Honda CB900F Hornet Manuals

Manuals and User Guides for Honda CB900F Hornet. We have 9 Honda CB900F Hornet manuals available for free PDF download: Service Manual, Owner's Manual, User Manual

Honda CB900F Hornet Service Manual (433 pages)

Brand: Honda | Category: Motorcycle | Size: 39 MB

A few Words about Safety
2
Service Information
2
For Your Safety
2
Important Safety Precautions
2
How to Use this Manual
3
Contents
3
Symbols
4
General Information
5
Service Rules
5
Model Identification
6
Frame Serial Number
6
Throttle Body Identification Number
6
Vehicle Identification Number
6
Specifications
7
Lubrication System
9
Fuel System
9
Cooling System
10
Cylinder Head/Valves
10
Clutch/Gearshaft Linkage
11
Alternator/Starter Clutch
11
Crankcase/Piston/Cylinder
11
Crankshaft/Transmission
12
Front Wheel/Suspension/Steering
13
Rear Wheel/Suspension
13
Hydraulic Brake
14
Battery/Charging System
14
Ignition System
14
Electric Starter
15
Lights/Meters/Switches
15
Torque Values
16
Engine
16
Insulator Clamp (Throttle Body Side)
18
Insulator Clamp (Cylinder Head Side)
18
Exhaust Pipe Stud Bolt
18
Frame
19
Tools
21
Lubrication and Seal Points
22
Cable and Harness Routing
26
California Type Only
37
Emission Control System
39
Source of Emissions
39
Crankcase Emission Control System
39
Exhaust Emission Control System ( Secondary Air Supply System)
40
Evaporative Emission Control Systrem (California Type Only)
41
Noise Emission Control System
41
Emission Control Information Labels (USA Only)
42
Vacuum Hose Routing Diagarm Label (California Type Only)
42
Body Panel Locations
43
Frame/Body Panels/Exhaust System Contents
44
Troubleshooting
44
General
44
Seat Removal and Installation
45
Side Cover Removal
45
Air Cleaner Housing Side Cover Removal and Installation
45
Rear Cowl Removal and Installation
46
Front Fender Removal and Installation
46
Rear Fender Removal and Installation
47
Muffler Removal
48
Muffler Disassembly and Assembly
48
Muffler Installation
49
Exhaust Pipe Removal
49
Exhaust Pipe Installation
50
Maintenance Contents
51
Maintenance Schedule
53
Fuel Line
54
Throttle Operation
54
Choke Operation
55
Air Cleaner
55
Crankcase Breather
56
Spark Plug Removal
56
Spark Plug Inspection
56
Valve Clearance Inspection
57
Reusing a Spark Plug
57
Replacing a Spark Plug
57
Valve Clearance Adjustment
60
Oil Level Inspection
62
Engine Oil and Filter Change
62
Recommended Engine Oil
62
Engine Idle Speed
63
Radiator Coolant
63
Recommended Antifreeze
64
Secondary Air Supply System
65
Evaporative Emission Control System (California Type Only)
65
Drive Chain Slack Inspection
66
Drive Chain Adjustment
66
Drive Chain Cleaning and Lubrication
67
Sprocket Inspection
67
Sprocket Replacement
68
Brake Fluid
70
Drive Chain Guide Plate Inspection
70
Front Brake
70
Rear Brake
70
Brake Pad Wear
71
Brake System Inspection
71
Front Brake Pads
71
Rear Brake Pads
71
Brake Light Switch
72
Headlight Aim
72
Brake Pedal Height Adjustment
72
Clutch System
73
Side Stand
74
Front Suspension Inspection
74
Rear Suspension Inspection
74
Nuts, Bolts, Fasteners
75
Wheels/Tires
75
Rear Suspension Adjustment
75
Spring Pre-Load Adjuster
75
Steering Head Bearings
76
Lubrication System Diagram
77
Lubrication System Contents
78
Oil Pressure Inspection
80
Oil Strainer/Pressure Relief Valve
80
Oil Pump Removal
82
Oil Pump Disassembly
83
Oil Pump Inspection
83
Oil Pump Assembly
84
Oil Pump Installation
85
Oil Cooler Removal
85
Oil Cooler Inspection
86
Oil Cooler Installation
86
Fuel System (Programmed Fuel Injection)
88
Fuel System Contents
89
System Location
92
System Diagram
93
Pgm-Fi (Programmed Fuel Injection) System
94
Self-Diagnostic Procedures
94
To Read the Stored Problem Data
94
Self-Diagnostic Reset Procedures
95
Peak Voltage Inspection Procedure
96
Test Harness Connection
96
Test Harness Terminal Layout
97
Pgm-Fi Self-Diagnosis Malfunction Indicator Lamp (Mil) Failure Codes
98
Pgm-Fi Mil 1 Blink (Map Sensor)
100
Pgm-Fi Mil 2 Blinks (Map Sensor)
102
Pgm-Fi Mil 7 Blinks (Ect Sensor)
104
Pgm-Fi Mil 8 Blinks (TP Sensor)
106
Pgm-Fi Mil 9 Blink (Iat Sensor)
110
Pgm-Fi Mil 11 Blinks (Vehicle Speed Sensor)
112
Pgm-Fi Mil 12 Blink (No. 1 Injector)
114
Pgm-Fi Mil 13 Blink (No.2 Injector)
117
Pgm-Fi Mil 14 Blinks (No.3 Injector)
120
Pgm-Fi Mil 15 Blinks (No.4 Injector)
123
Pgm-Fi Mil 18 Blinks (Cam Pulse Generator)
126
Pgm-Fi Mil 19 Blinks (Ignition Pulse Generator)
128
Pgm-Fi Mil 20 Blinks (E2-Prom)
130
Fuel Line Inspection
132
Fuel Pressure Inspection
132
Fuel Flow Inspection
134
Fuel Pump Inspection
135
Fuel Pump Removal
135
Fuel Filter Replacement
136
Fuel Filter Installation
136
Fuel Cut Relay Inspection
136
Fuel Tank Removal
137
Air Cleaner Housing Removal
141
Air Cleaner Housing Disassembly
142
Air Cleaner Housing Assembly
143
Air Cleaner Housing Installation
144
Throttle Body Removal
146
Throttle Body Disassembly
146
Top View
147
Rear View
147
Throttle Body Vacuum Tube Routing
148
Right Side View
148
Throttle Body Assembly
149
Injector Inspection
150
Injector Removal
150
Injector Installation
151
Pressure Regulator Removal/Installation
151
Starter Valve Cable/Throttle Stop Control Knob Removal
152
Starter Valve Cable/Throttle Stop Control Knob Installation
152
Starter Valve
153
Starter Valve Arm
153
Link Arm
153
Starter Valve Assembly
154
Starter Valve Synchronization
156
Map Sensor
158
Output Voltage Inspection
158
Map Sensor Removal/Installation
158
IAT Sensor Removal/Installation
159
ECT Sensor Removal/Installation
159
Cam Pulse Generator Removal/Installation
160
TP Sensor Inspection
161
Input Voltage Inspection
161
Output Voltage Inspection with Throttle Fully Open
161
Output Voltage Inspection with Throttle Fully Closed
161
Bank Angle Sensor Inspection
162
Calculate Result Comparison
162
Bank Angle Sensor Removal/Installation
163
Engine Stop Relay Inspection
163
ECM (Engine Control Module) Removal/Installation
164
Power/Ground Line Inspection
164
Power Input Line
164
Pair Solenoid Valve Removal/Installation
165
Pair Solenoid Valve Inspection
165
Evaporative Emission Control System (California Type Only)Evaporative Emission (Evap) Canister Removal/Installation
166
Evap Purge Control Solenoid Valve Removal/Installation
166
Evap Purge Control Solenoid Valve Inspection
166
System Flow Pattern
167
Cooling System Contents
168
Coolant (Hydrometer Test)
170
Coolant Gravity Chart
170
Coolant Replacement Preparation
171
Radiator Cap/System Pressure Inspection
171
Replacement/Air Bleeding
171
Thermostat Removal
173
Thermostat Inspection
173
Thermostat Installation
174
Radiator Removal
174
Radiator Disassembly
175
Radiator Assembly
177
Water Pump
179
Radiator Installation
179
Mechanical Seal Inspection
179
Water Pump Removal
180
Water Pump Installation
181
Rediator Reserve Tank Removal
182
Radiator Reserve Tank Installation
182
Engine Removal/Installation Contents
184
Drive Sprocket Removal
186
Engine Removal
187
Engine Installation
189
Drive Sprocket Installation
191
Cylinder Head/Valves Contents
194
Cylinder Compression Test
197
Cylinder Head Cover Removal
197
Cylinder Head Cover Disassembly/Assembly
198
Camshaft Removal
199
Camshaft Inspection
202
Camshaft Holder Inspection
202
Cam Chain Guide B
203
Camshaft Oil Clearance
203
Cylinder Head Removal
204
Cylinder Head Disassembly
205
Cylinder Head Inspection
206
Valve Lifter Bore
207
Valve Filter
207
Valve Spring
207
Cam Chain Tensioner/Cam Chain Guide
207
Valve/Valve Guide
208
Valve Guide Replacement
209
Valve Seat Inspection/Refacing
210
Valve Seat Refacing
211
Cylinder Head Assembly
213
Cylinder Head Installation
214
Camshaft Installation
216
Cylinder Head Cover Installation
221
Cam Chain Tensioner Lifter Removal
222
Cam Chain Tensioner Lifter Installation
223
Clutch/Gearshift Linkage Contents
225
Right Crankcase Cover Removal
227
Clutch Removal
228
Clutch Lifter Lever
228
Clutch Inspection
230
Clutch Lifter Bearing
230
Clutch Center
231
Clutch Lifter Piece
231
Clutch Disc
231
Clutch Plate
231
Clutch Outer Needle Bearing Replacement
232
Clutch Outer/Clutch Outer Guide
232
Clutch Outer Needle Bearing Installation
233
Gearshaft Linkage Removal
236
Shift Fork/Shift Drum Removal
237
Gearshaft Linkage Inspection
237
Shift Drum/Shift Fork Inspection
238
Shift Drum/Shift Fork Installation
239
Gearshaft Linkage Installation
239
Right Crankcase Cover Installation
240
Alternator/Starter Clutch Contents
243
Alternator Cover Removal
244
Stator Removal
244
Stator Installation
245
Flywheel Removal
245
Starter Clutch Inspection
247
Starter Clutch Disassembly
247
Starter Clutch Assembly
248
Flywheel Installation
249
Alternator Cover Installation
250
Crankcase/Piston/Cylinder Contents
253
Crankcase Separation
255
Piston/Connecting Rod Removal
256
Piston Removal
256
Piston Disassembly
256
Piston Inspection
257
Cylinder Inspection
258
Connecting Rod Inspection
259
Side Clearance Inspection
259
Crankpin Bearing Inspection
259
Crankpin Bearing Selection
260
Bearing Installation
261
Crankpin Bearing Selection Table
261
Piston Assembly
262
Piston Installation
262
Crankcase Combination
264
Crankshaft Removal
270
Primary Drive Sub-Gear Removal
271
Primary Drive Sub-Gear Installation
271
Starter Clutch Needle Bearing Replacement
272
Starter Clutch Needle Bearing Installation
272
Main Journal Bearing
273
Starter Clutch Needle Bearing Inspection
273
Bearing Inspection
273
Oil Clearance Inspection
273
Bearing Selection
274
Main Journal Bearing Selection Table
275
Bearing Thickness
275
Transmission Removal/Disassembly
276
Mainshaft Bearing Replacement
278
Transmission Assembly
279
Transmission Installation
281
Front Wheel/Suspension/Steering Contents
283
Handlebar Removal
285
Handlebar Installation
287
Inner Weight Replacement
288
Front Wheel Removal
292
Front Wheel Inspection
293
Front Wheel Disassembly
293
Axle
293
Wheel Bearing
293
Front Wheel Assembly
294
Wheel Balance
295
Front Wheel Installation
296
Fork Removal
297
Fork Disassembly
298
Fork Inspection
301
Fork Tube/Slider/Damper
301
Fork Assembly
302
Fork Tube Bushing
302
Fork Installation
306
Steering Stem Removal
307
Bearing Race Replacement
309
Steering Stem Assembly
310
Steering Head Bearing Pre-Load
314
Rear Wheel/Suspension Contents
316
Rear Wheel Removal
318
Rear Wheel Inspection
319
Wheel Rim Runout
319
Driven Sprocket
319
Rear Wheel Disassembly
320
Driven Flange Bearing Removal
320
Rear Wheel Assembly
321
Wheel Bearing Removal
321
Wheel Bearing Installation
321
Driven Flange Bearing Installation
322
Wheel Balance Installation
324
Shock Absorber Removal
325
Shock Absorber Inspection
326
Needle Bearing Replacement
326
Shock Absorber Disposal Procedure
328
Swingarm Removal
329
Swingarm Disassembly/Inspection
329
Pivot Bearing Replacement
331
Swingarm Assembly
332
Swingarm Installation
334
Hydraulic Brake Contents
337
Brake Fluid Replacement/ Air Bleeding
340
Brake Fluid Draining
340
Brake Fluid Feeling/Bleeding
341
Brake Pad/Disc
343
Front Brake Pad Replacement
343
Rear Brake Pad Replacement
344
Front Master Cylinder Removal
346
Brake Disc Inspection
346
Front Master Cylinder Disassembly
347
Front Master Cylinder Inspection
348
Front Master Cylinder Assembly
349
Rear Master Cylinder Removal
351
Rear Master Cylinder Disassembly
352
Rear Master Cylinder Inspection
353
Rear Master Cylinder Assembly
353
Front Brake Caliper Removal
355
Rear Master Cylinder Installation
355
Front Brake Caliper Inspection
357
Front Brake Caliper Assembly
357
Front Brake Caliper Installation
358
Rear Brake Caliper Removal
359
Rear Brake Caliper Disassembly
359
Rear Brake Caliper Inspection
360
Rear Brake Caliper Assembly
361
Brake Pedal Removal
362
Rear Brake Caliper Installation
362
Brake Pedal Installation
363
Battery/Charging System Diagram
365
Battery/Charging System Contents
366
Battery Removal/Installation
370
Voltage Inspection
370
Battery Testing
371
Battery Charging
372
Charging System Inspection
373
Current Leakage Inspection
373
Charging Voltage Inspection
373
Alternator Charging Coil Inspection
374
Regulator/Rectifier
374
System Inspection
374
Regulator/Rectifier Removal/Installation
375
Ignition System System Diagram
377
Ignition System Contents
378
Ignition System Inspection
381
Ignition Coil Primary Peak Voltage
381
Ignition Pulse Generator Peak Voltage
382
Ignition Coil Removal/Installation
384
Ignition Pulse Generator Removal
384
Ignition Pulse Generator Installation
385
Ignition Timing
387
Electrical Starter System Diagram
389
Electrical Starter Contents
390
Starter Motor Removal
393
Starter Motor Disassembly
393
Starter Motor Inspection
394
Starter Motor Assembly
396
Starter Motor Installation
398
Starter Relay Switch
399
Operation Inspection
399
Groud Line Inspection
399
Starter Relay Voltage Inspection
399
Diode Removal
400
Diode Inspection
400
Diode Installation
400
Starter Relay Switch Removal/Installation
400
Lights/Meters/Switches System Location
401
Lights/Meters/Switches Contents
402
Headlight
405
Bulb Replacement
405
Bulb Removal
406
Bulb Installation
406
Turn Signal Bulb Replacement
407
Turn Signal Removal/Installation
408
Tail/Brake Light Bulb Replacement
408
License Light Bulb Replacement
409
Combination Meter Removal
409
Combination Meter Disassembly
410
Combination Meter Assembly
411
Combination Meter Installation
411
Tachometer System Inspection
412
Speedometer/Speed Sensor System Inspection
413
Speed Sensor Removal/Installation
414
Coolant Temperature Gauge/Sensor Inspection
415
ECT Sensor Unit Inspection
416
Oil Pressure Switch Inspection
417
Oil Pressure Switch Removal/Installation
418
Fan Motor Control Relay Inspection
419
Fuel Reserve Sensor Inspection
419
Ignition Switch Inspection
420
Ignition Switch Removal/Installation
420
Handlebar Switches
421
Clutch Switch
422
Neutral Switch
422
Side Stand Switch Inspection
423
Side Stand Switch Istallation
423
Turn Signal Relay Inspection
424
Horn
424
Wiring Diagrams
425
Troubleshooting Contents
426
Engine Does Not Start or Is Hard to Start
426
Engine Lacks Power
427
Poor Performance at Low and Idle Speed
428
Poor Performance at High Speed
429
Poor Handling
429
Index
430

Honda CB900F Hornet Service Manual (432 pages)

Brand: Honda | Category: Motorcycle | Size: 88 MB

2. Frame/Body Panels/Exhaust System

44
- Table of Contents
  44
- Seat
  45
- Side Cover
  45
- Air Cleaner Housing Side Cover
  45
- Rear Cowl
  46
- Front Fender
  46
- Rear Fender a
  47
- Rear Fender B
  47
- Muffler/Exhaust Pipe
  49
- Lbf-Ft)
  52
- Nom
  52
__ ~~~?~~

282
- Nom (1.0 Kqf-Rn, 7 Lbf-Ft)
  291
- Nom (4.0 29 Ibfoft)
  294
- Kqf-Rn
  315
- Lbf-Ft)
  317