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    2 views407 pages

    Revuetechnique 900rr

    Uploaded by

    Dover Dan

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 407
    TES a HOW TO USE THIS MANUAL This service manual describes the service procedures for tho CBRGOORA. Follow the Maintenance Schedule (Section 3) recom mendations te ensure thet the vehicle Is In peak oper- ating condition and the emission levais are within the standards set by the U.S. Environmental Profection Agency and Celifornia Air Resources Board Ferforming the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period, Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for resmoval/installa- tion of components that may be required to perform service described in the following sactions. Soction 4 through 18 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 the firet page of the section. Most sections start with an assemhly or system illus: tration, service information and troubleshooting for the section, The subsequent pages give detailed pro- cedures I you con't know the source of the trouble, go to seo- tion 21, Troubleshooting, CONTENTS GENERAL INFORMATION EE ] FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM EB COOLING SYSTEM E ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES ENGINE AND DRIVE TRAIN | CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH | CRANKCASE/PISTON/CYLINDER 11] | CRANKSHAFT/TRANSMISSION me 12) : FRONT WHEEL/SUSPENSION/ — STEERING REAR WHEEL/SUSPENSION HZ) HYDRAULIC BRAKE HASSIS | BATTERY/CHARGING SYSTEM IGNITION SYSTEM [_sarrenvonancncsvsrem AT [_vawrrion sverem 17 [eecrmestamen ELECTRIC STARTER ELECTRICAL LIGHTS/METERS/SWITCHES DB WIRING DIAGRAM am 20) ——— TROUBLESHOOTING El INDEX, Of Issue: Decembe a Garena SAPS EN Ga SYMBOLS ‘The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Be | eensie net iver ontiohre ein TR | vse moitenu ieotion inure oie engine ot and otvdenum gets in of 7 SEH [Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent) Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI#2 or ifm | eaulvalenti, Example: Molykote® 8R-2 plus manufactured by Dow Corning, U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Gil, Japan. Use molybdenum disulfide grease (comtaining more than 3% molybdenum disulfide, NLGI#2or | equivalent) Rifipy | Exempla: Molykote® 08-2 plus, manufactured! by Dow Corning, U.S.A | Honda Moly 60 (U.S.A. only) | Rovol ASP manufactured by Rocol Limited, U.K. Racal Paste manufactured by Sumico Lubricant, Japan Use silicone groaso. Apaly a locking agent. Use # middle strength locking agent unless otherwise specified, Apply sealant Use DOT 4 brake fluid, Use the recommended brake fluid unless otherwise specified. Use Fork or Suspension Fluid 1. GENERAL INFORMATION GENERAL SAFETY oo SERVICE RULES 12 MODEL IDENTIFICATION 13 SPECIFICATIONS 14 TORQUE VALUES 113 TOOLS 17 LUBRICATION & SEAL POINTS CABLE & HARNESS ROUTING EMISSION CONTROL SYSTEMS 1-19 (U.S.A. ONLY) 1:36 EMISSION CONTROL INFORMATION LABELS (U.S.A. ONLY) 1:39 GENERAL SAFETY CARBON MONOXIDE Ifthe engine must be running to do some work, make sure the area is well ventilated, Never run the engine in an enclosed ares, om + The exhausi contains polsonous carbon monoxide gos thor cam cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evac: ation system in an enclosed area GASOLINE Work in a well ventilated aroa, Koop cigarattes, flames, tt sparks awey from the work area ar where gasoline is, stored Mmm + Gasoline is exremely flammable and is explosive under cer~ tain condi HOT COMPONENTS a + Engine und exhaust system ports become very hor and remain hot for some time ajter the engine has been running. Wear insulated gloves or wait unt the engine and exkaust system have cooled before handling these part USED ENGINE OlL x= + Used engine oil may cause skin cancer if repeatedly left in ‘contact with the skin for prolonged periods, Alshough thls is unlikely unless you handle used oil un a daily buss, iis itl aduisable to thoroughly wash your hands with soap and ater as soon as possible after handling used oi. KEEP OUT OF REACH OF CHILDREN, BRAKE DUST Never use an air hose or dry brush to clean the broke assemblies. Uso OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to mini= mize the hazard caused by airborne asbestos fibers. rer Inhaled asbestos fibers have been found 10 cause respiratory disease and eancer. BRAKE FLUID CAUTION + Spilting fait on painted, plawio ar rubber parts wit! damage them. Piace a clean shop towel over these paris whenever the snatem is serviced. KEEP OUT OF REACH OF CHILDREN, 44 = GENERAL INFORMATION BATTERY HYDROGEN GAS & ELECTROLYTE Rt + The battery giver aff explosive gazes, keep sparks, flames and clyarettes away. Provide adequate ventilation when charging The baitery contains sulfuric acid (electrolyte). Contact with skin for eyes may eause severe burns. Wear prosecive clothing and u face shield. = If electrolyte gets om your skin, fiush with water. = If electroyie gets in your eyes, lush with water for af least 15 minutes and calla physician immediasly, + Blecirlyie is puisonows — If swallawed, drink large quantities of water or milk and fol- love with milk of magnesia or vegetable oil and call a physi- cian, KEEP OUT OF REACH OF CHILDREN. SERVICE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts thet don’t mect HONDA's design specifications may cause damage to the motorcycle. 2. Use the spacini tacia designed for this product to avoid damage and incorroct assombly. 3. Use only matric tools whan eorvicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4, Install naw gaskets, O-rings, cotter pins, and lock plates when reassembling, 5. When tightening halts or nuts, bagin with the larger diameter or inner bolt first, Then tighten to the specified torque iagonelly in incremental stops unless a particular sequence is specifies. 6. Cleen parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly, 7. After reassembly, check all parts for proper installation and operation. 8, Route all electrical wires as show on pages 1-71 through 1-31, Cable and Harness Routing. 1.9 GENERAL INFORMATION MODEL IDENTIFICATION (1) The frame serial number is stamped on the right side of the steering head, NTIFICATION NUMBER (VIN) 2) The engine serial numbor is stamped on the right (3) The Vehicle Identification Number (VIN) is located side of the upper crankease. on right side of the frame near the steering head on the Safety Certification Label (4) The carburetor identification numbers are stamped ~ (8) The color sched as shown. When ordering ttl the intake side of the carburetor body as shown. color-coded parts, always specity the designsted color code. 1.3 GENERAL INFORMATION GENERAL Ire $$ SPECIFICATI ONS — GENERAL en SPECIFICATIONS, SHENGONS | Brera ona OBE im 808 Overall wratn“96—E: 58 0 | fer fbn 88 overt igm Geer tw mm fn) Aer 3h ‘as mm (en) Whonbnse 400 mm 88m) Sen reg somm@ts in Fooragheight ‘9-9 Sea mm 501m ser 3 ea mm G58 Ground dearanes 4 mm in) Bry waane "Sear: co mmowcannsn ype | 183 by 40 ts) Caitomia we teen [to iba ner‘rste maoeanada yoo | 180s 387 bs) Caiforia wpe tha 03 1b0) can wight "El~'97 so atmeacanaan ype 28H 488 be) Caitornintype 208 Ho 459) Atersn @sttowemnada ype OD 448 bo Caltrns yee Zoo g (ses) | Maximum weight capacity TET tetrneeCanada ype | 16049 (988 be) Gsttoriaype | Yeo ig as ot aner‘or sa strowcatoria ype | 18049 (353 Io) Cena woe 184 kg G82 oe FRAN Frame pe 7 Diemena Front arenson Telveopie fork Front wheel travel | 110 mm (4.3 in) | faa supersion | Senge Rear ea el sn (9 in fear camper Nrogen ga lee damper, wih reserve tank Fromnmass 36 tseroaee Aor 7: {Bova zh oer 1 feartve sae 8 ta0 28 7 Aer 3 yess 2m 17 03 Tue brane Trhagetone wich rom bake Fear race Esetor ana Seaton 96-97 So mm 25m for ssmmia7 in) Fut tank eapaiy 10 or (478 US ga. 2.96 Imo gal Furl ant ters capacty abl age U3 ea, 077 mp aal ENGRE Gove ane ake 79x 80mm 290 x26 ir Balacora SN3 cn i) | Comprosion rai ot | Vavevain Chain dive and DOH | Fiatevtve opens FBewwe favernr@ote) i O°BTOC.) mm OOtin Setee Be anpe [ater babe | kter's) | vnouet vee Spans 45-2806 [ ENGINE 1 | LOCATION MATERIAL REMARKS Crankcase mating surface Liquid sealant | (Three Bond 12078 or equivalent) tance Oil pressure ewiteh threads | Do not apply to the thread hesd. 3-4mm (01-02 in) im | IE | Thermo unit threads Coating width: 6.547 mm GENERAL INFORMATION c ENGINE (Cont'd) LOCATION MATERIAL REMARKS: | Cylinder head semi-circular cut-out Sealant Bot10mmy) 5- 10mm. | = | oylindor fad bol thveads and seating since Molybdenum dieifide | Camshat lobesjournals oil(amixture ef | Valve Iter outer siding surface engine oll and 12 Valve stom (valve guide sliding surface) Trolybdenum disulfide Connecting rod serail end reese) | Piston pin sliding surface Main journal bearing surface Connecting rod bearing surface Crankshaft journals Maia, CB, C8 shifter gear (shift fork grooves) 10 xd mm pin outer surface Primary drive goar and sub gear sliding surface APPLY AREA \ | Clutch outer needle bearing | _| Pison ring sliding area Engine oil Main journal 8 mm bolt threads and seating surface (after removing anti rust oil additive) Cylinder heed special bolt (after removing antirust oil additive) Oil strainer packing il coater center bolt throads and coating surface Oil filter cartridge threads and O-ring Flywhee! bolt threads and seating surface Starter one-way clutch sliding surface Connecting rod nut threads Clutch center lock nut threads | APPLY AREAS Cluch disc surface - Each gear teeth and rotating surface Each beating Each O-ring Other rotating area and sliding surface 7 Grankshat: hole cap threads Multi-purpose grease Eech oil seal lips ss 1-20 GENERAL INFORMATION ENGINE (Cont'd) LOCATION MATERIAL REMARKS: Cylinder head senling holt threads Gyiinder head cover breather joint threads Lower crankcase sealing bolt threads Sterter one-way clutch outer bolt threads Oil pump driven sprocket holt threads ‘Shift drum set plate belt threads ‘Shift drum canter bolt throads Mainshafi bearing set plate boll threads Cam sprocket halt threads Cylinder heed cover breather plate bolt threads Airsuction valve tightening bolt threads Locking agent j- FRAME ~7} Coating width: 65+ 7 mm LOCATION MATERIAL REMARKS: ‘Steering heed bearing sliding surface Steering head dust seal lips Swingarm pivot bearing and dust seal lips Wheel dust seal lips Resr wheel side collar inner surface Shock absorber needle bearing and dust seal lips Shock link needle bearing and dust ses! lips Footpeg sliding area Passenger footpeg sliding ere Rear brake pedal pivot sliding area Throwle pipe sliding arua Clutch lever pivot Pillion seat catch hook Fillion seat pivot Gearshift padal link pivot Gearshift pedal link tie-rod ball joints Side stand pivot surtace Threitle pipe cable end area Mulki-purpose grease Molybdenum disulfide grease ‘Shoek absorber spring Adjuster eam surlace Molybdenum paste Sieering stem top threads Driven sprocket nut threads and seating surface Throttle cable casing inner Choke cable casing inner Clutch cable casing inner Brake pipe joint threads Engine ail Brake master cylinder cups Srake caliper piston seals DOT 4 brake fluid Brake caliper dust seals Front brake lever pivot and piston tips Rear master cylinder boot inside and push rod tips Brake caliper slide pin surface Silicone grease Front brake caliper assembly torx bolt threads Fork socket bolt threads Locking agent Handle grip rubber inside Honda Sand A ar Honda Hand Grip Cement (U.S.A. only) Fork cap O-ring Fork oil seal lips | Pro Honda Suspension Fluid 88-8. 1-21 GENERAL INFORMATION CABLE & HARNESS ROUTING — 4) COMBINATION METER 9 (5) COMBINATION METER 4 (BLACK) CONNECTOR (BLACK) CONNECTOR (1) POSITION LIGHT CONNECTOR (8) HEADLIGHT SOCKETS (10) FIGHT HANDLEBAR SWITCH (16) TURN SIGNAL RELAY 6P (RED| CONNECTOR \ (17) HEADLIGHT RELAYS | (9) TURN SIGNAL 6° (11) RIGHT HANDLEBAR SwTCH Aware connector | (4° aP ED) CONNECTOR 112) TURN SIGNAL 6? (BLACK) CONNECTOR (73) IGNITION SwiTcH 6P/ _IBLACK) CONNECTOR [14) RIGHT TURN SIGNAL CONNECTORS —_{18) LEFT TURN SIGNAL CONNEC 1OHS 1.99> GENERAL INFORMATION After 97: (3) TURN SIGNAL RELAY (2) HEADLIGHT \ (4) HEADLIGHT LOWRELAY HIGH RELAY mel Pr cyone caste (1) THROTTLE CABLES (6) CLUTCH CABLE G) COMBINATION METER 20P CONNECTOR: (10) RIGHT TURN (9) HEADLIGHT SOCKETS, a Te) LEFT TURN SIGNAL CONNECTORS SIGNAL CONNECTORS (2) RIGHT HANDLEBAR SWITCH {P (RED) CONNECTOR (1) LEFT HANDLEBAR SWITCH &P (NATURAL) CONNECTOR, (3) RIGHT HANDLEBAR SWITCH 7 2 (RED) CONNECTOR (6) IGNITION SWITCH 6P (BLACK) CONNECTOR —__ ~—"y-14) LEFT HANDLEBAR SWITCH 8 (BLACK) CONNECTOR (5) FUSE Box 1-23 GENERAL INFORMATION. "96-'97: (3) IGNITION SWITCH WIRE (2) BIGHT HANDLEBAR SWITCH WIRE | (4) LEFT HANDLEBAR i" SWITCH WIRE 1-24 GENERAL INFORMATION Attor 97: 2) CLUTCH SWITCH CONNECTORS. (THROTTLE CARLES 3) LEFT HANDLEBAR, SWITCH WIRE \g) CLUTCH CABLE (5) CHOKE CABLE i 2 (10) RIGHT HANDLEBAR” SwiTcH WE /“y HEADLIGHT SOCKETS (8) FUSE BOX (7) MAIN WIRE HARNESS. 1-25 GENERAL INFORMATION. "96 -'97: (2) THROTTLE CABLES 13) CHOKE CABLE Vet, (1) LEFT HANDLEBAR, SWITCH WIRE L (5) HEADLIGHT RELAYS 1-26 GENERAL INFORMATION After 97: (2) FRONT COWL SIAY (Q)IGNITION SWITCH / (3) LEFT HANDLEBAR WIRE SWITCH WIRE (4) CLUTCH CABLE aS 4 / (10) RIGHT HANDLEBAR, SWITCH WIRE (9) FRONT POSITION LIGHT WIRE (7) LEFT TURN SIGNAL CONNECTORS 1227 GENERAL INFORMATION ete %e _J)_ (21 FAN moTOR SWITCH CONNECTOR craoaron AG PSD __-(3) BYPASS HOSE |) WATER PUMP TO-CYLINDER HEAD HOSE (8) OIL COOLER, WATER TUBES (6) WATER PUMP-TO-WATER JOINT HOSE [ after ‘97: a 8 _—— o Qe (2) THERMOSTAT CASE (3) WATER BYPASS \ HOSE Twareh puMP TO-CYLINDER HEAD HOSE J) GENERAL INFORMATION (3) AIR BLEED TUBE (4) SIPHON TUBE / (2) THERMO SENSOR CONNECTOR Alter ‘97: (S)AIR BLEED TUBE (4) SIPHON TUBE J | ny ~__/ (2) THERMO SENSOR CONNECTOR L~ \ / 1-29 GENERAL INFORMATION "96 -'97: (1) THROTTLE SENSOR WIRE ) CHOKE CABLE i (3) AIR BLEED TUBE __ (a) MAIN WIRE HARNESS (5) BATTERY NEGATIVE CABLE We OE 93 ly weuTraCSwircu wie CN o" NS es Aer 97 vars | (4) SIDE STAND. SWITCH WIRE (3) ALTERNATOR WIRE 1-30 GENERAL INFORMATION (4) THROTTLE CABLES (9) BATTERY POSITIVE CABLE <7 (2) STARTER RELAY SWITCH (3) REGULATORRECTIFIER (11) MAIN WIRE HARNESS (8) OlL PRESSURE SWITCH WIRE ELOY GY SHEEOW TUBE (9) FUEL TANK DRAIN TUBE 1-31 GENERALINFORMATION [1) CRANKCASE BREATHER TUBE (2) CARBURETOR AIR VENT TUBE we a (7) FUL TUBES S GENERAL INFORMATION RF BI: (1) CHOKE CABLE (11) THROTTLE CABLES: L/ (10) FAN MOTOR SWITCH WIRE?) (2) MAIN WIRE HARNESS |g) BATTERY NEGATIVE. (6) ALTERNATOR wart (6) SIDE STAND SWITCH WIRE 1-33 GENERAL INFORMATION (1)IGNITION CONTROL MODULE (8) BRAKE LIGHT SWITCH WIRE (7) REAR BRAKE HOSE 1.24 GENERAL INFORMATION SECONDARY AIR SUPPLY SYSTEM ROUTING (CALIFORNIA TYPE ONLY) (3) EVAPORATIVE EMISSION (EVAP) PURGE CONTROL VALVE (2) EVAPORATIVE EMISSION (EVAP) CANISTER (1) EVAPORATIVE EMISSION (EVAP) CARBURETOR AIR VENT CONTROL VALVE / "96-97: (6) AIR CLEANER HOUSING (6) CYLINDER, HEAD (7) CARBURETOR (8) FUEL TANK (a) EvaP PURGE CONTROL VALVE < 11) EVAP CAV CONTROL VALVE (2) EVAP CANISTER: 1-35 GENERAL INFORMATION. EMISSION CONTROL SYSTEMS (U.S.A. ONLY) ‘The US. Environmental Protection Agency and California Air Resources Geard (CARB) roguire manufsclurers to certity thet theis matereyeles comply with applicable exhaust emissions standards during their useful life, when operated and tnaintained according to the instructions proviced, and that motorcycles built after January 1, 1883 comply with applicable noise emission standards for one year ar 6,000 km [3,730 miles) after the time of sale to the ultimate purchaser, wher! Operated and maintained according to the instructions provided. Compliance with the terms of the Disiributor’s Limitec Werranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the omissions system warranty in effect. SOURCE OF EMISSIONS: ‘The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emissions is very impor tant because, under certain conditions, thay react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but fis tox. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, 10 reduce caibon monoxide and hydra carbons. CRANKCASE EMISSION CONTROL SYSTEM. Tho ongine is equipped with a closed erankcase system to provent discharging crankcase emissions inta the atmosphere. Blow-by ges is returned ta the combustion chamber through the air cleaner and carburetor. Lf [AIR CLEANER HOUSING _— (2) CARBURETOR As

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