Honda V65 MAGNA Shop Manual Download Page 178

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Summary of Contents for V65 MAGNA

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Page 2: ...s motorcycle read the TECHNICAL FEATURES in section 23 If you don t know the source of the trouble go to section 24 TROUBLESHOOTING ALI INFORMATION ILI USTRATIONS pi RECTIONS AND SPECIFICATIONS INCLUD...

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Page 4: ...or HONDA recommended parts design ifications may damage the motorcycle Use the special tools designed for this product Use only metric tools when servicing this motorcycl e fasteners The use of inc re...

Page 5: ...on the steering head right side V65MAGNA The color label is attached to the frame behind the left side cover The vehicle identification number VIN is on the steering head left side The engine serial...

Page 6: ...alve clearance Engine weight Idle speed F brake lining swept area Rear brake lining swept area Fuel capacity Fuel reserve capacity Caster angle Trail Front fork oil capacity Type Cylinder arrangement...

Page 7: ...ve gear oil capacity 170 cc 5 7 oz after diassembly 130cc 4 4 oz after draining ELECTRICAL Ignition Full transistor ignition Ignition timing F mark 10 0 BTDC at idle Full advance 37 BTDC at 3 800 rpm...

Page 8: ...0 12 14 Camshaft chain guide A 1 12 20 25 2 0 2 5 14 18 Oil filter 1 20 15 20 1 5 2 0 11 14 Out put gear case 2 8 21 25 2 1 2 5 15 18 Socket bolts Valve adjustment nuts 16 7 21 25 2 1 2 5 15 18 APPlY...

Page 9: ...Steering stem nut 1 24 90 120 9 0 12 0 65 87 Front fork top pinch bolts 2 7 9 13 0 9 1 3 7 9 Front fork bottom pinch bolts 2 10 45 55 4 5 5 5 33 40 Steering stem pinch bolt 1 8 18 30 1 8 3 0 13 22 Fro...

Page 10: ...OOO 13 6 mm hex wrench 07917 3230000 quiValenttool commercially 15 available Shaft holder 07923 6890101 13 Final piniqn holder 07924 ME90000 14 Shaft puller 07931 ME40000 inion puller set 07935 MBOOOO...

Page 11: ...16 Attachment 42 x 47 mm 07746 0010300 7 13 14 16 Attachment 52 x 55 mm 07746 0010400 13 14 16 Attachment 62 x 68 mm 07746 0010600 13 Pilot 17 mm 07746 0040400 13 Pilot 20 mm 07746 0040500 16 Pilot 30...

Page 12: ...not use wires or harnesses with a broken insulator Repair by wrapping them with a pro tective tape or replace them Protect wires and harnesses with electrical tape or tube if they are contact a sharp...

Page 13: ...GENERAL INFORMATION V65MAGNA CLAMPS SPEEDOMETER WIRE THROTTLE CABLES FRONT BRAKE HOSE 1 10 CLUTCH HOSE CHOKE CABLE 12 Date of Issu Dec 1982 HONDA MOTOR vv L ILJ...

Page 14: ...NA BATTERY BREATHER TUBE STARTER RELAY STARTER MOTOR WIRE GENERAL INFORMATION ALTERNATOR WI RE ALTERNATOR WIRE BATTERY GROUND CABLE OIL PRESSURE SWITCH c 1 ULSE GENERATOR WIRE REAR BRAKE SWITCH Date 1...

Page 15: ...FORMATION THROTTLE CABLES CLUTCH PIPE COOLING FAN MOTOR WIRE THERMOSTATIC SWITCH FUEL HOSES 1 12 MAIN HARNESS 14 CifJ HONDA V65MAGNA COOLANT RESERVE TANK OVERFLOW TUBE Date ofl ssue Dec 1982 HONDA MOT...

Page 16: ...stem which routes crankcase emissions through the air cleaner and into the combustion chamber Condensed crankcase vapors are accumulated in a storage tank which must be emptied periodically See the Ma...

Page 17: ...3IE TO REAR CYLINDER LUBRICATION FRONT CYLINDER EX CAMSHAFT FRONT CYLINDER IN CAMSHAFT OILPIPE OIL FILTER OIL STRAINER ijf V65MAGNA SHIFT FORK SHAFT I 0 16 Date of Issue Dec 1982 HONDA MOTOR...

Page 18: ...SIFICATION SE or SF VISCOSITY I I I I I I SAE 10W 40 I I I Other viscosities shown in the chart may be I used when the average temperature in your I I riding area is within the indicated range I I I I...

Page 19: ...BOND or its equivalent to the bolt threads 07506 3000000 07510 4220100 or commercially available equivalent Oil contamination 1 Oil or filter not changed often enough 2 Head gasket faulty 3 Worn pisto...

Page 20: ...ER CHANGE NOTE Change engine oil with the engine warm and the motorcycle on its center stand to assure complete and rapid draining Stop the engine Remove the oil filler cap cylinder head oil drain plu...

Page 21: ...dition 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 RELIEF VALVE OIL STRAINER RELIEF VALVE...

Page 22: ...indicator switch Check that the oil pressure warning indicator goes out after one or two seconds If the oil pressure warning indicator stays on stop the engine immediately and determine the cause Oil...

Page 23: ...ner stay Remove the oil strainer stay Make sure the a rings are in good conditions DISASSEMBLY Remove the oil pump body cover and remove the dowel pin Remove the drive pin from the rotor shaft Cii J V...

Page 24: ...ERVICE LIMIT 0 20 mm 0 008 in Measure the pump body clearance STANDARD 0 15 0 22 mm 10 006 0 009 in SERVICE LIMIT 0 35 mm 0 014 in Remove the rotor shaft and measure the pump end clear ceo 2 0 07 mm 1...

Page 25: ...ft Insert the drive pin into the rotor shaft Align the slots in the inner rotor with the drive pin 01 L PUMP BODY ROTOR SHAFT DRIVE PIN V65MAGNA OUTER ROTOR DRIVE PIN INNER ROTOR Install the dowel pin...

Page 26: ...pin and install the oil pipe NOTE Make sure the a rings are installed on the strainer stay and oil pipe Install the oil strainer and oil pan DOWEL PINS a RING the oil pump driven sprocket into the dri...

Page 27: ...ll 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 HYPOID GEAR OIL API...

Page 28: ...I I I I I DRIVESHAFT JOINT LITHIUM BASED MULTIPURPOSE GREASE FOOT PEG PIVOT SWING ARM PIVOT BRAKE PEDAL PIVOT I I I I I I I I I I I I THROTTLE GRIP SHIFT PEDAL PIVOT FOOT PEG PIVOT STEERING HEAD BEARI...

Page 29: ...MEMO 28 QHONDA V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD...

Page 30: ...15 VALVE CLEARANCE 3 8 SIDE STAND 3 16 CARBURETOR SYNCHRONIZATION 3 10 SUSPENSION 3 16 CARBURETOR IDLE SPEED 3 11 WHEELS 3 17 RADIATOR COOLANT 3 11 STEERING HEAD BEARINGS 3 18 RADIATOR CORE 3 12 NUTS...

Page 31: ...g 200 Ibs 32 225 2 25 32 225 2 25 Cold tire pressure psi kPa kg cm2 load 90 kg 200 Ibs load to vehicle capacity load 32 225 2 25 40 280 2 80 Bridgestone L303 G508 Tire brand Dunlop F11 1 627 Front for...

Page 32: ...1 I I 3 12 3 12 2 10 3 13 3 13 3 14 3 14 3 15 3 15 3 15 3 15 3 16 3 16 3 18 3 17 3 18 HEN RIDING IN DUSTY AREAS iWHEN RIDING IN RAIN OR AT FULL THROTTLE U S A ONLY EADINCiS REPEAT AT THE FREQUENCY INT...

Page 33: ...nd install the mounting bolts Be carefu I 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 fuel line...

Page 34: ...hrottle 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 major adjustments are made with the lo...

Page 35: ...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 to fully closed Ma...

Page 36: ...nes AIR CLEANER ELEMENT CRANKCASE BREATHER Remove the plug from the drain tube to empty any deposits Install the drain plug NOTE Service more frequently when riding in rain or at full throttle or if t...

Page 37: ...on the fly wheel aligns with the crankcase rear mating surfaces LEFT CRANKCASE COVER VALVE CLEARANCE NOTE F MARK REAR CRANKCASE MATING SURFACES Inspect and adjust valve clearance wh ile the engine is...

Page 38: ...ight drag feeler gauges Both feeler gauges should adjustment Measure and adjust the intake and exhaust valve clearances as described below Rotate the crankshaft clockwise to align the T1 3 mark with t...

Page 39: ...IZATION NOTE Synchronize the carburetors with the engine at normal operating temperature transmission in neutral and motorcycle on the center stand Remove the plugs from the No 1 2 3 and 4 cylin der h...

Page 40: ...all other engine adjustments are within specifications 41 The engine must be warm for accurate adjust ment Ten minutes of stop and go riding is sufficient engine shift to NEUTRAL and place t I I its c...

Page 41: ...then disconnect the spark plug caps and remove the spark plugs Insert the compression gauge Open the throttle all the way and crank the engine with the starter motor NOTE Crank the engine until the ga...

Page 42: ...e battery HOLDER BOLT MAINTENANCE UPPER LEVEL LINE The battery electrolyte contains sulphuric acid Protect your eyes skin and clothing If electrolyte gets in your eyes flush them thoroughly with water...

Page 43: ...ks and signs of leakage Tighten any loose fittings Replace hoses and fittings as required BRAKE DISC BRAKE DISC ARROW ARROW BRAKE PADS III BRAKE PEDAL HEIGHT Adjust brake pedal height so the pedal is...

Page 44: ...justment HEADLIGHT AIM Adjust horizontally by loosening both headl ight bracket mounting bolts Adjust vertically by loosening both headlight case mounting bolts NOTE Adjust the headlight beam as speci...

Page 45: ...end with a spring scale GOOD o V65MAGNA NO GOOD x SUSPENSION m Do not ride a vehicle with faulty suspension Loose worn or damaged suspension parts impair vehicle stability and control FRONT Check the...

Page 46: ...rce to see if the swingarm bearings are worn Replace the bearings if there is any looseness page 16 15 Check the shock absorbers for leaks or damage Tighten all rear suspension nuts and bolts WHEELS N...

Page 47: ...bar rotation Raise the front wheel off the ground and check that the handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing by turning...

Page 48: ...V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD MEMO 47...

Page 49: ...FUEL SYSTEM HONDA V65MAGNA 4 0 48 Date of Issue Dec 1982 HONDA MOTOR CO LTD...

Page 50: ...disassembling fuel system parts note the locations of the O rings Replace them with new ones on reassembly III The float bowls have drain screws that can be loosened to drain residual gasoline III Fu...

Page 51: ...t carburetor synchronization 4 Carburetor faulty 5 Fuel contaminated Misfiring during acceleration 1 Ignition system faulty Backfiring 1 Ignition system faulty 2 Carburetor faulty Poor performance dri...

Page 52: ...ng bolts Lift the fuel tank up and put the support arm down Remove the air cleaner cover and element Remove the right and left air chamber covers Remove the bolt attaching the thermostat housing to th...

Page 53: ...left side NOTE It may be necessary to loosen the engine mount bolts and move the engine on its rubber mounts to provide clearance for car buretor removal VACUUM CHAMBER REMOVAL Remove the four vacuum...

Page 54: ...eedles and shorter springs than the No 2 and No 4 carburetors FUEL SYSTEM COMPRESSION SPRING DIAPHRAGM VACUUM PISTON Push the needle holder in and turn it 60 degrees with an 8 mm socket Then remove th...

Page 55: ...HOLE FLOAT CHAMBER REMOVAL Remove the four float chamber screws and the float chamber FLOAT LEVEL Measure the float level with the carburetor inclined 15 0 _45 0 from vertical and the float tang just...

Page 56: ...alve for grooves and nicks Inspect the operation of the float valve FUEL SYSTEM FLOAT PIN VALVE SEAT FLOAT VALVE Remove the starter jet main jet and slow jet Remove the float valve seat and filter Dat...

Page 57: ...misadjustment Do not remove the plugs unless the pilot screws are being removed Cover all opening with tape to keep metal particles out when the plugs are drilled FILTER V65MAGNA VALVE SEAT Center pun...

Page 58: ...ION Damage to the pilot screw seat will 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 INSTALLATION Install th...

Page 59: ...nd remove the choke rod V65MAGNA AIR CHAMBER SCREWS CHOKE RODS AND LEVERS CHOKE ROD Carefully separate the No 3 carburetor from the assembly Then separate the No 4 carburetor CAUTION Separate the carb...

Page 60: ...ns Carefully separate the No 1 and No 2 carburetors FUEL SYSTEM THROTTLE LINK FUEL JOINT PIPE No 2 CARBURETOR Remove the choke arm collar and remove the choke arm and spring Remove the choke valve nut...

Page 61: ...stall the choke arm and spring while hooking the arm to the groove in the choke valve Install the choke arm collar ARM VALVE SPRING NUT COLLAR Coat the new a rings with oil and install them on the fue...

Page 62: ...n the fuel and air joint pipes Put the No 3 and No 4 carburetors together with the joint pipes Loosen the synchronization adjusting screws until there is no tension Install the synchronization springs...

Page 63: ...o 4 CARBURETOR Install the choke rods and levers using the nuts and new cotter pins No 2 SYNCHRONIZATION No 4 SYNCHRONIZATION SPRING SPRING CHOKE RODS AND LEVERS CHOKE ROD FUNNEL GROMMETS Make sure th...

Page 64: ...urning the synchronization adjusting screws Inspect throttle operation as described below Open the throttle slightly by pressing the throttle linkage Then release the throttle Make sure that it return...

Page 65: ...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 3 turns out CAUTION Damage to th...

Page 66: ...line 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 are no f...

Page 67: ...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 disconnecting the fuel lines turn the...

Page 68: ...e 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 that can be easily...

Page 69: ...LLATION r iiJ HONDA V65MAGNA 45 70 N m 4 5 7 0 kg m 33 51 ft Ib o 18 28 N m 18 28 N m 1 8 2 8 kg m _ a 1 8 2 8 kg rYl 13 20 ft Ib 3 20It lb 8 12 N m 0 8 1 2 kg m 6 9 ft Ib 5 0 68 Date of Issue Dec 198...

Page 70: ...LATION SERVICE INFORMATION GENERAL SPECIFICATIONS Engine dry weight Oil capacity TORQUE VALUES Engine hanger bolt 8 mm bolt 10 mm bolt Sub frame bolts Upper Lower Rear axle nut Rear axle pinch bolt Fi...

Page 71: ...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 pressure switch and pulse generator R...

Page 72: ...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 ENGINE REMOVAL INSTALL...

Page 73: ...under the engine NOTE The jack height must be continuously adjust ed so that mounting bolts can be removed and so stress is rei ieved from other bolts until they are removed Remove the engine mountin...

Page 74: ...lly 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 2 NOTE Route the wires and cab...

Page 75: ...hen 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 12 N m 0 8 1 2 kg m 6 9 ft I...

Page 76: ...R V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD MEMO 75...

Page 77: ...COOLING SYSTEM HONDA V65MAGNA 6 0 76 Date of Issue Dec 1982 HONDA MOTOR CO LTD...

Page 78: ...ap on p essurized 125 6 C 258 F ED Use only distilled water and ethylene glycol in the cooling system A 50 50 mixture is recommended for maximum corro sion protection Do not use alcohol based antifree...

Page 79: ...re 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 9 0 15 kg...

Page 80: ...eplace 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 and run until there are no air bubbles in the c...

Page 81: ...T AIR CHAMBER COVER SCREW Disconnect the wire from the temperature sensor Remove the bolt that attaches the thermostat housing to the air chamber Loosen the hose bands Remove the thermostat housing AI...

Page 82: ...at room temperature or if it responds at temperatures other than those specified Technical Data Start to open 80 to 84 C 176 183 F 8 mm minimum 0 31 in Valve lift when heated to 95 C 203 F for five mi...

Page 83: ...URE SENSOR WIRE RADIATOR COOLING FAN REMOVAL Remove the seat 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 Loosen...

Page 84: ...the upper radiator hose band Remove the radiator mounting bolts Remove the radiator while pulling the upper and lower hoses off LOWER RADIATOR HOSE UPPER RADIATOR HOSE BAND THERMOSTATIC SWITCH WIRES D...

Page 85: ...hing the fan motor to the fan shroud FAN MOTOR FAN SHROUD SCREWS RADIATOR INSPECTION Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with com pressed air...

Page 86: ...ALLATION Install 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...

Page 87: ...ove 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 gearshift arm and left footpeg bracket Di...

Page 88: ...earing deterioration Replace the water pump as an assembly if necessary a RING I WATER PUMP COVER INSTALLATION Apply a coat of clean engine oil to a new a ring and install it in the water pump groove...

Page 89: ...cover Install the water pump cover and torque the bolts DOWEL PINS O RING WATER PUMP COVER Install the left foot peg bracket Align the punch marks on the gearshift arm and the spindle and install the...

Page 90: ...r j V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD MEMO 89...

Page 91: ...CLUTCH 25 35 N m 2 5 3 5 kg m 1B_T 90 4 7 N m 3 5 ft Ib 10 4 0 7 k 9 25 35 N m 18 25 ft Ib 2 5 3 5 kg m Dec 1982 Date of Issue TOR CO LTD HONDA MO...

Page 92: ...CYLINDER CLUTCH SLAVE CYLINDER 7 2 7 3 7 4 7 6 7 8 CLUTCH COVER REMOVAL STARTER CLUTCH DISASSEMBLY CLUTCH DISASSEMBLY CLUTCH ASSEMBLY STARTER CLUTCH ASSEMBLY CLUTCH COVER INSTALLATION 7 11 7 11 7 13...

Page 93: ...5 30 012 mm 1 1809 1 1816 in 30 08 mm 1 184 in Spring free height 4 6 mm 0 18 in 3 6 mm 0 14 in Spring preload length 115 135 kg 2 mm 254 298Ib 0 08 in Disc thickness 3 72 3 88 nim 0 147 0 153 in 3 1...

Page 94: ...age 1 Air bubbles in hydraulic system 2 Low fluid level 3 Hydraulic system leaking 4 Hydraulic system sticking 5 Plates warped Date of Issue Dec 1982 HONDA MOTOR CO LTD 93 Motocycle creeps with clutch...

Page 95: ...ave 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 may not...

Page 96: ...p and secondary cup as a set Coat all parts with clean DOT 4 brake fluid before assembly Install the spring primary cup and piston CAUTION When installing the cups do not allow the lips to turn inside...

Page 97: ...all the clutch lever Connect the clutch switch wires to the switch terminals Fill the reservoir and bleed the clutch system page 7 4 CLUTCH SLAVE CYLINDER DISASSEMB LY Remove the left crankcase rear c...

Page 98: ...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 the clutch lever slowly and wa...

Page 99: ...r 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 secure the hose Remove the master cylinder Remove the push...

Page 100: ...remove the piston Use the air in short spurts Remove the spring from the slave cylinder Remove the oil and piston seals Clean the piston groove with clutch fluid Check the piston spring for weakness o...

Page 101: ...ke fluid before assembly Be certain the piston seal is seated in the piston groove Place the piston in the cylinder with the oil seal end facing out Install the insulator and slave cylinder Connect th...

Page 102: ...el pins CLUTCH COVER BRAKE PEDAL RIGHT FOOTPEG STARTER CLUTCH DISASSEMBLY Remove the starter idler gear shaft and gear STARTER IDLER GEAR IDLE GEAR SHAFT Remove the alternator cover Hold the flywheel...

Page 103: ...d needle bearing from the starter clutch Inspect the rollers for smooth operation Remove the starter clutch cover by removing the three bolts Remove the clutch rollers plungers and springs Check the r...

Page 104: ...er guide release bearing and lifter rod LIFTER PLATE CLUTCH Install the rear brake pedal Shift the transmission into high gear and apply the rear brake NOTE When the engine is not in the frame shift t...

Page 105: ...ch pressure plate Remove the clutch plates and discs Remove clutch center B and the one way clutch as an assembly Remove clutch center A and washer V65MAGNA ONE WAY CLUTCH 7 14 104 Date of Issue Dec 1...

Page 106: ...ing for damage or excessive play If the needle bearing is difficult to remove from the clutch housing use the following tools Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 35 mm 07746...

Page 107: ...DISC Replace the clutch discs if they show sings of scor ing or discoloration Measure the thickness of each disc SERVICE LIMIT 3 1 mm 0 12 in Replace any discs that are thinner than the service limit...

Page 108: ...ch for smooth operation Check the rollers for excessive wear Measure the 1 0 of clutch center B SERVICE LIMIT 74 50 mm 2 933 in CLUTCH Measure the 0 0 of the one way clutch inner SERVICE LIMIT 57 7 mm...

Page 109: ...e oil pump drive sprocket and install the clutch outer over the gu ide OIL PUMP DRIVE SPROCKET V65MAGNA PINS CLUTCH OUTER CLUTCH OUTER GUIDE Install clutch center A and the washer CLUTCH CENTER A WASH...

Page 110: ...nter should turn counterclockwise freely and should not turn clockwise Coat the discs and plates with clean engine oi I Install the clutch discs and plates as shown CAUTION Do not pull clutch center B...

Page 111: ...cing out Install the lock nut Place the transmission in 6th gear Apply the brake and tighten the lock nut NOTE When servicing the clutch with the engine out of the frame shift the transmission into ge...

Page 112: ...R ROD LIFTER GUIDE BEARING LIFTER PLATE Install the snap ring SNAP RING STARTER CLUTCH ASSEMBLY Install the primary drive gear onto the crankshaft while moving the primary driven subgear with a screwd...

Page 113: ...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 lb NOTE Apply a locking agent to the bolt threads ROLLER V65MAGNA IDLER...

Page 114: ...th a universal holder and tighten the starter clutch bolt to the specified torque TORQUE 80 100 N m 8 0 10 0 kg m 58 72 ft Ib Install the alternator cover CLUTCH COVER INSTALLATION Install the dowel p...

Page 115: ...Install the clutch cover Install the right footpeg and rear brake pedal Fill the crankcase with oil page 2 3 V65MAGNA CLUTCH COVER 7 24 114 BRAKE PEDAL RIGHT FOOTPEG Date of Issue Dec 1982 HONDA MOTOR...

Page 116: ...rii V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD MEMO 115...

Page 117: ...GEARSHIFT LINKAGE Cii HONDA V65MAGNA 8 0 116 Dec 1982 Date of Issue OR co LTD HONDA MOT...

Page 118: ...n the frame It 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 hydraulic system 2 Shif...

Page 119: ...utch cover and clutch assembly section 7 V65MAGNA LEFT CRANKCASE REAR COVER GEARSHIFT PEDAL Remove the oil pump driven sprocket bolt Remove the oil pump drive chain drive and driven sprockets Remove t...

Page 120: ...spring Pull the gearshift spindle assembly out of the crank case Remove the neutral stopper arm bolt arm and spring GEARSHIFT LINKAGE DRUM STOPPER ARM GEARSHIFT SPINDLE NEUTRAL STOPPER ARM ARM BOLT D...

Page 121: ...e 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 washer neutral stopper arm spring and...

Page 122: ...pindle and check 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 sprock...

Page 123: ...earshift 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 2 3 8 6 122 GEARSHIFT PEDAL V6...

Page 124: ...r j V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD MEMO 123...

Page 125: ...ALTERNATOR 9 0 80 100 N m 8 0 10 0 kg m 58 72 ft Ib 124 HOND A V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD...

Page 126: ...ION FLYWHEEL REMOVAL STATOR REMOVAL STATOR INSTALLATION FLYWHEEL INSTALLATION SERVICE INFORMATION GENERAL TORQUE VALUE Alternator rotor Flywheel bolt TOOLS Common Universal holder Rotor puller Date of...

Page 127: ...over Hold the flywheel with a universal holder and re move the flywheel bolt UNVERSAL HOLDER 07725 0030000 FLYWHEEL SOLT Remove the flywheel with the rotor puller Remove the woodruff key from the cran...

Page 128: ...g the bolts and wire clamp STATOR INSTALLATION Install the stator and wire clamp STATOR WIRE CLAMP Install the left crankcase rear cover Route the alternator leads according to the diagram in Section...

Page 129: ...y 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 Ib Install the alternator cover Check engine oil level...

Page 130: ...GUONDA V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD MEMO 129...

Page 131: ...52 N m 4 8 5 2 kg m 35 38 ft Ib _ o rtl l 1 ocD D I c 20 25 N m 2 0 2 5 kg m 7 10 ft Ib 21 25Nm 2 1 2 5 kg m 15 18 ft Ib 48 52 N m 4 8 5 2 kg m 35 38 ft Ib 18 20 N m 1 8 2 0 kg m 13 14 ft Ib 10 0 130...

Page 132: ...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 clearance 0 05 0 25 mm 0 002...

Page 133: ...38 ft Ib 21 25 N m 2 1 2 5 kg m 15 18 ft Ib 45 50 N m 4 5 5 0 kg m 33 36 ft Ib Apply LOCTITE to the threads 18 20 N m 1 8 2 0 kg m 13 14 ft Ib 07984 2000000 07942 3290100 07943 M B40000 07757 0010000...

Page 134: ...he rear cylinder head COOLANT DRAIN BOLTS 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 t...

Page 135: ...Remove the intake and exhaust cam sprocket bolts Turn the crankshaft clockwise one turn 360 and remove the other cam sprocket bolts SI ide the cam sprockets with the cam chain off the camshaft sprock...

Page 136: ...LVE DOWEL PINS EXHAUST CAMSHAFT CAMSHAFT CAM HOLDER INSPECTION Inspect the camshaft and holder journal surfaces for scoring scratches or evidence of insufficient lubrication CAMSHAFT RUNOUT Check cams...

Page 137: ...lengthwise on top of each camshaft journal riJ J V65MAGNA PLASTIGAUGE A B Install the camshaft holders and tighten in a crisscross pattern NOTE Do not rotate the camshaft when using plastigauge TORQU...

Page 138: ...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 pipes and hose Remove the wate...

Page 139: ...the tensioner slipper base WASHER TENSIONER 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 gaske...

Page 140: ...e cam chain tensioner slipper for damage or excessive wear Inspect the spring for good tension replace if necessary CYLINDER HEAD DISASSEMBLY Remove the rocker arm shaft and rocker arms Remove the roc...

Page 141: ...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 damaging the gasket surfaces Gaskets...

Page 142: ...ARM SHAFT AND SPRING INSPECTION Measure each rocker arm shaft 0 0 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 1...

Page 143: ...in Subtract each valve stem 0 0 from the corres ponding guide 1 0 to obtain the stem to guide clearance SERVICE LIMIT IN 0 08 mm 0 003 in EX 0 10 mm 0 004 in NOTE If the stem to gu ide clearance excee...

Page 144: ...d 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 ream the new valve guides NOTE Use cutting oil on the rea...

Page 145: ...round If the valve face is rough worn unevenly or contacts the seat improperly the valve must be replaced Inspect the valve seat If the seat is too wide too narrow or has low spots the seat must be gr...

Page 146: ...ward the head VALVE STEM SEAL CYLINDER HEAD VALVE RETAINER VALVE COTTERS Install the valve cotters CAUTION To prevent loss of tension do not com press the valve spring more than necessary to install t...

Page 147: ...rm Install and tighten the rocker arm shaft bolt TORQUE 45 50 N m 4 5 5 0 kg m 33 36 ft lb ROCKER ARM j V65MAGNA ROCKER ARM SHAFT BOLT SPRING O RING CYLINDER HEAD INSTALLATION Clean the cylinder head...

Page 148: ...sed in the direction of the arrow insert a pin or piece of wire through the hole in the tensioner base and tensioner TENSIONER BASE TENSIONER HOLE Pass the cam chain through the cam chain tensioner an...

Page 149: ...erior oil pipe with washers onto the cylinder and cylinder head r iiJ HONDA V65MAGNA OIL PIPE Install the water pipes and hose and tighten the hose bands securely 10 18 WATER HOSE 148 OIL PIPE Date of...

Page 150: ...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 disulfide greas...

Page 151: ...e 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 camshaft holders you may damage the holde...

Page 152: ...s WIRE CYLINDER HEAD VALVE 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 s...

Page 153: ...aft 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 each front camshaft counterclockwise 4...

Page 154: ...tensioner Front Rear Cylinders Check the front to rear cylinder camshaft timing as follows NOTE When the T1 3 mark aligns with the rear crankcase mating surface the index lines on all cam sprockets s...

Page 155: ...der 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 damage or deterioration NOTE Cle...

Page 156: ...rilJ V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD MEMO 155...

Page 157: ...CRANKCASE 11 0 6mm 10 14 N m 1 0 1 4 kg m 7 10 ft Ib 156 HOND A V65MAGNA 8mm 21 25 N m 2 1 2 5 kg m 15 18 ft Ib Date of Issue Dec 1982 HONDA MOTOR CO LTD...

Page 158: ...before disassembling the crankcase Oil pan Refer to section 2 Oil pump Refer to section 2 Water pump Refer to section 6 Clutch starter clutch Refer to section 7 Gear shift linkage Refer to section 8...

Page 159: ...utput gear case mounting bolts and output gear case Measure the th ickness of the output gear case gasket and note it NOTE Whenever removing the output gear case perform output gear case gasket select...

Page 160: ...emove the following parts e Piston and connecting rods Section 12 e Crankshaft Section 12 lID Shift fork and shift drum Section 13 lID Transmission Section 13 Drive the countershaft bearing out of the...

Page 161: ...um Section 13 G Transmission Section 13 Crankshaft Section 12 G Piston and connecting rods Section 12 Apply molybdenum disulfide grease to the shift Fork grooves of the M2 C5 and C6 gears V65MAGNA 11...

Page 162: ...el pin CRANKCASE 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 47 N m 4...

Page 163: ...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 164: ...r iJ HONDA V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD MEMO 163...

Page 165: ...CRAN KSHAFT PISTON _ FRONT 12 0 164 ij HONDA V65MAGNA 1 30 34 N m 3 0 3 4 kg m 22 25 ft lb Date of Issue Dec 1982 HONDA MOTOR CO LTD...

Page 166: ...0 028 0 052 mm 0 0011 0 0020 in 0 07 mm 0 003 in Cylinder 1 0 79 500 79 515 mm 3 1299 3 1305 in 79 60 mm 3 133 in Warpage 0 05 mm 0 002 in Piston Ring to groove Top 0 015 0 045 mm 0 0006 0 0018 in 0 1...

Page 167: ...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 Excessive carbon build up on pisto...

Page 168: ...connecting rods and pistons out through the top of the cyl inder bores CAUTION On engines with high mileage inspect the cylinders for a ridge just above the highest point of ring travel Any ridge mus...

Page 169: ...their correct piston position PISTON PISTON RING INSPECTION Measure the piston ring to groove clearance SERVICE LIMIT 0 10 mm 0 004 in TOP SECOND Remove the piston rings and mark them to indicate the...

Page 170: ...rom 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 and Y axis SERVICE LIMIT 79 60...

Page 171: ...in 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 exceeds the service limit rep...

Page 172: ...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 Ibs of tension to the other...

Page 173: ...d 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 tighten them evenly TORQUE 30 34 N m 3 0...

Page 174: ...urnals on the lower crankcase and tighten them evenly in 2 3 steps in the sequence shown TORQUE VALUES 6 mm bolt 10 14 N m 1 0 1 4 kg m 7 10 ft Ib 8 mm bolt 21 25 N m 2 1 2 5 kg m 15 18 ft Ib 10 mm bo...

Page 175: ...sure the crankpin 0 0 NOTE The letters A or B on each crank weight is the code for each crankpin 0 0 Cross reference the crank pin and rod codes to deter mine the replacement bearing color CRANKPIN 0...

Page 176: ...ht is the code for the adjacent main journal 0 0 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 40 000 mm 39 992 mm cio I 4...

Page 177: ...ND 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 damage the piston and pist...

Page 178: ...ting 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 as the oil hole i...

Page 179: ...inal 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 and rod into the cylin...

Page 180: ...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 without binding...

Page 181: ...NDA V65MAGNA a Q c D I r 90 110 N m 0 C 9 0 11 0 kg m r c r a e 65 80 ft Ib 70 80 N m II 7_0 8_0 k m 51 58 ft Ibl 0 ia tf 30 34N m m 3_0 3 4 k m 22 25 ft Ibl to e L Date of Issue Dec 1982 TO HONDA MOT...

Page 182: ...000 31 016 mm 1 2205 1 2211 in 31 18 mm 1 228 in Gear bushing M5 M6 C2 C3 C4 30 950 30 975 mm 1 2185 1 2195 in 30 93 mm 1 218 in 0 0 Gear bushing M5 C4 27 995 28 016 mm 1 1022 1 1030 in 28 05 mm 1 104...

Page 183: ...2 Shift fork bent 3 Shift shaft bent 4 Shift claw bent 5 Shift drum cam grooves damaged 30 34 N m 3 0 3 4 kg m 22 25 ft lb 21 25 N m 2 1 2 5 kg m 14 18 ft Ib 90 110 N m 9 0 11 0 kg m 65 80 ft Ib 70 80...

Page 184: ...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 removing the counters...

Page 185: ...r bushings SERVICE LIMITS M5 M6 C2 C3 C4 gear bushing 0 0 30 93 mm 1 218 in M5 C4 gear bushing 1 0 28 05 mm 1 104 in Measure the 0 0 of the mainshaft and counter shaft SERVICE LIMITS A at M5 bushing 2...

Page 186: ...t driven gear shaft wedging it against the vise to lock the shaft Unstake the inner bearing race lock nut with a drill or grinder Be careful that metal particles do not enter the bearing and that the...

Page 187: ...ERSHAFT BEARING REPLACEMENT NOTE The countershaft must be removed before replacing bearing Place the bearing holder in a vise with soft jaws or shop towel NOTE Do not damage the bearing holder especia...

Page 188: ...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 NOTE Place...

Page 189: ...ing 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 Ib Place the case into a vise with soft jaws Install and tighten a new countershaft nut to...

Page 190: ...e and loosen the output driven gear bearing inner race lock nut using a special lock nut wrench and shaft holder LOCI NUT WRENCH 30 64 mm 07916 MBOOOOO SHAFT HOLDER 07923 6890101 DRIVEN GEAR BEARING n...

Page 191: ...o a vise with 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...

Page 192: ...NT 52 x 55 mm 07746 0010400 TRANSMISSION DRIVER 07749 0010000 PILOT 30 mm 07746 0040700 LOCK NUT WRENCH 30 64 mm 07916 MBOOOOO OUTPUT DRIVEN GEAR INSTALLATION NOTE When the gear set driven gear bearin...

Page 193: ...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 Ib Torque wrench scale reading 64 73 N m 6 4 7 3 kg m 46 53 ft lb Stake both new lock nuts...

Page 194: ...ays wear gloves when handling a heated gear case TRANSMISSION BEARING BEARING REMOVER 17 mm Remove the bearing with the bearing remover Drive a new bearing into the output gear case Date of Issue Dec...

Page 195: ...oth contact pattern after removing the drive gear ri J V65MAGNA Contact is normal if Prussian Blue in transfered to the approximate center of each tooth and slightly to the side COUNTERSHAFT If the pa...

Page 196: ...N Place the output gear case in a vise with 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 count...

Page 197: ...stment 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 when thickness of the shim is cha...

Page 198: ...embly 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 CLEARANCE 0 3 0 4 mm 0 012 0 016 in...

Page 199: ...R FORK RIGHT FORK LOCK WASHER V65MAGNA FORK GUIDE SHAFT Remove the bearing stopper plates Remove the shift drum GEAR SHIFT DRUM AND SHIFT FORK INSPECTION Inspect the shift drum end for scoring scratch...

Page 200: ...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 1 0 Measure the shift fork claw thickness SERV...

Page 201: ...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 TORQUE 1...

Page 202: ...ft 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 TRANSMISSION DRIVER ATTACHMENT 30 mm I...

Page 203: ...collar Cl C5 Install the C3 gear and splined collar Install the stopper washer while aligning the tab of the stopper washer with groove in the splined collar Assemble the C2 C5 and C1 gears washers a...

Page 204: ...5MAGNA Install the lower crankcase Refer to Section 11 NOTE Check the oil orifice for clogging before installing the lower crankcase TRANSMISSION OIL ORIFICE Date of Issue Dec 1982 HONDA MOTOR CO LTD...

Page 205: ...NA 8 mm 23 28 N m 2 3 2 8 kg m 17 20 ft Ib 10 mm 35 45 N m 3 5 4 5 kg m 25 33 ft Ib 100 120 N m 10 12 kg m 72 87 ft Ib cC t iV y CJO 41 45 70 N m 0 4 5 7 0 kg m 33 51 ft Ib 14 0 204 Date of Issue Dec...

Page 206: ...VICE LIMIT Final gear oil Capacity 170 cc 5 7 ozs after disassembly Recommended oil Hypoid gear oil API GL 5 Above 5 C 41 F SAE 90 Below 5 C 41 F SAE 80 Gear backlash 0 08 0 18 mm 0 003 0 007 in 0 30...

Page 207: ...E90000 07931 ME40000 or Pinion puller set 07935 MBOOOOO or Pinion puller 07931 4630200 and Pinion puller attachment kit 07931 M BOOOOO 07931 4630300 07934 M BOOOOO 07945 3330300 07749 0010000 07746 00...

Page 208: ...lace 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 tugging sl...

Page 209: ...shaft Check the damper Iifter and cam for wear or damage CAUTION Discard the stop ring and install a new one upon reassembly DAMPER LIFTER SPRING STOP DAMPER CAM STOP RING Remove the oil seal and oil...

Page 210: ...ING FREE LENGTH DAMPER CASE 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 reve...

Page 211: ...er 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 0010000 and attachment 07746 0010100...

Page 212: ...ING GEAR BEARING BEARING PULLER COMMERCIALLY AVAILABLE CASE COVER 01 L SEAL REPLACEMENT Remove the oil seal from the case cover and press in a new oil seal PINION GEAR REMOVAL Install the pinion joint...

Page 213: ...nut wrench RETAINER WRENCH 07910 ME80000 PINION HOLDER 07924 ME90000 PINION PULLER ATTACHMENT KIT WITH SHAFT PULLER OR 07931 MBOOOOO WITH PINION 07931 ME40000 PULLAR 07931 4630200 Pull off the pinion...

Page 214: ...nion adjustment spacer PINION RETAINER OIL SEAL REPLACEMENT Remove the O ring and oil seal from the pinion retainer Drive a new oil seal into the retainer Coat a new O ring with oil and install it ont...

Page 215: ...er 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 shown RING GEAR BEARING OIL SEAL Cii J V65MAGNA P...

Page 216: ...nion gear spacer NOTE When the gear set pin ion bearing and or gear case has been replaced use a 2 0 mm thick spacer PINION BEARING PINION SPACER Press the bearing onto the pinion gear shaft with the...

Page 217: ...ed torque TORQUE 100 120 N m 10 12 kg m 72 87 ft Ib RING GEAR ASSEMBLY Install the original spacer onto the ring gear NOTE If the gear set pinion bearing ring gear bear ing and or gear case is replace...

Page 218: ...in ATTACHMENT 42 x 47 mm 07746 0010300 If the clearance exceeds the service limit remove the ring gear Heat the gear case cover to approx materly 80 0 C 176 0 F and remove the stop pin by tapping the...

Page 219: ...ontact pattern check Place the wave washer and ring gear into the gear case Apply gear oil to the lip of the oil seal on the gear case cover and install the gear case cover Tighten the cover bolts in...

Page 220: ...replace the pinion spacer Replace the pinion spacer with a thicker one if the contacts are too high toward the face DRIVE TRAIN NORMAL I _ TOE __ HEEL IFACE FLANK COAST SIDE TOO HIGH I FACE tv DRIVE S...

Page 221: ...once 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...

Page 222: ...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 holder tool Make sur...

Page 223: ...90 Below 5 C 41 F SAE 80 OIL CAPACITY 80 cc 2 7 oz DISTANCE COLLAR DUST GUIDE PLATE Keeping the damper case vertical place the damper spring onto the damper cam and install the final drive gear case...

Page 224: ...he axle nut TORQUE 85 105 N m 8 5 10 5 kg m 61 76 ft Ib Tighten the three final gear case attaching nuts TORQUE 45 70 N m 4 5 7 0 kg m 33 51 ft Ib Tighten the axle pinch bolt TORQUE 20 30 N m 2 0 3 0...

Page 225: ...kg m 22 33 ft Ib V65MAGNA 40 50 N m 4 0 5 0 kg m 29 36 ft Ib 25 30N m 2 5 3 0 kg m 18 22 ft Ib 9 13 N m 0 9 1 3 kg m 7 9 ft Ib 45 55 N m 4 5 5 5 kg m 33 40 ft Ib 18 28 N m l 1 8 2 8 kg m 13 20 ft Ib 3...

Page 226: ...10ft lb STANDARD SERVICE LIMIT Axle shaft runout 0 2 mm 0 01 in Front wheel rim runout Radial 0 3 mm 0 01 in max 2 0 mm 0 08 in Axial 0 3 mm 0 01 in max 2 0 mm 0 08 in Wheel bearing play 0 03 mm 0 001...

Page 227: ...ngs 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 Incorrect fluid weight i...

Page 228: ...the bolt attaching the horn bracket The bracket and horns will come off as an assembly Remove the coupler box cover HORN BRACKET FRONT WHEEl SUSPENSION FUSE HOLDER COVER Disconnect all wire couplers...

Page 229: ...ight mounting bolt Disconnect the wire coupler and remove the head light CASE REMOVAL INSTALLATION Remove the headlight case mounting bolts and the headlight case Install the headlight case in the rev...

Page 230: ...bolts and bracket turn signal assemblies Install the headlight bracket in the reverse order of removal FRONT WHEEL SUSPENSION HEADLIGHT BRACKET BOLT INSTRUMENTS INDICATOR LIGHT BULB REPLACEMENT Remove...

Page 231: ...new bulb does not light inspect the wiring for an open or short circuit or loose connections INSTRUMENT REMOVAL Remove the coupler box cover page 15 3 Remove the headlight and case page 15 4 Disconnec...

Page 232: ...e instruments upside down or damping fluid will leak onto the inside ofthe lens Remove the meter setting nuts and meters Remove the meter lower cover screws and lower covers FRONT WHEEL SUSPENSION SCR...

Page 233: ...ing for a short or open circuit or check for loose connections ASSEMBLY INSTALLATION Lubricate the speedometer cable before reconnect ing it Assemble and install the instruments in the reverse order o...

Page 234: ...ignition switch Install the ignition switch in the reverse order of removal DISASSEMBLY ASSEMBLY Open the wire clamp Insert the ignition key and tu rn it to between the ON and OFF detent positions Pu...

Page 235: ...S REMOVAL Disconnect the clutch switch wi res Remove the clutch master cylinder Disconnect the choke cable from the choke lever Remove the left handlebar switch jf V65MAGNA CYLINDER CHOKE LEVER CHOKE...

Page 236: ...nt brake switch wires Remove the brake master cylinder Remove the handlebar set screw Loosen the handlebar pinch bolt and remove the handlebar FRONT WH EEL SUSPENSION MASTER CYLINDER HANDLEBAR PINCH B...

Page 237: ...holder onto the lower holder with its punch mark facing 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 handleba...

Page 238: ...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 Ib Connect the brake light switch wires PUNCH MARK BRAKE LIGHT SWITCH WIRES UP MAR...

Page 239: ...master cylinder Align the end of the holder with the punch mark on the handlebar Tighten the upper bolt first then tighten the lower bolt TORQUE 10 14 N m 1 0 1 4I g m 7 10 ft lb Connect the clutch s...

Page 240: ...NOTE Do not operate the front brake lever after removing the calipers To do so will cause difficulty in fitting the brake disc between the brake pads Loosen the axle pinch bolt Loosen and remove the f...

Page 241: ...Remove the wheel bearings and the distance collar from the hub NOTE If the bearings are removed they should be replaced with new ones V65MAGNA WHEEL BEARING REMOVER HEAD 15 mm 07746 0050400 COMMERCIA...

Page 242: ...LAY WHEEL INSPECTION Check the rim runout by placing the wheel in a truing stand Turn the wheel slowly and read the runout using a dial indicator SERVICE LIMITS RADIAL RUNOUT 2 0 mm 0 08 in AXIAL RUNO...

Page 243: ...DRIVER Pack all bearing cavities with grease Drive in the right bearing first and press the distance collar into place NOTE Be certain the distance collar is in position before installing the left be...

Page 244: ...aligning the tangs with the slots Install the left seal Install the right seal Apply grease to the inner seal lip and insert the side collar Attach new gaskets to each brake disc FRONT WHEEL SUSPENSIO...

Page 245: ...the caliper mounting bolts TORQUE 30 45 N m 3 0 4 5 kg m 22 33 ft Ib AI ign the speedometer gearbox with the tang on the left fork leg as shown Tighten the axle to the specified torque TORQUE 55 65 N...

Page 246: ...the caliper holder and disc CAUTION After installing the wheel apply the brakes several times and recheck the clearance on both sides Failure to provide clearance will damage the brake discs and affe...

Page 247: ...RKS 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 V65MAGNA 15 22 246 Date of Is...

Page 248: ...bottom bridge If service of the air joints is necessary remove the following parts coupler box page 15 3 headlight and case page 15 4 instru ments page 15 6 Remove the two screws attaching the fork a...

Page 249: ...h soft jaws or a shop towel and remove the fork tube cap CAUTION I Do not damage the sliding surface O RINGS AIR JONT HONDA V65MAGNA JOINT PIPE SEAL CONNECTOR O RING Remove the fork spring spacer and...

Page 250: ...ed in removing the bolt The piston and rebound spring can now be removed from the right fork FRONT WHEEL SUSPENSION HEX WRENCH 6 mm 07917 3230000 OR COMMERCIALLY AVAILABLE Remove the dust seal sponge...

Page 251: ...om inside the slider FORK TUBE FORK SLIDER 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 252: ...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 fatigue...

Page 253: ...f the entire surface Check the back up ring replace it if there is any distortion at the points shown BUSHING HONDA V65MAGNA BACK UP RING CHECK POINTS hf COPPER SURFACES ANTI DIVE CASE Remove the four...

Page 254: ...der of disassembly FRONT WHEEL SUSPENSION CHECI BALL VALVE SPRING NOTE Apply a Thread Lock Agent to the threads of the screws and socket bolts before assembly Apply ATF to the piston and piston a ring...

Page 255: ...able solvent and wipe them off completely DUST FORK PLASTIC SEAL SEAL CONNECTOR TUBE WASHER I CAP NAP SPONGE AIR JOINT RING SEAL llJJ lI AIR VALVE FORK OIL SEAL TUBE SPACER FORK CK UPRING 1 TUBE SLIDE...

Page 256: ...stall 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 Ibl Place the slider bushing over the fork tube and rest it on the slider Put the back up ring...

Page 257: ...AGNA DUST SEAL SPONGE SEAL PLASTIC WASHER SNAP RING SLIDER BUSHING 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 I stall the fork spri...

Page 258: ...ove Install the air 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 temporari Iy tighten the lower...

Page 259: ...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 14 21 ft lb Install the bolt caps Fill the fork t...

Page 260: ...eel page 15 15 brake three way joint Remove the angle sensor FRONT WHEEL SUSPENSION BRAKE THREE WAY JOINT Loosen the steering stem pinch bolt Remove the steering stem nut fork top bridge front forks a...

Page 261: ...A Loosen the bearing adjustment nut and remove the steering stem Check the steering stem bearings for damage or wear BEARING REPLACEMENT NOTE Replace the bearing and bearing race as a set Remove the b...

Page 262: ...s been involved in an accident examine the area around the steering head for cracks Remove the lower bearing race with the special tool NOTE Drive the upper bearing outer race into the head pipe with...

Page 263: ...ring cavities with bearing grease Insert the steering stem into the steering head pipe and install the bearing retainer and upper bearing inner race Install and tighten the bearing adjustment nut TORQ...

Page 264: ...torque TORQUE 14 16 N m 1 4 1 6 kg m 10 12 ft Ib Check to be sure that the bearings operate smooth ly Install a new bearing adjustment nut lock washer aligning the tabs with the grooves in the nut Be...

Page 265: ...tabs up into the lock nut grooves LOCK WASHER V65MAGNA LOCK NUT Install the front forks page 15 33 Install the fork top bridge and tighten the stem nut TORQUE 90 120 N m 9 0 12 0 kg m 65 87 ft lb Tigh...

Page 266: ...HONDA V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD MEMO 265...

Page 267: ...6 2 0 kg m 12 14 ft Ib 90 120 N m 9 0 12 0 kg m 65 87 ft Ib 16 0 r iJ HONDA V65MAGNA 40 50 N m 4 0 5 0 kg m 29 36 ft Ib 30 40 N m 3 0 4 0 kg m 22 29 ft Ib 85 105 N m 8 5 10 5 kg m 61 76 ft Ib 45 70 N...

Page 268: ...ading will be less than the torque actually applied to the lock nut The specification given is the actual torque applied to the lock nut not the reading on the torque wrench when used with the lock nu...

Page 269: ...e 4 Bent rim 5 Loose axle 6 Swingarm bearings worn 7 Loose wheel bearings Soft suspension 1 Shock fluid leaking 2 Shock absorber worn internally 16 Hard suspension Bent shock absorber Suspension noise...

Page 270: ...nd 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 wheel REAR WHEEl SUSPENSION AXL...

Page 271: ...the hub Remove the oil seal from the hub Inspect the condition of the bearings page 16 5 Remove the bearings with the bearing remover shaft 07746 0050100 and head 07746 0050600 Remove the distance col...

Page 272: ...the bearing play Rotate the wheel by hand to determine the general condition of the bearing Replace any bearings that are noisy or that have excessive play SERVICE LIMIT 0 03 mm 0 001 in WHEEL RIM RUN...

Page 273: ...ed 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 STA LUBE NLGI 2 Other lubricants of equivale...

Page 274: ...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 Date of Issue Dec 1982 H...

Page 275: ...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 85 105...

Page 276: ...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 cowl and rear grip R...

Page 277: ...ly 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 damper adjuster springs and steel balls...

Page 278: ...press the spring 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 SE...

Page 279: ...OPPER RING i O WASHER IiI O STEELBALLS i l 5 0 o UPPER RETAINER UPPER SPRING SEAT Q SPRING _YA ADJUSTER SPRINGS DAMPER Set the shock absorber in the compressor with the attachment and compress the spr...

Page 280: ...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 Ib Install the rear cowl and rear grip Inst...

Page 281: ...right pivot bolt lock nut CALIPER TORQUE ROD SWINGARM PIVOT LOCK NUT WRENCH 07908 4690001 OR KS HBA 08 469 U S A ONLY PIVOT CAP LOCK NUT Remove the right pivot bolt using an 17 mm socket bit Remove t...

Page 282: ...tely 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 is removed Install...

Page 283: ...EFT PIVOT BOLT SOCKET BIT 17 mm 07703 0020500 COMMERCIALLY AVAILABLE IN U S A Tighten the right pivot bolt to 40 N m 4 0 kg m 29 ft Ib loosen it and retighten to the specified torque TORQUE 16 20 N m...

Page 284: ...ORQUE 18 25 N m 1 8 2 5 kg m 13 18 ft Ib Secure the nut with a new cotter pin Install the final gear page 14 19 Install the shock absorbers page 16 13 Install the rear wheel page 16 8 REAR WHEEl SUSPE...

Page 285: ...HYDRAULIC BRAKES V65MAGNA 4 7 N m 004 0 7 kg m 2 9 5 1 ft Ib t i 30 45 N m 3 0 4 5 kg m 22 33 ft Ib Q V 0 b 25 35 N m 12 5_37m 1B 25ft b V 17 0 284 Date of Issue Dec 1982 HONDA MOTOR CO LTD...

Page 286: ...0 30 mm 0 012 in Front master cylinder 1 0 15 870 15 913 mm 0 6248 0 6265 in 15 93 mm 0 627 in Front master piston 0 0 15 827 15 854 mm 0 6231 0 6242 in 15 8 mm 0 62 in Front caliper piston 0 0 31 94...

Page 287: ...ydraulic system 3 Pads glazed or worn excessively Brakes drag 1 Hydraulic system sticking 2 Sticking piston s 3 Incorrect rear brake pedal adjustment 17 2 Brakes grab 1 Pads contaminated 2 Disc or whe...

Page 288: ...luid 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 degreasing agent BRAKE FLU...

Page 289: ...ress 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 slowly and wait...

Page 290: ...and caliper bolt Remove the calipers PAD PIN RETAINER BOLT HYDRAULIC BRAKE CALIPER PIVOT BOLTS Remove the pad pin retainer and pull the pad pins out of the caliper Remove the brake pads Position the p...

Page 291: ...er 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 the retainer cl ip...

Page 292: ...place 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 LIMIT FRONT 4 0 mm 0 16 in REAR 6 0 mm 0 24...

Page 293: ...ose bolt cover the end of the hose to prevent contamination Secure the hose to prevent fluid from leaking out Remove the master cylinder Remove the piston boot and the circlip from the master cylinder...

Page 294: ...ce the master cylinder piston cylinder and spring as a set Assemble the master cylinder Coat all parts with clean brake fluid before assembly Install the spring and primary cup together Dip the piston...

Page 295: ...o sealing washers Install the brake lever Fill the reservoir to the upper level and bleed the brake system according to page 17 4 V65MAGNA OIL HOSE BOLT PUNCH MARK BRAKE CALIPERS REMOVAL Place a clean...

Page 296: ...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 pistons and cyl inders for scoring scratches or other damage...

Page 297: ...mm 1 263 in REAR 30 29 mm 1 193 in ASSEMBLY If the piston boots are hardened or deteriorated replace them with new ones Tth piston seals must be replaced with new ones whenever they are removed Coat...

Page 298: ...positioned between the pads CAUTION I Be careful not to damage the pads REAR RETAINER CLIP BRAKE HOSE CALIPER BOLT BOLT BRAKE HOSE BOLT Install the caliper pivot bolt and caliper bolt Connect the brak...

Page 299: ...nect the brake hoses from the master cylinder CAUTION Avoid spilling brake fluid on painted or plastic surfaces to prevent paint damage Remove the master cylinder attaching bolts and remove the master...

Page 300: ...DY PRIMARY CUP AND SPRING HYDRAULIC BRAKES PISTON PUSH ROD REAR MASTER CYLINDER 1 0 INSPECTION Measure the inside diameter of the master cylinder bore SERVICE LIMIT 14 005 mm 0 5533 in Check for score...

Page 301: ...taching bolt Connect the push rod end and brake pedal shaft with the joint pin Secure the joint pin with a new cotter pin Connect the brake hoses to the master cylinder and tighten the brake hose bolt...

Page 302: ...der push rod end and install the joint pin Secure the joint pin with a new cotter pin Install the brake pedal aligning the punch marks on the shaft and pedal Tighten the brake pedal bolt TORQUE 24 30...

Page 303: ...5MAGNA 1ir IGNITION SWITCH l ex w FUSE 30A 1 _ C l ED i REDIWHITE R 4 4 VOLTAGE r U L SENSOR l f0 B Ie J I GREEN REGULATOR RECTIFIER o J J W ALTERNATOR BATTERY CHARGING SYSTEM 18 0 302 Date of Issue D...

Page 304: ...d on the motorcycle disconnect the battery cables Do not smoke and keep flames away from a charging battery The gas produced by a battery will explode ifflames or sparks are brought near II All chargi...

Page 305: ...attery connection Low power engine running 1 Battery undercharged Low fluid level One or more dead cells 2 Charging system failure 18 2 304 Intermittent power 1 Loose battery connection 2 Loose chargi...

Page 306: ...panying table Replacll the battery if sulfation is evident or if the space below the cell plates is filled with sediment 1 30 1 29 1 28 l a D U u U w a j 1 25 1 24 1 256 The battery contains sulfuric...

Page 307: ...ht 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 ammeter between the bat...

Page 308: ...DIRECTION CONTINUITY BATTERY CHARGING SYSTEM REDMHITE f probe e probe I YELLOW GREEN II RED WHITE YELLOW REVERSE 01 RECTION NO CONTINUITY probe e probe I GREEN YELLOW II YELLOW RED WHITE z o I U UJ 0...

Page 309: ...TEM HONDA V65MAGNA PULSE GENERATORS BATTERY SPARK UNITS IGNITION SWITCH OFF TO TACHOMETER 1 3 2 4 1 3 IGNITION COILS 1 2 SPARK PLUGS SPARK UNITS PULSE GENERATORS 19 0 308 Date of Issue Dec 1982 HONDA...

Page 310: ...adjustments can be made SPECIFICATIONS 19 4 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 Spark pl...

Page 311: ...ted 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 coil and plug Between spark u...

Page 312: ...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 coil resistance RESI...

Page 313: ...ess than half full Disconnect the pulse generator coupler and measure the coi I resistance RESISTANCE Approximately 480 ohms Between white yellow and yellow leads 1 3 cylin ders Between white blue and...

Page 314: ...page 7 23 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 the spark units with n...

Page 315: ...V65MAGNA STARTER MOTOR CLUTCH SWITCH BATTERY DIODE GREEN RED I SHIFT INDICATOR GREEN GREEN STARTER RELAY SWITCH RELAY COIL IGNITION SWITCH 8 EB STARTER BUTTON BATTERY 20 0 314 Date of Issue Dec 1982...

Page 316: ...ING Starter motor will not turn Battery discharged Faulty ignition switch Faulty starter switch Faulty gear change switch Faulty starter relay switch Loose or disconnected wire or cable Clutch diode o...

Page 317: ...ng the starter motor Disconnect the starter motor cable at the motor Remove the starter motor mounting bolts and the starter motor V65MAGNA STARTER CABLE STARTER MOTOR BOLTS O RING REAR COVER 20 2 CAS...

Page 318: ...ashers Inspect the commutator bars for discoloration Bars discolored in pairs indicate grounded armature coils NOTE Do not use emery or sand paper on the com mutator Check for continuity between pairs...

Page 319: ...ted 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 starter motor in the reverse o...

Page 320: ...e 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 full Remov...

Page 321: ...MEMO 320 V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD...

Page 322: ...is useful when checking to find out whether or not there is an electrical connection between the two points An ohmmeter is needed to measure the resistance of a circuit such as when there is a specifi...

Page 323: ...eads from the bottom Then tighten it to the specified torque TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft Ib NOTE Do not overtighten the switch or the crank case may be damaged BRAKE LIGHT SWITCH Check the r...

Page 324: ...less than half full Check for continuity between each terminal and ground in each gear position 0 0 0 0 Lg R Bk Y W B R W Br Y G O GROUND 0 2nd N 4th 1st 5th 3rd I code Y I Positjo OD REMOVAL Remove...

Page 325: ...CH HORN BUTTON Headlight Hi Low Switch TURN SIGNAL SWITCH HI MIDDLE N LO B W to B B W to W to B B W to W HL2 Hi Lo Hi 0 0 N 0 0 Lo 0 D Color code B W B W TURN SIGNAL SWITCH Turn Signal Switch LEFT OFF...

Page 326: ...FF Color code Bk Bk W IGNITION SWITCH Remove the fuel tank and disconnect the ignition switch coupler Check continuity of terminals on the ignition switch coupler in each switch position SWITCH POSITI...

Page 327: ...h 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 wit...

Page 328: ...static switch located in the left tank of the radiator Run the engine until coolant temperature reaches 88 92 C 191 197 F The fan motor should start running The fan motor should stop when the coolant...

Page 329: ...empera ture sensor With the engine cold use an ohmmeter to measure resistance between the temperature sensor terminal and the engine Check the temperature of the coolant V65MAGNA TEMPERATURE SENSOR RA...

Page 330: ...ld move all the way to the right CAUTION Do not leave the temperature sensor wire grounded for longer than a few seconds or the temperature gauge will be damaged TACHOMETER If the tachometer does not...

Page 331: ...when the ignition switch is turned on If the light do not operate properly turn the ignition switch on Check the source voltage at the black brown lead If there is no voltage check and repair the sou...

Page 332: ...evented by the slippage of the one way clutch CLUTCH CENTER ONE WAY CLUTCH ONE WAY CLUTCH OUTER CLUTCH OUTER COMP Construction The one way clutch is installed with the clutch center inside the clutch...

Page 333: ...ar 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 engine compression braking POWER FLOW DIAGRAM FRICTION DISC...

Page 334: ...n 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 can be conne...

Page 335: ...MEMO 338 r iJ HONDA V65MAGNA Date of Issue Dec 1982 HONDA MOTOR CO LTD...

Page 336: ...lty ignition switch 8 Faulty pulse generator 3 Test cylinder compression LOW COMPRESSION 1 Low battery charge 2 Improper valve clearance too COMPRESSION NORMAL small I 3 Valve stuck open 4 Worn cylind...

Page 337: ...E SPEED INCREASES BUT MOTOR lIo 1 Clutch slipping CYCLE DOES NOT ACCLERATE WELL 2 Worn clutch disc plate WHEN CLUTCH IS RELEASED 3 Warped clutch disc plate INCORR ECT 110 FOULED OR DISCOLORED _ ENIGNE...

Page 338: ...ed jet NO CLOGGED JETS t 4 Check valve timing CORRECT t 5 Check valve spring tension NOT WEAKENED INCORRECT 1 Improper valve clearance 2 Faulty spark unit 3 Faulty pulse generator FUEL FLOW RESTRICTED...

Page 339: ...c 5 0 1 J c v tf oV Zt LUcl l1 d J j I Z J l1 tJ It e r b 2 17 1 l l1o r It Ij jJwdCJ I Oafl l7 c IJ PI lt 7 1e 3 l t 1M j s A lill 1 1 1 5 t l l O liJ 3 U5 9 lJi it BIf 0 70 V t I r 1 If e r 3 l 80...

Page 340: ...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 neutral position Perform the...

Page 341: ...position and connect a jumper wire to the B Bk and Br B leads The turn signal switch should return to the neutral position Perform the same test for the right turn position SPEED SENSOR Disconnect th...

Page 342: ...11T l2 N BlK G G t Y dj I 8r Vll 8 R 8 8r 8r l Al WI G 8 TU8E 0 1 1 G 8riW l R m 8r8r G0 8 Y 19lR W G Gr 8 FUSE f l TUBE 9P _ WHTl IDA J MINI G l 1 8fflgiR r 8i l Y m 3 W yyG GO 8Brr I 1 1 IG VI STOP...

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