1991–1999 Honda CB750 Nighthawk Service & Repair Manual (P/N 0-89287-750-2)

• Coverage: Covers 1991-1993 and 1995-1999 Honda CB750 Nighthawk models in a 412-page PDF; the 1994 model year is outside this manual’s stated coverage.
• Engine repair: Documents engine removal and installation plus cylinder-head, camshaft, cam-chain tensioner, hydraulic-tappet, valve, cylinder-block, piston, connecting-rod, crankcase, crankshaft, alternator-shaft, and lubrication-system service.
• Clutch and transmission: Walks through clutch release and clutch-pack service, external gearshift linkage repair, transmission troubleshooting and overhaul, mainshaft/countershaft inspection, and internal shift-mechanism assembly.
• Fuel and emissions: Covers carburetor synchronization, separation and overhaul, float-level inspection, fuel shutoff-valve testing, and the model-specific crankcase-breather, evaporative-emission, and secondary-air systems.
• Electrical diagnosis: Includes charging and regulator/rectifier tests, stator and rotor service, ignition and starting-system fault isolation, switch-continuity diagrams, connector references, and an all-model wiring diagram.
• Chassis work: Details wheels and hubs, tubeless tires, drive chain and sprockets, front forks, steering-head bearings, rear shocks and swingarm, front disc-brake service and bleeding, and rear drum-brake repair.

CB750 Model and Serial Coverage

Clymer manual M436 is a Clymer-published service and repair manual rather than Honda factory literature. Its engine and frame serial-number table separates 49-state and California versions by model year: RC38E engine numbers, RC380 frame numbers for 49-state bikes, and RC381 frame numbers for California bikes. Published start and end ranges are provided through 1996; the 1997-1999 listings are open-ended because final production endpoints were unavailable when the book was prepared.

The manual states that its procedures are geared to the home mechanic. In practice, the deeper repair work is best suited to experienced owners or technicians who can safely use precision measuring tools, electrical test equipment, pullers, bearing drivers, torque wrenches, and spring compressors.

Engine, Clutch, and Transmission Work

Top-end coverage goes beyond routine tune-up work. It includes camshaft removal and timing, hydraulic-tappet inspection and bleeding, cylinder-head disassembly, valve and guide service, cylinder-block inspection, and piston and connecting-rod small-end work. The lower-end chapters address engine removal, the oil cooler, oil pump, pressure-relief valve and strainer, crankcase separation, crankshaft and alternator-shaft service, connecting rods, bearing-insert selection, and post-rebuild break-in.

The clutch material identifies the release mechanism, friction-disc arrangement, judder spring, pressure plate, and clutch outer. Transmission repair extends to mainshaft and countershaft disassembly, gear and bushing inspection, shift forks, shift drum, stopper components, and final reassembly.

Troubleshooting and Technical References

A dedicated troubleshooting chapter covers hard starting, spark testing, compression and leakdown checks, engine noises, lubrication faults, hydraulic tappets, clutch and gearshift complaints, carburetor problems, charging, ignition, electric starting, front suspension, steering, and brakes. The electrical chapter adds resistance, voltage, and continuity tests for the alternator and regulator/rectifier circuits, pulse generator, ignition coils, starter, relays, switches, lighting, meters, horn, and fuses.

Diagram support includes an ignition-system schematic, starting-system electrical diagram, horn-switch continuity and connector view, clutch assembly exploded view, California evaporative-emission system layout, and the all-model wiring diagram at the back of the book. Chapter-end tables supply component-specific torque specifications, capacities and recommended lubricants, pressure-test data, wear limits, clearances, bearing-selection data, adjustment specifications, and electrical test values.

Special Tools and Component-Specific Cautions

Named tool callouts include the Honda Hydraulic Tappet Bleeder P/N 07973-MJ00000, clutch center holder P/N 07HGB-00100A, locknut wrench P/N 07716-0020203, and flywheel puller P/N 07933-2160000, with equivalent tools noted where the manual permits them.

The clutch section warns that forcing the staked clutch-center locknut loose can damage the mainshaft threads. The hydraulic-tappet procedure warns against bleeding a tappet with wire, which can damage the unit, and stresses returning each tappet to its original position.

Engine removal, fuel-system work, brake service, and rear-shock spring removal involve heavy parts, flammable gasoline, hazardous brake fluid, and stored spring force. Support the motorcycle securely, use the specified lifting and compression equipment, and follow the manual’s safety warnings before beginning repair work.