Honda 2005 CB900F User's Manual
Contents
1. NYAL o 5 lt gs 823288255855 TTT uv3u 1331 s LF 95 S25 NHOH 1g 4 s 4 HJ T 9 H 77 id T It Hi 4 MSS 09ACL MECACL 3c H LHOIMGVSH LHOIT TWNOIS Nun 9 9 LHOIH LF m i 9 ng 5 YOSNAS 09 AB A MBELANI 1 915 NYNL LHOIY oH go a YOSNAS on 27 wia YOLOW B ng Nv4 94 n r YOSNAS 3Su3A3H z 1905 HOSNAS A suo dl WA 20 e 2 8 ma Br v uo1o3rNi 5 ma a A HOLIMS Le Pre NIB 15 3415 wia 112 gg 1305 28 oz8 9y 2 5 M 4 5 zo o 9or A9 T 2p EET S953 5 Ee fnis C 3NiSNS ERE YOSNAS MS wr o YOSNIS Fal NENNEN 0 ETA FIONV U i Por 2952 5 M wc EL ws UT s sc8o 89 553280 c vl 109 NOLLINDI INYA GION310S NOLLINSI JO3fNI LS0VHX3 1842 o 80 80 3e 22 M H wig wia ess EP mw 2556 5 3AIVA GION31 T JOYLNOD TAIVA IONTIOS 29 46 YOLVOIGNI 1303 avide Cw YOLVOIGNI Id ae A YOLVOIGNI 35185399 10 Wid ER aQ lt 9 YOLVOIGNI TVHIO3N 777 B WOLVOIONI W738 HOIH 2 u313A0d0 831L3Welel ggrrcccr mp lt 8 25 9 228 E amp2. Ibf ft 02005 American Honda Motor Co Inc All Rights Reserved 1 Remove the carton cover and check for damage The CB900F is crated at the factory in either a covered or uncovered crate You may receive either one CARTON COVER STRAP CARDBOARD TOP HBA Covered crate Cut the strap and remove the carton cover Remove the cardboard top T Ee he M Uncovered crate When stacking protect the motorcycle from falling objects and bad weather Check the motorcycle for hidden damage If you find damage follow the instructions on the Delivery and Damage Claims Guidelines wall chart Reorder No 50477 before proceeding 2 Remove the master cylinder and the clutch lever assembly Remove the bolt and the front brake master cylinder Do not allow the master cylinder to hang by its hose The weight of the assembly could damage the hose Remove the bolt and the clutch lever assembly CLUTCH LEVER ASSEMBLY 3 Remove the front shipping brace Remove the nuts and the front shipping brace 2005 American Honda Motor Co Inc All Rights Reserved 1 2005 CB900F 4 Remove the crate frame and the loose parts carton BRACES Remove the bolts and braces Using two people lift off the crate frame being careful not to damage the motorcycle Cut the strap and remove the loose CARTON parts carton Keep the You
3. and Your Motorcycle Riding Tips amp Practice Guide booklet separate and hand deliver to the customer at the time of delivery 2 02005 American Honda Motor Co Inc All Rights Reserved 5 Loose Parts Information Unpack the remaining loose parts and check them against this illustration and list DESRIPTION OTY PART NUMBER STEP 1 Handlebar 1 53100 MCZ 000 8 2 Mirrors 2 88210 000 14 3 Tool kit 1 89010 MCZ 000 15 4 Owner s Manual 1 31MCZ630 15 5 Riding Tips amp Practice Guide 1 GO0045 4 6 Manual bag 1 77251 342 000 15 7 Attaching Parts Screw washer 5 x 20 mm 1 93892 05020 07 7 Screw washer 5 x 25b mm 1 93892 05025 07 7 Handlebar Holder 2 53131 MCZ 000 8 Socket bolt 8 x 32 mm 4 96600 08032 10 8 Socket bolt cap 8 mm 4 91455 KEA 000 8 Handlebar weight 1 53105 MK4 620 9 Oval crew 6 x 65 mm 1 90191 KBG 000 9 Master cylinder holder 2 45517 166 006 10 amp 12 Flange bolt 6 x 22 mm 2 90101 MBZ G00 10 Screw washer 5 x 45 mm 1 93892 05045 07 11 Screw washer 5 x 35 mm 1 93892 05035 07 11 Flange bolt small head 6 x 22 mm clutch side 2 96001 06022 07 12 Socket bolt 8 x 22 mm 2 90157 ME9 000 13 f missing order from Helm Inc f missing order from Resolve Corp Missing Parts or Shipping Damage Identify missing parts by referring to the Loose Parts Information section Order the parts using normal parts ordering procedures Claims for missing loose parts or those damaged during transit sho
4. e INVA PEIN 3 a n P emen BON Tx CES ome ki d 1 GIONGIOS NIB 4 TOYLNOD 18 i H21IMS 1 ENEN iNOW Avisa 0011 Z91N Z0 00 an 5 8 HOLOW Nyd m 1 710021 YOLOANNOO IDAHO mn HOLIMS HOLMS ETT MLLAZL 9015 YALYVLS NOLYNINATII YOLWOIGNI HOLWOINI TWNOIS TWNOIS NunLIHOIH NunLL331 9 9 V 4 L 15 2005 American Honda Motor Co Inc All Rights Reserved
5. step They are intended to be used by the experienced technician one who only needs a brief reminder of the set up sequence e Descriptive text The descriptive text explains in detail what is to be done during that step This explanation is intended as a guide for the technician needing additional information e Photographs Line art The photographs or line art support both the sub headings and the detailed text Te Indicates the Set up section Indicates the Pre delivery section Modifications and Accessories Modifications that you may have made or should make in the future to any Honda product shall be deemed by our company to have been performed at your sole risk and responsibility and without our company s or the manufacturer s approval or consent implied or expressed We further disclaim any and all liability obligation or responsibility for any defects of modified parts or of the modified product and for any claims demands or causes of action for damage to property or for personal injuries resulting from the modification of said Honda product Torque Table ITEM SIZE TORQUE Handlebar bolts 8 mm 27 2 8 kgf m 20 Ibf ft Handlebar weight 6 mm 10 1 0 kgf m 7 Ibf ft Master cylinder holder bolts 6 mm 12 1 2 kgf m 9 Ibf ft Clutch lever holder bolts 6 mm 12 1 2 kgf m 9 Ibf ft Footpeg socket bolts 8 mm 27 2 8 kgf m 20 Ibf ft Rear axle nut 93 9 5 kgf m 69
6. 2005 CB900F SET UP INSTRUCTIONS HONDA Set up and pre delivery service must be performed by an authorized Honda motorcycle dealer MPD 10969 0501 02005 American Honda Motor Co Inc All Rights Reserved Issued March 2005 IMPORTANCE OF PROPER SET UP AND PRE DELIVERY SERVICE FOR YOUR CUSTOMER S SAFETY Proper set up and pre delivery service are essential to rider safety and the reliability of the machine Any error or oversight made by the technician assembling and servicing a new machine can result in faulty operation damage to the machine or injury to the rider WARNING Improper set up or pre delivery service can create an unsafe condition that can cause your customer to be seriously hurt or killed Follow the procedures and precautions in this manual and the service manual carefully FOR YOUR SAFETY Some of the most important safety precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing set up and pre delivery service Only you can decide whether or not you should perform a given task WARNING Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed Follow the procedures and precautions in this manual carefully IMPORTANT SAFETY PRECAUTIONS Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment Wh
7. 38 nny 330 A31 OEIL 330 938 0 NO 3344 440 3304 NO A35 no ZH M iva 91 15 91 NI euval o8 Am 2 00 lt lt lt lt lt lt HOLIMS GYVZVH HOLIMS H3 1HVIS SIS NEHME RAMS HOLIMS YIWNIG H LIMS TWNOIS NYNL H LIMS NOILLIND uw a 7 Pur n 7 3sNaon Od TIWL NHOH YILIN voL 9 15 3UHM M 2200 lt lt lt d qu voi N3349 1 51 Ni33iD 9 ana 1HON 91 ama dois Nun vor AMOUR a Movie d LE YOLOW SSYd SLHOMav3H vol NMOH8 29 Xovi8 18 u3luvis HOLIMS NOILISOd HOLIMS WAL3INOGO HOLOW voz 9 4 NYOH e HAWG e TVNDIS HOLNT9 YOSNAS HOLIMS 03345 5 9 anano wa HVOL AZL 29 Hyon ft HOSNAS du VNSIS 193 NUAL ZXMGIMLZAZL 55 520 255 ee SIHOMIVLONY VOE VI NIV 3574 HOLIMS 1 1 L A4 TET AV13uU HALYVLS wade mr 49 was 9 HO1VH3N35 ore p LE i 35104 H EH HOLIMS 5 a Ei AWN d NOLLINDI H9 IT 3g En n vor JJvYg 9 9 9 e ow uvad MWOo w0 NO N9 NO 59520 T S M8 ECACL 1 C wan Exei um 1 1 9 M 1NOB3 1391 xt a pigen AWN az pm 1 AMEZAZL x I 17 o m Zgor
8. Attach the handlebar weight Align the tab on the handlebar weight with the recess in the handlebar Insert the weight into the handlebar and attach it with a 6 x 65 mm oval head screw Torque the screw Torque 10 N m 1 0 kgf m 7 Ibf ft 10 Install the front brake master cylinder Place the master cylinder assembly on the handlebar Align the edge of the assembly with the punch mark on the handlebar Set the master cylinder holder with its UP mark facing up on the assembly Attach it using two 6 x 22 mm flange bolts Torque the two bolts starting with the top one Torque 12 N m 1 2 kgf m 9 Ibf ft Connect the brake light wires to the master cylinder terminals 11 Install the turn signal switch Position the switch assembly on the handlebar by inserting its pin into the hole in the handlebar and aligning the end cap with the groove in the switch assembly Attach the switch assembly using a 5 x 45 mm screw washer in the front hole and a 5 x 35 mm screw washer in the rear hole Torque the screw washers starting with the front one Torque 4 N m 0 4 kgf m 3 Ibf ft 02005 American Honda Motor Co Inc All Rights Reserved HANDLEBAR WEIGHT FRONT BRAKE MASTER CYLINDER nex J E LES QU oz jw B INER SWITCH A Z IN CONNECTORS zs Ew za x 22 mm UP MARK FLANGE BOLTS END CAP SCREW WASHER SCREW WASHER 2005 CB900F 12 Install the clutch lever assembly Positi
9. e discs using m Pro Honda Brake Cleaner or equivalent and a clean shop towel 14 Install the mirrors Thread the mirrors into their mounts and secure them by tightening their lock nuts A LOCK NUT BEN 15 Store the Owner s Manual and tool kit Insert the ignition key into the seat lock Turn the key clockwise to release the seat Pull the seat back and off the motorcycle 2005 American Honda Motor Co Inc All Rights Reserved T 2005 CB900F 15 Store the Owner s Manual and tool kit cont Place the tool kit in the holder and secure it with the rubber restraining strap TOOL KIT Place the Owner s Manual in its bag and secure it in the holder located on the bottom of the seat If the pre delivery inspection is to be completed directly after set up leave the seat off If not reinstall the seat OWNER S MANUAL 8 62005 American Honda Motor Co Inc All Rights Reserved 16 Check the cables hoses and wire harness routing IS oe LANDS THROTTLE CABLES 2 V PS e J 2 RIGHT HANDLEBAR SWITCH WIRE f LEFT HANDLEBAR SWITCH WIRE Ne Oe WE FRONT BRAKE HOSE NEGATIVE POSITIVE BATTERY CABLE BATTERY CABLE A PA P ee BATTERY 2 a BRI 2005 American Honda Motor Co Inc All Rights Reserved 2005 CB900F 17 Service and install the battery 10 Service the battery only if the mot
10. en performing the set up or pre delivery service be especially careful of the following e Read the instructions before you begin and make sure you have the tools and skills required to perform the tasks safely e o prevent the machine from falling on you park it on a firm level surface using the proper stand s to provide firm support Make sure the engine is off before you begin any servicing procedures This will help eliminate several potential hazards e Carbon monoxide poisoning from engine exhaust be sure there is adequate ventilation whenever you run the engine e Burns from hot parts let the engine and exhaust system cool before touching Injury from moving parts do not run the engine unless the instruction tells you to do so Even then keep your hands fingers and clothing away To reduce the possibility of a fire or explosion be careful when working around gasoline or batteries Use only a nonflammable solvent not gasoline to clean parts Keep all cigarettes sparks and flames away from the battery and all fuel related parts 02005 American Honda Motor Co Inc All Rights Reserved 2005 CB900F How To Use This Manual Follow the complete sequence of steps as shown Do not short cut any steps The sequence has been established to ensure the unit is properly assembled The individual steps are composed of three components e Sub heading The large sub headings are a brief description of the
11. on Torque the axle nut and tighten the lock nuts on both sides Torque 93 N m 9 5 kgf m 69 Ibf ft Check the tire pressure Front 36 psi Rear 41 psi Complete the Set Up Pre Delivery Checklist Complete an On Road Set Up Pre Delivery Checklist Reorder No 50299 by checking the boxes confirming that the steps were done 02005 American Honda Motor Co Inc All Rights Reserved wo wm 49 o m 8 40109 HOLWNYALIV na wa ta wow00 61 0 u3HlL2
12. on the clutch lever assembly on the left side of the handlebar Loosely attach it using its holder and two 6 x 22 mm small head flange bolts Be sure the holder s UP mark is facing up Align the split between the holder and lever assembly with the punch mark on the handlebar Torque the two bolts starting with the top bolt first Torque 12 N m 1 2 kgf m 9 Ibf ft Connect clutch switch connectors to the switch terminals 13 Remove the motorcycle from the crate base Route a sling under the steering stem Be sure not to trap any cables hoses or wires between the sling and the frame Route another sling through the rear wheel Attach the slings to a fork lift or similar lifting device and apply just enough tension to the slings to support the motorcycle Use a spreader board if needed to prevent the sling from rubbing on the rear body 6 2005 American Honda Motor Co Inc All Rights Reserved 13 Remove the motorcycle from the ER i crate base cont mm BRACE 8 Removethe6and8mm bolts and right crate WU A BRACE N A shipping brace Remove the 6 and8 mm bolts and left crate shipping brace Discard the bolts Install and torque the 8 x 22 mm socket bolts securing the footpeg brackets Torque 27 N m 2 8 kgf m 20 Ibf ft Lower the side stand and place the motorcycle on a level surface Remove the slings E Clean both sides of all the brak
13. orcycle has been sold or is to be used as a demonstration vehicle Remove the seat see step 15 Remove the bolt then pull back the right side cover from the motorcycle Follow the instructions included on the battery case and in Service Letter 48 The battery used in this motorcycle is a pre charged maintenance free type The electrolyte has already been added to the battery Do not connect the motorcycle battery cables to the battery terminals until the motorcycle is ready for delivery Place the ignition in the OFF position Remove the battery hold down strap and battery Remove the protective cap from the positive battery terminal Slide the battery terminal nut into the battery positive terminal Connect the battery positive cable to the positive battery terminal tighten the bolt coat the terminal with dielectric grease then pull the red cover over the positive terminal Set the battery into the battery box Install the battery hold down strap Slide the battery terminal nut into the battery negative terminal Connect the battery negative cable to the negative battery terminal tighten the bolt coat the terminal with dielectric grease then pull the cover over the negative terminal Reinstall the side cover and seat SIDE COVER NES unt Au A 2 b w NEGATIVE CABLE 2005 American Honda Motor Co Inc All Rights Rese
14. rks If the level is low add the recommended oil as detailed above Do not add oil above the upper level mark 22 Check the coolant level Check the coolant level at the reserve tank located behind the side cover on the left side If required add Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing silicate free corrosion inhibitors to restore the level to the UPPER mark 02005 American Honda Motor Co Inc All Rights Reserved 13 2005 CB900F 23 24 25 26 14 Check the idle speed THROTTLE STOP SCREW Support the motorcycle on its side stand on a firm level surface Connectatachometerto the engine Place the transmission in neutral Start the engine and warm it to the normal operating temperature Verify the engine idle speed Idle speed 1 200 100 rpm Use only the throttle stop screw to make idle speed adjustments Verify the drive chain slack Place the motorcycle on the side stand and put the transmission in neutral Check the drive chain slack midway on the lower chain run Drive chain slack 30 40 mm 1 3 16 1 9 16 in Adjust the slack by loosening the axle nut and the adjustment lock nuts Turn the adjustment bolts to set the proper chain slack 30 40 mm 1 3 16 1 9 16 in Set the wheel alignment using the alignment marks on the swingarm and the notches on the axle holders Be sure both sides are set to the same positi
15. rved 18 Check the throttle operation Check the throttle cable for damage Check that the throttle returns from all open positions to the fully closed position smoothly and automatically in all steering positions Measure the throttle grip free play Throttle grip free play 2 4 mm 1 16 3 16 in To adjust tree play LOCK NUT ADJUSTER e Make small adjustments at the throttle grip adjuster Loosen the lock nut and turn the adjuster Tighten the lock nut after adjusting e Make large adjustments at the throttle body ADJUSTER end Loosen the lock nut and the adjuster nut Tighten the lock nuts after adjusting LOSS y s SREYA 5 S dis NIP 44 2597 LOCK NUTS 2005 American Honda Motor Co Inc All Rights Reserved 11 2005 CB900F 19 Check the clutch lever free play Measure the clutch lever free play at the lever tip Clutch lever free play 10 20 mm 3 8 13 16 in To adjust the free play ADJUSTER e Make small adjustments at the lever end of the cable Loosen the lock nut and turn the adjuster Tighten the lock nut after adjusting Before making any large adjustments loosen the lever adjuster lock nut turn the adjuster in completely then turn it out one or two turns Make large adjustments at the engine end of the cable Loosen the lock nut and turn the adjustment nut Tighten the lock nut after adjusting 20 Adjust the brake light switch Turn on the igni
16. tion switch Adjustthe rear brake light switch so the light comes on as the brake begins to engage Avoid turning the switch body Turning the switch body will twist the wires and could x cause a short circuit UN lg To adjust turn the adjuster not the body NS ADJUSTER 12 2005 American Honda Motor Co Inc All Rights Reserved 21 Check the engine oil FILLER CAP Before starting the engine remove the anti rust coating from the engine and exhaust system using a mild detergent and water Rinse with clean water Support the motorcycle in an upright position on a firm level surface Check the oil inspection window to be sure the engine has oil If no oil is present in the window remove the oil filler cap and add the recommended oil to bring the level up to between the upper and lower level marks Oil recommendation Pro Honda GN4 or HP4 without molybdenum additives 4 stroke oil or an equivalent motorcycle oil Viscosity weight SAE 10W 40 classification SF or higher Do not use oils labeled as energy conserving on the circular API service label JASO T 903 standard MA Crankcase capacity 3 5 Liters 3 7 US Quarts Start the engine and let it idle for 3 5 minutes then shut it off Wait 2 3 minutes and supporting the motorcycle in an upright position check the oil inspection window The oil level should be between the upper and lower level ma
17. uld be submitted to American Honda not the carrier After completing repairs submit a Transportation Claim via IM For complete details please refer to the Warranty Policy and Procedures Manual 02005 American Honda Motor Co Inc All Rights Reserved 3 2005 CB900F 6 Remove the front shipping bracket Remove the bolts and front shipping bracket from the handlebar mount FRONT SHIPPING BRACKET i 7 Install the throttle grip Remove the protective wrap from the throttle grip switch assembly Slide the throttle grip switch assembly onto yu the right side of the handlebar Move the grip sm until the pin in the switch assembly drops into Ley the hole in the handlebar Close the bottom half of the switch assembly and secure the halves using a 5 x 20 mm screw washer in the front hole and a SCREW WASHER 5 x 2b mm screw washer in the rear hole Torque the screw washers starting with the front one Torque 4 N m 0 4 kgf m 3 Ibf ft 8 Install the handlebars Align the handlebar punch mark with the top edge of the lower holder HANDLEBAR Set the upper holders onto the handlebar with their punch marks to the front Attach the handlebar using four 8 x 32 mm socket bolts Torque the four bolts starting with the front two Torque 27 N m 2 8 kgf m 20 Ibf ft PUNCH MARK M Attach the socket bolt caps to the handlebar bolts 4 02005 American Honda Motor Co Inc All Rights Reserved 9
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