Honda V 45 SABRE-VF750S 1982 Shop Manual Download Page 60

Page: 60 / 376

Summary of Contents for V 45 SABRE-VF750S 1982

Page 1: ......

Page 2: ...right side The engine serial number is stamped on top of the right crankcase HONDA V45 V45 MAGNA BEGINNING F NO RC071 CMOOOOOI E NO AC07E 4000001 The vehicle identification number VIN is on the steer...

Page 3: ...e Iligllly explosil t Do not smoke or allow f1ames or sporks neor he battery especially while harging il 1 Use genuine HONDA or HONDA recommended parts and lubricants or their equivalent Parts that do...

Page 4: ...1019O H1 8 T less 13019O H17 Tubeleu 32 Pli 225 kPII 2 25 kll cm n pli 225 kPII 2 25 kll em 32 psi 1225 kP 2 25 kll cm 40 PI 2S0 kP 2 80 kil ern Double di 904 em 1140 1 sq inl Drum 201 em 31 2 sq ill...

Page 5: ...gnal Instrument lights Neutral indicator Turn signal indicator High beam indicator POSition light Date of Issue October 1982 HONDA MOTOR CO LTD V45 SABRE No 1 Left rear No 1 u n fronl No 3 Right rear...

Page 6: ...20 15 20 1 5 2 0 11 14 Out put gear case 2 21 25 2 0 2 5 15 18 Socket bolts 3 30 34 3 0 3 4 22 25 Valve adjustment nuts 16 7 21 25 2 1 2 5 15 18 Drain bolt 1 12 35 40 3 5 4 0 25 29 Connecting rod nuts...

Page 7: ...4 0 22 29 Front brake caliper bolts 2 8 20 25 2 0 2 5 14 18 Front brake caliper pivot bolts 2 10 25 30 2 5 3 0 18 22 Brake hose bolts 10 25 35 2 5 3 5 18 25 Engine hanger bolts 2 8 20 30 2 0 3 0 14 22...

Page 8: ...2 5 13 18 10 mm bolt and nut 30 40 3 0 4 0 22 29 12 mm bolt and nut 50 60 5 0 6 0 36 43 1 6 _ Item 5 mm screw 6 mm screw 6 mm flange bolt and nut 8 mm flange bolt and nut 10 mm flange bolt and nut 8...

Page 9: ...reamer 5 5 mm Preload inspection tool Date of Issue May 1982 HONDA MOTOR CO LTD GENERAL INFORMATION Part No Remarks Ref Sect 07908 MBOOOOO KS AH OOa MBO 3 07916 MBOOOOO U S A only 13 14 07924 MBOOOOO...

Page 10: ...V45 SABRE MAGNA 07780 0012100 Equivalent is commercially 10 07780 0012000 available in U S A 07780 0014000 07781 0010100 Part No Alternate Tool 07401 0010001 07703 0020500 Equivalents are 07506 300000...

Page 11: ...ABLE HARNESS ROUTING FRONT BRAKE HC THROTTLE CAE L FUEL e PULSE GENE TO WIRE l p r SWITCH CABLE TH O T E CABLES CLUTCH BRAKE HOSE CLAMP CABLE BRAKE CABLE BATTERY EA1 HE TUBE GENERATOR WIRE OVER FLOW T...

Page 12: ...on chamber Condensed crankcace vapors are accumulated in a storage tank which must be emptied periodically See the Maintenance Schedule in Section 3 CARBURETOR EMISSION CONTROL INFORMATION LABEl An Em...

Page 13: ...LINDER EX CAMSHAFT ij FRONTCYLINDER IN CAMSHAFT it HONDA V45 3 TO REAR CYLINDER 1 011 L PIPE SH IFT OF SHAFT MAIN5HAFT OIL ORI I E COUNTERSHAFT PUMP OIL FILTER 01 L Sn AINIEA 2 0 Date of Issue May 198...

Page 14: ...rance Final drive gear Oil cap city Recommended 011 Date of Issue May 1982 0 HONDA MOTOR CO LTD 2 9 liter 3 1 US qt 2 5 Imp qt after draining 3 0 liter 3 2 US Qt 2 6 Imp Cit after disassembiv Use HOND...

Page 15: ...g m 11 14 ft Ib Apply 3 BON D or it s eQuivalent to the bolt threads 07506 3000000 b 07510 4220100 or commerCIa y aV81 a e 1 Oil or filter not changed often enough 2 Head gasket fualty 3 Worn piston r...

Page 16: ...complete and rapid draining Stop the engine Remove the oil filler cap cylinder head oil drain plug engine bottom oil drain plug and drain the oi1 Remove the oil filter with a filter wrench and let th...

Page 17: ...the relief vallie is removed Install the oil 51rainar and oil pan Install the exhaust pipes Fill the crankcase with the recommended oil page 2 1 OIL PRESSURE CHECK Warm the engme up to normal operati...

Page 18: ...seconds If the oil pressure warning indicator stays on stop the engine immediately and determine the cause OIL PUMP REMOVAL NOTE The oil pump can be removed with the engine mounted in the frame Drain...

Page 19: ...d conditions Remove the oil pump by removing the mounting bolts DISASSEMBLY Remove the oil pump body cover and remove the dowel pin Remove the drive pin from the rotor shift Measure the rotor tip clea...

Page 20: ...Otor shaft and measure the pump end clearance STANDARD 0 02 0 07 mm 0 001 0 003 in SERVICE LIMIT 0 10 mm 0 004 in ASSEMBLY Install the outer rotor into the body and insert the rotor shaft Insert the d...

Page 21: ...all the dowel pins and O ring and install the oil pump Install the strainer stay with a new pin al ld install the oil pipe NOTE Make sure the D rings afe installed on the strainer stay and oil pipe In...

Page 22: ...ld face the crankcase Install the washer and tighten the bolt Install the dowel pins and a new gasket IImali the right side cover Instalt the water pump any page 6 131 Install the exhaust system Fill...

Page 23: ...ED 01 L HVPOID GEAR OIL API GL 5 SAE 90 Above SOC 41 FJ SAE 80 IBelowSoC 41 F Reinstall the oil filler cap and wipe the gear case clean CHANGE Aemove the oil filler cap Remove the drain bolt to drain...

Page 24: ...FORK GEARSHAFT PEDAL PIVOT IA T F Date of Issue October 1982 HONDA MOTOR CO LTO PIVOT I I I I I I I PAO LlNK I FOOT PEG PIVOT 25 I I I I I SIDE AND CENTER STAND PIVOT LUBRICATION REAR SHOCK ABSORBER A...

Page 25: ...OR CORE SERVICE INFORMATION GEN ERA L Engme oil Engine oil filter Final drive gear oil SPECIF ICATI ONS Engine Spark plugs See page 2 3 See page 2 3 See page 2 10 BATTERY BRAKE FLUID BRAKE SHOE PAD WE...

Page 26: ...Front 110J90 1861H Up to 90 kg 200 lbsl 32 225 2 25 lood 90 kg 200 fbs load 32 225 2 25 to vehicle cllpacity load Bridgestone L303 Dunlop HONDA V45 I j V45 MAGNA Rear 130190 17 68H 130 90 1667Hj 32 2...

Page 27: ...FRONT e f I il l I f o CLUTCH FLUID 1 c c I CLUTCH SYocST cE M _______ r Miifsi t i iiii r 2 HEAD COMES FIRST 1 3 1B SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS...

Page 28: ...HEAD BEARINGS ODOMETER READING NOTE 3 3 14 17 7 I 3 15 3 16 I I SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICAllY QUALIFIED IN TH...

Page 29: ...e the right side cover Remove the fuel filter from the holder Clip the fuel line inlet side closed Disconnect the fuel lines from the filter Replace the fuel filter with a new one when indicat ed by t...

Page 30: ...t the throttle grip flange FREE PLAY 2 6 mm 1 8 1 4 ii ll Adjustment can be made at either end of the throttle cable Minor adjustments are made with th upper adjuster and major adjustments are mad wit...

Page 31: ...MAGNA There should be no free play Adjust if necessary bv IOOUlning the choke cable clamp on the carburetor end moving the choke cable casing 50 the choke lever is fulty open Tighten Ihe clamp Pull t...

Page 32: ...uel tank is less than half full Drain it if it is more than half full Remove the tank mounting bolts and tift the fuel tank up and hold it in place with the tank support od Remove the air cleaner cove...

Page 33: ...UGS RECOMMENDED SPARK PLUGS NGK NO Standard DPR8EA 9 X24EPR U9 For cold climiate Below SoC 41 Fl OPR7EA 9 X22EPR U9 For extended high speed riding DPR9EA 9 X27EPR U9 Disconnect the spark plug caps Cle...

Page 34: ...the crankcase rear mating surfaces VALVE CLEARANCE NOTE Inspect and adjust 1118 clearance while the engine is cold Below 3S C 9S FI Drain coolant from engine nd frame page 6 3 NOTE Drain the coolant i...

Page 35: ...gauges should remain inserted during adjustment Hold the adjusting screws and tighten the lock nuts TORQUE 21 25 N m 2 1 2 5 kll m 15 18 ft Ib The lock nuts will come loose iflIot tightened 10 tile c...

Page 36: ...ll the vClC lum gauge adapte Connect the vacuum gauges ADJUSTMENT NOTE The No 1 carburetor cannot be adjusted It is the base carburetor Start the engine and adjust the idle speed ID LE SPEED 1 000 100...

Page 37: ...er all other engine adjustments are within spe ifications The engine must be warm for accurate adjust ment Ten minutes of stop and go riding is sufficient Warm up the engine shift to NEUTRAL end plaC1...

Page 38: ...ine then disconnect the spark plug caps and remove the spark plugs Insert the compression gauge Open the throttle all the way and crank the engine with the starter motor Crank the eogine until the gau...

Page 39: ...upper level line Reinstall the battery NOTE Add only distilled water Tap water will shorten the service life of the battery The balll ry electrolyte contains sulphUric ocid PrQtect your eyes skin alld...

Page 40: ...plication of the rear brake pedal BRAKE SYSTEM Inspect the brake hoses and Ittings for delerio ration cracks and signs 01 leakage Tighten any IOO 8 fittings Replace hoses and fittings as reQuired BRAK...

Page 41: ...rake pedal is depressed 20 mm 3 4 in and brake engagement begins Adjust by holding the switch body and turning thelKljuSling nut Do not turn the switch body_ NOTE The front brake light switch does not...

Page 42: ...f the level is low CAUTION Do not remove the cover until the hand lebar M been turned JO lhilt the reunooir slellei Avoid operating the dutch lever with the cap remo ed Fluft l will squirt out If the...

Page 43: ...the forks are cold Place the vehicle on its center stand Remove each air valve cap end measure the air pressure AIR PRESSURE 6 14 psi 40 100 kPe 0 4 1 0 kg cm2 ANTI DIVE SYSTEM INSPECTION t WARNING Se...

Page 44: ...k absorber air pressure REAR SHOCK ABSORBER AIR PRESSURE 14 57 psi 100 400 kP 1 4 kg c m1 NOTE Cneck tne air pressure wnen tne rear shock absorber is cold Adjust tne rebound damping accordmg to the fo...

Page 45: ...e the tires if the tread depth reaches the following limit Minimum tread depth Front 1 5 mm 1 1 6 in Rear 2 0 mm 3 32 in STEERING HEAD BEARINGS NOTE Check that the control cables do not inter fere wit...

Page 46: ...FUEL SYSTEM 4 0 8 Cij HONDA V45 Date of Issue January 1982 HONDA MOTOR CD lTO...

Page 47: ...stem parts note the locations of the O rings Replace them with new ones on reassembly The float bowls have drain screws that can be loosened to drain residual gasoline Fuel pump inspection is in secti...

Page 48: ...etor synchroniution 4 Carburetor faulty 6 Fuel contaminated Misfiring during accelention 1 Ignition system faulty s ckfiring 1 Ignition system faulty 2 Carburetor faulty Poor performance dri eabillty...

Page 49: ...ments Remove both air cleaner case screws and air cleaner cases Remove tht right ignition coil mounting bolts Remove the screw attach ing the water pipe to the air charrber Remove the air enamber COll...

Page 50: ...sen all the carburetor bands Remove the carburetor5 from the intake pipes Also remove the NO 1 intake pipe from the cylinder head Disconnect the spark plug wire clamps on the heat shield Remove the ca...

Page 51: ...nd element Remove the air cleaner case mounting bolt and case loosen the air cleaner connecting bands and remove the air cleaner case Disconnect the spark plug lead clamps on the heat shield Remove th...

Page 52: ...ke and throttle cables Remove the carburetor embly from the rightside NOTE It may be necessary to loo n the engine mount bolts and move the engine on its rubber mounts to provide clearance for car bun...

Page 53: ...ding or other damage Check the diaphragm for deterioration and tears INSTALLATION Installation is essentially the reverse of removal I stall the chamber cover so that its cavity aligns with the hole i...

Page 54: ...and the float tang just contacting the float valve Specification V45 Magrnl 7 2 mm 0 28 in V45 Sabre 8 3 mm 0 33 in NOTE Measure the float nearSf the float valve Adjust the float level by carefully be...

Page 55: ...in jet and slow jet Remove the float valve seat and filter Inspect the float valve seat and filter for grooves nicks or deposits ASSEMBLY Assemble the float chamber components in the reverse order of...

Page 56: ...drill point Drill through the plug with 8 4 mm 5 32 in drill bit being careful not to drill into the pilot screw CAUTION Be careful not to drill into the pilot screw All pilot SerE Wi must be replaced...

Page 57: ...o their original position as notld during removal Perform pilot rew adjustment if new pilot screws are instilled page 4 18 NOTE Do not install new plugs on new pilot screw holes until after adjustment...

Page 58: ...4 carburetor CAUTION Separate the ctIrburetors horizontally to pre vent datrnlge to the joint pipes Disconnect the throttle link from the No 1 end 2 carburetors by removing the cotter pins 4 12 RODS N...

Page 59: ...or Remove the choke valve nut spring and valve Oleck the choke valve and spring for nicks grooves or other damage Date of Issue May 1982 HONDA MOTOR CO LTO No 1 CAIRBLIRETOR NUT 61 FUEL SYSTEM No 2 CA...

Page 60: ...r Coat the new O rings with oil and install them on the fuelloint pipe for No 1 and No 2 carburetors Instlll the fuel joint pipe to the No 1 and No 2 carburetors Reconnect the thronle linkage between...

Page 61: ...until ther is no tension Instill the synchronization springs Install the thrust springs between the throttle valve shafts Make sure the fuel joint and air joint pipes are securelv installed Date of l...

Page 62: ...el pins are in place Place thl air chamber Ol ef the carburetors aligning the dowel pins with the carburetor holes Attach the air chamber to the carburetors with the eight screws Connect the tuellines...

Page 63: ...hrottle Make sure that choke valye operation is smooth by moving the choke linkage Close the choke valve by turning the choke linkage Aele e the choke linkage and make sure that it returns smoothly CA...

Page 64: ...e manufac turer s instructions 4 Adjust the idle speed with the throttle stop screw IDLE SPEED 1 000 100 rpm 5 Turn nch pilot screw 1 2 turn out from the initial setting 6 If the engine speed increase...

Page 65: ...the filler cap for blockage Check that fuel is flowing out of the fuel vallie freely If fuel flow is restricted clean the fuel Itrainer NOTE 00 not overtighten the fuel val111 tock nut V45 SABRE V45SA...

Page 66: ...uel tube Irom the carburelOr Inspect the fuel tube for fuel flowing out Drain the remaining fuel in the fuel valve and fuel tube apprOK 5 10 cel If the fuel flow stops the automatic fuel valve is oper...

Page 67: ...NER CASE CHAMBE R Check the air cleaner case for deterioration CRANKCASE VENTILATION SYSTEM Check that the breather tube is not restricted V45SABRE V45MAGNA 0 Date of Issue May 1982 HONDA MOTOR CO LTD...

Page 68: ...0 rpm with the throttle stop screw Dnve new pilot screw plugs into the pilot screw bores page 4 18 NOTE adjustment must b de at high alti e to ensure proper high altitude operation Attach 8 Vehicle Em...

Page 69: ...80 N m 7 0 8 0 kg m 51 58 ft lbl 11 35 45 N m 3 5 4 5 kg m 25 33 ft lb 60 80 N m 6 0 8 0 kg m 43 58 ft Ibl 45 10N m 4 5 7 0 kg m 33 51 ft lb 30 40 N m 3 0 4 0 kg m 22 29 ft lbl ____ 8 28 N m 18 28 N...

Page 70: ...18 28 N m t1 8 2 8 kg m 13 20 tt b 5 ENGINE REMOVAL INSTALLATION 5 2 5 3 5 8 30 40 N m 22 29 ft Ib 8 14 N m l d J 10 8 1 4 kg m _O 6 10 ft b 18 28 N m 1 8 2 8 kg m 13 20 ft Ib ______ l8 t2 N m 0 8 1...

Page 71: ...anel lOp bolt Final gear case nut Exhaust pipe jomt nut Muffler mount bolt Exhaust chamber mount bolt E haust pipe clamp bolt 5 2 84 7 kg 187 Ib 3 0 liter 3 2 U S qt 20 30 N m 12 0 3 0 kg m 14 22 ft I...

Page 72: ...and the coolant page 6 3 Loosen the water pump hose band Remove the clutch slave cylinder NOTE Do not operate the clutch lever after removing the clutch slave cylinder To do so will cause difficulty i...

Page 73: ...re coupler Dilconnect the gearshift indicator switch coupler and wire connector Disconnect the engine ground cable 5 4 7 Cii HONDA V45 SABRE MAGNA ALTERNATOR WIRE COUPLER COUPLE A ANle CONNECTOR HOND...

Page 74: ...by removing the bolt Disconnect the oil pressure switch wire and pulse generatOf wire coupler Disconnect the starter motor cable and spark plug caps Date of IlSue May 1982 Cl HONDA MOTOR CO LTO ENGINE...

Page 75: ...t chamber mount bolts Remoye the exhaust muffler mount bolts and joint nuts loosen the exhaust pipe clamp bolts and remove the exhaust muHler Remove the rear wheel page 17 3 and the final gear page 14...

Page 76: ...pport under the eogine NOTE The jack height must be continuously adjust ed so that mounting bolts can be removed and so rtren is rel ieved from other bolts until they are removed Remove the engine mou...

Page 77: ...l Page 2 1 Fill the cooling system Page 6 3 Perform the following inspection and ad justments Throttle operation Page 3 6 Clutch Page 3 18 Install the e haust system Install new exhaust pipe joint gas...

Page 78: ...COOLING SYSTEM 6 0 HONDA V45 SABRE MAGNA Date of Issue January 1982 Cl HONDA MOTOR CO l TO...

Page 79: ...ief pressure Free ing point Hydrometer test Coolant capacity Radiator and engine Reserve tank Total system Thermostat Boilinll point with SO 50 mixture TOOLS Special 0 75 1 05 kg cm2 10 7 14 9 psi 55...

Page 80: ...ssure for at least six seconds NOTE Before installing the cap on the tester apply wate to seating wrfaces RADIATOR CAP RELIEF PRESSURE 0 9 0 15 kg cm1 12 8 2 1 Psi Preuurize the radiator engme and hos...

Page 81: ...water pump coyer and cylinder heidi Replace the dr in plug and bolb Fill the system with I SO SO mil tur of distilled wat T and ethylene glycol Bleed iT from the radiator Start the engine and run unti...

Page 82: ...nd right air cleaner c se Loosen the rach tor upper hose band and remove the water pipe attaching screw Disconnect the wire connector from the temper ature sensor Remove the thermostat housing cover b...

Page 83: ...drain the coolant page 6 3 Remove the right radiator cover and right air chamber cover Remove the bolt attaching the thermostet housing to the lir chamber LOOMn the hose bands Remove the thermostat ho...

Page 84: ...t responds at temperatures other than those 5Pecified TeChnical Oat Start to open SOO to 84D C 1176 183 F 8 mm minimum 0 31 in Valve lift when hleated to 95 C 203 F for five minutes INSTALLATION IV45...

Page 85: ...cleaner case element and cover Fill the cooling system page 6 3 INSTALLATION V45 MAGNA Insert the thermostat into the housing Install a new a dng on the thermostat housing cover Install the thermostat...

Page 86: ...otor wire coupler trom the wire harneu On the V45 SABRE remove the radiator lower hose cover On the V45 MAGNA remove the right air chamber cover and right and left radiator covers Disconnect the wires...

Page 87: ...ove the right and left radiator cover bolts and nuts covers and radiator grille Remove the fan shroud with the fan by removing the four bolts Remove the fan attaching screws and remove the fan from th...

Page 88: ...t from between core fins with com pressed air If insects tc are clogging the radiator wash them off with low pressur water ASSEMBLY Install the fan over the motor shaft Apply a locking agent to the fa...

Page 89: ...s on the radiator In t811 the radiator on thl frame and tighten the mounting bolts and nuts Connect the inlet aod outlet hoses and tighten the hose bands Connect the wire coupler to the thermostatic s...

Page 90: ...ain plug from the lower left frame and drain the coolant Remove the drain h at the water pump and dr in the coolant from ttie cylinders Disconnect the water hose from the water pump cover Remove the w...

Page 91: ...o a new Coring and install it in the water pump groove Align the water pump shaft groove with the oil pump shaft and insert the water pump in the crankcase Insert a new O ring over the end of the wate...

Page 92: ...torque the bolts TORQUE 7 5 10 5 N m 0 75 1 05 ka m 6 8 ft Ib Connect the water ho and tighten all the hose bands Inst 1I the cr nkC M rear cover Tighten the drain plug It the left sub frame Fill the...

Page 93: ...CLUTCH 25 35 N m 2 5 3 5 kg m 8 2 ft b 7 0 iii 5 7 N m 0 5 0 7 kg m 4 5 tt lb HONDA V45 SABRE MAGNA 25 35 N m 2 5 3 5k m 18 25 ft Ib Date of Issue January 1982 e HONDA MOTOA CO LTO...

Page 94: ...SLAVE CYLINDER 7 8 47 53 N m 4 7 5 3 kg m 80 100 N m 8 0 10 0 kg m 58 72 ft bl CLUTCH COVER REMOVAL STARTER CLUTCH DISASSEMBLY CLUTCH DISASSEMBLY CLUTCH ASSEMBLY STARTER CLUTCH ASSEMBLY CLUTCH COVER I...

Page 95: ...mmon Universal holder Extension bar lock nut wrench 17 27 mm Driver Attachment 42 47 mm Pilot 35 mm 7 2 STANDARD 14 000 14 043 mrn 0 5512 0 5524 in 13 957 13 984 mm 10 5495 0 5506 in 38 100 38 162 mm...

Page 96: ...bubbles in hydraulic system 2 low fluid level 3 Hydraulic system leaking 4 Hydraulic system sticking 5 Ptates warped O te of Issue January 1982 e HONDA MOTOR CO LTD Motocycle creepi with clutch diMing...

Page 97: ...rent types of flUid since they may not be compatible Close the bleed valve till the reservoir and install the diaphragm To prevent piltOll overtr el and clutCh fluid see page keep a 20 mm 3 4 in space...

Page 98: ...R CYLINDER DISASSEMBLY Drain clutch fluid from the hydraulic system Remove the reer view mirror and clutch lever Disconnect the clutch switch wires and remove the clutch hose CAUTION Avoid spilling cl...

Page 99: ...ster cylinder 1 0 Check the master cylinder for scores scratches or nickl SERVICE LIMIT 14 06 mm 0 553 in MASTER PISTON 0 0 INSPECTION Measure the master pinon 0 0 SERVICE LIMIT 13 94 mm O 549 in Chec...

Page 100: ...Pilei the mISter cylinder on the handlebar and innall the holder and the two mounting boilS Tighten the top bolt first then the bottom bolt Instill the oil hose with the bolt and its two sealing washB...

Page 101: ...d spilling clutch fluid on painled sur I faces Remove the slave cylinder Place I shop towel over the piston to cushion the piston when it is e pelled and position the cylinder with the piston down App...

Page 102: ...the piston for scoring or scratches Measure the outside diameter of the piston with a micrometer SERVICE LIMIT 38 02 mm 1 497 in CYLIN DER 1 0 INSPECTI ON Check the slive cylinder for scoring or sera...

Page 103: ...e certain the piston seal is seated in the piston groove Place the piston in the cylinder with the oil seal end facing out Install the insulator and slave cylinder Connect the clutch hose with the oil...

Page 104: ...Almove the clutch cover gasket and dowel pins STARTER CLUTCH DISASSEMBLY Remove the starter idle gear shaft and gear Remove the alternator cover Hold the flywheel w ith a universal holder Date of Inu...

Page 105: ...ary drive gear Remove the startar driv n gear and needle bearing from tha starter dutch Inspect the rollers for smooth ope ti on R mov the starter clutch colier by removing the thr bolts Remove the cl...

Page 106: ...rate the clutch lever after removing the clutch To do so will cause difficulty in reassembling the clutch Remove the bolts artd clutch springs NOTE loosen the bolts In a crisscrou pattern in 2 3 steps...

Page 107: ...e clutch spring free length SERVICE LIMIT 34 0 mm fl 34 i 1 CLUTCH DISC INSPECTION ReplKe the clutch discs if they show signs of 5Coring or discoloration Measure the thickness of each disc SERVICE LIM...

Page 108: ...CH OUTER INSPECTION Check the slots in the clutch outer for nicks cuts or indentations made by the friction discs Check the clutch outet needle bearing for damage or excessive play If the needle beari...

Page 109: ...mlin haft Instill the needle be ring into the clutch outer Align the holes in thl clutch out r with the pins on the oil pump drive sprocket and in5t811 the clutch outer Install the clutch center 7 16...

Page 110: ...with the clutch holder and tighten the lod nut TORQUE 47 53 N m 4 7 5 3 kg m 34 38 ft lb Coat the discs and plates with clean engine oil Install the clutch discs and platM as shown Date of Issue Janua...

Page 111: ...ifter guide Install the clutch springs plain washers and bolts NOTE Tighten the bolts evenlv in 2 3 steps In e crisscross pattern STARTER CLUTCH ASSEMBLY Install the primary drive gear onto the cranks...

Page 112: ...l the dowel pin Insutt the starter clutch cover aligning the dowel pin hole with the dowel pin and tighten the bolts TORQUE 26 30 N m 12 6 3 0 kg m 19 22 ft lb NOTE Apply a lock iog agent to the bolt...

Page 113: ...the flywheel with 8 universal holder and tighten the starter clutch bolt to the specified torque TORQUE 80 100 N m 8 0 10 0 kw m 58 72 ft rb Instali the alternator cover CLUTCH COVER INSTALLATION Ins...

Page 114: ...HONDA V45 install tne clutch cover Fill the cr nkcase with oil page 2 3 Date of Issue Mav 1982 HONDA MOTOR CO LTD CLUTCH CLUTCH COVER 7 21 _ _...

Page 115: ...GEARSHIFT LINKAGE 8 0 r j HONDA V45 Date of Issue May 1982 e HONDA MOTOR CO l TO...

Page 116: ...1 8 1 8 2 8 4 It the shift forks drum and transmission require servicing remove the engine and separate the crankcase TROUBLESHOOTING Hlrd to Ihift 1 Improper clutch hydraulic system air bubbles in sy...

Page 117: ...ft crankcaw rear cover Remove the gearihift pedal clutch colier and clutch assembly hection 7 Remove the oil pump driven sprocket bolt Remove the oil pump drive chain drive and driven sprockets 8 2 ON...

Page 118: ...e drum stopper arm nut arm and spring Puillhe gearshift spindle assemblv out of the crank 0fi0 Remove the neutral stopper arm bolt arm and spring Date of Issue January 1982 C HONDA MOTOR CO LTO GEARSH...

Page 119: ...of the shift drum tmert the five pins in the holes of the cam plate Align the cam plate hole with the dowel pin on the shift drum and Install the cam plate Tighten the bolt securelv Install the washer...

Page 120: ...t securely_ Rotate the gearshift spindle and check the linkage for smooth operation Install the oil pump drive and driven sprockeu with drive chain and tighten the driven sprocket bolt securely NOTE T...

Page 121: ...marks on the gearshift pedal and gearshift spindle and install the gearshift pedal assembly Install the left crankcase rear cover and fill the crankcase with oil page 2 3 8 6 I HONDA V45 Date of Issu...

Page 122: ...ALTERNATOR 9 0 8 0 10 0 kg m 58 72 ft lb 0 _ _ _ _ _ _ _ _ r j HONDA V45 Date of Issue January 1982 C HONDA MOTOR CO LTO...

Page 123: ...rs removal and installat ion of the alternator Refer to section 18 for troubleshooting and inspection of the alternator TORQUE VALUE Altlmltor rotor Flywheel bolt TOOLS Common Universal holder Rotor p...

Page 124: ...the alternator cover Hold the flywheel with a universal holder and re move the flywheel bolt Remove the flywheel with the rotor remover Aemove the woodruff key from the crankshaft 9 2 _ UNIVERSAL HOL...

Page 125: ...lts and wire clamp STATOR INSTALLATION Instalt the stator and wire clamp Route the alternator leads properly and connect the alternator wire coupler to the wire harness Secure the alternator leads wit...

Page 126: ...yway with the key in the crankshaft Hold the flywheel with 8 universal holder and torque the flywheel bolt TORQUE 80 100 N m 8 0 10 0 kg m 58 72 ft lbl Install the alternator cover Check engine oil le...

Page 127: ...kg m 15 18 ft lb 33 37 N m 10 14 N m Cfj HONDA V45 1 0 1 4 k m 7 10 ft tb 45 50 N m 4 5 5 0 kg m 33 36 ft lbl 3 3 3 7 kg m 24 27 ft lbl 10 0 18 20 N m 11 8 2 0 kg m 13 14 ft tbl 0 20 25 N m 2 0 2 5 kg...

Page 128: ...2 kg cm2 184 28 psi Camshaft Cam height IN 35 335 35 495 mm t1 3911 1 3974 in 35 3 mm 1 39 in EX 35 335 35 495 mm 1 3911 1 3974 in 35 3 mm 1 39 in Runout 0 10mm 0 004 in End ctearance 0 05 0 25 mm 0 0...

Page 129: ...m 24 27 ft lbl 21 25 N m 2 1 2 5 kg m 15 18 ft lb 45 50 N m 4 5 5 0 kg m 33 36 ft lb 18 20 N m 1 8 2 0 kg m 13 14 ft lb 07984 2000000 07942 3290200 or 07742 0020200 07757 0010000 07742 0010100 Engine...

Page 130: ...ad Remove the cylinder head cover and COlier base from the rear cylinder head Remove the oil pipe and cam chain guide mounting bolts and remOlle the cam chain guide Remove the alternator cover and rot...

Page 131: ...until the T2 4 mark aligns with the rear cr nkuse mating surface Clean the camshaft sprockets with contact cleanet Index the front cylinder camshaft sprockets with the top of the cylinder head Use a...

Page 132: ...Inspect the camshaft and holder journal surfaces for scoring scratches or evidence of insufficient lubrication CAMSHAFT RUNOUT Check camshaft runout with a dial indicator Support both ends of the cam...

Page 133: ...plestigauge lengthwise on top of each camshaft journal Install the camshaft holders and tighten in a crisscross pattern NOTE Do not rotate the camshaft when using plastigauge TORQUE A 6 mm BOLT B 8 mm...

Page 134: ...l cemshaft and recheck the oil clearanet Replace the cylinder h ad and camshaft holders f the clearance still ct eds service limits CYLINDER HEAD REMOVAL Loosen the water hose clamp Remove the water p...

Page 135: ...pin and remove the tlnsioner slipper base R mov the cylinder head bolts Remove the cylinder heads using a screw driver at the pry points Aemov the front and rear cylinder head gaskets and dowel pins 1...

Page 136: ...ssive wear Inspect the cam enl lin tensioner slipper for damage or excessive wear Inspect the spring for good tension replace if necessary CYLINDER HEAD DISASSEMBLY Remove the rocker arm shaft and roc...

Page 137: ...arts to ensure correct reassembly Remov the valvI stem 5eals Ramove carbon deposits from the combustion chamber and clean off the head gasket surfaces NOTE Avoid damaging the gasket wrfaces Gaskets wi...

Page 138: ...Measure tach rocker arm shaft 0 0 SERVICE LIMIT 11 93 mm 0 470 Inl Ins t the shaft for wear or damage nd c lculate the shaft to rocker arm clearance SERVICE LIMIT 0 12 mm 0 005 in Inwatt the rocker a...

Page 139: ...55 mm O 219 in Subtract each valve stem 0 0 from the corres pond ng guide I D to obtain Ihe tem to guide clearance SERVICE LIMIT IN EX NOTE 0 08 mm 0 003 in 0 10 mm 0 004 in If the stem to guide clea...

Page 140: ...m side of the cylinder head NOTE Cylinder head heat should still be at l00 C 1212 Fl for installation of the new guides Let the cylinder head cool to room temperature and ream the new valve guides NOT...

Page 141: ...N The W1ll1u cannot be ground If the l Owe oce i rough worn u lellen y or contacts the seat improperly the valve must be replDced Inspect the vallll seat If the seat is too wide too narrow or has low...

Page 142: ...ls should face in Instalt the valve cotters CAUTION To pre ent loss of tension do not com press the vallie spring more than necessary to install he valve keepers Thread the lorge retainer on the compr...

Page 143: ...Ib CYLINDER HEAD INSTALLATION Clean the cylinder head surface of any gasket material Install the dowel pins and new head gaskets Install the front cylinder cam chain guide with the Wisher and clip NO...

Page 144: ...ss the cam chain through the cam chain tensioner and install the tensioner slipper as shown NOTE Check that the lower end of the slipper fits in the slipper base correctly Tighten the cylinder head bo...

Page 145: ...r and cylinder head InSlall the water pipes and hose and tighten the hose bands securely CAMSHAFT INSTALLATION Lubricate the camshaft journal surfaces of the cylinder head with molybdenum disulfide gr...

Page 146: ...kets with contact cleaner and wipe dry On a piece of paper draw two Hnes one vertical one horizontal perpendicular to each other goo Use a protector and draw two diagonal tines at a 450 angle Center t...

Page 147: ...nges and loosely insull the sprocket bolts NOTE Apply II locking agent to the thrnds and underside of the bolt heads before irutalla tlon Install the camshaft holders Do not torque the bolu until ever...

Page 148: ...one turn 360 and install the other cam sprocket bolts NOTE Apply a locking agent to the threads and underside of the sprocket bolt heads Tighten the cam sprocket bolts to the speCified torque TORQUE...

Page 149: ...on the 011 pipe base plate aligning the bolt holes Tighten the bolts to the speCified torque TORQUE CAM CHAIN GUIDE 20 25 N m 12 0 2 5 kg m 14 18 fl Ibl OIL PIPE 10 14 N m 11 0 1 4 kg m 7 10 ft lb Pu...

Page 150: ...91skl near the arrow casting on the inside of th cover Apply seelant to the hod cover gaskets Install the front CYlmder head cOlier end gasket Install the rear cylinder head COVlr base cover and gask...

Page 151: ...0 8mm 21 25 N m 2 1 2 5 kg m 15 18 ft lb J 6mm 10 14 N m 1 0 1 4 kg m 7 10 ft lb 6mm 10 14 N m HONDA V45 1 0 1 4 kg m 7 10 ft lb 9mm 30 34 N m 3 0 3 4 kg m 22 25 ft Ib Date of Issue May 1982 C HONDA M...

Page 152: ...removed before disassembling the crankcase Oil pan Refer to section 2 Oil pump Refer to section 2 Water pump Refer to section 6 Clutch starter clutch Refer to section 7 Gear shift linkage Refer to se...

Page 153: ...embling crankcase Removi the mamshaft Maring holder by removing the screw aod bolts Remove the crankcase bolt located below the holder Turn the engine over and remOll1 the lower crank case bolts NOTE...

Page 154: ...e for ease of reinstallation Separate the crankcase Remolle the following parts Piston and connecting rods Section 12 Crankshaft Section 13 Shift fork and shift drum Section 131 Gear shift indicator s...

Page 155: ...d shift drum Section 13 Transmission Section 13 Crankshaft S ction 12 Pinon and connecting rods Section 12 Apply molybdenum disulfide grease to the shift fork groovltS of the M2 C4 and C6 gears 11 4 H...

Page 156: ...T THIS AREA Assemble the crankcase halves aligning the shift fork claws with the gears Tighten the bolts to the specified torque values in the sequence shown TORQUE VALUES 9 mm bolt 30 34 N m 3 0 3 4...

Page 157: ...d during dis assembly refer to page 13 6 for gasket selection procedures Early production engines had gaskets that were not marked The gasket Is crushed O OS mm when the output gear case is installed...

Page 158: ...CRANKSHAFT PISTON 30 34 N m 3 0 3 4 kg m 22 25 ft lb FRONT 12 0 66 Date of Issue May 1982 C HONDA MOTOR CO l TO...

Page 159: ...mm 0 0011 0 0020 in 0 08 mm 0 003 in CVlinder 17 70 10 mm 2 76 in 1 0 70 000 70 015 mm 2 755 2 756 In Warpage 0 10 mm 0 004 in PIston Ring to groove Top 0 015 0 045 mm 0 0006 0 0018 in 0 10 mm 10 004...

Page 160: ...rn cylinder or piston ring Excessiye smoke 1 Worn cylinder piston or piston rings 2 Improperiy installed piston rings 3 Damaged piston or cylinder Overheating 1 Excessive carbon build up on piston hea...

Page 161: ...he connecting rods and piston out through the top of the cvlinder bores CAUTION On engines with high milettge inspect the cylinders for a ridge just abov the highest point of rillg travel Any ridge mu...

Page 162: ...piston position PISTON PISTON RING INSPECTION Measure the piston ring to groove clearance SERVICE LIMIT 0 10 mm 0 004 in TOP SECOND Remove the piston rings and mark them to indicate the correct cylin...

Page 163: ...e bonom and 90 to the piston pin hole SERVICE LIMIT 69 85 mm 2 750 in Inspect the cvlinder bores for wear or damage Mlnure the cylinder 1 0 at three levels in X and Y IX is SERVICE LIMIT 70 10 mm 12 7...

Page 164: ...iCe LIMIT 17 98 mm 10 70 in Calculate the piston pin to piston clearance SERVICE LIMIT 0 04 mm 0 002 in Measure the connecting rod small end 1 0 If the reading e ceeds the service limit replace the ro...

Page 165: ...001 in CAM CHAIN LENGTH MEASUREMENT Place the cam chain on the camshaft sprockets with the punch marks positioned as indicated Secure one camshaft sprocket and apply 13 kg 29 Ibs of tension to the ot...

Page 166: ...rd the exhaust pares Remember the front and rear cylinder exhaust ports au opposite direc tions Install the bearing caps and rods on the correct crankpins and tighten them evenlv TORQUE 30 34 N m 3 0...

Page 167: ...on the lower crankcase and tighten them evenly in 2 3 steps in the sequence shown TORQUE VALUES 6 mm bolt 10 14 N m 1 0 1 4 kg m 7 10 ft lbl 9 mm bolt 30 34 N m 13 0 3 4 kg m 22 25ft lbl NOTE Do not r...

Page 168: ...ers A 8 or C on each crank weight is the code for each cr nk pin 0 0 Cross refer nce the crankpin and rod codes to deter mine the re tacement bearing color CR NI PlN 0 0 CODE NO A 35 97 36 ooomm 36SSl...

Page 169: ...0 NOTE A number 1 2 or 3 on each crank weight is the code for the adjacent main journal 0 0 Cross reference the case and journal codes to deter mine the replacement bearing 60 E CV k w1 C IB own o IG...

Page 170: ...iston domes nng lands and skirts Carefully install the piston rings onto the piston Stagger the ring end gaps as shown NOTE Be careful not to damage the piston and piston rings during assembly All rin...

Page 171: ...cylinder connecting rod and piston assembly Nole that the rear cylinder connecting rods are marked MBO R Install the pistons on the rear rods so that the intake IN mark is facing the same direction a...

Page 172: ...ts original position as noted during removal NOTE The piston intake IN marks should be facing each other as shown ___ Compress the piston rings with a rmg compressor and insert the piston and rod into...

Page 173: ...e bearing caps are installed in their correct location as marked during remOllill Tighten the nuts in two or more steps After tightening the bolts check that the rods move freely without binding Assem...

Page 174: ...SMISSION 90 110 N m 1 0 kg m 9 0 1 65 80 ft lbl 70 80 N m 51 58 ft Ib p D B D kg m 13 0 0 182 ONDA Q R SAIIRE V45 MAGNA r 0 G 30 34 N m 22 25 ft lb 3 0 3 4 kg m May 1982 0 Date of I U OTOR CO l T C HO...

Page 175: ...n gear 15a set When using the lock nut wrench use I deflecting beam type torque wrench 14 20 inches long The lock nut wrench in creases the torque wrenche s leverage so the torque wrench reading will...

Page 176: ...emoyer weight Common DriYer Pilot 30 mm Attachment 52 55 mm Attachment 42 47 mm Pilot 17 mm DriYer Attachment 25 mm TROUBLESHOOTING Hard to wift 1 Clutch slaye cylinder sticking 2 Shift fork bent 3 Sh...

Page 177: ...asket is on it measure it and record that measurement Replace the gasket with one of the same thickness If you had to measure the old gasket replace it with one that is 0 05 mm thicker to compensate f...

Page 178: ...28 94 mrn 1 139 in M5 1 0 25 04 mm 0 986 in elI D 20 40 mm 0 803 in C4 1 0 25 04 mm 10 986 in Measure the 0 0 of the mainshah and tounler haft SERVICE LIMITS A at MS bushing 24 90 mrn 0 980 in B tn Cl...

Page 179: ...ing it against the ise to lock the shaft Unstake the inner beiring race lock nut with a drill or grinder Be careful that metal particles do not enter the bearing and the threads on the shaft are not d...

Page 180: ...TERSHAFT BEARING REPLACEMENT NOTE Countershaft must be removed before replac ing bearing Place the bearing holder In a vise with soft jaws or shop towel NOTE Do not damage the bearing holder especiall...

Page 181: ...ced as a set if they or the gear case or bearing require replacement Place the countershaft and countershaft bearing holder into a press Press the countershaft into the bearing NOTE Place the pilot th...

Page 182: ...seats against the case Then tighten to the specified torque TORQUE 30 34 N m 3 0 3 4 kg m 22 25 ft lb Place the case mto a vIse with soft jaws Install and t ighten a new countershah nut to the specif...

Page 183: ...t the shift shaft spindle boss Unuake and loosen the output driven gear bearing inner race lock nut Remove the driven gear bearing holder mounting bolts and remove the gear and holder from the case Da...

Page 184: ...e with wft jaws Unstake and remove the output driven gear bearing outer face lock nut from the holder Press the output driven gear from the holder Place the bearing holder in ill press and press the b...

Page 185: ...TALLATION NOTE Remove the center guide from the dis assembly tool before using When the gear set driven gear bearing and or gear case has been replaced use a shim 0 30 rnm 0 012 in thick for initial r...

Page 186: ...a11 a new bearing inner race lock nut and tighten it to the specified torque TORQUE 70 80 N m 7 0 8 0 kg m 51 58 ft lb Torque wrench seala reading 64 73 N m 6 4 7 3 kg m 46 53 ft lb Stake both new loc...

Page 187: ...ION Always wear gloves when handling a heated gear case Remove the bearing with the bearing remover Drive a new bearing into the output gear case Date of Issue May 1982 HONDA MOTOR CO LTD TRANSMISSION...

Page 188: ...n after removing the drive gear Contact is normal if Prusian Blue in transtered to the appro Cimate center of each tooth and slightly to the side If the pattern is nOt correct remove nd replace the dr...

Page 189: ...t a horizontal type dial indicator on the counter shaft as shown Hold the driven gear with the shaft holder and rotate the countershaft by hand until gear slack is taken up Turn the countershaft back...

Page 190: ...SELECTION NOTE The output gear must be assembled for th iS selection procedure to be accurate This selection IS only necessary when the gear set drive gear beanng or gear case is replaced or If the o...

Page 191: ...r thickness mm distance A STANDARD 35 00 0 10 mm 1 378 0 004 in Select the correct gasket thickness to obtain the standard distance A by using the formula below DISTANce Po STO GASKET DISTANCE THICKNE...

Page 192: ...nstall the output gear case assembly and new gasket ontO the lower case Assemble the transmission with the origmal spacer Measure the clearance between the bearing and spacer with a feeler gauge CLEAR...

Page 193: ...mounting boh Remove the shift fork shaft and l1ift forks Remove the shift drum GEAR SHI FT DRUM AND SH IFT FORK INSPECTION Inspect the shift drum end for scoring scratches or evidence of insufficient...

Page 194: ...rk surfaces Cheek for scratches scoring or evidence of insuf ficient lubrication SERVICE LIMIT 13 90 mm 0 547 in Measur the right and left shift fork 1 0 Mlnur the shift fork claw thickness SERVICE LI...

Page 195: ...lock washer and tighten the center fork _ bolt TORQUE 16 20 N m 11 6 2 0 kv m 12 14 ft Ibl Bend the lock washer tabs up Applv a locking agent to the scraw threads and install the bearing stOPptlf pin...

Page 196: ...ools Check the gears for freedom of movement or rota tion on the shaft Check that the snap rings are seated in the grooves 13 22 c jj HONDA V45 SABRE MAGNA DRIVER ii i46 xI lO OF 07945 3710200 Al C iM...

Page 197: ...in the M6 gear bushing with the hole in the mainshaft COUNTERSHAFT Before placing the countershaft in the crankcase install the C4 and C6 gears washers and collar Date of Issue May 1982 HONDA MOTOR C...

Page 198: ...ile aligning the tab of the stopper washer w ith the groove in the spline collar Assemble the C2 C5 and C1 gears washers and collars Install the lower crankcase Aefef to Section 11 NOTE Check the oil...

Page 199: ...m 23 28 N m 2 3 2 8 kg m 17 20 ft lb 10 mm 35 45 N m 3 5 4 5 k n 25 33 ft lbl 100 120 N m 10 12 kg m 72 87 ft Ib 72 87 ft lbl er C y HONDA V45 45 70 N m 4 5 7 0 kg m 33 51 ft Ib Date of Issue Mav 1982...

Page 200: ...is the actual torque applied to the lock nut not the reading on the torque wrench when used With the lock nut wrench The torque wrench scale reading is given with the actual torque specification SPECI...

Page 201: ...ange 2 Scored driven flange and wheel hub 3 Worn or scored drive pinion and spllOes 4 Worn pinion and ring gears 5 Excessive backlash between pinion and ring gear 6 Oit level too low Oil luk 1 Clogged...

Page 202: ...ring as described above Remol e the dril e shaft from the final gear case as described below Insert the axle through the gear Cnt and secure the case in a I ise with soft jaws or shop rags by clamp in...

Page 203: ...the dnve shaft Check the damper lifter and cam for wear or damage Remove the oit seat and 01 seal guide from the damper case NOTE Replace the oil seal with 8 new one if it is removed 14 4 Cif HONDA V...

Page 204: ...OIL CAPACITY 80 cc 2 7 ozl ASSEMBLY lnsta 1 the damper cam spring into the damper case Drive the oil seal guide and oil seal in with the driver and attachment Assemble the remaining parts in the reve...

Page 205: ...Gear Puller Attachment 07947 6340201 Separate the ring gear from the case cover by tapping the cover with a 50ft hammer The oil seal will come out with the ring gear if the tool is used remove and di...

Page 206: ...PINION GEAR REMOVAL Unstake the pinion shaft nut Install the pinion jOint holder onto the pinion joint and remove the pinion shaft nut Remove the tool and pinion joint Date of Issue Mav 1982 HONDA MO...

Page 207: ...ner with the pinion retainer wrench Pull off the pinion assembly with the pinion puller 14 8 J HONDA fe V45 SAaRE MAGNA LOC TAB BOLT AETAINER PINION PULLER ATTACHMENT KIT 07931 4630200 and PINION PULL...

Page 208: ...ment spacer PINION RETAINER OIL SEAL REPLACEMENT Remoye the a ring and oil Sial from the pinion retainer Drive a new oil seal into the relamer Coat a new a ring with 011 and install it onto the reta i...

Page 209: ...lYs _ar glol t s when handling the g ar case after it has been heated Remove the ring gear shaft oil seal Dnve a new oil seal into the case using the drivtr 07749 0010000 and attachment 107945 33303 0...

Page 210: ...ion bearing andlor gear case nil been replaced use 8 2 0 mm thick spacer ____________ J Press the inboard inner race onto the pinion gear using thll special toot Install the pinion gear bearing outer...

Page 211: ...onto the ring gear NOTE If the gear set pinion bearing ring gear bear ing and or gear case is replaced install a 2 0 mm thick spacer Place the ring gear bearing over the ring gear shaft Place a new ri...

Page 212: ...ceeds the limit heat the gear case cover to approximately SOoC 176 F and remove the stop pin bv tapping the cover c WARNING Always wear gloves when handling the gear COM after it liar been heated Inst...

Page 213: ...contact pattern check Place the wave washer and ring gear into the gear case Apply gear 011 to the lip of the oil sui on the gear case cOver and install the gear case cover Tighten the cover bolts in...

Page 214: ...e measurements DIFFEAENCE OF MEASUREMENT SERVICE LIMIT 0 10 mm 0 004 in If the difference in measurements exceeds the limit It indicates that the bearing i not in talled squarely Inspect the bearings...

Page 215: ...ace of the pinion joint and Install the pinion joint Install the pinion joint holder tool and tighten the pinion nut TORQUE 100 120 N m 10 12 kg m 72 87 ft Ib Remove the pinion joint holder tool MIke...

Page 216: ...ard plate and torQue the bolts Install the distance collar FINAL DRIVE INSTALLATION Fill the damper case with the recommended type and amount of lubricant RECOMMENDED OIL HYPOIO GEAR OIL API GL 5 Abov...

Page 217: ...nuts To ease axle installation do not tighten the gear case nuts until after the axle is installed Install the rear wheel page 17 71 Tighten the axle nut TORQUE 55 65 N m 5 5 6 5 kg m 40 47 ft lbl Tig...

Page 218: ...kg m 40 47 ft lb 15 0 18 28 N m 11 8 2 8 kg m 13 20 ft lb 228 f J HONDA V45 45 50 N m 14 5 5 0 kg m 33 36 ft lb _ 80 120 N m 8 0 12 0 kg m 58 87 ft lb 3 N m 0 9 1 3 kg m 7 9 ft lb 45 55 N m 4 5 5 5 k...

Page 219: ...t lb 15 25 N m 1 5 2 5 kg m 11 18ft lbJ late of Issue May 1982 HONDA MOTOR CO LTO 15 2 INSTRUMENTS V45 MAGNA 15 12 15 3 HANDLEBARS 15 15 15 4 FRONT WHEEL 15 19 15 5 FRONT FORKS 15 25 15 6 STEERING STE...

Page 220: ...ront fork bottom pinch bolt 1 5 2 STANDARD 0 3 mm 0 01 in max 0 3 mm 0 01 in max 531 9 mm 20 94 in Right 375 cc 112 7 oll Left 390 cc 13 2 oz Right 390 cc 03 2 ozl Left 405 cc 13 7 ozl 40 100 kPa OA l...

Page 221: ...07946 3710601 or 07946 3710600 07964 MBOO200 07749 0010000 07746 0010300 07746 0040300 07716 0020400 or commercially available 07716 0020500 or commercially available 1 Unevenly adjusted right and lef...

Page 222: ...case mounts and headlight case Install the headlight case in the reverse order of remov 1 After installation adjust the headlight aim page 3 17 BRACKET REMOVAL INSTALLATION OiICoonect the instrument...

Page 223: ...T V45 MAGNA REMOVAL Remove Ihe two headlight mounting screws Disconnect the wire coupler and remove the head light CASE REMOVAUINSTAll ATION Remove the headlight case mounts and headlight case Install...

Page 224: ...g screw and sealed beam unit from the rim Assemble the headlight in the reverse order of disassembly After inSlaliation adjust the headlight aim page 3 18 IGNITION SWITCH REMOVAL INSTALLATION Remove t...

Page 225: ...and turn it to between the ON and OFF detent positions Push in the lugs in the IOls and pull the contact base from the switch Assemble the ignition switch in the reyerse order of disassembly Dlte of...

Page 226: ...SASSEMBLY NOTE Do not disassemble any parts excluding the bulbs instrument cover and panel Remove the four instrument cover screws and cover Aemove the instrument bulb Ockets R place Iny burnt out bul...

Page 227: ...ONDA V45 INSTRUMENT ASSEMBlYI INSTALLATION Assemble end install the instruments in the reverse order of disassembly and removal Date of Issue May 1982 237 HONDA MOTOR CO LTD FRONT WHEEL SUSPENSION 15...

Page 228: ...tne odometer wire couplers Remove the odometer sening screws Remove the turn signal angle n50r anaching SCfeWIi Remove the angle sensor and disconnect the Wife connectors Remove the odometer 15 10 _ 2...

Page 229: ...lb check for continUity If bulb does not light inspect the wiring for an open or short circuit ODOMETER DISASSEMBLY Remove the two odometer setting screws and open the cover Remove the plinted circuit...

Page 230: ...stall the odometer order of d isassembly and remov 1 in the reverse INSTRUMENTS V45 MAGNA INDICATOR LIGHT BULB REPLACEMENT Remove the headlight and case page 15 5 move the instrument lower cover attac...

Page 231: ...ght and case page 15 5 Disconnect the speedometer cable rom the insnu ments Di Connect the inS rument wire couplers Remove the instrument mounting nuts and instru ments DISASSEMBLY Remove the instrume...

Page 232: ...a replacement bulb does not light check the wiring for a shon or open circuit or check for loose connections ASSEMBLY INSTALLATION Lubricate the speedometer cable before reconnect Ing Assemble and ins...

Page 233: ...Disconnect the clutch switch wiras Remove the left handlebar switch Remove the clutch master cylinder Disconnect the choke cable from the choke lell r Date of Issue January 1982 e HONDA MOTOR CO l TO...

Page 234: ...dlebar switch and disconnect the front brake switch wires Remove the brake master cylinder On the V45 SABRE loosen the handlbar pinch bolt and remove the handlebar 15 16 244 MASTER eYl IN ER r HONDA V...

Page 235: ...ION Apply grease to the throttle grip sliding surface and slide the throttle grip over the handlebar On the V45 SABRE install the handlebars end tighten the pinch bolts TORQUE 20 30 N m 12 0 3 0 kg m...

Page 236: ...e holder with the handleb3l punch mark V45 MAGNA Tighten the upper bolt first then the lower bolt Install the right handlebar switch and connect the brake light switch wires Connect the choke cable to...

Page 237: ...lle the caliper NOTE Do not operate the front brake lever after removing the caliper To do so will cause difficulty in fitting the brake disc between the brake pads On the V45 SABRE remOlle the axle h...

Page 238: ...ide collar and right seal Remove the left seal and speedometer gear retainer Remove the wheel bearings and the d istance collar from the hub NOTE If the bearings are removed they should be replaced wi...

Page 239: ...in a truing stand Spin the wheel slowly and read the runout using a dial indicator SERVICE LIMITS RADIAL RUNOUT 2 0 mm to 08 in A XIAL RUNOUT 2 0 mm 0 08 in NOTE The wheel cannot be repaired and must...

Page 240: ...distance collar into place NOTE Be certain the distance collar I in position before installing the bearings Orive in Ihe left bearing sQuarely NOTE Drive the bearing into position makmg sure that it...

Page 241: ...ll the brake disc with the A mark on the right and the disc with the l mark on the left TOR QUE 25 30 N m 2 5 3 0 kg m 18 22 ft Ib Install the speedometer gearboll in the wheel hub aligning the tangs...

Page 242: ...th a 0 7 mm 0 028 in feeler gauge If the gauge cannot be Inserted pull the right fork out until the gauge can be inserted On the V45 SABRE torque the axle holder nuts starting with the forward nut TOR...

Page 243: ...e following parb handlebars V45 SABAEl brake calipers front fender Remove the fork brace On the V45 SABRE remove the brake hose two way joint mounting bolts Date of Issue May 1982 HONDA MOTOR CO LTO 2...

Page 244: ...e cap may become a projectile The cap is also under spring pressure Use care when removing and wear eye and ace protection Hold the fork tube in a vise With soft jaws or a shop towel and remove the fo...

Page 245: ...l and snap ring Pull the fork tube out until resistance from the slider bushing is felt Then move it in and out tapping the bushing lightly unt il the fork tube separates from the slider The slider bu...

Page 246: ...n the left fork remove the circlip oil lock valve spring and spring seat from the piston Remove the piston and rebound spring from the fork tube INSPECTION FORK SPRING FREE LENGTH Measure the fork spr...

Page 247: ...total indicator reading to determine the actual runout SERVICE LIMIT 0 20 mm 0 008 in BUSHING BACK UP RING Visually inspect the slider and fork tube bushings Replace the bushings jf there is excessiv...

Page 248: ...lts and remove the anti dille case Remove the piston and spring Remove the boots pivot bolt collar and SlOp rubber Check the spring and piuon for wear or damage 15 30 258 jJ HON DA V45 PIVOT BOLT COLL...

Page 249: ...8 case in the revene order of disauembly NOTE Apply a Thread Lock Agent to the threads of the screws and socket bolts before assembly Apply ATF to the piston and pistonQ ring Apply silicone grease to...

Page 250: ...iston into the fork tube On tne left fork install the spnng seat valve spring oil lock valve and circlip on the piston Place the oil lock piece on the end of the piston and insert the fork tube into t...

Page 251: ...up ring and an old bustling or equivalent tool on tOp Drive the bushing into place with the seal driver and remove the old bushing or equivalent tool Coat a new oil seal With ATF and install it with...

Page 252: ...2 ezl V45 MAGNA 390 cc 13 2 Ol 405 cc t13 7 od Install the fork spring spring seat and spacer in thl fork tube NOTE Note the spring direction the narrow pitches should face toward the top Install and...

Page 253: ...e tightening the front fork pinch bolts front lender brake caliPt fs front wheel Fill the fork tubes with air to 40 100 kPa 0 4 1 0 kg em 6 14 psi CAUTION Use only a hand operated air pump to fill the...

Page 254: ...15 6 handlebar s page 15 151 front wheel page 15 19 steering stem nut tront fork page 15 251 fork top bridge Straighten the lock washer tabs and remove the lock nut and Ioct washer Loosen the bearing...

Page 255: ...steering stem Remoye the upper bearing race with the special tool Remove the lower bearing race with the special tool NOTE If the motorcYcle has been inyolved in an accident examine the area around t...

Page 256: ...press the lower bearing inner race over the stem with the speci l tool INSTALLATION Pack the bearing cavities with bearing grease Insert the steering stem into the steering head pipe and Instali the b...

Page 257: ...the nut does not tighten after turning the steering stem the first or second time remove the nut arn f Inspect it and the steering stem thr els for dirt or burrs Instal 8 new bearing adjustment nut lo...

Page 258: ...ove the nut turn it over and reinstall it Bend two lock washer tabs up into the lock nut grooves In tall the front forks page 15 351 InsUII the fork top bridge and tighten the stem nut TORQUE 80 120 N...

Page 259: ...5 3 5 kg m 18 25 f t lb o 270 I 30 40 N m 3 0 4 0 kg m 29 ft lb r V HONDA V45 SABRE MAGNA L 1 N m 2 5 3 5 kg m 18 25 ft lbl 25 30 N m 2 5 3 0 kg m 8 12ft lb 20 25 N m 2 0 2 5 kg m 14 18 ft lb Date of...

Page 260: ...le SPECIFICATIONS Front disc thickness Front disc funout Front master cylinder 1 0 FrOnt master piston 0 0 Front caliper piston 0 0 Front caliper cVlinder 1 0 TORQUE VALUES Brake hose bolt Front brake...

Page 261: ...orn excessively Srlkas drag 1 Hydraulic system sticking 2 Sticking piston s 3 Incorrect rear brake pedal adjustment 16 2 Brakes grab or pull to one lid 1 Pads contaminated W HONDA V45 2 One side of fr...

Page 262: ...luid stops flowing out of the bleed valve t WARNING A contaminaTed broke disc or pod reduces sfOpping pown Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing...

Page 263: ...lever open the bleed valv8 1 2 turn and then close the 118Iv8 NOTE Do 001 release the brake lever until the bleed valve hes been closed 2 Release the brake lever slowly and wait several IeCOflds after...

Page 264: ...d pin retainer and caliper bolts Pivot the caliper up out of the way Remove the pad pin retainer and pull the pad pins out of the caliper Remove the brake pads Position the pad spring in the caliper a...

Page 265: ...he pad pin retainer over the pad prns Push the retliner down to secure the pins Install the pad pin retainer bott Pivot the caliper down so the brake disc is position ed between the p ds making sure n...

Page 266: ...em Remove the brake lever and rear view mirror f rom the master cylinder Disconnect the brake hose A void spilling brake fluid on painted surfaces Place a rag oller the fuel tank whellever he brake sy...

Page 267: ...ake tight switch from the master cylinder body if necessary Clean the inside of the master cylinder and reservoir with brake fluid INSPECTION Mitasure the master cylinder 1 0 Check the master cylinder...

Page 268: ...ON When installing the cups do not allow the lips to tum inside Out Be certain the circlip is seated firmly in the groove Install the piston and clip Install the boot Place the master cylinder on the...

Page 269: ...the caliper pivot collar and boots Remove the pistons from the caliper If necessary apply compressed air to the caliPer fluid inlet to get the piston out Place a shop rag under the caliper to cushion...

Page 270: ...INSPECTION Check the pistons for scoring scratches or other faults Measure the piston d iameter with ill micro meter SERVICE LIMIT 30 14 mm 1 187 in CYLINDER INSPECTION enede the caliper cylinder for...

Page 271: ...pad 5pring on the caliper bracket as shown Inspect the condition of the caliper pivot bolt boot Apply silicone grease or brake fluid to the caliper pivot bolt Install the caliper assembly over the bra...

Page 272: ...43 51 ft lb 35 45 N m 3 5 4 5 kg m 25 33 f olb 17 0 1 cp 10_ 0 N m 9 0 12 0 kg m ft Ib f J HONDA V45 20 30 N m 2 0 3 0 kg m ft lb 60 70 N m 6 0 7 0 kg m 43 51 fHb 60 80 N m 6 0 8 0 43 58 N m 4 5 7 0 k...

Page 273: ...12 0 kg m 65 87 ft Ibl Date of Issue May 1982 o HONDA MOTOR CO LTD 17 REAR BRAKE 1 L SUSPENSION 17 2 17 2 17 3 17 8 SHOCK ABSORBER V45 SABRE 17 10 SHOCK ABSORBER V45 MAGNA 17 18 SWINGARM 35 45 N m 3...

Page 274: ...wingarm bea rings worn 7 Worn tires Soft suspension 1 Weak spring s 2 Insufficient fluid in shock absorber V45 SABRE 3 Shock absorber air pressure incorrect V45 SABRE 17 2 60 80 N m 6 0 8 0 kg m 43 58...

Page 275: ...stop bolt cap and stop bolt Remove the brake adjusting nut and the brake rod Loosen the axle pinch bolt and remove the rear axle Move the wheel to the right to separate it from the final drive gear c...

Page 276: ...d read the axle runout with a dial indicator The actual axle runout is 1 2 of total indicator reading SERVICE LIMIT 0 2 mm 10 01 in WHEEL BEARINGS Place the wheel in a truing stand and check the wheel...

Page 277: ...LIMITS RADIAL RUNOUT AXIAL RUNOUT 2 0 mm 0 08 in 2 0 mm 0 08 in The wheel cannot be serviced and must be replaced if the above limits are exceeded DAMPER RUBBER Replace the wheel if they are damaged o...

Page 278: ...eated 17 6 NOTE c j HONDA V45 SABRE MAGNA Use lithium based MULTIPURPOSE grease with MoS2 additive as follows MOLYKOTE BA2 S manufactured bv Dow Corning U S A MULTIPURPOSE M 2 manufactured by Mitsubis...

Page 279: ...g gear s final driven flange engage ment splines Engage the rear wheel with the final drive case mak ing sure the splines are correctly aligned Loosen the three final gear Cilse nuts Insert the rear a...

Page 280: ...st the rear brake page 3 17 REAR BRAKE PANEL LINING THICKNESS INSPECTION Mellsure the feaf brake lining thidtness SERVICE LIMIT 2 0 mm 0 08 in DISASSEMBLY Aemove the rear brake arm Aemove the cotter p...

Page 281: ...indicator Install the brake arm aligning the punch marks and tighten the brake arm bolt TORQUE 24 30 N m 2 4 3 0 kg m 17 22 ft Ib Date of Issue January 1982 e HONDA MOTOA CO lTD 293 REAR WHEEL SUSPEN...

Page 282: ...ide covers seat and tool box Remove the shock absorber lower mounting bolt Remove the shock absorber upper mounting bolt and remove the shock absorber from the frame 17 10 294 i HONDA V45 SABRE MAGNA...

Page 283: ...er Remove the stop ring and remove the back up plate Pour 300 cc 10 1 oz of ATF in a clean container Place the shock ab Orber in a press with an Oil Seal Drivel Attachment as shown Place the se in the...

Page 284: ...t azse NOTE Spill as little ATF IS possible to prevent air from entering the shock Air in the shock will cause the damping to be too soft o The oil seal wilt not be pressed out if there is air in the...

Page 285: ...lip Remoye the air valve stem Connect a hose to the air valve and position the end of the hose up Place the shock absorber into a hydraulic preu with the oil seal driver and attachment Preu the oil s...

Page 286: ...nstall the air valve Install the shock case boot INSTALLATION Apply paste grease containing more than 45 of molybdenum to the upper and lower mounting bushings NOTE Use paste grease contaming more tha...

Page 287: ...just the air pressure page 3 20 SHOCK ABSORBER LINKAGE REMOVAL Remove the following parts Shock absorber lower mounting bolt Shock arm to swing arm bol15 _ Shodo link to frame bolts Shock linkage usem...

Page 288: ...hings for wear or damage Inspect the dust seals for damage Replace parts as necessary SHOCK LINKAGE INSTALLATION Apply paste grease containing more than 45 molybdenum to the bushings and dust seals Se...

Page 289: ...FRAME 60 70 N m 6 0 7 0 kg m 43 51 ft Ib SHOCK LlNK TO SHOCK ABSORBER 38 48 N m 3 8 4 8 kg ffi 28 35 ft lbl SHOCK lINK TO 5HQCK ARM 60 70 N m 6 0 7 0 kg m 43 51 ft Ibl SHOCK ARM TO 5WINGARM 60 70 N m...

Page 290: ...Place the collar 52486 463 QOOO or equivalent in the shock s bottom joint before puning shock in compressor Set the rear cushion in the compressor as shown and compress thll spring 30 mm by turning th...

Page 291: ...uster the spring lower seat spring upper seat and stopper rubber on the damper NOTE Install the spring with the tightly wound end facing down Date of Issue January 1982 HONDA MOTOR CO LTD SPRING UPPER...

Page 292: ...ICI BW the upper joint on Hold the upper joint in a vise and t ighten the lock nut l curely NOTE Check that the lock nut is seated against the rod s bottom thread Al ign the spring seat with the uppe...

Page 293: ...e shock absorbers Remove the swingarm pivot caps and loosen the right pivot bolt lock nut Remove the right pivot bolt USing the 17 mm socket bit Remove the left pivot bolt and remove the swing arm Rem...

Page 294: ...h the swingarm and behind the left grease retainer plate end bearing race Slide the shaft remover 07936 3230100 or equivalent into the collar and drive the bearing race out NOTE Replace the bearing in...

Page 295: ...times Retighten the right pivot bolt to the specified torque Tighten the lock nut while holding the right pivot bolt TORQUE 100 130 N m 10 0 13 0 kg m 72 94 ft lbJ Install the final gear page 14 19 Co...

Page 296: ...ON SWITCH AEGULATOR RECTIF IER ALTERNATOR L _ j w BATTERY CHARGING SYSTEM 18 0 t GREEN REO WHITE VOLTAGE Ir SENSOR IC ReGULATO R RECTIF IER 1 RED I _ w FUSE JOA _ m 1 MAIN SWITCH BLACK Date of Issue J...

Page 297: ...rged on the motorcycle disconnect the battery cables f WAANING Do not smo and kup jJatMJ away from 0 charginr bolter The las produC d by Q battery will uplode iffMmes or sparks ore brought nNr All cha...

Page 298: ...ction Low pow r Ingine running 1 Battery undercharged Low fluid IlvII One or more dead cells 2 Charging system failure 18 2 Intermittent power r j HONDA V45 1 loose battery connection 2 Loose charging...

Page 299: ...FIC GRAVITY 1 270 1 290 20 C 68 FI 1 270 1 290 Fully charged Below 1 260 Undercharged NOTES The battery must be recharged if the spe cific gravity is below 1 230 The specific gravity varies with the t...

Page 300: ...s ow charging is preferred Route the breather tube as shown on the battery caution label After installing the battery coat the terminals with clean grease CHARGING SYSTEM CURRENT TEST NOTE Be sure the...

Page 301: ...move the seat Disconnect the regulator rectifier couplers Check for oontinuitv between the leads with an ohmmeter NOTE The test results shown are for a positive ground ohmmeter and the opposite result...

Page 302: ...Connect a voltmeter across the battery Check regulator performance with the engine fUnning The regulator must divert ClJrrent to ground when battery voltage reaches 14 0 15 0 V 18 6 I HONDA Jy V45 SAB...

Page 303: ...SPARK PLUGS 19 0 HONDA V45 lONG NESTOP SWITCH z GiNIl ON COILS GENERATORS IGNITION COILS 1 3 2 4 2 4 TO TACHOMETER 1 3 SPARK UNITS SPARK UNITS ENGINE STOP IGNITION SWITCH SWITCH PULSE GENERATORS Dati...

Page 304: ...d and no adjustments can be made SPECIFICATIONS NO NGK Spark plug Standard X24EPA U9 OPASEA 9 For cold climate Below SoC 41 F X22EPR U9 DPR7EA 9 For extended high speed driving X27EPA U9 DPR9EA 9 Spar...

Page 305: ...or shorted wires Between ignition switch and engine stop SWitch Between spark unit and engine top switch Between spark unit and Ignition coil Between ignition coil and plug Between spark unit and pul...

Page 306: ...leads Remove the coils by removing the attaching bolts CONTINUITY TEST Mea ure the primary coil resistance RESISTANCE 2 8 ohms Measure the secondary coil resistance with the spark plug caps in place R...

Page 307: ...C fC C uC C C n C C CuC tions TRANSISTORIZED IGNITION SYSTEM PULSE GENERATOR TEST Remove the right side cover Disconnect the pulse generator coupler and measure the coil resistance RESISTANCE Approxi...

Page 308: ...rs InstalL the clutch coyer page 7 20 Recheck the ignition timing page 3 10 SPARK UN IT If Ihe pulse generators ignition coils and wiring afe good and the ignition timing is not within specification r...

Page 309: ...MOTOA FUSE 30A STAR TER BunON STARTER MOTOR BUnON STARTER RELAY SWITCH HONDA V45 SABRE MAGNA RElLA SWITCH DIODe STARTER ______ I CLUTCH SWITCH IGNITION SWITCH SH IFT INDICATOR GREEN BATTERY 322 Date...

Page 310: ...y gear change switch Faulty starter relay switch Loose or disconnected wire or cable Clutch diode open Starter motor turns engine slowly Low specific gravity Excessive resistance in circuit Binding in...

Page 311: ...at the ballf f Y before suvicing h starter motor Disconnect the starter motor cable at the motor Remove the st rter motor mounting bolts nd stlrter motor CASE AND FIELD COIL REAR COVER SHIMS CABLE ERM...

Page 312: ...r of thrust washers Inspect the commutator bars for discoloration Bars discolored in pairs indicate grounded armature coils NOTE Do not use emery or sand paper on the com mutator Check for continuity...

Page 313: ...orted to the motor case ASSEMBLY INSTALLATION Assemble the tarter motor Align the casl notch w ith the brush holder P Install the rear cover aligOing its slot With the brush holder pin Install the sta...

Page 314: ...witch terminals Connect a 12 V battery to the switch cable termi nals The switch is normal if there is continuity CLUTCH DIODE REMOVAL Remove the fuel tank Remove the clutch diode from the wire harnes...

Page 315: ...respond with the band color AU plastic plugs have tocking tabs thlt must be released before disconnecting and must be aligned when reconnecting The following color codes u are indicated throughout thi...

Page 316: ...he crankcase and leave twO threads from the bonom Then tighten it to the specified torque TOROUE 15 20 N m 11 5 2 0 kg m 11 14ft lbl NOTE Do nOt over tighten the switch to prevent crankcase from damag...

Page 317: ...ween each terminal and ground in each oear position V45 SABRE l 1 WII ANI Jeri GIO GROUND I 411 _ 00 1 _ V45MAGNA lelR GtO 00 1 l t J 0 0 t ti REMOVAL Remove the gear change switch cover Aemove the ge...

Page 318: ...tch HI MIDDLE N 8 W to B B WtoWtoB B Wto W LO TURN SIGNAL SWITCH LEFT OFF RIGHT Gr to O 8r B to LB W BrlS to LB W and O w Gr to LB BrlS to Orw HORN BUTTON LG to G with button depressed No continuity w...

Page 319: ...USH IINI Color code RIB G STARTER BUTTON Bk to Yf R with button pushed in Bk A to B W with out Starter Button BAT2 ST OUT START Color coda Bk VIR ENGINE STOP SWITCH RUN 8k to Bk W OFF No continuity En...

Page 320: ...Br W to Bf continuity Br to R continuity PA BAT IG TL TL J S R 8k 8 W 8 CLUTCH SWITCH Check continuity of the clutch lever safetyl switch with the clutch released and applied R place if neceuary FUEL...

Page 321: ...ess Move the float to full and empty and check the fuel gauge indication If the fuel gauge does not indicate the proper tevel replace it with a new one Move the float to the empty position and check t...

Page 322: ...will not light when the ignition switch is turned ON with the amount of fuel in the fuel tank above 6 5 liters 1 72 USgal If the warning light goes on check for a ort circuit In the wire harness or co...

Page 323: ...the thermostatic switch and short them together with a jumper wire as shown Turn the ignition switch on The cooling fan motor should start running If it starts replace the fan thermostatic switch and...

Page 324: ...engine Check the temperature of the coolant Aun the engine and measure the change in resistance of the sensor with the engine at operating temper ature Temperature 60 C 8SoC 140 F t18SoF Resistance Oh...

Page 325: ...be dam RADIATOR RESERVOIR SENSOR Disconnect the wire coupler from the reservoir sensor Cheek for continuity between the sensor leads COOLANT MORE THAN LOWER LEVEL CONTINUITY COOLANT lESS THAN LOWER LE...

Page 326: ...lead to the black yellow wire and negative test lead to the greenl black wire Set the voltmeter to the 25 VDC scale Turn the ignition switch on and slowly turn the front wheel and walch the voltmeter...

Page 327: ...not available check and repair the wiring of the appropriate source circuit TRIP LOG If the trip log does not operate properly check the source voltage at the black brQwn positive and the red green ne...

Page 328: ...OLTAGE 5 V If there is no voltage replace the sensor unit HEADLIGHT SENSOR V45 SABRE Turn the ignition switch on Check the source voltage at the blecklbrown lead If there is no voltage check and repai...

Page 329: ...EL SENSOR Y45 SABRE Remove the battery electrolyte level sensor from the battery Measure the resistance of the sensor RESISTANCE 680 ohms Date of Issue May 1982 IS HONDA MOTOR CO l TO SWITCHES BATTERY...

Page 330: ...GIW leads while turning the sensor arm slowlV from Ihe left to the right The resistance should increase smoothlv TURN SIGNAL SWITCH Di5CX nnect the cancel unit coupler Turn the turn signal switch to...

Page 331: ...Alternately CANCEL UNIT If the angle sensor turn signal Witch and speed sensor afe normal and there is flO open or ShOft circuit replace the cancel unit with a new one TURN SIGNAL CIRCUIT SPEEDOMETER...

Page 332: ...I c i fC j I Ii r llli I tI t i IITt jl I o t c P f i Ii 1 II hi t i j 1 0 i l6ih j I 6 _ i l n...

Page 333: ...i I I 1 N I In I g II Ie 0 21 1 I I J I I r I I i i Ii h r iT Jt I T t5 f HtmmF w J 1 i IW I U i v r I J III III I II iii P 1 I 01 r J 1 l p I 1 i I 1 11 H4 I j i J n 31 z 0 n C i 1...

Page 334: ...OR CHOKE SYSTEM ANTI DIVE FRONT SUSPENSION 23 2 23 3 23 4 23 5 AUTOMATIC TURN SIGNAL CANCELLING SYSTEM V45 SABRE 23 6 ELECTRIC SPEEDOMETER TACHOMETER Speedometer V45 SABRE FUELAWATER TEMPERATURE GAUGE...

Page 335: ...tt nene check Iui ad is the hydrlulic flu id e e voir level AUlomJltic cam chain edjune Carbu ton with byltatUr Iv The carburetors deli r the proPer mounl of ir fuel mi lu intO the cylinder unde IU op...

Page 336: ...inst the cam chain at all times The lock plate prevents backward movement of the lock rod and tensioner slipper CAM GUIDE TENSIONER SPRING TENISICI ER ARM TENSIONEA SLIPPER OPERATION As the cam chain...

Page 337: ...ge a stream of fuel into the carburetor venturi CHOKE JET2 DIAPHRAGM CHOKEVALVI MAIN AIR JET THROTTLE CIRCUIT SLOW JET NEEDLE MAliN JET When the throttle valve is opened vacuum in the manifold now wor...

Page 338: ...brake disc is sqUHZed by the brake pact5 causing the brake caliper to pivot on its bracket mounting bolt This movement causes the pivot bolt to push the piston in uncovering the oil control orifice Si...

Page 339: ...When Iha eontrol unit applies current 10 ii it rltturns the turn 1 n a1 switch knob to the eenter position ANG LE SENSO R A contaca type potentiometer the angle senSOr is located in lhe bottom 01 the...

Page 340: ...are in the cancel lation area shown in the graphs 2 If it has been more than 5 seconds since the turn signal switch was activated and road speed is mofe than 45 km h 28 mph 3 If the motorcycle travel...

Page 341: ...w Ill know at all times the water temperature in the cooling system a temperature indicator is installed The sensor uses a thermIstor whose resistance decreases with a fise in temperature allowing mor...

Page 342: ...on the electromagnet is energized pulling the armature up This stretches the diaghragm and forms a vacuum sucking fuel in through the inlet check valve As the armature is pulled further the contact p...

Page 343: ...inched lUi ll tank vent ho V45 MAGNA WEAK OR NO SPARK 11 Faully sperk plugs 2 Fouled spark plugs 3 Faulty spark unit 4 Broken or shorted high tension wiret 51 Faulty spark unit 6 Broken or Ihonlld ign...

Page 344: ...Justmtl t 121 Wom I _1 CORRECT t 7 T I cylinder c Gmp _ion TOO LOW In VII lluck open 121 Worn cyllndlr end pl on ringl NORMAL 131 u king hNd gllSk I ImprO vel timl lSl 8 Ch k CIIrburitor for clogging...

Page 345: ...CLOGGED JETS t 4 Check 1111111 1 timing CORRECT t 6 Check valve ring n ion NOT WEAKENED INCORRECT 1 Improper velw clOSllrance 2 Faulty spark unit 3 Faulty pulse gener lor FUEL FL OW RESTRICTEO 1 I Le...

Page 346: ...ES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITIEN PER MISSION HONDA MOTOR CO LTD Service Publications Office Dat...

Page 347: ...ng LIGHTS Headlight high low beam VF750C ITEM DIMENSIONS Overall width FRAME Caster angle Front fork oil capacity ENGINE MaKimum horsepower MaKimum torque CARBUAETION Pilot screw initial sening 25 2 3...

Page 348: ...escription Attachment Date of Issue October 1982 HONDA MOTOR CO l TD Q tv 1 Q ty 5 83 V45 SABRE MAGNA ADDENDUM Thread Qia mmJ Torque N m kg m ft lb Remarks 24 45 55 4 5 5 5 33 40 Thread Dia mm Torque...

Page 349: ...THEA JO UNIT TURN I CANCEL UNIT I CUJT H HOSE CHOKE CABLE i 4 SIPEE DO ETI A WIAE CLUTCH 83 V45 SABRE MAGNA ADDENDUM TURN SIGNAL RELAY RADIATOR TANK BATTERY LE ELSENSQR REGULATOR I E AESER V E W 1 OV...

Page 350: ...REO NO PULSE GEr RATOR WIRE FRONT HOSE CABLES CLAMPS OIL PRESSURE SWITCH A THROTTLE CABLES CLUTCH HO SE BRAKE HOSE CLAMP CABLE BRAKE CABLE CHOKE CABLE HOSE CABLE TERNATOA WIRE r0 HONDA V45 J O BATTERY...

Page 351: ...llow it to idle for 2 3 minutes Stop the engine and support the motorcvcle on the center stand Check the oil level with the dipstick after a few minutes Do not screw in the cap when making this check...

Page 352: ...GE BATTERY I L oft BRAKE FLUID FRONT I I I I I I 3 15 w DWEAR I 16 0 w II w 2 z CLUTCH FLUID I I I I I I ft 3 18 0 il TEM I I 3 18 w Z 0 z 1 l 21 BE SERVICED BY AN AUTHORIZED HONDA DEALER UNLESS THE O...

Page 353: ...NT 2 1 1 1 1 1 1 3 15 w l I I e f o WEAR 1 1 I 3 16 w 1 1 1 I 3 i7 1 w 1 i z CLUTCH FLUID 1 I I I I 11 3 18 0 3Ts EM I s i I z I 0 2 I z SHOULD BE SERV ICED BY AN AUTHORIZED HONDA DEALER UNLESS THE OW...

Page 354: ...elements in goar oil SAE 80 90 and SQueeze oul the excess Install the remolled parts in the reverse order of di iJ embly 4 FUEL SYSTEM V45 SABRE SERVICE INFORMATION SPECIFICATIONS Venturi die I dentif...

Page 355: ...t page 25 9 Remove the air cleaner case Remove the air cleaner base cOver screws and base cover Remove the thermostat cover boh and disconnect the ground cable Date of Issue October 1982 C HONOA MOTOA...

Page 356: ...and remove the carburetors from the left side FLOAT CHAMBER FLOAT AND JET Remove the needle jet holder and needle jet NOTE If the needle jet is difficult to remove care fully preu the needle jet from...

Page 357: ...s shown 0 0 0 0 AIR CLEANER CASE CHAMBER r 0 l Check the air cleaner case for deterioration FU aD 1 CRANKCASE VENTILATION SYSTEM Check that breather tube is not restricted Date of Issue October 1982 H...

Page 358: ...ch center lock nut TOOLS Special Mainshaft holder CLUTCH SNAP RING CLUTCH LIFTER PAlTE SPRING STANDARD 3 9 mm 10 15 in 74 414 74 440 mrn 2 9296 2 9307 in 57 755 57 768 mm 2 2738 2 2743 in 45 55 N m 14...

Page 359: ...When the engine is not in the frame shift the transmission into gear and use the shaft holder 07923 6890101 to hold the output shaft Remove the lock nut and lock washer Remove the clutch spring set pl...

Page 360: ...h IS a unit Remove clutch center A and the washer INSPECTION CLUTCH SPRING Measure the clutch spring free height_ Replace the spring if it is shorter than the service limit SERVICE LIMIT 3 6 mm 0 14In...

Page 361: ...ooth operation Check the rollers for excessive wear Measure the 1 0 of clutch center B SERVICE LIMIT 74 50 mm 2 933 in Measure the 0 0 of one way dutch inner SERVICE LIMIT 57 74 mm 2 273 in Date of Is...

Page 362: ...mOlle use the following tools Driver 07749 0010000 Attachment 37 Ie 46 mm 07746 0010200 Pilot 35 mm 07746 0040800 CLUTCH ASSEMBLY Install the drive sprocket spacer Install the clutch outer guide over...

Page 363: ...grooved side facing in over the one way clutch Turn center B counter clockwise as you Install it Make sure the one way clutch assembly is i lStalled co ecrly by turning clutch center B It should tum c...

Page 364: ...te Install the clutch spring set plate clutch spring and washer NOTE Install the clutch Pring with dished face towards the inside Install the lock washer with its dished face towards the inSide 25 20...

Page 365: ...out of the frame shift the transmission into gear and uS the Shaft Holder 07923 6890101 to hold the output shaft TORQUE 45 55 N m 14 5 5 5 kg m 33 40 It fb Install the clutch lifter rod Install the c...

Page 366: ...0 016 inl B 0 45 mm 0 018 in C 0 5 mm 0 020 inl 0 0 55 mm 10 022 in E 0 6 mm 0 024 in COUNTERSHAFT INSPECTION For 1983 models it is no longer necessary to select an output gear case gasket before sele...

Page 367: ...removal procedures refer to the base manual NOTE Do not leave fingerprints on the bulb they may create hot spots If possible wear clean gloves when installing the halogen bulb If you do touch the bulb...

Page 368: ...3 V45 SABRE MAGNA ADDENDUM INSTRUMENTS V45 SABRE Assemble and install the instruments in the reverse order of disassembly and removal 25 24 386 r HONDA V45 Date of Issue October 1982 HONOA MOTOR CO l...

Page 369: ...emove the check valve setting screw valve spring and check ball DISASSEM8lY ASSEMBlY A sponge washer and a plastic seal washer have been added to the fork tube assemblies be en the dust seal and the s...

Page 370: ...AR WHEEL ASSEMBLY W HONDA V45 Apply liquid seallnt to the final driven flange matmg surface and use a thread lock agent on the bolt threads Tighten the bolts to the specified torque TORQUE 50 60 N m 5...

Page 371: ...nit Make a circuit using pilot light T7 3W dry battery 12Vj and the unit as shown The pilot tights should come on and go off after 2 3 second If the unit is good check the wire harness for a open circ...

Page 372: ...J Z w to w a z c l 2c 20 0 1 v c a cC v I v E cC a cC Q z N f i ii C j I _ j ig l...

Page 373: ...0 C m 0 i iEtB j l I q 1I1l g N I 0 m I IE Q h 0 0 J II I L IJ J J i I I I I I g L ____ r i i C I I l I 1 U i Jl 1 J 1 a I q r s ttttittt1ttItt1 ttj fiJ J J 1tm1W c I I t p u an f n i I f C z C en l...

Page 374: ...ssion braking force is prevented by the slippage of the one way clutch ONIE VVA CLUTCH ONE WAY t t lITC HOUTER __ C OUTER Construction The one way clutch is installed with the clutch center inside the...

Page 375: ...lock up the one way clutch AI will slip just enough to prevent the wheel from locking without losing the benefit of maximum engine compression braking POWER FLOW DIAGRAM CLUTCH OUTER r FRICTION DISC C...

Page 376: ...raking the fiber scope causes the bUlzer to sound due to interrupted transmission of light from the LED to the photo tran sistor A 9V dry battery is used to operate the system The wire can be connecte...

Search results

Summary of Contents for V 45 SABRE-VF750S 1982

Reviews:

Honda V 45 SABRE-VF750S 1982, Shop Manual, Page: 60 / 376

Search results

Summary of Contents for V 45 SABRE-VF750S 1982

Reviews: