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Содержание VF1000F 1985

Страница 1: ...http honda vf1000 com The data contained in this file is for non commercial use only No warranties express or implied are given for the accuracy of this material...

Страница 2: ...VFl OOOF VF 1 OOOFL II...

Страница 3: ...u de rendre son utilisation peu sure On comprendra par ailleurs que ces avertissements ne peuvent couvrir toutes les fayons de proceder aune revision que celle ci soit recommandee par Honda ou non ni...

Страница 4: ...ost sections start with an assembly or system ill ustra tion service information and troubleshooting for the section The subsequent pages give detailed procedures_ If you don t know the source of the...

Страница 5: ...which can be highly explosive Do not smoke or allow flames or sparks near the battery especially while charging it 1 Use genuine HONDA or HONDA recommended parts and lubricants or their equivalent Par...

Страница 6: ...de of the steering head 3 CARBURETOR ID ENTIF ICATION NUMBER The carburetor identification number is stamped on the left side of the carburetor body 1 2 VF1000F 1 1 r _ _ 2 ENGINE SERIAL NUMBER The en...

Страница 7: ...pacity 4 liters 1 1 US gal 0 9 Imp gal Caster angle 29 Trail length 116 mm 4 6 in Front fork oil capacity Right 455 em3 15 4 US oz 16 0 Imp oz Left 475em3 16 1 USoz 16 7Impoz ENGINE Type Water cooled...

Страница 8: ...1 888 F inal reduction 2 529 Gear ratio I 2 733 Gear ratio II 1 894 Gear ratio III 1 500 Gear ratio IV 1 240 Gear ratio V 1 037 Gearshift pattern Left foot operated return system l N 2 3A 5 ELECTRICAL...

Страница 9: ...4 Oil fHter 1 20 15 20 11 5 2 0 11 14 Countershaft bearing holder 3 8 21 25 12 1 2 5 15 18 Drive sprocket 1 10 50 54 1 5 0 5 4 36 39 Valve adjustment nuts 16 7 21 25 1 2 1 2 5 15 18 Drain plug 1 12 35...

Страница 10: ...35 45 13 5 4 5 25 331 bolts Handlebar pinch bolts 2 8 30 40 3 0 4 0 22 291 Rear brake actuat ing arm 1 6 10 15 1 0 1 5 7 11 Side stand 1 10 35 45 3 5 4 5 25 331 Engine rear hanger bolts lupperl 1 10 6...

Страница 11: ...ocket 07916 3710100 Steering stem removal installation 15 24 15 26 Bearing race remover 07946 3710500 Ball race removal 15 25 Ball race remover 07953 4250002 Ball race removal 15 24 15 25 Steering ste...

Страница 12: ...n 07716 0020500 installation Bearing remover shaft 07746 0050100 Front wheel bearing removal 15 8 Rear wheel bearing removal 16 5 Bearing remover head 15 mm 07746 0050400 Front wheel bearing removal 1...

Страница 13: ...ube if they contact a sharp edge or corner Clean the attaching surface thoroughly before applying tape Do not use a wire or harness with a broken insulator Repair by wrapping them with protective tape...

Страница 14: ...GENERAL INFORMATION 1 VF1000F MODEL 2 TH ROTTlE CAB lES 4 WATER HOSES 6 CHClKE CABLE 5 RADIATOR OVERFLOW TUBE 71 CLUTCH HOSE 9 FRONT BRAKE HOSE 81 SPEEDOMETER CABLE 1 10...

Страница 15: ...GENERAL INFORMATION 1 VF1000F 1I MODE L 2 RADIATOR OVER FLOW TUBE 4 FRONT BRAKE HOSE 6 WATER HOSES CAB LE 9 CLUTCH HOSE 7 SPEEDOMETER CABLE 11 FRONT BRAKE HOS 10 01 L HOSE 1 11...

Страница 16: ...6 CHOKE CABLE 7 SPEEDOMETER CABLE i 8 THERMOSTATIC SWITCH 10 VF1000V 11 MODEL 9 HEAD GHT COUPLER 13 CLUTCH HOSE 14 CHOKE CAB LE 18 DIMMER RELAY 15 SPEEDOMETER CABLE DUAL HEADLIGHT MODEL ONLY 17 HEADL...

Страница 17: ...MAIN FUSE 7 COO RESERVE TANK 5 PULSE GENERATOR WIRE BREATHER TUBE 8 BATTERY BREATHER TUBE 6 STARTER MOTOR CABLE 10 RADIATOR OVERFLOW TUBE 12 CRANKCASE BREATHER HOSES 11 FUEL LINES 14 TU N SIGNAL RELAY...

Страница 18: ...FRONT CYLINDER EXHAUST CAMSHAFT 2 FRONT CYLINDER INTAKE CAMSHAFT 13 VF1000F 1 1 only __ __ I 3 OIL COOLER II 4 TO OIL PAN I 12 OIL FILTER 2 0 I 5 TO REAR CYLINDER I 10 OIL PUMP 11 OIL STRAINER 8 MAIN...

Страница 19: ...u de rendre son utilisation peu sure On comprendra par ailleurs que ces avertissements ne peuvent couvrir toutes les fayons de proceder aune revision que celle ci soit recommandee par Honda ou non ni...

Страница 20: ...t section Most sections start with an assembly or system illustra tion service information and troubleshooting for the section The subsequent pages give detailed procedures If you don t know the sourc...

Страница 21: ...which can be highly explosive Do not smoke or allow flames or sparks near the battery especially while charging it 1 Use genuine HONDA or HONDA recommended parts and lubricants or their equivalent Par...

Страница 22: ...de of the steering head 3 CARBURETOR ID ENTIF ICATION NUMBER The carburetor identification number is stamped on the left side of the carburetor body 1 2 VF1000F 1 1 r _ _ 2 ENGINE SERIAL NUMBER The en...

Страница 23: ...pacity 4 liters 1 1 US gal 0 9 Imp gal Caster angle 29 Trail length 116 mm 4 6 in Front fork oil capacity Right 455 em3 15 4 US oz 16 0 Imp oz Left 475em3 16 1 USoz 16 7Impoz ENGINE Type Water cooled...

Страница 24: ...1 888 F inal reduction 2 529 Gear ratio I 2 733 Gear ratio II 1 894 Gear ratio III 1 500 Gear ratio IV 1 240 Gear ratio V 1 037 Gearshift pattern Left foot operated return system l N 2 3A 5 ELECTRICAL...

Страница 25: ...4 Oil fHter 1 20 15 20 11 5 2 0 11 14 Countershaft bearing holder 3 8 21 25 12 1 2 5 15 18 Drive sprocket 1 10 50 54 1 5 0 5 4 36 39 Valve adjustment nuts 16 7 21 25 1 2 1 2 5 15 18 Drain plug 1 12 35...

Страница 26: ...35 45 13 5 4 5 25 331 bolts Handlebar pinch bolts 2 8 30 40 3 0 4 0 22 291 Rear brake actuat ing arm 1 6 10 15 1 0 1 5 7 11 Side stand 1 10 35 45 3 5 4 5 25 331 Engine rear hanger bolts lupperl 1 10 6...

Страница 27: ...ocket 07916 3710100 Steering stem removal installation 15 24 15 26 Bearing race remover 07946 3710500 Ball race removal 15 25 Ball race remover 07953 4250002 Ball race removal 15 24 15 25 Steering ste...

Страница 28: ...n 07716 0020500 installation Bearing remover shaft 07746 0050100 Front wheel bearing removal 15 8 Rear wheel bearing removal 16 5 Bearing remover head 15 mm 07746 0050400 Front wheel bearing removal 1...

Страница 29: ...ube if they contact a sharp edge or corner Clean the attaching surface thoroughly before applying tape Do not use a wire or harness with a broken insulator Repair by wrapping them with protective tape...

Страница 30: ...GENERAL INFORMATION 1 VF1000F MODEL 2 TH ROTTlE CAB lES 4 WATER HOSES 6 CHClKE CABLE 5 RADIATOR OVERFLOW TUBE 71 CLUTCH HOSE 9 FRONT BRAKE HOSE 81 SPEEDOMETER CABLE 1 10...

Страница 31: ...GENERAL INFORMATION 1 VF1000F 1I MODE L 2 RADIATOR OVER FLOW TUBE 4 FRONT BRAKE HOSE 6 WATER HOSES CAB LE 9 CLUTCH HOSE 7 SPEEDOMETER CABLE 11 FRONT BRAKE HOS 10 01 L HOSE 1 11...

Страница 32: ...6 CHOKE CABLE 7 SPEEDOMETER CABLE i 8 THERMOSTATIC SWITCH 10 VF1000V 11 MODEL 9 HEAD GHT COUPLER 13 CLUTCH HOSE 14 CHOKE CAB LE 18 DIMMER RELAY 15 SPEEDOMETER CABLE DUAL HEADLIGHT MODEL ONLY 17 HEADL...

Страница 33: ...MAIN FUSE 7 COO RESERVE TANK 5 PULSE GENERATOR WIRE BREATHER TUBE 8 BATTERY BREATHER TUBE 6 STARTER MOTOR CABLE 10 RADIATOR OVERFLOW TUBE 12 CRANKCASE BREATHER HOSES 11 FUEL LINES 14 TU N SIGNAL RELAY...

Страница 34: ...FRONT CYLINDER EXHAUST CAMSHAFT 2 FRONT CYLINDER INTAKE CAMSHAFT 13 VF1000F 1 1 only __ __ I 3 OIL COOLER II 4 TO OIL PAN I 12 OIL FILTER 2 0 I 5 TO REAR CYLINDER I 10 OIL PUMP 11 OIL STRAINER 8 MAIN...

Страница 35: ...US qt 2 55 Imp qt after draining VF1000F 11 3 7 liters 3 9 US qt 3 3 Imp qt after disassembly 3 0 liters 3 2 US qt 2 64 Imp qt after draining Oil recommendation OIL VISCOSITIES Use HONDA 4 STROKE 01...

Страница 36: ...ft Ib 10 14 N m 1 0 1 4 kg m 7 10 ft Ib 10 14 N m 1 0 1 4 kg m 7 10 ft Ib 07506 3000000 07510 4220100 07912 6110001 Oil or filter not changed often enough Head gasket faulty Worn piston rings Low oil...

Страница 37: ...pressure with the oil pressure warning light The light should go off within 2 3 seconds after the engine starts If it does not stop the engine and check the oil pump oil circuit and or oil pressure sw...

Страница 38: ...filler cap dipstick Start the engine and let it idle for 2 3 minutes then stop the engine Make sure that the oil level is at the upper level mark on the dipstick Make sure that there are no oil leaks...

Страница 39: ...ndition and install the oil strainer aligning its groove with the lug on the oil strainer tube pipe On VF1000F 11 model make sure that the O ring on the oil pump of the oil cooler circuit is in good c...

Страница 40: ...lant or equivalent to the pressure switch threads and install TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft lb Connect the oil pressure swtich wire Start the engine and check the oi pressure warning light The...

Страница 41: ...d with the engine mounted in the frame Drain the engine oil Remove the clutch cover Remove the oil pump driven sprocket by removing the bolt and washer Remove the oil pan page 2 4 Remove the oil strai...

Страница 42: ...cotter pin and the oil strainer tube from the oil pump body_ DISASSEMBLY Oil cooler pump VF1000F 1I model only Remove the oil cooler pump cover Remove the dowel pin inner and outer rotors from the pum...

Страница 43: ...dy Measure the rotor tip clearance SERVICE LIMIT 0 20 mm 0 008 in Measure the pump body clearance SERVICE LIMIT 0 35 mm 0 014 in On VFl OOOF II model remove the oil cooler pump page 2 8 Remove the rot...

Страница 44: ...rotor with the drive pin Install the dowel pin and the pump body cover 6 1 i TER ROTOR I 5 ROTOR SHAFT MP BODY 4 DRIVE PIN 2 BODY COVER Oil cooler pump VF1000F 1I model only 2 DOWEL PIN Insert the dr...

Страница 45: ...ghten the three mounting bolts Make sure that the oil pump shaft rotates freely On VF1000F 11 model install the O ring and collar onto the oil cooler pump outlet making sure that the D ring is in good...

Страница 46: ...m off with low pressure water Carefully straighten any bent fins REMOVAL Drain the engine oil page 2 3 Disconnect the oil inlet and outlet hoses at the elbows by removing the four bolts Remove the two...

Страница 47: ...I 4 SHOCK ABSORBER MOUNT BUSH INGS Page 16 12 I I I I 1 THROTTLE AND CHOKE CABLE Ii3ijijffi 18 STEERING HEAD BEARI NG i 17 FRONT FORK 16 SILICONE CALIPER PIVOT Ii3ijijffi I I I I I 15 SPEEDOMETER I DR...

Страница 48: ...STEM HOSES CONNECTIONS 3 10 SERVICE INFORMATION ERAL 1gine oil See page 2 3 9ine oil filter See page 2 3 _ __ port the motorcycle on the center stand on a level surface before starting any work En the...

Страница 49: ...n for SW and optional for other models TORQUE VALUES Front 100 90V18 V250 250 2 50 36 250 2 50 36 G531 K500 Valve adjusting screw lock nut Rear axle nut 21 25 N m 2 1 2 5 kg m 15 18 ft lb 85 105 N m 8...

Страница 50: ...M SlOE STAND SUSPENSION UTS BOLTS FASTENERS HEELS STEERING HEAD BEARINGS NOTE 1 NOTE 2 YEAR R Y EAR R MONTH MONTH I 2 YEARS R MONTH I 2 YEARS oR C R R C C C R R R R R R I L EV ERY 1 000 km 600 mi I I...

Страница 51: ...the fuel filter with a new one when indicated by the maintenance schedule page 3 3 Remove the seat and left frame side cover Disconnect the regulator rectifier and alternator wire couplers and neutral...

Страница 52: ...ir cleaner case Adjust by loosening the lock nut and turning the adjuster Tighten the lock nut and recheck throttle operation Install the air cleaner case and fuel tank and check throttle free paly on...

Страница 53: ...CLEANER Remove the fuel tank Remove the air cleaner case cover screws and the cover Remove the spring clip and the air cleaner element Discard the element in accordance with the maintenance schedule...

Страница 54: ...ing by hand until the spark plug bottoms Then tighten the spark plugs another 1 2 turn with a spark plug wrench to compress the plug washer Connect the spark plug caps VALVE CLEARANCE NOTE Inspect and...

Страница 55: ...ag on both feeler gauges Both feeler gauges should remain inserted during adjustment Hold the adjusting screws and tighten the lock nuts TORUQE 21 25 N m 2 1 2 5 kg m 15 18 fHb CAUTION The lock nuts w...

Страница 56: ...VF1 OOOF il model remove the under cowl page 14 1 Remove the plugs from the No 1 2 3 and 4 cylinder head ports and install the vacuum gauge adapters Connect the vacuum gauges Start the engine and adj...

Страница 57: ...rating temperature The level should be between the UPPER and LOWER level lines If necessary remove the reserve tank cap and fill to the UPPER level line with a 50 50 mixture of distilled water and ant...

Страница 58: ...mber and or the piston crown DRIVE CHAIN Turn the engine off place the motorcycle on its center stand and shift the transmission into neutral Check slack in the drive chain lower run midway between th...

Страница 59: ...or the replacement chain or sprockets will wear rapidly Lubrication and cleaning The drive chain on this motorcycle is equipped with small O rings between the link plates The O rings can be damaged b...

Страница 60: ...and fill the reservoir to the upper level mark with DOT 4 brake fluid from a sealed container Check the entire system for leaks if the level is low CAUTION Do not remove the reservoir cap until the ha...

Страница 61: ...ning the adjusting nut Do not turn the switch body Turn the adjusting nut clockwise if the brake light comes on too late HEADLIGHT AIM NOTE Adjust the headlight beam as specified by local laws and reg...

Страница 62: ...tand Check the rubber pad on the side stand for deterioration and wear Replace the rubber pad if wear extends to the wear line NOTE When replacing use a rubber pad with the mark Over 260 Ibs ON LY Che...

Страница 63: ...rmly applying the brakes Position Anti dive damper force 1 LIGHT ANTI DIVE 2 MEDIUM 3 HARD 4 MAXIMUM ANTI DIVE Inspect and jf necessary repair the system Refer to section 15 REAR Place the motorcycle...

Страница 64: ...shOUld be checked when tires are COLD Check the tires for cuts imbedded nails or other sharp Objects RECOMMENDED TIRES AND PRESSURES Front Rear Tire size 100 90V1B 140 BOV17 V250 V250 140 BOVR17 V250...

Страница 65: ...ot interfere with handlebar rotation Raise the front wheel off the ground and check that the handlebar rotates freely If the handlebar moves unevenly binds or has vertical movements adjust the steerin...

Страница 66: ...i j i j FUEL SYSTEM CIRCUIT D ESSENCE KRAFTSTO FFSYSTEM 4 0...

Страница 67: ...e locations of the O rings Replace them with new ones on reassembly The float bowls have drain screws that can be loosened to drain residual gasoline Fuel pump inspection is in section 21 The No 1 and...

Страница 68: ...incorrect Incorrect carburetor synchronization Carburetor faulty Fuel contaminated Misfiring during acceleration Ignition system faulty Backfiring Ignition system faulty Carburetor faulty Poor perform...

Страница 69: ...ne at the fuel tank outlet tube Disconnect the fuel level sensor wire coupler Remove the two fuel tank mounting bolts and fuel tank Turn the fuel valve ON and drain the fuel into a clean container Che...

Страница 70: ...attaching screws and the air cleaner case Check the air cleaner case seal rubbers for deterioration or damage Install the air cleaner case in the reverse order of removal CRANKCASE VENTILATION SYSTEM...

Страница 71: ...chamber by removing the three bolts Disconnect the fuel line Loosen all carburetor insulator bands and remove the carburetor assembly from the intake pipes Remove the insulator plate from the carburet...

Страница 72: ...cks scratches or other damage Make sure the piston moves up and down freely in the chamber NOTE No 1 and No 3 carburetors use thinner jet need les and shorter springs than the No 2 and No 4 carburetor...

Страница 73: ...h the hole in the carburetor and secure with at least two screws before releasing the vacuum piston NOTE Be sure t he thinner jet needles and shorter springs are installed in the No 1 and No 3 carbure...

Страница 74: ...order of disassembly PILOT SCREW REMOVAL NOTE The pilot screws are factory pre set and should not be removed unless the carburetors are overhauled Turn each pilot screw in and carefully count the numb...

Страница 75: ...screws in the other carburetors for proper pilot screw adjustment CARBURETOR SEPARATION Remove the No l to No 2 carburetor attaching screw and No 3 to No 4 carburetor attaching screw Remove the screws...

Страница 76: ...prevent damage to the joint pipes Disconnect the throttle link from the No 3 and 4 caburetors by removing the cotter pins Carefully separate the No 3 and No 4 carburetors Remove the choke arm collar...

Страница 77: ...while hooking the arm to the groove in the choke valve Install the choke arm collar Coat the new O rings with oil and install them on the fuel jOint pipe for No 3 and No 4 carburetors Install the fuel...

Страница 78: ...pes Loosen the synchronization adjusting screws until there is no tension Install the synchronization springs Install the thrust springs between the throttle valve shafts Make sure the fuel joint and...

Страница 79: ...the air chamber over the carburetors aligning the dowel pins with the carburetor holes Attach the air chamber to the carburetors with the eight screws Install the No to No 2 carburetor attaching scre...

Страница 80: ...on page 3 5 Carburetor choke page 3 51 Carhuretor ole speE O Ipage 3 10 Carburetor synchroniZJt on page 3 9 PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE NOTE The pilot screws are factory pre set and no...

Страница 81: ...screw 11 Perform steps 8 9 and 10 for the No 2 3 and 4 carburetor pilot screws FUEL PUMP REMOVAL INSTALLATION Do not allow flames or sparks near gasoline Wipe up spilled gasoline at once Remove the se...

Страница 82: ...Ib 8 35 45 N m 3 5 4 5 kg m 25 33 ft Ib 35 45 N m 3 5 4 5 kg m 25 33 ft Ib l 1 VF1000F 1i MODEL 5 0 60 70 N m 24 30 N m 2 4 3 0 kg m 17 22 ft Ib 6 0 7 0 kg m 43 51 ft Ib f 26 32 N m 50 54 N m 5 0 5 4...

Страница 83: ...silicone wax Apply a heat resist and black paint if the black chrome plating is scratched or scored SPECIFICATIONS Engine dry weight Oil capacity TORQUE VALUES Drive sprocket bolt n9ine rear upper han...

Страница 84: ...e the following components carburetor page 4 5 main radiator page 6 6 auxiliary radiator VF1000F 11 model only page 6 9 _ Disconnect the ground cable from the battery Disconnect the pulse generator wi...

Страница 85: ...F1000F 1i model remove the oil pipes from the oil pan Loosen the muffler bands remove the muffler mounting bolts and remove the left and right mufflers Loosen the rear exhaust pipe bands Remove the fr...

Страница 86: ...ng the slave cylinder and tie the lever to the handle grip with a string Remove the drive sprocket cover Loosen the axle nut drive chain adjusting bolt lock nuts and adjusting bolts Remove the drive s...

Страница 87: ...cylinder temporarily install it to the drive sprocket cover release the clutch lever from the handle grip by removi ng the string and then tighten the slave cylinder mount bolts The slave cylinder is...

Страница 88: ...COOLING SYSTEM CIRCUIT DE REFROIDISSEMENT KOHLSYSTEM VF1000F VF1000F 1I 6 0...

Страница 89: ...tor cap relief pressure 7S 10S kPa 0 7S 1 0S kg cm2 10 7 14 9 psi 55 Distilled water 45 ethylene glycol _32 C 2SoF Freezing point Hydrometer test SO Distilled water SO ethylene glycol _37 C _34 F 45 D...

Страница 90: ...oes not hold pressure or if relief pressure is too high or too 1 COOLING SYSTEM TESTER low It must hold specified pressure for at least six seconds NOTE I Before installing the cap on the tester apply...

Страница 91: ...Remove the radiator cap Remove the lower cowl Remove the drain bolts from the front cylinders and drain the coolant from the front cylinders On VF1000F 11 model remove the drain plug from the auxilia...

Страница 92: ...n to flow out of the bleed hole Continue to run the engine until there are no air bubbles in the coolant and the level stabilizes Stop the engine and add coolant up to the proper level if necessary Re...

Страница 93: ...Technical Data Start to open 80 to 84 C 176 183 FI 8 mm minimum 0 31 inl Valve lift when heated to 95 C 203 F for five minutes INSTALLATION Install the thermostat into the housing Install a new O rin...

Страница 94: ...and grille Disconnect the radiator hoses and remove the radiator MAIN RADIATOR INSPECTION Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with compressed...

Страница 95: ...ry to disconnect the radiator hoses when removing the cooling fan Turn the ignition switch off and disconnect the battery negative cable from the battery On VF1000F model remove the fairing Disconnect...

Страница 96: ...e the fan motor wire properly page 1 9 _ AUXILIARY RADIATOR REMOVAL VF1000F model Drain the coolant from the auxiliary radiator at the thermostat housing Remove the headlight with its bracket Disconne...

Страница 97: ...ect the thermostatic switch wire coupler Disconnect the radiator hoses Remove the auxiliary radiator bracket mount bolts and the auxiliary radiator with the brackets Remove the brackets from the auxil...

Страница 98: ...removing the three bolts NOTE To prevent the clutch system from air contamination and the slave cylinder piston from falling squeeze the clutch lever immediately after removing the slave cylinder and...

Страница 99: ...nd water pipe and tighten the hose bands securely Install the dowel pins and install a new O ring in the groove of the water pump cover Install the water pump cover and torque the bolts Install the dr...

Страница 100: ...CLUTCH 7 0 80 90 N m 9 0 kg m 80 58 65 ft Ib...

Страница 101: ...80 90 N m 8 0 9 a k g m 58 65 f t Ibl EMBRAYAGE KUPPLUNG 7 0...

Страница 102: ...Snap ring pliers Lock nut wrench Common Universal holder Driver Attachment 42 x 47 mm Pilot 40 mm Gear holder 7 1 Cylinder 1 0 Piston 0 0 Cvlinder 1 0 Piston D O O ter gu de 1 0 Spr ng free neight Clu...

Страница 103: ...eder to the slave cylinder bleed valve Pump the brake bleeder and loosen the bleed valve Add fluid when the fluid level in the master cylinder reservoir is low NOTE Check the fluid level often while b...

Страница 104: ...e with DOT 4 brake fluid from a sealed container Install the diaphragm set plate and reservoir cap CLUTCH MASTER CYLINDER D SASSEMBLY Drain the clutch fluid from the hydraulic system page 7 3 Disconne...

Страница 105: ...sure the master cylinder 1 0 SERVICE LIMIT 14 06 mm 0 553 in Measure the master piston 0 0 SERVICE LIMIT 13 94 mm 0 549 in ASSEMBLY NOTE Handle the master piston spring primary cup and secondary cup a...

Страница 106: ...aling washers and tighten the bolt TORQUE 25 35 N m 12 5 3 5 kg m 18 25 ft lb Connect the clutch switch wires Fill and bleed the clutch system page 7 3 CLUTCH SLAVE CYLINDER DISASSEMBLY Place a contai...

Страница 107: ...ng or scratches Measure the inside diameter of the cy linder bore SERVICE LIMIT 33 68 mm 11 326 in ASSEMBLY Assemble the slave cylinder in the reverse order of dis assembly The oil seals must be repla...

Страница 108: ...utch system page 7 3 CLUTCH COVER REMOVAL Drain the engine oil page 2 3 Remove the clutch cover gasket and dowel pins STARTER CLUTCH DISASSEMBLY Remove the starter idle gear shaft and gear Remove the...

Страница 109: ...nd 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...

Страница 110: ...If the engine is not in the frame shift the transmission into gear and use the universal holder 07725 0030000 to hold the drive sprocket Remove the lock nut and lock washer Remove the clutch spring s...

Страница 111: ...ide INSPECTION Clutch spring Measure the height of the clutch spring SERVICE LIMIT 4 2 mm 0 165 in Replace the spring if it is shorter than the service limit Clutch disc Replace the clutch discs if th...

Страница 112: ...e SERVICE LIMIT 0 30 mm 0 012 in One way clutch Inspect the one way clutch for smooth operation Check the rollers for excessive wear Measur the J D of clutch center B SERVICE LIMIT 74 47 mm 2 932 in M...

Страница 113: ...00 Attachment 42 x 47 mm 07746 0010300 Pilot 40 mm 07746 0040900 Clutch outer guide Measure the 1 0 of the clutch outer guide SERVICE LIMIT 30 08 mm 1 184 in CLUTCH ASSEMBLY Instal l the clutch outer...

Страница 114: ...facing up Turn it counterclockwise as you install it Install the one way clutch clutch center B assembly over the mainshaft NOTE Make sure the one way clutch assembly is installed correctly by turning...

Страница 115: ...acing out Place the transmission in 5th gear and apply rear brake Install and tighten the lock nut NOTE If servicing the clutch with the engine out of the frame shift the transmission into gear and ho...

Страница 116: ...thrust washer on the crankshaft Install the springs plungers and rollers into the starter clutch Install the dowel pin Install the starter clutch cover aligning the dowel pin hole with the dowel pin...

Страница 117: ...ll the starter clutch Mesh the gear holder between the primary drive and driven gears to hold the crankshaft and tighten the primary gear bolt TORQUE 85 105 N m 8 5 10 5 kg m 61 76 ft Ibl Install the...

Страница 118: ...CLUTCH CLUTCH COVER INSTALLATION Install the dowel pins and a new gasket Install the clutch cover Fill the crankcase with oil page 2 3 7 18...

Страница 119: ...GEARSHIFT LINKAGE MECANISME DE SELECTION DES VITESSES CHALTGERSTANGE 8 0...

Страница 120: ...serviced with the engine in the frame If the shift forks drum and transmission require servicing remove the engine and separate the crankcase TROUBLESHOOTING Hard to shift Air bubbles in the clutch hy...

Страница 121: ...m the shift spindle Remove the clutch cover and clutch assembly Section 7 Remove the oil pump driven sprocket bolt Remove the clutch outer guide and remove the oil pump drive chain drive and driven sp...

Страница 122: ...ing and washer Remove the shift drum cam plate bolt and cam plate GEARSHIFT LINKAGE INSTALLATION Install the dowel pin in the hole of the shift drum Insert the five pins in the holes of the cam plate...

Страница 123: ...rely Assemble the gearshift spindle and return spring and install as shown Install the tab washer onto the stopper arm bolt Install the drum stopper arm collar spring washer and nut over the arm bolt...

Страница 124: ...driven sprockets with the IN mark on the driven sprocket facing to the crankcase Tighten the driven sprocket bolt securely Install the clutch assembly and cover Section 7 Align the punch marks on the...

Страница 125: ...ALTERNATOR ALTERNATEUR LICHTMASCHINE 9 0 85 105 N m 8 5 10 5 kg m 61 76 ft lbl...

Страница 126: ...N FLYWHEEL INSTALLATION This section covers removal and installation of the alternator Refer to section 18 for troubleshooting and inspection of the alternator TORQUE VALUE Alternator rotor Flywheel b...

Страница 127: ...he main harness Install the left frame side cover flYWHEEL INSTALLATION Install the woodruff key into the crankshaft Install the flywheel by aligning its keyway with the key in the crankshaft Hold the...

Страница 128: ...14_ 3 4 7 kg m 31 34 ft Ibl 8 12N m I 10 8 1 2 kg m 6 9 ft I bl ____________ i l 18 20 N m 11 8 2 0 kg m 13 14 ft Ibl CYLINDER HEAD VALVE CULASSE SOUPAPES ZYLINDERKOPF VENTI LE 43 47 N m 14_3 4 7 kg...

Страница 129: ...Cam height Runout Journal O D Bearing hole I D Ojl clearance Rocker arm Rocker arm I D Shaft O D Valve Valve stem O D Valve guide I D FRONT IN EX Both ends Center Both ends Center IN EX Stem to guide...

Страница 130: ...ft lb 07984 2000000 07742 001 0100 07743 0020000 07757 0010000 07780 0012100 07780 0012900 07780 0010300 07780 0010800 07780 0014000 07781 0010101 CYLINDER HEADIVALVE Engine top end problems usually...

Страница 131: ...el tank page 4 3 Disconnect the breather hoses from the air cleaner case and rear cylinder head cover Remove the spark plug caps from the rear cylinder plugs and remove the ignition coil with their br...

Страница 132: ...ating surfaces Place rags or shop towels in the rear cylinder head to prevent parts from being dropped into the crankcase Remove the rear cylinder intake and exhaust cam sprocket bolts Turn the cranks...

Страница 133: ...d in their original locations Remove the intake and exhaust camshafts and cam sprockets CAMSHAFT INSPECTION Support both ends of the camshaft with V blocks Check the camshaft runout with a dial indica...

Страница 134: ...E LIMIT 24 07 mm 0 948 in Calcu late the camshaft iournal oil clearance SERVICE LIMITS Both ends 0 10 mm 0 004 in Center 0 20 mm 0 008 in If the oil clearance exceeds the service limits determine if a...

Страница 135: ...ach a piece of wi re to the cam chain to prevent it from falling into the crankcase Remove the cam chain tensioner base Remove the exhaust pipe from the rear cylinder head Remove the water pipes and O...

Страница 136: ...he cylinder head gasket and dowel pins CAM CHAIN TENSIONER INSPECTION Check the cam chain tensioner for damage or spring weakness Check the tensioner slipper for wear or damage Replace if necessary CY...

Страница 137: ...on do not compress the valve springs more than necessary to remove the cotters NOTE Mark all disassembled parts to ensure correct reassembly Remove the valve stem seals Remove carbon deposits from the...

Страница 138: ...r or damage and calculate the shaft to rocker arm clearance SERVICE LIMIT 0 12 mm 0 005 in Inspect the rocker arm shaft spring for wear or damage VALVE SPRING INSPECTION Measure the free length of the...

Страница 139: ...f the stem To guide clearance exceeds the service limits with new guides replace the valves NOTE Reface the valve seats whenever the valve guides are replaced page 10 12 VALVE GUIDE REPLACEMENT Heat t...

Страница 140: ...or other hand lapping tool Remove the valve and inspect the face CAUTION The valves cannot be ground If the valve face is rough worn unevenly or contacts the seat improperly the valve must be replaced...

Страница 141: ...e spring more than necessary to install the valve cotters Tap the valve stems gently with a soft hammer to firmly seat the cotters NOTE Support the cylinder head above the work bench surface to preven...

Страница 142: ...t to damage it Install the dowel pins and a new gasket Install the cylinder head Install the cylinder head and temporarily tighten the cylinder head nul Blow the oil pipe and oil control bolt with com...

Страница 143: ...ain tensioner in the direction shown while pushing back the tensioner rod lock plate until the holes in the tensioner base and tensioner align and insert a pin or piece of wire through the holes Pass...

Страница 144: ...haft make sure the cam chains don f jam at the cam chain tensioners or at the crankshaft Install the intake and exhaust camshaft5 and sprockets through the rear cylinder cam chain as shown Turn the ca...

Страница 145: ...k plate back and hold the arm by inserting a pin through the holes in the tensioner base and arm Check the camshaft marks are still facing uP then align the cam sprocket index lines with the top of th...

Страница 146: ...x lines with the top of the cylinder head and place me cam chai n on the sprockets Align the T2 4 mark with the rear crankcase mating surface by turning the crankshaft counterclockwise 90 Slide the ca...

Страница 147: ...bolts and cylinder head bolts and nuts in a crisscross pattern in 2 3 steps TORQUE 9 mm 43 47 N m 4 3 4 7 kg m 31 34 ft Ib 8 mm 21 25 N m 2 1 2 5 kg m 15 18 ft lb 6 mm 10 14 N m 1 0 1 4 kg m 7 10 ft I...

Страница 148: ...nder head cover NOTE Install the front cylinder head cover with its insulator grooves facing up Tighten the cylinder head cover bolts TORQUE 8 12 N m 0 8 1 2 kg m 6 9 ft lb Install the removed parts i...

Страница 149: ...CRANKCASE CARTER MOTEUR KURBELGEHAUSE 8mm 21 25 N m 12 1 2 5 kg m 15 18 It lb 11 0 6mm 10 14 N m 1 4 kg m 7 10 ft Ib 1 0 6mm 10 14 N m 11 0 1 4 kg m 7 10 ft lb 9mm 38 42 N m 3 8 4 2 kg m 27 30 It 1 b...

Страница 150: ...ling 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 Gearshift linkage Refer to section 8 Alternator Refer t...

Страница 151: ...caps by removing the three bolts Remove the O rings from the caps and pipes Remove the mainshaft bearing holder by removing the screw and bolts Remove the upper crankcase bolts Turn the engine over a...

Страница 152: ...t fork and shift drum Section 13 Transmission Section 13 Crankshaft Section 12 Piston and connecting rods Section 12 Front and rear cylinder cam chain guides and slipper bases Apply molybdenum disulfi...

Страница 153: ...3 14 16 20 23 and 24 have washers TORQUE 9 mm 38 42 Nom 3 8 4 2 kg m 27 30 ft Ib 8 mm 21 25 Nom 2 1 2 5 kg m 15 18 ft Ib 6 mm 10 14 Nom 1 0 1 4 kg m 7 10 ft Ib Tighten the upper crankcase bolts to the...

Страница 154: ...rings onto the ends of the connecting pipes and assemble the connecting pipes and pipe caps Install new 0 rings in the grooves of the pipe caps and install the caps onto the crankcase Tighten the thr...

Страница 155: ..._ FRONT CRANKSHAFT PISTON VILEBREQUIN PISTON KU RBELWE LLE KO LBEN 12 0...

Страница 156: ...0 08 mm 0 003 in Main journal oil clearance 0 020 0 044 mm 0 0008 0 0017 in 0 08 mm 0 003 in Cylinder 1 0 77 000 77 015 mm 3 0315 3 0321 in 77 10 mm 3 035 in Taper 0 05 mm 0 002 in Dut of round 0 05...

Страница 157: ...r uneven compression Worn cylinder or piston ring Excessive smoke Worn cylinder piston or piston rings Improperly installed piston rings Damaged piston or cylinder Overheating Excessive carbon build u...

Страница 158: ...nd pistons out through the top of the cylinder bores CAUTION On engines with high mileage inspect the cylinders for a ridge just above the highest point of ring travel Any ridge must be removed with a...

Страница 159: ...ll carbon deposits Inspect the piston for cracks or other damage and the ring grooves for excessive wear and carbon build up Measure the piston ring ta groove clearance SERVICE LIMIT 0 10 mm 0 004 in...

Страница 160: ...0 50 mm Measure each piston pin hole 1 0 SERVICE LIMIT 20 06 mm 0 790 in Measure each piston pin 0 0 SERVICE LIMIT 19 98 mm 0 787 in Calculate the piston pin ta piston clearance SERVICE LIMIT 0 04 mm...

Страница 161: ...be parallel to each other Replace the cam chain if it is longer than the service limit BEARING INSPECTION MAIN BEARING Inspect the bearing inserts for unusual wear or damage Reinstall the upper crankc...

Страница 162: ...crankpln NOTE Do not put the plastigauge over the oil hole in the crankpin The bearing tabs should face toward the exhaust ports Remember the front and rear cylinder exhaust ports face opposite direc...

Страница 163: ...rent from the No 2 and No 3 main bearings No 1 and No 4 bearings have the grooves in their J D and No 2 and No 3 bearings have no grooves MAIN BEARING SELECTION TABLE CRANKSHAFT 0 0 1 CODE NUMBER 1 CR...

Страница 164: ...er of the color paint marks The rear cylinder bearing has two marks and front cylinder bearing has one mark CRANKPIN BEARING SELECTION TABLE 1 CRAN KPIN 0 0 A B CODE LETTER CONNECTING ROD 39 992 40 00...

Страница 165: ...The cylinders are arranged in the order of No 1 2 3 4 from the alternator side 1 WEIGHT CODE ALPHABETICAL CODE 1 2 CONNECTING RODS i 3 4 CONNECTING RODS 2 ROD CODE 4 ROD CODE A B C 0 E 1 ROD CODE i 3...

Страница 166: ...tons piston pins or connecting rods Make sure that the piston pin clips are properly seated Align the notches on the crankpin bearing inserts with the grooves in the connecting rod and cap and install...

Страница 167: ...y Flip the upper crankcase over Install and torque the connecting rod caps TOROUE 30 34 N m 3 0 3 4 kg m 22 25 It lbl NOTE Be sure the bearing caps are installed in their correct location as marked du...

Страница 168: ..._ FRONT CRANKSHAFT PISTON VILEBREQUIN PISTON KU RBELWE LLE KO LBEN 12 0...

Страница 169: ...0 08 mm 0 003 in Main journal oil clearance 0 020 0 044 mm 0 0008 0 0017 in 0 08 mm 0 003 in Cylinder 1 0 77 000 77 015 mm 3 0315 3 0321 in 77 10 mm 3 035 in Taper 0 05 mm 0 002 in Dut of round 0 05...

Страница 170: ...r uneven compression Worn cylinder or piston ring Excessive smoke Worn cylinder piston or piston rings Improperly installed piston rings Damaged piston or cylinder Overheating Excessive carbon build u...

Страница 171: ...nd pistons out through the top of the cylinder bores CAUTION On engines with high mileage inspect the cylinders for a ridge just above the highest point of ring travel Any ridge must be removed with a...

Страница 172: ...ll carbon deposits Inspect the piston for cracks or other damage and the ring grooves for excessive wear and carbon build up Measure the piston ring ta groove clearance SERVICE LIMIT 0 10 mm 0 004 in...

Страница 173: ...0 50 mm Measure each piston pin hole 1 0 SERVICE LIMIT 20 06 mm 0 790 in Measure each piston pin 0 0 SERVICE LIMIT 19 98 mm 0 787 in Calculate the piston pin ta piston clearance SERVICE LIMIT 0 04 mm...

Страница 174: ...be parallel to each other Replace the cam chain if it is longer than the service limit BEARING INSPECTION MAIN BEARING Inspect the bearing inserts for unusual wear or damage Reinstall the upper crankc...

Страница 175: ...crankpln NOTE Do not put the plastigauge over the oil hole in the crankpin The bearing tabs should face toward the exhaust ports Remember the front and rear cylinder exhaust ports face opposite direc...

Страница 176: ...rent from the No 2 and No 3 main bearings No 1 and No 4 bearings have the grooves in their J D and No 2 and No 3 bearings have no grooves MAIN BEARING SELECTION TABLE CRANKSHAFT 0 0 1 CODE NUMBER 1 CR...

Страница 177: ...er of the color paint marks The rear cylinder bearing has two marks and front cylinder bearing has one mark CRANKPIN BEARING SELECTION TABLE 1 CRAN KPIN 0 0 A B CODE LETTER CONNECTING ROD 39 992 40 00...

Страница 178: ...The cylinders are arranged in the order of No 1 2 3 4 from the alternator side 1 WEIGHT CODE ALPHABETICAL CODE 1 2 CONNECTING RODS i 3 4 CONNECTING RODS 2 ROD CODE 4 ROD CODE A B C 0 E 1 ROD CODE i 3...

Страница 179: ...tons piston pins or connecting rods Make sure that the piston pin clips are properly seated Align the notches on the crankpin bearing inserts with the grooves in the connecting rod and cap and install...

Страница 180: ...y Flip the upper crankcase over Install and torque the connecting rod caps TOROUE 30 34 N m 3 0 3 4 kg m 22 25 It lbl NOTE Be sure the bearing caps are installed in their correct location as marked du...

Страница 181: ...16 20 N m 12 14 ft Ib 1 6 2 0 kg m TRANSMISSIONS E VlTESSE BOlTE D GETRIEBE 21 25 N m 15 18 ft lb 2 1 2 5 kg m 13 0 I I...

Страница 182: ...Gear bushing M4 M5 gear 30 950 30 975 mm 1 2185 1 2195 in 30 94 mm 1 218 in 0 0 C2 C3 gear 30 950 30 975 mm 1 2185 1 2195 in 30 93 mm 1 218 in Gear bushing M4 27 995 28 016 mm 1 1022 1 1030 in 28 04...

Страница 183: ...t Clutch slave cylinder sticking Shift fork bent Shift shaft bent Shift claw bent Shift drum cam grooves damaged Transmission jumps out of gear Gear dogs worn Shift shaft bent Shift drum stopper broke...

Страница 184: ...C2 gear stopper ring spline collar C3 gear and bushing from the shaft then remove the countershaft from the lower crankcase Check gear dogs dog holes and gear teeth for excessive or abnormal wear or e...

Страница 185: ...REPLACEMENT Drive the countershaft bearing out of the lower crankcase Drive a new countershaft bearing into the crankcase using the special tools SHIFT FORK AND SHIFT DRUM REMOVAL Bend the lock washe...

Страница 186: ...rk surfaces SERVICE LIMIT 13 90 mm 0 547 in Measure the right and left shift fork 1 0 SERVICE LIMITS I D right and left fark 14 04 mm 0 553 inl Measure the shift fork claw thickness SERVICE LIMIT 6 1...

Страница 187: ...k that the snap rings are seated in the grooves 1 MAINSHAFT Ml I M4 COUNTERSHAFT Before installing the countershaft in the crankcase install the C5 gear and snap ri ng Install the countershaft into th...

Страница 188: ...oil hole in the countershaft Secure the C2 gear with the snap ring Install the thrust washer needle bearing C1 gear and thrust washer onto the countershaft Install the countershaft bearing holder bolt...

Страница 189: ...TRANSMISSION Install the mainshaft then reassemble the upper and lower 1 crankcase see Section 11 13 8...

Страница 190: ...FAIRING CARENAGE VERKLEIDUNG 14 0...

Страница 191: ...er by turning them counterclockwise Move the front wheel fully to right or left and remove the ower cowl being careful not to damage it Install the lower cowl in the reverse order of removal FAIRING V...

Страница 192: ...t and right rear view mirrors Remove the two cap nuts and the fairing Install the fairing in the reverse order of removal SEAT COWL Remove the seat left and right frame side covers Remove the two bolt...

Страница 193: ...ear turn signal stays and seat lock base by removing the two socket bolts and three 8 mm bolts Remove the starter relay switch from the right side of the rear fender Remove the turn signal relay from...

Страница 194: ...b 18 25 N m 30 40 N m 3 0 4 0 kg m 22 29 ft Ib 55 65 N m 5 5 6 5 kg m 40 47 ft lb 1 8 2 5 kg m 13 18 ft Ib FRONT WHEEL SUSPENSION ROUE SUSPENSIO AVANT VORDER RAD FEDE RUNG 30 40 N m 3 0 4 0 kg m 22 29...

Страница 195: ...Front fork cap Front fork socket bolt Anti dive case socket bolts 15 1 STANDARD 377 3 mm 14 85 in 455 cc 15 4 US OZ 16 0 Imp oz 475 cc 16 1 US OZ 16 7 Imp oz 0 40 kPa 0 0 4 kg cm2 0 6 psi 1 0 1 6 kg 2...

Страница 196: ...le Wheel installed incorrectly Front wheel wobbling Bent rim Worn front wheel bearings Faulty tire Axle nut tightened improperly Soft suspension Weak fork springs Insufficient fluid in forks Fork air...

Страница 197: ...cylinder Remove the right handlebar switch housing screws Remove the handlebar retainer ring Loosen the handlebar pinch bolt and remove the right handlebar from the fork tube Remove the throttle grip...

Страница 198: ...e the clutch master cylinder Remove the left handlebar switch housing screws Disconnect the choke cable from the choke lever and remove the left handlebar switch housing Remove the handlebar retainer...

Страница 199: ...in with the rear side of the slit and tighten the pinch bolt TORQUE 30 40 N m 3 0 4 0 kg m 22 29 ft lb Install the handlebar retainer ring Align the locating tab of the handlebar switch housing with t...

Страница 200: ...e forward screw first then tighten the rear screw Place the clutch master cylinder on the handlebar and install the holder with the UP mark facing up Align the index mark on the holder with the punch...

Страница 201: ...eg and anti dive piston Remove the left axle holder Jack up the engine until the forks clear the front axle and remove the front wheel DISASSEMBLY Remove the front axle nut and axle Remove the spacer...

Страница 202: ...the runout using a dial indicator SERVICE LIMITS RADIAL RUNOUT 2 0 mm 0 08 in AXIAL RUNOUT 2 0 mm 0 08 in NOTE The wheel cannot be repaired and must be replaced with a new one if the service limits a...

Страница 203: ...uses a tubeless tire For tubeless tire repair refer to the Honda Tubeless Tire Manual Drive a new right wheel bearing in squarely first until it is fully seated install the distance collar then drive...

Страница 204: ...hub aligning its tangs with the slots in the hUb Apply molybdenum disulfide grease to the dust seal lips and install the dust seal Fill the speedometer gear box with grease and install the plain wash...

Страница 205: ...t dot on the side wall must be located next to he valve stem Remount the tire if necessary Remove the dust seal and speedometer gearbox from the wheel Mount the wheel tire and brake disc assemblv in a...

Страница 206: ...N m 1 0 1 5 kg m 7 9 ft Ib Tighten the caliper bracket mount bolt TORQUE 30 40 N m 3 0 4 0 kg m 22 29 ft Ib Connect the speedometer cable and secure it with the screw Measure the clearance between ea...

Страница 207: ...the retainer rings and remove the left and right handlebar from the fork tubes Loosen the fork top and bottom pinch bolts Pull each fork tube out of the top bridge NOTE Because of the friction caused...

Страница 208: ...h soft jaws or shop towel and remove the fork tu be cap CAUTION Do not damage the sliding surface Remove the spacer washer and fork spring Drain the fork fluid by pumping the fork up and down several...

Страница 209: ...ed out by the fork tube bushing Remove the oil lock piece from inside the slider Remove the oil seal back up ring and slider bushing from the fork tube NOTE Do not remove the fork tube bushings unless...

Страница 210: ...370 mm 14 6 in Check the fork tube fork slider and piston for score marks scratches or e cessive or abnonnal wear Replace any components which are worn or damaged Check the fork piston ring for wear...

Страница 211: ...own ANTI DIVE CASE Remove the four socket bolts and remove the anti dive case Remove the circlip from the collar emove the collar and boot from the anti dive piston Remove the rubber seal spring pisto...

Страница 212: ...on and piston O ring Apply silicone grease to the pivot bolt collar 4 SPRING i 2 DETENT BAL Tighten the anti dive case socket bolts TORQUE 6 9 N m 0 6 0 9 kQ m 4 7 ft lb Check the opera tion of the co...

Страница 213: ...hread it into the piston Tighten with a 6 mm hex wrench NOTE Temporarily install the fork spring and fork cap bolt to tighten the socket bolt TORQUE 15 25 N m 1 5 2 5 kg m 11 18 ft lbl Place the slide...

Страница 214: ...p oz Left fork 475cc 16 1 US OZ 16 7Impoz Install the fork spring spring seat and spacer in the fork tube NOTE Note the spring direction the small coil end must face toward the bottom Install and torq...

Страница 215: ...tighten the two screws Install the fuse holder cover VF1000F model only Install the forks and temporarily tighten the bottom pinch bolts Install the fork stop rings in the grooves in the fork tube Pu...

Страница 216: ...front fender Install the following parts front wheel page 15 12 fairing page 14 1 With the front brake applied pump the forks up and down several times Tighten the front fender mounting bolts Fill th...

Страница 217: ...ndlebars page 15 3 front wheel page 15 6 brake hose 3 way joint fuse holder on VF1000F model page 21 6 steerings stem nut cap on VF1000F 11 model Loosen and remove the steering stem nut Remove the for...

Страница 218: ...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 grease retainer Remove the bearing inner race a...

Страница 219: ...examine the area around the steering head for cracks 1 LOCK NUT 2 LOCK WASHER A 4 UPPER BEARING INNER 10 DUST SEAL RACE 5 UPPER BEARING OUTER_______ RACE 11 UPPER BEARING 6 GREASE RETAINER ____ 7 LOWE...

Страница 220: ...he steering stem Install the grease retainer onto the steering stem Insert the steering stem into the steering head Install the upper bearing and upper bearing inner race into the steering head Instal...

Страница 221: ...ighten the steering stem nut TOROUE 90 120 N m 9 0 12 0 kg m 65 87 ft lb Tighten the fork top bridge pinch bolt TOROUE 20 30 N m 2 0 3 0 kg m 14 22 ft lb STEERING HEAD BEARING PRELOAD Install the fron...

Страница 222: ...kg m 29 36 It b 18 25 N m 1 8 2 5 kg m 13 18 It b i 20 30 N m g 2 0 3 0 kg m _______ 14 22 It b Qt 85 105 N m 8 5 10 5 kg m 61 76It b REAR WHEEl SUSPENSION ROUE SUSPENSION ARRIERE HI NTE RRAD AU FHAN...

Страница 223: ...nt 32 x 35 mm Attachment 37 x 40 mm Attachment 42 X 47 mm Attachment 52 x 55 mm Attachment 62 x 68 mm Pilot 17 mm Pilot 20 mm Pilot 25 mm Driver Bearing remover shaft Bearing remover head 20 mm 16 1 R...

Страница 224: ...ings worn Worn tires Soft suspension Weak spring Insufficient fluid in shock absorber Shock absorber air pressure incorrect Hard suspension Incorrect fluid weight in shock absorber Bent shock absorber...

Страница 225: ...the rear wheel is removed the caliper piston will move out and make reassembly difficult DISASSEMBLY Remove the rear brake disc Remove the dust seal Remove the final driven sprocket and driven flange...

Страница 226: ...a dial indicator SERVICE LIMITS RADIAL RUNOUT 2 0 mm 0 08 in AXIAL RUNOUT 2 0 mm 0 08 in NOTE The wheel cannot be serviced and must be replaced if the above limits are exceeded Final driven sprocket C...

Страница 227: ...the driven flange bearing out First drive a new right wheel bearing in squarely until it is fully seated install the distance collar then drive a new left wheel bearing in squarely TOOLS Right wheel...

Страница 228: ...r to the Tubeless Tire Manual 1 4 0 11 19 Do not get grease on the brake disc or stopping power will be reduced Install the rear axle sleeve final driven flange and driven sprocket If the driven sproc...

Страница 229: ...s After installing the wheel apply the brake several times Then check that the wheel rotates freely Recheck wheel installation if the brake drags or if the wheel does not rotate freely Tighten the rea...

Страница 230: ...electric panel and breather separator out of the frame Remove the shock absorber lower mounting bott Remove the shock absorber upper mounting bolt tilt the shock absorber rearward and remove it from t...

Страница 231: ...Place the shock absorber in a hydraulic press with an 01 L SEAL DRIVER ATTACHMENT positioned as shown Place the air hose in the oil and press the shock absorber several times until the damper is fille...

Страница 232: ...k absorber Press the oil seal out by compressing the shock absorber Leave the shock absorber for another 5 minutes to let any remaining ATF drain out NOTE Do not tilt the shock absorber or ATF will fl...

Страница 233: ...special tools using a hydraulic press until the oil seal driver stops at the edge of the outer case Install the back up ring Install the stop ring being certain that it is seated in the ring groove in...

Страница 234: ...topper ring Press a new spherical bearing in the shock upper mount Install the other stopper ring Install the damping force adjuster cable bracket and connect the cable to the lever INSTALLATION Apply...

Страница 235: ...Remove the front exhaust pipe joint nuts and exhaust chamber mounting bolts loosen the rear exhaust pipe con necling band and lower the exhaust chamber Remove the shock arm bolt and the shock arm from...

Страница 236: ...n the each bolt in the order listed_ TORQUE SHOCK LINK TO SHOCK ABSORBER 40 50 N m 4 0 5 0 kg m 29 36 ft Ib SHOCK LINK TO SHOCK ARM 40 50 N m 4 0 5 0 kg m 29 36 ft Ib SWINGARM PINCH BOLT 20 30 N m 2 0...

Страница 237: ...right swing arm pivot bolts Remove the swing arm from the frame Remove the drive chain slider from the sw ingarm PIVOT BEARING REPLACEMENT Remove the pivot collar from the swing arm s right pivot Rem...

Страница 238: ...tall the snap ring Apply molybdenum disulfide grease to the inside of new needle bearing Press the needle bearing in the swing arm s left pivot using a hydraulic press Install the dust seals into both...

Страница 239: ...en the left pivot bolt TORQUE 85 105 N m 8 5 10 5 kg m 61 76 ft Ib Install the gearshift arm onto the shift spindle aligning the punch marks on the arm and spindle Tighten the gearshift arm bolt Conne...

Страница 240: ...e rod bolt V X Install the rear brake hose clamp onto the torque rod Install the drive chain cover onto the swing arm Install the rear wheel page 16 7 Tighten the rear brake torque rod bolt and secure...

Страница 241: ...30 40 N m 3 0 40 k 2 g m 2 29 ft lb 25 35 N m 2 5 3 5 kg m 18 25 ft lb HYDRAULlSgHRAULlQUE E BREMSE HYDRAU FREIN HY LIe BRAKE 17 0 I...

Страница 242: ...854 mm 0 6231 0 6242 in 15 815 mm 0 6226 in Front caliper piston 0 0 31 948 31 998 mm 1 2578 1 2598 in 31 940 mm 1 2575 in Front caliper cylinder 1 0 32 030 32 080 mm 1 2610 1 2630 in 32 090 mm 1 263...

Страница 243: ...ver pedal too hard Sticking piston s Clogged hydraulic system Pads glazed or worn excessively Brake drag Hydraulic system sticking Sticking piston s Brakes grab Pads contaminated Disc or wheel misalig...

Страница 244: ...ve Loosen the bleed valve and pump the brake lever or pedal until no more fluid flows out of the bleed valve BRAKE FLUID FILLING AIR BLEEDING Fill the brake fluid reservoir with DOT 4 brake fluid from...

Страница 245: ...ing in the caliper as shown Install the new p ds in the caliper Install the pad pins one pad pin first then install the other pin by pushing the pads against the caliper to depress the pad spring Plac...

Страница 246: ...er down so that the brake disc is positioned between the pads being careful not to damage the pads Install the caliper mount bolt and tighten it TORQUE 20 25 N m 2 0 2 5 kg m 14 18 ft lb Tighten the p...

Страница 247: ...Apply silicone grease to the caliper pivot bolt and install the caliper mount bolt and pivot bolt TIghten the bol ts TORQUE Caliper mount bolt 20 25 N m 2 0 2 5 kg m 14 18 ft Ib Caliper pivot bolt 25...

Страница 248: ...er Remove the rear view mirror VF1000F model only Remove the brake lever and brake light switch from the master cylinder body Remove the piston boot Remove the snap ring f om the inside of the master...

Страница 249: ...led be sure the joint pin is installed with its arrow mark facing the adjuster arm Install the rear view mirror VF1000F model only Place the master cylinder on the handlebar and install the holder wit...

Страница 250: ...nd of the hose to prevent contamination Loosen the pad pin retainer bolt Remove the caliper mount bolt and pivot bolt and remove the caliper from the bracket DISASSEMBLY Remove the followi n9 brake pa...

Страница 251: ...The piston and dust seals must be replaced whenever they are removed Check the pivot boots and replace them if they are hardened or deteriorated Coat the piston and dust seals with clean brake fluid a...

Страница 252: ...t bolt TORQUE 20 25 N m 2 0 2 5 kg m 14 18 ft Ibl Tighten the pad pin retainer bolt TORQUE 8 13 N m 0 8 1 3 kg m 6 9 ft Ibl Connect the brake hose to the cal ip r with the oil bolt and two sealing was...

Страница 253: ...inder and actuating arm toget her Remove the cotter pin washer and joint pin and disconnect the actuating arm from the master cylinder push rod DISASSEMBLY Remove the rubber boot Remove the snap ring...

Страница 254: ...nd master piston with the secondary cup into the master cylinder being careful not to allow the lips of the cups to turn inside out Install the snap ring so that it is firmly seated in the groove Inst...

Страница 255: ...ake switch spring to the actuating arm Install the right footpeg bracket Tighten the bracket bolts Tighten the rear brake master cylinder mount bolts Connect the rear brake hose with the fluid bolt an...

Страница 256: ...EEN I CONTACTEURD ALLUMAGE 2 BATIERIE 3 ALTERNATEUR 4 REGULATEUR REDRESSEUR 5 JAUNE 6 ROUGE BLANC 7 ROUGE 8 FUSIBLE 30 A 9 NOIR 10 DETECfEUR DE TENSION 11 VERT 1 IC 4 REGULATOR RECTIFIER II ZONDSCHALT...

Страница 257: ...e Alternator Capacity Voltage regulator TROUBLESHOOTING No power key turned on Dead battery Low fluid level Low specific gravity Charging system failure Disconnected battery cable Main fuse burned out...

Страница 258: ...st be recharged if the specific gravity is below 1 230 The specific gravity varies with the temperature as shown in the accompanying table Replace the battery if sulfation is evident or if the space b...

Страница 259: ...g is preferred Route the breather tube as shown on the battery caution label After installing the battery coat the terminals with clean grease CHARGING SYSTEM CURRENT TEST NOTE Be sure the battery is...

Страница 260: ...between the leads with an ohmmeter NOTE The test results shown are for a positive ground ohmmeter and the opposite results will be obtained when a negative ground ohmmeter is used NORMAL DIRECTION CO...

Страница 261: ...LUMAGE 4 BLOC D ALLUMAGE 5 BOUGIE D ALLUMAGE 6 GENERATEURS D IMPULSION 7 BATTERIE 8 FUSIBLE 10 A 9 FUSIBLE PRINCIPAL 30 A 7 BATTERY 2 ENGI NE 1 IGNITION SWITCH STOP SWITCH 3 IGN ITION COILS lOA 5 SPAR...

Страница 262: ...tems one for the No 1 and No 3 cylinders and one for the No 2 and NO 4 cylinders Determine which sub system is faulty then proceed to the detailed tests below Engine cranks but will not start Engine s...

Страница 263: ...ve the spark plug wires from the ignition coil by loosening the retainer nuts Measure the secondary coil resistance without spark plug wires and caps RESISTANCE 13 6 15 4 kD Replace any faulty parts w...

Страница 264: ...SE GENERATOR Remove the fuel tank page 4 3 Disconnect the pulse generator wire coupler Measure the pulse generator coil resistance between the white yellow and yellow terminals for 1 3 cylinders or be...

Страница 265: ...timing is not in specification replace the spark unit with a new one and recheck the ignition timing Remove the seat Remove the rear compartment under cover Disconnect the spark unit wire couplers and...

Страница 266: ...1 COMMUTATEUR D EMBRAYAGE 2 BOTON DE DEMARREUR 3 CONTACTEUR DE RELAIS DE DEMARREUR 4 DEMARREUR 5 BATTERIE 6 CONTACTEUR DE POINT MORT 7 CONTACTEUR D ALLUMAGE 8 FUSIBLE PRINCIPAL 30 A 9 BOBINE DE RELAIS...

Страница 267: ...aulty neutral switch Faulty starter relay switch Loose or disconnected wire or cable Clutch diode open Starter motor turns engine slowly Low specific gravity in battery Excessive resistance in circuit...

Страница 268: ...emove the three screws and the rear cover Remove the brushes from he brush holder OSP8Ct the brushes and measure the brush length SERVICE LIMIT 6 5 mm 0 26 in Measure the brush spring tension with a s...

Страница 269: ...ontinuity between pairs of commutator bars There should be continuity Also make a continuity check between individual commutator bars and the armature shaft There should be no continuity ASSEMBLY INST...

Страница 270: ...ON Depress the starter switch button with the ignition ON The coil is normal if the starter relay switch clicks Connect an ohmmeter to the starter relay switch terminals Connect a 12 V battery to the...

Страница 271: ...nect the negative probe to the8terminal There should be continuity Check for continuity in the reverse direction There should be no continuity NOTE The test results shown are for a positive ground ohm...

Страница 272: ...d before disconnecting and must be aligned when reconnecting The following color codes used are indicated throughout this section and on the wiring diagram Bu Blue BI Black Br Brown G Green Gr Grey Lb...

Страница 273: ...torque TORQUE 10 14N m 1 0 1 4 kg m 7 10 ft lb NOTE To prevent crankcase damage do not overtighten the switch BRAKE LIGHT SWITCH REAR Check the rear brake light switch for continuity with the rear bra...

Страница 274: ...s Remove the drive sprocket mount bolts and drive sprocket page 5 4 Remove the oil bolt Remove the countershaft bearing cover by removing the mount bolt Remove the neutral switch cover bolts and cover...

Страница 275: ...ket and tighten the drive sprocket mount bolt TORQUE 50 54 N m 5 0 5 4 kg m 36 39 ft lb Install the clutch slave cylinder drive sprocket cover and gearshift pedal in the reverse order of removal CLUTC...

Страница 276: ...dlebar cluster switches as follow Continuity should exist between the color coded wires in each chart DIMMER SWITCH COLOR Bu W W Bu 3 TURN SIG L SWITCH Lo v N r Hi PASSING SWITCH COLOR WIG Bu FREE PUS...

Страница 277: ...ay between the ON and OFF detent positions Push the lugs that are locked in the slots then pull the contact base from the switch NOTE On G and ND models if the ignition switch lock cylinder must be re...

Страница 278: ...the thermostatic switch located in auxiliary radiator If the fen motor does not stan disconnect the black and green leads from the thermostatic switch and short them together with a jumper wire Turn...

Страница 279: ...thermosensor wire Drain the coolant and remove the thermosensor from the thermostat case page 6 4 Suspend the sensor in oil over a burner and measure the resistance through the sensor as the oil heats...

Страница 280: ...ative wires VOLTAGE 5V If there is no voltage replace the sensor unit HEADLIGHT SINGLE HEADLIGHT MODEL Remove the fairing page 14 1 Remove the three screws and headlight from the headlight base Discon...

Страница 281: ...the two upper bolts and remove the lower bolt and the headlight Disconnect the headlight couplers Remove the rubber caps bulb retainers and bulbs and replace the bulbs with new ones Install the headli...

Страница 282: ...ght lens with it TOP mark facing up and secure with four clips INSTRUMENTS REMOVAL Remove the fairing page 14 1 Remove the four mount nuts and speedometer cable from the instruments Replace the bulbs...

Страница 283: ...tem If the problem still appears check continuity between the yellow wire terminal of the wire harness instrument coupler and the yetlow wire of the 1 3 cylinder ignition coil Repair or replace wire h...

Страница 284: ...e order of removal HORN NOTE On models VF1000F the fairing must be removed page 14 1 The horn is normal if it is sound when a 12 V battery is connected across the horn wire terminals Replace the horn...

Страница 285: ...circuit is normal Check the fuel gauge needle for correct indication by moving the float up and down FLOAT POSITION NEEDLE POSITION UPPER FULL F FULL LOWER EMPTY E EMPTY FUEL PUfWP RELAY Remove the le...

Страница 286: ...1T f S lo P S Nl s uc T so r l S IO U1 PI 1 do I ok 0 r Ii r r c r T r T l SWlIO i i4o liel i MlZ l Nt 1 TA TE i SIl1I U L SlOP St II U TroG S TCH IIoulottdt lu do r 11 1 I SI G 8HZ HLI MLl BAT4 Il EB...

Страница 287: ...QIl 2 I L 5 T 6 LEn TI RN ll lliC TOR t l I d 7 I 3 II S Ar S 1 ClVTO SWlTCi Coo P U f j T1RI SI DIloUI Vi l j 5 1TC I r r __ __tIL 11 1 N t t U SIARltII SWIIe IiGI i SlOPS ITO fIool r 11 tot 811 2 EE...

Страница 288: ...n coil 6 Faulty ignition switch 7 Faulty pulse generator 8 Faulty ignition coils LOW COMPRESSION _ 1 Low battery charge 2 Improper valve clearance too small 3 Valve stuck open 4 Worn cylinder and pist...

Страница 289: ...4 Improper valve timing 8 Check carburetor for clogging CLOGGED 1 Carburetor not serviced frequently enough NOT CLOGGED 9 t Remove spark plug FOULED OR DISCOLORED 1 Plugs not serviced frequently enou...

Страница 290: ...valve clearance clearance 2 Faulty spark unit CORRECT 3 FaultY pulse generator t 2 Disconnect fuelline at carburetor FUEL FLOW RESTR ICTED I n Fuel tank emptY FUEL FLOWS FREELY l 2 Clogged fuel line 3...

Страница 291: ...in Luftdr hinten solo m Bel Bremsflussigkeit Spez Bremsbelag Typ vorne Bremsbelag Typ hinten GabelholmfOllmenge rechts GabelholmfOlimenge links Gabelblspezifikation Luftdruck Teleskopgabel Luftdruck S...

Страница 292: ...Batterie FIOssigkeitsstand P P P P P P Antriebskette und Kettenrader der Beanspruchung entsprechend P P P P P P Bremsbelage Pedalspiel Dichtheit P P P P P P BremsfiOssigkeit P P A po P A Ventilspiel P...

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