2002–2007 Honda CB900F / 919 / Hornet Service & Repair Manual (P/N 61MCZ00)

This Honda Motor Co., Ltd. service manual covers the 2002–2007 CB900F / 919 / Hornet, including California and non-California configurations. The December 2001 edition is marked 61MCZ00 on the back cover.

• Engine repair: Engine removal and installation, cylinder-head and valve service, camshaft timing, piston inspection, and crankcase separation.

• Clutch and transmission: Clutch disassembly, gearshift-linkage repair, shift-drum and fork inspection, transmission disassembly and reassembly, and starter-clutch service.

• PGM-FI diagnosis: MIL fault-code charts, sensor and injector circuit tests, fuel-pressure checks, and starter-valve synchronization.

• Cooling and lubrication: Radiator pressure testing, thermostat inspection, coolant replacement and bleeding, oil-pressure diagnosis, and oil-pump service.

• Wheels and suspension: Wheel-bearing replacement, fork disassembly, steering-stem adjustment, shock-absorber inspection, and swingarm pivot-bearing replacement.

• Hydraulic brakes: Fluid replacement and bleeding, pad and disc inspection, plus front and rear master-cylinder and caliper disassembly.

• Electrical systems: Battery and charging tests, ignition diagnosis, electric-starter overhaul, lighting and instrument checks, wiring diagrams, and cable routing.

Honda wrote this manual for qualified professional technicians with motorcycle-service training and the appropriate workshop tools and equipment.

Engine, Valve Train and Transmission

Valve service: Shim-under-bucket valve adjustment is supported by shim-selection calculations, camshaft installation, and cam-chain timing procedures. Cylinder-head work extends to valve-guide replacement and valve-seat refacing. The removal notes warn that uneven release of the camshaft-holder bolts can break the holder.

Internal engine work: Crankcase separation opens access to the crankshaft and transmission. Crankpin and main-journal bearing-selection tables match component identification codes to bearing grades, helping identify the correct inserts during a rebuild. Incorrectly positioned inserts can obstruct oil passages and cause engine seizure.

Clutch inspection covers the friction discs, plates, springs, and judder spring. Transmission procedures address gear dogs, bushings, shafts, and shift components; separate instructions cover the alternator, flywheel, and one-way starter clutch.

PGM-FI Fault Tracing and Emissions Equipment

The MIL charts connect fault indications with checks of sensor circuits, individual injectors, and cam and ignition pulse generators. The PGM-FI system diagram and ECM terminal views help distinguish wiring faults from failed components before replacing the control module.

Diagnostic equipment references include ECU test harness 07YMZ-0010100, used as a pair. Fuel-system procedures also cover pump delivery, pressure-regulator replacement, and starter-valve synchronization. Throttle-body service retains the factory-set throttle adjustments.

California-specific coverage includes the EVAP canister, purge-control solenoid, and vacuum-hose routing. The PAIR secondary-air system, intake-air duct control components, and emission-control information labels are also documented.

Oil Circulation and Cooling-System Tests

The lubrication-system diagram traces oil delivery to the engine and transmission. Service procedures cover the pressure-relief valve, oil strainer, pump inspection, and oil cooler.

Cooling-system flow illustrations and the coolant gravity chart accompany leak testing and thermostat checks. Water-pump service covers leak inspection and assembly replacement when the mechanical seal is defective.

Forks, Steering and Hydraulic Brakes

Fork service covers seals, bushings, springs, and damper inspection. A damaged fork damper is replaced as an assembly; the procedure does not describe rebuilding its internal valving.

Rear-suspension coverage includes shock removal, inspection, mounting-bearing replacement, and swingarm service. Wheel-balance checks, steering-bearing adjustment, chassis dimensions, and body-panel and exhaust-system removal round out the chassis information.

Brake sections include piston and bore measurements, seal replacement, and bleeding. Work on pressurized fuel systems and hydraulic brakes requires the protective equipment and workshop precautions described in the manual.

Charging, Starting and Instrument Circuits

Charging diagnosis separates battery condition, current leakage, stator faults, and regulator/rectifier problems. Ignition tests use coil and pulse-generator peak-voltage measurements.

The electric-starter chapter covers armature, brush, and relay checks. Lighting and instrument procedures address the speed sensor, tachometer, temperature gauge, and safety-interlock switches, supported by system schematics and connector views.

A Preview of Valve, Throttle and Head-Bolt Specifications

These examples represent a small selection of the manual's adjustment and assembly data.

Throttle-grip free play is specified at 2–4 mm. Intake-valve clearance is 0.16 ± 0.03 mm with the engine cold, below 35°C (95°F).

The cylinder-head installation section specifies 48 N·m for the 9 mm mounting bolts, with molybdenum disulfide oil solution on their threads and seating surfaces.

Search, Chapter Access and PDF Contents

Text search and diagram detail: OCR text supports searches through the text sections, although recognition errors can affect matches. Embedded bookmarks link to the service chapters. The main wiring-diagram page has no searchable text; its small connector numbers and wire-color labels require zooming.

Supplied as one printable, English-language 432-page PDF. The total already includes both covers, three introductory pages, two memo pages, and the two-page index.