Honda Magna VF750C, Service Manual

Page 1: ...1994 2003 MAGNA VF750C CD HONDA MOTOR CO LTD 1994 ...

Page 2: ......

Page 3: ...some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe Please understand that those warnings could not cover all conceivable ways in which service whether or not recommended by Honda might be done or of the possibly hazardous consequences of each conceivable way nor could Honda investigat...

Page 4: ...tents on the first page of the section Most sections describe the service procedure through system illustration Refer to the next page 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 2 1 Troubleshooting All information illustrations directions and specifi cations incl...

Page 5: ...ferentiated 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 in...

Page 6: ...pose grease Lithium based multi purpose grease NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide N LGI 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 ...

Page 7: ...MEMO ...

Page 8: ...d before handling these parts 1 General Information Lubrication Seal Points 1 17 Cable Harness Routing 1 20 Emission Control System U S A Only 1 27 Emission Control Information Labels U S A Only 1 30 Used Engine Transmission Oil Used engine oH or transmission oil in two stroke may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Althrough this is unlikely unless ...

Page 9: ... of an unstable gas can cause a fire or explo sion resulting in serious injury The shock absorber contains nitrogen under high pres sure Allowing fire or heat near the shock absorber could lead to an explosion that could result in serious injury Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explo sion and serious injury if it is heated or pierc...

Page 10: ... the carburetor body intake side General Information 1 FRAME SERIAL NUMBER 1 The frame serial number is stamped on the right side of the steering head 3 VEHICLE I DENTIFICATION NUMBER 3 The vehicle Identification Number VIN is located on the Safety Certification Label on the left side of the steering head 5 COLOR LABEL 5 The color label is attached as shown When ordering color coded parts always s...

Page 11: ...pension Swingarm Rear wheel travel 100 mm 3 94 in Rear damper Double effect type Front tire size 120 80 17M C 61V Rear tire size 150 80 15M C 70V Tire brand Front Rear K555F K555 Dunlop Front brake Hydraulic brake Rear brake Internal expanding shoe Caster angle 32 Trail length 137 mm 5 39 in Fuel tank capacity 13 91iter 3 7 US gal 3 11mp gal Fuel tank reserve capacity 3 3 liter 0 87 US gal 0 37 Im...

Page 12: ... 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 ...

Page 13: ...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 t...

Page 14: ... 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 5...

Page 15: ...08 0 115 0 121 2 5 0 10 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 H 0 010 0 035 0 0004 0 0014 16 994 17 000 0 6691 0 6693 16 98 0 669 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 10 0 04 0 015 0 045 0 0006 0 0018...

Page 16: ... 2203 30 950 30 975 1 2185 1 2195 30 950 30 975 1 2185 1 2195 24 985 25 006 0 9834 0 9845 28 000 28 021 1 1024 1 1032 27 995 28 016 1 1022 1 1029 0 020 0 062 0 0008 0 0024 0 005 0 046 0 0002 0 018 0 02 5 0 066 0 0001 0 0026 0 025 0 066 0 0001 0 0026 24 959 24 980 0 9826 0 9835 27 967 2 7 980 1 1011 1 1016 0 005 0 047 0 0002 0 0019 0 020 0 054 0 0008 0 0021 0 015 0 049 0 0006 0 00 1 9 0 015 0 049 0...

Page 17: ...commended fork oil Fork oil level Fork oil capacity Steering bearing preload 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 402 5 15 85 0 2 0 01 r Rear Suspension 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 ...

Page 18: ...without plug wire Pulse generator resistance At 20 C 68 F CR8EH9 U24FER9 CR9EH9 U27FER9 0 8 0 9 0 03 0 04 12 BTDC at idle 2 000 rpm 2 4 0 23 27 kO 13 17 k0 450 550 0 Starter System r Starter motor brush length Starter clutch driven gear O D 12 0 13 0 0 47 0 51 47 175 47 200 1 8573 1 8583 6 5 0 26 47 16 1 857 Lights Meters Switches Main fuse Fuse Headlight high low beam Tail brake light Position li...

Page 19: ...pecial tool 9 Apply grease to the threads and flange surface 10 UBS bolt 11 U nut 12 ALOC bolt Replace with a new one r Engine Item O ty Maintenance Timing hole cap 1 Lubrication Oil pressure switch 1 Oil filter 1 Oil filter stud bolt 1 Oil drain bolt 1 Oil pump bolt 3 Oil pump driven sprocket bolt 1 Oil pipe nut After 94 1 Fuel Systems Connecting tube band screw 4 Cooling Systems Water pump cover...

Page 20: ... 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 nu...

Page 21: ...en sprocket nut 5 12 108 10 8 79 Note 11 Brake System Brake hose bolt 2 10 35 3 5 25 Caliper bracket bolt 2 8 31 3 1 22 Note 12 Front brake hose clamp nut 2 6 12 1 2 9 Note 11 Front master cylinder holder bolt 2 6 12 1 2 9 Front master cylinder reservoir cover screw 2 4 1 5 0 15 1 1 Front brake light switch screw 1 4 1 2 0 12 0 9 Front brake lever pivot bolt 1 6 1 0 1 0 7 nut 1 6 6 0 6 4 3 Pad pin...

Page 22: ...driver attachment Steering stem socket wrench Ball race remover attachment driver handle Ball race remover Attachment 52 x 55 mm Steering stem driver Driver Tool Nunber 07HAA PJ701 00 07HMH M R 1 0 1 02 or 07HMH M R 1 0 1 0B 07NMH MW00 1 1 0 or 07PMH MZ20 1 1 0 07506 3000000 075 1 0 4220 1 00 0740 1 00 1 0000 07908 422020 1 07MMA MV90 1 0A 07757 00 1 0000 07959 KM30 1 0 1 07HMG MR70002 07HMD M L00...

Page 23: ... x 30 mm 07946 1870100 Pilot 22 mm 07746 0041000 Attachment 32 x 35 mm 07746 0010100 Pilot 15 mm 07746 0040300 Needle bearing remover attachment 07GMD KT70200 Bearing remover or M967X 038 XXXXX U S A only Attachment 30 mm 07746 0030300 U S A only Driver 07749 0010000 Brake Snap ring pliers 07914 3230001 Charging System Alternator Flywheel holder 07725 0040000 Rotor puller 07733 0020001 Electric St...

Page 24: ... end bearing small end Valve stem valve guide sliding surface VaJve lifter outer sliding surface Camshaft lobes journals M3 4 C5 and shifter gear shift fork grooves Shift fork shaft sliding area Shift drum Primary drive gear sliding area Each gear Cylinder head cover gasket mating surface cover side Material Liquid sealant Molybdenum disulfide oil A mixture of 1 2 engine oil and 1 2 molybdenum dis...

Page 25: ...ter clutch outer cover bolt Oil filter stud bolt threads Cylinder head sealing bolt threads Oil pressure switch threads Liquid sealant Thermo sensor threads Lower crankcase bolt 9 mm threads Engine oil Cylinder head bolt 9 mm threads and flange surface Camshaft holder bolt 6 mm threads and flange surface Piston sliding surface pin hole ring Connecting rod bolt and nut threads Starter clutch bolt t...

Page 26: ...m bearings Swingarm dust seal lips Front wheel dust seal lips Rear wheel dust seal lips Rear wheel sliding surface driven flange Rear engine mounting nut threads and seating surface Each bearing Each dust seal lips Throttle cables Engine oil Choke cable Clutch cable Speedometer cable Steering stem lock nut threads Flywheel bolt threads and flange surface Handle grip inner surface Honda Bond A Hond...

Page 27: ... 6 COMBINATION METER WIRE HARNESS 5 HIGH BEAM TURN SIGNAL NEUTRAL INDICATOR WIRE HARNESS 10 9P RED CONNECTOR TURN SIGNAL SWITCH HORN SWITCH DIMMER SWITCH 1 20 9 9P BLACK ECTOR STARTER SWITCH ENGINE STOP SWITCH 1 LEFT HANDLEBAR SWITCH WIRE HARNESS 2 CLUTCH CABLE 3 SPEEDOMETER CABLE ...

Page 28: ... 5 IGNITION SWITCH WIRE HARNESS General Information 2 EVAPORATIVE EMISSION PURGE CONTROL VALVE 3 CLUTCH CABLE 1 21 ...

Page 29: ...General Information 1 22 10 HIGHT BEAM TURN SIGNAL NEUTRAL INDICATOR WIRE 6 STARTER MOTOR CABLE 5 PULSE SECONDARY AIR INJECTION PIPES CALIFORNIA TYPE ONLY ...

Page 30: ...LY 6 EVAPORA VE EMISSION PURGE CONTROL VALVE CALIFORNIA TYPE ONLYl 5 FUEL General Information EVAPORATIVE EMISSION CARBURETOR AIR VENT CONTROL VALVE CALIFORNIA TYPE ONLYl FUEL TAN K BREATHER TUBE 4 REAR PULSE SECONDARY AIR INJECTION CONTROL VALVE CALIFORNIA TYPE ONLYl 1 23 ...

Page 31: ...General Information 1 THERMO SENSOR WIRE 7 ALTERNATOR WIRE 6 ENGINE GROUND CABLE 3 IGNITION PULSE GENERATOR WIRE 1 24 5 NEUTRAL SWITCH WIRE 4 STARTER MOTOR CABLE ...

Page 32: ... 8 IGNITION PULSE GENERATOR CONNECTOR 6 SIDE STAND SWITCH H t jrF N CONNECTOR 4 STARTER MOTOR CABLE General Information 1 MAIN WIRE HARNESS 2 N EUTRAL SWITCH CONNECTOR 1 25 ...

Page 33: ...General Information 1 26 4 FUEL TANK BR THEA TUBE 149 STATES CANADIAN TYPE 7 RIGHT TURN SIGNAL WIRE 9 TAIL STOP LIGHT WIRE AND SWITCH ...

Page 34: ...with the terms of the Distributor s Warranties for Honda Motor cycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect Source Of Emissions The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon mono...

Page 35: ...mount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor This model has two pulse secondary air injection control valves with built in check valves The PAIR check valves prevent reverse air flow through the system The pulse secondary air injection control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engine dece...

Page 36: ...ontrol System 2 FUEL TANK 3 EVAPORATIVE EVAP CAN ISTER 4 FRESH AIR 5 DRAIN TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replace ment of any device or element of design incorporated into any new vehicle for purpose of noise co...

Page 37: ... label on the right down tube as shown After re adjusting the carburetor back to standard settings for low alitude remove the update label Vacuum Hose Routing Diagram Label California Type Only The Vacuum Hose Routing Diagram Label is on the rear fender as shown The seat must be removed to view it Route the vacuum hoses as shown on this label 1 l VACUUM HOSE ROUTING LABEL 1 30 1 EMISSION CONTROL I...

Page 38: ...ork in a well ventilated area Smoking or allowing flames or sparks in the working area or where gasoline is stored can cause a fire or explosion This section covers removal and installation of the frame body panels fuel tank and exhaust system Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine When installing the exhaust pipe install all the fasteners loosely N...

Page 39: ...harness between the seat and frame Fuel Tank Removal Installation Gasoline is extremely flammable and is explosive under certain conditions Remove the seat above Turn the fuel valve OFF Disconnect the fuel tube Remove the mounting bolt and collar Disconnect the breather tube Remove the fuel tank Install the fuel tank in the reverse order of removal After installation turn the fuel valve ON and che...

Page 40: ... side cover in the reverse order of removal Front Side Cover Removal Installation Remove the front side cover mounting screw Then remove the cover by sliding it forward Install the front side cover in the reverse order of removal NOTE At installation align the tab of the front side cover with the groove of fuel tank mount bracket Frame Body Panels Exhaust System 1 HOLE 14 BOSSES 1 FUEL TANK BRACKE...

Page 41: ...Frame Body Panels Exhaust System Exhaust System Removal Installation 1 4 5 __ _ 7 c2 1 2 1 1 5 3 c39 3 9 28 2 c44 4 4 32 7 9 8 c27 2 7 20 c21 2 1 1 5 2 4 ...

Page 42: ...Installation page 2 61 2 Rear cylinder head mount bolt 1 3 Rear cylinder heat mount bracket bolt 2 4 Rear cylinder head mount bracket 1 5 Rear exhaust pipe band bolt 1 Loosen the band bolt 6 Front exhaust pipe protector 1 7 Front exhaust pipe band bolt 1 Loosen the band bolt 8 Muffler mounting bolt 1 9 Muffler assembly 1 1 0 Rear exhaust pipe joint nut 2 1 1 Rear exhaust pipe 1 1 2 Exhaust pipe ga...

Page 43: ...pipe with groove of the rear exhaust pipe protector Adjust the clearance by moving the protector Standard 2 5 mm 0 08 0 1 9 in Tighten the exhaust pipe protector bolt Torque 1 2 N m 1 2 kg m 9 ft lbl Exhaust Pipe muffler Mounting Fasteners Tightening When tighten the exhaust pipe muffler mounting fasteners while push the exhaust pipe to inside 2 6 1 EXHAUST PIPE ...

Page 44: ...allation page 2 2 Side covers removal installation page 2 3 Procedure O ty Remarks Removal Order Installation is in the reverse order of removal 1 Rear turn signal light connector 4 Disconnect the connector 2 Brake taillight connector 3 Disconnect the connector 3 Rear fender mounting bolt nut 8 4 4 Grab rail 2 5 Rear fender assembly 1 6 Sub frame 1 2 7 ...

Page 45: ... CAUTION Do not scratch and damage the windscreen Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Upper fairing mounting bolt 3 2 Upper fairing 1 At installation align the tab of the upper fairing stay with the hole of the cable guige 2 8 ...

Page 46: ...ent Remove the screws plastic washers and rubber washers Remove the windscreen and upper fairing stays Installation is in the reverse order of removal Frame Body Panels Exhaust System 1 STAYS 4 SCREW 3 PLASTIC WASHER 2 9 ...

Page 47: ...MEMO ...

Page 48: ...e Maintenance Schedule Air Cleaner Service Information 3 1 Valve Clearance 3 2 Drive Chain 3 4 Headlight Aim 3 5 Refer to Common Service Manual for items not included in this manual Refer to Specifications Section 1 for maintenance data 3 5 3 8 3 1 0 3 1 ...

Page 49: ...n Adjustment page 3 5 Fuel tank 1 7 Spark Plug Wear damage color 1 6 Suspension Loose wear damage 1 5 Brake Drum Shoe wear 1 4 Wheel Damage runout corrosion 1 3 Tire Wear damage air pressure 1 2 Brake Light Switch Operation 1 1 Reserve Coolant Tank Cap 1 0 Oil Level Gauge Oil level check replacement 3 2 1 Throttle Grip Operation free play 2 Brake Lever Air in system 3 Master Cylinder Level check f...

Page 50: ...ear damage 9 Caliper Pad wear 8 Brake Hose leakage deterioration damage 7 Oil Filter Replacement 6 Carburetor Choke Operation Maintenance 1 Synchronization Adjusting Screw Carburetor synchronizatron page 5 1 4 Middle cover 2 Fuel line Damage leakage 3 Drive chain Free play lubrication replacement page 3 8 4 Side stand Operation 5 Throttle Stop Screw 3 3 ...

Page 51: ... I I I Note 5 Secondary Air Supply System Note 4 I I I Note 5 Evaporative Emission Control System Note 4 I I Note 5 Drive Chain Every 600 mi 1 000 km I L Note 5 en Brake Fluid Note 3 I I R I I R Note 5 w Brake Shoe Pad Wear I I I I I I Note 5 0 Brake System I I I I Note 5 w I Brake Light Switch I I I Note 5 I w Headlight Aim I I I Note 5 a z Clutch System I I I I I I I Note 5 0 c Side Stand I I I ...

Page 52: ...sively dirty or damaged Install the removed parts in the reverse order of removal Valve Clearance Inspection NOTE Inspect and adjust the valve clearance while the engine is cold Below 35 C 95 F Remove the following timing hole cap seat page 2 2 fuel tank page 2 2 rear cylinder head cover page 8 2 Remove the lower radiator hose guide Remove the lower radiator mounting bolts loosen the upper mountin...

Page 53: ...the right crankcase cover Check the valve clearances for the No 4 cylinder Turn the crankshaft clockwise 3 4 turn 270 and align its T 1 mark with the index mark on the right crankcase cover Check the valve clearances for the No 3 cylinder Turn the crankshaft clockwise 1 4 turn 90 and align its T2 mark with the index mark on the right crankcase cover Check the valve clearances for the No 2 cylinder...

Page 54: ...ss Example Recorded valve clearance 0 1 6 mm Old shim thickness 1 725 mm Specified valve clearance 0 20 mm A 0 1 6 0 20 1 725 A 1 685 NOTE Make sure of the correct shim thickness by measuring the shim with micrometer Replace the valve seat if a carbon deposit results in a calculated dimension of over 2 800 mm Install the newly selected shim on the valve retainer Apply molybdenum disulfide oil to t...

Page 55: ... with the UP mark facing up Tighten the cover bolts Torque 1 0 N m 1 0 kg m 7 ft lbl Install the removed parts in the reverse order of removal Drive Chain Replacement The MAGNA VF750C uses a drive chain with a staked master link Loosen the drive chain Assemble the special tool I s T ooL I Drive chain cutter NOTE 07HMH MR1 0 1 02 or 07HMH MR1 0 1 0B U S A only When using the special tool follow the...

Page 56: ...AUTION 07HMH MR1 0 1 02 or 07HMH MR1 0 1 0B U S A only 07NMH MW001 1 0 or 07PMH MZ201 1 0 Never reuse the old drive chain master link master link plate and 0 rings Install the new drive chain Assemble the new master link 0 rings and plate CAUTION Insert the master link from the inside of the drive chain and install the plate with the identification mark facing the outside Assemble and set the driv...

Page 57: ... for cracks In there is any cracking replace the master link 0 rings and plate CAUTION Drive chain with clip type master link must not be used Headlight Aim An improperly adjusted headlight may blind oncoming drivers or it may fail to light the road for a safe distance VF750CD Adjust the headlight aim horizontally and vertically turning the adjusting screws as shown VF750C Refer to section 2 of th...

Page 58: ...efer to section 4 of the Common Service Manual for the switch location see page 1 8 2 of this manual The service procedures in this section must be performed with the engine oil drained When removing and installing the oil pump use care not to allow dust or dirt to enter the engine If any portion of the oil pump is worn beyond the specified service limits replace the oil pump as an assembly After ...

Page 59: ...Lubrication System Lubrication System Diagram AFTER 94 9 OIL PRESSURE RELIEF VALVE 4 2 1 CAMSHAFT ...

Page 60: ...olt 12 2 Oil pan 1 3 Gasket 1 4 Pressure relief valve 1 5 0 ring 1 6 Oil strainer 1 7 0 ring 1 8 Oil pipe 2 9 0 ring 4 1 0 Oil pump driven sprocket bolt 1 11 Oil pump driven sprocket 1 12 Oil pump mounting bolt 3 13 Oil pump assembly 1 14 Dowel pin 2 Lubrication System Exhaust system removal installation page 2 4 Water pump removal installation page 6 7 Remarks Installation is in the reverse order...

Page 61: ...tion Requisite Service Oil pump removal installation page 4 3 Procedure Disassembly Order 1 Cotter pin 2 0 ring 3 Oil strainer pipe 4 Bolt 5 Pump cover 6 Dowel pin 7 Feed pump cover 8 Dowel pin 9 Outer rotor 1 0 Inner rotor 1 1 Rotor shaft 1 2 Drive pin 1 3 Washer 1 4 Oil pump body 4 4 O ty Remarks Assembly is in the reverse order of disassembly 1 1 1 3 After installation check that the rotor shaf...

Page 62: ...ire or explosion CAUTION To prevent damage be sure to removed the diaphragms before cleaning air and fuel passages with compressed air The diaphragms might be damaged Refer to section 2 for fuel tank removal and installation When disassembling fuel system parts note the locations of the 0 rings Replace them with new ones on reassem bly Before removing the carburetors place the suitable container u...

Page 63: ... rich Fuel contaminated deteriorated Intake air leak Idle speed misadjusted Float level misadjusted Fuel tank breather tube clogged Pilot screw misadjusted Slow circuit or starting enrichment circuit clogged Emission control system malfunction California Type Only Evaporative emission carburetor air vent control valve faulty Evaporative emission purge control valve faulty Loose disconnected or det...

Page 64: ...crew 6 Front pulse secondary air injection control valve air intake tube 7 Rear pulse secondary air injection control valve air intake tube 8 Crankcase breather tube 9 Air cleaner housing Q ty 3 1 2 1 3 1 1 1 1 Air cleaner removal installation page 3 5 Remarks Installation is in the reverse order of removal California type only California type only California type only California type only Move th...

Page 65: ...Fuel System Carburetor Removal Installation 5 4 ...

Page 66: ...o 5 vacuum tube from the 3 way joint 5 No 1 1 vacuum tube from the No 1 carburetor 6 No 10 vacuum tube from the 3way joint 7 Left middle cover stay assembly 8 Fuel tube 9 No 6 vacuum tube from the AVCV 1 0 Throttle cable 1 1 Connecting tube band screw 1 2 Carburetor assembly Carburetors draining O ty Remarks Installation is in the reverse order of removal 1 Remove the choke cable from the left mid...

Page 67: ...Fuel System Carburetor Separation 1 5 26 5 6 ...

Page 68: ...arburetor 17 No 3 carburetor 1 8 Thrust spring 1 9 Sub air joint pipe tube 0 ring 20 No 6 vacuum tube joint pipe 0 ring 21 No 5 vacuum tube from the No 1 2 carburetor 22 Front collared dowel pin 23 Rear collared dowel pin 24 Center collar 25 Fuel tube joint pipe o ring 26 Starting enrichment valve link assembly Separate No 2 carb from No 1 carb 27 arburetor connecting bolt 28 Throttle link 29 No 2...

Page 69: ...Fuel System Carburetor DisassemblyIAssembly 23 1 2 1 5 1 4 0 ring gasket 5 8 ...

Page 70: ...1 5 Needle jet holder 1 6 Slow jet 17 Pilot screw 18 Spring 1 9 Washer 20 0 ring Starting Enrichment Valve Disassembly Order 21 Valve nut 22 Spring 23 Starting earchment valve Air Cut Off Valve Disassembly Order 24 Air cut off valve cover screw 25 Air cut off valve cover 26 0 ring 27 Air cut off valve Q ty Remarks Assembly is in the reverse order of disassembly 3 1 1 NOTE At installation be carefu...

Page 71: ...Fuel System Carburetor Combination 27 D D No 1 CARBURETOR 25 0 RING COTIER PIN 5 5 1 0 ...

Page 72: ...he No 1 2 craburetor 1 0 Sub air joint pipe tube 0 ring 1 1 No 6 vacuum tube joint pipe 0 ring 1 2 No 5 vacuum tube to the No 3 carburetor 1 3 No 3 carburetor 1 4 Thrust spring Assemble No 4 carb with No 1 2 3 carb 1 5 Choke cable holder 1 6 No 4 carburetor 17 Thrust spring 1 8 No 5 vacuum tube to the No 4 carburetor 1 9 Carburetor connecting nut 20 Return spring 21 Plastic collar 22 Starting enri...

Page 73: ...ul not to damage the diaphragm Do not remove the jet needle holder by pushing the jet needle Installation Install the jet needle holder into the vacuum piston until you felt the click Install the vacuum piston page 5 8 Carburetor Body Cleaning Clean the fuel strainer in the float valve using the com pressed air from the float valve seat side 5 1 2 1 JET NEEDLE HOLDER If 2 4 mm SCREW 3 VACUUM PISTO...

Page 74: ...Carburetor Tube Routing California Type Only g g 5 TO EVAP PURGE CONTROL VALVE 2 FUEL TUBE 3 TO EVAP CAV CONTROL VALVE 4 TO SUB AIR CLEANER Fuel System 5 1 3 ...

Page 75: ...ed tube and pinch the tube with a clip Connect the vacuum gauge tube to the No 4 cyli nder intake port adaptor 49 States type Remove the No 1 cylinder intake port vacuum plug Connect the vacuum gauge adaptor to the No 1 cylinder intake port California type Disconnect the No 1 cyl i nder vacu u m tube from the engine intake port Connect the vacuum gauge tube to the No 1 cyli nder intake port adapto...

Page 76: ...m 0 8 in Hg of the base carburetor NOTE The base carburetor is the No 1 carburetor Synch ronize to specification by turning the adjusting screws Recheck the idle speed and each cylinder intake vacuum pressure so it is within 20 mm 0 8 in Hg of the base car buretor reading after snapping the throttle grip 3 4 times Remove the vacuum gauge and adaptors Fuel System 1 THROTTLE STOP SCREW KNOB 1 SCREW ...

Page 77: ...states California type 07MMA MV9010A Initial Opening 49 states type 2 1 2 turns out California Canadian type 2 3 8 turns out 2 Warm up the engine to operating temperature 3 Stop the engine and attach the tachometer according to the manufacturer s instruction 4 Start the engine and adjust the idle speed with the throttle stop screw knob Idle Speed 49 states type 1 000 100 rpm California Canadian ty...

Page 78: ...art that can be easily removed from the vehicle Sustained operation at an altitude lower than 1 500 m 5 000 feet with the carburetor adjusted for high altitude may cause the engine to idle roughly and the engine may stall in traffic If may also cause engine damage due to overheating When the vehicle is to be operated continuously below 1 500 m 5 000 feet turn each pilot screw counterclock wise 1 2...

Page 79: ...connect and remove ttie following No 10 vacuum tube air injection hose PAIR control valve mounting bolt air intake hose PAIR control valve Installation is in the reverse order of removal After installing check the tubes for loose connections and kinks Install the radiator page 6 5 Rear cylinder Remove the seat page 2 2 Disconnect and remove the following air intake hose air injection hose PAIR con...

Page 80: ...lant at the reserve tank Do not remove the radiator cap except to refill or drain the system All cooling system services can be done with the engine in the frame Avoid spilling coolant on painted surfaces After servicing the system check for leaks with a cooling system tester Refer to section 25 of the Common Service Manual for fan motor switch and thermo sensor inspection Troubleshooting Engine T...

Page 81: ...Cooling System System Flow Pattern 1 SIPHON TUBE 5 THERMOSTAT 2 RESERVE TANK 3 WATE PUMP 6 2 ...

Page 82: ...ion 5 of the Common Service Manual Remove the water pump drain bolt and sealing washer Remove the radiator cap screw and radiator cap and drain the coolant Remove the cylinder drain bolts and sealing washers and drain the coolant I nstall the water pump drain bolt with a new sealing wash er Install the cylinder drain bolts with new sealing washers Refill the coolant to upper level Cooling System 2...

Page 83: ...using bolt 10 Cylinder head to housing hose 1 1 Thermostat housing 1 2 Thermo sensor 6 4 Q ty 1 1 1 1 3 1 1 1 1 1 2 1 1 6 Coolant refilling Section 5 of the Common Service Manual Remarks Installation is in the reverse order of removal Loosen the clamp screw and disconnect the hose At installation install the thermostat with its bleed hole facing right side while aligning it with the grooves in the...

Page 84: ...or switch connector 1 5 Radiator mounting bolt 3 6 Radiator assembly 1 Cooling System 4 Front side cover removal installation page 2 3 Remarks Installation is in the reverse order of removal Loosen the clamp screw and disconnect the hose Loosen the clamp screw and disconnect the hose Remove it after releasing the projection on the right radi ator stay CAUTION During removal and installation be car...

Page 85: ...ing fan shroud bolt 4 Cooling fan nut 5 Cooling fan 6 Fan motor mounting nut 7 Fan motor 8 Fan motor switch 9 0 ring 6 6 O ty Remarks Assembly is in the reverse order of disassembly 1 Release the two grooves from u nder of radiator then remove the radiator grill 1 3 At installation install the ground eyelet joint with the bolt 1 1 At installation align the cooling fan groove with the fan motor sha...

Page 86: ...ng bolt 2 6 Water pump cover 1 7 0 ring 1 8 Dowel pin 2 9 Pump to engine hose 1 10 Water pump body 1 1 1 0 ring 1 Cooling System GN OIL PUMP SHAFT Coolant refi l l Section 5 of the Common Service Manual Remarks Installation is in the reverse order of removal Loosen the clamp screw and disconnect the hose Loosen the hose clamp screw and disconnect it At installation align the cut out of the water p...

Page 87: ...MEMO ...

Page 88: ...installed in the frame Oil pump Section 4 Carburetor Section 5 Water pump Section 6 Camshaft cylinder head Section 8 Clutch Section 9 Gearshift linkage Section 10 Alternator Section 1 5 Pulse generator Section 1 6 Starter clutch Section 17 Starter motor Section 17 The following components require engine removal for service Piston connecting rod cylinder Section 1 1 Crankshaft transmission Section ...

Page 89: ...Engine Removal Installation Engine Removal Installation c39 3 9 28 19 027 0 7 20 1 2 1 1 1 3 25 26 c44 4 4 32 28 7 2 7 27 c39 3 9 28 3 c54 5 4 39 24 c9 0 9 6 5 21 22 c27 0 7 20 J Cs1 5 1 37 1 5 10 9 8 ...

Page 90: ...ube 1 5 Drive sprocket bolt 1 6 Washer 17 Drive sprocket 1 8 Brake pedal linkage joint pinch bolt joint 19 Right foot peg bracket bolt 20 Right foot peg bracket assembly 21 Gearshift link joint bolt joint 22 Left foot peg bracket bolt 23 Left foot peg bracket assembly 24 Front cylinder head mounting bolt nut Washer 25 Collar f624 x 30 mm 26 Front engine mounting bolt nut 27 Front engine mounting b...

Page 91: ... bracket Tighten the 10 mm front cylinder head mounting bolts CD and Torque 54 N m 5 4 kg m 39 ft lb Tighten the 8 mm engine mounting bracket bolts and Torque 39 N m 3 9 kg m 28 ft lb Tighten the 1 0 mm engine mounting bolts l and Torque 44 N m 4 4 kg m 32 ft lb Tighten the 1 2 mm engine mounting nut Torque 64 N m 6 4 kg m 46 ft lb 7 4 ...

Page 92: ... tube If there is smoke in the tube check for a seized piston ring Compression Too Low Hard Starting Or Poor Performance At Low Speed Valves Incorrect valve adjustment Burned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Cylinder piston Worn stuck or broken piston ring Worn or damage cylin...

Page 93: ...Cylinder Head Valves Camshaft Removal 8 2 AFTER 95 Except some 96 early production units Revised July 1995 94 95 Magna VF750C CD 1995 American Honda Motor Co Inc All Rights Reserved MSV 691 3 9504 ...

Page 94: ... bolt 1 1 Washer 1 2 Rear cylinder head cover 1 3 Head cover gasket 1 4 Cam chain tensioner sealing bolt washer 1 5 Cam chain tensioner mounting bolt 1 6 Cam chain tensioner 1 7 Gasket 1 8 Camshaft holder bolt Q ty 1 1 1 6 1 1 4 2 6 4 4 1 1 1 1 2 1 1 1 6 Muffler removal installation page 2 4 Spark plug cap removal installation Front PAIR control valve removal installation California type only page...

Page 95: ...Cylinder Head Valves Cylinder Head Removal Installation 2 c 44 4 4 32 1 c 1 2 1 2 9 6 4 3 c 13 1 3 9 8 4 ...

Page 96: ...2 8 Muffler removal installation page 2 4 Air suction pipe removal installation California type only Procedure Q ty Removal Order 1 Cylinder head 6 mm bolt 8 8 2 Cylinder head 9 mm bolt washer 3 Cylinder head protector bolt 6 4 Cylinder head protector 2 5 Cylinder head 1 6 Cylinder head gasket 1 7 Dowel pin 2 Thermostat removal installation page 6 4 Air suction pipe removal installation California...

Page 97: ...Cylinder Head Valves Cylinder Head DisassemblyIAssembly GROOVE LUG 8 6 4 j s TooL I e page 1 1 5 e 10 HANDLAPPING TOOL DOWN 2 1 3 51 91 1 1 l s TooL I page 1 1 5 ...

Page 98: ...Valve lifter 3 Valve shim 4 Valve spring cotter 5 Valve spring retainer 6 Valve spring 7 Intake valve 8 Exhaust valve 9 Stem seal 1 0 Valve spring seat 1 1 Valve guide Q ty Remarks Assembly is in the reverse order of disassembly 2 NOTE Align the groove of the insulator with the lug of the cylinder head 8 NOTE Remove using a handlapping tool Do not damage the cylinder head lifter sliding surface 8 ...

Page 99: ...lves Camshaft Installation 2 1 8 8 AFTER 95 Except some 96 early production units 7 9 c 1 2 1 2 9 I N r EX Revised July 1 995 94 95 Magna VF750C CD 1 995 American Honda Motor Co Inc All Rights Reserved MSV 691 3 f9504l ...

Page 100: ...g bolt 1 0 Cam chain tensioner sealing bolt washer 1 1 Head cover gasket Q ty 8 1 2 4 1 1 6 1 1 2 1 1 1 Muffler removal installation page 2 4 Radiator removal installation page 6 4 Front PAIR control valve removal installation California type only page 5 1 8 Remarks Refer to page 8 1 0 for installation NOTE Apply Honda Bond A or equivalent to the head cover and install the gasket with IN mark faci...

Page 101: ...ubricate the camshaft journal surface of the cylinder head camshaft holder and cam lobes with molydenum disulfide oil Install the camshafts onto the rear cylinder head The R EX timing mark on the rear exhaust camshaft sprocket is level with the cylinder head upper edge as shown Check that the R IN timing mark on the rear i ntake camshaft sprocket is level with the cylinder head upper edge as shown...

Page 102: ... piece of steel 1 5 mm 1 9 mm 1 5 mm 8 5 mm 4 5 mm MATERIAL THICKNESS 1 0 mm Install the new gasket and cam chain tensioner to rear cylinder head Torque the cam chain tensioner mounting bolts Torque 12 N m 1 2 kg m 9 ft lbl Remove the cam chain tensioner stopper tool Install the cam chain tensioner sealing bolt and washer Make sure the timing marks on the camshaft sprockets are level with the cyli...

Page 103: ... EX timing mark on the front exhaust camshaft sprocket is level with the cylinder head upper edge as shown Check that the F IN timing mark on the front intake camshaft sprocket is level with the cylinder head upper edge as shown Install the camshaft holders in the correct positions checking the identification marks on the holders and cylinder head Install the cam chain guide Torque the cam shaft h...

Page 104: ...sher Make sure the timing marks on the camshaft sprockets are level with the cylinder head upper edge When The Rear Cylinder Camshaft Only Was Removed Align the T2 mark with the i ndex mark on the right crankcase cover Remove the front cylinder head cover page 8 2 Make sure 2 cylinder is TDC on the compression stroke If it is not turn the crankshaft clockwise 360 and make sure T2 mark aligns with ...

Page 105: ...ead upper edge as shown Install the camshaft holders in the correct positions check ing the identification marks on the holders and cylinder head Install the cam chain guide Torque the cam shaft holder bolts in the sequence shown Torque 12 N m 1 2 kg m 9 ft lb Turn the cam chain tensioner shaft com pletely in clock wise and secure it using the special tool l a TooL I Tensioner stopper 07NMG MY9010...

Page 106: ...aligns with the index mark on the right crankcase cover Rotate the crankshaft clockwise 90 to align the T2 mark with the index mark on the right crankcase cover Install the camshaft holder dowel pins onto the front cylin der head Lubricate the camshaft journal surface camshaft holder and cam lobes with molybdenum disulfide oil Install the csmshafts onto the front cylinder head Check that the F EX ...

Page 107: ... Turn the cam chain tensioner shaft completely in clock wise and secure it using the stopper tool This tool can easily be made from a thin 1 mm thickness piece of steel 1 5 mm lr 1 5 mm 13 5 mm J 3 mm I I 1 I MATERIAL THICKNESS 1 mm 8 5 mm 3 5 mm Install a new gasket and cam chain tensioner Torque the cam chain tensioner mounting bolts Torque 12 N m 1 2 kg m 9 ft lb 8 1 6 2 IDENTIFICATION MARKS 1 ...

Page 108: ...ole protector 07HMG MR70002 Not available in U S A Insta l l the valve spring compressor onto the valve and compress the valve spring CAUTION To prevent loss of tension do not compress the valve springs more than necessary Remove the valve cotters l a TooL I Valve spring compressor 07757 0010000 Valve spring compressor attachment 07959 KM30101 Installation is in the reverse order of removal Cylind...

Page 109: ...MEMO ...

Page 110: ...sengagement When the clutch does not disengage or the vehicle creeps with clutch disengaged inspect the transmission oil level before servicing the clutch system Troubleshooting Clutch Slips When Accelerating Incorrect clutch adjustment Worn clutch discs Weak clutch springs Tra n s m i s s i o n o i l m ixed with m o lybd e n u m o r graphite additive Motorcycle Creeps With The Engine Idling Incor...

Page 111: ...Clutch System Right Crankcase Cover Removal Installation 6 7 c1 2 1 2 9 1 c27 2 7 20 2 c27 2 7 20 Jl ru 20 30 mm 0 8 1 2 in 9 2 ...

Page 112: ...ut 1 1 2 Right foot peg bracket bolt 2 3 Right foot peg bracket 2 4 Front exhaust pipe protector bolt 2 5 Front exhaust pipe protector 1 6 Evaporative emission canister pipe bolt 1 California type only 7 Right crankcase cover bolt 13 NOTE Install the clamps in the correct positions and clam p the starter motor cable 8 Right crankcase cover 1 9 Gasket 1 1 0 Dowel pin 2 9 3 ...

Page 113: ...Clutch System Clutch Removal 9 4 3 1 3 1 2 1 0 l a TooL I page 9 9 8 7 ...

Page 114: ...ter rod 8 Clutch disk A clutch plate 9 Clutch disk B 1 0 Judder spring 1 1 Spring seat 1 2 Clutch center lock nut 13 Spring washer 1 4 Clutch center 1 5 Clutch outer 1 6 Needle bearing 17 Oil pump driven sprocket bolt 1 8 Oil pump driven sprocket 1 9 Clutch outer guide 20 Oil pump drive chain 21 Oil pump drive sprocket 22 Collar Q ty 5 5 1 1 1 1 1 8 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Starter clutch rem...

Page 115: ...Clutch System Clutch Installation 1 0 0 9 6 ...

Page 116: ... 1 1 Er 1 1 1 1 1 1 r 1 8 8 1 1 1 1 1 5 5 Clutch System Right crankcase cover installation page 9 2 Remarks NOTE Lubricate the inner and outer sliding surfaces with a engine oil Install them as an assembly Install the drive sprocket with the boss side facing out Clean and apply a locking agent to the threads Installation page 9 8 OUT SIDE mark facing cover Hold the clutch center with the special t...

Page 117: ... new lock nut to the specified torque Torque 90 N m 9 0 kg m 65 ft lb I s TooL I Clutch center holder 94 only Lock nut wrench 26 x 30 mm 07724 0050001 Equivalent commercially available in U S A 07716 0020203 Stake a new lock nut with a center punch NOTE Be careful not to damage the mainshaft threads Clutch Outer Installation Install the clutch outer onto the mainshaft Turn the oil pump driven spro...

Page 118: ... To Shift I mproper oil viscosity I ncorrect clutch adjustment Bent shift forks Bent shift fork shaft Bent fork claw Loose stopper plate bolt Damaged stopper plate and pin Damaged gearshift spindle Damaged shift drum groove Damaged guide pin Transmission Jumps Out Of Gear Worn shift drum stopper arm Worn gear engagement dogs or slots Weak or broken shift arm return spring Loose stopper plate bolt ...

Page 119: ...Gearshift Linkage Drive Sprocket Cover Removal Installation 1 4 ___ _ _ ____ ii 111 c 1 2 1 2 9 1 0 2 9 3 c10 1 0 7 1 2 1 3 ...

Page 120: ... sprocket cover 1 5 Gasket 1 6 Dowel pin 2 Disassembly Order Assem bly is in the reverse order of disassembly 7 Clutch lifter piece 1 Remove the piece by turning the lifter arm clockwise 8 Clutch lifter arm 1 9 Return spring 1 1 0 Washer 1 1 1 Dust seal 1 1 2 Drive chain guard bolt 2 1 3 Drive chain guard 1 1 4 Drive sprocket cover rubber bolt Washer 212 1 5 Drive sprocket cover rubber 1 1 0 3 ...

Page 121: ...Gearshift Linkage Gearshift Linkage Removal Installation 8 SHIFTER PLATE ASSEMBLY 1 1 0 4 ...

Page 122: ...wel pin 1 1 2 Washer 1 1 3 Stopper arm spring 1 1 4 Stopper arm assembly 1 1 5 Collar 1 1 6 Dowel pin 2 1 7 Shift d r u m bearing stopper plate 1 Water pump removal installation page 6 7 Remarks I nstallation is in the reverse order of removal NOTE When removing and installing turn the linkage cover slightly clockwise Insta l l the shifter collar i nto the spindle hole and the return spring onto t...

Page 123: ...MEMO ...

Page 124: ...e that they are reinstal led in their original locations Remove the piston cylinder sleeve and connecting rod as an assembly Be careful not to damage the crankshaft main journal bearing while removing or installing the crankshaft All bearing inserts are select fitted and are identified by color code Select replacement bearings from the selection table page 1 1 16 After installing new bearings rech...

Page 125: ...Crankshaft Piston Transmission Crankcase Separation 6 5 1 1 2 ...

Page 126: ...shaft bearing stopper plate 3 U pper crankcase bolt 6 m m washer 4 Cable guide 5 U pper crankcase bolt 10 mm washer Lower Crankcase Side 6 Lower crankcase bolt 6 mm 7 Lower crankcase bolt a mm 8 Lower crankcase bolt 9 mm 9 Lower crankcase 1 0 Dowel pin 11 Oil orifice 12 0 ring Q ty 3 1 7 1 2 2 8 1 8 1 3 11 Alternator cover removal page 1 5 10 Oil pump removal page 4 3 Remarks Loosen gradually Loos...

Page 127: ...Crankshaft Piston Transmission Crankshaft Connecting Rod Removal Installation 01 2 1 2 9 1 1 cw 7J 4 1 1 4 AFTER 94 1 1 naa c1 2 1 2 9 1 c33 3 3 24 9 0g c1 2 1 2 9 cw c1 2 1 2 9 ROTATING DIRECTION ...

Page 128: ...aring 5 Crankshaft 4 Connecting rod bearing 3 Connecting rod piston assembly 2 Connecting rod bearing cap 1 Connecting rod bearing cap nut Q ty Remarks Installation is in the reverse order of removal 8 4 NOTE Note the direction of the bearing cap 4 CAUTION Do not try to remove the connecting rod piston as sembly from the bottom of the cylinder The oil ring will become wedged in the gap between the...

Page 129: ...Crankshaft Piston Transmission Piston DisassemblyIAssembly 1 I N MARK 2 4 IDENTIFICATION 1 0 t 20 mm 0 8 in OR MORE 1 1 6 ...

Page 130: ... lfide oil to the piston pin and connecting rod smal l end 2 NOTE Identify the front connecting rod by the marking M L7 F I nstall the piston on the front connecting rod so that the I W mark on the piston head faces the oil hole side of the connecting rod It is not necessa ry to remove the piston rings un less they need replacing 2 2 NOTE Identify the rear connecting rod by the marking ML7 R Insta...

Page 131: ...Crankshaft Piston Transmission Transmission Removal Installation 1 1 1 8 ...

Page 132: ...ation Order 6 Shift drum 5 Shift fork 4 Shift fork shaft 3 Dowel pin 2 Countershaft bearing set plate 1 Mainshaft countershaft assembly Q ty Remarks 1 Remove the mainshaft and countershaft as an assem bly Disassembly page 1 1 10 1 2 1 1 1 3 1 1 3 I n sta l l t h e m with the i d entificat i o n m a r k R R i g ht C Center L Left side facing the rig ht side as shown 1 1 1 Fit i n the upper crankcas...

Page 133: ...3 1 production units 94 95 and some 96 early production units AFTER 95 Except some 96 early production units 1 2 8 5 4 t L 1 3 1 0 71 SHIFTER GEAR 71 GEAR SLIDI NG m GROOVE m SURFACE 9 8 7 6 3 1 1 1 1 0 Revised July 1 995 94 95 Magna VF750C CD 1 995 American Honda Motor Co Inc All Rights Reserved MSV 691 3 19504 ...

Page 134: ...ce Transmission removal installation page 1 1 81 Procedure Q ty Remarks Disassembly Order Assem bly is in the reverse order of disassembly 1 Needle bearing case 2 Needle bearing 3 Thrust washer 4 M2 gear 1 7TI 51 Collar 6 Spline washer 7 Snap ring 8 M3 M4 gear 20 22TI 9 Snap ring 1 0 Spline washer 1 1 M 5 bushing 1 2 M5 gear 28TI 1 3 Washer 1 4 Mainshaft M 1 gear 1 3TI Revised July 1 995 94 95 Mag...

Page 135: ...Crankshaft Piston Transmission Countershaft DisassemblyIAssembly 1 4 1 5 3 7D SHIFTER GEAR I GROOVE 7ll GEAR SLIDING I SURFACE 1 1 1 2 6 22 1 0 1 5 1 8 ALIGN OIL HOLES 23 8 9 1 2 1 3 1 6 1 7 1 9 20 ...

Page 136: ... Q ty Remarks Disassembly Order Assem bly is in the reverse order of disassembly 1 Needle bearing case 1 2 Needle bearing 1 3 Thrust washer 1 4 C1 gear 37T 1 5 Needle bearing 1 6 Thrust washer 1 7 C5 gear 29T 1 8 Snap ring 1 9 Spline washer 1 1 0 C4 gear 27T 1 1 1 C4 spline bushing 1 Align the oil holes of the bushing and countershaft 1 2 Tanged washer 1 At assembly fit the tangs i nto the lock wa...

Page 137: ...Crankshaft Piston Transmission Crankcase Combination 0 31 3 1 221 51 c 23 2 3 1 71 6 1 1 1 4 c 1 2 1 2 91 7 1 81 c 1 2 1 2 91 c 39 3 9 28 ALI G N 9 ...

Page 138: ...r crankcase bolt 8 mm 7 Lower crankcase bolt 6 mm washer 8 U pper crankcase bolt 10 mm washer 9 Cable guide 1 0 U pper crankcase bolt 6 mm washer 1 1 Mainshaft bearing set plate 1 2 Mainshaft bearing set plate bolt Q ty 1 1 1 3 1 I 2 2 J 7 1 1 3 Gearshift iinkage instal lation page 1 0 4 Cylinder head camshaft installation page 8 2 Engine instal lation page 7 2 Remarks CAUTION Do not apply sealant...

Page 139: ... numbers 1 2 or 3 on the crank weight are the codes for the main journal O D s Cross reference the case and journal codes to determine the replacement bearing color codes Main Journal Bearing Selection Table Unit mm in 37 000 37 005 37 006 37 01 1 37 012 37 018 nal 1 4567 1 4569 1 4569 1 4572 1 4572 1 4574 1 34 007 34 013 Yellow Green Brown 1 3389 1 339 1 2 34 001 34 006 1 3386 1 3388 3 33 995 34 ...

Page 140: ... k weight a re the codes for the crank pin O D s Cross reference the crankpin and rod codes to determine the replacement bearing color NOTE One painted mark identifies the front connecting rod bearings and two painted marks the rear Connecting Rod Bearing selection Table Unit mm in 35 995 36 000 35 989 35 994 35 982 35 988 1 4171 1 4173 1 4169 1 4171 1 4166 1 4169 39 000 39 005 1 1 5354 1 5356 39 ...

Page 141: ...ght but th rough coating of liquid sealant to the crankcase mating surface except to the main bearing jour nal bolt lower crankcase 9 mm area and the oil passage area as shown Crankcase Bolt Location Clean the crankcase 9 mm bolts thoroughly with solvent and blow them dry Apply clean engine oil to the 9 mm bolt th reads and seat ing surface and install them Loosely install all the lower crankcase ...

Page 142: ...nkcase bolts the sealing washers and cable guide Torque the 1 0 mm bolts and then the 6 mm bolts Torque 10 mm bolt 39 N m 3 9 kg m 28 ft lb 6 mm bolt 12 N m 1 2 kg m 9 ft lb Crankshaft Piston Transmission UPPER CRAN KCASE SIDE 1 1 1 9 ...

Page 143: ...MEMO ...

Page 144: ...safety stand or hoist Do not use the oil filter as a jack point Troubleshooting Hard Steering Steering head bearing adjustment nut too tight Faulty steering head bearings Insufficient tire pressu re Faulty tire Steers To One Side Or Does Not Track Straight Bent fork Bent front axle Wheel instal led incorrectly Faulty steering head bearings Bent frame Work wheel bearing Worn swingarm pivot componen...

Page 145: ...Front Wheel Suspension Steering Handlebar Removal Installation 1 c2 3 2 3 1 7 1 1 0 1 5 1 2 2 ...

Page 146: ...hrottle pipe 1 7 Handlebar O ty Remarks I nstal lation is in the reverse order of removal 2 2 2 1 Align the split between the holder and lever support with the punch mark on the handlebar and face the holder U P mark upward Tighten the upper bolt first then the lower bolt 2 Tighten the front screw first then the rear screw 1 Align the locating pin in the left handlebar switch with the hole in the ...

Page 147: ...ront wheel support the motorcycle using a safety stand or hoist Do not operate the brake lever after the front wheel removed Procedure Q ty Remarks Removal Order I nstallation is in the reverse order of removal 1 Speedometer cable 1 2 Axle bolt 1 3 Axle pinch bolt 4 4 Front axle 1 At installation apply a thin coating of grease to the front axle 5 Front wheel assembly 1 At installation align the pr...

Page 148: ...the Common Service Manual Requisite Service Front wheel removal instal lation page 1 2 4 Procedure Removal Order 1 Brake disc bolt 2 Brake disc 3 Dust seal 4 Speedometer gear retainer 5 Right wheel bearing 6004 U U 6 Distance collar 7 Left wheel bearing 6004 UU Q ty Remarks Instal lation is in the reverse order of removal 6 1 I nstall with stamped side outward 2 At instal lation apply grease to th...

Page 149: ...Front Wheel Suspension Steering Fork Removal Installation 9 c 27 2 7 20 8 c 1 2 1 2 9 1 1 0 c 39 3 9 28 3 5 c 31 3 1 22 1 2 6 ...

Page 150: ...r 3 Front fender 4 Brake hose clamp 5 Caliper bracket bolt 6 Caliper assembly 7 Front turn signal bolt collar 8 Front turn signal assembly 9 Fork pinch bolt upper 1 0 Fork pinch bolt lower 1 1 Fork assembly I Q ty 4 1 1 1 2 1 2 2 2 2 2 2 Upper fairing removal installation VF750CD page 2 8 Remarks Instal lation is in the reverse order of removal Only loosen the bolts Only loosen the bolts If the fo...

Page 151: ...Front Wheel Suspension Steering Fork Disassembly 1 10 1 2lr Ja il l i 1 8 s 1 9 9 171 8 1 2 8 1 4 6 7 91 14 15 lB 1 6 ...

Page 152: ... Order 1 Fork cap 2 0 ring 3 Spacer 4 Spring seat 5 Fork spring 6 Dust seal 7 Stopper ring 8 Fork socket bolt 9 Sealing washer 1 0 Fork piston 1 1 Fork piston ring 1 2 Rebound spring 1 3 Fork tube 1 4 Oil seal 1 5 Back up ring 1 6 Slider bushing 1 7 Fork tube bushing 1 8 Oil lock piece 1 9 Fork slider Q ty Remarks 1 1 1 1 1 After removing pour out any remaining fork oil T When removing do not dama...

Page 153: ...Front Wheel Suspension Steering Fork Assembly 3 4 s P e c 8 0 8 5 8 8 c 20 2 0 14 1 2 1 0 2 1 3 5 c 23 2 3 17 1 8 17 15 ...

Page 154: ...rk installation page 1 2 6 Remarks Replace with a new one if it was removed from the piston Insert into the fork tube Insert onto the piston Replace with a new one if it was removed from the fork tube If the socket bolt turns with the fork piston temporarily install the fork spring spacer and fork cap then tighten the socket bolt Wrap vinyl tape around the fork tube top end to avoid damaging the o...

Page 155: ...e 1 15 f tl __ 1 4 J a T hpage 1 2 13 15 J s T I page 1 2 13 J a T I page 12 13 13 NOTE Use the specified grease Urea based multi purpose grease for Extreme pressure example EXCELITE EP2 manufactured by KYODO YUSHI Japan Shell Stamina EP2 orequivalent 1 2 1 2 SHORTER TABS Bend down LONGER TABS Bend up ...

Page 156: ...ng stem 7 Dust seal 6 Steering head bearing adjustment nut 5 Lock washer 4 Lock nut 3 Top bridge 2 Th rust washer 1 Steering stem nut Q ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 Er 1 1 1 Meter removal instal lation page 1 8 7 Headlight removal installation page 1 8 6 Remarks After removing remove the fork Remove after straightening the lock washer tabs Replace if removed U se ...

Page 157: ...der page 1 2 2 Tighten the upper holder bolts Torque 5 N m 0 5 kg m 3 6 ft lb Adjust the handlebar straight ahead by tap the end of han dlebar Make sure that the length A and B are equal Tighten the lower holder nuts Torque 27 N m 2 7 kg m 20 ft lb Tighten the upper holder bolts page 1 2 2 Torque 23 N m 2 3 kg m 17 ft lb Make sure that the length A and B are equal 1 2 1 4 2 U PPER HOLDER ...

Page 158: ...g agent Any attempt to mount automobile tires on a motorcycle rim may cause the tire bead to separate from the rim with enough explosive force to cause serious injury or death When servicing the rear wheel support the motorcycle using a safety stand or hoist Refer to the section 1 4 for brake system information Tubeless ti re removal repai r and remounting procedu res are covered in the section 1 ...

Page 159: ...Rear Wheel Suspension Rear Wheel Removal Installation 1 5 1 8 7 022 2 2 1 6 1 2 c93 9 3 63 2 9 1 0 1 3 2 ...

Page 160: ...t Adjust the drive chain free play after installing the wheel Apply thin layer of grease to the rear axle surface Procedure Q ty Removal Order 1 Brake adjusting nut 1 2 Brake rod 1 3 Spring 1 4 Brake rod joint piece 1 5 Drive chain adjusting nut 2 6 Cotter pin 1 7 N ut 1 8 Washer 1 9 Rubber cushion 1 1 0 Brake stopper arm pivot bolt 1 1 1 Brake stopper arm 1 1 2 Rear axle nut washer 1 1 1 3 Drive ...

Page 161: ...Rear Wheel Suspension Rear Wheel DisassemblyIAssembly 8 3 9 7 2 8 6 1 1 1 0 3 1 3 4 4 5 c1 08 1 0 8 79 4 ...

Page 162: ...led into the wheel h u b Replace wheel bearings as a set For wheel bearing replacement refer to the section 1 of the Common Service Manual Requisite Service Rear wheel removal instal lation page 1 3 2 Procedure Disassembly Order 1 Dust seal Driven Flange Disassembly Order 2 Driven flange assembly 3 Driven flange collar 4 Driven flange bearing 6305 U U 5 Driven sprocket nut 6 Driven sprocket 7 Driv...

Page 163: ...and or hoist Adjust the shock absorber to the softest position for disassembly Procedure O ty Remarks Removal Order I nstal lation is in the reverse order of removal 1 Shock absorber mounting bolt upper 1 2 Plain washer 1 3 Shock absorber mounting bolt lower 1 NOTE Move the muffler outside remove the mounting bolt 4 Shock absorber assembly 1 1 3 6 ...

Page 164: ... shock absorber removal installation page 13 6 Procedure Q ty Disassembly Order 1 U pper seat 1 2 Spring cover 1 3 Spring 1 4 Preload adjuster 1 5 Damper unit assembly 1 Remarks Assembly is in the reverse order of disassembly See page 1 3 8 Install the spring with the small coi l end toward the bottom 1 3 7 ...

Page 165: ...h e s h ock a bs o r b e r c o m p ressor s l ow l y a n d remove the shock absorber Remove the spring cover and shock absorber spring I nstall the spring with the smal l coil end toward the bot tom Install the spring cover I nstal l the special tools and compress the shock absorber spring I nstall the spring seat securely l a TooL I Shock absorber compressor 07959 3290001 Loosen t h e s h o c k a...

Page 166: ... bolt 4 Drive chain cover 5 Shock absorber lower mounting bolt 6 Cap 7 Swingarm pivot nut 8 Swingarm pivot bolt 9 Swingarm assembly Q ty j 1 2 2 1 1 1 Rear Wheel Suspension 71 Cas 8 9 651 6 c39 3 9 28 1 Drive sprocket cover removal instal lation page 10 2 Remarks Insta llation is in the reverse order of removal t Adjustment page 13 10 NOTE Move the muffler outside remove the mounting bolts 1 3 9 ...

Page 167: ... Remove the lock nut while holding the adjusting bolt Remove the adjusting bolt Installation Tighten the adjusting bolt Torque 15 N m 1 5 kg m 1 1 ft lb Tighten the lock nut while holding the adjusting bolt Torque 64 N m 6 4 kg m 46 ft lb Tighten the pivot lock bolt Torque 39 N m 3 9 kg m 28 ft lb 1 3 1 0 1 LOCK N UT 1 ADJUSTING BOLT ...

Page 168: ...r cushion 5 Brake stopper arm 6 Drive chain slider screw 7 Drive chain slider 8 Right pivot collar 9 Left pivot collar 1 0 Dust seal 1 1 Distance collar 1 2 Needle bearing 1 3 Snap ring 1 4 Bal l bearing Q ty 1 1 1 1 1 2 1 1 1 2 1 1 1 1 Rear Wheel Suspension 2 022 2 2 1 6 7 61 06 0 6 431 Remarks Assembly is in the reverse order of disassembly Apply grease to the lip Install it into the groove secu...

Page 169: ...ot 15 mm Attachment 30 mm 07GMD KT70200 07946 MJ00100 M967X 038 XXXX 07949 3710001 07746 0040300 07746 0030300 P ress the need l e bea ring i nto the swi n g a rm with the marked side facing out NOTE The bearing surface should be flush with the pivot inside surface as shown l s rooL I Driver Attachment 28 x 30 mm Pilot 22 mm 07749 0010000 07946 1870100 07746 0041000 Press the ball bearing in until...

Page 170: ... of fluid as they may not be compatible Always check brake operation before riding the motorcycle Troubleshooting Front Brake Brake Lever Soft Or Spongy Air bubbles in the hydrau lic system Leaking hydrau lic system Contaminated brake pad disc Worn caliper piston seal Worn master cylinder piston seal Worn brake pad disc Contaminated caliper Caliper not sliding properly Low fluid level Clogged flui...

Page 171: ...e caliper pistons against the pads after the pad replacement The brake pad replacement can be done without disconnecting the hydraulic system Always replace the brake pads i n pai rs to assure even disc pressu re Procedure Q ty Remarks Removal Order Instal lation is in the reverse order of removal 1 Pad pin plug 1 After removing the pad pin plug loosen the pad pin 2 Pad pin 1 I nsert the pin pushi...

Page 172: ...painted plastic or rubber parts Place a rag over these parts whenever the system is serviced Requisite Service Front brake pad replacement page 1 4 2 Procedure Removal Order 1 Brake hose bolt 2 Sealing washer 3 Brake hose eyelet joint 4 Caliper bracket bolt 5 Front brake caliper assembly O ty 1 2 1 2 1 Brake fluid replacement air bleeding Section 1 7 of the Common Service Manual Remarks Instal lat...

Page 173: ...Bracket pin bolt boot 4 Caliper pin bolt boot 5 Bracket pin bolt 6 Caliper pin bolt 7 Caliper piston 8 Dust seal 9 Piston seal 1 4 4 O ty Remarks Assembly is in the reverse order of disassembly 1 Note spring djrection as shown 1 1 1 Install into the bracket groove secu rely 1 At installation apply a locking agent to the threads 1 At instal lation apply a locking agent to the threads 2 At i nsta l ...

Page 174: ...ual Procedure Q ty Remarks Removal Order Instal lation is in the reverse of order of removal 1 Right rearview m irror 1 Loosen the mounting nut and remove the mirror 2 Front brake lever pivot bolt nut 1 1 3 Brake lever 1 4 Front brake hose bolt 1 5 Front brake hose 1 At i nstal lation press the hose end against the stopper while tightening the hose bolt 6 Sealing washer 2 7 Brake light switch conn...

Page 175: ... system air bleeding Section 1 7 of the Com mon Service Manual Procedure Q ty Remarks Disassembly Order Assem bly is i n the reverse order of disassembly 1 Reservoi r cover 1 2 Diaphragm plate 1 3 Diaphragm 1 4 Brake light switch 1 5 Boot 1 6 Snap ring 1 CAUTION Be certain the snap ring is fully seated in the groove 7 Stopper plate 1 8 Master piston assembly 1 9 Spring 1 I nstal l the spring with ...

Page 176: ... clean a contami nated drum with a high quality brake degreasing agent Requisite Service Rear wheel removal instal lation page 1 3 2 Procedure Disassembly Order 1 Brake arm pinch bolt 2 Brake arm 3 Brake indicator 4 Felt seal 5 Cotter pin 6 Cotter pin plate 7 Brake shoe 8 Shoe spring 9 Brake cam 1 0 Brake panel Q ty Remarks Assembly is in the reverse order of disassembly 1 1 At installation align ...

Page 177: ... 3 Brake rod joint piece 1 4 Brake pedal pivot bolt nut 1 1 5 Collar 1 6 Dust seal 2 7 Brake pedal linkage joint pinch bolt 1 Align the punch marks 8 Brake pedal linkage assem bly 1 9 Cotter pin 2 1 0 Joint pin 2 1 1 Brake pedal linkage joint 1 1 2 Brake pedal 1 1 3 Brake light switch spring 1 1 4 Brake pedal return spring 1 1 5 Cotter pin 1 1 6 Joint pin 1 17 Brake rod linkage 1 1 8 Brake rod 1 1...

Page 178: ...e replaced when it reaches the end of its service life CAUTION The battery caps should not be removed Attempting to remove the sealing caps from the cells may damage the battery Battery can be damaged if over charged or undercharged or if left to discharge for long periods These same condi tions contribute to shortening the life span of the battery Even under normal use battery performance deterio...

Page 179: ...arging System Alternator System Location 4 ALTERNATOR 1 5 2 1 BATIERY 3 REGULATOR RECTIFIER 3 REGULATOR RECTIFIER 2 MAIN FUSE 30 A 2 MAIN FUSE 30 A 1 BATIERY 1 2 V 1 0 Ah R Red W White Y Yel low G G reen ...

Page 180: ... the battery condition Measure the battery current leakage ampere leak test page 1 5 6 Standard 0 01 mA max Correct Inspect the regulated voltage page 1 5 6 Standard 14 15 5 V 3 000 rpm Not charging Incorrect Correct Check the regu lator rectifier page 1 5 7 Incorrect Correct Shorted wire harness Faulty ignition switch Check the battery using the battery tester I ncorrect Correct 0 h pen c1rcu1t 1...

Page 181: ...or charging coil resistance at the regulator rectifier connector page 1 5 7 Connection Yellow Yellow Standard 0 1 1 0 0 Normal Check the regulator rectifier unit page 1 5 8 Abnormal Abnormal Check the charging coil resistance at the alter nator connector page 1 5 9 w_ J l lfW l lt Connection Yellow Yellow Standard 0 1 1 0 0 Abnormal Normal L Poorly connected alternttor connector Open or short circ...

Page 182: ...ice Seat removal instal lation page 2 2 Procedure Removal Order 1 Battery holder band 2 Negative terminal 3 Positive terminal 4 Battery O ty Remarks Instal lation is in the reverse order of removal 1 r After instal lation apply clean g rease to the cable end battery terminals and bolts At installation pul l the cover over the positive termi nal 1 1 5 5 ...

Page 183: ...ent Leakage 0 01 rnA max If current leakage exceeds the specified val ue a shorted circuit is likely Regulated Voltage Ampere Inspection If the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death NOTE Before performing this ...

Page 184: ... lights and the other electrical equipment should b OFF Use fu l ly charged battery to make this test in order to get a correct measurement Regulated Battery terminals Charging current 14 15 5 V 3 000 rpm 0 0 5 A 3 000 rpm Regulator Rectifier System Inspection Remove the seat page 2 2 Disconnect the regulator rectifier connectors Check the connectors for loose or corroded terminal Measu re the fol...

Page 185: ...ital type 07308 0020001 SANWA Analogue type Select the following range SANWA x kO KOWA x 1 00 Using an old battery stored in the m u lti meter can cause inaccu rate readi ngs Check the battery if the multimeter resistance is incorrect When using the KOWA multimeter remember that all readings should be multiplied by 1 00 Replace the regu lator rectifier unit if the resistance value between the term...

Page 186: ...or Measure the resistance between the Yellow wire terminals and check for no contin uity between each terminal and body ground Standard 0 1 1 0 0 20 C 68 F Replace the stator if the resistance is out of specification or if there is continuity between Yel low wire terminal and ground Charging System Alternator 1 ALTERNATOR 3P CONNECTOR 1 5 9 ...

Page 187: ...Charging System Alternator Alternator Removal Installation 5 4 6 1 5 1 0 7 012 1 2 9 1 c12 1 2 9 LIQUID SEALANT AREA ...

Page 188: ...ion page 2 2 Procedure Removal Order 1 Alternator connector 2 Left crankcase cover bolt 3 Left crankcase cover 4 Gasket 5 Dowel pin 6 Stator wire holder 7 Stator mounting bolt 8 Stator assembly Flywheel Removal Order 9 Flywheel bolt 1 0 Washer 1 1 Flywheel O ty Remarks Instal lation is in the reverse order of removal 1 6 1 1 2 1 4 1 At installation apply sealant to the grommet and instal l the gro...

Page 189: ...MEMO ...

Page 190: ...trol module ICM may be damaged if dropped Also if the connector is disconnected when current is present the excessive voltage may damage the unit Always turn off the ignition switch before servicing o Ignition timing cannot be adjusted since the Ignition control module ICMI is non adjustable If ignition timing is i ncorrect check the system components and replace any faulty parts o A fau lty ignit...

Page 191: ...ATOR 6 CLUTCH SWITCH DIODE 7 MAIN FUSE 30 A BI Br Lg BI IIJ lll l I I a 0 J IGNITION COILS SPARK PLUGS 1 6 2 4 L B ATT ___ ERY 3 FUSE 1 0 A 1 SIDE STAND I N DICATOR DOWN 2 ENGINE STOP SWITCH BlfW o BI Y Bia 8 NEUTRAL G J SWITCH G W 5 1CM UP 9 SIDE STAND SWITCH ___ I t_ G W Y o G R iii iii 1 2 CLUTCH SWITCH 00 1 0 IGNITION PU LSE GENERATOR Bl BLACK Y YELLOW Bu BLUE G GREEN R RED W WHITE Lg LIGHT GR...

Page 192: ...ontrol module ICM connector with the igni tion switch ON and the engine stop switch at R U N page 1 6 8 14 1 J Connection Black White Green Standard Battery voltage Battery voltage measured Measu re the ignition pu lse generator resis tance at the i g n ition control module I C M connector page 1 6 8 Connection Black Yellow Black White Standard 450 550 0 Normal 1 No voltage t t l 1 _____ _ Faulty ...

Page 193: ...reen Black No continuity Normal Fau lty ignition control module ICM 1 6 4 Abnormal Abnormal Connection Light green Red Ground Standard Continuity in neutral No continuity in any gear Normal Abnormal I j Faulty neutral switch Open circuit in Light green Red wire Loose or poor neutral switch connector contacts Side stand u Green White Green Continuity Side stand down Yellow Black Green Continuity No...

Page 194: ...nition control module ICM connec tor Connection No 1 3 Black White Black Yellow No 2 4 Black White Black Blue Standard 2 4 0 Normal Faulty ignition control module ICM No spark condition remains with the faulty pair Abnormal Remove the faulty ignition coils and check the ignition coi l resistance page 1 6 8 Standard Primary 2 4 0 Between the plug caps 23 27 kO Between the spark plug wire 13 17 kO A...

Page 195: ...ith known good spark plug and conduct spark test Standard 23 27 kO Abnormal Remove the spark p l u g cap a n d measure resistance of the ignition coi l page 16 9 Standard 13 17 kO Normal Poor contact of spark plug cap Faulty spark plug cap Faulty spark plugs 1 6 6 Normal Condact spark test on good ignition coil Abnormal T 1 Faulty ignition coil ...

Page 196: ...e ignition control module ICM passes to ground via the side stand switch The ignition control module ICM monitors lines a and b and provides spark only when one or both of those lines is connected to ground via the neutral switch or the side stand switch Check the side stand indicator function Normal 1 Open circuit in G reen White wire Abnormal Normal Check for continuity between each terminal of ...

Page 197: ...r Black Yellow Black White coil Neutral switch line Black Light green Body ground Side stand switch line Black G reen Black Ground line G reen Body ground Ignition Coil Inspection Measu re the primary coi l resistance between the termi nals Standard 2 4 0 Measure the resistance between the spark plug caps Standard 23 27 kO 1 6 8 1 CON NECTOR Standard Battery voltage should register with the igniti...

Page 198: ...0 Refer to page 1 6 1 1 for ignition pulse generator replace ment Ignition Coil Removal Installation Front Remove the air cleaner housing page 5 3 Remove the spark plug caps from spark plugs Disconnect the ignition coil primary wi res from the coil Remove the ignition coil mounting bolts and front ignition coil Instal lation is in the reverse order of removal Rear Remove the seat and left side cov...

Page 199: ...ls Installation is in the reverse order of removal Ignition Control Module ICM Removal Installation Remove the battery case mounting bolts Move the battery case left ward and disconnect the igni tion control module ICM connector Remove the ignition control module ICM I nstallation is in the reverse order of removal 1 6 1 0 1 BOLTS 2 PRIMARY WIRES 3 I G N ITION COIL 2 BATTERY CASE ...

Page 200: ...generator connector 2 Oil pressure switch terminal 3 Ignition pulse generator wire grommet 4 Ignition pulse generator mounting bolt 5 Ignition pulse generator assembly 6 Dowel pin Q ty 1 1 1 3 1 2 Remarks Installation is in the reverse order of removal At installation apply sealant to the wire g rommet and install the into the rotor cover g roove securely Route the ignition pulse generator wire as...

Page 201: ...sed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death Stop the engine and remove the timing hole cap Connect a timing light to the spark plug wire Start the engine and let it idle The timing is correct if the F mark aligns with the i ndex mark on the right crankcase cover I ncrease the engine speed by rotating the th rottle stop scre...

Page 202: ...ion cu rrent If current is applied to the starter motor whi le the engine is not turning over the starter motor may be damaged For the following components inspections refer to the Common Service Manual or the fol lowing pages for the parts locations see page 17 2 of this manual System Location Component Inspection method Remarks Clutch switch diode Section 24 of the Common Service Manual Starter ...

Page 203: ... SWITCH DIODEI 5 CLUTCH SWITCH DIODE 94 2000 S STARTER RELAY SWITCH MAIN FUSE 30 A 10 IGNITION SWITCH 4 BATTERY 3 FUSE 15 A 6 MAIN 12 NEUTRAL INDICATOR 13 SIDE STAND INDICATOR 1 7 2 3 FUSE 10 A FUSE 30 A 121 STARTER SWITCH a 1 ENGINE ST0 5 CLUTCH SWITC i 1 1 CLUTCH SWITCH DIODE Lg 81 1 1 T I I G R R 1 Lg R 7 SIDE STAND C 8 NEUTRAL SWITCH SWITCH DOWN UP Bl BLACK y YELLOW Bu BLUE G GREEN L Y BI R RE...

Page 204: ...hart below Gear Position Side Stand Clutch Lever Starter Motor Up In Any Gear Down Starter motor will not turn Check for loose or poorly con nected battery te rm i n a l s a n d o p e n e d o r s h o rted batte ry cable Normal Check for loose or poorly con nected sta rter relay switch terminals and 4P connector Normal j Pulled in Operates Released Does Not Operate Pulled in Does Not Operate Releas...

Page 205: ...tarter relay switch connector and check the relay coil ground line as below for continuity 1 Green Red terminal to clutch switch diode to neutra l switch l i n e with transm ission into neutral and clutch lever released 2 G reen Red terminal to cl utch switch to side stand switch line in any gear except neu tral and with the clutch lever pulled in and the side stand up Continuity 1 7 4 l Starter m...

Page 206: ...harness Remove the starter relay switch Connect a fu l ly charged 12 V battery to the starter relay switch Normal Loose or poor contact of the starter relay Check the continuity between the switch large terminal Battery Connection Yellow Red Green Red 1 1 Standard Continuity switch connector Abnormal 1 Faulty starter relay switch Starter motor turns when the transmission is in neutral but does not...

Page 207: ...attery Poorly connected battery termina l cable Poorly connected starter motor cable Faulty starter motor Starter motor turns but engine does not turn Starter motor is running backward Case assembled improperly Terminals connected improperly Faulty starter clutch Damaged reduction gear Starter relay switch clicks but engine does not turn over Crankshaft does not turn due to internal mechanical eng...

Page 208: ...g the starter motor NOTE I Route the wire and cables properly page 1 20 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Flange nut 1 After instal lation install the rubber cap 2 Starter motor cable eyelet 1 3 Starter motor mounting bolt 2 4 Starter motor 1 Disassembly page 1 7 8 5 0 ring 1 Apply oil when installing 1 7 7 ...

Page 209: ...Electric Starter Starter Clutch Starter Motor DisassemblyIAssembly 6 8 1 C5 0 5 3 6 9 1 6 2 3 4 5 ALIG N 1 7 8 ...

Page 210: ...nal holding nut 1 0 Washer 1 1 Insulated washer 1 2 0 ring 1 3 Brush holder assembly 1 4 Brush and terminal 1 5 0 ring 1 6 Rear cover Electric Starter Starter Clutch Q ty Remarks Assembly is in the reverse order of disassembly 3 1 Align the index marks on the front cover and case 1 1 1 Align the index marks on the rear cover and case 1 1 1 2 1 3 1 1 Align the holder tab with the rear cover groove ...

Page 211: ...Electric Starter Starter Clutch Starter Clutch Removal Installation 1 tf tt 90 9 0 65 i a TooL I page 1 7 1 1 1 7 1 0 WIDE GROOVE SCREW DRIVER ...

Page 212: ... gear assembly 1 Electric Starter Starter Clutch Pu lse generator removal instal lation page 16 1 1 Remarks I nstal lation is in the reverse order of removal Use the gear holder 07724 0010100 as shown Apply clean engine oil to the threads Disassembly assem bly page 17 12 At installation align the wide groove with the wide tooth of the crankshaft NOTE When primary drive gear removaVinstal lation al...

Page 213: ... gear 2 Starter clutch outer cover bolt 3 Starter clutch outer cover 4 Roller 5 Plunger 6 Spring 7 Starter clutch outer 1 7 1 2 7 1 6 Q ty Remarks Assembly is in the reverse order of disassembly 1 Rotate clockwise when instal ling 3 Apply a locking agent to the th reads at instal lation 1 Align the pin on the outer with the hole of the cover when i nstalling 3 Be careful not to pop them out 3 3 1 ...

Page 214: ...alcohol Be sure to install the dust cover after replacing the bulb All plastic connectors have locki ng tabs that must be released before disconnecting and must be aligned an d engaged fully when recon necting Always turn off the ignition switch before disconnecting any electrical component A continuity test can be made with switches installed on the motorcycle Check the battery condition before p...

Page 215: ...Lights Meters Switches System Location 1 FRONT BRAKE LIGHT SWITC 8 NEUTRAL 6 COOLANT TEMPERATURE INDICATOR U N IT 5 FUSE BOX 7 SIDE STAND SWITCH 1 8 2 ...

Page 216: ...ator 1 c _ o _ m _ e _ s _ o _ n __ connectors Turn the ignition switch ON Indicator does not come on Normal Connect the coo l a nt tem peratu re i n d icator 1 _ con n ecto rs Disconnect the thermo senso r connector and tu rn the i g n ition switch O N Check the coolant temperature indicator oper ation Abnormal Short circuit i n Light green Black wire Faulty thermo sensor page 1 1 1 Fau lty coola...

Page 217: ...ON Indicator come on Abnormal Check the coolant tem peratu re ind icator 4P to connector and body ground for continuity Abnormal Check the voltage between the coolant tem 1 peratu re i n d icator 4P co n n ecto r a n d body ground turn the ignition switch ON Normal 1 8 4 Blown indicator bulb Open circuit i n Light green Black wire Open circuit in Green wire Open circuit in Black Brown wire Faulty ...

Page 218: ... headlight bulb Installation is in the reverse order of removal NOTE Install the dust cover with its TOP mark facing up Tail Brake Light Bulb Remove the screws and tail brake light lens Remove the tail brake light bulb by turning it counterclock wise Install a new bulb in the reverse order of removal Turn Signal Light Bulb Remove the screw and turn signal l ight lens Remove the turn signal light b...

Page 219: ...ecified by local laws and regulations After installation route the wires and cable properly page 1 20 Requisite Service Upper fairing removal installation VF750CD page 2 8 Procedure Q ty Remarks Removal Order I nstal lation is in the reverse order of removal 1 Screw 2 2 Headlight connector 1 3 Headlight assembly 1 4 Headlight case bolt nut 2 2 5 U pper fairing stay 1 VF750CD only 6 Headlight case ...

Page 220: ...cover removal instal lation page 2 3 Procedure Removal Order 1 Speedometer cable 2 Combination meter connector 3 Com bination meter mounting bolt guide 4 Combination meter assembly Q ty 1 3 2 2 1 U pper fairing removal instal lation VF750CD page 2 8 Remarks Installation is in the reverse order of removal Disassembly Assembly page 1 8 8 1 8 7 ...

Page 221: ...the indicator bulbs out of the meter Remove the wire harness clamp Disconnect the meter terminals and remove the wire har ness Separate the meter rear covers and meter stay Assemble the meters in the reverse order of disassembly NOTE Connect the proper color wire to the meter termi nals Y G Yellow Green G Green 1 8 8 1 SCREWS 1 REAR COVERS ...

Page 222: ... between each color of wire terminal as shown i n the chart below There should be continuity between the o o positions on the following chart u nder the conditions shown here Green White Yel low Black G reen Side stand up Side stand down Removal Installation Disconnect the side stand switch 3P Green connector Remove the side stand switch mounting bolt and side stand switch Instal l the switch i n ...

Page 223: ...MEMO ...

Page 224: ...T 12Y1 4WI2 STARTDtS I lT OI 162 ST HL HLI FREE I QiQ PUSH STNiftll MOTOR 19 Wiring Diagram 11 32 CP liLAC a BROWN YELlOW 0 ORANGE BLUE lb LIGHT BLUE GREEN UGHT GREEN REO PINK WIITE GRAY 0030Z MZ5 6700 u z C c C u l 31 ...

Page 225: ...I UGIIT 12V1 4WX2 00 00 IQNITlCfi COIL IIIGHT II AR TIA I 1GML 12V21W lAAlE AND l t llltc T 12V32 3cp REAR lAAKE UGtiT SWITCH 81 BUCK 8 BROWN y YELLOW ORANGE a llltlE LIGHT lUI GA EN l t LIGHT GREEN PINK WHITE GRAY 0030Z MZ5 ABOO ...

Page 226: ...e when the bolt was tightened first time The standard bolt is applicable to the female threads that were made by means of the plastic deformation during tightening the CT bolt The service replacement parts of the parts tightened with the CT bolts have the threads When the CT bolt replacement is req u i red use new CT bolt or Honda genuine standard bolt length CAUTION I Do not use the length standa...

Page 227: ...MEMO ...

Page 228: ...sible Cause Clogged fuel tube or fuel strainer screen Sticking float valve Clogged fuel tank breather tube Disconnected or faulty auto fuel valve vacuum tube Faulty spark plugs Fou led spark plugs Faulty ICM Broken or shorted spark plug wires Broken or shorted ignition coils Faulty ignition switch Fau lty ignition pulse generator Faulty engine stop switch Loose or disconnected ignition system wire...

Page 229: ...ncrease Restricted fuel flow j Clogged m uffler Pinched fuel tank breather 5 Check ignition timing I ncorrect Faulty ICM Faulty ignition pulse generator Correct 6 Test cylinder compression Too Low Valve stuck open Worn cylinder and piston rings Normal Leaking head gasket Improper valve timi ng 7 Check carbu retor for clogging Clogged Carburetor not serviced frequently enough Not clogging 8 Remove ...

Page 230: ...ubleshooting Possible Cause Excessive carbon built u p in com bustion cham ber Use of poor quality fuel Clutch slipping Lean fuel mixtu re Wrong type of fuel Worn piston and cyli nder Wrong type of fuel Excessive carbon built u p i n com bustion cham ber Ignition timing too advanced Faulty ICM Lean fuel mixture Possible Cause Improper ignition timing Faulty ICM See Fuel System section Loose insula...

Page 231: ...or clogged juts Not clogged t 4 Check valve timing I ncorrect _ _ _ _ _ __ _ _ __ Correct 5 Check valve spring VVeak Not VVeakened Poor Handling 1 I f steering i s heavy Possible Cause Faulty ICM Fau lty ignition pu lse generator Clogged fuel line Clogged fuel tank breather Clogged fuel strainer screen Clean Cam sprocket not installed properly Faulty spring Possible Cause Steering stem adjusting n...

Page 232: ...on 1 8 6 High Altitude Adjustment U S A Only 5 1 7 Ignition Coil I nspection 1 6 8 Removal Instal lation 1 6 9 22 Index Ignition control Module ICM Removal Installation 1 6 1 0 Ignition Pu lse Generator Inspection 1 6 9 Removal I nsta llation 1 6 1 1 Ignition Switch Replacement 1 8 9 Ignition System I nspection 1 6 8 Ignition Timing 1 6 1 2 Liquid Sealant Application 1 1 1 8 Lubrication Seal Point...

Page 233: ...Does Not Start Or Is Hard To Start Engine Lacks Power Frame Body Panels Exhaust System Front Wheel Suspension Steering Fuel System Gearshift Linkage Ignition System Lights Meters Switches Lubrication System Poor Handling Poor Performance At High Speed Poor Performance At Low And Idle Speeds Rear Wheel Suspension U pper Fairing Removal Instal lation VF750CD Valve Clearance Water Pump Removal Instal...

Page 234: ...23 44 Crankcase 23 16 Rear Shock Absorber 23 45 Crankshaft 23 17 Rear Wheel 23 46 Cylinder Head Cover 23 18 Right Crankcase Cover 23 47 Evaporation Canister 23 19 Seat 23 48 Frame 23 20 Side Cover 23 49 Front Brake Caliper 23 21 Speedometer Tachometer 23 50 Front Brake Master Cylinder 23 22 Stand 23 52 Front Cylinder Head 23 23 Starting Motor 23 53 Front Fender 23 24 Steering Stem 23 54 Front Fork...

Page 235: ...LNR 17254 KAZ 000 001 2 08 09 COVER SUB A CLNR 17256 MM4 000 001 16 56 10 TUBE SUB A CLNR 17258 MZ5 000 001 11 07 Description Q ty Price 11 STOPPER 17259 MZ5 000 001 11 42 12 TUBE A BREATHER 17355 MZ5 000 001 3 22 13 SCREW 5X12 90105 MB1 000 004 2 02 14 SCREW PAN 5X19 90141 KT8 000 003 3 65 15 SCREW PAN 4X40 90141 MZ5 000 005 7 11 16 NUT SPECIAL 6X7 61304 958 003 replaces 90301 471 000 002 2 64 17...

Page 236: ... 18617 MZ5 740 002 12 13 10 CONTROL VALVE RR 18620 MZ5 740 001 153 78 11 TUBE 18625 MZ5 740 001 31 86 12 TUBE 18626 MZ5 740 001 10 66 Description Q ty Price 13 PIPE R FR AIR 18640 MZ5 740 001 47 54 14 GSKT AIR FEED PIPE 18645 MT4 730 004 1 96 15 PIPE L FR AIR 18645 MZ5 740 001 47 54 16 PIPE RR AIR 18650 MZ5 740 001 99 53 17 BOLT 90007 PY3 000 002 2 88 18 CLAMP TUBE D17 91405 MF5 860 002 2 51 19 CL...

Page 237: ...EL 31110 MZ5 004 001 386 83 04 STATOR 31120 MZ5 004 001 332 99 05 CLAMP CABLE 32111 MZ5 000 001 6 36 06 BOLT FLANGE 6X32 90001 GHB 690 005 2 96 Description Q ty Price 07 BOLT FLANGE 6X60 90001 GHB 750 001 3 93 08 BOLT FLANGE 10X35 90003 MN4 000 001 4 76 09 BOLT SOCKET 6X40 90116 375 000 004 3 18 10 WASHER 10X25X4 90405 ML0 000 001 4 76 11 PIN DOWEL 8X14 94301 08140 002 1 00 ...

Page 238: ... 32601 MZ5 000 001 27 51 07 SWITCH ASSY 35850 MR5 007 001 83 87 08 RUB SHOCK ABSORBER 35856 MR5 000 001 6 95 Description Q ty Price 09 BOX ASSY BATTERY 50330 MZ5 000 001 86 89 10 BODY KEY 83507 422 000 001 2 76 11 STOPPER KEY BODY 83508 KBG 000 replaces 83508 438 000 001 2 04 12 BOLT SOCKET 5X9 90111 MR5 000 002 1 87 13 NUT SPECIAL 6X7 61304 958 003 replaces 90301 471 000 003 2 64 14 PIN SPRING 2X...

Page 239: ... 64220 MZ5 870ZB 001 579 87 07 STAY COWL 64505 MZ5 870 001 19 36 08 STAY A R COWL 64506 MZ5 870 001 33 87 09 STAY A L COWL 64507 MZ5 870 001 33 87 Description Q ty Price 10 STAY B R COWL 64508 MZ5 870 001 17 18 11 STAY B L COWL 64509 MZ5 870 001 17 18 12 BOLT SPECIAL 6X17 90085 MZ1 000 002 2 84 13 SCREW PAN 6X14 90106 KBV 000 001 3 09 14 SCREW TRUSS 5X20 90109 MT3 000 006 2 00 15 NUT 5MM 90111 KW3...

Page 240: ... 75 99 08 PIN TENSIONER 14531 MZ5 000 001 7 04 09 GUIDE B CAM CHAIN 14546 MZ5 000 002 28 15 10 GUIDE FR CAM CHAIN 14620 MZ5 000 001 50 43 Description Q ty Price 11 GUIDE RR CAM CHAIN 14625 MZ5 000 001 51 58 12 STAY 14627 MZ5 000 001 23 11 13 BOLT FLANGE 6X10 90004 GHB 600 replaces 90001 GHB 600 002 2 47 14 BOLT FLANGE 6X25 90004 GHB 670 replaces 90001 GHB 670 004 2 22 15 BOLT 6X14 90009 MZ8 H00 re...

Page 241: ...00 14905 KT7 013 016 6 78 14 SHIM TAPPET 1 325 14906 KT7 013 016 6 78 14 SHIM TAPPET 1 350 14907 KT7 013 016 6 78 Description Q ty Price 14 SHIM TAPPET 1 375 14908 KT7 013 016 6 78 14 SHIM TAPPET 1 400 14909 KT7 013 016 6 78 14 SHIM TAPPET 1 425 14910 KT7 013 016 6 78 14 SHIM TAPPET 1 450 14911 KT7 013 016 6 78 14 SHIM TAPPET 1 475 14912 KT7 013 016 6 78 14 SHIM TAPPET 1 500 14913 KT7 013 016 6 78...

Page 242: ... 325 14946 KT7 013 016 6 78 14 SHIM TAPPET 2 350 14947 KT7 013 016 6 78 14 SHIM TAPPET 2 375 14948 KT7 013 016 6 78 14 SHIM TAPPET 2 400 14949 KT7 013 016 6 78 Description Q ty Price 14 SHIM TAPPET 2 425 14950 KT7 013 016 6 78 14 SHIM TAPPET 2 450 14951 KT7 013 016 6 78 14 SHIM TAPPET 2 475 14952 KT7 013 016 6 78 14 SHIM TAPPET 2 500 14953 KT7 013 016 6 78 14 SHIM TAPPET 2 525 14954 KT7 013 016 6 ...

Page 243: ...Appendix A Part Numbers 23 10 Carburetor Assembly ...

Page 244: ...Z5 740 001 480 69 22 CARBURETOR ASSY 4 16104 MZ5 670 001 480 69 22 CARBURETOR ASSY 4 16104 MZ5 740 001 480 69 23 LEVER STARTER 16121 MZ5 600 002 30 40 24 FUNNEL AIR 16141 MZ5 600 004 20 85 Description Q ty Price 25 STAY JOINT 16169 MZ5 670 001 21 11 26 COLLAR 16172 MZ5 670 001 19 36 27 COLLAR 16173 MZ5 670 001 15 85 28 COLLAR 16174 MZ5 670 001 19 36 29 COLLAR 16175 MZ1 000 004 9 40 30 T JOINT 1617...

Page 245: ... 2 95 15 SCREW PAN 16080 MV4 000 012 1 67 16 BOLT WASHER 5X16 16082 PH9 005 012 2 16 17 TOP 16107 MZ5 671 004 38 78 Description Q ty Price 18 SCREW 16108 MW0 750 004 1 73 19 PISTON VACUUM 16111 MZ5 600 004 119 21 20 PLATE STAY 16119 MZ2 600 001 13 64 21 PLATE STAY 16119 MZ5 600 001 13 96 22 STAY WIRE 16119 MZ5 670 001 17 35 23 VALVE FLOAT 16155 MN9 004 004 23 04 24 HOLDER NEEDLE JET 16165 MN4 013 ...

Page 246: ...A01 replaces 35100 MZ5 007 001 49 44 09 BASE 35102 MR1 000 001 9 75 10 COLLAR 35103 MR1 000 001 15 58 11 COVER 35110 MZ5 000 001 14 45 Description Q ty Price 12 KEY BLANK TYPE1 35121 MR1 770 001 7 38 12 KEY BLANK TYPE2 35122 MR1 770 001 7 38 13 GROMMET A CLNR HSG 83551 GE2 000 004 3 18 14 BOLT BREAK OFF 90107 MR1 000 002 6 16 15 BOLT FLANGE 6MM 90113 KW3 000 002 2 84 16 SCREW RR COVER 90114 GB6 92...

Page 247: ...001 3 78 04 LABEL DRIVE CHAIN 87507 MZ5 670 001 3 78 05 MARK 87512 MZ3 670 001 4 51 06 LABEL DRIVE TYPE2 87560 MW0 670ZB 001 4 62 Description Q ty Price 07 LABEL R201 TYPE1 87565 MZ5 670ZA 001 2 16 07 LABEL NH1 TYPE2 87565 MZ5 670ZB 001 2 16 07 LABEL Y124 TYPE3 87565 MZ5 670ZC 001 2 16 08 LABEL FUEL TYPEG 87586 MR6 670ZA 001 2 33 08 LABEL FUEL TYPEB 87586 MR6 670ZF 001 2 22 ...

Page 248: ...4 10 PLATE CLU PRESS 22350 ML7 000 001 52 03 11 PIECE CLUTCH JOINT 22366 KE8 000 001 8 73 12 SPRING CLUTCH 22401 KZ3 000 replaces 22401 ML7 000 005 3 51 13 SPRING JUDDER 22402 ML7 000 001 17 18 Description Q ty Price 14 ROD CLUTCH LIFTER 22850 MZ5 000 001 24 56 15 GEAR PRIMARY DRIVE 23110 ML7 010 001 167 74 16 SPRING 23115 MG8 300 003 2 33 17 BOLT WASHER 6X25 90022 MM5 000 005 2 33 18 NUT LOCK 22M...

Page 249: ...00 001 5 65 12 PIN DOWEL 10X16 90701 MV9 670 002 3 38 13 OIL SEAL 8X25X8 91204 MB0 013 001 3 18 Description Q ty Price 14 O RING 7 7X2 3 91301 PC9 003 replaces 91308 283 000 91313 393 003 001 1 45 15 PIN DOWEL 8X14 94301 08140 001 1 00 16 BOLT FLANGE 6X12 95701 06012 00 002 0 72 17 BOLT FLANGE 6X28 95701 06028 00 002 0 85 18 BOLT FLANGE 6X35 95701 06035 00 001 0 75 19 BOLT FLANGE 6X40 95701 06040 ...

Page 250: ...9 08 BRG C FR CONN ROD 13226 ML7 690 004 10 18 08 BRG D FR CONN ROD 13227 ML7 690 004 8 58 08 BRG E FR CONN ROD 13228 ML7 690 004 9 09 09 BEARING A RR 13234 ML7 690 004 9 09 Description Q ty Price 09 BRG B RR CONN ROD 13235 ML7 690 004 9 09 09 BRG C RR CONN ROD 13236 ML7 690 004 10 18 09 BRG D RR CONN ROD 13237 ML7 690 004 9 09 09 BRG E RR CONN ROD 13238 ML7 690 004 9 09 10 CRANKSHAFT 13310 MZ5 00...

Page 251: ...3 MZ5 000 004 7 04 06 COVER RR CYL HD 12321 MZ5 305 001 181 64 07 COVER A CYL HD 12340 MZ5 000 004 135 39 08 GASKET CYL HD CVR 12391 MT4 000 002 22 42 Description Q ty Price 09 PLUG HEX 6MM 12392 MJ0 000 008 3 55 10 CLIP B TUBE 16106 KW7 900 001 2 38 11 BOLT CYL HD CVR 90002 MZ5 000 008 8 53 12 BOLT SPECIAL 6X34 90003 MZ5 000 008 11 09 12 BOLT 6X34 5 90003 MZ5 920 008 6 09 12 RUBBER MOUNTING 90543...

Page 252: ... TUBE 17414 MZ5 740 001 16 58 14 PIPE 17415 MZ5 740 001 81 68 15 TUBE 17416 MZ5 740 001 17 44 16 VALVE 17440 MZ5 740 001 60 45 Description Q ty Price 17 RUBBER 17451 ME5 760 001 9 24 18 TUBE 17525 MZ5 740 001 8 38 19 TUBE 18630 MZ5 740 001 12 94 20 JOINT B WASHER TUBE 38562 663 920 001 4 57 21 COLLAR 6 3X13 50324 425 010 002 3 96 22 RUBBER 84703 MN5 000 002 3 51 23 CLAMP TUBE 12 5MM 90661 GHB 610 ...

Page 253: ...CUMULATOR 57071 SB0 800 001 4 04 14 BOLT UBS 8X60 90029 MG8 000 002 3 89 15 BOLT FLG 10X105 90101 MZ5 000 002 7 69 Description Q ty Price 16 BOLT FLANGE 8X25 90103 MZ5 000 008 3 09 17 BOLT FLG 12X265 90105 MM8 880 001 17 84 18 BOLT 90107 MJ1 000 002 3 51 19 BOLT 90116 MZ5 000 001 22 76 20 SCREW TRUSS 90133 SD4 000 002 1 05 21 CAP R LOCK NUT 90302 ME5 000 002 13 84 22 WASHER FLAT 10MM 94102 10700 r...

Page 254: ...412 36 06 PISTON 45107 MN5 006 002 28 75 07 SPRING PAD 45108 ML7 922 001 4 85 08 BRACKET L FR 45110 MZ6 006 001 91 77 09 RETAINER 45112 MS9 611 001 4 29 Description Q ty Price 10 BOLT A PIN 45131 ML7 921 001 11 71 11 PIN BOLT 45131 166 016 001 6 00 12 BUSH PIN 45132 166 016 001 4 29 13 BOOT B 45133 MA3 006 001 4 29 14 CALIPER SUB ASSY 45150 MZ5 305 001 342 69 15 PLUG PIN 45203 MG3 016 001 4 00 16 ...

Page 255: ... HOLDER 45517 MR1 671 001 19 49 09 PLATE DIAPHRAGM 45518 MM5 006 001 8 09 10 DIAPHRAGM 45520 MM5 006 001 11 47 Description Q ty Price 11 MASTER CYLINDER SET 45530 MN9 305 001 38 51 12 LEVER R HANDLEBAR 53175 MR1 671 001 14 31 13 BOLT R 90114 MA5 671 001 7 15 14 BOLT OIL 10X22 90145 MS9 612 replaces 90145 MS9 611 002 5 29 15 NUT CAP 6MM 90201 415 000 001 1 58 16 WASHER OIL BOLT 90545 300 000 004 2 ...

Page 256: ...TER 16214 MB0 000 001 3 51 09 BAND A INSULATOR 16219 MM4 000 002 8 07 10 BAND B INSULATOR 16220 MM4 000 002 8 07 11 BOLT FLANGE 9X93 90007 ML7 920 008 7 85 Description Q ty Price 12 BOLT SOCKET 6X28 90012 MZ5 000 006 1 60 13 BOLT FLG 6X45 5 90017 MA6 000 008 2 62 14 BOLT FLG 6X39 5 90019 MA6 000 008 2 25 15 BOLT STUD 6X28 90035 MZ5 000 004 3 87 16 WASHER 9MM 90445 MM4 000 008 2 82 17 WASHER 5MM 90...

Page 257: ...58 MZ5 000 001 16 56 02 GUIDE FR 45451 473 000 001 5 15 03 FENDER FR NH1 61100 MZ5 000ZC 001 154 96 03 FENDER FR Y124P 61100 MZ5 000ZD 001 154 96 Description Q ty Price 03 FENDER FR R201 61100 MZ5 000ZE 001 154 96 04 PLATE FR FENDER 61103 MZ5 000 001 11 33 05 BOLT 6X25 90080 MG8 000 004 3 07 ...

Page 258: ...MZ5 912 replaces 51420 MZ5 671 001 295 28 11 PIECE OIL LOCK 51432 MV9 003 002 18 85 12 RING PISTON 51437 MM5 003 002 4 22 13 PIPE SEAT 51440 MZ5 671 002 48 46 Description Q ty Price 14 RING 51447 KA4 711 002 3 55 15 BOLT FR FORK 51454 MM9 671 002 44 11 16 SEAL SET FR FORK 51490 MN8 305 002 25 16 17 FORK ASSY L FR 51500 MZ5 912 replaces 51500 MZ5 671 001 Call For Price 18 CASE L LOWER 51520 MZ5 671...

Page 259: ...15 44650 MZ5 325 001 526 65 07 RETAINER GEAR BOX 44680 ML7 000 001 3 76 08 TIRE 120 80 17 44711 MZ5 024 replaces 44710 MZ5 004 44711 MZ5 004 44711 MZ5 014 001 138 46 Description Q ty Price 08 TIRE 120 80 17 44711 MZ5 024 001 138 46 10 BOX ASSY 44800 ML7 691 001 73 35 11 GEAR SPEEDOMETER 44806 ML7 691 001 22 22 12 WASHER 44809 ML7 003 002 2 25 13 DISK FR BRAKE 45251 MS9 750 001 273 18 14 BOLT DISK ...

Page 260: ...ER TUBE 17316 611 000 001 5 55 13 TANK FUEL TYPE5 17520 MZ5 A40ZA 001 590 71 14 TUBE 17525 MZ5 000 001 13 18 15 CUSHION FR 17611 KE5 000 002 4 15 Description Q ty Price 16 RUB RR FUEL TANK 17613 MR7 000 001 12 55 17 CAP FUEL FILLER 17620 KR3 751 001 66 87 18 PROTECTOR HOSE 64233 MR7 300 002 4 04 19 SCREW OVAL 5X12 90111 MZ5 000 001 2 82 20 BOLT 90128 KL4 000 001 7 24 21 COLLAR 90502 MZ5 000 001 3 ...

Page 261: ... 02 GASKET L 11343 MZ5 000 001 4 57 03 GASKET R 11394 MY7 000 001 18 08 04 GASKET SHIFT COVER 11632 MY7 000 001 9 47 05 GASKET 11636 MY7 000 001 12 98 06 GASKET OIL STRAINER 15154 ML7 000 001 5 20 07 GASKET 19226 ML7 000 001 3 53 08 WASHER 10MM 90403 MG7 000 002 2 62 09 WASHER 6 5MM 90463 ML7 000 006 2 25 10 GSKT CONNECTING CAP 91301 MB0 000 002 3 05 11 O RING 48 1X3 6 91301 ML7 003 001 3 11 Descr...

Page 262: ...WL PLUNGER 24329 KA3 740 002 2 07 15 COLLAR 24329 KT7 000 001 3 89 16 STOPPER DRUM 24430 MR7 000 001 18 04 Description Q ty Price 17 COLLAR DRUM STOPPER 24434 MR7 000 001 6 36 18 SPRING 24435 KBV 000 001 3 40 19 SPINDLE GEARSHIFT 24610 MR7 000 001 79 90 20 SPRING 24651 MR7 000 001 5 71 21 PIN 24652 035 000 001 3 13 22 PLATE 24655 MR7 000 001 9 67 23 SWITCH NEUTRAL 35600 KE8 003 replaces 35600 KE8 ...

Page 263: ... 001 30 80 12 GRIP L HANDLE 53166 MM8 000 001 20 11 13 CAP GRIP END 53167 MM8 000 002 7 09 14 BRACKET HANDLEBAR 53172 MR1 000 001 25 53 15 LEVER L HANDLEBAR 53178 KV0 000 001 13 96 Description Q ty Price 16 BOLT CABLE ADJ 53192 268 000 001 5 45 17 MIRROR ASSY R 88110 MZ5 003 001 56 29 18 MIRROR ASSY L 88120 MZ5 003 001 56 29 19 BOLT L 90113 438 000 001 5 96 20 NUT CAP 6MM 90201 415 000 001 1 58 21...

Page 264: ...25 84 04 BRIDGE FORK TOP 53300 MZ5 000 001 217 98 05 EMBLEM WING MARK 86150 MR1 760 001 5 91 06 BOLT SOCKET 8X30 90112 KM4 000 002 2 98 Description Q ty Price 07 BOLT SOCKET 8X32 90154 ME9 000 004 4 47 08 NUT STEERING STEM 90304 415 000 001 15 02 09 NUT FLANGE 8MM 90309 428 731 002 2 98 10 WASHER 90503 283 000 001 3 51 11 WASHER 90535 KB9 000 002 4 67 12 CAP 8MM 91455 MB0 010 004 2 95 ...

Page 265: ...01 78 44 12 NUT UNIT HOLDER 33128 471 003 001 1 20 13 CVR ADJUSTING SCREW 33136 111 671 002 1 44 14 COVER RUBBER 33180 MJ0 010 001 11 67 Description Q ty Price 15 BULB 12V60 55W 34901 MC7 601AH replaces 34901 MC7 601 001 7 65 16 CASE HEADLIGHT 61301 MN0 003 001 73 70 17 COLLAR 61304 292 000 002 2 73 18 STAY HEADLIGHT 61305 MZ5 000 001 49 05 19 RUBBER 61315 MZ5 000 004 2 07 20 COLR HEADLIGHT STAY 6...

Page 266: ...Part Numbers 23 33 Mark VF750C 1994 1997 Description Q ty Price 01 MARK A TYPE1 87121 MZ5 300ZA 002 34 98 01 MARK A TYPE2 87121 MZ5 300ZB 002 34 98 Description Q ty Price 01 MARK A TYPE3 87121 MZ5 300ZC 002 34 98 ...

Page 267: ... A Part Numbers 23 34 Mark VF750C 1998 2003 Description Q ty Price 01 MARK TYPE5 87121 MZ5 A00ZA 002 24 02 01 MARK TYPE6 87121 MZ5 A40ZA 002 20 96 Description Q ty Price 01 MARK TYPE7 87121 MZ5 M10ZA 002 22 60 ...

Page 268: ...3 MARK TYPE1 87121 MZ5 950ZA 002 26 47 03 MARK TYPE2 87121 MZ5 950ZB 002 26 47 03 MARK TYPE3 87121 MZ5 A10ZA 002 23 38 Description Q ty Price 03 MARK TYPE4 87121 MZ5 A10ZB 002 21 73 04 STRIPE R TYPE1 87123 MZ5 950ZA 001 93 75 04 STRIPE R TYPE2 87123 MZ5 950ZB 001 93 75 04 STRIPE R TYPE3 87123 MZ5 A10ZA 001 82 16 04 STRIPE R TYPE4 87123 MZ5 A10ZB 001 76 33 05 STRIPE L TYPE1 87124 MZ5 950ZA 001 93 7...

Page 269: ...VF750C2 1998 2000 Description Q ty Price 98 STRIPE RR TYPE5 80111 MZ5 A30ZA 001 70 87 98 STRIPE RR TYPE6 80111 MZ5 A30ZB 001 Description Q ty Price 99 STRIPE RR TYPE7 80111 MZ5 A50ZA 001 71 89 00 STRIPE RR TYPE8 80111 MZ5 A70ZA 001 73 13 ...

Page 270: ... 96 68 14 GASKET MUFFLER 18391 MB0 891 002 13 58 15 GASKET MUFFLER 18391 ML8 000 002 13 73 16 PIPE L FR EX 18420 MZ5 981 replaces 18420 MZ5 003 001 114 12 Description Q ty Price 17 RUB MUFFLER SETTING 18421 MB0 000 002 4 98 18 COLLAR 18422 MB0 000 002 5 22 19 CVR L FR EX PIPE 18440 MZ5 003 001 106 57 20 JOINT L RR CYL HD 18450 MZ5 003 001 87 87 21 CVR L RR EX PIPE 18480 MZ5 003 001 99 99 22 RUBBER...

Page 271: ...13 001 11 98 12 PIPE A OIL 15511 MZ5 000 001 38 51 13 PIPE B OIL 15512 ML7 000 001 14 04 14 BOSS OIL FILTER 90019 MB0 000 001 6 80 Description Q ty Price 15 BOLT WASHER 6X12 90021 MM5 000 001 4 00 16 NUT U 6MM 90301 473 003 001 2 15 17 O RING 6X2 91307 ML7 004 002 1 87 18 O RING 14 6X3 7 91309 MB0 003 002 2 93 19 O RING 14 8X2 2 91313 MG7 004 replaces 91313 MB0 003 001 2 35 20 O RING 21 2X2 4 9133...

Page 272: ...46530 MZ5 000 001 10 51 16 ROD RR 46540 MZ5 000 001 44 51 17 BOLT TIE ROD 90065 MN4 000 001 3 89 18 BOLT CHANGE PIVOT 90115 KAF 000 001 14 96 Description Q ty Price 19 BOLT SOCKET 10X52 90153 MW0 000 001 5 04 20 NUT 90201 700 000 001 0 55 21 WASHER 10 3MM 90527 230 000 001 1 44 22 DUST SEAL 17X23X3 91206 968 003 002 2 98 23 BOLT HEX 6X18 92101 06018 0A 001 0 62 24 NUT HEX 6MM 94001 06020 0S 001 0 ...

Page 273: ... 415 000 003 12 98 08 GEN IGNITION PULSE 30300 MZ5 003 replaces 30300 MZ5 000 001 98 46 09 BOLT FLANGE 12X45 90023 MA6 000 001 7 96 Description Q ty Price 10 WASHER 12X30X4 5 90401 KK9 960 001 7 91 11 WASHER 18X10 2 90405 ML7 000 001 2 84 12 PIN DOWEL 8X8 90702 MB0 000 002 2 73 13 BEARING 30X35X17 91022 MB0 004 replaces 91022 MB0 003 001 26 51 14 ROLLER 15X13 91101 516 000 003 4 53 15 BOLT FLANGE ...

Page 274: ...HOSE FR 19502 MZ5 000 001 13 64 20 HOSE RR HEAD WATER 19503 MZ5 000 001 12 42 21 GUIDE WATER HOSE 19504 MZ5 000 001 7 71 Description Q ty Price 22 CLAMP B WATER HOSE 19506 KS6 700 004 6 13 23 CLAMP HOSE 30 37 19516 GAG 003 004 10 95 24 CONNECTOR GROUND 32152 MB3 000 001 1 33 25 REFLECTOR FR 33740 KR3 671 002 22 31 26 SENDING UNIT 37750 PC1 004 001 43 83 27 SWITCH THERMOSTAT 37760 MT2 003 001 49 49...

Page 275: ...7 TUBE 43124 MZ5 000 002 5 48 08 DUST SEAL BRAKE CAM 43134 300 000 001 1 62 09 CAM RR BRAKE 43141 MB0 010 replaces 43141 MB0 000 001 28 64 Description Q ty Price 10 INDICATOR RR BRAKE 43145 ME5 000 001 4 58 11 SPRING RR 43151 346 000 002 4 64 12 ARM RR BRAKE 43410 MZ5 000 001 26 58 13 BOLT FLANGE 8X25 90107 MZ5 000 001 3 65 14 NUT U 18MM 90305 KZ4 891 replaces 90305 KZ4 890 001 11 42 15 WASHER 18X...

Page 276: ...ER 16214 MB0 000 002 3 51 09 BAND A INSULATOR 16219 MM4 000 002 8 07 10 BAND B INSULATOR 16220 MM4 000 002 8 07 11 BOLT FLANGE 9X93 90007 ML7 920 008 7 85 Description Q ty Price 12 BOLT SOCKET 6X28 90012 MZ5 000 006 1 60 13 BOLT FLG 6X45 5 90017 MA6 000 008 2 62 14 BOLT FLG 6X39 5 90019 MA6 000 008 2 25 15 BOLT STUD 6X22 90036 MZ5 000 004 4 29 16 WASHER 9MM 90445 MM4 000 008 2 82 17 WASHER 5MM 904...

Page 277: ... BRKT NUMBER PLATE 80101 MZ5 670 001 40 85 11 STAY RR REFLECTOR 80102 MM8 010 001 17 82 12 GROM ENGINE COVER 80103 GJ5 000 002 1 55 13 FENDER A RR 80105 MZ5 000 001 66 36 Description Q ty Price 14 SUB FRAME RR 80125 MZ5 000 001 149 92 15 GROMMET SIDE COVER 83601 MN5 000 001 2 25 16 RUBBER 84702 MF2 670 002 3 11 17 BOLT 8X56 90064 KK3 830 004 3 55 18 BOLT 90215 ML0 000 002 1 60 19 NUT 90305 SH3 000...

Page 278: ...0 MZ5 671 002 306 24 02 BUSH RR SHOCK 52485 KR3 003 002 3 76 03 COLLAR RUBBER BUSH 52486 GA7 003 002 2 91 04 BUSH RUBBER UPPER 52489 GS3 003 002 3 58 Description Q ty Price 05 BOLT FLANGE 8X16 90106 MB2 000 002 3 18 06 WASHER PLAIN 90501 MZ5 000 002 1 91 07 BOLT FLANGE 10X35 95817 10035 00 replaces 95801 10035 00 002 1 23 ...

Page 279: ...0G 42704 MB0 000 AR 9 07 08 WEIGHT 20G 42705 MB0 000 AR 10 36 08 WEIGHT BALANCE 20 42705 MCF D60 AR 10 36 Description Q ty Price 08 WEIGHT BALANCE 30 42706 MCF D60 replaces 42706 MB0 000 AR 10 36 09 TIRE RR 42711 MZ5 024 replaces 42710 MZ5 004 42711 MZ5 004 001 152 63 11 VALVE RIM 42753 ML7 004 001 9 67 12 NUT FLANGE 12MM 90306 KF0 003 005 3 15 13 OIL SEAL 34X62 2X7 90753 MG5 670 001 9 20 14 BEARI...

Page 280: ...001 18 08 06 CAP OIL FILLER 15611 MB0 000 001 7 36 07 DIPSTICK OIL 15650 ML7 000 001 10 67 08 CLAMP SWITCH WIRE 35211 443 760 004 2 93 Description Q ty Price 09 BOLT FLANGE 6X28 90004 GHB 680 replaces 90001 GHB 680 011 2 16 10 BOLT FLANGE 6X32 90001 GHB 690 002 2 96 11 O RING 48 1X3 6 91301 ML7 003 001 3 11 12 O RING 22X3 0 91307 425 003 replaces 91301 250 000 001 1 47 13 O RING 8 4X2 4 91316 MJ8 ...

Page 281: ... 96 02 SEAT ASSY 77200 MZ5 000 001 308 50 03 STAY A RR SEAT 77206 MZ5 000 001 15 89 04 STAY B RR SEAT 77207 MZ5 000 001 12 82 Description Q ty Price 05 RUBBER B 77215 GC2 000 002 3 96 06 SEAT ASSY RR 77300 MZ5 000 001 188 28 07 BOLT 8X12 90125 KR3 000 003 3 07 08 NUT FLANGE 6MM 94050 06080 006 0 23 ...

Page 282: ... 2 16 03 GROMMET A CLNR HSG 83551 300 000 004 2 96 04 COVER R SIDE NH1 83650 MZ5 000ZC 001 95 47 04 CVR R SIDE Y124P 83650 MZ5 000ZD 001 84 82 Description Q ty Price 04 CVR R SIDE R201 83650 MZ5 000ZE 001 142 83 05 COVER L SIDE NH1 83750 MZ5 000ZC 001 84 82 05 CVR L SIDE Y124P 83750 MZ5 000ZD 001 84 82 05 CVR L SIDE R201 83750 MZ5 000ZE 001 152 19 ...

Page 283: ...Appendix A Part Numbers 23 50 Speedometer Tachometer ...

Page 284: ...OVER TACHOMETER 37252 MZ5 008 001 59 10 22 RUBBER 37253 MK4 611 002 2 33 23 RUBBER TACHOMETER 37254 MK4 611 001 7 15 24 RUBBER 37255 MK4 611 002 2 33 Description Q ty Price 25 CUSHION RUBBER 37255 MZ5 008 002 2 44 26 GROMMET TACHOMETER 37257 MK4 601 001 5 13 27 SOCKET 37562 MZ5 008 001 43 49 28 BOX ASSY PILOT 37600 MZ5 008 001 80 14 29 COLLAR 37606 MR1 008 002 4 00 30 RUBBER SETTING 37607 MZ5 008 ...

Page 285: ...MZ5 A80 replaces 35700 MZ5 305 001 41 75 02 BAR SIDE STAND 50532 MZ5 000 001 69 70 03 SPRING SIDE STAND 50541 KV3 830 001 6 04 Description Q ty Price 04 BOLT 90108 MR5 000 001 6 31 05 BOLT SPECIAL 6X16 90147 MCE 950 replaces 90147 MK6 671 001 1 84 06 NUT SIDE STAND 90203 MF9 710 001 2 84 ...

Page 286: ... 901 001 17 73 03 SPRING CARBON BRUSH 31204 KS5 901 002 2 20 04 BOLT SETTING 31205 MN0 008 003 3 93 05 HOLDER SET BRUSH 31206 KW1 901 001 18 91 Description Q ty Price 06 RING 31207 KS5 901 002 2 58 07 NUT WASHER 6MM 90071 MB0 000 002 1 53 08 O RING 91309 MA6 000 001 2 93 09 O RING 91320 MB0 000 001 1 82 10 BOLT FLANGE 6X25 96001 06025 00 002 0 93 ...

Page 287: ...53214 371 010 001 9 56 06 THREAD UPPER 53220 422 000 001 24 84 07 LOCK HANDLEBAR 53600 086 007 replaces 53600 126 921 001 34 24 Description Q ty Price 08 SCREW 6X12 90164 028 000 002 1 25 09 THREAD 90302 425 830 001 16 51 10 WASHER LOCK 90506 425 830 001 5 67 11 BEARING HEAD PIPE 91015 KT8 005 001 30 15 12 BEARING HEAD PIPE 91016 KT8 005 001 30 15 13 BOLT FLANGE 6X12 95701 06012 00 001 0 72 14 BOL...

Page 288: ...AIN STEP 50661 MN0 000 002 8 16 09 RUB PILLION FOOTPEG 50716 371 660 replaces 50710 377 000 002 10 78 10 WASHER 50712 413 000 002 2 62 Description Q ty Price 11 BAR PILLION STEP 50715 MN0 000 002 25 25 12 BOLT HEX 6X12 92101 06012 0A 002 0 53 13 BOLT CAP 6X12 92501 06012 0A 002 1 75 14 WASHER PLAIN 6MM 94101 06800 replaces 94101 06000 94101 06080 002 0 30 15 WASHER PLAIN 8MM 94101 08000 002 0 40 1...

Page 289: ...1 KR6 000 002 1 87 14 SWINGARM SET 52200 MZ5 305 001 627 52 15 BOLT RR 90127 393 000 001 3 82 16 BOLT RR 90133 286 000 001 3 51 Description Q ty Price 17 BOLT FLANGE 6X12 90154 ML0 000 002 1 67 18 NUT U 14MM 90305 GE8 003 001 3 05 19 WASHER A 90524 030 000 replaces 90505 425 000 001 1 04 20 WASHER 6X20 90512 KF9 900 001 2 33 21 WASHER 6X9 90513 405 000 replaces 90513 428 900 001 0 98 22 BEARING 22...

Page 290: ...6 03 SOCKET TAILLIGHT 33703 MZ5 671 001 51 15 04 GSKT TAILLIGHT LENS 33709 KB7 003 001 3 31 05 BULB 12V27 8W 34906 425 771 001 3 18 Description Q ty Price 06 COLLAR 80135 MZ5 000 002 9 98 07 SCREW TAP 4X40 90105 GAM 000 002 3 87 08 WASHER 5MM 91409 VM0 770 002 2 33 09 BOLT HEX 5X35 92101 05035 0A 002 1 28 10 WASHER SPRING 5MM 94111 05000 002 0 50 ...

Page 291: ...H PIN 89230 MB1 000 001 15 98 06 WRENCH 8MM 99001 08000 001 1 89 07 SPANNER 10X12 99001 10120 001 1 72 08 SPANNER 14X17 99001 14170 001 2 75 Description Q ty Price 09 SCREWDRIVER 1 NO 2 99003 10000 001 1 75 10 SCREWDRIVER 3 NO 2 99003 30000 001 0 82 11 GRIP 99003 50000 001 1 80 12 HANDLE 12MM 99006 12000 001 2 60 13 WRENCH EYE 22MM 99006 22000 001 3 31 14 WRENCH EYE 27MM 99006 27000 001 3 49 15 BA...

Page 292: ...1 48 18 18 BOLT SPECIAL 10MM 90037 422 003 001 5 78 19 WASHER 25X31X1 5 90451 MR7 000 002 3 89 20 WASHER 28X34X1 5 90452 MR7 000 003 4 58 Description Q ty Price 21 WASHER 20X1 00 90454 428 000 001 2 02 22 WASHER B 22MM 90455 ML7 000 002 3 89 22 WASHER A 22MM 90456 ML7 000 002 3 89 22 WASHER C 22MM 90457 ML7 000 002 3 89 23 WASHER 25MM 90456 MA6 000 001 2 02 24 WASHER 10 2MM 90459 438 000 001 4 67 ...

Page 293: ...02 34 20 10 REFLECTOR L RR 33455 MN0 003 001 15 69 11 STAY R FR 33490 MZ5 000 001 39 56 12 STAY L FR 33491 MZ5 000 001 39 56 Description Q ty Price 13 TURN SIGNAL ASSY 33600 MR1 000 001 49 11 14 REFLECTOR R RR 33605 MR1 000 001 27 04 15 TURN SIGNAL ASSY 33650 MR1 000 001 49 11 16 REFLECTOR L RR 33655 MR1 000 001 27 04 17 STAY RR 33690 MZ5 000 002 23 75 18 BULB 12V23W32CP 34905 268 671 002 1 67 19 ...

Page 294: ...E A WATER 19521 ML7 000 001 72 16 07 JOINT WATER 19523 MT4 000 002 24 76 08 HOSE A WATER 19525 ML7 000 001 6 31 Description Q ty Price 09 BOLT FLANGE 6X12 90004 GHB 610 replaces 90001 GHB 610 001 2 33 10 GSKT CONNECTING CAP 91301 MB0 000 002 3 05 11 O RING 18 3X2 3 91301 147 023 002 1 42 12 SEAL WATER PIPE 91315 MB0 013 001 1 95 13 O RING 21 2X2 4 91331 PC9 003 002 1 95 14 BOLT FLANGE 6X22 96001 0...

Page 295: ...4 GHB 630 replaces 90001 GHB 630 002 2 75 14 BOLT FLANGE 6X10 90011 HB9 000 002 1 67 15 BOLT 6X12 CT200 90013 883 000 001 1 34 16 BOLT 6X75 90021 MZ5 000 001 6 78 Description Q ty Price 17 BOLT 6X95 90025 MZ5 000 002 8 53 18 BOLT FLANGE 6X25 90121 MV9 670 002 2 11 19 WASHER 6 5MM 90463 ML7 000 003 2 25 20 WASHER TANK RUBBER 90503 898 000 002 2 06 21 WASHER BRAKE ARM 90525 GC4 700 001 1 73 22 OIL S...

Page 296: ...003 001 203 22 12 RECTIFIER SILICON 31700 196 000 001 20 76 13 WIRE HARNESS 32100 MZ5 670 001 409 25 14 HORN LOW 38120 MZ5 003 001 48 47 15 RELAY TURN SIGNAL 38301 KK9 952 001 46 75 Description Q ty Price 16 SUSPENSION 38306 GE7 000 001 3 71 17 INDICATOR UNIT 38710 MZ5 003 001 66 65 18 BRACKET RR 50333 MZ5 000 001 21 73 19 BRACKET FR 50334 MZ5 000 001 21 58 20 PLATE 50336 MR1 000 001 8 09 21 STRAP...

Page 297: ...MEMO ...

Page 298: ... Gasket 24 4 Right Crankcase Cover Gasket 24 5 Shift Cover Gasket 24 6 Sprocket Cover Gasket 24 7 NOTE Diagrams must be printed without using any scaling to fit paper Some of the diagrams must be printed on larger than letter sized paper or must be pieced together using the guides included on the images ...

Page 299: ...Appendix B Gasket Diagrams 24 2 Alternator Cover Gasket NOTE Description Part Number Alternator Cover Gasket 11636 MY7 000 Material Thickness Paper 0 0218 Grey area is a thin bead of sealant ...

Page 300: ...endix B Gasket Diagrams 24 3 Cam Chain Tensioner Gaskets Description Part Number Cam Chain Tensioner Gasket Front 12194 KW3 880 Cam Chain Tensioner Gasket Rear 12194 HC5 740 Material Thickness Paper 0 0218 ...

Page 301: ...Appendix B Gasket Diagrams 24 4 Oil Pan Gasket Description Part Number Oil Pan Gasket 11315 MY7 000 Material Thickness Paper 0 0218 ...

Page 302: ...Appendix B Gasket Diagrams 24 5 Right Crankcase Cover Gasket Description Part Number Right Crankcase Cover Gasket 11394 MY7 000 Material Thickness Paper 0 0218 ...

Page 303: ...Appendix B Gasket Diagrams 24 6 Shift Cover Gasket Description Part Number Shift Cover Gasket 11632 MY7 000 Material Thickness Paper 0 0218 ...

Page 304: ...Appendix B Gasket Diagrams 24 7 Sprocket Cover Gasket Description Part Number Sprocket Cover Gasket 11343 MZ5 000 Material Thickness Paper 0 0218 ...

Page 305: ... 1 ...

Page 306: ...61 MZ509 HONDA MOTOR CO LTD TOKYO JAPAN MADE FROM 50 RECYCLED PAPER MINIMUM 1 0 POST CONSUMER CONTENT DRC 3750 03 08 PRINTED I N USA ...