HONDA CB900F 2005 User Manual

2005 CB900F SET-UP INSTRUCTIONS

Set-up and pre-delivery service must be performed by an authorized Honda motorcycle dealer.

MPD 10969 (0501) 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. 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.

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:

• 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 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.

To r qu e Tab l e

ITEM SIZE TORQUE

Handlebar bolts 8 mm 27 N·m (2.8 kgf·m, 20 lbf-ft)

Handlebar weight 6 mm 10 N·m (1.0 kgf·m, 7 lbf-ft)

Master cylinder holder bolts 6 mm 12 N·m (1.2 kgf·m, 9 lbf-ft)

Clutch lever holder bolts 6 mm 12 N·m (1.2 kgf·m, 9 lbf-ft)

Footpeg socket bolts 8 mm 27 N·m (2.8 kgf·m, 20 lbf-ft)

Rear axle nut -------- 93 N·m (9.5 kgf·m, 69 lbf-ft)

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.

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.

Remove the bolt and the clutch lever assembly.

BOLTS

CLUTCH LEVER ASSEMBLY

UNCOVERED CRATE

MASTER CYLINDER

3. Remove the front shipping brace.

Remove the nuts and the front shipping brace.

NUT

2005 CB900F

4. Remove the crate frame and the loose parts carton.

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 parts carton.

Keep the You and Your Motorcycle - Riding Tips & Practice Guide booklet separate and hand-deliver to the customer at the time of delivery.

PARTS CARTON

STRAP

BOLTS

BRACES

5. Loose Parts Information.

Unpack the remaining loose parts and check them against this illustration and list.

DESRIPTION QTY PART NUMBER STEP

1. Handlebar 1 53100-MCZ-000 8

2. Mirrors 2 88210-MCC-000 14

3. Tool kit 1 89010-MCZ-000 15

4. Owner’s Manual 1 31MCZ630* 15

5. Riding Tips & Practice Guide 1 G0045** 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 25 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 & 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

*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.

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