.5, 76) Top bridge pinch bolt 22 (2.2, 16) Handlebar upper holder bolt 27 (2.8, 20) Handlebar lower holder nut 27 (2.8, 20) Self-lock nut...
  • Page 22 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION HYDRAULIC BRAKE THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Front brake caliper bleed valve 5.4 (0.6, 4.0) Rear brake caliper bleed valve 5.4 (0.6, 4.0) Front brake caliper mounting bolt 45 (4.6, 33) Replace with new ones.

  • Page 23: Lubrication & Seal Points

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE MATERIAL LOCATION REMARKS Liquid sealant Crankcase mating surface See page 13-5 (Three Bond 1207B or Alternator cover mating surface See page 11-4 equivalent) Alternator wire grommet mating surface See page 11-5 Right crankcase cover mating surface See page 12-6...
  • Page 24 Steering stem adjust nut Engine oil Steering head bearing adjusting nut threads Swingarm pivot nut Honda bond A or equivalent Handlebar grip rubber inside Rear brake caliper bracket pad retainer Silicone grease Brake caliper main and sub slide pin sliding surfaces 0.4 g (0.016 oz)

  • Page 25: Special Tool List

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION SPECIAL TOOL LIST TITLE TOOL No TOOL NAME MAINTENANCE 07708-0030400 Valve Adjusting Wrench ( □3 ) 07HAA-PJ70101 Oil Filter Wrench 07HMH-MR10105 Chain Tool Set PGM-FI SYSTEM 070MZ-0010300 SCS short connector 07ZAJ-RDJA110 Male Pin Prove IGNITION SYSTEM 07HGJ-0020100 Peak Voltage Adaptor...
  • Page 26 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION TITLE TOOL No TOOL NAME REAR WHEEL/SUSPENSION 07746-0050500 Remover Head 17 mm 07746-0050100 Bearing Remover Shaft 9 x 200L 07749-0010000 Driver Handle, 15 x 135L 07746-0010300 Attachment, 42 x 47 mm 07746-0040400 Pilot 17 mm 07946-1870100 Bearing Driver Attachment, 28 x 30...

  • Page 27: Cable & Harness Routing

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION CABLE & HARNESS ROUTING FRONT BRAKE HOSE A LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE CLUTCH CABLE CLUTCH SWITCH WIRE 50 - 70 mm (2.0 - 2.8 in) 1-21...
  • Page 28 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION LEFT HANDLEBAR SWITCH WIRE FRONT BRAKE LIGHT SWITCH FRONT BRAKE HOSE A WIRE CONNECTORS Contact. RIGHT HANDLEBAR SWITCH WIRE CLUTCH SWITCH WIRE METER 24P CONNECTOR 150 - 170 mm (5.9 - 6.7 in) 60 - 80 mm (2.4 - 3.1 in) LEFT FRONT TURN SIGNAL...
  • Page 29 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION Contact. FRONT BRAKE HOSE D Contact. FRONT WHEEL SPEED SENSOR WIRE FRONT BRAKE HOSE D FRONT WHEEL SPEED SENSOR WIRE Clip the marking part of the sensor wire. Clip the marking part of the sensor wire.
  • Page 30 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION HEADLIGHT SUB HARNESS RIGHT FRONT TURN SIGNAL LIGHT 2P (Light blue) CONNECTOR HEADLIGHT SUB HARNESS LEFT FRONT TURN SIGNAL LIGHT 2P (Orange) CONNECTOR RIGHT FRONT TURN SIGNAL LIGHT 2P CONNECTOR LEFT FRONT TURN SIGNAL LIGHT 2P CONNECTOR 1-24...
  • Page 31 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION CLUTCH CABLE FRONT WHEEL SPEED SENSOR WIRE FAN MOTOR WIRE CLUTCH CABLE LEFT HANDLEBAR SWITCH WIRE IMMOBILIZER RECEIVER IGNITION SWITCH WIRE 4P CONNECTOR HEADLIGHT 6P CONNECTOR MAIN WIRE HARNESS 1-25...
  • Page 32 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION METER 24P CONNECTOR Contact. IMMOBILIZER RECEIVER 4P CONNECTOR FRONT BRAKE HOSE A RIGHT HANDLEBAR SWITCH WIRES FUEL TANK STRAP 1-26...
  • Page 33 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION A/F SENSOR 4P CONNECTOR (CH model) RIGHT HANDLEBAR FRONT BRAKE PIPE B FERRITE CORE SWITCH WIRES RIGHT HANDLEBAR SWITCH 8P CONNECTOR RIGHT HANDLEBAR SWITCH (APS) 6P CONNECTOR FRONT BRAKE PIPE C MAIN WIRE HARNESS (to RIGHT HANDLEBAR SWITCH) No.2 IGNITION COIL SIPHON HOSE...
  • Page 34 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION Except CH model: LEFT HANDLEBAR SWITCH WIRE MAIN WIRE HARNESS IGNITION SWITCH 2P CONNECTOR LEFT HANDLEBAR SWITCH 8P CONNECTOR No.1 IGNITION COIL FRONT WHEEL SPEED SENSOR 2P CONNECTOR 1-28...
  • Page 35 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION CH model: LEFT HANDLEBAR SWITCH WIRE MAIN WIRE HARNESS IGNITION SWITCH 2P CONNECTOR (CH model) FERRITE CORE LEFT HANDLEBAR SWITCH No.1 IGNITION COIL 8P CONNECTOR FRONT WHEEL SPEED SENSOR 2P CONNECTOR 1-29...

  • Page 36: Clutch Cable

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION MAIN WIRE HARNESS (to HORN) CLUTCH CABLE A/F SENSOR WIRE MAIN WIRE HARNESS (to HORN) 15° ± 5° REAR RIGHT REAR A/F SENSOR WIRE RIGHT 1-30...

  • Page 37: Main Wire Harness

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION SIDESTAND SWITCH WIRE MAIN WIRE HARNESS (to OIL PRESSURE SWITCH) 45° ± 5° 30 - 50 mm (1.2 - 2.0 in) A/F SENSOR DRAIN HOSE (from FUEL TANK) DRAIN HOSE (from RADIATOR RESERVE TANK) 1-31...
  • Page 38 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION TBW UNIT 6P CONNECTOR IAT SENSOR 2P CONNECTOR MAP SENSOR 3P CONNECTOR No.2 FUEL INJECTOR 2P CONNECTOR MAIN WIRE HARNESS No.1 FUEL INJECTOR 2P CONNECTOR Install the tape fixed side to the fuel pump. FUEL TANK DRAIN HOSE BANK ANGLE SENSOR...
  • Page 39 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION REAR BRAKE HOSE B REAR BRAKE HOSE A NEUTRAL/SHIFT SPINDLE SWITCH 2P CONNECTOR SIDESTAND SWITCH 2P CONNECTOR Contact. REAR BRAKE LIGHT SWITCH 2P CONNECTOR Contact. REAR WHEEL SPEED SENSOR REAR BRAKE PIPE C REAR BRAKE PIPE B 2P CONNECTOR FUEL PUMP...
  • Page 40 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION ALTERNATOR WIRE FUEL TANK DRAIN HOSE SUB WIRE HARNESS SIDESTAND (to NEUTRAL/SHIFT SWITCH WIRE SPINDLE SWITCH) ALTERNATOR MAIN WIRE HARNESS WIRE (to OIL PRESSURE SWITCH) GP SENSOR 3P CONNECTOR 1-34...
  • Page 41 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION STARTER MOTOR CABLE BATTERY (–) NEGATIVE CABLE CKP SENSOR 3P CONNECTOR ECT SENSOR 2P CONNECTOR Contact. VS SENSOR 3P CONNECTOR ALTERNATOR WIRE SUB WIRE HARNESS (to NEUTRAL/SHIFT SPINDLE SWITCH) RESERVE TANK OVERFLOW HOSE 1-35...
  • Page 42 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION Gray tape Horizontal. Contact or horizontal. SHIFT SPINDLE SWITCH NEUTRAL SWITCH SIPHON HOSE REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE HOSE B REAR BRAKE HOSE A 1-36...
  • Page 43 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION PAIR CONTROL SOLENOID VALVE PAIR AIR SUCTION HOSE (from AIR CLEANER) PAIR AIR SUCTION HOSE (to ENGINE) SPARK PLUG WIRE (CH model) (CH model) SPARK PLUG WIRE CRANKCASE BREATHER HOSE REAR BRAKE PIPE C PAIR CONTROL SOLENOID VALVE 2P CONNECTOR...
  • Page 44 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION STARTER RELAY SWITCH 4P CONNECTOR MAIN FUSE (30 A) BATTERY 33P (Gray) CONNECTOR EVAP PURGE CONTROL SOLENOID VALVE 2P CONNECTOR 39P CONNECTOR POWER BOX 33P (Black) CONNECTOR MAIN WIRE HARNESS (to BRAKE/TAIL LIGHT) MAIN WIRE HARNESS (to ECM) MAIN WIRE HARNESS...
  • Page 45 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION Contact. BRAKE/TAIL LIGHT 3P CONNECTOR USB CHARGER 2P CONNECTOR LICENSE LIGHT 2P CONNECTOR BCU 39P CONNECTOR RIGHT TURN SIGNAL LIGHT 2P (Light blue) CONNECTOR LEFT TURN SIGNAL LIGHT 2P (Orange) CONNECTOR 1-39...
  • Page 46 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION REGULATOR/RECTIFIER 3P (Gray) CONNECTOR MAIN WIRE HARNESS (to REGULATOR/RECTIFIER) ALTERNATOR WIRE REGULATOR/RECTIFIER 3P (Black) CONNECTOR MAIN WIRE HARNESS (to GROUND) EVAP CANISTER DRAIN HOSE SIPHON HOSE FUEL TANK DRAIN HOSE 1-40...
  • Page 47 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION REAR WHEEL SPEED SENSOR WIRE REAR BRAKE HOSE B REAR WHEEL SPEED SENSOR WIRE (Clip the marking part of the sensor wire.) MAIN WIRE HARNESS Contact. REAR BRAKE LIGHT SWITCH WIRE GROUND TERMINAL REAR BRAKE HOSE B REAR WHEEL SPEED SENSOR WIRE...

  • Page 48: Rear Brake Light Switch

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION REAR BRAKE HOSE A Contact. Contact. REAR BRAKE HOSE B REAR BRAKE LIGHT SWITCH REAR WHEEL SPEED SENSOR WIRE 1-42...
  • Page 49 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION FUEL PUMP UNIT 5P CONNECTOR FUEL TANK-to- EVAP CANISTER HOSE FUEL TANK DRAIN HOSE FUEL FEED HOSE (Install the tape fixed side to the fuel pump.) LICENSE LIGHT WIRE LEFT TURN SIGNAL LIGHT WIRE RIGHT TURN SIGNAL LIGHT WIRE 1-43...
  • Page 50 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION REAR REAR LEFT RIGHT 45° 45° LEFT LOWER 45° 45° 45° 22.5° 22.5° 25° REAR REAR REAR 45° LOWER LOWER LOWER 1-44...
  • Page 51 dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION FRONT 28° 52° 8° 8° AIR CLEANER HOUSING DRAIN HOSE 1-45...

  • Page 52: Source Of Emissions

    Carbon monoxide does not react in the same way, but it is toxic. Uncontrolled fuel evaporation also releases hydrocarbons to the atmosphere. Honda Motor Co., Ltd. utilizes various system to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.

  • Page 53: Three Way Catalytic Converter

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) The exhaust emission control system is composed of a pulse secondary air supply system, a three-way catalytic converter and PGM-FI system. SECONDARY AIR SUPPLY SYSTEM The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port.

  • Page 54: Noise Emission Control System

    dummyhead dummyhead CB750 Hornet Shop Manual GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM Fuel vapor from the fuel tank is routed into the EVAP canister where it is absorbed and stored while the engine is stopped. When the engine is running and the EVAP purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn into the engine. FUEL TANK EVAP CANISTER THROTTLE BODY...

  • Page 55: Frame/Body Panels/Exhaust System

    dummytext CB750 Hornet Shop Manual 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION························ 2-2 REARVIEW MIRROR···························· 2-11 TROUBLESHOOTING ···························· 2-2 REAR COWL A/REAR COWL B/ SEAT CENTER COWL·························· 2-11 BODY PANEL LOCATIONS····················· 2-3 REAR CENTER COWL ························· 2-13 SEAT ··················································· 2-4 REAR FENDER A ································ 2-13 SIDE COVER ········································...

  • Page 56: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION FRAME/BODY PANEL S/EXHAUST SYSTEM GENERAL • This section covers removal and installation of the body panels and exhaust system. • When disassembling, mark and store the mounting fasteners to ensure that they are reinstalled in their original locations. •...

  • Page 57: Body Panel Locations

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS [16] [6]/[7]/[8] [20] [15] [25] [13] [12] [26] [10] [14] [17] [18] [21] [19] [11] [23] [27] [22] [24] [1] Front seat page 2-4 [15] Rear cowl B page 2-11 [2] Rear seat page 2-4...

  • Page 58: Front Seat

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL/INSTALLATION FRONT SEAT Remove the socket bolts [1] and front seat [2] by pulling it rearward. Remove the grommets [3] and collars [4] if necessary. Installation is in the reverse order of removal. •...

  • Page 59: Side Cover

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER REMOVAL/INSTALLATION Remove the following: – Front seat (page 2-4) – Socket bolts [1], [2] Release the tabs [3], boss [4] from the grommet and remove the side cover [5]. Installation is in the reverse order of removal.
  • Page 60 dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM HEADLIGHT COWL REMOVAL/INSTALLATION Remove the headlight side cowls (page 2-5). Remove the socket bolts [1], [2], [3] and headlight cowl [4]. Installation is in the reverse order of removal. HEADLGHT INNER COVER REMOVAL/INSTALLATION Remove the meter (page 21-8).
  • Page 61 dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM HEADLIGHT STAY REMOVAL/INSTALLATION Remove the following: – Headlight (page 21-3) – Left/right turn signal light (page 21-5) Remove the headlight 4P (Gray) connector [1] and immobilizer receiver 4P connector [2] from the headlight stay [3].
  • Page 62 dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM HEADLIGHT UPPER STAY REMOVAL/INSTALLATION Remove the headlight stay (page 2-7). Turn the clutch adjust bolt [1] and align the slits to disconnect the clutch cable. Remove the pivot nut [2], pivot bolt [3] and clutch lever [4].
  • Page 63 dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM FRONT SHELL REMOVAL/INSTALLATION Remove the shroud A (page 2-8). Remove the socket bolts [1], [2] and front shell [3]. Installation is in the reverse order of removal. SHROUD B REMOVAL/INSTALLATION LEFT SIDE Remove the following: [2] [1] –...

  • Page 64: Right Side

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM RIGHT SIDE Remove the following: – Right handlebar switch connector clip [1] – Socket bolt [2] – Socket bolt [3] – Clip [4] Release the boss [5] from the grommet [6]. Remove the shroud B [7], grommet [8] and joint duct [9].

  • Page 65: Rear View Mirror

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM REARVIEW MIRROR REMOVAL/INSTALLATION Slide the boot [1] off from the lock nut [2]. Loosen the lock nut (left-hand threads) and remove the rearview mirror [3]. Remove the mirror adaptor [4]. Installation is in the reverse order of removal. TORQUE: Rearview mirror adaptor bolt: 20 N·m (2.0 kgf·m, 15 lbf·ft)
  • Page 66 dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the clips [1], screws [2] and rear cowl B [3] from the rear cowl A [4]. Remove the clips [5] and rear cowl A from the seat center cowl [6]. Assembly is in the reverse order of disassembly.

  • Page 67: Rear Fender A

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM REAR CENTER COWL REMOVAL/INSTALLATION Remove the rear cowl A/rear cowl B/seat center cowl (page 2-11). Remove the clips [1] and rear center cowl [2]. Installation is in the reverse order of removal. REAR FENDER A REMOVAL/INSTALLATION Remove the rear seat (page 2-4).
  • Page 68 dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the tapping screws [1] and rear fender cover [2]. Remove the socket bolts [3], collars [4], mount rubbers [5], socket bolt [6], collar [7], mount rubber [8] and rear fender stay [9] from the rear fender A [10].

  • Page 69: Rear Fender B

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER B REMOVAL/INSTALLATION Remove the following: – Brake/tail light (page 21-7) – BCU (page 21-26) – USB charger (page 21-25) – ECM (page 4-58) – Starter relay switch (page 6-8) –...

  • Page 70: Front Fender

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the following: – Front wheel (page 16-10) – Brake hose joint bolt [1] – Brake hose clamp cap nut [2] – Wire clip [3] – Socket bolts [4] –...
  • Page 71 dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM DRIVE SPROCKET COVER REMOVAL/INSTALLATION Remove the pinch bolt [1] and gearshift arm [2]. Release the wire band [3]. Remove the bolts [4], drive sprocket cover [5], drive chain guide [6], collars [7] and wire clip [8], if necessary Align remove the wire band.
  • Page 72 dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM MAIN STEP BRACKET REMOVAL/INSTALLATION • For right main step bracket removal/installation, refer to following: – Brake pedal (page 18-22) – Rear master cylinder (page 18-16) Remove the socket bolts [1], left main step bracket [2] and cover [3].
  • Page 73 dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER REMOVAL/INSTALLATION Loosen the muffler band bolt [1]. Remove the following: – Nut [2] – Bolt [3] – Washer [4] – Muffler [5] – Collar [6] – Grommet [7] – Gasket [8] Installation is in the reverse order of removal.

  • Page 74: Exhaust Pipe

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE REMOVAL/INSTALLATION Remove the following: – Right shroud B (page 2-9) – Muffler (page 2-19) Remove the wire band [1] and disconnect the A/F sensor 4P (Black) connector[2]. Remove the wire bands [3]. Remove the wire clips [1].

  • Page 75: Stud Bolt Replacement

    dummyhead dummyhead CB750 Hornet Shop Manual FRAME/BODY PANELS/EXHAUST SYSTEM STUD BOLT REPLACEMENT Remove the exhaust pipe (page 2-20). Thread two nuts onto the stud bolt and tighten them together, and use a wrench on them to turn the stud bolt out.
  • Page 76 dummyhead dummyhead CB750 Hornet Shop Manual MEMO...

  • Page 77: Maintenance

    SERVICE INFORMATION························ 3-2 SECONDARY AIR SUPPLY SYSTEM······ 3-14 MAINTENANCE SCHEDULE ··················· 3-2 EVAPORATIVE EMISSION CONTROL SYSTEM ············································ 3-15 HONDA DIAGNOSTIC SYSTEM ··············· 3-4 DRIVE CHAIN ····································· 3-16 FUEL LINE ··········································· 3-4 DRIVE CHAIN SLIDER ························· 3-19 THROTTLE OPERATION ························ 3-4 BRAKE FLUID ····································...

  • Page 78: Service Information

    * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by a dealer. Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: 1.
  • Page 79 * Should be serviced by a dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by a dealer. Honda recommends that a dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: 1.

  • Page 80: System Inspection

    CB750 Hornet Shop Manual MAINTENANCE HONDA DIAGNOSTIC SYSTEM SYSTEM INSPECTION Check the Honda diagnostic system as follows: 1. Remove the front seat (page 2-4). 2. Turn the ignition switch OFF. 3. Remove the dummy connector [1] from the DLC [2].

  • Page 81: Air Cleaner

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE THROTTLE BODY (CH model only) Remove the throttle body (page 7-14). Clean the throttle bores [1] and throttle valve [2] surfaces by lightly rubbing with a shop towel soaked with a commercially available carburetor cleaner until the carbon deposits are completely removed.

  • Page 82: Crankcase Breather

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE CRANKCASE BREATHER Check the air cleaner housing drain hose [1]. • Service if the deposits level can be seen in the drain hose. If necessary, remove the drain plug [2] from the drain hose and drain the deposits into a suitable container.

  • Page 83: Valve Clearance

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE Check the gap between the center and side electrodes with a wire type feeler gauge [1]. • To prevent damaging the iridium center electrode, use a wire type feeler gauge to check the spark plug gap.
  • Page 84 dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE Check the No.1 cylinder intake valve clearances by inserting a feeler gauge [1] between the valve lifter and cam lobe. Adjust the valve clearance by changing the valve lifter shim (page 3-10). Rotate the crankshaft clockwise and align the "2T"mark [1] on the pulser plate with the index mark [2] of the right crankcase cover.
  • Page 85 dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE Check the No.2 cylinder exhaust valve clearances by inserting a feeler gauge [1] between the rocker arm roller and cam lobe. Adjust the No.2 cylinder exhaust valve clearance by loosening the lock nut [1] and turning the adjusting screw [2] until there is a slight drag on the feeler gauge [1]/[2] [3].
  • Page 86 dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE Check the No.1 cylinder exhaust valve clearances by inserting a feeler gauge [1] between the locker arm roller and cam lobe. Adjust the No.1 cylinder exhaust valve clearance by loosening the lock nut [1] and turning the adjusting screw [2] until there is a slight drag on the feeler gauge [3].

  • Page 87: Oil Level Inspection

    If the level is below the lower level [2], on the dipstick, add the recommended engine oil to the upper level [3]. RECOMMENDED ENGINE OIL: Honda "4-stroke motorcycle oil" or an equivalent motor oil. API service classification: SJ or higher...

  • Page 88: Engine Oil Capacity

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE ENGINE OIL CHANGE Warm up the engine. Stop the engine and remove the oil filler cap/dipstick. Place an oil pan under the engine to catch the engine oil, then remove the engine oil drain bolt [1] and sealing washer [2].

  • Page 89: Engine Idle Speed

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE Clean the oil filter attaching surface of the crankcase. Apply engine oil to new oil filter cartridge threads and O-ring [1]. Install and tighten the oil filter cartridge [2] to the specified torque using the special tool. TOOL: Oil Filter Wrench [3] 07HAA-PJ70101...

  • Page 90: Radiator Coolant

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE RADIATOR COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER" [1] and "LOWER" [2] level lines. If necessary, add the recommended coolant (page 1-7). Remove the front seat (page 2-4).

  • Page 91: Evaporative Emission Control System

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM Lift and support the fuel tank (page 7-6). Check the hoses between the fuel tank [1], EVAP canister [2], EVAP purge control solenoid valve [3] and throttle body [4] for deterioration, damage or loose connection.

  • Page 92: Drive Chain

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE DRIVE CHAIN Amputation hazard. Never inspect or adjust the drive chain while the engine is running. SLACK INSPECTION Turn the ignition switch OFF, support the motorcycle on its sidestand, and shift the transmission into neutral. Check the slack in the drive chain lower run midway between the sprockets.

  • Page 93: Cleaning And Lubrication

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE CLEANING AND LUBRICATION Clean the drive chain [1] with a chain cleaner designed specifically for O-ring chains. Use a soft brush if the drive chain is dirty. Do not use a steam cleaner, high pressure cleaner, wire brush, volatile solvent such as gasoline and benzene, abrasive cleaner or a chain cleaner NOT designed specifically for O-ring chains to clean the drive chain.
  • Page 94 dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE REPLACEMENT This motorcycle uses a drive chain with a staked master link. Fully slacken the drive chain (page 3-16). Remove the drive chain using the special tool. 1 LINK • When using special tool, follow manufacturer's instruction.

  • Page 95: Drive Chain Slider

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE DRIVE CHAIN SLIDER Check the drive chain slider for wear or damage. The drive chain slider must be replaced if it is worn to the wear limit indicator [1] (page 17-11). BRAKE FLUID Spilled fluid can damage painted, plastic or rubber parts.

  • Page 96: Brake Pads Wear

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE REAR BRAKE Place the motorcycle on a level surface, and support it in an upright position. Check the rear brake fluid reservoir level. If the level is near the lower level line [1], check the brake pad wear (page 3-20).

  • Page 97: Brake Lever Adjustment

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE BRAKE LEVER ADJUSTMENT Turn the adjuster [1] until the numbers align with the index mark [2] while pushing the lever forward in the desired position. After adjustment, check that the lever operates correctly before riding.

  • Page 98: Clutch System

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE CLUTCH SYSTEM Measure the clutch lever freeplay at the end of the clutch lever [1]. FREEPLAY:10 – 20 mm (0.4 – 0.8 in) Minor adjustment is made with the upper adjuster [1] at the clutch lever side.

  • Page 99: Front Suspension Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brakes and compressing the front suspension several times. Check the entire assembly for signs of leaks, damage or loose fasteners. Replace the damaged components which cannot be repaired.

  • Page 100: Nuts, Bolts, Fasteners

    dummyhead dummyhead CB750 Hornet Shop Manual MAINTENANCE NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-11). Check that all safety clips, hose clamps and cable stays are in place and properly secured. WHEELS/TIRES Support the motorcycle securely and raise the front wheel off the ground.

  • Page 101: Pgm-Fi System

    dummytext CB750 Hornet Shop Manual 4. PGM-FI SYSTEM SERVICE INFORMATION························ 4-2 VS SENSOR ······································· 4-60 PGM-FI SYSTEM LOCATION··················· 4-3 GP SENSOR ······································· 4-60 PGM-FI TROUBLESHOOTING SHIFT SPINDLE SWITCH······················ 4-61 INFORMATION······································ 4-4 MAP SENSOR····································· 4-61 PGM-FI SYMPTOM TROUBLESHOOTING ···························· 4-7 IAT SENSOR ······································ 4-61 PGM-FI SYSTEM DTC INDEX ··················...

  • Page 102: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM SERVICE INFORMATION PGM-FI SYSTEM GENERAL • This section covers electrical system service of the PGM-FI system. For other service and fuel supply system, see Fuel System section (page 7-2). • A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before proceeding.

  • Page 103: Pgm-Fi System Location

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM PGM-FI SYSTEM LOCATION IAT SENSOR IMMOBILIZER RECEIVER MAP SENSOR METER VS SENSOR BANK ANGLE SENSOR EVAP PURGE CONTROL SOLENOID VALVE STARTER RELAY SWITCH/ MAIN FUSE (30 A) IGNITION SWITCH CLUTCH SWITCH IGNITION COIL PAIR CONTROL SOLENOID VALVE FUEL INJECTOR...

  • Page 104: Pgm-Fi Troubleshooting Information

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting.

  • Page 105: Dtc Readout

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM GST (Generic Scan Tool) INFORMATION • The GST can readout the DTC, stored data, current data and other ECM condition. How to connect the GST Turn the ignition switch OFF. Remove the front seat (page 2-4). Remove the dummy connector [1] from the DLC [2].

  • Page 106: Erasing Stored Dtc

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM Reading current DTC with the meter Turn the ignition switch ON. 1. Push and hold the SEL switch [1] to the right until the SETTING mode is displayed. 2. Push the down side of the SEL switch to select the SERVICE menu, and push it to the right.

  • Page 107: Pgm-Fi Symptom Troubleshooting

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM The ECM connector terminals (wire harness side) are numbered as shown WIRE HARNESS SIDE TERMINAL LAYOUT: in the illustration. – ECM 39P (Black) connector A [1] – ECM 33P (Black) connector B [2] –...
  • Page 108 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM PGM-FI SYSTEM DTC INDEX • When using GST or MCS, check the lighting or blinking state of the MIL and then refer to DTC index. • Follow the prior diagnosis notes before performing the troubleshooting, refer to the PRIOR DIAGNOSIS (page 4-11). Meter Detected display/...
  • Page 109 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM Meter Detected display/ Refer to DTC name (Driving page blinks Cycle) Random/multiple Cylinder Misfire Detected (Random/multiple Cylinder Misfire Detected A) (When the MIL is blinking) P0300 4-27 Random/multiple Cylinder Misfire Detected (Random/multiple Cylinder Misfire Detected B) (When the MIL is lighting) CKP Sensor Variation Not Learned P0315...
  • Page 110 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM Meter Detected display/ Refer to DTC name (Driving page blinks Cycle) APS 1 Sensor Circuit Range Problem P2121 4-49 (APS 1 (TCP) Circuit Range/performance) APS 1 Sensor Circuit Low P2122 (APS 1 (TCP) Low Voltage) 4-50 APS 1 Sensor Circuit High P2123...
  • Page 111 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM PGM-FI SYSTEM DTC TROUBLESHOOTING PRIOR DIAGNOSIS Before processing the DTC troubleshooting, check as follows: • Check for loose or poor contact on the DTC related connectors (each sensor, solenoid, unit etc.), then recheck the DTC.

  • Page 112: Yes - Go To Step

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0031/P0032 Probable cause: • Faulty A/F sensor heater or its related circuit • Faulty ECM Symptom/Fail-safe function: • Fuel consumption deterioration • Detected value feedback stops 1. A/F Sensor Heater Line Open Circuit Inspection Disconnect the ECM 39P connector (page 4-58).
  • Page 113 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. A/F Sensor Inspection Replace the A/F sensor with a new one (page 4-63). Connect the disconnected connector(s). Erase the DTC (page 4-6). Start the engine and wait for a minute. Check the DTC with GST or MCS. Is same DTC indicated? –...
  • Page 114 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0106 Probable cause: • Faulty MAP sensor or its related circuit • Contaminated intake manifold or throttle bore • Faulty ECM Symptom/Fail-safe function: • Rough idling • Driveability deterioration 1. MAP Sensor Inspection Replace the MAP sensor with a new one (page 4- 61).
  • Page 115 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 3. MAP Sensor Signal Line Short Circuit Inspection Check for continuity between the wire harness side MAP sensor 3P connector [1] and ground. CONNECTION: Yellow – Ground Is there continuity? – Short circuit in the Yellow wire –...
  • Page 116 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0112/P0113 Probable cause: • Faulty IAT sensor or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine operates normally 1. IAT Sensor Output Line Open Circuit Inspection Disconnect the ECM 39P connector (page 4-58). Disconnect the IAT sensor 2P connector (page 4- 61).
  • Page 117 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. IAT Sensor Inspection Replace the IAT sensor with a new one (page 4-61). Erase the DTC (page 4-6). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS. Is same DTC indicated? –...
  • Page 118 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 2. ECT Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side ECT sensor 2P connector [1] and ground. CONNECTION: Blue/yellow – Ground Is there continuity? – Short circuit in the Blue/yellow wire Bu/Y –...
  • Page 119 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P011B Probable cause: • Faulty ECT sensor or its related circuit • Insufficient coolant • Faulty thermostat • Faulty water pump • Clogged coolant passage • Faulty IAT sensor or its related circuit •...
  • Page 120 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0122/P0123 Probable cause: • Faulty TP sensor or its related circuits • Faulty ECM Symptom/Fail-safe function: • Engine operates at idle speed • HSTC does not operate 1. TP Sensor 1 Input Voltage Inspection Turn the ignition switch OFF.
  • Page 121 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. TP Sensor 1 Inspection Replace the throttle body (TP sensor) (page 7-14). Connect the disconnected connector(s). Erase the DTC (page 4-6). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS.
  • Page 122 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0131/P0132 Probable cause: • Faulty A/F sensor or its related circuit • Faulty ECM Symptom/Fail-safe function: • Fuel consumption deterioration • Detected value feedback stops 1. A/F Sensor Output Line Open Circuit Inspection Disconnect the A/F sensor 4P connector (page 4- 63).
  • Page 123 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. A/F sensor Inspection Replace the A/F sensor with a new one (page 4-63). Connect the disconnected connector(s). Erase the DTC (page 4-6). Start the engine and wait for a minute. Stop the engine. Check the DTC with GST or MCS.
  • Page 124 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0201/P0202 Probable cause: • Faulty fuel injector or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine does not start (Fuel injectors, fuel pump and ignition shut down) 1. Fuel Injector Input Voltage Inspection Disconnect the fuel injector 2P connectors (page 7- 15).
  • Page 125 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. Fuel Injector Inspection Replace the fuel injector with a new one (page 7- 15). Connect the disconnected connector(s). Erase the DTC (page 4-6). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS.
  • Page 126 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0222/P0223 Probable cause: • Faulty TP sensor or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine operates at idle speed • HSTC does not operate 1. TP Sensor 2 Input Voltage Inspection Disconnect the TBW unit 6P connector (page 7-14).
  • Page 127 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. TP Sensor 2 Inspection Replace the throttle body (TP sensor) (page 7-14). Connect the disconnected connector(s). Erase the DTC (page 4-6). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS.
  • Page 128 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0315 Probable cause: • Faulty CKP sensor • Faulty crank pulse initialize learning • Faulty ECM Symptom/Fail-safe function: • Engine operates normally • This DTC is erased at the 1 D/C (driving cycle) after detecting the system normally.
  • Page 129 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0335 Probable cause: • Faulty CKP sensor or its related circuits • Faulty ECM Symptom/Fail-safe function: • Engine does not start (Fuel injectors, fuel pump and ignition shut down) 1. CKP Sensor Input Voltage Inspection Turn the ignition switch OFF.
  • Page 130 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. CKP Sensor Inspection Replace the CKP sensor with a new one (page 4- 64). Connect the disconnected connector(s). Erase the DTC (page 4-6). Start the engine and wait for 10 seconds. Check the DTC with GST or MCS.
  • Page 131 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 3. Ignition Coil Primary Coil Signal Line Short Circuit Inspection Check for continuity between the wire harness side ignition coil wire connector [1] and ground. CONNECTION: No.1: Brown – Ground No.2: Pink – Ground Is there continuity? –...
  • Page 132 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 2. PAIR Control Solenoid Valve Signal Line Open Circuit Inspection Disconnect the ECM 33P (Black) connector (page 4-58). Check for continuity between the wire harness side PAIR control solenoid valve connector [1] and ECM 33P connector [2].
  • Page 133 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0443 Probable cause: • Faulty EVAP purge control solenoid valve or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine operates normally 1. EVAP Purge Control Solenoid Valve Input Voltage Inspection Disconnect the EVAP purge control solenoid valve 2P connector (page 7-19).
  • Page 134 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. EVAP Purge Control Solenoid Valve Inspection Replace the EVAP purge control solenoid valve with a new one (page 7-19). Connect the disconnected connector(s). Erase the DTC (page 4-6). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS.
  • Page 135 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 3. ECM Inspection Replace the ECM with a new one (page 4-58). Connect the disconnected connector(s). Erase the DTC (page 4-6). Perform the test ride (page 4-11). Check the DTC with GST or MCS. Is same DTC indicated? –...
  • Page 136 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 3. Sub VB Relay Line Open Circuit Inspection Check for continuity between the wire harness side sub VB relay connector [1] and ECM 39P connector [2]. CONNECTION: Black – A8 Is there continuity? –...
  • Page 137 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P062F Probable cause: • Faulty ECM Symptom/Fail-safe function: • Hard to start • Does not hold the self-diagnosis data – The MIL come on (the DTC can be readout and erased only by GST or MCS). 1.
  • Page 138 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0704 Probable cause: • Faulty clutch switch or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine operates normally 1. Clutch Switch Output Line Open Circuit Inspection Disconnect the clutch switch 2P connector (page 21-20).
  • Page 139 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P0722 Probable cause: • Faulty VS sensor or its circuit • Faulty ECM Symptom/Fail-safe function: • Engine operates normally 1. VS Sensor Ground Line Open Circuit Inspection Disconnect the VS sensor 3P connector (page 4- 60).
  • Page 140 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. VS Sensor Signal Line Open Circuit Inspection Disconnect the ECM 33P (Gray) connector (page 4- 58). Check for continuity between the wire harness side VS sensor 3P connector [1] and ECM 33P connector [2].
  • Page 141 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 3. Bank Angle Sensor Signal Line Open Circuit Inspection Check for continuity between the wire harness side bank angle sensor 2P connector [1] and ECM 39P connector [2] terminals. CONNECTION: Red – A37 Is there continuity? –...
  • Page 142 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P1658/P1659 Probable cause: • Faulty TBW relay or its related circuit • Blown fuse TBW (10 A) • Faulty ECM Symptom/Fail-safe function: • Motorcycle speed is limited: approximately 120 km/h (75 mph) (for DTC P1658) •...
  • Page 143 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. TBW Relay Inspection Replace the TBW relay with a new one (page 21- 24). Connect the disconnected connector(s). Erase the DTC (page 4-6). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS.
  • Page 144 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 2. Throttle Body Inspection Check the throttle bores [1] and valves visually for carbon deposits. Is there contamination? – Clean the throttle bores and valves carefully. – GO TO STEP 3. 3. TBW System Inspection Replace the throttle body with a new one (page 7- 14).
  • Page 145 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P1702/P1703 Probable cause: • Faulty GP sensor or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine operates normally 1. GP Sensor Input Voltage Inspection Disconnect the GP sensor 3P connector (page 4- 60).
  • Page 146 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. GP Sensor Inspection Replace the GP sensor with a new one (page 4-60). Connect the disconnected connector(s). Erase the DTC (page 4-6). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS.
  • Page 147 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 3. Shift Spindle Switch Inspection Replace the shift spindle switch with a new one (page 4-61). Erase the DTC (page 4-6). DTC P1708: Operate the UP shift three times or more. DTC P1709: Operate the DOWN shift three times or more.
  • Page 148 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 3. Shift Stroke Sensor Output Line Short Circuit Inspection Check for continuity between the wire harness side shift stroke sensor 4P connector [1] and ground. CONNECTION: White – Ground Is there continuity? –...
  • Page 149 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 2. TBW Motor Line Short Circuit Inspection 1 Check for continuity between the wire harness side TBW motor 6P connector [1] and ground. CONNECTION: Red – Ground G/Bl Green/black – Ground Is there continuity? –...
  • Page 150 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P2122/P2123 Probable cause: • Faulty APS 1 or its related circuit • Faulty ECM Symptom/Fail-safe function: • Engine operates at idle speed 1. APS 1 Input Voltage Inspection Disconnect the right handlebar switch (APS) 8P connector (page 21-17).
  • Page 151 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. APS 1 Inspection Replace the right handlebar switch (APS) (page 21- 17). Connect the disconnected connector(s). Erase the DTC (page 4-6). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS.
  • Page 152 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 3. APS 2 Output Line Short Circuit Inspection Check for continuity between the wire harness side right handlebar switch (APS) 8P connector [1] and ground. CONNECTION: Gray – Ground Is there continuity? –...
  • Page 153 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 2. TP Sensor Inspection Replace the throttle body (TP sensor) (page 7-14). Connect the disconnected connector(s). Erase the DTC (page 4-6). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS. Is same DTC indicated? –...
  • Page 154 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P2158 Probable cause: • Faulty rear wheel speed sensor or its related circuit • ABS modulator has DTC (CAN lines included) • Faulty ECM Symptom/Fail-safe function: • Engine operates normally • HSTC does not operate •...
  • Page 155 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC P2195/P2196 Probable cause: • Faulty A/F sensor or its related circuit • Faulty fuel injector or its fuel pressure too low • Faulty ECT sensor • Faulty ECM Symptom/Fail-safe function: • Hard to start at a low temperature •...
  • Page 156 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM DTC U0001 • When other DTC is displayed, together with U0001, troubleshoot the other DTC first. Probable cause: • Faulty CAN line(s) • Faulty CAN connected unit(s) Symptom/Fail-safe function: • CAN communication failure 1.
  • Page 157 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 4. CAN Line Short Circuit Inspection Check for continuity between the wire harness side ECM 39P connector [1] and ground. CONNECTION: A31 – Ground A30 – Ground Is there continuity? – • Short circuit in the Brown wire •...

  • Page 158: Mil Circuit Troubleshooting

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM 2. Meter Inspection Replace the meter with a new one (page 21-8). Connect the disconnected connector(s). Erase the DTC (page 4-6). Turn the ignition switch ON and wait for 10 seconds. Check the DTC with GST or MCS. Is same DTC indicated? –...

  • Page 159: Power/Ground Line Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM POWER/GROUND LINE INSPECTION Disconnect the ECM 39P connector (page 4-58). POWER INPUT LINE Measure the voltage between the wire harness side ECM 39P connector [1] and ground. CONNECTION: A11 (+) – Ground (–) There should be battery voltage with the ignition switch turned ON.
  • Page 160 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM VS SENSOR REMOVAL/INSTALLATION Remove the bolt [1], VS sensor [2] and O-ring [3]. Disconnect the VS sensor 3P connector [4]. Installation is in the reverse order of removal. • Replace the O-ring with a new one. •...

  • Page 161: Map Sensor

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM SHIFT SPINDLE SWITCH REMOVAL/INSTALLATION Remove the radiator reserve tank (page 8-9). Remove the nut [1], shift spindle switch wire [2], shift spindle switch [3] and sealing washer [4]. Installation is in the reverse order of removal. TORQUE: Shift spindle switch: 12 N·m (1.2 kgf·m, 9 lbf·ft)

  • Page 162: Ect Sensor

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM ECT SENSOR REMOVAL/INSTALLATION Drain the coolant (page 8-5). Disconnect the ECT sensor 2P connector [1]. Remove the bolt [2], ECT sensor [3] and O-ring [4]. Installation is in the reverse order of removal. •...
  • Page 163 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM A/F SENSOR REMOVAL/INSTALLATION Remove the shroud B (page 2-9). Remove the wire band [1] and disconnect the A/F sensor 4P connector [2]. Remove the wire bands [3]. Remove the wire clips [1]. Remove the A/F sensor [1] using the special tool.

  • Page 164: Ckp Sensor

    dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM CKP SENSOR REMOVAL/INSTALLATION Disconnect the CKP sensor 3P connector [1]. Remove the bolt [2], CKP sensor [3] and O-ring [4]. Installation is in the reverse order of removal. TORQUE: CKP sensor bolt: 12 N·m (1.2 kgf·m, 9 lbf·ft) •...
  • Page 165 dummyhead dummyhead CB750 Hornet Shop Manual PGM-FI SYSTEM CRANK PULSE LEARNING RESET PROCEDURE 1. Connect the SCS short connector to the DLC (page 4-5). 2. Turn the ignition switch ON. Open the throttle grip fully within 5 seconds. Close the throttle grip completely within 3 seconds. Wait for more than 10 seconds.
  • Page 166 dummyhead dummyhead CB750 Hornet Shop Manual MEMO...

  • Page 167: Ignition System

    dummytext CB750 Hornet Shop Manual 5. IGNITION SYSTEM SERVICE INFORMATION························ 5-2 SYSTEM DIAGRAM ······························· 5-5 TROUBLESHOOTING ···························· 5-3 IGNITION SYSTEM INSPECTION ············· 5-6 SYSTEM LOCATION ······························ 5-4 IGNITION COIL ····································· 5-8...

  • Page 168: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual IGNITION SYSTEM SERVICE INFORMATION IGNITION SYSTEM GENERAL • The ECM may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive voltage may damage the module. Always turn off the ignition switch before servicing. •...

  • Page 169: Troubleshooting

    dummyhead dummyhead CB750 Hornet Shop Manual IGNITION SYSTEM TROUBLESHOOTING • Inspect the following before diagnosing the system. – faulty spark plug – loose spark plug cap or spark plug wire connection – water got into the spark plug cap (Leaking the ignition coil secondary current) •...

  • Page 170: System Location

    dummyhead dummyhead CB750 Hornet Shop Manual IGNITION SYSTEM SYSTEM LOCATION ENGINE STOP SWITCH STARTER RELAY SWITCH/ MAIN FUSE (30 A) No.2 IGNITION COIL BATTERY BANK ANGLE SENSOR IGNITION SWITCH SPARK PLUGS No.1 IGNITION COIL POWER BOX - FI/START FUSE (10 A) CKP SENSOR - SUB VB/IGN FUSE (10 A) - ENG STOP RELAY...

  • Page 171: System Diagram

    dummyhead dummyhead CB750 Hornet Shop Manual IGNITION SYSTEM SYSTEM DIAGRAM MAIN FI/START FUSE FUSE IGNITION (30 A) (10 A) SWITCH R/Bl Bl/W BATTERY STOP RELAY Bl/W Bl/W Bl/Br ENGINE STOP SWITCH Bl/W Bl/W Bl/W Bl/W Bl/W BANK ANGLE SENSOR CKP SENSOR No.1 IGNITION COIL/ No.2 IGNITION COIL/ SPARK PLUG...

  • Page 172: Ignition System Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark at the plug, check all connections for loose or poor contact before measuring the peak voltage. • Use a commercially available digital multimeter with an impedance of 10 MΩ/DCV minimum.
  • Page 173 dummyhead dummyhead CB750 Hornet Shop Manual IGNITION SYSTEM With the connectors connected, connect the peak voltage adaptor [2] or Imrie tester probes to the ignition coil primary terminal [3] and ground. TOOL: Imrie diagnostic tester (model 625) or Peak Voltage Adaptor 07HGJ-0020100 with commercially available digital multimeter (–)

  • Page 174: Ignition Coil

    dummyhead dummyhead CB750 Hornet Shop Manual IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Remove the shroud B (page 2-9). Left side shown: [3]/[4] Disconnect the primary wire connectors [1]. Remove the wire clip [2], bolts [3], spacers [4] and ignition coil [5]. Remove the connector [6] from the stay [7].

  • Page 175: Electric Starter

    dummytext CB750 Hornet Shop Manual 6. ELECTRIC STARTER SERVICE INFORMATION························ 6-2 SYSTEM DIAGRAM ······························· 6-4 TROUBLESHOOTING ···························· 6-2 STARTER MOTOR································· 6-5 SYSTEM LOCATION ······························ 6-3 STARTER RELAY SWITCH ····················· 6-8...
  • Page 176 dummyhead dummyhead CB750 Hornet Shop Manual ELECTRIC STARTER SERVICE INFORMATION ELECTRIC STARTER GENERAL If the current is kept flowing through the starter motor causing it to turn while the engine is not cranking over, the starter motor may be damaged. •...
  • Page 177 dummyhead dummyhead CB750 Hornet Shop Manual ELECTRIC STARTER SYSTEM LOCATION STARTER SWITCH/ ENGINE STOP SWITCH STARTER RELAY STARTER RELAY SWITCH/ MAIN FUSE (30 A) IGNITION SWITCH CLUTCH SWITCH POWER BOX - FI/START FUSE (10 A) STARTER MOTOR - ENGINE STOP RELAY BATTERY SIDESTAND SWITCH NEUTRAL SWITCH...
  • Page 178 dummyhead dummyhead CB750 Hornet Shop Manual ELECTRIC STARTER SYSTEM DIAGRAM MAIN FI/START FUSE IGNITION FUSE (30 A) SWITCH (10 A) R/Bl Bl/W Bl/W Y/Bu STARTER SWITCH STARTER Bl/Br RELAY ENGINE STARTER BATTERY SWITCH STOP RELAY SWITCH STARTER MOTOR ENGINE STOP RELAY Bl/W Bl/W...

  • Page 179: Starter Motor

    dummyhead dummyhead CB750 Hornet Shop Manual ELECTRIC STARTER STARTER MOTOR REMOVAL/INSTALLATION Remove the ABS modulator (page 19-24). [2]/[3]/[4] Release the rubber cap [1]. Remove the starter motor cable terminal nut [2] and washer [3] and disconnect the starter motor cable [4]. Remove the bolts [5] and disconnect the battery (–) negative cable [6].
  • Page 180 dummyhead dummyhead CB750 Hornet Shop Manual ELECTRIC STARTER DISASSEMBLY/ASSEMBLY The coil may be damaged if the magnet pulls the armature against the motor case. SETTING BOLTS 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) FRONT COVER O-RING SEAL RING ARMATURE MOTOR CASE TERMINAL BOLT SEAL RING WASHER...

  • Page 181: Front Cover

    dummyhead dummyhead CB750 Hornet Shop Manual ELECTRIC STARTER INSPECTION FRONT COVER Check the oil seal [1] in the front cover for deterioration, wear, or damage. Turn the inner race of the bearings [2] in the front cover with your finger. The bearing should turn smoothly and quietly.

  • Page 182: Starter Relay Switch

    dummyhead dummyhead CB750 Hornet Shop Manual ELECTRIC STARTER STARTER RELAY SWITCH REMOVAL/INSTALLATION Disconnect the battery negative (–) cable (page 20-5). Remove the starter relay switch cover [1]. Disconnect the starter relay switch 4P connector [1]. Remove the bolts [2]. Disconnect the starter motor cable [3] and battery positive (+) cable [4].

  • Page 183: Fuel System

    dummytext CB750 Hornet Shop Manual 7. FUEL SYSTEM SERVICE INFORMATION························ 7-2 AIR CLEANER HOUSING ····················· 7-12 COMPONENT LOCATION ······················· 7-3 THROTTLE BODY ······························· 7-14 FUEL LINE INSPECTION ························ 7-4 FUEL INJECTOR ································· 7-15 FUEL TANK ·········································· 7-6 SECONDARY AIR SUPPLY SYSTEM······ 7-16 FUEL FILLER CAP ································...
  • Page 184 dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM SERVICE INFORMATION FUEL SYSTEM GENERAL • Before disconnecting the fuel feed hose, relieve fuel pressure from the system (page 7-4). • Seal the intake port with a piece of tape or a clean cloth to keep dirt and debris from entering the engine after the throttle body has been removed.

  • Page 185: Component Location

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM COMPONENT LOCATION 10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)

  • Page 186: Fuel Line Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM FUEL LINE INSPECTION FUEL PRESSURE RELIEVING • Before disconnecting fuel feed hose, relieve pressure from the system as follows. 1. Turn the ignition switch OFF. 2. Lift and support the fuel tank (page 7-6). 3.

  • Page 187: Fuel Pressure Normalization

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM FUEL PRESSURE NORMALIZATION 1. Connect the fuel pump unit 5P (Black) connector [1]. 2. Turn the ignition switch ON with the engine stop switch " ". • Do not start the engine. The fuel pump will run for about 2 seconds, and fuel pressure will rise.

  • Page 188: Fuel Flow Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM FUEL FLOW INSPECTION Disconnect the quick connect fitting from the fuel pipe side (page 7-4). Release the fuel feed hose [1] from the wire band [2] Wipe off spilled out and place the end of the fuel feed hose into an gasoline.
  • Page 189 dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM REMOVAL/INSTALLATION Disconnect the quick connect fitting from the fuel pump unit side (page 7-4). Release the strap [1] from the fuel tank. Disconnect the fuel tank drain hose [2] and fuel tank-to- EVAP canister hose [3].

  • Page 190: Fuel Filler Cap

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM FUEL FILLER CAP REMOVAL/INSTALLATION Remove the following: – Socket bolts [1] – Fuel filler cap [2] – Breather seal [3] • A pressure release can be heard when opening the fuel cap, but this is not blockage of the passage. If checking for clog in the passage of the fuel tank side is necessary, apply air pressure to the breather hose end with the fuel filler cap opened.
  • Page 191 dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM REMOVAL Remove the fuel tank (page 7-6). Clean around the fuel pump unit. Loosen the fuel pump unit mounting nuts [1] in a crisscross pattern in 2 or 3 steps and remove them. Remove the set plate [2] and fuel pump unit [3].
  • Page 192 dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM Visually inspect the suction filter [1] for dirt, debris, or clogging. Replace the fuel pump unit if necessary. Remove the fuel pump [2] and pressure regulator [3]. Remove the O-ring [4] from the fuel pump. Remove the fuel unit/stay [1].
  • Page 193 dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM Install a new O-ring [1] onto the fuel pump [2]. Install the fuel pump into the fuel filter. • Route the green wire [3] as shown. Install a new O-ring [1] onto the flange [2]. Install the fuel filter assembly [3] into the flange.

  • Page 194: Installation

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM INSTALLATION Install new dust seal [1] and fuel pump gasket [2] into the fuel pump unit properly. • Be careful not to pinch any dirt or debris. Install the fuel pump unit [1] and set plate [2] as shown. Install the fuel pump mounting nuts [3] and tighten them to the specified torque in the sequence as shown.
  • Page 195 dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM Remove the left intake duct [1]. Align Loosen the air cleaner connecting hose band screws [1]. Remove the bolt/washer [2] and air cleaner housing [3]. Installation is in the reverse order of removal. TORQUE: Air cleaner housing joint screw: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

  • Page 196: Throttle Body

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM THROTTLE BODY REMOVAL/INSTALLATION Remove the air cleaner housing (page 7-12). Disconnect the following: – MAP sensor 3P connector [1] – TBW 6P connector [2] – Fuel feed hose [3] – Hose (EVAP purge control solenoid valve-to-throttle body) [4] –...

  • Page 197: Fuel Injector

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM FUEL INJECTOR REMOVAL/INSTALLATION Disconnect the fuel feed hose from the fuel pipe (page 7-4). Remove the following: – Fuel injector 2P connectors [1] – Bolts [2] – Fuel injector assembly [3] – Fuel injector [1] –...

  • Page 198: System Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to normal operating temperature. Stop the engine. Remove the air cleaner housing (page 7-12). Check that the hose joint (secondary air intake port) [1] of the air cleaner housing is clean and free of carbon deposits.

  • Page 199: Pair Control Solenoid Valve Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM Remove the bolts [1], washers [2], stay [3] and PAIR control solenoid valve [4]. Remove the hoses [5] and grommet [6]. Installation is in the reverse order of removal. • Install the hoses as shown. [1]/[2] PAIR CONTROL SOLENOID VALVE INSPECTION...
  • Page 200 dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM PAIR CHECK VALVE REMOVAL/ INSTALLATION Remove the air cleaner housing (page 7-12). Remove the PAIR air suction hose [1], bolts [2] and check valve cover [3]. Remove the PAIR check valves [1] and port plates [2]. Installation is in the reverse order of removal.
  • Page 201 dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM EVAP PURGE CONTROL SOLENOID VALVE REMOVAL/INSTALLATION Remove the front seat (page 2-4). Disconnect the following: – EVAP purge control solenoid valve 2P connector [1] – Hose [2] (EVAP purge control solenoid valve-to- throttle body) –...

  • Page 202: Evap Canister

    dummyhead dummyhead CB750 Hornet Shop Manual FUEL SYSTEM EVAP CANISTER REMOVAL/INSTALLATION Remove the battery (page 20-5). Remove the EVAP purge control valve (page 7-19). Remove the EVAP canister drain hose [1] out of the frame. Remove the EVAP canister [2]. Disconnect the following: –...

  • Page 203: Cooling System

    dummytext CB750 Hornet Shop Manual 8. COOLING SYSTEM SERVICE INFORMATION························ 8-2 THERMOSTAT HOUSING ······················· 8-7 TROUBLESHOOTING ···························· 8-2 RADIATOR/COOLING FAN ····················· 8-7 SYSTEM FLOW PATTERN······················ 8-3 RADIATOR RESERVE TANK··················· 8-9 SYSTEM TESTING································· 8-4 WATER PUMP ···································· 8-10 COOLANT REPLACEMENT ···················· 8-5 WATER PUMP COVER·························...

  • Page 204: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual COOLING SYSTEM SERVICE INFORMATION COOLING SYSTEM GENERAL Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages.

  • Page 205: System Flow Pattern

    dummyhead dummyhead CB750 Hornet Shop Manual COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR CAP RADIATOR THERMOSTAT WATER PUMP RADIATOR RESERVE TANK...

  • Page 206: System Testing

    dummyhead dummyhead CB750 Hornet Shop Manual COOLING SYSTEM SYSTEM TESTING RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the right shroud B (page 2-9). Remove the radiator cap [1]. Wet the sealing surfaces of the cap [1], then install the cap onto the tester [2]. Pressurize the radiator cap using the tester.

  • Page 207: Coolant Replacement

    dummyhead dummyhead CB750 Hornet Shop Manual COOLING SYSTEM COOLANT REPLACEMENT REPLACEMENT/AIR BLEEDING • When filling the system or reserve tank with coolant, or checking the coolant level, place the motorcycle in an upright position on a flat, level surface. Remove the right shroud B (page 2-9). Remove the front seat (page 2-4).
  • Page 208 dummyhead dummyhead CB750 Hornet Shop Manual COOLING SYSTEM THERMOSTAT REMOVAL/INSTALLATION Drain the coolant (page 8-5). Remove the bolts [1] and the thermostat cover [2]. Remove the thermostat [1] from the thermostat housing. Installation is in the reverse order of removal. TORQUE: Thermostat cover bolt: 12 N·m (1.2 kgf·m, 9 lbf·ft)

  • Page 209: Thermostat Housing

    dummyhead dummyhead CB750 Hornet Shop Manual COOLING SYSTEM THERMOSTAT HOUSING REMOVAL/INSTALLATION Remove the following. – Thermostat (page 8-6) – Hose band [1] – Bypass hose [2] – Bolts [3] – Sealing washer [4] – Thermostat housing [5] – O-ring [6] Installation is in the reverse order of removal.

  • Page 210: Radiator Cap

    dummyhead dummyhead CB750 Hornet Shop Manual COOLING SYSTEM • Be careful not to damage the radiator fins. Remove the front wheel speed sensor wire clip [1] and release the wire [2] from the fan motor cover guides [3]. Remove the radiator [4]. Installation is in the reverse order of removal.

  • Page 211: Radiator Reserve Tank

    dummyhead dummyhead CB750 Hornet Shop Manual COOLING SYSTEM RADIATOR RESERVE TANK REMOVAL/INSTALLATION Remove the following: – Front seat (page 2-4) – Drive sprocket cover (page 2-17) – Swingarm (page 17-11) Remove the reserve tank cap [1]. Remove the socket bolts [2], then release the boss of the radiator reserve tank [3] from the hole of frame.

  • Page 212: Mechanical Seal Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Check the bleed hole [1] of the water pump for signs of coolant leakage. • A small amount of coolant weeping from the bleed hole is normal. •...
  • Page 213 dummyhead dummyhead CB750 Hornet Shop Manual COOLING SYSTEM WATER HOSE BAND INSTALLATION Install a new water hose bands [1] onto the water hose [2] then connect the water hoses. Pinch the ear portion of the water hose band with a pincher until the pinched area clearance as shown to secure water hose.
  • Page 214 dummyhead dummyhead CB750 Hornet Shop Manual MEMO...

  • Page 215: Lubrication System

    dummytext CB750 Hornet Shop Manual 9. LUBRICATION SYSTEM SERVICE INFORMATION························ 9-2 OIL PUMP ············································ 9-5 TROUBLESHOOTING ···························· 9-2 OIL STRAINER······································ 9-7 LUBRICATION SYSTEM DIAGRAM·········· 9-3 PISTON OIL JET ··································· 9-8 OIL PRESSURE INSPECTION ················· 9-4...
  • Page 216 dummyhead dummyhead CB750 Hornet Shop Manual LUBRICATION SYSTEM SERVICE INFORMATION LUBRICA TION SYSTEM GENERAL Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil.

  • Page 217: Lubrication System Diagram

    dummyhead dummyhead CB750 Hornet Shop Manual LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFT PISTON CAM CHAIN TENSIONER LIFTER CRANKSHAFT FRONT BALANCER SHAFT PISTON OIL JETS OIL ORIFICES A ENGINE OIL FILTER CARTRIDGE REAR BALANCER SHAFT CLUTCH MAINSHAFT EOP SWITCH OIL PUMP OIL ORIFICES B COUNTERSHAFT OIL STRAINER...

  • Page 218: Oil Pressure Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual LUBRICATION SYSTEM OIL PRESSURE INSPECTION Remove the engine oil filter cartridge (page 3-12). Apply engine oil to the O-ring and install the attachment oil pressure [1] onto the oil filter boss. TOOL: Attachment Oil Pressure 070MJ-0010101 Apply engine oil to the O-ring and engine oil filter cartridge threads.

  • Page 219: Oil Pump

    dummyhead dummyhead CB750 Hornet Shop Manual LUBRICATION SYSTEM OIL PUMP REMOVAL/INSTALLATION Remove the right crankcase cover (page 12-4). Remove the oil pump mounting bolts [1] and oil pump [2]. Remove the O-ring [1] and oil pump packing [2]. Align Installation is in the reverse order of removal. •...

  • Page 220: Lubrication System Specifications

    dummyhead dummyhead CB750 Hornet Shop Manual LUBRICATION SYSTEM DISASSEMBLY/ASSEMBLY • Dip all parts in clean engine oil. OIL PUMP DRIVEN GEAR OIL PUMP BODY SNAP RING DOWEL PINS OIL PUMP BODY GASKET ENGINE OIL FEED PUMP OUTER ROTOR ENGINE OIL FEED PUMP INNER ROTOR DRIVE PIN DOWEL PINS...

  • Page 221: Oil Strainer

    dummyhead dummyhead CB750 Hornet Shop Manual LUBRICATION SYSTEM OIL STRAINER REMOVAL Drain the engine oil (page 3-12). Remove the exhaust pipe (page 2-20). Loosen the bolts [1] in a crisscross pattern in 2 or 3 steps. Remove the following: – Bolts –...
  • Page 222 dummyhead dummyhead CB750 Hornet Shop Manual LUBRICATION SYSTEM PISTON OIL JET REMOVAL/INSTALLATION Remove the cylinder (page 14-12). Remove the oil jet bolt [1] and piston oil jet [2]. Remove the O-ring [1]. Installation is in the reverse order of removal. •...

  • Page 223: Cylinder Head/Valve/Camshaft

    dummytext CB750 Hornet Shop Manual 10. CYLINDER HEAD/VALVE/CAMSHAFT SERVICE INFORMATION······················ 10-2 ROCKER ARM ···································· 10-6 TROUBLESHOOTING ·························· 10-2 CAM CHAIN TENSIONER/LIFTER ·········· 10-8 COMPONENT LOCATION ····················· 10-3 CAMSHAFT ······································· 10-10 CYLINDER COMPRESSION ·················· 10-4 CYLINDER HEAD ······························· 10-14 CYLINDER HEAD COVER····················· 10-4 INSULATOR ······································...
  • Page 224 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT SERVICE INFORMATION CYLINDER HEA D/VALVE/CAMSHAF T GENERAL • This section covers service of the cylinder head, valves, rocker arms and camshaft. These services can be done with the engine installed in the frame. •...

  • Page 225: Component Location

    dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT COMPONENT LOCATION 10 N·m (1.0 kgf·m, 7 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) + 115° 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 10-3...

  • Page 226: Cylinder Compression

    dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT CYLINDER COMPRESSION Warm up the engine to normal operating temperature. Stop the engine, and remove the spark plugs (page 3- Temporarily connect the IAT sensor 2P connector. Install the compression gauge [1] into the spark plugs hole.
  • Page 227 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT INSTALLATION Install new plug pipe seals [1] to the cylinder head cover. • Install the plug pipe seals with their sentences [2] facing the inside of the engine. Install a new cylinder head cover packing [3] to the cylinder head cover.

  • Page 228: Rocker Arm

    dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT ROCKER ARM REMOVAL Remove the following: – Cylinder head cover (page 10-4) – Timing hole cap (page 3-7) Turn the crankshaft clockwise and align the "1T" mark [1] with the index mark [2] of the right crankcase cover. Make sure that the "1"...
  • Page 229 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT INSPECTION Inspect the following parts for damage, abnormal wear, deformation, burning. – Rocker arm A – Rocker arm B – Rocker arm shaft Measure each part according to CYLINDER HEAD/ VALVE/CAMSHAFT SPECIFICATIONS (page 1-7). Replace any part if it is out of the service limit.

  • Page 230: Cam Chain Tensioner/Lifter

    dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Apply molybdenum oil solution to the rocker arm sliding area and thrust surface. Apply molybdenum oil solution to the rocker arm shaft outer surface. Temporarily install the suitable 8 mm bolt [1] to the rocker arm shaft [2].

  • Page 231: Cam Chain Tensioner Removal

    dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Installation is in the reverse order of removal. • Apply more than 0.5 cm engine oil to the cam chain tensioner [1] slit end surface of shaft. • Replace the gasket with a new one. •...
  • Page 232 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT CAMSHAFT REMOVAL Remove the rocker arms (page 10-6). Turn the crankshaft clockwise and align the "2T" mark [1] with the index mark [2] of the right crankcase cover. Make sure that the index lines [3] on the cam sprocket aligns with the upper surface of the cylinder head and "2"...

  • Page 233: Camshaft Oil Clearance

    dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Remove the valve lifters [1] and shims [2]. • Do not allow the shims to fall into the crankcase. • Mark all valve lifters and shims to ensure correct reassembly in their original locations. •...
  • Page 234 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Install the camshaft holders A [1] and B [2] in the correct locations (page 10-12). • Be careful not to drop the plastigauge. Apply engine oil to the threads and seating surfaces of the camshaft holder bolts.
  • Page 235 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Install the shims [1] and valve lifters [2]. • Do not allow the shims to fall into the crankcase. • Install all valve lifters and shims in their original locations. Apply molybdenum oil solution to the camshaft journal [1], cam lobes and thrust surfaces.
  • Page 236 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Apply molybdenum oil solution to the left camshaft holder A and right camshaft holder A insides. Install the left camshaft holder A [1] and right camshaft holder A [2]. • The left camshaft holder A and right camshaft holder A have the following identification marks: –...
  • Page 237 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Disconnect the breather hose [1]. Remove the cylinder head bolts [2]. Loosen the cylinder bolts [3]. Loosen the cylinder head bolt/washers [1]. • Loosen the cylinder head bolt/washers in a crisscross pattern in 2 or 3 steps. Lift up the cylinder head [1] to get the clearance for cam chain guide [2] removal.
  • Page 238 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Remove the gasket [1] and dowel pins [2]. DISASSEMBLY Remove the following: – Insulator (page 10-24) – Spark plugs (page 3-6) TOOL: Tappet Hole Protector 26 x 28 [1] 07999-4220000 Install the tappet hole Protector 26 x 28 into the valve lifter bore.
  • Page 239 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Remove carbon deposits from the combustion chamber [1]. INSPECTION Inspect the following parts for damage, abnormal wear, deformation, burning or clogs in oil passages. – Cylinder head – Valve springs – Valves –...

  • Page 240: Valve Seat Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT VALVE GUIDE REPLACEMENT Disassemble the cylinder head (page 10-16). Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. Heat the cylinder head to 100 – 150°C (212 – 302°F) Do not use a torch with a hot plate or oven.

  • Page 241: Valve Seat Refacing

    dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Reface the valve seat (page 10-19) in the following cases: – Valve seat contact area is too wide or too narrow – Valve seat contact surface is not center – Damaged valve seat contact face •...
  • Page 242 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT ASSEMBLY VALVE COTTERS EXHAUST VALVE OUTER SPRING SPRING RETAINER EXHAUST STEM SEAL EXHAUST VALVE INNER SPRING INTAKE VALVE SPRING INTAKE STEM SEAL SPRING SEAT VALVE GUIDE INTAKE EXHAUST STEM SEAL STEM SEAL INTAKE VALVE EXHAUST VALVE 10-20...
  • Page 243 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Blow through the oil passage in the cylinder head with compressed air. Install the spring seats [1]. Apply molybdenum oil solution to the inside of new stem seals. Install new intake stem seals [2] and exhaust stem seals [3].
  • Page 244 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Tap the valve stems gently to seat the valve cotters firmly using a hammer and suitable shaft [1]. • Support the cylinder head above the work bench surface to prevent valve damage. Install the following: –...
  • Page 245 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT Install and tighten the cylinder head bolt/washers [1] to the specified torque. TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft) + 115° • Tighten the cylinder head bolt/washers in a crisscross pattern in 2 or 3 steps. Tighten the cylinder bolts [2].
  • Page 246 dummyhead dummyhead CB750 Hornet Shop Manual CYLINDER HEAD/VALVE/CAMSHAFT INSULATOR REMOVAL/INSTALLATION Remove the throttle body (page 7-14). Remove the insulator mounting bolts [1] and insulator [2]. Remove the O-rings [3] from the insulator. Installation is in the reverse order of removal. TORQUE: Insulator mounting bolt: 12 N·m (1.2 kgf·m, 9 lbf·ft)

  • Page 247: Alternator/Starter Clutch

    dummytext CB750 Hornet Shop Manual 11. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION······················ 11-2 STATOR ············································ 11-5 TROUBLESHOOTING ·························· 11-2 FLYWHEEL ········································ 11-6 COMPONENT LOCATION ····················· 11-3 STARTER CLUTCH ····························· 11-8 ALTERNATOR COVER························· 11-4 11-1...

  • Page 248: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION ALTERNATOR/STARTER CLUT CH GENERAL • This section covers service of the alternator and starter clutch. All service can be done with the engine installed in the frame. • For alternator charging coil inspection (page 20-8) •...

  • Page 249: Component Location

    dummyhead dummyhead CB750 Hornet Shop Manual ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION 157 N·m (16.0 kgf·m, 116 lbf·ft) 11-3...

  • Page 250: Alternator Cover

    dummyhead dummyhead CB750 Hornet Shop Manual ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER REMOVAL/INSTALLATION Drain the engine oil (page 3-12). Remove the following: – Drive sprocket cover (page 2-17) – Water pump cover (page 8-10) Release the wire clip [1]. Disconnect the alternator 3P (Gray) connector [2]. Remove the alternator cover bolt [1].
  • Page 251 dummyhead dummyhead CB750 Hornet Shop Manual ALTERNATOR/STARTER CLUTCH Installation is in the reverse order of removal. 25 – 30 mm (1.0 – 1.2 in) • Clean any oil from the alternator cover thoroughly. • Apply liquid sealant (TB1207B manufactured by 10 –...
  • Page 252 dummyhead dummyhead CB750 Hornet Shop Manual ALTERNATOR/STARTER CLUTCH FLYWHEEL REMOVAL Remove the alternator cover (page 11-4). Remove the starter idle gear shaft [1] and starter idle gear [2]. Remove the starter reduction gear shaft [3] and starter reduction gear [4]. Hold the flywheel [1] using the special tool and loosen [2]/[4] the flywheel mounting bolt [2].
  • Page 253 dummyhead dummyhead CB750 Hornet Shop Manual ALTERNATOR/STARTER CLUTCH INSPECTION Inspect the following parts for scratches, damage, abnormal wear, or deformation. – Starter idle/reduction gear shaft – Starter idle/reduction gear – Woodruff key – Needle bearing Replace if necessary. INSTALLATION Install the woodruff key [1]. •...
  • Page 254 dummyhead dummyhead CB750 Hornet Shop Manual ALTERNATOR/STARTER CLUTCH STARTER CLUTCH REMOVAL Remove the flywheel (page 11-6). Make sure that the starter driven gear [1] turns counterclockwise smoothly does turn clockwise. Remove the starter driven gear while turning the starter driven gear counterclockwise. Hold the flywheel [1] using the special tool.
  • Page 255 dummyhead dummyhead CB750 Hornet Shop Manual ALTERNATOR/STARTER CLUTCH INSTALLATION Apply engine oil to the starter one-way clutch sliding surface. Install the starter one-way clutch [1] to the starter clutch outer [2]. Install the starter clutch assembly [3]. Hold the flywheel [1] using the special tool. TOOL: Holder Flywheel [2] 07725-0040001...
  • Page 256 dummyhead dummyhead CB750 Hornet Shop Manual MEMO...

  • Page 257: Clutch/Gearshift Linkage

    dummytext CB750 Hornet Shop Manual 12. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION······················ 12-2 PULSER PLATE ································· 12-15 TROUBLESHOOTING ·························· 12-2 PRIMARY DRIVE GEAR ······················ 12-16 COMPONENT LOCATION ····················· 12-3 GEARSHIFT LINKAGE ························ 12-17 RIGHT CRANKCASE COVER ················ 12-4 GEARSHIFT ARM/ GEARSHIFT PEDAL ··························· 12-21 CLUTCH·············································...
  • Page 258 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION CLUTCH/GEARSHIFT LINKAGE GENERAL • This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame. • Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motorcycle creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.
  • Page 259 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION 12 N·m (1.2 kgf·m, 9 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 147 N·m (15.0 kgf·m, 108 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12-3...

  • Page 260: Right Crankcase Cover

    dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-12). Remove the bolt [1] and clutch cable stay [2]. Disconnect the clutch cable [3] from the clutch lifter lever [4]. Remove the right crankcase cover bolts [1]. Turn the clutch lifter lever [2] counterclockwise to disengage the lifter lever slit from the clutch lifter pin.
  • Page 261 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE CLUTCH LIFTER LEVER REMOVAL/INSTALLATION Remove the right crankcase cover (page 12-4). Hook Remove the clutch lifter lever [1] and return spring [2]. Installation is in the reverse order of removal. • Align the return spring end with the clutch lifter lever groove.
  • Page 262 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE INSTALLATION Clean the right crankcase cover mating surfaces 10 – 15 mm thoroughly. (0.4 – 0.6 in) Apply liquid sealant (TB1207B manufactured by Three Bond or equivalent) to the right crankcase cover mating surface as shown.
  • Page 263 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE Connect the clutch cable [1] to the clutch lifter lever [2]. Install the bolt [3] and clutch cable stay [4]. • Align the clutch cable stay hole with the right crankcase cover boss. Fill the engine with the recommended engine oil and check that there are no oil leaks (page 3-12).
  • Page 264 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE Unstake the clutch center lock nut [1]. Unstake • Be careful not to damage the mainshaft threads. Install special tool. TOOL: Clutch Center Holder 07724-0050002 P.D. 48-135 [1] Loosen the clutch center lock nut [2] while holding the clutch center with the special tool.
  • Page 265 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE Remove the needle bearing [1], washer [2] and clutch outer guide [3]. INSPECTION Check the following for scratches, damage, abnormal wear and deformation: – Clutch pressure plate cam areas [1] – Clutch pressure plate grooves [2] –...
  • Page 266 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE Inspect the following parts for scratches, damage, abnormal wear and deformation. Replace if necessary. – Clutch springs – Clutch spring seats – Clutch lifter pin – Clutch friction discs/plates – Judder spring –...
  • Page 267 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE INSTALLATION WASHER CLUTCH OUTER CLUTCH CENTER THRUST WASHER SPRING WASHER CLUTCH CENTER LOCK NUT 147 N·m (15.0 kgf·m, 108 lbf·ft) CLUTCH PLATES A (6 pcs) JUDDER SPRING CLUTCH SEAT FRICTION DISC B JUDDER SPRING CLUTCH...
  • Page 268 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE Apply molybdenum oil solution to the clutch outer guide entire surface. Apply engine oil to the needle bearing. Install the clutch outer guide [1], washer [2] and needle bearing [3]. Apply molybdenum oil solution to the primary driven gear teeth and clutch outer sliding area.
  • Page 269 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE Stake the clutch center lock nut [1]. Stake • Be careful not to damage the mainshaft threads. Apply molybdenum oil solution to the entire surface of judder spring seat and judder spring. Install the judder spring seat [1] and judder spring [2] onto the clutch center [3] as shown.
  • Page 270 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE Install the clutch lifter pin [1]. Apply engine oil to the entire surface of clutch friction disc B. Install the clutch friction disc B [1] onto the clutch pressure plate B [2]. Install the clutch plate B [3] onto the clutch friction disc •...
  • Page 271 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE Apply engine oil to the clutch springs. [1]/[3] Install the clutch springs [1], clutch set plate [2] and clutch set plate bolts [3]. Tighten the clutch set plate bolts in a crisscross pattern in 2 or 3 steps to the specified torque.

  • Page 272: Primary Drive Gear

    dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE INSTALLATION Install the pulser plate [1]. Align • Align the pulser plate wide tooth with the crankshaft wide tooth. Apply engine oil to the pulser plate bolt threads and seating surface. Install the washer [1] and pulser plate bolt [2]. •...
  • Page 273 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE INSTALLATION Apply engine oil to the primary drive gear teeth. Align Align Install the primary drive gear [1] with its "OUT" mark [2] facing out. • Align the primary drive gear wide tooth with the crankshaft wide tooth.
  • Page 274 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE Remove the shift drum center bolt [1]. Remove the shift drum center [1] while holding the shift drum stopper arm [2] using a screwdriver as shown. Remove the following: – Dowel pin [1] –...
  • Page 275 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE INSPECTION Inspect the following parts for damage, abnormal wear and deformation. Replace if necessary. – Shift drum center – Shift drum stopper arm – Shift drum return spring – Gearshift spindle INSTALLATION Install a new oil seal [1] until it is fully seated.
  • Page 276 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE Apply locking agent to the shift drum center bolt threads (page 1-11). Install and tighten the shift drum center bolt [1] to the specified torque. TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft) Install the thrust washer [1] onto the gearshift spindle [2].
  • Page 277 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE GEARSHIFT ARM/GEARSHIFT PEDAL REMOVAL/INSTALLATION Remove the pinch bolt [1] and gearshift arm [2] from the gearshift spindle [3]. Align Remove the gearshift pedal pivot bolt [1]. Remove the gearshift pedal [2]. Check the tie-rod ball joint dust cover for deterioration or damage, replace them if necessary.
  • Page 278 dummyhead dummyhead CB750 Hornet Shop Manual CLUTCH/GEARSHIFT LINKAGE CLUTCH LEVER BRACKET REMOVAL Remove the following: – Rearview mirror (page 2-11) – Clutch switch (page 21-20) – Clutch lever (page 2-8) – Bolts [1] – Bracket holder [2] – Clutch lever bracket [3] Remove the following: –...

  • Page 279: Crankcase/Transmission/Balancer

    dummytext CB750 Hornet Shop Manual 13. CRANKCASE/TRANSMISSION/BALANCER SERVICE INFORMATION······················ 13-2 FRONT BALANCER SHAFT ················· 13-14 TROUBLESHOOTING ·························· 13-2 REAR BALANCER······························ 13-17 COMPONENT LOCATION ····················· 13-3 BREATHER COVER···························· 13-18 CRANKCASE······································ 13-4 LOWER CRANKCASE 20 MM CAP ······· 13-18 TRANSMISSION ·································· 13-7 13-1...

  • Page 280: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER SERVICE INFORMATION CRANKCASE/TRANSMISSION/BALANCER GENERAL • Be careful not to damage the crankcase mating surfaces when servicing. • Clean the oil passages before assembling the crankcase halves. • Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly. •...

  • Page 281: Component Location

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER COMPONENT LOCATION 20 N·m (2.0 kgf·m, 15 lbf·ft) + 65° 24 N·m (2.4 kgf·m, 18 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 17.5 N·m (1.8 kgf·m, 13 lbf·ft) 14 N·m (1.4 kgf·m, 10 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 23 N·m (2.3 kgf·m, 17 lbf·ft)
  • Page 282 dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER CRANKCASE SEPARATION Remove the necessary parts for separating the crankcase by referring to SERVICE INFORMATION (page 13-2). Place the engine upside down. Remove the baffle plate bolts [1] and baffle plate [2]. Remove the following: –...
  • Page 283 dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER Remove the following: – Dowel pins [1] – Oil orifice A [2] – Oil orifice B [3] Remove the main journal bearings [1] and front balancer shaft bearings [2] from the lower crankcase if necessary.
  • Page 284 dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER Apply molybdenum oil solution to the front balancer shaft [1] bearing and thrust surfaces. Install the dowel pins [2], oil orifice A [3] and oil orifice B [4], onto the upper crankcase. • Install the oil orifice A and B with their narrow hole side facing the upper crankcase.

  • Page 285: Shift Fork/Shift Drum

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER Apply locking agent to the baffle plate bolts threads (page 1-11). Install the baffle plate [1] and baffle plate bolts [2]. Tighten the baffle plate bolts to the specified torque: TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the removed parts to the crankcase by referring to Service Information (page 13-2).
  • Page 286 dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER Remove the shift drum bearing setting bolt/washer [1]. Remove the shift drum bearing [1] and shift drum [2]. MAINSHAFT Remove the shift forks/shift drum (page 13-7). Remove the mainshaft bearing set plate bolts [1] and set plate [2].
  • Page 287 dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER DISASSEMBLY/ASSEMBLY Clean all disassembled parts in solvent thoroughly. • Do not expand the snap ring more than necessary for removal. To remove a snap ring, expand the snap ring and pull it off using the gear behind it. •...
  • Page 288 dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER COUNTERSHAFT : Gear teeth, rotating surfaces SNAP RING : Bushing surfaces, needle bearing surfaces SPLINE WASHER and shifter gear grooves/spline area C2 GEAR (35T) BUSHING COUNTERSHAFT COUNTERSHAFT BEARING SET RING OIL SEAL SNAP RING SPLINE WASHER C4 GEAR (33T) LOCK WASHER...

  • Page 289: Specifications

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER • Align the lock washer tabs with the spline washer grooves. CORRECT INCORRECT • Always install the thrust washers and snap rings with the chamfered (rolled) edge facing away from the thrust load. •...
  • Page 290 dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER INSTALLATION MAINSHAFT Install the mainshaft assembly [1] into the upper crankcase. Apply engine oil to the right mainshaft bearing. Install the right mainshaft bearing [2] into the upper crankcase. • Install the bearing into the crankcase with the marked side facing out.
  • Page 291 dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER The shift forks have the following identification marks: – "C" mark [1]: mainshaft shift fork – "RL" mark [2]: left/right countershaft shift fork Apply molybdenum oil solution to the shift fork shaft outer surface. Install the mainshaft shift fork [1] into the M3/M4 gear with the identification marks facing toward the right side of the engine.

  • Page 292: Bearing Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER FRONT BALANCER SHAFT • Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. REMOVAL/INSTALLATION Separate the crankcase halves (page 13-4).

  • Page 293: Oil Clearance Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER OIL CLEARANCE INSPECTION • Do not rotate the front balancer shaft during inspection. Clean the journal surface of the front balancer shaft with solvent and blow them with compressed air. Clean off any oil from the bearing inserts and balancer journal.

  • Page 294: Bearing Selection

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER Measure the compressed plastigauge at its widest point on the balancer journal to determine the oil clearance. SERVICE LIMIT: 0.043 mm (0.0017 in) If the oil clearance exceeds the service limit, select a correct replacement bearing (page 13-16).

  • Page 295: Bearing Installation

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER BEARING INSTALLATION Clean the bearing outer surfaces and crankcase : Align bearing supports. Apply molybdenum oil solution to the front balancer shaft bearing sliding surfaces. Install the balancer bearing inserts [1] aligning each tab with each groove of the crankcase bearing supports.
  • Page 296 dummyhead dummyhead CB750 Hornet Shop Manual CRANKCASE/TRANSMISSION/BALANCER BREATHER COVER REMOVAL/INSTALLATION Remove the starter motor (page 6-5). Disconnect the breather hose [1]. Remove the following: [2]/[3] – Bolts [2] – Washers [3] – Breather cover [4] – Gasket [5] Installation is in the reverse order of removal. •...

  • Page 297: Crankshaft/Piston/Cylinder

    dummytext CB750 Hornet Shop Manual 14. CRANKSHAFT/PISTON/CYLINDER SERVICE INFORMATION······················ 14-2 MAIN JOURNAL BEARING ··················· 14-6 TROUBLESHOOTING ·························· 14-2 CRANKPIN BEARING ·························· 14-9 COMPONENT LOCATION ····················· 14-3 PISTON/CYLINDER ···························· 14-12 CRANKSHAFT ···································· 14-4 14-1...

  • Page 298: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER SERVICE INFORMATION CRANKSHAFT/PISTON/CYLIND ER GENERAL • The crankcase must be separated to service the crankshaft, cylinder and piston/connecting rod. • Mark and store the connecting rods, crankpin bearing caps, crankpin bearings and main journal bearings to be sure of their correct locations for reassembly.

  • Page 299: Component Location

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER COMPONENT LOCATION 27 N·m (2.8 kgf·m, 20 lbf·ft) + 120° 14-3...

  • Page 300: Side Clearance Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER CRANKSHAFT • Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. SIDE CLEARANCE INSPECTION Separate the crankcase halves (page 13-4).

  • Page 301: Installation

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER INSPECTION Support the crankshaft [1] on both end journals. Set a dial gauge on the crankshaft. Rotate the crankshaft two revolutions (720°) and read the runout. SERVICE LIMIT: 0.03 mm (0.001 in) INSTALLATION Apply molybdenum oil solution to the main journal The bearing tabs bearing surfaces on the upper crankcase and crankpin...

  • Page 302: Main Journal Bearing

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER Install the crankpin bearings [1]. Align • Install the bearings in their original locations. Apply molybdenum oil solution to the crankpin bearing surface on the crankpin bearing caps [2]. Install the crankpin bearing caps. •...

  • Page 303: Service Limit

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER OIL CLEARANCE INSPECTION Clean off any oil from the bearing inserts and main journals. Install the crankshaft onto the upper crankcase. Put a strip of plastigauge [1] lengthwise on each main Do not rotate the journal avoiding the oil hole.
  • Page 304 dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER MAIN JOURNAL BEARING SELECTION Record the crankcase bearing support I.D. code letters [1] from left side of the upper crankcase as shown. • Letters (A, B or C) on the left side of upper crankcase are bearing support I.D.

  • Page 305: Crankpin Bearing

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER BEARING INSTALLATION Clean the main journal bearing outer surfaces and Align crankcase bearing inserts. Apply molybdenum oil solution to the main journal bearing sliding surfaces. Install the main journal bearings [1]. • Install the main journal bearing by aligning each tab with each groove.
  • Page 306 dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER Install the crankpin bearing caps [1]. Align • Align the I.D. code number on the crankpin bearing caps and connecting rods. Apply engine oil to the crankpin bearing cap bolt (reuse) threads and seating surfaces. Install and tighten the crankpin bearing cap bolts [1] to the specified torque in 2 or 3 steps alternately.
  • Page 307 dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER If you are replacing the crankshaft, record the corresponding crankpin O.D. code letter [1]. • Letters (A, B, or C) on the crank weight are the crankpin O.D. codes from left to right. If you are reusing the crankshaft, measure the crankpin O.D.
  • Page 308 dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER PISTON/CYLINDER PISTON/CONNECTING ROD/ CYLINDER REMOVAL • Before piston removal, place a clean shop towel around the connecting rod to prevent damaging the cylinder sleeve. • Do not try to remove the piston/connecting rod assembly from bottom of the cylinder.

  • Page 309: Piston Ring Removal

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER PISTON REMOVAL Remove the piston pin clips [1]. Push the piston pin [2] out of the piston [3] and connecting rod [4]. Remove the piston. PISTON RING REMOVAL Spread each piston ring ends and remove them by lifting up at a point opposite the gap.

  • Page 310: Piston Installation

    dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER PISTON RING INSTALLATION Clean the piston ring grooves thoroughly. Install the piston rings. • Apply engine oil to the piston ring entire surfaces and piston ring grooves. • Avoid piston and piston ring damage during installation.
  • Page 311 dummyhead dummyhead CB750 Hornet Shop Manual CRANKSHAFT/PISTON/CYLINDER PISTON /CONNECTING ROD/ CYLINDER INSTALLTION Install the dowel pins [1] and a new gasket [2]. Install the cylinder [1] and bolts [2]. Apply engine oil to the piston and cylinder inner surface. Install the piston/connecting rod assemblies [1] into the cylinders using a commercially available piston ring compressor tool [2].
  • Page 312 dummyhead dummyhead CB750 Hornet Shop Manual MEMO...

  • Page 313: Engine Removal/Installation

    dummytext CB750 Hornet Shop Manual 15. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION······················ 15-2 ENGINE REMOVAL ····························· 15-4 COMPONENT LOCATION ····················· 15-3 ENGINE INSTALLATION ······················ 15-8 15-1...

  • Page 314: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE REMOVAL/INSTALLAT ION GENERAL • A hoist or equivalent is required to support the motorcycle when removing and installing the engine. • A floor jack or other adjustable support is required to support and maneuver the engine. Do not use the oil filter as a jacking point.

  • Page 315: Component Location

    dummyhead dummyhead CB750 Hornet Shop Manual ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION 44 N·m (4.5 kgf·m, 32 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 10 N·m (1.0 kgf·m, 1.5 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 64 N·m (6.5 kgf·m, 47 lbf·ft) 2.0 N·m (0.2 kgf·m, 1.5 lbf·ft)
  • Page 316 dummyhead dummyhead CB750 Hornet Shop Manual ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 3-12). Fully slacken the drive chain (page 3-16). Remove the following: – Throttle body (page 7-14) – Ignition coil (page 5-8) – PAIR control solenoid valve (page 7-16). –...
  • Page 317 dummyhead dummyhead CB750 Hornet Shop Manual ENGINE REMOVAL/INSTALLATION Remove the sidestand switch wire clip [1]. Disconnect the ECT sensor 2P connector [1]. Remove the wire clip [1]. Disconnect the alternator 3P (Gray) connector [2]. Disconnect shift spindle/neutral switch connector [1]. 15-5...
  • Page 318 dummyhead dummyhead CB750 Hornet Shop Manual ENGINE REMOVAL/INSTALLATION Remove the following: – Drive sprocket bolt [1] – Washer [2] – Drive sprocket [3] Remove the right engine hanger bolt [1]. Remove the left engine hanger bolt [1]. Remove the right engine hanger plate nuts [1], right engine hanger plate [2] and bolts [3].
  • Page 319 dummyhead dummyhead CB750 Hornet Shop Manual ENGINE REMOVAL/INSTALLATION Remove the left engine hanger plate nuts [1], left engine hanger plate [2] and bolts [3]. Remove the nut [1] and rear upper engine hanger bolt [2]. Remove the nut [1] and rear lower engine hanger bolt [2].
  • Page 320 dummyhead dummyhead CB750 Hornet Shop Manual ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION Place the engine in the frame, then loosely install all the bolts, hanger plates and nuts by referring to COMPONENT LOCATION (page 15-3). • Place the jack or other adjustable support under the engine.
  • Page 321 dummyhead dummyhead CB750 Hornet Shop Manual ENGINE REMOVAL/INSTALLATION Install the right engine hanger plate bolts [1], right engine hanger plate [2] and nuts [3]. Tighten the nuts to the specified torque. TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft) Install and tighten the left engine hanger bolt [1] to the specified torque.
  • Page 322 dummyhead dummyhead CB750 Hornet Shop Manual ENGINE REMOVAL/INSTALLATION Connect the shift spindle/neutral switch 2P connector [1]. Connect the alternator 3P (Gray) connector [1]. Install the wire clip [2] as shown. Connect the ECT sensor 2P connector [1]. Install the sidestand switch wire clip [1]. 15-10...
  • Page 323 dummyhead dummyhead CB750 Hornet Shop Manual ENGINE REMOVAL/INSTALLATION Install the switch wire [1] and terminal screw [2] to the EOP switch [3]. Tighten the screw to the specified torque. TORQUE: 2.0 N·m (0.2 kgf·m, 1.5 lbf·ft) Install the rubber cap [4]. Install the following: [3]/[4] –...
  • Page 324 dummyhead dummyhead CB750 Hornet Shop Manual MEMO...

  • Page 325: Front Wheel/Suspension/Steering

    dummytext CB750 Hornet Shop Manual 16. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION······················ 16-2 FRONT WHEEL·································· 16-10 TROUBLESHOOTING ·························· 16-2 FORK ··············································· 16-15 COMPONENT LOCATION ····················· 16-3 STEERING STEM ······························· 16-32 HANDLEBAR ······································ 16-4 16-1...

  • Page 326: Troubleshooting

    dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION FRONT WHEEL/SUSPENSION/STEERING GENERAL • When servicing the front wheel, fork, or steering stem, support the motorcycle using a safety stand or hoist. • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
  • Page 327 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION 27 N·m (2.8 kgf·m, 20 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft)
  • Page 328 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the following: – Rearview mirrors (page 2-11) – Handle ends [1] – Bolts [1] – Bracket holder [2] – Clutch lever bracket [3] – Screws [1] – Left handlebar switch housings [2] –...
  • Page 329 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING – Screws [1] – Right handlebar switch housing [2] – Screw [1] – Caps [1] [1]/[2] – Socket bolts [2] – Handlebar upper holders [3] – Handlebar [4] (from the throttle grip/right handlebar switch) 16-5...
  • Page 330 INSTALLATION Clean the inside surface of the handlebar grip [1] and outside surface of the handlebar [2]. Apply Honda bond A or equivalent to the inside surface of the grip. Wait 3 – 5 minutes and install the grip. Rotate the grips for even application of the adhesive.
  • Page 331 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Install the front brake master cylinder [1], holder [2] and Align bolts [3]. Align the end of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first, then the lower bolt.
  • Page 332 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Install a new handle ends [1]. Install the rearview mirrors (page 2-11). Check the clutch lever freeplay (page 3-22). THROTTLE GRIP REMOVAL/ INSTALLATION Remove the handlebar (page 16-4). Remove the wire band [1], screws [2], APS [3] and throttle grip [4].

  • Page 333: Handlebar Lower Holder Removal/Installation

    dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Installation is in the reverse order of removal. • Apply grease to the throttle grip [1] and APS [2] contacting surfaces as shown. TORQUE: 2.0 N·m (0.2 kgf·m, 1.5 lbf·ft) 3 mm (0.1 in) 5 mm (0.2 in)

  • Page 334: Left Side

    dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL REMOVAL Remove the bolts [1] and both brake calipers [2]. • Support the brake caliper with a piece of wire so that it does not hang from the brake hose. •...

  • Page 335: Installation

    dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Install the right and left side collars [1]. LEFT SIDE: RIGHT SIDE: Apply a thin coat of grease to the front axle outer surface. • Do not apply grease to the threads of the front axle and contacting surface of the axle holder.
  • Page 336 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Tighten the axle pinch bolts [1] to the specified torque. TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) Check the air gap between the front wheel speed sensor bracket and pulser ring (page 19-21). INSPECTION Turn the inner race of each bearing with your finger.
  • Page 337 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY/ASSEMBLY • Install each dust seal with the flat side facing out so that it is flush with the wheel hub. • Align the front wheel rotation mark with brake disc rotation mark. •...

  • Page 338: Wheel Bearing Replacement

    [3]. Remount the tire if necessary. • The wheel balance must be checked when the front tire is remounted. • Stick-type balance weights should be used on this motorcycle. Use Honda genuine balance weights. – Before installing weights, remove...
  • Page 339 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Mount the wheel, tire and brake discs assembly on an inspection stand [1]. Spin the wheel, allow it to stop, and mark the lowest (heaviest) part of the wheel with chalk. Do this two or three times to verify the heaviest area. If the wheel is balanced, it will not stop consistently in the same position.
  • Page 340 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING When the fork will be disassembled, loosen the fork cap [1], but do not remove it yet. TOOL: Fork Bolt Wrench [2] 070MA-MGP0100 While holding the fork leg [1], loosen the bottom bridge pinch bolt [2].
  • Page 341 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Install the fork leg [1] through the bottom bridge and top Route the wires, Front bridge. cables and hoses properly (page 1- Align the top end of the fork outer tube with the upper 21).
  • Page 342 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY RIGHT SIDE Remove the fork cap [1] with the special tool. Take care not to scratch the cap TOOL: head. Fork Bolt Wrench 070MA-MGP0100 Push the outer tube [1] slowly down, and gently seat the dust seal [2] onto the axle holder [3].
  • Page 343 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Remove the fork spring [1]. Pour out the fork fluid by pumping the outer tube [2] several times. Remove the spring joint [1] and spring collar [2]. Remove the dust seal [1]. Remove the stopper ring [2].
  • Page 344 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Carefully remove the slider bushing [1] by prying the Do not damage the slot with a screwdriver until the slider bushing can be slider bushing, pulled off by hand. especially the sliding surface. To Remove the following: prevent loss of –...
  • Page 345 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Pour out the fork fluid by pumping the outer tube [1] up and down several times. Push the fork cap down to compress the fork spring, then remove the stopper ring [1] from the groove in the slide pipe.
  • Page 346 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Remove the spring joint [1] and spring collar [2]. Remove the dust seal [1]. Remove the oil seal stopper ring [2]. Be careful not to scratch the slide pipe sliding surface. Pull the slide pipe assembly [1] out until you feel resistance from the slider bushing.
  • Page 347 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING INSPECTION Inspect the following parts for damage, abnormal wear, bend, deformation, scoring and teflon coating wear. – Outer tube – Slide pipe – Fork spring – Rebound spring – Piston rod (right fork only) –...
  • Page 348 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY RIGHT SIDE SLIDE PIPE FORK CAP OUTER TUBE ASSEMBLY 35 N·m (3.6 kgf·m, 26 lbf·ft) O-RING LOCK NUT FORK SPRING 18 N·m (1.8 kgf·m, 13 lbf·ft) STOPPER RING STOPPER SEAT SLIDER ROD GUIDE CASE BUSHING GUIDE...
  • Page 349 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING When installing the fork dust seal and oil seal, wrap the edge, groove and oil holes of the slide pipe with tapes [1]. Apply fork fluid to new dust seal lips and oil seal lips. Install the dust seal [1], stopper ring [2] and oil seal [3].
  • Page 350 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Install a new O-ring [1] to the rod guide case [2]. [9] [6] Install the piston ring [3], rebound spring [4] and rod guide case to the piston rod [5]. Install the stopper seat [6] in the direction shown. Install a new O-ring [7] to the fork cap [8].
  • Page 351 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Apply fork fluid to the O-rings [1]. Install the piston rod assembly by pushing the rod guide case [2] into the slide pipe assembly. Install the stopper ring [1] into the groove in the slide pipe.
  • Page 352 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING LEFT SIDE SLIDE PIPE FORK CAP OUTER TUBE ASSEMBLY 35 N·m (3.6 kgf·m, 26 lbf·ft) FORK SPRING O-RING LOCK NUT 18 N·m (1.8 kgf·m, 13 lbf·ft) STOPPER RING STOPPER SEAT SLIDER REBOUND SPRING BUSHING GUIDE BUSHING...
  • Page 353 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING When installing the fork dust seal and oil seal, wrap the edge, groove and oil holes of the slide pipe with tapes [1]. Apply fork fluid to new dust seal lips and oil seal lips. Install the dust seal [1], stopper ring [2] and oil seal [3].
  • Page 354 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Install the spring collar [1] and spring joint [2]. • Install the spring collar into the slide pipe assembly with the stepped side facing down. Install the fork spring [1] into the slide pipe assembly with the tightly wound side facing up.
  • Page 355 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Tighten the lock nut [1] until it stops. Install the rebound spring [2] to the fork rod with large I.D. side facing up. Install the stopper seat [3] in the direction shown. Apply recommended fork oil to a new O-ring [1], and install it to the fork cap [2].

  • Page 356: Steering Stem

    dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING STEERING STEM REMOVAL Remove the following: – Shroud B (page 2-9) – Headlight upper stay (page 2-8) – Handlebar (page 16-4) Disconnect the immobilizer receiver 4P connector (page 22-10). Disconnect the ignition switch 2P connector [1]. Remove the wire clamp [2].

  • Page 357: Bearing Replacement

    dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Loosen the steering bearing adjusting nut [1] using the special tool. TOOL: Locknut Wrench 5.7 x 50 [2] 07916-3710101 While holding the steering stem, remove the adjusting nut and upper dust seal [3]. Remove the following: –...
  • Page 358 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Install the stem nut [1] onto the steering stem [2] to prevent the threads from being damaged when removing the lower inner race [3]. Remove the lower inner race with a chisel or equivalent tool, being careful not to damage the stem.
  • Page 359 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Apply specified grease to the upper and lower bearings and bearing races (page 1-18). LOWER OUTER RACE LOCK NUT LOCK WASHER LOWER STEERING BEARING ADJUSTING NUT UPPER DUST SEAL UPPER INNER RACE LOWER INNER RACE LOWER DUST SEAL UPPER STEERING...
  • Page 360 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Install the following: – Lower steering bearing [3] – Upper steering bearing [4] – Upper inner race [5] – Steering stem [6] – Upper dust seal Apply engine oil or grease to the threads of the adjusting nut [1].
  • Page 361 dummyhead dummyhead CB750 Hornet Shop Manual FRONT WHEEL/SUSPENSION/STEERING Install a new lock washer [1], aligning its bent tabs with the grooves in the adjusting nut. Install the lock nut [2] until it contacts with the lock washer. Further tighten the lock nut, within 90°, to align its Do not over-tighten grooves with the tabs of the lock washer.
  • Page 362 dummyhead dummyhead CB750 Hornet Shop Manual MEMO...

  • Page 363: Rear Wheel/Suspension

    dummytext CB750 Hornet Shop Manual 17. REAR WHEEL/SUSPENSION SERVICE INFORMATION······················ 17-2 CUSHION LINKAGE····························· 17-8 TROUBLESHOOTING ·························· 17-2 SHOCK ABSORBER ··························· 17-10 COMPONENT LOCATION ····················· 17-3 SWINGARM······································· 17-11 REAR WHEEL····································· 17-4 17-1...

  • Page 364: Service Information

    • Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBELESS TIRE APPLICABLE". • Use Honda genuine replacement bolts and nuts for all suspension pivot and mounting point. • After the rear wheel installation, check the brake operation by applying the brake pedal.

  • Page 365: Component Location

    dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION COMPONENT LOCATION 54 N·m (5.5 kgf·m, 40 lbf·ft) 88 N·m (9.0 kgf·m, 65 lbf·ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 88 N·m (9.0 kgf·m, 65 lbf·ft) 44 N·m (4.5 kgf·m, 32 lbf·ft) 17-3...
  • Page 366 dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL/INSTALLATION Loosen the axle nut [1]. Support the motorcycle using a hoist or equivalent and raise the rear wheel off the ground. Turning the lock nuts [2] and adjusting bolts [3] so the wheel can be moved forward all the way.

  • Page 367: Suspension Specifications

    dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION Remove the following: LEFT SIDE: – Left side collar [1] – Right side collar [2] Installation is in the reverse order of removal. TORQUE: Rear axle nut: 88 N·m (9.0 kgf·m, 65 lbf·ft) •...
  • Page 368 dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION DISASSEMBLY/ASSEMBLY DRIVEN FLANGE COLLAR DRIVEN FLANGE BRAKE DISC DAMPER BEARING (6204UU) RUBBERS DUST SEAL DRIVEN SPROCKET SPROCKET NUTS 128 N·m (13.1 kgf·m, 94 lbf·ft) BRAKE DISC BOLT 42 N·m (4.3 kgf·m, 31 lbf·ft) PULSER RING DUST SEAL O-RING...
  • Page 369 dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION Drive in a new right side bearing (brake disc side) squarely with the marked side facing up until it is fully seated. Install the distance collar. Drive in a new left side bearing squarely with the marked side facing up until it is fully seated on the distance collar.

  • Page 370: Cushion Linkage

    dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION CUSHION LINKAGE REMOVAL/INSTALLATION Support the motorcycle using a hoist or equivalent and raise the rear wheel off the ground. Remove the following: – Nuts [1] – Bolts [2] – Cushion connecting rod plates [3] –...
  • Page 371 dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION BEARING REPLACEMENT Press the needle bearings out of the cushion arm using the special tools. TOOLS: Driver Handle 15 x 280L [1] 07949-3710001 Attachment, 22 x 24 mm [2] 07746-0010800 Pilot 17 mm [3] 07746-0040400 Apply molybdenum disulfide grease to new needle bearing rolling areas.

  • Page 372: Shock Absorber

    dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION SHOCK ABSORBER REMOVAL/INSTALLATION Remove the following: [1]/[2] – Cushion linkage (page 17-8) – Nut [1] – Bolt [2] – Shock absorber [3] Installation is in the reverse order of removal. TORQUE: Shock absorber upper mounting nut: 54 N·m (5.5 kgf·m, 40 lbf·ft) INSPECTION Inspect the following parts of the shock absorber for...
  • Page 373 dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION SWINGARM REMOVAL/INSTALLATION Remove the following: [1]/[2] – Drive chain cover (page 2-17) – Rear wheel (page 17-4) – Shock absorber (page 17-10) – Left pivot cover (page 2-18) – Right pivot cover (page 18-22) (Temporarily install the right rider footpeg bracket assembly.) –...
  • Page 374 dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION DISASSEMBLY/ASSEMBLY SNAP RING DUST SEAL DISTANCE COLLAR BALL BEARINGS (6003) NEEDLE BEARING RIGHT PIVOT COLLAR NEEDLE BEARING DUST SEAL LEFT PIVOT DUST SEAL COLLAR DUST SEAL CUSHION LINKAGE PIVOT COLLAR DRIVE CHAIN ADJUSTING BOLT DRIVE CHAIN LOCK NUT...
  • Page 375 dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION BEARING REPLACEMENT SWINGARM PIVOT BEARING Remove the snap ring [1]. Remove the ball bearings [1] using the special tools. TOOLS: Bearing Remover Shaft Set, 17 mm 07936-3710300 Remover Handle [3] 07936-3710100 Weight, Remover [4] 07741-0010201 Remove the distance collar [5].
  • Page 376 dummyhead dummyhead CB750 Hornet Shop Manual REAR WHEEL/SUSPENSION Apply grease to the rotating areas of new ball bearings [1]. Press the ball bearings in the right pivot with the marked side facing up until they are fully seated, using the special tools. TOOLS: Driver Handle, 15 x 135L [2] 07749-0010000...

  • Page 377: Hydraulic Brake

    dummytext CB750 Hornet Shop Manual 18. HYDRAULIC BRAKE SERVICE INFORMATION······················ 18-2 FRONT MASTER CYLINDER················ 18-14 TROUBLESHOOTING ·························· 18-2 REAR MASTER CYLINDER·················· 18-16 COMPONENT LOCATION ····················· 18-3 FRONT BRAKE CALIPER ···················· 18-18 BRAKE FLUID REPLACEMENT/ REAR BRAKE CALIPER······················ 18-20 AIR BLEEDING ··································· 18-5 BRAKE PEDAL ··································...

  • Page 378: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE SERVICE INFORMATION HYDRAULIC BRAKE GENERAL Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Spilling brake fluid will severely damage instrument lenses and painted surface.
  • Page 379 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE COMPONENT LOCATION FRONT: 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 45 N·m (4.6 kgf·m, 33 lbf·ft) 17 N·m (1.7 kgf·m, 13 lbf·ft) 18-3...
  • Page 380 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE REAR: 34 N·m (3.5 kgf·m, 25 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 17 N·m (1.7 kgf·m, 13 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 18-4...

  • Page 381: Brake Fluid Replacement/Air Bleeding

    dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING FRONT Turn the handlebar so the reservoir is level. Remove the following: – Screws [1] – Reservoir cap [2] – Set plate [3] – Diaphragm [4] Connect a bleed hose [1] to the caliper bleed valve [2].
  • Page 382 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE REAR Remove the reservoir stay mounting bolt [1]. Hold the reservoir [1] and remove the reservoir mounting bolt [2] and reservoir stay [3]. Temporarily install the reservoir stay [1] with the mounting bolt [2] as shown. 18-6...
  • Page 383 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE Remove the following: – Screws [1] – Reservoir cap [2] – Set plate [3] – Diaphragm [4] Temporarily install the reservoir [1] onto the stay [2] with the mounting bolt [3]. Connect a bleed hose [1] to the caliper bleed valve [2]. Loosen the bleed valve and pump the brake pedal until no more fluid flows out of the bleed valve.
  • Page 384 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE BRAKE FLUID FILLING/AIR BLEEDING Fill the reservoir to the upper level line [1] with DOT 4 Front: brake fluid from a sealed container. Connect a commercially available brake bleeder to the bleed valve. Operate the brake bleeder and loosen the bleed valve.
  • Page 385 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE Remove the reservoir mounting bolt [1] and reservoir For rear brake: [2]. Install the diaphragm [1], set plate [2], reservoir cap [3] and tighten the screws [4] to the specified torque. TORQUE: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) Install the reservoir and tighten the mounting bolt.
  • Page 386 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE Install the reservoir stay [1] and reservoir mounting bolt [2] to the reservoir [3] as shown. Install and tighten the reservoir stay mounting bolt [1]. 18-10...

  • Page 387: Brake Pad/Disc

    dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE BRAKE PAD/DISC BRAKE PAD REPLACEMENT • Always replace the brake pads in pairs to ensure even disc pressure. • Check the fluid level in the reservoir as this operation causes the fluid level to rise. FRONT Loosen the brake pad pin [1].
  • Page 388 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE Remove the brake pad pin [1], then remove the brake pads [2] and pad spring [3]. Clean the inside of the caliper body especially around the caliper pistons. Install new brake pads into the caliper body. Set the pad spring and install the pad pin.

  • Page 389: Brake Disc Inspection

    [3]. brake pedal after removing the pads. • If the pad spring was removed, apply Honda Bond A or equivalent to the retainer seating surface. Make sure the pad spring [1] is installed in position. Install the brake pads [2] so that their ends are rest on the pad retainer [3] properly.

  • Page 390: Front Master Cylinder

    dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE FRONT MASTER CYLINDER REMOVAL/INSTALLATION Drain the brake fluid from the front brake hydraulic system (page 18-5). Remove the following: When removing the oil bolt, cover the – Right rearview mirror (page 2-11) end of the brake –...
  • Page 391 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY Disassemble and assemble the front master cylinder as following illustration. • Do not allow the piston cup lips to turn inside out. • Install the snap ring with the chamfered edge facing the thrust load side and be certain it is firmly seated in the groove.

  • Page 392: Rear Master Cylinder

    dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE REAR MASTER CYLINDER REMOVAL/INSTALLATION Drain the brake fluid from the rear brake hydraulic system (page 18-5). Disconnect the brake hose [1] by removing the oil bolt When removing the [2] and sealing washers [3]. oil bolt, cover the end of the brake Loosen the master cylinder mounting bolts [4].
  • Page 393 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY • Do not allow the piston cup lips to turn inside out. • Install the snap ring with the chamfered edge facing the thrust load side and be certain it is firmly seated in the groove.

  • Page 394: Front Brake Caliper

    dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE INSPECTION Check the following parts for scoring, scratches, deterioration or damage. Replace if necessary. – Master cylinder – Master piston – Piston cups – Spring – Boot FRONT BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake fluid from the front brake hydraulic system (page 18-5).
  • Page 395 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY For brake pad removal/installation (page 18-11). • The caliper piston removal/installation can be done without disassembling the caliper body. • When removing the caliper pistons with compressed air, place a shop towel over the pistons to prevent damaging the pistons and caliper body.

  • Page 396: Rear Brake Caliper

    dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE REAR BRAKE CALIPER REMOVAL/INSTALLATION Drain the brake fluid from the rear brake hydraulic system (page 18-5). Remove the following: – Oil bolt [1] When removing the – Sealing washers [2] oil bolt, cover the –...
  • Page 397 dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE DISASSEMBLY/ASSEMBLY • When removing the caliper piston with compressed air, place a shop towel over the piston to prevent damaging the piston and caliper body. Do not use high pressure or bring the nozzle too close to the fluid inlet.

  • Page 398: Brake Pedal

    dummyhead dummyhead CB750 Hornet Shop Manual HYDRAULIC BRAKE BRAKE PEDAL REMOVAL/INSTALLATION Remove the socket bolts [1] and right rider footpeg bracket assembly [2]. Remove the following: – Switch spring [1] – Return spring [2] – Cotter pin [3] – Joint pin [4] –...

  • Page 399: Anti-Lock Brake System (Abs)

    dummytext CB750 Hornet Shop Manual 19. ANTI-LOCK BRAKE SYSTEM (ABS) SERVICE INFORMATION······················ 19-2 ABS INDICATOR CIRCUIT TROUBLESHOOTING ························· 19-10 SYSTEM LOCATION ···························· 19-3 ABS DTC TROUBLESHOOTING ··········· 19-12 SYSTEM DIAGRAM ····························· 19-4 WHEEL SPEED SENSOR ···················· 19-21 ABS TROUBLESHOOTING INFORMATION···································· 19-5 ABS MODULATOR ·····························...

  • Page 400: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) SERVICE INFORMATION ANTI-LOCK BRAKE SYSTEM (ABS) GENERAL • The ABS modulator may be damaged if dropped. Also if a connector is disconnected when current is flowing, the excessive voltage may damage the control unit. Always turn off the ignition switch before servicing. •...

  • Page 401: System Location

    dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) SYSTEM LOCATION POWER BOX - ABS MAIN FUSE (10 A) - ABS MOTOR FUSE (30 A) - ABS FSR FUSE (30 A) - METER/ILLUMI/HORN FUSE (10 A) METER FRONT BRAKE LIGHT SWITCH BATTERY IGNITION SWITCH...

  • Page 402: System Diagram

    dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) SYSTEM DIAGRAM FRONT BRAKE LIGHT SWITCH Bl/Bu MAIN FUSE IGNITION METER/ILLUMI/ SWITCH HORN (10 A) (30 A) R/Bl R/Bl Bl/R REAR BRAKE LIGHT SWITCH R/Bl ABS MAIN (10 A) BATTERY Bl/W ABS MOTOR (30 A) MR+B...

  • Page 403: Abs Troubleshooting Information

    dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING INFORMATION SYSTEM DESCRIPTION SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When there is any abnormality, the problem and the associated part can be detected by reading the DTC.
  • Page 404 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) DTC READOUT • The DTC is not erased by turning the ignition switch OFF while the DTC is being output. Note that turning the ignition switch ON again does not indicate the DTC. To show the DTC again, repeat the DTC readout procedures from the beginning. •...

  • Page 405: Inspection At Abs Modulator Connector

    dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) ERASING STORED DTC • The stored DTC can not be erased by simply disconnecting the battery negative (–) cable. Connect the MCS to the DLC (page 4-5). Erase the DTC with the MCS while the engine is stopped. To erase the DTC without MCS, refer to the following procedure.
  • Page 406 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) ABS SYSTEM DTC INDEX • The ABS indicator might blink in the following cases. Correct the faulty part. – Incorrect tire pressure. – Tires not recommended for the motorcycle were installed (incorrect tire size). –...
  • Page 407 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) Detection Refer Function failure Symptom/Fail-safe function Power circuit under voltage • Stops ABS operation • Input voltage (too low) • ABS MAIN fuse (10 A) 19-19 Power circuit over voltage •...

  • Page 408: Abs Indicator Circuit Troubleshooting

    dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) ABS INDICATOR CIRCUIT TROUBLESHOOTING ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON) • Before starting this inspection, check the initial operation of the meter (page 21-8). 1.

  • Page 409: Yes - Go To Step

    dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) 2. Indicator Signal Line Open Circuit Inspection Short the wire harness side ABS modulator 18P connector [1] terminal to the ground with a jumper wire [2]. CONNECTION: 13 – Ground Turn the ignition switch ON with the engine stop switch "...
  • Page 410 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) 6. Power Input Line Open Circuit Inspection Install the ABS MAIN fuse (10 A). Turn the ignition switch ON. Measure the voltage between the wire harness side ABS modulator 18P connector [1] terminal and ground.
  • Page 411 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) 2. Front Wheel Speed Sensor Condition Inspection Inspect the area around the front wheel speed sensor: Check that there is iron or other magnetic deposits between the pulser ring and wheel speed sensor, and the pulser ring slots for obstructions.
  • Page 412 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) 5. Front Wheel Speed Sensor Line Open Circuit Inspection Short the wire harness side ABS modulator 18P connector [1] terminals with a jumper wire [2]. CONNECTION: 8 – 17 Check for continuity between the wire harness side front wheel speed sensor 2P connector [3] terminals.
  • Page 413 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) 2. Rear Wheel Speed Sensor Condition Inspection Inspect the area around the rear wheel speed sensor: Check that there is no iron or other magnetic deposits between the rear pulser ring and rear wheel speed sensor, and the rear pulser ring slots for obstructions.
  • Page 414 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) 5. Rear Wheel Speed Sensor Line Open Circuit Inspection Short the wire harness side ABS modulator 18P connector [1] terminals with a jumper wire [2]. CONNECTION: 6 – 15 Check for continuity between the wire harness side rear wheel speed sensor 2P connector [3] terminals.
  • Page 415 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) DTC 5-1/5-2/5-3 (Pump Motor) 1. Fuse Inspection Turn the ignition switch OFF. Remove the power box cover (page 21-24). Check the ABS MOTOR fuse (30 A) for blown. Is the fuse blown? –...
  • Page 416 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) 5. Failure Reproduction Turn the ignition switch OFF. Connect the ABS modulator 18P connector. Erase the DTC (page 19-7). Test-ride the motorcycle above 30 km/h (19 mph). Recheck the DTC (page 19-6). Is the DTC 5-1, 5-2 or 5-3 indicated? –...
  • Page 417 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) 4. Failure Reproduction Turn the ignition switch OFF. Connect the ABS modulator 18P connector. Erase the DTC (page 19-7). Test-ride the vehicle above 30 km/h (19 mph). Recheck the DTC (page 19-6). Is the DTC 5-4 indicated? –...
  • Page 418 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) 4. Failure Reproduction Turn the ignition switch OFF. Connect the ABS modulator 18P connector. Erase the DTC (page 19-7). Test-ride the motorcycle above 30 km/h (19 mph). Recheck the DTC (page 19-6). Is the DTC 6-1 or 6-2 indicated? –...

  • Page 419: Wheel Speed Sensor

    dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) WHEEL SPEED SENSOR AIR GAP INSPECTION Support the motorcycle securely using a hoist or Front side shown: equivalent and raise the wheel off the ground. Measure the air gap between the caliper bracket and pulser ring at several points by turning the wheel slowly.
  • Page 420 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) Remove the nuts [1] and radiator mount bolts [2]. Remove the radiator [3] from the stay [4]. Pull down the radiator. [1]/[2] [1]/[2] Remove the harness clips [1] and sensor wire [2] from the fan cover.

  • Page 421: Rear Wheel Speed Sensor Removal/Installation

    dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) Remove the bolt [1], wire clamp [2] and harness clip [3]. Remove the mounting bolt [1] and front wheel speed sensor [2]. Installation is in the reverse order of removal. •...

  • Page 422: Abs Modulator

    dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) Remove the following: [2]/[3] – Wire clamps [1] – Bolts [2] – Clamps [3] – Wire clip [4] – Rear wheel speed sensor mounting bolt [5] – Rear wheel speed sensor [6] Installation is in the reverse order of removal.
  • Page 423 dummyhead dummyhead CB750 Hornet Shop Manual ANTI-LOCK BRAKE SYSTEM (ABS) Remove the oil bolts [1], brake hoses [2] and sealing washers [3]. Remove the brake pipe clamp [4]. Loosen the brake pipe joint nuts [5] to disconnect the brake pipes [6]. •...
  • Page 424 dummyhead dummyhead CB750 Hornet Shop Manual MEMO...

  • Page 425: Battery/Charging System

    dummytext CB750 Hornet Shop Manual 20. BATTERY/CHARGING SYSTEM SERVICE INFORMATION······················ 20-2 BATTERY··········································· 20-5 TROUBLESHOOTING ·························· 20-3 CHARGING SYSTEM INSPECTION ········ 20-6 SYSTEM LOCATION ···························· 20-4 REGULATOR/RECTIFIER ····················· 20-7 SYSTEM DIAGRAM ····························· 20-4 ALTERNATOR CHARGING COIL ··········· 20-8 20-1...

  • Page 426: Service Information

    dummyhead dummyhead CB750 Hornet Shop Manual BATTERY/CHARGING SYSTEM SERVICE INFORMATION BATTERY/CHARGING SYSTEM GENERAL • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.

  • Page 427: Troubleshooting

    dummyhead dummyhead CB750 Hornet Shop Manual BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. Battery Test Remove the battery (page 20-5). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210 or BATTERY MATE or equivalent Is the battery in good condition? –...

  • Page 428: System Location

    dummyhead dummyhead CB750 Hornet Shop Manual BATTERY/CHARGING SYSTEM SYSTEM LOCATION BATTERY MAIN FUSE (30 A) ALTERNATOR REGULATOR/RECTIFIER SYSTEM DIAGRAM MAIN FUSE (30 A) Bl/G BATTERY REGULATOR/RECTIFIER ALTERNATOR 20-4...

  • Page 429: Voltage Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the front seat (page 2-4). Turn the ignition switch OFF. Disconnect the negative (–) cable [1] first and then disconnect the positive (+) cable [2] by removing the terminal bolts. Remove the rubber strap [3] and the battery [4].

  • Page 430: Charging System Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE TEST Remove the front seat (page 2-4). Turn the ignition switch OFF. Remove the terminal bolt and disconnect the negative (–) cable [1] from the battery. (–) Connect the ammeter (+) probe to the negative (–) cable and ammeter (–) probe to the battery negative (–) terminal [2].

  • Page 431: Battery Charging Line Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER REMOVAL/INSTALLATION Disconnect the alternator 3P (Gray) [1] and regulator/ rectifier 3P (Black) [2] connectors. Remove the bolts [3] and regulator/rectifier [4]. Installation is in the reverse order of removal. SYSTEM INSPECTION Check connectors for loose contact or corroded terminals.

  • Page 432: Alternator Charging Coil

    dummyhead dummyhead CB750 Hornet Shop Manual BATTERY/CHARGING SYSTEM ALTERNATOR CHARGING COIL CHARGING COIL INSPECTION Disconnect the alternator 3P (Gray) connector (page 20-7). Measure the resistance between the wire harness side alternator 3P (Gray) connector [1] terminals. CONNECTION: Yellow – Yellow STANDARD: 0.1 –...

  • Page 433: Lights/Meters/Switches

    dummytext CB750 Hornet Shop Manual 21. LIGHTS/METERS/SWITCHES SERVICE INFORMATION······················ 21-2 BRAKE LIGHT SWITCH······················· 21-20 SYSTEM LOCATION ···························· 21-2 CLUTCH SWITCH······························· 21-20 HEADLIGHT ······································· 21-3 NEUTRAL SWITCH····························· 21-21 TURN SIGNAL LIGHT ·························· 21-5 SIDESTAND SWITCH·························· 21-22 LICENSE LIGHT ·································· 21-6 HORN ··············································· 21-23 BRAKE/TAILLIGHT······························...
  • Page 434 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES SERVICE INFORMATION LIGHTS/METERS/SWITCHES GENERAL • Check the battery condition before performing any inspection that requires proper battery voltage. • A continuity test can be made with the switches installed on the motorcycle. • The following color codes are used throughout this section. R = Red Bl = Black Br = Brown...
  • Page 435 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES HEADLIGHT REMOVAL/INSTALLATION Remove the following: – Headlight cowl (page 2-6) – Bolt/washers [1] – headlight [2] – Grommets [3] – Collars [4] Disconnect the headlight 6P connector [5]. Installation is in the reverse order of removal. TORQUE: 8.5 N·m (0.9 kgf·m, 6.3 lbf·ft) 21-3...
  • Page 436 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES POWER/GROUND LINE INSPECTION HEADLIGHT 6P CONNECTOR IGNITION SWITCH HEADLIGHT (10 A) R/Bl HEADLIGHT 1. Headlight Power Input Line Inspection Disconnect the headlight 6P connector (page 21-3). Turn the ignition switch ON. Measure the voltage at the wire harness side 6P connector terminal and ground.

  • Page 437: Turn Signal Light Removal/ Installation

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT TURN SIGNAL LIGHT REMOVAL/ INSTALLATION FRONT Remove the headlight inner cover (page 2-6). Left side shown: Disconnect the following: – Left turn signal light 2P (Orange) connector [1] – Left turn signal light 2P (White) connector [2] –...

  • Page 438: License Light

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES LICENSE LIGHT REMOVAL/INSTALLATION Refer to rear fender A (page 2-13). BULB REPLACEMENT Remove the screws [1] and license light cover [2]. Pull out the license light bulb [3] and replace it with a new one.
  • Page 439 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES BRAKE/TAILLIGHT REMOVAL/INSTALLATION Remove the rear center cowl (page 2-13). Disconnect the brake/taillight 3P (Black) connector [1]. Remove the following: – Bolt/washers [2] – Brake/taillight [3] – Collars [4] – Grommets [5] Installation is in the reverse order of removal. 21-7...

  • Page 440: Initial Operation Check

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES METER INITIAL OPERATION CHECK When the ignition switch is turned ON, the meter will show opening display. If the meter does not show opening display, check the meter power/ground line (page 21-10). If the power/ground lines are normal, replace the TFT module/circuit board assembly (page 21-9).
  • Page 441 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DISASSEMBLY/ASSEMBLY SCREWS UNDER CASE GASKET TFT MODULE/CIRCUIT BOARD ASSEMBLY UPPER CASE 21-9...
  • Page 442 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES POWER/GROUND LINE INSPECTION POWER INPUT LINE Disconnect the meter 24P connector (page 21-8). Measure the voltage between the wire harness side meter 24P connector [1] and ground. Bl/R TOOL: Male Pin Prove 07ZAJ-RDJA110 Connection: Black/red (+) –...

  • Page 443: Date & Time Setting Procedure

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DATE & TIME SETTING PROCEDURE Turn the ignition switch ON. 1. Push the select switch [1] to the right and hold it until the “SETTING” mode screen is displayed. 2. Press the select switch to the down to select the "GENERAL"...
  • Page 444 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES HSVCS HSVCS SCREEN TRANSITION Turn the ignition switch ON. Push and hold the SEL switch [1] to the left until the HSVCS main screen is displayed. Make sure the Bluetooth indicator and smartphone indicator are appeared.

  • Page 445: Engine Oil Pressure Indicator/ Eop Switch

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES ENGINE OIL PRESSURE INDICATOR/ EOP SWITCH REMOVAL/INSTALLATION Drain the engine oil (page 3-12). Remove the following: – Dust cover [1] – Bolt/washer [2] – Wire terminal [3] – Oil pressure switch [4] Installation is in the reverse order of removal. •...

  • Page 446: Fuel Meter Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES FUEL LEVEL SENSOR FUEL METER INSPECTION If the fuel meter displays the circuit faulty pattern as shown with ignition switch is ON, check for open or Open circuit short circuit in the Blue wire between the meter and fuel pump unit.

  • Page 447: Ignition Switch

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES IGNITION SWITCH INSPECTION Remove the shrouds B (page 2-9). Remove the dust cover [1] and disconnect the ignition switch 2P connector [2]. Check for continuity between the wire terminals of the ignition switch connector in each switch position. Refer to the wiring diagram for the terminals and switch status (page 23-2).
  • Page 448 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES Remove the top bridge pinch bolt [1] and clamp [2]. Remove the harness clips [3]. [1]/[2] Remove the screws [1] and left handlebar switch [2]. Installation is in the reverse order of removal. •...

  • Page 449: Right Handlebar Switch

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES INSPECTION • Before inspection, check that there is no DTCs. Disconnect the left handlebar switch 8P connector (page 21-15). Measure the resistance between the switch side 8P connector [1] terminals when each switch is operated. W/Bu G/Bu CONNECTION:...
  • Page 450 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES Remove the top bridge pinch bolt [1] and clamp [2]. Remove the wire band [3]. Remove the front master cylinder (page 18-14). Remove the screws [1] and right handlebar switch housing cover [2]. Remove the screw [3] and right handlebar switch [4].
  • Page 451 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DISASSEMBLY/ASSEMBLY Remove the right handlebar switch (page 21-17). Remove the wire band [1], screws [2], APS [3] and throttle grip [4]. Remove the holder [1]. Installation is in the reverse order of removal. •...

  • Page 452: Clutch Switch

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH INSPECTION FRONT Disconnect the wire connectors [1] from the front brake light switch and check for continuity between the switch terminals. There should be continuity with the brake lever squeezed, and there should be no continuity with the brake lever is released.

  • Page 453: Neutral Switch

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES Remove the screw [1], clutch switch [2] and wire bands Align [3]. Installation is in the reverse order of removal. • Align the clutch switch hook with clutch lever holder cut-out. TORQUE: Clutch switch screw: 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) INSPECTION Disconnect the clutch switch 2P connector (page 21-...

  • Page 454: Sidestand Switch

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES SIDESTAND SWITCH REMOVAL/INSTALLATION Lift and support the fuel tank (page 7-6). Disconnect the sidestand switch 2P connector [1]. Remove the wire clip [1]. Remove the mounting bolt [1] and sidestand switch [2]. Installation is in the reverse order of removal. TORQUE: Sidestand switch mounting bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft)
  • Page 455 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES INSPECTION Disconnect the sidestand switch 2P connector (page 21-22). Check for continuity between the switch side 2P connector terminals. There should be continuity only when the sidestand is retracted. HORN REMOVAL/INSTALLATION Disconnect the horn connectors [1]. Remove the bolt [2] and horn [3].

  • Page 456: Control Relay

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES CONTROL RELAY REMOVAL/INSTALLATION TBW RELAY/FUEL RELAY/ENG STOP RELAY/SUB VB RELAY Remove the following: – Front seat (page 2-4) – Power box cover [1] – TBW relay [2] – Fuel relay [3] – Eng stop relay [4] –...

  • Page 457: Relay Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES RELAY INSPECTION Remove the relay (page 21-24). Connect an ohmmeter to the relay [1] terminals as shown. Connect a 12 V battery [2] to the relay terminals as shown. There should be continuity only when the 12 V battery is connected.
  • Page 458 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the following: – Rear seat (page 2-4) – Band [1] – Tool bag [2] – Band [3] – BCU [4] Disconnect the BCU 39P connector [5]. Installation is in the reverse order of removal. POWER/GROUND LINE INSPECTION BCU 39P CONNECTOR Bl/G...
  • Page 459 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES 2. BCU Back-up Voltage Line Inspection Turn the ignition switch OFF. Measure the voltage between the wire harness side 39P connector terminal and ground. TOOL: Male Pin Prove 07ZAJ-RDJA110 CONNECTION: Back-up 1 Red (+) – Ground (–) (BAT1): Back-up 2 Gray (+) –...
  • Page 460 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES BODY CONTROL SYSTEM DIAGRAM IGNITION HEADLIGHT MAIN FUSE SWITCH (10 A) (30 A) R/Bl R/Bl R/Bl R/Bl OP (10 A) BATTERY METER/ILLUMI/ HORN (10 A) Bl/R R/Bl IGN2 HORN IN BACK UP (10 A) BAT1 LEFT HANDLEBAR SWITCH H/L LO...
  • Page 461 CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES BODY CONTROL SYSTEM DTC INDEX • After confirming the MID displays, perform the troubleshooting according to the DTC index. Refer Meter Honda DTC name displays code blinks page – – Ignition power failure (low voltage) 21-30 –...
  • Page 462 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES BODY CONTROL SYSTEM DTC TROUBLESHOOTING • Before starting the troubleshooting, check for loose or poor contact in the BCU related circuit. DTC B1 (1-1) IGNITION POWER FAILURE (LOW VOLTAGE) Probable cause: • Faulty battery or its related circuit •...
  • Page 463 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B3 (3-1) BACK-UP 1 FAILURE (LOW VOLTAGE) Probable cause: • Faulty battery or its related circuit • Blown fuse BACK UP (10 A) • Charging system malfunction • Faulty BCU or its power/ground line Symptom/Fail-safe function: •...
  • Page 464 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B4 (4-1) BACK-UP 2 FAILURE (LOW VOLTAGE) Probable cause: • Faulty battery or its related circuit • Blown fuse OP (10 A) • Charging system malfunction • Faulty BCU or its power/ground line Symptom/Fail-safe function: •...
  • Page 465 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B4 (4-3) BACK-UP 2 FAILURE Probable cause: • Faulty battery • Charging system malfunction • Faulty BCU 1. Recheck DTC Read the DTC. Is the DTC B4 (4-3) indicated? – GO TO STEP 2. –...
  • Page 466 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B11 HEADLIGHT DIMMER/ PASSING LIGHT CONTROL SWITCH FAILURE LEFT HANDLEBAR SWITCH 8P CONNECTOR BCU 39P CONNECTOR SW 2 (DIMMER) HEADLIGHT DIMMER SWITCH PASSING LIGHT CONTROL SWITCH DTC B11 (11-1) HEADLIGHT DIMMER/PASSING LIGHT CONTROL SWITCH FAILURE (LOW VOLTAGE) Probable cause: •...
  • Page 467 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B11 (11-2) HEADLIGHT DIMMER/PASSING LIGHT CONTROL SWITCH FAILURE (HIGH VOLTAGE) Probable cause: • Open circuit in the related wire • Faulty switch • Faulty BCU Symptom/Fail-safe function: • Headlight works normally 1. Recheck DTC Read the DTC.
  • Page 468 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B12 TURN SIGNAL SWITCH FAILURE LEFT HANDLEBAR SWITCH BCU 39P CONNECTOR 8P CONNECTOR HAZARD/LIGHTING SW 6 SWITCH (HAZ/TURN) TURN SIGNAL CANCEL SWITCH TURN SIGNAL LEFT SWITCH TURN SIGNAL RIGHT SWITCH DTC B12 (12-1) TURN SIGNAL SWITCH FAILURE (LOW VOLTAGE) Probable cause: •...
  • Page 469 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B12 (12-2) TURN SIGNAL SWITCH FAILURE (HIGH VOLTAGE) Probable cause: • Open circuit in the related wire • Faulty switch • Faulty BCU Symptom/Fail-safe function: • Turn signal light works normally 1. Recheck DTC Read the DTC.
  • Page 470 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B21/B22/B23/B24 TURN SIGNAL LIGHT FAILURE TURN SIGNAL LIGHT 2P CONNECTORS BCU 39P CONNECTOR O (Left side) Lb (Right front) Lb (Right rear) Lb (Right side) CONNECTOR COLLAR: - O (Left side) - Lb (Right side) O (Left rear) O (Left front) W/L_FR...
  • Page 471 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES 2. Turn Signal Light Line Short Circuit Inspection Check for continuity between the BCU 39P connector and ground. TOOL: Male Pin Prove 07ZAJ-RDJA110 CONNECTION: Left side: Orange – Ground Right side: Light blue – Ground Is there continuity? –...
  • Page 472 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B35 (35-1) HORN RELAY FAILURE (SHORT CIRCUIT) Probable cause: • Faulty horn • Faulty BCU Symptom/Fail-safe function: • Horn does not turn OFF 1. Horn Inspection Replace the horn with a known good one and recheck.
  • Page 473 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B81 HORN/FUNCTION/SEL LEFT/ SEL RIGHT SWITCH FAILURE LEFT HANDLEBAR SWITCH BCU 39P CONNECTOR 8P CONNECTOR HORN SW 7 (HORN/FN) SWITCH FUNCTION SWITCH SEL LEFT SWITCH SEL RIGHT SWITCH DTC B81 (81-1) HORN/FUNCTION/SEL LEFT/SEL RIGHT SWITCH FAILURE (SHORT CIRCUIT) Probable cause: •...
  • Page 474 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B81 (81-2) HORN/FUNCTION/SEL LEFT/SEL RIGHT SWITCH FAILURE (OPEN CIRCUIT) Probable cause: • Open circuit in the related wire • Faulty switch • Faulty BCU 1. Recheck DTC Read the DTC. Is the DTC B81 (81-2) indicated? –...
  • Page 475 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B82 MODE/SEL UP/SEL DOWN SWITCH FAILURE LEFT HANDLEBAR SWITCH BCU 39P CONNECTOR 8P CONNECTOR SW 4 (MODE/SEL UP) MODE SWITCH SEL UP SWITCH SEL DOWN SWITCH DTC B82 (82-1) MODE/SEL UP/SEL DOWN SWITCH FAILURE (SHORT CIRCUIT) Probable cause: •...
  • Page 476 dummyhead dummyhead CB750 Hornet Shop Manual LIGHTS/METERS/SWITCHES DTC B82 (82-2) MODE/SEL UP/SEL DOWN SWITCH FAILURE (OPEN CIRCUIT) Probable cause: • Open circuit in the related wire • Faulty switch • Faulty BCU 1. Recheck DTC Read the DTC. Is the DTC 82-2 indicated? –...

  • Page 477: Immobilizer System (Hiss)

    dummytext CB750 Hornet Shop Manual 22. IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION······················ 22-2 DIAGNOSTIC CODE INDICATION ·········· 22-7 SYSTEM LOCATION ···························· 22-2 TROUBLESHOOTING ·························· 22-9 SYSTEM DIAGRAM ····························· 22-3 IMMOBILIZER RECEIVER···················· 22-10 KEY REGISTRATION PROCEDURES ····· 22-4 REPLACEMENT PARTS FOR PROBLEM········································· 22-12 22-1...
  • Page 478 dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) SERVICE INFORMATION IMMOBILIZ ER SYSTEM (HISS) GENERAL • When checking the immobilizer system (HISS), follow the steps in the troubleshooting flow chart (page 22-9). • Keep the immobilizer key away from the other vehicle's immobilizer key when using it. The jamming of the key code signal may occur and the proper operation of the system will be obstructed.
  • Page 479 dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) SYSTEM DIAGRAM MAIN FUSE FI/START IGNITION (30 A) SWITCH FUSE (10 A) R/Bl Bl/W STARTER RELAY STARTER BATTERY RELAY SWITCH G/Bl O/Bu IMMOBILIZER RECEIVER Bl/G METER 22-3...

  • Page 480: Key Registration Procedures

    dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) KEY REGISTRATION PROCEDURES When the key has been lost, or additional spare key is required: 1. Obtain a new transponder key. 2. Grind the key in accordance with the shape of the original key. 3.
  • Page 481 dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) When the ignition switch is faulty: 1. Obtain a new ignition switch assembly. 2. Remove the ignition switch (page 21-15). 3. Connect the SCS short connector to the DLC (page 22-7). 4.
  • Page 482 dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) 21.Wait two seconds or more, then the indicator remains on for approx. two seconds, then it blinks four times repeatedly. • The immobilizer system (HISS) enters the registration mode. Registration of the original key used in step 5 is cancelled. •...

  • Page 483: Diagnostic Code Indication

    dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) When the ECM is faulty: 1. Obtain a new ECM and two new transponder keys. 2. Grind the keys in accordance with the shape of the original key. 3. Replace the ECM with a new one (page 4-58). 4.
  • Page 484 dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) DIAGNOSTIC CODE When the system (ECM) enters the diagnostic mode from the normal mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE ECM data is Faulty ECM Replace the ECM. abnormal. 10 sec. Code signals Faulty immobilizer Follow the troubleshooting (page cannot send or...
  • Page 485 dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) TROUBLESHOOTING The immobilizer indicator comes on for approx. two seconds then it goes off, when the ignition switch is turned ON with the properly registered key with the engine stop switch turned " " and the immobilizer system (HISS) functions normally.

  • Page 486: Immobilizer Receiver

    dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) Diagnostic code is indicated (Code signals cannot send or receive) 1. Immobilizer Receiver Power Input Line Inspection Check the immobilizer receiver power input line (page 22-11). Is the input line normal? –...

  • Page 487: Power Input Line Inspection

    dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) INSPECTION Remove the headlight (page 21-3). Remove the immobilizer receiver 4P connector [1] from the stay and disconnect it. POWER INPUT LINE INSPECTION Turn the ignition switch ON with the engine stop switch "...

  • Page 488: Replacement Parts For Problem

    dummyhead dummyhead CB750 Hornet Shop Manual IMMOBILIZER SYSTEM (HISS) Disconnect the ECM 33P (Gray) connector (page 4-58). Check for continuity between the ECM 33P connector [1] and immobilizer receiver 4P connector [2] terminals of the wire harness side. CONNECTION: Orange/blue – Orange/blue There should be continuity.

  • Page 489: Wiring Diagram

    dummytext CB750 Hornet Shop Manual 23. WIRING DIAGRAM WIRING DIAGRAM ······························ 23-2 PGM-FI SYSTEM DIAGRAM ·················· 23-3 23-1...
  • Page 490 dummyhead dummyhead CB750 Hornet Shop Manual WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM ENGINE BANK A/F SENSOR STOP ANGLE Beige Light Green SWITCH TBW UNIT FRONT REAR FRONT IMMOBILIZER No.2 No.1 SENSOR FUEL PUMP UNIT ABS MODULATOR WHEEL WHEEL RECEIVER IGNITION IGNITION Black Orange...
  • Page 491 dummyhead dummyhead CB750 Hornet Shop Manual WIRING DIAGRAM PGM-FI SYSTEM DIAGRAM MAIN FUSE (30 A) IGNITION SWITCH FI/START (10 A) R/Bl Bl/W SUB VB/IGN (10 A) Y/Bu BATTERY STARTER SWITCH Bl/Br STARTER RELAY SWITCH ENGINE STOP SWITCH FUEL PUMP (15 A) R/Bl FAN (15 A) TBW (10 A)

  • Page 492: Index

    HEADLIGHT SIDE COWL·······································2-5 CLUTCH···························································· 12-7 HEADLIGHT STAY················································2-7 CLUTCH LEVER BRACKET································ 12-22 HEADLIGHT UPPER STAY·····································2-8 CLUTCH SWITCH ············································· 21-20 HONDA DIAGNOSTIC SYSTEM ······························3-4 CLUTCH SYSTEM ·············································· 3-22 HORN····························································· 21-23 COMPONENT LOCATION ···································· 16-3 HSVCS ··························································· 21-12 ALTERNATOR/STARTER CLUTCH···················· 11-3 IAT SENSOR ····················································· 4-61 CLUTCH/GEARSHIFT LINKAGE························...
  • Page 493 dummytext CB750 Hornet Shop Manual INDEX OIL PUMP··························································· 9-5 SIDESTAND OIL STRAINER ···················································· 9-7 FRAME/BODY PANELS/EXHAUST SYSTEM········2-21 PGM-FI SYMPTOM TROUBLESHOOTING················ 4-7 MAINTENANCE ··············································3-22 PGM-FI SYSTEM DIAGRAM································· 23-3 SIDESTAND SWITCH ········································ 21-22 PGM-FI SYSTEM DTC INDEX ································ 4-8 SPARK PLUG ······················································ 3-6 PGM-FI SYSTEM DTC TROUBLESHOOTING ·········...
  • Page 494 CB750 Hornet Shop Manual Honda Motor Co., Ltd. 2023 Published by Honda Motor Co., Ltd. Book number : 62MLB01 Printed in Japan A 2023.3...

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