Honda InterceptorVF700F Shop Manual Download Page 1

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Summary of Contents for InterceptorVF700F

Page 1: ...IilONTfDA SHOPMANUAL vF70 0 FtvF750 INTETICEPTOFI ...

Page 2: ...ntainssome warningsand cautionsagainstsome specific service methods whichcouldcausePERSONALINJURYto service personnel orcoulddamage a vehicleor renderit unsafe Please understand thatthosewarningscouldnotcoverallconceivableways in which service whether or not recommendedby Honda might be done or of the possiblehazardous consequences of eachconceivable way nor couldHondainvestigate all suchways Anyo...

Page 3: ...bsequent pages givedetailed procedures lf youarenotfamiliarwith thismotorcycle read TECHNICAL FEATURES section22 lf youdon tknowthe sourceofthetrouble goto section23 TROUBLESHOOTING All Information illustrations directionsand specifications included in this publication are based on the latest product information availableat the time of approvalfor printing Honda Motor Go Ltd reservesthe right to m...

Page 4: ...ust contains poisonous carbon monoxide gos F tlr illn Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flamesor sparks in your working oreo SERI ICE RUTES Use genuineHONDA or HONDA recommendedpartsand lubricantsor their equivalent Partsthat do not meet HONDA s designspecifications may damagethe motorcycle Usethe special tools designed for this product...

Page 5: ...ameserial rightside The engine serialnumberis stamped on the right sideof the uppercrankcase d Thecolor labelisaffixedto the rearfender underthe seat The vehicleidentification number VlN righttubeof the frame is on the upper The carburetoridentificationnumbersare eachcarburetor stampedonto M 1 2 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 6: ...ea Rearbrake liningswept area Fuelcapacity Fuelreservecapacity Casterangle Trail Frontfork oil capacity Doubledisc 904 cm2 14Osq in 83 84 Singledisc49Ocm2 76 sq in After 84 VF7OOF Singledisc452 cmz 70 sq in 22 liters 5 8US gal 4 8lmp gal 4 liters 1 1US gal 0 9 lmpgal 28 1o 96 mm 3 8in VF7SOF Right 360 cc 12 2oz Left 380 cc 12 8ozl VF7OOF Right 350 cc 11 9oz Left 37Occ 12 5ozl After 84 VFTOOF Right...

Page 7: ...tion GearratioI Gear ratioll Gear ratiolll GearratiolV GearratioV Gearshiftpattern Wet multi plate 5 speed 2 152 VF750F 2 588 VF700F 2 750 2 733 1 895 1 500 1 240 1 074 Leftfootoperated return system l N 2 3 4 5 ELECTR ICAL lgnition lgnition timing F mark Fulladvance Starting system Alternator Batterycapacity Sparkplug Fulltransistor ignition VF750F 10o BTDCat idle VF700F l5 BTDCat idle 37 BTDCat ...

Page 8: ...8 12 15 20 12 t6 8 1 2 6 91 o 1 4 7 101 1 1 2 5 15 18 3 3 7 24 27 8 0 10 0 58 721 8 0 10 0 58 721 6 2 6 8 45 491 3 0 3 4 22 25 12 o 2 5 14 181 11 o 1 4 7 101 14 5 5 0 32 36 11 8 2 0 13 141 i2 6 3 0 19 221 1 6 2 0 12 141 2 1 2 5 15 18 1 5 2 O 11 141 2 0 2 5 14 18 5 0 5 4 36 39 2 1 2 5 15 18 3 5 4 0 25 291 3 0 3 4 22 251 0 8 1 2 6 9 1 5 2 O 11 141 1 2 1 6 9 121 _l ApptvLOCTITE 271 L to the threads I...

Page 9: ...0 50 4 0 5 0 29 36 40 50 4 0 5 0 29 36 40 50 4 0 5 0 29 36 20 30 2 0 3 0 14 221 85 105 8 5 1 0 5 61 76 85 105 8 5 1 0 5 61 76 18 25 11 8 2 5 13 18 30 40 3 0 4 0 22 291 80 100 8 0 1 0 0 58 72l 35 40 3 5 4 0 25 291 85 105 8 5 1 0 5 61 76 35 45 3 5 4 5 25 33 30 40 3 0 4 0 22 291 10 15 1 0 1 5 7 111 35 45 3 5 4 5 25 33 45 55 4 5 5 5 33 40 24 30 Q 4 3 O 17 221 35 45 3 5 4 5 25 33 35 45 3 5 4 5 25 33 Fr...

Page 10: ...able in U S A t or Gearholdermodified f L Not available in U S A Steering stemdriver LAttachment U S A only or 07404 0020000or Vacuum gauge U S A only Equ ivalent toolcommercially available in U S A r U S A only lncluded in l Turbokit 07924 MC70001 07924 MC70000 07924 4150000 07946 37 10601 07964 M800200 M9378_021_XXXXX 2 5 3 12 3 1 1 7 5 14 21 14 27 16 8 16 16 14 32 14 35 14 20 7 1 1 7 2 2 15 15 ...

Page 11: ...Bearing remover corret 15 mm Bearingremovercorret 20 mm 07746 0010100 07746 0010200 07746 0010300 07746 0010400 07746 0010500 07746 0040300 o7746 0040400 07746 0040500 07746 0040600 07746 0040700 07749 0010000 07757 001 0000 07746 0050100 07746 0050400 07746 0050600 Equivalent tool comrnercially available in U S A 15 5 7 16 15 15 14 15 14 33 11 3 14 34 15 6 15 6 14 15 15 1 5 15 6 15 15 15 6 7 16 7...

Page 12: ... are contact a sharp edgeor corner Cleanthe attachingsurfacethoroughly beforeapplying tape Do not use wires or harnesses with a broken insulator Repairby wrappingthem with a pro tectivetapeor replace them Route wire harnesses to avoid sharpedgesor corners Also avoid the projected ends of bolts and screws Keepwireharnesses awayfrom the exhaust pipes andotherhot parts Be sure grommetsare seatedin th...

Page 13: ...LUTCH PIPE FRONT BRAKE HOSES STARTER ENGINE STOP SWITCH COUPLER METER LLUMINATION L E R SPEEDOMETER CABLE SPEEDOMETER CABLE CHOKE CABLE I G N I T I O N C O I L HIGH TENSION4 W I R E S THERMOSTAT OIL PRESSURE SWITCH THROTTLE CABLES MAIN HARNESS BRAKE HOSE THERMOSTATIC SWITCH WIRE 1 1 0 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 14: ... T SWITCH WIRE REARBRAKEHOSE T U R NS I G N A L ELAY EL CUT OFF RELAY REGULATOR R E C T I F I E R REGULATOR R E C T I F I E R COUPLER FANMOTOR RELAY I G N I T I O N C O I L SPARKPLUG CAP O I L P R E S S U R E SWITCH GROUND CABLE STARTERMOTOR RADIATOR BREATHER TUBE L BATTERY BREATHER TUBE Dateof lssue January 1983 OHONDA MOTORCO LTD 1 1 1 ...

Page 15: ...L I G H T D I M M E R HORNSWITCH COUPLER COOLING FAN FUSE C H O K E C A B L E COOLING FAN MOTORS H I G HT E N S I O N W I R E S RADIATOR HOSE RESERVE TANK F U E LP U M P L R E A RT U R N S I G N A L W I R E THROTTLE CABLES I G N I T I O N C O I L S MAIN HARNESS S P A R K U N I T B R A K EA N DT A I L L I G H TS E N S O R CHOKECABLE B R A K EA N DT A I L L I G H T S P A R K U N I T 1 1 2 Dateof lss...

Page 16: ... Controlof hydrocarbons isveryimportantbecause undercertainconditions they reactto form photochemical smogwhensubjected to sunlight Carbonmonoxidedoesnot reactin the same way but it istoxic Honda Motor Co Ltd utilizes lean carburetorsettingsas well as other systems to reducecarbon monoxideand hydrocarbons El EXHAUST EMTSSTON CONTROL SYSTEM E The exhaustemission control systemiscomposed of leancarb...

Page 17: ...herthan for purposes of maintenance repairor replacement of any deviceor elementof designincorporated into any new vehicle for the purpose of noisecontrolpriorto its saleor deliveryto the ultimatepurchaser or while it is in use or 2 the useof the vehicle aftersuchdevice or element of design hasbeenremoved or rendered inoperative by any person AMONGTHOSEACTSPRESUMED TO CONSTITUTE TAMPERING ARE THE ...

Page 18: ...the seat as shown Instructions for obtainingthe updatelabel are given in Service LetterNo 132 VACUUM HOSE ROUTINGLABEL After 83 California model only TheVacuumHoseRoutingLabelis attachedto the fuel tank belowthe seat Routethe vacuumhoses as described on this label EMISSION CONTROL INFORMATION LABEL VEHICLE EMISSION CONTROL INFORMATION UPDATELABEL VACI U I FICSE ROUTING DIAGRAT tl itIt il il Y tNt0...

Page 19: ...LUBRICATION I FRONTCYLINDER EX CAMSHAFT FRONTCYLINDER IN CAMSHAFT TOREARCYLINDER SHIFTFO I FI C E K SHAFT o t Lo O I L F I L T E R COUNTERSHAFT 2 O O I LS T R A I N E R O I L P U M P Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 20: ...3 0 liters 3 2 US qt 2 6 lmp qt afterdisassembly Oil recommendation UseHONDA4 STROKE OIL or equivalent API SERVICE CLASSIFICATION SE or SF VISCOSIW SAE 10W 40 Otherviscosities shown in the chart may be usedwhen the averagetemperaturein your ridingarea is within the indicatedrange orL vrscostTrEs 1 0 1 0 Oilpressure atoil pressure switch 5 4 t O 7kg cm2 77 10 psi at 5 OOO rpm 80oC 176oF Oil pumpdel...

Page 21: ...l Oil contamination 1 Oil or filternot changed oftenenough 2 Headgasket faulty 3 Wornpistonrings Low oil pressurg 1 Oil level low 2 Pressure reliefvalvestuckopen 3 Pluggedioif pibk upscreen 4 Oil pumpworn 5 External oil leaks Highoil prossurB 1 Pressure reli ef valvestuckclosed 2 Plugged oil f ilte r gallery or metering orifice 3 Incorrect oil being used No oil pressure 1 Oillevel low 2 Oil pumpdr...

Page 22: ...n plug anddraintheoil Removethe lower radiator cowl lower radiator mounting bolts and brakcet Swing the radiator away from the engine but don t disconnectits hoses Remove the oil f ilterwith a filter wrenchand let the remaining oil drain out Discardthe oil f ilter Checkthat the sealing washer on the drainplugis in goodcondition and install the plug Replace the oil filter with a new one Checkthat t...

Page 23: ...hen everthe reliefvalveisremoved Install theoil strainer andoil pan Install theexhaust pipes Fill the crankcase with the recommended oil page 2 1t OItPRESSURE CI ECI Warmthe engineup to normaloperating temper ature approximately 80 C 176 F Stop the engineand disconnect the oil pressure switch wire Removethe oil pressureswitch and connectan oil pressuregauge to the pressureswitch hole page 2 5 Chec...

Page 24: ...catorgoes out afteroneor two seconds lf the oil pressure warningindicator stays on stop theengine immediately anddetermine thecause OItPU P R E M O V A L NOTE The oil pump can be removedwith the engine mounted in the f rame Remove the lowerradiator Drainthe engine oil Remove the exhaust system Remove the rightcrankcase cover Remove the oil pumpdrivensprocket by removing theboltandwasher Removethe ...

Page 25: ...s Straightenand removethe cotter pin holdingthe oil strainer tube Remove the oil strainer stay Remove the oil pumpbody cover Remove the dowelpin Remove the innerrotor anddrivepin OILSTRAINER TUBE OIL PUMPBODYCOVER DOWEL PIN INNERROTOR O R I N G S 2 6 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 26: ...ERVICE LIMIT 0 20mm 0 008in Measure thepumP bodY clearance STANDARD 0 15 0 22 mm 0 006 0 009 inl SERVICE LIMIT 0 35 mm 0 014 inl Remove the rotorshaftandmeasure the pump endclearance STANDARD 0 02 0 07mm 0 001 0 003 in SERVICE LIMIT 0 10mm 0 004 in 2 7 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 27: ...the innerrotorwith thedrivepin OUTER ROTOR ROTOR SHAFT D R I V E P I N INNER D O W E L P I N Installthe dowel pin and oil Makesurethe oil strainertube condition pump body cover O rings arein good O R I N G S A l r l ffi mi i O I LS T R A I N E R T U B E Installthe oil strainertube with a new cotterpin I COTTER PIN Dateof lssue January 1983 O HONDAMOTOR CO LTD 2 8 ...

Page 28: ...OTE The lN mark on the drivensprocket should facethe crankcase Installthe wdsher andtightenthe bolt Installthe dowelpinsanda newgasket Installthe rightcrankcase cover lnstallthe exhaust system Fill the enginewith the recommended oil page 2 1t CONTROT CABTE TUBRICATIOI Periodically disconnectthe throttle cablesat their upperends Thoroughlylubricate the cables andtheir pivot pointswith a commerciall...

Page 29: ...EG PIVOT LIJBRICATIOl POIl TS 1 CABLE LUBRICANT THROTTLE AND CHOKE CABLE CABLELUBRICANT SPEEDOMETER CABLE STEERING HEAD BEARINGS WHEEL BEARINGS Whenreplaced SPEEDOMETER D R I V E G E A R o o Gl B R A K E CLUTCH AND BRAKE LEVERPIVOTS GEARSHAFT PEDALPIVOT FOOT PEG PIVOT t ltrilEil WHEEL BEAR INGS When replacedl F R O N T F O R K A T F D R I V EC H A I N SAE80_90 GEAROIL S I D EA N D CENTER STANDA PI...

Page 30: ...TEMHOSES CONNECTIONS EVAPORATIVE EMISSION CONTROL 3_12 SYSTEM CYLINDERCOMPRESSION DRIVECHAIN BATTERY BRAKEFLUID BRAKE SHOE PADWEAR BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT AIM CLUTCH SIDE STAND SUSPENSION NUTS BOLTS FASTENERS WHEELS STEERING HEAD BEARINGS 3 1 3 3 3 4 3 4 3 5 3 6 3 6 3 7 3 7 3 8 3 10 3 11 3 11 3 12 3 12 3 13 3 15 3 16 3 17 3 17 3 17 3 18 3 18 3 18 3 19 3 19 3 21 3 21 3 21 Standard...

Page 31: ...inslack 15 25 mm 5 8 1 in Tires Tiresize Front Rear M120 80 16 M130 80 18 Coldtire pressure kpa kg cm2 psi Up to 90 kS 200lbs load 22512 25 321 22512 25 32l 90 kg 200lbs load to vehicle capacity load 22512 25 321 280 2 80 40 Tirebrand Bridgestone G511 G510 Dunlop F 1 1 K627 Suspension air pressure Front 0 40 kPa 0 0 4 kglcm2 0 6 psi Rear so 300 kPa 0 5 3 0 kg cm2 7 43 psi TOOLS Special Vacuumgause...

Page 32: ...WHICHEVER COMES FrRSr I EVERY c B ODOMETER READING NOTE 4 a t E o LlJ l LIJ E z I a I t FUELLINES I I 3 4 FUELFILTER R 3 4 THROTTLE OPERATION I I I 3 5 CARBURETOR CHOKE I I I 3 6 AIR CLEANER NOTE1 R R R 3 6 CRANKCASE BREATHER NOTE2 c c c c c c 3 7 SPARKPLUGS R R R R R R 3 7 VALVECLEARANCE I 3 8 ENGINE OIL YEAR R R R R 2 3 ENGINE OILFILTER YEAR R R R R 2 3 CARBURETOR SYNCHRONIZATION 3 1 0 CARBURETO...

Page 33: ... sidecover Removethe electric panel mounting bolts and remove the coolantreserve tank Unclip the fuel filter holder from the bottom of the electric panel Disconnect the fuel outlet line from the fuel filter Pullthe fuelf ilterout thenclip the inletlineclosed Disconnect the fuel inletline lnstallthe fuelfilter After installing turn the fuel valveon and check that thereareno fuel leaks F U E LL I N ...

Page 34: ...ottlegrip f lange FREEPLAY 2 6 mm 118 114inl Adjustment can be made at either end of the throttle cable Minoradjustments aremadewith the upperadjuster andmajoradjustments aremadewith the loweradjuster after removing the fuel tank and air cleaner case Adjust the loosening the lock nut andturningthe adjuster Tightenthe lock nut andrecheck throttleoperation Installthe air cleaner caseand fuel tank an...

Page 35: ...hoke leveron the carburetor after removingthe fuel tank and air cleaner case Thereshouldbe no freeplay Adjust if necessary by loosening the chokecable clamp on the carburetor and movingthe choke cable casing sothechokelever isfully open Tighten theclamp Pushthe chokeleverup all the wayto fully closed Makesurethe chokevalveis fully closed by check ing for freeplay in the cablebetween the leveron th...

Page 36: ... Clean anydirt fromaround thesparkplugbases Remove anddiscard thesparkplugs Measure the new sparkpluggapsusinga wire type feelergauge SPARKPLUGGAP 0 8 0 9mm 0 031 0 035 in Adjust by bendingthe side electrode carefully With the plug washerattached threadeachspark plug in by handto prevent crossthreading Continue tighteningby hand until the sparkplug bottoms Then tightenthe sparkplugsanother1 2turn ...

Page 37: ...ator page 6 5 Remove the sparkplugcaps Remove the front andrearcylinderheadcoverbolts andboth cylinderheadcovers Remove the alternator cover INSPECTION Measure and adjustthe intake and exhaustvalve clearances asdescribed below Rotatethe crankshaft counterclockwise to alignthe T1 3 markwith the crankcase matingsurfaces Make surethe No 1 piston is at TDC T6p Dead Center on the compression stroke R E...

Page 38: ...ator page 6 5 Remove the sparkplugcaps Remove the front andrearcylinderheadcoverbolts andboth cylinderheadcovers Remove the alternator cover INSPECTIOI Measure and adjustthe intake and exhaustvalve clearances asdescribed below Rotatethe crankshaft counterclockwise to alignthe T1 3 markwith the crankcase matingsurfaces Make surethe No 1 piston is at TDC Top Dead Center on the compression stroke R E...

Page 39: ...ethe crankshaft 90ocounterclockwise to align the T2 4 mark with the crankcase matingsurfaces andcheckthe valve clearances for the No 4cylinder Adjust usingthe procedures for the No 1 cylinder Rotate the crankshalt27O counterclockwise to align the T1 3 mark with the crankcase mating surfaces andcheckthe valve clearances for the No 3 cylinder Adjustusingthe procedures for the No 1 cylinder Rotate th...

Page 40: ... 1 IZATIOl NOTE Synchronize the carburetors with the engine at normaloperating temperature transmission in neutraland motorcycle on thecenterstand Removethe plugsfrom the No 1 2 3 and 4 cylinderheadports and installthe vacuumgauge aclapters Connect thevacuum gauges ADJUSTMENT NOTE The No 4 carburetor cannot beadjusted lt is the basecarburetor Starttheengine andadjust the idlespeed IDLESPEED VF750F...

Page 41: ...armup the engine shiftto NEUTRAL andplace the motorcycle on itscenter stand Turn the throttlestopscrewasrequired to obtain thespecif iedidlespeed IDLESPEED VF750F 1 000t 100rpm VF700F 1 200t 100rpm RADIATOR COOLA IT No 3ADJUSTING No 1ADJUSTING SCBEW SCREW Remove the frameleft sidecover Checkthe coolantlevelof the reserve tank with the engine runingat normal operating tempqrature The level shouldbe...

Page 42: ...gsurface COOLING SYSTEM HOSES c0NNECTr0tus Inspectthe hosesfor cracksor deterioration replaceif necessary Checkthe tightness of all hoseclamps EVAPORATIVE EMISSION CONTROT SYSTEM After 83Galifornia model only Checkthe fueltankbreather tubebetweenthetank capandthe canister andthevacuumtubebetween the canisterandthe purgecontrolvalvefor deteri oration clogging damageor loosejoints or con nections PU...

Page 43: ...reading stopsrising The maximumreading isusually reached within 4 7seconds COMPRESSION PRESSURE 1 300t 200kPa 13 0t 2 Okglcm2 185 t 28 psi lf compression islow checkfor the following lmpropervalve clearance Leakyvalves Leaking cylinder head gasket Wornpiston ring cylinder lf compression is high it indicatesthat carbon depositshave accumulated on the combustion chamber and orthe P iston crown CANIS...

Page 44: ...Make sure that the samealignment marks on both adiusting plates align with the ends of the swingarm Tighten theadjusting bolt locknuts Tighten therearaxlenut TOROUE 85 105 N m 8 5 10 5kg m 61 76 ft tb Recheck chainslack andfreewheelrotation Lubricate the drivechainwith SAE 80 or 90 gear o i l Checkthe chainwearlabel lf the redzoneon the labelalign or is beyond the rearendof theswing arm after the ...

Page 45: ... Removethe battery holder bolt then swingthe holderout of the waY Disconnect the negative cableat the battery then disconnect the positive cable Disconnectthe battery breather hose from the battery Pull the battery out removethe filler capsand adddistilledwaterto the upperlevelline Reinstall the fillercapsandthe battery NOTE Add only distilled water Tap water will shorten the service life of the b...

Page 46: ...f fluid asthey are not compatible Referto section16 for brakebleeding procedures BRAI E PAD II TAR Checkthe brakepadsfor wearby lookingthrough the slot indicatedby the arrowcaston the caliper assembly Replace the brakepadsif the wearlineon the pads reaches the edgeof the brakedisc page 16 5 CAUTION Always replace the brake pads in pairs to assureevendiscpreswre BRAIfi SYSTEM lnspectthe brake hoses...

Page 47: ...g screwclockwise to direct the beam toward the right side of the rider NOTE Adjust the headlightbeam as specifiedby locallawsandregulations CL JTC1 Checkthe clutchfluid reservoir level lf the level nearsthe lower level mark fill the reservoir with DOT 4BRAKE FLUID until the level isbetween the upperandlowerlevelmark Checkthe entiresystem for leaks if the levelis low CAUTION HORIZONTALADJUSTING SCR...

Page 48: ...estandlowerendwith a spring scale SlJSPENSION Do not ride a vehicle with faulty suspension Loose worn or damaged suspensionparts impair vehiclestability ond control F R O N T Checkthe actionof the front forksby compressing themseveral times Check the entirefork assembly for leaks or damage Replacedamagedcomponentswhich cannot be repa ired Tighten all nutsandbolts Check the front fork air pressure ...

Page 49: ...and Move the rear wheel sidewayswith force to seeif the swingarmbearings areworn Replacethe bearingsif there is any looseness page 15 14t Check theshock absorber for leaks ordamage Tighten allrear suspension nuts andbolts Remove the frameleft sidecover Removethe valve cap and measurethe shock absorber air pressure REARSHOCKABSORBER AIR PRESSURE 50 300 kPa 0 5 3 0 kglem2 7 43 psi NOTE Check the air...

Page 50: ...res if the treaddepth reaches the following limit Minimumtreaddepth Front 1 5mm 1 16in Rear 2 0mm 3 32in STIERIl O EAD BEARIl GS NOTE Check that the control cablesdo not inter ferewith handlebarrotation Raise the front wheel off the ground and check that the handlebarrotatesfreely lf the handlebar moves unevenly binds or has vertical movement adjust the steeringhead bearing by turning the steering...

Page 51: ...II E Nf f DA V45 INTER CEPTOR MAINTENANCE MEMO l I i l I I Dateof lssue October 1983 O HONDAMOTORCO LTD 3 21 ...

Page 52: ...IIOTVXDA V45 INTERGEPTOR FUEL SYSTEM fp 0 E 0 E c 0 DD tuo F F o D tr K a s 4 o Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 53: ...ntjet needles thinner andshortersprings thanthe No 2 andNo 4 carburetors Do not interchange theseparts TOOLS Special Valveguidedriver 7 mm Pressurepump Vacuumpump Common Floatlevelgauge SPECIFICATIONS 07942 823OOO0 U S A only ST AH 255 MC7 U S A only ST AH 260 MC7 U S A only 07401 0010000 Gasoline is extemely flommable and is explosive under certain conditions Work in a v ell ventiloted area Do no...

Page 54: ...the fairing Disconnectthe breatherhose and removethe air cleaner case by removing fivescrews Remove the heatinsulator plate Disconnect the choke andthrottle cables from the carburetor Loosenall carburetorbandsand removethe car buretorassembly from the intakepipes AIR CLEANER CASE CHOKE CABLE THROTTLECABLES 4 3 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 55: ...umchambercovers springs pistonsor iet needles betweencar buretors Removethe compression spring diaphragm and vacuum piston Inspect the vacuum pistonfor wear nicks scratchesl or otherdamage Makesurethe pistonmoves up anddown freelyin thechamber NOTE No 1 and No 3 carburetors usethinnerjet needles andshortersprings thanthe No 2 and No 4 carburetors COMPRESSION SPRING COVER 4 4 DIAPHRAGM Dateof lssue...

Page 56: ... diaphragm asfollows Insertthe vacuumpistoninto the carburetor Stick your finger into the carburetorbore and hold the vacuumpiston in the full throttle position then turn down the diaphragmso its lip fits into the carburetorgroove Installthe chambercover aligningits cavity with the hole in the carburetor and secure with at least two screws beforereleasing the vacuumpiston NOTE Be sure the thinner ...

Page 57: ...elwith the carburetor inclined 15 45 from vertical and the float tang just contacting the float valve FLOATLEVEL 7 0 mm 0 28in Adjustthe float levelby carefullybending the float tang FLOATANDJETS Remove the float pin float andfloat valve FLOAT LEVEL GAUGE 07401 0010000 FLOATCHAMBER SCREWS FLOAT FLOATPIN 4 6 Dateof lssue January 1983 HONDAMOTORCO LTD ...

Page 58: ...ainjet andslowjet Remove thefloatvalve seat andf ilter Inspectthe float valveseatand filter for grooves nicksor deoosits ASSEMBLY Assemblethe float chambercomponentsin the reverse orderof disassemblY FUEL SYSTEM MAINJET FLOATVALVE SEAT FILTE R VALVE SEAT VALVE SEAT FLOATVALVE STARTER JET 4 7 Dateof lssue January 1983 HONDAMOTORCO LTD ...

Page 59: ...rewplug to centerthe drillpoint Drill throughthe plugwith a 4 mm 5 32in drill bit beingcarefulnot to drill into the pilot screw CAUTION Be carefulnot to dill into the pilot screw All pilot screws mustbereplaced evenif only one requiresit for properpilot screwadjust ment page 4 16 Force a self tapping 4 mm screw H C 069399 P N 93903 35410 into the drilled plug and continueturning the screwdriver un...

Page 60: ...ATION Installthe pilot screws and returnthem to their original position asnotedduringremoval Performpilot screwadjustment if new pilot screws areinstalled page 4 16 NOTE Do not installnew plugsuntil afteradjust menthasbeenmade made lf you replace the pilot screwin onecar buretor you must replace the pilot screws in the other carburetors for properpilot screwadjustment CARBIJRETOR SEPARATION Remove...

Page 61: ...henseparate the No 2 carburetor CAUTION Separatethe carburetors horizontally to pre vent damageto thejoint pipes Disconnect the throttle link from the No 3 and 4 caburetors by removing the cotterpins SYNCHRONIZATION SPR INGS t I N o 2 CARBURETORSPR INGS A I R J O I N T N o 4 PIPES CARBURETOR CHOKE LEVERS ANDRODS CHOKE ROD No 1 CARBURETOR THROTTLE LINK 4 10 Dateof lssue January 1983 O HONDAMOTORCO ...

Page 62: ...ate the No 3 and No 4 carburetors Remove the chokearmcollarandremove the choke armandspring Remove thechokevalvenut springandvalve No 3 CARBURETOR CHOKEVALVE Checkthe chokevalve andspringfor nicks grooves or otherdamage NUT S P R I N G Dateof lssue January 1983 O HONDAMOTORCO LTD 4 1 1 ...

Page 63: ...w O rings with oil and install them on the fueljoint pipefor No 3 andNo 4 carburetors Install the fueljoint pipeto the No 3 andNo 4 carbu retors Reconnect the throttle linkage between the No 3 andNo 4 carburetors usingnewcotterpins F U E LJ O I N TP I P E T H R O T T L E L I N K S P R I N GC O L L A R NUT O R I N G S Pr l N o 4C A R B U R E T O wr iffin iffi COTTER PINS N o 3 C A R B U R E T O R 4...

Page 64: ...G N o 2 C A R B U R E T O R No 3 SYNCHRONIZATION No 1 CARBURETOR THRUST SPRING 3 CARBURETOR I N T I I I I I F U E LJ O Loosenthe synchronization adjustingscrews thereisno tension Install thesynchronization springs Installthe thrust springs between the throttle shafts Make sure the fuel securely installed joint and air joint pipesare until valve IZATIONSPRING No I SYNCHRONIZAT ON S P R I N G 4 13 D...

Page 65: ... chamber dowelpinsarein place funnels grommets and Place the air chamber overthe carburetors aligning the dowelpinswith the carburetor holes Attachthe air chamber to the carburetors with the eightscrews F U N N E L GROMMETS CHOKE RODS ANDLEVERS CHOKEROD DOWEL PINS 4 14 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 66: ...e is no drag when opening andclosing thethrottle Makesurethat chokevalveoperationis smoothby moving thechokelinkage Close the chokevalveby turningthechokelinkage Release the choke linkageand make surethat it returns smoothly CARBURETOR II STATIATIOl lnstallation isessentially the reverse of removal NOTE Routethe throttle and chokecables properly page 1 10 to 1 121 Performthe followinginspections a...

Page 67: ...its manufac turer sinstructions Adjust the idle speedwith the throttle stop screw IDLESPEED VF750F 1 000t 100rpm VF700F 1 200r 100rpm 5 Turn each oilot screw112turn out from the initialsetting lf the enginespeedincreases by 50 rpm or more turn eachpilot screwout by successive 1 2 turns until enginespeeddropsby 50 rpm or less Adjust the idle speedwith the throttle stop screw Turn the No 1 carbureto...

Page 68: ...o fuelleaks AIR CtTAl ER CASE CHAMBER Checkthe air cleaner casesealrubbers for deteriora tion CRAN KCASE VENTI LATION SYSTEM Check thatthe breather tubeisnot restricted A I R C L E A N E R C O V E R S E A LR U B B E R I N L E T A I R DUCTS e I R E L E M E N T S E A LR U B B E R SYSTEM B R E A T H E R SEPARATOR I u fl U 4 1 7 B R E A T H E R H O S E qSEALRUBBER A I R C L E A N E R C A S E Dateof ls...

Page 69: ...t the carburetormust be readjusted as follows to improvedriveabilityand decrease exhaust emissions NOTE This adlustment must be madeat high alti tudeto ensure properhighaltitude operation warm up the engineto operating temperature stop andgodrivingfor 10minutes issufficient Remove eachpilot screwplug page 4 8 Turn eachpilot screwclockwise1 turn Adjust the idle speed with the throttlestopscrew IDLE...

Page 70: ...r the instrument assembly Disconnect the PCVhoses fromthe 3 wayjoint the No 2 carburetor and the rightcharcoal canister Remove the PCVfrom itsmount Refer to the rout inglabelattached tothefueltankbelowtheseatfor hoseconnections Connecta vacuumpumpto the 8 mm LD hosethat goesto the 3 wayjoint Apply the specified vacuum to the PCV SPECIFIED VACUUM 250mm 9 8in Hg Thespecif iedvacuumshouldbemaintained...

Page 71: ...oesnotflow out CAUTION Rernove the pumps installthe PCVon its mount route and reconnectthe hoses accordingto the VacuumHoseRoutingLabel NOTE Be carefulnot to bend twist or kink the tubeswheninstalling Slidethe endof eachtubecompletely onto itsfittingandsecurewith the hoseclamps Securewith the hose clampswhenev er specif ied Check that the hosesare not contacting sharpedges or corners PRESSURE PUMP...

Page 72: ...If IOIS E A VII5 INTERCEPTOR FUEL SYST EM MEMO I U L 21 Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 73: ...L INSTALLATION 24 30N m 2 4 3 Oks m 17 22 ft lbl W r 50 54N m 5 0 5 4kg m 36 39ft rb N b W 35 45 N m 3 5 4 5 ks m 25 33 ft tb 35 45N m 3 5 4 5ks m 25 33ft lbl 45 55 N m 4 5 5 5 ks m 33 40 ft lb Dateof lssue January 1983 HONDAMOTORCO LTD 5 O ...

Page 74: ...mpounded siliconwax The followingpartsor components can be servicedwith the engineinstalledin the frame Clutch Gearshiftlinkage Frontcylinderhead SPECIFICATIONS Enginedry weight Oil capacity TOROUE VALUES Drive sprocketbolt Enginerear hangerbolts Enginecenterhangerbolts Enginefront hangerbolts Sub framebolts Alternator Starter motor Carburetors 81 5 kg 180 lb 83 84 3 0 liters 3 2U S qtz After 84 2...

Page 75: ...move the clutchslave cylinder NOTE Do not operate the clutchleverafterremoving the clutch slavecylinder lt will causedif ficulty when reinstallingthe slavecylinder Remove thegearshift armfrom the shiftshaft Disconnect the neutralswitchwire connectorand alternator wirecoupler Remove the drivesprocket cover CLUTCH SLAVECYLINDER G E A R S H I F T A R M ALTERNATOR WIRECOUPLER NEUTRAL SWITCH WIRECONNEC...

Page 76: ...et with the drivechain Removethe air cleanercaseand the carburetors page 4 3 Removethe sparkplug capsfrom the sparkplugs Remove the rightandleft mufflers ENGINEREMOVAL INSTALLATION DRIVESPROCKET BOLT D R I V E C H A I N AIR CLEANER CASE 5 3 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 77: ...tsideof the frame Remove the rearexhaust pipeclampbolts Removethe front exhaustpipe attachingnuts at thefront cylinder heads Remove the exhaust chamber from the engine Disconnect the starter motor motor cablefrom the starter ITONTT A V45 INTER CEPTOR BOLT REAREXHAUST PIPE CLAMPBOLTS BOLT STARTER MOTOR CABLE 5 4 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 78: ...ousing Disconnectthe battery negativecable from the battery terminal Freethe starter motorcable fromtheclamp Placethe floor jack or other adjustable support underthe engine NOTE The jack heightmust be continuously adjust ed to relievestress from boltsthat arebeing removed Removethe enginehangerboltsfrom the right side Removethe f rame to sub irame bolt THERMOSTAT HOUSING 5 5 Dateof lssue January 1...

Page 79: ...r theengine intoplace CAUTION Carefully align mounting points with the iack to prevent damngeto mounting bolt threads and wire harness and cables Tightenall fasteners to the torquevalues givenon page5 1 NOTE Routethe wiresandcables properly pages 1 1 0 t h r u1 12 Fill the crankcase to the properlevelwith the recommended oil Page 2 1 Fillthecooling system Page 5 3 Performthe followinginspection an...

Page 80: ...ffithffrrcrA 4 rl 1ffilEPtoR ENGI NE REMOVAil MSTALLAT IOfiI MEMO I U S Date of lssue l nuary 1983 O HONDA MOTOR EO LTD ...

Page 81: ...IIONTf A V45 INTER CEPTOR COOLINGSYSTEM 6 O Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 82: ...typumpmechanical seal 2 Deteriorated O rings Engine temperature too high 1 Faultytemperature gauge or gauge sensor 2 Thermostat stuckclosed 3 Faultyradiator cap 4 Insuf ficientcoolant 5 Passages blocked in radiator hoses or waterjacket 6 Fanblades bent 7 Faultyfanmotor Do not remoye the radiator cap when the engineis hot The coolant is under pressureond severe scoldingcould result Theenginemust be...

Page 83: ... hold specified pressure for at leastsixseconds NOTE Beforeinstalling the capon the tester apply waterto sealing surfaces RADIATOR CAPRELIEFPRESSURE 75 105 kPa 0 75 1 05kg cm2 10 7 14 9 psil Pressurize the radiator engineand hoses and check for leaks CAUTION Excessivepressure can damage the radistor Do not exceed1 05 kglcm2 14 9 psi Repairor replacecomponentsif the systemwill nor hold specified pr...

Page 84: ...overand cylinder heads Replace thedrainplugandbolts Fill the system with a 50 50 mixtureof distilled waterandethylene glycol Bleed airfromthe radiator Start the engine and run until thereare no air bubblesin the coolant and the levelstabilizes o Stoptheengine andaddcoolant up to the proper levelif necessary o Reinstall the radiator cap o Checkthe levelof coolantin the reserve tank and fill to the ...

Page 85: ...ersand fuel tank Drainthecoolant page 6 3 Disconnect the temperature sensorwire connector from the sensor Removethe thermostat two bolts housingcoverby removing Remove the thermostat from the housing WIRECONNECTOR TEMPERATURE SENSOB THERMOSTAT HOUSING COVE R HOUSING 6 4 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 86: ... to B4oc 176 183 F Valvelift 8 mm minimum 0 31in whenheated to gSoC 203 F for fiveminutes INSTALLATION Installthe thermostat into the housing Install the thermostathousingcover with a new O ring Connect the temperaturesensorwire connector Installthe fuel tank frame side coversand seat Fill the coolingsystem page 6 3 RAoTAT0R C00U1 G FAl REMOVAL Removethe lowerradiatorcowl and radiatordrain plugand...

Page 87: ...nnectthe joint hosefrom the upperradiator Remove the fairing page 14 3 Disconnect the fan motor wire couplersfrom the mainharness at the rightside Remove the upperradiatormountboltsandremove the radiatorfrom theframe RADIATOR GRILLE RADIATOR SIDE COVERS RADIATOR OVERFLOW TUBE 1 HOSE CLAMP 6 6 MOUNT BOLTS Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 88: ...or Loosenthe lower hoseclamp and lowerhose disconnect the disconnect the Disconnect the wiresfrom the thermostatic switch Remove the lowerradiatormount bolt and remove the radiatorfrom the bracket DISASSEMB LY Remove the fan shrouds with the fansandmotors THERMOSTATIC SWITCH 6 7 Dateof lssue Januarv 1983 O HONDAMOTOR CO LTD ...

Page 89: ...e shroudby remov ingthe threescrews RADIATOR INSPECTION Inspectthe radiatorsoldered joints and seams for leaks Blow dirt out from betweencore fins with com pressed air lf insects etc areclogging the radiator washthemoff with low pressure water FANSHROUD NUT FANMOTOR 6 8 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 90: ... water pump as an assemblyif the mechanical sealis leaking R E M O V A L Drainthecoolant page 6 3 Remove theclutchslave cylinder NOTE Do not operatethe clutch leverafter removing the clutch slavecylinder To do so will cause difficulty in reinstallingthe slave cylinder Removethe gearshiftarm from the shift shaft Remove the drivesprocket cover ryq WATER PUMP T E L L T A L E H O L E CLUTCH SLAVECYLIN...

Page 91: ... off the water pump from the crankcase Removethe water pipe from the water pump INSPECTION Checkthe water pump for mechanical sealleakage andbearing deterioration Replace the waterpumpasanassembly if necessary PIPE CLAMP HOSE BANDS WATER PIPE WATERPUMP WATER O R I N G PUMP ASSEMBLY O R I N G COVER BOLTS WATER PUMP COVER WATERHOSE DRAINBOLT 6 1 0 Dateof lssue October 1983 OHONDAMOTORCO LTD ...

Page 92: ...erthe endof the waterpipe Connect the waterpipeto thepumphose andwater pipecap Installthe dowelpinsand installa new O ringin the groove of thewaterpumpcover Installthe waterpumpcoverandtorquethe bolts Connect the waterinlethose lnstallthe drive sprocketcover gearshiftarm and clutchslave cYlinder Fillthecooling system page 6 3 GROOVE WATERPIPECAP O RING WATERPIPE O ring t he oil in t h e WATERPUMP ...

Page 93: ...ITOilTDA V45 INTERCEPTOR CLUTCH SYSTEM dw V 6 W 6 cm tb g 4 7 N m 40 70 kg 35 61 in op k 7 O Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 94: ...TCHFLUID REPLACEMENT A I R B L E E D I N G CLUTCHMASTERCYLINDER CLUTCHSLAVE CYLINDER CLUTCHCOVERREMOVAL 7_1O STARTERCLUTCHDISASSEMBLY 7_1O CLUTCHDISASSEMBLY 7_12 CLUTCHASSEMBLY 7 17 STARTERCLUTCHASSEMBLY 7_20 CLUTCHCOVER INSTALLATION 7 22 7 2 7 3 74 7 5 7 8 19 22 ttlbl 7 1 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 95: ...0 07716 0020500 l 07716 0020399 J or equivalent in U S A 07749 001 0000 07746 0010200 07746 0040800 07725 0030000 STANDARD S E R V I C E L I M I T Clutchmaster cylinder Cylinder l D 14 000 14 043 mm 0 5512 0 5524 in 14 06 mm 0 553 in Piston O D 13 957 13 984 mm 0 5495 0 5506 in 13 94 mm 0 549 in Clutchslave cylinder Cylinder l D 38 100 38 162 mm 1 5000 1 5024 inl 38 18 mm 1 503 in Piston O D 38 03...

Page 96: ...will not disengage 1 Air bubbles in hydraulic system 2 Low fluid level 3 Hydraulic system leaking 4 Hydraulic system sticking 5 Plates warped Motocyclecreeps with clutch disengaged 1 Air bubbles in hydraulic system 2 Low fluid level 3 Hydraulic system leaking 4 Hydraulic system sticking 5 Plates warped Excessive leverpressure 1 Hydraulic system sticking 2 Liftermechanism damaged Clutchoperationfee...

Page 97: ...differenttypesof f luid sincethev may not be compatible Close the bleed valve fill the reservoir and install the diaphragm To prevent piston overtraveland clutch fluid see page keep a 20 mm l3l4 inl spacer between the handlebargrip and lever when bleedingthe clutch system Pump up the systempressure with the lever until there are no air bubbles in the fluid flowing out of the reservoir smallhole an...

Page 98: ...Tighten the bleed valve TOROUE 4 7 N m 0 4 0 7ks m 35 61in lb Fillthefluidreservoir to theupper level CLUTCH ASTER CYLINOER DISASSEMBLY Drain clutch fluid from the hydraulic system Removethe rearview mirror and clutch lever Disconnect the clutch switch wires and remove the clutch hose cAUTtOr Avoid spilling clutch fluid on painted surfaces Place a rag over the fuel tank whenever the clutch systemi...

Page 99: ...D Check the mastercylinderfor scores scratcnes or nicks SERVICE LIMIT 14 06 mm 0 553 in M A S T E R P I S T O NO D I N S P E C T I O N Measure themaster oistonO D SERVICE LIMIT 13 94 mm 0 549 in Checkthe primaryandsecondary cupsfor damage before assemblv LUTCHMASTER C Y L I N D E R CLUTCH SWITCH w i P R I M A R Y C U P S P R I N G I sEcoNDARY N cup w l _ PlsToN Dateof lssue January 1983 HONDAMOTOR...

Page 100: ...all the holder with the UP markfacing up and the two mountingbolts Align the mark of the holderwith the handlebar punchmark Tighten the top bolt first then the bottom bolt Install the oil hosewith the boltanditstwo sealing washers Installthe pushrod end pieceinto the clutch lever holeandinstallthe clutchlever Connect the clutch switch wires to the switch terminals Fill the reservoirand bleed the c...

Page 101: ...ard placea shoptowel over the pistonto cushion the pistonwhenit isexpelled and position the cylinder with the piston down Apply compressed air to the fluid inletto remove thepiston Usetheair in shortspurts Remove the spring fromthe slave cylinder Remove theoil andpistonseals Clean the pistongroove with clutchfluid Check the piston spring for weakness or damage PISTO AIR NOZZLE S P R I N G N SEAL S...

Page 102: ...erbore SERVICE LIMIT 38 18mm 1 503 inl ASSEMBLY Assemble the slave cylinderin the reverse orderof disassembly The oil sealsmust be replaced with newoneswhenever thev havebeenremoved Lubricate the pistonandpistonseal with a medium gradeof Hi Temperature silicone grease or brake fluidbefore assembly Be certainthe piston sealis seatedin the piston groove Placethe piston in the cylinderwith the sealen...

Page 103: ...page 7 4 CLUTC COI ER REil Ot AL Drain theengine oil Remove the clutchcover gasket anddowelpins STARTER CLUTCI DISASSEMBTY Remove the starteridlegearshaftandgear Remove the idlergearby rotatingthe starter clutch clockwisewith a wrench or by rotatingthe idler gear clockwiseto turn the starter motor shaft counte iclockwise CLUTCH COVER A R T E RI D L E RG E 7 1 0 Dateof lssue January 1983 HONDAMOTOR...

Page 104: ...ing from the starterclutch lnspect the rollersfor smoothoperation Remove the starter clutch cover by removing thethreebolts Removethe clutch rollers plungers and springs Checkthe rollersfor excessive wear CLUTCH SYSTEM GEARHOLDER07924 MC7OOO2 or modified 07924 MC7 O001 or 07924 MC7 O000 or 079244 1SOOOO P R I M A R Y D R I V E N S U BG E A R P R I M A R Y D R I V E G E A R d d s p d STARTERCLUTCHC...

Page 105: ...t the transmission rearbrake NOTE lf the engineis not in the frame shift the transmission into gear and usethe universal holder 07725 0030000 to hold the drive sprocket Remove the lock nut andlockwasher Removethe clutch springset plate clutch spring andtwo washers 5th gearand applythe SNAPRING LOCKNUTWRENCH 17 x27 mm 07716 00203000 R EOUIVALENT BEAR ING into EXTENSION IN U S A C L U T C H L I F T ...

Page 106: ...sure Plate Remove the clutchplates anddiscs RemoveclutchcenterB an assembly andthe one wayclutch as f DISCS AND PLATES TCHCENTER B ONEWAY C CLUTCH CENTER A Remove clutchcenterA andwasher r I h CLUTCH PRESSURE PLATE 7 1 3 Dateof lssue January 1983 HONDAMOTORCO LTD ...

Page 107: ...m 0 15in Replace the springif it is shorterthan the service limit CLUTCH DISC Replacethe clutch discsif they show signsof scoring or discoloration Measure thethickness of each disc SERVICE LIMIT 3 1mm 0 12in Replace any discsthat arethinnerthan the service limit CLUTCH OUTER C L U T C H O U T E R G U I D E 7 1 4 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 108: ...eeler gauge SERVICE LIMIT 0 30mm 0 012 inl ONEWAYCI IJTCHINSPECTION Inspectthe one way clutch for smoothoperation Checkthe rollers for excessive wear Measure the l D of clutchcenter B SERVICE LIMIT 74 47mm 2 932in CLUTCH SYSTEM usrng 7 1 5 Dateof lssue January 1983 O HONDAMOTOR CO LTD ...

Page 109: ...e cltrtch outer or excessive play clutch outer for nicks cuts the friction discs needlebearingfor damage lf the needle bearing isdifficult to remove from clutchhousing usethefollowing tools Driver 07749 0010000 Attachment 37 x 40 mm O7746 0010200 Pilot 35 mm O77 46 0040800 O C L U T C HO U T E R G U I D E Measure the l D of the clut chout erguide SERVTCELIMIT 25 08m m 0 987in tne Dateof lssue Janu...

Page 110: ...guide lnstallclutchcenterA andthe washer Placethe clutch center B with the groovedside facingdown Installthe one way clutch into the clutchcenterB with itsflanged cage facinguP Installthe clutchinnerintothe one way clutchwith its grooves facingup Turn it counterclockwise as you installit CLUTCHOUTER CLUTCHCENTERA CLUTCH OUTERGUIDE WASHER GROOVES NTERB OIL PUMPDRIVESPROCKET CLUTCH ONE WAY CLUTCH CL...

Page 111: ...blyis installed correctly by turning the clutch centerB Theclutchcentershouldturn clock wise freely and should not turn counter clockwise Coat the discs and plateswith clean andinstallthem engineoil lnstallthe clutchpressure plate CLUTCHCENTERB Turnsclockwise ONE WAY CLUTCH CLUTCHPRESSURE PLATE 7 1 4 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 112: ...ck washerwith its dishedfacetowards the inside Place the transmission in 5th gear NOTE lf servicing the clutch with the engineout of the frame shift the transmission into gear and hold the drive sprocket with the HOLDER07725 0030000 TOROUE 62 68 N m 6 2 6 8ks m 45 49 ft lb r I f LOCKWASHER LOCKNUTWR 1 7x 2 7 m m o7716 0020300 0R EOUTVALENT tN U S A 7 1 9 Dateof lssue January 1983 OHONDA MOTORCO LT...

Page 113: ...the snaP ring STARTER CTUTCI ASSTMBLY Installthe primarydrive gearonto the crankshaft while movingthe primarydrivengearwith a screw driver lnstallthe thrustwasher on thecrankshaft L I F T E R P L A T E B E A R I N G L I F T E R G U I D E SNAPRING P R I M A R Y D R I V EG E A R THRUST WASHER 7 2o Dateof lssue Januarv 1983 O HONDAMOTORCO LTD ...

Page 114: ...th the dowelpin andtightenthe bolts TOROUE 26 30 N m 2 6 3 0 kg m 19 22 ft lbl NOTE Apply a locking agentto the bolt threads Installthe starterdrivengearby turningit clockwise Align the punch markson the starterclutchand crankshaft andinstallthe starterclutch R O L L E R PLUNGER DOWEL PIN STARTER DRIVERGEAR CLUTCH COVER PUNCH MARKS 7 2 1 Dateof lssue January 1983 HONDAMOTORCO LTD ...

Page 115: ...80 100 N m 8 0 10 0 ks m 58 72 ft lb Installthe starteridlergearandshaft CTUTC COI ER IIISTALIATIOl Install thedowelpinsanda newgasket GEARHOLDER07924 MC70OO2 or modified 07924 MC7 O00 1 or 07924 MC7 0000or 07924 41 5O0O0 STARTER CLUTCH ij IDLERGEARSHAFT STARTER IDLERGEAR DOWEL PINS 7 22 Dateof lssue January 1983 OHONDAMOTOR CO LTD ...

Page 116: ...IIONIf DA V45 INTER CEPTOR CLUTCH SYSTEM UTCHCOVER Instal I the clutch cover Fill the crankcase wit h oil page 2 3 7 23 Dateof lssue January 1983 O HONDAMOTOR CO LTD ...

Page 117: ...IIOilTf DA V45 INTERCEPTOR GEARSHIFT LINKAGE w nP r nw W wb 8 O Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 118: ... engine andseparate the crankcase TRoUBt tSH0oTtl C Hardto shift 1 Air bubbles in theclutchhydraulic system 2 Shift forksbent 3 Shift clawbent 4 Shiftdrum camgrooves damaged Transmission jumpsout of gear 1 Geardogsworn 2 Shiftshaftbent 3 Shiftdrum stopperbroken 4 Shiftforksbent SERVICEINFORMATION TROUBLESHOOTING GEARSHIFT LINKAGEREMOVAL GEARSHIFT LINKAGEINSTALLATION 8 1 8 1 8 2 8 4 8 1 Dateof lssu...

Page 119: ...lutch assembly Section7 Remove theoil pumpdrivensprocket bolt Remove the oil pumpdrivechain driveanddriven sorockets Removethe drum stopper collar andarm arm nut washer spring G E A R S H I F T A R M SHIFTSHAFT O I LP U M P D RI V E R I V ES P R O C K E T O I LP U M P D R I V E N S P R O C K E TB O L DRUMSTOPPER ARM 8 2 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 120: ...sher Pullthe gearshift spindle assembly out of the crank case WW G E A R S H I F T S P I N D L E Remove the neutral stopper springand washer arm bolt arm and TAB WASHER N E U T R A L S T O P P E R A R M ARM BOLT 8 3 Dateof lssue JanuarV 1983 O HONDAMOTOR CO LTD ...

Page 121: ... thefivepinsin t e holes of thecamplate Alignthe camplateholewith the dowelpinon the shiftdrumandinstall the camplate Tighten the boltsecurely Installthe washer neutralstopperarm springand armbolt Tightenthe armbolt securely CAMPLATE HOLE ARM BOLT SHIFTDRUMCAMPLATE D O W E L P I N N E U T R A L S T O P P E R A R M a 4 S P R I N G Dateof lssue January 1983 O HONDAMOTOR CO LTD ...

Page 122: ... washeronto the stopperarm bolt Installthe drum stopperarm collar spring washer andnut overthe armbolt Tightenthe nut securely Rotatethe gearshift spindleand checkthe linkage for smoothoperation R E T U R N S P R I N G G E A R S H I F T S P I N D L E TABWASHER DRUMSTOPPER ARM 8 5 Dateof lssue January 1983 O HONDAMOTOR CO LTD ...

Page 123: ...t hasan lN mark that mustfacethe crankcase Installthe clutchassembly andcover section 7 Align the punch marks on the gearshift arm and gearshift spindleand installthegearshift armon the shiftshaft Fill the crankcase with recommended oil page 2 3 G E A R S H I F T A R M SHIFT SHAFT O I LP U M P D R I V E DRIVENSPROCKET BOLT 8 6 Dateof lssue January 1983 O HONDAMOTOR CO LTD ...

Page 124: ...TflCTTTf DA V45 INTERCEPTOR GEARSHIFT LINKAGE MEMO Dateof lssue January 1983 O HONDAMOTORCO LTD 8 7 ...

Page 125: ...IIONTf DA V45 INTER CEPTOR ALTERNATOR 80 100N m 8 0 10 0 ks m 58 72 ft tb 9 O Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 126: ...section covers removal andinstallation of the alternator Referto section17 for troubleshooting andinspection of the alternator 80 100 N m 8 0 10 0 kg m 58 72ft lb 07725 0040000 07733 0020001 or07933 3290001 SERVICEINFORMATION FLYWHEELREMOVAL STATORREMOVAL STATOR INSTALLATION FLYWHEELINSTALLATION 9 1 9 2 9 3 9 3 9 3 9 1 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 127: ...over Hold the flywheelwith the flywheel holder and remove the flywheelbolt Remove the flywheelwith the rotor puller Remove the woodruffkeVfrom the crankshaft R O T O R P U L L E R 07733 00200010R F L Y W H E E L H O L D E R 07725 0040000 A L T E R N A T O R C O V E R F L Y W H E E L B O L T 9 2 Dateof lssue January 1983 O HONDAMOTOR CO LTD ...

Page 128: ...p and connectthe alternatorwire couplerto themainharness lnstallthe frameleft sidecover TLY J ETL I STATLATIO N Installthe woodruffkey intothe crankshaft lnstallthe flywheelby aligning its keyway with the key in the crankshaft Hold the flywheelwith the flywheel holder and torquethe flywheelbolt TOROUE 80 100 N m 8 0 10 0 ks m 58 72 ft lb lnstallthe alternator cover Checkengineoil leveland add if n...

Page 129: ...1 2 N m 16 d 6 Y u 9w x 21 25N m 2 1 2 5 kg m 45 50 N m t r h he flf ru ffi fu r J llrF hp 18 20 N m 1 8 2 0kg m 13 14 ft lb g 5 u w 38 42 N m 10 14N m 1 0 1 4kg m 7 10 ft lb 10 o 3 8 4 2 kg m 27 30 ft lb Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 130: ... N T LEFT S P E C I F I C A T I O N S c o o o STANDARD S E R V I C E L I M I T Compression pressure 1 300 t 200kPa 113 x 2 kglcm2 184 28Psi Camshaft Cam height I N 35 335 35 495 mm 1 391 1 1 3974in 35 3mm 1 39in EX 35 335 35 495 mm 1 391 1 1 3974 in 35 3 mm 1 39 in Runout 0 10mm 0 004 in End clearance 0 05 0 25 mm 0 002 0 010 in 0 30mm 0 012 in Oil clearance Center 0 131 0 191 mm 0 0052 0 0075 in ...

Page 131: ...nding rod or stethoscope Low compression 1 Valves Incorrect valve adjustment Burned or bentvalves Incorrect valve timing Broken valve spring 2 Cylinder head Leaking or damaged headgasket Warped or cracked cvlinderhead 3 Cylinder andpiston Refer to Section 12 8 12 N m 0 8 1 2ks m 6 9ft lb 10 14N m 1 0 1 4 ks m 7 10ft tb 21 25 N m 2 1 2 5kg m 15 18 ft lb 38 42 N m 3 8 4 2kg m 27 30ft lb 21 25 N m 2 ...

Page 132: ...sidecoversandfuel tank Remove the rearcylinderheadcover Remove the oil line andcamchainguiderhounting bolts andthe camchainguide Removethe alternatorcoverand rotatethe crank shaftcounterclockwise until the camchainhasfree play Remove the oil line by pullingup the middleof the chain Remove the alternator cover F R O N T C Y L I N D E R H E A DC O V E R REARCYLINDER HEADCOVER CAMCHAINGUIDE 10 3 Date...

Page 133: ...r cylinder cam sprocket bolts Turnthe crankshaft counterclockwise until theT2 4 markalignswith the rearcrankcase matingsurface Cleanthe camshaft sprockets with contactcleaner Index the front cylinder camshaftsprockets with the top of the cylinder head Use a water proof maker NOTE Some camshaftsprocketsmay have perma nent indexdotsasshownandwill not require marking Slidethe cam sprockets andchains ...

Page 134: ...CAMSHAFT CAM I N S P E C T I O N Inspect the camshaft for scoring scraches lubrication H O L D E R and holder journal surfaces or evidence of insufficient C A M S H A F T R U N O U T Checkcamshaftrunout with a dial indicator Support both ends of the camshaftwith V blocks Use 112of the total indicatorreadingto determine runout SERVICELIMIT 0 10 m m 0 004in CAMSHAFT HOLDER 10 5 Dateof lssue January ...

Page 135: ... of each camshaft journal Install the camshaftholdersand tighten in a crisscross pattern NOTE Do not rotate the camshaft when using plastigauge The camshaft holderboltsin each corner of the cylinderheadare longerthan the others B ffi TOROUE A 6mm BOLT B 8 mm BOLT C 9 mm BOLT 10 14 N m 1 0 1 4kg m 7 10 ft lb 21 25 N m 2 1 25 kg m 15 18 ft lbl 38 42 N m 3 8 4 2ks m 27 30 ft lb PLASTIGAUGE 10 6 Dateo...

Page 136: ...linderhead and camshaft holders if theclearance stillexceeds service limits CYLII DER I TAD RE OI AL NOTE The front cylinderheadcan be removed with the engineinstalled But to removethe rear cylinder head you must removethe engine Loosen thewaterhoseclamps Remove the waterpipesandhoses Remove the waterpipeO rings Remove the oil pipeandsealing washers CAMCHAINTENSIONER BASE Removethe front and rearc...

Page 137: ...IONER BASE P I N Remove the slipperclip washer andpin andremove thetensioner base Flemove thecylinder headbolts Removethe cylinderheadsusinga screwdriver at the pry points Removethe front anddowelpins and reai cylinder head gaskets PRY POINT DOWEL PINS 10 a Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 138: ...or excessive wear Inspectthe cam chain tensionerslipperfor damage or excesslve wear Inspect the spring for good tension replace if necessary Remove the rockerarmshaftandrockerarms Removethe rocker arm spring and O ring from the shaftbolt FRONTCYLINDER CAM CHAINSLIPPER BASE ry b REARCYLINDER CAM C H A I NG U I D E F R O N T C Y L I N D E R C A MC H A I NG U I D E T E N S I O N E R S L I P P E R CYL...

Page 139: ... Mark all disassembled partsto ensure correct reassembly Remove the valve stemseals Remove carbon deposits from the combustion chamberand cleanoff the head gasketsurfaces NOTE Gaskets will come off easier if soaked in solvent CAUTION Do not damagethegasketsurfaces C Y L I N D E R H E A DI N S P E C T I O N Checkthe sparkplug hole and valveareas for cracks Checkthe cylinderhead for warpagewith a st...

Page 140: ... E C T I O N Measure eachrockerarm shaftO D SERVICE LIMIT 11 93m m 0 470in Inspectthe shaft for wear or damageand calculate the shaftto rockerarm clearance SERVICE LIMIT 0 12 m m 0 005in Inspect the rocker arm shaft spring for wear or damage VALVESPRI NGINSPECTION Measure the freelengthof the innerandoutervalve springs S E R V I C E L I M I T INNER lN EX 40 25mm 1 58in OUTER lN EX 42 23mm 1 66in C...

Page 141: ...tract each valve stem O D from the corres pondingguide LD to obtainthe stem to guide clearance SERVICE LIMIT lN 0 08mm 0 003 in EX 0 10mm 0 004 in lf the stem to guide clearanceexceedsthe service limitswith new guides replace the valves NOTE Reface the valve seats whenever the valve guidesare replaced page10 13 burning scratches guide and measure V A L V EG U I D ER E A M E R 07984 2000000 NOTE lf...

Page 142: ...f NOTE Cylinder head heat should still be at 100 C 212 Fl for installation of the new guides Let the cylinder head cool to room temperature andreamthe newvalveguides NOTE Usecuttingoil on the reamer duringthis operation Rotate the reamerin the samedirection wheninserting andremoving Reface the valve seats page 10 14 and clean the cylinder head thoroughly to remove any metal oarticles V A L V EG U ...

Page 143: ...rly the valvemust bereplaced lnsoect the valveseat lf the seatistoo wide too narrow or haslow spots the seatmustbeground NOTE Follow the refacermanufacturer s operating instructions SEAT WIDTH 0 99 1 27 mm 0 039 0 050 in S E R V I C E L I M I T 1 5mm 0 06in After cutting the seat to the valve face and Dressure After lapping washany cylinder headandvalve apply lapping compound lap the valve using l...

Page 144: ... retainers The springls tightly wound coils shouldfacetoward the head Install thevalve cotters cAuTtot To prevent a loss of tension do not com press the valvespring more than necessaryto install the valvekeepers Tap the valvestemsgentlywith a soft hammerto f irmly seatthecotters NOTE Supportthe cylinderheadabovethe work bench surface to prevent possible valve damage f r if 1 il VALVE COTTERS x VAL...

Page 145: ...m 33 36 ft lb CYLII DER IEAD I STATLATION Clean the cylinder head surfaceof any gasket material Installthe rearcylindercam chainguidewith the washer andclip Install thefrontcylinder camchainguide Installthe front cylindercam chainslipperbase NOTE Be careful not to drop the washer clip or bolts into the crankcase R E A RC Y L I N D E R F R O N T C Y L I N D E R C A MC H A I NG U I D E R O C K E R A...

Page 146: ...aseand t ensioner Place the cVlinder headon t he cylinder Passthe cam chain through the cam chaintensioner and installthe tensionerslipperasshown NOTE CYLINDERHEAD VALVE TENSIONER BASE M F T E N S I O N E R GASKET DOWEL PINS Check that the lower end o in the slipperbasecorrectlY T E N S 1 O N E R S L I P P E R C L I P P I N TENSIONER BASE 10 17 Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 147: ...the speci fied torque after all cylinderheadbolts are instal led Installthe exterioroil pipe cylinderand cylinderhead Installthe water pipes hose clamps securely with washersonto the and hosesand tighten the I O I LP I P E CYLINDER HEADBOLTS il1 WATERHOSES WATERPI 1 0 1 8 Dateof lssue January 1983 HONDAMOTOR CO LTD ...

Page 148: ...xhaust IN FR IF Front cylinder intake Thecamshaftsprocketsare interchangeable CAMSHATT I1 STALLATION Lubricatethe cylinder headcam bearingsurfaces with molybdenum disulfide grease Rear Cylinder Camshafts Turn the crankshaft couterclockwise until the T1 3 mark on the flywheel rotor alignswith the rear crankcase matingsurfaces CAUTION When tuming the crankshaft make sure the cam chains don t jam at ...

Page 149: ...shaft from seatingfully in the cylinderhead back the adjuster out allthe way CAUTION If you force a valve open while installing the camshaftholders you may damage the holers or the camshaftbearing surfaces Placethe camshaftholdersin the samelocations noted during removal The groovein the bottom of the holdermust alignwith the camshaft locating ridge Installthe camshaft holderbolts but do not tight...

Page 150: ...ire throughthe lock holes Checkthat the camshaftmarksare still facingup then align the sprocketindex lineswith the top of the rearcylinderhead Place the cam chainon the sprockets I N D E XL I N E S Slidethe sprockets onto the camshaftflanges and install the sprocketbolts in the exposedholes Checkthat tfre sprocketindex linesalignat T1 3 Unlockthe camchaintensioner SPROCKET BOLTS I N D E XL I 1o 21...

Page 151: ...e 90 degrees 1 4 turnl until the T2 4 mark aligns with the rear crankcase matingsurfaces CAUTION lilhen turningthe uankshaft makesurethe cam chain doesn t jam at the cam chain tensioner or at thecrankshaft lnstall the intake and exhaust camshaftsand sprocketsthrough the front cylinder cam chain asshown Turn the camshafts so the camshaft marksfaceup Rotate each front camshaftconterclockwise 45 degr...

Page 152: ...t T2 4 Unlockthecamchaintensioner 46 PINS P E R M A N E N T I N D E XD O T S O R N E WI N D E XM A R K o Valve TimingInspection Checkthe front to rear cylindercamshaft timing as follows o Whenthe T1 3 markaligns with the rearcrank casematingsurface the indexlineson all cam sprocketsshould align with the top of the cylinder heads o All camshaft markswill eitherfaceup or down Turn the crankshaftas r...

Page 153: ...4 N m 1 0 1 4kg m 7 10 ft lbl Lubricate the camlobeswith oil Adjustthe valve clearance page 3 8 lnstallthe newcylinderheadcovergasket NOTE Clean the gasket beforeapplying sealant Apply sealantto the cylinder head cover gasket Installthe rear cylinder headcover with its tabs facingforward and installthe front cylinderhead coverwith itstabsfacingdown Tightenthe cylinderheadcoverbolts TOROUE 8 12 N m...

Page 154: ...Dateof lssruc l JanuffV 1983 O HONDA MCFfOR G O LTD ...

Page 155: ...b 8 m m 21 25 N 2 1 2 5 15 1 m kg m 1 I t qq B o J 6 m m 10 14 N m 1 0 1 4ks m 7 10 ft lb bt 6 m m 10 14N m b 9 m m 30 34 N 3 0 3 4 bb h b b qb bb b g h 7 m ks m 22 25 ft 1 0 1 4ks m 7 10 ft tb 1 1 O Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 156: ...or Cylinder heads Startermotor TOROUE VALUES 9 mm bolt 8 mm bolt 6 mm bolt TOOLS Special Driver Common Attachment 52 x 55 mm Refer to section 2 Referto section2 Referto section 6 Referto section 7 Refer to section 8 Referto section 9 Refer to section 10 Referto section19 30 34N m 3 0 3 4 kg m 22 25 ft lb 21 25N m 2 1 2 5 kg m 15 18ft lb 10 14 N t t 0 1 4 kg m 7 10 ft lb 07949 3710000 07746 001 040...

Page 157: ...n kcase Remove the countershaft bearing cover Removethe neutralswitch cover and the switch pase 20 3 Removethe mainshaft thescrewandbolts bearing holderby removing Remove the uppercrankcase bolts NEUTRALSWITCH COVER n l m i i i i j i ii i i i i f r i i i COUNTERSHAFT BEARING COVER MAINSHAFIBEAR INGHOLDE R 1 1 2 Dateof lssue October 1983 HONDAMOTORCO LTD ...

Page 158: ...the crankcase Remove thefollowing parts Piston andconnecting rods Section 12 o Crankshaft Section 12 Shiftfork andshiftdrum Section 13 o Transmission Section 13 Drivethe countershaftbearingout of the case CRANKCASE ASSEMBTY Drivethe countershaft bearinginto the crankcase ATTACHMENT 52 x 55 mm 07746 0010400 D R I V E R 07949 3710000 COUNTERSHAFT BEAR ING Dateof lssue January 1983 O HONDAMOTORCO LTD...

Page 159: ... andshiftdrum Section 13 Transmission Section 13 o Crankshaft Section 12 o Piston andconnecting rods Section 12 Apply molybdenum disulfidegrease to the shift fork grooves of theM213 C4andCbgears C 5G E A R C4GEAR M2l3GEAR 1 1 4 Dateof lssue January 1983 O HONDAMOTOR CO LTD ...

Page 160: ...ll thedowelpin intothe lowercrankcase Assemble the crankcase halves aligning the shift forkswith the gears Tightenthe bolts to the specified torquevaluesin the sequence shown TOROUEVALUES 9 mm bolt 30 34 N m 3 0 3 4 kg m 22 25 ft lbl 8 mm bolt 21 25 N m 12 1 2 5ks m 14 18 ft lbl 6 mm bolt 10 14 N m 1 0 1 4ks m 7 10 ft lb Tightenthe bolts in a crisscross patternandin 2 3 steps mmBOLT 1 1 5 Dateof l...

Page 161: ...4 N m 1 0 1 4kg m 7 10 ft lb NOTE Make sure that the plain washers are under the 8 mm bolt headsandthe batteryground cableis underthe 6 mm bolt headasshown Install the mainshaft bearing screwandbolts holderandtighten the Install the neutralswitch and cover page20 3 Install the dowel pins and a new gasketon the countershaft bearing covermountingsurface MAINSHAFT BEAR INGHOLDER NEUTRAL SWITCH COVER ...

Page 162: ...CASE Apply grease to the countershaft oil seallip in the countershaftbearingcover then install it being carefulnot to damage the oil seallip COUNTERSHAFT BEARING COVER O I LS E A L 1 1 7 Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 163: ...IIOilTEDA V45 INTER CEPTOR CRANKSHAFT PISTON s f f i b 4ffi 22 2sr b b r FRoNr ffiPr D u 12 O Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 164: ... 03mm 0 001in Crankpin oil clearance 0 028 0 052 mm 0 001 1 0 0020 inl 0 08mm 0 003 in Mainjournal oil clearance 0 020 0 044 mm 0 0008 0 0017 in 0 06mm 0 002 in Cylinder t D 70 000 70 015 mm r2 755 2 756 inl 70 10 mm 2 76 inl Warpage 0 10mm 0 004 in Piston Ring to groove clearance Top 0 015 0 045mm 0 0006 0 0018 in 0 10mm 0 004 in Second 0 015 0 045 mm 0 0006 0 0018 in 0 10mm 0 004in Ring end gap ...

Page 165: ...nevencompression 1 Worncylinder or pistonring Excessivg smoke 1 Worncylinder pistonor pistonrings 2 lmproperly installed pistonrings 3 Damaged piston or cylinder Overheating 1 Excessive carbonbuild upon pistonhead 2 Blockedor restricted flow of coolant 3 Stickingthermostat Knockingor abnormal noise 1 Wornpistons andcylinders 2 Excessive carbonbuild upon pistonhead a 12 2 Dateof lssue January 1983 ...

Page 166: ...ions Pushthe connectingrods and thetop of the cylinderbores CAUTION pistonsout through On engines with high mileage inspect the cylinders for a ridge just above the htghest point of ring travel Any ridge must be re moved with an automotive type ridge reomer before removing the pistons to allow the pistons and rings to passthrough the cylinder B E A R I C Y L I N D E R W E A RR I D G E 12 3 Dateof ...

Page 167: ...their correct pistonposition P I S T O N P I S T O N R I N G I N S P E C T I O N Measure the pistonring to groove clearance SERVICE LIMIT 0 10mm 0 004 in TOP SECOND Remove the pistonringsandmarkthemto indicate thecorrect cylinder andpistonposition Clean the piston crown removingall oosr ts Inspect the pistonfor cracks or other the ring groovesfor excessive wear build up i carbon de damageand and c...

Page 168: ... Takemeasurements 10 mm 0 4in from the bottom and90 to thepistonpin hole SERVICE LIMIT 69 85mm 2 750 in Inspectthe cylinderboresfor wear or damage Measure the cylinderl D at threelevels in X andY axts SERVf CE LIMIT 70 10mm 12 76inl Calculate the piston to cylinder clearance SERVICE LIMIT 0 10mm 0 004 in Oversize pistons areavailable in thefollowing sizes 0 25 0 50 0 75and1 00mm f 12 5 Dateof lssu...

Page 169: ...Measure eachpistonpinO D SERVICE LIMIT 17 98 mm 0 70in Calculate the pistonpin to piston clearance SERVICE LIMIT 0 04mm 0 002in Measurethe connecting rod small end l D lf the readingexceeds the service limit replace the rod SERVICELIMIT 18 08m m 0 712in Dateof lssue January 1983 O HONDAMOTOR CO LTD 12 6 ...

Page 170: ...0 001 in C A M C H A I N L E N G T H I N S P E C T I O N Placethe cam chain on the camshaftsprockets with the indexlinespositioned asindicated Secureone camshaftsprocketand apply 13 kg 29lbs of tension to theother Then measure the distance between the indexlines assnown SERV CELIMIT 326 120 mm 12 84in NOTE The liidex lines should be parallelto each other Replace the camchainif it is longer thanthe...

Page 171: ...e oil hole in the main bearing journalof thecrankshaft Install the main bearings on the correctjournals in the lower crankcase then assemble and tighten the boltsevenlyin 2 3 steps in the sequence shown TOROUE VALUES 6 mm bolt 10 14N m 1 0 1 4kg m 7 10ft tb 9 mm boft 30 34 N m 3 0 3 4 kg m 22 25ft lbl NOTE Do not rotatethe crankshaft duringinspec tion Remove the lowercrankcase and measure the com ...

Page 172: ...bearingtabs should facetoward the exhaustports Rememberthe front and rear cylinder exhaustports faceopposite directions Installthe bearing capsand rods on the correct crankpins andtighten themevenly TOROUE 30 34 N m 3 0 3 4 kg m 22 25 llbl NOTE Do not rotate the cranksha t during inspec tion Removethe caps and measurethe compressed plastigauge on eachcrankpin O I L C L E A R A N C E S E R V I C E ...

Page 173: ...crankpin and rod codesto select the correct replacementbearing CRANKPI N O D CO DELETTER B 35 992 36 000 mm 35 984 35 992mm 35 976 35 984 mm z J o J 1 39 000 39 O08 mm E Yellow D Green C Brown 2 39 008 3 9 0 1 6m m D Greenl C Brown B Black 39 016 39 024 mm C Brown B Black A Blue BEARING INSERT THICKNESS A Blue 1 502 1 506 mm 0 0591 0 0593 in B Bfack 1 498 1 5O2 mm 0 0590 0 0b91in C Brown 1 494 1 4...

Page 174: ...70 35 976 35 984 11 4164 1 41671 39 000 39 O08 1 s354 1 53571 D Green c Brown B Black 39 008 39 016 1 5357 1 5361 C Brown B Black A Bluel c 39 016 39 024 1 5361 1 5364 B Black A Blu A Blue SELECTION TABLE ENGINE NO RCl5E2001587 U n i t m m i n l IiIAIN JOURNA c A s E l D 1 2 3 36 000 36 008 11 4173 1 41761 35 992 36 000 1 4170 1 41131 35 984 35 992 11 4167 1 41701 39 000 39 008 1 5354 1 5357 E Y l...

Page 175: ...nd 2 con nectingrods or No 3 and 4 connecting rodsin accordance with the selection table NOTE lt is not necessary to performthe weight selection between the No 1 and 3 or No 2 and4 connecting rods The o mark in the table indicates that the matchingis possiblein the crossed codes The cylindersarearranged in the orderof No 1 2 3 4 from thealternator side SELECTION TABLE WEIGHT CODE ALPHABETICAL CODE...

Page 176: ...rings theyshould rotate freely withoutsticking Coatthe rod ssmallendwith molybdenum disulfide grease Rearcylinders Note that the rear cylinder connectingrods are marked MBO F or MB2 R for the VF750F and MB1 F for theVF700 Installthe pistonson the rearconnectingrods so that the intake lN mark isfacing opposite theoil holein the rod TOP SECOND S I D ER A I L SPACER S I D ER A I L GAP R E A RC Y L I ...

Page 177: ... Do not interchangethe pistons piston pinsor connectingrods Make sure that the piston pin clips are properlyseated Align the hole in the connectingrod bearinginsert with the hole in the connectingrod and installthe insert Install theconnecting rod capbearing insert Apply molybdenum disulfidegrease to theconnect ingrod bearings CYLI NDER IDENTIFICATION MARK VF75OF shown V FTOOF M B 1 R O I LH O L E...

Page 178: ...pistonringswith a ring compressor andinsertthe pistonandrodintothecylinder until the rod seats on thecrankpin NOTE Becarefulnot to damage the pistonsor rings duringassembly Flipthe uppercrankcase over Install andtorquetheconnecting rodcaps TOROUE 30 34 N m 3 0 3 4 ks m 22 25ft lbl NOTE Be surethe bearingcapsare installed in their correct locationas markedduring removal Tighten thenutsin two or mor...

Page 179: ...EIOIVDA V45 INTER CEPTOR TRANSMISSION 21 25 N m 2 1 2 5ks m 15 18 ft tb 16 20N m 1 6 2 0 ks m 12 14ft lb Y I F rr t g q b lh m d A a 13 O Dateof lssue Januarv 1983 O HONDAMOTORCO LTD ...

Page 180: ...7 959 27 980 mm 1 1007 1 1016in 27 94mm 1 100 in Cl gear 25 959 25 980 mm11 3220 1 O228 inl 25 94mm 1 021in C2 C3gear 30 950 30 975 mm 1 2185 1 21 95 in 30 93 mm 1 218 in Gearbushing t D M4 24 995 25 01 6 mm 0 9840 0 9849 in 25 04mm 0 986 in c 1 22 020 22041 mm 0 8669 0 8678 in 22 06 mm 0 869 in Mainshaft O D at M4 24 97 7 24 990 mm 0 9833 0 9839in 24 92mm 0 981 in Countershaft O D atC1 21 97 9 22...

Page 181: ...mon Driver 07746 0030100 Attachment 25 mm 07746 00 0200 For oriver 07945 371o2o0 TROUBTES1 OOIIl G Hardto shift 1 Clutchslave cylindersticking 2 Shiftfork bent 3 Shift shaftbent 4 Shiftclawbent 5 Shiftdrumcamgrooves damaged Transmission jumpsout of gear 1 Geardogsworn 2 Shift shaftbent 3 Shiftdrumstopperbroken 4 Shiftforksbent 13 2 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 182: ... thedowelpinsfrom thecrankcase Inspect the backlash of eachgear SERVICE LIMIT lst 0 20mm 0 008inl 2nd 0 17mm 0 007in 3rd 4th Sth 0 18mm 0 007in Remove the mainshaft Remove the countershaft bearing holderbolts MAINSHAFT COUNTERSHAFT BEARING HOLDER 13 3 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 183: ... evidence of insufficient lubrication Measure the l D of eachgear SERVICE LIMIT M4 M5 gear 28 04mm 1 104in Cl gear 26 04mm 1 025in C2 C3 gear 31 04 mm 11 222inl Measure the O D of the gearbushings SERVICE LIMIT M4 M5 27 94mm 1 100in Cl 25 94mm 1 021in C2 C3t 30 93mm 1 218in Calculatethe clearance betweenthe gearbushings andthe gears SERVICE LIMIT M4 M5 0 10mm 0 004in G l 0 10mm 0 004 in C2 C3 0 11...

Page 184: ...m 0 869in rd Measure theO D of themainshaft andcountershaft SERVICE LIMIT Mainshaft atM4bushing 2492mm 0 981 inl Countershaft atC1bushingl 21 96 mm 0 865 inl Calculate the clearance between the bushing and shaft SERVICE LIMIT M4bushing to haft 0 06mm 0 002in C1bushing toshaft 0 10mm 0 004 in 13 5 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 185: ...the bearing stopperplates Remove the shiftdrum G E A R S H I F T D R U M A N DS H I F T FORKINSPECTION lnspectthe shift drum end for scoring scratches or evidence of insufficient lubrication Checkthe shiftdrumgrooves for damage R I G H TF O R K C E N T E R F O R K L E F T F O R K LOCKWASHER FORKSHAFT S H I F TD R U M ffi BEARING STOPPER PLATES 13 6 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 186: ...es Measure the shift fork shaft O D at right and left shiftfork surfaces Check for scratches scoringor evidence of insuf ficientlubrication SERVICELIMIT 13 90mm 0 547in Measure the rightandleft SERVICE LIMITS l D rightandleft forkl shiftfork LD 14 04mm 0 553in 13 7 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 187: ...aring stopperplates lnstallthe shift fork shaftso that the oil holeegrd istowardthe right Installthe shiftforksonto the shaft Installa new lock washerandthe bolt to thecenter shiftfork andtightenthe bolt TOROUE 16 20 N m 1 6 2 0 ks m 12 14 ft lb Bendup the lockwasher s tabs 83ONLY S H I F TF O R KS H A F T BEARING STOPPER PLATES O I L H O L E 13 8 Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 188: ...ON ASSEil BLY M A I N S H A F T Install themainshaft bearing withthespecial tools Checkthe gears for freedomof movement or rota tion on the shaft Checkthat the snapringsareseated in the grooves D R I V E R 07746 00301 000R 07945 371 0200 Dateof lssue January 1983 HONDAMOTORCO LTD 13 9 ...

Page 189: ...arandsnapring 7w Install theC3gear andspline collar Installthe stopper washer whilealigning the tab of the stopperwasherwith the groovein the spline collar Assemblethe C2 C4 and C1 gears washers and colIars 8 i r lxr rij nffi e STOPPER WASHER S P L I N E C O L L A R 1 3 1 0 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 190: ...tall the countershaftbearingholder bolts and tightenthem TOROUE 21 25 N m 2 1 2 5 kg m 15 18 ft lb Checkthat the oil orificeisclear Installthe mainshaft thenreassemble the upperand lowercrankcase see Section11 MAINSHAFT Dateof lssue October 1983 O HONDAMOTORCO LTD 1 3 1 1 ...

Page 191: ...1 14 35 45 55 N m 4 5 5 5kg m 33 40ft rb 30 40 N m 3 0 4 0kg m 22 29 tt lbl 55 65 N m 5 5 6 5ks m 40 47 ft rb 18 25N m 1 8 2 5 kg m 13 18ft lbl g a e GD a 20 25 N m 2 0 2 5ks m 14 18ft lbl 30 40 N m 3 0 4 0kg m 22 29 t tlbl 9 13 N m 0 9 1 3 ks m 7 10 ft lbl 14 O Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 192: ...5 N m 4 5 5 5 kg m 33 40ft lb 30 40 N m 3 0 4 0 kg m 22 29ft tbl 30 40 N m 3 O 4 0 ks m 22 29 ft tbl 20 25 N m 2 0 2 5kg m 14 18 ft lb 35 40 N m 3 5 4 0 kg m 25 29 ft lb 83 After 83 SERVICE INFORMATION TROUBLESHOOTING HEADLIGHT INSTRUMENTS FUSEHOLDER REPLACEMENT 14 1 tGNtTtON SWTTCH 14_2 HANDLEBARS 14_3 FRONT WHEEL 14_3 FRONT FORKS 14_5 STEERING STEM 14 6 14 7 14 11 14 18 14 31 STANDARD SERVICE LI...

Page 193: ...e 4 Axlenuttightened improperly Soft suspension 1 Weak fork springs 2 Insufficient fluid in forks 3 Forkair pressure incorrect Hardsuspension 1 Incorrect fluidweightin forks 2 Forkairpressure incorrect 3 Bentfork tubes 4 Clogged f luid passage 5 Clogged anti dive orifice Frontsuspension noise 1 Wornslider or guide bushings 2 Insuff icient f luidin forks 3 Loose iront fork fasteners 4 Lackof grease...

Page 194: ...ws Disconnect the headlight coupler Installthe headlight in the reverse orderof removal Checkthe headlightaim and adjustit if necessary pase 3 18 INSTRUMEIITS REMOVAL Remove the fairing Remove the headlight with the mount bolt andnuts its bracketby removing F A I R I N G H E A D L I G H T H E A D L I G H T R I M 14 3 Dateof lssue October l 983 HONDAMOTORCO LTD ...

Page 195: ...acket DISASSEMBLY Remove the odometerresetknob Removethe instrumentpod from the instrument panel Remove the instrument bulbsockets Replace anyburntbulbs lf the bulb doesnot light inspect the wiringfor an openor shortcircuit SPEEDOMETER CABLE I N S T R U M E N T W I R E COUPLER ODOMETER RESET KNOB INSTRUMENT POD INSTRUMENT PANEL 14 4 Dateof lssue January 1983 HONDAMOTORCO LTD ...

Page 196: ...the headlightbracket page14 3 Disconnect the fuse holderwire coupler Removethe fuse holdercover Removethe two attachingscrewsand removethe fuse holderfrom the fork bridge lnstall the fuse holder in the reverseorderof re moval NOTE Be sure to routthe fuse holderwire properly pages1 10 thru 1 12 83 84 After FUSEHOLDER 44 Dateof lssue October 1984 AmericanHondaMotorCo Inc 1984 All RightsReserved 14 5...

Page 197: ...tthe ignition switch wire coupler Remove the ignition switch mounting bolts and removethe ignition switch Install the ignition switch in the reverseorder of removal DISASSEMB LY ASSEMBLY Pryopenthe retainer Insertthe ignitionkey andturn it so it is between the ON andOFF detentpositions partway IGNITION SWITCH MOUNTING BOLTS v 14 6 Dateof lssue JanuarY 1983 O HONDAMOTORCO LTD ...

Page 198: ...rom the switch Assemble the ignition switch in the reverse orderof disassembly l AI DtEBARS REMOVAL Disconnect the front brakeswitchwires Remove the front brakemaster cylinder Remove the righthandlebar switch SLOTS LUGS FRONT BRAKE MASTER CYLINDER RIGHTHANDLEBAR SWITCH Dateof lssue January 1983 O HONDAMOTORCO LTD 14 7 ...

Page 199: ...H MASTER CYLINDER Disconnect theclutchswitchwires Remove theclutchmaster cylinder Remove the left handlebar switch Disconnect the choke cablefrom the choke lever LEFTHANDLEBAR SWITCH CHOKE LEVER CHOKECABLE 14 A Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 200: ...e throttle gripslidingsurface and slide thethrottlegripoverthehandlebar lnstallthe handlebars onto the fork tubesand on the handlebarspacers aligningthe pin on the bottomof the handlebar with the holein the spacer Tightenthe handlebar pinchbolts TORQUE 30 40 N m 3 0 4 0 ks m 22 29ft lbl Install thehandlebar retainer rings STOPPER RING H A N D L E B A R P I N C H B O L T R E T A I N E R R I N G PIN...

Page 201: ... mastercylinderholderwith the UP markfacingup Align the indexmark on the holderwith the punch mark on the handlebar andtightenthe upperbolt first thentightenthe lowerbolt Connect thechokecableto thechokelever Align the left handlebarswitch locatingpin with the hole in the handlebar andinstallthe left handle barswitch Tighten the upper screw first then tighten the lowerscrew UP MARK P U N C H M A R...

Page 202: ...eholder NOTE lf you squeeze the froht brake leverafterthe caliper is removed the caliper piston will moveout andmakereassembly difficult UP MARK R I G H TF R O N T C A L I P E R FRONTWHEEL SUSPENSION CLUTCH MASTER CYLINDER A X L EH O L D E R Removethe speedometer cable connectthe speedometer cable Removethe left front caliper andanti dive pistoncase Remove the left axleholder set screwand dis from...

Page 203: ...acer from the rightside Remove the speedometer gearbox from the left side Remove the left andrightbrakediscmountingbolts anddiscs Remove the dustseal from both sides Remove the speedometer ratainer from the left side SPACER SPEEDOMETER GEARBOX B R A K ED I S C 14 12 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 204: ...heck the rim runout by placingthe wheel in a truing stand Spin the wheelslowly and readthe runoutusing a dialindicator SERVICE LIMITS RADIAL RUNOUT 2 0mm 0 08in AXIAL RUNOUT 2 0 mm 0 08in NOTE The wheel cannot be repairedand must be replaced with a new one if the service limits areexceeded FRONTWHEE L SUSPENSION PLAY AXLE INSPECTION Set the axle in V blocksand measure the runout SERVICE LIMIT 0 2m...

Page 205: ...ear ingsanddistance collar NOTE Neverreinstall old bearings oncethe bearings areremoved they mustbe replaced with new ones ASSEMBLY B E A R I N G R E M O V E R H E A D 07746 0050400 NOTE Thecastwheelhasno rim band The front wheelusesa tubeless tire For tubelesstire repair refer to the Honda Tubeless TireManual 14 14 Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 206: ...ng that it is fully seatedand facingout squarely making sure that the sealed sideis ATTACHMENT 42 x 47mm07746 0010300 PILOT 15mm07746 0040300 Installthe speedometer gearretainerin the left side of the wheelhub aligningitstangswith the slotsin thehub lnstallthe left dustseal Placenew gasketson the disc mountingflange then installthe left disc with its L mark facing out Tightenthe discmountingbolts ...

Page 207: ...e andinstall theplainwasher anddrivegear Installthe speedometer gearboxin the wheelhub aligning thetangs with theslots Install the front axleandaxlenut Tighten theaxle nut TOROUE 55 65 N m 5 5 6 5 ks m 40 47 ft lb NOTE There are flats on the oppositeend of the axle soyou canholdthe axlewhiletorquing theaxlenut Clean the agent brakediscswith a highqualitydegreasing SPEEDOMETER GEAR BOX TANGS SLOTS ...

Page 208: ... 5 ks m 14 18 ft lb Tighten thecaliper mountbolt TOROUE 30 40 N m 3 0 4 0 ks m 22 29 ft lb Connectthe speedometer cableand secureit with the setscrew Measure the clearance between eachsurface of the left brakediscand the left caliperholderwith a 0 7 mm 0 028 in feeler gauge lf the gaugeinserts easily tightenthe forward left axle holder nut to the specified torque thentightenthe rearnut lf the feel...

Page 209: ...parts fairing headlight instruments handlebars front wheel handlebar spacers Remove the front fenderandfork brace Loosen the fork upperandlowerpinchbolts HANDLEBAR SPACERS F R O KB R A C E F R O N TF E N D E R UPPER PINCH BOLTS LOWER PINCH BOLTS 14 1A Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 210: ...e airjoint O rings you ll haveto turn the tubeswhile pulling down Remove the fork stoprings Pull eachfork tube out of the fork bottom bridge lf replacement of the air joint the two screwswhich attach to the top bridge rsnecessary remove the fork air joint F O R KS T O P R I N G 14 19 Dateof lssue January 1983 OHONDA MOTORCO LTD ...

Page 211: ...acer andwasher Drainthe fork fluid by pumpingthe fork up and downseveral times Hold the fork sliderin a visewith soft jaws or a shoptowel Remove the socketbolt with a hexwrench NOTE Temporarilyinstallthe springand fork cap if difficulty is encountered in removingthe socketbolt The piston and rebound spring can be removed from the rightfork HEXWRENCH 6mm 07917 3230000 OREOUIVALENT WASHER 14 2c Date...

Page 212: ... from the slider bushingis felt Then move it in and out tappingthe bushinglightlyuntil the fork tube separates from the slider The sliderbushingwill beforcedout by the forktubebushing Remove the oil lockpiecefrom insidethe slider FOAMSEAL 83 84 Shown SNAPRINGPLIERS 07914 3230001 OR EQUIVALENT IN U S A DUST I I bl SEAL SNAPRING F O R KS L I D E R PLASTIC WASHER F O R KT U E E J Dateof lssue October...

Page 213: ...removethe circlip oil lockvalve spring and springseatfrom the piston Removethe piston and reboundspring from the fork tube INSPECTION FORKSPRING FREELENGTH Measure theforkspring freelength SERVICE LIMIT 47Omm 18 5in 83 84 SLIDER BUSHING OILSEAL PISTON After 84 OILSEAL SLIDER BUSHING FORK TUBEBUSHING SPRING SEAT CIRCLIP OILLOCKVALVE SPRING 14 22 Dateof lssue October 1984 AmericanHondaMotorCo Inc 19...

Page 214: ...rk tube in V blocksandcheckitsrunout SERVICE LIMIT 0 20mm 0 008in BUSHING BACK UP RING Visuallyinspectthe sliderand fork tube bushings Replace the bushings if thereis excessive scoring or scratching or if the teflon is worn so that the copper surfaceappearson more than 3 4 of the entiresurface Check the back upring replaceit if there is any distortionat the pointsshown BUSHING BACK UP RING CHECK P...

Page 215: ...e pistonand spring Remove the boots pivotboltcollarandstoprubber After 84 Remove the pistonand spring Removethe boot pivot bolt collar and rubber bushing Checkthe springand pistonfor wear or damage 183 8a After 84 Aftcr 84 RUBBER BUSHING 83 84 PISTON After 84 Wa Dateof lssue October 1984 r AmericanHondaMotorCo Inc 1984 All RightsReserved 14 24 ...

Page 216: ...kthe orificefor clogging scoring excessive wear or damage Replaceif necessary Assemblethe anti divecasein the reverse orderof disassembly NOTE Applya ThreadLockAgentto the threads of the screws and socket bolts before assembly ApplyATFto the pistonandpistonO ring Apply siliconegreaseto the pivot bolt collar Installthe pivot bolt collarbootholderas shown Checkthe operationof the collarand piston 83...

Page 217: ... end of the piston NOTE On the right fork installthe oil lock piece aligning theflatsidesof theoil lockpiece and pistonend DUSTSEAL O I L S E A L SNAPRING ss a 9 3 l i l i l u ll l g g s n l l t4 U g BACK UP R I N G S L ID ER B U S H I N G F O R KB R A C E FORK SPRING F 8 d g g F CJ D e g PISTON p i l n H A g FORKTUBE BUSHING S NOTE Only one bushingis usedafter 84 SPRING SEAT VALVE SPRING S L ID E...

Page 218: ...overtheforktubeandrest it on the slider Put the back upring and an old bushingor equivalent toolon top Drivethe bushinginto placewith the sealdriver and removethe old bushingor equivalent tool Coat a new oil seal with ATF and installit with the sealmarkings facingup Drivethe sealin with the sealdriver Installthe snapringwith its radiused edgefacing down and installthe dustseal NOTE On 83 and 84 do...

Page 219: ...12 7ozl Install theforkspring springseatandspacer inthe forktube NOTE Notethe springdirection the closelywound coilsmust facedown in the tube Installand torquethe fork tube cap NOTE On the right fork align the cavityon the dampingadjusterrodwith the flat sidein the piston BOTTOM TOP FOR E CAP K TUB I 14 28 Bevised February 1986 AmericanHondaMotorCo Inc 1986 All RightsReserved MSV98418602 83 _ 85 V...

Page 220: ...stop rings in the groovesin the fork tube Pushthe fork tubesup until the stop ringscontact theairjoints Tightenthe bottompinchbolts TOROUE45 55 N m 4 5 5 5 kg m 33 40 ft lb Tightenthe top pinchbolts TOROUE 9 13 N m 0 9 1 3kg m 7 10ft lb F O R KS T O P R I N G TOPPINCH BOLTS BOTTOMPINCHBOLTS 14 29 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 221: ...gbolts Fillthefork tubeswithair RECOMMENDER PRESSURE 0 40 kPa 0 0 4 kg cm2 0 6 psi CAUTION Useonly a hand operated air pump to fiil thefork tubes Do not usecompressed air Maximumpressure is 300 kPa 3 kglcm2 43 psi Do not exceedthis or fork tube component damage mayoccur With the front brakeapplied pump the forks up and down several times Placethe motorcycleon its centerstand Checkthe air pressure ...

Page 222: ...gnitionswitch brakehose3 waY joint LOCKNUTWRENCH 30 x 32 mm 07716 0020400or EOUIVALENTIN U S A Loosen andremove the steering stemnut Remove the forks Loosenthe top bridgepinch bolt and removethe top bridgewith the fork airjoint EXTE NStO N 077 16 0020500 OREOUIVALENT U S A BRAKEHOSE 3 WAYJOINT T O PB R I D G E Dateof lssue October 1983 O HONDAMOTORCO LTD 14 31 ...

Page 223: ...e steering stem Check the steeringstem bearings for damageor wear B E A R I N G R E P L A C E M E N T NOTE Replacethe bearingand bearing race as a set Remove the grease retainer Removethe bearinginner raceand dustsealfrom thesteering stem STEERING STEM SOCKET 0791 6 37101 00 I I ti I BEAR ING LOCKWASHER 83 shown 14 32 DUSTSEAL Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 224: ...EARING RACEREMOVER 07946 3710500 BALLRACEREMOVER 07953 4250002 BALLRACEREMOVER 07953 4250002 r LocKNUr GD S TLOCK WASHER g oRrNG ADJUsTMEN NUT t 7r e V oust senl I UPPER BEARINGINNER 61q fu RAcE fft EuppeR BEARTNG ourER s UPPER BEARING LOWER BEARING OUTER RACE After 83 LOWER BEARING e RACE re S GREASE RETAINER tS J ro wF F l RF ART NG6 1 l1 p p 2 i S toyEff_B EARINGINNER i s Date of lssue October ...

Page 225: ...then insertthe steeringstemintothe steering head Install the bearing relainer and upper bearing inner race After 83 Installthe lower bearingand grease retaineronto the steeingstem then insertthe steeringstem into the steeringhead Installthe upperbearingand inner race DRIVER 07749 0010000 ATTACHMENT 42 x 47 mm 07746 001 0300 ATTACHMENT 52 x 55 mm 07749 0010400 STEERING STEM DRIVER 07946 MBOOOOO OR ...

Page 226: ... adlust mentnut to thesame torque lnstalla new bearing adjustment nut lock washer aligning the tabswith the grooves in the nut Bend two opposite tabsdown intothe grooves NOTE DO NOT installa usedbearing adjustment nut lockwasher Handtighten the locknut Hold the adjustment nut and further tightenthe lock nut only enoughto alignitsgrooves with the lockwasher tabs NOTE lf the lock nut groovescannot b...

Page 227: ...rthe engine and wheel off theground Positionthe steering stem to the raise the front straightahead position Hook a spring scaleto the fork tube and measure the steeringheadbearingpreload NOTE Make sure that there is no cableand wire harness interference The preload should be within 1 0 1 6 kg 2 21 3 53lb for rightandleftturns lf the readings do not fall within the range lower the front wheeland ad...

Page 228: ...rtoilrxDA V45 INTER CEPTOR FRONTWHEEL SUSPENSION MEMO L 14 37 Dateof lssue January 1983 O HONDAMOTORCO LTD I ...

Page 229: ...61 76ft tb 40 50 N m 4 0 5 0 kg m 29 36 ft rb 18 25N m 1 8 2 5 kg m 13 18ft lb 40 50N m 4 0 5 0ks m 29 36ft tb 20 30 N m 2 0 3 0kg m 14 22 ft lbl 80 100N m 8 0 10 0 ks m 58 72ft rb 30 40 N m 3 0 4 0ks m 85 105 N m 15 O 8 5 10 5kg m 61 76 ft lb Dateof lssue January 1983 O HoNDA MoToR cO LTD ...

Page 230: ... m 29 36ft lb 40 50N m 4 0 5 0 ks m 29 36ft lb 40 50N m 4 0 5 0 ks m 29 36ft lb 20 30 N m 2 0 3 0kg m 14 22t d bl 85 105N m 8 5 10 5 ks m 61 76 ft lb 18 25N m 1 8 2 5 ks m 13 18ft lb 30 40 N m 3 0 4 0kg m 22 29ft lbl 80 100N m 8 0 10 0 ks m 58 72 ft lb 35 40N m 3 5 4 0 kg m 25 29ft lb 85 105N m 8 5 10 5 kg m 61 76ft lb 8 m m 1 0m m 07931 MA70000 07965 MC701 00 07965 ME701 00 07965 M 8001 00 07746 ...

Page 231: ...6 Swingarm bearings worn 7 Worntires Soft suspension 1 Weakspring 2 Insufficient f luid in shockabsorber 3 Shockabsorber air pressure incorrect Hardsuspension 1 Incorrect fluid weightin shockabsorber 2 Bentshockabsorber 3 Shockabsorber air pressure incorrect Sucpenrion noise 1 Shockcase binding 2 Loosefasteners 15 2 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 232: ...wheel is removed the caliperpistonwill moveout andmakereassembly difficult DISASSEMB LY Remove the rearbrakedisc Remove thedustseal Remove the finaldriven together NOTE sprocket and drivenflange Do not separatethe driven sprocket and flange unless replacementof the driven sprocket or flangeis necessary Removethe dust sealfrom the final drivenflange LOCKNUT DRIVECHAINADJUSTING BOLT AXLb R E A RB R ...

Page 233: ...hand Replace the bearings with newonesif they arenoisyor haveexcessive play R E A RW H E E LR I M R U N O U T Checkthe rim for runout by placingthe wheel truing stand Spin the wheel slowly and read runoutusinga dial indicator SERVICE LIMITS RADIAL RUNOUT 2 0mm 0 08in AXIAL RUNOUT 2 0mm 0 08in NOTE The wheel cannot be serviced and must be replaced if the abovelimitsareexceeded PLAY t n a the 15 4 D...

Page 234: ... S Replacethe damPerrubbers or deteriorated if thev are damaged B E A R I N G R E P L A C E M E N T Remove the wheelbearings Drivethedriven flange sidebearing out NOTE Neverreinstall old bearings oncethe bearings areremoved they must be replaced with new ones REAR WHEEL SUSPENSION GOOD REPLACE ry B E A R I N G R E M O V E R S H A F T 07746 00501 00 B E A R I N G R E M O V E R H E A D 2 0m m 07746 ...

Page 235: ...ing tools DRTVER 07749 0010000 ATTACHMENT 62 x 68mm 07746 0010500 PlLOT 25 mm 07746 0040600 CAUTION Dive the bearingsin squarely with the sealed end facing out making sure they are fully seated ASSEMBLY NOTE The rearwheeluses a tubeless tire For tube lesstire repairs refer to the Tubeless Tire Manual 35 40N m 3 5 4 0 ks T 6 F I N A LD R I V E NF L A N G E 80 100 8 0 10 N m 0 kg m h t N I Wb 58 72 ...

Page 236: ...TORQUE 80 100N m 8 0 10 0ks m 58 72 ft lb lnstall the dustseal Install thebrake disc andtighten thebolts TOROUE 35 40 N m 3 5 4 0kg m 25 29fb lbl lnstall thedust seal lnstallthe left andrightsidespacers D R I V E NF L A N G E LEFTSIDESPACER REARWHEEL SUSPENSION D R I V E N S P R O C K E T RIGHTSIDESPACER DUSTSEAL R E A RB R A K ED I S C DUSTSEAL 15 7 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 237: ...ly Tightenthe rearaxlenut TOROUE 85 105N m 8 5 10 5ks m 61 76 ft tb Adjsutthedrivechainslack page 3 13 Sl OCl ABSORBER REMOVAL Place the motorcycle on itscenterstand Remove the seatandleft framesidecover Removethe breatherseparator and the electric panel Remove the shockabsorber lowermountingbolt Removerthe shockabsorber uppermountingbolt tilt the shockabsorberrearwardand removeit fromtheframeby p...

Page 238: ...e grease gunwith ATF Automatic Transmission Fluid and connectthe attachment hose to the shock absorberair valve Keep the shockupright Wrapa shoptowelaroundthe oil seal Pump ATF into the shock absorberthrough the attachmenthose to force the oil sealand guide bushing out TheATF will alsocomeout Let the shockabsorber standfor another10 min utes to allow all of the ATF to drain from the outercase Do n...

Page 239: ...ndof the shockabsorber Dip the oil seal in ATF and install it onto the damper CAUTION Be carefulnot to ddmagethe oil sealduring installation J D A M P E R O I L ATFOR EOUIVALENT OILSEAL Pressthe oil sealinto the hydraulicpress until the oil edge of the outerca shockabsorber with a sealdriverstopsat the O I LS E A LD R I V E R 07965 MB00100 TAPE ATTACHMENT 07965 MC701 00 TTACHMENTRING 07965 ME70100...

Page 240: ...m to the uppermountingbushings NOTE Use pastegrease containingmore than 45o o of molybdenum asfollows MOLYKOTE G n PASTE manufactured by Dow Corning U S A Locol Paste manufactured by Sumico Lubricant Japan Otherlubricants of equivalent quality Install theshock absorber in theframeandtighten theupper andlower mounting bolts TOROUE 40 50 N m 4 0 5 0ks m 29 36 ft lb BOOTS STOPRING GROOVE BACK UP RING...

Page 241: ...nch bolt and shock link shaft Removethe shockarms from the frame LINKAGE PIVOTINSPECTION Checkthe linkageneedlebearings bushings for 83 and collarsfor wear or damage Inspectthe dust sealsfor damage Replace partsas necessary SHOCK LINKAGE INSTALIATION 83 Applypastegrease containing morethan4O molybdenum to the bushingsand dust seals See noteon page15 11 After 83 Apply molybdenumdisulfidegreaseto th...

Page 242: ...bl SHOCKLINK TO SHOCK ARM 40 50 N m 4 0 5 0 kg m 29 36 ft lbl SWINGARM PINCHBOLT 2O 3ON m 2 0 3 0 kg m 14 22 tt lbl Installthe mufflers Slt NGARlY REMOVAL Remove the rearwheel page 15 3 Remove the rightmuffler Remove the shocklink pinchbolt and shocklink shaft Removethe left and right swingarmpivot bolts S H O C K L I N KP I N C H B O L T S H O C K L I N KS H A F T LEFTPIVOTBOLT RIGHTPIVOTBOLT S H...

Page 243: ...rame Removethe drivechain sliderfrom the swingarm PIVOT BEARING REPLACEMENT Removethe pivot collarfrom the swingarm s right pivot Remove the dustseal Remove the snapring and driveout the right pivot bearings L O C KP I N TOROUERODBOLT h il w D R I V E C H A I N S L I D E R DUSTSEAL PIVOTCOLLAR S N A PR I N G 15 14 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 244: ... R W O O D E N 07749 00 10000 BLoc K ATTACHMENT 32 x 35 mm 07746 0010100 PILOT 20 mm 07746 0040500 DR I V E R 07749 0010000 Drivea new needle pivot CAUTION bearinginto the swingarm left To prevent swingarm damage support the swingarmasshown Drive pivot new ball bearings into the swingarm right ffi IN U S A ATTACHMENT 3T x 40 mm 07746 0010200 PILOT 17mm 07746 0040400 r I jt j i 1 5 1 5 Dateof lssue...

Page 245: ...ivechainslider Install the swingarm in theframe Makesurethat the rearbraketorquerod sflanged washer isinstalled in the swingarm pivot Connectthe rearbraketorque rod to the swingarm andtightenthe Pivotbolt TOROUE 18 25 N m 1 8 2 5 kg m 13 18 ft lb Secure the bolt with the lockPin LOCKPIN S N A PR I N G PIVOTCOLLAR D R I V E C H A I N S L I D E R 1 5 1 6 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 246: ...pivot bolt TOROUE 85 105 N m 8 5 10 5kg m 61 76 ft rb Connectthe swingarmand shock link and install the shock link shaft and shocklink pinch bolt Tighten theshocklink pinchbolt TOROUE 20 30 N m 2 0 3 0 ks m 14 22 ft lb lnstall the rightmuffler Install the rearwheel page 15 8 S H O C K L I N KP I N C H B O L T SHOCK LINKSHAFT Dateof lssue January 1983 O HONDAMOTORCO LTD 15 17 ...

Page 247: ...i rz zs 6t ff W 4 s tr Ngwh _ i dgwl 1 r 1i3 li lirn ru r kp q t 30 40N m 3 0 4 0 kg m 22 29it lbl flt 25 40N m a 2 5 4 0 kg m N 18 2eft rb t g v 20 25N m 2 0 2 5 kg m 14 18ft lb I tu r tr 20 25N m 2 0 2 5 ks m 14 18ft lb 16 0 Dateof lssue January 1983 HONDAMOTORCO LTD ...

Page 248: ...m 1 0 1 5kg m 7 11 ft lb SERVICE INFORMATION TROUBLESHOOTING BRAKEFLUID REPLACEMENT AIR BRAKE PAD DISC FRONTMASTERCYLINDER BRAKECALIPERS REAR MASTERCYLINDER BLEEDING 16 1 16 2 16 3 16 5 16 8 16 10 16 14 ITEM STANDARD S E R V I C E L I M I T Frontdiscthickness 4 5 5 2 mm 0 177 0 205inl 4 0mm 0 157 in Frontdiscrunout 0 30 mm 0 012 in Frontmaster cylinderl D 15 870 15 913mm 0 6248 0 6265 in 15 925 mm...

Page 249: ...aminated 2 Lowfluid level 2 Discor wheelmisaligned 3 Hydraulic system leaking Brakeleverlpedal too hard Brakechatteror squeal 1 Stickingpiston s 1 Pads contaminated 2 Clogged hydraulicsystem 2 Excessive discrunout 3 Pads glazed or worn excessively 3 Caliper installed incorrectly 4 Discor wheelmisaligned Brakedrag 1 Hydraulic system sticking 2 Sticking piston s 16 2 Dateof lssue January 1983 O HOND...

Page 250: ...dal Stop operatingthe leveror pedalwhenfluid stops flowingout of the bleedvalve B R A K E F L U I D F I L L I N G NOTE Do not mix differenttypesof fluid since they maynot becompatible Closethe bleedvalve fill the reservoir and install the cover To prevent piston overtraveland brake fluid see page keep a 20 mm 3 a in spacerbetweenthe handlebargrip and lever when bleeding the front brakesystem Whenb...

Page 251: ...f a Mityvac BrakeBleeder or equivalent not avail able bleedthe system asfollows 1 Connect a bleeder tubeto the bleeder valve 2 Squeezethe brake leveror depressthe brake pedal open the bleedvalve1 2 turn and then closethe valve NOTE Do not release the brakeleveror pedaluntil the bleedvalvehasbeenclosed 3 Release the brakeleveror pedalslowly andwait several secondsafter it reaches the end of its tra...

Page 252: ...per Removethe caliperbolt bolt Left caliper Removethe caliperpivot anti dive link bolt Remove the caliperfrom the bracket and pivot bolt and Removethe padpin retainerand pull the pad out of the caliper Remove the brakepads Position the padspringin the caliperasshown Pushthe caliperpistons in allthe way prns LEFTCALIPER PADPINS PADSPRING 16 5 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 253: ... the padpins Push the retainer downto secure the pins Installthe padpin retainer bolt Install the caliper to the bracket so the disc is positionedbetweenthe pads beingcarefulnot to damage the pads Right caliper Tighten the caliperbolt and pivot bolt Left caliper Tighten the caliper pivot bolt and anti dive link bolt PADPIN PADS R E T A I N E R R I G H T C A L I P E R LEFTCALIPER 16 6 Dateof lssue ...

Page 254: ...eplace the rearbrakepadsusingthe samemethod asusedfor front brakepadreplacement D I S C T H I C K N E S S Measure the thickness of eachdisc SERVICE LIMIT FRONT 4 0mm 0 16in REAR 6 0mm 0 24in BRAKEDISC WARPAGE Measure brakediscfor warpage SERVICE LIMIT 0 30mm 0 012in HYDRAULIC BRAKE CALIPER BOLT Dateof lssue January 1983 O HONDAMOTORCO LTD 16 7 ...

Page 255: ...the end of the hoseto preventcontamination Secure the hoseto preventfluid from leaking out Disconnect the front brakeswitchwires Remove the front brakemaster cylinder Remove the pistonboot andthe snapringfrom the master cylinderbody Remove the secondary cupandpiston Thenremove theprimary cupandspring Removethe brake light switch from the master cylinderbody if necessary Cleanthe inside of the mast...

Page 256: ...p the master cylinder piston cylinder and spring as a set don t substituteindividual parts Assemble the mastercylinder Coat all partswith cleanbrakefluid beforeassembly Install thespring andprimarycuptogether Dip the pistoncup in brakefluid beforeassembly CAUTION l lhen installing the cups do not allow the lips to turn inside out and becertain the snaping isfirmly seatedin the groove Install thepi...

Page 257: ... B R A K E C A L I P E R R E M O V A L Placea cleancontainerunderthe caliperand dis connectthe brakehosefrom thecaliper cAuTtol Avoid spillingbrakefluid onpaintedsurfaces Rightcaliper Removethe caliperpivot bolt and caliperbolt andremove the caliper Left caliper Removethe caliperpivot bolt and anti dive link bolt andremove the caliper R E A R B R A K E C A L I P E R R E M O V A L Placea cleanconta...

Page 258: ...to get the pistonout Placea shop rag underthe caliperto cushionthe pistonwhenit is forcedout Usethe air in shortspurts Examine the pistons and cylinders for scoring scratches or otherdamage and replace if necessary Pushthe piston sealsin and lift them out then discard them Clean the pistonsealgrooves with brakefluid CAUTION Be careful not to damagethe piston sliding surfaces PIVOTCOLLAR Dateof lss...

Page 259: ...LY lf the collar bootsare hardened or deteriorated replace themwith newones The piston sealsmust be replaced with new ones wheneverthey are removed Coat the sealswith silicone grease or brakefluid before assembly Installthe pistonswith the dishedendstowardthe pads Apply midium grade of Hi Temperature silicon grease to thecollarandinside of thecollargrease Installthe collarbootsandcollarmakingsuret...

Page 260: ...allthe caliperpivot bolt and caliperbolt andtightenthemsecurely Left caliper Installthe caliperpivot bolt and anti divelink bolt andtightenthemsecurely Connectthe brake hose to the caliperwith the bolt andtwo sealing washers Fill the brake fluid reservoir and bleedthe brake system page16 4 REARBRAKE CALIPER INSTALLATION Makesurethat the retainer clip isin positionon the caliperbracket Inspectthe c...

Page 261: ...with the bolt andtwo sealing washers Fill the rearbrakefluid reservoir andbleedthe rear brakesystem page16 4 REAR YIASTER CYTINDER R E M O V A L Drain the rearbrakehydraulic Removethe brake hose bolt brakehose system page16 3 and disconnectthe Loosen the rearmaster cylindermountbolts Remove the rightfootpegbracket Unhook the rear brake switch spring from rearbrakeactuating arm the SEALING WASHERS ...

Page 262: ...he rearbrakeactuating arm bolt and the middlearm Removethe cotter pin washerand joint pin and disconnect the brakeactuating armfrom the master cylinder pushrod Removethe rearmastercylinderfrom the footpeg bracket HYDRAULIC BRAKE MASTER CYLINDER HOSE ACTUATING ARM BOLT SPR ING COTTER PIN 1 6 1 5 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 263: ...master pistonandprimary cuP Clean allpartswith brake fluid C Y L I N D E R I D I N S P E C T I O N Measure the inside diameter of the master cvlinder bore SERVICELIMIT 14 055 mm 0 5533 in Checkfor scores scratches or nicks PISTON O D INSPECTION Measure themaster Piston O D SERVICE LIMIT 13 945 mm 0 5490 in Checkthe primarycup andpistoncup for damage SNAPRING I S N A PR I N GP L I E R S o r E O 079...

Page 264: ...rod andsnapring lnstallthe rubbercover INSTALLATION Install the mastercylinder to the right footpeg _ bracket Connectthe rearbrakeactuating arm to the master cylinderpushrod with the joint pin andsecure the joint pin with the washer anda newcotterpin Installthe actuating arm onto the rearbrakepedal shaft aligningthe punch markson the arm and shaft Hook the rear brake pedal ieturn springto the actu...

Page 265: ...tallthe rightfootpegbracket Tightenthe bracketbolt Tightenthe rearbrakemaster cylindermountbolts Connectthe rearbrakehosewith the fluid bolt and two sealing washers Fill andbleedthe rearbrakesystem page16 4 MASTER CYLINDER HOSE BRAKE TCHSPRING ACTUATINGARM RIGHTFOOTPEG BRACKET MASTER CYLINDER MOUNT BOLTS F L U I DB O L T 1 6 1 8 Dateof lssue January 1983 HONDAMOTOR CO LTD ...

Page 266: ...IIONTXDA V45 INTERCEPTOR HYDRAULIC BRAKE MEMO l L L Dateof lssue January 1983 O HONDAMOTORCO LTD 1 6 1 9 ...

Page 267: ...EM IilONTDA V45 INTERCEPTOR BATTERY ALTERNATOR REGULATO R RECTIFIER r llJ F F cll BATTERY CHARGING SYSTEM 3 o J J UJ RED WHITE VOLTAGE SENSOR REGULATOR RECTIFIER ALTERNATOR 17 O Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 268: ...d on the motorcycle disconnect the battervcables o All charging system components canbetestedon the motorcvcle Alternatorremovalis in Section9 S P E C I F I C A T I O N S Do not smoke or allow flames near a charging battery Thegasproduced by a battery will exptode if flnmes or sparks are brought near Battery Capacity 12V 14AH Specific gravity 1 280120 C 68 F Charging rate 1 4amoeres maximum Voltag...

Page 269: ...ailure 2 Loose batteryconnection Low power engine running 1 Batteryundercharged Low fluid level Oneor moredeadcells 2 Charging system failure Intermittentpower 1 Loosebatteryconnection 2 Loosecharging system connection 3 Loose starting system connection 4 Looseconnection or shortcircuitin ignition system 5 Looseconnection or shortcircuitin lighting system Charging system failure 1 Loose brokenor s...

Page 270: ...ficgravityis 1 27O L290 at 20 C 69 F er r r uo u BATTERYHOLDER NOTES The batterymust be recharged if the spe cificgravityisbelow1 230 The specific gravityvaries with the tempe ratureasshownin the accompanying table Replace the battery if sulfationis evident or if thespace belowthecellplates isf illed with sediment 1 3 1 1 3 0 1 2 9 1 2 8 1 2 7 1 2 5 1 2 4 BATTERY IEMPERATURE VS SPECIFIC GRAVITY 1 ...

Page 271: ...n the batteryterminals as snown Start the engine and allow it to idle Check the voltage by r aising t he engine speed gradually Thevoltage shouldbemaintained withinthe regulatedvoltage REGULATEDVOLTAGE 14 0 15 0 V lf voltageexceeds 15Vwhen raisingthe enginespeed the likelihood is o Open or short circuit blackwire of the regulator rectifier o Loose or poorly connected regulator rectifier coupler o ...

Page 272: ...fier couplers Checkfor continuitybetween the leads with an ohmmeter NOTE The test resultsshown are for a positive ground ohmmeter and the oppositeresults will be obtained whena negative ground ohm meterisused NORMALDlRECTION CONTINU ITY BATTE RY CHARG ING SYSTEM ALTERNATOR COUPLER R E G U L A T O R R E C T I F I E R C O U P L E R probe O probe YELLOW G R E E N t l RED WHITE YELLOW RED WHIT E G R E...

Page 273: ... TEST Connect a voltmeteracross the battery Check regulatorperformance with the engine running The regulatormust divert currentto ground when battery voltagereaches14 O 15 0V IIONTDA V45 INTERCEPTOR BLACK r7 6 Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 274: ...ITCDNIf DA V45 NTERCEPTON MEMO Dateof lssue January 1983 O HONDAMOTORCO LTD 17 7 ...

Page 275: ...AGRAM 1 3C Y L I N D E R SPARKUNIT PULSE GENERATORS ENGINE STOP SWITCH I G N I T I O N C O I L S PULSE GENERATORS BATTERY WHITECOUPLER I G N I T I O N C O I L SPARKUNITS T I I BATTERYt J_ 2 4C Y L I N D E R SPARKUNIT SPARK PLUG 18 O REDCOUPLER Dateof lssue January 1983 O HONDAMOTORCO LTD ...

Page 276: ...nbemade TOOL Special Timinginspection cover 07998 M800000 SPECIF ICATIONS ND N G K Sparkplug Standard X24EPR U9 DPR8EA 9 Forcoldclimate Below50c 41 F X22EPR U9 DPRTEA 9 For extendedhigh speeddriving X27EPR U9 DPR9EA 9 Sparkpluggap 0 8 0 9mm 0 031 0 035 in lgnition timing At idte VF750F 1oo VFToOF 150BTDC Fulladvance 37 BTDC 3 300 rpm Pulse generator air gaP 0 3 0 9mm 0 012 0 035 in _ l Date of lss...

Page 277: ...witch OFF Poorlyconnected brokenor shorted wires Between ignitionswitchandengine stopswitch Between spark unitandengine stopswitch Between spark unit andignition coil Between ignition coilandplug Between spark unit andpulse generator Faultyignition coil Faultyignition switch Faultyspark unit Faultypulse generator Engine startsbut runspoorly lgnitionprimary circuit Faultyignition coil Loose or bare...

Page 278: ...ank CONTINUITY TEST Disconnect thecoilsprimaryleads Measure theprimary coilresistance RESISTANCE 2 8 O Measurethe secondarycoil resistance with spark plugcapsin place RESISTANCE 21 28 k O I G N I T I O NC O I L T E R M I N A L S 18 3 Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 279: ...Q Between white yellow andyellowleads 1 3 cy Iinders Betweenwhite blueand blue leads 2 4 cy linders PULSEGENE RATORREPLACEMENT Remove the clutchcover page 7 10 Removethe pulsegeneratormounting bolts and pulsegenerators Installnewpulsegenerators Measure the air gap betweenthe pulsegenerator androtor AIR GAP 0 3 0 9 mm 0 012 0 035in fnstallthe clutch coverlpageT 22l Recheck the ignition timing page ...

Page 280: ...e timing lightto the hightensionwire of the No 1 or No 3 cylinder Starttheengine andcheckthe ignition timing AT IDLE SPEED The dark line 1 3F should align with the index mark on the timingcover 1 300 1 750 rpm The advance starts 3 100 3 500rpm The advance ends and the l T1t lTite between Connectthe timing lightto the hightensionwire of the No 2 or No 4 cylinderand checkthe igni tion timingfor No 2...

Page 281: ...ARTER BUTTON STARTER RELAYSWITCH BATTERY CLUTCH SWITCH GR E E N STARTER MOTOR STARTER RELAYSWITCH G R E E N R E D FUSE 30A T F 3 U J r IJJ z STARTER BUTTON RELAYCOIL IGNITION SWITCH I NEUTRALINDICATOR NEUTRAL SWITCH BATTERY 19 O Dateof issue January 1983 O HONDAMOTORCO LTD ...

Page 282: ...cessive resistance in circuit 3 Bindingin startermotor Startermotorturns but engine doesnot turn 1 Faultystarter clutch 2 Faultystartermotorgears 3 Faultystartermotoror idlegear Startermotor andengine turns but engine does not start 1 Faultyignition system 2 Engine problems Low compression FouledsparkPlugs SERVICEINFORMATION TROUBLESHOOTING STARTERMOTOR STARTERRELAY SWITCH CLUTCHDIODE 19 1 19 1 19...

Page 283: ...motor cableat the motor Removethe starter motor mountingbolts and startermotor C A S E A N D F I E L DC O I L REAR S HI M S A R M A T U R E B R U S H S P R I N G O R I N G F R O N T C O V E R STARTER CABLE B R U S H H O L D E R COVER 19 2 C A B T E T E R M I N A L A N D B R U S H E S Dateof lssue October 1983 O HONDAMOTORCO LTD ...

Page 284: ...ONTINUITY BETWEEN COMMUTATOR BAR PAIRS NORMAL COMMUTATOR BARSAND ARMATURESHAFT NORMAL NOTE Record the location and number of shims Inspect thecommutator Barsdiscolored in pairs coiIs NOTE Do not use emery or sand paperon the com mutator Checkfor continuitybetweenpairsof commutator oars Thereshould becontinuity Also makea continuitycheckbetween individual commutator bars andthearmature shaft Theres...

Page 285: ...it isshorted to the motorcase ASSEM BLY INSTA LLATION Assemble the starter motor Align the casenotch with the brushholderpin NOCONTINUITY BETWEEN CABLE TERMINAL ANDMOTOR CASE NORMAL CONTINUITY BETWEEN C A B L E T E R M I N A L A N D B R U S H W I R E I N S U L A T E D N O R M A L BRUSH HOLDER NOTCH P I N P I N REARBRACKET f Install the rearcoveraligning holder pin Installthe startermotor in remova...

Page 286: ...lif the starter relayswitchclicks Connectan ohmmeterto the starterrelayswitch terminals Connecta 12 Y battervto the switchcabletermi nats Theswitchisnormalif thereiscontinuity CTUTCI DIOOE R E M O V A L Removethe fuel tank Removethe clutch diode from the wire harness l STARTER RELAYSWITCH CLUTCHDIODE Dateof lssue Januarv 1983 O HONDAMOTORCO LTD 19 5 ...

Page 287: ...nofirtDA V45 INTERCEPIOR ELECTRIC STARTER NORMALDlRECTION CONTINUITY REVERSE DIRECTION NOCONTINUITY lNSPECTION Checkfor continuitywith an ohmmeter 19 6 Jfr Date of lssue October 1983 O HONDA MOTOR CO LTD ...

Page 288: ...dewithout removing the part from the motorcycle Simplydisconnect the wiresand connecta continuitytesteror volt ohmmeter to theterminals or connections o A continuitvtesteris usefulwhen checking to find out whetheror not there is an electrical connection betweenthe two ooints An ohmmeteris needed to measure the resistance of a circuit suchaswhenthereisa specific coil resistance involv ed or whenche...

Page 289: ...lling the switch Screwthe switch into the crankcasebut stop two threadsfrom the bottom Then tighten it to the specified torque TOROUE 15 20 N m 1 5 2 0ks m 11 14ft lb NOTE To preventcrankcase damage do not over tightenthe switch BRAIfi TIG I SltITC Check the rear brake light switch for continuity with the rearbrakeapplied Check the front brake light switchfor continuity with the front brakeapplied...

Page 290: ...ver Removethe neutral switch attachingscrewsand the switch INSTALLATION lnstall the neutralswitch in the reverse order of removal Tighten the switch mounting screws T O R O U E 7 1 1 N m 0 7 1 1 ks m 5 8 ft lb lnstallthe neutralswitchcover CTUTCH SITITC1 Checkcontinuityof the clutchlever safety switch with the clutch released and applied Replaceif necessary _ L _ CLUTCH APPLI ED CONTINUITY CLUTCHR...

Page 291: ...HI_LOSWITCH rr H E A D L I G H T H I MIDDLE N LO HI_LOW SWITCH BUAV to Bu BUAV to Wto Bu Bu Wto W I TURNSIGNAL SWITCH LEFT Grto O BrAru to LB W O F F BrlW to LB Wand O W RIGHT Grto LB BrlV t to O W HORNBUTTON LG to W G with button depressed No continuity with button released TURNSIGNALSWI Headlight Hi Low Switch HL2 Hi Lo Hi c N C c Lo c Colorcode Bu W Bu W Turn SignalSwitch vtl L R P1 PR P L LEFT...

Page 292: ...adlight Disconnect the ignitionswitchcoupler Checkcontinuityof terminals on the ignitionswitch couplerin eachswitchposition SWITCH POSITION LOCK No continuity _ OFF No continuity ON R to Bl BrlW to Br continuity PARK Brto R continuity IG ST H L l HL2 OUT o o START c c Colorcode BI Y R BI R BUAV ENGINESTOPSWITCH STARTER IGNITION SWITCH Terminal Position PA BATl I G TLr TLz P _ ON G o O F F LOCK Col...

Page 293: ...ea fully charged battery or false readings may result Battery voltageshould be above 12 5 V lf the fuel pump flow capacityis belowthe specif i cation measure thevoltage at thefuelpumpcoupler Replace the fuelpumpif battery voltage is present FUEL PUMP RTLAY Checkfor a burntsub fuse Checkthe relay couplerfor impropercontactand looseness Measure the voltagebetweenthe relay blackwire and a body ground...

Page 294: ...sor in the full andemptyfloat positions RESISTANCE FULL 3 5 9 5 Q EMPTY 9O 1OO O Turn the ignitionswitchON Connectthe fuel levelsensor couplerto the wire harness Movethef loatto full andemptyandcheck the fuel gaugeneedlein both positions lf the fuel gaugedoesnot indicatethe properlevel replace it with a newone i rrr F U L L F U E LG A U G E F U L L FUELLEVELSENSOR EMPTY 2o 7 Dateof lssue January 1...

Page 295: ...t 50 50 mixture and checkthe temperature at which the switchopensandcloses Makesurethatthereisno switch continuity with room temperatureand gradually raisethecoolant temperature Theswitch should be continuity close at 98 1 O2oC 208 215oF NOTE Maintainthe high teperature for 3 min utes beforetesting continuity A sudden changein temperature will causeanerror in the reading Do not letthethemometer or...

Page 296: ...re sensor from the thermostat case Suspend the unit in oil overa burnerand measure the resistance throughthe unit asthe oil heatsup 12V BATTERY OHMMETER TEMPERATURE SENSOR THERMOMETER Temperature 60 c g50c 1 1 0 C 120 C 140 F 1 9 5 0 F 23oo F 24goF Resistance 104 0s 43 9Q 20 3s 1 6 1 Q NOTE Oil must be usedas the heatedliquid to checkoperation above100 C 212 F You ll get false readingsif either th...

Page 297: ...sparkunit with a newoneandrecheck the oPeration lf the problemstill appears replace the sparkunit with the originalone and tachometer with a new one BRAI T AND TAItLIG T SENSOR Turnthe ignition switchon Checkthe sourcevoltageat the black brownlead lf there is no voltage checkand repairthe source circu it lf there is voltage measurethe voltageat the white yellow positive and green yellow negative w...

Page 298: ...TM SSIL ffiA M sTP lm T L rilDrclTm ruft srNL dfrER m sfr Eml sTF silTq slrq ffrun v45 TNTERCEPTOR VF75OF REARSTF LIqT Sftrq A ffiAOLtgT B SETER c IUm srillL FRoilT REAR 8RAXE rcil o FRorlT POSrlil rErERLrgT TArL I q L w ms m l ffii IHERMoStrrcH m l P L R o H Oto 1 Dateof lssue Oaober 1984 AmericanHondaMotorCo Inc 1984 All RightsReserved ...

Page 299: ...qtL FMT R rRmA E ffi qr msrlrfl TETERLr T utL t qr 4 r t 1l J J l I ilzr iI FUS rln Il IM gML REUY l w bot tr STF AD TAIL LIST I I e I E P I b I _l I S O Svrfl I otL mEsSuRE strrcH 0 u l q E o R uq YE fl G ffi m IHTE WN ffre Udr 1 ffiffi qft r rtrRMosilTCN 00302 tB2 6700 21 1 I ...

Page 300: ...uELCUT ftTIY ruEtrum R RURTUfr 9il1 l Wcp lr L RSn IUm gqll llw r llr THENMOINIT msl sroF fs a I Lixefo i rbd l P p q I P E b LjPARX P REfuLATOR NECTIFIER 00302 M82 9000 as x r 1 41 lr ii ill A 6ril lltttt o LGNTSW TCN rcNrlot colL 0 u q w i l Y YELLOI O fire aE u uqT e m k uqTqEi R M P H i l T THTE O qft q fit Dateof lssue October 1984 American HondaMotorCo Inc 1984 All RightsReserved ...

Page 301: ... rusEtoA msmd METER Lrqr rAtL 5 ruS rOA rflrfl FUEL SiART CHARGE 6 ruSE roA P SXTNG 7 rusE roa FAN M010R ST LBI sWtrCN TNERMO SWlCH SIIRTERMAGNflK L GNT SWITCH tetTtot colL L FW TW SIilL I rcgTlil LIqI lIv3z 3co 2 lr ffn roStlld Tm gqAL OilMER ffi SIITS ste s TcN stlRtER sflts srtTcH cflltNufv ffi sre sffq qMM R SW ICH u r loc R MT TR gqIL I ro Tlil LISI t v t rt t t A l l IG TU fL2 a a r 21 2 ffi...

Page 302: ...Hydraulically assisted the clutch requires a lighter lever pull compared to cable operated motorcycle clutches This system also provides a consistently smooth feeling when the clutch lever is pulled ih and released The hydraulic system automatically compensates for wear and the only mainte nance check required is the hydraulic fluid Carburetors with bystart r valva The carburetors deliver the prop...

Page 303: ...rtionof the clutchinneris splined to the transmission s mainshaft asis normal But it only controls about two fifthes of the clutchplates anddiscs Thisportionof the clutchtransmits poweranddeceleration forces in theusual manner o Theouterportionof the clutchinneris not splined to the transmission s mainshaft lt controls aboutthree f ifthes of the clutch plates and discs This portion transmitspower ...

Page 304: ...event the wheelfrom locking without losingthe benefitof maximum engine compression braking CLUTCH C E N T E R CLUTCH CENTER ONE WAY CLUTCH OUTER ONE WAY CLUTCH ONE WAY CLUTCH I N N E R ONE WAY CLUTCH I N N E R ONE WAY CLUTCH OUTE CLUTCH OUTTER COMP CLUTCH OUTER CLUTCH CENTER oRDINARYPOWER FLOW BACKLOAD CLUTCH OUTER M A I N S H A F T POWER FLOW DIAGRAM F R I C T I O N D I S C ONEWAY CLUTCHOUTER CLU...

Page 305: ...ITONTf DA V45 INTERCEPIOR TECHNICAL FEATURES MEMO Dateof lssue January 1983 O HONDAMOTORCO LTD 22 4 ...

Page 306: ...or fuel filter 3 Stickingfloat valve 4 Faultyf uel pump 5 Faulty fuel pump relay 6 Pinchedfuel tank vent nose WEAK OR NO SPARK I Faultysparkplugs 21 Fouled spark plugs 3 Faulty sparkunit l4l Broken or shorted high tension wires 5 Faulty sparkunit 6 Broken or shorted ignition coil l7l Faulty ignition switch 8 Faulty pulsegenerator LOW COMPRESSION Low battery charge lmproper valveclearance too small...

Page 307: ...aminated oil VALVE TRATNNOT LUBRICATED__ 1 Ctogged oit passage PROPER LY POSSIBLECAUSE Brake dragging Worn or damaged wheel bearings Wheel bearing needslubrication Drive chaintoo tight Rearaxle nut excessively tight Faulty tire valve Clutch slipping Worn clutch disc plate Warped clutch disc plate Carburetor choke closed Cloggedair cleaner Restricted fuel flow Clogged muffler Cloggedfuel tank vent ...

Page 308: ...ingintake pipe 3 NO LEAK I v 4 Perfoimsparktest GOODSPARK l2l 3 1 FUELFLOWRESTRICTED CLOGGED INCORRECT WEAK Check tire andsuspensions pressures 1 lmproper valveclearance 21 Faulty spark unit 31 Faulty pulsegenerator 1 Fueltank empty Ql Cloggedfuel line 31 Cloggedfuel tank breatherhole 4 Cloggedfuel valva 5 Faulty fuel pump Clean Camsprocket not installed propeny Faultyspring 4 5 l2l 1 QI 3 4 5 1 t...

Page 309: ...ESGDIIIIf A VI5 NIERCEPTOR MEMO e rf r l V t Date of lssue JanuarY 1983 O HONDA MOTOR CO LTD ...

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