Honda Cb900f Cb919 2002-2003 Service Repair Manual

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This manual covers the CB900F and CB919 models produced between 2002 and 2003, also known as the Hornet in certain markets. These motorcycles are powered by a liquid-cooled, DOHC, 16-valve...

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Typ: Motorcycle

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Art.-Nr: 104729

Stichworte: 2002 2003 B Models Cb900f Cb919 Honda Marine Motorcycle Outboard Engines

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Beschreibung

This manual covers the CB900F and CB919 models produced between 2002 and 2003, also known as the Hornet in certain markets. These motorcycles are powered by a liquid-cooled, DOHC, 16-valve inline-four engine with a displacement of 998 cc, delivering approximately 110-115 horsepower. Known for their strong mid-range torque and comfortable ergonomics, these bikes were designed for versatile riding, suitable for commuting, touring, and spirited performance. The legacy of engineering excellence and reliability underpins these models, which are positioned as capable sport-naked motorcycles. This comprehensive service repair manual is designed to assist owners, mechanics, and technicians in maintaining and repairing the CB900F/CB919. It provides detailed information on all major systems, including engine mechanicals, fuel and ignition systems, cooling, transmission, clutch, brakes, suspension, and the electrical system. The manual includes step-by-step procedures for routine maintenance, troubleshooting, component replacement, and full engine and gearbox rebuilds. With abundant illustrations, diagrams, and technical specifications, this manual serves as an authoritative resource for ensuring the optimal performance and longevity of your motorcycle.

🏷️ Basic Information

Identification

Make:

Honda

Model:

CB900F / CB919

Model Alias:

Hornet (in some markets)

Model Code:

CB900F (SC48)

Model Year:

2002-2003

👋 Introduction

Market Position

Market Segment:

Sport Naked / Standard Motorcycle

Target Audience:

Enthusiast owners, independent repair shops, and DIY mechanics.

Competitive Analysis

Key Competitors:

Yamaha FZ1, Suzuki Bandit 1200, Kawasaki ZRX1200.

Key Features

Engine Type:

Liquid-cooled, DOHC, 16-valve, inline-four cylinder.

Design Philosophy:

Emphasis on strong mid-range torque and comfortable ergonomics for versatile riding.

Manual Advantage:

Provides dealer-level repair information, enabling significant cost savings on maintenance and repairs.

📋 Manual Details

Coverage Areas

Coverage Years:

2002, 2003

Covered Models:

Honda CB900F, Honda CB919

Page Count

Estimated Page Count:

Approximately 400-600 pages (typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Service Repair Manual

Manual Category:

Professional Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

File Format:

Printability:

Printable pages for workshop use

Searchability:

Searchable text for quick information retrieval

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, disassembly, inspection, assembly, tuning, valve clearance adjustment, camshaft timing, piston and cylinder inspection.

Fuel System:

Carburetor cleaning, adjustment, synchronization, fuel pump inspection, fuel tank service, fuel filter replacement.

Ignition System:

Spark plug service, ignition coil testing, ECU diagnosis, ignition timing.

Cooling System:

Radiator service, coolant flush and refill, thermostat inspection, cooling fan operation, water pump inspection.

Transmission Gearbox:

Gearbox disassembly, inspection, assembly, clutch plate replacement, gear selection mechanism service.

Clutch System:

Clutch lever adjustment, clutch cable inspection/replacement, clutch fluid replacement (if hydraulic), clutch assembly and disassembly.

Brakes:

Brake pad replacement, brake caliper service, brake fluid flush and replacement, master cylinder inspection, brake line inspection, rear brake mechanism.

Suspension:

Front fork service (oil change, seal replacement), rear shock absorber inspection and adjustment, linkage inspection.

Electrical System:

Wiring diagrams, battery testing and maintenance, charging system (stator, rectifier/regulator), lighting, horn, starter motor, fuses.

Frame Chassis:

Frame inspection, steering head bearing service, swingarm inspection and lubrication.

Exhaust System:

Exhaust pipe inspection, muffler service, exhaust gasket replacement.

Bodywork:

Fairing removal and installation, seat service, fuel tank removal/installation, fenders.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain adjustment and lubrication, brake fluid level checks.

Troubleshooting:

Detailed fault finding charts and diagnostic procedures for common issues.

Repair Rebuild:

Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly.

Component Replacement:

Instructions for replacing parts such as brake pads, clutch plates, fork seals, bearings, etc.

Electrical Diagnostics:

Troubleshooting electrical circuits, testing components like the stator and regulator/rectifier.

Suspension Tuning:

Information on adjusting suspension settings for different riding conditions.

Technical Depth

Depth Level:

Comprehensive Workshop Level

Diagnostic Capability:

Advanced diagnostics and fault finding

Rebuild Scope:

Full engine and gearbox rebuild procedures

Technical Illustrations:

Abundant illustrations, diagrams, and photographs

📊 Manual Specifications

File Format

File Quality:

High-resolution, professional grade

Print Quality

Print Recommendation:

Recommended for printing specific sections or the entire manual for workshop use.

Binding Type

Binding Type If Printed:

N/A (Digital Download)

Paper Type

Paper Type If Printed:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

SC48E

Engine Type:

Liquid-cooled, four-stroke, DOHC, 16-valve inline-four

Displacement:

998 cc (60.9 cu in)

Bore X Stroke:

71 mm x 61.5 mm (2.8 in x 2.4 in)

Compression Ratio:

9.0:1

Carburetion:

Four 36mm CV carburetors (Keihin or similar)

Firing Order:

1-2-4-3

Performance

Horsepower:

Approx. 110-115 hp @ 8,500 rpm (manufacturer claimed)

Torque:

Approx. 70-75 lb-ft @ 6,500 rpm (manufacturer claimed)

Fuel System

Fuel Delivery:

Carbureted

Fuel Tank Capacity:

4.5 US gal (17 L)

Lubrication System

Oil Type:

SAE 10W-40 API SG or higher motorcycle oil

Oil Capacity With Filter:

Approx. 3.4 US qt (3.2 L)

Oil Filter Part Number:

Honda 15410-MFJ-001 or equivalent aftermarket (e.g., K&N KN-145)

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Clutch Type:

Wet, multi-plate

Final Drive:

Chain Drive

Features

Gear Ratios:

Specific gear ratios are detailed within the manual.

Transmission Fluid:

Motorcycle-specific multi-purpose gear oil (refer to manual for specific viscosity and API rating).

📐 Dimensions

Exterior

Overall Length:

Approx. 83.1 inches (2111 mm)

Overall Width:

Approx. 30.3 inches (770 mm)

Overall Height:

Approx. 46.7 inches (1186 mm)

Wheelbase:

Approx. 58.1 inches (1475 mm)

Weights

Dry Weight:

Approx. 441 lbs (200 kg)

Curb Weight:

Approx. 481 lbs (218 kg)

Max Load Capacity:

Refer to owner's manual/manual for specific rider and luggage capacity.

🛡️ Safety Features

Ratings

Safety Certification:

Designed to meet relevant safety standards for motorcycles of its era.

Active Features

Braking System:

Dual hydraulic disc front brakes, single hydraulic disc rear brake. Optional ABS was not commonly available for this model in these years.

Passive Features

Frame Construction:

Steel diamond frame for rigidity and stability.

Lighting:

Halogen headlight, LED taillight (standard).

💡 Technology Features

Infotainment

Infotainment Features:

N/A (This model predates advanced infotainment systems on motorcycles).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids beyond basic braking).

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles (4,800 km) or 6 months, whichever comes first.

Air Filter Interval:

Inspect every 3,000 miles (4,800 km), clean or replace as needed.

Spark Plug Interval:

Replace every 12,000 miles (19,000 km) or as indicated by wear.

Valve Clearance Interval:

Inspect every 7,500 miles (12,000 km).

Fluid Specifications

Coolant Type:

Honda coolant or equivalent permanent type antifreeze (50/50 mix with distilled water).

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid.

Fork Oil Type:

Honda SS-7 or equivalent (10W viscosity). Refer to manual for exact quantity.

Known Issues

Common Wear Items:

Clutch wear, brake pad wear, chain and sprockets, suspension seals.

Potential Electrical Issues:

Stator or rectifier/regulator failure can occur with age and mileage, leading to charging issues.

Carburetion Tuning:

Carburetors may require periodic synchronization and cleaning for optimal performance, especially after sitting for extended periods.

📚 Vehicle History

Brand Heritage

Honda Legacy:

Honda is renowned for its engineering prowess, reliability, and performance across a wide range of vehicles, including its motorcycles.

Model Evolution

Cb900F Lineage:

The CB900F (SC48) evolved from earlier Honda CB series motorcycles, particularly the CB750, offering a larger displacement engine and modern performance characteristics.

Target Market Positioning:

Positioned as a versatile sport-naked bike, suitable for commuting, touring, and spirited riding.

Production

Production Period:

2002-2007 (globally, with variations in market availability).

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Recognitions

Industry Recognition:

While specific awards for the 2002-2003 model year are not widely documented, the CB919 was generally well-received for its balance of performance, comfort, and value in the sport-naked category.

Ratings

Owner Satisfaction:

Generally high owner satisfaction due to Honda's reputation for reliability and the bike's user-friendly nature.