Honda V65 Magna-VF1100C 1983 Shop Manual Download Page 275

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Summary of Contents for V65 Magna-VF1100C 1983

Page 1: ...SHOP MANUAL V65 MAGNA VF11DOC...

Page 2: ...ar with this motorcycle read the TECHNICAL FEATURES in section 23 If you don t know the source of the trouble go to section 24 TROUBLESHOOTING ALL INFORMATION ILLUSTRATIONS Dl RECTIONS AND SPECIFICATI...

Page 3: ...rnings Jnd cautions against some specific service methods which could cause PER SONAL INJURY to service personnel or cotlfd clama Je a vehicle or render ir unsafe Please understand thi tl those warnin...

Page 4: ...Do not smoke or allow flames or sparks near the barury especia ly while charging it 1 Use genuine HONDA or HONDA recommended parts and lubricants or their equivalent Parts that do not meet HONDA s des...

Page 5: ...on the steering head right side serial number is stamped on top of the right c rankcase 1 2 The color label is attached to the frame behind the left side cover The vehicle identification number VIN is...

Page 6: ...Valve clearance Cold Engine we ight Idle speen After 85 800 mm 31 5 ini 350 mm 13 8 in 155 mm 6 1 in 245 kg 540 b 265 kg 584 lh Double cradle Telescopic fork 160 mm 6 3 in Swingarm Shuck absorber 11 2...

Page 7: ......

Page 8: ...0 8 0 51 58 Valve adjustment nuts 16 7 2 1 25 2 1 2 5 15 18 Apply oil to the Drain bolt 1 12 35 40 3 5 4 0 25 29 l thread and seating Connecting rod nuts 8 8 30 34 3 0 3 4 22 25 surface Drum stopper...

Page 9: ...2 3 5 0 2 0 35 1 4 2 5 1 2 0 1 0 2 0 7 1 4 2 3 5 0 2 0 35 1 4 2 5 1 2 0 1 0 2 0 7 1 4 10 14 1 0 1 4 7 10 30 45 3 0 4 5 22 33 18 25 1 8 2 5 13 1 8 90 120 9 0 12 0 65 87 16 20 1 6 2 0 12 14 100 130 10...

Page 10: ...220201 07908 4690001 07908 MB00 00 079 10 4630100 0791 4 3230001 07916 3710100 07916 4220000 07916 MBOOOOO 07917 3230000 07923 6890101 07926 ME90000 0793 1 ME40000 0793 1 4630300 07936 37 10100 07936...

Page 11: ...r head 15 mm Bearing removor head 20 mm Valve spring compressor Rear shock absorber ccmprenor 1 8 07746 001 0100 07746 0010200 07746 01 0300 07746 0010400 07746 0010600 07746 0040300 07746 040400 0774...

Page 12: ...sharp edge or corner Clean surfaces thoroughly before applying tape Do not use wires or harnesses with a broken insulator Repair by wrapping them with pro tective tape or replace them Route wire harne...

Page 13: ...ERAL INFORMATION 83 84 85 CLAMPS 83 84 85 CHOKE CABLE 83 84 85 EQUALIZER PIPE FRONT BRAKE HOSE CLUTCH HOSE 1 10 r 4 I I ______ _ I _ _ I I i FUSE I BOX J 83 84 85 METER IGNITION SWITCH TURN SIGNAL MET...

Page 14: ...83 84 85 83 84 85 BATTERY CABLE STARTER MOTOR WIRE GENERAL INFORMATION CLAMP _ _ i ALTERNATOR WIRE OIL PRESSURE SWITCH GENERATOR 1 11...

Page 15: ...MATION 83 84 85 THROTTLE CABLES COOLING FAN MOTOR WIRE MAIN HARNESS COOLANT RESERVE TANK OVERFLOW TUBE f ADIATOR OVERFLOW TUBE _f i i I FUEL HOSE 11 I f 1 THERMOSTATIC SWITCH FUEL RESE RVE SENSOR 83 F...

Page 16: ...GENERAL INFORMATION After 83 FUEL PUMP After 85 THROTTLE CABLES WIRE BANDS CHOKE CABLE 1 13...

Page 17: ...KE HOSE CLUTCH HOSE I After 85 1 14 _ SPEEDMETER CABLE THROTTLE CABLES I I I ii i I j I I THEMOSTATIC SWITCH After 85 ENGINE STOP IGN ITION SWITCH METER TURN SIGNAL CANCEL UNIT COOLAN T RESERVE TANK O...

Page 18: ...ANGF SWITCH WIRE _ CLAMPS After 85 GENERAL INFORMATION CLAMP _____ ALTERNATOR WIRE BATTERY BREATHER TUBE j STARTER _ ____ _ RELAY STARTER MOTOR WIRE ALTE RNATOR Wl RE OIL PRESSURE SWITCH PULSE GENERAT...

Page 19: ...GENERAL INFORMATION After 85 California model AIR VENT CONTROL VALVE iAVCV 1 16 CANISTER AIR VENT CONTROL VALVE AVCV L...

Page 20: ...he combustio n process produces carbon monoxide and hydrocarbons Control of hydrocarbo ns is very important because under certa in cond itions they react to form photochemical smog when subjected to s...

Page 21: ...carburetor After 85 This model comnlies with California Air Resources Board evaporative emission requ irements Fuel vapor from the fuel tank and carburetor is directed into Lhe t harcoal canister wher...

Page 22: ...ED BELOW 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust guscs 2 Removal of or puncturing of any part of the intake system 3 Lack of proper ma...

Page 23: ...LUBRICATION COUN TERSHAFT 2 0...

Page 24: ...ies shown in the chart may be used when the averane temperature in your riding area is within the indicated range OIL VISCOSITIES CHART r SAE IOW 40 SAE IOW 30 I 0 20 4 0 6G 80 100 F l o 10 o 10 20 c...

Page 25: ...4 kg m 7 10 ft lb Apply 3 BOND or its equivalent to the bolt threads 07506 3000000 II 1 bl I 075 10 _ 4220 100 or commercia y ava1 a e eqUiva ent 1 Oil or filter not changed often enough 2 Head gasket...

Page 26: ...ove the canister California model only Remove the oil filler cap cylinder head oil drain plug engine bottom oil drain plug and drain the oil Remove the oil filter with a filter wrench and let the rema...

Page 27: ...e Make sure the 0 ring is in good condition when ever the relief valve is removed Install the oil strainer and oil pan Install the exhaust pipes Fill the crankcase with the recommended oil page 2 1 OI...

Page 28: ...ut after one or two seco1 ds 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 mounte...

Page 29: ...holding the oil strainer stay Remove the oil strainer stay Make sure the O rings are in good conditions DISASSEMBLY Remove the oil pump body cover and remove the dowel pin Remove the drive pin from t...

Page 30: ...or tip clearance SERVICE LIMIT 0 20 mm 0 008 in Measure the pump body clearance SERVICE LIMIT 0 35 mm 0 014 in Remove the rotor shaft and measure the pump end clearance SERVICE LIMIT 0 10 mm 0 004 in...

Page 31: ...dy and insert the rotor shaft Insert the drive pin into the rotor shaft Align the slots in the inner rotor with the drive pin Install the dowel pin and oil pump body cover 2 8 01 L PUMP BODY OUTER ROT...

Page 32: ...tall the oil strainer and oil pan Place the oil pump driven sprocket into the drive chain NOTE The IN mark on the driven sprocket should face the crankcase Install the washer and tighten the bolt Inst...

Page 33: ...bolt to drain all oil from the final gear case Install the drain bolt securely Fill the gear case with the recommended oil up to the correct level above OIL CAPACITY 130 cc 4 4 oz RECOMMENDED OIL 83 H...

Page 34: ...ORK A T F THROTTLE GRIP SWING ARM PIVOT fiiiiW FOOT PEG PIVOT SHIFT PEDAL PIVOT BRAKE PEDAL PIVOT I I I I I I I I I I I SIDE AND CENTER STAND PIVOT LUBRICATION DRIVEN FLANGE SPINDLES AND PINS LITHIUM...

Page 35: ...UID 3 7 After 84 FRONT BRAKE LEVER 3 7 BRAKE PAD WEAR 3 8 BRAKE SYSTEM 3 8 BRAKE LIGHT SWITCH 3 9 HEADLIGHT AIM 3 9 CLUTCH 3 14 After 84 CLUTCH LEVER 3 15 SIDE STAND 3 16 SUSPENSION 3 16 3 16 WHEELS S...

Page 36: ...t ire pressure psi kPa kg cm2 90 kg 200 lbs load to vehicle capacity load 40 280 2 80 1 Bridgestone 32 225 2 251 L303 I G508H T ire brand Dunlop L J _ _ r F L K627 Front fork air pre ssure 0 6 psi 0 4...

Page 37: ...SYNCHRONIZATION I I I I 3 14 0 r 4 4 4 CARBURETOR IDLE SPEED I I I I I I I 3 15 r 4 r 4 r E RADIATOR COOLANT I I A 3 16 W r 1 r 1 r 1 RADIATOR CORE I I I 3 16 COOLING SYSTEM HOSES I I 1 1 3 16 CONNEC...

Page 38: ...111 t 1 A 2 10 BATTERY MONTH c p fl 1 10 i P 1 3 18 BRAKE FLUID Z YEARS R I t R I 0 1 1 1 lt R 3 18 w t ___ _ _ It f I l I 1 BRAKE PAD WEAR 1 i j 3 19 0 BRAKE SYSTEM l r I c 11 1 J ii I I 3 19 w t BRA...

Page 39: ...nto place and install the mounting bolts Be careful not to pinch or kink the vent and fuel lines FUEL FILTER Remove the seat Remove the fuel filter from the holder Unclip the fuel lines Disconnect the...

Page 40: ...asure throttle grip free play at the throttle grip flange FREE PLAY 2 6 mm 1 8 1 4 in Adjustment can be made at either end of the throttle cable Minor adjustments are made with the upper adjuster and...

Page 41: ...ee play Adjust if necessary by loosening the choke cable clamp on the carburetor and moving the choke cable casing so the choke lever is fully open Tighten the clamp Pull the choke lever all the way t...

Page 42: ...it level can be seen in the transparent section of the drain tube SPARK PLUGS RECOMMENDED SPARK PLUGS NGK NO Standard DPRSEA 9 X24EPR U9 For cold climiate DPR7EA 9 X22EPR U9 Below 5 C 41 F For extende...

Page 43: ...he F mark on the fly wheel aligns with the crankcase rear mating surface VALVE CLEARANCE 83 84 85 NOTE Inspect and adjust valve clearance while the engine is cold Below 35 C 95 F Remove the heat guard...

Page 44: ...gauges should remain inserted during adjustment Hold the adjusting screws and tighten the lock nuts TORQUE 21 25 N m 2 1 2 5 kg m 15 18 h lb CAUTION The lock nuts will come loose ifnot tightened to th...

Page 45: ...C 95 F ___________________J NOTE Drain the coolant into a clean container for reuse Scheduled coolant replacement is every 2 years or 24 000 miles 38 600 km Remove the right and left frame side cover...

Page 46: ...witch and turn the radiator valve to SHUT Loosen the coolant drain plug on the sub frame page 6 3 once to release coolant pressure then retighten the drain plug Loosen the lower radiator hose band and...

Page 47: ...ith the crankcase mating surfaces in com pression stroke Make sure that the No 1 piston is at TDC Top Dead Center on the compression stroke Insert the camshaft holder as shown and tighten it Check the...

Page 48: ...with the crankcase matmg surface and check the valve clearance for No 4 cylinder Adjust if necessary using the procedure for No 1 cylinder Install the removed parts except the radiator cap in the reve...

Page 49: ...ation Remove the gauge adapters and install the plugs CARBURETOR IDLE SPEED NOTE Inspect and adjust idle speed after all other engine adjustments are within specifications The engine must be warm for...

Page 50: ...f distilled water and anti freeze Reinstall the cap and frame side cover RADIATOR CORE Check the air passages for clogging or damage Straighten bent fins and collapsed core tubes Remove insects mud or...

Page 51: ...crown EVAPORATIVE EMISSION CONTROL SYSTEM California model only Check the system hoses for damage deterioration clogging or loose connections Check the charcoal canister for cracks or damage Refer to...

Page 52: ...level nears the lower level mark fill the re servoir with DOT 4 BRAKE FLUID to the upper level mark Check the entire system for leaks CAUTION Do not remove the cover until the handle bar has been tur...

Page 53: ...s for deterio ration cracks and signs of leakage Tighten any loose fittings Replace hoses and fittings as required BRAKE PEDAL HEIGHT Adjust brake pedal height so the pedal is 30 mm 1 1 4 in above the...

Page 54: ...t beam as specified by local laws and regulations An improperly adjusted headlight may blind oncoming drivers or it may fail to light the road for a safe distance CLUTCH Check the clutch fluid reservo...

Page 55: ...he side stand assembly for freedom of movement Make sure the side stand is not bent NOTE When replacing use a rubber pad with the mark Over 260 lbs ONLY Spring tension is correct if the measure ments...

Page 56: ...system by riding the motorcycle and firmly applying the brakes Position Anti dive damper force I LIGHT ANTI DIVE II MEDIUM Ill HARD IV MAXIMUM ANTI DIVE Inspect and if necessary repair the system Refe...

Page 57: ...e tires Replace the tires if the tread depth reaches the following limit Minimum tread depth Front 1 5 mm 1 16 in Rear 2 0 mm 3 32 in STEERING HEAD BEARINGS NOTE Check that the control cables do not i...

Page 58: ......

Page 59: ...o 1 and No 3 carburetors use different jet needles thinner and shorter springs than the No 2 and No 4 carburetors Do not interchange these parts 85 Refer to the label on the air cleaner cover below th...

Page 60: ...ition system faulty 2 Idle speed incorrect 3 Incorrect carburetor synchronization 4 Carburetor faulty 5 Fuel contaminated Misfiring during acceleration 1 Ignition system faulty Backfiring 1 Ignition s...

Page 61: ...l tank until it is one half empty before raising the tank Remove the seat and front fuel tank mounting bolts Lift the fuel tank up and put the support arm down Remove the air cleaner cover and element...

Page 62: ...e clamp and disconnect the choke and throttle cables Loosen the carburetor bands and remove the car buretor assembly from the left side NOTE It may be necessary to loosen the engine mount bolts and mo...

Page 63: ...nd vacuum piston Inspect the vacuum piston for wear nicks scratches or other damage Make sure the piston moves up and down freely in the chamber Note that the No 1 and No 3 carburetors use thinner jet...

Page 64: ...allation is essentially the reverse of removal Install the chamber cover so that its cavity aligns with the hole in the diaphragm Be sure the thinner jet needles and shorter springs are installed in t...

Page 65: ...After 85 8 0 mm 0 31 in Measure the float level nearest the float valve 83 84 85 Adjust the float level by carefully bending the float tang After 85 Replace the float assembly if it is out of specific...

Page 66: ...ilot screw plugs are factory installed to prevent pilot screw misadjustment Do not remove the plugs unless the pilot screws are being removed Cover all opening with tape to keep metal particles out wh...

Page 67: ...pilot screws CAUTION Damage to the pilot screw seat wi 1 occur if the pilot screw is tightened against the seat Remove the pilot screws and inspect them Replace them if they are worn or damaged INSTA...

Page 68: ...rods Remove the cotter pins and washers and remove the choke rod Carefully separate the No 3 carburetor from the assembly Then separate the No 4 carburetor CAUTION Separate the carburetors horizontall...

Page 69: ...e cotter pins Carefully separate the No 1 and No 2 carburetors Remove the choke arm collar and remove the choke arm and spring Remove the choke valve nut spring and valve FUEL JOINT PIPE No 2 CARBURET...

Page 70: ...nut Install the choke arm and spring while hooking the arm to the groove in the choke valve Install the choke arm collar Coat the new O rings with oil and install them on the fuel joint pipe for No 1...

Page 71: ...No 4 carburetors together with the joint pipes Loosen the synchronization adjusting screws until there is no tension Install the synchronization springs Install the thrust springs between the throttl...

Page 72: ...hoke rods and levers using the nuts and new cotter pins Make sure the air chamber funnels grommets and dowel pins are in place 4 14 No 2 CARBURETOR THRUST SPRING No 4 CARBURETOR No 2 SYNCHRONIZATION S...

Page 73: ...djusting screws Inspect throttle operation as described below Open the throttle slightly by pressing the throttle linkage Then release the throttle Make sure that it returns smoothly Make sure that th...

Page 74: ...0 rpm change 1 Turn each pilot screw clockwise until it seats lightly and back it out to the specification given This is an initial setting prior to the final pilot screw adjustment INITIAL OPENING 83...

Page 75: ...d gasoline at once Check the vent hole of the filler cap for blockage Check that fuel is flowing out of the fuel valve freely If fuel flow is restricted clean the fuel strainer Make sure that there ar...

Page 76: ...restricted FUEL PUMP Remove the seat and side covers Disconnect the fuel pump coupler Remove the fuel pump mounting bolts Disconnect the fuel lines from the pump and remove the pump NOTE Before disco...

Page 77: ...tion Attach a Vehicle Emission Control Information Update label onto the frame as shown Refer to Service Bulletin SL132 for information on obtain ing the label NOTE Do not attach the label to any part...

Page 78: ...rol valve do not use high air pressure sources Use a hand operated air pump only Plug the hose that goes to the No 2 4 carburetors Remove the vacuum pump and connect it to the hose that goes to the No...

Page 79: ...r to the routing label on rear fender behind the seat for hose connections Connect a vacuum pump to the hose that goes to the No 3 cylinder intake port Apply the specified vacuum to the A VCV SPECIFIE...

Page 80: ...hose that goes to the carburetor air joint pipe Plug the hose that goes to the carburetor air joint pipe While applying vacuum to the AVCV hose that goes to the No 3 cylinder intake port apply air pr...

Page 81: ...5 45 N m 3 5 4 5 kg m 25 33 ft lb 2 0 3 0 kg m 14 22 ft lb 5 0 8 14 N m 0 8 1 4 kg m 6 10 ft lb 85 105 N m 8 5 1 0 5 kg m 61 76 ft lb 45 70 N m 4 5 7 0 kg m 33 51 ft lb 18 28 N m 1 8 2 8 kg m 18 28 N...

Page 82: ...ds SPECI FICATIONS Engine dry weight Oil capacity TORQUE VALU ES Engine hanger bolt 8 mm bolt 10 mm bolt Sub frame bolts Upper Lower Rear axle nut Rear axle pinch bolt Final gear case nut A lternator...

Page 83: ...aust chamber mount bolt Remove the exhaust muffler mount bolts and joint nuts Loosen the exhaust pipe clamp bolts and remove the exhaust mufflers Disconnect the wire couplers for the alternator oil pr...

Page 84: ...cover front bracket Remove the clutch slave cylinder NOTE Do not operate the clutch lever after removing the clutch slave cylinder To do so will cause difficulty in reinstalling the slave cylinder ENG...

Page 85: ...oor jack or other adjustable support under the engine NOTE The jack height must be continuously adjust ed so that mounting bolts can be removed and so stress is relieved from other bolts until they ar...

Page 86: ...ce CAUTION Carefully align mounting points with the jack to prevent damage to mounting bolt threads and wire harness and cables Tighten all fasteners to the torque values given on page 5 1 NOTE Route...

Page 87: ...tighten all bolts and nuts then torque them in the order given below 1 Tighten the exhaust pipe joint nuts TORQUE 8 14 N m 0 8 1 4 kg m 6 10 ft lb 2 Tighten the exhaust chamber mounting bolt TORQUE 8...

Page 88: ...COOLING SYSTEM 83 84 85 6 0...

Page 89: ...nspections SPECIFICATIONS Radiator cap relief pressure 0 75 1 05 kg cm2 10 7 14 9 psi 55 Distilled water 45 ethylene glycol 32 C 25 F Freezing point 50 Distilled water 50 ethylene glycol 37 C 34 F 45...

Page 90: ...essure is too high or too low It must hold specified pressure for at least six seconds NOTE Before installing the cap on the tester apply water to sealing surfaces RADIATOR CAP RELIEF PRESSURE 0 75 1...

Page 91: ...s at the water pump cover and cylinder heads Replace the drain plug and bolts Fill the system with a 50 50 mixture of distilled water and ethylene glycol Bleed air from the radiator Start the engine a...

Page 92: ...r attaching screw and the cover Disconnect the wire from the temperawre sensor Remove the bolt that attaches the thermostat housing to the air chamber Loosen the hose bands Remove the thermostat housi...

Page 93: ...tat if valve stayes open at room temperature or if it responds at temperatures other than those specified Technical Data Start to open 80 to84 C 176 183 F 8 mm minimum 0 31 in Valve lift when heated t...

Page 94: ...t and raise the fuel tank after mak ing sure that the tank is less than half full Remove the drain plug and drain the coolant page 6 3 83 84 85 Loosen the radiator side cover attaching bolts and nuts...

Page 95: ...n the upper radiator hose band Remove the radiator mounting bolts Remove the radiator while pulling the upper and lower hoses off DISASSEMBLY Remove the four nuts attaching the fan shroud to the radia...

Page 96: ...an motor to the fan shroud After 85 Remove the nuts attaching the fan motor to the fan shround RADIATOR INSPECTION Inspect the radiator soldered joints and seams for leaks Blow dirt out from between c...

Page 97: ...l the upper and lower hoses onto the radiator Install the radiator onto the frame and tighten the mounting bolts Connect the upper and lower hoses and tighten the hose bands Connect the wires to the t...

Page 98: ...anical seal is leaking REMOVAL Remove the drain plug from the lower left frame and drain the coolant Remove the drain bolt at the water pump and drain the coolant from the cylinders Remove the gearshi...

Page 99: ...earing deterioration Replace the water pump as an assembly if necessary INSTALLATION Apply a coat of clean engine oil to a new O ring and install it in the water pump groove Align the water pump shaft...

Page 100: ...ter pump cover Install the water pump cover and torque the bolts Install the left foot peg bracket Align the punch marks on the gearshift arm and the spindle and install the gearshift arm Install the...

Page 101: ...CLUTCH 7 0 0 4 0 7 kg 4 7N m m 3 5 ft lb a 25 35N m I 2 5 3 5 k g m 18 25 ft lb...

Page 102: ...UTCH SLAVE CYLINDER 63 67 N m 6 3 6 7 kg m 7 2 7 3 7 4 7 6 7 8 AFTER 85 rb fJ J 80 100 N m 8 0 10 0 kg m 0 0 7 CLUTCH CLUTCH COVER REMOVAL 7 11 STARTER CLUTCH DISASSEMBLY 7 11 CLUTCH DISASSEMBLY 7 13...

Page 103: ...er holder bolt TOOLS Special Snap ring pliers Lock nut wrench Common Universal holder Driver Attachment 42 x 47 mm Pilot 36 mm 7 2 STANDARD 16 870 15 913 mm 0 6248 0 6266 in 16 827 16 854 mm 0 6231 0...

Page 104: ...ticking Clutch lever too hard 5 Plates warped 1 Sticking piston s 2 Clogged hydraulic system Excessive lever pressure 1 Hydraulic system sticking Clutch slips 2 Lifter mechanism damaged 1 Hydraulic sy...

Page 105: ...en the slave cylinder bleed vlave and pump the clutch lever Stop operating the lever when no fluid flows out of the bleed valve CLUTCH FLUID FILLING NOTE Do not mix different types of fluid since they...

Page 106: ...clutch system will be impaired 1 Squeeze the clutch lever open the bleed valve 1 2 turn then close the valve NOTE Do not release the clutch lever until the bleed valve has been closed again 2 Release...

Page 107: ...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 prevent contamination and...

Page 108: ...ks SERVICE LIMIT 15 93 mm 0 627 in MASTER PISTON 0 0 INSPECTION Measure the master piston O D SERVICE LIMIT 15 80 mm 0 622 in Check the primary and secondary cups for damage before assembly 83 84 CLUT...

Page 109: ...Tighten the top bolt first then the bottom bolt TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft lb Install thll oil hose with the bolt and its two sealing washers Install the push rod end piece into the clutch...

Page 110: ...e cylinder If the piston removal is hard place a shop towel over the piston to cushion t he piston when it is expelled and position the cylinder with the piston down Apply compressed air to the fluid...

Page 111: ...mm 1 503 in ASSEMBLY Assemble the slave cylinder in the reverse order of disassembly The oil seals must be replaced with new ones whenever they have been removed Lubricate the piston and piston seal...

Page 112: ...r cover Fill the clutch fluid reservoir with DOT 4 brake fluid and bleed the clutch system page 7 4 CLUTCH COVER REMOVAL Drain the engine oil Remove the brake pedal and right footpeg Remove the clutch...

Page 113: ...r clutch bolt Remove the starter clutch assembly and spacer Shift the primary driven subgear with a screw driver to take preload off the primary drive gear and remove the primary drive gear 7 12 UNIVE...

Page 114: ...SPECTION Inspect the driven gear for damage or excessive wear Measure the driven gear O D SERVICE LIMIT 54 16 mm 2 132 in CLUTCH DISASSEMBLY NOTE Do not operate the clutch lever after removing the clu...

Page 115: ...gear and use the MAIN SHAFT HOLDER P N 07923 6890100 to hold the final shaft Remove the lock nut and lock washer Remove the clutch spring set plate clutch spring and washer Remove the clutch pressure...

Page 116: ...cks cuts or indentations made by the friction discs Check the clutch outer needle bearing for damage or excessive play If the needle bearing is difficult to remove from the clutch housing use the foll...

Page 117: ...of the clutch spring as shown SERVICE LIMIT 3 6 mm 0 14 in Replace the spring if its height is less than the service limit CLUTCH DISC Replace the clutch discs if they show sings of scor ing or discol...

Page 118: ...plate using a feeler gauge SERVICE LIMIT 0 30 mm 0 012 in ON E WAY CLUTCH INSPECTION Inspect the one way clutch for smooth operation Check the rollers for excessive wear Measure the 1 0 of clutch cen...

Page 119: ...Install the clutch outer guide over the mainshaft Install the needle bearing into the clutch outer Align the holes in the clutch outer with the pins on the oil pump drive sprocket and install the clu...

Page 120: ...clutch by turning it clockwise Install the one way clutch clutch center 8 assembly over the mainshaft NOTE Make sure the one way clutch assembly is installed correctly by turning the clutch center B T...

Page 121: ...tes or a plate with fall bet ween clutch centers A and B This will prevent the clutch from disengaging Install the clutch pressure plate Install the clutch spring set plate clutch spring and washers N...

Page 122: ...frame shift the transmission into gear and hold the output shaft with the HOLDER 07923 6890101 TORQUE 63 67 N m 6 3 6 7 kg m 46 48 ft lb Install the clutch lifter rod Install the clutch filter plate...

Page 123: ...ft Install the starter idler gear and shaft Install the springs plungers and rollers into the starter clutch Install the dowel pin Install the starter clutch cover aligning the dowel pin hole with the...

Page 124: ...marks on the starter clutch and crankshaft and install the starter clutch Hold the flywheel with a universal holder and tighten the starter clutch bolt to the specified torque TORQUE 80 100 N m 8 0 1...

Page 125: ...H COVER INSTALLAliON Install the dowel pins and a new gasket Install the clutch cover Install the right footpeg and rear brake pedal Fill the crankcase with oil page 2 3 7 24 DOWEN PINS BRAKE PEDAL RI...

Page 126: ...GEARSHIFT LINKAGE AFTER 85 8 0...

Page 127: ...e engine in the frame 8 1 8 1 8 2 8 4 If the shift forks drum and transmission require servicing remove the engine and separate the crankcase TROUBLESHOOTING Hard to shift 1 Air bubbles in the clutch...

Page 128: ...e the left footpeg and gearshift pedal Remove the clutch cover and clutch assembly section 7 Remove the oil pump driven sprocket bolt Remove the oil pump drive chain drive and driven sprockets Remove...

Page 129: ...the drum stopper arm nut arm and spring Pull the gearshift spindle assembly out of the crank case Remove the neutral stopper arm bolt arm and spring GEARSHIFT LI NKAGE DRUM STOPPER ARM GEARSHIFT SPIND...

Page 130: ...e of the shift drum Insert 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 securely Install the was...

Page 131: ...eck the linkage for smooth operation Install the oil pump drive sprocket washer on the shaft Install the oil pump drive and driven sprockets with drive chain and tighten the driven sprocket bolt secur...

Page 132: ...KAGE Align the punch marks on the gearshift pedal and gearshift spindle and install the gearshift pedal assembly and left footpeg Install the left crankcase rear cover and fill the crankcase with oil...

Page 133: ...ALTERNATOR 80 100 N m 58 _72 ft lb 8 0 10 0 kg m 9 0...

Page 134: ...ENERAL This section covers removal and installation of the alternator Refer to section 18 for inspecting and troubleshooting TORQUE VALUE Alternator rotor Flywheel bolt TOOLS Common Universal holder R...

Page 135: ...engine oil Remove the alternator cover Hold the flywheel with a universal holder and re move the flywheel bolt Remove the flywheel with the rotor puller Remove the woodruff key from the crankshaft 9 2...

Page 136: ...and wire clamp STATOR INSTALLATION Install the stator and wire clamp Install the left crankcase rear cover Route the alternator leads according to the diagram in Section 1 and connect the alternator w...

Page 137: ...igning its keyway with the key in the crankshaft Hold the flywheel with a universal holder and torque the flywheel bolt TORQUE 80 100 N m 8 0 10 0 kg m 58 72 ft lb Install the alternator cover Check e...

Page 138: ...CYLINDER HEAD VALVE 8 12 N m 0 8 1 2 kg m 6 I 9 tt lb E4 E4 10 0 18 20 N m 1 8 2 0 k g m 13 14 ft lb cf 48 52 N m 4 8 52 k g m 35 38 f t lb...

Page 139: ...Compression pressure 13 2 kg cm2 184 28 psi Camshaft Cam height IN 35 335 35 495 mm 1 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 10 mm 0 004 in End cl...

Page 140: ...lb 1 35 in 3 0 kg 37 7 mm 6 6 lb 1 48 in 0 05 mm 0 002 in 45 50 N m 4 5 5 0 kg m 33 36 ft lb Apply LOCKTITE 271 to the threads 18 20 N m 1 8 2 0 kg m 13 14 ft lb 07984 2000000 07942 3290100 07943 MB4...

Page 141: ...the rear cylinder head Remove the oil pipe and cam chain guide mounting bolts and remove the cam chain guide Remove the alternator cover and rotate the crank shaft clockwise until the cam chain has f...

Page 142: ...ke and exhaust cam sprocket bolts Turn the crankshaft clockwise one turn 360 and remove the other cam sprocket bolts Slide the cam sprockets with the cam chain off the camshaft sprocket flanges Remove...

Page 143: ...LDER INSPECTION 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...

Page 144: ...the journals Lay a strip of plastigauge 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 plastiga...

Page 145: ...camshaft and recheck the oil clearance Replace the cylinder head and camshaft holders if the clearance still exceeds service limits CYLINDER HEAD REMOVAL Loosen the water hose clamp Remove the water...

Page 146: ...sher and pin and remove the tensioner slipper base Remove the cylinder head bolts Remove the cylinder heads using a screw driver at the pry points PRY POINT Remove the front and rear cylinder head gas...

Page 147: ...nsioner for damage or excessive wear Inspect the cam chain tensioner slipper for damage or excessive wear Inspect the spring for good tension and replace if necessary CYLINDER HEAD DISASSEMBLY Remove...

Page 148: ...ad NOTE Mark all disassembled parts to ensure correct reassembly Remove the valve stem seals Remove carbon deposits from the combustion chamber and clean off the head gasket surfaces NOTE Avoid damagi...

Page 149: ...R ING INSPECTION Measure each rocker arm shaft O D SERVICE LIMIT 11 93 mm 0 470 in Inspect the shaft for wear or damage and calculate the shaft to rocker arm clearance SERVICE LIMIT 0 12 mm 0 005 in I...

Page 150: ...ERVICE LIMIT 5 55 mm 0 219 in Subtract each valve stem 0 0 from the corres ponding guide 1 0 to obtain the stem to guide clearance SERVICE LIMITS IN 0 08 mm 0 003 in EX 0 10 mm 0 004 in NOTE If the st...

Page 151: ...w guides in from the rocker arm side of the cylinder head NOTE Cylinder head heat should still be at 100 C 212 F for installation of the new guides Let the cylinder head cool to room temperature and r...

Page 152: ...e and inspect the face CAUTION The valves cannot be ground If the valve face is rough worn unevenly or contacts the seat improperly the valve must be replaced lnseect the valve seat If the seat is too...

Page 153: ...nd coils should face toward the head Install the valve cotters CAUTION To prevent loss of tension do not com press the valve spring more than necessary to install the valve keepers Position the large...

Page 154: ...e rocker arm shaft and install the rocker arm Install and tighten the rocker arm shaft bolt TORQUE 45 50 N m 4 5 5 0 kg m 33 36 ft lb CYLINDER HEAD INSTALLATION Clean the cylinder head surface of any...

Page 155: ...ection of the arrow insert a pin or piece of wire through the hole in the tensioner base and tensioner Pass the cam chain through the cam chain tensioner and install the tensioner slipper as shown NOT...

Page 156: ...NDER HEAD VALVE Install the exterior oil pipe with washers onto the cylinder and cylinder head Install the water pipes and hose and tighten the hose bands securely 10 18 OIL PIPE WATER HOSE PIPES OIL...

Page 157: ...ntake EX FR EF Front cylinder exhaust IN FR IF Front cylinder intake The camshaft sprockets are interchange able Rear Cylinder Head Lubricate the cylinder head cam bearing surfaces with molybdenum dis...

Page 158: ...degrees one turn If a valve clearance adjuster keeps the camshaft from seating fully in the cylinder head back the adjuster out all the way CAUTION If you force a valve open while installing the camsh...

Page 159: ...e lock holes Check that the camshaft marks are still facing up then align the sprocket index lines with the top of the rear cylinder head Place the cam chain on the sprockets Slide the sprockets onto...

Page 160: ...cam chain tensioner or at the crankshaft Install the Intake and exhaust camshafts and spro ckets through the front cylinder cam chain as shown Turn the camshafts so the camshaft marks face up Rotate...

Page 161: ...er Front Rear Cylinders Check the front to rear cylinder camshaft timing as follows NOTE When the Tl 3 mark aligns with the rear crankcase mating surface the index lines on all cam sprockets should al...

Page 162: ...b Tighten the cam shaft holder 6 mm bolts TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft lb Lubricate the cam lobes with oil Adjust the valve clearance page 3 9 Inspect the cylinder head cover gasket for damag...

Page 163: ...CRANKCASE ___ _ 8mm 21 25 N m 15 18 ft lb 2 1 2 5 kg m 6mm 10 14 N m 7 10 ft lb 1 0 1 4 kg m 10mm 43 47 N m 31 34 ft lb 4 3 4 7 kg m 11 0...

Page 164: ...must be removed before disassembling the crankcase Oil pan Refer to section 2 Otl pump Refer to section 2 Water pump Clutch starter clutch Gear shift linkage Alternator Cylinder heads Starter motor TO...

Page 165: ...the screw and bolts Remove the output gear case mounting bolts and output gear case Measure the thickness of the output gear case gasket and note it NOTE Whenever removing the output gear case perfor...

Page 166: ...parate the crankcase Remove the following parts Piston and connecting rods Section 12 Crankshaft Section 12 Shift fork and shift drum Section 13 Transmission Section 13 Drive the countershaft Jearing...

Page 167: ...arts Shift fork and shift drum Section 13 Transmission Section 13 Crankshaft Section 12 Piston and connecting rods Section 12 Apply molybdenum disulfide grease to the shift fork grooves of the M2 C5 a...

Page 168: ...AS Install the dowel pin 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 VALVES 10 mm bolt 43 4...

Page 169: ...the screw and bolts Install a new output gear case gasket with one of the same thickness as removed NOTE Early production engines had gaskets that were not marked The gasket is crushed 0 05 mm when th...

Page 170: ...CRANKSHAFT PISTON 30 34 N m 3 0 3 4 kg m 22 25 ft lb FRONT 12 0...

Page 171: ...045 mm 0 0006 0 0018 in clearance Second 0 015 0 045 mm 0 0006 0 0018 in Ring end gap Top 0 20 0 35 mm 0 008 o 014 in Second 0 20 0 35 mm 0 008 o 014 in Oil Side rail 0 20 0 70 mm 0 008 0 028 in Pist...

Page 172: ...mpression or uneven compression 1 Worn cylinder or piston ring Excessive smoke 1 Worn cylinder piston or piston rings 2 Improperly installed piston rings 3 Damaged piston or cylinder Overheating 1 Exc...

Page 173: ...their locations Push the connecting rods and pistons out through the top of the cylinder bores CAUTION On engines with high mileage inspect the cylinders for a ridge just above the highest point of ri...

Page 174: ...ston pins to indicate their correct piston posit ion 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 mar...

Page 175: ...s 10 mm 0 4 in from the bottom and 90 to the piston pin hole SERVICE LIMIT 79 35 mm 3 124 in Inspect the cylinder bores for wear or damage Measure the cylinder 1 0 at three levels in X andY axis SERVI...

Page 176: ...90 in Measure each piston pin 0 0 SERVICE LIMIT 19 98 mm 0 787 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 ex...

Page 177: ...1 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 lbs of tension to the other...

Page 178: ...The bearing tabs should face toward the exhaust ports Remember the front and rear cylinder exhaust ports face opposite direc tions Install the bearing caps and rods on the correct crankpins and tight...

Page 179: ...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 lb 8 mm bolt 21 25 N m 2 1 2 5 kg m 15 18 ft lb 10 mm bolt 43 47 N m...

Page 180: ...code number or measure the crankpin O D NOTE The letters A or B on each crank weight is the code for each crankpin O D Cross reference the crankpin and rod codes to deter mine the replacement bearing...

Page 181: ...or 2 on each crank weight is the code for the adjacent main journal O D Cross reference the case and journal codes to deter mine the replacement bearing MAIN JOURNAL 0 0 CODE NO 1 2 39 992 39 984 40...

Page 182: ...he cam chain PISTON AND ROD INSTALLATION Clean the piston domes ring lands and skirts Carefully install the piston rings onto the piston Stagger the ring end gaps as shown NOTE Be careful not to damag...

Page 183: ...cylinder connecting rod and piston assembly Note that the rear cylinder connecting rods are marked MB4 R Install the pistons on the rear rods so that the intake IN mark is facing the same direction a...

Page 184: ...s returned to its 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 ring compressor and insert the piston...

Page 185: ...5 ft lb NOTE Be sure the bearing caps are installed in their correct location as marked during removal Tighten the nuts in two or more steps After tightening the bolts check that the rods move freely...

Page 186: ...TRANSMISSION 13 0...

Page 187: ...rench scale reading is given with the actual torque specification SPECIFICATIONS STANDARD SERVICE LIMIT Transmission Backlash low 0 089 0 179 mm 0 0035 0 0070 in 0 24 mm 0 009 in 2nd 3rd 4th 5th 6th 0...

Page 188: ...der sticking 2 Shift fork bent 3 Shift shaft bent 4 Shift claw bent 5 Shift drum cam grooves damaged 13 2 30 34 N m 3 0 3 4 kg m 22 25 ft lb 21 25 N m 2 1 2 5 kg m 15 18ft lb 90 110 N m 9 0 11 0 kg m...

Page 189: ...d 3rd 4th 5th 6th 0 18 mm 0 007 in Remove the mainshaft and countershaft Remove the output gear case Index the countershaft bearing holder to the output gear case for ease of reassembly NOTE When remo...

Page 190: ...f the gear bushings SERVICE LIMITS MS M6 C2 C3 C4 gear bushing 0 0 30 93 mm 1 218 in MS C4 gear bushing I D 28 05 mm 1 104 in Measure the O D of the mainshaft and counter shaft SERVICE LIMITS A at MS...

Page 191: ...edging it against the vise to lock the shaft Unstake the inner bearing race lock nut with a rill or grinder Be careful that metal particles do not enter the bearing and that the threads on the shaft a...

Page 192: ...of the bearing holder COUNTERSHAFT BEARING REPLACEMENT NOTE The oountershaft must be removed before replacing bearing Place the bearing holder in a vise with soft jaws or shop towel NOTE Do not damage...

Page 193: ...ar must be replaced as a set if they or the gear case or the bearing require replacement Place the countershaft and countershaft bearing holder into a press Press the countershaft into the bearing NOT...

Page 194: ...l the drive gear bearing holder 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 into a vise with soft jaws Install and tighten a ne...

Page 195: ...shaft spindle boss Unstake and loosen the output driven gear bearing inner race lock nut using a special lock nut wrench and shaft holder Remove the driven gear bearing holder mounting bolts and remo...

Page 196: ...ith soft jaws Unstake and remove the output driven gear bearing outer race lock nut from the holder Press the output driven gear from the holder Place the bearing holder in a press and press the beari...

Page 197: ...72 ft lb OUTPUT DRIVEN GEAR INSTALLATION NOTE When the gear set driven gear bearing and or gear case have been replaced use a shim 0 30 mm 0 012 in thick for initial re ference Place the output driven...

Page 198: ...teps TORQUE 30 34 N m 3 0 3 4 kg m 22 25 ft lb Install 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 scale reading 64...

Page 199: ...ea _ r_g _l ov _e_s_w_h_e_n_h _a _ n_ d_ lin _g _ a_h _e at _e_ d case Remove the bearing with the bearing remover Drive a new bearing into the output gear case TRANSMISSION BEARING REMOVER 17 mm HAN...

Page 200: ...ection of rotation Check the gear tooth contact pattern after removing the drive gear Contact is normal if Prussian Blue in transfered to the approximate center of each tooth and slightly to the side...

Page 201: ...th soft jaws or a shop towel Set 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...

Page 202: ...eplace the countershah gear adjustment shim with a thinner one If the backlash is too small replace the counter shaft shim with a thicker one Backlash is changed by about 0 06 0 07 mm 0 002 0 003 in w...

Page 203: ...Install the output gear case assembly and new gasket onto the lower case Assemble the transmission with the original spacer Measure the clearance between the bearing and spacer with a feeler gauge CL...

Page 204: ...Remove the shift fork shaft and shift forks Remove the bearing stopper plates Remove the shift drum GEAR SHIFT DRUM AND SHIFT FORK INSPECTION Inspect the shift drum end for scoring scratches or evide...

Page 205: ...t fork surfaces Check for scratches scoring or evidence of insuf ficient lubrication SERVICE LIMIT 13 90 mm 0 547 in Measure the right and left shift fork I D Measure the shift fork claw thickness SER...

Page 206: ...ing stopper plates Install the shift forks and shaft CAUTION Install the shift fork shaft so that the plugged end is toward the left side Install the lock washer and tighten the center fork bolt TORQU...

Page 207: ...t bearing with the special tools as shown Check the gears for freedom of movement or rota tion on the shaft Check that the snap rings are seated in the grooves MAINSHAFT M5 I M4 TRANSMISSION DRIVER 07...

Page 208: ...efore placmg d C6 gears washers install the C4 an nd splined colla g the tab of Install the C3 gear washer while allg mthe splined ns washer WI I tall the stoppe th groove In the stopper l iar shers a...

Page 209: ...Install the lower crankcase Refer to Section 11 NOTE Check the oil orifice for clogging before installing the lower crankcase TRANSMISSION OIL ORIFICE 13 23...

Page 210: ...RAIN 8 mm 23 282 N8 kmg m 17 20 ft lb 2 3 10 mm 35 454 N5 kmg m 25 33 ft lb 3 5 rJ 100 120 N m rf 10 12 kg m 72 87 ft lb li __ 100 120N m J 10 12kg m 72 87 ft lb 0 y 45 70N m I 4 5 7 0 kg m 33 51 ft l...

Page 211: ...ad Damper case oil capacity Damper cam spring free length TORQUE VALUES Pinion bearing retainer Pinion nut Gear case cover bolt 10 mm 8mm Final gear case attaching nut Rear axle nut Axle pinch bolt ST...

Page 212: ...MB00300 07910 4630100 07926 ME90000 07931 ME40000 or Pinion puller set 07935 MBOOOOO 07931 4630300 07934 MBOOOOO 07945 3330300 or Pinion puller 07931 4630200 and Pinion puller attachment kit 07931 M8...

Page 213: ...tability Place an oil drain pan under the damper case to catch the damper oil that will spill out Separate the damper unit from the gear case by gently revolving the damper in a circular motion while...

Page 214: ...fter from the drive shaft Check the damper lifter and cam for wear or damage CAUTION Discard the stop ring and install a new one upon reassembly Remove the oil seal and oil seal guide from the damper...

Page 215: ...e shaft ASSEMBLY Install 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 reverse order of disasse...

Page 216: ...er If the ring gear stays in the cover do the following Place the cover in a press with the ring gear down Make sure the cover is well supported Press the ring gear out of the cover with driver 07749...

Page 217: ...cover and press in a new oil seal PINION GEAR REMOVAL Install the pinion joint holder onto the pinion joint and remove the pinion shaft nut Remove the tool and p1nion jo1nt ATTACHMENT 32 x 35 mm 07746...

Page 218: ...retainer with the lock nut wrench it _ 3 PINION HOLDER 07926 MEOOOOO PINION PULLER ATTACHMENT KIT WITH SHAFT PULLER OR 07931 MBOOOOO WITH PINION 07931 ME40000 PULLAR 07931 4630200 Pull off the pinion...

Page 219: ...tool Remove the pinion adjustment spacer PINION RETAINER OIL SEAL REPLACEMENT Remove the 0 ring and oil seal from the pinion retainer Drive a new oil seal into the retainer Coat a new 0 ring with oil...

Page 220: ...e after it has been heated NOTE Use bearing remover 35 mm 07936 3710400 to remove ring gear case bearing Remove the ring gear shaft oil seal Drive a new oil seal into the case using the special tools...

Page 221: ...r NOTE When the gear set pinion bearing and or gear case have been replaced use a 2 0 mm thick spacer Press the bearing onto the pinion gear shaft with the special tools shown Install a new 0 ring ove...

Page 222: ...n place then tighten it to the specified torque TORQUE 100 120 N m 10 12 kg m 72 87 ft lb RING GEAR ASSEMBLY Install the original spacer onto the ring gear NOTE If the gear set pinion bearing ring gea...

Page 223: ...xceeds the service limit remove the ring gear Heat the gear case cover to approx materly 80 C 176 F and remove the stop pin by tapping the cover Always wear gloves when handling the gear case after it...

Page 224: ...a gear tooth contact pattern check Place the wave washer and ring gear into the gear case Apply gear oil to the lip of the 011 seal on the gear case cover and install the gear case cover Tighten the c...

Page 225: ...on spacer Replace the pinion spacer with a thicker one if the contacts are too high toward the face Replace the pinion spacer with a thinner one if the contacts are too low to the flank side The patte...

Page 226: ...more Compare the difference of the three measurements DIFFERENCE OF MEASUREMENT SERVICE LIMIT 0 10 mm 0 004 in If the difference in measurements exceeds the limit it indicates that the bearing is not...

Page 227: ...contact surface 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 lb Remove the pinion joint holde...

Page 228: ...F SAE 80 OIL CAPACITY 80 cc 2 7 oz After 83 RECOMMENDED OIL HYPOID GEAR OIL SEA 80 OIL CAPACITY 80 cc 2 7 oz Keeping the damper case vertical place the damper spring onto the damper cam and install th...

Page 229: ...RQUE 85 105 N m 8 5 10 5 kg m 61 76 ft lb Tighten the three final gear case attaching nuts TORQUE 45 70 N m 4 5 7 0 kg m 33 51 ft lb Tighten the axle pinch bolt TORQUE 20 30 N m 2 0 3 0 kg m 14 22 ft...

Page 230: ...FRONT WHEEL SUSPENSION 30 45 N m 3 0 4 5 k g m 22 33 ft lb 18 30 N m 1 8 3 0 k g m 13 22 ft lb 15 0 5 30 N m 2 5 3 0 k g m 18 22 9 13 N m ft lb g m 7 9 ft lb A 0 9 1 3 k...

Page 231: ...fork stabilizer bolts After 85 Front brake master cylinder holder bolt Clutch master cylinder holder bolt STANDARD 0 3 mm 0 01 in max 0 3 mm 0 01 in max 414 7 mm 16 33 in Right 565 cc 19 1 oz Left 58...

Page 232: ...2 Worn front wheel bearings 3 Faulty tire 4 Axle nut tightened improperly Soft suspension 1 Weak fork springs 2 Insufficient fluid in front forks 3 Front fork air pressure incorrect Hard suspension 1...

Page 233: ...the horn terminals Remove the bolt attaching the horn bracket The bracket and horns will come off as an assembly Remove the coupler box cover Disconnect all wire couplers and connectors in the coupler...

Page 234: ...STALLATION Remove the headlight mounting screw 83 84 85 Pull out the headlight from the headlight case After 85 Remove the headlight mounting bolt Disconnect the wire coupler and remove the head light...

Page 235: ...rse order of removal BRACKET REMOVAL INSTA LLATION Remove the coupler box cover page 15 3 Disconnect the front tum signal wire connectors Remove the headlight bracket mounting bolts and bracket turn s...

Page 236: ...ve the instrument lower cover attaching screws and lower cover Remove the indicator panel attaching screws and panel Replace any inoperative bulbs After installing a new bulb check for continuity If t...

Page 237: ...u ments Disconnect the instrument wire couplers Remove the instrument mounting nuts and instru ment DISASSEMBLY Remove the instrument lower cover CAUTION Do not leave the instruments upside down or da...

Page 238: ...bulbs If a replacement bulb does not light check the wiring for a short or open circuit or check for loose connections ASSEMBLY INSTALLATION Lubricate the speedometer cable before reconnect ing it Ass...

Page 239: ...h mounting bolts and ignition switch Install the ignition switch in the reverse order of removal DISASSEMBLY ASSEMBLY 83 84 85 Open the wire clamp Insert the ignition key and turn it to between the ON...

Page 240: ...OFF detent positions Cut the wire clamp NOTE Replace the wire clamp with new one when ever it is removed Remove the three screws Push the lugs into the slots and pull the contact base from the switch...

Page 241: ...ENSION HANDLEBARS 83 84 85 REMOVAL INSTALLATION Disconnect the clutch switch wires Remove the clutch master cylinder Disconnect the choke cable from the choke lever EBAR SWITCH Remove the left handleb...

Page 242: ...dlebar switch and disconnect the front brake switch wires Remove the brake master cylinder Remove the handlebar set screw Loosen the handlebar pinch bolt and remove the handlebar 15 12 MASTER CYLINDER...

Page 243: ...ing forward Tighten the forward bolts first then tighten the rear bolts TORQUE 40 50 N m 4 0 5 0 kg m 29 36 ft lb Install the bolt caps and handlebar cover Install the right and left handlebars into t...

Page 244: ...the end of the holder with the handlebar punch mark Tighten the upper bolt first then the lower bolt TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft lb Connect the brake light switch wires Install the right an...

Page 245: ...Tighten the upper bolt first then tighten the lower bolt TORQUE 10 14 N m 1 0 1 4 kg m 7 10ft lb Connect the clutch screw wires AFTER 85 REMOVAL INSTALLATION Disconnect the clutch switch wires Remove...

Page 246: ...le from the choke lever Remove the two screws and open the right handle bar switch Disconnect the throttle cable wires Disconnect the brake switch wires Remove the brake master cylinder Remove the bol...

Page 247: ...r holder aligning the punch mark with the upper 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 r...

Page 248: ...screw FRONT WHEEL REMOVAL Remove the speedometer cable set screw and the speedometer cable Remove the right and left side caliper assemblies by removing the bolts NOTE Do not operate the front brake l...

Page 249: ...FRONT WHEEL SUSPENSION DISASSEMBLY Remove the brake disc mounting bolts and discs SIDE COLLAR Remove the side collar and right seal SEAL Remove the left seal and speedometer gear retainer 15 19...

Page 250: ...E INSPECTION Set the axle in V blocks and measure the runout SERVICE LIMIT 0 2 mm 0 01 in WHEEL BEAR ING INSPECTION Turn the inner race of each bearing with your finger The bearings should turn smooth...

Page 251: ...removed they should be replaced with new ones ASSEMBLY 83 84 85 AFTER 85 I NOTE The cast wheel does not use a rim band The front wheel uses a tubeless tire For tubeless tire repair refer to the HONDA...

Page 252: ...ive in the left bearing squarely NOTE Make sure that the bearings are fully seated and that the sealed sides are facing out Install the speedometer gear retainer in the wheel hub aligning the tangs wi...

Page 253: ...ing the tangs with the slots Clean the brake discs with a high quality degreasing agent INSTALLATION Fit the calipers over the discs taking care not to damage the brake pads Install the caliper mounti...

Page 254: ...can be inserted Tighten the axle pinch bolt to the specified torque TORQUE 18 30 N m 1 8 3 0 kg m 13 22 ft lb There should still be at least 0 7 mm 0 028 in clearance between the caliper holder and d...

Page 255: ...KS REMOVAL Remove the following parts front wheel brake calipers front fender Remove the fork brace Release fork air pressure Loosen the fork upper and lower pinch bolts FRONT WHEEL SUSPENSION FORK BR...

Page 256: ...Remove the fork stop rings Pull each fork tube out of the bottom bridge If service of the air joints is necessary remove the following parts coupler box page 15 3 headlight and case pages 15 4 and 15...

Page 257: ...ise with soft jaws or a shop towel and remove the fork tube cap CAUTI ON I Do not damage the sliding surface Remove the fork spring spacer and washer Force out the fork fluid by pumping the fork up an...

Page 258: ...d spring can now be removed from the right fork 83 84 85 Remove the dust seal sponge seal and plastic washer Discard the sponge seal and plastic washer After 85 Remove the dust seal NOTE Do not reinst...

Page 259: ...ve the oil seal back up ring and slider busing from the fork tube NOTE Do not remove the fork tube bushing unless it is necessary to replace it with a new one From the left fork remove the circlip oil...

Page 260: ...ider and piston for score 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 fati...

Page 261: ...4 of the entire surface Check the back up ring replace it if there is any distortion at the points shown ANTI DIVE CASE Remove the four socket bolts and remove the anti dive case Remove the piston an...

Page 262: ...semble the anti dive case in the reverse order of disassembly NOTE Apply a Thread Lock Agent to the threads of the screws and socket bolts before assembly Apply ATF to the piston and piston 0 ring App...

Page 263: ...lammable solvent and wipe them off completely I 83 85 83 85 PLASTIC FORK WASHER z SEAL CONNECTOR TUBE SNAP 83 85 l CAP RING SPONGE S AIR JOINT Ofi J AIR VALVE FORK OIL SEAL 83 85 SEAL 1 S _ SPACER FOR...

Page 264: ...rily install the fork spring and fork tube cap to tighten the socket bolt TORQUE 15 25 N m 1 5 2 5 kg m 11 18 ft lb Place the slider bushing over the fork tube and rest it on the slider Put the back u...

Page 265: ...ot needed Pour the specified amount of ATF into the fork tube CAPACITY Right fork 565 cc 19 1 oz Left fork 580 cc 19 6 oz Install the fork spring spring seat and spacer in the fork tube NOTE Note the...

Page 266: ...r joint pipe connectors with new seals and O rings over both ends of the air joint pipe and loosely tighten the connectors Install the front forks and temporarily tighten the lower fork pinch bolts In...

Page 267: ...nd headlight With the front brake applied pump the front forks up and down several times Tighten the front fork stabilizer mounting bolts TORQUE 18 28 N m 1 8 2 8 kg m 13 20 ft lb Install the bolt cap...

Page 268: ...page 15 6 ignition switch page 15 9 handlebars page 15 11 front wheel page 15 18 brake three way joint Remove the angle sensor Loosen the steering stem pinch bolt Remove the steering stem nut fork br...

Page 269: ...ring stem Check the steering stem bearings for damage or wear BEARING REPLACEMENT NOTE Replace the bearing and bearing race as a set 83 Remove the bearing from the steering stem After 83 Remove the be...

Page 270: ...he area around the steering head for cracks Drive the upper bearing outer race into the head pipe with the special tools Drive the lower bearing outer race into the heacf pipe with the special tool 15...

Page 271: ...ing inner race After 83 Install the lower bearing and grease retainer onto the steering stem then insert the steering stem into the steering head Install the upper bearing and inner race Install and t...

Page 272: ...ock 5 times to seat the bearings then tighten the adjustment nut to the same torque After 83 Tighten the adjustment nut to the specified torque TORQUE 19 21 N m 1 9 2 1 kg m 14 15 ft lb Install a new...

Page 273: ...tabs up into the lock nut grooves Install the front forks page 15 36 Install the fork top bridge and tighten the stem nut TORQUE 83 84 85 80 120 N m 8 0 12 0 kg m 58 87 ft lb After 85 90 120 N m 9 0...

Page 274: ...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 within 1 0 1 6 kg 2 21 3 53 lb for right and lef...

Page 275: ...2 94 ft lb 16 20 N m 1 6 2 0 kg m 12 14 ft lb 16 0 90 120 N m 9 0 12 0 kg m 65 87 ft lb 45 70 N m 4 5 7 0 kg m 33 51 ft lb 30 40 N m 3 0 4 0 kg m 22 29 ft lb 83 84 85 85 105 N m 8 5 10 5 kg m 61 76 ft...

Page 276: ...bolt Swing arm pivot lock nut Rear brake torque rod Final gear case attaching nut TOOLS Upper Lower After 85 Special Shock absorber compressor attachment Swingarm pivot lock nut wrench Socket bit 17...

Page 277: ...n tires Bent shock absorber 2 Tire pressure incorrect 3 Faulty tire Suspension noise 4 Bent rim 1 Shock case binding 5 Loose axle 2 Loose fasteners 6 Swingarm bearings worn 7 Loose wheel bearings Soft...

Page 278: ...motorcycle on its center stand and remove the axle nut Loosen the axle pinch bolt and remove the rear axle Move the wheel to the right to separate it from the final drive gear case Remove the rear whe...

Page 279: ...e runout with a dial indicator The actual axle runout is 1 2 of total indicator reading SERVICE LIMIT 0 2 mm 0 01 in WHEEL BEARING INSPECTION Turn the inner race of each bearing with your finger The b...

Page 280: ...iven flange out of the hub Remove the oil seal from the hub Inspect the condition of the bearings page 16 4 Remove the bearings with the bearing remover shaft 07746 0050100 and head 07746 0050600 Remo...

Page 281: ...ey are fully seated 16 6 NOTE Us lithium based MULTIPURPOSE grease with MoS2 additive as follows MOLYKOTE BR2 S manufactured by Dow Corning U S A MULTIPURPOSE M 2 manufactured by Mitsubishi Oil Japan...

Page 282: ...Install a new oil seal into the hub Install the final driven flange onto the hub and tighten the bolts Install the rear disc and tighten the bolts REAR WHEEL SUSPENSION FINAL DRIVEN FLANGE 16 7...

Page 283: ...inal drive case making sure the splines are correctly aligned Insert the rear axle through the swing arm washer caliper bracket side collar hub and final drive gear Tighten the axle nut TORQUE 83 84 8...

Page 284: ...at Remove the tool box Remove the right and left shock absorber upper mount bolts Remove the two bolts attaching the rear cowl and rear grip Remove the rear cowl attaching screws and remove the rear c...

Page 285: ...e the shock absorber DISASSEMBLY Lightly compress the damper upper adjuster and remove the adjuster stopper ring Remove the upper adjuster cover Release the shock from the compressor tool Remove the d...

Page 286: ...30 mm by turning the com pressor handle Remove the upper retainer through its cutout and remove the compressor SPRING FREE LENGTH Measure the rear shock absorber spring free length SERVICE LIMIT 244...

Page 287: ...wound end facing up STOPPER RING ____ 0 WASHER SPRING ADJUSTER SPRINGS UPPER SPRING SEAT Q Set the shock absorber in the compressor with the attachment and compress the spring Install the upper retai...

Page 288: ...compress the damper upper adjuster and install the stopper ring INSTALLATION Install the shock absorber and tighten the lower mount bolt or nut TORQUE 30 40 N m 3 0 4 0 kg m 22 29 ft lb Install the re...

Page 289: ...garm pivot caps and loosen the right pivot bolt lock nut Remove the right pivot bolt using a 17 mm socket bit Remove the left pivot bolt and remove the swing arm Remove the boot from the swingarm 16 1...

Page 290: ...n be expanded completely Slide the weight again with enough force to remove the race INSTALLATION NOTE Replace the inner and outer bearing races as a set Replace the grease retainer plate when ever it...

Page 291: ...m 9 0 12 0 kg m 65 87 ft lb Tighten the right pivot bolt to 40 N m 4 0 kg m 29 ft lb loosen it and retighten to the specified torque TORQUE 16 20 N m 1 6 2 0 kg m 12 14 ft lb Move the swingarm up and...

Page 292: ...d to the swingarm and tighten the nut TORQUE 18 25 N m 1 8 2 5 kg m 13 18 ft lb Secure the nut with a new cotter pin Install the final gear page 14 18 Install the shock absorbers page 16 13 Install th...

Page 293: ...2 N m 0 7 1 4 ft lb 0 1 0 2 kg m I L _ _ t i I 11 25 35 N m f 2 5 3 5 kg m l 1B 25 ft lb t t cfJ 30 45 N m 3 0 4 5 kg m 33ftlb f go 0 30 45 N m 22 33 ft lb ijt 3 0 4 5 kg m i IIJ _ I 25 35N m 18_25ft...

Page 294: ...nt caliper cylinder I D 32 030 32 080 mm 1 2610 1 2630 in Rear master cylinder 1 0 14 000 14 043 mm 0 5512 0 5529 in Rear master piston 0 0 13 957 13 984 mm 0 5495 0 5506 in Rear caliper cylinder I D...

Page 295: ...gned 3 Hydraulic system leaking Brake chatter or squeal Brake lever pedal too hard 1 Pads contaminated 1 Sticking piston s 2 Excessive disc runout 2 Clogged hydraulic system 3 Caliper installed incorr...

Page 296: ...ver or pedal when no fluid flows out of the bleeder valve A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degr...

Page 297: ...lever or depress the brake pedal open the bleed valve 1 2 turn and then close the valve NOTE Do not release the brake lever until the bleed valve has been closed 2 Release the brake lever or pedal slo...

Page 298: ...d pin retainer bolt and caliper bolt Remove the calipers 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 as shown Push...

Page 299: ...en install the other pin by pushing the pads against the caliper to depress the pad spring Place the pad pin retainer over the pad pins Push the retainer down to secure the pins Check to be sure that...

Page 300: ...the rear brake pads using the same method as used for front brake pad replacement DISC THICKNESS Measure the disc thickness with a micrometer SERVICE LIMITS FRONT 4 0 mm 0 16 in REAR 83 84 85 6 0 mm...

Page 301: ...on painted or plastic surfaces Place a rag over the fuel tank whenever the brake system is serviced NOTE When removing the oil hose bolt cover the end of the hose to prevent contamination Secure the...

Page 302: ...and reservoir with brake fluid INSPECTION Measure the master cylinder 1 0 Check the master cylinder for scores scratches or nicks SERVICE LIMIT 15 93 mm 0 627 in Measure the master piston O D SERVICE...

Page 303: ...ng bolts Align the end of the holder with the punch mark on the handlebar and tighten the upper bolt first then tighten the lower bolt TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft lb Install the oil hose wit...

Page 304: ...f necessary apply compressed air to the caliper fluid inlet to get the piston out Place a shop rag under the caliper to cushion the piston when it is expelled Use the air in short spurts Examine the p...

Page 305: ...es PISTON INSPECT ION Check the pistons for scoring scratches or other faults Measure the piston diameter with a micro meter SERVICE LIMITS FRONT 31 940 mm 1 2575 in REAR 30 140 mm 1 1866 in CYLI NDER...

Page 306: ...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 brake disc so that the disc is positioned betw...

Page 307: ...end and rear brake pedal shaft Place a clean drain pan under the master cylinder and disconnect the brake hoses from the master cylinder CAUTION Avoid spilling brake fluid on painted or plastic surfa...

Page 308: ...ecessary to apply a small amount of air pressure to the fluid outlet to remove the master piston and primary cup Clean all parts with brake fluid REAR MASTER CYLINDER I D INSPECTION Measure the inside...

Page 309: ...Be certain the snap ring is seated firmly in the groove Install the primary cup and piston Install the push rod and snap ring ASSEMBLY Install the master cylinder and tighten the attaching bolt Conne...

Page 310: ...brake pedal shaft and install it in the frame Hook the brake return spring correctly Connect the pedal shaft to the master cylinder push rod end and install the joint pin Secure the joint pin with a n...

Page 311: ...ATTERY CHARGING SYSTEM ALTERNATOR 0 1 1 w r A GREEN BATTERY CHARGING SYSTEM 18 0 BATTERY RED WHITE 11E D 1 r a i R w FUSE 30A 1 I CD VOLTAGE r SENSOR 8 1 IC 1 ___ MAIN I SWITCH LACK REGULATOR RECTIFIE...

Page 312: ...ect the battery cables 11 111 Do not smoke and keep flames away from a charging battery The gas produced by a battery will explode ifflames or sparks are broughtnear All charging system components can...

Page 313: ...m failure 2 Loose battery connection Low power engine running 1 Battery undercharged Low fluid level One or more dead cells 2 Charging system failure 18 2 Intermittent power 1 Loose battery connection...

Page 314: ...tes is filled with sediment _ 1 1 1 lt l The battery contains sulfuric acid Avoid comacr with skin eyes or clothing Allfidote Flush wirll water and get prompt medical af ention CHARGING Remove the bat...

Page 315: ...emove the frame right side cover Disconnect the black wire at the regulator rectifier coupler Disconnect the headlight Disconnect the battery positive cable at the battery terminal and connect an amme...

Page 316: ...meter is used NORMAL DIRECTION CONTINUITY probe e probe I YELLOW GREEN II RED WHITE YELLOW REVERSE DIRECTION NO CONTINUITY probe I GREEN II YELLOW VOLTAGE REGULATOR PERFORMANCE TEST e probe YELLOW RE...

Page 317: ...IGNITION SYSTEM 2 l SPARK PLUGS 19 0 IGNITION COILS 1 3 2 4 TO TACHOMETER 1 3 SPARK UNITS SPARK UNITS BATTERY IGNITION SWITCH OFF PULSE GENERATORS a w 1 1 1...

Page 318: ...ON SYSTEM is used and no adjustments can be made SPECIFICATIONS NO NGK Spark plug Standard X24EPR U9 OPR8EA 9 For cold climate Below 5 C 41 F X22EPR U9 OPA7EA 9 For extended high speed driving X27EPR...

Page 319: ...p swtich OFF Poorly connected broken 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 coi...

Page 320: ...ing bolts life the fuel tank up and hold it in place with the tank support rod Disconnect the ignition wire leads Remove the coils by removing the attaching bolts CONTINUITY TEST Measure the primary c...

Page 321: ...he support rod Be sure that the tank is less than half full Disconnect the pulse generator coupler and measure the coil resistance RESISTANCE Approximately 480 S1 Between white yellow and yellow leads...

Page 322: ...tall the clutch cover page 7 24 Recheck the ignition timing page 3 8 SPARK UNIT If the pulse generators ignition coils and wiring are good and the ignition timing is not within specification replace t...

Page 323: ...ELECTRIC STARTER STARTER MOTOR STARTER BUTTON 8 BATTERY 20 0 STARTER RELAY SWITCH STARTER RELAY SWITCH GREEN RED DIODE SHIFT INDICATOR GREEN w C z CLUTCH r u r SWITCH a U t w C I GREEN...

Page 324: ...ulty starter switch Faulty 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 resista...

Page 325: ...ve cable at the battery before servicing the starter motor Disconnect the starter motor cable at the motor Remove the starter motor mounting bolts and the starter motor 0 RING ARMATURE REAR COVER SHIM...

Page 326: ...he location and number 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...

Page 327: ...tinuous or if it is shorted to the motor case ASSEMBLY INSTALLATION Align the case notch with the brush holder pin Install the rear cover aligning its slot with the brush holder pin Install the starte...

Page 328: ...ry to the switch cable termi nals The switch is normal if there is continuity CLUTCH DIODE REMOVAL Lift the fuel tank up and hold it in place with the support rod Be sure the tank is less than half fu...

Page 329: ...lowing color codes are used throughout this section and on the wiring diagram 83 84 B Black G Green Br Brown Lg Light Green y Yellow A Red 0 Orange p Pink L Blue w White Lb Light Blue Gr Gray After 84...

Page 330: ...e crankcase and leave two threads from the bottom Then tighten it to the specified torque TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft lb NOTE Do not overtighten the switch or the crank case may be damaged B...

Page 331: ...nal and ground in each gear position 83 84 lg R B Y W l RIW Br Y G 0 GROUND L l y 1 4 1 4 1 _o_ 4 N 2nd Jrd 4th After 84 code Y IPositi 0 r 1 o l 0 o _ _ _ _ _ _ 1 Lg R 81 Y W Bu RIW Br Y G 0 GROUND L...

Page 332: ...L l W toW to L l W toW Hl2 Hi Hi 0 o N Lo 0 LO Bu W to Bu Bu W to W to Bu Bu W toW Color code L W l TURN SIGNAL SWITCH 83 84 LEFT OFF RIGHT After 84 LEFT RIGHT Gr to 0 Br W to LB W Br W to LB W and 0...

Page 333: ...E PUSH 0 Color code 81 Y R ENGINE STOP SWITCH 83 84 RUN B to B W OFF No continuity Engine Stop Switch BAT2 OFF RUN OFF Color code B _ IG o B W HL1 0 B R HL1 81 R SWITCHES 83 84 After 84 Horn Button Ho...

Page 334: ...Tl1 TL2 0 o r o B Br W Br ON PARK R to B Br W to Br continuity Br to A continuity r nal PA BAT1 IG FAN TL1 Positioil r p 0 0 ON 0 1 0 t o 0 OFF r LOCK Color Br R B L 0 Br W code CLUTCH SWITCH TL2 0 B...

Page 335: ...ltiply it by 12 Multiplied measurement should be in the specified fuel pump standard delivery STANDARD DELIVERY 614 cc 22 oz 10 min CAUT ION Voltage at the battery terminal should be above 12 5V Low b...

Page 336: ...ire If there is continuity replace the fuel pump relay If there is no continuity replace the wire harness THERMOSTATIC SWITCH The cooling fan motor is actuated by the thermo satic switch located in lo...

Page 337: ...minutes before testing continuity A sudden change of temperature will cause error of tempera ture reading between the thermometer and the switch Do not let the thermometer or switch touch the pan a i...

Page 338: ...ge segments should move all the way to the right CAUTION Do not leave the temperature sensor wire grounded for longer than afew seconds or the temperaturegauge will be damaged TACHOMETER If the tachom...

Page 339: ...a few seconds and go out when the ignition switch is turned on If the light does not operate properly turn the ignition switch on Check the source voltage at the black brown lead If there is no voltag...

Page 340: ...RN SIGNAL SWITCH Disconnect the cancel unit coupler Turn the turn signal switch to the left position and connect a jumper wire to the B Bk and Br B leads The turn signal switch should return to the ne...

Page 341: ...sensor are normal and there is no open or short circuit replace the cancel unit with a new one TURN SIGNAL CIRCUIT SPEEDOMETER POSITION LIGHT TURN SIGNAL SWITCH CANCEL UNIT IGNITION SWITCH SUB FUSE 1M...

Page 342: ...signal switch coupler Check for continuity between the switch terminals in each position RIGHT Br Bu to 0 W and Gr to Lb LEFT Br Bu to Lb W and Gr to 0 HOLD the knob to left or right P to G PUSH the k...

Page 343: ...source voltage at the gray wire terminal while grounding the blue black wire of the turn signal relay coupler If there is no voltage replace the turn signal relay POSITION LIGHT RELAY INSPECTION Remo...

Page 344: ...ion switch ON Check the voltage between the blue black and green wire terminals of the control unit wire coupler VOLTAGE SV min Turn the turn signal switch to the left or right position The voltmeter...

Page 345: ...witch has been turned ON with the amount of fuel in the fuel tank below 3 liters 0 8 US gal NOTE The light will not go on immediately after the ignition switch is turned ON If the light does not go on...

Page 346: ...rl SVilTCH eJ L TtPNATO SPARK UN TS l 1 FU L RESERVOiR SEPt s ft 0 I LR S o Ctf SWITCH HOfl SWITC 4 PUl S GEt EAAlOR OfL PRtSSURE 1 ITCH 11 v L ll 1 A Btac v no Green Reel Whi 1 R AI 1 U ll l SK NAL 1...

Page 347: ...ITION G 1 TEMP METER LIGHT L M _ _A LIGHT TAIL IW1 12V34W I w f 11 1 B tlrt t mlr A 1 J p FA N MOTO HERL MO IL GIL th SWITCH THI AMO I Y r 1 1B w L A II L SPEEDOMETER LIGHT 1 I l er l J I l 3 HT 12V3...

Page 348: ...T STOP LIGHT SWifCH 1 __ _a wv IGNITION COILS W G 2P HI GL MIN G v WG SPARK UNITS BATTERY 12VI8AH TURN SIGNAL FUEL CUT MAIN RELAY RELAY FUELPUMP l 0 PL TURN SIGNAL CHECK UNIT STUB l TUB R REAR TURN SI...

Page 349: ...WITCH ENQII jE STOP L l t _1_ SWITCH STARTER SWITCH SPARK UNIT FUEl RESER IOIR SENSOR 0 ALTERNATOR OIMVER SWITCH SWITCH PULSE GENERATOR TUR II SIGNAL CANCEL UNIT G 8 LESE SOA OIL PRESSURE SWITCH B Bia...

Page 350: ...TURN SIGNAL SWITCH BATJ I TLI TLl PA HLI HLl c ST IG AT _ w R L PI PR OFF FIIEE lo f orr 11 Jo OH IOfO lok POSH 0 k RUN lok N p OFF L of IOro 22 2 PL OIL PRESSURE INDICATOR STOP AND TAIL INDICATOR FUE...

Page 351: ...FUEL PUMP B IUBE L TUBE L TUBE A TO IIL ruli PL TURN SIGNAL CHECK UNIT PULSE GENERATOR OIL PRESSURE SWITCH a Black Y Ye low L Boue G Green R Red w whole R REAR TURN SIGNAL 12V32CP 23W c LICENSE LIGHT...

Page 352: ...IN IITV sr rU SwiTCH N STOP W 1 4 IATI II TL1 Ill 0 HLI HL2 1G ST IG 1 8AT2 OH orr I I Q 9 IATIOI I I YILIH I lilt I PII OTUll CI I HT v G R 1 WIRING DIAGRAMA Y O SlOP AN0 TAIL UGIIT r f TOP AJiO T 0...

Page 353: ...m iP M I TURN SIGNAl CANCEL UNIT S UI 1G FAN Tl RZ orr 0 PI OT 1 A11P IIVIW I REAR STOP UGt Fl ISE I HtAOUGtiT 2 foiETER UGHT 3 CTURH Slr HAL STOP MIJAH FOSITIOII foi TER UGHT n t l SW ITCH OOHTINUIT...

Page 354: ...W G Sw1l G lOiN SWITCH HO 8AT3 FREE w f R IIIH F VEl P NP J IP BI MINI 81 a WG PilOT lAif CHECK NT AE U ATOIVAECTnR y llw WIRING DIAGRAMA UCOiC UGHT IIVIW v 3 58t STOP AICI TAll UGH1 r _ t L AEAA MN...

Page 355: ...on braking force is prevented by the slippage of the one way clutch CLUTCH CENTER Construction ONE WAY CLUTCH ONE WAY CLUTCH OUTER CLUTCH OUTER COMP The one way clutch is installed with the clutch cen...

Page 356: ...When there is a backloading on the clutch caused by the rear wheel nearing lock up the one way clutch A will slip just enough to prevent the wheel from locking without losing the benefit of maximum en...

Page 357: ...wire Function Braking the fiber scope causes the buzzer 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...

Page 358: ...ignition coil 7 Faulty ignition switch 8 Faulty pulse generator 3 Test cylinder compression LOW COMPRESSION 1 Low battery charge 2 Improper valve clearance too COMPRESSION NORMAL small l 3 Valve stuc...

Page 359: ...ORRECT 1 Improper valve adjustment 2 Worn valve seat CORRECT t 7 Test cylinder compression TOO LOW 1 Valve stuck open 2 Worn cylinder and piston rings NORMAL 3 Leaking head gasket t 4 Improper valve t...

Page 360: ...check for clogged jet NOT CLOGGED JETS t 4 Check valve timing CORRECT t 5 Check valve spring tension NOT WEAKENED INCORRECT 1 l Improper valve clearance 2 Faulty spark unit 3 Faulty pulse generator FU...

Page 361: ......

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Honda V65 Magna-VF1100C 1983, Shop Manual

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