Magna VF750C Manual Download Page 23

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Summary of Contents for VF750C

Page 1: ...nstallation of components that may be required to perform service described in the following sections Sections 4 through 19 describe parts of the motorcycle grouped according to location Find the section you want on this page then turn to the table of contents on the first page of the section Most sections describe the service procedure through system illustration Refer to the next page for detail...

Page 2: ...talled The sequence of steps represented numerically are differentiated from the ones represented alphabetically to notify the reader that they must perform these steps separately The illustrations may contain symbols to indicate necessary service procedures and precautions that need to be taken Refer to the next page for the meaning of each symbol Also in the illustration is a chart that lists in...

Page 3: ... purpose grease Lithium based multi purpose grease NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NLGI 2 or equivalent Example Molykote G...

Page 4: ...nd exhaust system parts become very hot and remain hot for some time after the engine is run Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts Used Engine Transmission Oil Used engine oil or transmission oil in two stroke may cause skin cancer if repeatedly left In contact with the skin for prolonged periods Althrough this is unlikely unless ...

Page 5: ... of an unstable gas can cause a fire or explo sion resulting in serious injury The shock absorber contains nitrogen under high pres sure Allowing fire or heat near the shock absorber could lead to an explosion that could result in serious injury Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explo sion and serious injury if it is heated or pierc...

Page 6: ...n the carburetor body intake side General Information 1 FRAME SERIAL NUMBER 1lThe frame serial number is stamped on the right side of the steering head 3 VEHICLE IDENTIFICATION NUMBER 3 The vehicle Identification Number VIN is located on the Safety Certification Label on the left side of the steering head 5 COLOR LABEL 5 The color label is attached as shown When ordering color coded parts always s...

Page 7: ...ust valve opens at 1 mm lift Exhaust valve closes at 1 mm lift Lubrication system Oil pump type Cooling system Air filtration Crankshaft type Engine dry weight Firing order Cylinder arrangement Cylinder number 2 332 mm 91 8 in 854 mm 33 6 in 1 136 mm 44 7 in 1 190 mm 46 9 in 1 652 mm 65 in 710 mm 28 in 290 mm 11 4 in 155 mm 6 1 in 229 kg 505 lbs 231 kg 509 lbsl 230 kg 507 lbs 232 kg 511 lbs 247 kg...

Page 8: ...reduction Final reduction 2 500 40 16 Gear ratio 1st 2 846 37 13 Gear ratio 2nd 1 882 32 17 Gear ratio 3rd 1 450 29 20 Gear ratio 4th 1 227 27 22 Gear ratio 5th 1 035 29 28 Gear ratio 6th Gear ratio reverse Gearshift pattern Left foot operated return system 1 N 2 3 4 5 Electrical Ignition system Full transistor ignition Starting system Starter motor Charging system Triple phase output alternator R...

Page 9: ... 0 005 FueiSystem Carburetor identification number 49 states type California type Canadian type Main jet Slow jet Pilot screw initial opening Pilot screw high altitude adjustment Float level Carburetor vacuum difference Base carburetor For carburetor synchronization Idle speed 49 states type California type Canadian type Throttle grip free play Pulse secondary air PAIR injection system California ...

Page 10: ... head to 212 300 F 100 150 C Valve spring free length Valve lifter O D Valve lifter bore I D Standard 1 275 kPa 184 9 psi 13 0 kg cm2 500 rpm 0 16 0 02 0 006 0 001 0 25 0 02 0 010 0 001 35 980 36 140 1 4165 1 4228 35 670 35 830 1 4043 1 4106 0 030 0 072 0 0012 0 0028 24 949 24 970 0 9822 0 9831 25 000 25 021 0 9843 0 9851 4 475 4 490 0 1762 0 1767 4 465 4 480 0 4758 0 1764 4 500 4 512 0 1772 0 177...

Page 11: ...k Second ring mark 70 000 70 015 2 755 2 756 70 10 2 759 0 10 0 004 0 10 0 004 0 10 0 004 With IN mark facing to the intake side 69 970 69 990 2 755 2 756 69 85 2 750 10 0 4 17 002 17 008 0 6694 0 6695 17 02 0 670 0 010 0 035 0 0004 0 0014 16 994 17 000 0 6691 0 6693 0 002 0 014 0 0001 0 0005 0 016 0 040 0 0006 0 0016 0 015 0 050 0 0006 0 0019 0 015 0 045 0 0006 0 0018 0 20 0 35 0 008 0 014 0 35 0...

Page 12: ...t M5 gear 0 020 0 062 0 0008 0 0024 at C2 gear 0 005 0 046 0 0002 0 018 at C3 gear 0 025 0 066 0 0001 0 0026 at C4 gear 0 025 0 066 0 0001 0 0026 Mainshaft O D at M5 gear bushing 24 959 24 980 0 9826 0 9835 24 95 0 982 I I I Countershaft O D at C2 gear bushing 27 967 27 980 1 1011 1 1016 27 96 1 101 I 811 1 Gear to shaft clearance Gear bushing to shaft clearance at M5 gear 0 005 0 047 0 0002 0 001...

Page 13: ...d coil facing down Fork fluid 122 4 80 521cc 17 62 US oz 18 29 Imp oz 0 1 0 15 kg m Unit mm in Service Limit 1 5 0 06 2 0 0 08 0 2 0 01 2 0 0 08 2 0 0 08 60 g 2 1 oz 60 g 2 1 oz 402 5 15 85 0 2 0 01 Rear Suspension r Shock absorber spring free length Shock absorber spring adjuster standard position Shock absorber spring direction 241 8 9 52 2nd groove Small coil end facing down 237 0 9 33 Brakes T...

Page 14: ...ry without plug wire Pulse generator resistance At 20 C 68 F Starter System Starter motor brush length Starter clutch driven gear O D CR8EH9 U24FER9 CR9EH9 U27FER9 0 8 0 9 0 03 0 04 12 BTDC at idle 2 000 rpm 2 4 n 23 27 kO 13 17 kO 450 550 n 12 0 13 0 0 47 0 51 47 175 47 200 1 8573 1 8583 6 5 0 26 47 16 1 857 r Lights Meters Switches Main fuse Fuse Headlight high low beam Tail brake light Position...

Page 15: ...a special tool 9 Apply grease to the threads and flange surface 10 UBS bolt 11 U nut 12 ALOC bolt Replace with a new one Engine Item O ty Thread Torque Remarks dia mm N m kg m ft lbl Maintenance Timing hole cap 1 45 18 1 8 13 Note 9 Lubrication Oil pressure switch 1 PT 1 8 12 1 2 9 Note 1 Oil filter 1 20 10 1 0 7 Note 6 Oil filter stud bolt 1 20 18 1 8 13 Note 2 Oil drain bolt 1 12 34 3 4 25 Oil p...

Page 16: ...Cam chain tensioner slipper bolt 2 6 12 1 2 9 Note 2 Cam chain slipper bolt 2 6 12 1 2 9 Note 2 Connecting rod bearing cap nut 8 8 33 3 3 24 Note 6 Sealing bolt 1 8 18 1 8 13 Note 2 Alternator Left crankcase cover bolt 6 6 12 1 2 9 Flywheel bolt 1 10 83 8 3 61 Note 6 Stator mounting bolt 3 6 12 1 2 9 Ignition System Pulse generator mounting bolt 3 6 10 1 0 7 Starter Clutch Starter motor flange nut...

Page 17: ...n sprocket nut 5 12 108 10 8 79 Note 11 Brake System Brake hose bolt 2 10 35 3 5 25 Caliper bracket bolt 2 8 31 3 1 22 Note 12 Front brake hose clamp nut 2 6 12 1 2 9 Note 11 Front master cylinder holder bolt 2 6 12 1 2 9 Front master cylinder reservoir cover screw 2 4 1 5 0 15 1 1 Front brake light switch screw 1 4 1 2 0 12 0 9 Front brake lever pivot bolt 1 6 1 0 1 0 7 nut 1 6 6 0 6 4 3 Pad pin ...

Page 18: ...6 mm 60 EX 07780 0014500 30 mm 60 IN 07780 0014000 cutter holder 4 5 mm 07781 0010600 Compression gauge attachment 07JMJ KY20100 Tensioner stopper 07NMG MY90100 Not available in U S A Clutch Gearshift Linkage Lock nut wrench 26 x 30 mm 07716 0020203 94 only Extension bar 07716 0020500 94 only Clutch center holder 07724 0050001 Equivalent commercially available in U S A Crankshaft Transmission Univ...

Page 19: ... x 30 mm 07946 1870100 Pilot 22 mm 07746 0041000 Attachment 32 x 35 mm 07746 0010100 Pilot 15 mm 07746 0040300 Needle bearing remover attachment 07GMD KT70200 Bearing remover or M967X 038 XXXXX U S A only Attachment 30 mm 07746 0030300 U S A only Driver 07749 0010000 Brake Snap ring pliers 07914 3230001 Charging System Alternator Flywheel holder 07725 0040000 Rotor puller 07733 0020001 Electric St...

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Page 21: ...rter clutch outer cover bolt Oil filter stud bolt threads Cylinder head sealing bolt threads Oil pressure switch threads Liquid sealant Thermo sensor threads Lower crankcase bolt 9 mm threads Engine oil Cylinder head bolt 9 mm threads and flange surface Camshaft holder bolt 6 mm threads and flange surface Piston sliding surface pin hole ring Connecting rod bolt and nut threads Starter clutch bolt ...

Page 22: ...eel sliding surface driven flange Rear engine mounting nut threads and seating surface Each bearing Each dust seal lips Throttle cables Engine oil Choke cable Clutch cable Speedometer cable Steering stem lock nut threads Flywheel bolt threads and flange surface Handle grip inner surface Honda Bond A Honda Hand Grip Cement U S A only Front brake lever pivot and piston tips Silicone grease Brake cal...

Page 23: ...ormation Cable Harness Routing 10 9P RED CONNECTOR TURN SIGNAL SWITCH HORN SWITCH DIMMER SWITCH 8 RIGHT HANDLEBAR SWITCH WIRE HARNESS 9 9P BLACK CONNECTOR STARTER SWITCH ENGINE STOP SWITCH 1 20 3 SPEEDOMETER CABLE ...

Page 24: ... 5 IGNITION SWITCH WIRE HARNESS 4 HORN WIRE General Information 2 EVAPORATIVE EMISSION PURGE CONTROL VALVE 3 CLUTCH CABLE 1 21 ...

Page 25: ...General Information 1 22 6 STARTER MOTOR CABLE 5 PULSE SECONDARY AIR INJECTION PIPES CALIFORNIA TYPE ONLYl ...

Page 26: ...LIFORNIA TYPE ONLY 6 EVAPORATIVE EMISSION PURGE CONTROL VALVE CALIFORNIA TYPE ONLY General Information 2 EVAPORATIVE EMISSION CARBURETOR AIR VENT CONTROL VALVE CALIFORNIA TYPE ONLY 4 REAR PULSE SECONDARY AIR INJECTION CONTROL VALVE CALIFORNIA TYPE ONLY 1 23 ...

Page 27: ...General Information 1 24 1I THERMO SENSOR WIRE 5 NEUTRAL SWITCH WIRE 4 STARTER MOTOR CABLE ...

Page 28: ... 6 SIDE STAND SWITCH tl h Ct r r c CONNECTOR 4 STARTER MOTOR CABLE General Information 1 l MAIN WIRE HARNESS 21 NEUTRAL SWITCH CONNECTOR 3 RADIATOR OVERFLOW TUBE 1 25 ...

Page 29: ...General Information 1 26 6 NEUTRAL SWITCH CONNECTOR 1 FRAME GROUND 3 SIDE STAND SWITCH WIRE 4 FUEL TANK BREATHER TUBE 49 STATES CANADIAN TYPE 7 RIGHT TURN SIGNAL WIRE 9 TAIL STOP LIGHT WIRE ...

Page 30: ...ith the terms of the Distributor s Warranties for Honda Motor cycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect Source Of Emissions The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monox...

Page 31: ...rable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor This model has two pulse secondary air injection control valves with built in check valves The PAIR check valves prevent reverse air flow through the system The pulse secondary air injection control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engi...

Page 32: ...l System 2 FUEL TANK 3 EVAPORATIVE MISSION EVAP CANISTER 4 FRESH AIR 5 DRAIN TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replace ment of any device or element of design incorporated into any new vehicle for purpose of noise ...

Page 33: ...ch an update label on the right down tube as shown After re adjusting the carburetor back to standard settings for low alitude remove the update label Vacuum Hose Routing Diagram Label California Type Only The Vacuum Hose Routing Diagram Label is on the rear fender as shown The seat must be removed to view it Route the vacuum hoses as shown on this label 1l VACUUM HOSE ROUTING LABEL 1 30 1l EMISSI...

Page 34: ...ork in a well ventilated area Smoking or allowing flames or sparks in the working area or where gasoline is stored can cause a fire or explosion This section covers removal and installation of the frame body panels fuel tank and exhaust system Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine When installing the exhaust pipe install all the fasteners loosely N...

Page 35: ...nch the wire harness between the seat and frame Fuel Tank Removal Installation Gasoline is extremely flammable and is explosive under certain conditions Remove the seat above Turn the fuel valve OFF Disconnect the fuel tube Remove the mounting bolt and collar Disconnect the breather tube Remove the fuel tank Install the fuel tank in the reverse order of removal After installation turn the fuel val...

Page 36: ...r in the reverse order of removal Front Side Cover Removal Installation Remove the front side cover mounting screw Then remove the cover by sliding it forward Install the front side cover in the reverse order of removal NOTE At installation align the tab of the front side cover with the groove of fuel tank mount bracket Frame Body Panels Exhaust System 1 HOLE 14 BOSSES 1 FUEL TANK BRACKET 3 FRONT ...

Page 37: ...Frame Body Panels Exhaust System Exhaust System Removal Installation 14 3 c39 3 9 28 2 c44 4 4 32 7 9 8 c27 2 7 20 c21 2 1 15 2 4 ...

Page 38: ...ear exhaust pipe protector 1 Installation page 2 6 2 Rear cylinder head mount bolt 1 3 Rear cylinder heat mount bracket bolt 2 4 Rear cylinder head mount bracket 1 5 Rear exhaust pipe band bolt 1 Loosen the band bolt 6 Front exhaust pipe protector 1 7 Front exhaust pipe band bolt 1 Loosen the band bolt 8 Muffler mounting bolt 1 9 Muffler assembly 1 10 Rear exhaust pipe joint nut 2 11 Rear exhaust ...

Page 39: ... pipe with groove of the rear exhaust pipe protector Adjust the clearance by moving the protector Standard 2 5 mm 0 08 0 19 in Tighten the exhaust pipe protector bolt Torque 12 N m 1 2 kg m 9 ft lb Exhaust Pipe muffler Mounting Fasteners Tightening When tighten the exhaust pipe muffler mounting fasteners while push the exhaust pipe to inside 2 6 1 EXHAUST PIPE ...

Page 40: ...allation page 2 2 Side covers removal installation page 2 3 Procedure O ty Remarks Removal Order Installation is in the reverse order of removal 1 Rear turn signal light connector 4 Disconnect the connector 2 Brake taillight connector 3 Disconnect the connector 3 Rear fender mounting bolt nut 8 4 4 Grab rail 2 5 Rear fender assembly 1 6 Sub frame 1 2 7 ...

Page 41: ... CAUTION Do not scratch and damage the windscreen Procedure O ty Remarks Removal Order Installation is in the reverse order of removal 1 Upper fairing mounting bolt 3 2 Upper fairing 1 At installation align the tab of the upper fairing stay with the hole of the cable guige 2 8 ...

Page 42: ...haust System Windscreen Replacement 1 STAYS Remove the screws plastic washers and rubber washers _ Remove the windscreen and upper fairing stays Installation is in the reverse order of removal 4 SCREW 3 PLASTIC WASHER 2 9 ...

Page 43: ...de Maintenance Schedule Air Cleaner 3 1 Valve Clearance 3 5 3 8 3 10 3 2 Drive Chain 3 4 Headlight Aim 3 5 Service Information Refer to Common Service Manual for items not included in this manual Refer to Specifications Section 1 for maintenance data 3 1 ...

Page 44: ...tion Adjustment page 3 5 Fuel tank 17 Spark Plug Wear damage color 16 Suspension loose wear damage 15 Brake Drum Shoe wear 14 Wheel Damage runout corrosion 13 Tire Wear damage air pressure 121 Brake Light Switch Operation 11 Reserve Coolant Tank Cap 10 Oil Level Gauge Oil level check replacement 3 2 1 Throttle Grip Operation free play 2 Brake Lever Air in system 3 Master Cylinder level check fluid...

Page 45: ...r damage 9 Caliper Pad wear 8 Brake Hose Leakage deterioration damage 7 Oil Filter Replacement 6 Carburetor Choke Operation Maintenance 1l Synchronization Adjusting Screw Carburetor synchronizatron page 5 14 Middle cover 2 Fuel Line Damage leakage 3 Drive chain Free play lubrication replacement page 3 8 4 Side stand Operation 5 Throttle Stop Screw 3 3 ...

Page 46: ...em I I I Note 5 Secondary Air Supply System Note 4 I I I Note 5 Evaporative Emission Control System Note 4 I I Note 5 Drive Chain Every 600 mi 1 000 km I L Note 5 Brake Fluid Note 3 I I R I I R Note 5 w Brake Shoe Pad Wear I I I I I I Note 5 0 Brake System I I I I Note 5 w 1 Brake Light Switch I I I Note 5 I w Headlight Aim I I I Note 5 a z Clutch System I I I I I I I Note 5 0 U5 Side Stand I I I ...

Page 47: ...essively dirty or damaged Install the removed parts in the reverse order of removal Valve Clearance Inspection NOTE Inspect and adjust the valve clearance while the engine is cold Below 35 C 95 F Remove the following timing hole cap seat page 2 2 fuel tank page 2 2 rear cylinder head cover page 8 2 Remove the lower radiator hose guide Remove the lower radiator mounting bolts loosen the upper mount...

Page 48: ...ankcase cover Check the valve clearances for the No 4 cylinder Turn the crankshaft clockwise 3 4 turn 270 and align its T1 mark with the index mark on the right crankcase cover Check the valve clearances for the No 3 cylinder Turn the crankshaft clockwise 1 4 turn 90 and align its T2 mark with the index mark on the right crankcase cover Check the valve clearances for the No 2 cylinder Adjustment R...

Page 49: ...ickness Example Recorded valve clearance 0 16 mm Old shim thickness 1 725 mm Specified valve clearance 0 20 mm A 0 16 0 20 1 725 A 1 685 NOTE o Make sure of the correct shim thickness by measuring the shim with micrometer o Replace the valve seat if a carbon deposit results in a calculated dimension of over 2 800 mm Install the newly selected shim on the valve retainer Apply molybdenum disulfide o...

Page 50: ...e Install the cover bolt washer with the UP mark facing up Tighten the cover bolts Torque 10 N m 1 0 kg m 7 ft lb Install the removed parts in the reverse order of removal Drive Chain Replacement The MAGNA VF750C uses a drive chain with a staked master link Loosen the drive chain Assemble the special tool Is TOOL I Drive chain cutter NOTE 07HMH MR10102 or 07HMH MR1010B U S A only When using the sp...

Page 51: ...te holder CAUTION 07HMH MR10102 or 07HMH MR1010B U S A only 07NMH MW00110 or 07PMH MZ2011 0 Never reuse the old drive chain master link master link plate and 0 rings Install the new drive chain Assemble the new master link 0 rings and plate CAUTION Insert the master link from the inside of the drive chain and install the plate with the identification mark facing the outside Assemble and set the dr...

Page 52: ...for cracks In there is any cracking replace the master link a rings and plate CAUTION o Drive chain with clip type master link must not be used Headlight Aim o An improperly adjusted headlight may blind oncoming drivers or it may fail to light the road for a safe distance VF750CD Adjust the headlight aim horizontally and vertically turning the adjusting screws as shown VF750C Refer to section 2 of...

Page 53: ...fer to section 4 of the Common Service Manual for the switch location see page 18 2 of this manual The service procedures in this section must be performed with the engine oil drained When removing and installing the oil pump use care not to allow dust or dirt to enter the engine If any portion of the oil pump is worn beyond the specified service limits replace the oil pump as an assembly After th...

Page 54: ...Lubrication System Lubrication System Diagram AFTER 94 1 CAMSHAFT 4 2 ...

Page 55: ...tion page 9 4 6 Water pump removal installation page 6 7 Procedure O ty Remarks Removal Order Installation is in the reverse order of removal 1 Oil pan bolt 12 At installation tighten the bolts as shown 2 Oil pan 1 3 Gasket 1 4 Pressure relief valve 1 5 0 ring 1 6 Oil strainer 1 7 0 ring 1 8 Oil pipe 2 9 0 ring 4 10 Oil pump driven sprocket bolt 1 Apply a locking agent to the threads 11 Oil pump d...

Page 56: ...on Requisite Service Oil pump removal installation page 4 3 Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Cotter pin 1 2 0 ring 1 3 Oil strainer pipe 1 4 Bolt 3 After installation check that the rotor shaft turns freely 5 Pump cover 1 6 Dowel pin 2 7 Feed pump cover 1 8 Dowel pin 2 9 Outer rotor 1 Install with the punch mark facing the oil pump body 10 ...

Page 57: ... or explosion CAUTION To prevent damage be sure to removed the diaphragms before cleaning air and fuel passages with compressed air The diaphragms might be damaged Refer to section 2 for fuel tank removal and installation When disassembling fuel system parts note the locations of the 0 rings Replace them with new ones on reassem bly Before removing the carburetors place the suitable container unde...

Page 58: ...an rich Fuel contaminated deteriorated Intake air leak Idle speed misadjusted Float level misadjusted Fuel tank breather tube clogged Pilot screw misadjusted Slow circuit or starting enrichment circuit clogged Emission control system malfunction California Type Only Evaporative emission carburetor air vent control valve faulty Evaporative emission purge control valve faulty Loose disconnected or d...

Page 59: ...ntrol 2 California type only valve bolt 4 Rear pulse secondary air injection control 1 California type only valve air intake pipe 5 Air cleaner housing screw 3 6 Front pulse secondary air injection control 1 California type only valve air intake tube 7 Rear pulse secondary air injection control 1 California type only valve air intake tube 8 Crankcase breather tube 1 9 Air cleaner housing 1 Move th...

Page 60: ...Fuel System Carburetor Removal Installation 12 7 5 4 ...

Page 61: ... order of removal 1 Choke cable 1 Remove the choke cable from the left middle cover stay 2 Throttle stop screw 1 Remove the throttle stop cable from the left middle cover stay 3 Sub air cleaner case tube 1 4 No 5 vacuum tube from the 3 way joint 1 California type only 5 No 11 vacuum tube from the No 1 1 California type only carburetor 6 No 10 vacuum tube from the 3way joint 1 California type only ...

Page 62: ...Fuel System Carburetor Separation 1 D 5 26 5 6 ...

Page 63: ...4 carburetor 1 13 No 5 vacuum tube from the No 4 carburetor 1 California type only 14 Thrust spring 1 15 Choke cable holder 1 Separate No 3 carb from No 1 2 carb 16 No 5 vacuum tube from the No 3 carburetor 1 California type only 17 No 3 carburetor 1 18 Thrust spring 1 19 Sub air joint pipe tube 0 ring 2 1 4 20 No 6 vacuum tube joint pipe 0 ring 2 2 4 21 No 5 vacuum tube from the No 1 2 6 3 Califo...

Page 64: ...Fuel System blyIAssembly Carburetor Disassem 15 14 ...

Page 65: ...y groove 5 Jet needle holder 1 Removal installation page 5 12 6 Jet needle holder spring 1 7 Jet needle washer 1 1 Float Chamber Disassembly Order 8 Float chamber cover screw 3 9 Float chamber 1 10 0 ring 1 11 Float pin 1 12 Float 1 13 Float valve 1 14 Main jet 1 15 Needle jet holder 1 16 Slow jet 1 17 Pilot screw 1 18 Spring 1 19 Washer 1 20 0 ring 1 Starting Enrichment Valve Disassembly Order 21...

Page 66: ...Fuel System Carburetor Combination I 23 0 RING COTTER PIN 5 5 10 ...

Page 67: ...l tube joint pipe 0 ring 2 3 6 6 Center collar 1 7 Rear collared dowel pin 1 8 Front collared dowel pin 1 9 No 5 vacuum tube to the No 1 2 craburetor 6 3 California type only 10 Sub air joint pipe tube 0 ring 2 1 4 11 No 6 vacuum tube joint pipe 0 ring 2 2 4 12 No 5 vacuum tube to the No 3 carburetor 1 California type only 13 No 3 carburetor 1 14 Thrust spring 1 Assemble No 4 carb with No 1 2 3 ca...

Page 68: ...ul not to damage the diaphragm Do not remove the jet needle holder by pushing the jet needle Installation Install the jet needle holder into the vacuum piston until you felt the click Install the vacuum piston page 5 8 Carburetor Body Cleaning Clean the fuel strainer in the float valve using the com pressed air from the float valve seat side 5 12 1 JET NEEDLE HOLDER 3 VACUUM PISTON 1 JET NEEDLE HO...

Page 69: ...Carburetor Tube Routing California Type Only l 5 TO EVAP PURGE CONTROL VALVE 2 FUEL TUBE 3 TO EVAP CAV CONTROL VALVE 4 TO SUB AIR CLEANER Fuel System 5 13 ...

Page 70: ...nnected tube and pinch the tube with a clip Connect the vacuum gauge tube to the No 4 cylinder intake port adaptor 49 States type Remove the No 1 cylinder intake port vacuum plug Connect the vacuum gauge adaptor to the No 1 cylinder intake port California type Disconnect the No 1 cylinder vacuum tube from the engine intake port Connect the vacuum gauge tube to the No 1 cylinder intake port adaptor...

Page 71: ... 8 in Hg of the base carburetor NOTE The base carburetor is the No 1 carburetor Synchronize to specification by turning the adjusting screws Recheck the idle speed and each cylinder intake vacuum pressure so it is within 20 mm 0 8 in Hg of the base car buretor reading after snapping the throttle grip 3 4 times Remove the vacuum gauge and adaptors Fuel System 1 THROTILE STOP SCREW KNOB 1 SCREW No 3...

Page 72: ...20201 49 states California type 07MMA MV9010A Initial Opening 49 states type 2 1 2 turns out California Canadian type 2 3 8 turns out 2 Warm up the engine to operating temperature 3 Stop the engine and attach the tachometer according to the manufacturer s instruction 4 Start the engine and adjust the idle speed with the throttle stop screw knob Idle Speed 49 states type 1 000 100 rpm California Ca...

Page 73: ...h the label to any part that can be easily removed from the vehicle Sustained operation at an altitude lower than 1 500 m 5 000 feet with the carburetor adjusted for high altitude may cause the engine to idle roughly and the engine may stall in traffic If may also cause engine damage due to overheating When the vehicle is to be operated continuously below 1 500 m 5 000 feet turn each pilot screw c...

Page 74: ...sconnect and remove the following No 10 vacuum tube air injection hose PAIR control valve mounting bolt air intake hose PAIR control valve Installation is in the reverse order of removal After installing check the tubes for loose connections and kinks Install the radiator page 6 5 Rear cylinder Remove the seat page 2 2 Disconnect and remove the following air intake hose air injection hose PAIR con...

Page 75: ...lant at the reserve tank Do not remove the radiator cap except to refill or drain the system All cooling system services can be done with the engine in the frame Avoid spilling coolant on painted surfaces After servicing the system check for leaks with a cooling system tester Refer to section 25 of the Common Service Manual for fan motor switch and thermo sensor inspection Troubleshooting Engine T...

Page 76: ...Cooling System System Flow Pattern 1 SIPHON TUBE 5 THERMOSTAT 2 RESERVE TANK 4 RADIATOR 3 WATER PUMP 6 2 ...

Page 77: ...tion 5 of the Common Service Manual Remove the water pump drain bolt and sealing washer Remove the radiator cap screw and radiator cap and drain the coolant Remove the cylinder drain bolts and sealing washers and drain the coolant Install the water pump drain bolt with a new sealing wash er Install the cylinder drain bolts with new sealing washers Refill the coolant to upper level Cooling System 2...

Page 78: ...mostat 1 9 Thermostat housing bolt 1 10 Cylinder head to housing hose 2 1 1 Thermostat housing 1 12 Thermo sensor 1 6 4 6 Coolant refilling Section 5 of the Common Service Manual Remarks Installation is in the reverse order of removal Loosen the clamp screw and disconnect the hose At installation install the thermostat with its bleed hole facing right side while aligning it with the grooves in the...

Page 79: ...on is in the reverse order of removal 1 Radiator siphon tube 1 2 Radiator upper hose 1 Loosen the clamp screw and disconnect the hose 3 Radiator lower hose 1 Loosen the clamp screw and disconnect the hose 4 Fan motor switch connector 1 5 Radiator mounting bolt 3 6 Radiator assembly 1 Remove it after releasing the projection on the right radi ator stay CAUTION During removal and installation be car...

Page 80: ...ly 1 Radiator grill 1 Release the two grooves from under of radiator then remove the radiator grill 2 Fan motor switch connector 1 3 Cooling fan shroud bolt 3 At installation install the ground eyelet joint with the bolt 4 Cooling fan nut 1 5 Cooling fan 1 At installation align the cooling fan groove with the fan motor shaft 6 Fan motor mounting nut 3 7 Fan motor 1 8 Fan motor switch 1 At installa...

Page 81: ...ng bolt 2 6 Water pump cover 1 7 0 ring 1 8 Dowel pin 2 9 Pump to engine hose 1 10 Water pump body 1 11 0 ring 1 Cooling System GN OIL PUMP SHAFT 10 Coolant refill Section 5 of the Common Service Manual Remarks Installation is in the reverse order of removal Loosen the clamp screw and disconnect the hose Loosen the hose clamp screw and disconnect it At installation align the cut out of the water p...

Page 82: ... serviced with the engine installed in the frame Oil pump Section 4 Carburetor Section 5 Water pump Section 6 Camshaft cylinder head Section 8 Clutch Section 9 Gearshift linkage Section 10 Alternator Section 15 Pulse generator Section 16 Starter clutch Section 17 Starter motor Section 17 The following components require engine removal for service Piston connecting rod cylinder Section 11 Crankshaf...

Page 83: ... Removal Installation Enwne Removal Installation Eng1ne 7 32 c39 3 9 28 c9 0 9 6 5 22 c27 0 7 20 11 10 9 26 28 c44 4 4 32 27 c39 3 9 28 7 2 ...

Page 84: ...uto fuel valve mounting bolt 2 7 Auto fuel valve 1 8 Front air suction pipe joint bolt 4 California type only 9 Front air suction pipe 2 10 Gasket 2 11 Rear air suction pipe joint bolt 4 12 Rear air suction pipe 2 13 Gasket 2 14 No 4 vacuum tube 1 15 Drive sprocket bolt 1 16 Washer 1 17 Drive sprocket 1 18 Brake pedal linkage joint pinch bolt joint 1 1 Align the punch marks 19 Right foot peg brack...

Page 85: ...g bracket Tighten the 10 mm front cylinder head mounting bolts CD and Torque 54 N m 5 4 kg m 39 ft lb Tighten the 8 mm engine mounting bracket bolts and J Torque 39 N m 3 9 kg m 28 ft lbl Tighten the 10 mm engine mounting bolts and Torque 44 N m 4 4 kg m 32 ft lb Tighten the 12 mm engine mounting nut Torque 64 N m 6 4 kg m 46 ft lb 7 4 ...

Page 86: ...eather tube If there is smoke in the tube check for a seized piston ring Compression Too Low Hard Starting Or Poor Performance At Low Speed Valves Incorrect valve adjustment Burned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Cylinder piston Worn stuck or broken piston ring Worn or damage...

Page 87: ...ylinder Head Valves Camshaft Removal 7 8 2 AFTER 95 Except some 96 early production units t 7 1 Revised July 1995 94 95 Magna VF750C CD 1995 American Honda Motor Co Inc All Rights Reserved MSV 6913 9504 ...

Page 88: ... 10 Rear cylinder head cover bolt 4 11 Washer 4 12 Rear cylinder head cover 1 13 Head cover gasket 1 14 Cam chain tensioner sealing bolt washer 1 1 15 Cam chain tensioner mounting bolt 2 16 Cam chain tensioner 1 17 Gasket 1 18 Camshaft holder bolt 16 19 Cam chain guide 1 20 Camshaft holder 4 21 Camshaft IN EX 2 22 Cam chain 1 23 Dowel pin 8 Muffler removal installation page 2 4 Spark plug cap remo...

Page 89: ...Cylinder Head Valves Cylinder Head Removal Installation 4 3 c13 1 3 9 8 4 ...

Page 90: ... 2 8 Muffler removal installation page 2 4 Air suction pipe removal installation California type only Procedure Q ty Removal Order 1 Cylinder head 6 mm bolt 8 8 2 Cylinder head 9 mm bolt washer 3 Cylinder head protector bolt 6 4 Cylinder head protector 2 5 Cylinder head 1 6 Cylinder head gasket 1 7 Dowel pin 2 Thermostat removal installation page 6 4 Air suction pipe removal installation Californi...

Page 91: ...Cylinder Head Valves Cylinder Head DisassemblyIAssembly HANDLAPPING TOOL GROOVE LUG 10 191 11 is TOOL page 1 15 8 6 ...

Page 92: ...Assembly is in the reverse order of disassembly 1 Insulator 2 NOTE Align the groove of the insulator with the lug of the cylinder head 2 Valve lifter 8 NOTE Remove using a handlapping tool Do not damage the cylinder head lifter sliding surface 3 Valve shim 8 4 Valve spring cotter 16 NOTE Removal Installation page 8 17 To prevent loss of tension do not compress the valve spring more than necessary ...

Page 93: ... Head Valves Camshaft Installation 17 c 10 1 0 7 AFTER 95 Except some 171 20 c 13 1 3 9 96 early production units IN EX 2 1 95 Magna VF750C CD Revised Jul 9 o i c _All Ri hts Re 1995 American Honda 0 0 MS 6913 ...

Page 94: ...ounting bolt 10 Cam chain tensioner sealing bolt washer 11 Head cover gasket 12 Rear cylinder head cover 13 Washer 14 Rear cylinder head cover bolt 15 Head cover protector rubber 16 Head cover protector 17 Head cover protector bolt 18 Breather plate 19 Breather case 20 Breather case bolt 21 Breather tube 22 Side stand switch connector 23 Auto fuel valve Q ty 8 1 2 4 1 16 1 1 2 1 1 1 1 4 4 6 2 4 1 ...

Page 95: ...cylinder head Lubricate the camshaft journal surface of the cylinder head camshaft holder and cam lobes with molydenum disulfide oil Install the camshafts onto the rear cylinder head The R EX timing mark on the rear exhaust camshaft sprocket is level with the cylinder head upper edge as shown Check that the R IN timing mark on the rear intake camshaft sprocket is level with the cylinder head upper...

Page 96: ...ess piece of steel 15mm 19 mm 15mm 8 5mm 4 5mm MATERIAL THICKNESS 1 0 mm Install the new gasket and cam chain tensioner to rear cylinder head Torque the cam chain tensioner mounting bolts Torque 12 N m 1 2 kg m 9 ft lb Remove the cam chain tensioner stopper tool Install the cam chain tensioner sealing bolt and washer Make sure the timing marks on the camshaft sprockets are level with the cylinder ...

Page 97: ...d Check that the F EX timing mark on the front exhaust camshaft sprocket is level with the cylinder head upper edge as shown Check that the F IN timing mark on the front intake camshaft sprocket is level with the cylinder head upper edge as shown Install the camshaft holders in the correct positions checking the identification marks on the holders and cylinder head Install the cam chain guide Torq...

Page 98: ...washer Make sure the timing marks on the camshaft sprockets are level with the cylinder head upper edge When The Rear Cylinder Camshaft Only Was Removed Align the T2 mark with the index mark on the right crankcase cover Remove the front cylinder head cover page 8 2 Make sure 2 cylinder is TDC on the compression stroke If it is not turn the crankshaft clockwise 360 and make sure T2 mark aligns with...

Page 99: ...d upper edge as shown Install the camshaft holders in the correct positions check ing the identification marks on the holders and cylinder head Install the cam chain guide Torque the cam shaft holder bolts in the sequence shown Torque 12 N m 1 2 kg m 9 ft lbl Turn the cam chain tensioner shaft completely in clock wise and secure it using the special tool Is TooL I Tensioner stopper 07NMG MV90100 N...

Page 100: ...0 and make sure T1 mark aligns with the index mark on the right crankcase cover Rotate the crankshaft clockwise 90 to align the T2 mark with the index mark on the right crankcase cover Install the camshaft holder dowel pins onto the front cylin der head Lubricate the camshaft journal surface camshaft holder and cam lobes with molybdenum disulfide oil Install the camshafts onto the front cylinder h...

Page 101: ... N m 1 2 kg m 9 ft lb Turn the cam chain tensioner shaft completely in clock wise and secure it using the stopper tool This tool can easily be made from a thin 1 mm thickness piece of steel 15 mm 13 5 mm 15mm 8 5mm 3 5mm MATERIAL THICKNESS 1 mm Install a new gasket and cam chain tensioner Torque the cam chain tensioner mounting bolts Torque 12 N m 1 2 kg m 9 ft lb 8 16 1 TENSIONER SHAFT 2 TENSIONE...

Page 102: ...t hole protector 07HMG MR70002 Not available in U S A Install the valve spring compressor onto the valve and compress the valve spring CAUTION To prevent loss of tension do not compress the valve springs more than necessary Remove the valve cotters I8 TOOL I Valve spring compressor 07757 0010000 Valve spring compressor attachment 07959 KM30101 Installation is in the reverse order of removal Cylind...

Page 103: ...lutch disengagement When the clutch does not disengage or __ the vehicle creeps with clutch disengaged inspect the transmission oil level before servicing the clutch system Troubleshooting Clutch Slips When Accelerating Incorrect clutch adjustment Worn clutch discs Weak clutch springs Transmission oil mixed with molybdenum or graphite additive Motorcycle Creeps With The Engine Idling Incorrect clu...

Page 104: ...Clutch System Right Crankcase Cover Removal Installation 6 10 7 c12 1 2 9 1 c27 2 7 20 2 c27 2 7 20 9 2 ...

Page 105: ...nut 1 1 2 Right foot peg bracket bolt 2 3 Right foot peg bracket 2 4 Front exhaust pipe protector bolt 2 5 Front exhaust pipe protector 1 6 Evaporative emission canister pipe bolt 1 California type only 7 Right crankcase cover bolt 13 NOTE Install the clamps in the correct positions and clamp the starter motor cable 8 Right crankcase cover 1 9 Gasket 1 10 Dowel pin 2 9 3 ...

Page 106: ...Clutch System Clutch Removal ...

Page 107: ...essure plate bearing 1 5 Clutch lifter guide 1 Detach from the pressure plate bearing only when replacing the bearing 6 Stopper ring 1 7 Lifter rod 1 8 Clutch disk A clutch plate 8 8 9 Clutch disk B 1 Larger 1 0 than clutch disc A 10 Judder spring 1 11 Spring seat 1 12 Clutch center lock nut 1 Unstake the lock nut Hold the clutch center with the special tool page 9 8 13 Spring washer 1 14 Clutch c...

Page 108: ...Clutch System Clutch Installation 7 6 AFTER 94 11 fit c110 11 0 Is rooL 1 page 9 8 21 2 JY 012 1 2 9 2 0 9 6 ...

Page 109: ... 1 Installation page 9 8 9 Clutch center 1 10 Spring washer 1 OUT SIDE mark facing cover 11 Clutch center lock nut 1 Hold the clutch center with the special tool page 9 8 Stake the lock nut with a punch 12 Spring seat J Install the spring seat and judder spring on the clutch 13 Judder spring center as shown 14 Clutch disc B 1 Larger I D than clutch disc A 15 Clutch disc A clutch plate 8 8 16 Lifte...

Page 110: ...r with the clutch center holder and tighten the new lock nut to the specified torque Torque 90 N m 9 0 kg m 65 ft lbl I8 TOOL I Clutch center holder 94 only Lock nut wrench 26 x 30 mm 07724 0050001 Equivalent commercially available in U S A 07716 0020203 Stake a new lock nut with a center punch NOTE Be careful not to damage the mainshaft threads Clutch Outer Installation Install the clutch outer o...

Page 111: ...o Shift Transmission Jumps Out Of Gear Improper oil viscosity Worn shift drum stopper arm Incorrect clutch adjustment Worn gear engagement dogs or slots Bent shift forks Weak or broken shift arm return spring Bent shift fork shaft Loose stopper plate bolt Bent fork claw Damaged or bent shift fork Loose stopper plate bolt Damaged stopper plate and pin Gearshift Pedal Will Not Return Damaged gearshi...

Page 112: ...Gearshift Linkage Drive Sprocket Cover Removal Installation 12 14 ___ _ _ c12 1 2 9 10 2 ...

Page 113: ...ive sprocket cover 1 5 Gasket 1 6 Dowel pin 2 Disassembly Order Assembly is in the reverse order of disassembly 7 Clutch lifter piece 1 Remove the piece by turning the lifter arm clockwise 8 Clutch lifter arm 1 9 Return spring 1 10 Washer 1 11 Dust seal 1 12 Drive chain guard bolt 2 13 Drive chain guard 1 14 Drive sprocket cover rubber bolt washer 2 2 15 Drive sprocket cover rubber 1 10 3 ...

Page 114: ...Gearshift Linkage Gearshift Linkage Removal Installation 8 SHIFTER PLATE ASSEMBLY 10 4 ...

Page 115: ... dowel pin 1 2 4 Gear shift spindle assembly 1 Install the shifter collar into the spindle hole and the return spring onto the return spring pin 5 Washer 1 6 Shifter collar 1 7 Shifter plate attaching bolt 2 8 Shifter plate assembly 1 Lubricate each part with engine oil and assembly as illustrated Install on the shift drum center with the drum center positioned at any gear stop except neutral 9 Sh...

Page 116: ...to damage the crankshaft main journal bearing while removing or installing the crankshaft All bearing inserts are select fitted and are identified by color code Select replacement bearings from the selection table page 11 16 After installing new bearings recheck them with plastigauge to verify clearance Apply molybdenum disulfide oil to the main journals and crankpins during assembly Troubleshooti...

Page 117: ...Crankshaft Piston Transmission Crankcase Separation 6 5 11 2 ...

Page 118: ...tion Order Upper Crankcase Side 1 Mainshaft bearing stopper plate bolt 3 2 Mainshaft bearing stopper plate 1 3 Upper crankcase bolt 6 mm washer 7 1 Loosen gradually 4 Cable guide 5 Upper crankcase bolt 10 mm washer 2 2 Lower Crankcase Side 6 Lower crankcase bolt 6 mm 8 Loosen in a gradual crisscross pattern 7 Lower crankcase bolt 8 mm 1 8 Lower crankcase bolt 9 mm 8 Loosen in a gradual crisscros p...

Page 119: ...Crankshaft Piston Transmission Crankshaft Connecting Rod Removal Installation AFTER 94 11 LW 012 1 2 9 9 cw 012 1 2 9 7 LW 012 1 2 9 11 4 ...

Page 120: ... chain tensioner slipper bolt 1 10 Rear cam chain tensioner slipper 1 11 Front rear cam chain slipper bolt 2 12 Front rear cam chain slipper 1 Installation Order 12 Front rear cam chain slipper 1 11 Front rear cam chain slipper bolt 2 Clean and apply a locking agent to the threads 10 Rear cam chain tensioner slipper 1 9 Rear cam chain tensioner slipper bolt 1 Clean and apply a locking agent to the...

Page 121: ... ranKsnanti IStontl ransm ss1on Piston DisassemblyIAssembly 1 ft IN MARK 2 4 MARK IDENTIFICATION 10 A 20 mm 0 8 in __ _ I OR MORE mm 0 8 n OR MORE 11 6 ...

Page 122: ...king ML7 F Install the piston on the front connecting rod so that the IN mark on the piston head faces the oil hole side of the connecting rod o It is not necessary to remove the piston rings unless they need replacing 4 Front connecting rod 2 5 Rear piston assembly 2 NOTE o Identify the rear connecting rod by the marking ML7 R Install the piston on the rear connecting rod so that the IN mark on t...

Page 123: ...Crankshaft Piston Transmission Transmission Removal Installation 6 4 1 5 11 8 ...

Page 124: ...ge 11 10 12 2 Countershaft bearing set plate 1 3 Dowel pin 1 4 Shift fork shaft 1 5 Shift fork 3 6 Shift drum 1 Installation Order 6 Shift drum 1 5 Shift fork 3 Install them with the identification mark R Right C Center L Left side facing the right side as shown 4 Shift fork shaft 1 3 Dowel pin 1 2 Countershaft bearing set plate 1 Fit in the upper crankcase securely 1 Mainshaft countershaft assemb...

Page 125: ...6 early 3 1 94 95 and some 96 early production units AFTER 95 Except some 96 early production units production units 13 10 SHIFTER GEAR GEAR SLIDING mGROOVE mSURFACE 11 10 12 9 8 5 4 8 7 6 3 Revised July 1995 94 95 Magna VF750C CD 1995 American Honda Motor Co Inc All Rights Reserved MSV 6913 9504 ...

Page 126: ... Common Service Manual for inspection information Requisite Service Transmission removal installation page 11 8 Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Needle bearing case 1 2 Needle bearing 1 3 Thrust washer 1 4 M2 gear 17T 1 5 Collar 1 94 95 and some 96 early production units 6 Spline washer 1 7 Snap ring 1 8 M3 M4 gear 20 22T 1 9 Snap ring 1 10...

Page 127: ...Crankshaft Piston Transmission Countershaft DisassemblyIAssembly 3 SHIFTER GEAR EJ GROOVE GEAR SLIDING EJ SURFACE 11 12 10 15 18 6 8 9 12 13 16 17 19 20 ...

Page 128: ...edure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Needle bearing case 1 2 Needle bearing 1 3 Thrust washer 1 4 C1 gear 37T 1 5 Needle bearing 1 6 Thrust washer 1 7 C5 gear 29T 1 8 Snap ring 1 9 Spline washer 1 10 C4 gear 27T 1 11 C4 spline bushing 1 Align the oil holes of the bushing and countershaft 12 Tanged washer 1 At assembly fit the tangs into the lock wa...

Page 129: ...Crankshaft Piston Transmission Crankcase Combination 11 14 c12 1 2 9 7 10 8 c12 1 2 9 c39 3 9 28 ALIGN 9 10 c 12 1 2 9 ...

Page 130: ...ty Remarks Combination Order 1 Upper crankcase 1 CAUTION Do not apply sealant around the oil passage area and main journal bearing area Refer to page 11 18 for detail for the application area 2 Oil orifice 0 ring 1 1 Install it as illustrated 3 Dowel pin 3 4 Lower crankcase 1 At installation make sure the shift forks engage properly with the corresponding gears 5 Lower crankcase bolt 9 mm I Tighte...

Page 131: ...ht NOTE The numbers 1 2 or 3 on the crank weight are the codes for the main journal O D s Cross reference the case and journal codes to determine the replacement bearing color codes Main Journal Bearing Selection Table Unit mm in 37 000 37 005 37 006 37 011 37 012 37 018 j nal 1 4567 1 4569 1 4569 1 4572 1 4572 1 4574 1 34 007 34 013 y 11 G Brown 1 3389 1 3391 e ow reen 34 001 34 006 2 1 3386 1 33...

Page 132: ... the codes for the crank pin O D s Cross reference the crankpin and rod codes to determine the replacement bearing color NOTE One painted mark identifies the front connecting rod bearings and two painted marks the rear Connecting Rod Bearing selection Table Unit mm in A B c g e 35 995 36 000 35 989 35 994 35 982 35 988 e 1 4171 1 4173 1 4169 1 4171 1 4166 1 4169 1 39 000 39 005 Yellow Green Brown ...

Page 133: ...ealant to the crankcase mating surface except to the main bearing jour nal bolt lower crankcase 9 mm a rea and the oil passage area as shown Crankcase Bolt Location Clean the crankcase 9 mm bolts thoroughly with solvent and blow them dry Apply clean engine oil to the 9 mm bolt threads and seat ing surface and install them Loosely install all the lower crankcase bolt Make sure the upper and lower c...

Page 134: ...rankcase bolts the sealing washers and cable guide Torque the 10 mm bolts and then the 6 mm bolts Torque 10 mm bolt 39 N m 3 9 kg m 28 ft lb 6 mm bolt 12 N m 1 2 kg m 9 ft lb Crankshaft Piston Transmission UPPER CRANKCASE SIDE 11 19 ...

Page 135: ...fety stand or hoist Do not use the oil filter as a jack point Troubleshooting Hard Steering Wheel Turns Hard Steering head bearing adjustment nut too tight Faulty wheel bearing Faulty steering head bearings Faulty speedometer gear Insufficient tire pressure Bent front axle Faulty tire Brake drag Steers To One Side Or Does Not Track Straight Soft Suspension Bent fork Insufficient fluid in fork Bent...

Page 136: ...Front Wheel Suspension Steering Handlebar Removal Installation 1 1 10 15 iiiiB 12 2 ...

Page 137: ...the rear screw 6 Left handlebar switch housing 1 Align the locating pin in the left handlebar switch with the hole in the handlebar 7 Handle grip 1 Apply Honda Bond A or Honda Hand Grip Cement U S A only to the inside surface of the grip 8 Switch housing side protector 1 9 Brake light switch connector 2 10 Master cylinder 1 Align the split between the holder and master cylinder body with the punch...

Page 138: ...front wheel support the motorcycle using a safety stand or hoist Do not operate the brake lever after the front wheel removed Procedure O ty Remarks Removal Order Installation is in the reverse order of removal 1 Speedometer cable 1 2 Axle bolt 1 3 Axle pinch bolt 4 4 Front axle 1 At installation apply a thin coating of grease to the front axle 5 Front wheel assembly 1 At installation align the pr...

Page 139: ...Common Service Manual Requisite Service Front wheel removal installation page 12 4 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Brake disc bolt 6 2 Brake disc 1 Install with stamped side outward 3 Dust seal 2 At installation apply grease to the dust seal lips 4 Speedometer gear retainer 1 5 Right wheel bearing 6004 UU 1 6 Distance collar 1 7 Left wheel bea...

Page 140: ...Front Wheel Suspension Steering Fork Removal Installation c 12 1 2 9 1 3 12 6 6 9 c 27 2 7 20 7 5 c 31 3 1 22 ...

Page 141: ...Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Front fender bolt 4 2 Front fender collar 1 3 Front fender 1 4 Brake hose clamp 1 5 Caliper bracket bolt 2 6 Caliper assembly 1 7 Front turn signal bolt collar 2 2 8 Front turn signal assembly 2 9 Fork pinch bolt upper 2 Only loosen the bolts 10 Fork pinch bolt lower 2 Only loosen the bolts If the fork leg will be disasse...

Page 142: ...Front Wheel Suspension Steering Fork Disassembly 1 12lr 18 13 191 171 8 12 8 21 31 4 6 7 14 15 e 16 ...

Page 143: ...emarks Disassembly Order 1 Fork cap 1 2 0 ring 1 3 Spacer 1 4 Spring seat 1 5 Fork spring 1 After removing pour out any remaining fork oil 6 Dust seal J When removing do not damage the fork tube 7 Stopper ring 8 Fork socket bolt 1 9 Sealing washer 1 10 Fork piston 1 11 Fork piston ring 1 Do not remove it unless replacement is necessary 12 Rebound spring 1 13 Fork tube 1 14 Oil seal 1 15 Back up ri...

Page 144: ...Front Wheel Suspension Steering Fork Assembly 3 4 s 6 p 2 c 23 2 3 17 18 17 15 14 page 1 15 10 9 c 8 0 8 5 8 LW 8 c 20 2 0 14 12 10 ...

Page 145: ...e 1 7 Sealing washer 1 8 Fork socket bolt 1 If the socket bolt turns with the fork piston temporarily install the fork spring spacer and fork cap then tighten the socket bolt 9 Slider bushing 1 10 Back up ring 1 11 Oil seal 1 Wrap vinyl tape around the fork tube top end to avoid damaging the oil seal during installation Use fork seal driver 07947 KA50100 and attachment 07947 KF00100 for fork seal ...

Page 146: ...ension Steering Steering Stem Removal Installation 1 c 105 10 5 76 8 12 12 17 6 c 30 3 0 22 ls TooL page 1 15 4 14 Is TooL page 12 13 1111 115JI hpage12 131 112 v I page 12 131 Iii 113 II Bend down LONGER TABS Bend up ...

Page 147: ...h driver 07953 15 Lower bearing outer race MJ10200 or M9360 277 91774 U S A only for upper outer race removal Use race remover 07946 3710500 for lower outer race removal 16 Lower holder nut washer 2 2 17 Lower holder 2 Installation Oder 17 Lower holder 2 16 Lower holder nut washer 2 2 Tightening procedure page 12 14 15 Lower bearing outer race 1 Replace as a set if necessary 14 Upper bearing outer...

Page 148: ... upper holder page 12 2 Tighten the upper holder bolts Torque 5 N m 0 5 kg m 3 6 ft lb Adjust the handlebar straight ahead by tap the end of han dlebar Make sure that the length A and Bare equal Tighten the lower holder nuts Torque 27 N m 2 7 kg m 20 ft lb Tighten the upper holder bolts page 12 2 Torque 23 N m 2 3 kg m 17 ft lb Make sure that the length A and B are equal 12 14 ...

Page 149: ...ing agent Any attempt to mount automobile tires on a motorcycle rim may cause the tire bead to separate from the rim with enough explosive force to cause serious injury or death When servicing the rear wheel support the motorcycle using a safety stand or hoist Refer to the section 14 for brake system information Tubeless tire removal repair and remounting procedures are covered in the section 16 o...

Page 150: ...Rear Wheel Suspension Rear Wheel Removal Installation 15 18 12 c93 9 3 63 9 10 13 2 ...

Page 151: ...or hoist Adjust the drive chain free play after installing the wheel Apply thin layer of grease to the rear axle surface Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Brake adjusting nut 1 2 Brake rod 1 3 Spring 1 4 Brake rod joint piece 1 5 Drive chain adjusting nut 2 Loosen the adjusting nut fully 6 Cotter pin 1 7 Nut 1 8 Washer 1 9 Rubber cushion 1 10 Br...

Page 152: ... 1 iiiiiiWt ...

Page 153: ...stalled into the wheel hub Replace wheel bearings as a set For wheel bearing replacement refer to the section 1 of the Common Service Manual Requisite Service _ Rear wheel removal installation page 13 2 Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Dust seal 1 At assembly apply grease to the dust seal lips Driven Flange Disassembly Order 2 Driven flange...

Page 154: ...or hoist Adjust the shock absorber to the softest position for disassembly Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Shock absorber mounting bolt upper 1 2 Plain washer 1 3 Shock absorber mounting bolt lower 1 NOTE Move the muffler outside remove the mounting bolt 4 Shock absorber assembly 1 13 6 ...

Page 155: ...r shock absorber removal installation page 13 6 Procedure O ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Upper seat 1 See page 13 8 2 Spring cover 1 3 Spring 1 Install the spring with the small coil end toward the bottom 4 Preload adjuster 1 5 Damper unit assembly 1 13 7 ...

Page 156: ...Loosen the shock absorber compressor slowly and remove the shock absorber Remove the spring cover and shock absorber spring Install the spring with the small coil end toward the bot tom Install the spring cover Install the special tools and compress the shock absorber spring Install the spring seat securely Is TOOL I Shock absorber compressor 07959 3290001 Loosen the shock absorber compressor slow...

Page 157: ...Loosen the shock absorber compressor slowly and remove the shock absorber Remove the spring cover and shock absorber spring Install the spring with the small coil end toward the bot tom Install the spring cover Install the special tools and compress the shock absorber spring Install the spring seat securely Is TOOL I Shock absorber compressor 07959 3290001 Loosen the shock absorber compressor slow...

Page 158: ...10 2 Procedure O ty Remarks Removal Order Installation is in the reverse order of removal 1 Frame pivot lock bolt j Adjustment page 13 10 2 Frame pivot lock nut 3 Frame pivot adjusting bolt 4 Drive chain cover 1 5 Shock absorber lower mounting bolt 2 NOTE Move the muffler outside remove the mounting bolts 6 Cap 2 7 Swingarm pivot nut 1 8 Swingarm pivot bolt 1 9 Swingarm assembly 1 13 9 ...

Page 159: ...TE Remove the lock mit while holding the adjusting bolt Remove the adjusting bolt Installation Tighten the adjusting bolt Torque 15 N m 1 5 kg m 11 ft lb Tighten the lock nut while holding the adjusting bolt Torque 64 N m 6 4 kg m 46 ft lb Tighten the pivot lock bolt Torque 39 N m 3 9 kg m 28 ft lb 13 10 1 LOCK NUT 1 ADJUSTING BOLT ...

Page 160: ... page 13 9 Procedure Q ty Remarks Disl ssembly Order Assembly is in the reverse order of disassembly 1 Cotter pin 1 2 Nut 1 3 Plain washer 1 4 Rubber cushion 1 5 Brake stopper arm 1 6 Drive chain slider screw 2 7 Drive chain slider 1 8 Right pivot collar 1 9 Left pivot collar 1 10 Dust seal 2 Apply grease to the lip 1 1 Distance collar 1 12 Needle bearing 1 13 Snap ring 1 Install it into the groov...

Page 161: ...Driver Pilot 15 mm Attachment 30 mm 07GMD KT70200 07946 MJ00100 M967X 038 XXXX 07949 3710001 07746 0040300 07746 0030300 Press the needle bearing into the swingarm with the marked side facing out NOTE The bearing surface should be flush with the pivot inside surface as shown iuooq Driver Attachment 28 x 30 mm Pilot 22 mm 07749 0010000 07946 1870100 07746 0041000 Press the ball bearing in until it ...

Page 162: ... fluid as they may not be compatible Always check brake operation before riding the motorcycle Troubleshooting Front Brake Brake Lever Soft Or Spongy Air bubbles in the hydraulic system Leaking hydraulic system Contaminated brake pad disc Worn caliper piston seal Worn master cylinder piston seal Worn brake pad disc Contaminated caliper Caliper not sliding properly Low fluid level Clogged fluid pas...

Page 163: ...caliper pistons against the pads after the pad replacement The brake pad replacement can be done without disconnecting the hydraulic system Always replace the brake pads in pairs to assure even disc pressure Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Pad pin plug 1 After removing the pad pin plug loosen the pad pin 2 Pad pin 1 Insert the pin pushing the ...

Page 164: ... painted plastic or rubber parts Place a rag over these parts whenever the system is serviced Requisite Service Front brake pad replacement page 14 2 Procedure Removal Order 1 Brake hose bolt 2 Sealing washer 3 Brake hose eyelet joint 4 Caliper bracket bolt 5 Front brake caliper assembly Q ty 1 2 1 2 1 Brake fluid replacement air bleeding Section 17 of the Common Service Manual Remarks Installatio...

Page 165: ...f disassembly 1 Pad spring 1 Note spring djrection as shown 2 Caliper bracket 1 3 Bracket pin bolt boot 1 4 Caliper pin bolt boot 1 Install into the bracket groove securely 5 Bracket pin bolt 1 At installation apply a locking agent to the threads 6 Caliper pin bolt 1 At installation apply a locking agent to the threads 7 Caliper piston 2 At installation install the piston with the dished end towar...

Page 166: ...Manual Procedure O ty Remarks Removal Order Installation is in the reverse of order of removal 1 Right rearview mirror 1 Loosen the mounting nut and remove the mirror 2 Front brake lever pivot bolt nut 1 1 3 Brake lever 1 4 Front brake hose bolt 1 5 Front brake hose 1 At installation press the hose end against the stopper while tightening the hose bolt 6 Sealing washer 2 7 Brake light switch conne...

Page 167: ...air bleeding Section 17 of the Common Service Manual Procedure O ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Reservoir cover 1 2 Diaphragm plate 1 3 Diaphragm 1 4 Brake light switch 1 5 Boot 1 6 Snap ring 1 CAUTION Be certain the snap ring is fully seated in the groove 7 Stopper plate 1 8 Master piston assembly 1 9 Spring 1 Install the spring with the small coil ...

Page 168: ... clean a contami nated drum with a high quality brake degreasing agent Requisite Service Rear wheel removal installation page 13 2 Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Brake arm pinch bolt 1 2 Brake arm 1 At installation align the punch marks on the brake cam and arm 3 Brake indicator 1 At installation align the wide tooth with the wide slot in...

Page 169: ...g 1 3 Brake rod joint piece 1 4 Brake pedal pivot bolt nut 1 1 5 Collar 1 6 Dust seal 2 7 Brake pedal linkage joint pinch bolt 1 Align the punch marks 8 Brake pedal linkage assembly 1 9 Cotter pin 2 10 Joint pin 2 11 Brake pedal linkage joint 1 12 Brake pedal 1 13 Brake light switch spring 1 14 Brake pedal return spring 1 15 Cotter pin 1 16 Joint pin 1 17 Brake rod linkage 1 18 Brake rod 1 14 8 ...

Page 170: ... replaced when it reaches the end of its service life CAUTION The battery caps should not be removed Attempting to remove the sealing caps from the cells may damage the battery Battery can be damaged if over charged or undercharged or if left to discharge for long periods These same condi tions contribute to shortening the life span of the battery Even under normal use battery performance deterior...

Page 171: ...Charging System Alternator System Location 1 BATIERY 3 REGULATOR RECTIFIER 4 ALTERNATOR 15 2 2 MAIN FUSE 30A 2 MAIN FUSE 30A lil 1 BATIERY 12 V 10 Ah R Red W White Y Yellow G Green ...

Page 172: ...for check the battery condition Measure the battery current leakage ampere leak test page 15 6 Standard 0 01 mA max Correct Inspect the regulated voltage page 15 6 Standard 14 15 5 V 3 000 rpm Not charging Incorrect Correct Check the regulator rectifier page 15 7 Incorrect Correct L Shorted wire harness Faulty ignition switch Faulty regulator rectifier Incorrect Correct l j Open circuit in wire ha...

Page 173: ...on Yellow Yellow Standard 0 1 1 0 0 Normal Check the regulator rectifier unit page 15 8 Abnormal 1 i Open circuit in wire harness Abnormal Abnormal Poorly connected connectors Check the charging coil resistance at the alter nator connector page 15 9 7 ________ m 1lf fWflP JI Connection Yellow Yellow Standard 0 1 1 0 0 Abnormal Normal L Poorly connected alternttor connector Open or short circuit in...

Page 174: ...ervice Seat removal installation page 2 2 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Battery holder band 1 2 Negative terminal r After installation apply clean grease to the cable end 3 Positive terminal battery terminals and bolts At installation pull the cover over the positive termi nal 4 Battery 1 15 5 ...

Page 175: ... Current Leakage 0 01 mA max If current leakage exceeds the specified value a shorted circuit is likely Regulated Voltage Ampere Inspection If the engine must be running to do some work make sure the area is well ventilated Never run the engine in an endosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death NOTE Before performing thi...

Page 176: ...t all the lights and the other electrical equipment should b OFF Use fully charged battery to make this test in order to get a correct measurement Regulated Battery terminals Charging current 14 15 5 V 3 000 rpm 0 0 5 A 3 000 rpm Regulator Rectifier System Inspection Remove the seat page 2 2 Disconnect the regulator rectifier connectors Check the connectors for loose or corroded terminal Measure t...

Page 177: ...pe 07308 0020001 SANWA Analogue type Select the following range SANWA x kO KOWA x 100 Using an old battery stored in the multimeter can cause inaccurate readings Check the battery if the multimeter resistance is incorrect When using the KOWA multimeter remember that all readings should be multiplied by 100 Replace the regulator rectifier unit if the resistance value between the terminals is abnorm...

Page 178: ...tor 3P connector Measure the resistance between the Yellow wire terminals and check for no continuity between each terminal and body ground Standard 0 1 1 0 n 20 C 68 F _ Replace the stator if the resistance is out of specification or if there is continuity between Yellow wire terminal and ground 1 ALTERNATOR 3P CONNECTOR 15 9 ...

Page 179: ...Charging System Alternator Alternator Removal Installation 5 15 10 7 012 1 2 9 20 30 mm 0 8 12 i t LIQUID SEALANT AREA ...

Page 180: ...lation page 2 2 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Alternator connector 1 2 Left crankcase cover bolt 6 3 Left crankcase cover 1 4 Gasket 1 5 Dowel pin 2 6 Stator wire holder 1 7 Stator mounting bolt 4 8 Stator assembly 1 At installation apply sealant to the grommet and install the grommet securely into the groove in the left crankcase cover Flyw...

Page 181: ... module ICM may be damaged if dropped Also if the connector is disconnected when current is present the excessive voltage may damage the unit Always turn off the ignition switch before servicing Ignition timing cannot be adjusted since the Ignition control module ICM is non adjustable If ignition timing is incorrect check the system components and replace any faulty parts A faulty ignition system ...

Page 182: ... 7 MAIN FUSE 30 A 13 NEUTRAL INDICATOR 6 CLUTCH SWITCH DIODE BI Br Lg BI I a 1 SIDE STAND INDICATOR DOWN 1 Y Bia 8 NEUTRAL t G SWITCH G W To Tachometer BI Yi r 1 1 1 IGNITION COILS 5 ICM CD SPARK 1111 PLUGS 16 2 UP 9 SIDE STAND SWITCH l GfW o G R iii iii 12 CLUTCH SWITCH 00 10 IGNITION PULSE GENERATOR Bl BLACK Y YELLOW Bu BLUE G GREEN R RED W WHITE Lg LIGHT GREEN ...

Page 183: ...t the ignition control module ICM connector with the igni tion switch ON and the engine stop switch at RUN page 16 8 Connection Black White Green Standard Battery voltage Battery voltage measured No voltage II l 1 l Faulty ignition switch or engine stop switch Open circuit in wire harness Loose or poor connector contact Measure the ignition pulse generator resis 1 A_b_n_o_r_m_a_l_ 1 Check the igni...

Page 184: ...en Black No continuity Normal I Faulty ignition control module ICM 16 4 Abnormal Abnormal Connection Light green Red Ground Standard Continuity in neutral No continuity in any gear Normal Abnormal I j Faulty neutral switch Open circuit in Light green Red wire Loose or poor neutral switch connector contacts Side stand up Green White Green Continuity Side stand down Yellow Black Green Continuity Nor...

Page 185: ...on control module ICM connec tor Connection No 1 3 Black White Black Yellow No 2 4 Black White Black Blue Standard 2 4 0 Normal Faulty ignition control module ICM No spark condition remains with the faulty pair Abnormal Remove the faulty ignition coils and check the ignition coil resistance page 16 8 Standard Primary 2 4 0 Between the plug caps 23 27 kO Between the spark plug wire 13 17 kO Abnorma...

Page 186: ...ark plug and conduct spark test No spark Standard 23 27 kO Abnormal Remove the spark plug cap and measure resistance of the ignition coil page 16 9 Standard 13 17 kO Normal Poor contact of spark plug cap Faulty spark plug cap Faulty spark plugs 16 6 Spark t N_o_r_m_a_l_ t Condact spark test on good ignition coil Abnormal Srk t ___ Faulty ignition coil ...

Page 187: ... the ignition control module ICM passes to ground via the side stand switch The ignition control module ICM monitors lines a and b and provides spark only when one or both of those lines is connected to ground via the neutral switch or the side stand switch Check the side stand indicator function Normal 1 Open circuit in Green White wire Abnormal Normal Check for continuity between each terminal o...

Page 188: ...tor Black Yellow Black White coil Neutral switch line Black Light green Body ground Side stand switch line Black Green Black Ground line Green Body ground Ignition Coil Inspection Measure the primary coil resistance between the termi nals Standard 2 4 0 Measure the resistance between the spark plug caps Standard 23 27 kO 16 8 1 CONNECTOR Standard Battery voltage should register with the ignition s...

Page 189: ...to page 16 11 for ignition pulse generator replace ment Ignition Coil Removal Installation Front Remove the air cleaner housing page 5 3 Remove the spark plug caps from spark plugs Disconnect the ignition coil primary wires from the coil Remove the ignition coil mounting bolts and front ignition coil Installation is in the reverse order of removal Rear Remove the seat and left side cover page 2 2 ...

Page 190: ...on coils Installation is in the reverse order of removal Ignition Control Module ICM Removal Installation Remove the battery case mounting bolts Move the battery case left ward and disconnect the igni tion control module ICM connector Remove the ignition control module ICM Installation is in the reverse order of removal 16 10 2 PRIMARY WIRES 3 IGNITION COIL 2 BATTERY CASE ...

Page 191: ...stallation is in the reverse order of removal 1 Ignition pulse generator connector 1 2 Oil pressure switch terminal 1 3 Ignition pulse generator wire grommet 1 At installation apply sealant to the wire grommet and install the into the rotor cover groove securely 4 Ignition pulse generator mounting bolt 3 5 Ignition pulse generator assembly 1 Route the ignition pulse generator wire as shown 6 Dowel...

Page 192: ...sed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death Stop the engine and remove the timing hole cap Connect a timing light to the spark plug wire Start the engine and let it idle The timing is correct if the F mark aligns with the index mark on the right crankcase cover Increase the engine speed by rotating the throttle stop screw k...

Page 193: ... current If current is applied to the starter motor while the engine is not turning over the starter motor may be damaged For the following components inspections refer to the Common Service Manual or the following pages for the parts locations see page 17 2 of this manual System Location Component Inspection method Remarks Clutch switch diode Section 24 of the Common Service Manual Starter motor ...

Page 194: ...ELAY SWITCH MAIN FUSE 30 A 10 IGNITION SWITCH 4 BATTERY 3 FUSE 15 A 12 NEUTRAL INDICATOR 13 SIDE STAND INDICATOR h 91 STARTER MOTOR 6 MAIN 3 FUSE 10 A FUSE 30A L 121 STARTER SWITCH 3 1 ENGINE ST0 5 CLUTCH SWITCi 1 1 CLUTCH SWITCH DIODE Lg 81 1 1 TI I G R R o 1 Lg R 8 NEUTRAL SWITCH UP DOWN j_ V Bl BLACK y YELLOW w 7 SSWIDEITCSTHAND L Y B I Bu BLUE G GREEN R RED W WHITE Lg LIGHT GREEN 17 2 ...

Page 195: ...dicated the chart below Gear Position Side Stand Clutch Lever Starter Motor Up In Any Gear Down Starter motor will not turn Check for loose or poorly connected battery terminals and opened or shorted battery cable Normal Check for loose or poorly connected starter relay switch terminals and 4P connector Normal j Pulled in Operates Released Does Not Operate Pulled in Does Not Operate Released Does ...

Page 196: ...il ground line as below for continuity 1 Green Red terminal to clutch switch diode to neutral switch line with transmission into neutral and clutch lever released 2 Green Red terminal to clutch switch to side stand switch line in any gear except neu tral and with the clutch lever pulled in and the side stand up Continuity 17 4 Because a large amount of current flows do not use thin wires Starte l ...

Page 197: ...sters Remove the starter relay switch 1 N_o_rm_a_l Loose or poor contact of the starter relay Connect a fully charged 12 V battery to the switch connector starter relay switch Check the continuity between the switch large terminal Battery Connection Yellow Red Green Red Standard Continuity Abnormal r Faulty starter relay switch Starter motor turns when the transmission is in neutral but does not t...

Page 198: ...battery Poorly connected battery terminal cable Poorly connected starter motor cable Faulty starter motor Starter motor turns but engine does not turn Starter motor is running backward Case assembled improperly Terminals connected improperly Faulty starter clutch Damaged reduction gear Starter relay switch clicks but engine does not turn over Crankshaft does not turn due to internal mechanical eng...

Page 199: ...ing the starter motor NOTE J Route the wire and cables properly page 1 20 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Flange nut 1 After installation install the rubber cap 2 Starter motor cable eyelet 1 3 Starter motor mounting bolt 2 4 Starter motor 1 Disassembly page 17 8 5 0 ring 1 Apply oil when installing 17 7 ...

Page 200: ...Electric Starter Starter Clutch Starter Motor DisassemblyIAssembly 16 3 4 5 ALIGN 17 8 ...

Page 201: ...nt cover 1 Align the index marks on the front cover and case 3 Lock washer 1 4 0 ring 1 5 Motor case 1 Align the index marks on the rear cover and case 6 Insulated washer 1 7 Washer 1 8 Armature 1 9 Brush terminal holding nut 2 10 Washer 1 11 Insulated washer 3 12 0 ring 1 13 Brush holder assembly 1 Align the holder tab with the rear cover groove 14 Brush and terminal 1 15 0 ring 1 16 Rear cover 1...

Page 202: ...Electric Starter Starter Clutch Starter Clutch Removal Installation WIDE GROOVE 1 n 9o 9 o ss ls Tooq page 17 11 17 10 ...

Page 203: ...100 as shown Apply clean engine oil to the threads 2 Washer 1 3 Starter clutch assembly 1 Disassembly assembly page 17 12 At installation align the wide groove with the wide tooth of the crankshaft 4 Needle bearing 1 5 Primary drive gear guide 1 6 Starter reduction gear shaft 1 7 Starter reduction gear washer 1 1 8 Primary drive gear assembly 1 NOTE When primary drive gear removaVinstallation alig...

Page 204: ...r Assembly is in the reverse order of disassembly 1 Starter driven gear 1 Rotate clockwise when installing 2 Starter clutch outer cover bolt 3 Apply a locking agent to the threads at installation 3 Starter clutch outer cover 1 Align the pin on the outer with the hole of the cover when installing 4 Roller 3 Be careful not to pop them out 5 Plunger 3 6 Spring 3 7 Starter clutch outer 1 17 12 ...

Page 205: ...h alcohol Be sure to install the dust cover after replacing the bulb All plastic connectors have locking tabs that must be released before disconnecting and must be aligned and engaged fully when reconnecting Always turn off the ignition switch before disconnecting any electrical component A continuity test can be made with switches installed on the motorcycle Check the battery condition before pe...

Page 206: ...Lights Meters Switches System Location 18 2 1 FRONT BRAKE LIGHT SWITCH 7 SIDE STAND SWITCH 5 FUSE BOX ...

Page 207: ...t temperature indicator 1 c_o_m_e_s_o_n__ connectors Turn the ignition switch ON Indicator does not come on Connect the coolant temperature indicator connectors Disconnect the thermo sensor connector and turn the ignition switch ON Check the coolant temperature indicator oper ation Abnormal Normal Short circuit in Light green Black wire Faulty thermo sensor page 1 11 Faulty coolant temperature ind...

Page 208: ...ch ON Indicator come on Check the coolant temperature indicator 4P 1 A_b_n_orm_a_l connector and body ground for continuity Normal Check the voltage between the coolant tem 1 __A_b_no_r_m_a_l perature indicator 4P connector and body ground turn the ignition switch ON Normal 18 4 Blown indicator bulb Open circuit in Light green Black wire Open circuit in Green wire Open circuit in Black Brown wire ...

Page 209: ...he headlight bulb Installation is in the reverse order of removal NOTE Install the dust cover with its TOP mark facing up Tail Brake Light Bulb Remove the screws and tail brake light lens Remove the tail brake light bulb by turning it counterclock wise Install a new bulb in the reverse order of removal Turn Signal Light Bulb Remove the screw and turn signal light lens Remove the turn signal light ...

Page 210: ...pecified by local laws and regulations After installation route the wires and cable properly page 1 20 Requisite Service Upper fairing removal installation VF750CD page 2 8 Procedure O ty Remarks Removal Order Installation is in the reverse order of removal 1 Screw 2 2 Headlight connector 1 3 Headlight assembly 1 4 Headlight case bolt nut 2 2 5 Upper fairing stay 1 VF750CD only 6 Headlight case 1 ...

Page 211: ...side cover removal installation page 2 3 Upper fairing removal installation VF750CD page 2 8 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Speedometer cable 1 2 Combination meter connector 3 3 Combination meter mounting bolt guide 2 2 4 Combination meter assembly 1 Disassembly Assembly page 18 8 18 7 ...

Page 212: ...Pull the indicator bulbs out of the meter Remove the wire harness clamp Disconnect the meter terminals and remove the wire har ness Separate the meter rear covers and meter stay Assemble the meters in the reverse order of disassembly NOTE Connect the proper color wire to the meter termi nals V G Yellow Green G Green 18 8 1 REAR COVERS ...

Page 213: ... for continuity between each color of wire terminal as shown in the chart below There should be continuity between the 0 0 positions on the following chart under the conditions shown here Green White Yellow Black Green Side stand up Side stand r down Removal Installation Disconnect the side stand switch 3P Green connector Remove the side stand switch mounting bolt and side stand switch Install the...

Page 214: ...Chapter 19 is the wiring diagram It is a fold out in the manual so the two parts will need to be printed and pasted together if needed ...

Page 216: ...ADLIGHT r I I 94 95 only 12Y32 3CP Gl 1 94 95 only LEFT REAR TURN SIGNAL 12Y32CP 15A FRONT REAR BRAKE TURN SIGNAL HORN OIL NEUTRAL TAIL METER LIGHT Bl BLACK 8r BROWN YELLOW 0 ORANGE Ill BLUE Lb LIGHT BLUE G GREEN 1 4 LIGHT GREEN RED p PINK STARTERMOTOA WHITE Gr GRAY 0030Z MZ5 6700 19 1 ...

Page 217: ...t were made when the bolt was tightened first time The standard bolt is applicable to the female threads that were made by means of the plastic deformation during tightening the CT bolt The service replacement parts of the parts tightened with the CT bolts have the threads When the CT bolt replacement is required use new CT bolt or Honda genuine standard bolt length CAUTION I Do not use the length...

Page 218: ...Possible Cause Clogged fuel tube or fuel strainer screen Sticking float valve Clogged fuel tank breather tube Disco lnected or faulty auto fuel valve vacuum tube Faulty spark plugs Fouled spark plugs Faulty ICM Broken or shorted spark plug wires Broken or shorted ignition coils Faulty ignition switch Faulty ignition pulse generator Faulty engine stop switch Loose or disconnected ignition system wi...

Page 219: ... Valve Train Lubricate Properly 21 2 Drive chain too tight Pressure Low Faulty tire valve Engine Speed Not Changed Clutch slipping When Clutch Is Released Worn clutch discs plates Engine Speed Does Not Increase Incorrect Too Low Clogged Fouled Or Discolored Incorrect Valve Train Not Lubricate Properly Warped clutch discs plates Weak clutch spring Carburetor chock closed Clogged air cleaner Restric...

Page 220: ...utch slipping Lean fuel mixture Wrong type of fuel Worn piston and cylinder Wrong type of fuel Excessive carbon built up in com bustion chamber Ignition timing too advanced Faulty ICM Lean fuel mixture Possible Cause Improper ignition timing Faulty ICM See Fuel System section Loose insulator clamps Damaged insulator 4 Perform spark test Weak Or Intermittent Spark Faulty carbon or wet fouled spark ...

Page 221: ... 2 If either wheel is wobbling 3 If the motorcycle pulls to one side 21 4 Possible Cause Faulty ICM Faulty ignition pulse generator Clogged fuel line Clogged fuel tank breather Clogged fuel strainer screen Clean Cam sprocket not installed properly Faulty spring Possible Cause Steering stem adjusting nut too tight Damaged steering head bearings Excessive wheel bearing play Bent rim Improperly insta...

Page 222: ...lation 18 6 High Altitude Adjustment U S A Only 5 17 Ignition Coil Inspection 16 8 Removal Installation 16 9 22 1ndex Ignition control Module ICM Removal Installation 16 10 Ignition Pulse Generator Inspection 16 9 Removal Installation 16 11 Ignition Switch Replacement 18 9 Ignition System Inspection 16 8 Ignition Timing 16 12 Liquid Sealant Application 11 18 Lubrication Seal Points 1 17 Lubricatio...

Page 223: ...e Does Not Start Or Is Hard To Start Engine Lacks Power Frame Body Panels Exhaust System Front Wheel Suspension Steering Fuel System Gearshift Linkage Ignition System LightS Meters Switches Lubrication System Poor Handling Poor Performance At High Speed Poor Performance At Low And Idle Speeds Rear Wheel Suspension Upper Fairing Removal Installation VF750CD Valve Clearance Water Pump Removal Instal...

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