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. When performing the set-up or pre-delivery
service, be especially careful of the following:
• Read the instructions before you begin, and make sure you have the tools and skills required to
perform the tasks safely.
• To 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:
• Carbon monoxide poisoning from engine exhaust—be sure there is adequate ventilation
whenever you run the engine.
• 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.
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:
• Sub-heading—The large sub-headings are a brief description of the step. They are intended
to be used by the experienced technician, one who only needs a brief reminder of the
set-up sequence.
• 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.
• Photographs/Line art—The photographs or line art support both the sub-headings and the
detailed text.
Indicates the Set-up sectionIndicates 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.
The CB900F is crated at the factory in either a
covered or uncovered crate. You may receive
either one.
Covered crate:
Cut the strap and remove the carton cover.
Remove the cardboard top.
CARTON COVER
COVERED CRATE
STRAP
CARDBOARD TOP
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. S0477)
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.
Unpack the remaining loose parts and check them against this illustration and list.
1.
4.
3.
5.
DESRIPTIONQTYPART NUMBERSTEP
1. Handlebar153100-MCZ-0008
2. Mirrors288210-MCC-00014
3. Tool kit189010-MCZ-00015
4. Owner’s Manual131MCZ630*15
5. Riding Tips & Practice Guide1G0045**4
6. Manual bag177251-342-00015
7. Attaching Parts:
Screw/washer, 5 x 20 mm193892-05020-077
Screw/washer, 5 x 25 mm193892-05025-077
Handlebar Holder253131-MCZ-0008
Socket bolt, 8 x 32 mm496600-08032-108
Socket bolt cap, 8 mm491455-KEA-0008
Handlebar weight153105-MK4-6209
Oval crew, 6 x 65 mm190191-KBG-0009
Master cylinder holder245517-166-00610 & 12
Flange bolt, 6 x 22 mm290101-MBZ-G0010
Screw/washer, 5 x 45 mm193892-05045-0711
Screw/washer, 5 x 35 mm193892-05035-0711
Flange bolt, small head, 6 x 22 mm (clutch side)296001-06022-0712
Socket bolt, 8 x 22 mm290157-ME9-00013
6.
2.
7.
*If missing, order from Helm Inc.
**If 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 should be submitted to American Honda, not the carrier. After completing repairs, submit
a Transportation Claim via iN. For complete details, please refer to the Warranty Policy and
Procedures Manual.
Remove the bolts and front shipping bracket
from the handlebar mount.
7. Install the throttle grip.
Remove the protective wrap from the throttle
grip/switch assembly.
Slide the throttle grip/switch assembly onto
the right side of the handlebar. Move the grip
until the pin in the switch assembly drops into
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
5 x 25 mm screw/washer in the rear hole.
Torque the screw/washers, starting with the
front one.
BOLTS
FRONT SHIPPING BRACKET
PIN
HOLE
5 x 20 mm
SCREW/WASHER
5 x 25 mm
SCREW/WASHER
Torque: 4 N·m (0.4 kgf·m, 3 lbf-ft)
8. Install the handlebars.
Align the handlebar punch mark with the top
edge of the lower holder.
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 lbf-ft)
Attach the socket bolt caps to the
handlebar bolts.
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 lbf-ft)
HANDLEBAR WEIGHT
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 lbf-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.
FRONT BRAKE
MASTER CYLINDER
HOLE
UP MARK
SWITCH
CONNECTORS
6 x 22 mm
FLANGE BOLTS
END CAP
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.
Position 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.
PUNCH MARK
UP MARK
BOLTS
Torque the two bolts, starting with the top
bolt first.
Torque: 12 N·m (1.2 kgf·m, 9 lbf-ft)
Connect the 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.
CONNECTORS
SLING
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.
Service the battery only if the motorcycle
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.
Before starting the engine, remove the antirust coating from the engine and exhaust
system using a mild detergent and water.
Rinse with clean water.
FILLER CAP
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
• API 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)
UPPER
LEVEL
MARK
LOWER
LEVEL
MARK
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 marks. 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.
Support the motorcycle on its side stand on a
firm, level surface.
Connect a tachometer to 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
U s e o n l y t h e th r ot tl e st o p s c r ew t o m a k e i dl e
speed adjustments.
24. 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:
THROTTLE STOP SCREW
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.
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 position.
Torque the axle nut and tighten the lock nuts
on both sides.
Torque: 93 N·m (9.5 kgf·m, 69 lbf-ft)
25. Check the tire pressure.
Front: 36 psi Rear: 41 psi
26. Complete the Set-Up/
Pre-Delivery Checklist.
Complete an On-Road Set-Up/Pre-Delivery
Checklist (Reorder No. S0299) by checking the