HONDA CB900C-CB900F HOW TO USE THIS MANUAL Follow the Maintenance Schedule recommenda: tions to ensure that the vehicle is in peak oper: ating condition and the emission levels are within the standards set by the U.S. Enivron. mental Protection Agency. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period, Sections 1 through 3 apply to the whole motor- cycle, while sections 4 through 21 describe parts of the motorcycle, grouped according to location Find the section you want on this page, then turn to the table of contents on page 1 of that section Most sections start with an assembly or system illustration, service information and trouble shooting for the section. The subsequent pages give detailed procedures. If you are not familiar with this motorcycle, read the TECHNICAL FEATURES in section 22. If you don’t know the source of the trouble, go to section 23, TROUBLESHOOTING. Service information for 1981 and later models is in the Addendums beginning with Section 24, ‘ALL INFORMATION, ILLUSTRATIONS, DIREC. TIONS 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 NO-| TICE AND WITHOUT INCURRING ANY OBLIGA. TION WHATEVER. NO PART OF THIS PUBLICATION MAY BE RE-| PRODUCED WITHOUT WRITTEN PERMISSION. | HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OFFICE GENERAL INFORMATION LUBRICATION INSPECTION AND ADJUSTMENT FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVE CYLINDER/PISTON CLUTCH GEARSHIFT LINKAGE ENGINE SUBTRANSMISSION CRANKCASE TRANSMISSION CRANKSHAFT/PRIMARY SHAFT FRONT WHEEL/SUSPENSION REAR WHEEL/SUSPENSION FINAL DRIVE HYDRAULIC BRAKE BATTERY/CHARGING SYSTEM il — IGNITION SYSTEM ELECTRIC STARTER ELECTRICAL] t ‘SWITCHES TECHNICAL FEATURES TROUBLESHOOTING rr i ena] ‘81 CB9O0C ADDENDUM ‘81 CB9OOF ADDENDUM "82 CB900C *F ADDENDUM Date of Issue: March, 1982 HONDA MOTOR CO., LTD.HONDA CB900C 2 MODEL IDENTIFICATION 4 YY Y BEGINNING WITH F No. SCO4-2000046 F No, SCO4—2001669 [CANADA model] a The frame serial number is stamped on the steering head The vehicle identification number (VIN) is on the right side. steering head left side. Y NUMBER, ‘The engine serial number is stamped on top of the right The carburetor identification number is on the carbure crankcase tor body left side. Date of Issue: Novernber, 1980 © HONDA MOTOR CO., LTD.(2?) HONDA ©) CB900C L.GENERAL INFORMATION. GENERAL SAFETY w SERVICE RULES mW SPECIFICATIONS 1-2 TORQUE VALUES 1-4 |_ SPECIAL TOOLS/COMMON TOOLS 1~7 GENERAL SAFETY IM If the engine must be running t0 do some work, make sure the area is wellwentilated. Never run the engine in a closed area, The exhaust contains poisonous carbon monoxide gas. Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks in your working area SERVICE RULES CABLE & HARNESS ROUTING MAINTENANCE SCHEDULE 1-11 EMISSION CONTROL SYSTEM 1-12 EMISSION CONTROL INFORMATION LABEL 1-12 The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. In case of contact, flush ‘thoroughly with water and call a doctor if your eyes were exposed. ‘The battery generates hydrogen gas which can be highly explosive. Do not smoke or allow flames or sparks near the battery, especially while charging it 1. Use geniune HONDA or HONDA-recommended parts and lubricants or their equivalent. Parts that do not meet HONDA’s design specifications may damage the motorcycle, 2. Use the special tools designed for this product. 3. Use only metric tools wien servicing this motorcycle. Metric bolts, nuts, and serews are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motoreyele. 4, Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling 5. When tightening bolts or nuts, begin with larger-diameter or inner bolts first, and tighten to the specified torque diagonally, unless a particular sequence is specifies. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check al Date of Issue: November, 1980 © HONDA MOTOR CO., LTO. arts for proper installation and operation, 1-1 |4_GENERAL INFORMATION SPECIFICATIONS HONDA CB900C When @ genuine Honda fairing is installed i) ITEM DIMENSIONS. Overall length Overall width Overall height Wheelbase Seat height Foot peg height | Ground clearance | Dry weight Curb weight FRAME Type Front suspension, travel Rear suspension, travel Gross vehicle weight rating Vehicle capacity load Front tive size Rear tire size Cold tire |_(200 Ibs) load Rear capacity load Rear Front brake, lining swept area Rear brake, lining swept area Fuel capacity | Fuel reserve capacity Caster angle Trail Front fork oil cap Type Cylinder arrangement Bore and stroke Displacement Compression ratio | Valve train Maximum horsepower Maximum torque Oil capacity ENGI Lubrication system Air filtration Cylinder compression | Intake vale Opens Closes Exhaust vive Opens Closes Valve clearance (Cold) Engine weight Idle speed t Upto 90kg Front pressures | Up to vehicle Front 2,310 mm (90.9 in} 915 mm (360 in) 1,170 mm (46.1 in) 1/580 mm (62.2 in) v 780 mm (30.7 in} 330 mm (130 in} 150 mm ( 5.9 in} 259 kg (571 Ib) 277 kg (611 tb) Double era — Telescopic fork 160 mm (6.3 in) Swing arm/Shock absorber, 101 mm (4.0 in} 485 kg (1,070 Ib) 208 kg (460 Ib) 110/90-18-62H Universal pattern 130/90-16-67H Universal pattern | 2.25 kglem? (32 psi)» 2.8 (40 ps) 2.25 kalem? (32 psi) 2.25 ka/om? (32 psi) *2.8 (40 psi) 2.8 kglom? (40 psi) Double dise broke 1200 em? (186.0 a in) Single disc brake 653m? (101.2 sa in) Lv 1655 liters (4.4 US gal, 36 Imp gal) 45 liters (1.2 US ga, 1.0 Imp gal) 29 124 mm (4.9 in} 280 * 2.5 cc (9.5 + 0.008 ozs) Air cooled 4:stroke Vertical in-line four 64.5 x 69.0 mm (2.54 x 2.72 in) 902 em? (55.0.cu in) east Chain driven DOHC 4 Valves per cylinder 184 BHP/8,500 rpm 7.8 kg-m (56.4 ft-1b}/7,000 rpm 4.5 liters (4.8 US at, 4.0 Imp qt) after disassembly 2 3.5 liters (3.7 US at, 3.0 Imp at after draining Wet sump Paper | 12.0 2.0 kg/em? (170 * 28 sib 10° (BTOC) at 1 mm lft, 63° (BTDC) at O lift 35° (ABDG) at 1 mm lift, 98° (ABDC) at 0 lift —) 40° (BBDC) at 1 mm lift, 70° (8BDC) at O life (ATDC) at 1 mm lift, 93° (ATDC) at O ite Is IN: 905-0: mm (002-0005 in) 106 kg (234 tb) 1,000 # 100 cpm —, a 1-2 Date of Issue: November, 1980 © HONDA MOTOR CO, LTD.->\HONDA Cc ‘CB900C GENERAL INFORMATION LJ CANADA model rem I CARBURETION | Carburetor type VB, 32 mm (1.26 inl venturi bore {certification number vea3a [Ve438) | Pilot screw initial setting See page 4-17 Float level 15.5 mm (061 in) DRIVETRAIN) Clutch Wier, multi-plate | Transision Seapeed constant mesh with dul range | subtransmission Primary reduction 1.000 (28/28)/2.041 149/24) |_ Fiat etcon 3.091 (34/11) ~ | Secondary reduction (subtransmission] | (High range) | 0.638 (30/47) W (Low range) | 0.721 (31/43) Third eduction | 1.200 18/18) Gear ratio | 2.375 (38/16) Gear ratio | 1-789 (34/18) Gear ratio Ii 1-381 (32/23) Gear ratio IV 1-160 (29/25) Gear ratio V 0.964 (27/28) Gear shift pattern Lefe foot operated return system, EN-2345 Subtransmission gear oil capacity | 0,60 lites (0.61 US qt, 0.53 Imp at) Final drive gear oil capacity 0.15 liters (0.16 US gt, 0.13 Imp at | eLecrRICAL Ignition Transistorized — Ignition timing "FU" mark 10° BTDC at idle Full advance 38.5" BTDC at 3,200 rpm Starting system Starting motor Gonerator “Tvee phase A.C. generator 266 W/5,000 pm Battery capacity 12V-14.AH | Spark plug t- 7 —— ( }: Canada model For cold climate | | below Standard j | _ scrarr nck | ND NGK [ ND OBA | x2aesu | Deca | xz7ESU |[Onses) | pxz4esn-uj | (oraes) | [x27ESR-U) Spark plug gap 0.60.7 mm (0.024-0.028 i) — Firing order 1-2-4-3 Fuse/Main fuse 10/30. LIGHTS | Heaatihe (ihlow bso 60/85 W H4 BULB (Phillips 2342/09 or equivalent) | Tait/stopiight | siz7w 3/32 SAE NO. 1187 Front turn signal/running light | 23/8 W 32/3 ep SAE NO. 1034 Vv Rear turn signal | 23w 32ep SAE NO. 1073 Speedometer light 34w 2ep SAE NO.87 Tachometer light 34w 2ep SAE NO.57 Neutral indicator 34w 2ep SAE NO.57 Tura signal indicator 34w 2ep SAE NO.57 High beam indicator | s4w 2ep SAE NO.57 | Rear suspension air pressure | warning fight 34w 2ep SAE NO. 87 Date of Issue: November, 1980 © HONDA MOTOR CO., LTD. 1-3GENERAL INFORMATION CB900C TORQUE VALUES ENGINE = tem Q'ty | Thread Dia (mm) | Torque kg-m (fib) Remarks I” ener asd ever 8 $ os 1216-8) : | cam notder | 24 6 a —rrCS—t—“—OOS—SCSCO | Cainer ead 2 ry a6- 40126-20) [Laide rene totmrents| | Cam sprocket 54 7 2.2— 2.6 (16-19) paca undersa ones ae io [12180 py ayanona Crankease: | | 8 j 2.1~ 2.5 (15-18) 1 sulfide grease to threads AG. generator joa n | e0-10.0 158-72) | “and underside of ats = | inary sate 1 2 80-100(50-721 | Main shaft 1 16 3.8- 4.2 (28-30) | conrating rd ut 8 32) | Oil Filter center bolt | 2.8- 3.2 (20-23) | it pretsreiteh 1 15- 20(11-14) | Apply Hav selnt Newt eh i tee 2042-14 Oi ran oug J 4 “ 35- 4.0(25-29) Oil pine | 2 0 21 2815-18) Spark advancer 1 8 3.3- 3.7(24-27) | - apply LocTiTe®271 Starting clutch 3 8 2.6— 3.0 (19-22) ‘to the threads — | Subtransmission 9 8 | 3.0- 3.4 (22-25) ileal enck bot 1 2 | 20-2861 Oit rain bolt 1 8 16 20012-10) | * CHASSIS item Oty | Thread Dia (mm) | Torque kovm (fb) Remarks ] Sterng ser at 1 ™ 80-12.0188-87) | pppy ito veo Seeing tp | | ta tery Armaee sate Handabr hor aio 18-26 (13-1—) || when instaling@geruine | Front fork op bridge 2) 9 09-121 7-9) Front fork bolt 2 a 18+ a0(11-22) | seacing stam 2 0 45 85 (02-40) Front axle holder 4 i a0- 40(22-29) Y Front axle nut ey 12 5.5~ 6.5 (40-47) | Front fork weketbott | 2 8 18+ 2(11-18) Fromtorkdainoott =| 8 os- 0914.2-7) Front fork hose (R) | 1 10 1.6= 2.0(11=14) Front fork hot join (ty | 1 a a4 07(20-51) - Revised September 1982 1-4 ‘© American Honda Metor Co, Ine. 1982 - All Rights Reserved sv 4518 8209GENERAL INFORMATION 7 —————— GENERAL INFORMATION 7 trem Vay | Thread bia imm) | Torque kgm (fib) | Remarks Front fork hose connector | 1 8 0.4- 0.7 (2.9-5.1) | Front fork sir valve 1 | 8 | 0.4 0.7(2.9-5.1) Front/rear brake disc 5 8 | 27- 3.3(20-24) | ups Brake caliper carrier | 2 to 30- 4.0(22-20) | Fear axle nut fee 18 8.0-10.0 (58-72) Rear axle holding bolt 1 8 24~ 2.9(17-21) Rear brake peda! holder 2 | 10 35-45 (25-33) | Rear brake pedal | 8 | 18+ 2s113-18) Rear brake torquelink = | 1 8 19-23-17) | Rear shock absorber [ee 10 3.0~ 4.0 (22-29) | Rear shock absorber in | | bolt 1 4 4.0- 6029-36) | Engine hanger bol s | 10 | a5. asizs-an | | Rear shock absorber rod | | | tock mut | 2 n 35- 6.0 (25-49) | Fear shock absorber | Birvae (Sway ond) | 1 8 0.4- 0.7 (2.9-5.1) Fear shock absorber hose | connector (-way joint) 2 8 os 1.2(58-9 | Rear shock sbsorber | hose joint } 2 | 8 04-0.7(29-51) | Rear shock absorber hose joint (3:way) } 2 | 10 | tS 2011-14) Rear shock absorber air sensor 1 | 10 os 1.2158-9) | | 3way joint eo 14 | 19+ aan Swing arm pivot bolt | | | iRignd) =| a | 6 5.0- 7.0 (36-51) (Leto 1 35 | .8- 20012-14 Swing arm pivot nut 1 38 50- 7.0(96-5) | Final gear caso 3 0 | 35~ 45 (25-33) uss Final gear case cover | 2 10 | 35+ 45 (25-33) j 6 | 8 | 23- 2817-201 Final gear case drain bolt | | 6 1.0- 1.4( 7-10) Filler cap bolt 1 | 30 1.0- 1.4( 7-10) Pinion nut 1 16 4.0- 5.0 (29-36) Ss Date of Issue: February, 1960 @ HONDA MOTOR CO.,LTD. 1-5@€ HONDA CB900C GENERAL INFORMATION Torque specifications listed above are for important fasteners. Others should be tightened to standard torque values below. * STANDARD TORQUE VALUES | tem Torque Values kg-m (ft1b) | hem Torque Values kg-m (ft-lb) 8 mm bolt and nut 1.8 2.5 (13-18) 6 mm flange bolt and nut | 1.0 -1.4( 7-10) SSS Date of sue: February, 1980 1-6 © HONDA MOTOR CO, LTDHONDA CB900C GENERAL INFORMATION 9 TOOLS Y | © SPECIAL TOOLS Tool Nome Tool Ne oy Oil pressure gave 07506~3000000 1 | 26 | Oil presure gouge tachment Lr Primary gear holder 07924—4250000 1o4 85, 86 rotor pul | 07033~4250000 _ Bearing race remover | 07953—4250001 1 15-24 Carburetor adjusting wrench 079084220100 1 | oan | Carburetor pilot screw wrench 07908—4220201 1 | saz | snap ring lis | orore-szs0001 | 1 | 17. 81748 Steering tem seker 07816-3710100 1) 428 | mm hollow set wrench 079173230000 1 14-16, 1419, | Bearing race remover | 07946-3710500 } 1 14-24 Steering stem ever 07946-3710600 1) 1423 Baring driver atachment 07946-3710700 _ Piston base o7ass-so00000 =| 28 Valve ite holder 79644720001 1 | a7 — 078642000000 1 | 614, 615 CT 79644220000 2 78 Valve lifter bore pratetr | o79e0-4220000 1 en a | o7e17-s71000 1 | ee Clutch adjusting wrench | 079083230000 1 | 318 Valve seat etter 248 mm 07780-0010100 7) Valve seat etter 27.5 mm 07780-00200 1 | ‘Valve seat flat cutter 28 mm | 07780-0012100 Joa | ‘Valve seat flat cutter 30 mm 077800012200 1 oe Valve sat interior cutter 30 mm 0780-0014000 1 Vale seat cute holder 6.5mm 077810010100 1 J Retainer wrench A 07910—4610100 1 | 108 Retainer wrench 8 079104610200 1 | 1010, 10-11, 1014 Damper compressor 079644610000 1 | 10-4106 Preoad inspection tol 079084610000 1 | 1018 ‘Subtransmission base 079654610000 1 | 109 Bearing driver | 07946-83400 1 1424 }chuten center node 07928-3710000 1 | ease Bearing remover se o7o36_eeo0100 «| «1 asta | PA.T adjust wrench 079084690001 1 | 1816 Fina eainer wrench 079103710000 1 | 16 4,16 6.1612 Oit sel diver tachment 079466020100 1 | 16 7.1610 Retainer wrench B L_omero-ssa0i00 | 1 | re 9.1607 Oncor one Febuary, 1660 HONDA MOTOR CO, LTO. 1-710_GENERAL INFORMATION @™eNEr Tool Name Toot No. ow Ret. Page| Dis/assembly tool A 07966~3710100 1 165 | Preload inspection tool 07924~3710000 1 16 3, 16-11, 1614 | it seal remover 07948~4630100 1 166 Final assembly disassembly base A 07965~4630100 1 16 3,16 9 Disassembly too! B 07965~4630300 1 165 Gear eenter guide 07965~4630500 i 165 Oil sea! guide 07973~4630100 1 16:10 O-ring guide | 07973-4630200 | 1 16:10 Pinion ger dislessembly toot o7gai—4630200 | 1 | 612 * COMMON TOOLS Tool Name PartNo. [Oty] __ Alternate Tool PartNo. | __-Rel, Page Float level gauge 074010010000 | 1 | 48 Retainer wrench A | 077100010100 | 1 | Bearing retainer wrench | 079102830000 | 5. 3 m8 | 07710-0010200| 1 | Bearing retainer wrench | 07020-22801" | a.13, 14:19, Retainer wrene - earing retainer wrenc! ‘seo0000 | 11> Retainer wrench body | 077100010401 | t [ret 1499.15: 3) Lock nut wreneh 17716 -0020100 | 1 83,88 20x 24mm a | Extension bar 07716-0020500 1 | | 83,88 | Valve guide remover 55 mm Valve guide driver 8 Bearing driver outer 37 x40. mm Bearing driver outer 42x47 mm Bearing driver outer 52x 55 mm Bearing driver handle outer A Bearing driver handle outer B Bearing driver handle ‘outer C Bearing driver inner 25mm Valve spring compressor Drive pilot 15 mm, Drive pilot 20 mm Front fork oil seal Driver body Attachment (E) 07742~0010100 077420020200 07746~-0010200 07746-01030 07746-0010400 | 07748-00100 07746--0020100 07746-0030100 (07746 -0030200 077570010000 (97746-0040300 07746~-0040400 07747-0010100 077470010600 Valve guide driver Valve guide driver Bearing driver Bearing driver Bearing driver Driver handle attachment Bearing driver Bearing driver | Valve spring compressor Fork seal driver 07942-3290100 | 6.15 07942-3290200 | 6-15 (079464300200 | 10-11, 15.14 07945-33010 | 10-12, 14-13, 15: 6 9370100 | 3290000 (07949-61100 07946 241,15 6 1012, 141,16. 6 | we 6.16.7, 1610 |ovo4s-2250201| 1312, 3413 | | | | oveas-s710200| 102,128 07957-3290001 6-11 aia | 15- 6,16 6 07947-3710100| 14.19 1-8 Date of Issue: November, 1980 © HONDA MOTOR CO., LTD.HONDA ©) ‘CB900C GENERAL INFORMATION 11 “~~ CABLE & HARNESS ROUTING A CHOKE CABLE yr SPARK UNITS TACHOMETER SHOCK ABSORBER CABLE ‘AIR HOSES FRONT BRAKE PULSER GENERATOR, ‘SX OIL PRESSURE SWITCH, NEUTRAL SWITCH WIRE couPLeR REAR SPEEDOMETER BRAKE HOSE CABLE > MAIN FUSE TURN SIGNAL RELAY FRONT BRAKE HOSE BATTERY DRAIN TUBE DUAL RANGE TRANSMISSION BREATHER TUBE AC. GENERATOR WIRES CARBURETOR OVERFLOW TUBES Date of lssue: February, 1980 © HONDA MOTOR CO.,LTD. 1-9HONDA CB900C 12_ GENERAL INFORMATION WIRE BANDS CHOKE CABLE CLAMP INSTRUMENT j ‘CLUTCH CABLE COUPLER | y ABSORBER AIR HOSES LEFT SIDE SWITCH COUPLER, FUSE HOLDER RIGHT SIDE SWITCH COUPLER THROTTLE COUPLER CABLES : CLUTCH CABLE BRAKE HOSE CHOKE CABLE ‘SPEEDOMETER CABLE TACHOMETER CABLE wiRe HARNESS Date of Issue! February, 1980 1-10 @ HONDA MOTOR CO., LTDHONDA CB900C MAINTENANCE SCHEDULE Perform the PRE-RIDE INSPECTION in the Owner’s Manual at each scheduled maintenance period. {INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY. GENERAL INFORMATION _13 c: CLEAN R REPLACE A: ADJUST L LUBRICATE = | WHICHEVER READING (NOTE 3) FREQUENCY S I as 1 eee ee -iedesed | a + 3 | ITEM ~~~) Every Refer to as * | FUEL LINES Page 3- 3 wo [| THROTTLE OPERATION Page 33 = > COaReURETOR-CHOKE Page 34 e AIR CLEANER NOTET Page 3 4 2 [| cRANKCASE BREATHER NOTE? Page 35 5) sean puues Page: 5 2? |_Vatve clearance Page 3- 6 2 |_| encine ow YEAR Page 2 3 3|_| encineou ricer YEAR Page 2-3 2 [7 | CAM CHAIN TENSION Page 3:10 “ [ET CARBURETOR-SYNCHRONIZE Page 3-10 ~ *_| CARBURETOR-IDLE SPEED Page 3-11 | [2 [orive shart soint Page 2-12 *T-FINAL DRIVE LUBRICANT Page 2.9,12| I BATTERY MONTH Page 314 E | rake FLUID Seaman ld |e fe deta] [er] eagesta # (1 enaKe pap Wear ee Ss BRAKE SYSTEM CP a7 FJ Page 3-15 2 | erake Licht switcH is aes a es teas 3 [= CHeAouiGHr aint I CE TT Page 3716 @/_] cuutcu CT Pepe 3217 2 |_| sive sano ita a |p [aa rages NN 2" | SUSPENSION 1 1 1 1 1 1 1 Page 3-19 g NUTS, BOLTS, FASTENERS ep [1 [7 FJ Page 3:20 (fe [awreeus COO eT Page 320 = _STEERING HEAD BEARING 1 1 1 1 Page 3-21 \ __*_ SHOULD BE SERVICED BY AN AUTHORIZED HONDA 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 AN AUTHORIZED HONDA DEALER NOTES: 1. SERVICE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS. 2. SERVICE MORE FREQUENTLY WHEN RIDING IN RAIN OR AT FULL THROTTLE. (U.S.A. ONLY) 3. FOR HIGHER ODOMETER READINGS, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED eS HERE. Date of Issue: February, 1980, © HONDA MOTOR CO.,LTD. dan(~\ HONDA 14 GENERAL INFORMATION eo CB900C EMISSION CONTROL SYSTEM ‘The CBSOOC is equipped with two Emission Control Systems EXHAUST EMISSION CONTROL SYSTEM ‘The exheust emission control system is composed of lean carburetor settings, and no adjustments should be made except idle speed adjustment with the throttle stop screw. ‘The exhaust emission control system is separate from the crankcase emission control system, CRANKCASE EMISSION CONTROL SYSTEM “The engine is equipped with a closed erankease system to prevent discharging crankcase emissions into the atmosphere Blow-by gos is returned to the combustion chamber through the air cleaner and earburetor. Liquids are collected in the storage tank Air Cleaner Transparent Section ‘Storage Tank Drain Plug — <= Fresh Air = Blow-by Gas Crankease EMISSION CONTROL INFORMATION LABEL ‘An Emission Control information Label is located on the frame as shown. It contains basic tune-up specifications Vehicle Emission Control Information label Date of sue: February, 1980 1-12 @ HONDA MOTOR CO.,LTDMEMO D: us © HONDA MOTOR CO., LTD.C3 HONDA 16 LUBRICATION CB900C ENGINE LUBRICATION DIAGRAM EXHAUST CAMSHAFT 2 oe ich oi strainer “44 2 SuBTRANSMISSION TROCHOID OIL PUM, FINAL DRIVEN Roca i Date of Issue: February, 1980 © HONDA MOTOR CO., LTD. \ FINAL DRIVE OIL FILTER SCREEN GEAR SHAFT(Pp) HONDA 2 LUBRICATION . Ss/ CB900C [SERVICE INFORMATION 2-1 OlL PUMP eer || | TROUBLESHOOTING 2-2 — SUBTRANSMISSION OIL zea || SUBTRANSMISSION OIL PUMP 2-10 ENGINE OIL LEVEL 2-3 | ENGINE OIL & FILTERCHANGE 2-3. FINAL DRIVE OIL 2-12 OIL STRAINER CLEANING 2-4 — ORIVE SHAFT COUPLING 2-12 | | OIL PRESSURE CHECK 2-4 CONTROL CABLE LUBRICATION 2-12 | OIL COOLER INSPECTION 2-5 LUBRICATION POINTS 2413 | SERVICE INFORMATION GENERAL INSTRUCTIONS il pressure relief valve: Sev Saction 13 {CRANKSHAFT/PRIMARY SHAFT). SPECIFICATIONS Engine oi! Oil eapacity 23.5 lit (3.7 US at, 3.0 Imp atl at change 45 hit (4.7 US gt, 3.9 Imp qt) at disassembly Orvecommendaton | On VISCOSITIES | |, Ye HONDAS STROKE OI or cause “sees APLSERVICE CLASSIFICATION SE a ~ | viscosity SAE 10W—a0 Other viscosities shown in the chart may be l used when the average temperature in your riding area is within the indicated range = aaa . Oil pump delivery Engine 41 lit (43 US qt, 36 Imp qt}/min, at 7,000 rpm LL _ Cooler 18 it (19 US at, ¥6 Imp atin. at 7.000 rom pee Oil pressure {_ tet pressure ste) | 5 Kafem* (78) at 7,000 rom (80°C/176"FY Oil pump service data Mi ee Teme \ Foor tip tesrance (Engne/Gooier) | 018mm 10059) | 0.20 mm 0.008 [Pomp body clewange(Engne/Go0l#) | 015-0. mm (0058-0087 in| 0.38 mm (014 ml] [Pump end clarance (ngine/Gooler) | _0.02-0.07 mm (0.008-0.028 in) “| 0.10 mm (0.008 Subtransmission [ema ae aan Iypoid gear oil SAE #80 [Recommended eit Final drive gear (Oil capacity 150 cc (6.1 02) Recommended oi Hypoid gear oi! Above S°C/ai"F Q ! Below 5°C/41°F Date of lsue: February. 1980, : © HONDA MOTOR CO.,LTD. 2-118_LUBRICATION TOOLS ‘Special Oil Pressure Gauge 197506~3000000 Oil Pressure Gauge Attachment _-07510~-4220100 common Driver handle A (07748-0010000 or 0794-61100 Bearing driver outer 52x 55mm 07746-0010400 or 07946-9370100 TORQUE VALUES Engine oil drain plug 3.5-4.0 kg-m (25-29 feb} Engine oil filter bott 2.8-3.2 kg-m (20-23 feb} il pressure switch 1.5-2.0kg-m (11-14 fib) Apply Loctite @ Subtransmission oil drain bolt 1.6-2.0 kg-m (12-14 feb) Sutransmission oil level check bolt 3.5~4.5 kgm (25-33 ft-lb) Subtransmission cover 3,0-3.4 kgim (22-25 fib) TROUBLESHOOTING Oil level too tow 1. External oil leaks 2, Worn piston rings 3, Worn valve guide or seal Oil contamination 1. Oil or filter not changed often enough 2. Head gasket faulty 3. Warn piston rings High oil pressure 1. Pressure elie valve stuck open 2. Plugged ol filter, gallery, or metering or orifice 3, Incorrect oil being used No oil pressure 1. Oi evel ow 2. Oil pump drive gear broken 3. Oil pump faulty 4, Internal oil leakage Low oil pressure 1. Oil level low 2, Pressure relief valve stuck open 3, Plugged oil pick-up screen 4. Oil pump worn 5. External oil leaks, Date of ssve= February, 1980 2-2 HONDA MOTOR CO., LTO_2\ HONDA ¢ / CB900C LUBRICATION 19 > ENGINE OIL LEVEL Run the engine and allow to idle for 23 rminutes. ‘Stop the engine and support the motorcycle fon the center stand. Check the oil level with the filler cap dipstick after a few minutes Do not screw in the cap when making this check If the level is below the lower level mark ‘on the dipstick, fill to the upper level mark. Check the oil pressure warning light. This light should go off when the engine starts. If it does not, check the oil pump function and/or oil circuit. ENGINE OIL & FILTER CHANGE NOTE Change engine oil with the engine warm and the mortoreyele on ite center stand to assure complete and rapid draining Warm the engine to normal operating tem: perature Stop the engine, Place the motorcycle on its center stand, Remove the oil filler cap, drain plug and oil filter bolt and drain the oil Make sure that the sealing washer on the drain plug and the O-rings on the oil filter bolt and oil filter cover are in good condition. After completely draining, replace the oil filter and install the oil filter bolt and drain plug. Fill the crankcase with 3.5 lit (3.7 US qt, 3.0 Imp at) of the recommended oil Install the oil filler cap. Start the engine and let it idle for 2-3 minutes. ‘Stop the engine, ‘Add the recommonded oil to the upper level Make sure that there are no oil leaks UPPER LOWER DRAIN PLUG. 35-40 kgm (25-29 OIL FILTER BOLT 2.8-3.3 kgm (20-23 feb) OIL FILTER O-RINGS Date of Issue: February, 1980 © HONDA MOTOR CO., LTD.20_LUBRICATION OIL STRAINER CLEANING NOTE [The oit strainer can be removed with the engine mounted in the frame Remove the oil filler cap, drain plug and oi filter bolt Remove the exhaust pipes, Disconnect the ail cooler hoses. Remove the oll pan bolts and oil pan. Remove and clean the oil strainer Check the operation of the pressure relief valves. {ostall the oil strainer and oil pan. Connect the oil hoses and install the exhaust pipes. Fill the crankease with recommended oil (Page 23) OIL PRESSURE CHECK Warm the engine up to normal operating temperature (approximately 80°C/176"F) Stop the engine, Remove the oil pressure switch, Connect an oll pressure gauge to the pressure switeh hole Check the oil level OIL PAN PRESSURE RELIEF VALVES OIL STRAINER SCREEN OIL PRESSURE GAUGE ATTACHMENT 07510-82010 February, 1980 HONDA MOTOR CO.,LTD.Start the engine. Check the oil pressure at 7,000 rpm. OIL PRESSURE: 5.5 kglem? (78 psi) at 7,000 rpm (80"c/176"F) Stop the engine Apply Loctite ® to the pressure switch threads and instal TORQUE: 1.5-2.0 kgm (11-14 fttb) Connect the ol pressure switeh, ‘Start the engine. Check that the oil pressure warning light goes ‘ut. If the oil pressure warning light stays on, stop the engine immediately and determine the cause. Refer to page 21-2 for warning switch OIL COOLER INSPECTION Check for damage to the oil cooler core. lean the core if necessary, OIL PUMP REMOVAL NOTE The oil pump can be removed with the | engine mounted in the frame. Drain the engine oll Remove the let foot peg. Remove the subtransmission shift pedal Remove the gearshift pedals. Remove the oll pump cover LUBRICATION 21 OIL PRESSURE : GAUGE 07506-30000 (Not available in U.S.A.) OIL COOLER SUBTRANSMISSION SHIFT PEDAL / GEARSHIFT PEDAL Date of [ssue: November, 1980 9 HONDA MOTOR CO., LTD.22_ LUBRICATION Remove the oil pump. ‘OIL PUMP DISASSEMBLY lL PUMP Remove the oil pump body cover. BODY cover Remove the inner and outer rotors Remove the drive pin and drive shaft. RIVE ee T ee BODY 8 &, 64 Boy covER OUTER ROTOR INNER ROTOR ourel ROTOR (TOENGINE) — (TOCOOLER) (TO COOLER) 26 ‘© HONDA MOTOR CO,, LTD.)\ HONDA ‘) “cago0¢ / INSPECTION Measure the rotor tip clearance. LUBRICATION 23 STANDARD: 0.15 mm (0.059 in} SERVICE LIMIT: {0.20 mm (0.008 in) Ne si ie same for the engine and cooler pumps. Measure the pump body clearance. STANDARD: 0.15-0.22 mm (0.059-0.087 in) Bp SERVICE LIMIT: PF 0.35 mm (0.014 in) Measure the pump end clearance. ‘STANDARD: 0.02-0.07 mm (0,008-0.028 in}. SERVICE LIMIT: 0.10 mm (0.004 in} Date of sue: Febrvary, 1980 if © HONDA MOTOR CO, LTO 2-724_LUBRICATION ASSEMBLY Install the engine outer rotor into body A Insert the drive shaft Insert the drive pin into the drive shaft. ‘Align the slots in the inner rotor with the drive pin. Install body 8. Insert the drive pin into the shaft. Align the slot in the inner rotor with the drive pin, Install the side covers. Tighten the screws. « 2) HONDA 6) “cB900¢ DRIVE SHAFT DRIVE PIN INNER ROTOR BODY 8 2-8 Date of Issue: February, 1980 © HONDA MOTOR CO., LTD.?) HONDA @ CB900C INSTALLATION Install a new gasket. Engage the oll pump drive and driven gears Install the dowel pin, Tighten the oll pump mounting bolts. Install the oil pump cover. NOTE Inst the sealing washers and bots 1] the "7 mark points. Tighten the oil pump cover bolts. Install the gearshift pedal and left foot peg Fill the engine with the recommended oil (age 2-3) SUBTRANSMISSION OIL CHECK Place the motorcycle on its center stand. Shift the subtransmissian into low position. Remove the protector cover. Remove the oll check bolt. Check that the subtransmission is filled to the lower edge of the inspection hole with oil If the il level is low, check for cil leaks. ‘Add the recommended oil until it reaches the ower edge of the inspection hole, CHANGE Remove the oil filler cap. Remove the drain bolt and drain the oil Install the drain bolt TORQUE: 1.6-2.0 kg-m (12-14 ftlb) Fill the subtransmission with the recom- mended oil up to the lower edge of the inspection hole. OIL CAPACITY: 600 cc (20.4 02) RECOMMENDED OIL: HYPOID GEAR OIL SAE #80 GASKET ou Fume PYSEALING WASHERS AND BOLTS ) © LUBRICATION 25 DOWEL PIN FILLER CAP 1.6-2.0 kg-m (nz. Date of Issue: February, 1980 © HONDA MOTOR CO., LTD.)\ HONDA / C€B900C 26 LUBRICATION SUBTRANSMISSION OIL PUMP REMOVAL Drain the subtransmission oll (Page 2.9) Remove the subtransmission cover (Page 103} Remove the shift drum. Remove the O-ring Heat the case around the bearing evenly with a1 kw dryer for 3 minutes. Remove the bearing, tapping the case lightly with a plastic hammer, ‘Be sure 10 wear gloves when removing the heated bearing Remove the circ. Remove the oil pump assy OIE PUME Ay Clean the filter screen with compressed ait CAUTION: _ ‘Do not remove the FILTER SCREEN Date of suo: February, 1980 2-10 @ HONDA MOTOR CO, LTO,LUBRICATION 27 INSTALLATION Clean the oil purnp assy., bearing and cover thoroughly. Iostall the oil pump assy, aligning the oi pump boss with the cover groove. Install the circlio and drive the bearing into the cover. Lubricate the oil pump and bearing wit hypoid gear oil, SAE #80, Install the shift deur, Turn the rear wheel or drive gear by hand so that the slot in the drive gear shaft collar is Install the case cover with the il pup drive shaft boss aligned with the collar slot and new Oring CAUTION | ind suff ety encounter i08) Do not ate te coe wi | Tighten the cover bolts. TORQUE: 3.0-34 kgm (22-25 lb) Install the exhaust pipe heat shield. Fill the case with the recommended oil (page 29) Install the removed parts (page 10-8), DRIVER HANDLE A 0749-01000 Br 08 079¢9-6110000 y IG BEARING DRIVER 52 x 58 mm 07946-9370100 DRIVE GEAR SHAFT Date of Issue: November, 1980 © HONDA MOTOR CO,, LTO.28 LUBRICATION FINAL DRIVE GEAR OIL CHECK Place the motorcycle on its center stand, Remove the oil filler cap. Check that the final gear case is filled up to the lower edge of the ol filler cap hole. Check for leaks, if the level is low. Pour fresh cil through the oil filler hole until it reaches the lower edge. CHANGE Remove the al filler cap, Remove the drain bolt to drain all oil from the final gear case Install the drain batt securely Fill the gear case with the recommended oil Up to the correct level. OIL CAPACITY: 150.c¢ (5.1 02) RECOMMENDED OIL: HYPOID GEAR OIL. API, GL-5. 10 (Above 5°C/41°F) ORIVE SHAFT COUPLING Pump LITHIUM-BASED multipurpose grease through the drive shaft joint grease fitting. CONTROL CABLE LUBRICATION Periodically, disconnect the throttle and clutch cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant. ee. OL LEVEL A GREASE FITTING (q?)HONDA Ss) CB900C ‘OIL ORAIN BOLT, EE EET ENPTEENEEETTT 2-12 Date of Issue: November, 1980 © HONDA MOTOR CO., LTD.HONDA CB900C LUBRICATION 23 LUBRICATION POINTS CLUTCH AND BRAKE ey “EVER Pivors i D qanorme | D GRIP ee or [CABLE 1 SUBTRANSMISSION [CABLE LUBRICANT] REAR SHOCK ABSORBER (HYPOID GEAR OIL) CLUTCH, THROTTLE (ATED API, GL-5 SAE #80 AND CHOKE CABLES ! | | Ad or [Aace CoBATCANT] SPEEDOMETER AND | TACHOMETER CABLES SWING ARM | PivoT STEERING HEAD BEARINGS 1 FINAL DRIVER GEAR / SIDE AND FRONT FORK (HYPOID GEAR OIL) / CENTER PEDALPIVOT = (A.T.F.) Doe ee ~ API, GL-ssae STAND DRIVE GEAR 30~00 | fea pivot DRIVE SHAFT 4 i (LITHIUM-BASED MULTIPURPOSE GREASE) ORIVE SHAFT JOINT —_(LiTHIUM 8aseo muLTiPURPOSE GREASE) L Date of se November, 1900 © HONDA MOTOR CO,, LTD. 2-13(2) HONDA Ss CB900C MEMO Date of Issue: February, 1980 © HONDA MOTOR CO., LTD.@ HONDA 3 ) “cas00c INSPECTION AND ADJUSTMENT. [SERVICE INFORMATION 3-1 ~ | BATTERY a4 | | FUEL LINES 3-3 BRAKE FLUID 314 | THROTTLE OPERATION 3-3 BRAKE PAD WEAR 3415 | | CARBURETOR CHOKE 3-4 BRAKE SYSTEM 3415 AIR CLEANER 3-4 — BRAKELIGHT SWITCH 3-16 | | CRANKCASE BREATHER 3-5 HEADLIGHT AIM 3-16 SPARK PLUGS 3-5 CLUTCH 3-17 VALVE CLEARANCE 3-6 SIDESTAND 318 CAM CHAIN TENSIONER 3410 SUSPENSION 319 CARBURETOR SYNCHRONIZATION 3-10 NUTS, BOLTS, FASTENERS 3-20 CARBURETOR IDLE SPEED 3-11 WHEELS 3-20 IGNITION TIMING 3-12 STEERING HEAD BEARINGS aa | ‘SPARK ADVANCER 3-13 | | CYLINDER COMPRESSION 3413 SERVICE INFORMATION GENERAL INSTRUCTIONS Engine ol See page 2: 3 Engine ol filter See page 2- 3 + Subtransmission oi See page 2- 8 + Final drive gear ei See page 2.12 TOOLS Special Valve lifter holder (07964~4220001 Vacuum gauge (07404—0020000 or M937B-021-XXXXX (U.S.A. only) Carburetor adjusting wrench _-07908-4220100 Clutch adjusting wrench 07908~3230000 SPECIFICATIONS Spark plug: Recommended spark plug 1}. Conede model For cold climate =n Standard below 5°C (41°F) : ND | NG NO | NGK— XHESU DBEA X27ESU DaEA Dx2aesn-u) | (ORBEA] [x27ESR-U)__ (ORDEAL Pluggep 0.6-0.7 mm {0.02-0.03 in} Date of Issue: November, 1980 © HONDA MOTOR CO.,LTD. 3-132_INSPECTION AND ADJUSTMENT Ignition timing Atidle Advance start Full advance Valve clearance: Cold (Below 351 95°F) Idle speed Carburetor synchronization Cylinder compression Throttle grip free play Clute lever free play (g@)HONDA () “cBg00c 10°BTDC, 1,700 rpm 38°30" BTDC at 3,200 rpm 0.06~* Intako/Exhaust 1.13 mm {0.002-0,005 in) 1,000 # 100 rpm Vacuum difference of each eylinder 60 mm Hg (2.4 in Hg) or lass 12 kglem? (170+ 28 psi) 2-6 mm (1/8~1/4 in) 10-20 mm (3/8-3/4 in) Tire in Rear Tiresze _ ce | 130/90 16 67H _| Upw are O01) | 228,80 } : load [2.8 (40 psi)! | 2.25 (32) Golde mesures epg ODT oadto |= 8 a a si | vehicle capacity load (2.8 (40 psi)) "BRIOGESTONE i $708 f G50 | [__Tie bana [ountoe I ci ia? {| When a genuine Honda fairing is installed ‘Suspension air pressure Front 0.81.1 kg/cm? (11~16 psi) 3-2 Rear 20-45 kgicm? (28-64 psi) Date of Issue: November, 1980 © HONDA MOTOR CO., LTD. FUEL LINES Replace any parts which show deterioration, damage or leakage THROTTLE OPERATION NOTE mp may flood the The accelerator carburetors during Check for smooth thrattle grip full opening ‘and automatic full clasing in all. steering positions. Check the throttle cables and replace them if they are deteriorated, kinked (or damaged. Lubricate the throttle cables (page 2-13) if throttle operation is not smooth Measure throttle grip free play at the throttle arp flange. FREE PLAY: 2-6 mm (1/8—1/4 in) Ajustment can be made at either end of the throttle cable. Minar adjustments are made at the upper end and major adjustments are ‘made at the lower end, after removing the fuel tank ‘Adjust by loosening the lock nut and turning the adjuster Tighten the tock nut. Recheck throttle operation. INSPECTION AND ADJUSTMENT 33 FUEL LINE Lock NUT DECREASE PLAY INCREASE PLAY UPPER ADJUSTER 2-6 mm (1/8-1/4 in) ADJUSTER LOCK NUTS. Date of fssue: February, 1980 9 HONDA MOTOR CO. LTO. 3-334_INSPECTION AND ADJUSTMENT CARBURETOR CHOKE Remove the fuel tank. Operste the choke knob and check for smooth operation. Pall the choke knob up all the way to fully closed. Make sure that the choke valve is fully closed at the carburetors by moving the lever. ‘Adjust by loosening the choke cable clamp 1nd moving the choke cable casing Tighten the clamp, holding the choke lever fully closed, Push the choke knob down all the way to fully open. Make sure the choke valve is fully open by checking for free play in the cable between the lever and eable cating Install the fuel tank ‘Adjust the choke operating frietion by turning the adjuster The choke knob must move smoothly and stay where positioned. AIR CLEANER Remove the two air cleaner cover screws and Pull out the air cleaner element set spring and remove the element. ioe + FULLY OPEN CHOKE CABLE cLaMp CHOKE KNOB: RUBBER COVER ADJUSTER INCREASE SW is RESISTANCE DECREASE RESISTANCE AIR CLEANER cover: ELEMENT SET SPRING Date of Issue: February, 1980 @ HONDA MOTOR CO., LTO.)\ HONDA «) “cB900c Clean the element by tapping it lightly to loosen dust. Blow away the remaining dust by applying compressed sir from inside the element Replace the element if itis excessively dirty, torn or damaged. Install the element, element set spring and aie cleaner cover. CRANKCASE BREATHER Remove the plug from the drain tube to drain deposits Install the drain plug. NOTE Service more frequently when ridden in rain, or at full throttle or if the deposit level can be seen in the wansparent section of the drain tubes. SPARK PLUGS RECOMMENDED SPARK PLUG | x27esu NO | pavesr-u} Standard | D9EA NGK | (oR9eA) X24ES.U For cok chimate [\> | PX24ESR-U) below 5°C (41°F) | D8eA NSK | (oRseAl {1 Canada model Clean any dirt from around the spark plug base, Disconnect the spark plug caps. Remove and discard the spark plugs. Measure the new spark plug gaps using 2 wire-type feeler gauge. ‘SPARK PLUG GAP: 0.6-0.7 mm (0.024—0.028 in) Adjust by bending the side electrode careful: y, With the plug washer attached, thread the spark plugs in by hand to prevent erossthread: ing Tighten the spark plugs another 1/2 turn with 4 spark plug wrench to compress the plug washer. Connect the spark plug caps. INSPECTION AND ADJUSTMENT 35 0.6-0.7 mm (0.024-0.028 in) SIDE ELECTRODE CENTER ELECTRODE Date of Issue: February, 1980 © HONDA MOTOR CO., LTD. 3-536_INSPECTION AND ADJUSTMENT. HONDA CB900C VALVE CLEARANCE NoTE * Inspect and adjust valve clearance while the engine is cold. (Below 35°C, 95°F) + Lean the motorcycle right and left 10 drain residual oil from the cylinder head, Remove the right and left side covers and seat. ‘Turn the fuel valve OFF and remove the fuel ‘ube and fuel tank Remove the tachometer cable, Remove the spark plug caps. Remove the cylinder head cover bolts and cylinder head cover. Remove the A.C. generator cover. INSPECTION Measure intake and exhaust valve clearances by inserting a feeler gauge between the cam shaft and valve lifter shim. VALVE CLEARANCE: (0.06-0.13 mm (0.020.008 in) Rotate the crankshaft clockwise (from the fight side} and align the index mark on the exhaust camshaft right end with the front cylinder head mating surface. Check and record the valve clearance: of the No. 1 EX. and No. 3 EX. Rotate the camshaft 90" clockwise (via the crankshaft 180°) and check the: No. 1 IN, and No. 31N. Rotate the camshaft 80° clockwise and check the: ‘No. 2 EX. and No. 4 EX. Rotate the camshaft 90° clockwise and check the! ‘No, 2 IN. and No. 4 IN. CYLINDER HEAD COVER FEELER GAUGE 3-6 Date of Issue: February, 1980 © HONDA MOTOR CO”, LTD.INSPECTION AND ADJUSTMENT _37 ADJUSTMENT NOTE [- Adjustment shims are available in 0.05 mm increments, from 2.30 t0 | 350mm, |. The No. 2 EX. shim must be L__tomoved from the front ‘Select a replacement shim to achieve the speci: fied valve clearance, using the following pro- cedures Rotate the valve lifter until the notch is facing the spark plug, Rotate the crankshaft so that the valve being adjusted is at maximum lft Insert the Valve Lifter Holder tool between the camshaft and two adjacent lifters INSTALL THE SPECIAL TOOL VALVE LIFTER HOLDER eacTion PROPERLY (079688220001 When the vabe lifter holder & depress | ing a pair of valves, make sure the | \ apposite par of aes does nor open. | Rotating the crankshaft 100 far or in | the wrong direction may cause the in- | take and exhaust valves to srke and damage eachother. | VALVE LIFTER HOLDER (079644220001 VALVE LIFTER HOLDER Rotate the crankshaft one turn so the cam lobes turn away from the valve liter holder. Date of ave’ February, 1980 © HONDA MOTOR CO., LTO. 3-738_INSPECTION AND ADJUSTMENT. Remove the shim with tweezers Measure the thickness of the removed shim With a micrometer Select a replacement shim using the chart on Page 39. {Insert the replacement shim. CAUTION: “Make sure the opposite pair of valves does not open. The valves could be bent or damaged if the crankshaft is rotated incorrectly. Rotate the crankshaft in the proper direction nti the valves are at maximum lift Remove the special ool “Valve Lifter Holder". Rotate the crankshaft 23 revolutions to fully seat the replacement shim. Recheck the valve clearance. TWEEZERS p/ HONDA CB900C SHIM SHIM MICROMETER 3-8 Date of Issue: February, 1980 © HONDA MOTOR CO., LTO.INSPECTION AND ADJUSTMENT 39 (?\HONDA ()"ce900¢ pst sos va nung “en tae (orelive| Perens Solan estcossteeeniaiee Bets ‘Avessanau j1 snipe pi ‘ose [svt love [see foresee [ore 6 ed a wususoece/ uns 104 sO onlavelove|see ore |srelece|are ore|soe|oos] — [asonico Salon Gooner fovelsrefacfarc|arefavelorefnctoot|acefae| Pires SS ose} sre lore| see) ore|szeloze|siclove oo |s6z/o6z [sez 990-290 ose|seclove|see]ore| see] ove] sre|ore|soe|ooe| sez lose (see joez]sez fore| 1so-ev0 {ost |svs| ave |arelore ees fore|arc|ore|soe|ooe|sez{anc|sezlone|sce[oce|see| | ovo-ara ost sve [ore] sec|oee[eze]ore| sve[ore|soe| ooe|sez|osz|sazloaz| sce [oc e]sez [one woes ase|svelove|see]ore| seclore|sre ‘sot | oore| sez |o6'z| sez lowe | scz|oez|s9z [owe] sez ose, 1e0-1z0 ese|svelove]see|ore|see/oze]svelore|soe|ooe|sez|ocz|sezloue|scc|oce|seelooz|ssz|ore|sv2| | sr0-eee ost | svt |ovt| sre |ore ace svelore|soc love] 562/062) swe] onz|srz|ove| saz o9z]esz jose| sre [ore] wow | [ove [sve ore] soe] ore]see oct [srlore|soe|ooe [see love] relon [sce] ore] sez oez|avelose|srelore|see| | are-3r0 [zone [see Joee] see] see]sr fore |sot[ one] sue [one fanelon ese oe] sve] one me] one [are |ave [reluee 300-100 poe - Il I L l L i "5200-20001 cL BO™ SONVAVETO AIWHQNVORVIS INNO WOWIOSIGS HIS SNH war ose ‘ww 94 3-9 Date of Issue: February, 1980 HONDA MOTOR CO., LTD.40_INSPECTION AND ADJUSTMENT, CAM CHAIN TENSIONER © DYNAMIC. FRONT LOCK BOLT oc Start the engine and allow it to idle and tighten the cone lock nut and bolt at the front of the cylinde head Loasen and tighten both top and bottom lock When the tensioner front tack bolt and rear jonod, the tensioners will pravide the correct tension, [Adjust cam chain tension while the Remove th and bol Tighten the bolt while rotating the crankshaft clockwise Tighten the lock nut. Loosen both top and battom lock nuts on the Tighten the lack ute while rotating th crankshaft clockwise When the tensioner front lock bolt and rear lock nuts are loosened, the tensioners will provide the correct tension CARBURETOR SYNCHRONIZATION onan 49373-02400 (USA. env) NOTE _ ‘Synchronize the carburetors with the | engine at normat operating temperature, | transmission in neutral ancl motoreycle fon the | Flemove both side covers and seat. Turn the fuel valve OFF and remove the fuel Tine and fuel tank. Prepare a longer fuel line and connect it between the fuel tank and carburetor Position the fuel tank higher than normal Femove the cylinder head port plugs and Install the vacuum gauge adapters. ‘Connect the vacuum gauges. Date of fuer November, 1980 3-10 © HONDA MOTOR CO.,LTD.ADJUSTMENT NoTE The No.2 carburetor cannot be ad Start the engine and adjust the idle speed, IDLE SPEED: 1,000 + 100 rpm Check that the difference in vacuum readings is 60 mm Hg (2.4 in Hg) or les. {Adjust by loosening the lock nuts and turning the adjusting serews with the carburetor ad justing wrench. Hold the adjusting serews and tighten the lock Recheck the idle speed and synchronization. Remove the gauge and install the plugs. Install the fuel tank, fuel tube, seat and both side covers CARBURETOR IDLE SPEED NOTE _ Tnspect and adjust idle speed after all other engine adjustments are within specifications. ‘The engine must be warm for accurate idle adjustment. Ten minutes of stop and:-go riding i sufficient. Warm up the engine, shift to NEUTRAL, and place the motoreycle on its center stand. Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: 1,000 + 100 rpm INSPECTION AND ADJUSTMENT _41 CARBURETOR ADJUSTING WRENCH (079084220100 THROTTLE STOP SCREW ea INCREASE SPEED Date of Issue: February, 1980 © HONDA MOTOR CO., LTD, 3-1142_INSPECTION AND ADJUSTMENT (g@?)HONDA Ss) _¢B900C IGNITION TIMING © DYNAMIC Remove the pulser generator cover. Connect 8 stroboscopic timing light to the No. ‘oylinder’s high tension wire. Start the engine and let it idle. IDLE SPEED: 1,000 + 100 rpm ‘Aim the timing light at the timing mark The “1.4 Fl" mark should align with the index mark ADJUSTMENT ‘Adjust by loosening the two pulser base plate screws and rotating the plate, Tighten the screws and recheck the timing * static. Remove the pulser generator cover. Rotate the crankshaft counterclockwise and align the "1.4 S-F" mark with the index mark NOTE Either No. 1 or No. 4 piston must be near T.D.C. of the compression stroke at this time, The timing is correct if the narrow projection of "1-4" pulser generator aligns with the rotor tooth 1-4 PULSER, GENERATOR "EI" MARK BASE PLATE ‘SCREWS. 3-12 Date of Issue: February, 1980 © HONDA MOTOR CO,, LTD.(@)HONDA ‘/ _cB900c INSPECTION AND ADJUSTMENT 43 Ee Nar crion AND ADUSTNENTE | SPARK ADVANCER INDEX Mani Remove the pulser generator cover: Connect a timing light to the No. 1 high tension wire Start the engine. Bring engine speed to 3,100 rpm or above and ccheck that the index mark is between the full advance marks. CAUTION » not allow engine speed to exceed 500 rom or engine damage may rest. Replace the advancer assembly if it is not functioning property 4 Install the pulser generator cover ‘ADVANCE MARK CYLINDER COMPRESSION Warm up the engine. ‘Stop the engine and remove the fuel tank. Disconnect the spark plug caps and remove the spark plugs. Insert the compression gauge. (Open the choke and throttle valves fully CCrank the engine with the starter motor. NOTE ‘Crank the engine until the gauge reading stops rising. The maximum reading is usually reached within 4-7 seconds. ‘COMPRESSION PRESSURE: 122 kalom® (170 + 28 psi) H compression is low, check the following = Leaky valves = Improper valve clearance — Leaking cylinder head gasket — Worn piston/ring/eylinder H compression is high, it indicates that carbon deposits have accumulated on the combustion ‘chamber or the piston crown. Dae of isms Febany, 1980 = @ HONDA MOTOR 60, L10 3-1344_ INSPECTION AND ADJUSTMENT BATTERY Remove the right and left side covers. Remove the seat. Disconnect the ground cable at the battery terminal. Disconnect the positive cable at the starter celay. Remove the battery holder plate bolt Remove the battery. Inspect the battery fluid level When the fluid level nears the lower level, refill with distilled water to the upper level NOTE ‘Add only distilled water. Tap water will shorten the service life of the battery. The battery electrolyte contains sulfurie ‘acid. Protect your eyes, skin and cloth ing, In case of contact, flush thoroughly | pth water and ell @ doctor if ee trolyte gets in your eves Replace the battery, if sulfation forms or sedimants accumulate on the bottom, BRAKE FLUID (Check the front and rear brake fluid reservoir level If the level nears the lower level mark, fil the reservoir with SAE J1703 or DOT-3 BRAKE FLUID to the upper level mark. Check the entire system for leaks, if the level is tow CAUTION: + Do not remove the cover until. the Jandlebar has been turned so that | «Gott opting te rae lever with thecspremove | ket wt ur ou te ever pula BATTERY HOLDER, (¢) HONDA (©) “cas00c POSITIVE GROUND CABLE CABLE UPPER LEVEL UPPER LVEL COWER LEVEL 3-14 Date of Issue: February, 1980 © HONDA MOTOR CO., LTD.HONDA CB900C BRAKE PAD WEAR Remove the cap from the caliper and check for brake pad wear Replace the brake pads if the red line on the top of the pads reaches the edge of the brake disc (Refer to Section 17), CAUTION: Always replace the brake pads in pairs fo-assure even disc pressure. [to assure even ais BRAKE SYSTEM Check that there i no deterioration, damage (oF eaks in brake lines or fittings REAR BRAKE PEDAL HEIGHT Adjust the pedal height so that the distance between the pedal and upper face of the footped is correct. CAUTION: [improper brake pedal height adjustment can cause brake drag, PEDAL HEIGHT: 15—20 mm (5/8~3/4 in) INSPECTION AND ADJUSTMENT 45 PADS BRAKE CALIPER Date of Issue: February, 1980 © HONDA MOTOR CO. LTD. 3-1546_INSPECTION AND ADJUSTMENT. Adjust as follows; Loosen the stopper bolt lock nut. Serew in the stopper bolt Loosen the adjusting bolt lock nut. Turn the adjusting bolt until the correct pedal height is obtained. Tighten the lock nut securely Screw out the stopper bolt until it touches the brake pivot arm, then turn the stopper bolt clockwise 1/2—1 turn, Tighten the stopper bolt lock nut After adjusting pedal height, adjust the brake light switeh, BRAKE LIGHT SWITCH ‘Adjust the brake light switch so that the brake light will light when the brake pedal is depressed and the brake begins engagement Note Do not turn the switeh body. +The front brake light switch does not squire adju Adjust by turning the switch adjusting nut as shown, HEADLIGHT AIM ‘Adjust vertically by loosening both headlight ‘case mounting bolts. ‘Adjust horizontally by turning the adjusting serew on the headlight rim, Turn the adjusting screw clockwise to direct the beam toward the right side of the rider NOTE ‘Adjust the headlight beam as specified by lo ws and regulations, ‘An improperly adjusted headlight may | ‘lind oncoming drivers, or it may fail 10 light the road fora safe distance. 3-16 (Pp) HONDA (©) “ca900c X USTING BOLT e STOPPER BOLT STOPPER 8OLT Lock NUT ADJUSTING SCREW ADJUSTING NUT Date of Issue: February, 1980 © HONDA MOTOR CO., LTD.¢ ) HONDA t= / CB900C CLUTCH Inspect the clutch lever free play at the end of the lever. FREEPLAY: 10-20 mm (3/8-3/4 in) ADJUSTMENT Loosen the upper adjusting bolt’s lack nut and ‘turn the adjusting bolt until the correct free play is obtained, Tighten the lock nut NOTE (D0 not expose the adjusting bolt threads | more than 8 mm (5/16 in. If adjustment cannot be made with the clutch lever adjusting bolt, screw the adjusting bolt all the way in and back out 1 turn Adjustment must be made at the clutch hous ing. Loosen the lower clutch cable adjusting lock ‘nut and turn the adjusting nut all the way out to obtain maximum free play, Date of fssue: February, 1980 @ HONDA MOTOR CO.,LTD. — 10-20 mm (3/8-3/4 in) INSPECTION AND ADJUSTMENT _47 LOCK NUT ADJUSTING BOLT INCREASE PLAY a | y f LOCK NUT 3-1748_ INSPECTION AND ADJUSTMENT Remove the clutch lifter cap, loosen the cluteh lifter lock nut. Then turn the adjusting screw clockwise until a sight resistance is fel. From this position, tue the clutch adjusting sorew counterclockwise 1-1-1/2 tuen, and tighten the lock nut. Install the lifter cap, Turn the clutch cable lower adjusting nut so that there is 10-20 mm (3/8-3/4 in} of free play at the end of the clutch lever. Tighten the lock nut. ‘Any minor adjustment neccessary can be ‘obtained with the adjusting bolt and fock nut at the clutch lever, After adjustment, be sure all lock nuts are tightened securely. Check to see that the clutch is not slipping and is property disengaging SIDE STAND (Check the rubber pad for deterioration or wear. Replace if any wear exceeds to the wear line as shown. Check the side stand spring for damage and loss of ‘tension, and the side stand assembly for freedom of movement and bending NOTE When replacing, use a rubber pad with the mark “OVER 260 tbs ONLY". Spring tension is correct if the measure ments fall within 1.5-2.5 kg (33-85 Ib} when pulling the side stand lower end with a spring scale. SIDE STAND (HONDA \) “cB900c Lock NuT ~ ADJUSTING SCREW CLUTCH ADJUSTING WRENCH 07908-3230000 WEAR LINE REPLACE | 3-18 Date of Issue: February, 1980 @ HONDA MOTOR CO., LTD.(?)HONDA ‘) “eas00c SUSPENSION INSPECTION AND ADJUSTMENT _49 Do not ride a vehicle with faulty suspen- sion, Loose, worn or damaged suspension parts impair vehicle stability and control. FRONT Check the action of the front forks by com pressing them several times. Check the entire fork assembly for leaks or damage, Replace damaged components which cannot be repaired, Tighten all nuts and bolts. Place the vehicle on its center stand Remove the valve cap and measure the front fork air pressure. FRONT FORK AIR PRESSURE: 0.8-1.1 kgem? (11-16 psid NoTE Cheek the front fork air pressure wher the front forks are col REAR Place the motorcycle on its center stand, Move the rear wheel sideways with force to see if the swing arm bearings are worn Replace if excessively worn [page 15-13) Check the shock absorbers for leaks or damage. Tighten all rear suspension nuts and bolts Date of issue: November, 1980 5 © HONDA MOTOR CO,, LTD. 3-1950_INSPECTION AND ADJUSTMENT. (g) HONDA CB900C Remove the let side cover. Remove the valve cap and measure the rear shock absorber air pressure, REAR SHOCK ABSORBER AIR PRESSURE: 2.0-4.5 kglem? (28-64 psi) NOTE (Check the air pressure when the rear [ shock absorbers are cad. NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts ened to correct torque values, Check all coter pins and safety clips. tight WHEELS NOTE Tire pressure should be checked when | tires are COLD. Check the tires for cuts, imbedded nails, or other sharp objects RECOMMENDED TIRE PRESSURE AND TIRE SIZE: Ti 28 Trrofoa-t8 130/90-16 Tap {os |eanecity fg (a0)) | 2840) i srioce. | trond [punop | Fit {1 When a genuine Honda fairing is instal, (Check the front and rear wheels for true Measure the tread depth at the center of the tires, Replace the tires if the tread depth reaches the following limit. Minimum tread depth: Front: 1.5 mm (1/16 in) Rear: 2.0mm (3/32 in) 3-20 Date of Issue: February, 1980 © HONDA MOTOR CO, LTD. =STEERING HEAD BEARINGS NOTE - ‘Check thatthe control cables donot L interfere with handlebar rotation Raise the front wheel off the ground, ‘Check that the handlebar rotates freely If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing by turning the steering head adjusting rut [page 14-25) INSPECTION AND ADJUSTMENT _51 HEAD BEARINGS Date of Issue: February, 1980 ) HONDA MOTOR CO., LTD. 3-2152_FUEL SYSTEM CB900C 6 a gr s / Ss 08 —oommng ”)-» cy Na 612 kg-em 28-42 ka-cm (5~10 ind) (24-36 in-io} Ss (35-82 in-b) 4 ue of ur abronry, 1980 O° @ HONDA MOTOR CO, LTD[SERVICE INFORMATION a= TROUBLESHOOTING a CARBURETOR REMOVAL a VACUUM CYLINDER DISASSEMBLY 4— PILOT SCREW a FLOAT AND JETS a AIR CUTOFF VALVE DISASSEMBLY 4— ACCELERATOR PUMP DISASSEMBLY a | COMPONENT ASSEMBLY 4 FLOAT LEVEL a L SERVICE INFORMATION GENERAL INSTRUCTIONS eae wwna 4. FUEL SYSTEM . CARBURETOR SEPARATION 4-8 LINKAGE a CARBURETOR ASSEMBLY 4-12 FAST IDLE ADJUSTMENT 4-16 ACCELERATOR PUMP ADJUSTMENT 4—16 CARBURETOR INSTALLATION 4-16 PILOT SCREW ADJUSTMENT 4-17 LIMITER CAP INSTALLATION 4-18 FUEL TANK 4-19 AIR CLEANER 4-19 Use caution when working with gasoline. Always work in a well-ventilated area and away from sparks or open flames + When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly * The float bowls have drain plugs that can be loosened to drain residual gasoline. TOOLS Common Float gouge Special Carburetor Throttle Wrench Carburetor Pilot Serew Wrench 07401-00100 079084220100 079084220200 TORQUE VALUES Front bracket 40-60 kg em (35~52 ind} Rear bracket 28-42 kg-em (24-36 in-b} Choke valve 6-12 kg-em { 5-10 indb) SPECIFICATIONS {1 canada model [esa aa Bam (3) Identification | veasaivesse] [Fat ee —_— LL Manet CT aes 10002 1009 | “Thott ai ree oy 6 mm (8-4/4 [—Fatiate ere Pilot screw initial opening I See page 4-17 Date of lesue: February, 1980 © HONDA MOTOR CO., LTO.s4_ FUEL SYSTEM TROUBLESHOOTING Engine cranks but won't start 1, No fuel in tank 2. No fuel 0 carburetor 3. Engine tlooded with fuel 4 No spark at plug (ignition malfunction) 5. Air cleaner clogged 6. Intake air leak 7. Improper choke operation B. Improper throttle operation Hard starting or stalling after starting Improper choke operation Ignition malfunction Fast idle speed incorrect Carburetor malfunction Fuel contaminated ltake air leak 7. Idle speed incorrect Rough idle 1 Ignition malfunction 2. le speed incorrect 3, Incorrect carburetor synchronization 4. Carburetor malfunction 5. Fuel contaminated Misfiring during acceleration 1. Igition malfunction 2, Faulty aireutoft valve Backtiring 1. tgnition malfunction 2, Carburetor malfunetion 3. Fauly air-cutott valve Poor performance (driveability) and poor fuel 1. Fuel system clogged 2. Ignition maifunetion Lean mixture Clogged fuel jets Piston stuck closed Faulty float valve Float level iow Fuel cap vent blocked Fuel strainer sereen clogged Restricted fuel line Air vent tube clogged Intake air leak Rich mixture Clogged air jets Faulty float valve Float valve too high Air-cutoff valve sticking closed 1 2 3 4. Choke stuck closed 5. rn Dirty air cleaner Date of Issue: February, 1980 © HONDA MOTOR CO., LTO.\ HONDA / €B900C € CARBURETOR REMOVAL Remove the loft and right frame side covers. Remove the seat. ‘Turn the fuel value “OF” and disconnect the fuel line Remove the fuel tank (page 4-19) Loosen the air cleaner mounting bolt, Loosen the air cleaner connecting bands ‘Move the ar cleaner to the rear Loosen the carburetor insulator bands, Drain residual fuel into a container by loosen: ing each drain serew. Remove the carburetor assembly. Disconnect the throttle and choke cables VACUUM CYLINDER DISASSEMBLY Remove the vacuum cylinders from the carburetor bodies. Carefully lift the vacuum piston out with the needle and compression spring Inspect the vacuum piston and cylinder for wear. nicks, scratches or other damage. Make sure that the piston and jet needle move up ‘and down freely in the cylinder. Remove the full open stopper. Remove the needle set screw. ‘Separate the jet needle from the piston Inspect the needle and seat for deposits, bending, grooves, or other damage. Date of Issue: February, 1980 © HONDA MOTOR CO., LTD. FUEL SYSTEM_55 AIR CLEANER MOUNTING BOLT CARBURETOR THROTTLE CABLES AIR CLEANER, ts / a ; WW / FULLOPEN STOPPER NEEDLE SET SCREW 4 JET NEEDLE VACUUM PISTON 43