High Altitude Adjustment Usa only

When the vehicle is to be operated continuously above 6,500 feet (2,000 m), the carburetors must be readjusted as described below to improve driveability and decrease exhaust emissions. Warm up the engine to operating temperature. Stop-and-go driving for 10 minutes is sufficient to warm the engine. Turn each pilot screw clockwise 1 2 turn. Adjust the idle speed to 1,000 100 rpm with the throttle stop screw.

Vacuum Cylinder Disassembly

Remove the vacuum cylinders from the carburetor bodies. Carefully lift the vacuum piston out with the needle and compression spring. Inspect the vacuum piston and cylinder for wear, nicks, scratches or other damage. Make sure that the piston and jet needle move up and down freely in the cylinder. Remove the full open stopper. Remove the needle set screw. Separate the jet needle from the piston. Inspect the needle and seat for deposits, bending, grooves, or other damage. VACUUM CYLINDER...

Inspection

Remove the frame right and left side covers. Turn the ignition switch on. Measure battery voltage. Connect a DC voltmeter to regulator R W wire and ground. Read the voltage, it should be equal to the battery voltage. Check wire and battery cable connections, if not. Connect a DC voltmeter to the stator six pole connector B and W wires, without disconnecting them. Read the voltage, it should be equal to the battery voltage. Check the wire and battery cable connections (photo), if battery voltage...

Air Hose Connector

Apply grease to a new O-ring and place it on the end of the air hose. Connect the air hose to the left front fork cap. Connect the air hose to the connector in the right fork cap and tighten it. Install the removed parts in the reverse order of removal. Fill the fork tubes with air to 0.8 -1.1 kg cm2 (11 -16 psi). Use only a hand operated air pump to fill the fork tubes. Do not use compressed air. Maximum pressure is 3 kg cm2 (43 psi). Do not exceed this or fork tube component damage may occur....

N01 Cam Lobes

Loosely install the F and L camshaft holders. Install the G and K holders loosely, positioning the camshaft so its flange fits into the slot in the K holder. Install and tighten the camshaft sprocket bolts, following the same procedures described for exhaust camshaft installation. Tighten the camshaft holder bolts in a crisscross pattern. Adjust the intake cam chain tensioner with the lock nut on the front of the engine (page 3-10). Recheck the crankshaft and camshaft sprocket alignment....

Steering Step Set Plate

Turn the steering stem lock-to-lock 5 times to seat the bearings. Repeat the bearing tightening and steering stem turning sequence twice. If the nut does not tighten after turning the steering stem the first or second time, remove the nut and inspect it and the steering stem threads for dirt or burrs. Install a new bearing adjustment nut lock washer aligning the tabs with the nuts grooves.

Valve Stemtoguide Clearance

Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide. Measure and record each valve stem O.D. SERVICE LIMITS IN 5.47 mm (0.215 in) EX 5.45 mm (0.214 in) IN 5.475-5.490 mm (0.2156-0.2161 in) EX 5.455-5.470 mm (0.2148-0.2154 in)

Oil Seal Guide 079734630100

Push the retainer into place with the retainer wrench until the oil seal guide is contacted. Be careful not to damage the O-rings. The retainer has extra fine threads, and it is very easy to crossthread. Remove the oil seal and O-ring guides when retainer B seats against the bearing outer. Thread the retainer into the case by hand. Turn the pinion shaft intermittently. Stop tightening the retainer when pinion shaft rotating resistance is felt. Do not overtighten the retainer.

Starter Clutch Assembly

Install the springs, plungers and rollers. Tighten the locking bolts to the specified torque. TORQUE 2.6-3.0 kg-m (19-22 ft-lb) NOTE Apply a locking agent to the locking bolt's threads. Align the pin on the spark advancer unit with Install the spacer aligning the tangs with the holes, and tighten the advancer lock bolt to the specified torque.

Cb900c Torque Spec

Torque specifications listed above are for important fasteners. Others should be tightened to standard torque values below. standard torque values 6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 4-6 (0.4-0.6, 3-4) 8-12 (0.8-1.2, 6-9) 18-25 (1.8-2.5, 13-18) 35-40 (3.5-4.0, 22-29) 50-60 (5.0-6.0, 36-43) 6 mm flange bolt and nut 8 mm flange bolt and nut 10 mm flange bolt and nut 3-5 (0.3-0.5, 3-4) 7-11 (0.7-1.1, 5-8) 10-14 (1.0-1.4, 7-10) 20-30 (2.0-3.0, 14-22) 30-40...

Field Coil Inspection

CABLE TERMINAL-MOTOR CASE NO CONTINUITY NORMAL Check for continuity from the cable terminal to the motor case and from the cable terminal to the brush wire. Replace the starter motor if the field coil is not continuous or if it is shorted to the motor case. Align the case notch with the brush holder CABLE TERMINAL BRUSH WIRE CONTINUITY NORMAL CABLE TERMINAL BRUSH WIRE CONTINUITY NORMAL

Piston Pin Clip

Inspect the piston ring-to-groove clearance. NOTE Mark the rings so that they can be returned to their original locations. Inspect the pistons for damage and cracks ring grooves for wear. TOP 0.09 mm (0.004 in) SECOND 0.09 mm (0.004 in) Insert each piston ring into the cylinder, and inspect the end gap. 0.5 mm (0.02 in) 0.5 mm (0.02 in) 1.1 mm (0.04 in) 0.15-0.30 mm (0.006-0.012 in) 0.15-0.30 mm (0.006-0.012 in) 0.3-0.9 mm (0.012-0.035 in) Measure the piston 0. D. at the skirt. NOTE...

Rear Master Cylinder Assembly

Handle the master cylinder piston, cylinder and spring as a set. Assemble the master cylinder. Coat all parts with clean brake fluid. Dip the piston cup in brake fluid before assembly. When installing the cups, do not allow the lips to turn inside out. Be certain the snap ring is seated firmly in the Install the primary cup and piston. Install the push rod and circlip. Install the boot, nut and rod eye. Install the master cylinder on the master cylinder bracket. Connect the brake hose and brake...

Wet Plug

POSSIBLE CAUSE Fuel tank empty Clogged fuel tube or fuel filter Sticking float valve Clogged fuel tank cap breather hole Faulty spark plugs Fouled spark plugs Faulty spark unit Broken or shorted high tension wires Faulty A.C. generator Broken or shorted ignition coil Faulty ignition switch Faulty pulser generator Low battery charge Improper valve clearance Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Seized valve Improper valve timing Improper choke operation...

Dual Range Subtransmission

Power from the main transmission countershaft is transmitted to the drive shaft as follows Reduction drive gears (43T, 47T) - Reduction driven gears (31T, 30T) Damper lifter - Final drive gear Final driven gear Drive shaft. The dual transmission has two speed ranges, high (Ratio 0.638), and low (Ratio 0.721). Gear selection is by means of a foot pedal. Low range (LO) Winding mountin roads or sporty riding where extra power and acceeleration are desired. High range (HI) Highway riding and for...

Adjusting Spring Preload

Rotate the rebound damping adjuster with the hook spanner to select one of the three positions. Move the compression damping adjuster lever to position 1 or 2. For both adjusters, damping force increases as Be sure to adjust both shock absorbers equally. recommended damping adjuster positions

M5 Od C1 Od C1 Id

30.93 mm 1.218 in 24.93 mm 0.981 in 22.06 mm 0.869 in Measure the O.D. of the mainshaft and countershaft. A at M4 gear 27.930 mm 1.0996 in B at C3 gear 27.941 mm 1.1000 in C at C1 bushing 21.930 mm 0.8634 in Calculate the clearance between the gear and gear shaft or bushing. SERVICE LIMITS M5 to M5 bushing M4 to shaft C1 to C1 bushing C1 bushing to shaft 0.12 mm 0.005 in 0.10 mm 0.004 in 0.10 mm 0.004 in 0.10 mm 0.004 in 0.10 mm 0.004 in

Final Driven Flange

Grease with MoS2-additive as follows MOLYKOTE BR2-S manufactured by Dow Corning, U.S.A. MULTIPURPOSE M-2 manufactured by Mitsubishi Oil, Japan Other lubricants of equivalent quality. Do not get grease on the brake disc. Pack all bearing cavities with grease. Press the distance collar into place from the left Drive the right ball bearing first, then the left ball bearing.

Headlight Case Removal

Remove the headlight and disconnect all wires at their couplers and connectors. To remove the headlight case, unscrew the headlight case mounts. Remove the retaining screws and horizontal adjusting screw from the rim. Remove the two sealed beam unit retaining screws, and sealed beam unit. Assembly is essentially the reverse of disassembly. After assembly, adjust the headlight beam Page 3-16 .

Subtransmission Case Installation

Attach the subtransmission case to the engine. Install the subtransmission page 10-6 . Tighten the subtransmission case mounting bolts. Install the master cylinder holder bolts, then the master cylinder mounting bolts. Install the brake pedal and right exhaust pipe heat shield. Fill the subtransmission with the recommended oil page 2-9 . 0.61 U.S. qt. OIL TYPE Hypoid Gear Oil API, GL-5 SAE 80

Choke Disconnected On Cb900c

Remove the left handlebar switch. Disconnect the clutch cable. Disconnect the brakelight switch wires. Remove the right handlebar switch and throttle grip. Remove the front brake master cylinder with the brake lever. Remove the handlebar upper holders and handlebar.

Headlight Case Installation

Route the wires into the headlight case through the headlight case hole. Main wire harness Right turn signal wires Left turn signal wires Horn wires Instrument wires Right handlebar switch wires Fuse holder wires Left handlebar switch wires Qfh HOMDA 186 FRONT WHEEL SUSPENSION CB900C Align the index marks on the headlight case with the punch marks on the brackets.

Fork Seal Driver 079473710100

07917 3230000

WRENCH 6 mm 07917-3230000 OR COMMERCIALLY AVAILABLE- HEX. WRENCH 6 mm 07917-3230000 OR COMMERCIALLY AVAILABLE- Pull the fork tube out until resistance from the slider bushing is felt. Then move it in and out, tapping the bushing lightly until the fork tube separates from the slider. The slider bushing will be forced out by the fork tube bushing. Remove the slider bushing from the fork tube. Remove the piston and rebound spring from the fork tube. Remove the oil lock piece from inside the...

X24esru Dr8esl

Clean any dirt from around the spark plug bases. Measure the spark plug gaps using a wire-type feeler gauge. Adjust by bending the side electrode carefully. With the plug washer attached, thread the spark plugs in by hand to prevent cross-thead-ing. Tighten the spark plugs another 1 2 turn with a spark plug wrench to compress the plug washer.

Vehicle Emission Control Information Update Label

Operation at any altitude lower than 5,000 feet 1,500 m with the carburetors adjusted for high altitudes may cause the engine to idle roughly and stall. When the vehicle is to be operated continuously below 5,000 feet 1,500 m , turn each pilot screw counterclockwise to its original position against its stop. Adjust the idle speed to 1,000 100 rpm. Be sure to do these adjustments at low altitude.