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ACE Manual

Shadow ACE 750

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Gilang Dhikapati Abiwata
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2K views426 pages

ACE Manual

Shadow ACE 750

Uploaded by

Gilang Dhikapati Abiwata
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
MOTORCYCLES, MOTOR SCOOTERS OR ATV! HOW TO USE THIS MANUAL ‘This service manual describes the service procedures | for the VT70C/CD/CDA/C3/CD3. Follow the Maintenance Schedule (Section 3) recom- mendations to ensure that the vehicle is in peak ‘operating condition and the emission levels are within the standards set. Performing the first scheduled maintenance is very important. It compensates for the initial wear that ‘occurs during the break-in period ENGINE AND DRIVE TRAIN 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. Section 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 start with an assembly or system illustration, service information and troubleshooting for the section. ‘The subsequent pages give detailed procedure. Ifyou don’t know the source ofthe trouble, goto section 21 Troubleshooting, ALL INFORMATION, ILLUSTRATIONS, DIREC- ‘TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE CHASSIS CONTENTS GENERAL INFORMATION GB | FRAME/BODY PANELS/EXHAUST | 3 Syetew i MAINTENANCE [iE LUBRICATION SYSTEM FUEL SYSTEM [coouncsystem OR [cLuTCH/GEARSHIFTLINKAGeE = "ALTERNATOR/STARTER CLUTCH E [cvunperHeapjvatves sR CRANKSHAFT/TRANSMISSION E FRONT WHEEL/SUSPENSION/ STEERING 13 REAR WHEE: L/BRAKE/SUSPENSION I ] HYDRAULIC BRAKE i TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION. WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PEP:MISSION. THIS MANUAL IS WRITTEN FOR SONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA HONDA MOTOR CO., LTD. ‘SERVICE PUBLICATION OFFICE ELECTRICAL BATTERY/CHARGING SYSTEM i IGNITION SYSTEM gg CeuectricstarTeR si LIGHTS/METERS/SWITCHES _ E [wirincpiacramM = sss PD “TROUBLESHOOTING 2B ie CB INDEX Date of Issue: June, 2000 © HONDA MOTOR CO,, LTD. SYMBOLS ‘The symbols used throughout this manual show specific service procedures. if supplemeritary information is required | pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. Ropiace the partis) with new ones) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution . (mixture of the engine oil and molybdenum gréase in a ratio of 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 Sam RBH | Earp: Noiykote? BR? plus manufactured by Dow Coming, USA NH “Se Am 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* BR-2 plus, manufactured by Dow Corning, US.A. Honda Moly 60 (U.S.A. oniy) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply @ locking agent. Use a middle strength locking agent unless otherwise specified. SEB | sppiysoatant, a Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. MME | Use Fork or Suspension Fi ‘ ‘J 1. GENERAL INFORMATION GENERAL SAFETY 11 TOOLS 117 SERVICE RULES 1-2 LUBRICATION & SEAL POINTS 1-19 MODEL IDENTIFICATION 13 CABLE & HARNESS ROUTING 1-22 SPECIFICATIONS 1-4 EMISSION CONTROL SYSTEMS = 1-34 TORQUE VALUES 1-13 EMISSION CONTROL INFORMATION LABELS 1:36 GENERAL SAFETY ‘CARBON MONOXIDE USED ENGINE OIL. 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, WR 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. 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 under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS: CC — Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. CE _ Used engine oi! may cause skin cancer if repeatedly left in contact with the skin for profonged periods. Although this is unlikely unless you handle used oil on a dally basis, its 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. BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies. BRAKE FLUID CAUTION: _ Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP QUT OF REACH OF CHILDREN. GENERAL INFORMATION COOLANT Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the engine ethylene glycol does ignite, you will not see any flame, but you can be burned, VRE + Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flame. + Coolant (ethylene glycol) can cause some skin irritation and is poisonous if swallowed, KEEP QUT OF REACH OF CHILDREN. + Koop out of reach of pets. Some pets are attracted to the ‘smell and taste of coolant and can dle Ifthey drink it. + Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could seald you. CAUTION: Using coolant with silicate Inhibitors may cause promature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. Itt contacts your skin, wash the affected areas immediately with soap and water. If it contacts your eyes, flush them thoroughly with fresh water and get immediate medical attention. If it is swallowed, the vietim must be forced to ‘vomit, then rinse mouth and throat with fresh water before obtaining medical attention. Because of those dangers, always keop from the reach of children. Recycle used coolant in an ecologically correct manner. SERVICE RULES BATTERY HYDROGEN GAS & ELECTROLYTE Ln - + The battery gives off explosive gases; keep sparks, flames and cigarettes avvay. Provide adequete ventilation when charging + The battery contains sulfurie 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. =H electrolyte gets in your eyes, flush with water for at least 16 minutes and calla physilan immediately. Electrolyte is poisonous. = if swallowed, drink large quantities of water oF milk and follow with milk of magnesia or vegetable oil and ‘calla physician. KEEP OUT OF REACH OF CHILDREN. 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA’s design specifications may cause damage to the motorcycle, 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metrie tools when servicing the motorcycle, Metric bolts, nuts and screws are not interchangeable with English fasteners, 4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembiing. 5, When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly 7. Alter reassembly, check all parts for proper installation and operation 8. Route all electrical wires as shown on pages 1-22 through 1-33, Cable and Harness Routing. GENERAL INFORMATION MODEL IDENTIFICATION FRAME SERIAL NUMBER, (1) The frame serial number is stamped on the right side of the steering head. ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER (2) The engine serial number is stamped on the right (3) The Vehicle Idenfication Number (VIN) is attached side of the crankcase below the rear cylinder. con the left side of the steering head. CARBURETOR IDENTIFICATION NUMBER COLOR LABEL (4) The carburetor identification numbers are stamped (6) The color label is attached on the frame back of the (on the intake side of tho carburetor body as shown. loft side cover. When ordering color-coded parts, always specify the designated color code. 1-3 GENERAL INFORMATION SPECIFICATIONS ren SPECIFICATIONS DIMENSIONS | Overall langth 280 mm 8. Overt wen 80 nnn) Over heigt rete: 1.435 mm (447i) \rsocore02 (9 - 2000): 1135 04.7 (ater 2000 nto mm 427) vrrsocae03 | {ito mm (3) wheelbasa {sts mm (e360) Seat ognt a0 78 Footoeg heloht Boa (119 round soeanoe 14s mm i) Dryweisht 22849 Ib Curb weight | 246 kg (642 Ibs) | Maximur weight capacity ‘Ho 49 675 bo) FRAME | Frametyoe Double eae Front suspension | Telaseope fork | Font wheel avel eommssin) Rear suspension Saigon Rear wel Wave some (5 in fect camper Nivogon gas filed damper Frome ae tose. 33 Rua trosie towo-te Me77S rebrand Bridgestone Frome Grote: 6702 Dunlop Front b4odReer D408 Front bake Hyaraute single cise broke Fear bake Inernel exparsing shoe Caster ante soso" ‘ral engin 187 mn (62) Fol tant capacity Ie Ter (870 US gol 3.08 mp gab I Flot tank Yeorve spacty Sb tor 0.88U8 val, 781m gel ENGINE | Bore and stroke 7.0 780 mm (3.11 X29) Diplocrmant pis enr oui) Conrescon fs bot Vave ain Sion, link chen dive and OHC with rocker arm | mtakeveNe opens SBTOG et mm loos nit oiase 2" aBbC Exhaust vole opens Soveape Sloes carbo Lubrication system | Fores pessure and wet sump Oitpunp type Trochold Coating eyseom gut cooled aireaton Paper iter | Cantona type Caitype, bv main jourats Engine cry weight Saseg ist be) Fira order Front 908 Rear 412° Front Gyr rangement ‘foo cynder SV ranveraa Chine number Prone 42 Roa CARBURETOR] Carburetor toe CV (Constant Velocity) dua carburetor with ful pump Tete bore Stmmitin GENERAL INFORMATION GENERAL (Cont'd) rem ‘SPECIFICATIONS DRIVE TRAIN | Clutch system Multi-plate, wat Clutch operation system Mechanical type Transmission Constant mesh, 5-speed Primary reduction 1.887 (65/39) Final reduction 2412 (4117) Gear ratio ast | 3.167 (38/12) 2nd | 2.000 (34/17) 3rd | 1.500 (30/20) ath | 1.174 (27/23) 5th | 1.042 (25/24) Gearshift pattern ELECTRICAL | Ignition system Starting system Loft foot operated return system, 1-N-2-3-4-5 Full transistor digital ignition Electric starter motor Charging system | Triple phase output alternator Regulator/rectifior SCR shorteditriple phase, full wave rectification Lighting system Battery 1-5 GENERAL INFORMATION ; LUBRICATION SYSTEM Unitrin) Tem STANDARD SERVICE LIMIT Engine oll capacity at draining 2.2 liter (2.32 US at, 1.94 Imp ai) [ —— at cisassombly 2.9 iter (9.06 US at, 2.55 Imp ct) 7 - at oil fiter change 2. iter (2.54 US qt, 2.17 Imp at) — Recommended engine oil HONDA GN4 4-stroke olor equivalent = motor oi [API service classification SF or SG ee —__| Viscosity: SAE 10¥V-40 il pressure at oil pressure switch '530 kPa (6.4 kgficm’, 77 psi) at — | 5,500 rpm (80"C)176°F) = Oil pump rotor Tip clearance |_.0.15 (0.006) 0.20 (0.008) [ Body clearance | 0.15 -0.22 01006 0.009) eas 001) | Side clearance 0,020.07 (0.001 - 0.003) 0.10 (0.004) + FUEL SYSTEM Tem SPECIFICATIONS Covburator identification | state [98 Vora number wpe VoFFJ =| vores - VDFEC 8 EFSUCT VOFES we VDFFS | Main jet Front _ v5 | [Ree - #0 ‘Slow jet 7 #40 Pilot serew "nitaifinal opening See page S22 Float level 7.0 mn (0.28 in) Base carburetor (for synehwonization) oar cylinder (#1) - idle speod 1,000 +100 rpm Carburetor vacuum difference 27 kPa (20 mm Hg, 0.7 in Hg) PAIR control valve spe ‘Throttle grip free play Fuel pump fiow capacity ied vacuum 325 mm Hg (12.8 in ig) 2-6 mm (1/12 Vain) Minimum 900 em? (30.4 US 02, 31.7 Imp oz) per minute at 12V. SPECIFICATIONS - COOLING SYSTEM ITEM Coolant capacity Radiator and engine Ress Radiator cap relief pressure ‘Thermostat | Begins to open Fully open [Valve lit Recommended antifreeze Standard coolant concentration 175 ter (7.85 US at 154 imp at) Out iter (0.42 US at, 0.35 Imp at 108 ~ 137 kPa (1.1 — 1.4 kgflom’, 16-20 psi ‘8 mm (0.3 in} minimum Pro Honda HP Coolant or an equivalent high quality ethylene alycol antifreeze containing corrosion protection inhibitors 50% mixture with soft water GENERAL INFORMATION > CLUTCH SYSTEM ete: mm fn mem STANDARD SERVICE Limit (Clutch lever free play 10-20 (78-3) — [Clutch spring freelength 455 (179) 9073) Clutch disc thickness [A — 2.62 2.78 (0.103 -0.107) 23 (0.08) 8 — 2.82 ~3.08 (0.115 0.121) 2.6 (0.10) “Clutch plate warpage ~ — [0.20 0012) | Clute outer guide 1B. Tarai 22076 a8888 0.8688) 72.03 (0867) 0.0. | 29.994 30.007 (1.1809 ~ 7.1814) 29.98 (1.180) _| Oil pump drive sprocket LD. 30,025 — 30.145 (1.1821 ~ 1.1868) 30.15 (1.187) Mainshafi 0.0. at clutch outer guide 21,967 21.980 (0.8648 — 0.8654) 21.95 (0.864) > ALTERNATOR/STARTER CLUTCH tt ITEM ‘STANDARD SERVICE LiniT Starter driven gear Lio. 40,000 ~ 40.021 (7.5748 — 1.5756) "40.10 (1.578) foo: ‘57.749 — 67.768 (2.2736 ~ 2.2743) 57.73 (2273) Starter clutch outer 1D. T4.A14— 74,440 (2.9297 ~ 2.9907) 74.48 (2.931) ¢ CYLINDER HEAD/VALVES Lee: rae fn) Tem STANDARD SERVICE LIMIT Cylinder compression 1,278 = 98 kPa (13.0 LO Kgi/om, — 18514 psi) at 400 rpm Cylinder head warpage — —= [0.10 (0.004) Valve, Valve clearance IN | 0,730.17 (0.005 - 0.007) — valve guide | &X__| 018-022 10.00 = Valve stem 0.0, IN| 5.475~ 5.490 (0.2156 ~ 0.2161) 5.46 (0.216) | EX__| 6.555 — 6.570 (0.2580 - 0.2587) 655 Valve guide 1. IN | 5.500 ~5.512 (0.2165 ~ 0.2170) 5.56 EX _| 6.600 ~ 6.615 (0.2598 - 0.2604) Siem-to-guide clearance IN | 0.010 0.037 (0.0004 — 0.0075) EX | 0.030 0.060 (0.0012 0.0024) 0.11 (0.004) | Valve guide projection above | IN 19.50.77) — —— eylinder head ex [80070 s — Valve seat width INEX | 0.90 -1.1010.035 -0.085) 75 (006) “Valve spring free length TN | 42.14 01.659) — 40.58 (1.598) EX__| 42.83 (1.686) 41.25 (1.628) Camshaft] Gam abe height IN| 38381 (15117) ~ [30.10 1.500) | EX | sa.4o7 1.512) _ 138.20 (1504) [Sournal 0.0. [21.959 21.900 (0.8646 - 0.8654) 21.90 0862) Runout ~ 0.030 (0.072 10.05 (0.002) Oil clearance 0.050 ~ 0.111 (0.0020 ~ 0.0084) (0.13 (0.005) —_Preenttication marks [res Front,“": Rear = Rocker arm 1D. — TINEX | 12000- 12.016 (04724-0478) 12.05 (0.474) Rocker arm shaft 0.D. INVEX | 11.966 ~ 11.986 (0.4711 - 0.4718) | 11.83 (0.466) Rocker arm-to-rocker arm shaft clearance 0.016 ~ 0.082 (0.0006 — 0.0020) [0.97 0.003) 1-7 GENERAL INFORMATION > CYLINDER/PISTON Units men Gin} rem STANDARD ‘SERVICE LIMIT Cylinder 40. | 71000 76.075 (2.1102 - 3.1108) 73.108.110) [out of round —— 0,06 (0.002) [Teper — (0.06 (0.002) | Warpage =<: 0.10 (0.004) Piston, piston | Fist “IN” mark facing towerd the intake side — rings: Fiston 0.0. ‘78.97 ~ 78.99 (3.109 - 3.110) 78.90 (3.106) _ [Piston 0.D. measurement point 7=17 mm (03-01 in) from bottom ofskit | __ ——__| Piston pin bore. 118.002 ~ 18.008 (0.7087 - 0.7030) ) | Piston pin 0.0. 17.994 18.000 (0.7086 0.7087) 77.98 (0.708) _| Piston-o-piston pin dearanas 0.002 ~ 0.014 (0.0001 - 0.0008) 0.04 (0.002) _| Piston ring-toving | Top 0,028 — 0.085 (0.0010 0.0022) 0.08 (0.003) | eroovecearance’ | Second 1.015 0.048 (0.0006 0.0078) 20710003) | [Piston ring end gap | Top | 88-2800| 0.20 ~0.35 (0.008 0.014) 2510.02) | ‘ter 200| 0.18 ~0.26 (0,008 - 0.010) 0.4 (0.02) ‘Second | 36-200 | 0:35 0.60 (0.014 - 0.020) 07 (0.08) | : ‘ter 2000| 0.25 = 0.40 (0,010 - 0.016) 0.6002 | | Oil(side rein | 0.20~0.80 (0.008 0.031) [10 10.08) Piston ring mark | Top [eR mark | ‘Second =RN” mari “| Cylindort piston clearance 10.010 0.045 (0.0004 - 6.0078) 0.10 (0.004) Connecting rod small end LD. 18.016 - 18.034 (0.7083 0.7100) reo7(o.71) | Connecting rod-to-pston pin clearance 0.016 0.040 (0.0006 - 0.0076) 0.06 0.0021 1-8 GENERAL INFORMATION ~ CRANKSHAFT/TRANSMISSION Uni Te STANDARD SERVICE LIMIT Crankshaft | Side clearance 0.05 ~0.20 (0,002 0,008) 0.30 (0072) Runout — 0.08 0.001), Crank pin ofl clearance 0.028 ~ 0,082 0.0071 - 0.0020), [0.07 (0.003) Main journal oil clearance | 0.030 - 0.046 (0.0012 - 0.0018) 0.07 (0.003) Transmission | Gear LD. M3, 28,000 28,021 (1.1024 - 1.1032) 78.08 (1.108) €1,C2, Ch 31.000 31.025 (1.2 31.05 (1.222) Bushing OD. M3, MS 27.969 27.960 {1.1007 7.94 (1.100) - ¢1.C2, Ce 30,950 30.975 (1.2185 - 1.2195) 30.93 (1.218) Bushing LD. Ma 25,000 25.021 {0.9843 - 0.9851) 25.06 (0.986) 2 77.995 ~ 28.016 (1.1021 ~ 1.1030) 28.06 (1.108) Ma, MB 0,020 ~ 0,062 (0.0008 - 0.0024) 0.10 0.008) 1, C2, Ca 0.025 ~ 0,075 (0.0070 - 0.0030) 0.11 (0.004) [Mainshat 0.0. | M3 bushing | 24972 24.999 (0.9831 - 0.9840) 24.95 0.982) [case journal A | 19.980 - 19.993 (0.7866 - 0.7871) 73,96 (0.786) Case journal 8 | 21.967—21 980 (0.8648 - 0.8654) 21.94 (0.064) Countershaft 0.0. | C2 bushing [2795004 Case journal A 27.95 (1.100) - Case journal B 19.96 (0.786) Bushing-to-shaft | M3 10.007 - 0.049 (0.0003 - 0.0019) 0.08 (0.003) Clearance c2 (0.049 (0.0006 - 0.0019) 10.08 (0.003) Shift fork, fork | Fork 1D. 13.000 13.021 (0.5118 ~ 0.5126) 73.04 (0513) stan Claw thickness | 5.93 - 6.00 (0.233 ~ 0.236) 5.6 (0.22) Fork shaft 0. 12,966 ~ 12.984 (0.5106 ~ 0.5112) 12.80 (0508) Shift drum 0.0. (at left sido journall 11966 17.984 (0.4711 = 0.4718) 11.94 (0.470) GENERAL INFORMATION - FRONT WHEEL/SUSPENSION/STEERING Voit mm tnt ITEM STANDARD SERVICE LIMIT Minimurm tire tread depth = 1.5 (0.06) Coldtire pressure | Up to 90 kg (200 Ib) load 200 KPa (2.00 kgf/cm’, 29 psi) - — Upto maximum weight capacity | 200 kPa (2.00 kgf/cm, 29 psi) —_ | ‘Axle runout - - (0.20 (0.008) Wheol rim runout | Radial - - 2.0(0.08) Axial 2.0 (0.08), i nce (wage) i balance weight - — @0g R10) "Spring free lenath 30841794) 2973 (11.701 Tube runout 020 (0.008) ‘Steering head bearing preload | Recommended fork fluid Pro-Honda Suspen: — | oil level 308 (4.3) — il capacity 514 +2.5 cm’ (17.4+ 0.08 US o7, — | 18.0 + 0.09 Imp o2) 0.43 ~ 1.04 kgf (0.95 = 2.30 Ib) nits mm Cin ; REAR WHEEL/BRAKE/SUSPENSION Unit: ee dn} Tem STANDARD SERVICE LIMIT ‘Minimum tire treed depth —= 2,0 (0.08) Coldtire pressure | Up to 80 kg (200 Ib) load 200 KPa (2.0 kalo, 28 psi — | Up to maximum weight eapacity | 250 kPa (2.60 kgf/em, 36 psi) ‘Axio runout - — — 0 (0.008) | Wheol im runout | Radial — .0 (0.08) ‘Axial - = 2.0 (0.08) Whee! hub-to-rim distance [ioage 148) — Whee! balance weight = 70.9 (25 02) Drive chain slack - 15-25 5-1) 40(1375) Drive chain link aL — Drive chain size [DID 525 V8 — RK 525 SMOZS — Rear brake Drum 1D, Z 180.0 ~ 180.3 (7.08 -7.10) 181 7.13) Lining thick 510.2) 200.1) Brake pedal height 50 mm (2.0 in) above the top of the footneg |__ —— Brake pedal treo play 20-30 (9/4 ~ 1-14) — Shock absorber spring preload adjuster setting | and position — 1-10 GENERA! \L INFORMATION - HYDRAULIC BRAKE - Lok mm Gnh ew STANDARD SERVICE LiniiT | Specified brake fluid ee [pots _ | Brake pad wear indicator _ —= Togroove | Brake disc thickness - 5.86.2 (0.23 -0.24) 5(0.2) Brake disc runout - — 030 0.012) | Master cylinder LD. 11.000 11.083 (0.4331 1105 (0.435) Master piston 0.0. 10.957 ~ 10.986 (0.4314 — 0.4324) 10.948 (0.4309) nder LD. 27.08 (1.085) Caliper piston 0.0. 25,935 ~ 26.968 (1.0604 ~ 1.0617) [268s (1.080) > BATTERY/CHARGING SYSTEM Tem SPECIFICATIONS Battew | Capacity 218A — Current leakage I 1.0 mA max Voltage 20°C/6a*)] Fully charged 13.0- 13.2 | Needs charging Below 12.3 V - Charging euront | Normal 1.4 N5- 10h ‘Quick 6OAthmax | Alternator | Capacity 345 W/5,000 rpm Charging coil resistance (20°C/68: 3a | Regulatorrecttier regulated voltage 44 15 V4,000 rom IGNITION SYSTEM mem SPECIFICATIONS [Spark plug NGK DENSO Standard DPREEAS X24EPR-US | For eold climate (below 5CI41"F) DPRIEAS XZ2EPRUS - tended high speed riding DPROEA 9 XZTEPRUS Spark plug gep 0,80 - 0.80 mn (0.081 0.035 in) Ignition coil primary peak voltage “il 100 V minimum __| Ignition pulse generstor peak voage or viii — Ignition timing “F* mark © BTDC at 1,000 rem Advance | Start 3,000 + 200 rpm | [Stop 5,500 + 200 rpm Full advance 245" BTDC 2¢ 5,500 rom 1-11 GENERAL INFORMATION - ELECTRIC STARTER Untesrom tiny TEM STANDARD SERVICE Linirr Starter motor brush length 12.5 (0.49) [6.5 (0.26) ; LIGHTS/METERS/SWITCHES TEM ‘SPECIFICATIONS Bulbs Headlight (High/Low — 2V— 80/8 — [Braker ight Front turn signalunning fi i Tav- 26 WX2 ~ Rear turn signal ight TeV 21WX2 License light TV —4CP Speedometer | VT750C av_aaw light yrrsocbico2 ('38- 2000), ~ VI780CD1002 (tar 2000) v750ca/CD3 fave | Turn signal indicator 1v-3aW | igh beam indicator ~ - Ww-346w Neutral ingicator - Ww-34W \V7s0cD/C02 tater 2000) 1-34 vT7S0C3/CD3 [. ae Oit indicator | VT50C0/C02 (ter 2000) tov ae vrisocajco3 Temp indicator | VT7S0C0,C02 (ter 2000) | vi7s0c3/CD3 BSE. - Fuse Main fuse 308 Sub fuse 0x4, 5AXT Fan motor | Stars to close (ON) ~ : ‘98 102 °C (208-216 °F) ‘ewiteh Starts to open (OFF) _ 93-97°C (199-2077) Coolant “Starts to close (ON) 112 = 118°C (259 - 270 °F) swith “"" | Starts to open (OFF) Below 108 °C (252 °F) 1-12 GENERAL INFORMATION TORQUE VALUES TORQUE ‘TORQUE FASTENER TYPE Nem (kghm, tbe) FASTENER TYPE Nem (kgfm, Ibftt) 5 mm hex bolt and nut 5(0.5,3.6) | Smmscrew - 4 (044,29) 6 mm hex bolt and nut 10(1.0,7) | 6mm screw 9 (0.9, 6.5) 8 mm hex bolt and nut 22(2.2, 18) | 6 mm fienge bolt (8 mm head) 9 (0.9, 65) 10 mm hex bolt and nut 34(3.5,25) | 6 mm flange bolt (10 mm head) and nut, 12(1.2,8) 412 mm hex bolt and nut 54(65, 40) | 8mm flange bolt and nut 26 (2.7, 20) 40 mm flange bolt and nut 39 (4.0, 29) + Torque specificaton: NOTES: 1. Apply sealant to the threads. 2. Apply a locking agent to the threads. 3. Apply grease to the threads. 4. Stoke. ted below are for important fasteners. + Others should be tightened to standard torque values listed abov 3. Apply oil to the threads and flange surface, 5 6. Apply oil to the threads and O-ring 7. Usnut. 8 ALOC bolt: replace with a new one. 9. Left hand threads 10. CT bolt 11. CT bolt (one-side only) r ENGINE THREAD TORQUE rem ony DIA. (mm) | Nem (kgfim, bt) | REMARKS ‘MAINTENANCE: ‘Spark plug 4 2 14 (1.4, 10) Crankshaft hole cap 1 2 18115, 11) | NOTES Timing hole cap 1 30 115,11) | NOTES Valve adjusting screw lock nut 6 7 23(23,17) | NOTES Oil drain bolt 1 1“ 30 (3.1, 22) Oil fter cartridge 1 20 10(10,7) | NOTES Vacuum plug 2 5 30.3, 2.2) LUBRICATION SYSTEM: Oil pressure switch 1 P18 12(1.2,9) | NOTE1 Oil pressure switch cord terminal screw 1 4 2 (0.2, 1.4) Oil pump cover bolt 6 13(13,8) | NOTEt0 COOLING SYSTEM: Water pump cover bolt 3 6 131138) | NOTE 10 CLUTCH/GEARSHIFT LINKAGE: Clutch liter plate bolt 4 6 12(1.2,9) Clutch center lock nut 1 18 128 (130,98) | NOTE 4,5 Primary drive gear bott 1 2 88(9.0,65) | NOTES Gearshift return spring pin 1 8 23:23, 17) Oil pump driven sprocket bott 1 6 15(15,11) | NOTE2 ENGINE MOUNTING: Left rear cover bolt } 4 6 72(0.2,9) Drive sprocket bolt | 2 6 10(10,7) Drive chain guide plate bolt | 2 6 120.2,9) | NOTEN. 1-13 GENERAL INFORMATION ENGINE (Cont'd) me [or | aSTeAm mm stn | REMARKS ALTERNATORSTARTER LUTE Flywheel bolt 1 2 127 (13.0,94) | NOTE 5,9 Stator mounting socket bolt 4 6 | “12012,9) | NoTe2 Starter one-way clutch hosing bolt 6 8 29(3.0,22) | NOTE2 Ignition pulse generator bolt | 2 6 12(12,9) | NOTE2 crinsee essences 10mm nut 8 10 | 4744.8, 35) NOTE 5 Cylinder head fin socket bolt 5 6 101.0,7) | CRANKCASE/CRANKSHAFT/TRANSMISSION: | Connecting rod bearing cap nut a) 8 33(4,25) | NOTES ELECTRIC STARTER: | 1-14 GENERAL INFORMATION > FRAME F THREAD trem aty DIA. (mm) REMARKS, FRAME/BODY PANELS/EXHAUST SYSTEM: ] Exhaust pipe joint nut 4 8 25 (2.6, 18) Muffler bracket nut 52 8 28 (2.7, 20) ‘Muffler mounting bolt | 2 8 26 (2.7, 20) Front soat bolt }o4 8 26 (2.7, 20) Rear seat bolt 1 6 910.9, 6.5) Rear fender 8 mm bolt 6 8 26 (2.7, 20) Grab rail 10 mm bolt 2 10 64 (65, 47), 24 mm nut 1 7 88 (9.0, 65), 14mm bolt 1 1“ 108 (11.0, 80) Fuel tank bolt Joa 8 19 (1.9, 14) Fuol valve 1 2 34 (3.5, 25), Battery box bolt 1 6 10(1.0, 7) Tool box cover screw 4 4 240.2, 1.4) MAINTENANCE: Air cleaner housing cover bolt 6 6 240.2, 1.4) Side stand assembly 2 10 34 (3.5, 25), Side stand pivot bolt 1 10 10 (1.0, 7), lock nut 1 10 29 (3.0, 22) Brake pedal stopper lock nut 1 6 10 (1.0,7) Spoke nipple 104 4 4104, 2.9) ‘COOLING SYSTEM: Radiator mounting bolt 1 6 210.2, 1.4) Radiator coolant drain bolt 2 6 13.(1.3,9), Fan motor bolt 3 5 310.3, 2.2) Cooling fan nut 1 5 310.3, 2.2) Radiator filler bolt 2 6 910.9, 6.5) ‘Thermostat housing cover bolt 2 6 910.8, 6.5) Fan motor switch 1 Pr ve 8(08,58) | NOTE? ‘Water pump cover bolt 2 6 13.(1.3,9), ENGINE MOUNTING: Front engine mounting bolt 2 10 54 (55,40) | Rear engine mounting bolt 1 10 54 (5.5, 40) Front engine bracket bolt 2) 8 26 (2.7, 20) Rear engine bracket bolt 2 8 26 (2.7, 20) Gearshift arm pinch bolt 1 6 12(1.2,9), CLUTCH GEARSHIFT LINKAGE: Footpeg set arm bolt 4 8 26 (2.7, 20) Gearshift pedal pivot bolt 1 10 34 (3.5, 25) FRONT WHEEL/SUSPENSION/STEERIN( Steering stem nut 1 24 103 (10.5, 76) +See page 13-40 Top thread A 1 26 — Top thread 8 1 26 — | Top bridge pinch bolt 2 8 26 (2.7, 20) Bottom bridge pinch bolt 2 10 49 (5.0, 36) Handlebar upper holder bolt 4 8 23 (2.3, 17) Handlebar lower holder nut 2 8 26 (2.7, 20) Handlebar switch screw 4 5 310.3,2.2) | Clutch lever holder bolt 2 6 12(1.2,9) Front axie 1 4 59 (6.0, 43) Front axle pinch bolt 2 8 22 (2.2, 18) Front brake dise bolt 6 a 42(43,31) | NOTES Fork cap 2 38 222.2, 18) Fork socket bolt 2 8 29(3.0,22) | NOTE2 1-15 GENERAL INFORMATION > FRAME (Cont'd) . THREAD TORQUE Ween ri DIA (mm) | Nem (kgf-m, Ibf-fey | REMARKS REAR WHEEL/SUSPENSION: ] Fear axle nut 1 8 93(95,69) | NOTE? Driven sprocket nut 5 2 98 (90,65) | NOTET Rear shock absorber mounting bolt 4 8 25 (2.7, 20) Swingarm pivot aut }o4 “ 83 (900,65) | NOTE? Swingarm pivot adjusting bolt Joa 26 25 (25, 18) ‘Swingarm pivot lock nut 1 26 64 (6.5, 47) Drive chain slider sorew 2 5 310.3, 22) Brake pedal pivot bot 1 i} 34 (8.5, 25) Rear brake stopper arr bolt 2 8 20.20, 14) Rear brake arm bolt 1 8 2980, 22) Rear brake mice ro joint bolt 1 10 34 (85, 25) HYDRAULIC BRAKE: ‘Brake caliper mounting bolt 2 8 | 3061.22) | NoTE6 Caliper pin bolt 1 8 26 (27, 20) Bracket pin bolt 1 8 73(13,9) Pad pin 1 10 1818, 13) Pad pin plug 1 70 | 303,22) Broke caliper bleeder 1 8 6108,4.3) Brake lever pivot bolt Joa 6 (0.1.0.7) Brake lever pivot nut 1 6 606,43) Master eylinder holder bolt 2 8 a3) Master cylinder cover screw 2 4 2 (0.2, 1.4) | Front brake light switch sorow 1 4 4 (041,027) Brake hose oil bolt 2 | 34035, 25) BATTERY /CHARGING SYSTEM: Battery box cover screw 3 6 1110.7) LIGHTS/METERS/SWITCHES: Side stand switch mounting belt 1 6 10(10,7) | NOTES Thermasensor 1 er ve 121129) | NOTE? 1-16 TOOLS NOTES: 1. Alternative tool. 2. Newly provided tool. 3. Equivalent commercially available in U.S.A, 4. Not available in U.S.A. GENERAL INFORMATION DESCRIPTION Carburetor float level gauge Oil pressure gauge Vacuum gauge attachment Oil pressure gauge attachment Gear holder | Flywhee! holder Rotor puller Valve guide remover, 5.5 mm Valve guide remover, 6.8 mm Valve guide driver attachment (IN) (EX) Attachment, 32X38. mm Attachment, 37 X 40. mm ‘Attachment, 42 X 47 mm ‘Attachment, 62 X 65 mm Attachment Pilot, 12 mm Pilot, 15 mm Pilot, 20 em Pilot, 25 em Pilot, 30 mm Pilot, 22 mm Bearing remover shaft Bearing remover head, 17 mm Bearing remover head, 20 mm Attachment, 28 X 30 mm Driver Valve spring compressor Valve seat cutter Seat cutter, 27.5 mm (48° IN) Seat cutter, 35 mm (45° EX) Flat cutter, 28 mm (32° IN) Flat cutter, 96 mm (32° EX) Interior cutter, 30 mm (60° IN) Interior cutter, 37.5 mm (60" EX) Cutter holder, 5.5 mm (IN) Cuttor holder, 8.6 mm (EX) Valve agjusting wrench Snap ring pliers Steering stem socket, Bearing remover set Remover weight — Remover handle = Bearing remover set Attachment, 28 X 30 mm Bearing race remover Driver shaft ‘Attachment Slider weight Driver attachment set ‘TOOL NUMBER (07401 - 0010000 (07506 - 3000000 (07510 ~ 3000200 (07510 ~ 4220100 (07724 - 0010100 07725 - 0040000 07733 - 0020001 (97742 -0010100 (07742 -0010200 (07743 - 0020000 07743 ~ MF50100 0743 ~ MF50200 (0746 - 0010100 (07746 -0010200 (07746 - 0010300 07746 - 0010400 (0746 ~ 0030300 (0746 0040200 (07746 - 0040300 0746 0040500 0746 - 0040600 0746 0040700 07746 - 0041000 (07746 - 0050100 07746 ~ 0050500 (07746 - 0050600 0746 - 1870100 07749 ~ 0010000 07757 -0010000 07780 - 0010200 0780 - 0010400 0780 -0012100 07780 - 0012300 0780 - 0014000 07780 0014100 0781 ~ 0010101 0781 - 0010202 07908 - KES0000 07914 ~ 3230001 07916 -3710101 07936 - 3710001 0741 ~0010201 07936 -3710100 07936 ~3710600 07946 - 1870100 07946 - 3710500 (07946 ~ M0000 ‘07946 - 00200 (07947 ~ KA50100, 07947 ~ KF00100 ] j j J] REMARKS NOTES NOTE 1: O7LM4-001000A (U.S.A only} NOTES NOTES NOTE 1: 07933-3280001 NOTE 4 8,14 12,1314 12,13 8 4 12,13, 14 2 8 12,14 13,14 18 13,14 12,13, 14 10 NOTES | NOTE 1:07908-KE80100 (U.S.A. only) | 3 2,14, 15 13 2 NOTE 1: 079163710100 NOTE 4 NOTE 1: 078363710208 (US. only) r07936:3710200 NOTE 4 1-17 GENERAL INFORMATION DESCRIPTION ‘TOOL NUMBER REMARKS: REF. SEC. Driver shaft Ball race remover = Driver attachment - Driver handle Valve guide reamer, 5.510 mm (IN) Valve guide reamer, 6.612 mm (EX) ‘Swingarm pivot lock nut wrench Oil filter wrench Peak voltage adapter Drive chain tool set ‘Spoke wrench Clutch center holder Pilot screw wrench 794s - 3710001 07953 - MJ10000 (07953 - MJ10100 (07953 ~ M1020 7984 - 2000001 07984 - 220001 o7GMa- «T7020 O7HAA- PJ70100 07H, - 0020100 O7HMH ~ MR10103 o7JMA~ MR60100 o7JMB~ MNO3Ot O7KMA ~ MS60101 NOTE 1; 07984-20000 (US.A only) NOTE 1: 07384-2E20000 (USA only) NOTE 4 NOTE 1: O7HMH-MR70108 (USA. only) NOTES NOTE 2 NOTE 1:07HG8-0070108 (07HGB-001010A and (07HG8-0010208 or (O7HGB-0010208 (USA. only) 4 13 10 10 1“ 3 ” 3 3,13,14 8 1-18 GENERAL INFORMATION LUBRICATION & SEAL POINTS r ENGINE LOCATION MATERIAL REMARKS. Camshaft lobes/journals Valve stem (valve guide sliding surface) Rocker arm slipper surface Rocker arm shaft outer surface Connecting rod bearing surface Crankshaft journals Clutch outer guide outer surface Transmission gear shift fork groove Transmission collar inner and outer surface Transmission spline collar outer surface Connecting rod small end inner surface Molybdenum disulfide oll (a mixture of 1/2 engine oll and 12 molybdenum disulfide grease Piston outer surface Piston ring outer surface Piston pin outer surface Primary drive gear bolt threads and seating surface Flywhee! bolt threads and seating surface ‘Starter one-way clutch sliding lock surface Starter idle and reduction gear shaft outer surface Clutch center lock nut threads Clutch lifter arm-to-right crankcase cover sliding surface Clutch lifter rod-to-right crankcase cover sliding surface Clutch dise outer surface Cylinder stud bolt threads Cylinder head 8 mm bolt threads Valve adjusting screw threads and seating surface Connecting rod boltinut threads and seating surface Cylinder head mounting bolt and nut seating surface Cylinder head cover mount rubber seal whole surface Transmission gear tooth Ol filter cartridge threads and O-ring Each bearings rolling area Each O-rings Engine oll Air cleaner housing-to-chamber band inside surface Crankshaft hole cap threads Timing hole cap threads Each oil seal lips Multi-purpose grease il pressure switch threads 3-4mm (0.12 -0.16 in} Right and left crankcase mating surface Fan motor switch threads Sealant 1-19 r ENGINE (Cont'd) LOCATION MATERIAL, REMARKS. Right crankcase cover mating surface (After 2000) Sealant Cam sprocket bolt threads Starter one-way clutch housing bolt threads il pump driven sprocket bolt threads Stator wire holder socket bolt threads Gearshift cam plate bolt threads Transmission bearing set plate bolt threads Countershaft oi! seal sot plate bolt threads Cam chain tensioner set plate bolt threads Stator mounting bolt threads i filter boss crankcase side threads Ignition pulse generator bolt threads Loft erankcase cover bolt threads (marked “A” A Locking agent | Coating width: 65+ 1mm (0.26+0.08 in) Cylinder head cover-to-gasket groove HONDA BOND Aor equivalent 1-20 GENERAL INFORMATION pr FRAME LOCATION MATERIAL REMARKS. ‘Steering head bearing sliding surface Steering head dust seal lips Clutch lever pivot bolt sliding surface Throttle grip inner surface Throttle pipe rolled-up portion Throttle cable end. Rear wheel axle sliding surface Rear brake cam sliding surface Rear brake shoe-to-cam sliding surface Roar brake anchor pin sliding surface Rear brake pedal and rod pivot sliding surface Rear brake pivot bolt sliding surface ‘Swingarm pivot dust seal lips ‘Swingerm pivot needle bearing rolling area Side stand pivot sliding area Main and pillion step pivot sliding area Each dust seal lips Each oil seal lips Multi-purpose grease Spreading 1.0-2.0¢ Spreading 02-03 Spreading 0.5 ~1.0g Spreading 0.5 ~1.0g Spreading 1.0.9 Side stand pivot sliding surface Gearshift pedal pivot sliding surface Molybdenum disulfide grease Spreading 1.06 Brake master piston Brake caliper piston seals ‘Thermosensor threads ‘Sealant Cylinder joint collar O-ring Steering top threads Engine oll Roar brake cam felt seal Brake master cylinder cups DOT 4 brake fluid Brake lever pivot and piston tips Brake caliper dust seals Brake caliper slide pin sliding surface Brake caliper bracket pin sliding surface Silicone grease ‘Spreading 0.1 g min. Spreading 0.4.g min. Spreading 0.4.9 min. Brake caliper slide pin threads Brake caliper bracket pin thr Front fork socket bolt threads Locking agent ‘Axle and distance collar whole surface Gear oil Drive chain ‘480 - 90 gear oil Handle grip rubber inside Pro-Honda Spreading 80 % min. Handgrip Cement or equivalent Brake caliper bracket-to-retainer seating area Threebond #1621 Front fork rebound spring Front fork spring Fork cap O-ring Pro:Honda Suspension Fluid SS-8 Inside cables Cable lubricant 1-21 GENERAL INFORMATION CABLE & HARNESS ROUTING vr750 : \VT750CD/CD2 ('38 - 2000) LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE vi7s0¢ : \VT750C0/CD2 {'38 - 2000) : TURN SIGNAL WIRES LEFT HANDLEBAR SWITCH AGHT HANDLEBAR SWITEY 9P (WHITE) CONNECTOR. TURN SIGNAL RELAY 9P (RED) CONNECTOR ‘SPEEDOMETER 6P (BLACK) CONNECTOR INDICATOR LIGHT 6? (BLACK) CONNECTOR HEADLIGHT CONNECTOR 1-22 GENERAL INFORMATION \VT7S0CD/CD2 (After 2000) : \vT75003/CD3 : RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE TURN SIGNAL WIRES. \VI7S0CD/CD2 (After 2000) : \v1750C3/CD3 LEFT HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH 9P (WHITE) CONNECTOR: TURN SIGNAL RELAY 9P (RED) CONNECTOR SPEED SENSOR SP (WHITE) CONNECTOR T INDICATOR LIGHT 6? (BLACK) CONNECTOR HEADLIGHT CONNECTOR 1-23 GENERAL INFORMATION GENERAL INFORMATION GENERAL INFORMATION FRONT RIGHT SPARK PLUG WIRE FRONT IGNITION COIL IGNITION COIL PRIMARY WIRES FRONT LEFT STARTING ENRICHMENT FUEL PUMP OUTLET TUBE SPARK PLUG WIRE VALVE CONTROL CABLES 1-26 GENERAL INFORMATION FUEL FILTER, FUEL TANK BREATHER TUBE STARTER RELAY SWITCH IMAIN FUSE yy - FUEL PUMP OUTLET TUBE SDE STAND SUATCH OIL PRESSURE SWITCH wire ALTERNATOR WIRE SIDE STAND SWITCH NEUTRAL SWITCH WIRE WIRE 1-27 GENERAL INFORMATION GENERAL INFORMATION REAR LEFT IGNITION CONTROL MODULE ‘SPARK PLUG WIRE REAR RIGHT FUEL TANK BREATHER TUBE SPARK PLUG WIRE STARTER MOTOR CABLE FUEL TANK BREATHER TUBE 1-29 GENERAL INFORMATION vr750c : \i7s0CD/CD2 ('98 - 2000) : IGNITION CONTROL MODULE FUEL PUMP 2P (WHITE) CONNECTOR ENGINE SUB-HARNESS 2P (BLACK) CONNECTOR FUEL CUT RELAY IGNITION SWITCH 3P (WHITE) CONNECTOR: REGULATOR/RECTIFIER, FUSE 80x IGNITION COIL (REAR) SIDE STAND SWITCH ‘3P (GREEN) CONNECTOR 1-30 GENERAL INFORMATION \VT750CD/CD2 (After 2000) vi7s0c3/cD3 : IGNITION CONTROL MODULE ENGINE SUB-HARNESS 2P (BLACK) CONNECTOR, FUEL PUMP. 2P (WHITE) CONNECTOR IGNITION SWITCH 3P (WHITE) CONNECTOR PILOT LAMP CHECKER REGULATOR/RECTIFIER, IGNITION Coit (REAR) ALTERNATOR FUSEBOX 3P (WHITE) CONNECTOR SIDE STAND SWITCH 3° (GREEN) CONNECTOR 1-31 GENERAL INFORMATION GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) NOTE: ‘The hoses shown below are numbered as they appear on the Vacuum Hose Routing Diagram Label. (io TUBE . EVAPORATIVE EMISSION = @7UBE PURGE CONTROL @Tuse VALVE 1-33 GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency, Transport Canada, and California Air Resources Board (CARB) require ‘manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one 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 Limited Warranty for Honda Motorcycle 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 from photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way. but itis toxic. Honda Motor Co.,Ltd, utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons. EXHAUST EMISSION CONTROL SYSTEM ‘The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system. CRANKCASE EMISSION CONTROL SYSTEM ‘The engine is equipped with » closed crankcase system to prevent discharging crankcase emission into the atmosphere. Blow by gas is returned to the combustion chamber through the air cleaner and carburetor. DRAIN TUBE AIR CLEANER CRANKCASE BREATHER cover Or FRESH AIR, :BLOW-BY GAS 1-34 , GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) Je 0 This model complies with California Air Resources Board evapor ion requirements. Fuel vapor from the fuel tank and carburetors is routed into the evaporative emission (EVAP) canister where itis absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission (EVAP) purge control valve is open, fuel vapor in the EVAP canister is drawn into the engine through the carburetor. At the same time, the EVAP + carburetor air vent (CAV) control valve is open and air is drawn into the carburetor through the valve, EVAP PURGE CONTROL VALVE JP + DRAIN EVAP CANISTER EVAP CAV CONTROL VALVE EVAP CAV ‘CONTROL VALVE (ENGINE STOP) + TO OPEN AIR (2: FRESH AIR @ : FUEL VAPOR NOISE EMISSION CONTROL SYSTEM. | TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing | hereof: (1) The removal or rendering inoperative by any person, other than for purpases of maintenance, repair or replacement, ‘of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or [delivery to the ultimate purchaser or while itis in use; 2) the use of the vehicle after such device or element of design has {boon removed or rendered inoperative by any person. 7 @ AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1, Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conduete exhaust gases. 2, Removal of, or puncturing of any part of the intake system. 3. Lack of 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 manufacturer. | 1-35 GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS 1-36 ‘An Emission Control Information Label is located on the inside of the left side cover as shown. The left side caver must be removed to read it. Refer to page 2-3 for side cover removal. It gives base tune-up specifications. VEHICLE EMISSION CONTROL INFOR- MATION UPDATE LABEL ‘After making a high altitude carburetor adjustment, attach an update label on the inside of the left side cover as shown, Instructions for obtaining the update label are given, in Sorvice Letter No. 132. When readjusting the carburetors back to the low altitude specifications, be sure to remove this update label VACUUM HOSE ROUTING DIAGRAM LABEL (CALIFORNIA TYPE ONLY) The Vacuum Hose Routing Diagram Label is on the inside of the left side cover as shown. ‘The left side cover must he removed to read it. Refer to page 2-3 for side cover removal. VACUUM HOSE ROUTING EMISSION CONTROL DIAGRAM LABEL. INFORMATION LABEL 7 a AD) UPDATE LABEL EMISSION CONTROL INFORMATION LABEL (Canada type only) (VEHICLE EMISSION CONTROL INFORMATION UPDATE “HONDA OTOR CO,.1D 0 ‘Wis VEMICLE Mas BEEN ADJUSTED To InPROVE EWIsSION CONTROL PERFORMANCE WHEW OPERATED AT HIGH ALTITUDE ALTITUDE PERFORMANCE ADJUSTMENT INSTRUCTIONS. [ARE AVAILABLE’ AT YOUR AUTMORIZED HONDA DEALER. VACUUM HOSE ROUTING DIAGRAM ENGINE FAMILY—{———_] EVAPORATIVE FAMILY—[——] CALIFORNIA VEHICLE 2. FRAME/BODY PANELS/EXHAUST SYSTEM ‘SERVICE INFORMATION TROUBLESHOOTING SEAT STEERING COVER SIDE COVER 24 24 22 23 24 FUEL TANK 24 REAR FENDER 26 GRAB RAIL 2-6 EXHAUST PIPE/MUFFLER 27 SERVICE INFORMATION GENERAL + Gasoline is extremely flammable and is explosive under certain conditions. Work in @ well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline Is stored can cause a fire or explosion. + Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated ‘gloves or wait until the engine and exhaust system have cooled before handling these parts. 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 Tead to death. Run the engine in an open area or with an exhaust avacuation system in enclosed area. + Work in a well ventilated area, Smoking or allowing flarmes or sparks in the work area or where gasoline is stored can cause a fire or explosion, + This section covers removal and installation of the body panels, fuel tank and exhaust system. + Always replace the exhaust pipe gaskets when removing the exhaust pipe from the engine, + Always inspect the exhaust system for leaks after installation. TORQUE VALUES Exhaust pipe joint nut Matfer bracket nut Muffler mounting bolt Front seat bolt Rear seat bolt Roar fender bolt Grab rail 10 mm bolt 24 mm ut 14 mm bolt Fuel tank bolt Fuel valve Battery box bolt Tool box cover screw TROUBLESHOOTING Excessive exhaust noise * Broken exhaust system + Exhaust gas leak Poor performance * Deformed exhaust system + Exhaust gas leak + Clogged muffler 25Ne (2.5 kgfem, 18 lb-ft) 26 Nem (2.7 kgfem, 20 Ibfet) 26 Nem (2.7 kgfrm, 20 Ife) 26 Nem (2.7 kgfrm, 20 Ibe) 8 Nem (0.9 kam, 6.5 Ibff) 26 Nem (2.7 kgfem, 20 Ibe) 64 Ne (6.5 kafem, 47 Ib) 88 Nem (9.0 kgfem, 65 Ibfft) 108 Nem (17.0 kgf+m, 80 Ibfeft) 19 Nem (1.9 kgfem, 14 Ibfeft) 134 Nem (3.5 kgfem, 25 Ibfft) 10 Nem (7.0 kgf, 7 Ibftt) 2. Nem {0.2 kgfem, 1.4 IDF) FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL CAUTION: Be careful not to damage the rear fender surface. Romove the rear seat mounting bolt. Slide seat forward and lift up to remove the rear seat. Remove the front seat mounting bolt. Slide flont seat back and lift up to remove the front seat. INSTALLATION CAUTION: Be careful not to damage the rear fender surface. Install the front seat by inserting the hook of the seat under the raised lip of the fuel tank and push the seat forward. Align the bolt holes and tighten the bolt to the speci fied torque. TORQUE: 26 Nem (2.7 kgfem, 20 Ibf-t) FRAME/BODY PANELS/EXHAUST SYSTEM Install the rear seat by inserting the hook of the seat ‘over the front seat mounting bolt and push the seat backward. ‘Align the bolt holes and tighten the bolt to the speci- fied torque. TORQUE: 9 Nem (0.9 kgfem, 65 Ibf-ft) STEERING COVER REMOVAL/INSTALLATION ‘cauriol Be careful not to break the steering cover tabs. Remove the fuel tank (page 2-4). Remove the trim clips. Remove the right and loft covers as assembly. Remove the joint clip and separate the covers. Installation is in the reverse order of removal. NOTE: Check that the wire harness do not interfere with handlebar rotation. 2-3 FRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER GROMMETS Nom Be careful not to dislodge the grommets in the trai Release the cover bosses from the grommets and side cover. Bosses Installation is in the reverse order of removal. NOTE: At installation, align the cover bosses on the frame. ‘grommet. FUEL TANK FUEL TUBE PRM Gasoline is extremely flammable and Is explosive under certain conditions. NOTE: Before disconnecting fuel tube, turn the fuel valve “OFF. REMOVAL/INSTALLATION Remove the seat (page 2-2). \Vi7s0cac03 and Remove the speedometer (page 19-12). \vi7socoreo2 (ater 2000 Disconnect the fuel tube and air vent tube (to EVAP. canister: California type only} from the fuel tank. a " ‘AIR VENT TUBE. VA \ FRAME/BODY PANELS/EXHAUST SYSTEM Remove the fuel tank mounting bolt, washer and collar. Slide and remove the fuel tank to the back. Installation Is in the reverse order of removal ‘TORQUE: Fuel tank mounting belt: 19 Nem (1.9 kgfom, 14 Ibf-ft) CAUTION: Be careful not to pinch the wire harness between the fuel tank and the frame. BOLT No’ ‘After installation, turn tho fuel valve “ON" and check the fuel line for leakage. DISASSEMBLY/ASSEMBLY Loosen the fuel valve nut and remove the fuel valve. Remove the fuel strainer soreen and O-ring, Check that the fuel strainer screen is not clogged or damaged. Clean or replace if necessary. Assembly is in the reverse order of disassembly. NOTE: Always replace the O-ring with a new one. ‘TORQUE: Fuel valve nut: 34 Nem (3.5 kgfem, 25 Ibfft) Ss FUEL VALVE BODY 2 y & . FUEL STRAINER SCREEN FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER REMOVAL NOTE: Be careful not to scratch the fender or deform the ‘connector stay. Remove the front and rear seat (page 2-2) Remove the right side cover (page 2-4). Disconnect the tail/brake light connectors inside the connector boot. Remove the bolts, washers and the rear fender. Installation i in the reverse order of removal. ‘TORQUE: 26 Nem (2.7 kafom, 20 Ibftt) GRAB RAIL NOTE: ‘The rear fender must be removed from the frame before servicing the each side grab rails. LEFT SIDE Loosen the left grab rail mounting nut located on the left shock absorber mounting bolt. Remove the bolt, washer and left grab ral RIGHT SIDE Romovo the right side shock absorber (page 14-18). Remove the 10 mm bolt, washer, 14mm bolt and right grab rail Installation is in the reverse order of removal, ‘TORQUE: 10 mm bolt: 64 Nem (6.5 kgf+m, 47 Ibfft) 24 mm nut: 88 Nem (9.0 kgf+m, 65 Ibfeft) 14 mm bolt: 108 Nem (11.0 kgfem, 80 Ib) REAR FENDER CONNECTORS WASHER BOLT WASHER 14mm BOLT GRAB RAIL FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE/MUFFLER Gam Do not service the exhaust system while itis hot. caumi When removing/installing the exhaust pipe/muffter, loosen/tighten the exhaust system fasteners in the order as follows. REMOVAL Remove the exhaust pipe joint nuts Remove the muffler bracket nuts and exhaust pipe/ muffler assembly, Remove the front and rear gaskets. Remove the exhaust pipe joint collar. JOINT COLLAR 2-7 FRAME/BODY PANELS/EXHAUST SYSTEM The exhaust pipe protectors can be protector) and remove it. removing the exhaust system N9 not reuse rotactor. Penis are t reuse the removed protector INSTALLATION Install the exhaust pipe protectors. Install the exhaust pipe joint collar. Install the new gaskets, Drive the exhaust pipe protector using the plastic hammer and break the lock tab (reverse side of the removed without Lock TAB PLASTIC HAMMER. Break the lock tab -_ PROTECTOR PROTECTOR FRAME/BODY PANELS/EXHAUST SYSTEM Always inspect tho ‘exhaust system for ‘oaks alter instalation. Install the muffler assembly, Temporarily install the all nuts. Nott Tighten the muffler bracket nuts to the specified torque, “a TORQUE: 26 Nem (2.7 kgfom, 20 tbf-tt) 2 Tighten the exhaust pipe joint nuts to the specified ~ torque. TORQUE: 25 Nom (2.5 kgfom, 18 lbfstt) MEMO 3. MAINTENANCE SERVICE INFORMATION 3-1 EVAPORATIVE EMISSION CONTROL R\AINTENARCE: SCHEDULE 3g SYSTEM (CALIFORNIA TYPE ONLY) 3-17 DRIVE CHAIN 3-18 FUEL LINE 3-4 BRAKE FLUID 3-22 THROTTLE OPERATION 3-4 BRAKE SHOE/PAD WEAR 323 | CARBURETOR CHOKE 3-5 BRAKE SYSTEM 3-23 AIR CLEANER 3-6 BRAKE LIGHT SWITCH 3-25 CRANKCASE BREATHER 3-7 HEADLIGHT AIM 3-25 SPARK PLUG 3-7 CLUTCH SYSTEM 3-26 VALVE CLEARANCE 3-9 SIDE STAND 3:26 ENGINE OIL/OIL FILTER 31 SUSPENSION 3-27 CARBURETOR SYNCHRONIZATION 3-14 NUTS, BOLTS, FASTENERS 3-27 ENGINE IDLE SPEED 3415 WHEELS/TIRES 3-28 RADIATOR COOLANT 3-16 STEERING HEAD BEARINGS 3-29 COOLING SYSTEM 316 SERVICE INFORMATION GENERAL + Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated ares. Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion. + lf 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. Run the engine in an open area or with an exhaust evacuation system in enclosed area. + Place the motorcycle on a level ground before starting any work SPECIFICATIONS rem SPECIFICATIONS Throttle orp tree play - 2-8mm (2-4 in) Spark plug - NGK DENSO Standard - DPRAEAS X2AEPR-UB | For cold climate (below 5/81) DPR7EAS X226PR-U9 For extend high speed riding DPRSEAS XZ7EPR-US Spark plug gap (0.80 — 0.90 mm (0.031 0.035 in) | Valve clearance | IN (0.13 ~ 0.17 mm (0.005 ~ 0.007 in) x (0.18 — 0.22 mm (0.007 - 0.009 in) _ | MAINTENANCE rem SPECIFICATIONS Engine oil capacity | at draining 2.2 liter (2.32 US at, 1.94 Imp atl at disassembly | 23 liter (3.06 US at, 2.55 Imp atl atl filter change 24 liter (2.54 US at, 2.11 Imp at! Recommended engine oll HONDA GN4 4-stroke oll or equivalent motor oil API service classification SF or SG Viscosity: SAE 10W-40 [Engine ite speed 4,000 # 100 rpm rburetor vacuum 274Pa (20 mm Hg, 0.7 in He) Drive chain slack 15-25 mm (85-1 in) Drive chain link 722 Drive chain size | DID. 5258 RK 525 SMB Brake pedal height 50 mm (2.0 in) above the top of the footpog Brake pedal free play 20 — 30 min (9/4 = 1-1/4 ind Recommended brake fuid ~ [oor Clutch lever free play - 10-20 mm @/8— 3/4 in) Tiresieo Front 120180-17 68S Rear 170/80-15 MC 778, Tire brand Bridgestone Front | G701 Rear (6702 Dunlop Front | D408 [Rear A404 Tire air pressure | Upro.90kg 20016) | Front | 200 kPa (2.00 kaliem, 29 psid load Rear 200 kPa (2.00 kaflom?, 29 psid Uptomaximum [Front 200 kPa (2.00 kgtlor’, 29 psi weighteapecity | Rear 250 kPa (2.50 kal/cm®, 36 psi) ‘Minimum tive ead depth Front | 1.5 mm (0.08in) Rear 2.0 mim (0.08 TORQUE VALUES Air cleaner housing cover bolt Spark plug Crankshaft hole cap Timing hole cap Valve adjusting screw lock nut Oil drain bolt il fiter cartridge Vacuum plug Roar axle nut Spoke nipple Side stand assembly Side stand pivot bolt lock nut Brake pedal stopper lock nut TOOLS Valve adjusting wrench Vacuum gauge attachment il fier wrench Drive chain tool set Spoke wrench 2.Nem (0.2 kgfem, 1.4 tft) 42 Nem (1.2 kgfem, 9 Ibfeft) 15 Nem (1.5 kgtem, 11 Ibfett) 15 Nem (1.5 kgtom, 11 Ibfett) 23 Nem (2.3 kgfrm, 17 loft) 34 Nem (3.5 kgfrm, 25 Ibf-f) 410 Nem (1.0 kgf, 7 Ibfft) 3Nem (0.3 kgfem, 2.2 lbftt) 88 Nem (8.0 kgfem, 68 Ibfft) Nem (0.4 kafrm, 2.9 IDF) 34 Nem (3.5 kgfem, 25 Ibfft) 10 Nem {7.0 kgfem, 7 bfeft) 29 Nem (3.0 kafem, 22 Ibfeft) 10 Nem (7.0 kgfim, 7 Ibfeft) Apply grease to the threads Apply grease to the threads Apply oil to the threads and seating surface Apply oil to the threads and O-ring Unt 07908-KE90000 07510-30020 O7HAA-PJ70100 O7HMH-MR10103 or 07 HMH-MR70108 ( (O7JMA-MR60100_ or equivalent commer cof 07908-KE90100 (U.S.A. only) oF O7LMJ-0O1000A (U.S.A. only} A. only) ly availabl in USA, 3-2 MAINTENANCE MAINTENANCE SCHEDULE Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period, I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate, ‘The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools. Consult your authorized HONDA dealer. = FREQUENCY ‘ODOMETER READING (NOTE 1) Os inoo i ass] « [8 [72] 16 [20] 20] rere ITEMS — Note |x100km | 10 | 64 |128)192/256|220|384| TO PAGE (ot | FUEL LINE | ot I a4 | * | THROTTLE OPERATION: imo 1 * | CARBURETOR CHOKE yo 2 | AIR CLEANER NOTE | R E [ [crankcase BREATHER NOTES elelelele @ |_| spank ptuc | fetta & |» | VALVE CLEARANCE 1 itott 2 | [encine ow 7 - al [rl fr 2 [_Tenawe ou uren {tei te & | = | CARBURETOR SYNCHRONIZATION _ i 1 1 Z|* [ENGINE iuesPeeD —_ Peron RADIATOR COOLANT NOTE 4 “| ' R = [ cooLne system (eh + [EVAPORATIVE EMISSION CONTROL SYSTEM | NOTES | Tooth RIVE CHAIN EVERY 500 mi (800 km) JL | [BRAKE FLUID NoTes | Tpi[R[t [ile |__| BRAKE SHOE/BRAKE PAD WEAR tapas 5 || BRAKE SYSTEM Hotbahn| a © | | pnaxe uGHT switch men I= [aeaouaeram Teter is 3 |__| cuurcu system - TACs stefan fe B ‘SIDE STAND I 1 1 1 2 | * | SusPension - i 2 | * | NUTS, BOLTS, FASTENERS _ cnet fay sa 2 [=| wieetsmines cpa e pe] sae +] STEERING HEAD BEARINGS [as a * Should be serviced by an authorized HONDA dealer, unless the owner has proper tools and service data andiis mechanically qualified. ** In the interest of safety, we recommend these items be serviced only by an authorized HONDA dealer. NOTES: 1, At higher odometer reading, repeat at frequency interval established here, 2. Service more frequently when riding in unusually wet or dusty areas. 3. Service more frequently when riding in rain or at full throttle. 2 every 2 years, oF at indicated odometer interval, whichover cames first. Replacement requires mechanical 65, California type only. 3-3 MAINTENANCE FUEL LINE Romove the left side cover (page 2-4). Check the fuel lines for deterioration, damage or leakage Replace the fuel lines if necessary. Aso check the fuel valve vacuum tube for damage, Replace the vacuum tube if necessary. FUEL FILTER Pull the fuel filter out, clip the inlet line closed and remove the filter. Replace the fuel filter with new one, if necessary (page 5-28). THROTTLE OPERATION Check for any deterioration or damage to the throttle cables. Check the throttle grip for smooth operation. Check that the throttle grip returns from the full open to the full closed position smocthly and automatically in all steering positions. Ifthe throttle grip does not return properly, lubricate the throttle cable, overhaul and lubricate the throttle grip housing. For cable lubrication: Disconnect the throttle cables at their upper ends (page 13:8). Thoroughly lubricate the cables and their pivot points with a commercially, available cable lubricant or a light weight cil. If the throttle grip still does not return properly, replace the throttle cables. a Reusing a damaged or abnormally bent or kinked throttle cable can prevent proper throttle side ‘operation and may lead to a loss of throttle control while riding. With the engine idling, turn the handlebar all the way to the right and left to ensure that idle speed does not change. IF idle speed increases, chack the throttle grip free play and the throttle cable connection. 7 VACUUM TUBE MAINTENANCE Measure the throttle grip free play at the throttle drip flange, FREE PLAY: 2~ 6 mm (1/12 - 1/4 in)

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