Magna Vf750c User manual

r'··

Introduction

This service manual describes the service procedures for

the

MAGNA

VF750C/CD.

This Model Specific Manual includes every service proce-

dure

that

is

of

a specific nature

to

this

particular model.

Basic service procedures

that

are common

to

other Honda

Motorcycle/Motor Scooter/ATVs

are

covered in the Com-

mon Service Manual. This Model Specific Service Manual

should

be

used together

with

the Common Service Manu-

al

in order

to

provide complete service information on all

aspects

of

this motorcycle.

Follow the Maintenance Schedule (Section 3) recommen-

dations

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

California

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 and 3 apply

to

the

whole

motorcycle.

Section 2 illustrates procedures

for

removal/installation

of

components

that

may be required

to

perform service

described in

the

following

sections.

Sections 4 through

19

describe parts

of

the

motorcycle,

grouped according

to

location.

Find

the

section you

want

on

this

page, then

turn

to

the

table

of

contents

on

the

first

page

of

the

section.

Most

sections describe the service procedure through

system illustration. Refer

to

the

for

details on

how

to

use

this

manual.

If

you are

not

familiar

with

this

motorcycle,

read Tech-

nical Feature in section 20.

If

you

don't

know

the

source

of

the

trouble, go

to

sec-

tion

21

Troubleshooting.

All information, illustrations, directions and specifi-

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

to

make changes

at

any

time

without

noticeand

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

Issue: June,

1994

©HONDA

MOTOR CO., LTD.

How

To

Use

This

Manual

Finding The Information You Need

• This manual is

~into

sections which cover each

of

the

major

comonents'of

the~motorcycle.

To quicklyfind the 88Ction you are interested in, the first page

of

each sectiomi'is marked

with

a black tab

that

lines up

with

one

of

the

thumb

index tabs before this page.

The

first

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 provided

in

the last chapter

to

directly locate

the

information you need.

Note

On

the Explanation Method

Of

This Manual

• The removal and installation

of

parts are for the

most

part illustrated by large and clear illustrations

that

should provide

the

reader

with

visual aid in 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 installed.

• The sequence

of

steps represented numerically are differentiated from

the

ones represented alphabetically

to

notify

the reader that they must perform these steps separately.

• The illustrations may contain symbols

to

indicate necessary service procedures and precautions

that

need

to

be taken.

Refer

to

the next page

for

the meaning

of

each symbol.

• Also

in

the illustration is a chart

that

lists 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 are provided

to

supplement the illustrations when datailed explanation

of

the

procedure is

necessary or illustrations alone

would

not

suffice.

• Service procedures required before or

after

the procedure described on

that

particular page, or inspection/adjustment

procedures required following

the

installation

of

parts, are described under the title Requisite Service.

• Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual.

System illustration Symbols

I

'\

Detailed description

of

the

procedure

j

Part name Number

of

parts Extra notes or precaution

the

service procedure

Symbols

The symbols used

throughout

this

manual

show

specific service procedures.

If

supplementary information is required pertain-

~

ing

to

these symbols,

it

would

be

explained specifically in

the

text

without

the

use

of

the symbols.

tl

Replace

the

part(s)

with

new

one(s) before assembly.

Is.

TOOL I Use special tool.

lo.P.

TOOL' Use optional tool. These

tools

are obtained as you order parts.

c Torque specification.

10

N·m

(

1.0

kg-m, 7 ft-lb)

10(1.0,7)

, 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 multi-purpose grease NLGI # 2 or equivalent).

Use molybdenum disulfide grease (containing more than

3%

molybdenum disulfide, NLGI

#2

or

~

equivalent).

Example: Molykote® BR-2 plus manufactured by

Dow

Corning, U.S.A.

Multi-purpose

M-2

manufactured

by

Mitsubishi Oil Japan

Use molybdenum disulfide paste (containing more than

40%

molybdenum disulfide, NLGI

#2

or

equivalent).

~

Example: Molykote® G-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 grease.

'=- Apply a locking agent. Use

the

agent

of

the

middle strength, unless otherwise specified.

_..,

..

Apply

sealant.

I Use brake fluid DOT

4.

Use

the

recommended brake fluid, unless

otherwise

specified.

...

Use Fork or Suspension Fluid.

1.

General

Information

~------------------~--

General Safety 1-1 Lubrication & Seal Points

1-17

Model Identification

1-3

Cable & Harness Routing

1-20

Specifications

1-4

Emission Control System (U·.S.A. Only) 1-27

Torque Values

1-12

Emission Control Information Labels

Tools

1-15

(U.S.A Only)

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 area.

• The exhaustcotains poisonous carbon monoxide gas

that

maycause loss

of

consciouness and maylead

to

death.

Run

the engine in

an

open area 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-

der certain conditions.

KEEP

OUT

OF

REACH

OF

CHILDREN.

Hot

Components

• Engine and exhaustsystem parts become very hot and

remain

hot

for some time afterthe engine is run. Wear

insulated gloves or

wait

until the engine and exhaust

system have cooled before handling these parts.

Used Engine/Transmission Oil

• Used engine oil (ortransmission oil in two-stroke) may

cause skin cancer

if

repeatedly

left

In

contact

with

the

skin

for

prolonged periods. Althrough 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 afterhandling usad oil.

KEEP

OUT

OF

REACH

OF

CHILDREN.

Brake Dust

Never use

an

air hose or dry brush

to

clean brake assem-

blies. Use

an

OSHA-approved vacuum cleaner or alternate

method approved by OSHA, designed to minimize the haz-

ard caused by airborne asbestos fibers.

• Inhaled asbestos fibers have been found

to

cause

respiratory disease and cancer.

Brake Fluid

CAUTION

• Spilling fluid on painted, plastic or rubber parts will

damage them. Place a clean shop

towel

over these

parts wheneverthe system isserviced.

KEEP

OUT

OF

REACH

OF

CHILDREN.

1-1

General Information

Coolant

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.

• Avoid spilling engine coolant on

the

exhaust system

or engine parts. They may be

hot

enough

to

cause the

coolant

to

Ignite and

bum

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

hot.

The coolant is under pressure and could scald

you.

• Keep hands and clothing

away

from

the cooling fan,

as

it

starts automatically.

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

immediate medi-

cal attention.

If

it

is swallowed,

the

victim

must

be

forced

to

vomit,

then rinse

mouth

and

throat

with

fresh

water

be-

fore obtaining medical attention. Because

of

these dangers,

always store coolant in a safe place,

away

from

the reach

of

children.

1-2

Nitrogen Pressure

For shock absorbers

with

a gas-filled reservoir:

• Use

only

nitrogen

to

pressurize the shock absorber.

The use

of

an unstable gas can cause a fire or explo-

sion resulting in serious injury.

• The shock absorber contains nitrogen under high pres-

sure.

Allowing

fire

or

heat near

the

shock absorber

could lead

to

an explosion

that

could result in serious

injury.

• Failure

to

release

the

pressure from a shockabsorber

before disposing

of

it

may lead

to

a possible explo-

sion and serious injury

if

it

is heated

or

pierced.

To prevent the possibility

of

an

explosion, release the nitro-

gen by pressing the valve core. Then remove the valve stem

from the shock absorber reservoir. Dispose

of

the oil

in

a

manner acceptable

to

the Environmental Protection Agen-

cy

(EPA).

Before disposal

of

the shock absorber, release the nitrogen

by pressing the valve core. Then remove the valve stem from

the shock absorber.

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, drinklarge quantities

of

water or milk

and

follow

with

milk

of

magnesia

or

vegetable oil

and call a physician.

KEEP

OUT

OF

REACH

OF

CHILDREN.

Model

Identification

'94

MAGNA

VF750C

shown

(2) ENGINE SERIAL NUMBER

(2)The engine serial number is stamped on the right side

of

the upper crankcsase.

(4) CARBURETOR ID.ENTIFICATION NUMBER

(4)The carburetor indentification number is stamped on the

carburetor body intake side.

General Information

(1) FRAME SERIAL NUMBER

(1lThe frame serial number is stamped on

the

right side

of

the steering head.

(3) VEHICLE IDENTIFICATION NUMBER

(3)The vehicle Identification Number (VIN) is located on the

Safety Certification Label on the

left

side

of

the

steering

head.

(5) COLOR LABEL

(5)The color label is attached as

shown.

When ordering

color-coded parts, always specify the designated color

code.

1-3

General Information

Specifications

r-

General

------------------------------------,--------------------------------------------,

Dimensions

Frame

Engine

1-4

Item

Overall length

Overall

width

Overall height

Wheel base

Seat height

Footpeg height

Ground clearance

Dry

weight

(VF750C)

(VF750CD)

(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

type

Front suspension

Front wheel travel

Rear suspension

Rear wheel travel

Rear damper

Front tire size

Rear tire size

Tire brand (Front/Rear)

Front brake

Rear brake

Caster angle

Trail length

Fuel

tank

capacity

Fuel

tank

reserve capacity

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

2,332

mm

(91.8

in)

854

mm

(33.6

in)

1,136

mm

(44.7 in)

1,190

mm

(46.9

in)

1,652

mm

(65

in)

710

mm (28 in)

290

mm

(11.4

in)

155

mm (6.1 in)

229

kg

(505

lbs)

231 kg

(509

lbsl

230

kg

(507

lbs)

232

kg (511 lbs)

247

kg

(545

lbs)

249

kg

(549

lbs)

248

kg

(547

lbs)

250

kg (551 lbs)

180

kg

(397

lbs)

Double cradle

Telescopic

fork

150

mm (5.91 in)

Swingarm

Specifications

100

mm

(3.94

in)

Double

effect

type

120/80-17

61V

150/80-15M/C

70V

K555F/K555

(Dunlop)

Hydraulic brake

Internal expanding shoe

32°

137

mm

(5.39

in)

13.9

lit (3.7 US gal, 3.1 Imp gal)

3.3

lit

(0.87

US gal,

0.

73

Imp gall

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

Trochoid

Liquid cooled

Paper filter

Unit-type, 4 main journal

80.3

kg

(177

lbs)

1-90°

-4-270°

-3-90°

-2-270°

-1

4 cylinder

90°

V LEFT

FRONT

General Information

-General (Cont'dl Item Specifications

Carburetor Carburetor

type

CV (Constant Velocity) type,

with

flat

valve

Venturi diameter

33

mm

(1.30

in)

Drive Train Clutch system Multi-plate,

wet

Clutch operation system Cable operating

Transmission 5 speeds

Primary reduction

1.939

(64/33)

Secondary reduction

--

Third reduction

--

Final reduction 2.

500

(40/16)

Gear ratio

1st

2.846

(37/13)

Gear ratio 2nd

1.882

(32/17)

Gear ratio 3rd

1.450

(29/20)

Gear ratio

4th

1.227

(27/22)

Gear ratio 5th

1.035

(29/28)

Gear ratio

6th

--

Gear ratio reverse

--

Gearshift pattern Left

foot

operated return system

1-N-2-3-4-5

Electrical Ignition system Full transistor ignition

Starting system Starter

motor

Charging system Triple phase

output

alternator

Regulator/rectifier

type

SCR

shorted/triple phase, full-wave rectification

Lighting system Battery

AC regulator

type

--

1-5

General Information

Unit: mm (in)

....-

Lubrication

-----------------.-------------------;-------,

Item

Engine oil capacity

at

draining

at

disassembly

at

oil filter change

Recommended engine oil

OIL VISCOSITIES

[liT

0

20

"10

60

80

100·~

•20•10

0

10

20

30

"'I'C

Oil

pressure

at

oil pressure

switch

Oil pump rotor

tip

clearance

CD

body clearance ®

end clearance @

Standard Service Limit

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)

--

Use Honda GN4 4-stroke Oil or equivalent

API Service Classification:

SF

or

SG

Viscosity: SAE

10W-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,

71.1-85.3

psi)

at

6,000

rpm

(80°C/176°F)

0.

10

(0.004)

0.15-0.22

(0.006-0.009)

0.02-0.09

(0.001-0.004)

0.15

(0.006)

0.35

(0.014)

0.10 (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 injection control valve vacuum

pressure

VP31A

VP30A

VP32D

#102

#40

see page

5-1

6

see page

5-17

13.7

(0.54)

Within

20

mmHg

(0.8

inHg)

No. 1 carburetor

1,000

±

100

rpm

1,1

00

± 1

00

rpm

1,000

±

100

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

2.4

£

(0.6

US gal,

0.5

Imp gal)

0.4

£ (0.1 US gal,

0.09

Imp gal)

107.9

kPa

(1.1 kg/cm2,

15.64

psi)

80-84°C

(176-183°F)

95°C

(203°F)

8.0

(0.315)

min.

General Information

Unit: mm

(in)

Cylinder Head

--------------,--------------,---..:...._

__

__:_:,

Item

Cylinder compression

Cylinder compression synchronization difference

Valve clearance

IN

EX

Cylinder head warpage

Cam lobe height

CD

IN

EX

Camshaft runout @

Camshaft oil clearance

HOLD

Camshaft journal O.D.

Camshaft holder I.D.

Valve stem O.D.

IN

EX

Valve guide I.D.

IN

EX

Stem-to-guide clearance

IN

EX

(California type)

Valve guide projection above cylinder head

IN

EX

Valve seat

width

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 spring free length

Valve lifter O.D.

Valve lifter bore I.D.

Standard

1,275

kPa

(184.9

psi,

13.0

kg/cm2

)/

500

rpm

0.16 ±

0.02

(0.006

±

0.001)

0.25

±

0.02

(0.010

±

0.001)

35.980-36.140

(1.4165-1.4228)

35.670-35.830

(1.4043-1.4106)

0.030-0.072

(0.0012-0.0028)

24.949-24.970

(0.9822-0.9831)

25.000-25.021

(0.9843-0.9851)

4.475-4.490

(0.1762-0.1767)

4.465-4.480

(0.4758-0.1764)

4.500-4.512

(0.1772-0.1776)

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)

1.0

(0.04)

37.86

(1.49)

25.978-25.993

(1.0225-1.0233)

26.010-26.026

(1.0240-1.0246)

Service Limit

0.

10

(0.004)

35.95

(

1.4153)

35.64

(1.4031)

0.05

(0.002)

0.10

(0.004)

24.94

(0.982)

25.05

(0.986)

4.46

(0. 175)

4.45

(0.175)

4.56

(0.179)

4.56

(0.179)

1.5

(0.06)

36.1 (1.42)

25.96

(1.022)

26.04

(1.025)

1-7

General Information

Unit: mm (in)

-Clutch System

Item

Standard Service Limit

Clutch lever free play

10-20

(0.4-0.8)

--

Clutch outer guide I.D.

24.995-25.012

(0.9841-0.984

7)

25.08

(0.987)

Clutch spring free length

44.4

(1.75)

41.2(1.62)

Clutch disc thickness A

2.92-3.08

(0.115-0.121)

2.5

(0.10)

B (Judder spring side)

2.92-3.08

(0.115-0.121)

2.5

(0.10)

Clutch palte warpage

--

r-

Cylinder/Piston

--------------...----------------.---------,

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)

d

~H

Cylinder-to-piston clearance

Piston pin O.D.

Piston-to-piston pin clearance

Connecting rod-to-piston clearance

Top ring-to-ring groove clearance

Second ring-to-ring groove clearance

Top ring end gap

Second ring end gap

Oil ring (side rail) end gap

Top ring mark

Second ring mark

70.000-70.015

(2.755-2.756)

70.10

(2.759)

0.10 (0.004)

0.

10 (0.004)

0.10

(0.004)

With

"IN"

mark facing

to

the intake side

69.970-69.990

(2.755-2.756)

69.85

(2.750)

10

(0.4)

17.002-17.008

(0.6694-0.6695)

17.02

(0.670)

0.010-0.035

(0.0004-0.0014)

16.994-17.000

(0.6691-0.6693)

0.002-0.014

(0.0001-0.0005)

0.016-0.040

(0.0006-0.0016)

0.015-0.050

(0.0006-0.0019)

0.015-0.045

(0.0006-0.0018)

0.20-0.35

(0.008-0.014)

0.35-0.50

(0.014-0.020)

0.20-0.80

(0.008-0.031)

Install

with

the marked side up

Install

with

the

marked side up

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

------------------,---------------~---------.,

Connecting rod small end I.D.

Connecting rod big end side clerance

radial clearance

Crankshaft runout

CD

Crankpin oil clearance

Connecting rod bearing selection

Main journal oil clearance

Main journal bearing selection

1-8

17.016-17.043

(0.6699-0.6706)

0.10-0.30

(0.004-0.012)

0.030-0.052

(0.0012-0.0020)

See

page

11-9

0.019-0.037

(0.0007

-0.0015)

See page 11-8

17.04

(0.671)

0.40

(0.016)

0.05

(0.002)

0.08

(0.003)

0.05

(0.019)

General Information

Unit: mm

(in)

r-

Transmission Item Standard Service Limit

Transmission gear I.D.

M5

28.000-28.021

(1.1

024-1.

1

032)

28.04

(1.104)

C2

31.000-31.016

(1.2205-1.2211)

31.04

(1.222)

C3

31.000-31.016

(1.2205-1.2211)

31.04

(1.222)

C4

31.000-31.016

(1.2205-1.2211)

31.04

(1.222)

Transmission gear bushing O.D.

M5

27.959-27.980

(1.1007-1.1016)

27.94

(1.010)

C2

30.970-30.995

(1.2193-1.2203)

30.95

(1.219)

C3

30.950-30.975

(1.2185-1.2195)

30.93

(1.218)

C4

30.950-30.975

(1.2185-1.2195)

30.93

(1.218)

Transmission gear bushing I.D.

M5

24.985-25.006

(0.9834-0.9845)

27.94

(1.010)

C2

28.000-28.021

(1.1024-1.1032)

28.04

(1.104)

C3

27.995-28.016

(1.1022-1.1029)

28.04

(1.104)

Gear-to-bushing clearance at

M5

gear

0.020-0.062

(0.0008-0.0024)

--

at C2 gear

0.005-0.046

(0.0002-0.018)

--

at C3 gear

0.025-0.066

(0.0001-0.0026)

--

at C4 gear

0.025-0.066

(0.0001-0.0026)

--

Mainshaft O.D. at

M5

gear bushing

24.959-24.980

(0.9826-0.9835)

24.95

(0.982)

I@

I

~

~~

I

Countershaft O.D.

at

C2 gear bushing

27.967-27.980

(1.1011-1.1016)

27.96

(1.101)

I

811!!1~~

~

Gear-to-shaft clearance

--

Gear bushing-to-shaft clearance at

M5

gear

0.005-0.047

(0.0002-0.0019)

--

at

C2 gear

0.020-0.054

(0.0008-0.0021)

--

at C3 gear

0.015-0.049

(0.0006-0.0019)

--

at

C4

gear

0.015-0.049

(0.0006-0.0019)

--

Shift fork

claw

thickness L

6.43-6.50

(0.253-0.256)

6.40

(0.252)

c

6.43-6.50

(0.253-0.256)

6.40

(0.252)

R

6.43-6.50

(0.253-0.256)

6.40

(0.252)

Shift fork I.D. L

14.016-14.034

(0.5518-0.5525)

14.043

(0.5529)

c

14.016-14.034

(0.5518-0.5525)

14.043

(0.5529)

R

14.016-14.034

(0.5518-0.5525)

14.043

(0.5529)

Shift fork shaft O.D.

13.973-13.984

(0.5501-0.5506)

13.965

(0.5498)

1-9

General Information

,...-

Wheel/Tires Item

Minimum tire tread depth

(FR)

(RRl

Cold tire pressure

Up

to

90

kg

(200

lb) load

(FRl

Up

to

90

kg

(200

lbl load

(RRl

Up

to maximum weight capacity

(FRl

Up

to

maximum weight capacity

(RR)

Front and rear axle runout

Front and rear wheel rim runout (Radial)

Wheel balance weight (Front)

(Rear)

Drive chain slack

Drive chain size/link (DID)

(RK)

,...-

Front Suspension

Fork spring free length

Fork spring direction

Fork tube runout

Recommended fork oil

Fork oil level

Fork oil capacity

Steering bearing preload

(Axial)

Standard

--

250

kPa

(2.50

kg/cm2,

36

psi)

250

kPa

(2.50

kg/cm2,

36

psi)

250

kPa

(2.50

kg/cm2,

36

psi)

290

kPa

(2.90

kg/cm2,

42

psi)

--

20-30

(3/4-1·3/16)

DID

50V4/118

RK

50

MFOZ1/118

410.7

(16.17)

Tapered coil facing

down

Fork fluid

122

(4.80)

521cc

(17.62

US

oz,

18.29

Imp

oz)

0.1-0.15

kg-m

Unit: mm (in)

Service Limit

1.5

(0.06)

2.0

(0.08)

--

0.2

(0.01)

2.0

(0.08)

2.0

(0.08)

60

g (2.1

oz)

60

g (2.1

oz)

--

402.5

(15.85)

0.2

(0.01)

-Rear Suspension

----------------.-----------------r----------.

Shock absorber spring free length

Shock absorber spring adjuster standard position

Shock absorber spring direction

241.8

(9.52)

2nd groove

Small coil end facing

down

237.0

(9.33)

,...-

Brakes

-----------------~---------------T---------~

Front

Rear

1-10

brake fluid

brake pad wear indicator

CD

~

brake disc thickness

brake disc runout

master cylinder I.D.

master piston O.D.

caliper cylinder I.D.

caliper piston O.D.

brake pedal free play

brake drum I.D.

brake lining thickness

DOT 4

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)

To the groove

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-

Battery/Charging System Unit: mm

(in)

Item Standard Service Limit

Alternator/charging coil resistance (at

20°C/68°F)

o.1-1.o

n

--

Regulator/rectifier regulated voltage/amperage

14-15.5

V/below

0.5

A/3,000

rpm

--

Battery capacity

12

V-10

Ah

--

Battery charging rate (Normal)

1.2

A

(5-10hl

--

(Quick) 5 A (1h)

--

Battery voltage (fully charged

20°C/68°F)

Over 13.1 V

--

(needs charging

20°C/68°F)

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

Starter motor brush length

Starter clutch driven gear O.D.

CR8EH9

U24FER9

CR9EH9

U27FER9

0.8-0.9

(0.03-0.04)

12

° BTDC at idle

2,000

rpm

2-4

n

23-27

kO

13-17

kO

450-550

n

12.0-13.0

(0.47-0.51)

4

7.175-4

7.200

(

1.8573-1.8583)

6.5

(0.26)

47.16

(1.857)

r-

Lights/Meters/Switches

-----------..,..---------------.----------,

Main fuse

Fuse

Headlight (high/low beam)

Tail/brake light

Position 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

85°C

(185°F)

120°C

(248°F)

Fan

motor

switch

Starts

to

close

(ON)

Stops

to

open

(OFF)

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

12V

1.7Wx

1,

12V

1.4Wx2

12

v 3 w

12

v 3 w

12 V

3W

12

v 3 w

12

v 3 w

12V

3W

39-49

n

14-18

n

97-103°C

(207-217°F)

92-98°C

(198-208°Fl

1-11

General Information

Torque

Values

r-

Standard

Fasteners Type Torque Fasteners Type Torque

N·m

(kg-m,

ft-lbl

N·m

(kg-m,

ft-lbl

5 mm hex

bolt

and

nut

5 (0.5, 3.5) 5

mm

screw

4 (0.4,

31

6

mm

hex

bolt

and

nut

10

(1.0,

7)

6

mm

screw

9 (0.9,

7)

8

mm

hex

bolt

and

nut

22

(2.2,

16) 6

mm

flange

bolt

(8

mm

head) 9 (0.9,

7)

10

mm

hex

bolt

and

nut

35

(3.5,

25) 6

mm

flange bolt (10

mm

head)

and

nut

12

(1.2,

9)

12

mm

hex bolt and

nut

55

(5.5,

40) 8

mm

flange

bolt

and

nut

27

(2.7,

20)

1

0

mm

flange

bolt

and

nut

40

(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

molybdenum 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 tool.

9.

Apply

grease

to

the

threads and flange surface.

10. UBS bolt.

11.

U-nut.

12. ALOC bolt; Replace

with

a

new

one.

-Engine

Item

O'ty

Thread Torque Remarks

dia. (mm) N•m (kg-m,

ft-lbl

Maintenance:

Timing hole cap 1

45

18

(1.8,

13) Note 9

Lubrication:

Oil pressure

switch

1

PT

1/8

12

(1.2,

9) Note 1

Oil

filter

1

20

10

(1.0,

7)

Note 6

Oil

filter

stud

bolt

1

20

18

(1.8,

13) Note 2

Oil drain

bolt

1

12

34

(3.4,

25)

Oil pump

bolt

3 6

13

(1.3,

9)

Oil pump driven sprocket

bolt

1 6

18

(1.8,

13) Note 2

Oil pipe

nut

(After

'94)

1 6

12

(1.2,

9) Note

11

Fuel Systems:

Connecting

tube

band

screw

4 5 1

(0.1,

0.7)

Cooling Systems:

Water

pump

cover 2 6

13(1.3,9)

Water

pump

mounting

bolt

2 6

13

(1.3,

9)

Cylinder Head:

Spark plug 4

10 12

(1.2,

9)

Head cover

protector

8 6

10

(1.0,

7)

Cylinder head cover bolt 8 6

10

(1.0, 7)

Breather case

bolt

6 6

10

(1.0,

7)

Cylinder head

protector

bolt

12

6

12

(1.2,

9)

Cylinder head sealing bolt 4

18

44

(4.4,

32) Note 2

Cylinder head

bolt

(9 mm)

16

9

44

(4.4,

32) Note 6

Cylinder head

bolt

(6 mm) 4 6

12

(1.2,

9)

Camshaft holder

bolt

32

6

12

(1.2,

9) Note 6

Cam chain tensioner

mounting

bolt

4 6

12

(1.2,

9)

Boost

joint

bolt

-5 4 (0.4, 2.9)

1-12

General Information

-Engine

Item

Q'ty

Thread Torque Remarks

dia.(mm)

N·m

(kg-m, ft-lb)

Clutch/Gearshift Linkage

Right crankcase cover

bolt

13

6

12

(1.2,

9)

Clutch cable holder bolt 1

10

23

(2.3,

17)

Clutch spring bolt 5 6

12

(1.2,

9)

Clutch center lock

nut

('94)

1

22

90

(9.0,

65) Note 5, 6

(After

'94)

1

22

110

(11.0,

80) Note 5, 6

Gearshift link

joint

bolt 1 6 9 (0.9, 6.5)

Change pedal

pivot

bolt

1 8

27

(2.7,

20)

Drive sprocket cover bolt 3 6

10

(1.0,

7)

Drive sprocket cover rubber bolt 2 6

12

(1.2,

9)

Drive sprocket bolt 1

10

51

(5.1,

37)

Shift

drum center bolt 1 8

23

(2.3,

17) Note 2

Shift

return spring pin 1 8

23

(2.3,

17)

Crankcase/Crankshaft:

Upper crankcase bolt

(10

mm) 2

10

39

(3.9,

28)

Upper crankcase bolt (6 mm) 7 6

12

(1.2,

9)

Lower

crankcase bolt (9 mm) 8 9

31

(3.1,

22) Note 6

Lower crankcase bolt (8 m) 1 8

23

(2.3,

17)

Lower crankcase bolt (6 mm) 8 6

12

(1.2,

9)

Cam chain tensioner slipper

bolt

2 6

12

(1.2,

9) Note 2

Cam chain slipper bolt 2 6

12

(1.2,

9) Note 2

Connecting rod bearing cap

nut

8 8

33

(3.3,

24) Note 6

Sealing bolt 1 8

18

(1.8,

13) Note 2

Alternator:

Left crankcase cover bolt 6 6

12

(1.2,

9)

Flywheel bolt 1

10

83

(8.3,

61) Note 6

Stator mounting bolt 3 6

12

(1.2, 9)

Ignition System:

Pulse generator mounting

bolt

3 6

10

(1.0,

7)

Starter Clutch:

Starter

motor

flange

nut

1 6

10

(1.0,

7)

Starter

motor

case bolt 2 5 5

(0.5,

3.6)

Starter clutch bolt 1

12

90

(9.0,

65) Note 6

Starter clutch outer cover bolt 3 8

40

(4.0,

29) Note 2

Lights/Meters/Switches:

Neutral

switch

1

10 12

(1.2,

9)

-Frame

Item

Q'ty

Thread Torque Remarks

dia. (mm) N•m (kg-m, ft-lb)

Engine mounting:

Front cylinder head mounting bolt 2

10

54

(5.4, 39)

Front engine mounting bracket bolt 4 8

39

(3.9,

28)

Front engine mounting

bolt

2

10

44

(4.4,

32)

Rear

engine mounting bracket bolt 2 8

39

(3.9,

28)

Rear engine mounting bolt 1

12

64

(6.4,

46) Note 9

Rear cylinder head

mount

bolt 2

10

44

(4.4,

32)

Rear cylinder head

mount

bracket bolt 4 8

39

(3.8,

28)

1-13

General Information

-Frame

Item

O'ty

Thread Torque Remarks

dia. (mm) N•m (kg-m,

ft-lbl

Front Suspension:

Handlebar upper holder bolt 4 6

23

(2.3, 17)

Front fender bolt 4 6

12

(1.2,

9)

Steering stem

nut

1

24

105(~,76)3

1-

page 12-12

Lock

nut

1

26

Steering head bearing adjusting

nut

1

26

30

(3.0, 22)

Fork pinch bolt (upper) 2 8

27

(2.7, 20)

(lower) 2

10

39

(3.9, 28)

Fork cap 2

37

23

(2.3, 17)

Fork socket bolt 2 8

20

(2.0, 14) Note 2

Fork drain bolt 2 6 8 (0.8, 5.8)

Rear Suspension:

Frame pivot adjusting bolt 1

20

15(1.5,11)~

f-

page

13-10

Frame lock

nut

1

20

64

(6.4, 46)

Frame lock bolt 1

10

39

(3.9, 28)

Swingarm pivot

nut

1

14

89

(8.9, 65) Note

11

Chain slider screw 2 5 6 (0.6, 4.3)

Chain tensioner 2 8

22

(2.2, 16)

Shock absorber mounting bolt (upper) 2 8

27

(2.7, 20)

(lower) 2

10

37

(3.7, 27)

Wheels:

Speedometer cable screw 1 5 4 (0.4, 2.9)

Rear

axle

nut

1

18

93

(9.3, 63) Note

11

Front axle bolt 1

14

59

(5.9, 43)

Axle pinch bolt 4 8

22

(2.2, 16)

Brake disc bolt 6 8

42

(4.2, 30) Note 12

Driven sprocket

nut

5

12

108

(10.8, 79) Note

11

Brake System:

Brake hose bolt 2

10

35

(3.5, 25)

Caliper bracket bolt 2 8

31

(3.1, 22) Note 12

Front brake hose clamp

nut

2 6

12(1.2,9)

Note

11

Front master cylinder holder bolt 2 6

12

(1.2,

9)

Front master cylinder reservoir cover screw 2 4

1.5

(0.15,

1.1)

Front brake light

switch

screw 1 4

1.2

(0.12,,0.9)

Front brake lever

pivot

bolt 1 6 1 (0.1, 0.7)

nut

1 6 6 (0.6, 4.3)

Pad

pin plug 1

10

2.5

(0.25, 1.8)

Pad

pin 1

10

18

(1.8, 13)

Brake caliper bleeder bolt 1 8

5.5

(0.55, 4)

Brake caliper bracket pin bolt 1 8

13

(1.3,

9)

Note 2

Brake caliper pin bolt 1 8

23

(2.3, 17) Note 2

Rear

brake pedal pivot bolt 1

10

39

(3.9, 28)

Rear

brake pedal linkage

joint

pinch bolt 1 8

27

(2.7, 20)

Rear

brake arm pinch bolt 1 8

29

(2.9, 21) Note 12

Rear

brake stopper arm

nut

2 8

22

(2.2, 16)

Frame/Exhaust Systems:

Exhaust pipe

joint

nut

8 8

12

(1.2,

9)

Exhaust pipe band bolt 4 8

21

(2.1, 15)

Exhaust pipe protector bolt 6 6

12(1.2,9)

Muffler

mounting bolt 2 8

27

(2.7, 20)

Lights/Meters/Switches:

Side stand pivot bolt 1

10 10

(1.0,

7)

nut

1

10

30

(3.0, 22)

Side stand

switch

1 6

10

(1.0,

7)

Others:

Footpeg bracket bolt 4 8

27

(2.7 20)

Fuel valve 1

22

23

(2.3, 17)

1-14

------------

-----------------------------

----------

-----

----

----·---

General Information

Tools

Description Tool Nunber Applicability

Maintenance:

Oil filter wrench

07HAA-PJ70100

Drive chain cutter

07HMH-MR10102

or

07HMH-MR1010B

U.S.A. only

Link plate holder

07NMH-MW00110

or

07PMH-MZ20110

Lubrication:

Oil pressure gauge

07506-3000000

Oil pressure gauge attachment

07510-4220100

Fuel System:

Float level gauge 07401

-0010000

Pilot screw wrench (Canadian type)

07908-4220201

(49 states, California type)

07MMA-MV9010A

Cylinder Head/Cylinder/Piston:

Valve spring compressor

07757-0010000

Valve spring compressor attachment

07959-KM301

01

Tappet hole protector

07HMG-

MR70002

Not

available in U.S.A.

Valve guide drivier

07HMD-ML00101

Valve guide reamer,

4.5

mm 07HMH

-ML001

01

Valve seat

cutter

seat cutter,

24.5

mm

(45°

EX)

07780-0010100

29

mm

(45°

IN)

07780-0010300

flat cutter,

25

mm

(32°

EX)

07780-0012000

30

mm

(32°

IN)

07780-0012200

interior cutter,

26

mm

(60°

EX)

07780-0014500

30

mm

(60°

IN)

07780-0014000

cutter holder,

4.5

mm

07781-0010600

Compression gauge attachment

07JMJ-KY20100

Tensioner stopper

07NMG-MY90100

Not available in U.S.A.

Clutch/Gearshift Linkage:

Lock

nut

wrench,

26

x

30

mm

07716-0020203

'94

only

Extension bar

07716-0020500

'94

only

Clutch center holder

07724-0050001

Equivalent commercially

available in U.S.A.

Crankshaft/Transmission:

Universal bearing puller

07631-0010000

Inner driver C

07746-0030100

Attachment, I.D.

25

mm

07746-0030200

Front Wheel/Suspension/Steering:

Bearing remover shaft

07746-0050100

Bearing remover head,

20

mm

07746-0050600

Attachment,

42

x 47 mm

07746-0010300

Pilot,

20

mm

07746-0040500

Fork seal driver

07947-KA50100

Fork seal driver attachment

07947-KF00100

Steering stem socket wrench

07916-3710101

Ball race remover

07953-MJ10000

-attachment

07953-MJ10100

or

07953-MJ1000A

U.S.A. only

-driver handle

07953-MJ10200

or

M9360-277-91774

U.S.A. only

Ball race remover

07946-3710500

Attachment, 52 x

55

mm

07746-0010400

Steering stem driver

07946-

MBOOOOO

Driver

07749-0010000

1-15

General Information

Description Tool Number Applicability

Rear Wheel/Suspension:

Bearing remover shaft

07746-0050100

Bearing remover head,

20

mm

07746-0050600

Attachment,

42

x

47

mm

07746-0010300

Pilot,

20

mm

07746-0040500

Attachment, 52 x 55 mm

07746-0010400

Attachment,

62

x

68

mm

07746-0010500

Pilot,

25

mm

077

46-0040600

Shock absorber compressor

07959-3290001

Driver shaft

07946-MJ00100

or

07949-3710001

U.S.A. only

Attachment,

28

x

30

mm

07946-1870100

Pilot, 22 mm

07746-0041000

Attachment,

32

x

35

mm

07746-0010100

Pilot, 15 mm

077

46-0040300

Needle bearing remover attachment

07GMD-KT70200

Bearing remover or

M967X-038-XXXXX

U.S.A. only

Attachment,

30

mm

07746-0030300

U.S.A. only

Driver

07749-0010000

Brake:

Snap ring pliers

07914-3230001

Charging System/Alternator:

Flywheel holder

07725-0040000

Rotor puller

07733-0020001

Electric Starter/Starter Clutch:

Gear holder

07724-0010100

Electrical Equipment:

Digital multimeter (KOWAl

07411

-0020000

Equivalent commercially

available in U.S.A.

Analog tester

07308-0020001

(SANWA) Not available in U.S.A.

or TH-5H (KOWAl

1-16

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Magna VF750C User manual

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