1994-2003
MAGNA® VF750C/CD
©HONDA MOTOR CO., LTD. 1994
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,.------
Important Safety Notice
-------,
INM@ii�h
Indicates a strong possibility of severe personal injury or death if instructions are not followed.
CAUTION:
Indicates a possibility of personal injury or equipment damage if instructions are not followed.
N OTE:
G ives helpful information .
Deta iled descriptions of sta ndard workshop procedures, safety principles and service operations a re not included . It
is i mportant to note that this manual contains some warnings and cautions against some specific service methods which
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe . Please understand
that those warnings could not cover a l l conceivable ways in which service, whether or not recommended by Honda,
might be done or of the possi bly hazardous consequences of each conceivable way, nor could Honda investigate all
such ways . Anyone using service procedu res or tool s, whether or not recommended by Honda, m ust satisfy h imself
thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected .
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Contents
Introduction
This service manual desc�ibes the service procedures for
the M A G N A V F 7 50C/C D .
G eneral I nformation
This Model S pecific Manual includes every service proce­
d u re that is of a specific nature to this particular m odel .
Basic service procedu res that are common to other Honda
Motorcycle/Motor Scooter/ATVs are covered in the Com­
mon Service Manual . This M odel Specific Service Manual
should be used together with the Common Service Manu­
al in order to provide complete service information on all
a spects of this motorcycl e .
Follow t h e M aintenance Schedule (Section 3) recommen­
d ations to ensure that the vehicle is in peak operating
condition and the emission levels are within the standards
set by the U . S . Environmental Protection Agency and the
C alifornia Air Resources Board . Performing the first
scheduled maintenance is very important. It compensates
for the initial wear that occurs during the break-in period .
Sections 1 an d 3 apply to the whole motorcycl e .
Section 2 illustrates procedu res f o r removal/instal lation
of components that may be required to perform service
described in the following sectio n s .
Sections 4 t h r o u g h 1 9 describe parts of the m otorcycle ,
g rouped according to locatio n .
Find t h e section y o u want on this page, then turn t o the
table of contents on the first page of the sectio n .
Most sections describe t h e service procedure throug h
syste m illustration . Refer t o t h e next page for details o n
h o w t o u s e this m a n u a l .
Frame/Body Panels/Exhaust System
Maintenance
Lubrication System
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cations included in this publication are based on the
latest product information available at the time of
approval for printing. Honda Motor Co., LTD .
reserves the right t o make changes a t any time
without notice and without incurring any obligation
whatever. No part of this publication may be
reproduced without written for permission. This
manual is written for persons who have acquired
basic knowledge of maintenance on Honda motor­
cycles, motor scooters or ATVs .
HONDA MOTOR CO ., LTD .
Service Publications Office
Date of I ssue: J u n e, 1 99 4
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O N DA M OTOR Cmanuals
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.
Engine Removal/Installation
Cylinder Head/Valves
Clutch System
Crankshaft/Piston/Transmission
0
·
;;
0
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Front Wheel/Suspension/Steering
Rear Wheel/Suspension
Brake System
Charging System/Alternator
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·
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All information, illustrations, directions and specifi­
Cooling System
Gearshift Linkage
If y o u a re n o t familiar with this motorcycle, read Tech­
nical Feature in section 2 0 .
If you don't k n o w the source o f the trouble, go t o sec­
tion 2 1 Trou bleshooting .
Fuel System
jjj
Ignition System
Electric Starter/Starter Clutch
Lights/Meters/Switches
Wiring Diagram
Technical Feature
Troubleshooting
Index
How To Use This Manual
Finding The Info rmation You Need
•
•
This manual is devided into sections which cover each of the
m ajor comonents of the motorcycl e .
T o quickly find t h e section you a r e i nterested in, t h e first page
of each sections is m arked with a black tab that lines up with
one of the t h u m b index tabs before this page .
The fi rst page of each section lists the table of contents wi­
thin the section .
Read the service information and trobleshooting related to
the section before you begin working .
An index of the entire book is p rovided in the last chapter
to d irectly locate the information you need .
N ote On the Explanation M ethod Of This M anual
•
•
•
•
•
•
•
•
The removal and installation of parts are for the most part illustrated by l a rg e and clear i llustrations that should provide
the reader with visual aid i n understanding the major point for servicing .
The system illustrations are augmented by call outs whose numbers or letters indicate the order in which the parts should
be removed or insta l led .
The sequence of steps represented nu merically a re d ifferentiated from the ones represented alphabetically to notify
the reader that they m u st perform these steps separately.
The i ll u strations 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 symbo l .
Also in the i l l u stration is a chart that lists information such as the order in which the parts is removal/installed, the name
of the part , and some extra notes that may needed .
Step by step instructions a re provided to supplement the illustrations when datailed explanation of the procedu re is
necessary or i l lu strations alone would not suffice.
Service procedures requi red before or after the procedu re described on that particular page, or inspection/adjustment
procedures requ i red following the instal lation of parts, are described under the title Requisite Service .
Standard workshop procedures a n d knowledge covered in the Common Service Manual are abbreviated in this manual .
Detailed d escription
of the procedure
Symbols
System i ll ustration
-
....................
.......... _...._._, ... .......,....,..
I!SI
---
lllil
---
Step
sequence
(numerals
o r a l p h a bets)
-
Cllwfully ............ ....... ............ ..
......., ....... _ .... ,.._......
...... .... g.,.
....
......... .,___,,
...... .... .,..
._._..... .... 13-111
....
, . ......
. ......... .. ........ ....
�
---··--
--
..,_
-
-
.. ........
t.eflllly,.. .... � ...........
....
, . ......
. ......... .. ......... ....
-
12-14
Part name
N u m ber of parts
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l
111UNMGDIWD
Extra notes or precaution
related to the service proced u re
1'--'
h
..u...
._..
u.....
12-16
$ymbols
The sym bols used throughout this manual show specific service procedu res . If supplementary information is required pertain­
ing to these symbols, it would be explained specifically in the text without the use of the sym bols.
-
Replace the part(s) with new one(s) before assembly.
ls.TOOl!
Use special too l .
lo.P�OOLI
Use optional tool . These tools are obtained as you order parts .
c
Torque specification . 1 0 N·m ( 1 . 0 kg-m , 7 ft-lb)
1 0 ( 1 . 0 , 7)
,
,
-�
�
......
�
0..
.t•.a!
I
...
Use recommended engine oil , unless otherwise specified .
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1 : 1 ) .
Use multi-purpose grease ( Lithium based m ulti-purpose g rease N LG I # 2 or equivalent) .
Use molybdenum disulfide g rease (containing more than 3% molybdenum disulfide , N LG I # 2 o r
equivalent) .
Example: Molykote® BR-2 plus manufactured by Dow Cornin g , U . S . A .
M ulti-purpose M-2 manufactured b y Mitsu bishi Oil Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide , N LGI # 2 or
equivalent) .
Example: Molykote® G-n Paste manufactured by Dow Corning , U . S . A .
Honda Moly 60 ( U . S . A . only)
Rocol ASP manufactured by Rocol Limited , U . K .
Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone g rease .
Apply a locking agent. Use the agent of the middle strength , unless otherwise specified .
Apply sealant.
Use brake fluid DOT 4. Use the recommended brake fluid , unless otherwise specified .
Use Fork or Suspension Fluid .
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MEMO
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1 General Information
.
General Safety
Model Identification
Specifications
Torque Values
Tools
1-1
Lubrication & Seal Points
1-4
Emission Control System (U.S.A. Only) 1-27
1-3
1-12
1-15
Cable & Harness Routing
Emission Control Information Labels
(U.S.A Only)
1-17
1-20
1-30
General Safety
Carbon Monoxide
If the engine must be running to do some work, make sure
the area is well ventilated. Never run the engine in an en­
closed a rea .
Used Engine/Transmission Oil
•
Used engine oH
(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
•
The exhaust cotains poisonous carbon monoxide gas
unless you handle used oil on a daily basis, it is still
that may cause loss of consciouness and may lead to
advisable to thoroughly wash your hands with soap
death.
and water as soon as possible after handling used oil.
KEEP OUT OF REACH OF CHILDREN.
Run the engine in an open a rea or with an exhaust evacua­
tion system in an enclosed area.
Gasoline
Work in a well ventilated area. Keep cigarettes, flames or
sparks away from the work area or where gasoline is stored.
•
Gasoline is extremely flammable and is explosive un­
Brake Dust
Never use an air hose or dry brush to clean brake assem­
blies. Use an OSHA-approved vacuum c leaner or a lternate
method approved by OSHA, designed to m inimize the haz­
ard caused by airborne asbestos fibers .
•
der certain conditions. KEEP OUT OF REACH OF
Inhaled asbestos fibers have been found to cause
respiratory disease and cancer.
CHILDREN.
Brake Fluid
Hot Components
CAUTION
•
•
Engine and exhaust system parts become very hot and
remain hot for some time after the engine Is run. Wear
insulated gloves or walt until the engine and exhaust
system have cooled before handling these parts.
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Spilling fluid on painted, plastic or rubber parts wiU
damage them. Place a clean shop towel over these
parts whenever the system is serviced. KEEP OUT OF
REACH OF CHILDREN.
1-1
General Information
Coolant
Nitrogen Pressure
Under some conditions, the ethylene glycol in engine coolant
is combustible and its flame is not visible . If the ethylene
glycol does ignite, you will not see any flame, but you can
be burned .
For shock a bsorbers with a gas-fi lled reservoir:
•
Use only nitrogen to pressurize the shock absorber.
The use of an unstable gas can cause a fire or explo­
•
The shock absorber contains nitrogen under high pres­
sion resulting in serious injury.
•
Avoid spilling engine coolant on the exhaust system
or engine parts. They may be hot enough to cause the
sure. Allowing fire or heat near the shock absorber
could lead to an explosion that could result in serious
coolant to ignite and burn without a visible flame.
Coolant (ethylene glycol) can cause some skin irrita­
tion and is poisonous if swallowed. KEEP OUT OF
REACH OF CHILDREN.
•
Do not remove the radiator cap when the engine is
•
you.
Keep hands and clothing away from the cooling fan,
as it starts automatically.
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 pierced.
hot. The coolant is under pressure and could scald
If it contacts your skin, wash the affected areas immedi­
ately with soap and water. If it contacts your eyes, flush
them thoroughly with fresh water and get i mmediate medi­
cal attention . If it is swallowed , the victim m ust be forced
to vomit, then rinse mouth and throat with fresh water be­
fore obtaining medical attentio n. Because of these dangers,
always store coolant in a safe place, away from the reach
of chi ldren .
To prevent the possibility of an explosion, release the nitro­
gen by pressing the valve core . Then remove the valve stem
from the shock a bsorber reservoi r . Dispose of the oil i n a
manner acceptable to the Environmental Protection Agen­
cy ( E PA) .
Before d isposal of the shock a bsorber, release the nitrogen
by pressing the valve core . Then remove the valve stem from
the shock a bsorber.
Battery Hydrogen Gas & Electrolyte
•
The battery gives off explosive gases; keep sparks,
flames and cigarettes away. Provide adequate venti­
lation when charging.
•
The battery contains sulfuric acid (electrolyte). Con­
tact with skin or eyes may cause severe burns. Wear
protective clothing and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water
•
for at least 15 minutes and call a physician im­
mediately.
Electrolyte is poisonous.
- If swallowed, drink large quantities of water or milk
and follow with milk of magnesia or vegetable oil
and call a physician. KEEP OUT OF REACH OF
CHILDREN.
1-2
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General Information
Model Identification
'94 MAGNA VF750C shown
(1) FRA M E SERIAL N U M BE R
( 1) The frame serial number is stamped on the r i g h t side o f
t h e steering head .
( 2 ) E N G I N E SERIAL N U M BE R
( 2 ) The e n g i n e serial number is sta m ped on t h e right s i d e of
the upper cran kcsase .
(4) CARBU RETOR I D EN T I FI CATI O N N U M BER
(4) The carburetor indentification number is stamped on the
carburetor body intake side .
(3) V E H I C LE I DE N T I F I CATI O N N U MBER
( 3 ) The vehicle Identification N u m ber (VI N ) 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, a lways specify the desig nated color
code.
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1-3
General Information
Specifications
r-
General
Dlmel.....
Specifications
Item
Overall length
Overall
OveraA
width
height
'94-'00
After '00
(VF750C)
(VF750CD)
Wheelbase
Seat height
Footpeg height
Group clearance
Dry weight
(VF750C: 49 states, Canadian type)
(VF750C: California type)
(VF750CD: 49 states, Canadian type)
(VF750CD: California type)
Curb weight
(VF750C: 49 states, Canadian type)
(VF750C: California type)
(VF750CD: 49 states, Canadian type)
(VF750CD: California type)
Maximum weight capacity
Frame
Engine
2,332 mm
2,338 mm
854 mm
1,136 mm
1,1go mm
1,652 mm
7 10 mm
290 mm
155 mm
(91.8 in)
( 92 .0 in)
(33.6 in)
(44.7 in)
(46.9 in)
(65 in)
(28 in)
(11.4 in)
(6.1 in)
229 kg
231 kg
230 kg
232 kg
(5051bs)
(509 lbs)
(507 lbs)
(511 lbs)
247
249
248
250
180
kg (545 lbs)
kg (549 lbs)
kg (547 lbs)
kg (551 lbs)
kg (397 lbs)
Frame type
Front suspension
Front wheel travel
Rear suspension
Rear wheel travel
Rear damper
Front tire size
Rear tire size
T ire brand (Front/Rear)
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Fuel tank reserve capacity
Double cradle
Telescopic fork
150 mm (5.91 in)
Swingarm
100 mm (3.94 in)
Double effect type
120/80- 17M/C 61V
150/80 - 15M/C 70V
K555F/K555 (Dunlop)
Hydraulic brake
Internal expanding shoe
32 '
13 7 mm (5.39 in)
13.91iter (3 . 7 US gal, 3.11mp gal)
3.3 liter (0.87 US gal, 0.37 Imp gal)
Bore and stroke
Displacement
Compression ratio
Valve train
Intake valve opens (at 1 mm lift)
Intake valve closes (at 1 mm lift)
Exhaust 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
70 .0 x 48.6 mm (2.76 x 1.91 in)
748.1 cc (45.65 cu-in)
10.8:1
Silent multi-link chain drive and DOHC
10· BTDC
25"ABDC
35' BBDC
-5.ATDC
Forced pressure and wet sump
1-4
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Trochoid
Liquid cooled
Paper filter
Unit-type, 4 main journal
80.3 kg (1n lbs)
1 -go· -4 - 270. -3- go• -2 - 270. -1
4 cylinder oo· v
LEFT
G
8
-
8
8
-
FRONT
General Information
r-
General (Cont'dl
Item
Specifications
Carburetor
Carburetor type
Venturi diameter
CV (Constant Velocity) type,with flat valve
33 mm (1.30 in)
Drive Train
Clutch system
Clutch operation system
Transmission
Primary reduction
Secondary reduction
Third reduction
Final reduction
Gear ratio 1st
Gear ratio 2nd
Gear ratio 3rd
Gear ratio 4th
Gear ratio 5th
Gear ratio 6th
Gear ratio reverse
Gearshift pattern
Multi-plate, wet
Cable operating
5 speeds
1.939 (64/33)
Electrical
Ignition system
Starting system
Charging system
Regulator/rectifier type
Lighting system
AC regulator type
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---
2.500
2.846
1.882
1 .450
1.227
1.035
(40/16)
(37/13)
(32/17)
(29/20)
(27/22)
(29/28)
---
Left foot operated return system 1-N-2-3-4-5
Full transistor ignition
Starter motor
Triple phase output alternator
SCR shorted/triple phase,full-wave rectification
Battery
--
1-5
General Information
Unit: mm (in)
r-
Lubrication ------.---,--,
Standard
Item
Engine oil capacity at draining
at disassembly
at oil filter change
Recommended engine oil
OIL VISCOSITIES
I
I
I
I
o
-20
zo
-oo
40
o
eo
10
eo
20
:so
tOO •F
Oil pump rotor tip clearance G)
body clearance ®
end clearance @
---
Use Honda GN4 4-stroke Oil or equivalent
API Service Classification: SF or SG
Viscosity: SAE 1 0W - 40
Other viscosities shown in the chart may
be used when the average temperature in
your riding area is within the indicated
range.
490 - 588 kPa ( 5 - 6 kg/cm2, 7 1 . 1 - 8 5 . 3
psi) at 6 , 000 rpm (80°C/ 1 7 6°F)
0. 1 0 (0. 004)
0. 1 5 - 0. 2 2 (0. 00 6 - 0. 009)
0. 0 2 - 0. 09 ( 0. 0 0 1 - 0. 004)
0. 1 5 ( 0 . 006)
0. 3 5 ( 0. 0 1 4)
0. 1 0 ( 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 type)
Pulse secondary air inje'ction control valve vacuum
pressure
--,
--
40 'C
Oil pressure at oil pressure switch
--,
3. 0 lit ( 3. 2 US qt, 2. 6 Imp qt)
3.8 lit ( 4. 0 US qt, 3 , 3 Imp qt)
3. 1 lit ( 3. 3 US qt, 2. 7 Imp qt)
Service Limit
VP31A
VP30A
VP3 2 D
# 1 02
# 40
see page 5- 1 6
see page 5- 1 7
1 3. 7 ( 0. 54)
Within 20 mmHg ( 0. 8 inHg)
No. 1 carburetor
1 ,000 ± 1 00 rpm
1 , 1 00 ± 1 00 rpm
1 , 000 ± 1 00 rpm
2 - 6 ( 1 /8 - 1 /4)
PAIR check valves are buit in to the PAIR
control valve
Cooling System --------.---,.--,
Cooling capacity (Radiator and engine)
(Reserve tank)
Radiator cap relief pressure
Thermostat begins to open
Thermostat fully open
Thermostat valve lift
1-6
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2. 4 i (0. 6 US gal, 0. 5 Imp gal)
0. 4 i ( 0. 1 US gal, 0.09 Imp gal)
1 0 7.9 kPa ( 1 . 1 kg/cm2, 1 5. 64 psi)
80 - 84°C ( 1 76 - 1 83°F)
9 5°C ( 203°Fl
8. 0 ( 0. 3 1 5) min.
General Information
Unit: mm (in)
Cylinder Head --------.--.--,
Item
Standard
Service Limit
1,275 kPa (184.9 psi, 13.0 kg/cm2)/
500 rpm
Cylinder compression
Cylinder compression synchronization difference
Valve clearance IN
EX
Cylinder head warpage
Cam lobe height CD IN
(California type)
IN
EX
(California type)
EX
Camshaft runout ®
Camshaft oil clearance
0.16 ± 0.02 (0.006 ± 0.001)
0.25 ± 0.02 (0.010 ± 0.001)
35.980-36.140 (1.4165�1.4228)
0.10 (0.004)
35.95 (1.4153)
35.670-35.830 (1.4043-1.4106)
35.64 (1.4031)
0.030-0.072 (0.0012-0.0028)
0.05 (0.002)
0.10 (0.004)
H O LO
Camshaft journal O . D .
Camshaft holder I.D.
Valve stem O . D .
IN
EX
IN
Valve guide I .D .
EX
Stem-to-guide clearance IN
EX
Valve guide projection above cylinder head I N
EX
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 (0.1772-0.1776)
4.500-4.512 (0.1772-0.1776)
0.010-0.037 (0.0004-0.0015)
0.020-0.047 (0.0008-0.0019)
15.30-15.50 (0.602-0.610)
15.30-15.50 (0.602-0.610)
24.94 (0.982)
25.05 (0.986)
4.46 (0. 1 75)
4.45 (0.175)
4.56 (0.179)
4.56 (0.179)
1.0 (0.04)
37.86 (1.49)
25.978-25.993 (1.0225-1.0233)
26.010-26.026 (1.0240-1.0246)
1.5 (0.06)
36.1 (1.42)
25.96 (1.022)
26.04 (1.025)
Before guide installation:
1. Chill the valve guides in the
freezer section of the refrigerator
for about an hour.
2. Heat the cylinder head to
212-300°F (100-150°C)
Valve
Valve
Valve
Valve
seat width
spring free length
lifter O . D .
lifter bore I.D.
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1 -7
General Information
Unit: mm (in)
..- Clutch System
Standard
Item
10-20 (0.4-0.8)
24.995-25.012 (0.9841-0.9847)
44.4 (1.75)
2.92-3.08 (0.115-0.121)
2.92-3.08 (0.115-0.121)
Clutch
Cl utch
Clutch
Clutch
lever free play
outer guide I . D .
spring free length
disc thickness A
B (Judder spring side)
Clutch palte warpage
--
Service Limit
--
25.08 (0.987)
41.2 (1.62)
2.5 (0.10)
2.5 (0.10)
--
..- Cylinder/Piston
70.000-70.015 (2.755-2.756)
Cylinder I . D .
Cylinder out of round
Cylinder taper
Cylinder warpage
Piston mark direction
Piston O . D . ( D )
Piston O . D . measurement point (H)
Piston pin hole O . D . (d)
----
With "IN" mark facing to the intake side
69.970-69.990 (2.755-2.756)
10 (0.4)
17.002-17.008 (0.6694-0.6695)
70.10 (2.759)
0.10 (0.004)
0.10 (0.004)
0.10 (0.004)
--
69.85 (2.750)
--
17.02 (0.670)
d
!""-"'
W'
[OJ ( 1'--<'l (0] � H
Cylinder-to-piston clearance
Piston pin O . D .
Piston-to-piston p i n clearance
Connecting rod-to-piston clearance
Top ring-to-ri ng groove clearance
Second ring-to-ring groove clearance
Top ring end gap
Second ring end gap
Oil ring (side ra i l ) end gap
Top ring mark
Second ring mark
D
�
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)
0.35-0.50 (0.014-0.020)
0.20-0.80 (0.008-0.031)
I nstal l with the marked side u p
I nstal l with the marked side u p
--
16.98 (0.669)
---
0.10 (0.04)
0.10 (0.004)
0.5 (0.02)
0.7 (0.03)
1.00 (0.039)
---
Crankshaft ------.---�--�
17.016-17.043 (0.6699-0.6706)
17.04 (0.671)
0.10-0.30 (0.004-0.012)
0.40 (0.016)
Connecting rod small end I . D .
Connecting rod big end side clerance
rad ial clearance
Crankshaft ru nout G)
Crankpin oil clearance
Connecting rod bearing selection
Main journal oil clearance
Main journal bearing selection
1-8
Downloaded from www.Manualslib.com manuals search engine
0.05 (0.002)
0.030-0.052 (0.0012-0.0020)
See page 11-9
0.019-0.037 (0.0007-0.0015)
See page 11-8
0.08 (0.003)
0.05 (0.019)
General Information
Unit: mm ( i n )
Transmission ------.--,--,
Standard
Item
Service Limit
Transmission gear I . D . M 5
C2
C3
C4
Transmission gear bushing O . D . M 5
C2
C3
C4
Transmission gear bushing I . D . M 5
C2
C3
Gea r-to-bushing clearance a t M 5 gear
at C 2 gear
at C 3 gear
at C4 gear
M a inshaft O . D . at M5 gear bushing
2 8 . 000 - 28 . 021 (1.1024 - 1.1032)
31 . 000 - 31 . 016 (1. 2 2 0 5 - 1 . 2 211)
31. 000 - 31. 016 ( 1 . 2205 - 1.2 211)
31. 000 - 31 . 016 (1. 2205 - 1 . 2 211)
2 7 . 9 59 - 2 7 . 980 (1. 1007 - 1 . 1016)
30 . 9 70 - 30 . 9 9 5 (1. 2193 - 1 . 2 203)
30 . 9 50 - 30 . 9 7 5 (1. 218 5 - 1 . 219 5)
30 . 9 50 - 30 . 9 7 5 (1. 218 5 - 1 . 2195)
24. 9 8 5 - 2 5 . 006 ( 0 . 9 8 34 - 0 . 9845)
2 8 . 000 - 2 8 . 021 (1.1024 - 1.1032)
2 7 . 99 5 - 2 8 . 016 (1.10 2 2 - 1 . 1 029)
0 . 0 20 - 0 . 062 (0.0008 - 0 . 0024)
0 . 00 5 - 0 . 046 ( 0 . 0002 - 0 . 018)
0 . 02 5 - 0 . 066 ( 0 . 0001 - 0 . 0026)
0 . 0 25 - 0 . 066 ( 0 . 0001 - 0 . 0026)
24. 9 5 9 - 24. 980 ( 0 . 9 8 26 - 0 . 9 83 5)
2 8 . 04
31. 04
31. 04
31. 04
2 7 . 94
30 . 9 5
30. 9 3
30 . 9 3
2 7 . 94
2 8 . 04
2 8 . 04
Countershaft O . D . at C 2 gear bushing
2 7 . 967 - 2 7 . 980 (1. 1011 - 1 . 1016)
2 7 . 96 (1.10 1 )
Gear-to-shaft clearance
Gear bushing-to-shaft clearance at
at
at
at
Shift fork claw thickness L
c
R
Shift fork I . D . L
c
R
S hift fork shaft O . D .
0 . 00 5 - 0 . 047 ( 0 . 0002 - 0 . 0019)
0 . 0 20 - 0 . 054 ( 0 . 0008 - 0 . 0021)
0 . 015 - 0 . 049 ( 0 . 0006 - 0 . 00 1 9)
0 . 015 - 0 . 049 ( 0 . 0006 - 0 . 0019)
6 . 43 - 6 . 50 ( 0 . 2 5 3 - 0 . 2 56)
6 . 43-6 . 50 (0. 2 5 3 - 0 . 2 56)
6 . 4 3 - 6 . 50 ( 0 . 2 53 - 0 . 2 56)
14. 016 - 14 . 034 ( 0 . 5518 - 0 . 5 5 2 5)
14. 016 - 14 . 034 (0 . 5518 - 0 . 5 5 2 5)
14. 016 - 14 . 034 (0 . 5 518 - 0 . 5 5 25)
13 . 9 7 3 - 13 . 984 ( 0. 5 50 1 - 0 . 5 506)
6 . 40 (0. 2 5 2 )
6 . 40 ( 0 . 2 5 2 )
6 . 40 (0. 2 5 2 )
1 4. 043 (0. 5 5 2 9)
14. 043 ( 0 . 5 52 9 )
1 4. 043 ( 0. 5 5 2 9 )
1 3 . 96 5 ( 0 . 5498)
M5 gear
C 2 gear
C 3 gear
C4 gear
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(1.104)
(1. 2 2 2 )
(1. 2 2 2 )
(1. 2 2 2 )
(1. 010)
(1. 219)
(1. 218)
(1. 218)
(1. 010)
(1. 104)
(1. 104)
24. 9 5 ( 0 . 9 8 2 )
1 -9
General Information
r-
Unit: mm ( i n )
Wheel/Tires
Minimum tire tread depth (FR)
(RR)
Cold tire pressure U p to 90 kg (200 lb) load (FR)
Up to 90 kg (200 l b) load ( R R )
Up to maximum weight capacity (FR)
Up to maximum weight capacity (RR)
Front and rear axle runout
Front and rear wheel rim runout ( Radial)
(Axial)
250
250
250
290
kPa
kPa
kPa
kPa
(2.50
(2.50
(2.50
(2.90
kg/cm2,
kg/cm2,
kg/cm2,
kg/cm2,
36
36
36
42
psi)
psi)
psi)
psi)
-----
--
0.2 (0.01)
--
2.0 (0.08)
2.0 (0.08)
60 g (2.1 oz)
60 g (2.1 oz)
--
20-30 (3/4-1·3/16)
D I D 50V4/118
RK 50 MFOZ1/118
----
Front Suspension -------.---.---,
402.5 (15.85)
410.7 (16.17)
Rear Suspension
Tapered coil facing down
0.2 (0.01)
Fork fluid
122 (4.80)
521cc (17.62 U S oz, 18.29 I m p oz)
0.1-0.15 kg-m
-----�---�--�
Shock absorber spring free length
Shock absorber spring adjuster standard position
Shock absorber spring di rection
-
--
--
Fork spring free length
Fork spring d i rection
Fork tube runout
Recommended fork oil
Fork oil level
Fork oil capacity
Steering bearing preload
r-
1.5 (0.06)
2.0 (0.08)
--
--
Wheel balance weight (Front)
( Rear)
Drive chain slack
Drive chain size/link ( D I D)
IRK)
r-
Service Limit
Standard
Item
241.8 (9.52)
237.0 (9.33)
2nd g roove
Small coil end facing down
Brakes ------�--,---�
brake fluid
DOT 4
Front
brake pad wear ind icator
G)
~
Rear
1 - 10
brake disc thickness
brake disc runout
master cylinder J . D .
master piston O . D .
calipe r cylinder J . D .
caliper piston O . D .
brake pedal free play
brake drum J . D .
brake lining thickness
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To the groove
6.0 (0.24)
11.0-11.043 (0.4331-0.4348)
10.957-10.984 (0.4314-0.4324)
25.400-25.450 (1.000-1.0020)
25.335-25.368 (0.9974-0.9987)
20-30 (0.8-1.2)
180-180.3 (7.086-7.098)
5.0 (0.2)
5.0 (0.20)
0.25 (0.01)
11.055 (0.4352)
10.945 (0.4309)
25.461 (1.002)
25.33 (0.997)
181 (7.12)
2.0 (0.08)
General Information
r-
Unit: mm (in)
Battery/c harging System
Item
Alternator/charging coil resistance (at 20°C/68°F)
Regulator/rectifier regulated voltage/amperage
Battery capacity
Battery charging rate (Normal)
(Quick)
Battery voltage (fully charged 20°C/68°F)
(needs charging 20°C/68°F)
r-
Service Limit
Standard
0.1-1.0 0
14-15.5 V/below 0.5 A/3,000 rpm
12 V-10 Ah
1.2 A (5-10h)
5 A (1h)
Over 13.1 V
Below 12.5 V
--------
Ignition System ------.--..,
Spark plug
(Standard NGK)
(Standard NIPPONDENSO)
(For cold climate/below 5°C/41°F NGK)
(For cold climate/below 5°C/41°F NIPPONDENSO)
(For extended high speed riding NGK)
(For extended high speed riding NIPPONDENSO)
Spark plug gap
Ignition timing "F" mark
Advance start
stop
Full advance
Ignition coil resistance (Primary: at 20°C/68°F)
(Secondary with plug cap)
(Secondary without plug wire)
Pulse generator resistance (At 20°C/68°F)
Starter System
CR8EH9
U24FER9
CR9EH9
U27FER9
0.8-0.9 (0.03-0.04)
12° BTDC at idle
2,000 rpm
2-4 0
23-27 kO
13-17 k0
450-550 0
--------,--r--�
12.0-13.0 (0.47-0.51)
47.175-47.200 (1.8573-1.8583)
Starter motor brush length
Starter clutch driven gear O.D.
6.5 (0.26)
47.16 (1.857)
- Lights/Meters/Switches -------.....---,-
Main fuse
Fuse
Headlight (high/low beam)
Tail/brake light
Position light bulb
Front turn signal lights
Rear turn signal lights
Instrument lights
Oil pressure warning indicator
Side stand indicator
Coolant temperature indicator
High beam indicator
Turn signal indicator
Neutral indicator
Coolant temperature sensor resistance
Fan motor switch
85°C (185°F)
120°C (248°F)
Starts to close (ON)
Stops to open (OFF)
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30 A
10 A x 3,15 A X 1
12 v 60/55 w
12 V 32/3 cp
12 V 3 cp x 2
12 V 32/3 cp x 2
12 V 32 cp x 2
12 V 1.7 W X 1,12 V 1.4 W
12 v 3 w
12 v 3 w
12 v 3 w
12 v 3 w
12 v 3 w
12 v 3 w
39-49 0
14-18 0
97-103°C (207-217°F)
92-98°C (198-208°F)
X
2
1- 1 1
General Information
Torque Values
r-
Standard
Fasteners Type
5 mm hex bolt and nut
6 mm hex bolt and nut
8 mm hex bolt and nut
10 mm hex bolt and nut
12 mm hex bolt and nut
Torque
N·m (kg-m, ft-lb)
5
10
22
35
55
(0.5,3.5)
(1.0,7)
(2.2,16)
(3.5,25)
(5.5,40)
Fasteners Type
5 mm screw
6 mm screw
6 mm flange bolt (8 mm head )
6 mm flange bolt ( 10 mm head) and nut
8 mm flange bolt and nut
10 mm flange bolt and nut
Torque
N·m (kg-m, ft-lb)
4
9
9
12
27
40
(0.4,3)
(0.9,7)
(0.9,7)
(1.2,9)
(2.7,20)
(4.0,29)
Torque specifications listed below are for important fasteners. Others should be tightened to standard torque values listed above .
Notes:
1. Apply sealant to the threads.
2. Apply a locking agent to the threads.
3 . Apply molybdenu m disulfide oil to the threads and flange surface .
4. Left hand threads .
5. Stake .
6. Apply oil to the threads and flange surface .
7. Apply clean engine oil to the 0-ring .
8 . Torque wrench scale reading using a special too l .
9 . Apply grease t o t h e threads a n d flange surface .
10. UBS bolt.
11. U-nut.
12. ALOC bolt; Replace with a new one.
r-
Engine
O'ty
Thread
dia . (mml
Torque
N•m (kg-m, ft-lbl
1
45
18 (1.8,13)
Note 9
1
1
1
1
3
1
1
PT 1/8
20
20
12
6
6
6
12
10
18
34
13
18
12
Note 1
N ote 6
Note 2
Connecting tube band screw
4
5
Water pump cover
Water pump mounting bolt
2
2
6
6
4
8
10
6
6
6
6
18
9
6
6
6
5
Item
Remarks
Maintenance :
Timing hole cap
Lubrication :
Oil
Oil
Oil
Oil
Oil
Oil
Oil
pressure switch
filter
filter stud bolt
drain bolt
pump bolt
pump driven sprocket bolt
pipe nut (After '94)
(1.2,9)
(1.0,7)
(1.8,13)
(3.4,25)
(1.3,9)
(1.8,13)
(1.2,9)
Fuel Systems :
Cooling Systems:
Cylinder Head :
Spark plug
H ead cover protector
Cylinder head cover bolt
Breather case bolt
Cylinder head protector bolt
Cylinder head sealing bolt
Cylinder head bolt (9 m m )
Cylinder head bolt (6 m m )
Camshaft holder bolt
Cam chain tensioner mounting bolt
Boost joint bolt
1 -12
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8
6
12
4
16
4
32
4
-
1
N ote 2
Note 11
(0.1,0.7)
13 (1.3,9)
13 (1.3,9)
12
10
10
10
12
44
44
12
12
12
4
(1.2,9)
(1.0,7)
(1.0, 7)
(1.0,7)
(1.2,9)
(4.4,32)
(4.4,32)
(1.2,9)
(1.2,9)
(1.2,9)
(0.4,2.9)
N ote 2
N ote 6
N ote 6
General Information
r-
Engine
Q'ty
Thread
dia. (mml
13
1
5
1
1
1
1
3
2
1
1
1
6
10
6
22
22
6
8
6
6
10
8
8
12
23
12
90
110
9
27
10
12
51
23
23
2
7
8
1
8
2
2
8
1
10
6
9
8
6
6
6
8
8
39
12
31
23
12
12
12
33
18
left crankcase cover bolt
Flywheel bolt
Stator mounting bolt
6
1
3
6
10
6
12 (1.2,9)
83 (8.3,61)
12 (1.2,9)
Pulse generator mounting bolt
3
6
1
2
1
3
6
5
12
8
10
5
90
40
1
10
12 (1.2,9)
Q'ty
Thread
dia . (mml
2
4
2
2
1
2
4
10
8
10
8
12
10
8
Item
Torque
N·m (kg-m, ft-lb)
Remarks
Clutch/Gearshift Linkage
Right crankcase cover bolt
Cl utch cable holder bolt
Cl utch spring bolt
C l utch center lock nut ('94)
(After '94)
Gearshift link joint bolt
Change pedal pivot bolt
Drive sprocket cover bolt
Drive sprocket cover rubber bolt
Drive sprocket bolt
Sh ift drum center bolt
Sh ift return spring pin
(1.2,9)
(2.3,171
(1.2,9)
(9.0,65)
(11.0,80)
(0.9,6.5)
(2.7,20)
(1.0,7)
(1.2,9)
(5.1,37)
(2.3,17)
(2.3,17)
N ote 5, 6
N ote 5, 6
N ote 2
Crankcase/Crankshaft :
U pper crankcase bolt (10 m m )
U pper crankcase bolt (6 m m )
lower crankcase bolt (9 m m )
lower cran kcase bolt (8 m )
lower crankcase bolt (6 m m )
Cam chain tensioner slipper bolt
Cam chain sli pper bolt
Connecting rod bearing cap nut
Sealing bolt
(3.9,28)
(1.2,9)
(3.1,22)
(2.3,17)
(1.2,9)
(1.2,9)
(1.2,9)
(3.3,24)
(1.8,13)
N ote 6
N ote
N ote
N ote
N ote
2
2
6
2
Alternator:
N ote 6
Ignition System :
10 (1.0,7)
Starter Clutch:
Starter
Starter
Starter
Starter
motor
motor
clutch
clutch
flange nut
case bolt
bolt
outer cover bolt
(1.0,7)
(0.5,3.6)
(9.0,65)
(4.0,29)
N ote 6
N ote 2
Lights/Meters/Switches :
N eutral switch
.--- Frame
Item
Torque
N•m (kg-m. ft-lbl
Remarks
Engine mounting:
Front cylinder head mounting bolt
Front engine mounting bracket bolt
Front engine mounting bolt
Rear engine mounting bracket bolt
Rear engine mounting bolt
Rear cylinder head mount bolt
Rear cylinder head mount bracket bolt
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54
39
44
39
64
44
39
(5.4,39)
(3.9,28)
(4.4,32)
(3.9,28)
(6.4,46)
(4.4,32)
(3.8,28)
N ote 9
1-13
General Information
r-
Frame
Item
O'ty
Thread
dia. (mm)
Torque
N•m (kg-m. ft-lb)
4
4
1
1
1
2
2
2
2
2
6
6
24
26
26
8
10
37
8
6
23 (2.3, 17)
12 (1.2,9)
105 (10.5,76)
1
1
1
1
2
2
2
2
Remarks
Front Suspension :
Handlebar upper holder bolt
Front fender bolt
Steering stem nut
lock nut
Steering head bearing adjusting nut
Fork pinch bolt (upper)
(lower)
Fork cap
Fork socket bolt
Fork drain bolt
30
27
39
23
20
8
(3.0,22)
(2.7, 20)
(3.9,28)
(2.3,17)
(2.0, 14)
(0.8,5.8)
20
20
10
14
5
8
8
10
15
64
39
89
6
22
27
37
(1.5,11)
(6.4,46)
(3.9,28)
(8.9,65)
(0.6,4.3)
(2.2,16)
(2.7,20)
(3.7,27)
1
1
1
4
6
5
5
18
14
8
8
12
4
93
59
22
42
108
(0.4,2.9)
(9.3,63)
(5.9,43)
(2.2, 16)
(4.2,30)
(10.8,79)
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
2
10
8
6
6
4
4
6
6
10
10
8
8
8
10
8
8
8
35
31
12
12
1.5
1.2
1
6
2.5
18
5.5
13
23
39
27
29
22
(3.5,25)
(3.1,22)
(1.2,9)
(1.2,9)
(0.15, 1. 1)
(0.12,,0.9)
(0.1,0.7)
(0.6,4.3)
(0.25,1.8)
(1.8,13)
(0.55,4)
(1.3,9)
(2.3,17)
(3.9,28)
(2.7,20)
(2.9,21)
(2.2. 16)
8
4
6
2
8
8
6
8
12
21
12
27
1
1
1
10
10
6
10 (1.0,7)
30 (3.0,22)
10 (1.0,7)
4
1
8
22
27 (2.7 20)
23 (2.3,17)
Rear Suspension :
Frame pivot adjusting bolt
Frame lock nut
Frame lock bolt
Swingarm pivot nut
Chain slider screw
Chain tensioner
Shock absorber mounting bolt (upper)
(lower)
=:]
page 12-12
Note 2
.=j
page 13-10
Note 11
Wheels:
Speedometer cable screw
Rear axle nut
Front axle bolt
Axle pinch bolt
Brake disc bolt
Driven sprocket nut
Note 11
Note 12
Note 11
Brake System:
Brake hose bolt
Caliper bracket bolt
Front brake hose clamp nut
Front master cylinder holder bolt
Front master cylinder reservoir cover screw
Front brake light switch screw
Front brake lever pivot bolt
nut
Pad pin plug
Pad pin
Brake caliper bleeder bolt
Brake caliper bracket pin bolt
Brake caliper pin bolt
Rear brake pedal pivot bolt
Rear brake pedal linkage joint pinch bolt
Rear brake arm pinch bolt
Rear brake stopper arm nut
1
Frame/Exhaust Systems:
Exhaust pipe joint nut
Exhaust pipe band bolt
Exhaust pipe protector bolt
Muffler mounting bolt
(1.2,9)
(2.1, 15)
(1.2,9)
(2.7,20)
Lights/Meters/Switches:
Side stand pivot bolt
nut
Side stand switch
Others:
Footpeg bracket bolt
Fuel valve
1- 14
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Note 12
Note 11
Note 2
Note 2
Note 12
General Information
Tools
Description
Tool Nunber
Applicability
Maintenance :
Oil filter wrench
Drive chain cutter
07HAA - PJ 7 0 1 00
07H M H - M R 1 0 1 02
or 07H M H - M R 1 0 1 0B
07N M H - MW00 1 1 0
or 07PM H - MZ20 1 1 0
Link plate holder
U . S . A . only
Lubrication :
Oil pressure gauge
Oil pressure gauge attachment
Fuel System:
Float level gauge
Pilot screw wrench
(Canadian type)
(49 states , Cal ifornia type)
Cylinder Head/Cylinder/Piston:
Valve spring com pressor
Valve spring compressor attachment
Tappet hole protector
Valve guide drivier
Valve guide reamer, 4. 5 mm
Valve seat cutter
seat cutter, 24. 5 m m ( 4 5 ° EX)
29 m m (45 ° I N )
flat cutter, 2 5 m m ( 3 2 ° EX)
30 m m ( 3 2 ° I N )
interior cutter, 26 m m ( 6 0 ° EX)
30 m m (60° I N )
cutter holder, 4. 5 m m
Compression g a u g e attach ment
Tensioner stopper
Clutch/Gearshift Linkage :
Lock nut wrench, 26 x 30 mm
Extension bar
Clutch center holder
07 506 - 3000000
07 5 1 0 - 42 20 1 00
0740 1 - 00 1 0000
07908 - 42 2020 1
0 7 M M A - MV90 1 0A
0 7 7 5 7 - 00 1 0000
07959 - KM 30 1 0 1
0 7 H M G - M R 70002
0 7 H M D - M L00 1 0 1
07H M H - M L00 1 0 1
07780 - 00 1 0 1 00
07780 - 00 1 0300
07780 - 00 1 2000
07780 - 00 1 2 200
0 7 7 80 - 00 1 4 500
07780 - 00 1 4000
0778 1 - 00 1 0600
07JMJ - KY 20 1 00
0 7 N M G - MY90 1 00
07 7 1 6 - 0020203
07 7 1 6 - 0020500
0 7 7 2 4 - 00 5000 1
Crankshaft/Transmission :
U niversal bearing puller
Inner d river C
Attachment, I . D . 2 5 m m
Front Wheel/Suspension/Steering:
Bearing remover shaft
Bearing remover head , 20 m m
Attachment, 42 x 47 m m
Pilot, 20 m m
Fork seal d river
Fork seal d river attachment
Steering stem socket wrench
Ball race remover
- attachment
- d river handle
Ball race remover
Attachment, 5 2 x 55 mm
Steering stem d river
Driver
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N ot available i n U . S . A .
N ot available in U . S . A.
' 94 only
'94 only
Equivalent commercia l ly
available in U . S . A .
0763 1 - 00 1 0000
07 746 - 0030 1 00
0 7 746 - 0030200
07746 - 0050 1 00
07746 - 0050600
07746 - 00 1 0300
07 746 - 0040500
07947 - KA 5 0 1 00
07947 - KF00 1 00
079 1 6 - 3 7 1 0 1 0 1
0 7 9 5 3 - MJ 1 0000
0 7 9 5 3 - MJ 1 0 1 00
or 0 7 9 5 3 - MJ 1 000A
0 7 9 5 3 - MJ 1 0 200
or M 9 3 60 - 2 7 7 - 9 1 7 7 4
07946 - 3 7 1 0 500
07746 - 00 1 0400
07946 - M BOOOOO
07 749 - 00 1 0000
U . S . A . only
U . S . A . only
1- 1 5
General Information
Description
Tool Number
Applicability
Rear Wheel/Suspension :
Bearing remover shaft
Bearing remover head, 20 m m
Attachment, 42 x 47 m m
Pilot, 20 m m
Attachment, 52 x 55 m m
Attachment, 62 x 68 m m
Pilot, 25 m m
Shock absorber compressor
Driver shaft
Attachment, 28 x 30 m m
Pilot, 22 mm
Attachment, 32 x 35 m m
Pilot, 15 m m
Needle bearing remover attachment
Bearing remover
Attachment, 30 m m
Driver
07746-0050100
07746-0050600
07746-0010300
07746-0040500
07746-0010400
07746-0010500
07746-0040600
07959-3290001
07946-MJ00100
or 07949-3710001
07946-1870100
07746-0041000
07746-0010100
07746-0040300
07GMD-KT70200
or M967X-038-XXXXX
07746-0030300
07749-0010000
U.S.A. only
U.S.A. only
U.S.A. only
Brake :
Snap ring pliers
07914-3230001
Charging System/ Alternator:
Flywheel holder
Rotor puller
07725-0040000
07733-0020001
Electric Starter/Starter Clutch :
Gear holder
07724-0010100
Electrical Equipment :
Digital m u ltimeter (KOWAl
Analog tester
1- 1 6
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07411-0020000
07308-0020001 (SANWAl
or TH-5H (KOWAl
Equivalent commercially
available in U.S.A.
Not available in U.S.A.
General Information
Lubrication & Seal Points
�
Engine
-----�--�--�
Location
Material
Crankcase mating surface
Liquid sealant
Remarks
•
•
Wipe off the excess sealant
Do not apply the sealant to
near the bearing
0
L....
-
..J
Right crankcase cover mating surface
20-30 mm
(0.8-1.2 i )
1 (""
'
l
.)T
�----·--..�
T
Left crankcase cover mating surface
20-30 mm
(0.8-1.2 in)
��
0
0
,\
0
--===::w
Cylinder head semi-circular cut-out
Crankshaft main bearing thrust surface
Connecting rod big end bearing
small end
Valve stem (valve guide sliding surface)
VaJve lifter outer sliding surface
Camshaft lobes/journals
M3/4,C5 and shifter gear (shift fork grooves)
Shift fork shaft sliding area
Shift drum
Primary drive gear sliding area
Each gear
Cylinder head cover gasket mating surface
(cover side)
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Molybdenum disulfide oil
(A mixture of 1/2 engine oil
and 1/2 molybdenum disulfide
grease)
Honda Bond A
1-17
General I nformation
-
Engme
.
Location
Material
Right crankcase cover rubber plate bolt threads
Drive chain guard bolt threads
Crankcase sealing bolt threads
Oil pump d riven sprocket bolt threads
Cam chain tensioner sli pper bolt threads
Cam chain slipper bolt threads
Mainshaft bearing set plate bolt threads
Shift drum bearing set plate bolt threads
Shift drum center bolt
Starter clutch outer cover bolt
Oil filter stud bolt threads
Cylinder head sealing bolt threads
Locking agent
Oil pressure switch threads
Thermo sensor threads
Liquid sealant
Lower crankcase bolt (9 mm) threads
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 threads and seating surface
Flywheel bolt threads and seating surface
Oil filter threads
Clutch disc lining surface
Clutch center lock nut
Each bearing
Engine oil
Clutch l ifter guide
Timing hole cap threads
Each oil seal li ps
Each 0-ring
M u lti-purpose g rease
1-18
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Remarks
-
-
Clean and apply to the threads
Apply a re a : 5.5-7.5 mm
General I nformation
�
Location
Material
Side stand pivot bolt sliding surface
Rear brake pedal linkage sliding surface
Rear brake pedal pivot surface
Rear brake spindle sliding surface
Right/left footpeg sliding surface
Gearshift pedal pivot surface
Throttle pipe sliding surface
Clutch lever pivot bolt sliding surface
Multi-purpose grease
Steering head bearings
Steering head bearing dust seal lips
'94-'02:
Multi-purpose grease
After'02:
Urea based multi-purpose
grease for Extreme pressure
(example: EXCELITE EP2
manufactured by KYODO
YUSHI, Japan, 'Shell Stamina
EP2)
Or equivalent
Apply thin coat of grease
Swingarm pivot nut flange surface
Swingarm bearings
Swingarm dust seal lips
Front wheel dust seal lips
Rear wheel dust seal lips
Rear wheel sliding surface (driven flange)
Rear engine mounting nut threads and seating
surface
Each bearing
Each dust seal lips
Multi-purpose grease
Throttle cables
Choke cable
Clutch cable
Speedometer cable
Steering stem lock nut threads
Flywheel bolt threads and flange surface
Engine oil
Handle grip inner surface
Honda Bond A
Front brake lever pivot and piston tips
Brake caliper pin bolt sliding surface
Brake caliper bracket pin bolt sliding surface
Brake cam sliding surface
Brake anchor pin sliding surface
Silicone grease
Brake caliper pin bolt threads
Brake caliper bracket pin bolt threads
Fork socket bolt threads
Locking agent
Front fork oil seal/dust seal lips
Front fork
Fork fluid
Brake master cylinder
DOT 4 brake fluid
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Remarks
Honda Hand Grip Cement
(U.S.A. only}
Clean and apply to the threads
1- 19
General Information
Cable & Harness Routing
(8) RIGHT HANDLEBAR
SWITCH WIRE HARNESS
(1) LEFT HANDLEBAR
SWITCH WIRE HARNESS
(6) COMBINATION METER WIRE HARNESS
(5) HIGH BEAM/TURN "SIGNAL/
NEUTRAL INDICATOR WIRE HARNESS
(2) CLUTCH CABLE
3) SPEEDOMETER
CABLE
(10) 9P-RED CONNECTOR
(TURN SIGNAL SWITCH
HORN SWITCH,
DIMMER SWITCH)
(9) 9P-BLACK
ECTOR
(STARTER SWITCH, ENGINE
STOP SWITCH)
1-20
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General Information
(5) IGNITION
SWITCH WIRE
HARNESS
(2) EVAPORATIVE
EMISSION
PURGE
CONTROL
VALVE
(3) CLUTCH CABLE
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1-21
General Information
(10) H I G HT BEAM/T U R N S I G NAL/
N E UTRAL I N D I CATO R W I R E
( 6 ) STARTER M O T O R CABLE
1-22
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( 5) PULSE SECON DARY AIR I NJECTIO N
PIPES (CALI F O R N I A TYPE O N LY)
General Information
(8) FRONT
PULSE SECON DARY
A I R I NJ ECT I O N
CONTROL
VALVE
(CALI F O R N I A
TYPE O N LY)
EVAPO RATIVE E M I S S I O N
CAR B U R ETOR
AIR VENT C O N TRO L VALVE
(CALI F O R N I A TYPE ONL Yl
FUEL TAN K B REATHER
TUBE
(6) EVAPORA VE E M I S S I O N
PURGE CONTROL VALVE
(CALI F O R N I A TYPE O N LYl
( 5) FUEL
(4) REAR P U L S E SECON DARY A I R
I N J ECTIO N C O N T R O L VALVE
(CALI F O R N I A TYPE ONL Yl
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1 -23
General Information
( 1 } THERMO SENSOR
WIRE
( 7} ALTERNATOR W I R E
(6) E N G I N E G R O U N D CABLE
(5) N EUTRAL SWITCH W I R E
1-24
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(3) I G N IT I O N PULSE GENERATOR
WIRE
(4) STARTER MOTOR CABLE
General Information
(1) M A I N W I R E HARN ESS
(8) I G N IT I O N PULSE G E N E RATO R
C O N N ECTOR
(6) S I D E STA N D SWITCH
C O N N ECTOR
--..\----H--t:;;�.>.;:jrF'N
2) N EUTRAL
SWITCH
C O N N ECTOR
(4) STARTER MOTOR
CABLE
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1-25
General I nformation
A N D SWITCH
T H EA TUBE
(4) F U E L TAN K BR
149 STATES, CANADIAN TYPE)
(7) RIGHT TURN SIGNAL WIRE
( 9 ) TAI L/STOP LIGHT W I R E
1 -26
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General Information
Emission Control System
The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify that
their motorcycles comply with applicable exhaust emissions standard during their useful life,when operated and maintained
according to the instructions provided,and that motorcycles built after January 1 , 1 98 3 comply with applicable noise emis­
sion standards for 1 year or 6 , 000 km ( 3. 730 miles) after the time of sale to the ultimate purchaser,when operated and
maintained according to the instructions provided. Compliance with 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 monoxide does not
react in the same way,but it is toxic.
Honda Motor Co.,ltd. utilizes lean carburetor settings as well as other systems,to reduce carbon monoxide and hydrocarbons.
Crankcase Emission Control System
The crankcase emission control system routes crankcase emissions through the air cleaner and into the combustion chamber.
( 1 ) AIR CLEANER
(2) CARBURETOR
FRESH AIR
.. : (4) BLOW-BY GAS
<=:>: ( 3 )
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1-27
General Information
Exhaust Emission Control System (Pulse Secondary Air Injection System)
California type only
The exhaust emission control system consists of a pulse secondary air injection system which introd uces filtered air i nto the
exhaust gases i n the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in
the exhaust system . This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable
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 bu ilt-in check valves . The PAI R check valves prevent
reverse air flow through the syste m . The pulse secondary air i njection control valve reacts to high intake manifold vacuum
and will cut off the supply of fresh air du ring engine deceleration, thereby preventing afterburn i n the exhaust syste m .
No adjustments t o t h e secondary air supply system should b e made, although periodic inspection o f t h e components is recom­
mended .
(1I FRONT PU LSE SECON DARY A I R I NJECTIO N ( PA I R )
C O N T R O L VALVE
(2) AIR CLEA N E R
(4) EXHAUST PORT
1-28
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General I nformation
Evaporative Emission Control System ( California Type Only)
This vehicle compl ies with the Cal ifornia Air Resou rces Board req uirements for control of evaporative em issions .
Fuel vapor from the fuel tank and carburetor is routed into the evaporative emission canister where it is a bsorbed and stored
while the engine is stopped . When the engine is running and the evaporative emission purge control diaphragm valve i s open
fuel vapor in the evaporative emission canister is drawn into the engine through the carburetor. At the same time, the evaporative
emission carburetor air vent control valve is open and air is drawn into the carburetor through the valve .
(1) EVAPO RATIVE E M I S S I O N ( EVAP) PU R GE CONTROL VALVE
(2) F U E L TAN K
(3) EVAPORATIVE
( EVAP)
CAN I STER
(4) FRESH AIR
(6) EVAPORATIVE E M I S S I O N CARBURETOR
A I R VENT ( EVAP CAV) CONTROL VALVE
'
(5) DRAIN
c:::> : (7) FRESH A I R
.. : ( 8 ) F U E L VAPOR
Noise Emission Control System
TAM P E R I N G WITH T H E N O I S E CONTROL SYSTEM I S PRO H I BITE D : 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, repa i r or replace­
ment, of any device or element of design incorporated i nto any new vehicle for purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is i n use; or (2) the use of the vehicle after such device or element of design
has been removed or rendered inoperative by any person .
Among those acts presumed to constitute tampering are the acts listed belo w :
1. Removal o f , or puncturing t h e muffler, baffles, header pipes or a n y other component w h i c h conducts exhaust gases .
2 . Removal of, or puncturing of any parts of the intake syste m .
3. lack o f proper maintenance .
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified
by the manufactu rer.
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1 - 29
General Information
Emission Control Information labels
(U.S.A. Only)
An Emission I nformation Label is located on t h e frame a s
show n . T h e right s i d e cover must be removed t o v i e w i t .
I t g ives basic tune-up specifications.
( 1 ) E M I SS I O N CONTROL I N FORMATION LAB E L
Vehicle Emission Control Information Update Label
After making a high altitude carburetor adjustment, attach a n
update l abe l on the right d o w n tub e as shown .
After re-adjusting the carburetor back to standard settings for
low alitude, remove the update label .
( 1 ) U PDATE 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 .
( 1 l VAC U U M HOSE ROUTI N G LABEL
1 - 30
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VAC U U M H O S E R O U T I N G D I A G RAM
ENG I NE FAM I L YE V A P O R A T I V E F A M I L YCAL I FORN I A VEH I CLE
2 . Frame/Body Panels/Exhaust System
Service Information
2- 1
Front Side Cover Removal/I nstallation
2- 3
Trou bleshooting
2- 1
Exhaust System Removal/I nstallation
2-4
Seat Removal/Installation
2-2
Rear Fender Removal /Installation
2- 7
Fuel Tank Removal/Installation
2-2
Side Cover Removal/Installation
2-3
U pper Fairing Removal/Installation
(VF7 50C D )
2-8
Service Information
•
•
•
•
•
•
•
Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.
Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
Work in a well ventilated area : Smoking or allowing flames or sparks in the working area or where gasol ine is stored can
cause a fire or explosion .
This section covers removal and instal lation of the frame body panels, fuel tank and exhaust system .
Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engi n e .
When insta l l i ng t h e exhaust pipe, install a l l t h e fasteners loosely . Next, tig hten t h e exhaust p i p e joint nuts first, t h e n tight­
en th� mounting fasteners . If you tighten the mounting fasteners first, the exhaust pipe may not seat properly .
Always inspect the exhaust system for leaks after insta llatio n .
Troubleshooting
Excessive Exhaust Noise
•
•
Broken exhaust system
Exhaust gas leak
Poor Performance
•
•
•
Deformed exhaust system
Exhaust gas leak
Clogged m uffler
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2- 1
Frame/Body Panels/Exhaust System
Seat Removal/Installation
Remove t h e seat b y removing t h e th ree mounting bolts .
(2) BOLTS
During seat installation, align the seat hook with the frame
hook and holes of the seat with the bosses on the side covers .
I nsta ll the three mounting bolts .
CAUTION
Be careful not to pinch the wire harness between the
seat and frame.
(5) BOSS
Fuel Tank Removal/Installation
•
Gasoline is extremely flammable and is explosive under
certain conditions .
( 1 ) FUEL TANK
Remove the seat (a bove ) .
Turn the fuel valve O F F .
D iscon nect t h e fuel tube .
Remove the mounting bolt and collar.
Disconnect the breather tube .
Remove the fuel tan k .
I nstall t h e f u e l t a n k in t h e reverse order of remova l .
After i nsta llation, turn t h e fuel valve O N a n d check t h e fuel
line for leakage .
I nstall the seat (above ) .
(4) FUEL TUBE
2 -2
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(3) BR EATH ER TUBE
Frame/Body Panels/Exhaust System
Side Cover Removal/Installation
P u l l t h e cover bosses from t h e grom mets .
Slide the cover boss down from the hole in the seat and re­
move the side cover.
( 1 ) HOLE
NOTE
I
•
Be careful not to damage the boss .
I nstall the side cover in the reverse order of removal .
14) BOSSES
Front Side Cover Removal/Installation
Remove the front side cover mounting screw . Then remove
the cover by sliding it forward .
I nstal l the front side cover in the reverse order of removal .
( 1 ) FUEL TAN K BRAC K ET
N OTE
•
At installation, align the tab of the front side cover with
the g roove of fuel tank mount bracket .
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2-3
Frame/Body Panels/Exhaust System
Exhaust System Removal/Installation
( 1 4)
---'�-__,�-==_...::;"'7""-++-+---�
( 5)--
c
2 1 ( 2 . 1 . 1 5)
(3)
c
39 ( 3 . 9. 28)
c
44 (4.4, 32)
\
(2)
( 7)
(9)
2 -4
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(8)
c
2 7 ( 2 . 7, 20)
c
21 ( 2 . 1 , 1 5)
Frame/Body Panels/Exhaust System
NOTE
•
When insta l l i ng the exhaust pipe/muffler, always tig hten the exhaust pipe joint nuts first, then tighten the mounting
fasteners, see next pag e .
Procedure
Q'ty
Removal Order
(1)
(2)
( 3)
(4)
( 5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1 )
( 1 2)
( 1 3)
( 1 4)
( 1 5)
Rear exhaust pipe protector
R e a r cylinder h e a d mount bolt
Rear cylinder heat mount bracket bolt
Rear cylinder head mount bracket
Rear exhaust pipe band bolt
Front exhaust pipe protector
Front exhaust pipe band bolt
M uffler mounting bolt
Muffler assembly
Rear exhaust pipe joint nut
Rear exhaust pipe
Exhaust pipe gasket
Front exhaust pipe joint nut
Front exhaust pipe
Exhaust pipe gasket
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1
1
2
1
1
1
1
1
1
2
1
1
2
1
1
Remarks
I nstallation is in the reverse order of removal .
I nstal lation (page 2-61
Loosen the band bolt .
Loosen the band bolt .
2- 5
Frame/Body Panels/Exhaust System
Rear Exhaust Pipe Protector Installation
I nstal l the rubber cap to the rear exhaust pipe hoo k .
A l i g n t h e h o o k o f t h e rear exhaust pipe with groove o f t h e rear
exhaust pipe protector .
Adjust t h e clearance b y moving the protector .
Standard : 2 -5 m m (0.08 - 0 . 1 9 in)
Tighten the exhaust pipe protector bolt.
Torque : 1 2 N•m ( 1 . 2 kg-m, 9 ft-lbl
Exhaust Pipe/muffler Mounting Fasteners
Tightening
When tighten the exhaust pipe/muffler mounting fasteners,
while push the exhaust pipe to inside .
( 1 ) EXHAUST PI PE
2- 6
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Frame/Body Panels/Exhaust System
Rear Fender Removal/Installation
( 5)
(1)
NOTE
•
Route the wire harness properly (page 1 -20) .
Requ isite Service
•
Seat remova l/installation (page 2-2) .
Procedure
•
O'ty
Removal Order
(1)
(2)
(3)
(4)
( 5)
(6)
Rear turn signal light connector
Brake/tai l l ight connector
Rear fender mounting bolt/nut
Grab rail
Rear fender assembly
Sub frame
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4
3
Side covers removal/installation (page 2-3)
Remarks
I nstal lation is in the reverse order of remova l .
D isconnect the connector.
Disconnect the connector .
8/4
2
1
1
2-7
Frame/Body Panels/Exhaust System
Upper Fairing Removal/Installation (VF 7 50CD)
CAUTION
•
Do not scratch and damage the windscreen .
Procedure
Q'ty
Removal Order
(1)
(2)
2-8
Upper fairing mounting bolt
Upper fairing
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Remarks
I nstal lation is in the reverse order of remova l .
3
1
At i nstallation, align the tab of the upper fairing stay with
the hole of the cable g u i g e .
Frame/Body Panels/Exhaust System
Windscreen Replacement
( 1 ) STAYS
Remove the screws, plastic washers and rubber washers .
Remove the wi ndscreen and upper fairing stays .
I nsta llation is in the reverse order of remova l .
(4) SCREW
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(3) PLASTI C WAS H E R
2-9
MEMO
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3 . Maintenance
Service I nformation
3- 1
Valve Clearance
3-5
Service Access G u ide
3-2
Drive Chain
3 -8
Maintenance Schedule
3-4
Headlight Aim
3- 1 0
Air Cleaner
3- 5
Service Information
•
•
Refer to Common Service Manual for items not included in this manual .
Refer to Specifications ( Section 1) for mai ntenance data .
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3- 1
Maintenance
Service Access Guide
•
•
The following shows the locations of the parts that m u st be removed for the m a i ntenance items listed below.
Refer to the Common Service Manual for items not included in this manual .
Refer to section 2 ( F rame/Body Panels/Exhaust System ) . for the parts that m ust be removed for service.
For example: Air Cleaner (Conta mination, clogging, replacement) : Parts
Rear Fairing - The part required to be removed for service .
•
( 1 ) Throttle Grip (Operation, free play)
( 1 8) Valve Clearance ( I nspection/Adj ustment : page 3-5)
• Fuel tank
(2) Brake Lever (Air in system )
( 3 ) Ma ster Cylinder
( Level check, fluid replacement)
( 1 7) Spark Plug (Wear, damage, color)
( 1 6) Suspension
(Loose, wear, damage)
(4) Headlight (Ai m : page 3- 1 0)
( 1 5) Brake Drum
(Shoe wear)
( 1 4) Wheel
( Damage, runout,
corrosion)
( 1 3) Tire
(Wear, damage, air pressure)
( 1 2) Brake Light Switch (Ope ration)
( 5 ) Wheel
( Damage, runout,
corrosion)
(6) Tire
(Wear, damage, air pressure)
( 7) Radiator Cap
( Coolant replacement)
( 8 ) Pulse Secondary Air I njection System
(California type only; Air leaks,
d eterioration, damage)
·
( 1 1 ) Reserve Coolant Tank Cap
( 1 0) Oil Level Gauge (Oil level check, replacement)
3-2
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( 9) Brake Peda l ( Free play, height)
Maintenance
( 1 3) Air Cleaner
( Contamination, clogging, replacement; page 3-5)
• Fuel tank
( 1 ) Synchronization Adjusting Screw
(Carbu retor synchronizatro n ; page 5- 1 4)
• M iddle cover
( 1 2) C l utch lever ( Free play)
( 1 1 ) Steering Head Bearing ( Damage)
(2) Fuel line (Damage, leakage)
( 1 0) Suspension
( loose, wear, damage)
(9) Caliper ( Pad wear)
( 8 ) Brake Hose
( leakage , deterioration,
damage)
(3) Drive chain
( Free play, lubrication ,
replacement; page 3-8)
(4) Side stand (Operation)
(7) Oil Filter ( Replacement)
(6) Carburetor Choke ( Operation)
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( 5) Throttle Stop Screw
3-3
Maintenance
Maintenance Schedule
Perform the PRE-R I D E I N SPECT I O N in the Owner's Manual at each sched uled maintena nce period .
1 : I nspect and clean, Adjust, Lubricate, or Replace if necessary .
R: Replace, C: Clea n , L: Lubricate, A: Adjust
The following items require some mechanical knowleg e . Certai n items (particularly those ma rked * and * * ) may req uire more
technical information and tools. Consult their authorized Honda dealer.
�
Note
x
s
en
�
w
Note 5
Carbu retor Choke
I
I
I
Air Cleaner
Spark Plug
*
Note 2
I
I
R
R
I
R
I
R
I
R
I
Valve Clearance
Engine Oil
R
R
R
R
Engine Oil Filter
R
R
R
R
I
I
I
*
Carburetor Synchronization
*
Carbu retor Idle Speed
Radiator Coola nt
I
I
I
I
I
I
R
I
I
I
I
I
I
Cooling System
Secondary Air Supply System
N ote 4
*
Evaporative Emission Control
System
Note 4
Brake Shoe/Pad Wear
I
I
*
Brake Fluid
I
Note 3
*
!:::
I
I
Every 600 mi ( 1 , 000 km) I , L
Note 3
I
I
R
I
I
R
I
I
I
I
I
I
I
I
I
*
Brake Light Switch
I
I
I
*
Headlight Aim
I
I
I
Brake System
0
c;;
I
384
*
�
a:
z
0
Refer
To
Page
I
w
....I
w
320
24
I
en
I<(
1 92 256
20
I
Drive Chain
w
16
Throttle Operation
....I
w
en
en
128
12
*
I<(
Q
64
8
*
w
a:
z
10
4
Fuel Line
w
0
1 00 km
0. 6
*
�
!:::
x
1 , 000 mi
Odometer Rading ( N ote 1 )
Clutch System
I
I
I
I
I
I
I
I
I
I
I
�
w
Side Stand
*
Suspension
I
I
I
*
0
z
N uts, Bolts , Fasteners
I
I
I
**
Wheels/Tires
I
I
I
**
Steering Head Bearings
I
I
I
en
z
*
I
I
Note 5
Note 5
3- 5
Note 5
3- 5
Note 5
Note 5
5- 1 4
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
Note 5
1- 12
Note 5
Note 5
Should be serviced by an authorized Honda dealer, unless the owner has the proper tools and service data and is mechani­
cally qualified .
* * I n the i nterest of safety, we recommended these items be serviced only by an authorized Honda dealer.
Notes: 1. At higher odometer readings, repeat at the frequency i nterval established here .
2 . Service more frequently when riding in u n usually wet or dusty areas.
3 . Replace every 2 years, or at indicated odometer interval , whichever comes first . Replace requires mechanical ski l l .
4. California type only.
5 . Refer to Common Service M a n u a l .
3-4
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Maintenance
Air Cleaner
Remove
Remove
Remove
Remove
the
the
the
the
fuel tank (page 2-2) .
front side cover (page 2-3 ) .
two screws a n d airduct stopper.
air duct by sliding it backward .
( 1 l A I R D UCT STO PPER
Remove the nine screws and air cleaner housing cover/air
cleaner.
Remove the air cleaner from the air cleaner housing cover.
Discard the a i r cleaner in accordance with the maintenance
schedule .
Also, replace the element any time it is excessively d i rty or
damaged .
I nstall the removed parts in the reverse order of remova l .
Valve Clearance
Inspection
NOTE
•
I nspect and adjust the valve clearance while the engine
is cold ( Below 3 5 ° C/9 5 ° 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
mounting bolt and swing the radiator forward , then secure it
out of the way.
CAUTION
•
Be careful not to damage the radiator fins.
Remove the front cylinder head cover (page 8-2) .
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3- 5
Maintenance
Turn the crankshaft clockwise and align its "T 1 " mark with
the index mark on the right crankcase cover.
( 1 ) I N DEX MARK
Make sure that N o . 1 piston is at TDC (Top Dead Center) on
the compression stroke.
If it is not on the com pression stroke, turn the crankshaft one
full turn (360 ° ) clockwise .
( 2) "T 1 " MARK
I nsert the feeler gauge between the valve l ifter and the cam
lobe.
Check the valve clearances for the N o . 1 cyl inder i ntake and
exhaust valves using a feeler gauge .
Valve clearance :
IN: 0 . 1 6 ± 0.02 mm (0.006 ± 0 . 0 0 1 in)
EX: 0 . 25 ± 0.02 mm (0.0 1 0 ± 0.001 in)
NOTE
•
Record the clearance for each valve for reference in shim
selection if adjustment i s required .
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 N o . 4 cylinder.
( 1 ) The cylinder n u m bering is g iven below :
( 3 ) LEFT
Turn the crankshaft clockwise 3/4-turn ( 2 7 0 ° ) and align its
"T 1 " mark with the index mark on the right crankcase cover .
( 2 ) FRONT
C h ec k t h e valve clearances f o r th e N o . 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 t h e valve clearances f o r t h e N o . 2 cylinder.
Adjustment
Remove the camshafts (page 8-2 ) .
Remove the valve lifters a n d s h i m s .
NOTE
•
•
•
•
Shims may stick to the inside of the valve l ifte r .
Do no t al low t he shims t o fal l i nto the crankcase .
Mark all lifters and shims to ensure correct reassembly.
The valve lifter can be easily removed with a valve lap­
ping tool or magnet .
The shims can be easily removed with tweezers or a
magnet.
3 -6
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(4) Firing order
(5) # 1 - 90 ° - # 4 - 2 7 0 ° - # 3 - 90 ° - # 2 - 2 7 0 ° - # 1
( 1 )VALVE LIFTER
Maintenance
Clean the valve shim contact area in the valve lifter with com­
pressed a i r .
Measure the shim thickness and record i t .
( 1 I SHIM
NOTE
•
Sixty-five different shim thickness are available : from the
thinnest ( 1 . 200 mml to the thickest ( 2 . 800 mml in in­
tervals of 0.025 mm.
Calculate the new shim thickness using the equation below.
A = B - C + D
A: New shim thickness
B: Recorded valve clearance
C: Specified valve clearance
D: Old shim thickness
Example :
Recorded valve clearance : 0 . 1 6 mm
Old shim thickness: 1 . 725 mm
Specified valve clearance : 0 . 20 mm
A = 0 . 1 6 - 0 . 20 + 1 . 725
A = 1 .685
NOTE
•
•
e e e e
1 . 80 m m
1 .825 mm
1 . 85 mm
1 .875 mm
Make sure of the correct shim thickness by measuring
the shim with m icrometer.
Replace the valve seat if a carbon deposit results in a
calculated d imension of over 2 . 800 m m .
I nstall t h e newly selected s h i m on t h e valve retainer.
Apply molybdenum d isulfide oil to the valve l ifter.
I nstall the valve l ifter in the valve l ifter holes.
NOTE
•
I nstall the unchange shims and valve l ifters in their origi­
nal locations.
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3-7
Maintenance
I nstall the camshaft and camshaft holders (page 8-8) .
Rotate the camshafts by rotating the crankshaft clockwise
several times.
Recheck the valve clearance .
( 2 ) GROOVES
( 1 ) COVER GASKET
Apply Honda Bond A to the cylinder head cover g rooves as
show n .
I nstall t h e cover gasket w i t h t h e " I N " m a r k facing t h e intake
side .
I nstal l the cover bolt washer with the " U P" mark facing u p .
Tighten t h e cover bolts .
Torque: 1 0 N·m ( 1 .0 kg-m, 7 ft-lbl
I nstal l the removed parts in the reverse order of remova l .
( 3 ) CYLI N D E R H EAD COVE R
Drive Chain
Replacement
The MAG NA VF7 50C uses a drive chain with a staked master
link.
Loosen the drive chain.
Assemble the special too l .
I s.TooL I
Drive chain cutter
07HMH - M R 1 0 1 02 or
07HMH - M R 1 0 1 0B
( U . S . A . only)
NOTE
•
When using the special tool , follow the manufacture's
operating instructions.
(11 1 s . TooL I D R I V E C H A I N CUTTER
3- 8
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M aintenance
locate the crim ped pin ends of the master li n k from the out­
side of the chain and remove the l in k with the d rive chain
cutter .
! s TooL !
Drive chain cutter
07HMH-MR 1 0 1 02 or
07HMH-MR 1 0 1 0B
( U . S.A . only)
NOTE
•
When using the special tool, follow the manufacture's
operating instructions.
Remove the d rive chai n .
Remove the excess drive chain l i n ks from the new drive chain
with the d rive chain cutter .
NOTE
•
( 1 ) 1 LI
��
�
( 21 MASTER LI N K
Include the master lin k when you count the d rive chain
links.
Standard link: 1 1 8 link
I II
Replacement chain : RK 50 MFOZ 1
: DID 50 V4
I s.TooL I
Drive chain cutter
Link plate holder
LJ
lT
I
f-o!ICI--- ( 3) 1 1 8 L I N K
07HMH-MR 1 0 1 02 or
07HMH-MR 1 0 1 0B
( U . S .A. only)
07NMH-MW00 1 1 0
or 07PMH-MZ20 1 1 0
CAUTION
•
Never reuse the old drive chain, master link, master link
plate and 0-rings.
CAUTION
•
Insert the master link from the inside of the drive chain
and install the plate with the identification mark facing
the outside.
lOS:
1 .2- 1 .4 mm
I n stall the new d rive chai n . Assemble the new m aster link, 0rings and plate .
(41 1 s. TooL I DRIVE C H A I N CUTTER
I
( 1 ) MASTER L I N K
Assemble and set the drive chain cutter .
Make sure t h a t the master link p i n s are i nstalled properly.
Measuring the master link pin length projected from the plate .
Standard length : 1 .2-1 .4 mm (0.05-0 .06 in)
Stake the master link pins.
\
. ( 21 1 s . Tool I DRIVE C H A I N CUTTER
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3-9
Maintenance
Make sure that the pins are staked properly by measuring the
diameter of the staked area using a slide calipers .
( 1 1 S L I DE CALIPER
Diameter of the staked area :
DID: 5 . 50 - 5 .80 mm (0. 2 1 7 - 0 . 228 in)
RK: 5 . 5 5 - 5.85 mm (0 . 2 1 0 - 0 . 230 in)
After staking, check the staked area of the master link for
cracks . In there is any cracking, replace the master link, 0rings and plate .
CAUTION
•
Drive chain with clip-type master link must not be used .
0
Headlight Aim
•
An improperly adjusted headlight may blind oncoming
drivers, or it may fail to light the road for a safe distance.
V F 7 50C D :
Adjust the headlight a i m horizontally and vertically, turning the
adjusting screws as shown .
V F 7 50C :
Refer to section 2 of the common Service Manua l .
3- 1 0
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( 1 1 A D J U STI N G SCREWS
X
Service Information
Troubleshooting
Lubrication System Diagram
4- 1
4- 1
4. Lubricatio n System
Oil Pump Removal/Installation
Oil Pump Disassembly I Assembly
4-2
4-3
4-4
Service Information
•
•
•
•
•
•
•
•
If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and
may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods.
Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your
hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN.
The o i l p u m p can be serviced with the engine i n sta l led i n the frame.
For o i l pressu re check, refer to section 4 of the Common Service M a n u a l ; for the switch l ocation, see page 1 8-2 of this
manual
The service procedu res i n this section must be performed with the engine o i l dra i ned.
When removi ng and i n sta l l i ng the o i l pu m p use ca re not to a l l ow dust or d i rt to enter the engi ne.
If a ny portion of the o i l p u m p is worn beyond the specified service l i m its, replace the o i l p u m p as a n assem bly.
After the o i l p u m p has been i n sta l led check that there a re no o i l leaks and that o i l pressu re is correct.
Troubleshooting
Oil Level Low
O i l cons u m ption
External o i l leak
Wo rn pisto n ring or i ncorrect piston ring i n sta l lation
Worn va lve g u ide or sea l
•
•
Low Oil Pressure
Clogged o i l stra i ner screen
O i l p u m p worn or damaged
I ntern a l oil leak
Pressu re rel i ef va lve stuck open
I ncorrect o i l bei n g used
Low oil level
•
•
•
•
•
•
•
Low Or No Oil Pressure
Clogged o i l orifice
I nco rrect o i l being used
•
•
•
High Oil Pressure
Plugged o i l fi lter, gallery, or metering orifice
Pressu re rel i ef va lve stuck closed
I ncorrect o i l being used
•
No Oil Pressure
O i l level too low
O i l p u m p d rive chain or sprocket broken
O i l p u m p damaged ( rotor shaft)
I nternal o i l leaks
•
•
•
•
•
•
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4- 1
Lubrication System
Lubrication System Diagra m
AFTE R '94
( 1 ) CAM SHAFT
(9) OIL PRESS U RE
RELIEF VALVE
•
4-2
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Lubrication System
Oil Pump Removal/Installation
_,
: 0-ring
)«j��- ( 10) r:w
c 18 (1.8, 1 3)
N OTE
•
•
Use ca re to keep d ust or d i rt out of the engine.
After in sta l l ation, check that there a re no o il leaks.
Requisite Service
•
•
E ngine o i l d ra i n i n g/refi l l ing
Cl utch remova l/i nsta l l ation ( page 9-4, 6)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1 )
(12)
(13)
(1 4 )
Removal Order
O i l pa n bolt
O i l pa n
Gasket
Pressu re rel ief va lve
0-ri n g
Oil strainer
0-ri n g
O i l pipe
0-ri ng
O i l p u m p d riven sprocket bolt
O i l p u m p d riven sprocket
O i l p u m p m ounting bolt
O i l p u m p assem bly
Dowel pin
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•
•
O'ty
12
1
1
1
1
1
1
2
4
1
1
3
1
2
2-4)
Exha ust system remova l/i nsta l lation ( page
Water p u m p rem ova l/i nsta l latio n ( page 6-7 )
Remarks
I nsta l l ation is in the reverse o rder of remova l.
At insta l lation, tighten the bolts as shown.
Apply a locki ng agent to the th reads.
4-3
Lubrication System
Oil Pu mp Disassembly I Assembly
( 1 3)
( 1 2)
(1 1 )
( 1 0)
(1)
Sit
(2)
.,
NOTE
•
•
•
•
If any portion of the o i l p u m p is worn beyond the specified service l i m it, replace it as a n assem bly.
Before assem bly them, clean a l l d isassem bled pa rts thoroughly with clean engine o i l .
Refer to section 4 of the Com m o n Service M a n u a l for i nspection i nformation.
Refer to page 1 -6 for specification.
Requisite Service
•
O i l pu mp remova l/i nsta l lation ( page 4-3)
Procedure
(1 )
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1 )
( 1 2)
( 1 3)
( 1 4)
Disassembly Order
Cotter pin
0-ring
Oil stra i ne r pipe
Bolt
Pu m p cover
Dowel pi n
Feed p u m p cover
Dowel pin
Outer rotor
Inner rotor
Rotor shaft
Drive pin
Washer
O i l p um p body
4-4
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O'ty
Remarks
Assem bly is i n the reverse order of d isassem bly.
1
1
1
3
1
2
1
2
1
1
1
1
1
1
After i n sta l lation, check that the rotor shaft turns freely.
Insta l l with the punch m a rk facing the o i l p u m p body.
Insta l l a l ig n i n g the cut out with the d rive pin.
I n sta l l i n the rotor shaft hole.
Service Information
Troubleshooting
Air Cleaner Housing Removal/
Installation
Carburetor Removal/Installation
Carburetor Separation
Carburetor Disassembly I Assembly
Carburetor Combination
Carburetor Tube Routing
(California Type Only)
5-1
5-2
5-3
5-4
5. Fuel System
Carburetor Synchronization
Pilot Screw Adjustment
High Altitude Adjustment
(U .S.A. Only)
5-6
Evaporative Emission Canister (EVAP
Canister) Removal/Installation
(California Type Only)
5- 1 0
Pulse Secondary Air Injection Control
Valve (PAIR Control Valve) Removal/
Installation (California Type Only)
5-8
5- 1 3
5- 1 4
5- 1 6
5- 1 7
5- 1 8
5- 1 8
Service Information
•
•
•
Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.
Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind,
resulting in loss of vehicle control.
Work i n a wel l venti l ated a rea. Smoking or a l lowi ng flames or spa rks i n the work a rea or where gaso l i n e is sto red
ca n ca use a fi re 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 tan k remova l and i nsta l lation.
When d i sasse m b l i ng fuel system pa rts, note the locations of the 0-rings. Replace them with new ones on reassem ­
bly.
Before removi ng the carbu retors, place the suitable container under the carbu retor d ra i n tu be, loosen the drain bolts
a n d d ra i n the carbu retors.
After removi ng the carbu retor, wra p the i ntake port of the engine with a shop towel or cover it with pieces of tape to
prevent any foreign material from d ropping i nto the engine.
The vac u u m c h a m ber a n d float c hamber can be serviced with the carbu retors assem bled.
Cal ifornia Type On ly:
All hoses used in the evaporative em ission control system a re n u m bered for identification. When connecti ng one of
these hose, com pa re the hose n u m ber with the Vac u u m Hose Routi ng Diagram Label, page 1 -30, and ca rbu reto r
tu bes routi ng, page 5- 1 3.
•
•
•
•
•
•
NOTE
•
If the veh icle is to be stored for more than one month, d ra i n the float bowls. Fuel left i n the float bowls may ca use
clogged jets resulting i n h a rd sta rti ng or poor d riveab i l ity.
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5- 1
Fuel System
Troubleshooting
Engine Won't Start
Too m uch fuel getting to the engine
- Air cleaner clogged
- Flooded carbu retor
I ntake a i r leak
Fuel conta m i nated/deteriorated
No fuel to carbu retor
- Fuel stra i ner clogged
- Fuel tube clogged
- Fuel va lve stuck
- F loat level m i sadjusted
- Fuel ta n k breather tube clogged
Lean Mixture
Fuel jets clogged
Float va lve fa u lty
Float level too low
Fuel l i n e restricted
Carbu retor a i r vent tube clogged
I nta ke air leak
Th rottle va lve fa u lty
Vac u u m piston fa u lty
Cal ifornia Type On ly: Evaporative em ission carbu re­
tor a i r vent control va lve fa u lty
•
Afterburn When Engine Braking is Used
Lea n m ixtu re i n slow circuit
Ai r cut-off va lve ma lfu nction
E m ission control system m a lfu nction (Cal ifornia Type
O n ly)
.
- Pu lse secondary a i r su pply system fa u lty
- Loose, d isconnected or dete rio rated hoses of the
em ission contro l system
•
•
•
Backfiring Or Misfiring During Acceleration
Ignition system fa u lty
Fuel mixtu re too lean
•
•
Poor Performance (Driveability) And Poor Fuel Economy
Fuel system clogged
Ignition ma lfu nction
E m ission control system ma lfu ncti on (Cal ifornia Type
On ly)
- Loose, d isconnected or deterio rated hoses of the
e m ission control t!YStem
•
•
•
•
•
•
•
•
•
•
•
Rich Mixture
Sta rting en rich ment va lve i n ON position
Float valve fa u lty
F loat level too h i g h
Ai r jets clogged
Air clea ner conta m i n ated
Flooded carbu retor
•
•
•
•
•
•
Engine Stall, Hard To Start, Rough Idling
Fuel l i ne restricted
Ignition ma lfu nction
Fuel m ixtu re too lean/rich
Fuel conta m i n ated/deteriorated
I ntake a i r leak
Idle speed m i sadjusted
Float level m i sadjusted
Fuel tan k breather tube clogged
Pi lot screw m i sadjusted
Slow c i rcuit or sta rting enrichment circuit clogged
E m ission control system m a lfu nction (Cal ifornia Type
On ly)
- Evapo rative e m i ssi on carbu retor a i r vent control
valve fa u lty
- Evaporative emission p u rge control valve fa u lty
- Loose, d i sconnected or deterio rated hoses of the
em ission control system
•
•
•
•
•
•
•
•
•
•
•
5-2
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_
Fuel System
Air Cleaner Housing Removal/Installation
Requisite Service
•
Fuel ta n k remova l/i nsta l lation (page 2-2)
•
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Removal Order
Left m i d d l e cover stay bolt
Right m iddle cover stay bolt
Front pu lse secondary a i r i njection
va lve bolt
Rea r pu lse secondary air i njection
va lve a i r i nta ke pipe
Air cleaner housing screw
Front pu lse secondary air i njection
va lve a i r i ntake tu be
Rea r pu lse secondary air i njection
va lve a i r i nta ke tu be
Cra n kcase breather tu be
Air cleaner housing
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Air cleaner remova l/i nsta l lation ( page 3-5)
Remarks
Q'ty
Insta l l ation is in the reverse order of remova l .
3
1
control
2
Ca l ifornia type only
control
1
Cal ifornia type only
control
contro l
3
1
1
1
1
Ca l ifornia type only
Ca l ifornia type only
Move the air cleaner housing out of the carbu retor o n
t h e left.
CAUTION
• Be careful not to damage the air cleaner housing during removal/ installation.
5-3
Fuel System
Carburetor Removal/Installation
5-4
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Fuel System
•
Gasoline is extremely flammable and is explosive under certain conditions.
Work i n wel l venti lated a rea. Smoking or a l l ow flames or spa rks i n the worki ng a rea or where gasol i n e is stored ca n
ca u se a fi re or explostion.
•
N OTE
I
•
Route the cables and tu bes properly ( page 1 -20).
Requisite Service
•
Air cleaner housing remova l/i nsta l lation ( page 5-3)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1)
( 1 2)
Removal Order
Choke cable
Th rottle stop screw
S u b-ai r cleaner case tu be
No. 5 vac u u m tube (from the 3 way joint)
No. 1 1 vac u u m tu be (from the No. 1
carbu retor)
No. 10 vac u u m tube (from the 3way joint)
Left middle cover stay assembly
Fuel tu be
No. 6 vacu u m tube (from the AVCV)
Th rottle ca ble
Con n ecti ng tu be band screw
Carbu retor assembly
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•
Carbu retors d ra i n i ng
O'ty
Remarks
1
1
Insta l lation is i n the reverse order of remova l .
Remove the choke ca ble from the left m iddle cover stay.
Remove the th rottle stop ca ble from the left m iddle cover
stay.
1
1
1
Ca l ifornia type only
Cal ifornia type only
1
1
1
1
2
4
1
Ca l ifornia type o n ly
Discon nect the i g n ition switch connector.
Ca l ifornia type only
O n ly loosen.
5-5
Fuel System
Carburetor Separation
(1)
,
�
(5)
5-6
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(26)
Fuel System
Requisite Service
•
Carbu retor remova l/i nsta l lation ( page 5-4)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7 )
(8)
(9)
( 1 0)
(1 1)
Separate No. 4 carb. from No. 1 /2/3 carb.
Air cha m ber screw
Lock plate
Air cham ber/a i r fu n nel
0-ri ng
Choke ca ble
Sta rting enrichment va lve arm screw
Plastic washer
Sta rting enrichment va lve a rm
Plastic col l a r
Return spring
Carbu retor connecti ng nut
•
Carbu retor synchron ization ( page 5- 1 4)
Remarks
Q'ty
12
4
4/4
4
1
4
4
2
4
2
6
NOTE
Loosen the n uts g ra d u a l ly and a lternately.
Do not remove the con necti ng bolts.
•
•
( 1 2)
( 1 3)
( 1 4)
( 1 5)
No . 4 carburetor
No. 5 vacuum tube (from the No. 4 carbu retor)
Th rust spri ng
Choke cable holder
(22)
(23)
(24)
(25)
(26)
Separate No. 3 carb. from No. 1 /2 carb.
No. 5 vacuum tube (from the No. 3 carburetor)
No. 3 carb u retor
Thrust spring
S u b-a i r j o i nt pi pe/tu be/0-ring
No . 6 vacu u m tu be/joint pi pe/0-ring
No. 5 vac u u m tube (from the No. 1 /2
carbu retor)
F ront col l a red dowel pin
Rear col l a red dowel pin
Center col l a r
Fuel tu be/j oint pi pe/o-ri ng
Sta rti ng en richment va lve l i n k asse m bly
(27)
(28)
(29)
(30)
Separate No. 2 carb. from No. 1 carb.
�arbu retor connecting bolt
Th rottle l i n k
No. 2 carbu retor
No. 1 ca rbu retor
( 1 6)
( 1 7)
( 1 8)
( 1 9)
(20)
(2 1 )
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1
1
1
1
1
1
1
2/1/4
2/2/4
6/3
Cal ifornia type only
Cal ifornia type only
Ca l ifornia type only
1
1
1
2/3/6
1
3
1
1
1
5-7
Fuel System
Carburetor DisassemblyI Assembly
(23)
( 1 2)
( 1 5)
( 1 4)
�:
5-8
0-ring, gasket
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Fuel S ystem
NOTE
•
•
Vac u u m cham ber, float chamber and jets ca n be serviced with out sepa rati ng the carbu reto rs.
N ote the location of the each ca rburetor parts so they can be back i n thei r origi na l locati on.
Requisite Service
•
Carbu retor sepa ration ( page 5-6)
Procedure
(1)
(2)
(3)
Disassembly Order
Vacuum Chamber Disassembly Order
Vac u u m ch am ber cover screw
Vac u u m cha m ber cover
Diaphragm spring
Q'ty
Remarks
Assembly is i n the reverse order of d isasse m bly.
3
1
1
NOTE
At i n sta l lation, be ca refu l not to damage the spri n g .
NOTE
At insta l lation, a l i g n the tab of the d i a p h ra g m with the
carbu reto r body g roove.
Remova l/i nsta l l ation ( page 5- 1 2)
•
(4)
Di aph ra g m/vacu u m piston
1
•
(5)
(6)
(7)
J et need le holder
J et need le holder spring
J et need le/washer
1
1
1/1
Float Chamber Disassembly Order
Float chamber cover screw
Float chamber
0-ri ng
Float pin
Float
Float va lve
Main jet
Need le jet holder
Slow jet
Pilot screw
Spring
Washer
0-ri ng
3
1
1
1
1
1
1
1
1
1
1
1
1
Starting Enrichment Valve Disassembly
Order
(2 1 ) Valve n ut
(22) Spring
(23) Sta rti ng earchment va lve
4
1
1
(8)
(9)
( 1 0)
(1 1)
( 1 2)
( 1 3)
( 1 4)
( 1 5)
( 1 6)
( 1 7)
( 1 8)
( 1 9)
(20)
(24)
Air Cut Off Valve Disassembly Order
Ai r cut off va lve cover screw
1
(25)
(26)
Air cut off valve cover
0-ri ng
1
3
(27)
Air cut off va lve
1
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At i nsta l lati o n , be s u re the d i a p h ra g m a n d s p r i n g a re
properly seated, then tight them.
Do not lose the spring when va lve cover rem ova l .
At i nsta l latio n , i n sta l l the n ew 0-ri n g with its flat side
towa rd the carbu retor body.
5-9
Fuel System
Carburetor Combination
(27 )
D
�
D
No. 1 CAR B U R ETOR
,
5- 1 0
(25)
: 0-RING, COTIE R PIN
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(5)
Fuel System
NOTE
o
o
o
No. 1 carbu retor is the base carbu retor.
Before tighte n i ng the carbu retor con necti ng bo lt/n ut, check there is no cleara nce between each of the carbu retor
joi nts.
Tig hten the each connecti ng bolts/n uts g rad u a l ly a nd a lternately, be su re the bolt thread projections a re eq u a l
h i g h . Hold t h e n ut and tighten t h e other n ut on other side.
Requisite Service
o
Carbu reto r remova l/i nsta l lation ( page 5-4)
(1)
(2)
(3)
o
Procedure
Q'ty
Assemble No. 2 carb. with No. 1 carb.
Th rottle l i n k
No. 2 carbu retor
Carbu retor connecti n g bolt
1
1
3
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1 )
( 1 2)
( 1 3)
( 1 4)
Assemble No. 3 carb. with No. 1 /2 carb.
Sta rting e n rich ment va lve link assembly
Fuel tu be/joint pi pe/0-ri ng
Center col l a r
Rea r col l a red dowel pin
F ront co l l a red dowel pin
No. 5 vacu um tube (to the No. 1/2 crabu retor)
S u b-ai r j oi nt pi pe/tu be/0-ring
No. 6 vac u u m tu be/j oi nt pi pe/0-ring
No. 5 vacu u m tube (to the No. 3 carbu retor)
No. 3 carbu retor
Thrust spri ng
1
2/3/6
1
1
1
6/3
2/1 /4
2/2/4
1
1
1
( 1 5)
( 1 6)
(17)
( 1 8)
( 1 9)
Assemble No. 4 carb. with No. 1 /2/3 carb.
Choke ca ble holder
No. 4 carbu retor
Thrust spring
No. 5 vacu u m tube (to the No. 4 carbu retor)
Carbu retor connecti ng n ut
1
1
1
1
6
Carbu retor synchron ization ( page 5- 1 4)
Remarks
Refer to the d rawi ng for the com b i nation of the washer.
Cal ifornia type only
Ca l ifornia type o n ly
Ca l ifornia type o n ly
CAUTION
Tighten each nuts gradually and alternately with the
above procedure. Do not over-tighten the nuts.
o
(20)
(21 )
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
Return spring
Plastic col l a r
Sta rting en richment valve a rm
Plastic washer
Sta rting en rich ment va lve arm screw
Choke ca ble
0-ri ng
Air cham ber/a i r fu nnel
Lock plate
Air cha m be r screw
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2
4
2
4
4
1
4
4/4
4
12
5- 1 1
Fuel System
Jet Needle Holder Removal/Installation
( 1 ) J ET N E E DLE HOLDER
Removal
Remove the vacu u m piston ( page 5-8).
Te m p o ra r i l y i n st a l l the 4 m m sc rew or e q u i v a l e n t
(Exam ple; vacu u m cham ber screw).
Pu l l the screw and remove the jet needle ho lder.
If
CAUTION
•
•
Be careful not to damage the diaphragm.
Do not remove the jet needle holder by pushing the
jet needle.
Installation
I n sta l l the jet need le holder i nto the vacu u m piston u ntil
yo u felt t h e cl ick.
(2) 4 m m SCREW
(3) VAC U U M PISTO N
( 1 ) J ET N E I: DLE HOLDER
I nsta l l the vacu u m piston ( page 5-8) .
(4) J ET N E E DLE
Carburetor Body Cleaning
Clean the fue l stra i ne r i n the float va lve u s i n g the com­
pressed a i r from the float va lve seat side.
( 1 ) FLOAT VALVE SEAT
5- 1 2
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Fuel System
Carburetor Tube Routing (California Type Only)
(2) F U E L TUBE
(3) TO EVAP CAV CONTROL VALVE
g�g�==='
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( 5)
TO EVAP
PURGE
CONTROL
VALVE
(4) TO
SU B-AI R CLEAN E R
5- 1 3
Fuel System
Carburetor Synchronization
( 1 ) V�C U U M PLUG
NOTE
•
•
Refer to section 2 of the Co m m o n Service M a n u a l
for carbu retor synchron ization proced u re.
Synchron ize the carbu retors with the engine at nor­
mal operati ng tem perature, the tra nsm ission i n neu­
tra l and the m oto rcyc l e s u p p o rted sec u re l y o n a
level s u rface.
Remove the left and right middle covers.
Remove the No. 2 cyl i nder i ntake port vac u u m p l u g .
Con n ect t h e vac u u m g a u g e adaptor t o t h e No. 2 cyl inder
i ntake port.
D i sco n n ect t h e N o . 4 cyl i n d e r v a c u u m t u b e fro m t h e
engine i ntake port, a pply vac u u m t o t h e d isconnected tu be
and pinch the tube with a clip.
C o n n ect the vac u u m g a u g e t u b e to the No. 4 cyl i n d e r
i nta ke p o rt adaptor.
( 1 ) VAC U U M TUBE
49 States type:
Remove the No. 1 cyl inder i nta ke port vac u u m p l u g .
( 1 ) VAC U U M TUBE
Connect t h e vac u u m gauge adaptor t o t h e No. 1 cyl i nder
i ntake port.
California type:
D i sco n n ect t h e N o . 1 cyl i n d e r va c u u m t u b e from t h e
engine i ntake port.
C o n n ect the vac u u m g a u g e t u be to the N o . 1 cyl i n d e r
i ntake p o rt adaptor.
49 States type:
Remove the No. 3 cyl i nder i ntake port vacu u m p l u g .
Connect t h e vac u u m g a u g e adaptor t o t h e No. 3 cyl inder
i nta ke port.
California type:
D i sco n n ect the N o . 3 cyl i n d e r va c u u m t u b e fro m t h e
engine i ntake port.
C o n n ect the vacu u m g a u g e t u b e to the N o . 3 cyl i n d e r
i nta ke port adaptor.
( 1 ) VACU U M TUBE
5- 1 4
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Fuel System
Sta rt the engine.
Turn t h e th rott l e sto p sc rew knob and a dj u st t h e i d l e
speed .
( 1 ) THROTTLE STOP SCREW KNOB
Idle speed: 49 states type: 1 ,000 ± 1 00 rpm
California type: 1 , 1 00 ± 1 00 rpm
Canadian type: 1 ,000 ± 1 00 rpm
Check the each carbu reto r i ntake vacu u m pressu re is with­
in 20 mm (0.8 i n ) Hg of the base carbu retor.
N OTE
•
( 1 ) SCREW ( N o . 3 CAR BU RETO R )
The base carbu retor is the No. 1 carbu retor.
Syn c h ro n i z e to s pecificat i o n by t u r n i n g t h e a d j u st i n g
screws.
Recheck the id le speed and each cyl i nder i ntake vacu u m
pressu re s o i t is with i n 2 0 m m (0.8 i n ) Hg of the base ca r­
bu retor read in g after snapping the.th rottle grip 3 - 4 times.
Remove the vacu u m gauge and adaptors.
( 1 ) ... . ..... ,... ...
( N o . 2, 4 CARBU RETOR )
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5- 1 5
Fuel System
Pilot Screw Adjustment
Idle Drop Procedure
•
•
If the engine m ust be running to do some work,
make sure the area is well ventilated. Never run the
engine in an enclosed area.
The exhaust contains poisonous carbon monoxide
gas that may cause loss of consciousness and may
lead to death.
NOTE
•
•
•
•
M ake s u re the carbu retor synch ron izati o n is with i n
specification before pilot screw adj u stment ( page 51 4).
The pilot screw is facto ry pre-set and no adju stment
is necessary u n less it is replaced.
The e n g i ne m u st be wa rm fo r accu rate adju stment.
Ten m i n utes of stop-and-go riding is sufficient.
U se a ta c h o m ete r with g ra d u at i o n of 50 r p m o r
s m a l l e r t h a t w i l l a c c u rate l y i n d i c a t e a 5 0 r p m
change.
( 1 ) I •. -;;;OL I PI LOT
SCREW
WRE N C H
1. Using the special pilot screw wrench, turn each pi lot
screw clockwise u nti l it seats l i g htly. Then back it out
to the specification.
CAUTION
•
Damage to the pilot screw seat will occur if the pilot
screw is tightened against the seat.
(2) PI LOT SCREW
I s . TOOL I
Pilot screw wrench: Canadian type: 07908 - 4220201
49 states, California type: 07MMA - MV901 0A
Initial Opening: 49 states type: 2-1 /2 turns out
California, Canadian type: 2-3/8 turns out
2. Warm u p the engine to operati ng tem peratu re.
3. Stop the engine and attach the tachometer acco rd i n g
t o t h e man ufactu rer's instruction.
4. Sta rt the e n g i n e and adj u st the idle speed with the
th rottle stop screw knob.
Idle Speed:
49 states type: 1 ,000 ± 1 00 rpm
California, Canadian type: 1 , 1 00 ± 1 00 rpm
( 1 ) THROTTLE STOP SCREW KNOB
5. Tu rn N o . 1 ca rbu retor p i l ot screw in or out slowly to
obta i n the h i ghest engine speed .
6. Perform step 5 fo r a l l the ca rbu retor pilot screws.
7. Lig htly open the th rottle 2 3 ti mes, adj u st the i d l e
speed with t h e th rottle stop screw.
8. Turn N o . 1 carbu retor pilot screw in g rad u a l ly u ntil the
engine speed d rops 50 rpm.
9. Tu rn N o . 1 ca rbu retor pilot screw cou nterclockwise to
the fi n a l o pe n i n g from the positio n in step 8.
-
Final Opening: 49 states type: 3/4 turns out from step 8
California, Canadian type: 1 /4 turns out from step 8
1 0. Perform steps 8 and 9 fo r the No. 2, 3 and 4 carbu retor
pilot screws.
5- 1 6
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©
Revised: July, 1 995, '94 - '95 Magna VF750C/CD
1 995 American Honda Motor Co., Inc. - All Rights Reserved
MSV 69 1 3 fQ�04\
Fuel System
High Altitude Adjustment
(U. S. A. Only)
When the ve h icle i s t o be o pe rated conti n u ou sly a bove
2,000 m (6,500 feet), the carbu retors m u st be readj usted as
fo l l ows to i m p rove d rivea b i l ity a n d decrease ex h a u st
em ission.
Wa rm u p the engine to operati ng tem peratu re. Stop and
go rid i n g for ten m i n utes is sufficient.
Turn each p i l ot screw clockwise 1/2 turn.
High Altitude Adjustment: 1 /2 turn in
i s. TOOL I
Pilot screw wrench
07908 - 4220201
07MMA - MV901 0A
(U .S.A. only)
Adj ust the idle speed to 1 ,000 ± 1 00 rpm (Cal ifornia: 1 , 1 00
± 1 00 rpm) with the th rottle stop screw knob.
N OTE
•
T h i s adj u stment m u st be made at h i g h a ltitude to
ensure proper h i g h a ltitude operati o n .
VEHICLE EMISSION CONTROL INFORMATION UPDATE
• HONDA
MOTOR CO., LTD
THIS VEHICLE HAS BEEN ADJUSTED TO
IMPROVE EMISSIO N . CONTROL PERFORMANCE
WHEN OPERATED AT HIGH ALTITUDE.
�
�
�.
ALTITUDE PERFORMANCE ADJUSTMENT INSTRUCTIONS
ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER.
Attach a Ve h icle E m ission Control I nfo rmation La be l on
the right down t u be as shown i n t he label position i l l ustra­
tion.
NOTE
•
•
Do n ot attach the label to any part that ca n be easily
rem oved from the veh icle.
( 1 ) E M ISSION CONTROL
I N FOR MATI O N U P DATE LAB E L
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 sta ll i n traffic. If may also cause
engine damage due to overheating.
When the veh icle is to be ope rated conti n u ously below
1 ,500 m (5,000 feet), turn each p i l ot screw cou nterclock­
wise 1 /2 turn to its o ri g i n a l position a n d adj u st the i d l e
speed t o 1 ,000 ± 1 00 r p m (Ca l iforn i a : 1 , 1 00 ± 1 00 rpm ).
Be s u re t o m a ke these adjustment at low a ltitude.
Remove the Veh icle E m i ssion Control U pdate La bel that is
attached to the rig ht down tube afte r adj usti ng for low a lti­
tude.
( 1 ) PI LOT SCREW
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5- 1 7
Fuel System
Evaporative Emission Can ister
(EVAP Canister)
Removal/Installation
(California Type Only)
Disconnect the No. 4 tube.
Disconnect the No. 1 tube.
Remove the bolts and EVAP ca n i ster.
Insta l lation is i n the reverse order of remova l .
Pulse Secondary Air Injection
Control Valve (PAIR Control Valve)
Removal/Installation
(California Type Only)
( 1 )AIR I N J ECTIO N HOSE
\
CAUTION
•
To prevent damage to the PAIR control valve, do
not use high air pressure sources. Use a hand oper­
ated air pump only.
Front cylinder
Remove the rad iator ( page 6-5) .
Disconnect and remove t tie fol l owi ng:
- No. 1 0 vac u u m t ube
- a i r i njection h ose
- PAI R control va lve m o u nting bolt
- a i r i ntake h ose
PAI R control va lve
(5) PAI R CONTROL VALVE
( 1 ) No. 1 0 TUBE
�
Insta l lation is i n the reverse order of remova l .
After insta l l ing, check the tubes for loose con nections and
kinks.
I nsta l l the rad iator ( page 6-5).
Rear cylinder
Remove the seat ( page 2-2) .
Disconnect and remove the fol lowi ng:
- a i r i ntake hose
- air i njection h ose
- PAI R control va lve m o u nting bolt
- No. 10 vac u u m tube
- PAI R contro l va lve
Insta l l ation is in the reverse order of remova l .
After i nsta l l i ng, check t h e tu bes for loose connections a n d
kinks.
Insta l l the seat ( page 2-2) .
5·- 1 8
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(2) AIR I NTAKE
HOSE
(4) BOLTS
(3) AI R I NJ ECTI O N : HOSES
6. Coo l i n g System
Service Information
Troubleshooting
System Flow Pattern
Coolant Draining
6- 1
Thermostat Removal/Installation
6-2
Radiator Disassembly I Assembly
6- 1
Radiator Removal/Installation
6-3
Water Pump Removal/Installation
6-4
6-5
6-6
6-7
Service Information
•
•
•
•
•
•
•
•
Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot
and the coolant is under pressure may cause serious scalding.
Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes.
- If any coolant gets in your eyes, rinse them with water and consult a doctor immediately.
- If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately.
- If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water.
KEEP OUT OF REACH OF CHILDREN.
Add coo lant at the reserve ta nk. Do not remove the radiator cap except to refi l l or d ra i n the system .
All coo l i n g system services can be done with the engine i n the fra me.
Avoid spi l l i ng coolant on pai nted surfaces.
Afte r servici ng the system, check for leaks with a cool ing system tester.
Refer to section 25 of the Common Service M a n u a l for fa n motor switch and thermo sensor i nspection.
Troubleshooting
Engine Temperature Too High
Fau lty rad iator cap
I n sufficient coolant
Passages blocked i n radiator, hoses or wate r jacket
Air i n system
Fau lty water p u m p
Thermostat stuck closed
Fau lty tem peratu re gauge or thermo sensor
Fau lty coo l i n g fa n motor
Fau lty fa n motor switch
I ncorrect fa n s h roud insta l lation
Engine Temperature Too Low
Fau lty tem pe ratu re gauge or thermo sensor
Thermostat stuck open
Fau lty coo l i n g fa n motor switch
•
•
•
•
•
•
•
•
•
•
•
•
•
Coolant Leaks
Fau lty water p u m p mecha n ical sea l
Dete rio rated/fa u lty 0-ri ngs
Damaged or deteriorated gasket
Loose hose connection or cla m p
Damaged or deteriorated hose
Fau lty rad iator cap
•
•
•
•
•
•
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6- 1
Cooling System
System Flow Pattern
( 1 ) SIPHON TU BE
(5) TH E R MOSTAT
(2) RESERVE TAN K
(3) WATE
6-2
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PUMP
Cooling System
Coolant Draining
•
Wait until the engine i s cool before servicing the
cooling system . Removing the radiator cap while
the engine is hot and the coolant is under pressure
may cause serious scalding.
N OTE
•
For coo l a nt replace m e nt, refe r to section 5 of the
Common Service M a n u a l .
{2) SEALI N G WASH E R
Remove t h e wate r p u m p d ra i n bolt and sea l i n g washer.
Remove the radiator cap screw and radiator cap and d ra i n
t h e coola nt.
Remove the cylinder d ra i n bolts and sea l i n g washers and
d ra i n the coolant.
( 1 ) SEALI N G WAS H E R S
I nstal l the water p u m p d ra i n bolt with a new sea l i ng wash­
e r.
I n sta l l the cyl inder d ra i n bolts with new sea l i ng washers.
Refi l l the coolant to upper leve l .
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6-3
Cooling System
Thermostat Removal/Installation
(6)
(5)
Requisite Service
•
Coolant d rain in g ( page 6-3)
Procedure
(1 )
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1 )
( 1 2)
Removal Order
Right middle cover
G round wire connecto r
Thermo sensor con n ecto r
Radiator u pper hose
Thermostat housing cover bolt/term i n a l
Thermostat housing cover
0-ri ng
Thermostat
Thermostat housing bolt
Cyl i nder head-to-housing hose
Thermostat housing
Thermo sensor
6-4
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•
Q'ty
Coo l a nt refi l l i n g (Section 5 of the Com m o n Service
Manual)
Remarks
I nsta l lation is in the reverse order of remova l .
1
1
1
1
3/1
1
1
1
1
2
1
1
Loosen t h e c l a m p screw and d isconnect t h e hose.
At i nsta l l ation, i n sta l l the therm ostat with its bleed hole
facing right side while a l i g n i ng it with the g rooves i n the
housing.
Loosen the clamp screws a nd d isconnect the hoses.
At i n sta l lation, apply sea l a nt to the th reads of the sensor.
Cooling System
Radiator Removal/I nsta l lation
(4)
Requisite Service
•
•
Coolant d ra i n i ng ( page 6-3)
Coolant refil l (Section 5 of the Common Service Manual)
Procedure
(1)
(2)
(J)
(4)
(5)
(6)
Removal Order
Radiator siphon tube
Radiator u pper hose
Radiator lower hose
Fan motor switch connector
Radiator m o u nting bolt
Radiator asse m bly
•
Front side cover rem ova l/i nsta l l ation ( page 2-3)
Remarks
Q'ty
Insta l lation is in the reverse order of remova l .
1
1
1
1
3
1
Loosen t h e c l a m p screw and d i sco nnect t h e hose.
Loosen the c l a m p screw and d isconnect the hose.
Remove it after releasing the p rojection on the right radiator stay.
CAUTION
During removal and installation, be careful not to damage the radiator core.
•
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6-5
Cooling System
Radiator Disassembly I Assembly
(5)
\� (7}
an:n.•
-���
(8)
:.
llliiii'
CAUTION
I
Be careful not to damage the radiator core.
o
Requisite Service
o
Radiator remova l/i nstal l ation ( page 6-5)
Procedure
O'ty
Remarks
Assem bly is in the reverse order of d i sasse m bly.
R e l ease the two g rooves fro m u nd e r of rad i ator, t h e n
remove t h e radiator g ri l l .
Disassembly Order
(1)
Radiator g ri l l
1
(3)
( 2)
Fan motor switch connector
Coo l i ng fan s h roud bolt
1
3
(4)
Coo l i ng fan n ut
Coo l i ng fan
1
1
Fan m otor m o u nting n ut
Fan m otor
Fan motor switch
0-ri ng
3
1
1
1
(7)
(5)
(6)
(8)
(9)
6-6
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At i n sta l lati o n , i n sta l l the g ro u n d eye let j o i nt with the
bolt.
At i n sta l lation, a l i g n the coo l i n g fan g roove with the fan
motor shaft.
At i n stal l ation, apply seal a nt to the switch th reads.
Cooling System
�GN
Water Pump Removal/Installation
O I L P U M P S HAFT
Requisite Service
•
•
Coolant d ra i n i n g ( page 6-3)
Drive sprocket cover remova l/i nsta l lation ( page 1 0-2)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
Removal Order
Exhaust p ipe protector
Gears h ift l i n k joint bolt/jo int
Radiator lower hose
Water pump cover bolt
Water pu m p m o u nting bolt
Water pump cover
0-ri ng
Dowel pin
P u m p-to-engine hose
Water p u m p body
(1 1)
0-ri ng
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•
Q'ty
Coo l a nt refi l l ( S e ct i o n 5 of t h e C o m m o n S e rv i c e
Manual)
Remarks
I n sta l l ation is i n the reverse order of remova l .
1
1/1
1
2
2
1
1
2
1
1
1
Loosen t h e clamp screw and discon nect t h e hose.
Loosen the hose cla m p screw and disconnect it.
At i n sta l l ation, a l ig n the cut-out of the water p u m p shaft
with the o i l p u m p shaft.
At insta l l ation, apply the engine oil to the new 0-ri ng.
6- 7
MEMO
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7 . Engine Removal/Instal lation
Service Information
7- 1
Engine Removal/Installation
7-2
Service Information
•
•
•
During remova l and i n sta l lation, su pport the motorcycle using a safety stand or hoist.
The fol l owing components can be serviced with the engine i nsta l led i n the frame.
- O i l pump (Sectio n 4)
- Carbu retor (Sectio n 5)
- Water p u m p (Section 6)
- Ca mshaft/cylinder head (Section 8)
- Cl utch (Section 9)
- Gears h ift l i n kage (Section 1 0 )
- Alternator (Section 1 5)
- Pu lse generator (Sectio n 1 6)
- Sta rter cl utch (Section 1 7 )
- Sta rte r motor (Section 1 7 )
The fol l owing components req u i re engine rem ova l for service.
- Piston/connecti ng rod/cyli nder (Section 1 1 )
- Cra nkshaft/transmission (Section 1 1 )
- S h ift forks/shift drum (Section 1 1 )
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7- 1
Engine Removal/Installation
Engine Removal/Installation
(7)
c
c
54 ( 5.4, 39)
(24)
3 9 (3.9, 28)
c
9 (0.9, 6.5)
(2 1 )
( 1 9)
0
(22)
c
27 (0.7, 20)
( 1 2)
J?)
C
(1 1)
.,
27 (0.7, 20)
s 1 (5. 1 , 37)
( 1 5)
( 1 3)
(25)
( 1 0)
.,
(9)
(26)
c
7-2
44 (4.4, 32)
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(28)
(27)
c
39 (3.9, 28)
(3)
(8)
Engine Removal/Installation
CAUTION
I
•
Do not support the engine using the oil filter.
NOTE
•
•
•
•
•
S u pport the m otorcycle using safety sta nd or a hoist.
A floor jack or other adjusta ble su pport is req u i red to support a nd m a neuver the engine. The jack height m u st be
conti n u a l ly adjusted to rel ieve stress for ease of bolt remova l .
Turn the ignition switch OFF and disconnect the battery g ro und (-) term i n a l .
N ote the d i rection of the engine m o u nting bolts.
Route the wi re ha rnesses and tu bes properly ( page 1 -20) .
Requisite Service
•
•
•
Fuel tan k rem ova l/i nsta l l ation (page 2-2)
Carbu retor remova l/i nsta l lation ( page 5-4)
Exha u st system remova l/i nsta l latio n ( page 2-4)
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1 )
( 1 2)
( 1 3)
( 1 4)
( 1 5)
( 1 6)
(17)
( 1 8)
( 19)
(20)
(21 )
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31 )
(32)
(33)
Removal Order
Alternator 3P con n ector
I g n ition pu lse generator 3P connector
Sta rter m otor cable
G ro u n d ca ble eyelet
Spark plug cap
Auto fuel va lve m o u nting bolt
Auto fuel va lve
F ro nt air suction pipe joint bolt
F ront air suction pipe
Gasket
Rea r a i r suction pipe joint bolt
Rea r a i r suction pi pe
Gasket
No. 4 vacu u m tube
Drive sprocket bolt
Washer
Drive sprocket
Brake pedal l i n kage j oint pinch bolt/joint
R i g ht foot peg bracket bolt
Rig ht foot peg bracket assem bly
Gearshift l i n k joint bolt/joint
Left foot peg bracket bolt
Left foot peg bracket assembly
Front cylinder head mounting bolt/nut/Washer
Col l a r (f624 x 30 m m )
F ro nt engine m o u nti ng bolt/n ut
F ro nt engine m o u nti ng bracket bolt
F ront engine m o u nti ng bracket
Rea r engine m o u nti ng bolt/nut
Col l a r (f62 1 x 29.8 m m )
Rear engine m o u nting bracket bolt/n ut
Rea r engine m o u nting bracket
E n g i n e assem bly
•
•
•
Drive sprocket cover remova l/i nsta l latio n ( page 1 0-2)
Radiator rem ova l/i nsta l lation ( page 6-5)
Right m i d d l e cover stay remova l/i nsta l l ation
Remarks
Q'ty
I n sta l lation is in the reverse order of rem ova l .
1
1
1
1
4
2
1
4 2 2 4 2 2 1 1
1
1
1/1
2
1
1/1
2
1
2/2/2
2
2/2 4 2
1/1 1
2/22
1
Ca l ifornia type on ly.
Align the punch ma rks.
Align the punch m a rks.
Tightening procedu re ( page 7-4)
Apply clean g rease to the n ut threads and flange surface.
Move the engine assembly out of the fram e to right.
CAUTION
Carefully align mounting points with the jack to prevent damage to mounting bolt threads, wire harnesses
and cable.
•
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7-3
Engine Removal/Installation
Engine Mounting Bolt lightening Procedure
Loosely i n sta l l a l l engine m o u nting bolts, n uts a nd engine
mounting bracket.
Tig hten the 1 0 mm front cyl i nder head m o u nting bolts
and ® .
CD
Torque: 54 N·m (5.4 kg-m, 39 ft-lb)
Tig hten the 8 mm engine m o u nting bracket bo lts
@ , @ and ® .
@, @,
Torque: 39 N·m (3.9 kg-m, 28 ft-lb)
Tig hten the 1 0 mm engine m o u nting bolts
@.
Torque: 44 N·m (4.4 kg-m, 3 2 ft-lb)
Tig hten the 1 2 mm engine m o u nting n ut @ .
Torque: 64 N·m (6.4 kg-m, 46 ft-lb)
7-4
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®, @, @l and
8. Cyl i nder Head/Va lves
Service Information
Troubleshooting
Camshaft Removal
8- 1
Cylinder Head Removal/Installation
8-2
Camshaft Installation
8- 1
Cylinder Head Disassembly I Assembly
8-4
8-6
8-8
Service Information
•
•
•
•
•
Front a n d rea r cyl inder head service ca n be done with the engine i n the fra me.
Camshaft l u b ricati ng o i l is fed through o il passages i n the cyl i n der head. Clean the o il passages before assem b l i n g
t h e cyl i nder head. F i l l t h e cyl inder h e a d oi l pockets with t h e clean e n g i n e o il o f t h e proper type a n d viscosity.
Clean a l l d i sassem bled pa rts with clean so lvent a n d d ry them by b lowi ng them off with co m p ressed a i r befo re
inspection.
When d i sassem bli ng, m a rk a n d store the disassem bled pa rts to ensu re that they a re rei nsta l led i n thei r proper loca­
tions.
The cyl i nder n u m beri ng is g iven below:
( 1 ) FRONT
..
Troubleshooting
•
•
E n g i n e top-en d problems usua l ly affect engine performa nce. These ca n be diagnosed by a com p ression or leak down
test, or by tracin g noises to the top-en d with a sou n d i n g rod or stethoscope.
If performa nce is poor at low speeds, check for white smoke i n the cra n kcase breather tube. If there i s smoke i n the
tube, check for a seized piston ring.
Compression Too Low, Hard Starting Or Poor
Performance At Low Speed
Va lves
- I ncorrect va lve adjustment
- Bu rned or bent va lves
- I ncorrect va lve t i m i n g
- Broken va lve spri n g
- Un even va lve seati ng
•
Cyl i n der head
- Lea king or damaged head gasket
- Wa rped or cracked cyl i nder head
Cyl inder/piston
- Worn, stuck or broke n piston ring
- Worn o r damage cyli nder a n d piston
•
•
Excessive Noise
Cyl inder head
- I ncorrect va lve adj ustment
- Sticki n g va lve or broken va lve spri n g
- Da maged or worn ca mshaft
- Loose or worn ca m cha i n
- Worn o r damaged c a m cha i n
- Worn or damaged ca m cha i n tensioner
- Worn ca m sprocket teeth
Cyl i nder, piston
- Worn cyl i nder and piston
- Wo rn piston pin and piston pin hole
Rough Idle
Low cyl i n der compression
•
Compression Too High, Overheating Or Knocking
•
Excessive carbon b u i ld-up i n cyl i n der head or on top
of piston
Piston Knocking
Worn cyl i n der, piston or piston ring
Worn piston pin a n d piston p i n hole
Worn connecti n g rod sma l l end
•
•
Excessive Smoke
Cyli n der head
- Worn va lve stem or va lve g u i de
- Da maged stem sea l
Cyl i n de r, piston
- Worn cyl i n der, piston, or piston rings
- I m proper i nstal lation of piston ri ngs
- Scored or scratched piston or cyli nder wall
•
•
Excessive Smoke
Worn, stuck, or broken piston ring
•
•
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Abnormal Noise
•
Worn cyli n der a n d piston
8- 1
Cylinder Head/Valves
Camshaft Removal
AFTER '95 (Except some '96 early production units)
8- 2
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Revised : July, 1 995, '94 - '95 Magna VF750C/CD
© 1 995 American Honda Motor Co. , Inc. - All Rights Reserved
MSV 691 3 (9504)
Cylinder Head/Valves
N OTE
•
•
•
•
•
Service the front cyli nder camshaft using the sa me proced u re as the rea r cyl i nder.
Remove the ca m chain tensioner before removi ng the camshaft.
The "T1 " ti m i n g ma rks on the sta rter cl utch a re for rea r cyl inder head service.
The "T2 " ti m i ng ma rks on the starter cl utch a re for front cyl i nder head service.
Be carefu l n ot to d rop pa rts i nto the e n g i ne ope n i ng .
Requisite Service
Rear cylinder:
Fuel tan k remova l/i nsta l lation ( page 2-2)
Spark pl u g cap remova l/i nsta l latio n
•
•
M uffler remova l/i nsta l lation ( page 2-4)
•
Front cylinder:
Fuel tan k remova l/instal l ation ( page 2-2)
Radiator remova l/i nsta l lation ( page 6-5)
•
•
•
•
Procedure
(1)
(2 )
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1 )
( 1 2)
( 1 3)
( 1 4)
( 1 5)
( 1 6)
( 1 7)
( 1 8)
Removal Order
Side sta nd switch con nector
Auto fuel valve
B reathe r t u be
B reather case bolt
Breathe r case
B reathe r plate
Head cover protector bolt
Head cover protector
Head cover p rotector rubber
Rear cyl i nder head cover bolt
Washer
Rear cyl inder head cover
Head cover gasket
Cam chain tensioner sea l i n g bolt/washer
Cam ch ain tensioner m o u nting bolt
Cam cha i n tensioner
Gasket
Camshaft holder bolt
Spark p lug cap remova l/i nstal lation
Front PAI R control va lve rem ova l/insta l lation
(Ca l ifornia type only pa ge 5- 1 8)
Remarks
Q'ty
1116114
2
6
4
4
1
1
1/1
2
1
1
16
Rea r cyl inder head o n ly.
NOTE
Before loose n i ng, a l i g n the "T1 " (front cyli nder: "T2 " )
m a rk o n the sta rter cl utch with the i n dex m a rk o n the
right cra n kcase cover, and m a ke s u re the No. 1 piston
(front cyl i n der: No. 4 pisto n ) is on com p ression stroke.
If it is not o n the com pression stroke, turn the cra n kshaft clockwise 360° a n d a l i g n the m a rks aga i n .
Loosen t h e holder bolts i n a g ra d u a l , crisscross
pattern.
•
•
( 1 9)
(20)
(2 1 )
(22)
Cam cha i n g u ide
Camshaft holder
Camshaft I N/EX
Cam chain
1
4
2
1
(23)
Dowel pin
8
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Dera i l the ca m chain from the sprocket a n d attach a
piece of mechanic's wire to it to prevent it from d ropping
i nto the cra n kcase.
8-3
Cylinder Head/Valves
Cyl inder · Head Removal/Installation
(2)
c
44 (4.4,
32)
(1)
c
1 2 ( 1 .2, 9)
,
(6)
(4)
(3)
c
8-4
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13 ( 1 .3, 9)
Cylinder Head/Valves
NOTE
•
•
•
Service the front cyl i nder head using the sa me proced u re as the rea r cyl i nder.
Apply e n g i n e o i l to the seat a n d threads of the cyl i nder head bo lts.
Before removi ng the engine m ounting bolts from the cyl i nder head, support the e n g i n e with a jack or oth er s u p­
port to avoid over-loading the other bolts.
Requisite Service
Rear cylinder:
Ca mshaft remova l/i nsta l lation ( page 8-2, 8)
Carbu retor remova l/i nsta l lation ( page 5-4)
•
•
•
•
Front cylinder:
Ca mshaft remova l/i nsta l lation ( page 8-2, 8)
M uffler remova l/i nsta l lation (page 2-4)
Air suction p ipe remova l/i nsta l lation (Ca l ifornia type
o n ly)
•
•
•
•
Thermostat remova l/i nsta l lation ( page 6-4)
Air suction pipe remova l/i nsta l latio n (Ca l ifornia type
on ly)
Carbu retor remova l/i nsta l lation i page 5-4)
Thermostat rem ova l/i nsta l lation (page 6-4)
•
Procedure
(1)
(2)
Removal Order
Cyl inder head 6 m m bolt
Cyl inder head 9 m m bolt/washer
(3)
(4)
(5)
(6)
Cyl i nder
Cyl i nder
Cyl i nder
Cyl i n der
(7)
Dowel pin
head protector bolt
head protector
head
head gasket
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Remarks
Q'ty
8�8]
6
2
1
1
•
•
Loosen the fasteners in a criss-cross pattern i n 2 or 3
steps.
Refer to page 8- 1 7 for insta l l ation.
Disasse m bly ( page 8-6)
Insta l l with the U P m a rk facing up a n d " I N " m a rk facing i nta ke side.
"
"
2
8-5
Cylinder Head/Valves
Cylinder Head Disassembly I Assembly
HANDLAPP I N G TOOL
DOWN
(4)
j s.TooL I ---- . e
( page 1 - 1 5) � �
�
G ROOVE
LUG
e
( 1 0) ------�
( 2 ) ?1
�
()� (3)
�
( 51
�(91
(11)
l s.TooL I ( page 1 - 1 5)
8-6
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Cylinder Head/Valves
NOTE
•
•
•
•
Service the front cyl inder head using the sa me proced u re as the rea r cyl i nder head.
M a rk a l l pa rts d u ring d i sassem bly so they can be placed back thei r orig i n a l position.
Remove carbon deposits from the com bustion cha m ber and clean off the head gasket s u rface, before asse m bly.
- Avoid damaging the gasket s u rface.
- Gaskets wi l l come off easier soaked in solve nt.
Va lve g u ide replacement see Section 9 of the Com mon Service M a n u a l .
Requisite Service
•
Cyl in d er head remova l/i nsta l lation (page 8-4)
Procedure
(1)
Disassembly Order
I n s u l ator
Remarks
Q'ty
2
Assem bly is in the reverse order of d isassembly
NOTE
Align the g roove of the insu lator with the l u g of the
cyl inder head.
NOTE
Remove using a hand lapping tool . Do not d amage the
cyli nder head-l ifter sliding s u rface.
•
(2)
Va lve l ifter
8
•
(3)
(4)
Valve shi m
Va lve spring cotter
8
16
NOTE
Remova l/I nsta l lation ( page 8- 1 7 )
To prevent loss of tension, d o not com press the va lve
spri ng m ore than necessa ry.
•
•
(5)
(6)
Valve spring retainer
Va lve spring
8
8
(7)
(8)
I ntake valve
Exha u st valve
:=r
At i n sta l lation, i nsta l l the va lve springs with the tig htly
wou l d coi ls end facing the com bustion cham ber.
NOTE
Before i n sta l lation, l u b ricate each va lve stem with
molybde n u m disu lfide o i l .
Stem seal
Valve spring seat
Valve g u ide
8
8
8
Va lve g u i de projection ( page 1 -7 )
(9)
( 1 0)
(1 1)
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•
8-7
Cylinder Head/Valves
Camshaft Installation
AFTER '95 ( Except some '96 early production units)
IN
r: �
@
...
@
EX
(2)
(9)
(7)
-
c
1 2 ( 1 .2, 9 )
(1)
8-8
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©
Revised : July, 1 995, '94 - '95 Magna VF750C/CD
1 995 American Honda Motor Co., Inc. - All Rights Reserved
MSV 691 3 f9504l
Cylinder Head/Va lves
NOTE
•
•
•
Service the front cyl inder camshaft using the same proced u re as the rea r cyl inder.
Each ca mshaft has an identification m a rk. Use these ma rks d u ri n g insta l l ation to ensure that the camshafts a re
properly located.
REAR I NTAKE: " R R " , " I N "
FRONT I NTAKE: " F R " , " I N "
REAR EXHAUST: "RR", " EX"
FRONT EXHAUST: " F R " , "EX"
Be ca refu l not to d rop a ny pa rts i nto the engine opening.
Requisite Service
Rear cylinder:
Fuel tan k remova l/i nsta l lation ( page 2-2)
Spark plug cap remova l/i nsta l latio n
•
•
Front cylinder:
Fuel ta n k remova l/i nsta l lation ( page 2-2)
Spark p l u g cap remova l/i nsta l l ation
•
•
•
•
M uffle r re mova l/i nsta l lation ( page 2-4)
•
Procedure
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(11)
Installation Order
Dowel pi n
Cam chain
Ca mshaft I N/EX
Camshaft holder
Ca m chain g u ide
Camshaft holder bolt
Gasket
Ca m cha i n tensioner
Cam chai n tensioner m o u nting bolt
Ca m cha i n tensioner sea l i n g bolt/washer
Head cover gasket
Remarks
Q'ty
8
1
24116112
1/1
1
Radiator remova l/i nsta l lation ( page 6-4)
F ront PAI R control valve removal/i nsta l l ation
(Ca l ifornia type only page 5- 1 8)
Refer to page 8- 1 0 for i nsta l l ation
NOTE
Apply Honda Bond A or equ iva lent to the head cover
and i n sta l l the gasket with " I N " m a rk facing the i ntake
side.
•
( 1 2)
( 1 3)
( 1 4)
Rear cyli nder head cover
Washer
Rea r cyl i nder head cover bolt
1
4
4
I n sta l l with the " U P" m a rk facing u p.
Tighten the bolts i n the o rder shown.
Tig hten the G) bolt again after tighte n i n g the othe r
bolts.
•
•
( 1 5)
( 1 6)
( 1 7)
( 1 8)
( 1 9)
(20)
(21 )
(22)
(23)
Head cover protector rubber
Head cover protector
Head cover protector bolt
B reather plate
Breather case
B reather case bolt
Breather tube
S ide sta nd switch connector
Auto fuel va lve
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6
2
4
1161-
•
•
I n sta l l with the " U P" m a rk facing u p a n d " I N " m a rk facing the i ntake side.
Rear cyl inder head o n ly.
1-
1-
8-9
Cylinder Head/Valves
Camshaft Installation
E a c h ca m s h aft h a s an i d e ntificat i o n m a rk. I n sta l l t h e
camshafts i n the correct positions, noting t h e identification
m a rks below:
Front Intake:
Front Exhaust:
Rear Intake:
Rear Exhaust:
( 1 ) EX or I N MAR K
"FR", "IN"
"FR", "EX"
"RR", "IN"
"RR", "EX"
(2) F R or R R MARK
When Both Front And Rear Cylinder Camshaft Were
Removed
•
( 1 ) I N DEX MARK
Rear cylinder
Align the "T1 " m a rk on the sta rter cl utch with the i n dex
mark on the right c ra n kcase cover.
(3) "T1 " MARK
I n sta l l the c a m s h aft h o l d e r dowel p i n s o nto the rea r
cyl i nder head.
Lubricate the camshaft journal su rface of the cyl i nder
head, camshaft holder and ca m lobes with molyden u m
disulfide o i l .
(2) R I G HT CRAN KCASE COVE R
(2) " R-I N " MARK
I n sta l l the camshafts o nto the rea r cyl i nder head.
The " R-EX" ti m i ng m a rk on the rea r exhaust ca mshaft
sprocket is level with the cyl i nder head u pper edge as
shown .
Check that the " R-I N " ti m i ng m a rk on the rea r i ntake
camshaft sprocket is level with the cyl i nder head u pper
edge as shown.
I nsta l l the ca m s h aft h o l ders in the correct positi ons,
checki ng the identification m a rks o n the h o lders and
cyli nder hea d.
In sta l l th e cam chain g u ide.
8- 1 0
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(3) REAR CYLI N D E R H EAD
U PPER EDGE
Cylinder Head/Valves
•
Rear cylinder (cont'dl
Torq u e t h e c a m s h aft h o l d e r bo lts i n the seq u e nce
shown.
Torque: 1 2 N·m ( 1 .2 kg-m, 9 ft-lb)
Turn the ca m chain tensioner shaft fu lly in (clockwise)
secu re it using special tool .
I •.TooL I
Tensioner stopper
( 1 ) TE N S I O N E R SHAFT
07NMG - MY901 00
(Not available in U.S.A.)
Cam c h a i n tensioner stopper too l ca n easily be made
from a thi n ( 1 mm th ickness) piece of steel .
15 mm
19 mm
1 5 mm
(2) I a .TooL I TE N S I O N E R STOPPER TOO L
8.5 m m
( 1 ) CAM CHAI N TE N S I O N E R
4.5 m m
MATE RIAL TH ICKN ESS: 1 .0 m m
Insta l l the new gasket a n d cam c hai n tensioner to rea r
cyl i nder head.
Torq u e the ca m chain tensioner m o u nting bolts.
Torque: 12 N·m ( 1 .2 kg-m, 9 ft-lbl
Remove the ca m c hai n tensioner stopper tool .
Insta l l the c a m c h a i n tensioner sea l i ng bolt a n d washer.
(1)
� TE N S I O N E R
�O
L
Make s u re the ti m i ng ma rks on the ca mshaft sprockets
a re level with the cyl i nder head u pper edge.
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8- 1 1
Cylinder Head/Valves
•
Front cylinder
Rotate the cra n kshaft clockwise 90° to a l i g n the "T2 "
mark with the i n dex m a rk on the right cra n kcase cover.
( 1 ) I N DEX MARK
(3) "T2" MARK
I n sta l l the camshaft holder dowel p i n s o nto the front
cyli nder head.
(2) R I G HT CRAN KCASE COVER
( 1 ) " F-I N " MAR K
(2) " F-EX" MARK
Lubricate the camshaft journal surface, camshaft holder
and cam lobes with m o lybdenum d i s u lfide o i l .
Insta l l t h e ca mshafts onto t h e front cyl inder head.
Check that the F EX tim i ng m a rk o n the front exha u st
camshaft sprocket is level with the cyl i nder head u pper
edge as shown.
"
-
"
Check that the " F-I N " timing m a rk on the front i ntake
camshaft sprocket is level with the cyl i nder head u pper
edge as shown.
I n sta l l the ca m s h aft h o l d e rs in the correct posit i o n s,
checki ng the i d e ntification m a rks on the h o l d e rs a n d
cyli nder head.
Instal l the cam chain g u ide.
Torq u e the cam s h aft h o l d e r bo lts in the seq u e nce
shown.
Torque: 1 2 N·m ( 1 .2 kg-m, 9 ft-lbl
8- 1 2
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(3) FRONT CYLI N DER H EAD
UPPER EDGE
cylinder Head/Valves
•
Front cylinder (cont'd)
Turn the cam chain tensioner shaft com pletely in (clock­
wise) and secu re it using the stopper tool .
Th is tool c a n easily b e made from a thi n ( 1 m m thick­
ness) piece of steel.
( 1 ) TE NSIONE R S HAFT
15 m m 1 3.5 mm
-
J
I
...
-
3 mm
I
'
1 5 mm
--
r- lr
I
MATE R IAL TH ICKNESS: 1 m m
+
8.5 m m
(2) TE NSIONE R STOPPER TOO L
3.5 m m
(2) CAM CHAI N
TE N S I O N E R
Insta l l a new gasket a n d ca m cha i n tensioner.
Torq ue the cam cha i n tensioner mo unting bolts.
Torque: 12 N·m ( 1 .2 kg-m, 9 ft-lb)
Remove the cam c hai n tensioner stopper tool .
Insta l l the c a m chain tensioner sea l i ng bolt a n d washer.
M a ke s u re the ti m i n g ma rks on the camshaft sprockets
a re level with the cyl i nder head u pper edge.
When The Rear Cylinder Camshaft Only Was Removed
( 1 ) I N DEX MARK
A l i g n the " T2 " m a rk with the i ndex m a rk on the right
cra n kcase cover.
Remove the front cyli nder head cover ( page 8-2).
M a ke s u re #2 cyl i nder is TDC on the com p ression stroke.
If it is n ot, t u rn the c ra n ks haft c l oc kwise 360° a n d m a ke
s u re "T2" m a rk a l ig n s with the i ndex mark o n the right
cra n kcase cover.
Rotate the cra n ks haft c lockwise 270° to a l ig n the "T1 "
m a rk with the i ndex m a rk on the right cra n kcase cover.
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/
(3) "T2 " MARK
(2) R I G HT CRANKCASE COVER
8- 1 3
Cylinder Head/Valves
I nsta l l the ca mshaft holder dowel pins in the rea r cyl i nder
head.
Lubricate the camshaft journal su rfaces, ca mshaft holder
and cam lobes with molybden u m d isu lfide oil.
I n sta l l the camshafts onto the rea r cyl i nder head.
Check that the " R-EX" ti m i n g m a rk o n the rea r exh a u st
camshaft sprocket is level with the cyl i n d er head u pper
edge as shown.
C h ec k that the " R- I N " t i m i n g m a rk on the rea r i ntake
camshaft sprocket i s level with the cyl i nder head u pper
edge as shown .
(3) REAR cYLI NDER H EAD
U PPER EDGE
I«
('Ali
Insta l l the camshaft holders i n the correct positions, check­
i n g the identification m a rks on the ho ld ers a n d cyl i nder
head.
I nsta l l the cam chain g u ide.
Torq ue the cam shaft holder bolts i n the seq uence shown.
Torque: 1 2 N·m ( 1 .2 kg-m, 9 ft-lb)
Turn the cam c h ain tensioner shaft com pletely in (clock­
wise) and secu re it using the special too l .
l a.TooL I
Tensioner stopper
07NMG - MY901 00
(Not available in U.S.A.)
Cam cha i n tensioner stopper tool can easily be made from
a th i n (1 mm th ickness) piece of steel .
1 5 mm
19 mm
8.5 m m
1 5 mm
4.5 m m
MATE RIAL TH ICKNESS: 1 .0 m m
8- 1 4
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(2) I a. TooL I TE N S I O N E R STOPPE R TOOL
Cylinder Head/Valves
I n sta l l a new gasket a n d ca m chain tensioner.
( 1 ) CAM CHAI N TE N S I O N E R
Torque the cam chain tensioner mounting bolts.
Torque: 12 N·m ( 1 .2 kg-m, 9 ft-lb)
O�
( 1 ) I a.TooL I TE NS l O N E R
ST
Remove the cam chain tensioner stopper tool .
I nsta l l the cam chain tensioner sea l i n g bolt a n d washer.
M a ke s u re the ti m i n g ma rks on the ca mshaft sprockets a re
level with the cyl i nder head u pper edge.
When The Front Cylinder Camshaft Only Was Removed
( 1 ) I N DEX MARK
A l i g n the " T 1 " m a rk with t h e i n dex m a rk on t h e right
cra n kcase cover.
Remove the rea r cylinder head cover ( page 8-2) .
M a ke s u re #1 cylinder is TDC on the com p ression stroke.
If it is n ot, turn the cra n kshaft c lockwise 360° a n d m a ke
s u re " T 1 " m a rk a l ig n s with the i ndex m a rk on the right
cra n kcase cover.
Rotate the cra n kshaft clockwise 90° to a l ign the "T2 " m a rk
with the index m a rk on the right cra n kcase cover.
I n sta l l the camshaft holder dowel pins onto the front cylin­
der head.
(3) "T1 " MARK
(2) RIGHT CRAN KCASE COVER
( 1 ) " F-I N " MARK
(2) " F-EX" MARK
L u b ricate the ca m s h aft j o u rn a l su rface, camshaft holder
a n d cam lobes with m olybden u m disu lfide o i l .
I nsta l l t h e csmshafts onto t h e front cyl inder head.
Check that the " F-EX" ti m i n g m a rk o n the front exhaust
ca m s h aft sprocket i s l evel with the cyli nder head u pper
edge as shown.
C h ec k t h at t h e " F- I N " ti m i n g m a rk o n the front i nta ke
ca m s h aft s procket is leve l with the cyl i n de r head u pper
edge as shown.
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(3) FRONT CYLINDER H EAD
U PPER EDGE
8- 1 5
Cylinder Head/Valves
I nsta l l the ca mshaft holders in the correct positions, check­
i n g the i ndetification m a rks on the holders and cyl i nder
head.
I nsta l l the cam cha i n gu ide.
(2) IDE NTIFICATIO N MARKS
To rq u e the cam sh aft h o l d e r bo lts in the seq u e nce as
shown .
Torque: 12 N·m ( 1 .2 kg-m, 9 ft-lb)
Turn the cam c h a i n tensioner shaft co m pletely in (clock­
wise) and secu re it using the stopper tool .
This tool c a n easily b e made from a th i n ( 1 m m th ickness)
piece of steel .
( 1 ) TE N S I O N E R SHAFT
1 5 m m 1 3.5 mm
-
..
.
J
.I
3 mm
I
1 5 mm
-
lr
- ----1
I
+
8.5 m m
(2) TE N S I O N E R STOPPER TOOL
3.5 m m
MATE RIAL THICKNESS: 1 m m
I nsta l l a new gasket a n d cam chain tensioner.
Torq ue the cam cha i n tensioner m o u nting bolts.
Torque: 12 N·m ( 1 .2 kg-m, 9 ft-lb)
8- 1 6
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(2) CAM CHAI N
TE N S I O N E R
Cyl i nder Head/Valves
Remove the cam chain tensioner stopper tool .
I n sta l l the cam chain tensioner sea l i n g bo lt a n d washer.
Ma ke s u re the ti m i n g ma rks on the camshaft sprockets a re
level with the cyl inder head u pper edge.
Valve Cotter Removal/Installation
Remove the va lve l ifte rs and shi ms.
N OTE
•
•
•
M a rk the positions of a l l va lve l ifte rs and s h i m s to
ensure correct reassem bly.
It is easy to remove the va lve lifte r with a va lve lap­
ping too l or magnet.
Remove the s h i ms with tweezers or a magnet.
I nsta l l the ta ppet hole protector i nto the va lve l ifter bore.
l s .TooL I
Tappet hole protector
( 1 ) l s.TooL I TAPPET H O LE PROTECTO R
07HMG - MR70002
Not available in U.S.A
I n sta l l the va lve s p r i n g com presso r o nto the va lve a n d
com p ress the va lve spri ng.
CAUTION:
•
To prevent loss of tension, do not compress the
valve springs more than necessary.
Remove the va lve cotters.
l a.TooL I
07757 - 001 0000
Valve spring compressor
Valve spring compressor attachment
07959 - KM30101
I nsta l lation is i n the reverse order of remova l .
(2) I s .TooL I COMPRESSOR
6 m m BOLT
Cyl i nder Head Bolt Installation
Apply engine oil to the seating su rface and threads, then
tig hten the cyl i n der head m o u nting bolts g ra d u a l ly in a
crisscross pattern i n the order as shown .
Torque:
6 mm bolt: 1 2 N·m ( 1 .2 kg-m, 9 ft·lb)
9 mm bolt: 44 N·m (4.4 kg·m, 32 ft·lb)
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8- 1 7
MEMO
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Service Information
Troubleshooting
Right Crankcase Cover Removal/
Installation
9- 1
9· 1
9. Clutch System
Clutch Removal
Clutch Installation
9-4
9-6
9-2
Service Information
•
•
Cl utch mai ntenance can be done with the engine i n the frame.
Transm ission oil viscosity a n d level have a n effect on cl utch d isengagement. When the c lutch does not d isengage or
th e veh icle creeps with cl utch d isengaged, inspect the transm ission o i l level before servicing the cl utch system .
Troubleshooting
Clutch Slips When Accelerating
I ncorrect cl utch adj ustment
Worn cl utch discs
Wea k cl utch springs
T ra n s m i s s i o n o i l m i x e d w i t h m o l y b d e n u m o r
g ra p h ite additive
Motorcycle Creeps With The Engine Idling
I ncorrect cl utch adjustment
Clutch plates wa rped
Fau lty cl utch l ifter
I ncorrect engine o i l weight
•
•
•
•
•
•
•
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•
9- 1
Clutch System
Right Crankc ase Cover Remov al/Insta llation
(6)
(7)
c
(1)
c
27 (2.7. 20)
(2)
c
1 2 ( 1 . 2. 9)
27 (2.7. 20)
Jl.ru
20 - 30 m m
(0.8 - 1 .2 i n ) �
· ==�
=®:
=---
9 -2
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Clutch System
Requisite Service
•
E n g i ne o i l d ra i n i n g/refi l l i n g
Procedure
(1)
( 2)
(3)
(4)
(5)
(6)
(7)
Removal Order
Brake peda l pivot bolt/nut
Rig ht foot peg bracket bolt
Rig ht foot peg bracket
F ront exha u st pi pe protector bolt
F ront exhaust p i pe protector
Eva porative em i ssion can i ster p i pe bolt
Ri g ht cra n kcase cover bolt
Remarks
Q'ty
Insta l lation is in the reverse o rder of remova l ,
1/1
2
2
2
1
1
13
Ca l ifornia type only
NOTE
I n stal l the cla m ps in the correct positions a n d cla m p the
sta rter m otor cable.
•
(8)
(9)
( 1 0)
Ri g ht cra n kcase cover
Gasket
Dowel pin
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1
1
2
9-3
Clutch System
Clutch Removal
( 1 3)
( 1 2)
l a .TooL I ( page 9 -8)
( 1 0)
(9)
(7)
(3)
9-4
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Clutch System
NOTE
•
When rem ovi ng the o i l p u m p d riven sprocket, loosen the sprocket bolt before removi ng the cl utch assem bly. The
bolt is treated with a locki ng agent so be ca refu l not to damage the bolt when loosen ing.
Requisite Service
•
Right c ra n kcase cover removal ( page 9-2)
Procedure
(1)
(2)
(3)
(4)
(5)
Removal Order
Cl utch spring bolt
Cl utch spring
Cl utch pressure plate
Cl utch press u re plate bearing
C l utch l ifter guide
(6) Stopper ring
(7) · Lifter rod
(8) Clutc h disk A/cl utch p late
(9) Cl utch disk B
( 1 0) J udder spring
( 1 1 ) Spring seat
( 1 2) Cl utch center lock n ut
•
Remarks
Q'ty
5
5
1
1
1
1
1
8/8
1
1
1
1
Deta c h fro m t h e p r es s u re p l ate b e a r i n g o n l y w h e n
replacing the bea ri ng.
La rger I . D. tha n cl utch disc A
•
•
{ 1 3)
( 1 4)
( 1 5)
( 1 6)
(17)
( 1 8)
( 1 9)
( 2 0)
(2 1 )
(22)
Spring washer
C lutch center
C lutch outer
N eedle bearing
O i l pu m p d riven sprocket bolt
O i l p u m p d riven sprocket
Cl utch outer g u ide
O i l pu m p d rive chain
O i l p u m p d rive sprocket
Col l a r
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1
1
1
1
1
1 1
1 1 1
Sta rter cl utch remova l ( page 1 7- 1 0)
•
Unstake the lock n ut.
Hold the clutch center with the special tool ( page 9-8).
Remove them as a n assem bly.
9-5
Clutch System
Clutch Installation
( 1 0)
0
9-6
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Clutch System
Requisite Service
•
Sta rter cl utch in sta l lation ( page 1 7- 1 0)
Procedure
Installation Order
(1)
(2)
Col l a r
C l utch outer guide
•
Right crankcase cover i nstallation ( page 9-2)
Q'ty
1
1
Remarks
NOTE
Lubricate the i n ner and oute r sliding s u rfaces with a
engine oil.
Insta l l them as an assembly.
Install the drive sprocket with the boss side facing out.
•
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1)
Oil p u m p d rive sprocket
O il pump d rive chain
Oil p u m p d riven sprocket
Oil pu m p d riven sprocket bolt
Needle bea ring
Cl utch outer
Cl utch center
Spring washer
Cl utch center lock n ut
( 1 2)
( 1 3)
( 1 4)
( 1 5)
( 1 6)
(17)
( 1 8)
( 1 9)
(20)
(2 1 )
(22)
Spring seat
J udder spring
Cl utch d isc B
Clutch d isc A/cl utch plate
Lifter rod
Stoppen ring
Cl utch l ifter g u ide
Pressu re plate bearing
Pressu re plate
C lutch spring
Cl utch spring bolt
Er
1
1
1
1
1
1
- •
•
Clean and apply a locking agent to the threads.
Instal lation (page 9-8).
"OUT SIDE" mark facing cover.
Hold the clutch center with the special tool ( page 9-8) .
Stake the lock nut with a punch.
- I nsta l l the spring seat and judder spring on the clutch
center as shown.
Larger I . D. than clutch disc A.
•
•
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� =r
1
8/8
1
1
1
1
1
5
5
Instal l
I nsta l l
Instal l
Instal l
the lifter rod as shown.
securely into the l ifter guide g roove.
into the pressure plate bearing.
into the pressure plate.
Tighten them in a gradual, crisscross pattern.
9-7
Clutch System
(3) I s.TooL I
Clutch Center Lock Nut
G
CLUTCH CE NTER
HOLDER
Removal
U nstake the c l utch center lock n ut.
D
( 1 ) U N STAKE
N OTE
•
Be ca refu l not to d a m age the m a i nshaft threads.
Hold the c l utch cente r with the spec i a l too l a n d loosen the
cl utch center l ock n ut. Rem ove the tools and the lock n ut.
I s. TooL I
Clutch center holder
'94 only:
Lock nut wrench, 26 x 30 mm
(2) [ s.TooL I
07724 - 0050001
Equivalent commercially
available in U.S.A.
077 1 6 - 0020203
LOCK N UT
WRE N C H ('94 O N LYl
( 1 ) STAKE
*
Installation
H o l d the cl utch center with the cl utch center holder, a n d
tig hten t h e new l ock n ut t o the specified torq u e .
Torque: 90 N·m (9.0 kg-m, 65 ft-lb)
I s.TooL I
Clutch center holder
'94 only:
Lock nut wrench, 26 x 30 mm
07724 - 0050001
Equivalent commercially
available in U.S.A.
077 1 6 - 0020203
Stake a new lock n ut with a cente r punch.
(3) I s.TooL I
CLUTCH CE NTE R
HOLDER
N OTE
•
Be ca reful not to damage the m a i nshaft th reads.
( 1 ) O I L PU M P DR IVE S PROCKET
Clutch Outer Installation
I n sta l l the c l utch outer onto the m a i nshaft.
Turn the oil p u m p d riven sprocket a n d a l i g n the pins on
the oil pump d rive sprocket with the h o les of the c l utch
o uter.
(3) CLUTCH OUTE R
9 -8
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(2) P I N S
Service Information
Troubleshooting
Drive Sprocket Cover Removal/
Installation
1 0- 1
1 0- 1
1 0. Gearsh ift Li n kage
Gearshift Linkage Removal/
Installation
1 0-4
1 0-2
Service I nformation
•
•
The gearsh ift l i nkage m a i ntena nce ca n be done with the e n g i n e i n the fra me.
N eve r a l l ow fo re i g n materials to get i nto the e ng in e .
Troubleshooting
Hard To Shift
•
•
•
•
•
•
•
•
•
•
I m proper o i l viscosity
I nco rrect c l utch adjustment
Bent shift fo rks
Bent shift fo rk shaft
Bent fo rk claw
Loose stopper plate bolt
Damaged stopper plate a n d p i n
D a m a g e d gearshift s p i n d l e
Damaged s h ift d r u m g roove
Damaged g u ide p i n
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Transmission Jumps Out Of Gear
•
•
•
•
•
Worn s h ift d r u m stopper a rm
Worn gea r engagement dogs or s lots
Wea k or broken s h ift arm return spring
Loose stopper p late bolt
Damaged or bent shift fo rk
Gearshift Pedal Will Not Return
•
•
Wea k or b roken gearsh ift s p i n d l e retu rn spri n g
Bent gearshift s p i n d l e
1 0- 1
Gearshift Linkage
Drive Sprocket Cover Removal/Installation
(9)
(3)
c
1 0 ( 1 .0, 7)
( 1 2)
( 1 3)
( 1 4)
c
1 0- 2
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____.ii!111
....::;:
....,:;:
_
:,__
__
1 2 ( 1 .2, 9)
Gearshift Linkage
Procedure
Q'ty
Removal Order
(1)
(2)
(3)
(4)
(5)
( 6)
Cl utch ca bl e h o l d e r bolt
C l utch cable/h o l der
Drive sprocket cover bolt
Drive sprocket cove r
G asket
Dowel p i n
I nsta l lation is in the reve rse order of rem ova l .
1
1
3
1
1
2
Disassembly Order
(7)
(8)
(9)
( 1 0)
(1 1 )
( 1 2)
( 1 3)
( 1 4)
( 1 5)
C l utch l ifter piece
C l utch l ifter arm
Return spring
Washer
Dust sea l
D rive c h a i n g u a rd bolt
D rive c h a i n g u a rd
D rive sprocket cover rubber bo lt/Washer
D rive sprocket cover r u b be r
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Remarks
1
1
1
1
1
2
1
212
1
Assem bly is in the reverse order of d i sasse m bly.
Rem ove the piece by t u r n i n g the l ifter a rm clockwise.
1 0-3
Gearshift Linkage
Gearshift Linkage Removal/Installation
(8) S H I FTE R PLATE ASSEM BLY
(1)
1 0 -4
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Gearshift Linkage
N OTE
•
•
•
G e ars h ift l i n kage service can be perfo rmed with the e n g i n e in the fra me.
When removi ng the wate r pu m p, it is not necessa ry to d iscon nect the water h oses.
Afte r i n sta l l ation, check the gears h ift l i n kage fo r proper operatio n .
Requisite Service
•
D rive sprocket cove r re m ova l/i nsta l lation ( page 1 0-2)
Procedure
•
G ea rsh ift l i n kage cove r bolt/washer
Gea rshift l i n kage cover
Remarks
O'ty
Removal Order
(1)
(2)
I nsta l lation is i n the reve rse order of remova l .
5/2
1
NOTE
•
(3)
(4)
Gasket/dowe l p i n
Gear s h ift s p i n d l e a sse m bly
1 /2
1
Washer
S h ifter col l a r
S h ifter plate attach i n g bolt
S h ifter plate asse m b ly
1
1
2
1
( 1 0)
S h ift drum cente r bolt
S h ift d r u m cente r
1
1
(11)
( 1 2)
( 1 3)
( 1 4)
Dowel p i n
Washer
Sto pper a rm spri n g
Stopper a rm asse m b ly
1
1
1
1
( 1 5)
( 1 6)
(17)
Co l l a r
Dowel p i n
S h ift d r u m bea ri n g stopper p late
1
2
1
( 5)
(6)
(7)
(8)
(9)
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Water p u m p re m ova l/i nsta l lation ( page 6-7 )
When rem ovi n g a n d i n sta l l i ng , turn the l i n kage cove r
s l i g htly c lockwise.
I n sta l l t h e s h ifte r co l l a r i nto t h e s p i n d l e h o l e , and the
retu rn spring onto the return spri n g p i n .
L u b ricate e a c h pa rt w i t h e n g i n e o i l , a n d assem b l y a s
i l l ustrated. I nsta l l o n the sh ift d r u m ce nte r with the d r u m
center positioned a t any gea r stop except neutra l .
Apply a locki n g agent t o the t h reads.
I n sta l l by a l i g n i n g the cut out with the d owe l p i n as
shown .
I n sta l l t h e s n a p r i n g w i t h t h e c h a m fe red s i d e fac i n g
i nside, a n d seat fu l l y i n the flan g e col l a r g roove.
1 0-5
MEMO
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1 1 . Cra n kshaft/ Piston /Tra nsmissio n
Service Information
Troubleshooting
Crankcase Separation
Crankshaft/Connecting Rod Removal/
Installation
Piston DisassemblyI Assembly
Transmission Removal/Installation
Mainshaft DisassemblyI Assembly
1 1 -1
1 1 -1
1 1 -2
1 1 -4
1 1 -6
1 1 -8
Countershaft DisassemblyIAssembly
Crankcase Combination
Crankshaft Bearing Replacement
Connecting Rod Selection
Liquid Sealant Application
Crankcase Bolt Location
1 1-12
1 1-14
1 1-16
1 1 -18
1 1-18
1 1-18
1 1-10
Service I nformation
•
•
Th is section cove rs cra n kcase sepa ratio n for service of the cra n kshaft, cyl i n d e r sl eeve, piston a n d transm issio n .
The fol l owing pa rts m u st be removed before servici ng.
Service Item
Con necting rod
Removed Components
•
•
Cra n ks haft
Tra n s m ission
•
•
•
•
•
•
•
•
Cyl i nder head ( page 8-2)
Piston ( page 1 1 -6)
•
•
Sta rter cl utch ( page 1 7- 1 0)
Cra n kcase separation ( page 1 h2)
•
Gea rshaft l i n kage ( page 1 0-4)
•
Cra n kcase sepa ration ( page 1 1 -2)
•
F lywheel (page 1 5- 1 0)
Connecti n g rod bea ring ca p (page 1 1 -4)
•
Cra n kcase sepa ratio n ( page 1 1 -2)
•
M a rk a n d store the bea ring i nse rts fo r reasse mbly. If the i nserts � re i m properly i n sta l led they wi l l block the o i l h oles,
ca using insufficient l u brication and eventua l engine se izu re .
Prior to asse m b l i n g the cra n kcase ha lves a pply a sea lant to the i r mati ng s u rface. Wi pe off excess sea l a nt thoro u g h ly.
M a rk a n d store the d i sasse m bled pa rts to ensure that they a re re insta l led i n their o r i g i n a l l ocati ons.
Remove the piston, cyl i nder s leeve a n d connecting rod as an asse m b ly.
Be ca refu l not to damage the cra n kshaft m a i n journal bea ring wh i l e rem ovi ng or i n sta l l i n g the cra n kshaft.
A l l bea ring i nserts a re select fitted and a re identified by color code. Select replacem e nt bea rings fro m the selection
table (page 1 1 - 1 6).
After i n sta l l i ng new bea rings, recheck them with plastigauge to verify cleara nce.
Apply m o lybde n u m disu lfide o i l to the m a i n j o u rnals a n d cra n kpins d u ri n g asse m b ly.
Troubleshooting
Cylinder Compression Is Too Low, Or Engine Is Hard To
Start
•
•
Wo rn, stuck or broken piston ring
Worn or da maged cyl inder or piston
Cylinder Compression Is Too High, Or Engine Overheats
Or Knocks
•
Carbon deposits on the cyl i n der head a n d/or piston
Piston Sounds
•
•
•
Worn cyl i n d e r, piston and/or piston ring
Worn piston p i n hole a n d piston p i n
W o r n co n n ecti ng rod s m a l l end
Excessive Smoke
•
•
Worn, stuck or broken piston ring
Weak va lve ste m sea l
Excessive Noise
•
•
•
•
Worn connecti ng rod big-end bea ring
Bent connecti ng rod
Worn cra n kshaft m a i n bearing
Worn transm ission bea ring
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Engine Vibration
•
Excessive cra n kshaft ru n o ut
Hard To Shift
•
•
•
•
•
•
•
•
I m p roper cl utch operation
I ncorrect transm issi o n o i l wei g ht
I ncorrect c l utch adjustment
Bent s h ift fork
Bent fo rk shaft
Bend fork claw
Da maged s h ift d ru m ca m g rooves
Bent s h ift spi n d l e
Transmission Jumps Out Of Gear
•
•
•
•
•
•
Worn gear dogs or slots
Bent fork shaft
B ro ken s h ift d r u m stopper
Worn or bent s h ift forks
B roken s h ift l i nkage return spri ng
Worn gear s h ift fork claw
1 1 -1
Dl
Crankshaft/Piston/Transmission
Crankcase Separation
(6)
(5)
1 1 -2
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Crankshaft/Piston/Transmission
N OTE
•
Before removi ng the parts, m a ke a note of their locati o n fo r correct i n sta l l at i o n .
Requisite Service
•
•
7-2)
E n g i n e remova l ( page
C l utch rem ova l ( page 9-4)
Procedure
(1)(2)
(3)
(4)
(5)
(7)
(6)
(8)
(9)
( 1 0)
(11)
(12)
•
•
Alte rnator cove r re m ova l (page 1 5- 1 0)
O i l p u m p re mova l ( page 4-3)
Remarks
Q'ty
Separation Order
Upper Crankcase Side
M a i nshaft bea r i n g sto pper p l ate bolt
M a i nshaft bea r i n g sto pper p late
U pper cra n kcase bolt, 6 m m/washer
Ca bl e g ui d e
U pper cra n kcase bo lt, 10 m m/washer
Lower Crankcase Side
Lowe r cra n kcase bo lt, 6 mm
Lowe r cra n kcase bo lt, a · m m
Lowe r cra n kcase bo lt, 9 mm
Lowe r cra n kcase
Dowe l p i n
O i l orifice
0-ri n g
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3
1
7�1, ]
2/2
8
1
8
1
3
Loosen g ra d u a l ly.
Loosen in a g ra d u a l , crisscross patter n .
Loosen i n a g ra d u a l , crisscros � patter n .
1
1
1 1 -3
Crankshaft/Piston/Transmission
Crankshaft/Con necting Rod Removal/Installation
AFTE R '94
(1 1 )
c
0
(11)
1 2 ( 1 .2. 9 )
cw
--:7J
naa
1 2 ( 1 .2, 9)
,
c
(9)
0g
c
(1)
33 (3.3, 24)
1 2 ( 1 .2, 9)
(4)
�--- ( ) cw
c
1 2 ( 1 .2, 9 )
ROTATI N G
D I R ECTIO N
1 1 -4
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Crankshaft/Piston/Transmission
N OTE
•
•
•
M a rk a l l pa rts d u ri n g d i sassembly so they can be re placed i n the i r ori g i n a l locations.
A l l bea ring inserts a re se l ect fitted a n d a re identified by co lor code. Select repl acement bea ri ngs from the code
ta ble ( page 1 1 - 1 6). After i nsta l l i n g new bea rings, recheck them with plastigauge to verify the clea rance.
Apply m o lybde n u m disu lfide o i l to the con necting rod/m a i n j o u rn a l bea rin gs, m a i n j o u rn a l a n d cra n kpi n .
Requisite Service
•
Refer to Service I nformation ( page 1 1 - 1 )
Procedure
I nsta l lation is in the reverse order of remova l .
Removal Order
(1)
(2)
Connecti ng rod bea ri ng cap n ut
Con necting rod bea ring ca p
Remarks
Q'ty
8
4
N OTE
Note the d i rectio n of the bea ring ca p.
•
(3)
Connecti n g rod/piston assem bly
4
CAUTION
Do not try to remove the connecting rod/piston assembly from the bottom of the cylinder. The oil ring
will become wedged in the gap between the cylinder
liner and the upper crankcase.
•
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1)
(12)
( 1 2)
(1 1 )
( 1 0)
(9)
(8)
(7)
(6)
Connecti ng rod bea ring
Cra n kshaft
Cra n kshaft main j o u rn a l bea ring
Front ca m c h a i n tensioner s l i pper bolt
F ront ca m chain tensioner s l i pper
Rea r ca m chain tensioner s l i pper bolt
Rea r cam c h a i n tensioner s l i pper
F ro nt/rear cam c h a i n s l i pper bolt
F ront/rea r cam ch a i n s l i pper
8
1
8
1
1
1
1
2
1
Wi pe a l l o i l fro m bea ring seating a reas.
Wi pe a l l o i l from bea ring seating a reas.
Installation Order
Fro nt/rear cam cha i n s l i pper
F ro nt/rear cam chain s l i pper bolt
Rea r ca m c h a i n tensioner s l i pper
Rea r cam cha i n tensioner s l i pper bolt
Front ca m cha i n tensioner s l i pper
F ront ca m chain tensioner s l i pper bolt
Cra n kshaft main journal bea ring
1
2
1
1
1
1
8
Clean a n d apply a l ocki ng agent to the th reads.
Clea n a n d apply a l ocking agent to the threads.
Clean a nd apply a l ocking agent to the th reads.
NOTE
At insta l l ation, a l i g n the oi l h o l es between the cra n kc a s e a n d bea r i n g , a n d t h e b e a r i n g ta b s w i t h t h e
g roove i n the cra n kcase.
•
(5)
(4)
Cra n kshaft
Con necting rod bea ring
1
8
NOTE
At i n sta l l ation, a l i g n the o i l h o les betwee n the connecting rod and bea ring, a n d the bea ri n g tabs with the
g roove i n the con n ecti ng rod and beari n g ca p.
N OTE
Each connecti ng rod has an identification m a rk; " M L7F " (Front), " M L7-R" ( Rear).
• At i n sta l l a t i o n , i n sta l l the c o n n e c t i n g r o d/ p i st o n
asse m bly with the o i l h o l e on the connect i n g rod facing opposite the rotati ng d i rection of the cra n kshaft.
•
(3)
Con nect i n g rod/piston assembly
4
•
(2 )
(1)
Connecti ng rod bea ring cap
Con necting rod bea ring cap n ut
4
8
N OTE
At i n sta l l ati o n , a p p l y e n g i n e o i l to the th rea d s a n d
seati ng su rface of the n ut.
Tig hten the n uts g ra d u a l ly and a lternate ly.
•
•
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1 1 -5
Crankshaft/Piston/Transmission
Piston Disassembly I Assembly
(1)
,
.,
" I N " MARK
(2)
(4)
I DE NTIFICATI O N
( 1 0)
,
.--�-t-20 m m (0.8 i n ) OR M OR E
1 1 -6
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Crankshaft/Piston/Transmission
N OTE
I
•
Apply mo lybden u m d isu lfide o i l to the connecti ng rod sma l l end and piston p i n .
Requisite Service
•
Pisto n rem ova l ( page 1 1 -4)
Procedure
Remarks
Q'ty
Disassembly Order
Assem bly is in the reve rse order of d i sasse m bly.
(1)
Pisto n p i n c l i p
8
CAUTION
• Do not reuse the piston pin clips.
(2)
Piston p i n
4
N OTE
Apply mo lybde n u m disu lfi de o i l to the piston p i n a n d
connecti n g rod sma l l e n d .
N OTE
• Identify the fro nt con nect i ng rod by the m a rk i ng " M L7F " . I nsta l l the piston on the front con n ecti n g rod so that
the " I W m a rk on the pisto n head faces the o i l hole side
of the con necti ng rod .
• It is n ot necessa ry t o rem ove the p iston ri n g s u n less
they need replacing.
•
(3)
F ront piston asse m b l y
2
(4)
(5)
F ront con n ecti ng rod
Rea r piston asse m b l y
2
2
N OTE
Id entify the rea r con n ecti ng rod by the m a rk i n g " M L7R " . I nsta l l the piston on the rea r con nect i n g rod so that
the " I N " m a rk o n the piston head faces the side opposite the con necti n g rod oil h o l e .
It i s n ot n ecessa ry t o rem ove the p i ston ri n g s u n l ess
they need replaci n g .
•
•
(6)
(7 )
(8)
(9)
( 1 0)
Rea r con n ecti n g rod
Top ri ng
Secon d ring
Side ra i l
S pacer
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2
: J
At i n sta l lati o n , i n sta l l the piston r i n g s with t h e i r m a rks
faci n g u p .
8
4
1 1 -7
Crankshaft/Piston/Transmission
Transmission Removal/Installation
, (1)
1 1 -8
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Crankshaft/Piston/Transmission
N OTE
Turn the m a i nshaft a n d cou ntershaft to ensure that the gears turn smoothly after reassem bly.
After i nsta l lati o n , l u b ricate gears with clean reco m m ended e n g in e o i l .
•
•
Requisite Service
•
Refer to service I nformation ( page 1 1 - 1 )
Procedure
Remarks
Q'ty
Removal Order
(1)
M a i nshaft/co u ntershaft asse m b ly
1
(2)
(3)
(4 )
(5)
(6)
Cou ntershaft bea r i n g set plate
Dowe l pin
S h ift fo rk s h a ft
S h ift fo rk
S h ift d r u m
1
1
1
3
1
(6)
(5)
S h ift d r u m
S h ift fo rk
1
3
(4)
(3)
(2)
(1)
S h ift fo rk shaft
Dowe l pin
Cou ntershaft bea ri ng set plate
M a i nshaft/co u ntershaft asse m b ly
1
1
1
1
•
•
Remove the m a i nshaft a n d cou ntershaft as a n assem bly.
Disassembly ( page 1 1 - 1 0, 1 2 )
Installation Order
I n sta l l t h e m w i t h t h e i d e n t i f i c at i o n m a r k ( R : R i g ht ,
C: Center, L: Left) side fac i n g t h e rig ht s i d e as s h own .
Fit i n the u pper cra n kcase secu rely.
I nsta l l the m a i nshaft a n d cou ntershaft as a n asse m bly.
F i t t h e c o u nte rs h aft bea r i n g set pin a n d p l ate in the
u pper cran kcase g roove, a n d the dowel p i n i n the hole
i n the need le bea r i n g case.
•
•
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1 1 -9
Crankshaft/Piston/Transmission
Mainshaft Disassembly I Assembly
( 1 4)
( 1 3)
( 1 0)
( 1 2)
(11)
(9)
( 5)
'94 - '95 (and some '96 early
production units)
(7)
- '
AFTER '95
(Except some '96 early
production units)
t-L-����==�
( 1 3) ( 1 0)
GEAR
(4)
(5)
(1)
�==�---
---:71) : S H I FTE R
m G ROOVE
(8)
( 1 2)
94 95
(and some '96 early
production units)
'
(1)
(3)
(9)
(8)
(7)
(6)
(3)
---:71) : GEAR S L I D I N G
m S U RFACE
1 1 -1 0
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©
Revised: July, 1 995, '94 - '95 Magna VF750C/CD
1 995 American Honda Motor Co., Inc. - All Rights Reserved
MSV 691 3 19504)
Crankshaft/Piston/Transmission
N OTE
•
•
•
Apply mo lybden u m o i l sol ution to the sh ifter gear g rooves. Apply o i l to a l l s l i d i n g su rfaces of the m a i nshaft, c o u n ­
tershaft a n d bush i n gs.
I n sta l l the thrust washers a n d snap ri ngs with the cha mfe red edge faci n g the th rust load side.
Refe r to section 1 3 of the C o m m o n Service M a n u a l fo r inspection i nformatio n .
Requisite Service
•
Tra n s m ission rem ova l/i nsta l l ation ( page 1 1 -81
Procedure
Q'ty
Disassembly Order
(1)
(2)
(3)
(4)
(51
(6)
(7)
(8)
(9)
( 1 0)
(11)
( 1 2)
( 1 3)
( 1 4)
N eedle bea ri ng case
N eed le bea ring
Thrust washer
M 2 gear ( 1 7TI
Co l l a r
S p l i n e washer
S n a p ring
M3/M 4 gea r (20/22TI
S n a p ri n g
S p l i n e washer
M 5 bush i n g
M5 gear (28TI
Washer
M a i nshaft/M 1 gea r ( 1 3TI
Revised: July, 1 995, '94 -· '95 Magna VF750C/CD
© 1 995 American Honda Motor Co. , Inc. - All Rights Reserved
691 3 f9504l
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Remarks
Asse m bly is in the reve rse o rder of d i sasse m bly.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
'94 - '95 (and some '96 early production units)
1 1 -1 1
Crankshaft/Piston/Transmission
Countershaft Disassembly I Assembly
ALI G N O I L HOLES
( 1 4)
(2 2)
( 1 5)
( 1 0)
(3)
(6)
--:7D : S H I FTE R G EAR
. I GR O OVE
-:7ll : G EAR S LI D I N G
. I S U R FACE
1 1 -1 2
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(8)
( 1 5)
(9)
(23)
( 1 8)
( 1 2)
( 1 3)
( 1 6)
( 1 7)
( 1 9)
(20)
Crankshaft/Piston/Transmission
N OTE
•
•
•
Apply mo lybde n u m o i l so l ution to the sh ifte r gear g rooves. Apply o i l to a l l s l i d i n g su rfaces of the m a i n shaft, c o u n ­
tershaft a n d bush i n gs .
I nsta l l the th rust washers a n d snap rings with the cha mfe red edge faci n g to the th rust load side.
Refe r to secti on 1 3 of the co m m o n Service M a n u a l fo r i nspection i nfo rmati o n .
Requisite Service
•
Transm ission remova l/i nsta l lation ( page 1 1 -8)
Procedure
Q'ty
Disassembly Order
(1)
(2)
(3)
(4)
(5)
(6)
(7 )
(8)
(9)
( 1 0)
(1 1 )
(12)
( 1 3)
( 1 4)
( 1 5)
( 1 6)
(17)
( 1 8)
( 1 9)
(20)
(2 1 )
(22)
(23)
N eed le bea ri ng case
N eedle bea ring
Thrust washer
C 1 gea r (37T)
Needle bea ring
Thrust washer
C5 gea r ( 29T)
Snap ri n g
S p l i ne washer
C4 gea r ( 27T)
C4 spl i ne bush i n g
Ta nged washer
Lock washer
C3 s p l i n e b u s h i n g
C3 gear ( 29T)
S p l i n e washer
S n a p ri n g
S h ifter gea r
S n a p ri n g
Spline washer
C2 gea r (32T)
C2 bush i n g
Cou ntershaft
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Remarks
Assem bly is in the reve rse order of d i sasse m bly.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
A l i g n the o i l h o les of the b u s h i n g a n d cou nte rshaft.
At asse m b ly, fit the ta ngs i nto the lock wash e r c ut-outs.
1 1 -1 3
Crankshaft/Piston/Transmission
Crankcase Combination
-,0
c
3 1 (3. 1 , 2 2 1
1 2 ( 1 . 2, 91
(7)
ALI G N
(51
c
23 (2.3, 1 71
(6)
(9)
<1
c
1 1 -14
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(81
1 2 ( 1 .2, 91
c
39 (3.9, 28)
Crankshaft/Piston/Transmission
CAUTION
Install the oil orifice with the larger inner diameter side facing the lower crankcase.
If the lower crankcase installation is difficult, make sure the transmission assembly is installed correctly.
•
•
N OTE
•
Refe r to page 1 1 - 1 8 fo r cra n kcase sea l a nt a rea and deta i l of the bolt l ocati ons.
Requisite Service
•
•
•
•
O i l pu m p i nsta l lation ( page 4-3)
Sta rter m otor i n sta l lati on ( page 1 7-7 )
Alte rnator i n sta l l ation ( page 1 5- 1 0)
C l utch i n sta l latio n ( page 9-6)
Procedure
•
•
•
Q'ty
Remarks
1
CAUTION
Do not apply sealant around the oil passage area and
main journal bearing area.
Combination Order
(1)
U pper cra n kcase
Gearshift i i n kage i n sta l lati o n ( page 1 0-4)
Cyl i nder head/ca mshaft i n sta l l atio n ( page 8-2 )
E n g i n e i n sta l latio n ( page 7-2)
•
(2)
(3)
( 4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(11)
( 1 2)
O i l orifice/0-ring
Dowe l p i n
Lower cra n kcase
Lowe r cra n kcase bo lt, 9 mm
Lower cra n kcase bolt, 8 mm
Lowe r cra n kcase bo lt, 6 m m/washer
U pper cra n kcase bo lt, 10 m m/washer
Ca bl e g u ide
U pper cra n kcase bo lt, 6 m m/washer
M a i nshaft bea ring set plate
M a i nshaft bea ring set plate bolt
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Refe r to page 1 1 - 1 8 fo r deta i l fo r the a p p l icatio n a rea.
I nsta l l it as i l l ustrate d .
1/1
3
1
!I
�
2 2
7/1
1
3
A t i n sta l lati on, m ake s u re the shift fo rks engage properly
with the correspo n d i n g gea rs.
f.-Tig hte n i n g o rder ( page 1 1 - 1 8)
J
Tig hten i n g order ( page 1 1 - 1 9 )
A l i g n t h e cut out o f t h e shift fo rk shaft with t h e set plate.
Clean and a pply a l ocki ng agent to the bolt th reads.
1 1 -1 5
Crankshaft/Piston/Transmission
Crankshaft Bearing Replacement
Main Journal Bearing Selection
Record the cra n kcase I . D . code letters from the pad o n the
left side of the upper cra n kcase.
N OTE
The letters (A, B or C) on the u pper cra n kcase a re the
codes fo r the m a i n j o u rn a l I . D . s . fro m t h e l eft to
rig ht.
( 1 ) CRAN KCASE 1.0. CODE
Reco rd the co rrespo n d i n g m a i n j o u r n a l O . D . code n u m ­
be rs from t h e cra n k weig ht.
N OTE
•
2
The n u m bers ( 1 ,
or 3) on the cra n k wei g ht a re the
codes fo r the main j o u rn a l O. D.s.
( 1 ) MAI N J O U R NAL O.D. CODE
C ross-refe rence the case a n d journal codes to determ i n e
t h e replacement bea ring co l o r codes.
Main Journal Bearing Selection Table:
U n it: mm ( i n )
�:�:
�.������ �
nal
�
�
�
37.000 37.005 37 .006 37.01 1 37.0 1 2 37 .018
( 1 .4567 - 1 .4569) ( 1 .4569 - 1 .4572) ( 1 .4572 - 1 .4574)
1
34 007 - 34 0 1 3
·
·
( 1 .3389 - 1 .339 1 )
Yellow
G reen
B rown
2
34.001 - 34.006
( 1 .3386 - 1 .3388)
G reen
B rown
Black
33.995 - 34.000
3
( 1 .3368 - 1 .3385)
Brown
B l a ck
Blue
Beari ng thickness:
Blue:
Black:
B rown:
G reen:
Yel low:
l
Th ick
Th i n
1 1 -1 6
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( 1 ) MAI N J O U R NAL BEAR I N G S
Crankshaft/Piston/Transmission
Connecting Rod Bearing Selection
I n spect the con necti ng rod bea ring and cra n kpin oil clea r­
a n ce (See section 1 4 of the Co m m o n Service M a n u a l ) .
Record t h e con necti ng r o d I . D. code n u m be r ( 1 , 2 or 3) o r
measu re the I. D . wi th the bea r i n g cap i n sta l l ed with out
bea r i n g i n sert.
( 1 ) CO N N ECTI N G ROD I . D. CODE
If you re p l ace the c ra n ks h aft, record the co rrespo n d i ng
cra n kp i n O . D . code n u m be r (A, B or C ) .
If you a re re u s i n g the c ra n ks h aft, measu re the c ra n kp i n
O . D . with a m icrometer.
N OTE
•
N u m be rs (A, B o r C) o n t he c ra n k we i g ht a re t h e
codes for t h e c ra n k p i n O . D.s.
Cross-refe rence the cra n kp i n a n d rod codes to dete rm i ne
the replacement bea ri n g color.
( 2 ) REAR
N OTE
•
One pa i nted mark identifies the fro nt connecti n g rod
bea rings and two pai nted ma rks the rea r.
Connecting Rod Bearing selection Table:
U n it: m m ( i n )
�����:��
�::�����
:
�
�
35.995 36.000 35.989 35.994 35.982 35.988
( 1 . 4 1 7 1 - 1 .4 1 73) ( 1 . 4 1 69 - 1 .4 1 7 1 ) ( 1 . 4 1 66 - 1 . 4 1 69)
1
39.000 - 39.005
( 1 .5354 - 1 .5356)
Yellow
Green
Brown
2
39.006 - 39.01 1
( 1 .5357 - 1 .5359)
G reen
B rown
Black
3
39.01 2 - 39.0 1 8
( 1 .5359 - 1 .536 1 )
Brown
Black
Blue
(3) CON N E CTI N G R O D BEAR I N G
Bearing thickness:
Blue:
B lack:
Brown:
G reen:
Yel l ow:
l
Thick
Th i n
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1 1 -1 7
Crankshaft/Piston/Transmission
Connecting Rod Selection
T h e weight code is sta m ped on t h e co n n ecti ng rod u s i n g
a n a l p h a betical code.
I f a co n n ecti n g rod req u i res re p l a ce m e nt, you s h o u l d
select a rod with the same weight code a s t h e o ri g i n a l . B ut
if that is u nava i lable, you may use one of the oth e rs speci­
fied i n the c h a rt.
O ri g i n a l rod code
(The rod you wi l l
be re placi n g )
A
B
c
Othe r rod code
o n that sa m e
cra n kp i n
R eplace m e nt rod
code
B
A, B or C
c
A or B
A
B or e
B
A, B or C
c
A or B
A
B or C
B
A, B or C
( 1 ) CO N N E CTI N G RO D WE I G HT CODE
0
Cran kcase Bolt Location
o
( 1 ) LIQU I D
S EALANT
AREA
LOWE R CRAN KCASE S I D E :
Clean t h e cra n kcase 9 m m bo lts th o ro ug h ly with solvent
an d blow them d ry.
Apply clean e n g i n e oil to the 9 m m bolt th reads a n d seat­
i n g su rface a n d i nsta l l them .
Loosely i nsta l l a l l the l ower cran kcase bolt.
M a ke s u re t h e u p p e r a n d l ow e r c ra n kc a s e a re s e at ed
secu rely.
2
F rom the i nside to o utside, torq u e the l owe r cra n kcase 9
mm bo lts i n a crisscross pattern i n or 3 steps.
Torque: 31 N·m (3.1 kg-m, 22 ft-lbl
Torq ue the 8 m m bo lts, and then the 6 mm bo lts.
Torque: 8 mm bolt: 23 N·m (2.3 kg-m, 17 ft-lbl
6 mm bolt: 12 N·m ( 1 .2 kg-m, 9 ft-lbl
9 x 88
1 1 -1 8
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0
0
Liquid Sealant Application
Apply a l i g ht but th ro u g h coating of l i q u i d sea l a nt to the
cra n kcase mati ng su rface exce pt to the main bea ri n g j o u r­
n a l bolt ( l ower cra n kcase, 9 m m ) a rea a n d the o i l passage
a rea as shown .
0
Crankshaft/Piston/Transmission
Loose ly i nsta l l a l l the u pper cra n kcase bo lts, the sea l i n g
was h e rs a n d ca b l e g u i de.
U PPER CRAN KCASE S I D E :
To rq u e the 1 0 m m bo lts, a n d then the 6 m m bo lts.
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)
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1 1 -1 9
MEMO
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1 2. Front Wheel/Suspension/Steeri n g
Service Information
Troubleshooting
Handlebar Removal/Installation
Front Wheel Removal/Installation
Front Wheel Disassembly/Assembly
1 2- 1
1 2- 1
1 2-2
1 2-4
Fork Removal/Installation
Fork Disassembly
Fork Assembly
Steering Stem Removal/Installation
1 2-5
1 2-6
1 2-8
1 2- 1 0
1 2- 1 2
Service Information
•
•
•
•
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
Refer to section 1 4 fo r b ra ke system i nfo rmati o n .
Refe r to section 1 8 fo r l i g ht, mete r a n d switc h i nformati o n .
When servicing the front whee l , fo rk or steeri n g stem , su pport the m otorcycle sec u rely with a safety sta n d o r h o i st.
Do n ot use the oil fi lter as a jack poi nt.
Troubleshooting
Hard Steering
•
•
•
•
Steering head bea ring adj ustment n ut too tight
Fau lty stee ri ng head bea rings
I n s ufficient t i re pressu re
F a u lty t i re
Steers To One Side Or Does Not Track Straight
•
•
•
•
•
•
•
Bent fo rk
Bent front axle
Wheel i n sta l led i ncorrectly
Fau lty stee ring head bea rings
Bent fra me
W o r k w h e el bea ri ng
Worn swi n g a rm pivot components
Wheel Turns Hard
•
•
•
•
Soft Suspension
•
•
•
•
Front Wheel Wobbling
•
•
•
Bent ri m
Worn front wheel bea ri ngs
Fa u lty ti re
U n ba l a nced t i re a n d wheel
•
•
•
I ncorrect fl u i d wei g ht
Bent fo rk tu bes
C logged fl u i d passage
Hi g h ti re pressu re
Front Su1pen1ion Noisy
I nsufficient fl u i d i n fork
•
•
•
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I nsufficient fl u i d i n fork
Wea k spri ngs
L ow fl u i d level in fork
Low t i re p ressu re
Hard Suspension
•
•
Fau lty wheel bea ring
Fau lty speedomete r gear
Bent front axle
B ra ke d ra g
Loose fo rk fasteners
Lack of g rease i n speedometer gear
1 2- 1
Front Wheel/Suspension/Steering
Handlebar Remova l/Insta l lation
(1)
c
2 3 ( 2 .3, 1 7 )
(1)
( 1 0)
( 1 5)
1 2-2
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,
Front Wheel/Suspension/Steering
Contaminates in the system may cause a reduction or loss of braking ability.
•
N OTE
•
•
•
U s i n g wi res, h a n g the front bra ke master cyl i n der at least as h i g h as the positi o n it was orig i n a l l y i n sta l l e d at to
prevent a i r fro m getting i nto the master cyl i nder. Do not twist the brake hose.
Ro ute the ca bles a n d wi re harnesses properly ( page 1 -20).
After i nsta l l i ng the h a n d lebar, adjustthe th rottle ca b l e
the c l utch ca b l e
•
the c h o ke ca b l e
•
•
Procedure
O'ty
Removal Order
I nsta l lati o n is in the reve rse o rde r of remova l .
2
(3)
(4)
Rea rview m i rror
Wi re ba n d
C l utch switch con necto r
C l utch lever asse m b l y
2
2
1
(5 )
(6)
Le ft h a n d lebar switc h h o u s i n g screw
Left h a n d lebar switch h o u s i n g
2
1
(7)
Handle grip
1
(8)
(9)
( 1 0)
Switch h o u s i n g side protector
B ra ke l i g ht switch con n ector
Master cyl i n d e r
1
2
1
(1 1 )
( 1 2)
R i g ht h a n d lebar switch h o u s i n g screw
R i g ht h a n d lebar switch h o u s i n g
2
1
( 1 3)
( 1 4)
H a n d l e ba r h o l d e r bolt
H a n d le ba r u pper h o l der
4
2
( 1 5)
( 1 6)
(17)
Th rott le ca b l e e n d
Th rottle p i pe
H a n d lebar
2
1
1
(1)
(2)
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Remarks
A l i g n the s p l it betwee n the h o l d e r a n d l ever support with
the punch m a rk o n the h a n d l e b a r a n d face th e h o l d e r
" U P" m a rk u pwa rd .
Tig hte n the u pper bolt fi rst, then the l ower bolt.
Tig hten the fro nt screw fi rst, t hen the rea r screw.
A l i g n the l ocati ng pi n i n the l eft h a n d l e b a r switch with
the h o l e in the ha ndlebar.
Apply H o n d a Bond A or H o n d a H a n d G ri p Cement
( U .S .A. o n ly) to the inside su rface of the g ri p .
A l i g n the s p l it between the h o l d e r a n d m a ster cyl i n d e r
body with the pu nch m a rk o n t h e h a n d l e b a r a n d face t h e
h o l d e r " U P" m a r k u pwa rd .
Tig hten the upper bolt fi rst, then the l ower bolt.
Tig hten the front sc rew fi rst, then the rea r screw.
A l i g n the l ocati n g p i n i n the right h a n d lebar switch with
the h o l e in the h a n d lebar.
Tig hten the front bo lts fi rst, then the rea r bo lts.
I n sta l l the upper h o l d e r with its p u n c h m a r k fac i n g forwa rd .
P lace the h a n d lebar o nto the l ower h o l d e r a n d a l i g n the
punch m a rks o n the h a n d l e b a r with m ati n g s u rface of
the h a n d lebar h o l der.
1 2-3
Front Wheel/Suspension/Steering
Front Wheel Removal/Insta llation
c
59 (5.9, 43)
(2)
(1)
(3)
c
2 2 (2.2. 1 6)
(7)
•
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
CAUTION
•
Do not use the oil filter as a jack point.
N OTE
•
•
When servicing the front wheel, support the m otorcycl e u s in g a safety sta nd or h o i st.
Do not operate the b ra ke leve r after the front wheel rem oved .
Procedure
Q'ty
Removal Order
I nsta l l ation is in the reve rse order of rem ova l .
(1 )
(2)
(3)
(4)
Speedometer ca ble
Axle bolt
Axle p i nch bolt
F ront axle
1
1
4
1
(5)
F ront wheel assembly
1
(6)
Side co l l a r
Speed ometer gear b o x assem bly
1
1
(7)
1 2-4
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Remarks
At i n sta l l ation, a pply a t h i n coati ng of g rease to the front
axle.
At i n sta l latio n , a l i g n the p rojection of the speedometer
gea r box with the projection on the fork leg.
Front Wheel/Suspension/Steering
Front Wheel Disassembly I Assembly
(2)
(2)
(1 )
c
42 (4.2, 30)
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
•
N OTE
Always replace wheel bea rings as a set.
For wheel bea ring replacement, refer to section 1 of the C o m m o n Service M a n u a l .
•
•
Requisite Service
•
F ro nt wheel remova l/i n sta l lati o n ( page 1 2-4)
Procedure
Removal Order
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Brake d i sc bolt
Brake d i sc
Dust sea l
Speedometer gear reta i ne r
R i g ht w h e e l bea ri n g (6004 U U )
Distance co l l a r
Left wheel bea ring (6004 U U )
Remarks
Q'ty
I n sta l latio n is i n the reverse order of rem ova l .
6
1
2
1
1
1
1
I nsta l l with sta m ped side o utwa rd .
At i n sta l latio n , apply g rease to the d u st sea l l i ps.
N OTE
At asse m b ly, d rive in the left side bea r i n g fi rst, then the
right side bea r in g .
•
(8 )
F ront wheel/ti re
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1/1
1 2-5
Front Wheel/Suspension/Steering
Fork Removal/Installation
(9)
c
c
27 ( 2 . 7 , 20)
(8)
1 2 ( 1 . 2 , 9)
(1)
( 1 0)
c
39 (3.9, 28)
(3)
(5) .,
c
3 1 (3. 1 , 2 2 )
1 2-6
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Front Wheel/Suspension/Steerin g
CAUTION
Support the removed caliper so that it does not hang from the brake hose. Do not twist the brake hose.
•
N OTE
•
If the fork legs wi l l be d i sassem bled, tem porarily tig hten the bottom bridge pinch bolt to l oosen the fo rk cap.
Requisite Service
•
F ront wheel remova l/i nsta l latio n ( page 1 2-4)
•
Procedure
(6)
(7)
(8)
(9)
( 1 0)
F ro nt fender bolt
F ront fender col l a r
F ront fen der
Brake hose c l a m p
Ca l i pe r bracket bolt
C a l i pe r asse m bly
F ront turn s i g n a l bo lt/co l l a r
F ro nt turn signal assembly
Fork p i nch bolt ( u pper)
Fork pinch bolt ( l ower)
Remarks
Q'ty
Removal Order
(1)
(2)
(3)
(4)
(5)
U pper fairing remova l/i nsta l lation (VF750CD: page 2-8)
I n sta l latio n is in the reverse order of rem ova l .
4
1
1
1
2
1
I
2/2
2
2
2
O n ly l oosen the bolts.
Only l oosen the bo lts.
If the fo rk leg wi l l be disasse m bled, tem pora rily tig hten
the bottom pi nch bolt to l oosen the fork cap.
At i nsta l lati on , a l i g n the tops of fo rk tu bes with the u pper
su rface of the top bridge.
•
•
(11)
Fork asse m b l y
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2
1 2- 7
Front Wheel/Suspension/Steering
Fork Disassembly
(1
(1)
�
(10)
(12
( 1 8)
lr-----...Ja!:§il�l!'i(
-------s
�(4)
�
�(7)
6)
(19
(91..
(14)
�(15)
lB------< 1 6)
� (9) � 1 7 1
(8)
1 2-8
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Front Wheel/Suspension/Steering
•
The fork cap is under spring pressure. Use care when removing it. Use face protection.
N OTE
•
•
If the fo rk piston m oves with the socket bolt d u ri n g rem ova l , tem po ra ri l y i nsta l l the spri ng, spacer a n d the fo rk
cap.
Always replace the o i l sea ls with new ones.
Requisite Service
•
Fork rem ova l ( page 1 2-6)
Procedure
Q'ty
Remarks
Disessembly Order
(1)
(2)
(3)
(4)
(5 )
(6)
(7 )
(8)
(9)
( 1 0)
(1 1 )
( 1 2)
( 1 3)
( 1 4)
( 1 5)
( 1 6)
(17)
( 1 8)
( 1 9)
F o rk ca p
0-ring
S pacer
Spr i ng seat
F o r k spring
Dust seal
Stopper ri n g
Fork socket bolt
Sea l i n g washer
Fork piston
Fork piston ri n g
Rebo u n d spring
F o rk tu be
O i l sea l
Back u p ring
Slider bushing
Fork tu be bush i n g
O i l lock piece
F o rk sl ider
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1
1
1
1
1
�T
1
1
1
1
1
1
1
1
1
1
1
1
Afte r removi n g , p o u r out any rem a i n i n g fo rk o i l .
When rem ovi n g , do n ot damage the fork t u be .
Do n ot rem ove it u n less rep l acement is necessary.
Do not remove it u n less replacement is n ecessa ry.
1 2-9
Front Wheel/Suspension/Steering
Fork Assembly
(2)
17)
� 1 7) c
�
(3)
�-
-------s
(4)
( 1 3)
P
(8)
c
1 2- 1 0
., ...
e�
c
20 ( 2.0,
8 (0.8, 5.8)
1 4)
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23 (2.3,
( 1 8)
~
(5)
( 1 5)
Front Wheel/Suspension/Steering
N OTE
•
•
•
Always replace the o i l sea ls with new ones.
Coat the new o i l sea l with the reco m mended fo rk o i l a n d i nsta l l it with its m a rk fac i n g u p .
After assem b l i n g the fo rk legs, i n sta l l each fo rk leg i nto the lowe r fo rk bridge fi rst, then torq u e the fo rk cap.
Requisite Service
•
Fork d i sa sse m bly ( page 1 2-8)
Procedure
•
Fork i nsta l lati on ( page 1 2-6)
Remarks
Q'ty
Assembly Order
(1)
(2)
(3)
(4)
(5)
Rebo u n d spring
Fork piston ri n g
Fork piston asse m b l y
O i l l o c k piece
F o rk tu be b u s h i n g
1
1
1
1
1
(6)
F o r k tu be
Sea l i n g was he r
F o r k socket b o lt
1
1
1
Slider b u s h i n g
Back u p ring
O i l sea l
1
1
1
(7 )
(8 )
(9)
( 1 0)
(11)
Replace with a new one if it was removed from the piston .
I nsert i nto the fo rk tube.
I n se rt onto the pisto n .
Replace with a new one i f i t was re moved fro m t h e fo rk
tube.
If the socket bolt turns with the fork pisto n, tem porarily
i nsta l l the fork spri n g , spacer a n d fo rk cap, then tig hten
the socket bolt.
•
•
( 1 2)
( 1 3)
Stopper r i n g
Dust sea l
1
1
( 1 4)
Fork spri n g
1
( 1 5)
( 1 6)
(17)
( 1 8)
S p r i n g seat
S pacer
0-ri n g
F o r k ca p
1
1
1
1
Wra p vinyl ta pe a ro u nd the fo rk tube top e n d to avo i d
d a m a g i n g the o i l sea l d u ri n g i nsta l lati o n .
U s e fo rk sea l d river (07947 - KA50 1 00) a n d atta c h ment
(07947 - KF00 1 00) fo r fo rk sea l i nsta l l at i o n .
Afte r i n sta l l i n g , co m p ress the fo rk tu be fu l ly a n d p o u r t h e
specified a m o u nt o f fo rk fl u i d ( page 1 - 1 0) i nto the fo rk
tube.
Wi pe all oil off the spri n g thoro u g h ly using a cl ea n , l i nt
free c loth a n d i nsta l l with the ta pered e n d fac i n g down .
Apply o i l to the new 0-ri n g .
CAUTION
Be careful not to cross-thread the fork cap.
Screw in the cap, but do not tighten yet.
•
•
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1 2- 1 1
Front Wheel/Suspension/Steering
Steering Stem Removal/Installation
,,, c
c
6)
1 •.-;;c,..
30 (3.0, 22)
I ( page 1 - 1 5)
-�
NOTE
-!f'tl-...,..::::..__ ( 1 4)
J a.T
-. h pag e 1 2-1 3)
(5)
.,
(8)
T
( 1 5) J s. -. I ( page 1 2- 1 3)
J a.T
-. I (page 1 2-1 3)
(13)
NOTE
--------�
Use the specified grease : Urea based multi-purpose grease for
Extreme pressure (example: EXCELITE
EP2 manufactured by KYODO YUSHI
Japan, 'Shell Stamina EP2) or equivalent
1 2- 1 2
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SHORTER TABS:
Bend down
LONGER TABS:
•
Bend up
•
Front Wheel/Suspension/Steering
N OTE
•
•
•
Replace the bea rings a n d races as a set.
At i n sta l latio n , a p p ly g rease to a l l bea ring a rea.
Check the stee ring head bea ring preload ( page 1 - 1 0) after torq u i n g the ste m n ut.
Requisite Service
•
•
Fork rem ova l/i nsta l lati o n ( page 1 2-6)
H a n d lebar rem ova l/i n sta l l ation ( page 1 2-2)
Procedure
•
•
M eter rem ova l/i nsta l lati on ( pa g e 1 8-7 )
Head l i g ht re m ova l/i nsta l l ation ( pa g e 1 8-6)
Remarks
Q'ty
Removal Order
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1 )
( 1 2)
( 1 3)
( 1 4)
( 1 5)
Steeri n g ste m n ut
Th rust was h er
Top bridge
Lock nut
Lock was h er
Stee ri n g head bea ri ng adjustment nut
Du st seal
Stee ring stem
U pper bea ring inner race
U pper bea r i ng
Lowe r bea ring
Lowe r bea ri ng i n n e r race
D u st seal
U pper bea ring o uter race
Lowe r bea ring o uter race
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Afte r re movi ng, remove the fo rk.
Remove, after stra i g hte n i n g the lock was h e r ta bs.
-
Replace if rem oved.
U se race re m o v e r atta c h m e nt ( 079 5 3 - M J 1 0 1 00 o r
07953 - M J 1 000A [ U . S .A. o n ly ) ) with d rive r (07953 MJ 1 0200 or M9360 - 277 - 9 1 77 4 [ U . S.A. on ly]) for u pper
outer race remova l .
U s e r a c e re mover (07946 - 37 1 0500) fo r l owe r o uter
race re mova l .
•
•
( 1 6)
(17)
Lower h o l d e r n ut/washer
Lower h o l d e r
2/2
2
Installation Oder
(17)
( 1 6)
( 1 5)
( 1 4)
( 1 3)
(12)
(1 1 )
( 1 0)
(9)
(8)
( 7)
{6)
(5)
(4)
(3)
(2 )
(1)
Lowe r h o l d e r
Lowe r h o l d e r n ut/washer
Lowe r bea r i n g o uter race
U pper bea ri ng o uter race
D u st sea l .
Lowe r bea ring i n n e r race
Lowe r bea ri n g
U pper bea r i ng
U pper bea ri ng i n n e r race
Steering stem
Du st s e a l
Steering head bea ring adjustment n ut
Lock was h e r
Lock n ut
Top bridge
Th rust was h e r
Steering ste m nut
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2
2/2
11111111
1
Er
1
1
1
Tig hte n i n g proce d u re ( pag e 1 2- 1 4) .
Replace as a set, if n ecessary.
U se attach me nt, 52 x 55 m m (077 46 - 00 1 0400) and drive r (07749 - 00 1 0000) fo r l ower o uter race i n sta l l atio n .
U s e attachment, 4 2 x 4 7 m m (07746 - 00 1 0300) a n d d river (07749 - 00 1 0000) fo r u pper o uter race i n sta l lati o n .
Use steering stem d river (07946 - M BOOOOO) f o r l ower
i n n e r race i n sta l lati o n .
•
•
•
I n sta l l ati o n : refe r t o section 1 8 o f t h e Co m m o n S e rvice
M a n u a l ( Reta i n e r-Type Ba l l Bea r ing s ) .
Tem po rarily i n sta l l fo rk a n d torq u e the n ut.
1 2- 1 3
Front Wheel/Suspension/Steering
Handlebar Lower Holder Nut Tightening Procedure
I nsta l l the h a n d lebar l owe r h o l d e r.
Loose ly i n sta l l the washers a n d n uts.
I nsta l l the h a n d lebar and upper h o l d e r ( page 1 2-2).
Tig hten the u pper holder bo lts.
Torque: 5 N·m (0.5 kg-m, 3.6 ft-lb)
Adj ust the h a n d lebar stra i g ht-a head by tap the end of h a n­
d l ebar. Make s u re that the l ength A and B a re eq u a l .
Tig hten t h e lower h o l d e r n uts.
Torque: 27 N·m (2.7 kg-m, 20 ft-lb)
Tig hten the u pper holder bolts ( page 1 2-2).
Torque: 23 N·m (2.3 kg-m, 1 7 ft-lb)
Make s u re th at th e l ength A and B a re eq u a l .
1 2- 1 4
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( 2 ) U PPER HOLDER
1 3 . Rea r Wheel/Suspensio n
Service Information
Troubleshooting
Rear Wheel Removal/Installation
Rear Wheel DisassemblyI Assembly
1 3- 1
1 3- 1
1 3-2
1 3-4
Shock Absorber Removal/Installation
Shock Absorber DisassemblyIAssembly
Swingarm Removal/Installation
Swingarm DisassemblyIAssembly
1 3-6
1 3-7
1 3-9
1 3- 1 1
Service I nformation
•
•
•
•
•
•
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry
brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by
OSHA, designed to minimize the hazard caused by airborne asbestos fibers.
A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contami­
nated drum with a high quality brake degreasing 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 rea r wheel, su pport the moto rcycle using a safety sta n d or hoist.
Refe r to the section 1 4 fo r bra ke system i nformatio n .
Tubeless ti re rem ova l , repa i r, a n d re m o u nting proce d u res a re covered i n the section 1 6 of the Com m o n Service
Manual.
Troubleshooting
Soft Suspension
•
•
•
•
Wea k spri ng
O i l leakage from d a m per u n it
I nco rrect suspension adjustment
Low ti re pressu re
Hard Suspension
•
•
•
•
•
I nco rrectly suspension adj u stment
Bent swi ngarm pivot
Damaged swi ngarm pivot bea rings
Bent d a m per rod
High ti re pressu re
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Steers To One Side Or Does Not Track Straight
•
•
Bent rea r axle
Ax le a l i g n ment/cha i n adj u stment n ot eq u a l o n both
sides
Rear Wheel Wobbling
•
•
•
•
•
•
Bent rim
Worn rea r wheel bea ri ngs
Fau lty ti re
U n ba l a nced ti re a n d wheel
Low ti re pressu re
Fau lty swi n g a rm pivot bea rings
1 3- 1
Rear Wheel/Suspension
Rear Wheel Removal/Installation
( 1 5)
( 1 8)
(7)
0
(2)
(9)
( 1 0)
1 3-2
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22 ( 2 . 2 . 1 6)
c
( 1 2)
93 (9.3, 63)
Rear Wheel/Suspension
•
•
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry
brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA
designed to minimize the hazard caused by airborne asbestos fibers.
A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoe and clean a contami·
nated drum with a high quality brake degreasing agent.
N OTE
•
•
•
When se rvicing the rea r whee l , su pport the moto rcycle u s in g a safety sta n d or hoist.
Adj u st the d rive cha i n free play after i n sta l l i n g the whee l .
Apply th i n layer of g rease to the rea r axle su rface.
Procedure
Q'ty
Removal Order
(1 )
(2 )
(3)
(4)
(5)
(6)
(7 )
(8)
(9)
( 1 0)
(11)
(12)
( 1 3)
( 1 4)
B ra ke adj usti ng n ut
B ra ke rod
Spring
B ra ke rod j o i nt piece
Drive c h a i n adjusti n g nut
Cotte r p i n
N ut
Washer
R u bber cushion
Brake sto pper a r m pivot bo lt
Brake stopper arm
Rea r axle n ut/washer
Drive c h a i n adj uste r
Drive c h a i n
( 1 5)
( 1 6)
(17)
( 1 8)
( 1 9)
Rea r axle
Rea r wheel asse m bly
R i g ht side col l a r
Left side c o l l a r
B ra ke panel assembly
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Remarks
I n sta l latio n is in the reve rse order of remova l .
1
1
1
1
2
1
1
1
1
1
1
1/1
1
1
1
1
1
1
1
Loosen t h e adjusti n g n ut fu l ly.
M ove the rea r wheel forwa rd an d rem ove the d rive c h a i n
from t h e d riven sprocket.
Disassembly ( page 1 4-7 ) .
1 3-3
Rear Wheel/Suspension
Rear Wheel Disassembly I Assembly
(9)
(7)
(4)
(8)
.,
(3)
( 2)
-�
(1 1 )
1 3-4
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(8)
( 1 0)
-
(5)
c
(6)
(3)
(4)
1 08 ( 1 0.8, 79)
Rear Whee/Suspension
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry
brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA
designed to minimize the hazard caused by airborne asbestos fibers.
A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean contaminat­
ed drums with a high quality brake degreasing agent.
•
•
N OTE
•
•
•
For d riven sprocket rem ova l , l oosen the sprocket n uts with the d riven flange i n sta l led i nto the wheel h u b.
Replace wheel bea rings as a set.
For wheel bea ring replacement, refer to the sectio n 1 of the Co m m o n Service M a n u a l .
Requisite Service
•
Rea r wheel rem ova l/i nsta l latio n ( page 1 3-2)
Procedure
Q'ty
Disassembly Order
(1)
D u st sea l
1
Remarks
Assem bly is in the reve rse order of d i sasse m b ly.
At asse m bly, apply grease to the d u st sea l l i ps.
Driven Flange Disassembly Order
(2)
(3)
(4)
(5)
(6)
(7 )
Driven fla nge assembly
- Driven flange c o l l a r
- D riven flange bea ri ng (6305 U U )
- Driven sprocket nut
- Driven sprocket
- D riven flange
1
1
1
5
1
1
(8)
(9)
( 1 0)
(11)
( 1 2)
0-ri n g
Rea r wheel d a m pe r
Left wheel bea ring (6304 U U )
Distance col l a r
R i g ht wheel bea ri n g (6204 U U )
1
5
1
1
1
( 1 3)
Rea r wheel/ti re
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Drive i n the rig ht side bea ri n g fi rst, then the l eft si de
bea ri n g .
1/1
1 3-5
Rear Wheel/Suspension
Shock Absorber Removal/Installation
c
2 7 (2.7, 20)
N OTE
•
•
When servicing the shock a bsorber, support the m otorcycle u s i n g a safety sta nd or hoist.
Adj ust the shock a bsorber to the softest position fo r d i sasse m b ly.
Procedu re
Removal Order
(1)
(2)
(3)
S h ock a bsorber m o u nt i n g bolt ( u pper)
P l a i n washer
S h ock a bsorber m o u nt i ng bolt ( l ower)
Remarks
O'ty
I nsta l latio n is in the reve rse o rder of re m ova l .
1
1
1
N OTE
M ove the m uffler outside, rem ove the m o u nting bolt.
•
(4)
S h ock a bsorber assem bly
1 3-6
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1
Rear Wheel/Suspension
Shock Absorber Disassembly I Assembly
( 1 ) I a.TooL I ( page 1 3-8)
�
(3)
Requisite Service
•
Rea r shock a bsorber remova l/i nsta l lation ( page 1 3-6)
Procedure
Q'ty
Disassembly Order
(1)
(2)
(3)
U pper seat
Spring cover
Spring
1
1
1
(4)
(5)
Preload adj uster
Damper u n it asse m b l y
1
1
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Remarks
Assem bly is i n the reverse order of d i sasse m bly.
See page 1 3-8.
I nsta l l the spring with the s ma l l coi l end towa rd the
bottom .
1 3-7
Rear Wheel/Suspension
Spring, Upper Seat Removal/Installation
( 1 ) I a . TooL I COMPRESSOR
I n sta l l t h e sh ock a bsorber com p resso r o n t he s h ock a b­
sorber.
l a.TooL I
Shock absorber compressor
07959 - 3290001
C o m p ress t h e s h oc k a bs o r b e r s p r i n g a n d re m ove t h e
u pper seat.
CAUTION
•
Do not compress the spring more than necessary.
L o o s e n t h e s h o c k a b s o r b e r c o m p re s s o r s l o w l y a n d
rem ove the shock a bsorber.
Remove the spring cover and shock a bsorber spri n g .
I nsta l l t h e spri n g with the sma l l coi l end towa rd the bot­
tom .
I n sta l l t h e spring cove r.
( 1 ) DOWN
I nsta l l the spec i a l tools and com p ress the shock a bsorber
spri n g .
I nsta l l t h e s p r i n g seat sec u re ly.
l a .TooL I
Shock absorber compressor
07959 - 3290001
L o o s e n t h e s h o c k a b s o r b e r c o m p re s s o r s l o w l y a n d
rem ove the shock a bsorber.
1 3-8
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Rear Wheel/Suspension
Swingarm Removal/Installation
/
(7 1
-�
Cas
c(1)
(8.9, 651
(6)
39 (3.9,
28)
�
c 37 (3.7 , 27 )
Requ isite Service
•
Rear wheel rem ova l/i nsta l lation ( page
1 3-2)
Procedure
(1 )
(2)
(3)
(4)
( 5)
(6)
(7 )
(8)
(9)
•
Drive s procket cove r remova l/i nsta l latio n ( page
Remarks
Q'ty
Removal Order
Frame pivot lock bolt
F ra m e p ivot l ock nut
F ra m e pivot adj u sti n g bolt
Drive c h a i n cover
S h ock abso rber l ower m o u nting bolt
Cap
Swi n g a rm pivot n ut
Swi n g a rm pivot bolt
Swi ngarm asse m b l y
�1 j
2
2
1
1
10-2)
I n sta l lation is in the reve rse o rder of re mova l .
t- Adj u stment ( page
1 3-10)
N OTE
M ove the m uffle r o utsi de, rem ove the m o u nt i n g bolts.
•
1
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--
--
- -� ----- ·�--�--- ---- -
1 3-9
Rear Wheel/Suspension
( 1 ) L O CK N UT
Frame Pivot Adjusting Bolt Adjustment
�
Removal
Remove the pivot lock bolt.
Remove the adjusting bolt lock n ut.
NOTE
•
R e m ove the lock n ut wh i l e h o l d i n g t h e a dj u sti n g
bolt.
Remove the adjusti ng bolt.
Installation
Tighten the adjusting bolt.
Torque: 15 N·m ( 1 .5 kg-m, 1 1 ft-lb)
Tighten the lock n ut wh i l e holding the adjusti ng 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)
1 3- 1 0
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( 1 ) ADJ U STI N G BOLT
Rear Wheel/Suspension
Swingarm DisassemblyI Assembly
(5)
(2)
0
22 (2.2, 1 6)
�
(7 )
� (61 0 6 (0.6, 431
N OTE
•
F o r p ivot bea ring replacement, see next page.
Requisite Service
•
Swi ng a rm rem ova l/i nsta l l ation ( page 1 3-9)
Procedure
Disassembly Order
(1)
(2)
(3)
( 4)
( 5)
(6)
(7 )
(8)
(9)
( 1 0)
(11)
( 1 2)
( 1 3)
( 1 4)
Cotter p i n
N ut
Pla i n washer
R u bber cushion
Brake stopper arm
D rive chain slider screw
D rive c h a i n s l i d e r
R i g ht pivot col l a r
Left pivot col l a r
Dust sea l
Dista nce col l a r
Needle bea ring
S n a p ri ng
Ba l l bea ring
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Remarks
Q'ty
1
1
1
1
1
Assembly is in the reverse order of disassembly.
2
1
1
1
2
Apply grease to the l ip.
1
1
1
1
Insta l l it i nto the groove securely.
1 3- 1 1
Rear Wheel/Suspension
Swingarm Pivot Bearing Replacement
Press the rig ht pivot bea ring ( b a l l bea ring) out of swi ngarm.
l s.rooL I
Driver Shaft
07946 - MJ00100 or
07949 - 37 1 0001
(U.S.A. only)
Set the need l e bea ring rem over o nto the l eft pivot bea ring
( need le bea ri n g ) as shown .
Needle bearing remover attachment
07GMD - KT70200
07946 - MJ001 00
Driver Shaft
or (U.S.A. only):
Bearing remover
M967X - 038 - XXXX
Driver
07949 - 37 1 0001
07746 - 0040300
Pilot, 15 mm
07746 - 0030300
Attachment, 30 mm
P ress t h e n e e d l e b e a r i n g i nto t h e swi n g a rm w i t h t h e
m a rked side faci ng out.
( 1 ) N E E DLE
BEARI N G
N OTE
•
The bea ring su rface s h o u l d be fl us h with the p ivot
i nside su rface as shown .
l s.rooL I
Driver
Attachment, 28 x 30 mm
Pilot, 22 mm
07749 - 001 0000
07946 - 1 8701 00
07746 - 0041 000
Press the ba l l bea ri ng in u nt i l it bottoms in the swi n g a r m .
l •.rooL 1
Driver
Attachment, 32 x 35 mm
Pilot, 1 5 mm
1 3- 1 2
07749 - 001 0000
07746 - 001 0100
07746 - 0040300
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/
/
( 41 P I LOT
/
/
/
/
Service Information
Troubleshooting
Front Brake Pad Replacement
Front Brake Caliper Removal/
Installation
Front Brake Caliper DisassemblyI
Assembly
1 4- 1
1 4- 1
1 4-2
1 4-3
1 4-4
1 4. Bra ke System
Front Master Cylinder Removal/
Installation
Front Master Cylinder DisassemblyI
Assembly
Rear Brake Panel DisassemblyI
Assembly
Brake Pedal Removal/Installation
1 4-5
1 4-6
1 4-7
1 4-8
Service I nformation
•
•
•
•
•
•
•
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry
brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA
designed to minimize the hazard caused by airborne asbestos fibers.
A contaminated brake disc, drum, pad or shoe reduces stopping power. Discard contaminated pads/shoes and
clean a contaminated disc/drum with a high quality brake degreasing agent.
S p i l led b rake fl u i d wi l l seve re ly damage i nstrument lenses a n d pai nted s u rfaces. It is a lso h a rmfu l to some rubber
pa rts. Be ca refu l whenever you re move the reservo i r cap: m a ke s u re the reservoi r i s h o rizonta l fi rst.
N ever a l low conta m i nates ( d i rt, wate r, etc . ) to get i nto an o pe n rese rvo i r.
Once the hydra u l ic system has been opened, or if the bra ke fee l spon gy, the syste m m ust be b l e d .
Always use fresh DOT 4 b ra ke fl u i d from a sea led conta i ner when servici ng the syste m . Do n ot m i x d ifferent types of
fl u i d as they may not be com pati b le .
Always check brake ope ration before r i d i n g the m oto rcycle.
Troubleshooting
Front Brake:
Brake Lever Soft Or Spongy
•
•
•
•
•
•
•
•
•
•
•
•
•
•
A ir bu bbles i n the hyd ra u l i c system
Lea ki n g hydra u lic syste m
Conta m i nated b rake pad/d isc
Worn ca l i pe r piston seal
Worn master cyl i nd e r piston seal
Worn b ra ke pad/d isc
Conta m i n ated ca l i pe r
Ca l i pe r n ot s l i d i n g properly
Low fl u i d level
Clogged fl u i d passag e
Warped/defo rmed b rake d i sc
Sticking/worn ca l i pe r piston
Stick i n g/wo rn master cyl i n d e r piston
Conta m i n ated master cyl i n d e r
Rear brake:
Poor Brake Performance
•
•
•
•
•
•
•
•
•
•
I m properly adj u sted brake
Worn b ra ke l i n i ng s
Wo rn b ra ke d r u m
Worn brP.ke c a m
I m properly i n sta l led brake l i n i ngs
Brake l i n kage needs l u bri c ation
Conta m i nated bra ke l i n i n gs
Conta m i n ated bra ke d r u m
Worn b ra ke sh oes at cam contact a rea
I m proper e n ga g em ent between brake arm a n d cam
se rrations
•
•
•
•
•
•
•
Clogged/restricted b ra ke system
Sticki n g/wo rn ca l i pe r piston
Ca l i pe r not s l i d i n g properly
Clogged/restricted fl u i d passage
Wo rn ca l i pe r piston sea l
Sticki ng/wo rn master cyl i n de r piston
Bent b ra ke l eve r
Brakes Drag
•
•
•
•
•
Conta m i nated brake pad/d i sc
M isa l i g ned wheel
Worn bra ke pad/d i sc
Wa rped/deformed b ra ke d i sc
Ca l i pe r not s l i d i n g properly
Brake Pedal Hard Or Slow Return
•
•
•
•
•
•
Worn/broke n retu rn spring
I m properly adj u sted b ra ke
Sticking b ra ke d r u m d u e to conta m i nation
Worn b ra ke s h oes at cam co ntact a rea
B ra ke l i n kage needs l u b ricatio n
I m properly i nsta l led bra ke l i n i ngs
Brake Squeaks
•
•
•
•
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lEI
Brake Lever Hard
Worn brake l i n i ng s
Worn b ra ke d r u m
Conta m i nated b ra ke l i n i ng s
Conta m i n ated bra ke d r u m
1 4- 1
Brake System
Front Brake Pad Replacement
ALI G N
\
(2 )
l
I
/!
I
0
•
•
2 .5 ( 0 . 2 5 . 1 .8)
------- . - - -
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated
disc with a high quality brake degreasing agent.
Check the brake system by applying the brake after the pad replacement.
N OTE
•
•
•
Operate the brake l ever to seat the ca l i per pi ston s agai nst the pads after the pad rep lacement.
The b ra ke pad rep lacem e nt can be done without d i sco n n ecti n g the hyd ra u l ic system .
Always repl ace the b ra ke pads i n pai rs to assu re even d i sc p ressu re .
Procedure
Q'ty
Remarks
1
1
2
I n sta l latio n is in the reve rse order of remova l .
After rem ovi ng the pad p i n p l u g , l oosen the pad p i n .
I nsert the p i n , push i ng the pads agai nst the pad spri n g .
At i nsta l latio n, positio n the pad o nto the pad reta i ne r i n
t h e ca l i per a s shown.
Removal Order
(1)
(2)
(3)
Pad p i n p l u g
Pad p i n
B ra ke pad
1 4-2
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Brake System
Front Brake Caliper Removal/Installation
( 3)
c
(1)
3 5 ( 3 .5 , 2 5 )
( 5)
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contam inated
disc with a high quality brake degreasing agent.
Check the brake system by applying the brake after bleeding air from the system.
•
•
CAUTION
Avoid spilling brake fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
•
Requisite Service
•
F ront brake pad replacement ( page 1 4-2)
Procedure
•
O'ty
Removal Order
(1)
(2)
(3)
(4)
( 5)
Remarks
I n sta l latio n is i n the reverse order of rem ova l .
B ra ke h ose bolt
Sea l i n g washer
B ra ke h ose eyelet j o i nt
1
2
1
Ca l i per b racket bolt
F ront brake ca l i pe r asse m b ly
2
1
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B ra ke fl u i d replacement/a i r bleed i n g
( Section 1 7 o f t h e Com m o n Service M a n u a l )
A t i n sta l l at i o n , p ress t h e b ra ke h o s e e n d a g a i n st t h e
stopper w h i l e tighte n i n g t h e h ose bolt.
1 4-3
Brake System
Front Brake Caliper Disassembly I Assembly
(7)
.,
(8)
(6)
1
c
23 (2.3, 1 7)
oa /c 5. 5 (0 . 55, 41
I
�
(3)
CAUTION
Avoid spilling brake fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
•
Requisite Service
•
F ront bra ke ca l i pe r rem ova l/i n sta l latio n ( page 1 4-3)
Procedure
Remarks
O'ty
Disassembly Order
(1)
(2)
(3)
((45))
(6)
(7)
(8)
(9)
Pad spring
Ca l i pe r b racket
B racket p i n bolt boot
Ca l i per p i n bo lt boot
B racket p i n bolt
Ca l i pe r p i n bolt
C a li pe r piston
Dust sea l
Piston sea l
1 4-4
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Asse m bly is in the reverse order of d i sassem bly.
N ote spring dj rection as shown.
1
1
1
1
1
1
I n sta l l i nto the b racket g roove secu re ly.
At i nsta l l ation, apply a l ocki n g agent to the th reads.
At i nsta l lati on , a pply a l ocki n g agent to the th reads.
At i n sta l l at i o n , i n sta l l t h e p i st o n with t h e d i s h e d e n d
towa rd t h e ca l i per.
2
� =r
r-
CAUTION
Be careful not to damage the piston · sliding surface
when removing the seals.
•
Brake System
Front Master Cylinder Removal/Instal lation
( 1 0)
(2)
c
1 (0. 1 , 0.7)
(1)
(3)
(8)
c
(9)
12 ( 1 .2, 9)
CAUTION
Avoid spilling brake fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is
serviced.
When removing the hose bolt, cover the end of the brake hose to prevent contamination.
Do not allow foreign material to enter the system.
•
•
•
N OTE
I
•
Use DOT 4 bra ke fl u i d from a sea led conta i ner.
Requisite Service
•
Brake system a i r b l eed i n g (Section 1 7 of the Com m on Service M a n u a l )
Procedure
Q'ty
Removal Order
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
R i g ht rea rview m i rro r
F ront b ra ke l ever pivot bo lt/nut
B ra ke lever
F ront b ra ke h ose bolt
F ront b ra ke hose
1
1/1
1
1
1
Sea l i n g washer
B ra ke l i g ht switch co n n ecto r
Maste r cyl i nder holder bolt
2
2
2
Maste r cyl i nd e r h o l d e r
Maste r cyl i nder assem bly
1
1
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Remarks
I n sta l latio n is in the reverse of o rder of rem ova l .
Loosen the m o u nting n ut a n d rem ove the m i rror.
At i nsta l lati o n , p ress the hose e n d a g a i n st the sto pper
wh i l e t i g hte n i n g the h ose bolt.
At i n sta l lation, tig hten the upper bolt fi rst, then th� l ower
bolt.
I nsta l l the holder with its " U P" m a rk faci n g u p .
At i n sta l lation, a l ig n the mating su rface with the p u nch
m a rk o n the h a n d lebar.
1 4-5
Brake System
Front Master Cylinder Disassembly I Assembly
K..---
C
1 . 5 (0. 1 5, 1 . 1 )
"---- ( 1 )
(2)
-
NOTE
Replace the master piston , spring, cu ps, stopper p late, s n a p ring a n d boot as a set.
•
Requisite Service
•
•
Front m aster cyl i nder remova l/i nsta l latio n ( page 1 4-5)
B ra ke system a i r bleed i n g ( Section 1 7 of the Com mo n Service M a n u a l )
Procedure
Q'ty
Disassembly Order
(5)
(6)
Reservoi r cover
D i a p h ra gm pl ate
Dia p h ra gm
B ra ke l i g ht switch
Boot
Snap ring
1
1
1
1
1
1
(7)
(8)
(9)
Stopper plate
Master p i ston assembly
Spring
1
1
1
(1)
(2)
(3)
(4)
Remarks
Assem bly is i n the reverse order of d i sasse m b ly.
CAUTION
Be certain the snap ring is fully seated in the groove.
•
14-6
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I nsta l l the spring with the sm a l l coi l e n d faci ng the
piston .
Brake System
Rear Brake Panel Disassembly IAssembly
� ( 1 ) 0 29 (2 .9, 2 1 )
(4)
,
( 2 ) ------4....,
( 1 0)
�
(5)
(9)
(5)
•
•
.,
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry
brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA
designed to minimize the hazard caused by airborne asbestos fibers.
A contaminated brake drum or shoe reduces stopping power. Discard contaminated shoes and clean a contami­
nated drum with a high quality brake degreasing agent.
Requisite Service
•
Rear wheel remova l/i n sta l lation ( page 1 3-2)
Procedure
Q'ty
Disassembly Order
Assembly is in the reverse order of d isassem bly.
(1)
(2)
Brake a rm pinch bolt
B ra ke a rm
1
1
(3)
Brake i n d icato r
1
(4 )
F e lt sea l
Cotter pin
Cotte r p i n plate
Brake s h o e
Shoe spri ng
B ra ke cam
1
2
1
2
2
1
Brake panel
1
(5)
(6)
(7 )
(8 )
(9)
( 1 0)
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Remarks
At i n sta l l atio n , a l i g n the p u nch m a rks on the brake cam
and arm.
At i n sta l lati o n , a l i g n the wide tooth with the wide slot i n
the bra ke ca m .
I n sta l l with c losed end faci n g out.
At i n sta l l at i on , a pply s i l icone g rease to the s l i d i n g s u rface a n d cam porti o n .
1 4-7
Brake System
Brake Pedal Removal/Installation
( 1 6) -
( 1 4)
c
Procedure
�
27 (2.7, 20)
(8)
Removal Order
(1)
(2)
(3)
( 4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(11)
( 1 2)
( 1 3)
( 1 4)
( 1 5)
( 1 6)
(17)
( 1 8)
B rake rod adj usti ng n ut
B rake rod spri ng
Brake rod j o i nt piece
B rake ped a l p ivot bo lt/n ut
Col l a r
Dust sea l
B ra ke ped a l l i n kage j o i nt pinch bolt
B rake ped a l l i n kage assem bly
Cotte r pin
J o i nt p i n
B ra ke ped a l l i n kage j o i nt
B ra ke ped a l
B rake l i g ht switch spring
B ra ke ped a l return spring
Cotte r p i n
J o i nt p i n
B ra ke rod l i n kage
B rake rod
1 4-8
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Remarks
Q'ty
I n sta l l ation is i n the reverse o rd e r of rem ova l .
1
1
1
1/1
1
2
1
1
2
2
1
1
1
1
1
1
1
1
A l i g n the p u n ch m a rks.
1 5. Charg i n g System/ Alternator
Service Information
System Location
Troubleshooting
Battery Removal/Installation
1 5- 1
1 5-2
1 5-3
1 5-5
Charging System Inspection
Regulator/Rectifier
Alternator
Alternator Removal/Installation
1 5-6
1 5-7
1 5-9
1 5- 1 0
Service i nformation
•
•
•
•
The battery gives off explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation
when charging or using the battery in an enclosed space.
The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protec­
tive clothing and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least 1 5 minutes and call a physician immediately.
Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magnesia or
vegetable oil and call a physician.
KEEP OUT OF REACH OF CHILDREN.
Always tu rn off the i g n ition switch before d isco nnecti ng any electrica l com ponent.
•
CAUTION
•
Some electrical components may be damaged if terminals or connectors are connected or disconnected while
the ignition switch is ON and current is present.
For extended sto rage, rem ove the batte ry, g ive it a fu l l charge, and store it i n a cool , d ry space. For maxi m u m service
l ife, charge the stored battery eve ry two weeks.
For battery rem a i n i n g i n a stored m otorcycle, disconnect the negative batte ry ca ble fro m the batte ry termi n a l .
•
•
N OTE
•
The m a i ntena nce free battery m u st be replaced when it reaches the end of its service l ife.
CAUTION
•
•
•
•
•
•
•
•
•
The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage the
battery.
Battery can be dam aged if ove r charged or u ndercharged, or if left to d i sc h a rge for long periods. These same condi­
tions contri b ute to shorte n i n g the " l ife spa n " of the batte ry. Even u nder normal use, batte ry performa nce dete rio rates
after 2-3 years.
Batte ry voltage may recover afte r battery charg i n g , but u nder heavy load, batte ry voltage wi l l d ro p q u ickly a n d even­
tua l ly die out. For this reason, the charg i n g system is often suspected to be the pro b l e m . If one of the battery cel l s is
shorted a n d batte ry voltage does not i ncrease, the reg u lato r/rectifier suppl ies excess voltage to the battery. U nder
these conditions, the electrolyte level goes down qu ickly.
Befo re tro u bleshooti ng the charg i n g syste m , check the proper use a n d m a i ntena nce of the battery. Check if the bat­
tery is frequently u n d e r heavy load, such as havi ng the head l ight a n d ta i l l i g ht ON fo r long periods of t i m e without rid­
i n g the m otorcycle.
The battery wi l l self-d ischarge when the m otorcycle is not is use. For this reason, charge the battery every two weeks
to prevent su lfati on from form i n g .
F i l l i n g a new batte ry with e lectrolyte wi l l prod uce some voltage, but i n order to achieve its maxi m u m performa nce,
a lways charg e the battery. Also, the batte ry l ife is lengthened when it is i n itia l-charged.
When checki ng the charg i n g system , a lways fol l ow the steps i n the tro u b l eshooti ng fl ow c h a rt ( page 1 5-::S).
For battery testing/c h a rg i ng , refe r to Section 22 of the Com m o n Service M a n u a l .
For charg i n g system location, see page 1 5-2.
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1 5- 1
Charging System/Alternator
System Location
( 1 ) BATIE RY
( 2 ) MAI N F U S E
30 A
(3) R E G U LATOR/RECTI F I E R
( 2) MAI N F U S E
30 A
( 1 ) BATIE RY
1 2 V 1 0 Ah
-
(3) R E G U LATOR/
RECTI F I E R
(4) ALTE R N ATOR
1 5-2
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R: Red
W: Wh ite
Y: Yel low
G : G reen
Charging System/Alternator
Troubleshooting
Battery Overcharging
Fa u lty reg u lato r/rectifier
•
Battery Undercharging
N OTE
•
I n order to o bta i n an accu rate test read i n g when c h a rg i n g the system , the battery m u st be fu l l y c h a rged a n d i n
good con d iti o n . See Com m o n Service M a n u a l Section 22 fo r check the battery co n d iti o n .
Meas u re the battery c u rrent leakage a m pere
( leak test: page 1 5-6).
I ncorrect
Check the reg u lator/rectifi e r ( page 1 5-7 ) .
Standard: 0.01 mA max.
Correct
Correct
I ncorrect
•
•
I n s pect the reg u l ated voltage ( page 1 5-6).
Correct
�
S h o rted wi re h a rness
Fau lty i g n ition switch
Check the battery u s i n g t he battery tester.
I ncorrect
Standard: 1 4 - 1 5.5 V/3,000 rpm
•
•
Correct
.
!
.
•
0 pen c 1 rcu 1t 1 n w1 re h a rness
•
Poorly c o nnected con nectors
E lectric system over- l o a d i n g
F a u lty battery
.
.
N ot c h a rg i n g
•
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1 5-3
Charging System/ Alternator
Abnorm a l
Check t h e voltage between t h e reg u lat o r/recti- 1----. . Open c i rc u it in wire h a rness
fi e r batte ry c h a rg i n g l i n e a n d g ro u n d l i n e
• Poorly connected con n ecto rs
( page 1 5-7 ) .
Connection: Red/White ( + ) - Green (-)
Standard: Battery voltage
N o rm a l
Check t h e a lternator (charg i n g coi l ) resistance
at the reg u l ator/rectifier con n ecto r ( page 1 5-7 ) .
Abnormal
Check the charg i n g coi l resista nce at the a lte r­
nator connecto r ( page 1 5-9) .
.--;?
�w_ J
Connection: Yellow - Yellow
Standard: 0.1 - 1 .0 0
Connection: Yellow - Yellow
Standard: 0.1 - 1 .0 0
Normal
Abno r m a l
Normal
Check the reg u lator/rectifie r u n it ( page 1 5-8) .
Abnormal
Normal
1 5-4
•
•
•
t
Poorly con n ected a ltern tor con necto r
Open or s h ort c i rcuit i n Yel l ow wi re
Fau lty a lternator
1-------� • F a u lty reg u l ator/rectifi e r
'-----. •
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L
l!lfW!l#)lt
Fau lty battery
Charging System/ Alternator
Battery Removal/Installation
N OTE
Always turn the i g n ition switch OFF befo re re m ovi n g or i nsta l l i n g the batte ry.
•
Requisite Service
•
Seat rem ova l/i nsta l lation ( page 2-2)
Procedure
Removal Order
(1)
(2)
(3)
(4)
Batte ry h o l d e r ba n d
Negative term i n a l
Positive term i n a l
Battery
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O'ty
1
� =r
Remarks
I n sta l lation is in the reve rse o rder of rem ova l .
-
•
•
After i nsta l latio n , apply clea n g rease to the ca b l e e n d ,
battery te rm i n a l s a n d bo lts.
At i nsta l l ation, pu l l the cover over the positive ter m i nal.
1
1 5-5
Charging System/Alternator
Charging System Inspection
( 1 ) A M M ETER
Leakage Test
Turn the i g n ition switch off, a n d d iscon n ect the g ro u n d (-)
cable from the battery.
Connect the a m m eter (+) probe to the g ro u n d ca b l e a n d
the a m m eter (-) probe t o the battery (-) term i n a l .
With t h e i g n ition switch off, check for cu rrent leakage.
N OTE
•
•
When measu ring the cu rrent u s i n g a tester, set it to
a h ig h ra nge, a n d then bring the ra nge down to a n
ap propriate leve l . C u rrent flow l a rger t h a n t h e ra n g e
selected may bl ow o ut the fus e i n the teste r.
Wh i l e meas u r i n g c u rrent, do n ot t u r n the i g n it i o n
switch O N . A sudden s u rge o f cu rrent m a y b l ow out
the fuse in the teste r.
(2) G R O U N D CABLE
Specified Current Leakage: 0.01 rnA max.
If cu rrent leakage exceeds the specified va l ue, a s h o rted
c i rc u it i s l i kely.
Regulated Voltage/Ampere Inspection
•
•
If the engine m ust be running to do some work,
make sure the area is well-ventilated. Never run the
engine in an enclosed area.
The exhaust contains poisonous carbon monoxide
gas that may cause loss of consciousness and may
lead to death.
N OTE
•
Befo re perfo rm i n g t h i s test, be s u re t he batte ry i s
fu l l y c h arged a n d that the voltage betwee n its termi­
n a l s i s g reater than 1 3.0 V.
Sta rt t he e n g i n e and wa rm it to ope rati n g te m pe ratu re,
then turn the i g n ition switch O F F .
Connect the m u lti meter betwee n the batte ry term i n a l s .
i a.TooL I
Digital multimeter
Analogue tester
1 5-6
0741 1 - 0020000
Equivalent commercially
available in U.S.A.
07308 - 0020001
(Not available in U.S.A.)
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( 1 ) BATTERY
Charging System/Alternator
Disco n n ect the sta rte r re lay switch con n ecto r a n d remove
the m a i n fuse (30 A).
Reco n n ect the co n n ecto r o nto the re lay switc h .
( 1 ) (+) PRO B E : R E D/WH ITE
C o n n ect the a m m eter betwee n the fuse h o l d e r term i n a l s
as shown.
Sta rt the engine a n d i ncrease the engine speed g ra d u a l ly
a n d check that the voltage a n d a m pe re a re reg u l ated .
CAUTION
•
•
•
Be careful not to short any tester probes.
Although the current could be measured when the
ammeter is connected between the battery positive
terminal and the positive cable, a sudden surge of
cu rrant to the sta rter motor could damage the
ammeter.
Always turn the ignition switch OFF when conduct­
ing the test. Disconnecting the ammeter or wire
when currant is flowing may damage the ammeter.
N OTE
•
•
Befo re ma k i n g this test, a l l the l i g hts a n d the othe r
e l ectrica l eq u i p m e nt s h o u l d b� OFF.
U se fu l ly c h a rged batte ry to m a ke this test i n order
to get a correct measurement.
Regulated:
Battery terminals:
Charging current:
1 4 - 1 5.5 V/3,000 rpm
0 - 0.5 A/3,000 rpm
Regulator /Rectifier
System Inspection
R e m ove the seat ( page 2-2 ) .
Disco n n ect t h e reg u lato r/rectifi e r con n ecto rs.
C h eck the co n n ecto rs fo r l oose o r corroded term i n a l .
Measu re the fo l l owing betwee n co n nector term i n a l o f the
wi re h a rness side.
I
Item
·
Terminals
Specification
Batte ry c h a rg i n g
line
Red/Wh ite (+)
a n d G reen (-)
Batte ry voltage
s h o u l d reg ister.
G ro u n d l i n e
G reen a n d g ro u n d
Conti n u ity exist.
C h a rg i n g coi l
line
Yel l ow a n d Ye l l ow
0. 1 - 1 .0 (}
(20°C/68°F)
( 1 ) R E G U LATO R/RE CTI F I E R 4P CO N N E CTO R
(WI R E HAR N ESS S I D E )
If the c h a rg i n g co i l l i n e rea d i n g is o ut of s pecificati o n ,
check t h e a lternator ( page 1 5-9 ) .
( 1 ) R E G U LATO R/RECTI F I E R 3P CO N N E CTOR
(WI R E HAR N ESS S I D E )
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1 5 -7
Charging System/Alternator
Unit Inspection
Provided the ci rc u it on the wi re h a rness side is n o rm a l a n d
there a re no loose co n n ections a t the co n n ecto rs, i n spect
t h e reg u l ator/rectifi e r u n it by m e a s u r i n g t h e res i sta nce
between the term i n a ls.
N OTE
•
•
You' l l get fa lse rea d i n g s if the p robes touch you fi n­
gers.
U se t h e spec ifi ed m u lt i m eters. U s i n g oth e r eq u i p­
ment may not a l l ow you to o bta i n the correct resu lts.
This is due to the cha racte ristic of sem ico n d ucto rs,
w h i c h h a v e d i ffe r e n t v a l u e s d e p e n d i n g o n t h e
appl ied voltage.
Specific Multimeter:
0741 1 0020000 (KOWA Digital type)
- 07308 - 0020001 (SANWA Analogue type)
-
•
•
•
-
Select the fo l l owing ra nge:
SANWA: x kO
KOWA: x 1 00
U s i n g a n o l d batte ry sto red i n t h e m u lti m ete r c a n
cause i n accu rate rea d i ngs. C h eck the batte ry if t h e
m u lti m eter resista nce is i ncorrect.
When u s i n g the KOWA m u lt i m ete r, re m e m be r that
a l l rea d i ngs s h o u l d be m u lt i p l ied by 1 00.
Replace the reg u lato r/rectifi e r u n it if the resi sta nce va l u e
betwee n t h e term i n a l s is a b n o rm a l .
�
( 1 ) YELLOW
Yellow
Red/White
------
�
Yellow
500 - 1 0k
Yellow
500 - 1 0k
�
Yellow
500 - 1 0 k
�
�
G reen
700 - 1 5k
500 - 1 0k
500 - 1 0 k
----
Yellow
Yellow
Green
�
�
�
�
�
�
------
�
---500 - 10k
�
�
----
Removal/Installation
( 1 ) R E G U LATO R/RE CTI F I E R
Disco n nect the reg u lator/rectifier co n n ecto rs.
Remove the m o u nting n uts a n d reg u l ator/rectifie r u n it.
I n sta l l ation is i n the reve rse order of rem ova l .
( 3 ) N UTS
1 5-8
(3) R E D/WH ITE
U n it· 0
Red/White
e
p
�
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(2) GREEN
Charging System/Alternator
Alternator
N OTE
•
It is not necessa ry to remove the stato r to m ake this
test.
Remove the fuel ta n k ( page 2-2 ) .
Disco n n ect the a lternator 3P con n ecto r.
Measu re the resista nce between the Ye l l ow wi re term i n a l s
a n d c h e c k fo r n o conti n u ity betwee n e a c h term i n a l a n d
body g ro u n d .
( 1 ) A LTE R N ATOR 3P CO N N E CTOR
Standard: 0.1 - 1 .0 0 (20°C/68°F)
Replace the stato r if the resista nce is o ut of specification
o r if there is co nti n u ity between Ye l low wi re term i n a l a nd
g ro u n d .
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1 5 -9
Charging System/Alternator
Alternator Removal/Installation
(5)
(4)
(1)
-
0 12 (1. 2 , 9)
(7)
(6)
) c 12 (1. 2 , 9)
LIQU I D SEALANT AREA
1 5- 1 0
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Charging System/Alternator
N OTE
•
•
•
The e n g i n e o i l wi l l ru n out when the l eft cra n kcase cove r is re m oved . Set a clean o i l pa n u nd e r the e n g i n e a n d a d d
the reco m m ended o i l t o the specified leve l after the i n sta l lati o n .
The l eft cra n kcase cove r (stato r) is magnetica l ly attached to the flywheel, be ca refu l to the remova l/i n sta l lati o n .
Apply a l i g ht but thoro u g h coati n g of l i q u i d sea l a nt to the cra n kcase as s h own .
Requisite Service
•
F u e l ta n k rem ova l/i n sta l l ation ( page 2-2)
Procedure
O'ty
Removal Order
(1)
(2)
(3)
(4)
( 5)
(6)
(7)
(8)
Alternato r con nector
Left cra n kcase cove r bolt
Left cra n kcase cove r
Gasket
Dowel p i n
Stato r w i re h o l d e r
Stator m o u nt i n g bolt
Stato r asse m bly
I n sta l lation is i n the reverse order of rem ova l .
1
6
1
1
2
1
4
1
Flywheel Removal Order
(9)
( 1 0)
(11)
F lywheel bolt
Was h e r
F lywhe e l
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Remarks
1
1
1
At i n stal latio n , apply sea l a nt to the g ro m met a n d i n sta l l
the g ro m m et sec u re l y i nto t h e . g roove i n t h e l eft
cra n kcase cover.
I n sta l lation is in the reverse order of remova l .
Apply clean e n g i n e o i l to the bolt th reads.
Before i n sta l lation, wipe an y o i l off the mati ng s u rface of
the c ra n kshaft a n d flywhe e l .
1 5- 1 1
MEMO
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Service Information
System Location
Troubleshooting
Ignition System Inspection
Ignition Coil Inspection
Ignition Pulse Generator Inspection
1 6- 1
1 6-2
1 6-3
1 6-8
1 6-8
1 6-9
1 6. I g n ition System
Ignition Coil Removal/Installation
Ignition Control Module (ICM)
Removal/Installation
Ignition Pulse Generator
Removal/Installation
Ignition liming
1 6-9
1 6- 1 0
1 6- 1 1
1 6- 1 2
Service Information
o
o
H the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an
enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
CAUTION
o
o
o
o
o
o
o
o
Some electrical components may . be damaged if terminals o� connectors are connected or disconnected while
the ignition switch is ON and current is present.
When checki n g the i g n ition system , a lways fo l low the steps in the tro u b leshooti n g flow c h a rt ( page 1 6-3).
The I g n ition control m od u l e ( I C M ) may be da m aged if d ropped. Also, if the con n ecto r is d i sco n n ected when c u rrent is
present, the excessive voltage may damage the u n it. Always turn off the i g n ition switch befo re servici n g .
I g n ition ti m i ng ca n n ot be a dj u sted si nce the I g n ition control m o d u l e ( I C M I is n o n-adj u sta b l e . If i g n iti on ti m i n g i s
i nco rrect, check the system components a n d replace any fa u lty parts.
A fa u lty i g n ition system is often related to poorly con nected or co rroded co n necto rs. Check those con nections before
proceed i n g .
U se spark p l u g s of the correct heat ra nge. U s ing spark p lu g s with an i nco rrect h eat ra nge ca n d am ag e the e n g i n e .
Refer to Sectio n 2 o f the C o m m o n Service M a n u a l .
For neutra l switch i nspectio n , refer to Section 25 of the Common Service M a n u a l . For switch l ocatio n , see page 1 6-2
of t h i s manual ( System Locat i o n ) .
For· side sta n d switch , e n g i n e sto p switch a n d i g n ition switch i n s pecti o n , check for conti n u ity c h a rt of the W i r i n g
D i a g ra m , page 1 9- 1 . Disco n n ect the i g n ition a n d e n g i n e sto p switch co n necto rs i n the front side cover ( page 2-3), side
sta n d switc h con n ector u n der the fue l ta n k a n d check it.
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1 6- 1
...
�
Ignition System
System Location
( 1 3) N E UTRAL
I N DICATOR ---,ff---.,;�
(6) CLUTCH
SWITCH
DIODE
(9) S I D E STA N D SWITCH
( 7 ) MAI N F U S E (30 A)
(8) N E UTRAL SWITCH
( 1 3) N E UTRAL I N DICATO R
(6) C LUTCH SWITCH DIODE
( 1 1 ) I G N ITION SWITCH
B I/Br
(3) F U S E 1 5 A
R �<r RfBI
B I/Br
( 7 ) MAI N F U S E 30 A
L--___.
(4) B ATT E RY
a
·"�
( 1 ) S I D E STA N D I N DICATO R
Y/B i
�------� G/W
UP
� :t_I
iii iii
( 5 ) 1CM
S PAR K
PLUGS
1 6-2
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I
�
G
(!)
(8) N E UTRAL
SWITCH
J
(9) S I D E STA N D
SWITCH
--
0;
....J
DOWN
...----___,,
I IJ)ll l l� I
a:
(3) F U S E 1 0 A
(2) E N G I N E STO P SWITCH
B lfW �o- B I
I G N ITION
COILS
--®-- Lg/B I
-
G/W ---<Y o-G/R -------'
00
( 1 2) CLUTCH SWITCH
( 1 0) I G N ITION PU LSE G E N E RATO R
Bl . . . . .
Y ......
Bu . . . .
G ......
R ......
W .....
Lg . . . . .
B LACK
YELLOW
BLUE
GREEN
RED
WH ITE
L I G HT G R E E N
Ignition System
Troubleshooting
•
I n spect the fo l lowi ng befo re d iagnosing the system .
- Loose spa rk p l u g caps o r spark p l u g wi re con nections.
- Wate r i n the spa rk plug ca p.
- Loose o r poo r contact of i g n ition system co n nectors.
No Spark At All Plugs (Faulty Input System)
•
If there is no spa rk to the p l ugs, the p roblem cou l d be the i n p ut to the i g n ition syste m ( i g n ition pu lse g e n e rator,
powe r i n put c i rc u it of the i g n ition control mod u l e ( I C M ) , neutra l switch , o r side sta n d switch beca use if contro l s the
i g n ition control module ( I C M ) ) .
Check if the batte ry voltage i s measu red be­
twee n powe r sou rce i n put l i n e at the i g n ition
contro l mod u l e (ICM) co n n ecto r with the i g n i­
tion switch ON a n d the e n g i n e stop switch at
14------1 ���.,J
R U N ( page 1 6-8) .
No voltage
�(
l ...
tt/
.._
_. • F a u lty i g n ition switch or e n g i n e sto p switch
1------,::.____.
•
""
/
Connection: Black/White (+) - Green (-)
Standard: Battery voltage
•
O pen c i rc u it i n wire h a rness
Loose o r poo r con n ecto r contact
Batte ry voltage
measured
A b n o rm a l
M e a s u re t h e i g n it i o n p u lse g e n e rato r res i s­ 1-----______--..t Check the i g n ition p u l se g e n e rato r ( pag e 1 69).
t a n c e at t h e i g n it i o n c o n t r o l m o d u l e ( I C M )
con n ecto r ( page 1 6-8).
Connection: Black/Yellow - Black/White
Standard: 450 - 550 0
Connection: Black/Yellow - Black/White
Standard: 450 - 550 0
Ab n o r m a l
Normal
Normal
1
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•
•
•
�
+
•
Fau lty i g n ition p u l se g en e rator
O pen c i rc u it in B l ack/Wh ite wire
Open c i rc u it i n B lack/Ye l l ow wire
Loosen or poor i g n ition p u lse generator con­
nector contacts
1 6-3
Ignition System
C h eck the n e utra l switc h at the i g n ition con­
trol module (ICM) co n n ector ( page 1 6-8).
�
/
Connection: Black/Light green - Ground
Standard:
Continuity in neutral
No continuity in any gear except neutral
Abnormal
Normal
Connection: Light green/Red - Ground
Standard: Continuity in neutral
No continuity in any gear
Abnorm a l
Normal
•
•
Check the side sta n d switch a t i g n ition control
m o d u l e ( I C M ) con necto r ( page 1 6-8) .
I
•
j
Fa u lty n e utra l switch
Open c i rc u it in Light g reen/Red wi re
Loose or poor neutra l switch con necto r co ntacts
Abnormal
�
�
Side stand u�
Green/White - Green: Continuity
Side stand down:
Yellow/Black - Green: Continuity
Side stand up:
Black/Green - Black: Continuity
Side stand down:
Black/Green - Black: No continuity
Normal
Normal
•
•
•
Fau lty i g n ition control m o d u l e ( I C M )
1 6-4
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•
J
Abno r m a l
•
•
F a u lty side sta n d switch
Open c i rc u it in G reen/Wh ite wi re
Open c i rc u it in Yel l ow/Black w i re
Loose or poor side sta n d switch con n ecto r con­
tacts
Ignition System
No Spark At Either Ignition Group
If there is no spa rk at eithe r g ro u p, the problem is proba bly i n the primary coi l side of the i g n ition system ( i g n ition
co i l , o r u n it a n d i g n ition coi l c i rcu it) .
•
�
�
Switch the i g n ition co i l p ri m a ry term i n a l con­
nection between the fa u lty pa i r and good pa i r.
Try spa r k test aga i n .
" N o spark"
con d iti o n
Rem ove t h e fa u lty i g n ition coi l s a n d check the
i g n ition coi l resista nce ( page 1 6-8) .
rem a i n s with
the fa u lty pa i r
" N o spark" con d ition
shift to other pa i r
Standard:
Primary: 2 - 4 0
Between the plug caps: 23 - 27 kO
Between the spark plug wire: 1 3 - 1 7 kO
Abno r m a l
•
•
•
�
Fa u lty i g n ition c oi l
Fau lty spa rk p l u g w i re
Fau lty spa rk p l u gs
M ea s u re resi sta n c e o f t h e i g n it i o n p ri m a ry
coi l at i g n ition control m o d u l e ( I C M ) con nec­
tor.
Abnorm a l
�------... • Poor or l oose i g n ition coi l con nector contacts
Connection:
No. 1 -3: Black/White - Black/Yellow
No. 2-4: Black/White - Black/Blue
Standard: 2 - 4 0
•
•
•
Open c i rc u it in B lack/Wh ite w i re
Open c i rc u it i n Black/Ye l low w ire
Open c i rc u it i n Black/B l ue w i re
Normal
•
�
F a u lty i g n ition control m o d u l e ( I C M )
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1 6-5
Ignition System
No Spark At One Plug (Trouble In Secondary Coil Side)
•
Fau lty spark p l u g is m ost l i kely.
R e p l a c e ( s u s p e c t e d bad s p a r k p l u g ) w i t h
known g o o d s p a r k p l u g a n d c o n d u ct s p a r k
test.
Normal
Standard: 23 - 27 kO
Condact spa rk test o n good i g n ition coi l .
Abnormal
R e m ove the s p a r k p l u g cap, a n d m e a s u re
resista nce of the i g n ition coi l ( page 1 6-9).
Abnormal
Standard: 1 3 - 1 7 kO
N o rm a l
•
•
•
�
Poor contact of spark p l u g cap
Fau lty spark p l u g cap
Fau lty spa rk plugs
1 6-6
T"
1--------... . Fau lty i g n ition c o i l
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Ignition System
Engine Starts, But Side Stand Switch Does Not Function
NOTE
The side sta nd switch s h o u l d fu nction as fo l l ows:
When the tra nsm ission is sh ifted i nto a gear from neutra l with the side sta n d down, the i g n ition s h uts off a n d the
e n g i n e sto ps.
When i n neutra l , the neutra l switch l i ne (a ) of the i g n ition control m o d u l e ( I C M ) is co n nected to g ro u n d via the side
sta n d switc h .
W h e n t h e s i d e sta n d is up, t h e s i d e sta nd switch l i n e ( b ) o f t h e i g n ition control m o d u l e ( I C M ) passes t o g ro u n d v i a
the s i d e sta n d switc h . T h e i g n ition control m o d u l e ( I C M ) m o n itors l i nes ( a ) a n d ( b ) , a n d provides spark o n l y when
one o r both of those l i nes is connected to ground via the neutra l switch o r the side sta n d switc h .
•
•
Check the s i d e sta n d i n d icato r fu nction.
Normal
1--------... • Open ci rc u it i n G reen/Wh ite w i re
Abnorm a l
Normal
Check for conti n u ity between each term i n a l of 1--------....
side sta n d switch as fo l l ows.
.
•
•
Loose or poor contact of rel ated con n ectors
Open ci rc u it in G reen/Wh ite w i re
B u rnt i n dicator b u l b
�-->,....-<.)C.:::
Side stand up: Green/White - Green
Side stand down: Yellow/Black - Green
Abnormal
'----- · Fau lty side sta nd switch
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1 6-7
Ignition System
Ignition System I nspection
N OTE
•
C h eck t h e syste m co m po n e nts a n d wi res ste p- by­
ste p a c c o r d i n g to t h e t ro u b l e s h o ot i n g c h a rt o n
pages.
Remove the seat ( page 2-2 ) .
Disco n n ect t h e con n ecto r fro m the i g n ition control m o d u l e
( I C M ) a n d cond uct th ese tests a t the co n necto r.
( 1 ) CO N N ECTO R
Standard
Terminals
Item
Battery voltage s h o u l d reg ister with the i g n ition
switch O N a n d the engine sto p switch at R U N .
Powe r sou rce i n put l i n e
B l ack/Wh ite (+) - G reen (-)
I g n ition pri m a ry coi l
N o . 1 -3: B l ack/Wh ite - B lack/Ye l l ow
N o . 2-4: B l ack/Wh ite - B lack/B l u e
I g n ition pu lse generato r
coi l
B l ack/Ye l l ow - B l ack/White
Ne utra l switch l i n e
B lack/Lig ht g reen - Body g ro u n d
Conti n u ity i n neutra l
No co nti n u ity i n a ny gear exce pt n e utra l
Side sta n d switch l i n e
B lack/G reen - B lack
Co nti n u ity with the side sta n d u p
N o co nti n u ity with t h e s i d e sta n d d own
G ro u n d l i n e
G reen - Body g ro u n d
Conti n u ity
Ignition Coil Inspection
2-4 0
450 - 550 0
( 1 ) I G N ITION C OI L
Measu re t h e p ri m a ry co i l res i sta nce betwe e n t h e te r m i ­
nals.
Standard: 2 - 4 0
Measure the resista nce betwee n the spa rk p l u g caps.
( 1 ) I G N ITION CO I L
Standard: 23 - 27 kO
( 2 ) S PA RK P L U G CAPS
1 6-8
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Ignition System
If the measu red va l u e out of the specification, rem ove the
spa rk plug caps fro m the spark plug wi res a n d measu re
the resista nce betwee n the spark p l u g wires.
Standard: 1 3 - 1 7
kO
( 1 ) I G N ITIO N CO I L
---�------>�
Ignition Pulse Generator Inspection
( 2 ) S PARK PL U G W I R E S
N OTE
•
It is n ot n ecessa ry to re m ove t h e p u l se g e n e rato r
fro m the e n g i n e .
Remove the fue l ta n k ( page 2-2 ) .
Disco n n ect t h e i g n ition pu lse generato r 3P (Wh ite ) con n ec­
tor.
M e a s u re the re s i sta n c e betwe e n the B l a ck/Ye l l ow a n d
B lack/Wh ite term i n a ls.
Standard: 450 - 550
0
( 1 ) PU LSE G E N E RATO R 3 P CON N E CTOR
R efe r to page 1 6- 1 1 fo r i g n ition p u l se g e n e rato r re p l ace­
m e nt.
Ignition Coil Removal/Installation
( 1 ) P R I MARY
WIRES
Front
R e m ove the a i r clea n e r h o u s i n g ( page 5- 3 ) .
Remove the spa rk p l u g ca ps fro m sp a rk p l ugs.
Disco n n ect the i g n ition co i l p r i m a ry wi res from the co i l .
R e m ove t h e i g n ition c o i l m o u nting bo lts a n d front i g n ition
co i l .
I n sta l lati o n is i n t h e reve rse order o f re m ova l .
( 1 ) BOLTS
Rear
R e m ove the seat a n d l eft side cove r ( page 2-2, 3 ) .
R e m ove the fuse b o x stay bo lts a n d fra me grou n d ca b l e .
Revised: July, 1 995, '94 - '95 Magna VF750C/CD
Co.search
, I n c . -engine
All Rights Reserved
1 995
American Honda Motor
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04\
1 6-9
Ignition System
Remove the spark p l u g caps from spark pl ugs.
Discon nect the i g n ition coi l pri m a ry wi res from the coi l .
Remove the i g n ition coil m o u nting bolts a n d fro nt i g n ition
coils.
( 1 ) BOLTS
(2) P R I MARY WIRES
I n sta l latio n is i n the reverse o rder of rem ova l .
(3) I G N IT I O N COIL
Ignition Control Module (ICM)
Removal/Instal lation
Remove the battery case m o u nting bolts.
M ove the battery case l eft wa rd and d isco n n ect the i g n i­
tion control modu l e ( I C M ) con necto r.
Remove the i g n ition control m od u l e ( I C M ) .
I nsta l l ation is i n the reverse order o f removal .
( 2 ) BATTE RY CASE
1 6- 1 0
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Ignition System
Ignition Pulse Generator Removal/Installation
Requisite Service
•
•
R i g ht cra n kcase cover re mova l/i nsta l lation ( page 9-2)
F u e l ta n k rem ova l/i n sta l l ation ( page 2-2)
Procedure
Removal Order
(1)
(2)
(3)
(4)
(5)
(6)
Q'ty
I n sta l latio n is in the reverse o rd e r of remova l .
I g n ition p u l se g e n e rator con necto r
O i l pressu re switch term i n a l
I g n ition pu lse g e n e rato r w i re g ro m m et
1
1
1
I g n ition p u l se g e n e rato r m o u nti n g bolt
I g n ition pu lse generato r asse m bly
Dowel pin
3
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Remarks
1
At i nsta l latio n , apply sea l a nt t o t h e wi re g ro m met, a n d
i n sta l l t h e i nto t h e rotor cover g roove sec u rely.
R oute the i g n ition pu lse generato r w i re as s h own.
2
1 6- 1 1
Ignition System
Ignition liming
N OTE
•
•
The i g n ition co ntro l m o d u l e ( I C M ) system is facto ry
p re - s et a n d c a n n ot be a d j u st e d . I g n i t i o n t i m i n g
i nspectio n proced u res a re g iven to i n spect the fu nc­
t i o n of t h e i g n it i o n control m o d u l e ( I C M ) c o m po­
nents.
If t h e ti m i n g a p p e a rs wro n g , c h e c k a n ot h e r s p a r k
p l u g wire fo r confi rmat i o n.
Wa r m u p the e n g i n e t o operati ng tem perat u re .
•
•
If the engine must be running to do some work,
make sure the area is well-ventilated. Never run the
engine in an enclosed area.
The exhaust contains poisonous carbon monoxide
gas that may cause loss of consciousness and may
lead to death.
Stop the e n g i n e and rem ove the t i m i n g h o l e cap.
Connect a ti m i n g l i g ht to the spark p l u g wire.
Sta rt the e n g i n e and l et it i d l e .
T h e ti m i n g is correct if the F m a rk a l i g n s with the i ndex
m a rk o n the right cra n kcase cove r.
"
"
I ncrease the e n g i n e speed by rotat i n g t h e t h rott l e sto p
screw k n o b a n d m a ke s u re the " F " m a rk beg i n s t o m ove
cou nterclockwise at a p p roxi m ately 2,000 rpm .
Check t h e ti m i n g h o l e cap's 0-ri ng fo r d a m age, rep l ace the
new one if desi red.
Apply g rease to the th reads, and i n sta l l t h e ti m i n g h o l e
cap.
Torque: 18 N·m ( 1 .8 kg-m, 1 3 ft-lb)
1 6- 1 2
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( 1 ) I N DEX MARK
( 2 ) "F" MARK
1 7 . E lectric Starter /Starter Cl utch
1 7- 1
Service Information
System Location
Troubleshooting
Starter Motor Removal/Installation
1 7-2
1 7-3
Starter Motor Disassembly/Assembly
Starter Clutch Removal/Installation
Starter Clutch Disassembly/Assembly
1 7-7
1 7-8
1 7- 1 0
1 7- 1 2
Service Information
•
•
•
•
Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing
serious injury.
A wea k battery may be u na b l e to tu rn the starte r motor q u ickly e n o u g h , or su pply adeq u ate i g n ition cu rrent.
If c u rrent is appl ied to the sta rter m oto r wh i le the e n g i n e is n ot turn i n g ove r, the sta rte r m oto r may be damaged.
For the fol l owi n g components i nspections, refe r to the C o m m o n Service M a n u a l or the fo l lowi n g pages; fo r the pa rts
l ocatio n s, see page 1 7-2 of this m a n u a l (System Locatio n ) .
Component
Inspection method
Cl utch switch diode
Section 2 4 of the Common Service M a n u a l
Sta rter m otor
Section 2 4 of the Co m m o n Service M a n u a l
C l utch switch
Section 25 of the Common Service M a n u a l
N e utra l switch
Sectio n 2 5 of the Com m o n Service M a n u a l
I g n ition switch
Check fo r co nti n u ity o n the conti n u ity c h a rt of
the Wiring Diagram, page 1 9- 1 .
S i d e sta n d switch
See page 1 8-9.
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Remarks
Torque: 1 2 N·m ( 1 .2 kg-m, 9 ft-lb)
1 7- 1
Electric Starter/Starter Clutch
System Location
( 1 3) SIDE STAND
INDICATOR
1 1 1 ENGINE STOP SWITCH
( 1 2 ) NEUTRAL
INDICATOR
(2) STARTER SWITCH
(3) FUSE BOX
( 1 0 A,1 5 AI
(After 2000:
CLUTCH SWITCH
DIODE I
(4)
BATTERY
( 5) CLUTCH SWITCH
DIODE
( :'94 - 2000)
( 1 0) IGNITION
SWITCH
(8) NEUTRAL SWITCH
(S)
( 1 0) IGNITION SWITCH
(3) FUSE 1 5 A
�
�
(1 2) NEUTRAL
INDICATOR
(4) BATTERY
(3) FUSE 1 0 A
.
Lg/81
(6) MAIN
FUSE
30 A
121 STARTER SWITCH
�
1 •1 T I� I
1 ) EN GINE ST0
'--+--
i
( 5) CLUTCH SWITC
DIODE
G/R
Lg/R
( 1 3) SIDE STAND
INDICATOR
(8) NEUTRAL SWITCH
L------Y/BI
1 7-2
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STARTER RELAY SWITCH
(MAIN FUSE 30 A)
a
�
1
( 1 1 ) CLUTCH SWITCH
/R �
(7) SIDE STAND
SWITCH
DOWN
�
C)
UP
Bl ..... BLACK
. . .... YELLOW
Bu .... BLUE
G ...... GREEN
R ...... RED
W ..... WHITE
Lg ..... LIGHT GREEN
y
Electric Starter/Starter Clutch
Troubleshooti ng
N OTE
•
•
•
Check fo r the fo l l owi ng befo re tro u b l eshooti ng the system .
- B l own m a i n fuse (30 A ) o r s u b fuse ( 1 0 A).
- Loose batte ry and sta rte r motor cable.
- Disc h a rged battery.
The sta rte r moto r s h o u l d ope rate when the tra n s m ission is in n e utra l .
The sta rte r moto r s h o u l d ope rate when the tra n s m ission is i n a ny gea r as i n d icated the c h a rt be l ow.
Gear Position
Side Sta n d
Up
I n Any Ge a r
Down
Cl utch Lever
Sta rte r M otor
P u l led i n
Operates
Released
Does N ot O pe rate
P u l led i n
Does N ot Ope rate
Released
Does N ot Ope rate
Starter motor will not turn
Abnorm a l
C h ec k fo r loose or poorly co n n ected batte ry 1------i., . Poorly con nected batte ry term i n a l s
te r m i n a l s a n d o p e n e d o r s h o rt e d b a tt e ry
O p e n o r s h o rt c i rcu it batte ry ca ble
ca b l e .
•
Normal
Abnorm a l
C h eck fo r l oose o r poorly con nected sta rte r 1------• · Poorly con n ected term i n a l s of 4P co n n ecto r
re lay switch term i n a l s a n d 4P con n ecto r.
Normal
j
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1 7-3
Electric Starter/Starter Clutch
Abnormal
C h eck fo r l oose or poorly c o n n ected sta rte r r------. . Poorly con nected batte ry te rm i na l s
moto r cable, a n d o p e n ca b l e .
• O p e n c i rc u it i n sta rte r m otor ca b le
Normal
C l icks
With the i g n ition switch " O N " push the sta rte r r-----1 C o n n ect the sta rte r m otor term i n a l to the batbutto n a n d check fo r a " C l ick" sou n d fro m the
tery positive term i n a l d i rectly.
( Beca use a l a rge a m o u nt o f cu rrent flows, d o
sta rte r relay switch .
n ot u s e t h i n wi res)
-
l
-
N o c l ick
Sta rte r m otor turns
Disco n n ect sta rter re lay switch co n nector, a n d
check t h e re lay co i l g ro u n d l i n e as below fo r
conti n u ity:
1 . G reen/Red term i n a l-to-cl utch switch d iode­
•
to- n e utra l switch l i n e (with t ra n s m i s s i o n
•
i nto ne utra l a n d c l utch l ever re lease d ) .
2. G reen/Red term i n a l -to-cl utch switch-to-si d e
sta n d switch l i n e ( i n any gear except neu­
N o conti n u ity
tra l , a n d with the c l utch l ever p u l led i n a n d �------.... •
the s i d e sta nd u p ) .
•
•
•
•
Cont i n u ity
1 7-4
�
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1
-
Sta rter m oto r does not turn
•
�
F a u lty sta rter motor
Loose o r d i sco n n ected sta rter m oto r cable
F a u lty sta rte r relay switch
Fa u lty n e utra l switch
F a u lty cl utch switch
Fa u lty side sta n d switch
Loose or poor co ntact of con n ecto r
Open ci rc u it i n wi re h a rness
Electric Starter/Starter Clutch
N o Vo lta ge
C o n n ect the sta rte r re l a y switc h co n n ecto r. �-----=--• .
With t h e i g n i t i o n switc h O N a n d t h e sta rte r
•
b utto n pushed, measure the sta rte r relay vo lt•
age at the sta rte r switch co n necto r.
•
•
•
Fau lty i g n ition switch
Fau lty e n g i n e sto p switch
Fau lty sta rter switch
Bl own out m a i n or s u b fuses
Loose or poor co ntact of co n necto r
Open ci rcuit i n wi re h a r n ess
Connection: Yellow/Red (+) - Body ground (-)
Standard: Battery voltage
Batte ry vo lta ge registe rs
Normal
Rem ove the sta rte r re lay switc h .
�------• • Loose or poor contact of the sta rter re lay
C o n n ect a fu l ly c h a rged 1 2 V batte ry t o t h e
switch con n ecto r
sta rter re lay switc h .
Check the conti n u ity between the switch l a rge
term i n a l .
Battery Connection:
Yellow/Red (+) - Green/Red 1-1
Standard: Continuity
Abnorm a l
1-------.. • F au lty sta rte r re lay switch
Starter motor turns when the transmission is in neutral, but does not turn with transmission in any gear with the side
stand up, and the clutch lever pulled in.
Abnorm a l
C h eck that the side sta nd switch is operati ng 1-------___,• . F a u lty side sta n d switch
properly with the i g n ition O N .
B u rnt b u l b
O p e n c i rc u it i n wire h a rness
•
•
Normal
1
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1 7-5
Electric Starter/Starter Clutch
Check the cl utch switch operatio n .
Abnormal
1------ • F a u lty cl utch switch
Normal
Check the side sta nd switch ( page 1 8-9) .
Abnormal
1------ • Fau lty side sta n d switch
Normal
L----
•
•
Starter motor turns slowly
•
•
•
•
Low specific g ravity i n battery ( o r dead battery)
Poorly con n ected battery term i na l ca b l e
Poorly con n ected sta rter m otor ca b le
Fau lty sta rte r m otor
Starter motor turns, but engine does not turn
•
•
•
Sta rter m otor is ru n n i n g backward
- Case assem bled i m p ro perly
- Te rm i n a l s con n ected i m p roperly
Fau lty sta rter cl utch
Da maged red uct i o n g e a r
Starter relay switch "clicks", but engine does not turn over
•
•
Cra n kshaft does n ot turn d u e to i nternal mecha n ical e n g i n e p roblem
Excessive red uctio n gear frictio n
1 7-6
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Open c i rc u it i n wi re h a r n ess
Loose o r poor co ntact of con n ector
Electric Starter/Starter Clutch
Starter Motor Removal/Installation
.$B fl (5)
•
With the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor.
N OTE
I
•
R oute the wi re a n d cables properly ( page 1 -20).
Procedure
Q'ty
Removal Order
(1)
(2)
(3)
(4)
(5)
F l a nge n ut
Sta rte r m otor cable eye let
Sta rter motor m o u nt i n g bo lt
Sta rter m otor
0-ri ng
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1
1
2
1
1
Remarks
I nsta l latio n is in the reverse order of remova l .
After i nsta l latio n , i nsta l l the r u b be r cap.
Disasse m b ly ( page 1 7-8)
Apply o i l when i n sta l l i ng .
1 7-7
Electric Starter/Starter Clutch
Starter Motor Disassembly I Assembly
(6)
(8)
(1)
C
5 (0.5, 3.6)
(9
( 1 6)
(2)
(3)
(4)
�
(5)
ALI G N
1 7-8
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Electric Starter/Starter Clutch
Requisite Service
•
Sta rte r m otor re m ova l/i nsta l lati o n ( page 1 7-7 ) .
Procedure
Q'ty
Disassembly Order
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
( 1 0)
(1 1 )
( 1 2)
( 1 3)
( 1 4)
( 1 5)
( 1 6)
Case bolt
F ront cove r
Lock was he r
0-ri ng
M otor case
I ns u lated was h e r
Was h e r
Arm atu re
Brush term i n a l h o l d i n g n ut
Was h e r
I n s u l ated wash e r
0-ri n g
B ru s h h o l d e r asse m bly
Brush a n d term i n a l
0-ri n g
Rea r cover
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Remarks
Asse m bly is i n the reve rse order of d isasse m b ly.
3
1
1
1
1
1
1
1
A l i g n the i ndex m a rks on the fro nt cove r a n d case .
A l i g n the i ndex m a rks on the rea r cover a n d case.
2
1
3
1
1
1
1
1
A l i g n the h o l d e r ta b with the rea r cover g roove.
1 7-9
Electric Starter/Starter Clutch
Starter Clutch Removal/Installation
W I D E G ROOVE
(1
tf!!t
�t. 90 (9.0, 65) i a.TooL I ( pa ge
1 7- 1 1 )
SCREW DR IVE R
1 7- 1 0
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Electric Starter/Starter Clutch
Requisite Service
•
R i g ht cra n kcase cover re mova l/i nsta l lati on ( page 9-2)
Procedure
Removal Order
•
Remarks
Q'ty
(1)
Sta rter c l utch bolt
1
(2)
Was h e r
Sta rter cl utch asse m bly
1
1
Pu lse generato r re m ova l/i n sta l lati o n ( pa g e 1 6- 1 1 )
I nsta l lati o n is in the reve rse order of rem ova l .
U s e t h e gear h o l d e r (07724 - 00 1 0 1 00) a s s h own .
Apply clean e n g i n e o i l to the t h reads.
•
•
(3)
•
•
(4)
(5)
(6)
(7)
(8)
Needle bea ring
Pri m a ry d rive gear g u id e
Sta rter redu ction gear shaft
Sta rter red uctio n gear/washer
Pri m a ry d rive gear asse m b l y
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1
1
1
1/1
1
Disasse m bly/assem bly ( page 1 7- 1 2)
At i n sta l lati on, a l i g n the wide g roove with the wide
tooth of the cra n kshaft.
N OTE
When pri m a ry d rive gear remova Vi n sta l lati o n , a l i g n i n g
t h e pri m a ry d rive g e a r a n d s u b-gear ( a nti·backlash
gear) teeth with a screw d river.
•
1 7- 1 1
Electric Starter/Starter Clutch
Starter Clutch Disassembly I Assembly
(7 )
(1)
(3)
r
c
(2)
40 (4.0, 29)
(6)
Requisite Service
•
Sta rter cl utch rem ova l/i nsta l latio n ( page 1 7- 1 0 ) .
Procedure
Q'ty
Disassembly Order
(1)
(2)
(3)
Sta rter d riven gear
Sta rter cl utch outer cove r bolt
Sta rte r cl utch outer cover
1
3
1
(4)
(5)
(6)
Roller
Plunger
Spring
Sta rte r cl utch outer
3
3
3
1
(7 )
1 7- 1 2
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Remarks
Asse m bly is i n the reve rse order of d isasse m bly.
Rotate clockwise, when i n sta l l i n g .
Apply a l ocki ng agent to the th read s at i n sta l lati o n .
A l i g n the p i n on the o uter with the h o l e of the cove r
when i nsta l l i ng .
Be ca refu l not to pop them out.
1 8. Lig hts/Meters/Switch es
Service Information
System Location
Troubleshooting
Bulb Replacement
Headlight Removal/Installation
Combination Meter Removal/
Installation
1 8- 1
1 8-2
1 8-3
1 8-5
Combination Meter DisassemblyI
Assembly
Ignition Switch Replacement
Side Stand Switch
1 8-8
1 8-9
1 8-9
1 8-6
1 8-7
Service I nformation
•
•
•
•
•
•
•
•
•
A halogen headlight bulb becomes very hot while the headlight is ON, and remains hot for a while after it is
turned OFF. Be sure to let it cool down before servicing.
Use an electric heating element and heated water/coolant mixture for the thermo sensor inspection. Keep all
flammable materials away from the burner. Wear protective clothing, insulated gloves and adequate eye protec­
tion.
An improperly adjusted headlight may bling on-coming drivers, or it may fail to light the road for a safe distance.
N ote the fo l l owing when re placing the h a logen h ea d l i g ht b u l b.
- We a r clean g l oves w h i l e replacing the b u l b. Do n ot put fi nger pri nts on the head l i g ht b u l b, as they may create h ot
spots on the b u l b a n d cause it to break.
- If you to uch the b u l b with yo u r ba re h a nds, clean it with a clotch m o i ste ned with a lco h o l .
- Be s u re t o i n sta l l the d u st cove r afte r re pl aci ng t h e bu l b.
A l l p l a stic c o n n ecto rs have locki ng tabs that m u st be re leased befo re d i sco n n ecti n g , a n d m u st be a l i g n e d a n d
engaged fu l l y when recon necti ng .
Always turn off the i g n ition switch before d i sco n n ecti n g any e l ectrica l component.
A conti n u ity test can be m a d e with switches i n sta l led on the m oto rcycle.
C h eck the batte ry co n d ition befo re perfo rm i n g any i n s pection that req u i res proper battery voltage.
F o r t h e fo l l owi n g c o m p o n e nt l ocati o n s see t h e Co m m o n S e rvice M a n u a l or page 1 8-2 of t h i s m a n u a l ( S yste m
Locati o n ); fo r i n s pections, refer to the a p p l icable pages.
Inspection method
Component
F ront bra ke l i g ht switch
Section 25 of the Com m o n Service M a n u a l
Horn
Section 2 5 of the Com m o n Service M a n u a l
H a n d le ba r switch
Check fo r conti n u ity on the conti n u ity c h a rt
of t h e Wiring Diagra m , page 1 9- 1
I g n ition switch
N e utra l switch
Section 25 of the Com mo n Service M a n u a l
O i l p ressure switch/
wa r n i n g l i g ht
Section 2 5 of the Com m o n Service M a n u a l
Rear b ra ke l i g ht switch
Section 2 5 of the Co m m o n Service M a n u a l
T u r n s i g n a l l i g hts
Section 25 of the Co m m o n Service M a n u a l
Remarks
Torque: 1 2 N·m ( 1 .2 kg-m, 9 1b-ftl
Apply sea l a nt to the t h reads.
O i l pressu re c heck: Section 4 o f t h e
Com m o n Service M a n u a l .
Torque: 1 2 N · m ( 1 .2 kg-m, 9 lb-ft)
Apply sea l a nt to the t h reads.
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1 8- 1
Lights/Meters/Switches
System Location
( 1 ) F R O N T B RAKE LI G HT
SWITC
(8) N E UTRAL
(6) COOLANT TE M P E RATU R E
I N DI CATOR U N IT
(7) S I DE STA N D SWITCH
1 8-2
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(5) F U S E BOX
Lights/Meters/Switches
Troubleshooting
Coolant Temperature Indicator
•
Turn the i g n ition switch O N , check that the tem perat u re i n d icato r l ig ht comes on fo r 3 seconds then goes out.
Coolant Temperature Indicator Remain ON
I nd icator
co m es o n
Disco n n ect the coo l a nt tem perat u re i n d icator 1---________
con n ecto rs. Turn the i g n ition switch O N .
•
S h o rt c i rc u it i n Li g ht g ree n/B lack wi re
•
F a u lty thermo sensor (page 1 - 1 1 )
I n d icato r does n ot come o n
Normal
C o n n ect t h e c o o l a nt t e m pe ratu re i n d icato r 1-------_.
co n n ecto rs . D i sc o n n ect t h e t h e r m o s e n s o r
co n n ecto r a n d t u r n t h e i g n it i o n switch O N .
Check the coo l a nt tem pe ratu re i n d icator o per­
atio n .
Abnorm a l
•
•
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Fa u lty coo l a nt tem pe ratu re i n d icato r u n it
S h o rt c i rc u it i n G reen/B l ue wi re
1 8-3
Lights/Meters/Switches
Coolant Temperature Indicator Remains OFF
I n d icator does
not come on
Disco n n ect the cool a nt tem peratu re i n d icato r 1-------.
co n n ecto rs. Co n n ect a j u m pe r wi re to the 4P
co n nector a n d body g ro u nd, t u rn the i g n ition
switch O N .
•
•
B l own i n d icator b u l b
Open c i rc u it i n L i g ht g reen/B l ack wi re
I n d icato r come o n
Abnormal
C h eck t h e coo l a nt tem pe ratu re i n d i cato r 4P to-----�-,....
con n ecto r a n d body g ro u n d for co nti n u ity.
Abnormal
Ch eck the voltage betwee n the coo l a nt te m - 1-------.
p e rat u re i n d i c a t o r 4 P c o n n ecto r a n d b o d y
g round, t u r n t h e i g n ition switch O N .
•
Open c i rc u it i n G reen w i re
•
Open c i rc u it i n Black/B rown w i re
•
Faulty cool a nt tem peratu re i n d icato r u n it
Normal
1 8-4
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Lights/Meters/Switches
Bulb Replacement
( 1 ) R ETAI N E R
Headlight Bulb
•
A halogen headlight bulb becomes very hot while
the headlight is ON, and remain hot for a while after
it is turned OFF. Be sure to let it cool down before
servicing.
Remove the head l i g ht ( page 1 8-6) .
P u s h t h e reta i n i n g tabs a n d re m ove the h ea d l i g ht b u l b
socket. Remove t h e d ust cove r.
( 2 ) B U LB
U n hook the b u l b reta i n e r and rem ove the hea d l i g ht b u l b.
I n sta l lation is i n the reverse order of rem ova l .
N OTE
•
I n sta l l the d u st cover with its "TO P " m a rk faci n g u p.
Tail/Brake Light B ulb
(2) LENS
Remove the screws a n d tai l/brake l i g ht lens.
Remove the ta i l/bra ke l ig ht bulb by turning it cou nterclock­
wise.
I n sta l l a new b u l b in the reverse o rder of remova l .
( 1 ) SCREW
Turn Signal Light Bulb
R e m ove the screw a n d t u rn signal l ight lens.
(3) B U LB
�
Rem ove the turn s i g n a l l i g ht b u l b by t u rn i n g it cou nter­
clockwise.
I n sta l l a n ew b u l b in the reverse order of remova l .
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1 8-5
Lights/Meters/Switches
Headlight Removal/Installation
An improperly adjusted headlight may blind on-comil'!g drivers, or it may fail to light the road for a safe distance.
•
N OTE
Adj ust the hea d l i g ht bea m as specified by loca l l aws a n d reg u l ations.
After i n sta l l ation, route the wi res a n d ca ble properly ( page 1 -20).
•
•
Requisite Service
•
U pper fa i r i n g rem ova l/i nsta l l ation (VF7 50CD: page 2-8)
Procedure
Q'ty
Removal Order
(1)
(2)
(3)
( 4)
(5)
(6)
Screw
Head l i g ht con necto r
Head l i g ht assembly
Head l i g ht case bolt/nut
U pper fa i r i n g stay
Head l i g ht case
1 8-6
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Remarks
I nsta l lati o n is in the reverse order of re m ova l .
2
1
1
2/2
1
1
VF750CD o n ly.
Lights/Meters/Switches
Combination Meter Removal/Installation
N OTE
Ro ute the wi res a n d cables properly ( page 1 -20).
•
Requisite Service
•
F ront side cove r re mova l/i nsta l lati o n ( page 2-3)
Procedure
•
Q'ty
Removal Order
(1)
(2)
(3)
(4)
Speedomete r cable
Com b i n ation meter con n ecto r
Com bi nation mete r m o u nting bolt/g u ide
Com bi nation meter assem bly
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U pper fa i r i n g re mova l/i nsta l latio n (VF750CD: page 2-8)
Remarks
I n sta l l ation is in the reve rse order of rem ova l .
1
3
2/2
1
Disasse m b l y/Assem bly ( page 1 8-8)
1 8- 7
Lights/Meters/Switches
Combination Meter Disassembly I
Assembly
( 1 ) SCREWS
Remove t h e screws a n d c l a m ps.
Remove the meter rea r cover and m ete r stay.
P u l l the i n d icator b u l bs out of the m eter.
Remove the wi re h a rness c l a m p .
Discon nect the meter term i n a ls, a n d rem ove the wire h a r­
ness.
Separate the m eter rea r covers and m eter stay.
Asse m b l e the meters i n the reverse order of d i sasse m b ly.
N OTE
•
C o n n ect th e proper co l o r w i re to t h e m ete r term i ­
nals.
Y/G: Yellow/Green
G: Green
1 8-8
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( 1 ) REAR COVE R S
Lights/Meters/Switches
Ignition Switch Replacement
Remove the l eft m i d d l e cover stay assem bly ( page 5-4).
Remove the screw a n d i g n ition switch cove r.
Remove the i g n ition switch m o u nt i n g bo lts us i n g a d ri l l,
then rem ove the switc h .
I nsta l l the new i g n ition switch a n d n e w m o u nting bolts.
Tighten the m o u nt i n g bolts u nt i l the head twist off.
I n sta l l the left m i d d l e cove r stay a sse m b ly ( page 5-4).
(3) COVER
( 2 ) M O U NTI N G BO LTS
.,
Side Stand Switch
Inspection
Disco n n ect the side sta n d switch 3P ( G reen ) connecto r a n d
check fo r conti n u ity betwee n e a c h color o f wi re term i n a l
as shown i n t h e c h a rt below.
( 1 ) S I DE STA N D SWITCH CO N N ECTOR
There s h o u l d be conti n u ity between the o-o positio n s on
the fol l ow i n g c h a rt u nder the con d itions shown here.
G reen/Wh ite
Sid e
sta n d
up
Yel low/Black
G reen
,....
�
Side
stan d
down
,....
�
,....
�
,....
�
Removal/Installation
Disco n n ect the side stan d switch 3P ( G reen) connector.
R e m ove the s i d e sta n d switc h m o u nt i n g b o l t a n d s i d e
stan d switc h .
I n sta l l t h e switch i n the reverse order o f remova l .
Torque: 1 0 N·m ( 1 ,0 kg-m, 7 ft·lb)
N OTE
•
A l i g n t h e switc h p i n with t h e s i d e sta n d ho l e a n d
a l ig n the switch g roove with the s i d e stan d retu rn
spring h o l d i ng p i n .
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1 8-9
MEMO
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19. Wirin g Dia g ra m
'94 - 2000:
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12Y1.4WI2
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STNiftll MOTOR
liLAC<
YELlOW
BLUE
.. .
GREEN
REO
WIITE
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BROWN
ORANGE
LIGHT BLUE
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PINK
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BUCK
YELLOW
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BROWN
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LIGHT lUI:
LIGHT GREEN
PINK
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20. Tech n ical Featu re
CT Bolt
( 1 ) STA N DARD TH R EAD
Some pa rts of this m oto rcycle a re tig htened with the CT
b o lts, i . e . C o m b i n a t i o n T h re a d b o lts w h i c h m a ke t h e
fe m a l e th reads when they screw i n .
T h e l ower h a lf o f t h e C T bolt featu res t h e co m bi n ation of
the sta n d a rd t h reads a n d the low th reads.
When t h e CT bolt i s screwed i nto t h e u nt h re a d e d p i l ot
hole, the bolt m a kes the fe m a l e t h reads i n the p i l ot h o le by
d efo rm i n g t h e wa l l of the h o l e . Few c h i ps a n d shavings
a re produced this time, which is d iffe rent fro m t h rea d i n g
b y a mach i n e .
N OTE
•
•
•
( 1 ) AFTE R PLASTIC
DEFOR MAT I O N
W h e n t h e CT bolt is re u s e d , t i g hten t h e bolt with
care n ot to ru i n the fe m a l e threads that were made
when the bolt was tightened fi rst t i m e .
The sta n d a rd bolt is a pp l ica b l e to the fem a l e th reads
that were made by means of the plastic d eformation
d u ri n g tig hte n i n g the CT bolt.
The service rep lacement pa rts of the pa rts tig hte ned
with the CT bolts h ave the th reads.
( 2 ) I NTROD U CT I O N PART
(3) LOWE R HALF O F BOLT
( CO M B I NATION OF STA N DA R D
T H READS A N D LOW T H R EADS)
'----- ( 4 ) U PP E R HALF OF B O LT
(STA N DA R D T H READS)
14------ £ '----+1
W h e n the CT bolt re p l a c e m e n t i s req u i red, use new CT
bolt o r Ho n d a gen u i n e sta n d a rd bo lt ( l en gth £ ).
CAUTION
I
•
( 1 ) CT BOLT
Do not use the length £ ' standard bolt.
(3) I NTRO D U CT I O N
PART
Application list
Parts
Bolt
Qty
B reather case, Rear cyl i n d e r head cove r
M6
6
Cyl i n d e r head fi n , Cyl i n d e r head
M6
12
Oil pump
M6
3
Wate r p u m p
M6
3
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( 2 ) STAN DARD
BOLT
20- 1
MEMO
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2 1 . Troubleshooti ng
Engine Does Not Start Or Is Hard
To Start
Engine Lacks Power
Poor Performance At Low And Idle
Speeds
21 -1
2 1 -2
Poor Performance At High Speed
2 1 -4
2 1 -4
Poor Handling
2 1 -3
Engine Does Not Start Or Is Hard To Start
r
Possible Cause
1 . Check the fue l flow to ca rbu retor -- N ot Reac h i n g Carbu retor ----R•ac
no carbu retor
•
•
•
•
2 . Perfo rm a spa rk test
------
Wea k Or No Spark ------•
•
•
Good Spa rk
•
•
•
•
•
•
•
r
3. Test cyl i n d e r com p ression
com
----
Low Com p ression ------•
•
•
ess i o n N o r m a l
•
•
•
4. Sta rt b y fol lowi n g normal ---- E n g i n e Sta rts But Stops
p roced u re
------1•
•
•
•
•
•
5. Remove a n d i nspect spark p l u g
--
Wet P l u g
..,.
_________
•
•
•
•
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Clogged fue l tu be or fue l stra i n e r
scree n
Sticking float va lve
Clogged fue l ta n k b reather tu be
Disco n n ected or fa u lty a uto fue l
va lve vacu u m t u b e
Fau lty s p a r k p l u g s
Fou led s p a r k p l u g s
Fau lty I C M
B roken or s h o rted spark p l u g wi res
B ro ke n or s h o rted i g n ition co i l s
Fau lty i g n ition switch
Fau lty i g n ition p u l se g e n e rato r
Fau lty e n g i n e stop switch
Loose or d i sco n n ected i g n ition
system wi res
Va lve stuck open
Worn cyl i n d e r a n d piston ri n g s
Damaged cyl i n d e r head gasket
Seized va lve
I m proper va lve ti m i n g
I m p roper choke o peration
Carbu retor i nco rrectly a dj u sted
I nta ke p i pe leaki n g
I m proper i g n ition t i m i n g ( F a u lty
I C M or i g n ition p u l se g e n e rato r)
F u e l conta m i n ated
F looded carbu retor
Ch oke closed
Th rottle va lve o pe n
Air c l e a n e r d i rty
fD
21 -1
Troubleshooting
Engine Lacks Power
Possible Cause
1 . Raise wheels off the g ro u n d
a n d s pi n b y h a n d
W h e e l s Do N ot S p i n F reely
.
.
.
B ra ke d ragg i n g
Worn or d a m aged wheel bearings
Drive c h a i n too tig ht
.
F a u lty t i re valve
.
.
.
.
C l utch s l i p p i n g
Worn cl utch d iscs/pl ates
Warped c l utch d iscs/pl ates
Wea k c l utch spring
.
.
.
.
.
Carbu retor chock cl osed
C l ogged a i r c l ea n e r
Restricted fue l flow
C l ogged m uffler
Pi nched fuel ta n k b reather
.
.
F a u lty I C M
F a u lty i g n ition p u lse g e n e rato r
.
.
.
.
Valve stuck open
Worn cyl i nd e r a n d piston rings
Lea king head gasket
I m p roper va lve ti m i ng
Wheel Spins Freely
'
2. Check tire press u re
Pressu re Low
Pressu re N o r ma l
+
3. Accel e rate ra pidly from
l o w t o second
E n g i n e Speed N ot C h a nged
When C l utch Is Released
E n g i ne S peed Lowe red
When C l utch I s R e leased
+
4. Accel e rate l i g htly
E n g i n e S peed Does N ot
I ncrease
E n g i n e S peed I ncrease
j
5. Check i g n ition ti m i n g
I nco rrect
Correct
'
Too Low
6. Test cyl i nd e r com p ression
Normal
�
7 . Check carbu reto r for c l og g i ng
--
Clogged
.
Fou led O r Disco l o red
.
Carbu retor n ot serviced freq u e ntly
enough
N ot clogg i n g
+
8. Remove spark p l u g
.
Not fou led Or Disco l o red
i
9. Check oil l eve l a n d condition
I nco rrect
Correct
•
1 0. Remove cyl i nd er head cover
a n d i n spect l u b ricatio n
Valve Tra i n L ub ricate P roperly
2 1 -2
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Va lve Tra i n N ot L u b ricate
Properly
P l u g s not serviced freq u e ntly
enough
Spa rk p l u g s a re i ncorrect h eat
ra n g e
.
.
.
O i l l evel too h i g h
O i l level too l ow
Conta m i n ated o i l
.
.
Clogged o i l passag e
C l ogged o i l contro l orifice
Troubleshooting
Possible Cause
1 1 . Check for e n g i n e ove rheati n g -- Overheati n g
-------.
N ot Overheati n g
•
•
j
•
•
•
1 2 . Accel e rate or run at h i g h speed
--
E n g i n e Knocks
--------..
•
•
E n g i n e Does N ot Knock
•
•
•
Excessive ca rbon b u i lt-u p in comb u stion cha m be r
Use of poor q u a l ity fue l
C l utch s l i pp i n g
Lea n fue l m ixtu re
Wrong type of fue l
Worn piston a n d cyl i nd e r
Wro n g type of fue l
Excessive carbon b u i lt-u p i n com­
bustion cha m be r
I g n ition ti m i n g too a dva nced
(Fau lty I C M )
Lea n fue l m i xtu re
Poor Performance At Low And Idle Speeds
Possible Cause
1 . Check i g n ition t i m i n g
------
I ncorrect
-------t�
•
I ncorrect
-------
•
I m proper i g n ition ti m i n g
( F a u lty I C M )
Correct
+
2 . C heck ca rbu reto r p i l ot screw
adj u stment
---
See F u e l System section
Correct
+
3. C h eck fo r leaking i nta ke pipe --- Lea king
--------•
•
•
Loose i n s u l ator c l a m ps
Damaged i n s u l ator
N o Leak
+
4. Perfo rm spark test
-------
Good Spark
Wea k Or I nterm ittent Spark
----t�
•
•
•
•
•
•
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Fau lty carbon or wet fou led spa rk
plug
Fau lty I C M
F a u lty i g n ition coi l
B ro ke n or s h o rted spa rk p l u g wi res
Fau lty e n g i n e stop switch
Fau lty i g n ition p u l se g e n e rator
Troubleshooting
Poor Performance At High Speed
Possible Cause
1 " Check i g n ition t i m i n g
------
I nco rrect
__..
_________
•
•
F a u lty I C M
Fau lty i g n ition p u lse g e n e rato r
Correct
�
2. Disc n nect fu e l tube at carbu retor - F u e l F l ow Restricted
__..
_____
•
•
F u e l F l ows Freely
•
+
3. Remove the ca rbu reto r a n d c h eck - C l ogged
fo r clogged j uts
C l ogged fue l l i n e
C l ogged fuel ta n k breather
C l ogged fuel stra i n e r screen
------
•
C l ea n
__..
•
Cam sprocket n ot i n sta l led properly
-----
•
Fa u lty spri n g
N ot clogged
t
4. Check va lve t i m i n g
I ncorrect
_________
Correct
•
5. Check va lve spri ng
VVea k
N ot VVea kened
Poor Handling
1 . I f steering i s heavy
------•
Possible Cause
•
•
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Stee r i n g ste m adj usti n g n ut too
tig ht
Damaged stee r in g head bea rings
Air Cleaner
Ho u s i n g Rem ova l/I nsta l lati on . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . .. .. .. .. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . .. ..
Rem ova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batte ry Remova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Peda l Rem ova l/I nsta l l ati o n . . . . . . . . . . . . . . . . . . . . .
B u l b Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CT Bolt (Tec h n ical Feat u re)
..... .... ...... .........
Ca bl e & Ha rness Routi n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft I n sta l lation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carbu reto r Com bi nation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disasse m bly/Assem b l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rem ova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sepa rati o n . . . . . . . . . . . . . . . . . . . . .
... ........ .... .. ..
Syn c h ro n izatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tu be R o uti ng ( Ca l ifornia Type O n ly) . . . . . . . . . . . .
C h a rg i n g System I nspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C l utch I nsta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C o m b i n ation Mete r Disasse m bly/Assembly . . . . . . . . . .
Rem ova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Co n n ecti n g Rod Selection . . . . . .
.............................
Coo l a nt D ra i n i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cou ntershaft Disasse m b l y/Asse mbly . . . . . . . . . . . . . . . . . . . .
Cra n kcase Bolt Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C o m b i n ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sepa ratio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C ra n kshaft Bea r i n g Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Cra n kshaft/Con n ecti ng Rod Remova l/I nsta l latio n . . .
Cyl i nder Head Disasse m bly/Assem bly . . . . . . . . . . . . . . . . . . .
Remova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D rive C h a i n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D rive S p rocket Cove r Remova l/I nsta l lati o n . . . . . . . . . . . .
E m ission Control I nfo rmatio n La bels
( U .S .A. O n ly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E m i ssio n Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E n g i n e Rem ova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eva porative E m ission Ca n i ster ( EVAP Ca n i ste r)
Remova l/I n sta l l ation
( C a l ifo r n i a Type O n ly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E x h a u st Syste m Remova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . .
Fork Assem bly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disasse m b l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rem ova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F ront Brake Ca l i per Disasse m bly/Asse m bly . . . . . . . . . . .
Rem ova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F ront Brake Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F ront Master Cyl i nder Disassembly/Assem bly . . . . .
Rem ova l/I nsta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F ront Side Cover Rem ova l/I n sta l latio n . . . . . . . . . . . . . . . . . .
F ront Wheel Disasse m bly/Assembly . . . . . . . . . . . . . . . . . . .
Rem ova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Ta n k Remova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gea rshift Li n kage Remova l/I n sta l lati o n . . . . . . . . . . . . . . . . .
Genera l Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H a n d lebar Rem ova l/I n sta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hea d l i g ht Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remova l/I nsta l lati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H i g h Altitude Adj ustment ( U .S.A. O n ly) . . . . . . . . . . . . . . .
I g n ition Coi l I nspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3-5
5-3
1 5-9
1 5- 1 0
1 5-5
1 4-8
1 8-5
20- 1
1 -20
8-8
8-2
5- 1 0
5-8
5-4
5-6
5- 1 4
5- 1 3
1 5-6
9-6
9-4
1 8-8
1 8-7
1 1-18
6-3
1 1-12
1 1-18
1 1-14
1 1 -2
1 1-16
1 1 -4
8-6
8-4
3-8
1 0-2
22. I ndex
I g n ition contro l Mod u l e ( I C M )
Remova l/I n sta l l atio n
.... ... ...... ... ...... ..
I g n ition Pu lse Generato r I n s pection . . . . . . . . . . . . . . . . .
Remova l/I nsta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I g n ition Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I g n ition Syste m I nspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I g n ition Ti m i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liq u i d Sea l a nt Appl ication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication & Sea l Poi nts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Syste m D i a g ra m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M a i n s h aft Disasse m bly/Assem bly . . . . . . . . . . . . . . . . . . . . . . . .
M a i ntena nce Sched u l e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O i l P u m p Disassembly/Asse m b l y . . . . . . . . . . . . . . . . . . . . . . .
Remova l/I n sta l lation . . . . . . . . . . . . . . . . . . . . . .
Pu lse Seco n d a ry Ai r I njection Control Valve
( PA IR Control Va lve) Rem ova l/I n sta l l ation
(Cal ifornia Type O n ly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pi lot Screw Adj u stment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Disasse m bly/Asse m b ly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rad iator Disasse m b l y/Asse m b l y . . . . . . . . . . . . . . . . .
Remova l/I nsta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Brake Pa n e l Disasse m bly/Asse m bly . . . . . . . . . . . . . .
Rea r Fender Rem ova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . .
Rea r Wheel Disasse m b ly/Asse m b l y . . . . . . . . . . . . . . . . . . . . . . . .
Remova l/I n sta l l atio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reg u lator/Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R i g ht C ra n kcase Cover Rem ova l/I n sta l l ation . . . . . . . . .
Seat Remova l/I nsta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Access G u i de . . .
. .. .. ...... ....... . ... .
Service I nfo rmatio n ( B ra ke System ) . . . . . . . . . . . . . . . . . . . . .
( C h a rg i n g System/Alte rnato r) . . . . . . . . . . . . . . . . . . . . . .
(Cl utch System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Coo l i n g System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Cra n ks haft/Piston/Tra nsm issi o n ) . . . . . . . . . . . . . . .
(Cyl i n d e r HeadNalves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( E l ectric Sta rter/Sta rte r C l utc h ) . . . . . . . . . . . . . . . . . . . .
( E n g i ne Remova l/I n sta l lati o n )
.... . ..... ....
( F ra m e/Body Pa n e l s/Ex h a u st System ) . . . . . . .
( F ro nt Wheel/Suspension/Stee ri n g ) . . . . . . . . . . . . .
( F u e l System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( G e a rs h ift Li n kage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( I g n ition Syste m ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( Lig hts/Mete rs/Switches) . . . . . . . . . . . . . . . . . . . . . .
( L u b ricati o n Syste m ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( M a i nte na nce) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Rear Wheel/S uspens i o n ) . . . . . . . . . . . . . . . . . . . . . . . . .
S h ock Abso rber Disasse m bly/Assem bly . . . . . . . . . . . . . . .
Remova l/I nsta l lati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Cover Remova l/I n sta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Sta nd Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c
e
a
Remova l/I n sta l l ati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sta rter Moto r Disasse m b l y/Assem bly . . . . . . . . . . . . . . . . . . . .
Rem ova l/I n sta l l ati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Stem Rem ova l/I n sta l l ation . . . . . . . . . . . . . . . . . . .
Swi n g a rm D isassem bly/Assem b l y . . . . . . . . . . . . . . . . . . . . . . . . . .
Remova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System F l ow Patte rn . . . . . . . . . . . . . . . . . . . . .
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1 -30
1 -27
7-2
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5- 1 8
2-4
1 2- 1 0
1 2-8
1 2-6
1 4-4
1 4-3
1 4-2
1 4-6
1 4-5
2-3
1 2-5
1 2-4
2-2
1 0-4
1-1
1 2-2
3- 1 0
1 8-6
5- 1 7
1 6-8
1 6-9
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1 6- 1 0
1 6-9
1 6- 1 1
1 8-9
1 6-8
1 6- 1 2
1 1-18
1-17
4-2
1 1-10
3-4
1 -3
4-4
4-3
5- 1 8
5- 1 6
1 1 -6
6-6
6-5
1 4-7
2-7
1 3-4
1 3-2
1 5-7
9-2
2-2
3-2
1 4- 1
1 5- 1
9- 1
6- 1
1 1-1
8- 1
1 7- 1
7-1
2-1
1 2-1
5- 1
1 0- 1
1 6- 1
1 8- 1
4- 1
3-1
1 3- 1
1 3-7
1 3-6
2-3
1 8-9
�i �:; ������ oi��·���·�·bi�ii.\'����·t;j�·:::::::::::::::::::: 1 7 ���
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17-10
1 7-8
1 7-7
1 2- 1 2
1 3- 1 1
1 3-9
6-2
22- 1
flJI
Index
System Location (Charg i n g System/Alternator)
( E lectric Sta rter/Sta rter Cl utc h ) . . . . . . . . . . . . . . . . . . . .
( I g n ition System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( Lig hts/Meters/Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat Remova l/I nsta l latio n . . . . . . . . . . . . . . . . . . . . . . . . . .
Too l s
Torq ue Va l ues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transm ission Remova l/I n sta l l ation . . . . . . . . . . . . . . . . . . . . . . . .
Tro u bleshooti ng ( B ra ke System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Charg i n g System/Alternato r) . . . . . . . . . . . . . . . . . . . . . .
(Cl utch System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Coo l i ng System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Cran kshaft/Piston/Transm issio n ) . . . . . . . . . . . . . . .
(Cyl i nder HeadNa lves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( El ectric Sta rter/Sta rter Cl utc h ) . . . . . . . . . . . . . . . . . . . .
( E n g i n e Does N ot Sta rt Or Is H a rd To Sta rt)
( E n g i n e Lacks Powe r) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( F rame/Body Panels/Ex ha ust System ) . . . . . . . .
( F ront Wheel/Suspension/Steer i n g ) . . . . . . . . . . . .
( F u e l System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Gea rs h ift L i n kage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( I g n ition System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( Li g hts/Meters/Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( L u b ri cation System ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( Poor H a nd l i n g ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( Poor Performa nce At H i g h S peed ) . . . . . . . . . . . .
(Poor Performance At Low And Idle Speeds) . .
( Rear Wheel/Suspe ns i o n ) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
U pper Fairing Remova l/I n sta l latio n (VF750CD) . . . . . . .
Valve Cleara nce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water P u m p Remova l/I nsta l lation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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22-2
Downloaded from www.Manualslib.com manuals search engine
1 5-2
1 7-2
1 6-2
1 8-2
6-4
1-15
1-12
1 1 -8
1 4- 1
1 5-3
9- 1
6- 1
1 1 -1
8- 1
1 7-3
21-1
2 1 -2
2-1
1 2- 1
5-2
1 0- 1
1 6-3
1 8-3
4- 1
2 1 -4
2 1 -4
2 1 -3
1 3- 1
2-8
3-5
6-7
1 9- 1
(232)
23. Appendix: Part Numbers
Air Cleaner
23-2
Mark VF750C (1994-1997)
23-33
Air Suction Valve
23-3
Mark VF750C (1998-2003)
23-34
Alternator
23-4
Mark VF750CD (1996-1997)
23-35
Battery
23-5
Mark VF750C2 (1998-2000)
23-36
Bikini Cowl
23-6
Muffler
23-37
Cam Chain
23-7
Oil Pump
23-38
Camshaft
23-8
Pedal
23-39
Carburetor Assembly
23-10
Pulse Generator
23-40
Carburetor Components
23-12
Radiator
23-41
Carburetor Side Cover
23-13
Rear Brake Panel
23-42
Caution Label
23-14
Rear Cylinder Head
23-43
Clutch
23-15
Rear Fender
23-44
Crankcase
23-16
Rear Shock Absorber
23-45
Crankshaft
23-17
Rear Wheel
23-46
Cylinder Head Cover
23-18
Right Crankcase Cover
23-47
Evaporation Canister
23-19
Seat
23-48
Frame
23-20
Side Cover
23-49
Front Brake Caliper
23-21
Speedometer Tachometer
23-50
Front Brake Master Cylinder
23-22
Stand
23-52
Front Cylinder Head
23-23
Starting Motor
23-53
Front Fender
23-24
Steering Stem
23-54
Front Fork
23-25
Step
23-55
Front Wheel
23-26
Swingarm @ Drive Chain
23-56
Fuel Tank
23-27
Taillight
23-57
Gasket Kit A
23-28
Tools
23-58
Gasket Kit B
23-28
Transmission
23-59
Gearshift Drum
23-29
Turn Signal
23-60
Handle Switch Cables
23-30
Water Pipe
23-61
Handlebar
23-31
Water Pump
23-62
Headlight
23-32
Wire Harness
23-63
Downloaded from www.Manualslib.com manuals search engine
23-1
Appendix A: Part Numbers
Air Cleaner
#
01
02
03
04
04
05
06
07
08
09
10
Description
CLIP, DRAIN TUBE
15772-GB5-670
AIR CLEANER
17210-MZ5-000
COVER, A/CLNR HSG
17220-MZ5-000
AIR CLEANER HOUSING
17230-MZ5-910 (replaces 17230-MZ5-000)
AIR CLEANER HOUSING
17230-MZ5-740
PIPE, AIR
17234-MZ5-740
CASE, SUB A/CLNR
17251-KT8-000
DUCT
17251-MZ5-000
FILTER, SUB A/CLNR
17254-KAZ-000
COVER, SUB A/CLNR
17256-MM4-000
TUBE, SUB A/CLNR
17258-MZ5-000
23-2
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
004
$2.45
11
001
$11.42
001
$47.21
12
001
$3.22
001
$67.73
13
004
$2.02
001
$88.79
14
003
$3.65
001
$84.37
15
005
$7.11
001
$15.15
16
002
$2.64
001
$17.60
17
001
$3.27
001
$44.45
18
002
$0.43
001
$2.08
19
001
$31.53
001
$16.56
20
001
$0.97
001
$11.07
NI
STOPPER
17259-MZ5-000
TUBE A, BREATHER
17355-MZ5-000
SCREW (5X12)
90105-MB1-000
SCREW, PAN (5X19)
90141-KT8-000
SCREW, PAN (4X40)
90141-MZ5-000
NUT, SPECIAL (6X7)
61304-958-003(replaces 90301-471-000)
CLIP, SWITCH CORD
91400-MR8-000
SCREW-WASHER (5X10)
93891-05010-07
BULK HOSE (12X1000)
95005-12001-10M
BOLT, FLANGE (6X45)
95701-06045-07 (replaces 95701-06045-00)
TIE, CABLE
32901-VB5-800
001
$2.10
Appendix A: Part Numbers
Air Suction Valve
#
01
02
03
04
05
06
07
08
09
10
11
12
Description
CLIP B, FUEL HOSE
16968-MC7-000
JOINT, VACUUM TUBE
17201-MG9-000
CLIP, BREATHER TUBE
17369-KB4-670
CONTROL VALVE, FR.
18600-MZ5-740
HOSE A
18612-MZ5-740
HOSE A, RR. AIR
18613-MZ5-740
HOSE C, RR. AIR
18615-MZ5-740
TUBE, FR.
18616-MZ5-740
STAY, FR.
18617-MZ5-740
CONTROL VALVE, RR.
18620-MZ5-740
TUBE
18625-MZ5-740
TUBE
18626-MZ5-740
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
006
$4.67
13
002
$12.51
14
004
$2.78
15
001
$129.72
16
002
$19.67
17
002
$18.62
18
001
$20.69
19
001
$17.16
20
002
$12.13
21
001
$153.78
22
001
$31.86
23
001
$10.66
Description
PIPE, R. FR. AIR
18640-MZ5-740
GSKT, AIR FEED PIPE
18645-MT4-730
PIPE, L. FR. AIR
18645-MZ5-740
PIPE, RR. AIR
18650-MZ5-740
BOLT
90007-PY3-000
CLAMP, TUBE (D17)
91405-MF5-860
CLIP, TUBE (B7)
95002-02070
BULK HOSE (3.5X1000)
95005-35001-20M
BULK HOSE (3.5X1000)
95005-35001-20M
*95701-06016-08
95701-06016-00
BOLT, FLANGE (6X20)
95701-06020-00
Q’ty
Price
001
$47.54
004
$1.96
001
$47.54
001
$99.53
002
$2.88
002
$2.51
010
$0.82
001
$5.42
002
$5.42
008
$0.73
004
$0.60
23-3
Appendix A: Part Numbers
Alternator
#
01
02
03
04
05
06
Description
GASKET
11636-MY7-000
COVER, ALTERNATOR
11641-MZ5-920 (replaces 11641-MZ5-000)
FLYWHEEL
31110-MZ5-004
STATOR
31120-MZ5-004
CLAMP, CABLE
32111-MZ5-000
BOLT, FLANGE (6X32)
90001-GHB-690
23-4
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$12.98
07
001
$329.16
08
001
$386.83
09
001
$332.99
10
001
$6.36
11
005
$2.96
Description
BOLT, FLANGE (6X60)
90001-GHB-750
BOLT, FLANGE (10X35)
90003-MN4-000
BOLT, SOCKET (6X40)
90116-375-000
WASHER (10X25X4)
90405-ML0-000
PIN, DOWEL (8X14)
94301-08140
Q’ty
Price
001
$3.93
001
$4.76
004
$3.18
001
$4.76
002
$1.00
Appendix A: Part Numbers
Battery
#
01
02
03
04
05
06
07
08
Description
BATTERY (YTX12-BS)
31500-HF1-678 (replaces 31500-HA0-686,
31500-HF1-677, 31500-KM1-836, 31500KM1-837)
CABLE
32401-MZ5-000
CABLE, STARTER MOTOR
32410-MZ5-000
COVER
32411-230-000 (replaces 32411-253-000)
COVER
32414-MZ5-000
CABLE
32601-MZ5-000
SWITCH ASSY.
35850-MR5-007
RUB, SHOCK ABSORBER
35856-MR5-000
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$69.17
09
10
001
$25.07
11
001
$51.75
12
001
$5.60
13
001
$4.04
14
001
$27.51
15
001
$83.87
16
001
$6.95
17
Description
BOX ASSY., BATTERY
50330-MZ5-000
BODY, KEY
83507-422-000
STOPPER, KEY BODY
83508-KBG-000 (replaces 83508-438-000)
BOLT, SOCKET (5X9)
90111-MR5-000
NUT, SPECIAL (6X7)
61304-958-003 (replaces 90301-471-000)
PIN, SPRING (2X14)
94305-20141
BAND F, BATTERY
95012-17001
BOLT, FLANGE (6X12)
96001-06012-00
FUSE, BLADE (30A)
98200-33000
Q’ty
Price
001
$86.89
001
$2.76
001
$2.04
002
$1.87
003
$2.64
001
$0.67
001
$5.89
003
$0.78
002
$0.67
23-5
Appendix A: Part Numbers
Bikini Cowl
#
01
02
03
04
05
06
06
07
08
09
Description
CLIP, SCREEN MOLDING
64102-MJ0-000
MOLDING, WINDSCREEN
64105-MZ5-870
WINDSCREEN
64150-MZ5-870
WASHER
64205-166-610
RUBBER, BIKINI COWL
64215-MZ5-870
COWL SET (TYPE10)
64220-MZ5-870ZA
COWL SET (TYPE9)
64220-MZ5-870ZB
STAY, COWL
64505-MZ5-870
STAY A, R. COWL
64506-MZ5-870
STAY A, L. COWL
64507-MZ5-870
23-6
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
002
$3.58
10
001
$8.60
11
001
$218.56
12
006
$1.62
13
001
$35.91
14
001
$579.87
15
001
$579.87
16
001
$19.36
17
001
$33.87
18
001
$33.87
Description
STAY B, R. COWL
64508-MZ5-870
STAY B, L. COWL
64509-MZ5-870
BOLT, SPECIAL (6X17)
90085-MZ1-000
SCREW, PAN (6X14)
90106-KBV-000
SCREW, TRUSS (5X20)
90109-MT3-000
NUT (5MM)
90111-KW3-003
WASHER (5MM)
90501-MY2-700
BOLT, FLANGE (8X16)
95701-08016-08
BOLT, FLANGE (6X50)
96300-06050-07
Q’ty
Price
001
$17.18
001
$17.18
002
$2.84
001
$3.09
006
$2.00
006
$3.55
006
$1.60
002
$0.85
002
$1.30
Appendix A: Part Numbers
Cam Chain
#
01
02
03
04
05
06
07
08
09
10
Description
GSKT, TENSIONER HOLE
12194-HC5-740
GSKT, TENSIONER HOLE
12194-KW3-880
CHAIN, CAM
14401-MZ5-921 (replaces 14401-MZ5-003)
TENSIONER, FR.
14510-MZ5-770 (replaces 14510-MZ5-000)
TENSIONER, RR.
14515-MZ5-770 (replaces 14515-MZ5-000)
LIFTER ASSY., RR.
14520-MZ5-003
LIFTER ASSY., FR.
14530-MZ5-003
PIN, TENSIONER
14531-MZ5-000
GUIDE B, CAM CHAIN
14546-MZ5-000
GUIDE, FR. CAM CHAIN
14620-MZ5-000
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
001
$1.78
11
001
$51.58
001
$1.67
12
001
$23.11
002
$89.02
13
002
$2.47
001
$108.09
14
004
$2.22
001
$108.09
15
002
$1.15
001
$75.99
16
002
$1.33
001
$75.99
16
002
$0.93
001
$7.04
17
002
$2.25
002
$28.15
18
001
$1.95
001
$50.43
19
GUIDE, RR. CAM CHAIN
14625-MZ5-000
STAY
14627-MZ5-000
BOLT, FLANGE (6X10)
90004-GHB-600 (replaces 90001-GHB-600)
BOLT, FLANGE (6X25)
90004-GHB-670 (replaces 90001-GHB-670)
BOLT (6X14)
90009-MZ8-H00 (replaces 90009-ME5-000)
WASHER (6MM)
90442-397-000
WASHER (6MM)
90502-KBV-000
WASHER (6.5MM)
90463-ML7-000
PIN (6MM)
90607-ME5-000
BOLT, FLANGE (6X14)
95701-06014-00
002
$0.63
23-7
Appendix A: Part Numbers
Camshaft
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
14
14
14
14
14
14
Description
SEAL, EX. VALVE STEM
12208-ML0-721
SEAL, VALVE STEM
12209-MZ5-003
CAMSHAFT, FR. IN.
14110-MZ5-000
CAMSHAFT, RR. IN.
14120-MZ5-000
CAMSHAFT, FR. EX.
14130-MZ5-000
CAMSHAFT, RR. EX.
14140-MZ5-000
VALVE, IN.
14711-MT4-000
VALVE, EX.
14721-MY3-000
LIFTER, VALVE
14731-MT4-010 (replaces 14731-MT4-000)
SPRING, VALVE
14751-MZ5-003
RETAINER, VLV SPR
14771-KW3-900
SEAT, VALVE SPRING
14775-PM3-000
COTTER, VALVE
14781-ML0-720
SHIM, TAPPET (1.200)
14901-KT7-013
SHIM, TAPPET (1.225)
14902-KT7-013
SHIM, TAPPET (1.250)
14903-KT7-013
SHIM, TAPPET (1.275)
14904-KT7-013
SHIM, TAPPET (1.300)
14905-KT7-013
SHIM, TAPPET (1.325)
14906-KT7-013
SHIM, TAPPET (1.350)
14907-KT7-013
23-8
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
008
$8.07
14
008
$7.69
14
001
$261.83
14
001
$278.02
14
001
$258.56
14
001
$261.83
14
008
$25.73
14
008
$45.22
14
016
$33.35
14
016
$7.96
14
016
$8.36
14
016
$3.38
14
032
$2.71
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
Description
SHIM, TAPPET (1.375)
14908-KT7-013
SHIM, TAPPET (1.400)
14909-KT7-013
SHIM, TAPPET (1.425)
14910-KT7-013
SHIM, TAPPET (1.450)
14911-KT7-013
SHIM, TAPPET (1.475)
14912-KT7-013
SHIM, TAPPET (1.500)
14913-KT7-013
SHIM, TAPPET (1.525)
14914-KT7-013
SHIM, TAPPET (1.550)
14915-KT7-013
SHIM, TAPPET (1.575)
14916-KT7-013
SHIM, TAPPET (1.600)
14917-KT7-013
SHIM, TAPPET (1.625)
14918-KT7-013
SHIM, TAPPET (1.650)
14919-KT7-013
SHIM, TAPPET (1.675)
14920-KT7-013
SHIM, TAPPET (1.700)
14921-KT7-013
SHIM, TAPPET (1.725)
14922-KT7-013
SHIM, TAPPET (1.750)
14923-KT7-013
SHIM, TAPPET (1.775)
14924-KT7-013
SHIM, TAPPET (1.800)
14925-KT7-013
SHIM, TAPPET (1.825)
14926-KT7-013
SHIM, TAPPET (1.850)
14927-KT7-013
Q’ty
Price
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
Appendix A: Part Numbers
#
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
Description
SHIM, TAPPET (1.875)
14928-KT7-013
SHIM, TAPPET (1.900)
14929-KT7-013
SHIM, TAPPET (1.925)
14930-KT7-013
SHIM, TAPPET (1.950)
14931-KT7-013
SHIM, TAPPET (1.975)
14932-KT7-013
SHIM, TAPPET (2.000)
14933-KT7-013
SHIM, TAPPET (2.025)
14934-KT7-013
SHIM, TAPPET (2.050)
14935-KT7-013
SHIM, TAPPET (2.075)
14936-KT7-013
SHIM, TAPPET (2.100)
14937-KT7-013
SHIM, TAPPET (2.125)
14938-KT7-013
SHIM, TAPPET (2.150)
14939-KT7-013
SHIM, TAPPET (2.175)
14940-KT7-013
SHIM, TAPPET (2.200)
14941-KT7-013
SHIM, TAPPET (2.225)
14942-KT7-013
SHIM, TAPPET (2.250)
14943-KT7-013
SHIM, TAPPET (2.275)
14944-KT7-013
SHIM, TAPPET (2.300)
14945-KT7-013
SHIM, TAPPET (2.325)
14946-KT7-013
SHIM, TAPPET (2.350)
14947-KT7-013
SHIM, TAPPET (2.375)
14948-KT7-013
SHIM, TAPPET (2.400)
14949-KT7-013
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
14
016
$6.78
016
$6.78
Description
SHIM, TAPPET (2.425)
14950-KT7-013
SHIM, TAPPET (2.450)
14951-KT7-013
SHIM, TAPPET (2.475)
14952-KT7-013
SHIM, TAPPET (2.500)
14953-KT7-013
SHIM, TAPPET (2.525)
14954-KT7-013
SHIM, TAPPET (2.550)
14955-KT7-013
SHIM, TAPPET (2.575)
14956-KT7-013
SHIM, TAPPET (2.600)
14957-KT7-013
SHIM, TAPPET (2.625)
14958-KT7-013
SHIM, TAPPET (2.650)
14959-KT7-013
SHIM, TAPPET (2.675)
14960-KT7-013
SHIM, TAPPET (2.700)
14961-KT7-013
SHIM, TAPPET (2.725)
14962-KT7-013
SHIM, TAPPET (2.750)
14963-KT7-013
SHIM, TAPPET (2.775)
14964-KT7-013
SHIM, TAPPET (2.800)
14965-KT7-013
SHIM, TAPPET (2.825)
14966-KT7-013
SHIM, TAPPET (2.850)
14967-KT7-013
SHIM, TAPPET (2.875)
14968-KT7-013
SHIM, TAPPET (2.900)
14969-KT7-013
Q’ty
Price
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
016
$6.78
23-9
Appendix A: Part Numbers
Carburetor Assembly
23-10
Downloaded from www.Manualslib.com manuals search engine
Appendix A: Part Numbers
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
19
20
20
21
21
22
22
23
24
Description
ROD SET, LINK
16018-MZ5-600
JOINT SET
16026-MZ5-600
JOINT SET, FUEL
16027-MB6-671
JOINT SET
16027-MZ5-600
LEVER SET, LINK
16035-MZ5-600
GASKET B SET
16040-MZ5-600
JOINT SET, FUEL
16047-KE7-003
JOINT SET
16047-MZ5-600
SPRING
16050-MZ5-600
SPRING
16051-MZ5-670
SPRING
16053-MB0-671
SCREW-WASHER
16081-KAZ-000
BOLT
16083-MZ5-670
BOLT
16084-MZ5-670
WASHER, PLAIN
16085-MV4-000
WASHER
16090-MZ5-600
CARBURETOR ASSY.
16100-MZ5-670
CARBURETOR ASSY.
16100-MZ5-740
CARBURETOR ASSY. 1
16101-MZ5-670
CARBURETOR ASSY. 1
16101-MZ5-740
CARBURETOR ASSY. 2
16102-MZ5-670
CARBURETOR ASSY. 2
16102-MZ5-740
CARBURETOR ASSY. 3
16103-MZ5-670
CARBURETOR ASSY. 3
16103-MZ5-740
CARBURETOR ASSY. 4
16104-MZ5-670
CARBURETOR ASSY. 4
16104-MZ5-740
LEVER, STARTER
16121-MZ5-600
FUNNEL, AIR
16141-MZ5-600
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$45.42
25
001
$31.65
26
001
$28.47
27
001
$31.65
28
001
$31.51
29
002
$13.73
30
001
$32.87
31
002
$30.27
32
001
$9.69
33
002
$7.91
34
001
$7.09
35
004
$2.22
36
002
$23.65
37
001
$23.65
38
004
$1.95
39
004
$2.95
40
001
$1,644.16
41
001
$1,644.16
42
001
$480.69
43
001
$480.69
44
001
$480.69
45
001
$480.69
46
001
$480.69
47
001
$480.69
48
001
$480.69
49
001
$480.69
002
$30.40
004
$20.85
Description
STAY, JOINT
16169-MZ5-670
COLLAR
16172-MZ5-670
COLLAR
16173-MZ5-670
COLLAR
16174-MZ5-670
COLLAR
16175-MZ1-000
T-JOINT
16179-MB2-881
BASE, AIR CLEANER
16188-MZ5-600
TUBE (15X170)
16195-MZ5-670
TUBE, FUEL
16197-MZ5-670
TUBE, FUEL
16198-MZ5-671
TUBE
16199-MZ5-670
T-JOINT
17193-MN5-000
T-JOINT
17194-MN5-000
SCREW, PAN (4X16)
93500-04016-0G
NUT, FLANGE (6MM)
94050-06000
CLIP, TUBE (B18)
95002-02089
CLIP, TUBE (B10)
95002-02109
CLIP, TUBE (B12)
95002-02129
CLIP, TUBE (B12.5)
95002-02139
BULK HOSE (4.5X1000)
95005-45001-20M
BULK HOSE (4.5X1000)
95005-45001-20M
BULK HOSE (4.5X1000)
95005-45001-20M
BULK HOSE (5.5X3000)
95005-55003-20M
BULK HOSE (5.5X3000)
95005-55003-20M
BULK HOSE (7X1000)
95005-70001-50M
Q’ty
Price
001
$21.11
001
$19.36
001
$15.85
001
$19.36
004
$9.40
001
$22.62
001
$149.59
001
$4.64
001
$12.65
001
$15.31
001
$3.62
001
$13.60
002
$8.89
016
$0.47
006
$0.72
008
$0.76
004
$1.02
004
$1.02
001
$1.02
001
$19.42
001
$19.42
002
$19.42
001
$18.33
001
$18.33
001
$7.63
23-11
Appendix A: Part Numbers
Carburetor Components
#
01
02
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
Description
GASKET SET A
16010-MZ5-600
NEEDLE SET, JET
16012-MZ5-600
NEEDLE SET, JET
16012-MZ5-670
FLOAT SET
16013-MY1-000
CHAMBER SET, FLOAT
16015-MV9-670
SCREW SET
16016-MAS-670 (replaces 16016-MV9-730)
CHAMBER SET, FLOAT
16023-MV9-670
SCREW SET
16028-MZ5-600
SCREW SET
16029-MZ5-600
PLATE SET, VALVE
16037-MV4-000
GASKET SET C
16041-MZ5-600
VALVE SET, STARTER
16046-MV9-670
SPRING
16051-MV4-000
SPRING
16051-MZ5-600
SPRING
16052-MV4-000
SCREW, PAN
16080-MV4-000
BOLT-WASHER (5X16)
16082-PH9-005
TOP
16107-MZ5-671
23-12
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
004
$32.85
18
004
$1.73
004
$34.20
19
004
$119.21
004
$33.85
20
001
$13.64
004
$36.55
21
001
$13.96
002
$100.65
22
001
$17.35
004
$17.36
23
004
$23.04
002
$127.01
24
004
$14.63
003
$32.13
25
004
$59.62
001
$24.80
26
001
$0.60
004
$18.07
27
002
$0.30
004
$12.42
28
004
$5.42
004
$47.54
29
004
$5.20
004
$13.67
29
004
$5.20
004
$7.91
30
004
$8.38
003
$2.95
31
004
$4.56
012
$1.67
004
$8.24
012
$2.16
SCREW
16108-MW0-750
PISTON, VACUUM
16111-MZ5-600
PLATE, STAY
16119-MZ2-600
PLATE, STAY
16119-MZ5-600
STAY, WIRE
16119-MZ5-670
VALVE, FLOAT
16155-MN9-004
HOLDER, NEEDLE JET
16165-MN4-013
VALVE ASSY., AIR CUT
16510-MZ2-650
SCREW-WASHER (4X10)
93892-04010-00 (replaces 93892-04010-10)
SCREW-WASHER (5X10)
93892-05010-00 (replaces 93892-05010-10)
BULK HOSE (3.5X1000)
95005-35001-20M
JET, MAIN (#102)
99101-GHB-1020 (replaces 99101-393-1020)
JET, MAIN (#102)
99101-GHB-1020
JET, SLOW (#40)
99103-MT2-0400
JET, SLOW AIR (#110)
99108-MW0-1102 (replaces 99108-MW01100)
JET (#110)
99108-MY1-1100
004
$38.78
31
Appendix A: Part Numbers
Carburetor Side Cover
#
01
02
03
04
05
06
07
08
09
10
11
Description
CVR, CARBURETOR SIDE
17255-MZ5-000
BASE, R.
17256-MZ5-000
BASE, L.
17266-MZ5-000
PROTECTOR
17267-MZ5-300
COVER SET, L.
17268-MZ5-000
CABLE, CHOKE
17950-MZ5-000
LOCK SET
35010-MZ5-000
SWITCH, COMBINATION
35100-MZ5-A01 (replaces 35100-MZ5-007)
BASE
35102-MR1-000
COLLAR
35103-MR1-000
COVER
35110-MZ5-000
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$72.38
12
001
$48.58
12
001
$46.88
13
001
$12.13
14
001
$91.70
15
001
$23.56
16
001
Call For Price
17
001
$49.44
18
001
$9.75
19
001
$15.58
20
001
$14.45
Description
KEY, BLANK (TYPE1)
35121-MR1-770
KEY, BLANK (TYPE2)
35122-MR1-770
GROMMET, A/CLNR HSG
83551-GE2-000
BOLT, BREAK OFF
90107-MR1-000
BOLT, FLANGE (6MM)
90113-KW3-000
SCREW, RR. COVER
90114-GB6-920
BOLT, FLANGE (6X10)
95701-06010-00
*95701-06016-08
95701-06016-00
BOLT, FLANGE (6X30)
95701-06030-00
BOLT, FLANGE (6X35)
95701-06035-00
Q’ty
Price
001
$7.38
001
$7.38
004
$3.18
002
$6.16
002
$2.84
001
$1.18
002
$0.75
002
$0.73
001
$0.83
001
$0.75
23-13
Appendix A: Part Numbers
Caution Label
#
01
02
03
04
05
06
Description
DIAGRAM
87135-MZ5-740
LABEL, HIGH ALTITUDE
87139-463-670
LABEL, TIRE
87505-MZ5-670
LABEL, DRIVE CHAIN
87507-MZ5-670
MARK
87512-MZ3-670
LABEL, DRIVE (TYPE2)
87560-MW0-670ZB
23-14
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$3.27
07
001
$5.02
07
001
$3.78
07
001
$3.78
08
001
$4.51
08
001
$4.62
Description
LABEL (R201) (TYPE1)
87565-MZ5-670ZA
LABEL (NH1) (TYPE2)
87565-MZ5-670ZB
LABEL (Y124) (TYPE3)
87565-MZ5-670ZC
LABEL, FUEL (TYPEG)
87586-MR6-670ZA
LABEL, FUEL (TYPEB)
87586-MR6-670ZF
Q’ty
Price
001
$2.16
001
$2.16
001
$2.16
001
$2.33
001
$2.22
Appendix A: Part Numbers
Clutch
#
01
02
03
04
05
06
07
08
09
10
11
12
13
Description
SPROCKET
15131-ML7-000
CLUTCH (OUTER)
22100-MZ5-010 (replaces 22100-MZ5-000)
GUIDE, CLUTCH
22116-MB0-000
COLR, CLUTCH (OUTER)
22117-ML7-690
CENTER, CLUTCH
22120-ML7-010 (replaces 22120-ML7-000)
SEAT, JUDDER SPRING
22125-ML7-000
DISK, CL FRICTION
22201-MS6-620 (replaces 22201-KG0-980,
22201-KM4-000)
DISK B, CL FRICTION
22202-ML4-611
PLATE, CLUTCH
22321-MR7-000 (replaces 22321-ML7-000)
PLATE, CLU PRESS
22350-ML7-000
PIECE, CLUTCH JOINT
22366-KE8-000
SPRING, CLUTCH
22401-KZ3-000 (replaces 22401-ML7-000)
SPRING, JUDDER
22402-ML7-000
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$28.64
14
001
$349.77
15
001
$22.93
16
001
$8.11
17
001
$96.21
18
001
$8.11
19
008
$11.24
20
001
$12.51
008
$10.64
001
$52.03
23
001
$8.73
24
005
$3.51
25
001
$17.18
21
22
Description
ROD, CLUTCH LIFTER
22850-MZ5-000
GEAR, PRIMARY DRIVE
23110-ML7-010
SPRING
23115-MG8-300
BOLT-WASHER (6X25)
90022-MM5-000
NUT, LOCK (22MM)
90231-MK7-670
NUT, LOCK (22MM)
90231-MZ7-000
WASHER (22MM)
90432-MB0-010
GUIDE
90509-MR7-000
BEARING (16003)
91011-KK6-013 (replaces 91008-362-000,
91008-KK6-000, 91010-HC0-003)
BEARING (35X42X30)
91024-MB0-003
CIRCLIP (32MM)
94510-32000
CLIP (15MM)
94601-15000
Q’ty
Price
001
$24.56
001
$167.74
003
$2.33
005
$2.33
001
$7.93
001
$8.22
001
$6.58
001
$35.22
001
$12.09
001
$56.71
001
$0.97
001
$0.68
23-15
Appendix A: Part Numbers
Crankcase
#
01
02
03
04
05
06
07
08
09
10
11
12
13
Description
CRANKCASE SET
11000-MZ5-000
GUIDE, HOSE
11337-MZ5-000
RECEIVER
22821-MZ5-000
SWITCH, OIL PRESSURE
35500-MJ4-024
BOLT, FLANGE (6X96)
90003-PC9-000
BOLT, UBS (9X88)
90014-ML7-000
BOLT, UBS (9X108)
90016-ML7-000
BOLT, FLANGE (10X20)
90130-126-900
WASHER (10MM)
90403-MG7-000
WASHER (6.5MM)
90463-ML7-000
ORIFICE (1.0)
90701-ML7-000
PIN, DOWEL (10X16)
90701-MV9-670
OIL SEAL (8X25X8)
91204-MB0-013
23-16
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
001
$2,318.80
14
001
$1.45
001
$7.62
001
$1.00
001
$22.47
002
$0.72
001
$32.20
002
$0.85
001
$4.37
001
$0.75
004
$7.33
003
$0.85
004
$8.73
002
$0.97
002
$3.18
003
$0.98
002
$2.62
001
$1.70
003
$2.25
002
$1.03
001
$5.65
001
$1.02
002
$3.38
002
$2.72
001
$3.18
O-RING (7.7X2.3)
91301-PC9-003 (replaces 91308-283-000,
91313-393-003)
PIN, DOWEL (8X14)
94301-08140
BOLT, FLANGE (6X12)
95701-06012-00
BOLT, FLANGE (6X28)
95701-06028-00
BOLT, FLANGE (6X35)
95701-06035-00
BOLT, FLANGE (6X40)
95701-06040-00
BOLT, FLANGE (6X45)
95701-06045-07 (replaces 95701-06045-00)
BOLT, FLANGE (6X50)
95701-06050-00
BOLT, FLANGE (6X55)
95701-06055-00
BOLT, FLANGE (6X65)
95701-06065-00
BOLT, FLANGE (8X45)
95701-08045-00
BOLT, FLANGE (10X90)
95701-10090-00
15
16
17
18
19
20
21
22
23
24
25
Appendix A: Part Numbers
Crankshaft
#
01
01
01
02
02
02
03
04
05
06
07
08
08
08
08
08
09
Description
RING SET, PISTON
13011-MT4-315
RING SET (OS 0.25)
13021-MT4-315
RING SET (OS 0.50)
13031-MT4-315
PISTON
13101-MZ5-000
PISTON (OS 0.25)
13102-MZ5-305
PISTON (OS 0.50)
13103-MZ5-305
PIN, PISTON
13111-MZ5-000
ROD, FR. CONNECTING
13210-ML7-020
BOLT, CONNECTING ROD
13213-ML7-020
NUT, CONNECTING ROD
13215-ML7-000
ROD, RR. CONNECTING
13220-ML7-020
BEARING A, FR.
13224-ML7-690
BRG B, FR. CONN ROD
13225-ML7-690
BRG C, FR. CONN ROD
13226-ML7-690
BRG D, FR. CONN ROD
13227-ML7-690
BRG E, FR. CONN ROD
13228-ML7-690
BEARING A, RR.
13234-ML7-690
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
004
$39.05
09
004
$35.42
09
004
$38.65
09
004
$53.41
09
004
$53.41
10
004
$53.41
11
004
$18.15
11
002
$164.95
11
008
$6.31
11
008
$3.07
11
002
$164.95
12
004
$9.09
12
004
$9.09
12
004
$10.18
12
004
$8.58
12
004
$9.09
13
004
$9.09
Description
BRG B, RR. CONN ROD
13235-ML7-690
BRG C, RR. CONN ROD
13236-ML7-690
BRG D, RR. CONN ROD
13237-ML7-690
BRG E, RR. CONN ROD
13238-ML7-690
CRANKSHAFT
13310-MZ5-000
BEARING A
13313-ML7-691
BEARING B
13314-ML7-691
BEARING C
13315-ML7-691
BEARING D
13316-ML7-691
BEARING E
13317-ML7-691
BEARING A
13323-MR7-013
BEARING B
13324-MR7-013
BEARING C
13325-MR7-013
BEARING D
13326-MR7-013
BEARING E
13327-MR7-013
CLIP (17MM)
94601-17000
Q’ty
Price
004
$9.09
004
$10.18
004
$9.09
004
$9.09
001
$809.82
004
$10.02
004
$10.02
004
$10.02
004
$10.02
004
$10.02
004
$10.02
004
$10.02
004
$10.02
004
$10.02
004
$10.02
008
$0.82
23-17
Appendix A: Part Numbers
Cylinder Head Cover
#
01
02
03
04
05
06
07
08
Description
COVER, BREATHER
12230-MZ5-000
GASKET, BTHR CVR
12231-MZ5-920 (replaces 12231-MZ5-000)
COVER, FR. CYL HD
12311-MZ5-A00 (replaces 12311-MZ5-000)
RUBBER A
12312-MZ5-000
RUBBER B
12313-MZ5-000
COVER, RR. CYL HD
12321-MZ5-305
COVER A, CYL HD
12340-MZ5-000
GASKET, CYL HD CVR
12391-MT4-000
23-18
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$73.92
09
001
$12.02
10
001
$166.66
11
008
$3.09
12
004
$7.04
12
001
$181.64
12
004
$135.39
13
002
$22.42
14
Description
PLUG, HEX. (6MM)
12392-MJ0-000
CLIP B, TUBE
16106-KW7-900
BOLT, CYL HD CVR
90002-MZ5-000
BOLT, SPECIAL (6X34)
90003-MZ5-000
BOLT (6X34.5)
90003-MZ5-920
RUBBER, MOUNTING
90543-MZ5-920
BOLT, FLANGE (6X25)
90123-VA4-800
RUBBER, SETTING
90543-MV9-670
Q’ty
Price
008
$3.55
001
$2.38
008
$8.53
008
$11.09
008
$6.09
008
$4.42
006
$1.74
008
$3.89
Appendix A: Part Numbers
Evaporation Canister
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
Description
CLIP, TUBE
15772-MB3-000
CLIP, BREATHER TUBE
15772-500-010 (replaces 15772-500-013)
JOINT, FUEL TUBE
16958-MB0-000
JOINT, VACUUM TUBE
17201-MG9-000
TUBE, OPEN AIR
17290-MZ5-740
VALVE ASSY.
17300-MZ5-740
TUBE
17301-MZ5-740
RUBBER, SETTING
17305-MJ4-771
CANISTER
17410-MR1-682
TUBE
17411-MZ5-740
TUBE
17412-MZ5-740
TUBE
17413-MZ5-740
TUBE
17414-MZ5-740
PIPE
17415-MZ5-740
TUBE
17416-MZ5-740
VALVE
17440-MZ5-740
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
003
$1.62
17
004
$3.09
18
001
$8.29
19
001
$12.51
20
001
$13.66
21
001
$192.58
22
001
$14.18
23
001
$8.11
24
001
$241.47
25
001
$14.80
26
001
$6.98
27
001
$14.46
28
001
$16.58
29
001
$81.68
30
001
$17.44
31
001
$60.45
Description
RUBBER
17451-ME5-760
TUBE
17525-MZ5-740
TUBE
18630-MZ5-740
JOINT B, WASHER TUBE
38562-663-920
COLLAR (6.3X13)
50324-425-010
RUBBER
84703-MN5-000
CLAMP, TUBE (12.5MM)
90661-GHB-610
CLIP, TUBE (B7)
95002-02070
CLIP, TUBE (B8)
95002-02080
CLIP, TUBE (B12)
95002-02120
BULK HOSE (3.5X1000)
95005-35001-20M
BULK HOSE (3.5X1000)
95005-35001-20M
BULK HOSE (3.5X1000)
95005-35001-20M
BULK HOSE (4.5X1000)
95005-45001-20M
BOLT, FLANGE (6X25)
95701-06025-07
Q’ty
Price
001
$9.24
001
$8.38
001
$12.94
001
$4.57
002
$3.96
002
$3.51
001
$1.16
008
$0.82
004
$0.82
005
$0.90
001
$5.42
001
$5.42
001
$5.42
001
$19.42
002
$0.75
23-19
Appendix A: Part Numbers
Frame
#
01
02
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Description
COLR, FR. WHEEL SIDE
44311-045-670
FRAME
50100-MZ5-600 (replaces 50100-MZ5-000)
FRAME
50100-MZ5-740
PLATE, R. FR.
50136-MZ5-000
PLATE, L. FR.
50137-MZ5-000
PLATE, R. RR.
50138-MZ5-000
PLATE, L. RR.
50139-MZ5-000
PLATE, RR. ENG HGR
50141-MZ5-000
COLLAR, ENG HGR
50350-MZ5-000
COVER, R. FR. SIDE
50650-MZ5-000
HOLDER ASSY., HELMET
50710-GB4-007
HOLDER ASSY., HELMET
50710-086-007
COVER, L. FR. SIDE
50750-MZ5-000
NUT, ACCUMULATOR
57071-SB0-800
BOLT, UBS (8X60)
90029-MG8-000
BOLT, FLG (10X105)
90101-MZ5-000
23-20
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$3.76
16
001
$1,794.77
17
001
$1,794.77
18
001
$21.64
19
001
$21.64
20
001
$29.60
21
001
$29.60
22
001
$12.00
23
002
$9.15
24
001
$47.84
25
001
$51.71
27
001
$45.65
28
001
$72.97
29
001
$4.04
30
002
$3.89
31
002
$7.69
32
Description
BOLT, FLANGE (8X25)
90103-MZ5-000
BOLT, FLG (12X265)
90105-MM8-880
BOLT
90107-MJ1-000
BOLT
90116-MZ5-000
SCREW, TRUSS
90133-SD4-000
CAP, R. LOCK NUT
90302-ME5-000
WASHER, FLAT (10MM)
94102-10700 (replaces 90503-MZ5-000)
CLIP (15)
90690-GHB-601
CLIP, CABLE (8MM)
90690-GHB-631
CLIP, CABLE (25MM)
90690-GHB-671
NUT, FLANGE (8MM)
94050-08070
NUT, FLANGE (10MM)
90303-428-900 (replaces 94050-10070)
NUT, FLANGE (12MM)
94050-12000
BOLT, FLANGE (10X35)
95701-10035-07
BOLT, FLANGE (10X45)
95701-10045-02
BOLT, FLANGE (10X85)
95701-10085-00
Q’ty
Price
008
$3.09
001
$17.84
002
$3.51
001
$22.76
002
$1.05
002
$13.84
002
$0.57
001
$1.69
003
$1.60
004
$1.60
002
$0.33
002
$2.62
001
$0.76
002
$1.35
002
$2.45
001
$1.95
Appendix A: Part Numbers
Front Brake Caliper
#
01
02
03
04
05
06
07
08
09
Description
SEAL SET, PISTON
06451-GE2-405
PAD SET, FR.
06455-MS9-405
SCREW, BLEEDER
43352-568-003
CAP, BLEEDER
43353-461-771
CLPR, L. FR. BRAKE
45100-MZ5-006
PISTON
45107-MN5-006
SPRING, PAD
45108-ML7-922
BRACKET, L. FR.
45110-MZ6-006
RETAINER
45112-MS9-611
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
002
$8.67
10
001
$40.00
11
001
$5.07
12
001
$3.96
13
001
$412.36
14
002
$28.75
15
001
$4.85
16
001
$91.77
17
001
$4.29
Description
BOLT A, PIN
45131-ML7-921
PIN, BOLT
45131-166-016
BUSH, PIN
45132-166-016
BOOT B
45133-MA3-006
CALIPER SUB-ASSY.
45150-MZ5-305
PLUG, PIN
45203-MG3-016
PIN, HANGER
45215-ML7-922
BOLT (8X32)
90101-MZ8-000
Q’ty
Price
001
$11.71
001
$6.00
001
$4.29
001
$4.29
001
$342.69
001
$4.00
001
$8.11
002
$5.31
23-21
Appendix A: Part Numbers
Front Brake Master Cylinder
#
01
02
03
04
04
05
06
07
08
09
10
Description
SWITCH, FR. STOP
35340-MM5-600
HOSE, FR. BRAKE
45126-MZ5-003
BOOT
45504-410-003
SPRING
45506-KA3-731
SPRING
45506-KA3-831
M/CYL SUB-ASSY, FR.
45510-MZ8-305
PROTECTOR
45512-MA6-006
CAP, MASTER CYLINDER
45513-MR1-016 (replaces 45513-MR1-006)
HOLDER
45517-MR1-671
PLATE, DIAPHRAGM
45518-MM5-006
DIAPHRAGM
45520-MM5-006
23-22
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
001
$15.44
11
001
$38.51
001
$55.67
12
001
$14.31
001
$9.24
13
001
$7.15
001
$4.15
14
002
$5.29
001
$3.71
15
001
$1.58
001
$241.36
16
004
$2.18
001
$3.38
17
001
$2.07
001
$23.25
18
002
$0.32
001
$19.49
19
001
$0.70
001
$8.09
20
MASTER CYLINDER SET
45530-MN9-305
LEVER, R. HANDLEBAR
53175-MR1-671
BOLT, R.
90114-MA5-671
BOLT, OIL (10X22)
90145-MS9-612 (replaces 90145-MS9-611)
NUT, CAP (6MM)
90201-415-000
WASHER, OIL BOLT
90545-300-000
CIRCLIP
90651-MA5-671
SCREW, FLAT (4X12)
93600-04012-1A
SCREW-WASHER (4X12)
93893-04012-07 (replaces 93893-04012-17)
BOLT, SOCKET (6X22)
96600-06022-10 (replaces 96700-06022-10)
002
$1.20
001
$11.47
Appendix A: Part Numbers
Front Cylinder Head
#
01
01
02
03
04
05
06
07
08
09
10
11
Description
CYLINDER HEAD, FR.
12010-MZ5-315
CYLINDER HEAD, FR.
12010-MZ5-316
GUIDE, VALVE (OS)
12204-MT4-305
GASKET, CYL HD
12251-MT4-014 (replaces 12251-MT4-004)
FIN A, CYLINDER HEAD
12350-MZ5-000
RUBBER, SEAT
12352-MZ5-300
FIN B, CYLINDER HEAD
12360-MZ5-000
INSULATOR, CARB
16211-MZ5-000
JOINT, BOOSTER
16214-MB0-000
BAND A, INSULATOR
16219-MM4-000
BAND B, INSULATOR
16220-MM4-000
BOLT, FLANGE (9X93)
90007-ML7-920
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$834.03
12
001
$834.03
13
008
$16.15
14
001
$46.67
15
001
$113.93
16
002
$2.44
17
001
$73.62
18
002
$38.78
19
001
$3.51
20
002
$8.07
21
002
$8.07
22
008
$7.85
Description
BOLT, SOCKET (6X28)
90012-MZ5-000
BOLT, FLG (6X45.5)
90017-MA6-000
BOLT, FLG (6X39.5)
90019-MA6-000
BOLT, STUD (6X28)
90035-MZ5-000
WASHER (9MM)
90445-MM4-000
WASHER (5MM)
90452-323-000
SCREW, PAN (5X8)
93500-05008-0A
PIN, DOWEL (8X14)
94301-08140
PIN, DOWEL (12X20)
94301-12200
BOLT, FLANGE (6X30)
95701-06030-00
SPARK PLUG (CR9EH9)
98059-59916 (replaces 98059-58926,
98059-59910)
Q’ty
Price
006
$1.60
008
$2.62
008
$2.25
004
$3.87
008
$2.82
002
$0.85
001
$0.45
008
$1.00
002
$1.17
002
$0.83
002
$8.14
23-23
Appendix A: Part Numbers
Front Fender
#
01
02
03
03
Description
CLAMP B, BRAKE HOSE
45158-MZ5-000
GUIDE, FR.
45451-473-000
FENDER, FR. *NH1*
61100-MZ5-000ZC
FENDER, FR. *Y124P*
61100-MZ5-000ZD
23-24
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$16.56
03
001
$5.15
04
001
$154.96
05
001
$154.96
Description
FENDER, FR. *R201*
61100-MZ5-000ZE
PLATE, FR. FENDER
61103-MZ5-000
BOLT (6X25)
90080-MG8-000
Q’ty
Price
001
$154.96
001
$11.33
004
$3.07
Appendix A: Part Numbers
Front Fork
#
Description
Q’ty
Price
#
01
FORK ASSY., R. FR.
51400-MZ5-912 (replaces 51400-MZ5-671)
SPRING, FR. FORK
51401-MZ5-671
COLLAR, SPRING
51402-KV3-701
SEAT, SPRING
51403-KF0-003
PIPE, FR. FORK
51410-MZ5-671
RING, BACK-UP
51412-MB4-003
BUSH, GUIDE
51414-KCR-003 (replaces 51414-MN5-003)
BUSH, SLIDER
51415-KCR-003 (replaces 51415-MM8-003)
SPRING, FR. REBOUND
51416-KF0-003
CASE, R. (LOWER)
51420-MZ5-912 (replaces 51420-MZ5-671)
PIECE, OIL LOCK
51432-MV9-003
RING, PISTON
51437-MM5-003
PIPE, SEAT
51440-MZ5-671
001
Call For Price
14
002
$66.38
15
002
$18.24
16
002
$3.76
17
002
$246.51
18
002
$7.33
18
002
$10.64
19
002
$8.78
20
002
$5.22
21
001
$295.28
22
002
$18.85
23
002
$4.22
24
002
$48.46
25
02
03
04
05
06
07
08
09
10
11
12
13
Downloaded from www.Manualslib.com manuals search engine
Description
RING
51447-KA4-711
BOLT, FR. FORK
51454-MM9-671
SEAL SET, FR. FORK
51490-MN8-305
FORK ASSY., L. FR.
51500-MZ5-912 (replaces 51500-MZ5-671)
CASE, L. (LOWER)
51520-MZ5-671
CASE, L. (LOWER)
51520-MZ5-912
BOLT, FLANGE (8X45)
90109-MR7-000
BOLT, SOCKET (8MM)
90116-KV3-701
GASKET, FR.
90543-273-000
WASHER (8MM)
90544-283-000
DUST SEAL
91254-MM8-003
O-RING (21.7X3.5)
91356-KF0-003
BOLT, HEX. (6X8)
92101-06008-0A
Q’ty
Price
002
$3.55
002
$44.11
002
$25.16
001
Call For Price
001
$218.67
001
$218.67
004
$3.89
002
$3.07
002
$1.60
002
$2.05
002
$13.55
002
$2.93
002
$0.63
23-25
Appendix A: Part Numbers
Front Wheel
#
Description
Q’ty
Price
#
Description
Q’ty
Price
01
WEIGHT (10G)
42704-MB0-000
WEIGHT (20G)
42705-MB0-000
WEIGHT, BALANCE (20)
42705-MCF-D60
WEIGHT, BALANCE (30)
42706-MCF-D60 (replaces 42706-MB0-000)
VALVE, RIM
42753-ML7-004
AXLE, FR. WHEEL
44301-MZ5-000
COLR, FR. WHEEL SIDE
44311-MM8-000
COLLAR, FR.
44620-MT3-000
WHEEL SUB-ASSY., FR.
44650-MZ5-335 (replaces 44650-MZ5-305,
44650-MZ5-315, 44650-MZ5-325)
RETAINER, GEAR BOX
44680-ML7-000
TIRE (120/80-17)
44711-MZ5-024 (replaces 44710-MZ5-004,
44711-MZ5-004, 44711-MZ5-014)
AR
$9.07
08
001
$138.46
AR
$10.36
10
001
$73.35
AR
$10.36
11
001
$22.22
AR
$10.36
12
002
$2.25
001
$9.67
13
001
$273.18
001
$47.29
14
006
$4.87
001
$13.69
15
001
$7.96
001
$13.07
16
002
$24.45
001
$526.65
17
001
$6.93
001
$3.76
18
TIRE (120/80-17)
44711-MZ5-024
BOX ASSY.
44800-ML7-691
GEAR, SPEEDOMETER
44806-ML7-691
WASHER
44809-ML7-003
DISK, FR. BRAKE
45251-MS9-750
BOLT, DISK (8X24)
90105-MV9-003
BOLT, FR. AXLE
90305-ML7-000
BEARING (6004UU)
91054-MAM-003 (replaces 91054-MN8-741)
DUST SEAL (28X42X8)
91257-MAY-003 (replaces 91257-KA3-711,
91257-KA3-712)
DUST SEAL (45X55X5)
91258-ML7-003 (replaces 91258-ML7-004)
001
$6.56
001
$138.46
01
01
01
02
03
04
05
06
07
08
23-26
Downloaded from www.Manualslib.com manuals search engine
Appendix A: Part Numbers
Fuel Tank
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Description
CLIP, OIL DRAIN TUBE
15771-551-000
CLIP, BREATHER TUBE
15772-500-010 (replaces 15772-500-013)
T-JOINT
16180-195-731
PETCOCK ASSY.
16950-MZ5-672 (replaces 16950-MZ5-670,
16950-MZ5-671)
SCREEN SET
16952-KAZ-000
TUBE B, FUEL
16952-MZ5-000
TUBE A, FUEL
16956-MZ5-000
O-RING
16958-KM9-005
LEVER, PETCOCK
16963-MZ5-000
MARK, FUEL
16965-MZ5-300
PETCOCK ASSY., AUTO
16970-MZ5-003 (replaces 16970-MZ5-000)
CLIP, BREATHER TUBE
17316-611-000
TANK, FUEL (TYPE5)
17520-MZ5-A40ZA
TUBE
17525-MZ5-000
CUSHION, FR.
17611-KE5-000
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$5.73
16
002
$3.20
17
001
$10.18
18
001
$79.82
19
001
$20.44
001
$1.33
001
$10.40
001
$2.95
001
$7.40
001
$6.09
001
$155.16
001
$5.55
001
$590.71
001
$13.18
002
$4.15
20
21
22
23
24
25
26
27
28
29
Description
RUB, RR. FUEL TANK
17613-MR7-000
CAP, FUEL FILLER
17620-KR3-751
PROTECTOR, HOSE
64233-MR7-300
SCREW, OVAL (5X12)
90111-MZ5-000
BOLT
90128-KL4-000
COLLAR
90502-MZ5-000
SCREW-WASHER (4X16)
93892-04016-00 (replaces 93892-04016-10)
SCREW-WASHER (4X20)
93892-04020-10
CLIP, TUBE (B7)
95002-02070
CLIP, TUBE (B8)
95002-02080
BULK HOSE (3.5X1000)
95005-35001-20M
BULK HOSE (4.5X1000)
95005-45001-20M
BOLT, FLANGE (6X12)
96001-06012-00
COVER SET, PETCOCK
16953-MN5-023 (replaces 16953-MN5-003)
Q’ty
Price
001
$12.55
001
$66.87
002
$4.04
001
$2.82
001
$7.24
001
$3.62
002
$0.33
002
$1.35
002
$0.85
003
$0.85
001
$5.62
001
$20.17
002
$0.82
001
$42.18
23-27
Appendix A: Part Numbers
Gasket Kit A
#
00
01
02
03
04
05
Description
GASKET KIT A
06111-MZ5-010 (replaces 06111-MZ5-000)
GSKT, TENSIONER HOLE
12194-HC5-740
GSKT, TENSIONER HOLE
12194-KW3-880
SEAL, EX. VALVE STEM
12208-ML0-721
SEAL, VALVE STEM
12209-MZ5-003
GASKET, BTHR CVR
12231-MZ5-920 (replaces 12231-MZ5-000)
Q’ty
Price
#
001
$171.63
06
001
$1.78
07
001
$1.67
08
008
$8.07
09
008
$7.69
10
001
$12.02
11
Q’ty
Price
#
001
$58.31
12
001
$10.31
13
001
$4.57
14
001
$18.08
15
001
$9.47
16
001
$12.98
17
001
$5.20
18
001
$3.53
19
002
$2.62
006
$2.25
002
$3.05
001
$3.11
Description
GASKET, CYL HD
12251-MT4-014 (replaces 12251-MT4-004)
GASKET, CYL HD CVR
12391-MT4-000
GASKET, EX. PIPE
18291-MN4-920
WASHER (6.5MM)
90463-ML7-000
RUBBER, SETTING
90543-MV9-670
O-RING (21.2X2.4)
91331-PC9-003
Q’ty
Price
002
$46.67
002
$22.42
004
$4.22
002
$2.25
008
$3.89
002
$1.95
Q’ty
Price
002
$1.42
001
$1.47
001
$2.07
002
$1.87
001
$2.93
002
$2.93
001
$2.35
001
$1.45
001
$1.95
001
$1.87
001
$1.95
001
$0.50
Gasket Kit B
#
00
01
02
03
04
05
06
07
08
09
10
11
Description
GASKET KIT B
06112-MZ5-000
GASKET, OIL PAN
11315-MY7-000
GASKET, L.
11343-MZ5-000
GASKET, R.
11394-MY7-000
GASKET, SHIFT COVER
11632-MY7-000
GASKET
11636-MY7-000
GASKET, OIL STRAINER
15154-ML7-000
GASKET
19226-ML7-000
WASHER (10MM)
90403-MG7-000
WASHER (6.5MM)
90463-ML7-000
GSKT, CONNECTING CAP
91301-MB0-000
O-RING (48.1X3.6)
91301-ML7-003
23-28
Downloaded from www.Manualslib.com manuals search engine
20
21
22
23
Description
O-RING (18.3X2.3)
91301-147-023
O-RING (22X3.0)
91307-425-003 (replaces 91301-250-000)
O-RING (32.95X2.62)
91302-MB0-013
O-RING (6X2)
91307-ML7-004
O-RING
91309-MA6-000
O-RING (14.6X3.7)
91309-MB0-003
O-RING (14.8X2.2)
91313-MG7-004 (replaces 91313-MB0-003)
O-RING (7.7X2.3)
91301-PC9-003 (replaces 91308-283-000,
91313-393-003)
SEAL, WATER PIPE
91315-MB0-013
O-RING (8.4X2.4)
91316-MJ8-003
O-RING (21.2X2.4)
91331-PC9-003
WASHER, DRAIN (12MM)
94109-12000
Appendix A: Part Numbers
Gearshift Drum
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
Description
FORK, R. GEARSHIFT
24211-MZ5-000
FORK
24212-ML7-000
FORK, L. GEARSHIFT
24213-ML7-000
SHAFT
24261-ML7-000
DRUM, GEARSHIFT
24310-MZ5-000
CENTER
24312-KT7-752
PIN, SHIFTER
24315-HA0-000
SHIFTER, DRUM
24321-KT8-030
COLLAR, SHIFTER
24322-MM4-000
PAWL A, RATCHET
24324-KA3-711
PAWL B, RATCHET
24325-KA3-711
PLUNGER, PAWL
24326-KBH-901
PLATE, GUIDE
24328-MR7-010
SPRING, PAWL PLUNGER
24329-KA3-740
COLLAR
24329-KT7-000
STOPPER, DRUM
24430-MR7-000
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
001
$52.64
17
001
$6.36
001
$58.36
18
001
$3.40
001
$66.61
19
001
$79.90
001
$35.95
20
001
$5.71
001
$132.91
21
001
$3.13
001
$26.78
22
001
$9.67
001
$9.58
23
001
$14.33
001
$39.36
24
001
$3.15
001
$4.00
25
002
$3.76
001
$10.02
26
001
$2.18
001
$10.02
27
001
$11.40
002
$4.56
28
002
$3.51
001
$13.07
29
001
$1.02
002
$2.07
30
001
$0.57
001
$3.89
31
002
$0.97
001
$18.04
32
COLLAR, DRUM STOPPER
24434-MR7-000
SPRING
24435-KBV-000
SPINDLE, GEARSHIFT
24610-MR7-000
SPRING
24651-MR7-000
PIN
24652-035-000
PLATE
24655-MR7-000
SWITCH, NEUTRAL
35600-KE8-003 (replaces 35600-KE8-010)
WASHER (14MM)
90451-155-000
WASHER (12MM)
90485-MR7-000
WASHER, OIL BOLT
90545-300-000
BEARING (16005)
91008-374-003
PIN, DOWEL (8X31.5)
91104-KT7-000
CIRCLIP (12MM)
94510-12000
CIRCLIP (14MM)
94510-14000
BOLT, FLANGE (6X45)
95701-06045-07 (replaces 95701-06045-00)
ROLLER (4X8)
96220-40080
001
$0.33
23-29
Appendix A: Part Numbers
Handle Switch Cables
#
01
02
03
04
05
06
07
08
09
12
13
14
15
Description
CABLE A, THROTTLE
17910-MZ5-910 (replaces 17910-MZ5-000,
17910-MZ5-770)
CABLE B, THROTTLE
17920-MZ5-910 (replaces 17920-MZ5-000,
17920-MZ5-770)
ADAPTER
17962-MR1-000
CABLE, CLUTCH
22870-MZ5-770 (replaces 22870-MZ5-000)
SWITCH, STARTER STOP
35013-MZ8-U10 (replaces 35130-MZ5-671)
SWITCH, TURN SIGNAL
35200-MZ5-671
SWITCH, FR. LEVER
35330-413-003
HOLDER
45517-MR1-671
GRIP ASSY., R.
53145-MM8-000
GRIP, L. HANDLE
53166-MM8-000
CAP, GRIP END
53167-MM8-000
BRACKET, HANDLEBAR
53172-MR1-000
LEVER, L. HANDLEBAR
53178-KV0-000
23-30
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
001
$25.63
16
001
$5.45
001
$56.29
001
$25.63
BOLT, CABLE ADJ.
53192-268-000
MIRROR ASSY., R.
88110-MZ5-003
MIRROR ASSY., L.
88120-MZ5-003
BOLT, L.
90113-438-000
NUT, CAP (6MM)
90201-415-000
NUT, FIXING
90321-MA6-750
BAND, WIRE HARNESS
90651-MA6-720
BAND, CABLE (120MM)
90674-WA8-003
SCREW, PAN (5X20)
93500-05020-0B
SCREW, PAN (5X22)
93500-05022-0B
SCREW, PAN (5X25)
93500-05025-0B
SCREW, PAN (5X32)
93500-05032-0B
BOLT, SOCKET (6X22)
96600-06022-10 (replaces 96700-06022-10)
001
$56.29
001
$5.96
001
$1.58
001
$7.91
004
$2.78
004
$1.80
001
$0.67
001
$0.70
001
$0.63
001
$0.91
002
$1.20
17
18
001
$14.64
19
001
$26.47
20
001
$64.44
21
001
$102.59
22
001
$16.64
22
001
$19.49
23
001
$30.80
24
001
$20.11
25
002
$7.09
26
001
$25.53
27
001
$13.96
Appendix A: Part Numbers
Handlebar
#
01
02
03
04
05
06
Description
HANDLEBAR
53101-MZ5-000
HLDR, HANDLE (UPPER)
53131-MM8-000
HLDR, HANDLE (LOWER)
53231-MM8-000
BRIDGE, FORK TOP
53300-MZ5-000
EMBLEM, WING MARK
86150-MR1-760
BOLT, SOCKET (8X30)
90112-KM4-000
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$142.97
07
002
$14.58
08
002
$25.84
09
001
$217.98
10
001
$5.91
11
002
$2.98
12
Description
BOLT, SOCKET (8X32)
90154-ME9-000
NUT, STEERING STEM
90304-415-000
NUT, FLANGE (8MM)
90309-428-731
WASHER
90503-283-000
WASHER
90535-KB9-000
CAP (8MM)
91455-MB0-010
Q’ty
Price
004
$4.47
001
$15.02
002
$2.98
001
$3.51
002
$4.67
004
$2.95
23-31
Appendix A: Part Numbers
Headlight
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Description
HDLT (12V 60/55W)
33100-MK7-671
RIM, HEADLIGHT
33101-MK7-671
STAY
33102-MK7-671
SCREW, BEAM ADJ.
33103-MK7-671
SCREW, SPECIAL
33104-MK7-671
NUT, SPECIAL
33105-MK7-671
SCREW, SPECIAL
33106-MK7-671
SPRING
33107-MK7-671
SPRING, SETTING
33108-MK7-671
NUT, BEAM ADJUSTING
33117-415-003
HEADLIGHT UNIT
33120-MK7-671
NUT, UNIT HOLDER
33128-471-003
CVR, ADJUSTING SCREW
33136-111-671
COVER, RUBBER
33180-MJ0-010
23-32
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$182.85
15
001
$47.61
001
$8.07
002
$3.22
002
$2.33
002
$3.33
001
$2.33
002
$2.98
002
$2.33
002
$1.60
001
$78.44
001
$1.20
002
$1.44
001
$11.67
16
17
18
19
20
21
22
23
24
25
26
27
Description
BULB (12V60/55W)
34901-MC7-601AH (replaces 34901-MC7601)
CASE, HEADLIGHT
61301-MN0-003
COLLAR
61304-292-000
STAY, HEADLIGHT
61305-MZ5-000
RUBBER
61315-MZ5-000
COLR, HEADLIGHT STAY
61316-MK7-000
BOLT, CAP (6MM)
90132-MK7-000
NUT, CAP (6MM)
90201-425-700
NUT, U (6MM)
90301-MG3-000
SCREW, PAN (5X16)
93500-05016-0B
SCREW, TAP (4X10)
93901-34210
WASHER, SPRING (5MM)
94111-05000
CLIP (4X90)
94591-49000
Q’ty
Price
001
$7.65
001
$73.70
002
$2.73
001
$49.05
004
$2.07
002
$2.33
002
$2.25
002
$3.33
002
$5.40
002
$0.68
002
$0.47
002
$0.50
002
$2.38
Appendix A: Part Numbers
Mark VF750C (1994-1997)
#
01
01
Description
MARK A (TYPE1)
87121-MZ5-300ZA
MARK A (TYPE2)
87121-MZ5-300ZB
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
002
$34.98
01
002
$34.98
Description
MARK A (TYPE3)
87121-MZ5-300ZC
Q’ty
Price
002
$34.98
23-33
Appendix A: Part Numbers
Mark VF750C (1998-2003)
#
01
01
Description
MARK (TYPE5)
87121-MZ5-A00ZA
MARK (TYPE6)
87121-MZ5-A40ZA
23-34
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
002
$24.02
01
002
$20.96
Description
MARK (TYPE7)
87121-MZ5-M10ZA
Q’ty
Price
002
$22.60
Appendix A: Part Numbers
Mark VF750CD (1996-1997)
#
01
01
02
02
02
02
03
03
03
Description
MARK (TYPE10)
64221-MZ5-870ZA
MARK (TYPE9)
64221-MZ5-870ZB
STRIPE, RR. (TYPE1)
80111-MZ5-950ZA
STRIPE, RR. (TYPE2)
80111-MZ5-950ZB
STRIPE, RR. (TYPE3)
80111-MZ5-A10ZA
STRIPE, RR. (TYPE4)
80111-MZ5-A10ZB
MARK (TYPE1)
87121-MZ5-950ZA
MARK (TYPE2)
87121-MZ5-950ZB
MARK (TYPE3)
87121-MZ5-A10ZA
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$20.29
03
001
$20.29
04
001
04
001
$96.40
04
001
$79.53
04
001
$79.53
05
002
$26.47
05
002
$26.47
05
002
$23.38
05
Description
MARK (TYPE4)
87121-MZ5-A10ZB
STRIPE, R. (TYPE1)
87123-MZ5-950ZA
STRIPE, R. (TYPE2)
87123-MZ5-950ZB
STRIPE, R. (TYPE3)
87123-MZ5-A10ZA
STRIPE, R. (TYPE4)
87123-MZ5-A10ZB
STRIPE, L. (TYPE1)
87124-MZ5-950ZA
STRIPE, L. (TYPE2)
87124-MZ5-950ZB
STRIPE, L. (TYPE3)
87124-MZ5-A10ZA
STRIPE, L. (TYPE4)
87124-MZ5-A10ZB
Q’ty
Price
002
$21.73
001
$93.75
001
$93.75
001
$82.16
001
$76.33
001
$93.75
001
$93.75
001
$82.16
001
$76.33
23-35
Appendix A: Part Numbers
Mark VF750C2 (1998-2000)
#
98
98
Description
STRIPE, RR. (TYPE5)
80111-MZ5-A30ZA
STRIPE, RR. (TYPE6)
80111-MZ5-A30ZB
23-36
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$70.87
99
001
00
Description
STRIPE, RR. (TYPE7)
80111-MZ5-A50ZA
STRIPE, RR. (TYPE8)
80111-MZ5-A70ZA
Q’ty
Price
001
$71.89
001
$73.13
Appendix A: Part Numbers
Muffler
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
Description
MUFFLER, R. EX.
18100-MZ5-003
MUFFLER, L. EX.
18200-MZ5-003
GASKET, EX. PIPE
18291-MN4-920
RUBBER
18293-ME9-000
PIPE, R. FR. EX.
18320-MZ5-981 (replaces 18320-MZ5-003)
CVR, R. FR. EX. PIPE
18340-MZ5-003
JOINT, R. RR. CYL HD
18350-MZ5-003
BAND, R. EX. PIPE
18373-ML4-003
BAND, EX. PIPE
18373-KAB-000 (replaces 18373-MN1-670)
BAND, L. EX. PIPE
18374-ML4-003
BAND, L. EX. PIPE
18374-MN1-670
BAND, EX. PIPE COVER
18376-MR1-000
CVR, R. RR. EX. PIPE
18380-MZ5-003
GASKET, MUFFLER
18391-MB0-891
GASKET, MUFFLER
18391-ML8-000
PIPE, L. FR. EX.
18420-MZ5-981 (replaces 18420-MZ5-003)
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$699.35
17
001
$699.35
18
004
$4.22
19
002
$1.95
20
001
$114.12
21
001
$105.55
22
001
$87.87
23
001
$21.73
24
001
$15.44
25
001
$12.42
26
001
$10.95
27
006
$6.45
28
001
$96.68
29
002
$13.58
30
002
$13.73
31
001
$114.12
32
Description
RUB, MUFFLER SETTING
18421-MB0-000
COLLAR
18422-MB0-000
CVR, L. FR. EX. PIPE
18440-MZ5-003
JOINT, L. RR. CYL HD
18450-MZ5-003
CVR, L. RR. EX. PIPE
18480-MZ5-003
RUBBER, STOPPER
50501-KT7-810
RUBBER, BATTERY BOX
83618-GF0-751
BOLT (8X50)
90109-MZ5-000
BOLT, FLANGE (8X35)
90161-ML7-000
NUT, SPECIAL (6MM)
90304-HB3-771
NUT, FLANGE (6MM)
94050-06000
NUT, FLANGE (8MM)
94050-08070
WASHER, PLAIN (8MM)
94103-08000
WASHER, PLAIN (8MM)
94103-08700
WASHER, SPRING (6MM)
94111-06800
BOLT, FLANGE (6X20)
95701-06020-00
Q’ty
Price
002
$4.98
002
$5.22
001
$106.57
001
$87.87
001
$99.99
002
$3.09
001
$3.05
002
$5.11
004
$2.84
004
$4.76
004
$0.72
002
$0.33
002
$0.29
002
$0.45
004
$0.50
006
$0.60
23-37
Appendix A: Part Numbers
Oil Pump
#
Description
Q’ty
Price
#
01
PAN, OIL
11211-MZ5-000
GASKET, OIL PAN
11315-MY7-000
FILTER SET, OIL
15010-MCE-H51 (replaces 15010-MW0-000)
PUMP ASSY., OIL
15100-MZ5-003
SPROCKET
15134-MZ5-000
CHAIN, OIL PUMP
15140-ML7-003
PIPE, OIL STRAINER
15151-ML7-000
STRAINER, OIL
15153-ML7-690
GASKET, OIL STRAINER
15154-ML7-000
VALVE ASSY., RELIEF
15220-MZ5-000
FILTER, OIL
15410-MFJ-D01 (replaces 15410-MM9-013)
PIPE A, OIL
15511-MZ5-000
PIPE B, OIL
15512-ML7-000
BOSS, OIL FILTER
90019-MB0-000
001
$151.28
15
001
$10.31
16
001
$21.67
17
001
Call For Price
18
001
$27.53
19
001
$29.55
20
001
$26.24
21
001
$14.87
22
001
$5.20
23
001
$26.78
001
$11.98
001
$38.51
001
$14.04
001
$6.80
02
03
04
05
06
07
08
09
10
11
12
13
14
23-38
Downloaded from www.Manualslib.com manuals search engine
24
25
26
27
Description
BOLT-WASHER (6X12)
90021-MM5-000
NUT, U (6MM)
90301-473-003
O-RING (6X2)
91307-ML7-004
O-RING (14.6X3.7)
91309-MB0-003
O-RING (14.8X2.2)
91313-MG7-004 (replaces 91313-MB0-003)
O-RING (21.2X2.4)
91331-PC9-003
BOLT, DRAIN (12MM)
92800-12000
WASHER, DRAIN (12MM)
94109-12000
PIN, COTTER (2.0X35)
94201-20350 (replaces 94201-20250,
94201-20280, 94201-20320)
PIN, DOWEL (8X14)
94301-08140
BOLT, FLANGE (6X14)
95701-06014-00
BOLT, FLANGE (6X28)
95701-06028-00
BOLT, FLANGE (6X40)
95701-06040-00
Q’ty
Price
001
$4.00
001
$2.15
002
$1.87
002
$2.93
001
$2.35
001
$1.95
001
$1.73
001
$0.50
001
$0.65
002
$1.00
002
$0.63
012
$0.85
003
$0.85
Appendix A: Part Numbers
Pedal
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
Description
PEDAL, GEARSHIFT
24705-MZ5-700 (replaces 24705-MZ5-000)
RUBBER, DUST SEAL
24706-MK3-770
ARM, GEARSHIFT
24706-MZ5-000
COVER, DUST
24724-422-000
RUB, GEARSHIFT PEDAL
24781-KR3-770
SWITCH, RR. STOP
35350-MZ5-003
SPRING, STOP SWITCH
35357-MF8-000
ROD, RR. BRAKE
43451-MZ5-000
PIN
43456-MK7-000
PEDAL, BRAKE
46500-MZ5-000
ARM, RR.
46501-MZ5-000
SPRING SET
46513-KY7-000
TUBE
46515-KY7-000
COLLAR, RR.
46515-MM8-000
ARM, RR.
46530-MZ5-000
ROD, RR.
46540-MZ5-000
BOLT, TIE ROD
90065-MN4-000
BOLT, CHANGE PIVOT
90115-KAF-000
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$54.18
19
002
$3.51
20
001
$35.67
21
002
$5.67
22
001
$2.65
23
001
$12.13
24
001
$3.71
25
001
$24.84
26
002
$6.45
27
001
$62.88
28
001
$29.73
29
001
$7.96
30
001
$3.86
31
001
$8.89
32
001
$10.51
33
001
$44.51
34
001
$3.89
35
001
$14.96
Description
BOLT, SOCKET (10X52)
90153-MW0-000
NUT
90201-700-000
WASHER (10.3MM)
90527-230-000
DUST SEAL (17X23X3)
91206-968-003
BOLT, HEX. (6X18)
92101-06018-0A
NUT, HEX. (6MM)
94001-06020-0S
NUT, HEX. (6MM)
94002-06000-0S
NUT, FLANGE (8MM)
94050-08000
NUT, FLANGE (10MM)
94050-10000
PIN, SPLIT (2.0X12)
94201-20120
PIN, SPLIT (2.0X15)
94201-20150
SPRING A, BRAKE ROD
95014-73100
JOINT, BRAKE ARM
95015-32001
NUT B
95015-42000
PIN, JOINT
95015-53000
BOLT, FLANGE (8X25)
95701-08025-00
BOLT, FLANGE (6X20)
96001-06020-00
Q’ty
Price
001
$5.04
001
$0.55
001
$1.44
002
$2.98
001
$0.62
001
$0.63
001
$1.60
001
$0.67
001
$0.93
001
$0.47
002
$0.35
001
$0.53
001
$0.49
001
$1.40
001
$2.42
001
$1.00
001
$0.83
23-39
Appendix A: Part Numbers
Pulse Generator
#
01
02
03
04
05
06
07
08
09
Description
GEAR (21T/83T)
28101-ML7-920
PIN (10X36.5)
28102-ML7-000
GEAR (48T)
28110-MB0-010
FLANGE
28115-MZ5-000
CLUTCH, STARTER
28120-MZ5-000
SPRING
28125-MT4-000
CAP
28126-415-000
GEN, IGNITION PULSE
30300-MZ5-003 (replaces 30300-MZ5-000)
BOLT, FLANGE (12X45)
90023-MA6-000
23-40
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$76.41
10
001
$6.56
11
001
$109.19
12
001
$73.01
13
001
$152.21
14
003
$1.42
15
003
$12.98
16
001
$98.46
17
001
$7.96
Description
WASHER (12X30X4.5)
90401-KK9-960
WASHER (18X10.2)
90405-ML7-000
PIN, DOWEL (8X8)
90702-MB0-000
BEARING (30X35X17)
91022-MB0-004 (replaces 91022-MB0-003)
ROLLER (15X13)
91101-516-000
BOLT, FLANGE (8X14)
95701-08014-08
BOLT, FLANGE (6X25)
96001-06025-00
ROLLER (6X15)
96220-60150
Q’ty
Price
001
$7.91
001
$2.84
002
$2.73
001
$26.51
003
$4.53
003
$0.78
003
$0.93
001
$0.62
Appendix A: Part Numbers
Radiator
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
Description
RADIATOR COMP
19010-MZ5-P00 (replaces 19010-MZ5-671)
SHROUD
19015-MZ5-003
FAN, COOLING
19025-MN4-003
MOTOR ASSY., FAN
19030-MZ5-003
CAP, RADIATOR
19045-MY3-671
RUBBER
19051-KA3-830
COLLAR
19052-MN8-000
TANK, RESERVE
19101-MZ5-000
CAP, RESERVE TANK
19104-MB0-700
TUBE, RESERVE TANK
19106-MZ5-000
GRILLE, RADIATOR
19112-MZ5-670 (replaces 19110-MZ5-000)
PROTR, RADIATOR HOSE
19120-MZ5-910 (replaces 19120-MZ5-000)
PROTR, RADIATOR HOSE
19121-MZ5-000
THERMOSTAT ASSY.
19300-ML7-003
COVER, THERMOSTAT
19311-MZ5-000
COVER, THERMOSTAT
19315-MV9-670
HOSE, RADIATOR
19500-MZ5-000
HOSE, RADIATOR
19501-MZ5-000
HOSE, FR.
19502-MZ5-000
HOSE, RR. HEAD WATER
19503-MZ5-000
GUIDE, WATER HOSE
19504-MZ5-000
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$612.40
22
001
$57.00
23
001
$42.05
24
001
$240.71
25
001
$30.69
26
004
$2.67
27
003
$2.04
28
001
$30.89
29
001
$9.24
30
001
$25.16
31
001
$70.69
32
001
$36.55
32
001
$10.15
33
001
$33.89
34
001
$60.67
34
001
$48.56
35
001
$20.91
36
001
$29.96
37
001
$13.64
38
001
$12.42
39
001
$7.71
40
Description
CLAMP B, WATER HOSE
19506-KS6-700
CLAMP, HOSE (30-37)
19516-GAG-003
CONNECTOR, GROUND
32152-MB3-000
REFLECTOR, FR.
33740-KR3-671
SENDING UNIT
37750-PC1-004
SWITCH, THERMOSTAT
37760-MT2-003
NUT, SPECIAL (6X7)
61304-958-003 (replaces 90301-471-000)
NUT, SERRATE (5MM)
90315-MK3-003
WASHER, FR.
90556-MB4-000
O-RING (13.5X1.4)
91307-PH7-660 (replaces 91307-611-000)
O-RING (47.5X2)
91311-KE8-000
O-RING (45.5X2.5)
91373-733-003
SCREW, TAPPING (3X8)
93901-22180
NUT, FLANGE (6MM)
94050-06000
CLIP, TUBE (B10)
95002-02100
BULK HOSE (5.5X3000)
95005-55003-20M
BOLT, FLANGE (6X12)
95701-06012-00
BOLT, FLANGE (6X22)
95701-06022-00
BOLT, FLANGE (6X10)
96001-06010-00
BOLT, FLANGE (6X22)
96001-06022-00
BOLT, SOCKET (6X25)
96600-06025-07
Q’ty
Price
004
$6.13
004
$10.95
001
$1.33
002
$22.31
001
$43.83
001
$49.49
001
$2.64
004
$1.67
001
$1.91
001
$1.72
001
$1.64
001
$3.20
001
$0.47
001
$0.72
003
$0.90
001
$18.33
002
$0.72
001
$0.72
003
$0.85
003
$0.91
003
$0.88
23-41
Appendix A: Part Numbers
Rear Brake Panel
#
01
02
03
04
05
06
07
08
09
Description
SHOE KIT, BRAKE
06430-MZ5-003
AXLE, RR. WHEEL
42301-MZ5-003
COLR, RR. WHEEL SIDE
42311-MZ1-610 (replaces 42311-MZ1-000)
COLLAR, RR.
42313-MZ5-000
PANEL, RR.
43100-MJ1-832
WASHER, ANCHOR PIN
43102-319-000
TUBE
43124-MZ5-000
DUST SEAL, BRAKE CAM
43134-300-000
CAM, RR. BRAKE
43141-MB0-010 (replaces 43141-MB0-000)
23-42
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$40.27
10
001
$47.41
11
001
$16.18
12
001
$15.69
13
001
$182.85
14
001
$4.96
15
002
$5.48
16
001
$1.62
17
001
$28.64
Description
INDICATOR, RR. BRAKE
43145-ME5-000
SPRING, RR.
43151-346-000
ARM, RR. BRAKE
43410-MZ5-000
BOLT, FLANGE (8X25)
90107-MZ5-000
NUT, U (18MM)
90305-KZ4-891 (replaces 90305-KZ4-890)
WASHER (18X32X2)
90401-KZ4-890
WASHER, RR. AXLE
90559-MJ0-630
PIN, COTTER (2.5MM)
94201-25300 (replaces 94201-25200,
94201-25250)
Q’ty
Price
001
$4.58
002
$4.64
001
$26.58
001
$3.65
001
$11.42
001
$3.58
001
$10.16
002
$0.53
Appendix A: Part Numbers
Rear Cylinder Head
#
01
01
02
03
04
05
06
07
08
09
10
11
Description
CYLINDER HEAD, RR.
12020-MZ5-315
CYLINDER HEAD, RR.
12020-MZ5-316
GUIDE, VALVE (OS)
12204-MT4-305
GASKET, CYL HD
12251-MT4-014 (replaces 12251-MT4-004)
FIN A, CYLINDER HEAD
12350-MZ5-000
RUBBER, SEAT
12352-MZ5-300
FIN B, CYLINDER HEAD
12360-MZ5-000
INSULATOR, CARB
16211-MZ5-000
JOINT, BOOSTER
16214-MB0-000
BAND A, INSULATOR
16219-MM4-000
BAND B, INSULATOR
16220-MM4-000
BOLT, FLANGE (9X93)
90007-ML7-920
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$834.03
12
001
$834.03
13
008
$16.15
14
001
$46.67
15
001
$113.93
16
002
$2.44
17
001
$73.62
18
002
$38.78
19
002
$3.51
20
002
$8.07
21
002
$8.07
22
008
$7.85
Description
BOLT, SOCKET (6X28)
90012-MZ5-000
BOLT, FLG (6X45.5)
90017-MA6-000
BOLT, FLG (6X39.5)
90019-MA6-000
BOLT, STUD (6X22)
90036-MZ5-000
WASHER (9MM)
90445-MM4-000
WASHER (5MM)
90452-323-000
SCREW, PAN (5X8)
93500-05008-0A
PIN, DOWEL (8X14)
94301-08140
PIN, DOWEL (12X20)
94301-12200
BOLT, FLANGE (6X30)
95701-06030-00
SPARK PLUG (CR9EH9)
98059-59916 (replaces 98059-58926,
98059-59910)
Q’ty
Price
006
$1.60
008
$2.62
008
$2.25
004
$4.29
008
$2.82
002
$0.85
002
$0.45
008
$1.00
002
$1.17
002
$0.83
002
$8.14
23-43
Appendix A: Part Numbers
Rear Fender
#
01
02
03
04
05
06
07
08
09
09
09
10
11
12
13
Description
REFLECTOR, REFLEX
33741-MS6-921
RUB, METER CUSHION
37215-MA6-008
GROMMET, ENG HGR
50370-HA2-770
RUBBER, BATTERY
50383-GB6-300
GROM, SPEAKER PANEL
64266-MG9-770
COLLAR, ROTO-STOP
75133-960-000
GRAB RAIL, R.
77330-MZ5-000
GRAB RAIL, L.
77340-MZ5-000
FENDER B,REAR
80100-MZ5-000YB (replaces 80100-MZ5000ZC)
FENDER B *Y124P*
80100-MZ5-000ZD
FENDER B, RR. *R201*
80100-MZ5-000ZE
BRKT, NUMBER PLATE
80101-MZ5-670
STAY, RR. REFLECTOR
80102-MM8-010
GROM, ENGINE COVER
80103-GJ5-000
FENDER A, RR.
80105-MZ5-000
23-44
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$10.55
14
002
$2.33
15
003
$1.51
16
002
$3.24
17
001
$2.45
18
002
$2.58
19
001
$105.00
20
001
$105.00
21
001
$164.39
22
001
$180.00
001
$154.24
001
$40.85
001
$17.82
002
$1.55
001
$66.36
23
24
25
26
27
28
Description
SUB-FRAME, RR.
80125-MZ5-000
GROMMET, SIDE COVER
83601-MN5-000
RUBBER
84702-MF2-670
BOLT (8X56)
90064-KK3-830
BOLT
90215-ML0-000
NUT
90305-SH3-000
NUT, CAP (8MM)
90443-107-000
WASHER, PLAIN (8MM)
90518-921-000
PLUG, CONE TYPE
90899-422-610
CLIP, WIRE
91406-166-000
BOLT, HEX. (6X10)
92101-06010-0G
NUT, HEX. (6MM)
94002-06070-0S
NUT, FLANGE (5MM)
94050-05000
NUT, FLANGE (6MM)
94050-06070
BOLT, FLANGE (6X12)
95701-06012-00
Q’ty
Price
001
$149.92
001
$2.25
002
$3.11
004
$3.55
002
$1.60
002
$3.65
004
$2.30
004
$1.12
003
$1.45
002
$2.93
002
$0.67
002
$0.55
001
$0.60
002
$0.73
002
$0.72
Appendix A: Part Numbers
Rear Shock Absorber
#
01
02
03
04
Description
SHOCK ABSORBER, RR.
52400-MZ5-672 (replaces 52400-MZ5-671)
BUSH, RR. SHOCK
52485-KR3-003
COLLAR, RUBBER BUSH
52486-GA7-003
BUSH, RUBBER (UPPER)
52489-GS3-003
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
002
$306.24
05
002
$3.18
002
$3.76
06
002
$1.91
002
$2.91
07
BOLT, FLANGE (8X16)
90106-MB2-000
WASHER, PLAIN
90501-MZ5-000
BOLT, FLANGE (10X35)
95817-10035-00 (replaces 95801-10035-00)
002
$1.23
002
$3.58
23-45
Appendix A: Part Numbers
Rear Wheel
#
01
02
03
04
05
06
07
08
08
08
Description
SPROCKET (40T)
41200-MZ5-770 (replaces 41200-MA3-000,
replaces 41200-MZ5-670)
ARRESTER, NOISE
41212-MK4-010 (replaces 41212-MK4-000)
DAMPER, RR. WHEEL
41241-MM5-000
SLEEVE, RR. AXLE
42606-MS2-000
FLANGE, FINAL DRIVEN
42610-MS2-000
COLLAR, RR.
42620-MZ5-000
WHEEL SET, RR.
42650-MZ5-305
WEIGHT (10G)
42704-MB0-000
WEIGHT (20G)
42705-MB0-000
WEIGHT, BALANCE (20)
42705-MCF-D60
23-46
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
001
$127.81
08
AR
$10.36
001
$152.63
001
$8.29
005
$10.47
11
001
$9.67
001
$15.93
12
005
$3.15
001
$243.35
13
001
$9.20
001
$19.36
14
001
$23.11
001
$705.94
001
$23.13
AR
$9.07
001
$24.36
AR
$10.36
001
$3.07
AR
$10.36
WEIGHT, BALANCE (30)
42706-MCF-D60 (replaces 42706-MB0-000)
TIRE, RR.
42711-MZ5-024 (replaces 42710-MZ5-004,
42711-MZ5-004)
VALVE, RIM
42753-ML7-004
NUT, FLANGE (12MM)
90306-KF0-003
OIL SEAL (34X62.2X7)
90753-MG5-670
BEARING,BALL RADI
91051-MBT-611 (replaces 91051-MAT-003,
91051-MM5-003)
BEARING (6204UU)
91052-MM5-003
BEARING (6304UU)
91053-MM5-004
O-RING (69X2)
91302-MS2-003
BOLT, STUD (12X28)
92918-12028-0E
005
$2.15
09
15
16
17
18
Appendix A: Part Numbers
Right Crankcase Cover
#
01
02
03
04
05
06
07
08
Description
COVER, R. CRANKCASE
11330-MZ5-920 (replaces 11330-MZ5-000)
CAP (45MM)
11332-MZ5-000
PLATE, R. COVER
11333-MV8-900
RUB, R. COVER DAMPER
11334-MT7-300
GASKET, R.
11394-MY7-000
CAP, OIL FILLER
15611-MB0-000
DIPSTICK, OIL
15650-ML7-000
CLAMP, SWITCH WIRE
35211-443-760
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
001
$405.03
09
011
$2.16
001
$25.67
10
002
$2.96
001
$14.84
11
001
$3.11
001
$31.35
12
001
$1.47
001
$18.08
13
001
$1.87
001
$7.36
14
002
$1.00
001
$10.67
15
BOLT, FLANGE (6X28)
90004-GHB-680 (replaces 90001-GHB-680)
BOLT, FLANGE (6X32)
90001-GHB-690
O-RING (48.1X3.6)
91301-ML7-003
O-RING (22X3.0)
91307-425-003 (replaces 91301-250-000)
O-RING (8.4X2.4)
91316-MJ8-003
PIN, DOWEL (8X14)
94301-08140
BOLT, FLANGE (6X10)
95701-06010-00
001
$0.75
004
$2.93
23-47
Appendix A: Part Numbers
Seat
#
01
02
03
04
Description
RUB, SEAT MOUNTING
77110-KA3-730
SEAT ASSY.
77200-MZ5-000
STAY A, RR. SEAT
77206-MZ5-000
STAY B, RR. SEAT
77207-MZ5-000
23-48
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
002
$3.96
05
001
$308.50
06
001
$15.89
07
001
$12.82
08
Description
RUBBER B
77215-GC2-000
SEAT ASSY., RR.
77300-MZ5-000
BOLT (8X12)
90125-KR3-000
NUT, FLANGE (6MM)
94050-06080
Q’ty
Price
002
$3.96
001
$188.28
003
$3.07
006
$0.23
Appendix A: Part Numbers
Side Cover
#
01
02
03
04
04
Description
RUBBER B, STOPPER
50354-428-000
CAP, STEP HOLDER END
50713-ML0-720
GROMMET, A/CLNR HSG
83551-300-000
COVER, R. SIDE *NH1*
83650-MZ5-000ZC
CVR, R. SIDE *Y124P*
83650-MZ5-000ZD
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
002
$2.09
04
002
$2.16
05
004
$2.96
05
001
$95.47
05
001
$84.82
Description
CVR, R. SIDE *R201*
83650-MZ5-000ZE
COVER, L. SIDE *NH1*
83750-MZ5-000ZC
CVR, L. SIDE *Y124P*
83750-MZ5-000ZD
CVR, L. SIDE *R201*
83750-MZ5-000ZE
Q’ty
Price
001
$142.83
001
$84.82
001
$84.82
001
$152.19
23-49
Appendix A: Part Numbers
Speedometer Tachometer
23-50
Downloaded from www.Manualslib.com manuals search engine
Appendix A: Part Numbers
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Description
BULB (12V3W)
34908-KM1-671
BULB (12V1.7W)
34908-MB9-871
BULB (12V1.4W)
34908-MN8-700
METER, COMBINATION
37100-MZ5-671
SPEEDOMETER ASSY.
37200-MZ5-671
COVER, SPEEDOMETER
37202-MZ5-008
RUBBER, SPEEDOMETER
37204-MK4-611
BRKT, METER (LOWER)
37211-MZ5-008
BRKT, METER (UPPER)
37212-MZ5-008
RUBBER
37213-MW3-671
COVER, METER BRACKET
37214-MZ5-008
CLAMP
37215-KM1-670
RUB, BRACKET SETTING
37215-MW3-671
GUIDE, R. CABLE
37216-MZ5-000
GUIDE, L. CABLE
37217-MZ5-000
KNOB, TRIP METER
37220-MB4-671
SOCKET
37224-MZ5-008
BAND, SELF-LOCK
37226-MZ5-008
WASHER, PLAIN
37244-MA6-008
TACHOMETER ASSY.
37250-MZ5-671
COVER, TACHOMETER
37252-MZ5-008
RUBBER
37253-MK4-611
RUBBER, TACHOMETER
37254-MK4-611
RUBBER
37255-MK4-611
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
006
$1.68
25
001
$1.95
26
002
$2.27
27
001
$974.79
28
001
$363.85
29
001
$58.98
30
001
$7.15
31
001
$65.47
32
001
$57.34
33
001
$7.27
34
001
$70.22
35
001
$1.53
36
003
$1.60
37
001
$8.82
38
001
$10.78
39
001
$10.04
001
$35.71
002
$2.35
003
$1.60
001
$409.83
001
$59.10
002
$2.33
001
$7.15
002
$2.33
40
41
42
43
44
45
Description
CUSHION, RUBBER
37255-MZ5-008
GROMMET, TACHOMETER
37257-MK4-601
SOCKET
37562-MZ5-008
BOX ASSY., PILOT
37600-MZ5-008
COLLAR
37606-MR1-008
RUBBER, SETTING
37607-MZ5-008
CAP
37618-MB2-008
SOCKET, METER
37619-MZ5-671
CABLE, SPEEDOMETER
44830-MT3-000
CABLE (INNER)
44831-MM5-000 (replaces 44831-443-720)
SCREW, TRUSS (4X12)
90106-KN8-008
SCREW-WASHER (3X10)
90108-GN2-008
SCREW, TAP (4X14)
90109-MZ5-008
SCREW, PAN (2X6)
90158-KM7-911
O-RING (6.8X1.9)
91306-PJ4-000 (replaces 91301-027-000,
91310-MC7-003)
SCREW, OVAL (5X20)
93700-05020-0G
SCREW-WASHER (4X16)
93891-04016-07
SCREW, TAP (4X12)
93903-24310
NUT, HEX. (6MM)
94002-06070-0S
WASHER, PLAIN (8MM)
94101-08700
BOLT, FLANGE (8X16)
95701-08016-08
Q’ty
Price
002
$2.44
001
$5.13
001
$43.49
001
$80.14
002
$4.00
002
$4.62
001
$1.60
001
$117.14
001
$23.23
001
$4.46
004
$1.51
002
$1.65
002
$3.24
001
$1.42
001
$1.43
001
$0.35
002
$0.37
001
$0.47
003
$0.55
003
$0.45
002
$0.85
23-51
Appendix A: Part Numbers
Stand
#
01
02
03
Description
SWITCH, SIDE STAND
35070-MZ5-A80 (replaces 35700-MZ5-305)
BAR, SIDE STAND
50532-MZ5-000
SPRING, SIDE STAND
50541-KV3-830
23-52
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
Description
Q’ty
Price
001
$41.75
04
001
$6.31
001
$69.70
05
001
$1.84
001
$6.04
06
BOLT
90108-MR5-000
BOLT, SPECIAL (6X16)
90147-MCE-950 (replaces 90147-MK6-671)
NUT, SIDE STAND
90203-MF9-710
001
$2.84
Appendix A: Part Numbers
Starting Motor
#
01
02
03
04
05
Description
MOTOR ASSY., STARTER
31200-MZ5-003
TERMINAL SET, BRUSH
31201-KS5-901
SPRING, CARBON BRUSH
31204-KS5-901
BOLT, SETTING
31205-MN0-008
HOLDER SET, BRUSH
31206-KW1-901
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$455.40
06
001
$17.73
07
002
$2.20
08
003
$3.93
09
001
$18.91
10
Description
RING
31207-KS5-901
NUT-WASHER (6MM)
90071-MB0-000
O-RING
91309-MA6-000
O-RING
91320-MB0-000
BOLT, FLANGE (6X25)
96001-06025-00
Q’ty
Price
002
$2.58
002
$1.53
001
$2.93
001
$1.82
002
$0.93
23-53
Appendix A: Part Numbers
Steering Stem
#
01
02
03
04
05
06
07
Description
CLAMP A, BRAKE HOSE
45131-MZ5-000
CLAMP
53105-MZ5-000
STEM, STEERING
53200-MZ5-000
DUST SEAL
53213-MB4-771
DUST SEAL
53214-371-010
THREAD (UPPER)
53220-422-000
LOCK, HANDLEBAR
53600-086-007 (replaces 53600-126-921)
23-54
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$10.53
08
001
$6.60
09
001
$320.76
10
001
$9.20
11
001
$9.56
12
001
$24.84
13
001
$34.24
14
Description
SCREW (6X12)
90164-028-000
THREAD
90302-425-830
WASHER, LOCK
90506-425-830
BEARING, HEAD PIPE
91015-KT8-005
BEARING, HEAD PIPE
91016-KT8-005
BOLT, FLANGE (6X12)
95701-06012-00
BOLT, SOCKET (10X25)
96700-10025-10
Q’ty
Price
002
$1.25
001
$16.51
001
$5.67
001
$30.15
001
$30.15
001
$0.72
002
$1.48
Appendix A: Part Numbers
Step
#
01
02
03
04
05
06
07
08
09
10
Description
PIN, STEP BAR JOINT
50603-033-010
BAR, R. STEP
50612-MR1-000
BRACKET, R. STEP
50615-MZ5-000
SPRING, STEP RETURN
50617-MB1-700
STOPPER, STEP RUBBER
50619-MN0-000
BRACKET, L. STEP
50625-MZ5-000
BAR, L. STEP
50642-MR1-000
RUBBER, MAIN STEP
50661-MN0-000
RUB, PILLION FOOTPEG
50716-371-660 (replaces 50710-377-000)
WASHER
50712-413-000
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
002
$2.55
11
001
$21.58
12
001
$88.37
13
002
$4.55
14
002
$13.18
001
$91.59
001
$21.58
002
$8.16
002
$10.78
002
$2.62
15
16
17
18
19
Description
BAR, PILLION STEP
50715-MN0-000
BOLT, HEX. (6X12)
92101-06012-0A
BOLT, CAP (6X12)
92501-06012-0A
WASHER, PLAIN (6MM)
94101-06800 (replaces 94101-06000,
94101-06080)
WASHER, PLAIN (8MM)
94101-08000
PIN, SPLIT (1.6X12)
94201-16120
PIN, SPLIT (2.0X15)
94201-20150
PIN A, PILLION STEP
95015-81000
BOLT, FLANGE (8X18)
95701-08018-00
Q’ty
Price
002
$25.25
002
$0.53
002
$1.75
002
$0.30
002
$0.40
002
$0.43
002
$0.35
002
$1.58
004
$0.83
23-55
Appendix A: Part Numbers
Swingarm @ Drive Chain
#
01
01
01
02
03
03
04
05
06
07
08
09
10
11
12
13
14
15
16
Description
CHAIN SET, DRIVE
06405-MZ5-P20 (replaces 06405-MZ5-405)
CHAIN SET, DRIVE
06405-MZ5-407
CHAIN SET, DRIVE
06405-MZ5-P20
CASE, DRIVE CHAIN
40510-MZ5-000
MASTER LINK
40535-MW0-305
MASTER LINK
40535-MW0-306
AXLE, RR. WHEEL
42301-KBG-000
ARM, RR.
43431-MZ5-000
RUBBER, STOPPER ARM
43434-ME1-670
COLR, PIVOT DISTANCE
52102-MM5-000
COLLAR B, SWINGARM
52105-MM2-670
COLLAR B, PIVOT
52106-ML4-000
COLLAR
52120-MJ0-010 (replaces 52120-MJ0-000)
PLATE
52121-MJ0-000
SLIDER, CHAIN
52170-MZ5-000
WASHER, CHAIN SLIDER
52171-KR6-000
SWINGARM SET
52200-MZ5-305
BOLT, RR.
90127-393-000
BOLT, RR.
90133-286-000
23-56
Downloaded from www.Manualslib.com manuals search engine
Q’ty
Price
#
001
$168.18
17
001
$307.34
18
001
$168.18
19
001
$102.29
20
001
$5.18
21
001
$5.18
22
001
$26.85
22
001
$12.65
23
001
$2.73
24
001
$24.15
25
001
$8.11
26
001
$16.45
27
002
$42.35
28
002
$15.93
29
001
$36.36
30
002
$1.87
001
$627.52
31
001
$3.82
32
001
$3.51
Description
BOLT, FLANGE (6X12)
90154-ML0-000
NUT, U (14MM)
90305-GE8-003
WASHER A
90524-030-000 (replaces 90505-425-000)
WASHER (6X20)
90512-KF9-900
WASHER (6X9)
90513-405-000 (replaces 90513-428-900)
BEARING (22X29X30)
91071-MJ0-003
BEARING, NEEDLE
91071-MJ0-004
OIL SEAL (22X31X5)
91205-965-003
DUST SEAL (22X35X7)
91213-MB2-003 (replaces 91213-MB2-006)
SCREW, TAP (5X12)
93901-25280
NUT, HEX. (8MM)
94001-08000-0S
NUT, HEX. (8MM)
94030-08000
WASHER, PLAIN (8MM)
94101-08000
WASHER (10MM)
94111-10000
PIN, COTTER (2.0X35)
94201-20350 (replaces 94201-20180,
94201-20200, 94201-20250, 94201-20280,
94201-20320)
CIRCLIP (35MM)
94520-35000
BEARING (6202)
96100-62020-10
Q’ty
Price
002
$1.67
001
$3.05
001
$1.04
001
$2.33
001
$0.98
001
$27.96
001
$27.96
001
$4.71
001
$5.87
002
$0.47
004
$0.52
002
$0.48
001
$0.40
001
$0.60
002
$0.65
001
$1.00
001
$8.90
Appendix A: Part Numbers
Taillight
#
01
02
03
04
05
Description
TAILLIGHT UNIT
33701-MZ5-671
LENS, TAILLIGHT
33702-MC4-671
SOCKET, TAILLIGHT
33703-MZ5-671
GSKT, TAILLIGHT LENS
33709-KB7-003
BULB (12V27/8W)
34906-425-771
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Q’ty
Price
#
001
$103.47
06
001
$22.96
07
001
$51.15
08
001
$3.31
09
001
$3.18
10
Description
COLLAR
80135-MZ5-000
SCREW, TAP (4X40)
90105-GAM-000
WASHER (5MM)
91409-VM0-770
BOLT, HEX. (5X35)
92101-05035-0A
WASHER, SPRING (5MM)
94111-05000
Q’ty
Price
002
$9.98
002
$3.87
002
$2.33
002
$1.28
002
$0.50
23-57
Appendix A: Part Numbers
Tools
#
01
02
03
04
05
06
07
08
Description
BAG, SERVICE BOOK
77251-GR1-000
TOOL SET
89010-MZ5-000
WRENCH, PLUG (16.5)
89216-MT3-000
WRENCH, HEX. (5MM)
89221-429-000
WRENCH, PIN
89230-MB1-000
WRENCH (8MM)
99001-08000
SPANNER (10X12)
99001-10120
SPANNER (14X17)
99001-14170
23-58
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Q’ty
Price
#
001
$3.38
09
001
$52.58
10
001
$19.29
11
001
$4.22
12
001
$15.98
13
001
$1.89
14
001
$1.72
15
001
$2.75
Description
SCREWDRIVER 1 (NO.2)
99003-10000
SCREWDRIVER 3 (NO.2)
99003-30000
GRIP
99003-50000
HANDLE (12MM)
99006-12000
WRENCH, EYE (22MM)
99006-22000
WRENCH, EYE (27MM)
99006-27000
BAG, TOOL (160MM)
99008-01600
Q’ty
Price
001
$1.75
001
$0.82
001
$1.80
001
$2.60
001
$3.31
001
$3.49
001
$1.51
Appendix A: Part Numbers
Transmission
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
Description
MAINSHAFT (13T)
23211-ML7-920
PLATE
23212-ML7-000
COUNTERSHAFT
23220-MT4-000
GEAR (37T)
23421-ML7-000
GEAR (17T)
23431-MV8-900
GEAR (32T)
23441-MV8-900
COLLAR (28MM)
23442-ML7-000
GEAR
23451-MZ5-000
GEAR (29T)
23461-MV8-900
GEAR (27T)
23481-MV8-900
COLLAR (28X13.5)
23482-MR7-000
GEAR
23491-MZ5-010
COLLAR (25X12)
23495-MB0-000
GEAR
23501-MZ5-010
COLLAR (25X18.4)
23512-MZ5-000
SHIFTER
23521-MV8-900
SPROCKET (16T)
23801-MCJ-000 (replaces 23801-ML7-920)
BOLT, SPECIAL (10MM)
90037-422-003
WASHER (25X31X1.5)
90451-MR7-000
WASHER (28X34X1.5)
90452-MR7-000
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Q’ty
Price
#
Description
Q’ty
Price
001
$146.95
21
001
$2.02
001
$8.73
22
002
$3.89
001
$223.89
22
002
$3.89
001
$110.83
22
002
$3.89
001
$40.44
23
001
$2.02
001
$92.55
24
001
$4.67
001
$19.96
25
001
$7.71
001
$110.83
26
001
$7.71
001
$101.60
27
002
$2.91
001
$98.99
28
001
$6.36
002
$22.11
29
003
$2.91
001
$99.68
30
001
$30.56
001
$18.78
31
001
$40.07
001
$112.42
32
001
$22.58
001
$21.00
33
001
$11.24
001
$65.32
34
001
$1.03
001
$48.18
35
003
$0.73
001
$5.78
36
WASHER (20X1.00)
90454-428-000
WASHER B (22MM)
90455-ML7-000
WASHER A (22MM)
90456-ML7-000
WASHER C (22MM)
90457-ML7-000
WASHER (25MM)
90456-MA6-000
WASHER (10.2MM)
90459-438-000
WASHER (28MM)
90463-MR7-000
WASHER, LOCK (28MM)
90464-MR7-000
CIRCLIP (25MM)
90601-107-000
SET-RING (68MM)
90602-MR7-000
CIRCLIP (28MM)
90602-MM5-000 (replaces 90603-MN4-000)
BEARING (20MM)
91022-MT4-000
BEARING (22MM)
91023-MZ5-003
BEARING (22X26X11)
91026-MB4-003
OIL SEAL (40X68X7.2)
91207-MR7-003
PIN B, DOWEL (8X10)
94302-08100
*95701-06016-08
95701-06016-00
BEARING (6305)
96100-63050-00
001
$11.98
002
$3.89
003
$4.58
23-59
Appendix A: Part Numbers
Turn Signal
#
Description
Q’ty
Price
#
01
SUB-WIRE, R. RR.
32360-MZ5-000
SUB-WIRE, L. RR.
32365-MZ5-000
WINKER LIGHT ASSY
33400-MK7-P00 (replaces 33400-MN0-003)
LENS, FR.
33401-MK7-672
BASE, R. FR.
33402-MK7-671
REFLECTOR, R. RR.
33405-MN0-003
GASKET
33407-MK7-671
TURN SIGNAL, L. FR.
33450-MN0-003
BASE, L. FR.
33452-MK7-671
REFLECTOR, L. RR.
33455-MN0-003
STAY, R. FR.
33490-MZ5-000
STAY, L. FR.
33491-MZ5-000
001
$14.73
13
001
$10.69
14
001
$49.09
15
004
$8.46
16
002
$34.20
17
001
$18.04
18
004
$3.07
19
001
$38.04
20
002
$34.20
21
001
$15.69
22
001
$39.56
23
001
$39.56
24
02
03
04
05
06
07
08
09
10
11
12
23-60
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Description
TURN SIGNAL ASSY.
33600-MR1-000
REFLECTOR, R. RR.
33605-MR1-000
TURN SIGNAL ASSY.
33650-MR1-000
REFLECTOR, L. RR.
33655-MR1-000
STAY, RR.
33690-MZ5-000
BULB (12V23W32CP)
34905-268-671
BULB (12V23/8W)
34905-425-671
COLLAR
84702-KV0-670
SCREW, SPECIAL (6X8)
90380-MZ5-000
SCREW, TAP (4X25)
93901-34610
NUT, FLANGE (8MM)
94050-08080
BOLT, FLANGE (6X30)
96001-06030-07
Q’ty
Price
001
$49.11
001
$27.04
001
$49.11
001
$27.04
002
$23.75
002
$1.67
002
$4.33
002
$4.00
004
$3.58
008
$0.20
002
$0.25
002
$1.15
Appendix A: Part Numbers
Water Pipe
#
01
02
03
04
05
06
07
08
Description
CLIP B, TUBE
16106-KW7-900
PIPE, CONNECTING
19507-MB0-000
CAP A
19508-MZ5-000
CAP B
19509-MZ5-000
CLAMP (24-32MM)
19516-ML7-691
PIPE A, WATER
19521-ML7-000
JOINT, WATER
19523-MT4-000
HOSE A, WATER
19525-ML7-000
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Q’ty
Price
#
Description
Q’ty
Price
001
$2.38
09
001
$2.33
001
$17.71
10
002
$3.05
001
$32.62
11
002
$1.42
001
$41.04
12
001
$1.95
002
$10.95
13
002
$1.95
001
$72.16
14
005
$0.91
002
$24.76
15
BOLT, FLANGE (6X12)
90004-GHB-610 (replaces 90001-GHB-610)
GSKT, CONNECTING CAP
91301-MB0-000
O-RING (18.3X2.3)
91301-147-023
SEAL, WATER PIPE
91315-MB0-013
O-RING (21.2X2.4)
91331-PC9-003
BOLT, FLANGE (6X22)
96001-06022-00
BOLT, FLANGE (6X35)
96001-06035-00
003
$1.00
001
$6.31
23-61
Appendix A: Part Numbers
Water Pump
#
Description
Q’ty
Price
#
01
COVER, L. CRANKCASE
11340-MZ5-000
RUBBER, L.
11342-MZ5-300
GASKET, L.
11343-MZ5-000
GUIDE, DRIVE CHAIN
11365-MZ5-000
COVER, CHANGE
11630-MZ5-000
GASKET, SHIFT COVER
11632-MY7-000
WATER PUMP ASSY.
19200-MZ5-010 (replaces 19200-MZ5-000)
COVER, WATER PUMP
19220-MZ5-000 (replaces 19221-MZ5-305)
GASKET
19226-ML7-000
LEVER, CLUTCH
22710-MZ5-000
SPRING, CLUTCH LEVER
22815-MZ5-000
PIECE
22852-ML0-780
BOLT, FLANGE (6X16)
90004-GHB-630 (replaces 90001-GHB-630)
BOLT, FLANGE (6X10)
90011-HB9-000
BOLT (6X12) (CT200)
90013-883-000
BOLT (6X75)
90021-MZ5-000
001
$360.59
17
001
$33.87
18
001
$4.57
19
001
$16.04
20
001
$64.40
21
001
$9.47
22
001
$185.14
23
001
$57.43
24
001
$3.53
25
001
$31.58
26
001
$3.09
27
001
$5.40
28
002
$2.75
29
002
$1.67
30
001
$1.34
31
001
$6.78
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
23-62
Downloaded from www.Manualslib.com manuals search engine
Description
BOLT (6X95)
90025-MZ5-000
BOLT, FLANGE (6X25)
90121-MV9-670
WASHER (6.5MM)
90463-ML7-000
WASHER, TANK RUBBER
90503-898-000
WASHER, BRAKE ARM
90525-GC4-700
OIL SEAL (12X20X6)
91201-427-003
OIL SEAL (13X22X5)
91204-KE8-003
O-RING (10.5X6.5)
91301-ML0-781
O-RING (32.95X2.62)
91302-MB0-013
PIN, DOWEL (8X14)
94301-08140
BOLT, FLANGE (6X32)
96001-06032-00
BOLT, FLANGE (6X35)
96001-06035-00
BOLT, FLANGE (6X40)
96001-06040-00
BOLT, FLANGE (6X60)
96001-06060-00
BOLT, FLANGE (6X75)
96001-06075-00
Q’ty
Price
002
$8.53
002
$2.11
003
$2.25
002
$2.06
001
$1.73
001
$3.91
001
$2.58
001
$2.07
001
$2.07
004
$1.00
001
$0.95
001
$1.00
002
$1.02
002
$1.18
001
$1.47
Appendix A: Part Numbers
Wire Harness
#
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Description
RUBBER
30401-GB6-000
RUBBER, SPARK UNIT
30405-MT6-000
MODULE, IGN CONT
30410-MZ5-671
COIL, IGNITION
30510-KT7-023
SPACER
30520-ML7-000
CAP ASSY.
30700-KAF-010
WIRE 1, IGNITION
30731-MZ5-000
CORD,HIGH/T
30731-KEA-505 (replaces 30732-MZ5-000)
CORD,HIGH/T
30731-KEA-505 (replaces 30733-MZ5-000)
CORD,HIGH/T
30731-KEA-505 (replaces 30734-MZ5-000)
RECTIFIER, REGULATE
31600-MZ5-003
RECTIFIER, SILICON
31700-196-000
WIRE HARNESS
32100-MZ5-670
HORN (LOW)
38120-MZ5-003
RELAY, TURN SIGNAL
38301-KK9-952
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Q’ty
Price
#
001
$4.22
16
001
$19.40
17
001
$502.46
18
002
$89.99
19
004
$2.89
20
004
$25.56
21
001
$19.87
22
001
$19.87
23
001
$19.87
24
001
$19.87
25
001
$203.22
26
001
$20.76
27
001
$409.25
28
001
$48.47
29
001
$46.75
Description
SUSPENSION
38306-GE7-000
INDICATOR UNIT
38710-MZ5-003
BRACKET, RR.
50333-MZ5-000
BRACKET, FR.
50334-MZ5-000
PLATE
50336-MR1-000
STRAP, CABLE (105MM)
90672-SB2-003
BOLT, HEX. (6X22)
92101-06022-4J
BOLT, HEX. (6X28)
92101-06028-4J
NUT, FLANGE (6MM)
94050-06070
NUT, FLANGE (6MM)
94050-06080
BOLT, FLANGE (8X12)
95701-08012-07
BOLT, FLANGE (6X12)
96001-06012-00
FUSE, BLADE (10A)
98200-31000
FUSE, BLADE (15A)
98200-31500
Q’ty
Price
001
$3.71
001
$66.65
001
$21.73
001
$21.58
001
$8.09
001
$2.75
002
$2.33
002
$1.82
002
$0.73
002
$0.23
001
$0.75
002
$0.78
004
$0.67
002
$0.67
23-63
MEMO
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24. Appendix: Gasket Diagrams
Alternator Cover Gasket
Cam Chain Tensioner Gaskets
24-2
24-3
Oil Pan Gasket
24-4
Right Crankcase Cover Gasket
24-5
Shift Cover Gasket
24-6
Sprocket Cover Gasket
24-7
NOTE
•
•
Diagrams must be printed without using any scaling to fit paper.
Some of the diagrams must be printed on larger than letter sized paper, or must be pieced together using the guides
included on the images
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24-1
Appendix B: Gasket Diagrams
Alternator Cover Gasket
Description
Alternator Cover Gasket
Material
Paper
NOTE
•
Grey area is a thin bead of sealant
24-2
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Part Number
11636-MY7-000
Thickness
0.0218”
Appendix B: Gasket Diagrams
Cam Chain Tensioner Gaskets
Description
Cam Chain Tensioner Gasket - Front
Cam Chain Tensioner Gasket - Rear
Material
Paper
Downloaded from www.Manualslib.com manuals search engine
Part Number
12194-KW3-880
12194-HC5-740
Thickness
0.0218”
24-3
Appendix B: Gasket Diagrams
Oil Pan Gasket
Description
Oil Pan Gasket
Part Number
11315-MY7-000
Material
Paper
24-4
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Thickness
0.0218”
Appendix B: Gasket Diagrams
Right Crankcase Cover Gasket
Description
Right Crankcase Cover Gasket
Part Number
11394-MY7-000
Material
Paper
Downloaded from www.Manualslib.com manuals search engine
Thickness
0.0218”
24-5
Appendix B: Gasket Diagrams
Shift Cover Gasket
Description
Shift Cover Gasket
Material
Paper
24-6
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Part Number
11632-MY7-000
Thickness
0.0218”
Appendix B: Gasket Diagrams
Sprocket Cover Gasket
Description
Sprocket Cover Gasket
Material
Paper
Downloaded from www.Manualslib.com manuals search engine
Part Number
11343-MZ5-000
Thickness
0.0218”
24-7
,,1¼
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6 1 MZ509
H O N DA M OTO R CO. , LTD. TOKYO, JAPAN
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M A D E F R O M 5 0 % RECYCLED PAPER
M I N I M U M 1 0% POST-CONSUMER CONTENT
D RC 3750 .03.08
P R I NT E D I N U SA