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Honda CBR900 - User Manual

Honda CBR900
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Summary

General Information

Service Rules

Procedures for using genuine parts and tools, and general maintenance practices.

Model Identification

Details on identifying the motorcycle model and its components.

Specifications

Technical data and specifications for the motorcycle.

Torque Values

Specified torque settings for various fasteners.

Tools

Recommended tools for service and maintenance.

Lubrication & Seal Points

Locations and types of lubricants and sealants required.

Cable & Harness Routing

Diagrams showing the routing of cables and wiring harnesses.

Emission Control Systems

Information on emission control systems and regulations.

Emission Control Information Labels (U.S.A. Only)

Details about emission control labels specific to the USA market.

Frame;Body Panels;Exhaust System

Body Panel Locations

Identification of major body panel locations on the motorcycle.

Service Information

General service notes and precautions for body panels and exhaust system.

Torque Values

Specified torque settings for frame, body panels, and exhaust system fasteners.

Troubleshooting

Common problems and solutions for frame, body panels, and exhaust system.

Seat

Procedures for removing and installing the seat.

Pillion Seat;Rear Cowl

Procedures for removing and installing the pillion seat and rear cowl.

Middle;Lower Cowl

Procedures for removing and installing the middle and lower cowls.

Upper Cowl

Procedures for removing and installing the upper cowl.

Inner Middle Cowl

Procedures for removing and installing the inner middle cowl.

Inner Panel

Procedures for removing and installing the inner panel.

Front Fender

Procedures for removing and installing the front fender.

Rear Fender

Procedures for removing and installing the rear fender.

Seat Rail

Procedures for removing and installing the seat rail.

Muffler;Exhaust Pipe

Procedures for removing and installing the muffler and exhaust pipe.

Maintenance

Service Information

General service information and warnings for maintenance.

Maintenance Schedule

Recommended maintenance intervals and tasks.

Specifications

Technical specifications relevant to maintenance tasks.

Torque Values

Specified torque settings for maintenance-related components.

Tools

Tools required for specific maintenance procedures.

Troubleshooting

Common maintenance issues and their solutions.

Fuel Line

Procedures for inspecting and maintaining the fuel line.

Throttle Operation

Procedures for checking and adjusting throttle operation.

Air Cleaner

Procedures for inspecting and replacing the air cleaner element.

Spark Plug

Procedures for inspecting and replacing spark plugs.

Valve Clearance

Procedures for inspecting and adjusting valve clearance.

Engine Oil;Oil Filter

Procedures for checking and changing engine oil and oil filter.

Engine Idle Speed

Procedures for checking and adjusting engine idle speed.

Radiator Coolant

Procedures for checking and replacing radiator coolant.

Cooling System

General inspection and maintenance of the cooling system.

Secondary Air Supply System

Information on the secondary air supply system.

Evaporative Emission Control System (California Type Only)

Maintenance of the evaporative emission control system for California models.

Drive Chain

Procedures for inspecting, cleaning, and lubricating the drive chain.

Brake Fluid

Procedures for checking and replacing brake fluid.

Brake System

General inspection of the brake system.

Brake Lever Adjustment

Procedures for adjusting brake lever position.

Brake Pedal Height Adjustment

Procedures for adjusting brake pedal height.

Brake Light Switch

Procedures for adjusting the brake light switch.

Headlight Aim

Procedures for adjusting headlight aim.

Clutch System

Procedures for inspecting and adjusting the clutch system.

Side Stand

Procedures for inspecting and checking the side stand.

Suspension

Procedures for inspecting and adjusting front and rear suspension.

Nuts, Bolts, Fasteners

Checking tightness of chassis nuts and bolts.

Wheels;Tires

Procedures for checking tire pressure and condition.

Steering Head Bearings

Procedures for checking steering head bearings.

Lubrication System

Service Information

General service information and precautions for the lubrication system.

Specifications

Technical specifications related to the lubrication system.

Torque Values

Specified torque settings for lubrication system components.

Tools

Tools required for lubrication system service.

Troubleshooting

Common problems and solutions for the lubrication system.

Oil Pressure Inspection

Procedures for inspecting engine oil pressure.

Oil Strainer;Pressure Relief Valve

Procedures for removing and inspecting the oil strainer and pressure relief valve.

Oil Pump

Procedures for removing, disassembling, and inspecting the oil pump.

Oil Cooler

Procedures for removing and installing the oil cooler.

Fuel System (Programmed Fuel Injection)

Service Information

General service information and warnings for the fuel system.

Troubleshooting

Common problems and solutions for the fuel system.

System Location

Identification of fuel system components on the motorcycle.

System Diagram

Wiring diagrams for the fuel injection system.

PGM-FI Self-Diagnosis Malfunction Indicator Lamp (MIL) Failure Codes

Diagnostic codes indicated by the Malfunction Indicator Lamp (MIL).

Peak Voltage Inspection Procedure

Procedure for inspecting peak voltage in the fuel system.

Test Harness Connection

How to connect the test harness for diagnostics.

Test Harness Terminal Layout

Layout of test harness terminals for ECM connectors.

PGM-FI MIL 1 Blink (MAP Sensor)

Troubleshooting procedure for MAP sensor faults indicated by 1 MIL blink.

PGM-FI MIL 2 Blinks (MAP Sensor)

Troubleshooting procedure for MAP sensor faults indicated by 2 MIL blinks.

PGM-FI MIL 7 Blinks (ECT Sensor)

Troubleshooting procedure for ECT sensor faults indicated by 7 MIL blinks.

PGM-FI MIL 8 Blinks (TP Sensor)

Troubleshooting procedure for TP sensor faults indicated by 8 MIL blinks.

PGM-FI MIL 9 Blinks (IAT Sensor)

Troubleshooting procedure for IAT sensor faults indicated by 9 MIL blinks.

PGM-FI MIL 11 Blinks (Vehicle Speed Sensor)

Troubleshooting procedure for Vehicle Speed Sensor faults indicated by 11 MIL blinks.

PGM-FI MIL 12 Blinks (No. 1 Injector)

Troubleshooting procedure for No. 1 Injector faults indicated by 12 MIL blinks.

PGM-FI MIL 13 Blinks (No. 2 Injector)

Troubleshooting procedure for No. 2 Injector faults indicated by 13 MIL blinks.

PGM-FI MIL 14 Blinks (No. 3 Injector)

Troubleshooting procedure for No. 3 Injector faults indicated by 14 MIL blinks.

PGM-FI MIL 15 Blinks (No. 4 Injector)

Troubleshooting procedure for No. 4 Injector faults indicated by 15 MIL blinks.

PGM-FI MIL 18 Blinks (Cam Pulse Generator)

Troubleshooting procedure for Cam Pulse Generator faults indicated by 18 MIL blinks.

PGM-FI MIL 19 Blinks (Ignition Pulse Generator)

Troubleshooting procedure for Ignition Pulse Generator faults indicated by 19 MIL blinks.

PGM-FI MIL 21 Blinks (O₂ Sensor;California Type Only)

Troubleshooting for O₂ sensor faults (California) indicated by 21 MIL blinks.

PGM-FI MIL 23 Blinks (O₂ Sensor Heater;California Type Only)

Troubleshooting for O₂ sensor heater faults (California) indicated by 23 MIL blinks.

PGM-FI MIL 33 Blinks (E²-PROM)

Troubleshooting for E²-PROM faults indicated by 33 MIL blinks.

PGM-FI MIL 34 Blinks (EGCV and Air Intake Valve Servo Motor Potentiometer Voltage)

Troubleshooting EGCV/Air Intake Valve Servo Motor voltage faults indicated by 34 MIL blinks.

PGM-FI MIL 35 Blinks (EGCV and Air Intake Valve Servo Motor)

Troubleshooting EGCV/Air Intake Valve Servo Motor faults indicated by 35 MIL blinks.

Fuel Line Inspection

Procedures for inspecting the fuel line for leaks or damage.

Fuel Flow Inspection

Procedures for inspecting fuel flow rate.

Fuel Pump

Procedures for inspecting and replacing the fuel pump.

Fuel Filter Replacement

Procedures for replacing the fuel filter.

Fuel Tank

Procedures for removing and installing the fuel tank.

Air Cleaner Housing

Procedures for removing and installing the air cleaner housing.

Throttle Body

Procedures for removing and installing the throttle body.

Injector

Procedures for inspecting and installing injectors.

Pressure Regulator

Procedures for removing and installing the pressure regulator.

Fast Idle Wax Unit

Procedures for disassembling and inspecting the fast idle wax unit.

Starter Valve

Procedures for disassembling and assembling the starter valve.

Starter Valve Synchronization

Procedures for synchronizing the starter valves.

MAP Sensor

Procedures for inspecting and removing/installing the MAP sensor.

IAT Sensor

Procedures for removing and installing the IAT sensor.

ECT Sensor

Procedures for removing and installing the ECT sensor.

Cam Pulse Generator

Procedures for removing and installing the cam pulse generator.

TP Sensor

Procedures for inspecting and testing the TP sensor.

Bank Angle Sensor

Procedures for inspecting and installing the bank angle sensor.

Engine Stop Relay

Procedures for inspecting the engine stop relay.

ECM (Engine Control Module)

Procedures for inspecting the ECM.

Power;Ground Line Inspection

Inspecting power and ground lines for the ECM.

PAIR Solenoid Valve

Procedures for inspecting the PAIR solenoid valve.

EVAP Purge Control Valve (California Type Only)

Procedures for removing and inspecting the EVAP purge control valve.

O₂ Sensor (California Type Only)

Procedures for removing and inspecting the O₂ sensor.

EGCV and Air Intake Valve

Procedures for inspecting the EGCV and air intake valve.

Variable Air Intake Valve

Procedures for disassembling and assembling the variable air intake valve.

Cooling System

Service Information

General service information and warnings for the cooling system.

Specifications

Technical specifications for the cooling system.

Torque Values

Specified torque settings for cooling system components.

Troubleshooting

Common problems and solutions for the cooling system.

Coolant (Hydrometer Test)

Procedure for testing coolant gravity using a hydrometer.

Radiator Cap;System Pressure Inspection

Procedures for inspecting the radiator cap and system pressure.

Coolant Replacement

Procedures for replacing engine coolant and bleeding the system.

Thermostat

Procedures for removing, inspecting, and installing the thermostat.

Radiator

Procedures for removing and installing the radiator.

Water Pump

Procedures for inspecting, removing, and installing the water pump.

Radiator Reserve Tank

Procedures for removing and installing the radiator reserve tank.

Engine Removal;Installation

Service Information

General service information and precautions for engine removal/installation.

Service Data

Key specifications and data for engine service.

Torque Values

Specified torque settings for engine mounting and related components.

Lower Bracket Removal

Procedures for removing the lower bracket assembly.

Summary

General Information

Service Rules

Procedures for using genuine parts and tools, and general maintenance practices.

Model Identification

Details on identifying the motorcycle model and its components.

Specifications

Technical data and specifications for the motorcycle.

Torque Values

Specified torque settings for various fasteners.

Tools

Recommended tools for service and maintenance.

Lubrication & Seal Points

Locations and types of lubricants and sealants required.

Cable & Harness Routing

Diagrams showing the routing of cables and wiring harnesses.

Emission Control Systems

Information on emission control systems and regulations.

Emission Control Information Labels (U.S.A. Only)

Details about emission control labels specific to the USA market.

Frame;Body Panels;Exhaust System

Body Panel Locations

Identification of major body panel locations on the motorcycle.

Service Information

General service notes and precautions for body panels and exhaust system.

Torque Values

Specified torque settings for frame, body panels, and exhaust system fasteners.

Troubleshooting

Common problems and solutions for frame, body panels, and exhaust system.

Seat

Procedures for removing and installing the seat.

Pillion Seat;Rear Cowl

Procedures for removing and installing the pillion seat and rear cowl.

Middle;Lower Cowl

Procedures for removing and installing the middle and lower cowls.

Upper Cowl

Procedures for removing and installing the upper cowl.

Inner Middle Cowl

Procedures for removing and installing the inner middle cowl.

Inner Panel

Procedures for removing and installing the inner panel.

Front Fender

Procedures for removing and installing the front fender.

Rear Fender

Procedures for removing and installing the rear fender.

Seat Rail

Procedures for removing and installing the seat rail.

Muffler;Exhaust Pipe

Procedures for removing and installing the muffler and exhaust pipe.

Maintenance

Service Information

General service information and warnings for maintenance.

Maintenance Schedule

Recommended maintenance intervals and tasks.

Specifications

Technical specifications relevant to maintenance tasks.

Torque Values

Specified torque settings for maintenance-related components.

Tools

Tools required for specific maintenance procedures.

Troubleshooting

Common maintenance issues and their solutions.

Fuel Line

Procedures for inspecting and maintaining the fuel line.

Throttle Operation

Procedures for checking and adjusting throttle operation.

Air Cleaner

Procedures for inspecting and replacing the air cleaner element.

Spark Plug

Procedures for inspecting and replacing spark plugs.

Valve Clearance

Procedures for inspecting and adjusting valve clearance.

Engine Oil;Oil Filter

Procedures for checking and changing engine oil and oil filter.

Engine Idle Speed

Procedures for checking and adjusting engine idle speed.

Radiator Coolant

Procedures for checking and replacing radiator coolant.

Cooling System

General inspection and maintenance of the cooling system.

Secondary Air Supply System

Information on the secondary air supply system.

Evaporative Emission Control System (California Type Only)

Maintenance of the evaporative emission control system for California models.

Drive Chain

Procedures for inspecting, cleaning, and lubricating the drive chain.

Brake Fluid

Procedures for checking and replacing brake fluid.

Brake System

General inspection of the brake system.

Brake Lever Adjustment

Procedures for adjusting brake lever position.

Brake Pedal Height Adjustment

Procedures for adjusting brake pedal height.

Brake Light Switch

Procedures for adjusting the brake light switch.

Headlight Aim

Procedures for adjusting headlight aim.

Clutch System

Procedures for inspecting and adjusting the clutch system.

Side Stand

Procedures for inspecting and checking the side stand.

Suspension

Procedures for inspecting and adjusting front and rear suspension.

Nuts, Bolts, Fasteners

Checking tightness of chassis nuts and bolts.

Wheels;Tires

Procedures for checking tire pressure and condition.

Steering Head Bearings

Procedures for checking steering head bearings.

Lubrication System

Service Information

General service information and precautions for the lubrication system.

Specifications

Technical specifications related to the lubrication system.

Torque Values

Specified torque settings for lubrication system components.

Tools

Tools required for lubrication system service.

Troubleshooting

Common problems and solutions for the lubrication system.

Oil Pressure Inspection

Procedures for inspecting engine oil pressure.

Oil Strainer;Pressure Relief Valve

Procedures for removing and inspecting the oil strainer and pressure relief valve.

Oil Pump

Procedures for removing, disassembling, and inspecting the oil pump.

Oil Cooler

Procedures for removing and installing the oil cooler.

Fuel System (Programmed Fuel Injection)

Service Information

General service information and warnings for the fuel system.

Troubleshooting

Common problems and solutions for the fuel system.

System Location

Identification of fuel system components on the motorcycle.

System Diagram

Wiring diagrams for the fuel injection system.

PGM-FI Self-Diagnosis Malfunction Indicator Lamp (MIL) Failure Codes

Diagnostic codes indicated by the Malfunction Indicator Lamp (MIL).

Peak Voltage Inspection Procedure

Procedure for inspecting peak voltage in the fuel system.

Test Harness Connection

How to connect the test harness for diagnostics.

Test Harness Terminal Layout

Layout of test harness terminals for ECM connectors.

PGM-FI MIL 1 Blink (MAP Sensor)

Troubleshooting procedure for MAP sensor faults indicated by 1 MIL blink.

PGM-FI MIL 2 Blinks (MAP Sensor)

Troubleshooting procedure for MAP sensor faults indicated by 2 MIL blinks.

PGM-FI MIL 7 Blinks (ECT Sensor)

Troubleshooting procedure for ECT sensor faults indicated by 7 MIL blinks.

PGM-FI MIL 8 Blinks (TP Sensor)

Troubleshooting procedure for TP sensor faults indicated by 8 MIL blinks.

PGM-FI MIL 9 Blinks (IAT Sensor)

Troubleshooting procedure for IAT sensor faults indicated by 9 MIL blinks.

PGM-FI MIL 11 Blinks (Vehicle Speed Sensor)

Troubleshooting procedure for Vehicle Speed Sensor faults indicated by 11 MIL blinks.

PGM-FI MIL 12 Blinks (No. 1 Injector)

Troubleshooting procedure for No. 1 Injector faults indicated by 12 MIL blinks.

PGM-FI MIL 13 Blinks (No. 2 Injector)

Troubleshooting procedure for No. 2 Injector faults indicated by 13 MIL blinks.

PGM-FI MIL 14 Blinks (No. 3 Injector)

Troubleshooting procedure for No. 3 Injector faults indicated by 14 MIL blinks.

PGM-FI MIL 15 Blinks (No. 4 Injector)

Troubleshooting procedure for No. 4 Injector faults indicated by 15 MIL blinks.

PGM-FI MIL 18 Blinks (Cam Pulse Generator)

Troubleshooting procedure for Cam Pulse Generator faults indicated by 18 MIL blinks.

PGM-FI MIL 19 Blinks (Ignition Pulse Generator)

Troubleshooting procedure for Ignition Pulse Generator faults indicated by 19 MIL blinks.

PGM-FI MIL 21 Blinks (O₂ Sensor;California Type Only)

Troubleshooting for O₂ sensor faults (California) indicated by 21 MIL blinks.

PGM-FI MIL 23 Blinks (O₂ Sensor Heater;California Type Only)

Troubleshooting for O₂ sensor heater faults (California) indicated by 23 MIL blinks.

PGM-FI MIL 33 Blinks (E²-PROM)

Troubleshooting for E²-PROM faults indicated by 33 MIL blinks.

PGM-FI MIL 34 Blinks (EGCV and Air Intake Valve Servo Motor Potentiometer Voltage)

Troubleshooting EGCV/Air Intake Valve Servo Motor voltage faults indicated by 34 MIL blinks.

PGM-FI MIL 35 Blinks (EGCV and Air Intake Valve Servo Motor)

Troubleshooting EGCV/Air Intake Valve Servo Motor faults indicated by 35 MIL blinks.

Fuel Line Inspection

Procedures for inspecting the fuel line for leaks or damage.

Fuel Flow Inspection

Procedures for inspecting fuel flow rate.

Fuel Pump

Procedures for inspecting and replacing the fuel pump.

Fuel Filter Replacement

Procedures for replacing the fuel filter.

Fuel Tank

Procedures for removing and installing the fuel tank.

Air Cleaner Housing

Procedures for removing and installing the air cleaner housing.

Throttle Body

Procedures for removing and installing the throttle body.

Injector

Procedures for inspecting and installing injectors.

Pressure Regulator

Procedures for removing and installing the pressure regulator.

Fast Idle Wax Unit

Procedures for disassembling and inspecting the fast idle wax unit.

Starter Valve

Procedures for disassembling and assembling the starter valve.

Starter Valve Synchronization

Procedures for synchronizing the starter valves.

MAP Sensor

Procedures for inspecting and removing/installing the MAP sensor.

IAT Sensor

Procedures for removing and installing the IAT sensor.

ECT Sensor

Procedures for removing and installing the ECT sensor.

Cam Pulse Generator

Procedures for removing and installing the cam pulse generator.

TP Sensor

Procedures for inspecting and testing the TP sensor.

Bank Angle Sensor

Procedures for inspecting and installing the bank angle sensor.

Engine Stop Relay

Procedures for inspecting the engine stop relay.

ECM (Engine Control Module)

Procedures for inspecting the ECM.

Power;Ground Line Inspection

Inspecting power and ground lines for the ECM.

PAIR Solenoid Valve

Procedures for inspecting the PAIR solenoid valve.

EVAP Purge Control Valve (California Type Only)

Procedures for removing and inspecting the EVAP purge control valve.

O₂ Sensor (California Type Only)

Procedures for removing and inspecting the O₂ sensor.

EGCV and Air Intake Valve

Procedures for inspecting the EGCV and air intake valve.

Variable Air Intake Valve

Procedures for disassembling and assembling the variable air intake valve.

Cooling System

Service Information

General service information and warnings for the cooling system.

Specifications

Technical specifications for the cooling system.

Torque Values

Specified torque settings for cooling system components.

Troubleshooting

Common problems and solutions for the cooling system.

Coolant (Hydrometer Test)

Procedure for testing coolant gravity using a hydrometer.

Radiator Cap;System Pressure Inspection

Procedures for inspecting the radiator cap and system pressure.

Coolant Replacement

Procedures for replacing engine coolant and bleeding the system.

Thermostat

Procedures for removing, inspecting, and installing the thermostat.

Radiator

Procedures for removing and installing the radiator.

Water Pump

Procedures for inspecting, removing, and installing the water pump.

Radiator Reserve Tank

Procedures for removing and installing the radiator reserve tank.

Engine Removal;Installation

Service Information

General service information and precautions for engine removal/installation.

Service Data

Key specifications and data for engine service.

Torque Values

Specified torque settings for engine mounting and related components.

Lower Bracket Removal

Procedures for removing the lower bracket assembly.

Honda CBR900 Specifications

General IconGeneral
Compression Ratio11.0:1
Transmission6-speed
IgnitionComputer-controlled digital
Front SuspensionTelescopic fork
Rear SuspensionPro-Link single shock
Front BrakesDual hydraulic disc
Rear BrakesSingle hydraulic disc
Dry Weight185 kg
Seat Height810 mm
Fuel Capacity18 liters
EngineLiquid-cooled, inline four-cylinder

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