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Honda V30 Magna, Manual

The Honda V30 Magna is a classic cruiser motorcycle known for its powerful V4 engine and sleek design. For those looking to maintain or repair their bike, a free manual can be downloaded from manualshive.com. Get the manual to ensure your V30 Magna stays in top condition.

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Summary of Contents for V30 Magna

Page 1: ...SHOP MANUAL V3 MAIiN VF500C...

Page 2: ...some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe Please understand that those warni...

Page 3: ...section The subsequent pages give detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING ALL INFORMATION ILLUSTRATIONS DIREC TIONS AND SPECIFICATIONS INCLUDED...

Page 4: ...parks near the battery especially while charging it 1 Use genuine Honda or Honda recommended parts and lubricants or their equivalents Parts that don t meet Honda s design specif ications may damage t...

Page 5: ...d s right side The engine serial number is stamped on the right side of the upper crankcase 1 2 HONDA V30 MAGNA COLOR LABEL The color label is affixed to the frame behind the left side cover The vehic...

Page 6: ...NS 2 200 mm 86 6 in 735 mm 28 9 in 1 180 mm 46 5 in 1 500 mm 59 1 in 760 mm 29 9 in 335 mm 13 2 in 130 mm 5 1 in l81 kg 399 Ib 194 kg 428 Ib Dou ble cradle Telescopic fork Travel 160 mm 6 3 in Swing a...

Page 7: ...5 21 1 375 33 24 1 154 30 26 1 000 28 28 Left foot operated return system Full transistor 15 1 700 rpm 37 3 000 rpm ELECTRIC MOTOR 0 28 kw 5 000 rpm 12V 12AH Spark plug _ _ _ _ N G K N D 1 Standard DP...

Page 8: ...GENERAL INFORMATION Thread dia mm Torque N m kg m ft Ib Remarks 6 8 12 0 8 1 2 6 9 6 10 14 1 0 1 4 7 10 8 21 25 2 1 2 5 15 18 8 30 34 3 0 3 4 22 25 5 9 12 0 9 1 2 6 9 22 45 55 4 5 5 5 32 40 7 18 20 1...

Page 9: ...0 25 29 25 35 2 5 3 5 18 25 24 30 2 4 3 0 17 22 10 14 1 0 1 4 7 10 35 45 3 5 4 5 25 32 35 45 3 5 4 5 25 32 35 45 3 5 4 5 25 32 35 45 3 5 4 5 25 32 35 45 3 5 4 5 25 32 20 28 2 0 2 8 15 20 18 28 1 8 2 8...

Page 10: ...7506 3000000 07912 6110001 07404 0020000 07908 KE70000 ST AH 255 MC7 ST AH 260 MC7 07942 823000 07914 3230001 07942 MA60000 07984 MA60000 0751 0 MB001 01 07946 3710500 07946 M BOOOOO 07947 3710101 079...

Page 11: ...07746 0040300 Attachment 52 x 55 mm 07746 0010400 Driver 07749 0010000 Bearing remover shaft 07746 0050100 Remover head 15 mm 07746 0050400 Remover head 17 mm 07746 0050500 Remover head 20 mm 07746 0...

Page 12: ...an the attaching surface thoroughly before applying tape Do not use wires or harnesses with damaged insulation Repair by wrapping them with a pro tective tape or replace them Route wire harnesses to a...

Page 13: ...TION LEFT HANDLEBAR SWITCH WIRE MAIN HARNESS 1 10 r iiJ HONDA V30 MAGNA f J 1 RIGHT HANDLEBAR SWITCH WIRE SPEEDOMETER CABLE HARNESS BAND CLUTCH HOSE RADIATOR OVER FLOW TUBE Date of Issue July 1984 HON...

Page 14: ...HONDA V30 MAGNA STARTER MOTOR CABLE Date of Issue July 1984 HONDA MOTOR CO LTD BRAKE HOSE GENERAL INFORMATION PULSE GENERATOR OIL PRESSURE SWITCH WIRES 1 11...

Page 15: ...ERAL INFORMATION CLUTCH HOSE REAR RIGHT TURN SIGNAL WIRE l 1 12 TAILLIGHT LlGHTWIRES HONDA V30 MAGNA ALTERNATOR WIRE REAR LEFT TURN SIGNAL WI RE SPARK UNITWIRES Date of Issue July 1984 HONDA MOTOR CO...

Page 16: ...mbustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight C...

Page 17: ...g thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the...

Page 18: ...ached to the frame behind the left side cover Route the vacuum hoses as shown on this label VACUUM HOSE ROUTING DIAGRAM LABEL I EMISSION CONTROL INFORMATION LABEL The Vehicle Emission Control Informat...

Page 19: ...LUBRICATION HONDA V30 MAGNA NOTE 00 not for the th get to install rust washer 2 OI 2 5 35N m _0 2 5 35 k g m 18 25 ft Ib O a te o f ls s HONOAue July 1984 MOTOR CO LTO...

Page 20: ...or equivalent API Service Classification SE or SF Viscosity SAE 10W 40 Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range...

Page 21: ...t changed often enough 2 Head gasket faulty 3 Worn piston rings low oil pressure 1 Oil level low 2 Pressure relief valve stuck open 3 Plugged oil pick up screen 4 Oil pump leaks 5 External oil leaks 6...

Page 22: ...lete and rapid draining Stop the engine Remove the canister and canister bracket California model only Remove the oil filler cap and engine oil drain plug and drain the oil Remove the oil filter with...

Page 23: ...ft Ibl Connect the oil pressure switch wire Start the engine Check that the oil pressure warning light goes out after one or two seconds If the oil pressure warning light stays on stop the engine imm...

Page 24: ...il page 2 1 Oil PUMP REMOVAL NOTE The oil pump can be removed with the engine mounted in the frame Remove the exhaust chamber pipes and muffler assembly page 5 3 Drain the engine oil page 2 3 Remove t...

Page 25: ...ump driven sprocket onto the oil pump shaft and turn it until the cut out of the water pump shaft is vertical Remove the three oil pump mounting bolts Remove the oil pump Remove the dowel pin oil pass...

Page 26: ...he pump shaft Remove the inner and outer rotors from the pump body INSPECTION Measure the rotor tip clearance SERVICE LIMIT 0 20 mm 0 008 in Measure the pump body clearance SERVICE LIMIT 0 35 mm 0 014...

Page 27: ...e body with the cut out of the inner rotor facing out Insert the drive pin into the hole in the pump shaft and install the pump shaft into the pump aligning the drive pin with the cut out of the inner...

Page 28: ...Install the oil pump and tighten it with three bolts Make sure that the oil pump shaft rotates freely by turning the pump shaft Install the a rings over both ends of the oil pass pipe Install the oil...

Page 29: ...her and bolt TORQUE 13 17 N m 1 3 1 7 kg m 9 12 ft Ib Install the right crankcase cover Install the exhaust pipe and muffler assembly in the reverse order of removal Fill the crankcase with the recomm...

Page 30: ...TEERING HEAD BEARINGS DUST SEALS SPEEDOMETER DRIVE GEAR Date of Issue July 1984 HONDA MOTOR CO LTD g FRONT FORK ATF CLUTCH AND BRAKE LEVER PIVOTS GEARSHAFT PEDAL PIVOT THROTTLE GRIP tiWffi BRAKE PEDA...

Page 31: ...oil filter See page 2 3 The cylinder numbering is given below SPECI FICATIONS Engine Spark plugs 3 COOLING SYSTEM HOSES CONNECTIONS CHASSIS DRIVE CHAIN BATTERY BRAKE FLUID BRAKE SHOE PAD WEAR BRAKE S...

Page 32: ...30 mm 3 4 1 1 4 in Up to 90 kg 200 Ib load 90 kg 200 Ib load to vehicle capacity load Bridgestone Dunlop Front 100 90 18 56H 200 2_00 28 200 2 00 28 l303 F11 HONDA V30 MAGNA Rear 130 90 1667H 200 2 00...

Page 33: ...YSTEM HOSES I I I I 3 13 CONNECTIONS EVAPORATIVE EMISSION CONTROL NOTE 3 I I I 3 12 SYSTEM DRIVE CHAIN I L EVERY 300 mi 500 krn 3 13 en BATTERY MONTH I I I I I I I 3 15 2 BRAKE FLUID MONTH I I I I R I...

Page 34: ...l tanks Page 4 21 Remove the battery Page 15 3 Remove the battery box Disconnect the fuel pump coupler Disconnect the fuel lines from the carburetor and sub tank Remove the mounting nuts and fuel pump...

Page 35: ...free play can be adjusted at either end of the throttle cable Replace any damaged parts before beginning this adjustment Minor adjustments are made with the upper throttle cable adjuster Adjust free...

Page 36: ...ening the choke cable clamp on the carburetor and moving the choke cable casing so the choke lever is fully open Tighten the clamp Move the choke lever on the handlebar both ways and measure the choke...

Page 37: ...element any time it is excessively dirty or damaged CAUTION Because the paper filter is viscous type which contains oil do not clean it by blowing with air Install a new element into the air cleaner...

Page 38: ...er gauge SPAR K PLUG GAP 0 8 0 9 mm 0 03 0 04 in Adjust by bending the side electrode carefully With the plug washer attached thread each spark plug in by hand to prevent crossthreading Continue tight...

Page 39: ...oosen the six bolts and remove the alternator cover Remove the inspection hole cap from the right crankcase cover by loosening it Rotate the crankshaft counterclockwise at the fly wheel side and align...

Page 40: ...to align the TR mark with the index mark and check the valve clearances for the No 3 cylinder Adjust by using the procedures for the No cylinder Rotate the crankshaft counterclockwise to align the TF...

Page 41: ...be adjusted It is the base carburetor Start the engine and adjust the idle speed IDLE SPEED 1 300 100 rpm Check that all carburetors are within 60 mm 2 4 in Hg Synchronize to specification by turning...

Page 42: ...hey are securely con nected and are not kinked or clogged Replace any damaged or deteriorated tubes If a purge control valve problem is suspected refer to test procedures on page 4 19 RADIATOR COOLANT...

Page 43: ...SYSTEM HOSES CONNECTIONS Inspect the hoses for cracks or deterioration and replace if necessary Check the tighteness of all hose clamps CHASSIS DRIVE CHAIN Clean the drive chain with a non flammable...

Page 44: ...ck is obtained CAUTION Make sure that the same alignment marks on both adjuster align with the edge of the swingarm Tighten the adjusting bolt lock nuts Tighten the rear axle nut TORQUE 70 90 N m 7 0...

Page 45: ...he following Remove the battery holder bolt then swing the holder out of the way Disconnect the negative cable at the battery then disconnect the positive cable Disconnect the battery breather hose fr...

Page 46: ...rent types offluid as they are not compatible Refer to section 14 for brake bleeding procedures BRAKE SHOE PAD WEAR FRONT BRAKE PAD Check the brake pads for wear by looking through the slot indicated...

Page 47: ...e pedal is 10 20 mm 3 8 3 4 in below the top of the foot peg CAUTION Incorrect brake pedal height can cause brake drag To Adjust Loosen the stopper bolt locknut and turn the stopper bolt Retighten the...

Page 48: ...vertically by loosening the headlight case mounting bolts and moving the headlight Adjust horizontally by loosening the headlight case bracket mount bolts and moving the headlight right or left Tight...

Page 49: ...tion or wear If wear extends to the wear line replace the pad Check the side stand spring for damage and loss of tension Check the side stand for damage and freedom of movement Make sure the force req...

Page 50: ...check for worn swingarm bearings Replace the bearings if there is any looseness Check the shock absorber for leaks or damage Tighten all rear suspension nuts and bolts NUT BOLTS FASTENERS Check that...

Page 51: ...k the front and rear wheels for trueness Sec tion 12 and 13 Measure the tread depth at the center for the tires Replace the tires if the tread depth reaches the following limits Minimum tread depth Fr...

Page 52: ...o not interchange the jet needles The No 1 and No 4 carburetors use differ ent jet needles from the No 2 and No 3 car buretors 4 0 Date of Issue October 1984 HONDA V30 MAGNA American Honda Motor Co In...

Page 53: ...ave drain screws that can be loosened to drain residual gasoline A fter 84 The No 1 and No 4 carburetors use different jet needles than the No 2 and No 3 carburetors Do not interchange the jet needles...

Page 54: ...speed incorrect 3 Incorrect carburetor synchronization 4 Carburetor faulty 5 Fuel contaminated Misfiring during acceleration 1 Ignition system faulty Backfiring 1 Ignition system faulty 2 Carburetor...

Page 55: ...and remove the case cover Disconnect the choke and throttle cables at the carburetor Disconnect the fuel line Disconnect the purge lines from the canister at the PCV California only Loosen all the ca...

Page 56: ...up and down freely in the chamber Push the needle holder in and turn it 60 degrees with an 8 mm socket Then remove the needle holder spring and needle from the piston NOTE After 84 The No 1 and No 4 c...

Page 57: ...he vacuum piston into the carburetor Stick your finger into the carburetor bore and hold the vacuum piston in the full throttle piston then turn down the diaphragm so its lip fits into the carburetor...

Page 58: ...for deformation or fuel inside the float Inspect the float valve for grooves and nicks Replace if necessary FLOAT VALVE SEAT INSPECTION Remove the float valve seat and filter I spect the float valve s...

Page 59: ...ats lightly CAUTION Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat Blow all jet and body openings clean with com pressed air INSTALLATION Install the jet ho...

Page 60: ...at tang Install the float chamber and secure it with the screws PILOT SCREW REMOVAL NOTE The pilot screws are factory pre set and should not be removed unless the carbure tors are overhauled The pilot...

Page 61: ...ed plug and continue turning a screwdriver until the plug rotates with the screw Pull the screw head with pliers to remove the plug Use compressed air to clean the pilot screw area and remove metal sh...

Page 62: ...crew in one car buretor you must replace the pilot screws in the other carburetors for proper adiust ment CARBURETOR SEPARATION Bend the lock plate tabs down and remove the eight bolts Remove the air...

Page 63: ...he carburetor horizontally to pre vent damage to the joint pipes Disconnect the throttle link from the No 3 and 4 carburetors by removing the cotter pins Carefully separate the No 3 and No 4 carbureto...

Page 64: ...y install the choke valve spring and nut Install the choke valve arm and spring by sliding the clevis of the choke valve arm onto the groove of the choke valve Tighten the choke valve nut Insert the c...

Page 65: ...nd No 4 carburetors Reconnect the throttle link between the No 3 and No 4 carburetors using new cotter pins Coat new O rings with oil and Install them on the fuel and air joint pipes Put the No 1 and...

Page 66: ...y installed Install the choke link between No 2 and No 3 carburetors using the washers and new cotter pins Install the choke links between No 1 and No 3 and No 2 and No 4 carburetors using spring wash...

Page 67: ...lace the air cleaner base over the carburetors aligning the dowel pins with the carburetor holes Install the new lock plates and the eight bolts Tighten the bolts and secure them by bending the lock p...

Page 68: ...oosen the connecting bands on the rear cylinder head intake pipes Fit the carburetors into place on the cylinder heads and into the rear intake pipes Tighten all intake pipe connecting bands Make sure...

Page 69: ...fac turer s instructions 4 Adjust the idle speed with the throttle stop screw IDLE SPEED 1 300 100 rpm 5 Turn each pilot screw 1 2 turn out from the initial setting 6 If the engine speed increases by...

Page 70: ...ude to ensure proper high altitude operation Attach a Vehicle Emission Control Information Update label onto the frame as shown NOTE Do not attach the label to any part that can be easily removed from...

Page 71: ...ort Apply the specified vacuum to the PCV SPECIFIED VACUUM 250 mm 9 8 in Hg The specified vacuum should be maintained Replace the PCV if vacuum is not maintained Connect a pressure pump to the 10 mm I...

Page 72: ...over Remove the fuel tank stay bracket Remove the air cleaner case bolts and cover screws Lift up the air cleaner cover and remove the air cleaner case BREATHER TUBE 4 20 HONDA V30 MAGNA CASE COVER AI...

Page 73: ...an container Reconnect the fuel line to the fuel valve after draining FUEL TANK REMOVAL Remove the seat and the left and right side covers Remove the fuel tank attaching bolts and pivot shaft Lift the...

Page 74: ...from the frame and lift it off Disconnect the fuel line from the fuel valve on the tank side and remove the sub tank FUEL PUMP REMOVAL Drain the fuel from the fuel system See page 4 21 Remove the fol...

Page 75: ...onnect the fuel lines and disassemble the fuel pump fuel filter and fuel valve from the bracket FUEL PUMP INSTALLATION Connect the fuel lines as shown Install the fuel pump filter and valve on the pum...

Page 76: ...r installation TO FUEL VALVE FUEL TANK INSTALLATION Installation is the reverse order of removal After installation check that there are no fuel leaks 4 24 CiiJ HONDA V30MAGNA Set the rubber mount int...

Page 77: ...line Turn the fuel valve ON Turn the ignition switch Of and let fuel flow into the beaker for 10 seconds then turn the ignition switch off Multiply the amount in the beaker by 6 to determine the fuel...

Page 78: ...ENGINE REMOVAL INSTALLATION 25 35N m 2 5 3 5 kg m 18 25 ft Ib 5 0 8 12 N m 0 8 1 2 kg m 6 9 ft Ib Cii HONDA V30 MAGNA Date of Issue July 1984 HONDA MOTOR CO LTD...

Page 79: ...frame socket bolt Exhaust chamber Drive sprocket bolt Rear axle nut Gearshift arm pinch bolt Date of Issue July 1984 HONDA MOTOR CO LTD Upper Lower Upper Lower Alternator Starter motor Carburetors App...

Page 80: ...nd right side covers Remove the fuel tank Page 4 21 Disconnect the negative cable from the battery Drain the engine oil Page 2 3 Drain the coolant and remove the radiator Page 6 6 Remove the frame fro...

Page 81: ...the gearshift linkage and left foot peg Remove the drive sprocket cover Loosen the axle nut and drive chain adjusters Straighten the lock plate tabs and loosen the drive sprocket bolts Remove the lock...

Page 82: ...nuts Loosen the exhaust pipe bands and remove the exhaust pipes Loose n the exhaust chamber mounting bolts Loosen the rear exhaust pipe band bolts then remove the exhaust chamber 5 4 HONDA V30MAGNA E...

Page 83: ...ct the choke cable and throttle cables from the carburetors Disconnect the spark plug caps Remove the front frame cross bar Remove the air cleaner case Page 4 20 Date of Issue July 1984 HONDA MOTOR CO...

Page 84: ...ort the bottom of the engine with a jack or oth er adjustable support CAUTION Be careful not to bind the wires and cables under the engine when removing the engine Remove the following three engine mo...

Page 85: ...not forget to install the engine mount collar Carefully align mounting points with the jack to prevent damage to mounting bolt threads wire harnesses and cables Tighten all fasteners to the torque val...

Page 86: ...COOLING SYSTEM 6 0 CiJ HONDA V30MAGNA Date of Issue July 1984 HONDA MOTOR CO lTD...

Page 87: ...sensor inspections SPECI FICATIONS Radiator cap relief pressure 75 105 kPa 0 75 1 05 kg cm2 11 15 psi Freezing point Hydrometer test 55 Distilled water 45 ethylene glycol 32 C 25 F 50 Distilled water...

Page 88: ...pres sure for at least six seconds NOTE Before install ing the cap on the tester wet the sealing surfaces RADIATOR CAP RELIEF PRESSURE 75 105 kPa 0 75 1 05 kg cm2 11 15 psi Pressurize the radiator eng...

Page 89: ...adiator cap Remove the seat fuel tank and frame side covers Remove the battery Page 15 3 Remove the battery box Drain coolant from the reservoir tank Remove the reservoir tank Reinstall the reservoir...

Page 90: ...GIl Start the engine and run until there are no air bubbles in the coolant and the level stabilizes Stop the engine and add coolant up to the proper level if necessary Reinstall the radiator cap Check...

Page 91: ...the outer thermostat housing cover Disconnect the temperature sensor wire connec tor from the sensor_ Loosen the hose band Remove the thermostat housing mounting bolt Remove the thermostat housing co...

Page 92: ...heated to 95 C 203 F for five minutes INSTALLATION Install the thermostat into the housing fnstall the thermostat housing cover with a new a ring Connect the temperature sensor sire connector Install...

Page 93: ...r Disconnect the cooling fan motor coupler Loosen the hose bands and disconnect the upper and lower radiator hoses from the radiator Date of Issue July 1984 HONDA MOTOR CO LTD COOLING SYSTEM THERMOSTA...

Page 94: ...e the radiator mounting bolts and radiator CAUTION Be careful not to damage the radiator fins DISASSEMBLY Remove the screws and bolts left and right covers and radiator grill 6 8 HONDA V30MAGNA SWITCH...

Page 95: ...tic switch if necessary Be careful not to damage the radiator body Remove the fan blade nut and washer Remove the cooling fan from the motor shaft Remove the fan motor from the shroud by remov ing the...

Page 96: ...en core fins with com pressed air If insects etc are clogging the radiator wash them off with low pressure water ASSEMBLY INSTALLATION Assemble and install the radiator in the reverse order of removal...

Page 97: ...Replace the water pump as an assembly if the mechanical seal is leaking REMOVAL Drain the coolant page 6 3 Remove the gearshift linkage and left foot peg Remove the slave cylinder cover page 7 4 Date...

Page 98: ...e grip Remove the drive sprocket cover Loosen the hose bands and disconnect the water hose from the water pump cover Remove the four bolts and the water pump cover Remove the hose clamp from the water...

Page 99: ...water pump shaft groove with the oil pump shaft and insert the water pump in the crank case Connect the water hose to the water pump and attach the hose Install the dowel pin on the water pump Insert...

Page 100: ...ll it on the left crankcase cover release the clutch lever from the handle grip and then tighten the slave cylinder mount bolts Install the slave cylinder cover Install the right foot peg and gearshif...

Page 101: ...CLUTCH SYSTEM 25 35 N 2 5 3 5 kg m 18 25 ft Ib i 5 7 N m 0 0 5 0 7 kg m 4 5 ft Ib 7 0 CiJ HON DA V30 MAGNA 25 35 N m 2 5 3 5 kg m 18 25 ft Ib Date of Issue July 1984 HONDA MOTOR CO LTD...

Page 102: ...HONDA V30MAGNA 60 70 N m 6 0 7 0 kg m 43 51 ft Ib J9a 50 60 N m 5 0 60 k g m 36 43 ft Ib gate of Issue July 1984 HONDA MOTOR CO LTD 7 E 7 1...

Page 103: ...2 mm 1 402 in Clutch Outer bushing J D 29 000 29 021 mm 1 1417 1 1426 in 29 06 mm 1 144 in Outer guide O D 28 967 28 980 mm 1 1404 1 1409 in 28 93 mm 1 139 in Spring free length 35 420 mm 1 3945 in 34...

Page 104: ...ng 2 Discs worn 3 Spring weak Clutch will not disengage 1 Air bubbles in hydraulic system 2 Low fluid level 3 Hydraulic system leaking 4 Hydraulic system sticking 5 Plates warped Date of Issue July 19...

Page 105: ...the lever when no fluid flows out of the bleeder valve CLUTCH SYSTEM FI LING NOTE Do not mix different types of fluid They are not compatible If a mytyvac bleeder is not available perform the followin...

Page 106: ...eeder valve Add fluid when the level in the master cylinder reservoir is low NOTE If air is entering the bleeder hose from around the bleeder valve thread seal the threads with teflon tape Check the o...

Page 107: ...cylinder CAUTION A void spilling clutch fluid on painted surfaces Place a rag over the fuel tank whenever the clutch system is serviced NOTE When removing the oil bolt cover the end of the hose to pre...

Page 108: ...dy INSPECTION CD MASTER CYLINER 1 0 Check the master cylinder for scores scratches or nicks Measure the master cylinder 1 0 SERVICE LIMIT 14 06 mm 0 554 in Date of Issue July 1984 HONDA MOTOR CO LTD C...

Page 109: ...he cups do not allow the lips to turn inside out Install the washer Install the circlip making sure it is seated firmly in the groove Install the boot and push rod Install the clutch switch Install th...

Page 110: ...ct the clutch switch wires to the switch ter minals Fill the reservoir and bleed the clutch system page 7 4 CLUTCH SLAVE CYLINDER REMOVAL Remove the slave cylinder cover Page 7 4 Remove the clutch oil...

Page 111: ...o remove the piston Use the air in short spurts Remove the spring from the piston Remove the oil and piston seals Clean the piston groove with clutch fluid Check the piston spring for weakness or dama...

Page 112: ...whenever they have been removed Lubricate the piston and piston seal with a medium grade of Hi Temperature silicone grease or brake fluid before assembly Be certain the piston seal is seated in the p...

Page 113: ...d the two sealing washers TORQUE 25 35 N m 2 5 3 5 kg m 18 25 ft Ib Fill the clutch fluid reservoir and bleed the clutch system page 7 4 Install the slave cylinder cover RIGHT CRANKCASE COVER REMOVAL...

Page 114: ...flywheel with universal holder Remove the starter clutch bolt Remove the starter clutch assembly NOTE If you are going to rebuild the starter clutch loosen the starter clutch bolts with the starter cl...

Page 115: ...or smooth operation Remove the starter clutch cover by removing the three bolts Remove the clutch rollers plungers and springs INSPECTION Check the rollers for excessive wear and the springs for weakn...

Page 116: ...the starter clutch Install the dowel pin Install the starter clutch cover aligning the dowel pin hole with the dowel pin and tighten the bolts TORQUE 26 30 N m 2 6 3 0 kg m 19 22 ft Ib NOTE Apply a l...

Page 117: ...driven gear by turning it clock wise INSTALLATION Install the primary drive gear onto the crankshaft with the large chamfered side facing in Install the collar and thrust washer onto the crank shaft 7...

Page 118: ...TORQUE 50 60 N m 5 0 6 0 kg m 36 43 ft Ibl Install the alternator cover Install the starter id Ie gear and shaft by rotating the starter clutch clockwise with a wrench or by rotat ing the idle gear c...

Page 119: ...h lever immadi ately after removing the clutch pressure plate and tie the lever to the hand grip Remove the bolts and clutch springs NOTE Loosen the bolts in crisscross pattern in 2 3 steps Remove the...

Page 120: ...ove the oil pump driven sprocket and then remove the oil pump drive sprocket and clutch outer guide Date of Issue July 1984 HONDA MOTOR CO LTD CLUTCH SYSTEM CLUTCH CENTER HOLDER 07724 0050000 OR EQUIV...

Page 121: ...show signs of scor ing or discoloration Measure the thickness of each disc SERVICE LIMIT A 2 6 mm 0 10 in B 3 3 mm 0 13 in Replace any disc that is thinner than the service limit ED CLUTCH PLATE Chec...

Page 122: ...scs Measure the 1 0 of the clutch outer bushing SERVICE LIMIT 29 06 mm 1 144 in Measure the 0 0 of the clutch outer guide SERVICE LIMIT 28 93 mm 1 139 in INSTALLATION SPRING SEAT Date of Issue July 19...

Page 123: ...olt TORQUE 13 17 N m 1 3 1 7 kg m 9 12 ft Ib Install the clutch outer onto the mainshaft aligning the lugs on the clutch outer boss with the grooves in the oil pump drive sprocket flange Install the c...

Page 124: ...m 6 0 7 0 kg m 43 51 ft Ib Coat the 9 discs and 8 plates with clean engine oil and install them as shown below Install the spring seat and damper spring as shown Date of Issue July 1984 HONDA MOTOR CO...

Page 125: ...Install the release bearing and lifter guide into the clutch pressure plate Install the pressure plate aligning the 0 marks on the pressure plate and clutch center NOTE Before installing the pressure...

Page 126: ...starter clutch page 7 16 Install the starter idle gear page 7 17 Install a new gasket and the dowel pins Install the right crankcase cover and tighten the bolts in a crisscross pattern Fill the crankc...

Page 127: ...8 0 HONDA V30MAGNA 20 28 N m 15 20 ft Ib 2 8 kg m 2 0 july 1984 Date of Issue TOR CO LTD HONDA MO...

Page 128: ...8 2 8 3 8 4 8 4 8 6 8 8 CD If the shift forks drum and transmission require servicing remove the engine and separate the crankcase TORQUE VALUE Flywheel bolt Gearsh ift arm pinch bolt TOOLS Common Uni...

Page 129: ...tely after removing the slave cylin der and tie the lever to the handle grip Remove the drive sprocket cover gasket and dowel pin Remove the oil pipe clamp bolt Place a container under the alternator...

Page 130: ...oupler Remove the alternator wire clamp Remove the stator by removing four bolts being careful not to damage the stator coil Date of Issue July 1984 HONDA MOTOR CO LTD AlTERNATOR GEARSHI FT LINKAGE FL...

Page 131: ...clamp Install the seat FLYWHEEL INSTALLAliON Clean the inside of the flywheel Check the taper portion of the crankshaft and clean Install the flywheel onto the crankshaft old the flywheel with the un...

Page 132: ...tall the clutch slave cylinder NOTE When installing the clutch slave cylinder tem porally install it to the left crankcase cover release the clutch lever from the handle grip and then tighten the slav...

Page 133: ...from air con tamination and the slave cylinder piston from falling squeeze the clutch lever immediately after removing the slave cylinder and tie the lever to the handle grip Drain the coolant Page 6...

Page 134: ...bolts and remove the spindle guide plate and spring as a set Remove the drum shifter Remove the neutral stopper arm and spring by removing the nut Date of Issue July 1984 HONDA MOTOR CO LTD ALTERNATO...

Page 135: ...netary gears on the gearshift spindle for wear or damage Check the drum shifter for wear or damage Check the ball bearing in the linkage case for damage or excessive play GEARSHIFT LINKAGE INSTALLATIO...

Page 136: ...tall the washer and nut and tighten the nut Assemble the drum shifter Install the drum shifter with its punch mark aligned with the mark on the gerashift drum Assemble the spindle and guide plate Date...

Page 137: ...e careful not to shift the drum shifter from the neutral position Tighten the bolts and nut Install the return spring Install the dowel pins and a new gasket Install the gearshift linkage cover Check...

Page 138: ...NOTE When installing the clutch slave cylinder tem porarily install it to the left crankcase rear cover release the clutch lever and then tighten the slave cylinder bolts Install the slave cylinder co...

Page 139: ...g m 15 18 ft Ib l l 9 0 NOTE The tightely would coils should face in NOTE HONDA V30 MAGNA NOTE I Apply locking agent I Do not forget to install the washer 45 55 N m 4 5 5 5 kg m 32 40 ft Ib 18 20 N m...

Page 140: ...2 kg cm2 170 28 psi Camshaft Cam height IN 35 22 35 38 mm 1 387 1 393 in 35 18 mm 1 385 in EX 35 12 35 28 mm 1 383 1 389 in 35 08 mm 1 381 in Runout 0 05 mm 0 002 in Oil Both sides Inside 0 110 0 190...

Page 141: ...2 MA60000 07984 MA60000 07510 MB00101 07757 0010000 07743 0020000 HONDA V30 MAGNA Engine top end problems usually affect engine performance These can be diagnosed by a compression test or by tracing n...

Page 142: ...the front cylinder head radiator Page 6 6 front frame cross bar fuel tank From the rear cylinder head fuel tank rear ignition coil Remove the spark plug caps Date of Issue July 1984 HONDA MOTOR CO LT...

Page 143: ...pe and the pipe Remove the timing hole cap from the right crank case cover Remove the alternator cover page 8 2 Turn the crankshaft at the flywheel side counter clockwise and align the TF mark for the...

Page 144: ...ts Slide the cam sprockets with the cam chain off the camshaft sprocket flange Remove the camshaft holder bolts and holders NOTE Mark all disassembled parts to ensure correct reassembly Remove the cam...

Page 145: ...ck camshaft runout with a dial indicator Support both ends of the camshaft with V blocks_ Use 1 2 of the total indicator reading to determine runout SERVICE liMIT 0 05 mm 0 002 in CAM HEIGHT Using a m...

Page 146: ...2 1 2 5 kg m 15 18 ft Ib Hl lJ 10 14 N m 1 0 1 4 kg m 7 10 ft Ib Remove the camshaft holders and measure the width of each plastigauge The widest thickness determines the oil clearance SERVICE LIMITS...

Page 147: ...and sealing washers from the cylinder head Remove the front and rear cam chain tensioner base mounting bolts Pull the cam chain tensioner base up Remove the slipper clip washer and pin and remove the...

Page 148: ...ve the four cylinder head bolts Remove the cylinder heads using a screwdriver at the pry points Remove the front and rear cylinder head gaskets and dowel pins Date of Issue July 1984 HONDA MOTOR CO LT...

Page 149: ...sioner slipper for damage or excessive wear Inspect the spring for proper tension CYLINDER HEAD DISASSEMBLY Remove the rocker arm shaft and rocker arms Remove the rocker arm spring washer and O ring f...

Page 150: ...als and discard them NOTE Replace the stem seals with new ones when ever they are removed Remove carbon deposits from the combustion chamber and clean the head gasket surfaces NOTE Avoid damaging the...

Page 151: ...damage ROCKER ARM Inspect the rocker arms for wear or damage to the camshaft contact surface or for a clogged oil hole Measure the 1 0 of each rocker arm SERVICE LIMIT 12 05 mm 0 474 in VALVE SPRING...

Page 152: ...ubtract each valve stem 0 0 from the corres ponding guide 1 0 to obtain the stem to guide clearance SERVICE LIMITS IN 0 07 mm 0 003 in EX 0 10 mm 0 004 in NOTE If the stem to guide clearance exceeds t...

Page 153: ...the combustion chamber side of the cylinder head CAUTION When driving the valve guide out be careful not to damage the head Adjust the tool setting depth by a pair of vernier calipers DEPTH 11 5 mm 0...

Page 154: ...light coating of Prussian blue to each valve face Lap each valve and seat using a rubber hose or other hand lapping tool Remove the valve and inspect the face CAUTION The valves cannot be ground If t...

Page 155: ...insert the valve into the valve guide To avoid damage to the stem seal turn the valve slowly when inserting Install the valve springs and retainers The spring s tightly wound coils should face in Inst...

Page 156: ...Install the O ring and spring washer onto the rocker arm shaft Apply engine oil to the rocker arm shaft and install the rocker arm Apply liquid sealant to the thread of the rocker arm shaft Install a...

Page 157: ...ts Install the cylinder head and head bolts but do not torque the bolts yet With the cam chain tensioner arm raised and lock plate lowered in the direction of the arrow insert a pin or piece of wire i...

Page 158: ...e oil pass pipe and oil bolt for clogging cracks or other damage Do not forget to install the sealing washers Install the oil pass pipe to the cylinder head with the oil bolt TORQUE 20 25 N m 2 0 2 5...

Page 159: ...ylinder exhaust Place with the locating ridge toward the left side EX R Rear cylinder exhaust Place with the locating ridge toward the right side IN F Front cylinder intake Place with the locating rid...

Page 160: ...and exhaust cam shafts and sprockets through the cam chain Align the l E 2 1 index line of the exhaust cam sproket with the top of the cylinder head Aling the 1 1 2 E index line of the intake cam spr...

Page 161: ...er head Install the front cylinder cam chain over the cam sprockets Slide the sprockets onto the camshaft flanges and install the sprocket bolts in the exposed holes Install the eight dowel pins to ea...

Page 162: ...Install the cam chain guide Tighten all cylinder head bolts in the sequence shown TORQUES IT ID 30 34 N m 3 0 3 4 kg m 22 25 ft Ib rnJ 21 25 N m 2 1 2 5 kg m 15 18 ft Ib i 1 10 14 N m 1 0 1 4 kg m 7 1...

Page 163: ...Insert the compression gauge Open the throttle all the way and crank the engine with the starter motor NOTE Crank the engine until the gauge reading stops rising The maximum reading is usually reached...

Page 164: ...0 21 25 N m 2 1 2 5 kg m 15 18 ft Ib 6mmBOLT 10 14 N m 1 0 1 4 kg m 7 10 ft Ib 8 mm BOLT 30 34 N m HONDA V30MAGNA 3 0 3 4 k g_m 22 25 ft Ib 10 21 25 N m 2 1 2 5 kg m 15 18 ft Ib Date of Issue July 198...

Page 165: ...DARD SERVICE LIMIT Crankshaft Connecting rod big end side clearance 0 10 0 30 mm 0 004 0 012 in 0 40 mm 0 016 in Runout 0 03 mm 0 001 in Crankpin oil clearance 0 028 0 052 mm 0 0011 0 0020 in 0 07 mm...

Page 166: ...Excessive smoke 1 Worn cylinder piston or piston rings 2 Improperly installed piston rings 3 Damaged piston or cylinder Overheating 1 Excessive carbon build up on piston head 2 Blocked or restricted f...

Page 167: ...ass pipe mounting bolt and the oil pass pipe Remove the water pipe cap bolts water pipe and caps Remove the water pipe mounting bolt and the water pipe Date of Issue July 1984 HONDA MOTOR CO LTD CRANK...

Page 168: ...shaft main journal bolts NOTE Remove the bolts in two or more steps and in a crisscross pattern to prevent damage to the crankcase Separate the lower crankcase from the upper crank case NOTE Do not pr...

Page 169: ...move the connecting rod bearing caps and note their locations Push the connecting rods and pistons out through the top of the cylinder bores Mark the rods pistons bearings and caps as you remove them...

Page 170: ...ton ring to groove clearance SERVICE LIMIT TOP SECOND 0 10 mm 0 004 in Remove the piston rings and mark them to indicate the correct cylinder and piston position Using a piston push the ring into the...

Page 171: ...0 0 NOTE Take measurements at 10 mm 0 4 in from the bottom and 90 0 to the piston pin hole SERVICE LIMIT 59 85 mm 2 356 in Measure each piston pin hole 1 0 SERVICE LIMIT 16 06 mm 0 632 in PISTON PIN M...

Page 172: ...ollowing sizes 0 25 0 50 0 75 and 1 00 mm CONNECTING ROD SMALL END Measure the connecting rod small end I D If the reading exceeds the service limit replace the rod SERVICE LIMIT 16_08 mm 0 633 in Exa...

Page 173: ...RANKPIN OIL CLEARANCE Inspect the bearing inserts for unusual wear or damage Wipe all oil from the bearing inserts and crankpins Put a piece of plastigauge on each crankpin NOTE Do not put the plastig...

Page 174: ...e crankshaft in place Put a piece of plastigauge on each journal NOTE Do not put the plastigauge over the oil hole in the main bearing journal of the crankshaft Install the main bearing inserts on the...

Page 175: ...od bearing clearance is beyond tolerance select replacement bearings as follows The code number 1 or 2 stamped on each con necting rod identifies its inside diameter 1 0 The code letter A or B stamped...

Page 176: ...2 Green Brown 1 2595 in BEARING INSERT THICKNESS A Brown 1 494 1 498 mm 0 0588 0 0590 in B Green 1 490 1 494 mm 0 0587 0 0588 in C Yellow 1 486 1 490 mm 0 0585 0 0587 in MAIN BEARING The code letter A...

Page 177: ...ON Install the main bearings into the upper and lower crankcases Apply molybdenum disulfide grease to the main bearings Install the cam chains onto the crankshaft Place the crankshaft into the upper c...

Page 178: ...that the front cylinder connecting rods are marked MJ8 F Install the pistons on the front connecting rods so that the intake IN mark is facing the same direc tion as the oil hole in the rod 10 14 HOND...

Page 179: ...e inserts with the grooves in the rods and caps Apply molybdenum disulfide grease to the connect ing rod bearings Coat the cylinders piston rings grooves and pistons with oil To prevent damaging the c...

Page 180: ...rod caps TORQUE 30 34 N m 3 0 3 4 kg m 22 25 ft Ibl NOTE Be sure the bearing caps are installed in their correct locations as marked during removal Tighten the nuts in two or more steps After tighten...

Page 181: ...nt to the area near the main bearings Install the dowel pin NOTE Make sure the oil control orifice is not clogged Apply molybdenum disulfied grease to the crank shaft main bearings Apply liquid sealan...

Page 182: ...d torque diagonally starting with inner bolts first TORQUE 8 mm BOLT 21 25 N m 2 1 2 5 kg m 15 18 ft Ib 6mmBOLT 10 14N m 1 0 1 4 kg m 7 10 ft Ib Tighten the upper crankcase bolts to the specified torq...

Page 183: ...TRANSMISSION 11 0 HONDA V30 MAGNA Date of Issue July 1984 HONDA MOTOR CO LTD...

Page 184: ...ear M5 gear C1 gear C2 gear at M5 gear at C1 gear at C2 gear 07746 00301 00 07746 0030200 STANDARD SERVICE LIMIT 25 000 25 021 mm 0 9843 0 9851 in 25 05 mm 0 986 in 23 000 23 021 mm 0 9055 0 9063 in 2...

Page 185: ...3 Bent gearshift fork shaft 4 Bent gearshift claw 5 Worn shift drum cam groove 6 Worn guide pin Transmission jumps out of gear 1 Worn gear dogs 2 Bent gearshift fork shaft 3 Damaged shift drum stoppe...

Page 186: ...OVAL Separate the crankcase Section 10 Remove the bearing setting plate Remove the mainshaft assembly and countershaft assembly Remove the oil seal Date of Issue July 1984 HONDA MOTOR CO LTD TRANSMISS...

Page 187: ...gear dogs slots and gear teeth for excessive or abnormal wear or evidence of insufficient lubri cation Measure the 1 0 of each gear SERVICE LIMITS M5 M6 gear 25 05 mm 0 986 in C1 gear 23 05 mm 0 789 i...

Page 188: ...1 mm 0 792 in 25 11 mm 0 989 in MAINSHAFT COUNTERSHAFT Measure the 0 0 of the mainshaft and counter shaft SERVICE LIMITS Mainshaft at M5 21 92 mm 0 863 in Countershaft at C1 19 95 mm 0 785 in Counters...

Page 189: ...haft SHIFT FORK AND SHIFT DRUM REMOVAL Remove the gearshift linkage section 8 Lock two 6 mm nuts on the stopper arm pin and remove the pin Remove the bearing stopper plate 11 6 MAINSHAFT BEAR NG HONDA...

Page 190: ...ft forks Remove the shift drum INSPECTION CD SHIFT FORK Inspect the shift forks to make sure they are not bent Measure the shift fork I D SERVICE LIMIT 12 04 mm 0 474 in Measure the shift fork claw th...

Page 191: ...ERVICE LIMIT 11 90 mm 0 469 in SHIFT DRUM Inspect the shift drum end for scoring scratches or evidence of insufficient lubrication Check the shift drum grooves for damage CRANKCASE Inspect the shift d...

Page 192: ...pin using two nuts Install the shift forks and shift fork shaft NOTE Install the shift forks so that their marks face toward the right side of the engine Right shift fork R mark Center shift fork c ma...

Page 193: ...o the sliding surfaces of the countershaft and each gear and bushing Assemble the countershaft NOTE Check the gears for freedom of movement or rotation on the shaft Check that the snap rings are seate...

Page 194: ...y molybdenum disulfide grease to the sliding surfaces of the mainshaft and each gear and bushing Assemble the mainshaft NOTE Check the gears for freedom of movement and rotation on the shaft Check tha...

Page 195: ...the mainshaft Install the bearing set ring onto the upper crankcase Install the mainshaft and countershaft onto the upper crankcase aligning their locating points with the dowel pin and bearing set r...

Page 196: ...Install the bearing setting plate NOTE Before installing the lower crankcase check that the oil orifices are clear Install the lower crankcase Section 10 Date of Issue July 1984 HONDA MOTOR CO LTD TR...

Page 197: ...DA V30 MAGNA 25 35 N m 2 5 3 5 kg m 18 25 ft Ib 80 120 N m L 8 0 12 0kg m 58 87 ft Ib _____9 13 N m 0 9 1 3 kg m 7 9 ft Ib 3 5 4 0 kg m 25 29 ft Ib 30 40 N m 12 0 SOCKET BOLT 15 25 N m 3 0 4 0 kg m 2...

Page 198: ...ment nut Steering stem nut Brake disc Front fork upper pinch bolt Front fork lower pinch bolt Front fork stabilizer bolts Master cylinder holder bolt Date of Issue July 1984 HONDA MOTOR CO LTD Radial...

Page 199: ...07964 MB00200 07916 3710100 07949 3710001 or 07949 3710000 07749 0010000 07746 0010300 07746 0040300 07716 0020400 or equivalent in U S A 07716 0020500 or equivalent in U S A 07746 0050100 or equivale...

Page 200: ...ke switch wires Remove the front brake master cylinder Remove the switch housing screws Disconnect the throttle cables then remove the switch Remove the switch housing Date of Issue July 1984 HONDA MO...

Page 201: ...cylinder socket bolts and clutch master cylinder Remove the left switch housing mount screws and left switch housing Remove the handle cover and upper holder caps 12 4 HONDA V30 MAGNA CLUTCH MASTER C...

Page 202: ...e punch mark with the outside face of the lower holder Place the upper holders on the handlebar with the punch marks facing forward Tighten the forward bolts first then tighten the rear bolts TORQUE 2...

Page 203: ...en the forward screw first then tighten the rear screw Place the front brake master cylinder on the handle bar and install the master cylinder holder with the UP mark facing up Align the holder mating...

Page 204: ...e UP mark facing up Align the holder mating surface with the punch mark on the handlebar and tighten the upper bolt Connect the clutch switch wires Connect the left and right handlebar switch wire con...

Page 205: ...acing the wheel in a truing stand and spinning the wheel by hand Replace the bearings with new ones if they are noisy or have excessive play CD WHEEL RIM Check the rim runout by placing the wheel in a...

Page 206: ...e actual runout is 1 2 of the total indicator reading SERVICE LIMIT 0 2 mm 0 01 in DISASSEMBLY Remove the speedometer gear box Remove the brake disc socket bolts and disc Date of Issue July 1984 HONDA...

Page 207: ...ement remove the bear ings and distance collar NOTE Never reinstall old bearings once the bearings are removed they must be replaced with new ones 12 10 HONDA V30MAGNA SIDE COLLAR DUST SEAL BEARING RE...

Page 208: ...into place NOTE Be certain the distance collar is in position before installing the right bearing Drive in the left bearing squarely NOTE Drive the bearing into position making sure that it is fully...

Page 209: ...he wheel hub aligning its tangs with the slots in the hub Install the dust seal Apply oil or grease to the brake disc bolt threads Install the brake disc and tighten the bolts to the specified torque...

Page 210: ...the tire balance mark a paint dot on the sidewall must be located next to the valve stem Remount the tire if necessary Mount the wheel with brake discs and tire in an inspection stand Spin the wheel...

Page 211: ...n the speedometer gear box with the boss on the left fork leg as shown Install the axle and collar Remove the support block from under the engine Tighten the axle to the specified torque TORQUE 55 65...

Page 212: ...wheel page 12 7 Remove the brake caliper and bracket Pull off the bolt caps Remove the front fender and fork brace Remove the bottom bridge cover Date of Issue July 1984 HONDA MOTOR CO LTD FRONT WHEEl...

Page 213: ...TION I Do not damage the sliding surface Depress the air valve and release front fork air pres sure CAUTION If air pressure is not released before dis assembling the fork cap may become a projectile T...

Page 214: ...damage the fork slider Remove the socket bolt with a hex wrench NOTE Temporarily install the spring and fork tube cap if difficulty is encountered in removing the bolt Remove the dust seal sponge sea...

Page 215: ...ill be forced out by the fork tube bushing Remove the oil seal back up ring and slider bushing from the fork tube NOTE Do not remove the fork tube bushing unless it is necessary to replace it with a n...

Page 216: ...core marks scratches or excessive or abnormal wear Replace any components which are worn or damaged Check the fork piston ring for wear or damage Check the rebound spring for fatigue or damage Set the...

Page 217: ...up ring Replace it if there is any distorition at the points shown ASSEMBLY Before assembly wash all parts with a high flash point or non flammable solvent and wipe them off completely PISTON FORKCAP...

Page 218: ...kg m 11 18 ft Ib Place the slider bushing over the fork tube and rest it on the slider Put the back up ring and an old bushing or equivalent tool on top Drive the bushing into place with the seal dri...

Page 219: ...all the spring spring seat and collar NOTE Note the spring direction the small diameter end faces down Install and torque the fork tube cap TORQUE 15 30 N m 1 5 3 0 kg m 11 22 ft Ibl Install the air v...

Page 220: ...nder brake calipers front wheel Tighten the front fork brace to the specified torque TORQUE 18 28 N m 1 8 2 8 kg m 13 20 ft Ib Install the bolt caps Fill the fork tubes with air to 0 40 kPa 0 0 4 kg c...

Page 221: ...e box page 18 7 Remove the front forks page 12 15 Remove the steering stem nut and washer Remove the fork top bridge Straighten the lock washer tabs and remove the lock nut and lock washer 12 24 HORNS...

Page 222: ...upper bearing Inspect the ball races coner races and steel balls for wear or damage Replace them if necessary Date of Issue July 1984 HONDA MOTOR CO LTD FRONT WHEEL SUSPENSION STEERING EXTENSION BAR...

Page 223: ...t 07953 MJ 1OOOA LOWER Race Remover 07946 3710500 Attachment 37 x 40 mm 07746 0010200 Driver 07949 3710001 or 07949 3710000 Drive the upper and lower ball races into the steer ing head using the tools...

Page 224: ...aQd then drive a new lower cone race in Install the dust seal and lower bearing on the steering stem Install the grease holder Date of Issue July 1984 HONDA MOTOR CO LTD JI FRONT WHEEl SUSPENSION STEE...

Page 225: ...1 9 2 3 kg m 14 17 ft Ibl Install a new lock washer Bend two oposite tabs down into the grooves of the adjusting nut NOTE I Do not install a used lock washer Hand tighten the lock nut Hold the adjust...

Page 226: ...spring scale to the fork tube and measure the steering head bearing preload NOTE Make sure that there is no cable or wire harness interference The preload should be with in 1 1 1 6 kg m 2 42 3 53 Ib f...

Page 227: ...m 58 80 ft Ib j 1 3 1 7 kg m 9 12 ft Ib 13 17 N m 18 25 N m 1 8 2 5 kg m 13 18 ft Ib 13 0 30 40 N m HONDA V30 MAGNA 20 30 N m 2 0 3 0 kg m 14 22 ft Ib J 60 70 N m 6 0 7 0 kg m 43 51 ft Ib 3 0 4 0 kg m...

Page 228: ...t bolt right left Swing arm pivot bolt lock nut Shock absorber mount bolt upper lower Final driven sprocket Brake arm bolt 4 9 5 0 mm 0 19 0 2 in 70 90 N m 7 0 9 0 kg m 51 65 ft Ib 18 25 N m 1 8 2 5 k...

Page 229: ...Loose wheel bearings 3 Faulty tire 4 Loose axle 5 Tire pressure incorrect 6 Swing arm bearings worn 7 Worn tires Soft suspension 1 Weak spring Hard suspension 1 Bent shock absorber Suspension noise 1...

Page 230: ...connect the brake rod Remove the chain cover Move the rear wheel forward and remove the drive chain from the driven sprocket Remove the axle shaft and collar from the wheel Remove the rear wheel INSPE...

Page 231: ...read the runout using a dial indicator SERVICE LIMITS RADIAL RUNOUT 2 0 mm 0 08 in AXIAL RUNOUT 2 0 mm 0 08 in NOTE The wheel cannot be serviced and must be replaced if the above limits are exceeded C...

Page 232: ...final driven flange Remove the final driven sprocket and driven flange together NOTE Do not separate the driven sprocket and flange unless replacement of the driven sprocket or flange is necessary Rep...

Page 233: ...llar If the bearing needs replacement drive out the wheel bearing using the bearing remover 20 mm 07746 0050600 and remover shaft 07746 0050100 or equivalent tools NOTE If the bearing is removed it sh...

Page 234: ...eft side bearing into the wheel hub first with the sealed end facing out Install the distance collar into place Drive the right side bearing in squarely with the sealed end facing out Date of Issue Ju...

Page 235: ...p and dust seal Install the center collar Install the damper rubbers Apply grease to a new O ring and install it on the wheel hub Install the final driven flange Install the collar Check wheel balance...

Page 236: ...assembly between the rear fork legs set the right side spacer and insert the rear wheel Loosely install the rear axle nut Install the drive chain on the final driven sprocket Adjust the drive chain P...

Page 237: ...a new cotter pin Connect the brake rod with brake arm spring and adjusting nut Adjust the rear brake Page 3 17 REAR BRAKE Remove the rear wheel and remove the brake panel from the rear wheel LINING TH...

Page 238: ...he anchor pins and brake cam Contaminated brake linings reduce stopping power Keep grease off the brake linings Wipe any excess grease off the cam Install the brake cam Install the brake shoes and ret...

Page 239: ...ll it on the brake panel Install the wear indicator on the brake arm 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 13 12 FELT...

Page 240: ...ressor and compress the shock spring Place the upper joint in a vise and pull the shock rod out Loosen the lock nut and remove the upper joint Loosen the compressor and remove the shock absorber from...

Page 241: ...SERVICE LIMIT 249 9 mm 9 84 in ASSEMBLY Place the spring adjuster spring lower seat spring spring upper seat and stopper rubber on the damper UPPER JOINT SPRING A UPPER SEAT q LOCK NUT SPRING LOWER SE...

Page 242: ...in a vise and tighten the lock nut securely NOTE Check that the lock nut is seated against the rod s bottom thread Align the spring seat with the upper joint while releasing the compressor INSTALLATIO...

Page 243: ...llowings chain guard rear wheel rear shock absorber lower mount bolt Loosen the lock nut and remove the pivot bolt and lock nut Remove the left pivot bolt and swing arm 13 16 HONDA V30 MAGNA RIGHT PIV...

Page 244: ...bolt Remove the brake torque link INSPECTION Remove the dust seals bearings and grease holder Check the bearings for wear or damage Check the swing arm for cracks or damage Date of Issue July 1984 HO...

Page 245: ...them into the swing arm Apply grease to the dust seal lips and install the dust seals into the swing arm pivot 13 18 HONDA V30 MAGNA BEARING REMOVER SET 30 mm 07936 8890100 OR BEARING REMOVER 30 mm 07...

Page 246: ...bolt TORQUE 80 110 N m 8 0 11 0 kg m 58 80 ft Ib Tighten the right pivot bolt Tighten to 25 N m 2 5 kg m 18 ft Ib first then loosen to the specified torque TORQUE 13 17 N m 1 3 1 7 kg m 9 12 ft Ib Tig...

Page 247: ...EAR WHEEl BRAKE SUSPENSION Install the rear shock absorbers and chain adjusters Install the rear wheel Page 13 9 Install the chain guard 13 20 HONDA V30MAGNA Date of Issue July 1984 HONDA MOTOR CO LTD...

Page 248: ...RAKES 30 40 N m 3 0 4 0 kg m 22 29 ft Ib 14 0 HONDA V30MAGNA 25 30 N m 25 35 N m 2 5 3 5 kg m 18 25 ft Ib 2 5 3 0 kg m 18 22 ft Ib j 20 25N m 2 0 2 5 kg m 14 18 ft lbT Date of Issue July 1984 HONDA MO...

Page 249: ...riding the motorcycle SPECI FICATIONS ITEM Front disc thickness Front disc warpage Front master piston O D Front caliper piston O D Front caliper cylinder I D TORQUE VALUES Caliper bracket mount bolt...

Page 250: ...tons 2 Clogged hydraulic system 3 Pads glazed or worn excessively Brake drag 1 Hydraulic system sticking 2 Sticking pistons Brakes grab 1 Pads contaminated 2 Disc or wheel misaligned Brake chatter or...

Page 251: ...or pad reduces stopping power Dsicard contaminated pads and clean a contaminated disc with a high quality brake cleaning agent BRAKE FLUID FILLING NOTE Do not mix different types of fluid They are no...

Page 252: ...r equivalent to the bleed valve Pump the brake bleeder and loosen the bleeder valve Add fluid when the level in the master cylinder reservoir is low NOTE If air entering the bleeder hose from around t...

Page 253: ...Remove the caliper mount bolt Lift the caliper by pivoting it with the caliper pin bolt then remove the caliper Remove the retainer bolt and retainer Remove the pad pins from the caliper Remove the pa...

Page 254: ...AKES Push the caliper pistons in all the way Position the pad spring in the caliper as shown Install the new pads in the caliper Install the pad pins 14 6 HONDA V30MAGNA Date of Issue July 1984 HONDA...

Page 255: ...per to the bracket so the disc is posi tioned between the pads being careful not to damage the pads Tighten the caliper mounting bolts TORQUE 20 25 N m 2 0 2 5 kg m 14 18 ft Ib BRAKE DISC DISC THICKNE...

Page 256: ...spilling brake fluid on painted surfaces Place a rag over the fuel tank whenver the brake system is being serviced NOTE When removing the fluid hose bolt cover the end of the hose to prevent contamin...

Page 257: ...cylinder and reservoir with clean brake fluid INSPECTION Measure the master cylinder 1 0 Check the master cylinder for scores scratches or nicks SERVICE LIMIT 14 055 mm 0 5533 in Date of Issue July 1...

Page 258: ...he master cylinder Coat all parts with clean brake fluid before assembly Install the spring and primary cup together CAUTION When installing the cups do not allow the lips to turn inside out and be ce...

Page 259: ...tall the mirror Connect the brake light switch wires Fill the reservoir to the upper level and bleed the brake system according to page 14 3 BRAKE CALIPERS FRONT BRAKE CALIPER REMOVAL Place a clean co...

Page 260: ...xamine the pistons and cylinders for scoring scratches or other damage and replace if necessary Push the piston seals in and lift them out then discard them Clean the piston seal grooves with clean br...

Page 261: ...rd the pads Then install the piston boots Install the collar boots and collar making sure that the boots are seated in the collar and caliper grooves properly Install the pad spring Install the pads p...

Page 262: ...o damage the pads Install the caliper bracket mounting bolts and tighten them securely Connect the brake hose to the caliper with the bolt and two sealing washers TORQUE 25 35 N m 2 5 3 5 kg m 18 25 f...

Page 263: ...NATOR s o J J W l l j1L j I I lV 1 BATTERY HONDA V30 MAGNA REGULATOR RECTIFIER FUSE 30 A RED WHITE R r ED1 1 0 IGNITION W I SWITCH I BLACK RED a l VOLTAGE SENSOR r I FUSE 15A 1 BLACK _ REGULATOR RECTI...

Page 264: ...t be charged on the motorcycle disconnect the battery cables Do not smoke or allow flames near a charging battery The gas produced by a battery will explode if flames or sparks are brought near All ch...

Page 265: ...tion Low power engine running 1 Battery undercharged Low fluid level One or more dead cells 2 Charging system failure 15 2 Intermittent power 1 Loose battery connection 2 Loose charging system connect...

Page 266: ...230 The specific gravity varies with the tempe rature as shown in the accompanying table Replace the battery if sulfation is evident or if the space below the cell plates is filled with sediment The...

Page 267: ...ution label on the frame After installing the battery coat the terminals with clean grease CHARGING SYSTEM CURRENT TEST NOTE Be sure the battery IS In good condition be fore performing this test Warm...

Page 268: ...TOR CONTINUITY TEST Remove the seat Disconnect the alternator and regulator rectifier coupler Check for continuity between the leads and be tween the leads and ground Replade the stator if there is no...

Page 269: ...LLOW REVERSE DIRECTION NO CONTINUITY G probe I GREEN II YELLOW VOLTAGE REGULATOR PERFORMANCE TEST e probe YELLOW RED WHITE Connect a voltmeter across the battery Check regulator performance with the e...

Page 270: ...ITION SYSTEM DIAGRAM IGNITION COILS 1 3 2 2 4 1 3 SPARK PLUGS SPARK UNITS 16 0 HONDA V30MAGNA ENGINE STOP SWITCH SPARK UNITS ENGINE STOP SWITCH IGNITION SWITCH ON OFF BATTERY 1 PULSE GENERAROR Date of...

Page 271: ...used and no adjustments can be made SPECI F ICATIONS ND NGK Spark plug Standard X24EPR U9 DPR8EA 9 For cold climate Below 5 C 41 F X22EPR U9 DPR7EA 9 For extended high speed driving X27EPR U9 DPR9EA 9...

Page 272: ...or shorted wires Between ignition switch and engine stop switch Between spark unit and engine stop switch Between spark unit and ignition coil Between ignition coil and plug Between spark unit and pu...

Page 273: ...gnition coil and spark plug wires CONTINUITY TEST Measure the primary coil resistance RESISTANCE 2 Sn Check the continuity between the primary terminal and bracket There should be no continuity NOTE M...

Page 274: ...d and ground There should be no continuity PULSE GENERATOR REPLACEMENT Remove the right crankcase cover page 7 12 Remove the pulse generator mounting bolts and remove the pulse generators Install new...

Page 275: ...d and the ignition timing is not within specification replace the spark units with new ones and recheck the ignition timing Warm up the engine Connect the timing light to the high tension wire of the...

Page 276: ...nected wire or cable 7 Clutch diode open 8 Faulty clutch switch Starter motor turns engine slowly 1 Low specific gravity in battery 2 Excessive resistance in circuit 3 Binding in starter motor Date of...

Page 277: ...he oil filter page 2 3 Disconnect the starter motor cable from the starter motor by removing the nut Remove the starter motor mounting bolts and the starter motor CASE O RING REAR COVER SHIMS STARTER...

Page 278: ...he 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 between pairs of commutator b...

Page 279: ...MBLY Assemble the starter motor in the reverse order of disassembly by noting followings Align the case notch with the brush holder pin Install the rear cover aligning its slot with the brush holder p...

Page 280: ...nals 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 harness INSPECTIO...

Page 281: ...n electrical failure check the continuity of the electrical path through the part A continuity check can usually be made without removing the part from the motorcycle Simply disconnect the wires and c...

Page 282: ...out the headlight Disconnect the headlight coupler and remove the headlight HEADLIGHT BULB REPLACEMENT Remove the seal rubber Remove the bulb set spring and replace the bulb 18 2 HONDA V30 MAGNA SCREW...

Page 283: ...ctors Loosen the adjusting bolts Remove the headlight case mounting bolts and headlight case INSTALLATION Installation is the reverse order of removal NOTE Route the wires properly Page 1 11 Adjust th...

Page 284: ...d 18 3 Disconnect the speedometer cable Remove the mounting nuts and instruments DISASSEMBLY Remove the three screws and lower cover Remove the screw and disconnect the meter wires Remove the indicato...

Page 285: ...ove the meter bracket BULB REPLACEMENT Pull out the bulb socket and replace the bulb ASSEMBLY Assembly is the reverse order of removal Date of Issue July 1984 HONDA MOTOR CO LTD LIGHTS SWITCHES INSTRU...

Page 286: ...reverse order of re moval After the installation check the warning and indi cator light for proper opeartion fUSE HOLDER REMOVAL Remove the bottom bridge cover Remove the screws and fuse holder cover...

Page 287: ...is the reverse order of removal IGNITION SWITCH INSPECTION Remove the headlight page 18 2 and disconnect the ignition switch coupler black 6P Check continuity of terminals on the ignition switch coupl...

Page 288: ...ion key and turn it so is partway between the ON and OFF detent positions Push in the lugs that are locked in the slots then pull the contact base from the switch Assemble the ignition switch in the r...

Page 289: ...ch chart when that position is selected HEAD LIGHT HI LO SWITCH Position Hl Ho Hi lo 0 N 0 D Hi 0 D COLOR Br W W Bu HORN BUTTON Ho BAT3 FREE PUSH 0 D Color code 19 WIG TURN SIGNAL SWITCH W l R P PR Pl...

Page 290: ...BRAKE SWITCH Disconnect the front brake light switch wires from the switch There should be continuity with the brake lever applied and no continuity with the lever released Replace the switch if neces...

Page 291: ...The warning light should come on If the warning light comes on replace the oil pres su re switch If the warning light does not come on check the fuse indicator bulb and wire connections Replace or rep...

Page 292: ...lant and remove the temperature sensor from the thermostat case Suspend the unit in oil over a heater and measure the resistance through the unit as the oil heats up Temperature 50 C 80 C 100 C 120 C...

Page 293: ...nd check the temperatures at which the switch opens and closes Make sure that there is no switch continuity with room temperature and gradually raise the coolant temperature The switch should be conti...

Page 294: ...el tank Turn the ignition switch ON the fuel reserve warning light should come on If the warning light does not come on remove the seat disconnect the Gr BI wire and ground it to the frame The warning...

Page 295: ...does not come on disconnect the check relay coupler Check voltage between the BI Br and G terminals There should be battery Voltage If no voltage check the harness and fuse and repair or replace if n...

Page 296: ...2V32t 23W OJ Lb G LlCENS LIGHT A tube 12V4cp 8W BI O _G 1 j Br cJ l Br 1 I I G Yc J J G Y r STOP ANO TAIL LIGHT I 12V32 3t 21 BWI Hil HEAOLIGHT 12VIO 55W t t Eil L I I I t l l i 1 l I I I I I n II I l...

Page 297: ...uel filter 3 Sticking float valve 4 Faulty fuel pump 5 Fau Ity fuel pump relay 6 Pinched fuel tank vent hose 1 Faulty spark plugs 2 Fouled spark plugs 3 Faulty spark unit 4 Broken or shorted high tens...

Page 298: ...on TOO LOW II 1 Valve stuck open 2 Worn cylinder and piston rings NORMAL 3 Leaking head gasket t 4 Improper valve timing 8 Check carburetor for clogging CLOGGED Carburetor not serviced frequently enou...

Page 299: ...carburetor FUEL FLOWS FREELY 3 Remove carburetors and check for clogged jets NO CLOGGED JETS t 4 Check valve timing CORRECT t 5 Check valve spring tension NOT WEAKENED INCORRECT l l Improper valve cl...

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Can-Am DS250 Instructions Manual preview
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