2005 CB900F SET-UP INSTRUCTIONS Set-up and pre-delivery service must be performed by an authorized Honda motorcycle dealer. ©2005 American Honda Motor Co., Inc.
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.
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.
1. Remove the carton cover and check for damage. COVERED CRATE CARTON COVER The CB900F is crated at the factory in either a covered or uncovered crate. You may receive either one. STRAP CARDBOARD TOP Covered crate: Cut the strap and remove the carton cover. Remove the cardboard top. Uncovered crate: UNCOVERED CRATE When stacking, protect the motorcycle from falling objects and bad weather. Check the motorcycle for hidden damage.
2005 CB900F 4. Remove the crate frame and the loose parts carton. BOLTS 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 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. 2 PARTS CARTON STRAP BOLTS ©2005 American Honda Motor Co., Inc.
5. Loose Parts Information. Unpack the remaining loose parts and check them against this illustration and list. 2. 1. 4. 3. 7. 5. 6. 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.
2005 CB900F 6. Remove the front shipping bracket. BOLTS Remove the bolts and front shipping bracket from the handlebar mount. FRONT SHIPPING BRACKET 7. Install the throttle grip. PIN Remove the protective wrap from the throttle grip/switch assembly. HOLE 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.
9. Attach the handlebar weight. 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 lbf-ft) 10. Install the front brake master cylinder. 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.
2005 CB900F 12. Install the clutch lever assembly. PUNCH MARK 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. UP MARK Torque the two bolts, starting with the top bolt first. BOLTS CONNECTORS Torque: 12 N·m (1.
13. Remove the motorcycle from the crate base (cont.). LEFT SIDE: RIGHT SIDE: BRACE BRACE Remove the 6 and 8 mm bolts and right crate shipping brace. Remove the 6 and 8 mm bolts and left crate shipping brace. Discard the bolts. BOLTS BOLTS Install and torque the 8 x 22 mm socket bolts securing the footpeg brackets. Torque: 27 N·m (2.8 kgf·m, 20 lbf-ft) BOLT Lower the side stand and place the motorcycle on a level surface. Remove the slings.
2005 CB900F 15. Store the Owner’s Manual and tool kit (cont.). STRAP TOOL KIT Place the tool kit in the holder and secure it with the rubber restraining strap. Place the Owner's Manual in its bag and secure it in the holder located on the bottom of the seat. BAG 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 ©2005 American Honda Motor Co., Inc.
16. Check the cables, hoses, and wire harness routing. CLUTCH CABLE THROTTLE CABLES RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE NEGATIVE (-) BATTERY CABLE POSITIVE (+) BATTERY CABLE BATTERY ©2005 American Honda Motor Co., Inc.
2005 CB900F 17. Service and install the battery. 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.
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.) 2 – 4 mm (1/16 – 3/16 in.) To adjust free play: LOCK NUT ADJUSTER • Make small adjustments at the throttle grip adjuster. Loosen the lock nut and turn the adjuster. Tighten the lock nut after adjusting.
2005 CB900F 19. Check the clutch lever free play. Measure the clutch lever free play at the lever tip. 10 – 20 mm (3/8 – 13/16 in) Clutch lever free play: 10 - 20 mm (3/8 - 13/16 in) To adjust the free play: LOCK NUT ADJUSTER • Make small adjustments at the lever end of the cable. Loosen the lock nut and turn the adjuster. Tighten the lock nut after adjusting.
21. Check the engine oil. FILLER CAP Before starting the engine, remove the antirust 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.
2005 CB900F 23. Check the idle speed. THROTTLE STOP SCREW 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 Use only the throttle stop screw to make idle speed adjustments. 24. Verify the drive chain slack. Place the motorcycle on the side stand and put the transmission in neutral.
1 2 3 4 5 6 COLOR R/Bl LOCK OFF ON R Bu/O IG BAT1 DIODE G Bl/Br G O MINI COLOR Lb O Gr Lb/W O/W 5 9P G O/W Lb/W Lb O CLUTCH SWITCH Bl Bl Hi Lo COLOR Bu/W W HL Bu Hi DIMMER SWITCH (N) KEY ON Gr PL L PR 3P Bl O/W N P G G Lb/W Lb O KEY OFF L 4 KEY OFF LOCK PIN R TURN SIGNAL SWITCH W 3 TURN SIGNAL RELAY G Bu Lo O/W G O G W Bu 2 Bu/R R KEY IGNITION SWITCH LEFT FRONT TURN SIGNAL LIGHT 12V23/8W HEADLIGHT 12V60/55W (LO) (HI) Lb/W G Lb P/G R/G RI
